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FEM9.756 Engl PDF
FEM9.756 Engl PDF
EUROPEENNE DE LA
MANUTENTION 9.756
Section IX
SERIES LIFTING 08.2004 (E)
EQUIPMENT
Copyright: FEM Section IX Available in German (0), English (E), French (F) Sources see end of the document
Within the scope of application of this rule, it is stated which hazards are covered. For hazards not covered by
this rule, the hoists, where applicable, shall comply with EN 292.
1 Scope
This Rule applies to hand-operated and power driven hoists for the lifting and lowering of loads and persons in
special domains of application.
This Rule defines the requirements for the design and construction of hand-operated and power driven hoists
which are used for special applications.
Rope hoists winding in single layers with round steel wire ropes. (Annex A, fig. 1);
Chain hoists with round steel link chains (Annex A, fig. 2) or roller chains;
Belt hoists (Annex A, fig. 3), where a belt is wound onto a drum in one winding in several layers.
Rope hoists winding in single layers with round steel wire ropes (Annex A, fig. 4);
Rope hoists winding in several layers with round steel wire ropes (Annex A, fig. 5).
Power driven within the meaning of this rule signifies electrically, hydraulically or pneumatically driven.
This rule covers the hazards indicated in clause 4, which may arise during commissioning, operation and
maintenance of the hoists.
This rule also applies to hoists which are intended to be used for the lifting of persons in theatre applications.
Hoists for assembling and mounting purposes may be single /:mists or several hoists operated in groups. There
are no load movements above persons involved.
When using several hoists for group travels above persons, further hazards may arise which are not considered
within the framework of this rule. In such a case, the requirements for the individual hoists are to be made in
accordance with this rule, as far as this rule is applicable.
Pending the publication of a new rule defining the requirements for control and monitoring during use for group
travels above person, a risk analysis according to EN 954 and EN 1050:1996 may be used in individual cases to
prove the use of these hoists.
Among others, a risk analysis shall assess the following, additional risks:
- setting-up mode;
• user information;
- etc.
- etc.
EN 292-1: 1991 Safety of machinery, Basic concepts, general principles for design.
Part 1: Basic terminology, methodology, ISOIDIS 12100~ 1
EN 294:1994 Safety of machinery - Safety distances to prevent danger zones being reached by the
upper limbs
EN 349: 1994 Safety of machinery - Minimum gaps to avoid crushing of parts of the human body
EN 418: 1994:1994 Safety of machinery - Emergency stop equipment, functional aspects - Principles for
design
EN 818-7:2002 Short link chain for lifting purposes - Safety - Part 7: Finetolerance hoist chain, Grade
T (Types T, OAT, DT) .
EN 954-2: 1999 Safety of Machinery - Safety-related parts of control systems - Part 2: Validation
EN 982:1996 Safety of machinery - Safety requirements for fluid power systems and their
components - Hydraulics
EN 983: 1996 Safety of machinery - Safety requirements for fluid power systems and their
components - Pneumatics
EN 13411-1 :2002 Terminations for steel wire ropes - Safety - Thimbles for steel wire rope slings
EN 13411-2:2002 Terminations for steel wire ropes- Safety - Part 2: Splicing of eyes for wire rope slings
EN 13411-4·:2002 Terminations for steel wire ropes,... Safety - Part 4: Metal and resin socketing
prEN 13411-3:1999 Terminations for steel wire ropes- Safety - Part 3: Ferrule-secured eyes
prEN 13411-6:1999 Terminations for steel wire ropes - Safety - Part 6: Asymmetric wedge socket c1evis
prEN 14492-2:2002. Cranes - Power driven winches and hoists - Part 2: Power driven hoists·
ISO 4308-1: 1986 Cranes and lifting appliances - Selection of wire ropes - Part 1: General
ISO 4309: 1990 Cranes - Wire ropes - Code of practice for examination and discard
SS 7905-1 :2001 Lifting equipment for perforrilance, broadcast and similar applications -
Part 1: Specification for the design and manufacture of above stage equipment
(excluding trusses and towers) .
DIN 15400:1990 Lifting hooks, materials, mechanical properties, lifting capacity and stresses.
DIN 56925:1997 Theatre engineering, stage machinery - Scenery hoist - Safety requirements and
testing
FEM 1.001 (10.1998) Rules for the design of hoisting appliances, booklets 1 - 8
FEM 9.511 (06.1986) Rules for the design of series lifting equipment - Classification of mechanisms
FEM 9.661 (06.1986) Rules for the design of series lifting equipment - Dimensions and design of rope reeving
components
FEM 9.571 (10.1988) Series lifting equipment - Chain qualities, selection criteria and requirements
FEM 9.683 (10.1995) Series lifting equipment - Selection of lifting and travel motors
FEM 9.752 (07.2003) Series hoist mechanisms with adjustable speed electrical power drive systems - Low
voltage adjustable frequency AC power driven systems.
FEM 9.755 (06.1993) Measures for achieving safe working periods for motorized serial hoist units..
FEM 9.761 (01.1995) Lifting force limiters for controlling the loading of motorized series hoists mechanisms.
FEM 9.852 (07.1998) Power driven series hoist mechanisms - Standardised test procedure for verification of
the dassification
FEM 9.901 (12.1991) Rules for the design of series lifting equipment and cranes equipped with series lifting
. equipment
Compensating sheaves are rope sheaves which the wire rope runs over during operation generally for no longer
path than three times its diameter
Example: Pneumatic series lifting equipment with a rated capacity of 1000 kg at a rated pneumatic pressure
of 6,3 bar
3.22 Lifting and lowering Iimiters (terminal stopping switch and final limit switch)
Limiting devices which limit the upward and downward movement (see EN 12077-2:1998).
For specific cases, second movement limiting devices may be required (see EN 12077-2:1998, clause 5.6.1.4;
EN 60204-32:1998)
No Hazards Requirements
Relevant clause(s)
of this document'
No Hazards Requirements
Relevant clause(s)
-. of this document
7.1 Hazards from contact with or inhalation of harmful fluids, gases, 5.4,5.11.6,5.11.7,
mists, fumes, and dusts 5.12
No Hazards Requirements
Relevant clause(s)
of this document
No . Hazards Requirements·
Relevant clause(s)
ofthis document
4.1.1 Hoists for assembling and mounting purposes, no load movement above persons
(Single hoists or hoists in groups)
(Risk consideration single hoists used above persons, cases of application nos. 5, 6 and 11, 12, see
figure A7, A8).
