EXE RISE D8+, User And Service Manual

Page 1: ...0 1000 2000 kg SF 8 DC LVC 150 300 600 1200 kg D8 DC LVC EXCLUSIVELY DISTRIBUTED BY LITEC ITALIA S R L Via Martin Luther King 70 I 31032 Casale sul Sile TV Italy Tel 390422997300 Fax 390422997399 www exetechnology com www litectruss com ORIGINAL INSTRUCTION ...

Page 2: ...r hoist Before using the hoist please fill in the following information referred to the hoist identification plate Such information must be communicated every time that the LITEC Italia S r l service department or your local distributor is contacted If you are in doubt or need any further information please contact us Customer Name and address 1 Customer Name and address 2 Model number Instruction...

Page 3: ... 2 4 SAFETY WARNING FOR INCORRECT USE 16 2 5 SAFETY WARNING FOR RESIDUAL RISKS 17 2 6 SAFETY WARNING FOR ELETRICAL CONNECTION 18 3 EXE Rise CHAIN HOIST INFORMATION 19 3 1 GENERAL DESCRIPTION 19 3 2 IDENTIFICATION 20 3 2 1 Type of Control 20 3 3 COMPONENTS DESCRIPTION 23 3 3 1 Chain 24 3 3 2 Hook 25 3 3 3 Chain Bag Bracket 27 3 3 4 Chain Stop 27 3 3 5 Carabiner Quick link 28 3 3 6 Chain Guide Plate...

Page 4: ... LOWERING AND DISCONNECTING THE LOAD 47 5 3 LIMIT SWITCH SETTING AND REPLACEMENT 48 5 4 TURN 1000kg SINGLE REEVE IN 2000kg DOUBLE REEVE 50 6 INSPECTIONS 52 6 1 INITIAL AND EACH ASSEMBLY INSPECTION AND CONTROLS 52 6 2 FREQUENT AND PERIODICAL INSPECTION 53 6 2 1 Chain Inspection 54 6 2 2 Hook Inspection 56 6 2 3 Chain Bag Inspection 56 6 3 PERIODICAL CONTROLS 56 6 4 EXTRAORDINARY INSPECTION 57 7 MAI...

Page 5: ...at is being lifted front view 36 Figure 22 Example of secondary safety component attached directly to the load that is being lifted 36 Figure 23 Example of secondary safety component attached below the hoist bypassing the hoist lifting mechanism front view 37 Figure 24 Example of secondary safety component attached below the hoist bypassing the hoist lifting mechanism perspective view 37 Figure 25...

Page 6: ...ain stop code 28 Table 11 Chain bag bracket Carabiner technical data 29 Table 12 End chain bracket Carabiner technical data 29 Table 13 Brake technical data 32 Table 14 Chain bag characteristic 33 Table 15 Chain bag dimensions 33 Table 16 Chain bag size 33 Table 17 Bolts 34 Table 18 Minimum frequent inspections 54 Table 19 Minimum periodic inspections 55 Table 20 Troubleshooting based on hoist beh...

Page 7: ... the possibility of any damage to persons or equipment For health and safety reasons people operating assembling disassembling transporting and maintaining the chain hoist should wear adequate Personal Protection Equipment like but not limited to gloves noise protection hard hats and safety shoes This manual and the other documents contained in the packing are an integral part of the supply and mu...

Page 8: ...of measure kW Power supply operating voltage Brake number of brakes Years of construction IP Rating code International Protection Rating first digit is the solid protection and second digit is the liquids protection FEM class European Federation of Materials handling and safety Factor Chain size units of measure mm in according to EN DIN 818 7 Serial number Safety Factor SF and Double Brake this i...

Page 9: ...can be used in place of the words SAFETY INSTRUCTIONS 1 4 TERMS AND DEFINITIONS Operator it is intended a person who by virtue of training and professional experience has a specific competence in the field of safety and mechanical equipment and is familiar with the related national rules on health protection and safety at work and with the rules of good technical practice technical regulations iss...

Page 10: ...S DOCUMENT WARRANTY POLICY 1 For a period of 12 month we undertake to repair free of charge any damage attributable to faulty materials or workmanship provided that the appliance is forwarded freight paid to our works or one of the EXE contract service organisations 2 The guarantee period begins with the day of the delivery proven by a purchase receipt like an invoice or delivery note or their cop...

