Stagemaker SR Quick start guide

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Technical
guide

TECHNICAL GUIDE
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1UPDATE HISTORY .......................................................................................................................................................5
2GENERAL......................................................................................................................................................................6
2.1 General description................................................................................................................................................6
2.2 Mounting positions.................................................................................................................................................6
2.2.1 Normal position.............................................................................................................................................. 6
2.2.2 Inverted position.............................................................................................................................................6
2.3 Identifying the key parts of the hoist.......................................................................................................................7
2.4 Standard features...................................................................................................................................................8
2.5 Optional features..................................................................................................................................................10
2.6 Sound level ..........................................................................................................................................................10
2.7 Certifications, standards and other technical documents.....................................................................................10
2.8 Product range.......................................................................................................................................................11
2.9 Hoist weight..........................................................................................................................................................11
3MAIN COMPONENTS .................................................................................................................................................12
3.1 Motor....................................................................................................................................................................12
3.1.1 Hoisting motors.............................................................................................................................................12
3.2 Gear.....................................................................................................................................................................13
3.2.1 Hoisting gear ................................................................................................................................................13
3.2.2 AGMA rating.................................................................................................................................................13
3.3 Electrics................................................................................................................................................................14
3.3.1 Cable inputs..................................................................................................................................................14
3.3.2 Wiring principle –Configuration A................................................................................................................15
3.3.3 Wiring principle –Configuration B................................................................................................................16
3.4 Hoisting brakes ....................................................................................................................................................17
3.4.1 Double brake................................................................................................................................................18
3.4.2 Brake coil voltages and resistance...............................................................................................................19
3.5 Overload device: Slipping clutch..........................................................................................................................20
3.6 Limit switch...........................................................................................................................................................21
3.6.1 Micro switch operated limit switch................................................................................................................21
3.6.2 Rotating limit switch (option).........................................................................................................................24
3.6.3 Functional description of the limit switch......................................................................................................25
3.6.4 Adjusting the hoist limit switch......................................................................................................................25
3.7 Chain reeving components ..................................................................................................................................26
3.7.1 Chain drive ...................................................................................................................................................26
3.7.2 Chain sprocket..............................................................................................................................................27
3.8 Suspension hook..................................................................................................................................................28
3.8.1 Fixed suspension hook.................................................................................................................................28
3.8.2 Rotating upper hook.....................................................................................................................................28
3.9 Hooks...................................................................................................................................................................29
3.9.1 Hook blocks and bottom hook blocks...........................................................................................................30
3.10 Hoisting chains.................................................................................................................................................31
3.10.1 Safety factors according to standards..........................................................................................................31
3.10.2 Chains ..........................................................................................................................................................31
3.10.3 Chain bags ...................................................................................................................................................32
3.10.4 Chain loading table.......................................................................................................................................33
3.11 Pendant............................................................................................................................................................34
4LUBRICATION.............................................................................................................................................................35
4.1 Chain....................................................................................................................................................................35
4.2 Gear.....................................................................................................................................................................35
5LIST OF MATERIALS AND COATINGS......................................................................................................................36
6STAGEMAKER PRODUCT CODE EXAMPLE............................................................................................................37
7LOAD RANGE AND DUTY CLASSES ........................................................................................................................38
7.1 Hoist classifications..............................................................................................................................................38
8STAGEMAKER RANGE OF FLIGHT CASE................................................................................................................40
9STAGEMAKER RADIO LOAD CELL SYSTEM ..........................................................................................................45