T
Use above persons'
I
I
Use with a view of Use without a view of
the load movement the load movement
I
I I I
Hoist Hoist Hoist Hoist
statically dynamically statically dynamically
loaded loarled loaded load,ed
I
I I I I I
Hoist firmly Hoist mobile -loist firmly installed Hoist firmly Hoist mobile Hoist firmly in-
installed or mobile installed stalled or mobile
I I I I
I I I I 1 I I I I I I
Load Load Load Load Sce- Load Load Load Load Load Sce- Load
se- not se- not nic dyna- se· not se- not nic dyna-
cured secured cured secured move- - mic cured secured cured secured move - mic
ment ment
8008 00 8 0 0 8 88
FEM-Oocument 9.756 08.2004 (0) Page 17 of57
5 Safety requirements and/or measures .
5.0 General
Power driven hoists shall be classified in groups of mechanisms in accordance with ISO 4301 :1986-1 or
FEM 9.511 (06.1986) according to the operational requirements and conditions of application.
Power driven hoists be constructed in accordance with prEN 14492-2:1998, FEM 1.001 (10.1998) and
FEM 9.901 (12.1991Y.
Hoists shall have sufficient strength properties in accordance with the requirements of this rule and, if
relevant, the requirements of Annexes Band C and the relevant EN standards. This shall also apply
considering normal wear and ageing.
Supporting construction elements of the hoists shall be made of hardly inflammable materials.
Accessible parts shall not possess sharp edges, sharp angles or protruding parts which may cause
injuries. In particular edges shall be trimmed, f1anged or cut. .
Construction,location or safeguarding of moving parts lying in the kinematic chain (shafts, fans, wheels,
gearwheels, belts, couplings) shall offer protection against hazards caused by possible contact of
exposed persons during intended use.
The hazard of burning during a hoisting operation, caused by contact of the skin of the operator with hot
surfaces of the hoist, shall be reduced in accordance with the principles of EN 563.
In the following, it is assumed that the hoists, concerning use, are dimensioned in relation to hook path
and cycle frequency.
5.1.1 Hoists for assembling and mounting purposes, no load movement above persons (single
hoists or several hoists operated in groups)
Assembling hoists, whether mobile or firmly installed, are power driven hoists in accordance with
FEM 9.761 (05.1998) and hand-operated hoists in accordance with prEN 13157:19~8, exclusively for
load transport during assembling. The instructions for use shall contain particular information describing
the use of these assembling hoists. Also hoists constructed as so-called climbing hoists may be used as
assembling hoists. Assembling hoists are preferably marked as SUCh.
When using several assembling hoists, the loads shall be distributed equally. During the lifting and
lowering operation, the working area shall be cordoned off for reasons of protection of persons. After
lifting, the loads shall be secured.
The information in the instructions for use, in partiCUlar the information relating to the rated load (reduced
capacity) and the possibility of an overloading, shall be observed.
Capacity and nature of the suspension point shall be appropriate for the intended purpose of the hoist.
.The instructions for use shall contain information relating to this particular purpose and also relating to
the necessity of an obligation to carry out maintenance as well as indications about the maintenance
periods. . .
Principally, a first and second lifting and lowering Iimiter in accordance with 5.2.5 shall be provided
(terminal stopping switch and final limit switch).
Power driven hoists shall be used in accordance with FEM 9.761 (05.1998). Additional requirements for
the hoist are described for the corresponding cases·of application.
Hand-operated hoists shall be used only for cases of application 1 to 6. Additional requirements for the
hoist are described for the corresponding cases of application.
5.1.2.1 Case ofappllcation 1 (static load, hoist firmly installed, load secured after lifting off)
Direct acting lifting force Iimiters in the kinematic: chain are admissible.
After lifting, the loads shall be secured.
Where one hoist possesses several falls or where several hoists are operated in groups, the load
distribution shall be known.
During the lifting and lowering operation, the working area shall be cordoned off for reasons of protection
of persons.
5.1.2.2 Case of application 2 (static load, hoist firmly installed, load not secured after lifting off)
Fault exclusion by dimensioning the complete hoist for 2 times the rated load; for dimensioning, 400 full
load life hours in accordance with FEM 9.511 (06.1986) shall be taken as a basis.
The rated load shall be known. For a hoist with several falls, also the load distribution shall be known.
Example: Rated load e.g. 500 kg, 1Bm. use of one hoist in 1Bm, with a rated capacity of 1000 kg.
Direct acting lifting force Iimiters lying in the kinematic chain between the load and the securing devices
are admissible, but shall be set to 2 times the rated load..
Hand-operated hoists shall be dimensioned for 2 times the rated load. During the lifting and lowering
operation, the working area shall be cordoned off for reasons of protection of persons.
As soon as the load is positioned, the power driven hoist shall be separated from the energy supply
(5.11.3, 5.12.3, 5.13.3).
Appropriate measures shall prevent an unauthorized restarting (e.g. key-lockable disconnecting device).
5.1.2.3 Case of application 3 (static load, hoist mobile, load secured after lifting off)
As case of application 1.
5.1.2.4 Case of application 4 (static load, hoist mobile, load not secured after lifting off)
Fault exclusion by dimensioning the complete hoist for 2 times the rated load; for dimensioning, 400 full
load life hours in accordance with FEM 9.511 (06.1986) shall be taken as a basis.
The rated load shall be known. Also, in case of a hoist with several falls, the load distribution shall be
known.
Example: Rated load e.g. 250 kg, 1Bm. Use of one hoist in 1Bm, with a rated capacity of 500 kg.
Independent from their rated capacity, power driven hoists shall be equipped with a lifting force Iimiter in
accordance with 5.2.2, the triggering limit of which is set ace. to the rated load.
Hand-operated hoists shall be dimensioned for 2 times the rated load. The rated load shall be known.
For a hoist with several falls, also the load distribution shall be known.
During the lifting and lowering operation, the working area shall be cordoned off for reasons of protection·
of persons.
a) Use of a hand-operated or power driven hoist and installation of an additional, appropriate protective
device against load dropping, acting directly on the load.
