SQP2 - Movecat
Contents
1. 2008 12 Safety of machinery safety related parts of control systems Part 1 General principles for design DIN 56950 2004 05 Event technology machinery installations Safety requirements and inspections DIN EN ISO IEC 17025 2005 08 General requirements for the competence of testing and calibration laboratories BGV C 1 GUV V C 1 Event and production locations for staged performance BGV D 8 GUV VD 8 Winches lifting and pulling devices gt gt igvw SQ P2 BGI 810 3 Edition 02 2008 Safety at productions and events overhead loads BGG GUV G 912 Edition 04 2009 Guidelines for the testing of machinery installations on stages and in studios igvw SQ Q2 Edition 2010 General principles for event rigging gt gt igvw SQ P2 3 Definitions D 8 Electric chain hoist The D 8 electric chain hoist conforms to the requirements set out in BGV D 8 for the industrial operation of lifting gear and is not to be used for moving or holding loads overhead In event and stage technology a D 8 chain hoist may only be used to lift loads during setup and dismantling D 8 Plus Electric chain hoist The D 8 Plus Electric chain hoist is constructed and dimensioned in such a way that the moving of overhead loads is possible provided that no persons are standing under the load and that it is not necessary to install safety backups when the hoist is switched off C 1 Electric chain hoist The C 1 Electric chain hoist is based on th2. Illustration of the compensator principle i i i i i i i i i i i i i i i i i i i i i i i The greater the height of the construction the greater the displacement of the centre of gravity when there are tolerances in synchronisation or an asymmetrical load distribution 34 Table of contents gt gt igvw SQ P2 Appendix Ill A sample handover protocol Declaration concerning the correct construction and readiness for use of electric chain hoists manufacture place of manufacture customer company address person responsible supplier company address person responsible The supplier herewith declares to the customer that all equipment and materials utilised by him in the construction of the electric chain hoist conform with the corresponding regulations and accepted technical standards He furthermore declares that the complete assembly of the electric chain hoist has been carried out in accordance with the corresponding regulations and accepted technical standards and that the electric chain hoist is handed over to the customer as being ready to use The required documents and individual certificates are to be enclosed These include for example the material certificates the static calculations or the protocols of necessary inspections that have been carried out date signature of supplier date signature of customer 35 gt gt igvw SQ P2 Appendix I
3. For stage drives and the installation process of area loads or guided loads using C 1 electric chain hoists overload cut off and underload cut off are to be set in a suitable ratio to the actual load Experience has shown values approximately 20 above or below the actual weight to be correct e For stage drives that are to run automatically e g at discotheques trade fairs and exhibitions the lifting path must be situated outside the area to which any persons have access The area around the path must be closed off with safety equipment This kind of operation needs to be monitored and controlled using suitable control units gt gt igvw SQ P2 6 Inspections The contractor is obliged to provide safe electric chain hoists In order to ensure that only electric chain hoists are put to use that are ina proper condition an inspection is necessary not only before they are first put on the market but also before each one is used for the first time To ensure that the electric chain hoists operate safely during set up and use they must be inspected in connection with their operational use This way possible deficiencies or damage can be detected soon enough to be corrected Repeated inspections are necessary in order to recognise in due time deficiencies and damage that can occur during the operation of electric chain hoists After significant modification or an overhaul an inspection is necessary to check that the chain hoist has been re
4. Hamburg SWR WDR and ZDF Notes on use This pdf file is annotated with interactive links and bookmarks In the table of contents a mouse click on an item leads straight to the corre sponding chapter At the bottom of each page is a link that leads back to the table of contents gt gt igvw SQ P2 gt gt igvw SQ P2 Table of contents Preliminary note eisen ee 3 1 Area ofapplication u nen aen een 7 2 Normative and informal references 4242444444444nnennennnnnnnnnnnnene nennen 7 3 BI 91110111 PESSRPBPEBETEIPELEEL ERBE BESPEBBERLEFEHREENLLEETERRPEEFERHEFTRRLSIFSRFERLLERDERLOPEEIFPERHERFEEER 9 A SUP 6 APERERPREIIEEDNSPESPPEEECHERTULEUPEETEERRDEERUNEEUPERLFTLLFENSSESTE TERLEILHELFUURSTPERBEBETSILTERFEEN 13 4 1 Constructional requirements usnsensnnesnennnnnnennnnnennennnnnnnn nennen 14 4 1 1 Electricalequipmentandcontrolmechanisms 15 4 1 2 Protection against over orunderloading uu 424444n nennen 16 4 1 3 System dependent requirements for the holding of loads in the air above DONS OMS ae aaar EEERREUEEEORLE ER EL SEES UERUENEDEEEERDLERUENEENEUTEEDERERCERENS TREEREN 17 4 1 4 System dependent requirements for the moving of loads in the air above PESON S octroie aiea EOS ODE RRESDE EUER FEENLEERERUETESTLLFEERTEROEREUETRELERER 19 4 2 Information Torusers esasassi seen aan 21 4 3 Labelllng a2 2 ne ee ner 22 4 4 Contents of operating manuals
