Tractel Tirak Series User manual

1
Electrically powered endless hoist
for materials handling
TIRAK®
series
T 1000
tirak®
TIRAK®
series
X 300
X 400
X 500
X 700
X 800
X 1020
TIRAK®
series
X 3050
Original Operating Instructions
This instruction manual must be available
for the user at all times.
Additional copies may be obtained on request.
With TIRAK®wire ropes
of different lengths
on winders
www.tractel.com

2
Contents
Information for this manual 2
Notes for manufacturers of installation 3
with built-in TIRAK
®
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
materials handling 5
3.4 Noise emission 5
3.5 Main components and
operating controls 6
3.6 Technical data 7
3.7 Increasing the capacity 7
3.8 Anchoring examples 8
3.9 Safety devices
3.9.1 Primary brake 8
3.9.2 Emergency stop 8
3.9.3 Phase control relay 8
3.9.4. Load limiting device 8/9
3.9.5 Manual operation
3.9.5.1 Emergency descent 9
3.9.5.2 Manual lifting 9
3.10 Residual risks 10
4. Setting up
4.1 Required equipment 10
4.2 Anchoring the TIRAK
®
hoist
4.2.1 Anchoring devices and
dimensions 10/11
4.2.2 Anchoring of the TIRAK
®
hoist 12/13
4.3 Wire rope exit
4.3.1 Slack wire rope 13
4.3.2 Use of wire rope winders 13
4.4 Electric connections 14
4.5 Electric controls 15
Page
4.6 Wire rope installation
4.6.1 Preparing the wire ropes 15
4.6.2 Wire rope installation 16
5. Operation
5.1 Checks before starting 17
5.2 Weekly check of wire rope and cable 17
5.3 Operation
5.3.1 Stop/EMERGENCY STOP 17
5.3.2 Service operation 17
5.4 Securing moving loads 18
5.5 Manual operation
5.5.1 Emergency descent 18
5.5.2 Manual lifting 18
6. Troubleshooting 18/19/20
7. Out of Operation
7.1 Temporary stoppage 20
7.2 End of operation 20
8. Maintenance/Checks/Repair
8.1 Maintenance
8.1.1 Hoist 21
8.1.2 Wire ropes 21
8.1.3 Motor, brake, and gear box 21
8.2 Checks
8.2.1 Essential checks 22
8.2.2 Safety inspection 23
8.3 Repair 23
9. Spare Parts 23
9.1 Hoist 23
9.2 Motor and brake 23
9.3 Electrical control 23
9.4 Nameplates and labels 23
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 28.

3
Notes for manufacturers of an installation with built-in TIRAK®
Important!
The manufacturer of an installation for lifting/
pulling/driving loads in which a TIRAK
®
hoist is
built in must indicate all instructions for the safe
use of this installation at the corresponding points
of the instructions which must be prepared for
the installation by the manufacturer.
STOP
Merely enclosing these instructions does not
satisfy the requirements of the EC Machinery
Directive or the applicable standards!
(without code word)
Explanation of symbols used
Safety advices
Symbol Code word Meaning Possible consequences of non-compliance
IMMEDIATE or
DANGER possibly imminent Fatal or serious injuries!
danger:
IMMEDIATE or
DANGER possibly imminent
danger through Fatal or serious injuries!
dangerous
voltage:
Possibly
CAUTION dangerous Injuries to persons
situation: or damage to property.
Other advices
Possibly
Attention dangerous Damage to appliance.
situation: or its surroundings.
Important Useful tips for
optimum working: None
Directions
Instruction to operation/
documentation in writing.