The rated load shall be known. For a hoist with several falls, also the load distribution shall be
known.
or
b) redundant design of the power driven hoist (load handling attachments, hoisting media, drive,
gearboxes, pneumatic and hydraulic drives incl. supply, supporting parts, suspension); direct acting
lifting force Iimiters are admissible only for pneumatically or hydraulically driven hoists. Each hoist
shall be dimensioned for the rated load (at least 1Bm, 400 full load hours)
and
the monitoring of the loading of the individual hoists shall be effected by indirect acting lifting force
limiters the triggering limit of which is set acc. to the rated load
and the compensating lever shall be provided with cushioning devices which, in case of failure of
one hoist, minimize the forces of the rearrangement impact.
The rated load shall be known. For a hoist with several falls, also the load distribution shall be known·
or
c) fault exclusion by dimensioning the complete power driven hoist (load handling attachments,hoisting
media, drive, gearbox, pneumatic and hydraulic drives incl. supplies, supporting parts, suspension)
for 2 times the rated load; for the dimensioning, 400 full load life hours in accordance with FEM 9.511
(06.1986) shall be taken as a basis.
The rated load shall be known. For a hoist with several falls, also the load distribution shall be
known.
Example: Rated load e.g. 250 kg, 1Bm. Use of one hoist in 1Bm, with a rated capacity of 500 kg.
and
independent of its rated capacity, the hoist is equipped with a lifting force Iimiter in accordance with
5.2.2, the triggering limit of which is set ace. to the rated load.
The use of direct acting lifting force Iimiters is admissible; however, these shall be set at a value of
2 times the rated load, and the use of an additional, indirect acting lifting force limiter the triggering
limit of which is set acc. to the rated load is always required
and
the hoist is equipped with two safeguarding measures acting independently from each other.
- two brakes acting independently from each other under each operating condition;
- two seat valves independent from each other and arranged in series, orcombinations of safety
devices against pipe breaks and clamping devices.
Each one of these safeguarding measure~ shall be capable to brake down and hold the load alone. It
shall be possible to check the effectivity of each of these safeguarding measures individually.
and
or
d) Hand-operated hoists shall be dimensioned for 2 times the rated load and shall be equipped .
additionnally with a second brake. Each brake shall be capable of braking down and holding the
load.
It shall be possible to check the brakes individually.
The rated load shall be known. For a hoist with several falls, also the load distribution shall be
known.
When determining the change-over points, overrun paths caused by response delays of the safety
elements shall be taken into account. .
5.1.2.7 Cases of application 7 -12 (as 1 -6, but load is not always or safely visible)
Hand~operated hoists shall be used only for cases 8 and 9 of application.
In addition to the requirements for cases of application 1 - 6, an underload switch-off in accordance with
5.2.6 shall be fitted.
If one hoist contains several falls, all falls shall be monitored individually.
5.1.3 Single hoists for transport of persons (in theatre applications only)
Transport of persons in theatre applications is not covered by the Machinery Directive (see part
98/37/EG).
Principally, the requirements of 5.1.2 shall apply; in addition, the recovery of a person in the event of
hoist failure shall be possible.
Otherwise, the requirements for the single hoist are the same as for cases ofapplication 5, 6, 11 and 12.
5.2 Devices
5.2.1 Manually actuated control devices
Control devices for starting power driven hoists shall be designed such that the drive is interrupted when
the actuating elements are released.
Actuating elements of control devices shall be designed, arranged and marked in such a way that their
assignments, direction of operation and switching state are unmistakably recognisable (FEM 9.941 and
EN 12077-1).
In dark or non-illuminated environments, the direction of movement of the hoist shall be clearly indicated
when actuating the control device for the hoisting command.
If the manually actuated control devices are used only for setting mode, it shall be ensured that the
setting mode has priority over the normal operation (e.g. automatic mode, control system overridden).
Lifting force Iimiters shall satisfy the requirements of FEM 9.761 (01.1995) "Series lifting equipment-
lifting force Iimiters for controlling the loading of motorised series hoist mechanisms".
Safety-related components of lifting force Iimiters shall correspond at least to category 1, electronic
evaluation devices incorporated in these shall correspond at least to category 2 according to EN 954-
1:1997.
The necessity to prOVide a rated capacity indicator in accordance with EN 12077-2:1998 shall be verified
by carrying out a risk analysis for the respective case of application.
In the case of a direct acting lifting force limiter, the setting shall be done in a way that a load of 110 % of
the rated capacity can be lifted at the maximum rated hoisting speed to perform the dynamic overload
.test without changing the setting of the lifting force Iimiter. It shall be ensured that when all tolerances are
taken into account a load of 160 % of the rated capacity shall not be lifted with this setting.
In the case of an indirect acting lifting force Iimiter, the setting shall be done in a way that a load of more
than 125 % of the rated capacity will trigger the Iimiter with all tolerances being taken into consideration.
When the lifting force limiter is triggered, this load shall not be lifted over a distance greater than the lifting
path travelled during one second at rated hoisting speed.
Electrically powered hoists shall be designed according to 5.13.5, pneumatically powered hoists shall
designed according to 5.11.4 and hydraulically powered hoists shall be designed according to 5.12.4 of
this rule.
The mechanical limit speed of the motor shall not be reached in this case.
After the lifting and lowering Iimiters have been triggered, motion in the opposite direction shall still be
possible.
It shall be possible to verify that the lifting and lowering Iimiters are functioning properly.
After triggering of a Iimiter, it shall be ensured that the Iimiter does not return to its neutral position until
the part that has triggered the Iimiter has left the corresponding limited area. The lowering Iimiter shall
ensure that the minimum engagement of the hoisting medium is maintained at any time during operation.
The lowering Iimiter shall also stop the movement in order to prevent unwanted winding into the opposite
direction.
If for mobile cases of application of the hoist (3-6 and 9-12) the first movement Iimiter needs to be
readjusted, this shall be done only by specially trained staff.
Apart from the aforementioned Iimiters, second Iimiters shall be provided according to EN 12077-2:1998,
clause 5.6.1.4. Indication and restart are not necessary if the second Iimiter is a friction clutch designed
to absorb the kinetic energy.
If for ,a movement a second Iimiter is provided behind the first, such a second limiter should possess
another circuit than the first and should initiate a stop function of category 0 (see subclause 9.2.2 of
EN 60204-32:1998).
Power circuits for the first Iimiters may contain electronic devices (see subclause 9.4 of EN 60204-
32:1998). ,
The second Iimiters shall be of the electromechanical type and shall have a positive opening function
(see subclause 3.46 of EN 60204-32:1998).
