GEDA AB 450 Operating Manual
Temporary suspended personnel lift (pl)
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- Assembly and operating manual (52 pages) ,
- Operating manual (72 pages) ,
- Assembly and operating manual (96 pages)
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Summary of Contents for GEDA AB 450
- Page 1 Operating Manual Complete machine GEDA AB 450 / 650 Temporary suspended personnel lift (PL) Incomplete machine GEDA AB 450 / 650 Winch for incorporation in a machine BL 061GB 2010/07 Edition 005 Original instructions...
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Page 2: Table Of Contents
® GEDA AB 450 / AB 650 Declaration of Conformity (complete machine) Declaration of Incorporation (incomplete machine) GUIDE .......................... 6 .............................. 6 MAGES ..........................6 ARNING NOTICES ..........................7 BBREVIATIONS ............................. 7 MPRINT GEDA ........................8 REPRESENTATIVES IDENTIFICATION DATA ....................9 ....................... - Page 3 ® GEDA AB 450 / AB 650 ........................23 ACHINE OPERATION 8.7.1 Complete machine ........................23 8.7.2 Incomplete machine ........................24 ........................24 ORESEEABLE MISUSE ........................... 24 ACHINE HAZARDS 8.10 ................25 AZARD SOURCES EXISTING RESIDUAL HAZARDS 8.10.1 Moving, rotating, pointed and sharp-edged parts ..............25 8.10.2...
- Page 4 ® GEDA AB 450 / AB 650 13 MOUNTING ........................ 39 13.1 DA 6 / DA 1 ........................39 UTRIGGER 13.2 DA 6 ......................40 RACING THE OUTRIGGER 13.3 ........................ 41 LIGNING THE OUTRIGGER 13.4 ................42 USPENDING THE ROPES FROM THE OUTRIGGER 13.5...
- Page 5 ® GEDA AB 450 / AB 650 BL 061GB Page 5 of 64 2010/07 Edition: 005...
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Page 6: Guide
® GEDA AB 450 / AB 650 Guide You will come across a series of illustrations and symbols while reading this manual which are intended to help you navigate through and under- stand this manual. The different meanings are explained below. -
Page 7: Abbreviations
® GEDA AB 450 / AB 650 Abbreviations The following abbreviations may be used in the manual. max. maximum Newton metre min. minimum km/h kilometres per hour mins. minutes miles per hour etc. et cetera inc. including poss. possible/possibly if nec. -
Page 8: Geda Representatives
® GEDA AB 450 / AB 650 GEDA representatives Bergkamen Subsidiary Gera Subsidiary GEDA Dechentreiter GmbH & Co. GEDA Dechentreiter GmbH & Co. KG Northwest branch East branch Marie-Curie-Strasse 11 Ernst-M.-Jahr Strasse 5 59192 Bergkamen-Rünthe 07552 Gera Tel. +49 2389 9874-32 Tel. -
Page 9: Identification Data
Spare parts are ordered exclusively through the manufacturer/representa- tive. Only original GEDA spare parts may be used. Only original GEDA spare parts guarantee full function as well as safety and reliability. The use of unapproved spare parts releases us from any liability for damage arising as a consequence of such use. -
Page 10: Technical Data
Strength class 1960 N/m² Nominal diameter 8.3 mm Minimum breaking strength 51 kN Actual breaking strength 53 kN WARNING The winches must be operated only using original GEDA ropes. BL 061GB Page 10 of 64 2010/07 Edition: 005... -
Page 11: Emissions
® GEDA AB 450 / AB 650 Electrical connection The cables provided by the customer must be designed such that: • they correspond to the connected load of the machine. • no interference voltages or interference frequencies occur. • the response behaviour of the safety equipment meets the relevant legal requirements. -
Page 12: Tightening Torques
® GEDA AB 450 / AB 650 Tightening torques 3.1.1 Mechanical screw connections without torque control Data refers to bolts in strength class 8.8 Tightening torque Tightening torque 25 Nm M 16 210 Nm M 10 49 Nm M 18... -
Page 13: Construction Alternatives
The manual and the conformity declaration relate solely to the construction alternatives presented below. The operating licence and the conformity declaration will cease to be valid in the case of other construction alterna- tives. If other construction alternatives are required, please contact GEDA. Permitted construction alternatives 4.1.1... -
Page 14: Straight Construction Of The Pl With 1 Winch Up To A Maximum Of 2 M
® GEDA AB 450 / AB 650 4.1.2 Straight construction of the PL with 1 winch up to a maximum of 2 m PL constructed from platform segments of 1-2 m, using one winch. Winch fastened with C-clamp. Outriggers suitable for the winch. -
Page 15: Rated Load Tables
® GEDA AB 450 / AB 650 Rated load tables Cable working platform with 2 x GEDA AB 450 Length Total weight of Rated Total weight of Rated Maximum of PL the suspended load the suspended load number structure –... -
Page 16: Cable Working Platform With 1 Xgeda Ab 450
® GEDA AB 450 / AB 650 Cable working platform with 1 x GEDA AB 450 Length Total weight Rated load Maximum of PL of the suspended structure – number of C-clamp people in the PL 186 kg 200 kg 1.5 m... -
Page 17: Outrigger Da 6 / Da 1
® GEDA AB 450 / AB 650 Outrigger DA 6 / DA 1 Verification of stability The stability must be verified for each usage site. Verification consists of: • proving the load capacity of the roof structure. If necessary bring in construction experts. -
Page 18: Counterweights
® GEDA AB 450 / AB 650 Counterweights Number of counterweights ( ) per beam at 25 kg with a rope length of 100 m 6.2.1 Winch 450 with outrigger DA 6 / DA 1 Abspannseil Guy rope Gegengewichte Counterweights 0.6*... -
Page 19: Supporting Forces
® GEDA AB 450 / AB 650 Supporting forces The table below gives the maximum supporting forces (in kg) occurring at point A per beam in the event of a falling load being caught. The value given must be halved to ascertain the individual wheel loads. -
Page 20: Parapet Bracket
® GEDA AB 450 / AB 650 Parapet bracket Verification of safety Verification of the safety of the parapet bracket consists of: • proving the load capacity of the parapet. The load capacity must be verified for each usage site. If necessary bring in construction ex- perts. -
Page 21: Safety Information
Prior to assembly and first use, the operating manual must be read and understood in its en- tirety. Non-compliance with the safety information releases GEDA from any liability. Proper use 8.1.1... -
Page 22: Tests Prior To Delivery
® GEDA AB 450 / AB 650 Tests prior to delivery The following tests have been carried out prior to delivery: • Static test with 1.5 times the maximum load capacity. o Loading for approx. 10 minutes • Dynamic test with 1.25 times the maximum load capacity. -
Page 23: Machine Limitations
Any unauthorised modifications that are carried out shall ex- clude the manufacturer from any liability. Prohibition of certain activities The following activities may only be carried out by GEDA employees on account of potential sources of errors which cannot be detected (by the operating company): •... -
Page 24: Incomplete Machine
Starting or operating the complete or incomplete machine without having read the manual beforehand is strictly prohibited. The manual must be kept safe for future use. GEDA shall not be liable for any damage arising from non-compliance with the manual. Foreseeable misuse Any use that deviates from the conditions specified above and the stated purpose is strictly prohibited. -
Page 25: Hazard Sources / Existing Residual Hazards
AB 450 / AB 650 8.10 Hazard sources / existing residual hazards As with all complex machinery, there are also sources of potential hazards in the case of GEDA machines. These are: 8.10.1 Moving, rotating, pointed and sharp-edged parts •... -
Page 26: Other Relevant Documents
8.14 GEDA training sessions GEDA conducts detailed training sessions in order to enable the highest degree of safety and economic efficiency when operating the machine. When the machine is delivered, the operating company and its personnel will receive extensive instruction in function, operation, maintenance, ser- vicing and troubleshooting. -
Page 27: Obligations Of The Operating Company
® GEDA AB 450 / AB 650 Obligations of the operating company Obligation of training / qualification The operating company clearly defines the responsibilities of the person- nel for operation/installation/maintenance. The operating company is obliged to train all persons authorised to use the machine in the correct... -
Page 28: Accessibility To Necessary Information
® GEDA AB 450 / AB 650 Accessibility to necessary information The operating company must ensure that the manual required for the rele- vant task is available to all persons who are commissioned with operation, servicing and maintenance/assembly. The operating company must ensure that the individuals in question have read and understood the necessary manuals. -
Page 29: Transporting Suspended Loads Over The Machine
The corresponding instructions/manuals must be made available. 9.10 Following the instructions of GEDA assembly engineers If the machine is installed by GEDA assembly engineers, their instructions must be followed. 9.11 Provision of personal protective equipment The operating company must provide personal protective equipment ap- propriate to the respective place of use and purpose. -
Page 30: Regarding Use By Authorised People
® GEDA AB 450 / AB 650 Regarding use by authorised people 10.1 Assembly/maintenance/servicing specialist A person who, on account of his/her qualified professional education, training and experience, is able to recognise risks and potential hazards during work/assembly/maintenance/repair work on the machine and can eliminate these by introducing appropriate measures. -
Page 31: Obligatory Safety Instructions
® GEDA AB 450 / AB 650 Obligatory safety instructions 11.1 Basic conduct when working with the machine • The machine must be used with an awareness of hazards, in a technically fault-free condition and according to the instructions in this manual. -