TECHNICAL GUIDE
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TECHNICAL GUIDE
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04/2014
1UPDATE HISTORY
Section
Changes
Date
Handled by
All
First draft version
10/2012
ISOTAPA
All
First correction round
12/2012
ISOTAPA
2.8, 3.1.1, 3.2.1
Separate versions for SI 50 Hz / SI 60 Hz / IMP 60 Hz created
12/2012
ISOTAPA
2.2
Hoist configuration
01/2014
JYB
2.4
Standard features
01/2014
JYB
2.5
Options
01/2014
JYB
3.4
„lbf‟ units added to brake torque values
12/2012
ISOTAPA
3.4.1
Double brake
01/2014
JYB
3.3.1
Cable gland illustration modified
01/2013
ISOTAPA
2.7 & 2.8
Duty cycle modified
02/2013
ISOTAPA
2.4
NEMA class changed
02/2013
ISOTAPA
2.8, 2.9, 3.1.1,
3.2.1, 3.4, 3.6.3,
3.7.3, 3.8, 3.9.,
3.10
SR10 data added
06/2013
ISOTAPA
3.10
Safety factor on lifting chain (grade 80 & 100)
03/2014
JYB
3.11
Controller info added
03/2014
JYB
3.6.3, 3.6.4
Limit switch info modified, new illustrations (2-step/4-step limit switch) added
Q2/2013
ISOTAPA
3.6.3, 3.6.4
Limit switch info modified, new illustrations Limiflux added
03/2014
JYB
3.4
Brake measurement info added
06/2013
ISOTAPA
6
Data added to product code table (hoisting speed, power supply, control voltage,
HOL, etc.)
06/2013
ISOTAPA
6
Product code update
03/2014
JYB
2.8
Loads 1600 kg (1 ½ ton) and 2000 kg (2 ton), 2 falls, added to the Product range
table
09/2013
ISOTAPA
2.8, 6
Units changed from „lbs‟ to „ston‟ (60 Hz IMPversion)
09/2013
ISOTAPA
2.5
Information concerning the second brake as an optional feature modified
09/2013
ISOTAPA
2.5
Information about BGV-D8+ hoists added
09/2013
ISOTAPA
3.4.2
Brake coil voltage tables harmonized, „1 phase‟ info removed
09/2013
ISOTAPA
All
Product arguments, Chainflux, Limitflux, Perfectpush
03/2014
JYB
8
Flight case
03/2014
JYB
9
Radio load cell
04/2014
JYB

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2GENERAL
2.1 General description
STAGEMAKER® hoists for showbusiness are electric chain hoists that are designed to handle stage and theatrical
equipment and enable the safe and accurate positioning of speakers, lighting systems, stage sets, sceneries, etc.
STAGEMAKER® hoist‟s features and options, compact design and on-going adaptability (R&D, close corporation
with the entertainment industry) make this system the best choice for your stage productions. Its CE- and CSA-
certification ensure the quality process.
2.2 Mounting positions
2.2.1 Industrial suspension = Body Up
Industrial suspension is where the hoist is mounted with load chain down and hoist body up. The hook block
attaches to the load and moves up and down. The hoist body is stationary.
2.2.2 Climbing hoist = Body Down
Climbing hoist is where the hoist is mounted with load chain up and hoist body down. The hoist body attaches to
the load and moves up and down with the load. Hoists in the inverted position are easier to install and setup
because all the cabling is at the same level, and the hoist is at truss level.

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2.3 Identifying the key parts of the hoist
Pos.
Part
Description
1
Hoisting machinery
Equipment composed of hoist frame, hoisting motor, gear, clutch and brake
2a
Upper hook
Fixed suspension, normally used when hoist is operated in normal position
2b
Upper hook
Rotating upper hook, normally used when hoist is operated in inverted position
3
Lower Hook block
Lower hook block Includes hook housing, hook forging and rubber grip
4
Chain bag
Bag where the lifting chain is gathered and stored
5
Control cable + plug
Plug for connecting power or controls to the hoist
6
Buffers
Rubber buffers at each corner to protect hoist against external shocks
7
Handles
Integrated handles for easy carrying of hoist
8
Chain guide
Chainflux type chain guide for precise chain alignment

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2.4 Standard features
Mechanics
Single fall up to 500 kg
D8 as standard, BGV-D8+ ready
New “Perfect Push”, patented concept, 5 pocket load wheel, fitted with 5 intermediate teeth. This innovation
provides improved chain guiding and chain flow, to help reduce the risk of chain jamming.
Mechanical overload device (clutch)
Disc brake(s) are located after the motor and the clutch, on a separate load path. It's directly linked to the load
and will hold the load even in case of motor or clutch failure.
Double brake
Two or three step helical gear
Sprocket on output shaft in cantilever position
Operation temperature -20°C to +40°C with rated load and speed
Hoist body has epoxy powder 70µm thickness paint, C2 according to EN12944-2 and EN12944-5
DIN type upper and lower hook
Blued black load chain
Rubber buffers on the hoist body
Handles
Maximum relative humidity 90%
Maximum altitude 1000 m
CHAINFLUX Design provides a horizontal flow of the chain as it comes off of the load wheel.This design, along
with the high strength aluminum construction, allows for a more fluid flow of the chain into the chain bagand
helps reduce the risk of chain jamming.Drain in housing to avoid water collection in load wheel compartment.
Chain guide CHAINFLUX contains drain hole, the purpose of which is to avoid water collection in load wheel
compartment.

