| PREFACE a! This Installation, Operation & Maintenance Manual has been compiled to guide the ‘Customer/Operating personnel purchase purchasing "REVA" Electric Wire Rope Hoist to become familiar with usage and maintenance of equipment. The need of safety is much more important for lifting devices since loads are hoisted and moved overhead & any failure can lead to monetary loss or fatal accident. The performance of equipment is related not only to the intensity of its use but to its care and maintenance too. Hence, proper lubrication, systematic inspection/maintenance of the mechanical parts like gears, wire rope and electrical equipment like motors, brakes, limit switches and control gears is most important. Do not postpone the minor trouble & follow the old adage "Prevention is better than cure".CONTENTS INTRODUCTION a eee DOS” AND DONTS’ INSTALLATIONS ee LUBRICATION a WIRE ROPE (FORT WILLIAMS/USHA MARTIN) & HOOK BLOCK: STORAGE & HANDLING OF Wike ROPES INSPECTION OF WiRE ROPES IN USE Rope Care WHEN TO CHANGE 4 ROPE BRAKE @CFAILSAFEEMCO) WIRING ’ INSTRUCTIONS FOR DSL INSTALLATION. OF ELI "AR Motors (CROMPTON KIRLOSKAR) Cowreo1 Pane, n TROUBLE DIAGNOSISREMEDY CHART (ELECTRICAL) eee) {A} Contros PANEL 3 (BLMorors “4 {C] Brake 15 ‘TROUBLE SHOOTING FLOWCHART (ELECTRICAL) GADRAWING DIMENSIONAL DETAILSINTRODUCTION ‘Thank you for purchasing REVA's EWRH, the first Indian ISO-9001 certified company incorporating 100% helical, hardened & profile ground gears, manufactured from low catbon alloy steel. We thus offer you a truly world class product optimally engineered and manufactured according to a standard quality assurance plan. Itisa 100% in house production offered inrnodular design, manufactured serially using latest State-of- the-Art technology conforming to IS:3938-1983. The product is widely recognised by the industry (or its pesformance. It is compact and cost effective and has been designed keeping in view the customer needs. Optimum use of electrical energy has been taken into account for achieving speeds with liberal margins for voltage fluctuations, ambient temperature, gear efficiency etc. 1,.FRAME Steel plate & sheet fabricate drugged in construction machined and bolted, 2, GEARCASES Gear cases are fabricated duly shot blasted, stress relieved and machined on upte date CNC machining centre 3. GEAR AND PINIONS REVA choose to make all their Gears & Pinions in-house ensuring their quality, compatibility & serviceability, all gears and pinions integral with shafts are made from case-hardening low-carbon allow steels and are hardened to 56-60 HRC, These are helical & profile ground for running in oil bath to give noiseless movement with maximum efficiency to save on consumed electricity. All gears and pinions confirm to DIN-7/AGMA-12 standard 4. ROPEDRUM Drum from seamless steel pipe or fabricated from steel plates, revalves on heavy-duty self-aligning roller ‘bearings. The machined spiral grooves accommodate rope in one layer allowing two full turns of rope in the drum when the hookisatthe lawest position. Dram size corresponds to relevant IS. 5. ROPE GUIDE AND RETAINER Casted rope guide leads the rape into spiral grooves m the drum and retains it in the grooves preventing over-lapping on ot loosening off the drum. 6. WIRE ROPE Ungalvanised extra flexible wire rope of 6x37-6x36 construction of breaking strength 180Kg/muv’ made of ‘best plough steel conforming to IS: 2266 with factor of safety appropriate to the class of duty is used for every wire rope hoist. 7. Hook BLOCK Standard forged trapezoidal section hooks conforming ta 1S 3815/TS: 8610 are wsed, Hook is carried in steel crosshead on the thrust ball bearing. The hook sheaves ate supported on ball bearings. Sheaves dimensions correspondta relevantiS. 