Smart Lift SL 380 MIDI User Manual

User Manual

N.A. Christensensvej 39, DK-7900 Nykøbing Mors

US SL 380 MIDI 03-2016

Model/type: SL 380 MIDI – 0.95 hp

Tlf.: +45 97 72 29 11 Fax: +45 97 72 39 11

E-mail:

smart@smartlift.dk; www.smartlift.dk

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Table of Contents:

Table of Contents 2

Introduction 3

EU Declaration of Conformity 4

General Description 5

Transport/Handling/Putting into Operation/Storage 6

Technical Data, Safety Rules 7

Overview/ - General Description 8

Operation for Vacuum function 10

Control for arm and yoke 10

Important Operation (vacuum & electric functions) 11

Electric Functions 11

Charger & Battery Case 12

View of Vacuum system (top and bottom of machine) 13

Control Box 14

Switches and Alarms 14

Control Panel for arm and yoke 15

Load Diagram 16

Stop-Down Troubleshooting of SmartLIFT 17 - 26

Information and manual charger 27

Wiring Diagrams 29-31

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Introduction

Congratulations on your new SL 380 MIDI. Smart Lift has been designed and constructed so as to safeguard product users against accidents as far as at all possible. Unfortunately, certain functions in a machine cannot be safeguarded. This is why safety rules have been prepared by way of warnings in this instruction. Read these safety rules on the following pages before putting your Smart LIFT into operation, and imagine how you may, in your daily use of the machine, ensure that warnings and safety rules will be adhered to.

Yours Sincerely, Nicolai T. Jørgensen

Smartlift A/S N.A. Christensensvej 3 9 DK - 7900 Nykøbing Mors Telephone: +45 9772 2911 E-mail : smart @smartlift.dk

www.smartlift.dk

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EU Declaration of Conformity

Manufacturer Smartlift A/S N.A. Christensensvej 39 DK - 7900 Nykøbing Mors

Hereby declares that: The machine/system: Lift Model/type: SL 380 MIDI – 0.95 hp Serial No.: Year/Month: 2016

has been made in conformity with Council directive

- Machine directive 2006/42EC

- Low voltage directive 2006/95/EC + 2014/35/EU

- EMC directive 2014/30/EU

The following standards have been applied:

DS/EN ISO 12100 (Safety of machinery - General principles for design -- Risk assessment and risk reduction)

DS/EN ISO 14121-2 (Safety of machinery - Risk assessment -- Part 2: Practical guidance and examples of

methods)

DS/EN ISO 13857 (Safety of machinery - Safety distances to prevent hazard zones being reached by upper and

lower limbs)

DS/EN ISO 13849-1 (Safety of machinery - Safety-related parts of control systems - Part 1: General principles for

design)

DS/EN 13155+A2 (Cranes - Safety - Non-fixed load lifting attachments)

DS/EN ISO 3691-1 (Industrial trucks - Safety requirements and verification - Part 1: Self-propelled industrial

trucks, other than driverless trucks, variable-reach trucks and burden-carrier trucks)

DS/EN ISO 3691-5:2015 (Industrial trucks - Safety requirements and verification - Part 5: Pedestrian-propelled

trucks)

DS/EN 60204-32 (Safety of machinery - Electrical equipment of machines - Part 32: Requirements for hoisting

machines)

DS/EN ISO 13856-3 (Safety of machinery - Pressure-sensitive protective devices - Part 3: General principles for

design and testing of pressure-sensitive bumpers, plates, wires and similar devices)

Date: Signature: ____________ ____________________________________ Nicolai T. Jørgensen, Director

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General Description/List of Spare Parts

Pos.no.

Product

Number

Vacuum

1

Pump 007

2

Suction Cup diam. 11.8 "

4

Replacement rubber t/suction cup

1 5 Slide Valve w/lock, vacuum

1

6

Vacuummeter diam.63 ¼", stainless

1

11

Hose Coupling

2

12

Spiral Hoses

2

13

Vacuum Guard

1

16

Acoustic alarm, Vacuum

1

19

Stainless Spring

4

21

Actuator – Tilting function LA 36

1

22

Actuator – Side Change

1

23

Actuator – Telescopic Arm

1

Power Supply

25

Battery 62 AK/Battery Case

2

26

Charger CTEK MULTI

1

Wheels

24 V

31

Safety Switch/Telemecanique

1

32

Control Panel

1

33

Emergency Stop

1

34

Control, Lift Arm

1

36

Control, Side Change

1

37

CE Connector

1

38

Ermax Main Switch 24 V

1

Various

41

Lift Eye

1

44

Handle

3

45

Weight Blocks 1.18 in

11

46

Supporting Leg

2

3 Check Valve ½", vacuum 1

10 Hose Set 1

15 Alarm Light, Vacuum 1

17 Line Filter 1

20 Clamp MRX.80 P-M10-25 6

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24 Actuator – Lift Arm LA 36 2

