Comeup CP-750T - User Manual

This document is an instruction manual for COMEUP Electric Winches. It covers operation, maintenance, and safety precautions for various models of electric winches manufactured by Comeup Industries Inc.

The primary function of these devices is to lift, pull, and lower loads. The manual emphasizes that the winches are not to be used for lifting, supporting, or transporting personnel. They are designed for safe and dependable service when operated according to the provided instructions.

Important Technical Specifications:

The manual provides detailed specifications for different winch models, including:

• Wire Rope Selections:

  • Lifting Capacity at 50Hz (kg): Ranges from 200 kg (CP-200) to 5,000 kg (CWG-34000).
  • Wire Rope Diameter (mm): Varies from 6 mm to 22.4 mm.
  • Wire Rope Length (m): Ranges from 30 m to 200 m.
  • Construction: Typically 6 x 19 or 6 x 24.
  • Minimum Breaking Strength (kg): From 2,010 kg to 23,300 kg.
  • Safety Factor at 50Hz: Ranges from 4.2 to 10. The manual states that the minimum breaking force of the rope should be twice the winch rating (EN 14492-1 Section 5.15.6).
  • D/d Ratio: The ratio of the pitch circle diameter of the drum to the rope diameter. A 12:1 D/d ratio is suggested for most pulling applications, and 15:1 for lifting and lowering. The rope drum mean diameter must be at least 10 times the wire rope diameter (EN 14492-1 Section 5.7.2).

• Brake Specification:

  • Coil Volt (V): Ranges from 110V to 440V, including DC 220V for some models.
  • Brake Disc Diameter (mm x q'ty): Varies by model, e.g., 95 x 1, 95 x 2, 150 x 1, 140 x 1, 170 x 1, 188 x 2, 200 x 2.
  • Resistance Ohm (Black & Blue wires): Provided for each voltage and model.
  • Brake Gap (mm): Ranges from 0.3 mm to 0.6 mm.

• Power Lead and Switch Cord Sections:

  • Power Lead (mm²): From 1.5 mm² to 8.0 mm², depending on the winch model.
  • Switch Cord (mm²): From 1.25 mm² to 3.5 mm², depending on the control type (direct or indirect) and winch model.
  • The length of both power lead and switch cord is subject to the distance being less than 20 meters.

• Pendant Switch Selections:

  • Direct Control: CPB-213 (30A, 3a contacts) and PB-331 (30A, 3a + Emergency Stop contacts).
  • Indirect Control: CPB-161 (3A, 2a contacts) and PB-306 (3A, 2a + Emergency Stop contacts).

• Low Voltage Control Selections:

  • LV-320 (Plastic Cover): IP55 grade, comes with magnetic switch, relay, and transformer. Ratings: 5 kW (for CWG-30375, CP-750T/900T) and 7.5 kW (for CWG-30565/30750, 31500, 380-440V).
  • LV-360 (Steel Cover): IP44 grade, comes with magnetic switch, relay, and transformer. Ratings: 7.5 kW (for CWG-30565/30750, 31500, 220V) and 15 kW (for CWG-34000).

• Percentage Duty Cycle (%ED): Calculated as (Tb / (Tb + Ts)) * 100 (%), where Tb is total sum of operating hours and Ts is total sum of stopping hours. All electric winches are rated at a 25% percentage duty cycle (%ED).

Usage Features:

• General Safety Precautions: Emphasizes confirming compliance with conditions, securing the winch, using suitable pulleys and ropes, proper grounding, checking for smooth operation without load, and ensuring even wire rope winding.
• Installation Precaution: Warns against operating in extreme temperatures (-10°C to 40°C), high humidity (>90%), organic chemistry or explosive powder conditions, heavy acid or salty conditions, rain or snow, or heavy general powder conditions, as these can cause malfunction, explosion, rust, short circuits, or performance issues.
• Handling Precautions: Prohibits lifting loads above rated capacity, transporting persons, ignoring faulty accessories, standing under winching operations, operating in rain or snow, and stresses the importance of connecting power leads directly to the main source and anchoring cranes with ballasted containers and wire rope.
• Up and Down Switching: Explains how to lift (press ↑ button), lower (press ↓ button), and stop (release button) loads. Emergency stop function (optional) is activated by pressing the button and released by rotating it clockwise.
• Wire Rope Replacement: Details the procedure for inserting and fixing the wire rope to the drum, ensuring accurate winding to prevent load swing and damage. Specific instructions are provided for winches rated less than 500 kg, including how to attach the wire rope to the hook body using a round head pin and R-dowel.
• Horizontal Load Reversing: Describes how two pieces of wire rope can be spooled onto the first layer of a grooved drum, with one winding on and the other off equally, ensuring correct grooving.
• Cart Puller Capacity: Provides guidance on choosing the right winch for pulling applications, considering factors like total load, rolling resistance, track gradient, track curvature, and track conditions. It includes a calculation example for determining minimum required cart puller capacity.
• Compliance with EU Directives: States that electric winches comply with EN 14492-1, European Machinery Directive 2006/42/EC, European Directive on Electromagnetic Compatibility (EMC) 2004/108/EC, and European Low Voltage Directive (LVD) 2006/95/EC.
• Optional Accessories for EN 14492-1 Compliance: Lists low voltage control, remote control with an emergency stop button, rope drum cover, and up and down limits protection devices as necessary for compliance.

Maintenance Features:

• Limited One (1) Year Warranty: Covers mechanical and electrical components against defects in material and workmanship for one year from the original purchase date. Exclusions include wire rope assemblies after initial use, fitness for a particular purpose, product finish, merchantability, and failures due to improper installation, operation, or modification.
• Oil Replacement: Emphasizes the importance of gear lubrication for long winch life. Winches are pre-lubricated at the factory. Re-lubrication is recommended every 250 working hours or after repair/disassembly. Recommended lubricants include Castrol Alpha Spheerol L-EP 2 or HT-740-0 grease, or Castrol Alpha Series, SP-220/460 oil. Specific lubricant quantities (0.5 It to 3.41 It) are provided for various CP and CWG models.
• Brake Replacement and Adjustment:
  • For CP-200/250/300/500/500T, CWG-30075 winches: No adjustment function; replace the brake disc if worn (thickness < 8.5 mm from standard 9 mm, or brake distance > 1.5% of rope length wound in 1 min).
  • For CP-750T/900T, CWG-10151/30151/30375/30565/30750/31500/34000 winches: Replace the brake disc if worn (thickness < 12 mm from standard 14 mm, or brake distance > 1.5% of rope length wound in 1 min). Detailed adjustment procedures are provided, involving loosening/tightening nuts to achieve specific brake gaps (0.35 mm, 0.45 mm, 0.6 mm) and then releasing by proper wraps (5.5 to 9.5 wraps).
• Checking Reference: Outlines daily and periodic checks to be performed by a specified person.
  • Daily Checks: Visual inspection of brake performance, motor staining/damage, remote control outer damage, wiring earth line attachment, wire rope kink phenomena/broken wires/diameter decrease/deformation/corrosion, weight hook/tackle block distortion/damage/loosening, drum flange rupture/wearing, gear train damage/warning, fastenings loosening, and marking label condition.
  • Periodic Checks (3 Months/20 Hours, 1 Year, 3 Years/250 Hours): Include decomposition checks for brake lining wear and spring escaping, measuring insulation condition (10MΩ min) for motor and remote control, and measuring oil feeding/lubrication for couplings in gear trains.
• Trouble Shootings: Provides a table of common symptoms (no reaction, motor buzzes, failing in restarting, failing to lift load, brake not opening completely, crossed rotation, grease leakage), their possible causes, and remedies (e.g., connect correctly, check power source, check/replace brake assembly, rewind/replace motor, reduce load, replace centrifugal switch, replace brake disc, check voltage, adjust brake gap, replace oil seal).