Page 32: Supplementary Safety Instructions - Transporting The Machine/Disposing Of The Machine
Provide sufficient space to open doors and covers. • Welding, burning and grinding work on the machine must only be carried out following consultation with and approval from GEDA. • In the event of wind speeds > (45 km/h), bring the car down to the ground and cease operation. -
Page 33: Additional Safety Notes - Servicing/Repairs/Electrical Components
Make sure that no hazards will arise as a result of the ma- chine being started up. • Welding, burning and grinding work on the machine must only be carried out following consultation with and approval from GEDA. BL 061GB Page 33 of 64 2010/07 Edition: 005... -
Page 34: Additional Safety Notes - First Commissioning / Daily Commissioning
® GEDA AB 450 / AB 650 11.5 Additional safety notes – first commissioning/daily commissioning Make sure that: • All safety features are present and functioning • All connections are properly connected • All parts are correctly installed • There is no discernible damage to the rope of the winch •... -
Page 35: Overview Of Warning Signs To Be Observed
® GEDA AB 450 / AB 650 Overview of warning signs to be observed 12.1 Electric shock DANGER Electric shock Parts remain live even after operating the EMERGENCY OFF / EMERGENCY STOP or after switching off the machine at the master switch. -
Page 36: Installing The Controller
® GEDA AB 450 / AB 650 12.5 Installing the controller WARNING Danger of death Incorrect installation of the controller (in the case of two winches) leads to a loss of tilt limitation fall from the working platform. Only install controller on the longitudinal side of the working platform. -
Page 37: Approach Plate Limit Switch
® GEDA AB 450 / AB 650 12.8 Approach plate limit switch WARNING Danger of death The approach plate limit switch absolutely must be installed before first commissioning. Fall protection absolutely must be worn for in- stallation. If necessary, a safety distance must be provided above the working... -
Page 38: Servicing
® GEDA AB 450 / AB 650 12.12 Servicing WARNING The entire manual must be read for all service/repair work. Work is prohibited if the nature and scope of the work to be carried out is unclear or the resulting hazards and measures which must be introduced to avert said hazards are unclear. -
Page 39: Mounting
® GEDA AB 450 / AB 650 Mounting 13.1 Outrigger DA 6 / DA 1 Transport outrigger to the roof in pieces. Transport counterweights to the roof. Assemble outrigger as shown above and secure with the socket pins. -
Page 40: Bracing The Da 6 Outrigger
® GEDA AB 450 / AB 650 13.2 Bracing the DA 6 outrigger Open the lock (A) on the bracing fully. Guide the rope (B) over the col- umn (9) and secure with socket pins (C). Pin rope to the counterweight support (8). -
Page 41: Aligning The Outrigger
® GEDA AB 450 / AB 650 13.3 Aligning the outrigger WARNING: When working at locations where there is a risk of falling, personal protective equipment (PPE) absolutely must be worn and appropriately se- cured. If the PPE is fastened to the outrigger,... -
Page 42: Suspending The Ropes From The Outrigger
® GEDA AB 450 / AB 650 13.4 Suspending the ropes from the outrigger Suspend the load hook in the suspension bracket. Mount the limit switch of the ap- proach plate (1) between the ropes. Safety rope Drive rope... -
Page 43: Mounting The C-Clamp / Chassis And Distance Pieces
® GEDA AB 450 / AB 650 13.6 Mounting the C-clamp / chassis and distance pieces Mounted using screws M 10 x 90, strength class 8.8, with self-locking nuts (DIN 985) and 2 plain washers. Mounting the bottom section Tilt the working platform onto its side or have it lifted by two installation engineers. -
Page 44: Fastening The Winch To The C-Clamp
® GEDA AB 450 / AB 650 13.7 Fastening the winch to the C-clamp Mount the winches to the truss of the C-clamp using the adapter (1). Tightening torque of the bolts = 80 Nm. Hook the winch (2) into the latch and fold it up vertically. -
Page 45: Fastening The Winch To The End Face Of The Working Platforms
® GEDA AB 450 / AB 650 13.8 Fastening the winch to the end face of the working platforms Never use the winch retainer without a pro- tection plate (2). Mount the winch retainer (1) to the car. Position the winch (2) horizontal- ly on the winch retainer (1) and swing upwards. -
Page 46: Installing The Controller
® GEDA AB 450 / AB 650 13.9 Installing the controller WARNING Danger of death Incorrect installation of the controller (in the case of two winches) results in a loss of tilt limitation. Fall from the working platform. Only install the controller on the longitudinal side of the working platform. -
Page 47: Connecting The Controller
® GEDA AB 450 / AB 650 13.10 Connecting the controller Hook the tension relief (7) of the mains supply cable to the bracket of the control switch box. Connect the mains plug to the mains supply cable (8). -
Page 48: Installing The Drive Rope And Safety Rope
® GEDA AB 450 / AB 650 13.11 Installing the drive rope and safety rope 13.11.1 Installing the C-clamp ATTENTION The drive and safety ropes must not be mixed up. Ensure that the rope are not twisted. Insert the drive rope (1) and safety rope (2) into the C-clamp as shown. -
Page 49: Assembly On The Winch
® GEDA AB 450 / AB 650 13.11.2 Assembly on the winch CAUTION Damage to the winch. Check rope for damage before introducing it. There must be no discernible protruding strands, kinks or defor- mations in the rope. In the event of any noticeable noises or uneven retraction: Immediately pull out the rope and check the end of the rope and the winch. -
Page 50: Approach Plate Limit Switch
20 cm above the ground. In order to prevent the rope from becoming dam- aged, dirtied or twisted, it is imperative that the rope is rolled up. GEDA accessories product documentation. BL 061GB Page 50 of 64... -
Page 51: Disassembly
® GEDA AB 450 / AB 650 Disassembly The winches are in principal disassembled in reverse order to assembly. Operation 15.1 Winch controls 15.1.1 Simple control EMERGENCY STOP 1) Press in the event of danger. UP button (2) Press and hold to move the working platform upwards. -
Page 52: Central Control Box
® GEDA AB 450 / AB 650 15.1.2 Central control box EMERGENCY STOP (1) Press in the event of dan- ger. UP button (2) Press and hold to move the working platform upwards. DOWN button (3) Press and hold to move the working platform down- wards. -
Page 53: Safety Features
® GEDA AB 450 / AB 650 Safety features 16.1 Emergency lowering The emergency lowering allows controlled lowering of the working platform in the events of a fault or in the event of a power failure. Pull slightly on the brake lever (1) on the motor of the winch (right and left). -
Page 54: Rope Stop
® GEDA AB 450 / AB 650 16.2 Rope stop The rope stop automatically triggers when the suspension rope breaks or if the working platform is slanting by more than 10°. The rope stop can be manually triggered by engaging the lever. The fol- lowing events can result in the rope stop being triggered. -
Page 55: Breakage Of The Suspension Rope
® GEDA AB 450 / AB 650 16.2.3 Breakage of the suspension rope If a suspension rope breaks, the rope stop will be triggered by centrifugal forces. Replace the broken suspension rope with a new suspension rope. Press the UP button until the broken rope is pulled out of the winch. -
Page 56: Faults
® GEDA AB 450 / AB 650 Faults WARNING Only have troubleshooting and fault elimination carried out by authorised personnel trained especially for this kind of work. Remove mains plug before working on the electrical system. Fault Cause Remedial action... -
Page 57: Rescuing People Trapped Inside
® GEDA AB 450 / AB 650 Rescuing people trapped inside Rescue may become necessary if e.g. • there is no mains voltage • the electrical system has malfunctioned • the drive has failed • the rope stop has been triggered. -
Page 58: Inspections
® GEDA AB 450 / AB 650 18.2 Inspections During the inspections, all safety-related characteristics of the machine are checked by means of appropriate procedures for condition, presence and function. Appropriate procedures are: • Visual inspections, examination of operation and efficacy testing •... -
Page 59: General Overhaul
® GEDA AB 450 / AB 650 18.3 General overhaul The general overhaul after 500 h (L3) must only be performed by the manufacturer or by a person authorised by the manufacturer. Documenting the results The operator must document the results of inspections. The documenta- tion must be kept for a reasonable period of time –... -
Page 60: Servicing
® GEDA AB 450 / AB 650 SERVICING WARNING The entire manual must be read for all service/repair work. Work is prohibited if the nature and scope of the work to be carried out is unclear or the resulting hazards and measures which must be introduced to avert said hazards are unclear. -
Page 61: Inspect Rope Stop
® GEDA AB 450 / AB 650 19.2 Inspect rope stop WARNING The rope stop must be inspected every 5 years by the manufacturer. To do this, remove the rope stop and send to the manufacturer. The rope stop test must only be carried out by a qualified person specifi-... -
Page 62: Daily Cleaning
® GEDA AB 450 / AB 650 Daily cleaning Execution, necessary safety clothing, cleaning agents and equipment ac- cording to the applicable instructions from the operating company. WARNING Danger of death Risk of fire as a result of using combustible clean- ing materials. -
Page 63: Options
® GEDA AB 450 / AB 650 Options 21.1 Raising the DA 6 outrigger It is possible to raise the DA 6 outrigger by 900 mm. All information pro- vided above relating to use and to the forces and counterweights remains unchanged by raising the outrigger. -
Page 64: Cold Package
® GEDA AB 450 / AB 650 21.2 Cold package At temperatures of under – 20 °C the ma- chine can no longer be operated. The cold package (1) monitors the ambient temperature and disables the upward travel path at lower temperatures, so that it is only possible to travel to the ground station.