R & M Stagemaker SM10, Installation & Maintenance Manual

Page 1: ...cert Hoist Springfield Ohio USA SM10 Installation Maintenance Manual 800 955 9967 www rmhoist com June 2006 STAGEMAKER CONCERT ELECTRIC CHAIN HOIST SM10 INSTALLATION MAINTENANCE MANUAL JOB NO SERIAL N...

Page 2: ...ls Handling Inc STAGEMAKER COMPACT Concert Hoist Springfield Ohio USA SM10 Installation Maintenance Manual 800 955 9967 web www rmhoist com June 2006 5 June 2006 i SM10 M I MANUAL 2006 0 doc LEAVE THI...

Page 3: ...ion B Single speed 230 Volt Wiring Diagram 15 3 8 Configuration B Single speed 460 Volt Connections 16 3 9 Configuration B Single speed 460 Volt Wiring Diagram 17 3 10 Configuration B Wiring Diagram L...

Page 4: ...allation Normal Position 44 6 12 Limit Switches 45 6 12 1 Upper and Lower Travel Safety Limit Switch 45 6 12 2 Rotary Geared Limit Switch 45 6 12 3 Rotary Geared Limit Switch Assembly Part Numbers 46...

Page 5: ...information and suggestions for hoist installation maintenance and inspection personnel This manual should be used in conjunction with the STAGEMAKER Concert Electric Chain Hoist Operator s Manual to...

Page 6: ...tential hazards proper operation load limitations and more DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentiall...

Page 7: ...maintain and operate a hoist in accordance with the ASME B30 16 Safety Standard OSHA Regulations and ANSI NFPA 70 National Electric Code If the hoist is installed as part of a total lifting system it...

Page 8: ...AKER Concert Electric Chain Hoist Operator s Manual prior to operating the hoist 1 5 Placards and Instructions READ and OBEY all Danger Warning Caution and Operating Instructions on the hoist and in t...

Page 9: ...t the job site Each complete electric chain hoist is load tested at the factory at 125 of the nameplate rated capacity All hoists are designed for the type of mounting specified by the purchaser The a...

Page 10: ...ENDED LOAD ON HOIST UNATTENDED A SUSPENDED LOAD MUST ALWAYS BE TIED OFF USING APPROPRIATE CHAINS CABLES OR OTHER REDUNDANT LOAD BEARING MEANS BEFORE ACCESS TO THE AREA BENEATH THE LOAD IS PERMITTED 1...

Page 11: ...June 2006 7 SM10 M I MANUAL 2006 0 doc 2 4 Load Hook Throat Opening ANSI B30 16 1998 recommends that the throat opening of a load hook be measured and recorded prior to putting a hoist into service an...

Page 12: ...ls Handling Inc STAGEMAKER COMPACT Concert Hoist Springfield Ohio USA SM10 Installation Maintenance Manual 800 955 9967 web www rmhoist com June 2006 5 June 2006 8 SM10 M I MANUAL 2006 0 doc LEAVE THI...

Page 13: ...cable or conductors have sufficient capacity to maintain the hoist supply voltage by 5 percent of nominal voltage under all operating conditions Poor voltage regulation may cause motor overheating or...

Page 14: ...main power supply to the hoist motor leads via a terminal strip A motor brake rectifier circuit board ACF is provided to operate the D C hoist motor brake assembly The above connection diagram shows t...

Page 15: ...P9 PIN NUMBER TWIST LOCK MALE PLUG L16 20P 3 POLE GRD BLACK L1 L1 X WHITE L2 L2 Y RED L3 L3 Z GREEN PE GROUND PE GROUND G WIRING DIAGRAM LABELS CONFIGURATION A CODE DESCRIPTION L1 POWER SUPPLY PHASE O...

Page 16: ...ECTIONS AS FOLLOWS 1 BRAKE LEAD NUMBER 1 TO TERMINAL X1 14 2 BRAKE LEAD NUMBER 2 TO K22 TERMINAL 4 3 CONTROL TRANSFORMER SUPPLY TERMINAL 127 TO FUSE FIOO 4 CONTROL TRANSFORMER JUMPERS ON T100 PER ABOV...

