INSTALLATION AND MAINTENANCE MANUAL LM CHAIN HOIST LOADMATE® LM10 STEPLESS CHAIN HOIST English STD-R-KHA-F-CQD-ENG This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 THIS PAGE INTENTIONALLY LEFT BLANK 2/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc. All rights reserved.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 m m CAUTION: Read the instructions supplied with the product before installation and commissioning. CAUTION: Keep the instructions in a safe place for future reference. Table of contents 1 2 3 4 5 6 7 INTRODUCTION ........................................................................................................................................ 6 1.1 Contact Information ......................................................................................
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5 Electricity (Inverter) ........................................................................................................................... 31 7.5.1 Technical data – D2S INVERTER ............................................................................................. 31 7.5.2 Basic description ........................................................................................................................ 32 7.5.3 Main components ...............
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.8 9.9 9.10 9.11 Push Button Assembly – Horizontal Pairs of Buttons ....................................................................... 94 Push Button Assembly – Horizontal Pairs of Buttons ....................................................................... 95 Push Button Assembly – Vertical Pairs of Buttons (Option) .......................................................... 96 Push Button Assembly – Vertical Buttons (Option) ................................
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 1 INTRODUCTION 1.1 Contact Information Please do not hesitate to use the following contact information in the event that you may need assistance: R&M MATERIALS HANDLING, INC. 4501 Gateway Boulevard Springfield, OH 45502 General Telephone: 937 - 328-5100 Toll Free Telephone (US): 800 - 955-9967 General Fax: 937 - 325-5319 Parts Department Fax (US): 800 - 955-5162 Parts Dept. Fax (other): 937 - 328-5162 Website: www.rmhoist.com 1.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 1.4 Safety Read and understand this manual before using the hoist. Important issues to remember during installation, operation, maintenance, and inspection are provided at the hoist control stations, at various locations on the hoist, in this manual, and in the LoadMate® Electric Chain Hoist Operator’s Manual.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 The words SHALL and SHOULD are used throughout this manual in accordance with definitions in the ASME B30 standards as follows: SHALL indicates a rule is mandatory and must be followed. SHOULD indicates a rule is a recommendation, the advisability of which depends on the facts in each situation.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 NOTICE: m It is a responsibility of the owner / user to install, inspect, test, maintain, and operate a hoist in accordance with the ASME B30.16 Safety Standard, OSHA Regulations, and ANSI / NFPA 70, National Electric Code. If the hoist is installed as part of a total lifting system, it is also the responsibility of the owner / user to comply with the applicable ASME B30 volume that addresses other types of equipment used in the system.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 2 INSTALLATION m DANGER: Before installing, removing, inspection, or performing any maintenance on a hoist, the main switch shall be de-energized. Lock and tag the main switch in the deenergized position in accordance with ANSI Z244.1. Follow other maintenance procedures outlined in this manual and ASME B30.16. 2.1 General Prior to installation, the unit shall be checked thoroughly for damage during shipment or handling at the job site.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 2.3 Mounting Below are three types of mounting: 1. 2. 3. 4. Hook Mounted Base Mounted Coupling Mounted Trolley Mounted – NOT SHOWN – is accomplished via a Hook or Trolley Coupling to the Trolley Assembly. Figure 1. Mounting Types For all trolley-mounted hoists, refer to appropriate trolley manual for trolley installation instructions. After a trolley-mounted hoist has been assembled to a beam, check for balance.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 2.5 Electrical Connection The user / owner must provide the main power supply hardware (cable, conductor bar, fuses, disconnect switch, etc.). m CAUTION: Make sure that the power supply voltage is the same as that shown on hoist serial plate / nameplate. m CAUTION: Make sure that fuses and other current overload devices are in place to protect the power supply.