Handicare MilkyWay SystemRoMedic User manual

MilkyWay
MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
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MilkyWay
Handbook
Instructions for design and installation
MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
June 2014

MilkyWay
MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
Index
Index / 2
1: Introduction
1.1: Definitions
1.2: Straight rails
1.3: Rail curves
1.4: Installation methods
1.4.1: Installation on the ceiling
1.4.2: Concealed rails
1.4.3: Installation on the walls
1.5: Power supply
1.5.1: In-rail charging with Conductor rail and insulator
1.6: Installation heights
2: Important information
2.1: General instructions for installation of rails
2.2: Safety
2.3: Point load recommendations
3: Basic rail systems
3.1: Installation of rails
3.2: Connecting rails and rail curves
3.3: Installation of a straight rail, example
3.4: Installation of rail curves, example
3.5: Shunting rail, 50400141-142 (only for Reda)
3.6: Turntable, 50400233-234
3.6.1: Changing rail exit direction
3.6.2: Installation, example
3.6.3: Parts list and function
4: Rail systems with full room coverage - (x-y)/traverse systems
4.1: Single cross-rails
4.2: Supported cross-rails
4.3: Installation of a rail system with full room coverage, example
4.4: Transition gate, 50400226 / 50400237-238
4.4.1: Connecting a basic rail system with an (x-y)/traverse system
4.4.2: Installation, example
4.4.3: Transition gates between two systems with full room coverage
4.4.4: Heights, systems with transition gates
4.4.5: Testing of safety devices
5: Accessories - ceiling lift units
5.1: Ceiling lift units
5.2: Mounting the ceiling lift unit in the rail
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Index / 3
Index
6: Connecting to power supply
6.1: End point charging / in-rail charging
6.2: Connecting the conductor rails
6.3: Conducting cables
6.4: Rail systems with full room coverage
6.4.1: In-rail charging
6.4.2: End point charging
6.4.3: Connecting to charger point
6.5: Turntable, electrical
6.5.1: Internal wiring diagram
7: Weight testing procedure
8: Ceiling fixtures - brackets and pendants
8.1: Ceiling bracket standard, 50400319
8.2: Universal bracket 55, 50400039
8.3: Ceiling bracket quick, 50400236
8.4: Pendant F, 50400163-165
8.5: Pendant R, 50400078-082
8.6: Pendant angled, 50400301-305
8.7: Threaded rod support kit, 50400192
8.8: Side support kit, 50400075
9: Wall fixtures - brackets and vertical supports
9.1: Wall bracket small, 50400119
9.2: Wall bracket wide, 50400120
9.3: Wall bracket (plaster), 50400159
9.4: Wall bracket parallel, 50400121
9.5: Wall bracket parallel (plaster), 50400160
9.6: Vertical support adjustable, 50400190 / 50400242
9.6.1: Vertical support adjustable, angled installation
10: Accessories and installation equipment
10.1: Extension rail, 50400318
10.2: Traverse trolley 3000 flex, 50400251
10.3: Traverse trolley 6500 flex, 50400252
10.4: Installation equipment
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MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
RAL 9010
1: Introduction
1: Introduction / 4
A stationary lifting solution, consisting of a ceiling lift unit mounted either on a permanently installed rail system
or on a freestanding lift stand, is an ergonomically ideal alternative that eliminates manual lifting and allows the
caregiver to always choose the optimal working stance. Furthermore, the lift system is always in place, it requires
a minimum of floor space and it is very easy to manoeuvre. Another advantage is that the system provides a
large lifting area and the possibility of both low and very high lifting.
Handicare’s SystemRoMedic™ MilkyWay is a complete, ingeniously simple and safe rail system for permanent
installation on the ceiling and/or on the walls. Each MilkyWay rail system is individually designed, in close cooperation
with the customer, allowing for adaptation to specific conditions and for meeting of specific requirements.
Together with an optional choice of ceiling lift unit and the appropriate lifting accessories, MilkyWay offers un-
limited possibilities for design and adaptation of the perfect stationary lifting solution for all settings, rooms and
lifting needs.
Material and surface coating
• Powder-coated aluminium (straight rails and rail curves)
• Powder-coated steel (fixtures; brackets and pendants)
• Stainless steel available on request (recommended when used in harsh environments such as swimming pools)
All powder-coated MilkyWay parts are white (RAL 9010).
At an additional charge, they can also be supplied in various other colours or
with a bare metal finish.
All MilkyWay products are CE-marked.
Customized design
Each MilkyWay rail system is individually designed in close cooperation with the customer.
Scaled drawings show the completed system and its function within the room(s).
Easy to install
MilkyWay offers flexibility in every detail. This allows for a comprehensive range of alternative system designs as well
as for easy installation.
MilkyWay rail systems must be designed, assembled, installed and inspected by qualified and authorized
personnel and in accordance with the ”MilkyWay Installation check list” and other instructions issued by
Handicare AB.
MilkyWay has been designed to meet the highest safety standards. The rail system should be inspected and assessed
for safety at least once per year.
More information
For more information about MilkyWay; available parts, article numbers and technical
data, please consult the “MilkyWay Technical information” document or contact your local
Handicare and SystemRoMedic™ partner. All contact details can be found on our website,
www.handicare.com.

MilkyWay
MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
1.1: Definitions
1: Introduction / 5
Basic rail systems
A basic rail system consists of one or more
straight rails, with or without curves and switches
for increased room coverage, flexibility and utility.
Rail systems with full room coverage - (x-y)/traverse systems
A rail system with full room coverage consists of a pair of fixed (primary) rails (6) and one or two (secondary)
cross-rails/traverse rails. Each cross-rail is mounted on a pair of traverse trolleys (4) and can travel sideways in the
fixed rails along the total width of the lift system. This rail system allows the ceiling lift unit, which is mounted on a
cross-rail, to travel in all directions and be used anywhere in the room. Two rail systems with full room coverage can
be connected by means of transition gates.
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MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
1) Shunting rail
2) Fixtures
3) Transition gate
4) Traverse trolleys
5) Ceiling lift unit
6) Fixed rails/primary rails
7) Cross-rail/traverse rail/secondary rail
8) Turntable
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1: Introduction / 6
A basic rail system and a rail system with full room coverage, (x-y) system, can also be connected by means of
transition gates (3).
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1: Introduction / 7
1.2: Straight rails
MilkyWay straight rails are available in three different rail profiles and in several lengths. All MilkyWay rails are
prepared for in-rail charging. For more information about available MilkyWay straight rails; article numbers and
technical data, please consult the “MilkyWay Technical information” document.
Each rail profile offers its own unique performance
Rail 64 is the standard straight rail. It can be used in basic rail systems, with or without curves
and switches. It is used in most applications installed using ceiling brackets and/or pendants.
Rail 64 can be supported with a bolt-on rail for higher rigidity, see 4.2: Supported cross-rails.
Rail 120 features a higher profile and is therefore more rigid. It is used in applications with a
longer free span between attachment points. Rail 120 is often used as a secondary rail in a
(x-y)/traverse system or as a long single rail in a basic rail system.
Rail 160 features the highest profile and rigidity. It is used in applications with a free span of up to
7000 mm between attachment points, usually in large rooms with vertical supports.
Rail 160 can also be used as a secondary rail in large (x-y)/traverse systems.
Art. No. 50400262-276
Art. No. 50400277-294
Art. No. 50400295-299
64
60,30
120
60,30
160
60,30

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MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
600
600
R760
90°
R760
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200
45°
R
500
Rail curve 64-22.5 W, 50400231
R760
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200
22,5°
±2°
Rail curve 64-15 W, 50400232
R760
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200
15°
±2°
1: Introduction / 8
1.3: Rail curves
MilkyWay includes rail curves in 15°, 22.5°, 45° and 90° variants. The curves are available in one rail profile: 64 x 60 mm.
All MilkyWay rail curves are prepared for in-rail charging. For more information about available MilkyWay rail
curves; article numbers and technical data, please consult the “MilkyWay Technical information” document.
Rail curve 64-45 W, 50400227
R760
Rail curve 64-90 W, 50400228

MilkyWay
MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
1.4: Installation methods
MilkyWay offers several different alternatives for installation of straight rails and rail curves on the ceiling. Depending
on factors such as ceiling height, material and structure, different ceiling brackets and/or pendants can be used.
MilkyWay also features several alternatives for wall-mounting of free bearing rail systems.
Regardless of which installation method is used, the completed installation must always comply with the
requirements for safety. It is also essential for the performance that deflection of the rails is avoided,
see 2: Important information.
1.4.1: Installation on the ceiling
Ceiling brackets
Ceiling brackets are available in several models. The choice depends, among other factors, on the structure and
material of the ceiling. Ceiling brackets feature different build-in dimensions and are installed with one or two fixings.
Ceiling brackets can be easily installed on concrete, flush with the surface, and adjusted from the rail.
For more information about MilkyWay ceiling brackets, see 8: Ceiling fixtures - brackets and pendants.
Pendants
Pendants enable installation of a rail system onto a high ceiling, while still allowing for the correct distance between
rail and floor (2300 mm). Pendants are available in several models and variants. All pendants are very stable and
easy to install. They are also, either steplessly or with fixed intervals, variable in length to enable correct height
adjustment. This feature facilitates both design and installation of the system. It also enables adaptation to the
room and the lifting needs at hand.
For more information about MilkyWay pendants, see 8: Ceiling fixtures - brackets and pendants.
1: Introduction / 9
Installation with ceiling bracket
Installation with pendant

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MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
1: Introduction / 10
Unistrut/wooden beam
Threaded rod
Nut
Washer
Rail 64
Washer
Locking nut
Threaded rod support kit
The threaded rod support kit is used when the rail system needs to be installed under joists. The fixing point is
in a beam (e.g. a steel channel or a 100 x 100 mm wooden beam) resting on a minimum of three joists.
For more information about MilkyWay Threaded rod support kit, see 8: Ceiling fixtures - brackets and pendants.
Ceiling
Joist
1.4.2: Concealed rails
In some applications, the rail system can be concealed by an inner ceiling. A concealed rail system can also be
installed in preparation for subsequent installation of ceiling lift units and, in a new building, the fixed rails of a rail
system with full room coverage can be installed in preparation for later installation of cross-rails. In these cases, the
inner ceiling must be prepared with installation hatches.
All fixtures must be securely installed with double self-locking nuts. Install the entire rail system and carry
out the final safety tests before mounting the inner ceiling.
For more information about all available MilkyWay ceiling fixtures; article numbers and technical data, please consult
the “MilkyWay Technical information” document.

MilkyWay
MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
1.4.3: Installation on the walls
Wall brackets
For free bearing installations, the end of the rails can be attached to the wall using wall brackets. Wall brackets are
available in several models, see 9: Wall fixtures - brackets and vertical supports. The choice depends, among other
factors, on the wall structure and material.
1: Introduction / 11
Wall bracket wide Wall bracket parallel (plaster)
Vertical support
Vertical support is an alternative fixture for wall-mounting of free bearing rail systems, see 9: Wall fixtures - brackets
and vertical supports. When there are doubts about the load bearing capacity of the wall, vertical supports should
be chosen. Before installation, the condition of the floor must be determined in order to decide if the floor can carry
the extra point load created by the vertical supports.
For more information about all available MilkyWay wall fixtures; article numbers and technical data, please consult
the “MilkyWay Technical information” document.

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MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
1: Introduction / 12
1.5: Power supply
MilkyWay rail systems can be powered in many different ways. All models of RiseBasic and RiseAtlas, except the
high humidity and SmartPark special versions, feature easy and convenient hand control charging as standard.
The charging station for these ceiling lift units are integrated in a small and discreet holder and parking place for
the hand control. The hand control holder with charging station is easily installed on the wall, in convenient proximity
of the ceiling lift unit’s parking place.
The lift units can also be charged either anywhere in the entire rail system (in-rail charging) or at the end of the
primary and/or secondary rails (end point charging).
Basic rail systems - options for charging
A: End point charging. Use the charger and the charging connectors for the rail supplied with the ceiling lift unit.
Read the user manual before installation.
B: In-rail charging. Use the charger supplied with the ceiling lift unit. Conductor rail and insulator, which are available
as accessories, are required. Carbon sliders mounted on top of the lift unit are used for power transfer.
Read the user manual before installation.
(x-y)/traverse systems - options for charging
A: End point charging. Use the charger and the charging connectors for the rail
supplied with the ceiling lift unit. Traverse trolleys designed for end point
charging are required. An extension cable for the traverse trolley may be
required depending on the overhang. Read the user manual before installation.
B: In-rail charging. Use the charger and the charging connectors for the rail
supplied with the ceiling lift unit. Traverse trolleys designed for in-rail charging
and conductor rail and insulatior, for both primary and secundary rails, are
required. Carbon sliders mounted on top of the lift unit and in one of the trolleys
are used for power transfer. An extension cable for the traverse trolley may be
required depending on the overhang. Read the user manual before installation.
1.5.1: In-rail charging with conductor rail and insulator
MilkyWay conductor rail and insulator are available in several lengths and are supplied in pairs, see 10.4: Installation
equipment. If several lengths need to be joined, the conductor rails must be connected by means of a brass joint.
For more information; article numbers and technical data, please consult the “MilkyWay Technical information” document.

MilkyWay
MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
1.6: Installation heights
The height of the rails above floor level can be critical in some applications. Below are indicated some basic
dimensions close to ”worst case”. The person shown is 1900 mm tall, and the lifting sling is size XL.
The dimensions may vary a lot. The rail shown is the rail with the lowest profile, Rail 64, installed with ceiling
brackets. For dimension (A) see 4.1: Single cross-rails.
1: Introduction / 13
A
220
ca. max. 1100 0-2000

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2: Important information / 14
2: Important information
2.1: General instructions for installation of rails
All rails, including primary and secondary rails in a (x-y)/traverse system, must be installed horizontally. The ceiling or
floor alone is not accurate enough as a reference to horizontal. True to spirit level is required.
Overhang Free span
Straight and true to spirit
The rails must be installed horizontally. In case of uneven surfaces, the mounting base must be straightened out by
means of washers, blocks, shims or similar.
The rails must be installed observing maximum free span and overhang limits. It is also essential for the performance
that deflection of the rails is avoided. The deflection for a fully loaded system must be less than 5 mm per running
meter. Reduce the distance between fixing points to achieve this. For detailed information about maximum free span
and overhang for different rail profiles installed on different types of ceilings and walls using different types of fixtures,
please consult the ”MilkyWay Technical information” document; Span details.
The inside of the rails must be completely clean after installing. Even small filings or borings can affect the
performance, making traversing uneven.
The ends of all rails must be fitted with endstops. If there is a risk that the endstop may fall out, the endstop must be
installed with secure screws.

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2: Important information / 15
2.2: Safety
MilkyWay rail systems must be designed, assembled, installed and inspected by qualified and authorized
personnel according to instructions issued by Handicare AB. Only fixing elements approved by Handicare AB
and suitable for the specific installation may be used.
Regional regulations, as well as the intended applications for different installations, may vary significantly. Before
deciding on how to install the rails, it is important to determine the condition of both the ceiling, the walls and the floor.
Specific fixings for installation of the rails are not included and general recommendations cannot be made. All
decisions on fixings and anchorage for a specific rail system must be made by the installer or the constructional
engineer in charge. Should fixings be supplied, the installer is responsible for evaluation of their suitability for the
application at hand.
Minimum requirements on ceilings
Apart from the required static strength, each attachment point in the ceiling construction must be rated to withstand
a load of at least 2 times the rated load of the entire rail system. The construction of the ceiling must not be critically
damaged by the ceiling lift unit being driven into the endstops. This can only be calculated by an engineer and/or the
owner of the building. For more information; see 2.3: Point load recommendations.
Minimum requirements on walls
Apart from the required static strength, the walls must be rated to withstand a load of at least 2 times the rated load
of the entire rail system. The construction of the walls must not be critically damaged by the ceiling lift unit being
driven into the endstops. This can only be calculated by an engineer and/or the owner of the building.
Testing the rail system
All ceiling lift systems must be weight tested immediately after completion of the installation. Use of a lift system to
lift and/or transfer any person prior to certification by weight testing is strictly prohibited.
For more information; see 7: Weight testing procedure.
Safe working load
Different products on the same ceiling lift system (ceiling lift unit, sling bar, lifting sling, scales and other lifting
accessories) may have different allowed safe working loads. The lowest allowed safe working load always
determines the safe working load of the entire assembled system. Always check the safe working load for the
ceiling lift unit and all lifting accessories before use. Contact your local Handicare and SystemRoMedic™ partner if
you have any questions.

MilkyWay
MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
The load upon each attachment point (ceiling bracket/pendant) is considered “point load.”
The structure of building must be able to support the load imposed upon it at each attachment point.
Installation of a MilkyWay ceiling lift system requires that the existing structure, to which the rail system is attached,
is able to withstand the loads imposed upon it by the ceiling lift system. Performance of structural check is the
responsibility of others.
MilkyWay requires a two (2) times safety rating. Maximum point load for each support attachment point is based
upon the maximum lifting capacity of the ceiling lift unit plus the estimated weight of ceiling lift equipment at
support attachment point multiplied by a safety factor of two (2).
Standard system consists of a basic rail system or (x-y)/traverse system utilizing 1 ceiling lift unit.
Bariatric system consists of a basic rail system or (x-y)/traverse system utilizing 2 ceiling lift units.
Maximum lifting capacity: standard system
Standard system 230 – Maximum capacity – 230 kg / 507 lbs
Standard system 285 – Maximum capacity – 285 kg / 625 lbs
Maximum lifting capacity: bariatric system
Bariatric system 460 – Maximum capacity – 460 kg / 1014 lbs
Bariatric system 570 – Maximum capacity – 570 kg / 1256 lbs
Estimated weight of the ceiling lift system equipment (lift motor, rails, pendant/ceiling bracket,
traverse carrier, etc.) at each support location for standard system is 27 kg / 59 lbs.
Estimated weight of the ceiling lift system equipment (lift motors, rails, pendant/ceiling bracket,
traverse carrier, etc.) at each support location for bariatric system is 45 kg / 99 lbs.
Standard systems:
230 kg / 507 lbs: 285 kg / 630 lbs:
230 kg + 27 kg = 257 kg / 566 lbs working point load 285 kg + 27 kg = 312 kg / 687 lbs working point load
257 kg x 2 = 514 kg / 1133 lbs maximum point load 312 kg x 2 = 624 kg / 1375 lbs maximum point load
Bariatric systems:
230 kg / 507 lbs: 285 kg / 630 lbs:
(230 kg x 2) + 45 kg = 505 kg / 1113 lbs working point load (285 kg x 2) + 45 kg = 615 kg / 1355 lbs working point load
505 kg x 2 = 1010 kg / 2226 lbs maximum point load 615 kg x 2 = 1230 kg / 2711 lbs maximum point load
2: Important information / 16
2.3: Point load recommendations

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MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
3: Basic rail systems / 17
3.1: Installation of rails
Basic rail systems are normally installed on the ceilling or on the walls, see 1.4: Installation methods.
NB! For basic rail systems connected to (x-y)/traverse systems, see 4.4.4: Heights, systems with transition gates.
3.2: Connecting rails and rail curves
Two or more straight rails and/or rail curves can be connected to each other to create a rail featuring the required
lenght and direction. Joint bracket provides a convenient solution for secure connection, see 10.4: Installation
equipment.
When installing shorter rail systems, the rail system can, to an advantage, be assembled on the floor. Thereafter, the
rail system is lifted up to the ceiling as one unit. The conductor rails for power supply can be inserted in full length in
the pre-assembled rail system.
3: Basic rail systems
Joint bracket, 50400316
MilkyWay Rail

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MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
3.3: Installation of a straight rail, example
Ceiling lifts are often used for transfers to and from bed, wheelchair and toilet. A basic rail system with a short straight
rail of 2500 mm can be the right solution for these situations. In the below installation example, regular ceiling/wall
brackets and 2.5 kN fixings are selected.
1) Select starting point (lowest point).
2) Decide where to mount the charger or transformer.
3) Decide orientation.
3: Basic rail systems / 18
5) Lift up the rail in position for installation.
6) Mark out the holes for fixings.
7) Prepare the fixings in accordance with the
instructions of the supplier.
8) Check that the inside of the rail is clean;
no filings or borings left.
9) Install the rail on the wall or ceiling.
NB! In some systems, it is not possible to insert the lift module after lifting up the rail.
10) Check that the rail is straight and horizontal.
11) Insert the lift module (if not done before lifting the rail).
12) Mount the endstops at the rail ends.
13) Connect the cables (see 6: Connecting to power supply) and check that they are connected correctly.
14) Plug in the hand control and check the functions.
15) Perform a final test of all functions including weight testing, see 7: Weight testing procedure.
For detailed information about maximum free span and overhang for different rail profiles installed on different
types of ceilings and walls using different types of fixtures, please consult the ”MilkyWay Technical information”
document; Span details.
4) Install the brackets and endstops in the rails. If ceiling fixtures are used, the overhang must not exceed the
specified distance. Wall brackets are located at the rail ends. If possible - as it is the case with concrete ceilings
- the remaining brackets must be evenly distributed. If the ceiling is constructed around joists, the brackets are
normally fixed to the feet of the joists.

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3: Basic rail systems / 19
3.4: Installation of rail curves, example
All curves must be installed by means of a fixture in the midpoint (1) of the centerline. Curves of 15, 22.5, 45 or 90
degrees must have the two remaining fixtures close to the rail joint - in the curve (2) or in the straight rail (3).
Closest possible distance is 110 mm from mounting hole to rail joint.
Combinations of straight rails and rail curves can, to an advantage, be assembled on the floor and thereafter installed
as one unit. This method significantly facilitates marking out the location of fixtures. Furthermore, it allows for the
conductor rail to be inserted in full length.
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2 and 3

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MilkyWay Handbook • Version 3 - 20140616 © Handicare AB
A: Mounting holes
B: Adjustment screws
C: Sensor
D: Joint brackets
E: Motor
3.5: Shunting rail, 50400141-142 (only for Reda)
MilkyWay shunting rail switches between two very short pieces of straight rail. The desired curve (15, 22.5, 45 or 90
degrees) can be mounted subsequently. The switch is electrically operated and features built-in rectification.
Therefore, polarity is not an issue for the switch motor. Polarity is determined by the requirements of the lift module.
The switch can be installed directly on the ceiling using the 6 mounting holes (A). If the rails are lowered from the
ceiling - as is the case when the switch is connected to a traverse system - adjustable pendants can be can be used
as fixtures.
Safety
The switch is secured against unintended switching while the lift has passed the switch by means of the sensor (C),
detecting a magneto on the lift module. During installation, the switch (C) may be reversed to the opposite position.
This can be corrected by passing a magneto close to the switch.
The lift module cannot run out of the rail, due to checkblocks mounted at the sides of the rail switching.
3: Basic rail systems / 20
For more information about all available MilkyWay shunting rails; article numbers and technical data, please consult
the “MilkyWay Technical information” document.