Operating instructions / assembly instructions Telescope hoisting ... · 3 PHOENIX hoisting column ... Machine safety DIN EN ISO 12100-1 ... Do not use the motor to drive to mechanic

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PHOENIX hoisting column

BA_PHOENIX_EN-R1 03/2013 Revision Index 1

COLUMBUS McKINNON Engineered Products GmbH Niederlassung Heilbronn Ochsenbrunnenstraße 10 74078 Heilbronn /Germany

Telefon +49 7131 28 71 0 Telefax +49 7131 28 71 11 [email protected] www.pfaff-silberblau.com

Operating instructions / assembly instructions Telescope hoisting column PHOENIX

www.alltec.de – www.pfaff-silberlblau.com

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Subject to technical modifications Figures without guarantee

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Table of contents

1 General information and safety ............................................................................................. 3 1.1 Introduction .................................................................................................................... 3 1.2 Explanation of the symbols............................................................................................ 3 1.3 Glossary......................................................................................................................... 3 1.4 Intended use .................................................................................................................. 4 1.5 Accident prevention regulations - Guidebooks .............................................................. 4 1.6 General safety information............................................................................................. 4 1.7 Type plate ...................................................................................................................... 5 1.8 Technical specifications................................................................................................. 5 1.9 Dimensions.................................................................................................................... 6

2 Receipt of goods, storage, transport .................................................................................... 7 2.1 Receipt of goods............................................................................................................ 7 2.2 Transport ....................................................................................................................... 7 2.3 Storage .......................................................................................................................... 7

3 PHOENIX hoisting column ..................................................................................................... 7 3.1 Short safety nut – wear indicator (option) ...................................................................... 8 3.2 Safety-trap nut (optional with Ba screws) ...................................................................... 8

4 Assembly ................................................................................................................................. 8 4.1 Assembly of the inductive limit switches........................................................................ 9 4.2 Mechanical fastening ..................................................................................................... 9

5 Initial operation ....................................................................................................................... 10

6 Maintenance and inspection.................................................................................................. 10 6.1 Maintenance plan .......................................................................................................... 11 6.2 Lubricants ...................................................................................................................... 16

7 Decommissioning ................................................................................................................... 16

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1 General information and safety

1.1 Introduction

These operating instructions describe Columbus McKinnon PHOENIX hoisting columns. Please refer to our order confirmation or the catalog "PHOENIX hoisting columns" for details on the layout, design and permissible operating conditions for the drives. Always observe and follow this operating manual when using the equipment.

• Read these operating instructions carefully before assembly or initial operation and have them available to all responsible persons.

• Observe the safety information. • Store the operating instructions and documents carefully.

1.2 Explanation of the symbols

Practical information

Warning against a general hazard. Risk of injury if ignored.

Warning against electrical voltage. Severe risk of injury if ignored.

Information on safety screw jack

Important information for use in spaces with explosion hazards

Important information

Assembly and setting information

Disposal

1.3 Glossary

Merkur (M1/M2/M3) Worm gear screw jack size 1 / 2 / 3 QLGB Quick lift gear box Tr Trapezoidal thread spindle Ba Ball thread spindle ASS ALLTEC sliding thread screw P Screw pitch DIN German industry standards EN European norm ISO International standard ID Intermittent duty in % / h

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1.4 Intended use

PHOENIX hoisting columns are incomplete machines and are intended for installation in complete machines or for assembly with several machines into a system. They are drive elements that are employed for converting rotational movement into longitudinal movement and for reducing speed or converting torque. The drive system may only be used for its designated purpose. They may be used only under the application conditions specified in the operating instructions, in the technical documentation or in the order confirmation. Operation outside the respective performance limitations / ambient conditions is not permitted. Not suitable for use in spaces with explosion hazards. Not suitable for use in aggressive environments, unless constructed especially for these applications. Modifications to the screw jacks as well as the attachment of additional devices are only permitted with our express and written authorisation. Pay attention to the technical data and functional description!

1.5 Accident prevention regulations - Guidebooks

Observe the relevant instructions, regulations, and standards in the country of use. In Germany, these are currently:

Rules and regulations

EC machinery directive 2006/42/EC

Machine safety DIN EN ISO 12100-1 DIN EN ISO 12100-2

Lift devices DIN EN 1494

Lifting tables EN 1570 Lift work platforms EN 280 Loading platforms EN 1756 Car hoists EN 1493 Stages and studios BGV C1

Stage mechanics, safety equipment

DIN 56950

Non-electric devices for use in spaces with explosion hazards Guideline 94/9/EC (ATEX)

1.6 General safety information

Assembly, service, commissioning and maintenance only by authorised personnel familiar with the relevant regulations.

