Tractel Dynasafe Mecha 3.2 Betriebsanleitung

Universele mechanische lastbegrenzer DynasafeTM

Mecha 3.2 & 7

Limitador de carga mecánico universal DynasafeTM

Mecha 3.2 & 7

Limitatore di carico meccanico universale

DynasafeTM Mecha 3.2 & 7

Universal mechanical load limiter DynasafeTM

Mecha 3.2 & 7

Limiteur de charge mécanique universel DynasafeTM

Mecha 3.2 & 7

Mechanischer Universal-Hubkraftbegrenzer

DynasafeTM Mecha 3.2 & 7

Dynasafe™ Mecha 3.2 & 7

Installation, operating and maintenance manual English Original manual EN

Manuel d’installation, utilisation et maintenance Français Traduction de la notice originale FR

Installations, Gebrauchs und Wartungsanleitung Deutsch Übersetzung der Originalanleitung DE

Handleiding voor installatie, gebruik en

onderhoud Nederlands Vertaling van de oorspronkelijke handleiding NL

Manual de instalación, de utilización y de

mantenimiento Español Traducción del manual original ES

Manuale d’installazione, d’impiego e di

manutenzione Italiano Traduzione del manuale originale IT

Figure, Abbildung, Figuur, Figura, Φιγούρα, Figur, Kuva, Figur, Rysunek, Рисунок

Fig. 1

1112

Fig. 2

Fig. 3

Fig. 4

1. General warning

1. For your safety and to ensure safe, e󰀩cient use

of the equipment described in this manual, make

sure you have carefully read this manual and

are perfectly familiar with the instructions given

before you install the load limiter. A copy of this

manual must be available at all times to equipment

operators. Additional copies can be supplied upon

request.

2. Do not use the load limiter if any label on the device

or any of its accessories are not clearly legible. Do

not use the load limiter if any markings, as indicated

at the end of this manual, are not clearly legible.

Identical labels can be supplied upon request and

must be fastened to the load limiter before you

continue to use the device.

3. Make sure that all persons who will be using

the load limiter are completely familiar with the

operating methods and the safety requirements

involved when using this device. This manual

must be available to all users of the device. Your

load limiter must only be used under controlled,

supervised conditions.

4. The load limiter covered by this manual must only

be installed and set into service under conditions

ensuring appropriate installer safety in compliance

with application regulations.

5. Each time, before using the load limiter, check that

the load limiter and its accessories are in visibly

good condition. Never use a device which is not in

visibly good condition. Return the load limiter to the

manufacturer for overhaul if any malfunctions are

observed.

6. Take all necessary steps to prevent shock or impact

to your load limiter.

7. The load limiter must never be used for any purpose

other than those described in this manual. Never

use the load limiter for a load exceeding the working

load limit indicated on the device. In its standard

version, the load limiter must never be used in an

explosive atmosphere.

8. The load limiter must not be used in a man-lifting

line without rst checking the utilisation factors

required to ensure the safety of persons, and more

generally, the applicable safety regulations for the

load line in which the device will be used.

9. Tractel® shall not be liable for any actions resulting

from use of this device in an installation conguration

not described in this manual.

10. Tractel® shall not be liable for any actions resulting

from unauthorised modications to the device or

removal of any parts from the device.

