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GEDA 500Z Operating Manual

Construction hoist/transport platform
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Operating Manual
Construction Hoist/Transport Platform
For passengers and materials
Original Operating Manual

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Summary of Contents for GEDA 500Z

  • Page 1 Operating Manual Construction Hoist/Transport Platform For passengers and materials Original Operating Manual...

  • Page 3: Eu Declaration Of Conformity

    Type: 500 Z/ZP 2 Serial number: 05T... / 000210 ... Type: GEDA 500 ZP/1000 Z Serial number: 05T... / 000210 ... Year of construction: Refer to name plate on the machine is in compliance with all pertinent provisions of the following directives at the time of being put on the market.

  • Page 5: Table Of Contents

    500 Z/ZP 2 Table of contents Table of contents General information Information on the operating manual Abbreviations Identification data Manufacturer's name and address Information about the author and industrial property rights Patents Instructions for the operating company Intended use 1.8.1 Assembly, service/maintenance specialist 1.8.2 Operating personnel...
  • Page 6 Table of contents 500 Z/ZP 2 4.3.2.1 Loading door / Ramp 4.3.3 Platform access landing level 4.3.3.1 Barrier with mechanical lock 4.3.3.2 Barrier with electromagnetic lock 4.3.4 Securing loading and unloading points 4.3.4.1 "Standard/Standard Basic" landing level safety gate 4.3.4.2 "Comfort"...
  • Page 7 500 Z/ZP 2 Table of figures Table of figures Fig. 1: UNI-X-MAST Fig. 2: UNI-Mast Fig. 3: Anchoring diagram Fig. 4: Platform A Fig. 5: Required space platform A Fig. 6: Platform B Fig. 7: Required space platform B Fig. 8: Platform C Fig.
  • Page 8 Table of figures 500 Z/ZP 2 Fig. 48: Ground control for enclosure (AUTOMATIC) Fig. 49: Electric module for landing level safety gate Fig. 50: Activating the platform control Fig. 51: Selector switch for operating mode, assembly Fig. 52: Platform control for assembly Fig.

  • Page 9: General Information

    500 Z/ZP 2 General information General information Information on the operating manual This operating manual is an essential aid to operating the machine successfully and hazard-free (refer to chapter 2.1 Residual risks, page 18). This operating manual contains important instructions on how to operate the machine safely, correctly and efficiently.

  • Page 10: Safe Working

    General information 500 Z/ZP 2 DANGER Type and source of the hazard: Danger to life Consequence: Death/serious injury Probability: imminent  Measure for preventing the hazard WARNING Type and source: Risk of injury Consequence: Serious injury Probability: possible  Measure for avoiding CAUTION Type and source: Risk of injury Consequence: Minor injury...

  • Page 11: Abbreviations

    < less than kip. kilopound ± plus/minus Identification data Machine type: GEDA 500 ZP/1000 Z 2 Serial number: 05T... / 000210 ... _______________ Machine type: GEDA 500 Z/ZP 2 Serial number: 05T... / 000210 ... _______________ Year of construction: Refer to name plate...

  • Page 12: Manufacturer's Name And Address

    07552 Gera Tel. +49(0)2389 9874-32 Tel. +49(0)365 55280-0 Fax. +49(0)2389 9874-33 Fax. +49(0)365 55280-29 U.S. subsidiary Korea Subsidiary GEDA USA, LLC GEDA KOREA 1151 Butler Road 1708, (MetroDioVill Bldg., Singongdeok-dong) 199, League City (Houston), TX 77573 Baekbeom-ro, Mapo-gu, Tel. +1(713) 621 7272 Seoul 04195 Fax.

  • Page 13: Information About The Author And Industrial Property Rights

    Violations are an offence and incur an obligation to pay compensation. All rights to exercise industrial property rights are reserved by GEDA . Patents Some components in our machines are protected by patent rights. To find out how to request information about these, refer to http://www.geda.de/...
  • Page 14 General information 500 Z/ZP 2 Any replacement and wearing parts that are used must correspond to the technical requirements stipulated by GEDA . This is ensured with original replacement parts. Only employ qualified and/or trained personnel for the tasks described in this manual.

