R&m Stagemaker sm1 Manual

This document and the information contained herein, is the exclusive property of R&M Materials Handling, Inc., and represents a non-public, confidential and proprietary trade secret that

may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M Materials Handling, Inc.

INSTALLATION AND

MAINTENANCE MANUAL

STAGEMAKER

SM1

English

STD-R-KHA-F-CQD-ENG

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

mCAUTION: Read the instructions supplied with the product before installation and

commissioning.

mCAUTION: Keep the instructions in a safe place for future reference.

Table of contents

1 INTRODUCTION ........................................................................................................................................ 5

1.1 Contact Information ........................................................................................................................... 5

1.2 Warranty ............................................................................................................................................ 5

1.3 Disclaimer .......................................................................................................................................... 5

1.4 Safety................................................................................................................................................. 6

1.5 Placards and Instructions .................................................................................................................. 8

2 INSTALLATION ......................................................................................................................................... 9

2.1 General .............................................................................................................................................. 9

2.2 Lubrication ......................................................................................................................................... 9

2.3 Mounting .......................................................................................................................................... 10

2.4 Load Hook Throat Opening ............................................................................................................. 11

3 ELECTRICAL CONNECTIONS AND DIAGRAMS.................................................................................. 12

3.1 Control Fuses .................................................................................................................................. 12

3.2 Configuration A – Single-speed – 208 or 230 Volt Connections ..................................................... 13

3.3 Configuration A – Single-speed – 208 or 230 Volt Wiring Diagram ................................................ 14

3.4 Configuration A – Pigtail Pin-out Connections – R&M Standard..................................................... 15

3.5 Configuration B – Single-speed – 208 or 230 Volt Connections ..................................................... 16

3.6 Configuration B – Single-speed – 208 or 230 Volt Wiring Diagram ................................................ 18

3.7 Configuration B – Wiring Labels ...................................................................................................... 19

3.8 Configuration B – Pigtail Pin-out Connections – R&M Standard..................................................... 20

3.9 Configuration C – Single-speed – 208 or 230 Volt Connections ..................................................... 22

3.10 Configuration C – Power Circuit – 208 or 230 Volt Wiring Diagram................................................ 23

3.11 Configuration C – Control Circuit – 208 or 230 Volt Wiring Diagram .............................................. 24

3.12 Configuration C – Wiring Labels ...................................................................................................... 25

3.13 Configuration C – Pigtail Pin-out Connections – R&M Standard..................................................... 26

3.14 Configuration S – Single-speed – 115 Volt Connections ................................................................ 28

3.15 Configuration S – Single-speed – 115 Volt Wiring Diagram............................................................ 29

3.16 Configuration S – Wiring Labels ...................................................................................................... 30

3.17 Configuration S – Pigtail Pin-out Connections – R&M Standard..................................................... 31

3.18 Cable Assemblies ............................................................................................................................ 33

4 INITIAL START-UP.................................................................................................................................. 35

4.1 General ............................................................................................................................................ 35

4.2 Correcting the Direction of Hook Travel .......................................................................................... 35

4.3 Operational Checks – No Load ....................................................................................................... 36

4.4 Operational Checks – With Load ..................................................................................................... 36

5 HOIST OPERATION ................................................................................................................................ 37

6 MAINTENANCE ....................................................................................................................................... 38

6.1 Basic Hoist Construction (Inverted Position) ................................................................................... 38

6.2 Basic Hoist Position (Normal Position) ........................................................................................... 39

6.3 Motor / Body..................................................................................................................................... 40

6.4 Hoist Motor Brake and Load-Limiting Device .................................................................................. 40

6.4.1 Slip Clutch Operation (see Figure 14) ......................................................................................... 40

6.4.2 Slip Clutch Adjustment after Installation ...................................................................................... 42

6.4.3 Hoist Motor Brake Adjustment (see Figure 14) ........................................................................... 43

6.5 Load Chain....................................................................................................................................... 44

6.5.1 General ........................................................................................................................................ 44

6.5.2 Maintenance Inspection............................................................................................................... 44

6.5.3 Load Chain Specifications (see Figure 15).................................................................................. 47

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

6.5.4 Removing the Load Chain ........................................................................................................... 47

6.5.5 Installing the Load Chain ............................................................................................................. 48

6.6 Fall Stop Assembly .......................................................................................................................... 50

6.6.1 General ........................................................................................................................................ 50

6.6.2 Fall Stop Installation .................................................................................................................... 50

6.7 Chain Container............................................................................................................................... 51

6.8 Limit Switches.................................................................................................................................. 52

6.8.1 Upper and Lower Travel Safety Limit Switch............................................................................... 52

6.8.2 Rotary Geared Limit Switch ......................................................................................................... 53

6.9 Brake Coil Specifications ................................................................................................................. 54

6.10 SM1 Motor Data............................................................................................................................... 55

6.11 Hooks............................................................................................................................................... 56

6.11.1 General .................................................................................................................................... 56

6.11.2 Inspection................................................................................................................................. 57

6.11.3 Hook Dimensions and Specifications ...................................................................................... 57

6.11.4 Body Hook (Normal Position) .................................................................................................. 58

7 PREVENTATIVE MAINTENANCE .......................................................................................................... 59

7.1 Maintenance and Inspection Table.................................................................................................. 59

7.2 Lubrication ....................................................................................................................................... 60

7.2.1 Load Chain Cleaning and Lubrication ......................................................................................... 60

7.3 Recommended Technical Support for Various Spare Parts............................................................ 61

7.4 Torque (lb-ft) Specifications for Fasteners ...................................................................................... 61

7.5 Troubleshooting ............................................................................................................................... 62

8 PARTS ILLUSTRATION .......................................................................................................................... 64

8.1 Hoist Body (NORMAL position shown)............................................................................................ 64

8.2 Helical Gear Mechanism & Brake.................................................................................................... 66

8.3 Lifting Assembly............................................................................................................................... 68

8.4 Control Panel Assembly – Configuration A ..................................................................................... 70

8.5 Control Panel Assembly – Configuration B & C .............................................................................. 71

8.6 Control Panel Assembly – Configuration S ..................................................................................... 72

8.7 SM1 Pigtail Connectors ................................................................................................................... 73

8.8 Pickle Assembly............................................................................................................................... 73

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

1 INTRODUCTION

1.1 Contact Information

Please do not hesitate to use the following contact information in the event that you may need assistance:

R&M MATERIALS HANDLING, INC.

4501 Gateway Boulevard

Springfield, OH 45502

General Telephone: 937 - 328-5100

Toll Free Telephone (US): 800 - 955-9967

General Fax: 937 - 325-5319

Parts Department Fax (US): 800 - 955-5162

Parts Dept. Fax (other): 937 - 328-5162

Website: www.rmhoist.com

1.2 Warranty

All sales are subject to the R&M Materials Handling, Inc. Standard Terms and Conditions of Sale (Revision

101707), a copy of which is available at www.rmhoist.com or upon request from R&M Materials Handling,

Inc. customer service/sales representatives and the terms of which are incorporated as if fully rewritten

herein.

1.3 Disclaimer

This manual has been prepared by R&M MATERIALS HANDLING, INC. to provide information and

suggestions for hoist installation, maintenance, and inspection personnel. This manual should be used in

conjunction with the

STAGEMAKER

®COMPACT Concert Hoist Operator’s Manual to teach safe operating

practices to all personnel associated with hoist operations and maintenance.

It is NOT intended that the recommendations in this manual take precedence over existing plant / site safety

rules and regulations or OSHA regulations. However, a thorough study of the following information should

provide a better understanding of proper installation, maintenance, and inspection procedures that are to be

followed in order to afford a greater margin of safety for people and machinery in the area of hoist

operations.

It must be recognized that this is a manual of recommendations for the Hoist Installation, Maintenance, and

Inspection personnel and its use is permissive, not mandatory. It is the responsibility of the hoist owner to

make personnel aware of all federal, state, and local codes and regulations. The owner is responsible for

providing instruction and ensuring that certain installation, maintenance, and inspection personnel are

properly trained.

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

1.4 Safety

Read and understand this manual before using the hoist.

Important issues to remember during installation, operation, maintenance, and inspection are provided at the

hoist control stations, at various locations on the hoist, in this manual, and in the STAGEMAKER®

COMPACT Concert Hoist Operator’s Manual. These issues are indicated by DANGER, WARNING, or

CAUTION instructions or placards that alert personnel to potential hazards, proper operation, load

limitations, and more.

DANGER: Indicates an imminently hazardous situation, which, if not avoided, will result in death

or serious injury.

WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in death

or serious injury.

CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may result in minor

or moderate injury. It may also be used to alert against unsafe practices.

Taking precedence over any specific rule, however, is the most important rule of all:

“USE COMMON SENSE”

It is a responsibility of the hoist owner / user to establish programs to:

1. Train and designate hoist operators, and

2. Train and designate hoist inspectors / maintenance personnel.

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

The words SHALL and SHOULD are used throughout this manual in accordance with definitions in the

ASME B30 standards as follows:

SHALL indicates a rule is mandatory and must be followed.

SHOULD indicates a rule is a recommendation, the advisability of which depends on the facts

in each situation.

Hoist operation, hoist inspection, and hoist maintenance personnel training programs should be based on

requirements in accordance with the latest edition of:

ASME B30.16 Safety Standard for Overhead Hoists (Underhung)





NOTE: When using the

STAGEMAKER

®COMPACT Concert Hoist in the Inverted position,

ASME B30.16 Section 16-0.1 states that this ASME standard does not apply when “drawing both

the load and the hoist up or down the load chain(s) or rope(s) of the hoist.” See WARNING below.

Such training should also provide information for compliance with any Federal, State, or Local Code

requirements, and existing plant safety rules and regulations.

If an overhead hoist is installed as part of an overhead crane or monorail system, training programs should

also include requirements in accordance with the latest editions, as applicable, of:

•ASME B30.11 Safety Standard for Monorails and Underhung Cranes

•ASME B30.17 Safety Standard for Overhead and Gantry Cranes, Top Running Bridge,

Single Girder, Underhung Hoist.







NOTE: It is a responsibility of the owner / user to install, inspect, test, maintain, and operate a

hoist in accordance with the ASME B30.16 Safety Standard, OSHA Regulations, and ANSI /

NFPA 70, National Electric Code. If the hoist is installed as part of a total lifting system, it is also

the responsibility of the owner / user to comply with the applicable ASME B30 volume that

addresses other types of equipment used in the system.





NOTE: Further, it is the responsibility of the owner / user to require that all personnel who will

install, inspect, test, maintain, and operate a hoist read the contents of this manual,

STAGEMAKER® COMPACT Concert Hoist Operator’s Manual, ASME B30.16 Safety Standards

for Overhead Hoists (Underhung), OSHA Regulations, and ANSI / NFPA 70, National Electric

Code. If the hoist is installed as part of a total lifting system, all personnel must also read the

applicable ASME B30 volume that addresses other types of equipment used in the system.

WARNING: Failure to read and comply with any one of the limitations noted in this manual

can result in product failure, serious bodily injury or death, and / or property damage.

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

R&M MATERIALS HANDLING, INC. has no direct involvement or control over the hoist’s operation and

application. Conforming to good safety practices is the responsibility of the owner, user, and operating

personnel.

Only those Authorized and Qualified Personnel who have shown that they have read and have understood

this manual and the STAGEMAKER® COMPACT Concert Hoist Operator’s Manual should be permitted

to operate the hoist.

The owner / user SHALL ensure that all Operators read and understand the STAGEMAKER® COMPACT

Concert Hoist Operator’s Manual prior to operating the hoist.

1.5 Placards and Instructions

READ and OBEY all Danger, Warning, Caution, and Operating Instructions on the hoist and in this manual

and STAGEMAKER® COMPACT Concert Hoist Operator’s Manual. Make sure that all placards are in

place and legible.

Failure to comply with safety precautions in this manual and on the hoist is a safety violation that may result

in serious injury, death, or property damage.

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

2 INSTALLATION

DANGER: Before installing, removing, inspecting, or performing any maintenance on a

hoist, the main switch shall be de-energized. Lock and tag the main switch in the de-

energized position in accordance with ANSI Z244.1. Follow other maintenance procedures

outlined in this manual and ASME B30.16.

2.1 General

Prior to installation, the unit shall be checked thoroughly for damage during shipment or handling at the job

site.

Each complete electric chain hoist is load tested at the factory at 125% of the nameplate-rated capacity.

All hoists are designed for the type of mounting specified by the purchaser. The adequacy of the supporting

members (monorail beams, cranes, hangers, supports, framing, etc.) is the responsibility of user / owner and

shall be determined or verified by qualified personnel.

Read the instructions contained in this manual and the STAGEMAKER® COMPACT Concert Hoist

Operator’s Manual as well as any other related manuals. Observe the warning tags attached to the unit

before the installation is started.

2.2 Lubrication

The hoist gear case comes completely pre-lubricated with grease. The load chain requires lubrication prior to

first use. Chain lubricant is included with shipment of each new chain hoist.

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

2.3 Mounting

Below are the basic mounting positions for

STAGEMAKER

® COMPACT Concert Hoists:

Figure 1. Inverted Mounting and Normal Mounting

INVERTED

(us

ually associated with a temporary installation)

NORMAL

(usually associated with a permanent installation)

mWARNING:

Do not use hoist to lift people or suspend loads over people.

Do not leave a freely suspended load on hoist unattended.

A suspended load must always be tied off using appropriate chains, cables or other redundant load

bearing means before access to the area beneath the load is permitted (1).

Failure to do so could result in property damage, death or serious injury to personnel.

(1) If the load cannot be tied off due to the nature of the application, redundancies and/or advanced safety

features, including but not limited to multiple/redundant hoists, dual brakes on the hoist, a minimum ten

to one safety factor on load bearing components, load monitoring devices, etc. used either individually

or, as circumstances dictate, in conjunction with one another, must be incorporated into the design of the

system.

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

2.4 Load Hook Throat Opening

mCAUTION: ANSI B30.16-1998 recommends that the throat opening of a load hook be measured

and recorded prior to putting a hoist into service and that a gauge be made to provide a quick

visual inspection for a bent hook as required during routine inspections. Record this

information before initial start-up. See section 6.11 for more detailed hook information.

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

3 ELECTRICAL CONNECTIONS AND DIAGRAMS

The user / owner must provide the main power supply hardware (cable, conductor bar, fuses, disconnect

switch, etc.).

mCAUTION: Make sure that the power supply voltage is the same as that shown on hoist serial

plate / nameplate.

mCAUTION: Make sure that fuses and other current overload devices are in place to protect the

power supply.

mCAUTION: Make sure that power cable or conductors have sufficient capacity to maintain the

hoist supply voltage by ±5 percent of nominal voltage under all operating conditions. Poor

voltage regulation may cause motor overheating or sluggishness, and chattering / inoperative

motor brake(s) and controls.

mCAUTION: Do not use power supply cables with solid conductors.

mWARNING: Failure to properly ground the hoist presents the danger of electric shock.

mWARNING: An improper or insufficient ground connection creates an electrical shock hazard

when touching any part of the hoist or trolley.

mDANGER: Before installing, removing, inspection, or performing any maintenance on a hoist,

the main switch shall be de-energized. Lock and tag the main switch in the de-energized position in

accordance with ANSI Z244.1. Follow other maintenance procedures outlined in this manual and

ASME B30.16.

3.1 Control Fuses

The control fuse holder for the single-phase 115 volt control panels is installed as a wire mounted in-line fuse

holder. The in-line housing separates for fuse replacement. The control fuse holders for hoists with three

phase power supplies are cylindrical and mounted to the printed circuit control boards (labeled F100).

POWER CONTROL FUSE

SUPPLY VOLTAGE SIZE

3 – PHASE 115 VAC 500 mA

3 – PHASE 48 VAC 630 mA

1 – PHASE 115 VAC 250 mA

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

3.2 Configuration A – Single-speed – 208 or 230 Volt Connections

Configuration A utilizes direct connection of a three-phase 208 or 230 volt main power supply to the hoist

motor leads via a terminal strip. A motor brake rectifier circuit board (ACF) is provided to operate the D.C.

hoist motor brake assembly.

Figure 2. Configuration A Connections

The SM1 three-phase motor is only available as a two-speed. Therefore, the above layout shows the

connection of the high-speed motor leads and motor brake coil leads to the ACF direct control board.

The connections are the same for both 208 Volts and 230 Volts. The brake coil supply voltage from the AFC

brake control card is 90 - 100 volts DC for both 208 Volts and 230 Volts.

TRANSFORMER

(+)

(-)

BRAKE

OPT.

MOTOR

LEADS

SINGLE-SPEED CONNECTIONS FOR

SM1 TWO-SPEED MOTOR

208/230V – 3 PHASE

BRAKE

LEADS

ACF

CARD

POWER

SUPPLY

(+)

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

3.3 Configuration A – Single-speed – 208 or 230 Volt Wiring Diagram

Figure 3. Configuration A – Single-speed – 208 or 230 Volt Wiring Diagram

MOTOR

LEADS

NOT IN

USE:

AFC

CONTROL

X1:

OPTIONAL BRAKE #2

DELAYED

X5:

POWER

LEADS

(-)

(+)

(-)

(+)

BRAKE #1

2W 2U

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

3.4 Configuration A – Pigtail Pin-out Connections – R&M Standard

Table 1. POWER ONLY – PIGTAIL WITH PLUG

WIRE COLOR

AWG 12 – 4 COND

CONTROL PANEL

CONNECTIONS

MALE CE PLUG

BLUE (ME420P9)

PIN NUMBER

TWIST LOCK

MALE PLUG (L16-20P)

3 POLE + GRD

BLACK L1 1 X

WHITE L2 2 Y

RED L3 3 Z

GREEN PE (GROUND) PE (GROUND) G

Table 2. WIRING DIAGRAM LABELS

CODE DESCRIPTION

L1 POWER SUPPLY – PHASE ONE

L2 POWER SUPPLY – PHASE TWO

L3 POWER SUPPLY – PHASE THREE

PE GROUND

(-) MOTOR BRAKE COIL SUPPLY – VOLTS DC

(+) MOTOR BRAKE COIL SUPPLY – VOLTS DC

1W MOTOR LEAD W – SLOW

2W MOTOR LEAD W – FAST

1U MOTOR LEAD U – SLOW

2U MOTOR LEAD U – FAST

1V MOTOR LEAD V – SLOW

2V MOTOR LEAD V – FAST

mCAUTION: The above pin-out connections reflect R&M’s standard connections. There are no

industry standards for the above pin connections. Always check the wiring of any equipment before

applying power.

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

3.5 Configuration B – Single-speed – 208 or 230 Volt Connections

NOTE: THIS CONTROL IS NOT RECONNECTABLE!

Figure 4. Configuration B – Single-speed – 208 or 230 Volt Connections

The SM1 can only be connected to the specific voltage noted on the hoist serial tag. The SM1 three-phase

motor is only available as a two-speed motor. The single-speed SM1 offering is obtained by connecting the

high-speed motor leads of the two-speed motor.

The fuse holder, F100, is located as indicated on the control panel layout. The fuse is easily removed by

loosening the top of the cylindrical holder.

F100

( + )

( - )

BRAKE

COIL

T100

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3.6 Configuration B – Single-speed – 208 or 230 Volt Wiring Diagram

Figure 5. Configuration B – Single-speed – 208 or 230 Volt Wiring Diagram

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secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of R&M MATERIALS

3.7 Configuration B – Wiring Labels

Table 3. Configuration B – Wiring Labels

CODE DESCRIPTION

L1 POWER SUPPLY – PHASE ONE

L2 POWER SUPPLY – PHASE TWO

L3 POWER SUPPLY – PHASE THREE

PE GROUND

(-) MOTOR BRAKE COIL SUPPLY – VOLTS DC

(+) MOTOR BRAKE COIL SUPPLY – VOLTS DC

1W MOTOR LEAD W – SLOW

2W MOTOR LEAD W – FAST

1V MOTOR LEAD V – SLOW

2V MOTOR LEAD V – FAST

1U2U MOTOR LEAD U

K21 UP CONTACTOR

K22 DOWN CONTACTOR

K25 FAST CONTACTOR - (NOT IN USE)

T100 CONTROL TRANSFORMER

F100 CONTROL CIRCUIT FUSE

S221/S222 TRAVEL LIMIT SWITCHES (OPTIONAL)

F291 THERMAL PROTECTION SWITCH

X1 – 1 TERMINAL STRIP – CONTROL VOLTAGE SUPPLY - HOT

X1 – 2 TERMINAL STRIP – HOIST UP CONNECTION

X1 – 3 TERMINAL STRIP – HOIST DOWN CONNECTION

X1 – 4 TERMINAL STRIP – HOIST FAST CONNECTION - (NOT IN USE)

X1 – 9 TERMINAL STRIP – CONTROL NEUTRAL

X1 – 30, 31 TERMINAL STRIP – MOTOR THERMAL CONNECTIONS

X1 – 21, 22 TERMINAL STRIP – UPPER LIMIT SWITCH CONNECTIONS

X1 – 23, 24 TERMINAL STRIP – LOWER LIMIT SWITCH CONNECTIONS

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