Page 11: ...defects of the goods shall be deemed valid or applicable without the written notification of the purchaser if it is not received by the vendor within one year from the shipping date The vendor is not liable for any damage injury or loss due to improper use of the goods if before such damage injury or loss such goods are 1 damaged or used in an improper manner following the delivery of the vendor t...

Page 12: ...and it contains the following documents attached Declaration of conformity of EXE Rise chain hoist Declaration of conformity of chain Declaration of conformity of hook Wiring Diagrams These documents are an integral part of the manual and they are an integral part of the hoist ...

Page 13: ...rall analysis the dynamic forces must also be considered Use of the hoist under conditions other than those described can result in accidents that may cause injuries and or material damages Check that the electrical supply system to be used is adequate and conforms to local standards Supplementary to the manual the local statutory regulations governing general accident prevention and environmental...

Page 14: ... the limit switches should be avoided The manufacturer accepts no responsibility for damage to equipment and third parties ensuing from such action Special attention shall be taken when hoists are used in or near aggressive environments e g Salt water or chloroform The aluminum and steel alloys used might not be particularly suitable for such environments Special attention to protect the chain sha...

Page 15: ...is document strictly is prohibited Maintenance shall be solely executed by LITEC Italia S r l authorised persons Keep the hoist clean and efficient by carrying out the suggested maintenance program Avoid bumping of a hoist With bumping is meant frequently pressing the start and stop button to adjust the hoist position Do not load hoist beyond the rated capacity Overload can cause failure of some l...

Page 16: ...4 SAFETY WARNING FOR INCORRECT USE Do not lift people Using the EXE Rise chain hoist to carry people is strictly forbidden Do not use the hoist if it is damaged malfunctioning or functioning in an unusual way or exhibits unusual or incorrect movement or anomalous noises Do not use the hoist if the chain is distorted corroded damaged or worn out Do not make modifications nor apply accessories other...

Page 17: ...main after the carrying out of all the safety measures taken by the manufacturer and which therefore must be managed by the user The most serious residual risks are indicated on the hoists safety labels These are as listed below Table 1 Residual risk dangerous zone and person exposed Course of action to eliminate or reduce risk Malfunction or falling load due to overload Do not exceed the hoist lo...

Page 18: ...correct voltage A fluctuation of 10 is allowed In order to prevent a voltage drop the user should ensure there is the minimum number of connections as possible in any power cable run Keep length of power cables as short as possible see table below and remove corrosion on the contacting pins of the electrical connectors as it might lead to a voltage drop In order to minimize the voltage drop betwee...

Page 19: ...ain hoist consists in several parts In Figure 2 and in Table 3 are reported main of these Table 3 EXE Rise chain hoist parts Figure 2 EXE Rise chain hoist parts COD TITLE DESCRIPTION A BODY The body s made in cast aluminium to be as light yet as strong as possible The matt black finish is corrosion resistant and non reflective B CHAIN The chain is in Zinc Galvanized with grade of steel equal to 80...

Page 20: ...V EXE Vario 20 m min CCC load capacity 10 015 150 kg 025 250 kg 030 300 kg 050 500 kg 060 600 kg 100 1000 kg 120 1200 kg 200 2000 kg DDD model hoist S8 SF 8 SF 8 1 D8 SF 8 SF 5 1 1 brake D8 D8 SF 10 1 DB SF 8 SF 5 1 2 brake EE chain length in meter max length 100 m 220 lbs F chain bag size XS S M L X XL Table 4 EXE Rise chain hoist identification For example LT XRH1D112DB 20M is EXE Rise chain hoi...

Page 21: ...en they are inverted DC hoists have an integrated mechanical emergency overload device known as the slip clutch This slip clutch is adjustable but changes to this device must only be performed by an officially trained and competent person A chain stop a two part metal block is attached to the end of the load chain 11 links form the end which prevents the chain from running through the hoist should...

Page 22: ...hosen direction until it reaches a mechanical stop on the chain or until the electrical limit switch reaches its pre set end point Once the limit switch is activated the hoist can only be run by reversing the direction of travel Any control unit used to power EXE Rise LVC hoists must provide an un inverted three phase power supply An incorrect sequence of phases make the hoist run in a different d...