Page 17: ...10 M I MANUAL 2006 0 doc 3 5 Configuration B Single speed 208 Volt Wiring Diagram 1 1 X1 14 X1 1 X1 3 PE T100 F100 X1 10 K10 A1 A2 K21 A2 A1 K22 A1 A2 L2 L3 K10 1 2 3 4 5 6 03 02 230 01 230 L1 127 K21...

Page 18: ...ECTIONS AS FOLLOWS 1 BRAKE LEAD NUMBER 1 TO TERMINAL X1 14 2 BRAKE LEAD NUMBER 2 TO K22TERMINAL 4 3 CONTROL TRANSFORMER SUPPLY TERMINAL 115 TO FUSE FI00 4 CONTROL TRANSFORMER JUMPERS ON T100 PER ABOVE...

Page 19: ...10 M I MANUAL 2006 0 doc 3 7 Configuration B Single speed 230 Volt Wiring Diagram T1 1 1 X1 14 X1 1 X1 3 PE T100 F100 X1 10 K10 A1 A2 K21 A2 A1 K22 A1 A2 L2 L3 K10 1 2 3 4 5 6 03 02 230 01 230 L1 115...

Page 20: ...ECTIONS AS FOLLOWS 1 BRAKE LEAD NUMBER 1 TO TERMINAL X1 14 2 BRAKE LEAD NUMBER 2 TO K21 TERMINAL 2 3 CONTROL TRANSFORMER SUPPLY TERMINAL 115 TO FUSE FI00 4 CONTROL TRANSFORMER JUMPERS ON T100 PER ABOV...

Page 21: ...SM10 M I MANUAL 2006 0 doc 3 9 Configuration B Single speed 460 Volt Wiring Diagram 1 1 X1 14 X1 1 X1 3 PE T100 F100 X1 10 K10 A1 A2 K21 A2 A1 K22 A1 A2 L2 L3 K10 1 2 3 4 5 6 03 02 230 01 230 L1 115 K...

Page 22: ...NTACTOR K22 DOWN CONTACTOR T100 CONTROL TRANSFORMER F100 CONTROL CIRCUIT FUSE 230 VOLT OR 460 VOLT F101 CONTROL CIRCUIT FUSE 208 VOLT ONLY S221 TRAVEL SAFETY LIMIT SWITCH UP OPTIONAL S222 TRAVEL SAFET...

Page 23: ...OUND G CONTROL ONLY PIGTAIL WITH PLUG CONFIGURATION B WIRE COLOR AWG 16 7 COND CONTROL PANEL CONNECTIONS TWIST LOCK FEMALE RECEPTACLE L14 20R 3 POLE GRD ORANGE UP W BLUE COMMON X BLACK on WHITE DOWN Y...

Page 24: ...5 June 2006 20 SM10 M I MANUAL 2006 0 doc 3 12 Configuration C 230 Volt Single Speed Connections SENSOR BEARING MAX SUPPLY CURRENT 50mA SUPPLY VOLTAGE 11 30V MAX MODULATION 500mV MAX CURRENT 100mA TYP...

Page 25: ...t com June 2006 5 June 2006 21 SM10 M I MANUAL 2006 0 doc 3 13 Configuration C Power Circuit 230V Wiring Diagram X1 PE L2 L3 K10 1 2 3 4 5 6 L1 1 BRAKE COIL U W 2 V 5 2 3 4 5 4 1 6 1 3 2 6 K21 K22 R4...

Page 26: ...X1 9 X1 1 A1 A2 K10 K21 A2 A1 K22 A1 A2 K21 K22 22 21 X1 5 X1 4 X1 3 22 21 K25 A1 A2 S222 X1 2 F29 S221 24 GRD B 24 GR A B BRG RE BL WH BLUE X1 7 X1 8 X1 6 UP DOWN MAIN A 1 2 3 4 13 8 6 9 12 11 5 7 1...

Page 27: ...UP CONTACTOR K22 DOWN CONTACTOR K25 FAST CONTACTOR NOT IN USE WITH SINGLE SPEED T100 CONTROL TRANSFORMER F1 thru F3 CONTROL CIRCUIT FUSES F291 MOTOR THERMAL PROTECTION DEVICE S221 ROTARY GEARED UP LI...

