Hoist Drives. Operating manual. for hoist drives. Status : April, 2016

Transcription

1 Operating manual for hoist drives Status : April, 2016 Copyright ABM Greiffenberger Antriebstechnik GmbH, Friedenfelser Straße 24, Marktredwitz, 2013

2 Table of contents 1. General safety information General Explanation of symbols Personnel Mechanical hazard Thermal hazard General General instructions Used terms Modification of the product Liability and warranty claims Addresses Specification Construction of the hoist drive (schematic diagram) Name plate Type designation Standards and guidelines CE conformity Intended use Optional modules Preparation of the drives for operation Motor Brake Preparation of the drives for operation Shipment and packaging Transport and storage Mechanical installation Electrical installation Commissioning Commissioning after longer downtimes Operation Safety instructions Error diagnosis and fault removal Maintenance Safety instructions Maintenance Spare parts Decommissioning and disposal Decommissioning Recycling and disposal List of images... 33

3 10. List of tables Index Annex A Spezifikation Hubwerk B Rectifier B1 Bridge Rectifier B2 Fast Excitation Rectifier C Motor D Screw tightening torques E Lubrication G Mounting drawings... 40

4 1. General safety information 1.1. General Any work for the transport, storage, installation, commissioning and maintenance may be carried out with the personal protective equipment required for the work Explanation of symbols Signal words: Signal word field with signal word DANGER WARNING CAUTION Meaning Indicates a hazard with a high degree of risk which leads to death or severe injuries if it is not prevented. Indicates a hazard with a medium degree of risk, which can lead to death or severe injuries if it is not prevented. Indicates a hazard with a low degree of risk which can cause minor or moderate injuries if it is not prevented. Table 1 : Signal words and their meaning The safety instructions in this operating manual are structured as follows: Signal word with illustration HAZARD Actions to prevent the hazard 1.3. Personnel Any work for the transport, storage, installation, commissioning and maintenance must only be carried out by qualified specialist personnel. The binding specifications for the qualification of electrically qualified persons and electrically skilled personnel apply as defined in DIN VDE

5 1.4. Mechanical hazard Transport, assembly, commissioning and decommissioning, as well as maintenance and inspection work must only be carried out using the personal protective equipment required for the respective work, and only by trained specialist personnel while the machine is idle, deenergised and cooled off Thermal hazard WARNING HOT MACHINE PARTS Hot machine parts can cause burns in case of skin contact Do not touch hot surfaces! If possible, the manufacturer of the complete machine has to provide suitable touch guards! Wear the personal protective equipment for maintenance or troubleshooting work! Observe the cool-down times! Electric mains must not be in contact with hot surfaces. 5

6 2. General 2.1. General instructions Before working with the drive, carefully read the operating manual. This way, you ensure a riskfree and smooth function of the drive. The instructions of this operating manual must be observed. Special designs can deviate in technical details! This operating manual and all associated special documentations must be kept in close proximity to the drive. The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design Used terms Term Motor Drive Table 2 : Used terms Hereinafter used for Three-phase motor Gear motor Hoist Drive 2.3. Modification of the product The drive itself must not be changed. Adjacent constructions by the customer must not obstruct the heat flow by means of convection and heat conduction. A heat input into the drive from the outside is not allowed Liability and warranty claims The drive must only be operated in compliance with the specifications in the operating manual. In case of property and personal damage caused by improper handling or noncompliance with the safety instructions, any liability and warranty claim expires. 6

7 2.5. Addresses Germany ABM Greiffenberger Antriebstechnik GmbH Postfach 140 Friedenfelser Str. 24 D Marktredwitz D Marktredwitz Phone: Fax: sales@abm-drives.com USA ABM DRIVES INC Ford Circle, Suite E Milford, Ohio Phone: Fax: abmus@abm-drives.com Austria ABM Antriebstechnik GmbH Ortstrasse 18/1/5-7 A Vösendorf Phone: Fax: abm-austria@abm-antriebe.de France ABM Systèmes d'entraiment S.A.R.L. 40, rue Jean Monet Melpark Bat. 5 F Mulhouse Phone: Fax: infofr@abm-drives.com P.R. China ABM Drives (Suzhou) Co., Ltd. Kuachun Industrial Area Unit 9G, Chun Hui Lu, Weiting Town VR China Suzhou Phone: Fax: infocn@abm-drives.com Turkey ABM Greiffenberger Hareket Sistemleri Ticaret Limited Şirketi Barbaros Mah. Bezirgan Sok. No:3 Deluxia Suites A Blok Daire:17 Batı Ataşehir-İstanbul, TR Phone: Fax: abmtr@abm-drives.com India ABM Drives India Private Limited Lunkad Sky Vista, 308 Viman Nagar, Near Dorabji Mall, Opp New Airport Road, Pune Phone:

8 3. Specification 3.1. Construction of the hoist drive (schematic diagram) Deviations are possible depending on the design. Image 1 : Construction of the hoist drive [1] Motor [6] Oil filling screw [2] Name plate motor [7] Housing [3] Terminal box [8] Housing cover [4] Drum attachment [9] Oil gauge glass [5] Lifting eye [10] Lubrication plate 8

9 Brake Hoist Drives 3.2. Name plate Name plate (Example) Abbreviation Unit Designation Mot D = three-phase motor Nr Serial number TNr ABM part number IKL Insulation class UT C Max. allowed ambient temperature IP Type of protection (motor/brake) T2 = tropical protection Type ABM type designation Operating mode kw Motor rated power V Motor connection voltage Hz Frequency motor voltage Switching type of the motor (Y / delta) A Rated current of the motor Cos-Phi of the motor 1/min Rated speed at the gear shaft // motor shaft TS Nm Brake torque V Brake connection voltage A Rated current of the brake CB μf Operating capacitor for single-phase motors CA μf Starting capacitor for single-phase motors Table 3 : Field description at the name plate 9

10 Brake Hoist Drives UL-Name plate (Example) Abbreviation Unit Designation Serial-No. PNo. INSL Cl Serial number ABM part number Insulation class AMB C Max. allowed ambient temperature ENCL Type Duty kw V Hz A 1/min Type of protection / IP class (motor/brake) T2 = tropical protection ABM type designation Operating mode Motor rated power Motor connection voltage Frequency motor voltage Wiring type of the motor ( Y / ) Rated current of the motor Cos-Phi of the motor Tq Nm Braking torque V A Rated speed at the motor shaft or gear shaft Brake connection voltage Rated current of the brake Cop μf Operating capacitor for single-phase motors Cs μf Starting capacitor for single-phase motors Table 4 : Field description at the UL-name plate 10

11 Lubrication plate Number Designation 1 Date 2 ABM Order Number 3 Consecutive Number 4 Type designation 5 Lubrication type 6 Lubricant volume 7 Ratio Table 5 : Field description at the name plate } ABM Serial Number 11

12 3.3. Type designation This documentation applies to ABM drives with the following type designation (example): ZFB100 / GH12500 / 4D132Md4x-12/2 Brake designation Gear designation Motor designation Type designation brake See operating manual brake Type designation gear GH = hoist drive Designation GHX = hoist drive extended version 1. addition Frame size 2. addition Customer specific information (A, S ) Type designation motor 3 = die-cast case Casing key 4 = extruded casing - = bearing plate motor Motor type D = three-phase motor B= reinforced coil 1. addition G= non-ventilated 2. addition Motor size (peak height) and packet length Number of poles 3. addition Addition s : special version Addition x : alloyed rotor FL: forced ventilated 4. addition for 1 st addition G EL: external ventilation DL: open-circuit ventilated Table 6 : type designation ABM hoist drives 12

13 3.4. Standards and guidelines The motors comply with the following standards: Standard Title EN ISO Safety of machinery -- General principles for design -- Risk assessment and risk reduction EN A1 IEC / EN IEC / EN IEC / EN IEC / EN IEC / EN IEC / EN Cranes. Power driven winches and hoists. Power driven hoists Rotating electrical machines - part 1: Rating and performance Rotating electrical machines - part 5: Degrees of protection provided by the integral design of rotating electrical machines (IP code) - Classification Rotating electrical machines - part 7: Classification of types of construction and mounting arrangements Rotating electrical machines - part 8: Terminal markings and direction of rotation Rotating electrical machines - part 9: Noise limits Rotating electrical machines - part 14: Mechanical vibration of certain machines with shaft heights 56 mm and higher - Measurement, evaluation and limits of vibration severity FEM1.001 Rules for the design of hoisting appliances, Parts 1, 2, 3, 4, 5, 8 und 9 FEM9.901 Table 7 : Standards and specifications Rules for the design of series lifting equipment and cranes equipped with series lifting equipment If the products fall within their scope, the following guidelines and directives apply: Number 2006/95/EC 2011/65/EU Directive EC 1907/2006 Table 8 : Guidelines Abbreviated designation Low-Voltage Directive RoHS directive REACH Furthermore the asynchronous motors fulfil the protective regulations of the low voltage directive. According to the Guide to application of Directive 2006/42/EC 222 the declaration of conformity only refers to the machinery directive. 13