5. IV Check list for regular inspectionS seesssssreesrreerssrrrrseenressrrnennresnnneena 36 gt gt igvw SQ P2 The solutions described in this igvw Standard do not rule out the validity of other solutions that guarantee the same standard of safety as laid down within the technical regulations of other member nations of the European Union or Turkey or other member states of the European Economic Area Please note Wherever possible gender free nouns and pronouns have been used Where this is not possible the male noun or pronoun has been used to improve readability but also is meant to refer to females gt gt igvw SQ P2 1 Area of application The Standard applies to the supply and use of electric chain hoists in event engineering 2 Normative and informal references DIN EN 818 7 2008 09 Short link chain for lifting purposes Safety part 7 Fine tolerance hoist chain Grade T Types T DAT and DT DIN EN 60204 32 2009 03 Safety of machinery Electrical equipment of machines Part 32 Requirements for hoisting machines DIN EN 61508 2002 11 Functional safety of electric electronic programmable safety related electronic systems DIN EN 62061 DIN VDE 0113 50 2005 10 Safety of machinery Functional safety of electric electronic and programmable electronic safety related control systems DIN EN 62079 2001 11 Preparation of instructions structuring content and presentation DIN EN ISO 13849 1
6. damage wear mounting adherence to tolerances 39 Herausgeber gt gt 18gVW Interessengemeinschaft Veranstaltungswirtschaft der fachverband Deutsche Theatertechnische Gesellschaft EVVC amp in Zusammenarbeit mit VBG Ihre gesetzliche Unfallversicherung Informationen unter www igvw org
7. gt gt 1gVW Standards der Qualit t Standards of Quality gt gt SQP2 Chain hoist October 2010 der fachverband gt gt igvw SQ P2 Legend Some explanatory notes regarding the structure of the standards SQ Standard of Quality O Organisation P Code of practice working procedure Q Qualification 1 2 3 consecutive numbering O Organisation Documentation Internal set up and organisation of operations Documentation and certification of processes P Code of practice working procedure Supply and use of working materials Q Qualification Qualification of skilled workers and specialists gt gt igvw SQ P2 Preliminary note SQ Standards are intended to define the quality levels required of services pro vided within the event technology industry SQ Standards take into consideration current legal positions and on that basis provide a description of the industry s specialised working procedures They contain a summary of the applicable legal norms and requirements in areas of industrial safety and health protection This Quality Standard has been developed by the responsible working group of the igvw Entertainment Technology Industry Association in cooperation with the DGUV German Social Accident Insurance and the working group of the safety engineers from the German public broadcasting organisations ARD ZDF medienakademie ARTE BR Bavaria DR DW HR IRT MDR NDR ORF RB RBB RBT RTL SF SR Studio
8. leakage functioning connection between engine parts 37 38 gt gt igvw SQ P2 generation of noise lubrication efficiency if necessary to be self locking condition wear 4 3 Brakes condition functioning 4 4 Steel chains chains chain links chain rollers chain wheels clamping mechanism safety of pinch points condition functioning mobility wear extension pitch fissures securing of bolts e g with rivet heads or rings 4 5 Load hooks distortion wear fissures corrosion pinching in hook apertures securing of hook nuts securing of hooks 5 Special safety devices signal equipment operating limit switch emergency cut off switch slack chain switch gt gt igvw SQ P2 safety edges re start security speed regulator display systems load limiting systems condition functioning completeness effectiveness mounting distortion mobility of the switching elements cleanliness condition of pressure springs inevitability 6 Locking devices condition functioning effectiveness 7 Electrical and electronic equipment cables conduits movable cables strain relief cable entry points shut off options group drive safety devices switchgear position limit switches Insulation and condition of covering functioning effectiveness
9. of fall see BGI 810 3 e When D 8 and D 8 Plus electric chain hoists are used their drive mechanism and brakes must be powered down when persons are underneath Before set up a visual inspection must be made of the electric chain hoists and all parts and appliances that are necessary for the job on hand e g slinging equipment controls cables tools and working equipment see 6 3 1 e Electric chain hoists are to be hung in such a way that the chain does not make contact anywhere and cannot become twisted when wound In particular the attachment of a load for instance a truss to more than one electric chain hoist must not be allowed to cause the chain to become twisted e When self climbing hoists are used it must be ensured that the chain will run easily into the chainbox The chain must also run easily in and out when it is slack and not loaded When compound chain hoists are used it must be ensured that the multiple chain strands do not become twisted e In special cases of operation for instance ground support loudspeaker towers the chains of the electric chain hoists may be diverted with pulleys The circumference of the pulley must measure at least 10 x the pitch length of the size of chain being used The profile of the pulley must be shaped in such a way that the load works only on the flat chain links and the standing chain links are not subjected to bending stress The pulleys must be made of a material that will not dam
