EN

Explosion-protected wire rope hoists (ATEX)_ Operating and Maintenance Instructions

AS7. ex/Zone 22 Category II 3 D

Zone 22 (ATEX)

Fundamental information
You have purchased a product manufactured by STAHL CraneSystems GmbH. This wire rope hoist has been constructed in compliance with the applicable standards and regulations Inspect hoist for damage caused in transit immediately upon delivery. Report damage caused in transit and after consulting the manufacturer/supplier repair or have repaired before installation and commissioning. Do not install or commission a damaged hoist!

Assembly installation commissioning tests maintenance and elimination of faults

may only be carried out by an Ex specialist

Terms employed User Whoever uses and employs the wire rope hoist or has it operated by suitable trained personnel is considered to be the user (employer/company). Trained personnel Trained personnel are persons who have been instructed and trained in the duties with which they are entrusted and the risks which may arise from incorrect behaviour, have been advised on the necessary protective devices, precautions, applicable regulations, accident prevention regulations and prevailing conditions and have proven their ability. Skilled electrician A skilled electrician possesses knowledge and experience on electrical equipment arising from specialist training and, with knowledge of the applicable standards and regulations, is able to assess the work with which he is entrusted and detect and avoid possible risks. Definition of a qualified person (Ex specialist): A qualified person is one with the necessary qualification, based on theoretical and practical knowledge of hoists, in particular with regard to explosion protection, for the required activities as listed in the operating instructions. The person must be in a position to assess the safety of the installation in conjunction with the application. Persons with the authority to undertake certain maintenance work on our products include service engineers of STAHL CraneSystems GmbH and trained fitters with the corresponding certification.

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Seminars: Comprehensive understanding of material handling products is a prerequisite for the correct use of equipment. Competent and practically oriented, we impart the specialist knowledge required for the correct use, monitoring and care of your installation. Please ask for our seminar programme.

Contents

Zone 22 (ATEX)

1 Safety instructions

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11

Symbols .......................................................................................................................... 4 Mechanical components.............................................................................................4 Operating instructions ................................................................................................. 5 Use for intended purpose ............................................................................................ 5 Safety-conscious operation........................................................................................ 5 Organisational safety precautions............................................................................. 5 General regulations ...................................................................................................... 6 Installation, commissioning, maintenance and repairs ......................................... 6 Warranty......................................................................................................................... 6 Periodic tests................................................................................................................. 6 After sales service........................................................................................................ 6

2 Getting to know the wire rope hoist 3 Installation

.................................................................................................................................................... 7 3.1 3.2 3.3 3.4 3.5 4.1 5.1 5.2 Stationary wire rope hoist ........................................................................................... 8 Double rail crab............................................................................................................. 9 Travel limit switches................................................................................................... 10 Electrical equipment .................................................................................................. 11 Reeving rope................................................................................................................ 14 Commissioning ............................................................................................................ 15 Duties of crane operator ........................................................................................... 16 Operating control pendant ........................................................................................ 17

4 Commissioning 5 Operation 6 Inspection and maintenance

.................................................................................................................................................. 18 6.1 Inspection intervals .................................................................................................... 19 6.2 Maintenance intervals ............................................................................................... 20 6.3 Hoist motor brake ....................................................................................................... 21 6.4 Travel motor brake...................................................................................................... 22 6.5 Hoist limit switch......................................................................................................... 23 6.6 Overload cut-off .......................................................................................................... 25 6.7 Crane test ..................................................................................................................... 25 6.8 Rope drive .................................................................................................................... 26 6.9 Crab ............................................................................................................................... 31 6.10 Gear............................................................................................................................... 32 6.11 Remaining service life................................................................................................ 32 6.12 General overhaul ........................................................................................................ 33 7.1 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 9.1 9.2 9.3 What is to be done if? ................................................................................................ 34 FEM classification ...................................................................................................... 36 Operating conditions .................................................................................................. 36 Hoist .............................................................................................................................. 37 Crab ............................................................................................................................... 37 Cable cross-sections and supply cable lengths.................................................... 38 Tightening torques for screws.................................................................................. 39 Lubricants..................................................................................................................... 39 Noise level.................................................................................................................... 40 Circuit diagrams .......................................................................................................... 40 Serial number .............................................................................................................. 41 Hoist .............................................................................................................................. 41 Travel motor ................................................................................................................. 41

7 Fault-finding 8 Technical data

9 Wearing parts

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Subject to technical alterations; errors and printing errors excepted.

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Safety instructions

Zone 22 (ATEX)

1.1 Symbols

Transport The wire rope hoist is delivered on a special pallet. This enables the hoist to be loaded and unloaded safely with a fork-lift truck. If the wire rope hoist is to be transported suspended, it must be attached by eyebolts (M24), see sketch.

Explosion protection The explosion-protected wire rope hoist and its equipment are constructed according to European norms (ATEX). Parts bearing this symbol are explosionprotected, (type of protection "dustproof housing" IP 66). Work on these components may only be carried out by skilled personnel that has been especially trained on explosion protection.

Safety at work This symbol marks all information on safety at work where risks to life and limb are entailed.

Warning of electrical voltage Covers such as hoods and caps which are marked with this symbol may only be opened by "qualified persons or suitably instructed personnel".

Warning of suspended load It is forbidden for persons to stand under suspended loads. This entails risks to life and limb!

Safety in operation Information marked with this symbol must be observed to avoid damage to the wire rope hoist or the goods transported.

In these operating instructions, these symbols mark particularly important information on risks and safety in operation.

1.2 Mechanical components

"Mechanical explosion protection" refers to all mechanical sub-assemblies (nonelectrical sub-assemblies). These include for example 1) Rope drive with drum and load suspension equipment 2) Gear 3) Trolley and crane wheels These sub-assemblies have been manufactured in such a way, relating to the specific order, that they do not present any risks when used for the intended purpose. To ensure lifetime safety, these sub-assemblies must be inspected and serviced carefully in accordance with these operating instructions.

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Safety instructions

Zone 22 (ATEX)

1.3 Operating instructions

Read carefully and follow the operating instructions. The operating instructions are required by the EC Machinery Directive and EC Directive 94/9. The operator is legally required inter alia by EC Directive 99/92 to observe them.

1.4 Use for intended purpose

Wire rope hoists are intended for lifting freely movable and guided loads that cannot tilt. Depending on their design, they are for stationary or mobile use. If loads are to be towed horizontally, or in the case of guided loads, automatic operation, continual deadweight or constantly repeated hoisting motions, the individual application must be assessed. Please contact the manufacturer in case of doubt. Do not carry out any alterations or modifications. Additional fitments must be authorised by the manufacturer (STAHL CraneSystems).The declaration of conformity may be invalidated. Not permitted: Exceeding the safe working load Transporting persons Pulling loads at an angle Pulling loads loose Pulling or towing loads if the wire rope hoist has not been especially designed for this application. Manipulating the overload cut-off, apart from corrections as described on page 35. Operating the hoist with slack rope. If the hoist forms "part of a machine," the person placing it on the market must ensure that the hoist meets the specific regulations of the application

1.5 Safety-conscious operation

The AS7. ex/Zone 22 wire rope hoists are constructed according to the state of the art and equipped with an overload cut-off. In spite of this, dangers may arise from incorrect use or use for an unintended purpose. The operator is responsible for ensuring that work is carried out with safety in mind and avoiding risks, see page 2. Read the operating instructions before starting to work with the wire rope hoist. Do not lift any loads heavier than the rated load. Standing under a suspended load is forbidden. Danger to life and limb! Observe the "Duties of crane operator", see page 17. Before starting work, find out where the EMERGENCY STOP button is (usually in the control pendant). Do not put your hand between edges which might pinch or cut. Do not use the emergency limit switch (ultimate limit switch for highest and lowest hook position) as an operational limit switch. Report damage and defects to the wire rope hoist (abnormal noises, impaired braking function, deformations, ...) to the person responsible immediately. Do not use the wire rope hoist until the faults have been eliminated. Do not remove information plates from the wire rope hoist. Replace illegible or damaged plates. Have hoist inspected by the relevant authority before commissioning.