Page 28: ...L14 20R 3 POLE GRD ORANGE UP W BLUE COMMON X BLACK on WHITE DOWN Y GREEN GRD G POWER CONTROL PIGTAIL WITH PLUG CONFIGURATION C WIRE COLOR AWG 12 4 COND CONTROL PANEL CONNECTIONS MALE PLUG HARTING 16...

Page 29: ...SM10 M I MANUAL 2006 0 doc 3 17 Cable Assemblies THE ABOVE CABLE SYSTEMS SCHEMATIC SHOULD BE USED IN ESTIMATING THE TOTAL CONNECTED LENGTH THIS LENGTH SHOULD BE COMPARED TO THE MAXIMUM ALLOWABLE IN T...

Page 30: ...AWG 14AWG 16AWG ONE HOIST HOIST A 58 FEET 7 8 AMPS 36 FEET 7 8 AMPS 23 FEET 7 8 AMPS TWO HOISTS HOISTS B C 29 FEET 7 8 AMPS NOTE IF ANY CIRCUIT HAS TWO 2 WIRE SIZES USE SMALLER WIRE SIZE VALUES MAXIMU...

Page 31: ...ation to beam flange See appropriate trolley manual for details Check direction of hook travel to make certain that it corresponds to respective control button that is depressed That is does hook trav...

Page 32: ...ition up to check that load block makes proper contact with limit switch and that limit switch or slip clutch functions properly Note limit switches not provided for inverted position use Run empty lo...

Page 33: ...perator s Manual that was delivered with this hoist BEFORE PROCEDING WITH THE NORMAL OPERATION OF THIS HOIST THE OPERATOR S SHALL BE TRAINED IN ACCORDANCE WITH THE STAGEMAKER Concert Electric Chain Ho...

Page 34: ...9967 web www rmhoist com June 2006 5 June 2006 30 SM10 M I MANUAL 2006 0 doc 6 MAINTENANCE 6 1 Basic Hoist Construction Inverted Position INVERTED POSITION Figure 6 1 1 SWIVEL HOOK BLOCK ASSEMBLY 2 E...

Page 35: ...ance Manual 800 955 9967 web www rmhoist com June 2006 5 June 2006 31 SM10 M I MANUAL 2006 0 doc 6 2 Basic Hoist Construction Normal Suspension NORMAL SUSPENSION Figure 6 2 1 BODY TOP HOOK 2 FLEXIBLE...

Page 36: ...c disc brake The brake brings the load to a smooth and quick stop and holds the load when the motor is not energized An energized coil releases the hoist brake A load limiting device slip clutch is in...

Page 37: ...components are mounted on or around the motor shaft item 1 2 Item 4 the motor shaft rotor is connected to the motor shaft item 1 by way of a splined connection 3 Item 3 the friction rotor is attached...

Page 38: ...BRAKE ADJUSTING NUT SEE FIGURE 6 3 Make sure the motor is NOT running before placing a socket wrench on the adjusting nut item 5 before making adjustments Do not touch any moving components The slip c...

Page 39: ...slide it over nut item 5 Figure 6 3 Turn nut in required direction INCREASE CAPACITY Turn nut clockwise to increase the torque DECREASE CAPACITY Turn nut counterclockwise to decrease the torque Turn t...

Page 40: ...r gap item X figure 6 4 of the motor brake has been reached or will be exceeded before next inspection readjust air gap Minimum air gap Maximum air gap X 0 008 0 2 mm X 0 020 0 5 mm Before adjusting b...

Page 41: ...d as follows A Slightly loosen turn one of three motor brake mounting screws ITEM 10 B Use wrench and turn adjusting sleeve ITEM 11 to reduce air gap ITEM X C Use feeler gauge to check air gap Tighten...

Page 42: ...ollowing 1 Wear or cracks of the links 2 Twisted or deformed load chain 3 Dirty or poor lubrication of load chain A qualified person SHALL be designated to routinely conduct an in depth inspection of...

Page 43: ...mm MINIMUM Maximum pitch allowed t 0 736 18 7 mm MAXIMUM Maximum length allowed 11t 7 862 19 7 mm MAXIMUM 6 7 2 Load Chain Specifications see Figure 6 5 Chain Feature Specification Chain type Standard...

