Yale SLE 3 User manual

ba-o.4.1.3-en-2.2-y
Before installing hoist, fill in the information below.
Refer to the Hoist and Motor data plates.
Model No. _____________________________________
Serial No. _____________________________________
Purchase Date _____________________________________
Voltage _____________________________________
Rated Load _____________________________________
Follow all instructions and warnings for inspecting, maintaining and operating this product.
The use of any hoist presents some risk of personal injury or property damage. That risk is greatly increased if proper
instructions and warnings are not followed. Before using this hoist, each operator should become thoroughly familiar with all
warnings, instructions and recommendations in this manual. Retain this manual for future reference and use.
Forward this manual to operator. Failure to operate equipment as directed in manual may cause injury.
Electronic Control Unit SLE 3
Operation Manual

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Contents
1General information .......................................................................................................................................................................................... 5
1.1 General information on these operating instructions.................................................................................................................................. 5
1.2 Contents of the operating instructions .......................................................................................................................................................... 5
1.3 Approvals / Test marks..................................................................................................................................................................................... 5
1.4 Disclaimer / Loss of warranty .......................................................................................................................................................................... 5
1.5 Symbols.............................................................................................................................................................................................................. 6
1.6 Target group....................................................................................................................................................................................................... 7
1.7 Warranty claims................................................................................................................................................................................................. 7
1.8 Misuse................................................................................................................................................................................................................. 7
1.9 Commissioning / Operation / Documentation............................................................................................................................................... 7
1.10 Standards and directives.................................................................................................................................................................................. 8
1.11 Intended use....................................................................................................................................................................................................... 8
2General safety instructions.............................................................................................................................................................................. 9
2.1 Installation requirements.................................................................................................................................................................................. 9
2.1.1 Protective conductor .................................................................................................... 9
2.2 Residual risks................................................................................................................................................................................................... 10
3Product and functional description .............................................................................................................................................................. 11
3.1 Description ....................................................................................................................................................................................................... 11
3.2 Load sensor...................................................................................................................................................................................................... 11
3.3 Front view......................................................................................................................................................................................................... 12
3.4 Block diagram SLE 3....................................................................................................................................................................................... 13
3.5 Schematic circuit diagram ............................................................................................................................................................................. 14
3.6 Safety functions............................................................................................................................................................................................... 14
3.6.1 Overload cut-off.......................................................................................................... 14
3.6.2 Sensor errors.............................................................................................................. 15
3.7 Control and monitoring functions................................................................................................................................................................. 15
3.7.1 Actuation..................................................................................................................... 15
3.7.2 Relay outputs ............................................................................................................. 16
3.7.3 Motor management.................................................................................................... 16
3.7.4 Operating time counter .............................................................................................. 18
3.7.5 Temperature monitoring for hoist and travel motors................................................. 18
3.7.6 Signaling relays.......................................................................................................... 19
4Installation ........................................................................................................................................................................................................ 20
4.1 Dimensions....................................................................................................................................................................................................... 20
4.2 Attachment possibilities................................................................................................................................................................................. 20
4.3 Cable connection............................................................................................................................................................................................. 20
4.4 Cables ............................................................................................................................................................................................................... 20
4.5 Mounting........................................................................................................................................................................................................... 20
5Commissioning, tests, settings and maintenance ..................................................................................................................................... 21
5.1 Commissioning and regular tests................................................................................................................................................................. 21
5.2 Change to the cut-off point ............................................................................................................................................................................ 22
5.3 Settings............................................................................................................................................................................................................. 22
5.3.1 Testing bay function................................................................................................... 22
5.3.2 Activating the testing bay function ............................................................................. 23
5.4 Crane test.......................................................................................................................................................................................................... 24
5.4.1 Activation of the function "Crane test": ...................................................................... 24
5.4.2 Deactivation of the crane test .................................................................................... 24
5.5 Documentation of changes to the cut-off point .......................................................................................................................................... 25
5.6 Device or sensor replacement....................................................................................................................................................................... 26
5.7 Maintenance..................................................................................................................................................................................................... 26
5.8 Wear parts ........................................................................................................................................................................................................ 26
6Error and warning messages, faults............................................................................................................................................................. 27
6.1 Operation.......................................................................................................................................................................................................... 27
6.2 Error state indicators ...................................................................................................................................................................................... 28
6.3 Warning messages.......................................................................................................................................................................................... 29
7Decommissioning............................................................................................................................................................................................ 30
8Technical data.................................................................................................................................................................................................. 31
8.1 Rating plates .................................................................................................................................................................................................... 33