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 2.6 Three Phase Power Connections Figure 2. Three Phase Control Box Power Connections Minimum cable sections: 2 Power supply: AWG 16 (1.50 mm ) Auxiliary current: AWG 18 (0.75 mm ) Control box/hoist: AWG 18 (1.00 mm ) 2 2 13/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 2.7 m m m 2.8 m m m m m m m m m Electricity WARNING: In case of IT network, remove the filter FU1 before any operation WARNING: Before any operation on the electric box, check that the hoist supply is disconnected. WARNING: An isolator switch should be installed at a maximum of 6 meters from the hoist. Specific Instructions for Inverter CAUTION: Check that the device cover is properly installed. CAUTION: High voltages are present in this device.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 3 INITIAL START-UP m WARNING: 3.1 Before connecting power to hoist, check all “motion” buttons on pendant control assembly to make sure that they operate freely without binding or sticking. Check pendant cable and strain relief connection to ensure that they are not damaged. Start-Up Procedure If any problems or malfunctions occur during the start-up, refer to Chapter "Troubleshooting", to find out the reason. All problems must be solved before continuing.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 3.3 m Correcting the Direction of Hook Travel WARNING: DO NOT change control leads in pushbutton enclosure or at motor relays. DO NOT change nameplates on pushbutton assembly. The upper/lower safety limit switch is wired in series with “UP” control circuit as furnished from factory. Changing pushbutton control leads or nameplates will prevent the upper safety travel limit switch from functioning properly.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 3.6 Make sure that movement will not cause any danger to the environment or to the crane itself. Avoid driving close to the limit areas. Check limit switches manually if possible. Check the run commands on the display panel and correct the hoisting direction. The arrow rotates clockwise if S1 is applied and counter-clockwise if S2 is applied. Drive direction S1 at minimum speed for 5 to 10 seconds. Accelerate to full speed. Run 5 to 10 seconds. Stop.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 4 HOIST OPERATION m m m WARNING: BEFORE PROCEEDING WITH THE NORMAL OPERATION OF THIS HOIST, THE OPERATOR/(S) SHALL BE TRAINED IN ACCORDANCE WITH THE LoadMate® Electric Chain Hoist Operator’s Manual AS SUPPLIED WITH THIS HOIST.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 5 LOW HEADROOM TROLLEY Figure 3. Low headroom trolley 5.1 Description – Technical Characteristics (low headroom trolley) NOTE: The trolley you have just purchased must be used only with the nominal load indicated on the rating plate. NOTE: The trolley’s service life will depend upon the level of duty, the average operating time, the number of starts and the maintenance applied to it. 5.1.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 5.1.2 Environmental Data Ambient temperature: -10°C to +40°C Protection degree: IP55 as standard Sound level: 70 decibels at 1 m 5.1.3 Optional equipment Limit Switch: This cuts off the directional movement when the trolley reaches the end of its run. Electric Actuation Device: This actuates the supply line; the slide block must not exceed the rolling profile (A). Brush: This allows for earthing, due to the brush rubbing on the profile element.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 6 SWIVEL TROLLEY 6.1 Description – Technical Characteristics (swiveling trolley to 3.2 tons) NOTE: The trolley you have just purchased must be used only with the nominal load indicated on the rating plate. NOTE: The trolley’s service life will depend on the level of duty, the average operating time, the number of starts and the maintenance applied to it. 6.1.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 6.2 Installation of Swivel Trolley The service life of the trolley depends upon the way it is installed. The instructions in this manual must be followed carefully for the installation, use and maintenance of the hoist. Any use contrary to these instructions can be dangerous. Do not use hoist until this manual has been fully read and understood. Always keep this manual near the hoist, available to the operator and the person in charge of maintenance.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Figure 4. Drive wheel and idler wheel/side plates Adjust drive wheel and idler wheel/side plates as shown above. 6.3 Electric Swivel Trolley Figure 5. Electric swivel trolley Table 1. Electric swivel trolley HOIST TYPE SWIVELING TROLLEY TYPE CAPACITY NUMBER OF WHEELS WHEEL DIAMETER MOTOR TYPE C05 SWIV32 0 – 1 ton 4 100 2 x TMU 1 (35 Hz) C10 SWIV32 0 – 2 tons 4 100 2 x TMU 2 (100 Hz) C16-20-25 SWIV32 0 – 3.