If, for testing purposes, an overriding device is provided for the first Iimiter, this shall be only a hold-ta-run
control device.
If a hoist possesses several load falls, all falls shall be monitored individually.
The triggering limit of the underload switch-off device is reached when one of the following conditions
applies: ' ,
For cases of application 5, 6 and 11, 12, all safety-related parts of control systems listed hereafter shall
conform to category 3 of EN 954-1: 1997.
5.3 Couplings
Couplings shall be made in such a way that in case of a failure of elastic elements, there is a positive
engagement of metal parts.
5.4 Brakes
Brakes of hoists shall be constructed in such away that movements are decelerated and that unwanted
movements are prevented. In addition to the rated capacity of the hoist, the moment of inertia of the
rotating masses, the triggering limit of the lifting force Iimiter and the maximum speed in the downward
direction at rated capacity (e~g. in the event of phase failure, see 5.2.4) shall also be considered in this
respect.
In addition to letters a) to d), brakes shall automatically. engage in the case of 3-phase motors when two
phases of the electrical power supply of the corresponding drive (= motor) are interrupted.
If a brake spring breaks, this shall not result in unintentional load movements. Brake springs shall be
designed as compression springs, e.g. helical springs, which are guided and secured against
intertwining. .
If the braking force is supplied by prestressed springs, the failure of any spring in the braking system
shall not reduce the available braking torque by more than 20 %. This can be achieved, for example:
- When using less than 5 helical springs, these shall be dimensioned such that the wire diameter is
greater than pitch/2 in the working condition to prevent screwing in of the two spring parts in the
event of a wire break.
Brake linings shall be made of asbestos-free material. It shall be easily possible to check the wear of the
brake Iinings~
It shall be possible to check, adjust and replace the brake or the brake linings. If a constructive
connection is provided between the brake lining and brake lining holder, it shall be ensured that this
connection cannot loosen unintentionally.
5.5 Gearboxes
Gearboxes shall be dimensioned according to the expected loads taking into account the classification in
groups of mechanisms according to ISO 4301:1986 or FEM 9.511 (06.1986). .
The lateral deflection of the wire rope from the groove level shall not exceed 4 0 (1: 15). Here, type and
quality of the rope shall be taken into account.
Consideration shall be given to the maximum lateral deflection of the wire rope (ex) when designing the
shape of rope grooves (figure 1).
1'-1-/
Ij~
I
'Q!\
Figure 1
The rope running off the rope drum shall neither come into contact with the rope already wound on the
drum nor with the tip of the unwound groove profile. In the case of rope sheaves, the rope shall not run
on the edge of the groove section.
Rope drives shall be dimensioned in accordance with ISO 4308-1 :1986 or FEM 9.661 (06.1986).
Suitable measures are, for example, rope guides used together with limiting devices according to 5.2.5,
flanged drum end plates or casings.
Rope drums shall be provided with rope grooves. The rope grooves shall be provided with a groove
radius of (0,525 to 0,55) x nominal rope diameter. The rope groove depth shall be between 0,30 and
0,45 of the. nominal rope diameter.
The distance between the rope grooves shall be selected such that a sufficient distance remains
between the individual rope windings on the rope drum taking into consideration the tolerances of the
rope diameter.
Rope drums shall be designed such that the ropes can be securely attached to them without damage by
bending. The fiXing points shall be arranged in such a way that the ropes can be fixed without hindrance.
Rope run-on points shall be guarded to prevent accidental ingress of parts of the human body.
Flanged drum end plates shall protrude beyond the top layer of the rope wound on the drum by at least
1,5 times the nominal rope diameter.
For hand-operated hoists, the rope drums shall be provided with grooves for the cases of application 2,
4, 5, 6. The ropes shall be wound only in a single layer.
5.7.3 Ropes
Ropes used in rope drives shall be designed suitably for the particular application and be made of
suitable materials so that they withstand the permissible stresses.
Ropes shall be rated for a period of service that exceeds the inspection intervals specified by the
. manufacturer (for intended use).
In the case of a non-guided load suspended by a single rope, rotation-resistant ropes shall be used.
. Suitable rope designs are those that comply, for example, with ISO 2408:1985.
Rope ends shall be made in such a way that the. rope structure does not loosen.
For hand-operated hoists, the rope safety shall be at least 8 (ratio minimum breaking load to rated load).
For the cases of application 5, 6 and 11, 12, the ratio of the minimum breaking load to rated load shall be
at least 10.
The distance between the edge of the sheaves and the protective components shall not exceed 0,5 x
rope diameter.
If a rope sheave breaks, the rope shall not slip off the sheave shaft.
Rope grooves on rope sheaves shall have a groove radius of (0,525 bis 0,55) x nominal rope diameter.
The opening angle of the rope sheave shall be symmetrical and between 30° C and 60° C.
The depth of the grooves shall not be less than 1,4 x rope diameter.
Rope run-on points on rope sheaves shall, with the exception of compensating sheaves, be covered
and, in the hand area, be designed in such a way as to largely prevent manual ingress.
Sheave diameters shall be dimensioned in accordance with the group of mechanisms. In case of hand-
operated hoists, the deflection sheave diameter shall be at least 20 x d.
Appropriate means shall prevent ropes from lifting off the predetermined rope drum grooves as a result
of slack rope.
Rope drives shall be arranged iil such a way that damage to the ropes by contact between them and
with fixed and moving structures is prevented.
FEM document
.
9.756 08.2004
. (E) Page 26 of 57
The fastening elements shall be matched to the rope and drum contours. The rope shall not be led over
edges.
In the case of wire ropes which are not of the non-twisting type, the rope suspension shall be made in
such a way that it is not possible for the wire rope to twist about its longitudinal axis. For non-rotating
resp. rotation-resistant wire ropes, the suspension may allow the wire rope to twist about its longitudinal
axis.
Rope suspensions shall be dimensioned such that they can accomodate 2,5 times the static rope tensile
force at rated capacity without permanent deformation. This requirement shall apply to all parts in direct
contact with the rope.
Round thimbles, symmetrical socket clevis and wire rope grips are not allowed as rope end connections.
The rope end connections shall be in accordance with the following standards:
5.8.2 Chains
Round steel link chains shall be in accordance with EN 818-7:2002.
Roller chains shall be in accordance with ISO 60Q:1997 (see also DIN 8187). The ratio of minimum
breaking force to rated load for roller chains shall not be less than 6.
For cases of application 5, 6, 11 and 12, the ratio of minimum breaking force to rated load for round steel
link chains and roller chains shall be at least 10.
Chain run-on points on chain wheels and sprockets shall be provided with protection in the hand area to
prevent manual ingress.
Chain run-in points on chain guides shall be of such narrow design that a hazard caused by manual
ingress is largely prevented.
The chain end shall be fastened to the chain box to prevent the chain from falling out completely.
The risk analysis for use above persons shall take into account a hazard caused both by the chain falling
out of the chain box and the chain box or parts of it falling down.
Connections on chain suspensions which can be opened shall be secured to prevent them from
unintentionally opening. The state of the fastening shall be verifiable.
. 5.9.2 Belts
Belts used as load-bearing media in lifting appliances shall be of appropriate design for the particular
operating conditions and be made of suitable materials so that they withstand the permissible stresses,
and shall be rated for a period of service exceeding the inspection interval specified by the manufacturer.
Discarding criteria shall be externally recognizable. A sufficient period of service shall remain between
readiness for discarding and rupture. The discarding criteria shall be clearly defined in the operating
instructions. Attention shall be drawn to maintenance and care of the belt by means of instructions.
, ,.
,
- damage caused by sharp edges or temperature influences does not lead to sudden failure of the
belt;
- contact with the belt does not constitute a hazard of injury due to the nature of the belt, e.g. in the
case of thin steel belts.
- material/materials;
- dimensions;
The ratio of minimum breaking force of the belt to rated load shall not be less than 5 for belts with a
metallic inlay and not less than 7 for belts with no metallic inlay.
For cases of application 5, 6, 11 and 12, the ratio between minimum breaking .force and rated load shall
be at least 10.
If slack belt is possible, provisions shall be made to ensure tight winding of the belt. It shall be ensured
that the belt is not able to run off the side of the sheave or drum. Rims shall be designed in such a way
that they do not damage the belt which runs against them.
If inclined pulling is possible, measures shall be taken to avoid excessive loading in the edge zones, e.g.
moveable suspension of the lifting appliance.
The fastening shall be able to accomodate a force amounting to 2,5 times the static belt tensile force at
rated capacity, allowing for the friction of two windings remaining on the drum. The specific friction values
of the particular materials shall be considered for calculation of the friction torque. It shall be assumed
that lubricants are present on the materials.
It shall be ensured that a minimum of two remaining windings cannot be unwound and that the belt
cannot be wound onto the drum in the wrong direction.
Threaded connections on belt suspension devices shall be locked to prevent self-loosening. The state of
the fastening shall be verifiable.
5.10 Trolleys
5.10.1 General
Trolleys may be constructed either as an integral part of the hoist or as an independent device for
attaching the load or the hoist. .
5.10.3 Brakes
Trolleys that move also vertically shall be controlled by a brake system at any time.
Power driven trolleys shall be controlled by a brake system at any time. The brake system shall be
designed such that is possible to brake down movements, to hold the trolley and to avoid unintended
movements.
In addition, brakes shall automatically engage in the case of 3-phase motors when two phases of the
electrical power supply of the corresponding drive (::: motor) are !nterrupted.
e) self-locking drives;
f) automatical brakes;
Unless the working conditions so require, manually moved trolleys do not need to be fitted with a braking
system. .
Note: Suitable measures include among others trolley drop stops integrated into the design, or
derailment protection achieved by suitable geometry of the wheel bolts.
Climbing of the trolley shall be prevented in the case of monorail trolleys. This can be achieved by means
of appropriate design of the trolley components, for example.
HazardS resulting from falling components in the event of failure of a guide or travel element shall be
prevented. This is achieved, for example, by selecting suitable materials and sufficiently dimensioning
the components, taking into consideration the use for which they are intended.
The power driven travelling movement at the end of the hoistway shall be limited by using a limit switch-
off with a buffer provided as final limit stopping device.
Where several trolleys are used on one hoistway, collision of the trolleys shall be avoided by providing
suitable distances. .
For the cases of application 5, 6, 11 and 12, the trolleys shall be overdimensioned using a factor 2 to
rated load.
Components include, for example, valves, maintenance devices, line connectors. Operating materials
include, for example, the motor lubricant.
A sufficient air pressure shall be available at all parts of the equipment to fulfill all functions under all
operating conditions.
Filters shall be provided if contaminants can cause hazards, e.g. in control circuits.
The emergency stop function shall correspond to category 0 (EN 418: 1994).
In case of indirect control, one of the two following requirements shall be fulfilled:
- The emergency stop function shall interrupt the main air circuit via an additional main air valve; this
valve shall be designed in such a way that sticking of the piston will not occur, or
- valve selection and a unit delivered together with the hoist providing the required air quality
(admissible dust content, admissible water content, oil content) ensure that sticking of the main air
valve piston will not occur. .
Note: Such a unit normally consists of filter, pressure regulator and oiler.
In case of direct control one of the following two requirements shall be fulfilled:
- The emergency stop function shall interrupt directly the main air circuit or .
- The actuating elements and the energy switching part of the hand control shall be positively
connected. The positive locking shall be designed in a way that the energy switching part can be .
retumed by hand to a stable neutral position.
Pull cord controls may be used, provided that they fulfill the above-mentioned requirement.
For hand controlled hoists in accordance with clause 5.2.1 of this rule, the requirement in EN 418: 1994
clause 4.1.12, according to which the resetting of the .Emergency stop" shall not be permitted to initiate
restarting, is fulfilled by the fact that restarting solely due to resetting of the emergency stopping device is
excluded owing to the automatically resetting operating elements.
The response times in pneumatic control air systems depend on control line lengths. If need be, long
response times shall be kept as short as possible (e.g. by additional valves).
Power valves shall have sufficient venting cross sections in their neutral position to prevent malfunction
of the motor and brake.
Control devices for the starting of hoists shall be constructed in such a way that the working speed ofthe
drive, if variable by means of the control device, increases (resp. decreases) with rising (resp. falling)
path of actuation.
When using pneumatic motors, significant differences in lifting and lowering speed of hoists may arise.
The occurring maximum speed shall be taken into account when dimensioning the hoist.
Those adjustable safety devices which can cause a hazardous situation if their pre-set values are
modified shall be secured against unauthorised readjustment.
