Read and understand this Operation & Maintenance Manual before operating or servicing this equipment. Operation & Maintenance SCANDO 450 & 650 Construction Hoist XXX Translation XXX Translation Original instructions This manual is only applicable if the manufacturing number indicated below corresponds to the manufacturing number stamped on the identification sign of the equipment. Where there is a conflict contact your ALIMAK representative. YOUR HOIST HAS: Manufacturing No.: Year: Part No.
FOREWORD This product is designed and manufactured to meet strict quality and safety standards. This manual is intended to provide advice and instructions to the operator and qualified service personnel so that they can safely control the situations which can occur when the product is used, and can carry out the required service and maintenance on the product. This manual shall always be available in the box on the machine intended for this purpose.
CONTENTS IMPORTANT SAFETY INSTRUCTIONS OPERATING INSTRUCTIONS SERVICE AND MAINTENANCE TROUBLESHOOTING Appendix: Check LIST Tightening Torque Text and illustrations by Håkan Lindström Copyright © Alimak AB, 2004. All rights reserved.
IMPORTANT SAFETY INSTRUCTIONS Safety instructions............................................... C 1 The user’s own protective measures.................
C1 Important Safety Instructions Over the years serious accidents have occurred during the erection and dismantling of rack and pinion hoists. Common to these accidents has been the ”human factor”, i.e. non adherence to proper safety procedures and common sense. This document affects the personnel involved in the erection, dismantling and servicing of such equipment.
C2 General – Read all Warning and Instruction Signs. – Keep the work area clean. Any oil spillage must be removed immediately to avoid the risk of slipping. – Never climb on the mast. – During erection, dismantling or hoistway inspection, the hoist must always be operated from the car roof. When working from the car roof take precautions to avoid being struck by mast ties, cable guides, landings, counterweight, structure openings, etc. while hoist is moving.
C3 Electrical power Work performed on electrical equipment must be carried out by competent personnel, trained for such work. The power supply must be switched off and locked before work is performed. Sound level in hoist car Sound level in the hoist car during travel was measured at: ≤ 85 db(A). Spare parts Unauthorized spare parts are not to be used. Only ”Alimak Genuine Spare Parts” are to be installed.
C4 Inspection after major modifications or accidents Inspection and testing should be carried out after major modifications or after an accident to make certain that the hoist operates properly. Working under the hoist car When working under the hoist car, always secure the car mechanically, by safe means, i.e. the car to mast lock device. Or other suitable certified object. The hoist’s main disconnect switch must always be turned off and padlocked during the operation. Stop blocks of rubber Part.
D0 OPERATING INSTRUCTIONS Instructions for use.............................................. Operating instructions....................................... If the hoist does not start.................................... If the hoist suddenly stops.................................. If the hoist has been driven against the final limit cam..................... Securing the position of the car on the mast.......................................... Emergency access to car and enclosure...........
D1 Instructions for use Instructions to the user/operator on how the equipment is to be handled are presented below. These instructions will also be found on a plate in the hoist car. Illegible and missing signs must be replaced. SAFETY INSTRUCTIONS Prior to any use of this hoist perform daily safety procedures below, as well as any required maintenance and lubrication specified in the Operator’s Manual. DAILY PRE-OPERATION CHECKS 1.
D2 Operating instructions Control equipment, relay control with joystick 1. Check that there is nothing which can constitute an obstacle in the path of the hoist. Keep this constantly under observation. 2. Switch on the main ON/OFF switch at the ground landing. d1 3. Make sure that the maximum permissible load, according to the information on the load plates in the hoist, is not exceeded. 4. Close the landing gates and the hoist car gates fully. 5.
Control equipment, ALC with keypad D3 Press the button(s) for required landing. The hoist will automatically stop at the selected landing. Example: If you want to stop at the 12th landing; Push button 1 + 2 and end finish by pushing the ENT.
D4 Alimak Lift Control ALC Two different control systems In the main software there are two different control systems available: Semi-Automatic (or Stop Next Landing) and Collective. The ALC system automatically selects the control system. Semi-Automatic control system This is the most common control system available in the ALC controller and operates without any landing cams. The position of the hoist is determined by counting impulses generated by the pulse encoder attached to the car.
