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CM Lodestar F-2 - User Manual

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Before installing hoist, fi ll in the information below.
Model Number
Serial No.
Pur
chase Date
V
oltage
Rated Load
RATED LOADS 1/8 TO 3 TONNES
125 KG TO 3000 KG
Follow all instructions and warning for inspecting,
maintaining and operating this hoist.
The use of any hoist presents some risk of personal injury
or property damage. That risk is greatly increased if proper
instructions and warnings are not followed. Before using
this hoist, each operator should become thoroughly familiar
with all warnings, instructions and recommendations in this
manual. Retain this manual for future reference and use.
Forward this manual to operator. Failure to operate equipment
as directed in manual may cause injury.
ELECTRIC CHAIN HOIST
OPERATING, MAINTENANCE
& PARTS MANUAL
P/N: 00001996 (REV AC) 627NH October 2014
Distributed by Ergonomic Partners
Sales@ErgonomicPartners.com
www.ErgonomicPartners.com
Tel: (314) 884-8884

Table of Contents

Questions and Answers

Summary

Safety Precautions

TO AVOID INJURY: (Serious;Fatal)

Crucial safety instructions for hoist operation to prevent injury or death.

TO AVOID INJURY: (Minor;Moderate)

Crucial safety instructions for hoist operation to prevent minor or moderate injury.

Hoist Safety Guidelines

Do Not Lift More Than Rated Load

Emphasizes adhering to the hoist's maximum weight capacity to prevent accidents.

Do Not Operate Damaged or Malfunctioning Hoist

Warns against using a hoist that is damaged or not functioning correctly.

Proper Inspection Procedures

Outlines visual inspection procedures for hoists before use, including warning notices.

Proper Lifting Techniques

Provides guidance on proper lifting techniques and ensuring clear areas around the load.

Maintenance Best Practices

Covers essential maintenance aspects like cleaning and lubrication for safe operation.

Foreword

General Information and Specifications

Hoist Specifications

Details technical specifications of Lodestar Electric Chain Hoists, including load capacity and speed.

CM Repair and Replacement Policy

Outlines the policy for repair or replacement of defective Lodestar Hoists under warranty.

Accessories

Hook Suspensions

Describes swivel and rigid hook suspensions for suspending hoists from trolleys or fixed structures.

Lug Suspension

Details rigid lug suspensions used for attaching hoists to specific trolleys.

Series 635 Low Headroom Trolley

Explains manual push-type trolleys designed for Lodestar hoists, adjustable for beams.

Universal Trolley

Describes universal trolleys with independent controls, adaptable to various CMCO hoist products.

Series 635 Motor Driven Trolley

Covers motor-driven trolleys with independent controls, adjustable for beams.

Latchlok Hooks

Introduces Latchlok hooks as replacements for standard upper and lower hooks.

Chain Container

Explains the accessory used to hold slack chain, recommended for applications where chain might interfere.

Installation Procedures

Unpacking Information

Instructs on inspecting the hoist for damage upon receipt and checking power supply compatibility.

Installing the Suspension

Provides detailed steps for installing hook or lug suspensions on single, double, and triple reeved units.

Attaching Load Chain

RRS & Single Reeved Models

Details the process of attaching load chain to RRS and single reeved hoists.

Triple Reeve Load Chain Attachment

Explains how to attach load chain for triple reeved hoists.

Dead End Block Chain Attachment

Specific instructions for attaching load chain to the dead end block on particular hoist models.

Power Supply and Electrical Connections

Three Phase Hoist Configuration

Discusses factory arrangement for three-phase hoists and how to change voltage using a voltage change board.

Power Phasing Check

Explains how to check and correct motor rotation direction for three-phase hoists to prevent damage.

Load Chain Inspection and Voltage Checks

Checking for Twist in Load Chain

Instructions for checking load chain twist on specific models, including reversing capsizing.

Checking for Adequate Voltage at Hoist

Ensures sufficient electrical power for proper hoist operation.

Signs of Inadequate Electrical Power

Lists symptoms of low voltage operation, such as noisy operation and motor stalling.

