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GORBEL G-Force iQ Series, Installation & Operation Manual

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GORBEL G-Force iQ Series Installation & Operation Manual Download Page 1

IMPORTANT!

DO NOT DESTROY

Installation &

Operation Manual

Month

Year

Gorbel

®

 Dealer

Date

G-Force®

Q and iQ Series

Gorbel

®

 Customer Order No. / Serial No.

®

Go to www.gorbel.com/support/warrantyregistration.aspx 

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Service Package and request your free G-Force® Q and 

iQ Series Service Manual.

Summary of Contents for G-Force iQ Series

Page 1: ...ear Gorbel Dealer Date G Force Q and iQ Series Gorbel Customer Order No Serial No Go to www gorbel com support warrantyregistration aspx to register your G Force sign up for our Platinum Service Package and request your free G Force Q and iQ Series Service Manual ...

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Page 3: ...ose Installation Option 14 Step 5H Remote Mount Force Sensing Slide Handle Installation 15 Step 5I Remote Mount Force Sensing Hub Handle Installation 16 Step 6 Electrical Power Connection 17 Step 7 Initial Power Up 17 Step 8 Float Mode and Final Steps 18 19 Step 9 Expansion I O Block Mounting Instructions Option 20 Lift Functionality 21 23 Controls Interface Features 24 Program Mode Overview Basic...

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Page 5: ...ot operate hoist to extreme limits of travel of cable without irst checking for proper limit switch action 7 Avoid sharp contact between two hoists or between hoist and end stop 8 Do not tamper with or adjust any parts of the hoist unless spe cifically authorized to do so 9 Never use the load cable as a sling 10 Do not divert attention from load while operating hoist 11 Never leave a suspended loa...

Page 6: ... at any time the G Force is in use excluding Float Mode Float Mode Press the G Force logo button with only the load weight handing from the unit Applying additional force will cause unit to drift The wire rope should never be more than 15 out of vertical while the G Force is in use The G360 must be level at all times Do not impact the G Force into end stops repeatedly or at a speed faster than a n...

Page 7: ...e mounted handle applications by mounting the slide handle at both the top and bottom mounting points diagram D page 23 10 Do not mount any objects to the G Force slide handle grip i e switches Additional objects may interfere with the travel of the sliding handle grip and affect the overall speed and functionality of the unit 11 Do not mount any load bearing components to the blue housing of the ...

Page 8: ...ing humans Failure to comply with any one of the limitations noted herein can result in serious bodily injury and or property damage Check Federal State and Local regulations for any additional require ments WARNING Prior to installation consult a qualified structural engineer to determine if your support structure is ade quate to support the loadings created during normal operation of the G Force...

Page 9: ...G The G Force was designed and fully life tested in the installation orientations shown above Any modification to the installation orientation of the G Force without the written consent of Gorbel Inc Engineering will immediately void the warranty CAUTION As a normal safety precaution check for obstructions in the crane and G Force travel 5 9 18 Rev U ...

Page 10: ...interface between the operator and the lifting device See the Lift Functionality section page 21 and Controls Interface Features section page 24 for additional functionality located at the handle The Gorbel slide handle can accommodate either a Gorbel load hook or tooling supplied by others Tooling must meet the guidelines set forth by Gorbel Inc see Tooling Integration Guidelines on page 3 Improp...

Page 11: ... Force is to be used on a non Gorbel bridge system a universal adapter trolley is required diagram 3B Note The customer must provide two 2 hoist trolleys when the unit will run in a non Gorbel bridge system 3 2 Ensure the power cord from the actuator is facing the festooning side of the bridge monorail Remove the end stop from the bridge and install the G Force actuator into the track Immediately ...

Page 12: ...onnector diagram 4D 4 5 Assure that the coils of the coil cord are centered around the wire rope when properly installed 4 6 Use the 16mm shoulder bolt and M12 jam nut to retain the coil cord footer to the thimble in the wire rope Note The shoulder bolt and jam nut will be used to retain the handle or collector in the next step 4 7 If applicable connect air hose coil cord to supply line from the a...

Page 13: ...e on the Slide Handle Retaining Nut and a 21 drill bit to drill a hole completely through the threads of the hook and the opposite side of the nut Hammer the included M4x36mm spring into the hole until it is flush with the surface of the nut diagram 5A2 5A 9 Continue to Step 6 on page 17 STEP 5B REMOTE MOUNTED SLIDE HANDLE INSTALLATION 5B 1 Ensure the wire rope is still fed through the center of t...

