Verlinde STAGEMAKER MASTER SM5 1002 m1, Manual

Page 1: ...above information without notice 11 2008 STAGEMAKER MASTER SM5 English 18 9 2008 2 Bld de l Industrie B P 20059 28501 Vernouillet cedex France T l phone 33 02 37 38 95 95 Fax 33 02 37 38 95 99 Web sit...

Page 2: ...t 16 6 11 Environmental data 16 6 12 Printed circuit board 2 lifting speeds with emergency stop 17 6 13 Electric board direct voltage control ACF 18 6 14 Printed circuit board 1 lifting speed 1 phase...

Page 3: ...ain 42 11 4 2 Replacement of the chain 42 11 4 3 Measuring the wear on the chain 43 11 5 Suspension hook 43 11 5 1 Measurement of the wear on the suspension and lifting hooks 44 11 6 Spare parts repla...

Page 4: ...fting assembly 62 16 7 Lifting assembly 64 16 8 Lifting assembly 66 16 9 Electric box 3 phases 68 16 10 Electric box Stepless 69 16 11 Standard limit switch up and down 70 16 12 Gear limit switch OPTI...

Page 5: ...e excess loads Before operation check that the load is correctly fastened and installed on the hook The hook safety latches should be closed correctly Do not drive the hook block into the bottom of th...

Page 6: ...nce agent Never use the hoist to extract loosen or pull sideways Do not touch the moving components Do not operate the hoist if your physical condition does not allow it Never use the hoist when in ba...

Page 7: ...rts that are compatible with the type of hoist Never use suspect spare parts or parts whose origin is not known Make sure that the limit stops are in place Never pull the load slantwise maximum angle...

Page 8: ...cal or electrical by an unauthorized party or without our prior agreement The guarantee only applies for original factory installed spare parts For the duration of the guarantee the vendor undertakes...

Page 9: ...ve information without notice 11 2008 5 Acceptance of the material Visually inspect the packaging to ensure that it is intact If not notify it as required Check that the hoist corresponds to your orde...

Page 10: ...8 12 5 SM5 508 m1 500 8 32 0 85 43 1Bm 4 8 12 5 SM5 1004 m1 1000 2 4 16 0 85 43 1Bm 4 8 12 5 SM5 1002 m1 1000 2 8 0 42 43 1Bm 4 8 12 5 The slipping clutch is factory adjusted at a value of 140 5 of a...

Page 11: ...put shaft 2 Gears 5 Chain guide 3 Brake slipping clutch housing assembly 6 Electrical box The hoist which you have just purchased should only be used with a maximum load equal to the nominal load refe...

Page 12: ...peration of the hoist Kinematic chain 1 Motor 2 Chain sprocket 3 Gear 4 Brake slipping clutch Technical advantage The position of the slipping clutch allows should it slip the load to be held in all c...

Page 13: ...1 2008 6 5 Attachment of the hoist 1 Suspension hook 2 Base mounting 3 Suspension L or attachment using the coupling part 6 6 Environmental data Ambient temperature 20 C to 40 C Protection class IP55...

Page 14: ...tput shaft 2 Gears 5 Chain guide 3 Brake slipping clutch housing assembly 6 Electrical box The hoist which you have just purchased should only be used with a maximum load equal to the nominal load ref...

Page 15: ...on without notice 11 2008 6 8 Operation of the hoist Kinematic chain 1 Motor 2 Chain sprocket 3 Gear 4 Brake slipping clutch Technical advantage The position of the slipping clutch allows should it sl...

Page 16: ...weight Refer to dimensional drawings 6 10 Attachment of the hoist 1 Suspension hook 2 Base mounting 3 Suspension L or attachment using the coupling part 6 11 Environmental data Ambient temperature 20...

Page 17: ...ing 2V motor supply 3 lowering 1U L01 motor supply 4 hoisting speed selector 2U L01 motor supply 5 emergency stop GROUND WIRES 6 right electric trolley ground terminal 4 connections see previous page...

Page 18: ...les a rapid brake acceleration As the hoist is not equipped with contactor control electric s ACF Card 1 Hoisting speed 1 Connection to be done 2 Hoisting speed Power supply 1 speed Power supply 2 spe...

