RUD ICE-Balancer Installation instructions

1
ICE-Balancer
RUD Ketten
Rieger & Dietz GmbH u. Co. KG
73428 Aalen
Tel. [phone]
Fax [phone]
[email protected]
www.rud.com
RUD-Art.-Nr.: 7903516-EN / 07.020
> ICE-Balancer <
User instruction
This safety instruction / declaration of the manufacturer has to
be kept on le for the whole lifetime of the product.
Translation of the original user instruction
EN
EG-Einbauerklärung
entsprechend der EG-Maschinenrichtlinie 2006/42/EG, Anhang II B und ihren Änderungen
Hersteller:
RUD Ketten
Rieger & Dietz GmbH u. Co. KG
Friedensinsel
73432 Aalen
Hiermit erklären wir, dass die nachfolgend bezeichnete unvollständige Maschine den
grundlegenden Anforderungen der Maschinenrichtlinie 2006/42/EG (Anhang 1) entspricht.
Die nachfolgend bezeichnete unvollständige Maschine darf, in der gelieferten Ausführung
erst dann in Betrieb genommen werden, wenn festgestellt wurde, dass die Maschine, in
die diese unvollständige Maschine eingebaut werden soll, den Anforderungen der EG-
Maschinenrichtlinie 2006/42/EG entspricht.
Produktbezeichnung: ICE-Wippe
_____________________________________________
IW
_____________________________________________
Folgende harmonisierten Normen wurden angewandt:
DIN EN ISO 12100 : 2011-03
_________________ _________________
_________________ _________________
_________________ _________________
_________________ _________________
_________________ _________________
Folgende nationalen Normen und technische Spezifikationen wurden außerdem angewandt:
BGR 500, KAP2.8 : 2008-04
_________________ _________________
_________________ _________________
_________________ _________________
_________________ _________________
_________________ _________________
Die speziellen Unterlagen zur unvollständigen Maschine nach Anhang Vll Teil B
wurden erstellt und werden auf begründetes Verlangen in geeigneter Form übermittelt.
Für die Zusammenstellung der Konformitätsdokumentation bevollmächtigte Person:
Michael Betzler, RUD Ketten, 73432 Aalen
Aalen, den 26.09.2016 Dr.-Ing. Arne Kriegsmann,(Prokurist/QMB)
_____________________________________________
Name, Funktion und Unterschrift Verantwortlicher
EC-Mounting declaration
According to the EC-Machinery Directive 2006/42/EC, annex II B and amendments
Manufacturer: RUD Ketten
Rieger & Dietz GmbH u. Co. KG
Friedensinsel
73432 Aalen
We hereby declare that the following incomplete machines correspond to the basic re-
quirements of the Machinery Directive 2006/42/EC (annex 1). The following incomplete
machine, in the delivered machine, may only be put into operation when the machine
in which the incomplete machine shall be assembled, has been tested according to the
requirements of the EC-Machinery Directive 2006/42/EC.
Product name: ICE-Balancer
_____________________________________________
IW
_____________________________________________
The following harmonized norms were applied:
DIN EN ISO 12100 : 2011-03
_________________ _________________
_________________ _________________
_________________ _________________
_________________ _________________
_________________ _________________
The following national norms and technical specifications were applied:
BGR 500, KAP2.8 : 2008-04
_________________ _________________
_________________ _________________
_________________ _________________
_________________ _________________
_________________ _________________
The special documents about the incomplete machine according to annex VII part B
have been created and can be handed over in a suitable form on request.
Authorized person for the configuration of the declaration documents:
Michael Betzler, RUD Ketten, 73432 Aalen
Aalen, den 26.09.2016 Dr.-Ing. Arne Kriegsmann,(Prokurist/QMB)
_____________________________________________
Name, function and signature of the responsible person
Simple test, management and
documentation subject to mandatory testing
operating resources, equipment and components.
ICE-Balancer