14 3.5. CE conformity 14

15 3.6. Intended use The hoist drives serve as a drive unit for lifting devices. Ambient conditions Requirement Ambient temperatures -15 up to +40 C Installation height 1000 m above sea level Humidity Up to 50% (at +40 ) Up to 90% (at room temperature) Table 9 : Operating conditions according to EN or EN Increased operating conditions, e.g. extended temperature range are according to the data sheet. The use in explosive areas is forbidden. An overload can cause damages to the drive. The maximum load is specified in the data sheet. In order to prevent an overheating of the drive, it must be ensured that sufficient space is available for the unobstructed ventilation. The fan cowls must not be covered. When using several drives in close proximity, it must be ensured that it is possible to prevent a suction of warm exhaust air. The technical data on the name plate must be observed. The documentation must be complied with. For applications in which the failure of a gear or motor could cause a danger to persons, corresponding safety precautions must be provided. The motor is no independently functional machine and it is intended for the integration into another machine. The commissioning is prohibited until it has been determined that the machine complies with the regulations of the EC directives. Observe additionally the operating manuals for electric motor/gear motor and brakes. You can find these and other manuals after registration in the download area at Optional modules Brake with microswitch (for monitoring release or wear) Brake with manual release Increased protection class (IP65) Incremental encoder External fan 15

16 4. Preparation of the drives for operation This chapter presents additional informations to the operating manuals for electric motor/gear motor and brakes. You can find these and other manuals after registration in the download area at Motor Hoist motor usages must comply with the corresponding mode of operations (see table 15, annex C). It is imperative to conform to the permitted on times and cycles per hour. Low speed windings must be activated for at least 1 sec. on all starts and stops. Minimum and maximum speeds and on times for inverter duty motors are equal to the permitted mode of operations of two speed motors (12/2 poles). Example: Hoist Duty Service Classification: FEM 2m Motor Duty Cycle: S3 40 % (based on cycle time of 10 min) Starts or Stops per Hour: 240 c/h On Time (ED): 1/3 in low speed winding (approx. 500 RPM) equals 1.3 min. 2/3 in high speed winding (approx RPM) equals 2.6 min. Permitted Starts or Stops per Hours (c/h): 1/3 in high speed winding (approx RPM) equals 80 c/h 2/3 in low speed winding (approx. 500 RPM) equals 160 c/h Thermal Protection Motor windings can be protected from overheating by PTC-thermistors or thermal sensors. Single speed motors have 3 PTC-thermistors and 3 thermal sensors, two speed motors have 6 PTC-thermistors and 3 thermal sensors (2 in high-speed winding and 1 in low-speed winding). ABM motors are designed for insulation class F. When the temperature of the motor exceeds the rated operating temperature (ROT = 155 C for Iso F) the relay is activated and triggers the power cut-off. After cooling down below ROT, the low resistance of the PTC-thermistor will allow the motor (transformer) to be re-started. Control-relays suitable for use in conjunction with PTC s are produced by several manufacturers. 16

17 4.2. Brake Rectifiers for two speed motors (12/2- or 8/2pole) are typically connected to the star points of the winding (tagged 1U2-1V2-1W2 / 2U2-2V2-2W2). The voltage of the star points will be calculated as follows: (e.g. power supply of 400V): 400V 230V 3 Most brakes are supplied with 98 V DC or 195 V DC coils depending on rectifier and power supply voltage. To avoid a long overrun brakes should get switched on DC-side. Wiring diagrams Inverter driven motors require a separate brake supply voltage (B225). 17