27 Wheel, EK-MASSIV 2

30 Supporting Wheel 2

35 Control, Telescopic Arrm/Tilt 1

39 Fuse 30 Amperes Control

40 Lock Split 1

42 Lock Fitting, transport frame 1

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47

47a

On/OFF Switch for Drive Motor

1

47b

Fuse 80 Amperes Motor

1

50

Safety Clamp

1

51

Safety Switch

1

Drive

Motor 0.95 hp /24 V 1

48 Regulating Lever 1

49 Curtis Motor Control 1

52 Forward and Back Switch 1

53 Protective Cap for forward and back switch 1

Transport/Handling

Smart Lift is for indoor use.

Prior to transport, switch off all electronics on main switch (pos. 38).

Smart Lift to be fastened securely in truck/trailer for transport and protected against rain and snow.

Lifting by crane or similar: Always lift Smart Lift in lift eye intended for this purpose (pos. 41).

NEVER lift under Smart LIFT by forks (truck and similar)

For transport on the transport frame, Smart Lift must always be fastened in the lock fitting (pos.

42).

Do not expose to rain and snow

Putting into Operation

Prior to putting into operation, insert vacuum hoses, and charge battery fully.

If the yoke has been dismantled, be aware that the washer is placed between the castle nut and the yoke.

Storage

Always switch off your Smart Lift on the main switch (pos. 38), before storage.

Smart Lift should be kept in a dry place. Moisture may affect the machine functionality.

Batteries should always be fully charged.

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Technical Data

Total Height

53.15 in

Total Width

2559 in

Total Length

91.34 in

Net Weight

824 lb

Weight Blocks

39.3 lb x 11 units = 432 lb

Total Weight incl. 11 weight blocks

1256 lb

24 V DC

Charger 230 V – CE connector

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Safety Rules ( Pages 9, 11, 14)

Daily Use

Your Smart LIFT may only be used by persons who have been given qualified training in the operation of this machine and its safety functions. Before use, user should check that there are no loose objects on the machine since this would entail breakdown and danger risks.

WARNING! Vacuum!

Working at the machine will entail danger if the various safety devices, pressure gauge (pos. 6), and acoustic alarm (pos. 16) are faulty. Work may not be lifted until the light and acoustic alarms (pos.15, pos. 16) have stopped. Do NOT lift moist or greasy work by the suction cups.

WARNING! Risk of overturning!

This machine MUST stand on a horizontal, firm, and stable base, with its supporting legs (pos. 46) unfolded.

WARNING!

Prior to using the lift yoke, check that nut and lock split have been securely fastened. Always see that weight blocks (pos. 45) have been locked using lock split (pos. 40).

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Telescopic Arm

21 – Actuator tilting function

2- Suction Cups diam. Vacuum Chamber

25 – Battery Case ,

12 – Spiral Hoses

46 – Supporting Leg with wheels (30)

41 – Lift Eye

50 – Safety Clamp

24- Actuator lifting arm

27-WheeEK - MASSIV

WARNING! Explosion Danger!

This machine may NOT be used in ATEX area. (Explosion danger environment).

DANGER!

Staying under the lifted work is strictly prohibited.

PROHIBITED!

May NOT be used for person lifting.

Overview/ - General Description (pages 8, 9, 11, 14)

11.8 in

Battery 62 AK

8

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2-circuit vacuum safety system

5 – Slide Valve w/lock

32 – Control Panel in holder

5- Slide Valve w/lock, Vacuum

31- Overload safety breaker

6 – Two vacuummeters. One for

ON/OFF Switch

Switch for high and low speed (turtle/rabbit)

48 + 52 - Regulating lever,

12 – Spiral Hoses 2

each vacuum circuit

Forward/back

10 – Hose Set

vacuum circuits

51 – Safety Switch for back function

for activation and deactivation of vacuum suction 2-circuit system

26 – Battery Charger

37- CE Connector for battery charger

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Operation of VACUUM function: (page 13)

This function (pos. 5) will switch vacuum on and off. The vacuum pump is controlled by a vacustat. The pump starts at -0,53 and stops at -0,62. The vacuum function is operated by the slide valve and safety button on top of the arm. To activate vacuum push the slide valve forward. To deactivate vacuum pull out the safety button and pull back the handle on the slide valve.