2ICE-Balancer
Before use or assembly of ICE-Balancer
please read user instruction carefully. Make
sure that you have understood all subject
matters. Non-observance can lead to per-
sonal and material damage and eliminates
warranty.
1 Safety instructions
ATTENTION
Wrong assembled or damaged compo-
nents as well as improper use can lead to
injuries of persons and damage of objects
when load drops.
Please inspect all components before
each use.
• Keep all body parts like ngers, hands, arms, etc.
out of the hazardous area during the lifting opera-
tion.
• Any technical modications at the ICE-Balancer
are prohibited.
• Keep persons out of the hazardous area.
• Detention under a oating load is forbidden.
• Jerkily lifts with shock loads must be avoided.
• When the lift starts, pay attention to a stable posi-
tion of the load. Avoid swinging of the load.
• Damaged or worn ICE-Balancer must no longer be
used.
• Bear in mind extreme circumstances or shock loads
when choosing the used components.
• The ICE-Balancer must not be used under load with
an limit inclination angle of 10° (see picture 11).
• The inclination angle ß must not exceed 45° (see
picture 13 and 14).
• ICE-Balancers must only be used by designated
and trained persons by observing the BGR 500 /
DGUV 100-500 requirements, chapter 2.8, and
outside Germany acc. to the country specic re-
gulations.
2 Intended use
ICE balancers will be installed into 4-leg sling assem-
blies ( 2x 2-leg), to achieve an equal load distribution
to all 4 legs (picture 17). The length tolerances of the
single legs will be compensated by the disposition of
the ICE-Balancer.
Please observe that the ICE balancer does not exceed
the limit inclination angle of 10° (picture 11). By the
special bottom shape of the ICE balancer you can
realize very easy the limit inclination angle of 10°.
During use make sure that the 2-leg sling
with the balancer will not be used seperatly.
Observe the safety instructions: „Lifting means used
for lifting of loads must especially avoid that loads
shift unattended or drop in free fall.“
ICE-Balancers must only be used in the here explai-
ned usage.
You can calculate with 4 load bearing strands if the
following criteria are fullled (BGR 500 / DGUV 100-
500):
• Two 2-leg slings, therof one sling with a balancer.
• Both 2-leg slings will be attached to one hook
(single or double crane hook)
• Symmetrical load spreading
• Max. inclination angle ß 45°
WARNING
The 2-leg sling with the balancer must not
be used seperatly as 2-leg sling. Lifting
means for lifting of loads must avoid that
loads can shift unintentional. (compare
with work safety requirement, attachment
1, chapter 3.2.3)
3 Assembly- and instruction manual
3.1 General information
• Capability of temperature usage
When used at temperatures higher than 200°C
the working load limits (WLL) of the ICE-Balancer
must be reduced as follows:
-60°C up to 200°C no reduction
200°C up to 250°C minus 10 %
250°C up to 300°C minus 40 %
Temperatures exceeding 300°C are prohibited!
• ICE-Balancer must not be used with aggressive
chemicals such as acids, alkaline solutions and
their vapours.
• The balancer head consists of the following com-
ponents:
Size 6-16 mm
IAK-/ISAK-Master Link
VV-SCH/VC-SCH
ICE-Balancer
IVS ICE-Connecting Link

3
ICE-Balancer
3.2 Hints for the assembly
3.2.1 Assembly of masterlinks and shackles
Please observe obsolutely the correct sizing of ma-
sterlinks, shackles and balancers during assembly
and repairing (see table 2).
During the assembly of the balancer head please
proceed as follows:
1. Please meet the following component adjustment
while balancer head is assembled (picture. 1):
Shackle bow
ICE-Balancer
Pic. 1: Component adjustment
IAK-Master Link
Shackle pin
2. Attach shackle bow into IAK-Master Link.
3. Move shackle bow plus IAK Master link over the
top hole of the balancer.
4. Close shackle by moving the shackle pin through
the balancer connecting hole.
5. Turn shackle pin completely in and secure it always
with a cotter or a sleeve pin. The shackle must now
be rm connected to the balancer.
HINT
The bow of the shackle must always be
secured:
Cotter pin for VC-SCH 5.0 and VC-SCH 6.0
Sleeve pin for VV-SCH 10, 13 and 16
Pic. 2: Assembled
balancer with shackle
3.2.2 Assembly of chain strands
(by using connectors)
The chain strands will be connected to the balancer
by using IVS ICE-Connecting Links.
Sequence of assembly:
In the following description the assembly of the con-
necting link will be described exemplarily with the
example of a ICE-Balancer and an ICE chain.
1. Install last chain link into the nose (Pic. 3). In this
case there is no additional connector necessary.
Pic. 3: Install chain into
nose
HINT
At the beginning of the bow rounding, chain
link can be turned by 90° within the bow
(Pic.4).
Pic. 4: Turn chain link
2. Position chain strand to the bottom of the bow part
(Pic. 5).
Pic. 5: In connect half
attached chain
3. Put into the second bow part a desired connecting
part, f.e. a masterlink (Pic. 6).
Pic. 6: Assembly of the second bow part

