Metalfab Electric Chain Hoist ER User Manual

Owner's Manual

ELECTRIC

CHAIN HOIST

ER and NER

SERIES

EFFECTIVE: May 28, 2004

1/8 Ton through 5 Ton Capacity

Code, Lot and Serial Number

WARNING

This equipment should not be installed, operated o maintained by any person who has not read and understood all the contents of this manual. Failure to read and compl with the contents of this manual can result in serious bodil injury or death, and/or property damage.

Table of Contents

Section Page Number

1.0 Important Information and Warnings ……………………………………………………………………… 4

1.1 Terms and Summary

1.2 Warning Tags and Labels

2.0 Technical Information…………………………………………………………………………….………….8

2.1 Specifications

2.2 Dimensions

3.0 Preoperational Procedures ……………………………………………………………………………… 12

3.1 Fill Gear Box with Oil

3.2 Chain

3.3 Mounting Location

3.4 Mounting the Hoist

3.5 Electrical Connections

3.6 Preoperational Checks and Trial Operation

4.0 Operation …………………………………………………………………………………………………...19

4.1 Introduction

4.2 Shall’s and Shall Not’s for Operation

4.3 Hoist Controls

5.0 Inspection ………………………………………………………………………………………………….. 22

5.1 General

5.2 Inspection Classification

5.3 Frequent Inspection

5.4 Periodic Inspection

5.5 Occasionally Used Hoists

5.6 Inspection Records

5.7 Inspection Methods and Criteria

Section Page Number

6.0 Maintenance & Handling …………………………………………………………………………………. 29

6.1 Count/Hour Meter

6.2 Lubrication

6.3 Motor Brake

6.4 Load Chain

6.5 Friction Clutch and Mechanical Load Brake with Friction Clutch

6.6 Storage

6.7 Outdoor Installation

7.0 Troubleshooting …………………………………………………………………………………………… 35

8.0 Material Safety Data Sheets ………………………………………………………………………………38

8.1 ER Model Gear Box Oil

8.2 NER Model Gear Box Oil

8.3 (N)ER Model Load Chain Grease

9.0 Warranty …………………………………………………………………………………………………… 51

10.0 Parts List ……………………………………………………………………………………………………53

1.0 Important Information and Warnings

1.1 Terms and Summary

This manual provides important information for personnel involved with the installation, operation and maintenance

of this product. Although you may be familiar with this or similar equipment, it is strongly recommended that you read this manual before installing, operating or maintaining the product.

Danger, Warning, Caution and Notice

Throughout this manual there are steps and procedures that can present hazardous situations. The following signal words are used to identify the degree or level of hazard seriousness.

DANGER

WARNING

CAUTION

NOTICE

Danger indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury, and property damage.

Warning indicates an imminently hazardous situation which, if not avoided, could result in death or

serious injury, and property damage.

Caution indicates a potentially hazardous situation which, if not avoided, may result minor or

moderate injury or property damage.

Notice is used to notify people of installation, operation, or maintenance information which is

important but not directly hazard-related.

CAUTION

These general instructions deal with the normal installation, operation, and maintenance situations encountered with the equipment described herein. The instructions should not be interpreted to anticipate every possible contingency or to anticipate the final system, crane, or configuration that uses this equipment. For systems using the equipment covered by this manual, the supplier and owner of the system are responsible for the system’s compliance with all applicable industry standards, and with all applicable federal, state and local regulations/codes.

This manual includes instructions and parts information for a variety of hoist types. Therefore, all instructions and parts information may not apply to any one type or size of specific hoist. Disregard those portions of the instructions that do not apply.

Record your hoist’s Code, Lot and Serial Number (see section 10) on the front cover of this manual for identification and future reference to avoid referring to the wrong manual for information or instructions on installation, operation, inspection, maintenance, or parts.

Use only Harrington authorized replacement parts in the service and maintenance of this hoist.

WARNING

Equipment described herein is not designed for and MUST NOT be used for lifting, supporting, or transporting people, or for lifting or supporting loads over people.

Equipment described herein should not be used in conjunction with other equipment unless necessary and/or required safety devices applicable to the system, crane, or application are installed by the system designer, system manufacturer, crane manufacturer, installer, or user.

Modifications to upgrade, rerate, or otherwise alter this equipment shall be authorized only by the original equipment manufacturer.

Equipment described herein may be used in the design and manufacture of cranes or monorails. Additional equipment or devices may be required for the crane and monorail to comply with applicable crane design and safety standards. The crane designer, crane manufacturer, or user is responsible to furnish these additional items for compliance. Refer to ANSI/ASME B30.17, “Safety Standard for Top-Running Single Girder Cranes”; ANSI/ASME B30.2 “Safety Standard for Top-Running Double-Girder Cranes”; and ANSI/ASME B30.11 “Safety Standard for Underhung Cranes and Monorails”.

