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  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

    Page 1

    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    XLXLXLXLCrane, Hoist andCrane, Hoist andCrane, Hoist andCrane, Hoist and

    Hoisting MotorHoisting MotorHoisting MotorHoisting Motorduty classificationduty classificationduty classificationduty classification

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

    Page 2

    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    INDEXINDEXINDEXINDEX

    1 INTRODUCTION1 INTRODUCTION1 INTRODUCTION1 INTRODUCTION.................................................................................................................................................................................................................................................................................................................................................................................................................................... 3333

    2 DUTY GROUPS BY FEM-STANDARD2 DUTY GROUPS BY FEM-STANDARD2 DUTY GROUPS BY FEM-STANDARD2 DUTY GROUPS BY FEM-STANDARD............................................................................................................................................................................................................................................................................................................................ 33332.1 Crane Duty Group ................................................................................................. 32.2 Hoist Duty Group.................................................................................................... 42.3 Connection between crane and hoist duty group.................................................. 4

    3 DETERMINE ONE WORK CYCLE3 DETERMINE ONE WORK CYCLE3 DETERMINE ONE WORK CYCLE3 DETERMINE ONE WORK CYCLE............................................................................................................................................................................................................................................................................................................................................ 5555

    4 DETERMINE LOAD SPECTRUM (Q)4 DETERMINE LOAD SPECTRUM (Q)4 DETERMINE LOAD SPECTRUM (Q)4 DETERMINE LOAD SPECTRUM (Q) ................................................................................................................................................................................................................................................................................................................................ 66664.1 Figure .................................................................................................................... 64.2 Calculation............................................................................................................ 8

    5 DETERMINE CRANE DUTY GROUP5 DETERMINE CRANE DUTY GROUP5 DETERMINE CRANE DUTY GROUP5 DETERMINE CRANE DUTY GROUP ................................................................................................................................................................................................................................................................................................................................ 9999

    6 DETERMINE HOIST DUTY GROUP6 DETERMINE HOIST DUTY GROUP6 DETERMINE HOIST DUTY GROUP6 DETERMINE HOIST DUTY GROUP ....................................................................................................................................................................................................................................................................................................................................11111111

    7 SAFE WORKING PERIOD (SWP) AND LIFE TIME7 SAFE WORKING PERIOD (SWP) AND LIFE TIME7 SAFE WORKING PERIOD (SWP) AND LIFE TIME7 SAFE WORKING PERIOD (SWP) AND LIFE TIME ....................................................................................................................................................................................................................................................18181818

    8 MOTOR RATING8 MOTOR RATING8 MOTOR RATING8 MOTOR RATING ............................................................................................................................................................................................................................................................................................................................................................................................................................222222228.1 Intermittent duty .................................................................................................. 228.2 Short time duty .................................................................................................... 248.3 Connection between short time and intermittent duty.......................................... 258.4 The effect of external cooling fan ........................................................................ 268.5 KCI hoisting motors .............................................................................................. 27

    9 CLASSIFICATION OF TRAVELLING MACHINERIES9 CLASSIFICATION OF TRAVELLING MACHINERIES9 CLASSIFICATION OF TRAVELLING MACHINERIES9 CLASSIFICATION OF TRAVELLING MACHINERIES ........................................................................................................................................................................................................................................28282828

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

    Page 3

    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    1111 INTRODUCTION INTRODUCTION INTRODUCTION INTRODUCTION

    This document explains the basic theory behind the criteria on how cranes andhoists are classified and calculated. The theory is based on FEM standards. Usingsimple examples the theory hopefully kept as simple as possible. Understanding andfollowing these crane and hoist design guidelines ensure that correct equipment isalways used.

    This document includes:

    - Introduction to CraneCraneCraneCrane and Hoist Duty GroupsHoist Duty GroupsHoist Duty GroupsHoist Duty Groups- Determine one Work CycleWork CycleWork CycleWork Cycle- Determine Load SpectrumLoad SpectrumLoad SpectrumLoad Spectrum (Figure/Calculating)- Determine Crane Duty GroupCrane Duty GroupCrane Duty GroupCrane Duty Group (3 steps)- Determine Hoist Duty GroupHoist Duty GroupHoist Duty GroupHoist Duty Group (7 steps)- Safe Working PeriodSafe Working PeriodSafe Working PeriodSafe Working Period (SWP)- MotorMotorMotorMotor Rating- KCIKCIKCIKCI Hoisting Motors- Duty GroupDuty GroupDuty GroupDuty Group of Travelling machineries

    2222 DUTY GROUPS BY FEM-STANDARD*) DUTY GROUPS BY FEM-STANDARD*) DUTY GROUPS BY FEM-STANDARD*) DUTY GROUPS BY FEM-STANDARD*)

    2.12.12.12.1 Crane Duty Group According to FEM standard the use of cranes is divided to crane duty groups whichare:

    A1, A2, A3, A4, A5, A6, A7, A8, A9A1, A2, A3, A4, A5, A6, A7, A8, A9A1, A2, A3, A4, A5, A6, A7, A8, A9A1, A2, A3, A4, A5, A6, A7, A8, A9.

    A1 corresponds the lightest crane use and A9 the heaviest.

    The crane duty group is determined by following factors:

    1)1)1)1) Load spectrum (Q)**)

    2)2)2)2) Class of utilization (U)***)

    *) FEM = Fdration Europene de la Manutention.

    **) Load Spectrum indicates the frequency of maximum and smaller loadings during examined time period.See chapter Determine load spectrum on page 6 for more details.

    ***) Class of utilization is determined according to number of hoisting cycles during crane life time. See chapterDetermine crane duty group, step 2/3 on page 9 for more details.

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

    Page 4

    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    2.22.22.22.2 Hoist Duty Group All KCI electric hoists are designed and rated according to FEM standards. FEMstandard is based on different use of hoist in different applications.

    According to FEM standard the use of hoists is divided to hoist duty groups whichare:

    ... M3 (1Bm), M4 (1Am), M5 (2m), M6 (3m), M7 (4m), ...... M3 (1Bm), M4 (1Am), M5 (2m), M6 (3m), M7 (4m), ...... M3 (1Bm), M4 (1Am), M5 (2m), M6 (3m), M7 (4m), ...... M3 (1Bm), M4 (1Am), M5 (2m), M6 (3m), M7 (4m), ...

    M3 (1Bm) corresponds the lightest use of hoists and M7 (4m) the heaviest.

    Hoist duty group are determined by following factors:

    1)1)1)1) Load spectrum (Q)2)2)2)2) Average operating time per day (t)*)

    3)3)3)3) Other factors

    So that the safe working period (SWP) of hoist is not exceeded.

