Schmalz SK-JU-110-2000-SRS63-3000-VSL-EX Manual

www.schmalz.com
EN
Ergonomic Handling Solutions
Operating and Maintenance Instructions
Jib Cranes for Potentially Explosive Atmospheres
30.30.01.00226/03 | 09.2019

www.schmalz.com
Note
These operating and maintenance instructions were originally written in German.
Store in a safe place for future reference.
Subject to technical changes without notice. No responsibility is taken for printing or other types of
errors.
Published by
© J. Schmalz GmbH, 09.2019
This document is protected by copyright. J. Schmalz GmbH retains the rights established thereby.
Reproduction of the contents, in full or in part, is only permitted within the limits of the legal provisions
of copyright law. Any modifications to or abridgments of the document are prohibited without explicit
written agreement from J. Schmalz GmbH.
Contact
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.schmalz.com
Contact information for Schmalz companies and trade partners worldwide can be found at
www.schmalz.com/salesnetwork

Contents
Operating and Maintenance Instructions Jib Cranes for Potentially
Explosive Atmospheres
www.schmalz.com
1Safety instructions...............................................................................................6
1.1 Classification of safety instructions ...................................................................................6
1.2 Warnings ...........................................................................................................................7
1.3 Mandatory symbols ...........................................................................................................7
1.4 Regulations in these instructions.......................................................................................8
1.5 General safety instructions................................................................................................8
Explosion protection..........................................................................................................81.5.1 Fundamental safety instructions........................................................................................91.5.2
1.6 Intended use....................................................................................................................10
1.7 Non-intended use............................................................................................................12
1.8 Requirements and instructions for installation, maintenance and operating staff...........12
1.9 Installation location/workplace requirements ..................................................................14
Installation location requirements....................................................................................141.9.1 Workplace requirements .................................................................................................151.9.2
1.10 Danger zone definition ....................................................................................................16
1.11 Operating range of the jib crane......................................................................................17
1.12 Emissions........................................................................................................................17
1.13 Personal protective equipment........................................................................................17
2Product description ...........................................................................................18
2.1 Description.......................................................................................................................18
Column-mounted jib crane with flat jib ............................................................................182.1.1 Wall-mounted jib crane with flat jib..................................................................................182.1.2 Column-mounted jib crane with flat jib ............................................................................182.1.3 Wall-mounted jib crane with flat jib..................................................................................182.1.4 Column-mounted jib crane with articulated-arm jib.........................................................192.1.5 Wall-mounted jib crane with articulated-arm jib ..............................................................192.1.6
2.2 Flat jib..............................................................................................................................20
2.3 Flat jib..............................................................................................................................20
2.4 Articulated-arm jib ...........................................................................................................21
2.5 Type plate........................................................................................................................21
2.6 Description of component parts.......................................................................................22
Pivot bearing....................................................................................................................222.6.1 Crane column..................................................................................................................232.6.2 Wall bracket / clasp bracket ............................................................................................232.6.3 Steel profile......................................................................................................................242.6.4 Transport trolley...............................................................................................................242.6.5 Bracings...........................................................................................................................242.6.6 End stops.........................................................................................................................252.6.7 Cable trolley.....................................................................................................................252.6.8 Terminal clamps..............................................................................................................252.6.9 Slewing angle limiter .......................................................................................................252.6.10 Attachments.....................................................................................................................262.6.11 Electrical switches...........................................................................................................262.6.12
3Technical Data..................................................................................................27
4Delivery, packaging and transport.....................................................................28

