Transcript
(With Optional Payload Cable Management System)
Installation, Operation & Maintenance Manual Models 2, 3, 4, 6, 12 and 18
The Will-Burt Company 169 South Main Street Orrville, Ohio 44667 Telephone 330-684-7015 www.willburt.com TP-4857301-E October 2014
Installation, Operation, And Maintenance Manual
RibbonLift™ and Cobra™ Warranty Will-Burt warrants its RibbonLift™ and Cobra™ masts to be free from defects in material and workmanship for a period of two (2) years, with such time period running from the date of shipment by Will-Burt. WillBurt shall not be responsible for any damage resulting to or caused by its products by reason of failure to properly install, maintain or store the product; use of the product in a manner inconsistent with its design; unauthorized service, alteration of products, neglect, abuse, accident, or acts of God,. This warranty does not extend to any component parts not manufactured by Will-Burt; provided, however, Will-Burt’s warranty herein shall not limit any warranties by manufacturers of component parts which extend to the buyer. THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, AND NO REPRESENTATIONS, GUARANTEES OR WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, A WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR NON-INFRINGEMENT ARE MADE BY WILL-BURT IN CONNECTION WITH THE MANUFACTURE OR SALE OF ITS PRODUCTS. NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY ON BEHALF OF WILL-BURT. Claims for defects in material and workmanship shall be made in writing to Will-Burt within thirty (30) days of the discovery of defect. Failure to provide notice as required hereby shall be conclusive evidence that the product was in conformity with the warranty, and Will-Burt shall be released from any and all liability relating to the product. Will-Burt may either send a service representative or have the product returned to its factory at Buyer's expense for inspection. If judged by Will-Burt to be defective in material or workmanship, the product will be replaced or repaired at the option of Will-Burt, free from all charges except authorized transportation. THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REMEDIES. THE LIABILITY OF WILL-BURT WHETHER IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE, SHALL NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION, ANY PRODUCT OR PART FOUND BY WILL-BURT TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP. WILL-BURT SHALL NOT BE LIABLE FOR COST OF INSTALLATION AND/OR REMOVAL, OR BE RESPONSIBLE FOR DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE
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Document History Manual TP-4857301 TP-4857301 TP-4857301 TP-4857301 TP-4857301 TP-4857301
TP-4857301-E
Version 00 A B C D E
Date October 2012 December 2012 September 2013 November 2013 September 2014 October 2014
Remarks Will-Burt First Release Updated Table 4-1 Added Warnings for Guy Wire Tension New Guy Wire and Limit Mechanism Updated Table 5-2 Fuses. Updated Table 4-1
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TABLE OF CONTENTS CHAPTER 1 OVERVIEW ........................................................................................ 1-1 CHAPTER 2 INSPECTION ...................................................................................... 2-1 CHAPTER 3 INSTALLATION ................................................................................ 3-1 Orientation ........................................................................................................... 3-1 Input Power .......................................................................................................... 3-1 Emergency Stop ................................................................................................... 3-2 Control ................................................................................................................. 3-2 Limit Switches ..................................................................................................... 3-3 Leveling ............................................................................................................... 3-4 Optional Systems ................................................................................................. 3-4 CHAPTER 4 OPERATION ....................................................................................... 4-1 Ribbon Engagement ............................................................................................. 4-1 Maximum Lift Capacity....................................................................................... 4-2 Bending Moment Limitations .............................................................................. 4-2 Guy Wire Tension ................................................................................................ 4-3 CHAPTER 5 MAINTENANCE ................................................................................ 5-1 Ribbon Maintenance ............................................................................................ 5-1 Gearmotors, Motors, and Gearboxes ................................................................... 5-1 Limit Switches ..................................................................................................... 5-1 Fuses .................................................................................................................... 5-2 CHAPTER 6 OPTIONAL EQUIPMENT ................................................................. 6-1 Payload Cable Management System .................................................................... 6-2 DMX Control – Fleenor Design .......................................................................... 6-4 Dynamic Guy System .......................................................................................... 6-6 Heavy Duty .......................................................................................................... 6-6 Column Cover ...................................................................................................... 6-7 Trailer Hitch Carrier ............................................................................................ 6-7 CHAPTER 7 TROUBLESHOOTING ....................................................................... 7-1
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SAFETY SUMMARY SIGNAL WORD DEFINITION Per the ANSI Z535.4 standard, the following signal words and definitions are used to indicate hazardous situations: DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices. GENERAL SAFETY PRECAUTIONS The following are general safety precautions that are not related to any specific procedures and therefore do not appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during many phases of operation and maintenance.
