HADEF 28/06 AP-EX, Installation, Operating And Maintenance Instructions

Page 1: ... APHL and APPL Explosion proof design II 2G IIB c T4 or II 2D c 135 C II 2G IIB c T3 or II 2D c 200 C DANGER Not to be used with IIC gases and IIB gases hydrogen sulphide and ethylene oxide and light metal and shock sensitive dusts It is not allowed to use the equipment in area at risk from explosion where gas AND dust does both exist at the same time o Installation Operating and Maintenance Instr...

Page 2: ...of care of the owner 4 2 3 Requirements for the operating personnel 5 2 4 Appropriate use 5 2 5 Basic safety measures 6 2 6 Explosion protection 8 3 Transport and Storage 11 3 1 Transport 11 3 2 Safety device for transport 11 3 3 Storage 11 4 Description 11 4 1 Areas of application 11 4 2 Design 11 4 3 Functions 12 4 4 Important components 12 5 Technical data 13 6 Installation 14 6 1 Trolley 14 6 ...

Page 3: ...pany works acc to a certified quality assurance system as per EN ISO 9001 The production of components at our work is subject to strict intermediate checks After assembly the products are subject to a final test with overload For the operation of hoists the national accident prevention apply in Germany amongst others Lifting equipment for use in areas prone to explosion complies with current legis...

Page 4: ...ation must be carried out in accordance with all current legislation standards and regulations for areas prone to explosion 2 1 Warning notice and symbols Warnings and notice are shown as follows in these instructions DANGER This means that there is a high risk that leads if it is not avoided to death or severe injury WARNING This means that there is a risk that could lead if it is not avoided to ...

Page 5: ...r use in area prone to explosion must from customer s side be earthed with a shunting resistor of 10 6 Ω against earth WARNING It is not allowed to make constructive changes of the equipment 2 3 Requirements for the operating personnel The units may only be operated by qualified persons that are appropriately trained and that are familiar with it They must have their employer s authorization for o...

Page 6: ...ccident prevention regulations UVV Should the hoist be used outside of Germany please pay attention to the national regulations that apply Supporting structures and load attached devices used in conjunction with this equipment must provide an adequate safety factor to handle the rated load plus the weight of the equipment In case of doubt consult a structural engineer If the equipment has not been...

Page 7: ...area at risk from explosion where gas AND dust does both exist at the same time During assembly and operation of explosion proof equipment the relevant regulations of i e BG Chemie about the use of equipment in area at risk from explosion must be adhered to by the user owner Please make sure that external ventilation is sufficient Please wear conductive shoes Gloves should have a shunt resistance ...

Page 8: ...ne 1 Use in zone 2 G EX atmosphere G D caused by gas steam fog caused by dust IIB explosion group IIA IIB IIC limit gap widths MESG 0 9 mm limit gap widths MESG 0 9 0 5 mm limit gap widths MESG 0 5 mm c type of protection c k construction safety encapsulation of liquids T4 Temperature class gas es for dust only the temper ature in C is stated T1 T2 T3 T4 T5 T6 limit temperature 450 C limit tempera...

Page 9: ...y very rarely occur for T6 for specific gas air mixtures such as carbon disulphide IIC our hoists are not rated for these temperature classes and must not be used for these classes Temperature class Ignition tem perature of gas C max surface temperature of the operating material in C T1 450 450 T2 300 450 300 T3 200 300 200 T4 135 200 135 T5 100 135 100 T6 85 100 85 2 6 3 EX zone classification Ar...

Page 10: ...10 5 52 181 01 01 07 2 6 4 Explosion hazards recognizing and preventing ...

Page 11: ... the units against the effects of weather such as rain hail snow direct sunshine dust etc we recommend to use a cover in parking position If the device is set up in a continuously humid environment with strong temperature fluctuations the correct functionings are endangered by the forming of condensation Ambient temperature 20 C up to 50 C Power operated units 20 up to 40 C Humidity 100 or less bu...