11. Tractel® shall not be liable from any actions

resulting from any disassembly operations or

repairs performed on the device without Tractel®

Contents

1. General warning ...................................................... 5

2. Denitions and pictograms ...................................... 6

2.1. Denitions ........................................................6

2.2. Pictograms .......................................................6

3. Description of load limiter DynasafeTM

Mecha 3.2 & 7........................................................6

3.1. Presentation.....................................................6

3.2. Operating principle...........................................6

3.3. Marking ............................................................7

3.4. Technical specications....................................7

3.5. Designation, characteristics and outline

dimensions.......................................................8

4. Installation of load limiter DynasafeTM

Mecha 3.2 & 7........................................................8

4.1. Parts list of load limiter and its environment.....8

4.2. Installing the load limiter on the wire rope........9

4.3. Load limiter electrical connection.....................9

4.4. Connection diagram.........................................9

5. Threshold adjustment..............................................9

5.1. Factory preset load limiters............................10

5.2. Adjustment of a safety threshold....................10

5.3. Adjustment of a safety threshold and an

intermediate threshold ...................................10

5.4. Adjustment of a safety threshold and a

“Wire rope slack” threshold............................10

6. Maintenance and periodic verication ................... 11

7. Prohibited uses...................................................... 11

8. Declaration of conformity....................................... 11

9. Transport and storage ........................................... 11

10. Product disposal and environmental protection... 11

11. Regulations and standards..................................12

delivered into a state of commissioning (or connection

to other elements for commissioning).

“Supervisor”: Individual or party responsible for the

management and safe use of the product described in

the manual.

“Technician”: Qualied person familiar with the

product, in charge of the maintenance operations

described and permitted in the manual.

“Operator”: Individual using the product in accordance

with the instructions in this manual

2.2. Pictograms

“DANGER”: When placed at the beginning of

a paragraph, it indicates instructions for preventing

injuries ranging from minor to fatal and also

environmental damage.

“IMPORTANT”: When placed at the beginning

of a paragraph, it indicates instructions for preventing

product failure or damage which would not directly

endanger the life or health of operators or other

individuals and/or which may harm the environment.

“NB”: When placed at the beginning of a

paragraph, it indicates the necessary precautions to

apply for e󰀩cient and ergonomic installation, use and

maintenance.

: When placed on the product itself or a product

component, it indicates the need to read the operating

and maintenance manual.

authorisation, especially as concerns replacement

of genuine spare parts by parts from another

source.

12. For denitive removal from service of the device,

the device must be scrapped under conditions

preventing re-use of the device. All environment

protection regulations must be observed.

13. Before using this device with complementary

equipment relaying its signals on an operating

system, the user or installer must rst ensure that

an analysis has been carried out to determine the

specic risks involved in the operating conguration

implemented, and all appropriate safety measures

must be taken accordingly.

14. The load limiter covered by the manual satises

the requirements of the European regulations and

must be veried for compliance with the regulations

of any other country in which it may be used, prior

to commissioning and use. All applicable safety

regulations must be observed.

2. Denitions and pictograms

2.1. Denitions

In this manual, the following terms are dened as

follows:

“Product”: Item or equipment described in this manual

and delivered complete in the standard version, or in its

various existing models.

“Installation”: All the operations required to bring

the complete product from the state in which it was

3. Description of load limiter DynasafeTM Mecha 3.2 & 7

3.1. Presentation

The load limiter DynasafeTM Mecha 3.2 & 7 is a mechanical load limiter for wire ropes operating on the principle of a

potential-free contact which is tripped when the tension in the wire rope exceeds the preset limit.

This load limiter is specially designed to manage one or two safety thresholds on small and medium capacity

overhead travelling cranes.

3.2. Operating principle

The operating principle of DynasafeTM Mecha 3.2 & 7 is based on the deformation of the load limiter body through a

tangential force, which is proportional to the force exerted on the wire rope when pulled.

When the deformation of the load limiter body is above a limit, the integrated micro-switch opens.

The contact is automatically reset once the tension in the wire rope is below the set limit increased by a hysteresis

value depending of the e󰀨ort.

3.3. Marking

See gure 1.

1Adjustment screw and locknut for threshold 1

2Adjustment screw and locknut for threshold 2

3Option: factory setting parameters for threshold 1

4Option: factory setting parameters for threshold 2

5Protection index

6Microswitch interrupting capacity and voltage

7Device serial number

8Identication

9Symbol indicating «You must read the user manual»

10 QR Code leading to tracinfo, that contains CE certicate, present manual

11 Compatible wire rope diameters

12 Capacity on strand (working load limit)

All indications and labels a󰀩xed on the product by the manufacturer must be kept fully legible. If any

indications and labels are removed or damaged, they must be replaced before continuing to use the product.

