Shiploader Cleveland

Cleveland Cascades Ltd
Contents
Introduction 3 Section 2 Cascade Installation Instructions 37

Equipment Safety Instructions 4 Cascade Commissioning Procedure 41
Cascade Loading Instructions 45
Section 1 Equipment Description 6
Cascade Maintenance Instructions 47
Head Chute Assembly 6
Cascade Cleaning Procedure 49
Cable Reeling Drum/Catenary 7
Cascade Control Requirements 51
Winch Assembly & Limits 8
Cascade Fault Finding 56
Hand Winding Instructions 11
Bolt Tightening Torques 57
Back Up Switches 12
Head Chute Flange Connection 59
Overload Monitoring System 13
Explosive atmosphere overload 16 Section 3 Declaration of Incorporation 60
monitoring system
Cascade Cones & Liners 17 Section 4
Technical Specification and Drawings
Liner Anti-Static System 20
Parts List
Strop Assembly 21
Drawings
Shroud Assembly 24
Electrical Drawings
Speed Reducer Assembly 25
Carrier Assembly 27 Section 5 Reference Manuals
Carrier Spill Doors 28 CD Rom Only
Material Detection System 29
Skirt Assembly 30
Closed Hatch Loading 31
Trimmer Assembly 33
Resitain Valve 35
Tilt Switches 36
Product Manual - for Cascade Ship and Silo Loaders 2

Introduction
The Cleveland Cascade Chute
The Cleveland Cascade loading chute is a specialist loading system designed to control the
flow of bulk materials in a mass flow, this is a single steam of material moving in high volume
at very low speed through the chute. In order for the chute to perform successfully in this
manner, the product feed to the chute should be as per the designed rate for which the chute is
arranged.
Any deviations from this design rate may adversely affect the chutes performance. A thorough and
detailed understanding of the Cascade chute is required in order to effectively commission a new
system to ensure safe and reliable long term operations.
Cleveland Cascades always recommends that CCL trained engineers are employed on site for the
chutes installation and commissioning when new, in order to ensure the system is arranged correctly
and commissioned to perform with optimum results.
In order to arrange site services for your Cascade chute, please contact Cleveland Cascades as
follows;
Brian Thirlwall (Commercial Dept)
Cleveland Cascades Limited, Unit 22 Dukesway,
Teesside Industrial Estate, Thornaby,
Stockton On-Tees, TS17 9LT United Kingdom
The Cascade system uses the principle of mass flow at low velocity. Mass flow reduces
the liberation of dust and low velocity down the Cascade virtually eliminates the movement
of dust-laden air within the surrounding shroud. The shroud eliminates the adverse effects
of side winds.
This manual covers the complete range of Cascade Chutes supplied for ship and silo loading.
A full description of all Cascade Chute assembly’s can be found in Section 1.
Please note that your system may or may not contain all of these assemblies,
depending on its specification.
To identify the parts described for your Cascade Chute, please use the Parts List and Drawings
in Section 4.
This manual contains important safety and operational notes that must be followed by the user/
operator. If there are any query’s regarding the operation of the Cascade Chute, contact Cleveland
Cascades Ltd for further information or assistance.
Cleveland Cascades Ltd cannot take any responsibility for damage caused from incorrect
use of the Cleveland Cascade Chute system.
The information in this manual has been carefully evaluated and checked.
We reserve the right to effect technical changes or amendments resulting in future developments.

Equipment Safety Instructions
1. Unloading
The Cascade Chute will have been supplied packaged for suitable transportation. Reference should
be made to the weights noted on each package prior to handling and suitable equipment and
methods selected to safely handle these loads.
2. Installation
Prior to undertaking any installation work a responsible person should read all the information relating
to the Cascade Chute as set out in the Product Manual.
A risk assessment should be undertaken for the installation work and all instructions and warnings
set out in the Product Manual, followed.
The particular risks identified in undertaking the installation are those associated with lifting the
equipment into position. In this case a competent person should consider the various factors such
as the weight to be lifted and the provisions provided for attaching, in selecting a safe method.
Particular reference should be made to the arrangement drawings where any specific points
regarding the installation, will have been noted.
Care should be taken in ensuring that the actual installation matches the details shown on the
arrangement and assembly drawings. If any aspects of the work are unclear then Cleveland
Cascades should be contacted for clarification.
Careful attention should be paid to the specification of the fasteners used in making the main load
bearing connections of the chute onto the material handling equipment. Details of these will be found
on the Technical Specification, and by reference to the item number on the arrangement drawing.
As the chute is fitted with electrical equipment, the connections should only be made by a competent
person and in strict accordance with the connection diagrams and instructions. Attention should be
paid to ensuring that proper electrical isolations are carried out when working on this or any other
part of the chute.
The hoist winch included within the chute should never be used for any other purpose than those
specified in the installation and operating instructions.
If required, our own engineers can assist in the installation of your Chute to your existing loading
equipment. Using factory-trained engineers helps you adhere to your completion schedules and
assists in system integration in the confidence that high standards of engineering practises are being
employed in accordance with our ISO9001 quality system.
Using an experienced Cleveland Cascades Ltd engineer to commission your loading chute can save
you time and money, by thoroughly checking the installation, but most importantly, by ensuring the
system is set up correctly to optimise throughput and minimise maintenance costs.
For additional information or to discuss how Cleveland Cascades Ltd can help you to maximise
performance and control costs, please contact us at enquiries@clevelandcascades.co.uk

Equipment Safety Instructions
3. Operation
Only competent persons, who have received suitable training and instruction in its use, should
undertake the operation of the chute. The chute should never be used for any other purpose than for
which it was specifically designed. The material being handled should not be different to that which
was specified for the chutes design. Any variations could adversely affect its operation and advice
should be sought from Cleveland Cascades prior to any change of use. The chute is a suspended
load and as such any persons should stand well clear of it, in a safe position. It is important that prior
to loading with the chute, the recommended pre-operation checks are carried out (see Section 2,
page 44). As the chutes control operates under a semi-automatic operation, personnel working in or
around the vicinity of the equipment need to be made aware that the chute can automatically move
without warning.
At no time should any additional load be suspended from the chute.
4. Maintenance
The chute should be regularly maintained in accordance with the guidelines set out in the Product
Manual (Section 2, page 47). In undertaking any maintenance on the chute the necessary isolations
of the electrical systems should be applied to prevent the risk due to the moving parts of the
equipment. Safe systems of access to facilitate maintenance should be carefully considered.
5. Guarding
The design of the chute is such that it contains moving parts and in particular areas where steel
ropes under load are moving. Where practical local guarding has been used to protect people in
the vicinity of the equipment from coming into contact with these parts. In some circumstances the
aspect of guarding due to the positioning of the moving parts on the existing equipment will have to
be considered by the operator of the equipment. This should be considered in conjunction with the
guarding policy used on the equipment to which the chute is fitted.
6. Sound levels
Operation of the Cascade Chute with powder materials will not likely give rise to sound levels
exceeding 70 dB at a typical operator position, 5m from the chute. For other materials and
particularly granular and lumpy materials, the sound levels could be in excess of 70 dB.

Section 1
Head Chute Assembly
The head chute connects the end of the boom conveyor to the Cascade
Chute. The head chute controls the material feed from the end of the conveyor
and directs the flow into the Cascade Chute by a series of deflector cones.
The head chute is designed to suit the loading boom. There are fixed, pivoting and
double pivoting types.
To guide the material from the boom conveyor into the Cascade chute a number of deflector
cones are fitted. The defectors may be adjustable; these can be adjusted during commissioning,
for details see the general arrangement drawing for head chute type.
The deflector cone adjustment allows the correct flow into the Cascade cone.
Electrical connections are terminated at the head chute level or connected by a reeling drum
system where fitted.
The shroud is suspended from anchor brackets fixed to the head chute cowl.
The shroud can be fitted by lifting the top section of the shroud and connecting the six hooks to the
cowl anchor brackets. An elasticated cuff at the top of the shroud forms a seal with the head chute.
The three strop mountings are on the underside section of the head chute, the shroud must be
lowered to gain access to these.
The head chute cowl section must remain horizontal +/- 0.5°, when the Cascade chute is in
operation.
On a fixed head chute installation, this must be checked and adjusted before the Cascade is
operated. Where the boom can operate at a range of angles, the lower head chute section must
remain horizontal, this can be achieved by adjusting the counterweights, supplied. See general
arrangement drawing for details of the range of angles that the head chute will function correctly.
DEFLECTOR
FIXED HEAD CHUTE
PIVOTTING HEAD CHUTE
LOWER DEFLECTOR

Section 1
Cable Reeling Drum/Catenary
The cable reeling drum is a mechanical spring return drum. This is

mounted on the lower head chute steel work above the Cascade Chute.
The reeling drum cable is attached to the carrier via the cable grip of which in turn is attached
to a lug secured to the carrier frame.
The cable grip transfers all of the pulling force of the reeling drum to a long section of the
cables outer insulation, it eliminates any pulling force on the terminal box cable gland.
The cores of the reeling drum cable are ferruled and have markers attached.
These cores need to be connected to the terminals bearing the same title as the cable markers within
the carrier terminal box.
Follow the drawings in Section 4 for details of wiring connections.
Maintenance
The areas of maintenance that require inspection are
1. Condition of the cable. Check for cracks in
the outer cover, check the security of the
compression glands. JUNCTION BOX
2. Check the bearing for wear.

3. Check the slip ring brushes and springs for
wear and tension. REELING DRUM
Note: The reeling drum springs have a BUMP STOP

limited pull off beyond the range of the
Cascade Chute length. If too many pre- CABLE GRIP
turns are given to the drum before the cable
is connected, it is possible to reach the
spring pull off limit before the cable is fully
extended. This can result in damage CABLE TO CASCADE
to the cable / reeling drum.
Catenary
This is used when you are unable to use/fit a reeling drum onto the head chute.
This is connected from the head chute, along the shroud and connected onto the carrier.
The catenary is a flexible cable which will move up and down with the chute, when the chute is
extended or retracted.

Section 1
Winch Assembly & Limits
The winch units fitted to operate the Cascade chute are normally of two types.
1. Triple spool winch, normally fitted directly to the head chute.
2. Drum winch. Normally mounted along the boom away from the Cascade Chute.
Note: Some gearbox units are supplied without oil and require filling before use.
1. Triple Spool
The hoist winch consists of a braked geared motor that is mounted to the side of the head chute.
The upper end of the output shaft from the gearbox has a triple rope spool arrangement
mounted to it, which collects the hoist ropes. The spool shaft is used to drive a rotary limit switch
to provide the operating limits for the winch. The triple spool has three anchor points near the
centre of the spool, three nuts lock the rope ends to the centre of the spool. The length of the
lifting ropes allows for three safety turns, the safety turns lock the rope to the spools. The rope
anchors only secure the rope to the drum they are not designed to hold the Cascade loads.
To check the oil level in the gearbox the mounting position needs to be referred to in the
manufacturer’s manual.
Use the following drawing as a guide.
ROPE KEEP
SHEAVE BRACKET
ROPE ANCHORS
WINCH

Section 1
2. Drum Winch
Winch assembly and limits
The hoist winch unit consists of a braked geared motor that is directly mounted to the side of the
winch drum. The drum is divided into three sections for each rope that connects to the Cascade
carrier. A bearing supports the non-drive end of the drum shaft and the shaft is used to drive a rotary
limit switch to provide the operating limits for the winch.
The drum has three anchor points for each rope. The length of the lifting ropes allows for three safety
turns, the safety turns lock the rope to the drum. The rope anchors only secure the rope to the drum
they are not designed to hold the Cascade loads.
To check the oil level in the gearbox, the mounting position needs to be referred to in the
manufacturer’s manual.
The winch frame must be mounted with bolts suitable for the maximum safety loads that winch
ropes are designed for. Please refer to your technical information and drawings for bolt-specifications.
Please note: Check oil label on the gearbox for type and quantity.
Typical installation for drum winch.
MOTOR BRAKE
DRUM MOTOR
LIMIT SWITCH

Section 1
Winch brake
The winch brake is integral with the winch motor and operates when the supply to the hoist motor is
removed. The operation of the brake needs to be connected for fast action to reduce the over run of
the winch motor.
When the chute is lowering and the winch contacts are de-energized, the momentum of the chute
and residual magnetism in the motor will cause the motor to become a generator. If the supply for
the winch brake is derived from the motor phase supply, then this generated e.m.f will continue to
energize the brake causing the motor to run past the point when the winch contact was de-energized.
The use of auxiliary contacts on the winch contactors to isolate the brake supply prevents this motor
run on and gives fast acting brake functionality as explained below.
The winch motor is designed for direct on line start and should be controlled via a motor reversal kit
(two mechanical and electrical interlocked motor contactors with overload unit). Two auxiliary contact
blocks on the winch motor contactors, WINCH UP & WINCH DN, should be used for fast acting
brake functionality. The winch brake unit is fed from either a six terminal rectifier, or from a three
phase supply. The brake should be supplied through normally open auxiliary contacts on the motor
contactors, (the brake is a failsafe unit, this means that it has to be energised to release it) the brake
supply can then be broken immediately via these external contacts when the motor supply contactors
are de-energised, thus the brake is applied immediately.
See electrical specification for project specific brake wiring.
Winch limits
The winch limits allow for adjustment of the Cascade Chute from fully extended to fully retracted
positions, as shown in the general arrangement drawing with the maximum and minimum chute
lengths. Care must be taken when adjusting the top limit so that when the chute is raised into the
head chute, no collision occurs which could damage the top cone. When the lower limit is set, do
not allow the last cone to lift out of the carrier section and check that the rope is not beyond the three
safety turns on the spools.
To adjust the limits see the manufacturer’s manual in Section 5.
Ropeways
The ropeways connect the winch to the Cascade carrier; the three ropes
are routed to positions around the top of the head chute with sheaves, WINCH LIMITS
the ropes then hang vertical and pass through rope guides connected to
the shroud rings.
The sheave assembly consist of the bracket with a pin-mounted sheave;
If nylon sheaves are used, they have self-lubricating properties, but
should be greased regularly from the grease point at the end of the pin.
The rope guide keeps the rope in contact with the sheave at all times.
Note: The rope and related equipment must be inspected at the GEARBOX
beginning of each work period and particularly following any incident
that could have damaged the rope or installation. The entire length
of the rope should be inspected and particular attention paid to the
winch, sheave assemblies and terminations at both ends of the rope.

Section 1
Hand Winding Instructions
Overview
The main winch motor has been supplied with a double ended output shaft which can be utilised in
the event of power failure to hand wind the motor to extend /retract the chute as required.
Safety
Hand winding must only be carried out by authorised personnel who have received suitable
training and instructions in the chutes operation as failure to follow instructions and procedures
may result in injury or damage.
The electrical supply to the winch must be isolated before commencing hand winding.
The hand crank and brake release lever must only be fitted during hand winding and must be
removed prior to returning to normal service.
Hand winding is physically demanding and could take a considerable amount of time so it is
recommended that more than one operative is present.
Operation
Attach brake release lever to brake using fixings provided ensuring that there is no accidental
operation of brake.
Attach hand crank to motor shaft using key and fixings provided.
Constant pressure must be applied to the hand crank prior to operating the brake,as manually
overriding the brake may cause the chute to move.
With the brake release lever operated (brake lifted) proceed to wind the hand crank until the chute
reaches its desired height.
Release pressure on the brake (brake operated) and proceed to remove the hand crank followed
by the brake release lever before returning the chute to normal operation
SPOOL WITH GUARD
GEARBOX
MOTOR
HAND CRANK HANDLE
Typical spool winch with manual brake release and hand winding.
Note: A typical gear ratio would be in the region of 280:1 meaning hat the motor would need
rotating 280 times to rotate the output shaft on the gear once, in real terms this means each
time the crank is rotated the chute will extend/retract by ~5mm.

Section 1
Back Up Switches
The Ultimate limit switch is fitted as a back up to the hoist winch

system high limit.
The ultimate limit switch helps to protect against the Cascade cone from colliding with the head
chute protection in the event of a malfunction of the hoist winch limit or the minimum chute
length brings the position of the Cascade cone stack,close to the head chute cowl section.
Although the ultimate limit switch may be supplied in different formats the principle of operation
remains the same.
SLACK ROPE SWITCH ARM
WINCH MOTOR
ADJUSTABLE
MOUNT
ULTIMATE LIMIT
SWITCH
DETAIL OF ULTIMATE LIMIT SWITCH

ROPES
DETAIL OF SLACK ROPE SWITCH ASSEMBLY
The slack rope switch is fixed onto the head chute.

The switches are situated directly below a slack rope switch arm, which are fixed onto the face of the
sheave bracket.
If the rope is tight the lever arm compresses the SRS plunger, therefore closing the contact. If the
rope is slack, the lever arm releases the SRS plunger opening the contact, this open contact should
stop the carrier from extending.

Section 1
Overload Monitoring System
The overload system is designed to protect the bridge / boom from

exceeding its designed working limit.
The load cell is connected to the strop mounting bracket on the “A” Strop.
See the general arrangement drawing for details.
The load detected by the overload system is the static weight of the Cascade section (see Cones
& Liners and Strops) plus the weight of the material running through the cones. The reading on
the display is summed to give the total load of the chute section being weighed.
The system measures the mV output from a load cell. This mV signal is then processed to give 2
adjustable alarm trigger points which are relayed through two volt free relay contacts. The processing
unit can also provide a variable analogue output current (4-20mA) which can be relayed to a second
remote processing unit or PLC.
Description
There are two variants of the Overload System one for non-explosive atmospheres and the other for
explosive atmospheres.
The non-explosive atmospheres system comprises of a load cell with 10m of cable attached (CC-
LC1), a hinged junction box (CC-SJB2), to be located by the customer and a London Electronics
Process Meter housed within CC-SJB2.
The explosive atmospheres system consists of a certified load cell with its cable terminated in an
intrinsically safe terminal Box attached to the head chute assembly and a certified signal converter
which is to be located in a designated safe area by the customer.
Load cell
The load cell is pre-calibrated to give 2mV/V output at full load. The London Electronics unit has a
10V supply to power the cell which will give a span of 0 to 20mV. The signal converter unit has a 5V
supply to power the cell which will give a span of 0 to 10mV.
Note: The load cell should be removed from the head chute or the connections earthed
if during construction, any electrical welding sets are being used in this area.
STROP BRACKET
PROCESS METER UPPER SECTION
LOAD CELL
TERMINAL BOX
STROP BRACKET
LOWER SECTION
SECTION VIEW
TERMINALS

Section 1
SJB2
This enclosure must be mounted in an easily accessible area, within 10m of the load cell. The
enclosure contains the London Electronics Meter which processes the mV signal to give two relay
outputs which are configured as overload and under load alarm indicators. The meter can also give
an analogue 4-20mA output signal to be used with another remote meter (the maximum length of the
signal cable is 500m) for display and alarm indication.
Test function
Inside SJB2 a variable mV signal simulates a load rising from zero to full scale and enables operation
of the set points to be verified. Operation of a toggle switch and variable pot give this function.
Typical enclosure dimensions: 300w x 400h x 210d

Section 1
Set point adjustment

We would recommend that the set point adjustment should normally be undertaken by a Cleveland
Cascade Engineer, who will have evaluated your particular chute and its operating loads. The set
point for the overload in AL1 is pre-set to a figure that has been calculated at the normal running
weight, to enable you to adjust the set points follow the details below. The estimated loads are
recorded on the calibration sheet, use these figures when commissioning the overload system.
Guidance to set point loading

Before commissioning trials commence, the display setting for AL1
is set at a load below the safe working load of the boom / bridge. With the Cascade lowered to its full
extension, allow the feed to increase to the maximum loading rate. From the reading on the display,
raise the setting for AL1 to read 5% higher than the maximum loading rate.
Programming set points
To alter the load setting for the alarms 1 to 4:
Pressing the alarms button momentarily will allow you to view the current settings. Each press
will illuminate in turn alarm AL1 to 4 annunciators.
To change alarm settings, keep the button held for 3 seconds, which will cause the value
to have one digit brighter than the others. This may be changed in value using the up / down
buttons and the digits may be selected using the digit select push button.
The alarm action is determined by the first character H – high, L – low, o -off.
When changes have been made to the settings press OK. The display will return to the kgs reading.

Section 1
Explosive atmosphere overload monitoring system
This description assumes that the Pepperl + Fuchs KFD2-WAC2-(EX)1.D Barrier Unit is being used.
Press [ESC] + [OK] simultaneously for 1 second, this allows you to access the programed set
points. To select a menu item press [OK], to return press [ESC], press the [ ] and [ ] arrow buttons
to navigate the menu/sub-menu.
Use the arrow buttons to navigate to the UNIT menu and press [OK], then using the arrow buttons
select kg and press [OK] then press [ESC] to return to the previous menu.
Use the arrow buttons to navigate to the INPUT menu and press [OK], again using the arrow buttons
navigate to the SENSOR menu and press [OK], using the arrow buttons navigate to the EXCITATION
menu and press [OK], use the arrow buttons to set EXCITATION to 5V and press [OK], press [ESC]
to return to the EXCITATION menu. Use the arrow buttons to navigate to the SENSITIVITY menu and
press [OK], select 2.0mV/V using the arrow buttons and press [OK] then press [ESC] to return to the
SENSITIVITY menu. Use the arrow buttons to navigate to the CELL RATING menu and press [OK],
select multiply the cell rating by three using the arrow buttons and press [OK] then press [ESC] to
return to the CELL RATING menu. Use the arrow buttons to navigate to the RATE menu and press
[OK], select norm and press [OK] then press [ESC] to return to the previous menu. Select the CELL
DETECT menu and press [OK] then select on and press [OK], press [ESC] twice.
Navigate to the TRIGGER 1 menu and press [OK] select TARE and press [OK] then press [ESC] to
return to the TRIGGER 1 menu. Navigate to the TRIGGER 2 menu and press [OK] select TARE and
press [OK], press [ESC] twice.
Navigate to the OUTPUT menu and press [OK], navigate to the RELAY 1 menu (this is designated as
the high alarm) and press [OK], navigate to the TRIP (on) menu and press [OK], navigate to the TRIP
menu and press [OK] select VALUE in kg (from cal sheet) and press [OK] then press [ESC] to return
to the previous menu. Navigate to the MODE menu and press [OK] select Passive and press [OK],
press [ESC] three times.
Navigate to the RELAY 2 menu (this is designated as the low alarm) and press [OK], navigate to the
TRIP (on) menu and press [OK], navigate to the TRIP menu and press [OK] select VALUE in kg (from
cal sheet) and press [OK] then press [ESC] to return to the previous menu. Navigate to the MODE
menu and press [OK] select Passive and press [OK], press [ESC] three times.
A shorting link should be used to temporarily connect pins 13 & 14 (Approx 1 second duration), this
will zero the display.

Section 1
Cascade Cones & Liners
The suspended Cascade cones are alternate type ‘A’ and type ‘B’ cones.
Each cone is alternately inclined towards the adjacent cone, controlling
the flow of material.
The angle and spacing of the cones is set with the strops, which are supplied based on design
throughput output rates as per the supply agreement. Experience tells us that these ideal, steady
rates are often difficult to achieve and so it is recommended that Cleveland Cascades service
personnel are employed to commission the chute. They will ensure that the cascade setup at it’s
optimum to cope with the actual loading rates / fluctuations seen on site.
Each cone is fitted with a suitable liner, details of which can be found in the Parts List in Section 4.
Cone Liners
Wear resistant liners are fitted to the cones. The abrasive nature of the product being loaded in the
Cascade Chute, will be a factor in the choice of liner material fitted. Other factors have been taken
into consideration, for example material size, normal running temperature and feed rate.
The Parts List in Section 4 of the manual gives the details of the liners fitted in the Cascade Chute.
Note: The performance of the liner may be affected if specification of material being loaded
is changed. Consult Cleveland Cascades for details.
Strop Connection
The cones are suspended from three strops; each cone has 3 attachments moulded into or bolted
to the cone rim. See Section 1, page 21 for strop assembly description.
Cone Liners
The cones are supplied in two types, The ‘A’ and ‘B’
EYE OR INSERT IN 3
cones have the cone attachment 180 degrees apart. POSITIONS, EQUI-SP
It is important to have alternate ‘A’ and ‘B’ cones in ON CONE RIM
the cone stack.

CUT POSITION ON ‘A’
TYPE CONE, EYE IS
ON SHORT FACE.
CUT POSITION ON ‘B’

TYPE CONE, EYE IS
ON LONG FACE.
Sketch showing eye position and direction of bevel cut for ‘A’ & ‘B’ type cones.

Section 1
The diagram shows a typical layout showing an ‘B’ cone in the top position.
Check the detail on the general arrangement drawing for the correct top cone in the Cascade Chute
supplied.
B STROPS
B TYPE CONE
A STROP
A TYPE CONE
The removal of cones from a Cascade Chute during service / strop change procedure
In order to remove cones from the Cascade cone stack, the following steps should be followed.
1. Place the Cascade chute into its parked position (fully retracted at high limit).
2. Disconnect the shroud from the head-chute cowl in order to expose all three strop /
head-chute connections (See Figure 1).
3. Disconnect all three strops from the head-chute by removing the strop pins from the
strop brackets (If fitted, ensure the anti-static lead attached to the head chute is disconnected).
4. Lower the Cascade chute into its maintenance stand or trailer, or into a position where
the skirt assembly can easily be removed (approximately 1m from the quay).
5. Remove the skirt assembly.
6. With the skirt assembly removed, check to see if the material detection probes are protruding
beyond the exit of the chute and if so, raise their position until the tips of the probes are well
inside the steel carrier cone.
7. Lower the chute onto the quay.
8. Disconnect all three hoist ropes from the carrier eye bolts and transfer them to the lifting eyes
situated on the shroud bottom ring.
9. Because the hoist ropes are now connected to the shroud assembly, the hoist can now be used to
raise the complete shroud clear of the Cascade cone stack, and therefore fully exposing the cones
(See Figure 2).
10. Disconnect the three strops from the cone eye connections.
11. Using all three of the strop anchor points, remove each cone individually via a safe means of lifting.
Please note: Prior to attempting this activity, it is important to take reference from the technical
specification document in order to determine the combined weight of the cone and liner.

Section 1
HOIST ROPE
SHROUD BOTTOM
RING
Figure 1
RAISE SHROUD USING

HOIST ROPES
Figure 2

Section 1
Liner Anti-Static System
The Cascade cones are fitted with conductive liners that path to earth
to discharge any static build up.
Liner Anti-Static System
The purpose of the liner anti-static system is to prevent electrostatic charge accumulation within the
cascade chute. The system consists of UHMW (Ultra High Molecular Weight) polyethylene liners on
all chute running surfaces, these have a very high impact strength and a low surface resistivity, p ≤
10^9 Ohm . All liners have stainless steel bonding strips attached, which in turn connect to the cones
stainless steel bonding links. The interconnecting cone links, carrier assembly links and head chute
assembly links form one statically conductive path to earth and when connected correctly should
have a resistance value of ≤ 10^6 Ohm.
Prior to leaving our factory the ‘liner material’ and ‘static bonding path to earth’ for each chute are
tested in accordance with BS EN 60079-32-2:2015 and BS EN 61340-2-3-2000, to ensure that all
electrostatic hazards have been reduced to an absolute minimum.
Due to packaging constraints during transportation the cone stack may be separate from the carrier
and head chute assembly on arrival at site. The cone stack will have all anti-static interconnecting
links made with two free ends at the top and bottom of the cone stack. These must be connected to
the respective anti-static links of the carrier and head chute during chute assembly. Once the chute
has been assembled a continuity test of the anti-static bonding system to earth must be carried out
before any material can be loaded. The test can be carried out with a meter capable of measuring
resistance, the value of resistance measured must be ≤ 10^6 Ohm. Note, on delivery to site, all
free ends of the anti-static bonding system will have a laminated A4 sheet attached with a message
reminding the construction team of the importance of connecting all free ends of the anti-static
bonding system.
Special Anti-static measures for sulphur loading chutes
We give special consideration to the selection of liner material for sulphur
loading chutes, due to the special properties of sulphur with reference to dust
cloud formation. The minimum ignition energy (MIE) for a sulphur dust cloud is
very low, 15mJ at 35g/m³ given an average particle size of
< 150µm therefore it is essential that any charge build-up be dissipated as
quickly as possible. It is for this reason that, for sulphur loading chutes we use a
liner material with a surface resistivity r ≤ 10^6 Ohm. This value is the same as
that recommended by BS EN ISO 284:2012 for antistatic type conveyor belts. STATIC
EARTH
To ensuring that electrostatic discharge is kept to an absolute minimum within STRAP
sulphur loading chutes it is a requirement that the ship loader delivery system
and delivered material comply to the following:
1. The Rubber used on the conveyor systems taking the material into our
chutes should be anti-static and adherent to the British Standard BS EN ISO EARTH STRAP
CONNECTION
284:2012
2. The sulphur should be in the form of prills, granules, pastilles or flakes EARTH
STRAP
3. The moisture content of the material should be a constant minimum 3% LINER
4. The surrounding atmosphere humidity level should be 60%
Static earth connections are placed on all connecting parts, with separate connection supplied from the
head chute to the clients steelwork. Most connections will be fixed in place by CCL trained technicians,
any connections that are loose due to transport/packaging restrictions will have a laminated sheet
attached showing instructions of where to connect.