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Electrics
Single speed motors either 1500 rpm or 3000 rpm
The Limitflux is a built-in limit switch device in the CHAINFlux MKII® that‟s allow to control setting of hoist or
hook position in industrial suspension or climbing configuration (on version B only).
Motor thermal protection, protection class IP55, tropical impregnation
Motors are TENV type with insulation class F
All components connected by plugs
Low voltage control 48 VAC or 115 VAC when hoist is configuration B
Electrics on one main printed circuit board (PCB) in configuration B
Separate brake rectifier connected to contactor
IP55 / NEMA 3R protection
Upper and lower limit switches for configuration B with industrial chain guide

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2.5 Optional features
Mechanics
BGV-D8+ ready (static safety factor 10)
Manual brake release
Upper suspension fixed eye
Hook block with safety load hook, self locking
Lockable rotation of hook forging
Soft rain cover. Hoist can be operated with rain cover fitted.
Soft rain cover
Electrics
2- or 4-step rotating geared limit switches. 4-step limit switch increases the hoist length.
2.6 Sound level
Maximum noise level: 60 dB
2.7 Certifications, standards and other technical documents
The product fulfills the requirements of the following standards: EC, CSA, ASME B30.16 and ASME HST-1.
ASME duty rating H3 or H4 depending on hoist type and hoisting speed
For information about ASME Hoist Duty Service Classification, reference ASME publication catalog ASME
HST-1M (latest edition) for electric chain hoists.
External sound level tested
RoHS compliant

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2.8 Product range
S.W.L.
*
[kg]
Frame
size
Falls
Duty group
ISO
Chain
size
Gear life
[h]
Motor type
Motor
power
[kW]
Hoisting
speed
[m/min]
Max. temp
[°C]
ED%
Starts/hour
250
SR2
1
M5
4 x 11
1600
MT07CA200
0.23
4
+40
40
240
SR2
1
M4
4 x 11
800
MT07CA104
0.45
8
+40
30
180
SR5
1
M4
5 x 14
800
MT08CA106
0.9
16
+40
30
180
500
SR5
1
M5
5 x 14
1600
MT08CA200
0.45
4
+40
40
240
SR5
1
M4
5 x 14
800
MT08CA106
0.9
8
+40
30
180
SR10
1
M4
7 x 20
800
MT10CA106
1.8
16
+40
30
180
1000
SR10
1
M5
7 x 20
1600
MT10CA200
0.9
4
+40
40
240
SR10
1
M4
7 x 20
800
MT10CA106
1.8
8
+40
30
180
1600
SR10
2
M4
7 x 20
800
MT10CA106
1.8
4
+40
30
180
2000
SR10
2
M4
7 x 20
800
MT10CA106
1.8
4
+40
30
180
*According D8
2.9 Hoist weight
Frame size
Hoist weight [kg]
Chain [kg/m]
Without chain
With 20 m of chain
Single brake
Double brake
Single brake
Double brake
SR2
20.1
21.5
27.5
28.9
0.37
SR5
29.6
30.5
41
41.9
0.57
SR10
44.8
46.8
66.8
68.8
1.1

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3MAIN COMPONENTS
3.1 Motor
3.1.1 Hoisting motors
The hoisting motor is specially designed for hoisting purposes with good efficiency. The motor has an aluminum
frame with cooling ribs for efficient cooling.
Motor type
Power
[kW]
Speed
n/rpm
Cos φ
Nbr of
pole pairs
230 V –Amps
380–415 V –Amps
Io
In
Ist
Io
In
Ist
MT07CA200
0.23
1410
0.71
2
1.2
1.4
5.1
0.7
0.8
2.9
MT07CA104
0.45
2630
0.73
1
2.6
3.2
11.2
1.5
1.8
6.6
MT08CA200
0.45
1390
0.82
2
2
2.4
10.5
1.1
1.4
6.2
MT08CA106
0.9
2850
0.77
1
3.6
4.4
18.3
2
2.5
10.5
MT10CA200
0.9
1350
0.70
2
3.3
4
16.8
1.9
2.3
9.8
MT10CA106
1.8
2780
0.68
1
7.9
9.8
33.5
3.8
4.9
20.9
* NOTE: The size of main fuse for the hoisting motors is the following:
230-240 V
380-415 V
10A gG/6A Am
6A gG/4A aM
Abbreviations
lo
Current without load
In
Nominal current
lst
Starting current

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3.2 Gear
3.2.1 Hoisting gear
The hoisting gear of the chain hoist has two or three helical steps. It is specially developed for hoisting appliances.
It is lubricated with oil in a way that will last for the designed working period of the hoist.
2-step gears
3-step gears
Frame size
Main hoisting speed [1 fall (m/min)]
Gear type
Ratio
SR2
4
2-step
39.382
SR 2
8
2-step
39.382
SR 5
4
3-step
49.894
SR 5
8
3-step
49.894
SR 5
16
3-step
25.286
SR 10
4
3-step
71.777
SR 10
8
3-step
71.777
SR 10
16
3-step
35.832
3.2.2 AGMA rating
Hoisting gears for SR 2-SR 5 are AGMA class 10 (AGMA 390.03 and AGMA 2000-A88).