It is forbidden to transport people or to stay in the danger area of devices without particular precautions.

Not suitable for use in spaces with explosion hazards!

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• Never grasp, cover, or block moving parts.

• Do not remove or disable the safety devices.

• The operational and safety limit switches have to ensure that the lifting process stops safely at the end positions. Do not use the motor to drive to mechanic end stops, as this could destroy the hoisting columns.

• To prevent contact with rotating/moving parts, fasten protective covers (such as bellows, shaft caps) or make those areas of the machine inaccessible.

• Ball thread spindles and multi-geared trapezoidal thread screws are not self-locking. An appropriate brake device needs to be integrated into the system.

• No lateral forces on the screw. Observe maximum loads.

• Risk assessment by manufacturer of overall system.

1.7 Type plate

Year of construction mm.yyyy Inspection no. 123456

PH56-M1A-ST-ST-600-0-940-24:1-Tr36x6-L-R

Columbus McKINNON Engineered Products GmbH

Ochsenbrunnenstraße 10, 74078 Heilbronn/Germany

Tel. +49 (0)7131/2871-0 Fax +49 (0)7131/2871-11 www.alltec.de

1. PH56 = PHOENIX with profile pipe size 5 (161x161 mm) and profile pipe size 6 (183x183 mm) - also

single-step if necessary: PH34,45,56 and double-step: PH35,46 and three-step: PH36 2. M1A = fitting position - large profile bottom (see Page 8 in PH catalog) 3. ST = standard plate top (240x240x15mm) - (see page 11 in PH catalog) - also SO possible = special

plate in size desired by customer 4. ST = standard plate bottom (240x240x15mm) - (see page 11 in PH catalog) - also SO possible =

special plate in size desired by customer 5. 600 = hoist - (see page 11 in PH catalog) 6. 0 = extension - (see page 11 in PH catalog) 7. 940 = base building height (height in retracted state) - (see page 11 in PH catalog) 8. 24:1 = transmission from gear within the hoisting column - (see page 11 in PH catalog) - possible use

of Merkur 1,2,3 and QLGB-G15 9. Tr36x6 = screw type, diameter and pitch (see page 11 in PH catalog) 10. L = drive side "left" (see page 8 in PH catalog) 11. R = output side "right" (see page 8 in PH catalog)

1.8 Technical specifications

Single-step Double-step PHOENIX

PH34 (M1) PH45 (M2) PH56 (M3) PH46 (M2 / M3)

Standard hoist1 [mm] 700 1000 1000 1000

Lifting speed 2[m/min] 0,45 0,9 0,5 2,25 0,44 0,75 1,25 2 8

Motor power [kW] (Diagram 1.1) 0,25 0,373 0,55 0,75 1,1 1,13 0,75

3 1,2

3 1,7

3

Transmission i [-] 16:1 16:1 4:1 24:1 24:1 6:1

Screw pitch P [mm] 5 10 6 7 12 20 (Ba) 3

32

Max centr. load Fa dyn [kN] 5 10 5 25 15 10 10 54

1 Hoist can be increased by deviating from standard (up to 4,500 mm) 2 Vary lifting speed depending on i, P, n and diagram 3 Motor with brake 4 Maybe gear with oil filling

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1.9 Dimensions

Max load Fa [kN]

Single-step Double-step Loading La5

[mm] PH34 PH45 PH56 PH46

100 5 10 20 10

200 5 8 10 7

300 4 5 7 5

400 - 4 5 3

500 - - 4 -

Single-step Double-step Dimensions

PH34 PH45 PH56 PH46

A 139x139 161x161 183x183 183x183

B - - - 161x161

C 117x117 139x139 161x161 139x139

L1 210 210 210 210

L2 240 240 240 240

L3 420 490 520 -

L33 465 550 580 580

L4 80 90 100 100

L5 260+hoist

300+hoist 340+hoist 375 + 1/2 hoist

5 Higher loading can also be achieved by increasing the basic structure height L5 by VL 3 Motor with brake

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2 Receipt of goods, storage, transport

2.1 Receipt of goods

Startup with defective hoisting columns is forbidden.

Immediately check if the contents of delivery correspond with the shipping documents upon receipt. No other warranties can be approved for subsequent defect claims. Claims on defects and incompleteness must be made immediately at CMCO Engineered Products. Claims on perceivable damages due to transport are to be reported to the transport company immediately.

Small parts such as limit switches are usually delivered unattached and packed individually.

2.2 Transport

• Lift/transport the hoisting columns by the appropriate hoisting points.

• Pay attention to the attachment parts. No person is to stand under suspended loads.

