155 เครน32ตัน

Documentation
Client : Berli Jucker

Project :Kampangpetch Phase II
No. : 839.13.04.036+037
Test certificate and technical data sheet
HU~I for KULI electric hoist I crane travel drives
C ustomer: Berli Jucker Public Company Limited, 99 Soi Rubia, Sukhumvit 42 Road, Phrakanong, Klongtoey,
10110 Bangkok, Thailand
Order No.: 1233000476 dated 22.04.2013, Project: Kampangpetch Phase II (Nl3MH048 Stock)
Type: RS - ZE Z 5320 U4 F45 So. + RS - F X 3100 U4 F45 Serial-No.: 839 .13.04.036 + 839.13.04.037
Lifting capacity: 32.000 kg + 10.000 kg FEM duty class: 1 Am + 3 m
Reeving: each 4 Lifting speed : 2,5. 0,5 m min · 5,0 1, 1 tTumin Lifting height: 16m - 17m
Operating voltage: 400 V 50 Hz. Control voltage: 48 V
The hoist was supplied with contactor control equtpment and frequency inverter.
Type Motor-No. kW poles IN A % DC s/h
Main hoist motor 1 180.240.410 1307450 15,5/3,8 4/ 16 33,2/ 18,5 30 180

Auxiliary hoist motor 1 160.240.420 L 1307385 9,6/2,4 4/16 22,0/12,5 50 300
Cross travel motor 1 096.055.481 1308984 1,0 4 2,6 50 300
Cross travel motor 2 096.055.481 1308985 1,0 4 2,6 50 300
Crane travel motor 1
Crane travel motor 2
Remarks: incl. electromechanical lifting force limiter (main hoist .,.. auxiliary hoist), wheel gauge: 3.000 mm
(main ho1st}, incl. seQarate ventilator (main hoist}, auxiliaa hoist is mechanically couQled
Ty(!: RS - ZE Z 5320 L/4 F45 So.i Fabr.-Nr.: 839.13.04.036:
Rope certificate: The fo llowing rope was fitted to the cable drum of the KULI electric hoist:
Diameter: 0 20 mm Length: 74 m
Min. breaking strength 314 kN
Hook certificate: The following hook of forged steel was fitted to the bottom block of the electric hoist:
Smgle hook complying with DIN 15401 No.: RN 12 V
Material: 34CrNiMo6 complymg with DIN 15400
Measuring length of the opemngs of the hook marked by center drills 180 mm
T:rn: RS - F X 3100 L/4 F4Ss Fabr.-Nr.: 839.13.04.037:
Rope certificate: The following rope was fitted to the cable drum of the KULI electric hoist:
Diameter: 0 14 mm Length: 78 m
Min. breaking strength 137,45 kN
Hook certificate: The following hook of forged steel was fitted to the bottom block of the electric hoist:
Single hook complying with DIN 15401 No.: RN 5 V
Material: 34CrNiMo6 complying with DIN 15400
Measuring length of the openings of the hook marked by center drills 115 mm
Preliminary inspection:
The calculations in accordance with the rules of engineenng produced a sufficient safety margin against fai lure.
The drawings comply with the calculations.The regulations for the prevention of acc1dents, VDE guidelines,
DIN standards and FEM design principles are complied with.
Construction inspection :
The inspection of the construction showed that the construction was in accordance with the drawings.
Test certificate:
The electric hoist was tested on our test bench with nominal load at rated current and additionally with 25 %
overload at rated current as weil as with nominal load at J0 o,o undervoltage. The hoist was released for after a
successfull test.
D-42805 Remscheid, 07.08.2013

Delivery time: August 2013
HELMUT KE MPKES GM BH
i. 4-. f11/}1/
Original
Te 02191 / 434- 0 Postf 100562

Fax : 02191 I 434-45
HELMUT KEMPKES GMBH D 42805 Remscheid
electric hoists
Type RS
Maintenance and
Operating instructions
Translation of the original version of Maintenance and Operating instructions
02/12
Operating instructions Type RS
Tables of contents
1 General 3
2 Determinated use 4
3 Selection of operating people 4
4 Description 5
5 Load Spectrometer Type with Electronical Lifting Force
Limiter 6
5.1 Structure 6
5.2 FUNCTIONS OF THE Last LSM 6
5.3 Screens in integrated LC-display 7
5.4 Extraordinary status messages in the LC-display 7
5.5 Clamp plan LSM 100 8
6 Electro-mechanical lifting force limiter 9
7 Before operation 10
8 During operation 10
9 After operation 11
10 After expiry of the theoretical duration of service 11
11 Breakdowns 11
12 Sound emission 11
13 Assembly 12
13.1 Equalizing sheave and rope anchor transverse bars 13
14 Maintenance and repair 13
15 Brakes 14
16 Brake adjustment 18
17 Wire rope 21
18 Rope guide 25
19 Load hook 25
20 Maintenance table 26
We kindly ask to fill in the below mentioned data, enabling to react quickly in case
of any queries. .
Order No.: Year of construction:
Capacity t: Type:
FEM-classification: Lifting height m:
Output kW: Lifting speed m/min:
HELMUT KEMPKES GmbH 02/2012 2

1 General
Being products of long experience in the design of lifting equipment linked to must mod-
ern manufacturing methods and extensive quality and test procedures. KULI Electric
Wire Rope Hoists are long life and low maintenance lifting machines.
KULI Electric Wire Rope Hoists comply with the EC Machinery Directive 2006/42/ EC
and with the Low Tension Directive 2006/95/ EC as well as the German Regulations for
Prevention from Accidents, German Standards (DIN) and the relevant FEM-Rules for
calculation. The conformity to the rules is certified by the declaration of conformity.
Durability and proper operation of an electric hoist depends mainly on appropriate use
and maintenance. It is there force essential to study the operating instructions before
assembly and commissioning and to take into account the relevant remarks. Moreover
is to be made sure that the operating instructions are permanently at the operators
disposal.
Acc. to § 25 BGV D6 " Rules for prevention from accidents with

cranes" the crane must be inspected by an authorised expert before
bringing into service. For stationary hoists or for manually movable
trolley hoist up to capacity of 1,0t the inspection can be carried out
by en expert according to § 23 section 1 BGV D8 “Winches, Lifting
and Tension Equipment”. The inspection by an expert must be in-
duced by the user of the crane, unless otherwise agreed upon.
Acc. to § 26 BGV D6 " Rules for prevention from accidents with cra-
nes" the crane must be inspected by an expert once a year. This
inspection must be registered in the crane book. The inspection
must be induced by the user. Kind and scope of this inspection are
described in BGG 905 “Rules for inspection of cranes”.
Experts
Experts are persons, who are familiar with the rules for working security, rules for
avoiding accidents and technical rules and who have sufficient knowledge about
cranes and crane components to decide on the actual condition of cranes.
Authorized Experts (acc. to BGV D6)

Authorized experts are persons, who are experts of the technical controlling, only per-
sons who are authorized by the trade association having liability for industrial safety
and insurance.
Exemption from liability
The company Helmut Kempkes GmbH is not liable for damage occurring after misuse,
inappropriate maintenance and repair or under terminated application.

2 Determinated use
KULI Electric Wire Rope Hoists are exclusively designed to lift, to lower and to move
loads within the limit of maximum load capacity and its classification in accordance
with FEM-Rule 9.511.
The transport of persons is strictly prohibited.
Also prohibited: to tear off fixed or jammed loads, to slide loads, to lift loads in angled
position, to pull vehicles, unattended load hanging in hook, to move loads over human
beings, to let load falling into slack rope.
It is also not allowed tipping operation in each and every direction.
It is strictly forbidden to take out of function any safety device (electrically or mechani-
cally.
All above mentioned indications are not subject to completeness. Depending of loca-
tion of use and purpose of use there are to be obeyed any rules applicable for use
cranes.
Conditions of use
KULI Electric Wire Rope Hoists can be operated in an ambient temperature rang-
ing from -10°C to +55°C. Temperatures below 0°C require control panel heating
in case of frequency inverter controlled movements. Heating elements in control
panel are to be switched on permanently. Therefore the mains switch has to be
switched on. In order to guarantee a safe function of the hoist trolleys and crabs
after longer outages it is necessary to check the lifting and travel motions as
well as the function of the limit switches in regular intervals depending on ambi-
ent condition, but at least all 3 (three) months.
Attention
Non-determinated use may lead to damages, accidents and even
might cause death of persons.
3 Selection of operating people

KULI Electric Wire Rope Hoists may only be operated by persons over the age of 18.
They must be authorised by the works management and must be (made) familiar with
the lifting equipment, the regulations for the prevention of accidents and the instruc-
tions of operation.
They must further be capable to coordinate unerringly the signs on the push button
station and the senses of movement of the hoist.
Operation by persons under alcohol or drugs is forbidden.
Additionally we refer to BGG 921 Rules for selection. Instruction and Proof of Compe-
tence of cranes operators of the trade association.

4 Description
The KULI Electric Wire Rope Hoist consists essentially of 4 main parts:
1.Rope drum with rope guide, rope and limit switch bar. The rope drum is held in
maintenance-free bearings.
The rope guide is made from low wearing ultramid for the protection of drum and rope.
For ropes of 20 mm dia. and more it is made of cast iron. Cast iron rope guides are
available for all hoists except size 2.
If required, rope drums of all hoists from size 1 and up can be machined with right and
left hand grooving.
2.Planetary gearbox 2 – steps for sizes 1 to 3

3 – steps for sizes 4 to 9
Toothings are made of high grade steel. Teeth of planet wheels and of pinions are
hardened, the gearbox is lubricated for life time.
3.Hoist motor
The hoist motor is a maintenance-free cylindrical rotor squirrel cage motor, available
for either single speed or dual speed rated 1:4,5. Optionally, the single touring motor
is deliverable for operation by frequency inverter and would include encoder.
4.Brake
The brake is a weatherproof D.C. disc brake with an anchor disc of stainless steel
(optional). It is controlled in the D.C. circuit through auxiliary contacts of the hoisting
contactors.
Figure 4.1: KULI-Electric hoist

5 Load Spectrometer Type LSM with Electronical Lifting Force

Limiter
In consideration of the overall load configuration and the number of operating hours,
the KULI – LSM calculates the full load life taken up to now. In addition to that, it
switches off the lifting movement in case the nominal load has been exceeded. It can
be set at appox. 110% or optionally 115% of the nominal load. It furthermore inte-
grates additional important functions that ensure a safe functioning of the hoisting
device.
5.1 Structure
Basically, the KULI – LSM consists of the following components:
5.1.1 Load measure pin with strain gauges in full bridge connection
The strain gauges measure the cable traction force in the bolt at the cable end
connections; in case of twin winches in the upper roll axis.
5.1.2 Proportional amplifier

The amplifier is cast-in in a housing of protection class IP 65. The resistance
change of the strain gauges in the load measure pin will be transformed into a
load-proportional signal.
5.1.3 Signalling line

The screened line 4 x 0,5 mm² will be used for the signal transmission from the
amplifier to the load spectrometer and is suitable for outdoor operations. It has a
colour coding according to DIN 47100. (With construction sets without towing
devices not contained in scope of delivery.)
5.1.4 Load spectrometer Type LSM

The LSM is built-in into contactor cabinet and will be fixed on a top hat rail in the
crane control system. It analyses the incoming data and shows them in the dis-
play.
5.2 Functions of the LSM

a) Switches off the lifting procedure when nominal load is exceeded by
approx. 15% (but still possible to bring it down).
b) Functional check of the overload switch-off via selection by means of the
Menu – button. Simulation of 115% of the nominal load by pressing the
button longer than 3 s.
c) Possible to connect a second load measuring pin with amplifier for
measuring a load sum (optional).
d) Possible to connect motor PTC thermistors of two motors with two wind-
ings each and temperature rise indication.
e) Possible to connect an external alarm equipment (horn, alarm lamp, etc.)
when nominal load has been reached.
f) RS 232 – interface for connecting a PC.
g) Status signalling via an integrated LC-display.

5.3 Screens in integrated LC-display

When the LSM is turned on, the serial number of the device will be shown for
approx. 4s by means of the following message: Ser. No.# xxxxxxxx.
By pressing the Menu – button for approx. 3 s, it is possible to change the menu
language from German to English and vice versa. This does not work with the
overload simulation (paragraph f).
The following displays must be activated by pressing the Menu – button:

a) Standard screen: percentage of the current nominal load of measuring
bolt 1 and 2: <KULI-LSM 100>
1: 0% / 2: 0%
b) Number of temperature rise alerts for windings 1-4 (4 displays).
c) Number of switching cycles of the lifting contactor (lift 1, lift 2, lower 1,
lower 2)
d) Duration of full load life already taken in h:min:s.
e) Number of operating hours of lifting unit in h:min:s.
f) Overload simulation. (pressing of the Menu – button longer than 3s)
g) Number of overload switch-offs (lifting load ≥ 115% of nominal load)
If the Menu – button will not be pressed for more than 10 s, the display returns
to the standard screen a).
5.4 Extraordinary status messages in the LC-display

a) Overload
With a fixed load of more than approx. 115% of the nominal load, the lift-
ing process will be switched off. The display shows the message: Over-
load. Then, the load must be lowered in order to relieve the lifting unit. Af-
ter a couple of seconds the display returns to the standard screen (5.3 a)
and operation can be continued.
b) Err: Wire Break
If there is no defined voltages at the measuring input 1, e.g. caused by a
wire fracture in the measuring line or a defective measuring pin or ampli-
fier, the display shows the message Err: Wire Break and the lifting proc-
ess will be switched off. The defect must be remedied by trained electri-
cians. If the defect has been removed, the error message can be deleted
by quitting (switch device on and off) the device.

5.5 Clamp plan LSM 100
Designation of clamps:
X1: Current output of load sums
1.1: minus
1.2: plus X7: Inputs to switching cycle measurement
7.1: Lifting slowly
X2: Measuring input winding temperature Motor 1 7.2: Lowering slowly
2.1: PTC winding 1 7.3: Lifting fast
2.2: PTC winding 2 7.4: Lowering fast
2.3: GND 7.5: N (together)
X3: Measuring input winding temperature Motor 2 X8: Overload

3.1: PTC winding 1 8.1 and 8.2 and/or 8.3 and 8.4 are normally closed.
3.2: PTC winding 2 With load sum ≥ 115 % of the nominal load, 8.1/8.2
3.3: GND and 8.3/8.4 open.
X4: Connection measuring pin 1 X9: Load / Nominal load

4.1: +12 V The contact of a relay (230 V~ / 8 A) closes with 100
4.2: GND % load sum
4.3: + 1-10 V (quasi 4..20 mA)
X10: Temperature rise Motor 2
X5: Connection measuring pin 2 Break contact of a relay
5.1: +12 V
5.2: GND X11: Temperature rise Motor 1
5.3: + 1-10 V (quasi 4..20 mA) Break contact of a relay
X6: RS-232connection for PC or RS-868 transmis- X12: Supply voltage / 90-250 V / 50/60 Hz
sion path 12.1: L1
6.1: GND 12.2: N
6.2: Transmission data from LSM
6.3: Received data to LSM

6 Adjustment of the electro mechanical lifting force limiter
The hexagonal screw located at the switch does allow to adjust the limiter to the load
at which it shall be switched off. Adjustment is to be done in that way that rated load
can be lifted but in the event of 15 % overload lifting movement is to be interrupted.
The interruption is only for the lifting movement, lowering can still be effected. The cup
springs are prestressed by bolt and countered by nut.
That prestress may in no case be amended.
The cup springs have lifetime lubrication and need not to be relubricated.
Switching point to be set

to rated load + 15 %
Figure 6.1: Electro-mechanical lifting force limiter

7 Before operation
Prior to operation, the operator has to examine the hoist for any visual defects. The
function of the brakes and the limit switches have to be tested. If any defects are found
that impair the safety of operation, the hoist has to be stopped and the foreman or the
works manager has to be informed.
Evident defects are e.g.:

Load slips
Damage to or loss safety equipment or covers.
Damage to the wire rope (see also “Dismantling of the ropes”).
Deformation of the load hook.
Cracks on the supporting structure or on the carriages.
Bare electric parts or conductors.
Damaged push button station.
Attention !
In case of such defects to be seen operation is to be stopped
immediately as otherwise it may lead to damages, accidents or even
death of persons.
8 During operation
The following are examples of undeterminated use and therefore forbidden operations:
Transport of persons
Exceeding the rated load capacity or the group classification.
Moving loads above persons.
Leaving suspended loads unattended.
Lowering, lifting or shifting loads by inching.
Tearing off jammed loads.
Sliding loads (i.e. pulling at angle).
Pulling vehicles.
Operational use of emergency limit switches.
Slack rope.
Using of hoist in higher FEM classification than destined.
Attention !
Non-attendance may lead to damages, accidents or even death of per-
sons.
In case of outdoor operation: If not agreed to the contrary, operation has to be

stopped at wind force 7.
Subject hoist lowering movement in case of frequency controlled motor it can be per-
formed a rather remarkable lifting movement at first moment prior to lowering move-
ment.