Section 1
Strop Assembly
The Cascade cones are suspended from strops.

Each strop has a series of loops stitched to it. The loops are used to connect the strop
to the cone connection eye. The loops are spaced to give the correct cone angle.
An Identification label is stitched at the top and contains the following information:
Chute Number
Strop Type (A or B)
Strop Drawing Number
Part Number
Cone Angle / Spacing
Material from which the Strops are produced
The diagram below shows a typical layout showing an ‘B’ cone in the top position.
Check the detail on the main drawing for the correct top cone in the Cascade Chute supplied.
B STROPS
B TYPE CONE
A STROP
A TYPE CONE
The cones are fixed to the strop with a cone attachment bobbin. There are two types of cone eye
connection. The double bush & ferrule type, and the single bush type. Refer to the Part List and
Drawings for cone attachment type used.
Care must be taken when connecting the strops to the cones. The three correct strop loops must
be attached to the same cone, when the strops are fitted, start connecting from the lowest cone and
work upwards. Check each cone is connected and each part of the attachment bobbin is connected.

Section 1
Strop Assembly
Double bush & ferrule cone attachment
CONE CONNECTION EYE STROP LOOPS
FERRULE
PLASTIC WASHER
Single bush cone attachment
PLASTIC BUSH
CENTRE INSERT
STROP LOOP
PLASTIC WASHER

Section 1
Strop Assembly
Maintenance
As the Strops act as the main support for the Cascade Cones and also give the correct spacing,
it is important that the Strops are inspected and replaced at regular intervals. Check for fraying in
the main strop and attachment loop. Although the strops are designed to take 7 times the normal
running load, the strength can be significantly reduced if the strops are worn or damaged.
The life span of the Strops can differ due to the environmental conditions in which the Chute
operates, usage of the Chute, and the product passing through the Chute. A good preventative
maintenance plan and inspection routine is an effective method of ensuring Strop failures do not
occur. If you operate a “High Duty” Chute, we would recommend that your Strops be replaced
every 12-18 months, or every 2,000,000 tonnes of product handled, whichever occurs first. If you
are operating a “Low Duty” Chute, we would recommend replacing every 18-24 months, or again
every 2,000,000 tonnes handled, whichever occurs first.
This kind of maintenance ensures that the Strops in service are always in good condition with
a High Factor of Safety in respect to the Chute’s normal working load.
Information on your Chute’s duty rate is available from Cleveland Cascades Limited.
PLEASE NOTE
These guidelines are based on generalised information, each product and site environment differs
and so the life of strops cannot be guaranteed, they are a wearing part within the chute and the
operations and maintenance of the chute should treat them as a critical item. Care should be taken
to monitor the condition of the strops over their service life and develop an understanding of their
safe working life. The chute is designed for the confirmed rates, any deviation on the material rate,
may result in problems and reduce the lifespan of the strops. Please contact Cleveland Cascades if
unsure.

Section 1
Shroud Assembly
The shroud assembly consists of a telescopic cover located over the

Cascade cones, and prevents side-winds from generating dust emissions.
The top section of the shroud includes a steel ring complete with six attachment hooks from
which the shroud is suspended. An elasticated cuff at the top of the shroud forms a seal with
the head chute.
At the bottom of the shroud is a steel ring that locates on the carrier. On this ring are three lifting
lugs. These lugs enable the hoist winch to be used to lift the shroud from the carrier over the stack
of cones for installation / removal. The intermediate shroud connecting rings have three rope guides
attached to them, through which the winch ropes pass.
Maintenance
The shroud requires a visual inspection of the fabric, small tears and rips can be patched, but shroud
sections should be replaced if they have excessive areas of wear and tear, or large holes.
The Cascade Chute should be fully extended at the end of each loading cycle to clear any trapped
material that may be trapped within lower folded shroud sections.
SHROUD TOP RINGS

(WITH HOOKS)
TOP (SEALING) SECTION
CONNECTING RING
WITH ROPE GUIDES
INTERMEDIATE SECTION
CONNECTING RING
WITH ROPE GUIDES
BOTTOM SECTION
BOTTOM RING

Section 1
Speed Reducer Assembly
For very long chutes, or chutes handling very dusty products,

a Speed Reducer may be required.
The speed reducer is located at the lower section of the Cascade Chute; the speed
reducer function is to control the flow of the material at the final exit of the Cascade
to ensure material is in mass flow at low velocity at all times during loading.
The speed reducer consists of a cone carrier section and three or four independently
supported cones with an exit cone at the bottom section.
The rigid framework supports the speed reducer cones. Adjustment of the cone is available
at the cone anchor point on the rigid frame.
Where a stand is supplied to the larger unit, the stand has outrigger legs to give additional
stability to the height of the speed reducer.
SPEED REDUCER
TOP CARRIER
SPEED REDUCER
DEFLECTOR CONES
FRAMEWORK
SPEED REDUCER
OUTLET CONE

Section 1
Speed Reducer Assembly
Speed Reducer Maintenance
CHECK EYEBOLTS AND

ROPE CONNECTORS
CHECK SHROUD
FOR DAMAGE
CHECK SECURITY OF
CONE SUPPORTS
CHECK SECURITY OF
CONE ADJUSTERS

Section 1
Carrier Assembly
The carrier is the cone-carrying framework located at the lower section

of the Cascade Chute.
The lifting points located on the carrier are fitted with three eyebolts, which are for attachment
and adjustment of the hoist ropes. Steel spacers are used on the eyebolts to adjust the level
of the carrier.
Two or more openings are provided in the carrier to give access for inspection or adjustment of the
material detection probe. These openings are fitted with a spilling hatch that will protect the chute
from blocking if any of the detection systems fail (See carrier spill doors, page 28).
The skirt assembly or trimming spout attaches to the underneath of the carrier, to minimize dust
emission from the top of the material pile.
ROPE ANCHOR
MATERIAL DETECTION PROBE

Section 1
Carrier Spill Doors
The spill door is designed to open when material builds up behind it.
During normal chute operation material will flow through the chute, however, due to a
mechanical / electrical component failure or overfeeding of the chute, it is possible
that material can spill and build up behind the spill door. In these circumstances the spill
door will be forced open. The spill doors are sized to allow spilling at an equal rate to that
of the chute’s feed rate, in order to contain the blockage within the carrier.
Description
The spill door is a membrane stretched over a circular outlet and secured using an elastic cord
with a safety lanyard.
The membrane is made from PVC coated Polyester and the elastic cord is a polyester braided rubber.
Operation
The membrane will be forced off by the pressure of material building up behind it and is retained
by the lanyard attached to the door. If the membrane is forced off, the cause should be investigated
and the membrane refitted.
Maintenance
Remove the membrane weekly and check that no dust has accumulated behind it. Clean the
membrane, check the tension in the elastic cord and refit.
CARRIER
LIFTING POINTS
LIFTING POINTS
SPILL DOOR
TILT SWITCH

Section 1
Material Detection System
The material detection system typically consists of two probes

mounted on adjustable brackets located inside the carrier. The probes are
pre-wired to a junction box mounted on the outside of the carrier.
The vertical position of the probe can be altered to suit different material repose
characteristics. The probe has a sensitivity adjustment located inside the enclosure /
housing at the top of the probe.
The probe needs to be positioned so that it detects material as the material pile builds, but is out
of the direct material flow. The adjustment allows the positioning to give the best control of
the hoist winch raise system.
JUNCTION BOX
ADJUSTMENT
BRACKET
VIBRATION PROBE
Operation
Inside the probe head the control unit has a relay output, this is a single pole changeover contact, as
the probe changes state the contact gives a choice of normally open and normally closed connections.
The connection of the probe to the Cascade control needs to be considered for fail-safe operation.
All material detection systems are wired with normally closed contacts, when the vibration probes
are in their normal state (uncovered).
When the vibration probe detects material the relay connection opens to operate the winch control
timers. The opening connection in the probe allows the whole system of wiring to be fail-safe, if there
is any damage to the reeling drum cable or the wiring in the terminal boxes back to the control panel
the fault would react like a signal from the probe. As with the fail-safe for the probe failure, the chute
would initially raise and then shut down the material feed conveyor.

Section 1
Skirt Assembly
The skirt assembly consists of an attachment ring to which are bolted

a number of rubber leaves with a canvas over cover.
The skirt attaches to a flange at the bottom of the carrier and is designed to aid maximum
dust control at the point of material delivery from the Cascade.
The skirt sits over the apex of a material pile during loading to form a seal between the material and
the chute.
The two connection brackets are to allow easy connection to the flange fitting on the carrier, two bolts
can be used to hold the skirt assembly in position through these brackets while the flange is bolted.
The segmented skirt opens as the pile of material builds below the carrier. The dust seal is maintained
provided that the skirts maintain contact with the material.
Maintenance
Check the inner rubber leaves for wear, the rubber leaves should hang free. Replace leaves
which are excessively worn or damaged.
Change the canvas outer skirt if the bottom edge becomes ripped or frayed.
CONNECTION BRACKETS
SKIRT RUBBER LEAVES

Section 1
Closed Hatch Loading
The Hatch Charger is designed to be used when filling a closed hatch vessel.
This section attaches to the carrier assembly and is used to guide the falling product into
the ships hatch.
The skirted outlet must be removed from the loading chute, and the hatch charger
installed in it’s place.
Lower the chute to the ground and detach the skirt
Install the Hatch

Charger onto
the Chute

Section 1
Closed Hatch Loading
The hatch cover is removed and the chute

is lowered into position and centred on the
hatch by an on-deck operator.
HATCH CHARGER
UPPER SECTION
HATCH CHARGER
LOWER SECTION
HATCH CHARGER LOWERED INTO POSTION

The lower section of the Hatch Charger should
sit on the hatch throughout operation. To help
this section to stay in place, counterweights
may be installed using the two upright bars as
shown above.
Once securely on the hatch, loading can begin
at a reduced rate.
COUNTERWEIGHTS The charger has a telescopic action to allow
for movement of the vessel during loading
of up to 500mm. An operator should be
present on deck at all times to monitor the
hatch charger. They must extend and lower
the chute to maintain the inner tubes position
within the hatch seat (lower section) at a mid-
HATCH CHARGER AT MID POINT point in the travel range, thus to ensure the
charger does not come away from the hold
during loading (vessel lowering away from
charger) and to also ensure the chute does
not come to rest on the charger and vessel
with the hoist ropes becoming slack (vessel
rising towards the hatch charger).
RUBBER SEAL
Note:- Auto levelling can be provided as an

option.
HATCH CHARGER AT MAXIMUM DROP
The midpoint of the range of motion will expose around 650mm of the guides, as shown above.

Section 1
Trimmer Assembly
360° Trimmer Spout

The standard trimming spout is an extension to the lower carrier assembly. It allows limited
loading of material beyond the range of the boom / bridge travel. It also allows directional loading
for inaccessible storage areas.
The trimming spout rotates on a bearing fitted between the carrier frame and the rotating bobbin.
It is driven by a geared motor fitted onto the carrier frame. The motor allows the trimming spout
to be rotated clockwise and anti-clockwise from the operator’s controls.
The spout can be fitted after the carrier assembly is raised approximately 1.5 metres from ground
level. To connect the trimming spout use the two raised lugs to connect the flange to the bottom
of the chute with two bolts, connect the spout fully by bolting the two flanges together.
Note: The operation of the trimming spout must be above the material pile at all times.
The tip of the trimming spout is not designed to be buried in the loading material. If the exit
of the trimming spout becomes blocked the material detection probes operate as normal,
once material has backed up the trimmer spout to their position
Trimmers which have a slewing ring are fitted with an Auto lubrication system. The grease quantity will
be administered at varying rates to ensure the efficiency of the moving components. This will require
regular checks or possible replacement over time.
SLEW RING GUARD

TRIMMER MOTOR
PINION GEAR
WHEEL WITH
GUARD
SLEWING RING
TRIMMER WITH LINER TILT SWITCH
Trimmers which have a slewing ring are fitted

with an Auto lubrication system. The grease Trimmers with a tilt switch are fitted
quantity will be administered at varying to trimmers with a reduced rotation
rates to ensure the efficiency of the moving of 350°
components. This will require regular checks
or possible replacement over time.

Section 1
Trimmer Assembly
Trimmer Control
The trimmer motor requires a reversing control from a three phase supply.
Operator controls should be push button for clock and anti-clock directions.
3 Phase Supply / Trimmer Motor
Note:- Trimmers fitted with tilt switches, have a proximity switch set to limit rotation to 350º,
this will prevent the cable becoming entangled.

Section 1
Resitain Valve
The resitain valve is fitted on the base of the speed reducer or carrier.
The valve is designed to close the exit of the Cascade Chute when the
loading operation has been completed.
A motor driven actuator operates two ‘trap doors’. The doors hang vertical when the valve
is open and swing together and seal the exit when closed.
A set of pre-adjusted limits are fitted and tested by Cleveland Cascades Ltd during the assembly
of the Chute. These limits will be set at the fully open and fully closed positions.
Note:- The Resitain valve should be in the closed position when manovering the chute around.
The resitain valve should not be allowed to close during loading. An Interlock should
be provided to isolate the feed conveyor when the valve is closed. The valve should also be
open before loading and conveyors should be unable to start until the valve is open.
RESITAIN VALVE DOORS
MDS PROBE
RESITAIN MOTOR
ACTUATOR LINK ROD
MDS PROBE
RESITAIN VALVE

Section 1
Tilt Switches
The two tilt switches are suspended from chains anchored to the
Carrier or Speed Reducer.
The main purpose of having a tilt switch installed, is to prevent downward movement from
the chute as the tilts touch the top of the material pile.
The Tilt Switch probe should be positioned to a point near the bottom of the Skirt
(approx 200mm above).
Adjusting the chain links can alter the height of the tilt switches to give the correct level of control.
The tilt switches open circuit when the angle of the body is beyond 25 degrees from vertical.
The two tilt switches have normally closed contacts and are wired in series to the contacts T1
& T2. The circuit requires a true off delay time to operate the control circuit. See the electrical
control requirements in Section 2.
The timer is required to remove spurious trips if the tilt switches are knocked or vibrated.
The time delay for the switching should be 0.3 to 0.5 secs.
If the loading operation requires the chute to be moved down the side of a loaded pile, the tilt
switches may interfere with the loading operation of the winch and will require to be overridden
to allow the chute to be lowered and still placed close to the pile to give good dust control.
CHAIN SUSPENDED
TILT SWITCH

Section 2
Cascade Installation Instructions
PLEASE NOTE: These are generic Installation Instructions. Bespoke Installation Guides
are available upon request from Cleveland Cascades Limited.
Head Chute Connection

The installation notes are guides to installing all types of Cascade Chutes and equipment.
A risk assessment on site, method statement, suitability of lifting and access equipment is
the responsibility of the installer.
If pivoting, the head chute should be trial assembled before installation.
The rope routes through the sheave pulleys should be checked for alignment.
Any internal deflectors should be fitted at ground level or a low level as access may be restricted
when the head chute is installed.
If applicable to the head chute design install the winch / hoist onto the head chute and check the oil level.
The load cell cable should have the six connecting wires earthed during the installation in order
to prevent damage that may be caused by welding near the head chute section.
The reeling drum and any other ancillary equipment should be fitted to the head chute before
lifting, as access will be easier at ground level.
Four suitable lifting points are provided on the head chute near the cowl section. Lifting equipment
should be provided to lift the complete head chute in one single lift. The upper pivoting section
should be locked / lashed in to a position that will mate with the boom interface flange when the
head chute is lifted. A transportation link is provided with pivoting head chutes to allow the head
chute to be lifted in a rigid position.
Lift the complete head chute and bolt up the interface flange (refer to the supplied Bolt Torque
Tightening sheet and Head Chute flange connection document for further guidance). Remove any
temporary lock / lashing to the upper section if fitted. Check the alignment of the rope ways from
the winch location, and position of the head drum feed in to the top deflector cone. Adjust the top
deflector to an angle specified in the general arrangement drawing.
Fit any covers seals and guards to the head chute. The winch ropes should be run from the head
chute through the rope sheaves and to the winch location.

Section 2
Electrical Connections
Cleveland Cascades supply all cables up to the head chute section. Any cables from the ship
loader control panel to the cascade chute and operator station to the cascade chute are to be
supplied by the customer, unless previously agreed.
The overload panel SJB2 requires mounting in a location near the load cell on the head chute.
If a single box system, a defence standard cable should be ran to this panel from the ship loader
control panel, again this cable is to be supplied by the customer unless previously agreed. If a two
panel system the panel MPB1 can be located in the main control panel for the cascade controls
and a cable ran between the two.
If possible the cable should be run away from power cables with large inductive loads.
The overload system is tested before delivery; only function tests are required on installation.
The material detection level probes, tilt switches, trimmer motor power and resitain valve (when
supplied with the chute), wiring is terminated in a terminal box / box’s on the carrier assembly
prior to dispatch. The continuity of these connections is then followed through the reeling drum /
drum’s cable to the head chute. A cable is then required to be run from the main control panel
to the head chute.
A chute control philosophy is supplied with the chutes Electrical specification. This details the
equipment function and how the various pieces of electrical equipment should be controlled. This is
to aid the customers control system designer to incorporate the chute control, into the ship loader
control system.

Section 2
Cascade Connection
Because of transport height restrictions the Cascade cones stack is normally supplied partly
assembled on the carrier section. The instructions below may include work that is complete
in our workshop. With the head chute assembly fitted to the boom use the following procedure
to connect the cascade section. Reference should be made to the drawings contained in
Section 1 of the manual.
1. The partly assembled Cascade Chute should be positioned on the ground. Using a crane or other
suitable lifting device the cones on the separate pallet should be lifted into the existing stack of
cones on top of the carrier. Care should be taken when lifting the cones. Lift one cone at a time,
each cone is to be lifted from the three connection eyes around the cone rim. It is important to
ensure that the sequence of alternate type ‘A’ and type ‘B’ cones is built up, finishing with the
correct type of cone at the top of the stack, see the general arrangement drawings. It is important
to ensure that the ‘A’ and ‘B’ type cones are orientated correctly so that when chute is extended
the liner faces on successive cones are opposite each other.
2. The next stage is to complete the attachment of the three strops to the cones that have been
added to the stack. This work should be carried out starting from the lowest cone working
upwards. There are two types of cone eye connection used, refer to the Part List for the cone
attachment type used on your chute. The standard (light duty) type uses a centre ferrule and two
outer bushes. The centre ferrule is placed in the hole through the cone connection eye in the cone
rim. The bushes are inserted into the strop loop with the flange facing inwards. The two washers
are located on the outside of the loops. The bolt should be passed through the whole assembly
and the locking nut tightened so that the whole assembly is free from movement. For the single
bush type. The metal tube insert is placed inside the nylon bush. The bush is then inserted into
the single loop on the strop. The washer is then placed on the outside of the loop. The assembly
is then fitted to the cone bracket (heavy duty) and fixed with the bolt and nut. This process should
then be repeated for each strop on each cone, taking care to make sure that there are no twists
in the strops.
3. The shroud should be lifted on to the carrier using the lifting lugs provided on the bottom ring.
The shroud should be placed on the carrier so that the rope guides sit above the rope attachment
points on the carrier and the lower shroud ring creates a good dust seal on the foam strip.
The Cascade Chute may be supplied complete with the cones and strops attached the shroud
may also be fitted if there are no height restrictions in the container.
4. Having completed this work, the Cascade Chute can then be installed onto the loading unit.
The Cascade should be moved into position, directly below the loader unit taking care to ensure
its correct orientation for connection on to the head chute. Reference should be made to the
general arrangement drawing which shows the connection position for the ‘A’ strop. The green
patch, sewn at the top of the strop, can identify this strop. With the chute in position the hoist ropes
should be lowered down towards the carrier. The thimble eye connections on the end of the ropes
should be passed through the holes on the rope guides attached to the shroud and connect to
the eyebolts on the carrier, using the shackles provided.

Section 2
5. The hoist winch should then be connected in order to raise the chute up towards the feed chute
and cowl, to enable connection. The winch brake should be checked for fast action braking at this
stage by lifting the carrier 0.5m off the ground and checking to see that the winch does not run
on. At this stage the carrier should be checked to make sure that it is suspended level from the
three hoist ropes. Before checking the level, run the system up and down a few times to allow the
hoist ropes to find their natural position in the spool. Adjustment can be made to the level at the
eyebolts on the carrier should this be necessary. If adjustment is required in excess of provided
doughnut spacers on the eyebolts then this should be undertaken at the rope anchors on the
hoist winch. Check that the ropes are running in the spools / drums before adjustment.
6. Electrical connections should then be made to the terminal box / box’s on the carrier from the
cable reeling drum. An anchor point on the carrier locates the cable grip on the reeled cable.
The cable end is glanded or plugged into the terminal box / box’s mounted on the carrier.
7. The chute should be raised to a height, that allows the strops to be connected to the head chute.
Care should be taken when raising the chute, to prevent the cones from colliding with any part
of the supporting structure, this could result in damage to the cones (This is due to the winch
limits not being set). With the chute in position, the three strops should be attached to the strop
connection brackets by removing the pin, placing the strop loop through the bracket and then
replacing the pin (passing it through the loop at the end of each strop). With the pin in position
within the bracket and through the strop, the retaining clip should be passed through the hole at
the end of each pin.
Because the adjustment of the winch limits is carried out during commissioning it is
important that the maximum and minimum chute extents are not exceeded until the
limit switch is correctly adjusted. After successful commissioning the shroud should be
connected to the head chute by raising the shroud assembly top ring to the head chute
cowl and attaching the six hooks onto the head chute.

Section 2
Cascade Commissioning Procedure
The commissioning notes are guides to installing all types of Cascade

Chutes and equipment.
Before any operation of the Cascade Chute is undertaken, the following commissioning
procedure must be followed.
If the Cascade is supplied with a winch unit / trimmer unit, check the gearbox oil level as detailed in
the manufacturer’s instruction manual. This check must be carried out as premature failure of the unit
could occur.
The following procedure assumes that all work set out in the installation section has been completed,
and that the winch and head chute installation is complete and carried out to the details shown in the
general arrangement drawing.
1. Disconnect the shroud from the head chute if already connected by releasing the six shroud
attachment hooks. If the shroud is attached to a larger system, a shroud hand winch is a manual
winch, rope and sheave way assembly that is used to aid in the removal and re attachment of the
shroud. The hand winch is normally located on the head chute in an accessible area and has two
ropes on a drum. The ropes attach to the shroud 180° apart via an eyebolt and shackle. The lever
can then be turned to raise and lower the shroud once the shroud hooks are detached.
2. Check the security of the hoist ropes where they attach to the carrier. The plain nut should be
tight with a split pin passing through the bolt and spread open on one side.
3. Check the rope path of the three hoist ropes and ensure that all the rope keeps are in position
on the rope sheave assemblies.
4. Check that the winch brake wiring is connected for fast action braking. This is to prevent any run
on.
5. Check that the carrier is hanging level from the three hoist ropes and adjust the steel eyebolt
spacers if necessary. Carry out this task after running the system up and down a few times to
allow the ropes to find their natural position on the spool / drum.
6. Extend the chute so that the last cone just remains seated in the carrier and set the lower limit
switch on the hoist winch.
Note: The reeling drum springs have a limited pull off beyond the range of the Cascade Chute
length. If too many pre-turns are given to the drum before the cable is connected, it is possible
to reach the spring pull off limit before the cable is fully extended. This can result in damage
to the cable / reeling drum.
7. The chute should be raised and the winch upper limit switch operating position set. Reference
should be made to the minimum retracted position indicated on the arrangement drawing when
setting this limit switch position. The ultimate limit switch should then be let to operate 250mm
above the winch limit.
8. Check the angles of any adjustable deflectors in the head chute and set at the angle shown in
the general arrangement drawing.
9. Extend the chute, check that tilt activation stops the chute extending, continue to extend the
chute to it’s full extension. Visually check to see that adjacent cones and liner faces are inclined
towards each other and that the A and B cones form a symmetrical pattern from the top cone
to the lowest cone. Check that there are no twists in the 3 strops connecting the cones.
10. Measure the inclination angle of each cone and compare this against the angle specified in the
technical specification. The angles measured should be within 0.5 of a degree either way of the
angle specified.

Section 2
11. Small adjustments can be made to the cone angles by adding or removing shims on the
‘A’ strop bracket.
12. Check that the head chute is hanging level. Adjust the level, add or remove counterbalance
weights to the front of the head chute if a pivoting chute is fitted. The ‘A’ strop bracket can
be adjusted with shims if required.
13. Check the operation of the material detection system. This can be carried out by simulating the
presence of material against each of the material detection probes. The chute should then raise
automatically by a maximum height of 200mm. If the raise height is greater than this, then it will
be necessary to make adjustments to the timer settings in the winch control circuit that controls
the duration of operation of the hoist motor. There should not be a delay between the material
detection probe operating and the operation of the hoist winch. The tilt switches, if fitted, can also
be simulated by tilting the body beyond 15º from the vertical position. There should be a delay
setting of approximately 0.5 seconds applied to the tilt switch controller to remove spurious trips
from the tilt switches.
14. The shut down operation of the material detection system should be checked by continuing to
operate the probe after the chute has automatically raised. The feed conveyor to the Cascade
Chute should stop within 3 to 5 seconds after the chute has risen if the probe remains activated.
15. The operation of the load cell overload system should be checked. This can be carried out by
the use of the test signal from the toggle switch and variable test pot SJB2. As the test signal is
increased operation of the programmed alarm points and stopping of the material feed conveyor
can be verified. A power failure check should be undertaken to make sure that this also stops
the material feed conveyor. Return the toggle switch to read the load cell when this is completed.
16. The operation of the resitain valve should be checked so that the conveyor start signal is healthy
when the valve doors are opened and the conveyor shuts down or fails to start when the valve is
closed.
17. The rotating trimming motor should be fully rotated in both directions to check that the
meshing gears run smoothly and the directions are correct. Also if electrical limit switches are
incorporated, their functionality should be verified.
Only after all of the above checks have been fully completed, should any tests loading material
be carried out.
18. Before any loading with material commences, the shroud should be disconnected from the
head chute if not already, so that it is possible to observe the material flow within the cones.
19. The initial loading trial should commence with a loading rate of less than 50% of the maximum
required rate. The chute should be extended so that it is positioned approximately 300mm above
the floor of the ship, with the skirt at the bottom of the chute in contact with the floor.
20. The conveyor system feeding the material should then be started and the material flow through
the cones should be observed.

Section 2
21. The rate should be increased in increments up to maximum capacity. At each stage, the level
to which material is building within each cone should be recorded together with the loading rate.
At maximum rate, the material should be building up within the cones to a level not exceeding
the top of the cone liner.
If the material is building up above the liner or it is not filling the cones to the correct level, the
system should be stopped and a new set of strops with a different cone angle fitted. If in doubt,
contact Cleveland Cascades Limited for advice. Additional strops are not always supplied.
At each stage of increased loading rate, observation should be made of any oscillation of the
cones. If violent oscillation of the cones is observed, then the system should not be operated at
that particular loading rate, as this would result in premature wear to the strops. If operation is
required at a loading rate where oscillation occurs, it will be necessary to fit a new set of strops
with a different cone angle. Should material spillage occur from the adjustable deflector in the
head chute, the angle of the deflector should be increased to stop the spillage.
22. The operation of the material detection system should be checked. As the material builds
beneath the chute, and the exit starts to block, the hoist winch should automatically raise the
chute. The height which the chute is raised should be a maximum of 200mm, with the skirts
always in contact with the pile of material already loaded. If this is not correct, the timer in the
control circuit for the winch should be adjusted accordingly. The probes should be positioned as
low as possible in the carrier but out of the material flow, adjustment of the probe height is by the
two M10 bolts on the probe bracket mounting. If the probes are mounted too high in the carrier it
is possible that the probe will not detect the material.
23. The overload system will require to be set up. The over load system is pre-set with a value below
the weight of a blocked chute. The recommended value is based on taking a measurement of the
chute when it is running at full rate and maximum extension.
The measurement that is taken will represent the maximum normal load that the chute should reach.
The setting that we recommend is 5% higher than this figure; a typical cone at normal running weight
would increase the weight by 300 – 400% when it is fully blocked. This method of setting the alarm
will give the earliest shut down of the conveyor feed without introducing nuisance trips.
To alter the load setting for the alarms 1 to 4: Pressing the alarm button momentarily will allow
you to view the current settings. Each press will illuminate in turn alarm AL1 to 4 annunciators.
To change alarm settings, keep the button held for 3 seconds, which will cause the value
to have one digit brighter than the others. This may be changed in value using the up /
down buttons, and the digits may be selected using the digit select push button.
The alarm action is determined by the first character H – high, L – low, o -off.
Each alarm has a hysteresis value with a HY prompt.
Note: No hysteresis values are set for chute applications..
When changes have been made to the settings press OK. The display will return to the KG reading.
24. The shroud should then be reconnected to the cowl, using the six connecting hooks. The chute should
then be extended and retracted, to ensure that the shroud collects neatly and that the hoist ropes pass
smoothly through all the rope guides attached to the connecting rings between each shroud section.
Observation of the Cascade Chute should be carried out during the first loading periods; changes
in loading rates or material density may affect the performance of the Cascade Chute. If there is a
change of material, re-check the Cascade Chute operation when this material is loaded.
Continued operation at low rates may increase the dust emission and will shorten cone liner wear.