If a below-the-hook lifting device or sling is used with a hoist, refer to ANSI/ASME B30.9, “Safety Standard for Slings” or ANSI/ASME B30.20, “Safety Standard for Below-the-Hook Lifting Devices”.

Hoists and cranes, used to handle hot molten material may require additional equipment or devices. Refer to ANSI Z241.2, “Safety Requirements for Melting and Pouring of Metals in the Metalcasting Industry”.

Electrical equipment described herein is designed and built in compliance with Harrington's interpretation of ANSI/NFPA 70, “National Electrical Code”. The system designer, system manufacturer, crane designer, crane manufacturer, installer, or user is responsible to assure that the installation and associated wiring of these electrical components is in compliance with ANSI/NFPA 70, and all applicable Federal, State and Local Codes.

Failure to read and comply with any one of the limitations noted herein can result in serious bodily injury or death, and/or property damage.

DANGER

HAZARDOUS VOLTAGES ARE PRESENT IN THE CONTROL BOX, OTHER ELECTRICAL COMPONENTS, AND CONNECTIONS BETWEEN THESE COMPONENTS.

Before performing ANY mechanical or electrical maintenance on the equipment, de-energize (disconnect) the main switch supplying power to the equipment; and lock and tag the main switch in the de-energized position. Refer to ANSI Z244.1, “Personnel Protection – Lockout/Tagout of Energy Sources”.

Only trained and competent personnel should inspect and repair this equipment.

NOTICE

It is the responsibility of the owner/user to install, inspect, test, maintain, and operate a hoist in accordance with ANSI/ASME B30.16, “Safety Standard for Overhead Hoists”, OSHA Regulations and ANSI/NFPA 70, National Electric Code. If the hoist is installed as part of a total lifting system, such as an overhead crane or monorail, it is also the responsibility of the owner/user to comply with the applicable ANSI/ASME B30 volume that addresses that type of equipment.

It is the responsibility of the owner/user to have all personnel that will install, inspect, test, maintain, and operate a hoist read the contents of this manual and applicable portions of ANSI/ASME B30.16, “Safety Standard for Overhead Hoists”, OSHA Regulations and ANSI/NFPA 70, “National Electric Code”. If the hoist is installed as part of a total lifting system, such as an overhead crane, the applicable ANSI/ASME B30 volume that addresses that type of equipment must also be read by all personnel.

If the hoist owner/user requires additional information, or if any information in the manual is not clear, contact Harrington or the distributor of the hoist. Do not install, inspect, test, maintain, or operate this hoist unless this information is fully understood.

A regular schedule of inspection of the hoist in accordance with the requirements of ANSI/ASME B30.16 should be established and records maintained.

1.2 Warning Tags and Labels

The warning 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 Warning Tag Attached to Hoist

2.0 Technical Information

2.1 Specifications

2.1.1 Product Code

2.1.2 ER and NER Models - Harrington ER series hoist are available in two versions, the ER and NER. These two versions are equipped with different options as standard equipment. The NER has a friction clutch mechanism that provides over winding protection. The ER has a mechanical load brake/friction clutch combination and an electronic count/hour meter in the control circuit. Refer to Figure 2-1 for the visual differences between the ER and NER.

Figure 2-1 Identifying ER verses NER Models

2.1.3 Operating Conditions and Environment

Temperature range: -4° to +104°F (-20° to +40°C)

Humidity: 85% or less

Enclosure Rating: Hoist Meets IP 55, Pendant Meets IP65

Supply Voltage: Standard 208-230/460V-3-60, Optional 575V-3-60, Special Voltages Available

Single Speed Dual Speed

ASME Duty Classification: H4 H4

Intermittent Duty Rating: 60% ED

360 starts per hour

Short Time Duty Rating: 60 min. 30/10 min.

