USER MANUAL - XLNT: advanced technologies
Contents
1. When the user sends an initialize command to the CyberHoist the mains contactor is en gaged This powers the flux vector drive speed control device or just drive hereafter and the brake circuit he initialize signal can be cut by the upper and lower limits and by the thermal overload sensor not shown in this figure thus cutting power to the motor and putting the brakes on The flux vector drive takes a few seconds to initialize When done the motor and brakes can be powered When the motor is powered the drive monitors torque in the motor to the gear box and only when the motor supplies enough torque are the brakes released initialise flux vector drive ni circuits Figure 3 internal block function dashed lines are dataconnections solid lines are power connections For further information on the internal safety system in the CyberHoist and co operation amongst CyberHoists we refer to the XLNT InMotion3D Software user manual xint anced technologies 2 Chapter 4 Safety 4 1 Risk assessment The user shall make a risk assessment based on all plans drawn up for the particular show the CyberHoists will be used in Although other involved parties might2. Read this first It is extremely important to read ALL safety information and instructions provided in this manual and any accompanying documentation before installing and operating the products described herein Read Chapter 4 Safety before planning and rigging a show it contains specific guidance for safe in stalling and use of CyberHoists CyberHoists are only to be installed and operated by competent persons For competence require ments see Preface Reed all cautions and warnings during installation and use of this product Keep this instruction manual for future reference This unit does not contain any user serviceable parts Do not open this unit Doing so will void warranty and might present a risk Servicing must be per formed by qualified personnel only Servicing is required when the apparatus has been damaged in any way such as power supply cord or plug damage if liquid has been spilled or has fallen into the apparatus the apparatus has been exposed to rain or moisture does not operate normally has been dropped or when it is due for periodic inspection and or servicing This unit is designed for indoor use Do not use this unit outdoor or in a wet or damp environment or near water Do not install near any heat sources such as radiators heat registers stoves or other devices includ ing amplifiers that produce heat This unit is not designed for residential use designed as 89 336 EEC Class A device Do no
3. lifting persons and performer flying CyberHoists are not intended for lifting people or performer flying Performer flying means mov ing performers during an artistic performance as excluded from the scope in the Machine Directive 2006 42 EG But since 250 500 have an overall design factor of 10 and 20 the manufacturer foresees that some users might do so nevertheless Though the manufacturer strongly discourages flying of persons and performer flying by CyberHoists some information and guidance 15 provided for the user in Chapter 4 Safety Since individual situations in the flying of persons or performer flying are impossible to foresee by the manufacturer the user shall entirely be held responsible this case for any damage and injuries to goods equipment and persons Only when the products are used a manner intended by the manu facturer can the manufacturer be held liable for the malfunctioning of his product If the user Is left with any questions regarding the intended use It is his responsibility to consult the manufacturer outdoor use CyberHoists are designed according IP50 class protection and are not intended for outdoor use The manufacturer however recognizes the market s wish to use CyberHoists in outdoor stages commonly used by touring bands at pop festivals etc The manufacturer strongly discourages the use of Cyber Hoists in these and other outdoor situations but some information and guidance
4. Due to the dynamics that come with fast lifting loads all CyberHoists models have 1 ton parts all though the rated capacity might only be 500 or 250 kg The same applies for the slinging and construc tions that hold the CyberHoist they shall also be rated for 1 ton minimum xlnt advanced technologies xlnt advanced technologies Chapter 5 Storage transport and reception 5 1 General handling To avoid damage to the interior electronics handle CyberHoists with care and always travel flight cases on wheels At maximum only stack two flight cases with CyberHoists on each other WARNING A full flight case weights up to 135 kg 300 lbs preferably use a fork lift to stack and unstack the cases In case you need to do this quite a few times call in enough colleagues pay attention to your body position while lifting and lowering straight back bend your knees etc to avoid serious injury to your back Wear safety shoes to avoid injuring your feet by the flight case Wear gloves to avoid injuries to your hands 5 2 Storage CyberHoists can be stored as supplied by the manufacturer For regular storage and for transport the following conditions need to be maintained temperature between 5 409 C 41 104 F humidity between 30 70 the environment shall not condensing dust as long as your CyberHoist is properly packed in e g a flight case there are no special conditions concerning dust T
5. Warning Never dump your equipment CyberHoists contain electrical parts and lubri cation greases that are not environmentally friendly and should get special treatment so that is will be destroyed it in an environmentally safe way xlnt advanced technologies Annex Technical Specifications Safe Working Load see note below cH 1000 EUJUS 500 EU US CHz250 EU US Speed limits see note below NOTE actual speed limits may vary by the actual loading of the hoists see chapter 7 Instructions for Safe Use and Annex 1 Acceleration and deceleration limits type maximal ac and deceleration upward downward CH 1000 EU US 0 005 ms 2 0 91 TU 8 9 CH 500 EU US 0 190 m s 0 62 Tis CH 250 EU US 0 381 15 8 2 1251182 Supply voltage Tolerances Idle current consumption Peak current consumption Max duty cycle Brake type Power connector Data connector Standard chain length Self weight Weight incl XLNT flight case Weight XLNT flight case XLNT flight case size Type of hook on chain Chain type Weight of chain Max wear on chain Type of lubricant 3 phase 400 V EU type 3 phase 208 V US type 596 380 420 V EU type 197 218 V US type 5 6 A EU type 13 A US type depends on application ask XLNT personnel for advice Double individually controlled 190 V DC EU type 100 V DC US type Harting 10 pin Ethercon CAT5 RJ45 22
6. Figure 5 Harting 10 pin power connector Figure 6 Ethercon data connector xlnt advanced technologies A xx 5 X 2 Power distro XX XD XXX 1 Cyberhoist Emergency Ethernetswitch mmm Figure 7 cabling scheme for a CyberHoist installation xlnt advanced technologies 2 InMotion3D controller Ethernetswitch Right Figure 8 fitting the cables close to the slings m Connect the data switch to the CyberHoist Manager Only use 5 CAT 5e or 6 cabling For distances up to 50 metres use STP FIP or SFTP For distances from 50 100 metres use UTP cable at longer lengths the FTP cable dampens the signal too much n Install a power chord from the distro to the CyberHoist Manager o Install the emergency switch in the near vicinity of the CyberHoist Manager p Install other emergency kill switches if your Risk Evaluation indicates to do so 6 2 Powering up the system When all actions above have been completed and when the power supply is in order you can
7. software to secure all releasable parts in the lifting chain directly above the CyberHoists like shackle pins etc to position the chain bag In such a position that the CyberHoist will not start rotating around its vertical axis when a load is applied or when the chain starts slanting during movements WARNING Never lift a CyberHoist on your own its too heavy Always call in the help of a colleague to avoid personal injury a Mount the CyberHoists on the main grid attach it to its slinging means always motor up b Put the power break out for the CyberHoists on the main grid c Tie the safety cable of the power break out to your main grid d Put the data switch on the main grid Tie the safety cable of the data switch to the main grid f Check with an suitable instrument the supplied power at your location single phase as well as 3 phase power supply For specifications and tolerances see Annex 1 In case the supply voltage is not what it should be contact the local responsible person and wait before switch ing on the equipment until the proper voltage has been provided g Provide power to the DataMotion ethernet switch either by the network itself power over LAN or by a 100 240 V 50 60 Hz single phase power with neutral and ground Please refer to XLNT DataMotion User Manual for detail specifications xlnt advanced technologies h Put the power distribution cabinet in place
8. 3900 mA 5 2600 mA 1300 mA 0 63Kg 125Kg 188Kg 250Kg Load Figure 11 b Power consumption of CH 250 EU xlnt advanced technologies 13000 mA 11700 mA 10400 mA 20 m min 9100 mA 7800 mA 6500 mA zt Ld Drive Current 5200 mA 0 16 m min 3900 mA 2600 mA 1300 mA 0 mA 0 125Kg 250Kg 375Kg 438Kg 500Kg Load Figure 11 c Power consumption of CH 500 EU 13000 mA 11700 mA 10400 mA 7800 6500 mA Drive Current 5200 mA 0 8 m min 3900 mA 2600 mA 1300 mA 0 mA 0 250Kg 500Kg 750Kg 875Kg 1000Kg Load Figure 11 d Power consumption of CH 1000 EU xlnt advanced technologies 2 100 96 ay ay 80 96 70 96 60 D 50 N EEHENHNEN CH 500 40 20 20 10 90 0 0 10 20 3090 4090 50 60 70 80 90 100 Load Figure 12 Safe percentage of WLL vs speed 100 90 80 70 60 N 50 0 zo 40 20 20 10 96 0 0 10 20 3090 4090 5090 6090 70 80 90 100 Load Figure 13 Safe travel distances for CH 1000 vs speed EU and US models Figure 12 shows the maximum relative speed at given relative load for EU and US types For loads above the nominal speed the energy dissipation the drive and gear box Increases rapidly Figure 13 shows the relative distance that can safely be travelled when loading a 1000 kg CyberHoist above 75 of its WLL 750
9. focus on other topics the user of the CyberHoist shall use his rigging plan as a basis for his part of the risk assessment International standards as well as local laws and regulations shall be complied with the process of the risk as sessment 4 2 Outdoor use As stated in chapter 1 the CyberHoist is only IP class 5 0 and not intended for outdoor use However in the case the user decides to take the responsibility and consequences of outdoor use the following information and directions may help to avoid problems ATTENTION This information and guidance is not extensive and certainly not enough to have all risks covered Outdoor use 15 completely for the user s own responsibility including any course of events resulting from mechanical or electrical malfunctioning or breakdown of one or more CyberHoist or a combination of equipment which includes one or more CyberHoists Forced cooling rain The CyberHoist makes use of forced air cooling When moisture 15 present small droplets of water will be sucked inside the housing So even when you have provided a proper roof above the CyberHoists in case of a thick fog like rain the CyberHoist will get wet Small rain droplets are also formed by heavy rain due to splatter of the large drops on surfaces The use of rain covers normally used on electric chain hoists in outdoor situations is NOT permitted see next paragraph Forced cooling air CyberHoists make use of electrical b
10. kg This is due to the fact that at high loads the electronic braking system needs to dissipate more and more energy xlnt advanced technologies 2 xlnt advanced technologies Contact Information Head office XLNT Advanced Technologies Manufacturing BV Tel 31 30 247 9999 Fax 31 30 247 9998 info dxlnt at com WWW xlnt at com Visiting Address Proostwetering 50 3543 AH Utrecht The Netherlands
11. m 72 ft lifting capacity 23 3 m of chain total 80 kg including chain 122 kg 270 lbs 42 kg 93 lbs 720 x 600 x 670 mm LxWxH incl wheels Safety Latch lock Gunnebo 6B6 7 8 8 6 8 x 17 8 mm see CyberHoist Service Manual 1 08 kg m 2 38 lbs m see CyberHoist Service Manual Metal SBC2 Operation amp control CyberHoists can only be operated and controlled by configuring them in the InMotion 3D software running from a Apple computer see InMotion 3D Software Manual and controlled an Ethernet network At the present time a control device commonly known as a pickle is not available 650 287 1 ir Tj 1 T 1753 1 qi 0 tr qi TT 4 Figure 9 dimensions xlnt advanced technologies Annex 2 Power Consumption NOTE These figures are Indicative individual hoists may differ from diagrams shown below 6500 mA 7 mm um um um um um um um um um um um um um um um mm mm umm mm mu mu mm 5850 mA 5200 250 500 EU 4550 mA 3900 mA 3250 mA 2600 2 m d CH 1000 EU se Drive Current 1950 mA gt 1300 mA pat 650 mA 63Kg 125Kg 188Kg 250Kg 375Kg 438Kg 500Kg 750Kg 875Kg 1000Kg Load Figure 10 a Power consumption of EU models 6500 mA Max 5850 mA 5200 mA 4 CH 250 EU a 36 m min 550