8. MOTORS & BRAKES High starting torque, crane duty, totally enclosed squirrel cage induction motors, in international frame sizes ‘of Crompton make are used, Motors conform to 1S:325. All motors used are S4 duty suitable for 4 LS+ 0% V, 5025% Hz, 40% CDF, 150 starts/hour, 50°C AMB temperature, Motors suitable for different voltages & frequencies can be provided. Reva Industries Lissited IDC disc brake isa standard feature. Ifrequired different brakes can alsa be supplied. 9. WHEELS Closed die forged from medium carbon steels, these wheel's are machined on CNC lathes for accurate bore & ‘tead profile. Supported on two large dia ball bearings for better rolling effect 10. CONTROLS The operation is through pendent push button station or radio remote control having control voltage of 24V for maximum safety of operator through flush - type hold on push buttons housed in a IP-$5 enclosure Other control voltage can also be given if required. Individual motors are protected by HRC fuses, solid- state/ thermal overload relays, single phasing & wrong sequence preventers. Limit switches for over hoisting, over lowering are also provided. We can also provide AC drives for obtaining speed control. Soft start & soft stop cenalsobe provided 11. EQUALISING SHEAVE BRACKET Bracket bent to shape from steel sheets holds C. I. sheaves running in sealed ball bearings. Free rope end clamp is also mounted on this bracket. 12. TROLLEY Electric Wire Rope hoist can be supplied for fixed mounting or with hand geared or electric driven trolleys according to the purchaser's requirements. 13. CREEP SPEED Not provided in the standard models but can be equipped if required, at an extra cost. For 1/10" of the main hoisting speed by means of an additional motor and planetary gearing, AC Drives can also be used for this feature. 14, ACCESSORIES © Brakes & limit switches for Cross- Travel movement is not provided in standard hoist upto & including 3t capacity. Beyond 3t both brake & limit switch is provided, Should you however desire to have limit switch and brake in hoists upto 3t these can be provide at an extra cost. © Electronic dynamic braking is available atextra cost. This gives tremendous life tothe hoist brake. 40 CPGB ACT GEAR, 2 BOX) (HIRE ROPE, | DRU to 8 ~~ CONTROL : ——| sverwa PANEL | CT WHEEL 3.0 MHEQ {EQUILISING NA oo ‘BRACKET 16 MHGB (GEAR BOX) 6.0 MHBB ~ (BOTTOM BLOGG, Reva Industries LimitedFOR TROUBLE FREE OPERATION OF ELECTRIC WIRE ROPE HOIST Dos’ DONTS’ 1) Tighten all visible muts & screws 1) Lift overload 2) Switch off the main supply before wiring 2) Lift imbalanced Load 3) Switch off Main switch & put a placard to warn when a) Repairing/Replacing electrical parts b) Checking/Rectifying faults 3) Lift obliquely. 4) Use only dedicated slings of sufficient strength 4) Inactivate safety upper limit switch 5) Leave the hoist with suspended load 6) Walkistay under suspended load, Reva Invustries LimitedINSTALLATIONS 01, Check the width of Beam & note deviations in the same at approximately every 2 m over entire length Table 1. a 2 Flange width (B) [m.m.] : | Upto 80/90 100 5 140/150 1s | 210 cea Sey ee ee ae . L eh ee oe v pais | £ * Preferred Y Can be adjusted 03. Set distance between wheel flanges as illustrated (Fig 1) = B+ R/2 (R = Smm max.) Only two pair wheels need to be adjusted when flange widths are ‘according to above table 1 04, When flange widths are lower than stipulated, both sides wheel pairs need to be adjusted by suspending ‘the hoist on the beam till the hoist frame is parallel in vertical plane thus precluding wheels from not touching the beam which avoids skidding (Rotation ‘wlo Translation) Fig. 2 Remove Sige Plotes 122, In case of monorail having free end, {installation shall be as shown in Fig. 3 otherwise Fig. 2 Reva Industries Limited 4Fig 3: Installation of Mono Rail Hoist having Free End ) Remove LUBRICATION During installation’ & maintenance ‘open the Breather Plug & fill the gear box with ISO NG_220 oil (or