  • Page 15: Intended Use

    500 Z/ZP 2 General information Intended use The 500 Z/ZP 2 is a rack-and-pinion hoist constructed vertically that is suitable for temporary use at construction sites. Any other locations or intended uses require written approval from the manufacturer. The 500 Z/ZP 2 is a construction material hoist and a transport platform that is temporarily erected and •...
  • Page 16 General information 500 Z/ZP 2 Transport platform equipped for operation as per EN 16719 • roof over the complete platform (refer to chapter 4.5.1 Roof, page 84). • landing level platform access (refer to chapter 4.3.3 Platform access landing level, page 58) - as a barrier with electromagnetic lock - as a barrier with mechanical lock (two separate actions), or •...

  • Page 17: Assembly, Service/Maintenance Specialist

    500 Z/ZP 2 General information 1.8.1 Assembly, service/maintenance specialist A person who, due to qualified professional education, training and experience, is able to recognise risks and potential hazards during assembly/maintenance/repair work on the machine and subcomponents and can rectify these by introducing appropriate measures. 1.8.2 Operating personnel The machine may only be operated by persons who, based on their...

  • Page 18: General Safety Information

    General safety information 500 Z/ZP 2 General safety information The machine has been designed and built according to the state of the art and recognised safety rules. Nevertheless, hazards for personnel or third parties and/or damage to machinery and other tangible assets can occur during use, e.g. if the machine: •...

  • Page 19: Safety Instructions For Operating Personnel

    500 Z/ZP 2 General safety information Safety instructions for operating personnel The operating manual must be kept within reach at all times at the location where the machine is used. The machine may only be used in a technically flawless condition, in accordance with the intended use, in a safety conscious manner, with awareness for the hazards and in compliance with this operating manual! In particular, faults that could impair safety must be eliminated...

  • Page 20: Safety Instructions For Transport

    General safety information 500 Z/ZP 2 Safety instructions for transport Immediately report transport damage and/or missing parts to the supplier. During transport tasks, wear a safety helmet, safety shoes and protective gloves! Never walk below suspended loads! Only use appropriate, standardised and tested lifting devices (forklifts, cranes) and load attachment gear (lifting beam, round slings, lifting straps, rope slings, chains) for transport at the assembly site.

  • Page 21: Safety Instructions For Operation

    500 Z/ZP 2 General safety information Safety instructions for operation Only operate the machine in accordance with the operating manual, when it is in full working order, and in a safety and hazard- conscious manner. If work is interrupted, switch the machine off at the main switch and secure it with a padlock against being switched on again.

  • Page 22: Safety Instructions For Maintenance And Troubleshooting

    General safety information 500 Z/ZP 2 Safety instructions for maintenance and troubleshooting Operating personnel must be informed about how to carry out special work and repair work before starting. Deadlines that are stipulated or stated in the maintenance manual for recurring tests/inspections must be adhered to.
  • Page 23 500 Z/ZP 2 General safety information Do not make any changes, additions or modifications to the machine. This also applies to the installation and adjustment of safety devices such as limit switches. Immediately replace damaged or detached information and warning signs, as well as safety labels.

  • Page 24: Safety When Working On The Electric System

    General safety information 500 Z/ZP 2 Safety when working on the electric system If there are faults on the electrical system of the machine, it must be shut down immediately using the main switch and secured with a padlock or the mains plug must be disconnected! Work on the electrical equipment of the machine must only be carried out by qualified electricians working in accordance with electrical engineering regulations! Only professional electricians may access the...

  • Page 25: Technical Data

    500 Z/ZP 2 Technical data Technical data Operating and environmental conditions The machine may only be operated when the following operating and environmental conditions are adhered to: • Storage in dry rooms, in order to prevent corrosion. • No jolts or vibrations. •...

  • Page 26: Emissions

    Technical data 500 Z/ZP 2 Emissions Sound pressure level: < 78 L Tightening torques Special mechanical screw connections with torque control Mast - elements to one another Tightening torque 150 Nm 110 lbf ft Width across flats (AF) 24 mm Couplings Tightening torque 50 Nm...

  • Page 27: Electrical Connected Loads

    500 Z/ZP 2 Technical data Electrical connected loads A construction site distribution cabinet (in accordance with IEC 60439- 4:2005) with a - min. 3 x 16 A fuse protection of the supply point and a - residual current device (RCD) are required.

  • Page 28: Speeds

    Access height (threshold level): min. 0.32 m Installed height (H): max. 100 m Erection height (H): GEDA 500 ZP/1000 Z 2 (refer to chapter 3.8.5 Platform 500 ZP/1000 Z 2, page 41) Assembly site elevation: max. 1000 m (3289') (metres above sea level)

  • Page 29: Mast

    500 Z/ZP 2 Technical data Mast UNI-X-MAST Only original GEDA mast sections may be used! UNI-X-MAST Uni-Mast (item no. 03350) (item no. 01150) Fig. 1: UNI-X-MAST Fig. 2: UNI-Mast If UNI-X-Mast parts UNI-Mast parts are installed together, only the anchoring spacings and anchoring forces for the Uni-Mast apply! Length 1.5 m...