Page 14: ...d handle with bracket to the tooling Assure that the mounting arrangement does not affect the operating function of the slide handle 5B 11 Connect the extension cable from the G360 to the remote mounted slide handle Securely clamp the remote mount coil cord extension cable to the tooling as needed 5B 12 Continue to Step 6 on page 17 WARNING Remote mounted G Force handles must be mounted at both th...

Page 15: ...embly diagram 5C3 5C 10 Continue to Step 6 on page 17 Note On suspended pendant equipped systems the wire rope swivel assembly must be installed before AC power is applied to the system or a limit switch error will occur 501 11000 error codes To clear this fault you will have to must be done in this order 1 Install wire rope swivel assembly or other weighted device on wire rope 2 Disconnect AC pow...

Page 16: ...ct the operating function of the pendant handle Note If necessary a collar clamp mounting bracket option can be used to attach the pendant handle to the tooling diagram 5D3 5D 10 Connect the extension cable from the G360 to the remote mounted pendant handle Securely clamp the remote mount coil cord extension cable to the tooling as needed 5D 11 Continue to Step 6 on page 17 16 mm Shoulder Bolt M8 ...

Page 17: ...ers as shown and ensure hardware is now completely tightened If an air hose is being installed leave hardware loose for now 5E 6 While holding the handle or G360 loop the pulley through the wire rope and slip the pulley and side spacers down between the plates diagram 5E3 page 14 5E 7 Align the holes in the plates with the spacers and the bearings insert the pulley pin and install the snap ring on...

Page 18: ...r into mating connector or the underside of the actuator 5F 6 While holding the G360 loop the pulley through the wire rope and slip the pulley and side spacers down between the plates diagram 5E3 5F 7 Align the holes in the plates with the spacers and the bearing insert the pulley pin and install the snap ring on the pulley pin 5F 8 Using the supplied cap screws and lockwashers attach the coil cor...

Page 19: ... order to function correctly For Slide handles the mounting holes on the tooling must be aligned to avoid any binding of the handle and the bolts at each end of the handle must be tightened enough to prevent motion but not induce bending The included rubber washers must be mounted between the handle and tooling to prevent binding Additionally the handle must be captured via the hole in the top cap...

Page 20: ... risk of damaging the handle handlebars on Remote Force Sensing Hub Handles should not exceed 24 0 6m 12 or 0 3m in either direction in width or 24 0 6m from the face of the handlebar mounting plate diagram 5I3 Note To avoid damaging the handle do not apply more than 200 lbs 90 kg to the grip or handlebars Note Remote handles must be mounted rigidly in order to function correctly For Slide handles...

Page 21: ...p the handle grip to run the unit up and down Do this several times to get a feel for the unit The LCD displays RUN MODE HANDLE Standard Operation Pendant Handle Configuration Depress the up and down levers to run the unit up and down Do this several times to get a feel for the unit The LCD displays RUN MODE PENDANT Note The LCD backlight will shut off after 10 minutes of inactivity See the Lift F...

Page 22: ...ad downward towards the floor To move the load up lift up on the load towards the ceiling Note The direction and speed of travel is now being controlled by the amount of force that the operator exerts directly onto the load The higher the force exerted on the load the faster the unit moves Note An over speed detection routine checks if Float Mode reaches 90 of the maximum fully loaded lifting spee...

Page 23: ...re reference WARNING NEVER remove the load from the G Force while still in Float Mode The control system will interpret the removal of the load as operator intent to lift the load Therefore the unit will begin to drift up The speed of the unit drift directly correlates to the weight that was removed from the unit The heavier the weight the faster the unit will travel WARNING In Float Mode the live...

Page 24: ...INSTRUCTIONS OPTION DIMENSIONS TIP Expansion I O block mounting instructions only apply to iQ units with an I O block Diagram 9A Expansion I O block dimensions millimeters Diagram 9B Screw fastener drilling template 20 9 18 Rev U 42 53 85 ...

Page 25: ...74630 or by oth ers are attached to a mounting plate which in turn is connected to a force sensing device so that when the user applies a vertical force up or down this is interpreted as intent to move Speed of the unit is pro portional to the amount of force applied Forces in lateral directions are not detected Note There is no traditional OPS When the force applied to the handle exceeds a small ...