Control Panel (pos. 32) for arm and yoke: (pages 8, 9, 15)

Users should make a point of reading the function description below, so as to become familiar with the functioning of the machine.

Smart LIFT is operated manually. This machine generally has four functions which may be operated individually.

UP/DOWN function:

This function will make the arm move either up or down. The movement is made via the actuators, (pos. 24).

TILTING function:

This function will make the work turn round. The movement is made by actuator, (pos. 21).

TELESCOPIC ARM function:

The movement is made via actuator, placed under the lift arm, (pos. 23).

SIDE DISPLACEMENT function:

This movement is performed via actuator, placed between the two front wheels. (pos. 22).

Electric functions: (pages 9, 11, 14)

STOP/EMERGENCY STOP function:

The emergency stop button (pos. 33) is placed on the actual control panel. This button will switch off actuators, electric control, as well as drive motor.

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51 – Safety function f/back 32 – Control Panel placed in 31 – Overload Safety Switch

6 – Vacuummeter two (reading

5 – Slide Valve w/lock

suction 2-circuit system

48 + 52 - Regulating lever,

Switch for high and low speed (turtle/rabbit)

ON/OFF Switch

MAIN SWITCH: (Pos. 38) Placed on the battery case inside. Turn handle to switch off all electric functions.

DRIVE MOTOR, (pos. 47): The drive motor is activated by an on/off switch (pos. 47a). Then turn the regulating lever (pos. 48).

FORWARD AND BACK function, (pos. 52): Toggle switch forward and back

SAFETY function, (pos. 51): Activating the safety switch will stop the car, and the car will move forward.

Important Operation (vacuum & electric function)

on both pressure gauges to range between 0.6 – 0.7)

f/activation and deactivation of vacuum

holder

Forward/back

(machine moving forward automatically)

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49 – Curtis motor control

47b – Fuse 80 Ampere for propelling motor

25 – Two 12 Volt batteries

26 - CTEK charger for 24 volt

37 - 220 Volt connection via 3-pole CE connector

22 – Actuator for side

Charger

Victron Energy Blue Power Charger IP65 ( pos. 26) – Battery Charger for lead acid batteries.

The blue Power charger is a three state charger (bulk-absorption float). The absorption stage ends 2 hours after the charger current has reduced to 10% of the nominal current, with a maximum charge time of 18 hours. Connection to the mains or reduction of the output voltage to 12V resp. 24V due to a DC load will trigger a new charge cycle.

Also please refer to the attached user guide (page 28).

Battery Case

f/drive motor

change

12

View of Vacuum System

10 – Hose Set 2-circuit Double Vacuum

Chamber

Pipe connection

5 – Slide Valve

Load Diagram

17 – Line filter f/vacuum suction

1 – Vacuum pump

For max. stability at transport of sucked work, the

2 – Suction Cups,

(top of machine)

standard diam. 11.8 in

vacuum

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w/lock. Aktivating vacuum

suction cups are to be centred and adapted to the transport work chosen. Operation of yoke with

sucked work should always

be conducted with

caution

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44 – Battery indikator

38 – The main switch is placed on

34 – Controller lifting arm

39 - Fuse 30 Ampere

36 – Controller side shift

35 – Controller telescopic arm 15 – Alarm light - vacuum

16 – Acoustic alarm - vacuum

33 – Emergency stop

35 – Controller tilt of yoke

15 – Alarm light, vacuum

Switches and alarms

33 – Emergency stop

the back side of the battery case. Must be switched off after use.

16 – Acoustic alarm, vacuum

14

Control Panel for arm and yoke (pos. 32)

Lift Arm Down

Tilt back

Telescopic arm out

Side shift left

Lift arm up

Tilt forward

Telescopic Arm in

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Side shift right

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LOAD DIAGRAM

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Stop-Down Troubleshooting

For any fault on Smartlift, first look into the options below:

• Has anything visible been broken, or is anything unusual, about the machine? Is there any

murmuring or noise?