Electrocution Hazard! Contact with high voltage will result in death or serious injury. Observe general safety precautions for handling equipment using high voltage. Do not locate or operate equipment near electrical lines, cables or other unwanted sources of electricity. Do not operate equipment in lightning. Be certain electrical cables are undamaged and properly terminated. Always disconnect power before performing service, repair or test operations.
Safety Instruction - Read Manual! Failure to follow operating instructions could result in death or serious injury. Read and understand the operator’s manual before using the equipment.
Tip Over Hazard! Equipment tip over could result in death or serious injury. Do not operate in high winds. Operate on level ground only. Stand clear of equipment and payload during operation. Be certain equipment is level and secure before and during installation, operation and maintenance.
Safety Instruction - Trained Personnel Only! Death or serious injury could result if proper inspection, installation, operation and maintenance procedures are not observed. Installation, operation and maintenance to be performed by trained and authorized personnel only. Proper eye protection should be worn when servicing the equipment.
Health and Safety Hazard! Solvent used to clean parts is potentially dangerous. Avoid inhalation of fumes and also prolonged contact to skin. Safety Instruction - Do not look at lights! Do not look directly into lighting equipment when illuminated. Temporary impairment or permanent vision damage could occur.
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SPECIFIC SAFETY PRECAUTIONS The following are safety precautions that are related to specific procedures and therefore appear elsewhere in this publication for emphasis. These are recommended precautions that personnel must understand and apply during specific phases of installation, operation and maintenance.
Safety Instruction-Operation! Not for use in hazardous locations. Do not use in areas that have been classified as hazardous as defined in Article 500 of the National Electric Code.
Crush Hazard! Death or serious injury could result if equipment falls suddenly. Do not stand directly beneath the equipment or its payload. Be certain payload is properly installed and secured.
Fire Hazard! Cleaning solvent, used for maintenance, is flammable and can be explosive resulting in death or serious injury. Do not smoke. Use cleaning solvent in a well-ventilated area. Keep cleaning solvent away from ignition sources. Always store cleaning solvents in properly marked containers.
Relocation Hazard! Relocating the equipment during operation or after extension could result in death or serious injury. Do not relocate the equipment during operation or while extended. This applies especially to equipment mounted to vehicles. Operate the equipment only if the vehicle is stationary and the vehicle engine is off.
Equipment Extension Hazard! Extending equipment into obstructions could result in death or serious injury and could render the equipment inoperable and partially extended. Before applying power and operating the equipment, be certain there is sufficient clearance above and to all sides of the expected location of the fully extended equipment and payload. Keep all persons clear of equipment and equipment extension. Do not lean directly over the equipment.
Mounting Structure Hazard! Mounting equipment into a structure unable to resist the forces generated from customer-specific loading scenario could result in death or serious injury and could damage the equipment. Before operation, be certain mounting structure is capable of resisting forces generated from all loading and environmental conditions, including, but not limited to, equipment size and weight, payload size and weight, sail size, wind speed, guy line arrangement, support bracket or roof line location and base plate assembly. Safety Instruction – Operation! Make sure all power has been disconnected prior performing maintenance. Safety Instruction -Trained Personnel Only! Only trained and qualified personnel should perform installation, adjustments, and servicing. Only a properly trained and qualified certified electrician should perform electric installations and service.
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When re-lamping an installed light fixture, make sure all power to fixture is off and that the fixture is cool
Safety Instruction – Operation! At all times prior to equipment operation, insure that: 1.) 2.) 3.) 4.) 5.) 6.)
The equipment area is free of personnel and mechanical obstruction; All electrical cables are undamaged and properly terminated; The operator must have full view of the equipment during use; Any transit tie-downs on the payload have been removed; The vehicle is not moving; The area above the equipment is free of mechanical obstructions.
Immediately discontinue use and service unit if guy wires loose tension at any point in the column travel. Death or serious injury could occur. Safety Instruction-Operation! Lamps are extremely hot and should not come into contact with people or combustible and/or explosive materials. Do not operate if breakage occurs or unit is knocked over.
Entanglement Hazard! Tangled cables can cause equipment damage. Ensure control cables are not tangled and are free to pay out as equipment is extended.
Lifting Hazard! Manually lifting over 55 lbs. (25kg) is prohibited. In the UK, all lifting equipment must be thoroughly examined annually by a competent person according to the Lifting Operations and Lift Equipment Regulations 1998. Equivalent regulations exist in other EU states.
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CHAPTER 1
OVERVIEW
Thank you for purchasing a Will-Burt Ribbon Lift™ product. This compact, portable lift is designed to provide years of service when properly installed, operated, and maintained.
Will-Burt Ribbon Lift products are not designed or warranted for critical applications that include lifting and/or supporting people. Using this unit in these critical applications could cause death, personal injury, or severe property and environmental damage. The buyer fully assumes all risk associated with using a Ribbon Lift in critical applications including lifting and/or supporting people.
