Verlinde STAGEMAKER MASTER SM10 Series User manual

VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
STAGEMAKER®
-
MASTER SM10
English
-
-
-
13.11.2008
2, Bld de l’Industrie – B.P. 20059 – 28501 Vernouillet cedex – France
Téléphone: (33) 02 37 38 95 95 – Fax: [phone]
Web site : www.stagemaker.com
E-mail: cont[email protected]

STAGEMAKER®
-
--
-
2
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
13.11.2008


Read the instructions supplied with the product before installation and commissioning.


Keep the instructions in a safe place for future reference.
Table of content
1.......................................................................................................................................................... 1
2SAFETY INSTRUCTIONS............................................................................................................ 5
3Instructions for proper operation and maintenance. ............................................................... 6
3.1 Specific Instructions for Inverter ............................................................................................. 7
4Guarantee.................................................................................................................................... 9
5Acceptance of the material ...................................................................................................... 10
6Description - technical characteristics ................................................................................... 11
6.1 Types of hoist....................................................................................................................... 11
7Description - technical characteristics (SM Stepless) ........................................................... 13
7.1 Types of hoist....................................................................................................................... 13
7.2 Main sub-assemblies............................................................................................................ 14
7.3 Operation of the hoist........................................................................................................... 15
7.4 Hoist dimensions and weight................................................................................................ 15
7.5 Attachment of the hoist......................................................................................................... 16
7.6 Environmental data .............................................................................................................. 16
7.7 Main sub-assemblies (Double brake) ................................................................................... 17
7.8 Operation of the hoist........................................................................................................... 18
7.9 Hoist dimensions and weight................................................................................................ 18
7.10 Attachment of the hoist ..................................................................................................... 19
7.11 Environmental data ........................................................................................................... 19
7.12 Main sub-assemblies (Stepless)........................................................................................ 20
7.13 Operation of the hoist........................................................................................................ 21
7.14 Hoist dimensions and weight............................................................................................. 22
7.15 Environmental data ........................................................................................................... 23
7.16 Printed circuit board (2 lifting speeds with emergency stop).............................................. 24
7.17 Electric board (direct voltage control ACF) ........................................................................ 25
7.18 Main sub-assemblies (Stepless)........................................................................................ 26
7.19 Operation of the hoist........................................................................................................ 27
7.20 Hoist dimensions and weight............................................................................................. 27
7.21 Attachment of the hoist ..................................................................................................... 28
7.22 Environmental data ........................................................................................................... 28
7.23 Electricity (Inverter) ........................................................................................................... 29
7.23.1 Technical data –VLh 002 Inverter ............................................................................... 29
7.23.2 Basic description ........................................................................................................ 29
7.23.3 Main components ....................................................................................................... 30
7.23.4 Control methods ......................................................................................................... 30
7.23.5 Description of the control modes................................................................................. 32
7.23.6 EMC ........................................................................................................................... 33
7.23.7 Parameters adjustments............................................................................................. 34
7.23.8 Parameter descriptions............................................................................................... 36
7.23.9 Factory default parameters......................................................................................... 43
7.23.10 Speed supervision ...................................................................................................... 44
7.23.11 Drawings .................................................................................................................... 45
7.24 Description of Gear limit switch ......................................................................................... 46