1.6 Organisational safety precautions

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Only direct persons to operate the hoist if they have been trained or instructed in its use. Observe the legal minimum age! At regular intervals, check that work is being caried out in a safety-conscious manner. Observe the intervals specified for periodic tests. File the test reports in the test log book. Store the operating instructions within easy reach where the wire rope hoist is operated.

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1.7 General regulations

Safety regulations and accident prevention regulations. National regulations Regulations listed in the EC declaration of conformity. Statutory regulations relating to EC Directive 99/92.

1.8 Installation, commissioning, maintenance and repairs

Installation, commissioning, maintenance and repairs may be carried out by qualified persons only, see page 2. We recommend having installation carried out by STAHL CraneSystems qualified personnel trained on explosion protection. Use only original spare parts for repairs, otherwise the guarantee will become invalid. Do not carry out any alterations or modifications. Additional fitments must be approved by the manufacturer (STAHL CraneSystems). If the wire rope hoist is constantly operated out of doors and exposed to the elements without protection, we recommend fitting a small roof or at least "parking" the hoist under a roof.

1.9 Warranty

The guarantee will become invalid if these operating instructions are not observed for installation, operation, inspection and maintenance. Repairs and elimination of faults within the scope of the warranty may only be performed by qualified personnel (see page 2) after the manufacturer/supplier has been consulted and has given his approval. The warranty will become invalid if the hoist is modified or original spare parts not used.

1.10 Periodic tests

Hoists and cranes must be inspected by a qualified person, see page 2, at least once a year. The results of the test must be recorded and filed in the test log book. The remaining service life of the hoist acc. to FEM 9.755 must also be established during this inspection. The periodic tests must be adapted to the hoists use. Intensive use entails shorter maintenance intervals. All tests must be initiated by the user, see page 2. The components ensuring explosion protection must be checked every 3 years at the latest. As a rule, some of these are checked during the annual inspection (e.g. installation, attachment...) If the ambient conditions are severe, the intervals between the periodic tests must be shortened as necessary.

1.11 After sales service

With the purchase of this wire rope hoist, you have decided on a high-quality piece of lifting equipment. Our after sales service will give you advice on its correct use. In order to maintain the safety and constant availability of your wire rope hoist, we recommend concluding a maintenance agreement on the basis of which we will undertake the "periodic tests" on your behalf. Repairs will be carried out professionally and quickly by our trained personnel.

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2 Getting to know the wire rope hoist

Zone 22 (ATEX)

The modular concept of our series of wire rope hoists permits a multitude of variations on the basis of series components. Our certified quality assurance system to DIN ISO 9001/EN 29001 and our special inhouse process inspection to EC directive 94/9/EC guarantee consistently high quality.

The AS7. ex/Zone 22 wire rope hoist is designed for use in Zone 22 in accordance with EC directive 99/92/EC. The equipment category in accordance with EC directive 94/9/EC is II 3 D 120C for the electrical components and II 3 D c for the mechanical components. N.B.: Equipment in category II 2 D is necessary in the case of conductive dusts. (DIN EN 50281-1-2). If you have any questions, for example on hoists modified to customers specific applications, please contact one of our branches or subsidiaries. We will be pleased to advise you!

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1 Panel box for Zone 22 2 Gear 3 Rope drum 4 Rope guide with rope tensioner 5 Rope drum bearing 7 Ex Zone 22 motor 8 Ex Zone 22 brake 9 Fan 10 Fan cover 11 Stationary hoist, hoist for installation 12 Hoist with double-rail crab

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3.1 Stationary wire rope hoist

3.1.1 Possible installation positions

In standard design with rope lead-off vertically downwards, the wire rope hoist is bolted onto a horizontal surface by means of the foot holes. Please consult us in the case of other rope lead-offs. Use the fixing elements specified, see sketch. Take care that no distortion arises from unevenness, etc. Take up any lateral forces in the attachment by a support bar (see sketch *3).

3.1.2 Fleet angles The fleet angles given in the table can be obtained by rotating the rope guide on the rope drum and positioning the wire rope hoist accordingly. The rope guide must be adapted to the fleet angle. Observe also the radial rope exit angle .
Standard Type

By rotating rope guide

A 1 AS 70 18 30

B 3-10

C 55 on request

3.1.3 Angles of installation Install the wire rope hoist within the permissible range of angles. Hoists with rope drives with bottom hook blocks must always be installed horizontal to their longitudinal axis. The max. permissible rope exit angle acc. to standard is 4 for non-twist-free wire ropes, 1.5 for twist-free wire ropes. However at these angles a reduction in service life is to be expected. The wire rope must not touch the rope guide or structural elements. This could lead to increased wear and damage and higher temperatures and sparks at the point of contact that must be avoided at all costs in Ex areas.

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3.2 Double rail crab

Check track gauge Spw on crab and rail. L1 max - L1 min = 5 mm, see sketch. Check lateral play between rail and flange, see sketch. Bolt rubber buffers to crab or runway end stop. Fit suitable stops. Dimensions see sketch and table. The runway must meet the requirements of DIN 4132. The rail joints must be even on both running and guide surfaces; grind down if necessary.

Check that the crab runs smoothly over the whole runway without jamming or increased friction at the wheel flanges. Increased friction at the flanges due to poor beam quality or incorrect crab adjustment may lead to temperature rise or increased wear. This must be avoided at all costs.

D S [mm] 315 4,5-7 400 4,5-7,5

S as per table if crab is positioned symmetrically on runway. If asymmetrically, Sleft + Sright = 2 x S

End stops The crabs are equipped with buffers. Suitable end stops must be provided at the end of the runway.

Wheel b D [mm] 315 160 400 240

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3.3 Travel limit switches

The travel limit switch assembly is supplied ready-wired but not mounted and must be secured to the towing arm for the power supply. The switching contacts are designed for control current.

Switching functions: Pre-switching and limit switching in both directions of travel. The speed is switched over from "fast" to "slow" before the end of the runway is reached, and is cut off at the end of the runway. X = stop, left Y = stop, right Z = fast / slow

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3.4 Electrical equipment

For the sake of safety, have the wire rope hoist connected by a skilled electrician. Observe the relevant safety and accident prevention regulations! The skilled electrician must be acquainted with permissible clearances in air and creepage paths, and with cable glands in hazardous areas. Only electrical equipment approved for use in the relevant Ex Zone may be used!

3.4.1 Supply cable As fixed installed cables: NYY, NYM. As flexible cables: PVC, HO7RN-F or NGFLGu, or equivalent cables. See page 38 for minimum cross-section and maximum length.

3.4.2 Fusing NEOZED, DIAZED or NH fuses in operating class gL/gG see page 37. Observe the correct fuse sizes so that the crane switch contacts do not weld if there is a short circuit and overload protection of lead is ensured!

3.4.3 Emergency stop It must be possible to disconnect the system electrically from the operating position. This function can be provided by: EMERGENCY STOP button in the control pendant in conjunction with the crane switch contactor, main isolator, if this is directly accessible and positioned close to the operating position.

3.4.4 Main isolator must disconnect the wire rope hoist on all poles, must be lockable in OFF position, must be installed in an easily accessible place in the system, must be marked as such to avoid mistakes.

3.4.5 Disconnect switch is necessary if more than one floor-operated hoist is supplied with power, must be lockable in OFF position.

3.4.6 Overload cut-off - description of system prevents an overload being lifted. If an overload has been established, the load can only be lowered.The switch is set in the factory. Corrections are only permissible in special cases, see page 38. In certain applications, wire rope hoists may also be used without an overload cutoff. However in this case they do not meet the requirements of the EU directives and are not marked with the CE symbol.

