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Starke SMW Series Owner's Manual

Monorail wire rope hoist
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Monorail Wire Rope Hoist
V2.0 061824
1
STARKEAMERICA.COM

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  • Page 1 Monorail Wire Rope Hoist V2.0 061824 STARKEAMERICA.COM...

  • Page 2: Table Of Contents

    Table of Contents 1.0 Important Information........................ 6 1.1 Safety Precautions ........................ 6 1.2 Warnings ..........................6 2.0 General Description ........................7 2.1 User Manual .......................... 7 2.2 Operational Limits ......................... 7 2.3 Operational Specifications ....................8 2.4 Warranty ..........................8 2.5 Other Notes ...........................
  • Page 3 7.2 Hoist Lifting .......................... 25 7.2.1 Single Girder Hoists ............................ 25 7.3 System Commissioning ...................... 26 7.3.1 No-load check ............................. 26 7.3.2 Electrical System............................26 7.3.3 Pendant Control ............................26 7.3.4 Noise ................................27 7.3.5 Upper and Lower Limit Switch Calibration....................27 7.3.6 Travel Limit Switches ..........................
  • Page 4 12.1 Inspection .......................... 42 12.1.2 Pre-Use Inspection of System ........................42 12.1.3 Certification Post Overhaul and/or Modification ..................43 12.1.4 Routine Inspections ..........................43 12.2 Inspection Checklist ......................44 12.3 Wire Rope Maintenance ....................... 45 12.3.1 Inspection of Wire Rope....................45 12.3.2 Maintenance and Lubrication of Wire Rope ..............
  • Page 5 18.0 Hoist Dimensions ........................82 18.1 Hoist Dimension Drawing....................82 18.2 Hoist Dimension Measurements ..................83 Starke Products Warranty......................84 V2.0 061824 STARKEAMERICA.COM...

  • Page 6: Important Information

    DAMAGED CONDITION. Any attempt to do so will put you, others, and property at serious risk. 1.2.6 Repairs to this unit must be performed by a qualified repair facility. Contact Starke America to locate the nearest repair facility. See warranty information at the end of this manual.

  • Page 7: General Description

    Starke wire rope hoists are fit for the lifting and carrying of loads subject to the maximum load capacity, FEM group and load group for which it was designed. Load capacity, FEM group and load group are indicated in the data sheet or test booklet of each hoist.

  • Page 8: Operational Specifications

    The design, manufacture and operation of this device is in accordance with current CEN and ISO standards. 2.4 Warranty Starke will assume no liability for any damage(s) to the crane and/or hoist system, property or personnel resulting from improper installation, operation, maintenance by unauthorized personnel for claims by third parties.

  • Page 9: Typical Applications

    3.0 Typical Applications 3.1 Applications Starke electric wire rope hoists may be installed on overhead “I” shaped steel rails (straight or curved). They are widely used in plants, mining, railway, port, warehouse, good yards, and service industries. Electric wire rope hoists improve productivity.

  • Page 10: Safe Working Time

    3.4 Safe Working Time The load spectrum is as bellow: FEM has relevant standards about hoist accidents caused by material fatigue and aging. The following form is referred to during designing of hoists. Work Duty FEM (ISO) Usage Period 1Bm(M3) 1Am(M4) 2m(M5) 3m(M6)

  • Page 11: Estimation Of Safe Working Time

    3.5 Estimation of Safe Working Time Experienced service technicians should routinely check and record the service condition of wire rope hoist, then estimate the remaining safe working time according to accepted standard. 3.6 Solution for Limited Safe Working Time • Suspend use of hoist system •...

  • Page 12: Technical Descriptions

    4.0 Technical Descriptions 4.1 Components of Wire Rope Hoist Drawing Description Hoisting Transmission Lifting Motor Drum Device Trolley Frame Trolley Traveling Mechanism Hook Wire Rope Cabinet of Hoist V2.0 061824 STARKEAMERICA.COM...

  • Page 13: Lifting Motor

    4.2 Lifting Motor The standard lifting motor is a two-speed motor with electromagnetic disc brake. A variable speed motor is optional and has electromagnetic brake. Drawing Description Fan Cover Brake Pack Stator Rotor Junction Box Motor Frame motor are class F rated. When the temperature is above 150 ℃ , thermostats or sensors will Two-speed (variable-frequency) motor has (three) thermostats or sensors.
  • Page 14 Min. rotor Thickness The IP grade of standard electromagnetic disc brake is IP54, the highest IP grade can be up to IP56. Meanwhile, electromagnetic disc brake can alternatively install manual release lever. The brake uses dust-proof design, which doesn’t need other maintenance during normal operation. IMPORTANT NOTE: It is imperative to check brake clearances on a regular basis.

