STAGEMAKER COMPACT Concert Hoist

Transcription

1 : September 2005 STAGEMAKER COMPACT Concert Hoist

2 : September 2005 Contents 1 Introduction Mounting Positions Installation Types Basic Configuration Description Capacity, Speed, and Hoist Configuration Summary Performance Environment Sound Level Proper Installation Hoists for Ground Supports Hoist Configurations Hoist Configuration A Direct Motor Control for Mobile Installations Hoist Configuration B Low Voltage Control for Fixed or Mobile Installation Hoist Configuration C Programmable Control Hoist Configuration D BGV-C1 Enhanced Safety Features Hoist Configuration E without Motor Controls Hoist Configuration S Single-phase Motor and Control Controllers Group Controllers for Configuration A Hoists Group Controllers for Configuration B or S Hoists Pistol-Grip Pushbutton Controller for Configuration B or S Hoists Pushbutton Pendant Controller for Configuration B (SM16 SM25) or D Hoists Programmable Controller for Configuration C Controller for Configuration D Controllers Examples of Use Configuration A 8 Channel Controller Configuration A SC Controller, Hoist & Cable Configuration A SC Controller, Hoist & Cable + Splitters Configuration B & S Hoist & Cables (separate power & control), 3 rd -party Controller Configuration B & S Hoist & Cable (combined power & control), 3 rd -party Controller Configuration D Controller, Hoist, & Cable Pigtails/Cables/Connectors Rules Pigtail Options with Wiring Identification Pigtails with Plug Options Cables with Connectors Connector Types and Plug Wiring Identification Suggested Cable Selection Table

3 : September Hoist Motor Features Ambient Conditions Motor Cooling Hoist Motor Thermal Protection Brake Coil Resistance Hoist Gearbox Hoist Brake and Torque Limiting Device Load Chain, Load Sprocket and Chain Guide Hooks Load Block & Hook Load Hook Dimensions Swiveling Top Hook Fixed Top Hook Top Hook Dimensions Self Locking Hooks Low Voltage Control Hoist Limit Switch Upper and Lower Limit Switches Geared Limit Switch Hoist Protection Rating Capacity Plate Surface Treatment/Paint Specification Electronic Overload Devices Incremental Encoder SM1 Hoists SM5 or SM10 Hoists Model Description Conversions

4 : September Introduction 1.1 Mounting Positions Normal position is where the hoist is mounted with load chain down and hoist body up. The load block attaches to the load and moves up and down. The hoist body is stationary. All of the models (SM1 through SM25) can be mounted in the normal position. Inverted position is where the hoist is mounted with load chain up and hoist body down. The hoist body attaches to the load and moves up and down with the load. Hoists in the inverted position are easier to install and setup because all the cabling is at the same level, and the hoist is at truss level. Only SM1, SM5 or SM10 hoist when properly equipped can be mounted in the inverted position. Normal position Inverted position 1.2 Installation Types STAGEMAKER COMPACT concert hoists could be used in a mobile installation or a fixed installation. Careful consideration of the installation type and the mounting position should be taken before ordering so that the hoist can be properly equipped to meet the requirements. Mobile installation means the hoist is used in temporary or short-term setup. Hoists used in a mobile installation are typically mounted in the inverted position. Some examples of mobile installations: on-tour concerts, ground and roof supports, exhibitions, product presentations, and the circus. Local safety regulations must be followed at all times. These regulations could require: Additional safety such as a steel rope between the upper suspension point and the lower hook point of the load or a redundant system. De-rated capacity of the hoist Second brake For more advance lifting applications, use BGV-C1 Configuration D hoist providing enhanced safety features Fixed installation means the hoist is used in a more permanent or long-term setup. Some of examples of fixed installations: theaters, studios, and arenas. In fixed installations the hoist is mounted in the normal position and situated usually out-of-sight. Because of the out-of-sight situation, over-travel limit switches and low voltage control are mandatory. 4

5 : September Basic Configuration Description STAGEMAKER COMPACT concert hoists are offered in many configurations, each with its own control type and hoist features. Configuration A: Utilizes direct motor control for easier setup and cabling. The hoist is equipped so it can be mounted in the normal or inverted position. A direct motor control hoist in the inverted position is best suited for temporary or short-term setups. Full line voltage controller furnished separately. Configuration B: Utilizes low voltage control. The hoist (SM1, SM5, SM10) is equipped so it can be mounted in the inverted or normal position. Controller furnished separately. A pickle, which is used during stage setup, can be connected directly to the low voltage hoist control. The SM16, SM20 and SM25 hoists must always be mounted in the normal position and are furnished with a pushbutton pendant controller with E-stop. Configuration C: Utilizes low voltage control and a separate programmable controller. The hoist is mounted in the normal position, but when specially equipped, the hoist can also be mounted in the inverted position. The hoist is readily equipped for programmable control and sequencing. Controller furnished separately. Configuration D: Used where a higher degree of safety is needed. The hoist complies with enhanced safety regulations in accordance to DIN The enhanced safety features and low voltage control are operated from a standard or programmable controller. The hoist is mounted in the normal position, but when specially equipped, the hoist can also be mounted in the inverted position and must be operated from a nonprogrammable controller. Configuration E: Hoist is set up to utilize external controls, which are not included. The hoist is mounted in the normal position, but when specially equipped, the hoist can also be mounted in the inverted position. Configuration S: Utilizes single-phase motor control. The hoist is equipped so it can be mounted in the inverted or normal position. Controller furnished separately. A pickle, which is used during stage setup, can be connected directly to the single-phase controls. 5

