Issue August 2011

LIFTKET – wire rope winch (LSF)

Operating instructions - Orig inal -

Please do not use the wire rope winch before all operators have carefully read this manual and have signed the form on its rear cover.

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Content

1 Safety advice ........................................................................................................................................3 1.1 Advice for the use of the LIFTKET-wire rope winches ...............................................................................3 1.2 European regulations ............................................................................................................................3 1.3 Spare parts...........................................................................................................................................4

2 Technical overview................................................................................................................................5 2.1 Explanation of type designation ..............................................................................................................5 2.2 Technical data of the LIFTKET-wire rope winches ....................................................................................5

3 Assembly of the LIFTKET-wire rope winch ..............................................................................................6 3.1 LIFTKET-wire rope winch with wall bracket..............................................................................................6 3.2 LIFTKET-wire rope winch with foot support..............................................................................................7

4 Electrical connections............................................................................................................................7 4.1 Mains connection ..................................................................................................................................8 4.2 Electric connections for the pendant control ............................................................................................8 4.3 Mode of operation of the electric limit switch for lifting ..............................................................................8 4.3.1 Adjustment of the electric limit switch......................................................................................................9 4.3.2 Hazardous operations ...........................................................................................................................9

5 Directions and prohibitions for use........................................................................................................10 5.1 Directions for use ................................................................................................................................10 5.2 Prohibitions of use ..............................................................................................................................10

6 Maintenance.......................................................................................................................................10 6.1 Test and maintenance works................................................................................................................10 6.2 Replacement of the wire rope...............................................................................................................11 6.2.1 Replacement of the wire rope at the hook tackle ....................................................................................11 6.2.2 Replacement of the wire rope at the drum .............................................................................................11

7 Construction and mode of operation of the DC disk brake.......................................................................12 7.1 Construction and mode of operation of the DC disk brake.......................................................................12 7.2 Check of the BFK 457-08.....................................................................................................................13 7.3 Assembly of the DC disk brake.............................................................................................................13 7.4 Faults on the DC disk brake .................................................................................................................13

8 Lubrication .........................................................................................................................................14

9 Measures to be taken at the end of the end of the S.W.P........................................................................14

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1 Safety advice 1.1 Advice for the use of the LIFTKET-wire rope winc hes The LIFTKET-wire rope winches are designed to lift and to lower loads vertically in building and mounting trade and for different transportation tasks. Every other mode of use is prohibited and undertaken at the risk at of the operator. Refer to the manufacturer in advance for any special mode of use. The modern design of the LIFTKET-wire rope winch (LSF) guarantees safety and economic use with a high lifting speed and a high load capacity. The LSF should preferably be attached to a ceiling but it is also possible to mount these to walls with a special mounting kit (optional). The LSF is wear resistant and nearly maintenance free due to the closed oil filled gear box, the surface hardening of the toothed wheels made from high-strength steel, which are ball bearing supported. A wear resistant DC-brake ensures safe braking and holding of the load. Using the LSF to carry people is strictly prohibited ! Before initial operation, ensure that all electrical wires are connected safely, and are undamaged and that all equipment can be switched off at a main switch. It is the responsibility of the operator to ensure that all suspension points of the LSF unit are calculated to withstand the dynamic forces caused by the lifting equipment. The LSF unit can only be operated safely if correctly mounted, maintained and operated. For use of the LSF in an aggressive environment - pl ease consult the producer. The following safety advice is issued for both the maintenance and the operation of the LSF and for most standard uses. It may not necessarily cover all situations. If you are in any doubt, please contact your dealer. This manual will tell you how to operate the LSF and how to handle its suspension or its loads safely. It is compulsory to take care of the following safety advice. They may not be complete for each mode of use, please ask the producer or your local service partner if any question came up. You should keep this manual clean, complete and in a legible condition. Neither the manufacturer nor dealer accept responsibility for any damage or lack of functionality due to the following: • Carrying out inappropriate operations for a LSF • Product modification without the express authorization of the manufacturer • Inappropriate operation of the LSF • Operational errors • Failure to use the product as instructed in the manual

1.2 European regulations The basis for the assembly, first use, certification and maintenance of electric chain hoists are within Germany and within the area of the European community, the following regulations, and all recommendations of this manual. Please pay particular attention to the rules for the prevention of accidents and the statutory regulations

European Regulations

EG-Machine directive 2006/42/EG EG-Directive relating to electromagnetic compatibility 2004/108/EWG EG-electrical equipment designed for use within certain voltage limits 2006/95/EG

BGV accident prevention regulations

BGV A1 Principles of prevention BGV A3 (VBG 4) Electrical facilities and equipment BGV D6 (VBG 9) BGV accident prevention regulation for use in crane systems BGV D8 (VBG 8) BGV accident prevention regulation for electric winches, lifting and pulling equipment BGR 500 (VBG 9a) Hoisting accessories VBG 35 Wire rope winches for building trade BGV B3 (VBG 121) Noise BGG 905 Principles for checking of cranes

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Harmonized regulations

DIN EN ISO 12100-1 Safety of machinery; Basic terminology, methodology DIN EN ISO 12100-2 Safety of machinery; Technical principles and specifications EN 14492-2 Krane - Kraftbetriebene Winden und Hubwerke EN ISO 13849-1 Safety of machinery - Safety-related parts of control systems; General principles for

design EN 60034-1 Rotating electrical machines; Rating and performance EN 60034-5 Rotating electrical machines; Degrees of protection provided by the integral design of

rotating electrical machines EN 60204-32 Electrical equipment of machines; Requirements for hoisting machines EN 60529 Degrees of protection provided by enclosures (IP-Code) EN 60947-1 Low-voltage switchgear and control gear EN 61000-6-2 Electromagnetic compatibility, Immunity for industrial environments EN 61000-6-3 Electromagnetic compatibility, Emission standard for residential, commercial and light-

industrial environments EN 61000-6-4 Electromagnetic compatibility, Emission standard for industrial environments

Regulations and technical specifications

FEM 9.511 Rules for the design of series lifting equipment; Classification of mechanisms FEM 9.661 Rules for the design of series lifting equipment; Dimensions and design of rope

reeving components FEM 9.683 Series lifting equipment; Selection of hoisting and travelling motors FEM 9.751 Series lifting equipment; Power driven series hoist mechanisms; Safety FEM 9.755 Serial hoist units; Measures for achieving safe working periods DIN 15020 Teil 2, DIN 3069 Rope drives

The producers guarantee depends on consideration of these regulations and all of this manual. Please pay attention to chapter 5 especially! Other national regulations are valid for countries outside of the European community. Maintenance work for hoisting equipment has to be carried out by trained and authorised people only. The main switch has to be switched off before.

Trained specialists are highly qualified specialist personnel and have to have a theoretical training as well as long term experience in the field of winches, hoists or cranes. They have to have an excellent know-how of the special regulations and must be able to decide whether the lifting equipment is in a safe working condition or not. They have to fill in the forms of any maintenance work, repair work or test. The LSF has allowed only to be used by people who have complete knowledge of this manual; the manual should always available showing who has signed the form on the rear cover of this brochure. 1.3 Spare parts Only original spare parts must be used. The producers guarantee is given for those spare parts only. The producer cannot be held responsible for failures and breakdowns caused by use of not original or wrong spare parts.

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2 Technical overview

figure 1: layout of the LIFTKET-wire rope winch with foot support 2.1 Explanation of type designation Example: LSF 200 / 1 - 15 lifting speed [m/min] single fall version load capacity [kg] LIFTKET-wire rope winch 2.2 Technical data of the LIFTKET-wire rope winches LSF 200-15 LSF 175-19

duty group FEM 9.511 2m 2m

voltage 50 Hz, 3 phases [V] 400 400

motor power [kW] 0.55 0.55

load capacity [kg] 200 175

lifting speed [m/min] 15 19

max. lifting height [m] 100 100

wire rope- Ø DIN 3069 [mm] 5 5

min. break force of the wire rope [kN] 14.5 14.5

weight of the LSF [kg] 42 42

fuse [A] 10 10

cable for power supply [mm²] 5 G 1.5² 5 G 1.5²

intermittent duty (duty rate; starts per hour) 40% ED 120 S/h 40% ED 120 S/h

short time duty* [min] 40 40 * description of short time duty:

Short time duty means the permissible uninterrupted operating periods without cooling interval. After having reached the maximum running time a break is required and the LSF can be further used in intermittent duty mode., i.e. the LSF can be used keeping the max. duty rate.

table 1: technical data of the LIFTKET-wire rope winch

control box motor with DC brake power supply cable control pendant

rope drum actuator for electric limit switch for lifting hook tackle

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3 Assembly of the LIFTKET-wire rope winch 3.1 LIFTKET-wire rope winch with wall bracket

dimension of the fastening points

figure 2: assembly of the LIFTKET-wire rope winch with wall bracket Prepare the assembly of the LSF-wire rope winch onto the wall according to the dimensions as shown in figure 2. Assemble the LSF by the wall bracket. (Caution: The wall surface must be vertical!) Caution!

The suspension points have to be calculated to withstand the forces created by the winch with wall bracket. Screws M10 according to DIN 933 and strength class 8.8 have to be used. A tightening torque of 45 Nm is required.

Check that the rope winds properly onto the drum on initial use. If the rope winds onto one side of the drum only, please check if the winch is fitted absolutely horizontally. In case of loose rope the rope has to be wound down and after that wound up, guided by hand, so that it is tight on the drum. (Attention: Danger of injury - Use safety gloves!). Check that the whole distance covered by the load is clear of any obstructions. Check the unloaded hook to see if it moves in the directions shown by the symbols on the buttons of the control device. Run the hook carefully up to the upper hook position and check that the electric limit switch is working properly. After the limit switch has switched off lifting mode, lowering must still be possible. The electric cables must not be squeezed or pulled.

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3.2 LIFTKET-wire rope winch with foot support

dimension of the fastening points

figure 3: assembly of the LIFTKET-wire rope winch with foot support Prepare the assembly of the LSF on the wall according to the dimensions as shown in figure 3. Assemble the LSF by the wall bracket. (Caution: The wall surface must be horizontal!) Caution!

The suspension points have to be calculated to withstand the forces created by the winch with foot support. Screws M10 according to DIN 933 and strength class 8.8 to be used. A tightening torque of 45 Nm is required. (Caution: The wall surface must be horizontal!)

Test: Check the correct assembly according to point 3.1. 4 Electrical connections After installation, check that it has been done in accordance with the European regulations EN 60204-1 (20.2 and 20.3) or your national regulations. Details for this control are shown in the wiring diagram. The electric installation complies with the currently valid EN 60204 part 32. Please use the wiring diagram for your reference. All electric equipment complies with the standards DIN VDE 0100 part 726 respective EN 60204-1. The insulation class is IP 54.

supply for the motor 8 G 1.52 mains cable 4 G 1.52 cable for control pendant supply for electric limit switch in the winch casing figure 4: electrical connections

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4.1 Mains connection Work on the electric installation may only be carried out by qualified electricians. The mains power supply (main incoming line conductor) must be disconnectable at all poles by means of a mains switch (in accordance with EN 60204-1 section 5.3). Check that the mains voltage agrees with that specified on the type plate. Connect mains current supply lines and control line according to wiring diagram (if the control cable is not included in the delivery). The L1, L2, L3 and PE terminals for the mains connection are located in the separate control box. A cable 3 + PE (minimum cross section 1.5 mm²) is necessary for the connection. After connecting, press button for lifting. If the load moves downwards, interchange the L1 and L2 supply cores. Disconnect mains supply before! 4.2 Electric connections for the pendant control Connect the cable for the pendant control according to wiring diagram.

figure 5: pendant control 4.3 Mode of operation of the electric limit switch for lifting

figure 6: electric limit switch for lifting Caution!

The emergency limit switches should not be used under normal operation.

emergency stop lifting lowering

rope drum actuator for electric limit switch for lifting hook tackle

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4.3.1 Adjustment of the electric limit switch The load hook switches off the lifting motion by touching the actuator of the limit switch (see figure 6). The switch point is pre-set at the factory. The limit switch should be activated immediately after the hook touches the actuator. The switch cam is adjustable and attached to the shaft by a small threaded pin.

figure 7: winding scheme 4.3.2 Hazardous operations If the operator doesn’t switch off the lowering motion after the load has reached the ground or the winch is assembled higher than the length of rope allows, the rope could accidentally be fully released and rewound in the wrong direction. The direction of motion will no longer comply with the symbols on the buttons. An other reason for a wrong direction of motion may be, that the wire rope is trapped between loose windings / layers of the lower rope windings. In case of wrong motion direction the load will be lifted despite of the button for lowering is pressed. If the highest hook position is reached in this case, the limit switch won’t work any more and this could cause a rope or winch casing to break and the load to be dropped. If an error in the direction of motion direction of motion has been discovered, it is not permitted to continue to moving loads with the winch until the p roblem causing the malfunction has been rectified.

If the failure in direction motion is recognized during the operation, the rope must be driven back to the start point of wrong direction winding, the cause of malfunction has to be removed and after them the operation can be continued in the right direction. In case of wrong winding motion, if the hook tackle has touched the limit switch actuator, no further movement up or down will be possible. After disconnecting the power supply, the L1 and L2 wires must be interchanged to allow the hook to leave the limit switch area. The original connection must then be re-established and the problem which has led to the wrong lifting direction has to be sorted out as above.

Please ensure that the rope is wound up regularly and tightly and that the rope is undamaged (use safety gloves to tighten up the rope on the drum if loose).

Caution! When lowering the hook it is not permitted to release all rope from the drum. A minimum of four windings should remain on the drum to avoid winding in the wrong direction.

rope drum suspension plate unwinded rope

limit switch cam with threaded pin

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5 Directions and prohibitions for use 5.1 Directions for use Please solely use the LSF in accordance to the European regulations, harmonized regulations and local legislation and directives for different countries. Please pay particular attention to the rules for the prevention of accidents and the statutory regulations. Furthermore the following safety instructions should be applied: • The danger area of the LSF has to be blocked off and has to be marked by sign “Attention! Hoist in

operation” . • The suspended load should be visible all the times for the operator and if more than one person is

involved in the operation, they must be able to communicate with each other at all times.

• If the hoist is not in use the load must be on the ground and the main switch off. • No person is allowed underneath a suspended load • Any repair work must be carried out by trained personnel • If the motion of the winch endangers persons or goods, the emergency button has to be pressed and may only be

released after the problem has been rectified. The load has to be secured in the meantime. 5.2 Prohibitions of use • Starting operation before function inspection and without instruction • Transporting people • Moving loads heavier than the safe working load • Pulling loads which are tilted • Tearing off loads or goods • Moving of swinging loads • Using the LSF with people underneath the load • Transport of liquid metals • Using the winch with damaged rope • Using the winch if the direction of motion is different from the symbols on the control buttons • Usage of emergency limit switches under normal operation • Using the hoist without undertaking the regular inspection • Inching mode 6 Maintenance All maintenance work must be carried out by trained specialists and may only be carried out if the LSF is unloaded and the mains is switched off so that the power supply is disconnected. 6.1 Test and maintenance works The operation of the LSF is covered by the BGV D8 §23 „Winches, lifts and pulleys“ regulation in Germany. The winch has to be inspected by an trained specialist before first use and after any major changes. The design and method of manufacturing of the LSF has received a general approval. The dynamic and static tests are accomplished acc. to EC Machinery Directive by manufacturer. The suspension points and the unit itself have to undergo a yearly safety check by an trained person. Trained specialists are highly qualified specialist personnel or the manufacturer’s after-sales service personnel. If the hoist is in heavy use (two or three shifts, high percentage of work with nominal load, dusty or high temperature environment) this maintenance work should be done more frequently. All maintenance work must be entered in the crane log book included in the delivery. check

daily 3 month yearly

visual check of the whole equipment ●

function check • brake: braking distance under load • limit switch: switch-off up, down • wire rope: squeezed, bent, dented and broken wires

(DIN 15020 Bl.2), rust, condition of the windings

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maintenance / adjustment brake: control of the air gap

●

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check

daily 3 month yearly

lubrication of the wire rope ●

universal check • screw fittings • safety elements • hook tackle / load hook

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electrical control • power supply cable: squeezed, pulled off, condition of

insulation • control box: damages, sealing • control pendant: damages, proper function, emergency stop

and all electric accessories

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table 2: test and maintenance works 6.2 Replacement of the wire rope 6.2.1 Replacement of the wire rope at the hook tack le

wire rope suspension plate wedge hook mounting

assembly instructions: • screw off the suspension plate for wire rope • screw off hook mounting • punch out the wedge and pull out the wire

rope The assembly of the new wire rope should be done in the inverted order. • After assembly the tight fit of the wire rope has

to be checked.

figure 8: view of the hook tackle (dismantled) 6.2.2 Replacement of the wire rope at the drum The standard length of the wire rope is 81.5 m and the diameter of it 5 mm. The drum therefore is designed for 5 layers of wire rope.

assembly instructions: • Release the wire rope by pressing the down

button • Dismantle the shaft cover • Swivel the drum until the rope suspension

plate is visible behind its window • Disconnect power • Loosen the two rope suspension plate screws • Pull out the old rope • Fit the new rope through the hole in the drum

underneath the rope suspension plate and tighten the two screws in parallel

• Assemble the shaft cover • Reconnect power • Move the rope up properly and tightly (Use

safety gloves!) • Ensure that the direction of motion is

correct! figure 9: replacement of the wire rope at the drum

shaft cover

window of the end plate

suspension plate

wire rope drum

wire rope

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7 Construction and mode of operation of the DC disk brake 7.1 Construction and mode of operation of the DC di sk brake The DC disk brake consists of the magnetic body (1) concerning the magnetic coil and the mounting screws, the plate (2), the brake pressure springs, the brake disk with brake lining and the fan (3). The fan cover (4) protect the brake against mechanical damages.

5 2 1 3 4 figure 10: construction of the DC disk brake

figure 11: construction of the DC disk brake Mode of operation of DC disk brake The brake is supplied by a rectifier circuit which is located in the control box. It operates according to the fail safe principle. If there is a power failure, the brake acts automatically so that the load is held securely in every position. In this case, that the magnetic coil (1) is without power supply the anchor plate (2) will be pressed against the brake lining of the brake disk by the pressure springs. The brake disc is locked to the motor pinion shaft (5) using a feather key.

1 magnetic body 2 plate 3 fan 4 fan cover 5 motor pinion shaft

label / type plate magnetic coil

pressure spring rotor with brake lining hub anchor plate

distance bush flange hexagon screw DIN 912

SL

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7.2 Check of the BFK 457-08 The air gap between the magnetic coil (1) and the anchor plate (2) should be checked once a year or if the brake distance is to long. If the air gap is too large, the brake has to be replaced. Assembly instructions: Remove the fan cover (4). (Disconnect mains supply before!) 1. Push the thickness gauge between magnetic body (1) and anchor plate (2). 2. Check the air gap sLU. If the a maximum air gap of 0.5 mm is reached the brake has to be scraped and replaced by a

new one. 3. Screw on the fan cover (4). 4. Function check:

The nominal load must be held securely and braked securely out of motion. The braking should be smoothly.

The brake must be replaced, if the rotor has a thickness of 5.5 mm.

7.3 Assembly of the DC disk brake Assembly instructions: 1. Press the hub onto the shaft. 2. Secure the hub by use of a retaining ring against axial movement. 3. Assemble DC disk brake to the hub. 4. Screw the DC disk brake on the gear cover by use of the hexagon screws M5 5. Tighten the screws with equivalent torque of 5.5 Nm.

assembly of the hub onto the shaft

assembly of the DC disk brake on the gear cover

tightening by a torque wrench

figure 12: assembly of the DC disk brake

The disassembly should be done in inverted order!

Attention! For order of spare parts the complete type designation has to be submitted! 7.4 Faults on the DC disk brake Troubleshooting and fault elimination faults causes remedy

coil has contact to ground or between the windings

replace the brake

wiring wrong or defect check wiring diagram and correct wiring

rectifier wrong or defect compare wiring at rectifier with wiring diagram; especially correct setting of the bridge measure DC-voltage between terminals 5 and 6 If differences occur change the rectifier.

brake does not release, air gap is not zero

air gap too large replace the DC disk brake table 3: troubleshooting and fault elimination If the rectifier defects occur repeatedly, the brake shall be replaced even if no winding short circuit can be detected. Defect may occur only in warm operating condition.

gear cover hub retaining ring

DC disk hub brake

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8 Lubrication Gear box: The gear box is already filled with oil by the manufacturer. The oil must be changed if the LSF is going to be overhauled. The oil has to be disposed in accordance with the law of environmental protection. Use oil with a viscosity of 220 mm²/s at 40°C and an operating temperature of - 20°C to + 40°C. The necessary amount of oil is 0.25l. Alternative oils are: supplier oil designation

Castrol Alpha Zn 100

ESSO EP 100

Mobil Mobilgard 627

Shell Melina Oel 30 Gadinia 40

ELF Reduktelf SP 100

BP XP 100 BP Energol GR

table 4: alternative oils Wire rope: The rope must be cleaned and lubricated at regular intervals (3 months min.); if very dirty (concrete, cement) this work should be done more often. Hook tackle: The roller bearing on the load hook must be cleaned and lubricated with grease at least once a year. 9 Measures to be taken at the end of the end of the S.W.P. After the LSF or its components have reached the end of the S.W.P. the LSF or its components have to be overhauled or to be taken finally out of operation. The parts have to be disposed in accordance to the law of environment protection. Metals, rubber, plastics have to be disposed or recycled separately.

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The operators who have been instructed to this LIFTKET-wire rope winch and have read the manual and especially the safety advice.

Name, Surname Date Signature

The advice contained within this manual should be implemented by the appropriate skilled and qualified operators of LIFTKET-wire rope winches. Further information for other fields of operation are not considered herewith. If changes to the normal operations are discovered (such as unusual noise, vibrations, higher input current or frequently blowing fuses) the LIFTKET-wire rope winch has to should be taken out of operation and the load area has to be isolated because a fault is possible, which can result in danger to people or goods. The operator or owner of the LIFTKET-wire rope winch has to call a trained specialist to repair the LIFTKET-wire rope winch.

HOFFMANN Fördertechnik GmbH Wurzen Dresdener Straße 64-68 ● 04808 Wurzen ● BR Deutschland

Telefon: (03425) 89 24 – 0 ● Telefax: (03425) 89 24 – 99 ● E-Mail: sales@liftket.de ● Internet: www.liftket.de

08/2011 englisch