  • Page 15: Hoist Transmission Gearbox

    4.3 Hoist Transmission Gearbox The wire rope drum is driven by the lifting motor via the gearbox. The output shaft has been designed with a volute spline to achieve optimal transmission reliability. For optimal performance and longevity of the gearbox please strictly follow FEM recommendations, and with the use of high quality lubricants no other maintenance during safe working time should be required under normal use conditions.

  • Page 16: Drum And Guide Information

    4.4 Drum and Guide Information Drawing Description Left End Plate Rope Guide Rod Drum Rope Guide Right End Plate The drum is manufactured from seamless tube, and the surface is machined into rope races according to different model requirements, such as right-handed rotation or left-and-right handed rotation.
  • Page 17 Drawing Description Hex Bolt Spring Washer Washer Rope Guide Ring A Clamping Roller Pin A Rope Guide Ring B Washer Rope Guide C Snap Ring Hex Bolt Clamping Roller Spring Clamping Roller Frame Clamping Roller Pin B Snap Ring Clamping Roller V2.0 061824 STARKEAMERICA.COM...

  • Page 18: Upper And Lower Limits

    Two circles 4.5 Upper and Lower Limits The Starke wire rope hoist uses a screw type cam limit switch, which is installed on side plate of drum making it convenient for precise adjustment. The switch has two separate contacts to allow the hoist to slow down upon tripping the first limit and safely stop upon tripping the second limit providing safe load handling.

  • Page 19: Trolley Frame

    4.6 Trolley Frame The trolley frame of the hoist consists of the connecting tubes, adjusting rods, mount plates, and end frames. Wiring is installed inside the connecting tube. The size of trolley frame depends on capacity, lifting height, and some other elements of system design. 4.7 Motorized Trolley Motorized trolley includes a squirrel-cage motor and gearbox.

  • Page 20: Overload Limits

    When performing overload test on site, please disable overload limiter. After completion of testing be sure to enable the limiter. If the set point value of overload limiter is marginally different and needs recalibrated, please contact hoist Starke or professional maintenance personnel to reset overload limiter.

  • Page 21: Wire Rope

    4.9 Wire Rope The wire rope is a highly stressed part as well as the most vulnerable part of hoist system. To make sure safe operation is maintained, operators should strictly follow safety operation manual. Client should also frequently check and maintain wire rope. Routine maintenance includes but not limited to: •...

  • Page 22: Hook Assembly

    4.10 Hook Assembly Hook assembly usually made up by following components: • Hook Forging • Overhang Card • Hook Beam • Hanger Plate • Pulley Assembly The hook is a highly stressed part of the hoist. The daily inspection and maintenance of hook includes but not limited to the following: •...

  • Page 23: Hoist Electrical Controls

    5.0 Hoist Electrical Controls Power supply requirements for Starke standard wire rope hoists are 460/3/60Hz and drive power is 24V/1/60Hz. The configuration for a standard wire rope hoist and trolley is two speeds, contact your dealer for optional configuration. Our Gen 2.0 hoist systems are now utilizing Danfoss variable frequency drives as standard equipment driving the trolley motor.

  • Page 24: Wire Rope Data

    5.1 Wire Rope Data Diameter Minimum Strength Grade Extruded Rope Weight 2160 N/m ㎡ 33.34 kN 0.17 kg/m 2160 N/m ㎡ 58.84 kN 0.283 kg/m 2160 N/m ㎡ 111.8 kN 0.54 kg/m 2160 N/m ㎡ 207.9 kN 1.02 kg/m 6.0 Lubrication Information Gearboxes and bearings have lubricants installed before delivery and under normal circumstances are within safe operational working levels.

  • Page 25: Hoist Lifting

    7.2 Hoist Lifting Lifting strap or chain attaching points are called out on the hoist trolley frame with decals. Lift the hoist only by the lifting points on the trolley frame or damage will result. 7.2.1 Single Girder Hoists The width between the single girder beam flange and trolley wheels has not been adjusted before delivery.

  • Page 26: System Commissioning

    7.3 System Commissioning 7.3.1 No-load check Check operation of the system with no load before attempting to lift weight 7.3.2 Electrical System • Verify voltage and ampacity of the power supply circuit is in accordance with the hoist system specifications. Also verify proper phasing of power supply as hoist system is equipped with a phase monitor system that will prevent hoist from operating if phasing is incorrect.