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3.3 Electrics
3.3.1 Cable inputs
1
2
3
Pos.
Part
1
Free cable gland
2
Power supply
3
Control cable
* NOTE: Accepted outside diameters (O.D.) of the cable are: 15.9 mm –19.0 mm.

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3.3.2 Wiring principle –Configuration A
Pos.
Part
1
Hoisting motor
2
Main brake
3
Auxiliary brake
4
Direct control voltage board
5
Power supply
6
Pendant* or controller (option)
*Not available in North America for direct control hoist.

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3.3.3 Wiring principle –Configuration B
Pos.
Part
1
Hoisting motor
2
Thermal sensor
3
Main brake
4
Auxiliary brake
5
Limit switches
6
Control plug
7
Power plug
8
Power supply
9
Pendant or controller (option)

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3.4 Hoisting brakes
The chain hoist is equipped with a disc brake. There is one rotating disc with two lining surfaces. The brake coil is
energized by DC voltage coming from brake rectifier. The brake rectifier converts AC voltage into DC voltage. The
protection class is IP66. Rotating parts are not enclosed to ensure the self cleaning function.
The brake will last for the designed working period of the hoist. Its air gap can easily be checked at the brake coil,
through an inspection hole. The maximum possible aircap is indicated on a sticker attached to the brake and has to
be checked from there.
Brake lining criteria is indicated on the sticker placed next to the measurement hole.
In case the brake has worn more than the maximum criteria, contact authorized service personnel for brake
change.
Frame size
Brake torque [Nm/lbf]
Brake measurement [20°C]
[Nm]
[lbf]
[mm]
SR2
2.8
2.063
25.3
SR5
6.8
5.012
25.3
SR10
14
10.318
30

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3.4.1 Double brake
The main brake and auxiliary brake are assembled on the same hub. When the hoisting motion is required, the
service brake and the auxiliary brake are energized simultaneously from the brake board. When the hoisting motion
is stopped, the service brake is switched off immediately while the auxiliary brake stays energized for a few
milliseconds by the motor inductive effect.
The main brake is located in first place to allow the check of lining wear.
Frame size
Brake torque [Nm/lbf]
Main brake
Auxiliary brake
[Nm]
[lbf]
[Nm]
[lbf]
SR2
2.8
2.063
2.8
2.063
SR5
6.8
5.012
6.8
5.012
SR10
14
10.348
14
10.318
The double brake extends hoist length as follows:
Frame size
Length extension [mm]
SR2
52
SR5
30
SR10
52

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3.4.2 Brake coil voltages and resistance
Brake coil voltage
Motor voltage [Vac]
Frequency [Hz]
Brake voltage [Vd])
208V
3 phases
60
103
208V-230V / 460V reconnectable
3 phases
60
190
380V-415V
3 phases
50/60
190
440V-480V
3 phases
60
190
All values are also considered as +/-10% of nominal voltage.
Brake coil resistance
Frame size
Brake type
Brake torque
Rated voltage [V]
Coil resistance
[Nm]
[lbf]
min. [Ohm]
max. [Ohm]
SR 2
BFK457-06
2.8
2.063
103
496.6
564.9
SR 2
BFK457-06
2.8
2.063
190
1661
1949
SR 5
BFK457-06
6.8
5.012
103
496.6
564.9
SR 5
BFK457-06
6.8
5.012
190
1661
1949
SR 10
BFK457-08
14
10.318
103
398.9
449.8
SR 10
BFK457-08
14
10.318
190
1366
1552

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3.5 Overload device: Slipping clutch
The overload protection of the unit is ensured through a direct acting limiter of slipping clutch type. This device is
according to EN14492-2 requirements for such units.
It is set in such a way that it allows the unit to lift a load corresponding to the dynamic test load (110% –125% of
SWL) and prevents the unit from lifting a load of 160% of SWL.
The construction is such that the brake holds the load without any interaction with the clutch when the brake is not
energized. The wet clutch is situated inside the gear case.
Pos.
Part
1
Setting screw
2
Belleville washers
3
Clutch discs with lining

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3.6 Limit switch (on B version)
3.6.1 Micro switch operated limit switch with industrial chain guide (Std)
The lifting hook’s maximum up and down positions are secured by the electric limit switch located under
the chain guidance system.
The switches are activated alternately by the lifting hook’s upper cone and the slack fall stop.
electric limit switch