SAFETY INSTRUCTIONS
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4.1 Delivery............................................................................................................................28
Items included in delivery................................................................................................284.1.1 Check for completeness..................................................................................................284.1.2 Report damage................................................................................................................284.1.3
4.2 Packaging........................................................................................................................28
4.3 Transport.........................................................................................................................28
4.4 Removal of crane components........................................................................................29
5Installation.........................................................................................................30
5.1 Preparation of parts.........................................................................................................31
5.2 Tool list............................................................................................................................31
5.3 Electrical installation........................................................................................................32
Installation of electrical supply lines................................................................................325.3.1
5.4 Mechanical installation ....................................................................................................33
Positioning the crane column..........................................................................................335.4.1 Erecting the crane column with mobile base plate..........................................................365.4.2 Mounting the wall bracket................................................................................................365.4.3
5.5 Mounting the flat jib .........................................................................................................39
5.6 Pre-assembly of articulated-arm jib.................................................................................40
5.7 Pre-assembly of flat jib....................................................................................................40
5.8 Mounting the crane jib on the crane column or wall bracket...........................................41
Tool list............................................................................................................................415.8.1 Lower bearing mounting..................................................................................................41
5.8.2 Upper bearing mounting..................................................................................................455.8.3
5.9 Aligning the steel crane jib for column-mounted or wall-mounted jib crane....................46
5.10 Mounting the slewing angle limiter..................................................................................47
5.11 Mounting the crane buffer for crane rails ........................................................................48
5.12 Mounting the hoist...........................................................................................................48
5.13 Mounting the energy supply............................................................................................48
Vacuum power supply.....................................................................................................485.13.1
5.14 Establishing equipotential bonding..................................................................................49
Grounding points for vacuum tube lifter Jumbo Sprint EX blower ..................................505.14.1 Grounding points for vacuum tube lifter Jumbo Sprint EX ejector ..................................515.14.2 Connecting grounding wires............................................................................................525.14.3 Resistance measurement................................................................................................525.14.4
5.15 Preparing for operation....................................................................................................53
Other energy supply........................................................................................................535.15.1 Attaching the type plate...................................................................................................535.15.2
6Operation ..........................................................................................................54
6.1 General safety instructions regarding operation .............................................................54
6.2 Operation.........................................................................................................................55
6.3 Checks before starting work............................................................................................56
6.4 Erecting the crane column on a mobile base plate in another location...........................56
6.5 What to do in an emergency ...........................................................................................57
Production of an ignition source in a potentially explosive atmosphere..........................576.5.1 Falling load......................................................................................................................576.5.2
7Troubleshooting ................................................................................................58

SAFETY INSTRUCTIONS
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8Maintenance......................................................................................................59
8.1 General notes..................................................................................................................59
8.2 Service table....................................................................................................................60
8.3 Cleaning ..........................................................................................................................61
8.4 Spare parts......................................................................................................................61
8.5 Circuit diagram ................................................................................................................61
8.6 Expert approval ...............................................................................................................61
9Dismantling and disposal ..................................................................................62
9.1 Dismantling......................................................................................................................62
9.2 Disposal...........................................................................................................................62

SAFETY INSTRUCTIONS
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1 Safety instructions
1.1 Classification of safety instructions
Danger
This warning informs the user of a risk that will result in death or serious injury if it is not avoided.
DANGER
Type and source of danger
Consequence
►
Remedial action
Warning
This warning informs the user of a risk that could result in death or serious injury if it is not avoided.
WARNING
Type and source of danger
Consequence
►
Remedial action
Caution
This warning informs the user of a risk that could result in injury if it is not avoided.
CAUTION
Type and source of danger
Consequence
►
Remedial action
Attention
This warning informs the user of a risk that could result in damage to property if it is not avoided.
ATTENTION
Type and source of danger
Consequence
►
Remedial action
Important information for efficient and trouble-free use.

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1.2 Warnings
Explanation of the warning symbols used in the operating and maintenance instructions.
Icon
Description
Icon
Description
General warning symbol
Explosive atmosphere
Electrical voltage
Flying debris
Hand injury
Crushing injury warning
Suspended load
Fall hazard
Vacuum
Hearing damage
Warning of hot surfaces
1.3 Mandatory symbols
Explanation of the mandatory symbols used in the operating and maintenance instructions.
Icon
Description
Icon
Description
Wear ear protectors
Wear protective work shoes
Wear protective gloves
Disconnect mains plug
Adhere to the operating instructions
Wear eye protection