Page 12: ...ten we recommend to carry out a test run at least once a week and to switch on the motor several times during this test run In our experience this will prevent the brake from sticking 4 4 Important components NOTICE All hoists are fitted with high quality lifting gears of the reliable AK series 4 4 1 Motor Type of chain hoist Pneumatic motor 70 06AP 70 06AP EX 28 06AP 28 06 AP EX 29 06AP 29 06AP E...

Page 13: ...direct control 4 4 13 Special components only for hoists that are used in area at risk of explosion 5 Technical data Table 1 Capacity kg 1000 2000 2500 3200 5000 6300 6300 10000 hoisting unit AK 4 AK 6 AK7 AK 7 AK 7 AK 7 AK 8 AK 8 Number of chain falls 2 2 2 2 4 4 2 4 FEM 9 511 EN 818 7 2m 2m 2m 2m 2m 1 Bm 1 Bm 1 Bm load chain mm 5 x 15 7 x 21 9 x 27 9 x 27 9 x 27 9 x 27 11 3 x 31 11 3 x 31 load b...

Page 14: ...80 at the time of going to print this data had not been finalised air pressure 6bar 6 Installation DANGER Assembly disassembly and maintenance operations must only be carried out in an atmosphere not prone to explosion The assembly and installation depends on the local environment The hoist must be suspended in a way that it can position itself freely 6 1 Trolley For assembly on a beam a travel li...

Page 15: ... the side plates 1 with load bars 2 washers 6 distance tubes 5 hexagon nuts 3 and safety nuts 4 to adjusting value X as mentioned above Tighten the hexagon nuts 3 and safety nuts 4 and push the device onto the front face of the beam flange Insert the threaded rod 7 through the corresponding holes and tighten the nuts 8 9 Tighten nut 8 first then nut 9 If this is not possible for lack of space or f...

Page 16: ...hain container is supplied as a complete unit For the installation of the chain container the following must be observed Mount chain container 1 with screws 2 in the position provided 3 Let the load chain run smoothly into the chain container 1 The holding chain 4 which is already fixed to the chain container must be fastened with screw 6 at the position provided therefore at the hoist 5 in such a...

Page 17: ...ccessible for the operating personnel The shown control switches are only for the optical information They can be different acc the delivery Capacity Size Tool Use 1t 1 5t 2t 2 5t 3 2t 5t 6 3t 7 5t 10t SW36 SW46 SW55 SW60 SW75 load bolt 12 5 t 16t 60t SW22 SW24 load bolt with locking ring 1t 2t 2 5t 3 2t 5t 6 3t SW46 SW55 SW60 SW10 Load bolts bottom block 8t 16t 20t 50t 16t 8t 50t SW36 SW55 SW75 S...

Page 18: ...ons Illustration 10 Emergency release Hoist as option To drain the load at pressure drop in an emergency case a manual brake release is possible by lever A Illustration 11 NOTE A minimum weight of approx 20 of the rated load is necessary for lowering This value depends on application and ambient conditions CAUTION Run in of chain into the chain container for hoist with double lifting mechanism For...

Page 19: ...putting into operation for the first time Hoists of 1000 kg capacity and up or with more than one motor driven hoist movement i e lifting and trolley movement must be tested by a licensed qualified person before putting in operation An exception is hoists ready for operation acc validated national regulations with EU declaration of conformity Definition qualified person former expert A qualified p...

Page 20: ...ucing valve The oiler enriches the air with oil Setting of oil addition approx 2 drops of oil must be added per minute NOTICE HADEF does not assume any responsibility for damage caused by non observance of the instructions CAUTION Should the unit be assembled at the customer the maintenance unit is supplied without oil Before putting the unit into operation the main air supply line must be cleaned...

Page 21: ...f existent socket pins flap socket and safety devices are tightened and secured The oil levels in the gear boxes are sufficient All movements of the load comply with the symbols on the control switch The chains are correctly placed oiled and in good condition 11 Functional test 11 1 Checks before the initial start up Lifting gear Load chains must not be twisted Lubricate the load chain with gear o...