18 Supply Voltage Coil Voltage Bridge rectifier Fast-excitation-rectifier V DC V AC V AC 98V DC V AC V AC 136V DC V AC V AC 195V DC V AC - 340V DC Table 10 : Brake voltages (green = standard) Up to motor size 4D112 and brake type ZFB60, the PMBAF 400-S rectifiers are used. The PMBAF 400-S is a bridge rectifier with a maximum supply voltage of 400V~. From motor size 4D132 and brake types ZFB100 the PMG500-S rectifier must be used. The PMG500-S is a fast-excitation-rectifier that switches from bridge rectifying to one-way-rectifying after 500 ms of operation time with a maximum supply voltage of 500V~. Thermal sensors and PTC-Thermistors are not connected to the rectifier but to an additional terminal strip. You can find the technical datas of the rectifiers at annex B Brakes on two speed motors should not be applied directly from high speed. The hoist manufacturer is responsible to ensure that the motor is slowed down by the low speed winding before brakes are applied. Otherwise increased wear of the brake should be expected. If supplied via rectifier devices, the circuit can be interrupted on AC side or, respectively, on DC side. The latter switching type results in very short switching times of the brakes. The disadvantage with this type of switching is the occurrence of high peak voltages (sparking at switching contacts) which, however, can be prevented by means of protective wiring. In order to protect the switching contacts against burn-up, we recommend a varistor in parallel to the coil. The microswitch (optional) monitors release or wear of the brake. 18

19 5. Preparation of the drives for operation 5.1. Shipment and packaging The drive is delivered with suitable packaging. The outer packaging is taken back. Incoming control: - Check the completeness on the basis of the delivery note! Is the packaging damaged? - Check the delivery for damages (visual inspection)! In case of complaints If the delivery was damaged during transport: - Contact the forwarding agent immediately! - Keep the packaging (due to a possible inspection by the forwarding agent, or for the return of the goods)! Packaging for the return of the goods - Pack the motor shockproof Transport and storage During transport the drives must only be suspended at the provided lifting eyes. Do not attach additional loads to the motor. Only use suitable lifting means. Improper execution, unsuitable or damaged devices and tools can cause injuries and/or property damage. DANGER FALLING OBJECTS In case of improper transport, the drive could detach from the transport and lifting gear. Falling objects can cause severe injuries. Staying underneath the drive during transport is forbidden! Ensure secure fastening! 19

20 The following points must be observed for the storage: Storage in installation position, protect the drive against falling Slightly lubricate blank casing surfaces and shafts Store in dry, dust-free rooms Temperature without considerable fluctuations between -25 C and +55 C Relative humidity less than 60% No direct sunlight or UV light No aggressive, corrosive materials (contaminated air, ozone, gases, solvents, acids, lye, salts, radioactivity etc.) in the surroundings No shocks and vibrations Mechanical installation The mechanical connection of the electric motor has to be carried out by a specialist. Only carry out work at the drive when it is switched off and secured against restart. Before the installation, check the installation situation. Shearing and crushing points must be avoided when handling the drive. Fence off the working area. Use the personal protective equipment. Product-specific characteristics must be observed when selecting add-on components (fixtures) and for the later use of the complete machine. The mounting of drum to output shaft and gearbox must comply with ABM s mounting drawings (see annex G). Appropriate materials and surface treatment of the drum and drum flange must be used to assure a safe gearbox output torque transfer. The drum respectively the drum flange must be designed to use the load journal behind the external involute spline to carry loads. The external involute spline is only designed to transmit the output torque of the gearbox and not to carry any radial forces. 20

21 5.4. Electrical installation DANGER ELECTRIC SHOCK Electrical parts are energized with hazardous voltage. When touching these parts you will get an electric shock. Death or severe injuries are the result. Any work for electrical installations must only be carried out by qualified specialists! Connecting work must only be carried out in deenergized condition! Compare the mains voltage and mains frequency with the data on the rating plate. The allowed mains voltage fluctuation is +10%. Adjust the cross-sections of the connecting cables to the nominal current pursuant to the regulations. Connect and arrange the connection terminals according to the connection plan on the inside of the terminal box. Ensure that all connections including ground wire are tightly screwed. In order to avoid a tensile load of the terminals, mount the connection cables strainrelieved. No foreign matters, dirt or humidity may enter the terminal box. In order to ensure the type of protection when closing the terminal box, use the original seals. Close unused cable entries in a dust- and waterproof manner. 21