40/20% ED

120/240 starts per hour

Table 2-1 Hoist Specifications

Motor

Capacity

Code

(Ton)

1/8 (N)ER001H 57 0.75 4.2 2.1 5.0 x 1 5 68 0.37

1/4 (N)ER003S 39 0.75 4.2 2.1 5.0 x 1 5 68 0.37

1/4 (N)ER003H 60 1.2 5.7 2.9 6.3 x 1 5 84 0.57

1/2 (N)ER005L 15 0.75 4.2 2.1 6.3 x 1 4 70 0.57

1/2 (N)ER005S 30 1.2 5.7 2.9 6.3 x 1 5 84 0.57

1 (N)ER010L 16 1.2 5.7 2.9 8.0 x 1 4 90 0.93

1 NER010M 24 1.9 7.3 3.7 8.0 x 1 4 110 0.93

1 (N)ER010S 29 2.4 10.5 5.3 8.0 x 1 5 134 0.93

1 1/2 (N)ER015S 20 2.4 10.5 5.3 10.0 x 1 4 152 1.5

2 (N)ER020L 14 2.4 10.5 5.3 10.0 x 1 4 154 1.5

SINGLE SPEED

2 NER020M 24 3.8 14.9 7.5 10.0 x 1 4 181 1.5

2 (N)ER020S 28 4.7 18.3 9.2 10.0 x 1 5 240 1.5

2 1/2 (N)ER025S 23 4.7 18.3 9.2 11.2 x 1 4 247 1.9

3 NER030C 12 3.8 14.9 7.5 10.0 x 2 4 216 3.1

3 (N)ER030L 16 4.7 18.3 9.2 12.5 x 1 4 256 2.3

3 (N)ER030S 22 6.2 25.1 12.6 12.5 x 1 4 269 2.3

5 (N)ER050L 12 4.7 18.3 9.2 11.2 x 2 4 306 4.0

Lifting Speed

(ft/min)

Output

(Hp)

Current Draw

(amps)

208V or

230V

460V

Load

Chain

Wire

Diameter

(mm) x

Chain

Fall

Lines

Load

Sheave

Pockets

Net

Weight

(lbs)

Weight

for One

Addnl.

FT. of

Lift

(lbs)

1/8 (N)ER001HD 58/19 0.6/0.2

1/4 (N)ER003SD 29/10 0.6/0.2 2.9/2.4 1.5/1.2 5.0 x 1 5 79 0.37

1/4 (N)ER003HD 60/20 1.2/0.4 5.7/5.1 2.9/2.6 6.3 x 1 5 104 0.57

1/2 (N)ER005LD 14/5 0.6/0.2 2.9/2.4 1.5/1.2 6.3 x 1 4 84 0.57

1/2 (N)ER005SD 30/10 1.2/0.4 5.7/5.1 2.9/2.6 6.3 x 1 5 104 0.57

1 (N)ER010LD 14/5 1.2/0.4 5.7/5.1 2.9/2.6 8.0 x 1 4 108 0.93

1 (N)ER010SD 29/10 2.4/0.8 9.1/5.7 4.6/2.9 8.0 x 1 5 152 0.93

1 1/2 (N)ER015SD 20/7 2.4/0.8 9.1/5.7 4.6/2.9 10.0 x 1 4 165 1.5

DUAL SPEED

2 (N)ER020LD 15/5 2.4/0.8 9.1/5.7 4.6/2.9 10.0 x 1 4 168 1.5

2 (N)ER020SD 29/10 4.7/1.6 19.6/9.4 9.8/4.7 10.0 x 1 5 284 1.5

2 1/2 (N)ER025SD 23/8 4.7/1.6 19.6/9.4 9.8/4.7 11.2 x 1 4 295 1.9

3 (N)ER030LD 17/6 4.7/1.6 19.6/9.4 9.8/4.7 12.5 x 1 4 300 2.3

3 (N)ER030SD 23/8 6.1/2.0 24.1/10.6 12.1/5.3 12.5 x 1 4 320 2.3

5 (N)ER050LD 12/4 4.7/1.6 19.6/9.4 9.8/4.7 11.2 x 2 4 355 4.0

2.9/2.4 1.5/1.2

5.0 x 1

5790.37

2.2 Dimensions

Figure 2-2 Hoist Dimensions (See Table 2-3)

Table 2-2 Hook Dimension*

T = Top Hook

B = Bottom Hook

Units = inch

Capacity Code Hook a b c d e g

001H, 003S, 003H,

005L, 005S

010L, 010M, 010S T & B 1.4 0.9 1.2 0.9 1.7 1.2

015S

020S, 020M, 020L T & B 1.9 1.1 1.6 1.1 2.0 1.5

025S

030C, 030L, 030S T & B 2.2 1.4 1.9 1.4 2.4 1.7

050L T & B 2.6 1.7 2.2 1.7 2.5 1.8

T 1.1 0.7 0.9 0.7 1.4 1.1

B 1.1 0.7 0.9 0.7 1.4 0.9

T 1.9 1.1 1.6 1.1 2.0 1.5

B 1.7 1.0 1.4 1.0 1.9 1.3

T 2.2 1.4 1.9 1.4 2.4 1.7

B 2.0 1.2 1.7 1.2 2.1 1.6

*Refer to Section 5.7 for inspection dimensions and limits.