6 : September Capacity, Speed, and Hoist Configuration Summary Cap. (Ton) Cap. (kg) Frame Fall Speed (fpm) 60 Hz 50 Hz Hoist Configuration Speed (m/min) Speed (m/min) 1/16 60 SM /16 60 SM A B C D E S 1/8 125 SM /8 125 SM /4 250 SM /4 250 SM /4 250 SM /4 250 SM /2 500 SM /2 500 SM /2 500 SM /2 500 SM /2 500 SM SM SM SM SM / SM /8 9.6/2.4 8/ SM SM SM /8 9.6/2.4 8/2 2 1/ SM /6 7.6/ SM /3 3.8/0.9 3 Configuration available in Normal position or Normal/Inverted position if specially equipped Configuration available in Normal position only 6

7 : September Performance STAGEMAKER COMPACT concert hoists are designed for lifting and transporting of materials only. Under no conditions or circumstances, either during initial installation or in regular use, are hoists to be used for lifting or transporting of personnel. For additional safety, precautions such as redundant systems, safety lines from load to structure or enhanced safety features such as the BGV-C1 hoist can be used. 2.1 Environment The hoists are designed for indoor use and limited outdoor use where the ambient temperature is between 14 F [-10 C] and 104 F [40 C], elevation is less than 3300 ft [1000 m] and the relative humidity is less than 90%. The hoist control enclosure has protection rating of NEMA 3R type. The hoists can be used outdoors with some precautions such as specifying the hoist with a drain hole in the load sprocket compartment, covering the hoist body/enclosure with a vinyl rain cover, or protecting the hoist under a shelter. The vinyl rain cover would cover the hoist body/enclosure after the hoist is in position. The hoist cannot be operated when the vinyl rain cover is covering the hoist body/enclosure. Without these precautions, continuous exposure to extreme weather conditions will lead to damage of electrical components. 2.2 Sound Level The sound intensity level of the hoist in the assumed operating location does not exceed 75 db. 2.3 Proper Installation Hoists must be installed clear of any obstruction that could prevent the top and bottom hooks from being inline. Proper Improper 2.4 Hoists for Ground Supports Use single fall SM10 hoists for ground supports. Using a SM10 hoist reduces chain wear and risk of chain twisting. Idler wheels on the ground support must have matching grooves and proper pitch diameter. 7

8 : September Hoist Configurations 3.1 Hoist Configuration A Direct Motor Control for Mobile Installations Configuration A utilizes direct motor control for easier setup and cabling. Hoist is equipped so it can be mounted in either the normal or inverted position. A direct motor control hoist in the inverted position is best suited for temporary or short-term setups. Full line voltage controller furnished separately. Hoist features: Black load chain Non-reflecting matt black finish Swiveling top hook (except SM1, fixed top hook) Chain guide (SM5 and SM10, polyamide) Disc Brake Over-travel protection via the torque limiting device (1) Steel electrical enclosure (except SM1, NORYL plastic) ACF brake controller card Chain bag for 100 ft [30 m] of chain Handgrips No pigtail or plug Round cable gland for 5/16-9/16 [8-15 mm] diameter cable 208V/230V-3Ph-60Hz motor rating (1) Upper and lower limit (electrical) switches not available with direct motor control Available options: Self locking hook (SM5 and SM10) Fixed top hook (SM5 and SM10) Second brake (SM5 and SM10) Steel control enclosure for SM1 Vinyl rain cover Drain hole in the load sprocket compartment (SM5 and SM10 only) Power pigtail no plug (standard pigtail length is 18, longer lengths available) Blue CE male plug for pigtail Twist-lock male plug for pigtail Blue CE female receptacle Twist-lock female receptacle Controller: 4 channel compact controller in a hand case 8 channel compact controller in a hand case Accessories: Remote with GO button and E-stop and with 30 ft of cable Motor cables Single and twin flight cases (SM5, SM10 only) 8

9 : September 2005 Offering and Technical Data: Capacity (Ton) Model Speed (fpm) Falls Chain type (mm) Power (HP) Nominal Current 230 V Weight of Unit (1) (lbs) Chain weight (lb/ft) 1/16 SM1 068 M2-A x /16 SM M1-A x /8 SM1 128 M1-A x /4 SM5 254 M1-A x /4 SM5 258 M1-A x /4 SM M1-A x /2 SM5 504 M1-A x /2 SM5 508 M1-A x /2 SM M1-A x SM M1-A x SM M1-A x SM M1-A x SM M1-A x (1) approximate weight without chain Metric Offering and Technical Data [60 Hz]: Capacity (Kg) Model Speed m/min Falls Chain type (mm) Power (kw) Nominal Current 230 V Weight of Unit (1) (Kg) Chain weight (kg/m) 60 SM1 068 M2-A x SM M1-A x SM1 128 M1-A x SM5 254 M1-A x SM5 258 M1-A x SM M1-A x SM5 504 M1-A x SM5 508 M1-A x SM M1-A x SM M1-A x SM M1-A x SM M1-A x SM M1-A x (1) approximate weight without chain 9