Section 2
Use this check sheet (below) before putting the Cascade Chute into operation.
Pre-Operation Check Sheet
No. Item Description ✓
1 Check the ropes & ropeway
2 Check the top cone is correctly orientated to the head chute
3 Check that the carrier is level
4 Check the cone inclination
5 Check upper and lower winch limits for operation
6 Check the electrical connections
Check anti-static system resistance value to earth,

7
should be <=10^6 Ohm.
8 Check material detection system operation
9 Check overload system operation
10 Check that all guards are correctly fitted
11 Check that the reeling drum cable extends to maximum length
12 Check gearbox oil levels
13 Directional checks for winch and trimmer
14 Test slack rope function
15 Test tilt switch function
16 Test trimmer rotation limits

Section 2
Cascade Loading Instructions
These instructions are written on the understanding that all the installation work is complete,
and all functional tests have been undertaken by qualified personnel.
It is also on the understanding that the material being delivered is of the same specification as stated
in the questionnaire, and is being delivered at the specified rate in a consistent manner.
Before commencing operation of the chute for the first time, please ensure that all the checks listed
on the Pre-Operation Check List have been carried out. Thereafter, the Pre-Operation Check List
should be followed at a frequency set by the Operations Manager, but certainly no less frequently
than once per month.
Normal Loading Operation

1. The ship loader or silo system with the Cascade Chute attached should be positioned in the
required location for loading.
2. The operator should then lower the chute until the bottom of the chute is just above
the bottom of the hold of the ship / silo floor, or just above the pile of material already loaded.
It is important that the skirts are in contact with the floor or the pile of material to achieve
maximum dust control. If tilt switches are installed on the chute, lower until the tilt switches
activate or the chute reaches its low limit.
3. The material feed conveyor should then be started to deliver material to the Cascade Chute.
4. As the pile of material builds up and starts to block the exit of the chute, the chute will raise a
distance of approximately 200mm to clear the blockage. It is important that the chute is not raised
too high with the skirts losing contact with the pile of material, as this will result in an increase in
dust emission. The raising of the chute to form a material pile is done using the material detection
system inside the chute.
5. The chute should continue to be controlled in this way as the pile of material builds. Having formed
a pile of material of the required height the chute should be moved to a new position in the hold.
It is possible to continue to load as the chute is moved around the hold so long as the bottom of the
chute is maintained in close contact with the pile of material already loaded. The greater the drop
of material, the greater the resulting dust emission.
6. There are two approaches to the loading:
To load the material in discrete piles. As the first pile reaches its maximum height,
the Cascade is moved to a new position and the next pile is built up.
The first pile is built up to its working height and then the chute is moved forwards,
backwards or sideways. As the chute is slowly moved the pile builds up at the leading edge
of the skirt. It is important to keep the skirt in contact with the pile at all times to maintain
maximum dust control. When loading using this method it is important that small horizontal
movements are made with the chute.Each movement made should be 250-400mm
approximately, depending on the size of the chute.
7. At the end of the loading operation, the chute should be raised and lowered within the ship’s
hold to assist in cleaning any material build up from the inside of the chute. If a resitain valve
is used, the valve should be closed before moving the chute from the hold.
8. It is recommended that following the completion of a loading operation a visual inspection
of the chute is carried out. Lowering the shroud and extending the chute can facilitate this.

Section 2
Cascade Loading Instructions
9. If during loading, the Cascade chute MDS system or Overload system (load cell for chute weight
monitoring) are tripped the cause will be a blockage of material either cause by a surge in feed –
excess material backfilled, or perhaps a physical blockage within the chute caused by a lump
or foreign body trapped inside the chute at some point.
In order to relieve this blockage and re start loading the fault condition must be cleared.
Firstly, attempt a small raise of the chute using the remote control or operator panel controls.
The chute should be lifted by around 200mm in order to create some clearance between the
chute and existing product pile or vessel base, this clearance will create free space for product
inside of the chute to flow out. Observation should be made at the base of the chute following
this raise to see if product leaves the chute. If product pours out from the chute then this process
should be repeated until no product pours from the chute, following the recommended method
detailed in the control philosophy of the Electrical specification. Once product has stopped
running from the chute, the chute can be assumed to be empty. The panel signals should be
checked to see if the fault condition / alarm has cleared, if this is the case loading can be re
started.
Note – similar to lifting the chute using its hoist to create free space, the loader can also be
slewed off the pile or shuttled forwards / backwards off the pile by approximately 200mm to
give the same effect.
Note – should these methods not clear the chute, i.e. no product runs from the chute when
free space below is created – then it must be assumed that there is a physical blockage holding
material within the chute. In this case the chute must be inspected in order to find and remove
the blockage before loading can continue. Lowering the shroud and extending the chute can
facilitate this.

Section 2
Cascade Maintenance Instructions
N.B. Some of the chute options may not be included on your chute.
If defects or damage are detected, the shiploader should not be put into operation.
It should only be put back into service when the defect has been eliminated.
Prior to each loading session, a visual inspection of the chute should be carried out:
1. Check the telescopic shroud section for wears or tears.
2. The outlet section should be hanging level on the three ropes and the ropes should show
no signs of wear.
3. Clean any adhering material that may be on the chute components.
4. The material detection probes must be cleared of material build-up to give
maximum sensitivity.
5. Check that the electrical cables are free from fraying and damage.
6. The rope and related equipment must be inspected at the beginning of each work period and
particularly following any incident, which could have damaged the rope or installation. The entire
length of the rope should be inspected on a 3 monthly basis. With particular attention paid to the
winch, sheave assemblies and terminations at both ends of the rope. Excessive wear, broken
wires, distortion and corrosion are the usual signs of deterioration. An authorised competent
person must examine the ropes in accordance with the appropriate regulation.
7. The strops will need regular inspection; the stitching on each loop and the main strop attachment
loop should be examined. Check for fraying in the main strop and attachment loop. Replace if
worn or damaged.
Carry out a function test of all control components before loading commences.

Section 2
Cascade Maintenance Instructions
The maintenance periods listed are indicative. Ultimately, the Maintenance Manager will decide
on the required frequency based on the conditions and usage of the system.
PART INTERVAL MAINTENANCE SCHEDULE
Rope sheaves 50 hours Grease nipple
Head chute pivot bearings 100 hours Grease nipple
Trimmer bearing 100 hours Grease nipple
Trimmer bearing gear and

100 Hours approx Auto lubricator
pinion surface pile of material
Trimmer gearbox 3 years Fill from level plug
First 50 - 100 hours

Winch gearbox Fill from level plug
Every 2500 hours
Hoist ropes 3 months Inspect
12-18 months (High Duty)

Strops Replace
18-24 months (Low Duty)
For enquiries or information regarding Spares and Services, please contact our aftersales Dept.
Tel: + 44 1642 753260
Fax: +44 1642 753270
Email: aftersales@clevelandcascades.co.uk

Section 2
Cascade Cleaning Procedure
General
By its nature, the Cascade Chute has a large internal surface area which fine dust can stick to. Some
dusts will tend to accumulate but others may not. The main components of the Cascade system are
the head chute, Cascade, shroud and carrier and these are made as far as possible in such a way as
to reduce the potential for material to build up.
Main component description

Head chute
The head chutes are often designed to suit a particular shiploader. It has to be designed to cascade
the material and is usually designed with deflectors which are adjustable and removable to assist
with material control and replacement of wear parts. Making the deflectors adjustable increases the
potential for material to be trapped and makes cleaning more difficult. Where cleaning is an important
consideration integral deflectors can be considered.
Cascade
The Cascade is designed around the need to maintain control of the material and the need to be
able to telescope the chute. The cones are made with as few material trapping surfaces as possible
but some materials will stick and the surfaces can only be inspected and cleaned when the cones
are extended.
Shroud
The shroud folds as it is gathered onto the carrier when retracting the chute. It is designed to be up to
one metre longer than strictly necessary and this extra length remains folded on the carrier when the
chute is fully extended to provide a good seal. Dust can adhere to the shroud and material, both dust
and grains, can gather in the folds. Any material gathered in the folds can only be cleaned by fully
extending the shroud and this would normally mean extending the chute to up to one metre beyond
the operating limit.
Carrier
The carrier is a conical steel construction with two or more hatches for access to the material
detection probes and an inset for safe location of junction boxes and positioning any slewing
equipment. Internal fittings are kept to a minimum.

Section 2
Cascade Cleaning Procedure
Cleaning Procedure
Head chute
Open the hatch at the conveyor delivery or inspection windows and brush down. There will be no
places for material to gather in the conveyor chute, trolley chute or luffing pivot part of the head chute
permanently fixed to the trolley.
The washing water will then enter the Cascade head chute and tend to be retained inside the cones
and be delivered through the carrier.
The area of the head chute at the cowl level, where the shroud attaches, can be cleaned by lowering
the shroud and washing. Where access is not possible because the chute is in an operating position
and not brought back to the maintenance station, a wash ring could be installed to blast water at
these areas.
Cascade
Each cone can only be cleaned down when it is suspended clear of its immediate neighbour cones.
The standard way of achieving this is to provide a platform at the top of the stack of cones and raise
the cones on their strops using a winch. As each cone passes the platform it can be cleaned down
using a brush, compressed air or water.
Where the Cascade can be fully extended with the shroud lowered, the cones can be cleaned down
if adequate access can be provided.
Shroud
To free all the loose particles held in the folds of the shroud the shroud must be fully extended. If it is
then washed and raised and lowered any particles which can fall off will fall off. To wash the shroud in
situ, a wash ring will need to be installed below the cowl and the carrier lowered to a level below the
normal operating limit to ensure that the shroud is fully extended. This could be done with the boom
fully luffed so that the Cascade is over the berth.
Carrier
The carrier will be part-cleaned by the shroud washing water and can be checked by opening the
access hatches or opening the Carrier Spill Doors. Further cleaning can be carried out by either
brushing, compressed air or water through the opened Carrier Spill Doors.

Section 2
Cascade Control Requirements
Use this information for guidance to the operation requirements for the control system that
will operate the Cascade Chute. If the Cascade Chute is supplied without the control panel
we recommend that this information is followed for correct operation of the Cascade Chute.
Do not hesitate to contact Cascade staff for further information if required.
The control circuit shown below is for the timer circuit for lifting the chute when the material reaches
the probe.
Although the Cascade Chute has two level probes, the probe relay signals are connected in series
so they work as one single level switch.
The level probes are mounted on opposite sides of the carrier section and monitor the material
on both sides at the base of the cone stack.
There are two different stages of level detection required.

1. When the material pile has built-up sufficiently, this will operate one or both of the Material
Detection Probes. In turn, this will raise the Chute to the correct height over the pile.
2. When the Chute becomes blocked, one or both of the Material Detection Probes will detect this.
In turn, this will signal to stop the material flow into the Cascade Chute.
The chute receives a signal from the two level probes; the signal operates two timers (TMR1 & TMR2)
to give 2 different operations. The level probe detects the material as it rises up inside the carrier
section. The signal from the level probe opens a relay contact in the head of the probe and the signal
operates simultaneously the 2 timers TMR1 and TMR2.
TMR1 raises the Cascade Chute
TMR2 stops the material flow into the Cascade Chute
In the drawing on page 52, the connections 1 & 2 are the supply, the probe relay contacts 5 & 6 are in
series. The relay LR1 is energized from the probes when there is no material detected. When the
relay LR1 is energized the two contacts LR1-1&2 are open, when the material is detected by the
probe the contacts LR1-1&2 close and energises the timers.

Section 2
Operation of TMR1
The timer relay TMR1 operation is connected into the part of the control circuit that operates
the winch. The winch control will raise and lower the chute. For the standard chute application
the timer TMR1 is connected to operate the winch raise relay C1.
The winch operation raises the chute at a speed of approximately 6 meters per minute; this would
give 100mm of lift for each second the timer relay is closed. From the instant the signal from the relay
in the head of the level probe energises the timer TMR1, the timer relay operates the winch to raise.
The timer will keep the relay contact closed for the duration set. As soon as the timer has completed
the sequence the winch will stop raising the chute.
For the chute to rise for a second time, the timer must have a falling signal from the previous probe
operation. The timer cannot raise the winch for any longer than the set time duration will allow.
CC-VIBRATION PROBES
LEVEL RELAY
FOR FAIL SAFE
OPERATION
PULSE ON TIMER
(CHUTE RAISE)
DELAY ON TIMER
(BLOCKED CHUTE)

Section 2
Operation of TMR2 and Conveyor Interlocks

When the chute gives one signal from the level probe, this signal is used to raise the chute in
normal operation, and the second timer TMR2 is also monitoring the signal. This timer function
is connected to the control circuit of the material feed conveyor system of the ship loader.
The contact from TMR2 is shown in the retaining line for the relay SIR. If the probe is covered for a
longer period of time (5 to 10 secs) the contact will open and de-energise the relay SIR. The main
function of the relay SIR is to monitor the healthy circuits form the stop circuits, overload system,
winch motor overload and the timer TMR2. If the Relay SIR de-energises the material feed to the
chute must be stopped.
We consider this to be the most suitable way of providing a fail-safe operation. The drawings are for
guidance only. The actual circuit diagram may differ for the drawing but it should contain the main
elements of the controls shown.
The control circuit shown below shows the winch raise and lower circuit with the timer raise and
manual raise lower circuit.
The relays RL1 and 2 are from the overload system. RL1 is the overload. RL2 is the fail safe.
BLOCKED
STOP HEADCHUTE
PROBE
RESET IF REQ’D CONNECTED INTO FEED

CONVERYOR STOP CCT
SAFETY
INTERLOCK
RELAY
CC-WINCH
CC-WICH LIMIT HIGH
LIMIT HIGH ULTIMATE
RAISE
RAISE
CC-WINCH LIMIT LOW WINCH MOTOR
LOWER
LOWER
OPERATOR CONTROL PANEL

Section 2
Control Circuit Notes
TMR1
Multi-function type timer giving a set timed operation from a single pulse signal.
SUPPLY ON
OFF
LEVEL PROBE ON
OFF
TIMER ON <TIME ON> <TIME ON> <TIME ON>

OUTPUT
RELAY OFF
TMR2
A delay ‘on’ timer using the normally closed contact.
LEVEL PROBE / ON
SUPPLY
OFF
TIME DELAY <TIME DELAY>
TIMER ON
OUTPUT
RELAY OFF

Section 2
Tilt Switches
For tilt switches supplied with a control unit to provide an intrinsically safe system,
the control unit has a built in timer to take out spurious trips. For other applications see below.
For other applications the tilt switches timer needs to be connected into the control circuit. A ‘True Off
Delay’ timer is required. This timer is used to take out spurious trips. For example, the tilt switch will
operate if it is swinging around on the bottom of a chain. The signal will be a constant pulse on and
off as it swings. The true off delay timer will ignore the spurious trips and react only to full tilt signal.
SUPPLY ON
OFF
TILT SWITCH ON
OFF
TIMER ON
OUTPUT
RELAY OFF
Every time the tilt switch operates, the timer starts the timer sequence. Unless the tilt switch
gives a signal longer than the time set the output relay will not operate.
Although an On Delay timer would operate with this sequence, if the tilt switch has an opening
contact, it is not possible to connect an opening contact to an on delay timer unless it is a True
Off Delay with a constant supply.

Section 2
Cascade Fault Finding
FAULT POSSIBLE CAUSES

Large increase in dust at exit of chute Material spilling from cones. Lower the shroud to check
for spillage and establish the cause.
Horizontal oscillation of chute Too low feed rate for cone inclination. Increase feed rate
or change strops to give reduced cone inclination.
Chute automatically lifts on start up Material build up around the probe. Check for build
up and clean.
Faulty switch operation. Check switch operation by
simulating material.
Chute fails to lift when blocked by Probe not correctly adjusted. Check sensitivity setting
pile of material inside probe and vertical position of probe.
Power supply failure to probe. Check power supply
connections at probe.
Failure of switched signal. Check electrical connections
and wiring to probe.
Winch runs on after stopping Brake not connected for fast action operation.
See wiring diagram.
Lining on brake worn. Inspect and adjust / replace
as necessary.

Section 2
Bolt Tightening Torques
This table is applicable for all bolts where no other torque is specified and is valid only for coarse
threaded screws and nuts of the specified strength grades. Threads should be lubricated with oil.
Strength Grade
8.8 10.9 12.9
Size
Nm Nordlock Nm Nordlock Nm Nordlock
M8 25.0 29 34 37 39 43
M10 49 56 68 73 83 85
M12 88 97 122 126 147 146
M14 137 155 196 201 235 233
M16 215 237 304 306 372 355
M18 304 331 421 429 510 498
M20 431 464 598 600 716 696
M22 578 635 784 818 990 948
M24 745 800 1039 1034 1255 1199
M27 1088 1171 1530 1509 1854 1749
M30 1481 1596 2079 2058 2491 2385
M33 2020 2155 2825 2772 3394 3213
M36 2598 2776 3639 3576 4355 4145

Section 2
Bolt Tightening Torques
The following table is applicable to stainless steel bolts. The bolts should be well lubricated with a
molybdenum disulphide bearing lubricant and tightened slowly by hand to reduce the possibility of galling.
Property Class
A2-70 A4-80
Size
Nm Nordlock Nm Nordlock
M8 17 15 22 20
M10 33 30 44 39
M12 57 51 76 68
M14 91 81 121 108
M16 140 124 187 165
M18 195 173 261 231
M20 273 242 364 323
M24 472 418 629 557
M27 682 609 909 812
M30 930 831 1240 1108
M36 1620 1444 2160 1925

Section 2
Head Chute Flange Connection
Procedure for the installation of a Cleveland Cascade Head chute.

Identify the parts
Before beginning
Prepare the work area
Remove all items from the area of work to prevent any injury and barrier tape off your working
area to prevent any unauthorized person entering your work area.
Select the ideal lifting method for installation of the head chute connection flange. The selection
should be based on accessibility around the connection point, availability of the equipment and
overall weight of the lift. Common methods of lifting the head chutes to their connection flange
include cranes, forklift trucks and chain blocks. All equipment should be fit for the purpose and
should be accompanied by certified lifting accessories.
When installing the head chute difficulties may be encountered when trying to align bolt holes
between the two separate flanges. Two possible methods that can overcome the difficulties are
transferring the lift to chain blocks located close to the connection points or the use of larger slave
bolts. Remember to replace the slave bolts on completion with the specified nut and bolt.
With all connection points aligned, put all bolts into position. Apply the required grease to the bolt
covering the threads and also apply grease to the nut before fitting to the bolt.
The bolts should be tightened in a sequence to ensure a good seal. The sequences for tightening
the bolts are shown in the diagrams below.
All sequences should follow the same 13 9 5 1 3 7 11

tightening strategy.
• • • • • • •
This is to apply 30% of the required torque 15 • • 18
on the first pass, 60% on the second pass
21 • • 20
and 100% on the final. The required torque
settings vary per bolt and application. 19 • • 22
Please refer to earlier bolt tightening torque 17 • • 16
tables, unless values are otherwise stated • • • • • • •
on the Assembly drawings in section 4. • •
Ensure bolts are not over or under tightened. 12 8 4 2 6 10 14 1 3
Exceeding the required torque setting could
weaken the overall strength of the bolt. 5 7 9 11 13 15 17 4 2
• •
• • • • • • •
3 •
1 3
1 •
2 •
7 6 4 •
• • • • • • •
6 8 10 12 14 16 18
5 8
4 2

Section 3: Machinery Directive (2006/42/EC)

Declaration of Incorporation
Serial No. .................................CC864............................................................................

Issue Date: ................................. 11/08/2016............................................................................
Name & address Cleveland Cascades Ltd

of manufacturer: Unit 22 Dukesway
Teesside Industrial Estate
Thornaby
Stockton On-Tees
TS17 9LT
United Kingdom
Country of origin: United Kingdom
Description of goods: Cascade Chute (for the transfer of bulk materials)
This machinery must not be put into service until the machinery into which it is to be incorporated
has been declared in conformity with the provision of the Directive 2006/42/EC
The relevant technical documentation is compiled in accordance with the provisions of part B of
Annex VII of the machinery directive. All relevant information about the partly completed machinery
will be provided, in writing, on a reasoned request by the appropriate national authority to its
authorized representative. The name and address of the authorised representative, authorised to
compile the relevant technical documentation, is the Managing Director, Cleveland Cascades Ltd,
Unit 22 Dukesway, Teesside Industrial Estate, Thornaby, Stockton On-Tees, TS17 9LT, UK.
Name: Ian Barnard

Position in Company: Managing Director
Signature:
Place: Thornaby, UK

Section 3: Machinery Directive (2006/42/EC)

Declaration of Incorporation
Essential Health and Safety Requirements relating to the design and construction of the
partly completed machinery.
1.1 General Remarks

1.1.2: Principles of safety integration
1.1.3: Materials and products
1.1.5: Design of machinery to facilitate its handling
1.3 Protection Against Mechanical Hazards

1.3.1: Risk of loss of stability
1.3.2: Risk of break-up during operation
1.3.3: Risks due to falling or ejected objects
1.3.4: Risks due to surfaces, edges or angles
1.3.7: Risks related to moving parts
1.3.9: Risks of uncontrolled movements
1.6 Maintenance
1.6.1: Machinery Maintenance
4.1 General
4.1.2.1: Risks due to lack of stability
4.1.2.3: Mechanical strength
4.1.2.4: Pulleys, drums, wheels, ropes and chains
4.1.2.5: Lifting accessories and their components
4.3 Information and markings

4.3.1: Chains, ropes and webbing
4.3.2: Lifting accessories
Contact Cleveland Cascades Ltd

Unit 22, Dukesway, Teesside Industrial Estate, Thornaby,
Stockton-on-Tees, Cleveland, TS17 9LT, United Kingdom
Tel: +44 1642 753260 | Fax: +44 1642 753270
E-mail: enquiries@clevelandcascades.co.uk
Website: www.clevelandcascades.co.uk 61
GENERAL ARRANGEMENT
ITEM PART NUMBER QTY DESCRIPTION
1 45000171 1 1300 CARRIER ASSEMBLY WITH MDS PROBES + TILT SWITCHES

2 45640119 1 1300/1500 SKIRT ASSEMBLY - 1m SKIRT
3 45100519 1 CC864 CASCADE ASSEMBLY
4 45300825 1 ASSEMBLY OF COMPLETE HEAD CHUTE
5 45200120 1 1300 SHROUD ASSEMBLY - 18m LONG
6 45640171 1 1300 Tubular Skirt Assembly
HEADCHUTE ASSEMBLY
1 45300827 1 PIVOTING HEAD CHUTE ASSEMBLY