12. or in the direct vicinity of persons 15 strongly discouraged In the entertainment industry however one cannot imagine any show without lots of luminaires video projec tors or sound cabinets lifted above people This equipment 15 generally lifted with use of aluminium truss and electric chainhoists hanging immobile without power or control present to avoid possible hazards This is also known as overhead suspension But sometimes the design of the show requires moving objects be that some moving box trusses with luminaires or just a backdrop truss that needs to move up and down for change overs This is where the CyberHoist come in Some remarks considering the design and intended use of CyberHoists are necessary however overhead lifting Standard chain hoists require an overall safety factor 5 The 250 and 500 kg CyberHoist versions see table 1 are designed with an overall safety factor 20 and 10 since all three types are designed around a 1000 kg body Their safety factor is twice or more as required According to EU laws this allows lifting overhead or in the direct vicinity of persons be that personnel performers or public The CH 1000 can only be used for overhead lifting when loaded to no more than 500 kg Furthermore the CH 250 and 500 are rated for BGV C1 type applications Possible hazards that come with these lifting applications are addressed in chapter 4 Safety We strongly advise the user to read that chapter thoroughly
13. wheel WARNING In combination with slanted chains a poorly lubricated chain can lead to sudden and excessive wear of the chain guide chain and sprocket wheel The combi nation of heavy load a fast movement downwards and an emergency stop may lead to damage to the CyberHoist like the chain ripping a piece of the chain guide into the sprocket wheel causing damage to the sprocket wheel and chain It might even cause the chain to fail causing the Load to make a sudden uncontrolled movement collapse or even drop down at the risk of causing severe injury or damage to property Varying load due to position of the load Scenic movements of the load like roll and pitch cause the chains to slant and the chain hooks to move horizontally as well as vertically When these kind of movements are done fiercely the load will get redistributed on the hoists the load will increase at the hoists with highest hooks and diminish at the hoists with the lowest hooks At the end of such a scenic movement the load will hang completely on and right beneath the hoists with the highest hooks and the other chains will run slack Furthermore when such steep movements are carried out at high speed your load will start to swing This can be dangerous when you have multiple loads hanging very close to each other Int Keep this in mind when drawing up your rigging plan and while programming your show in InMotion3D anced technologies Figure 4 Slanted cha
14. Pay attention you ll be able to reach it easily and fast In case of emergency or technical problems ATTENTION The power distribution cabinet shall have an emergency stop with stop class 0 safety class 4 Meaning the power to the CyberHoists will be cut off in case the emergency stop is applied In case you want to build your own cabinet contact your XLNT dealer for specifications such as type of circuit breakers and appropriate wire gauges i Connect the distro to the local power supply j Connect the power break outs to the distro See figure 7 on the next page Note when cabling your equipment in the main grid always keep an extra 1 5 m length at both ends so that you can move the equipment a little without having to redo the cabling k Connect the CyberHoist power plug see figure 5 below to the power break out with a Hart ing 10 pin motor cable of suitable length i Connect the CyberHoist data connector with a Ethercon shielded cable to the data switch When connecting cables to the CyberHoist always keep 1 5 m extra length to be able to move the hoist a little cables should have enough slack but not too much to avoid getting caught by the moving objects always tape the cabling alongside your slings to prevent the cable from being pulled or torn in case the hoist turns around its vertical axes see figure 8 below pay attention to flimsy connections in cabling as they may loosen during use
15. Ve 1 E 2277 CSN 200 nmi Bj 2 N W Ey San TOS TOS Ws TOS fal gt Yos i 0 EM LN 7 0 T 7 LM 0 WF 2 CyberHoist CH 1000 500 250 EU US 2 a iS o c 2 o o G gt xlnt advanced technologies Declaration of Conformity Manufacturer s name XLNT Advanced Technologies Manufacturing BV Address Proostwetering 50 3543 AH Utrecht The Netherlands Declares that the products Name CH 1000 EU CH 1000 US CH 500 EU CH 500 US 250 EU CH 250 US Conform to the following EC Directives and international standards 2006 42 EC Machinery Directive 2006 95 EC Low Voltage Directive 89 336 EEC EMC Directive EN ISO 13849 1 2006 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN 60204 32 Safety of machinery Electrical equipment of machines Part 32 Requirements for hoisting machines EN 55022 2006 A1 2007 Information technology equipment Radio disturbance characteristics Limits and methods of measurement EN 61000 3 2 2000 Electromagnetic compatibility EMC Part 3 2 Limits Limits for harmonic cur rent emissions equipment input current 16 A per phase 61000 3 2 2006 Electromagnetic compatibility EMC Part 3 2 Li
16. ad Installation of electrical equipment like network switches computers power supplies and power supply systems xlnt advanced technologies Use of CAD software VectorWorks to design a 3D CAD files that can be imported in the InMotion3D software VectorWorks can be bought optionally when purchasing an InMotion3D system Use of show control software and the functioning in a team guided by a directors or directors with use of cue s commands Other documentation For information and instructions on operating and control of CyberHoists we refer to the XLNT Ad vanced Technologies InMotion3D User Manual For information and instruction on servicing CyberHoists we refer to the manual XLNT Advanced Technologies CyberHoist Service Manual and Owner s manual for ChainHoist CyberHoist SM10 1008 by Verlinde Used symbols and typographical signs Instruction numbers For numbering instructions this manual uses a digit followed by a brace Each paragraph starts a new sequencing Warning signs and notes The following type of message function like a tip or a reminder NOTE Only certified XLNT service personnel are allowed to do repairs on CyberHoists All repairs shall be logged in a service log This type of message indicates potential damage to your equipment or the prevention of proper func tioning ATTENTION Never place heat sources in the vicinity of a CyberHoist like the fan exhaust of a video projec
17. aler In the back of this manual dealers are listed Chapter 6 Installation and dismantling 6 1 Mounting the CyberHoist and installing the cabling NOTE Give all equipment and cables a visual inspection before installation to avoid problems later on See chapter 8 Inspection In the procedure described here we assume you have already provided for the proper rigging and slinging of the CyberHoists and that you are ready to take them out of their flight cases and install them In these instructions the term main grid is used by analogy It generally refers to supporting construction on which the CyberHoists are mounted Please read the user manuals of the XLNT DataMotion and XLNT PowerMotion or other equipment before you install and use them WARNING NEVER use the handles to attach the CyberHoist to the supporting struc ture They are only made to support the hoist s own weight They will brake when used as lifting attachment resulting in parts falling down at the risk of causing severe injury or damage to property The easiest way of installing CyberHoists is by using a main grid that you lower down to the opened flight cases You then attach the CyberHoists to your slings and lift them all together out their flight cases Pay attention to position the right hoist with the right identification on the right spot in case your show Is already set up e g when doing a tour It saves you the effort of re patching in the InMotion3D
18. er distro is a registered product of XLNT Advanced Technologies xlnt advanced technologies Contents Declaration of Conformity Read this first Foreword References Contents Chapter 1 Introduction 1 1 About the CyberHoist 1 2 Lifting applications 1 3 Operating Chapter 2 Technical description Chapter 3 Functioning Chapter 4 Safety 4 1 Risk assessment 4 2 Outdoor use 4 3 Lifting persons and performer flying 4 4 Risks due to the scenic movements 4 5 Slanted chains due to scenic movement 4 6 Stretch on lifting means 4 7 Power consumption 4 8 Power down when not in use 4 9 Capacity of slinging means 5 1 General handling 5 2 Storage 5 4 Reception 5 5 Included items Chapter 6 Installation and dismantling 6 1 Mounting the CyberHoist and installing the cabling 6 2 Powering up the system 6 3 Procedure for unmounting a CyberHoist Chapter 7 Operation Chapter 8 Maintenance and inspection 8 1 Prior to each use 8 2 After frequent use or use under special circumstances 8 3 During long periods of use 8 4 Periodical inspection 8 5 Long term storage Chapter 9 Decommissioning Annex A Technical Specifications Annex 2 Power Consumption Contact Information lt I O W N 10 11 13 13 13 13 14 14 16 16 16 16 17 17 17 17 18 18 21 22 23 24 24 24 25 25 25 25 26 28 32 Chapter 1 Introduction 1 1 About the CyberHoist CyberHoists are electr
19. es the use of InMotion3D 15 covered in the XLNT InMotion3D User manual we refer to that environmental conditions for operation The following conditions shall be met when operating CyberHoists Temperature 5 40 C 41 104 F Humidity 10 90 96 in a non condensing environment Dust Avoid dusty environments due to the forced cooling dust is sucked into the inlet Although the inlet is equipped with a filter dust will get into the cabinet itself and will stick around fans and parts on the inside preventing it from cooling properly Condensation After powering down the CyberHoists they can be packed in their cases immediately When transporting a CyberHoist always use a closed flight case ATTENTION When condensation has formed after powering down e g during the night in between concerts wait before powering up the hoists until condensation has evaporated xlnt advanced technologies Chapter 8 Maintenance and inspection 8 1 Prior to each use The user shall visually inspect the CyberHoist prior to each use for defects wear and tear and Irregu larities and if needed take action The term each use shall be interpreted as each time a CyberHoist Is installed for one show or consequent shows at one and the same location without altering the setup of the CyberHoists The following points are important absence of the type label on the housing of the chain hoist when damaged or absent the Cy berHo
20. f a system with some CyberHoists is used for a long period of time e g when touring for a period Longer than two months it will be necessary to plan some inspections during this period The user shall take care to stipulate this maintenance plan 8 4 Periodical inspection CyberHoists shall be inspected and tested by competent XL NT service personnel only Inspection in tervals shall be in accordance with local laws and regulations but are not to exceed a maximum of 12 months between inspections The findings of these inspections shall be logged 8 5 Long term storage When you want to store your CyberHoist for a long period the following procedure must be followed Make an entry in your maintenance logs when you take them out of service During the storage period no inspections are necessary During storage the environmental condition set in 3 4 should be maintained When put into service again an inspection and a test shall be done by a competent XLNT serviceman Findings of these inspections shall be logged Chapter 9 Decommissioning In case the equipment is taken out of service e g because the product has reached it s end of eco life is damaged beyond repair or what so ever it must be sent back to your local supplier They can take care of the dismantling the item in an environment friendly manner It can also be offered to a company specialized in dismantling and recycling this type of electronic equipment
