FEDERATION EUROPEENNE DE LA F.E.M. MANUTENTION 4.001 34 EDITION SECTION I REVISED HEAVY LIFTING APPLIANCES 1998.10.01 RULES FOR THE DESIGN OF HOISTING APPLIANCES BOOKLET 5 ELECTRICAL EQUIPMENT The total ard Edition revised comprises booklets 1 to S and 7 to9 Copyright by FEM Section | Also available in French and GermanDocument prepared by the technical commission of FEM (European Handling Federation) Section 1 « Heavy lifting and handling equipment ». FEM Section | Secretary ‘Cosette DUSSAUGEY 39-41, rue Louis Blane 92400 COURBEVOIE © 92038 PARIS LA DEFENSE CEDEX Fax : 33 1 47 17 62 60 E-mail : Mips@wanadoo.fr Document available near the following National Committees : BELGIUM AGORIA Diamant Building 8d A Reyers 80 B- 1030BRUXELLES. Fax 32 2 706 79 82 CZECH REPUBLIC Association of Czechostovak Manufacturers: Of Transport and Lifting Equipment ‘SYMAS. Kralovo Pole Cranes, as. (CZ -61200 BRNO Fax : 42 057262251 DANEMARK Confederation of Danish industries DK- 1787 COPENHAGEN Fax : 45 23 77 3410 DEUTSCHLAND V.D.MA. Fachgemeinschaft Fordertechnik Postfach 71 08 64 1D - 60498 FRANKFURT/MAIN Fax : 49 69 68.03 14 96 ENGLAND CEA Ambassador House Brigstock Road GB - THORNTON HEATH CRT 7S Fax: 44 2086447 ESPANA Asociacion Espanola de Manutencion (AEM) ETSEIB - PABELLON F Diagonal, 647 E- 08028 BARCELONA Fax: 34 93 401 60 58 FRANCE, MIPS 39-41, rue Louis Blane F-92400 COURBEVOIE Fax:33 147 17 62.60 ITALIA Associazione Italiana Sistemi Sollevamento, Elevazione, Movim Via L. Batistotti Sassi 11 |- 20433 MILANO Fax: 99 2 739 7843, LUXEMBOURG Fédération des Industries Luxembourgeois. Groupement des Constructeurs BP, 1304 L= 1013 LUXEMBOURG Fax : 352.43 23 28 NEDERLAND FME/GKT Postbus 190 NL- 2700 AD ZOETERMEER Fax: 31 79 353 1365 NORGE Norwegian FEM Groups Federation of Norwegian Engineering Industies (Oscars Gate 20 / Box 7072 H N-0306 OSLO 3 Fax : 47 2259 66 69 PORTUGAL FENAME - Fedoragao Nacional do Metal (ANEMM) Estrade do Pago do Lumiar Polo Tecnologica de lisboa - Lote 13, P- 1600 LISBOA Fax :351 1715.04 03 SCHWEIZ/SUISSE/SVIZZERA Verein Schweizerischer Maschinen- Industrielior (VSM) Kirchenweg 4 ‘CH - 8032 ZURICH Fax: 41 1 384 48 48 SUOMI Federation of Finnish Metal, Engineering and Electrotechnical Industries - FIMET Etelaranta 10 P.O. BOX 10 FIN - 00131 HELSINKI Fax : 368 9 624 462 SVERIGE ‘Swedish Association of Suppliers of ‘Mechanical Handling Equipment MHG ‘Storgatan 5 Box 6610 '§- 114 B5 STOCKHOLM Fax : 46 8 660 33 78The third edition of the "Rules for the design of hoisting appliances" dated 4987.10.01" included 8 booklets. An addition to this edition was compiled in 1998. This addition is incorporated in booklet 9, which also replaces booklet 6. This booklet forms part of the "Rules for the design of hoisting appliances" 3rd edition revised, consisting of 8 booklets : Booklet 1 - Object and scope Booklet 2 - Classification and loading on structures and mechanisms Booklet 3 - Calculating the stresses in structures Booklet 4 - Checking for fatigue and choice of mechanism components Booklet 5 - Electrical equipment Booklet 7 - Safety rules Booklet 8 - Test loads and tolerances Booklet 9 - Supplements and comments to booklets 1 to 8 NOTE: Booklet 9 must not therefore be used separately. "The item 5.8 « SELECTION OF MOTORS » was rewrite in 1992 in order to allow crane manufacturers to design motors, as precisely as possible. Item 5.8 is devided into 3 parts : 4rst part (5.8.1) : General determinations for the selection of motors and dimensionning of motors according to thermal aspects, usually applying on all sorts of drives in intermittent service in tis part, the item 5.8.1.4 « SQUIRREL-CAGE MOTOR » includes 2 method to calculate; suitable for asynchronous squirrel cage motor. ‘This method, given on a trial basis, has to be tested 2nd part (8.8.2) : Special determinations to dimension motors according to the maximum torque required for LIFTING motions and according to data on stress occuring during the use of these drives. ‘3rd part (5.8.3) : As in 2nd part, but this item applies on motors for HORIZONTAL motions.BOOKLET 5 ELECTRICAL EQUIPMENT SUMMARY FOREWORD POWER SUPPLY ~ Characteristics of power supply system « Voltage = Voltage drop = Cut-out and safety devices between supply system ‘and supply Lines ~ Supply systems = Conductor bars, cable reels «+ Safety conductor and current collectors “ (earth) Arrangement ++ Minimum gaps - Flexible supoly cables + faleulation of conductor bars «+ Calculation of the minimun cross section in relaticn to the current intensity and the thermal capacity of the line + Calculation of the cross-section in relation to the acnissible voltage drop INSTALLATION OF CABLES AND CONDUCTORS = Selection of cables and conductors = Calculation of cross-section of conductors = Installation conditions ELECTRICAL PROTECTIVE AND SAFETY EQUIPMENT ~ Safeguarding otors + Motors used in continuous duty or short tine duty (SI - 82 as per TEC 341) « Motors used in intermittent duty (S53 - $8 duty as per isc 341) = Safeguarding wiring = Safeguarding against absence or inversion of phase = Action of safety devices = "Protection against the effects of Lightning END LIMIT SWITCHES = Limit switches + Hoist mechantsn * Oerricking mechanism (main jib, auxiliary ‘bridge crane boom) « Cross travel, long travel end distribution mechanisn + Slewing mechanism ~ Load and load manent Liniters = Technical operation conditions SL 5.2.3,3.1 5.2.3.5.2. 5.3. 5.3.16 5.3.2. 5.3.3. 5a 5.al Seeds Seb 2. 5.t.2. Sulh.3 Belted 5.4.5. 5.5. 5.5.1. re s 5- a 5-10 5-10 5-10 5-10 9-10 SLL Sl Sell Selt s-L sh Su S12 5-12 s-12 S-12CONTROLS: = Components + Relays and contactors + Resistor units + Enclosures of housings and cabinets - Housings and cabinets ~ Type of controls Isolation Performance of control systens + Control circuit = Type of control + Energisation + Cab control = Floor control + Radio control + Multiple control ~ Control of mechanical brakes = Brake connected directly to the motor + Brake connected separately from the motor + Auxiliary brake ENVIRONENT = O11 drips = Ambient tenperature ~ Humidity = Degree of protection SELECTION OF MOTORS ~ Criteria for motor selection (IEC 34-1) + Remarks on the selection of motors + Degree of protection (IEC 34-5) «+ Indoor application ++ Outdoor application ++ Particular application ++ Explosive environments + Thermal calculation of the motor Mean equivalent torque Meen equivalent power + Squirrel cage motor + Power correction in function af ambient temperature and altitude + Cyclic duration Factor and number of working cycles per hour ~ Motors for vertical motions + Determination of required tarque + Cyclic duration factor and number of cycles per haur ~ Motors for horizontal mations + Determining the torque necessary + Cyclic duration factor and number of cycles per hour + Ratation + Span variation 5-2 Clause 5.8. 5.6.1. 5.6.1.1, 3.6.1.2. 5.6.2. 56.2014 5.6.3. 5.6.3.1. 5.6.3.2. 5.6.5.3. 5.6.6, 5.6.hLe 5.6.4.2. 5.6.4.3, 5.6 de 5.6.4.5. 5.6.5. 5.6.5.4 36.5.2. 5.6.5.3. 5.7. 57s 3.7.2. 5.7.3, 5.7.4, Pane a3 SB oa 5-13 Se13 So13 Sls So1a 5-4 5-14 Sel 514 S15 5-15, 5-15 Se15 5-16 5.6 5-16 S16 5.16 Sel6 5-16 S17 517 5-18 5-18 5-18 5-18 5-18 5-18 5-18 5-19 5-19 5-19 5-19 5-21 5-22 5-23 5-24 5-24 5-25 5-27 5-27 5-29 5-29 5-20LOAD LIFTING MEANS = Current supply = Lifting magnets + Mindings + Duty + Performance + Safety factor + Stand-by supply = Grabs . Drives + Degree of protection = Load turning equipnent + Design + Poner supply to turning parts + Degree of protection CHECKS AND MAINTENANCE. = Maintenance = Checks, = Regular checks ++ Simple checks s+ Comprehensive checks + Checks before cannissioning AUXILIARY ELECTRICAL, EQUIPMENT Lighting = Cabin + Working area lighting + Access and machinery cabinet lighting + Emergency Lighting = Heating and air-conditioning = Machinery cabinets + Cabin = Auxiliary circuit LIST OF SYMBOLS AND NOTATIONS 5.9. 5.9.16 5.9.2. 5.9.21. 5.9.2.2 5.9.2.3. 5.9.2.4, 5.92.55 5.9.3. 5.9.3.6 3.9.3.2. 5.9. 5.9. 5.9.4.2. 5.9.4.3. 5.10. 5.10.1. 3.10.2. 5410.2.16 5.10.2.1.1. 5.10.2.1,2. 5.10.22. 5. Salle SsMLLele 5.1.1.2. 5.1.1.3, SelL1ede 5.1.2. SelL2e1e 5.1.2.2. 5.11.3. See booklet 1 5-3 &-31 5-31 5-31 8-31 5-31 5-31 5-31 5-31 5-32 5-32 5-32 5-32 8-32 5-32 5-32 5-32 5-32 5-33 5-33 5-33 5-33 5-39 5-34 5-34 5-34 5-34 5-34 5-34 5-35 5-35 8-35 5-355.2. B2L2e 5.2.2. 5.2.3. 5.23.14 FOREWORD The electrical equipment for lifting appliances should conform to the applicable CENELEC standards. In the event of there being na applicable CENELEC standard the Following recommendations spply. POWER SUPPLY CHARACTERISTICS OF POWER SUPPLY SYSTEM VOLTAGE Tris document deals with low-voltage alternating current standardized power supply systems (< 1000 V). VOLTAGE ROP Voltage variation at the connection point of the supply line to the system shauld not exceed + 5 % of its rated value, under normal operating conditions. CUT-OUT AND SAFETY DEVICES BETWEEN SUPPLY SYSTEM AND SUPPLY LINES. ~ The power supply system should be switched off by switches conected to supply (live cut-out) } these devices should be rated for the fault level of the supply. Fused switches or circuit breakers can equally be used for this function. ~ Sector connection switches should be made available at easily accessible points within the lifting equipment area or should be remote-controlled. It is necessary for quick access to then to be possible. For portal cranes with enclosed conductor systems, or trailing cables, main isola~ ‘ting switches need not be fitted on the cranes. Also the requirement for quick access can be dispensed with if the crane can be de-energised from quay level. = In the case of multiple supply to one contact line, each supply should be fitted with @ switch (or contactor) connecting the supply : all of these supply conection switches should be released simultaneously when even @ single switch is operated. ~ Re-connection of a supply system with multiple supply should only be possible from 4 single point. Supaly connection switches along with their release points (control devices) should be marked as such. For exanple : supply connection switch for hoisting appliance no. = Supply connection switches and control equipment for re-comection should be equipped with safeguards against eny errors of unauthorized tripping. SUPPLY SYSTEMS CONDUCTOR BARS - CABLE REELS 5a5.23.11. 