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8.2 Type designation............................................................................................................................................................................................. 33

1 General information
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1General information
1.1 General information on these operating instructions
These operating instructions serve as safety manual in the sense of the safety stand-
ards for functional safety of the SLE 3 electronic control unit for the manufacturer's
hoists. They are aimed at the manufacturers, operators, commissioning engineers and
service personnel of hoists.
They contain requirements and information on intended use of the safety-based control
unit.
They must be available to the technical personnel of the machine manufacturer or
machine operator during the complete period of use and be followed at all times for
assembly, electrical installation, configuration, commissioning, maintenance and
diagnosis.
The safety instructions must be followed.
The chapter "Safety instructions" in the original operating instructions for the hoist
contains further requirements, and the chapter "Electrical installations" provides further
information and explanations, which must also be followed.
1.2 Contents of the operating instructions
These operating instructions contain information on the following subjects:
•Safety instructions
•Product and functional description
•Installation
•Commissioning and settings
•Testing
•Maintenance
•Error and warning messages, faults
•Decommissioning
•Technical data
•Approvals
The necessary expertise needed for planning and use of protective devices is not given
or imparted in the operating instructions.
1.3 Approvals / Test marks
See chapter - Technical data.
1.4 Disclaimer / Loss of warranty
The fundamental requirement for safe operation and achievement of the specified
product properties and performance features is:
•compliance with the operating instructions.
•Non-compliance will lead to a loss of liability and the warranty for the device and
hoist.

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1.5 Symbols
The safety instructions in the manual are subdivided according to the severity of
the hazard and the likelihood of it occurring.
The measures described to avoid the hazards must be followed.
DANGER
This symbol warns of a direct danger to the health and life of people.
Disregarding these warnings will lead to severe injuries, possibly also death.
WARNING
This symbol warns of possibly dangerous situations for the health and life of people.
Disregarding these warnings can lead to severe injuries, possibly also death.
CAUTION
This symbol warns of possibly dangerous situations for the health of people.
Disregarding these warnings can lead to injuries.
ATTENTION
This symbol warns of property and environmental damage.
Specific symbols:
Warning of electrical voltage
Covers such as hoods and lids marked with this symbol may only be opened by "electri-
cally skilled persons or competent persons".
Touching live parts can lead directly to death.
Warning of a suspended load
Any lingering of people under a suspended load is prohibited.
There is a danger of injury and death!
Warning of hand injuries
Danger of crush and cut injuries to the hands and fingers. The personal protective
equipment required for the specified activity should be worn to avoid injuries.
Requirements / Recommendation
Especially important information and tips for use of the product.

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1.6 Target group
ATTENTION
All work for installation and troubleshooting must be carried out by an electrically
skilled person, commissioning and maintenance by a competent person.
Electrically skilled person
An electrically skilled person is a person who on account of his technical training has
knowledge of and experience with electrical systems and, knowing the applicable
standards and regulations, is able to assess the work assigned to him and identify and
avert possible dangers.
The electrically skilled person must be familiar with operation of the product and
trained in this.
Definition of a competent person
A competent person is a person who on account of his vocational training, vocational
experience and recent vocational activity has the necessary technical knowledge to
test the equipment.
This person must be able to assess the safety of the system in dependence on the
case of use. Competent persons authorised to carry out certain maintenance work on
our products are the manufacturer's service technicians and trained technicians with
certificate.
1.7 Warranty claims
WARNING
Prerequisite for trouble-free operation of the device and fulfilment of warranty claims is
compliance with the operating instructions.
•Read the operating instructions before you work with the device.
•Always only use the device for its intended purpose. Pay attention to the contents in
the sections "Technical data", "Intended use" and "Misuse", particularly to the condi-
tions for transport, storage, installation, commissioning and operation.
•These operating instructions only describe the basic functions of the device.
•Do not open the enclosure to make unauthorised changes to the device.
•Always switch off the power supply when carrying out maintenance work (e.g.
replacement of the device).
1.8 Misuse
WARNING
They device may only be used according to the instructions and information in this
manual.
1.9 Commissioning / Operation / Documentation
WARNING
The SLE 3 only achieves its safety function when it has been programmed accordingly.
The commissioning of a hoist must be documented. This documentation must also
contain the overload cut-off point. The signature of the qualified person and the operator
is needed after commissioning (section “Commissioning and testing”).

