RSA Series Dock Levellers Hinged Lip Suspended Frame. Technical Characteristics nr. 3258

Transcription

1 RSA Series Dock Levellers Hinged Lip Suspended Frame Technical Characteristics nr

2 European Regulation 1.1 Regulations to be applied to dock levellers Every dock leveller will have to strictly follow the 98/37/CE of June 22 nd 1998, the EN 292/1 and EN 292/2 Machinery Safety: general technical principles for design regulation, and the EN 1398 European Regulation of type C. in the first part of the EN1398, it s said that all national rules conflicting with it have to be withdraw within February 1998, and the EN 1398 have to be applied without making any modification. Laws cannot be discussed, but only applied. Our dock levellers strictly follow the mentioned safety rules, without any modification. 1.2 Conformity Declaration Our dock leveller is monoblock structure; all the safety requirements are included to avoid, as much as possible, any risk. Each and every dock leveller is tested in our factory and only after positive result the conformity declaration is signed according to UNI CEI EN The signature of this declaration allows the CE marking. 1.3 User and instruction booklet The user s and instruction booklet contains all documents that state the conformity of the machinery to the regulation, the machinery description, the foreseen usage conditions and all installation, set-up, adjustment, utilization, maintenance and repair notes. The user s and instruction booklet is complete with electric and hydraulic diagrams. 1.4 Drawings and technical booklet For each dock leveller, it is foreseen a product technical booklet stating all the structure calculations and safeties. The technical booklet is available on request by the authorities to verify the conformity of our dock levellers to all safety need state by EN 1398 and EN 292 regulations. 2

3 Main safety requirements 2.1 Purpose of the dock leveller The dock leveller is static or mobile equipment, which is used to fill the distance between a loading dock or similar loading areas and the loading surface of a vehicle that can be at different levels. The dock leveller is not designed to lift or lower goods. The operation is therefore intended to lift the load, but only to modify the position of the dock leveller, without any load. The dock leveller is not suitable to carry loading if it is not perfectly resting in a balanced position on the vehicle surface. 2.2 Tripping risks due to the horizontal oscillation of the truck In the working position, the dock leveller must be left free of swinging both vertically and crosswise. Crosswise swinging, that equals to 5% of the total dock leveller width approximately, is obtained as a result of the particular structure flexibility of the Indupart leveller. The torsion value is measured without any load, the lip perfectly laying on the vehicle surface and is indicated, in mm, in the technical data of each leveller. This characteristic is obtained by using a series of beams welded directly below the upper frame, with a system similar to the lorries tray chassis. 2.3 Tripping risks due to the vertical oscillation of the truck In the working position, dock levellers must be free to vertically swing to suit the high of the lorry tray. An electro valve that makes the 3

4 cylinder drainage, rendering the leveller fluctuating, obtains this movement. 2.4 Danger situation If there is an electrical problem that stops the leveller in a danger situation you must eliminate it, as written in the EN 292/1, by duplication the critical components (Art 3.7.5) and by an automatic surveillance (Art ). In practice all of the Indupart dock levellers feature a group of valves that allow to finish the carrying steps. 2.5 Visibility of raised or lowered position of dock leveller The visible lateral components of dock levellers, in raised or lowered position, are clearly marked with yellow / black stripes. 2.6 Support device for maintenance Dock levellers are fitted with a mechanical device which, when operated, will support the leveller at its maintenance position without load. This device is part of the dock leveller and it is not possible for it to be unintentionally disengaged. 2.7 Crushing and shearing hazards Crushing and shearing hazards pit edges and dock levellers frame are avoided by using telescopic protection panels. The crushing and shearing hazards between the folded lip and the dock leveller frame are safeguarded with a vertical safety distance of at least 25mm between the lip edge and the frame components in rest position. Crushing and shearing hazards between dock levellers and vehicle loading surface are safeguarded if the control panel will be placed in a position to let the operator easily see all dock leveller movements. We supply one single control panel every dock leveller. 25mm 4

5 2.8 Automatic Security device Indupart dock levellers are provided with an emergency stop device, located directly in the raising cylinder, which, if the loading vehicle drives away before the dock leveller has returned to its resting position, reduce the lowering speed to not more than 0.05 m/s. The En 1398, Art , say that all parts subject to the overloading due to automatic security device must be designed to resist the overloading pressure in our dock levellers, the cylinder is designed to stand a high pressure. The operation of the security valve with a weight more than 2000 Kg, can cause permanent structure damages. The permanent deformation of the structure is foreseen by the European regulation EN 1398, because a rigid structure could not suit the upper frame torsion principal security requirements of a dock leveller (par. 2.2 and 2.3). 2.9 Dock leveller stop and automatic re-set prevention Activating the main switch and in the event of a power problem. All dock levellers movements are stopped. The power could be reactivated only by a manual action of the operator, to prevent any uncontrolled movement of the dock leveller Other safety requirements We remind you that all our dock levellers strictly follow the 98/37/CE of June 22 nd 1988, the EN 292/1 and EN 202/2 machinery safety: general technical principles for design and EN 1398 European Regulation of type C. We do not want to dilate, but if you want to go into a particular matter, our Quality service is at your disposal to answer all questions Technical Characteristics Power pack: We use external engine power pack, placed on the lower frame in a frontal position for an easy maintenance. Our valve group, as told before, is suitable to all safety requirements: in the event of a power problem the operator can finish safety his loading operation, and then easily bring the dock leveller back to its resting position: it s possible to close the lip manually unplugging the flexible pipe, and then bring the dock leveller in its original position with a weight of about 600 kg. On his top. Every dock levellers has got its own power pack Control Panel S20 (Dock Leveller and Sectional Door) 5

6 The control panel in addition to the dock leveller operation can feed and operate the sectional overhead door, too. Only one connection cable of the control panel to the geared motor including motor feeding, up down and block control dock leveller / sectional door allows an easy assembly without any possibility of mistake. We underline considerable safe of money for the customer because two independent feedings are usually requested: one for the dock leveller control panel and one for the geared motor. For further information see Technical description of Industrial sectional doors of Indupart. Feeding voltage 400 V (+-5%), 50 Hz three phase + earth + neutral. Neutral is necessary to obtain 220V single-phase to feed the geared motor of the sectional door Connection cables Power pack Control panel The connection of cables of electro-valve and motor are flameproof, 6 mtr long from pit edge. They are put together in special cable, suitable to be easy connected to the control panel. The cable length is enough to grant to place the control panel in a correct position. If you need to have a longer cable, it s possible to have a 10m length (with an extra price). We just want to remind that the operator must clearly see all dock leveller movements: this means that the control panel must be placed near the dock leveller. The cable is still connected to the power pack. Every dock leveller has got an independent control panel Lip A robotized milling machine automatically works our dock leveller lip. The milling process includes the bevelling along the entire length of the lip and the breaking of the milled corners. This avoids any damages to forklift wheels during loading operations. The lip is provided folder to perfectly lay to the truck body. If you need to load trucks with different width, it s possible to use a 3-sector lip: a central sector and two lateral ones that are automatically connection by a sphere device. It s possible to pull the lateral sectors down when you don t make sure of them, by performing a small manual pressure. Versatility of dock leveller width allows to suit the real body truck dimension. 6

7 Slope According to regulations, the dock levellers working slope can not be more than 12.5% in our dock levellers the maximum negative slope is mechanically limited. The maximum positive slope (as it is foreseen and extra lifting height for lip opening) is indicated by a red strip. The negative and positive slope values are indicated, in mm, in the technical data chapter. RIGHT SOLUTION H H = Extra working height range = Positive slope + lip length (400mm) - 30mm about WRONG SOLUTION H H = Extra working height range = Positive slope + lip length (400mm) - 30mm about Extra working height All our dock levellers have a positive wide extra working height sufficient to allow the complete opening of the lip in a way that is cannot crash into the truck body. In practise a suitable extra lifting height allows the dock leveller opening and closing even when the 7

8 truck is already under loading position (few centimetres from bumpers) Capacity Nominal charge 6000kg, of which 5400 kg (90%) concentrated on a single axis (forklift with four wheels, o minimum of each wheel = 250mm). The nominal charge is the weight of the maximum moving charge, including goods, operator and forklift. In its resting position, with the lip in vertical position and on its suitable stops, the dock leveller forms a level surface with the floor and it can over driven in all directions. On request, if you need to have a 3 wheel forklift passage or with lower o, the upper frame will be reinforced by two more beams. The stronger upper frame will reduce the lateral flexural torsion Back Hinges The back hinge is formed by 9 sectors, unitary 100mm long and pin diameter 30mm. The hinge is divided in 3 pieces to easily take the central pin away. (Note: in dock leveller of 1750mm wide, for space reasons, this hinge is composed by 7 sectors) Structure and pit fixing Indupart dock leveller are realized with mono block self-carrying structure. Equipped with sidewalls and support beam. The advantages of this structure are numerous: o It is possible to provide all securities to avoid, as much as possible, any risk as foreseen by the regulation EN 292. o Yellow/Black strips fixing into suitable punched seats. o Easy installation and displacement o Pit does not need any smooth walls, but only row finishing. Dock leveller side walls works as pit walls. Self carrying bar 8

9 NO YES Pit dimensions The necessary dimensions to realize pits are available for our customers on paper and on CD-ROM for additional information you can contact our technical department Pit Fixing Indupart is able to offer a large range of pit fixings (from traditional systems which foresee the locking of the dock leveller to iron round pieces plunged into concrete, Universal system, box shaped structure, dock leveller without sides to lay on the put bottom, structure on scaffold etc.), for every necessity of the customer. Drawings for all solutions are available, on paper and on CD, to all our customers. The fixing choice is at customers care: we suggest to choose the fixing type 8, which allows fire the floor finishing and the dock leveller installation. This solution foresees a pit edge realized with a frame fixing during the industrial floor casting Advantages of type 8 fixing The frame costs are highly repaid by installing the dock levellers on finished floors. They are the followings ones: o Installation with no mistakes. The dock leveller is directly unloaded into pit edge. o Clean work. It is not necessary any additional concrete casting; the dock levellers are not dirty and, in particular, hinges do not need any final cleaning to take possible concrete scraps away. o Cheap and continuous assembly. It is possible to install, at the same, dock levellers, sectional doors and dock shelters, reducing costs of transport, displacements and assembly times. o Delayed payment conditions. The supply of dock levellers is at finished floors: this means that the payment will start later. 9

10 Frames for pit edge Out ref TL The frames, for transport problems, are forwarded in 3 sectors (2 side bars and the front piece). The assembly instructions are delivered by Indupart, and they are very simple. The frames for pit edge are normally available in stock. If transport costs are very important, we advise to realize the frames on place. Every building, by using trade components are able to manufacture them by following the indications given by Indupart Plate bar welded on angle bar Welding Finished concrete dock Holders into concrete All value Quality of used components All Indupart dock leveller components are chosen according to only one principle: to rigid respect of quality parameters, to solve all the expressed and unexpressed exigencies to his customers. The hydraulic power pack, for example, is produced by Oil System Company, and is one of the best materials available on the market. Further on the power pack installs a particular valve group, where, in case of an electric problem, assure the maximum security in every situation. Each and every cylinder is tested and is designed to stand the pressure up to 800 atm Maintenance simplicity All components of Indupart dock levellers have been studied to allow an easy maintenance or replacement. The cylinders, for example, are fixing by means of pins, allowing an immediate and intuitive disassembly of the same ones without un-welding other items. The hydraulic power pack is placed in such a position of easy accessibility 10

11 without obliging the installer to go under the upper frame to do his job anymore Components unification The continuous technical renewal of Indupart products has obliged our Society to make technical choices able to grant to the customer additional features. All Indupart dock levellers of the same type (RSA, Extensible lip 500mm, Extensible lip 1000mm) have common components such as hydraulic power pack, lip and raising cylinder, control panel. In any case, Indupart grant a 48 hour delivery service for spare parts. 11

12 WARRANTY CERTIFICATE We declare that each single machine undergoes meticulous testing before being delivered. We guarantee therefore that each machine is free for defects when it leaves our warehouses. 1. All our machines are covered by warranty for 2 years. 2. All trade components used on our machines, as for example all control boxes and all hydraulic power packs, are covered by proprietors warranties provided by their manufacturers. 3. By warranty it is intended the complete cost-free replacement of the components of the machine found faulty from the beginning as a result of manufacturing faults. 4. All parts resulting faulty due to negligence or careless use (lack of observation of the instructions for the functioning of the machine), wrong installation or maintenance not performed according to the user s and instruction manual, or performed by unauthorized persons, shipping damage, or in general all circumstances that cannot be in any case related to manufacturing defects, are not covered by this warranty. 5. The manufacturer declines all responsibilities for damages that could, directly or indirectly, result to persons, things or animals, as a consequences due to lack of observance of all directions given in this user s and instruction manual and concerning, in particular, all warnings regarding installation, use and maintenance of the machine. 6. Changes regarding shipment and / or travelling allowance of personnel are excluded from this warranty. 12

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