5.2.3.1.2. 5.2.3.1,3. 5.25.2 Safety conductor and current collectors (earth) For supplies powered by contact Lines or collectors, an easily identifiable cowuctor bar or collector ring should be provided for the safety circuit ; the safety protective conductor should not be used as an active conductor. Hoisting appliances should be connected to the safety conductor vie sliding collectar shoes. Runners, rollers or any other roller systems must not be used as comections for the safety conductor. The current pick-ups for the safety conductors should be designed in such a way that they cannot be interchanged with the pick-ups for active conductors. Arrangement conductor bars should be arrenged or insulated with covering in such a way that no sccidental contact is possible. For exanple : when gaining access to, or walking on, the gangways or platforms of the Lifting equiptent. The conductors should be so arranged that Lifting tackle does not make contact with then even in the event of swinging of the load, Minimum gaps the minimum gap between live parts, and between live and earth parts should be guaranteed to be at least 10 m at the conductor bars in the case of positive ‘Quidence between the conductor bars and the current pick-up. For equipment which is built and checked in the works and for operational voltages less than or equal to 500 V, a gap of 6 mm is sufficient. If guidance is not of the positive type, the gap should be so selected that there is f@ minimum gap of 10 am. FLEXIBLE SUPPLY CABLES Flexible supply cables should be arranged and should move in such @ way that wear and tear is avoided. Winding druns should be designed in such a way that the ier dia~ meter of the drum is at least 10 tines the outer dianeter of the cable for cables up to 21.5 mm dianeter and at least 12.5 times the outer diameter of the cable for cables whose outer dianeter is greater then 21.5 mn, In the case of festoon-cable trolleys for cables of outer dieneter up to 8 mm, the nner curvature diameter should be at least 6.3 times the outer dianeter of the cable. For cables with outer dioneters greater than 8 nm, this should be at least 6 times the outer diameter. For cables mith an outer diameter greater than 12.5 mm, this should be at least 10 times the outer dianeter. In the case of flat cables, the thickness of the cable corresponds to the diateter of circular cables. ‘The constant tractive force acting on the conductor should be as low as possible. With non-reinforced, syrmetrical cable, this should be a maximum of 20 N/mm” applied to the total copper section of the whole of the conductors. 3552.3.3. 5.2.3.3.14 lihere the cable is moved at high speed or is of considerable weight, all necessary steps must be taken to prevent the cables fron being excessively stressed. ‘The cable winders should wind up the cable automatically. CALCULATION OF CONDUCTOR BARS cross-sections of the conductor bars are determined : = asa function of the maximun thermal intensity adniseible, = as a function of the maximun voltage drop adnissible. ‘These tno conditions each provide a minimum cross-section, the larger being the one to be selected. Calculation of the minimum cross-section in relation to the current intensity and the thermal capacity of the line ‘The minimun cross-sections in relation to the intensities are stated in the manufac- turer's catalogue. linen calculating the cross-section in relation to the rated thernal intensity Ty adnissible for the conductor bar which supplies several hoisting appliances, the actual simultaneous operation of the drive motors mist be taken into account. In the absence of this information, see table T.5.2.3.3.1. Table 7.5.2.3.3.1. For all lifting appliances as a whole (Iy) 1st motor 2nd motor 3ré motor ath motor Number of hoisting | most poverful appliances on one | motor Motors in decreasing order of power (1) ‘main contact Line a 1 x x 2 x x x 3 x x x 4 x x x x 5 x x x x Two hoisting appliances wor- x x x x king together (2) For drive by n motors in parallel, consider : Iy =n x Ty: Noninal current for one motor. Iy 365.2.3.3.2. Calculation of the cross-section in relation to the admissible voltage drop en calculating the voltage drop, the most unfavourable position of the hoisting ap- pliance in relation to the supply point must be considered. linen calculating the admissible voltage drop on a supply line used by several hoisting appliances, the start-up and rated current intensities of the motors opera~ ing simultaneously must be taken into account. In the absence of precise details, refer to table 1.5.2.3.3.2. Table 7.5.2.3.3.2+ For all the hoisting appliances as @ whole Number of appliances | teemotor znanotor srdnotor’ —senmotor on one main contact Line lp oy Ip IN Ip Wop oN 1 x x 2 x x x 3 x x 4 x x x $ x x x x 2 applisnees working x x x together 7 For squirrel-cage rotor motors' Ip (start-up current intensity), refer to the manu- facturer's catalogue. For slip-ring rotor motors, consider Ip to be approx. equal to 2 x Iy- For drive by n motors in parallel, consider : 9 x Ip or nx In. The motors should be arranged in the table in accordance with their start-up current intensity (Ip).53, 5.3L. 5.3.2, Calculation of three-shase section i: VE+L+ Typ -cosg “1? (=?) Mew i s = Cross-section in mn £ = Effective length of the ine in m Tyot = Sum Of Ip and Ty currents according in anpére du = Adnissible voltage drop in volts © = Electric conductivity in ——™ eT an? cos @ = Power factor INSTALLATION OF CABLES AND CONDUCTORS SELECTION OF CABLES AND CONDUCTORS The cables and conductors mst have the characteristics described in the CENELEC pub- ications HD 21, HD 22, HD 359 and HO 360 or at least the equivalent. Flexible cable for the cabling of hoisting appliances including cables for reels should preferably be selected from the H 07 RN-F Us/U~450/750 or H O7 WeF U,/U-850/750 or H O7 RIGH series. Rigid conductors fitted to the lifting apparatus should preferably be selected from the HO7 W-U or HO7 WR or H G7 RN-U or H 7 RIGR series. Bore wires and conductors can only be used for internal wiring cabinets and special electric enclosed spaces. For circuits with rated voltage of less than 250 V between conductors or between con ductor and earth, cables with a rated voltage Us/U = 300/500 V may be used. CALCULATION OF CROSS-SECTION OF CONDUCTORS The cross-section of the conductors should be determined by taking into account the mechanical strength required and the electrical load to be carried. For regular service, the voltage drop must be considered. @ Take inductive reactance into account for very long lines.5.33. ‘The cross-section of the conductors should be determined by taking into account. = the thermal capacity of the conductors in accordance with table 1.5.3.2. for exanple + Table 7.5.3.2. sectioney Permissible Gurrent for Insulated Conductors at ares Ambient Temperature 40°C for « Duty Factor of 100 & 6% 40% a a a 15. as 18 20 2,5 %6 26 30 a 3a 3A 40 6 ab 48 50. 10 a a 75 1s 82 7 105 25 198 120 145: % 135. 145, 175 50 168 180 210 70 207 240 270 35 250 270 330 120 292 319 380 150 335, 350 430 = Calculation of the voltage crop + HEE r YS £1 Cr cos @+ x sing) voltage drop Length starting current of the motor resistence per length unit reactance per length unit. Minimum adnissibie cross sectional area of copper conductors: = 1,5. mm? for multi strand conductors, = 0,75 nm? for flexible conductors with shielding, = 0,25 an? for Flexible conductors between electronic components. Conductars with solid cores are not accepted. ‘Type of protection for connection and distribution equiprents must be suitable for surrounding conditions, minimum degree of protection being at least IP 43 of IEC 14d. INSTALLATION CONDITIONS 59Bit. 5.H.h. SeHelele 541.2. 5.4.20 ‘The connections and Linking terminals should be placed in cabinets or boxes. Connection terminals whose accidental connection could be dangerous should be clearly separated unless their design precludes this risk. In order to ensure continual mechanical protection, the protective covering of the cables and conductors should enter housings through packing glands or such similar devices. The wires or conductors belonging to electrical circuits with different rated vol~ tages may be arranged within 2 single enclosure or may form part of the sane cable provided thet these wires or conductors are insulated against the highest rated vol- tage. Conductors having single insulation can only be installed in conduits or trunking Whose ends are Fitted with adequate protection. Non-sheathed conductors and cables which are fixed to parts of the framework should be protected, if necessary, against any mechanical wear and tear. ELECTRICAL PROTECTIVE AND SAFETY EQUIPMENT SAFEGUARDING MOTORS MOTORS USED IN CONTINUOUS DUTY OR SHORT TIME DUTY (Si - S2-AS PER TEC 341) In this case, for example, protection may be afforded : ~ either by suitably arranged thermal sensors within the motor, = or by inverse tine magnetic relay or timed thermal relay placed in each of the ‘supply phases. MOTORS USED IN INTERMITTENT DUTY (S3 - SB DUTY AS PER IEC 341) lihen the duty cycle, time and load are known and the rotor is rated accordingly, safeguarding against overloads is nat necessary. SAFEGUARDING WIRING The cross-section of a conductor should be determined according to the current inten= sity to which it is subject during both nomal running of the motor and starting-up or electrical braking, liether the load is protected or not, all wires should be safeguarded against any overcurrent, which could result fron a short-circuit or faulty insulation. ‘The protective device shall be rated for the appropriate short-circuit level. entici- pated. 