equivalent) upto oil level indicator. Fig 4: Lubrication Restore the plug Diagram back. If oil is contaminated, all ‘the oil should be taken oot by opening drain plug & fill it up with fresh one Cross travel gear ‘box, equalising sheave & electric motors generally are life lubricated with Servo, Gemv/80 greases. However during complete overhaul ‘or change over of any damaged bearing provision is made to replenish the same through grease nipples provided at appropriate location as shown in the Fig, 4. RAN FLUC Reva Industries Limired 5WIRE ROPE (FORT WILLIAMS/USHA MARTIN) & HOOK BLOCK: ‘The hoist is shipped duly reeved with wire rope & hook block assembly and is normally in readily installable condition. However in rare cases, during transit of long storage at site the rope may need ta be changed. The - following steps as illustrated in figure 5 need to be followed. © a0 ot pe cares Co &\ oy fe Fig 4:Rope Reeving - (0) mop gue (2) on nos dation for 4/1 Araingement Directions - sone nan Qos wa (2) Clamp the rope os shown in (1) a ©) Sani te etapecee (D) Stort reeving in the direction shown in (2) til the end of groove. 7 (2) Pass through the ope guide (3) (2) Pass through the nook block sheave 1 (4). fe) Then 10 the equalising sheave (3), (0. Tren to the hook Block sheave 2 ( 7 Anchor free end of tne rope to the (ope clamp, { { = Fig S:Rope Reeving (8) Rope some for 4/2 Arrangement 5) Rausing shane 2 tions {a) Pass the rope through equalising sheave (*) (b) Poss both end of the rope through the two = sheaves of bottorn block (2) (c) Then through the rope guide (3). () Get both the free ends clamped os shown in ~ (4) (e) Then start winding after ensuring that direction of rotation of the drum is same as the dir of reeving by switching on hoisting motor. (f) D0 proper lubrication. a Reva Industries Limited 6 -STORAGE & HANDLING OF WIRE ROPES Handling Improper handling or coiling of rope from reels or coils often results in the “springing” of strands and kinking of the rope both of which are very difficult to be corrected, It reduces the effective rope life considerably If the rope is supplied on a ree, it should be mounted on a shaft and rope laid off from the reel while it rotates. Suitable brakes should be applied on the flanges of the reel. Ifthe rope is supplied in large coils, these should be mounted on a tun-table with suitable brakes and the rope paid off while the turn-table rotates. Small coils of wire ropes can be made to roll along with the ground for uncoiling. Rope should neither be pulled straight from the coil while the coil rests on the ground, nor taken off turn by turn from reel while it is Iving on its flange on the ground. also never allow the reel to rotate at high speed (i.e exceeding 2 km per hour at any time) during pay off. Kinks ‘The wire ropes are damaged due to improper handling The most common form of damage is kink formation. which starts first. with the formation of a loop as illustrated and then the loop tightens when pulled up forming kink. The loop should immediately be removed by tuming the rope in other direction ‘The illustrations show stages of kink-formation a) How a kink starts (See fig, 5) b)_ When pull gets on. further damage 1s done ©) When kink is straightened. the wires may or may not be broken, but the damage is done and when rope is put to service. wires will quickly break Never use a rope that has been kinked unless the kinked portion is removed. Use Inspection of Wire Rope: Inspection of a rope in use is essential at regular intervals to observe the presence of excessive wear on the outside wires resulting in marked reduction of rope dia... broken wires. corrosion and pitting, state of lubrication, core condition, etc. ‘The reduction in diameter of a rope is generally due to excessive wear of outside wire and bedding-in. in cease of 4 fiber cored ropes. However. marked