10. the air above persons When C 1 electric chain hoists are used to move and hold loads above persons the control systems must in addition to the basic features listed in table 2 and depending on the type of load system at hand also fulfil the requirements described in table 5 Cs bei Kollisionsgefahr E1 E4 C 1 E1 E2 E4 ge 1 E3 C 1 E1 E3 E4 c1 Er C1 E14 E2 E4 c 53 Table of contents 19 gt gt igvw SQ P2 C4 Fi E3 F4 E1 63 u 1421 22 C4 ehEd oder oder C 1 E1 E2 C 1 2 Control Extensions E1 Underload switch off E2 Asynchronous group drive with group stop E3 Synchronous group drive E4 Control requirements collision lock Table 5 Demands on additional equipment for C 1 electro chain hoists The control unit must monitor movement and if necessary switch off in order to exclude the possibility of a collision of the loads being moved including all rigged objects or decoration Alternatively the control requirement E4 collision lock may be replaced by organisational measures Each person safety posts guarding a source of danger must have direct access to an emergency stop device 20 gt gt igvw SQ P2 4 2 Information for users The manufacturer must supply with the hoist a user manual in German that provides the user with information regarding the intended use of the electric chain hoist The manual must contain all information required for the safe and proper use of the e
11. 4uusennnnennnennnnnnnnnnnnnnnnnnennnnnennn nn 23 LOB UL T VPPRSIERPFERFFIOPESLENDERELLERTFTERERREBETEEPERTTEIEFEFEBENSPEEPBPELEFAEEPERFETFERFBERBERFEREIEREITEREESBER 25 5 1 Qualification and responsibility uu 44444Henennnnnnnnsnnnnnnnnnnnnnnnnnnnn 25 5 2 Assessment of risks connected with the use of electric chain HOISTS ecaa nE een ehe 26 5 3 Safety measures for the use of electric chain hoists 26 6 INSBecll nsa rn nee Ir Als 29 6 1 Basic principles of inspections 44444440eHHnennnnnennnnnnennnnnennennnnnnnn en 29 6 2 Inspections before USec Eea AAE E a a ANE AAA Ea 29 6 2 1 Inspections before manufacture nnsseessenensssnesnnennennnnnennennnnennn nn 30 6 2 2 Inspections before entry into service ueseessnneneensesnnnnnnnnnnnnnnnnn nn 30 6 3 Inspections during USe nessessnnsenessssnnnnnnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnr nn 30 6 3 1 Inspections during set up and use uuuenessensesnennnennnnnnnennnnnnnn nn 31 6 3 2 Regular inspections e u ee eneineneeee 31 6 3 3 Extraordinary inspections usseessnnennensssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 32 6 4 Documentation nesre a a a 32 Appendices Illustration of an electric chain hoist and self climbing hoist 33 II Illustration of the compensator principle 44444ssnennenneeneennennenen 34 III ASample handover Protocol moise a aaa abaa 35
12. V Check list for regular inspections object criteria User information 1 1 General labelling type plates Information on manufacturer year of manufacture type identification no dead weight engine type identification symbol D 8 D 8PLUS C 1 mounting legibility completeness durability 1 2 Safety and health protection identification danger notices condition perceptibility 1 3 User manual area of application content circuit diagrams legibility condition availability 2 Control devices 2 1 Protection against unauthorised use 36 gt gt igvw SQ P2 main control devices and their operating elements condition functioning mobility labelling shut off facility 2 2 Control devices for starting and stopping and their operating elements lifting lowering condition functioning mobility permanent marking of directions of movement protection against accidental triggering and unauthorised use reciprocal locking of operating elements in case of there being more than one control unit 2 3 Emergency control facilities functioning mobility ease of identification 3 Load bearing structure condition fissures distortion corrosion mobility and wear of steering spools bearings hinges attachment and safeguarding of detachable connections effectiveness of locking devices 4 Engines 4 1 Transmission
13. afe operation can be guaranteed 6 4 Documentation The results of all inspections are to be documented For the purpose of depicting the complete history of an electric chain hoist it is advisable to keep all inspection documents together in one book The documentation must be adequate and can contain the following declaration of compliance of the manufacturer inspection instructions and criteria of the manufacturer confirmation of inspections made by the manufacturer confirmation of inspections made before entry into service inspections made after substantial modification assessments of risk upon divergence from established inspection deadlines proof of regular inspections results of re examinations The documentation of inspections made during set up and use depends on the type of use of the electric chain hoist The written result of the last inspection must be kept available at the site of operation This can be provided by an inspection sticker on the electric chain hoist showing the date of the inspection the basis of the inspection and the name of the inspector If the documentation is compiled electronically suitable quality assurance measures are required for instance in accordance with EN ISO IEC 17025 2000 paragraph 5 4 7 32 gt gt igvw SQ P2 Appendices Appendix Illustration of an electric chain hoist and self climbing hoist Table of contents 33 gt gt igvw SQ P2 Appendix Il