9 After operation
When stopping operation, no load must remain suspended, the bottom block is to be
lifted into its highest position and the mains voltage is to be disconnected at the main
switch or the disconnecting switch.
Any suspended load has to be lowered to the ground or has to be secured through
supports.
To ensure safe function of hoist and trolley after longer period of time of non-use it is
necessary to verify on all movements incl. the function of emergency switch (in regular
periods of time, min. each quarter of year).
10 After expiry of the theoretical duration of service

In accordance with the regulations for the prevention of accidents (UVV, BGV D8) the
residual duration of service has to be determined and to be recorded annually. After
expiry of the service period of 10 years, the hoist has to be returned to the manufac-
turer for a general overhaul.
11 Breakdowns
In case of faults or a phase failure, the load has to be lowered very carefully inching
the down button in order to avoid that lowering of the load falls out of control through
over touring of the motor. It is to be made sure that motor does not get overheated.
Mind that this operation can only be performed if the brake is still working. Should the
function of the brake be impaired by a phase failure, the load has to be supported,
operation of the hoist must be stopped immediately and the fault must be remedied.
Attention !
The above procedure has to be carried out very carefully because there
is danger to life and limb. Make sure there are no unauthorised persons
in the working area.
12 Sound emission
The level of sound emission was measured at a distance of 1 m from the hoist while
lifting the nominal load.
Sound transmission and sound reflection from walls and steel structures were not
taken into account. The values of the following table represent the average from sev-
eral measurements. Doubling the measuring distance brings the sound level down by
3 dB (A)
Electric hoist size Sound level dB ( A)
Table 12.1: 1 79
Sound emission
2 81
3/4 84
5 90
6 91
7/9 84

13 Assembly
The KULI electric hoists should only be installed and commissioned by personnel
being qualified for carrying out this type of work. It will be necessary to comply with the
regulations for the prevention of accidents and with the VDE guidelines.
The side clearance between the rim of the flange and the rim of the runners should be
2-3mm on each side in case of a monorail trolley.
The side clearance between track rail and the flange of the runner wheels must be 2-
5mm on each side in the case of a double girder trolley.
The tracks must be free of dirt, oil and paint, with secure buffers fitted at the ends of
tracks.
In case of a low headroom monorail trolley fill load the counterweight box until the hoist
is perfectly balanced in the unloaded condition.
Attention !
Ensure that counterweight cannot fall out. Tighten all fixing bolts and fit
the necessary locking devices.
Check the wire rope for any damage that may have occurred during
transportation and thread it in the right sequence and without any
kinks through the bottom block (and return pulley in case off 4-fall
reeved hoists). Rope and rope wedge have to be housed in the wedge
pocket firmly.
Attention !
Secure the free end of the rope (approx. 10 cm long) with the rope
clamp from slipping (see lable hoist). Do not clamp free end to load
bearing rope fall. Check that the mains voltage corresponds to the
rated motor voltage. The direction of motion of the bottom block and of
the travelling trolley must correspond with the symbols on the push
button station. If this is not the case reverse 2 of the phases at the
mains supply terminals.
Attention !
In case of incorrect wiring sense of rotation of the hoisting
motor the emergency off stopping devices are out of order.
Result: the load could be lifted under the crane or under the
electric wire rope hoist, with consequence of load crash or
destruction of the load carrying structurals. Danger to life and
limb.
Attention !
Make sure that appropriately sized conductors and fuses are used
(see also motor table). Voltage drop allowance during motor start is
max. 5%.

Attention !
Limit switch actuators on the l.s. bar are set in the works for highest
and lowest position of the hook. The actuator for the lowest position
has to be reset after erection according to local conditions.
In lowest hook position the adjustment has to be avoiding slack rope.
Min. 1,5 windings of rope have to remain on the drum between rope
clamp and tensioning ring of the rope guide
In highest hook position the placement of the adjusting cottar has to
be providing a minimum distance of 100 mm between lower edge of
hoist body resp. lower edge of carrying beam to upper edge of bottom
block.
Attention !
Test the function on no-load in both directions for main and micro
hoisting. Check that the system switches off correctly.
Test the function of the brakes several times under full load in hook.
If the electric hoist had been stored for a long time before delivery or
has been out of function for a long time, it will be necessary to carry
out first service before commissioning
13.1 Equalizing sheave and rope anchor transverse bars

The Equalizing sheave and rope anchor transverse bars in the KULI wire rope hoists
are mounted on the non-corrugated hexagonal socket bolts acc. DIN 912 or on bear-
ing pins.
The bolts have to be checked and greased according to table 20.1 maintenance table.
The tightening torques are listed hereunder in table 13.1..
Equalizing sheave Anchor transverse bars

Bolt Tightening torques Nm Tightening torques Nm
M16 DIN 912 – 10.9 100
M20 DIN 912 – 10.9 200
M24 DIN 912 – 10.9 300
M30 DIN 912 – 10.9 750 400
Table 13.1: Tightening torques
14 Maintenance and repair

For safety reasons only use genuine parts. Warranty of the company Helmut Kempkes
GmbH will expire if non genuine spare parts are used or in case of inappropriate
maintenance and repair.
Maintenance and repair work should only be carried out by trained personnel who are
familiar with the operating instruction, the regulations for the prevention of accidents
and the VDE guidelines.

Attention !
Lifting motors, gearboxes or brakes should only be dismantled if the
bottom block is put on the ground and the rope drum is safely secured
from rotating (e.g. by means of a wooden wedge to be put between
drum and stay pins).
15 Brakes
The magnet brakes in KULI lifting motors are D.C. operated, wired to D.C. coming
from the rectifier installed on the brake control card being located in the terminal box of
the lifting motor.
The 2 contactors on the brake control card (for the auxiliary contacts on the hoisting/
lifting contacts) are not permitted to be bridged. If bridged the brake cannot perform
properly. Retarded closing of the brake causes extended braking distance significantly
and can lead to crash of the load.
To ensure proper functioning of the brake the brake is to be opened / closed in the
D.C. circuit as shown in the wiring diagram. This function is taken over by the auxiliary
contacts mounted on top of the hoisting contactors in the control panel.
Attention !
Each 2 contacts to be wired in series to achieve faultless switching. If
not there is accident risk caused by excessive brake gap.

Motortabelle / Table of Motors 50 Hz
Elektrozug Motor Nennstrom I N Nominal Current I N [A] Sicherung

Hoist Anlaufstrom I A Starting Current I A [A] Fuses H.R.C.
Typ Typ Upm/ 230V 380V 400V 500V cos 230V 380V 400V 500V
-1
kW min IN IA IN IA IN IA IN IA PhiN PhiA A A A A
1025L
092.075.410L 2.5 1375 11.6 41.5 7.0 25.0 6.7 24.0 5.4 19.2 0.73 0.75 20 16 16 10
1032L
1025L F45 2.5/ 13.6 53.0 8.2 32.0 7.8 30.5 6.3 24.4 0.68 0.84 25 20 20 16
112.140.450L 1400/305
1032L F45 0.6 6.3 9.0 3.8 5.5 3.6 5.2 2.9 4.2 0.58 0.70 16 10 10 6
1040L F45 3.5/ 1425/ 15.8 57.8 9.6 35.0 9.1 34.0 0.86 0.85 35 25 25 20
112.180.450L
1050L F45 0.8 300 7.7 11.2 4.7 6.8 4.4 6.5 0.56 0.60 20 10 10 6
2040L
112.140.410L 4.9 1430 21.5 92.0 13.0 55.0 12.4 53.0 9.9 42.4 0.73 0.75 35 35 35 20
2050L
2040L F45 4.9/ 19.2 86.5 11.6 52.6 11.0 50.0 8.8 40.0 0.84 0.79 35 25 25 20
132.190.420L 1395/325
2050L F45 1.2 12.7 23.4 7.7 14.7 7.3 13.5 5.9 10.8 0.48 0.64 25 20 20 16
2063L 112.140.411L 6.0 1370 24.0 92.0 14.5 55.0 13.8 53.0 11.0 42.4 0.84 0.75 50 35 35 25
6.0/ 23.7 86.5 14.3 47.5 13.6 50.0 10.9 40.0 0.91 0.79 50 35 35 25
2063L F45 132.190.430L 1325/290
1.5 13.2 23.4 8.0 12.8 7.6 13.5 6.1 10.8 0.60 0.64 35 20 20 20
2080L 132.190.412L 9.6 1400 38.3 128 23.2 77.0 22.0 97.0 16.2 59.2 0.79 0.75 63 35 35 35
9.6/ 1420/ 38.3 187.0 23.2 114.0 22.0 108.0 17.6 86.4 0.81 0.71 63 35 35 25
2080L F45 160.240.422L
2.4 340 21.8 52.0 13.2 31.6 12.5 30.0 10.0 24.0 0.46 0.64 50 35 35 30
3080L
132.190.410L 9.6 1400 38.3 128.0 23.2 77.0 22.0 97.0 16.2 59.2 0.79 0.75 63 35 35 35
3100L
3080L F45 9.6/ 38.3 187.0 23.2 114.0 22.0 108.0 17.6 86.4 0.81 0.71 63 35 35 25
160.240.420L 1420/340
3100L F45 2.4 21.8 52.0 13.2 31.6 12.5 30.0 10.0 24.0 0.46 0.64 50 35 35 25
4100L
4125L
132.190.411L 9.6 1400 38.3 128.0 23.2 77.0 22.0 97.0 16.2 59.2 0.79 0.75 63 35 35 35
4160L
4200L
4100L F45
4125L F45 9.6/ 1420/ 38.3 187.0 23.2 114.0 22.0 108.0 17.6 86.4 0.81 0.71 63 35 35 35
160.240.421L
4160L F45 2.4 340 21.8 52.0 13.2 31.6 12.5 30.0 10.0 14.0 0.46 0.64 50 35 35 25
4200L F45
4250L
132.190.410L 9.6 1400 38.3 128.0 23.2 77.0 22.0 97.0 16.2 59.2 0.79 0.75 63 35 35 35
4320L
4250L F45 9.6/ 38.3 187.0 23.2 114.0 22.0 108.0 17.6 86.4 0.81 0.71 63 35 35 35
160.240.420L 1420/340
4320L F45 2.4 21.8 52.0 13.2 31.6 12.5 30.0 10.0 24.0 0.46 0.64 50 35 35 35
5160L
5200L
160.240.410L 15.5 1370 61.2 292.0 37.0 177.0 35.2 169.0 28.1 135.2 0.79 0.72 100 50 50 50
5250L
5320L
5160L F45
5200L F45 15.5/ 57.8 248.0 35.0 156.0 33.2 140.0 26.6 112.0 0.87 0.76 100 50 50 50
180.240.410 1400/300
5250L F45 3.8 32.2 61.0 19.5 36.0 18.5 36.0 14.8 28.8 0.60 0.57 63 35 35 35
5320L F45
6200 FU
180.240.412 24.0 1465 79.6 490.0 48.5 300.0 46.0 282.0 37.0 225.0 0.82 0.53 80 80
6320 FU
6250 FU
180.240.411 24.0 1465 79.6 490.0 48.5 300.0 46.0 282.0 37.0 225.0 0.82 0.53 80 80
6400 FU
6200 F45 24.0/ 90.0 528.7 54.0 320.0 52.0 304.0 41.0 243.2 0.85 0.69 80 80 63
200.265.412 1445/350
6320 F45 6.0 47.0 130.5 28.0 79.0 27.0 75.0 21.3 60.0 0.49 0.60 50 50 50
6250 F45 24.0/ 90.0 528.7 54.0 320.0 52.0 304.0 41.0 243.2 0.85 0.69 80 80 63
200.265.411 1445/350
6400 F45 6.0 47.0 130.5 28.0 79.0 27.0 75.0 21.3 60.0 0.49 0.60 50 50 50
7250 FU
200.265.417 30.0 1470 93.0 615.0 58.5 390.0 53.7 355.0 43.0 290.0 0.86 0.50 80 80
7400 FU
7320 FU
200.265.416 30.0 1470 93.0 615.0 58.5 390.0 53.7 355.0 43.0 290.0 0.86 0.50 80 80
7500 FU
7250 F45 30.0/ 94.0 495.7 57.0 300.0 54.0 285.0 43.2 228.0 0.92 0.72 80 80 63
225.265.412 1400/320
7400 F45 7.5 52.0 105.7 31.0 64.0 29.5 61.0 21.3 48.8 0.49 0.47 50 50 35
7320 F45 30.0/ 94.0 495.7 57.0 300.0 54.0 285.0 43.2 228.0 0.93 0.72 80 80 63
225.265.411 1400/320
7500 F45 7.5 52.0 105.7 28.0 64.0 29.5 61.0 21.3 48.8 0.49 0.47 50 50 35

9320 FU
200.250.412 40.0 1465 124.0 745.0 75.5 470.0 71.6 430.0 57.5 345.0 0.88 0.51 100 100
9500 FU
9400 FU
200.250.411 40.0 1465 124.0 745.0 75.5 470.0 71.6 430.0 57.5 345.0 0.88 0.51 100 100
9630 FU
9320 F45 40.0/ 125.0 625.0 76.0 380.0 72.0 360.0 63.8 319.0 0.94 80 80 63
225.300.412 1365/310
9500 F45 10,0 63.0 144.9 38.0 87.4 36.0 82.0 34.2 78.7 0.52 25 125 100
9400 F45 40.0/ 125.0 625.0 76.0 380.0 72.0 360.0 63.8 319.0 0.94 80 80 63
225.300.411 1365/310
9630 F45 10.0 63.0 144.0 38.0 87.4 36.0 82.0 34.2 78.7 0.52 25 125 100
Figure 15.1 Terminal diagram for hoist motors size 1 to 5

Figure 15.2: Terminal diagram for hoist motors size 6 to 9
Figure 15.3: Terminal diagram for brake control card

16 Brake adjustment
Brakes are almost maintenance-free. It has to be verified only the air gap thickness of
brake lining and the torsional play between brake disc and brake hub.
Brake sizes 12, 14, 18 (single rotor brakes)
1. Remove hood and then fan blade (1)
2. Loosen fixation bolts (2).
3. Screw in the setting sleeves (6) into the magnet part (7) by means of a
open-end spanner
4. Tightened fixation bolts (2). Torque moments please see table 16.1
5. Check air gap by feeler gauge (see table 16.1) if necessary: to
be corrected
Brake sizes 23, 26, 30 (double rotor brakes)

1. Remove hood and then fan blade (1)
2. Loosen fixation bolts (2).
3. Screw in the setting sleeves (6) into the magnet part (7) by means of a
open-end spanner
4. Tighten firstly 3 bolts (2) in a staggered manner (each 120°) and counter
the bolts with the setting sleeves (6)
The countered fixation bolts to the tightened subject torque moments
prescribed in table 16.1
5. Check air gap by feeler gauge (see table 16.1). If necessary: to
be corrected
6. Sensitively brace the balance of the seeting sleeves to the opposite bra-
king surface
7. The balance of the fixation bolts to be tightened with applicable torque
moment (table 16.1)
Attention !
Ensure that the brake linings are always kept clean of grease and oil.
The gap (a) must in no way be increased more than 1.5 times the
value amin shown in the table at the bottom. Wider gaps will cause
brake troubles such as faults in realeasing the brake disc and
subsequent burning of motor windings or even to a drop of the load.
To substitution of the brake disc in case of insufficient thickness of the brake living is to
be done as follows
1. Remove hood and then fan blade.
2. Unscrew fixation bolts (2).
3. Disassemble magnet part and anchor plate
4. Pull brake disc off the hub and replace by new brake disc. In case of
double rotor brakes please also remove the intermediate anchor plate.
Both brake discs to be replaced by shifting the discs inclusive the inter-
mediate anchor plate on the hub.
5. Setting the brake as described before

