Operation Instructions (Translation)

Industriehebetechnik Operation Instructions (Translation) Single Sluice Gate Drive Type 1211/1212.1 1213.10 1211/1212.2 1214.2,5 1211/1212.3 1214.5 1211/1212.6 1214.10 1213.4 1215.5 1213.6 1215.10 Double Sluice Gate Drive Type 1280/1281.1,5 1285.20 1280/1281.3 1290.5 1280/1281.5 1290.10 1280/1281.10 1290.20 1285.8 1295.10 1285.12 1295.20 Tandem Sluice Gate Drive Typ 1285.40 1295.40 1290.40 Competence in lifting technology haacon hebetechnik gmbh Josef-Haamann-Str. 6 D-97896 Freudenberg/Main Telefono: +49 (0) 93 75/84-0 Fax: +49 (0) 93 75/84-66 e-mail: haacon@haacon.de Internet: www.haacon.dcom 094012_k_gb_schzug_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-84-66 1

Content 1. User groups....2 2. Safety instructions...2 3. General...2 4. Construction...2 5. Installation...3 6. Operation....4 7. Testing...4 8. Maintenance recommendations...5 9. Technical data...5 10. Spare parts...5 11. Dismounting and waste disposal....5 1. USER GROUPS Operator Specialist personnel Duties Operation, visual inspection Assembly, disassembly, repair, maintenance Tests 1. SAFETY INSTRUCTIONS Qualifications Instruction by means of the operating instructions; authorised person 1 Mechanic, Electrician Authorised person 2 per TRBS- 1203 (Technical expert) Where to use: Operate the equipment in accordance with the information in these operating instructions. Only use when in perfect working order. Only operate by trained personnel. Only use for the recommended application (i.e. pulling or pushing). Safe working practices First read the operating instructions! Always be conscious of safety and hazards when working. Observe lifting device and load during all movements. Report damage and deficiencies on the equipment immediately to the person responsible. Repair equipment first before continuing work! Do not leave the load suspended without supervision. Transport device protected against impacts and shocks, falling over or toppling. Do not Overload (--> technical data, type plate, payload plate) Run electric operation without end stop limit switch and overload protection. Impacts, blows, vibrations. Use exclusions Not to be used continuously except type 1215 / 1295. Not approved for use in explosive areas/environments. Not suitable for aggressive environments. Not suitable for lifting hazardous loads. Organisational measures Ensure that these operating instructions are always at hand. Ensure that only trained personnel work with the equipment. Check at regular intervals whether it is being used in a safety and hazard conscious manner. Assembly, maintenance and repair Only by specialist personnel! Only use original spare parts for repairs. Do not modify or alter safety-relevant parts! Additional attachments must not impact safety. Important! Should the sluice gate drive not have any locking device, the sluice gate must be secured against sinking bevor taking off the drive unit or the connection shaft. General safety instructions for electrical installations Work on electrical equipment may only be carried out by electrical specialists assigned by the operator and according to the electrotechnical regulations. Always keep unsupervised control cabinets locked. +50 C -20 C Further regulations to be observed are: German Industrial Health and Safety Ordinance (BetrSichV). Country-specific regulations. German Accident prevention regulations (BGV D8). 3. GENERAL Sluice gate drives are used on river courses, on sluices and on power stations for the regulation of the water levels and for the control of turbine outputs, for locking the ships, for draining and rinsing the storage lakes as well as for regulating the irrigation systems. These high quality gate drives of the Types 1211 / 1212 / 1213 / 1214 / 1215 (single sluice gate drive) or 1280 / 1281 / 1285 / 1290 /1295 (double sluice gate drive) have been proven for decades to be robust and reliable. The standard versions meet the pull-force range = 5-400 kn and are manufactured with numerous drive versions, both manual type and electric type. All sluice gate drives comply with the rules for preventing accidents of the German ordinance BGV D8 Hoists, Lifting Devices and Pulling Devices. 4. CONSTRUCTION 4.1 Types 1211/1212 and 1280/1281 1212 and 1280 with bushed bearings Housing of pressed steel sheet; toothed rack of hardened steel and of tempering steel as solid material with milled teeth; spur gears of high-quality hardened steel or of high-quality tempering steel; safety crank (SIKU) with integrated automatic mechanical brake prevents dropping of shutter; safety spring crank (SIFEKU) with integrated automatic mechanical brake, which works both in pulling direction and in pushing direction; automatic mechanical brake between electric drive and sluice drive. 4.2 Types 1213 and 1285 Housing of pressed and welded steel sheet; toothed rack of hardened steel and of tempering steel, rectangular solid material with milled teeth; spur gears of high-quality hardened steel or of high-quality tempering steel; bearings = boxed - automatic mechanical brake in the housing. 4.3 Types 1214 and 1290 Housing of cast steel and of special section tube; toothed rack of rectangular pipe with set-on toothed rack of tempering steel; spur gears of high-quality hardened steel or of high-quality tempering steel; bearings = boxed - automatic mechanical brake in the housing. 4.4 Types 1215 and 1295 Housing of section tube. Rack and pinion of rectangle tube with fitted gear rack of heat treatable steell. Gear rack pinion of high-quality, hardened steel. Bearing with lifetime lubricated roller bearings. Gear rack guide roller-mounted. Drive via spur wheel flat gear with brake motor or planetary gears with brake motor. 5. INSTALLATION Guarantee that the substructure is sufficiently dimensioned for gears and sluice gate drives (see torque, elevated load, technical data. the bolting faces are even. the output shaft gear and drive shaft of sluice gate drive are aligned. no transverse forces affect the gear racks. the sluice gate face is smooth running. 094012_k_gb_schzug_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-84-66 2

