Verlinde STAGEMAKER MASTER SM5 Series User manual

VERLINDE reserves the right to alter or amend the above information without notice. 11/2008
STAGEMAKER®
-
MASTER SM5
English
-
-
-
18.9.2008
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: [email protected]

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VERLINDE reserves the right to alter or amend the above information without notice. 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
4Guarantee.......................................................................................................................................8
5Acceptance of the material...........................................................................................................9
6Description – tecnical charactéristics.......................................................................................10
6.1 Types de palans......................................................................................................................10
6.2 Main sub-assembly.................................................................................................................11
6.3 Operation of the hoist..............................................................................................................12
6.4 Hoist dimensions and weight..................................................................................................12
6.5 Attachment of the hoist...........................................................................................................13
6.6 Environmental data.................................................................................................................13
6.7 Main sub-assembly (Double brake)........................................................................................14
6.8 Operation of the hoist..............................................................................................................15
6.9 Hoist dimensions and weight..................................................................................................16
6.10 Attachment of the hoist........................................................................................................16
6.11 Environmental data..............................................................................................................16
6.12 Printed circuit board (2 lifting speeds with emergency stop) ...............................................17
6.13 Electric board (direct voltage control ACF)..........................................................................18
6.14 Printed circuit board (1 lifting speed – 1 phase DVC)..........................................................19
6.15 Main sub-assembly..............................................................................................................20
6.16 Operation of the hoist..........................................................................................................21
6.17 Hoist dimensions and weight...............................................................................................21
6.18 Attachment of the hoist........................................................................................................22
6.19 Environmental data..............................................................................................................22
6.20 Description of Gear limit switch ...........................................................................................23
6.21 Description of the Gear limit switch (stepless).....................................................................24
7Installation of hoist (3 phases)...................................................................................................25
7.1 Electricity.................................................................................................................................25
7.1.1 Electrical connection ........................................................................................................26
7.1.2 Connection :.....................................................................................................................26
8Installation of hoist – stepless (3 phases) ................................................................................27
8.1 Electricity.................................................................................................................................27
8.1.1 Electrical connection ........................................................................................................27
8.1.2 Connection :.....................................................................................................................28
8.2 Lifting assembly......................................................................................................................29
8.2.1 Slack fall stop (in the chain bucket)..................................................................................29
8.2.2 Chain bucket ....................................................................................................................30
9Installation of hoist (1 phase).....................................................................................................31
9.1 Electricity.................................................................................................................................32
9.1.1 Electrical connection ........................................................................................................32
9.1.2 Connection :.....................................................................................................................32
10 Maintenance – Replacement of hoist.....................................................................................34
10.1 Maintenance table...............................................................................................................34

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10.2 Lubricants............................................................................................................................34
10.3 Brake/slipping clutch assembly ...........................................................................................35
10.3.1 Operation ......................................................................................................................35
10.3.2 Adjustment of the slipping clutch:..................................................................................35
10.3.3 Adjustment of the brake................................................................................................36
10.4 Thickness of brake lining.....................................................................................................36
10.5 Chain...................................................................................................................................36
10.5.1 Removal of the chain ....................................................................................................36
10.5.2 Replacement of the chain .............................................................................................37
10.5.3 Measuring the wear on the chain..................................................................................38
10.6 Suspension hook.................................................................................................................38
10.6.1 Measurement of the wear on the suspension and lifting hooks....................................38
10.7 Spare parts replacement table ............................................................................................39
10.8 Screw tightening torques (Nm)............................................................................................39
10.9 Discarding the hoist.............................................................................................................39
11 Maintenance – Replacement of hoist (inverter Æ250kg)......................................................40
11.1 Maintenance table...............................................................................................................40
11.2 Lubricants............................................................................................................................40
11.3 Brake/slipping clutch assembly ...........................................................................................41
11.3.1 Operation ......................................................................................................................41
11.3.2 Adjustment of the slipping clutch :.................................................................................41
11.4 Chain...................................................................................................................................42
11.4.1 Removal of the chain ....................................................................................................42
11.4.2 Replacement of the chain .............................................................................................42
11.4.3 Measuring the wear on the chain..................................................................................43
11.5 Suspension hook.................................................................................................................43
11.5.1 Measurement of the wear on the suspension and lifting hooks....................................44
11.6 Spare parts replacement table ............................................................................................45
11.7 Screw tightening torques (Nm)............................................................................................45
11.8 Discarding the hoist.............................................................................................................45
12 Maintenance – Replacement of hoist (inverter) ....................................................................46
12.1 Maintenance table...............................................................................................................46
12.2 Lubricants............................................................................................................................46
12.3 Brake/slipping clutch assembly ...........................................................................................47
12.3.1 Operation ......................................................................................................................47
12.3.2 Adjustment of the slipping clutch :.................................................................................47
12.4 Chain...................................................................................................................................48
12.4.1 Removal of the chain ....................................................................................................48
12.4.2 Replacement of the chain .............................................................................................48
12.4.3 Measuring the wear on the chain..................................................................................49
12.5 Suspension hook.................................................................................................................50
12.5.1 Measurement of the wear on the suspension and lifting hooks....................................50
12.6 Spare parts replacement table ............................................................................................50
12.7 Screw tightening torques (Nm)............................................................................................51
12.8 Discarding the hoist.............................................................................................................51
13 – Troubleshooting (3 phases).................................................................................................52
14 – Troubleshooting (1 phase)...................................................................................................53
15 – Troubleshooting (stepless)..................................................................................................54
16 - Illustrated catalogue..............................................................................................................55
16.1 Casings................................................................................................................................55
16.2 Mechanism / brake (3 phases) ............................................................................................57
16.3 Double Brake Mechanism ...................................................................................................58
16.4 Mechanism / brake (Stepless).............................................................................................59
16.5 Lifting assembly...................................................................................................................60

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16.6 Lifting assembly...................................................................................................................62
16.7 Lifting assembly...................................................................................................................64
16.8 Lifting assembly...................................................................................................................66
16.9 Electric box (3 phases)........................................................................................................68
16.10 Electric box (Stepless).........................................................................................................69
16.11 Standard limit switch up and down......................................................................................70
16.12 Gear limit switch (OPTION).................................................................................................71
16.13 Adjust limit switch (Stepless)...............................................................................................72
16.14 Mechanism / brake (1 phase)..............................................................................................73
16.15 Electric box (1 phase DVC) .................................................................................................74

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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.

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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.
Do not use the hoist with a power supply that is different to the one recommended (under-voltage or
over-voltage, absence of phase...).
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.

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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...).
Never pull the load slantwise.

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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

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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.

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6 Description – tecnical charactéristics
6.1 Types de palans
Type Load
Kg Number of
falls
Speed
m/min
(50Hz)
Speed
ft/min
(60Hz)
Motor
power
kW
Speed
reducing ratio FEM Group Chain
d / t
SM5 254 m1 250 1 4 16 0.42 43 1Bm 4,8 / 12,5
SM5 258 m1 250 8 32 0.85 43 1Bm 4,8 / 12,5
SM5 504 m1 500 4 16 0.42 43 1Bm 4,8 / 12,5
SM5 508 m1 500 8 32 0.85 43 1Bm 4,8 / 12,5
SM5 1004 m1 1000 2 4 16 0.85 43 1Bm 4,8 / 12,5
SM5 1002 m1 1000 2 8 0.42 43 1Bm 4,8 / 12,5
)The slipping clutch is factory adjusted at a value of 140% (+/- 5%) of a nominal load. Then, for
the maintenance operations, the setting value is 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.

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6.2 Main sub-assembly
1 Main casing 4 Chain sprocket with output shaft
2 Gears 5 Chain guide
3 Brake/slipping clutch/housing assembly 6 Electrical box
,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.

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6.3 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.
6.4 Hoist dimensions and weight
Refer to dimensional drawings
1 2 3 4

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6.5 Attachment of the hoist
•1. Suspension hook
•2. Base mounting
•3. Suspension L or // attachment using the coupling part
6.6 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 : 70 decibels

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6.7 Main sub-assembly (Double brake)
1 Main casing 4 Chain sprocket with output shaft
2 Gears 5 Chain guide
3 Brake/slipping clutch/housing assembly 6 Electrical box
,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
6
5

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6.8 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.
1 2 3 4

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6.9 Hoist dimensions and weight
Refer to dimensional drawings
6.10 Attachment of the hoist
•1. Suspension hook
•2. Base mounting
•3. Suspension L or // attachment using the coupling part
6.11 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 : 70 decibels

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6.12 Printed circuit board (2 lifting speeds with emergency stop)
HOIST SUPPLY PRINTED CIRCUIT BOARD
L1 hoist supply Terminal (1)
L2 hoist supply A Trolley
L3 hoist supply 11 0 V common
BR1 _brake 12 48 V Control power supply
BR2 + brake 13 F high speed
BR3 _ 2nd brake (OPTION) 14 D2 left
BR4 + 2nd brake (OPTION) 15 D1 right
1W motor supply B Control box
2W motor supply 1 Control power supply
1V motor supply 2 lifting
2V motor supply 3 lowering
1U-L01 motor supply 4 hoisting speed selector
2U-L01 motor supply 5 emergency stop
GROUND WIRES 6 right, electric trolley
ground terminal, 4 connections (see previous page) 7 left, electric trolley
PE motor 8 travelling speed selector
PE p.c. board (K10) C Options
PE trolley connection 30-31 thermal protection (replace the shunt)
PE power supply 20-21 top limit switch (replace the shunt)
TROLLEY CONNECTION (X24) 22-23 bottom limit switch (replace the shunt)
L01 electric trolley supply Fuse (2) See electric drawings
L02 electric trolley supply K10 Emergency stop contactor
L03 electric trolley supply K21 Lifting contactor
K22 Lowering contactor
K25 Reversal contactor
T100 Control transformer

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6.13 Electric board (direct voltage control ACF)
ACF board
The ACFG board controls electronically the brake. It enables a rapid brake acceleration. (As the hoist
is not equipped with contactor control electric’s)
ACF Card
1 Hoisting speed
(1) Connection to be done
2 Hoisting speed
Power supply 1 speed
Power supply 2 speeds
1 speed motor
2 speed motor Brake 1
Brake 2 (Option)
Reconnectable 1 speed motor
Brake 1
Brake 2
Delay
Star connection 400 Vac
Triangle connection 230 Vac
Motor Phases
CE male plug
Brake 1
Brake 2 (Option)
Delay
Delay

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6.14 Printed circuit board (1 lifting speed – 1 phase DVC)
HOIST SUPPLY PRINTED CIRCUIT BOARD
L1 ou N Hoist supply or neutral Power supply
L2 Hoist supply KAU-1 Hoist supply L1 or N
BR1 _ Brake KAU-3 Hoist supply L2
BR2 + Brake
U1 Winding motor U wire 1 Terminal
V1 Winding motor V wire 1 1 Terminal for U1 et V1 of the motor
U2 Winding motor U wire 2 2 Terminal for capacitor and loading resistor
V2 Winding motor V wire 2 3 Terminal for U2 of the motor
4 Terminal for V2 of the motor
GROUND WIRES 5 Terminal for + of the brake
ground terminal, 2 connections 6 Wire 1 and 2 for brake rectifier
PE motor
PE power supply ELEMENTS
C1 Brake rectifier
C10 Main capacitor
C11 Auxilary capacitor
KAU Emergency stop contactor
R10 Unloading resistor of C10
R11 Unloading resistor of C11
C10 C11
R10 &
R11

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6.15 Main sub-assembly
1 Main casing 4 Electrical box
2 Gears 5 Brake flange
3 Brake/slipping clutch/housing assembly
,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.