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1.10 Standards and directives
ATTENTION
Hoists in which SLE control equipment is installed are subject to the following directives
•Machinery Directive 2006/42/EC and
•EMC Directive 2014/30/EU
The SLE 3 was built in accordance with the following valid European standards and
regulations:
•IEC / EN 60204-32 –"Safety of machinery –Electrical equipment of machines –Part
32: Requirements for hoisting machines"
•EN 14492-2 –"Cranes –Power driven winches and hoists –Part 2: Power driven
hoists"
•ISO / EN 13849-1 –"Safety of machinery –Safety-related parts of control systems –
Part 1: General principles for design"
1.11 Intended use
ATTENTION
The SLE 3
•may only be used for control of a manually controlled single hoist from the manufac-
turer.
•is intended for industrial installations and may only be used in accordance with the
information in the technical documentation and the information on the rating plate.
•contains a safety-related overload cut-off that can, with due regard to the corre-
sponding standards specifically applicable to the machines / systems, be used for
the above-mentioned machines and systems in conjunction with a load sensor (see
chapter "Load sensor" for specification) up to category 2, PL d, according to
EN 13849-1.
•is a configurable device that only performs the safety functions after setting of the
safety-related parameter "Overload cut-off point"; this parameter may only be
changed by a competent person.
•is used in the control equipment as a central safety device for overload protection.
•is used in the hoist control equipment to actuate the motor.
•monitors the temperature of the motor by means of a thermistor (PTC).
ATTENTION
•The circuit diagrams and schematic circuit diagrams delivered with the hoist must be
observed and implemented in control equipment built by the customer.
•When integrating the control equipment delivered by the manufacturer in a general
control system or higher-level PLC, the product standards for hoists and the tech-
nical specifications regarding the functionality, signal sequence and timing of the de-
vice must be followed.
•The plant manufacturer is responsible for the overall system.
All faults and warnings that are indicated must be corrected immediately. If this is not
possible, the device, and therefore also the hoist it controls, must be taken out of service
until the fault has been corrected.
CAUTION
Any other use of the device or changes to the device itself, also during assembly
and installation, will lead to the loss of all warranty claims against the manufactur-
er.

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2General safety instructions
WARNING
You must follow the safety instructions:
•National and international directives and regulations must be followed for assembly,
commissioning, operation and period tests, in particular the Machinery Directive
2006/42/EC, safety rules and country-specific safety regulations.
•The manufacturer and operator of the machine / system must coordinate and observe
all applicable safety regulations with the responsible authorities on their own respon-
sibility.
•Detailed instructions for commissioning and tests are described in chapter 5.
2.1 Installation requirements
WARNING
For applications with the device, observe the following guidelines on electrical installation.
•Switch cabinet assembly, protection at least IP54.
•Implement wiring according to EN 60204-32.
•The load sensor cable must be shielded. Connect the shield to earth potential.
Observe the information in the chapter "Installation".
•The fuse may not exceed the value in the table "Technical data".
NOTICE
Sensor cables must be installed separately of main power cables, e.g. in spatially sepa-
rate ducts or bundles.
2.1.1 Protective conductor
WARNING
With a missing protective conductor, an electric shock hazard exists. Material damage,
severe injuries or death can result.
➢Connect the external protective earth system (PE) close to the terminals of the
phase conductor using a protective conductor for each mains connection.
Without a protective earth connection, malfunctions can arise during operation. The
protective earth connection facilitates protective equipotential bonding for protection
against electric shocks, as well as functional equipotential bonding for the avoidance of
electrical interference effects on electronic systems.

