Sky Climber Alpha 500, User Manual

Page 1: ...Edited by ZEABRON SHIP MANAGEMENT SINGAPORE PTE LTD Document Reference Skyclimber User Manual Version 2 0 User Manual ...

Page 2: ...IPTION 12 2 0 Introduction 12 2 1 General Features 12 2 2 Electric Air Powered Hoists 13 2 2 1 Technical Specifications 13 2 2 2 Controls 13 2 2 3 Crank Handle 14 2 2 4 Hoist Brake 14 2 3 Sky Lock Overspeed Sensitive FallArrest Device 15 2 4 Overload Underload Device 15 Section 3 OPERATION INSTALLATION REEVING 16 3 0 General 16 3 1 Sky Lock Overspeed Brake 16 3 1 1 Installation 16 3 1 2 Operation ...

Page 3: ...ield Inspection 27 5 2 Frequency of Inspections 27 5 3 Operators Safety Equipment Inspection 29 5 4 Sky Lock Overspeed Brake Inspection Functional checks 30 5 4 1 Work environment 30 5 4 1 1 Group 1 Normal 30 5 4 1 2 Group 2 Contaminated 30 5 4 1 3 Group 3 Freezing 30 5 4 2 Inspecting the Sky Lock Overspeed Brake 31 5 4 2 1 Inspecting Trip Performance of Mounted Sky Lock 31 5 4 2 2 Inspecting Load...

Page 4: ... manual is intended to remind experienced operators of the safe operating practices they should consistently follow Are you operating the system according to the book or have short cuts and omissions crept in Have we omitted anything important Do you disagree with anything in this Manual If so please let us know Zeaborn QHSE team by any possible means TO THE NEW SKY CLIMBER OPERATOR Sky Climber ho...

Page 5: ...AUTIONS are not all inclusive It is impossible for Sky Climber Europe to know evaluate and advise on every conceivable way in which our products may be used or serviced and of all possible resulting hazardous consequences It is therefore extremely important for anyone who uses a procedure about which this manual is silent to first satisfy himself that it will not jeopardize his own safety the safe...

Page 6: ... disconnect remove safety belts harnesses or lanyards until you are safely on the ground or until completely disembarked from suspended devices to a safe location 1 2 2 Use a short lanyard and maintain the rope grabs high on the lifeline aspractical 1 3 GENERAL 1 3 1 Know and understand the operation of this equipment Be sure that all persons who service erect dismantle or use this equipment are t...

Page 7: ...doubt consult a professional rigger engineer 1 4 3 Tiebacks additional support Wire sling or canvas sling of sufficient SWL Min 4 Tons must be used on all supporting devices Tiebacks must be kept tight and attached to a structural member being capable of supporting the entire suspended load as well as the support system Note Professionally designed Davit systems do not usually require tiebacks 1 4...

Page 8: ...in order to get the load back on the primary steel wire rope in case of a power failure This will enable you to reset the tripped Sky Lock Refer to section 2 2 3 on how to use the crank handle If Sky Lock has tripped due to overspeed do NOT crank the hoist up in order to try re setting the sky lock 1 6 1 3 Emergency brake release may be used for controlled lowering of the suspended equipment in ca...

Page 9: ...l buttons levers only by manual action It is not allowed to block the control push buttons by any other means 1 8 OPERATOR S SUPPORT WORK PLATFORM 1 8 1 Check stirrup bolts daily and verify that the bolts are still in position and tightened firmly 1 8 2 Never operate a suspended work cage or platform without having the guard rails toe boards bumpers lifelines lanyards and safety harnesses in posit...

Page 10: ...d or freezing environment 1 9 7 When using a hoist in or near a Marine or corrosive salty environment more frequent inspections are required In these applications a thorough 4 hours interval inspection of the hoists steel wire rope fittings and equipment has to be executed Make sure to replace all the components that get degraded by corrosion or wear WARNING The electric powered hoists are not rat...

Page 11: ...rk associated atmospheres such as acid washing the hoist and its supporting steel wire rope shall be protected from direct contact with the corrosive solutions and agents Each day on the final descent the steel wire rope shall be washed with a neutralizing solution and relubricated Stainless steel wire rope which is far more resistant to corrosion deterioration can be obtained from Sky Climber Dai...

Page 12: ...orkstations Sky Climber hoists are used to lift suspended platforms work cages Bosun chairs and other approved devices in suspended access operations All hoists are available in 4 different models Single Phase 220 240V 50 Hz 24V Control Voltage Single Phase 220 240V 60 Hz 24V Control Voltage Three Phase 380 415V 50 Hz 24V Control Voltage Three Phase 380 415V 60 Hz 24V Control Voltage Air WARNING A...

Page 13: ... 44 63kN 44 63kN 44 63kN 44 63kN 44 63kN Climbing Speed 8 5 m min 9 7 m min 8 5 m min 9 7 m min 8 5 m min Sky Lock III 8mm III 8mm III 8mm III 8mm III 8mm Alpha 500 Motor 50Hz 1 60Hz 1 50Hz 3 60Hz 3 Air Voltage Press 220 240V 220 240V 380 415V 380 415V 6 bar Current Flow 6 8 5 7 A 3 3 A 2 1 A 2 m min Power 0 88 0 88 kW 0 88 kW 1 1 kW 0 96 kW Motor speed 1420 1700 rpm 1400 rpm 1700 2800 rpm Weight ...