Attention !
The hoisting brakes are connected to DC and controlled in the DC
circuit through auxiliary contacts of the hoisting contactors. Otherwise,
delayed braking will occur and lead to danger of the load crashing.
Attention !
Hoisting brakes equipped with an adjustment ring must not be modi-
fied by changing position of the adjustment ring, danger of the load
crashing.
Fixing bolts
Anchor disc
Brake
Brake with
adjustment ring
Brake hub
Solenoid
Brake without
adjustment ring
Setting
Fan blade
Figure 16.1: Sectional drawing of hoist brake

Gap Tightening Thickness

Motor type Brake size mm torques of rotor
amin amax Nm mm
092.075.410L
112.140.450L 12 0.3 0,75 9,5 8,0
112.180.450L
112.140.410L
112.140.411L
14 0,3 0,75 23,0 7,5
132.190.420L
132.190.430L
132.190.410L
132.190.411L
Hubmotore
160.240.420L 18 0,4 1,0 23,0 10,0

160.240.421L
160.240.422L
160.220.410L 23
0,6 1,5 25,0 14,5
180.240.410 Double disc
200.265.411
200.265.412 26
0,7 1,7 50,0 16,5
225.265.412
225.300.411 30
0,7 1,7 50,0 16,5
a max: a + (1.5 x a)
Table 16.1: Table for setting air gap and thickness of rotor

17 Wire rope
The wire rope is a very essential part for the safety of operation and performance of an
electric wire rope hoist. It is therefore indispensable to check the rope permanently for
damages.
The rope is worn out and has to be replaced if any of the following criteria apply, i.e. if:
1. In any part of the rope the number of broken wires as listed in the below
table is found (Table: 17.1).
2. Nests of broken wires are found.
3. A strand is broken.
4. The diameter of the rope becomes less than 90 % of the nominal diame-
ter.
5. Deformations, birds caging, kinks, knots, contractions, loops or bends
become evident. (see fig.: 17.1-17.8).
4250-4320-5250
5320-6200-6250
7400-7500
9400-9500
3080-3100
2040-2050
4200-5160
4100-4125
6400-7250
7320-9320
1025
9630
1040
1050
2063
5200
4160
2080
6320
E-Zug Typ
Rope d / mm 7.5 7.5 9.4 9.4 14 16 18 20 23 23 25

Visible broken 1Bm / 1Am 5 7 5 2 12 12 12 12 12 9 9
wires 2m / 3m 10 14 10 4 24 24 24 24 24 18 18
In any length equal
45 45 57 57 84 96 108 120 138 138 150
6xdia.d=mm
Or visible broken 1Bm / 1Am 10 14 10 4 24 24 24 24 24 18 18
wires 2m / 3m 19 29 19 8 48 48 48 48 48 35 35
In any length equal 30xd =mm 225 225 282 282 420 480 540 600 690 690 750
Number of carring wires in the
152 168 152 84 288 288 288 288 288 208 208
outwards strands
Table 17.1: Rope discardment dependant to amount of broken wires
Dismantling of the rope

1. Lower the hook to the lowest position (the bottom block must be fully
supported).
2. Remove the rope from the rope anchor and out of the bottom block (and
the return sheave in case of 4-fall reeved hoists).
3. Dismantle the rope guide (see. “rope guide”) and uncoil the remaining
rope.
4. Unscrew the fixing bolts of the rope clamp(s) on the drum.
Attention!
Tie the rope, as it might fall off.

Fitting the rope

1. Unroll the rope and lay it flat. Make sure there are no kinks or twists in
the rope. Protected the rope from dirt.
2. Fix the rope on the rope drum and tighten the rope clamp(s) with a torque
wrench ( Table 17.2 ).
3. Then coil the rope into the drum to approximately halfway by pressing the
„lift“ push button. Let the rope slide through the hand, wearing leather
gloves and using a woolen rag, so that dirt will be removed from the rope
and the turns around the drum will be very taut.
4. See chapter „rope guide“ for remaining instructions.
Max. tightening
torque of rope
Bolt size
Hoist size clamp screws
Quality 8.8 (black, slightly oiled)
Nm
1025 - 1050 M6 DIN 912 4
2040 - 2080 M10 DIN 912 22
3080 - 3100 M12 DIN 7984 39
4100 - 5320 M12 DIN 7984 39
6200 - 9630 M16 DIN 912 95
Table 17.2:
The following are examples showing damages of ropes:
Figure 17.1: Wire rope with birds caging.
Figure 17.2: Wire rope with loops.

Figure 17.3: Wire rope with loose wires due to corrosion and abrasion.
Figure 17.4: Wire rope with knots.
Figure 17.5: Wire rope with cork-screw deformation.
Figure 17.6: Wire rope with contraction.

Figure 17.7: Wire rope with a kink.
Figure 17.8: Wire rope with a bend

18 Rope guide
The rope guide of plastic material is supplied as an entire unit. Use a normal metal
saw to cut through the rope guide in the middle of the plain surface for the guiding
block.
Cast iron rope guides consist in 2 parts in original supply.
How to change the rope guide:
1. Release the limit switch actuator (adjustable collar) for the lowest position of the
hook. Let the bottom block down to the floor.
2. Release the rope wedge and pull the rope through the bottom block (and through
the return pulley in case of 4-fall reeved hoists).
3. Unscrew the guide block and release it from the rope guide. If the rope guide is of
flexible plastic, bend it slightly outwards and pull it from the rope drum.
4. Then pull the rope through the guide slot in the rope guide. If necessary, replace
the rope guide ring as well by unscrewing and removing the fixing screw with pres-
sure springs.
5. When putting the new rope guide introduce the rope in to the slot from inside the
rope guide.
6. Reassemble the guiding block on the rope guide.
Attention !
Reset the limit switch actuators (collars) to avoid accidents. Check
whether the rope is run through the bottom block and the return pulley
correctly and free of twist.
19 Load hook
Replacing the load hook implies to replace it completely with crossbar, thrust bearing
and nut.
It must be replaced if the dimension “y” stated in the test certificate has increased by
more than 10 %, or if there are surface cracks or any wear and tear of the jaw of the
hook exceeding 5 %.
Attention !
Defect hook may cause down crashing of load, risk of accident.
Nut
Nut
Thrust bearing
Cross bar
Safety catch
Load hook
Figure 19.1: Load hook

20 Maintenance table
at commissioning
daily inspection
1st maintenance after 3 months
every 3 months
annual inspection
in case of repair
Test the function of the brakes and emergency limit switches (UVV VBG9
X X X X X §30/1)
Check rope fixing and rope itself for damages and broken wires. (See also
X X X X X „17“ wire rope)
Check air gap of the brake and adjust if necessary.
X X X Check thickness of rotor.
Clean and grease rope drum, rope guide and limit switch bar. Cast iron rope
X X X guides to be greased monthly.
X Check the trolley wheels and pinions for wear.

Check drive, bolted joints, welding seams, buffers and track
X X X Check and grease bearing positions of the equalising sheave and fixed point
cross-beams.
X X X Check electrical equipment.
X Check load hook for cracks, deformation and wear (see „18“, load hook)
X Lubricate pinion and gear rims of trolley runners with multi-purpose grease.
X Check gears as to oil resp. grease leakage.
X Change grease in all gear boxes and bearings acc. to the following table.
Table 20.1: Maintenance intervals
Gearbox type Qty. of lubricant Type and grade of lubricant
RS 1025L – RS 1050L 1.00 kg

Hoist gear
RS 2040L – RS 2080L 2.00 kg High pressure gear grease

with
RS 3080L – RS 3100L 3.00 kg
EP-additives
RS 4100L – RS 5320L 7.00 kg GP-OG DIN 51502, 51825
RS 6200L – RS 9630L 12.5 kg
Table 20.2: Grease lubricant table for hoisting gearbox

APPENDIX
Modifications reserved
Helmut Kempkes GmbH

Post Box 100562
D-42805 Remscheid
Tel.: +49/2191/434-0
Fax: +49/2191/434-45
E-Mail: export@kuli.com
URL: http://www.kuli.com

Declaration of incorporation of partly
2012 - 04
completed machinery
acc. to the EC Machine Directive 2006/42/EG Annex IIB
We herewith declare that the product

Foot mounted hoists RS F
Monorail hoist trolleys series RS EE / KE / WE
Monorail hoist trolleys series RS ZE
in their standard execution meet with the following regulations:

EC – Machine directive 2006/42/EC
EC – Low tension directive 2006/95/EC
EC – EMC directive 2004/108/EC
Applicable harmonised regulations, especially:

DIN EN ISO 12100 -1/-2 Safety of machinery
EN 60204 – 32 Electrical equipment of machines; requirements for hoisting machines
Applicable national regulations and technical specifications, especially:

BGV D 8 Accident prevention rules winches, hoists and pulling machines
FEM 9.511 Classification of mechanisms
FEM 9.755 Measures for achieving safe working periods
DIN 18800 -7 Steel structurals, fabrication, certification for welding
DIN 15018 -1/-2 Cranes, principles for steel structures, stress analysis
Responsible for compiling of the relevant technical documentation:

Dr.-Ing. H. Hölscher
Kuli Hebezeuge
Helmut Kempkes GmbH
Bismarckstr. 59
D 42853 Remscheid
The partly completed machinery is only permitted to be taken into operation if it is certified that the
operating final machinery is in accordance with the machinery directive 2006/42/EC
K U L I - HEBEZEUGE
Helmut Kempkes GmbH
EC – Certificate of Conformity
2012 - 04
acc. to the EC Machine Directive 2006/42/EG Annex IIA

Foot mounted hoists RS F
Monorail hoist trolleys series RS EE / KE / WE
Monorail hoist trolleys series RS ZE

Applicable harmonised regulations, especially:

DIN EN ISO 12100 -1/-2 Safety of machinery
EN 60204 – 32 Electrical equipment of machines; requirements for hoisting machines

BGV D 8 Accident prevention rules winches, hoists and pulling machines
FEM 9.755 Measures for achieving safe working periods
DIN 18800 -7 Steel structurals, fabrication, certification for welding
DIN 15018 -1/-2 Cranes, principles for steel structures, stress analysis

Kuli Hebezeuge
Helmut Kempkes GmbH
Bismarckstr. 59
D 42853 Remscheid
K U L I - HEBEZEUGE
Helmut Kempkes GmbH
List of Lubricants
The gear boxes of our hoists and travel drives are supplied
with lifetime lubricant ex works.
In case of repairs the Lubricants have to be used as mentioned in

our tables shown in our “Maintenance and Operating Instructions”
Modification reserved
Helmut Kempkes GmbH

Postfach 100562
D-42805 Remscheid
Tel.: 02191/434-0
Fax: 02191/434-45
HELMUT KEMPKES GmbH

travel drive
Type FGT/FG
operating and
maintenance instructions
Translation of the original version of Maintenance and Operating instructions
09/10
operating instructions FGT/FG
Contents
1 General 3
2 Use in accordance with requirements 3
3 Sound Emission 3
4 Description 4
4.1 Gearbox 4
4.2 Travel Motor 4
4.3 Brake 4
5 Assembly 5
6 Maintenance and repair 5
7 Brake adjustment 7

1 General
KULI - Travel Drives are durable and require low maintenance because of long-time
experience in manufacturing cranes, engaged with most modern fabrication technol-
ogy and comprehensive quality and production control.
The drives comply with the EC Machinery Directive 2006/42/ EC and with the Low
Tension Directive 2006/95/ EC as well as the German Regulations for Prevention
from Accidents, German Standards (DIN) and the relevant FEM-Rules for calculation.
The conformity to the rules is certified by the declaration of incorporation.
The service life and performance of a travel drive is ascertained by proper operation
and maintenance.
Therefore it is imperative to read the manual prior to installation and commissioning
and to observe the notes for the user.
Exemption from Liability

The company Helmut Kempkes GmbH is not liable for damage occur-
ring after misuse, inappropriate maintenance and repair or undertermi-
nated application.
2 Use in accordance with requirements

KULI - Travel Drives are to be used only for rail-bound vehicles. They are designed
for 50% duty cycle at max. 300 switches per hour. Moving rail-bound vehicles by jog-
ging is not allowed.
3 Sound Emission
The sound emission is 70 dB (A).

4 Description
KULI - Travel Drives type FGT / FG are used in KULI Wheel Bogies Type K, Type KL
and Type KS. There are 3 main constructional groups (Figure 4.1):
Figure 4.1: Travel Drive FGT / FG
4.1 Gearbox
The gearbox FGT is designed as a two-stage, the gearbox FG is designed as a
three-stage helical gearbox. The bearings are plain ball bearings and cylindrical roller
bearings, which are service life lubricated, as the whole gearbox is.
A torque support is included in the cast of the housing. With 2 pre-loaded buffers
mounted outside the gearbox housing, shocks during starting and stopping are re-
duced.
4.2 Travel Motor

The motor in FGT / FG-drives is a maintenance-low squirrel cage induction motor
with cylindrical rotor and soft start character. Optionally available are single-touring 4-
or 8-poles or double-touring 4/16-poles winding motors.
4.3 Brake
The brake is an all-weather DC-operated disc brake. The power feeding is DC-based
via auxiliary contacts at the travel contactor. According to needs the braking torque
can be adjusted by either removing brake springs or turning the adjustment ring.

5 Assembly
KULI - Travel Drives may only be mounted resp. put into operation by persons who
are familiar with those works.
This is also for installing electrical machines.
The rules to avoid accidents and VDE-regulations must be followed.
The travel drives are ready for mounting and are lubricated for life. All screws must
be checked and secured against self-loosening.
The brakes are generally adjusted for the nominal braking strength by the supplier.
All brakes are set to rated torque ex works.
Torque can be adjusted by removal of the outer brake springs 10 or by turning the
keyway nut. (see table 5.1 and figure 7.1)
The minimum braking torque should not be less than 60 % of the rated torque.
After a brake adjustment please always assure that in duty of a common work of 2
drives the braking property shall be simultaneously.
Attention !
All bolt joints must be inspected and secured against self-loosening.
Table 5.1: Brake adjustment
brake size rated torque number of reduced torque reduced torque

springs at outer by removing by turning the
ring the springs at adjusting ring
outer ring (slotted nut),
each screening
Nm St Nm Nm
06 2 4 6 3 - 2.3 4.2 0.1
08 8 3 4.6 0.36
10 16 3 9.1 0.6
12 32 3 18.3 1.2
travel motor travel motor

with one with two
speed speeds
Figure 5.1: Terminal plan

Table 5.2: Travel motors; motor table 50 Hz

Motor No of Fuses H.R.C. (A) Brake cos
poles 1 motor 2 motors
Type P/kW min-1 220 V 380 V 220 V 380 V Nm V ϕN ϕA
230 V 440 V 230 V 440 V
096.055.481 1,00 1435 4 8 180 0.71 0.70
095.055.451 0,27/0,10 1445/320 4/16 4 2 4 4 2 180 0.80 0.82
0.60 0.71
095.055.461 0,50/0,13 1445/310 4/16 4 4 16 6 4 180 0.77 0.87
0.66 0.84
094.075.421 1,60 1300 4 16 10 25 20 8 180 0.89 0.71
095.075.412 2,50 1375 4 25 20 50 35 45 103 0.73 0.75
094.075.461 1,00/0,20 1300/300 4/16 16 6 20 16 8 180 0.90 0.90
094.075.661 0.56 0.56
095.075.461 1,00/0,20 1405/335 4/16 16 6 20 16 8 180 0.84 0.84
095.075.661 0.54 0.54
113.140.461 1,60/0,30 1450/340 4/16 20 10 25 20 16 180 0.75 0.80
113.140.661 0.30 0.97