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2.2 Residual risks
WARNING
Unexpected start-up:
•Is prevented after the power supply is restored.
•The actuation control must also ensure this.
Physical injuries, e.g. crushing, severed limbs or even death.
The safety instructions are to be followed and applied!
WARNING
Direct contact with the power supply:
Deadly touch voltages can arise:
•from faulty wiring
•from not disconnecting the power supply when working on the control equipment
Physical injuries can remain, e.g. ventricular fibrillation, skin burns.
•The electrically skilled person must take this into consideration and take suitable
precautions.
WARNING
Failure of one of the downstream power elements
•Downstream power elements are not monitored by the SLE 3.
•Failure is to be prevented by the designer of the control equipment by suitable choice.
•In the event of failure the operator must have the power element replaced immediate-
ly by a competent person.

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3Product and functional description
3.1 Description
The SLE 3 is an electronic control unit for hoists. The device can be used to control pole-
changing or frequency-controlled drives. It contains a safety-related overload cut-off for
hoists in conjunction with a load sensor. It is a configurable system that only performs the
overload protection function after parameterisation and storage of the safety-relevant
parameter (overload cut-off point) in that the lifting movement is switched off safely.
The device also carries out other, non-safety related control and monitoring functions:
•Temperature monitoring for hoist and travel motors
•Display of system states via signalling relays
•Control of the lifting movements with motor management
•Counting of operating time
3.2 Load sensor
ATTENTION
The SLE 3 processes signals from passive DMS load sensors (see technical data).
The load sensor is a safety-relevant component. Due to this, only load sensors approved
by the manufacturer may be used. In the event of a defective load sensor, a sensor of
the same type must always be ordered and fitted. The load sensors are specified by the
manufacturer appropriately for the respective hoist and load and assigned internally.
Pay attention to the chapter "Device and sensor replacement" when replacing a load
sensor.
Fitting an unapproved load sensor will cancel the warranty and approval of the
device!

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3.3 Front view
Display board
S1: Selector switch motor management
S4: Setting cut-off point, rough
S2: Setting cut-off point, fine
S3: DIP switch: to activate the testing bay
functions, relay operation and motor man-
agement
S5: Enter button: e.g. crane test
WARNING
The setting of the stored cut-off point may only be changed by a qualified person.
Unauthorized changes will void the warranty!
S1
S4
Signaling and
status LEDs
S5
S3
S2

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3.4 Block diagram SLE 3
Legend
Supply
1: Power supply L
Analogue inputs load sensor
20: Ground DMS supply –S
21, 22: Load sensor input –IN / +IN
23: DMS power supply +S
2: Power supply reference point N
Actuation
3: Safety input lift S↑
4: Safety input lower S↓
5: Input fast S↕↕
Relay outputs hoist
6: Switching voltage of the relay L↑↓
7: Safety output lift slowly K↑
8: Safety output lift fast K↑↑
9: Safety output lower slowly K↓
10: Safety output lower fast K↓↓
Relay outputs cross travel
12...15 Relay outputs to
switch off the travel motors
if temperature too high left / right
1
16, 17: Thermistor input hoist motor 1
2
25, 26: Thermistor input travel motor 2
Signaling relay
27, 28: Signaling relay err
29, 30: Signaling relay option
ϑ1
ϑ2
Analogue inputs
load sensor
Signaling relay
Relay outputs
cross travel
Relay outputs
hoist
Control inputs
Power
supply
Connection terminals
Connection terminals