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3.4 Electrical equipment

(continued)

3.4.7 Test before first commissioning obliges the operator to have the installed, modified or repaired electrical equipment or electrical equipment combined into systems tested after the installation and erection work has been completed according to a special test in order to establish its proper condition as regards erection, installation and operation. A comprehensive functional test and safety inspection must be performed after installation to ensure safety in operation. This test is often subject to specific national regulations. After completion, the test must be recorded in the test log book. Faults must be eliminated before commissioning. We recommend having this test performed by the manufacturer (STAHL CraneSystems).

3.4.8 Mains connection Before a connection box or panel box is opened, the apparatus must be disconnected. Caution! Pay attention to the explosion hazard. If necessary call in site safety representative!

3.4.9 Connecting to mains Compare existing mains voltage and frequency with the information on the rating plate. Route cables into the hoist connection box through the dustproof Ex cable glands (IP 66). Connect according to the circuit diagrams supplied. Do not connect any live lead to the temperature sensors! Damaged temperature sensors cannot protect the motor. Check that the direction of rotation of the rope drum corresponds to the symbols on the control pendant : Press "slow up" button on control pendant. Never press down button first! If the hook moves upwards or does not move because the limit switch has disconnected in top hook position, the phase connection is correct. Crosscheck by pressing "slow down" button on control pendant. If the movement of the hook does not correspond to the symbols on the control pendant, interchange two phase conductors of the supply cable. Caution! If when the down button is pressed the wire rope hoist is disconnected in top hook position by the EMERGENCY limit switch because the phase connection is incorrect, all hoisting motions are locked. Releasing limit switch: 1. Release stop (A) on limit switch bar. (The limit switch moves to its starting position and the wire rope hoist can be operated.) 2. Interchange two phase conductors of the supply cable. 3. Caution, risk of accident! Reset limit switch, see page 24. Measure control voltage. If the measured value exceeds the rated control voltage by more than 10%, a different tapping point must be selected on the primary side of the control transformer. Caution! Risk of accident! If this is not observed, serious accidents or damage to the hoist may occur! Controls by others (option) (Only after consulting the manufacturer) If the controls are supplied by others, connect the temperature sensors of the hoist motor, the hoist brake, the overload cut-off and the emergency hoist limit switch according to our connection diagrams.
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3.5 Reeving rope

The wire rope is wound onto the drum in the factory. If not, see page 28, "Fitting wire rope". Proceed as follows to reeve the bottom hook block: Gripper pliers hold the rope securely. The wire rope hoist must be switched on in order to reeve the rope. All work must therefore be carried out with extreme care: for your safety and for troublefree functioning of the wire rope hoist! 1. Lay out the end of the rope not wound on the drum, or let it hang freely. 2. Check that the wire rope lies snugly on the rope drum, tighten if necessary. Avoid slack rope on the drum! Slack rope can destroy the rope guide and the wire rope. 3. Colour code the beginning of the rope on one side. 4. Reeve the end of the rope into the rope sheave(s) of the bottom hook block and return pulley(s), see page 14. Do not twist the rope; the colour coding facilitates checking. 5. Fasten the end of the rope in the rope anchorage, see page 14. 6. Perform several runs over the full height of lift without load. 7. Repeat with increasing loads. 8. Make any twisting in the rope visible by sticking on a paper tag. Severe twisting is shown by the bottom hook block's turning, especially when not under load. 9. If any twisting should occur, remove the wire rope and untwist by letting it hang freely or laying it out. Twisting in the wire rope prejudices safety and service life.

Any twisting should therefore be removed before subjecting the hoist to any further load. The rope could otherwise be permanently distorted and might have to be replaced!

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Reeving rope Reeve the rope as shown in the sketches and attach the end of the rope in the rope anchorage:

2
Fig. 1/1 2/1 4/1 2/2-1 4/2-1 8/2-1 12 1 + 13 L1-3: 2 + 14 L4: 3 + 15 4 5 + 16 6 + 16

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11.4

Rope anchorage Note information plate at rope anchorage. Insert end of rope into rope anchorage according to reeving, see sketches 11-16. Place rope around rope wedge 11.2 and pull it into the tapered rope recess 11.1 until the loose end of the rope projects by approx. 100 mm. Secure loose end of rope with rope clamp 11.3 approx. 50 mm from the end of the rope. Replace split pin (11.4) after dismantling it; bend ends of split pin up. 13 14

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4 Commissioning

Zone 22 (ATEX)

4.1 Commissioning

The wire rope hoist has been subjected to a final inspection by the manufacturer in accordance with the EC Machinery Directive. Commissioning must be carried out by a qualified person, see page 2. The "Safety instructions" on page 4...6 must also be observed.

The following checks must be carried out:

Check that the wire rope hoist is completed with the original accessories as supplied (e.g. bottom hook block), see page 14. Check correct selection and installation of all electrical equipment,see page 11, "Electrical equipment". The Ex symbol must be affixed to the hoist or crane. Electrical connection, see page 12. Check that the seating of fixing screws is firm and secure, see page 8, 39. Check correct functioning of runway end stops. The direction of motion of the load hook must correspond to the symbols on the control pendant. Check the presence and correct functioning of all safety devices. Check emergency hoist limit switch or combined operational and emergency hoist limit switch, see page 23. Check overload cut-off, see page 25. Confirm that commissioning has been duly carried out in the test log book in section "Confirmation of commissioning". If the wire rope hoist in conjunction with a crane system is to be subjected to a test load during the acceptance test, the overload cut-off must be bridged (see page 25, crane test). See circuit diagram.

Any fundamental alterations and modifications to the wire rope hoist, such as e.g welding on load-bearing components, structural alterations to load-bearing components, alteration of drives, alteration of speeds and motor outputs, replacing trolleys, etc. must be authorised by the manufacturer (STAHL CraneSystems GmbH). Also any work on or additions to the control must be authorised by the manufacturer. The manufacturer cannot accept any liability for malfunctioning after unauthorised work on the control. Our qualified personnel is available to perform a reacceptance test after authorised modifications.

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Operation

Zone 22 (ATEX)

5.1 Duties of crane operator

When working with wire rope hoists, the following points must be observed: Every day before starting work, check brakes and limit switches and inspect the system for any visible defects. Stop working with the crane if there are any defects which might prejudice its safety in operation. At close of work, secure cranes which are exposed to wind with the wind safeguard mechanism. The rope drum must be free of coarse foreign matter. Do not move loads above people. Do not leave suspended loads unattended, the control pendant must be within easy reach. Do not use emergency limit switch during normal operation. Do not load above rated capacity. Pulling loads at angles, dragging loads, or towing vehicles with the load or load suspension equipment is forbidden! Do not heave up any loads which are jammed. Approach final positions for hoisting, lowering and travel in normal operation only if an operational limit switch is fitted. Inching operation (repeated brief activation of the motor to achieve small movements) is not permissible. Motors and brakes could be subjected to an impermissible temperature rise. This would lead to the temperature control disconnecting and the load could then not be set down for some time. Switchgear and motors could be damaged. Do not move in the opposite direction until the hoist has come to a stop. Observe the safety instructions, see page 4-6. Do not allow load and bottom hook block to hit machines or structural steelwork. In adverse conditions (rust, aluminium, high impact speed) there is a risk of sparking. Avoid trolley and crane wheels slipping due to swinging of load or spinning of drive wheels. There is a risk of sparking and increased temperature rise.

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Operation

Zone 22 (ATEX)

5.2 Operating from control pendant

Standard version 2-step

Lifting/lowering: 1st step: slow 2nd step: fast Cross travel: right/left 1st step: slow 2nd step: fast Long travel: right/left 1st step: slow 2nd step: fast Emergency stop

5.3 Emergency stop

The emergency stop button is on the control pendant. Press emergency stop, the system comes to a halt. To release the emergency stop: turn the button in the direction shown.

