Gerriets TRUMPF 95 User manual

Operation Manual
Track System TRUMPF 95
Technic
E

2
Operation Manual / TRUMPF 951-4 Contents
Introduction
System Installation
System Operation
Safety Instructions
1
2
3
4
Contents
1.1 General Instructions
1.2 Approved Use of System
1.3 Unapproved Use of System – Safety Risks
1.4 Technical Data
1.5 Further Information
1.6 Load Capacity
1.7 Declaration of Conformity
1.8 System Options
1.9 Safety Information
2.1 Qualication of the set-up personnel
2.2 Preparation of the installation
2.2.1 Checking the completeness and integrity of the delivery
2.2.2 System Design
2.3 Mounting of the track
2.3.1 System Parts Mounting
• Walk-Along System
• Side Cord Operation
• Top Cord Operation
• Double Top Cord Operation
• Motors
2.3.2 Rope Attachment
2.3.3 Rope Operation Test
2.3.4 Curtain Attachment
2.3.5 Curtain Operation Test
2.3.6 Motor Installation
2.3.7 Initial start-up
2.3.8 List of appendices
3.1 Note concerning familiarization
3.2 Qualication of operators
3.3 Maintenance
3.4 System Modications
4.1 Risk assessment for potential hazards in the event of intended
use
Information Page
3
3
3
3
3
4
6
6
7
8
8
8
8 - 9
10 - 13
14 - 19
20 - 23
24 - 27
28 - 32
32 - 35
35
35
36
36
36
36
36
37
37
37
37
38
Subject to changes, errors and technical
modications. Errors accepted.
Depiction of safety instructions
Safety instructions are indicated by an icon and a
signal word. The signal word describes the severity
of the potential risk.
DANGER
Directly imminent risk to the life and
health of persons (serious injuries or
death)
WARNING
Potentially imminent risk to the life and
health of persons (serious injuries or
death)
CAUTION
Potentially dangerous situation (minor
injuries or damage to property)
NOTE
Application advice and particularly
useful information
IMPORTANT
Obligation for particular behaviour or an
activity for safe handling of the machine
Warning of specic risks
Risk due to electric voltage
Risk due to naked ames
Risk due to raised load
Risk of cuts
Risk of hand injuries
Risk of entrapment
Risk due to caustic uids
Risk due to hot surfaces
Risk of slipping
Risk of falling objects
TRUMPF 95 V 1.1 (June 2016)

3
Operation Manual / TRUMPF 951Introduction
1.1 General Instructions
Limits of track system
1.3 Operation Manual
1.4 Approved Use of System
Applications
1.2 Approved Use of System
1.5 Unapproved Use of
System
TRUMPF 95 is a track system for medium- and heavy-duty applications.
A top groove on track allows easy mounting of all accessories.
According to the order, the track system can be composed of the tracks, a motor and
cabling, track switches and control system, master runners and 2-wheel runners,...
The electrical installation ends at the connector box or the feeding cable.
Suspension points are only part of the system when they were part of the written order.
This operation manual is part of the TRUMPF 95 track system. It includes all neces-
sary instructions to assemble and to operate the track system safely and to prevent
accidents or damage.
TRUMPF 95 is approved for supporting and moving curtains and light-weight scenery
within the maximum load capacity of the track and the associated components. Do not
exceed load rating of track and runners.
The track system load capacity refers to textile curtains applications. For light-weight
scenery applications, specic runners must be used.
Only little changes are needed to install TRUMPF 95 under various sub-constructions:
Installation options are:
• Direct ceiling mounting.
• Hook clamp installation for use on truss and pipe battens.
• Wall mount bracket.
Curtain track operation options
• Walk-along track
• Side cord operation
• Top cord operation
• Double top cord operation
Motorized options for use with G-FRAME 54 control system (xed or variable speed):
• TRAC-DRIVE for side cord and top cord
• FRICTION-DRIVE for cord-free operation
You can nd further information in chapter “2.3 Track Mounting”.
WARNING
Unapproved use can result in serious injury or death.
Unapproved use of the system is any use different from the one mentioned
under approved use. TRUMPF 95 is not approved for supporting or moving
(ying) people.
Aluminium Track
Track weight: 900 g/m
Track section length: 6,00 m
Maximum distance between hanging points: 2,00 m
Minimum curve radius: 500 mm
Wheels: on ball bearing

4
Operation Manual / TRUMPF 951Introduction
2,00 m 25 kg 20 kg/m 40 kg
1,75 m 33 kg 30 kg/m 53 kg
1,50 m 44 kg 36 kg/m 54 kg
1,25 m 49 kg 43 kg/m 54 kg
1,00 m 49 kg 53 kg/m 53 kg
0,50 m 49 kg 107 kg/m 54 kg
2,00 m 25 kg 20 kg/m 40 kg
1,75 m 33 kg 30 kg/m 53 kg
1,50 m 44 kg 47 kg/m 71 kg
1,25 m 64 kg 56 kg/m 70 kg
1,00 m 64 kg 71 kg/m 71 kg
0,50 m 64 kg 141 kg/m 71 kg
1.15 TRUMPF 95
1.15 TRUMPF 95
40 mm / 1.57"40 mm / 1.57"
35 mm / 1.37"
35 mm / 1.37"
Length
[m]
Length
[m]
With Camlock Nut: 3115 0091
With Adjustable Nut: 3115 0071
Point load
[kg]
Point load
[kg]
Line load
q [kg/m]
Line load
q [kg/m]
Uniformly distributed load
F [kg]
Uniformly distributed load
F [kg]
2,00 m 25 kg 20 kg/m 40 kg
1,75 m 33 kg 30 kg/m 53 kg
1,50 m 44 kg 47 kg/m 71 kg
1,25 m 64 kg 70 kg/m 87 kg
1,00 m 79 kg 87 kg/m 87 kg
0,50 m 79 kg 174 kg/m 87 kg
1.15 TRUMPF 95
40 mm / 1.57"
35 mm / 1.37"
Length
[m]
With HD Adjustable Nut: 3115 0061
Point load
[kg]
Line load
q [kg/m]
Uniformly distributed load
F [kg]
1.6 Load Capacity IMPORTANT
When applying loads to the track system make sure under construction,
suspension points and xing elements are dimensioned correctly. Sometimes
you need to apply additional safety or operation factors to the applied load
(for example moving loads above persons).
The basis for dimensioning are considerations according to DGUV Information 215-
313 (formerly BGI 810-3) and DIN 56950. Components being part of suspensions are
dimensioned according to DIN 56950 for the double of their nominal load. A factor of
1,2 for dynamic forces is taken into account. If due to the use a higher dynamic factor is
expected, the indicated loads need to be reduced accordingly.
Tracks and their runners are considered as load-bearing devices like y-bars (Lastauf-
nahmemittel according to DIN 59650). The indicated loads take into account the type of
suspension (mounting nuts).

5
Operation Manual / TRUMPF 951Introduction
35 46
Ø10
Ø12 (x3)
56
40
8
9
79
9.3
88
90
81
74
72.5
64.5 35
Ø 50
46 28 60
100
56
108.1
90
94
LW=137 / HD=139.7
LW=92 / HD=94
LW=204 / HD=206.7
LW=178 / HD=180.7
LW=217 / HD=219.7
119
49.7
81
88
116.7
67
41
80
90.7
129.7
TRUMPF 95: Dimensioning
TRUMPF 95
Top Cord operation
2-Wheel Runner = LW
Side Cord Operation
HD Runner = HD
Double Top Cord Operation
G-TWIST: Ceiling Mounting Plate
All dimensions in mm
2-Wheel Runner + Curtain Hook Ceiling Mounting Plate Direct track mounting

6
Operation Manual / TRUMPF 951Introduction
You can nd further information, such as load capacity, dimensions and weight of all
track system parts in chapter “2.3 Track Mounting”, in the Gerriets Technic manual and
on our website www.gerriets.com.
IMPORTANT
The load capacity of the overall TRUMPF 95 system is determined by the
system’s weakest link. Do not load any component up to the maximum load
capacity as there is a risk of overloading hanging points.
The track system should be designed with the load capacity of the hanging points:
The track system’s load (point load or uniform distributed load) is secured by the
hanging points.
The center hanging points’ weight load is higher than the weight load of the hanging
points at the end of the track (see also chapter 2.2.2).
The load capacity of the hanging points depend on the mounting nuts used. Replacing a
standard camlock nut with an adjustable nut or a HD nut can increase the load capacity.
If you still need a higher load capacity, or a replacement is not possible, you must
reduce the distance between the hanging points.
To dene the maximum hanging point distance for a given load weight, see the diagram
above.
IMPORTANT
Near a track splice the load bearing capacity of the track is lesser.
Compensate this fact by putting a suspension at a maximum distance of
100 mm from each track splice.
IMPORTANT
Make sure that under construction, suspension points and xing elements
being not part of the track system are dimensioned correctly.
1.7 Declaration of Conformity
1.8 System Options
According to the EU machinery directive (2006/42/EC) the Trumpf 95 track is considered
as a machine when it is used with a motorized operation system.
If Gerriets GmbH is assigned with setting up a complete Trumpf 95 system including
motor and control system we will conduct a conformity assessment. The CE mark will
be applied to the system.
If you merely procure the system components from Gerriets GmbH in order to set up the
system yourself, you are considered as the manufacturer according to the EU machinery
directive (2006/42/EC). In this case you are obliged to conduct the conformity testing
procedure yourself and Gerriets GmbH will only deliver a declaration of incorporation.
Manual or motor operation and control systems:
• ROPE-DRIVE: Manual operation with a continuous loop hemp rope Ø 22 mm.
• HAND-DRIVE: manual operation with hand crank.
• FRICTION-DRIVE: motor operation without rope. The motor moves via drive wheel
along the track.
• TRAC-DRIVE: Motor operation with continuous loop rope.
• G-FRAME 54 control unit.
• G-FRAME 54 frequency controller.
• Hand held remote control.
• Track switch, 2 positions, manual or motor operation, available with switch controller.
• Track switch, 3 positions, manual or motor operation, available with switch controller.

7
Operation Manual / TRUMPF 95
1.9 Safety Information The operating company (contractor) assumes the overall responsibility for the operation
of the technical system.
If the Trumpf 95 track system was installed by Gerriets GmbH you can assume that the
system does not represent a source of avoidable hazards once it has been handed over
to you.
However, this assume that installation and operating instructions of this manual are
observed!
We recommend that you conduct a risk assessment for the specic conditions under
which the system is to be operated on your premises and make arrangements in order
to rule out as far as possible any damage due to inappropriate operation and residual
hazards.
The details in the table under 4.1 may help you
Please observe in particular the following regulations:
• BGV A1: Principles of Prevention
• BGV A3: Electrical Installations and Equipment
• BGV C1 / GUV-V C1: Staging and Production Facilities for the Entertainment Industry
• BGG 912 / GUV-G 912: Principles for Testing Mechanical Facilities in Stages and
Studios - Machinery Directive 2006/42/EEC
• BGI 810-0: Safety for Productions and Events - Guideline
• BGI 810-2: Television, Radio and Film; Work Safety at Production Facilities
Suspensions:
• BGI 810-3: Safety for Productions and Events - Overhead Loads
• Machinery Directive 2006/42/EC
• TRBS 2131: Electrical Hazards
• TRBS 2111: Mechanical Hazards - General Requirements
• DIN 56950: Entertainment Technology - Machinery Installations - Safety Requirements
and Inspections
1Introduction

8
Operation Manual / TRUMPF 952System Installation
2.1 Qualication of the
set-up personnel
2.2 Preparation of the installation
2.2.1 Checking the completeness
and integrity of the delivery
2.2.2 System Design
NOTE
We recommend having the initial installation performed by expert personnel
of the company Gerriets GmbH.
If the installation is to be performed by your own personnel, make sure the
installation is done only by qualied personnel who carefully observe the
installation manual including its appendices.
The electrical installation may be performed only by qualied electricians.
Check immediately after receiving whether the delivery is complete and in accordance
with the delivery note by comparing also with the images in chapter “2.3 Track
Mounting” and check that no transport damage has occurred.
For designing your custom track system, please note the following points:
When you determine the track system length you must include the curtain stacking
space (length of each runner and master runner) and length of the needed compon-
ents such as end stops, return pulley, head pulley and motors at the ends of the track
system.
Stacking space calculation for each side of curtain:
Number of runners (approx. 4-5 runners per meter) x lengths of each runner
+ length of master runner
+ lengths of head and return pulleys
+ length of end stop (+ motor)
These questions help you to dene the correct number and type of hanging points:
• Track: what kind of load (point load or uniform distribute load) is appropriate?
• Which system position/application bears the highest load capacity (open curtain,
scenery attached to 1 or to 2 scenery carriers)?
• If considering a span width of less than 2 m: Which is the highest possible load
capacity weight for the most stressed hanging points?
Regard your system as a multi-span girder. The spans next to the center hanging point
are loaded with the maximum load capacity. Multiply the span load weight times 1.375.
The result is the approx. maximum load capacity of the center hanging point.
For further questions please contact our customer service team.
P = Point load q = Uniform distributed load I = Distance between spans
l l
q
or
P
q
or
P

9
Operation Manual / TRUMPF 952System Installation
2.2.2 System Design • Does the value exceed the maximum load capacity?
• Use the diagram in chapter 1.4 to verify the maximum span width.
The distance between the track end hanging points and the end of the track should be
as short as possible.
IMPORTANT
The maximum load capacity of the track system (see diagram in chapter
1.6) must not be exceeded. In addition, pay attention to the load capacity of
each single component. The load capacity of all parts is specied in chapter
2.3.1”System Parts Mounting”.
The track system’s load capacity is lower at the joint of two track sections.
Place the hanging points less than 100 mm away from the joints/splice
points.
Ensure that TRUMPF 95 is mounted to a stable structure.
Plan the track conguration including the maximum weight load and dene where
accessory parts, such as hanging points or rope guides, are mounted in the top groove
of the track.
Depending on the site of operation, different safety regulations may apply.

10
Operation Manual / TRUMPF 95
Track Mounting
Track Splice
Connects two track sections.
• Weight: 260 g.
Art-No 3115 0011
Track, Straight
With groove on top of track for accessories mounting.
Art.-No. Colour Length cm Weight g/rm
3115 1011 black 600 900
3115 1012 silver 600 900
3115 1021 black up to 600 900
3115 1022 silver up to 600 900
If you shorten a track section, the cut must be straight and
at a right angle. Deburr the cut edge to ensure a precise joint
connection of the track sections.
Track, Curved - with Splice
• Technical Technical details: see Track, Straight.
• 1/4 circle, 90° curve.
Art.-No. Colour Radius cm Weight g/piece
3115 1041 black 50 1.067
3115 1042 silver 50 1.067
3115 1061 black 100 1.774
3115 1062 silver 100 1.774
3115 1081 black custom curve -
3110 1082 silver custom curve -
2System Installation
2.3 Mounting of the track
2.3.1 TRUMPF 95:
System Parts Mounting
Track sections can be mounted directly to the ceiling structure or preassembled on the
oor.
The installation location should be secured as to prevent objects from
overhead from falling down.
If working at heights cannot be avoided, make sure that persons are secured
accordingly to situation and regulation.
IMPORTANT
Please consider the system parts mounting instructions in the following
chapter.
The following pages include drawings and descriptions of the TRUMPF 95 track system
as well as mounting instructions and useful tips.
Depending on which mounting nut you select, three load capacities are given.
These values always refer as following:
• Standard camlock nut (3115 0091) – lowest load capacity.
• Adjustable nut (3115 0071).
• HD adjustable nut (3115 0061) – highest load capacity.
In case the measurements in your copy can not be read clearly, please use the TECHNIC
manual or go to www.gerriets.com.