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 6.3.1 Swiveling trolley (3.2 tons) Figure 6. Swiveling trolley (3.2 tons) - CAPACITY MAX 3.2 TONS (3200 KG) - RAY OF CURVE MINI 2.6 FEET 6.3.2 Swiveling trolley (3.2 to 5.0 tons) (NOT LOCALLY AVAILABLE) Figure 7. Swiveling trolley (3.2 to 5.0 tons) - CAPACITY MAX 3.2 TO 5 TONS (3200 TO 5000 KG) - RAY OF CURVE MINI 3.9 FEET 24/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 6.3.3 Procedure to adjust swivel trolley guide rollers 1. 2. 3. 4. 5. 6. Loosen nut “A” (8 plcs). Adjust guide rollers the maximum distance away from beam. Place swivel trolley on beam. Move trolley to curve section of beam. Adjust guide rollers allowing approximately 3/16” (4-5 mm) clearance per side using screw “B.” Tighten nut “A” (8 plcs). Figure 8. Swivel trolley guide rollers NOTE: Adjustments should be made with swivel trolley in radius of monorail.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7 MAINTENANCE 7.1 Basic Hoist Construction Figure 9. Basic Hoist Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. LOAD BLOCK ASSEMBLY (2-FALL SHOWN) LOAD CHAIN ELECTRICAL CONTROL ENCLOSURE TOP HOOK HOIST GEAR BOX ASSEMBLY CHAIN CONTAINER & HARDWARE HOIST BODY / MOTOR LOAD HOOK SAFETY LATCH FASTENER PIN 7.2 Motor / Body The hoist motors are designed to provide dependable hoisting service.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.3 Hoist Motor Brake and Load-Limiting Device The hoisting motor is equipped with a D.C. electromagnetic disc brake. The brake brings the load to a smooth and quick stop and holds the load when the motor is not energized. An energized coil releases the hoist brake to allow the hoisting motor to run freely when in use. The load-limiting device is a slip clutch and it is integrated into the design of the hoist motor brake.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 m CAUTION: SEE Figure 4 - Slip Clutch Adjustment. Make sure the motor is not running before placing tool on the nut (ITEM 5) to adjust it. Do not touch any moving components. The slip-clutch generates heat when slipping. ITEMS 3 & 4 absorb this heat. When these items become too hot, clutch adjustment may be difficult due to unstable behavior of friction surfaces. If this happens, allow brake & clutch assembly to cool before trying to re-adjust slip-clutch.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.4.2 Hoist Motor Brake Adjustment Figure 11. Cross Section of Hoist Motor Brake If maximum air gap of brake has been reached or will be exceeded before next inspection, readjust air gap. Minimum air gap X = 0.008” [ 0.2 mm ] Maximum air gap X = 0.020” [ 0.5 mm ] Before adjusting brake, remove load. Per ANSI Z244.1, lockout and tag main disconnect switch in deenergized position. Follow other maintenance procedures outlined in this manual and ASME B30.16. 1.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.4.3 Replacement Criteria for Motor Brakes Table 2. Replacement Criteria for Motor Brakes THICKNESS AS NEW REPLACE WHEN LM 01 LM 05 0.260 inches (6.6 mm) 0.370 inches (9.4 mm) 0.220 inches (5.6 mm) 0.330 inches (8.4 mm) LM LM LM LM 0.055 inches 0.406 inches 0.406 inches 0.406 inches 0.016 inches 0.366 inches 0.366 inches 0.366 inches 10 16 20 25 LM 01 /05 / 10 MODELS (1.4 mm) (10.3 mm) (10.3 mm) (10.3 mm) (0.4 mm) (9.3 mm) (9.3 mm) (9.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5 Electricity (Inverter) 7.5.1 Technical data – D2S INVERTER Table 3. Technical Data for D2S Inverter Power class Power (kVA) at 400V Output current In (A) Max. current 1min (A) Overload ability Max.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.2 Basic description Table 4. Basic Description Inverter Crane user interface Brake control Electrical Braking Control methods The specific crane features for the inverter hardware and the special software are achieved by combining the experience and know-how of crane applications with the latest technology. Interface with pre-designed locations for typical crane functions.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.4 Control methods Table 7. Three different control methods: 1 EP 2 MS 3 AU Electronic potentiometer function. Stepless control using a 2-step controller. Multistep control (2 steps) Requires programmable digital inputs for speed reference steps Automation control for any control device with an output in the range of 0 – 10V E.g. radio controls, process computers. All control methods are available without any changes in the hardware or software.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.5 Description of the control modes 7.5.5.1 MS2-control Figure 12. MS2-Control c_coms2a o o A. Pushbutton / controller position B. Speed 0) “decelerate to zero” 1) step 1 “drive minimum speed” 2) step 2 “drive maximum speed” 7.5.5.2 EP2-control Figure 13. EP2-Control c_coep2a o o A. Pushbutton / controller position B.