Extemal devices for the pneumatic power supply, if they are safety-relevant, shall have visible means,
such as e.g.:
lead-seals;
covers;
cups;
Extemal devices are e.g. inspection units normally consisting of filter, pressure regulator and oiler.
Visible means are not necessary if special tools specified by the manufacturer of the adjustable safety
device are necessary for the readjustment.
Movable elements, such as e;g. cylinders, shall be positioned or covered in such a way that a hazard for
persons or objects in the vicinity is excluded.
The components and materials used (e.g. metals, elastomeric materials, pressure liquids, greases) shall
be compatible with each other and shall withstand the operating conditions sufficiently. The user
FEM document 9.756 08.2004 (E) Page 32 of 57
information shall specify the pressure liquids to be used, as well as pressure and quantity of the liquid. If
contaminations can cause hazards, e.g. in control circuits, filters shall be provided.
Tubing shall be secured so that impermissible additional load (e.g. pressure, bending, temperature)
cannot occur during operation, and wear and corrosion are avoided.
Hoses shall be fixed in accordance with the manufacturer's specifications. Hoses may be arranged fixed
or flexible. They shall be fixed in such a way that during installation no torsional stress due to twisting
occurs. The bending radius shall not be smaller than the admissible value. Damaging contact with
obstacles or adjacing construction elements shall be prevented.
The composition of the seals shall be selected so that they are compatible with the chemical composition
of the fluids used and shall continuously withstand the intended operating temperature, the operating
pressure and the operating speed permanently. .
No inadmissible leakages or extrusion shall occur.
Normally, the requirement in EN 418:1994, clause 4.1.12, according to which the resetting of the
emergency stopping device shall not be permitted to initiate restarting, is fulfilled for hand-controlled
hoists according to clause 5.2.1 of this rule by the fact that restarting due to resetting of the emergency
stopping device is excluded owing to the automatically resetting operating elements.
In the event of power failure, the power valves shall positively assume their neutral position. For direct
controlled hoists, this requirement shall apply under the prerequisite that the actuating devices of the
control devices are released.
Power valves shall be constructed in such a way that even in the event of intemalleakages occurring
they shall not be capable to generate any driving movements.
Control devices for the starting of hoists shall be constructed in such a way that the working speed of the
drive increases (resp. decreases) with rising (resp. falling) path of actuation, if the working speed
depends on the actuation path.
A relief valve shall be provided in the retum pipe of the pressure fluid of the hoisting motor, so that
disturbances of pressure and flow are avoided when lowering the load.
For motors, where intemalleakage cannot be safely avoided, devices shall be provided which hold the
load in the event of energy failure, e.g. mechanical spring loaded brakes or self-locking gears.
5.12.5.2 Cylinders
The piston and the piston rod shall be connected to each other so that they, cannot detach during
operation.
The cylinders shall be installed in working devices in such a way that no inadmissible loads' due to
reaction occur.
Mechanical limit stops are admissible for limiting the strokes of cylinders, provided that they are
dimensioned such that they are able to absorb the occurring forces. Otherwise, the movements shall be
limited by using other devices (cushioning in the extreme positions, limit switches).
The system elements of hydraulic systems shall be selected and mounted in such a way that noise
generating pressure peaks and vibrations are avoided and that the noise emission shall not exceed the
specified maximum values.
In the event of a power failure, it shall be possible to stop all movements. This may be achieved either
automatically or by using a manually actuated control device.
Moving elements (e.g. cylinders) shall be positioned and/or covered in such a way that hazards for
persons or objects are excluded.
lead-seals;
- covers;
cups,
Visible means are not necessary if special tools specified by the manufacturer of the adjustable safety
device are necessary for readjustment.
5.12.8 Reservoir
The reservoir shall be equipped with a fluid-level gauge. The reservoir size shall be selected so that the
fluid cannot overflow at all operating states.
The reservoir shall be located in the installation so that the necessary inflow into the pump is ensured.
FEM document 9.756 08.2004 (E) Page 34 of 57
The reservoir size shall be selected so that a sufficient fluid quantity within the permissible temperature
range is available at all operating states.
5.12.9 Cooler/heating
If the permissible upper operating temperature value cannot be kept in the circuit by the container, a
cooler shall be provided. If the ambient temperature is lower than the lowest operating temperature, the
manufacturer shall provide for possibilities by means of which the liquid can be heated up to the required
temperature.
Note: This can be achieved e.g. by warming up the system without load or by fitting a heater.
5.12.10 Fire
Hydraulic systems shall be such that leaking fluid cannot cause a fire. Devices which may, ~each higher
temperatures when being operated (also electrical equipment through sparks or short-circuit), shall be
thermally separated from devices carrying oil by means of a suitable enclosure, in order to prevent
ignition. Under these circumstances, flame-retardant hydraulic fluid should be used.
5.13 The electrical equipment of single hoists operated above persons (5.2), hoists for
assembling purposes (5.1) or single hoists for the transport of persons (5.3).
The electrical equipment of hoists shall conform to EN 60204-32: 1998 with the following deviations:
- or by proving the conformity with the EMC Directive for the electrical and electronic componentries of
the hoist.
Disconnection of the electrical equipment from the mains power supply so that work may be
performed without the risk of electric shock or burning;
The crane disconnector shall meet the requirements of EN 60204-32: 1998 clauses 5.3.2 to 5.3.4.
For the nDisconnecf function, the mains power supply or crane switch shall fulfill the requirements of
EN 60204-32:1998 clauses 5.3.2 to 5.3.4.
The nswitch-off' function in the event of an emergency may be fulfilled by a crane switch according to EN
60204-32:1998 clause 5.3.7.
Note: The risk of a restart following resetting in the particular case of an internal fault occurring,
does not create a hazard as it is possible to stop the hand-controlled hoist anew.
Hoists with adjustable speed electrical power drive systems, low voltage adjustable frequency AC power
driven systems shall be dimensioned in accordance with FEM 9.752 (07.2003).
6.1 Series manufactured hoists used as single hoists in accordance with 5.1.1
Each hoist of the series shall be verified by an individual verification carried out in the plant, using the
method of individual verification specified in table 2. .
6.2 Series manufactured hoists used as single hoists in accordance with 5.1.2 and 5.1.3
Each hoist of the series shall be verified by an individual verification carried out in the plant, using the
method of individual verification specified in table 2~
The particular requirements for the hoist shall be taken into account for the intended case of application
and the selected type, and shall be verified by the individual verification.
