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8

TROUBLESHOOTING

8.1

Troubleshooting instructions

Problem

Possible cause

Solution

The hoist does not work.

The emergency stop button is
activated.

Deactivate the emergency stop
button.

A fuse is triggered.

Check the fuse for the main power
supply. Check the control voltage
fuse. For instructions on how to
check or replace the control voltage
fuse, see chapter Replacing the
control voltage fuse.

The temperature control (optional)
is activated.

Allow the system to cool.

The contactor terminal screws are
loose (only with the hard wired
control version).

Tighten the screws.

The main isolation switch is turned
off.

Turn on the main isolation switch.

The load cannot be lifted.

The hoist has an overload.

Reduce the load.

The slipping clutch is worn or
incorrectly adjusted.

Replace or adjust the slipping clutch.
For instructions, see chapter
Adjusting the slipping clutch.

The braking path

1)

is more than

10 cm (3.9 in).

The brake lining is worn.

Measure the brake lining (wear) and
replace the brake components, if
necessary. For instructions, see
chapter Checking the brake lining.

The lifting or lowering direction
does not correspond to the
direction indicated on the
controller

2)

.

The power supply is incorrectly
connected.

For the 3-phase hoist versions:
Change the two phases of the power
supply.

Abnormal noises are heard
when the load moves.

The chain components are not
correctly lubricated.

Lubricate the chain components. For
instructions, see chapter Lubrication.

The chain is worn.

Replace the chain. For instructions,
see chapter Replacing the chain.

The chain sprocket or the chain
guide is worn.

Replace the chain sprocket or the
chain guide.

The return sprocket

3)

is worn.

Replace the return sprocket.

For the 3-phase hoist versions: A
supply phase is missing (the load
moves slowly or not at all).

2)

Check the connection of the three
phases.

1)

Braking path: The distance that the load travels from the moment when the direction button on the

controller is released until the load stops completely.

OWNER’S MANUAL

This document and the information contained herein, is the exclusive property of Verlinde S.A.S and represents a non-
public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or
otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.S. Copyright 2020
© Verlinde S.A.S. All rights reserved.

6/2020

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Содержание STAGEMAKER 100618073

Страница 1: ...contained herein is the exclusive property of Verlinde S A S and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or othe...

Страница 2: ......

Страница 3: ...9 2 3 2 Prohibited use 19 2 3 3 Changes to the product 20 2 4 Safety devices 21 2 4 1 Hoist 21 2 5 Protective measures 21 2 5 1 Emergency stopping 21 2 5 2 Main isolation switch 22 2 5 3 Lockout tagou...

Страница 4: ...ioning 49 5 2 Commissioning preparations 49 5 3 Commissioning instructions 49 5 3 1 Checking the hoist before first run 49 5 3 2 Before lifting 50 5 3 3 Testing the hoist without load 51 5 3 4 Testing...

Страница 5: ...ng the chain bucket 98 7 5 2 Inspecting the chain wear 99 7 5 3 Lubrication instructions for the chain 102 7 5 4 Replacing the chain 105 7 5 5 Replacing the chain 107 7 6 Maintaining the hook 110 7 6...

Страница 6: ...linde S A S and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without t...

Страница 7: ...E Keep these instructions in a safe and accessible location for future reference The instructions must be accessible by personnel that is operating the equipment or that is exposed to the operating eq...

Страница 8: ...on switch is the power switch that the operator should normally use to turn power off or on Operator A person operating the product to handle loads Power supply The power is supplied to the motors thr...

Страница 9: ...is an entity which has been designed to perform common lifting and lowering operations within the limits that are specified by the duty class of the product see chapter Hoist duty class The hoisting...

Страница 10: ...terms under which seller s equipment and or services are warranted are defined pursuant to the warranty set forth in the contract between seller and customer for seller s products and or services and...

