MODE V6 Manuale utente

7/2015

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confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, or otherwise employed in

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V6 INTELLIGENT CHAIN HOIST USER MANUAL

7/2015

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confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, or otherwise employed in

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Table of contents

1 GENERAL INTRODUCTION............................................................................................. 5

1.1 Foreword: About this Manual..................................................................................... 5

1.2 Symbols Used in this Manual..................................................................................... 5

1.3 Safety Alert Symbols and Signal Words................................................................... 5

1.4 Questions and Comments.......................................................................................... 6

1.5 Exclusion of Warranty ................................................................................................. 6

1.6 Manual Use................................................................................................................... 7

1.7 Environmental Information.......................................................................................... 7

1.7.1 Lifecycle Environmental Impacts........................................................................ 7

1.7.2 Energy Consumption............................................................................................ 7

1.8 Terminology.................................................................................................................. 8

2 SAFETY FIRST!.................................................................................................................. 9

2.1 Personal Protective Equipment (PPE)...................................................................... 9

2.1.1 Fall Protection ......................................................................................................... 10

2.2 Fire Safety................................................................................................................... 10

2.3 Main Isolation Switch................................................................................................. 11

2.4 Emergency stop ......................................................................................................... 11

2.5 Owner's Responsibilities........................................................................................... 12

2.5.1 General Safety Issues........................................................................................ 12

2.5.2 Chain Hoist Machinery Safe Working Period (SWP) .................................... 14

2.5.3 How to Assess the Hoisting Machinery Safe Working Period..................... 14

2.6 Intended use of the product...................................................................................... 15

2.6.1 Duty Group........................................................................................................... 15

2.7 Operating Environment............................................................................................. 17

2.8 Safety During Installation.......................................................................................... 17

2.9 Safety during Usage.................................................................................................. 19

2.10 Safety during maintenance..................................................................................... 20

2.10.1 Lockout-Tagout Procedure.............................................................................. 22

2.11 Sound Intensity Level.............................................................................................. 23

3 IDENTIFICATION.............................................................................................................. 24

3.1 Hoist identification data............................................................................................. 24

3.2 Manufacturer............................................................................................................... 25

3.3 Standards and Directives.......................................................................................... 25

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4 CONSTRUCTION ............................................................................................................. 26

4.1 Identifying the key parts of the hoist........................................................................ 26

4.2 Main Functions........................................................................................................... 27

4.2.1 Hoisting Function................................................................................................ 27

4.2.2 Safety Functions................................................................................................. 28

4.3 Signs............................................................................................................................ 28

4.3.1 Safety Signs......................................................................................................... 28

5 INSTALLATION................................................................................................................. 29

5.1 Installation preparations............................................................................................ 29

5.1.1 Lifting the hoist.................................................................................................... 30

5.2 Electrical connections................................................................................................ 32

6 COMMISSIONING ............................................................................................................ 34

6.1 Commissioning preparations.................................................................................... 34

6.2 Checks before first run.............................................................................................. 35

6.3 Test Run Without Load ............................................................................................. 36

6.4 Test run with test load............................................................................................... 38

6.5 After test runs............................................................................................................ 39

7 INSTRUCTIONS FOR THE OPERATOR...................................................................... 40

7.1 Operator’s Responsibilities....................................................................................... 40

7.2 Checks to Be Done Before Every Working Shift................................................... 42

7.2.1 Checks to be performed by the operator......................................................... 42

7.2.2 Operational Checks with the Emergency Stop Button Pushed Down........ 43

7.2.3 Operational Checks with Controller Enabled.................................................. 43

7.3 Movements.................................................................................................................. 45

7.3.1 Motor Control Methods ...................................................................................... 46

7.3.2 Lifting and Lowering Motions............................................................................ 46

7.4 Load Handling............................................................................................................. 47

7.5 Load Control ............................................................................................................... 53

7.6 Safety Procedure After Using the Hoist.................................................................. 54

7.7 Hand Signals and Other Methods of Communication.......................................... 55

8 MAINTENANCE................................................................................................................. 56

8.1 Why You Must Care About Maintenance............................................................... 56

8.2 Service Personnel...................................................................................................... 57

8.3 Inspections.................................................................................................................. 57

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8.3.1 Daily Inspections................................................................................................. 57

8.3.2 Monthly inspections............................................................................................ 58

8.3.3 Quarterly inspections.......................................................................................... 58

8.3.4 Annual inspections.............................................................................................. 58

8.4 Lubrication................................................................................................................... 64

8.4.1 General lubrication instructions........................................................................ 64

8.5 Lubrication charts....................................................................................................... 66

8.6 Approaching Theoretical Calculated Lifetime........................................................ 67

8.6.1 Special Assessment........................................................................................... 67

8.6.2 General Overhaul................................................................................................ 67

8.7 Returning the Product to Use after a Long Period Out of Service...................... 68

8.8 Frame........................................................................................................................... 69

8.9 Motor........................................................................................................................... 70

9 DISMANTLING.................................................................................................................. 71

9.1 Dismantling the Product............................................................................................ 71