4
Follow all instructions and safety regu-
lations contained in this
manual to avoid injuries.
a) DO NOT overload the TIRAK
®
hoist.
b) DO NOT stand below a suspended load.
c) TIRAK
®
hoists must only be used for lifting, pull-
ing, lowering, and moving back-and-fro of loads
1)
.
Use for other purposes is not allowed.
d) TIRAK
®
hoists with standard electric equipment
must not be used in a potentially explosive at-
mosphere
2)
.
e) Anchoring, maintenance, and/or the operation of
TIRAK
®
hoists 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.
f) The operator has to know and to follow all rel-
evant local safety regulations, and maintenance
recommendations, as well as this operating in-
struction, and the operator must have been
instructed.
g) The operator must not start any movement of the
load until he has checked that the hoist and the
load are properly anchored, and that no person is
stood in the danger zone below any suspended
load, or until he has got a starting signal from the
slinger.
h) The operator must watch the load during all move-
ment operations of the hoist. If the operator is
unable to watch the complete working area, the
danger zone must be cordoned off, or a second
person must be positioned to enable the com-
plete working area to be watched and have
adequate means of communication with the hoist
operator during the whole operation.
i) The TIRAK
®
hoist has to be anchored so that the
wire rope under load is vertically entering the
hoist.
k) Use only the recommended TIRAK
®
rope in good
condition. Use only normally commercially avail-
able multi-purpose grease for the lubrication of
the rope. Do not use lubricants containing disul-
phide (e.g. Molycote
®
).
l) When using a rope other than the recommended
TIRAK
®
rope the warranty entitlement given by
GREIFZUG Hebezeugbau GmbH or other com-
pany of the TRACTEL Group shall not apply.
1) TIRAK
®
-Hoists for man riding on request.
2) TIRAK
®
-Hoists can be supplied for these applications on request.
1. Safety advice
m) Before starting the assembly check all parts for
completeness and error-free quality.
n) Only anchor the TIRAK
®
hoist at the points pro-
vided for this purpose (connection rods, anchor
points, or load pins).
o) When using self-securing nuts please observe
the following:
–the screw must protrude from the nut with at
least half its thread diameter;
–do not re-use nuts if they can be unscrewed
by hand!
p) Do not use the wire rope to fix the load, and do
not pull it over sharp edges.
q) Do not fix any load to the free wire rope end,
which exits from the winch at the opposite side to
the wire rope under load.
Exception: Use of a TIRAK
®
hoist of the type
series T 1000 in to-and-fro travel.
r) Never use a rope which is too short for the job
you are doing. When the load or machine is at its
lowest point, a minimum length of 1meter of wire
rope should be below the rope exit of the TIRAK
®
.
s) The ferrule of the wire rope hook must not reach
the TIRAK
®
-casing during lifting/pulling the load.
Exception: A limit switch for lifting limitation is
attached to the TIRAK
®
hoist (see accessories on
page 25).
t) The electrical connection of the TIRAK
®
as well
as of electrical accessories must be carried out
in accordance with EN 60204-1.
u) Checks and repairs to the electrical system must
only be carried out by qualified electricians.
v) Other checks and repairs must only be carried
out by GREIFZUG Hebezeugbau GmbH, an other
company of the TRACTEL Group or by a hoist
workshop.
w) GREIFZUG Hebezeugbau GmbH or other com-
pany of the TRACTEL Group shall assume no
liability for damages resulting from conversions
or alterations to the devices supplied by itself or
as a result of the use of non-original parts.

5
2. Exclusion of non-intended use
3. Machine description
3.1 Purpose
TIRAK
®
hoists of the series
X 300 , X 400 / X 500 , X 700 , X 800,
T 1020, X 1000, X 3050
are portable, electric driven hoists for
lifting, lowering, pulling, and
movement of loads
by means of a TIRAK
®
wire rope prescribed by the
manufacturer.
This wire rope is mandatory for the safe and trouble-
free working with TIRAK
®
hoists.
DIN
G
B
8
Fig. 1
3.3 Allowed TIRAK®wire rope for
materials handling
for TIRAK
®
-series Wire rope-Ø
X 300 8 mm
X 400
X 500
X 700
X 800
T 1000
X 1020 9 mm
X 3050 14 mm
Identification: one red strand.
Diamater indication on the ferrule:
3.4 Noise emission
TIRAK
®
series (Distance 1 m)
X 300/400:............................................................................max. 72 dB(A)
X 500/700/800/1020, T 1000:....................max. 70 dB(A)
X 3050................................................................................. max. 78,5 dB(A)
3.2 Working principle
Provided that TIRAK
®
hoists are aligned in the direc-
tion of pull, they will work in any position and in any
direction.
For either lifting or lowering there is one correspond-
ing push button. The wire rope is driven through the
winch with constantly equal safety, and the length of
wire rope i. e. the possible pulling length, is practi-
cally unlimited.
TIRAK
®
hoists with a capacity of 1000 kg or more
have an integrated load limiting device.
TIRAK
®
hoists of T 1000 series can pull in both
directions.
Indication
on the ferrulle:
example for
8 mm dia.
Use of standard TIRAK
®
hoists and other equipment for materials handling
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
5
5
3.5 Main components and operating controls
TIRAK®
series
T 1000
7
2
6
4a
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. Brake release lever
7. Wire rope
TIRAK®
series
X 300
X 400
X 500
X 700
X 800
X 1020
3
2
1
7
4b
7
4c
Fig. 2a
TIRAK®
series
X 3050
b
c
a
3
2
1
7
Fig. 2b
Fig. 2c
Fig. 2d
8
6
5