21. functioning of these switches NOTE Only certified XLNT service personnel are allowed to do repairs on the CyberHoists Repairs shall be logged WARNING The speed with which a CyberHoist can run its chain in combination with the fact that luminaries in the vicinity might heat up the chain might cause the lubri cation to evaporate quite quick Too little lubrication causes excessive wear and tear to the sprocket wheel and chain itself This can cause the chain to run out of the chain bag jam or even lead to the failure of the chain chain guides or the sprocket wheel Any one or a combination of these may cause the load to fall down or collapse at the risk of causing severe injury or damage to property 8 2 After frequent use or use under special circumstances When CyberHoist is frequently used e g because it s used a lot during long show period or when it s been used under specially harsh conditions e g near salt water it shall be inspected by an compe tent XLNT service technician xlnt advanced technologies 8 3 During long periods of use When CyberHoists are used frequently over a longer period a regular visual inspection is necessary done by a competent person Attention shall be made to the following lubrication of the chain tightening of the housing hooks condition and their ability to turn cabling on proper taping slack etc connectors their locking mechanisms Insulation et cetera I
22. ical chain hoists designed for the entertainment industry CyberHoists can be grouped to lift individual objects and to perform scenic movements during a show These objects can be trusses or truss constructions that carry luminaires pieces of scenery video equipment etc The way CyberHoists are operated is largely dictated by the design and directions given by one or more artistic persons in a show be that theatre pop concerts events etcetera Figure 1 the CyberHoist Three version of CyberHoists are available 1000 500 and 250 kg with speed limits of 10 20 and 36 m min resp They are available in EU 400 V and US 200 V types All CyberHoist have a design similar to the Stagemaker 5 10 Electrical Chainhoist with standard 1 ton components like motor housing brakes sprocket wheel and load protector The differences are found in gear boxes and speed control lers For precise specifications we refer to Annex A Specifications Tabel 1 CyberHoist versions loading speeds and classifications Ee mmn fing so m ln t SWL with overhead lifting taken into account X when loaded to 500 kg maximum advanced tecnnologies xlnt advanced technologies Tabel 2 Brief specifications 1 75 kW Nr of falls Mounting direction 1 2 Lifting applications In other industries lifting overhead
23. igure 2 gives an overview Figure 2 external parts and connections A top attachment Models with load cells have a load cell combined with a 3 25 ton shackle earlier models only have non rotating hooks latch lock type handles For handling the CyberHoist manually ONLY like taking in and out of the flight case not for lifting operations See below C connector Provides communication with other CyberHoists and XLNT InMotion3D software EtherCon connector type plug with RJ45 network connector inside chain bag Extra deep chain bag to prevent the chain from piling out of the bag and smooth operation at high speeds Provides power to the CyberHoist Harting 10 type lifting chain With lower hook latch lock type and swivelling WARNING NEVER use the handles to attach the CyberHoist to the supporting struc ture They are only made to support the hoist s own weight They will brake when used as lifting attachment resulting in parts falling down at the risk of causing severe injury or damage to property Chapter 3 Functioning Figure 3 shows an Internal block diagram of the CyberHoist It also explains the basic safety elements of the CyberHoists Power and data are fed into the CyberHoist 1 and 2 At first only the processor unit and internal fan are powered the fan starts rotating the processor unit initializes and starts communication After a few seconds the user can detect the CyberHoist in the network
24. ins and varying load due to scenic movement xlnt advanced technologies 2 Precision when mounting and installing the CyberHoists When chains get slanted the exact location of your slinging point matters extra The CyberHoists need to calculate the chain length for various positions with its hook horizontally displaced But a CyberHoist cannot actually detect where you attach it the only information that is used is from the CAD file so when you move your load into a steep position the chains will run quite slanted moving your slinging point a few centimeters towards the load can cause your chain to run slack and moving the slinging point a few centimeters away from the load can cause it to take extra load Either way it will give your Load additional horizontal movement 4 6 Stretch on lifting means Steel wire ropes and span sets are relatively stretchable compared to the chain of a chain hoist Span sets are made of fabric that is stretchable itself and steel wire ropes have a large initial stretch due to the setting of the strands when a force is applied When a CyberHoist is mounted from a high support ing construction using long steel wire ropes and span sets you need to take this stretch into account The dynamics due to scenic movements will alter the lengths in the lifting means and worse some times the system can go into resonance at certain speeds Take into account that your loads will need to cushion out when stop
25. ion of a new CyberHoist first use decom missioning et cetera Installation refers to unpacking mounting connecting or disconnecting of the hoists For operating the CyberHoists setting up and programming of a show etc we refer to the XLNT Ad vanced Technologies InMotion3D User Manual This manual is not intended for service or repair of CyberHoists only authorised XLNT service mechan ics are allowed to service or repair CyberHoists Important general remarks The user shall thoroughly read this and accompanying manuals The user shall familiarise him or herself with all safety information and Instructions provided this and accompanying manuals as well as In manuals of other products used for the Installation handling and operation of CyberHoists The user shall comply with local health and safety related laws and regulations regarding lifting over head lifting and overhead suspension see also chapter 4 Safety This manual shall be kept for future reference If the user feels that this manual has left any questions unanswered or that the answers provided within this manual are unclear it 15 the users responsibility to consult his local dealer or XLNT Ad vanced Technologies directly Competence requirements of the user CyberHoists shall only be installed and operated by competent persons Competent persons shall have proven skill sets that include but are not limited to the following subjects Rigging planni
26. is given in Chapter 5 Safety with which the user can make his own plan how to use the CyberHoists in the safest possible way Since individual outdoor situations are impossible to foresee by the manufacturer the manufacturer cannot be hold liable any for electrical or mechanical malfunctioning or breakdown nor for the con sequences thereof including but not limited to severe injury or death as a result of such use 1 3 Operating Each CyberHoist should be powered with 3 phase 400 models or 208 V US models and the power distribution unit must be equipped with an emergency stop In order to operate a CyberHoist it is nec essary to use a data network and an Apple computer with the XLNT InMotion3D Software CyberHoists can not be operated as a stand alone hoist The data network consists of CAT 5 type ethernet compo nents The InMotion3D Software has various modes a setup mode for attaching all the CyberHoist in use and prepping all individual hoists for a particu lar show In the setup mode the user also has to group the hoists into objects an edit mode to make things like presets cues and cue lists and a run mode to run all page lists containing cue lists xlnt advanced technologies xlnt advanced technologies Chapter 2 Technical description All 3 CyberHoist models consist of the same body and external elements like chain type upper and Lower attachments load cells etc F
27. ist needs be taken out of service and offered to a XLNT service point for inspection lubrication of the chain to guarantee a smooth running of the chain for the type of lubricant see chapter 2 specifications wear tear and damage to the chain entry this usually forecasts damage to the chain or sprocket wheel wear tear and damage to the chain check visually when there s any doubt call in a compe tent person who can check if the chains ability to perform safely has been compromised see specifications in the CyberHoist Maintenance Manual fastening of the housing and lifting handles check all socket head screws damage to the housing this indicates possible damage to the interior hook attached to the motor itself older models on damage bending correct working of the latch etc load cell it should be fastened though freely movable check for damages damaging a load cell will almost always give It an offset hook at the chain end check rotation fastening to chain correct functioning of latch mecha nism and inspect for possible damages and bending check the connectors of your power cable for damage and check the locking mechanism for correct functioning check the cable glands at the connector and the housing they should be tight and the insula tion should not have come out check hardware limit switches see XLNT InMotion3D User Manual Note that transport and handling 15 the main reason for mal
28. lanted Normally slanted chains 15 the one thing a rigger wants to prevent from happening it can damage chain chain guides and sprocket wheel But since the CyberHoists are meant for scenic movement slanted chains are inevita ble The following topics shall have the users attention Slinging method and used lifting means The attachment points in the supporting construction of the CyberHoist and the ones on its load will en dure horizontal forces as well as vertical forces and will make a pendular move with its slanted chain when it s load makes a scenical movement Pay attention to the following Use a slinging method that will not displace when horizontally loaded Give cabling to the CyberHoist enough slack so they cannot be torn Mount the CyberHoist in such a way that it will not rotate around its vertical axis by the weight of the chain bag when the chain gets slanted to avoid the cabling from getting wrapped around the CyberHoist Chain entrance and guidance In case the chain runs slanted from the hoist and the load is quite light compared to the capacity of the hoist the mass of the body of the hoist will cause the chain running in a non perpendicular direction to the hoist This causes wear to the chain the chain guides and the sprocket wheel The user shall ascertain at all times that the chain is well lubricated and runs smoothly in and out the chain guides as to prevent excessive wear to the guides chain and sprocket
29. m 3900 mA 3250 mA wet 0 32 m min Drive Current 2600 mA 1950 mA 1300 mA 650 mA 0 mA 0 63Kg 125Kg 188Kg 250Kg Load Figure 10 b Power consumption of CH 250 EU 6500 mA gt 5850 mA 5200 mA 500 S 4550 mA 3900 mA 3250 mA of of 0 16 m min Drive Current 2600 mA 1950 mA 1300 mA 650 mA 0 mA X t 0 125Kg 250Kg 375Kg 438Kg 500Kg advanced technologies Load 2 Figure 10 c Power consumption of CH 500 EU 13000 mA 11700 mA CH 1000 US onan 7800 mA uu 6500 mA Drive Current 5200 mA 4 0 8 m min 3900 mA 2600 mA 1300 mA 0 mA 0 250Kg 500Kg 750Kg 875Kg 1000Kg Load Figure 10 d Power consumption of CH 1000 EU 13000 mA um um um um um mm um um mm um um ME m m mu mu um 11700 mA 10400 mA CH 250 US 500 US 9100 mA 7800 mA 6500 mA QU Drive Current 5200 mA 7 3 1000 US suuna 3900 2600 1300 0 63Kg 125Kg 188Kg 250Kg 375Kg 438Kg 500Kg 750Kg 875Kg 1000Kg Load Figure 11 a Power consumption of US models 13000 mA v mm Max 11700 mA 10400 mA e CH 250 US 36 m min 9100 mA 7800 mA 6500 mA 2 Drive Current 0 32 m min 5200 mA
30. mits Limits for harmonic current emissions equipment input current 16 A per phase EN IEC 61000 3 3 1995 A1 2001 1S1 2005 Electromagnetic compatibility Part 3 3 Limitation of voltage changes voltage fluctuations and flicker in public low voltage supply systems for equipment with rated current 16 A per phase and not subject to conditional connection EN 55024 1999 A1 2002 EN 55024 1999 A2 2003 Information technology equipment Immunity charac teristics Limits and methods of measurement EN 150 1210018 2 Safety of Machinery EN 818 Chain Quality choice criteria and technical requirements DIN 15400 amp 15401 Lifting hooks for Hoists DIN 56950 Entertainment Industry Machinery installations Safety requirements and testing FEM 9 511 Classification of the mechanisms FEM 9 661 Dimensions and Quality of the drive and cable lifting block elements for mass produced lifting devices FEM 9 683 Choice of motors FEM 9 755 Steps to be taken to determine the operating periods for mass produces motorized lifting mechanisms S W P FEM 9 751 Motorized lifting mechanisms safety FEM 9 901 Bases for design for the mass produced lifting devices for traveling cranes equipped with mass produced lifting devices CH 500 CH 250 types meet BGV C1 requirements CH 1000 meets BGV C1 requirements if SWL is derated to 500 kg Dated 09 May 2008 M A van der Wel crant xlnt advanced technologies
31. ng International Health and Safety laws require a proper lifting plan when lifting loads with more than one crane see list with references below This is the case when using two or more CyberHoists to make scenic movements with all kind of Loads truss constructions etc In this plan calculations or measurements shall be elaborated of the loads and constructions to be lifted Loads on lifting means and loads on the supporting construction static as well as dynamic The in tended choreographic ways of movement shall be outlined spacial positions order speed in order to calculate all these loads Moreover a proper Risk Investigation and Evaluation shall be made References EU Directive 89 655 EEC 95 63 EC 2001 45 EC concerning the minimum safety and health require ments for the use of work equipment by workers at work UK LOLER 1998 NL Al 17 NPR 8020 1x Rigging plan in prep US DOE STD 1090 2004 Slinging methods on truss and construction beams and mounting of electric chain hoists in general The proper functioning of the CyberHoist system stands or falls with the precision with which the hoists are mounted this should exactly match the CAD file that is generated for the show Safety concerning scenic movements of loads during shows lifting objects in low light conditions and the ability to deal effectively with external disruptions to the show environment like work pressure and persons moving around and below the lo
32. o avoid rust the chain needs to be properly lubricated when stored For long term storage see chapter 8 Inspection and maintenance 5 3 Transport CyberHoists shall only be transported in flight cases on their wheels The flight cases shall not be turned on their side not be tipped It is advised to purchase flight cases from your XLNT dealer For transport conditions see 5 2 Storage 5 45 Reception When receiving a newly purchased CyberHoist the user shall carry out the following prior to the first USE Inspect the product on the exterior for possible damages caused during transport In case there is any damage immediately contact your XLNT dealer Inspect the type label on the CyberHoist for correct type of hoist 1000 500 250 correct type of operating voltage 400 208 Register the following in your logbooks for every CyberHoist date of first use type the serial number that 15 stated on the label on the CyberHoist the identification number that is stickered on the top and bottom of the housing of the Cyber Hoist the serial number on the load cell 5 5 Included items In the box you received from your XLNT dealer you should find the following items a CyberHoist XLNT CyberHoist user manual this manual declaration of conformity 11 by XLNT included in this manual In case a Manual 15 missing you can download it at www xlnt com or put a request at your local XLNT de
33. ped or started ATTENTION Avoid stretch as much as possible in the lifting means on which the CyberHoist is hung to avoid cushioning and even resonance in your movement You can take the following measures to avoid stretch avoid artificial fabrics like Span Sets for slinging keep steel wire ropes as short as possible when CyberHoists are installed in a main grid keep the spans shorter than the maximal allowable distances given the loading tables of this grid Try to install some extra motors or dead hangs to create a firm main grid 4 7 Power consumption CyberHoist are typically manufactured for 8 16 or 32 m min the nominal speeds running them at higher speeds is possible but requires significantly more current and power see annex 1 Power Con sumption The duty cycle of the hoist will decrease rapidly and the temperature might rise above the maximum causing the hoists to de initialize and put themselves to rest ATTENTION Carefully plan your show when driving your hoist at full speed and moni tor temperatures and power consumption regularly when driving at top speeds 4 8 Power down when not in use CyberHoists shall only be operated by competent persons as described in 1 3 prevent unauthorized operation when not in use or in the operator 5 absence the CyberHoists shall be de initialized or be cut off from power the operator shall log out of the InMotion3D controller 4 9 Capacity of slinging means
34. power up your system a Switch on the distro b Check whether all indicators give the proper signals see XLNT PowerMotion User Manual Make sure you have a green LED indicating that the supply voltage is present and the distro is functioning big orange LED when lt indicates a reset is necessary to switch on the power to the out lets This 15 the case when an emergency button hase been depressed while operating after the distro has been connected to the power supply to start operating c Reset the distro by pressing the reset button on the emergency controller d Switch on the emergency power unit UPS at the CyberHoist Manager and wait until it is on line Switch on the CyberHoist Manager and wait for it to power up f Check if the data switches have power either by the Ethercon cabling or by a separate power cable See XLNT DataMotion User Manual for explanation of all LEDs You re now ready to use and control the CyberHoists by the Manager for operating instructions and use of the InMotion3D software we refer to the InMotion3D manuals xlnt advanced technologies 2 6 3 Procedure for unmounting CyberHoist The following procedure describes the convenient way of unmounting a CyberHoist and packing it for transport and later use a Lift the chain without load until halfway the chain length b Shut off the power to the CyberHoists c Disconnect the power and data cable