Limit Switch Operation and Operating Instructions

Checking Limit Switch Operation

Procedure for verifying limit switch functionality, including TO AVOID INJURY warnings.

General Operating Instructions

Explains the Load-limiter, adjustable limit switches, and two-speed hoist operation.

Hoist Operating Steps

Provides basic operating steps for picking up loads, including overhead positioning.

Hoist Operation and Safety Procedures

Hoist with Low Headroom Trolley

Explains how to move hoists with low headroom trolleys, including using the control cord.

Hoist with Motor Driven Trolley

Details how to move hoists with motor-driven trolleys, emphasizing smooth stopping.

Safe Operating Instructions

Provides critical safety instructions for load handling and hook usage.

Avoid Choker Chain Use

Explains the consequences of using the load chain as a choker chain, such as loss of swivel effect.

Inspection Procedures

Service Classifications

Defines Normal, Heavy, and Severe service conditions for hoist usage.

Inspection Types and Frequencies

Outlines Frequent and Periodic inspection types and their required frequencies.

Preventative Maintenance Program

Recommends establishing a maintenance program to prolong hoist life and ensure reliability.

Suspension Inspection Criteria

Provides criteria for inspecting suspension components like brackets and bolts.

Hook Removal Criteria

Lists criteria for removing hooks from service, including damage, wear, and latch issues.

Inspection and Maintenance Schedules

Minimum Frequent Inspections

Specifies the minimum inspection frequency based on service type (Normal, Heavy, Severe).

Minimum Periodic Inspections

Details the minimum periodic inspection requirements based on service type and frequency.

Load Chain Inspection

Chain Cleanliness and Lubrication Check

Instruction to check the load chain for cleanliness and lubrication status.

Load Chain Link Inspection

Procedure for cleaning and inspecting load chain links for wear, cracks, or deformation.

Maintenance Details

Load-Limiter Information

Information on the Load-limiter's operation, service requirements, and proper model selection.

Hoist Lubrication Guide

Guidance on lubricating hoist gears, specifying lubricants and procedures.

Bearing Lubrication

Notes on bearing lubrication, specifically the lower hook thrust bearing.

Chain Guides, Liftwheel, and Sheave Lubrication

Instructions for lubricating chain guides, liftwheel, and lower sheave wheel during disassembly.

Load Chain Care

Emphasizes the importance of keeping load chain clean and lubricated to increase its life.

Trolley Lubrication Reference

Refers to the appropriate trolley manual for lubrication instructions.

Exterior Finish and Cleaning

Information on the hoist and trolley exterior finish, cleaning, and touch-up paint.

Temperature Rating and Operation

Specifies the normal ambient operating temperature range and factory contact for solutions outside this range.

Solid State Reverse Switch Operation

Details operating conditions for the solid-state reverse switch to prevent overheating and malfunction.

Brake Adjustments

DC Electric Brake Assembly

Describes the DC electric brake assembly and air gap adjustment requirements.

Limit Switch Adjustments

Setting the Upper Limit Switch

Step-by-step guide for adjusting the upper limit switch, including CAUTIONary notes.

Lower Limit Switch and Guide Conversion

Setting the Lower Limit Switch

Detailed procedure for setting the lower limit switch, including CAUTIONary notes.

Converting Limit Switch Guides

Instructions for converting limit switch guides, involving disassembly and reassembly.

Troubleshooting Hoist Issues

Hook Not Responding to Controls

Lists probable causes and remedies for the hook not responding to control inputs.

Incorrect Hook Movement Direction

Identifies probable causes and remedies for incorrect hook movement direction.

Troubleshooting Hoist Performance

Hook Lowers But Will Not Raise

Lists probable causes and remedies when the hook lowers but fails to raise.

Hook Raises But Will Not Lower

Lists probable causes and remedies when the hook raises but fails to lower.

Hook Lowers When Hoisting Control Operated

Lists probable causes and remedies for the hook lowering when hoisting control is activated.

Hook Does Not Stop Promptly

Lists probable causes and remedies for the hook not stopping promptly.

Hoist Operates Sluggishly

Lists probable causes and remedies for sluggish hoist operation.

Troubleshooting Motor and Limit Issues

Motor Overheating Causes and Solutions

Lists probable causes and remedies for motor overheating issues.