7
Rope Type TIRAK
®
Dead
Rated Dimensions
Hoist Capacity speed of Output rope weight
current
drive Ø approx. a b c
TIRAK
®
Model kg
2)
m/min –
3)
kW A mm kg
4)
mm mm mm
X 300 300 9D0,5 1,6 8 27 437 262 265
X 302 18 D 0,9 2,6 8 27 437 262 265
X 301 9W0,45 4,5 8 29 476 257 245
X 400 400 9D0,7 1,6 8 29 437 272 285
X 402 18 D 1,94 2,5 8 30 452 272 285
X 403 9/18 D 0,7/1,4 1,6/2,5 8 35 452 272 285
X 401 9W0,7 5,5 8 32 496 272 285
X 500 500 9D0,9 2,8 8 40 489 297 265
X 502 18 D 1,8 5,0 8 43 504 297 265
X 503 9/18 D 0,9/1,8 2,8/5,1 8 47 504 297 285
X 501 9W0,9 6,5 8 49 556 297 256
X 700 700 9D1,5 3,9 8 45 525 297 265
X 800 800 9D1,6 4,5 8 45 525 297 265
X 805 4,5/9 D 0,8/1,6 3/4,2 8 50 563 304 285
X 806 4,5/18 D 0,8/3,2 3,6/9 8 71 603 328 315
X 803 9/18 D 1,75/3,5 4/8 8 49 550 297 285
T 1000 980 9D1,9 4,6 8 71 580 336 311
T 1005 (1000
5)
)4,5/9 D 0,9/1,9 3,6/4,6 8 84 642 355 318
T 1006 4,5/18 D 0,9/3,8 4,0/9,7 8 94 679 386 348
T 1003 9/18 D 1,9/3,8 5,5/9,5 8 85 642 355 348
X 1020 980 9D1,9 4,6 9 45 525 297 265
X 1025 (1000
5)
)4,5/9 D 0,9/1,9 3,5/4,8 9 55 563 307 285
X 1026 4,5/18 D 0,9/3,8 4/9,6 9 71 605 332 315
X 1023 9/18 D 1,9/3,8 4,5/8,5 9 56 563 307 315
X 3050 3000
5)
6D3,8 9,9 14 105 669 400 372
X 3052 12
6)
D7,5 17 14 117 681 403 372
X 3053 6/12
6)
D3,8/7,5 9,9/19 14 156 786 428 442
3.6 Technical Data
Table 2
1) Hoist to 9 m/min = transmission group 1B
m
, Hoists over 9 m/min = transmission 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.
5) With load limiting device.
6) 60 % duty cycle at 12 m/min.
Design according to DIN 15020, transmission group 1B
m
resp. 1C
m
.
Technical modifications reserved.
Fig. 3 2·F
3·F!
2·F!
F
F
F
F2·F 2·F
Diversion
only!
F
F
F
F
F
F
2·F
LIFT
F
F
2·F
PULL
Explanation:
F means the TIRAK
®
hoist capacity –
e. g. F = 500 kg.
The drawing shows the required
strength of the anchor points,
anchoring devices, and pulleys –
e. g. 2·F = 1000 kg.
3.7 Increasing the capacity by
reeving the wire rope
If the capacity of the TIRAK
®
hoist is not sufficient in
direct lifting or pulling, it can be multiplied by reeving
the wire rope according to the block and tackle prin-
ciple.
But double capacity means half speed, triple ca-
pacity means 1/3 speed etc.
Important for horizontal pull:
Do not confuse the dead weight of the load
with the effort required to pull it: the TIRAK
®
has only to overcome the friction coefficient.
Attention! A competent person must check –
a) that the pulleys and the anchoring devices
as well as all anchor points are of sufficient
strength, and
b) that the pulleys are of the correct diameter.

8
3.8 Anchoring examples for materials handling
Fig. 4b
Fig. 4a
Pulling
Fig. 4c Fig. 4d
To-and-fro-Driving
Only TIRAK
®
T 1000
series
Fig. 4f
Fig. 4e
Lifting
Prevent the
load from
rotating!
3.9 Safety devices
3.9.1 Primary brake
Electromagnetic brake which closes automatically
–if the UP/Down-button is released
–in case of power supply failure.
3.9.2 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.
3.9.3 Phase control relay
In controls 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.
Correction: turn the phase inverter of the plug by
180(Fig. 6).
UP
DOWN
EMERGENCY
STOP
Fig. 5
Fig. 6
3.9.4 Load limiting device
TIRAK
®
-Models with 1000 kg capacity or more are
equipped with a 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 carrying capacity of the hoist.
3.9.4.1 Electronic pulling force limiting device
Possible causes for switching off:
–overload or
–blocking of the load when lifting/pulling.
Phase inverter
in CE-plug