Page 23: ... in the entertainment industry The EXE Rise clutch system is located outside the load path The DC brakes give a real instant response to electrical impulses thanks to a unique component specifically created for us The 5 pocket load wheel helical gears with dynamic lubrication and the precise aluminum chain guide make the EXE Rise series one of the quietest on the market Figure 3 EXE Rise chain hoi...

Page 24: ...h Gauge length 11t 11 links dsmax maximum welding diameter σmin minimum stress at breaking force Fmin Minimum Breaking Force MBF Amin minimum total ultimate elongation WLL max Working Load Limit Chain can be identified from the manufacturers stamped identification marks on the chain The stamps shown are repeated at regular intervals along the length of the chain Figure 5 Chain identification Permi...

Page 25: ... use Stainless Steel CHAIN SWIVEL HOOK SF 8 250 kg and D8 150 kg Figure 6 Lift chain hook with safety latch SF 8 250 kg and D8 150 kg SF 8 500 kg and D8 300 kg Figure 7 Lift chain hook with safety latch SF 8 500 kg and D8 300 kg DIMENSIONS mm a1 a2 d1 l1 b1 h1 b2 h2 30 24 16 102 19 22 15 19 DIMENSIONS mm A B D G H L O 73 51 15 16 20 64 18 ...

Page 26: ...200 kg Figure 9 Lift chain hook with safety latch SF 8 2000 kg and D8 1200 kg The standard ingress protection Level of IP55 means that when the hoist is used in wet environments adequate protection of the hoist body is required DIMENSIONS mm A B D G H L O 92 64 20 21 27 72 30 DIMENSIONS mm A B D G H L O 100 70 24 24 30 80 25 ...

Page 27: ... same models of the same manufacture Lifting speeds vary depending on the load and if the load is lifted or lowered 3 3 3 Chain Bag Bracket The chain bag bracket allows the hoist to be used motor up or down The design ensures the bag is positioned correctly to accept chain without the need for any adjustment reducing the chance of chain spills 3 3 4 Chain Stop Fits below dead end link on lifting c...

Page 28: ...alvanized and stamped with the DIN standard manufacturer s name and the carrying capacity Figure 13 End chain bracket Carabiner dimension Table 12 End chain bracket Carabiner technical data Litec Code CHB004 Commercial name Quick link Description Material Zinc Galvanized Carbon Steel Color black Diameter 6 mm DIN DIN 56927 SWL Safe Working Load 250 kg Safety Factor 10 1 Weight 47 g Litec Code Chai...

Page 29: ...t Plugs and sockets are produced from POLYAMIDE 6 as well as PC ABS The main characteristics of these materials are excellent impact resistance combined with high rigidity and solidity high thermal stability self extinguishing very good insulating qualities high disruptive strength high abrasion resistance high weathering resistance very good chemical resistance to various chemicals free from cadm...

Page 30: ...is released electromagnetically Figure 16 Double brake version The spring applied brake is designed for the conversion of mechanical work and kinetic energy into heat For operating speed Due to the static brake torque the brake can hold loads without speed difference Emergency braking is possible at high speed The more friction work the higher the wear Figure 17 Brake Features ...

Page 31: ...ical toothed gear and one or more secondary output stages pairs of straight toothed gears Accurate adjustment of cams by means of screws and positive opening NC contacts for safety functions Mechanical life of switches is 1 million operations and IP protection degree is classified IP66 IP67 and IP69K NEMA protection degree is classified Type 3 The Extreme temperature resistance is 40 C to 80 C It ...

Page 32: ...yvinyl chloride coated polyamide 65 PVC Nylon 840 35 Polyamide PP Yanr Multifilament 100 Melting Points 165 Color Black Classification Reaction to fire classification E combustible not inflammable partially fire retardant Conformity to EN 119925 2 Safely Factor 5 1 SPECIFICATIONS CHAIN BAG XS CHAIN BAG S CHAIN BAG M CHAIN BAG L CHAIN BAG XL Litec Code CHB032 CHB033 CHB034 CHB035 CHB036 External Di...

