OPERATING INSTRUCTIONS HOIST
Contents
1. Reference 38740 E Issue date 18 jul 2005 Revision B Page 9 of 11 Tel 32 3 451 05 00 E mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA All dimensions and data are indicative only The user must ensure that the equipment complies with local rules and regulations TITAN STEEL WIRE ROPE PowerfClimber ONLY USE POWER CLIMBER RECOMMENDED STEEL WIRE ROPES Type Greenflex Diameter 8 4 mm For use with hoist model All models of TITAN hoist Construction 5 x 26 WSR Warrington Seale Compacted HDPP High Density Polypropylene core Structure Right Hand Cross Lay Light Preformed Tolerance 0 0 2mm Tensile strength of wires 1960 N mm2 Minimum Breaking Load actual 52 3 kN Minimum Breaking Load calculated 66 0 kN Weight 0 255 kg m Treatment Galvanized Identification mark Green strand e The end of the steel wire rope should be brazed to form a ullet end with a maximum length of 10mm without loose or broken wires e Use protective gloves to manipulate the Steel Wire Ropes e If Steel Wire Ropes are too long carefully wind any extra cable into a loop or onto the wire holders and tie up leaving the coil suspended just clear of the ground WARNING Steel Wires Ropes must be replaced in any of the following condi2. C PowerfcClimber OPERATING Titan INSTRUCTIONS HOIST Models Single phase TITAN 501 and TITAN 651 hoist with Central Control box Three phase TITAN 503 and TITAN 653 hoist with Central Control box Conform to EN 1808 1999 and Machine Directive 2006 42 EC WARNING e All persons operating this equipment must read and completely understand this manual e All persons must be thoroughly trained in the use of the equipment it operational and safety features and they must also be capable of carrying out the daily checklist e Only authorized and physically fit persons shall operate the equipment e Any operation in violation of these instructions is at the operator own risk and may result in serious injuries e Keep this manual with the hoist at all times e Only use spare parts and steel wire rope from POWER CLIMBER e Itis not allowed to put the machinery into service until the machinery into which it is incorporated or of which it is to be a component has been found and declared to be in conformity with the provisions of Directive 98 37 EC and with national implementing regulation e On platforms with only ONE hoist on ONE walk through stirrup an Overspeed safety device is compulsory in addition to the standard slack rope safety device Manufacturer Power Climber b v b a Satenrozen 7 B 2550 Kontich BELGIUM Reference 38740 E Issue date 18 jul 2005 Revision B Page 1 of 11 Tel 32 3 451 05 00 E
3. suspension rope will avoid getting them twisted together E Carry out Daily Checklist Carry out the Daily Checklist prior to your first ascent to install the top limit switch striker plates Always check the suspension system for stability and safety before launching the platform F Install Top Limit Switch Striker Plates The striker plate activates the top limit switch and must be clamped on the safety wire at a distance of min 20cm from the Talurit clamp Clamp the striker plate to the safety rope ONLY so that the IMPORTANT suspension rope passes freely through the slot in the plate REMOVING the steel wire rope from the TITAN hoist Tip Remove the safety rope first and keep the suspension rope taut so that the slack rope safety device stays open and allows easy passage of the safety rope Safety rope Manually pull the safety rope out of the slack rope safety device by hand Suspension Push the owndbutton on the CCB until the suspension rope no longer rope comes out of the top of the hoist and pull out the remainder of the rope by hand Tip push up on the slack rope lever for easy removal of the suspension rope After work is over check that e The platform is cleared of tools and equipment e All power has been switched off e Equipment has been secured where it will not be accessible to be tampered with Reference 38740 E Issue date 18 jul 2005 Revision B P
4. bend in the end of the rope before feeding it into the hoist C Attach the TITAN hoist to the stirrup 1 Lift the TITAN up from the ground by pushing the ipdbutton on the CCB Line up the holes in the stirrup bar with the holes in the stirrup 2 Attach the TITAN hoist to the stirrup of the platform with M12 bolts and self locking nuts Make sure that the TITAN hoist is mounted with the main hoist label towards the inside of the platform Reference 38740 E Issue date 18 jul 2005 Revision B Page 4 of 11 Tel 32 3 451 05 00 E mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA Alll dimensions and data are indicative only The user must ensure that the equipment complies with local rules and regulations PowerfClimber TITAN INSTALLATION D Reeve the safety rope in the TITAN hoist At roof level uncoil the safety ropes and lay them on the roof surface Attach the safety ropes to the suspension system with the safety hooks fitted to the ropes and lower the ropes to the ground Verify that the rope is long enough Push back the slack rope lever or tension the suspension rope to open the jaws of the slack rope safety device and push the safety rope through the slack rope compartment Take out all slack by putting a weight on the tail end of the safety rope Tip Separately reeving the safety rope and the
5. mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA All dimensions and data are indicative only The user must ensure that the equipment complies with local rules and regulations PowerClimber TITAN HOIST TITAN Single Phase TITAN Three Phase MODEL TITAN 501 TITAN 651 TITAN 503 TITAN 653 Working Load Limit 5000N 6500N 5000N 6500N W L L 500 kg 650 kg 500 kg 650 kg Power Supply 230V 50Hz E 3 x 400V 50Hz N E Amperage at RUN 5 0 A 2 5A 2 5 A W L L START 20 0 A 24 0A 7 5A 7 5A Motor Power 0 76 kW 1 00 kw 0 76 kW 1 00 kW Diameter 8 4 mm Wire Rope Breaking Strength 40 kN 52 kN 40 kN 52 kN Hoisting Speed 8 0 m min UP 60 dBA Noise level DOWN 64 dBA IP Rate IP 54 Self weight of hoist 45kg 45 kg Top limit switch o Power emergency descent Nameplate serial no Electric motor Lower carrying handle Upper carrying handle Suspension rope Safety rope Slack rope lever Electrical Box and Motherboard Electric supply cable Reference 38740 E Issue date 18 jul 2005 Revision B Page 2 of 11 Tel 32 3 451 05 00 E mail Info PowerClimber be Website www PowerClimber be Fax 32 3 451 05 01 This document and all copies are the property of Power Climber BVBA All dimensions and data are indica
6. 1 05 00 E mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA All dimensions and data are indicative only The user must ensure that the equipment complies with local rules and regulations PowerClimber TITAN INSTALLATION A Install CCB and connect Power Supply 1 Install CCB on the rear platform guardrail away from the working area 2 Connect the control cables from the CCB to each TITAN hoist 3 Connect the main power supply cable to the male plug on the CCB and secure it to the mid rail of the platform using the cable retainer Note Both hoists have to be connected to the CCB for either hoist to operate B Reeve the suspension ropes in the TITAN hoist At roof level uncoil the suspension ropes and lay them on the roof surface Attach the suspension ropes to the suspension system with the safety hooks fitted to the ropes and lower the ropes to the ground Verify that the rope is long enough 1 Push back the slack rope lever and insert the suspension rope through the eye of the slack rope lever and into the hoist until it stops 2 Push the dipdbutton on the CCB and the steel wire rope passes through the hoist automatically The end of the rope will come out from the bottom of the hoist Make sure the outlet is free and the wire rope can come out Tip If there is any difficulty reeving the suspension rope it helps to put a small
7. Climber TITAN SAFETY DEVICES 6 Automatic Levelling System The central control box is fitted with an automatic levelling system that allows the platform to maintain a stable horizontal position An out of level condition can occur when one of the hoists is working faster than the other or if the load in the platform is not evenly distributed When the platform is in motion the automatic levelling system stops the hoist that is going too fast and allows the other hoist to catch up When both hoists are level again the levelling system is deactivated and both hoists will function simultaneously The automatic levelling system is activated when the platform is out of level by 3 6 The Automatic Levelling System can be tested by using the hoist selector switch to create and out of level condition Once the platform is out of level check that the hoist that is too high no longer works in the ipddirection and the hoist that is too low no longer works in ownddirection 7 Overheating protection for hoist electric motor The hoist motors are fitted with a thermal contact which cuts power to the motors in case of overheating When the overheating protection is activated the p movement is halted If a hoist motor has overheated allow it to cool down to continue The overheating protectors of both hoists are connected in series If one overheating protector is triggered then the dipd6movement of both hoists is halted 8 Overspeed Saf
8. Warning Never use the emergency manual descent when normal powered movement is possible 4 Top limit switch The top limit switch cuts the up movement when it is activated by the striker plate which is clamped onto the safety rope at the top of travel When the top limit switch is triggered the platform can be driven down but not up The top limit switches of both hoists are connected in series If one top limit switch is activated then the d ipd6movement of both hoists is halted 5 Phase Protector for three phase hoist ONLY All three phase central control boxes are fitted with a phase protector which cuts power supply if phases are reversed When the phases are correctly connected the GREEN kKGindicator light on the outside of the CBB AND the GREEN indicator light on the phase protector only visible when CBB is opened are ON and the hoists will operate If indicator lights are OFF use a screwdriver to reverse the phases in the phase reversal power plug of the CCB WARNING DO NOT change any connections in the central control box Reference 38740 E Issue date 18 jul 2005 Revision B Page 8 of 11 Tel 32 3 451 05 00 E mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA Alll dimensions and data are indicative only The user must ensure that the equipment complies with local rules and regulations Powerf
9. age 5 of 11 Tel 32 3 451 05 00 E mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA All dimensions and data are indicative only The user must ensure that the equipment complies with local rules and regulations PowerfClimber TITAN MAINTENANCE ROUTINE MAINTENANCE at least every 3 months under normal use or 50hrs whichever comes first Note No specialised training is required to perform this basic maintenance 1 Check all plugs socket connections of the hoist and central control box for any signs of water penetration 2 Make a general inspection of hoist for excessive wear and damage 3 Remove main cover and inspect mechanism for any signs of excessive dirt and corrosion If required blow out with air or rinse with water Check that traction roller rotates when reeving de reeving the steel wire rope through the hoist Check the slack rope safety device for excessive dirt and corrosion If required blow out with air or rinse with water Check that the slack rope lever can move smoothly up and down If necessary lubricate with a dry wax based spray lubricant Replace main cover Carry out the Daily Check List before using the platform Write a maintenance record indicating e Any discrepancies noted and action taken e Hour meter optional reading of the hoist gt 8 2 LAD ANNUAL MAINTENANCE to be carried out b
10. ety device OPTIONAL The overspeed safety device locks onto the suspension rope when the suspension rope passes through the hoist descent speed at more than 15 m min The overspeed safety device can also be triggered manually by pressing the manual release button To reset the overspeed safety device first drive the hoist up a few centimetres and then turn the reset knob clockwise in the direction of the arrow 9 Use of Handwheel to reset safety device in case of power failure If the slack rope safety device or overspeed safety device optional has been activated and there is no power to the platform it will be necessary to wind the hoist up a few centimetres manually to be able to reset the safety device 1 Pull out main power plug to cut off power supply 2 Remove plastic plug in the motor cover to expose shaft for the handwheel 3 Remove the hand wheel from its storage position and insert shaft into hub 4 Wind the hoist in the up direction counter clockwise 2 turn at the same time as you pull up on the brake lever to open the brake 5 Release brake lever and repeat TIP Grab the hand wheel firmly while opening the brake to prevent it from turning and going back down 6 The overspeed safety device optional must be reset manually The slack rope safety device resets automatically 7 Put plastic plug back on and return hand wheel to its storage position after use 8 Plug in main power plug and resume
11. les and regulations PowerfClimber TITAN SAFETY DEVICES 1 Automatic slack rope safety device The automatic slack rope safety device locks mechanically onto the safety rope if a the suspension rope looses tension or breaks b the platform gets out of level by max 14 degrees The slack rope safety device on the lower hoist will lock mechanically onto the safety rope This is in addition to the automatic levelling system and protects against a slow creep down of the hoist 2 Overload detection device The overload detection device of each hoist is factory set to stop the dipddirection of travel if the Working Load Limit WLL of the hoist is exceeded by 25 The RED warning light on the central control box wil come ON in case of overload The overload detection devices of both hoists are connected in series If one overload detection device is triggered then the up movement of both hoists is halted To release the overload detection device remove the excessive load Tip In addition to removing the excessive load it may be required to remove part of the normal load in order to reset the overload detection device Once the overload detection device is reset the platform can once again be loaded with the full normal load 3 No Powerddescent In the event of a power failure the platform can be lowered at a controlled speed approx 6 m min by pulling the dNo Powerd descent lever on the electro magnetic service brake
12. t both hoists are correctly plugged in the CCB Remove steel wire rope and repeat reeving procedure see Tip Remove excessive load to automatically reset overload Check for obstruction e g hitting the striker plate Check the power supply and the specifications of the power supply cable Single phase hoist only Start capacitor is defective Hoist to be checked by an approved service centre Service brake failure The thermal protection has been activated The slack rope safety device is activated and platform is tilted or has come to rest on an obstruction Slack rope mechanism is contaminated by grit or corrosion Hoist to be checked by an approved service centre Let the motors cool down to reset automatically Tip The no powerddescent will still operate when the overheating protector is tripped Use the hoist selector switch to bring platform to the horizontal level or go up to come off the obstruction Clean and lubricate slack rope safety device IF PROBLEM PERSISTS CONTACT YOUR LOCAL SERVICE REPRESENTATIVE Reference 38740 E Issue date 18 jul 2005 Revision B Page 7 of 11 Tel 32 3 451 05 00 E mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA Alll dimensions and data are indicative only The user must ensure that the equipment complies with local ru
13. ta are indicative only The user must ensure that the equipment complies with local rules and regulations TITAN TROUBLESHOOTING Hoists do not work when pressing the dip downd push button GREEN kKdlight OFF Probable cause No Mains power PowerfClimber Solution Check power that power plug is properly connected or go down using the emergency manual descent Three phase hoists only Phases are reversed Use screwdriver to reverse phases on the phase reversal power plug of the CCB Hoists do not work when pressing the aip downd push button RED warning light ON During reeving the hoist works in the ipddirection but the suspension rope does not reeve through Hoists work for just a moment in the fupd direction and then stop RED warning light ON The hoists do not work in the up direction RED warning light ON Hoist hums starts slowly or is sluggish or fails to lift the loaded platform The hoists work for a long time and then stop The electric motors are hot RED warning light ON The hoist turns both in the dipdand ownddirection but the platform does not come down Slack rope lever does not pivot properly Emergency stop button has been depressed Release emergency stop button Both hoists are not connected to the CCB Steel wire rope is not entering the hoist properly The platform is overloaded Top limit switch has been activated Serious voltage drop Check tha
14. tions More than 10 wires are broken on a length of 25cm Excessive corrosion Damage due to heat structure Reduction of the nominal diameter by more than 10 Kinking 1 crushing 2 bird caging 3 or any other distortion of the wire rope Reference 38740 E Issue date 18 jul 2005 Revision B Page 10 of 11 Tel 32 3 451 05 00 E mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA Alll dimensions and data are indicative only The user must ensure that the equipment complies with local rules and regulations PowerfClimber TITAN DAILY CHECKLIST TESTS MUST BE CARRIED OUT EVERY TIME BEFORE USING THE PLATFORM 1_ Visually inspect the platform for damaged loose or missing parts Check the suspension system for stability before launching the platform 2 Check that all counterweights are in place and secured Check that all steel wire ropes are hooked on properly to the suspension system Check that the GREEN OK indicator light on the CCB is ON Check that the Up Downdpush buttons and the hoist selector switch are functioning Push emergency stop button and check that the platform cannot go up or down turn button in direction of arrow to reset Push down on the Top Limit Switch and check that it cuts the dipddirection but that platform can be 6 driven in the o
15. tive only The user must ensure that the equipment complies with local rules and regulations Power Climber TITAN HOIST OK light GREEN light is ON when power is ON Three phase only Light is OFF when phase are reversed Hold to Run Up Down Push Buttons Warning light RED light is ON in case of the following Overload detector activated Top limit switch activated Emergency stop activated One Both hoist s not plugged in Thermal protector activated Emergency Stop Button Press to cut ALL power To reset twist the knob in the direction of the arrow on the top of the knob Hoist Selector Switch Left Both Right Allows operation of individual hoist for reeving de reeving or leveling Cable retainer Connection Male CEE plug plug to hoist 3 for incoming 10 pole plug E main power Female CEE plug supply Phase reversing plug on three phase models outlet for power tools single phase 230V 50Hz 16 Amp The TITAN hoist is a self reeving traction hoist powered by an electric motor The hoists and the central control box CCB are mounted on Temporary Suspended Platforms TSP and suspended with steel wire ropes from a suspension system The strength of the platform and the suspension system used in combination with the hoists must be in relation to the Working Load Limit WLL of the hoist Reference 38740 E Issue date 18 jul 2005 Revision B Page 3 of 11 Tel 32 3 45
16. wnddirection Repeat procedure for other hoist M Drive the platform 1 2 meters off the ground to continue the tests M a ON ONE HOIST ONLY Pull on the No Power emergency descent lever and check that the hoist can be lowered at a controlled speed b Continue releasing the service brake until the 7 slack rope safety device is activated about 14 degrees and keeps the platform from tilting further c Repeat the procedure by manually lowering the other end of the platform Run the platform to the top and during travel inspect the steel wire ropes for kinks broken wires or other damage 8 Inspect the trailing electrical supply cable for damage At the top of travel check that the top limit switch striker plates are correctly fitted and also that the top limit switches are operated by the striker plates DO NOT USE EQUIPMENT THAT IS NOT OPERATING PROPERLY NEVER OVERRIDE LIMIT SWITCHES AND SAFETY DEVICES Reference 38740 E Issue date 18 jul 2005 Revision B Page 11 of 11 Tel 32 3 451 05 00 E mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA All dimensions and data are indicative only The user must ensure that the equipment complies with local rules and regulations
17. y an authorized service centre 1 Completely strip the hoist clean and inspect all parts for wear and damage Replace worn parts when necessary Clean lubricate and re assemble the hoist Particular attention must be given to the slack rope safety device Place the hoist on a test rig and test that it can lift the rated Working Load Limit Check all plugs socket connections of the hoist and central control box for any signs of water penetration Reinstall the hoist and control box back on the platform and carry out the Daily Check List Write a maintenance record indicating e Repairs carried out and or parts replaced e Hour meter optional reading of the hoist v Ot EU Special conditions The frequency of inspection and maintenance also depends upon the environmental and working conditions e When working with abrasive adhesive or corrosive materials epoxy paint cement sand blasting acids salt water spraying the hoist should be protected with a suitable cover and the daily checklist carried out at least once a day e Always exercise caution regarding grounding arcing and insulation whenever welding or using electrical equipment Reference 38740 E Issue date 18 jul 2005 Revision B Page 6 of 11 Tel 32 3 451 05 00 E mail Info PowerClimber be Fax 32 3 451 05 01 Website www PowerClimber be This document and all copies are the property of Power Climber BVBA Alll dimensions and da
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