Hook Fails to Stop at Travel Limits

Lists probable causes and remedies for the hook failing to stop at travel limits.

Varying Hook Stopping Points

Lists probable causes and remedies for inconsistent hook stopping points.

Troubleshooting Two Speed Hoist Issues

Hoist Not Operating at Slow Speed

Lists probable causes and remedies for the hoist not operating at slow speed.

Hoist Not Operating at Fast Speed

Lists probable causes and remedies for the hoist not operating at fast speed.

Hook Not Raising at Slow Speed

Lists probable causes and remedies for the hook not raising at slow speed.

Hook Not Lowering at Slow Speed

Lists probable causes and remedies for the hook not lowering at slow speed.

Hook Not Raising at Fast Speed

Lists probable causes and remedies for the hook not raising at fast speed.

Hook Not Lowering at Fast Speed

Lists probable causes and remedies for the hook not lowering at fast speed.

Incorrect Direction at Different Speeds

Lists probable causes and remedies for incorrect direction at different speeds.

Electrical Data

Detecting Electrical Faults

Explains methods to detect electrical faults using ohmmeters and ammeters.

Hoist Component Electrical Data

Provides electrical data for hoist components, including resistance and current values.

Wiring Diagrams

Assembly Instructions

Swivel Hook or Lug Suspension Assembly

Instructions for assembling swivel hook or lug suspension onto hoist models.

Fastener Torque Specifications

Refers to tables for recommended torque values for fasteners.

Suspension Bolt Replacement Warning

Important note to replace suspension bolts whenever the suspension is removed.

Lower Hook Block Pin Installation

Detailed instructions for removing and installing the lower hook block pin, including precautions.

Load Chain Removal and Installation

Guidance on proper removal and installation of load chain to prevent dropped loads.

Load Chain Installation Methods

Details Method #1, Method #2, and Method #3 for load chain installation.

Chain Handling Instructions

Cutting Chain Safely

Provides recommended methods for cutting hardened CM® load chain.

Chain Stop Installation

Instructions for installing a chain stop mechanism to secure the load chain.

Upper Suspensions

Upper Suspension Assemblies (Models A-RRT-2)

Shows different types of upper suspension assemblies for hoist models.

Upper Suspensions for RRS Model

RRS Swivel Hook Assembly

Illustrates the assembly of a swivel hook for the RRS model.

RRS Lug Assembly

Depicts the assembly of a lug suspension for the RRS model.

RRS Rigid Hook Assembly

Shows the assembly of a rigid hook for the RRS model.

RRS Universal Trolley Lug Assembly

Illustrates the assembly of a universal trolley lug suspension.

Universal Trolley Upper Suspensions

Universal Trolley Suspension Kits

Illustrates and lists part numbers for universal trolley suspension kits based on model and reeving.

Lower Hook Blocks: Single Reeved

Single Reeved Model Parts

Lists part numbers for lower hook block assemblies for single-reeved models.

Lower Hook Blocks: Double & Triple Reeved

Double Reeved Model Parts

Lists part numbers for lower hook block assemblies for double-reeved models.

Triple Reeved Model Parts

Lists part numbers for lower hook block assemblies for triple-reeved models.

DC Brake Assemblies

Single Model Brake Assembly Details

Details brake assembly part numbers and corresponding hoist motor and brake coil voltages.

Control Cord and Station Assemblies

Single Speed Hoist Control Station

Lists part numbers for single speed hoist control station and cord assemblies.

Two Speed Hoist Control Station

Lists part numbers for two speed hoist control station and cord assemblies.

Contactor Plate Assemblies (DC Brake & Transformer)

Models A, AA, B, C, E, F & H (110;115 V)

Details parts for contactor plate assembly with DC brake and transformer for specific models.

Models A, AA, B, C, E, F & H (24;48 V)

Details parts for contactor plate assembly with DC brake and transformer for specific models.

Models A, AA, B, C, E, F & H (110 V)

Details parts for contactor plate assembly with DC brake and transformer for specific models.

Contactor Plate Assemblies (DC Brake, 1-Speed, Dual Voltage)

Models A, AA, B, C, E, F & H (220;230-380;415;460 V)

Lists parts for contactor plate assembly with DC brake, 1-speed, dual voltage units.

Contactor Plate Assemblies (DC Brake, 2-Speed Units)

Models A-2, AA-2, B-2, C-2, E-2, F-2 & H-2 (220;230 V)

Details parts for contactor plate assembly with DC brake, 2-speed units.

Models A, AA, B, C, E, F & H (550;575 V)

Lists parts for contactor plate assembly with DC brake, 2-speed units, 550/575V.

Contactor Plate Assemblies (DC Brake, 1-Speed Units)

Models J, L, R & RT (110;115 V)

Details parts for contactor plate assembly with DC brake, 1-speed, J, L, R, RT models.

Contactor Plate Assemblies (DC Brake, 1-Speed Units)

Models J, L, R & RT (220;230 V)

Lists parts for contactor plate assembly with DC brake, 1-speed, 220/230V units.

Contactor Plate Assemblies (DC Brake, 1-Speed Units)

Models J, L, R & RT (220;230 V Continuation)

Continuation of parts list for contactor plate assembly, 1-speed, 220/230V units.

Contactor Plate Assemblies (DC Brake, 1-Speed, Dual Voltage)

Models J, JJ, L, LL, R, RR, RT & RRT (220;230-380;415;460 V)

Parts list for contactor plate assembly, 1-speed, dual voltage units.

Contactor Plate Assemblies (DC Brake, 2-Speed Units)

Models J-2, JJ-2, L-2, LL-2, R-2, RR-2, RT-2 & RRT-2 (550;575 V)

Parts list for contactor plate assembly, 2-speed units, 550/575V.

Contactor Plate Assemblies (DC Brake, 2-Speed Units)

Models J-2, JJ-2, L-2, LL-2, R-2, RR-2, RT-2 & RRT-2 (220;230 V)

Parts list for contactor plate assembly, 2-speed units, 220/230V.

Contactor Plate Assemblies (DC Brake, 2-Speed Units)

Models J-2, JJ-2, L-2, LL-2, R-2, RR-2, RT-2 & RRT-2 (380;415;460 V)

Parts list for contactor plate assembly, 2-speed units, 380/415/460V.

Contactor Plate Assemblies (DC Brake, 2-Speed Units)

Models J-2, JJ-2, L-2, LL-2, R-2, RR-2, RT-2 & RRT-2 (550;575 V)

Parts list for contactor plate assembly, 2-speed units, 550/575V.

Contactor Plate Assembly (RRS Models)

RRS Models (1-Speed, Dual Voltage)

Parts list for contactor plate assembly with DC brake, 1-speed, dual voltage units for RRS models.

Contactor Plate Assembly (RRS Models)

RRS Models (2-Speed Units, 550;575 V)

Parts list for contactor plate assembly with DC brake, 2-speed units, 550/575V for RRS models.

Chain Container Installation

Chain Container Bucket Length Guide

Table correlating bucket length with hoist model and lift for chain containers.

RRS Chain Container Installation

Lubricants and Spare Parts

Recommended Lubricants

Lists recommended lubricants for various hoist components and their part numbers.

Recommended Spare Parts List

Lists essential spare parts recommended for inventory to ensure continued hoist service.

Warranty Information

Warranty and Liability Limitations

Details the seller's warranty terms, limitations, and buyer's remedies for defective products.

Foreword (VFD Supplement)

Adjustable Frequency Drive (VFD) Information

Electromotive Impulse •G+ Mini VFD Overview

Introduces the Impulse•G+ Mini adjustable frequency drives integrated into CM hoists.

VFD Warranty Disclaimer

States Electromotive Systems' warranty limitations regarding drive programming by untrained personnel.

General VFD Handling Precautions

Refers to the hoist manual for general instructions and lists environmental conditions to protect the hoist.

VFD Power Supply Requirements

Details power supply requirements and electrical connection procedures for hoists with VFDs.

VFD Operating and Safety Procedures

VFD Operating Instructions

Instructs to follow the hoist manual and use provided VFD operating methods.