5-195.4.3. 5.4. 5.4.5. 5.5. 5.5.1. B.SeLale 5521.2. SAFEGUARDING AGAINST ABSENCE OR INVERSION OF PHASES linen starting, the correct phase rotation must be ensured. If the absence of phases may occasion a danger, the appropriate safety measures must be taken. ACTION OF SAFETY DEVICES linen several motors drive the sane motion, the action of safety device should stop all of the motors for this movement. After a safety device has been activated, it should only be possible for the equip- ment to be started up again manually. PROTECTION AGAINST THE EFFECTS OF LIGHTNING For very tall pieces of hoisting equipment which are erected in particularly exposed locations, the effects of Lightning must be considered 1. on pieces of vulnerable structure (for example : jib support cable) 2. on anti-friction bearings or runners which form a Link between lerge parts of the frone (for exanple : slewing ring, travel runner). hen this is necessary, safeguarding against the effects of lightning should be carried out Following IEC TC al. For the safety of personnel, it is recomended that the rumer rails for the Lifting ‘equipnent are earthed. END LIMIT SWITCHES LIMIT SWITCHES The motorized motions of hoisting apparatus described in paragraphs 5.5.1.1. to 5.5.1.4. should be equipped at the minimm with a limit switch with automatic cut-out which safely prevents the end positions fron being over-run. It acts only as ‘a safety limit and not as a drive element. When the limit switches operate electrical circuits they shall satifsfy for each mechanism the follosing conditions. HOIST MECHANISH = Hoisting notion over hoist position, = Lowering motion over lower position for rope appliances if, with the hook on the ground, there is less than 2 turns of rope remaining on the drum, DERRICKING MECHANISM (MAIN JIB, AUXILIARY JIB, BRIDGE CRANE BOOM) = Derricking motion (highest admissible position) = Louering motion (lowest admissible position) ; in certain cases, this function may be carried out by a monent limiter. Sell5.5.1.3. 5.5.1.4. 5.5.2. 5.5.3. CROSS TRAVEL, LONG TRAVEL AND DISTRIBUTION MECHANISM If the travel or cross motion is driven fron a fixed control point, by means of remote control or radio control, these movements must be automatically Limited, In the case of a crane equiped with trolley travel on @ Jib with the exception of wall cranes, the trolley's movenent must be safety Limited as soon as the end positions are resched. These limit switches are not necessary for friction drive, if the trolley travel speed is less than or equal to 0.4 m/s and if the working load is less than 1000 kg. SLEWING MECHANISM If the use of equipment outside an authorized zone presents any risks, it should be equipoed with a limit switch. LOAD AND LOAD MOMENT LIMITERS If the lifting appliance is fitted with a load or load monent limiter and if designed for electrical operation, they shall satisfy the following technical conditions. TECHNICAL OPERATION CONDITIONS The positioning or operational limit switch should neither stop masses in motion, nor present extreme stress to part or all of the hoisting equiprent. A limit switch shouls bring about the arrest of mation by opening the electric eireuit and keeping it open as long as safety conditions ere not restored. A limit switch should be equipped with a safety device. These safety devices should be : = elther with a positively acting mechanism and driven with the least ruber of intermediary parts possible. ~ Or quick-break contacts (blade contacts, aicro-switches). In this case the circuit in which the contact is inserted should be protected against short circuits in order to ensure that the contacts do not weld together. = or by static systens (electronics) e.g. : proximity ewitches. If it is unavoidable to by-pass a safety device, this operation should only be able to be effected with the aid of a device which, when no longer actuated, automatically Te-inserts the safety device. After operation of an autonatic Limiter, movenent in the opposite direction must aluays renain possible. Housings for Liniters installed in dry places must conform to safety factor IP 43 at least. Housings for Limiters installed in hunid places ar out of doors should conform to safety factor IP 55 at least.3.6. 5.6.1. 5.6161. 5.6.1.2. 5.6.2. 5.6.2.1 fabient tenperatures should not affect operation of the Liniter. Tesperature ranges are = ~ indoor or cto + More = outdoor : - 30° to + 40°C CONTROLS COMPONENTS, RELAYS AND CONTACTORS Relays and contactors must comply with the requirenents of IEC 158-1 and IEC 158-1A, especially section 4.3.6. with regard to the category of use. In case the crane will be used at an altitude in excess of 1000 m, this shall be considered by selecting the contactors and relays. Reversing contactors should be of the electrically or mechanically interlocking type. The Lifting appliance can only be energised when all the control devices are in the off position. This off position can be determined either by @ checking circuit or by using a spring return. RESISTOR UNITS Resistor units, which are installed outside of electrical appliance roons, should be accommodated in suitable, protected housings, as a minimum of IP 10 for indoor use ‘and IP 13 for outdoor use as defined In TEC 144, Liquid resistors shall not be used. The temperature limit is determined by the resistor material. When designing the resistor units, the equivelent torque, cyclic duration factor and switching rate have to be considered. ENCLOSURE OF HOUSINGS AND CABINETS Snitching devices, switchgear and panels housing electrical equipment may be enclosed as follows + = in cabinets or housings, = in special enclosed spaces, = in the supporting structure (principally the crane girder) of the hoisting appliance « HOUSINGS AND CABINETS If separate housings and cabinets are used, they should be robust and have ainimum degrees of protection of IP 43 for indoor operation and IP 55 for cutdoor operation. Housings and cabinets should be provided with doors or a cover. 55.6.3. 5.6.3.1. 5.6.3.2. 3.6.3.3. 5.6.4. 5.6.8.1. If the doors carry electrical equipment, the doors, or the electrical equipment, should be earthed by a separate conductor. The doors or covers should be locksble when closed. ‘There should be a clear space of at least 400 mm in front of housings end cabinets ; ‘the floor should be free of obstacles and be sufficiently strong. TYPE OF CONTROL ISOLATION The Lifting appliance should be provided with an isolator which can be locked in the ‘open position. linen several appliances are on the sane supply, it is necessary to install a lockable isolator on each appliance. PERFORMANCE OF CONTROL SYSTEMS ‘The control system should be so designed that loads of up to 120 % of the nominal, load of the hoisting appliance may be moved safely. Lifting oF a full load at 0.95 of rated voltage should not result in lowering of the Joad, whatever the position of the control lever. Lowering of 2 full load should not be possible at more than 120 % of the nominal, speed, whatever the position of the control lever, unless permitted by the control scheme, For travelling and slewing units, starting and braking should be progressive in both directions. CONTROL CIRCUIT If the control circuit is fed by a transfomer (or transformer with rectifier), the secondary voltage should not exceed 250 V. Safety has to be ensured against incor- rect motion caused by insulation failure either in connecting the common polarity to the equipotential connection of the mass, or by an equivalent measure, as for example an insulation monitoring device. This pole shall not be interrupted by any suitch, contact or fuse. Suitable measures, should be taken to protect the other pole against overloads ar short-circuits. If the control circuit Is not fed by @ transformer, equivalent safety measures should be taken. TYPE OF CONTROL ENERGISATION The lifting appliance can only be energised when all the control devices are in the Off position. This off position can be determined either by a checking circuit or by using @ spring return.5.6.8.2. 5.6.4.3. 5.6 old 3.6.8.5. CAB CONTROL = The controls should be so arranged that the operator has an adequate view of the crane's working area. = The control for hoisting appliances should preferably be arranged on the right~ hand side of the operator's seat. = As an energency cut-out for ell motions, a red-push button switch should be loca~ ted in an easily accessible position on the control unit. This push-button switch should be of the mechanically unlocking type. FLOOR CONTROL Push-buttons or other switching devices, which autosatically return to their "off" position as soon as they are released, should be provided for the control of all motions by pendant control units. In addition to the controllers, a device for opening and closing the main contactor must be provided (as described in 5.6.4.2.). Except in the case of the direct-on-line control of motors, the voltage in pendant control units should not exceed 250 V. Housings of pendant control units should preferably be of fully insulating neterial or of material with protective insulation. Metal parts accessible fron the outside, lwbich pass through the insulation, should be separately earthed. ‘The surface of the housing must be @ vivid colour. For indoor operation, the degree of protection should be IP 43 at least, and for outdoor operation IP 55 at least, ‘as per IEC 144, Pendant control units should be suspended with a strain relic? arrangement. RADIO CONTROL For the radio control of a crane, sefety should be assured : = The systen used should be of the "fail-safe" type, and the receiver should only respond to the one code of the transmitter corresponding to each hoisting appliance. = In addition to the controllers for all motions, a device for switching the main contactar on and off should be provided. = Motions should be controlled by push-buttons ar snitches which are provided with an automatic spring return to the “off position. Control levers should be provided either with @ mechanical device for locking in the "off" position or with @ deadnan's handle circuit. The transmitter must have a minimum protection class IP 43 for indoor use and IP 55 for outdoor use. MULTIPLE CONTROL linen duplicate controls are required for the hoisting eppliance, only one control is to be in operation at any one time (e.g. : cab-control or floor control).5.6.5. 