If operation from inside the car is done by means of the keypad, access to the Stop Next Landing control system is automatic. The keypad is consisting of 15 push-buttons. 12 of them are for the collective system: 0 – 9, ENT and CLR. The other three push-buttons are for the Stop Next Landing system: Up, Down and Stop Next Landing, which operate in parallel with the collective system. On every landing there is one I/O-card with two external illuminated call buttons; one for each direction of travel.
D6 If the hoist does not start – check: – that the main ON/OFF switch at the ground landing is in the ”ON” position and that the hoist is supplied with electric power. – that no ”Emergency Stop Button” is in its depressed position. d7 – that the final limit switch is not activated. If the final limit switch is activated – see heading ”Manual cranking”. – that the roof trapdoor and car gates are fully closed. – that all the landing bars or gates are fully closed.
D7 Sliding 1. First check applicable items on previous page. 2. Switch off the main ON/OFF switch on the electrical cabinet. Manual sliding with the motor brake lever – Open the trap door and climb to the car roof. – Lift the brake lifter/-s on the motor to allow the car to slide down to the next lower landing. IMPORTANT: Only slide short distances with maximum 1/3 of normal operating speed. Stop at least 5 (five) minutes every 20 meters (65 ft.) so that the brakes have time to cool off.
D8 If the hoist has been driven against the lower final limit cam If, due to heavy load and poor brake function, the hoist has been driven against the final limit cam at the bottom landing so that the power to the drive unit has been cut off, the hoist can be cranked back manually to the normal landing level. The motor brake should be checked by trained/authorized personnel, before the hoist is put back into service. OFF WARNING! Crushing hazard.
D9 Securing the hoist car on the mast A car locking device is located behind a cover panel in the car wall – intended to be used during transport of the hoist base unit, or when service work is to be carried out on the mast under the car. The car locking device can be applied anywhere on the mast’s rack. Function Remove the cover panel. Push the cog segment in proper location and tighten it fully against the mast’s rack with the M-16 bolt provided.
D 10 Emergency access to car and enclosure Door in ground enclosure – Use the triangular key from the hoist tool kit to release the ground enclosure interlock and enable the door to be opened from the outside. Door lock of mechanical type with integrated electric switch or with separate electric switch – From the inside of the ground enclosure the door interlock is released by pushing the actuator on the door interlock.
D 11 Doors on car Door lock of solenoid type with integrated electric switch – From the inside of the car the door interlock is released by turning the solenoid’s lock shaft to unlocked position. – Use the key to manually push the lock solenoid in unlocked position to enable the door to be opened from the outside. Door lock of mechanical type with separate electric switch – Use the triangular key to open the trap door and climb up on the roof.
E0 SERVICE AND MAINTENANCE Service and maintenance.................................... Adjustment and wear limits............................... Optional centrifugal brake................................. Drop test................................................................ Resetting the safety device................................. Lubrication diagram........................................... Optional load ramp............................................. Preservation for long time storage.........
E1 Service and maintenance In order to avoid unnecessary breakdowns, those responsible for the service and maintenance of this equipment must regularly ensure that all scheduled maintenance work is carried out at the recommended intervals according to the maintenance program below. Adjustments and replacement as a result of inspection, must be carried out by trained/authorized service personnel. Only ALIMAK Genuine Spare Parts must be used. WARNING! Unintended operation.
E2 Interval Part Instructions 4. Gear box Check the oil level and refill, if necessary. Leaking seals shall be replaced by trained/authorized personnel. 5. Counter roller(s) Check that all bolt joints are properly tightened. at the rear of the machinery plate and safety hooks, guide rollers on the hoist car frame. 6. Attachment of Check that all screw joints are properly tightened.
Interval Part 26. Base slab/pit Instructions E3 Remove all debris (or trash), which may have fallen on/into the base (or pit). 27. Gates on hoist car and enclosures Check the function, attachment and wear on rollers and wire ropes. Check to ensure that rubber absorbers are in place. Also check that the rubber cover for the biparting gate is in place. Contact Alimak or representative if an oil leakage occurs on el./hydraulic load ramp – where applicable. 28.