Safety note If the rocker switch is no longer depressed by the operator, it returns to the 0 position, the hoist motion is automatically stopped (dead mans control). If the hoist malfunctions, e.g. the actual motion does not correspond to the motion intended in activating the rocker switch, release the rocker switch immediately. If the motion continues, press the emergency stop button.

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6 Inspection and maintenance

Zone 22 (ATEX)

This section deals with operational reliability, availability, and maintaining the value of your wire rope hoist. Although this wire rope hoist is practically maintenance-free, the components subject to wear (e.g. wire rope, brake) and components important for ensuring explosion protection must be inspected regularly. This is required by the accident prevention regulations. Inspection and maintenance must be carried out by qualified persons who have received special training in explosion protection, see page 2.

General information on inspection and maintenance Maintenance and repair work may only be carried out when the wire rope hoist is unloaded. Before starting, switch off and lock main isolator.

It is not permitted to work on live parts in areas exposed to explosion hazards! Dust deposits over 5 mm thick are not permissible. If any dust is deposited, it must be removed from indentations, corners and surfaces in good time. The electrical components (motor, control) and mechanical components (e.g. gear) have a surface temperature of max. 120C during normal operation at an ambient temperature of 50C. A dust deposit of above 5 mm prevents the heat being dispersed sufficiently (insulation) and an impermissible temperature rise will occur on the surfaces and in the adjoining layer of dust. The operator is obliged to prevent a 5 mm layer of dust by observing the hoist and cleaning operations at suitable intervals. Remove any dust which may be present before carrying out maintenance work! The dust must be removed to prevent it entering any open enclosures of the components during maintenance. Observe the requirements of the accident prevention regulations. Periodic tests including maintenance every 12 months, possibly earlier if so prescribed by national regulations, are to be performed by a fitter engaged by the manufacturer. The specified inspection and maintenance intervals apply for normal conditions of use. The inspection and maintenance intervals must be adapted accordingly if one or more the following conditions apply: if after evaluating the acutual use it can be seen that the theoretical useful life of the winch will be less than 10 years, in the case of operation in more than one shift or heavy duty in the case of adverse conditions (dirt, solvents, temperature, etc.) A general overhaul must be carried out after the useful lifetime has expired. Lubricants and lubrication points, see page 39.

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6 Inspection and maintenance

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6.1 Inspection intervals

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6.1.1 Every day Before starting work Check function of brake(s), see pages 21, 22 Hoist limit switch (2) EMERGENCY STOP, crane switch, see page 17 Rope (10), see page 27

6.1.2 Once a year Check suspension of control pendant (cable and steel wire must be correctly attached) Load hook (9), cracks, cold deformation, wear Overload cut-off (6), see page 25 Disconnect switch and main isolator, see page 11 PE connections and equipotential bonding Establish remaining service life, see page 32 Rope attachment (10), see page 26, rope sheaves, see page 30 Rope guide (12), see page 27,29 Drive parts (13), flanges, wheels etc., see page 31 Screw connections, welds End stops, buffers (14) Gear (15) Safety clearances Power supply cable Cable glands Current collector Switching functions

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6.2 Maintenance intervals

30

35

34

31 32

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6.2.1 Once a year Brake (30), measure air gap, replace brake disc if necessary, see page 21, 22 Grease rope (31) with brush, see page 39 Grease rope guide (32) and rope guide stop with brush, see page 39 Grease drive parts (33), gearing with brush Tighten clamping points for electric cables

6.2.2 Every 10 years Grease spline shaft gear/rope drum, toothed coupling of travel drive (34) Change oil in hoist gear (35) Change oil in travel gear (36)

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6.3 Hoist motor brake

Carry out work on the hoist brake only when the hoist is unloaded and the bottom hook block has been set down. "B" 6.3.1 Checking brake Remove fan cover (1) Remove plug (2) Measure air gap (S) with feeler gauge (F). N.B.: When measuring, ensure that the feeler gauge is pushed in at least as far as depth "a" and does not catch on shoulder (!). See table for max. permissible air gap (S). The brake is not adjustable. If the max. permissible air gap (S) has been reached, the brake disc (brake rotor) must be replaced. Replacement must be carried out by an Ex specialist.

6.3.2 Replacing brake disc (brake rotor) "A" Remove fan cover (1) Pull off fanwheel (3), remove feather key Disconnect brake Unscrew fixing screws (4) Remove magnet piece (5) together with armature disc (6) Remove brake disc (brake rotor) (7) Push new brake disc (brake rotor) (7) onto hub (8) and check radial play. If there is increased play in the gearing between brake disc (7) and hub (8) the hub (8) must be pulled off the motor shaft and replaced. Before removing hub (8) please contact the manufacturer.

Replace in reverse order. Ensure that the check hole for measuring the air gap is underneath. Ensure that the gasket (9) is firmly seated and positioned axially on the plane surface (see sketch, detail B).
Hoist motor type 12/2H73 Hoist brake M150 S S a min. max. [mm] [mm] [mm] Nm 0,5 1,6 30 22

Caution! If the max. value for permissible wear is not observed, an impermissible temperature rise may occur in the brake. Explosion protection is then no longer ensured. If hoist is subjected to excessive use, the maintenance intervals must be adapted accordingly. An air gap (Smin) which is too small may also cause an impermissible temperature rise due to the brake linings rubbing.

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6.4 Travel motor brake

Checking brake - SA-C ..

Remove fan cover (1) Remove plug (2) Measure air gap (S) with feeler gauge (F). See table for max. permissible air gap (S). If the max. permissible air gap (S) has been reached, the brake disc (brake rotor) must be replaced. Replacement must be carried out by an Ex specialist.

Replacing brake disc (brake rotor) - SA-C .. Remove fan cover (1) Pull off fanwheel (3), remove feather key Disconnect brake Unscrew fixing screws (4) Remove magnet piece (5) together with armature disc (6) and gasket (8). Remove brake disc (brake rotor) (7)

Replace in reverse order. Ensure that the check hole for measuring the air gap is underneath. Ensure that the gasket (9) is firmly seated and positioned axially on the plane surface (see sketch).
Type Motor type Brake Braking torque [Nm] 1,3 2,5 2,5 5 8 8 13 13 S min. [mm] 0,2 0,2 0,2 0,3 0,3 0,3 0,3 0,3 S max. [mm] 2,0 1,6 1,6 2,0 2,0 2,0 1,0 2,0

(4) 3xM4 3xM4 3xM4 3xM6 3xM6 3xM6 3xM6 3xM6 [Nm] 3 3 3 10 10 10 13 13

SA-C 67 xx 123 SA-C 67 xx 133 SA-C 67 xx 184 SA-C 67 xx 313 SA-C 67 xx 384 SA-C 67 xx 424 SA-C 67 xx 484 SA-C 67 xx 523

8/2F12/2xx.223 8/2F13/2xx.233 4F18/2xx.233 8/2F31/2xx.423 4F38/2xx.433 8/2F42/2xx.433 4F48/2xx.443 8/2F52/2xx.523

FDW 08 FDW 08 FDW 08 FDW 13 FDW 13 FDW 13 FDW 13 FDW 15

Caution! If the max. value for permissible wear is not observed, an impermissible temperature rise may occur in the brake. Explosion protection is then no longer ensured. If hoist is subjected to excessive use, the maintenance intervals must be adapted accordingly. An air gap (Smin) which is too small may also cause an impermissible temperature rise due to the brake linings rubbing.