5.6.5.1. 5.6.5.2. 5.7 BTL. CONTROL OF MECHANICAL BRAKES BRAKE CONNECTEO DIRECTLY TO THE MOTOR The brake circuit should be protected by a device which suitches off the motor and brake in the event of a malfunction. If the conductor’ to the brake is <5 m, this protection of breke is no longer neces~ sary. BRAKE CONNECTED SEPARATELY FROM THE MOTOR Precautions should be taken so that it is not possible for any uncontrolled movenents to occur before the brake operation is conpleted during starting and stopping, Where there is electrical braking, the mechanical brake should be applied only after electrical braking. Except for transitory conditions the brake must not be applied when the motor is ener- gised. AUXILIARY BRAKE Cranes which require particular safety, e.g. in steel works or with dangerous or melted loads, should be provided with an auxiliary brake. Under normal operating conditions, the auxiliary brake should always be applied on stopping, after the motion has been brought to a halt by the main brake. It rust be possible to adjust this delay. In the event of an emergency stop, the auxiliary brake should bé applied immediately. ENVIRONMENT OIL ORIPS No part of any lubricating or hydraulic system or ather equipnent containing oil shell be Tun or installed in such a position as to be able to cause oil drips onto the electrical equipment unless the equipment is protected fron damage fron this cause. AMBIENT TEMPERATURE All electrical equipment shell be suitable for operating continuously in an anbient temperature of - 20° to + 40° C. When the electrical equipment is installed in en Blosed spaces (or crane girders), means shal] be provided for ensuring that the permis- sible temperatures for the proper functioning of the electrical equipment are main- tained. However, if lower or higher ambient temperatures are envisaged, the user shall specify the temperature he requires the crane to work in and under these conditions ‘the equipment may either be designed for-the specified temperature or alternatively, heating or cooling may be provided. ss5.7.3. 5.7ke HUMIDITY ALL electrical equipment shall be suitable for use in atmospheres with an average relative hunidity of up to 60 &. If the humidity is expected to exceed this level, special precautions should be taken which may include the provision of anti-condensa- tion heaters and the varnishing of vulnerable parts. These details shall be by agreement between the purchaser and the manufacturer. DEGREE OF PROTECTION The minimum degree of protection has been specified in other chapters in this docu- tment for specific itens of installation. In the event that a higher or conplenentary degree of protection against dust is required by a particuler installation environ~ iment, it should be agreed between the purchaser and manufacturer. S175.8.1.1, 5.8.1.2, 5.8.1.2.1. 5.8.1.2.2. 5.81.23. CRITERIA FOR MOTOR SELECTION (IEC 34-1) - required powers-the thermal power is also included in these required powers, - maximum rated torque and maximum acceleration torque, - cyclic duration factor, - number of cycles/hour, = type of control (type of braking), } = speed regulation, } - type of power feed, } driving systems - degree of protection, (environment conditions), } - ambient temperature, ~ altitude, For the predimensioning of the motor, account has to be taken of : + the thermal calculation as per clause 58.1.3. - the maximum required torque : {for hoisting mechanisms as per clause 5.8.2.1 - for horizontal motions as per clause 5.8.3.1. ‘The motor has to comply with the two requirements. If the required torque diagrams, in order to define the mean equivalent torque (as per 5.8.1.3.1.) are not available, these can be assessed respectively with the help of tables T5.8.2.2a. and 7583.20 Remarks on the selection of motors ‘The selection of the motor should be agreed with the manufacturer in taking into account the torque and powers calculated in the following clauses and the real operating conditions of the motor. In the event of electronic power control, the definition of the motors has to be made in cooperation with the manufacturer, taking into account the cooling system and the speed range. Degree of protection (IEC 34-5) Indoor application For indoor application, under normal conditions, motors must comply wtih IP 23 at least. In dusty environment, motors must comply with IP 44 at least. Outdoor application For outdoor application, motors must comply with IP 54 at least. {In case of water condensation risk, care should be taken that the water condensation drain holes remain open. Particular application Motors may comply with a lower degree of protection il they are appropriately protected, or protected by external means for their particular application. 5-185.81.24, 5.8.13. 5.8.1.3. 5.8.1.3.2. Explosive environments In potentially explosive environments, motors must be explosion-proof as EN 50014-50020. ‘Thema! calculation of the motor Mean equivalent torque In order to carry out the thermal calculation, the mean equivalent torque must be determined as a function of the required torque during the working cycles, by the formula : iz M4y2ty+Mo2to4Mg2@tg tu +Mn?ty med = — tyttortg+— tty Where : t 4, o:t g, «tp ate the periods during which the different torque values are produced ; periods of rest are not taken into account. M 4.M 2,M 3,...M 9 are the calculated torque values, in taking into account all the inertia forces including the one of the rotor mass of the motor. In case of variable loads, at least a maximum of 10 successive working cycles for the predimensioning, must be taken into account (see definition 2.1.2.2.). Diagram 5.8.1.9.1. shows an example of the forque operation for 2 different cycles. ‘Mean equivalent power Starting from the mean equivalent torque, the mean equivalent power Pmed in kW is dofined by ‘the formula : Pmed a : where, Mmed mean equivalent torque in Nm a = speed of motor in mn ~* ‘The such defined motor can be selected in $3 duty if one single motion operation is not exceeding 10 minutes. ‘Should this not be the case, a special study has to be made. For the squirrel cage motors, the predimensioning will be carried out according to the method described in clause 5.8.1.4. For the motor selection, the mean equivalent power P meq should be corrected as a function of altitude if it exceeds 1000 m and the ambient temperature ifit deviates from 40 °C (See 5.8.1.5.) S19Diagram §.8.1.3.1, ‘Typical operation of torque for 2 different cycles : Hoisting motion ‘Horizontal motion tr: rest time tr: rest time Mi, M4,M7, M10, starting torque Mt, Ma Ma, M8, hoisting torque raising «M2, Ma, Me, Ma, M12, braking torque (M3, M6, M5, Mit, hoisting torque lowering M5, 8-20 starting torque working torque bbraking torque torque without load with wind5.81.4. ‘Squirrel cage motor ‘The following inequality has to be checked for the predimensioning of the squirrel cage motors 'p Jn? moy.19°3 (Ck (1+ 1 pg) PryeT > (1-0 Moy) P moy: tN + (PN = TES ) 'N 180 (tenn) PN-T= loss energy ot the motor working at its rated power (S1) during a time T (1-nmoy)-P moy-!N= 105s energy of the motor during the time ty (constant speed) inacycle 'b in? moy, 10-9 (@ moy —O. tg AE MON10S y lass energy ofthe motor during the stating and braking IN 180 phases, k= correction factor linked to the type of motor PN= nominal power in KW of the motor in continuous (S1) duty Kye efficiency of the motor at Py, speed of motor for power Prnoy in mnt Mmoy = mean resisting torque in Nm calculated in the same manner ‘a Mmed in removing the starting and braking phases. Timoy = efficiency of the motor at power Pmoy T= total time of cycle in s. IN + te T=tn+te +t stop ; tae N= operating time at constant speed during one cycle in s, te= equivalent time of starting and braking during one cycle in s. lay + 0.5 dicy +9 fey) Je total inertia of masses in motion referred to the motor shaft inkg m? decy = the number of complete starts during one cycle Sicy = the number of impulses during one cycle fey= the number of electrical brakings during one cycle Maco = the mean accelerating torque in Nn Maco = Mdmoy * Mmoy 5-215815 Momoy = ean starting torque of motor in Nm The following data has to be indicated by the motor manufacturer : Pye nominal power (kW) of motor in continuous (S1) duty 14...5/A = efficiency for 1/4 Pry ..5/4 Pry powers JM = ‘moment of inertia of motor in kg m? 94/4.5/4= speed of motor at 1/4 Pry ..5/4 Py in nm-t Mpmoy = mean starting torque of motor in Nm pity = ratio between the starting current and the current at Pry Cx= ‘correction factor linked to the type of motor In case the Cy factor is not mentioned in the manufacturer's catalogue, Cj shall be taken equal to 1 for motors of polarity equal or above 4. PB iat ‘These corrections are depending from the type of motor, the cooling method and the insulation class. The precise calculation can only be made by the motor manufacturer in supplying them with the following indications : = Pmed without correction - value of ambient temperature - altitude ‘The predimensioning can be based on the values indicated in Diagram 5.8.1.5 in using the formula : P'med = Pmed k P'moy = Pmoy tor squirrel cage motors k Pimoy Of Pimed = required nominal power of motor as function of altitude and ambient temperature. 