Страница 11: ...nical specification Data plate for CE labeled chain hoist 0 1 2 3 4 5 6 7 8 9 0 3 4 2 1 7 6 5 9 11 12 10 8 28 27 26 29 24 23 22 21 19 17 16 13 14 15 18 20 25 XXX 01 5 x 14 mm 10 0 m 16 0 m min 160 kg...

Страница 12: ...26 Motor duty rating A ratio of motor on to off time with the stated temperature 27 Reeving Number of falls 28 Designation of series or type Product type code 29 Product type Designation of the machi...

Страница 13: ...herein is the exclusive property of Verlinde S A S and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise emp...

Страница 14: ...ntial consequences Hazard symbols are indicated by a yellow triangle with black symbols and a black triangle band that is surrounded by a yellow border All personnel working on or in proximity of the...

Страница 15: ...er line hazard Noise hazard symbols Noise hazard OWNER S MANUAL This document and the information contained herein is the exclusive property of Verlinde S A S and represents a non public confidential...

Страница 16: ...always in black All personnel working on or in proximity of the equipment must understand and follow the information that is given in the prohibited action symbols Do not modify 2 1 5 Product safety...

Страница 17: ...risks Only competent persons are allowed to carry out operation and other tasks The responsibility of the owner is to Provide training and orientation Validate training methods Verify competence and...

Страница 18: ...ty to make sure that suitable and secure fixing points are available or provide an appropriate manlift If ladders must be used personnel must practice setting and securing the ladders before using the...

Страница 19: ...or handling dangerous substances consult the manufacturer or the representative of the manufacturer For example molten metal is considered a dangerous substance Examples of exceptional ambient conditi...

Страница 20: ...to the product could lead to death severe injury or property damage Always contact the manufacturer to get advance written approval for any product change or modification All modifications and correct...

Страница 21: ...es too high or low the mechanical or magnetic limit switches prevent the possible damage to the equipment When the chain stop touches the limit switch or is close to the hoist frame the limit switch i...

Страница 22: ...ed on The owner must identify and document the location and function of the main isolation switch and communicate this information to all operators NOTE Only operate the product if you know the locati...

Страница 23: ...e death severe injury or property damage Prevent the unintended release of energy by following the approved lockout tagout tryout procedures WARNING MACHINE MALFUNCTION HAZARD Operating the product wh...

Страница 24: ...dry powders or deoxygenating agents are required All personnel must be trained regularly in fire fighting methods in cooperation with local authorities and rescue organizations If there is a fire the...

Страница 25: ...ng Always follow the instructions Use appropriate personal protective equipment depending on the task To avoid hazardous situations and dangerous consequences leave all operation and maintenance work...

Страница 26: ...s separately Batteries Batteries and other energy storage components may contain hazardous substances Collect these items separately and recycle according to local regulations Plastics Recycle plastic...

Страница 27: ...tire supplier for recycling OWNER S MANUAL This document and the information contained herein is the exclusive property of Verlinde S A S and represents a non public confidential and proprietary trade...

Страница 28: ...re lifted or the distances that are traveled or both to remain within the requirements of the duty class Parameter Variables Lifting height and working distances Actual hoisting time and the average d...

Страница 29: ...ng motor 6 Slipping clutch 7 Brake single brake in the example OWNER S MANUAL This document and the information contained herein is the exclusive property of Verlinde S A S and represents a non public...

Страница 30: ...eed 160 of the rated capacity An overload slips the slipping clutch allowing the motor to continue running and preventing the hoist from taking an overload that can damage the hoist Brake torque path...

Страница 31: ...ly adapted to the chain drive NOTE To ensure a safe operation of the chain hoist it is recommended to use only a genuine chain Use a chain that is provided by the manufacturer of the chain hoist To re...

Страница 32: ...Note the following warnings that are related to the use of the manual brake release NOTE Extensive use and high lowering speed can make the brake lining wear out immediately NOTE Before using the hois...

Страница 33: ...pressing the lever and lowering the load within short intervals 3 5 2 Rotating geared limit switch The rotating geared limit switch is available as a 2 step or 4 step version The rotating geared limit...