STAGEMAKER®
-
--
-
3
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
8Installation of hoist (3 phases) ................................................................................................ 47
8.1 Electricity.............................................................................................................................. 48
8.1.1 Electrical connection...................................................................................................... 48
8.1.2 Connection :................................................................................................................... 48
8.2 Lifting assembly ................................................................................................................... 49
8.2.1 Slack fall stop (in the chain bucket)................................................................................ 49
8.2.2 Chain bucket.................................................................................................................. 50
9Installation of hoist (Stepless) ................................................................................................. 51
9.1 Electricity.............................................................................................................................. 52
9.1.1 START-UP PROCEDURE ............................................................................................. 52
9.1.2 Electrical connection...................................................................................................... 52
9.1.3 Connection :................................................................................................................... 52
9.1.4 Checks before the first test run ...................................................................................... 53
9.1.5 Test run without load...................................................................................................... 53
9.1.6 Test run with load .......................................................................................................... 53
9.1.7 Test run with overload.................................................................................................... 53
9.1.8 After the test run ............................................................................................................ 53
10 - Maintenance – Replacement of hoist................................................................................. 56
10.1 Maintenance table............................................................................................................. 56
10.2 Lubricants ......................................................................................................................... 56
10.3 Brake/slipping clutch assembly ......................................................................................... 57
10.3.1 Operation.................................................................................................................... 57
10.3.2 Adjustment of the slipping clutch:................................................................................ 57
10.3.3 Adjustment of the brake.............................................................................................. 58
10.4 Thickness of brake lining................................................................................................... 58
10.5 Chain ................................................................................................................................ 59
10.5.1 Removal of the chain.................................................................................................. 59
10.5.2 Replacement of the chain ........................................................................................... 59
10.5.3 Measuring the wear on the chain................................................................................ 60
10.6 Suspension hook .............................................................................................................. 60
10.6.1 Measurement of the wear on the suspension and lifting hooks ................................... 61
10.7 Spare parts replacement table .......................................................................................... 61
10.8 Screw tightening torques (Nm).......................................................................................... 62
10.9 Discarding the hoist........................................................................................................... 62
11 – Troubleshooting (3 phases)............................................................................................... 63
12 – Troubleshooting (Stepless) ............................................................................................... 64
12.1 Field repair actions............................................................................................................ 65
12.2 Typical functional problems............................................................................................... 65
12.3 Inverter fault codes............................................................................................................ 65
13 - Illustrated catalogue ........................................................................................................... 68
13.1 Casings............................................................................................................................. 68
14 - Illustrated catalogue (Stepless).......................................................................................... 71
14.1 Casings............................................................................................................................. 71
14.2 Mechanism / Brake (3 phases).......................................................................................... 73
14.3 Double Brake Mechanism ................................................................................................. 74
14.4 Mechanism / Brake (Stepless)........................................................................................... 75
14.5 Lifting assembly ................................................................................................................ 76
14.6 Lifting assembly ................................................................................................................ 78
14.7 Electric box (3 phases)...................................................................................................... 80
14.8 Electric box (Stepless) ...................................................................................................... 82
14.9 Upper and lower limit switch.............................................................................................. 84

STAGEMAKER®
-
--
-
4
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008

STAGEMAKER®
-
--
-
5
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
2 SAFETY INSTRUCTIONS


WARNING !
THE FOLLOWING INSTRUCTIONS FOR SAFE USE MUST BE FOLLOWED IN ORDER TO AVOID
PERSONAL INJURY OR MATERIAL DAMAGE
Do not let an unqualified person use the hoist.
Make sure that the safety rules are followed (personal
safety equipment, clearance of work areas, posting up of
instructions to be followed in the area...).
Always be ready during operation to press the
emergency stop button. This makes all functions
inactive.
Never lift more than the maximum working load
indicated on the hoist. Shocks or accidental collision of
the load with objects can cause excess loads.
Before operation, check that the load is correctly fastened
and installed on the hook. The hook safety latches should be
closed correctly.
Do not drive the hook block into the bottom of the hoist. Also do not drive the chain out of the
chain bag up to the slack fall stop. These may break the chain and allow the load to drop.
Never use the hoist to transport people.
Never twist the load chains (turning the hook block around...).
Never transport a load with people nearby. Do not pass the hook, with or without a load, above
a person. Never go under the load.
Never swing the load intentionally
Never remove the hook safety latches.
Never sling onto the hook jaw (as there is a risk of damage to
the hook and of the load falling).
Always lift the load from the floor. Never add load to a lifted
hook.
Do not let an unqualified person use
the hoist.
Never swing the load intentionally.

STAGEMAKER®
-
--
-
6
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
3 Instructions for proper operation and maintenance.