5-2213] 12 Feo ect 4 or > Pe eee eres! pune b—-—b > >4~_ > R~ 4 1 > ALTITUDE os | 1000 m_| oa L 52000 m_| 07 53000 m it s4000 m7] os 05 3 0 Fy 3 2 3 3 Ambient Temperature °C ‘Diagram 5.8.1.5 = Correction as function of ambiant temperature and atitude Note 1: The K>1 coatficient values are to be defined between the motor manufacturer and the hoisting appliances manufacturer. Note 2: The ambient temperature shall be indicated above an altude of 1000 m 5.8.1.6 Cyclic duration factor and number of working cycles per hour ‘The cyclic duration factor is given by the following formula = Operating time —D--— ‘Operating time + idle time x 100 (%) ‘The operating time and the number of operations per hour of the motors as well as the number of working cycles of the crane, are an important base for the thermal definition of the motors and which should be agreed between the user and the manufacturer of the crane. In case it is Not possible to give these indications in a precise manner, it should be referred to tables T $.8.2.2.a and 758324, 5-235.82 5.8.24 MOTORS FOR VERTICAL MOTIONS Determination of required torque For a hoisting motor, the required power to raise the maximum nominal load (PHymax) is defined in kW in taking account of the configuration of the transmission and of the reeving according to the following formula : Where Le VL ing speed in mvs ae efficiency of machinery lt gives the required torque to raise the maximum nominal load : Primax: 9 550 Pmax 8 n= rotating speed of the motor in mn-? {In order to be able to develop the necessary torque for acceleration, for lifting the test load or for ‘compensating for variations in the mains voltage and frequency, the torque developed by the motor ‘must satisty the following minimum condition : - For squirrel cage motors with direct starting : Minin 216 Mnmax Where Mri is the minimum torque of the motor during starting. For slip ting motors : Mmax 219 MNmax ‘Mmax being the maximum torque of the motor. For alltypes of motors which are fed by voltages and /or variable frequencies : Mmax 214 Mnmax 5-2458.22 The mechanical braking torque at the motor shaft Mr should at least be equal to = Sk p22 MNmax “1 Dynamic : Mg > 1,5 MNmax * 1? a ; : = Static: is the required minimum torque to prevent the SWL rotating the machinery. = Dynamic : is the braking torque produced bye the brake during the whole duration of a braking cycle. Inthe event of an electrical braking, it shall be capable to slow down the load in complete safety. Cyclic duration factor and number of cycles per hour In the case where no precise indications are given, the values mentioned in Table T .8.2.2.a can bbe chosen. 5-25Table T. 5.8.2.2a Indications for the number of cycles per hour and the cyclic duration factor for the vertical motions ‘Type of mechanism FM 9%. Derricking fiinged boom. Appliances with manual drive Derricking boom sib cranes for assembling ‘Assembling and ‘dismantling cranes for power stations machine shops... ‘Stocking and reclaiming transporters Hook’ 20-60 40 $2 15-30 min 2) ‘Stocking and reclaiming transporters Grab or magnet 25-80 0 - 100 $2 15-30 min 2) ‘Workshop cranes. 10-50 25 - 40 ‘Overhead travelling cranes, Pig breaking cranes Scrap charging cranes Grab or magnet 40 - 120 40 - 100 Ladle cranes. 3-10 ‘Soaking pit cranes 30-60 Stripper cranes, open hearth furnace charging cranes 10 14 Forge cranes. sa) 8 Bal). 8 12a 12b Unloading bridge cranes, Bridge cranes for containers Other bridge cranes (with crab and/or rotating crane) Hook or spreader Hook 20-60 20-60 40 i 40-60 82 15-30 min 2) ‘$2 15-30 min 3 Unloading bridge cranes, Bridge cranes (with crab andor rotating crane) Grab or magnet 20-60 40-100 60 $2 15-30 min 2) 4 Shipyard jib cranes, dismantling jb cranes Hook 20-50 15 ‘Wharf cranes (rotating on bridge crane..., floating cranes and shear legs Hook pe Wharf cranes (rotating on bbridge crane...) floating cranes and shear legs Grab or magnet 0 100 7 Floating cranes and shear legs for heavy lifts (usually >100t) 2) St $230 min 2) 8215-30 min Deck cranes Hook 40 Ls 19, Deck cranes Grab or magnet 60 20 Site tower cranes 40 - 60 25 - 40 2t Derrick cranes 2) Stor $230 min Stor $230 min 2 Railway cranes, admitted for railway traffic 10 1) This column comprises only some indicatory typical cases of utilisation 2) itis recommended for $1 and S2 to refer to the definition IEC 34-1 5-28583 5.8.3.1 MOTORS FOR HORIZONTAL MOTIONS In order to select travel motors correctly, all the necessary torque (or power) values must be considered, taking into account the starting time, the number of starting cyles per hour and the cyclic duration factor. The maximum transmissible torque of the travel motors is limited by the adhesion of the driven travel wheels ont their tracks. Determining the torque necessary ‘The maximum torque necessary is determined from the loadings specified in booklet 2 without taking into account the coetficient 3 m. Case | for cranes not exposed to wind Case I for cranes exposed to wind Case tila for cranes exposed to exceptional loadings (tor the determination of the brakes). ‘The travel motors must delivery the necessary torque for the acceleration and the maintaining of the speed. ~ Speed maintaining torque To determine the torque necessary for maintaining the speed, account has to be taken of the sum of forces (Ww) resisting to travel resulting from the deadweight, the oad and operating conditions such as: deformation of the running surface, “friction of the wheels on straight sections and in curves, - wind force, ~ gradients in the track, “necessary traction of power supply cable. ~ Acceleration torque (running up to speed) The acceleration torque shall take into account the sum of the accelaration forces of the mass of useful load and of the other masses put into motion. For the acceleration values, see Table T 2.2.3.1.1 (booklet 2). “The necessary torque can be calculated by the following formula (see diagram 5.8.1.9.1) Casel (a [msm_}+W9) v.60 My... Mp =~ sa 8-27Case ll The largest of the values from the results of the following formula shall be taken into account : (almsm_}+wg) v.60 My. and My... 2n.nn where : a: acceleration in m/s? (at constant speed a = 0) my: mass of useful load in kg Wo. Wg, Wag total travel resistance in N (in certain cases of utilisation, w can became negative) wo atzero wind Wg ata wind of 80 Nim? Wo5 at a wind of 250 Nim ve travel speed in m/s a: rotation speed of motors in ma ~t a: ‘overall efficiency of mechanism m: ‘equivalent mass in kg of all parts put into motion, excluding the load, which is Supposed to be concentrated at the suspension point of the load. M= Mg + Mot -71 Mm mass in kg of the whole of the elements, excluding the load, undergoing the same horizontal motion as the suspension point of the load. Mot ! equivalent mass in kg of the rotating parts referred to linear motion. ‘The inertia ofthe rotating masses, referred to linear motion is evaluated, using the the formula : Mot= So ( a 912 ve where mm: ‘speed of rotating masses mn-1 J: moment of inertia of all rotating masses in kgm? For determining the maximum torque of the motor, the highest value of the calculated torque shall bbe taken into account. For slip ring motors used for the horizontal motions, the starting resistances shall be so defined that the minimum torque delivered by the motor is never less than 1,2 times the torque required to maintain the travel speed. 5-285.8.3.2 58.3.3 5834 Cyclic duration factor and number of cycles per hour In the case where no precise indications are given, the values mentioned in Table T 5.8.3.2.a. can be chosen. Rotation Tie calculation is carried out in an analogous fashion to clause 5.8.8.1, angular speeds being substituted for the linear speeds. s ann If the span variation in the case of luffing jbs, leads to an elevation or to a lowering of the centre of gravity of the masses put into motion, the calculation can be carried out in an analogous fashion to clause 5.8.3 in inserting into the factor (w) the forces required to the vertical displacement of the centre of gravity. 5-29Table T. .8.3.2a Indications for the number of cycles per hour and the cyclic duration factor for the horizontal motions ie Type of appliance a ‘of mechanism FM % TD] Namber Designation Precisions conc. | of cycles | Rotation jeiteas Travel ‘the type of utilisation | per hour 1 | Appliances with manual drive 2 _| i cranes for assembling 2-35 2B 25-40 25-40 Assembling and 2-15 25 2 dismantling cranes for power stations machine shops | Stocking and reclaiming — | Hook 20-60 | 15-40 40-60 25-40 transporters 5 | Stocking and reclaiming ‘Grab or magnet 40 60 15-40 transporters 6__| Workshop cranes 25 - 40 25-40 7 | Overhead traveling Grab or magnet 40-120 40-60 | 60-100 cranes, Pig breaking cranes Scrap charging cranes 8 __| Ladle cranes 3-10 40 - 60 A0 - 60 9 | Soaking pit cranes 30 - 60 40. 40 - 60 40 - 60 10 | Stripper cranes, open 30 0 60 hearth furnace charging 10 40 40 cranes 11_[ Fore cranes é 700. a 25 12a [Unloading bridge cranes, | Hook or spreader | 20-60 | 15-40 40-60 15-40 Bridge cranes for containers 12 | Other bridge cranes (with | Hook 20-60 | 25-40 40-60 25-40 crab and/or rotating crane) 13 | Unloading bridge cranes, | Grab or magnet 20-80 40 40 - 100 15-60 Bridge cranes (with crab and/or rotating crane) 14 | Shipyard jib cranes, Hook 20-50 Ey 40 25-40 dismantling jb cranes 15 [Wharf cranes (rotating on_| Hook 40 bridge crane...), floating 25-40 40 15-25 cranes and shear legs 20 46 | Wharf cranes (rotating on | Grab or magnet 25-60 | 40-60 5-40 bridge crane...), floating cranes and shear legs 17 | Floating cranes and shear 2-10 legs for heavy lifts (usually 15-40 2100 t) 18 _{ Deck cranes Hook 30 - 60 40 419 | Deck cranes Grab or magnet 30-60 60 20_| Site tower cranes 20 21_| Derrick cranes. 