14. age the chain see DIN 56 950 2004 5 entertainment technology machinery installations safety requirements and inspections 5 2 5 2 driving chain pulleys and diverting chain pulleys for steel chains 27 28 gt gt igvw SQ P2 e It is accepted that there are two different ways of chain diversion in tower systems The chain host is attached to the foot of the tower whereby the electric chain hoist must be at a sufficient distance from the tower truss for it not to collide with the sleeve block The applied load of the tower is equal to twice the load to be lifted The chain hoist is attached to the sleeve block or the truss so that it rises and falls with the rig This works like a pulley The lifting capacity is doubled and the lifting speed halved The applied load of the tower is equal to the load to be lifted When a compensator is used care must be taken to ensure that the centre of gravity is not moved in an improper way and that the lifting capacity is great enough in all installation positions see Appendix II e Cables and wires must be laid so that they do not run over sharp edges are not squashed and not subjected to any tensile loads e The movement process of the electric chain hoist and the load must be overseen by the operator see BGV D 8 GUV V D 8 29 Initiating the movement of the load Instructions for the starting of movement processes must be given clearly and unequivocally e
15. ain hoists single span girders with or without flange hinged linked single span girders on more than two electric chain hoists Distributed loads on three electric chain hoists Statically indeterminate load systems In statically indeterminate load systems the reactions applied loads of the individual electric chain hoists and therefore of the suspension points have not been properly determined Statically indeterminate load systems are for instance Distributed loads on more than two electric chain hoists multi span girders Distributed loads on more than three electric chain hoists Moving loads 12 gt gt igvw SQ P2 4 Supply Electric chain hoists are available in a variety of designs and with differing safety features The choice of electric chain hoists is therefore of great importance whereby attention must be paid to possible risks that can be anticipated in specific operating conditions For non portable equipment installed in event locations electric chain hoists should always be used that conform to BGV C 1 GUV VC 1 on account of their method of use and the possible risks This requirement may only be deviated from when an assessment of the possible risks shows conclusively that other technical solutions provide adequate safety Table 1 Types of operation of electric chain hoists when persons are present below In the event industry electric chain hoists are to be used tha
16. application and when 23 gt gt igvw SQ P2 particular accessories are in use and details of specific safety equipment that is required in these situations operational mistakes that could normally be foreseeable and prohibited operations malfunction detection and identification repairing and re starting after an intervention recommended personal safety equipment and necessary training e information on maintenance by the user type and frequency of inspections with regard to safety functions f information on servicing by expert staff information on servicing work that requires particular expert knowledge or abilities and that therefore should only be carried out by trained staff e g maintenance staff or specialists instructions for servicing work e g the replacement of parts that requires no special knowledge and that therefore can be carried out by the user e g operating staff acquisition of spare parts and the carrying out of repairs drawing and diagrams that make it possible for the maintenance staff to rationally carry out their duties particularly fault detection g information concerning withdrawal from use on discard criteria for load carriers on discard criteria for the electric chain hoist with instructions on what to do when damage occurs on dismantling and disposal h instructions for emergency situations e g warnings about possible emissions or leakages of harmful substanc
17. ar operation of more than one electric chain hoist whereby in the case of a fault in one hoist the whole group is automatically stopped A distinction is made between distance and time synchronous drives Distance synchronous All electric chain hoists in one group cover the same distance in a given period of time Time synchronous The electric chain hoists in one group cover in a given period of time different distances Load is the sum of all weights and acting forces e g dynamic loads or failure pressures Working load limit is the load that the electric chain hoist is constructed to lift Specialist A qualified person A specialist is a person who can show that he has at least the following qualifications indicating aptitude competence and technical accomplishment e he has successfully completed a technical education e as a result of his current job practice he has sufficient technical know how and at least one year s practical experience in testing electric chain hoists within the event industry e he has sufficient knowledge of the legal principles workplace safety laws regulations and technical rules and standards the rules regulations and decisions of the social accident insurance current technical standards e g EN DIN and VDE Standards information supplied by the manufacturer of the machinery related devices that are to be tested potential risks involving the machinery r