35. reaking This process generates heat and the heat is conveyed outwards by forced cooling If the cooling is malfunctioning due to blocking of the air inlet or outlet the CyberHoist will overheat and shut itself down ATTENTION Do not block the ventilation gaps of the CyberHoists Always provide fresh airflow to the inlet and let heated air freely escape without being sucked in again Never place heat sources in the vicinity of a CyberHoist like the fan exhaust of a video projector or a luminary that produces much heat Never put a tight cover around the CyberHoists to protect it from rain etc the CyberHoist will overheat and shut itself down 4 3 Lifting persons and performer flying As stated in chapter 1 CyberHoists are not intended to use for lifting persons or performer flying How ever in case the user decides to do so nevertheless the following information and directions may help to avoid unwanted incidents ATTENTION This information and guidance is not extensive and certainly not enough to have all risks covered Flying of persons or performer flying is completely the user s own responsibility including any course of events resulting from mechanical or electri cal malfunctioning or breakdown of one or more CyberHoist or a combination of equip ment which includes one or more CyberHoists As stated in 4 1 a risk assessment shall be made for every event or show When lifting persons or flying performers special attention
36. s at the CyberHoist d Puta flight case right below the CyberHoist and open the lid Put the hook at the chain end in the triangular shaped cabinet in the corner this prevents it from getting tangled f Put the rest of the chain at the bottom of the case g Leave the partially filled chain bag attached to the CyberHoist h Remove the CyberHoist from its suspension i Put the CyberHoist gently into its flight case with the chain bag on the bottom of the case j older types of CyberHoist with power cable at the top lay the power chord perpendicular over the motor as to keep it clear from the foam blocks in the lid of the flight case k Close the flight case ATTENTION Never stack more than two flight cases on top of each other to avoid tumbling down Always transport CyberHoist cases on wheels tipping or turning over the cases can damage the internal electronics xlnt advanced technologies Chapter 7 Operation As stated in the introduction chapter 1 CyberHoists can only be operated with a controller running the InMotion3D software This combination of an Apple computer running InMotion3D often is referred to as the CyberHoist Manager or CHM The standard setup is with a redundant set of two dual core MacPro s including two monitors and two UPS es But in itself InMotion3D can be run from an iMac a MacBook Since InMotion3D is software and consequently will have frequent updat
37. shall be given to risks related to the persons or performers being moved risks related to the equipment used to do so fall protection that might be used XUL evacuation of the persons or performers that are lifted or flown in case of emergency mal functioning of equipment etc providing information about these persons or performers to emergency services and possibly laying down a protocol with these services In case of emergency providing adequate communication means with emergency services 4 4 Risks due to the scenic movements Scenic movements generate extra hazards e g during shows This probably means they occur in low light situations with the users view blocked by scenery or blinded by some lights The risk assess ment shall elaborate on how to deal with all these hazards that arise in a particular show The user shall have visual contact at all times with all objects Continuous visual contact may be accomplished by the user alone or with spotting colleagues at different corners of the stage and by staying In contact with each other possibly with an emergency stop or dead mans handle In their hand Infra red camera s can also help the user to maintain visual contact with the moving objects 4 5 Slanted chains due to scenic movement When a load is lifted by multiple CyberHoists and is given roll and or pitch movements see InMotion3D User Manual the chains will not run straight to ground but will run s
38. t block any ventilation openings Install in accordance with the manufacturer s instructions Do not defeat the safety purpose of the polarized or grounding type plug If the provided plug does not fit into your outlet consult an electrician for replacement of the obsolete outlet Protect the power cable from being walked on or pinched particularly at plugs convenience recepta cles and the point where they exit from the apparatus When damaged replace the power cable Unplug this apparatus during lightning storms or when unused for long periods of time WARNING ALL types of CyberHoists contain electrical parts that work with 3 phase 400 208V only qualified service personnel is allowed to open this device severe injury or even death may occur when handled incorrect Disclaimer All rights reserved Although the information in this manual has been compiled with care individual units or parts of it may vary in size ratings and functionality from what is included in this manual XLNT disclaims any liability for damage losses or other consequences suffered or incurred in con nection with the use of the measurements data or information contained in this manual XLNT may change this product without prior notice xlnt advanced technologies Foreword About this manual This user manual 15 to instruct the CyberHoist user in common handling and installation of Cyber Hoists Common handling refers to transport storage recept
39. tor or a luminary that produces much heat Never put a tight cover around the CyberHoists to protect it from rain etc the CyberHoist will overheat and shut itself down This type of message indicates a potential risk for personal injury damage to equipment or harm to the environment WARNING Never dump your computer equipment it contains electrical parts that are not environmentally friendly and should get special treatment Your UPS contains bat tery packs that should be treated separately in an environmentally friendly way And the following type of message indicates potential risk for severe personal injury and damage to equipment DANGER Be very cautious when moving only one hoist of a group the load may bend can be damaged or even collapse This may result in parts falling down at the risk of causing severe injury or damage to property References CyberHoist and Stagemaker are registered products of the Verlinde Lifting Equipment StageMaker Is a registered product of Verlinde Lifting Equipment EtherCon is a registered product of Neutrik AG Liechtenstein see www neutrik com Harting is registered product of the Harting Technology Group see www harting com MacBook Pro Mac Pro and iMac are registered products of Apple see www apple com XLNT InMotion 3D is a registered product of XLNT Advanced Technologies XLNT DataMotion ethernet switches are registered products of XLNT Advanced Technologies XLNT PowerMotion pow
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