Page 19: ...wire 1 Terminal V1 Winding motor V wire 1 1 Terminal for U1 et V1 of the motor U2 Winding motor U wire 2 2 Terminal for capacitor and loading resistor V2 Winding motor V wire 2 3 Terminal for U2 of t...

Page 20: ...rical box 2 Gears 5 Brake flange 3 Brake slipping clutch housing assembly The hoist which you have just purchased should only be used with a maximum load equal to the nominal load refer to the table a...

Page 21: ...16 Operation of the hoist Kinematic chain 1 Motor 2 Chain sprocket 3 Gear 4 Brake slipping clutch Technical advantage The position of the slipping clutch allows should it slip the load to be held in a...

Page 22: ...2008 6 18 Attachment of the hoist 1 Suspension hook 2 Base mounting 3 Suspension L or attachment using the coupling part 6 19 Environmental data Ambient temperature 10 C to 40 C Protection class IP55...

Page 23: ...d as follow 1 For upper limit switch Move the external adjustment disc 2 For lower limit switch Move the internal adjustment disc 3 Check the rotation direction of the disc by operating the hoist 4 Ea...

Page 24: ...2 Remove the guiding bar 1 3 For upper limit switch Move the adjustment disc 4 on the bottom side of the hoist 4 For lower limit switch Move the adjustment disc 3 5 Put the guiding bar 1 back into th...

Page 25: ...of the hook blocks locking plates and chain guide conform to the torques indicated in this manual refer to Screw tightening torques Check that the chain is not twisted Check that the slack fall stop...

Page 26: ...the power switches or the limitation or prevention equipment Never block adjust or remove the limit stops or switches to go higher or lower than these allow 7 1 2 Connection Remove the control box co...

Page 27: ...f the hook blocks locking plates and chain guide conform to the torques indicated in this manual refer to Screw tightening torques Check that the chain is not twisted Check that the slack fall stop is...

Page 28: ...e hoist Never shunt the isolators the power switches or the limitation or prevention equipment Never block adjust or remove the limit stops or switches to go higher or lower than these allow 8 1 2 Con...

Page 29: ...is in good condition every day 8 2 1 Slack fall stop in the chain bucket The slack fall stop is a safety component not a functional one A correct length of chain is required to avoid using it REMOVAL...

Page 30: ...STAGEMAKER 30 VERLINDE reserves the right to alter or amend the above information without notice 11 2008 8 2 2 Chain bucket...

Page 31: ...rectly positioned depending on whether for 1 or 2 falls Check that the tightening torques of the hook blocks locking plates and chain guide conform to the torques indicated in this manual refer to Scr...

Page 32: ...ctric power switch is off Do not use binding posts luster terminals etc to connect the power supply cable to the hoist Do not use rigid cable or cable with a section different to that indicated below...

Page 33: ...n without notice 11 2008 The electrical configuration can be different according to the specifications of the hoist See electrical drawing Do not change the travel direction labels in the control box...

Page 34: ...ually Qualified mechanic Lubrication of the idler sprocket Annually Operator Checking of the screw tightening torques and checking for signs of corrosion Annually Qualified mechanic Adjustment of the...

Page 35: ...the slipping clutch Hook a load of 1 25 times the nominal load into the hoist Note The machined adjustment value is 1 4 x the nominal load because the linings are not run in Remove the brake endcap an...

Page 36: ...ust the air gap by turning the adjusting screw 6 counterclockwise to reduce the airgap clockwise to increase it Tightens the locking screw 5 Make the same operation with the 2 other adjustment points...

Page 37: ...hain when changing it The metallic ring must be oriented towards the hoist body 1 fall chain Insert the last link in the small plastic hook of the insertion tool Insert the other side of the tool in t...

Page 38: ...at the same point of the chain will create a more important wear on the 2 3 links which are in the chain sprocket Never twist the lifting chains turning around of the hook block 10 6 Suspension hook...

Page 39: ...d manufacturer personnel Authorized manufacturer personnel Authorized manufacturer personnel Customer Authorized manufacturer personnel Authorized manufacturer personnel Customer Customer Customer Aut...

Page 40: ...ws Annually Qualified mechanic Lubrication of the idler sprocket Annually Operator Checking of the screw tightening torques and checking for signs of corrosion Annually Qualified mechanic Adjustment o...

