Knight D Series User manual

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D-SERIES
Servo Hoist
Maintenance and
Operation Manual
THIS MANUAL CONTAINS IMPORTANT INFORMATION REGARDING INSTALLATION, SAFETY, MAINTENANCE,
AND OPERATION OF THE KNIGHT GLOBAL SERVO HOIST AND SHOULD BE AVAILABLE TO ALL PERSONNEL
RESPONSIBLE FOR USING THE HOIST.
REV: 005_202112

KNIGHT D-SERIES SERVO HOIST OPERATION MANUAL
This manual provides important information for all personnel involved in the installation, operation
and maintenance of the Knight Global Servo Hoist. All personnel must read this document before
operating the equipment.
Every effort has been made to provide complete and accurate product information in this manual.
However, due to product improvements and changes, discrepancies and omissions may be
present. Visit our website at www.knightglobal.com for the updated information on all our
products.
It is the responsibility of the end user to exercise common sense and judgment when performing
the tasks described in this manual. If any procedure seems inaccurate, incomplete or unsafe
please put the equipment in a safe condition and contact Knight Global service department for
assistance. Knight Service department’s phone number is: [phone].
Throughout this manual there are steps and procedures that if not performed correctly can result
in personal injury or equipment damage. The following signal words are used to identify the level
of potential hazard.
WARNING
Indicates a hazard which will cause severe injury, death or substantial
equipment damage.
CAUTION
Indicates a hazard which can or will cause injury or equipment damage.
NOTE
Notifies personnel of installation, operation or maintenance information
which is important but not hazard related.

KNIGHT D-SERIES SERVO HOIST OPERATION MANUAL
1.SAFETY ........................................................................................................................................................ 1
A.General Safety Precautions .............................................................................................................. 2
B.Safety Devices ................................................................................................................................... 3
Motor Holding Brake .................................................................................................................. 3
Overload Capacity Protection .................................................................................................... 3
Run-Stop Push Button ............................................................................................................... 3
Safety Drop Stop (SDS) Chain .................................................................................................. 3
2.INSTALLATION ........................................................................................................................................... 4
A.Introduction ........................................................................................................................................ 5
B.Initial Setup ........................................................................................................................................ 6
Step 1: Unpacking .................................................................................................................... 6
Step 2: System Assembly ......................................................................................................... 6
Step 2a) Servo Hoist Trolley Installation: ................................................................. 6
Step 2b) Safety Cable Installation: ........................................................................... 7
Step 2c) 19-pin Coil Cable Installation: .................................................................... 8
Step 2d) 4mm and 5mm Chain Installation: ............................................................. 9
Step 3: Power Supply to Servo Hoist ..................................................................................... 10
Step 4: Releasing the Run-Stop button .................................................................................. 10
Step 5: Control Handle Set-up ............................................................................................... 1 1
Step 6: Test Hoist Movement ................................................................................................. 11
Step 7: Back-Up Software ...................................................................................................... 11
Step 8: Software Adjustments (If necessary) ......................................................................... 12
3.OPERATION .............................................................................................................................................. 13
A.Principle of Operation ..................................................................................................................... 13
B.Model Number .................................................................................................................................. 13
C.Servo Hoist Control Configuration ................................................................................................ 14
D.Servo Hoist Functionality Modes ................................................................................................... 15
Run-Stop .................................................................................................................................. 15
Shut Down ............................................................................................................................... 15
Start Up .................................................................................................................................... 15
No Mode .................................................................................................................................. 15
Lift Mode .................................................................................................................................. 15
Float Mode ............................................................................................................................... 16
Fault Mode ............................................................................................................................... 16
4.MAINTENANCE ......................................................................................................................................... 17
A.CHAIN INSPECTION ........................................................................................................................ 17
4.1 Inspection Overview .......................................................................................................... 17
4.2 Use of Chain Safely in Any Application ............................................................................. 18
4.3 Determining the Frequency of Chain Inspections ............................................................. 19
4.3.1 Service Rating Load Criteria ................................................................................. 19
4.3.2 Service Class (Duty Cycle) .................................................................................... 19
4.4 Type of Inspections ........................................................................................................... 20
4.4.1 Frequent Inspection (Visual) ................................................................................. 20
4.4.1.1 What to Look for During a Frequent Inspection ...................................... 20
4.4.2 Periodic Inspection (Documented) ........................................................................ 21
4.4.2.1 Recommendations for Periodic Inspections ............................................ 21
4.4.2.2 Recommended Record Keeping for Periodic Inspections ...................... 23
4.4.3 Chain Lubrication:.................................................................................................. 24
4.4.4 Load Chain Replacement: ..................................................................................... 24