Page 33: ...ller shall provide the required control and monitoring functions for save operation Controllers shall be chosen depeding on the power consumption of an individual hoist which can vary as well as its model direct controll or Low voltage control or the amount of hoist one would like to control at the same time We strongly advise to keep good view on the load being lifted Using more than two hoist on...

Page 34: ... to reduce the chance of twisted chain entering the hoist These chain guides are a consumable item and should be replaced if they become worn Badly worn plates can be a sign of misuse Eg Side loading of the chain Hooks The hooks are equipped with a sprung safety latch that prevents accidental release of loads when applied correctly to the hook If this spring latch does not engage against the point...

Page 35: ...n application where a suspended load can be increased by adding additional weight For example food lifts etc 3 4 2 Secondary Safety Component A secondary safety component is a second independent suspension element of equivalent capacity to the primary suspension point which is intended to prevent the fall of the load should the primary point fail Some application examples are illustrated here belo...

Page 36: ...st not be higher than 50 with maximum temperature of 40 C A higher relative humidity is allowed al lower temperatures ex RH 90 AT 20 C Altitude Maximum altitude at 3000m Electromagnetic environment The hoist is designed to work correctly in an industrial type electromagnetic environment falling within the emission and immunity limits provided by the harmonized rules currently in force Wind Wind ca...

Page 37: ...tric series LC2 K09 reversing contactors with 24 V AC coil for a rated power of 4 kW AC3 400V Mechanical limit switch 4 position with manual cam adjustment Maximum control Low Voltage Control cable length attachable to motor 50 m Maximum chain length managed by low voltage control hoist 60 m for single fall models and 30 m for double fall models Other voltages and frequency are available on reques...

Page 38: ...ke Power 20W 20W 25W 30W DC Brake Operating Voltage 105VDC 105VDC 105VDC 105VDC DC Brake Rated Torque 4Nm 4Nm 8Nm 16Nm DC Brake Rated Torque Reduction at the speed specified x 1500r min 87 1500 r min 85 1500 r min 85 1500 r min 83 1500 r min Clutch Characteristics Clutch is friction based force limiter Clutch outside the line of kinetic movement Clutch is friction based force limiter Clutch outsid...

Page 39: ...20W 25W 30W DC Brake Operating Voltage 105VDC 105VDC 105VDC 105VDC DC Brake Rated Torque 4Nm 4Nm 8Nm 16Nm DC Brake Rated Torque Reduction at the speed specified x 1500r min 87 1500 r min 85 1500 r min 85 1500 r min 83 1500 r min Clutch Characteristics Clutch is friction based force limiter Clutch outside the line of kinetic movement Clutch is friction based force limiter Clutch outside the line of...

Page 40: ...ise DRAWING 250kg SF 8 DC LVC and 150kg D8 DC LVC Figure 25 EXE Rise DRAWING 250kg SF 8 DC LVC and 150kg D8 DC LVC 500kg SF 8 DC LVC and 300kg D8 DC LVC Figure 26 EXE Rise DRAWING 500kg SF 8 DC LVC and 300kg D8 DC LVC ...

Page 41: ...00kg SF 8 DC LVC and 600kg D8 DC LVC Figure 27 EXE Rise DRAWING 1000kg SF 8 DC LVC and 600kg D8 DC LVC 2000kg SF 8 DC LVC and 1200kg D8 DC LVC Figure 28 EXE Rise DRAWING 2000kg SF 8 DC LVC and 1200kg D8 DC LVC ...

Page 42: ...t is the responsibility of the carrier The packaging should be disposed of in an environmentally friendly manner Ensure all routes and areas which are intended for handling are free from obstacles When working at height the user should employ relevant and suitable access and safety equipment Lifting shifting and handling operations must be carried out by trained personnel Do not halt for any reaso...

Page 43: ...sius Should the hoist not be operated immediately it is recommended to store it inside its packaging in a covered dry and clean area away from heat sources that might jeopardise its integrity 4 2 2 Unpacking and ground handling of the hoist Remove the hoist from its packaging Lift the hoist by the handles Check that the packaging label information are the same as those on the hoist plate Check tha...

Page 44: ... through the hoist and back This way correct storage of the chain in the bag or chain container is guaranteed 4 Connect the hook end of the chain to the fixing point at height The hoist can then be operated and run up to a working height position where the load to be connected 4 3 2 Mounting the hoist in motor up position 5 Use an appropriate method of lifting the hoist body and attach the anchora...