18. e fitted with an overload safety device An overload safety device is always required for D 8 Plus electric chain hoists If a load control system is installed it must guaranteed that any necessary switch off takes place sufficiently quickly see section 5 3 If in the course of the assessment of a risk it becomes necessary to measure a load this may not be done using the power supply of the motor because a load measurement must be possible when the electric chain hoist is stationary and thus in a power off status 16 gt gt igvw SQ P2 4 1 3 Load system dependent requirements for the holding of loads in the air above persons When D 8 or D 8 Plus electric chain hoists are used to hold loads above persons the actions listed in tables 3 and 4 must be clearly complied with Statically determinate load systems require additional measures when D 8 electric chain hoists are used Table 3 Additional measures to be taken when D 8 and D 8 Plus electric chain hoists are used for statically determinate loads Additional measures are to be taken when D 8 or D 8 Plus electric chain hoists are used for statically indeterminate load systems Table of contents 17 18 gt gt igvw SQ P2 Table 4 Additional measures to be taken when D 8 and D 8 Plus electric chain hoists are used for statically indeterminate loads Table of contents gt gt igvw SQ P2 4 1 4 Load system dependent requirements for the moving of loads in
19. e requirements of the BGV C 1 GUV V C 1 and is therefore fundamentally suitable for holding and moving overhead loads Please note The terms D 8 D 8 Plus and C 1 electric chain hoist are derived from the regulations of the DGUV German Social Accident Insurance Set up mode Set up mode denotes the hand controlled moving of loads with electric chain hoists in order to get them into position This normally takes place during rehearsal for staged performances Please note In set up mode persons may stand under the load provided the hoists and control units conform to the requirements of the BGV C 1 GUV VC 1 Electric chain hoist Electrically powered lifting device with round steel link chains as load bearers In contrast with the classical industrial usage of lifting gear in event technology the electric chain hoist is mainly used as a self climbing hoist Self climbing hoist describes the method of use in which the electric chain hoist climbs up its own chain See the diagram in the appendix Group drive is the simultaneous operation of more than one electric chain hoist using the same control unit 10 gt gt igvw SQ P2 Asynchronous group drive with group stop Is the asynchronous operation of more than one electric chain hoist controlled through the same unit whereby in the case of a fault in one hoist the whole group is automatically stopped Synchronous group drive with group stop is the monitored or regul
20. elated devices e he has knowledge of and experience in the use of appliances or tools gt gt igvw SQ P2 required for the testing e he is able to make a judgement on the safety status of machinery installations based on latest technical knowledge and can summarise this on a standardised check list Authorised expert a person qualified through particular specialised knowledge An authorised expert is someone who has for example completed a degree course at a university or technical college and has at least three years practical experience in the construction or testing of machinery related devices and who has successfully attended the authorisation course of the social accident insurance as per 36 BGV C 1 GUV VC1 Safety backup Second independent device that secures the load to prevent it from falling Compensator Mechanical appliance that balances asymmetrically distributed loads when more than one chain is being used Pitch of the chain The inner measurement T in mm of a chain link gt gt igvw SQ P2 Load system Combination of load load suspension means and sling gear Statically determinate load system In statically determinate load systems all loads and reactions applied loads of the individual electric chain hoists and therefore of the suspension points are known Statically determinate load systems are Loads on individual electric chain hoists point load Distributed loads on two electric ch
21. es and when possible information on cleaning agents to be used against the effects of those substances 24 gt gt igvw SQ P2 5 Use Only those electric chain hoists may be used that comply with the definitions listed in Section 4 Supply Electric chain hoists are to be used in accordance with the following regulations Use means the operation transport storage maintenance and inspection of working equipment Before electric chain hoists are put to use an evaluation of possible risks must be carried out in order to ascertain all measures necessary for a risk free use These measures must be capable of guaranteeing the workplace and health safety of all persons involved as well as preventing damage to buildings furnishings and working equipment The evaluation of possible risks must take into account the on site circumstances all operating conditions foreseeable accidents and the behaviour of the persons involved 5 1 Qualification and responsibility The duties of the responsible persons must be defined and differentiated The responsibility of the promoter and or owner of the venue remains unaffected The qualification required for the planning set up and dismantling as well as for the operation itself depends on the degree of risk involved Further information concerning the necessary qualifications is to be found in the igvw Standard SQ Q2 Competence in Event Rigging The supervisor in charge relea