Follow the instructions below in order to keep your equipment in good condition and to
keep your product safe
Never move or lift the hoist by the electric cables.
Do not set down the hoist without having an adapted support,
to avoid damaging the components on the underside (electric
cable, lifting chain, cable gland, chain bucket...).
Never modify the hoist unless the constructor has studied and
authorized the modification.
Never modify the values and adjustments of the safety
components, outside the limits provided for in the manual, or
without the approval of the constructor.
Never try to repair or modify the hoist without the
authorization of the constructor or a trained maintenance
agent.
Never block, adjust or remove the limit switches or stops
installed on the hoist without the authorization of the
constructor or a trained maintenance agent.
Never use the hoist to extract, loosen, or pull sideways.
Do not touch the moving components.
Do not operate the hoist if your physical condition does not allow it.
Never use the hoist when in bad repair (wear, deformation...).
Do not subject the hoist to brutal shocks.
Never use the lifting chain as a sling
Never use a hook other than in the vertical position.
Never distract the operator while the hoist is being operated.
Never leave a suspended load hanging, if it is not
necessary.
Never use the hoist as an earth reference for welding.
Do not use the hoist for a purpose or in an area for which it is not intended.
If manually moving the hoist, push the load.
Do not use the safety components (end buffers, emergency stop,…) as operation components.
Do not use the controls needlessly (avoid inching - stop-start operation of the buttons). This can
cause overheating and even damage to the hoist.
Make sure that the hoist is always clean.
If manually moving the hoist, push the load *
Material used outdoors should be
protected as well as possible
against bad weather conditions.

STAGEMAKER®
-
--
-
7
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
Do not use the hoist with a power supply that is different to the one recommended (under-voltage or
over-voltage, absence of phase...).
Handle the hoist by its structure, or by the devices provided for this purpose, or in its original packing.
Do not expose the hoist to an aggressive atmosphere (temperature, acidity...).
Make sure that the hoist is always clean and protected from corrosion (lubrication...).
Use the material under normal working conditions (ambient temperature, atmosphere...). Material
used outdoors should be protected as well as possible against bad weather conditions. The hoist should
be covered to avoid water going inside the chain bucket. In outdoor use a drain hole must be made to
the chain bucket’s bottom.
Store the hoist in its normal operating position (without load) away from aggressive atmospheres
(dust, humidity...).
The hoist should be installed by a competent person
Make sure that the hoist attaching and supporting structure is rigid.
The hoist should be maintained regularly, following the instructions in this manual.
Keep the moving components including the chain clean and oiled as indicated in this manual. The
components should only be replaced by original parts that are compatible with the type of hoist. Never
use suspect spare parts or parts whose origin is not known.
Make sure that the limit stops are in place.
Never pull the load slantwise, maximum angle 3 degrees.
Make sure that the load is correctly balanced before moving it.
Avoid lifting using only one point of the load. Use adequate
accessories (slings, lifting beam...). Pay attention to the center of
gravity of the load to be moved.
The elements used to hang the load should be free in relation to
the load to be moved (prefer a sling to a rigid beam).
When moving the load, make sure that it is sufficiently raised and
clear of surrounding machines and other objects.
Make sure that the hoist is vertical to the load before hoisting.
Avoid swinging the load or the hook when using the travelling
trolley or crane. In the case of several speeds, do the starting and
braking operations at low speed.
The use of several machines to move a single load should be
done by an experienced supervisor. All the necessary precautions
should be taken to carefully ensure the distribution of the loads and to avoid overloading a single
machine. The machines should be carefully checked before such an operation.
Notify the necessary people after a dangerous operation or if the hoist seems problematic (abnormal
noise, abnormal behaviour...).
3.1 Specific Instructions for Inverter


Check the device cover is properly installed.


High voltages are present in this device. Switch the power off and after the display turns
off, wait 5 minutes before opening the cover.


Insulation resistance test with a megger multimeter requires special precautions.


Do not make any measurements inside the device when it is connected to the main
supply.


Do not touch the components on the circuit boards. Electrostatic discharge may cause
damage or destroy the IC-circuits.
Never pull the load slantwise.

STAGEMAKER®
-
--
-
8
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008


Check all ventilation holes are clear and unobstructed.


Check that hot air coming from the brake resistors does not cause any danger.


It is forbidden to use radiophones or portable phones near this device with the doors
open.


Drive is not intended to be used in a low-voltage public network, which supplies
domestic premises. Radio frequency interference is expected if used in such a network.

STAGEMAKER®
-
--
-
9
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
4 Guarantee
Our electric chain hoists are guaranteed for two years from the date of delivery.
If for a reason outside the control of the vendor, the delivery is delayed, the time lag cannot exceed
three months.
If the use (installation) of the hoist is delayed, the corresponding extension of the guarantee (a single
extension limited to three months) must be requested, and written confirmation obtained.
The vendor undertakes to eliminate all operating errors originating from the concept, the execution,
the components or the materials themselves.


The guarantee does not cover normal wear, nor the failures resulting from lack of regular
and periodic maintenance. It does not cover damage due to a lack of supervision, to false
operation or to a bad utilization of the hoists, particularly due to overload conditions,
slantwise drawing, undervoltage or overvoltage or a connection error.
The guarantee does not apply when there is disassembly, modification or replacement of parts
(mechanical or electrical) by an unauthorized party or without our prior agreement.
The guarantee only applies for original, factory-installed spare parts.
For the duration of the guarantee, the vendor undertakes to replace or repair, free of charge, the parts
that are acknowledged to be damaged following examination by a qualified and authorized technical
service.
The guarantee excludes any other services or indemnities. The repairs covered by the guarantee are
carried out, as a rule, in the workshops of the vendor or authorized agent. When servicing of the
equipment is done outside these workshops, the labor costs for disassembly or assembly of these
parts are borne by the vendor when these are done exclusively by his staff or by an authorized agent.
The replaced parts become the property of the vendor and must be returned to the vendor at his
expense.
For components of a relative particular importance that are not manufactured by the vendor and
which carry the brand name of specialized manufacturers, the manufacturer’s guarantee (which can
vary according to the manufacturer) is applicable.


The guarantee does not apply for expendable parts defined by the manufacturer :
•Lifting chain
•Chain guide
•Rubber buffer
•Sprockets
•Chain bucket
•Hooks
•Friction and brake discs
•Control box cable

STAGEMAKER®
-
--
-
10
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
5 Acceptance of the material
Visually inspect the packaging to ensure that it is intact.
If not, notify it as required.
Check that the hoist corresponds to your order.
For transport reasons the chain bucket is delivered disassembled.

STAGEMAKER®
-
--
-
11
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
6 Description - technical characteristics
6.1 Types of hoist
Type Load
kg
Load
(T)
Speed
m / min.
Speed
ft / mn
Power
mot. / kW
Brins
falls
Chain
d/t
SM10 1004 m1 1000 1 4 16 0.9 1 6,8 / 17,8
SM10 1008 m1 1000 1 8 32 1,75 1 6,8 / 17,8
SM10 2002 m1 2000 2 2 8 0,9 2 6,8 / 17,8
SM10 2004 m1 2000 2 4 16 1,75 2 6,8 / 17,8


The slipping clutch is factory adjusted at a value of 140% (+/- 5%) of a nominal load. Then for
the maintenance operations, the setting value will be 125% of the nominal load. This difference
is due to the running in of the friction lining.


EN 14492-2 standard imposes a setting value included between 110 % and 160% of the
nominal load.