22 5.5. Commissioning Before commissioning, ensure that the drive is undamaged and non-choked. Ensure the proper installation of the safety devices. In order to check the rotational direction, switch the properly connected motor in uncoupled condition On/Off for a short time. Connect integrated temperature sensors (PTC thermistor or bimetal temperature sensor) to the control device. If a continuity test of the temperature sensors is required, this must be carried out with a measuring bridge (max. 5 V). During the test run under maximum load, the gear must be checked for: - Unusual noises such as milling, knocking or grinding noises - Unusual vibrations, oscillations and movements - Generation of steam and smoke The drive must be shut down and ABM must be contacted if an abnormality was determined during the aforementioned check tests. After the test run, the gear must be checked for leaks. All fixing bolts have to be retightened Commissioning after longer downtimes After longer downtimes (longer than 1 year), check the screw connections and bearings before the commissioning. Ensure that cooling airways, especially the openings of the fan cowls, are free from contaminations Before commissioning, replace the lubricant in the gear. Measure the insulation resistance. The maximum discharge current of the coil against the casing at 1500 V test voltage for the motors in supplied condition is 10 ma. The measurement must be carried out by a correspondingly qualified employee. 22

23 6. Operation 6.1. Safety instructions DANGER MOVING PARTS Rotating parts can cause injuries Never reach into moving parts and keep foreign materials away from these parts! Safety devices must be provided by the manufacturer of the complete machine and must not be removed or put out of operation! Observe the safety distance! During operation, motor surfaces must not be touched. The surfaces at the drives can become very hot. If required, provide a touch guard! WARNING HOT MACHINE PARTS Hot machine parts can cause burns in case of skin contact Do not touch hot surfaces! Observe the cool-down times! Carry out regular checks during the operation, depending on the operating conditions. In doing so, pay special attention to: Unusual or excessive noise or temperature generation, Loose fixing elements, The condition of the electric mains, Stronger vibrations, Changes in the rotational speed, Problems with the heat removal due to depositions on the drive system. In case of faults, contact the maintenance personnel immediately. 23

24 6.2. Error diagnosis and fault removal DANGER ELECTRIC SHOCK Electric parts Electrical parts are energized with hazardous voltage. When touching these parts you will get an electric shock. Death or severe injuries are the result. Any repair work must only be carried out by qualified specialists! Connecting work must only be carried out in deenergized condition! Fault Possible cause Remedy Motor does not start Blow when switching on Wrong rotational direction Fuse has blown Motor protection does not switch, error in the control Power supply interrupted Counter torque of the load is too big Voltage or frequency deviate severely from the target value, at least when switching on Coil defective Rotor streaks Drive blocked Gear fixture loose Motor connected incorrectly Replace the fuse Check the control of the motor protection, remove error Check connections, adjust if necessary Check load and reduce if necessary (check application) Provide better mains conditions; check the cross-section of the supply line Repair by manufacturer Repair by manufacturer Check components for free movement; remove foreign materials from the motor, if necessary Re-tighten the motor and gear fixture screws Interchange the two phases 24

25 Fault Possible cause Remedy Gearbox drive shaft does not rotate although the motor is rotating Motor hums and has a high power consumption Running noises Motor gets too hot Breakage in the gear Coil defective Rotor streaks Foreign materials inside the motor Bearing damage Gearing damage Oil deficiency Vibrations Motor switched in delta instead of Y, as intended Overload of the drive Insufficient cooling air, cooling airways blocked Cooling air is preheated Ambient temperature too high Heat removal impaired due to deposits Contact ABM-Service Repair by manufacturer Repair by manufacturer Cleaning of the interior, possibly by the manufacturer Installation of new grooved ball bearings, possible repair by manufacturer Contact ABM-Service Contact ABM-Service Remove cause, balance if necessary Correct the switching Check load and reduce if necessary Ensure free inlet and outlet of the supply air Provide fresh air Provide fresh air Clean the surface of the drives 25

26 Fault Possible cause Remedy Gear gets too warm Oil escapes from the gear or motor Unfavourable installation conditions Gear damage Seal defective Contact ABM-Service Contact ABM-Service Contact ABM-Service Oil escapes from pressure ventilation Incorrect oil level Dirty oil Oil change Oil change Table 11 : Error diagnosis 26

27 7. Maintenance 7.1. Safety instructions DANGER ELECTRIC SHOCK Electrical parts are energized with hazardous voltage. When touching these parts you will get an electric shock. Death or severe injuries are the result. Any maintenance work must only be carried out by qualified specialists! Maintenance work must only be carried out if the system is de-energised and secured against restart! 7.2. Maintenance WARNING HOT MACHINE PARTS Hot machine parts can cause burns in case of skin contact Do not touch hot surfaces! Observe the cool-down times! WARNING FUMES Chemical cleaning agents can be corrosive or develop hazardous fumes. Breathing difficulties, irritation or poisoning can be the result. Use the personal protective equipment! Observe the warning notices of the cleaning agent producer! 27