Tractel® can supply new marking materials on request.

3.4. Technical specications

Mecha 3.2 Mecha 7

Installation Directly on idle strand

Repeatability 1% FS 2% FS

Measurement sensor 2 integrated micro switches

Directly on idle strand

Contact 2 : 1 NO, 1 NC

Category 1 (as EN ISO 13849-1)

Cut-out voltage 250 VAC

Cut-out intensity 2A max/inductive load

4A max/resistive load

Connection Electrical cable, 7 conductors

Electrical output Cable gland

Length of cord 2 meters

Calibration system By means of micrometer screws

Hysteresis Between 50 and 200 kg depending

on the e󰀨ort Between 200 and 1000 kg depending

on the e󰀨ort

Operating temperature -30° to +80°C

Protection degree IP67

Material Aerospace quality aluminium

Surface treatment Anodizing Body

Maintenance None

Technical Data of the Micro switches:

• Type: V4NST7-UL

• According: UL, CSA, ENEC

• Mechanical life: 5 x 106cycles minimum (impact free actuation)

Maximum electrical ratings:

Recommended Maximum Electrical Ratings

Voltage (max) Load (A) Inductive load (A) Approval

V4NT7/V4NST7-UL 250 VAC 5 (0.75 pf) UL1054/CSA 22.2 No. 55 - 6.000 operations - 65° C

250 VAC 5 2 EN61058-1, T85, 10.000 operations

0 - 15 VDC 5 3 General rating - 50.000 operations (85° C)

15 - 30 VDC 5 3 General rating - 50.000 operations (85° C)

Safety considerations:

This device can be set for 2 overload trigger points

which can be set separately. For a safety function each

of them is a single channel considered as a “well tried

component” by Tractel®.

For a safety device with single channel, PL level is

determined by MTTFD (mean time between dangerous

failure) emanating from B10D monitoring.

B10d:

According the technical data of the switch, the

life duration is determined by maximum switching

operations. Tractel®considers B is 10.000 operations

for switching inductive load of 2 A (eg: contactor coil).

NOTE: B10d

can be better if the inductive load

is reduced.

MTTFD:

MTTFD must be evaluated by the integrator using the

formulas and diagrams of the standard EN ISO 13849-1

considering the B10d and category mentioned above

where

with

dop = the average number of hours of use per day

hop = the average number of days of use per year

tcycle = is the average time of use between the start of

two successive cycles of the component DynasafeTM

Mecha 3.2 & 7 in this case.

dop , hop and tcycle have to be dened by the installation

user.

Then, the MTTFD could be classied in a range: Low,

medium or high as proposed by EN ISO 13849-1 in

table 4

MTTFD

Denotation of

each channel

Range of

each channel

Low 3 years ≤ MTTFD< 10 years

Medium 10 years ≤ MTTFD< 30 years

High 30 years ≤ MTTFD≤ 100 years

Achieved PL:

After that, achieved PL is issued out by a diagram (gure

5 in EN ISO 13849-1) taking in consideration category,

DC monitoring capability and MTTFD. Without failure

detection DC factor is ‘none’ (no diagnostic coverage

possibility).

DANGER: The integrator must take care that

the inductive load could damage the device and

could reduce the electrical life duration. We strongly

recommend not to exceed an apparent power of 80VA

with 48VAC voltage max.

3.5. Designation, characteristics and outline dimensions

Type Code Wire rope

diameter (mm)

Capacity

(daN)

Width

(mm)

Length

(mm)

Thickness

(mm)

Weight

(kg)

Mecha 3.2 293599 From 5 to 16 From 200 to 3200 112 160 48 1.2

Mecha 7 198959 From 17 to 26 From 500 to 7000 112 160 49 1.2

4. Installation of load limiter DynasafeTM

Mecha 3.2 & 7

Product must be installed by a qualied technician.

