Tractel TIRAK T 1020 P User manual

1
TIRAK®
series
T 1020 P
tirak®
TIRAK®
series
X 300 P
X 400 P
X 500 P
X 720 P
X 820 P
X 1030 P
TIRAK®
series
X 2050 P
Original Operating Instructions
This instruction manual must be available for the
user at all times
Additional copies may be obtained on request.
Electrically powered endless hoist
for man-riding
www.tractel.com

2
Contents
Information for this manual 2
Notes for manufacturers of
suspended suspended access equipment 3
Explanation of symbols used 3
1. Safety Advice 4
2. Exclusion of non-intended use 5
3. Machine Description
3.1 Purpose 5
3.2 Working principle 5
3.3 Allowed TIRAK
®
wire rope for
man-riding 5
3.4 Noise emission 5
3.5 Main components and
operating controls 6
3.6 Technical data
3.6.1 TIRAK
®
hoists 7
3.6.2 BLOCSTOP
®
Fall arrest device 7
3.7 Typical examples 8
3.8 Safety devices
3.8.1 Primary brake 9
3.8.2 Emergency STOP 9
3.8.3 Phase control relay 9
3.8.4 Load limiting device 9
3.8.5 Manual operation 10
3.8.6 Fall arrest devices 10
3.8.7 Upper limit switch 11
3.9 Residual risks 11
4. Setting up
4.1 General 12
4.2 Required equipment 12
4.3 Anchoring the TIRAK
®
hoist
4.3.1 Anchoring devices and
dimensions 12-13
4.3.2 Anchoring the TIRAK
®
hoist 14
4.4 Installation of the fall arrest device
4.4.1 Evidence of carrying capacity 15
4.4.2 Dimensions of BSA devices 15
4.4.3 Anchoring the fall arrest device 16
4.4.4 Connection to the
TIRAK
®
control system 17
4.4.5 Dimensions of BSO Devices 18
Page
4.5 Slack wire rope
4.5.1 Slack wire ropes 18
4.5.2 Use of rope winders 18
4.6 Electric connections 19
4.7 Electric controls
4.7.1 Push button control UP/DOWN 20
4.7.2 Examples for central control 20
4.8 Wire rope installation
4.8.1 Preparing the rope 20
4.8.2 Lifting rope installation 21
4.8.3 Safety rope installation 22
5. Operation
5.1 Checks before starting 22
5.2 Daily checks 23
5.3 Weekly checks of wire rope and cable 24
5.4 Operation
5.4.1 Stop / EMERGENCY-STOP 24
5.4.2 Service operation 24
5.5 Manual operation
5.5.1 Emergency descent 25
5.5.2 Manual lifting 25
5.6 Action in the event of operation
of the fall arrest device 25
6. Troubleshooting 26-28
7. Out of operation 28
8. Maintenance
8.1 Maintenance
8.1.1 Hoist 29
8.1.2 Wire rope 29
8.1.3 Motor, brake, and gear box 29
8.1.4 BLOCSTOP
®
fall arrest device 29
8.2 Checks
8.2.1 Essential checks 30
8.2.2 Safety inspection 31
8.3 Repair 31
9. Spare parts
9.1 Hoist 32
9.2 Motor and brake 32
9.3 Elektric control 32
9.4 BLOCSTOP
®
fall arrest device 32
9.5 Nameplates and labels 32-33
Page
Date of edition
2nd Edition: February 2004
Copyright
The copyright of these assembly and operating
instructions shall remain with the manufacturer.
Address of the manufacturer:
GREIFZUG Hebezeugbau GmbH
Scheidtbachstraße 19-21
51469 Bergisch Gladbach
Germany
Phone: +49 / 22 02 / 10 04-0
Fax: +49 / 22 02 / 10 04-50 or -70
e-Mail: [email protected]
For addresses of other TRACTEL Group Companies see page 36.