22. he choice of electric chain hoists with regard to their lifting capacity must be made in such a way that no overload can occur It is sensible not to use an electric chain hoist to its full capacity When choosing attachment points within the building the dynamic load components e g impact coefficients must be taken into account in the calculation 26 gt gt igvw SQ P2 A load measurement must be made when the risk of an overload of individual elements exists e g attachment points suspension points electric chain hoists load suspension devices involving for instance line loads on more than two electric chain hoists area loads on more than three electric chain hoists guided loads e With lifting speeds of 8 m min or less in set up dismantling or installation modes the normal operator reaction will be quick enough so that it is sufficient to have acoustic warning signals that tell the operator to shut off the driving command when a safety device is activated Example an external load monitor not connected to the motor control unit e Before every set up it is compulsory to check that the attachment points in the building are in a proper condition This can be done with a visual inspection and a comparison of the data in the operator s documentation e When D 8 electric chain hoists are used to hold loads above persons safety backups are an absolute necessity Safety backups must be used that allow no distance
23. ions during use The safe status of the electric chain hoist should be sustained during use Within the framework of a period of use the contractor carries out risk assessments In this connection he must determine and evaluate the influences that cause damage taking into account the different kinds of operating mode and then devise and implement suitable measures to counteract them gt gt igvw SQ P2 As a result the contractor decides on the type and extent of inspections after set up and dismantling and after any unusual occurrences as well as on the deadlines for recurring inspections and the qualifications demanded of the person who is commissioned to carry them out 6 3 1 Inspections during set up and use During set up on site erection and each time before use the safe condition of the electric chain hoist must be established with a visual inspection and a functionality test These include a check for external damage or wear provision for the particular circumstances of the surroundings tests with the help of a check list The qualification of the person making the inspection depends on the job for which the electric chain hoist is being used and the amount of risk involved 6 3 2 Regular inspections Electric chain hoists are to be inspected according to the type and frequency of their use so that defects and damage can be detected in proper time The deadlines for inspection are laid down by the contractor as part
24. itions e g temperature humidity vibration electromagnetic radiation instructions for connection to power supplies particularly with regard to protection against electrical overload advice on disposal if necessary recommendations regarding safety measures to be taken by the user e g additional safety margins warning signs and signals c information on the electric chain hoist itself for instance an exact description of the electric chain hoist and accessories the complete designated range of operation including any possible prohibited uses whereby allowance should if necessary be made for the different models of the electric chain hoist diagrams particularly schematic illustrations of the safety functions details of noise and vibration that may be produced by the machine technical data on the electrical equipment safety related components of the electrical and electronic control systems data that confirms that the electric chain hoist complies with mandatory requirements declaration of conformity d information on the use and operation of the electric chain hoist e g on the intended utilisation a description of the operating elements handling and conduct during set up and dismantling operation and stop appliances particularly for emergency stops risks that could not be eliminated through the manufacturer s safety measures special risks that can occur in particular areas of
25. lectric chain hoist In this respect it must inform the user about the residual risks and warn him of them The user manual must be compiled according to the basic principles of EN 62079 The user manual must specify whether training is required personal protective clothing is required additional separative or non separative safety devices should possibly be provided for No possible use of the electric chain hoist may thereby be excluded that could reasonably be expected from the designation or description of an electric chain hoist The user manual must warn of foreseeable incorrect operation The user manual must cover transport set up and dismantling installation and setting up starting up use installation programming or conversion operation cleaning trouble shooting and maintenance of the electric chain hoist and when applicable shutdown e dismantling and e disposal 21 22 gt gt igvw SQ P2 4 3 Labelling The following labels must be permanently and visibly fixed to the electric chain hoist a unambiguous identification name and address of the manufacturer year and month of construction yy mm description of the machine description of the series or type serial number b mode of application designation D 8 D 8 Plus C 1 c information for safe operation e g mass expressed in kilogrammes of the electric chain hoist itself and or its detachable pa