Страница 34: ...counts the revolutions of the chain sprocket The internal gear ratio of the geared limit switch must be designed according to the total stroke of the chain hoist 3 PRODUCT DESCRIPTION This document an...

Страница 35: ...UP 1 Limit switch working DOWN stop GLS DOWN 1 2 2 step GLS microswitch or magnetic limit switch Limit switch UP stop Switch X3A 2 Limit switch DOWN stop Switch X4A 2 Slow speed UP GLS UP 1 Slow speed...

Страница 36: ...magnetic limit switch Limit switch UP stop Switch X3A 2 Limit switch DOWN stop Switch X4A 2 Slow speed UP GLS UP 1 Slow speed DOWN GLS DOWN 1 Free for customer use GLS UP 2 Free for customer use GLS D...

Страница 37: ...afety devices Be prepared in case equipment moves in the wrong direction during testing 9 Check that the supply voltage and frequency match the requirements of the equipment Check that the installed b...

Страница 38: ...n buckets that are made of hard plastic and steel It is not possible to use it with chain bags that are made of the soft canvas material NOTE Do not bundle the chain into the chain bucket 4 3 2 Tighte...

Страница 39: ...ifting device Lifting points on the hoist Lift the chain hoist from the suspension bracket If lifting points are available on the product they are marked with a sticker NOTE Before lifting the chain h...

Страница 40: ...e motor side loosen the four screws of the end cover on the motor side Remove the end cover 4 INSTALLATION This document and the information contained herein is the exclusive property of Verlinde S A...

Страница 41: ...Checks before operating 4 7 Suspending the chain hoist WARNING OVERLOAD HAZARD Overloaded components may cause malfunctions which could lead to serious injury death or damage to the product The suspe...

Страница 42: ...ook or a suspension bracket The rotating suspension hook is the standard suspension type the suspension bracket is available as an option 4 7 3 Attaching the hoist to the supporting structure WARNING...

Страница 43: ...ment and the information contained herein is the exclusive property of Verlinde S A S and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to thir...

Страница 44: ...ower supply cable that is attached to the power supply socket The short power supply cable is only a temporary cable which is not properly insulated Connecting the temporary cable to the power supply...

Страница 45: ...hase sequence Connect the yellow and green grounding wire with grounding GND 3 Slide the power supply cable assembly in place Connect the power supply plug to the power supply socket 4 Install the end...

Страница 46: ...limit switches After checking the operation of the limit switches adjust the upper and lower limits if needed To adjust the limits access the geared limit switch according to the following instructio...

Страница 47: ...e upper limit 1 and the set screw 2 is the lower limit 1 The set screw 3 is the upper limit 2 and the set screw 4 is the lower limit 2 OWNER S MANUAL This document and the information contained herein...

Страница 48: ...of the chain 5 Attach the limit stop directly behind the buffer The unloaded chain fall behind the limit stop must consist of at least five chain links 6 Place the chain in the chain bucket Attach the...

Страница 49: ...e laid down in DIN EN 12464 5 3 Commissioning instructions 5 3 1 Checking the hoist before first run Before running the commissioning tests check the following items 1 Check the supporting structure C...

Страница 50: ...the hook is in good condition and closes automatically Check that the hook forging rotates freely Measure the dimension of the hook opening of the the hook and the suspension hook Note the dimensions...

Страница 51: ...ents or operation could lead to death severe injury or property damage Only use the emergency stop button to stop the movement or operation of the product in an emergency situation 4 Check the limit s...

Страница 52: ...hat it is used as intended in all possible applications Check that the product is operated with only the maximum permissible load Check the operation of the safety devices for example by lifting an ov...

Страница 53: ...Check visually that the hoist or any other part has not been damaged in any way during commission testing Check that all tools and materials that are used during installation are removed from the hois...

Страница 54: ...ts are used for various tasks and purposes They can lift different types of loads and many different operators use them in different ways of operation The hoists are often regularly operated by non de...

Страница 55: ...ed NOTE If you press a push button for example hoist UP while the opposite direction push button is pressed for example hoist DOWN the lifting device does not change direction NOTE Sudden speed change...