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Zone 22 (ATEX)

6.5 Hoist limit switch

6.5.1 Testing emergency hoist limit switch Test at fast and creep speed without load. 1. Activate the "up" button on the control pendant carefully, observing the hoisting motion, until the limit switch disconnects in top hook position. 2 Minimum clearance "a" between bottom hook block and nearest obstacle, see table, if necessary reset the limit switch, see page 24. 3 Press the "down" button and check bottom hook position in the same way. 4 Minimum clearance between rope guide (S) and clamping claws (K) for rope anchorage = 20 mm, see sketch, if necessary reset limit switch, see page 24.

a [mm] 50 Hz 1/1 2/2-1 2/1 4/2-1 4/1 130 70 40 60 Hz 150 80 50

6.5.2 Testing combined operational and emergency hoist limit switch Test at fast and creep speed without load. 1 Activate the "up" button on the control pendant carefully, observing the hoisting motion, until the limit switch disconnects in the highest operational hook position. 2 Press override button (U) on control pendant and at the sametime the "up" button until the emergency limit switch disconnects. If the hoist does not continue to move, the emergency limit switch was activated in step 1 and the operational limit switch is not working. 3 Minimum clearance "a" see table. 4 Press "down" button and check bottom hook position in the same way. 5 Minimum clearance between rope guide (S) and clamping claws (K) for rope anchorage = 20 mm, see sketch, if this is not the case, reset limit switch. The clearances between the switching points for operational and emergency limit switches are set for normal operating conditions. ~40-60 mm in top hook position, ~ 80-120 mm in bottom hook position. They can however be adjusted if necessary.

Safety note: Incorrectly set limit switches may cause serious accidents!

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6.5.3 Setting emergency hoist limit switch See page 23, "Testing emergency hoist limit switch". 1. Before setting, perform several runs over the whole height of lift without load. 2. Press "up" button on control pendant until the bottom hook block has reached the desired position for the emergency hoist limit switch. Minimum clearance "a" between bottom hook block and the next obstacle, see table.

a [mm] 50 Hz 1/1 2/2-1 2/1 4/2-1 4/1 130 70 40 60 Hz 150 80 50

3. Push stop (A) for top hook position on the limit switch bar towards the rope guide and clamp in place with the screw. See sketch and table for position of stops. 4. Press "down" button and, if applicable, override button (U) and proceed analogously as above. 5. Minimum clearance between rope guide (S) and clamping claws (K) for rope attachment = 20 mm. 6. Check setting without load.

Safety note: Incorrectly set limit switches may cause serious accidents!

Maintenance of limit switches Maintenance work is restricted to checking the cut-off points. No maintenance or inspection is necessary on the limit switches themselves.

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6.6 Overload cut-off

The SLE2 overload cut-off with the sensor is set in the factory. Corrections are only permitted in special cases, see page 35. The factory settings are shown on a sketch under the front cover of the evaluation device.
S5

Testing overload cut-off If an overload is detected, the wire rope hoist is switched off in the upwards direction. Only lowering is then possible. Lifting is not possible until the wire rope hoist has been unloaded. Attach rated load +10% overload and take load up slowly. After the rope has been tautened the overload cut-off must disconnect the hoist.

W0795

Sensor of overload cut-off The sensor measures the axial force in the hoist gear and is maintenance-free. The setting may only be altered if the factory setting (4 mA without load) has changed. Measure current in "green" lead (at terminal 21). disconnect lead and measure current. A current of 40,3 mA without load must be present. No-load current >4mA Turn adjusting spindle (S) to the right No-load current <4mA Turn adjusting spindle (S) to the left

6.7 Crane test

1. Carefully remove front cover of evaluation device. 2. The cut-off point is increased by pressing button (S5) permitting the test load of 125% to be lifted.

Button (S5) pressed. Cut-off threshhold is raised.

W0902

III

II

err pw r

Safety note: Extremely heavy loads can be lifted. Risk of accident!

S5

The device automatically returns to the original cut-off point after 30 minutes.
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6.8 Rope drive

6.8.1 Rope and rope attachment - general information After commissioning a new wire rope hoist, or after replacing the rope, the rope of multi-fall hoists may twist. This can be seen from the bottom hook block turning, particularly when unloaded. Twisting in the rope prejudices safety and service life. Remove any twists! Regularly inspect the rope for twisting. To do so, run the hoist into highest and lowest hook positions without load. If any twisting is detected, untwist the rope immediately. See page 24, "Reeving rope" and see page 42, "Removing rope". Check rope. Take particular note of the sections of rope near rope pulleys, return pulleys or equalizing pulleys and in the region of the rope anchorage. If any of the following damage occurs, replace the rope immediately. 1 Excess visible wire fractures, see page 41, table. The rope must be free of load for testing to facilite detecting any broken wires when bending the rope by hand (approximately by radius of rope sheave). 2 Nest of wire fractures or broken strand. 3 Diameter reduced by 10% due to corrosion or wear (independent of breakage). 4 Diameter reduced due to structural changes over considerable sections. 5 Formation of baskets or loops, knots, necking, kinks or other mechanical damage. 6 Corkscrew-type deformation. Divergence due to deformation: 1/3x rope diameter. 7 In addition, the rope must be replaced as required by DIN 15020, FEM 9.661 and ISO 4309. 8 In certain applications (e.g. twist-free wire rope, constant deadweight, recurrent stopping position, automatic operation etc.) wire fractures may occur inside the rope without being visible from outside. Risk of accident! In case of doubt please contact the manufacturer.

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6.8.2 Replacement of wire rope due to broken wires Twist-free wire rope

Rope diameter [mm] Number of external strands Rope make-up * Broken wires visible 1Bm, 1Am 2m - 4m over a length of [mm] or Broken wires visible 1Bm, 1Am 2m - 4m over a length of [mm]

20 18 36X7+SE 6 11 120 11 22 600

25

Non-twist-free wire rope

Rope diameter [mm] Number of external strands Rope make-up * Broken wires visible 1Bm, 1Am 2m - 4m over a length of [mm] or Broken wires visible 1Bm, 1Am 2m - 4m over a length of [mm]

20 9 6x35+7FE 9 18 120 18 35 600

25 8 8x36W 12 24 150 24 48 750

* See data sheet for rope make-up

6.8.3 Removing rope guide Unscrew stop (a) of rope guide. Remove guide clip (c). Unscrew screws (d). Remove half-rings. Unhook rope tensioning spring.

a b
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6.8.4 Replacing rope The AS7 ex/Zone 22 wire rope hoists have a special rope which is the optimum for the most common applications. It is essential for the substitute rope to be equivalent to the original. Please consult the works certificate or the rope certificate to see which rope is fitted.

In the case of 2 wire ropes with different lays wire rope with right-hand lay (DS1) on rope drum with left-hand groove wire rope with left-hand lay (DS2) on rope drum with rigth-hand groove The direction of lay of the wire ropes makes a V-pattern (see sketch).

Removing rope Lower bottom hook block to just above the lowest hook position and set it down on a firm support. Release end of wire rope in rope anchorage (rope clamp with rope wedge). Run the remaining rope off the drum. Unscrew the fixing screws in the clamping plates on the rope drum.

Fitting rope Unroll new rope out straight if possible, without twists, kinks or loops. Protect rope from dirt. Attach rope to rope drum with all the clamping plates (do not forget the lock washers!) Allow the rope end to project by approx. 30-40 mm. Tightly wind about 5-10 turns onto the drum under power. Let the rope run through a greased rag. See page 39 for type of grease. Fit rope guide, see page 29 "Fitting rope guide". Reeve the loose end of the rope according to the number of falls, fasten with the rope wedge and secure with a rope clamp, see page 14 "Reeving rope". Retighten clamping plates. See table for tightening torques. Run in roipe under partial load.

M.. M16 M20 Nm 210 410

Caution! Risk of accident! After fitting a new rope, or shortening the old one, reset the hoist limit switch. See page 24, "Setting emergency hoist limit switch". If the new rope twists after some time in operation, untwist the rope immediately. See page 14, "Reeving rope" and "Removing rope".

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6.8.5 Fitting rope guide

Grease thread and groove in rope guide thoroughly. Push the half-ring with the threaded holes onto the drum (1). Block half-ring against the supporting frame with a wooden wedge (2). Push the spring into the guide groove of the half-ring (3) and hook the ends of the spring together. (Will be easier using special tool (a), see sketch.) Push the half-ring with the rope exit slot onto the drum so that the first empty groove of the drum engages the corresponding thread of the half-ring (4). Screw half-rings together with compression springs and bolts (5).