1.1 45130218 2 STANDARD 125mm STROP BRACKET ASSEMBLY
1.1.1 45130214 1 Standard 125mm Strop Bracket Base
1.1.2 45130215 2 Standard 125mm Strop Bracket Lug
1.2 45130222 3 Ø50 STROP PIN ASSEMBLY FOR 125mm STROPS
1.2.1 45130223 1 Ø50 STROP PIN FOR 125 WIDE STROP
1.2.2 10330005 1 EYEBOLT 8mm ST/ST 140kg SWL
1.2.3 10390057 1 R-CLIP TO SUIT Ø45-56 PIN
1.4 45900034 1 T95 LOAD CELL ASSEMBLY 2000-10000KG - 125mm STROPS
1.4.1 45920046 1 Ø31.7 x 109 PIN
1.4.2 45900037 1 Ø25.4 X 104 PIN
1.4.3 45900035 1 UPPER LOAD CELL BRACKET FOR T95 2000-10000KG
1.4.4 45920045 1 LOWER LOAD CELL BRACKET FOR T95 2000-10000 kg LOAD CELL
1.4.5 10310405 2 DIN 125 A - Ø33 WASHER
1.4.6 10310406 2 DIN 125 A - Ø27 WASHER
1.4.7 10390005 2 R CLIP Ø6 TO SUIT Ø28-40 SHAFT
1.4.8 10390052 2 ST STL Ø5mm R-CLIP FOR Ø20 - 28mm SHAFTS
1.5 45130279 2 10mm LOAD CELL PACK FOR 45900034
1.6 45490088 4 UNIVERSAL SHEAVE ASSEMBLY FOR Ø11 ROPE
1.6.1 45420115 1 SHEAVE BRACKET MULTI TYPE FOR Ø250 SHEAVE Ø45 PIN
1.6.2 45420101 1 SHEAVE PIN 45MM IN ST/ST
1.6.3 45420011 1 LOCK PLATE
1.6.4 10310029 2 WASHER - FLAT M8
1.6.5 10310030 2 SPRING WASHER M8
1.6.6 10310098 2 HEX HEAD SETSCREW M8 x 20
1.6.7 45490017 1 M8 x 1.0P ST/STL GREASE NIPPLE
1.6.8 45420230 1 SHEAVE Ø250 OILON PA6C FOR Ø45 PIN & Ø11 ROPE
1.7 45320251 1 HEAD CHUTE DEFLECTOR FABRICATION
1.8 45330253 1 HEAD CHUTE DEFLECTOR 6mm CERAMIC LINER x 1.5 m²
1.9 45320331 1 PH DEFLECTOR ADJUSTMENT LINK
1.10 45320466 2 HEAD CHUTE DEFLECTOR RETAINER
1.12 45300828 1 PIVOTING HEAD CHUTE FABRICATION
1.13 45460290 1 ULS ASSEMBLY - 600mm LONG SOLID ROD
1.13.1 45510009 2 M10 CHANNEL NUT (ZEBIDEE) BZP
1.13.2 10300011 2 WASHER - FLAT M10
1.13.3 10300127 2 SPRING WASHER M10
1.13.4 10300230 2 HEX HEAD SETSCREW M10 x 25 (USE 10300014)
1.13.5 10310221 4 WASHER - FLAT M4
1.13.6 10310294 2 CHEESE HEAD SCREW M4x40
1.13.7 10310092 2 NYLOC NUT M4
1.13.8 45460168 1 UNISTRUT - CANTILEVER ARM P2663/600 (HG)
1.13.9 45460249 1 ULS LIMIT SWITCH SUPPORT - HONEYWELL
1.13.10 10300027 4 WASHER - FLAT M12
1.13.11 10300028 2 NYLOC NUT M12
1.15 45340219 2 PIVOT BRACKET FOR Ø60 PIN
1.16 45340200 4 PB WASHER PLATE 100CTRS 50WIDE Ø20 BOLTS
1.24 45420231 4 Ø11 NYLON SHEAVE ROPE GUIDE
1.25 45370037 2 MODIFICATION TO 45370020 Ø60 PIVOT PIN
1.26 45340148 2 PIVOT PIN KEEP PLATE
1.41 45290233 1 SHROUD LIFTING EQUIPMENT
1.41.2 45420216 7 SHROUD PULLEY ASSEMBLY
1.41.2.1 45420214 1 SMALL SHEAVE Ø5-Ø80 (FEM M3)
1.41.2.2 45420215 1 SHROUD PULLEY SUPPORT BRACKET
1.41.2.3 45420217 1 Ø20 SHEAVE CENTRE PIN
1.41.2.4 49421002 1 Standard Keep Plate
1.41.2.5 45490026 1 GREASE NIPPLE M6
1.41.2.9 10310032 1 NYLOC NUT M8
1.41.2.10 10310029 2 WASHER - FLAT M8
1.41.2.11 10310523 1 HEX HEAD BOLT M8 x 55
1.41.2.12 10310002 2 WASHER - FLAT M5
1.41.2.13 10310131 2 SPRING WASHER M5
1.41.2.14 10310133 2 HEX HEAD SETSCREW M5 x 10
1.41.4 45290128 1 SLSB SUPPORT FROM 150x100x6 RHS
1.41.16 45290232 1 SHROUD LIFTING ROPE SET Ø5 x 1417kg MBL
1.41.25 45400074 1 HAND WINCH. DOUBLE COMPARTMENT WW500-GR/2D
1.41.26 45290127 1 SLSB SUPPORT
1.41.27 10300027 24 WASHER - FLAT M12
1.41.28 10300000 56 WASHER - FLAT M8
1.41.30 10300028 12 NYLOC NUT M12
1.41.36 10300002 28 NYLOC NUT M8
1.41.37 10300007 20 HEX HEAD BOLT M8 x 35
1.41.38 10300229 8 HEX HEAD SETSCREW M8 x 30 (SEE 10300006)
1.41.39 45290132 1 SLSB SUPPORT FROM 150x100x6 RHS
1.41.40 45010030 1 CARBINE HOOK ST/ST 8MM
1.46 45410299 1 HOIST ROPE SET Ø11 x 7770kg MBL
1.47 45400274 1 CC864 - WINCH ASSEMBLY
Rope spool (Triplex) Ø90 x 170mm Long Sha@, Ø11mm rope & Ø650 O.D - Root Ø250
1.47.1 45430130 1
1.47.1.1 10310071 3 WASHER - FLAT M16
1.47.1.2 10310072 3 NYLOC NUT M16
1.47.1.11 10300047 8 WASHER - FLAT M16
1.47.1.12 10300155 4 HEX HEAD BOLT M16 x 170
1.47.1.13 10300048 4 NYLOC NUT M16
1.47.2 45470004 2 OLDHAM COUPLING 12MM REF: 693-0809
1.47.3 45470005 1 COUPLING TORQUE DISC 692-8115
1.47.5 45490045 1 M24 Ø12MM LIMIT SWITCH SPIGOT
1.47.6 45430061 1 Ø170 SPOOL WASHER Ø26 HOLE
1.47.7 45460547 1 LSB SUPPORT LEG
1.47.8 45460548 1 LIMIT SWITCH BRACKET
1.47.9 10300096 5 WASHER - FLAT M30
1.47.10 10300310 4 HEX HEAD BOLT M30 x 120
1.47.11 10300095 4 NYLOC NUT M30
1.47.12 10300027 8 WASHER - FLAT M12
1.47.13 10300101 2 HEX HEAD SETSCREW M12 x 35 (USE 10300034)
1.47.14 10300028 4 NYLOC NUT M12
1.47.18 10300039 2 HEX HEAD BOLT M12 x 60
1.47.19 45400273 1 ex1503-vis132-siemens 132
1.47.20 45450278 1 CC864 - Guard Fabrication
1.47.21 45450276 1 Sheave Guard 50x50x5 RSA
1.47.22 45450277 1 Spool Cover Mount 50x50x5 RSA
1.47.23 10300000 12 WASHER - FLAT M8
1.47.24 10300229 2 HEX HEAD SETSCREW M8 x 30 (SEE 10300006)
1.47.25 10300002 6 NYLOC NUT M8
1.47.26 10300115 12 WASHER - FLAT M6
1.47.28 10300159 6 NYLOC NUT M6
1.47.30 10310002 4 WASHER - FLAT M5
1.47.31 10310401 2 SOCKET HEAD CAP SCREW M5 x 25
1.47.32 10310003 2 NYLOC NUT M5
1.49 45110176 16 Adhesive Non Acetic XTS320 (Orange) x 310ml Cartridge - High Temp.
1.51 45330549 1 PIVOTING HEAD CHUTE LINER SET 6mm CERAMIC x 2m²
1.52 45460351 1 SLACK ROPE SWITCH ASSEMBLY - 600mm Long With 120mm Bolt & 130mm Roller Guide
1.52.4 10300011 3 WASHER - FLAT M10
1.52.5 10300012 2 NYLOC NUT M10
1.52.10 10300027 2 WASHER - FLAT M12
1.52.11 10300028 1 NYLOC NUT M12
1.52.12 45460334 1 SLACK ROPE SWITCH ARM with extended rope pass
1.52.13 10300163 1 HEX HEAD BOLT M10 x 170
1.52.14 45460335 1 SLACK ROPE SWITCH ROLLER Ø35x130 LONG
1.52.16 10300043 1 HEX HEAD BOLT M12 x 120
1.52.20 45460204 1 T42270 SPRING (SEE PART NUMBER 4549-0043)
1.52.21 45590014 2 ST STL DEE TYPE SHACKLE Ø5mm BOW
1.52.22 45490005 1 EYENUT 8MM ST/ST TO DIN582/UNTESTED
1.53 45350170 2 BRUSH STRIP x 1310LG MADE FROM 45350040
1.54 45350107 4 BRUSH SEAL 620 LONG FROM 45350040
1.55 10310002 58 WASHER - FLAT M5
1.56 10310312 29 CHEESE HEAD SCREW M5x16
1.57 10310003 29 NYLOC NUT M5
1.58 10300027 31 WASHER - FLAT M12
1.59 10300028 15 NYLOC NUT M12
1.60 10300038 2 HEX HEAD BOLT M12 x 55
1.61 10310056 10 WASHER - FLAT M12
1.62 10310057 10 SPRING WASHER M12
1.63 10310049 10 HEX HEAD SETSCREW M12 x 35
1.64 10300302 4 HEX HEAD BOLT M12 x 50 (USE 10300037)
1.66 10300065 28 WASHER - FLAT M20
1.67 10300075 8 HEX HEAD BOLT M20 x 80
1.68 10300067 14 NYLOC NUT M20
1.69 10310040 8 WASHER - FLAT M10
1.70 10310041 8 SPRING WASHER M10
1.72 10310029 4 WASHER - FLAT M8
1.73 10310030 4 SPRING WASHER M8
1.75 10390074 5 M20 SQUARE WASHER
1.76 10300296 2 HEX HEAD BOLT M20 x 240
1.77 10300292 2 HEX HEAD BOLT M20 x 230
1.78 10300382 1 HEX HEAD BOLT M20 x 220
1.79 10300135 1 HEX HEAD BOLT M20 x 75
1.80 10300036 2 HEX HEAD BOLT M12 x 45
1.86 45350191 8 CWT
1.87 10390126 2 Ø25 STAINLESS STEEL LOCKING SHAFT COLLAR
1.90 10300011 14 WASHER - FLAT M10
1.91 10300021 4 HEX HEAD BOLT M10 x 70
1.92 10300012 7 NYLOC NUT M10
1.93 45390681 1 CC864 - Terminal Box Mount Plate
1.95 45450279 1 Sheave Guard To Suit 45490088 Sheave Bracket Assembly - Type 1
1.96 45460144 2 SRS-LIMIT SWITCH PACK
1.97 10300303 7 HEX HEAD BOLT M12 x 95 (SEE 10300128)
1.100 45390680 1 SRS Dust Cover
1.101 10300230 3 HEX HEAD SETSCREW M10 x 25 (USE 10300014)
1.102 45870016 1 20mm Drum mount Packer
1.103 45370038 3 Strop Pin & 'R' Clip Chain Assy
1.103.1 45130237 1 STROP PIN CHAIN ASSEMBLY
1.103.1.1 45490005 1 EYENUT 8MM ST/ST TO DIN582/UNTESTED
1.103.1.2 45390261 1 CHAIN 5 X 18.5 GRADE 24 GALVANISED 500mm LONG
1.103.1.3 45010030 1 CARBINE HOOK ST/ST 8MM
1.103.1.5 10310030 1 SPRING WASHER M8
1.103.1.6 10310029 1 WASHER - FLAT M8
1.103.1.7 10390068 2 DEE SHACKLE DIN 82101 A-M5
1.103.2 45130325 1 R' CLIP CHAIN ASSEMBLY
1.103.2.1 45010030 1 CARBINE HOOK ST/ST 8MM
1.103.2.2 10390068 2 DEE SHACKLE DIN 82101 A-M5
1.103.2.3 45390702 1 CHAIN 5 X 18.5 GRADE 24 ST/ST 350mm LONG
2 45300826 1 FIXED HEAD CHUTE ASSEMBLY
2.1 45340220 2 PIVOT HANGER FOR Ø60 BEARING
2.2 45320482 1 TOP DEFLECTOR
2.3 45340057 2 BEARING SPHERICAL PLAIN SKF REF: GE 60 TXE 2LS
2.4 45340058 4 CIRCLIP - INTERNAL M90 x 3
2.5 45300681 1 FIXED HEAD CHUTE
2.7 45330548 1 TOP DEFLECTOR LINER 6mm CERAMIC x 4m²
2.13 45330547 1 FHC LINER SET 6mm CERAMIC x 2.2m²
2.14 45110176 28 Adhesive Non Acetic XTS320 (Orange) x 310ml Cartridge - High Temp.
2.15 10300065 16 WASHER - FLAT M20
2.16 10300072 8 HEX HEAD BOLT M20 x 60
2.17 10300067 8 NYLOC NUT M20
3 45390461 1 TRANSPORT AND ASSEMBLY
3.1 45390460 1 LOCK BAR
3.2 45390459 1 TRANSPORT AND ASSEMBLY STAND 945mm HIGH
3.3 10300027 4 WASHER - FLAT M12
3.4 10300101 1 HEX HEAD SETSCREW M12 x 35 (USE 10300034)
3.5 10300028 2 NYLOC NUT M12
3.7 10300137 4 HEX HEAD BOLT M10 x 100
CASCADE ASSEMBLY
1 45100352 12 1300S PROFILED RIM B-TYPE CONE 45100218 WITH 6mm CERAMIC LINER
1.1 45100218 1 1300S PROFILED RIM B-TYPE CONE WITH 25mm DOUBLE STROP ATTACHMENTS
1.1.1 45100125 1 1300S PROFILED RIM B-TYPE CONE TO SC-361
1.1.1.2 45130200 3 Eye Insert Fabrication
1.1.2 45130041 3 STROP CONE ATTACHMENT (HD).
1.1.2.1 45130196 1 Strop Cone Attachment Ferrule
1.1.2.2 45130198 2 Strop Cone Attachment Sleeve to FR-SC-096
1.1.2.3 45130197 2 Strop Cone Attachment Washer
1.1.3 10310039 3 HEX HEAD BOLT M10 x 100
1.1.4 10310043 3 NYLOC NUT M10
1.2 45110169 7 GEOCELL HG ADHESIVE 400ML SAUSAGE
1.3 45110252 1 1300s 6MM CERAMIC LINER
2 45100351 12 1300S PROFILED RIM A-TYPE CONE 45100219 WITH 6mm CERAMIC LINER
2.1 45100219 1 1300S PROFILED RIM A-TYPE CONE WITH 25mm DOUBLE STROP ATTACHMENTS
2.1.1 45100124 1 1300S PROFILED RIM A-TYPE CONE TO SC-361
2.1.1.2 45130200 3 Eye Insert Fabrication
2.1.2 45130041 3 STROP CONE ATTACHMENT (HD).
2.1.2.1 45130196 1 Strop Cone Attachment Ferrule
2.1.2.2 45130198 2 Strop Cone Attachment Sleeve to FR-SC-096
2.1.2.3 45130197 2 Strop Cone Attachment Washer
2.1.3 10310039 3 HEX HEAD BOLT M10 x 100
2.1.4 10310043 3 NYLOC NUT M10
2.2 45110169 7 GEOCELL HG ADHESIVE 400ML SAUSAGE
2.3 45110252 1 1300s 6MM CERAMIC LINER
3 45120536 1 STROP SET CC864 - 59.5°x700x125mm WIDE - 24 CONES
SHROUD ASSEMBLY
1 45230133 1 1300S SHROUD TOP CLAMP ASSEMBLY

1.1 45230086 1 1300 Shroud Top Clamp Assembly
1.1.1 45230084 1 1300 Shroud Top Clamp Circular Angle
1.1.2 45230085 2 1300 Shroud Top Clamp Band
1.1.3 45200065 12 Top Ring Shroud Hook Bracket
1.2 10300047 12 WASHER - FLAT M16
1.3 10300062 6 HEX HEAD BOLT M16 x 120
1.4 10300048 6 NYLOC NUT M16
1.5 45200078 6 HOOK TOP ATTACHMENT (see 45200003)
1.6 10310111 12 COUNTERSUNK SCREW - SOCKET M8 x 25
1.7 10310029 14 WASHER - FLAT M8
1.8 10310032 12 NYLOC NUT M8
1.9 45510017 2 Shackle 6mm untested
1.10 45490005 2 EYENUT 8MM ST/ST TO DIN582/UNTESTED
2 45200024 1 SHROUD Top Section 1300S FR-INT-003
3 45230134 5 1300S SHROUD INTERMEDIATE CLAMP ASSEMBLY
3.1 10300000 24 WASHER - FLAT M8
3.2 10300002 12 NYLOC NUT M8
3.3 45230089 1 1300s Shroud Intermediate Clamp Assembly
3.3.1 45230088 1 1300S SHROUD INTERMEDIATE CIRCULAR ANGLE
3.3.2 45230087 2 1300S SHROUD INTERMEDIATE CLAMP BAND
3.4 45250034 3 ROLLER ROPEGUIDE ASSEMBLY WITH LONGER ROLLERS
3.4.1 10300115 2 WASHER - FLAT M6
3.4.3 10300159 1 NYLOC NUT M6
3.4.4 45250032 1 end clamp revised rope guide assembly
3.4.5 45250033 1 revised rope guide prototype main body fab
3.4.6 45250035 2 Small Nylon 6 Roller Cut From Length
3.4.7 45250036 2 Long Nylon 6 Roller Cut From Length
3.4.8 10310438 2 HEX HEAD BOLT M6 x 80
3.4.9 10310018 8 WASHER - FLAT M6
3.4.10 10310021 4 NYLOC NUT M6
3.4.11 10310440 2 HEX HEAD BOLT M6 x 120
3.4.12 10300000 4 WASHER - FLAT M8
3.4.13 10300002 2 NYLOC NUT M8
3.5 10300229 12 HEX HEAD SETSCREW M8 x 30 (SEE 10300006)
4 45210002 5 SHROUD 3m Int Section 1300S FR-INT-001
5 45240052 1 1300S SHROUD BOTTOM RING ASSEMBLY
5.1 45240050 1 1300s Shroud Bottom Ring Angle
5.2 45240051 1 1300s Shroud Bottom Ring Rod
5.3 45240048 3 Bottom Ring Lifting Lug
5.4 45240056 1 1300s Shroud Bottom Ring 6.5m x 25mm Ratchet Strap
CARRIER ASSEMBLY
1 45000121 1 1300 Carrier Fabrication

2 45500089 2 PROBE ASSEMBLY VEGAVIB S61
2.1 45510002 1 MDS PROBE BRACKET - Standard - (St/St)
2.2 45500009 1 1½" BSP STAINLESS STEEL LOCKNUT
2.3 45510070 1 UNISTRUT ( 0.5 METRE OF 4551-0010 )
2.8 45510036 2 M12 CHANNEL NUT (ZEBIDEE) LONG SPRING STAINLESS STEEL ZL12/SS
2.15 10310057 2 SPRING WASHER M12
2.16 10310056 2 WASHER - FLAT M12
2.18 10310041 2 SPRING WASHER M10
2.19 10310040 2 WASHER - FLAT M10
2.20 10310257 2 HEX HEAD SETSCREW M10 x 30 (SEE 10310036)
2.21 10310045 2 M10 CHANNEL NUT ST/ST(ZEBIDEE)
3 45510078 2 CARRIER PROBE BRACKET (STANDARD)
4 10300011 4 WASHER - FLAT M10
5 10300018 2 HEX HEAD BOLT M10 x 40
6 10300012 2 NYLOC NUT M10
7 45060065 3 SPILL DOOR Ø708mm FOR 1100S AND 1300S CARRIER
7.1 45060026 1 GREEN CANVAS COVER FOR Ø718 SPILL DOOR TO FR-SC-398
7.2 45060029 1 GRP ROD 683MM (ISSUE 0.1 OF 4506-0017)
7.3 10390030 1 STAINLESS STEEL HOUSING AND SCREWS ARCO REF 4231800
7.4 45060040 1 See 10390027. Zinc Plated Strangle Banding Arco Ref 4231400 (Spill Doors)
7.5 45060039 1 7MM SHOCK CORD REF: SH0007 (PER METRE)
8 45500084 2 IP65 TILT SWITCH ASSEMBLY
8.1 45490005 1 EYENUT 8MM ST/ST TO DIN582/UNTESTED
8.2 45520000 1 SHACKLE 10MM SCREW PIN GALV (UNTESTED)
8.5 10310029 1 WASHER - FLAT M8
8.6 45510018 3 CHAIN 5 X 18.5 GRADE 24 GALVANISED 1m LONG
8.7 45510017 2 Shackle 6mm untested
26 45010087 3 EYEBOLT ASSEMBLY
26.1 45010004 1 EYEBOLT 1¼ X 7" BZP LONG SHANK COLLARED
26.2 45010010 1 SHACKLE 4.75T SWL GREEN PIN BOW (SAFETY)
26.3 45010079 2 REMOVABLE DOUGHNUT FOR 1.1/4" EYEBOLT 15MM THK
26.4 45010080 2 REMOVABLE DOUGHNUT FOR 1.1/4" EYEBOLT 25MM THK
26.7 10310299 4 SOCKET HEAD CAP SCREW M8 x 60
26.8 10300385 1 1¼" Imperial Hex Nut
26.9 10300384 1 1 1/4'' NordLock Washer
27 45090102 1 200x170mm LABEL - NON CE
31 10310002 40 WASHER - FLAT M5
32 10310131 4 SPRING WASHER M5
33 10310334 4 SOCKET BUTTON HEAD SCREW M5x12
34 45090200 3 Ø10mm SPILL DOOR BEAD TO SUIT Ø680mm OPENING
35 45010126 18 10mm BLACK ST/STL P-CLIP (RS 2988081)
36 10310223 18 HEX HEAD SETSCREW M5 x 20
37 10310003 18 NYLOC NUT M5
SKIRT ASSEMBLY
1 45650001 1 SKIRT CANVAS 1300S/1500S (1000mm LONG) TO FR-SC-093 D

2 10300027 48 WASHER - FLAT M12
3 10300028 24 NYLOC NUT M12
4 45640120 1 1300-1500 SKIRT FABRICATION
4.3 45640123 4 SKIRT RING HANDLE
5 10300227 5 HEX HEAD BOLT M16 x 55
6 10300047 14 WASHER - FLAT M16
7 10300048 7 NYLOC NUT M16
8 45640034 24 SKIRT RUBBER 1000 LONG (PER PIECE) TO FR-SC-083 MANUFACTURED FROM 4646-0007
9 10300039 24 HEX HEAD BOLT M12 x 60
10 10300100 2 HEX HEAD BOLT M16 x 100
TUBULAR SKIRT ASSEMBLY

1.2 45640123 4 SKIRT RING HANDLE
2 45640172 1 1300S TUBULAR SKIRT - 6mm RUBBER 3.0 m²
4 10310056 48 WASHER - FLAT M12
5 10310059 24 NYLOC NUT M12
6 10300047 10 WASHER - FLAT M16
7 10300048 5 NYLOC NUT M16
8 10300227 5 HEX HEAD BOLT M16 x 55
PARTS LIST
ITEM QTY DESCRIPTION
1 1 1300 CARRIER ASSEMBLY WITH MDS
PROBES + TILT SWITCHES
2 1 1300/1500 SKIRT ASSEMBLY - 1m SKIRT
3 1 1300 SHROUD ASSEMBLY - 18m LONG
4 1 CC864 CASCADE ASSEMBLY
5 1 ASSEMBLY OF COMPLETE HEAD CHUTE
6 1 1300 Tubular Skirt Assembly
194 194 90 310 90 242 242 30

22
N o.
26
35
A A
310
66
310
1660
310
310
310
3223
3
310
4
A-A ( 1 : 12.5 )
PLAN VIEW ON INTERFACE FLANGE
CHUTE & BOOM STOWED ( 1 :33.3 )

BOOM AT +55
20705
18000
3549
3549
SIDE VIEW ( 1 :33.3 )

CHUTE RETRACTED AND OPERATIONAL
1045
BOOM AT -12
SIDE VIEW ( 1 :33.3 )

CHUTE RETRACTED AND OPERATIONAL
BOOM AT +12
1045
FULLY EXTENDED ELEVATION ( 1 : 33.3 ) FRONT VIEW ( 1 : 33.3 ) ADDITIONAL TUBULAR SKIRT ( 1 : 12.5 )
DO NOT SCALE - IF IN DOUBT ASK TOTAL MASS: 5998.9 kg

NOTE: THE FOLLOWING TOLERANCES APPLY U.N.O. CLEVELAND CASCADES LTD PROJECT Bedeschi SpA (0864)
Unit 22 Dukesway Teesside Industrial Estate
FAB ITEMS: MACHINED ITEMS: HOLE CENTRES:
Thornaby Stockton on Tees TS17 9LT
< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
TOLERANCE OF +/- 1mm United Kingdom TITLE
3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270 GENERAL ARRANGMENT
Date
www.clevelandcascades.co.uk A1
DRAWING Designed by Checked by Approved by THIS DRAWING IS A PRIVATE AND CONFIDENTIAL COMMUNICATION, AND
STATUS
Issued to Client Paul Wilson Peter Luke Paul Wilson 10/08/16
THE PROPERTY OF CLEVELAND CASCADES. IT MUST NOT BE COPIED OR
LOANED WITHOUT THE WRITTEN CONSENT OF CLEVELAND CASCADES DWG No: 0864-01-1001 Sheet 1 /1 REV A
PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 1 45390461 TRANSPORT AND
ASSEMBLY
2 1 45300826 FIXED HEAD CHUTE
ASSEMBLY
3 1 45300827 PIVOTING HEAD CHUTE
ASSEMBLY
ISOMETRIC VIEW

< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
TOLERANCE OF +/- 1mm United Kingdom TITLE ASSEMBLY OF COMPLETE HEAD
3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270
www.clevelandcascades.co.uk A2 CHUTE
DRAWING Designed by Checked by Approved by Date THIS DRAWING IS A PRIVATE AND CONFIDENTIAL COMMUNICATION, AND
STATUS
Released for Manufacture lambg Paul Wilson
LOANED WITHOUT THE WRITTEN CONSENT OF CLEVELAND CASCADES DWG No: 45300825 Sheet 1 /1 REV A
PARTS LIST
1 2 45340220 PIVOT HANGER FOR
60 BEARING
2 1 45320482 TOP DEFLECTOR
3 2 45340057 BEARING SPHERICAL
6 8 PLAIN SKF REF: GE 60
TXE 2LS
4 4 45340058 CIRCLIP - INTERNAL
M90 x 3
5 1 45300681 FIXED HEAD CHUTE
6 1 45330548 TOP DEFLECTOR LINER
6mm CERAMIC x 4m
7 1 45330547 FHC LINER SET 6mm
CERAMIC x 2.2m
8 28 45110176 Adhesive Non Acetic
XTS320 (Orange) x
2 310ml Cartridge - High
Temp.
9 16 10300065 WASHER - FLAT M20
8 7 10 8 10300072 HEX HEAD BOLT M20 x
60
11 8 10300067 NYLOC NUT M20
1 10 11 9
4 3
ISOMETRIC VIEW

< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270 FIXED HEAD CHUTE ASSEMBLY
Date
STATUS
PARTS LIST PARTS LIST PARTS LIST PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION
64 1 45390680 SRS Dust Cover 42 4 10310098 HEX HEAD SETSCREW M8 x 22 2 45350170 BRUSH STRIP x 1310LG 1 2 45130218 STANDARD 125mm STROP
65 3 10300230 HEX HEAD SETSCREW M10 20 MADE FROM 45350040 BRACKET ASSEMBLY
x 25 (USE 10300014) 43 5 10390074 M20 SQUARE WASHER 23 4 45350107 BRUSH SEAL 620 LONG 2 3 45130222 50 STROP PIN ASSEMBLY
66 1 45870016 20mm Drum mount Packer 44 2 10300296 HEX HEAD BOLT M20 x 240 FROM 45350040 FOR 125mm STROPS
67 3 45370038 Strop Pin & 'R' Clip Chain 45 2 10300292 HEX HEAD BOLT M20 x 230 24 58 10310002 WASHER - FLAT M5 3 1 45900034 T95 LOAD CELL ASSEMBLY
Assy 46 1 10300382 HEX HEAD BOLT M20 x 220 25 29 10310312 CHEESE HEAD SCREW M5x16 2000-10000KG - 125mm
68 4 10300021 HEX HEAD BOLT M10 x 70 47 1 10300135 HEX HEAD BOLT M20 x 75 26 29 10310003 NYLOC NUT M5 STROPS
48 2 10300036 HEX HEAD BOLT M12 x 45 27 31 10300027 WASHER - FLAT M12 4 2 45130279 10mm LOAD CELL PACK
49 8 45350191 CWT 28 15 10300028 NYLOC NUT M12 FOR 45900034
50 2 10390126 25 STAINLESS STEEL 29 2 10300038 HEX HEAD BOLT M12 x 55 5 4 45490088 UNIVERSAL SHEAVE
LOCKING SHAFT COLLAR 30 10 10310056 WASHER - FLAT M12 ASSEMBLY FOR 11 ROPE
51 1 45400274 CC864 - WINCH ASSEMBLY 31 10 10310057 SPRING WASHER M12 6 1 45320251 HEAD CHUTE DEFLECTOR
52 1 45300828 PIVOTING HEAD CHUTE 32 10 10310049 HEX HEAD SETSCREW M12 FABRICATION
63 FABRICATION x 35 7 1 45330253 HEAD CHUTE DEFLECTOR
53 14 10300011 WASHER - FLAT M10 33 4 10300302 HEX HEAD BOLT M12 x 50 6mm CERAMIC LINER x 1.5
55 7 10300012 NYLOC NUT M10 (USE 10300037) m
A 62 56 1 45390681 CC864 - Terminal Box Mount 34 28 10300065 WASHER - FLAT M20 8 1 45320331 PH DEFLECTOR
Plate 35 8 10300075 HEX HEAD BOLT M20 x 80 ADJUSTMENT LINK
57
57 4 10310034 HEX HEAD SETSCREW M10 36 14 10300067 NYLOC NUT M20 9 2 45320466 HEAD CHUTE DEFLECTOR
x 20 37 8 10310040 WASHER - FLAT M10 RETAINER
59 1 45450279 Sheave Guard To Suit 38 8 10310041 SPRING WASHER M10 10 1 45460290 ULS ASSEMBLY - 600mm
45490088 Sheave Bracket 39 4 10310278 HEX HEAD SETSCREW M10 LONG SOLID ROD
Assembly - Type 1 x 25 11 4 45340200 PB WASHER PLATE 100CTRS
29 28 27 60 2 45460144 SRS-LIMIT SWITCH PACK 40 4 10310029 WASHER - FLAT M8 50WIDE 20 BOLTS
61 7 10300303 HEX HEAD BOLT M12 x 95 41 4 10310030 SPRING WASHER M8 12 2 45340219 PIVOT BRACKET FOR 60
(SEE 10300128) PIN
62 2 45450280 Sheave Guard To Suit 13 4 45420231 11 NYLON SHEAVE ROPE
30 31 32 45490088 Sheave Bracket GUIDE
Assembly - Type 2 14 2 45370037 MODIFICATION TO
63 1 45450281 Sheave Guard To Suit 45370020 60 PIVOT PIN
27 61 62 51 45490088 Sheave Bracket 15 2 45340148 PIVOT PIN KEEP PLATE
Assembly - Type 3 17 1 45290233 SHROUD LIFTING
EQUIPMENT
18 1 45410299 HOIST ROPE SET 11 x
7770kg MBL
19 16 45110176 Adhesive Non Acetic XTS320
46
17 (Orange) x 310ml Cartridge
- High Temp.
20 1 45330549 PIVOTING HEAD CHUTE
33 28 27 LINER SET 6mm CERAMIC x
2m
51
21 1 45460351 SLACK ROPE SWITCH
59 ASSEMBLY - 600mm Long
With 120mm Bolt & 130mm
9 40 41 42
Roller Guide
49 50 52 PLAN VIEW ( 1 : 15 )
64 24 25 22
56 23 B
26 24 25
A 19 20
12 14 15 37 38 39
51
57 38 37
27 61 63
17
34 45 36 2 32 31 30
8 36 35 34 11 21 60
17
48 5 63
44 34 28
49 10 64 65 53 55
66
33
1
52
45 34 43
66 68 55 53
67 47 61 27 13 28
3 4 17
8 B 18
B ( 1 : 15 )
48
10
67 17
7 6
B
6 50 49 ISO VIEW 1 ( 1 : 15 )
DO NOT SCALE - IF IN DOUBT ASK
B TOTAL MASS: 1938.1 kg
REVISION HISTORY FAB ITEMS: MACHINED ITEMS: HOLE CENTRES:
REV DESCRIPTION DATE
< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
TOLERANCE OF +/- 1mm United Kingdom TITLE PIVOTING HEAD CHUTE
A-A ( 1 : 15 ) Amended to Suit For 'As Built' - (Shroud 3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270
www.clevelandcascades.co.uk A1 ASSEMBLY
B Lifting Equipment Replaced, Pin Replaced, 21/11/2016 DRAWING Designed by Checked by Approved by Date THIS DRAWING IS A PRIVATE AND CONFIDENTIAL COMMUNICATION, AND
Packer & Fixings Added For Reeling Drum). STATUS