Page 22: ...hain CAUTION If there is any visible damage and when the conditions for replacement are reached i e one or several dimensions in the table have been reached there is corrosion or elongation the chain must be replaced When replacing the chain also check the chain wheels Procedure Only insert new chains in an unloaded state and as the chains that are currently in the device i e not twisted Remove ch...

Page 23: ...oes not lift the permitted load the overload protection must be adjusted Adjustment may only be done by a service company authorised by the manufacturer DANGER The factory setting of the overload protection is secured by a seal Any guarantee becomes invalid if this setting is changed Should maintenance be necessary please contact a service company that is authorised by the manufacturer Depending o...

Page 24: ...vices out of operation and effect a General Overhaul Further use of the equipment is only allowed after a licensed qualified person has proofed that further use is possible without doubt and the conditions for further use have been determined These conditions have to be written down in the test book The owner user is responsible to make sure that these conditions are observed 13 2 Periodic checks ...

Page 25: ...everal of the dimensions fall below or exceed the dimensions in the table or if cracks or corrosion are found the parts must be replaced with original spare parts 13 3 Checking the load chain CAUTION The load chain must be tested over its entire length The measure of the load chain must be carried out especially in the areas which are subject to the highest wear Through the lifting movement these ...

Page 26: ...e measured values before commissioning Capacity kg X or Y mm H mm CAUTION When the dimension of hook opening width is deformed more than 10 or when the dimension of the hook bottom thickness is fallen short of by 5 due to wear the hook must be replaced DANGER In case of corrosion and or wear of the surface coating the hooks must be exchanged by original hooks or the coating must be renewed 13 5 In...

Page 27: ...e chain by approx 20 times compared to dry run with unlubricated chain Wash dirty chain with petroleum or a similar cleaner under no circumstances heat the chain If there are environmental influences that foster wear such as sand a dry lubricant should be used e g graphite powder When lubricating the chain s condition of wear should be checked CAUTION Do not use grease for lubrication of load chai...

Page 28: ...d Refill lubricant is normally not necessary Lubricate gear rim and pinion drive each year or if required more often with grease 14 6 Tension device Use Recommendation Interval Spur gear FUCHS RENOLIN PG 220 AK AP4 0 45 l AK AP6 1 00 l AK AP7 1 90 l AK AP8 1 90 l Lubricant change 3 years Planetary gear FUCHS RENOLIN PG 220 AK AP9 0 35 l AK AP10 3 l Lubricant change 3 years Spur gear Planetary gear...

Page 29: ...BIL TOTAL CASTROL KLÜBER Renolin PG 220 Tivela S 20 Glycolube 220 Degol GS 220 Glygoyle 30 CARTER SY 220 Klübersynth GH 6 220 Renolin PG 320 Tivela S 320 Glygolube 320 Degol GS 320 Glygoyle 320 Klübersynth GH 6 320 Renolin PG 460 Tivela S 460 Glygolube 460 Degol GS 460 Glygoyle 460 Alphasyn PG 460 Klübersynth GH 6 460 Renolit FEP2 Alvania EP2 Unirex EP2 Mobilux EP2 MULTIS EP2 Renolin B10 VG32 Tell...

Page 30: ...e for explosive atmosphere the motor must be returned to the manufactuerer for repair Rotor is rubbing Brake does not release See problem Brake does not release Defect of capacitor only for alternating current 1 Replace the capacitor Defect of starter relay only for alternating current 1 Replace the starter relay Phase failure only direct control Find the cause and repair Motor does not brake or h...

Page 31: ...that all operating material is disposed of in accordance with environmental regulations 17 1 Temporary decommissioning Measures are as above Also read the chapter Transport and storage 17 2 Final decommissioning disposal Measures are as above After disassembly ensure that the disposal of the equipment and any materials it contains is carried out in accordance with environmental regulations 18 Addi...