10 : September Hoist Configuration B Low Voltage Control for Fixed or Mobile Installation Configuration B utilizes low voltage control. The hoist (SM1, SM5, SM10) is equipped so it can be mounted in inverted or normal position. Controller furnished separately. A pickle, which is used during stage setup, can be connected directly to the low voltage hoist control. The SM16, SM20 and SM25 hoists must always be mounted in the normal position and are furnished with pushbutton pendant controller with E-stop. SM1, SM5, SM10 Hoist features: Black load chain Non-reflecting matt black finish Swiveling top hook (except SM1, fixed top hook) Chain guide (SM5 and SM10, polyamide) Disc Brake Over-travel protection via the torque limiting device (1) Steel control enclosure (except SM1, NORYL plastic) Chain bag for 100 ft [30 m] of chain Handgrips Low voltage (115 VAC) control No pigtail or plug for power or control Two round cable glands - 5/16-9/16 [8-15 mm] diameter cable Hoist motor thermal protection 230V-3Ph-60Hz power supply 1) Upper and lower (weight-operated) limit switches are not furnished on hoist in the inverted position SM16, SM20, SM25 Hoist features: Electro-zinc load chain Non-reflecting matt black finish Fixed top hook Standard chain guide Disc Brake Upper and lower limit switches (weight-operated) Torque limiting device ABS plastic control enclosure Chain container Low voltage (115 VAC) control No pigtail or plug for power or control Round cable gland for 5/16-9/16 [8-15 mm] diameter cable Hoist motor thermal protection 230V-3Ph-60Hz power supply Note: A mainline contactor is not furnished on SM1 hoists Mainline contactor is specially wired so it always energized when power to the hoist (SM5 and SM10 only) is applied. The mainline contactor in the hoist control panel for the SM16, SM20, and SM25 hoists is controlled by the E-Stop on the pushbutton controller. Available options: Fixed top hook (SM5 and SM10) Upper and lower (weight-operated) limit switches normal position only Self locking hook (SM5 and SM10) 10

11 : September 2005 Geared limit switch Second brake (SM5 and SM10) Steel control enclosure for SM1 Vinyl rain cover Drain hole in the load sprocket compartment (SM5 and SM10 only) Power pigtail no plug (standard pigtail length is 18, longer lengths available) Control pigtail no plug (standard pigtail length is 18, longer lengths available) Power & control pigtail no plug (standard pigtail length is 18, longer lengths available) Twist-Lock male plug for power pigtail 7 pin Socapex male plug for power & control pigtail Twist-Lock female receptacle for control pigtail Mating plug/receptacle for the supplied plug Custom plug for pigtail 460V-3Ph-60Hz or 208V-3Ph-60Hz power supply Controllers: 4, 8 or 12 channel controller with remote configured for combined power/control or separate power and control Pistol-grip pushbutton controller or Pickle (SM1, SM5, SM10) with pigtail (standard pigtail length is 18, longer lengths available). Plug is optional. Pushbutton controller with E-Stop button (SM16, SM20, SM25) Accessories: Motor cables Single and twin flight cases (SM5, SM10 only) Offering and Technical Data: Capacity (Ton) Model Speed (fpm) Falls Chain type (mm) Power (HP) Nominal Current 230 V Weight of Unit (1) (lbs) Chain weight (lb/ft) 1/16 SM1 068 M2-B x /16 SM M1-B x /8 SM1 128 M1-B x /4 SM5 254 M1-B x /4 SM5 258 M1-B x /4 SM M1-B x /2 SM5 504 M1-B x /2 SM5 508 M1-B x /2 SM M1-B x SM M1-B x SM M1-B x /2 SM T1-B 32/ x SM M1-B x SM M1-B x SM T1-B 32/ x ½ SM T1-B 24/ x SM T1-B 12/ x (1) approximate weight without chain 11

12 : September 2005 Metric Offering and Technical Data [60 Hz]: Capacity (Kg) Model Speed m/min Falls Chain type (mm) Power (kw) Nominal Current 230 V Weight of Unit (1) (Kg) Chain weight (kg/m) 60 SM1 068 M2-B x SM M1-B x SM1 128 M1-B x SM5 254 M1-B x SM5 258 M1-B x SM M1-B x SM5 504 M1-B x SM5 508 M1-B x SM M1-B x SM M1-B x SM M1-B x SM T1-B 9.6/ x SM M1-B x SM M1-B x SM T1-B 9.6/ x SM T1-B 7.2/ x SM T1-B 3.6/ x (1) approximate weight without chain 12

13 : September Hoist Configuration C Programmable Control Configuration C utilizes low voltage control and a separate programmable controller. The hoist is mounted in the normal position, but when specially equipped, the hoist can also be mounted in the inverted position. The hoist is readily equipped for programmable control and sequencing. Hoist features for standard requirements: Black load chain Non-reflecting matt black finish Fixed top hook Standard chain guide Disc Brake Torque limiting device Upper and lower limit switch (weight-operated) Steel control enclosure (except SM1, NORYL plastic) Chain bag for 100 ft [30 m] of chain Low voltage (48 VAC) control Connection pigtail with a Harting or equal (16 pin + ground) metallic male plug for control and power (standard pigtail length is 18, longer lengths available) Hoist motor thermal protection 230V-3Ph-60Hz + neutral power supply Sensor bearing with filter for positioning (SM5 and SM10) Incremental encoder for positioning (SM1) Note: Mainline contactor is specially wired so it always energized when power to the hoist (SM5 and SM10 only) is applied. Available options: Inverted mounting position - includes a polyamide (SM5 and SM10) chain guide, handgrips, and a swiveling top hook (except SM1). Upper and lower limit switches (weight-operated) are removed and a geared limit switch is added. Swiveling top hook (except top hook on SM1) Self locking hook (SM5 and SM10) Geared limit switch (except SM1 due to the supplied incremental encoder) Second brake (SM5 and SM10 only) Steel control enclosure for SM1 Vinyl rain cover Drain hole in the load sprocket compartment (SM5 and SM10 only) Load sensor for over/under load detection 208V-3Ph-60Hz + neutral Handgrips Control pigtail with female Twist-lock connector ( Controllers: Computer aided controller Accessories: Motor cables Single and twin flight cases (SM5, SM10 only) 13