• Use hoisting gear in good condition.

2.3 Storage

Storage period < 3 years

Check corrosion protection; renew or repair, if necessary. Check lubrication of moveable machinery, relubricate if necessary. Check grease/oil level of gears and refill if necessary.

Storage period > 3 years

Check corrosion protection; renew or repair, if necessary. Check lubrication of moveable machinery, relubricate if necessary. Clean screw and grease with fresh lubricant along the whole length. Drain gear oil, and fill gear unit with the prescribed oil quantity and quality. Regrease for grease lubrication.

General information

3 PHOENIX hoisting column

Feature Description

Rotating screw Ba2 Worm gear-driven trapezoidal screw, ball thread spindle or multi-gear Alltec sliding thread screw

Lifting travelling nut Ba2 Travelling nuts conduct the lift movement. Linear movement of hoist profiles.

Merkur 1,2,3,4,5 Worm gear with grease lubrication

Merkur (wiith OIL filling) 1,2,3,4,5 Worm gear with oil lubrication

QLGB G15, G50, G90 Quick lift gear box with low-viscosity grease or oil lubrication

Thread screw with grease lubrication

Suitable for an ambient temperature 0 to +70 °C

If temperatures deviate, a design by our technical office is necessary.

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3.1 Short safety nut – wear indicator (option)

Possible for single- or multi-step hoisting column with trapezoidal screw, ball thread spindle and Alltec sliding thread screw.

Principle: with progressing wear, Distance X decreases under pressure. With drawing load, Distance X increases (for documentation, see 6.1.6)

3.2 Safety-trap nut (optional with Ba screws)

If the Ba nut malfunctions, the Ba screw sets onto the thread of the trap nut. As a result, the power requirement of the drive motors is increased. The unit needs to be switched off by the controller or otherwise by a load monitor.

4 Assembly

1. Align PHOENIX hoisting column with a spirit level and then screw tight. 2. Make sure the PHOENIX hoisting column is parallel to the installed guides. For adjustment, always start

from the basic position with the least play between PHOENIX hoisting columns and guides and continue along the entire lift height.

3. Avoid distortions. The drive shaft must rotate easily and balanced across the entire hoist distance. For systems with multiple PHOENIX hoisting columns

4. Move the PHOENIX hoisting columns to the same height before depositing the load, aligning and fastening.

5. Place shims beneath uneven support surfaces (pieces of sheet metal). Check rotating direction of all PHOENIX hoisting columns.

• Distortions increase power consumption and reduce the service life!

• Avoid misalignment and angular offset.

• Provide movable load support points if necessary.

To even out alignment errors between the individual elements, use rotationally elastic couplings, rotationally elastic propeller shafts or cardan shafts.

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4.1 Assembly of the inductive limit switches

1. Screw in the displacement sensor until it is flush against the inside of the pipe wall.

2. Secure the sensor by tightening the hexagon nut and ensure that the sensor does not turn or the position changes.

1 Switching cam 2 Counter nut 3 Inductive sensor

Should the sensor stand out in the tube, it will break, and its sheared off parts must be removed from the gears. Observe the maximum tightening torque!

Material Type Maximum tightening torque [Nm]

Metal M 12 7

4.1.1 Inductive limit switch IB 120225 or IME 12-04BPOZCOK

LED display

Installed amplifier

Temperature -25 to +70°C

Protection class IP 67 according to EN 50010

Length 46 mm (without plug)

Voltage 10 - 30V

Output PNP, NC (opener)

Maximum current 200mA

Thread M 12x1

Connection M12 (90° angular plug, not included)

Switching distance IB...... = 3 mm

IME… = 4mm

Other IME.. = with UL permission

4.2 Mechanical fastening

Fastening of hoisting columns, see dimensions in Chap. 1.9

For the exact installtion dimensions, please request our dimensional diagrams.

1 3 2

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4.2.1 Screw tightening torques

Tightening torque M A [Nm]

Coarse-pitch thread

Quality 8.8 Quality 10.9 Quality 12.9

M 4 2,8 4,1 4,8

M 6 9,5 14 16,5

M 8 23 34 40

M 10 46 68 79

M 12 79 117 135

M 16 195 280 330

M 20 390 560 650

M 24 670 960 1120

M 27 1000 1400 1650

M 30 1350 1900 2250

M 36 2330

M 42 3676

M 45 5502

M 48 5636

M 56 8856

5 Initial operation

• Always observe and follow this operating manual when using the equipment.

• Any use other than the intended use is prohibited.

• Commissioning may only be performed by authorised personnel.

• Check lubrication level.

• Check limit switches.