Released for Manufacture Paul Wilson Gary Lamb
LOANED WITHOUT THE WRITTEN CONSENT OF CLEVELAND CASCADES DWG No: 45300827 Sheet 1 /1 REV B
PARTS LIST
1 1 45430130 Rope spool (Triplex) 90 x 170mm Long Shaft,
11mm rope & 650 O.D - Root 250
24 23 22 15
2
2 2 45470004 OLDHAM COUPLING 12MM REF: 693-0809
3 1 45470005 COUPLING TORQUE DISC 692-8115
4 1 45490045 M24 12MM LIMIT SWITCH SPIGOT
3
5 1 45430061 170 SPOOL WASHER 26 HOLE
17 23 22 24
6 5 10300096 WASHER - FLAT M30
2 7 4 10300310 HEX HEAD BOLT M30 x 120
5
8 4 10300095 NYLOC NUT M30
9 8 10300027 WASHER - FLAT M12
10 2 10300101 HEX HEAD SETSCREW M12 x 35 (USE 10300034)
11 4 10300028 NYLOC NUT M12
1 12 2 10300039 HEX HEAD BOLT M12 x 60
13 1 45400273 ex1503-vis132-siemens 132
14 1 45450278 CC864 - Guard Fabrication
15 1 45450276 Sheave Guard 50x50x5 RSA
14 16 1 45460547 LSB SUPPORT LEG
17 1 45450277 Spool Cover Mount 50x50x5 RSA
18 1 45460548 LIMIT SWITCH BRACKET
16 19 12 10300000 WASHER - FLAT M8
20 2 10300229 HEX HEAD SETSCREW M8 x 30 (SEE 10300006)
21 6 10300002 NYLOC NUT M8
22 12 10300115 WASHER - FLAT M6
4 A-A ( 1 : 5 ) 24 6 10300159 NYLOC NUT M6
26 4 10310002 WASHER - FLAT M5
27 2 10310401 SOCKET HEAD CAP SCREW M5 x 25
28 2 10310003 NYLOC NUT M5
13
7 6 8
A A
ISOMETRIC VIEW
18
12 11 9
LUBRICATION - SYNTHETIC LUBRICANT - SHELL OMALA S4 WE 320
QUANTITY - 7.6 LITRES APPROX 9 11 10 AC FAST ACTING BRAKE
16 25 19 21
IP66 VIS BRAKE UNIT.
FITTED WITH AN OIL EXPANSION TANK & PIPEWORK TO R/H/S OF
WINCH CASING DO NOT SCALE - IF IN DOUBT ASK TOTAL MASS: 624.6 kg
21 19 20 15 NOTE: THE FOLLOWING TOLERANCES APPLY U.N.O. CLEVELAND CASCADES LTD PROJECT Bedeschi SpA (0864)
PLEASE ENSURE CORRECT LUBRICATION FAB ITEMS:
< 1000mm +/-2mm
MACHINED ITEMS:
< 100mm +/-0.25mm
HOLE CENTRES:
POSITIONAL
TITLE
1001 TO 3000mm +/-3mm 100 TO 300mm +/-0.5mm TOLERANCE OF +/- 1mm United Kingdom
REFER TO LEVEL MARK ON GEAR UNIT. 3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270 CC864 - Winch Assembly
Date
STATUS
Modular Explosion Proof Brakes
IECLine
2013 rev 0
INDEX
PAG1 About VIS
PAG2 Application example, Main characteristics, Standards
PAG3 Certificates and available protection classes
PAG4 Identification and options
PAG5 Technical data - performance and options
PAG6 Technical data, Brake choice
PAG7 Technical data - Brake choice
PAG8 Overall Dimensions

Explosion proof Brakes
A product invented and produced by Coel Motori, Milano, Italy

About VIS
VIS is a product of COEL, specialized manufacturer of brake motors located in Italy.
Since 1976 COEL designed and munufactured brake motors making all the components including the
brake units in its facilities (see www.coelmotori.it for further details).
Thanks to this large experience, on 2005 we invented VIS, the modular ATEX brake system.
Our idea was based on the market demand of a easy solution to make a brake motor without modifica-
tion of the motors or extension of the certificates.
With more than 30 years of experience in manufacturing brakes, we defined a new oversized stand-
ard, able to guarantee a range of modular brakes designed for heavy duty.
More than 35 controls made in the production process make each VIS brake as a master piece.
All the components are tested 100%, all the working parameters controlled with functional tests made
on each brake.
The VIS brakes range is in continuous development in order to make the quality and performance
better and better.
For hoisting, travelling, positioning in Hazardous location the VIS brakes are the safe and reliable
solution.
What’s VIS?
The VIS Atex brake is an innovative modular flameproof spring applied disc brake unit.
The new concept is to apply an independent brake unit to a standard flanged explosion proof motor or to
a transmission unit. The flangess input and output follow both IEC or NEMA standards. The VIS brakes are
certified as independent components. It means that there are not coupling procedures in order to define
the certification.
Why VIS?
The VIS brake is available in B5 flange face to face version (IEC 63 to 280 ), NEMA standards (56 to 405)
and compact version for mounting in the rear part of a motor or to a transmission unit. This catalogue is
related to IEC Line.
The assembling is very fast.
Choosing the VIS brake, it’s very easy to make an explosion proof brake motor, reducing costs and
delivery time.
The performance of VIS brakes is particularly high and the strong structure makes them suitable for
very heavy duty and for every kind of application (hoisting, travelling, positioning...).
VIS brakes don’t need periodical maintenance such as adjustment of gap on work site.
The braking torque values are included between 5 to 2000 Nm (depending on frames) and the elec-
tromagnets fitted inside the VIS brakes can be AC three phase or DC for IEC and DC for NEMA.
The cost of a standard explosion proof motor plus the VIS brake is considerably lower than an
explosion proof brake motor and the delivery time and reliability are much better.
1
Application example
Standard B5 motor + VIS brake Standard B5 motor + VIS brake + gearbox unit
Main Characteristics
-PATENT pending design and concept system

-Three phase AC (IEC 80 to 160) or single phase DC electromagnets
-Totally closed
-IP66
-Power supply VAC24 to 690 50-60Hz three phase or VDC 24 to 300.
-F class insulation
-Thermally protected with dual metal protectors as standard
-Large terminal box with terminal board and fitted in rectifier (DC only)
-Very high resistance structure
-Designed for S1 duty without ventilation
Standards
The VIS series brakes are designed and approved for the following directives:
- ATEX Directive ATEX 94/9/CE-ATEX 95,Group II 2GD category - Group I M2 category, in compliance
with the normsEN 60079-1:2007, EN 60079-0:2009, EN 60079-31:2009
CERTIFICATE INERIS06 ATEX 0047 additions 01,02,03,04,05
- INMETRO Directive ABNT NBR IEC 60079-0:2008 ABNT NBR IEC 60079-1:2009
CERTIFICATE NCC Certificado N° NCC 11.0574 X
- IEC Ex Directive IEC 60079-0 : 2007-10 IEC 60079-1 : 2007-04 IEC 60079-31 : 2008 Groups I, II, III
CERTIFICATE IECEx INE 11.0037X
2
Certificates and available protection classes
For each certification of VIS brakes there are different protection levels avasilable as follows
ATEX IEC Ex
GAS
II 2 G Ex d II P 1 T P 2 Gb Tamb. : -50°C ÷ +55( for T5 Tamb:
+60°C) or -20°C ÷ +55( for T5 Tamb: +60°C).
DUSTS
II 2 D Ex tb IIIC T P 3 Db IP66 Tamb. : -50°C ÷ +55( for classe T100°C
Tamb: +60°C) or -20°C ÷ +55( for class T100°C Tamb: +60°C).
GAS and DUST

II 2 GD Ex d II P 1 T P 2 Gb
Ex tb IIIC T P 3 Db IP66
Tamb. : -50°C ÷ +55( for class T5 or T100°C Tamb: +60°C) or -20°C ÷ +55( for class
T5 or T100°C Tamb: +60°C).
I M2 Ex d I Mb Tamb. : -50°C ÷ +55°C oppure -20°C ÷+55°C
Pn are subjected to the following variations:
P1 for GAS groups if:

-.P1 = B : gas group IIB.
- P1 = C : gas group IIC.
P2/P3 for temperature classes/surface temperature:

- P2 = T3 P3 = T200°C
- P2 = T4 P3 = T135°C
- P2 = T5 P3 = T100°C
- 50°C ÷ + 55°C (for class T5 o T100°C Tamb: +60°C) = Amb Temp.

- 20°C ÷ + 55°C (for class T5 o T100°C Tamb: +60°C)= Amb temp for frames 250/280
T.cable : 80°C= Cable temperature
INMETRO
» Category: 2G / 2D /2GD
» Type of protection: Ex d / Ex tD A21
» Enclosure group: II B / II C
» Temperature class: T3 / T4 / T5
» Maximum surface temperature: T200°C / T135°C / T100°C
» Protection mode: IP66
» Ambient temperature -50°C +55°C (available as option on frames 63 to 225) or -20 +55°C (standard for
frames 63 to 280)
3
Options
- Hand release (not available for IEC frames 250 and 280)
- Ready for hand release kit
- PTC thermistors
- Anti condensation heaters
- Switch on brake opening or on hand release
- Special flange coupling
Hand release Hand release ready
Ordering a VIS brake
For ordering a VIS brake it’s necessary to supply the following information:
1) Type of certification required and protection classes needed

2) Input and output flange / shafts dimensions
3) If AC or DC
4) Voltage needed
5) Brake torque required
6) Options required
All the brakes are available in different voltages and brake torque values
Please see the performance data in order to correctly identify the brake
4
Technical data
General information
The spring-applied brake VIS is a single-disk brake with two friction surfaces.
The compression springs create the braking torque by friction locking. The brake is released electromag-
netically.
The spring-applied brake is designed for the conversion of mechanical work and kinetic energy in heating.
For operation characteristics see related paragraph.
Manual release (not applicable for IEC 250 and 280)
The manual release is an option available, it gives the possibility to release the brake in absence of current.
It is a mechanical lever mounted on 2 fulcrums points moving the mobile anchor.
Microswitch
The VIS brakes can be equipped with a microswitch for air-gap or wear monitoring or for hand relase
opening monitoring. The user must provide the corresponding electrical connection.
Thermistors
All the VIS brakes are equipped with a PTO thermal protection with temperature limit related to the
temperature class of the brake required. It must always be connected when operating in order to prevent
extra heating in hazardous areas.
In alternative, we can apply a PTC thermistor to have a constant monitoring of the brake temperature
through an exthernal PLC.
Performance Data (IEC version)
* values obtained with rectifier type WR2008
5
Technical data
Loads
IEC VIS brakes line is designed to be mounted in front of a flanged motor; the bearing used in the input
shaft has the only function to support the coupling between the motor and brake sahfts and cannot be
subjected to additional axial or radial loads. The output shaft admissible radial loads of IEC VIS brakes line
are described in the following tab.
Frame N Load at shaft center

63-71 250
80-90 380 N
100-112 550 max
132-160 790
180-225 1700
250-280 3400
Braking time
VIS brakes are suitable for application with disk sliding of the disk of 0,5 seconds maximum.
In case of longer time of sliding of the disk calculation, please contact us.
You can use the following formula in order to define the braking time:
Jtot: inertia moment at the motor shaft (Kgm2)
J tot x n tx
n: speed r.p.m.
+ Mf: braking moment (Nm)
± Mload) tx: brake time response (ms)
9.55 (Mf 1000
Mload: resistent moment to the load applied (Nm), positive or
negative depending on concordance with braking moment.
Note: for calculation of sliding time of the disc, consider the “tx” value at “0” .
Brake choice
AC or DC?
When you choose a VIS brake, it is important to define which version is better suitable for your applica-
tion and/or for your electrical equipment.
The 3 phase version is very quick both in engagement and braking times, so it is suggested for applica-
tion where there are high number of cycles per hour.
Since this brake is very quick it also creates more impact vibration in starting and braking operation compared
to DC.
The 3 phase brake is suitable to be connected direct on line with the same voltage of the motor you have
and without rectifier and it is available with voltages from VAC24 up to VAC690 Hz 50 or 60.
The DC version has a smooth perfromance, but can also be quick using a special rectifier for fast
braking connection cutting the DC current.
It is available from 24 to 300 VDC with rectifier.
6
Brake choice
Dimensioning
The size of the brake is mainly determined by the braking torque and the relevant inertia of the load,
braking time, speed, number of starts per hour.
The calculation of the brakes is generally related to the permissible friction energy. Since the VIS is an
explosion proof unit, we simply defined a limit related to the maximum parmissible sliding time of the
disc in dynamic application (see page 6 for more details).
This solution gives a simple parameter to choose the brake in a correct, easy and safe way.
If the brake is used as parking brake (coupled with a motor used with inverter), the calculation is not
relevant except the value of brake torque necessary; we suggest always to consider a brake torque
between 1,5 and 2,3 times the motor torque.
For further information or exact brake calculation choice, please contact us.
Versions
The VIS brakes are available in 3 main construction executions:
- IEC dimension for front mounting on B5 motor and output B5 or B14 or reduced B5
- NEMA dimension for front mounting on nema motor (for dimensions please contact us)
- Closed version for mounting in the rear side of a motor prepared for it.
Except theese configurations, we can manufacture customized versions with output flanges and shafts
made on specific request.
Voltages
AC 3ph Brakes
The AC 3ph brakes work in star/delta configuration like a common 3ph motor - the standard voltage is 230/
400 V 50Hz.
We can produce any AC voltage, 50 or 60 Hz with maximum 600V. The voltage tolerance on the nominal
one is +/- 5% on standard brakes. Different tolerance can be supplied on request.
DC Brakes
The DC brakes are supplied as standard rectifier inside the terminal box in order to supply the brake with
2x AC phases. The standard voltage is DC 195 with 400 VAC to the rectifier. We can produce different
voltages on request with a maximum of 300VDC coil.
DC brakes are stard supplied with WR2008 half wave rectifier providing fast engagement and braking
times.
Different rectifiers can be supplied for psecial applications.
7
Overall Dimensions
TYPE B5 63 71 80 90 100-112 132 160 180 200 225 250 280

(Kg) 15 16 32 34 50 78 82 135 150 175 265 265
A (+0/-1) 23 30 40 50 60 80 110 110 110 140 140 140
A1 25 31 41 51 61 81 111 111 111 141 141 141
B (+/-1) 140 160 200 200 250 300 350 350 400 448 550 550
B1 (+/-1) 140 160 200 200 250 300 350 350 400 450 550 550
C (h8) 95 110 130 130 180 230 250 250 300 350 450 450
C1 (H8) 95 110 130 130 180 230 250 250 300 350 450 450
D 11 j6 14 j6 19 j6 24 j6 28 j6 38 k6 42 k6 48 k6 55 m6 60 m6 65 m6 75 m6
D1 (E6) 11 14 19 24 28 38 42 48 55 60 65 75
d M4X10 M4X10 M6X20 M6X20 M8X20 M10X25 M10X25 M20X30 M20X30 M20X30 M20X30 M20X30
E 2,5 3,5 3,5 3,5 4 4 5 5 5 5 5 5
E1 4 4 4,15 4,15 5 5,5 5,5 6 6 8 8 8
F 10 10 12 12 14 18 18 21 21 21 26 26
G 169,5 176,5 207 217 236,5 277,5 309,5 366,5 366,5 396,5 378,5 378,5
H 185 185 215 215 240 265 265 282 282 282 328 328
H1 205 205 230 230 255 290 290 320 320 320 - -
I 125 125 125 125 125 125 125 125 125 125 125 125
L 168 175 236 246 276 322 352 410 410 440 450 450
M 145 145 196 196 216 242 242 300 300 300 310 310
N 115 130 165 165 215 265 300 300 350 400 500 500
N1 115 130 165 165 215 265 300 300 350 400 500 500
O 205 205 250 250 305 355 355 370 370 370 - -
P 9,5 9,5 11,5 11,5 14,5 14,5 18 18 18 18 18 18
P1 M8X16 M8X16 M10X18 M10X18 M12X18 M12X18 M16X21 M16 M16 n°8XM16 n°8XM16 n°8XM16
Q 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20
X 4 5 6 8 8 10 12 14 16 18 18 20
X1 4 5 6 8 8 10 12 14 16 18 18 20
Y 4 5 6 7 7 8 8 9 10 11 11 12
Z 12,5 16 21,5 27 31 41 45 51,5 59 64 69 79,5
Z1 (+0,1/-0) 12,8 16,3 21,8 27,3 31,3 41,4 45,4 51,9 59,4 64,4 69,4 49,9
IT IS POSSIBLE TO SUPPLY VERSIONS WITH B14 OR SPECIAL OUTPUT FLANGE/SHAFT

PLEASE CONTACT US FOR FURTHER DETAILS
8
a product of coel motori, via Campania 36/40 - Fizzonasco di Pieve Emanele, Milano, Italy
Tel +39 02 90420039 Fax +39 0290420747
www.visbrakes.com info@visbrakes.com
Data and descriptions of this catalogue are not binding and can be modified in any moment
PARTS LIST
1 7 45420216 SHROUD PULLEY
5 8 7 3
1 ASSEMBLY
2 1 45290128 SLSB SUPPORT FROM
150x100x6 RHS
3 1 45400074 HAND WINCH. DOUBLE
1 1 COMPARTMENT
4 7 5 8
WW500-GR/2D
4 1 45290127 SLSB SUPPORT
1 5 24 10300027 WASHER - FLAT M12
6 56 10300000 WASHER - FLAT M8
10 6 11
1 7 12 10300035 HEX HEAD SETSCREW
M12 x 40
7 8 5 8 12 10300028 NYLOC NUT M12
9 20 10300007 HEX HEAD BOLT M8 x
12 1 35
11 6 10 10 28 10300002 NYLOC NUT M8
11 8 10300229 HEX HEAD SETSCREW
1 M8 x 30 (SEE
10300006)
12 1 45290132 SLSB SUPPORT FROM
5 7 8 150x100x6 RHS
13 1 45290232 SHROUD LIFTING ROPE
13 - SLR1 2
SET 5 x 1417kg MBL
14 1 45010030 CARBINE HOOK ST/ST
8MM
13 - SLR2
14

< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270 SHROUD LIFTING EQUIPMENT
Date
STATUS
REVISION HISTORY CCL PARTS LIST
REV DESCRIPTION DATE ITEM QTY PART NUMBER DESCRIPTION MATERIAL MASS
C ITEM 7 INCREASED FROM M8 X 50 06/11/2015
1 1 45420214 SMALL SHEAVE 5- 80 (FEM M3) Nylon-6/6 0.094 kg
2 1 49421002 Standard Keep Plate Stainless Steel 316L 0.013 kg
3 1 45490026 GREASE NIPPLE M6 Stainless Steel 0.004 kg
7 1 10310523 HEX HEAD BOLT M8 x 55 Stainless Steel A2-70 0.028 kg
8 1 10310032 NYLOC NUT M8 Stainless Steel A2-70 0.006 kg
9 2 10310029 WASHER - FLAT M8 Stainless Steel 0.002 kg
2 10 1 45420215 SHROUD PULLEY SUPPORT BRACKET Mild Steel S235 1.055 kg
1 11 1 45420217 20 SHEAVE CENTRE PIN Stainless Steel Grade 304/1.4301 0.119 kg
14 2 10310002 WASHER - FLAT M5 Stainless Steel 0.000 kg
15 2 10310131 SPRING WASHER M5 Stainless Steel 0.000 kg
17 2 10310133 HEX HEAD SETSCREW M5 x 10 Stainless Steel A2-70 0.003 kg
11 3
9 8 7
10
ISOMETRIC VIEW ( 1 : 1.5 )
15 14 17
SIDE ELEVATION ( 1 : 1.5 ) FRONT ELEVATION ( 1 : 1.5 )

NOTE: THE FOLLOWING TOLERANCES APPLY U.N.O. CLEVELAND CASCADES LTD PROJECT STANDARD COMPONENTS (SC)
< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270 SHROUD PULLEY ASSEMBLY
Date
Released for Manufacture THE PROPERTY OF CLEVELAND CASCADES. IT MUST NOT BE COPIED OR
STATUS David Smiles Craig Gordon LOANED WITHOUT THE WRITTEN CONSENT OF CLEVELAND CASCADES DWG No: 45420216 Sheet 1 /1 REV C
CCL PARTS LIST
1 1 45420115 SHEAVE BRACKET MULTI TYPE FOR 250 SHEAVE 45 PIN
2 1 45420101 SHEAVE PIN 45MM IN ST/ST
3 1 45420011 LOCK PLATE
4 2 10310029 WASHER - FLAT M8
1
8 6 2 10310098 HEX HEAD SETSCREW M8 x 20
7 1 45490017 M8 x 1.0P ST/STL GREASE NIPPLE
8 1 45420230 SHEAVE 250 OILON PA6C FOR 45 PIN & 11 ROPE
6 5 4
2 7

< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
TOLERANCE OF +/- 1mm United Kingdom TITLE UNIVERSAL SHEAVE ASSEMBLY
www.clevelandcascades.co.uk A3 FOR 11 ROPE
STATUS R. BUCKLEY Gary Lamb LOANED WITHOUT THE WRITTEN CONSENT OF CLEVELAND CASCADES DWG No: 45490088 Sheet 1 /1 REV B
CCL PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION MATERIAL
1 1 45920046 31.7 x 109 PIN Stainless steel - 17-4
PH (H900)
2 1 45900037 25.4 X 104 PIN Stainless Steel 17-4 PH
( H900)
3 1 45900035 UPPER LOAD CELL
BRACKET FOR T95
2000-10000KG
4 1 45920045 LOWER LOAD CELL Welded Steel Mild
BRACKET FOR T95
2000-10000 kg LOAD CELL
5 2 10310405 DIN 125 A - 33 WASHER Steel, Mild
6 2 10310406 DIN 125 A - 27 WASHER Steel, Mild
7 2 10390005 R CLIP 6 TO SUIT 28-40 Stainless Steel Grade
7 5
SHAFT 304/1.4301
8 2 10390052 ST STL 5mm R-CLIP FOR Stainless Steel Grade
20 - 28mm SHAFTS 304/1.4301
5 2
6 8

< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
TOLERANCE OF +/- 1mm United Kingdom TITLE T95 LOAD CELL ASSEMBLY
www.clevelandcascades.co.uk A2 2000-10000KG - 125mm STROPS
STATUS
Released for Manufacture Gary Lamb Paul Wilson
REVISION HISTORY PARTS LIST
REV DESCRIPTION DATE ITEM QTY PART NUMBER DESCRIPTION
SRS PACKER & SRS SWITCH
04/07/2016 1 1 10300356 HEX HEAD SETSCREW M10 x 70
B MODEL REMOVED, EYEBOLT
ADDED. 2 3 10300011 WASHER - FLAT M10
3 2 10300012 NYLOC NUT M10
4 2 10300027 WASHER - FLAT M12
5 1 10300028 NYLOC NUT M12
6 1 45460334 SLACK ROPE SWITCH ARM with
8 extended rope pass
11 7 1 10300163 HEX HEAD BOLT M10 x 170
6
8 1 45460335 SLACK ROPE SWITCH ROLLER
35x130 LONG
9 1 10300043 HEX HEAD BOLT M12 x 120
10 1 45460204 T42270 SPRING (SEE PART NUMBER
4549-0043)
11 2 45590014 ST STL DEE TYPE SHACKLE 5mm
1 BOW
12 1 45490005 EYENUT 8MM ST/ST TO
2 3 7 DIN582/UNTESTED
12 10 11
BOLT FIXING SIZE

(DETERMINED BY ASSEMBLY SHOP)
4 5 9

< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
TOLERANCE OF +/- 1mm
United Kingdom TITLE SLACK ROPE SWITCH
3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270 ASSEMBLY - 600mm Long With
Date
www.clevelandcascades.co.uk A3 120mm Bolt & 130mm Roller Guide
STATUS
Released for Manufacture lambg Peter Luke
PARTS LIST
4 2 3 1 1 45390460 LOCK BAR
2 4 10300027 WASHER - FLAT M12
3 1 10300101 HEX HEAD SETSCREW M12 x 35 (USE 10300034)
4 2 10300028 NYLOC NUT M12
6 4 10300137 HEX HEAD BOLT M10 x 100
1
7 1 45390459 TRANSPORT AND ASSEMBLY STAND 945mm HIGH
4 2 5
6

NOTE: THE FOLLOWING TOLERANCES APPLY U.N.O. CLEVELAND CASCADES LTD PROJECT Bedeschi SPA (0791)
< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
TOLERANCE OF +/- 1mm United Kingdom TITLE TRANSPORT AND ASSEMBLY
www.clevelandcascades.co.uk A3 EQUIPMENT
STATUS R Buckley Gary Lamb LOANED WITHOUT THE WRITTEN CONSENT OF CLEVELAND CASCADES DWG No: 45390461 Sheet 1 /1 REV A
PARTS LIST
A ITEM QTY PART NUMBER DESCRIPTION
1 12 45100352 1300S PROFILED RIM
B-TYPE CONE
150
45100218 WITH 6mm
CERAMIC LINER -
674 **OBSOLETE**
2 12 45100351 1300S PROFILED RIM
1 - 'B' CONE TOP
339
A-TYPE CONE
45100219 WITH 6mm
CERAMIC LINER -
1061
2 - 'A' CONE **OBSOLETE**

3 1 45120536 STROP SET CC864 -
59.5 x700x125mm
339
WIDE - 24 CONES
3.1 2 - 125mm WIDE B-TYPE
STROP
3.2 1 - 125mm WIDE A-TYPE
STROP
3.1
16681
3.2
3.1
A ( 1 : 10 )
2 - 'B' CONE BOTTOM

< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270 CC864 CASCADE ASSEMBLY
Date
STATUS
CCL PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION MASS
1 1 45230133 1300S SHROUD TOP CLAMP 44.209 kg
B B ASSEMBLY
2 1 45200024 SHROUD Top Section 1300S 36.500 kg
FR-INT-003
3 5 45230134 1300S SHROUD INTERMEDIATE 32.388 kg
B CLAMP ASSEMBLY
4 5 45210002 SHROUD 3m Int Section 1300S 36.000 kg
1 FR-INT-001
5 1 45240052 1300S SHROUD BOTTOM RING 44.481 kg
ASSEMBLY
B ( 1 : 10 )
3
18000
B ( 1 :3 )

< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
5 3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270 1300 Shroud Assembly - 18m long
Date
STATUS
CCL PARTS LIST
1 1 45000121 1300 Carrier Fabrication
2 2 45500089 PROBE ASSEMBLY VEGAVIB S61
3 2 45510078 CARRIER PROBE BRACKET (STANDARD)
4 4 10300011 WASHER - FLAT M10
5 2 10300018 HEX HEAD BOLT M10 x 40
6 2 10300012 NYLOC NUT M10
7 3 45060065 SPILL DOOR 708mm FOR 1100S AND 1300S CARRIER
8 2 45500084 IP65 TILT SWITCH ASSEMBLY
26 3 45010087 EYEBOLT ASSEMBLY
27 1 45090102 200x170mm LABEL - NON CE
31 40 10310002 WASHER - FLAT M5
33 4 10310334 SOCKET BUTTON HEAD SCREW M5x12
34 3 45090200 10mm SPILL DOOR BEAD TO SUIT 680mm OPENING
1
35 18 45010126 10mm BLACK ST/STL P-CLIP (RS 2988081)
37 18 10310003 NYLOC NUT M5
3 5 4 6 26
A(1:3)
37 36 35 34 31 7
27
32 31 33

REVISION HISTORY
REV DESCRIPTION DATE NOTE: THE FOLLOWING TOLERANCES APPLY U.N.O. CLEVELAND CASCADES LTD PROJECT STANDARD COMPONENTS (SC)
C STANDARD EYEBOLT ASSEMBLY ADDED - 45010087 09/10/2013 FAB ITEMS: MACHINED ITEMS: HOLE CENTRES:
D 200x170mm LABEL & FIXINGS ADDED TO PARTS LIST 18/6/2014 < 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
TOLERANCE OF +/- 1mm United Kingdom TITLE 1300 Carrier Assembly with MDS
10mm HOOPS, 'P' CLIPS & M5 STAINLESS STEEL 29/10/2014 Probes & Tilt Switches
E www.clevelandcascades.co.uk A1
FIXINGS ADDED. DRAWING Designed by Checked by Approved by Date THIS DRAWING IS A PRIVATE AND CONFIDENTIAL COMMUNICATION, AND
F LABEL UPDATED TO NON CE MARKED AS STD 06/01/2016 STATUS