Commissioning of electric drives Power-driven sluice gates must always be equipped with a functional end position disconnection. The haacon control unit with level and frequency control recognizes the lower end position by a reference switch on the toothed rack. Setting accuracy approx. 0.3 mm. The upper end position is installed into the control unit in the factory. It can be indicated and modified in the SPS display. A gear limit switch, type MF2C, PT2C or GF4C, is built on to the shaft for drive units without control unit. Setting instructions: 1 - Position ʼOpen 2 - Position Closed zremove the cover. zdrive the rack to the lower stop position. zdetach the fixing screw (one turn). zturn the setscrew (upper cam) to the contactor (you will hear a click). zdrive the rack to the upper and position. zturn the setscrew (lower cam) to the contactor (you will hear a click). ztigthen the fixing screw. zdrive the rack carefully to the upper and lower stop and check the positions. If necessary repeat setting. zcheck the proper positioning of the sealing and tighten the cover. Observe the documentation of other manufacturers, if their gear limit switches are installed. Protection against overload The fuse is already built in for supplied control units (via current and effective power measurement). The customer must install the fuse protection, if he supplies the control unit for the power-driven sluice gates. The circuit diagram suggestion contains the necessary specifications for the supplied current and effective power protection. The permissible settings are defined in the order text and on the type label of the drive units. Changes only after consultation with haacon. zalways document settings and protect effective power measurement device with protective film. Insert air-vent screw into the transmission. 6. OPERATION Drive unit variants: 6.1 Crank handle Side drive fixed-mounted-on crank (standard); dismountable crank with crank radius adjustment (option). zmove the crank handle by 90 into operating position. A clockwise rotating of crank will lift the load; a counterclockwise rotating will lower the load (On some versions the rotating sense will be opposite). zthe locking bolt being pushed in, slide the dismountable crank up to the stop on the drive square. After having released the locking bolt the crank becomes locked. zafter having released the T-screw adjust the crank radius to the desired radius and fix accordingly. 6.2 Mitre gear with crank handle The mitre gear permits operating the sluice gate drive across the standard crank position, laterally or centrally to the sluice gate drive. The demultiplication reduces the crank force by approx. 1/3. All crank versions of 5.1 can be used. In the case of the types 1211/1212 and 1280/1281 the SIFEKU is mounted on the mitre gear. 6.3 Power drive 6.3.1 Electric drive unit 210444 Safety torque cutoff via effective power measurement device; emergency re-adjustment by rotating the motor shaft with the emergency crank. If in an emergency the unit must be manually operated, proceed as follows: Manual drive by plugging the crank into the seat of the motor shaft (e.g. in case of power outage or during set-up operation). During manual brake motor operation, screw in brake lifter lever and release exhaust brake. Brake release Emergency manual operating Note! Loosening the exhaust brake can cause the unsecured sluice gate face to descend. Therefore hold the crank handle and move the gate to the required position. After manual emergency operation remove and store brake lifter lever. 6.3.2 Electric drive unit 210350 Safety torque cutoff via effective power measurement device; emergency re-adjustment by changing over to crank operating. In case of emergency manual operating proceed as follows: Before operational release of the sluice system check shutoff limit switch, effective power measurement device and emergency stop devices for operational reliability see also notes in the haacon Electrical plan and/or circuit suggestion. Any bypassing of the limit switch function or of the safety switch function, e.g. by means of manual sluice gate change-over is forbidden! In case of sluice gate drives without automatic mechanical brake, alway comply with the Safety notes and/or reference labels for securing the shutter! Motorized operation Emergency mode zrelease coupling (retract). zinsert crank with pressed lock bolt and release lock bolt. zbring sluice gate face into the required position. zbefore changing to motor operation, remove crank and push coupling to home position. Note: If the coupler cannot be shifted, loosen with the help of a 5/6 mm wrench applied on motor fan impeller. For your own safety, secure the motor against starting. 094012_k_gb_schzug_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-84-66 3