Страница 56: ...the push button half way down step 1 the device accelerates until it reaches the preset slow speed If you press the push button half way down step 1 when the device moves above the preset slow speed t...

Страница 57: ...product Do not use the product outside the limits of its duty class or operating conditions NOTE If you notice any abnormal conditions or malfunctions in the product during the daily inspection repor...

Страница 58: ...move it verifies that the emergency stop button works properly 3 Check for smooth mechanical operation of each push button joystick or isolator on the controller 6 3 3 Checking the operation with the...

Страница 59: ...uipment 6 4 1 Setting up the controller WARNING UNCONTROLLED MOVEMENT HAZARD Releasing the emergency stop button and driving the hoist when it is unsafe could cause serious injury or death Never relea...

Страница 60: ...the center of gravity of the load Also make sure that the load is balanced When you begin to lift a load check that it is properly balanced before lifting it high off the ground If the load is not bal...

Страница 61: ...ock loading can occur in any situation where the load on the hoist suddenly increases or decreases The following list gives some examples on how shock loading can occur Change in the load balance can...

Страница 62: ...ed as safe to use Attaching the load The load is attached to the product with some kind of non fixed load lifting attachment The most common non fixed load lifting attachments are chains wire rope sli...

Страница 63: ...ered on the center line of the hook forging so that the load does not bend the hook shank Do not try to lift anything with the tip of the hook OWNER S MANUAL This document and the information containe...

Страница 64: ...lling forces Do not drag the load along the ground 6 OPERATION This document and the information contained herein is the exclusive property of Verlinde S A S and represents a non public confidential a...

Страница 65: ...the load WARNING MOVING LOAD HAZARD Operating the product when people are underneath or near the load could cause serious injury or death When operating the product make sure that there are no people...

Страница 66: ...to take up the slack from the chains or sling slowly before lifting the load from the ground 6 OPERATION This document and the information contained herein is the exclusive property of Verlinde S A S...

Страница 67: ...essary to avoid colliding with objects Lowering the load OWNER S MANUAL This document and the information contained herein is the exclusive property of Verlinde S A S and represents a non public confi...

Страница 68: ...not move the load before ensuring that it is properly attached to the lifting device 2 If the hoist has an alarm horn press the alarm horn push button to warn people nearby that a load is about to be...

Страница 69: ...y to use crane motions to remove the load from the hook The safety latch on the hook should prevent the load from being detached of the hook unintentionally OWNER S MANUAL This document and the inform...

Страница 70: ...e the contact points and stop the hook motion 6 6 Shutting down the equipment The following checks must be done after every working shift to ensure that the hoist is in a safe condition 1 Ensure that...

Страница 71: ...ed in these instructions could cause machine malfunction Any dismantling of the assemblies over and beyond the specified limits is forbidden Refrain from any actions that could affect the safety or in...

Страница 72: ...ersonnel that are authorized by the owner may also lubricate the product at the necessary intervals NOTE Mechanical maintenance work requires special skills and tools to ensure safe and reliable opera...

Страница 73: ...table briefly describes how it is done Record type Method Hour counter and log book The remaining DWP must be calculated in accordance with the ISO 12482 1 standard For instructions see chapter DWP c...

Страница 74: ...Load Lifting time Factor k3 Load spectrum factor 100 1 80 0 51 60 0 22 40 0 06 20 0 01 0 0 Total 100 Sum Divide by 100 Sum 100 Load spectrum factor Kmi 2 Check that the sum of the figures in the colum...

Страница 75: ...s and previous inspection intervals since the start of the design working period 2 The earlier S values S1 Si can be read from the log book For example S S1 S2 Si For example if you use S1 215 468 S2...

Страница 76: ...5 240 480 960 1920 3790 7500 40 4 280 560 1120 2240 4410 8750 30 3 320 640 1280 2560 5040 10000 20 2 360 720 1440 2880 5670 11250 10 1 400 800 1600 3200 6300 12500 0 0 1 Estimated remaining service l...

