Advance Lifts Dock Lifts 6000 Series Manual
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Motor Controllers (Typical)
Specifications:
Motor Starter with adjustable thermal overload.
50VA transformer with 24 VAC secondary fused at 4 amps (Standard)
100VA transformer with 115 VAC secondary fused at 1.6 amps (Optional)
Reset is manual or automatic (manual is standard, automatic is not to be used)
Enclosure is NEMA 12 JIC supplied with (4) conduit openings (motor, down
solenoid, power and push button station)
Completely wired with terminal strips for final secondary voltage control connections
All components UL, CSA
Overall dimensions: (approximate)
Metal Enclosures: 9”w x 12”h x 8”d
Typical motor controller – appearance may vary.
P 9-2
Transformer
Motor Starter
(Contactor)
Ground Lug
Motor Overload
Motor Overload
Reset Button
Terminal Strip
(Low Voltage)
12/12/07 X1 2 X2 1 H3 H2 4 X2 - XF X1 H4 H1 1L1 A1 6T3 4T2 2T1 6T3 4T2 2T1 5L3 3L2 96NC 97NO 98NO A2 95NC 22 NC 14 NO 13 NO 21 NC L 1 L 2 GROUND N TO DOWN SOLENOID GROUND ADVANCE LIFTS WIRING DIAGRAM FOR 230 VOLT SINGLE PHASE 5 HP PUSH BUTTON TRANSFORMER TERMINAL STRIP MOTOR STARTER OVERLOAD BK BK BK BK BK W W W R G BK = BLACK G = GREEN R = RED W = WHITE FLM 1 FLM 1 FNM 3-2/10 DOWN UP STOP RESET BK LOW VOLTAGE LINE VOLTAGE LOW VOLTAGE (FIELD WIRED) LINE VOLTAGE (FIELD WIRED) *MOTOR P1 T1 T8 T4 T5 P 9-3 3 4 4 3 INTERNAL MOTOR CONNECTIONS * TO CHANGE ROTATION SWAP T5 & T8 TYPICAL BREAK POINT FOR DOWN TRAVEL LIMIT SWITCH TYPICAL BREAK POINT FOR UP TRAVEL LIMIT SWITCH
P 9-4 5/23/06 X1 2 X2 1 H3 H2 4 X2 - XF X1 H4 H1 1L1 A1 6T3 4T2 2T1 6T3 4T2 2T1 5L3 3L2 96NC 97NO 98NO A2 95NC 22NC 14NO 13NO 21 NC L 1 L 2 GROUND N TO DOWN SOLENOID GROUND ADVANCE LIFTS WIRING DIAGRAM 230 VOLT THREE PHASE 5 & 7.5HP PUSH BUTTON TRANSFORMER TERMINAL STRIP MOTOR STARTER OVERLOAD BK BK BK BK BK W W W R G BK = BLACK G = GREEN R = RED W = WHITE FLM 1 FLM 1 FNM 3-2/10 DOWN UP STOP RESET L 3 3 4 3 4 MOTOR T4 T5 T6 T9 T3 T8 T2 T7 INTERNAL MOTOR CONNECTIONS T1 WIRE NUT LOW VOLTAGE LINE VOLTAGE LOW VOLTAGE (FIELD WIRED) LINE VOLTAGE (FIELD WIRED) TYPICAL BREAK POINT FOR UP TRAVEL LIMIT SWITCH TYPICAL BREAK POINT FOR DOWN TRAVEL LIMIT SWITCH
X1 2 X2 1 H3 H2 4 X2 - XF X1 H4 H1 1L1 A1 6T3 4T2 2T1 6T3 4T2 2T1 5L3 3L2 96NC 97NO 98NO A2 95NC 22NC 14NO 13NO 21 NC L 1 L 2 GROUND N TO DOWN SOLENOID GROUND ADVANCE LIFTS WIRING DIAGRAM 460 VOLT THREE PHASE 5 & 7.5HP PUSH BUTTON TRANSFORMER TERMINAL STRIP MOTOR STARTER OVERLOAD BK BK BK BK BK W W W R G BK = BLACK G = GREEN R = RED W = WHITE FLM .5 FLM .5 FNM 3-2/10 DOWN UP STOP RESET L 3 3 3 4 4 LOW VOLTAGE LINE VOLTAGE LOW VOLTAGE (FIELD WIRED) LINE VOLTAGE (FIELD WIRED) MOTOR T4 T7 T8 T5 T6 T9 T3 T2 INTERNAL MOTOR CONNECTIONS T1 WIRE NUTS P 9-5 TYPICAL BREAK POINT FOR UP TRAVEL LIMIT SWITCH TYPICAL BREAK POINT FOR DOWN TRAVEL LIMIT SWITCH
SERIES SPEED 103 5 18 00 104 5 18 00 105 5 18 00 2000 18 00 20 00 K 18 00 T SERIES 18 00 3000 18 00 4100 18 00 4200 36 00 4300 36 00 4400 36 00 6000 18 00 6100 18 00 6150 18 00 6200 6300 HO RS EP OW ER APP RO X F ULL L OAD AMP S MIN COP P E R WI R E S IZ E ( 7 5 C ) THW , THHN, T HW N,X HHW CIRCUIT BRE AKE R AMPSDUAL E LE MEN T, TIM E DEL AY FUSE A MPS HORS E PO W ERAPPR OX FULL LO AD AMPSMIN CO PPE R WIRE SIZE (75C) THW ,THHN,T HW N,X HHW CIRCUIT BRE AKER A MP SDUAL EL E ME NT , TIME DELAY FUSE AMPS 1 3. 6 14 15 5.611. 814 152. 8 1-1/ 2 5. 2 14 15 81-1/22. 614 154 2 6. 8 14 15 1023. 414 155. 6 3 9. 6 14 20 1534. 814 158 5 15. 2 12 30 2557. 