FIXATOR LM500+ User manual

INSTRUCTION MANUAL
Electrical winches LM500+
Réf
:
181300020
4
Page : 1/16
Version : 44/16
INSTALLATION – USE
MAINTENANCE
Monitoring of updates
Date Description
03/11/2016 Creation

INSTRUCTION MANUAL
Electrical winches LM500+
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SUMMARY / PLAN
1 GENERALITIES ............................................................................................................................................................... 3
1.1 D ESCRIPTION OF THE MACHINE .................................................................................................................................... 3
1.2 G ENERAL DESCRIPTION . ............................................................................................................................................... 3
1.3 C OMPLIANCE WITH GUIDELINES AND STANDARDS ; COMMISSIONING ..................................................................................... 3
1.4 S PECIFICATIONS ......................................................................................................................................................... 4
1.5 M ACHINE LOGBOOK , .................................................................................................................................................. 4
1.6 R ECOMMENDATIONS FOR USE AND GENERAL SAFETY ......................................................................................................... 4
1. A NCHORING .............................................................................................................................................................. 5
2 INSTALLATION AND USE ............................................................................................................................................... 5
2.1 I NSTRUCTIONS FOR INSTALLATION , ASSEMBLY , COMMISSIONING AND USE - TRAINING .............................................................. 5
2.1.1 Suspended installation............................................................................................................................................ 5
2.1.2 Installation with deflection ..................................................................................................................................... 5
2.1.3 Installation support on a basis ............................................................................................................................... 6
2.1.4 Reeving for lifting of load ....................................................................................................................................... 7
2.1.5 ower ...................................................................................................................................................................... 7
2.1.5.1 Hoist connection ............................................................................................................................................................. 8
2.1.5.2 Commissioning ................................................................................................................................................................ 8
2.1.6 Installation of cables for lifting ............................................................................................................................... 8
2.2 D IAGRAMS AND SAFETY EXPLANATIONS .......................................................................................................................... 9
2.2.1 Main dimensions .................................................................................................................................................... 9
2.2.2 Safety devices ....................................................................................................................................................... 10
2.3 D ESCRIPTION OF THE WORK OR CONTROL STATION .......................................................................................................... 10
2.4 N ORMAL USE .......................................................................................................................................................... 10
2.5 D ECOMMISSIONING .................................................................................................................................................. 11
2.6 W ARNINGS ABOUT CONTRAINDICATIONS ...................................................................................................................... 11
2. R ESIDUAL RISKS ....................................................................................................................................................... 11
2.8 T RANSPORTATION , HANDLING , STORAGE ...................................................................................................................... 11
3 MAINTENANCE - SETTINGS ......................................................................................................................................... 11
3.1 M AINTENANCE OPERATIONS ...................................................................................................................................... 11
3.1.1 reventive maintenance ....................................................................................................................................... 11
3.1.2 Adjusting of the brake .......................................................................................................................................... 12
3.1.3 Lubricating a hoist cable ....................................................................................................................................... 12
3.2 T ROUBLESHOOTING .................................................................................................................................................. 13
3.3 S PARE PARTS ........................................................................................................................................................... 13
3.4 D ISPOSAL ............................................................................................................................................................... 14
3.5 N OISE EMISSION ...................................................................................................................................................... 14
4 APENDICES .................................................................................................................................................................. 14
The original of this document is in French. No translation can replace the original.
Thank you for purchasing a FIXATOR product. In the following pages we give you details of instructions
allowing you to safely use and maintain your equipment in good working condition. Please read these
instructions prior to commissioning the equipment: no installation operation, use and maintenance should
be performed until this document has been fully understood. These operations must also be carried out by
clearly designated personnel suitably trained.
The following symbol will alert you to hazards to watch out for: .

