PUFFERS

Instructions and user manual - Rev. 5

Head office, registered office and operative base:79, Via degli Imprenditori37067 Valeggio sul Mincio (Verona) – ItalyTel. +39 045 7952209 Fax +39 045 7952174VAT No. IT03165700232www.pizzamigliosrl.com info@pizzamigliosrl.com

MANUFACTURERS OF LIFTING DEVICE COMPONENTS

P I ZZAM IGL IO SRL - PRODUZIONE ACCES SORI APPARECCHI D I SOLLEVAMENTO -

Company introduction

The Pizzamiglio Srl company has been founded recently from the ashes of the former Elettromeccanica F.lli Pizzamiglio Renato e Ivo Snc, established in 1982 by the brothers Renato and Ivo. Their twenty-year experience in the field of lifting gears started with the birth of their own business which dealt with elctro-mechanical maintenance focusing particularly on bridge cranes.

Thanks to the constant growth of customers' needs, the company starts the production of switchboards, the installation of industrial and home electrical systems and the manufacturing of structural works in the lifting field.

In order to offer a more complete range of products, in 1994 the company starts to produce trolleys and accessories for the lifting and handling of power supply cables for bridge cranes and the company to increase its turnover and expand its market.

The workshop equipment gradually increases with the introduction of work vehicles needed to the manufacturing of maintenance mechanical components. Indeed, the maintenance activity was growing more and more also thanks to the European Directive on occupational safety practices.

In 1996 the company starts manufacturing hydraulic brakes in accordance with the DIN 15435 (DIN System), and other crane components such as buffers and load limiting devices. Consequently, the company creates a wider range of bridge crane accessories and expands its commercial possibilities.

At the same time, the assistance activity to other companies increases and becomes one of the significant company activities and the company members' direct experience in this specific filed allows to develop and improve continually bridge crane accessories.

In 1997 the company moves to a new building in a small business area to meet the productive organization and the staff growth needs.

In 1998, the company starts the production and direct marketing of its "AQ Trolley" electric feeder systems with copper conductors for mobile applications.

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 2/16

In 2001 the company Elettromeccanica F.lli Pizzamiglio Snc obtains the certification of the Quality System in accordance with the ISO9002.

In 2002 the company divides and dedicates itself to the manufacturing of components for cranes. Nowadays, based on their installation experience, our technicians can meet the needs of the most demanding manufacturers and maintenance firms.

Our company is specialized in the production of :

• "Olivares" cable trolleys for bridge cranes, jib cranes and many other uses;

• "Olivares Feston" cable trolleys for dock and steelworks cranes;

• Electro-hydraulic fail-safe shoe brakes in accordance with the DIN15435, and broadband brakes;

• Brake band and engine couplings for shoe brakes;

• Spare asbestos-free brake shoes and flexible coupling in accordance with the DIN System requirements;

• Electro-hydraulic fail-safe disc brakes;

• Load limiting devices for bridge cranes;

• Telescopic control stops for bridge cranes;

• Iron puffers with rubber springs;

• Rubber buffers;

• Bus-bar system “Trolley AQ” for bridge-cranes.

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 3/16

Index

I N T R O D U C T I O N 2

CHAPITER 1

Preliminary remarks 5

CHAPITER 2

Company and product data 6

CHAPITER 3

Product description 7

CHAPITER 4

Choice of puffers 8

CHAPITER 5

Technical features 11

CHAPITER 6

Installation 13

CHAPITER 7

Safety features 14

CHAPITER 8

Maintenance 15

CHAPITER 9

Warranty 16

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 4/16

Introduction

This manual has been compiled to help installers and maintenance operators of PUFFERS produced by Pizzamiglio srl. It contains indications and warnings for correct installation and maintenance of these devices for a product’s long time life and safety use by the final user.

This documentation and its possible enclosures must be read carefully by the personnel working at any level before starting the installation, maintenance or adjustment of the puffers. Any intervention must be carried out with the help and in accordance with this manual. The employer must verify the training and qualification of the personnel before giving the authorization to make any intervention on the lifting gears.

IMPORTANT: each data contained in this publication is to be considered as indicative only. The manufacturer reserves the right to modify data without prior notice.

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 5/16

CHAPITER

1

Company and product data

Company data:

PIZZAMIGLIO SRL

79, Via degli Imprenditori

37067 Valeggio sul Mincio (VR) - ITALY

Tel. +39 045 7952209

Fax +39 045 7952174

P.iva: IT 0316570 023 2

http://www.pizzamigliosrl.com

E-mail: info@pizzamigliosrl.com

Product data:

Name of the product:

PUFFER

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 6/16

CHAPITER

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Product descriptions

The function required to the puffers is to void the kinetic energy of a mass that comes into collision with them. In cranes construction applications puffers have to dump the collision between the bridge or the trolley with the crane rail stops when electrical limit switch devices are out of order.