Page 44: ...st ready for the new chain 5 Remove chain container with all of old chain in chain container 6 Remove fall stop from old chain and save for use with new chain 2 FALL CHAIN 1 Remove load from hook bloc...

Page 45: ...KER COMPACT Concert Hoist Springfield Ohio USA SM10 Installation Maintenance Manual 800 955 9967 web www rmhoist com June 2006 5 June 2006 41 SM10 M I MANUAL 2006 0 doc 6 7 4 Installing the Load Chain...

Page 46: ...n insertion tool is not in the hoist removal procedure attach last link of chain onto hook of CHAIN INSERTION TOOL Figure 6 5 2 Insert other end of CHAIN INSERTION TOOL into chain opening closest to c...

Page 47: ...tainer strap with the snap clip provided FIGURE 6 6 6 9 Removing fall stop Figure 6 6 1 Remove cotter pin item 1 2 Slide up the tube item 2 3 Remove the two fall stop halves item 3 4 Slide tube item 2...

Page 48: ...ormal Position Figure 6 7 Removing Chain Container 1 Run chain out of container until fall stop approaches hoist body 2 Open threaded links item 3 3 Remove chain container by slipping handles of chain...

Page 49: ...it contacts the limit switch that is located on bottom side of hoist body Once switch is activated the up circuit is opened The fall stop activates lower limit switch when hook block is lowered to it...

Page 50: ...tches A NOT AVAILABLE NOT AVAILABLE B OPTIONAL OPTIONAL C OPTIONAL OPTIONAL D MUST USE 4 SWITCH LIMIT STANDARD E OPTIONAL OPTIONAL Note Rotary limit switch assembly cannot be added to a Hoist in the f...

Page 51: ...and specified by the user owner it is recommended that user owner measure actual throat opening of hook as originally furnished See Figure 6 8 Record throat dimension on above sketch Retain as a perma...

Page 52: ...s Handling Inc STAGEMAKER COMPACT Concert Hoist Springfield Ohio USA SM10 Installation Maintenance Manual 800 955 9967 web www rmhoist com June 2006 5 June 2006 48 SM10 M I MANUAL 2006 0 doc LEAVE THI...

Page 53: ...AD CAPACITY LBS TEST LOAD LBS FALLS MINIMUN FAILURE LOAD LBS CLASS 1389 2778 1 8752 025T 2205 4409 1 11023 025T 2756 5512 2 17361 05T 4409 8818 2 22046 05T HOOK DIMENSIONS INCHES M a1 a2 a3 b1 b2 e1 h...

Page 54: ...in prior to removing the Top Hook Removing Body Hook 1 Remove locking plate and pin 2 Pull pin out and remove hook Proper installation of body hook is critical for hoist balance Installing Body Hook 1...

Page 55: ...EAR MEASURE AND RECORD QUARTERLY INSPECTOR CHECK CHAIN HOOK BLOCK HARDWARE TO VERIFY TIGHTNESS QUARTERLY OPERATOR CHECK TOP BODY HOOK COUPLING HARDWARE FOR TIGHTNESS QUARTERLY OPERATOR CHECK SLIP CLUT...

Page 56: ...ION POINT QTY SPECIFICATIONS POSSIBLE BRANDS AS REQUIRED Oil or liquid grease Chain lubricant Ceplattyn or similar EP 90 AS REQUIRED GREASE without MoS2 KP 2 DIN 51 502 Soap based lithium Temperature...

Page 57: ...in bucket Slack fall stop Suspension hook Hook block assembly Control box Qualified Electrician Mechanic Qualified Electrician Mechanic Qualified Electrician Qualified Mechanic Qualified Mechanic Qual...

Page 58: ...Brake not releasing Check brake coil resistance Check air gap setting Adjust if necessary Check rectifier output voltage Load drifts more than 4 inches 100mm Brake lining worn Air gap on brake is too...

Page 59: ...pringfield Ohio USA SM10 Installation Maintenance Manual 800 955 9967 web www rmhoist com June 2006 5 June 2006 55 SM10 M I MANUAL 2006 0 doc 8 PARTS ILLUSTRATION 8 1 Hoist Body 1 2 3 4 5 6 7 8 9 10 1...

Page 60: ...ND CAP SET 8 9 10 1 8 MOTOR END CAP 1 9 M6 SCREW 13 10 DUST CAP 1 11 2240013 O RING 1 12 2240011 BRAKE HOUSING 1 13 2240013 SEAL 1 2249903 BRAKE END CAP SET 14 9 1 14 BRAKE END CAP 1 16 2218000 CABLE...

Page 61: ...PRING SET 1 2 2245025 ROTOR ASSEMBLY 1 2 SPEED MOTORS 1 3 2249941 CHAIN SPROCKET ASSEMBLY 1 4 2249937 PLANETARY GEARING 1ST STEP 1 5a 2249938 PLANETARY GEARING 2ND STEP 16 FPM 1 5b 2249951 PLANETARY G...

Page 62: ...nc STAGEMAKER COMPACT Concert Hoist Springfield Ohio USA SM10 Installation Maintenance Manual 800 955 9967 web www rmhoist com June 2006 5 June 2006 58 SM10 M I MANUAL 2006 0 doc 10 2241501 MOTOR SHAF...

Page 63: ...CT Concert Hoist Springfield Ohio USA SM10 Installation Maintenance Manual 800 955 9967 web www rmhoist com June 2006 5 June 2006 59 SM10 M I MANUAL 2006 0 doc 8 3 Load Chain Lifting Hardware 1 FALL 2...

Page 64: ...17 2 FALL SAFETY LATCH STEEL PLATE 1 2b 2242021 2 FALL LOAD HOOK STANDARD 1 2b 2267015 2 FALL LOAD HOOK SELF LOCKING 1 2c 2213333005 2 FALL CAPACITY STICKER 2 TON 2 fall only 1 2c 2213333012 2 FALL CA...

Page 65: ...MANUAL 2006 0 doc 8 4 Electrical Enclosure 3 Phase Power Supply Configuration A ITEM PART NUMBER DESCRIPTION QTY PER 1 52307759 METAL ELECTRICAL ENCLOSURE COVER BASE 1 2 834176 AFC BRAKE CONTROL CARD...

Page 66: ...METAL ELECTRICAL ENCLOSURE COVER BASE 1 2 52283994 FLEXIBLE CABLE PROTECTOR 2 3 2245062 CONTROL PANEL ASSEMBLY SINGLE SPEED 208 230 460V 115V CONTROL VOLTAGE 1 4 8040111 K10 MAINLINE CONTACTOR 115V C...

Page 67: ...ASE 1 2 52283994 FLEXIBLE CABLE PROTECTOR 2 3 POA CONTROL PANEL ASSEMBLY TWO SPEED 230 48V 115V CONTROL VOLTAGE USED WITH SINGLE SPEED ALSO 1 4 2243060 BRAKE RECTIFIER 4 WIRES 1 5 7983023 CONTROL TRAN...

Page 68: ...June 2006 5 June 2006 64 SM10 M I MANUAL 2006 0 doc 11 POA SENSOR BEARING CONTROL MODULE 1 12 ROTARY LIMIT SWITCH ASSY SEE SECTION 8 8 1 8 7 Chain Guide Assemblies ITEM PART NUMBER DESCRIPTION QTY PER...

Page 69: ...H SET 44 98 FT OF CHAIN 1 1c 2249077 4 POS SWITCH SET 0 43 FT OF CHAIN 1 1d 2249079 4 POS SWITCH SET 44 98 FT OF CHAIN 8 9 Connectors for Pigtails PIGTAILS CONNECTOR PART NUMBERS CONF TYPE CONNECTOR P...

Page 70: ...anual 800 955 9967 web www rmhoist com June 2006 5 June 2006 66 SM10 M I MANUAL 2006 0 doc 8 10 Pickle Assembly ITEM PART NUMBER DESCRIPTION 2309772102 COMPLETE ASSEMBLY 18 INCH PIGTAIL WITH PLUG 1 22...

Page 71: ...s Handling Inc STAGEMAKER COMPACT Concert Hoist Springfield Ohio USA SM10 Installation Maintenance Manual 800 955 9967 web www rmhoist com June 2006 5 June 2006 67 SM10 M I MANUAL 2006 0 doc LEAVE THI...