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This equipment should not be installed, operated or
all the contents of this manual. Failure to read and comply
with the contents of this manual can result in serious bodily
EFFECTIVE: Jul y 8, 2013
SMART LIMIT
for NER2 SERIES
ELECTRIC
CHAIN HOIST
1/8 and 5 Ton Capacities
Code, Lot and Serial Number
maintained by any person who has not read and understood
injury or death, and/or property damage.
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IMPORT ANT INFORMATION ON HOW TO USE THIS MANUAL
This OWNER’S MANUAL SUPPLEMENT is intended for use in combination with the “Owner’s Manual for
Electric Chain Hoist ER2 and NER2 Series 1/8 through 5 Ton Capacity ”. Refer to the Table of Contents below to
determine the location(s) of information pertaining to your hoist. References to the “Owner’s Manual for Electric Chain
Hoist ER2 and NER2 Series 1/8 through 5 Ton Capacity” will be designated by the use of the acronym “ER2OM”.
Table of Contents
Section Page Number
1.0 Important Information and Warnings ……………………………………………………… 4 and ER2OM
1.1 Terms and Summary ER2OM
1.2 Warning Tags and Labels 4
2.0 Technical Information……………………………………………………………….………….................... 5
2.1 Specifications 5
2.2 Dimensions 5
3.0 Preoperational Procedures …………………………………………………………..…...... 6 and ER2OM
3.1 Gearbox ER2OM
3.2 Chain ER2OM
3.3 Mounting Location ER2OM
3.4 Mounting the Hoist ER2OM
3.5 Electrical Connections ER2OM
3.6 VFD Setup (Dual Speed Only) ER2OM
3.7 Preoperational Checks and Trial Operation ER2OM
3.8 Activation 6
4.0 Operation …………………………………………………………………………………... 7 and ER2OM
4.1 Introduction ER2OM
4.2 Shall’s and Shall Not’s for Operation ER2OM
4.3 Hoist Controls ER2OM
4.4 Setting and Canceling the Smart Limit 7
4.5 Calibration of the Smart Limit 7
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Section Page Number
5.0 Inspection ……………………………… …… ……… ……… …………… ………………… 8 and ER2OM
5.1 General ER2OM
5.2 Inspection Classification ER2OM
5.3 Frequent Inspection ER2OM
5.4 Periodic Inspection ER2OM
5.5 Occasionally Used Hoists ER2OM
5.6 Inspection Records ER2OM
5.7 Inspection Methods and Criteria 8
6.0 Maintenance & Handling …………………………………………………………………………... ER2OM
6.1 Count/Hour Meter ER2OM
6.2 Lubrication – Load Chain, Hooks and S uspension ER2OM
6.3 Lubrication – Gearbox ER2OM
6.4 Motor Brake ER2OM
6.5 Load Chain ER2OM
6.6 Friction Clutch and Mechanical Load Brake w ith Fricti on Clutch ER2OM
6.7 Storage ER2OM
6.8 Outdoor Installation ER2OM
7.0 Troubleshooting …………………………………………………………………...………….……. ER2OM
8.0 Warranty ……………………………………………………………………………………………. ER2OM
9.0 Parts List ……………………………………………………………………………………………………10
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1.0 Important Information and Warnings
1.2 Warning Tags and Labels
The NER2 Smart Limit tag illustrated below in Figure 1-1 is supplied with each hoist shipped from the
factory. If the tag is not attached to your hoist’s pendant cord, order a tag from your dealer and install it.
Read and obey all warnings attached to this hoist. Tag is not shown actual size.
front back
Figure 1-1 NER2 Smart Limit Tag Attached to Hoist
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2.0 Technic al Inf ormation
Temperature range:
-4° to +104°F (-20° to +40°C)
Humidity:
85% or less
Noise Level:
85 dB or less (A scale: measured 1 meter away from electric chain hoist
Enclosure Rating:
Hoist Meets IP 55
Supply Voltage:
Dual Speed Standard: 208/230V-3-60 or 460V-3-60
Limits:
Limits:
Hoist Duty Rating:
ISO M4/M5; ASME H4
Rating:
120/240 starts per hour
Rating:
2.1 Specifications
2.1.1 Product Code
2.1.2 ER2 and NER2 Models - Harrington ER2 series hoist are available in two versions, the ER2 and NER2.
Smart Limits is available with dual speed NER2 only.
2.1.3 Operating Conditions and Environment
2.2
Number of Adjustable
Precision of Adjustable
Intermittent Duty
Short Time Duty
Dimensions
All dimensions are the same as the NER dual speed hoist dimensions shown in Table 2-3 of ER2OM,
except for the following:
• For 460V-3-60 NER2003HD and NER2005SD,
o a = 22.9 in (581 mm)
o d = 12.3 in (313 mm)
• For 460V-3-60 NER2005LD,
o a = 23.0 in (584 mm)
o d = 12.3 in (313 mm)
One upper limit and one lower limit
±10mm
Dual Speed
40/20% ED
30/10 min.
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3.0 Preoperational Procedures
3.8 Activation
3.8.1
3.8.2 In order to activate the Smart Limit option, turn the piano switch on the micro-computer assembly to ON
as shown in Figure 3-10.
3.8.3
3.8.4 The length of load chain must be registered before the Smart Limits is activated. The hoist will only
operate in low speed before the length of load chain is registered. The registration procedure is as
follow:
Ensure that the voltage of the electric power supply is proper for the hoist.
Figure 3-10 Piano Switch on the Micro-Computer Assembly
Do not put a load on the hoist when registering the length of load chain.
• Turn the hoist on and open up the controller cover.
• Locate the DIP switches on the interface board shown in figure 3-11. Turn switch number 8 on
(flip up). Do not change the positions of switches 1 through 7.
• With switch number 8 on, operate the hoist in the up direction until the upper limit switch
actuates.
• Operate the hoist in the down direction until the lower limit switch actuates.
• After reaching both upper and lower limits, turn switch number 8 off (flip down).
With the length of load chain registered with the unit, the hoist will operate in high speed. The
registration will also enable the soft stop feature. The soft stop feature allows the hoist to automatically
switch to low speed near its limits (upper/lower ultimate limits and upper/lower set limits).
Turn DIP switch 8 ON.
(Flip up.)
Figure 3-11 Piano Switch on the Micro-Computer Assembly
3.8.5
been replaced.
Be sure to register the length of load chain every time the hook or the chain has
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4.0 Operation
4.4 Setting and Canceling the Smart Limit
4.4.1
4.4.2 Smart limit is adjustable from the pendant for both upper and lower limits. The setting/canceling
procedure for the Smart Limit is as follow:
• Stop hook at the desired limit position.
• Press the Emergency Stop Button.
• To set the limit:
• To cancel the limit:
• Turn the Emergency Stop Button clockwise to allow hoist operation.
Register the length of load chain before setting or canceling the Smart Limit.
o For upper limit, depress the UP button to low speed for 5+ seconds.
o For lower limit, depress the DOWN button to low speed for 5+ seconds.
o For upper limit, depress the UP button to high speed for 5+ seconds.
o For lower limit, depress the DOWN button to high speed for 5+ seconds.
4.5 Calibration of the Smart Limit
4.5.1
a loss of power.
4.5.2
To avoid a potentially harzardous situation, peform a calibration of Smart Limit after
Do not put a load on the hoist when calibrating Smart Limit.
4.5.3 In case of a power loss, the set positions of Smart Limit may change. The hoist will only operate in low
speed until it is calibrated. The calibration procedure is as follow:
• Press the Emergency Stop Button.
• Depress the UP button to the high speed for 5+ seconds.
• Turn the Emergency Stop Button clockwise to allow hoist operation.
• Operate the hoist in the UP direction until the upper limit is actuated.
• With the upper limit switch actuated, press the Emergency Stop Button.
• Depress the UP button to the low speed for 5+ seconds.
• Turn the Emergency Stop Button clockwise to allow hoist operation.
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5.0 Inspection
5.7 Inspection Methods and Criteria
5.7.1 This section covers the inspection of specific items. The list of items in this section is based on
those listed in ANSI/ASME B30.16 for the Frequent and Periodic Inspection. In accordance with
ANSI/ASME B30.16, these inspections are not intended to involve disassembly of the hoist.
Rather, disassembly for further inspection would be required if frequent or periodic inspection
results so indicate. Such disassembly and further inspection should only be performed by a
qualified person trained in the disassembly and re-assembly of the hoist.
Table 5-10 Smart Limit Components Inspection Methods and Criteria
Item Method Criteria Action
Mounting screws Visual Mounting screws should not be loose.
Smart Limit precision Function
Photosensor mount Visual Photosensor mount should not be loose.
Trigger wheel mount Visual Trigger wheel mount should not be loose.
Micro-computer
assembly mount
Lead wire guard and lea d
wires (for 1/8 ton to 1/2
ton units)
Visual Micro-computer assembly should not be loose.
Visual
Precision of Smart Limit should not exceed +/10mm (0.4in).
Lead wires should be located against the lead
wire guard to prevent them from getting
entangled with the trigger wheel.
Tighten or replace
as required.
Repair or replace
as required.
Tighten or replace
as required.
Tighten or replace
as required.
Tighten or replace
as required.
Move the wires to
proper location.
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This Page Intentionally Left Blank
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9.0 Parts List
9.7 Smart Limit Parts
Figure 9-7-1 Smart Limits Parts
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1
Photosensor Assembly
1
ER2BI1669
Machine Screw with Spring
4
Smart Limit Label
1
80469
5
Micro-computer Assembly
1
ER2BEE00I5B7
7
Micro-computer Lead Wire
2
ER2BHE03I9B3
2V
TRF32C912
9
Trigger Wheel
2
ER2BS9674
11
Smart Limit Warning Tag
1
80476
12
Smart Limit Wiring Diagram
1
ER2BHE03I9B4
9.7 Smart Limit Parts
Figure
No.
