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Emergency Stop and Overload System
Emergency Stop and Overload System are standard on all MR-CE winches.
When emergency stop or overload valve is activated, winch drum rotation will
immediately cease.
When control valve senses a preset pressure difference between ports, a pilot signal
is sent to stop flow of air, winch drum rotation will immediately cease.
CAUTION
•
If winch continues to move (payout load) after emergency stop activates,
brake(s) are not holding load and may require adjustment or repair.
Refer to Dwg. MHP2619 on page 11, A. Emergency Stop Button; B. Push Down to
Stop Winch Movement; C. Overload Valve Reset Button; D. Twist Red Button to Reset;
E. Overload Valve Adjustment Screw.
Pendant Control:
Refer to “Emergency Stop” section and Dwg. MHP1892 on page 13, A. Pendant
Handle; B. “Emergency Stop” Button; C. “ON” Button; D. Winch Control Levers.
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Emergency Stop
Emergency stop device is located on the control valve. When activated, winch drum
rotation will immediately cease. To activate emergency stop, depress (push down)
red palm valve, located on top of control valve.
NOTICE
•
If winch overload occurs, overload device, if equipped, also stops winch. To
operate winch after an overload, reduce load and reset overload.
Emergency Stop Reset:
1. Rotate red stop button, in (counterclockwise) direction until red stop button
‘pops’ up.
2. Winch is ready to resume operation.
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Overload System (FA2.5i-MR-CE and FA5i-MR-CE Models Only)
There are two overload methods used on the FA2.5i-MR−CE and FA5i-MR-CE
winches.
Utility Mode:
The winch utilizes a direct acting load limiter to limit maximum line pull to 160% of
the rated line pull. The limiter is a pressure regulator that limits the supply air to a
pressure that will not allow the winch to pull beyond 160% of the rated line pull.
Man Rider Mode:
The overload system is based on differential pressure between air motor inlet and
exhaust. The overload system is factory preset to actuate at 150% (±25) of the Man
Rider (Personnel) rated line pull. When an overload is sensed, the overload valve
sends an air signal to the Emergency Stop Valve, shutting the valve, stopping winch
operation. If an overload shut-off occurs, reset overload valve, and operate winch in
payout direction to lower load. Refer to Dwg. MHP2619 on page 11.
CAUTION
•
Do not use winch to lift personnel in the utility mode. Selector valve must
be in the Man Rider position. Refer to Dwg. 45899051 on page 13, A. Man
Rider; B. NO Man Rider; C. Control Valve; D. Operating Instructions: Pull out
for utility operation, Push in for Man Rider operations.
To select between Man Rider and utility mode, pull valve out for Man Rider operation
and push in for utility. Refer to label part number 45899051, located on valve.
Checking Overload Valve Setting:
Proper test and adjustment of both overload methods should only be performed by
an Ingersoll Rand trained technician.
Utility Mode:
The winch shall not be able to lift a load greater than 160% of the rated utility load.
If this is possible, adjustment is required.
Man Rider Mode:
The winch shall not be able to lift a load greater than 150% of the rated Man Rider
(Personnel) load. If this is possible, adjustment is required.
1. Attach load line to a load that is calibrated to maximum rated load for mode
being tested.
2. Move control lever to haul-in position. If winch does not lift load, adjust the
adjustment screw. Refer to ‘Overload Valve Adjustment’ in Product Maintenance
Information Manual.
Setting the Overload:
Attach load line to a load that is calibrated to winch rated capacity for the mode
being tested. Shift control lever to haul-in position.
1. If overload valve activates, reset overload valve. Winch is ready for normal
operation.
2. If winch lifts load, lower load. Turn adjustment screw (counterclockwise) in 1/4
turn increments until overload valve activates when control lever is shifted to
haul-in position. After each 1/4 turn, retest winch.
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Winch Brakes
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Manual Drum Band Brake (Standard)
The manual drum band brake is applied by pushing down on handle and released
by pulling up. If handle is pushed down fully, it should lock in that position and
prevent band rotation, until released by operator. The brake must be kept properly
adjusted to hold required load. Refer to ‘Adjustments’ in “MAINTENANCE” section
in Product Maintenance Information Manual for instructions.
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Automatic Drum Band Brake
The automatic drum band brake is a spring applied, air released brake which utilizes
an air actuated, spring loaded cylinder, that automatically disengages brake when
motor is operated. Air pressure in cylinder overcomes spring pressure to release
brake. When control valve is placed in neutral position, air in cylinder is vented and
spring automatically engages brake to prevent drum rotation.
The cylinder clevis must be kept properly adjusted to hold required load.
NOTICE
•
Extended exposure to corrosive atmospheres can cause the band brake
lining to adhere to the drum. It is recommended when winch is not in
operation and in a no load condition that the band brake be left in a released
position.
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Automatic Disc Brake (Standard)
The automatic disc brake is a spring applied, air released brake. Using an air actuated,
spring loaded piston, the brake automatically disengages when motor is operated
and engages when throttle is returned to neutral position.
Air pressure ported through brake housing overcomes spring pressure and moves
piston which releases brake. When control valve is placed in neutral position, air is
vented, spring pressure overcomes air pressure and spring pressure moves piston,
engages brake and prevents drum rotation.
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Limit Switches
Limit switches are standard on -CE winches.
Pre-set limit switch settings prevent winch wire rope payout and haul-in by stopping
air flow to the winch motor when a set point has been reached. It is the owner’s and
operator’s responsibility to adjust winch operating limits prior to using the winch.
To adjust the limit switch set points, refer to ‘Limit Switches’ on page 6.
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Emergency Lowering
The following information is provided to allow for emergency lowering of a person
if air supply is lost to winch. These procedures should be used if no other method of
safely lowering personnel is available.
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Precautions
1. Emergency lowering operations must be performed by a minimum of two
personnel trained in the operation of the winch.
2. Communication must be established between lifted person and winch
operators. Operators should be able to visually monitor lifted person until
landed.
3. If line of sight between operators and lifted person is not possible, signals must
be conveyed to the operators.
4. The winch must be isolated from the supply air system during emergency
lowering operations.
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Procedure (-CE versions)
Three Way Valve
Refer to Dwg. MHP3143 on page 13, A. Normal Inlet Air Supply; B. Rotate handle
to use in normal condition; C. FRL; D. Emergency Lowering Inlet.
This device allows the person to be moved the shortest way to safety in case of
normal air supply failure. In the event of air supply failure, operate the three way
valve from normal air supply to the emergency inlet. For an emergency power
source, a 50 litre nitrogen bottle can be used.
1. Open the emergency power source. Rotate valve lever towards normal inlet air
supply side.
2. Ensure that downstream pressure is 5 to 7 bar.
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Form MHD56435 Edition 6