10 22 | Railway cranes, admitted 10 for railway traffic 1) This column comprises only some indicatory typical cases of utilisation 5-305.9. 5.91. 5.9.2.2. 5.92.36 592A 5.9.2.5. LOAD LIFTING MEANS CURRENT SUPPLY In view of the arduous duty to which current supply systems are subjected, the elec trical equipment must be selected and installed with special care. = Supply cables should be able to be wound on cable winders and their mechanical strength, resistance to external Influences and heat-resistence, must be suitable for the Service conditions. = Cable fixing means should be so selected that ell strain on the connections or danage to the cables is avoided. = Cables should be installed and guided in such a way as to exclude the possiblity of danage in normal service. LIFTING MAGNETS WINDINGS The insulation class of the windings should be selected according to the power loss, ‘the ambient tenperature and, if necessary, the heating caused by the goods handled. uty Lifting magnets are normally designed for 2 cyclic duration facter of 50 %. Other cyclic duration factors should be agreed between the manufacturer and user. PERFORMANCE The Lifting capacity of a lifting magnet should be specified for @ precise load at rated voltage and operating temperature of the magnet coil. SAFETY FACTOR The tear-off force should be at least twice the lifting capacity. STAND-BY SUPPLY If there is a stand-by power supply from batteries, the holding tine should be at Least 20 minutes. In this case, an automatic charging unit and a charge level indice- ‘tor should be provided. Use of the stand-by supply should be indicated visually and audibly for general warning. If the battery voltage level is not adequate, a device preventing the installation from being used should cone into effect. 5-315.9.3. 5.9.3.1. 5.9.3.20 5.9.4. 5.9.4.1. 5.94.26 5.9.4.3. GRABS DRIVES ‘The drive motor (electro-hydraulic or electro-nechanical drive) should be designed for 53, S4 or S6 duty depending on type and application, DEGREE OF PROTECTION In normal service, the motors and electrical equipment must comply with IP 55 at Least. For underwater operation the degree of protection must be IP 57 at least. Due to the special service conditions of this equipment, jolts and vibrations must be given particular attention. LOAD TURNING EQUIPMENT DESIGN Load turning equipment should be so designed that loads can be accelerated and braked without the ropas twisting. The arrangenent of the lifting ropes, the load, the 1if- ‘ting height, the centre of gravity and the monent of inertia of the load and loading beam 1f applicable should be taken into account in the design of the equipment. The installation of guides such as telescoping or articulated systems may be used in order to prevent the twisting of ropes. POWER SUPPLY TO TURNING PARTS For supplying electrical power to turning parts, the current supply system should be designed in accordance with the turning range. DEGREE OF PROTECTION If the turning motor is mounted on the supporting structure of the hoisting appliance, it mist comply with the degree of protection of the other motors on the structure at least. If the turning motor is mounted on the Icad Lifting means, it must comply with IP 44 at least for indoor operation and IP 55 for outdoor operation. CHECKS AND MAINTENANCE MAINTENANCE, The electrical equipment of a hoisting appliance should be maintained in good condi~ tion. Maintenance should be based on the duty class and load spectrum of the hoisting appliance and carried out in accordance with the instructions of the supplier or nanufacturer, 5-325.10.2. 5.10.21. $.10.2-1-1. 5,10.2.1.2. 5.10.2.2. CHECKS A distinction is made between regular checks and checks made before the appliance is comnissioned. Regular checks are subdivided into sinple checks and comprehensive checks. REGULAR CHECKS Simple checks The safety devices which can be checked from the control position are to be checked segulerly, in principale before the start of each workday, for their proper electric functioning. In particular, the following, at least, must be checked + = energency limit suitches, = brake functions, = energency cut-out. Comprehensive checks At least once a year, the electrical equipment of a hoisting appliance should be given a comprehensive check. Besides the above simple checks, the following should be checked thoroughly + = the settings and conditions of the electrical safety devices, = Snitegrity of protective earth systens, = integrity of equipotential circuits, insulation of all the electrical equipnent, = tightness of all connections, ~ predetermined resistance values, 1f any, = physical condition of cables and cable inlets, = physical condition of safety devices, = presence and condition of devices protecting against direct contact, = the technical performance of replaced parts is compatible with the proper functio- ning of the hoisting appliance. CHECKS BEFORE COMMISSIONING In addition te the comprehensive checks, the checks before commissioning include, at least : = checking that all the hoisting appliance's electrical equipment is in conformity with national regulations and standards, checking that the electrical equipment agrees with the circuit diagrans, Ghecking the switching sequence of the safety and control circuits, = checking the proper functioning and correct selection of the electrical conponents in accordence with the expected operating conditions for the hoisting appliance, checking that the performance data of motors is in conformity with their use. 5-33Sal. S.lLL. Sell LL. 5111.2. 5.11.13. S.LL4. = checking that the control system does not permit any uncontrolled excess spesds in normal operation, ~ Checking the correct settings for all the electrical equipment and its proper functioning. AUXILIARY ELECTRICAL EQUIPMENT LIGHTING CABIN = A fixed non-dazzling service lighting wlll be provided, so arranged that only the necessary illumination for the lighting of the control equipment is provided. = When the general area lighting equipment is not sufficient to permit access and exit out of the cabin in safety, supplementary portable Lighting will be provided ; this equipment must be able to work, even if the principal electrical circuits of the crane are isolated. WORKING AREA LIGHTING = hen the working area lighting is provided by the appliance, projectors will be suitably placed on the crane, so that a mininun illumination of 30 lux at ground level is gurarantesd, ~ This lighting circuit will be independent of the principal circuits of the hoisting appliance. = Precautions must be taken to avoid voltage drops produced by starting the motors cutting out the gas discharge lamps. ACCESS AND MACHINERY CABINET LIGHTING then the general area Lighting does not permit sufficient illumination, supplesentary Lighting independent of the principal circuits of the hoisting appliance will be Provided. The minimum illumination will be 30 Lux. EMERGENCY LIGHTING linen the lighting of the area does not permit exit out of the appliance in safety, a portable lamp, equipped with batteries will be provided. A battery charger must be provided In the cabin. 5-345.1.2. SAL2ds 51.2.2. 5.3, HEATING AND AIR-CONDITIONING MACHINERY CABINETS = Natural or forced ventilation will be provided to disperse thermal power generated by the machinery and its equiptent. where electronic equiprent is used and working conditions do not guarantee an anbient tenperature for proper functioning of the electronic equipnent, an eir con- ditioning unit will be provided. CABIN If necessary heating appliances will be provided in the cabin. This apparatus of black heat/non-radiant type shall be securely fixed. Tt must be provided with a thermostat and must have such a power to assure a minimum tenperature ‘of 15° C, taking into account the environent in which the equipnent is installed. This apparatus must be fed Independently of the principal circuits of the hoisting appliance. If required by the environment an air conditioning unit will be installed in the cabin to maintain a maxinum acceptable tenperature. This apparatus must be fed by circuit independent of the principal circuits of the hoisting appliance. AUXILIARY CIRCUIT If there is no possibility of supply fn the proximity, auxiliary circuits must’be pro- vided for maintenance purposes, as follows + = A circuit for portable Lighting with a minima power of 200 W, if the anbient Lighting is not sufficient to carry out maintenance. = Acireuit for portable tools with @ minima poner of 2 kW low voltage of 100 V or 220 V. This circuit must be protected by a differential circuit breaker of high sensitivity. These circuits will be independent of the principal circuits of the hoisting appliance and the voltage must be indicated near the socket outlet. All measures will be taken to avoid confusion between very-low-voltage and lon-voltage. 