SINGLE SPEED

DUAL SPEED

Hoist Code

(N)ER001H

(N)ER003S

(N)ER003H

(N)ER005L

(N)ER005S

(N)ER010L

NER010M

(N)ER010S

(N)ER015S

(N)ER020L

NER020M

(N)ER020S

(N)ER025S

NER030C

(N)ER030L

(N)ER030S

(N)ER050L

(N)ER001HD

(N)ER003SD

(N)ER003HD

(N)ER005LD

(N)ER005SD

(N)ER010LD

(N)ER010SD

(N)ER015SD

(N)ER020LD

(N)ER020SD

(N)ER025SD

(N)ER030LD

(N)ER030SD

(N)ER050LD

Table 2-3 Hoist Dimensions

Minimum

Headroom:

(in)

13.8 7.2 21.1 13.0 10.4 10.7 0.9 4.0 3.9

14.6 7.2 21.9 13.8 10.8 11.1 0.9 4.7 4.1

14.0 7.2 21.1 13.0 10.4 10.7 0.9 4.0 3.9

14.6 7.2 21.9 13.8 10.8 11.1 0.9 4.7 4.1

16.1 7.2 21.9 13.8 10.8 11.1 1.2 4.7 4.1

16.1 7.2 23.2 13.8 10.6 12.6 1.2 4.7 4.1

17.3 7.2 25.6 16.5 12.6 13.0 1.2 6.1 5.2

19.9 7.2 25.6 16.5 12.6 13.0 1.3 6.1 5.2

22.0 7.2 25.6 16.5 12.6 13.0 1.5 6.1 5.2

22.0 7.2 26.9 16.5 12.4 14.4 1.5 6.1 5.2

24.0 8.2 30.9 18.9 15.5 15.5 1.5 7.2 6.5

24.6 8.2 30.9 18.9 15.5 15.5 1.6 7.2 6.5

29.5 8.2 26.9 16.5 12.4 14.4 1.7 8.2 3.0

26.0 8.2 30.9 18.9 15.5 15.5 1.7 7.2 6.5

32.9 8.2 30.9 18.9 15.5 15.5 1.8 9.6 4.0

13.8 7.2 22.2 13.0 10.4 11.9 0.9 4.0 3.9

14.6 7.2 23.2 13.8 10.6 12.6 0.9 4.7 4.1

14.0 7.2 22.2 13.0 10.4 11.9 0.9 4.0 3.9

14.6 7.2 23.2 13.8 10.6 12.6 0.9 4.7 4.1

16.3 7.2 23.2 13.8 10.6 12.6 1.2 4.7 4.1

17.3 7.2 26.9 16.5 12.4 14.4 1.2 6.1 5.2

20.5 7.2 26.9 16.5 12.4 14.4 1.3 6.1 5.2

22.6 7.2 26.9 16.5 12.4 14.4 1.5 6.1 5.2

27.0 8.2 32.2 18.9 15.5 16.8 1.5 7.2 6.5

27.0 8.2 32.2 18.9 15.5 16.8 1.6 7.2 6.5

28.5 8.2 32.2 18.9 15.5 16.8 1.7 7.2 6.5

35.2 8.2 32.2 18.9 15.5 16.8 1.8 9.6 4.0

(ft)

(in)

*The "L" dimensions are based on the standard lift of 10 feet.

3.0 Preoperational Procedures

3.1 Fill Gear Box with Oil

3.1.1

3.1.2 For a new hoist the correct quantity and type of oil is supplied with the hoist in separate container(s).

3.1.3 Refer to Section 6.2 when replacing the gear oil or checking the gear oil level.

Table 3-1 Amount of Gear Oil

Capacity Code quarts liters

001H, 003S, 005L 0.74 0.7

003H, 005S, 010L,

010M

010S, 015S, 020L,

020M, 030C

020S, 025S, 030L,

030S, 050L

CAUTION

NER (with friction clutch).

Remove the fill plug from the top of the hoist and connect the flexible pour tube to the oil container. Pour in all of the oil from the separate container(s), then replace the fill plug.

The ER (with mechanical load brake/friction clutch) uses different gear oil than the

DO NOT use any oil or quantity other than that listed below.