reduction in rope diameter should be thoroughly investigated and its cause determined In case of broken wires, their number and distribution should be taken into account to calculate their effect ‘The inside wires and core can also be damaged due to lack of lubrication. Where corrosive conditions exist, these should be controlled by correct and timely lubrication. Rope Care = Do not allow your rope tobe stored ina damp or open place This causes deterioration af rope and fiber core. u Do not let your rope be mishandled when uncoiling or unreeling, This causes kinks to form, Do not cut a rope before it has been sized-even if it is a preformed rope, The lays can become loose. Do not use a rope that is not flexible enough for the size of your drum and pulleys. This causes bending, fatigue = Donot operate your rope on sheaves and drum with worn out grooves and broken flanges. This damages the rope = Do not subject the rope to severe overload and sudden jerks. This causes severe damage to rope and shortens its life u u => Do not load a rope beyond its safe working load. Reduction of safety factor may jeopardize not only Your rope, but also your equipment, your work and everything. Reva Industries Limited 7= Do not allow your rope to get dry and thereby corrosion setting in. Lubricate it with the best quality lubricant and at regular intervals. = Do not forget to check the conditions of your rollers. pulleys. drum and sheaves. The rope life depends -very much on the conditions of these ausiliaries Itis of utmost importance that proper care is taken in handling, fitting and maintenance of your rope. When to Change a Rope A close examination and regular inspection of rope will indicate if a new rope is to be put in, Following are the guiding Factors for putting in a new rope. When the number of visible broken per cracked wires exceeds 10 per cent of total number of outer wires within ‘one rope lay" ‘When wear on outer wires exceeds one-third of their diameter. ‘¢ When the loss in effective metallic area in the form of broken/cracked wires along with wear on outer wire exceeds 10 per cent. ¢ When gradual loss in rope strength due to wear or corrosion or bath exceeds 1/6th of the original rope strength. ‘When corrosion on wires show noticeable pitting and loosening of wires. ‘When rope gets deformed or distorted and the affected portion cannot be cut out However, the experience of the ropeman and statutory regulations are the final words as to when a rope is to be changed. ’ BRAKE (DC Fail Safe, EMCO) a) Details: Blown up diagram showing components (Fig 6) ai DEScePTiON une PUNE 9 are vountng wit amo mises * 188 +130 ‘OR2UE ARLUSTING ANE“ CRTON SLATE ¢ Tr] mento ats 2 wine tact pg 6: DC FAL SAFE BRAKE b) Switching & working: The brakes used are fail safe ie. the brakes releases when DC voltage is supplied to ‘them. On applying a DC supply to the coil, the magnetic field produced pulls the stator against the spring force and the rotor is fre to rotate ‘The hand release mechanism provides a mechanical way of releasing the brake, This can be used to temporarily move the load in case of power failure. b)_ Safety: The brakes must ran dry. Friction materials must be protected from frozen materials, lubricants. ete. ©) Adjustment: In case of excessive wear out adjustments can be carried out by maintaining a gap of 0.3 mm between stationary to friction plates. Reva Industries Limited 8WIRING Refer Electrical Wiring Circuit Diagram Fig. 12 & 13 for wiring, BOM (appendix 1) for replaceable spares and Fig. 7 for pendant functions. Fig 12: Power Circuit Diagram of EWRH ab ‘occu rosmasurt% “CEGENDS:- 2e13 FUSES FoR HOIST aet6 FUSES FORCT 27 FUSE FOR CONTROL TRANSFORMER 29 FUSE FOR CONTROL TRANSFORMER mt ‘CONTROL TRANSFORMER SLI NEUTRAL LINK 2C12_—_CONTACTOR FoR HOIST 203-4 © CONTACTOR FOR CT 20L1 OVERLOAD RELAY FOR HOIST 2012 —_OVERLOADRELAY