14 : September 2005 Offering and Technical Data: Capacity (Ton) Model Speed (fpm) Falls Chain type (mm) Power (HP) Nominal Current 230 V Weight of Unit (1) (lbs) Chain weight (lb/ft) 1/16 SM1 068 M2-C x /16 SM M1-C x /8 SM1 128 M1-C x /4 SM5 254 M2-C x /4 SM5 258 M2-C x /4 SM M1-C x /2 SM5 504 M1-C x /2 SM5 508 M1-C x /2 SM M1-C x SM M1-C x SM M1-C x SM M1-C x SM M1-C x (1) approximate weight without chain Metric Offering and Technical Data [60 Hz]: Capacity (Kg) Model Speed m/min Falls Chain type (mm) Power (kw) Nominal Current 230 V Weight of Unit (1) (Kg) Chain weight (kg/m) 60 SM1 068 M2-C x SM M1-C x SM1 128 M1-C x SM5 254 M2-C x SM5 258 M2-C x SM M1-C x SM5 504 M1-C x SM5 508 M1-C x SM M1-C x SM M1-C x SM M1-C x SM M1-C x SM M1-C x (1) approximate weight without chain 14

15 : September Hoist Configuration D BGV-C1 Enhanced Safety Features Configuration D utilizes low voltage control and must be operated with STAGEMAKER R8PRM-C1 controller (see Note). The hoist complies with enhanced safety regulations in accordance to DIN The hoist is mounted in the normal position, but when specially equipped, the hoist can also be mounted in the inverted position and must be operated from a nonprogrammable controller. Hoist features: Black load chain Non-reflecting matt black finish Fixed top hook Standard chain guide Two brakes Torque limiting device Low voltage (48 VAC) control with mainline contactor (1) Steel control enclosure Geared limit switch four switches Electronic type overload device Connection pigtail with a Harting or equal (16 pin + ground) metallic male plug for control and power (standard pigtail length is 18, longer lengths available) Diagnostic test plug Capacity de-rated by 50% from standard Chain bag for 100 ft [30 m] of chain Electronic overload relay Test facility for brakes and limit switches 230V-3Ph-60Hz power supply (1) Operation of the main line contactor is taken over by the controller. Available options: Inverted mounting position - includes a polyamide chain guide, handgrips, and a swiveling top hook Swiveling top hook Self locking hook Vinyl rain cover Drain hole in the load sprocket compartment (SM10 only) Hoist motor thermal protection 208V-3Ph-60Hz power supply Handgrips Controllers: STAGEMAKER 8 channel R8PRM-C1 controller Pushbutton controller with E-stop button Accessories: Motor cables Note: For group control of BGV-C1 hoists, the use of the R8PRM-C1 controller is mandatory. For single hoist applications, the hoist could be used without any restrictions. It just needs a pushbutton controller with E-stop. 15

16 : September 2005 Offering and Technical Data: Capacity (Ton) Model Speed (fpm) Falls Chain type (mm) Power (HP) Nominal Current 230 V Weight of Unit (lbs) Chain weight (lb/ft) 1/4 SM M1-D x /2 SM M1-D x /2 SM M1-D x SM M1-D x SM M1-D x (1) approximate weight without chain Metric Offering and Technical Data [60 Hz]: Capacity (Kg) Model Speed m/min Falls Chain type (mm) Power (kw) Nominal Current 230 V Weight of Unit (1) (Kg) Chain weight (2) (kg/m) 250 SM M1-D x SM M1-D x SM M1-D x SM M1-D x SM M1-D x (1) approximate weight without chain 16

17 : September Hoist Configuration E without Motor Controls Configuration E is set up to utilize external controls, which are not included. The standard hoist is mounted in the normal position, but when specially equipped, the hoist can also be mounted in the inverted position. Hoist features for normal mounting position: Black load chain Non-reflecting matt black finish Fixed top hook Standard chain guide Disc brake Brake rectifier Torque limiting device Upper and lower limit switches (weight-operated) Steel control enclosure Chain bag for 100 ft [30 meters] of load chain No controls Wiring to terminal strip Two round cable glands - 5/16-9/16 [8-15 mm] diameter cable 230V-3Ph-60Hz power supply Available options: Inverted mounting position - includes a polyamide chain guide, handgrips, and a swiveling top hook. Upper and lower limit switches (weight-operated) are removed. Sensor bearing with filter for positioning/speed supervision - for inverter control Load sensor for over/under-load detection Geared limit switch Vinyl rain cover Drain hole in the load sprocket compartment (SM5 and SM10 only) Second brake Self locking hook 460V-3Ph-60Hz or 208V-3Ph-60Hz power supply Hand grips Note: With inverter control, a separate contactor must be used to activate the brake. The maximum frequency (Hz) that could be applied to the motor is noted in the applicable Offering and Technical Data tables. 17

18 : September 2005 Offering and Technical Data: Capacity (Ton) Model Speed 60 Hz (fpm) Falls Chain type (mm) Power (HP) Max Hz. Nominal Current 230 V Weight of Unit (1) (lbs) Chain weight (lb/ft) 1/2 SM M1-E x SM M1-E x SM M1-E x SM M1-E x SM M1-E x (1) approximate weight without chain Metric Offering and Technical Data [60 Hz]: Capacity (Kg) Model Speed 60 Hz m/min Falls Chain type (mm) Power (kw) Max Hz. Nominal Current 230 V Weight of Unit (1) (Kg) Chain weight (kg/m) 500 SM M1-E x SM M1-E x SM M1-E x SM M1-E x SM M1-E x (1) approximate weight without chain 18