E4
Interval Part Instructions E5 53. Deformations/ mechanical damage Inspect the equipment visually in its entirety for deformation/mechanical damage to mast tubes, diagonal members of the mast sections, mast ties, gates, protective rails, floors, etc. This inspection and any actions, which may be necessary after the inspection must be performed by trained/authorized service personnel. 54.
E6 Adjustment and wear limits Car stopping positions Normally B – empty car Sill e2 B C Maximum C – with pay-load If the distance between actual stopping positions empty/ fully loaded car exceeds value A stated below, the brakes must be checked by trained/authorized service personnel. Note: Parking brakes for VFC operated hoists must ALSO be checked for proper function by testing with rated load or by torque wrench. Hoist type A B C with direct started el. motors 110 mm (4.3 in.) 40 mm (1.
Checking brake torque with torque wrench E7 To be carried out periodically by trained service personnel ONLY! If the machinery is of single motor design the hoist car must be lowered and resting on the buffer springs before checking is allowed to take place. WARNING! Violent stroke by the wrench Switch off and lock out power supply before checking brake torque. Can cause severe personal injury.
E8 Inspection of friction disc and electromagnet Motor brake type Binder WARNING! Unintended operation Bring the car down to rest on the buffer springs. Switch off, lock and tag the main switch before inspection can take place. Can cause severe bodily injury or death. Check air gap by means of a feeler gauge. Replace the friction disc Air gap A / B between magnet housing and armature The friction disc must be replaced before the air-gap exceeds maximum (B) mm. Nominal value (A) mm.
E9 16:1 – 16:3 16 20 5 8 17 11 25 24 21 9 2 7 22 1:2 1:1 10 18 4 19 13 23 26 IMPORTANT INFORMATION RE BRAKES FOR ALIMAK ELECTRIC MOTORS The manual brake release mechanism’s axial play must never be allowed to become ZERO due to its affect on the brake torque. Non existing axial play will cause overheating and damaged leading to a deterioration of the brake function. It is recommended to change brake disc(s) after 800 – 1000 operation hours, individually, depending on load.
E 10 Pinion Max. worn gear Check the wear with the aid of sliding caliper. New gear New gear = 38.5 mm (1.51 in.) Max worn gear = 37.1 mm (1.46 in.) e 53 The counter roller for the pinion must be changed when the pinion is replaced. Gauge Part No. 9098411-000 It is recommended to use Gadus S3 A1300C 2 to prevent crevice corrosion between shaft and pinion. (.31”) ø 8 mm e9 Max. worn rack New rack Rack Measure with a dia. 8 mm (.31 in.) gauge rod and sliding caliper. New rack = 39.9 mm (1.57 in.
E 11 B Guide roller Measure with sliding caliper. Dimensions New roller (mm) Worn-out roller (mm) A Ø 74 (Ø 2.91 in.) minimum Ø 68 (min. Ø 2.68 in.) A minimum 2 (min. .08 in.) B Guide rollers for mast tube dia. 76 mm are zinc plated (yellow roller face). Guide rollers for mast tube dia. 60 mm are iron-zinc plated (black roller face). Note that the ”wear” on the roller face must be equal – all around.
E 12 Adjustment of guide rollers NOTE: Guide rollers must only be adjusted when there is NO load in the car. The following adjustments are carried out by freeing the attaching bolt/nut of the roller and rotating the eccentric shaft with the tool provided until the correct setting is attained. Then retighten the bolt. Car support rollers 1. Adjust the upper support rollers so that the car structure is parallel to the front edge of the mast frame. 2.
E 13 Side roller for single motor drive unit The side roller must be adjusted when it is level with a horizontal frame of the mast. 3. Loosen the side roller and center the drive unit parallel on the mast tubes with the upper left side roller. Setting of overload sensing system Set the overload sensing system to trip at full load and additional 10% overload.
E 14 Gate rollers and gate interlockings Extensive wearing and damages on gate rollers or guide rails can cause improper function of the interlocking’s safety circuits. Avoid accidents by daily try to start the hoist with gate opened. The hoist must not start. If so – the cause of the failure must be determined and rectified. Be sure to check only one switch at a time.