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CHAPTER 2
INSPECTION
As the Ribbon Lift unit is removed from the crate or pallet inspect for obvious damage. Specifically make sure to inspect the enclosure wrap, the protective rubber ring bumpers attached to the top and bottom plates of the base (Figure 2-1), the optional dynamic guy cables (Figure 61), and the pendant control cord (Figure 2-2). Power and Control Connections
Enclosure Wrap Ring Bumpers
Enclosure Wrap Latches
Figure 2-1
Figure 2-2
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Ribbon Lift™
Pendant and Control Cord
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CHAPTER 3
INSTALLATION
Orientation All Ribbon Lift models, except the Model 18-30, can be configured in an upright or inverted orientation. Typical inverted units are mounted from an overhead truss or ceiling structure. Because of gravitational effects on the column, an inverted unit has approximately twice the lifting capacity of an upright unit. Operation of the unit, including the optional payload cable management system, is unaffected by its orientation. Input Power
To avoid serious injury or death, input power must be disconnected before servicing the unit
Input power for all Ribbon Lift models is factory specified as either AC or DC. Available AC and DC voltage levels are shown in *Same for 12-25 Standard and Heavy Duty
Table 3-1. Voltage levels must be determined prior to shipment and are not changeable after delivery.
Model Model 2-10 Model 3-12 Model 4-15 Model 6-20 Model 12-25* Model 18-30
AC Input Power 50/60 Hz single phase (± 10% VAC) 115 115 or 230 115 or 230 115 or 230 230 230
DC Input Power (± 25% VDC) 12 or 24 12 or 24 12 or 24 12 or 24 24 N/A
*Same for 12-25 Standard and Heavy Duty
Table 3-1
AC and DC Input Power
All AC powered models are controlled by a regenerative drive controller. The drive controller allows for speed control. DC powered models can be controlled by a regenerative drive controller with speed control or solenoids and relays (without speed control). To apply power to the unit, connect the input power to the plug located in the top of the base. The plug may or may not be recessed, depending on the unit specifications. If there are any questions regarding input power, please contact The Will-Burt Company.
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Emergency Stop All models are equipped with an emergency stop button (See Figure 3-1). For normal operation the red mushroom button should be in the Up/Out position (Pull Up/Out to allow power to the unit). In case of an emergency, push the Emergency Stop Down/In; the input power will be disconnected from the unit.
Power Receptacle
Pendant Control Receptacle
Fuse Holder Emergency Stop Button Figure 3-1
Emergency Stop Button
Control A pendant controller provides Up/Down control (Figure 3-2). The pendant control plug must be connected to the receptacle located on the top of the base (Figure 3-1). For units containing an electrical motor brake, the brake will disengage if either the up or down control button is actuated. If the control is shut down or if power is lost for any reason the brake will automatically engage and hold the rated load at any position. Extension and retraction speeds can be adjusted by rotating a potentiometer mounted on the end of the pendant (Figure 3-2). The standard gearmotor and the sprocket ratio will extend and retract the rated load at an approximate maximum speed according to (*Same for 12-25 Standard and Heavy Duty
Table 3-2).
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Unit Model 2-10 Model 3-12 Model 4-15 Model 6-20 Model 12-25* Model 18-30
Maximum Column Speed (in/sec) 2.5 3 4 6 8 8
Maximum Column Speed (mm/sec) 64 76 102 152 203 203
*Same for 12-25 Standard and Heavy Duty
Table 3-2
Standard Maximum Column Extension and Retraction Speeds
Pendant
Pendant control plug
Speed potentiometer
Figure 3-2 Pendant with speed control potentiometer Limit Switches Each Ribbon Lift is provided with extended and retracted limit switches, which have been set at the factory to stop the column extension at its maximum length (Figure 3-3), and the retraction of the column at 5-18 inches (127-457 mm) from the base assembly, depending on the model size (*Same for 12-25 Standard and Heavy Duty
Table 3-3).
Do not adjust the limits outside of the factory settings. Setting the retracted limit less than the factory setting, or the fully extended limit greater than the factor setting will cause damage to the unit.
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If the optional column cover is installed, the lower limit switch has been set to stop the column 2-3 inches (51-76 mm) from the fully compressed position of the cover. Maximum Column Maximum Column Model Extension (Feet) Extension (Meters) Model 2-10 10 3 Model 3-12 12 3.7 Model 4-15 15 4.6 Model 6-20 20 6.1 Model 12-25* 25 7.6 Model 18-30 30 9.1 *Same for 12-25 Standard and Heavy Duty
Table 3-3
Maximum Column Extension
Leveling The Ribbon Lift unit should be leveled before significant loads are applied to the payload plate. This is important for both upright and inverted units. With heavier payloads, a small offset at the top of the stroke can create a substantial bending moment on the ribbon. Refer to Bending Moment Limitations in the Operation section for calculated limits. Optional Systems If the Ribbon Lift that you purchased included any optional systems, please refer to the Optional Systems section for maintenance information.