19 : September Hoist Configuration S Single-phase Motor and Control Configuration S utilizes single-phase motor control. The hoist is equipped so it can be mounted in the inverted or normal position. Controller furnished separately. A pickle, which is used during stage setup, can be connected directly to the single-phase controls. Hoist features: Black load chain Non-reflecting matt black finish Swiveling top hook (except SM1, fixed top hook) Chain guide (SM5, polyamide) Disc Brake Over-travel protection via the torque limiting device (1) Chain bag for 100 ft [30 meters] of load chain Handgrips Low voltage (115 VAC) control Two round cable glands - 5/16-9/16 [8-15 mm] diameter cable Steel control enclosure (except SM1, NORYL plastic) Hoist motor thermal protection No pigtail for power or control 115V-1Ph-60Hz power supply (1) Upper and lower (weight-operated) limit switches do not work in the inverted position and are not furnished. Available options: Fixed top hook (SM5 only) Upper and lower (weight-operated) limit switches - normal position only Steel control enclosure for SM1 Vinyl rain cover Drain hole in the load sprocket compartment (SM5 only) Power pigtail no plug (standard pigtail length is 18, longer lengths available) Control pigtail no plug (standard pigtail length is 18, longer lengths available) Power & control pigtail no plug (standard pigtail length is 18, longer lengths available) Twist-Lock male plug for power pigtail 7-pin Socapex male plug for power & control pigtail Twist-Lock female receptacle for control pigtail Mating plug/receptacle for the supplied plug Second brake (SM5 only) Controllers: 4 or 8 channel controller Pistol-grip pushbutton controller or Pickle with pigtail with optional plug Accessories: Motor cables Single and twin flight cases (SM5 only) 19

20 : September 2005 Offering and Technical Data: Capacity (Ton) Model Speed (fpm) Falls Chain type (mm) Power (HP) Nominal Current 115 V Weight of Unit (1) (lbs) Chain weight (lb/ft) 1/16 SM1 084 M1-S x /8 SM1 124 M1-S x /4 SM1 252 M1-S x /4 SM5 254 M1-S x /2 SM5 504 M1-S x (1) approximate weight without chain Metric Offering and Technical Data [60 Hz]: Capacity (Kg) Model Speed m/min Falls Chain type (mm) Power (kw) Nominal Current 115 V Weight of Unit (1) (lbs) Chain weight (lb/ft) 60 SM1 084 M1-S x SM1 124 M1-S x SM1 252 M1-S x SM5 254 M1-S x SM5 504 M1-S x (1) approximate weight without chain 20

21 4 Controllers : September Group Controllers for Configuration A Hoists These group controllers are for controlling multiple hoists individually or together. The SC type controls are built in to a durable ABS plastic hand case. The control functions are inside the hand case. A remote with the GO button (run command) and E-stop is available as an option. Model Number of Description Enclosure Connection Channels SC4P-UL 4 Direct control without remote ABS Briefcase CE - 4p plug SC8P-UL 8 Direct control without remote ABS Briefcase CE - 4p plug Specifications: Direct control, configuration A hoists Single hoist up to 1.44HP [1.1kW] per channel at 230V-3Ph-60Hz Two hoists with intermediary CE splitter (up to 1.44 HP per channel at 230V-3Ph-60Hz) Individual hook level correction 3 position selector switch (UP-OFF-DOWN) per channel (group control) One GO (Run command) button (effective only on channels selected via selector switch) Emergency stop is a push-to-maintain, turn-to-release, red mushroom head push button Master-slave function up to two controllers Connected motor power: 4 or 8 x 1.44HP [1.1kW] at 230V-3Ph-60Hz Short circuit proofing: once at 10kA maximum 4.2 Group Controllers for Configuration B or S Hoists Third-party controller 4.3 Pistol-Grip Pushbutton Controller for Configuration B or S Hoists The pistol-grip pushbutton controller or pickle is available for the SM1, SM5 or SM10 hoist. The pickle cannot be used as a suspended pendant station because it does not include any type of strain relief. Features: Pigtail without plug (standard pigtail length is 18, longer lengths available) Pendant station is light in weight for easy handling and operation Two push buttons for up and down directions Contacts for motion buttons are mechanically interlocked and momentary type Optional Features: Longer pigtail cable lengths (in 1 ft increments up to 50 ft) Twist-lock male plug Extension cord with connectors Pistol grip Pushbutton Controller - shown with optional Twist-lock plug 21

22 : September Pushbutton Pendant Controller for Configuration B (SM16 SM25) or D Hoists The pushbutton pendant controller can be suspended from the hoist and is available for the SM16, SM20 and SM25 models and for the Configuration D hoist controller. Features: Pendant cord length matches hoist height of lift without plug Pushbutton enclosure ratings of NEMA 4, 4X, 5 and IP65 Suitable for indoor or outdoor use Pendant station is light in weight for easy handling and operation Strain relief Emergency Stop is a push-to-maintain, turn-to-release, red mushroom head button Two push buttons for each motion, one for each direction of travel Contacts for motion buttons are mechanically interlocked and momentary type Optional Features: Longer cable lengths Plug 4.5 Programmable Controller for Configuration C Third-party controller 4.6 Controller for Configuration D These controllers are designed specifically for the Configuration D hoist and provide a complete BGV-C1 package. The control functions are on the controller. A remote with a GO button (run command) and E- stop is available as an option. Model Number of Description Enclosure Connection channels B2PRMLV-C1 2 Low voltage control + controller Wall mount 16 pin Harting R4PRMLV-C1 4 Low voltage control + controller 19 6U rack in flight case 16 pin Harting R8PRMLV-C1 8 Low voltage control + controller 19 6U rack in flight case 16 pin Harting R12PRMLV-C1 12 Low voltage control + controller 19 6U rack in flight case 16 pin Harting Specification: Low voltage (48 VAC) control, Configuration D hoists, a BGV-C1 controller The control circuit of the mainline contactor in the hoist control panel becomes part of the RxPRM type controller. Single hoist up to 1.44HP [1.1kW] per channel at 230V-3Ph-60Hz 3 position selector switch (UP-OFF-DOWN) per channel (group control) One GO (run command) button (effective only on channels selected via selector switch) Emergency Stop Short circuit proofing: once at 10kA maximum Individual level correction Phase inversion capability on incoming CE plug Connection cable (2 ft length) for interconnection between controllers Available Options: Flight cases of different sizes for one, two or three racks Remote with a GO button and E-stop 22