6.3.3 Electric drive of type Auma SA 07.5, SA 10.1 or type SA 14.1 or similar drives Adjustment, operating and maintenance, see Operating Instructions Auma. 6.3.4 Electric drive unit 210445 Variable torque coupling Separate operating instructions apply to the use of the two-sided mechanical variable torque coupling. Manual emergency operation similar to 5.3.1. 6.3.5 Drive units for model 1215/1295 High-speed and continuous operation Flat gear with brake motor and console Flanged-mounted planetary gears with brake motor Manual emergency operation see 5.3.1 7. TESTING The equipment must be checked in accordance with the conditions of use and the operating conditions at least once per year by an authorised person 2 per TRBS 1203 (Technical expert) (testing per BetrSichV, 10, sect. 2 represents implementation of the EC guidelines 89/391/EEC and 95/63/EC or the annual occupational safety inspection per BGV D8, 23, sect. 2 and BGG956). These checks must be documented: Before commissioning. After significant alterations before recommissioning. At least once per year. In the event of unusual occurrences arising that could have detrimental effects on the safety of the winch (extraordinary tests, e.g. after a long period of inactivity, accidents, natural events). After repair works that could have an influence on the safety of the winch. Technical experts (AP2) are persons, who have sufficient knowledge based on their education and experience, in the areas of winches, lift and pull systems and the relevant official occupational health and safety rules, accident prevention regulations, guidelines and generally accepted engineering rules (e.g EN standards), to evaluate the operational safety of winches, lift and pull systems. Technical experts (AP2) are to be nominated by the operator of the equipment. The implementation of the annual occupational safety inspection as well as the training to obtain the aforementioned knowledge and skills can be provided by haacon hebetechnik. 8. MAINTENANCE RECOMMENDATIONS The operator determines the intervals themselves based on frequency of use and the operating conditions. Regular cleaning, no steam jets! Carry out visual check on inaccessible brakes / locks every 5 years at the latest, replace brake pads as required. General overhaul by the manufacturer after 10 years at the latest. ATTENTION! Inspection, maintenance and repair works only on an unloaded hoist. Work on brakes and locks only by qualified specialist personnel. Safety crank 1-3 30 max If sluggishness occurs during lowering, pour a few drops of oil into the gap in the crank cam. Safety cranks with a gap aperture >30 should be replaced. Repair must be carried out by only by the manufacturer. Mitre gear and drive unit The mitre gear is also provided with a cylindrical lubrication nipple by way of which the bearing points can be lubricated. Maintenance schedule: depending on use, but at least once a year. The worm gearing of the drive unit is lubricated for its lifetime, so it requires no maintenance. Follow these instructions and you, too, will continue to be pleased with your haacon gate drive. Brake motor Keep the motor ventilation clean Check at least once a year the brake clearance and adjust if necessary Consider the saftey regulations in chapter 1. Maintenance work only in disconnected conditon! Execution --> Operating instructions of motor supplier, chapter service or maintenance. Lubrication schedule Use Interval Measure Lubricant 50 x p.a. annually daily every 3 months several monthly times daily Maintenance plan Transmission lubricate (lubricating nipples on the end plate), clean and grease the gear racks Use Interval Measure Interval 50 x p.a. every 5 years daily every 2 years several annually times daily Renew transmission grease, replace strongly worn out parts Multi-purpose grease Rhenus Norlith o. similar Application range -25 C bis +100 C annually according to BGV D8 brake motor Retighten bolted racks 30 h after commissioning, then at least once a year. > see spare part drawing 9. TECHNICAL DATA See attached technical drawings (Electrical plan and/or circuit suggestion) Specific documents concerning electrotechnology. Operating instructions brake motor. 10. SPARE PARTS Please indicate when ordering: KVG-Nr.: Model: Order number from enclosed drawing documents. 11. DISMOUNTING AND WASTE DISPOSAL Make sure to observe the safety instructions. Dispose of the equipment and the substances within it in an environmentally responsible manner. Safety spring catch Within the framework of the annual operating safety checks always carry out a functional test. Check of the no-load torque: > 8 Nm re-lubricate the brake or eliminate the restraint; < 4 Nm the wear limit has been reached, replace the wearing parts; any broken brake spring must be replaced immediately! Dismounting of safety crank and of safety spring catch with load-free sluice gate drive only! 094012_k_gb_schzug_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-84-66 4

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