6 Maintenance and repair

For security reasons only genuine parts should be used. For damages caused by
using non-genuine parts or incorrect maintenance and repair Helmut Kempkes
GmbH will not be liable.
Maintenance and repair may only be conducted by persons who are familiar with the
users manual and the rules for avoiding accidents. KULI travel drives are, except of
brakes, free of maintenance.
Table 6.1: Lubrication
gearbox type req. quantity in lubricant – type

travel drive
kg
FGT.. (2-stage) 2,2 kg multipurpose grease, graphite-doped
FG... (3-stage) 2,0 kg FK – 2K DIN 51502, DIN 51825
7 Brake adjustment
KULI -Travel Drives are maintenance free except of the brakes.
The air gap of the brake is to be checked and adjusted if necessary.
Adjustment is effected as follows (see figure 7.1):
1. Remove hood, fan blade 1 and optional flywheel 2
2. 2Fixing bolt 3 to be unscrewed slightly
3. Bolt-in the setting sleeves 7 by spanner into solenoid 8
4. Fixing bolts 3 to be tightened again. Tightening procedure each bolt 120° in
a staggered manner, finally countered by setting sleeve
5. Check of air gap by feeler gauge
6. Balance of bolts tightened and countered
Attention !
Ensure that the brake linings are always kept clean of grease and oil.
The gap (a) must in no way increase more than 1.5 times the value
shown in the table at the bottom. Wider gaps will cause brake troubles
such as faults in releasing the brake disc and subsequent burning of
motor windings.
Figure 7.1: Section of the brake

To change the brake disc (see figure 7.1):

1. Remove hood fan blade 1 and optional flywheel 2
2. Unscrew fixing bolts
3. Remove solenoid 8 and anchor disc
4. Remove brake disc 5 off hub and replace by new disc
5. Adjust brake as described before
Attention !
The travel-drive brakes are connected to DC and controlled in the DC
circuit through auxiliary contacts of the travel-drive contactors.
Table 7.1: Adjustment of brakes (tightening torque and air gap)
brake size brake moment tightening torque air gap

Nm Nm mm
06 2 4 6 2.8 0.2
08 8 5.5
10 16 9.5
12 32 9.5 0.3
14 60 23.0
Modifications reserved
Helmut Kempkes GmbH
Post Box 100562
D-42805 Remscheid
Germany
Tel.: 02191/434-0
Fax: 02191/434-45

Declaration of incorporation of partly
2012 - 04
completed machinery
acc. to the EC Machine Directive 2006/42/EG Annex IIB

Travelling Drive FG / FGT


FEM 9.683 Selection of lifting and travel motors

Kuli Hebezeuge
Helmut Kempkes GmbH
Bismarckstr. 59
D 42853 Remscheid
The partly completed machinery is only permitted to be taken into operation if it is certified that the o-
perating final machinery is in accordance with the machinery directive 2006/42/EC
K U L I - HEBEZEUGE
Helmut Kempkes GmbH
ENGLISH Quick Start Guide - ATV312
S1A1094201
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand this quick start guide before performing any procedure with this drive.
• The user is responsible for compliance with all international and national electrical code requirements with respect to grounding of all
equipment.
• Many parts of this drive, including the printed circuit boards, operate at the line voltage. DO NOT TOUCH. Use only electrically insulated tools.
• DO NOT touch unshielded components or terminal strip screw connections with voltage present.
• DO NOT short across terminals PA/+ and PC/- or across the DC bus capacitors.
• Before servicing the drive:
- Disconnect all power, including external control power that may be present.
- Place a "DO NOT TURN ON" label on all power disconnects.
- Lock all power disconnects in the open position.
- WAIT 15 MINUTES to allow the DC bus capacitors to discharge.
- Measure the voltage of the DC bus between the PA/+ and PC/- terminals to ensure that the voltage is less than 42 Vdc.
- If the DC bus capacitors do not discharge completely, contact your local Schneider Electric representative. Do not repair or operate
the drive
• Install and close all covers before applying power or starting and stopping the drive.
Failure to follow these instructions will result in death or serious injury.
Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider
Electric for any consequences arising out of the use of this product.
Information below is designed to use single drive connected to single motor with a motor cable length less than 50 meters (164 ft).
In any other case, consult the ATV312 installation and programming manual on www.schneider-electric.com.
Check your cables before connecting the drive with motor (length, power, shielded or unshielded). Motor cable length is _______(< 50 meters, 164 ft)
1 Check the delivery of the drive

• Remove ATV312 from the packaging and check that it has not been damaged.
WARNING
DAMAGED DRIVE EQUIPMENT
Do not operate or install any drive or drive accessory that appears damaged.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
• Check that the drive reference printed on the label is the same as that on the delivery note corresponding to the
purchase order.
Write the drive Model Reference: _____________ ___________and Serial Number: ____________________________
2 Check the line voltage compatibility 8B0917121134

• Check that the line voltage is compatible with the supply range of the drive.
Line voltage _______ Volts / Drive voltage range _______ Volts
Drive range: ATV312 M2 = 200 ... 240 V single phase / ATV312 M3=200 ... 240 V three-phase
ATV312 N4 = 380 ... 500 V three-phase / ATV312 S6 = 525 ... 600 V three-phase
3 Mount the drive vertically

For a surrounding air temperature up to 50 °C (122 °F)
(a)
(a) (a)
(b)
(a)
(a) 50 mm (2 in.)
(b) 10 mm (0.4 in.)
See installation manual on www.schneider-electric.com for other thermal conditions.
www.schneider-electric.com 1/4 S1A10942 - 04/2010

4 Connect the drive: Power 5 Connect the drive:
• Wire the drive to the ground.
• Check circuit breaker rating or fuse rating (see recommended branch Control choice
circuit protection page 4).
• Check that the motor voltage is compatible with the drive voltage. [REMOTE configuration]
Motor voltage ______Volts. 5.1 (Control by external reference)
• Wire the drive to the motor.
• Wire the drive to the line supply. • Wire the speed reference:
6 + 7 + 8 + 9.1
+10 v
Do:
AI 1
COM
2.2 KΩ
RUN
REF
200...240 V MON
CONF
CAN
ERR
ATV312 M2 • Wire the command:

Control command 2-wire:
Parameter tCC = 2C
or
LI1: forward ATV 312
See page 4 LI2: reverse
200...240 V 24 V LI1 LI2 Do: 6 + 7 + 8 + 9.1
ATV312 M3
380...500 V Control uses 3-wire:

ATV312 N4 Parameter tCC = 3C
LI1: stop ATV 312
LI2: forward Do: 6 + 7 + 8 + 9.1
LIx: reverse 24 V LI1 LI2 LIx
525...600 V
ATV312 S6
Source
• Check SW1 = ‘’SOURCE’’ CLI
SINK
[LOCAL configuration]
5.2 (control by internal reference).
Do: 6 + 7 + 8 + 9.2
RUN
REF
MON CAN
CONF ERR
6 Apply power to the drive

• Check that used Logic Inputs are not active (see Li1, Li2, Lix ). ENT
• Apply power to the drive.
• At first power up, drive displays nSt (3-wire control) or rdY (2 -wire control), after pushed drive displays bFr.
• On next start-ups, drive displays nSt or rdY .
7 Set motor parameters

• See on the motor Nameplate to set the following parameters in drC menu.
Menu Code Description Factory setting Customer

setting
[Standard mot. freq]:
bFr 50.0
Standard motor frequency (Hz)
[Rated motor volt.]:
UnS drive rating
Nominal motor voltage on motor nameplate (V)
[Rated motor freq.]:
drC- FrS 50.0
Nominal motor frequency on motor nameplate (Hz)
[MOTOR CONTROL]
nCr drive rating
Nominal motor current on motor nameplate (A)
[Rated motorspeed]:
nSP drive rating
Nominal motor speed on motor nameplate (rpm)
[Motor 1 Cosinus Phi.]:
COS drive rating
Nominal motor cos ϕ on motor nameplate

7 Set motor parameters (continued)
• Set tUn parameter to YES.
Customer
Menu Code Description Factory setting
setting
drC- [Auto Tunning]:
tUn nO
[MOTOR CONTROL] Auto-Tunning for UnS, FrS, nCr, nSP, nPr and COS
DANGER DANGER
HAZARD OF ELECTRIC SHOCK OR ARC FLASH UNINTENDED EQUIPMENT OPERATION
• The Nominal Motor Parameters UnS, FrS, nCr, nSP, nPr and
• During auto-tuning, the motor operates at rated COS must be correctly configured before starting auto-tuning.
current. • If one or more of these parameters is modified after auto-tuning has
• Do not service the motor during auto-tuning. been performed, tUn will return to nO and the procedure must be
repeated.
Failure to follow these instructions will result in death
or serious injury. Failure to follow these instructions will result in death or serious injury.
8 Set basic parameters

Customer
setting
[Acceleration]:
ACC 3.0
Acceleration time (s)
[Deceleration]:
dEC 3.0
Deceleration time (s)
SEt- [Low speed]:
LSP 0.0
[SETTINGS] Motor frequency at minimum reference (Hz)
[High speed]:
HSP 50.0
Motor frequency at maximum reference (Hz)
[Mot. therm. current]:
ItH drive rating
Nominal current indicated on the motor's rating plate (A)
I-O- [Reverse assign.]:
rrS LI2
[INPUTS / OUTPUTS CFG] Reverse assignment
[2 preset speeds]:
PS2 LI3
Fun-> PSS- Preset speeds
[PRESET SPEEDS] [4 preset speeds]:
PS4 LI4
Preset speeds
Fun-> SAI- [Summing ref. 2]
SA2 AI2
[SUMMING INPUTS] Analog input
9 Set control choice

Menu Code Description 5.1 [REMOTE configuration] 5.2 [LOCAL configuration] Customer Setting
CtL- [Ref.1 channel]:
Fr1 Al1, Al2, Al3 AlU1
[COMMAND] Reference control
I-O- [2/3 wire control]: 2C: 2-wire
tCC LOC
[INPUTS / OUTPUTS CFG] Command control 3C: 3-wire
9.1 [REMOTE configuration] 9.2 [LOCAL configuration]

(Configuration factory setting)
MODE
3s
LOC rdY
Parameters factory settings:
Fr1 = AI1 Parameters factory settings:
tCC = 2C Fr1 = AIU1
tCC = LOC
rrS = LI2
PS2 = LI3 35.
1
PS4 = LI4
[Output frequency] (Hz)
10 Start the motor

Menus structure
= ENT MODE
ESC
3s LOC 2s
rdY rdY
rEN
These 3 parameters are MODE
only visible at first power up ESC ENT
of the drive. bFr 3s

Settings can be changed
35. [Output frequency] (Hz)
subsequently in menu: Fr1
drC- for bFr
CtL- for Fr1
I-O- for tCC. tCC
MODE
[SPEED REFERENCE] rEF-
Parameter selection
[SETTINGS] SEt-
[MOTOR CONTROL] drC-

= ENT
[INPUTS / OUTPUTS CFG] I-O-

ESC ESC Refer to the programming manual for
[COMMAND] CtL- SEt- ACC 15. comprehensive menu description.
ENT ENT
FUn- ESC
[APPLICATION FUNCT.] dEC 26. A dash appears after menu codes to
differentiate them from parameter codes.
[FAULT MANAGEMENT] FLt- ENT
Example:
[COMMUNICATION] COM- 26. [SETTINGS] (SEt-), ACC parameter.
SFr
[MONITORING] SUP- 1 flash
(save)
Short-circuit rating and branch circuit protection.

Enclosure
Input Output Branch
Voltage Containment Rating
withstand interrupt Circuit
Reference (Y) rating (3) (Z2)
rating (1) rating (X)(2) protection
(Type 1)
(Z1)
V KA KA KA A
ATV312H018M2 200-240 1 22 / Class J Fuse 6
Recommended fuse ratings for UL and CSA requirements. Components for use
ATV312H075M2 200-240 1 22 / Class J Fuse 15 together in accordance with standard UL508
ATV312HU11M2 200-240 1 22 / Class J Fuse 20
ATV312HU15M2 200-240 1 22 / Class J Fuse 20 Suitable For Use On A Circuit Capable Of Delivering Not More Than ___X____
ATV312HU22M2 200-240 1 22 / Class J Fuse 30 rms Symmetrical Amperes, ___Y____ Volts Maximum, When Protected by __Z
ATV312H018M3 200-240 5 22 22 Class J Fuse 3 1____ with a Maximum rating of__Z 2___.
ATV312H037M3 200-240 5 22 22 Class J Fuse 6
(1) Input withstand rating is that for which the product has been designed
thermally. Installation on a supply greater than this level will require additional
ATV312HU11M3 200-240 5 22 22 Class J Fuse 15
inductance to satisfy this level.
ATV312HU30M3 200-240 5 22 22 Class J Fuse 25 (2) Output interrupt rating relies on Integral solid state short circuit protection.
ATV312HU40M3 200-240 5 22 22 Class J Fuse 35 This does not provide branch circuit protection. Branch circuit protection must
ATV312HU55M3 200-240 22 22 22 Class J Fuse 50 be provided in accordance with the National Electrical Code and any additional
ATV312HU75M3 200-240 22 22 22 Class J Fuse 60 local codes. This is dependant on the type of installation.
ATV312HD11M3 200-240 22 22 22 Class J Fuse 80
(3) Enclosure Containment Rating is the maximum input short-circuit current
ATV312H037N4 380-500 5 22 100 Class J Fuse 3
at the drive input terminals with the specific branch Circuit Protection present
for which any internal component breakdown, will not create a shock, flame, fire
ATV312HU11N4 380-500 5 22 100 Class J Fuse 10 or expulsion hazard
ATV312HU15N4 380-500 5 22 100 Class J Fuse 10
ATV312HD11N4 380-500 22 22 100 Class J Fuse 50
ATV312H075S6 525-600 5 22 22 Class J Fuse 6
ATV312HU15S6 525-600 5 22 22 Class J Fuse 6
ATV312HD11S6 525-600 22 22 22 Class J Fuse 35

RS elektrozüge
Ersatzteilliste
Elektroseilzüge
Spare parts list

Electric wire rope hoists
Liste de pièces
Palans électriques à cable
Lista de piezas
Polipastos eléctricos de cable
05/13
Ersatzteilliste RS
Inhaltsverzeichnis
Table of contents
Table des matieres
Tabla de materias
RS 100 Seiltrommel, Rope drum, Tambour, Tambor

RS 110 Seiltrommel, Rope drum, Tambour, Tambor
RS 200 Getriebe, Gearbox, Reducteur, Reductor

RS 210 Getriebe, Gearbox, Reducteur, Reductor (10 – 30)
RS 220 Getriebe, Gearbox, Reducteur, Reductor (40 / 50)
RS 230 Getriebe, Gearbox, Reducteur, Reductor (60 / 70 / 90)
RS 300 Hubmotor, Hoist motor, Moteur de levage, Motor de elevacion

RS 310 Hubmotor, Hoist motor, Moteur de levage, Motor de elevacion
RS 310.1 Liste der Motore und Klemmenkasten, List of motor and terminal box,
Liste des moters et boite de bornes, Lista de Motor y caja de bornes
RS 400 Unterflasche, Bottom block, Moufles avec crochets, Motones con gan-
cho
RS 410 Unterflasche, Bottom block, Moufles avec crochets, Motones con gan-
cho
RS 500 Oberrolle und Seilfestpunkt, Sheave transverse bar and rope anchor
transverse bar, Traverse des poulies et traverses des points fixes, Travesano
de las poleas y traveranos de anclaje
RS 510 Oberrolle, Sheave transverse bar, Traverses des poulies, Travesanos de las
poleas
RS 520 Seilfestpunkt, Rope anchor transverse bar, Traverses des points fixes,
traversano de anclaje
RS 600 Normfahrwerk, Wheel bogies, Mecanisme de translation, Mecanismo de

translacion
RS 610 Typ, Type, Tipo-KS
RS 620 Typ, Type, Tipo-HF (12-20)
RS 630 Typ, Type, Tipo-K
RS 640 Typ, Type, Tipo-HF (220)
RS 650 Typ, Type, Tipo-ZE
RS 660 Typ, Type, Tipo-HF-KE (12-16)
RS 700 Fahrantrieb, Travel drive, Groupes d’ entrainment, Accionamiento

RS 710 Typ, Type, Tipo-F
RS 720 Typ, Type, Tipo-FP
RS 750 Typ, Type, Tipo-FA.2
RS 790 Typ, Type, Tipo-FGT/FG
RS 795 Typ, Type, Tipo-WG1/WG2/WG3
RS 1600 Technisches Datenblatt, Technical data sheet, Feuille technique, Hoja con
technicos

Ersatzteilliste RS
RS 110
No. Benennung Dénomination
Denomination Denominación
101 Gehäuseflansch, komplett Flasque du casier, complet
Housing flange, complete Brida de la carcasa, completa
102 Kugellager Roulement à billes
Ball bearing Rodamiento de bolas
103 Flanschring Bague d´étanchéité
Flange ring Empaquetadura
105 Gehäuseflansch, komplett Flasque du casier, complet
Housing flange, complete Brida de la carcasa, completa
106 Kugellager Roulement à billes
108 Verbindungsstange, komplett Tige de raccordement, complet
Stay pin, complete Tirante de unión, completo
109 Abdeckhaube, komplett Couvercle de protection
Protection cover, complete Tapa de proteccion
114 Seiltrommel Tambour de câble
Rope drum Tambor del cable
115 O-Ring Joint
Sealing ring Empaquetadura
116 Seilklemme Serre-câble
Rope clamp Garra del cable
117 Seilwickler, komplett Guide câble, complet
Rope guide, complete Guia del cable, completa
121 Endschalterstange, komplett Barre de fin de course, complet
Limit switch bar, complete Barra final de carrera, completa
124 Führungsschiene Rail de guidage
Guide rail Riel de guia
125 Haltewinkel Suspension
Bracket Suspensión
126 KULI – Schild Plaque – KULI
KULI – endcover plate Placa - KULI
127 Ring Anneau
Ring Anillo
128 Seil Câble en acier
Wire Rope Cable de acero

Ersatzteilliste RS
Motorseite Trommelseite
Motor side Drum side
Côté moteur Côté tambour
Lado motor Lado tambor
RS 210
201 Getriebe, komplett Réduteur, complet
Gearbox, complete Reductor, completo
202 Getriebegehäuse, komplett Carter du rédcteur, complet
Gear housing, complete Caja del reductor, completa
203 Kugellager Roulement
Bearing Rodamiento
204 Dichtring Joint détancheite radial
Shaft seal Empaquetadura radial
205 Planetenträger, komplett Disque planetaire, complet
Planet disc, complete Disco planetario, completo
211 Planetenträger, komplett Disque planetaire, complet
217 Verbindungswelle Arbre cannele
Spline shaft Arbol acanalado
218 Sicherungsring Circlip
Circlip Circlip
219 Entlüftungsschraube Vis dáération
Aeration screw Tornillo de airemiento
225 Fett (siehe Bedienungsanleitung) Graisse (voir instruction de service)
Grease (see manual) Grasa (mire instrucciones de servicio)

Ersatzteilliste RS
Getriebe/Gearboxes/Rèducteurs/Reductores Gr. 40/50
Trommelseite
Motorseite Drum side
Motor side Côté tambour
Côté moteur Lado tambor
Lado motor
RS 220
201 Getriebe, komplett Reducteur, complet
Gearbox, complete Reducteur, completo
202 Getriebegehäuse, komplett Carter du réducteur
Gear housing, complete Caja del reductor
203 Kugellager Roulement a billes
204 Dichtring Joint d´étancheite radial
205 Planetenträger, komplett Disque planétaire, complet
Aeration screw Tornillo de aireamiento
221 Ritzelwelle Arbre-pignon
Pinion shaft Arbol-pinón
222 Innenzahnkranz Couronne dentée
Gear rim Corona dentada
224 O-Ring Joint
Sealing ring Empaquetadura

Ersatzteilliste RS
Getriebe/Gearboxes/Rèducteurs/Reductores Gr. 60/70/90
Motorseite Trommelseite
Motor side Drum side
Côté moteur Côté tambour
Lado motor Lado tambor
RS 230
Denomonation Denominación
200 Getriebe, komplett Reducteur, complet
Gearbox, complete Reducteur, completo
201 Getriebegehäuse, komplett, Teil 1 Carter du réducteur, cpl. Partie 1
Gear housing, complete, part 1 Caja del reductor, cpl. Porción 1
202 Dichtring Joint d´étanchéite radial
204 Ritzelwelle Arbre-pignon
Pinion shaft Arbol-piñon
205 Innenzahnkranz Couronne dentée
Gear rim Corona dentada
207 Ritzel Pignon
Pinion Piñón
209 Getriebegehäuse, komplett Teil 2 Carter du réducteur, cpl. Partie 2
Gear housing, complete, Part 2 Caja del reductor, cpl. Porción 2
Aeration screw Tornillo de aireamiento

Ersatzteilliste RS
RS 310
Hubmotor/Hoist motor/Moteur de levage/Motor de elevacion
Sizes
Gr. 10 - 50 Sizes
Tam. Gr. 70/90
Tam

Ersatzteilliste RS
RS 310
301 Hubmotor, komplett Moteur de levage, complet
Hoist motor, complete Motor de elevación, completo
302 Gehäuse mit Stator und Wicklung Carter avec stator et bobine
Housing with stator and winding Carcasa con estator y bobina
303 Ankerwelle mit Rotor, komplett Arbre avec rotor, complet
Rotor with shaft, complete Arbol con rotor, completo
304 Lagerschild Flasque de palier
End plate Platillo del cojinete
305 Motorlagerschild Couvercle du moteur
Brake end motor cover Tapa del motor
306 Rillenkugellager Roulement
Bearing Rodamiento
307 Tellerfeder Ressort belleville
Belleville spring washer Resorte belleville
308 Lüfterflügel Ventilateur
Fan Ventilador
309 Lüfterhaube Couvercle de frein
Brake hood Tapa del freno
310 Federkraftbremse, komplett Frein électro-magnétique, complet
Electromagnetic brake, complete Freno electro-magnético, completo
311 Bremsscheibe Disque de frein
Brake disc Disco de freno
314 Tellerfeder Ressort belleville
Belleville spring washer Resorte belleville
315 Klemmenkasten Boites de bornes
Terminal box Cajas de bornes
317 Klemmbrett Plâque de bornes
Terminal board Placa de bornes
318 Endschalter, komplett Interruteur fin de course, comp.
Limit switch, complete Interruptor final de carrera, compl.
319 Endschalterstange, komplett Barre fin de course, complet
Limit switch bar, complete Barra final de carrera, completa
320 Faltenbalg Accordéon
Concertina walls Fuelle
321 Kondensatoren Condensateurs
Condensers Condensadores
323 Bremsplatine Commande életronique du frein
Electronic brake control card Mando electrónico del freno
324 Verbindungsteil Accouplement barre fin de course
Limit switch coupling Acoplamiento barra final de carrera

Ersatzteilliste RS
RS 410

401 Unterflasche, komplett Moufle, complet
Bottom block, complete Motón, completo
402 Gehäuse Carter du moufle
Housing Caja del motón
403 Seilrolle, komplett Poulie, complet
Rope sheave, complete Polea, completo
410 Lasthaken, komplett Crochet, complète
Hook, complete Gancho, completo
411 Axial-Rollenlager Butée
Thrust roller bearing Rodamiento axial
412 Hakensicherung, komplett Liguet de sécurité, complet
Safety catch, complete Lengueta de seguridad, completa

Ersatzteilliste RS
RS 510

510 Oberollentraverse, komplett Traverse de la poulie de renvoi, complet
Equalizing sheave transverse bar complete Travesaño de la polea de reenvio, completo
511 Seilrolle, komplett Poulie, compléte
Rope sheave, complete Polea, completa
512 Achse Axe
Axle Eje
513 Deckel Couvercle
Cover Tapa
514 Bolzen komplett mit Halter Tige cpl. avec garde
Pin cpl. with positioner Barra con fijador
515 Verschraubung, komplett Raccord à vis
Screw joint Atornilladura
516 Traverse Traverse
Transverse bar Travesaño

Ersatzteilliste RS
RS 520

501 Seilfestpunkttraverse, komplett Traverse de point fixe, complet
Rope achor traverse bar complete Travesaño de anclaje, completo
502 Traverse Traverse
Transverse bar Travesaño
503 Keilgehäuse mit Seilkeil Poche de cale avec cale
Rope pocket with rope wedge Caja de la cuña con cuña
504 Seilklemme, komplett Serre-cable, compléte
Rope clamp, complete Garra de cable, completa
505 Meßbolzen mit Verstärker Boulon de mesurage avec amplificateur
Measuring pin with amplifier Perno de medicion con amplificador
506 Achshalter Garde déssieu
Axle positioner Fijador del perno
507 Verschraubung, komplett Raccord a vis, complet
Screw joint, complete Atornilladura, completa
508 Bolzen ohne Überlastabschaltung Boulon sans interrupteur de sucharge
Bolt without overload cut-off Perno sin interruptor de sobrecarga
510 Überlastabschaltung, elektromechanisch Interrupteur de surcharge électro-mécanique
Overload cut-off, electro-mechanically Interruptor de sobrecarga, electro-mecanico
511 Tellerfedern Ressorts Belleville
Belleville springs Resortes Belleville
512 Bolzen mit Halter Boulon avec garde
Bolt with positioner Perno con fijador

Ersatzteilliste RS
Fahrantrieb FA Fahrantrieb FP
Travel drives Travel drives
Groupe déntrainment Groupe déntrainment
Accionamiento Accionamiento
Ohne Fahrantrieb
Without travel drives
Sans groupe dèntrainement
Sin accionamiento
RS 610
701 Laufrad, nicht angetrieben Galet non-entrainé
Wheel, undriven Rueda no accionada
702 Laufrad, angetrieben Galet entrainé
Wheel, driven Rueda, accionada
703 Flanschlager Flasque-bride
Bearing flange Brida de rodamiento
705 Antriebswelle Arbre dèntrainement
Drive shaft Arbol de accionamiento
707 Stellring Anneau de réglage
Adjusting collar Aro de adjuste con tornillo

Ersatzteilliste RS
HF 12-20 RS 620

604 Flanschlager, komplett Flasque-bride, complet
Bearing flange, complete Brida de rodamiento, completa
607 Antriebsritzel Pignon
Pinion Piñon
610 Ritzel Pignon
Pinion Piñon
611 Antriebswelle Arbre déntraînement
612 Verbindungsbolzen, komplett Boulon de suspension, complet
Suspension bolt, complete Perno de suspension, completo
621 Laufrolle, ohne Zahnkranz, komplett Galet sans couronne, complet
Trolley wheel, plain, complete Rueda sin corona, completa
622 Laufrolle, mit Zahnkranz, komplett Galet avec couronne, complet
Trolley wheel, geared, complete Rueda con corona, completa

Ersatzteilliste RS
K20-50 RS 630
1500 Fahrwerkskopf komplett angetrieben Mécanisme de trans. compl. entrainé
Complete wheel assembly, driven Mecanismo de transl. compl. accionado
1501 Fahrwerkskopf komplett nicht angetrieben Mécanisme de transl. compl. non entrainé
Complete wheel assembly, undriven Mecanismo de transl. compl. libre
1502 Gehäuse Carter seul
Housing Carcasa sola
1503 Laufrad Galet
Wheel Rueda
1504 Laufradwelle, angetrieben Arbre du galet entrainé
Wheel shaft, driven Arbol de la rueda accionada
1505 Laufradwelle, nicht angetrieben Arbre du galet non entrainé
Wheel shaft, undriven Arbol de la rueda libre
1513 Lager Roulement
Bearing Rodamiento
1514 Nilos-Ring Couvercle du roulement
Retaining ring Tapa del rodamiento
1517 Abschlußdeckel Couvercle en caoutchouc
Sealing cover Tapa de goma
1518 Abschlußdeckel Couvercle en caoutchouc
Sealing cover Tapa de goma
1519 Führungsrolle Galet de guidage
Guide roller Rueda de guia
1520 Exzenterbolzen Boulon exentrique
Eccentric bushing Perno excéntrico
1530 Drehmomentenstütze Support de couple
Torque support Apoyo de giro
1534 Kranpuffer Butée en caoutchouc
Rubber bumper Tope de goma

Ersatzteilliste RS
RS 640
HF 220
612 Verbindungsbolzen, komplett Tiges dássemblage, complet
Distance bar and stay pin, complete Perno de ensamblaje, completo
645 Tragbolzen, komplett Boulon de suspension, complet
Suspension bolts, complete Perno de suspension, completo

Ersatzteilliste RS
Angetrieben entrainé
Driven accionado
Nicht angetrieben non entraine

Undriven sin accionacion
ZE RS 650
741 Laufrad Galet
Wheel Rueda
742 Welle, angetrieben Arbre entrainé
Driven shaft Arbol accionado
743 Welle, nicht angetrieben Arbre court
Idle shaft Arbol corto
744 Kugellager Roulement
Bearing Rodamiento

Ersatzteilliste RS
HF – KE 12-16 RS 660
604 Lagerung, komplett Flasque-bride, complet
Bearing, complete Brida de rodamiento, completa
607 Ritzel Pignon
Pinion Piñon
610 Ritzel Pignon
Pinion Piñon
611 Antriebswelle Arbre déntraînement
612 Verbindungsbolzen, komplett Boulon de suspension, complet
Suspension bolt, complete Perno de suspension, completo

Ersatzteilliste RS
RS 710
F
802 Fahrmotor komplett Moteur de translation, complet
Travel motor, complete Motor de translación, completo
804 Ankerwelle mit Rotor Arbre avec rotor
Shaft with rotor Arbol con rotor
Brake and motor cover Tapa del motor
Fan Ventilador
Brake hood Tapa de freno
813 Klemmenkasten Boîte de bornes
Terminal box Caja de bornes
817 Getriebe komplett Reducteur complet
Gear box, complete Reductor, completo
818 Getriebegehäuse komplett Carter du réducteur, complet
Gear housing, complete Caja del reductor, completa
819 Planetenträger komplett Disque planétaire, complet
825 Antriebsritzel Pignon de sortie
Take-off pinion Piñon de salida

Ersatzteilliste RS
RS 720
FP
902 Fahrmotor komplett Moteur de translation, complet
Travel motor, complete Motor de translación, completo
Brake end motor cover Tape del motor
908 Lüfterfügel Ventilateur
Fan Ventilador
Brake hood Tapa de freno
910 Federkraftbremse komplett Frein electro-magnétique, complet
913 Klemmenkasten Boîte de bornes
Gear box, complete Reductor, competo
Gear housing, complete Caja del reducto, completa
Planet disc, complete Disco planetario, competo
Gear housing, complete Caja del reductor, completo
Ersatzteilliste RS
908 909 913 903 904 917
910 902
FA.2
RS 750

902 Fahrmotor komplett Moteur complet
Travelling motor, complete Motor completo
Housing with stator and winding Carcasa con stator y bobina
Fan Ventilador
910 Federkraftbremse komplett Frein electro-magnétique, complet
913 Klemmenkasten Boite de bornes
Gear box, complete Reductor completo

Ersatzteilliste RS
FGT/FG RS 790
Benennung Dénomination
907 Zusatzschwungmasse (optional) Volant à masse additionelle de centrifuge
Flywheel (optional) Volant con massa adicional de centrifuga
908 Lüfterflügel mit Bremsscheibe Ventilateur avec disque de frein
Fan with brake disc Ventilador con disco de freno
912 Bremsscheibennabe Disque de frein moyeu
Brake disk hub Disco de freno cubo
914 Klemmenkastenunterteil Partie inférieur de la boite à bornes
Terminal box bottom Parte inferior de la caja de bornes
915 Klemmenkastendeckel Couvercle de la boite à bornes
Terminal box cover Tapa de al caja de bornes
916 Klemmbrett Plochette à bornes
Terminal board Tabolero de bornes
917 Bremsplatine Commande electronique de frein
Electronic brake control card Tarjeta electronica de mando
940 Fahrgetriebe, komplett Reducteur, complet
Travel drive gear box, complete Reductor, completo
942 Zwischenwelle, komplett (nur bei 3-stufig) Arbre intermédiaire complet (seulement 3-trains)
Intermidiate shaft complete (onnly with 3-stage) Arbol intermedio completo (solamento 3-etapas)
943 Ritzelwelle, komplett Arbre-pignon compet
Pinon shaft, complete Arbol-pinon completo
944 Antriebshohlwelle, komplett Arbre dáttaque complet
Hollow drive shaft complete Arbol de saida completo
945 Getriebepuffer Buteés du support du couple
Bumpers for retaining mounting Topes de goma del reductor