Page 14: ...its load when there is a power failure and upward travel of the Sky Climber hoist is required Most of the time the distance over which the hoist is to be raised is very limited the main goal is to get the load back on the primary suspension steel wire rope in order to un load and re set the Sky Lock How to use the crank handle Disconnect power supply plug to central control box air distributionyok...

Page 15: ...ck See Figure 2 3 should be used with the right type of hoist see 2 2 1 These models provide a manual trip lever for manual activation or functional checking Installation operating procedures and functional checking procedures are defined in Section 5 4 2 Figure 2 3 2 4 OVERLOAD UNDERLOAD DEVICE The over underload device is a combined device which detects an overload or underload situation to avoi...

Page 16: ... support the descending load The wire rope cannot be released until the load on the Sky Lock brake is relieved NOTE Use always the right type of Sky Lock for the right type of Hoist See 2 2 1 3 1 1 Installation The Sky Lock brake is installed above and attached to the Sky Climber hoist with a coupling link The Sky Lock brake may also be attached to platforms as part of a secondary wire rope instal...

Page 17: ...nd wire rope below the Sky Lock brake If satisfactory operate hoist in up direction 5 to 10cm to relieve load on the Sky Lock brake then turn reset handle as indicated on the Sky Lock brake decal until the Sky Lock brake resets See Figure 3 2 Figure 3 2 WARNING Failure to inspect and functionally check Sky Lock brake operation at the beginning of each work shift in accordance with Section 5 4 2 co...

Page 18: ...NING Release Controlled Lowering Lever to set Hoist brake before releasing crank otherwise serious injury could result 3 2 2 Descent Controlled Lowering Lever If power fails and you desire to lower the hoist and its load Disconnect power at the pigtail connector Release Hoist brake by gently pulling Controlled Lowering Lever as far as it will go See Figure 3 3 3 4 CAUTION Partial release of Hoist ...

Page 19: ... booster transformer or of a separate power cord for each hoist is recommended 3 3 4 Power Cords Because of varying platform load source voltage and electrical system impedance it is impossible to recommend optimum electric cord wire sizes but Sky Climber recommended supply cable will be satisfactory in nearly all cases Extremely long drops may necessitate the use of a voltage booster transformer ...

Page 20: ...oist to come to a full stop before changing direction of travel Rapidly changing position of directional switch may result in loss of control 3 5 HOIST INSTALLATION AND REEVING These mounting and reeving instructions are directed to the reeving of a hoist mounted on the stirrup of a stage These same instructions are generally applicable to the reeving of Compact CX 500 Hoist mounted on work cages ...

Page 21: ...ed in the vertical position thread the prepared top see Section 4 1 2 into the hoist entrance guide Push rope into the unit until it stops Then move directional switch lever in UP direction while maintaining downward pressure on wire rope until self reeving starts Also insert the secondary rope into the Sky Lock WARNING Keep hands clear of pinch pint where wire rope enters Sky Lock brake and Hoist...

Page 22: ...Specifications Use only wire rope obtained from Sky Climber Use of other wire rope may impair the safety of personnel and Hoist performance WARNING Use of wire rope obtained from sources other than Sky Climber could result in serious personal injury and or property damage Steel wire rope for Compact and CX hoists Part n 51008304 Conform to ISO 2408 NBN 04 001 Rope diameter 8mm Construction 6x19S s...

Page 23: ...STORAGE 4 2 1 General Wire rope shall be stored in a coil as shown in Figure 4 2 or on a drum Stored wire rope shall be protected from physical abuse inclement weather and corrosive materials Figure 4 2 Do not drop wire rope from top of structure Wire rope shall be lowered hand over hand Unreeling or uncoiling of wire rope shall be done as shown in Figure 4 3 Use extreme care to avoid kinking or i...

Page 24: ... 4 4 Figure 4 4 Use of a secured loop in bitter end reduces the likelihood of inadvertently running off the bitter end In the event the tail line must be restrained consult your local Sky Climber Europe Office Galvanised wire rope supplied by Sky Climber is lubricated when it leaves the factory Under normal conditions further lubrication is not required 4 3 INSPECTION REPLACEMENT CRITERIA The full...

Page 25: ...e than two broken wires in the vicinity of end attachments g Evidence of core failure a lengthening of rope lay and a reduction in rope diameter suggests core failure h 5 reduction of wire rope diameter when measured under load WARNING Replacement rope shall be to Sky Climber s specifications Wire rope is measured across its largest dimensions on the outer limits of the strands See Figure 4 5 Figu...

Page 26: ...Braze both ends of wire rope See Figure 4 1 WARNING Always check rigging and wire rope clamps before each work shift 4 5 SKY CLIMBER WIRE WINDER The single or dual drum motorised Wire Winder is available as an accessory item The Wire Winder is intended for special applications where the tail line cannot hang free Secure the Wire Winder on the platform end stirrup or walkthrough stirrup Position to...