3
Notes for manufacturers of suspended access equipment
Important!
The manufacturer of “Suspended access equip-
ment (SAE)” (working platforms, baskets, seats or
similar) into which a TIRAK
®
device with corre-
sponding BLOCSTOP
®
fall arrest device is installed,
must indicate all notes of these operating in-
structions required for safe use at the
appropriate point of the instructions which the
manufacturer must prepare for the SAE.
Merely
enclosing these instructions
does not satisfy
the requirements of the
EC Machinery Directive or of the applicable stand-
ards!
Users of “Suspended access equipment” from
GREIFZUG GmbH or from another company of
the TRACTEL Group shall receive the complete
instructions for the corresponding installation.
Suspensions
and
Suspended platforms
Original
assembly and
operation instructions
STOP
Explanation of symbols used
Safety advice
Symbol Code word Meaning Possible consequences of non-compliance
IMMEDIATE or
DANGER possibly imminant Fatal or serious injuries!
danger:
IMMEDIATE or
DANGER possibly imminant
danger through Fatal or serious injuries!
dangerous
voltage:
Possibly
CAUTION dangerous Injuries to persons
situation: or damage to property.
Other advice
Possibly
Attention dangerous Damage to appliance.
situation: or its surroundings.
Important Useful tips for
optimum working: None
Directions
Instruction to operation/
documentation in writing.
(without code word)

4
1. Safety advice
1) TIRAK
®
hoists can be supplied for these applications on request.
i) Anchor TIRAK
®
hoist and BLOCSTOP
®
fall arrest
device so that the lifting or safety ropes are verti-
cal.
k) Only anchor TIRAK
®
hoist and BLOCSTOP
®
fall
arrest device at the points provided for this pur-
pose (connection rods, anchor points, or load
pins).
l) When using self-locking nuts please observe the
following:
–the screw must protrude from the nut with at
least half of its thread diameter;
–do not re-use nuts if they can be unscrewed
by hand!
m) DO NOT overload the TIRAK
®
hoist.
n) Use only the prescribed TIRAK
®
rope in perfect
condition. Use only normally commercially avail-
able multi-purpose greases for the required
lubrication of the rope. Do not use any lubricants
containing disulphide (e.g. Molycote
®
).
o) When using a rope other than the prescribed
TIRAK
®
rope, the warranty entitlement given by
GREIFZUG Hebezeugbau GmbH or other com-
pany of the TRACTEL Group shall not apply.
p) The electrical connection of the TIRAK
®
hoists
as well as of electrical accessories must be car-
ried out in accordance with EN 60204-1.
q) Checks and repairs to the electrical system must
only be performed by qualified electricians.
r) Other checks and repairs must only be performed
by GREIFZUG Hebezeugbau GmbH, other com-
pany of the TRACTEL Group or a hoist workshop.
s) GREIFZUG Hebezeugbau GmbH or an other com-
pany of TRACTEL Group shall assume no liability
for damage as a result of conversions and altera-
tions to the devices supplied by itself or as a
result of the use of non-original parts.
Follow all instructions and safety
regulations contained in this
manual to avoid injuries.
a) TIRAK
®
hoists for man-riding with BLOCSTOP
®
fall arrest devices are designed for installation in
“Suspended access equipment (SAE)”.
b) TIRAK
®
hoists with standard electric equipment
must not be used in a potentially explosive at-
mosphere
1)
.
c) Anchoring, maintenance, and/or the operation of
a TIRAK
®
hoist must only be done by persons,
who are familiar with it. Employees must have
received the instruction to anchor, maintain, and/
or operate the hoist by their employer.
d) They must be familiar with the relevant accident
prevention regulations e.g. “Hoists, lifting and pull-
ing devices”, “load carrying devices in hoist
operation”, “safety requirements on suspended
access equipment (EN 1808)” etc. and have been
instructed accordingly.
They must have read and understood the assem-
bly and operating instructions prepared by the
manufacturer of the SAE.
e) If more than one person is entrusted with one of
the above mentioned activities, the manufacturer
of the SAE must designate a supervisor who is
authorised to give instructions.
f) Only TIRAK
®
hoists, BLOCSTOP
®
fall arrest de-
vices, ropes, anchoring devices as well as leads
and control cables in good condition must be
used.
g) The safety equipment supplied with the TIRAK
®
hoist (e.g. the BLOCSTOP
®
fall arrest device)
must be assembled on the SAE.
The manufacturer of the SAE is respon-
sible for the installation of the limit
switches for LIFTING and if applicable
LOWERING.
h) Before starting with the assembly, please check
that all parts are complete and defect-free.