5.0; 5.1 Classification and construction Check of calculation; Dynamic overload test with 1,1 times the rated capacity and
static test with 1,25 times the rated capacity to check the
Functional check to verify the classification (see
mechanical strength.
FEM 9.852)
And
dynamic overload test with 1,1 times the rated capacity
and static test with 1,25 times the rated capacity to
check the mechanical strength and check of calculation.
5.2.1 . Control devices Functional check Functional check
Visual inspection Visual inspection
5.2.2.1 Hoisting Iimiters-
General Test by submitting the hoist to an overload condition and Test by submitting the hoist to an overload condition and .
checking that the controls have been overridden (see checking that the controls have been overridden (see EN
EN 12077-2:1998, clause 6) 12077-2:1998, clause 6)
Fricition torque Iimiters Test with rated capacity to confirm that the friction torque -
limiters satisfy the requirements of FEM 9.761 (01.1995)
after the hoisting movement having been stopped by the
housing of the hoist.
5.2.2.2 Triggering limits Test by increasing a freely supported load to confirm that Test by increasing the freely supported load, or acc. to a
the triggering limit of the load limiter is within the test method provided by the manufacturer to confirm that
tolerances defined by the manufacturer, and not without the triggering limit of the load limiter is within the
the admissible limit values. tolerances defined by the manufacturer, and not without
the admissible limit values.
5.2.3 Emergency stop function Functional check, visual inspection Functional check, visual inspection
5.2.4 Phase failure Test at rated capacity by interrupting one phase -
5.2.5 Hoisting and lowering Iimiters Functional check Functional check
5.2.6 Underload switch-off Functional check; if the hoist has several load falls, all Functional check
load falls shall be switched off individually.
5.11.3 Mains power Check of function of the device Visual check of the equipment
disconnection device
5.12.1 Safety in the event of Test that the hoist is always able to hold a suspended load -
pressure loss equal to the rated capacity when it is started up at
-90%
Hydraulic supply -80%
-70%
-60%
of the rated pressure.
Avoiding impermissible Visual inspection Visual inspection
additional stresses on
tubes
Avoiding impermissible Temperature measurement -
additional stresses on Visual inspection Visual inspection
hoses
5.12.2 • Environmental conditions Verification of the requirements of Directive 94/9/EG, Annex II -
5.12.3 Mains power Verification of the function of the device Visual check of the equipment
disconnection device
5.12.4 Control circuits and Functional check Functional check
control functions
Emergency stop Functional check, visual inspection Functional check, see also test for 5.2.3
Visual inspection .
5.1~.5; 5.12.5.1 Safe accomodation of Dynamic load test with 1,1 times the rated capacity at -
5.12.5.2 the hydraulic forces by. maximum permissible hydraulic pressure
motors
Holding of the load in the Functional check Functional check
event of internal leaks
Functional safety of Visual inspection Visual inspection
cylinders
Dynamic load test with 1,1 times the rated capacity at Functional check
maximum permissible hydraulic pressure.
5.12.6 Design of the brake Functional check as for 5.12.1 -
against unexpected
lowering of the load
5.12.7 Protective device against Check of circuit diagram Functional check
impermissibly high
Check of documentation: functional check
pressure
. Protection against Visual insp ection
changing preset values
of safety devices
Mechanical protection in Visual inspection Visual inspection
the case of moveable
elements
5.12.8 Reservoir Visual inspection
5.12.9 Cooler / heating Check of the conditions for use
5.12.10 Fire Visual inspection of the protective measures -
5.12.11 Explosion hazards Visual inspection of the design, check of the materials used
Emergency stop Functional check, visual inspection Functional check, see also test for 5.2.3, visual inspection
5.13.4 Overload protection of Check of calculation ace. to FEM 9.683 (10.1995) -
motors
5.13.5 Electric control circuits Functional check Functional check
and control functions
5.13.6 Electrical motors Check of calculation, functional check with 1,1 times overload Functional check
5.13.7 Specific requirements for Check of dimensloning ace. to FEM 9.752 (07.2003), Functional check
non-line-commutated functional check with 1,1 times overload
drives
The manufacturer shall provide operating instructions containing information and instructions for the
commissioning, use, regUlar tests and inspections and maintenance of the hoist. These operating·
instructions should comply with EN 292-2: 1991, clause 5.5.
The use for which the hoist is intended shall be clearly described. This also includes design limitations,
e.g. the group of mechanisms. The measures to be taken when the hoist has reached the end of its safe
working period shall be described in accordance with ISO 12482-1:1995.
Information regarding the utilisation of the lifting and lowering Iimiters during normal operation shall be
given.
Special features of the hoist, e.g. devices for lowering the load in the event of a power failure, shall be
described.
- The user shall ensure that the operating personnel are given the necessary training;
- The operating personnel shall always work in compliance with the operating instructions;
- The op'erating personnel shall always lift unrestrained loads supported from below with the minimum
speed available. Slack hoisting media (rope, chain, belt) shall first be tightened before lifting the load;
- All inspection, maintenance and repair work required to ensure the safe functioning of the hoist shall
be described, e.g. lubrication of ropes, chains, gearboxes, bearings, hooks, etc.;
- Inspection of wearing parts such as ropes, chains, hooks, belts, brake linings. Specification of test
and inspection intervals and wear criteria;
- Operating principle of safety devices and behavioural requirements in the event that these devices
are triggered, e.g. resetting the emergency stop device;
- Indication of data required for the purchase resp. replacement of the hoisting medium prescribed by
the manufacturer (rope, chain, belt). These are the identification number of the manufacturer or the
precise technical specifications of the load bearing means (Le. minimum breaking force, design of
ropes, diameter and pitch of chains);
For pneumatic and hydraulic hoists the data relating to pneumatic resp. hydraulic supply shall be
provided. This includes data regarding the necessary values for pressure, flow and quantity.of the
compressed air resp. hydraulic fluid; .
The manufacturer shall provide information on how to set and to check the lifting force Iimiter. Setting
and checking of the lifting force Iimiter shall be done according to the instructions of the manufacturer by
competent persons only. The manufacturer shall demand from these competent persons that the test
results be documented in the logbook of the hoist.
If the hoist is not fitted with a rated capacity indicator, the manufacturer shall inform the user that this
hoist shall be used only in those applications where the rated capacity does not vary with the position of
the load.