26. of the risk assessment taking into account existing information from the manufacturer influences that may cause damage operative experience other information on the latest state of technology During inspections any defects are assessed and decisions made on further use before the next regular inspection See Appendix IV Check list for regular inspections Inspections with set checks taking the operational and on site conditions into account are well proven within the event technology industry For D 8 electric chain hoists Inspection by a specialist every 12 months For D 8 Plus and C 1 electric chain hoists Inspection by a specialist every 12 months Inspection by an authorised expert every 48 months Deviation from these established deadlines must be justified in writing by the contractor Relevant reasons could be for instance the operating conditions maintenance intervals and frequency of use The results of the regular inspections are to be documented and kept available at the company 31 gt gt igvw SQ P2 6 3 3 Extraordinary inspections Extraordinary inspections are necessary in particular in the event of damage after a long period of disuse after substantial modification of the electric chain hoist The replacement of parts with ones of the same type is not considered to be a substantial modification The electric chain hoist may not be used again until an inspection has proved that s
27. possible Table 2 Constructional requirements for electric chain hoists 14 gt gt igvw SQ P2 4 1 1 Electrical fittings and control systems The installation of the power supply the control system and the choice of electrical equipment must prevent the occurrence of dangerous operating conditions in the event of a malfunction The electrical equipment e g contactor control wiring arrangement of electric chain hoists must in particular fulfil the requirements of DIN EN 60204 32 Safety of machinery Electrical equipment of machines Part 32 Requirements for hoisting machines The electrical equipment must fulfil the following minimum requirements e rotating field and phasing control e emergency off and stop switches within reach of the operator e protection against electric shocks e protection against accidental start up and automatic restart after failure and restoration of power protection against influences of the surroundings e selection of the direction of movement e control device for movement Additional requirements can be found in EN 60204 32 If electronic or electronically programmable control systems are used their safety related features must fulfil the requirements of a DIN EN 62061 DIN VDE 0113 50 or b DIN EN ISO 13849 or c DIN EN 61508 15 gt gt igvw SQ P2 4 1 2 Protection against over or underloading Electric chain hoists with a lifting capacity of more than 1000 kg must b
28. ractor may only provide electric chain hoists for which the manufacturer can supply the following inspection results and documents construction and manufacturing documentation in particular functional description danger and risk analysis construction and manufacturing documentation and proof of specifications compliance with the product documentation in particular construction and lifting capacity safety features and user manuals 6 2 2 Inspections before entry into service Inspections before entry into service are carried out on the electric chain hoist when it is ready for use For this the documentation from previous inspections inspections before manufacture and the declaration of compliance must be to hand The qualifications required of the inspecting person are dependent on the complexity of the individual electric chain hoist and the risks that could originate from it Before the electric chain hoist is put into service the contractor checks the following criteria completeness of the electric chain hoist proof of previous inspections declarations of compliance labelling compliance with selection criteria the reliable and safe condition and functionality of the safety devices the manufacturer s technical documentation see paragraphs 4 2 to 4 4 The contractor makes sure that the results of the inspections carried out before entry into service are documented and kept available 6 3 Inspect
29. rts dead weight working load limit in kilogrammes motor type nominal speed of the hoisting mechanism m min specifications of the power supply e voltage V current A e frequency Hz power kW duty cycle Labelling and inscriptions on the casing of the electric chain hoist should remain legible during its entire expected lifespan The use of symbols or written warning notices with the inscription Danger is prohibited The labelling should be supplemented by clear geometric forms that are conspicuous in all operating conditions The equivalents are D8 D 8 Plus C1 geometric forms of triangle D 8 square D 8 Plus and circle C 1 gt gt igvw SQ P2 4 4 Contents of operating manuals The operating manual or other written instructions must among other things contain a information on transport operation and storage of the electric chain hoist for instance storage conditions for the electric chain hoist dimensions mass information position of centre s of gravity information on use e g illustrations showing the attachment points of the electric chain hoist b information on the installation and commissioning of the electric chain hoist e g requirements for anchorage and shock absorption requirements for assembly and erection instructions for the attachment of loads space requirement for operation and maintenance permissible environmental cond