FoR CT ast DCDISC TYPE BRAKE FOR HOIST 22 DCDISC TYPE BRAKE FOR CT (FROM CENTRO TRANSECT) xn ' : zou 202 Reva Industries Limited hone ORR, Fig 7: Pendant rower romanats mecca rae, REV cShetereee a ‘ 2@-me 8 © ener oO) 2 @ rome Fig 13: Control Circuit Diagram for EWRH CONTROL PANEL LAYOUT 9INSTRUCTIONS FOR DSL INSTALLATION ‘The procedure for erecting the DSL shall be as under: 1. In Case of Wall Mounted = Panels Fip8: DSL Trolley © eset = The total length of DSL (mn) = + fut wot emo (Travel length x 1.2) + (Operating tn OR SO floor - 1) +2. => Cut specified cables according ta the DSL length and lay them on floor. Tie the cables except control cable with cable tie at an interval of 1/2 meter. Loosen the olley as shown in Fig(8). Place the grey colour trolley on cables at a distance of 2 meter from one end of the cable (the end. which shall be connected to the junction box) and insert them in proper gfooves and tighten the other tealleys at every 2.5 meter interval, All the cables, which are not moving on the auxiliary beam, shall be tied with cable tie. Put the proper lugs at both the ends of DSL and also put the ferrules with proper numbers at both ends as pet approved Electrical Drawing, = Fasten all the bolts assuring that the cables are properly placed in the decks made therein Now. this DSL. is ready for mounting on the ausiliary beam see Fig 9. Slide the trolleys from one side of the ng in mind that the grey colour trolley has to be near the hoist. The end of the cables which is near grey colour trolley shall be connected to the junction box fixed on the hoist. the other end of the orev covave 2 TROLLEYS T-POWER & CONTROL CABLE 2 DSL TROLLEY 3- HOIST 4. DSL PUSHER S-MAIN BEAM 6. AUXILLARY BEAM FOR DSI, TROLLEY CONTROL PANEL nox Fig 9: Aualiary Mono Rail Type DSL Reva industries Limited ocables shall be connected to panel box. mounted on the wall 2. In case of Contro} Pane! incegrat to electric hoist DSL system shall be as shown in Fig. 10 (Taut Wire Type) 3. In case there is no Auxiliary Mono rail for DSL arrangement power feeding system shall run through main mono rail as shown in Fig, 1 MAIN MONORAIL pec nore Fig }0:Taut Wire Type DSL coe DRAG ROPE rower caput POWER FEEDER Fig 11; DSL Trolley on Mono Rail Reva Industries Limited ay[D] PRocepuRE FOR CHANGING CONTACTS (SIZES D To F ONLY) 1) Disconnect all cables/wires I) Remove contactor from its mounting IM) Open side clamps. IV) Separate top housing and base V) Pull out the fixed contacts. VI) Separate contact carrier assembly Vil) Take out contact spring by compressing, Vill) Tilt and remove contacts. IX) Insert new contact and springs X) Assemble contact carrier & housing X1) Push in new fixed contacts, XID) Assemble top housing & base and close the clamps. TROUBLE DIAGNOSIS/REMEDY CHART (ELECTRICAL) [A] ConTrot PANEL S.NO TROUBLE. PROBABLE CAUSES REMEDY O1 | Hoisting/traversing Discontinuity in line Check all three lines & control Motion is in-operative. supply Protective Device Check for blown fuses. if it is so Operated first check for any short circuit than replace blown fuses Check for tnpping of overload relays. if operated then look for causes of over loading. It may be duc to application of more load then specified or under volta Remove extra load/ensure sted j voltage & then reset O/L relay by pressing reset knob | Check for over hoistingitravelmy traversing Operate the respective in reverse direction to reset limit switch 02 | Chattering of contactor Tighten connections Loose connection 03 | Contactors refuse to open Replace contacts, Contact welding 04 | Contactor refuse to hold Reconnect control/change coil Open contro! supply/contactor coil Reva Industries Limited Bn[B].Motors Te T SNO | TROUBLE PROBABLE CAUSES REMEDY [or ‘Mator misaligned Reahgn Coupling pulleys ou of Rebalance driven equipment. balance. Defective ball of roller Replace bearings bearing 02 | Bearing Ovesheats | Excess grease Reduce surplus grease. Insufficient grease Maintain proper quantity of grease. Deterioration of grease or | Remove old grease, wash bearing 2ubricant contaminated replenish with new grease Incorrect assembly Ensure bearing assembled squarely ot shaft Broken ball or rough races. | Replace bearings. 