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.5.3 AU/PO-control Figure 14. AU/PO-Control S1 c_coms6a S2 o o A. Reference B. Speed NOTE: AU control may be used with control device with an output in the range of 0 V – 10 V (for example radio or PLC). NOTE: PO control may be used with a controller with potentiometer. The operation is as follows : Driving command S1 or S2 is given separately and means “drive minimum speed” The speed linearly follows the analog input signal. 7.5.5.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Table 10. Electromagnetic Compatibility (EMC) Declaration of conformity CE-mark Environments With the declaration of conformity the manufacturer informs that device is manufactured to fulfill required EMC standards. The CE marking is a declaration by a manufacturer or importer located in the European Economic Area that a product complies with the safety and health requirements of the directive in question.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.7 Parameter adjustments 7.5.7.1 The display panel Figure 15. Display Panel The display panel is used for : Displaying the drive identification, electrical values, operating or fault parameters Altering the parameter settings START STOP reset enter Drive status indications: Motor is running, blinks when ramping down. Direction of motor rotation. Motor is not running. Power is on. In case of a fault, the symbol will not light up.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.7.2 Navigation on the control keypad Editing numerical settings m WARNING! Changing parameter settings during running may cause a hazardous situation. Parameter settings must not be changed during running. a) Pushing ► button takes you into the edit mode. As an indication, the parameter value starts to blink. b) Two different methods are available to change values. One is to set with ▲▼buttons till your desired value.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.9 Parameter descriptions 7.5.9.1 General Description Parameters are assorted to Groups. All Groups are not always listed in control panel. Groups are shown in the control panel according to password level and selected functions. This feature makes the viewable parameter menu simple and only needed parameters are shown. Letter front of the code number describes variable type.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 G1.2 Motor Parameters Code Name Min Max Unit Description P1.2.1 Motor Nominal Voltage Motor Selection 200 500 V Nominal motor voltage Un from motor nameplate. 0 13 P1.2.2 0 = Not Used 1 = Free Travel (see Note 1) 2 = MF06MA100 3 = MF06MA200 4 = MF06LA100 5 = MF06LA200 (MF06LA200, 0.45kW/400V; 0.55kW/460V) 6 = MF06LA20P (MF06LA200, 0.65kW/400V; 0.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 G1.2.5 U/f Settings, see Note 1 Code Name Min Max Unit Description P1.2.5.1 Zero Frequency Voltage P1.2.5.2 U/f Middle point Voltage P1.2.5.3 U/f Middle point Frequency P1.2.5.4 Torque Boost 0.00 40.00 % Output voltage at zero frequency, % of motor nominal voltage. 0.00 100.00 % Voltage in the selected middle point frequency, % of motor nominal voltage. 0.00 120.00 Hz Middle point frequency. 0 1 P1.2.5.5 IrAdd Motor 0 100 P1.2.5.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 G1.3 I/O Parameters Code Name Min Max P1.3.1 ROA1 0 12 P1.3.2 0.000 10.000 V Minimum value of analog input Ain1 for AU-control 0.000 10.000 V Maximum value of analog input Ain1 for AU-control P1.3.4 Ain1 Minimum Voltage Ain1 Maximum Voltage Aout Function 0 5 P1.3.5 Aout Zero Current 0.00 mA P1.3.6 Aout Nominal Current Aout Zero Curr Aout Nom Curr 100.00 Max Unit P1.3.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 M2 Monitoring Code Name Min Max V2.1 K7 0 1 State of relay output ROD1, which controls brake contactor V2.2 ROA1 0 1 State of relay output ROA1 V2.3 DID states .00000 .11111 State of digital input DID1-DID5 V2.4 Ain1 Input 0.00 10.00 V Value of analog input Ain1 V2.5 Motor Current A Measured motor current V2.6 Motor Voltage V Calculated motor voltage V2.7 Heat Sink Temperature DC-link Voltage °C Temperature of heat sink.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 I3.8.3.3 Firmware interface I3.8.3.4 System load S3.8.4 Application info A3.8.4.1 Application A3.8.4.1. Application id 1 A3.8.4.1. Application version 2 A3.8.4.1. Firmware interface 3 S3.8.5 Hardware info I3.8.5.2 Unit voltage I3.8.5.3 Brake chopper I3.8.5.4 Brake resistor S3.8.6 Options S3.8.6.1 NXOPT E3.8.6.1. Status 1 E3.8.6.1. Program version 2 S3.9 (not used) S3.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.9.3 Reverse Plugging When opposite drive command is active while the inverter is operating, the deceleration/acceleration ramp can be shorter than the normal ramp. Reverse plugging function is “on” if the driving frequency > 30% of the “Max Freq” (not the “Motor Nom Freq”). Reverse plugging function goes “off state” in opposite direction to original direction when driving frequency > 95% of reference frequency. The value can be set between 50 to 100%.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.10 Factory default parameters Table 13. Default Factory Parameters 400V 100Hz Label Code G 1.1. General Parameters P 1.1.1 Password P 1.1.2 Accel Time P 1.1.3 Decel Time P 1.1.4 Min Freq P 1.1.5 Max Freq P 1.1.6 Reverse Plugging P 1.1.7 Stop Function P 1.1.8 MSFreq2/Slowdown P 1.1.9 Multistep Freq 3 P 1.1.10 Multistep Freq 4 P 1.1.11 Input set G 2.2. Motor Parameters P 1.2.1 Motor Nom Volt P 1.2.2 Motor Selection P 1.2.3 Number of Motors G 1.2.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.11 Speed supervision Overspeed Monitor is a hoist motion speed supervision unit, which reads the pulse frequency from the hoist motor sensor bearing (48ppr). This pulse frequency is compared with a fixed oscillator frequency. As a result of frequency comparison, there are two different speed supervision functions : • overspeed supervision (rush control) • stall supervision Overspeed supervision is totally implemented by hardware.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.11.1 Overspeed Monitor adjustment Check maximum hoisting speed of application. Set with parameter P1.1.5. maximum Freq to value “Set up driving freq” from table Set parameter V2.10. visible on display Set switch S1 to value x0.5 and switch S2 to value 3 kHz. Drive with maximum speed Decrease value of switch S2 inch by inch until Overspeed Monitor trips.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.5.12 Drawings Table 15.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.6 7.6.1 m 7.6.2 Load Chain General CAUTION: A hoist SHALL NEVER be used if the load chain shows any evidence of mechanical damage or excessive wear. Never use the load chain as a sling. Use only original equipment chain as supplied by a factory authorized source. Improper load chain storage or installation can render the load chain unusable prior to the first lift.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 THIS PAGE INTENTIONALLY LEFT BLANK 51/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc. All rights reserved.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Figure 16. Chain Dimensions t 11 t t Ød P25004 Measure the following chain dimensions at several points on chain: (Figure 16) Dimensions of one link ( d x t ) where, d = diameter and t = pitch Length over 11 links ( 11 t ) Replace load chain if any one of these dimensions exceeds maximum allowed wear. Maximum allowed wear: Minimum link diameter allowed (d): 0.240” Maximum pitch allowed (t): 0.736” [18.7 mm] MAXIMUM 7.862” [199.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.6.3 Load Chain Specifications (see Figure 16) Chain type: Standard Load Chain Diameter (d) / pitch (t): 0.268” (6.8 mm) /0.701” (17.8 mm) Class: DAT Grade: H8S or HE G80 RAS Maximum working stress: 19,595 lbs/in (135.1 N/mm ) Hardened surface: 580 or 700 HV (Vickers Hardness) Thickness: 0.006” (0.14 mm) to 0.011” (0.28 mm) Standard: DIN 5684 - 8 Marking (10 x t): 1 or 16 2 2 H 8 S or A 8 Maximum working load, 1 fall: 2200 lbs.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.6.5 Installing the Load Chain Figure 17. Chain Installation Figure 17-A. Chain Orientation 1-FALL CHAIN INSTALLATION 1. Attach last link of chain onto hook of CHAIN INSERTION TOOL (item 1, Figure 17). 2. If the insertion tool is not in the hoist (removal procedure), insert other end of CHAIN INSERTION TOOL into chain opening closest to chain container side.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 2-FALL CHAIN INSTALLATION 1. If the chain insertion tool is not in the hoist (removal procedure), attach last link of chain onto hook of CHAIN INSERTION TOOL (item 1, Figure 17). 2. Insert other end of CHAIN INSERTION TOOL into chain opening closest to chain container. m CAUTION: For a 2-Fall load block assembly, make sure the chain weld on chain link faces inward toward chain wheel pocket on hoist and away from idler sprocket of hook block assembly.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.7 Fall Stop Assembly 7.7.1 General The slack fall stop is a safety stop, not a functional stop. The fall stop must be located at least six (6.0) inches [150mm] from end of last chain link. Figure 18. Cross Section of Slack Fall Stop 1 2 6'' 3 3 7.7.2 Removing fall stop (Figure 18) 1. 2. 3. 4. Remove cotter pin (item 1). Slide up the tube (item 2). Remove the two fall stop halves (item 3). Slide tube (item 2) off load chain. 7.7.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.8 Chain Container Figure 19. Chain Container Installation m CAUTION: Chain container must be installed for effective operation of travel limit switch. 7.8.1 Removing Chain Container (Figure 19) 1. Remove cotter pin (item 5) from end of pin (item 3). 2. Pull pin (item 3) out while supporting chain container (item 2). 3. Remove chain container (item 2). 7.8.2 Installing Chain Container (Figure 19) 1. Insert load chain into chain container (item 2).