  • Page 27: Noise

    7.3.4 Noise In normal use of the hoist system there will be obvious noise created by the operation of the mechanical components that comprise the system. In day-to-day use operators will learn what “normal” noise is as they become accustomed to the systems in operation. If excessive vibrations or loud noises become noticeable it is advisable to stop the use of the hoist system and contact appropriate maintenance personnel to determine the cause and resolution of the issue.

  • Page 28: Lifting Load Limiter

    8.0 Lifting Load Limiter V2.0 061824 STARKEAMERICA.COM...
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  • Page 32: Bcq-Hd (W) European Weight Limiter

    9.0 BCQ-HD (W) European Weight Limiter Instruction Manual Page 36-42 Please read the instruction manual carefully before using the product. The hardware drawings, styles and specifications listed in the manual are for reference only. All items are subject to change. V2.0 061824 STARKEAMERICA.COM...

  • Page 33: Overview

    9.1 Overview BCQ-HD (W) series hoisting weight limiter is an overload safety protection device mainly used in European single 1 beam and consists of a sensor and instrument. The main technical specification conforms to the requirements of GB/T 12602-2020 Technical specifications for Overload Protection Device of Hoisting Machinery.

  • Page 34: Installation And Adjustment

    9.4 Installation and Adjustment 9.4.1 Precautions 1. Please check if this product model is of appropriate capacity for your lifting equipment before installation. 2. Each time after starting up, press the self-test key to check whether the device is working normally. 3.
  • Page 35 BCQ-HD (W) European Weight Limiter Alarm Warning Clear Check Switch Shift Enter V2.0 061824 STARKEAMERICA.COM...

  • Page 36: Adjustments And Usage

    9.5 Adjustments and Usage 9.5.1 Keyboard Instructions Calibration Button: Press this button to enter the calibration function. It also has the function of Escape. Switch/Shift Button: Press this button to switch the weight display unit kg or lb, Switch and the corresponding indictor light will be on with Shift function. Shift Check Check Button: Press this button to check if the system of the instrument functions...

  • Page 37: Methods Of Adjustment

    9.5.3 Methods of Adjustment • CLEAR: For initial installation, due to the inconsistent weights of reel and steel cable, the instrument will display a value or display “0”, press the CLEAR button when no load is present. Long press the CLEAR button for over 3 seconds. When you hear the “beep” the instrument will display “0”, then release the CLEAR button which means the clearing operation is completed.

  • Page 38: Most Frequent Malfunctions And Solutions

    9.6 Most Frequent Malfunctions and Solutions 9.6.1 Unable to display the loaded weight. Malfunction: After installation it displays “0”. And after loaded still displays “0”. • Checking Methods: Long press both the ESC and SHIFT buttons for 3 seconds to view •...

  • Page 39: Trolley Frame

    10.0 Trolley Frame • Check for proper shaft alignment with frame. • Check that all fasteners are at proper torque specifications. • Check for proper clearance of 3 to 5 mm on flange drive wheels. • Check that trolley drive motor brake is functioning properly. 10.1 Load test inspection (100% rated load) 10.1.1 Motor current Check voltage and amperage on each leg of lifting motor power supply while under maximum...

  • Page 40: Testing System In Overload (110 To 125%)

    Please check that all documents included with the hoist system are in good order. Be sure to have all pre-use inspection documents properly filled out as well as owner required warranty cards and submitted to Starke. Keep inspection / maintenance logs in a safe place for reference in the service life of this hoist system.

  • Page 41: Operation Manual

    11.0 Operation Manual 11.1 Control Pendant The typical control device of a hoist or crane system is the pendant. Pendants can be wired or wireless and perform the same functional control over the hoist / crane system. Depending on the number of motions the system is capable of the number and function of buttons will vary by system.

  • Page 42: Inspection And Repair

    12.0 Inspection and Repair 12.1 Inspection It is recommended that a certified and accredited industrial hoist and crane service provider be utilized to inspect, maintain, and certify the hoist system. This organization should have the ability to provide the following. •...

  • Page 43: Certification Post Overhaul And/Or Modification

    IMPORTANT NOTE: According to differing jurisdictional requirements, the content of the inspections and testing may differ. If the load testing requirement is to be performed at 110% the of rated load for the dynamic test and 125% of the rated load for static test, please contact your dealer for guidance on this subject.

  • Page 44: Inspection Checklist

    IMPORTANT NOTE: Only properly trained and certified technical personnel are authorized to maintain and service Starke wire rope hoists. Starke shall not be held liable and will not take any responsibly for any failure of or injury caused using non-authorized parts or service personnel, or incorrect maintenance, or the lack thereof.