1.06

1.80

3.17 3.0

1.0

1.7

3.2 Chain

3.2.1 The quantity and location of the chain components including cushion rubbers, chain springs and striker

3.2.2 When the hoist is used without a chain container, the free end of the chain is attached to the hoist body

Figure 3-1 Oil Plug Locations

NER Gear Oil:

§ Harrington standard: Bonnoc M260 (NIPPON OIL)

§ Acceptable equivalent: Meropa 320 (TEXACO)

§ Acceptable equivalent: Meropa 320 (CALTEX)

ER Gear Oil:

§ Harrington standard: Antoil super B (NIPPON OIL)

§ Acceptable equivalent: Meropa No.68 (TEXACO)

plates depend on the hoist model, capacity and limits switches. Never operate the hoist with incorrect, missing or damaged chain components. Refer to the hoist's nameplate, Table 3-2, and Figures 3-2, 3-

3, and 3-4 and ensure that all chain components are in the correct location and properly installed.

as shown in Figure 3-4. Connect the no load end of the chain to Chain Guide A with the End Wire or End Suspender provided. For 5 ton hoist, connect the no load end of the chain directly to Chain Guide A if Chain Guide A is notched to accept the chain. Make sure the chain remains free of twists and the chain Stopper is installed on the correct link. Refer to Table 3-2 for proper placement of Stopper.

Figure 3-2 Chain Component Arrangement for Hoists with Upper Limit Switch Only.

Figure 3-3 Chain Component Arrangement for Hoists with Optional Upper and Lower Limit Switch.

Table 3-2 Chain Stopper Placement

Capacity Code Without Chain Container With Chain Container

001HD, dual speed with optional

upper/lower limit switch

001H, 003S, 003H, 005L, 005S, 010L, 010M, 010S, 015S, 020L,

link from the free end 3rd link from the free end

020M, 030C

020S, 025S, 030L, 030S, 050L 13th link from the free end 3rd link from the free end

Figure 3-4 Attachment of Chain to Hoist Body – No Chain Container

3.2.3 When the optional canvas chain container is used, unfold it fully and install it on the hoist body as shown in Figure 3-5. In this case the free end of the chain is not attached to the hoist body and the chain stopper is installed on the third link from the free end. To place the chain into the chain container, feed the chain into the chain container beginning with the free end. Take care to avoid twisting or tangling the chain. NEVER put all the chain into the container at once. Lumped or twisted chain may:

§ Upper Limit Switch Only - jam against the hoist body activating the friction clutch and potentially

damaging the chain.

§ Upper and Lower Limit Switch (Optional) - activate the down limit switch and stop the hoist during

lowering.

3.2.4

CAUTION

Each chain container indicates the maximum length of the load chain that can be stored in the container. The amount of chain the container must hold is equal to the lift on the hoist. DO NOT use a chain container with a storage capacity less than the lift length on the hoist. If all of the chain can not be stored in the container, the limit switch will not operate properly.

Figure 3-5 Attachment of Chain Container to Hoist Body

3.2.5 When using an optional steel chain container, refer to the assembly drawing and instructions provided

with the container for correct assembly and attachment.

3.2.6

WARNING

Make sure the bottom hook on 3 and 5 Ton double fall models is not capsized. See Figures 3-6 and 3-

7. Correct all chain irregularities before conducting the first hoist operation.

Figure 3-6 Twist in Load Chain – 3 and 5 Ton Double Fall Models

Verify that the load chain is not twisted or tangled prior to operating the hoist.

Figure 3-7 Capsized Hook and Chain – 3 and 5 Ton Double Fall Models

3.3 Mounting Location

3.3.1

3.3.2

WARNING

structure are adequate to support the hoist and its loads. If necessary consult a professional that is qualified to evaluate the adequacy of the suspension location and its supporting structure.

NOTICE

3.4 Mounting the Hoist

3.4.1 Manual Trolley - Follow instructions in Owner’s Manual provided with the trolley.

3.4.2 Motorized Trolley - Follow instructions in Owner’s Manual provided with the trolley.

3.4.3 Hook Mounted to a Fixed Location - Attach the hoist’s top hook to the fixed suspension point.

3.4.4

3.5 Electrical Connections

3.5.1

3.5.2

3.5.3

WARNING

that the hook’s latch is engaged.

CAUTION

applications of variable speed control for hoists.

DANGER

been de-energized (disconnected). Lock out and tag out in accordance with ANSI Z244.1 “Personnel Protection -Lockout/Tagout of Energy Sources”.

Prior to mounting the hoist ensure that the suspension and the supporting

See Section 6.7 for outdoor installation considerations.

Ensure that the fixed suspension point rests on the center of the hook’s saddle and

Ensure that the voltage of the electric power supply is proper for the hoist or trolley.

Do not apply variable speed control to the NER model hoist. Use the ER model for

Before proceeding, ensure that the electrical supply for the hoist or trolley has

3.5.4 This instruction applies to installations where the hoist is installed hook mounted to a fixed suspension point or installed on a manual trolley. In this case the hoist is controlled by a pendant with two push buttons – one for raising and one for lowering. Refer to the appropriate trolley Owner’s Manual if the hoist is installed on a motorized trolley.