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3.5 Schematic circuit diagram
3.6 Safety functions
3.6.1 Overload cut-off
The overload cut-off is designed according to Performance Level d, Category 2 in
accordance with ISO 13849-1.
As shown in the schematic circuit diagram, the DMS load sensor is supplied with power
(10 VDC) via the connections +S and -S. The load-proportional signal voltage ("load
signal") of the DMS sensor is connected at the connections +IN and -IN (mV).
The overload cut-off switches off in the following cases:
•If the signal voltage between the connections IN+ and IN- exceeds the cut-off thresh-
old setting while S↑ is active, the SLE 3 detects "overload" and switches the outputs
K↑ and K↑↑ off. The outputs are blocked until no overload is detected any more.
•If the signal voltage between the connections IN+ and IN- exceeds the cut-off thresh-
old setting while the outputs K↓ and K↓↓ are active or when stationary, the SLE 3
detects "overload" after a time of 800 ms and blocks the outputs K↑ and K↑↑ until
no overload is detected any more.
As a result of internal filter functions, the maximum response time of the cut-off when
lifting a load from the ground is 500 ms. For the total response time, the elasticity of the
crane system must also be taken into consideration.
"Overload" is acknowledged when the load on the hooks drops below 82.5 % of the
maximum lifting capacity and the safety input S↓ is active for a time of at least 2 seconds.
Switching of the outputs K↓ and K↓↓ is possible when an overload has been
detected!
Op. voltage
LIFT
Op. voltage
LOWER
Op. voltage
SIGNALS
Op. voltage
DRIVE
Load sensor

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3.6.2 Sensor errors
The load signal (+IN/-IN) from the DMS sensor is processed internally in the SLE 3 on
two channels and monitored permanently.
The following three types of sensor errors are detected
•broken cable
•short circuit
•differential error between the internal measuring amplifiers in the device –internal
error.
NOTICE
See chapter "Error messages" on error diagnosis and correction.
In all three cases of sensor errors the output relays K↑ and K↑↑ are switched off in
dependence on the actuation of the safety inputs S↑ and S↕↕ and indicated as error
code by the device LEDs.
The maximum response time for cut-off of the outputs is:
▪when input S↑ active = 850 ms
▪when input S↑ not active = 1950 ms
A sensor error is acknowledged when:
•the cause of the error no longer exists and
•the sensor signal is within the function limits and
•lift S↑ is not actuated.
WARNING
It remains possible to carry out the downwards movement (switching of the out-
puts K↓ and K↓↓) in the case of an overload or sensor error so that a suspended
load can be put down if necessary!
3.7 Control and monitoring functions
3.7.1 Actuation
The safety inputs S↑, S↓ and the input S↕↕ are read in in relation to N.
S↑ and S↓ are kept in the device on two channels in both controllers and evaluated
according to Category 2 Performance Level d.
Actuation of S↕↕ is only recognised if the corresponding direction S↑ or S↓ is active at
the same time.
If S↑ or S↓ is actuated from idle state, the SLE 3 switches the respective safety output
K↑ or K↓ after a maximum delay time of 300 ms.

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3.7.2 Relay outputs
The relay outputs switch the voltage connected to L↑↓ through to the downstream
actuators (e.g. contactor). The control voltage at L↑↓ must correspond to the power
supply at L.
The safety outputs K↑ and K↑↑ are actuated by a safe internal circuit according to
Category 2 Performance Level d. This circuit switches the safety outputs K↑ and K↑↑ off
in the case of an error or overload.
The safety outputs K↓ and K↓↓ are also actuated by a safe internal circuit according to
Category 2 Performance Level d.
This circuit switches the safety outputs K↓ and K↓↓ off in the event of an error (e.g.
excessively high temperature at the hoist motor).
The safety output K↑↑ or K↓↓ is only active in conjunction with the safety output K↑ or
K↓ respectively.
3.7.3 Motor management
The term motor management relates to the off-times for the lifting and lowering move-
ments.
The off-times for the example of lifting are explained below:
Starting at slow speed ta:
If S↑ and S↕↕ are actuated together, K↑ is switched on first. At the end of the off-time ta,
K↑↑ is switched on.
Stopping at slow speed tb:
If K↑ and K↑↑ are active, the output K↑↑ is switched off first at the end of actuation of S↑
and S↕↕. After the deceleration time tbhas passed, K↑ is no longer actuated either.
Off-time for slow (ts) and fast (tf) speed:
If S↑ or S↕↕ becomes inactive, K↑ and K↑↑ are also no longer actuated. If S↑ or S↕↕ is
switched on again directly afterwards, K↑ or K↑ and K↑↑ is only actuated again at the
end of the off-time for the slow tsor fast tfspeed.
Off-time for reversal of direction tr:
When the actuation reverses direction, the hoist is first stopped and the corresponding
safety output is actuated at the end of the off-time tr.
The length of the follow-up and off-times is set with the switch S1 and
the DIP switch S3_1.
WARNING
Changes to the settings of S1 and S3_1 may only be carried out by a qualified
person!

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Motor management table
This table shows the relationship between the settings and times:
Motor type
S1
S3
ts
tf
tr
ta
tb
[ms]
[ms]
[ms]
[ms]
[ms]
Unknown
0
600
1250
1250
500
500
12/2H33
1
250
500
500
0
250
12/2H42
2
250
500
500
0
250
12/2H62
3
250
500
500
0
250
12/2H71
4
400
750
750
300
300
12/2H72
5
400
750
750
300
300
12/2H73
6
400
750
750
400
400
12/2H91
12/2H92
7
600
1250
1250
500
500
Ex-Motor
A-xxx
A
400
750
750
0
0
Frequency-
controlled
F
0
0
0
0
0
Motor management parameters for motors from Yale and third-party motors
–F= Setting for operation with a frequency inverter
–In setting 8 … E, the highest setting, as in item 7, is retained
Operation with frequency inverter
When working with a frequency inverter, the switch S1 is set to "F" and the switch S3_1
to "on".
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
ON

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3.7.4 Operating time counter
The operating time counter integrated in SLE counts the total number of hours of
operation in which the hoist motor is actuated.
3.7.5 Temperature monitoring for hoist and travel motors
Thermistor input 1
The temperature of the hoist motor is monitored by default. When the motor thermistor
(input 1) is actuated, an error is indicated by the device LEDs and all lifting movements
(outputs K↓, K↓↓ and K↑, K↑↑,) are blocked.
The load can only be moved again after cooling of the hoist motor.
Thermistor input 2
The travel motor thermistor (PTC) is connected to input 2(if two or more travel motors,
for all). When a travel motor thermistor responds, the SLE 3 switches the relay outputs
left/right off and reports this via the device LED (as warning) that the travel motor(s) can
no longer be actuated.
When the motor has cooled down, the error is acknowledged automatically by the SLE 3
and left/right is switched on again.
•All thermistors must correspond to the specifications of DIN 44080.
•All thermistors can be replaced with resistors of ~300 Ωif the motors used do not
have thermistors.
ATTENTION: The hoist or cross travel motor is then no longer protected against
overheating.
Please observe the chapter "Technical data"!
If there is no thermistor connected to 2, the warning signal can be suppressed by
switching the slide switch S3_2 on.
The relay outputs left/right are switched irrespective of this.

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3.7.6 Signaling relays
CAUTION
The signalling relays “err”and "option" are used to output error messages and may not
be used for safety-relevant functions.
The signalling relays may only be parameterised by an electrically skilled person.
Both relays can be parameterised as normally-closed or normally-open contacts:
Relay
Normally-open
Normally-closed
option
S3_7 off
S3_7 on
err
S3_6 off
S3_6 on
err is switched in every error state that stops a lifting movement.
option is freely parameterisable. Parameterisation is dependent on the switch position
S3:
DIP switch:
Switch
S3_3
Switch
S3_4
Switch
S3_5
The option relay
0
0
0
does not switch
1
0
0
switches on overload
0
1
0
switches on overheating
1
1
0
switches on sensor error
0
0
1
switches on all errors that prohibit lifting and lowering
1
0
1
Switch-off pulse on overload: option relay switches
off for 500 ms and then on again
0
1
1
switches at 95 % of nominal load
1
1
1
not used
The settings are made during initial commissioning in the factory.

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4Installation
4.1 Dimensions
•100 × 110 × 75 mm (W × H × D)
4.2 Attachment possibilities
•Snap-on attachment on 35 mm top hat rail (EN 50022-35)
•Screw attachment enclosure bottom (M4) using pull-out sliders
4.3 Cable connection
See section “Technical data”.
4.4 Cables
Install sensor cables (load sensor, temperature sensor) and power lines separately of
each other. (Example: Installation in different ducts or spatially separate bundles)
The lengths of the cables for sensors and digital control signals may not exceed the
maximum values specified in the chapter "Technical data".
4.5 Mounting
Mounting in a switch cabinet, at least IP 54.