4.1. Parts list of load limiter and its

environment

See gure 2.

1Connecting cable

2Cable gland

3Adjustment screw and nutlock

4Assembling pin

5Nameplate

6Guide

7Switch cover

8Mobile half clamp

9Mounting screws and nut

10 Fixed half clamp

11 Compression pin

12 Deformation cell

13 Pull wire rope

14 Locking nut

4.2. Installing the load limiter on the wire

rope

IMPORTANT: Before applying a load and if no

factory presetting has been requested, make sure the

adjustment screws (rep 3 g.2) are un-screwed to the

maximum.

Failure to do so will result in risk of destruction of micro-

switches by crushing.

If the wire rope diameter does not correspond to the

load range, the load information will be the decisive

information.

a. Position the compression pin (11) in accordance

with the load and diameter of the cable (See

gure 3):

Requirement Exigence

Mecha 3.2 Mecha 7

1For a 5 to 8 mm

wire rope and for

loads between

200 daN and

900 daN

2For a 9 to 13 mm

wire rope and

loads between

200 daN and

1850 daN

For a 17 to

21 mm wire

rope and

loads between

500 daN and

4000 daN

3 For a 14 to

16 mm wire

rope and

loads between

200 daN and

3200 daN

For a 21 to

26 mm wire

rope and

loads between

700 daN and

7000 daN

b. Open the mobile half-clamp (8).

c. Make sure the pull wire rope (13) is free of any load.

d. Position the load limiter on the idle strand on the wire

rope near the xed point, with the cable gland (2)

pointing upward.

e. Close the mobile half-clamp (8) on the wire rope.

f. Tighten the mounting screws (9) (16 ± 2 Nm) in a

balanced way to avoid any risk of the load limiter

moving with respect to the wire rope. Too much

clamping force can result in damage to the clamp.

g. Check that the load limiter is correctly positioned by

performing a lifting movement up to the high limit

switch and check that the lifting equipment does

not touch the load limiter. If necessary, correct the

limit switch adjustment to keep su󰀩cient clearance

between the load limiter and the pulley block. Also

check, when the pulley block is at the high limit

switch, that the load limiter does not come into

contact with the crane structure.

4.3. Load limiter electrical connection

a. Correctly secure the electrical cable of the load

limiter up to the control cabinet Installation

b. Connect the control circuit contact wires as instructed

in §4.4

Micro switch interrupting capacity: 4 A / 250

VAC.

Reset micro switch depending on the hysteresis.

Safety feature should be managed by one of the NC

contacts of the load limiter; in this way, an overload

situation will be detected when the contacts open.

Applying this condition will also ensure a positive

safety function for the lifting machine in the event of

an accidental interruption of the link between the load

limiter and the control circuit.

The NO contacts are intended for management of slack

cable situations and/or situations where the operator

warning system has been triggered subsequent to

cross-over of one of the thresholds.

4.4. Connection diagram

See gure 4.

5. Threshold adjustment

Caution: it is essential that the Mecha 3.2 or

7 is correctly installed on the cable (see §4) before

adjusting the threshold.

In the example given below, we have arbitrarily

designated threshold S1 as the safety threshold and

threshold S2 as the complementary threshold. Since the

micro switches have the same characteristics, these

congurations can be inverted.

Tractel recommends placing a drop of varnish

or paint between the screws ref. 3 and the nuts ref. 14

(g. 2) in order to be able to check the maintenance

of equipment adjustment during periodic checks. A

misadjustment of the equipment could have serious

consequences for the installation.

The adjustment process should always be preceded by

a preload at 110% of the desired threshold.

