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Related Manuals for AUTOPSTENHOJ Masterlift 2.30
Summary of Contents for AUTOPSTENHOJ Masterlift 2.30
- Page 1 Masterlift 2.30 / 2.35 Installation instructions (TRANSLATED VERSION) ALWAYS KEEP Read the operating operating instructions instructions before ready to hand on the working with the unit unit Manual no.: 9000128GB Date: 10.07.2019...
- Page 2 2 / 44 Masterlift 2.30 / 2.35 9000128GB Before taking into operation check system compo- nents, control, emer- gency stop and safety equipment for conditi- on, damage and correct function! © AUTOPSTENHOJ GmbH Sandkampstr. 90 D – 48432 Rheine Tel.:...
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Page 3: Table Of Contents
9000128GB Masterlift 2.30 / 2.35 3 / 44 Table of contents General ............................... 5 Information for the installation instruction .................... 5 Explanation of symbols ........................5 Liability and warranty .......................... 6 Copyright protection ..........................6 Safety ..............................7 General ............................... 7 Work safety ............................ - Page 4 4 / 44 Masterlift 2.30 / 2.35 9000128GB Training of personnel in the operation of the lift ................. 39 Malfunction monitoring ........................39 Malfunction indication PLC control unit ..................... 39 Malfunction analysis .......................... 41 Overview: Wiring diagrams ......................43 Overview: Hydraulic diagrams ....................... 43...
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Page 5: General
9000128GB Masterlift 2.30 / 2.35 5 / 44 General Information for the installation instruction This installation instruction describes the installation of the lifting unit and the superstructure. Compliance with the notes on safety and procedural instructions is a prerequisite for the safe and proper installation of the lift. -
Page 6: Liability And Warranty
6 / 44 Masterlift 2.30 / 2.35 9000128GB Liability and warranty All information and notes in these installation instructions are provided under due consideration of valid regula- tions, the latest technical status of development as well as our years of expertise and experience. -
Page 7: Safety
9000128GB Masterlift 2.30 / 2.35 7 / 44 Safety This section gives an overview of all important security aspects for the optimal protection of personnel as well as for the safety and malfunction-free operation of the machine. Additionally, the individual chapters contain concrete safety notes, marked with safety symbols, for the preven- tion of immediate dangers. -
Page 8: Behavior In Case Of Danger Or Accidents
8 / 44 Masterlift 2.30 / 2.35 9000128GB Behavior in case of danger or accidents 2.4.1 Preventative Measures • Always be prepared for accidents or fire ! • Keep first aid equipment (first aid kit, blankets, etc.) and firefighting equipment close to hand. -
Page 9: Technical Data
9000128GB Masterlift 2.30 / 2.35 9 / 44 Technical data Connection values 3.1.1 PLC control unit Supply line via main switch 400V / 3p+N+PE / 50Hz Voltage power adaptor primary/secondary 230V AC / 24V DC Control voltage 24V DC Sensor voltage... -
Page 10: Hydraulic System
10 / 44 Masterlift 2.30 / 2.35 9000128GB 3.1.4 Hydraulic system Max. pressure of hydraulic pump 250 bar Hydraulic pump flow volume 10,6 l/min Max. flow volume of flow control valve 8,6 ± 0,8 l/min Without wheel-free device With wheel-free device... -
Page 11: Requirements Of The Place Of Installation
9000128GB Masterlift 2.30 / 2.35 11 / 44 Requirements of the place of Installation Lifts in this series consist of an above floor as well as an under floor component. They can be installed as stan- dard, basement or ceiling installation version. -
Page 12: Installation Of The Lifting Unit
12 / 44 Masterlift 2.30 / 2.35 9000128GB Installation of the lifting unit Overview of components The main components diagrammed in the following illustrations belong to this series Hydraulic valve of the Cover of the cassette hydraulic cylinder with sealing... - Page 13 9000128GB Masterlift 2.30 / 2.35 13 / 44 The main components for the installation of a Multilift frame are shown on the below illustration. Cover of the frame Connection block for hy- Suspension for with sealing draulic and pneumatic pump unit...
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Page 14: Placing, Aligning And Concreting The Steel Cassette
14 / 44 Masterlift 2.30 / 2.35 9000128GB Placing, aligning and concreting the steel cassette Before beginning assembly, check and determine the general layout, the placement of the control box, the steel cassette and the foundation measurements. For the construction of the foundation and the arrangement of the steel cassette, depending on the installation (on top of floor, flush with the floor, etc.) a foundation plan, agreed-upon by the manufacturer or architect is to... -
Page 15: Assembly Of The Hydraulic Components
9000128GB Masterlift 2.30 / 2.35 15 / 44 Assembly of the hydraulic components Before installation of the lifting unit, both the transport cover and the struts must be removed from the inside of the steel cassette. 4.3.1 Installation of the cylinder suspension - only for Multilift lifting units Before the cylinders can be suspended in the frame the cylinder suspensions have to fitted. -
Page 16: Setting Of The Hydraulic Cylinder
16 / 44 Masterlift 2.30 / 2.35 9000128GB 4.3.2 Setting of the hydraulic cylinder NOTE! When mounting older cassettes before setting the cylinder, put the bracket for the sensor ladder rack in the steel cassette (it does not belong to the delivery of the lifting unit). - Page 17 9000128GB Masterlift 2.30 / 2.35 17 / 44 Bracket for pump unit Transport locks and Transport locks and bleeding screws bleeding screws Hydraulic connections Sensor ladder rack Thread for ring screws Drive-on direction Mounting ledge Cylinder suspension Bottom bracket Fig. 7: Installation of hydraulic cylinder in Multilift-frame...