30. ses the electric chain hoists for use This clearance may not be given until it is proved that the inspections listed in section 6 of this Standard of Quality have been duly carried out A handover to another user must be recorded in written form see appendix III 5 2 Assessment of risks connected with the use of electric chain hoists The safe operation of electric chain hoists in the event industry can only be effected with proper consideration of all components and influences and the resulting safety related measures In this way it is possible to choose suitable working procedures and the necessary equipment The assessment of risks takes place during the planning phase and from the beginning takes all exigencies into account These are in particular the presence of persons under the load the type of load to be hoisted the type of operation 25 gt gt igvw SQ P2 the time framework All measures described in the following paragraphs are derived from the result ofthe assessment of risks 5 3 Safety measures for the use of electric chain hoists e The supervisor in charge must work out a set of instructions on the basis ofthe assessment of risks in order to regulate conduct during set up and dismantling as well as during the operation of electric chain hoists These instructions apply for the specific job and are to be distributed to the staff When the risk of workplace injuries and damage to health cannot be excluded through
31. stored to a proper condition If as a result of the inspection doubts arise about the safe operation of an electric chain hoist this hoist may not be put into use until the defects have been rectified and a second inspection has shown the electric chain hoist to be safe 6 1 Basic principles of inspections The manufacturer of electric chain hoists must make inspections on the basis of BGV C 1 GUV V C 1 Event and production locations for staged performance BGV D 8 Winches lifting and pulling devices BGG 912 GUV G 912 Guidelines for the testing of machinery installations on stages and in studios DIN EN 818 7 2008 09 Short link chain for lifting purposes Safety part 7 Fine tolerance hoist chain Grade T Types T DAT and DT DIN 56950 Entertainment technology machinery installations Safety requirements and inspections 6 2 Inspections before use When electric chain hoists are supplied for purchase the inspections listed in this section must be carried out or be shown to have been carried out Each purchase leads to a handing over to the buyer and is concluded with a formal commercial or administrative inspection as to whether the contractual agreement has been complied with and with a technical inspection and the handing over of the documentation required from the manufacturer or intermediary 29 30 gt gt igvw SQ P2 6 2 1 Inspections before manufacture The cont
32. t comply with the specifications laid down in paragraph 4 1 Constructional requirements Type off D8 D8 D 8 Plus C1 use with safety back up Holding of prohibited allowed allowed allowed Loads as per as per as per Table 3 Table 3 Table 3 Set up prohibited prohibited prohibited allowed dismantling or as per installation Table 4 IMovement prohibited prohibited prohibited allowed on stage as per Table 4 Complicated prohibited prohibited prohibited allowed movement as per on stage Table 4 13 gt gt igvw SQ P2 4 1 Constructional requirements Specific uses within the entertainment industry have different constructional requirements denen at en 3 atleast his as per Sin 56350 Dimension of Single lifting Double lifting Double lifting motor capacity capacity capacity Operating at least 5 at least 10 At leastT0 coefficient of the load bearing material tensile strength Slip clutch as yes no no protection against overloading Number of brakes 1 2 2 or a self locking gearbox Operating limit possible Possible yes switch Emergency limit no no yes switch Overload Slip clutch Protection against Cutout at 120 of monitoring overloading 1 the lifting capacity Underload no no as per load system monitoring 1 In statically indeterminate systems cutout at 120 of the lifting capacity In statically determinate load systems overload protection through slip clutch is
33. technical and organisational safety measures the employer must provide suitable personal protective equipment PPE and other aids which must be used in the intended manner by staff and other endangered persons A self employed individual must keep his PPE at hand and use it in the intended manner The PPE supplied for the set up and dismantling of electric chain hoists must in particular include Protective or safety shoes gloves headgear and if necessary PPE against a fall The operator of a building is responsible for the type load bearing capacity and quality of the attachment points within the building that are provided by him He must provide suitable documentation for instance a load capacity plan about these e The choice and dimensioning of all load bearing elements in the distribution of forces e g suspension point girder clamp shackle steel rope electric chain hoist truss must be made after consideration of the applied loads and risks that may occur in each specific case see BGI 810 3 If damage to the load carrying structure through an overload due to differences in synchronised speed of the electric chain hoists cannot be excluded D 8 and D 8 Plus electric chain hoists must be fitted with overload protection as per paragraph 4 1 3 C 1 electric chain hoists must be fitted with a control unit of the type C 1 E3 with the stipulated fault tolerance The group switch off must work in both directions e T
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