STAGEMAKER®
-
--
-
12
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008

STAGEMAKER®
-
--
-
13
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
7 Description - technical characteristics (SM Stepless)
7.1 Types of hoist
Type Load
kg
Number
of falls
Speed
m/min.
Motor
power kW
Speed
reducing ratio
FEM
group
Chain
d/t
SM10 508 v2 500 1 0,5 8 1,75 / 0,45 58 2 m 6,8 / 17,8
SM10 5016 v2 500 1 1 16 1,75 / 0,45 58 2 m 6,8 / 17,8
SM10 1008 v1 1000 1 0,5 8 1,75 / 0,45 58 1 Bm 6,8 / 17,8
SM10 2004 v1 2000 2 0,25 4 1,75 / 0,45 58 1 Bm 6,8 / 17,8


The slipping clutch is factory adjusted at a value of 140% (+/- 5%) of a nominal load. Then for
the maintenance operations, the setting value will be 125% of the nominal load. This difference
is due to the running in of the friction lining.


EN 14492-2 standard imposes a setting value included between 110 % and 160% of the
nominal load. (> 1000 kg)


ATTENTION ! In case of hoist 250 kg 1 fall or 500 kg 2 falls, the slipping clutch is factory
adjusted at a value of 250% of the hoist nominal load.

STAGEMAKER®
-
--
-
14
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
7.2 Main sub-assemblies
1- Main casing 6-
1-fall hook block/hook
2- Gears 7-
2-fall hook block/hook
3- Brake/slipping clutch/housing assembly 8-
Chain bucket
4- Chain sprocket with output shaft 9-
Electric box
5- Chain guide


The hoist which you have just purchased should only be used with a maximum load
equal to the nominal load (refer to the table above).


The length of its useful service life depends on the demands placed on it, the average
operating time, the number of start-ups and its maintenance.

STAGEMAKER®
-
--
-
15
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
7.3 Operation of the hoist
Kinematic chain
1. Motor
2. Chain sprocket
3. Gear
4. Brake/slipping clutch
Technical advantage
The position of the slipping clutch allows, should it slip, the load to be held in all cases by releasing
the control box button.
7.4 Hoist dimensions and weight
For hoist with standard chain bucket.

STAGEMAKER®
-
--
-
16
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
7.5 Attachment of the hoist
1. Suspension hook
2. Base mounting
3. L or // attachment using the coupling part
7.6 Environmental data
Ambient temperature : -20°C to +40°C
Protection class : IP55 as standard
Side pulling angle : 3 degrees maximum
Impact on the environment :
Sound level : 75 decibels

STAGEMAKER®
-
--
-
17
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
7.7 Main sub-assemblies (Double brake)
1- Main casing
2- Gears
3- Brake/slipping clutch/housing assembly
4- Chain sprocket with output shaft
5- Chain guide


The hoist which you have just purchased should only be used with a maximum load
equal to the nominal load (refer to the table above).


The length of its useful service life depends on the demands placed on it, the average
operating time, the number of start-ups and its maintenance.
1
2
3
4
3
5

STAGEMAKER®
-
--
-
18
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
7.8 Operation of the hoist
Kinematic chain
1. Motor
2. Chain sprocket
3. Gear
4. Brake/slipping clutch
Technical advantage
The position of the slipping clutch allows, should it slip, the load to be held in all cases by releasing
the control box button.
7.9 Hoist dimensions and weight
For hoist with standard chain bucket.
1 2 3 4

STAGEMAKER®
-
--
-
19
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
7.10 Attachment of the hoist
4. Suspension hook
5. Base mounting
6. L or // attachment using the coupling part
7.11 Environmental data
Ambient temperature : -20°C to +40°C
Protection class : IP55 as standard
Side pulling angle : 3 degrees maximum
Impact on the environment :
Sound level : 75 decibels

STAGEMAKER®
-
--
-
20
VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
7.12 Main sub-assemblies (Stepless)
1- Main casing 6-
1-fall hook block/hook
2- Gears 7-
2-fall hook block/hook
3- Brake/slipping clutch/housing assembly 8-
Chain bucket
4- Chain sprocket with output shaft 9-
Electric box
5- Chain guide


The hoist which you have just purchased should only be used with a maximum load
equal to the nominal load (refer to the table above).


The length of its useful service life depends on the demands placed on it, the average
operating time, the number of start-ups and its maintenance.