  • Page 30: Fig. 3: Anchoring Diagram

    Operation: Platform A, B, C, SL 5.0 m Assembly: max. 7.50 m W - 1.50 m 100 m Erection height (H): GEDA 500 ZP/1000 Z 2 (refer to chapter 3.8.5 Platform 500 ZP/1000 Z 2, page 41) BL145 GB 2023-11...
  • Page 31 500 Z/ZP 2 Technical data Inclination of mast max. installation height (H) for vertical installation in X and Y direction Example 1 Example 2 Installed height = 50 m Installed height = 100 m 50 m = 0.1 m 100 m = 0.2 m Check inclination during and following assembly using appropriate means.

  • Page 32: Load Capacity, Dimensions And Weights

    Technical data 500 Z/ZP 2 Load capacity, dimensions and weights Cable bin with trailing cable Weight 25 m lifting height 65 kg 50 m lifting height 80 kg 75 m lifting height 95 kg 100 m lifting height 110 kg Assembly plank Load capacity 120 kg...

  • Page 33: Platform A

    500 Z/ZP 2 Technical data 3.8.1 Platform A Fig. 4: Platform A Load capacity Construction hoist max. 850 kg Transport platform max. 500 kg / 5 persons 400 kg + 1 300 kg + 2 200 kg + 3 100 kg + 4 ----- kg + 5 Assembly up to the second mast tie...

  • Page 34: Fig. 5: Required Space Platform A

    Technical data 500 Z/ZP 2 Dimensions/required space Fig. 5: Required space platform A Height 2.3 m (2.5 m with roof) Weights Base unit with platform 825 kg Roof 24 kg Underrun protection 25 kg BL145 GB 2023-11...

  • Page 35: Platform B

    500 Z/ZP 2 Technical data 3.8.2 Platform B Fig. 6: Platform B Load capacity Construction hoist max. 850 kg Transport platform max. 500 kg / 5 persons 400 kg + 1 300 kg + 2 200 kg + 3 100 kg + 4 ----- kg + 5 Assembly up to the second mast tie...

  • Page 36: Fig. 7: Required Space Platform B

    Technical data 500 Z/ZP 2 Dimensions/required space Fig. 7: Required space platform B Height 2.3 m (2.5 m with roof) Weights Base unit with platform 825 kg Roof 24 kg Underrun protection 25 kg BL145 GB 2023-11...

  • Page 37: Platform C

    500 Z/ZP 2 Technical data 3.8.3 Platform C Fig. 8: Platform C Load capacity Construction hoist max. 800 kg Transport platform max. 500 kg / 5 persons 400 kg + 1 300 kg + 2 200 kg + 3 100 kg + 4 ----- kg + 5 Assembly up to the second mast tie...

  • Page 38: Fig. 9: Required Space Platform C Loading B-Side

    Technical data 500 Z/ZP 2 Dimensions/required space Fig. 9: Required space platform C loading B-side Fig. 10: Required space platform C loading C-side Height 2.45 m (2.5 m with roof) Weights Base unit with platform 884 kg Roof 24 kg Underrun protection 25 kg BL145 GB 2023-11...

  • Page 39: Platform Sl

    500 Z/ZP 2 Technical data 3.8.4 Platform SL Fig. 11: Platform SL Load capacity Construction hoist max. 850 kg With attached roof, underrun max. 670 kg protection and assembly plank Transport platform max. 500 kg / 5 persons 400 kg + 1 300 kg + 2 200 kg + 3 100 kg + 4...

  • Page 40: Fig. 12: Required Space Platform Sl

    Technical data 500 Z/ZP 2 Dimensions/required space Fig. 12: Required space platform SL Height 2.45 m (2.5 m with roof) Weights Base unit with platform 1000 kg Underrun protection 35 kg The roof is included in the weight figure for the base unit. BL145 GB 2023-11...

  • Page 41: Platform 500 Zp/1000 Z 2

    Platform 500 ZP/1000 Z 2 Special preconditions for the 500 ZP/1000 Z 2 The GEDA 500 ZP/1000 Z 2 has a maximum load capacity of 1000 kg when used as a material hoist and under special preconditions. These preconditions are: •...

  • Page 42: Speeds

    Technical data 500 Z/ZP 2 The GEDA 500 ZP/1000 Z 2 is available as "platform A", "platform B" and "platform C". The load capacity in each case applies only without special attachments. Installation of optional equipment (e.g. roof, underrun protection, assembly plank) increases the dead weight.

  • Page 43: Operation

    500 Z/ZP 2 Operation Operation The 500 Z/ZP 2 may only be operated by a qualified person appointed by the operating company. This person must be familiar with the operating manual, have sufficient experience and be informed about the risks involved in handling lifting gear. (refer to chapter 1.8 Intended use, page 15) Safety during operation •...

  • Page 44: Special Safety Instructions For Operation As A Material Hoist

    Operation 500 Z/ZP 2 4.1.1 Special safety instructions for operation as a material hoist • Operation of the material hoist must take place outside the hazard area. • The operator must always be able to observe the platform. • Transporting persons is prohibited! •...

  • Page 45: Commissioning

    500 Z/ZP 2 Operation Commissioning Main switch Control light, ready for operation Socket [blue] for ground control/manual control Socket [red] for electric module on the landing level doors (or dummy plug during assembly) Fig. 13: Ground station switch box Only with 2.00 m base enclosure with sliding door Socket [grey] for 2 m base enclosure with sliding door (or dummy plug without this base enclosure) The connected control of the 2.00 m base enclosure automatically...

  • Page 46: Safety Check Before Starting Work

    Operation 500 Z/ZP 2 4.2.1 Safety check before starting work Perform a test run with an empty platform and check that the entire travel path of the platform is clear. The platform must immediately stop when • an EMERGENCY STOP button is pressed. •...

  • Page 47: Operation/Function

    500 Z/ZP 2 Operation Operation/function Fig. 15: Overview Mast section Platform access, ground station (ramp/door) Mast tie Building platform access (barrier Cable guide with loading ramp) Base mast with foot section Roof Cable bin "Comfort" landing level safety gate Base enclosure "Standard"...

  • Page 48: Securing The Lowest Stop Position (Ground Station)

    Operation 500 Z/ZP 2 4.3.1 Securing the lowest stop position (ground station) The lowest stop position must be secured and marked to prevent unauthorized access. DANGER Danger to life from lowering platform  Never remain inside the cordoned area/base enclosure during operation.

  • Page 49: Cordon

    500 Z/ZP 2 Operation 4.3.1.1 Cordon The cordon may only be used in combination with the installed underrun protection! Fig. 16: Cordon Height = approx. 1.10 m Distance to moving hoist parts = min. 0.5 m WARNING Risk of injury from impaired view ...

  • Page 50: M Base Enclosure With Barrier (Option)

    Operation 500 Z/ZP 2 4.3.1.2 1.10 m base enclosure with barrier (option) Fig. 17: 1.10 m base enclosure with barrier Height = 1.10 m Distance to moving hoist parts = min. 0.5 m Opening  Raise the barrier. Closing  Lower the barrier until it rests on the enclosure post. The platform can be operated only when the barrier of the base enclosure is closed.

  • Page 51: Sliding Door For 2.00 M Base Enclosure (Option)

    500 Z/ZP 2 Operation 4.3.1.3 Sliding door for 2.00 m base enclosure (option) As an alternative to the 1.10 m base enclosure with barrier, the 2.00 m base enclosure with sliding door can be installed. The sliding door for the base enclosure is installed on the access side and it must be extended on-site, e.g.

  • Page 52: Fig. 19: Unlocking The Sliding Door Lock

    Operation 500 Z/ZP 2 Opening  Press and hold the button (1/2) until the door is pushed out of the lock. Fig. 19: Unlocking the sliding door lock  Use the door handle (3) or safety bar (4) to push open the sliding door.

  • Page 53: Fig. 22: Sliding Door For Base Enclosure Open

    500 Z/ZP 2 Operation Fig. 22: Sliding door for base enclosure open Operation with sliding door and high base enclosure - DOWN travel without stopping at the lower safety area - Control from the landing level to the ground station Emergency release Door lock from outside ...

  • Page 54: Fig. 24: Door Lock Unlocked

    Operation 500 Z/ZP 2 Door lock from the inside  In order to unlock the door lock, rotate the activating lever (3) in the opposite direction. Fig. 24: Door lock unlocked  After emergency release, the activating lever (3) must be reset! Fig.

  • Page 55: Platform Access At The Ground Station

    500 Z/ZP 2 Operation 4.3.2 Platform access at the ground station This access point to the platform can only be opened if the platform is stopped by the down limit switch at the ground station. 4.3.2.1 Loading door / Ramp Opening ...

  • Page 56: Fig. 27: Platform With Front Ramp

    Operation 500 Z/ZP 2 Front platform access points (For platforms A, B and C only) The front ramp is standard for platforms B and C. An additional ramp (1) or loading door (4) can be installed at the front of the platform. Fig.

  • Page 57: Fig. 29: Emergency Release For Ramp/Loading Door

    500 Z/ZP 2 Operation Opening the ramp/door  Insert the triangular key (3) into the lock and turn to the right.  Lift/lower the interlock hook (2) and carefully open the ramp (1)/loading door (4).  Remove the key (3). Fig.

  • Page 58: Platform Access Landing Level

    Operation 500 Z/ZP 2 4.3.3 Platform access landing level Access to the landing level/scaffolding is secured with a barrier. The loading ramp automatically folds down when the barrier is opened. The open loading ramp unlocks the landing level safety gate. Fig.

  • Page 59: Barrier With Mechanical Lock

    500 Z/ZP 2 Operation 4.3.3.1 Barrier with mechanical lock The barrier must only be opened when the platform is located at the landing level in front of a landing level safety gate. Two separate actions are required for opening the barrier. Opening ...

  • Page 60: Barrier With Electromagnetic Lock

    Operation 500 Z/ZP 2 4.3.3.2 Barrier with electromagnetic lock Option as replacement for the barrier with mechanical lock. The barrier is always locked and is automatically unlocked at the landing level (from the landing level stop bar). The barrier with loading ramp can only be opened at the landing level in front of a landing level safety gate.

  • Page 61: Securing Loading And Unloading Points

    2 m. Only landing level safety gates for the checked and approved GEDA hoists may be used which ensure safe transition to the building in conjunction with the platforms.

  • Page 62: Fig. 35: "Standard" Landing Level Safety Gate Closed (Tarpaulin)

    Operation 500 Z/ZP 2 "Standard" landing level safety gate closed (tarpaulin) (Option as per EN 16719) The retrofit kit article no. 1130276 can be used to retrofit the "Standard" landing level safety gate with a tarpaulin. These landing level safety gates can only be opened once the loading ramp has been completely opened.

  • Page 63: Comfort" Landing Level Safety Gate

    500 Z/ZP 2 Operation 4.3.4.2 "Comfort" landing level safety gate It is only possible to open this landing level safety gate when the unfolded unloading ramp is in contact with the sill of the landing level safety gate. Fig. 37: "Comfort" landing level safety gate no. 01212 "Comfort"...

  • Page 64: Fig. 39: "Comfort" Landing Level Safety Gate Closed (Filler Plate)

    Operation 500 Z/ZP 2 “Comfort” landing level safety gate closed (filler plate) (Option as per EN 16719) Fig. 39: “Comfort” landing level safety gate closed (filler plate) Opening  Press the lever (2A) in the direction of the arrow and push open the sliding door (2).

  • Page 65: Premium" Landing Level Safety Gate

    500 Z/ZP 2 Operation 4.3.4.3 “Premium” landing level safety gate It is only possible to open this landing level safety gate when the unfolded unloading ramp is in contact with the sill of the landing level safety gate. Landing level safety gate in accordance with EN 16719 Fig.

  • Page 66: Flexy" Landing Level Safety Gate

    Operation 500 Z/ZP 2 4.3.4.4 “FLEXY” landing level safety gate Landing level safety gate in accordance with EN 16719 It must be impossible to open the landing level safety gate unless the ramp lock was actuated by the loading ramp of the platform/hoist.

  • Page 67: Controls

    500 Z/ZP 2 Operation 4.3.5 Controls 4.3.5.1 Functional description The "transport platform" operating mode (platform control) has to be activated. The platform operator has to activate the platform control at the key switch on the platform control each time after entering the platform. For confirmation, a green control light above the platform control also lights The "Construction hoist"...
  • Page 68 Operation 500 Z/ZP 2 Further travel from the landing level limit switch is not possible in either direction. • Installation of the construction hoist includes safety devices for the loading and unloading points (refer to the assembly manual). Use as a material hoist The key switch on the platform control has to be set to "0".
  • Page 69 500 Z/ZP 2 Operation Use as a transport platform For operation as a transport platform used to transport passengers as per EN 16719, the following has to be installed: • a roof • a platform access on the building with a barrier, which is - secured with a mechanical lock and which can be operated with two separate actions - secured with an electromagnetic lock...

  • Page 70: Use As A Construction Hoist (External Control)

    Operation 500 Z/ZP 2 4.3.5.2 Use as a construction hoist (external control) [Ground control and electric modules at the landing levels] The loading door/ramp, barrier with unloading ramp and assembly plank must be closed and engaged. The assembly guard must be properly attached at the top.

  • Page 71: Fig. 45: Ground Control/Manual Control (Position I)

    500 Z/ZP 2 Operation Selector switch (13) to "I" position (dead man's control/MANUAL) Ground control/manual control EMERGENCY stop button UP button DOWN button Selector switch MANUAL (I) - AUTOMATIC (II) Fig. 45: Ground control/manual control (position I) Ground control for base enclosure EMERGENCY stop button UP button...
  • Page 72 Operation 500 Z/ZP 2 WARNING Risk of injury from platform moving downwards  Ensure that the downward travel path is clear.  Only then can downward travel be continued.  Hold down the DOWN button (4) or press it again. The system issues an alarm signal and after about 3 s, the platform will start moving and stop at the DOWN limit switch.

  • Page 73: Fig. 47: Ground Control/Manual Control (Position Ii)

    500 Z/ZP 2 Operation Selector switch (13) to "II" position (automatic travel) Ground control/manual control EMERGENCY stop button UP button DOWN button Selector switch MANUAL (I) - AUTOMATIC (II) Fig. 47: Ground control/manual control (position II) Ground control for base enclosure EMERGENCY stop button UP button...
  • Page 74 Operation 500 Z/ZP 2 Travelling DOWN  Press and release the DOWN button (4). The platform travels downwards and stops before the lower safety area. WARNING Risk of injury from platform moving downwards  Ensure that the downward travel path is clear. ...

  • Page 75: Fig. 49: Electric Module For Landing Level Safety Gate

    500 Z/ZP 2 Operation Electric module for landing level safety gate The electric module must be installed on the landing level safety gates if local regulations specify electrical monitoring of the landing level sliding door or control of an upper stop position is required. Control from the stop position is only possible in "Construction hoist"...

  • Page 76: Operation As Transport Platform (Platform Control)

    Operation 500 Z/ZP 2 4.3.5.3 Operation as transport platform (platform control) The transport platform can only be operated from the platform in dead man’s control. The platform only operates while the operating button is pressed. The platform control may only be used with adequate brightness levels (at least 50 lx)! The platform may only be accessed and exited at stop positions above 2 m at the installed landing level safety gates.
  • Page 77 500 Z/ZP 2 Operation In the lower safety area, the move command button (3/4) must be pressed for approx. 3 s until the platform moves. During this time, a warning signal is emitted. Each time after entering the platform, the platform control has to be activated! Travelling UP ...
  • Page 78 Operation 500 Z/ZP 2  Press and hold the DOWN button (4) again.  The system issues an alarm signal and after about 3 s the platform will start moving and stop at the DOWN limit switch. When leaving the platform, activation of the platform control is switched off automatically! BL145 GB 2023-11...

  • Page 79: Controls For Special Operation

    500 Z/ZP 2 Operation 4.3.6 Controls for special operation 4.3.6.1 Operation for assembly For assembly, it is only possible to operate the hoist from the platform in dead man's control. The platform only operates while the operating button is pressed. The ramp, barrier with unloading ramp and assembly plank must be closed and engaged.

  • Page 80: Fig. 52: Platform Control For Assembly

    Operation 500 Z/ZP 2 Emergency stop button UP button DOWN button LED display for "Transport platform" operating mode is activated. Only the buttons described here are enabled for assembly! Fig. 52: Platform control for assembly Travelling UP  Press and hold the UP button (3). ...

  • Page 81: Drop Test Control

    500 Z/ZP 2 Operation  Press the DOWN button (4) again and keep it pressed. The system issues an alarm signal and after about 3 s the platform starts moving and stops at the DOWN limit switch. Before operating the transport platform, the key switch (10) has to be set to position 0 and the key has to be removed! 4.3.6.2 Drop test control...

  • Page 82: Emergency Shutdown

    Operation 500 Z/ZP 2 4.3.7 Emergency shutdown In situations that present a risk to operating personnel or the machine, the machine can be shut down by pressing an EMERGENCY STOP button. An EMERGENCY STOP button is located at each control point. Fig.

  • Page 83: Interrupting Work - End Of Work

    500 Z/ZP 2 Operation Interrupting work – end of work Switch off and secure the machine when interrupting work and at the end of work.  Move the platform downwards until it stops at the DOWN limit switch. If there is a risk of frost, move the platform up a little so that the DOWN limit switch is clear.

  • Page 84: Equipment

    The company operating the platform is responsible for this!  GEDA recommends transporting passengers only with the roof installed! Function: To protect people against falling parts.

  • Page 85: Fig. 57: Roof With Assembly Opening

    500 Z/ZP 2 Operation Roof with assembly opening Platform SL The roof is firmly attached to the platform. Fig. 57: Roof with assembly opening Roof Assembly opening BL145 GB 2023-11...

  • Page 86: Assembly Plank

    Operation 500 Z/ZP 2 4.5.2 Assembly plank The assembly plank may only be used during assembly and for maintenance. The assembly plank is a thin, folding platform which helps with anchoring the mast sections from the platform (can also be used in front of a façade without frontal scaffolding).

  • Page 87: Overrun And Cable Protection

    500 Z/ZP 2 Operation 4.5.3 Overrun and cable protection The proximity switch (2) switches off before the drive pinion leaves the gear rack (e.g. during assembly) or before the traction on the trailing cable holder (1) is too great. Fig. 59: Overrun and cable protection The correct distance from proximity switch to gear rack is 3 - 5 mm.

  • Page 88: Document And Tool Box

    Operation 500 Z/ZP 2 4.5.4 Document and tool box The document and tool box contains: • 1 x triangular key for EMERGENCY release of the door lock and the barrier with electromagnetic interlock. Fig. 60: Document box The documents and tool box should contain: •...

  • Page 89: Operating Hours Counter

    500 Z/ZP 2 Operation 4.5.5 Operating hours counter An operating hours counter (1) is installed in the trolley switch box to record the operating hours (motor operating time). Fig. 61: Operating hours counter The switch box must be opened to read the counter. The switch box may only be opened by a qualified electrician! BL145 GB 2023-11...

  • Page 90: Accessories

    Operation 500 Z/ZP 2 Accessories 4.6.1 Underrun protection For platforms with underrun protection, a barrier is sufficient for securing the ground station! Function: Protects the transport platform against damage from hitting obstacles. WARNING Risk of injury from platform moving downwards ...

  • Page 91: Fig. 63: Underrun Protection Platform Sl

    500 Z/ZP 2 Operation Fig. 63: Underrun protection platform SL When the underrun protection is raised, control is interrupted by a limit switch. This only allows upward travel. Remove the obstacle from the travel path. Only this allows travel again. BL145 GB 2023-11...

  • Page 92: Cable Bin Cover

    Operation 500 Z/ZP 2 4.6.2 Cable bin cover For better protection against theft, a cover can be installed on the cable bin for the trailing cable. Assembly: Assembly of the cable bin cover is described in separate instructions. Fig. 64: Cable bin cover 4.6.3 Cold package The 500 Z/ZP 2 can be used down to a temperature of -20 °C.

  • Page 93: Mast Assembly Aid

    500 Z/ZP 2 Operation 4.6.4 Mast assembly aid The mast assembly aid can be used to easily lift or place mast parts onto the assembled mast. Function: For lifting and positioning mast sections during assembly/disassembly. Fig. 66: Lifting, positioning of mast parts 4.6.5 Single axle trailer A special single axle trailer is available for road transport of platforms A,...

  • Page 94: Malfunctions - Diagnosis - Repair

    Malfunctions – diagnosis – repair 500 Z/ZP 2 Malfunctions – diagnosis – repair WARNING Risk of injury from incorrect troubleshooting and fault elimination  Troubleshooting and the fault elimination may only be carried out by persons specially trained and authorized for this purpose. ...
  • Page 95 500 Z/ZP 2 Malfunctions – diagnosis – repair Meaning of the LED Lights up when machine is ready for operation Flashes when a machine lock is active Lights up when the EMERGENCY STOP button of the platform control is activated. Lights up in the event of phase failure or if the phase sequence is incorrect Lights up when a safety stop button is actuated.

  • Page 96: Fault Table

    Malfunctions – diagnosis – repair 500 Z/ZP 2 Fault table The following table lists potential malfunctions and the appropriate remedial action. Malfunction Cause Remedial action Green control light off Mains plug disconnected Connect the mains plug Mains switch off Switch on the main switch Lamp defective Replace lamp Phase failure...
  • Page 97 500 Z/ZP 2 Malfunctions – diagnosis – repair Platform only moves upwards Is the UP limit switch Check/replace the UP limit functioning properly switch Clearance for the proximity Adjust the clearance to the switch for monitoring the gear gear rack (3 - 7 mm) rack is too large Platform moved too high (refer to chapter 5.3.2 Platform has travelled too high, page 98)

  • Page 98: Rectify Fault

    Malfunctions – diagnosis – repair 500 Z/ZP 2 Rectify fault 5.3.1 Motor is not delivering full power • Voltage drop of more than 10 % of the rated voltage. • Select cable with larger cross-section. • The integrated thermal switches turn off the control current when overloaded.

  • Page 99: Fig. 69: Operating The Drop Test Control

    500 Z/ZP 2 Malfunctions – diagnosis – repair CAUTION Risk of injury from incorrect operation  Free movement using the drop test control may only be carried out by a competent person specifically appointed by the operating company who, due to their training, knowledge and practical experience, are able to evaluate the risks.

  • Page 100: Overload Detection Device Has Triggered

    Malfunctions – diagnosis – repair 500 Z/ZP 2 5.3.4 Overload detection device has triggered The platform is equipped with an overload detection device which prevents the platform from being operated when it is overloaded. If the platform is overloaded, the red control light on the platform lights up.

  • Page 101: Safety Gear Has Triggered

    500 Z/ZP 2 Malfunctions – diagnosis – repair 5.3.5 Safety gear has triggered The platform is equipped with safety gear that slows down the platform if it travels too fast. Further travel is not possible once the safety gear has been triggered. WARNING Risk of death from the safety gear being triggered ...

  • Page 102: Fig. 73: Safety Gear With Limit Switch

    Malfunctions – diagnosis – repair 500 Z/ZP 2  Release the lock nut (4) on the safety gear.  Rotate the safety-gear protective cover (5) to the left until the limit switch lug (6) engages in the slot of the protective cover.

  • Page 103: Retrieving The Platform

    500 Z/ZP 2 Malfunctions – diagnosis – repair Retrieving the platform Rescue may become necessary in the event that, e.g. • there is no mains voltage. • the electrical system malfunctions. • the drive has failed. • the safety gear has triggered. If the supervisor/platform operator does not feel confident or qualified to organise and carry out the rescue, notify the relevant authorities (rescue personnel).

  • Page 104: Rescue Action Plan

    Malfunctions – diagnosis – repair 500 Z/ZP 2 5.4.2 Rescue action plan Action 1: Check the operating mode. The LED display (7) must illuminate when the platform control is active!  In the event that the LED display (7) does not illuminate, the platform control must be activated at the key switch (5).

  • Page 105: Fig. 75: Mount For Brake Release Lever

    500 Z/ZP 2 Malfunctions – diagnosis – repair Action 2: Self-rescue using the EMERGENCY descent function. Triggering of the safety gear In order to prevent the safety gear engaging, the brake release lever has to be operated with extreme caution. Once the safety gear has engaged, the platform can no longer be moved and has to be lifted.
  • Page 106 Malfunctions – diagnosis – repair 500 Z/ZP 2 It is not possible to lower the platform by releasing the motor brakes if e.g. the safety gear has been triggered. WARNING Risk of injury from defective safety gear  Now check to ensure that no parts of the drive system are broken, damaged or unserviceable.

  • Page 107: Repair

    • Quantity required The name plate is located on the trolley of the base unit. Spare parts must conform to the manufacturer’s technical specifications! Only use original spare parts from GEDA. For service or repair work, please contact our customer service department: For the sales and customer service address, (refer to chapter 1.4...

  • Page 108: Disposal

    Disposal 500 Z/ZP 2 Disposal At the end of its useful life, the machine may need to be inspected for operational safety in accordance with national regulations, disassembled correctly and scrapped in an environmentally friendly way according to national provisions. It is prohibited to use parts from a machine that is being scrapped in other machines or to assemble such parts to produce a new machine.
  • Page 109 500 Z/ZP 2 Disposal BL145 GB 2023-11...
  • Page 110 GEDA GmbH Mertinger Strasse 60 86663 Asbach-Bäumenheim Tel.: +49 (0)9 06 / 98 09-0 Fax: +49 (0)9 06 / 98 09-50 E-Mail: info@geda.de Web: www.geda.de BL145 GB 2023-11...

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