Page 27: ...orm the indicated FIELD INSPECTION see Table I Corrective maintenance shall always be performed by a factory authorized service representative 5 2 FREQUENCY OF INSPECTIONS The Sky Climber Hoist and associated equipment should be inspected at intervals defined in Table I and related notes Table I represents inspection frequency for normal operation For severe use the time interval between inspectio...

Page 28: ... x RIGGING x x ELECTRICAL CONNECTIONS x x Table 1 Periodic inspection frequency Table notes 1 Frequency of inspection is dependent upon the Work Environment Normal check weekly Abrasive or caustic check daily Freezing check every two hours 2 Inspection method is different than Note 1 See instructions in Section 5 3 Return to Factory authorized service Centre every three months if used in contamina...

Page 29: ...y support the operator s weight Follow the rope grab manufacturer s instructions completely 5 3 3 Inspect lanyard safety belt or harness attachment hardware to ensure that all items are in good condition and can be attached or removed without difficulty Do not use webbed belts or lanyards with broken stitching See Figure 5 2 for the type of safety harness to be used during working at height Figure...

Page 30: ...taminated work environment can be identified as one in which one or more of the following categories of contaminants are used or are in close proximity to the operation Category A Abrasive Material e g sand grit dust welding etc Category B Caustic Material e g corrosive chemicals salty environment acids or fumes etc Category C Adhesive Material e g cement plaster paint caulking compound etc In suc...

Page 31: ...ance guide of the Sky Lock brake This procedure should clear the moisture from the inside of the Sky Lock brake and return it to a condition which will not be adversely affected by below freezing temperature unless subjected to additional moisture To confirm continued acceptable operation the Sky Lock brake must be inspected and functionally checked every two hours as noted above 5 4 2 Inspecting ...

Page 32: ...p the wire rope approximately 30 cm and release it let it drop The Sky Lock brake should trip and Lock onto the rope after a fall of not more than 10 cm See Figure 5 4 Figure 5 4 4 Reattach the Sky Lock brake to the Sky Climber hoist by either Raising the hoist and platform by using power to a position where the attaching bolt can be inserted or Resetting the Sky Lock brake using the reset lever a...

Page 33: ... overload switch shall not be activated at this load 5 Whenever the load on the platform exceeds the trigger level an audio alarm will occur and the overload device will prevent the hoist from moving upwards Compact 480kg CX500 600kg Alpha 500 600kg Alpha 800 960kg Table 2 Trigger levels overloaddevice 5 5 2 Calibration of the underload device 1 Raise the platform 10cm of the surface with the Sky ...

Page 34: ... 18 11 2020 Version 1 The rope housing drain holes at the bottom of the hoist must be kept open to prevent accumulation of moisture and other contaminants Check upon reeving and at the beginning of each work shift See Figure 5 5 Figure 5 5 ...

Page 35: ...tage by using a booster transformer On very long drops TOO much voltage is lost in the electric power cord Use shorter power supply cable with larger copper cross section or use a booster transformer Brake not releasing Check the brake release function by actuating the brake release lever manual when operating the hoist If the hoist functions at normal speed the problem is the brake adjustment or ...

Page 36: ...ST RUNS IN ONE DIRECTION ONLY Defective contactor Return the hoist to an authorized Service Centre MOTOR DOES NOTHING Lost POWER Restore POWER Thermal Overload Tripped motor feels hot After 20 minutes cooldown period try again Emergency stop switch engaged Disengage emergency stop by rotating the red knob ...

Page 37: ... sufficient rope move the platform and top rigging to new work location Reinstall the rigging and any guy ropes tieback and counterweights etc as required to provide safe rigging 4 Actuate Sky Climber hoists to take up slack rope until platform is just fully supported by suspension ropes 5 If a wire winder is used to store excess tail rope check to ensure that the rope is wound cleanly without kno...

Page 38: ...opes and bolts pins secure Rope condition OK Sky Lock snap check Emergency descent of each hoist checked and OK Stage working load below safe working load limit Stage condition bolts pins OK Central yoke box and overloads OK Hoist covers fitted Any service problems notified actioned B UNATTENDED EQUIPMENT Stage on overhead structure or moved into safe area Power off at source Power cable and wire ...

Page 39: ...re ropes connected correctly shackles moused 8 Steel wire ropes safely rigged to platform wire winders optional 9 All bolts in place andtightened 10 Additional securing arrangements for the Aluminum bracket in place 11 General suspension equipment conditionOK 12 Clamp plates safely connected to base channels WORKING PLATFORM 1 All components present 2 Unit set up as per set updrawing 3 All bolts a...

Page 40: ...re rope on storage drums 10 Drive to top of hold checking reeving of wire ropes and power cable 11 Ensure all users are thoroughly briefed in platform use 12 Briefly check all bolts pins and couplings UNATTENDED EQUIPMENT 1 Suspend platform to an inaccessible position which should be at least 3 meters above ground level 2 Anchor platform inside the hold to prevent damage to the equipment and prope...