614 1512 7-1/ 2 22 10 45 307-1/21114 2017.5 10 28 8 60 40101412 2520 HO RS EPOW ER APP RO X F ULL L OAD AMP S MIN COP P E R WI R E S IZ E ( 7 5 C ) THW , THHN, T HW N,X HHW CIRCUIT BRE AKE R AMPSDUAL E LE MEN T, TIM E DEL AY FUSE A MPS HORS E PO W ERAPPR OX FULL LO AD AMPSMIN CO PPE R WIRE SIZE (75C) THW ,THHN,T HW N,X HHW CIRCUIT BRE AKER A MP SDUAL EL E ME NT , TIME DELAY FUSE AMPS 1/ 2 9. 8 14 20 151/24. 914 158 3/ 4 13. 8 12 25 203/46. 914 1510 1 16 12 30 251814 1512 1-1/ 2 20 10 40 301-1/21014 2015 2 24 10 50 3021214 2517.5 3 34 8 70 5031710 3525 5 56 - - -5288 6040 TYPICAL MOTOR INFORMATION MOTORS 11 5 V OLT 1 PH AS E 23 0 V OLT 1 PH AS E 2 HOR SE POWER 2 2 5 5 5 5 N OTE: The se ta bles a re in tende d a s a g uide line , n ot to s upe rs ed e na tiona l or loca l e le ctr ic al cod es. 5 7.5 7.5 7.5 5 5 5 5 P 9-7 23 0 V OLT 3 PH AS E 46 0 V OLT 3 PH AS E TW O CYLINDE R UNITS, 5 HP MOTORS FOUR CY LIN DER UN ITS , 7.5 HP MOTORS P 9-6
1 2 3 4 5 6 7 SECTION 10. IDENTIFICATION AND LABEL PLACEMENT No. Qty. Location 1. (2) Centers of handrail, both sides 2. (1) Cylinder end, right side of platform 3. (4) Centered on each side of platform 4. (4) Upper vertical section of handrail 5. (2) Outer leg 6. (1 per bridge) Under bridge 7. (2) Torque tubes each end TYPICAL PLACEMENT (EACH DECAL KIT IS SUPPLIED WITH LOCATION INSTRUCTIONS) DECAL KITS BY MODEL/SERIES MODEL 1035 (P-005-765) MODEL 1045/55 & 6568 (P-004-407) SERIES 2000 (P-004-059) SERIES 2000K (P-003-993) T SERIES (P-023-350) SERIES 3000 (P-004-261) SERIES 4000 (P-004-375) SERIES 6000 (P-005-564) P 10-1 Capacity Stickers on all four sides of platform
SECTION 11. TROUBLESHOOTING A. Equipment does not rise; pump is running: (see also Section M) 1. The motor rotation may be reversed. See the installation procedure on how to jog the motor to check for proper rotation. If the lift has been installed for some time and the motor is 3-phase, it is possible that the plant wiring “upstream” has been changed during plant maintenance or alteration, and the motor is now running reversed. A hydraulic pump can only run reversed for a short time (possibly 10 to 20 seconds) without causing permanent pump damage. 2. Motor may be single phasing. Check wiring and overloads to be certain that each three-phase line is present at the motor. 3. Voltage at motor terminals may be too low to run the pump at existing load. Check voltage directly at motor terminals while pump is running under load. (Reading source voltage with the pump idling will not give accurate results). Inadequate or incorrect wiring can starve the motor of voltage and current and will show up at the motor terminals when the motor is drawing the higher current that is required while motor is loaded. 4. Check for a hydraulic hose leak or pinching, and correct as necessary. 5. Check under the pump coupling to insure the key way has not slipped off the pump shaft. 6. Check for oil shortage in the reservoir and correct by filling the reservoir. Refer to “Fluid Recommendations” in this manual for the correct fluid for your ambient temperature. 7. The suction filter in the reservoir or the pressure line filters in the pipe outlet of the power unit or the breather cap on the reservoir may be clogged. Clean as required. 8. Check if the load is exceeding equipment ratings causing the relief valve to bypass the fluid back to the reservoir. Never change the relief valve setting, these are 100% tested, adjusted, and locked at the factory. Any change in the relief valve setting could cause your equipment either not to lift its capacity, or cause dangerous forces in the equipment, and void your warranty. 