Page 26: ... the unit is overloaded The lift may be moved down to allow for the safe removal of the load Limit Switches The G Force is equipped with both mechanical upper and lower limit switches located in the actuator assembly When the upper limit switch is triggered the upward motion of the lift stops quickly at a controlled deceleration rate The controlled deceleration rate guarantees the load cannot come...

Page 27: ... remote mounted to the tooling The remote mounted handle is linked to the coil cord via an extension cable The handle operates exactly the same as if it were mounted in line The end user must supply Gorbel with the required length of the extension cable such that it can be safely routed and clamped to the tooling WARNING The tooling MUST be attached to the end of the wire rope with the G360 swivel...

Page 28: ... and safety program mode are available It allows a minimum safe operation on a unit with a damaged handle broken I O electronics or other damaged peripheral control components that would make it dangerous to run the unit if the component is used The unit is still inoperative if actuator components such as the drive motor or jog switches are damaged To activate service mode with the handle E stop p...

Page 29: ...sponding programmable menus V LIMITS MENU Virtual Limits menu option SPEED MENU Lift Speed adjustment RESPONSE MENU Lift Response acceleration adjustment SETTINGS MENU Programmable Features on both the Q and iQ units SETTINGS MENU 2 Programmable Features on iQ units only iQ only LED MENU Program the LED lights iQ only SERVICE MENU Customize and manage maintenance and service features CONFIGUR MENU...

Page 30: ...se this button to initiate float mode When the unit is in float mode use this button to select the desired item within the menu by pressing and releasing to advance to the next selection Press and hold this but ton for approximately three seconds until the unit enters program mode Once in program mode this button is used to select the desired menu Press and release this button to advance to the ne...

Page 31: ...ct Maximum Hoist Speed M RESPONSE MENU G Select Handle Control Response M SETTINGS MENU G Program Common Q iQ Custom Features SETTINGS MENU 2 N G Program iQ Features M LED MENU M M SERVICE MENU G Select Maintenance and Service Features M CONFIGUR MENU G User Accessible Hardware Configurations Activate Through CFG MENU ENABLE G Configure Blue LED Indicator DUAL ACT MENU M G Optional Configure Dual ...

Page 32: ...ORCE CHANGE OVLD LMT M G M G CHANGE SENSITIV M G TIMER SUB MENU M G FLOAT MO TIMER HANDLE TIMER M G M G CUSTOM TIMER M G FSH SUB MENU M G CHANGE 2 INLINE REMOTE ZERO FSH WEIGHT M G M G SET FRCE 2 LARGE SMALL M G RESET FSH TARE M G If FSH DEFAULT SETTING DEADBAND CENTER M G M G FM ANTI RECOIL M G UNLOAD STOP ON M G FM GAINS SUB MENU G M CALIBRAT LOD COEF ZERO LOD BIAS M G M G HARDWARE OPS ON M G PR...

Page 33: ... accessible For example if the G Force records a fault when Program Mode is activated the LCD will display LIMITED PRG MODE rather than PROGRAM MODE Safety Program Mode can be navigated just as Program Mode would be however the only menus available are V LIMITS MENU Virtual Limits menu option SPEED MENU Lift Speed adjustment RESPONSE MENU Lift Responsiveness Acceleration adjustment SERVICE MENU Cu...

Page 34: ... Handle is connected Q iQ Custom Features SETTINGS MENU ZERO WT DISP Record and tare out the handle weight for weight readout calculation WEIGHT READ ON_ READ OFF Toggle between enabling and displaying the load weight Once enabled weight is displayed two seconds into standard operation unit idling DISPLAY METRIC ENGLISH Toggle the unit of the weight readout display between pounds English and kilo ...

Page 35: ...imit between 15 and 45 lbs at 5 lb increments Anti Recoil Over Force Detection limits increased for 660 lb units New limits are between 30 and 90 lbs at 5 lb increments DEFAULT SETTINGS Unit reset to the default setup according to the configured detection method For example unit configured with Over Force Detection defaults to 35 lbs maximum force limit dropped weight profile checkup and condition...

Page 36: ...specially when handle is mounted on the tooling This sub menu allows one to set a Force Limit to account for different user s operating force thus reducing chance of false overload detection The limit should not be set larger than necessary as it reduces detection capability By default the limit is set at 15 lbs TO FORCE LBS NN Set Operating Force Limit to between 5 and 25 lbs in 1 lb increments C...