  • Page 45: Wire Rope Maintenance

    12.3 Wire Rope Maintenance 12.3.1 Inspection of Wire Rope Wire fractures will happen during normal use, because of continued wearing and fatigue stress. For safety reasons, it is required to check wire rope once a month. The hoist system shall be placed out of service and the wire rope must be changed if anyone of following three situations is discovered: •...

  • Page 46: Cleaning And Lubrication Of Rope Guide

    12.3.4 Cleaning and Lubrication of Rope Guide During normal use, the rope guide will receive lubrication through contact with the wire rope. It may also become necessary to separately lubricate the rope guide when maintaining the hoist. When lubricating, the rope guide should be removed from the drum assembly, and then apply grease to the friction surfaces.

  • Page 47: Troubleshooting

    13.0 Troubleshooting IMPORTANT NOTE: Lock out and tag out power supply before attempting any of these tests. Fault Description Possible Causes Recommended Action Remarks Check power supply and collector No power Check emergency stop and Hoist doesn’t operate contactor KI Lifting limiter is tripped Check limit switch Check phase sequence of main...
  • Page 48 Fault Description Possible Causes Recommended Action Remarks Power supply failure for Check wiring of and/or replace brake actuator brake pack Check wiring and power supply Brake doesn’t operate of brake coil Failure of rectifier Replace broken rectifier Braking not effective Clearance of brake disc Adjust clearance Insufficient lubrication of...

  • Page 49: Electrical Information

    14.0 Electrical Information 14.1 Electrical Specifications Electrical Data – Motor and VFD Unit Nominal Voltage: 460/3/60 Only Model Electrical Details (Danfoss VLT FC51 Equipped) Suggested Brake Nominal Fuse 2 Spd 2 Spd Trolley Model # Description Resistor Operating Rating Lifting 2 Spd Lifting Motor...

  • Page 50: Electrical Schematics

    14.2 Electrical Schematics V2.0 061824 STARKEAMERICA.COM...
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  • Page 56: Electrical Schematics 10 Ton Units

    14.3 Electrical Schematics 10 Ton Units V2.0 061824 STARKEAMERICA.COM...
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  • Page 62 Device Name Code Name Phase Sequence A-PS Contactor A-K1 Height Limitator Contactor A-K2 Trolley Limitator Contactor A-K4 Contactor A-F1 Contactor A-K3 Connector CZ11 Contactor E-KB Connector CZ12 Intermediate E-K1 Overload Limiter Relay Intermediate E-K2 Relay Intermediate E-K3 Relay Brake Resistor Inverter INVERTER V2.0 061824...

  • Page 63: Product Information

    15.0 Product information 15.1 Wire Rope Hoist Maintenance Form Below table to be filled in by client: Manufacturer: Address: Service hot line: Type: Serial number: Manufacture date: Working group: Rated load: Lifting height: Lifting speed: Electrical outlet: V2.0 061824 STARKEAMERICA.COM...

  • Page 64: Wire Rope Hoist Yearly Inspection Record

    16.0 Wire Rope Hoist Yearly Inspection Record Inspection items Test result Inspector Date V2.0 061824 STARKEAMERICA.COM...
  • Page 65 (Intentionally Left Blank) V2.0 061824 STARKEAMERICA.COM...

  • Page 66: Exploded Part Drawings And Part Lists

    17.0 Exploded Part Drawings and Part Lists 17.1 Single Girder Wire Rope General Drawing V2.0 061824 STARKEAMERICA.COM...

  • Page 67: Single Girder Wire Rope General Part List

    17.2 Single Girder Wire Rope General Part List Drawing Part Description Lifting Motor Assembly Drum Assembly Trolley Frame Hook Block Pulley Assembly Dead End & Load Cell Weight Kit Limit Switch Panel Assembly V2.0 061824 STARKEAMERICA.COM...

  • Page 68: A1 Lifting Motor Drawing

    17.3 A1 Lifting Motor Drawing V2.0 061824 STARKEAMERICA.COM...

  • Page 69: A1 Lifting Motor Part List

    17.4 A1 Lifting Motor Part List Part Numbers Drawing Part Description 3 Ton 5 Ton 10 Ton Gearbox Assy Includes Ref #1-20 600-43000 600-43001 600-43002 Hexagon Socket Head Cap Screws Dowel Pin Box Cover Plate Bearing Cylindrical Roller Bearing 310E Bearing Intermediate Disc Gear Intermediate Shaft Gear...