The rope guide must rest lightly on the drum and be able to be turned by hand. If this is not the case, the guide has been fitted incorrectly or the rope drum is damaged. Screw down stop to prevent it turning and grease (6). Bolt on guide clip (7).

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6.8.6 Inspection and maintenance of rope sheave Check rope sheaves for wear. We recommend having them checked by personnel trained by us. They should also be checked for easy running, indicating that the ball bearings are in good condition. Wear on rope sheave Notes on limits for wear
Rope sheave D new t min 375 7 375 7 400 8 450 11 450 11 480 10 on one side and at base on both sides and at base Measuring depth of base of groove with depth gauge

Part number 25 330 00 53 0 25 330 03 53 0 46 330 00 53 0 26 330 01 53 0 09 430 00 53 0 43 330 01 53 0

h max 37 35,5 33 39 39 36,5

h new 34 32,5 30 35 35 32,5

on both sides and at base

Measuring thickness of wall with special caliper gauge

The rope sheave must be replaced if the wall thickness as measured is <t min or the groove depth as measured is >h max. Furthermore, the rope sheave must be replaced when replacing the wire rope if the rope strands have dug into the base of the groove. Impressions of single wires are acceptable. A rope sheave must also be replaced if the radius of the base of the groove R has become too small for the new rope due to reduction in diameter of the old rope or wear. N.B. The negative profile of the rope in the base of the groove may provide optimum contact to the wire rope currently fitted. Rope sheaves should be rotated without load on the rope to check the easy and concentric running of the bearings. Bottom hook blocks The bottom hook block must be checked for damage. Deformations, cracks and cuts caused by impact must be assessed. The damage can only be assessed by trained maintenance personnel. The causes of damage indicating impact and friction stresses must be ascertained. If this type of stress is to be expected during normal operation of the hoist, measures must be taken to eliminate this source of danger. Retrofitting the bottom hook block with a low-sparking metal coating should be considered. There is a risk of impact sparks if bottom hook blocks swing and hit structural steelwork. Rusty steelwork and/or light metal increases the risk. There is a risk that dust may collect inside the protective covers of bottom hook blocks and may damage the roller bearings of the rope sheaves. This may lead to a temperature rise in the bearings. Dust deposits in bottom hook blocks must therefore be removed.
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6.9 Crab

Wheels, wheel drive and runway Visual inspection of wheels for wear. See tables for limits for wear. Visual inspection of runway girder for wear. Visual inspection of wheel flanges for wear. A high degree of wear on the flanges indicates that the trolley cants or is running with its weight heavily on one side. The causes of this must be ascertained and eliminated. The running characteristics can be improved by using a guide system. This avoids abrasion and the play of the track gauge can be reduced.

Bild

bLR

b min

k max [mm] 45 55 65 45 55 65 55 65 75

b1

d1

b2

max Spiel =b*-k kmin kmax 18 18 18 18 18 18 20 20 16,5 18 18 14 18 18 18 20 20 11,5

200

315
Bild 1 Bild 2

400

100 100 100 115 115 115 118,5 118,5 118,5

54 64 74 54 64 74 65 75 85

40 50 60 40 50 60 50 60 70

23 18 13 30,5 (29) 25,5 (24) 20,5 (19) 27,5 (26) 22,5 (21) 17,5 (16)

190

300

385

10,5 10,5 10,5 13,5 13,5 13,5 16 16 16

If any one of the limits for wear d1, b2 (b*-k) is attained, the part must be replaced.
W0903

( ) on machined faces = limit for wea

b LR

Inspection of lower flange on cranes with sectional gider The running surface of the trolley wheels must be checked for uneven wear and the causes of any such wear ascertained. Driven wheels must not display any slippage to the running surface which would cause increased abrasion and temperature rise. Inspection of rails on cranes and crane runways The rails must be laid parallel within the permissible tolerances (see page 9) to prevent the crab or crane jamming. Rail joints must provide a smooth surface to avoid impact and deformation. Inspection of buffer and buffer stop. Ensure that the buffer impact is taken up by the centre of the stop elements provided and that the materials exhibit no detrimental characteristics, see page 9. If the driven wheels spin without there being any travel motion (e.g. against the buffer stop), the temperature on the running surface may rise to an impermissible level. Spinning times of above 5 sec are dangerous. If there is a risk of the wheels spinning longer an electrical cut-off must be provided or the operating personnel trained.

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6.10 Gear

The gearing of AS hoists is hardened and has a high safety factor. With their minimum classification of 1 Bm or 1 Am to FEM 9.511 the gears have a long service life. All bearing points have roller bearings. During annual maintenance, check whether any oil has leaked (puddle of oil underneath the gear, drops of oil on the gearbox). If any loss of oil is ascertained, the oil must be changed and repairs scheduled if necessary. Note any gear noises from the hoist when under load and without load. Rough, noisy running, knocking sounds indicate possible faults. (See "Noise level" for information on normal noise level.) If any faults are detected, repairs must be scheduled. If there is any uncertainty, a fresh diagnosis can be made after consulting STAHL CraneSystems experts. 6.10.1 lstand c When the wire rope hoist is horizontal the oil level should reach the inspection plug. (The oil level inspection plug is marked in red.) c See page 39 for type and quantity of oil. Dispose of used oil correctly to protect the environment. a = Oil drainage plug b = Oil inspection plug c = Oil filling plug d = Oil inspection plug

6.11 Remaining service life

According to FEM 9.755, the operating mode and operating time must be established by the user and recorded in the test log book in order to calculate the remaining service life. After the service life has expired a general overhaul (S.W.P.) *1 must be carried out. Wire rope hoists are equipped ex factory with a suitable registration device. Various designs are used:

6.11.1 Operating hours counter in SLE2 evaluation device The operating hours counter in the evaluation device of the overload cut-off adds up the operating time of the hoist. In order to obtain the lifetime expired in full load hours, the operating hours must be calculated with load factor "k". This is carried out by qualified personnel, see page 2, during the annual "periodic test". If 90% of the theoretical full load lifetime has expired, a general overhaul (GO) must be scheduled and carried out at the earliest possible date. Seilzge sind ab Werk mit einem entsprechenden Erfassungsgert ausgerstet.

*1 Safe Working Period

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6.11.2 STAHL SMC Multicontroller (optional) The operating time of the hoist the full load operating hours are recorded. The SMC1 calculates the full load operating hours from the relevant hoisted load and the hoist operating time. The remaining service life is calculated with reference to the mechanism group and can be read off by means of a PC (laptop). If the theoretical full load lifetime has expired, this is also indicated by an illuminated red LCD, a general overhaul must be scheduled and carried out. Note: Reading the full load operating hours does not replace the prescribed tests including inspecting the wearing parts (rope, return sheaves...)

6.12 General overhaul

FEM9.511 D [h] 1Bm 400 1Am 800 2m 1600 3m 3200 4m 6400

The mechanism (motor and gear; not applicable to wearing parts) of the AS 7. ex/ Zone 22 wire rope hoist is classified according to FEM 9.511. The theoretical full load lifetime in hours shown opposite (D) is applicable for normal hoist applications. If the full load lifetime (D) minus the lifetime expired is nought, the wire rope hoist must be overhauled by the manufacturer. The rope drive is classified according to FEM 9.611. Components which are in the power flux may only be overhauled by the manufacturer. In particular, the criteria important for explosion protection must be observed.

As the service life of components such as gears is limited in accordance with the classification, it must be ensured that this is not exceeded. After the scheduled service life has expired hazards may arise, also with regard to explosion protection. Thus the operator must take the responsibility for the remaining service life and the necessity of a general overhaul. We cannot accept any liability for damage occasioned by non-observance.

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7 Fault-finding

Zone 22 (ATEX)

7.1 What is to be done if?

7.1.1 Wire rope hoist does not start, motor hums Not all power phases are present. 1 Check fuses, 2 Check supply cable, 3 Check control pendant and switchgear.