VFD Safety Procedures

Lists crucial safety procedures for lifting loads, avoiding overloads, and general safe operation.

VFD Inspection and Maintenance

VFD Inspection and Maintenance

Mentions checking wiring connections to the VFD and provides torque specifications for specific components.

Wiring Diagrams

VFD Keypad Operations

Using the Keypad for Programming

Explains how to access and enter drive application information using the keypad.

Keypad Functions Overview

Describes the keypad's 5-digit LED display, indicators, and keys.

Keypad LED and Button Functions

LED Operator Keys and Displays

Details the function of each key and display element on the LED operator.

LO;RE and RUN LED Indicators

Explains the meaning of the LO/RE and RUN LED indicators during operation.

VFD Parameters and Functions

Function LED Descriptions

Describes the status indicated by the Function LEDs (ALM, REV, DRV, FO_UT).

Understanding Drive Parameters

Introduces drive parameters and the recommendation to use qualified technicians for setting changes.

VFD Parameter Structure and Monitoring

Parameter Structure Overview

Explains the organization of drive parameters into groups and provides definitions for key monitoring functions.

Frequency Reference Setting

Defines how to set/display the drive operation speed in Hz.

Output Frequency Monitor

Explains how the output frequency (Hz) is displayed and cannot be changed via keypad.

Output Current Monitor

Describes how output current (Amps) is displayed and cannot be changed via keypad.

Monitor Selection

Details how pressing ENTER accesses monitor parameters, which are accessible during run command.

Parameter Programming Guide

Explains how to select, read, and change parameter settings using the keypad, with saving and exiting procedures.

Output Voltage Monitor

Explains how output voltage to the motor is displayed and cannot be changed via keypad.

User Access to Parameters

Allows quick access to parameters that can be programmed by the operator.

VFD Monitor Parameters List

Monitor Parameter Codes (MONITOR)

Lists monitor parameters related to frequency, output, status, and voltage.

Input Terminal Status

Shows the status of input terminals and their corresponding indications.

Output Terminal Status

Displays the status of output terminals.

Inverter Control Status

Indicates the inverter's operation status.

VFD Monitor Parameters and Fault Tracing

Monitor Parameters (MONITOR)

Lists monitor parameters for elapsed time, flash ID, terminal levels, and CPU status.

Fault Trace Parameters

Details parameters related to fault tracing, including current and last faults.

VFD Fault History and Maintenance Parameters

Fault Trace Parameters

Lists fault trace parameters for operation status, elapsed time, and speed reference.

Fault History Parameters

Provides a history of faults, including fault messages and elapsed times.

Maintenance Parameters

Lists parameters related to maintenance tasks like cumulative operation and cooling fan time.

VFD Maintenance and Motor Control Monitoring

Maintenance Parameters

Lists maintenance parameters for LED checks, kWh, CPU resources, and peak hold values.

Motor Control Monitoring Parameters

Lists parameters for monitoring motor control aspects like secondary current, excitation current, and output voltage.

Impulse•G+ Mini VFD Specifications

Adjustable Speed Control Methods

Multi-Step and Infinitely Variable Control

Explains the different speed control methods available for the Impulse•G+ Mini drive.

Factory Settings for VFD Parameters

Parameter Settings for Control Methods

Lists the default factory settings for various control parameters and notes on accessibility.

VFD Fault Codes and Corrective Actions

Fault Codes A-CPF23

Provides a table of fault codes, their descriptions, and corrective actions.

VFD Fault Codes and Corrective Actions (Continued)

Fault Codes CPF24-OV (Flashing)

Continues the table of fault codes, descriptions, and corrective actions for the drive.

VFD Fault Codes and Corrective Actions (Continued)

Fault Codes OV (Flashing) - PF

Continues the table of fault codes, descriptions, and corrective actions for the drive.

VFD Fault Codes and Corrective Actions (Continued)

Fault Codes UL1-UV3

Concludes the table of fault codes, descriptions, and corrective actions.

Electromotive Systems Limited Warranty

CM Lodestar F-2 Specifications

General IconGeneral
BrandCM
ModelLodestar F-2
CategoryChain Hoists
LanguageEnglish

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