Страница 77: ...owing means A time counter keeping track of the hoist operational hours runtime Manual bookkeeping diary logbook about the use and the operating conditions of the hoist NOTE The same hoisting machiner...

Страница 78: ...thout load X Check the chain lubrication Lubrication X X Check the function of the limit switches Testing the hoist without load X 1 Check the control cable and controller housing for damage Checking...

Страница 79: ...ive Reference Hoist Check the condition of the fixing of the covers Chain Measure the wear of the chain if the hoist is in continuous use check the wear of the chain more frequently For instructions o...

Страница 80: ...Check the condition and mounting of the securing components Annual inspections of the control devices Component Objective Pendant controller Check the condition and functionality of push buttons and...

Страница 81: ...he hoist 7 4 1 Checking the suspension The suspension type of the chain hoist is either a rotating suspension hook or a suspension bracket The rotating suspension hook is the standard suspension type...

Страница 82: ...To check the brake lining of the main brake locate the brake check hole in the brake assembly 5 Measure the depth of the gap in the brake check hole with a caliper 6 Compare the measured brake wear va...

Страница 83: ...ake 1 The secondary brake is the functional brake only if the main brake is damaged and not able to hold the load 1 2 IQ BFK457 06 COMPACT 190V DC Nr 13319905 20W 2 8NM DD MM YY max 20 C xx x mm NOTE...

Страница 84: ...the control board 1 6 Remove the three screws that hold the brake in place 7 MAINTENANCE This document and the information contained herein is the exclusive property of Verlinde S A S and represents...

Страница 85: ...en the screws of the end cover to the correct tightening torque OWNER S MANUAL This document and the information contained herein is the exclusive property of Verlinde S A S and represents a non publi...

Страница 86: ...r supply network 3 Remove the end cover on the motor side For more information see chapter Removing and installing the hoist covers 4 Pull out the control board 5 When the control board is a few centi...

Страница 87: ...brake matches with the data of the original brake You can find the brake data in the sticker that is attached to the brake 9 Remove the three screws that hold the brake in place OWNER S MANUAL This do...

Страница 88: ...side 7 MAINTENANCE This document and the information contained herein is the exclusive property of Verlinde S A S and represents a non public confidential and proprietary trade secret that may not be...

Страница 89: ...static test load of 125 of the rated capacity 7 4 5 Replacing the double brake 1 If a load is attached to the hook remove it 2 Disconnect the hoist from the main power supply network 3 Remove the end...

Страница 90: ...so that the parts do not fall apart 7 MAINTENANCE This document and the information contained herein is the exclusive property of Verlinde S A S and represents a non public confidential and proprieta...

Страница 91: ...e cables 1 and 2 2 1 1 Main brake 2 Secondary brake 11 Install the end cover on the brake side For more information see chapter Removing and installing the hoist covers 12 Tighten the screws of the en...

Страница 92: ...oving and installing the hoist covers 4 Pull out the control board 5 When the control board is a few centimeters out unplug the brake cables 1 and 2 from the control board 1 Main brake 2 Secondary bra...

Страница 93: ...nt brake matches with the data of the original brake You can find the brake data in the sticker that is attached to the brake 9 Remove the three screws that hold the brake in place OWNER S MANUAL This...

Страница 94: ...rews on the brake The screws are used during transportation to keep the brake components together Remove these two screws when you have installed the new double brake NOTE The top brake is the main br...

Страница 95: ...k that the brake works normally 1 First test the brake without any load 2 Then test the brake with a dynamic test load of 110 EUR or 125 US of the rated capacity Size of the dynamic test load depends...

Страница 96: ...w and fast speed If the chain hoist cannot lift the load remove the load Turn off the power to the chain hoist Proceed to step 3 If the chain hoist is able to lift the load proceed to phase 3 in step...

Страница 97: ...to step 6 6 Turn off the power to the chain hoist 7 Install the end cover on the brake side For more information see chapter Removing and installing the hoist covers 8 Tighten the screws of the end c...

Страница 98: ...hecker Connect the leads to both ends of the fuse If you cannot hear a beep the fuse is blown Multimeter or ohmmeter Connect the leads to both ends of the fuse Set the meter at 1 If the meter shows a...

Страница 99: ...e brake is applied Inspect the chain regularly for wear rust and corrosion Check the chain links for excessive pitting corrosion nicking gouging twisting or wear If you detect increased wear or other...

Страница 100: ...1 7 2 t mm 12 8 15 9 22 4 dm min mm 3 8 4 8 6 7 1 dn Nominal link thickness dimension 7 MAINTENANCE This document and the information contained herein is the exclusive property of Verlinde S A S and r...

Страница 101: ...ediately Check also the wear on the chain guide and the chain sprocket If necessary replace the chain guide and chain sprocket NOTE If any chain link is in some way defective replace the chain NOTE A...

Страница 102: ...have enough lubricant between the chain links The lubricant grease or oil must be applied on the contact surfaces between the chain links Make sure that you add the new layer of lubrication always on...

Страница 103: ...Failing to maintain the chain can result in a failure of the chain 1 Check the proper and sufficient lubrication of the chain visually between the chain links Figure 21 Well lubricated chain OWNER S...

Страница 104: ...information see chapter Inspecting the chain wear The following table describes the suggested lubrication intervals of the chain The data is based on use of the chain hoist as an industrial indoor ap...

Страница 105: ...of the chain fall To remove the end stop open the clutch Pull out the rubber plate or the magnetic limit switch activator depending on the configuration of the chain hoist 4 Disassemble the hook bloc...

Страница 106: ...it pulls the chain inside the chain hoist 7 Reassemble the hook block 7 1 Insert the rubber plate or the magnetic limit switch activator 2 on the new chain on the hook end of the chain 7 2 Insert the...

Страница 107: ...without replacing the chain sprocket replace the chain sprocket Because of the wearing it is recommended to replace the chain sprocket every time when the chain is replaced NOTE Replacement of the cha...

Страница 108: ...he hook block You do not need to open the hook block to remove or to replace the chain 6 Remove the chain from the chain hoist by driving the motor in the direction UP 7 MAINTENANCE This document and...

Страница 109: ...the chain inside the chain hoist 8 Guide the chain through the hook block You can use the chain insertion tool to help pulling the chain through the hook block 9 Straighten the chain There may not be...

Страница 110: ...r Fitting the chain bucket 13 Perform the functional tests and the load tests Perform the functional test up and down If local regulations require it perform also the load test Pay attention to the ch...

Страница 111: ...28 75 1 13 05 40 25 1 58 08 40 25 1 58 1 47 15 1 86 1 6 49 45 1 95 5 Measure the suspension hook opening If the maximum dimension of the hook opening X of the suspension hook is greater than the init...

Страница 112: ...ings in this product are lubricated for the design working period of the equipment Under normal operating conditions there is no need to add lubricant to the bearings The following points give you adv...

Страница 113: ...t Installation Trade name and number Quantity Factory installed Mobil ATF 320 Lubricated for the design working period of the product If you must add lubricant for the hoisting gear see the following...

Страница 114: ...nterval varies from a minimum of one week to one year depending on the usage Standard lubricant Installation Trade name and number Quantity Lubricate before first run Mobilgear 600 XP 220 As required...

Страница 115: ...ection does not correspond to the direction indicated on the controller2 The power supply is incorrectly connected For the 3 phase hoist versions Change the two phases of the power supply Abnormal noi...

Страница 116: ...formation contained herein is the exclusive property of Verlinde S A S and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties alter...

Страница 117: ...are permitted to dismantle the product Owner of the product nominates a person responsible for the dismantling process This person gives instructions and monitors the process All controls must be pla...

Страница 118: ...waste oil and grease in containers that are indicated for the purpose More detailed information on chemical handling as waste can be found on the safety data sheet of the chemical The safety data she...

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