7.1.2 Wire rope hoist does not start after a long stoppage, or starts with difficulty, motor hums Hoist brake is stuck. 1 Remove fan cover 2 Dismantle brake

7.1.3 Loud clicking when switching on Measure air gap, see page 21, 22. Replace brake disc if necessary, see page 21, 22.

7.1.4 Braking path too long Brake displacement too long. Brake lining worn. Replace brake disc, see page 21, "Hoist brake", see page 22, "Travel motor brake",

7.1.5 Bottom hook block and rope rotate Rope is twisted. Untwist rope, see page 28, "Replacing rope".

7.1.6 Load is not lifted SLE2 overload cut-off has been actuated or is defective. 1 Check setting, see page 25. 2 Actions for SLE2 LED I...III "on" and LED err => error. Actions to eliminate an error may only be performed by trained personnel.

16 17 18 19 20 21 UB UBS GD I+ 1
III II I err pw r

SLE2

W0800

Error specification - Sensor current <1mA Elimination of error - Check voltage supply - Check sensor current (terminal 21) - Check connecting cable - Replace sensor

Error specification - Overload

III

II

err pw r

Elimination of error - Remove load from hoist

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7.1 What is to be done if? (continued)

Error specification - Overtemperature

III

II

err pw r

Elimination of error - Allow motor to cool down - check PTC thermistors

Error specification - Control error

III

II

err pw r

Elimination of error - Check wiring (lifting terminal 3 and lowering terminal 4 are activated simultaneously)

Error specification - System error

III

II

I err pw r

Elimination of error - Check voltage (terminal 6 and terminal 11) - Switch load monitor off/on - Replace load monitor

Error specification - Sensor current >24 mA

III

II

err pw r

Elimination of error - Check sensor current (terminal 21) - Replace load monitor - Replace sensor

7.1.7 Correction of cut-off threshhold with electronic sensor The specific hoist installation conditions may make it necessary to correct the cutoff threshhold. Corrections to the cut-off threshhold may be carried out by trained personnel only. The evaluation device will only accept alterations of -20% to +8% on the factory setting. If these limits are exceeded, I and II flash. Permissible cut-off range exceeded or below target -lower cut-off threshhold (S2/S4) -raise cut-off threshhold (S2/S4)

S5

W0795

III

II

err pw r

- Rough adjustment with S4, ~16%/ switching position, - Fine adjustment with S2,~1%/switching position, see page 25. Caution: Do not exceed 110% nominal load

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8.1 FEM classification

Classification of mechanism, rope drive and motor acc. to FEM for AS 7...-.. ex/Zone 22

FEM

1/1 6300 8000 10000 12500

2/1 4/2-1 12500 16000 20000 25000

4/1 25000 32000 40000 50000

6/1

8/1

1Bm

1Am

2m

3m AS 7063-20

50000 63000 80000

63000 80000 100000 AS 7125-10 AS 7100-12

AS 7080-16

8.2 Conditions of use

The hoist is designed for use in industry and for the ambient conditions usual in industry. Special measures must be taken for particular applications such as e.g. high degree of chemical pollution, outdoor use, offshore application, etc. We will be pleased to advise you.

Equipment classification

Equipment group II, category 3D

Explosion protection

II 3D120C II 3D c 120C

Protection against dust and moisture to EN 60 529

IP66

Permissible ambient temperatures

-20C ... +40C (+60 as option)

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8.3 Hoist
Hoist type Motor *3

8.3.1 Pole-changing hoist motors

50 Hz kW %DC (T3) 20/40 20/40 20/40 20/40 c/h (T3) 240/120 240/120 240/120 240/120 220...240V In [A] 37/80 37/80 37/80 37/80 Ik[A] 77/423 77/423 77/423 77/423 380...415V In [A] 21/46 21/46 21/46 21/46 Ik[A] 44/243 44/243 44/243 44/243 480...525V In [A] 16,8/37 16,8/37 16,8/37 16,8/37 Ik[A] 35/194 35/194 35/194 35/194 cos phi k 0,59/0,63 0,59/0,63 0,59/0,63 0,59/0,63 220... 240V 100 100 100 100 Main fuse gL / gG *2 380... 480... 415V 525V [A] 63 63 63 63 63 63 63 63

Type
AS 7080-16 AS 7100-12 AS 7125-10 AS 7063-20 12/2H73 *1

FEM 9.682 4m 4m 4m 4m

3,8/24 3,8/24 3,8/24 3,8/24

Hoist type

Motor *3

60 Hz kW %DC (T3) 20/40 20/40 20/40 20/40 c/h (T3) 240/120 240/120 240/120 240/120 380...415V In [A] 24/53 24/53 24/53 24/53 Ik[A] 51/279 51/279 51/279 51/279 440...480V In [A] 21/46 21/46 21/46 21/46 Ik[A] 44/243 44/243 44/243 44/243 550...600V In [A] 16,8/37 16,8/37 16,8/37 16,8/37 Ik[A] 35/194 35/194 35/194 35/194 cos phi k 0,59/0,63 0,59/0,63 0,59/0,63 0,59/0,63

Type
AS 7080-16 AS 7100-12 AS 7125-10 AS 7063-20 12/2H73 *1

FEM 9.682 4m 4m 4m 4m

4,5/29 4,5/29 4,5/29 4,5/29

Main fuse gL / gG *2 380... 440... 550... 415V 480V 600V [A] 80 63 63 80 63 63 80 63 63 80 63 63

Motor currents at other voltages: Formula

*1 *2 *3

Operation only with special starting circuit via 12/24-pole winding The 2-pole starting current for main hoist and the rated current for the travel motor were taken into consideration when selecting the main fuse. The motors are designed for rated voltage ranges. In accordance with EN 60034 a voltage tolerance of 5% and a frequency tolerance of 2% apply on top of the rated voltage ranges. The maximum current occurring in the rated voltage range is given.

8.4 Crab

8.4.1 Pole-changing motors for double rail crabs

50 Hz 60 Hz

5/20 m/min 2/1 4/2-1 4/1 AS. 7063-.. 8/2 AS. 7063-.. kW % DC SA-C6734 423 0,46/2,0 20/40 SA-C6734 423 0,46/2,0 20/40 SA-C6734 423 0,46/2,0 20/40 SA-C6736 523 0,8/3,2 20/40 SA-C6734 523 0,8/3,2 20/40

2,5/10 m/min kW % DC SA-C6740 133 0,12/0,55 20/40 SA-C6740 133 0,12/0,55 20/40 SA-C6740 313 0,31/1,25 20/40 SA-C6742 313 0,31/1,25 20/4 SA-C6740 313 0,31/1,25 20/4

8/32 m/min kW % DC SA-C6730 423 0,49/2,0 20/40 SA-C6730 523 0,8/3,2 20/40 SA-C6730 523 0,8/3,2 20/40 SA-C6732 523 0,8/3,2 20/40 SA-C6730 523 0,8/3,2 20/40

6,3/25 m/min kW % DC SA-C6734 423 0,58/2,40 20/40 SA-C6734 423 0,58/2,40 20/40 SA-C6734 423 0,58/2,40 20/40 SA-C6736 523 0,96/3,84 20/40 SA-C6736 523 0,96/3,84 20/40

3,2/12,5 m/min kW % DC SA-C6740 133 0,14/0,66 20/40 SA-C6740 133 0,14/0,66 20/40 SA-C6740 313 0,36/1,50 20/40 SA-C6742 313 0,36/1,50 20/40 SA-C6740 313 0,36/1,50 20/40

10/40 m/min kW % DC SA-C6730 423 0,58/2,40 20/40 SA-C6730 523 0,96/3,84 20/40 SA-C6730 523 0,96/3,84 20/40 SA-C6732 523 0,96/3,84 20/40 SA-C6730 523 0,96/3,84 20/40

[kg] 25000

32000

AS. 7080-..

AS. 7080-..

40000

AS. 7100-..

AS. 7100-..

50000

AS. 7125-..

AS. 7125-..
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Other travel motor data

Index

Motor type P kW 0,09 0,37 0,12 0,55 0,31 1,25 0,49 2,00 n1 1/min 580 2510 560 2550 665 2650 670 3740 In A 0,9 1,1 1,2 1,9 1,4 2,7 1,7 3,9

...123 ...133 ...313 ...423 ...523

8/2F12/210.223 8/2F13/220.233 8/2F31/210.423 8/2F42/210.433 8/2F52/210.533

380...415 V, 50 Hz Ik cos phi DC k A % 1,4 0,76 20 3,4 0,89 40 1,6 0,73 20 5,1 0,9 40 3,2 0,84 20 9,2 0,89 40 4,7 0,83 20 18,0 0,89 40

Ac

P kW 0,11 0,44 0,14 0,66 0,36 1,5 0,58 2,40

n1 1/min 700 3100 670 3060 800 3180 800 3290

In A 0,9 1,1 1,2 1,9 1,4 2,7 1,7 3,9

800 500 600 360

440...480 V, 60 Hz Ik cos phi DC k A % 1,4 0,76 20 3,4 0,80 40 1,6 0,73 20 5,1 0,90 40 3,2 0,80 20 10,2 0,89 40 4,7 0,83 20 18,0 0,89 40

Ac

800 500 600 360

8.5 Cable cross sections and lengths of supply cable

Stationary Type of hoist motor Fixed installation in PVC conduit Power supply to hoist U 5% 380...415 V S L1 [mm] [m] 16 69 480...525 V S L1 [mm] [m] 10 67 Crab Bridge crane Fixed installation in PVC conduit Power supply to infeed (rising mains) U 1% 380...415 V S L2 [mm] [m] 16 14 480...525 V S L2 [mm] [m] 10 13 Crab Bridge crane Bridge crane

Festoon cable in free air - Festoon cable in free air - Festoon cable in free air flexible PVC-sheathed cable flexible PVC-sheathed cable flexible PVC-sheathed cable along runway along crane runway along crane bridge U 4% 50 Hz 380...415 V 480...525 V S L3 S L3 [mm] [m] [mm] [m] 10 30 10 47 60 Hz U 1,5% 380...415 V S L4 [mm] [m] 16 14 480...525 V S L4 [mm] [m] 10 14 U 2,5% 380...415 V S L5 [mm] [m] 16 34 480...525 V S L5 [mm] [m] 10 33

12/2 H73

440...480 V S [mm] 10 L1 [m] 49

440...480 V S [mm] 10 L2 [m] 10

12/2 H73

440...480 V S L3 [mm] [m] 10 35

440...480 V S L4 [mm] [m] 10 11

440...480 V S L5 [mm] [m] 16 39

S = Minimum cross-section L1...L5 = Max. supply cable length of the individual types of power supply sum of voltage drops <5 %. A loop impedance of max. 250 m was taken as basis for coordinating the short circuit protection of the power contactors and calculating the cable lengths. The minimum cross-sections take into consideration the overload protection of the cables corresponding to the types of cable and installation.

S(550...600 V, 60 Hz) = S(480...525 V, 50 Hz) S(440...460 V, 60 Hz) = S(380...415 V, 50 Hz)

L(550...600 V, 60 Hz) = L(480...525 V, 50 Hz) x 1.15 L(440...460 V, 60 Hz) = L(380...415 V, 50 Hz) x 1.15
BAS7Z22_2.FM

For larger cross-sections, the max. cable lengths are calculated as follows: L* = L x S* / S
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Zone 22 (ATEX)

8.6 Tightening torques for screws

All screws should be tightened with a torque spanner. See table for the tightening torques generally applicable for screws grade 8.8.
Tightening torques for screws grade 8.8
Thread M.. Tightening torque [Nm] M6 10 M8 25 M10 51 M12 87 M16 215 M20 430 M24 730 M30 1500 M36 2600

8.7 Lubricants

W0769

W0743

Position of lubrication point a Hoist gear Rope guide Wire rope

Type of lubricant Oil

Designation CLP 460 (PG 220) GOOF (GPGOOK) CLP 460 (PG 220) KPF1K

Quantity

Characteristics, makes
1 Viscosity: 460 /s/40C (220/s/40C), pour point: -20C (-40C) flash point: +265C (+320C), e.g.: Fuchs Renolin CLP 460*, Aral Degol BG 460, BP Energol GR-XP 460, Esso Spartan EP 460, Mobil Gear 634, Tribol 1100/460, (Shell Tivela Oil WB) 2 Soap base: Lithium + MoS2, dripping point: approx. 185C penetration: 310-340, operating temperature: -20to +120C e.g.: Aralub PMD1*, BP Multi-purpose Grease L21M, Esso Multi-purpose Grease M, Mobilith SHC 460, Shell Retinax AM, STABYL L-TS 1 Mo 3 Soap base: Synthetic (lithium), dripping point: approx 150C penetration: 400-430 (400-430), operating temperature: -20to +80C (-35to +130C), e.g.: Aralub FDP00, BP Energrease HT-00 EP, Esso Liquid Gear Grease, Shell Special, Gear grease H*, Mobilux Liquid grease EP 004, (Tivela Compound A)

AS 7..: 15000 ml

Grease

2500 g

k Spline shaft

Oil

SA-C 67 ..: 3000 ml

l Travel gear Wheel bearing (only for 400)

Grease

SA-C 67 ..: 100 g

Grease

KPF1K

400: 50 g

BAS7Z22_2.FM

(Lubricants for low operating temperatures, -40 ... +40C) Factory filling

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Zone 22 (ATEX)

8.8 Noise level

The noise level was measured at a distance of 1 m from the wire rope hoist. The mean noise level is calculated for one operating cycle (50% with nominal load, 50% without load). Instead of stating an emission value based on a workplace, the values from table 1 and 2 at measuring distance "h" can be used.

1
Type 1m AS 7. ex 77 2m 74 [db (A)] + / - 3 h [m] 4m 71

8m 68

16 m 65

2
Type 1m AS 7. ex 77 2m 71 [db (A)] + / - 3 h [m] 4m 65

8m 59

16 m 53

8.9 Circuit diagrams

See separate appendix

40

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Zone 22 (ATEX)

9.1 Serial number

When ordering original spare parts, please always indicate the serial number of the hoist.

9.2 Hoist

Hoist brake

Hoist type AS 7. ex

Hoist motor 12/2H73

Hoist brake M150 22 Nm

A Order no. 567 119 0

Rope guide
Hoist type AS 7. ex
W0770

B Order no. 47 330 00 43 0

C Order no. 46 330 08 43 0

D Order no. 46 330 00 43 0

Hoist limit switch

H E-A 02 E-A 04 E-A 12 E-A 14 Order no. 06 390 01 01 0 06 390 05 01 0 06 390 03 01 0 06 390 07 01 0

W0771

Wire rope (E) See works certificate or rope certificate for length and number of rope.

9.3 Travel motor

Travel motor brake

Fahrmotortyp Fahrmotorbremse F Order no. 8/2 F12/2xx. 223 8/2 F13/2xx. 233 8/2 F31/2xx. 423 8/2 F42/2xx. 433 8/2 F52/2xx. 523 FDW 08 FDW 08 FDW 13 FDW 13 FDW 15 2,5 Nm 2,5 Nm 5 Nm 8 Nm 13 Nm 567 100 0 567 100 0 567 360 0 567 360 0 567 361 0

Replacement and repairs may only be carried out by qualified personnel.

BAS7Z22_2.FM

01.06

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BAS7Z22_2.FM

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STAHL CraneSystems GmbH Daimlerstrae 6, 74653 Knzelsau, Germany Tel. +49 7940 128-0, Fax +49 7940 55665, info@stahlcranes.com www.stahlcranes.com

F-BA-9.2.1.z22-EN-05.06-mp

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