For the installation. and use of the hoist in a supporting structure, the manufacturer shall indicate the
triggering limit of the fitted lifting force limiter in order to enable the designer of the supporting structure to
take into account the static and dynamic forces which may occur if the lifting force limiter is triggered.
7.3 Marking
The provisions contained in EN 12644-2:2000 shall be complied with.
Each hoist shall be provided with the following information in a durable and easily legible manner on a
part which cannot be removed:
2. CE label;
4. Serial number;
5. Year of manufacture;
7. Rated capacity;
The rated capacity shall also be specified on the bottom block or hook with accessories;
8. Group of mechanisms;
A B c o
C == Rope guide with rope tensioner D == Rope drum (rope wound in single layer)
G == Hook
A == Bremsmotor B == Getriebe
E == Seilfestpunkt F == Umlenkrolle
G== Haken
~ tt
A
B
/ I
/ r h
c
-
1""'-'-'
-G G
D
~ E
~
F--_-J-I,..
0I
I = Chain box
A =Bremsmotor B =Getriebe
C = Rutschkupplung D = Kettenrad
E = Kettenfestpunkt F = Umlenkrad
G = KettenfOhrung H = Haken
I =Kettenspeicher
A = Moteur-frein B =Reducteur
C =Accouplement a friction D = Noix de chaine
G =Guide-chaine H =Crochet
I =Magasin achaine
t7'
. ,
A
B ~
/ /
/ r- h
c
E ,,1'--_ E
-- t- ;-ffi-l-lJI-t-
- o ~e77'-;---D
A = Bremsmotor B = Getriebe
C = Rutschkupplung o = Bandrolle (mehrlagige Bandwicklung)
E = BandfOhrung F= Haken
A = Moteur-frein B = Reducteur
B A
1
I rJ
~
I
I-
t- --
of
~
-
I--
-
~.
Iu
c B A
C: Seilanpresswalze
I
i B
Y
I 1
A~SZSVSJc
I
i R
A
I
1
Q
Additional requirements
for operation in aggressive environments and outdoors·
8.1 Requirements to be met by the hoist
Verification that the requirements are met may be provided by long-tenn tests in climate chambers, for
example.
Provision shall be applied in relation to a proper definition and classification of corrosivity environment as per
ISO 9223: 1992
ISO 8044: 1999 Corrosion of me~al and alloys - Basic tenns and definitions.
ISO 8407: 1991 Corrosion of metal and alloys - Removal of corrosion products from corrosion test
specimens.
ISO 8565: 1992 Metal and alloys - Atmospheric corrosion testing - General requirements for field
tests.
ISO 9223: 1992 Corrosion of metal and alloys - Corrosivity of atmospheres - Classification.
ISO 9224: 1992 Corrosion of metal and alloys - Corrosivity of atmospheres - Guiding values for the
corrosivity categories.
ISO 9225: 1992 Corrosion of metal and alloys - Corrosivity of atmospheres - Measurement of
pollution.
ISO 9226: 1992 Corrosion of metal and alloys - Corrosivity of atmospheres - Detennination of
corrosion rate of standard specimens for the evaluation of corrosivity.
8.4 General requirements for specific areas: structures, electrical equipment and motors; electric
cables, copper terminals,· a.s.o.
The following are listed as examples of corrosion in respect of various situations in aggressive environments:
a) Structures:
Selection of materials in relation of the temperatures..
Special requirements for marine environment applications.
c) Electric cables
Environmental conditions have a marked influence on the selection of electrical cables, particularly with
regard to the type of shielding.
Particular consideration shall be given to the cable runways.
d) Copper ends of cables and other similar parts of electrical equipment require specific protection when
being operated in the presence of ammonia and acetylene. .
Additional requirements
for operation at low temperatures « -10° C)
As to hoists for use at low temperatures, attention is drawn to the following, for example:
- suitability of lubricants;
- test of the complete series hoist under the specified operating conditions, as required.
[1] Directive 98/37/EC of the European Parliament and of the Council of 22 June 1998 on the
approximation of the laws of the Member States relating to machinery
[2] Directive 94/9/EC of the European Parliament and of the Council of 23 March 1994 on the
approximation of the laws of the Member States concerning equipment and protective systems
intended for use in potentially explosive atmospheres ..
Established by the Technical Committee of section IX of the Federation Europeenne de la Manutention (FEM)
Available from the above secretariat or from the following national committees of FEM:
Belgium Germany
AGORIAasbl Verband Deutscher Maschinen- und
Diamant Building Anlagenbau e.V. (VDMA)
Bd. A. Reyers 80 Fachverband F6rdertechnik und Logistiksysteme
B-1 030 Bruxelles Lyoner StraBe 18
Tel: +32-2-7068068 D-60528 Frankfurt-Niederrad
Fax:+32-2-706 79 88 Tel: +49-69-6603 1507
frank.semeels@agoria.be Fax:+49-69-6603 1496
www.agoria.be sabine.brose@vdma.org
www.vdma.org
Finland France
Technology Industries of Finland Syndicat des industries de materiels
Etelaranta 10, P.O.B. 10 de manutention (SIMMA)
FIN-00131 Helsinki 39/41, rue Louis Blanc
Tel: +358-9-192 31 F-92038 Paris la Defense Cedex
Fax:+358-9-624462 Tel: +33-1-47176327
pino.tunturi@teknologiateollisuus.fi Fax:+33-1-47176330
www.teknologiateollisuus.fi simma@wanadooJr
www.simma.com
Portugal Sweden
ANEMM Swedish Engineering Industries Association
Estrada do Payo do Lumiar Storgatan 5, p.a. Box 5510
Polo Tecnologico de Lisboa, Lote 13 S-11485 Stockholm
P-1600 Lisboa Tel: +46-8-782 08 00
Tel: +351-21-71521 72 Fax:+46-8-660 33 78
Fax:+351-21-715 04 03 kerstin.delgado@teknikforetagen.se
anemm@anemm.pt www.teknikforetagen.se .
www.anemm.pt
Switzerla·nd Spain
Swissmem Asociacion Espanola de Manutencion
Kirchenweg 4 ETSEIB-Pabellon F
CH-8008 ZUrich Diagonal,647
Tel: +41-1-3844111 E-08028 Barcelona
Fax:+41-1-384 42 42 Tel: +34-93-401 6060
b.waernier@swissmem.ch Fax:+34-93-401 6058
www.swissmem.ch fem-cne@jazzfree.com