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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  
    						
    							P 9-8  
    						
    							 
     
     
     
     
    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 
      
    						
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