Page 37: ...ing the dual Float Mode anti drop and auto home features LED Config Menu Programs the blue LED as an indicator LED MENU RESET LEDS Disable any custom feature e g anti drop from utilizing the blue LED as an indicator ANTI DROP Enables the blue LED on the control handle to act as an indicator for the anti drop function When this function is enabled and the anti drop output is off off is typically th...

Page 38: ...Input Output Module Diagnostic Mode displays the status of the eight configurable inputs and outputs on the LCD screen The inputs statuses are displayed in the first screen followed by those for the outputs The I O Point number of the input that measures incoming 24VDC or output that is turned on to provide 24VDC is displayed in each screen as numerical numbers 1 8 I O BLK1 DIAGNOSE iQ Only First ...

Page 39: ...s Float Mode option This step must be performed after zero load bias HARDWARE OPS ON Configure the unit to apply external OPS for FSH The IO point is AUX input Q or X67 IO Block iQ HARDWARE OPS OFF Configure the unit to apply software OPS as default IO point will be set back to default PRESET SUB MENU Access predefined sets of Q iQ feature configurations including factory default setup SUB MENU Pr...

Page 40: ...ation requirements Contact your Gorbel dealer for more details 5 Output External device control requires option al expansion 8 point input output block This output is controlled by input number 5 on the optional expansion 8 point input output block When that input is on output 5 on the iQ actuator input output module is on and vise versa 6 Output External device control requires option al expansio...

Page 41: ...ected i e Q iQ G Force stops at 10 25 lbs depending on unit capacity The Auto Home position programming is located at SETTINGS MENU 2 MENU 2 SET HOME Move the G Force to the desired position in the vertical travel before selecting the position setting in this menu 5 Input External device control used in conjunction with actuator output 5 This input controls input 5 on the actuator input output mod...

Page 42: ...Diagram H Q iQ Handle Configurations Note Numbers in Parentheses are Gorbel Part Numbers 38 9 18 Rev U ...

Page 43: ...Diagram I Actuator IO 474 CPU 39 9 18 Rev U ...

Page 44: ... J Handle IO Detail Slide Model Note Numbers in Parentheses are Gorbel Part Numbers CABLE ASSY 78666 OR SIMILAR CABLE ASSY 78671 OR SIMILAR CABLE ASSY 78681 OR SIMILAR CABLE ASSY 78681 OR SIMILAR 40 9 18 Rev U ...

Page 45: ...K Handle IO Detail Pendant Model Note Numbers in Parentheses are Gorbel Part Numbers CABLE ASSY 78681 OR SIMILAR CABLE ASSY 78681 OR SIMILAR CABLE ASSY 78666 OR SIMILAR CABLE ASSY 78671 OR SIMILAR 41 9 18 Rev U ...

Page 46: ...rope damage Check whether or not you have an extended wire rope with a standard length coil cord Check to see if the wire rope has been modified shortened for any reason Check for any interference with foreign objects tooling work surfaces etc The actuator is extremely noisy Check the condition of the wire rope Check for any external damage to the actuator covers Float Mode does not function corre...

Page 47: ...ervice Manual replacing the wire rope checking certain external input output modules or some other service related task If necessary check with your Gorbel distributor or contact Gorbel Inside Sales at 800 821 0086 for assistance Use the following table to identify the appropriate corrective action for the specific faulted condition If corrective action does not work refer to the optional Service ...

Page 48: ...shbutton states only a special Jog Mode is running etc 7 Startup Process Before Ready Mode On On Displays UNIT POWER UP Unit is starting up power up and executing necessary settings and self diagnostics 10 a Run Mode Overload Previous Slow Flash Indicates unit is overloaded factory or user defined while lifting 10 b Still Motion Previous Slow Flash Indicates unit maintains still for an extensive t...

Page 49: ...Steel Wire Rope 3 16 dia 19x7 Preformed Stainless Steel Wire Rope 3 16 dia 19x7 Preformed Stainless Steel Wire Rope 6 35mm dia 19x7 Preformed Stainless Steel Wire Rope 6 35mm dia 19x7 Preformed Stainless Steel Wire Rope 6 35mm dia 19x7 Preformed Stainless Steel Wire Rope 6 35mm dia 19x7 Preformed Stainless Steel Wire Rope 4 76mm dia 19x7 Preformed Stainless Steel Wire Rope 4 76mm dia 19x7 Preforme...