- Page 18 18 / 44 Masterlift 2.30 / 2.35 9000128GB Install preassembled cylinders in the steel cassette as follows: • Place the flat gasket on the foundation frame (not for Multilift-frames) • Screw two ring screws M 20 into the bearings and mount the cylinder into the cassette with a suitable lifting device.
- Page 19 9000128GB Masterlift 2.30 / 2.35 19 / 44 Attention! Only remove the transport locking plates (wooden plate) from the cylinder Ø123 after the first time the hydrauic unit is raised, otherwise the cylinder will slide into the base stuffing box.
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Page 20: Installation Of The Hydraulic Pump Unit
20 / 44 Masterlift 2.30 / 2.35 9000128GB 4.3.3 Installation of the hydraulic pump unit The pump unit will be delivered preassembled. Fasten the pump unit to the welded-on screws on the rear wall, as seen in the drive-on direction (see fig. 6). The unit must be levelled when mounting. - Page 21 9000128GB Masterlift 2.30 / 2.35 21 / 44 Fig. 11: Pump unit type "Fn" A) Solenoid valve for left hydraulic cylinder in drive-on direction B) Solenoid valve for right hydraulic cylinder in drive-on direction C) Hydraulic connection for left hydraulic cylinder in drive-on direction...
- Page 22 22 / 44 Masterlift 2.30 / 2.35 9000128GB When installing the pump unit in the Multilift frame the solenoid valves (a+b) are not placed directly on the pump unit but in the connecting block for each cylinder. The hydraulic hose, the solenoid valve plug and the air hose for emergency lowering must be connected to this block.
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Page 23: Installation Of The Control Unit Components
9000128GB Masterlift 2.30 / 2.35 23 / 44 Installation of the control unit components 4.4.1 Introduction The control unit is composed of two parts, the control box (with control board and power supply unit) and the terminal box which is installed in the cassette. The control unit of the type „Fn“ is also including two subdistribu- tions which get installed under the platforms. -
Page 24: Cable Connections
24 / 44 Masterlift 2.30 / 2.35 9000128GB 4.4.3 Cable connections For the connection between the control box and the cassette the following cables are needed: (intended for types "Standard and "Fn"): Cable Cores & sections Diameter Remarks Supply cable to the control 5x2,5mm²... -
Page 25: 4.4.4.1 Connection Of The Control Unit Type "Standard
9000128GB Masterlift 2.30 / 2.35 25 / 44 4.4.4.1 Connection of the control unit type “Standard” Terminal strip X5 Core to be con- Function allocation of the terminal (Control cable to termi- nected on the nal box) control cable Sensor 1 A Sensor –... -
Page 26: 4.4.4.2 Connection Of The Control Unit Type "Fn
26 / 44 Masterlift 2.30 / 2.35 9000128GB 4.4.4.2 Connection of the control unit type “Fn” Terminal strip X5 & X8 Core to be con- Function allocation of the terminal (Control cable to termi- nected on the nal box) control cable Sensor 2 A Sensor –... -
Page 27: 4.4.4.3 Connection Of Terminal Box Type „Standard
9000128GB Masterlift 2.30 / 2.35 27 / 44 4.4.4.3 Connection of terminal box type „Standard“ Motor supply cable Control cable from from control box control box Fig. 16: Connection of terminal box type „Standard“ 4.4.4.4 Connection of terminal box type „Fn“... -
Page 28: 4.4.4.5 Terminal Block On The Hydraulic Pump Unit
28 / 44 Masterlift 2.30 / 2.35 9000128GB 4.4.4.5 Terminal block on the hydraulic pump unit The terminal block on the hydraulic pump unit is fitted with a terminal strip that is provided with the cable-mar- kings U1, V1 and W1, as well as two crown sockets for the connection of the thermo switch. The earth connec- tion screw is on the flange of the hydraulic pump unit. - Page 29 9000128GB Masterlift 2.30 / 2.35 29 / 44 • The sensor ladder rack must be oiled before it is installed • Test to make sure the sensor block slides on the ladder rack. • Screw the sensor block onto the tappet.
- Page 30 30 / 44 Masterlift 2.30 / 2.35 9000128GB Washer and nut for fastening Threaded rod Forked suspension Fig. 20: Fitting on the upper bracket Attention ! First align the sensor ladder rack, the initiator and the driver to one another without tension in the lowest lift position, then tighten by hand the upper bracket.
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Page 31: Connection Of The Synchronization Bar
9000128GB Masterlift 2.30 / 2.35 31 / 44 Connection of the synchronization bar Thread always to the pump unit side of the steel cassette Screw head always on Thread M8 for earthing the side where the hy- connection draulic hoses lie Fig. -
Page 32: Connection Of Pneumatic Emergency Lowering
32 / 44 Masterlift 2.30 / 2.35 9000128GB Connection of pneumatic emergency lowering For the pneumatic emergency lowering a pneumatic hose (Polyamid Ø6 mm) is to be run through the conduit between the emergency lowering valve on the underside of the pump unit and the control box. The hose is to be positioned under the control box and to be led out laterally. -
Page 33: Installation Of Superstructure
9000128GB Masterlift 2.30 / 2.35 33 / 44 Installation of superstructure Repair platform superstructure type "Pv" The repair platform superstructure "Pv" can be delivered in different versions. You can choose between "stan- dard"- and "premium"-version. The features of the different versions can be found in the product descriptions. -
Page 34: Platform Superstructures Type "Fn" And "Fn Check-In
34 / 44 Masterlift 2.30 / 2.35 9000128GB • Run both of the cable guiding tubes from the underside of the stuffing box out through the bore (seal wash- er) in the carrier flange and screw it into the fastening plate. - Page 35 9000128GB Masterlift 2.30 / 2.35 35 / 44 Installation procedure: • Raise the lifting unit to approx. 70 cm. • With a lifting machine (forklift truck, etc.) lift a platform with almost completely preassembled wheel free device and from the underside of the platform lightly loosen the hydraulic hose on the wheel free cylinder.
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Page 36: Adjustment Of The Lift
36 / 44 Masterlift 2.30 / 2.35 9000128GB Adjustment of the lift The upper end position and the signal tone can be programmed on site. The control unit has special functions for this which can be activated by different button combinations... -
Page 37: Adjusting The Safety Zone
9000128GB Masterlift 2.30 / 2.35 37 / 44 Adjusting the safety zone Lower lift to bottom position for starting the signal tone. Attention ! The minimum distance between bottom edge of lifting platform and upper edge of floor or crushing edge must be at least 120 m ! Turn off the control unit in this position and wait 4 seconds. -
Page 38: Features For The Fn-Control Unit
38 / 44 Masterlift 2.30 / 2.35 9000128GB Features for the Fn-control unit With a lift of the type "Fn" (platform with wheel-free device) the wheel-free device is likewise supervised by the sensors in the synchronization. The same rules apply for the installation as for the main hydraulic (sensor 2/3 A [green] passes through the reference). -
Page 39: Installation Of The Cassette Cover
9000128GB Masterlift 2.30 / 2.35 39 / 44 Installation of the cassette cover Before the cassette is sealed and closed, an extensive performance check is to be done and the hydraulic hoses are to be tested for leakages. Place the flat irons in the U-brackets of the steel cassette near the stuffing boxes and place the rubber profile lists on them. - Page 40 40 / 44 Masterlift 2.30 / 2.35 9000128GB Malfunctions code table: Signal tones at Meaning Procedure failure No error Non failure Nothing BCC - error Parameter check-sum is Service wrong STM32 flash error Found failure in CPU- Service flash memory...
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Page 41: Malfunction Analysis
9000128GB Masterlift 2.30 / 2.35 41 / 44 Malfunction analysis In principle the cables are to be inspected after the installation and connection of the lift. In case of non-function the correct voltage supply is to be checked. The three phases and the neutral conductor of the supply cable must be firmly connected to the input terminals. - Page 42 42 / 44 Masterlift 2.30 / 2.35 9000128GB and left sides or if one side stops while the other side moves further, the LED's in the sensors must be ob- served. If irregularities are discovered, either the sensor is not correctly mounted or the valve plugs are interchanged.
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Page 43: Overview: Wiring Diagrams
9000128GB Masterlift 2.30 / 2.35 43 / 44 Overview: Wiring diagrams 10.1 Hydraulic pump unit 10.1.1 Connecting plan motor terminal frame (diagram no. 34806) 10.2 Superstructures without wheel-free device 10.2.1 Wiring diagram PLC control unit with signal tone (diagram no.: 9000471) 10.3... - Page 44 44 / 44 Masterlift 2.30 / 2.35 9000128GB Index Safety ...7 Safety Shoes ...7 Symboler Sensor ladder rack, installation ...28 Steel cassette concreting ...14 Explanation of Symbols ...5 Superstructure, installation ...33 Liability ...6 Superstructures type "F" and "F Check-in" ...33 Operating Manual ...5...
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