23 : September Controllers Examples of Use 5.1 Configuration A 8 or 12 Channel Controller Two SC4P-UL 4-channel controllers can be linked in a master-slave connection to create an eightchannel controller. SC8P-UL 8-channel controller is also available and can be linked in a master-slave connection to create a twelve-channel controller STA MAR C STA MAR Warning: Controllers with remote cannot be linked to controllers without remote. 23

24 : September Configuration A SC Controller, Hoist & Cable Shown here in a two-hoist, two-cable arrangement, power is supplied to the hoist with a cable equipped with CE connectors STA MAR C SC4P Controller 24

25 : September Configuration A SC Controller, Hoist & Cable + Splitters Shown here in a four-hoist, one main cable with splitters arrangement where main cable from controller is equipped with Socapex connectors and uses fan-out and fan-in cables. The fan cables are equipped with multiple CE connectors and one Socapex connector. Hoist cables are outfitted with CE connectors STA MAR C SC4P Controller 25

26 R&M Materials Handling, Inc STAGEMAKER COMPACT Concert Hoist : September 2005 Configuration B & S Hoist & Cables (separate power & control), 3rd-party Controller Shown here in a two-hoist, four-cable arrangement where power and control are supplied to each hoist through a separate power cable and a separate control cable. Cables are outfitted with Twist-lock connectors. Third-party controller 26

27 : September Configuration B & S Hoist & Cable (combined power & control), 3 rd -party Controller Shown here in a two-hoist, one cable arrangement where power and control is supplied to the hoist with a combined power and control cable. Cable is outfitted with Socapex connectors. Third-party controller (8-channel shown) 27

28 I POWER ON PHASEN FAILURE PG21 : September Configuration D Controller, Hoist, & Cable Shown here in a BGV-C1 controller in wall mount enclosure and with remote and connection cable HARTING R 1 R 2 POWER SUPPLY 3x400V O POWER ON R 1/1+2/2 REMOTE I HARTING HARTING 28

29 : September Pigtails/Cables/Connectors 6.1 Connector Rules Power Cable From hoist Male To controller Female Control Cable To hoist Female From controller Male Combined Power/Control Cable From hoist To controller Male Female 29

30 : September Pigtail Options with Wiring Identification Configuration A Power Pigtail 12 AWG / 4 C Black L1 White L2 Red L3 Green Ground Configuration B & S Power / Control Pigtail 16 AWG / 7 C B S Black L1 Hot White L2 Neutral Red L3 Not used Green Ground Ground Orange UP UP Blue Common Common Black on white DOWN DOWN Configuration B & S Power Pigtail 12 AWG / 4 C B S Black L1 Hot White L2 Neutral Red L3 Not used Green Ground Ground Control Pigtail 16 AWG / 7 C Orange UP Blue Common Black on white DOWN Green Ground Configuration B & S Power / Control Pigtail 16 AWG / 7 C B S Black L1 Hot White L2 Neutral Red L3 Not used Green Ground Ground Orange UP UP Blue Common Common Black on white DOWN DOWN Control Pigtail 16 AWG / 7 C Orange UP Blue Common Black on white DOWN Green Ground Control pigtail in this arrangement is for a pickle. 30

31 : September Pigtails with Plug Options Longer pigtail cable lengths are available (in 1 ft increments from 2 ft up to 50 ft). Configuration Description Cable Standard Length A Power pigtail with Blue CE male plug (420 P9) SJO Cable 12 AWG / 4 C 1.5 ft Example A & B Power pigtail with (3 prong + Gnd) twist-lock male plug (L16 20P) SJO Cable 12 AWG / 4 C 1.5 ft B & S Power/control pigtail with 7-Pin Socapex male plug (SX07LM) STO Cable 16 AWG / 7 C 1.5 ft B, C & S Control pigtail with twist-lock female receptacle (L14 20R) STO Cable 16 AWG / 7 C 1.5 ft C & D Power/control pigtail with 16-Pin Harting or equal male plug SJO Cable 14 AWG / 16 C 1.5 ft S Power pigtail with (2 prong + Gnd) twist-lock male plug (L5 20P) SJO Cable 12 AWG / 4 C 1.5 ft 31

32 : September Cables with Connectors Cable lengths are available in 5 ft increments from 25 ft up to 125 ft. The maximum cable length for the application must be selected in accordance to the amperage and maximum voltage drop. The length of Fan-in and Fan-out cables is 1.5 ft and they are not available in longer lengths. Configuration Description Cable Cable Length Example A Power cable with Blue SJO Cable 25 ft CE connectors 12 AWG / 4 C 125 ft A Extension multi cable with 19 pin connectors SJO Cable 25 ft 14 AWG / 16 C 125 ft A Fan-in cable 19 pin female receptacle with 4 CE Blue male plugs SJO Cable 14 AWG / 4 C 1.5 ft A Fan-out cable 19 pin male plug with 4 CE Blue female receptacles SJO Cable 14 AWG / 4 C 1.5 ft A & B B & S B, C & S Power cable with twistlock connectors Power/control cable with 7 pin Socapex connectors Control cable with twistlock connectors SJO Cable 25 ft 12 AWG / 4 C 125 ft STO Cable 16 AWG / 7 C 25 ft 125 ft STO Cable 25 ft 16 AWG / 7 C 125 ft C & D Power/control cable with Harting or equal connectors SJO Cable 14 AWG / 16 C 25 ft 125 ft S Power cable with twistlock connectors SJO Cable 25 ft 12 AWG / 4 C 125 ft 32