9.2 Disposal of Waste Material....................................................................................... 71

10 TECHNICAL DATA......................................................................................................... 73

10.1 Technical Features.................................................................................................. 73

10.2 Tightening torques................................................................................................... 73

APPENDIX: INSPECTING CHAIN WEAR........................................................................ 74

APPENDIX: INSPECTING THE HOOK OPENING......................................................... 76

APPENDIX: TROUBLESHOOTING (3 PHASES)........................................................... 77

APPENDIX: TRANSPORTING AND STORING THE PRODUCT................................ 78

APPENDIX: SAFE WORKING PERIOD (SWP) CALCULATION................................. 79

ANNEX, ANSI HAND SIGNALS......................................................................................... 82

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confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, or otherwise employed in

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1 GENERAL INTRODUCTION

1.1 Foreword: About this Manual

This manual offers guidance to enable safe and efficient operation of the equipment.

Taking the time to read this manual will help you to prevent damage to the equipment, and,

most importantly, personnel situated close to it. The equipment is designed to be safe when

used correctly. However, there are many potential hazards associated with incorrect operation

and these can be avoided when you know how to recognize and anticipate them.

This manual will also make you aware of your responsibilities with respect to the equipment and

help you to ensure that it is kept in a safe operating condition throughout its lifetime.

This manual is not intended as a substitute for proper training but provides recommendations

and methods for safe and efficient operation and maintenance. The equipment's owner must

ensure that operators are properly trained prior to operation and, at all times, comply with all of

the applicabIe and prevaiIing safety and other standards, rules and regulations.

1.2 Symbols Used in this Manual

Readers should familiarize themselves with the following symbols which are used in this

manual.

Indicates that the product is slowing down or is moving at its

slowest speed.

Indicates that the product is accelerating or moving at its highest

speed.

NOTE: Indicates items which require special attention by the reader.

There is no obvious risk of injury associated with notes.

1.3 Safety Alert Symbols and Signal Words

The following symbols are used in this manual to indicate potential safety hazards.

Obey all safety messages that follow this symbol to avoid possible

injury or death.

CAUTION

Indicates a potentially hazardous situation, which if not avoided, MAY

result in minor or moderate injury. It may also be used to alert against

unsafe practices.

7/2015

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confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, or otherwise employed in

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WARNING

Indicates a potentially hazardous situation, which if not avoided, COULD

result in death or serious injury.

DANGER

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT

AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

NOTICE

Addresses situations not related to personal injury, such as likely or

possible damage to equipment.

Shall

Indicates that a rule is mandatory and must be followed.

Should

Indicates that a rule is a recommendation, the advisability of which

depends on the facts in each situation.

1.4 Questions and Comments

Any questions or comments relating to the content of this manual and/or the operation,

maintenance and/or service of manufacturer products should be directed to:

www.modehoist.com

1.5 Exclusion of Warranty

All technical information and data in the workbook and tips are in line with the latest technical

level before publication, and draw lessons from the experience so far we faithfully and

instructions.

Involved in this manual to the continued development of the electric hoist, we reserve the right

to revise the technology, and not from the data in this manual, illustrations and specifications of

the other requirements.

Relevant specification, and the results show that, not necessarily, in full compliance with the

scope of supply or spare parts supply illustrations and diagrams are not drawn in proportion.

Everything will be subject to orders attached data.

Due to operational errors, ignoring the instructions or maintain undeserved and cause damage

to the operation of the fault, we shall not be responsible for.

We hereby made clear that only allows the use of animal husbandry, the company determined

by the original spare parts and accessories. This applies to the components of other

manufacturers.

For security reasons, that shall not be installed and used without the permission of spare parts

or accessories, also may not be modified without authorization. Or animal husbandry, company

shall not bear the resulting consequences.

For our cause accidental error or omission, by MODE according to the main scope of the

guarantee obligations in the contract (not including other requirements) guarantee obligations.

The names for the compensation according to law and extended out requirements, shall not

consider.

7/2015

This document and the information contained herein, is the exclusive property of MODE. And represents a nonpublic,

confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, or otherwise employed in

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1.6 Manual Use

Every person exposed to the manufacturer's equipment must, prior to OPERATING,

SERVICING AND/OR MAINTAINING SUCH PRODUCTS, read and understand the contents

of this manual and strictly adhere AND CONFORM THEIR CONDUCT WITH AND TO THE

INFORMATION, RECOMMENDATIONS AND warnings provided herein.

Note: Keep these instructions in a safe, accessible location for future

reference by personnel operating the equipment or exposed to the

equipment's operation.

Read and understand the contents of this manual prior to operating,

servicing, and or/maintaining the equipment. Failure to do so can

result in serious injury or death.

1.7 Environmental Information

Environmental aspects have been taken into account in designing and manufacturing this

product. To prevent environmental risks during use, please follow instructions for safe lubricant

handling and disposal of waste material. Proper use and maintenance improves environmental

performance of this product.

