Liftket STAGEKET Operating Instructions Manual Download | Manualshive

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7.7.1

Operation and emergency brake (double brake)

The operation and emergency brake operate independently. They are arranged in a row on the motor pinion shaft.
The motor-sided brake is the operation brake Y1 and the cap-sided brake is the emergency brake Y2. Both brakes
are DC-disk brakes acting according to the closed circuit current principle.

Motor pinion shaft

Rotor

Motor cover

Operation

Emergency

brake Y1

brake Y2

Figure 43: Configuration of the operation and emergency brake

Operation brake Y1

The magnet coil of the operation brake Y1 gets its power supply by the rectifier. The direct current (DC) is operated
by the auxiliary contacts of the contactors K2 and K3.

Emergency brake Y2

The magnet coil of the emergency brake Y2 gets its power supply by the rectifier too.
The rectifier is supplied by alternating current (AC) out of the motor lines (U and V) 1L1 and 1L2.
Due to this AC

– supply the incidence time of the emergency brake is longer than of the operation brake.

Separate test of the operation and emergency brake (DGUV V17 (BGV C1) only)

The DC

– supply of both magnetic coils are equipped with a plug connector.

These connectors are marked with “1” for the operation brake Y1and “2” for the emergency brake Y2.

To check the brakes separately there is a special plug “P”. This plug is supplying DC power, when the
electric chain hoist is ready for operation.

•

Check the operation brake Y1:

Open connector “2“ and connect this connector with the plug marked with “P”.
The emergency brake will remain open and the proper function of the operation brake can be
checked with nominal load

. Reconnect connector “2” after this procedure.

•

Check the emergency brake Y2:

Carry out the same as above but connect “P“ with supply connector “1”.
The operation brake will remain open. Now the function of the emergency brake can be checked
separately. The test has to be carried out with nominal load. The brake distance of the emergency
brake is longer than the brake distance for the operation brake.

Caution!

Reconnect the plug connectors 1

– 1 and 2 -2 after each test.

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Summary of Contents for STAGEKET

Page 1: ...perating instructions STAGEKET Electric chain hoists Please do not use the electric chain hoist before all operators have carefully read and understood this manual and signed the form on the rear cove...

Page 2: ...2 LIFTKET Hoffmann GmbH Dresdener Stra e 64 68 04808 Wurzen Germany 49 3425 89 24 0 49 3425 89 24 99 sales liftket de www liftket de Ho 08 2017 englisch Original operating instructions 2017...

Page 3: ...chain hoist 15 3 1 3 1 Hoist suspension with suspension eye 15 3 1 3 2 Hoist suspension with single hole suspension eye 16 3 1 3 3 Hoist suspension with hook suspension 17 3 1 4 Gear ventilation 18 3...

Page 4: ...ke 41 7 4 2 Replacement of the brake 42 7 5 Electric control of the brake 43 7 6 Troubleshooting on the brake 43 7 7 Functional check of the brake 43 7 7 1 Operation and emergency brake double brake 4...

Page 5: ...DIN EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems General principles for design DIN EN 60034 1 2010 Rotating electrical machines Rating and performance DIN EN 60034 5...

Page 6: ...d the dynamic forces caused by the lifting equipment The chain hoist can only be used when it is suspended according to specification and the outgoing chain can leave the hoist safely by its own weigh...

Page 7: ...initial operation before an expert or a trained specialist has inspected the equipment Do not carry out repairs without special knowledge Do not use the chain hoist with higher duty rate as marked on...

Page 8: ...tween moving and static parts There has to be a visibility of the load by the operator at any time or any movement has to be done with a second person who has visibility of the load and the operator D...

Page 9: ...simple building block system makes it easy to convert an electric chain hoists to different versions This allows the choice of single or double fall versions stationary or mobile with push or electri...

Page 10: ...in inverted use Electric chain hoists can be applied in inverted use The subsequent reconfiguration of the electric chain hoist is possible Required parts for reconfiguration order from manufacturer...

Page 11: ...box Oversize chain box with strainer strap Chain box Figure 3 Assembly options of electric chain hoists SB in normal use 2 1 4 Further completion possibilities Further completion possibilities will be...

Page 12: ...view Figure no Description 1 Hoist body 2 Gear cover 3 Cap for brake 4 Cap for gear cover 5 Brake 6 Clutch unit 7 Motor pinion shaft 8 Rotor 9 Stator 10 Sprocket wheel 3 1 10 2 4 Figure 4 Sectional v...