5-35FEDERATION EUROPEENNE DELA | —_F.E.M. MANUTENTION a SECTION | SEDITION REVISED HEAVY LIFTING APPLIANCES 1998.10.04 RULES FOR THE DESIGN OF HOISTING APPLIANCES BOOKLET 7 SAFETY RULES ‘The total 3rd Edition revised comprises booklets 1 to S and 7 to.9 Copyright by FEM Section | Also available in French and GermanDocument prepared by the technical commission of FEM (European Handling Federation) Section 1 « Heavy ‘ifting and handling equipment ». FEM Section | Secretary ‘Cosette DUSSAUGEY 39-41, rue Louis Biane ‘92400 COURBEVOIE 52 92038 PARIS LA DEFENSE CEDEX Fax :33 147 17 62 60 E-mail : Mips@wanadoor Document available near the following National Committees = BELGIUM FABRIMETAL Rue des Drapiers, 21 B- 1050 BRUXELLES. Fox 32.2 510 23 01 CZECH REPUBLIC Association of Czechosiovak Manufacturers, ff Transport and Lifting Equipment ‘SYMAS Kralove Pole Cranes, as. (GZ 61200 BRNO Fax : 42 057262251 DANEMARK Confederation of Danish Industries DK - 1787 COPENHAGEN Fax: 45 3377 3410 DEUTSCHLAND VDMA Fachgemeinschaft Fordertechnik Postfach 71 08 64 1D - 60498 FRANKFURT/MAIN Fax : 49 69 66 03 14.95, ENGLAND FMCEC Ambassador House Brigstock Road GB - THORNTON HEATH CR7 7G Fax: 44 181 6650447 ESPANA Asociacion Espanola de Manutencion (AEM) ETSEIB- PABELLON F Diagonal, 647 E - 08028 BARCELONA, Fax : 34 93 401 60 58 FRANCE MIPS 39-41, rue Louis Blanc F - 92400 COURBEVOIE Fax: 33 147 176260 ITALIA Associazione Italiana Sistemi Sollevamento, Elevazione, Movim Via L. Battistot Sassi 11 120133 MILANO Fax: 39.2 739 73 16 LUXEMBOURG Fédération dos Industrels Luxembourgeois Groupement des Constructeurs BP. 1304 L- 1013 LUXEMBOURG Fax : 352 43 23 28 NEDERLAND FMEIGKT Postbus 190 NU- 2700 AD ZOETERMEER Fax: 31 79.963 13 65 NORGE Norwegian FEM Groups Federation of Norwegian Engineering Industries Oscars Gato 20 / Box 7072 H N- 0306 OSLO 3 Fax : 47 22 59 66 69 PORTUGAL FENAME - Federagao Nacional do Metal (ANEMM) Estrade do Pago do Lumiar Polo Tecaologico de lisboa - Lote 13, P- 1600 LISBOA Fax: 3511715 04.03, ‘SCHWEIZ/SUISSE/SVIZZERA Verein Schwoizerischer Maschinen- Industrieller (VSM) Kirchenweg 4 CH - 8032 ZURICH Fax :41 1 384 48 48 SUOMI Federation of Finnish Metal, Engineering ‘and Electrotechnical industries - FIMET Eteldranta 10 P.O. BOX 10 FIN - 00131 HELSINKI Fax : 358 9 624 462 SVERIGE ‘Swedish Association of Suppliers of Mechanical Handling Equipment MHG Storgatan 5 Box 5510 §- 114 85 STOCKHOLM Fax : 46 8 660 33 78The third edition of the “Rules for the design of hoisting appliances" dated 1987.10.01 included 8 booklets. An addition to this edition was compiled in 1998. This addition is incorporated in booklet 9, which also replaces booklet 6. This booklet forms part of the "Rules for the design of hoisting appliances" 3rd edition revised, consisting of 8 booklets : Booklet 1 - Object and scope Booklet 2 - Classification and loading on structures and mechanisms Booklet 3 - Calculating the stresses in structures Booklet 4 - Checking for fatigue and choice of mechanism components Booklet 5 - Electrical equipment Booklet 7 - Safety rules Booklet 8 - Test loads and tolerances Booklet 9 - Supplements and comments to booklets 1 to 8 NOTE: Booklet 9 must not therefore be used separately.BOOKLET SAFETY RULES CONTENTS ‘SCoPE BASIS OF CALCULATIONS: MARKING AND PLATES: ~ Rating plate ~ Manufacturer's plete = Warning notices CONSTRUCTION REQUIREMENTS: = Clearances = Driver's cabs in general ~ Additional regulations regarding hoist-suspended driver's cabs ~ Ganguays and platforms Stairways and ladders MECHANICAL DEVICES = Rope and chain drives = Hook blocks, pulleys and other load carrying devices ~ Brokes HYDRAULIC EQUIPMENT SAFETY DEVICES = Devices for Liniting working motions ~ Safety against overloading and overturning AGEING OF APPLIANCES LIST GF SYMBOLS ANO NOTATIONS. 71 7 Clause Tole 7.2. 73. 7B.Le 732s 73.3. 7.4, Teed. The 7.4.3. Tobe. TAS. 7.5. 75d. 7.5.2. 7.5.3. 7.6. rT VTL WT.24 7.8. See Booklet 1 ru Tu 712 7-12 715 715 7-16 7477-2Tale 7.2. 13. 73k. SCOPE These rules are applicable to cranes and heavy lifting appliances covered by clause 1.4, of booklet 1 - “Object and Scope" (1). BASIS OF CALCULATIONS The calculation of crane structures and mechanisms shall be in accordance particularly with booklet 3 - "Design stresses in the structure" and booklet 4 ~ "Design and choice of mechanism components". MARKING AND PLATES Lifting appliances shall bear the following markings or plates, in the language of the ‘country in which the appliance will operate, or in a language accepted by the user. RATING PLATE ‘The Lifting capacity (and radius where applicable) shall be permanently marked in a visible position and shall be easily legible from the ground. ‘The Lifting capacity shall be the heaviest mass which may be hoisted by the crane, or by any hoisting accessory, either permanent or incorporated under certain conditions ; in the case of grabbing cranes, the lifting capacity shall be the permissible total weight of the grab and contents. In the case of lufFing cranes, the Lifting capacity corresponding to each radius shall be indicated in durable form showing appropriate graduations, and shall be clearly legible fron the ground. More detailed indications of permissible loads at different radii shall be obtainable from the manufacturer's operating erwal. In the case of cranes with more than one hoist, the 1ifting capacity of each heist shall be indicated on the relevant hook block. It should furthermore be indicated if all the hoists can be used at the same tine. a For builders tower cranes, the safety measures in preparation by the E.E.C. are also accepted by the F.E.M.7.3.2, 73.3. Te Tele Teblede MANUFACTURER'S PLATE Each lifting appliance, independent crab or winch shall be fitted at a convenient point with the maker's plate, detailing the following : = none of manufacturer, ~ year of manufacture, manufacturer's serial cunber, Lifting capacity in kgs and/or tonnes, ~ type. WARNING NOTICES A notice reading : "Do not stand under the load" shall be suitably located so as to be clearly visible. Crane access points shall be narked with a notice reading : "No access for unauthorised personnel”. Particularly dangerous areas shall be marked with a notice reading : "Danger - Crane" and, where necessary, by means of warning colour stripes. CONSTRUCTION REQUIREMENTS CLEARANCES ALL moving parts of lifting appliances, with the exception of handling and grabbing devices, in their most unfavourable position and under the most unfavourable Loading conditions shall be at least 0.05 m fron any fixed part of a building, at least 0.1 m fron eny guard rail or handrail and a minimm of 0.5 m from access areas, Access areas are all access ways authorised to persamel. This does not apply to working platforms. For railway loading profiles, the appropriate loading gauge shall be used ‘and there shall be a minim clearance of 0.5 m in access areas. Under no circunstan- ces shall fixed parts of any Lifting appliance encroach upon the railway clearance gauge. 7-8Teli L 2. Tehsl.3. hd. Tbe Th.2.20 Tlhe2.3. ‘The minimum vertical distance between the lover clearance line of a lifting appliance ‘and areas of general access below (from the floor as well as fron fixed or movable equipment belonging to the building, with the exception of working or service plat- forms or similar shall be at least 1.8 m in areas of general working access. From parts of stationary or mobile installations with limited walk-on or step-on access (such as roofs, heaters, machinery parts and cranes travelling below etc.) as well as from guard rails, the minimum vertical distance shall be 0.5 m. The minimum vertical distance between the upper clearance Line of a lifting appliance and fixed or moving parts above (e.g. between crab structures or guardrails on the fone hand and roof joists, pipelines or lifting appliances travelling overhead on the other) shall be not less than 0.5 m in maintenance areas and in the vicinity of plat- forms. This distance may be reduced to 0.1 m in the case of individval structural mmenbers, provided no danger to personnel results or that adequate precautions are ta- ken to eliminate the risks. DRIVER'S CABS IN GENERAL Driver's cabs shall be designed so that the driver has a clear view of all mork areas or so that he may adequately follow all operations with the aid of suitsble equipment. The driver's cab shell have sufficient roon for the driver to be able to reach or leave the controls without hindrance. Controls shall preferably be operated from a sitting position, but also fron a standing position when necessary. Driver's cabs shall have a minimum headroom of 1.9 m and shall be fitted with a guard rail of at least 1.0 m high. ‘Outdoor cabs, or those operating in unheated bays, shall be af enclosed construction, except in warm elinates. Driver's cabs in heated bays, or which are seldom used or of ‘an auxiliary nature may be of open construction. A protective shield shall be installed above the driver's cab when there is any danger of falling objects. Te layout of the cab and controls shall be ergonomically designed. The structural framework of the driver's cab shall be of non-combustible material, and the side panels and roof may optionally be of fire resistant materials. The floor of the driver's cab shall be covered with non-metallic, heat-insulating naterial. rsTod2.A, 7.4.2.5. Tolh.2.6 5 7827. 7.83. Tb Bole T.A3.2. 7h3.3. In cabs with windows less than 1.0 m fron the floor and glazed areas in the Floor, ‘the glazing shall be constructed or protected to a height of 1.0 m so that personnel cannot fell through then ; walkover windows shall be tread proof. Entrances shall be protected against accidental opening. Sliding doors and outward opening doors of driver's cabs mist lead on to landings. Tk must be possible to clean the windows of the driver's cab without risk. Glazed openings let into the floor of the driver's cab and those which are exposed to an in- creased risk of breakage or subjected to heat radiation when the crane is in ope- ration shall be made of suitable safety glass. Oriver's cabs shall be provided with adequate anti-glare Lighting to allow handling of the controls and, if necessary, can be ventilated. Enclosed driver's cabs for outdoor operation and cabins located in unheated bays must be provided with heating. Driver's cabs which are exposed to radiant heat shall be protected against heat radiation and of a heat-proof design, and they shall be air-conditioned in order ta ensure tolerable working conditions. Driver's cabs exposed to conditions presenting a health hazard, such as dust, vapours or gases, shall be protected against their entry and provided with a clean air supply. ADDITIONAL REGULATIONS REGARDING HOIST-SUSPENDED DRIVER'S CABS The permitted curber of persons and maximum load of the driver's cab shall be perma- rently and clearly incicated. Additional "Operating and maintenance instructions for hoist-suspended driver's cabs" shall be posted in the cab. Tt must not be possible for the driver's cab to spin or swing dangerously. Hoist suspended driver's cabins shall be provided with an anti-fall device. Alterna- tively, there may be two Independent means of suspension, provided that the driver's cabin remains secure should one means of suspension break, or should the drive or service brake fail. Each individual means of suspension shall be designed with a safety factor of not less than five times the full working load. 767.4.3.4. 