INSTRUCTION MANUAL
Electrical winches LM500+
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1Generalities
This notice covers the use of winches LM type 461.
1.1 Description of the machine
The LM is a portable electric reeving hoist for
unlimited hoisting cable movement (check
instructions on the hoist plate: "Type 461").
The standard equipment includes:
- the unit with its carrying handle and the safety
hook; engine with main brake and protected by
thermal probe
- 2 travel end stopper
- 1 pendant control station (2,5 m) double insulation
IP 65 3 buttons: ascent, descent and emergency stop
(extension: 200 m maximum)
- male/female plug and cable power (0.50m)
- 1 manual
The LM winch cannot be used to lift or move
people.
1.2 General description.
Diagram of typical installation:
This winch is designed for the lifting and traction of
loads. It is intended for professionals involved for
work, such as in an elevator shaft or on building
facades. The winch uses one steel cable (hoisting
cable).
The drive system consists of a pulley whose throat
has a special profile, and in which the cable is tight
under the effect of the load by two articulated
rollers. This allows an unlimited run of the hoisting
cable.
This technical design ensures a great security
provided you follow the instructions given in this
manual.
Each device carries labels information and
instructions. Constantly make sure that all these
labels are in place and legible.
The LM winch must be used exclusively with
special lifting cable, to fully ensure the safety and
efficiency.
Before its expedition by Fixator, each hoist is tested
to 110% of its capacity.
Additional kits exist:
ref : 540155
ref : 461021
Extensions to the pendant control station (5G1) :
-15m : ref 540134
-30m : ref 540136
1.3 Compliance with guidelines and standards;
commissioning
This machine complies with the European
Machinery Directive 2006/42/EC.
It is manufactured under a quality process according
to EN-ISO 9001: 2015.
A test prior to initial commissioning and after each
maintenance or dismantle must be performed with a

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static test coefficient of 1.25xWLL and a dynamic
test coefficient of 1.1xWLL.
1.4 Specifications
The LM500 winch has a working load limit of
500kg (WLL). It is displayed on the winch plate.
Type
070781
CMU / WLL (kg) 500 (1100lbs)
Motor P (kW) 1.1
Voltage (V) 230V-50/60Hz
I Nominal / start (A) @50Hz 7/21A
I Nominal / start (A) @60Hz 9/21A
Weight (kg) 32 (70lbs)
Dimensions (mm) 255x240x809
T° for use (° C) -10°C / +55°C *
Operating Speed (m/s) @50Hz 0.12 (7m/mn)
Operating Speed (m/s) @60Hz 0.14 (8m/mn)
Wire rope Ø and type Ø6.5 à 6.8 - 6x19
synthetic core
Minimum breaking load (kg) 2500 (5500lbs)
Upper limit switch Yes
Lower limit switch Yes
Service factor S3 60% 30cy/h
* Use between -20° and -10°C is possible
providing a gradual and uniform preheating
unloaded operation is carried out, then the load can
be applied as soon as the hoist reaches a T ° - 10°C.
1.5 Machine logbook,
The contents of the logbook of this machine are not
provided; it is up to the owner to create or acquire
one in which the following is noted:
- the name of the person in charge of
equipment
- operator names and dates / periods of use
- serial numbers of components
- the number of hours of use,
- the characteristics of the cables used
- the number of hours the cables are used,
- a record of incidents and actions taken to
remedy them
- forecast dates of periodic inspections and
record of actual dates of inspections
1.6 Recommendations for use and general
safety
Before using this equipment, ensure:
-that you read and understand this entire
manual
-that no obstacles will obstruct the required
motion
-that the periodic inspection has been
performed and recorded,
-that the electrical installation is designed and
protected according to current regulations
-that your material is stable and aligned, freely
with the load
-the load or machine movements will not trap
or crush you or other people; signal and block
access to the area under the load
-you can communicate with help in case of
need,
-that you have adequate lighting
ensure :
-every day the correct operation of the
mechanisms, brakes, and emergency stop
-periodically the electrical cables, limit
switches, structural elements and wire ropes
-regularly the presence of travel end stopper,
the presence of plates and safety instructions
(and their readability),
-safety of the suspension structure
-there is no accumulation of snow, ice, debris
or materials on the winch,
-that there are no obstructions on the façade or
in the shaft
-at the end of work, that the deactivation is
complete.
-If a charge is to be raised by multiple devices,
the installation of these must be preceded by a

