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8.5. REGULAR INSPECTIONS, SERVICE AND TESTING
According to prevailing national/international
occupational safety and health regulations, hoisting
1.
GENERAL INFORMATION
equipment must be inspected at least annually by a
NTRODUCING THE PROLYFT AETOS RANGE
Attention: All users must read these operating
competent person. Adverse working conditions may
instructions carefully prior to the initial operation. These
dictate shorter inspection periods.
instructions are intended to acquaint the user with the
The commissioning and inspection details can be
8.5. REGULAR INSPECTIONS, SERVICE AND TESTING
hen Simplicity in Motion is the ultimate goal, there's always a next level to
hoist controller and enable him/her to use it to the full
noted on the test certificate delivered with the hoist or in
According to prevailing national/international occupational safety and health
et. ProLyft invites you to take that level further with a product range that is fit
extent of its intended capabilities.
chapter 8.4 of this manual. Repairs may only be carried
regulations, hoisting equipment must be inspected at least annually by a
The operating instructions contain important information
meet the future
out by PROLYFT Service Points that use original
competent person. Adverse working conditions may dictate shorter inspection
on how to handle the hoist controller in a safe, correct and
PROLYFT spare parts.
periods.
economic way. Acting in accordance with these
t Ready for the Next Level
The inspection must determine that all safety devices
The commissioning and inspection details can be noted on the test certificate
instructions helps to avoid dangers, reduce repair costs
oLyft AETOS is the brand new ProLyft hoist range. The AETOS range is fully
are present and fully operational and cover the condition
and downtime and to increase the reliability and lifetime of
delivered with the hoist or in chapter 8.4 of this manual. Repairs may only be
uipped to meet future demands in lifting equipment and offers clever features
of the hoist, lifting gear, accessories and supporting
the hoist controller.
carried out by ProLyft Service Points that use original ProLyft spare parts.
d carefully engineered product attributes. The AETOS range comprises of a
constructions.
Anyone involved in doing any of the following work with
The inspection must determine that all safety devices are present and fully
the hoist controller must read the operating instructions
ndard 500kg and 1000kg hoist and will be expanded in the near future.
If required by the Occupational Health and Safety
operational and cover the condition of the hoist, lifting gear, accessories and
and act accordingly:
Organization, the results of the adequate inspections and
supporting constructions.
competent performance of repairs have to be
e Unique ProLyft Program
• Operation, including preparation, trouble shooting and
If required by the Occupational Health and Safety Organization, the results of
substantiated. If the electric hoist (with capacity of 1 t
oLyft sustains a unique service programme on its complete hoist range,
cleaning
the adequate inspections and competent performance of repairs have to be
and up) is installed in a carriage, or if the load is moved
• Maintenance, inspection, repair
veloped to offer maximum service and support for all hoist owners.
substantiated. If the electric hoist (with capacity of 1 t and up) is installed in a
• Transport
in one or several directions, the installation is considered
s program encompasses:
carriage, or if the load is moved in one or several directions, the installation is
as crane and inspections have to be carried out in
Installed network of trained and certified Service Points
considered as crane and inspections have to be carried out in accordance with
Apart from the operating instructions and the accident
accordance with BGV D6-Cranes.
Lifetime warranty
BGV D6-Cranes.
prevention act valid for the respective country and area
Individual identification - easy web-enabled track and trace functions
where the hoist controller is used, also the commonly
ProLyft Service database – automatic reminders for re-certification
8.6. LOAD CHAIN
accepted regulations for safe and professional work must
8.6. LOAD CHAIN
Test certificates worldwide available for owners of every hoist
The load chains are case-hardened and carry the designations 4x 12,2 DAT
be adhered to.
The load chains are case-hardened and carry the
The user is responsible for the proper and professional
(250kg), 5x 15,1 DAT(500kg) and 7,1 x20,5 DAT (1000kg).
designations 4x 12,2 DAT (250kg), 5x 15,1 DAT(500kg)
instruction of the operating personnel.
andard Features of the AETOS Range:
The AETOS electric hoists are specially designed to use this type of chain. For
and 7,1 x20,5 DAT (1000kg).
this reason only chains that have been approved by the manufacturer may be
Available in a 500kg and a 1000kg hoist body
The AETOS electric hoists are specially designed to use
used in the AETOS hoists.
Fixed speed of 4m/min
this type of chain. For this reason only chains that have
Suitable for entertainment use
Red CEE form plug 16Amp 4pin and cable with strain relief
been approved by the manufacturer may be used in the
The PROLYFT AETOS hoist controllers are specially
Lubricating the load chain
for power connection
AETOS hoists.
designed for use in the Entertainment industry. They must
The load chain is to be lubricated before initial operation and every month,
Yellow CEE form plug 16Amp 4pin and cable with strain relief
only control electric chain hoists that are suitable for use
however, latest after 50 operating hours. Adverse working conditions,
in the Entertainment industry.
for low voltage control (optional)
Lubricating the load chain
Combining the hoist controller with different type of
e.g. excessive dust or continued heavy duty can dictate shorter periods
Equipped with limit switches on all hoists
The load chain is to be lubricated before initial operation
electric chain hoists might lead to unwanted, unexpected
between lubrication.
and every month, however, latest after 50 operating
End limit switches are activated by chain stop for 100% repeatable accuracy
or dangerous situations.
•
Before the chain is lubricated it must be cleaned. Flame cleaning is
hours. Adverse working conditions,
and easy of use
The PROLYFT AETOS hoist controllers are not designed
forbidden. Use only cleansing methods and agents that do not corrode
e.g. excessive dust or continued heavy duty can dictate
External limit switches can be used for hoists used above a grid or false ceiling
to control hoists suspending or lifting loads above people.
the chain material. Avoid cleansing methods that can lead to hydrogen
shorter periods between lubrication.
Multiple voltage motor
brittleness, e.g. spraying or dipping chain in caustic solvents. Also avoid
• Before the chain is lubricated it must be cleaned. Flame
Chain bags for 30mtr up to 80mtr available
Read the manual of the electric chain hoists before
surface treatments that can hide cracks and flaws or other surface
cleaning is forbidden. Use only cleansing methods and
starting to operate them with the hoist controller.
5-pocket load wheel
damage.
agents that do not corrode the chain material. Avoid
Zinc-plated load chain
Regulations
•
The chain must be lubricated in a no-load condition so that lubricant can
cleansing methods that can lead to hydrogen
100% sealed aluminium transmission house without oil plugs
The accident prevention act and/or safety regulations of
enter between the links, e.g. by dipping in oil.
brittleness, e.g. spraying or dipping chain in caustic
Standard swivel hook on hoist body and hoist chain
the respective country for using manual and electric chain
•
Either motor oil of the viscosity 100, e.g. Shell Tonna T68 or Rocol
solvents. Also avoid surface treatments that can hide
IP 55 protection
hoists must be strictly adhered:
cracks and flaws or other surface damage.
DRY PTFE Spray can be used to lubricate the chain. For very dusty
• Europe:
• The chain must be lubricated in a no-load condition so
applications use a dry lubricant.
• Machine Directive 2006/42/EG
sily Adaptable:
that lubricant can enter between the links, e.g. by
• Safety of Machinery NEN 12100:2010
Covers 180 degree rotatable for motor-up use
Inspecting the load chain for wear
dipping in oil.
• Germany: BGV D6, BGV D8
Easy mounting of optional second brake
• Either motor oil of the viscosity 100, e.g. Shell Tonna
Load chains must be inspected every 3 months or the latest after 200
Brake shaft and electronics prepared for second brake
Additional regulations are in effect for lifting or suspending
T68 or Rocol DRY PTFE Spray can be used to
operating hours. Visually inspect the chain over its full length for deformation,
Output shaft prepared for rotary limit switch or encoder connection
loads over people.
lubricate the chain. For very dusty applications use a
cracks, flaws, elongation, wear or corrosive pitting. Link chains must be
Germany: SQ P2
All hoists can be double reeved
dry lubricant.
replaced when the nominal thickness (d: Fig. 16) on any part of the chain
The Netherlands: NPR8020-10
Swivelling chain bag bracket for motor-down and motor-up use
has been reduced by more than 10% or when the pitch t is elongated by
United
Kingdom: BS7950-1
Multiple voltage motor
Inspecting the load chain for wear
more than 5% or over 11 pitches (11 x t) by 2%. Nominal dimensions and
Load chains must be inspected every 3 months or the
wear limits are shown in the following table 4. Chains that do not fulfill all
Maintenance/Repair
latest after 200 operating hours.
requirements must be replaced immediately.
In order to ensure correct operation, not only the
Visually inspect the chain over its full length for
operating instructions, but also the conditions for
deformation, cracks, flaws, elongation, wear or corrosive
inspection and maintenance must be complied with. If
pitting.
defects are found or abnormal noise is to be heard stop
AETOS Range
AETOS Range
Link chains must be replaced when the nominal thickness
d on any part of the chain has been reduced by more
than 10% or when the pitch t is elongated by more than
5% or over 11 pitches (11 x t) by 2%. Nominal
using the hoist controller immediately.
dimensions and wear limits are shown in the following
Attention: Before starting t o work on electrical
table 2. Chains that do not fulfill all requirements must
components the power-supply is to be cut off.
be replaced immediately.
Table 4
2.
INCORRECT OPERATION
LINK CHAINS A= 4 X 12,2 DAT / B = 5 X 15,1 DAT / C = 7,1 X 20,5 DAT
Link chains A= 4 x 12,2 DAT / B = 5 x 15,1 DAT / C = 7,1 x 20,5 DAT
• Do not exceed the rated power capacity per controlled
Inspection
Inspection
Dim.
Dim.
Nominal Value [mm]
channel.
• Do not lift stuck or jammed loads.
A
• Do not shortly and frequently actuate the up/down
switch.
Length over
Length over
11 x t
11 x t
134,2
• Do not control hoists if the movement of the load is not
11 pitches
11 pitches
visible from the operating position.
Length of 1
t
Length of 1
t
12,2
• Do not control hoists if you are skilled for lifting loads
pitch
pitch
• Do not use cables with damaged strain reliefs and/or
Diameter
d
isolation.
Diameter
d
4
• Do not use any input- or output cables that are not
Mean
d1 +
4
suitable for the supplied voltage and / or current.
Mean
d1 +
thickness
d2
thickness
d2
• Do not use the Thuja data connection (link in, link out)
———-
2
with other network devices unless these devices are
2
Table 4
specified to be suitable for use in the Thuja data
network.
• Do not connect the controller to a mains connection that
is not properly fused.
• Do not use the controller without proper grounding.
• Do not connect more then one hoist on a single
channel.
ELECTRIC CONNECTIONS
3.
All electric connections must be used with respect for the
specified voltages and maximum power consumption.
Power input:
Replace the load chain
The power input connector is a 5pin CEEform connector
Replace the load chain
suitable for 3 phase 32Amp / 400Volt. 3 Phases, neutral
and ground.
1-strand design
1-strand design
•
Disassemble chain hook.
• Disassemble chain hook.
Depending on the type of controller it can be plugged in to
•
Unscrew both cylinder screws and separate the housing halves. Remove
• Unscrew both cylinder screws and separate the housing
either a 3 phase 400V or a 3 phase 230V mains
the foam stopper.
halves. Remove the foam stopper.
connections.
•
Remove the dead of the chain from the chain bag bracket. Remove the
• Remove the dead of the chain from the chain bag
chain end stop, by removing the 2 screws, remove the foam stop washer
Make sure the mains connection is fused at maximum
bracket. Remove the chain end stop, by removing the 2
32Amps per phase. It is advised to use circuit breakers
and remove the foam stopper.
screws, remove the foam stop washer and remove the
with a C or D characteristic.
•
Fitting the new chain.
foam stopper.
•
Cut the second to last link open on the loose end of the load chain to
• Fitting the new chain
Make sure the mains connection is properly grounded.
form a C. Remove the last link and connect the new chain. The new chain
• Cut the second to last link open on the loose end of
Improper grousing might lead to dangerous with the risk
must be fitted so that the welds on the standing links face towards the
the load chain to form a C. Remove the last link and
of electric shock.
chain guide and away from the load sheave. Operate the hoist in the
connect the new chain. The new chain must be fitted
lowering direction (DOWN-button) to feed the chain through the hoist.
so that the welds on the standing links face towards the
Maximum power consumption per hoist.
•
Fitting chain hook and chain end stop.
chain guide and away from the load sheave. Operate
Each hoist channel is capable of switching an electric
•
Slide the foam stoppers over the loose ends of the load chain and refit
chain hoist with maximum power consumption of 1,5kW.
the hoist in the lowering direction (DOWN-button) to
chain hook, foam stop washer and chain end stop. The chain end stop
feed the chain through the hoist.
Power output to the hoists
must be fitted so that the length over foam stopper and chain end stop
• Fitting chain hook and chain end stop.
For each 4 hoist channels there is a Harting 16 output
towards the end of the chain is 60cm.
• Slide the foam stoppers over the loose ends of the load
connector.
•
chain and refit chain hook, foam stop washer and chain
Connect dead end of the chain to the chain bag bracket.
•
Attention: Install new hex. nuts with clamping part.
end stop. The chain end stop must be fitted so that the
Make sure the cables (and each individual wire of the
•
length over foam stopper and chain end stop towards
Before initial operation lubricate the unloaded chain and test all hoist
cable) connected to the output connector are suitable for
functions under no-load condition.
the end of the chain is 60cm.
minimum 10Amps at 400V per wire.
• Connect dead end of the chain to the chain bag bracket.
• Attention: Install new hex. nuts with clamping part.
To avoid voltage drops longer cables should have bigger
wire diameters.
• Before initial operation lubricate the unloaded chain and
test all hoist functions under no-load condition.
! 1 4
page ! 4
14
Nominal Value [mm]
Wear Limit [mm]
Wear Limit [mm]
A
B
B
C
C
A
A
B
B
134,2 166,1 225,5 136,9 169,4 230,0
166,1
225,5
136,9
169,4
12,2
15,1
20,5
12,8
15,9
15,1
20,5
12,8
15,9
4
5
7,1
-
-
5
7,1
-
-
5
7,1
3,6
4,5
4
5
7,1
3,6
4,5
Fig. 16
WWW.PROLYTE.COM
C
C
230,0
21,5
21,5
-
-
6,4
6,4
Fig. 16
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