7.3.5. 7.83.6. 7.4.3.7. 7.4.3.8. 7.3.90 74.3410. If there is en enti-fall device and only one means of suspension, a minima safety factor of eight is necessary. Rope drives shall be designed as a minimm in accordance with mechanism group MB. The dianeter of the rope shall be not less than 6 ma, Ropes for outdoor duty shall be made of galvanised steel wire. On reaching a speed of 1.4 tines the nominal lowering speed the driver's cab shall automatically be brought to a halt. The driver's cab must be able to move independently of the load. All controls shall stop automatically as soon as the driver releases then. Normal and energency Limit switches shall be provided for the highest and loest po- sitions of the cab, with separate switching and operating systems. Emergency Limit switches shall directly switch off the main poner circuit and activate an audible warning signal. In the event of the driver's cab striking an obstacle or a suspension means becoming slack, all crane motions shall automatically shut down. Doviees for returning the crane to service shall not be of self re-setting type. If the travel speed of the driver's cab is greater than 40 m/min, devices shall be provided to reduce the speed promptly so that the buffers cannot be struck at a speed greater than 40 m/min, If the impact velocity is greater than 20 m/nin, energy ab- sorption buffers shall be provided. The driver's cab shall be provided with @ distress signal system independent of the electrical supply of the crane. It shall also be provided with a means of esergency descent, e.g. @ rope ladder or escape apparatus, which is always in the cab. ‘The user shall ensure that with the maximum stacking height of goods there is a sefety headroom of 0.5 m to the underside of the driver's cab in its highest working position. Tt aust only be possible to remotely operate the crane from the ground with the river's cab in its highest working position (see also 7.7.). 7Tht Tab. 2, Thebe Tehabahe Tbh Se Tehadhabe GANGWAYS AND PLATFORMS Easy and safe access to the driver's cab must be possible with the Lifting epplience in any position under normal working conditions. If the floor of the driver's cab is less than 5 m above ground level, access may be restricted to certain positions of the Lifting appliance, provided the driver's cab is fitted with appropriate energency exit eans, €.9. @ Tope ladder. Entry to the driver's cab should be preferebly from a platform at the sane level as the floor of the cab and provided with guard rails. Entry through the floor, or through the ceiling of the driver's cab shall be permissible only when necessitated by virtue of space restrictions. lihere entry is made directly via a staircase, a platform or a gangway, the horizontal gap to the driver's cab entrance shall not exceed 0.15 m and the difference in level between the platform and the driver's cab Floor shall not exceed 0.25 m. When the driver's cab cannot be reached directly from ground level in any positim of ‘the crane, and where the driver's cab floor is higher than 5 m from ground level, the crane installation shall be provided with appropriate gangrays, For certain ap- lances, such as overhead travelling cranes, access mey be Limited to certain posi- ‘tions of the crane, if sppropriate devices are provided which enable the driver to Leave the cab: Gangways, stairways, and platforms must have safe access with the lifting appliance in any position, Stairways and ladders in frequent use shall lead on to platforms or Ganguays. For such access, stairways are preferable to ladders. ALL operating locations and all equipment of the crane which requires regular inspec- ‘tion or maintenance must be provided with safe access, or be reached by means of por~ table work platforms. The above-mentioned locations when more than 2m above floor level, and also crane Jibs must be accessible via stairways, platforms, walkways or ladders. Steps shall be Fitted with guard rails on both sides (see also 7.4.5.2.) When work is carried out during erection, disnantling, testing, repairs and mainte nance at points situated more than 2m above floor level, appropriate measures shall be taken on cranes and jibs to ensure the safety of personnel (such as handrails, handgrips, safety devices, etc.) and to permit access of personnel to these points. Pulleys and moving parts placed at the end of jibs shall be designed so that no lubrication is necessary between erecting and disnantling the crane. If this is not the case, the jib must be provided with access. 787.4447. 7.8.8. 7.8.8.9. 7.4.0.10, 7.4.5. 7.451. The above-mentioned access to the Jib may be omitted when the latter can be lowered for the purpose of a complete visual check or when other constructions permit @ visual check. Staimmays, gangrays and platforms shall have a headroom of not less then 1.8 m. A clear passageway not less than 0.5 m wide must be provided in the vicinity of driven parts which nove relative to gangways and platforms ; this dimension may be reduced to 0.4 m Up to a height of 0.6 m by providing a hendrail. The clear width of passage- way between stationary parts shall be not less than 0.4m. ‘The clear headroom of little used access ways inside crane structures may be reduced to a minimum of 1.3 m, whilst at the sane time the width shall be increased to 0.7 m, varying Linedrly with the reduction in height. The headroom above platforms used only for maintenance purposes may be reduced to 1.3 m. Parts of crane installations with access shall be provided with continuous guard rails on those sides where there is a danger of falling from a height of over 1 m. ‘Toe guards shall be not less than 0.1 m high. Openings in guard rails shall be per— missible where adequate protective measures against falling are provided, Guard rails shall, as a rule, be not less than 1 m high and shall be provided with toe guards and intermediate rails. the height of the quard rails may be reduced to 0.8 m for pas~ Sageways where a clear height of 1.3m is permissible. Along gangways there shall be at least one handrail. For gangrays alongside building walls or a solid wall. construction, handrails shall be permissible in lieu of guard rails. Interruptions in the length of these shall rot exceed 1 m (e.g. for building colums, door openings). Platform surfaces shall be suitebly slip-proof. Holes, geps and openings in the flooring shall be restricted in size so that a 0.02 m dianeter ball cannot pass through. Gangways which are less then 0.5 m above exposed power Lines must be provided with solid flooring in those areas. lien gangways are located adjacent to pover lines, these lines must be protected against accidental contact. STAIRWAYS AND LADDERS Staimays and ladders shall be provided wherever the difference in level exceeds 0.5 m. Footholds provided with hand grips may be installed on vertical surfaces where the height does not exceed 2 m (e.g. end carriages). 7Th 5.26 7.4.5.3. Ladders shall be interrupted by intermediate landings if they exceed a height of 6 m. For great heights as, for exemple, in builder's tower cranes, additional intermediate platforns may be provided for which the vertical interval must be a maximum of 6 m. here there are space problems, a single continuous ladcer with platforms alongside ‘hay be installed. STAIRWAYS The slope of stairways shall not exceed 65°, the height of individual steps shall not exceed 0.25 m (0.2 m for tower cranes) and their depth shall not be less than 0.15 m. If possible, the following ratios shall be observed + 2.x step height +1 tread width = 0.65 m ‘The height interval between steps shall be constant. In the case of main stairways the guard rail posts shall be spaced not less than 0.6 m apart, but in the case of other staixways 0.5m shall suffice. Surface of treads shall be anti-slip. Stairways shall be provided with guard ralls on each side ; where there is a wall on fone side of the stairway a hendrail shall be sufficient on the wall side. LADDERS The length of rungs between side frames shall be no less than 0.3 m ; their pitch shall be constant and not exceeding 0.3 m. The rungs shall be at least 0.15 m avay fron fixed structural menbers. & rung shall be able to withstand a force of 1200 N at the centre without suffering permanent deformation. CLinb-through openings shall not be smaller than 0.63 x 0.63 mor Less then 0.8 m in diameter. Ladders over 5 m in height shall be provided with safety hoops starting at a height of 2.5 0, The distance between safety hoops shall be not greater than 0.9 m. They must be Intercomected by at least three equally spaced longitudinal stringers. In all cases, one longitudinal stringer must be placed at a point which is exectly opposite the vertical centre line of the ladder. ‘ie strength of safety hoops, reinforced by the longitudinal stringers, must be ed- equate to withstand a force of 1000 N distributed aver 0.1 m acting on any point of ‘the hoop, without any visible deformation. 7-10