They consist in an iron body with a base and a head relied by a rod and telescopic pipes that contains rubber springs operating in compression disposed in series separated by metal disks Ambient of work: either for indoors or outdoors installation. Range temperature: from –20°C to +50°C. The iron body is subject to powder coating painting cycle with polyester fit for outdoor in grey colour. The safety chain and the shackle are galvanized.

Warning: the function of puffers is to void the kinetic energy of a mass that comes into collision with them in according with energy values indicated on the following pages. Every other use mast be considered improper use.

Types: we produce several types of puffers with different length and for different values of energy. Type “C” with longer stroke is fit for hi-speed cranes because returns a lower reaction force.

Type 327/A Type 327/C

Pizzamiglio srl – PUFFERS Instructions – Rev. 5

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Choice of puffers

The choice of size and type of puffer mast is done in consideration of the energy that have to be voided.

If you need a couple of puffers for a crane, you need to know the weight of the bridge, the weight of the trolley and their sliding speed.

In the value of the crane weight you have to include every loads not swinging and disregard the load hung on the rope (ex CNR-UNI 10021-73, FEM part I, DIN 15018).

If there are installed reduction speed devices, the speed value considered into the account may be multiplied for a reduction coefficient of 0,7 (as standards shown above). However this coefficient can be omitted for greater safety.

Kinetic energy of the bumping mass is equally divided between the puffers if both the trolley and the barycentre are situated in the centre of the bridge. Otherwise a puffer will be more stressed than the other. So, in the calculation we can’t account half of the energy to each puffer but we mast to consider the position more unfavourable of the bumping mass.

For a quick counting of the energy that may devolp following the impact on the single puffer installed on the bridge you can use this formula:

Energy [ J ] = ( 0,5 * bridge mass [ t ] + trolley mass [ t ] ) * ( bridge speed [m/min’] )2 * 0,142

For a quick counting of the energy that may devolp following the impact on the single puffer installed on the trolley you can use this formula:

Energy [ J ] = ( 0,5 * trolley mass [ t ] ) * ( trolley speed [m/min’] )2 * 0,142

It results by a series of mathematical simplifications of the formula E=(1/2)*m*v² where “m” is the mass

expressed in kg done by the ratio between weight and coefficient 9,81 m/s² and “v” is the crane speed in the moment of the contact expressed in m/sec. For a simply accounting you can use to charts in next pages.

Note: For cranes with protruding beams you mast to take in account the greater force

impressed on the puffer.

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 8/16

CHAPITER

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0

10

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1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51

Mass (t)

Speed (m/min')

327/A

Chart for the choice of puffer 327/A series

Cross the speed value with the crashing mass value. The line located on the right of the individuated point identifies the puffer fit for the use requested.

Pizzamiglio srl – PUFFERS Instructions – Rev. 5

T50

K250

T40

T20

T30

K500

T3

T10

T2

T1

T5

9/16

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60

70

80

90

100

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120

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140

150

160

170

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190

200

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250

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51

Mass (t)

Speed (m/min')

327/C

Chart for the choice of puffer 327/C series

Cross the speed value with the crashing mass value. The line located on the right of the individuated point identifies the puffer fit for the use requested.

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 10/16

K500

T1

T2

T3

T5

T10

T15

T20

T30

T40

T50

Technical Features

PUFFER type 327/A

Tab. 327/A

TypeStroke max[mm]

Force[daN]

Energy[ J ] [Nm]

Overall dimensions [mm]Mass[kg]A B C D E F G H

K250 20 250 35 75 120 4 90 70 65 45 7 1,0K500 25 500 70 90 130 5 110 90 80 60 9 1,8T01A 25 1.000 160 120 140 6 135 115 105 85 11 3,9T02A 50 2.000 440 160 230 8 170 150 130 110 13 8,3T03A 50 3.000 720 170 240 8 205 175 160 130 15 11,7T05A 50 5.000 1.150 200 260 8 230 200 175 145 17 14,0T10A 75 10.000 4.400 260 360 10 310 260 260 210 19 31,6T15A 75 15.000 7.800 320 380 12 360 310 300 250 21 48,0T20A 80 20.000 10.000 350 390 12 410 350 340 280 27 64,0T30A 100 30.000 21.000 370 470 15 410 350 340 280 27 75,0T40A 150 40.000 38.000 370 600 15 440 380 370 310 34 111,0T50A 200 50.000 46.000 370 700 15 440 380 370 310 34 142,0

Data and features in this catalogue are not binding. The producer reserves the right to alter them without advance notice at any time.