28 CAUTION DUST When cleaning with compressed air or steam jet, dirt particles can be raised and inhaled, or they can reach into the eyes Use the personal protective equipment! Ensure proper extraction! ABM hoists are delivered ready to use. Please note the lubricant informations on the data sheet (also see annex E). Shortened maintenance intervals are strongly recommended if gearboxes are exposed to unfavourable ambient conditions, such as: High humidity dusty environment large ambient temperature fluctuations The quantity of lubricant is designed for a mounting angle of 0. Other mounting angles don t need other quantities, but in general the quantity of lubricant is adequate when the mid of the oil gauge glass is reached. Maintenance intervals Maintenance work Maintenance work for the machine operator: Regularly Depending on the dirt, clean the motor regularly along the entire cooling airway. Maintenance work for specialist personnel: Every 3000 operating hours, at least every six months Check oil level Regrease external spline. Visual check for leakages Check the coupling Check the gear for abnormal running noises and / or vibrations Every 3 years Every 5 years Oil change (for mineral oil) Oil change (for synthetic oil) Table 12 : Maintenance work 28

29 Operating hours Hoist Drives Oil bath - continuous temperature Image 2 : Oil change interval for normal operating conditions We recommend shortened change intervals in case of particularly difficult operating conditions such as high humidity, aggressive environment, severe temperature fluctuations, etc. Our gear motors are delivered ready-to-use. The first lubricant filling ex works lasts for approx. 10,000 operating hours for oil filling, for grease filling approx. 8,000 operating hours. For quantity and type of the lubricant, please see Annex E. In doing so, observe the instructions in your data sheet. When changing the lubricant, the gear must be cleaned thoroughly. DANGER HOT OIL In case of contact with hot oil, there is a risk of scalding Open the discharge carefully! Wear the personal protective equipment! Ensure that no dirt reaches the inside of the gear when changing the lubricant. Remove bypassing oil immediately using an oil binding agent. 29

30 7.3. Spare parts We expressly point out that spare and equipment parts, which were not delivered by ABM, were also not tested and approved by ABM. The installation and / or use of such products could therefore have a negative impact on the constructive properties of your drive. The liability of the manufacturer is excluded for damages arising from the use of non-original spare parts and non-original equipment. Request a separate spare parts drawing and list for your drive. 30

31 8. Decommissioning and disposal 8.1. Decommissioning First, remove the electrical connections DANGER ELECTRIC SHOCK Electrical parts are energized with hazardous voltage. When touching these parts you will get an electric shock. Death or severe injuries are the result. Any electrical work for the decommissioning must only be carried out by qualified specialists! Electrical work must only be carried out if the system is de-energised and secured against restart! Remove the lubricant Remove the drive from the machine Transport the drive to the work station prepared for the disassembly. Observe the instruction in the chapter Transport Protect the drive and the components against falling when disassembling DANGER FALLING OBJECTS Falling objects can cause severe injuries. Ensure secure fastening! 31

32 8.2. Recycling and disposal Divide the components into the following category for recycling: Electronic scrap Iron scrap Aluminium Non-ferrous metal such as motor coil Insulation material, cables Divide the auxiliary materials into the following category for recycling: Oil Grease Anticorrosive agents Dispose of the components in compliance with the national and local regulations. 32

33 9. List of images Image 1 : Construction of the hoist drive... 8 Image 2 : Oil change interval for normal operating conditions List of tables Table 1 : Signal words and their meaning... 4 Table 2 : Used terms... 6 Table 3 : Field description at the name plate... 9 Table 4 : Field description at the UL-name plate Table 5 : Field description at the name plate Table 6 : type designation ABM hoist drives Table 7 : Standards and specifications Table 8 : Guidelines Table 9 : Operating conditions according to EN or EN Table 10 : Brake voltages Table 11 : Error diagnosis Table 12 : Maintenance work Table 13 : Technical data of bridge rectifier PMBAF 400-S Table 14 : Technical data of fast excitation rectifier PMG 500-S Table 15 : Relationship between cyclic duration factor, number of cycles and starts/hour Table 16 : Screw tightening torques in Nm Table 17 : Lubricant amounts hoist drives Table 18 : Lubricant table