Page 45: ... protection on work place of the Country where the hoist is installed In order to avoid risk of electrocution and malfunction check that all cables powering the hoist are protected against possible external damages EXE Rise chain hoists are available in both direct and low voltage control They must be connected to a power and control system that is suitably designed to operate the chain hoists and...

Page 46: ...tructed in any way Do stay clear of moving chains Do ensure chain is lubricated at all times Call your EXE Rise supplier if the hoist does not work properly If damaged or worn parts are detected do not use the hoist Seek assistance for service of the unit During the movement of the load always appoint a responsible person to monitor and ensure the load is safe If the load encounters any obstructio...

Page 47: ...afety instructions 17 Switch of the hoist main circuit breaker to avoid un intended operation 5 2 LOWERING AND DISCONNECTING THE LOAD It shall be noted that lowering a load suspended on multiple hoist incorporates many more risk of overload as lifting If one hoist is not following the lift sequence it is very likely it immediate is overloading itself its suspension point and the pickup point at th...

Page 48: ...he maintenance of the limit switch the main power of the machinery shall be turned off Standard limit switches mounted in the LVC hoist allow 49 metre of travel Optional limit switches for chain lengths of 25 30m 75m and 100m are available 320kg LVC model and 160kg D8 hoist come without limit switch For a double reeved hoist like the 2000kg version the length of chain travel is double This reduces...

Page 49: ...w 8 the numbers on the screws refer to the cams counting from bottom to top then tighten the central screw 7 12 Insert the free end of the no drop wire 9 if used into one of the screws 4 then close the limit switch using the screws 4 check the proper positioning of the rubber 6 in the cover 03 and tighten the screws 4 with a torque of 80 100 cNm Figure 31 Limit switch adjustement ...

Page 50: ...cm long before modifying the hoist 2 Reverse barycenter rotating hoist body hook of 180 as in figure below Unscrew the screws of the plate rotate 180 and tighten the screws see figure 32 Figure 32 Reversing of barycenter 3 Procure lift chain hook with load well for 8x24mm chain and dead end block 8x24mm chain see figure 33 Figure 33 Required Components 4 Remove the lifting hook 5 Remove Aluminum F...

Page 51: ...e sure the chain is not twisted see figure 35 Figure 35 Replacement of the Chain hook 7 Re connect the chain to the aluminum frame block see figure 36 Figure 36 Re applying of the frame block 8 Run the chain minimum 2 meter through the lift hook to ensure good operation ...

Page 52: ... Identification and congruence of CE marking and the data plate on the EXE Rise body Correspondence between the power supply and that provided for the hoists Any visible damage to the hoist body hook chain bag carabiner and controller The value of the power supply is within the 10 limits of the nominal value Body work and Chain hook Connections to the hoist controller Chain bag connection Power an...

Page 53: ...ic can be performed Frequent Inspections These inspections are visual examinations by the operator or other designated personnel Records of such inspections are not required The frequent inspections are to be performed monthly for normal service weekly to monthly for heavy service and daily to weekly for severe service and they should include those items listed in Table 14 Periodic Inspections The...

Page 54: ...Change over links are those links which stop on resp immediately at the inlet of the drive and reversing wheels at constant stroke when switching from lifting to lowering Beside the contact point of 2 links need sufficient lubrication Inspecting the chain and chain wheel The chain must be inspected at regular intervals but at least once annually in accordance with the stipulations of ISO 7592 and ...

Page 55: ...nner pitch t of the individual link has increased in size by more than 5 as a result of wear The chain must also be replaced if the inner pitch 11t has increased in size by more than 2 along a measuring section of 11 chain links The lubricant shall sit at the contact points between to chain links as this part is subject to the utmost wear and tear Chain wheel inspection If the chain is found to ha...

Page 56: ...r equivalent standard They shall have a 5 1 safety factor as suitable for overhead suspension Some bags are supplied with a suitable rated captive spring hook Only rated hooks supplied by LITEC Italia should be used Any attaching devices should also be inspected Danged or worn devices should be discarded immediately and replace 6 3 PERIODICAL CONTROLS The hoist must be tested as often as deemed ne...