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 11/16

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PUFFER type 327/C (double spring - double stroke)

Tab. 327/C

TypeStroke max[mm]

Force[daN]

Energy[ J ] [Nm]

Overall dimensions [mm]Mass

[kg]A B1 C D E F G H1

T01C 50 1.000 250 120 220 6 135 115 105 85 13 5,2T02C 100 2.000 640 160 365 8 170 150 130 110 15 11,5T03C 100 3.000 1.100 170 385 8 205 175 160 130 17 15,8T05C 100 5.000 1.550 200 400 8 230 200 175 145 20 19,0T10C 150 10.000 7.200 260 500 10 310 260 260 210 26 42,3T15C 150 15.000 10.600 320 610 12 360 310 300 250 32 66,0T20C 160 20.000 14.000 350 640 12 410 350 340 280 35 82,8T30C 180 30.000 34.000 370 730 15 410 350 340 280 35 115,0T40C 220 40.000 47.000 370 900 15 440 380 370 310 40 157,0T50C 300 50.000 68.000 370 1.000 15 440 380 370 310 40 169,0

Data and features in this catalogue are not binding. The producer reserves the right to alter them without advance notice at any time.

Notes: dimensions indicated in this catalogue refer to our update drawings at the moment of printing of this document, however something may be changed in the meanwhile. Before preparing holes or arrangements take vision of the product and of his operation.

Pizzamiglio srl – PUFFERS Instructions – Rev. 5

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Installation

Mechanical mounting

During the installation of puffers is very important to check that them are positioned over the centre of the wheels and that crane-way locks surface are positioned with an angle of 90° with the puffer’s crushing axes. The altitude of the puffer axis mast be 0,6*D (where D is the wheel diameter).

The puffers are finished with powder coating painting with polyester fit for outdoor colour grey. The safety chain and the shackle are galvanized.

Note

Puffers are equipments bound to be incorporated in other machinery. Is forbidden to put them into service before that the whole machinery has been declared according to European Standard “Safety of Machinery” (2006/42/CE).

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 13/16

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Safety features

The constructor of the crane mast to choice a puffer suitable with the use of the crane in considering the environment, weather, air humidity, capacity and characteristics of the crane.

Warnings for installers and maintenance operators

Operate according your safety plan. Particularly use only certified ladders and scaffolds; use individual protection disposals and wear safety wear and shoes. Keep attention in your activity to safety of all persons around you. Packaging materials mast be recycled or sold-off in according to the country laws.

Instructions to the final user

The manufacturer or installer have to instruct the final user to don’t make his-self maintenance if not expert in cranes maintenance, particularly don’t insert grease into the puffer because it may alter or modify physical and chemical characteristics of rubber springs in compromising the device.

Check yearly the puffers functionality: verify the entireness of safety chain and gauge the total length of the puffer that mast not be reduced by more than 10% of stroke value.

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CHAPITER

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Maintenance

Our puffers do not need maintenance usually. They mast be painted with a paint suitable with the environment where the crane is installed: weather, air humidity, etc. Remember do not insert grease into the puffer because it may alter physical and chemical characteristics of rubber springs in compromising the device. Ageing of rubber springs cause a low reduction of their springiness. When the total length of the puffer will be reduced by more than 10% of stroke value the puffers mast be replaced. Verify also all the fixing screws are closed.

Insert into your crane maintenance’s check-list check of the puffers .

Spare parts

Are not provided spare parts. Please contact-us for more information.

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 15/16

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Warranty

We guarantee our products for 12 months from the delivery. The warranty applies only in reparation or change of parts that we recognize as faulty and excludes incidental or direct damages and cover only material fault. Warranty do not covers any defect that occurs to things or persons due to careless or improper storage or mounting such as keeping the product under conditions of high temperature and humidity or improper maintenance or tempering. For all sale conditions see the contract of sale.

Storage: store indoor at temperature between –20 and +50°C.

__________________________________________________________________________________

Data, draws and pictures contained in this publication are to be considered as indicative only. The manufacturer reserves himself the right to modify data without prior notice.

Pizzamiglio Srl79, Via degli Imprenditori • 37067 Valeggio sul Mincio (VR) - Italy

Tel. 045.7952209 • Fax 045.7952174info@pizzamigliosrl.com www.pizzamigliosrl.com

Pizzamiglio srl – PUFFERS Instructions – Rev. 5 16/16

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