LOANED WITHOUT THE WRITTEN CONSENT OF CLEVELAND CASCADES DWG No: 45000171 Sheet 1 /1 REV F
CCL PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION MATERIAL
1 1 45650001 SKIRT CANVAS 1300S/1500S (1000mm LONG) TO PE610 MATT
FR-SC-093 D TARPAULIN FABRIC
3 48 10300027 WASHER - FLAT M12 Galvanized Steel
4 5 10300227 HEX HEAD BOLT M16 x 55 Galvanized Steel 8.8
5 14 10300047 WASHER - FLAT M16 Galvanized Steel
6 7 10300048 NYLOC NUT M16 Galvanized Steel 8.8
8 24 45640034 SKIRT RUBBER 1000 LONG (PER PIECE) TO Canonflex Conveyor
FR-SC-083 MANUFACTURED FROM 4646-0007 Belting EP315/2 2+1
9 24 10300028 NYLOC NUT M12 Galvanized Steel 8.8
11 6 5
8
4 5 6
3 9 10

< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
TOLERANCE OF +/- 1mm United Kingdom TITLE 1300 / 1500 Skirt Assembly - 1m
www.clevelandcascades.co.uk A2 Skirt
STATUS
Released for Manufacture Gary Lamb Peter Luke
LOANED WITHOUT THE WRITTEN CONSENT OF CLEVELAND CASCADES DWG No: 45640119 Sheet 1 /1 REV C
PARTS LIST
1 1 45640120 1300-1500 SKIRT
FABRICATION
2 1 45640172 1300S TUBULAR SKIRT -
6mm RUBBER 3.0 m
3 48 10310056 WASHER - FLAT M12
4 24 10310059 NYLOC NUT M12
5 24 10310519 HEX HEAD SETSCREW M12
7 1 x 50
6 8
6 10 10300047 WASHER - FLAT M16
7 5 10300048 NYLOC NUT M16
8 5 10300227 HEX HEAD BOLT M16 x 55
5 3 4
ISO VIEW ( 1 :12 )

NOTE: THE FOLLOWING TOLERANCES APPLY U.N.O. CLEVELAND CASCADES LTD PROJECT Bedeschi SPA (0791)
< 1000mm +/-2mm
1001 TO 3000mm +/-3mm
< 100mm +/-0.25mm
100 TO 300mm +/-0.5mm
POSITIONAL
3001 TO 5000mm +/-5mm 300 TO 1000mm +/-1mm SIZE +/- 0.25 T:+44(0)1642 753 260 F:+44(0)1642 753270 1300 TUBULAR SKIRT
Date
STATUS
CLEVELAND CASCADES LTD
PROJECT NUMBER CC864
DOCUMENT TITLE ELECTRICAL SPECIFICATION
SUPPLY VOLTAGE 400VAC 3PH 50Hz
CONTROL VOLTAGE 24VDC
PROTECTION CLASS IP56 MINIMUM
CCL PAGE NUMBER Page 1 of 11 Rev A
ELECTRICAL SPECIFICATION
GENERAL DETAILS
CUSTOMER BEDESCHI S.p.A
CHUTE SPECIFICATION 1300 CASCADE CHUTE – SHIP LOADER
MATERIAL CLINKER AND CEMENT
AMBIENT TEMPERATURE FROM +25˚C TO +35˚C
SITE LOCATION PADANG, INDONESIA
ELECTRICAL DETAILS
CONTROL PANEL NOT INCLUDED
CCL ELECTRICAL ENGINEER CARL HESLOP
REV AMENDMENT DATE BY

0 Original Specification 04.08.2016 C.H
1 CC-OL1 changed from 230VAC model to 24VDC model 04.08.2016 C.H
2
A As Built 18.11.2016 C.H
Page | 1
SECTION 1: PARTS LIST
WINCH MOTOR
MANUFACTURER SIEMENS
POWER 11kW
SUPPLY VOLTAGE 400VAC 3PH 50Hz, FLC 21.5A
PROTECTION CLASS IP56
BRAKE DETAILS 3PH AC VIS Brake
OTHER PTC thermistors and anti-condensation heaters 230 VAC
QTY 1
FUNCTION Powers winch unit to allow extension / retraction of the chute.
WINCH LIMIT SWITCH

TAG CC-RC1
MANUFACTURER TER
TYPE Fox
OUTPUT 2 N/C contacts
QTY 1
CCL NUMBER 12960107
FUNCTION Defines travel distance of the chute in both directions. Stops winch
motor when switches are operated.
ULTIMATE HIGH LIMIT SWITCH

TAG CC-UH1
MANUFACTURER Honeywell
TYPE GLDB01A4J
OUTPUT 1 N/C contact
QTY 1
CCL NUMBER 45460224
FUNCTION Acts as a back up to winch limit switch. Stops the chute from
retracted too much. Prevents damage to cones / head chute.
Page | 2
SLACK ROPE LIMIT SWITCH

TAG CC-SR1
MANUFACTURER Honeywell
TYPE GLDB01C
OUTPUT 1 N/O contact held closed mechanically
QTY 1
CCL NUMBER 45460013
FUNCTION Mounted on rope sheaves. Stops winch motor when rope tension is
lost.
COLLISION DETECTION LIMIT SWITCH

TAG CC-TILT1, CC-TILT2
MANUFACTURER Ramsey
TYPE 20-39-25ft mercury tilt switch
OUTPUT 1 N/C contact
QTY 2
CCL NUMBER 45500006
FUNCTION Mounted on carrier. Stops winch motor when tilted more than 10 to
15 degrees.
MATERIAL DETECTION LIMIT SWITCH

TAG CC-MDS1
MANUFACTURER UWT Level Control
TYPE Rotonivo RN6004-021XA7N7A
OUTPUT Relay
QTY 2
CCL NUMBER 12960132
FUNCTION Mounted on carrier. Raises carrier upon contact with material.
REELING DRUM
TAG CC-RD1, CC/C05, CC/C06
MANUFACTURER Cavotec
TYPE FLT-22361420DC-4505 spring driven cable reel
LENGTH 27m of 5 core 1.5mm2 Semoflex cable on drum, includes dead turns
and 3m tail.
QTY 1
CCL NUMBER 45800078
FUNCTION Transfers electrical supply to carrier equipment.
Page | 3
TERMINAL BOX
TAG CC-TB1, CC-TB2, CC-TB3
MANUFACTURER Rittal
TYPE KL 1500.510 150mm x 150mm x 120mm
QTY 3
CCL NUMBER 12910232
TERMINAL BOX
TAG CC-TB4
MANUFACTURER Rittal
TYPE AE 1033.500 300mm x 300mm x 210mm
QTY 1
CCL NUMBER 12910233
CABLE GLAND
TAG CC-GLN1
MANUFACTURER CMP
TYPE A2 NPB M20s16 gland kit, part no. 20S16A2LSF2RA5
CLAMPING RANGE 3.2 – 8.7mm
QTY 1 (1 pack of 2)
CCL NUMBER 12970451
CABLE GLAND
TAG CC-GLN2
MANUFACTURER CMP
TYPE A2 NPB M20 gland kit, part no. 20A2LSF2RA5
CLAMPING RANGE 6.5 - 14mm
QTY 12 (6 packs of 2)
CCL NUMBER 12970452
CABLE GLAND
TAG CC-GLN3
MANUFACTURER CMP
TYPE A2 NPB M25 gland kit, part no. 25A2LSF2RA5
CLAMPING RANGE 11.1 - 20mm
QTY 4 (2 packs of 2)
CCL NUMBER 12970453
Page | 4
THREAD ADAPTOR
TAG CC-GLN4
MANUFACTURER CMP
TYPE 737 NPB adaptor M20 (male) to M25 (female)
QTY 2
CCL NUMBER 12970454
THREAD ADAPTOR
TAG CC-GLN5
MANUFACTURER CMP
TYPE 737 NPB adaptor PG13.5 (male) to M20 (female)
QTY 2
CCL NUMBER 12970455
CABLE GLAND
TAG CC-GLN6
MANUFACTURER LAPP
TYPE Skintop MS-M M32
CLAMPING RANGE 11 - 21mm
QTY 1
CCL NUMBER 12970341
FIXED CABLE
TAG CC/C07, CC/C08, CC/C09, CC/C10
MANUFACTURER Elettrotek Kabel
TYPE FG7OR, 0.6/1kV, 4 core 1.5mm2 part no. 46050G82040M15
OUTER DIAMETER 12mm
QTY 20m
CCL NUMBER 12900283
FIXED CABLE
TAG CC/C03, CC/C04
MANUFACTURER Elettrotek Kabel
TYPE FG7OR, 0.6/1kV, 5 core 1.5mm2 part no. 46050G82051M15
OUTER DIAMETER 14.5mm
QTY 10m
CCL NUMBER 12900284
Page | 5
LOAD CELL
TAG CC-LC1
MANUFACTURER Thamesside
TYPE T95 10 tonne 6 wire load cell
OUTPUT mV to overload display unit
QTY 1
CCL NUMBER 45900038
FUNCTION Monitor weight of chute
OVERLOAD DISPLAY UNIT

TAG CC-OL1
MANUFACTURER London Electronics
TYPE INT2-L-ANI-AL2-0-R-DC
OUTPUT Relay
PROTECTION CLASS Protected by enclosure CC-TB4
QTY 1
CCL NUMBER 12920331
FUNCTION Indicates overload alarm / zero load alarm
OTHER EQUIPMENT
MANUFACTURER DESCRIPTION QTY CCL No.
FLEXIBLE CONDUIT
The flexible conduit used is PMAFLEX PIS/PIH made from polyamide 12. It is CE approved for
use in Europe and UL approved for use in Canada and the USA. The conduit has good
mechanical strength and is self-extinguishing. It has a temperature range of -45 to 105˚C and
is resistant to UV radiation and common oils, acids, alkalis and solvents. Conduit fittings, if
used, are rated to IP66.
Page | 6
SECTION 2: CONTROL PHILOSOPHY
The wire ropes from the winch unit are attached to the carrier frame, the cascade cones are
attached to the head-chute section via three strops and are not physically attached to the
ropes or carrier section. If the chute is retracted from the fully extended position then the
cones are collected by the carrier section as it travels up, the cones sit one within the other,
supported by their rims.
The winch limit switch (CC-RC1) is a geared cam switch that is coupled to the winch output
shaft. The two cam switches are set independently during commissioning to indicate the
fully retracted / extended positions of the chute. The switches are wired normally closed.
When the chute is fully retracted, the switch designated as the high limit will be opened by
the corresponding cam. The control system should be configured so that an open high limit
contact will prevent the winch-up contactor from energising. When the chute is fully
extended, the switch designated as the low limit will be opened by the corresponding cam.
The control system should be configured so that an open low limit will prevent the winch-
down contactor from energising.
The ultimate high limit switch (CC-UH1) is a lever arm position switch mounted on a bracket
located underneath the head-chute section. It is mounted so that there is a small clearance
between the lever arm and the top cone when the chute is in its fully retracted position. This
clearance is normally set to approximately 50mm during the commissioning stage, note that
the lever arm is adjusted to suit individual chutes and that if a replacement switch is fitted
then this lever arm will need to be adjusted to maintain the correct setting. The switch is
wired normally closed and acts as a back up to the winch high limit. Material can build up on
the cone rims overtime which increases the height of the cone stack. This increase in height
will not be detected by the winch limit switch and, if the chute is not cleaned regularly, the
cones are at risk of colliding with the head-chute. If the height of the cone stack increases
more than the clearance gap that has been set, the rim of the top cone will operate the lever
arm and open the switch contacts. The control system should be configured so that an open
ultimate high limit contact will prevent the winch-up contactor from energising. An open
ultimate high contact should also give an indication that the chute should be cleaned. It is
recommended by CCL that the operation of the ultimate high limit switch should be viewed
as a fault by the control system as it is regarded as a back-up limit which should not be
operated under normal conditions.
The slack rope limit switch (CC-SR1) is a top roller plunger position switch. It is mounted on
the rope sheave and is operated by a pivoting arm connected to a spring.
The switch is wired normally open. When there is adequate tension on the winch ropes,
there will also be tension on the spring and the pivoting arm will be holding the roller
plunger down, closing the switch contacts. If tension in the winch ropes is lost, the spring
returns to its original length, lifting the pivoting arm and the slack rope limit switch contacts
will open. The control system should be configured so that an open slack rope contact will
prevent the winch-down contactor from energising. When there are multiple slack rope
switches, they are wired in series.
Page | 7
The collision detection limit switches (CC-TILT1 / CC-TILT2) are tilt switches that are attached
to supporting chain and hang vertically from the carrier section. They are wired normally
closed in series. The tilt switches should operate if they come into contact with the bottom
of the loading vessel or the skirt fitted to the carrier section. The control system should be
configured so that when the tilt switch contact is open the winch-down contactor will be
prevented from energising. It is recommended by CCL that the tilt switches operate on a one
second delay to filter out false signals when the tilt switches are moving in the air.
The material detection limit switch (CC-MDS1 / CC-MDS2) is a rotary paddle switch mounted
on an adjustable bracket inside the carrier section. The paddle is wired normally closed.
During loading, the material will pile up and come into contact with the paddle and the relay
contact will open. The control system should be configured so that when the relay contact
opens, the winch-up contactor is energised for a short period of time to lift the carrier out of
the material whilst allowing the skirt to remain in contact with the pile. It is recommended
by CCL to configure the control system so that the auto-raise time period can be easily
adjusted to aid the commissioning process. If the paddle remains in contact with the
material for more than five seconds, the control system should assume the chute is blocked
and remove the material feed to the chute. This condition should indicate a blocked chute
fault and restrict up travel to two second bursts with a delay in between to allow the
operator to try and loosen the blockage. Allowing the chute to be moved up continuously
with a blockage increases the chances of a motor overload and damage to the chute. The
control system should be configured so that the blocked chute timer can be easily adjusted
to aid the commissioning process.
IMPORTANT NOTE: There are delays built into the switching mechanism for the paddle
switches. There is a 1 second delay between the paddle stopping and the switch contacts
opening. There is a 3 second delay between the paddle resuming rotation and the switch
contacts closing.
These delays will need to be considered when setting the auto-raise and blocked chute
timers.
Page | 8
If there is a fault on the chute, the material feed to the chute must be stopped. All faults
must stop the winch operating apart from the following exceptions:
- Ultimate High Limit: Should be able to travel down until ultimate high contact closes.
- Blocked Chute: Should be able to travel up in 2 second bursts with a 2 second delay
in between.
-
The control system should be able to detect the following faults:
- Phase Failure
- Ultimate High Limit
- Winch Thermistors
- Winch Overload
- Blocked Chute
- Overload Alarms (high and low)
- E-stop Pressed (E-stop push button is not supplied by CCL)
The above list is a recommendation by CCL and is not exhaustive. More conditions can be
monitored if deemed necessary by the customer.
Page | 9
WINCH UNIT WIRING FOR FAST ACTING AC BRAKE
When the chute is lowering and the winch

contacts are de-energised, the momentum of
the chute and residual magnetism in the motor
will cause the motor to become a generator.
If the supply to the brake is derived from the

motor phase supply then this generated e.m.f
will continue to energise the brake causing the
motor to run past the point of when the
contactor was de-energised.
The use of auxiliary contacts on the winch

contactors to isolate the brake supply prevents
this motor run on and gives fast acting brake
functionality as explained below.
The winch motor is designed for direct on line

start and should be controlled via a motor
reversal kit (mechanically and electrically
interlocked motor contactors with overload
unit). There should be an auxiliary contact block
mounted on each of the contactors, WINCH UP
and WINCH DOWN, which can be used for fast
acting brake functionality as shown in the
schematic to the right.
The winch brake unit is fed from a rectifier with

built in terminals for the connection of external
contacts, or from a three phase supply via
auxiliary contacts. These contacts should be
normally open (the brake is a fail-safe unit
meaning it has to be energised in order for it to
be released). The brake supply can then be
broken immediately via these auxiliary contacts
when the motor supply contactors are de-
energised.
The image displayed demonstrates the concept

of fast action braking. The information on the
drawing is not project specific. Refer to the
electrical drawings for project specific
information.
Page | 10
OVERLOAD SYSTEM – LONDON ELECTRONICS
The switch and black pot within the overload unit control cabinet are there to perform a
trigger point check on the alarm value that is set, with the switch activated the black pot can
be rotated, this will alter the displayed value, to increase the value turn clockwise and anti-
clockwise to decrease the value, the pot is turned until the alarm trigger point is reached,
the alarm relay should then change state.
We send the display instrument out with the alarm value pre-set to our best estimate based
on modelled components. The alarm value figure should be checked during hot
commissioning, this is when the chute is fully extended and the correct amount of material is
flowing through it. You should note the indicated value during hot commissioning, take 5%
of this value and add this to the indicated value noted. This calculated result should be
checked with the pre-set alarm value we set, if different then you should enter your
calculated value as the alarm value.
To check and change the pre-set alarm value, press OK button successively until the AL2 LED
on the side of the instrument illuminates, the pre-set alarm value will be displayed, press
and hold the OK button until SET.Pnt is displayed then release the OK button, you can now
edit the value, the right most digit will be brighter than the others this indicates that this
digit can be increased or decreased by the arrow buttons, to move to the next digit press the
digit button and the next digit will illuminate brightly again this digit can be increased or
decreased, continue in this way until you have entered your calculated value, then press the
OK button.
To test that the new alarm trigger value has been accepted, press and hold the silver switch
and rotate the black pot until the display exceeds the new alarm value, the alarm relay
should change state.
Normally we would use a load cell, suitable for the calculated load the chute will encounter,
mounted to the head chute assembly and the ‘A’ strop. The cell is electrically connected to a
process meter with relay outputs, these are set to activate when preset load values are
reached. The overload value is initially set at 5% above the calculated dynamic load with the
chute fully extended, this value can be changed during commissioning to account for
differences in the calculated dynamic load value (based on ideal cone models) and the
measured value. This means of overload detection has its limitations, since the dynamic load
changes as the chute retracts, however the overload value is set at the worst case position,
so the designed load limit of the boom will never be reached before an overload alarm is
triggered.
Page | 11
United Kingdom
T:+44(0)1642 753 260 F:+44(0)1642 753270
www.clevelandcascades.co.uk
THIS DRAWING IS A PRIVATE AND CONFIDENTIAL COMMUNICATION, AND
LOANED WITHOUT THE WRITTEN CONSENT OF CLEVELAND CASCADES
United Kingdom
T:+44(0)1642 753 260 F:+44(0)1642 753270
United Kingdom
T:+44(0)1642 753 260 F:+44(0)1642 753270
United Kingdom
T:+44(0)1642 753 260 F:+44(0)1642 753270
United Kingdom
T:+44(0)1642 753 260 F:+44(0)1642 753270
United Kingdom
T:+44(0)1642 753 260 F:+44(0)1642 753270
United Kingdom
T:+44(0)1642 753 260 F:+44(0)1642 753270
EX
P M1 M4
M1 M2 M3
1
M5
2 4
M6
L
3
M4 M5 M6 M3
1 - Standard
Posizione morsettiera
Terminal board position
Lage des Klemmenkastens
M2
M1 M2 M3 M4 M5 M6
10 0,8 1,0 1,2 1,4 0,8 1,0 1,2 1,4 1,3 1,7 2,1 2,5 1,3 1,6 2,0 2,3 0,8 1,0 1,2 1,4 0,8 1,0 1,2 1,4
20 0,9 1,1 1,3 1,5 0,9 1,1 1,3 1,5 1,5 1,9 2,3 2,7 1,4 1,8 2,2 2,5 0,9 1,1 1,3 1,5 0,9 1,1 1,3 1,5
25 0,8 1,0 1,3 1,5 0,8 1,0 1,3 1,5 1,4 1,8 2,2 2,6 1,4 1,7 2,1 2,4 0,8 1,0 1,3 1,5 0,8 1,0 1,3 1,5
30 1,6 2,0 2,2 2,4 1,6 2,0 2,2 2,4 2,8 3,4 3,8 4,2 2,6 3,2 3,6 4,0 1,6 2,0 2,2 2,4 1,6 2,0 2,2 2,4
40 2,1 2,3 2,5 2,1 2,3 2,5 3,6 4,0 4,4 3,4 3,8 4,1 2,1 2,3 2,5 2,1 2,3 2,5
50 1,7 2,2 2,4 2,6 1,7 2,2 2,4 2,6 2,9 3,8 4,2 4,6 2,8 3,6 4,0 4,3 1,7 2,2 2,4 2,6 1,7 2,2 2,4 2,6
70 1,7 2,1 2,3 2,5 1,7 2,1 2,3 2,5 2,9 3,6 4,0 4,4 2,7 3,4 3,8 4,1 1,7 2,1 2,3 2,5 1,7 2,1 2,3 2,5
80 2,3 3,3 3,5 3,7 2,3 3,3 3,5 3,7 3,9 5,7 6,1 6,5 3,7 5,4 5,8 6,1 2,3 3,3 3,5 3,7 2,3 3,3 3,5 3,7
90 3,6 3,8 4,0 3,6 3,8 4,0 6,2 6,6 6,9 5,9 6,2 6,6 3,6 3,8 4,0 3,6 3,8 4,0
100 2,5 3,7 4,2 4,4 2,5 3,7 4,2 4,4 4,4 6,4 7,2 7,6 4,1 6,0 6,8 7,2 2,5 3,7 4,2 4,4 2,5 3,7 4,2 4,4
150 3,2 4,1 4,6 4,8 3,2 4,1 4,6 4,8 5,6 7,1 8,0 8,4 5,3 6,8 7,6 7,9 3,2 4,1 4,6 4,8 3,2 4,1 4,6 4,8
180 4,1 4,6 4,8 4,1 4,6 4,8 7,1 8,0 8,4 6,8 7,6 7,9 4,1 4,6 4,8 4,1 4,6 4,8
200 3,2 4,1 4,5 4,7 3,2 4,1 4,5 4,7 5,6 7,0 7,8 8,2 5,3 6,7 7,4 7,7 3,2 4,1 4,5 4,7 3,2 4,1 4,5 4,7
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
A. n2 < 5 rpm - Qualora la velocità uscita del

A. n2 < 5 rpm - in case the gearbox output speed is lower A. n2 < 5 rpm – Ist die Abtriebsdrehzahl des Getriebes
riduttore sia inferiore a 5 rpm, per il riempimento
than 5 rpm, please refill the oil following the quantity of niedriger als 5 rpm, fuer die Oelfuellung bitte auf die
fare riferimento ai quantitativi della posizione M4
mounting position M4 . (see item C); Vorgehensweise wie bei Position M4 beziehen.siehe Punkt C
(vedere punto C);
B. n2 < 1 rpm - once the output speed of the unit is lower B. n2 < 1 rpm – Ist die Abtriebsdrehzahl des Getriebes
B. n2 < 1 rpm - Qualora la velocità uscita del
than 1 rpm, please refill the oil following the quantity of niedriger als 1 rpm, fuer die Oelfuellung bitte auf die
riduttore sia inferiore a 1 rpm per il riempimento
mounting position M3.(see item C); Vorgehensweise wie bei Position M3 beziehen.siehe Punkt C
fare riferimento ai quantitativi della posizione M3
C. For M3 and M4 mounting positions is necessary to install C. Bei den Montagepositionen M3 und M4 ist es notwendig
(vedere punto C);
the OT oil tank. einen OT Öltank zu installieren.
C. Per le posizioni di montaggio M3 e M4 è
Attention Achtung OT Auswahl: Siehe Sektion E;
necessario installare il vaso di espansione OT.
OT selection: please see section E; OT Installation: Siehe Punkt 8.3 des
Attenzione
OT installing:please see point 8.3 of use & maintenance Benutzungs&Wartungshandbuches
Scelta grandezza OT: Sezione E;
manual. D. Bei den Ölmengenangaben handelt es sich um
Installazione OT : Punto 8.3 manuale uso e manutenzione.
D. Oil quantities listed in the table are approximate; to ensure approximative Werte; für den Erhalt einer korrekten
D. Le quantità di olio sono approssimative; per una
correct lubrication, please refer to the level mark on the gear Schmierung muss Bezug auf den am Getriebe
corretta lubrificazione occorre fare riferimento al livello
unit. gekennzeichneten Füllstand genommen werden.
segnato sul riduttore.
MT27IGBD0
MT27IGBD0.3
50
8.3.Vaso Espansione 8.3. Expansion tank 8.3 Expansionsgefäß
n2<5
max max
A max A
A
EX
Example Other
M3 M4 M1 Positions
n2<5
max
max A max
A
EXB
Example Other
M13 M46 M12 Positions
Carico / Filling plug / Einfüllschraube

Livello / Level plug / Schauglas
Sfiato / Vent plug/ Entlüftungsstopfen
1 - Verificare che il vaso di espansione si trovi 1 - Check that the oil tank is located in the 1 – Überprüfen Sie ob sich der Öltank an der
nella parte più alta del riduttore; highest part of the gearbox; höchsten Position des Getriebes befindet.
2 - Rimuovere il tappo di sfiato; 2 - Remove the breather plug; 2 – Entlüftungsventil entfernen.
3 - To facilitate the expulsion of air (only in oil
3 - Per facilitare la fuoriuscita dell'aria (solo in 3 – Um den Luftaustritt zu ermöglichen (nur in
filling phase) is possible to unscrew one of the
fase di riempimento) è possibile svitare uno dei der Befüllungsphase) kann man eines der
oil plugs from the top of the gearbox (for
tappi dalla parte superiore del riduttore (per
example the plug “A” as showed in the picture); Ölventile von der Oberseite des Getriebes
esempio il tappo "A" come da figura);
4 - During the oil filling phase, when the oil aufschrauben (zum Beispiel das Ventil „A“ im
4 - Durante la fase di riempimento, quando l'olio
reach the side plug “A”, please provide for Bild)
sale in corrispondenza del tappo "A",
screw the plug in order to avoid leaking; 4 – Während der Ölbefüllungsphase, wenn das
provvedere ad avvitare il tappo stesso;
5 - Continue in oil filling up to the level plug;
5 - Continuare nel riempimento fino al Öl auf den Stopfen „A“ kommt, die Schraube
6 - Tighten the breather plug;
raggiungimento del tappo di livello; festziehen)
6 - Avvitare il tappo di sfiato;
7 - Start the gearbox running-in for few 5 – Fortfahren mit der Ölbefüllung bis zum
7 - Fare girare il riduttore alcuni minuti e
controllare nuovamente il livello ; minutes, and check the oil level again ; Oelschauglas
8 - Dopo la messa in servizio della macchina 8 - After the startup of the unit with load, wait 6 – Entlüftungsventil festschrauben.
sotto carico del riduttore e dopo aver atteso la for the stabilization of operating temperatures 7 – Getriebe ein paar Minuten einschalten um
stabilizzazione delle temperature di esercizio and verify that the oil level is below the “max” den Ölstand zu kontrollieren.
verificare che il livello dell'olio non oltrepassi il mark level. 8 – Nach dem Start der Maschine unter Last
livello "max". und des Erreichens der Betriebstemperatur,
überprüfen Sie, ob der Ölstand unter dem
„maximal“ Standes ist.
MT27IGBD0
84
Automation
Basic
Motion
8. LUBRIFICAZIONE 8. LUBRICATION 8. SCHMIERUNG
Tabella 8.1/ Table 8.1 Tabelle 8.1
Oli Minerali Oli Sintetici Polialfaolefine (PAO) Oli Sintetici Poliglicoli (PG)
Produttore Mineral oils Poly-Alpha-Olefin synthetic oils (PAO) Polyglycol synthetic oils (PG)
Manufacturer Mineralöle Polyalphaolefine- Synthetiköle (PAO) Polyglykol-Synthetiköle (PG)
Hersteller ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG
150 220 320 150 220 320 150 220 320
Blasia Blasia Blasia Blasia SX Blasia SX Blasia S Blasia S Blasia S
AGIP 220 320
-
220 320 150 220 320
150
Degol BG Degol BG Degol BG Degol PAS Degol PAS Degol PAS Degol GS Degol GS Degol GS
ARAL 220 Plus 320 Plus 150 220 320 150 220 320
150 Plus
Energol Energol Energol Enersyn Enersyn Enersyn Enersyn Enersyn Enersyn
BP GR-XP 220 GR-XP 320 EPX 150 EPX 220 EPX 320 SG 150 SG-XP 220 SG-XP 320
GR-XP 150
Alpha SP Alpha SP AlphaSP Alphasyn EP Alphasyn EP Alphasyn EP Alphasyn PG Alphasyn PG Alphasyn PG
CASTROL 220 320 150 220 320 150 220 320
150
Ultra Gear Tegra Tegra Tegra
Ultra Gear Ultra Gear HiPerSYN HiPerSYN HiPerSYN
CHEVRON 220 320
Synthetic Synthetic Synthetic
150 220 320
150 Gear 150 Gear 220 Gear 320
Spartan EP Spartan EP Spartan EP Spartan S EP Spartan S EP Spartan S EP Glycolube Glycolube Glycolube
ESSO 220 320 150 220 320 150 220 320
150
Klüberoil Klüberoil Klüberoil Klübersynth Klübersynth Klübersynth Klübersynth Klübersynth Klübersynth
KLÜBER GEM 1-220 GEM 1-320 EG 4-150 EG 4-220 EG 4-320 GH 6-150 GH 6-220 GH 6-320
GEM 1-150
Mobilgear Mobilgear Mobilgear Mobilgear
Mobilgear Mobilgear Glygoyle
MOBIL XMP 220 XMP 320
SHC XMP SHC XMP SHC XMP Glygoyle 22 Glygoyle 30
HE320
XMP 150 150 220 320
MOLIKOTE L-0115 L-0122 L-0132 L-1115 L-1122 L-1132 - - -
Optigear BM Optigear Optigear Optigear
Optigear BM Optigear BM Optiflex A Optiflex A Optiflex A
OPTIMOL 220 320
Synthetic A Synthetic A Synthetic A
150 220 320
150 150 220 320
Q8 Goya 150 Goya 220 Goya 320 El Greco 150 El Greco 220 El Greco 320 Gade 150 Gade 220 Gade 320
OMALA OMALA OMALA OMALA OMALA OMALA
Omala HD Omala HD Omala HD
SHELL S2 G S2 G S2 G
150 220 320
S4 WE S4 WE S4 WE
150 220 320 150 220 320
Meropa Meropa Meropa Pinnacle EP Pinnacle EP Pinnacle EP Synlube CLP Synlube CLP
TEXACO 220 320 150 220 320
-
220 320
150
Carter EP Carter EP Carter EP Carter SH Carter SH Carter SH Carter SY Carter SY Carter SY
TOTAL 220 320 150 220 320 150 220 320
150
TRIBOL 1100/150 1100/220 1100/320 1510/150 1510/220 1510/320 800\150 800\220 800\320
Lubrificanti sintetici per uso alimentare / Food-grade synthetic lubricants / Synthetische Schmiermittel für den Lebensmittelbereich
Rocol Rocol
AGIP Foodlube — Foodlube
Hi-Torque 150 Hi-Torque 320
Gear Oil FM
ESSO —
220
—
Klüberoil 4 Klüberoil 4 Klüberoil 4
KLÜBER UH1 N 150 UH1 N 220 UH1 N 320
I riduttori, variatori e rinvii angolari STM forniti STM gearboxes, variators and right andgle Die mit oder ohne Schmiermittelfüllung
completi di lubrificante e non, possono essere drives, supplied with oil or empty, can be used in gelieferten Getriebe, Verstell- und
utilizzati, salvo diverse indicazioni, in ambienti rooms with a temperature from 0 C° and + 50 Winkelgetriebe der STM können, anderweitig
con temperature comprese fra 0 C° e + 50 C°. C°, unless otherwise indicated. In case of lautende Angaben ausgenommen, in
Per condizioni ambientali diverse consultare il different ambient conditions, please contact our Umgebungen mit Temperaturen zwischen 0 C°
ns. servizio tecnico. technical department. und + 50 C° verwendet werden. Bei Vorliegen
abweichender Umgebungstemperaturen
wenden Sie sich bitte an unseren technischen
Kundendienst.
MT01 IGBD 0.7 49