9. Check that the suction line fittings are not loose, causing the pump to pull in air instead of fluid. Check for a hairline crack on the suction port of the pump. The clear suction line should stay full of oil at all times, clear, and no air. Check that the natural curve of the suction hose in the reservoir doesn’t cause the filter to rise out of the fluid. Re-install the suction line without rotating it and the tension of the hose will free the suction hose to lie against the reservoir wall and the filter to lay flat near the reservoir bottom. If you have the short round “pancake” type of filter with the filter screen on the bottom of the filter, insure that it does not rest against the bottom of the reservoir, as this will restrict the flow to the pump. P 11-1
SECTION 11. TROUBLESHOOTING (Continued) 10. The down solenoid may be energized due to incorrect wiring, or mechanically stuck open, bypassing fluid. A. Check the wiring. Hold a non-magnetized screwdriver to the top of the down solenoid coil and press the up button. If you can feel magnetism, the wiring is faulty. B. Lightly tap the down solenoid to seat it properly. Do not bang it hard, as internal stem parts may be permanently damaged. The solenoid coil can be removed, and the down valve removed for cleaning as explained in the hydraulic “Component Information” section. C. Disconnect the pressure line from the valve manifold to the equipment. Place a pressure gauge at the valve output, using high-pressure reducers. Press the up button in a short jog and read the pressure. Press the down button to relieve the pressure. If the system will not put out the pressure indicated on the hydraulic diagram, the trouble is either the valves or pump. If a load is not available, then the maximum hydraulic system pressure can be checked on a gauge by raising the unit to its full height momentarily against its physical stops. Proceed to step 11 to determine which place the trouble exists. 11. The hydraulic pump may be inoperative. Disconnect a hydraulic line at the power unit, use a large bucket (5-gallon) and run the pump a short time. If no flow appears either the pump or pump motor coupling inside motor mounting flange is defective, or pump rotation is reversed. Connect a pressure gauge to the outlet of the pump, through a high-pressure tee and bleeder valve with hose to a bucket. Slowly turn the bleeder valve and see if the produces specified pressure. Do not close the valve all the way as the pressure buildup of a good pump could cause the pump to explode. If the pump does not put out the required pressure, then the problem is in other areas, such as a down solenoid valve leaking fluid back to the reservoir, allowing pressure not to be built up in the system. If the pump will not put out the required pressure, replace the pump. 12. Repeated continuous type operation of the equipment may cause thinning of oil due to heat buildup. Feel the side of the reservoir to check the temperature of the oil. The equipment is intended for dock type operation, not elevator type operation that would make the equipment cost several times as much. The thin oil can cause the equipment not to rise, and in time, ruin the hydraulic pump. This type of operation could void the warranty considerations. B. Equipment raises too slowly: 1. Small amounts of foreign material could stick in the down solenoid, bypassing some of the fluid. Lower equipment and clean the down solenoid valve. 2. Foreign material clogging the suction filter, breather cap, pressure line filter, or a hose that is pinched. See A-4, 5, 6, 7 and 9. 3. Low motor voltage. See A-3. 4. Load exceeding equipment ratings. See A-8. 5. Oil may be too thick (ambient temperature) for proper operation. Refer to “ Fluid Recommendations”. P 11-2