5
3.3 Allowed TIRAK®wire rope for
man-riding
for TIRAK
®
-Series Wire-rope-Ø
X 300 P 8 mm
X 400 P
X 500 P
X 720 P 9 mm
X 820 P
T 1020 P
X 1030 P 10 mm
X 2050 P 14 mm
Identification:
one red strand.
Diamater indication
on the ferrule:
2. Exclusion of non-intended use
Indication
on the
ferrulle:
example for
8 mm dia.
DIN
G
B
8
Fig. 1
3.4 Noise emission
TIRAK
®
-Series (Distance 1 m)
X 300/400 P:.....................................................................max. 72 dB(A)
X 500/720/820/1030 P, T 1020 P:......max. 70 dB(A)
X 2050 P .......................................................................... max. 78,5 dB(A)
3. Machine description
3.1 Purpose
TIRAK®hoists of the series
X300P, X 400 P, X 500 P, X 720 P,
X 820 P, X 1030 P, T 1020 P und X 2050 P
are portable, electric driven hoists for
Lifting and Lowering
of
“Suspended access equipment”
by means of a TIRAK®wire rope prescribed by
the manufacturer.
This wire rope is mandatory for the safe and
troublefree working with TIRAK®hoists.
3.2 Working principle
A TIRAK
®
hoist is installed on suspended access
equipment with which it moves up and down on wire
ropes.
For either lifting or lowering there is one correspond-
ing push button.
The wire rope is driven through the winch with con-
stantly equal safety, and the length of wire rope i. e.
the possible pulling length, is practically unlimited.
All TIRAK
®
hoists referred to in 3.1 have an integrated
load limiting device.
Use of standard TIRAK
®
hoists and other equipment for man-riding
under the following conditions is prohibited:
–at temperatures below -10
 Cor above +50  C,
for X 1030 to 2050 P series below -15
 Cor above +80  C
(for advice regarding gearbox oils for lower/higher temperatures
see chapter 8.3);
–in potentially explosive atmosphere.
Machines for these conditions can be supplied on request.
Table 1

6
6
5
3.5 Main components and operating controls
TIRAK®
Series
T 1020 P
68
2
7
5
4c
3
1
ab
c
b
c
a
1. Wire rope drive
mechanism
2. Motor
3. Gearbox
4. Controls
awith central control box
bat the terminal box
cwith pendant control, mounted on the terminal
box
dwith pendant control, with connector
5. Where appliable: connector to the central control
box
6. Always: connector to the upper limit switch
(at the TIRAK
®
terminal box)
7. Brake release lever
8. Lifting rope
TIRAK®
Series
X 300 P
X 400 P
X 500 P
X 720 P
X 820 P
X 1030 P
3
2
1
7
4b
5
6
8
4d
1+2
1 2
N
O
T
A
U
S
4a
Fig. 2a
TIRAK®
Series
X 2050 P
b
c
a
3
2
1
8
Fig. 2b
Fig. 2c
Fig. 2d
7
7

7
Type TIRAK
®
Dead-
Rope Rated- Dimensions
Hoist Capacity of Output rope weight
speed Current
drive Ø approx. a b c
TIRAK
®
Model kg
2)
m/min –
3)
kW A mm kg
4)
mm mm mm
X 300 P 300 9D0,5 1,6 8 28 437 272 285
X 302 P 18 D 0,9 2,6 8 28 437 272 285
X 301 P 9W0,5 4,5 8 29 476 272 285
X 400 P 400 9D0,7 1,6 8 29 437 272 285
X 402 P 18 D 1,4 2,5 8 30 485 272 285
X 401 P 9W0,7 5,5 8 32 485 250 220
X 500 P 500 9D0,9 2,8 8 39 485 297 250
X 502 P 18 D 1,8 5,0 8 39 495 297 250
X 503 P 9/18 D 0,9/1,8 2,8/5,1 8 41 495 297 250
X 501 P 9W0,9 6,5 8 43 546 297 256
X 720 P 700 9D1,5 3,9 9 43 546 297 256
X 820 P 800 9D1,25 4,0 9 48 525 297 285
X 822 P 18 D 3,5 7,0 9 60 563 307 285
X 823 P 9/18 D 1,75/3,5 4,5/9,0 9 61 563 307 315
T 1020 P 800 9D1,9 4,6 9 74 577 320 315
T 1023 P 9/18 D 1,9/3,6 5,5/9,5 9 84 645 320 315
X 1030 P 1000 9D1,9 4,6 10 48 525 297 285
X 1032 P 18 D 3,6 9,5 10 60 563 307 285
X 1033 P 9/18 D 1,9/3,6 5,5/9,5 10 61 563 307 315
X 2050 P 2000 6D2,2 6 14 85 650 400 340
X 2052 P 12 D 5,5 12 14 110 660 400 350
3.6 Technical Data
3.6.1 TIRAK®Hoists
Table 2
1) Hoist to 9 m/min = Driving group 1B
m
, Hoists over 9 m/min = Driving group 1C
m
2) If the capacity is not sufficient in direct pull, multiply it by reeving the rope according to the block and tackle principle.
3) D = 415 V three phase current; W =110/220 V single phase current. 4) Weight without wire rope.
a
b
c
for max. TIRAK
®
Dead
Fall Dimensions
Capacity wire rope Rope weight
arrest device speed Ø approx. a b c
BLOCSTOP
®
Model kg
1)
m/min mm kg mm mm mm
BSA 15-301 500 – 8 4 286 191 76
BSA 20-303 800 – 9 6 350 222 76
BSA 20-330 1000 – 10 6 350 222 76
BSA 35-305 2000 – 14 10,5 395 313 90
BSO 500 500 18 8 4,7 214 121 131
BSO 1020 800 18 9 6 251 140 131
BSO 1030 1000 18 10 6 251 140 131
BSO 2050 2000 18 14 14 408 150 183
Safety rope
Fig. 3
Table 3
3.6.2 BLOCSTOP®Fall arrest device
STOP
AUF
STOP
AUF
STOP
AUF
BSA 15-301 BSA 20-303 BSA 35-305 BSO 500 BSO 1020 BSO 2050
BSA 20-330 BSO 1030
Lifting rope
Design according to DIN 15020, transmission group 1B
m
or1C
m
.
Technical modifications reserved.
The BLOCSTOP
®
-Models BSO… can
if desired be equipped with a limit
switch which stops the downward travel
of the assigned hoist in the event of
the BLOCSTOP
®
being closed.

8
3.7 Typical Examples
1
2b
4
3
5
7
6
Platform
with
rear
suspension
Platform
with
end
suspension
1
2a
34
5
7
6
5
3
4
1
2b
7
6
Working cage
5
43
1
2b
7
6
Working seat
(Schematical Drawing)
1 TIRAK
®
2a BLOCSTOP
®
BSA
Fall arrest device
2b BLOCSTOP
®
BSO
Fall arrest device
3Lifting rope
4Safety rope
5Tensioning weight
on safety rope
6Upper limit switch
7Buffer plate for
upper limit switch
Fig. 4a Fig. 4b
Fig. 4c Fig. 4d

9
Fig. 7
Electronic load limiting device
START
0
0,5 s
TIH4X-G
A1 11 K I 1 I 2
(N) (L) (L)
10A 5A
U
12 14 Y1 Y2 A2
12 14
11
10 % 100
40 60
80
START
Hysterese (= I
S
x 0,5)
U
Y1 Y2
I
S
R
5A 250V~ 1000VA
A1 A2 K I1 I2 Y1 Y2 12 11 14
~
5 A
10 A
IN = 5 A, 10 A ~
GREIFZUG
U I
N
Speicher R
3.8 Safety devices
3.8.1Primary brake
Electromagnetic brake wich closes automatically
–if the UP/DOWN-button is released
–in case of power supply failure.
3.8.2 Emergency Stop
Pushing the red EMERGENCY STOP button in case
of emergency completely switches off the hoist con-
trol. To start after clearing the problem, turn the
EMERGENCY-STOP button clockwise until it re-
leases.
3.8.3 Phase control relay
On hoists with 3-phase motors, the integrated phase
control relay stops the operation, if the phases are
reversed. This prevents wrong coordination of the
UP/DOWN-buttons, which would prevent operation of
the load limiting device as well as the upper limit
switch.
Correction: turn the phase inverter of the plug by
180(Fig. 6).
Fig. 6
Control for
12
Speed Speed
UP
DOWN
EMERGENCY
STOP
Fig. 5
Reducing the switch-off threshold value
Setting to a lower threshold value e.g. as a result of a
lower carrying capacity of the suspended access
equipment, can only be carried out by a qualified
electrician or a hoist workshop (fig. 7):
A Pre-setting
A.1 Nominal curent
Turn upper regulator to the right as far as the
stop.
A.2 Start-bridging
Turn lower regulator to the right as far as the
stop.
3.8.4 Load limiting device
3.8.4.1 Electronic load limiting device
The load limiting device is set by the manufacturer in
such a manner that it switches off the lifting move-
ment at the latest when the load has reached 1.25
times the rated capacity of the hoist. A warning signal
(lamp or buzzer) must be provided for on the control
box which notifies the operator of the overload.
Possible causes for switching off:
–overloading of the suspended access equipment,
possibly as a result of unfavourable load distribu-
tion, or
–the suspended access equipment being blocked
by an obstacle during upward travel.
Action following switching off:
Press DOWN button,
–until the suspended access equipment is once
again on the ground and reduce the load to such
an extent that, or redistribute it until there is no
longer any overload
or
–until the suspended access equipment is free
from the obstacle which must be removed before
travel is continued.
Function of the load limiting device
The electronic load limiting device reacts to the cur-
rent consumption of the motor. The overload is
detected during lifting.
B. Setting
(Example for Tirak X 500 P)
B.1 Setting the overload
Attach overload = rated load + 25 %
(e. g. 625 kg)
During the lifting of the overload turn the upper
regulator to the left until the hoist stops.
Lower overload until the rope is slack.
Again lift overload – the hoist must stop as soon
as it comes under load.
Phase inverter
in CE-plug