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technical review by a competent technician
and then conducted according to this study,
including to ensure the constant distribution
of the load in suitable conditions.
During the operations of lifting, up and down,
the user must constantly observe the load and the
free end of the cable to prevent any risk of collision.
The load must be constantly guided (EN14492-2) ;
otherwise the use of rotation-resistant wire rope is
necessary.
Check and apply local regulations concerning
the installation, use, maintenance and control of
lifting devices.
See also contraindications §2.6
1.7 Anchoring
Verify that the anchoring point is strong enough for
the effort to apply.
If the anchoring is not provided by FIXATOR each
anchor must withstand, without any deformation, up
to 2.5 times the WLL of the winch, that is 1250 kg,
and remain stable when subjected to this load.
(special case of reeving 2:1, the resistance must be
of 5 times the WLL, that is 2500kg ; see §2.1.4)
If the fixing of the unit must be in a dangerous place
for the operator, the safety precautions provided for
by the work’s regulation must be taken to exclude
any risk uncontrolled in this operation. It is perhaps
better in this case to implement the hoisting cable
into the device before the anchoring operation.
2Installation and Use
2.1 Instructions for installation, assembly,
commissioning and use - training
Installation and use operations must be performed
by personnel specially trained by the manufacturer
or its dealers, duly authorized by their employer.
Depending on your country, regulatory inspections
may be necessary.
Make sure you have:
- a sufficient length of special cable Ø6.5-6.8
mm
- an adequate length of supply cable and
suitable number of wires with suitable cable
section,
- Accessories you may wish to use
2.1.1 Suspended installation
It's the simplest mounting and the most common.
Device in suspension and direct traction or lifting.
The anchoring of the device must be done
exclusively by its hook and never by its handle.
There is no way to anchor the hook of the cable to
the fixed point to get the device moving on the
cable.
The hook of the machine must be placed in the
body of the attachment
point, so that this body is at
bottom of hook. The pawl
of safety of the hook must
close completely.
If a gene appears in the
articulation of the
apparatus with the body of
fixing hook, it is necessary
to interpose a sling of
appropriate capacity.
Check each element
of connection capabilities
to ensure your safety.
2.1.2 Installation with deflection
- Device suspended ; indirect traction or lifting.
This case requires a deflection pulley anchored to a
fixed point.
- Device on ground and lifting through a deflection
pulley.

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The resistance of the pulley and its
anchorage must be calculated for a double effort of
the load.
2.1.3 Installation support on a basis
Use the optional ref 461021.
This type of installation requires special
precautions:
-The bearing surface on which the unit is
placed must be flat and horizontal.
-This surface must have a minimum Ø120mm
orifice for the passage of the two strands of
cable,
-The device must be positioned so that the
lifting wire rope, under load, does not rub
against the walls of the hole, and so that the
travel end stoppers on the wire rope can come
in contact with the switch levers.
-The device must be propped so that it will not
move on the support. (4 drillings Ø13
available)

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-The surface on which the unit is placed in
support must have the necessary stability and
strength in regard of the safety of the
operation.
-The load must be in free suspension.
With this arrangement, never lift the load
without having placed it beforehand at the vertical
of the hoist.
2.1.4 Reeving for lifting of load
Use the reeving kit ref 540155.
This assembly allows you to double the capacity
(working load 990 Kg) of the device. In return, the
speed is decreased by half.
The LM must not be otherwise than with this
reeving kit assembled. Additional system must not
be added.
The reeving kit consists of an anchor carrier strand
and a reeving block with a hook and a spring.
The user should note that when reeving, the
required length of wire rope is at least twice the lift
height, plus at least 1 meter of apparent slack
strand.
The limit spring mounted on the lower pulley is
intended to replace the high limit stop.
A stop may still be placed on the loose strand to
serve as low end stopper.
In case of reeving, double the maximum load
to be taken into account for the calculations of
security.
NOTA : take care to mount the pulley block so that
its limit spring is located on the cable between the
pulley and the entry in the hoist (see figure).
Check the triggering of your travel limit
switch before use; a repositioning of the stoppers
may be necessary depending on the configuration of
job.
Check the capacity of the anchoring points.
When operating with the reeving system, especially
the operator will ensure that the load is not turning
on itself, to avoid tangling the three strands of the
cable (two strands loaded and the slack side).
Stop immediately if the loose strand comes to
tangle with the other strands.
2.1.5 Power
The installer must ensure that the power supply is
compatible with the specification of the winch.
The power supply must be protected
upstream by a 30 mA differential switch. The
installation must be in accordance with EN 60204-
1. Power outlets must be calibrated to 16A.

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The power cable to the Liftho control box must be
flexible cable (Class 5). Beyond 30m, it must be
held in place by a suitable anchorage clamp.
EXTENSION SECTION (mm²) at 230V
Type : 0-50m 50-80m 80-
140m 140- 200m
3 wires
P+N+T 2.5² 13AWG
4.0²
11AWG
6.0²
9AWG 10.0² 7AWG
If the LM winch is powered by a generator, check
that it delivers at least the voltage and power
required at the start of the winch (min 6kVA).
2.1.5.1 Hoist connection
-Connect the button box to the socket on the
winch.
-Connect the main power plug.
2.1.5.2 Commissioning
-Unlock the emergency stop if
necessary
-Press the UP button to lift or pull the
load
-Press the DOWN button to lower the
load
At any time, in case of imminent danger or
need, press the Punch red button to stop any
movement of your hoist.
2.1.6 Installation of cables for lifting
Use protective gloves when handling wire
rope.
Check the condition of the cable and its length
(working height + 2m).
Check the condition of the hook and safety latch.
Avoid the formation of loops when unwinding..
The end of the cable should be clean and sharp.
pour votre sécurité, n’utiliser que des câbles
FIXATOR
Put the end stopper on the wire rope (the spring
being directed to the winch). Block with an Allen
key.
Insert the end of the wire rope through the bottom
opening A. press the UP button on the pendant
control while pushing the wire rope so that it
engages in the throat of the pulley.
When the rope come out through hole B, continue
the movement so as to obtain a sufficient length of
wire rope.
PS : a second stopper is provided to stop the
descent; position the spring on the side of the
winch:
A B

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Check the operation of the limit switches of the
winch.
For your safety, use only FIXATOR cables.
Ensure that the cable above the hoist (taut) does not
touch surfaces or angles.
Ensure that the outgoing winch cable (slack) is free.
Do not let the loaded rope become slack if the load
is not stable, resting on a strong enough support.
2.2 Diagrams and safety explanations
Installation and use operations must be
performed by personnel specially trained by the
manufacturer or its dealers, duly authorised by their
employer.
The maximum capacity of the hoist (WLL) should
be the basis for calculations of anchor strength.
2.2.1 Main dimensions

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2.2.2 Safety devices
-A main brake acts on the engine in case of
power supply failure
-An upper limit switch sensor stops lifting
when the spring touches the plate.
-A lower limit switch sensor stops lowering
when the spring touches the plate.
-An electrical emergency stop placed on
pendant control acts immediately and stops
the winch to the ascent and the descent.
-Mechanical locking prohibiting the
simultaneous action of the up and down
commands.
-Electrical protection of the pendant control :
class 2.
-Fuse protecting the command, in the electrical
box.
-Hooks with safety latch.
The 230V single-phase motor is protected against
excessive warm-ups by a probe inserted into the
coil. This probe prohibits operation by interrupting
the control circuit as long as the temperature of the
coil is not back to an acceptable value. In case of
intensive work or high duty, we suggest to allow a
15 minutes break every 45 minutes of work to avoid
overheating.
2.3 Description of the work or control station
"Up" and "down" hoist movements are controlled
from the pendant control.
Never stand under the load.
In case of a command error, wait for a complete
stop of motion before performing another
command. The control buttons are held type
buttons.
Limit stops are not operating devices but safety
devices. They should therefore not be used
voluntarily but only serve as shutoff devices in case
of involuntary exceedance of the expected travel.
Never stay or work under load. If necessary, have a
barrier of security on the floor around the area at the
vertical of the load.
Avoid heavy slipping: Wait for a complete
stop of your installation before resuming
movement.
Check regularly that no obstacle is located along the
path of movement (above and below the load).
2.4 Normal use
This hoist is designed for lifting loads.
It is designed for professionals involved,
for example, in work in elevator shafts or
on façades.
Press on «» to lift and on «» to lower.
Release the buttons to stop the movement.
If it is not stopped, press the Emergency
Stop. If it is not working, remove the main
plug and have your hoist maintained.

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2.5 Decommissioning
After work, or during an prolonged shutdown, or if
preventive maintenance tests (see §3) are not
satisfactory, put your load on the floor or a secure
access level. Disconnect the hook from the load
when it is resting stable on a fixed and solid
support.
The device can remain attached provided that it is
protected from the weather and in a dry place.
Snap your emergency stop.
Unplug and store your pendant control box.
Store your power supply cable.
2.6 Warnings about contraindications
It is forbidden to use this product:
-if you are not a trained professional
-to exert a force or lift a load greater than
500kg if it is not described in this manual,
-to lift people,
-in harsh conditions (extreme or corrosive
environment, high magnetic fields, etc.)
-in potentially explosive atmospheres
-to perform work on energized power lines,
-to carry loads themselves dangerous (molten
metals, acids, bases, radioactive material,
fragile loads etc)
-in combination with other lifting equipment if
it is not listed in this instruction manual,
-with loads with a wind surface area >2 m² if it
is not listed in this manual,
-with a wireless remote control system not
mentioned in this manual
-in the event of specific risks (wind> 14 m / s,
T ° <-10 ° C or> 55 ° C, storms etc)
-with worn or deformed cables
-with lubricated cables with products
containing bisulphite or MoS2 (Molykote ®,
etc)
-To apply a load on the loose strand of the
hoist.
-To use the wire rope as a means to sling the
load
2.7 Residual risks
The use of cable damaged or not suited to the
device is the major risk of accident and failure.
Check that your equipment has not been
subject to vandalism, theft, or damage.
Never disable the safety features.
Never swing a load voluntarily.
Do not block a control.
In case of continuous operation for more
than 30 ', the surface temperature of the motor can
begin to rise significantly.
2.8 Transportation, handling, storage
To transport your machine from one site to another,
remove the cables from your hoist.
Store the various components of your equipment in
a clean and dry place.
3Maintenance - Settings
Maintenance operations must be performed
by personnel specially trained by the manufacturer
or its dealers.
3.1 Maintenance operations
LM hoists must be reviewed at least once a year and
every 100h. In harsh environments (sandblasting,
marine, back and forth operation at full load, doubts
about the proper use etc) a higher frequency of
verifications may be required.
Load lifting winches are intended for a limited
lifetime; beyond that, a return to factory is
imperative.
For the hoist LM type 461, the ranking is A2.
In some countries, periodic audits and reviews of
commissioning are mandatory.
3.1.1 Preventive maintenance
These operations must be performed by a
competent person trained by FIXATOR or its
dealers. The FIX022 manual details these annual or
control operations.
Check:
Daily :
The quality of your anchors and of the 2 hooks
(latch).

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The good clamping of the travel end stoppers on
your cable.
The good general condition.
Monthly :
The proper functioning of the safety devices
(emergency stop, limit switches, brake).
The overall proper functioning by performing a full
movement at the rated load.
Every year and every 100h :
Check the groove pulley.
Check the bearings, rudder, gear...
Check the motor brake.
Control each security (cf §2.2.2) at the rated load.
Clean and grease the gears (e.g. BIMO EP or
Kluberplex AG11-462)
3.1.2 Adjusting of the brake
Remove the cap (5) that is on the ventilator lid (1).
Increasing the braking: turn the brake screw (6)
progressively counter clockwise and check that the
brake does not slide during the lowering.
Decreasing the braking : turn clockwise.
TO RELEASE THE BRAKE SYSTEM:
If necessary, it is possible to unlock the brake
manually, by pressing the (8) pivot. After each
operation, a load test must be performed.
FIXATOR or its dealers can train your staff for the
maintenance of your winches.
For your safety and to benefit from the full
guarantee of the manufacturer, use only original
FIXATOR parts (ask the complete list of spare
parts).
3.1.3 Lubricating a hoist cable
The hoisting cable must be regularly greased or
lubricated with Teflon.
For this, use for example:
- IGOL SHP 50 grease
- A lubricant spray PRO-LUBE Teflon.
Never use products containing bisulphite or MoS2
(Molikote).
Only cables recommended by FIXATOR provide
safe hoist operation. The removal’s criteria to
follow are those of the ISO4309.
The diameter should not be reduced by more than
10% (for wire rope Ø 6.5-6.8 mm) : min 6.1mm
The cables must be replaced in the following cases:
-More than 10 wires broken over a length of
20 cm for wire rope Ø 6.5-6.8 mm.
-“Basket” deformation or rupture of one of the
cable strands.
-Cable crushed, unravelling.
-Considerable oxidation
When using a plastic return pulley, they must be
replaced once they have been used with cables
having at least one broken wire.

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3.2 Troubleshooting
Faults
observed Potential causes of the fault Remedies
The motor
does not rotate The temperature sensor is activated The motor has a mechanical fault
The contactor in the hoist is out of order or
disconnected
The limit switch is activated
Fault in the control circuit
Fault in the power circuit
Power supply fault
Current escape to earth
Batteries of the remote control out-of-order
Wait for a drop in temperature
Check the motor
Reconnect or replace it
To be checked by a competent person
Check
The hoist does
not lift The grooved pulley is worn or dirty The condenser is disconnected or out of
order
The temperature sensor is activated
The motor is blocked
The contactor on the hoist is out of order or
disconnected
The limit switch is activated
Fault in the control circuit
Fault in the power circuit
Verification
Verification
Wait for a drop in temperature
Verification (maintenance)
Reconnect or replace it
To be checked by a competent person
The hoist does
not lower The temperature sensor is activated The motor is blocked
The contactors in the hoist are off or
disconnected
Error in the control circuit
Error in the power circuit
Wait until it cools
Check the motor
Reconnect or change
To be checked by a competent person
The motor is
powered but
stops (snoring
sound)
The capacitor is disconnected or out of
service (for single phase hoist only)
The motor is blocked
Power cable section too thin
Verification
Verification (maintenance)
Replace the power cable
The hoist does
not lift the
load
The groove pulley is worn or dirty
The capacitor is disconnected or out of
service (for single phase hoist only)
The temperature sensor is activated
Power cable section too thin
The wire rope is inserted in wrong way
Verification
Verification
Wait until it cools
Replace the power cable
Verification
Current too
high The brake is out of service The capacitor is disconnected or out of
service (mono phase hoist only)
The motor is blocked
Verification
Reconnect the capacitor or change it
Verification (maintenance)
Slow slide The groove pulley is worn or dirty
The brake is worn
The adhesion system is worn or dirty
Verification
Adjust the brake
Verification
3.3 Spare parts
Use only FIXATOR original spare parts.
Note and send the information listed on the plate
shown below before requesting parts.

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Main wear parts and estimated replacement
frequency (highly dependent on actual usage) :
Grooved pulley ref 462001 100h
S/A Travel limit ref 461022 400h
Pinion shaft ref 461024 /
Pressure system ref 461023 500h
Travel end stopper ref 462030 /
Capacitor ref 540144 /
Pendant control ref 462020 /
Motor cap ref 462021 /
Fuse ref 244612 /
3.4 Disposal
Disassembly and disposal of the hoist must be in
accordance with the current regulations in force.
Electrical components, gear oils, greases, etc ...
should be separated and sent to the appropriate
treatment locations.
3.5 Noise emission
The A weighted sound pressure levels at
workstations is less than or equal to 70 dB (A)
4Apendices
Installation examples, wiring diagrams, component
instructions …

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Version : 44/16
The original of this document is in French, no translation can replace it.
P.A. 8, rue du Bois Rinier - B.P. 10041 – 49181 ST BARTHELEMY D’ANJOU (France)
TEL : + 33 (0) 2 41 31 17 00 – FAX : + 33 (0) 2 41 31 17 10
http://www.FIXATOR.fr – e-mail : [email protected]