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1.4 Regulations in these instructions
WARNING
Failure to observe the instructions
Risk of fatal injuries
►
Do not start or use the jib crane until you have read and understood the
operating and maintenance instructions.
These operating and maintenance instructions are an integral part of the jib crane. They must
accompany it wherever it is transported.
These operating and maintenance instructions are specific to the items included in delivery from J.
Schmalz GmbH. They do not take into account any modifications to the jib crane made by the
customer, which are strictly prohibited.
These operating and maintenance instructions do not include the hoist attached to the jib crane (e.g.
vacuum tube lifter).
1.5 General safety instructions
Explosion protection1.5.1
DANGER
Ignition sources
Risk of explosion
►
When used in potentially explosive atmospheres:
Preclude possible ignition sources (e.g. hot surfaces, open flames, hot
gases or liquids, mechanically produced sparks, adiabatic compression,
shock waves, exothermic chemical reactions, thermal reactions, the
spontaneous combustion of dust, electric arcs or the discharge of static
electricity or propagating brush discharges).
Never allow the components of the jib crane to be hit with force (spark
discharge).
Never strike the components of the jib crane with objects or tools (spark
discharge).

SAFETY INSTRUCTIONS
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Fundamental safety instructions
1.5.2
WARNING
Ignoring the general safety guidelines
Personal injury/damage to plants or systems
►
The operating and maintenance instructions contain important information on
using the system. All users must have read and understood the operating and
maintenance instructions and keep them for later reference.
►
These operating and maintenance instructions are specific to the items included
in delivery from J. Schmalz GmbH. They do not take into account any
modifications to the system made by the customer, which are strictly prohibited.
►
The system may only be connected and operations started once the operating
and maintenance instructions have been read and understood.
►
Use only the connections, mounting holes and attachment materials that have
been provided.
►
Only qualified specialist personnel, mechanics and electricians may perform the
installation. Qualified specialist personnel are persons who have received
technical training and have the knowledge and experience –including
knowledge of applicable regulations –necessary to enable them to recognize
possible dangers and implement the appropriate safety measures while
performing tasks. The same applies to maintenance!
►
General safety regulations, European standards and VDE guidelines must be
observed and complied with.
►
Personnel and animals are not permitted to sit or stand in the danger zone.
►
The system must be used only to lift and transport suitable workpieces.
►
You are responsible for third parties in the working area of the system. In view
of this, responsibilities for the various tasks to be carried out on the system
must be clearly specified and adhered to.
►
Protect the components from damage of any kind.
All applicable laws and regulations must be adhered to at all times.
When using the jib crane, the statutory regulations, safety regulations, standards
and guidelines applicable at the location of use must be observed.
Check with the competent authorities for more information.
The safety instructions in these operating and maintenance instructions do not
replace these laws and regulations, but are to be regarded as a supplement to
them.

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1.6 Intended use
Schmalz jib cranes are intended exclusively for the transporting of loads. The loads are raised using
special hoists (e.g. vacuum tube lifter Jumbo).
The jib crane is intended only for commercial use. The order confirmation defines the specific use of
the jib crane.
The jib crane is classified as follows in accordance with ATEX directive 2014/34 EU:
Jumbo with 50-Hz blower Jumbo with 60-Hz blower Jumbo with ejector
II 3G IIB T4 II 3G IIB T3 II 2G c IIB T6
II 3D T135° C II 3D T200° C II 2D c T85° C
DANGER
Electrostatic charge on the load
Risk of explosion
►
During operation in potentially explosive atmospheres as defined by ATEX
1999/92 EC, ensure that the load does not pose a danger:
The load must be conductive. A measurement of potential is required.
Ensure that electrostatic charges cannot develop on loads during
lifting. Where necessary, connect them with equipotential bonding
(not included in the delivery)
Hoists may only be attached when hanging from the suspension bolt on the transport trolley or,
with articulated-arm jibs, to the designated mounting plate.
The load must be pushed and not pulled.
Avoid carrying the load diagonally to the transport trolley's direction of travel at an angle of more
than 5° from vertical.
Avoid a build up of rocking in loads.
Storing loads on the jib crane is prohibited.
Only the designated mounting holes and attachment materials must be used.
The operating, maintenance and servicing conditions specified in these operating and
maintenance instructions must be observed.
The maximum permissible load must not be exceeded.
The working area must be observed.
The jib crane is designed for the hoisting class HC3 and hoist HD1 in accordance with DIN EN
13001.
The jib crane is state of the art and operationally reliable, provided full
compliance with these instructions is assured. Incorrect handling of the crane
system could cause dangers to arise.