T95
FOLDED SHEAR BEAM LOAD CELL FOR

HIGH ACCURACY WEIGHING
capacities 2t - 20t
The T95 range comprises of a stainless steel load cell complete with tough, painted mounting assembly.
Although the assembly is used in compression, the cell is mounted in a pendulum and operated in tension. This
ensures that the load point is always maintained through the central axis of the cell, even when the assembly is
subjected to considerable movement or misalignment.
The T95 is most suitable for high accuracy applications where movement or vibration is present, eg mixers,
catalyst vessels, weighing platforms, axle weighers and vehicle weigh-in-motion (WIM) systems. The T95 load
cell is also available with ATEX intrinsically safe certification for all gas and dust zones.
For applications in aggressive environments where stress corrosion or acid attack is an issue, a special parylene
coating can be specified as an option. High temperature variants for operation up to 150°C are also available.
■ Stainless steel load sensor ■ Tough and durable paint finish with
Stainless Steel option
■ Fully welded construction sealed to IP68/IP69K
■ 5 year warranty
■ Ease of installation
■ Integral lift off prevention
■ Load cell is always in tension
■ Ideal in vibrating applications
■ OIML C3 approved
■ Unique damping feature
www.thames-side.com
T95
technical specification...
Model T95 ATEX and ICEEx Certification Dimensions

Code Safety Parameters Application Range (kg) 2000 - 10000 20000
A 137 187
II 1 GD B 66 87
Ui = 30 V, Pi = 1.3 W Suitable for all dust and gas zones
EX ia IIC T6 Ga C 35 40.5
Ci = 2.4nF, Li = 8 µH but require safety barriers
Ex ia IIIC T70ºC Da D 32 53
E 32.5 48
Suitable for Gas zone 2. No safety
II 3 G Ui = 30 V, Pi = 1.3 W F 26 36
barriers required. Maximum
Ex nA T6(Ta=-20˚C to +60˚C) Ci = 2.4nF, Li = 8 µH G 15 22
applied voltage of 42V is allowed
H 174 245
Suitable for all dust zones, 20, J 40 57
II 1 D K 182 252
21 and 22. No safety barriers
Ex ta IIIC T80˚C Da IP6X Um=18 V L 135 186
required. Excitation must be
Ta= (-20˚C < Ta < +60˚C) M 200 260
below 18V
N 135 185
P 16 20
Q 170 218
T95 Load Cell R
S
15
70
21
100
T 35 50
Load cell specification Units
Dimensions in mm
Load Cell Capacities 2000, 5000, 10000 20000 kg
+ ve input RED
OIML 3000 - divisions
Rated Output 2 2 mV/V +/-0.1% + ve sense BLACK
Combined Error < +/- 0.017 < +/- 0.05 %*
Non-repeatability < +/- 0.015 < +/- 0.02 %* + ve output GREEN
Temperature Effect on Zero Balance < +/- 0.002 < +/- 0.0025 %* / ˚C
Temperature Effect on Span < +/- 0.0012 < +/- 0.0035 %* / ˚C - ve sense WHITE
Compensated Temperature Range -10 to +40 -10 to +40 ˚C

- ve input BLUE
Operating Temperature Range -40 to +80 -40 to +80 ˚C
Safe Overload 150 150 %* - ve output YELLOW
Ultimate Overload 300 300 %* Electrical Connections

Zero Balance < +/- 2 < +/- 2 %* Via 6-core, 16/0.2mm, 5.7mm outer diameter,
screened polyurethane cable.
Input Resistance 380 380 Ω +/- 5
Screen not connected electrically to load cell.
Output Resistance 350 350 Ω +/- 5
Insulation Resistance > 5000 > 5000 MΩ @ 100V Construction
Recommended Supply Voltage 10 10 V Sensor element
High strength stainless steel type 17-4PH
Maximum Supply Voltage 15 15 V
Mounting assembly
Environmental Protection IP68 / IP69K IP68 / IP69K
Alloy steel, durable painted finish
Cable Length 10 20 m
Shafts
Cable Material Polyurethane Polyurethane Corrosion resisting hardened stainless steel
Nominal Shipping Weight load cell 4 11.5 kg
Nominal Shipping Weight assembly 14 38.5 kg Options
OIML C3 approved, 20t version available in
*With respect to rated output alloy steel
THAMES SIDE SENSORS LTD

DISTRIBUTED BY: Unit 10, io Trade Centre, Deacon Way,
Reading, Berkshire RG30 6AZ
tel: +44 (0) 118 941 1387
fax: +44 (0) 118 941 2004
sales@thames-side.co.uk
www.thames-side.com
Issue: T95.06.14
Our policy is one of continuous product enhancement. We therefore reserve the right to incorporate technical modifications without prior notification.
www.thames-side.com
Rotonivo 3000 / 6000 ®
Rotating level limit switch
The trusted, multifunctional and maintenance free unit for reliable level monitoring
of bulk goods – versatile, modular structure; for application in hazardous locations
(gas and dust). RN 6000 series SIL 2 compliant.
Rotonivo® 3000 / 6000
Suitable for virtually all bulk goods
Insensitive to dust, electrical charge, adhesion,
temperature and pressure
full detector
Simple and reliable measuring principle, easy
and fast installation
®
Application: Rotonivo paddle switches can be used as
full, demand or empty detectors in bulk good silos. They RN 3002 RN 3002
are suitable for applications in a wide variety of materials.
Rotonivo switches are available with international certificates RN 3001
demand detector
for applications in hazardous locations (gas and dust).
Types of Rotonivo flanges: RN 3004
Rotonivo ..002
Full detector with rope
extension or protection
tube, vertical installation
RN 3001
RN 3004
Rotonivo ..001 Rotonivo ..003
Standard design, Design with protection
empty detector
vertical, horizontal tube and angled extension,
and oblique horizontal installation
installation
Rotonivo ..004 RN 3003
Design with
protection tube,
vertical, horizontal
and oblique instal-
lation
Technical Data Housing types
Housing Aluminium IP 66 / NEMA Type 4 RN 3000 RN 6000 RN 6000 RN 6000

standard standard flameproof flameproof,
Pressure range -0.9 up to +10 bar (-13.1 up to +145 psi) increased
safety
Supply voltage Universal Voltage Electronic
AC: 24V / 48V / 115V / 230V, DC: 24V
Signal output Microswitch or Relais

SPDT / DPDT contact
Certificates ATEX II 1/2D and II 2G, INMETRO Various measuring vanes and special solutions
FM Cl. I, II, III, Div.1 Gr. A-G; Zone 1
CSA Cl. I, II, III Div.1 Gr. B-G; Zone 1
TR-CU, IEC Ex, EHEDG, NEPSI-Ex
Boot Rotonivo® 3005
shaped extra compact version
Process -40°C up to +1100°C (3001 / 3002) vane for installation in
temperature range (-40°F up to +2012°F) (3001 / 3002)
loading bellow
Hinged vane
Foldable version for
Bearing Encapsulated ball bearing with shaft sealing
easy insertion through
Process connection G 1", 1½" and 1¼"; a long socket
NPT 1½" and 1¼";
M30x1,5 and M32x1,5;
various flanges available
Material Aluminium or stainless steel 1.4305 (SS303) Rubber vane

For lightweight materials
Process connection or 1.4404 (SS316L)
(e.g. carbon black,
Material measuring Stainless steel 1.4301 (SS304) or 1.4305 styrofoam,
etc.)
(SS316) vane and shaft or 1.4404 (SS303L)
sc303103
UWT GmbH . Westendstr. 5 Tel.: +49 (0) 831/57 123-0 www.uwt.eu

87488 Betzigau . Germany Fax: +49 (0) 831/57 123-10 info@uwt.eu
London Electronics Ltd

INTUITIVE Panel Meters INT2-P Process I/P for 4-20mA, 0-10V etc.
Most Popular panel meter range INT2-I Process Integrator for flow totalising
INT2-T Temperature J,K,T,R,S, PT100
INT2-L 4 and 6 wire loadcells. 10V 120mA exc.
INT2-R Resistance meter. 4 wire sensing.
INT2-C Counter/Rate 6 digits, fully scalable
INT2-S Serial Data I/P for slave display
INT2-H Chronometer / Elapsed timer
INT2-M Millivolt input (shunt etc)

Also available without front-panel buttons
and with remote pushbuttons
Plug-in Output options...
Easy to use Isolated and scalable Analogue output

Clear, variable brightness display 4-20mA - Option ANI
0-10V - Option ANV
Available with digits up to 400mm high
-10 to +10V - Option ANB
Clear written manuals & video guides - online!
Fax +44 1462 850968

www.london-electronics.com
Saves you time and money

Generally available from stock Alarm relays rated 5A 250 VAC resistive
2 alarms - Option AL2
Plug-in options for quick upgrades
4 alarms - Option AL4
Calibration counter for audit trails 2 x SPCO - Option SPCO
Adjustable menu timeout for new users 2 x Solid state - Option DSS
Mirror image display for heads-up applications
Isolated Data output options

These are among the easiest of programmable panel meters RS232 - Option 232
Tel +44 1462 850967

RS485 - Option 485
to commission. And they offer high precision with long
Ethernet - Option EN
term reliability.
Profibus DP - Option PDP
If you normally programme meters via a menu system, you will 1/8 DIN format case, black polycarbonate, IP65 front
help@london-electronics.com
know how tedious and time consuming this can be. This is
why we designed the INTUITIVE series - to save you time. 91.5mm
The INTUITIVE family eliminates the need for menus. This

means faster commissioning and less stress for you.
48mm
44mm
Not only is the meter easy to adjust, the operating manual is
clear, simple and easy to understand.
nel
the pa
mm behind
96mm
You can directly access the setting you want with our unique 125 136mm
“Quick-Step” method. If you want to calibrate the zero, or the
scaling, or the analogue output, or the alarms, or the 11 point Panel cutout should be 92mm wide x 45mm high, +1mm, -0mm
linearisation facility, you get directly to that setting, not down
1/8 DIN. Depth behind panel 125mm max, including cables.
Tel +44 1462 850967
a long menu system via other steps or settings!

350 grammes typical weight
Ordering Guide. Create a full part number like this:-

Analogue Alarm Serial Data Display Supply Special
Meter input type Output Output Output Colour Voltage Requirements
Process INT2-P No output -0 No alarms -0 No data -0 Red -R 100-240VAC-AC None -0

Integrator INT2-I 4-20mA -ANI 2 alarms -AL2 RS232 -232 Green -G 11-30VDC -DC 8 memories*^ -MEM
Temp INT2-T 0-10V -ANV 4 alarms -AL4 RS485 -485 Yellow-Y
IP67 cover -SPC4
Fax +44 1462 850968
Loadcell INT2-L -10/+10V -ANB 2xSPCO -SPCO Ethernet^ -EN

Dual SS - DSS Profibus^ -PDP Factory Scaled -FS
Ohms INT2-R
Chrono INT2-H Plain lens -PL
Counter INT2-C Wall Box IP65 -WB
RS232 INT2-S2 Remote buttons^ -RB
RS485 INT2-S4 Example part number = INT2-P-ANI-AL2-0-R-AC-SPC4-FS Fast update^ -100X
Millivolt INT2-M
* Only available on -P and -L meters. ^ Reduces some options/specs.
An automated version of this guide is available at http://www.london-electronics.com/pl_int2.htm
17
INT2-C Versatile Counter / Totaliser / Frequency / RPM Display. NPN, PNP, contact, TTL up to 40Khz. Quadrature inputs up to
5kHz. 24V Excitation rated to 60mA. Also available to order for NAMUR inputs. 6 digit display capacity to 999999. A second input
port allows you to add two pulse trains together, subtract one from the other, gate pulses with a logic level or change count
direction by logic level. Up to 4 inputs can be simultaneously totalised
INT2- H Timer with either pure numeric readout up to 999999 or with clock format readout HH:MM:SS. Can count up from 0 or
down to 0 from a preset. Contact closure or logic inputs for start, stop and reset. Precision real-time clock included.
INT2- I Flow Integrator 4-20mA and 0-10V integrator. Accepts signals proportional to flow and calculates total. 24V Excitation
rated to 60mA. Stores total in non-volatile memory. Display range max 0-99990. Last digit selectable to count by 1, 2, 5, 10, 20 or
50. Remote logic inputs for tare (force to zero), reset, peak and valley. Rear panel security lock.
INT2-L Loadcell Display for 4 wire and 6 wire loadcells. An ideal general purpose weighing indicator. 10V excitation rated to
120mA . Last digit selectable to count by 1,2,5,10,20 or 50. Variable filtering / averaging. Remote logic inputs for tare (force to
zero), reset, peak and valley. Rear panel security lock. Alarm relays offer manual or automatic inflight correction. Includes an
independent scale and offset feature, separate from the calibration, so you can change from imperial to metric or any other
measurement ratio without having to recalibrate the meter.
INT2-M Scalable millivolt display. Ideal for use with DC Shunts for measuring high DC currents. We can offer with a special
current alarm feature for monitoring overload on DC motors, which can be set to ignore start-up current surge and only monitor
current after a preset time from startup. For loadcell or bridge input applications, see INT2-L
INT2-P Process display which accepts 4-20mA, 0-10V, 1-5V, 0-10mA input. Ideal for all general purpose process measure-
Fax +44 1462 850968

ments, such as flow, pressure, level, humidity etc. 24V Excitation rated to 60mA. Last digit count by 1,2,5,10,20 or 50. Variable
filtering / averaging. Remote logic inputs for tare (force to zero), reset, peak and valley. Rear panel security lock.
INT2-R Resistance Display for low to medium resistance measurements. 4 wire connection method gives precise results,
regardless of cable resistance. Ideal for QA checks of motor windings, lamp filaments, inductors, etc. Ranges to order, from 0-
100 milliOhms, up to 0-20 Kilohms
INT2-S2 or INT2-S4 Serial Data Display for slave and remote applications. Accepts RS232, RS422, RS485 in ASCII format.
Tel +44 1462 850967

Addressable 00 to FF. Able to extract data from complex strings. 300, 600, 1200, 2400, 9600 baud rate. You can also add strings
together to give a total value, useful in batching and totalising applications.
INT2-T Simple Temperature Display. Accepts J, K, T, N, R, S & PT100 DIN& ANSII sensors. Covers the full operating range of
each sensor type and displays in Degrees C or F.
. Anatomy of the INTUITIVE Mk2 series
= Detachable screw terminal
Optional Alarm
outputs
Excitation to
sensor(s)
Input Signal(s)
from sensor(s)
8.8.8.8.8.8.
8.8.8.8.8.8. 2 relays = option AL2
4 relays = option AL4
Normally open, normally
closed, normally
Digit OK energised or normally
Logic inputs
de-energised. Fully
Tel +44 1462 850967
Tare configurable, with

Reset adjustable hysteresis.
Peak/valley
Calibration Lock SPST or SPDT versions.
Alarm Lock 2 x SPCO option
2 x solid state option
Power Relays rated 2A at 250V

Optional Data Optional Isolated AC, from same phase.
100 - 240 VAC output scalable analogue You can add input or
or 11-30VDC RS232 output. output options to your
Fax +44 1462 850968
or 5V DC RS485 4-20mA = option ANI display at any time,

8 Watts Modbus 0-10V = option ANV whenever you need to
Ethernet -10 /+10V = option ANB upgrade or add or
600 Ohms drive change features.
For detailed technical information and manuals for this product, please see london-electronics.com where you
can find all our technical manuals and online streaming video guides to show you all you need to know.
18
New version 2014
Fox
Rotary limit switch
Fox is a device used to control the movement of industrial Options

machinery when in need of measuring the movement on
the basis of the rotation angle and/or of the number of shaft Fox can be fitted with different combinations of actuators
revolutions. Fox is made up by a gearmotor which transfers and motion detectors: sets of cams and microswitches
the movement to the cams and to the other movement (max. 4), potentiometers or encoders (max. 1), absolute
detection devices placed inside it through a primary input encoder Yankee 1 for set of cams and microswitches (max.
reduction step (worm gear and helical toothed gear) and 1). Furthermore, there is a special seat for the integrated
one or more secondary output steps (pairs of straight assembly of an incremental encoder Yankee 2 used for the
toothed gears). worm gear shaft movement detection and for managing all
other actuators and motion detectors. It is possible to fit
Fox is used on wind turbines to control the position of the together sets of cams and microswitches, potentiometers,
nacelle or the pitch angle of the blades. The motor that encoder and Yankee 1 and 2, thus creating a device
controls the rotation of a wind turbine on the yaw axis featuring redundancy and diversity.
(or of the blade around its longitudinal axis) transfers The limit switch is available with a flange for direct coupling
the movement to the limit switch. A rotary encoder reads to the motor. Different labels and colors are also available.
the rotation of the shaft, and its pulses are sent to a PLC
which controls the position of the nacelle or of the blade. Materials
The movement of the shaft is also transferred, through a
Fox features transmission and gear driving shafts made
gearmotor, to a series of cam switches: the appropriate
of stainless steel AISI 430F or AISI 303, worm gear
setting of the actuating point of the cams can signal up to
transmission shaft rotating on ball bearings, self-lubricating
four critical positions of the movement of the nacelle or of
techno-polymer gears and driving bushes, techno-polymer
the blade.
base and cover. All techno-polymers used for the enclosure
Features are wear resistant and protect the equipment against water
and dust.
Revolution ratios, ranging from 1:3 to 1:2800, result from
the combination of different secondary output steps. Each
cam can be set with great accuracy thanks to the cam
adjusting screws. The auxiliary switches are of a positive
opening type, thus suitable for safety functions.
Industrial Construction Industrial Stage Wind

lifting lifting automation technology energy
13012014-01
business partner
Standards - Markings - homologations
- Conformity to Community Directives: EN 60947-1 Low-voltage switchgear and controlgear
2006/95/CE: Low Voltage Directive EN 60947-5-1 Low-voltage switchgear and controlgear - Control
2006/42/CE: Machinery Directive circuit devices and switching elements - Electromechanical control
circuit devices
- Conformity to Standards:
EN 60529 Degrees of protection provided by enclosures
EN 60204-1 Safety of machinery - Electrical equipment of machines
EN 60204-32 Safety of machinery - Electrical equipment of machines
- Markings and homologations: C
- Requirements for hoisting machines
General technical specifications

- Storage ambient temperature: -40°C/+80°C - Maximum rotation speed: 800 rev./min.
- Operational ambient temperature: -40°C/+80°C - Cable entry: cable clamp M20, M20+M16, M20+M20
- Protection degree: - HALT test (data available on request)
IP 66 / IP 67 / IP 69K
- Markings and homologations: C SIL 1
- Insulation category: Class II
c SIL 2 (U pending)
Technical specifications of the microswitches
- Utilisation category: - The snap action switch PRSL0100XX has 1 NO + 1 NC change over
AC 15 / 250 V / 3 A max. contacts.
DC 13 / 60 V / 0.5 A max. - The snap action switch PRSL0110XX has 1 NO + 1 NC change over
- Rated thermal current: 10 A max. contacts, double break.
- Rated insulation voltage: 300 Vac - The slow action switch PRSL0111XX has 1 NC contact, double break.
- Mechanical life: 1.5x106 operations max. All NC contacts are of the positive opening operation type .
- Terminal referencing: according to EN 50013 The switches have the following reference for internal wiring.
- Connections: screw-type terminals
- Markings and homologations:
PRSL0100XX: C (general purpose)
PRSL0110XX-PRSL0111XX: C U (c pending)
12 14 13 21
11
11 14 22 12
PRSL0100XX PRSL0110XX PRSL0111XX
Overall dimensions (mm)

Standard With flange
142
117
75 109 84,8 129,1
Possible assemblies
With set of cams,
Yankee 1 absolute encoder and Yankee 1 Yankee 2
Yankee 2 incremental encoder absolute encoder incremental encoder
The data and the products illustrated in this brochure may be modified without notice. Under no circumstances can their description have a contractual value.
TER Tecno Elettrica Ravasi srl www.terworld.com

22012014-02
Via Garibaldi 29/31 - 23885 Calco (LC) - Italy

Registered Office - via San Vigilio 2 - 23887 Olgiate Molgora (LC) - Italy
Tel. +39 0399911011 - Fax +39 0399910445 - E-mail: info@terworld.com
Technical specifications of the microswitches
Code PRSL0100XX PRSL0110XX PRSL0111XX

AC 15
Utilisation category AC 15
DC13
125 V / AC 15
Rated operational voltage 230 V / AC 15 250 V
60 V / DC 13
2 A / 125 V / AC 15
Rated operational current 1 A / 230 V / AC 15 3A
0,5 A / 60 V / DC 13
Rated thermal current 6A 10 A
Rated insulation voltage 250 V~ 300 V~

Mechanical life 1,5x10 operations
6
1x106 operations
Terminal referencing According to EN 50013 According to EN 50013
screw-type terminals with self-lifting
Connections screw-type terminals with self-lifting pads
pads
1x2.5 mm2, 2x1.5 mm2
Wires 0,25 mm2 - 1,5 mm2 (UL: copper conductor (CU) 60°C or 75°C with soft or stiff
wire 14-16 AWG)
Tightening torque 0,5 Nm - 0,6 Nm 0,5 Nm
Switch type Single break, snap action Double break, snap action Double break, slow action
1NO + 1NC change over 1NC
1NO + 1NC change over
(All NC contacts are of the (All NC contacts are of the
Contacts (All NC contacts are of the positive
positive opening operation positive opening operation
opening operation type )
type ) type )
12 14 13 21
11
Scheme
11 14 22 12
Markings and C C U
homologations (general purpose) (c pending)
Technical specifications of the potentiometers
Code with support PA020001 PA020002

Ohmic value 10 kΩ 10 kΩ mechanical stop
Resolution Infinite
Independant linearity ± 1%
Life time 10x10 movements
6
Operational ambient temperature -55°C / +105°C

Continuos rotation (without stop) 360°
Continuos rotation (with stop) 333° ± 5°
Actual electrical angle 310° ± 5°
Ohmic value tolerance ± 20%
Code with support PA020003 PA020004 PA020005

Ohmic value 5 kΩ 10 kΩ 10 kΩ
Connections 4 turrets 3 turrets 4 turrets
Indipendent linearity (over AEA -3°) ≤±1% ≤ ± 0,35 % ≤±1%
Life time 5x10 movements
6

Mechanical angle 360° continuous
Actual Electrical Angle (AEA) 340° ± 5°
Ohmic value tolerance max ± 20 % at 20°C
13012014-03
Fox - Ro ta ry l i m i t s w i tc h
Technical specifications of the encoders
Code with support PA030001 PA030002
Resolution 36 pulses/rev. 150 pulses/rev.
Code Incremental
Supply voltage 4,5 Vdc min. to 30 Vdc max. (35 mA max. - no load)
Low: 500 mV max. at 10 mA
Output voltage High: (Vin – 0,6) at -10 mA (Vin – 1,3) at -25 mA
Output current 25 mA max. load per output channel
Output format Two channel (A, B) quadrature with Index (Z)
Phase sense A leads B clockwise (CW) from the mounting end of the encoder
Accuracy +/- 0,8 arc-min.
Outputs Push pull
Electrical protection Reverse polarity and output short circuit protected
Technical specifications of the absolute encoder Yankee1

Code PA01AA01 PA01AB01 PA01AC01
Analog Output Current 4÷20mA Voltage 0÷10V PWM 0÷100%
Power supply 12 ÷ 48 VDC / 12 ÷ 48 Vac
Protection against polarity inversion yes
Absorption 50 mA
Resolution 12 bit
Linearity +/- 0,5°
Max. hysteresis 0,1°
Setting Zero Point through button/wire
Signal increment direction CW (standard) / CCW (on request)
Connections terminal board
Technical specifications of the incremental encoder Yankee 2

Code Codes on request
Incremental A, B, Z
Output
Push-pull (0 ÷ Vcc)
Power supply 5 ÷ 30 VDC
Absorption 50 mA
Resolution 2 ÷ 1024 imp./rev.
Connections terminal board

13012014-04

Overall dimensions (mm)
Standard
48,5 74,5
38,1
7
56,2
46,1
18,1
5,5
8
140,6
31,6 109 75
105
117
8,5
44
Ø12h8
17
12
16 16
35,4 102 32
With flange
75,8 74,5
38,1
7
56,2
46,1
18,1
5,5
167,6 75
20,7 109
8
105
117
142
30,5
44
Ø12h8
Ø74
30,5
5
30,
5 30,
,2
Ø6
37,9 129,1 84,8

13012014-05
Detailed drawing
52
51
50
48
47
1 46
45
2
3
5
44
6 49
PRSL0100XX 43
4
PRSL0110XX
42
PRSL0111XX 41
40
39
38
7
36 37
35
8
9 34
33
10
32
11
31
12
30
16 15 14 13
24 25
22 26
23
27
21 28
29
17 18 19
20

13012014-06

Components
Switches
Ref. Drawing Description Scheme Code

13 21
1NO+1NC switch
PRSL0110XX
double break, snap action
14 22
4
11
1NC switch
PRSL0111XX
double break, slow action
12
12 14
1NO+1NC switch
6 PRSL0100XX
single break, snap action
11
Standard cam sets
Ref. Drawing No. and type of cams No. and type of switch Set code
2 cams D 2 PRSL0110XX switches FCL20001
Cams D+E 2 PRSL0110XX switches FCL20003
Cams D+E 2 PRSL0111XX switches FCL20004
2 cams E 2 PRSL0110XX switches FCL20005
Cams F + F + C + B 4 PRSL0110XX switches FCL40001
3
Cams F + F + C + B 4 PRSL0111XX switches FCL40002
Cams D + D + E + E 4 PRSL0110XX switches FCL40005
Cams D + D + E + E 4 PRSL0111XX switches FCL40006
Cams E + E + E + A 4 PRSL0110XX switches FCL40009
Cams E + E + E + A 4 PRSL0111XX switches FCL40010
Cams D + D + A + A 4 PRSL0110XX switches FCL40011
Cams D + D + A + A 4 PRSL0111XX switches FCL40012
2 cams D 2 PRSL0100XX switches FCN20001
Cams D+E 2 PRSL0100XX switches FCN20002
2 cams E 2 PRSL0100XX switches FCN20003
Cams F + F + C + B 4 PRSL0100XX switches FCN40001