Pendant Cord

The Pendant Cord connects to the hoist via a 5-pin (5P) Plug and Socket. Make this connection as follows:

§ Refer to Figure 3-8.

§ Insert the 5P Plug into the 5P Socket on the hoist and hand tighten the Screw Coupling.

§ Install the Cord Strain Relief Cable to the Cord Support on the bottom of the hoist.

Power Supply Cable - Hoist Connection

The Power Supply Cable connects to the hoist via a 4-pin (4P) plug and socket. Make this connection as follows:

§ Refer to Figure 3-8.

§ Insert the 4P plug of the Power Supply Cable into the 4P Socket on the hoist and hand tighten

the screw coupling.

§ Install the Cable Support Arm (pre-installed on the Power Supply Cable) on to the Socket Holder using the pre-installed Machine Screws and Lock Washers.

§ Use care to avoid twisting or kinking the Power Supply Cable.

Figure 3-8 Pendant and Power Supply Cable Connections

Power Supply Cable - Installation

If the hoist is hook mounted to a fixed support ensure that the Power Supply Cable is properly installed and supported between the hoist and the electrical power supply.

If the host is installed on a manual trolley, then the Power Supply Cable must be installed along the beam that the trolley runs on. For curved beams a special cable suspension system will be needed, and this instruction does not apply. For straight beams install the Power Supply Cable as follows:

§ Install a guide wire system parallel to the beam.

§ For a manual trolley the guide wire should be positioned slightly outside the hoist's Cable

Support as shown in Figure 3-8.

§ Use the Cable Trolleys supplied with the hoist to suspend the Power Supply Cable from the guide wire. Space the Cable Trolleys every 5 feet.

3.5.5 Connection to Electrical Power Source - The red, white, and black wires of the Power Supply Cable should be connected to an Electric Power Disconnect Switch or Circuit Breaker. This connection should be made so that the hoist is phased properly. Refer to Section 3.6.11 for instructions on how to check for correct power supply phase connection.

3.5.6 Fuse/Breaker Capacity -The hoist's power supply should be equipped with overcurrent protection such as fuses, which should be selected for 110% to 120% of total listed full load amperage, and should be dual element time-delay fuses. Refer to the motor nameplate for the full load amperage draw.

3.5.7

DANGER

shock hazard when touching any part of the hoist or trolley. In the Power Supply Cable the ground wire will be either Green with Yellow stripe or solid Green. It should always be connected to a suitable ground connection. Do not paint the trolley wheel running surfaces of the beam as this can affect grounding.

Grounding - An improper or insufficient ground connection creates an electrical

3.6 Preoperational Checks and Trial Operation

3.6.1

3.6.2

3.6.3 Measure and record the “k” dimension of all hooks on hoist. See Table 5-4 under Section 5,

3.6.4 Record the hoist's Code, Lot and Serial Number (from the name plate on the hoist; see section 10) in

3.6.5 Ensure that the hoist is properly installed to either a fixed point, or trolley, whichever applies.

3.6.6 If hoist is installed on a trolley, ensure that

3.6.7 Ensure that all nuts, bolts and split pins (cotter pins) are sufficiently fastened.

3.6.8 Pull down on the Pendant and ensure that the Cord Strain Relief Cable takes the force, not the

WARNING

other lifting attachments before use. Inspect all load suspension members for damage prior to use and replace or repair all damaged parts.

WARNING

Section 3.2.

“Inspection”.

the space provided on the cover of this manual.

n trolley is properly installed on the beam, and

n stops for the trolley are correctly positioned and securely installed on the beam.

Pendant Cord.

Confirm the adequacy of the rated capacity for all slings, chains, wire ropes and all

Verify and correct all chain irregularities prior to operating the hoist. Refer to

3.6.9

3.6.10 Confirm proper operation.

3.6.11

CAUTION

the rated value, electrical devices may not function normally.

n Before operating read and become familiar with Section 4 - Operation.

n Before operating ensure that the hoist (and trolley) meets the Inspection, Testing and Maintenance

requirements of ANSI/ASME B30.16.

n Before operating ensure that nothing will interfere with the full range of the hoist’s (and trolley’s)

operation.

WARNING

operation corresponds to the up-and-down commands issued from the pendant control; i.e. pushing the up button must cause the hoist to raise. If the hoist does not operate correctly, shut off and lockout /tagout the main power source to the hoist. Disconnect and switch any two of the three input power leads at the power source to correct the hoist’s motor phasing.