4ICE-Balancer
• RUD components have been designed as per DIN
EN 818 and DIN EN 1677 for a dynamic load of
20,000 load cycles.
• Observe and be aware that multiple load
cycles can occur during a lifting operation.
• Observe the risk of product damage caused
by high dynamical inuences at high load
cycle numbers.
• BG/DGUV Germany’s employer insurance
association recommends: At high dynamical
loading with a high number of load cycles
(permanent use), the stress at WLLacc. to FEM
class 1Bm (M3 acc. to DIN EN 818-7) must
be reduced.
Use a lifting chain with a higher WLL.
• Make sure that the load force happens in the
straight leg without being twisted, fold-over or
kinked.
• Leave hazardous area when possible.
• Monitor always attached or lashed loads.
• Read for all lifting means the RUD sling chain safety
instructions for RUD lifting means.
3.4 Hints for the usage
(limit of inclination angle)
• Before each usage please control the correct as-
sembly of the ICE-Balancer.
• Observe that the inclination angle of the ICE ba-
lancer does not exceed 10° (see pictures 10-12)
a


10°-edge
Pic. 10: In the ideal case no skewing of the balancer
should occure 10° edge
4. Assemble both bow parts together in such a way
that components are aligned (Pic. 7).
Pic. 7: Alignment of second bow part with rst bow
part
5. Install pin into the bore of the eye (Pic. 8). Both
bow parts are now connected with each other.
Pic. 8: Assembly of connecting pin
6. Secure the assembled connecting link as follows
(Pic. 9):
- Position the securing pin resp. the sleeve pin in
such a way, that the slot faces the outside.
- Knock sleeve pin in with a hammer.
Pic. 9: Securing of connecting pin
7. Finally check the correct assembly (see chapter 4
Inspection criteria).
3.3 General information regarding use
The whole lifting mean must be inspected regularly
by a competent person in regard of proper installa-
tion, strong corrosion, cracks at load bearing parts
and deformations (e.g. by the person responsible for
attachment). See section 4 Inspecting and repairing.
WARNUNG
Wrong assembled or damaged compo-
nents as well as improper use can lead to
injuries of persons and damage of objects
when load drops.
Please inspect all components before each
use.

5
ICE-Balancer
a

10°-edge
horizontal

10°-edge
horizontal
Pic. 11: Limit skewing inclination of 10° reached
(can be recognised by horizontal alignement of edge)
HINT
The maximum allowed balancer skewing
of 10° can be recognised by the specic
shape of the ICE-Balancer. The limit skew-
ing angle of 10° can be easily recognized.
• A skewing of the balancer under load by more
than 10° is prohibited (Pic. 12)!
The 10° edge is no longer aligned horizontal!
The skewing of the balancer is too big.
Pic. 12: Skewing of the balancer by more than 10° is
prohibited.
WARNING
Skewing of the balancer by more than
10° is prohibited. Should the limit skewing
angle exceed 10°, an ICE-CURT-GAKO
length adjustment has to be installed into
the 2-leg balancer sling or a shortening
element must be used. Make chain strand
either longer or shorter until the balancer
is within the 10° range.
3.5 Hints for the usage
(Inclination angle β)
• Pay attention that the inclination angle ß will not
exceed 45° (see picture 13 and 14).
Pic. 13: Max. inclination angle β = 45°
Pic. 14: Detailed view Pic. 13
4 Inspecting and repairing
4.1 Hints for the regularly inspection
The operator has to determine and dictate the nec-
essary inspection periods and the deadlines by a risk
assessment (see sections 4.2 and 4.3).
The persisting appropriateness of the lifting mean
must be checked by a competent person (auditor) at
least once per year.
Depending on the conditions of use e.g. frequent use,
increased wear or corrosion, it may be necessary to
carry out inspections at shorter intervals than once per
year. A verication is also required following damage
and after special events.

6ICE-Balancer
Table 1: Dimension chart of balancer Subject to technical modications
Pic. 15: Dimensioning of the ICE-Balancer
Chain
[mm]
Nomination WLL of
balancer [t]
inclination
angle of legs
0-45°
WLL of
balancer [t] in-
clination angle
of legs 0° (±7°)
parallel
A
[mm]
B
[mm]
C
[mm]
D
[mm]
T
[mm]
weight
[kg/pc.]
Ref. no.
6 IW-6 2.5 3.6 110 15 14 21 46 0.49 7904367
8 IW-8 4.25 6.0 150 20 18 26 59 1.15 7904370
10 IW-10 7.1 10.0 180 25 23 32 76 2.4 7904372
13 IW-13 11.2 16.0 240 30 28 38 91 4.37 7904375
16 IW-16 17 25.0 300 35 32 41 120 8.8 7904255
L1
Pic. 16: Assembled chains
VV-SCH or
VC-SCH
IVS
Chain
[mm]
Nomination
ICE-Balancer
head
Dimensions
IAK- and
IA-Link [mm]
Top
connection
Bottom
connection
Pitch of
balancer
head
L1 [mm]
Weight of
balancer
head
[kg/pc.]
Ref. no.
balancer
head
6 IWK-2S-6 18x90x160 VV-SCH10 (4 t) IVS-6 300 2.33 7904654
8 IWK-2S-8 26x100x180 VV-SCH13 (6.7 t) IVS-8 363 5.39 7904655
10 IWK-2S-10 32x110x200 VV-SCH16 (10 t) IVS-10 423 9.99 7904656
13 IWK-2S-13 36x140x260 VC-SCH 5.0 (25 t) IVS-13 554 17.5 7904657
16 IWK-2S-16 46x190x350 VC-SCH 6.0 (31.5 t) IVS-16 698 37.54 7904658
6 IWSAK-2S-6 26x190x350 VV-SCH 13 (6.7 t) IVS-6 504 5.85 7907155
8 IWSAK-2S-8 32x190x350 VV-SCH 16 (10 t) IVS-8 543 9.0 7907156
10 IWSAK-2S-10 36x250x460 VC-SCH 4.0 (16 t) IVS-10 701 17.17 7907157
13 IWSAK-2S-13 40x250x460 VC-SCH 5.0 (25 t) IVS-13 754 24.4 7907158
16 IWSAK-2S-16 47x250x460 VC-SCH 6.0 (31.5t ) IVS-16 808 37.2 7907159
Table 2: Datas of ICE-Balancer head Subject to technical modications
4.2 Inspection criteria for the regularly
examination carried out by the operator:
• Completeness of the ICE-Balancer.
• Deformations at the component.
• Check readability of nominal size and manufacturer sign
• Mechanical damage like notches especially at
areas with tensile stress.
4.3 Additional inspection criteria for the
competent person resp. auditor
• Reduction of cross section cause by wear of more
than 10 %
• Strong corrosion
• Additional inspections may be necessary de-
pending on the result of the risk assessment (e.g.
incipient cracks at load bearing parts).
4.4 Hints for the Repairing
• Repair works can only be carried out by the ma-
nufacturer or by experts disposing necessary
knowledge and required skills.
• Only RUD original spare parts must be used and
all repairing and overhauling operations must be
documented in the chain card le (of the complete
lifting mean) or use the RUD BLUE-ID-System.

7
ICE-Balancer
Example ICE-10 mm:
When using a standard 4-leg sling in the worst case
scenario, the user can calculate with only 2 load
bearing legs (WLL at 0-45°: 7.1 t)
DGUV 100-500 (BGR 500), chapter. 2.8 clause
3.5.3:
When lifting with multiple strands only two strands
can be assumed to be load bearing.
This is not valid if it is guaranteed that the load will be
distributed equally to 2 additional legs [...].
By using the ICE-balancer, the load distribution of a
2 x 2-leg sling will be forwarded to all 4 chain legs.
→ The here of resulting WLL will then be at an incli-
nation angle ß 0-45° 14.1 t.
ATTENTION
When using two 2-leg slings at a symme-
trical load distribution, one with a balancer,
and both slings are attached into the same
hook, 4 load bearing legs can be assumed.
The inclination angle ß must not exceed
45°.
Total weight to be lifted [t]
at 4-leg slings (2-leg + 2-leg with balancer)
Chain
[mm]
maximum allowed
inclination angle
β= 15°
maximum allowed
inclination angle
β= 30°
maximum allowed
inclination angle
β= 45°
6 6.9 6.2 5.1
8 11.6 10.4 8.4
10 19.3 17.3 14.1
13 31.0 27.7 22.6
16 48.3 43.3 35.3
Table 3: Datas of ICE-2-leg Masterlink (for balancer assembly)
Subject to technical modications
Table 4: Area of inclination angles
Subject to technical modications
Pic. 17: Pitch
Chain
[mm]
Nomination
ICE-2-Leg Mas-
terlink for balan-
cer assembly
Dimensions
IAK- and
IA-Link [mm]
Pitch
2-leg
IAK
L2 [mm]
additional
number of chain
links for length
adjustment
IVS
Weight
2-leg
IAK
[kg/pc.]
Ref. no.
2-leg
IAK
6 IAK 2S-6 18x90x160 266 2 1.8 7904659
8 IAK 2S-8 26x100x180 308 2 4.09 7904660
10 IAK 2S-10 32x110x200 368 2 7.37 7904661
13 IAK 2S-13 36x140x260 467 2 12.44 7904662
16 IAK 2S-16 46x190x350 603 2 24.87 7904663
6 ISAK-2S-6 26x190x350 456 3 5.1 7907150
8 ISAK-2S-8 32x190x350 478 3 8.64 7907151
10 ISAK-2S-10 36x250x460 628 2 14.6 7907152
13 ISAK-2S-13 40x250x460 667 2 20.12 7907153
16 ISAK-2S-16 47x250x460 713 2 28.98 7907154