• Pay attention to the proper polarization of the electrical installation and the motor's rotating direction.

• Start hoisting system without load. (lift 1x, lower 1x)

• Operate intermittently, gradually increasing the load.

• During initial operation, constantly control the operating temperature and the motor's power usage

• After 5 hours of operation, check that the screws are tight. Retighten where necessary.

6 Maintenance and inspection

Regular (at least 1x per year) inspection/maintenance must be performed by a person authorized by the operator (according to TRBS 1203)

*)6. All tests and modifications must be documented (e.g. machine file, inspection log).

Turn of power before maintenance and inspection of the system.

Observe the relevant safety regulations during maintenance and inspection. Support loads.

6 We recommend to have this check performed by the service of Columbus McKINNON Engineered Products.

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6.1 Maintenance plan

Regularly

Grease the screw. The lubrication intervals depend on the actual operating conditions and the operating time of the PHOENIX hoisting column. In case of doubt, please consult our representatives to find the right lubrication intervals.

Clean the screw of old grease and re-lubricate.

Lubricate the gear at the lubrication nipple (if available) Annually

For operational safety reasons, check the PHOENIX hoisting column at least once per year for wear of the translation thread in the travelling nut.

Wear indicator:

1. Drive hoisting column to 0-position

2. At the viewing slot, measure and record the distance between the travelling nut and the safety nut.

If the distance is < 3.5 mm, immediately replace the travelling nut and the safety nut.

Every 5 years or after 1000 hours of operation

- Merkur: Disassemble the gear, clean of all grease and fill with new grease

- Merkur with oil filling: Replace gear oil

6.1.1 Maintenance and lubrication of three-step telescope hoisting columns (e.g.: PH36)

Lubricate hoisting column only in extended state!

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6.1.2 Maintenance and lubrication of two-step telescope hoisting columns (e.g.: PH46)

Version with lubrication nipple in cover plate available optionally.

Lubricate hoisting column only in extended state!

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6.1.3 Maintenance and lubrication of single-step telescope hoisting columns (e.g.: PH56)

Version with lubrication nipple in cover plate available optionally. Lubricate hoisting column only in extended state!

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6.1.4 Lubrication of multi-step PHOENIX telescope hoisting columns

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6.1.5 Safety check of safety nut (safety nut available optionally)

1. Retract hoisting column 2. Remove lowest lock screw with screwdriver 3. Check if there is a gap between the travelling nut and the safety nut

For pressure load: Gap ≥≥≥≥ 3.5 mm / with drawing load: Gap ≤≤≤≤ 6.5 mm - Screw in lock cap - Begin operation of hoisting column

For pressure load: Gap ≤≤≤≤ 3.5 mm / with drawing load: Gap ≥≥≥≥ 6.5 mm - Screw in lock cap - Replace lifiting column or travelling nut and safety nut

6.1.6 Wear measurement log

We recommend recording the new condition and the wear measurement results (Measurement X).

Hoisting column 1

Hoisting column 2

Hoisting column 3

Hoisting column Signature

New condition

Dimension X 5 mm 5 mm 5 mm 5 mm

Measuring of wear _____________





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6.2 Lubricants

Ambient temperature

[°C]

Trapezoidal thread

Ball thread Alltec sliding

thread Merkur gear

Merkur gear with OIL

QLGB gear with OIL

-30 to 0 SKF LGLT 2 FORMAX 50 SKF LGLT 2 SKF LGLT 2 On request Klüber

Syntheso D 68 EP

-10 to +40 FORMAX 60 or Klüberplex GE 11 680

FORMAX 50 or Klüber

Stabutherm GH-461

FORMAX 60 or Klüberplex GE 11 680

Mobilux EP2 Shell Tivela

S150

Shell Tivela S150 or CLP

PG220

-15 to +80 FORMAX 60 FORMAX 50 FORMAX 60 Mobilux EP2 Shell Tivela

S150 Shell Tivela

S150

over +80 to +180 max

FORMAX 50 FORMAX 50 FORMAX 50 FORMAX 50 On request Klübersynth GH 6-680

Used lubricants are to be disposed of in accordance with legal requirements!

Unit size M1 M2 M3 M4 M5 M6 G15 G50 G90

Lubricant quantity (kg) 0,08 0,14 0,24 0,8 1,1 2,0 0,15 0,6 3,5

7 Decommissioning

When decomissioning the system, recycle or dispose of the various system components and/or screw jacks according to the legal requirements.

Documents

Operating instructions / assembly instructions Telescope hoisting ... · 3 PHOENIX hoisting column ... Machine safety DIN EN ISO 12100-1 ... Do not use the motor to drive to mechanic