E 15 Measuring the radial play of the rotating shaft on the safety device 1. Clamp a support (A) on the rack with the aid of a C-clamp – approximately 1 mm (.039”) above the safety device pinion. 2. Measure the play with a feeler gauge. 3. Lift the pinion with the aid of the cranking lever from the hoist tool kit or some other suitable tool and measure the play again. A Note that the pinion may not be turned, but must remain in precisely the same position during both measurements. 4.
E 16 Optional centrifugal brake1. WARNING! Unintended operation Bring the car down to rest on the buffer springs. Switch off, lock and tag the main switch before inspection can take place. Can cause severe bodily injury or death. Inspection of brake and brake lining 1. Disconnect the flexible ball joint (A) from the control device on the side where the Teleflex wire from the car release lever is located. 2.
E 17 Every 2nd year 1. Dismantle the brake motor from the centrifugal brake on the gearbox. 2. Clean and grease the brake hub with Aeroshell Grease 6, avoiding any contamination of the brake lining. Also check and replace the brake shoes when the brake linings are worn down to 3 mm (.12”). Reinstall and check that the brake hub is free to move. 3. Replace the control devices’ ball bearings (D) after 800 operating hours, or every 2nd year.
E 18 Drop test To be carried out by trained service personnel. A drop test with full load shall be carried out for each new installation and then at least twice a year – or in accordance with local safety regulations. DANGER! Brake malfunction hazard No one is allowed in the hoist during a drop test. Will cause severe bodily injury or death.
E 19 Release the push-button immediately if the safety device does not function and stop the hoist – at least 3 meters (10 feet) above the ground level. The brake(s) are applied when the push-button is released. If so, start the test from item 4 again. 7. Run the car upwards minimum 0.2 m (8 in.) with the drop test push-button box to release the mechanism of the safety device. Then take the car down to the normal lower landing by inching little by little with the drop test device.
E 20 Resetting the safety device If the safety device trips during normal operation, a careful check must be made of the motor brake(s), transmissions, pinion, rack and all guide and counter rollers by trained/ authorized service personnel, before the safety device can be reset. The cause of the tripping must be determined and rectified. e 20 The safety device may be reset after a drop test, without having to carry out the checks listed above.
E 21 Resetting Tightening torque 20 Nm 1. Switch off the car main switch. 2. Unscrew the screws (1) and remove the cover (2). 3. Unscrew the screws (3). 4. Use the sleeve (5) and the cranking lever (4) to back off the nut (7) until the end of the pin (6) is on a level with the end surface of the safety device. 5. Install the screws (3) and the cover (2) with the screws (1). 6. Remove the protective cover (9).
E 22 Lubrication diagramxxxxxx INTERVAL ITEM LUBRICATING POINT 60 operating hours 1 or at least once a 2 month LUBRICANT VOLUME INSTRUCTIONS Gear box/-es Safety device, and idle gear on the rear of the plate where applicable Check the oil level. Shell Gadus S3 V100 C Grease nipple. or equivalent Part No. 3001 396-250 3 Rack Alimak spec. grease We recommend use of a Also use spray to Part No.
E 23 1 3:1 2 3:2 11:1 4:2 4:1 11:2 9 20 11:3 ALIMAK 34627 - 1 /08
E 24 Pressure: Flow: Displacement: Speed: Power: Voltage: 100 bar 1.5 l/min. 1 cm 2 1500 rpm 0.
Maintenance instructions for optional el./hydraulic load ramp E 25 Exchange hydraulic oil every 1000 operating hours or at least once a year. Hydraulic oil according to ISOVG32 or Q8 Hindemith LT P/N. 3001225-020 Volume: 3 lit. Filler cap Part No. 3002302-703 Filter insertion Part No. 3002302-702 L R R Left limit switch (shown) for the load ramp must be adjusted so that the car stop circuit will cut off immediately when the ramp starts moving.