5 4 cams D 4 PRSL0100XX switches FCN40002
Cams D + D + E + E 4 PRSL0100XX switches FCN40003
4 cams E 4 PRSL0100XX switches FCN40004
Cams E + E + E + A 4 PRSL0100XX switches FCN40005
Cams D + D + A + A 4 PRSL0100XX switches FCN40006
13012014-07
Cam reference chart
Code for Code for Code for Code for
Cam Mechanical PRSL0110XX PRSL0100XX Cam Mechanical PRSL0110XX PRSL0100XX
angle PRSL0111XX switches angle PRSL0111XX switches
switches switches
A 180° PRSL7191PI PRSL7121PI D - PRSL7194PI PRSL7124PI
B 320° PRSL7192PI PRSL7122PI E 60° PRSL7195PI PRSL7125PI
C - PRSL7193PI PRSL7123PI F 72° PRSL7196PI PRSL7126PI
Sensors, potentiometers and encoders
Ref. Drawing Description Code

Yankee 1 - current output PA01AA01
1 Yankee 1 - voltage output PA01AB01
Yankee 1 - PWM output PA01AC01
42 Yankee 2 Codes on request
Potentiometer MCB 10 kΩ with support PA020001

Potentiometer MCB 10 kΩ mechanical stop with support PA020002
45+44 Potentiometer Sfernice 10 kΩ ±10% 4 pins with support PA020003
Potentiometer Sfernice 10 kΩ ±10% 3 pins with support PA020004
Potentiometer Sfernice 5 kΩ ±10% with support PA020005
44 Support for potentiometer PA020000
Encoder 36 pulses./rev. with support PA030001

47+46
Encoder 150 pulses./rev. with support PA030002
46 Support for encoder PA030000
Pinion gears

Pinion gear M10 Z12 with pin PRSL0911PI
17 Pinion gear M20 Z8 with pin PRSL0915PI
Other pinion gears available: see “Gears and pinion gears” catalog

13012014-08

Accessories
15+16+21 Flage with screws and pins PRSL0356PI
18 Innesto maschio con spina PRSL0919PI
19 Female coupling with pin PRSL0920PI
20 Coupling with pin PRSL0981PI
23 Feet PRTR0150PE
25+26+27
Fixing plate PRSL0425PI
+28+29
32 Cable clamp M20 PRPS0064PE
33 Cable clamp M16 PRPS0062PE
36 Cover holding wire PRVV9140PE
51+50 Cover with tightening rubber PA090005
Remarks
13012014-09
Standard limit switches
All standard limit switches are equipped with cams PRSL7194PI for PRSL0110XX and PRSL0111XX switches, PRSL7124PI for
PRSL0100XX switches and shafts made of stainless steel AISI 430F.
Switches
PRSL0100XX PRSL0110XX PRSL0111XX
12 14 13 21
Rated Real Number of 11
revolution revolution cams and

ratio ratio switches 11 14 22 12
1NO+1NC 1NO+1NC 1NC

Code Code Code
2 PFB9067A0016002 PFB9067E0016002 PFB9067E0016004
1 : 15 1 : 16 3 - PFB9067E0016007 PFB9067E0016008
4 PFB9067A0016003 PFB9067E0016003 PFB9067E0016005
2 PFB9067A0020001 PFB9067E0020003 PFB9067E0020005
1 : 20 1 : 20,21 3 - PFB9067E0020009 PFB9067E0020010
4 PFB9067A0020002 PFB9067E0020004 PFB9067E0020006
2 PFB9067A0027007 PFB9067E0027004 PFB9067E0027006
1 : 25 1 : 27,27 3 - PFB9067E0027008 PFB9067E0027009
4 PFB9067A0027008 PFB9067E0027005 PFB9067E0027007
2 PFB9067A0062006 PFB9067E0062005 PFB9067E0062006
1 : 50 1 : 62 3 - PFB9067E0062010 PFB9067E0062011
4 PFB9067A0062009 PFB9067E0062003 PFB9067E0062007
2 PFB9067A0075005 PFB9067E0075002 PFB9067E0075003
1 : 75 1 : 75,48 3 - PFB9067E0075005 PFB9067E0075006
4 PFB9067A0075006 PFB9067E0075001 PFB9067E0075004
2 PFB9067A0103009 PFB9067E0103004 PFB9067E0103005
1 : 100 1 : 103,44 3 - PFB9067E0103009 PFB9067E0103010
4 PFB9067A0103008 PFB9067E0103002 PFB9067E0103006
2 PFB9067A0162006 PFB9067E0162003 PFB9067E0162005
1 : 150 1 : 162,52 3 - PFB9067E0162007 PFB9067E0162008
4 PFB9067A0162007 PFB9067E0162004 PFB9067E0162006
2 PFB9067A0222005 PFB9067E0222003 PFB9067E0222004
1 : 200 1 : 222,58 3 - PFB9067E0222006 PFB9067E0222007
4 PFB9067A0222001 PFB9067E0222001 PFB9067E0222005
2 PFB9067A0254003 PFB9067E0254002 PFB9067E0254004
1 : 250 1 : 254,57 3 - PFB9067E0254006 PFB9067E0254007
4 PFB9067A0254004 PFB9067E0254003 PFB9067E0254005

13012014-10

Fox - Request form for non standard limit switches
Cam set Cams Revolution ratio
Standard Customised Codes for Codes for
cam set* cam set* PRSL0110XX PRSL0100XX 1:15 1:150
PRSL0111XX switches
1:20 1:200
SWITCHES
switches
CAMS
A (180°) PRSL7191PI PRSL7121PI 1:25 1:250
Standard Customised 1:50 1:300

cam set* cam set* B (320°) PRSL7192PI PRSL7122PI
1:75 1:450
SWITCHES
C PRSL7193PI PRSL7123PI
CAMS
1:100 1:
D PRSL7194PI PRSL7124PI Male coupling

Standard Customised
cam set* cam set*
E (60°) PRSL7195PI PRSL7125PI
Female coupling
SWITCHES
F (72°) PRSL7196PI PRSL7126PI

CAMS
Coupling
(Degrees correspond to mechanical angle)
* Mark theotherwise
number corresponding to the cam set required, if Switches
standard; mark the letters corresponding to the single
cams and switches required. (The three cam sets can have only
PRSL0110XX or PRSL0111XX switches). X PRSL0100XX Flange
Y PRSL0110XX
Standard cam sets
Switches Z PRSL0111XX Pinion gear
PRSL0100XX
PRSL0110XX
PRSL0111XX
Pre-set for Yankee 2

PRSL0911PI M10 Z12
Cams
Yankee 2 PRSL0912PI M12 Z10
D D 1 10 21
PRSL0913PI M14 Z10
D E 2 11 22
PRSL0914PI M16 Z10
E E 3 12 23
PRSL0915PI M20 Z8
Potentiometer
D D D - 13 24
PA020001 PRSL0916PI M5 Z12
E E E - 14 25
PA020002 PRSL0917PI M6 Z11
F F C B 4 15 26
PA020003 PRSL0918PI M8 Z12
D D D D 5 16 27
PA020004 PRSL0944PI M12 Z12
D D E E 6 17 28
PA020005
Customised M Z
E E E E 7 18 29
Encoder Cable clamp

E E E A 8 19 30
PA030001 M20 M20 + M16
D D A A 9 20 31
PA030002 M20 + M20
Shaft
Yankee 1 * Shaft made of stainless steel
PA01AA01 AISI 430F
Shaft made of high resistance
PA01AB01 stainless steel AISI 303
PA01AC01
* Programmable
13012014-11
Tilt Switches and Control Units 11/7/01 3:36 PM Page 1
Senses and Controls Solid & Liquid Levels
PRO-LINE
Tilt Switches and Control Units
Heavy-Duty
Light-Weight Heavy-Duty 2” Probe
(Plastic) Probe Standard Probe Model 20-32
Model 20-31 Model 20-39
Model 21-39
Stainless Steel
Probe Float Ball Control Unit
Model 20-30-SS Accessory Model 20-43
• Rugged, abrasion-resistant tilt • Conveyor belt misalignment detector. cuit in the control unit prevents momen-
switch. • Level control in volumetric batching. tary tilting of the switch from causing a
• Simple installation. • Crash probe for tripper car. false or premature contact transfer. An
• Control unit is solid state, printed • Starvation or no-flow detector for belt internal jump wire permits selection of
circuit board construction. and vibratory feeders. "Normal" condition either with the tilt
• Adjustable time delay to 10 sec- switch vertical or tilted. Two normally-
onds - Prevents false trips. The Pro-Line tilt switch is actuated when open and two normally-closed output
• Control unit standard NEMA 4X material rises to tilt the probe 15 contacts are available for connection to
enclosure (Model 20-43) or without degrees or more from its vertical posi- external alarms and/or controls.
enclosure (Model 20-43-1) for tion. The mercury switch is precisely Interruption of line power causes a relay
control panel mounting. positioned so that, regardless of direc- transfer.
• Performance proven in thousands of tion of tilt, the normally-closed contacts
are caused to open. The switches are Various probe assemblies are available
applications throughout the world.
encapsulated in various sizes to suit the for application with a wide variety of
• All probes include mounting
application. materials and environmental conditions
hardware.
(see chart on back side for description
APPLICATIONS The Model 20-43 control unit is of available probe assemblies.) The
• High level detector in bins and vessels housed in a NEMA 4X box with green control unit is also available without
containing a wide variety of materials. ("Normal") and red ("Alarm") indicating enclosure for mounting in other types of
• Chute or transfer point plug-up lights inside a clear front enclosure. enclosures and control panels (Model
detector. A 0-10 second adjustable time delay cir- 20-43-1.)
501 90th Avenue NW • Minneapolis, MN 55433

Tilt Switches and Control Units 11/7/01 3:36 PM Page 2
SPECIFICATIONS
METAL ENCLOSURE
PROBES (See Table Below) AVAILABLE
Contact Rating: MODEL 20-43 (NEMA 4X) UPON REQUEST
( Model 20-41 ) 4 amperes at 110 VAC.
( All Other Probes ) 1 ampere at 24 VDC,
Non-inductive
Temperature Rating: MODEL 20-43-1
-25°F - 180° F Standard (Board Only)
180°F - 390° F Special (20-39 C Series)
Below -25°F (20-39 B Series)
CONTROL UNIT (See Drawing)
Relay Contact Rating:
10 amperes at 115 VAC, non-inductive
( DPDT Contact Agreement )
Time Delay:
0-10 seconds, adjustable
Temperature Rating:
-40° F - +158° F
-40° C - +70° C
Case Size:
( Model 20-43 )
6.89" High x 4.92" Wide x 3.90" Deep
Printed Circuit Board Size:
( Model 20-43-1 ) 5.95" High x 4.4" Wide
Circuitry:
Selection of vertical or tilted probe position
for "normal" condition
Power Requirements:
20-43, 20-38 (metal box) are available in 110
or 220 VAC versions, 50/60Hz ±10% Dimensions shown
in inches and MM
(in parenthesis)
TILT SWITCH PROBE SELECTION TABLE

Overall (Including
Model No. Description Finish Length Diameter Hanger Assembly) Weight
20-39 Standard Probe Nickel Chrome 8 1/4" 1 1/4" 2 1/2" 1.5#

20-31 Light-Weight, 1" Plastic Probe PVC 9" 1" 2" 0.5#
20-32 Heavy-Duty, 2" Probe Acrylic Enamel 10" 2" 4" 8#
20-33 Buoyant, Plastic Slurry Probe PVC 19" 1" 1" 1#
20-30-SS Stainless Steel Probe 304 SS 10 1/4" 1" 2" 1#
20-39B *Low-Temp. (Below -25° F) Nickel Chrome 8 1/4" 1 1/4" 2 1/2" 1.5#
20-39C Hi-Temp. (180-390° F) Nickel Chrome 8 1/4" 1 1/4" 2 1/2" 1.5#
21-39 **Class I & II, FM Approved Nickel Chrome 8 1/4" 1 1/4" 2 1/2" 1.5#
20-41 Standard Probe, 110 VAC Nickel Chrome 8 1/4" 1 1/4" 2 1/2" 1.5#
20-41-SS Stainless Probe, 110 VAC 304 SS 10 1/4" 1" 2" 1#
* Requires Model 20-38 - B - 4 Control

** Requires Model 21-38 Control
Accessories include wear paddles, float balls and fins that are easily attached. Standard cable lengths are 25 feet unless otherwise specified.
501 90th Avenue N.W.

Minneapolis, MN 55433
(763) 783-2500 FAX: (763) 783-2525
www.thermoramsey.com
CERTIFICATION NO. 99-HOU-AQ-8174
Thermo Ramsey Companies in:
Australia Italy Spain
Canada Mexico The Netherlands
Germany South Africa United Kingdom
Catalog No. 20.400 (Rev. 9/01) Printed in U.S.A. SP

Modular Explosion Proof Brakes
IECLine
2013 rev 0
INDEX
PAG1 About VIS
PAG2 Application example, Main characteristics, Standards
PAG3 Certificates and available protection classes
PAG4 Identification and options
PAG5 Technical data - performance and options
PAG6 Technical data, Brake choice
PAG7 Technical data - Brake choice
PAG8 Overall Dimensions

Explosion proof Brakes
A product invented and produced by Coel Motori, Milano, Italy

About VIS
VIS is a product of COEL, specialized manufacturer of brake motors located in Italy.
Since 1976 COEL designed and munufactured brake motors making all the components including the
brake units in its facilities (see www.coelmotori.it for further details).
Thanks to this large experience, on 2005 we invented VIS, the modular ATEX brake system.
Our idea was based on the market demand of a easy solution to make a brake motor without modifica-
tion of the motors or extension of the certificates.
With more than 30 years of experience in manufacturing brakes, we defined a new oversized stand-
ard, able to guarantee a range of modular brakes designed for heavy duty.
More than 35 controls made in the production process make each VIS brake as a master piece.
All the components are tested 100%, all the working parameters controlled with functional tests made
on each brake.
The VIS brakes range is in continuous development in order to make the quality and performance
better and better.
For hoisting, travelling, positioning in Hazardous location the VIS brakes are the safe and reliable
solution.
What’s VIS?
The VIS Atex brake is an innovative modular flameproof spring applied disc brake unit.
The new concept is to apply an independent brake unit to a standard flanged explosion proof motor or to
a transmission unit. The flangess input and output follow both IEC or NEMA standards. The VIS brakes are
certified as independent components. It means that there are not coupling procedures in order to define
the certification.
Why VIS?
The VIS brake is available in B5 flange face to face version (IEC 63 to 280 ), NEMA standards (56 to 405)
and compact version for mounting in the rear part of a motor or to a transmission unit. This catalogue is
related to IEC Line.
The assembling is very fast.
Choosing the VIS brake, it’s very easy to make an explosion proof brake motor, reducing costs and
delivery time.
The performance of VIS brakes is particularly high and the strong structure makes them suitable for
very heavy duty and for every kind of application (hoisting, travelling, positioning...).
VIS brakes don’t need periodical maintenance such as adjustment of gap on work site.
The braking torque values are included between 5 to 2000 Nm (depending on frames) and the elec-
tromagnets fitted inside the VIS brakes can be AC three phase or DC for IEC and DC for NEMA.
The cost of a standard explosion proof motor plus the VIS brake is considerably lower than an
explosion proof brake motor and the delivery time and reliability are much better.
1
Application example
Standard B5 motor + VIS brake Standard B5 motor + VIS brake + gearbox unit
Main Characteristics
-PATENT pending design and concept system

-Three phase AC (IEC 80 to 160) or single phase DC electromagnets
-Totally closed
-IP66
-Power supply VAC24 to 690 50-60Hz three phase or VDC 24 to 300.
-F class insulation
-Thermally protected with dual metal protectors as standard
-Large terminal box with terminal board and fitted in rectifier (DC only)
-Very high resistance structure
-Designed for S1 duty without ventilation
Standards
The VIS series brakes are designed and approved for the following directives:
- ATEX Directive ATEX 94/9/CE-ATEX 95,Group II 2GD category - Group I M2 category, in compliance
with the normsEN 60079-1:2007, EN 60079-0:2009, EN 60079-31:2009
CERTIFICATE INERIS06 ATEX 0047 additions 01,02,03,04,05
- INMETRO Directive ABNT NBR IEC 60079-0:2008 ABNT NBR IEC 60079-1:2009
CERTIFICATE NCC Certificado N° NCC 11.0574 X
- IEC Ex Directive IEC 60079-0 : 2007-10 IEC 60079-1 : 2007-04 IEC 60079-31 : 2008 Groups I, II, III
CERTIFICATE IECEx INE 11.0037X
2
Certificates and available protection classes
For each certification of VIS brakes there are different protection levels avasilable as follows
ATEX IEC Ex
GAS
II 2 G Ex d II P 1 T P 2 Gb Tamb. : -50°C ÷ +55( for T5 Tamb:
+60°C) or -20°C ÷ +55( for T5 Tamb: +60°C).
DUSTS
II 2 D Ex tb IIIC T P 3 Db IP66 Tamb. : -50°C ÷ +55( for classe T100°C
Tamb: +60°C) or -20°C ÷ +55( for class T100°C Tamb: +60°C).
GAS and DUST

II 2 GD Ex d II P 1 T P 2 Gb
Ex tb IIIC T P 3 Db IP66
Tamb. : -50°C ÷ +55( for class T5 or T100°C Tamb: +60°C) or -20°C ÷ +55( for class
T5 or T100°C Tamb: +60°C).
I M2 Ex d I Mb Tamb. : -50°C ÷ +55°C oppure -20°C ÷+55°C
Pn are subjected to the following variations:
P1 for GAS groups if:

-.P1 = B : gas group IIB.
- P1 = C : gas group IIC.
P2/P3 for temperature classes/surface temperature:

- P2 = T3 P3 = T200°C
- P2 = T4 P3 = T135°C
- P2 = T5 P3 = T100°C
- 50°C ÷ + 55°C (for class T5 o T100°C Tamb: +60°C) = Amb Temp.

- 20°C ÷ + 55°C (for class T5 o T100°C Tamb: +60°C)= Amb temp for frames 250/280
T.cable : 80°C= Cable temperature
INMETRO
» Category: 2G / 2D /2GD
» Type of protection: Ex d / Ex tD A21
» Enclosure group: II B / II C
» Temperature class: T3 / T4 / T5
» Maximum surface temperature: T200°C / T135°C / T100°C
» Protection mode: IP66
» Ambient temperature -50°C +55°C (available as option on frames 63 to 225) or -20 +55°C (standard for
frames 63 to 280)
3
Options
- Hand release (not available for IEC frames 250 and 280)
- Ready for hand release kit
- PTC thermistors
- Anti condensation heaters
- Switch on brake opening or on hand release
- Special flange coupling
Hand release Hand release ready
Ordering a VIS brake
For ordering a VIS brake it’s necessary to supply the following information:
1) Type of certification required and protection classes needed

2) Input and output flange / shafts dimensions
3) If AC or DC
4) Voltage needed
5) Brake torque required
6) Options required
All the brakes are available in different voltages and brake torque values
Please see the performance data in order to correctly identify the brake
4
Technical data
General information
The spring-applied brake VIS is a single-disk brake with two friction surfaces.
The compression springs create the braking torque by friction locking. The brake is released electromag-
netically.
The spring-applied brake is designed for the conversion of mechanical work and kinetic energy in heating.
For operation characteristics see related paragraph.
Manual release (not applicable for IEC 250 and 280)
The manual release is an option available, it gives the possibility to release the brake in absence of current.
It is a mechanical lever mounted on 2 fulcrums points moving the mobile anchor.
Microswitch
The VIS brakes can be equipped with a microswitch for air-gap or wear monitoring or for hand relase
opening monitoring. The user must provide the corresponding electrical connection.
Thermistors
All the VIS brakes are equipped with a PTO thermal protection with temperature limit related to the
temperature class of the brake required. It must always be connected when operating in order to prevent
extra heating in hazardous areas.
In alternative, we can apply a PTC thermistor to have a constant monitoring of the brake temperature
through an exthernal PLC.
Performance Data (IEC version)
* values obtained with rectifier type WR2008
5
Technical data
Loads
IEC VIS brakes line is designed to be mounted in front of a flanged motor; the bearing used in the input
shaft has the only function to support the coupling between the motor and brake sahfts and cannot be
subjected to additional axial or radial loads. The output shaft admissible radial loads of IEC VIS brakes line
are described in the following tab.
Frame N Load at shaft center

63-71 250
80-90 380 N
100-112 550 max
132-160 790
180-225 1700
250-280 3400
Braking time
VIS brakes are suitable for application with disk sliding of the disk of 0,5 seconds maximum.
In case of longer time of sliding of the disk calculation, please contact us.
You can use the following formula in order to define the braking time:
Jtot: inertia moment at the motor shaft (Kgm2)
J tot x n tx
n: speed r.p.m.
+ Mf: braking moment (Nm)
± Mload) tx: brake time response (ms)
9.55 (Mf 1000
Mload: resistent moment to the load applied (Nm), positive or
negative depending on concordance with braking moment.
Note: for calculation of sliding time of the disc, consider the “tx” value at “0” .
Brake choice
AC or DC?
When you choose a VIS brake, it is important to define which version is better suitable for your applica-
tion and/or for your electrical equipment.
The 3 phase version is very quick both in engagement and braking times, so it is suggested for applica-
tion where there are high number of cycles per hour.
Since this brake is very quick it also creates more impact vibration in starting and braking operation compared
to DC.
The 3 phase brake is suitable to be connected direct on line with the same voltage of the motor you have
and without rectifier and it is available with voltages from VAC24 up to VAC690 Hz 50 or 60.
The DC version has a smooth perfromance, but can also be quick using a special rectifier for fast
braking connection cutting the DC current.
It is available from 24 to 300 VDC with rectifier.
6
Brake choice
Dimensioning
The size of the brake is mainly determined by the braking torque and the relevant inertia of the load,
braking time, speed, number of starts per hour.
The calculation of the brakes is generally related to the permissible friction energy. Since the VIS is an
explosion proof unit, we simply defined a limit related to the maximum parmissible sliding time of the
disc in dynamic application (see page 6 for more details).
This solution gives a simple parameter to choose the brake in a correct, easy and safe way.
If the brake is used as parking brake (coupled with a motor used with inverter), the calculation is not
relevant except the value of brake torque necessary; we suggest always to consider a brake torque
between 1,5 and 2,3 times the motor torque.
For further information or exact brake calculation choice, please contact us.
Versions
The VIS brakes are available in 3 main construction executions:
- IEC dimension for front mounting on B5 motor and output B5 or B14 or reduced B5
- NEMA dimension for front mounting on nema motor (for dimensions please contact us)
- Closed version for mounting in the rear side of a motor prepared for it.
Except theese configurations, we can manufacture customized versions with output flanges and shafts
made on specific request.
Voltages
AC 3ph Brakes
The AC 3ph brakes work in star/delta configuration like a common 3ph motor - the standard voltage is 230/
400 V 50Hz.
We can produce any AC voltage, 50 or 60 Hz with maximum 600V. The voltage tolerance on the nominal
one is +/- 5% on standard brakes. Different tolerance can be supplied on request.
DC Brakes
The DC brakes are supplied as standard rectifier inside the terminal box in order to supply the brake with
2x AC phases. The standard voltage is DC 195 with 400 VAC to the rectifier. We can produce different
voltages on request with a maximum of 300VDC coil.
DC brakes are stard supplied with WR2008 half wave rectifier providing fast engagement and braking
times.
Different rectifiers can be supplied for psecial applications.
7
Overall Dimensions
TYPE B5 63 71 80 90 100-112 132 160 180 200 225 250 280

(Kg) 15 16 32 34 50 78 82 135 150 175 265 265
A (+0/-1) 23 30 40 50 60 80 110 110 110 140 140 140
A1 25 31 41 51 61 81 111 111 111 141 141 141
B (+/-1) 140 160 200 200 250 300 350 350 400 448 550 550
B1 (+/-1) 140 160 200 200 250 300 350 350 400 450 550 550
C (h8) 95 110 130 130 180 230 250 250 300 350 450 450
C1 (H8) 95 110 130 130 180 230 250 250 300 350 450 450
D 11 j6 14 j6 19 j6 24 j6 28 j6 38 k6 42 k6 48 k6 55 m6 60 m6 65 m6 75 m6
D1 (E6) 11 14 19 24 28 38 42 48 55 60 65 75
d M4X10 M4X10 M6X20 M6X20 M8X20 M10X25 M10X25 M20X30 M20X30 M20X30 M20X30 M20X30
E 2,5 3,5 3,5 3,5 4 4 5 5 5 5 5 5
E1 4 4 4,15 4,15 5 5,5 5,5 6 6 8 8 8
F 10 10 12 12 14 18 18 21 21 21 26 26
G 169,5 176,5 207 217 236,5 277,5 309,5 366,5 366,5 396,5 378,5 378,5
H 185 185 215 215 240 265 265 282 282 282 328 328
H1 205 205 230 230 255 290 290 320 320 320 - -
I 125 125 125 125 125 125 125 125 125 125 125 125
L 168 175 236 246 276 322 352 410 410 440 450 450
M 145 145 196 196 216 242 242 300 300 300 310 310
N 115 130 165 165 215 265 300 300 350 400 500 500
N1 115 130 165 165 215 265 300 300 350 400 500 500
O 205 205 250 250 305 355 355 370 370 370 - -
P 9,5 9,5 11,5 11,5 14,5 14,5 18 18 18 18 18 18
P1 M8X16 M8X16 M10X18 M10X18 M12X18 M12X18 M16X21 M16 M16 n°8XM16 n°8XM16 n°8XM16
Q 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20 1XM20
X 4 5 6 8 8 10 12 14 16 18 18 20
X1 4 5 6 8 8 10 12 14 16 18 18 20
Y 4 5 6 7 7 8 8 9 10 11 11 12
Z 12,5 16 21,5 27 31 41 45 51,5 59 64 69 79,5
Z1 (+0,1/-0) 12,8 16,3 21,8 27,3 31,3 41,4 45,4 51,9 59,4 64,4 69,4 49,9
IT IS POSSIBLE TO SUPPLY VERSIONS WITH B14 OR SPECIAL OUTPUT FLANGE/SHAFT

PLEASE CONTACT US FOR FURTHER DETAILS
8
a product of coel motori, via Campania 36/40 - Fizzonasco di Pieve Emanele, Milano, Italy
Tel +39 02 90420039 Fax +39 0290420747
www.visbrakes.com info@visbrakes.com
Data and descriptions of this catalogue are not binding and can be modified in any moment

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Cleveland Cascades Ltd

Introduction 3 Section 2 Cascade Installation Instructions 37

Product Manual - for Cascade Ship and Silo Loaders 2

The Cleveland Cascade Chute

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Equipment Safety Instructions

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Equipment Safety Instructions

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FIXED HEAD CHUTE

PIVOTTING HEAD CHUTE

Product Manual - for Cascade Ship and Silo Loaders 6

The cable reeling drum is a mechanical spring return drum. This is

2. Check the bearing for wear.

Note: The reeling drum springs have a BUMP STOP

Product Manual - for Cascade Ship and Silo Loaders 7

Use the following drawing as a guide.

Product Manual - for Cascade Ship and Silo Loaders 8

Typical installation for drum winch.

Product Manual - for Cascade Ship and Silo Loaders 9

Product Manual - for Cascade Ship and Silo Loaders 10

SPOOL WITH GUARD

HAND CRANK HANDLE

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The Ultimate limit switch is fitted as a back up to the hoist winch

SLACK ROPE SWITCH ARM

DETAIL OF ULTIMATE LIMIT SWITCH

DETAIL OF SLACK ROPE SWITCH ASSEMBLY

The slack rope switch is fixed onto the head chute.

Product Manual - for Cascade Ship and Silo Loaders 12

The overload system is designed to protect the bridge / boom from

Product Manual - for Cascade Ship and Silo Loaders 13

Product Manual - for Cascade Ship and Silo Loaders 14

Set point adjustment

Guidance to set point loading

Product Manual - for Cascade Ship and Silo Loaders 15

Product Manual - for Cascade Ship and Silo Loaders 16

the cone stack.

CUT POSITION ON ‘B’

Product Manual - for Cascade Ship and Silo Loaders 17

Product Manual - for Cascade Ship and Silo Loaders 18

RAISE SHROUD USING

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4. The surrounding atmosphere humidity level should be 60%

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The Cascade cones are suspended from strops.

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Double bush & ferrule cone attachment

CONE CONNECTION EYE STROP LOOPS

Single bush cone attachment

Product Manual - for Cascade Ship and Silo Loaders 22

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The shroud assembly consists of a telescopic cover located over the

SHROUD TOP RINGS

TOP (SEALING) SECTION

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For very long chutes, or chutes handling very dusty products,

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Speed Reducer Maintenance

CHECK EYEBOLTS AND

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The carrier is the cone-carrying framework located at the lower section

MATERIAL DETECTION PROBE