R&M STAGEMAKER SM5 Manual

R&M Materials Handling, Inc STAGEMAKER®COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

08/14/02 Bulletin: RM-SM5-MAN-2001-1-ENG.doc

STAGEMAKER

STAGEMAKERSTAGEMAKER

STAGEMAKER®

®®

®COMPACT

COMPACTCOMPACT

COMPACT

Concert

ConcertConcert

Concert Hoist

HoistHoist

Hoist

SM5

INSTALLATION, OPERATION AND MAINTENANCE

INSTALLATION, OPERATION AND MAINTENANCEINSTALLATION, OPERATION AND MAINTENANCE

INSTALLATION, OPERATION AND MAINTENANCE

INSTRUCTIONS

INSTRUCTIONSINSTRUCTIONS

INSTRUCTIONS

JOB

JOBJOB

JOB NO

NONO

NO. :

. :. :

. :

SERIAL NO

SERIAL NOSERIAL NO

SERIAL NO. :

. :. :

. :

(RECORD HOIST SERIAL NUMBER FOR FUTURE REFERENCE)

R&M Materials Handling, Inc STAGEMAKER®COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

08/14/02 Bulletin: RM-SM5-MAN-2001-1-ENG.doc

Before proceeding with the installation, operation or maintenance of the hoist it is important that

installation, operating and maintenance personnel read this bulletin carefully in order to ensure

the safe and efficient use of the hoist.

It is strongly recommended that personnel responsible for the operation, inspection and servicing

of this hoist, read and follow the Safety Standard ANSI B30.16-1993 (or current revised edition).

This standard covers Overhead Hoists (under-hung) as promulgated by the American National

Standards Institute and is published by the American Society of Mechanical Engineers. Copies of

this publication are available from the Society at United Engineering Center, 345 East 47th St.,

New York, NY 10017.

If any instructions are unclear, contact the manufacturer or distributor of this hoist before

attempting to install or use the hoist.

IMPORTANT

Electrical wiring diagrams are included with this manual. Also, if an

optional push or motorized trolley has been purchased, a manual is

included with the trolley.

If these items are missing, contact the manufacturer or distributor

before attempting to install or use the hoist.

R&M Materials Handling, Inc.

4501 Gateway Boulevard

Springfield, OH 45502

Tel. 937-328-5100

Fax 937-325-5319

Visit our website: www.rmhoist.com

R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

TABLE OF CONTENTS

Section Page

Table of Contents .....................................................................................................i

Foreword...................................................................................................................iii

Warranty.........................................................................................................iii

Parts & Service...............................................................................................iii

Claims for Damage in Shipment....................................................................iii

1. Installation

General ...........................................................................................................1-2

Hoist Configuration........................................................................................1-2

Mounting........................................................................................................1-3

Lubrication .....................................................................................................1-3

Load Hook Throat Opening............................................................................1-3

Power Connections.........................................................................................1-3

2. Initial Start-Up

Proper Hook Motion (Hoist Motor Rotation).................................................2-1

No Load Operational Checks .........................................................................2-2

Torque Limiter................................................................................................2-2

Load/Run Test ................................................................................................2-2

3. Safe Operation Practices

General ...........................................................................................................3-1

Do’s and Don’ts (Safe Operation of Hoist)....................................................3-2

4. Operation/Maintenance

Typical Construction ......................................................................................4-1

Motors ............................................................................................................4-2

Brake/Torque Limiting Device.......................................................................4-2

Operation............................................................................................4-2

Adjustment of the Limiter ..................................................................4-3

Adjustment of the Brake.....................................................................4-4

Frame (Hoist Body)........................................................................................4-5

Load Chain .....................................................................................................4-5

Load Chain Inspection........................................................................4-5

Load Chain Replacement....................................................................4-6

Load Chain Removal..........................................................................4-7

Load Chain Installation.......................................................................4-7

Fall Stop Assembly........................................................................................4-9

Bottom Block, Load Wheel and Suspension Hook........................................4-9

Hook Specification.............................................................................4-10

Suspension Hook................................................................................4-11

Measurement of the Wear on the Suspension and Lifting Hook........4-11

R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

Upper & Lower Limit Switch.........................................................................4-11

Rotary Limit Switch.......................................................................................4-12

Controls..........................................................................................................4-13

AFC Board .........................................................................................4-13

PC Board Controls .............................................................................4-14

Hoist Circuit Diagram - Standard.......................................................4-14

Control Panel..................................................................................................4-15

Circuit Diagram..............................................................................................4-19

5. Preventative Maintenance

Maintenance Table .........................................................................................5-1

Lubricants.......................................................................................................5-2

Spare Parts Replacement Table......................................................................5-2

Screw Tightening Torques..............................................................................5-2

Troubleshooting..............................................................................................5-3

6. Spare Parts Identification

R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

iii

FOREWORD

This manual has been prepared to acquaint you with the procedures necessary for the installation,

operation and maintenance of the hoist you have purchased.

Proper installation is important for the performance of your equipment. Careful study of and

adherence to the instructions will help ensure safe, dependable operation. It is recommended that

this manual be readily accessible to operators as well as maintenance and safety personnel.

Information in this manual is subject to change without notice.

Warranty

R&M Materials Handling, Inc. provides a two (2) year limit warranty on electric chain hoists.

Please contact your Distributor for warranty details.

Parts and Service

R&M Materials Handling, Inc. distributes its products through a network of distributors. Please

contact your Distributor for parts, service, and warranty. A list of R&M Master Distributors is

listed on our website: www.rmhoist.com.

Claims for Damage in Shipment

All shipments are inspected and delivered to our carrier in good order. If damage is observed,

refuse shipment until the carrier makes the proper notation to that effect.

In the event of concealed loss or damage, notify the carrier immediately. By following these

suggestions you will encounter less difficulty collecting your claim.

R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

08/14/02 RM-SM5-MAN-2001-1-ENG

1-1

SECTION 1

INSTALLATION

Figure 1-1

1- Hoist body/motor 5- Chain guide assembly

2- Gears 6- 1-fall hook block

3- Brake/limiter/housing 7- 2-fall hook block

assembly 8- Chain container

4- Chain sprocket with 9- Electrical control panel

output shaft 10-Handle

IMPORTANT

Hoists are designed for lifting of material only. Under no conditions

or circumstances are hoists to be used for lifting or transporting of

personnel. Do not transport any load over personnel without

additional safety precautions.

R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

08/14/02 RM-SM5-MAN-2001-1-ENG

1-2

General

Each complete electric chain hoist is load tested in accordance to ANSI B30.16 at the factory at

125% of nameplate rated capacity, and is usually shipped assembled, unless otherwise stated on

order inquiry.

All hoists are designed for the type of mounting specified by the purchaser. The adequacy of the

supporting members (monorail beams, trusses, hangers, supports, framing, etc.) is the responsibility

of the user and shall be determined by qualified personnel.

Prior to permanent or field installation, units shall be checked thoroughly by qualified personnel for

damage during shipment or handling at the job site. Particular attention shall be taken to make sure

that the load chain and other mechanical or electrical components have not been damaged through

improper handling.

Read the instructions contained in this manual and observe the warning tags attached before

installation is started.

Hoist Configuration

STAGEMAKER®COMPACT concert hoists are offered in five basic configurations, each with its

own control type and hoist features.

ØConfiguration A: Direct motor control without control voltage. Full line voltage controller

furnished separately.

ØConfiguration B: Magnetic controls including a control transformer for controls and controller.

ØConfiguration B1: Standard (upright) hoist mounting position only. PC Board controls

and pendant controller furnished on the hoist.

ØConfiguration B2: Inverted or standard hoist mounting position. PC Board controls

furnished on hoist and controller ordinarily furnished separately.

ØConfiguration C: Programmable controller in conjunction with PC Board controls. Controls

furnished on the hoist and controller furnished separately.

ØConfiguration D: Mandatory safety features are standard. PC Board controls furnished on the

hoist and controller furnished separately.

ØConfiguration E: Variable Frequency Drive (inverter). VFD furnished by others separate from

hoist.

PC Board controls utilize magnetic (low voltage) controls. PC Board controls for the SM5 concert

hoists consist of controls (contactor, transformer, etc.) that are soldered to a circuit board, which

provides most of the internal connections.

WARNING

Before installing the hoist, make certain that the main power switch

supplying power to the hoist is in the open position.

R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

08/14/02 RM-SM5-MAN-2001-1-ENG

1-3

Mounting

The hoist body should be mounted from its suspension hook allowing the body to move in the

direction of the load chain pull and to hang in a straight line between the suspension hook and load

block during hoisting. Non compliance to this principle may result in severe damage to the

equipment. This is true if the hoist is used in the normal or inverted configuration.

Lubrication

The hoist gear reducer is lifetime grease lubricated needing no regular checking or maintenance.