2 Spring Pin 1 ES451005S
3
Washer
6 Pan Head Machine Screw 1 J1AK23001515
8 Transformer 1
10 Socket Set Screw 1 J1TD1103008
13 Lead Wire Guard 1 ER2BI9667
Machine Screw with Spring
14
Washer
Part Name
Parts per
Hoist
1 J1AP25000808
2 MS555010
Part Number
4V TRF92N912
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9.7 Smart Limit Parts
Figure 9-7-2 Smart Limits Parts
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1
Photosensor Assembly
1
ER2BI1669
Machine Screw with Spring
4
Smart Limit Label
1
80469
5
Micro-computer Assembly
1
ER2BEE00I5B7
7
Micro-computer Lead Wire
2
ER2BHE03I9B3
2V
TRF32C912
9
Trigger Wheel
2
ER2BS9674
11
Smart Limit Warning Tag
1
80476
12
Smart Limit Wiring Diagram
1
ER2BHE03I9B4
15
Spacer C Assembly
1
4V
ER2CS5684
16
Packing C
1
4V
ER2CS9117
9.7 Smart Limit Parts
Figure
No.
2 Spring Pin 1 ES451005S
3
Washer
6 Pan Head Machine Screw 1 J1AK23001515
8 Transformer 1
10 Socket Set Screw 1 J1TD1103008
13 Lead Wire Guard 1 ER2BI9667
Machine Screw with Spring
14
Washer
17 Socket Bolt 4 4V J1BE10505518
Part Name
Parts per
Hoist
1 J1AP25000808
2 MS555010
Part Number
4V TRF92N912
13
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9.7 Smart Limit Parts
Figure 9-7-3 Smart Limits Parts
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1
Photosensor Assembly
1
ER2BI1669
Machine Screw with Spring
4
Smart Limit Label
1
80469
5
Micro-computer Assembly
1
ER2BEE00I5B7
7
Micro-computer Lead Wire
2
ER2BHE03I9B3
2V
TRF32C912
9
Trigger Wheel
2
ER2BS9674
11
Smart Limit Warning Tag
1
80476
12
Smart Limit Wiring Diagram
1
ER2BHE03I9B4
9.7 Smart Limit Parts
Figure
No.
2 Spring Pin 1 ES451005S
3
Washer
6 Pan Head Machine Screw 1 J1AK23001515
8 Transformer 1
10 Socket Set Screw 1 J1TD1103008
Part Name
Parts per
Hoist
1 J1AP25000808
Part Number
4V TRF92N912
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9.7 Smart Limit Parts
Figure 9-7-3 Smart Limits Parts
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1
Photosensor Assembly
1
ER2BI1669
Machine Screw with Spring
4
Smart Limit Label
1
80469
5
Micro-computer Assembly
1
ER2BEE00I5B7
7
Micro-computer Lead Wire
2
ER2BHE03I9B3
2V
TRF32C912
9
Trigger Wheel
2
ER2BS9674
11
Smart Limit Warning Tag
1
80476
12
Smart Limit Wiring Diagram
1
ER2BHE03I9B4
9.7 Smart Limit Parts
Figure
No.
2 Spring Pin 1 ES451005S
3
Washer
6 Pan Head Machine Screw 1 J1AK23001515
8 Transformer 1
10 Socket Set Screw 1 J1TD1103008
Part Name
Parts per
Hoist
1 J1AP25000808
Part Number
4V TRF92N912
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9.7 Smart Limit Parts
Figure 9-7-4 Smart Limits Parts
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1
Photosensor Assembly
1
ER2BI1669
Machine Screw with Spring
4
Smart Limit Label
1
80469
5
Micro-computer Assembly
1
ER2BEE00I5B7
7
Micro-computer Lead Wire
2
ER2BHE03I9B3
2V
TRF32C912
9
Trigger Wheel
2
ER2BS9674
11
Smart Limit Warning Tag
1
80476
12
Smart Limit Wiring Diagram
1
ER2BHE03I9B4
9.7 Smart Limit Parts
Figure
No.
2 Spring Pin 1 ES451005S
3
Washer
6 Pan Head Machine Screw 1 J1AK23001515
8 Transformer 1
10 Socket Set Screw 1 J1TD1103008
Part Name
Parts per
Hoist
1 J1AP25000808
Part Number
4V TRF92N912
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www.harringtonhoists.com
Harrington Hoist s, Inc. Harrington Hoi sts – Western Division
401 West End Avenue 2341 Pomona Rincon R d. #103
Manheim, PA 17 54 5-1703 Corona, CA 92880-6973
Phone: 717-665-2000 Phone: 909-279-7100
Toll Free: 800-233-3010 Toll Free: 800-317-7111
Fax: 717-665-2861 F ax: 909-279-7500
NER2SLSUP
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