33 : September Connector Types and Plug Wiring Identification Configuration Description Use Standard Plug Wiring Illustration Pin Color Function A Blue CE male plug (420 P9) Blue CE female receptacle (420 C9) Power L1 Black L1 L2 White L2 L3 Red L3 G Green GND See male plug wiring L2 L2 L1 L3 L1 G L3 G A 19-pin Socapex male plug (SX19LMB) Power Pin Color 1 Black 1 2 White 1 3 Red 1 4 Green 1 5 Black 2 6 White 2 7 Red 2 8 Green 2 9 Black 3 10 White 3 11 Red 3 12 Green 3 13 Black 4 14 White 4 15 Red 4 16 Green 4 17 N/A 18 N/A 19 N/A pin Socapex female receptacle (SX19LFB) See male plug wiring A & B Twist-lock (3 prong + gnd) male plug (L16 20P) Twist-lock female receptacle (L16 20R) Power Pin Color Function X Black L1 Y White L2 Z Red L3 G Green GND See male plug wiring X Y Z G X Z G Y B & S 7-pin Socapex male plug (SX07LM) 7-pin Socapex female receptacle (SX07LF) Combined power and control Pin Color Function 1 Black L1 2 White L2 3 Red L3 * 4 Blk / wht UP 5 Green GND 6 Orange COMMON 7 Blue DOWN See male plug wiring * Not used for single-phase (Configuration S) 33

34 : September 2005 Configuration Description Use Standard Plug Wiring Illustration Pin Color Function Twist-lock female W Orange UP receptacle X Blue COMMON G (L14 20R) Y Blk / wht DOWN B, C & S Control G Green GND Twist-lock (3 prong X + gnd) male plug See male plug wiring W (L14 20P) Y C & D Harting or equal (16-pin + gnd) male plug Combined power and control Pin Color Function 1 Black 1 L1 2 White 1 L2 3 Red 1 L3 4 White 2 Common 8 Red 2 UP 11 Black 2 DOWN 13 Red 3 O Volt 14 White Vdc 15 Black 3 Encoder B 16 Green Ground Vdc PE Green GND X Y W G Harting or equal (16-pin + gnd) female receptacle See male plug wiring S Twist-lock (2 prong + gnd) male plug (L5 20P) Twist-lock female receptacle (L5 20R) Power Pin Color Function Brass Black L1 Silver White L2 Green Green GND See male plug wiring G W W G 34

35 : September Suggested Cable Selection Table The tables indicate the suggested maximum cable lengths between controller and hoist and also from hoist to hoist. The lengths have been calculated with a maximum voltage drop of 5% and an average ambient temperature of 86 o F. 16 AWG or 16 AWG + 14 AWG 208V-3Ph-60Hz 230V-3Ph-60Hz Length Max (ft) In Max. (A) Length Max (ft) In Max. (A) SM SM SM AWG or 14 AWG + 12 AWG 208V-3Ph-60Hz 230V-3Ph-60Hz Length Max (ft) In Max. (A) Length Max (ft) In Max. (A) SM SM SM V-3Ph-60Hz Length Max (ft) In Max. (A) 12 AWG 230V-3Ph-60Hz Length Max (ft) In Max. (A) SM SM SM AWG or 14 AWG + 12 AWG 12 AWG 115V/60Hz 115V/60Hz Length Max (ft) In Max. (A) Length Max (ft) In Max. (A) SM SM

36 : September Hoist Motor 7.1 Features IP55 protection Class F insulation Hoist motor thermal protection (for applicable configurations only) 7.2 Ambient Conditions The standard motor is designed for operation at an ambient temperature 10 C [14 F] and 40 C [104 F] and a maximum altitude of 1000 meters [3280 feet]. 7.3 Motor Cooling The hoist motors have ribbed outer frames to maximize convection cooling. Cooling fan is equipped on the PC5 motor, which is used on the SM16, SM20 and SM25 models. The cooling fan is driven directly by the motor shaft and is only effective when the motor is running. 7.4 Hoist Motor Thermal Protection The motor over-temperature protection is a normally closed; automatic reset thermal protector embedded in the stator windings and it is wired into the hoist control circuit. 7.5 Brake Coil Resistance Main Voltage Coil Voltage SM1 SM5 SM10 SM16/20/ VDC or VDC VDC VDC Unit of resistance is ohms. 8 Hoist Gearbox The SM10 hoists utilize a compact planetary gear train that is totally enclosed. The planetary gears are sintered and made with extremely accurate teeth. The SM1, SM5, SM16, SM20 and SM25 hoists utilize a multistage helical gear train that is totally enclosed. The multistage gears are fabricated from heat-treated steel and the teeth are machine cut. The gear case is sealed. Hoist Gear Type Gear Ratio Lubricant SM1 Multistage 134.2:1 Mobilgear SHC 220 SM5 Multistage 43.19:1 Mobilith SHC 007 SM10 Planetary 160.3:1 or 104.7:1 Mobilith SHC 007 SM16 Multistage 113:1 Mobilgear SHC 220 SM20 Multistage 113:1 Mobilgear SHC 220 SM25 Multistage 145:1 Mobilgear SHC 220 Mobilith SHC 007 is synthetic semi-fluid grease. It is capable of operating in extreme ambient conditions where the ambient temperature is less than minus 13 F or hotter than 130 F. 36