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.9 Vinyl Chain Bag (optional) Figure 20. Vinyl Chain Bag Installation Connection 7.9.1 Installing Vinyl Chain Bag (Figure 20) 1. Insert load chain into vinyl chain bag. Position vinyl chain bag onto hoist mounting bracket. 2. Align holes and insert cotter pin through appropriate bag connection holes for the specific model. 2.1. Use Item 1 connection holes for the Model 10 hoist. 3. Place washer onto pin. 4. Insert and secure cotter pin.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.10 Limit Switches 7.10.1 Upper and Lower Travel Safety Limit Switch The Upper and Lower Travel Limit Switch is an automatic reset type switch and connected to the control circuit. The switch housing is recessed into the underside of hoist body. The upper and lower limit switches are emergency protection devices and are not to be used as a continuous stop.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.10.2 Upper and Lower Rotary Travel Limit Switch (Optional Only on 3-Phase units) The rotary limit switch is adjustable and provides over-travel protection for the upper and lower limits of hoist travel. The limit switch is connected to the control circuit. Note: Not available on Single Phase – 115 Volt Models Note: Rotary limit switch assembly cannot be added to a Hoist.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.11 Hooks 7.11.1 General Check hooks for deformation or cracks. Hooks must be replaced if throat opening has increased by more than 15%, or if throat opening has more than 10-degree twist from plane of straight hook. Figure 22. Measuring Hook Deformation Due to many types and sizes of hooks that can be furnished and/or specified by the user / owner, it is recommended that user / owner measure the actual throat opening of hook as originally furnished. See Figure 22.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.11.2 Hook Inspection The wear on the top hook and the load hook SHALL be checked routinely. Measure the throat opening (dimension a2 - FIGURE 23). If the throat opening exceeds the maximum opening allowed, replace the hook. Damaged safety latches shall be replaced immediately. Figure 23.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.11.3 Top Hook Figure 24. Top Hook Orientation CHAIN CONTAINER BRACKET m CAUTION: Before removing Top Hook, de-energize the power to the hoist per ANSI Z244.1 and make certain that any load is removed from the load hook. Also support the total weight of the hoist, including chain, prior to removing the Top Hook. Removing Top Hook 1. Place hoist on workbench. Protect limit switches on bottom side of hoist. 2. Remove screw and locking plate. 3.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.12 Control Changes and Fuses The layouts and wiring diagrams found within this section are for standard hoist controls. Stepless hoists are available for 460 volt three-phase power supplies only. Control Circuit Fuse The control circuit fuse holder is located on terminal strip X1. The fuse holder top flips up to facilitate changing a defective fuse. Table 17.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.13 Stepless Solo Hoist – 460 Volt Wiring Diagram (page 1 of 3) 65/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 66/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc. All rights reserved.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 67/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc. All rights reserved.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.14 Wiring Diagram – 3 Button – Push Button 68/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.15 Wiring Diagram – 5 Button – Push Button 69/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 7.16 Wiring Diagram – 7 Button – Push Button 70/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 8 PREVENTATIVE MAINTENANCE 8.1 Maintenance and Inspection Table Table 18.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 8.2 Lubrication Table 19. Lubrication Specifications LUBRICATION POINT SPECIFICATIONS Chain Oil or Liquid grease Idler sprocket Slide bearing + bearing Grease (without MoS2) KP 2 (DIN 51 502) Soap-based lithium Approx. drip point + 500°F Worked penetration 509-563°F Operating temperature - 4°F - +266°F KP 0 K grease (DIN 51502) Soap-based lithium + MoS 2 Approx.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 8.3 Recommended technical support for various spare parts Table 20.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 8.5 Troubleshooting Table 22.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 8.6 Field repair actions The purpose of troubleshooting and field repair actions is primarily to determine whether the drive or external devices in fact cause the problems. After that, the next step is to detect the possibly damaged components inside the drive. If any damage inside the drive is caused by the environment (motor failure, brake failure, power supply problems etc.) it is very important to repair/change faulty items to prevent reoccurring problems.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 All faults are stored in the Fault History menu except F51 Stop-Limit, from there they can be seen if necessary. The fault history stores the last 5 fault codes. Table 23. Inverter Fault Codes Fault code Fault Possible cause Checking F1 Overcurrent Inverter has measured too high current (over 4*IN peak or over 2.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Table 20 Inverter Fault Codes (continued) Fault code Fault Possible cause Checking A F 14 Inverter overtemperature Temperature of heat sink is over acceptable operating level +90°C (194°F). Over-temperature warning is issued when the heat sink temperature exceeds +85°C (185°F) Check: ambient temperature inverter cooling fan operation cooling air flow through heat sink heat sink is not dirty Change Parameter P1.4.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9 PARTS ILLUSTRATION 9.1 Hoist Body 78/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Table 24.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.2 Gear Mechanism with Motor Brake (Stepless) Figure 25. Stepless Hoist Brake Mechanism Table 25.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 THIS PAGE INTENTIONALLY LEFT BLANK 81/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc. All rights reserved.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.3 Lifting Assembly 82/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc. All rights reserved.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Table 26.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.4 Controls Figure 26. Stepless Hoist Electric Box A3 T100 K1 K7 G1 c A1 a b FU1 X22 X23 X24 R1 NOTE: Inverter includes only one I/O Extension board slot. 84/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Table 27. Stepless Hoist Electric Box Parts List POS.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.5 Chain Guide Assembly – With Limit Switches Table 28. Chain Guide Assembly with Limit Switches Parts List ITEM 1 2 3 4 5 m PART NUMBER 2243050 52295974 7291040 52337705 DESCRIPTION MICRO-SWITCHES ASSEMBLY SPRING ASSEMBLY AND SUPPORT MICRO SWITCHES CABLE GUIDE SLIDES QTY 1 2 3 4 5 CAUTION: Cut off the main power supply before doing any work on the electrical cubicle.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 THIS PAGE INTENTIONALLY LEFT BLANK 87/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc. All rights reserved.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.6 Low Headroom Trolley 9.6.1 Low Headroom Trolley (Drive Components) 88/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Table 29.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.6.2 Low Headroom Trolley (Suspension Components) Figure 27. Low headroom trolley (suspension components) 90/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Table 30. Low Headroom Trolley (Suspension Components) ITEM C10 SHORT DESCRIPTION QTY CODE 1 LH Short Outreach Frame Assy 1 52391066 2 Fixed point assy (not applicable for 1-fall hoists) 1 52391076 to 65 ft. 1 52333407 66 to130 ft. 1 52328053 3 Chain bag (from 0 to 30 m) 4 Lifting chain galva. (Length: HOL + 5 ft.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.7 Electric trolley (Swiveling trolley 0 to 3.2 Tons (3200 Kg)) Figure 28. Electric trolley (swiveling trolley 0 to 3.2 tons (3200 Kg)) 5 NOTE: ECH is attached to swivel trolley through a mechanical connection. No top hook connection available. 92/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Table 31. Electric trolley (Swiveling trolley 0 to 3.2 Tons (3200 Kg)) ITEM DESCRIPTION Complete 2-speed motor drive 115Vc 460V 575V ≤ 3.2 Ton (3200 Kg) 208/230V 1 Complete inverter motor drive 115Vc 460V 575V 208/230V ≤ 1 Ton (1000 Kg) > 1 Ton ≤ 3.2 Ton QTY CODE 2 52306026 2 52306027 2 52306028 2 52299090 2 52304881 2 Idler side plate 2 52326596 3 Drive side plate 2 52326597 Swivel CHRD Kit 2.60 – 4.33 in.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.8 Push Button Assembly – Horizontal Pairs of Buttons Table 32.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.9 Push Button Assembly – Horizontal Pairs of Buttons 1 3 2 Table 33.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.10 Push Button Assembly – Vertical Pairs of Buttons (Option) 96/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 Table 34.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 9.11 Push Button Assembly – Vertical Buttons (Option) Table 35.
LM10 STEPLESS I&M MANUAL/EN/11.30.2010 THIS PAGE INTENTIONALLY LEFT BLANK 99/99 This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc. Copyright © (2010) R&M Materials Handling, Inc. All rights reserved.