  • Page 70: A1 Lifting Motor Part List (Continued)

    17.4 A1 Lifting Motor Part List (Continued) Part Numbers Drawing Part Description 3 Ton 5 Ton 10 Ton Bearing Washer Skeleton Oil Seal Motor Cover Shaft Sleeve Brake Includes 40 & 41 600-43009 600-43010 600-43011 Brake Disc (Not Shown) 600-43054 600-43055 600-43056 Hexagon Socket Head Cap...
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  • Page 72: A2 Lifting Device Drawing

    17.5 A2 Lifting Device Drawing V2.0 061824 STARKEAMERICA.COM...

  • Page 73: A2 Lifting Device Part List

    17.6 A2 Lifting Device Part List Part Numbers Part Description 3 Ton 5 Ton 10 Ton Limit Switch 600-43018 600-43019 600-43020 Connect Plate Connector Connecting Sleeve Hexagon Socket Head Cap Screws Flat Washer Left Flange Bearing Block Bearing Flat Washer Hexagon Socket Head Cap Screws Connecting Rod...

  • Page 74: A3 Trolley Device Drawing

    17.7 A3 Trolley Device Drawing V2.0 061824 STARKEAMERICA.COM...

  • Page 75: A3 Trolley Device Part List

    17.8 A3 Trolley Device Part List Part Numbers Drawing Part Description 3 Ton 5 Ton 10 Ton Motor 600-43033 600-43034 600-43035 I-Type Hex Nut Positioning Plate Supporting Tube Positioning Tube Coupling Transmission Shaft Bearing Block Bearing Retaining Hole for Ring Gear Trolley Frame A Safe Hook...

  • Page 76: A4 Bottom Hook Drawing

    7.9 A4 Bottom Hook Drawing V2.0 061824 STARKEAMERICA.COM...

  • Page 77: A4 Bottom Hook Part List

    7.10 A4 Bottom Hook Part List Part Numbers Drawing Part Description 3 Ton 5 Ton 10 Ton Lower Block Assy – Includes #1- 600-43036 600-43037 600-43038 Spring Washer Elastic Cylindrical Pin Outboard Side Cover 600-43039 600-43040 600-43041 Pulley Washer Bearing Retaining Ring for Hole Inner Lift Plate Pulley Shaft...

  • Page 78: A5 Fixed Pulley Device

    7.11 A5 Fixed Pulley Device V2.0 061824 STARKEAMERICA.COM...

  • Page 79: A5 Fixed Pulley Part List

    7.12 A5 Fixed Pulley Part List Part Numbers Drawing Part Description 3 Ton 5 Ton 10 Ton Pulley Assy – Includes #1-7 & 10-14 600-43045 600-43046 600-43047 Washer Bearing Retaining Ring Pulley Lift Plate Support Shaft Hanging Board Bushing Hexagon Socket Head Cap Screws Self-Locking Nuts Shaft Retaining Ring Retaining Ring Cover...

  • Page 80: A6 Rope End Device

    7.13 A6 Rope End Device V2.0 061824 STARKEAMERICA.COM...

  • Page 81: A6 Rope End Device Part List

    7.14 A6 Rope End Device Part List Part Numbers Drawing Part Description 3 Ton 5 Ton 10 Ton Wedge Assy – Includes #1-7 & 10- 600-43048 600-43049 600-43050 Wedge Joint Ganging Board Overload Protector 600-43050 600-43051 600-43052 Hanging Board Shaft Pin External Circlips Fixed Shaft Plate Spring Washer...

  • Page 82: Hoist Dimensions

    18.0 Hoist Dimensions 18.1 Hoist Dimension Drawing V2.0 061824 STARKEAMERICA.COM...

  • Page 83: Hoist Dimension Measurements

    18.2 Hoist Dimension Measurements 8” MIN 41 1/4” MIN 8 5/8” 21 5/8” 23” MIN 1 1/8” 1 3/4” 36 7/8” SMW0324-20 25” MAX 52 7/8” MAX 8” MIN 41 1/4” MIN 8 5/8” 21 5/8” 23” MIN 1 1/8” 1 3/4”...

  • Page 84: Starke Products Warranty

    ALL OTHER REPRESENTATIONS, EXPRESS OR IMPLIED, WARRANTY, OR LIABILITY RELATING TO THE CONDITION OR USE OF THE PRODUCT ARE SPECIFICALLY DISAVOWED, AND IN NO EVENT SHALL STARKE BE LIABLE TO BUYER, OR ANY THIRD PARTY, FOR ANY DIRECT OR INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES STARKE Starkeamerica.com/contact-us/...
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This manual is also suitable for:

Smw0324-20Smw0524-20Smw1021-20

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