03. | Motor Fails To Start} Main supply switched off | Check main switch Motor may be overloaded. | Reduce starting toad. disconnect load to see if motor will start light Wrangly connected Check with diagram and see that connections ate right Single Phasing Check for loose connections. If 50 tighten it 05 | Motor Fails Overload motor Reduce load Low motor voltage Ensure that nameplate voltage is available at motor terminals Open circuit Replace fuses. check overload relays 06 | Motor Runs And Then | Power failure Check for loose connections ta tine, Dies Down fuses and control gear Over load Examine overload relay & ensure | proper setts Reva Industries Limited u07 | Scraping Noise Fan rubbing fan covers Remove interference Fan striking insulation Clear fan Loose on bed plate Tighten holding bolts 0X | Magnetic Noise Air gap not uniform Check and correct bracket fits or bearings Loose bearings Correct or renew Rotor unbalance Rebalance. IC] Brake S.NO TROUBLE PROBABLE CAUSES REMEDY 01 | Brake Fails to Open Discontinuity” under Check rectifier for an input of 415 x Soltaye in de supply and output of 190 V DC. If input is ‘OK but output is absent replace i rectifier. If mput voltage ts less than ¥ specified voltage. correct the suppls voltage | Brake cou! bum Check its continuity if short replace the coil Optional: Also we can provide solid state overload relays with single phasing & phase reversal protection in place of conventional thermal overload relays with in built single phasing protection. Reva Industries Limited 5‘Trouble Shooting Flowchart (electrical) CSTART) (ist Notion Not Working? A Cheek fuses 2e1-2e3, Worn & 2C2 operation by presing pendent push buston, Nex Pan Measure DC V between 226 & 227 after switching on 2C1 or 2C2 | Check Voltage at 225 of 226 — Is — Voltage ve _| Replace #190 V (De) > RR ntact J Ne Check IP for Rectifier Check for Loose Connections Replace eae] Reva Industries Limited 16Check Fea ace O7. O/L Relay 2013 Repl a) No (Check Limit Switeh ve ‘Check for Loose Connection. ae aa inte Replace OM. 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EAR BOX | 03 INPUT ASSEMBLY 4.22 408 4.01.2 ‘Onc @ G) == [creawe | #22] oF ([ereaox [a2] ot | = i croaxs | #20 | 01 | CTGBCO | «10 | o2 || crew [419 | | eveaut | «08 01 roan | «1a OT] ease | +07) 01 crests | 417) Te] erosoP | e087 | 01 crore | 4.16 04 | crcae2 | 4.05 or crac} 415] 03 eraBeT | a8 | oF CieaNs | axe | 08 | crovoz | 403 | oF | creaor | ais] 2 | eraaer | <0F | 8 cresar [12] oF] craH@o | oi] oF croos [ett] OF] crea | 40 B00 Ther w| ev | BRE | ea | a 7 pexanc + namowaRe MarUrACTURED Reva Industries LimitedASSEMBLY FLOW CHART OF C. 7. WHEEL w rave WHEEL ASSEN \ 5.05 5.10 Ga) Ga Ge) Ges) Go) Gy Gon) 1.01 Reva Industries Limited 28 al crwacz | 808] 02 | ciwaw2 | 5.02 | OF crwact | 508 62) CTwami | 5.01 | 02. ea] 5.0 BBL crwaac | 5.07 | 08 | cla] 50 ast cone | Pre v0. ar. | parr cone [pat 10, | ar |Q OtyASSEMBLY FLOW CHART OF BOTTOM BLOCK WOOK ASSEMBLY 6.11 ‘wes? | 606 [01] wiaess | 612 | 02 | wna | 60 Par |p ear | CA |amr wo] ere | Shoe | PART Wo. | ary ‘Bec + HARON wauPictuaED Reva Industries Limited 30ASSEMBLY FLOW CHART OF BOTTOM BLOCK wneace | 6.11 wHees' | 610 wneso | 608 wnoe.s | 608 reas? | 607 weOaST | 6.06 wrease | 6.05 waaesn | 6.06 wraecr | 6.03_| oF woes [814 [ OF | wrserw | 6.02] oF [wapacs 6.13] 01 | wheBHK | ear] oF wio0se [6.12 | 0 | wos | 60 wggron Tver | a | Bm ae wo | rt. EARN + HARDRARE swreToRED Reva Industries Limited 4 w ; i OO® 6.04 +) 6.07 6.04 6.08 6.09 erg 32