• Have the batteries been charged, and the main switch switched on? (the On/Off button on the

drive handle shall have been switched on (lighting) to read battery voltage on battery indicator)

• Has the emergency stop button switched the machine off? (placed on grey control box)

• Has the safety switch been switched off on account of overloading (placed under pressure

switches)?

• Is the hose set intact, and has it been connected correctly?

Troubleshooting and remedying of faults will be divided into 3 overall categories:

1. Vacuum (machine capacity for sucking work)

2. Movements controlled via control panel up and down function of lift arm, tilting of

yoke, side displacement of machine.

3. Drive controlled by regulating lever – Forward and back function of machine.

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Slide Valve w/safety lock

suction.

Vacuum suction on both pressure

1. Stop-Down at Vacuum System

for activation and deactivation of vacuum

gauges to be 0.62 (between 0.6 – 0.7)

If – vacuum pump will not run.

Always check that there is power on the machine, and that it has not been disconnected by switch or by fuse in the control box. Relay for pump may also be defective.

If – vacuum pump runs constantly.

Check that the slide valve is closed (should be closed to generate vacuum). Read pressure gauge (should be about 0.60).

If – the pressure gauge indication is constantly about 0.7 or more.

In that case, there will be a fault on the vacuum guard.

If – the pressure gauge is constantly appr. 0.55 or less, and the pump is running.

In that case there would be a fault on the vacuum pump, or a leak on the hose connection between check valve and vacuum pump.

If – the pressure gauge indication drops after the main switch has been disconnected, and the slide valve closed.

In that case, there will be a fault – a leak between slide valve and check valve. Pressure gauge, slide valve or vacuum guard may be defective. If hoses are dismantled at couplings, and the pressure continues to drop, the fault will be with the slide valve.

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Bottom of Smartlift

Vacuum pumps

Check Valves 2 circuits

Vacuum Guard light green when

Vacuum Guard light red

suction reached

Filters

Vacuum filters

If – the vacuum pump starts and runs constantly, possibly with dropping pressure, when the slide valve is opened, in connection with suction of work.

Check that all suction cups bear correctly on the work, i.e. that the particular suction cup is parallel with the work, and that no parts of the suction cups protrude from the work (IMPORTANT !!!).

If – the vacuum pump starts and stops at very brief intervals.

Dismantle spiral hoses at couplings and close the slide valve if this has not been done already. If the vacuum pump still starts and stops at very brief intervals, there may be a fault on the check valve.

If – the vacuum pump starts and runs, and stops at brief intervals, possibly with dropping pressure on one or both pressure gauges, when the slide valve is opened, after correct suction of work.

Close slide valve. Disconnect one vacuum circuit at hose coupling, and then open the slide valve for vacuum suction again. If the vacuum suction on the pressure gauge for disconnected circuit is now constantly 0.6, there will be a fault on the hose set or at the suction cups in disconnected vacuum circuit. Test the same procedure in case of fault on the other vacuum circuit system. You may listen for leaks.

Vacuum Guard

pump is running (2 circuits system)

when correct vacuum

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The safety switch has correctly switched off

To re-establish function on the machine,

The telescopic arm is run back in, and work

2. Stop-Down at ”movements” controlled via control panel

If – no response to pushing control panel, all functions

Has emergency stop been released? Reconnect emergency stop by turning the release pressure. Check whether main switch is on (placed on battery case between lift actuators) – to be turned clockwise to switch on. Check whether the control panel connector is correctly placed in the control box. Have batteries been charged? – on/off button on handle for drive should be on to read battery indicator? Is 30-ampere fuse in control box OK? Has the safety switch been activated? If activated, try to deactivate by pulling in the telescopic arm, or act as follows:

the machine.

you may, for instance, using a screwdriver push up the switch, and the safety switch will resume its function

too heavy for the machine is lowered back in place. Should the safety switch switch off again at this manoeuvre, you may, using your body weight, push the machine in place by applying pressure on the weight blocks.

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Actuator for tilting

Actuators for lift

Emergency

Main switch to

Line should be in holders

If –no response when pushing control panel , individual functions,

Has the safety switch been activated? If activated, try one of the possibilities above. There may be a fault on actuators for movements, or when controlling these.

Actuators, and Control of these

For faults on movements of actuators, always first check visually and by review of the machine whether anything visible is wrong, or “wrong” from an acoustic point of view, from one of the actuators. Lines may be loose or torn, and bolts may be loose. Finally, the actual actuator telescopic arm may be bent. The machine has totally five actuators. 1 for tilting of yoke, 2 for lifting of arm, 1 for telescoping of arm, and 1 for side change.

be turned clockwise to be on

Stop

In particular lines at the bottom of these two lift actuators may, by carelessly wrong and unfortunate operation of SL-380, have been damaged at connector or line.