9
Action following switching off:
Press DOWN button,
–until the load has settled and reduce the load
until there is no longer any overload or
–until the load is free from the obstacle. Remove
the obstacle before continuing to lift or pull.
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/pulling.
Reducing the switch off threshold value
Setting to a lower threshold value e.g. as a result of a
lower carrying capacity of the components to which
the hoist or diverter pulleys are anchored, can only be
carried out by a qualified electrician or a hoist work-
shop (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.
B. Setting
(Example for TIRAK
®
X 1030)
B.1 Setting the overload
Attach overload = rated load + 25 %
(e. g. 1250 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.
Press UP button – the hoist must stop immedi-
ately.
Following each stopping of 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.
3.9.4.2 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.
Possible causes of switching off:
–overload or
–blocking of the load when lifting/pulling.
Action following switching off:
Press DOWN button,
–until the load has settled and reduce the load
until there is no longer any overload or
–until the load is free from the obstacle; remove
obstacle before continuing to lift or pull.
Fig. 7
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
I
N
= 5 A, 10 A ~
GREIFZUG
U I
N
Speicher R
START
0
0,5 s
TIH4X-G
A1 11 K I1 I2
(N) (L) (L)
10A 5A
U
12 14 Y1 Y2 A2
12 14
11
10 % 100
40 60
80
Electronic load limiting device
B.2 Setting the rated load
Attach rated load (e. g. 1000 kg) and lift the
nominal load from ground.
Turn lower regulator to the left as far as the
stop.
3.9.5 Manual operation
Details in chapter 5.5 on page 18
3.9.5.1 Emergency Descent
In case of power failure you can manually open
the brake with lever (1) (Fig. 8).
3.9.5.2 Manual lifting
With the brake opened the load can be lifted
with the hand wheel (2) placed on the motor shaft
(Fig.8).
2
1
Fig. 8

10
TIRAK
®
series
X 300/400 X 500 / 700 / 800 T 1000 X 3050
X 1020
Dimensions [mm]
a255 300 449 570
b220 267 250 360
c60 60 56 117
Ø d 10,5 10,5 - 16,1
e- 35 - 45
e
1
---35
f- 67 - 132
g- 26 28 40
h- 19 14 27
h
1
---70
Ø i - 16,5 16,5 30,1
k112 100 - -
l40 40 - 70
m12 12 - -
n98 98 - -
o32 32 - -
p26 26 - -
Ø q 13 13 - -
4. Setting up
4.1 Required equipment
a) TIRAK
®
of correct capacity, speed and voltage.
Machines with a capacity of 1000 kg or more
must have a built-in load limiting device.
b) TIRAK
®
wire rope with correct diameter and of
sufficient length. Grease to lubricate the rope
c) Electric supply cable of correct type and required
length, with correct number of wires and cross
sectional area.
d) Anchoring devices for fixing the load i.e. slings,
belts or similar of sufficient strength.
e) Pulleys for diverting or reeving the wire rope of
sufficient strength and diameter.
Check condition of all components.
3.10 Residual risks
CAUTION!
The following risks are not constructively
covered for the TIRAK
®
hoist :
On TIRAK
®
hoists without limit switch (standard
version):
a) Damage to the rope when the rope hook is
pulled as far as the TIRAK
®
housing. Conse-
quently observe rope hook during lifting/
pulling so as to be able to stop in time.
b) Running out of the slack wire rope end. Conse-
quently
–always ensure a sufficiently long rope;
–watch rope end during lowering/slacken-
ing so as to be able to stop in good time.
On TIRAK
®
hoists with load limiting device:
c) The load limiting device is set to the maximum
carrying capacity of the respective hoist. Should
a lower value be necessary e.g. due to a lower
carrying capacity of components to which the
hoist or diverter pulleys are anchored:
–have electronic load limiting device set by
a qualified person (see section 3.9.4);
–have mechanical load limiting device set by
the manufacturer.
d) The electronic load limiting device only de-
tects an overload during lifting/pulling. Therefore
particular care should be exercised when a load
carrying device (material container or similar) is
loaded when suspended or being lowered.
4.2 Anchoring the TIRAK®-Hoist
4.2.1 Anchoring devices and
dimensions
Table 3
Fig. 9
bc
a
Ø d
A
Series X 300/400
Dimension