10
B.2 Setting the rated load
Attach rated load (e. g. 500 kg) and lift the
nominal load from ground.
Turn lower regulator to the left as far as the
stop.
Press UP button – the hoist must stop immedi-
ately.
Following each stopping o f the hoist during
this setting procedure,
press the DOWN button
shortly
so that the upward travel is again possi-
ble.
Step by step
–turn the lower regulator slightly to the right,
–then press UP button,
until lifting of the suspended nominal load is
possible.
Important note for TIRAK
®
with 2 speeds
(pole changing motor):
The control system contains 2 load limiting
devices, the setting must be carried out for
both speeds.
3.8.4.2 Mechanical load limiting device
The load limiting device is installed in the rope drive
and switches off the UPWARD travel in the event of
overload.
A warning signal (lamp/buzzer) is triggered which
does not go off until the cause of the overload has
been removed.
Possible causes for the switching off:
–overload of the suspended access equipment,
possibly as a result of unfavourable load distribu-
tion
or
–the suspended access equipment being blocked
by an obstacle during upward travel
Action following switching off:
–reduce load to such an extent that, or redistribute
it until there is no longer any overload,
or
–move downwards until the suspended access
equipment is free from the obstacle which must
be removed before travel is continued.
2
1
Fig. 8
3.8.5 Manual operation
Details in chapter 5.5 on page 25.
3.8.5.1 Emergency Descent
In case of power failure you can manually open
the brake with lever (1) (Fig. 8).
3.8.5.2 Manual lifting
With the brake opened the suspended ac-
cess equipment can be lifted with the hand
wheel (2) placed on the motor shaft. (Fig. 8).
3.8.6 Fall arrest devices
Suspended access equipment must be equipped with
a fall arrest device which secures the load against
falling using a safety rope.
The two systems available from the manufacturer of
the TIRAK
®
hoists are described below.
3.8.6.1 BLOCSTOP
®
Model BSA
The fall arrest device model BLOCSTOP
®
BSA is
opened by the loaded lifting rope (fig. 9) and secures
the suspended access equipment against:
a) rupture of the lifting rope,
b) failure of the hoist,
c) interlocking/becoming caught during downward
travel with the result that the lifting rope is no
longer under tension,
d) inclined position of more than the maximum ad-
missible 14(on suspended platforms with the
two hoists attached at the ends).
3.8.6.2 BLOCSTOP
®
model BSO
The fall arrest device model BLOCSTOP
®
BSO is
released manually (fig. 10).
The speed of the safety rope is constantly monitored
and the clamping mechanism closed automatically in
the event of a sudden occurrence of excessive speed.
As a result, the suspended access equipment is se-
cured against
a) rupture of the lifting rope and
b) failure of the hoist
By pressing the EMERGENCY STOP button the fall
arrest device can also be closed manually in an emer-
gency. This offers the advantage that a defective
hoist can be replaced on the hanging man-riding de-
vice.
The viewing window serves to enable to check the
operation of the centrifugal weights during service.
See section 5.6 on page 25 for action in the event
of operation of the fall arrest device.