37 : September Hoist Brake and Torque Limiting Device The friction materials for the brake and the torque-limiting device are asbestos free. The hoist motor is equipped with a D.C. electromagnetic disc brake to bring the load to a smooth and quick stop and to hold the load when the hoist motor is not energized. Multiple springs are used to provide the clamping force. An energized coil releases the hoist brake. The motor brake on SM1, SM5, and SM10 is located in a sealed housing to provide a degree of protection against dirt or water penetration. The components are designed to dissipate the heat. On the other hand, the hoist brake on SM16, SM20 and SM25 hoists is located in a vented housing and a fan provides additional cooling. A built-in torque-limiting device prevents the lifting of excessive loads, which could damage the hoist and/or the supporting structural members. The torque-limiting device is set to slip at 125% of rated capacity, except configuration D hoists. The capacity in configuration D is de-rated 50% from standard to meet BGV-C1 regulations in which require a mechanical design factor of 10 to 1 minimum for the hoist. This includes the clutch, which is set at 250% of the de-rated capacity. The torque-limiting device on SM1, SM5 and SM10 concert hoists is a slip clutch that is integrated into the design of the hoist motor and brake. The slip clutch is adjustable for wear and offers these features: If the clutch slips, once power is removed the brake will engage and hold the load. In the absence of a limit switch, the slip clutch also serves as a safety device for over-travel for the upper and lower limits of hoist travel. The hoist body, made from high density-die cast aluminum, is designed to withstand the impact of load block and chain-stop. Overload limiting device Main shaft Brake Clutch adjusting nut Slip-clutch and electromagnetic brake (SM1, SM5, SM10) 37

38 : September 2005 The torque-limiting device on SM16, SM20 and SM25 concert hoists is integrated into the design of the hoist multistage gear train. Torque-limiting device in the gear train (SM16, SM20, SM25) 10 Load Chain, Load Sprocket and Chain Guide The load sprocket (or load wheel) has five (six on SM16) precision-machined chain pockets. The chain guide is a standard feature and it helps guide and hold the load chain in the pockets of the load wheel for safe operation and to prevent jamming. For the SM5 or SM10 hoist, a polyamide chain guide replaces the standard chain guide when the hoist is equipped for the inverted position. Load Chain Specifications Load chain ø x pitch (d x t) mm 3.1 x x x x x 31 Hoist model SM1 SM5 SM10 SM16 SM20/SM25 Class DAT DAT DAT DAT DAT Grade HE80S or HE G80 H80S or HE G80 H80S or HE G80 H80D or HE G80 H80D or HE G80 Min. Breaking strain (N/mm2) Surface Hardness: HV HV HV HV HV Standards DIN DIN DIN DIN DIN Cross-section area (mm2) Safe load limit of chain (kg) Min. Breaking force (kn) Min. total elongation 10% 10% 10% 10% 10% Dimension over 11 links (mm) (+0.35, -0.20) (+1.05, -0.25) 297 (+0.75, -0.40) 341 (+1.1, -0.5) Dimension over 11 links (in.) (+0.014, ) (+0.041, ) (+0.030, ) (+0.043, ) Weight per meter (kg/m) Weight per foot (lb/ft) Corrosion protection Black coated Black coated Black coated Electro-zinc Electro-zinc 38

39 11 Hooks : September Load Block & Hook The standard load hook is forged alloy steel. The hook is equipped with a spring-loaded safety latch and supported on a thrust bearing to allow the hook to rotate 360 easily even under load. The load block housing is enclosed and guards against load chain jamming during normal operating conditions. The sprocket in the two-fall load block equalizes the load. Hoist Fall Load Hook Nr Hook Class Hook Material SM P StE355 SM P StE355 SM T 34CrMo4 SM T 34CrMo4 SM T 34CrMo4 SM T 34CrMo4 SM T 34CrMo4 SM T 34CrMo4 SM T 34CrMo4 SM T 34CrMo4 SM T 34CrMo4 H 5.35 [136] 6.3 [160] 6.2 [157.5] 8.37 [212.5] 7.62 [193.5] [260.5] 9.37 [238] [346.5] [272] [272] [334] B 1.42 [36] 1.89 [48] 2.05 [52] 2.84 [72] 2.68 [68] 3.97 [100.8] 3.39 [86] 5.91 [150] 3.78 [96] 3.78 [96] 6.54 [166] D 1.42 [36] 1.34 [34] 2.05 [52] 2.36 [60] 2.68 [68] 2.84 [72] 2.84 [72] 2.91 [74] 3.15 [80] 3.15 [80] 3.74 [95] Load Block Housing material Aluminum alloy Aluminum alloy Aluminum alloy Aluminum alloy Aluminum alloy Aluminum alloy Cast steel Cast steel Cast steel Cast steel Cast steel D B H 39

40 : September Load Hook Dimensions øm t2 t1 a2 e3 a3 b1 h2 b2 a1 h1 Hook Forging Nr øm [14] 0.63 [16] [20] [24] [24] [30] øa [30] [36] [43] [50] 1.89 [48] [56] a [20] [26] [34] [40] [38] [45] a [34] [41] [49] [57] [54] 2.52 [64] b [19] [22] [29] [38] [35] [45] b [15] [19] [24] 1.26 [32] [29] [38] e [83] 3.78 [96] [105] [120] [115] [135] h [22] [28] [37] 1.89 [48] [44] [56] h [19] [24] 1.22 [31] [40] [37] 1.89 [48] t [32] [38] [43] [59] [53] [67] t [10] [13] [14] [24] [18] [24] Dimension a 2 is without safety latch. Hook dimensions are according to DIN