Make sure the load chain is free from contamination or dirt and adequately lubricated with SAE 80

grade oil. Bottom block must hang straight and load chain must be free of kinks or twists.

Load Hook Throat Opening

ANSI B30.16-1993 recommends that the throat opening of the load hook be measured and recorded

prior to putting the hoist into service and that a gage be made to provide a quick visual inspection

for a bent hook as required by monthly inspections. See Section 4.

Power Connections

Make sure that power supply voltage is the same as that shown on the hoist nameplate and that fuses

or other current overload devices are provided to protect the power supply. The power

source/conductors must have sufficient capacity to maintain the voltage at the hoist at ±10% of the

nominal voltage under all operating conditions. Standard nominal voltages are 230 and 460V. Poor

voltage maintenance can cause motor overheating or sluggishness, and chattering or inoperative

motor brakes and controls.

A wiring diagram is included in this manual showing the identification of the power lead

connections. Refer to this wiring diagram prior to start up and/or any electrical work. If the diagram

has been misplaced you may obtain one from R&M upon request. Be sure to mention the serial

number of the unit.

CAUTION

Make sure the main disconnecting switch is off and locked in the open

position before making any electrical connections.

R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

08/14/02 RM-SM5-MAN-2001-1-ENG

1-4

The customer must supply power cable, power distribution set, installation fusing and main

disconnect switch.

Figure 1-2

PS: Power supply connection for hoist configuration A

Combined power and controls for hoist configuration C or configuration D

PB: Controls, hoist configuration B1 or configuration B2

TR: Trolley connection, if motorized trolley is supplied, for hoist configuration B1 only.

Connection:

If the hoist is not supplied with a power cable pigtail or power plug at the hoist electrical enclosure,

then proceed as follows:

1. Remove the control box cover.

2. Insert the cable (PS) into the box through the PG cable gland. Cable gland accepts a

cable diameter of 8-15mm.

3. Connect phases L1, L2, L3 to K10 contactor, and the ground wire to the terminal board

(2).

4. Check that the terminals are correctly tightened, even unused terminals.

5. Tighten the power round cable PG gland.

6. Reinstall the control box cover. (Do not over-tighten cover screws.)

7. Check the hoist operation.

Note: When making electrical connections, refer to the wire identification markers for the various

power and control leads that are shown on the electrical diagrams. By doing so, this will help

prevent improper electrical connections which might cause severe damage to the equipment or

personnel.

Note: This electric chain hoist is furnished with motor and control circuit protection as standard,

which, in the Company’s interpretation, meets requirements of the National Electrical Code in effect

at time of shipment from our factory. The protective devices required for the power feed are

outlined in Article 610 of the NEC and are the responsibility of the user. It is recommended that the

user review Article 610 as well as other applicable Articles of NEC for compliance requirements.

Follow National, State and Local Codes when providing electrical service to the hoist.

Only a qualified electrician shall make all electrical connections.

R&M Materials Handling, Inc STAGEMAKER® COMPACT Concert Hoist

Springfield, Ohio USA SM5 Manual

: 800 955-9967 Revision 1

web: www.rmhoist.com

08/14/02 RM-SM5-MAN-2001-1-ENG

2-1

SECTION 2

INITIAL START-UP

WARNING

Before connecting the hoist to the power supply, check all

“motion” buttons or selector switches on your controller or push

button station to ensure that none of them bind or stick in any

position. Check pendant or controller cables to ensure that they

are not damaged and are wired to desired hoists.

Once power has been supplied to the hoist, several important no-load checks must be made.

Proper Hook Motion (Hoist Motor Rotation)

Since rotation direction of any three-phase AC motor can be changed by reversing any two of the

three lines feeding the motor, it is important that the direction of motion is correct with respect to

the button being depressed, or the selector setting.

To check/correct hook motion (motor rotation), carefully inch the up button and observe hook

motion. If hook does not travel up, stop the hoist and open the main power source disconnect.

WARNING

Do not attempt to reverse hoist motion by changing control leads

in the push button, controller or at the contactor, and do not

change the nameplate on the P/B. Safety switches of the control

circuit wiring as furnished from the factory are directional

sensitive. Changing the push button control leads, wiring inside

the controller or nameplates will prevent the safety switches

from functioning properly. This might create dangerous

situations.

IMPORTANT

Do not run the hoist with the DOWN button if direction is

reversed. To correct the direction of the hook block travel,

reverse any two leads supplying power to the controller, at the

main power source or at the lead in connections to the hoist. Do

not change the internal wiring of the hoist nor the controller.

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