34 11. Index Adresses... 7 Brake Commissioning Conformity Construction... 8 Decommissioning Disposal Error Fault removal Guidelines Installation... 20, 21 Insulation resistance Intended use Lubricant change Lubrication A B C D E F G I L M Modification... 6 Motor... 16, 38 Mounting Name plate... 9, 10, 11 Oil change Operation Optional modules Packaging Rectifier Recycling Safety... 4 Signal words... 4 Spare parts Specification Standards Storage Surface... 5, 23, 27 Terms... 6 Thermal Protection Transport Type designation Warranty... 6, 30 Wiring diagrams N O P R S T W Maintenance

35 Annex A Specification Hoist Shall the drive be used Indoor Outdoor Enclosure (IP) Hoisting load (kg) Hoisting velocity (m/min) (1 or 2 speed) Drum diameter (mm) Efficiency (Rope/Rope drum) (%) Rated power (kw) FEM Rating Duty cycle % CDF Start/stops per hour c/h Operating voltage (V) Frequency (Hz) Brake voltage (V) Brake torque (Nm) Other specification Reeving 35

36 B B1 Rectifier Bridge Rectifier Technical data of bridge rectifier PMBAF 400-S Type Bridge rectifier Rated voltage max. 400 V ± 10% 50 / 60 Hz AC Operating voltage max. 360 V DC Output current max. 2,0 A DC (T amb = 45 C) Table 13 : Technical data of bridge rectifier PMBAF 400-S 36

37 B2 Fast Excitation Rectifier Type Rated voltage Output voltage Technical data of fast excitation rectifier PMG 500-S Admissible ambient temperature Max. output current (T amb =45 C) Min. output current Max. switching power Over excitation time Recovery time Schnellerregungsgleichrichter V ± 10% 50 / 60Hz AC V = (500 ms) V = (cont.) -25 C bis +80 C 4,0 A = (500 ms) / 2,0 A = (cont.) 0,02 A = (500 ms) / 0,01 A = (cont.) 210 W (600 c/h) 500 ms ± 200 ms app. 150 ms Table 14 : Technical data of fast excitation rectifier PMG 500-S 37

38 C Motor Minimum values for the number of starts per hour, and also relationship for the minimum values between cyclic duration factor, number of cycles per hour and starts per hour given in table 15 Group of mechanisms Cycles/h Intermittend duty No. of starts / h CDF in % Short time duty Operating time in min. high speed low-speed 1 Dm M ,5 1,5 1 Cm M ,5 2 1 Bm M ,5 1 Am M m M ,5 3 m M m M m M > 60 6 Table 15 : Relationship between cyclic duration factor, number of cycles and starts/hour D Screw tightening torques Thread Strength class of screw connection Terminal board / steel nuts Terminal board / brass nuts M4 3, ,5 1,5 M5 6, ,4 3 M ,75 5 M ,5 10 M M M M M Tolerance of all tightening torques = 15% Delivery status for teminal boards: upper nut tightened with reduced moment Table 16 : Screw tightening torques in Nm 38

39 HC PG CLP Hoist Drives E Lubrication Hoist drive Oil Viscosity Class Lubricants Quantity GH 3201 VG cm 3 GH 5000 VG cm 3 GHX 63 VG cm 3 GH VG cm 3 GH VG cm 3 GH VG cm 3 GH VG 680 Table 17 : Lubricant amounts hoist drives cm 3 (90 ) cm 3 (0 ) Gear oils Type ISO VG 220 Degol BG 220 Energol GR-XP 220 Alpha EP 220 Renolin CLP 220 Mobilgear 600 XP 220 Omala S2 G Degol BG 680 Energol GR-XP 680 Alpha EP 680 Renolin SEW 680 Mobilgear 600 XP 680 Omala S2 G Degol GS 220 Enersyn SG-XP 220 Alphasyn GS 220 Renolin PG 220 Glygoyle HE 220 Tivela S Degol PAS Optigear Synthetic X220 Renolin Unisyn CLP 220 Mobil SHC 630 Omala 220 HD Table 18 : Lubricant table Observe the instructions on the data sheet of your drive! *Temp = recommended temperature range can be surpassed or under passed depending on the application Notes: CLP : Mineral oil, lubricating oil PG : Synthetic oil (polyglycol) HC : Synthetic oil l (Lubricant on the basis of poly-alpha-olefin - PAO) 39

40 G Mounting drawings 40

41 41

42 42

43 43

44 44

45 45

46 46