Check supply voltage before everyday use. If the voltage varies more than 10% of

The hoist must be connected to the power source such that its direction of

4.0 Operation

4.1 Introduction

DANGER

DO NOT WALK UNDER A SUSPENDED LOAD

WARNING

HOIST OPERATORS SHALL BE REQUIRED TO READ THE OPERATION SECTION OF THIS MANUAL, THE WARNINGS CONTAINED IN THIS MANUAL, INSTRUCTION AND WARNING LABELS ON THE HOIST OR LIFTING SYSTEM, AND THE OPERATION SECTIONS OF ANSI/ASME B30.16 and ANSI/ASME B30.10. THE OPERATOR SHALL ALSO BE REQUIRED TO BE FAMILIAR WITH THE HOIST AND HOIST CONTROLS BEFORE BEING AUTHORIZED TO OPERATE THE HOIST OR LIFTING SYSTEM.

HOIST OPERATORS SHOULD BE TRAINED IN PROPER RIGGING PROCEDURES FOR THE ATTACHMENT OF LOADS TO THE HOIST HOOK.

HOIST OPERATORS SHOULD BE TRAINED TO BE AWARE OF POTENTIAL MALFUNCTIONS OF THE EQUIPMENT THAT REQUIRE ADJUSTMENT OR REPAIR, AND TO BE INSTRUCTED TO STOP OPERATION IF SUCH MALFUNCTIONS OCCUR, AND TO IMMEDIATELY ADVISE THEIR SUPERVISOR SO CORRECTIVE ACTION CAN BE TAKEN.

HOIST OPERATORS SHOULD HAVE NORMAL DEPTH PERCEPTION, FIELD OF VISION, REACTION TIME, MANUAL DEXTERITY, AND COORDINATION.

HOIST OPERATORS SHOULD NOT HAVE A HISTORY OF OR BE PRONE TO SEIZURES, LOSS OF PHYSICAL CONTROL, PHYSICAL DEFECTS, OR EMOTIONAL INSTABILITY THAT COULD RESULT IN ACTIONS OF THE OPERATOR BEING A HAZARD TO THE OPERATOR OR TO OTHERS.

HOIST OPERATORS SHOULD NOT OPERATE A HOIST OR LIFTING SYSTEM WHEN UNDER THE INFLUENCE OF ALCOHOL, DRUGS, OR MEDICATION.

OVERHEAD HOISTS ARE INTENDED ONLY FOR VERTICAL LIFTING SERVICE OF FREELY SUSPENDED UNGUIDED LOADS. DO NOT USE HOIST FOR LOADS THAT ARE NOT LIFTED VERTICALLY, LOADS THAT ARE NOT FREELY SUSPENDED, OR LOADS THAT ARE GUIDED.

NOTICE

• Read ANSI/ASME B30.16 and ANSI/ASME B30.10.

• Read the hoist manufacturer’s Operating and Maintenance Instructions.

• Read all labels attached to equipment.

The operation of an overhead hoist involves more than activating the hoist’s controls. Per the ANSI/ASME B30 standards, the use of an overhead hoist is subject to certain hazards that cannot be mitigated by engineered features, but only by the exercise of intelligence, care, common sense, and experience in anticipating the effects and results of activating the hoist’s controls. Use this guidance in conjunction with other warnings, cautions, and notices in this manual to govern the operation and use of your overhead hoist.

4.2 Shall’s and Shall Not’s for Operation

WARNING

Improper operation of a hoist can create a potentially hazardous

situation which, if not avoided, could result in death or serious injury

and substantial property damage. To avoid such a potentially

hazardous situation THE OPERATOR SHALL:

• NOT lift more than rated load for the hoist.

• NOT operate unless load is centered under hoist.

• NOT use damaged hoist or hoist that is not working properly.

• NOT use hoist with twisted, kinked, damaged, or worn chain.

• NOT use hoist if the bottom hook is capsized (double fall hoists - see Section 3.2).

• NOT use the hoist to lift, support, or transport people.

• NOT lift loads over people.

• NOT apply load unless load chain is properly seated in the load sheave (and idle sheave for hoist with two chain falls).

• NOT use the hoist in such a way that could result in shock or impact loads being applied to the hoist.

• NOT attempt to lengthen the load chain or repair damaged load chain.

• NOT operate hoist when it is restricted from forming a straight line from hook to hook in the direction of loading.

• NOT use load chain as a sling or wrap load chain around load.

• NOT apply the load to the tip of the hook or to the hook latch.

• NOT apply load if binding prevents equal loading on all load-supporting chains.

• NOT operate beyond the limits of the load chain travel.

• NOT operate hoist with missing/damaged chain springs, cushion rubbers, stoppers or striker plates.

• NOT leave load supported by the hoist unattended unless specific precautions have been taken.