E 26 Lubrication instructions for optional EN approved low built gates Regularly grease the sliding surfaces inside the interlock post The greasing points in the middle of the interlock post can be reached through holes on the cover sheeting. Use a spray can with multipurpose oil type WD 40 or equivalent.
E 27 Preservation for long time storage The following precautions must be taken when storing equipment outside for more than 6 months. The interval 6 months must be reduced to 3 months for places with temperatures constantly below freezing or where high atmospheric humidity constantly occurs. Mechanical equipment 1. For the ultimate corrosion protection – fill the gear boxes full, with type of lubricant prescribed in the lubrication chart.
E 28 Re-commissioning after storage 1. Change the oil in the gear box/-es. Refill to normal operating level. Do not reuse old oil – no matter how clean it may appear, as it may contain condensed water. 2. Re-install machinery and safety device. 3. Remove all rust protective coatings and lubricate according to the lubrication chart. Sprays containing silicone Used in the right place, silicone is a very efficient lubricant. However, when it contaminates electrical apparatus the effect is disastrous.
F0 TROUBLESHOOTING Electrical troubleshooting.................................. F 1 Example..................................................................
Electrical troubleshooting Advice concerning procedures for troubleshooting All forms of troubleshooting require adapting the procedure to the function and structure of the equipment and to other conditions which may be local in nature. For example, the erection site, maintenance, previous operational problems, etc. The main principles of all forms of troubleshooting in electric systems are presented below. Troubleshooting is carried out with the aid of a test lamp or voltmeter.
F2 6. Check in the car M-panel that power occurs on all three phases of the incoming cable from the ground landing. 7. Check that the ”Up” and ”Down” pulses from the pushbuttons and control devices reach the electric cabinet in the car in the intended manner. 8. Make a trial run and check that the coil on the relevant contactor (Up, Down) receives power and that it is actuated. Check that the brake contactor is actuated and that the brake coil is energized so that the brake releases. 9.
F3 Example: Main principles for electric troubleshooting in stop circuit – control voltage 110V/50Hz or 127V/60Hz. The terminal numbers listed below apply to this diagram only. The procedure for testing other electric equipment with other terminal numbers is carried out in a corresponding manner as described below. 1. Switch on the main ON/OFF switch and close the gate/doors. 2. Check that the final limit switch is in the ”ON” position. 3.
Use the following pages for the Hoist’s periodic service intervals. Make additional copies as required.
Check List Items refer to the Service and Maintenance Instructions in the manual. Name of company Machine type Site Inspector Item Inspection 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 20 21 22 23 24 25 26 27 28 29 30 31 Serial No. Month Year Date Remark .......................
Date Item Inspection Remark ........................
Appendix Tightening torque Recommendations according to the chart on the following page apply in general except for: ALIMAK Mast bolt, dim. 1” UNC – Torque : 300 Nm (220 lbf x ft) – Spanner size : 1 1/2” ALIMAK Mast bolt, dim. M16 – Torque – Spanner size : : 125 Nm (92 lbf x ft) 24 mm Tube coupler for tube dia. 48 mm – Torque – Spanner size : : 80 Nm (60 lbf x ft) 23 mm Pivoted tube coupler for for tube dia.
Recommended torques The chart applies to galvanized bolts and nuts of strength class 8.8 – dry surface.
Additional copies... ...can be ordered using the ordering form below. ALIMAK AB Technical Document Dept. P.O.
Send pcs . . . . . . . . . . . . . . . . . . . . pcs . . . . . . . . . . . . . . . . . . . . pcs . . . . . . . . . . . . . . . . . . . . pcs . . . . . . . . . . . . . . . . . . . . pcs .................... .. Technical Description Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data sheet No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mast section bundle unit handling instructions 1. Always apply the lifting fork from the mast section’s short end in the mast section bundle unit, if possible. 2. If not, the bundle unit must be lifted with utmost care, on the racks in the center of the mast section. The rack’s machined surface must be turned away from the lifting fork. Take care not to damage the diagonal braces during applying / removing the lifting forks. Maximum allowed deformation less than < 3 mm ( 1/8 in. ). (Ref. MS 2/08).
9110340-000 OK! OK! OK! OK!