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Fault on lift actuator

Actuator for telescoping of arm

Actuator for side shift

Motor control for drive motor with fuse for

change.

80 A Fuse f/drive motor

If the lift actuators, or one of these, stop due to “unbalanced” load, one of

synchronously again.

Actuator for tilting

Safety switch for non-synchronous running on actuator

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the safety switches under the actuators will have switched off the power supply. The following may be done to re-establish normal function:

Pushing the operation panel button repeatedly to function ”down” will run lift actuators to bottom position, and both actuators should run

Here, too, all lines should be undamaged, and placed correctly at lead-ins etc.

same. Nothing to do with actuator for side

To check this actuator, remove the protective screen. In case of lacking or wrong function, check for any murmuring/noise and loose lines.

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Control box with controllers for all actuators

Faults on movement of actuators can be diagnosed by measuring systematically as described in the following two pages.

Controller for tilting

Controller for telecopi n g

Controller for lifting Controller for sideshi ft

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actuator

actuators

actuator

23

Synchronous controller (controller for lifting actuators)

Safety switch below the lifting

Clamp 1 and 13

Clamp 1 and 16

Clamp 1 and 10

Clamp 1 and 9

Aktuator 1, Clamp 1 and 7 + 1 and 8

Aktuator 2, Clamp 1 and 11 + 1 and 12

Controller for lifting actuators (2 pcs.) Voltage between clamps 1 and 2 must be approx. 24 Volt

actuators can be switched off.

Voltage between clamp 1 and 13 must be approx. 24 Volt

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Press up and down on the remote control. Voltage between clamp 1 and 9 and 1 and 10 must be approx. 24 Volt

Possible faults on pulses from lifting actuator can be checked by activating the control panel in steps. At the same time measure the voltage between clamps 1 and 7 as between 1 and 8 for actuator 1.

For actuator 2 between clamps 1 and 11 as between 1 and 12

The measuring device varies from 024 VOLT

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Clamp 1 and 4

Clamp 1 and 6

Clamp 1 and 7

Clamp 1 and 9

Clamp 1 and 10

Clamp 2 and 3

Clamp 8 and 14

Controller for single actuator (sideshift, tilt of yoke, telescopic arm)

(The illustration is from sideshift controller. The procedure is the same for tilt and telescoping)

No reaction on actuator for sideshift, tilt of yoke or telescopic arm.

Voltage must be + 24 Volt (Clamp 1 and 4)

Security switch can be abrupted

Voltage must be + 24 Volt between Clamps 1 and 6 as between 1 and 7

Fault on remote control when moving single actuators

Voltage must be + 24 Volt between clamps 1 and 9 as between 1 and 10

Activate the control panel for movement of tilt, sideshift or telescopic arm.

Voltage between clamps 2 and 3 must be 24 Volt or more

No reaction on movements and none of the above faults. Voltage between clamp 8 and 14 must be + 5 Volt If this is not the case, the print on the controller can be defective

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Fuse 80 A for drive

Regulation lever

High/low speed

Safety button for back

If the yoke has been dismantled, be aware

castle nut and the yoke.

Tighten by hand

ON/OFF-switch

3. Stop-Down at Drive Section

If - no response at activation on regulating lever (no click sound)

Check whether the main switch is on – to be turned clockwise to switch on. Has the red On/Off switch on the regulating lever been put into On position (green lamp on)? Have batteries been charged (check indicator)? Is the 80-ampere fuse beside the motor control under the screen at the front of the machine OK? Check regulating lever and cables for visible faults and damage. There may be no faults on lever or control unit. Control light on switch may show error code at various flash signals (contact Smartlift).

function. The machine drives forward when activated

that the washer is placed between the

forward/back

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Battery Charger Victron Energy - Blue Power Charger IP65

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For complete manual refer to:

https://www.victronenergy.com/upload/documents/Datasheet-Blue-Power-Battery-Charger-IP6590-135VAC-EN.pdf

LED indication Description

Yellow LED on: battery being charged. Yellow LED on and green LED on: absorption charge. Green LED on: battery fully charged, float charge.

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WIRING DIAGRAMS

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Smart Lift SL 380 MIDI User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual