Molift Rail System User manual

MRS19201 Rev C 2014-06-25
Molift Rail System
EN - Handbook

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English Manual
Content
Molift Rail System (MRS) – Introduction..................4
General...........................................................................4
1 How to use this handbook......................................5
2 Installation criteria – Principles...............................6
2.1 Site survey – Design criterias............................6
2.2 Lifting points.......................................................6
2.3 Mounting Molift Rail system............................7
2.4 Point loads.........................................................8
3 System Overview.......................................................9
3.1 Single rail system...............................................10
3.1.1 Ceiling mounted Straight rail system......11
3.1.2 Ceiling mounted Curve rail system.........13
3.1.3 Wall mounted Straight rail system..........14
3.2 Traverse rail system...........................................15
3.2.1 Ceiling mounted traverse system............16
3.2.2 Wall mounted traverse system................18
3.3 Combination of rail systems...........................20
3.3.1 Switch systems...........................................21
3.3.2 Climbing systems......................................23
4. Component Overview...........................................26
4.1 Attachment........................................................27
4.1.1 Ceiling Mounted System..........................27
4.1.2 Wall mounted System..............................29
4.2 Rails and Curves...............................................30
4.3 End Stops and End Caps................................32
4.4 Traverse Trolleys................................................33
4.5 Lift Motor Trolleys............................................35
4.6 Switches.............................................................36
4.7 Battery Charging..............................................37
4.8 Installation tools..............................................40
5. Design Conditions..................................................42
5.1 Lifting heights and lifting area.......................42
5.2 Design conditions – Attachments.................44
5.2.1 Ceiling mounted........................................44
5.2.2 Wall mounted............................................45
5.2.3 Attachments for curves...........................47
5.2.4 Side Support positioning.........................48
6 Installation methods...............................................54
7 Final Installation Procedure....................................56
7.1 Load test: Straight Rail System.......................56
7.2 Load test: Traverse Rail System......................56
7.3 Identification......................................................57
7.4 Installation Certification..................................57
8. System combinations – Case studies.................58
8.1 Single Rail system.............................................59
8.2 Traverse Rail system.........................................62
9. Installation instructions.........................................67
10. Maintenance.........................................................68
Service log...................................................................69
Checklist for installation of Molift Rail System......70
Periodic inspection for Molift Rail System..............71
Important
This User Manual contains important safety
instructions and information regarding the use of
the lifter and accessories.
In this manual the user is the person being lifted.
The assistant is the person operating the lifter.
Warning!
This symbol indicates important
information related to safety.
Follow these instructions carefully.
Visit www.molift.net for download of documen-
tation to ensure you have the latest version.
Revision table
Revision A. 2013-12- 09
First release
Revision B. 2014-02-18
Updated illustrations and miscellaneous
details. New front page.
Revision C. 2014-06-25
Removed IRC components and room-to-
room transfer Molift Air. Added boxed
traverese trolley.

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Molift Rail System (MRS)
Introduction
Molift Overhead Systems consist of a rail system,
Molift Rails System (MRS) combined with the lift
motor choices Molift AIR or Molift Nomad which
give innovative and efficient solutions when it
comes to lifting needs for disabled persons.
Molift Overhead Systems are easy and safe to use
and can solve most lifting situations. The func-
tional and user friendly design provides greater
access to the user and increases assistant and user
safety. Molift solution gives a highly flexible, inno-
vative, cost effective and profitable investment.
This handbook provides support and guidance to
installation performance of Molift overhead lift
systems and contains important information about
the design criteria and installation solutions. It is
important to thoroughly understand the content
of the handbook.
Conditions of Performing Installation
Lift and transfer of a person will always pose
a certain risk and only certified personnel are
allowed to install the equipment and accessories
covered by this technical manual.
Only personnel authorized by Etac
can perform installation of the
Molift overhead system and issue
the installation certificate, all in
accordance with Etac’s installation
instructions and this handbook.
The lifter is not intended to be operated by the
person being lifted. If a hoist is to be used by a
disabled person living on their own, then some
form of communication device shall be installed
in the area of use of the hoist so that in the event
of an emergency the disabled person is able to
summon assistance. This may, for example, be
the fitting of an alarm system or the supply of a
conveniently placed telephone, etc.
General
Declaration of conformity
The Molift Rail System and related accessories described in this handbook are CE marked
in accordance with EU Council Directive 93/42/EEC concerning medical devices, class 1, and
is manufactured in conformity with standards IEC 60601-1, IEC 60601-1-2 and NS-EN ISO
10535:2006.
Components made by other manufacturers
We recommend only using Etac Molift components. Etac shall not be liable for faults or accidents
that can occur when using components made by other manufacturers.
System should consist of only original MRS components. If not Decalaration of
conformity is not valid and Etac is not responisble for warranty of the system

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In order to design a lifting solution, create a speci-
fication, order the parts and install the overhead
systems You need following documents apart
from this Handbook:
- Molift Pricelist
- Molift Product catalogue
- Site survey
- Installation instructions
The Handbook is divided into nine main chapters.
Chapter 1 – Molift Rail System (MRS)
Introduction of Molift Rail System. General terms
and a description how to use this handbook.
Chapter 2 - Installation criteria – Principles
Description of the principles for installing a Molift
Rail System, Site survey process and how to handle
different constructions material in buildings.
Chapter 3 –System Overview
Overview of possible system configuration and
combinations of MRS.
Chapter 4 – Component Overview
This chapter describes the MRS products and
which components are available for different
design solutions.
Chapter 5 - Design Conditions
This chapter describes the design conditions, limi-
tations and possibilities how to combine the MRS
products to create a sufficient and safe Molift
Overhead System.
Chapter 6 - Installation methods
This Chapter describes work flow and tools for
survey and installation process.
Chapter 7 - Final Installation Procedure
This Chapter describes procedure for the final test-
ing and certification of installed rail system.
Chapter 8 - System combinations – Examples
This Chapter describes a few of the most common
design solutions of Molift Rail System. Shows com-
bination possibilities, measurements and examples
of specifications.
Chapter 9 - Installation instructions
This Chapter describe list of available Specific
Installation Instructions for the various mounting
options for MRS.
Chapter 10 - Maintenance
This Chapter describes how to perform periodic
inspection, service and repair to the rail system.
1. How to use this handbook

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2. Installation criteria – Principles
2.1 Site survey – Design criteria
A site survey is the first project input, and it is
of great importance that this is performed and
archived in a proper way. We recommend that all
points in our Site Survey template are considered,
and that existing on-site conditions are docu-
mented preferably with photos and drawings.
Depending of the size of a ceiling lift installation
project, it is also of importance to consider how to
organize logistics for a ceiling lift installation:
• When should the installation take place (in
larger building projects)?
• What floor is the installation to be done?
• How do we get the rails there? (Crane?
Elevator? Stairs?)
• How to install efficiently? Installations teams or
single workers?
• How to handle disposals (packaging materials)?
2.2 Lifting points
One important issue in the survey is to identify
and define lifting points and optimal placement of
the rail systems.
Figure: Furniture and lifitng points
100 cm

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2.3 Mounting Molift Rail System
The way of mounting a ceiling lift system is based
on the specific materials and structural design on
each specific site.
Ceiling materials:
- Concrete; hollow core slabs or compact
layers
- Wood structures (requires reinforcements
between rafters)
- Light materials (LECA, Siporex etc)
Wall materials:
- Concrete
- Bricks
- Wood structure
- Light walls (Gyproc/plasterboards)
Upright supports:
- Upright supports are used where the exist-
ing structure or other installations does not
allow fixing in walls or ceiling.
Reinforcements to existing structues
- Reinforcements must be installed if the
existing building structure OR the materials
are too weak for the installation
Figure: Example of reinforcement of wood wall
structure with upright reinforcement between two
studs for mounting of wall bracket or wall rail.
Figure: Example of reinforcement of wood ceiling
structure with joist hangers and reinforcement
between joists.
Figure: Example of reinforcement of wood ceiling
structure with lying joist over joists.

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2.4 Point loads
All systems should have minimum of two
anchoring (attachment) points.
One attachment point = one or more fixings
(expander bolts, chemical anchors etc.)
All attachment points of a ceiling lift system
should, according to prevailing standard EN-ISO
10535:2006, withstand a pullout force; the work-
ing load of the system installed times a safety
factor 1,5.
MRS attachment point Load Calculations:
• Molift Lift motors have 5 different weight
capacities within the range: 160 – 300 kg
Weight
capacity
Nomad Air
160 kg X
205 kg X X
230 kg X
255 kg X
300 kg X
• Standard ceiling lift system including any
straight rail or traverse system with 1 lift
motor.
• Estimated weight of equipment at pendant
support location for standard system =
approx. 30 kg
(includes: lift motor weight, rails, pendant,
traverse carrier, etc)
• Ultimate Point load for each support
attachment location is based upon the
maximum capacity of the lift motor +
estimated weight of the equipment at the
support attachment location times a safety
factor of 1,5
Example:
For a standard system with 200 kg motor:
200 kg = 200 kg – Safe Working Load
200 kg +30 kg = 230 kg – Working Load
230 kg x 1,5 = 345 kg – Ultimate Point
load
All fixings should always be tight-
ened with torque specified by the
anchor/fixture manufacturer.

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3. System Overview
Molift Rail System (MRS) is a ceiling hoist system built in three different main configurations:
1. Single rail system
2. Traverse rail system
3. Combination of single rail and traverse systems
The area below the track system is defined as the lifting area. The area below a straight rail system is
limited to the rail, while a traverse system gives lifting area below the area covered by the traversing
secondary rail.
Single rail system
Traverse rail system

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3.1 Single rail system
In a straight rail system the lift motor can be
moved horizontally along the rail path. By combin-
ing MRS curves and rails it is possible to create
single rail systems with expanded lifting area. The
curve rail system can only be mounted to ceiling
and does not allow wall mounting.
Lifting Area = Hatched area on floor under lifter.
3.1.1 Ceiling mounted Straight rail system
Can be mounted in four different ways:
1. Directly to ceiling without brackets
2. Mounted to ceiling with brackets
3. Suspended from the ceiling with telescopic
brackets
4. Suspended from the ceiling with threaded
rods
Figure: Ceiling mounted direct to ceiling without
brackets

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Figure: Ceiling mounted with open ceiling using
40mm brackets
Figure: Ceiling mounted with telescopic brackets

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Figure: Ceiling mounted with threaded rods

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3.1.2 Ceiling mounted Curve rail system
By combining MRS curves and rails it is possible
to create single rail systems with expanded lifting
area. This solution does not allow free standing or
wall mounting. Can be mounted to ceiling only.
Figure: Ceiling mounted with telescope brackets
Figure: Ceiling mounted with open ceiling using
40 mm brackets.

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3.1.3 Wall mounted Straight rail system
A wall mounted system is mounted on separate
wall brackets or on brackets connected to uprights
supported by the wall.
Figure: Wall mounted wall bracket
Figure: Wall mounted Wall brackets supported by
upright supports

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A traverse system is built up by two parallel
primary rails, a secondary rail connected to the
primary rails by a traverse trolley in each primary
rail. The lifting motor is connected in the second-
ary rail. This system allows full room coverage.
Primary rail
Secondary rail
3.2 Traverse System
Secondary Rail mounted
under Primary rails,
under trolley
Secondary Rail mounted
between Primary rails,
on top of trolley (Box-in)

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3.2.1 Ceiling mounted traverse system
Ceiling mounted traverse rail system can be
mounted in different ways:
1. Directly in ceiling without brackets
2. Directly in ceiling with brackets
3. Suspended from the ceiling with telescopic
brackets
4. Suspended from the ceiling with threaded
rods
Figure: Ceiling mounted without brackets direct
to ceiling
Figure: Ceiling mounted with brackets with open
ceiling profile

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Figure: Ceiling mounted telescopic brackets with
open ceiling profile
Figure: Ceiling mounted threaded rods with open
ceiling profile

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3.2.2 Wall mounted traverse system
A wall mounted system is mounted on separate
wall brackets, wall mounted rails or on brackets
connected to uprights supported by the wall and
the floor.
1. Primary rails mounted on separate wall
brackets.
2. Primary rails mounted on brackets connected
to uprights supported by the wall and the
floor.
3. Primary rails mounted on wall rails.
Figure: Wall mounted rail with wall brackets

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Figure: Wall mounted with wall brackets and
upright supports
Figure: Wall mounted rail direct to wall with wall
rail

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MRS allows a great variation of possibilities when
combining traverse systems and single rail system.
Transfer between different systems/rooms and
locations can be solved in several ways with MRS
The simplest way is by extending the single rail
track through doorway.
The systems can also be combined with different
switches such as Rail switch and Traverse switch.
Climbing from one system to next is also an
option both with permanently mounted lift motor
Molift AIR and portable lift motor Molift Nomad.
3.3 Combination of rail systems