    Hoist duty group also specifies the duty factor (ED%) and starting frequency(maximum allowed starts/h) of hoisting motors according to following table. If the dutyfactor or starting frequency of application exceeds the maximum values specified byhoist duty group. Then the starting frequency will determine required hoist group.

    Hoist GroupHoist GroupHoist GroupHoist Group M3M3M3M3(1Bm)(1Bm)(1Bm)(1Bm)

    M4M4M4M4(1Am)(1Am)(1Am)(1Am)

    M5M5M5M5(2m)(2m)(2m)(2m)

    M6M6M6M6(3m)(3m)(3m)(3m)

    M7M7M7M7(4m)(4m)(4m)(4m)

    Duty Factor 25% ED 30% ED 40% ED 50% ED 60% ED

    Max. Starts / hour 150 /h 180 /h 240 /h 300 /h 360 /h

    If the hoisting group is determined by the ED% or starts/h of hoisting motor the SWPfor complete hoist (machinery + motor) is specified by that hoist group even thoughthe SWP for machinery is longer.

    NOTE ! above is the requirement by FEM and is not how the KCI motors aredesigned. See page 27

    2.32.32.32.3 Connection between crane and hoist duty group The crane and hoist duty groups are determined separately and can be different.

    However, usually crane and hoist duty groups are calculated based on same inputvalues (life expectancy, number of work cycles, etc.).

    *) Average operating time per day means the time that hoisting motor is running. See chapter Determine hoistduty group, step 2/7 on page 11 for more details

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

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    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    3333 DETERMINE ONE WORK CYCLE DETERMINE ONE WORK CYCLE DETERMINE ONE WORK CYCLE DETERMINE ONE WORK CYCLE

    One Work Cycle in Hoisting Means One Work Cycle in Hoisting Means One Work Cycle in Hoisting Means One Work Cycle in Hoisting Means

    LiftingLiftingLiftingLifting the load or empty hook. RestRestRestRest period (can be trolley or bridge travel motion.) LoweringLoweringLoweringLowering the load or empty hook. RestRestRestRest periods (can be trolley or bridge travel motion.)

    NOTE !NOTE !NOTE !NOTE ! One work cycle does not include returning the hook back (with load orempty) to the starting position. Returning is considered as one work cycle.

    Work cycle for hoist and bridge travel can be determined in similar way.

    One work cycle is determined regardless of the loadregardless of the loadregardless of the loadregardless of the load in the hook (empty hook or fullload).

    HEIGHTHEIGHTHEIGHTHEIGHT

    HHHH

    VVVV

    TIMETIMETIMETIME

    Lifting Rest Lowering RestLifting Rest Lowering RestLifting Rest Lowering RestLifting Rest Lowering Rest

    Work cycleWork cycleWork cycleWork cycle

    On vertical axle is LIFTING HEIGHT. H is the average lifting height. On horizontal axle is TIME (not trolley travel). V is the hoisting speed.

    Starts / Work Cycle. Starts / Work Cycle. Starts / Work Cycle. Starts / Work Cycle. According to above one work cycle includes minimum 2 starts. Changing speedfrom slow speed to fast speed is not considered as one start in work cycledetermination. When number of starts (F) is calculated, FEM standard assumes an average of 6starts for each work cycle.

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

    Page 6

    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    4444 DETERMINE LOAD SPECTRUM (Q) DETERMINE LOAD SPECTRUM (Q) DETERMINE LOAD SPECTRUM (Q) DETERMINE LOAD SPECTRUM (Q)

    The load Spectrum indicates the frequency of maximum and smaller loadings duringexamined time period. Load Spectrum can be determined by

    1)1)1)1) Estimating from figure2)2)2)2) Exact calculation

    4.14.14.14.1 Figure

    LOAD SPECTRUM (Q)LOAD SPECTRUM (Q)LOAD SPECTRUM (Q)LOAD SPECTRUM (Q) PRACTICAL LOAD SPECTRUMPRACTICAL LOAD SPECTRUMPRACTICAL LOAD SPECTRUMPRACTICAL LOAD SPECTRUM

    LIGHTLIGHTLIGHTLIGHTOccasionallymaximumloading, routinelylow loading,medium deadload.

    Q1:Q1:Q1:Q1:kkkkpppp 0.125 0.125 0.125 0.125k k k k 0.50 0.50 0.50 0.50 Time %

    Load

    %

    100%

    33%10%

    10 40 50

    100%LL

    33%LL

    33%LL

    33%LL

    33%LL

    10%DL

    10%DL

    10%DL

    10%DL

    10%DL

    MEDIUMMEDIUMMEDIUMMEDIUMMore oftenmaximumloading, routinelylow loading,medium deadload.

    Q2:Q2:Q2:Q2:0.125 < k0.125 < k0.125 < k0.125 < kpppp 0.2500.2500.2500.2500.5 < k 0.5 < k 0.5 < k 0.5 < k 0.63 0.63 0.63 0.63 Time %

    Load

    %

    100%

    47%

    20%

    17 50

    73%

    17 17

    100%LL

    100%LL

    73%LL

    73%LL

    47%LL

    10%DL

    10%DL

    10%DL

    10%DL

    10%DL

    HEAVYHEAVYHEAVYHEAVYFrequentlymaximumloading, routinelymedium loading,large dead load.

    Q3:Q3:Q3:Q3:0.250 < k0.250 < k0.250 < k0.250 < kpppp 0.5000.5000.5000.5000.63 < k 0.63 < k 0.63 < k 0.63 < k 0.80 0.80 0.80 0.80

    Load

    %

    100%

    40%

    5050Time %

    100%LL

    100%LL

    100%LL

    100%LL

    100%LL

    40%DL

    40%DL

    40%DL

    40%DL

    40%DL

    VERYVERYVERYVERYHEAVYHEAVYHEAVYHEAVYRegularly maxi-mum loading,very large deadload.

    Q4:Q4:Q4:Q4:0.500 < k0.500 < k0.500 < k0.500 < kpppp 1.0001.0001.0001.0000.80 < k 0.80 < k 0.80 < k 0.80 < k 1.00 1.00 1.00 1.00

    Load

    %

    100% 80%

    1090Time %

    100%LL

    100%LL

    100%LL

    100%LL

    100%LL

    100%LL

    100%LL

    100%LL

    100%LL

    80%DL

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

    Page 7

    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    In the figure on previous page:

    LLLLLLLL = Live load.

    DLDLDLDL = Dead load. Dead load can be:

    1)1)1)1) Empty hook, or2)2)2)2) Hook + load, or 3)3)3)3) Hook + load carrying attachment.

    kp = Spectrum Factor*)

    k = Cubic Mean Value**)

    On vertical axis is LOAD (100% = rated load)

    On horizontal axis total hoisting TIME (100%100%100%100%).

    ExampleExampleExampleExample.

    - Load Spectrum = Light. Rated load = 10 ton. You can lift:

    - 10 ton 10% of total hoisting time

    - 3,3 ton 40% of total hoisting time

    - less than 1 ton (empty hook) 50% of hoisting time.

    *), **) k and kp are calculated from same basic values (kp = k3)

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

    Page 8

    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    4.24.24.24.2 Calculation Load Spectrum can be determined by calculating

    1)1)1)1) kp (= Spectrum Factor) or2)2)2)2) k (= Cubic Mean Value).

    Both kp and k are calculated from same basic information => kkkkpppp = (k) = (k) = (k) = (k)3333

    The kp (= Spectrum Factor) is calculated from following formula:

    p

    31 1

    32 2k = (

    mm

    ) nn

    + ( mm

    ) nn

    + ...max max max max

    A

    m1, m2, m3, m4... is the actual variable lifted load.

    mmax is the rated load.

    n1, n2, n3, n4... is the actual variable number of lifts.

    nmax is the total number of lifts.

    Example.Example.Example.Example.

    10 ton Crane (mmax = 10)

    - Loads lifted during one week (for example)

    mmmm1,2,3,41,2,3,41,2,3,41,2,3,4 nnnn1,2,3,41,2,3,41,2,3,41,2,3,4m1 = 1 tonne n1 = 100 timesm2 = 3.2 tonne n2 = 100 timesm3 = 5 tonne n3 = 30 timesm4 = 10 tonne n4 = 30 times

    Total number of lifts 260 times (nmax = 260)

    p

    3 3 3 3

    k = (1

    10)

    100260

    + (3,210

    ) 100260

    + (5

    10)

    30260

    + (1010

    ) 30

    260 = 0,176 B

    => Calculated load spectrum value is 0.125 < kp 0.250 (see figure onpage 8).

    => Calculated load spectrum is Q2Q2Q2Q2 (MEDIUM) (MEDIUM) (MEDIUM) (MEDIUM) during examined one week.

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

    Page 9

    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    5555 DETERMINE CRANE DUTY GROUP DETERMINE CRANE DUTY GROUP DETERMINE CRANE DUTY GROUP DETERMINE CRANE DUTY GROUP

    The crane duty group is determined by following factors:1)1)1)1) Load spectrum (Q),2)2)2)2) Class of utilization (U),

    STEP 1/3.STEP 1/3.STEP 1/3.STEP 1/3. Load Spectrum (Q). Load Spectrum (Q). Load Spectrum (Q). Load Spectrum (Q).

    Load spectrum is selected from figure or by calculating from pages 6 and 8.

    STEP 2/3.STEP 2/3.STEP 2/3.STEP 2/3. Class of Utilization (U). Class of Utilization (U). Class of Utilization (U). Class of Utilization (U).

    Class of Utilization is determined according to number of hoisting cycles (n) duringthe lifetime of crane. Crane lifetime can be determined according to customer'srequirements. In following example the life time of crane is 15 years.

    The number of hoisting cycles is calculated by following method.

    Example.Example.Example.Example.

    Loading cycles per hour Loading cycles per hour Loading cycles per hour Loading cycles per hour 30303030 Working hours / day (1-shift) Working hours / day (1-shift) Working hours / day (1-shift) Working hours / day (1-shift) 8888 Working days / week Working days / week Working days / week Working days / week 5555 Working weeks / year Working weeks / year Working weeks / year Working weeks / year 48484848 Lifetime in years Lifetime in years Lifetime in years Lifetime in years 15151515

    30 x 8 x 5 x 48 x 15 30 x 8 x 5 x 48 x 15 30 x 8 x 5 x 48 x 15 30 x 8 x 5 x 48 x 15 n = 864 000 cycles n = 864 000 cycles n = 864 000 cycles n = 864 000 cycles

    The Class of Utilization is selected from following table.

    U0U0U0U0 < nmax 16 000

    U1U1U1U1 16 000 < nmax 32 000

    U2U2U2U2 32 000 < nmax 63 000

    U3U3U3U3 63 000 < nmax 125 000

    U4U4U4U4 125 000 < nmax 250 000

    U5U5U5U5 250 000 < nmax 500 000

    U6U6U6U6 500 000 < nmax 1 000 000

    U7U7U7U7 1 000 000 < nmax 2 000 000

    U8U8U8U8 2 000 000 < nmax 4 000 000

    U9U9U9U9 4 000 000 < nmax

    Class of Utilization selection U6U6U6U6 (500 000 - 1 000 000).

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

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    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    STEP 3/3.STEP 3/3.STEP 3/3.STEP 3/3. Crane Duty Group. Crane Duty Group. Crane Duty Group. Crane Duty Group.

    Crane Duty Group is selected from following table.

    Load SpectrumLoad SpectrumLoad SpectrumLoad Spectrum Class of Utilization Class of Utilization Class of Utilization Class of Utilization (U)(U)(U)(U)

    (Q)(Q)(Q)(Q) U0U0U0U0 U1U1U1U1 U2U2U2U2 U3U3U3U3 U4U4U4U4 U5U5U5U5 U6U6U6U6 U7U7U7U7 U8U8U8U8 U9U9U9U9

    (Q1) LIGHT(Q1) LIGHT(Q1) LIGHT(Q1) LIGHT A1 A1 A1 A2 A3 A4 A5 A6 A7 A8

    (Q2) MEDIUM(Q2) MEDIUM(Q2) MEDIUM(Q2) MEDIUM A1 A1 A2 A3 A4 A5 A6 A7 A8 A8

    (Q3) HEAVY(Q3) HEAVY(Q3) HEAVY(Q3) HEAVY A1 A2 A3 A4 A5 A6 A7 A8 A8 A8

    (Q4) VERY HEAVY(Q4) VERY HEAVY(Q4) VERY HEAVY(Q4) VERY HEAVY A2 A3 A4 A5 A6 A7 A8 A8 A8 A8

    Example.Example.Example.Example.

    Load spectrum selection MEDIUMMEDIUMMEDIUMMEDIUM.

    Class of Utilization selection U6U6U6U6.

    Crane Group selectionCrane Group selectionCrane Group selectionCrane Group selection A6A6A6A6.

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

    Page 11

    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    6666 DETERMINE HOIST DUTY GROUP DETERMINE HOIST DUTY GROUP DETERMINE HOIST DUTY GROUP DETERMINE HOIST DUTY GROUP

    Hoist duty group is determined by following factors:1)1)1)1) Load spectrum (Q),2)2)2)2) Average operating time per day (t),3)3)3)3) Other factors

    STEP 1/7.STEP 1/7.STEP 1/7.STEP 1/7. Load Spectrum (Q). Load Spectrum (Q). Load Spectrum (Q). Load Spectrum (Q).

    Load spectrum is selected from figure or by calculating from pages 6 and 8.

    STEP 2/7.STEP 2/7.STEP 2/7.STEP 2/7. Average Operating Time per Day (t). Average Operating Time per Day (t). Average Operating Time per Day (t). Average Operating Time per Day (t).

    Average operating time per day means the time that hoisting motor is running.

    It is calculated according to following formula.

    t = 2 x H x N x TV x 60

    C

    HHHH Average hoisting height [m]Average hoisting height [m]Average hoisting height [m]Average hoisting height [m] The average height the load is lifted during ahoisting cycle. Selected according to working cycle see figure on page 5.

    NNNN Number of work cycles [cycles/h]Number of work cycles [cycles/h]Number of work cycles [cycles/h]Number of work cycles [cycles/h] One work cycle is determined by figureon page 5. Normally 15 cycles/h means light use and 60 cycles/h almostcontinuous use.

    TTTT Daily working time [h]Daily working time [h]Daily working time [h]Daily working time [h] Daily total working time of hoist including restperiods. For example 8 h = one shift, 16 h two shifts, 24 h = continuous.

    VVVV Hoisting Speed [m/min]Hoisting Speed [m/min]Hoisting Speed [m/min]Hoisting Speed [m/min] Hoisting speed using fast speed. If hoist is usedlong times with slow speed it must be taken into consideration. See step 4/7on page 13.

    Example.Example.Example.Example.

    H = 3 m N = 30 cycles/h T = 8 h V = 6,3 m/min

    =>t = 2 x H x N x T

    V x 60 = 2 x 3 x 30 x 8

    6,3 x 60 = 3,8 h / day D

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    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    STEP 3/7.STEP 3/7.STEP 3/7.STEP 3/7. Hoist Duty Group. Hoist Duty Group. Hoist Duty Group. Hoist Duty Group.

    Hoist Duty Group is determined from following table

    Load SpectrumLoad SpectrumLoad SpectrumLoad Spectrum Average operating time per day (t) [h/day]Average operating time per day (t) [h/day]Average operating time per day (t) [h/day]Average operating time per day (t) [h/day]

    (Q1) LIGHT (Q1) LIGHT (Q1) LIGHT (Q1) LIGHT t 2 2 < t 4 4 < t 8 8 < t 16 16 < t 24

    (Q2) MEDIUM(Q2) MEDIUM(Q2) MEDIUM(Q2) MEDIUM t 1 1 < t 2 2 < t 4 4 < t 8 8 < t 16

    (Q3) HEAVY(Q3) HEAVY(Q3) HEAVY(Q3) HEAVY t 0,5 0,5 < t 1 1 < t 2 2 < t 4 4 < t 8

    (Q4) VERY HEAVY(Q4) VERY HEAVY(Q4) VERY HEAVY(Q4) VERY HEAVY t 0,25 0,25 < t 0,5

    0,5 < t 1 1 < t 2 2 < t 4

    Hoist GroupHoist GroupHoist GroupHoist Group M3 (1Bm) M3 (1Bm) M3 (1Bm) M3 (1Bm) M4 (1Am)M4 (1Am)M4 (1Am)M4 (1Am) M5 (2m)M5 (2m)M5 (2m)M5 (2m) M6 (3m)M6 (3m)M6 (3m)M6 (3m) M7 (4m)M7 (4m)M7 (4m)M7 (4m)

    Duty Factor 25% ED 30% ED 40% ED 50% ED 60% ED

    Max. Starts / hour 150 /h 180 /h 240 /h 300 /h 360 /h

    Instruction:Instruction:Instruction:Instruction:

    Select the Load Spectrum Type (Figure or calculation, see earlier stages). Follow that LoadSpectrum line to the right, across the table and compare your Average Operating Time PerDay value (t) to the limits in the table. Stop where your calculated value (t) is between thelimits. Move down that same column to get your Hoist Group, Duty Factor and Max. Starts /h.

    Example.Example.Example.Example.

    Load spectrum selection MEDIUMMEDIUMMEDIUMMEDIUM (Example).

    Average operating time per day calculation t = 3.8 h/day.t = 3.8 h/day.t = 3.8 h/day.t = 3.8 h/day.

    Hoist Group selectionHoist Group selectionHoist Group selectionHoist Group selection M5 (2m).M5 (2m).M5 (2m).M5 (2m).

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    XL Sales ManualFEM Duty Classification

    KCI KONECRANES GROUPKCI HOISTS CORPORATION

    STEP 4/7.STEP 4/7.STEP 4/7.STEP 4/7. Duty Factor ED%. Duty Factor ED%. Duty Factor ED%. Duty Factor ED%.

    If considerable time for hoist operation time is for example running the hoistingmotor with slow hoisting speed it will result excessive hoisting motor heating and mustbe taken into consideration when determine Hoist Duty Group.

    The hoisting motor ED% determines how many % of a certain time (10 min) themotor can run (fast + slow speed). See chapter Motor Rating in page 22 for moredetails.

    The total running time the motor is allowed to run maximum. 33% slow speed and67% with fast speed. Hence we get a table for maximum continuous motor running inintermittent dutyintermittent dutyintermittent dutyintermittent duty use by FEM Standard.

    TOTALTOTALTOTALTOTAL Fast SpeedFast SpeedFast SpeedFast Speed Slow SpeedSlow SpeedSlow SpeedSlow Speed25% ED 2.5 min 1.7 min 0.8 min30% ED 3 min 2 min 1 min40% ED 4 min 2.7 min 1.3 min50% ED 5 min 3.3 min 1.7 min60% ED 6 min 4 min 2 min

    In Intermittent dutyIntermittent dutyIntermittent dutyIntermittent duty the examined time period is long ( hours, days..). this long timeperiod is divided into short 10 minute periods which are examined individually. Withinthe 10 minutes period the hoisting motor can run as shown in the above table. Thenmotor running is interrupted and the motor rests the remaining time in this 10 minuteperiod and allowed to cool down. These 10 minutes periods can be put one afteranother and the motor can be running accordingly as long as the SWP is finished if thenumber of motor starts are within the limits of the hoist duty group.

    In Short time dutyShort time dutyShort time dutyShort time duty the examined time period is short (minutes). Motor is runningcontinuously until running is interrupted. Then motor rests a long period (hours) to coolback to room temperature before it can be run again in short time duty.

    If the motor running time in intermittent dutyintermittent dutyintermittent dutyintermittent duty is longer than defined by ED% aboveyou must select new ED% and through that new Hoist Duty Group according to youractual motor running time.

  • 28.10.1999 KHH SAENXL08.BKCI Hoists Corporation reserves the right to alter or amend the above information without notice

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    NOTE !NOTE !NOTE !NOTE !

    All KCI hoisting motors are rated for minimum 40% ED for intermittent dutyintermittent dutyintermittent dutyintermittent duty. Hoistingmotors that are cooled down to room temperature can run continuously in short timeshort timeshort timeshort timedutydutydutyduty 15 minutes in fast speed or 10 minutes in slow speed. After short time dutyoperation motor must be cooled back to room temperature before it can be runagain in short time duty.

    Special applications with repeatedrepeatedrepeatedrepeated long continuous motor running times (e.g. verylong lifting heights) must be selected according to intermittent duty, not according toshort time duty.

    See chapter Motor Rating on page 22 for more details.

    Example.Example.Example.Example.

    - You calculated in steps 1 through 3 that the required Hoist Duty Group for theapplication is for example M4 (1Am) which defines 30% ED and total daily motorrunning time t 2 hours in Load Spectrum MEDIUM (Q2). (See table on page 12)

    - Hoist will be used through your 8 hour daily working time.

    - You estimate that the motor is running approximately. 3.5 minutes in every 10 minuteperiod in your normal daily use. 30% ED allows you to run the hoisting motor only 3minutes in every 10 minute period. Since KCI hoisting motors are designed for 40% EDthey will allow 4 min. continuous running. This means that M4 (1am) Hoist Group issufficient to guarantee proper operation of the hoist.

    - If you run the hoisting motor as above 3.5 minutes in every 10 minutes periodthrough your 8 hour working day the motor is running total 3.5 x 6 x 8 = 168 min = 2,8hours in a day. The maximum allowed total motor running time (t) for this LoadSpectrum (MEDIUM) is 2 hours which is less than in your application. This means thateven it is allowed to run the hoisting motor 3.5 minutes in every 10 minutes periodthrough a certain time period the maximum allowed total motor running times per dayshould not be exceeded. You have following choices to guarantee proper operationof the hoist:

    1) Reduce the length of the working day from 8 to 5,7 hours.2) Reduce the motor running time from 3,5 to 2,5 minutes in every 10 minutesperiod.3) Reduce the load spectrum from MEDIUM (Q2) to LIGHT (Q1) (max 4 hours aday).4) Change Hoist Duty group from M4 (1Am) to M5 (2m).

    - You also estimate that once a month (not your daily routine) you have to operate thehoist 4.5 minutes continuously when positioning a bigger piece.

    - Viewing the table on previous page you notice that 4,5 minutes continuous motorrunning is more than allowed for 30% ED and 40% ED motors.

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    - Since this situation only takes place once a month and so can be called short timeduty it is allowed to exceed the intermittent duty continuous motor running times if youcool down your motor to room temperature before starting to position the biggerpiece and also after positioning before running the motor again.

    - Since all KCI hoisting motors withstand 10 minutes continuous running in slow speedin short time duty it is not necessary to change the motor and hoist duty group.

    - If positioning the bigger piece (4,5 min total motor running) takes place once a dayit can not be considered as short time duty anymore. In this case you have to select amotor with 50% ED (max. 5 min) and through that Hoist Group M6 (3m) to guaranteeproper operation of the hoist.

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    STEP 5/7.STEP 5/7.STEP 5/7.STEP 5/7. Starts / h (F). Starts / h (F). Starts / h (F). Starts / h (F).

    Number of starts per hour is calculated according to following formula.

    F = 6 x NF = 6 x NF = 6 x NF = 6 x N

    WhereWhereWhereWhere

    F = Number of starts per hour6 = Six starts per work cycle according to FEM is assumed (see page 4).N = Work cycles per hour (see page 4.)

    ExampleExampleExampleExample

    - According to steps 1 through 3 we selected number of work cycles per hour is N = 30.

    - This gives us F = 6 x N = 6 x 30 = 180 starts/h.

    - Our calculated Hoist Group was M5 (2m). For that Hoist Group 240 starts perhour is allowed.

    - Our calculated starts/h is 180, which is less than 240.

    - This means that the motor and Hoist Group is suitable.

    If the operation of hoist requires more starts than assumed by FEM in abovecalculation (6 starts/cycle) you have to take that into consideration when calculating F= starts/h.

    If your calculated starts/h are above the max. starts/h stated by FEM in calculatedHoist Group you must select new Hoist Group through to your new starts/h.

    ExampleExampleExampleExample

    - You estimate that positioning a bigger piece to a machine requires 9 starts each time.

    - Calculate the starts per hour (the work cycle is the same N = 30).

    - New number of starts/h is F = 9 x N = 9 x 30 = 270 starts/h.

    - Our calculated Hoist Group was M5 (2m). For that Hoist Group 240 starts perhour is allowed.

    - Our calculated starts/h is 270, which is more than 240.

    - This means that you have to change Hoist Group from M5 (2m) to M6 (3m),which allows 300 starts/h.

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    STEP 6/7.STEP 6/7.STEP 6/7.STEP 6/7. Heat. Heat. Heat. Heat.

    Hoist Group calculation is based on normal weather conditions when operatingtemperature is maximum +40C (104F).

    For ambient temperatures between +40C (104F) and +55C (130F) you mustselect one step higher Hoist Group.(If calculated above M5 (2m), change to M6 (3m)).

    For ambient temperatures between +55C (130F) and +65C (150F) you mustselect two steps higher Hoist Group.(If calculated above M5 (2m), change to M7 (4m)).

    XL hoists should not be operated without special modification in temperatures over+65C (150F).

    STEP 7/7.STEP 7/7.STEP 7/7.STEP 7/7. FINAL Combination. FINAL Combination. FINAL Combination. FINAL Combination.

    Final FEM Group selection is a combinationcombinationcombinationcombination of

    1)1)1)1) Calculated Hoist Group (steps 1 through 3)

    2)2)2)2) Other factors (steps 4 through 6).

    All other factors raise the FEM group individually. All other factors raise the FEM group individually. All other factors raise the FEM group individually. All other factors raise the FEM group individually.

    Example:Example:Example:Example:

    - Calculated Hoist Group = 2m2m2m2m

    and - Operating Temperature +55C+55C+55C+55C => one Hoist Group higher => 3m3m3m3m

    and - Calculated 270 starts/h270 starts/h270 starts/h270 starts/h => one Hoist Group higher => 4m4m4m4m

    and so on....

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    7777 SAFE WORKING PERIOD (SWP) AND LIFE TIME SAFE WORKING PERIOD (SWP) AND LIFE TIME SAFE WORKING PERIOD (SWP) AND LIFE TIME SAFE WORKING PERIOD (SWP) AND LIFE TIME

    Previously all hoists were given an expected lifetime (normally 10 or 15 years).Regardless how the hoist is used during that period it was expected to last with normalmaintenance through out that time without major repairs or checking. Just recently anew FEM Standard was issued. In that standard the expected life time of hoist wasreplaced by Safe Working Period, which is calculated according to actual use of thehoist, not only by calendar time. The new standard applies only to hoists. The cranesteel structure is still calculated by expected lifetime even if it is called SWP in thisdocument.

    The total life time of hoist is divided into a number of Safe Working Periods (SWP). SWP(theoretical service life) is calculated in hours. The length of SWP is calculated by aformula based on the combination of actual lifted load and operating (running) time.This means that one SWP hour does not correspond to actual operating (running)This means that one SWP hour does not correspond to actual operating (running)This means that one SWP hour does not correspond to actual operating (running)This means that one SWP hour does not correspond to actual operating (running)hour.hour.hour.hour.

    The FEM standard defines the SWP (theoretical service life D) for different Hoist Groups(with k value = 1) as follows.

    Hoist GroupHoist GroupHoist GroupHoist Group M3M3M3M3(1Bm)(1Bm)(1Bm)(1Bm)

    M4M4M4M4(1Am)(1Am)(1Am)(1Am)

    M5M5M5M5(2m)(2m)(2m)(2m)

    M6M6M6M6(3m)(3m)(3m)(3m)

    M7M7M7M7(4m)(4m)(4m)(4m)

    Theoretical service life(D) SWP [hours]

    400 800 1600 3200 6300

    When hoist is new the theoretical service life of the hoist is determined by the HoistGroup from the above table and hoist is given the SWP (e.g. 1600 hours). When thehoist is used the remaining theoretical service life is reduced until it reaches value 0(zero). This can take anything from 1 to 100 years depending on how accurately hoistis used according to it's design criteria. (Hoist Group, Load Spectrum Q, running timeper day, See following page).

    When value 0 (zero) is reached the hoist is not allowed to be used, until it isinspected in detail (not by routine maintenance). This detailed inspection is calledGeneral Overhaul (GO) and is normally carried out by official KCI service agents. AfterGeneral Overhaul is done new theoretical service life (SWP) is given to the hoist.

    Since the Safe Working Period depends on the Hoist Group choosing it correctly hasbig influence on the length of actual SWP of hoist.

    For example if the hoist was manufactured to Hoist Group M3 (1Bm) (SWP = 400h) and the hoist is actually used according to Hoist Group M5 (2m) service theSWP will reach value 0 (zero) after 2,5 years of service [(400h/1600h) x 10 years] !!!

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    The theoretical service life (SWP) table is based on 10 years10 years10 years10 years expected Safe WorkingPeriod for new hoists. This means that the SWP value 0 (zero) is reached after 10 yearsof service if the hoist is used at that Load Spectrum and Hoist Group as originallyselected. The 10 years expected SWP can be displayed for various Load Spectrum and HoistsGroups as follows. Compare this table to "Selecting Hoist Group" on page 11.

    Hoist GroupHoist GroupHoist GroupHoist Group M3 (1Bm)M3 (1Bm)M3 (1Bm)M3 (1Bm) M4 (1Am)M4 (1Am)M4 (1Am)M4 (1Am) M5 (2m)M5 (2m)M5 (2m)M5 (2m) M6 (3m)M6 (3m)M6 (3m)M6 (3m) M7 (4m)M7 (4m)M7 (4m)M7 (4m)

    Load spectrumLoad spectrumLoad spectrumLoad spectrum Theoretical service life (D) [hours]

    (Q1) LIGHT(Q1) LIGHT(Q1) LIGHT(Q1) LIGHTkp 0.125

    3200t 2

    63002 < t 4

    125004 < t 8

    250008 < t 16

    5000016 < t 24

    (Q2) MEDIUM(Q2) MEDIUM(Q2) MEDIUM(Q2) MEDIUMkp 0.25

    1600t 1

    32001 < t 2

    63002 < t 4

    125004 < t 8

    250008 < t 16

    (Q3) HEAVY(Q3) HEAVY(Q3) HEAVY(Q3) HEAVYkp 0.5

    800t 0.5

    16000.5 < t 1

    32001 < t 2

    63002 < t 4

    125004 < t 8

    (Q4) VERY HEAVY(Q4) VERY HEAVY(Q4) VERY HEAVY(Q4) VERY HEAVYkp 1

    400400400400t 0.25

    8008008008000.25 < t

    0.5

    16001600160016000.5 < t 1

    32003200320032001 < t 2

    63006300630063002 < t 4

    The 10 years expected SWP means that for example- Hoists having hoisting Group M4 (1Am)- If it is used for HEAVYHEAVYHEAVYHEAVY (Q3) (kp = 0.5) Load Spectrum- If the hoist is used (hoisting motor running) 1111 hour a day (0.5 < t 1) the SWPexpectancy is 10 years.

    If the same M4 (1Am) hoist is used for example between 1111 and 2222 hours a day (1 < t 2) andandandand the Load Spectrum is MEDIUMMEDIUMMEDIUMMEDIUM (Q2) (kp = 0,25) the SWP expectancy is also 10years.

    If the same M4 (1Am) hoist is used for example between 1111 and 2222 hours a day (1 < t 2) andandandand the Load Spectrum is HEAVYHEAVYHEAVYHEAVY (Q3) (kp = 0,5) the SWP expectancy is now only 5years [(1600h/3200h) x 10 years]. To reach 10 years SWP expectancy in this applicationthe hoist must be manufactured to Hoist Group M5 (2m).

    You may have noticed that comparing this table and the table on previous pagethat hoistshoistshoistshoists are always given the SWP according to Load Spectrum VERY HEAVY (Q4) (k(k(k(kpppp= 1)= 1)= 1)= 1) which corresponds the heaviest hoist use. The other SWP hours are calculatedfrom these values by dividing them by kp (= Spectrum Factor) of that Load Spectrum. For example Hoist Group M4 (1Am).

    - VERY HEAVY: kp = 1 => = 800 h- HEAVY: kp = 0,5 => 800/0,5 = 1600 h- MEDIUM: kp = 0,25 => 800/0,25 = 3200 h- LIGHT: kp = 0,125 => 800/0,125 = 6300 h

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    The other Theoretical Service life values than VERY HEAVY are only reference valuesbecause when calculating the reduction of SWP (see next page) the actual LoadSpectrum is taken into consideration. The hours in above table will only tell thedifference on SWP expectancy between different Load Spectrums. For example if ahoist for HEAVY Load Spectrum is actually used according to MEDIUM load spectrumthe SWP expectancy will be doubled (e.g. 10 years to 20 years).

    The reduction of theoretical service life (the speed that SWP is approaching value 0(zero)) is calculated by following formula:

    S = f x (kS = f x (kS = f x (kS = f x (kp1p1p1p1 x T x T x T x T1111) + f x (k) + f x (k) + f x (k) + f x (kp2p2p2p2 x T x T x T x T2222) + f x (k) + f x (k) + f x (k) + f x (kp3p3p3p3 x T x T x T x T3333) + ...) + ...) + ...) + ...

    Where,

    S = Actual duration of service. This means the time (hours) that isreducing SWP (theoretical service life D), not running time.

    f = Factor which depends on the measuring method as follows:

    f = 1 If there is a recording device in the hoist that records operatingconditions (lifted load (load spectrum) and operating hours). (CU1unit !)

    f = 1,1 If the hoist is equipped with running time counter (e.g. elapsedtime counter) and the lifted load (load spectrum) is determined bythe user.

    f = 1,2 If both running time (e.g. elapsed time) and the lifted load (loadspectrum) is determined by the user.

    kp1,2,3,.. = Load spectrum factor which can be determined from figure orcalculated (see figure on pages 6 and 18)

    T1,2,3,... = Time that hoist is used (hoisting or lowering running time ONLY)

    Example:Example:Example:Example:- Hoist Group = 1Am, Hoist is equipped with elapsed time counter.

    - => Hoist was given 800 hours of SWP (theoretical service life D).

    - During ONE WEEK (can be any period) hoist is used1) by LIGHT Load Spectrum (kp = 0.125) - total hoisting and lowering time was recorded to be 10 hours - factor f = 1,1

    2) By HEAVY Load Spectrum (kp = 0.5) - total hoisting and lowering time was recorded to be 3 hours - factor f = 1,1

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    - According to previous formula during this one week period SWP is reduced

    1) S = f x (kp1 x T1) = 1.1 x (0.125 x 10) = 1.3752) S = f x (kp2 x T2) = 1.1 x (0.5 x 3) = 1.65

    - This means that- during 10 hours of LIGHT service SWP is reduced 1.375 hours- during 3 hours of HEAVY service SWP is reduced 1.65 hours- during whole week service the SWP is reduced 1.375 + 1.65 = 3.025 hours.

    - The remaining SWP is 800 - 3.025 797 hours after this ONE WEEK service.

    Hoists are long-life capital goods that are purchased for a long period of service.When selecting the hoist assumptions are made concerning Hoist Group and LoadSpectrum selection. If the hoist is not equipped with a recording device it becomesincreasingly probable that the actual service time before the general overhaul differsfrom theoretical.

    Keeping constant record of hoist operation and making manual calculations of theremaining SWP is difficult and time consuming although it should be carried out toensure best utilization of the hoist.

    Most KCI XL hoists include a Condition Monitoring Unit (CU1) which among otherfunctions calculates the remaining SWP. CU1 records every load you lift (load or emptyhook) and counts running time. The remaining SWP is calculated automatically by CU1according to the formula explained in this chapter. Using CU1 unit ensures the correcthoist condition monitoring at all times.

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    8888 MOTOR RATING MOTOR RATING MOTOR RATING MOTOR RATING

    Hoisting motors can be rated for1)1)1)1) Intermittent duty andandandand2)2)2)2) Short time duty

    8.18.18.18.1 Intermittent duty

    TemperatureTemperatureTemperatureTemperature

    Max temptemptemptemp.

    NormalNormalNormalNormalMotorMotorMotorMotorworkingworkingworkingworkingtemperaturetemperaturetemperaturetemperature

    Room temptemptemptemp.

    Motor runningrunningrunningrunning Motor coolingcoolingcoolingcoolingTimeTimeTimeTime

    STABILE TEMP.WARMINGWARMINGWARMINGWARMING UP

    10 minminminmin

    J

    Motor is at room temperature (+40C) (+104F).

    Time is divided to- Warming period

    During this period motor is gradually warming up from room temperatureuntil it reaches the maximum normal working temperature. This period canbe 1 to 4 hours.

    - Stable TemperatureDuring this period the motor temperature does not rise anymore. Maximumnormal working temperature is not exceeded even the motor running iscontinued similarly to the warming period.

    The examined time periods for motor running are 10 minutes long. These 10 minutesperiods are examined individually and can be put one after another.

    Within every 10 minute period- Motor is running andandandand- Motor is cooling (resting)

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    The ED% defines how many % of this 10 minutes period motor can run.For example 40% ED motor can run 4 minutes and it must rest 6 minutes before it canbe run again.

    The 4 minutes running does not have to be continuous (it can be 2 + 2 minutes) andin the beginning of the 10 minutes period as shown in the drawing. Motor can run theallowed time determined by ED% at any locations of the 10 minutes period as long asthe allowed number of motor starts/h is not exceeded. (See page 16.)

    From this 4 minutes running time (40% ED) motor is expected to run 33% with slowspeed and 67% with fast speed. (See page 12)

    The 10 minutes examined periods can be put one after another and motor can berun according to ED% within every 10 minutes period as long as the maximum totaldaily hoist running time (t) for that Load Spectrum is not exceeded. (see page 11).

    All KCI hoisting motors are rated for minimum 40% ED for intermittent duty withnominal load.

    If the hoist is equipped with an external fan that is running continuously it will- Increase the allowed motor running time within the 10 minutes period up to50%IE. 40% ED motor can run 4 + 2 = 6 minutes and rest 4 minutes.

    NOTE !NOTE !NOTE !NOTE !

    The motor running time in short time and intermittent duty depends on the motorloading as follows:

    - Fast speed: the bigger the load the more the motor is heating.- Slow speed: without load and with small over voltage motor heating increases.

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    8.28.28.28.2 Short time duty

    Temperature

    Max temp.

    Room temp.

    Motor running Motor coolingTime

    Normal Motor

    temperatureworking

    K

    Motor is at room temperature (+40C) (+104F).

    Motor is running continuously until it reaches the maximum allowed averagetemperature (+ 140C) (+ 284F) . The maximum short time duty running times for KCIhoisting motors are:

    - 15 min with fast speed orororor- 10 minutes with slow speed

    Motor running is interrupted.

    Motor cools back to room temperature. Depending on the motor type andconstruction and surrounding ventilation (temperature, fan), this can take from 2 to 5hours.

    Motor can run continuously for the next period (15 or 10 minutes).

    If the motor is not cooled down to room temperature and run again the continuousrunning time is naturally not as long as for cooled motor.

    If the hoist is equipped with an external fan that is running continuously it will- Not have major increase on the motor running time- Shorten the Motor cooling time up to 50%

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    8.38.38.38.3 Connection between short time and intermittent duty To achieve longest possible Short time duty running time hoisting motor ismanufactured with high heat capacity. This means that motor heats up slowly but onthe other hand also cools very slowly. (For Example the American "30 minutes" motors.)

    To achieve best possible Intermittent duty hoisting motor is manufactured for bestpossible cooling capability. This means normally that a motor heats up quickly but alsocools down quickly.

    All KCI Hoisting motors are designed to achieve efficient intermittent duty motorrunning times because normally operation of crane, excluding some specialapplications (e.g. very long lifting heights etc.), is very similar to intermittent duty withonly occasional short time duty operation peaks.

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    8.48.48.48.4 The effect of external cooling fanAll XL hoisting motors are equipped with a fan that is connected to the motor shaft.This fan will cool the motor only when the motor is rotating. Cooling ability of thestandard cooling fan fixed to motor shaft is shown on following figure.

    When the motor is rotatingcontinuously (ED=100%) the coolingability of the motor is 100%. Whenthe motor is not rotating (ED=0%) themotor is still releasing heat. Thecooling ability is now 40%.

    For example with ED 30% motor usethe cooling ability of the standardfan is 57% as shown in the figure.

    If the motor is equipped withadditional electric cooling fan that is rotating continuously even if the motor is notrotating, it's cooling ability is always 100%.

    Using the continuously cooling electric fan the improvement of the motor cooling

    ability for ED 30% motor use is 10057

    = 1.75 E This means that the motor cooling ability

    will increase 1.75 times using continuously rotating cooling fan. The above figure is forfast motor rotating speed. For slow speed the effect is even greater. In practicefollowing advantages can be achieved by adding an external cooling fan:

    1) In intermittent duty the ED% of motor can be increased by one step.(e.g. from ED 30% to ED 40%).

    2) The hoist can be used in higher ambient temperature without increasing the hoistduty group. (e.g. in ambient temperature between 40 C and 55 C the hoistnormal duty group is sufficient).

    3) Motor starts per hour can be one step higher (e.g. in Fem 1Am maximum starts/hare 180 as standard, with external fan number of starts can be increased to 240.(= Fem 2m)).

    4) When the use of the motor (=hoist) is less than 30 minutes the external fan doesnot improve the short time duty values (long continuous run), because theheating effect is too fast. However, using the external fan will shorten the motorcooling time allowing the start of the next continuous run period sooner.

    Additional electric cooling fan that can be connected to XL hoisting motors N1(MF09), N2 (MF10), N3 (MF11) and N4 (MF13). In motor size N5 (MF16) the separatecooling fan is installed as standard.

    3000 rpm motors

    (%)

    10 20 30 40 0 60 80 90 10

    10

    20

    30

    40

    50

    60

    70

    80

    90

    100

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    8.58.58.58.5 KCI hoisting motors

    To make the KCI hoisting motors withstand short and limited temporary use in Femclasses M3 (1Bm) and M4 (1Am), over the Duty class Specification and also decreasethe sensitiveness against the supply voltage fluctuation. Hoisting motors are designedaccording to the following table:

    MotorMotorMotorMotor N1 (MF09)N1 (MF09)N1 (MF09)N1 (MF09) N2 (MF10)N2 (MF10)N2 (MF10)N2 (MF10) N3 (MF11)N3 (MF11)N3 (MF11)N3 (MF11) N4 (MF13)N4 (MF13)N4 (MF13)N4 (MF13) N5 (MF16)N5 (MF16)N5 (MF16)N5 (MF16)

    FEMFEMFEMFEMClassClassClassClass

    HighSpd

    LowSpd

    TOTAL HighSpd

    LowSpd

    TOTAL HighSpd

    LowSpd

    TOTAL HighSpd

    LowSpd

    TOTAL HighSpd

    LowSpd

    TOTAL

    1Bm1Am

    ED % 27 13 40 27 13 40 27 13 40 27 13 40 27 13 40

    Starts/h 60 120 180 60 120 180 60 120 180 60 120 180 60 120 180

    2m ED % 27 13 40 27 13 40 27 13 40 27 13 40 27 13 40

    Starts/h 80 160 240 80 160 240 80 160 240 80 160 240 80 160 240

    3m ED % 33 17 50 33 17 50 33 17 50 33 17 50 33 17 50

    Starts/h 100 200 300 100 200 300 100 200 300 100 200 300 100 200 300

    4m ED % 40 20 60 40 20 60

    Starts/h 120 240 360 120 240 360

    The above table is for standard 2-speed pole change motors. If the hoisting motor isequipped with stepless speed control DynAHoist it will increase the ED% slightly.

    The standard KCI travelling machineries are normally designed to withstand FEM 2m duty.

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    9999 CLASSIFICATION OF TRAVELLING MACHINERIES CLASSIFICATION OF TRAVELLING MACHINERIES CLASSIFICATION OF TRAVELLING MACHINERIES CLASSIFICATION OF TRAVELLING MACHINERIES

    The hoist and bridge travelling machineries are classified in principle similarly tohoisting motors with the exception that the final duty group of the travelling machineryis one step lower than for hoisting motor by following figure:

    TravellingTravellingTravellingTravellingMachinery DutyMachinery DutyMachinery DutyMachinery DutyGroupGroupGroupGroup

    M3M3M3M3(1Bm)(1Bm)(1Bm)(1Bm)

    M4M4M4M4(1Am)(1Am)(1Am)(1Am)

    M5M5M5M5(2m)(2m)(2m)(2m)

    M6M6M6M6(3m)(3m)(3m)(3m)

    M7M7M7M7(4m)(4m)(4m)(4m)

    Duty Factor 20% ED 25% ED 30% ED 40% ED 50% ED

    Max. Starts / hour 120 /h 150 /h 180 /h 240 /h 300 /h

    Required travelling machinery duty group can be determined by calculating:

    1) The ED% of the travelling machinery2) Maximum starts per hour of travel motor

    The travelling machinery duty group is selected from the above table so that theintended use of the machinery is not exceeding the values in the table.

    NOTE !NOTE !NOTE !NOTE !

    Document "Tips for Crane Quotation and Erection" includes work sheets to determinecrane, hoist and travelling machinery duty groups.

    INDEXINTRODUCTIONDUTY GROUPS BY FEM-STANDARD*)Crane Duty GroupHoist Duty GroupConnection between crane and hoist duty group

    DETERMINE ONE WORK CYCLEDETERMINE LOAD SPECTRUM (Q)FigureCalculation

    DETERMINE CRANE DUTY GROUPDETERMINE HOIST DUTY GROUPSAFE WORKING PERIOD (SWP) AND LIFE TIMEMOTOR RATINGIntermittent dutyShort time dutyConnection between short time and intermittent dutyThe effect of external cooling fanKCI hoisting motors

    CLASSIFICATION OF TRAVELLING MACHINERIES