Page 50: ...d should be more frequent as the rope approaches the end of its useful life A designated person shall perform periodic inspections This inspection shall cover the entire length of rope The individual outer wires in the strands of the rope shall be visible to this person during the inspection Any deterioration resulting in appreciable loss of original strength such as described below shall be noted...

Page 51: ...greater than 1 64 4 mm for 1 4 6 35 mm diameter rope or 3 16 4 76 mm diameter rope 3 Broken wire removal criteria applies to wire rope operating on steel sheaves and drums However results of internal testing have shown that rope replacement follows the same criteria regardless of sheave or drum material 4 Attention shall be given to end connections Upon development of two broken wires adjacent to ...

Page 52: ...hile keeping tension on wire rope with other hand wearing a glove Continue until lower limit is engaged 5 Insert a medium sized screwdriver between the white colored wear ring and the actuator black casting where the wire rope exits the actuator right side This will keep the slack switch disengaged while jogging down the remainder of the rope diagram M 6 Face the unit with circuit board on your le...

Page 53: ...agram R 13 Using an M6 hex wrench remove the two M8 socket head cap screws from the blue colored rope retainer and slide retainer off of rope end towards you Set retainer and screws in front cover diagram S 14 Grasp wire rope with right hand where it exits actuator Keep rope from bending while pushing rope upward to unseat the stop sleeve from the anchor channel If this does not work use a medium ...

Page 54: ... to plate using the four previously removed socket head cap screws and lockwashers Torque hardware to compress lockwashers 7 Plug limit switch lead into circuit board limits receptacle making sure retention tab on plug is facing you 8 Using a clean cotton cloth wrapped around rope loosely near actuator entrance pull down on rope and press jog up button allowing rope to pass through cloth cleaning ...

Page 55: ...ration of hoist while traveling down is encountered the end effector or tooling on wire rope is not heavy enough to overcome the spring tension Loosen the outside nut one half turn and test the hoist operation full stroke up and down between each half turn adjustment of eyebolt nut until chattering is eliminated 5 All other conditions will require the outside nut to be adjusted by turning clockwis...

Page 56: ...le Height Height Under Hook and Span if applicable to your unit Level One Kit contains One Wire Rope Assembly One Coil Cord Assembly Level Two Kit contains One Wire Rope Assembly One Coil Cord Assembly One Hardware Kit Level Three Kit contains One Wire Rope Assembly One Coil Cord Assembly One Hardware Kit One Swivel Kit If your system is equipped with a Suspended Pendant Handle you can use the Lev...

Page 57: ...RIBUTOR NOT AN AGENT Gorbel and Purchaser agree that Purchaser has been put on notice that dealer or distributor is not Gorbel s agent in any respect for any reason Gorbel and Purchaser also agree that Purchaser has been put on notice that dealer or distributor is not authorized to incur any obligations or to make any representations or warranties on Gorbel s behalf other than those specifically s...

Page 58: ...inery Directive 2006 42 EC Standard EN 60204 Safety of Machinery Electrical Equipment of Machinery EN 81 3 2000 Safety rules for the construction and installation of lifts Part 3 Electric and hydraulic service lifts prEN 81031 Safety Rules for the construction and installation of lifts Lifts for the transport of goods only Part 31 Accessible goods only lifts Manufacturer s Name Gorbel Manufacturer...

Page 59: ...nery Directive 2006 42 EC Standard EN 60204 Safety of Machinery Electrical Equipment of Machinery EN 81 3 2000 Safety rules for the construction and installation of lifts Part 3 Electric and hydraulic service lifts prEN 81031 Safety Rules for the construction and installation of lifts Lifts for the transport of goods only Part 31 Accessible goods only lifts Manufacturer s Name Gorbel Manufacturer ...

Page 60: ...form the slack switch adjustment Check the coil cord and air hose clamps on the wear ring to insure the wear ring is moving freely inside the actuator opening Monthly 6 Handle Check for smooth operation of the handle Slide Handle Only Check operator present sensor for correct operation Use a gentle puff of compressed air or a soft cloth to clean the sensor Do not apply any pressure to the lens or ...

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