KNIGHT D-SERIES SERVO HOIST OPERATION MANUAL
B.PREVENTATIVE MAINTENANCE FOR KNIGHT SERVO HOIST .................................................. 25
4.5 Servo Hoists Inspections ................................................................................................... 25
4.5.1 Recommendations for Frequent Inspections for Servo Hoists (Visual) ................ 25
4.5.2 Periodic Inspection (Documented) ........................................................................ 25
4.6 Load and Safety Drop Stop Chain Replacement (Normal Maintenance) ......................... 28
4.6.1 Resetting the Encoder Offset ................................................................................ 33
4.7 Broken Chain Replacement .............................................................................................. 34
5.SOFTWARE ............................................................................................................................................... 36
A.Getting Started ................................................................................................................................. 37
B.Connecting to a Servo Hoist .......................................................................................................... 38
C.Backing up the Knight Servo Hoist Software ............................................................................... 41
D.Loading New Hardware with Existing Software ........................................................................... 46
E.Review the Hoist’s Knight Servo Studio Software ....................................................................... 52
F.Accessing the Servo Hoist’s Fault Log ......................................................................................... 91
6.PARAMETER DESCRIPTIONS ................................................................................................................. 93
A.bPRM Parameter Array ................................................................................................................... 93
B.bSTS Status Array ........................................................................................................................... 97
C.iPRM Parameter Array ................................................................................................................... 103
D.iSTS Parameter Array .................................................................................................................... 103
E.dPRM Parameter Array ................................................................................................................. 104
F.dSTS Parameter Array .................................................................................................................. 104
G.tPRM Parameter Array .................................................................................................................. 105
H.fPRM Parameter Array .................................................................................................................. 105
I.fSTS Status Array .......................................................................................................................... 112
7.TROUBLESHOOTING ............................................................................................................................. 115
A.Troubleshooting Screens ............................................................................................................. 115
7.1) Unable to Connect ......................................................................................................... 115
7.2) Can't Enter Lift Mode screen ......................................................................................... 116
7.3) Can't Enter Float Mode screen ...................................................................................... 117
7.4) Can't Move Up screen ................................................................................................... 117
7.5) Can't Move Down screen .............................................................................................. 119
7.6) Slow Flashing Red Light screen .................................................................................... 120
7.7) Fast Flashing Red Light screen .................................................................................... 120
7.8) Flashing Green Light screen ......................................................................................... 122
7.9) Alternating Red/Green Lights screen ............................................................................ 123
7.10) Solid Red Light screen ................................................................................................ 124
7.11) Solid Green Light screen ............................................................................................. 124
7.12) Solid Blue Light screen ............................................................................................... 125
7.13) Solid Green/Blue Lights screen ................................................................................... 125
7.14) Motion Drift screen ...................................................................................................... 126
B.System Activity screens including Faults, Warnings and Error Codes................................ 127
7.15) System Status screen ................................................................................................. 127
7.16) Alarms / Warnings screen ........................................................................................... 128
C.Troubleshooting Inputs and Outputs .......................................................................................... 129
7.17) I/O Status screen ......................................................................................................... 129
D.Troubleshooting Chart .................................................................................................................. 130
8.SPARE PARTS LIST ............................................................................................................................... 131
9.DECOMMISSIONING OF A SERVO HOIST ........................................................................................... 132
10.KNIGHT’S PERFORMANCE WARRANTY ............................................................................................. 133

KNIGHT D-SERIES SERVO HOIST OPERATION MANUAL
SECTION 1
SAFETY 1
1. SAFETY
Knight Global cannot be aware of or provide for all the procedures by which the Servo Hoist operations or
repairs may be conducted and the hazards which may result from each method. If operation or maintenance
not specifically recommended by Knight Global is conducted, it must be ensured that product or personnel
safety is not endangered by these actions. If not sure of an operation or maintenance procedure or step,
personnel should place the Servo Hoist in a safe condition and contact a supervisor and/or the Knight Global
service department for technical support. Modifications to upgrade, re-rate or otherwise alter this equipment
shall be authorized only by the original equipment manufacturer.
If a below-the-hook lifting device or sling is used with the Servo Hoist, refer to ANSI/ASME B30.9 “Safety
Standard for Slings”, or ANSI/ASME B30.20 “Safety Standard for Below-the-Hook Lifting Devices”.
Electrical equipment described in this manual are designed and built-in compliance with ANSI/NFPA 70,
“National Electrical Code”. It is the responsibility of the system designer, system manufacturer, crane or rail
manufacturer, installer, and user to ensure that the installation and associated wiring of the Servo Hoist and
components are in compliance with ANSI/NFPA 70, and all applicable Federal, State and Local Codes.
Hazardous voltages are present in the Servo Hoist and components. Only properly trained and competent
personnel should perform inspections or repairs on the Servo Hoist or accessories. Prior to performing any
maintenance (mechanical or electrical) on the Servo Hoist, de-energize (disconnect) the main switch
supplying power to the Servo Hoist. Lock out the power supply following standard plant procedures.
Ensure that the installation, inspection, testing, maintenance and operation are in compliance with
ANSI/ASME B30.16 “Safety Standard for Overhead Hoists”, OSHA Regulations, ANSI/NFPA 70, National
Electric Code, and applicable ANSI/ASME standards. This is the responsibility of the owner/operator.
All personnel that will install, operate, inspect, test or maintain the hoist should read this manual and be
familiar with all applicable portions of the referenced standards.
If clarification of any information in this manual or additional information is required, contact Knight Global.
Do not install, operate, inspect, test or maintain the hoist unless all information is understood.

KNIGHT D-SERIES SERVO HOIST OPERATION MANUAL
SECTION 1
SAFETY
2
A. General Safety Precautions
 Do not operate the Servo Hoist before reading this technical manual.
 Allow only personnel trained in safety and operation of this Servo Hoist to operate the Servo Hoist.
 If the Servo Hoist is locked out or a “DO NOT OPERATE” sign is on the Servo Hoist or controls, do
not operate the Servo Hoist until the lock or sign is removed by designated personnel.
 Do not use the Servo Hoist if the hook’s safety latch has been sprung or broken.
 If the Servo Hoist utilizes a hook, ensure the hook’s safety latch is engaged before operating the
hoist.
 Before each shift or prior to use, inspect the Servo Hoist in accordance with the procedures defined in
the Maintenance section of this manual.
 Never place your hand or fingers inside the throat area of a hook.
 Never operate a Servo Hoist with twisted, kinked or damaged chain.
 Only operate a Servo Hoist when the chain is centered over the hook. Do not “side pull” or “yard” the
chain.
 Do not force the hook into place by hammering.
 Ensure the load is properly seated in the saddle of the hook.
 Never run the chain over a sharp edge.
 Pay attention to the load at all times when operating the Servo Hoist.
 Ensure no personnel are in the path of the load.
 Do not lift the load over personnel.
 Never use a Servo Hoist for lifting or lowering people.
 Do not allow anyone to stand on a suspended load.
 Do not swing a suspended load.
 Never leave a suspended load unattended.
 Never cut or weld a suspended load.
 Do not operate a Servo Hoist if the chain is jumping, jamming, overloading or binding.
 Do not operate a Servo Hoist if it is generating excessive noise.
 Avoid collisions or bumping of the Servo Hoist.
 Do not operate a Servo Hoist when damaged or malfunctioning.
 Do not remove load or handling device until tension is released from the chain.
 Discontinue operation of a Servo Hoist after multiple unresolved faults. A system fault would be
signified by the Red light on the Run-Stop button continuously flashing or the Run-Stop button
having to be repeatedly reset.

KNIGHT D-SERIES SERVO HOIST OPERATION MANUAL
SECTION 1
SAFETY 3
B. Safety Devices
Motor Holding Brake
A motor holding braking system engages and holds the vertical axis in place in the event of a power outage or
when the Run-Stop button is pressed.
Overload Capacity Protection
Protects the equipment and prevents the operator from lifting or moving more weight than the system is rated
for. If the load weight exceeds the programmed capacity, the hoist will not lift any further until the excess
load is removed. Downward motion is permitted when overloaded to allow the user to safely set the weight
back down on a stable surface.
Run-Stop Push Button
If an operator needs to stop motion immediately, the operator pushes the Run-Stop button. The
system will not function until it is reset. To reset the system from the Run-Stop condition, the operator turns
the button clockwise to release it from the depressed position. All virtual limits and programs remain intact.
Safety Drop Stop (SDS) Chain
All Standard units have a Safety Drop Stop (SDS) chain included. The SDS Chain moves up and down the
vertical axis with the load chain. It provides load stabilization in the event of a catastrophic load chain
failure. This unique feature has a US Patent NO. 10,099,904 awarded as of 2018.

KNIGHT D-SERIES SERVO HOIST OPERATION MANUAL
SECTION 2
INSTALLATION
4
2. INSTALLATION
Prior to installation, visually inspect the Servo Hoist for signs of damage or missing parts.
CAUTION
Prior to installation, the chain must be lubed using a SAE 50 to 90 EP oil.
Follow the procedure detailed in section 4.4.3 “Chain Lubrication”
of this manual.
Knight Global recommends the use of Demag Chain Grease.
The part number of the Demag Chain grease tube is 665 009 44.
CAUTION
Prior to placing this unit into service, the owners and user are advised
to examine specific local and/or other regulations, including ANSI and
OSHA regulations that may apply to the use of this product.
WARNING
A falling load can cause injury or death. Before installing this hoist read
the “Safety” section of this manual.
Follow all procedures in this section for installation and set-up of the Servo Hoist.
Retain all product information supplied with the Servo Hoist for future reference.
Ensure that the supporting structure is able to support the weight of the system and load. The structure
should be able to support 300 percent of the combined weight of the Servo Hoist and load. Do not use a
supporting structure that tilts the Servo Hoist to one side or the other.
For safe and proper installation into a rail system, refer to the installation manual provided by the rail system
manufacturer.
When installation is complete and prior to placing the Servo Hoist into operation, inspect the Servo Hoist
following the instructions in section 4.4.2.1 “Recommendations for Periodic Inspections” in the
“Maintenance” portion of this manual.

KNIGHT D-SERIES SERVO HOIST OPERATION MANUAL
SECTION 2
INSTALLATION 5
A. Introduction
Prior to installing and operating the Knight Servo Hoist, all operators using this device should be familiar with
the main components of the lifting system. (Refer to Figure 2-1)
Servo Hoist: The Servo Hoist assembly is a powered lifting device. The upper drive assembly contains the
servo motor with holding brake, gearbox, servo drive, power contactor, 24 VDC Power Supply, regen board,
chain bucket, chain guide assembly, and AC Plug.
Coiled Cable Assembly: In most cases, a 19-pin coil cable carries signals from the control handle to the
Servo Hoist. Some examples are: Analog load cell voltages, digital inputs and outputs including direction
commands, Lift Mode, Float Mode, and Run-Stop signals. In some cases, a 19-pin straight cable carries
some or all of these signals to the Servo Hoist.
Control Handle: The main interface between the operator and the lifting device. The handle can be an
inline handle, a fixture handle, or a discrete up / down handle.
Figure 2-1
Trolley or Universal
Adapter Plate
Safety
Cable
19-pin
Coil Cable
Chain Nest
Control Handle
(Inline)
Load Shackle
Location
Servo Hoist

KNIGHT D-SERIES SERVO HOIST OPERATION MANUAL
SECTION 2
INSTALLATION
6
B. Initial Setup
Step 1: Unpacking
1a) Unpack the Servo Hoist. Lift the hoist carefully out of packaging.
1b) Keep the accompanying documents with the hoist or near the site of operation.
Step 2: System Assembly
Knight Servo Hoists are typically delivered pre-assembled; if not, read the following sections.
2a) Servo Hoist Trolley Installation
2b) Safety Cable Installation
2c) 19-pin Coil Cable Installation
2d) 4mm and 5mm Chain Installation
Step 2a) Servo Hoist Trolley Installation:
Prior to installation visually inspect the trolley for signs of damage or missing parts.
1) Slide the trolley or adapter plate into the trolley mounting plate on top of the Servo Hoist.
(Refer to Figure 2-2)
CAUTION
Ensure that there is a (2) two-point connection when using the universal
adapter plate to hang the hoist from a structure. (Refer to Figure 2-3)
2) Insert the (2) two ½-13x1¾” (grade 8 or better) socket head cap screws (SHCS) and
(2) two washers.
NOTE
The trolley should be mounted offset of the load distribution.
3) Secure the (2) two SHCS with (2) two ½-13 reverse lock nuts. As each bolt is tightened, the
reverse lock nut will get drawn into its slot and get trapped there.
4) Install the safety cable through the servo trolley or adapter and the trolley mounting plate.
(Refer to Step 2b “Safety Cable Installation”)
5) Roll hoist into rail system.
Figure 2-2
Figure 2-3