Ersatzteilliste RS
WG1/WG2/WG3 RS795
Benennung Dénomination
907 Zusatzschwungmasse (optional) Volant à masse additionelle de centrifuge
Flywheel (optional) Volant con massa adicional de centrifuga
908 Lüfterflügel mit Bremsscheibe Ventilateur avec disque de frein
Fan with brake disc Ventilador con disco de freno
912 Bremsscheibennabe Disque de frein moyeu
Brake disk hub Disco de freno cubo
914 Klemmenkastenunterteil Partie inférieur de la boite à bornes
Terminal box bottom Parte inferior de la caja de bornes
915 Klemmenkastendeckel Couvercle de la boite à bornes
Terminal box cover Tapa de al caja de bornes
916 Klemmbrett Plochette à bornes
Terminal board Tabolero de bornes
917 Bremsplatine Commande electronique de frein
Electronic brake control card Tarjeta electronica de mando
940 Fahrgetriebe, komplett Reducteur, complet
Travel drive gear box, complete Reductor, completo
942 Eingangswelle, komplett Arbre d´ entrée complet
Input shaft complete Arbol entrada completo
943 Zwischenwelle, komplett Arbre intermédiaire compet
Intermediate shaft, complete Arbol intermedio completo
944 Antriebshohlwelle, komplett Arbre dáttaque complet
Hollow drive shaft complete Arbol de saida completo
945 Drehmomentstütze getriebeseitig Support de couple, sens de reducteur
Torque support, gear side Apoyo de giro, dirección reductor

Ersatzteilliste RS
Änderungen vorbehalten
Helmut Kempkes GmbH
Postfach 100562
D-42805 Remscheid
Tel.: 02191/434-0
Fax: 02191/434-45
E-Mail: service@kuli.com

ENGLISH Quick Start Guide - ATV312
S1A1094201
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand this quick start guide before performing any procedure with this drive.
• The user is responsible for compliance with all international and national electrical code requirements with respect to grounding of all
equipment.
• Many parts of this drive, including the printed circuit boards, operate at the line voltage. DO NOT TOUCH. Use only electrically insulated tools.
• DO NOT touch unshielded components or terminal strip screw connections with voltage present.
• DO NOT short across terminals PA/+ and PC/- or across the DC bus capacitors.
• Before servicing the drive:
- Disconnect all power, including external control power that may be present.
- Place a "DO NOT TURN ON" label on all power disconnects.
- Lock all power disconnects in the open position.
- WAIT 15 MINUTES to allow the DC bus capacitors to discharge.
- Measure the voltage of the DC bus between the PA/+ and PC/- terminals to ensure that the voltage is less than 42 Vdc.
- If the DC bus capacitors do not discharge completely, contact your local Schneider Electric representative. Do not repair or operate
the drive
• Install and close all covers before applying power or starting and stopping the drive.
Failure to follow these instructions will result in death or serious injury.
Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider
Electric for any consequences arising out of the use of this product.
Information below is designed to use single drive connected to single motor with a motor cable length less than 50 meters (164 ft).
In any other case, consult the ATV312 installation and programming manual on www.schneider-electric.com.
Check your cables before connecting the drive with motor (length, power, shielded or unshielded). Motor cable length is _______(< 50 meters, 164 ft)
1 Check the delivery of the drive

• Remove ATV312 from the packaging and check that it has not been damaged.
WARNING
DAMAGED DRIVE EQUIPMENT
Do not operate or install any drive or drive accessory that appears damaged.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
• Check that the drive reference printed on the label is the same as that on the delivery note corresponding to the
purchase order.
Write the drive Model Reference: _____________ ___________and Serial Number: ____________________________
2 Check the line voltage compatibility 8B0917121134

• Check that the line voltage is compatible with the supply range of the drive.
Line voltage _______ Volts / Drive voltage range _______ Volts
Drive range: ATV312 M2 = 200 ... 240 V single phase / ATV312 M3=200 ... 240 V three-phase
ATV312 N4 = 380 ... 500 V three-phase / ATV312 S6 = 525 ... 600 V three-phase
3 Mount the drive vertically

For a surrounding air temperature up to 50 °C (122 °F)
(a)
(a) (a)
(b)
(a)
(a) 50 mm (2 in.)
(b) 10 mm (0.4 in.)
See installation manual on www.schneider-electric.com for other thermal conditions.

4 Connect the drive: Power 5 Connect the drive:
• Wire the drive to the ground.
• Check circuit breaker rating or fuse rating (see recommended branch Control choice
circuit protection page 4).
• Check that the motor voltage is compatible with the drive voltage. [REMOTE configuration]
Motor voltage ______Volts. 5.1 (Control by external reference)
• Wire the drive to the motor.
• Wire the drive to the line supply. • Wire the speed reference:
6 + 7 + 8 + 9.1
+10 v
Do:
AI 1
COM
2.2 KΩ
RUN
REF
200...240 V MON
CONF
CAN
ERR
ATV312 M2 • Wire the command:

Control command 2-wire:
Parameter tCC = 2C
or
LI1: forward ATV 312
See page 4 LI2: reverse
200...240 V 24 V LI1 LI2 Do: 6 + 7 + 8 + 9.1
ATV312 M3
380...500 V Control uses 3-wire:

ATV312 N4 Parameter tCC = 3C
LI1: stop ATV 312
LI2: forward Do: 6 + 7 + 8 + 9.1
LIx: reverse 24 V LI1 LI2 LIx
525...600 V
ATV312 S6
Source
• Check SW1 = ‘’SOURCE’’ CLI
SINK
[LOCAL configuration]
5.2 (control by internal reference).
Do: 6 + 7 + 8 + 9.2
RUN
REF
MON CAN
CONF ERR
6 Apply power to the drive

• Check that used Logic Inputs are not active (see Li1, Li2, Lix ). ENT
• Apply power to the drive.
• At first power up, drive displays nSt (3-wire control) or rdY (2 -wire control), after pushed drive displays bFr.
• On next start-ups, drive displays nSt or rdY .
7 Set motor parameters

• See on the motor Nameplate to set the following parameters in drC menu.
Menu Code Description Factory setting Customer

setting
[Standard mot. freq]:
bFr 50.0
Standard motor frequency (Hz)
[Rated motor volt.]:
UnS drive rating
Nominal motor voltage on motor nameplate (V)
drC- FrS 50.0
Nominal motor frequency on motor nameplate (Hz)
[MOTOR CONTROL]
nCr drive rating
Nominal motor current on motor nameplate (A)
[Rated motorspeed]:
nSP drive rating
Nominal motor speed on motor nameplate (rpm)
[Motor 1 Cosinus Phi.]:
COS drive rating
Nominal motor cos ϕ on motor nameplate

7 Set motor parameters (continued)
• Set tUn parameter to YES.
Customer
setting
drC- [Auto Tunning]:
tUn nO
[MOTOR CONTROL] Auto-Tunning for UnS, FrS, nCr, nSP, nPr and COS
DANGER DANGER
HAZARD OF ELECTRIC SHOCK OR ARC FLASH UNINTENDED EQUIPMENT OPERATION
• The Nominal Motor Parameters UnS, FrS, nCr, nSP, nPr and
• During auto-tuning, the motor operates at rated COS must be correctly configured before starting auto-tuning.
current. • If one or more of these parameters is modified after auto-tuning has
• Do not service the motor during auto-tuning. been performed, tUn will return to nO and the procedure must be
repeated.
Failure to follow these instructions will result in death
or serious injury. Failure to follow these instructions will result in death or serious injury.
8 Set basic parameters

Customer
setting
[Acceleration]:
ACC 3.0
Acceleration time (s)
[Deceleration]:
dEC 3.0
Deceleration time (s)
SEt- [Low speed]:
LSP 0.0
[SETTINGS] Motor frequency at minimum reference (Hz)
[High speed]:
HSP 50.0
Motor frequency at maximum reference (Hz)
[Mot. therm. current]:
ItH drive rating
Nominal current indicated on the motor's rating plate (A)
I-O- [Reverse assign.]:
rrS LI2
[INPUTS / OUTPUTS CFG] Reverse assignment
[2 preset speeds]:
PS2 LI3
Fun-> PSS- Preset speeds
[PRESET SPEEDS] [4 preset speeds]:
PS4 LI4
Preset speeds
Fun-> SAI- [Summing ref. 2]
SA2 AI2
[SUMMING INPUTS] Analog input
9 Set control choice

Menu Code Description 5.1 [REMOTE configuration] 5.2 [LOCAL configuration] Customer Setting
CtL- [Ref.1 channel]:
Fr1 Al1, Al2, Al3 AlU1
[COMMAND] Reference control
I-O- [2/3 wire control]: 2C: 2-wire
tCC LOC
[INPUTS / OUTPUTS CFG] Command control 3C: 3-wire
9.1 [REMOTE configuration] 9.2 [LOCAL configuration]

(Configuration factory setting)
MODE
3s
LOC rdY
Parameters factory settings:
Fr1 = AI1 Parameters factory settings:
tCC = 2C Fr1 = AIU1
tCC = LOC
rrS = LI2
PS2 = LI3 35.
1
PS4 = LI4
[Output frequency] (Hz)
10 Start the motor

Menus structure
= ENT MODE
ESC
3s LOC 2s
rdY rdY
rEN
These 3 parameters are MODE
only visible at first power up ESC ENT
of the drive. bFr 3s

Settings can be changed
35. [Output frequency] (Hz)
subsequently in menu: Fr1
drC- for bFr
CtL- for Fr1
I-O- for tCC. tCC
MODE
[SPEED REFERENCE] rEF-
Parameter selection
[SETTINGS] SEt-
[MOTOR CONTROL] drC-

= ENT
[INPUTS / OUTPUTS CFG] I-O-

ESC ESC Refer to the programming manual for
[COMMAND] CtL- SEt- ACC 15. comprehensive menu description.
ENT ENT
FUn- ESC
[APPLICATION FUNCT.] dEC 26. A dash appears after menu codes to
differentiate them from parameter codes.
[FAULT MANAGEMENT] FLt- ENT
Example:
[COMMUNICATION] COM- 26. [SETTINGS] (SEt-), ACC parameter.
SFr
[MONITORING] SUP- 1 flash
(save)
Short-circuit rating and branch circuit protection.

Enclosure
Input Output Branch
Voltage Containment Rating
withstand interrupt Circuit
Reference (Y) rating (3) (Z2)
rating (1) rating (X)(2) protection
(Type 1)
(Z1)
V KA KA KA A
Recommended fuse ratings for UL and CSA requirements. Components for use
ATV312H075M2 200-240 1 22 / Class J Fuse 15 together in accordance with standard UL508
ATV312HU11M2 200-240 1 22 / Class J Fuse 20
ATV312HU15M2 200-240 1 22 / Class J Fuse 20 Suitable For Use On A Circuit Capable Of Delivering Not More Than ___X____
ATV312HU22M2 200-240 1 22 / Class J Fuse 30 rms Symmetrical Amperes, ___Y____ Volts Maximum, When Protected by __Z
ATV312H018M3 200-240 5 22 22 Class J Fuse 3 1____ with a Maximum rating of__Z 2___.
(1) Input withstand rating is that for which the product has been designed
thermally. Installation on a supply greater than this level will require additional
inductance to satisfy this level.
ATV312HU30M3 200-240 5 22 22 Class J Fuse 25 (2) Output interrupt rating relies on Integral solid state short circuit protection.
ATV312HU40M3 200-240 5 22 22 Class J Fuse 35 This does not provide branch circuit protection. Branch circuit protection must
ATV312HU55M3 200-240 22 22 22 Class J Fuse 50 be provided in accordance with the National Electrical Code and any additional
ATV312HU75M3 200-240 22 22 22 Class J Fuse 60 local codes. This is dependant on the type of installation.
(3) Enclosure Containment Rating is the maximum input short-circuit current
at the drive input terminals with the specific branch Circuit Protection present
for which any internal component breakdown, will not create a shock, flame, fire
ATV312HU11N4 380-500 5 22 100 Class J Fuse 10 or expulsion hazard
ATV312H075S6 525-600 5 22 22 Class J Fuse 6

8391304036-37_BerliJucker_Katze
Characteristics
Reference ATV312HU22N4
Power 2.2 kW / 3 HP
Voltage 380/500V three phase
Hardware type Product on heatsink
Nominal current 5,5 A
Max. transient current 8,3 A
Structure
Card Reference Serial number Version or Program version Vendor name
Device ATV312HU22N4 XX X3 15 014 377 V5.1IE54 Schneider
Control Board XX Xf ff fff fff V5.1IE54 Schneider
HMI Board VX4A311/312(A) XX Xf ff fff fff V2.1IE07 Schneider
Configuration(s)
Name 8391304036-37_BerliJucker_Katze
Software release V5.1IE54

8391304036-37_BerliJucker_Katze
Device type ATV312
Reference ATV312HU22N4
Software release V5.1IE54
Configuration type Standard
Composition Control Board, HMI Board
Power 2.2 kW / 3 HP
Voltage 380/500V three phase
Hardware type Product on heatsink
Nominal current 5,5 A
Max. transient current 8,3 A
8391304036-37_BerliJucker_Katze 1/13 04.09.2013

Modified parameters
Minimum Maximum User
Code Short label Long label Current Value Default value
value value menu
ACC Acceleration Acceleration ramp time 0.1 s 3276.0 s 4.0 s 3.0 s -
Brake engage
BEN Brake engage frequency No Hz 5.0 Hz 0.2 Hz No Hz -
freq
Brake engage
BET Brake engage time 0.00 s 5.00 s 0.30 s 0.50 s -
time
Brake
BLC Brake logic assignment - - Relay R2 No -
assignment
BRA Dec ramp adapt. Decel ramp adaptation - - No Yes -
Brake release
BRL Brake release frequency 0.0 Hz 10.0 Hz 2.3 Hz 3.0 Hz -
freq.
Brake Release
BRT Brake release time 0.00 s 5.00 s 0.30 s 0.50 s -
time
Motor 1 Cosinus
COS Motor 1 Cosinus Phi 0.50 1.00 0.76 0.81 -
Phi
DEC Deceleration Deceleration ramp time 0.1 s 3276.0 s 4.0 s 3.0 s -
INC/DEC speed via
FR2 Ref.2 channel Configuration reference 2 - - Not assigned -
LI
FTD Freq. threshold Motor freq. threshold 0.0 Hz 500.0 Hz 15.0 Hz 50.0 Hz -
Brake release I
IBR Brake release current 0.0 A 7.4 A 5.2 A 5.1 A -
FW
ACCESS
LAC Level of access control - - Level 2 Level 1 -
LEVEL
Increase speed,Fault Select 2 preset
LI3A Config.LI3 Config. logic input 3 - - -
reset speeds
Reference 2 Select 4 preset
LI4A Config.LI4 Config. logic input 4 - - switching speeds -
LSP Low speed Low speed 0.0 Hz 50.0 Hz 5.0 Hz 0.0 Hz -
Rated mot.
NCR Nominal motor current 1.3 A 8.2 A 5.2 A 5.1 A -
current
Rated motor
NSP Nominal motor speed 0 rpm 32767 rpm 1410 rpm 1430 rpm -
speed
PS2 2 preset speeds 2 preset speeds assign. - - Not assigned Logic input LI3 -
PST Stop Key priority STOP key priority - - No Yes -
Freq. threshold
R1 R1 Assignment Relay ouput 1 assignment - - No drive flt -
reached
Brake control
R2 R2 Assignment Relay ouput 2 assignment - - Not assigned -
command
RFC Ref. 2 switching Select switching (1 to 2) - - Logic input LI4 Command ch = ch 1 -
RPT Ramp type Type of reference ramp - - S-Ramp Linear ramp -
RSF Fault reset Fault reset input assign. - - Logic input LI3 Not assigned -
U/F mot 1 Selection of the type of Cst. torque mot. SVC for const.
UFT - - -
selected voltage/frequency ratio motor 1 parallel appli.
+ speed
USP Increase spd input assign - - Logic input LI3 Not assigned -
assignment
User menu
value value menu
Output Phase
OPL Output phase loss - - OPF fault OPF fault 1
Loss
Fast settings
value value menu

Standard mot.
BFR Std. motor frequency - - 50Hz IEC 50Hz IEC -
freq
HSP High speed High Speed 5.0 Hz 60.0 Hz 50.0 Hz 50.0 Hz -
Mot. therm.
ITH Motor thermal current 1.1 A 8.2 A 5.5 A 5.5 A -
current
Inputs summary
value value menu
Configuration Configuration
AI1A AI1 assignment AI1 assignment - - -
reference 1 reference 1
Summing reference Summing reference
AI2A AI2 assignment AI2 assignment - - -
2 2
AI3A AI3 assignment AI3 assignment - - Not assigned Not assigned -
Forward direction Forward direction
select select
LI2A Config.LI2 Config. logic input 2 - - Reverse direction Reverse direction -
Increase speed,Fault Select 2 preset
reset speeds
Reference 2 Select 4 preset
switching speeds
LI5A Config.LI5 Config. logic input 5 - - Not assigned Not assigned -
LI6A Config.LI6 Config. logic input 6 - - Not assigned Not assigned -
ADJUSTMENTS
Accel / Decel
value value menu
BRA Dec ramp adapt. Decel ramp adaptation - - No Yes -
Frequency range
value value menu
HSP High speed High Speed 5.0 Hz 60.0 Hz 50.0 Hz 50.0 Hz -
JF2 Skip Frequency 2 Skip frequency 2 0.0 Hz 500.0 Hz 0.0 Hz 0.0 Hz -
JPF Skip Frequency Skip frequency 0.0 Hz 500.0 Hz 0.0 Hz 0.0 Hz -
TFR Max frequency Max. output frequency 10.0 Hz 500.0 Hz 60.0 Hz 60.0 Hz -
Low speed time
TLS Low speed time out 0.0 s 999.9 s 0.0 s 0.0 s -
out
Thermal protection
value value menu
Mot. therm.
ITH Motor thermal current 1.1 A 8.2 A 5.5 A 5.5 A -
current
Optimisation
value value menu
UFR IR compensation IR compensation 0% 100 % 20 % 20 % -
U/F mot 1 Selection of the type of Cst. torque mot. SVC for const.
UFT - - -
selected voltage/frequency ratio motor 1 parallel appli.
Speed loop
value value menu
SRF Speed loop filter Speed loop filter - - No No -
Detection Threshold
value value menu
CTD Current threshold Motor current detection 0.0 A 8.2 A 5.5 A 5.5 A -
FTD Freq. threshold Motor freq. threshold 0.0 Hz 500.0 Hz 15.0 Hz 50.0 Hz -
Motor therm.
TTD Motor thermal threshold 0% 118 % 100 % 100 % -
level
MOTOR CONTROL
Motor characteristics
value value menu
Motor 1 Cosinus
COS Motor 1 Cosinus Phi 0.50 1.00 0.76 0.81 -
Phi
Rated motor
FRS Nominal motor frequency 10.0 Hz 500.0 Hz 50.0 Hz 50.0 Hz -
freq.
Rated mot.
NCR Nominal motor current 1.3 A 8.2 A 5.2 A 5.1 A -
current
Rated motor
NSP Nominal motor speed 0 rpm 32767 rpm 1410 rpm 1430 rpm -
speed
65535
RSC Cold stator resist. Cold state stator resist. No mOhm No mOhm No mOhm -
mOhm
TUN Auto tuning Automatic tuning - - Not assigned Not assigned -
UNS Rated motor volt. Nominal motor voltage 100 V 500 V 400 V 400 V -
Switching mode
value value menu
Standard mot.
BFR Std. motor frequency - - 50Hz IEC 50Hz IEC -
freq
NRD Noise reduction Motor noise reduction - - Yes Yes -

SFR Switching freq. Drive switching freq. 2.0 kHz 16.0 kHz 4.0 kHz 4.0 kHz -
Speed scale
value value menu
Scale factor
SDS Customer scale factor 0.1 200.0 30.0 30.0 -
display
TERMINAL CONFIGURATION
Inputs / Outputs
value value menu
AI in current AI in current
AO1T AO1 Type Configuration of AO1 - - -
selected selected
Macro
CFG Macro config selection - - Factory settings Factory settings -
configuration
CRH3 AI3 max. value AI3 maximum value 4.0 mA 20.0 mA 20.0 mA 20.0 mA -
CRL3 AI3 min. value AI3 minimum value 0.0 mA 20.0 mA 4.0 mA 4.0 mA -
Analog./logic
DO Analog./logic output - - Not assigned Not assigned -
output
Freq. threshold
R1 R1 Assignment Relay ouput 1 assignment - - No drive flt -
reached
Brake control
R2 R2 Assignment Relay ouput 2 assignment - - Not assigned -
command
RRS Reverse assign. Reverse input assignment - - Logic input LI2 Logic input LI2 -
TCC 2/3 wire control 2 / 3 wire control - - 2-wire control 2-wire control -
TCT 2 wire type Type of 2 wire control - - Edge triggered Edge triggered -
CONTROL COMMAND

Control command
value value menu
FR1 Ref.1 channel Configuration reference 1 - - Analog input AI1 Analog input AI1 -
INC/DEC speed via
FR2 Ref.2 channel Configuration reference 2 - - Not assigned -
LI
ACCESS
LAC Level of access control - - Level 2 Level 1 -
LEVEL
LCC HMI command Remote terminal control - - No No -
PST Stop Key priority STOP key priority - - No Yes -
RFC Ref. 2 switching Select switching (1 to 2) - - Logic input LI4 Command ch = ch 1 -
APPLICATION FUNCTIONS
Summing inputs
value value menu
SA2 Summing ref. 2 Summing input 2 - - Analog input AI2 Analog input AI2 -
SA3 Summing ref. 3 Summing input 3 - - Not assigned Not assigned -
JOG
value value menu
JOG JOG Jog assignment - - Not assigned Not assigned -
Ramps configuration
value value menu
FRT Ramp 2 Ramp 2 freq. threshold 0.0 Hz 500.0 Hz 0.0 Hz 0.0 Hz -
threshold
INR Ramp increment Ramp increment - - tenths of seconds tenths of seconds -
RPS Ramp switch ass. Ramp switching input - - Not assigned Not assigned -
RPT Ramp type Type of reference ramp - - S-Ramp Linear ramp -
Current limitation
value value menu
Current
CLI Internal current limit 1.3 A 8.2 A 8.2 A 8.2 A -
Limitation
LC2 Current limit 2 I limit 2 input assign. - - Not assigned Not assigned -
Preset speeds choice
value value menu
PS16 16 preset speeds 16 preset speeds assign. - - Not assigned Not assigned -
PS8 8 preset speeds 8 preset speeds assign. - - Not assigned Not assigned -
DC injection
value value menu
Auto DC
ADC Automatic DC injection - - No injection No injection -
injection
PI regulator
value value menu
PID feedback
PIF PI fdbk assignment - - Not assigned Not assigned -
ass.
+/- speed
Code Short label Long label value value Current Value Default value menu
-Speed
DSP Down spd input assign. - - Not assigned Not assigned -
assignment
STR Reference saved Freq. reference stored - - No save No save -
+ speed
USP Increase spd input assign - - Logic input LI3 Not assigned -
assignment
Brake sequence
value value menu
Brake engage
BEN Brake engage frequency No Hz 5.0 Hz 0.2 Hz No Hz -
freq
Brake engage
BET Brake engage time 0.00 s 5.00 s 0.30 s 0.50 s -
time
BIP Brake impulse Brake release pulse - - No No -
Brake
BLC Brake logic assignment - - Relay R2 No -
assignment
Brake release
BRL Brake release frequency 0.0 Hz 10.0 Hz 2.3 Hz 3.0 Hz -
freq.
Brake Release
BRT Brake release time 0.00 s 5.00 s 0.30 s 0.50 s -
time
Brake release I
IBR Brake release current 0.0 A 7.4 A 5.2 A 5.1 A -
FW
Stop type
value value menu
DC injection
DCI DC brake via logic input - - Not assigned Not assigned -
assign.
FST Fast stop assign. Fast stop input assign. - - Not assigned Not assigned -
NST Freewheel stop input - - Not assigned Not assigned -
Freewheel stop
ass.
STT Type of stop Normal stop mode - - Stop on decel. ramp Stop on decel. ramp -
Motor 2
value value menu
CHP Motor switching Motor switching - - Not assigned Not assigned -
Manage limit switches
value value menu
Stop FW limit
LAF FW stop limit assignment - - Not assigned Not assigned -
sw.
Stop RV limit
LAR RV stop limit assignment - - Not assigned Not assigned -
sw.
FAULT MANAGEMENT
Fault behaviour
value value menu
ATR Automatic restart Automatic restart - - No No -
Derated
DRN Derated operation - - No No -
operation
External fault
ETF External fault input - - Not assigned Not assigned -
ass.
FLR Catch on the fly Catch a spinning load - - No No -
RP Product reset Product reset - - No No -
RSF Fault reset Fault reset input assign. - - Logic input LI3 Not assigned -
UnderV. Freewheel stop with Freewheel stop with
STP Ctrld stop on power loss - - -
prevention fault fault
Fault validation
value value menu
Fault inhibit
INH Fault inhibit input - - Not assigned Not assigned -
assign.
IPL Input phase loss Stop type - I/P phase loss - - Yes Yes -
Output Phase
OPL Output phase loss - - OPF fault OPF fault 1
Loss
Stop on fault mode
value value menu
CANopen fault Freewheel stop on Freewheel stop on
COL Stop type - CANopen fault - - -
mgt fault fault
External fault Freewheel stop on Freewheel stop on
EPL Stop type - external fault - - -
mgt fault fault
LFF Fallback speed Fall back speed 0.0 Hz 500.0 Hz 10.0 Hz 10.0 Hz -
LFL 4-20mA loss 4-20mA loss - - Ignore phase loss Ignore phase loss -
Overtemp fault Freewheel stop on Freewheel stop on
OHL Stop type - drive o/temp - - -
mgt fault fault
Overload fault Freewheel stop on Freewheel stop on
OLL Stop type - motor o/load - - -
mgt fault fault
Modbus fault Freewheel stop on Freewheel stop on
SLL Stop type - Modbus SLF - - -
mgt fault fault
Autotune fault
TNL Auto-tuning fault config. - - Yes Yes -
mgt
COMMUNICATION
Communication
value value menu

CANopen
ADCO Drive CANopen address 0 127 0 0 -
address
ADD Modbus Address Drive modbus address 1 247 1 1 -
CANopen bit
BDCO CANopen baudrate - - 125 kbps 125 kbps -
rate
ERCO Error code Error code CANopen 0 4 0 0 -
Forced local
FLO Forced local mode assign - - Not assigned Not assigned -
assign.
Modbus baud
TBR Modbus baud rate - - 19.2 Kbps 19.2 Kbps -
rate
TFO Modbus format Modbus com format - - 8-E-1 8-E-1 -
TTO Modbus time out Modbus time out 0.1 s 10.0 s 10.0 s 10.0 s -

0 1 2 3 4 5 6 7 8 9
F26_002_Kuli
42805 Remscheid
Bismarckstr. 59
Helmut Kempkes GmbH Phone. +49 (02191) -434-0
Fax +49 (02191) -434-45
e-mail Technik@kuli.com
Customer Berli Jucker PCL end customer

Street 99 Soi Rubia, Sukhumvit 42 Road Street
ZIP code / City 10110 BANGKOK ZIP code / City
Phone Phone
Fax Fax
e-mail e-mail
Project name 839.13.04.036_37_BerliJucker_ Place of installation

Manufacturer (company) Helmut Kempkes GmbH
Job number Kr45132931-3
make RS ZE Z 5320 L4 F45 So+F X 3100L4 F45
Project description Components f. DOG Crane Part feature RAL
Commission 829.13.04.036/37 input lead local
Responsible for project power supply 400 V AC, Prefuse max. 100A
Created on 2013 control voltage 48V
Project end Type Kuli-Double Girder Crane
Edit date 27.08.2013 environmental consideration Hallenbetrieb
by (short name) Regulation IEC 60204-32
degree of protection IP 54
Number of pages 9 Enclosures
2
Date 18.07.2013 829.13.04.036/37 Deckblatt =A
Helmut Kempkes GmbH
Ed. HG + GK
Appr Components f. DOG Crane Kr45132931-3 Page 1
Modification Date Name Original Replacement of Replaced by Page 9
0 1 2 3 4 5 6 7 8 9
+Kr
-0.L.1 / 5.0 -X10 10 -X01 10
2.1 / 4.3
-0.L.2 / 5.0 -X10 10

3/
-0.L.3 / 5.0 8/ 6 / 7.0
13
-Q01
/2.7 14
2 / 4.0
-X10 01
-X03 1
1
-F03 9 9
1.6 A 2 +EZ-S11 +EZ-S12
-X02 1 10 10
3 4
local 01 12 12
-T01 +PND-S01 +EZ-S11 +EZ-S12
400/48V Emergency stop 02 11 11
250VA 1 2
1 1
-F01 -F02
1 3 5 1.6 A 2 1.6 A 2 -X02 3
-Q01
/2.7 2 4 6
-W6 -W26
1 local
16 16 16
PE V / 2.9
-X03 3
-X10 03 -X01 3 31 31 32 20 20
-X10 03
+Kr
-X10 33
local
A1
-Q01
A2 Main contactor
-X01:L1 L2 L3 PE
-X10 20 -X10 20 20
V / 2.9
LC1D80E7
1 2
/2.0 3 4
/2.0 5 6
1 3 5 /2.2 13 14
-S100 21 22
2 4 6 /2.0 1 2
Vorsicherung max. 100A
1 3
Date 27.08.2013 829.13.04.036/37 Einspeisung =A
Helmut Kempkes GmbH
Ed. HG + GK
0 1 2 3 4 5 6 7 8 9
+Kr 3.9 / 2 2 / 3.0
33 13 21 11 01
-S02 -S10
34 14 22 Preselection 12 02
Main- /Auxiliary Hoist
34 14 21
-S03
33 13 22
local
+EZ-X02 6 7 8 9 17 18
local
6 7 8 9 4 4
+Kr-X10 6 7 8 9 17 18
+Kr-X10 6 7 8 9 17 18
-W02
6 7 8 9 4 4
-X01 6 7 8 9 -X01 17 -X01 18
13 23 33 43 13 23 33 43
-K09 -K09 -K09 -K09 -K10 -K10 -K10 -K10
/3.6 14 /3.6 24 /3.6 34 /3.6 44 /3.7 14 /3.7 24 /3.7 34 /3.7 44
A1 A1
A B C D E F G H
4.1 4.1 4.2 4.3 4.6 4.6 4.7 4.7 -K09 -K10
Main Hoist A2 Auxiliary Hoist A2
3.9 / v v / 3.5
13 14 /3.0 13 14 /3.3
23 24 /3.1 23 24 /3.4
33 34 /3.2 33 34 /3.4
43 44 /3.2 43 44 /3.5
2 4
Date 27.08.2013 829.13.04.036/37 Hub-Ansteuerung =A
Helmut Kempkes GmbH
Ed. HG + GK
0 1 2 3 4 5 6 7 8 9
2 / 2.9 2 / 6.0
3.0 3.1 3.2 3.2 3.3 3.4 3.4 3.5

A B C D E F G H
-X01 6.1 7.1 8.1 9.1 -X01 6.3 7.3 8.3 9.3
2.9 / 2.1
-X01 10 -X01 10
+EZ1 +EZ2
7 9 7 9
6 6 8 8 6 6 8 8
F11 -F12 11 F13 -F14 11

+EZ1-S13 +EZ2-S14
Overload 12 Overload 12
7 5 3 1 7 5 3 1
-S11 -S12
8 6 4 2 8 6 4 2
-X01 6.2 7.2 8.2 9.2 -X01 41 -X01 6.4 7.4 8.4 9.4 -X01 42
16 18 26 28 16 18 16 18 26 28 16 18
-KT1 -KT1 -K81 -KT2 -KT2 -K82
/4.4 15 /4.4 25 /4.4 15 /4.8 15 /4.8 25 /4.9 15
22 22 61 22 22 61
-K01 -K02 -K02 -K05 -K06 -K06
/4.1 21 /4.1 21 /4.1 62 /4.5 21 /4.6 21 /4.6 62
A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1
-K01 -K02 -K03 -K04 -KT1 -K81 -K05 -K06 -K07 -K08 -KT2 -K82
Mainhoist A2 Main Lower A2 Micro Hoist A2 Micro Lower A2 A2 A2 Mainhoist A2 Main Lower A2 Micro Hoist A2 Micro Lower A2 A2 A2
6.2/ v / 6.0
1 2 /5.1 1 2 /5.2 1 2 /5.3 1 2 /5.4 1 2 /5.6 1 2 /5.7 1 2 /5.8 1 2 /5.9

18 18 18 18
3 4 /5.1 3 4 /5.2 3 4 /5.3 3 4 /5.4 15 /4.0 15 /4.2 3 4 /5.6 3 4 /5.7 3 4 /5.8 3 4 /5.9 15 /4.5 15 /4.7
16 16 16 16
5 6 /5.2 5 6 /5.3 5 6 /5.3 5 6 /5.4 5 6 /5.7 5 6 /5.8 5 6 /5.8 5 6 /5.9
13 14 13 14 13 14 13 14 28 13 14 13 14 13 14 13 14 28
25 /4.2 25 /4.6
26 26
22 21 /4.2 22 21 /4.2 21 22 21 22 22 21 /4.6 22 21 /4.7 21 22 21 22
53 54 /5.0 61 62 /4.4 53 54 /5.0 53 54 /5.1 53 54 /5.5 61 62 /4.9 53 54 /5.5 53 54 /5.6
64 63 /5.0 73 74 /5.0 64 63 /5.0 64 63 /5.1 64 63 /5.5 73 74 /5.5 64 63 /5.5 64 63 /5.6
84 83 /5.0 84 83 /5.5
3 5
Date 27.08.2013 829.13.04.036/37 =A
Helmut Kempkes GmbH
Ed. HG + GK
0 1 2 3 4 5 6 7 8 9
Kr 2.1 / -0.L.1
-X10 1L1 -X01 1L1
1.L.1 / 6.4
2.1 / -0.L.2
-X10 1L2 -X01 1L2
1.L.2 / 6.4
2.1 / -0.L.3
-X10 1L3 -X01 1L3
1.L.3 / 6.4
1 3 5 1 3 5 1 3 5 1 3 5
-F04 -F05 -F06 -F07
50 A 25 A 32 A 20 A
2 4 6 2 4 6 2 4 6 2 4 6
Micro Hoist Micro Hoist Mainhoist Micro Hoist
1 3 5 1 3 5 1 3 5 1 3 5 1 3 5 1 3 5 1 3 5 1 3 5
-K01 -K02 -K03 -K04 -K05 -K06 -K07 -K08
/4.1 2 4 6 /4.1 2 4 6 /4.2 2 4 6 /4.2 2 4 6 /4.5 2 4 6 /4.6 2 4 6 /4.6 2 4 6 /4.7 2 4 6
-X01 2U 2V 2W PE -X01 PE 1U 1V 1W -X01 2U 2V 2W PE -X01 PE 1U 1V 1W
53 73 53 53 53 73 53 53
-K01 -K02 -K03 -K04 -K05 -K06 -K07 -K08
/4.1 54/4.1 74/4.2 54/4.2 54 /4.5 54/4.6 74/4.6 54/4.7 54
64 84 64 64 64 84 64 64
-K01 -K02 -K03 -K04 -K05 -K06 -K07 -K08
/4.1 63/4.1 83/4.2 63/4.2 63 /4.5 63/4.6 83/4.6 63/4.7 63
+EZ-M01 +EZ-M02
-X01 50 51 -X01 52 53
A1 A1
+EZ-Y01
M +EZ-Y02
M
A2 3~ A2 3~
15.5/3.8 KW 9,6/2,4 KW
8 8 6 6 -II- -II--II- -II- K K Y1 Y2 ~ ~ ~ ~ 8 8 6 6 -II- -II--II- -II- K K Y1 Y2 ~ ~ ~ ~
+EZ-UM01 +EZ-UM02
Brake Card Brake Card
4 6
Date 27.08.2013 829.13.04.036/37 Main-/Auxil.Hoist =A
Helmut Kempkes GmbH
Ed. HG + GK
0 1 2 3 4 5 6 7 8 9
4.9 / 2 /4.0 5.9 / 1.L.1

5.9 / 1.L.2
ND 13 21 33 5.9 / 1.L.3
-S04
right 14 22 34
1 3 5
-F09
22 14 34 10 A
2 4 6
-S05 Cross Travel Motor
left 21 13 33
local
6.2 / 5_ 5 / 6.2
13 1 3 5
-Q30 -K30
/6.8 14 /7.0 2 4 6
+Kr-X10 11 12 05 -R30
+Kr-X10 11 12 05
-X01-M04/5 T1
13 1/L1 3/L2 5/L3 13
-X01-M04/5 T2 12 11
-K30 -Q30
6.8 / 5 5_ / 6.7 /7.0 14 1-1,6A 14
L1 L2 L3 x1 x2 1.1A
I> I>
/6.4
I>
13 13 13 13 -L30 2/T1 4/T2 6/T3
-X01 11 12 05 10 -K14 -K13 -K12 -K11 Net Choke Coil
L1` L2` L3`
/6.2 14 /6.1 14 /6.1 14 /6.0 14
-X01-M03/4 PA PB
-A30
Altivar 312HU22 24V L1 L2 L3 PA PB R1A R2A
1 3 5
ws br grn ge 2,2kW, 5.5A PE
Cross Travel -K37
local /6.7 2 4 6
+EZ LI1
Frequency Converter
11 11A LI2
-S30 LI3
12 12A LI4
U V W R1C R2C
PE PE
A=>Anschlussquerschnitt
48V
PE
-X01 54 55 A1 A1
-K38 -K37
23 23 X01-M04/5 U1 V1 W1 PE PE A2 A2 -X01-M04/5 163 164
-K11 -K12 6.2 / v v / 7.0
/6.0 24 /6.1 24 13 14 1 2 /6.8
8 21 22 /7.0 3 4 /6.8 81
31 32 5 6 /6.9
43 44 13 14 /7.3
21 22
.. ..
A1 A1 A1 A1 +EZ
-K11 -K12 -K13 -K14
48V A2 48V A2 48V A2 48V A2
4.9 / v v / 6.7
13 14 /6.4 13 14 /6.4 13 14 /6.4 13 14 /6.3
23 24 /6.2 23 24 /6.2 23 24 23 24
33 34 /7.2 33 34 /7.2 33 34 33 34
43 44 43 44 43 44 43 44
-UM04 W1 V1 -UM05 W1 V1
U1 V1 W1 PE U1 V1 W1 PE
- + - +
A1 A1
-Y04
M -Y05
M
right left fast fast/slow A2
3 A2
3
-M04 -M05
1.0 KW 1.0 KW
5 7
Date 27.08.2013 829.13.04.036/37 Cross Travel =A
Helmut Kempkes GmbH
Ed. HG + GK
0 1 2 3 4 5 6 7 8 9
2.9 / 6
230V
X10-100 /
-X01 100
13
-K37
/6.7 14
-X01 153
21 16 18 33 33 +EZ
-K38 -K39 -K11 -K12
/6.7 22 /7.2 15 /6.0 34 /6.1 34 U1 U1
-M41
M -M51
M
1~ 1~
53 V1 V1
-K30
/7.0 54
A1 A1 -X01 20
-K30 -K39
Line Contacor A2 0.5-3 sec A2
6.8 / v Cross-Travel
1 2 /6.5
18 15 /7.1
3 4 /6.6 16
5 6 /6.6
13 14 /6.7
21 22
53 54 /7.0
6 8
Date 27.08.2013 829.13.04.036/37 Control Frequency =A
Helmut Kempkes GmbH
Ed. HG + GK
0 1 2 3 4 5 6 7 8 9
Parts list F01_001_FT
device tag Quantity designation Type number supplier Path function text
0
-A30 0
-A30 1 Frequency Converter ATV312HU22N4 Schneider Electric Frequency Converter
+EZ1-F11 1 Thermistor S01.170.05.600 THERMIK
-F04 1 Miniature circuit-breaker EP63 C50 AEG Micro Hoist
-F05 1 Miniature circuit-breaker EP63 C25 AEG =
-F06 1 Miniature circuit-breaker EP63 C32 AEG Mainhoist
-F07 1 Miniature circuit-breaker EP63 C20 AEG Micro Hoist
-F09 1 Miniature circuit-breaker EP63 C10 AEG Cross Travel Motor
+Kr-F01 0 Fuse 6.3*32mm, 1.6A ISMET
+Kr-F02 0 Fuse 6.3*32mm, 1.6A ISMET
+Kr-F03 0 Fuse 5*20mm, 1.6A ISMET
-K01 1 Contactor LC1D50AE7 Schneider Electric Mainhoist
-K02 1 Contactor LC1D50AE7 Schneider Electric Main Lower
-K03 1 Contactor LC1D25E7 Schneider Electric Micro Hoist
-K04 1 Contactor LC1D25E7 Schneider Electric Micro Lower
-K05 1 Contactor LC1D25E7 Schneider Electric Mainhoist
-K06 1 Contactor LC1D25E7 Schneider Electric Main Lower
-K07 1 Contactor LC1D18E7 Schneider Electric Micro Hoist
-K08 1 Contactor LC1D18E7 Schneider Electric Micro Lower
-K09 1 Auxiliary contactor CA2KN40E7 Schneider Electric
-K11 1 Auxiliary contactor CA2KN40E7 Schneider Electric right
-K12 1 Auxiliary contactor CA2KN40E7 Schneider Electric left
-K13 1 Auxiliary contactor CA2KN40E7 Schneider Electric fast
-K30 1 Contactor LC1D09E7 Schneider Electric Line Contacor Cross-Travel
-K37 1 Contactor LC1D09E7 Schneider Electric
-K39 1 Timer IK 7819,81 DOLD
-KT1 1 Timer IK 7825,82 DOLD
-KT2 1 Timer IK 7825,82 DOLD
-L30 1 Reactor VW3SKLN006H010 Schneider Electric Net Choke Coil
+EZ-M01 1 Squirrel-cage motor 180-240-410 Kempkes
+EZ-M02 1 Squirrel-cage motor 160-240-420L Kempkes
+EZ-M41 1 Fan 7856 ES PAPST
+EZ-M51 1 Fan 7856 ES PAPST =
-Q30 1 Motor overload switch GV2ME06 Schneider Electric 1-1,6A 1.1A
+Kr-Q01 0 Contactor LC1D80E7 Schneider Electric Main contactor
-R30 1 Brake Resistor VW3SKR056W00400A Schneider Electric
+EZ-S30 0 Limit switch - Crane XCR-F17 Schneider Cross Travel
+EZ1-S11 1 Main-/Micro Hoist Switch CG8 D-9873*01 E-V Kraus & Naimer
+EZ1-S13 1 Limit switch, Overload D-A1Z STW BERNSTEIN Overload
+EZ2-S12 1 Main-/Micro Hoist Switch CG8 D-9873*01 E-V Kraus & Naimer
+EZ2-S14 1 Limit switch, Overload D-A1Z STW BERNSTEIN Overload
-S04 0 Complete device, round, pushbutton XAC-9411/XEN-G1191 Schneider right
-S05 0 Complete device, round, pushbutton XAC-9412/XEN-G1191 Schneider left
-S100 0 Main / Emergency stop switch VBF-6GE Schneider
+Kr-S02 0 Complete device, round, pushbutton XAC-9411/XEN-G1191 Schneider
7 9
Date 26.07.2013 829.13.04.036/37 Parts list : - =A
Helmut Kempkes GmbH
Ed. HG
SCHN.XAC-9411/XEN-G1191 + GK
0 1 2 3 4 5 6 7 8 9
Parts list F01_001_FT
device tag Quantity designation Type number supplier Path function text
+Kr-S03 0 Complete device, round, pushbutton XAC-9412/XEN-G1191 Schneider

+Kr-S10 0 ZB2-BE102 Schneider Preselection Main- /Auxiliary Hoist
+PND-S01 0 Mushroom pushbutton ZA2-BS54 / ZB2-BE102 Schneider Emergency stop
+Kr-T01 0 Transformer MTDN 250/400/48 ISMET 400/48V 250VA
+EZ-UM01 1 Rectificador Main-/Micro Hoist 119.11.252 KEMPKES
+EZ-UM02 1 Rectificador Main-/Micro Hoist 119.11.252 KEMPKES =
+EZ-UM04 1 Rectifier Travel 119.10.153 KEMPKES
+EZ-UM05 1 Rectifier Travel 119.10.153 KEMPKES
+EZ-Y01 1 Electromagnetic brake FDB 30N D0 PRECIMA
+EZ-Y02 1 Electromagnetic brake BFK 458-18N LENZE
+EZ-Y04 1 Electromagnetic brake 458-08E LENZE
+EZ-Y05 1 Electromagnetic brake 458-08E LENZE
8
Date 26.07.2013 829.13.04.036/37 Parts list : SCHN.XAC-9412/XEN-G1191 =A
Helmut Kempkes GmbH
Ed. HG
- Len BFK 458-08E + GK

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Documentation

Client : Berli Jucker

Type Motor-No. kW poles IN A % DC s/h

Main hoist motor 1 180.240.410 1307450 15,5/3,8 4/ 16 33,2/ 18,5 30 180

D-42805 Remscheid, 07.08.2013

Te 02191 / 434- 0 Postf 100562

Translation of the original version of Maintenance and Operating instructions

HELMUT KEMPKES GmbH 02/2012 2

Acc. to § 25 BGV D6 " Rules for prevention from accidents with

Authorized Experts (acc. to BGV D6)

Exemption from liability

HELMUT KEMPKES GmbH 02/2012 3

3 Selection of operating people

HELMUT KEMPKES GmbH 02/2012 4

2.Planetary gearbox 2 – steps for sizes 1 to 3

Figure 4.1: KULI-Electric hoist

HELMUT KEMPKES GmbH 02/2012 5

5 Load Spectrometer Type LSM with Electronical Lifting Force

5.1.2 Proportional amplifier

5.1.3 Signalling line

5.1.4 Load spectrometer Type LSM

5.2 Functions of the LSM

HELMUT KEMPKES GmbH 02/2012 6

5.3 Screens in integrated LC-display

The following displays must be activated by pressing the Menu – button:

5.4 Extraordinary status messages in the LC-display

HELMUT KEMPKES GmbH 02/2012 7

5.5 Clamp plan LSM 100

X3: Measuring input winding temperature Motor 2 X8: Overload

X4: Connection measuring pin 1 X9: Load / Nominal load

HELMUT KEMPKES GmbH 02/2012 8

6 Adjustment of the electro mechanical lifting force limiter

Switching point to be set

Figure 6.1: Electro-mechanical lifting force limiter

HELMUT KEMPKES GmbH 02/2012 9

Evident defects are e.g.:

In case of outdoor operation: If not agreed to the contrary, operation has to be

HELMUT KEMPKES GmbH 02/2012 10

10 After expiry of the theoretical duration of service

HELMUT KEMPKES GmbH 02/2012 11

HELMUT KEMPKES GmbH 02/2012 12

13.1 Equalizing sheave and rope anchor transverse bars

Equalizing sheave Anchor transverse bars

14 Maintenance and repair

HELMUT KEMPKES GmbH 02/2012 13

HELMUT KEMPKES GmbH 02/2012 14

Motortabelle / Table of Motors 50 Hz

Elektrozug Motor Nennstrom I N Nominal Current I N [A] Sicherung

HELMUT KEMPKES GmbH 02/2012 15

Figure 15.1 Terminal diagram for hoist motors size 1 to 5

HELMUT KEMPKES GmbH 02/2012 16

Figure 15.2: Terminal diagram for hoist motors size 6 to 9

Figure 15.3: Terminal diagram for brake control card

HELMUT KEMPKES GmbH 02/2012 17

Brake sizes 23, 26, 30 (double rotor brakes)

HELMUT KEMPKES GmbH 02/2012 18

Figure 16.1: Sectional drawing of hoist brake

HELMUT KEMPKES GmbH 02/2012 19

Gap Tightening Thickness

160.240.420L 18 0,4 1,0 23,0 10,0

HELMUT KEMPKES GmbH 02/2012 20

Rope d / mm 7.5 7.5 9.4 9.4 14 16 18 20 23 23 25

Dismantling of the rope