5.1. Factory preset load limiters

When you purchase a load limiter DynasafeTM Mecha

3.2 & 7 with the factor preset option, the load limiter

is supplied with the adjustment screws and locknuts

locked with red varnish. The nameplate on the load

limiter indicates the threshold setting value and the

wire rope diameter for which the thresholds have been

adjusted.

5.2. Adjustment of a safety threshold

Preliminary conditions:

– Load limiter correctly mounted and wired.

– Adjustment screws unscrewed to the maximum.

– Hook free of any load.

Equipment required:

– A load (called «WLL») equivalent to 100% of the

nominal capacity authorized for the lifting machine.

– An additional load equivalent to 10% of the WLL.

ACTIONS REMARKS

Lift the two loads

(100% + 10% WLL)

by about 10 cm.

The additional 10% represents

the overload value authorized in

accordance with the European

directive.

2Adjust the safety

threshold S1.

Gradually screw in the threshold

adjustment screws (rep 3) until

the NC contact opens (§4.4).

Use a multimeter, for example,

to check the state of the contact.

When the calibration is achieved,

lock the adjustment screw

by tightening the locking nut

(g. 14).

3Tightening the

mounting screws

Lift a load equal to the WLL by

10cm, repeat this operation 3

times then, if required, tighten

the mounting screws (g.9) to

16 N.m +/- 2.

4Check correct

operation.

It must be possible to lift the

“WLL” load. It must not be

possible to lift the “WLL” load

+ 10%. Depending on the lifting

speed, the dynamic e󰀨ect

may produce an unintentional

overload. In this case, consult

with a technician capable of

integrating a signal ltering

device (example: timeout, etc.).

5.3. Adjustment of a safety threshold and

an intermediate threshold

This conguration satises a number of applications

such as, for example, fast lifting speed conditioned to

load lifted. Audible or visual signal triggered at 90% of

the WLL. etc.

Preliminary conditions:

– Load limiter correctly mounted and wired.

– Adjustment screws unscrewed to the maximum.

– Hook free of any load.

Equipment required:

– A load (called «WLL») equivalent to 100% of the

nominal capacity authorized for the lifting machine.

– An additional load equivalent to 10% of the «WLL».

– A load «X» equivalent to the value of the intermediate

threshold.

ACTIONS REMARKS

Lift the two loads

(100% + 10% WLL)

by about 10 cm.

The additional 10% represents

the overload value authorized in

accordance with the European

directive.

2Adjust the safety

threshold S1.

Gradually screw in the threshold

adjustment screws (rep 3) until

the NC contact opens (§4.4).

Use a multimeter, for example,

to check the state of the contact.

When the calibration is achieved,

lock the adjustment screw

by tightening the locking nut

(g. 14).

3Tightening the

mounting screws

Lift a load equal to the WLL by

10cm, repeat this operation 3

times then, if required, tighten

the mounting screws (g.9) to

16 N.m +/- 2.

4Check correct

operation.

"It must be possible to lift the

«WLL» load. It must not be

possible to lift the «WLL» load

+ 10%. Depending on the lifting

speed, the dynamic e󰀨ect

may produce an unintentional

overload. In this case, consult

with a technician

capable of integrating a signal

ltering device (example:

timeout, etc.)."

5Lift the intermediate

load “X”.

Wait for the load to stabilize

before adjusting the threshold.

Adjust the

intermediate

threshold S2.

Gradually screw in the threshold

adjustment screws (rep 3) until

the NC contact opens (§4.4).

Use an ohmmeter, for example,

to check the state of the contact.

When the calibration is achieved,

lock the adjustment screw

by tightening the locking nut

(g. 14).

7Check correct

operation.

Check that micro switch S2

opens when the load “X” is lifted.

5.4. Adjustment of a safety threshold and

a “Wire rope slack” threshold

This conguration is particularly designed to detect a

“Wire rope slack” situation or “presence of a minimum

load” below which the signal generated by the micro

switch will be processed, for example, to stop the down

movement of the lifting hook.

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