Page 41: ...e load torque and the motor torque on the brake are in the same direction Still when the motor is powered the cam system is slightly opened due to the inertia in the flywheel 8 until there is a balanc...

Page 42: ...ve the 2 fall hook block without disassembling it letting the chain run through it Let the rest of the chain slide through the chain sprocket 11 4 2 Replacement of the chain The chain should always be...

Page 43: ...uld be done by measuring the dimensions at several points of the chain of one link d and t and over 11 links 11 t Maximum wear allowed Minimum link thickness allowed d 4 30 mm Maximum pitch allowed t...

Page 44: ...uspension and lifting hooks should be checked regularly Damage safety catches should be replaced immediately Bottom hook see hook certificate If the maximum dimension a2 on the lifting hook is greater...

Page 45: ...thorized manufacturer personnel Customer Authorized manufacturer personnel Authorized manufacturer personnel Customer Customer Customer Authorized manufacturer personnel Authorized manufacturer person...

Page 46: ...ws Annually Qualified mechanic Lubrication of the idler sprocket Annually Operator Checking of the screw tightening torques and checking for signs of corrosion Annually Qualified mechanic Adjustment o...

Page 47: ...ll when the motor is powered the cam system is slightly opened due to the inertia in the flywheel 8 until there is a balance between the load torque and the motor torque The load is then lowered at th...

Page 48: ...lower chain guide Disassemble the fixed point of the chain Remove the 2 fall hook block without disassembling it letting the chain run through it Let the rest of the chain slide through the chain spr...

Page 49: ...f the chain anchor Insert the chain anchor and tighten the 4 screws torque 20 Nm 12 4 3 Measuring the wear on the chain This should be done by measuring the dimensions at several points of the chain o...

Page 50: ...ormal wear is noticed the pieces must be changed Disconnect the power supply before replacing any parts Spare part To be replaced by Qualification of the personnel Upper chain guide Output shaft PG ca...

Page 51: ...M10 M12 Standard screws 6 10 24 48 83 Self tapping screws 5 8 20 40 72 12 8 Discarding the hoist Once the hoist has been used for the FEM class duration all of the components must be checked by an aut...

Page 52: ...the load Slipping clutch worn or incorrectly adjusted Adjust or replace it Braking path of more than 10 cm Brake lining worn Adjust the brake and replace the brake components if necessary The travel...

Page 53: ...oad Slipping clutch worn or incorrectly adjusted Adjust or replace it Braking path of more than 10 cm Brake lining worn Adjust the brake and replace the brake components if necessary The travel direct...

Page 54: ...mpossible to lift the load Upper limit switch is activated Adjust it Braking distance longer than 10 cm during an emergency stop Brake lining worn Adjust the brake Slipping clutch and replace the brak...

Page 55: ...H 2 8P 1 1 52308700 Casing assembled with stator 500V 50Hz3PH 2 8P 1 1 52391642 Casing assembled with stator 400V 50HzBIM 2 8P 1 1 52308702 Casing assembled with stator 230V 50HzBIM 2 8P 1 1 52308703...

Page 56: ...alings 5 1 52308747 Brake cover set 6 1 52311213 Stickers set for SM5 7 1 2218000 Push button station fixing point 8 1 2219918 Set of load plate 250 Kg set of 10 8 1 2219920 Set of load plate 500 Kg s...

Page 57: ...e Description 1 1 2211016 Slipping clutch spring set 2 1 52305652 Rotor Assembly 3 1 52305659 Chain sprocket assembly 4 1 52305473 Gear wheel set 5 1 52308771 Gear assembly 6 1 52308772 Slipping clutc...

Page 58: ...embly 2 52305514 1 Double brake Limiter disk 3 52305516 1 Double brake Limiter axle 4 1 Brake 5 52308396 3 Screw 6 52305515 1 Second brake Support 7 52253277 1 Bearing 8 830860 1 Circlips 9 52305485 1...

Page 59: ...without notice 11 2008 16 4 Mechanism brake Stepless Pos Qty Code Description 1 1 52338099 Rotor Assembly 2 1 52339702 Chain sprocket assembly 3 1 52305473 Gear wheel set 4 1 52339704 Gear assembly 5...

Page 60: ...f locking type 1c 1 2219985 Set of 2 half casings with axle and screws 1d 1 2219937 Load plates 1 fall type 125Kg set of 10 1d 1 2219906 Load plates 1 fall type 160Kg set of 10 1d 1 2219907 Load plate...

Page 61: ...g set of 10 2d 1 2219913 Load plates 2 falls type 1000Kg set of 10 3 1 52309350 Chain anchor assembly 4 1 52309351 Upper and lower chain guide assembly 5a 1 2219990 Chain bucket 8m chain length capaci...

Page 62: ...f locking type 1c 1 2219985 Set of 2 half casings with axle and screws 1d 1 2219937 Load plates 1 fall type 125Kg set of 10 1d 1 2219906 Load plates 1 fall type 160Kg set of 10 1d 1 2219907 Load plate...

Page 63: ...1 2219913 Load plates 2 falls type 1000Kg set of 10 3 1 52309350 Chain anchor assembly 4 1 52309351 Upper and lower chain guide assembly 4a 2 3 52305498 Rubber buffer 5a 1 2219990 Chain bucket 8m chai...

Page 64: ...f locking type 1c 1 2219985 Set of 2 half casings with axle and screws 1d 1 2219937 Load plates 1 fall type 125Kg set of 10 1d 1 2219906 Load plates 1 fall type 160Kg set of 10 1d 1 2219907 Load plate...

Page 65: ...2 falls type 1000Kg set of 10 3 1 52309350 Chain anchor assembly 4 1 52309351 Upper and lower chain guide assembly standard 1 52391817 Upper and lower chain guide assembly inverted position 5a 1 22199...

Page 66: ...f locking type 1c 1 2219985 Set of 2 half casings with axle and screws 1d 1 2219937 Load plates 1 fall type 125Kg set of 10 1d 1 2219906 Load plates 1 fall type 160Kg set of 10 1d 1 2219907 Load plate...

Page 67: ...00Kg set of 10 3 1 52309350 Chain anchor assembly 4 1 52309351 Upper and lower chain guide assembly standard 1 52391817 Upper and lower chain guide assembly inverted position 4a 2 3 52305498 Rubber bu...

Page 68: ...d 575V60Hz48vac 2 1 2213025 PC board 400V50 60Hz115vac 2 1 2213014 PC board 460V60Hz115vac 2 1 2213015 PC board 230V60Hz115vac 2 1 2213017 PC board 230V 460V60Hz115vac standard 2 1 2213018 PC board 23...

Page 69: ...8 Sealing for electric cubicle 4 1 7983061 Contactor 48 Vac 4 1 1123051 Contactor 115 Vac 5 1 52314654 Transformer 400V50 60Hz48vac 5 1 52314653 Transformer 460V50 60Hz115vac 6 1 52300287 Inverter fil...

Page 70: ...11 Standard limit switch up and down POS QTY CODE DESCRIPTION 1 1 2214011 Upper chain guide 2 1 52305493 Lower chain guide 3 1 52293583 Set of 3 springs 4 1 52305660 Set of chain guide and limit switc...

Page 71: ...1 2008 16 12 Gear limit switch OPTION POS QTY CODE Description 1 1 52305505 Set of Gear cover 2 1 52305507 Shaft 3 1 52314475 Set of fixing screw for limit switch spacer pieces 3 4 5 6 1 52314755 Set...

Page 72: ...eserves the right to alter or amend the above information without notice 11 2008 16 13 Adjust limit switch Stepless POS QTY CODE Description 1 1 52337490 Set of Gea limit switch 40 m shaft rep 2 2 2 8...

Page 73: ...ase Pos Qty Code Description 1 1 2211016 Slipping clutch spring set 2 1 52315793 Rotor Assembly hoist with 1PH 3 1 52305659 Chain sprocket assembly 4 1 52305473 Gear wheel set 5 1 52308771 Gear assemb...

Page 74: ...2a 1 1113098 Main contactor KAU 230 Vac 50 60 Hz 2b 1 52314640 Capacitor 40uF for hoist with 1PH 230Vac 50 60 HZ 2c 1 52314641 Capacitor 5uF for hoist with 1PH 230Vac 50 60 HZ 2d 1 2243060 Rectifier 2...