• NOT allow the chain, or hook to be used as an electrical or welding ground.

• NOT allow the chain, or hook to be touched by a live welding electrode.

• NOT remove or obscure the warnings on the hoist.

• NOT operate a hoist on which the safety placards or decals are missing or illegible.

• Be familiar with operating controls, procedures, and warnings.

• Make sure the unit is securely attached to a suitable support before applying load.

• Make sure load slings or other approved single attachments are properly sized, rigged, and seated in the hook saddle.

• Take up slack carefully - make sure load is balanced and load-holding action is secure before continuing.

• Make sure all persons stay clear of the supported load.

• Protect the hoist’s load chain from weld splatter or other damaging contaminants.

• Report malfunctions or unusual performances (including unusual noises) of the hoist and remove the hoist from service until the malfunction or unusual performance is resolved.

• Make sure hoist limit switches function properly.

• Warn personnel before lifting or moving a load.

• Warn personnel of an approaching load.

CAUTION

Improper operation of a hoist can create a potentially hazardous

situation which, if not avoided, could result in minor or moderate

injury, or property damage. To avoid such a potentially hazardous

situation THE OPERATOR SHALL:

• Maintain a firm footing or be otherwise secured when operating the hoist.

• Check brake function by tensioning the hoist prior to each lift operation.

• Use hook latches. Latches are to retain slings, chains, etc. under slack conditions only.

• Make sure the hook latches are closed and not supporting any parts of the load.

• Make sure the load is free to move and will clear all obstructions.

• Avoid swinging the load or hook.

• Make sure hook travel is in the same direction as shown on controls.

• Inspect the hoist regularly, replace damaged or worn parts, and keep appropriate records of maintenance.

4.3 Hoist Controls

4.3.1 For hoists mounted to motorized trolleys follow the control instruction included in the trolley's Owner's Manual.

4.3.2 Single Speed Pendant Control – When using the pendant control depress the up button to raise the hoist or the down button to lower the hoist as shown in Figure 4-1 below. To stop motion release the buttons.

• Use the hoist manufacturer’s recommended parts when repairing the unit.

• Lubricate load chain per hoist manufacturer’s recommendations.

• NOT use the hoist load limiting or warning device to measure load.

• NOT use limit switches as routine operating stops. They are emergency devices only.

• NOT allow your attention to be diverted from operating the hoist.

• NOT allow the hoist to be subjected to sharp contact with other hoists, structures, or objects through misuse.

• NOT adjust or repair the hoist unless qualified to perform such adjustments or repairs.

4.3.3 Dual Speed Pendant Control – Pendant controls supplied with dual speed hoists have two step control buttons. For low speed depress the button to the first step and for high speed depress the button fully to the second step. Use the up button to raise the hoist or the down button to lower the hoist as shown in Figure 4-1 below. To stop motion release the buttons.

4.3.4

CAUTION

Make sure the motor completely stops before reversing direction.

Figure 4-1 Push Button Pendant Control

5.0 Inspection

5.1 General

5.1.1 The inspection procedure herein is based on ANSI/ASME B30.16. The following definitions are from ANSI/ASME B30.16 and pertain to the inspection procedure below.

n Designated Person – a person selected or assigned as being competent to perform the specific duties

to which he/she is assigned.

n Qualified Person – a person who, by possession of a recognized degree or certificate of professional

standing, or who, by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

n Normal Service – that distributed service which involves operation with randomly distributed loads

within the rated load limit, or uniform loads less than 65% of rated load for not more than 25% of the time.

n Heavy Service – that service which involves operation within the rated load limit which exceeds normal

service.

n Severe Service – that service which involves normal or heavy service with abnormal operating

conditions.

5.2 Inspection Classification

5.2.1 Initial Inspection – prior to initial use, all new, altered, or modified hoists shall be inspected by a designated person to ensure compliance with the applicable provisions of this manual.

5.2.2 Inspection Classification – the inspection procedure for hoists in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the hoist and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as FREQUENT and PERIODIC, with respective intervals between inspections as defined below.

5.2.3 FREQUENT Inspection – visual examinations by the operator or other designated personnel with intervals per the following criteria:

n Normal service – monthly

n Heavy service – weekly to monthly

n Severe service – daily to weekly

n Special or infrequent service – as recommended by a qualified person before and after each

occurrence.

5.2.4 PERIODIC Inspection – visual inspection by a designated person with intervals per the following criteria:

n Normal service – yearly

n Heavy service – semiannually

n Severe service – quarterly

n Special or infrequent service – as recommended by a qualified person before the first such

occurrence and as directed by the qualified person for any subsequent occurrences.

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Metalfab Electric Chain Hoist ER User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual