PUFFERS Instructions and user manual - Rev. 5 Head office, registered office and operative base: 79, Via degli Imprenditori 37067 Valeggio sul Mincio (Verona) Italy Tel. +39 045 7952209 Fax +39 045 7952174 VAT No. IT03165700232 www.pizzamigliosrl.com info@pizzamigliosrl.com MANUFACTURERS OF LIFTING DEVICE COMPONENTS
P I Z Z A M I G L I O S R L - P R O D U Z I O N E A C C E S S O R I A P PA R E C C H I D I S O L L E V A M E N T O - Company introduction The Pizzamiglio Srl company has been founded recently from the ashes of the former Elettromeccanica F.lli Pizzamiglio Renato e Ivo Snc, established in 1982 by the brothers Renato and Ivo. Their twenty-year experience in the field of lifting gears started with the birth of their own business which dealt with elctromechanical maintenance focusing particularly on bridge cranes. Thanks to the constant growth of customers' needs, the company starts the production of switchboards, the installation of industrial and home electrical systems and the manufacturing of structural works in the lifting field. In order to offer a more complete range of products, in 1994 the company starts to produce trolleys and accessories for the lifting and handling of power supply cables for bridge cranes and the company to increase its turnover and expand its market. The workshop equipment gradually increases with the introduction of work vehicles needed to the manufacturing of maintenance mechanical components. Indeed, the maintenance activity was growing more and more also thanks to the European Directive on occupational safety practices. In 1996 the company starts manufacturing hydraulic brakes in accordance with the DIN 15435 (DIN System), and other crane components such as buffers and load limiting devices. Consequently, the company creates a wider range of bridge crane accessories and expands its commercial possibilities. At the same time, the assistance activity to other companies increases and becomes one of the significant company activities and the company members' direct experience in this specific filed allows to develop and improve continually bridge crane accessories. In 1997 the company moves to a new building in a small business area to meet the productive organization and the staff growth needs. In 1998, the company starts the production and direct marketing of its "AQ Trolley" electric feeder systems with copper conductors for mobile applications. Pizzamiglio srl PUFFERS Instructions Rev. 5 2/16
In 2001 the company Elettromeccanica F.lli Pizzamiglio Snc obtains the certification of the Quality System in accordance with the ISO9002. In 2002 the company divides and dedicates itself to the manufacturing of components for cranes. Nowadays, based on their installation experience, our technicians can meet the needs of the most demanding manufacturers and maintenance firms. Our company is specialized in the production of : "Olivares" cable trolleys for bridge cranes, jib cranes and many other uses; "Olivares Feston" cable trolleys for dock and steelworks cranes; Electro-hydraulic fail-safe shoe brakes in accordance with the DIN15435, and broadband brakes; Brake band and engine couplings for shoe brakes; Spare asbestos-free brake shoes and flexible coupling in accordance with the DIN System requirements; Electro-hydraulic fail-safe disc brakes; Load limiting devices for bridge cranes; Telescopic control stops for bridge cranes; Iron puffers with rubber springs; Rubber buffers; Bus-bar system Trolley AQ for bridge-cranes. Pizzamiglio srl PUFFERS Instructions Rev. 5 3/16
Index I N T R O D U C T I O N 2 CHAPITER 1 Preliminary remarks 5 CHAPITER 2 Company and product data 6 CHAPITER 3 Product description 7 CHAPITER 4 Choice of puffers 8 CHAPITER 5 Technical features 11 CHAPITER 6 Installation 13 CHAPITER 7 Safety features 14 CHAPITER 8 Maintenance 15 CHAPITER 9 Warranty 16 Pizzamiglio srl PUFFERS Instructions Rev. 5 4/16
1 Introduction This manual has been compiled to help installers and maintenance operators of PUFFERS produced by Pizzamiglio srl. It contains indications and warnings for correct installation and maintenance of these devices for a product s long time life and safety use by the final user. This documentation and its possible enclosures must be read carefully by the personnel working at any level before starting the installation, maintenance or adjustment of the puffers. Any intervention must be carried out with the help and in accordance with this manual. The employer must verify the training and qualification of the personnel before giving the authorization to make any intervention on the lifting gears. IMPORTANT: each data contained in this publication is to be considered as indicative only. The manufacturer reserves the right to modify data without prior notice. Pizzamiglio srl PUFFERS Instructions Rev. 5 5/16
2 Company and product data Company data: PIZZAMIGLIO SRL 79, Via degli Imprenditori 37067 Valeggio sul Mincio (VR) - ITALY Tel. +39 045 7952209 Fax +39 045 7952174 P.iva: IT 0316570 023 2 http://www.pizzamigliosrl.com E-mail: info@pizzamigliosrl.com Product data: Name of the product: PUFFER Pizzamiglio srl PUFFERS Instructions Rev. 5 6/16
3 Product descriptions The function required to the puffers is to void the kinetic energy of a mass that comes into collision with them. In cranes construction applications puffers have to dump the collision between the bridge or the trolley with the crane rail stops when electrical limit switch devices are out of order. They consist in an iron body with a base and a head relied by a rod and telescopic pipes that contains rubber springs operating in compression disposed in series separated by metal disks Ambient of work: either for indoors or outdoors installation. Range temperature: from 20 C to +50 C. The iron body is subject to powder coating painting cycle with polyester fit for outdoor in grey colour. The safety chain and the shackle are galvanized. Warning: the function of puffers is to void the kinetic energy of a mass that comes into collision with them in according with energy values indicated on the following pages. Every other use mast be considered improper use. Types: we produce several types of puffers with different length and for different values of energy. Type C with longer stroke is fit for hi-speed cranes because returns a lower reaction force. Type 327/A Type 327/C Pizzamiglio srl PUFFERS Instructions Rev. 5 7/16
4 Choice of puffers The choice of size and type of puffer mast is done in consideration of the energy that have to be voided. If you need a couple of puffers for a crane, you need to know the weight of the bridge, the weight of the trolley and their sliding speed. In the value of the crane weight you have to include every loads not swinging and disregard the load hung on the rope (ex CNR-UNI 10021-73, FEM part I, DIN 15018). If there are installed reduction speed devices, the speed value considered into the account may be multiplied for a reduction coefficient of 0,7 (as standards shown above). However this coefficient can be omitted for greater safety. Kinetic energy of the bumping mass is equally divided between the puffers if both the trolley and the barycentre are situated in the centre of the bridge. Otherwise a puffer will be more stressed than the other. So, in the calculation we can t account half of the energy to each puffer but we mast to consider the position more unfavourable of the bumping mass. For a quick counting of the energy that may devolp following the impact on the single puffer installed on the bridge you can use this formula: Energy [ J ] = ( 0,5 * bridge mass [ t ] + trolley mass [ t ] ) * ( bridge speed [m/min ] ) 2 * 0,142 For a quick counting of the energy that may devolp following the impact on the single puffer installed on the trolley you can use this formula: Energy [ J ] = ( 0,5 * trolley mass [ t ] ) * ( trolley speed [m/min ] ) 2 * 0,142 It results by a series of mathematical simplifications of the formula E=(1/2)*m*v² where m is the mass expressed in kg done by the ratio between weight and coefficient 9,81 m/s² and v is the crane speed in the moment of the contact expressed in m/sec. For a simply accounting you can use to charts in next pages. Note: For cranes with protruding beams you mast to take in account the greater force impressed on the puffer. Pizzamiglio srl PUFFERS Instructions Rev. 5 8/16
Mas(t) Chart for the choice of puffer 327/A series Cross the speed value with the crashing mass value. The line located on the right of the individuated point identifies the puffer fit for the use requested. 327/A 140 130 120 T50 110 100 T40 90 80 70 T10 T20 T30 60 50 40 30 20 10 0 T5 T3 T2 T1 K500 K250 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 Speed (m/min') Pizzamiglio srl PUFFERS Instructions Rev. 5 9/16
Mas(t) Chart for the choice of puffer 327/C series Cross the speed value with the crashing mass value. The line located on the right of the individuated point identifies the puffer fit for the use requested. 327/C 250 240 230 220 210 200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 T1 K500 T2 T3 T5 T10 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 T15 T20 Speed (m/min') T30 T40 T50 Pizzamiglio srl PUFFERS Instructions Rev. 5 10/16
5 Technical Features PUFFER type 327/A Tab. 327/A Type Stroke max [mm] Force [dan] Energy [ J ] [Nm] Overall dimensions [mm] A B C D E F G H K250 20 250 35 75 120 4 90 70 65 45 7 1,0 K500 25 500 70 90 130 5 110 90 80 60 9 1,8 T01A 25 1.000 160 120 140 6 135 115 105 85 11 3,9 T02A 50 2.000 440 160 230 8 170 150 130 110 13 8,3 T03A 50 3.000 720 170 240 8 205 175 160 130 15 11,7 T05A 50 5.000 1.150 200 260 8 230 200 175 145 17 14,0 T10A 75 10.000 4.400 260 360 10 310 260 260 210 19 31,6 T15A 75 15.000 7.800 320 380 12 360 310 300 250 21 48,0 T20A 80 20.000 10.000 350 390 12 410 350 340 280 27 64,0 T30A 100 30.000 21.000 370 470 15 410 350 340 280 27 75,0 T40A 150 40.000 38.000 370 600 15 440 380 370 310 34 111,0 T50A 200 50.000 46.000 370 700 15 440 380 370 310 34 142,0 Data and features in this catalogue are not binding. The producer reserves the right to alter them without advance notice at any time. Mass [kg] Pizzamiglio srl PUFFERS Instructions Rev. 5 11/16
PUFFER type 327/C (double spring - double stroke) Tab. 327/C Type Stroke max [mm] Force [dan] Energy [ J ] [Nm] Overall dimensions [mm] A B1 C D E F G H1 T01C 50 1.000 250 120 220 6 135 115 105 85 13 5,2 T02C 100 2.000 640 160 365 8 170 150 130 110 15 11,5 T03C 100 3.000 1.100 170 385 8 205 175 160 130 17 15,8 T05C 100 5.000 1.550 200 400 8 230 200 175 145 20 19,0 T10C 150 10.000 7.200 260 500 10 310 260 260 210 26 42,3 T15C 150 15.000 10.600 320 610 12 360 310 300 250 32 66,0 T20C 160 20.000 14.000 350 640 12 410 350 340 280 35 82,8 T30C 180 30.000 34.000 370 730 15 410 350 340 280 35 115,0 T40C 220 40.000 47.000 370 900 15 440 380 370 310 40 157,0 T50C 300 50.000 68.000 370 1.000 15 440 380 370 310 40 169,0 Data and features in this catalogue are not binding. The producer reserves the right to alter them without advance notice at any time. Mass [kg] Notes: dimensions indicated in this catalogue refer to our update drawings at the moment of printing of this document, however something may be changed in the meanwhile. Before preparing holes or arrangements take vision of the product and of his operation. Pizzamiglio srl PUFFERS Instructions Rev. 5 12/16
6 Installation Mechanical mounting During the installation of puffers is very important to check that them are positioned over the centre of the wheels and that crane-way locks surface are positioned with an angle of 90 with the puffer s crushing axes. The altitude of the puffer axis mast be 0,6*D (where D is the wheel diameter). The puffers are finished with powder coating painting with polyester fit for outdoor colour grey. The safety chain and the shackle are galvanized. Note Puffers are equipments bound to be incorporated in other machinery. Is forbidden to put them into service before that the whole machinery has been declared according to European Standard Safety of Machinery (2006/42/CE). Pizzamiglio srl PUFFERS Instructions Rev. 5 13/16
7 Safety features The constructor of the crane mast to choice a puffer suitable with the use of the crane in considering the environment, weather, air humidity, capacity and characteristics of the crane. Warnings for installers and maintenance operators Operate according your safety plan. Particularly use only certified ladders and scaffolds; use individual protection disposals and wear safety wear and shoes. Keep attention in your activity to safety of all persons around you. Packaging materials mast be recycled or sold-off in according to the country laws. Instructions to the final user The manufacturer or installer have to instruct the final user to don t make his-self maintenance if not expert in cranes maintenance, particularly don t insert grease into the puffer because it may alter or modify physical and chemical characteristics of rubber springs in compromising the device. Check yearly the puffers functionality: verify the entireness of safety chain and gauge the total length of the puffer that mast not be reduced by more than 10% of stroke value. Pizzamiglio srl PUFFERS Instructions Rev. 5 14/16
8 Maintenance Our puffers do not need maintenance usually. They mast be painted with a paint suitable with the environment where the crane is installed: weather, air humidity, etc. Remember do not insert grease into the puffer because it may alter physical and chemical characteristics of rubber springs in compromising the device. Ageing of rubber springs cause a low reduction of their springiness. When the total length of the puffer will be reduced by more than 10% of stroke value the puffers mast be replaced. Verify also all the fixing screws are closed. Insert into your crane maintenance s check-list check of the puffers. Spare parts Are not provided spare parts. Please contact-us for more information. Pizzamiglio srl PUFFERS Instructions Rev. 5 15/16
9 Warranty We guarantee our products for 12 months from the delivery. The warranty applies only in reparation or change of parts that we recognize as faulty and excludes incidental or direct damages and cover only material fault. Warranty do not covers any defect that occurs to things or persons due to careless or improper storage or mounting such as keeping the product under conditions of high temperature and humidity or improper maintenance or tempering. For all sale conditions see the contract of sale. Storage: store indoor at temperature between 20 and +50 C. Data, draws and pictures contained in this publication are to be considered as indicative only. The manufacturer reserves himself the right to modify data without prior notice. Pizzamiglio Srl 79, Via degli Imprenditori 37067 Valeggio sul Mincio (VR) - Italy Tel. 045.7952209 Fax 045.7952174 info@pizzamigliosrl.com www.pizzamigliosrl.com Pizzamiglio srl PUFFERS Instructions Rev. 5 16/16