1.7.1 Lifecycle Environmental Impacts

The lifecycle stages are:

■production of materials,

■components and energy,

■transportation to factory,

■equipment manufacturing and assembIy,

■transportation to customer,

■assembly at site,

■use phase including maintenance and modernization,

■end of life dismantling and recycling of the materials.

1.7.2 Energy Consumption

Energy consumption during the use phase is the biggest environmental. Electricity is

needed for lifting and traveling motors as well as lighting, heating, cooling and other optional

electrical components as part of the hoist. Lighting may account for a significant part of total

electricity used.

7/2015

This document and the information contained herein, is the exclusive property of MODE. And represents a nonpublic,

confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, or otherwise employed in

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1.8 Terminology

The following terms and definitions are used in this manual:

ANSI

American National Standards Institute

ISO

International Organization for Standardization

Authorized personnel

Persons who are authorized by the owner and who have the necessary

training to carry out operation or service actions

Experienced service

person authorized by the

manufacturer

A person with service experience who is authorized by the manufacturer

to perform service actions.

CE marking

The CE-marking indicates that the product complies with the appropriate

EC directives.

Check

A visual and functional assessment (not a test) of the product without

dismantling.

Emergency brake

A brake that can be applied by the operator, or automatically upon loss of

power.

Electric panel

Power to the motors is controlled through the electric panel.

Operator

Person operating the product for the purpose of handling loads.

Inching

Making very small movements by repeatedly and momentarily pressing

the direction control.

Main isolation switch

The main isolation switch is the power switch which the operator should

normally use to turn off power.

Chain hoist

Drive mechanism for lifting and lowering the load.

Inspection

Looking for defects and checking the operation of the controls, limiting

and inspecting devices without loading the product. This is much more

than a check but does not normally require any part of the product to be

dismantled other than for removal or opening of covers or housings.

Power supply

Power is supplied to the motors via the power supply.

Controller

The pendant or other type of controller is used by the operator to give

commands to the product.

Qualified personnel

Workers with necessary qualifications based on theoretical and practical

knowledge of hoists. A qualified person must be in a position to assess

the safety of the installation in conjunction with the application. Persons

with the authority to undertake certain product maintenance work include

the manufacturers' service engineers and trained fitters with a

corresponding

certification.

Maximum capacity

Load that the product is designed to lift for a given operating condition

(e.g. configuration, position of the load).

Trolley (hoisting unit)

The trolley (hoisting unit) moves along the girder.

Sling

A sling is used to attach the hook to the load when the load cannot be

lifted directly by the hook.

7/2015

This document and the information contained herein, is the exclusive property of MODE. And represents a nonpublic,

confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, or otherwise employed in

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2 SAFETY FIRST!

Safety requirements must be understood and followed.

2.1 Personal Protective Equipment (PPE)

Note: This chapter proposes personal protective equipment to ensure

operator's full safety. Local regulations and requirements of the working

environment shall be followed.

For safety, operator or others in close proximity to the product may be required to wear

Personal Protective Equipment (PPE). Various types of PPE are available and must be

selected according to the requirements of the working environment. Some examples of

different types of PPE are:

Typical PPE

A. Hard hat

B. Hearing protection

C. Gloves

D. Safety shoes

E. Safety goggles

F. Face mask

G. Flashlight for use in case of power failure

H. Overalls

Appropriate clothing must be selected for each task. For example:

Fire-resistant clothing must be worn when welding, flame cutting or using an angle grinder.

Tear-resistant clothing must resist damage from sharp edges in the steel structure.

Anti-static clothing must be worn when working on electrical circuits so that components

do not get damaged by a discharge of static electricity.

When working with lubricants, clothing must prevent direct skin contact with the lubricant.

Clothing should be chosen with consideration to the temperature at the working site.

7/2015

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confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, or otherwise employed in

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2.1.1 Fall Protection

While personnel are performing inspection or maintenance work at heights, they must follow fall

protection procedures as required by local regulations. Fall prevention practices and fall

protection equipment aim to protect personnel working on or around the equipment from

exposure to falls.

If the equipment does not have a service platform or handrail, personnel must use a properly

fitted safety harness that is attached to the dedicated fixing points on the building or equipment

in order to prevent falls.

If the product does not have dedicated fixing points for fall protection, it is the owner's

responsibility to make sure that there are suitable fixing points in the building structure.

If ladders must be used, personnel must practice setting and securing the ladders before using

them for actual work.

A typical fall protection program may include:

● Documented and established site policies and procedures.

● Conducting site assessments for fall hazards.

● Selection of the proper fall protection system and equipment.

● Training on fall protection procedures and the proper use of fall protection systems.

● Inspection and proper maintenance of fall protection equipment.

● Measures to prevent falling objects.

● Rescue Plans.

If necessary, contact your supplier or service organization for assistance with designing your

fall protection program.

2.2 Fire Safety

In the event of a fire, only attempt to fight it if you can do so without putting yourself in danger.

Tum the power off if it is possible to do so. Evacuate the area. Notify other people about the

potential danger, and call for help.

WARNING

Never use a powder type fire extinguisher on high voltage.

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