Page 57: ...d out In particular extraordinary events include accidents modifications to the hoist prolonged downtime periods and natural phenomena Testing must be carried out only by authorised personnel duly authorised for the purpose In addition to the above inspection and testing procedure a preventive maintenance program should be established to prolong the useful life of the hoist and maintain its reliab...

Page 58: ... as well as hazard protection instructions should be followed Before carrying out any kind of maintenance repair cleaning or any activity that requires a manual intervention on the machine disconnect the power supply to the hoist Ensure the power cannot be re connected to the hoist be securing or clearly marking the plug do not connect 7 1 CHAIN MAINTENANCE Use of commercial or other manufacturers...

Page 59: ...a resolving agent suitable for the application 7 4 TROUBLESHOOTING TROUBLE PROBABLE CAUSE CHECK AND REMEDY 1 Hoist does not respond to the controller or control device a No voltage at hoist main line or control circuit switch open control line fuse blown or circuit breaker tripped a Close switch replace fuse blown b Phase failure power cable damaged power supply cable damaged broken stator winding...

Page 60: ...Low voltage a Correct low voltage conditions b Excessive load b See item 1H c Extreme external heating c Above an ambient temperature of 40 C 104 F the frequency of hoist operation must be limited to avoid overheating of motor Special provisions should be made to ventilate the space or shield the hoist from radiation d Frequent starting or reversing d Avoid excessive inching jogging or plugging Th...

Page 61: ... and D8 150kg DC LVC CODE DESCRIPTION CODE DESCRIPTION COVER GEAR BOX COVER ROTOR BRAKE FLANGE STATOR GEAR BOX HOUSING BRACKET GEAR BOX FLANGE FRAME BLOCK LOAD WHEEL HOUSING LIMIT SWITCH LOAD WHEEL FLANGE REVERSING CONTACTOR MOTOR HOUSE FUSES BODY SWIVEL HOOK RECTIFIER CHAIN SWIVEL HOOK TRASFORMER CHAIN STOP SCREW EXTERNAL CHAIN GUIDE LOAD WHEEL DOUBLE BRAKE ...

Page 62: ...8 300kg DC LVC CODE DESCRIPTION CODE DESCRIPTION COVER GEAR BOX COVER ROTOR BRAKE FLANGE STATOR GEAR BOX HOUSING BRACKET GEAR BOX FLANGE FRAME BLOCK LOAD WHEEL HOUSING LIMIT SWITCH LOAD WHEEL FLANGE REVERSING CONTACTOR MOTOR HOUSE FUSES BODY SWIVEL HOOK RECTIFIER CHAIN SWIVEL HOOK TRASFORMER CHAIN STOP SCREW EXTERNAL CHAIN GUIDE LOAD WHEEL DOUBLE BRAKE ...

Page 63: ...8 1000kg DC LVC SF 8 2000kg DC LVC and D8 600kg DC LVC D8 1200kg DC LVC CODE DESCRIPTION CODE DESCRIPTION COVER GEAR BOX COVER ROTOR BRAKE FLANGE STATOR GEAR BOX HOUSING BRACKET GEAR BOX FLANGE FRAME BLOCK LOAD WHEEL HOUSING LIMIT SWITCH LOAD WHEEL FLANGE REVERSING CONTACTOR MOTOR HOUSE FUSES BODY SWIVEL HOOK RECTIFIER CHAIN SWIVEL HOOK TRASFORMER CHAIN STOP SCREW EXTERNAL CHAIN GUIDE LOAD WHEEL D...

Page 64: ...parated from all other metals before sending for recycling To dispose of hydraulic oil please refer to the product safety report or data sheet It is prohibited to pour rejected liquids such as oils circuit liquids etc on the ground or into drainage systems Please dispose of components or fluids that may be hazardous to health or the environment in a manner compliant with local regulations During o...

Page 65: ...65 66 10 DECLARATION MODELS The declaration of conformity completed dated and signed is attached to this manual This document is integral part of the manual ...

Page 66: ...6 EXE RISE CHAIN HOIST IS EXCLUSIVELY DISTRIBUTED BY LITEC ITALIA S R L Via Martin Luther King 70 I 31032 Casale sul Sile TV Italy Tel 390422997300 Fax 390422997399 www exetechnology com www litectruss com ...