Page 13: ...ut by trained specialist in accordance with DGUV V54 BGV D8 24 3 1 Mechanical assembly 3 1 1 Hook tackle The hook tackle is used to attach loads for hoists in single fall version Rubber buffer with vu...

Page 14: ...ctions 3 1 2 Hook block The hook block is used to attach the load in double fall version Casing Radial ball bearing Load hook complete incl pressure bearing and hook nut Rubber buffer Sprocket wheel S...

Page 15: ...on The hole for the tandem trolley on the suspension eye must be on the chain box side Assembly The suspension eye section must be inserted into the specially provided suspension holes on the electric...

Page 16: ...ided single hole suspension eye to the special suspension holes of the electric chain hoist with suspension bolts Use washers and secure with split pins By rotating the suspension eye by 180 the singl...

Page 17: ...espective version on chain box side Assembly Fix the provided hook suspension eye to the special suspension holes of the electric chain hoist with suspension bolts Use washers and secure with split pi...

Page 18: ...d bottom oil filling screws Oil filler plug Serrated washer Figure 11 Oil filler plug 3 1 5 Chain box 3 1 5 1 Mounting the chain box Plastic chain box Canvas chain box Flip bag Figure 12 Types of chai...

Page 19: ...onditions are unknown If the hoist is fitted to a trolley the producer provides a tandem trolley to fit the chain box strainer strap see Figure 14 Take care that the strainer strap has to be tightened...

Page 20: ...ttach the rubber buffer for the lift limiter onto the remaining dead end of the chain 7 Attach the lift limiter onto the 3rd link of the dead end Figure 16 D in upright use and 0 5 m away from the end...

Page 21: ...falls 3 Loose the four screws part no 1 in Figure 18 of the chain guide than take the chain guide out of the hoist Figure 17 C and pull the U shaped fork back 4 Pull the chain end from the hook up to...

Page 22: ...ot be used regularly as an operational limit switch If the lift limiter has a vulcanised metal washer then this should be mounted towards the electric chain hoist body 3 2 Electric connections The ele...

Page 23: ...the load moves downwards swap L1 and L2 supply wires The mains supply must be turned off If the control is equipped with an emergency stop according to EN 60204 32 2008 it will be a red mushroom shape...

Page 24: ...ages are available on request If the control is equipped with an emergency stop in accordance with DIN EN 60204 32 2008 an additional contactor is also located in the control box and the emergency sto...

Page 25: ...V C1 8 Electronic overload protection to switch off lifting at more than 120 of the rated load Operating limit switch according to DGUV V17 BGV C1 8 for version with external operating limit switch Th...

Page 26: ...Therewith it is ensured that enough chain weight for moving the chain safely into the chain box is left over even if the hoist has reached its lowest lifting position Available equipment Required func...

Page 27: ...sition will be lower 3 6 2 External emergency limit switches Pin of limit switch for lowering Pin of limit switch for lifting Figure 24 External emergency limit switches Caution The emergency limit sw...

Page 28: ...ial control circuit or a computer control The standard incremental encoder provides 100 impulses per revolution Incremental encoders can be fitted additionally onto the extended shaft of a gear limit...

Page 29: ...locking nuts If the load on the hoist is less than the set value the suspension eye will swivel around one suspension bolt and activate a limit switch on the opposite side This switch cut off the powe...

Page 30: ...d sensor Figure 28 Integrated load sensor Suspension point Load centre of gravity Suspension eye with load sensor Load sensor Electric chain hoist Figure 29 Suspension eye with load sensor Adjusting s...

Page 31: ...riteria of load sensing equipment Type Integrated load sensor Suspension eye with load sensor Benefit Additional protection against inner overload chain jam Additional protection when approaching the...

Page 32: ...rectified After actuating an emergency limit switch and switching on the power the hoist can only be operated into the opposite direction C Bridging slack chain prevention To lower load by pressing th...

Page 33: ...girder must be installed by the user Push trolley Electric trolley with low voltage control 2 4 3 5 2 3 4 1 Push trolley with one suspension bolt crane component Electric trolley with one suspension...

Page 34: ...be connected with a distance rod to prevent a collision of the trolleys Electric chain hoists with motorised horizontal movements Please make sure that only trolleys or other machines are used which...

Page 35: ...Tightening torque Nm M16 1 5 75 Nm M22 1 5 150 Nm M36 1 5 560 Nm Table 7 Tightening torques Figure 34 Flexibility between chain hoist and trolley Caution Movement in the directions shown by the arrows...

Page 36: ...ns with two step switches Low voltage control The contactors for switching the trolley motor are located in a contactor box The contactor box must be assembled with two hexagon socket head cap screws...

Page 37: ...al Control Association T V are considered to be qualified to test cranes Trained specialists are highly qualified specialist personnel or the manufacturer s after sales service personnel 6 4 Additiona...

Page 38: ...imated they may have to be shortened due to hard operating conditions two or three shifts high percentage of work with nominal load dusty or high temperature environment this maintenance work has to b...

Page 39: ...for brake 5 Remove cap for brake 6 Loose the three fastening screws of brake unit 7 Remove worn out brake unit from the hub 8 Fit new brake unit onto the motor shaft 9 Fit the brake unit using the th...

Page 40: ...embly works should be done without load The electric chain hoist should be completely disconnected from power Power off 1 Loose screws of cap for gear cover 2 Remove cap 3 Disconnect brake cables 4 Lo...

Page 41: ...te type of the electric chain hoist has to be submitted Casing Motor shaft with hubs clutch spring and nuts Operation brake Emergency brake Fastening screws Figure 40 Assembly of the brake 7 4 Double...

Page 42: ...olts still remain in the motor cover 8 Remove worn out brake unit 9 Fit new double brake unit onto the motor shaft 10 Fit the brake unit using the self locking nuts 11 Tighten the nuts evenly tighteni...

Page 43: ...zero Coil has contact to ground or between the windings Replace the brake Wiring wrong or defect Check and correct wiring Rectifier defective or wrong Compare wiring at rectifier with wiring diagram...

Page 44: ...the emergency brake is longer than of the operation brake Separate test of the operation and emergency brake DGUV V17 BGV C1 only The DC supply of both magnetic coils are equipped with a plug connect...

Page 45: ...ment of the load will be prevented because the load can be held at every lifting point by the brake The clutch unit acts as a dry clutch with asbestos free linings The clutch is easily adjustable and...

Page 46: ...lectric chain hoist 13 12 11 8 Tag on the magnetic coil of the brake Figure 45 Adjustment of friction torque of the sliding clutch The sliding clutch is set with the test load by the manufacturer Afte...

Page 47: ...mbly group Caution The assembly has to be done in reversed order 7 10 Load chain Hoist chains are means of load carrying which require official approval It is therefore important to observe the guidel...

Page 48: ...dimensions Chain dimensions mm mm 4 12 5 15 5 2 15 7 22 7 2 21 Nominal diameter of link d in mm 4 5 5 2 7 7 2 Wear limit of diameter dm in mm 3 6 4 5 4 7 6 3 6 5 Length over 1 link t in mm 12 15 15 2...

Page 49: ...Construction of the brake type EFB Caution If the brake linings are worn so that the air gap is about 0 9 mm it is necessary to adjust the gap Readjustment of the brake type EFB 1 Dismantle the fan co...

Page 50: ...ifficult in practice to take note of the duty rate during the lifting operation We therefore give the following practical guidelines 8 1 Short time duty This duty type is not permissible for the slowe...

Page 51: ...load 20000 kg transported load After 30 minutes of operating time 1 5 minutes break for each minute of operating time must be taken i e 3 times the operating time This break is usually necessary for...

Page 52: ...lubrication The oil must be changed during general overhaul of the electric chain hoist in case of visible leakages in case of excessive breathing out of the gear vent after each opening of the gear...

Page 53: ...f the electric chain hoist the chain links must be lubricated over the whole length of the chain by a creeping gear oil Lubrication of chain Lubricate chain without load Lubricate the shaded areas of...

Page 54: ...bearings Supplier Lubricant Fuchs Renolit Duraplex EP2 EP3 Fuchs Lagermeister LX EP2 Table 1 Lubricants of bearings 11 4 Trolley Caution The gear pinion and the geared wheels of the electric trolley h...

Page 55: ...55 13 Example of Declaration of Conformity...

Page 56: ...56 14 Example of Declaration of Incorporation...

Page 57: ...57...

Page 58: ...d by appropriate skilled and qualified operators Further information about other operational conditions is not considered herewith In case of any deviations to the normal operations such as unusual no...

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