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CHAPTER 4
OPERATION
Ribbon Engagement During the initial extension of the Ribbon Lift unit, the column extension should be smooth. Figure 4-1 illustrates the proper tab engagement when the column is extended. Minor snapping noises may be heard and are acceptable. These noises are typically created as the drive sprockets disengage from the ribbon or the tabs engage with each other, and should diminish with repeated cycles. If there is a major noise issue during initial operation, tab engagement should be inspected to insure that all tabs are properly engaged over the full stroke of the column. Each unit has been thoroughly tested at the factory and will provide consistent tab engagement assuming no damage occurred during shipping.
If any of the tabs do not engage at any point in the cycle, discontinue use of the Ribbon Lift and contact the Will-Burt Company for instructions.
Complete interlocking of tabs as column extends
Figure 4-1
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Proper tab engagement
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Maximum Lift Capacity The maximum lift capacity for the Ribbon Lift models is shown in Table 4-1. Assumptions corresponding to these values include: - An indoor location - A level base - A static payload - A center of gravity in-line with the center of the column. All other conditions reduce the maximum load capacity, including but not limited to: - Dynamic payload - Unbalanced payload - Unsecured payload - Offset payload - The unit not leveled - Windy conditions
Catastrophic column buckling and serious injury or death could occur if maximum lift capacity values are exceeded. The Will-Burt Company recommends securely anchoring the base unit, utilizing holes in the mounting feet, or the holes that are provided in the bottom plate of the base. Maximum Lift Capacity [NO WIND] MODEL
Inverted Orientation
2-10
Upright Orientation 20 lbs (9.1kg)
3-12
50 lbs (22.7kg)
100 lbs (45.4kg)
4-15
115 lbs (52.2kg)
250 lbs (113.4kg)
6-20
200 lbs (90.7kg)
400 lbs (181.4kg)
12-25 Standard Duty 12-25 Heavy Duty 18-30
400 lbs (181.4kg)
800 lbs (362.9kg)
650 lbs (294.8kg)
1,000 lbs (453.6kg)
1,250 lbs (567kg)
-- NOT RATED --
Table 4-1
40 lbs (18.1kg)
Maximum Lift Capacity with Wind Conditions: (Extension Heights are De-rated/Reduced) 40MPH (64.4KPH)
60MPH (96.6KPH)
10 lbs (4.5kg) @ 5 ft (1.5m) 30 lbs (13.6kg) @ 6 ft (1.8m) 100 lbs (45.4kg) @ 9 ft (2.7m) 180 lbs (81.6kg) @ 12 ft (3.7m) 250 lbs (113.4kg) @ 20 ft (6.1m) 250 lbs (113.4kg) @ 20 ft (6.1m) 1,000 lbs (453.6kg) @ 25 ft (7.6 m)
-- NOT RATED --- NOT RATED -50 lbs (22.7kg) @ 7 ft (2.1m) -- NOT RATED -250 lbs (113.4kg) @ 15 ft (4.6m) 250 lbs (113.4kg) @ 15 ft (4.6m) 1,000 lbs (453.6kg) @ 20 ft (6.1 m)
Orientation vs. Maximum Lift Capacity
Bending Moment Limitations Please contact Will-Burt if your application involves offset loading, non-vertical loading or will operate in any high and/or gusty wind conditions.
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Guy Wire Tension The guy system should be inspected for proper tension before operation. There should be equal tension on all three cables throughout the column stroke.
Immediately discontinue use and service unit if guy wires loose tension at any point in the column travel. Death or serious injury could occur.
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CHAPTER 5
MAINTENANCE
Scheduled maintenance will vary depending on factors that include payload weight, cycles, unlevel surfaces, and exposure to environmental conditions. Will-Burt can repair units in the field or at the factory. Please contact the Will-Burt Company if repair assistance is needed. Ribbon Maintenance The tabs should properly engage during column extension as shown in Figure 4-1. Will-Burt recommends that the ribbons be inspected on a weekly basis for tab deformations and cracks emanating from the sprocket drive holes or tabs. Periods between inspections should not exceed 500 cycles. With proper maintenance, the expected mean time before failure (MTBF) for the ribbons range from approximately 1000 to 2000 cycle. The ribbon should maintain its surface brightness throughout the lifetime of the product. Grease has been applied to the tabs and sprocket holes at the factory. It may be necessary to periodically clean these areas to prevent contaminant buildup on the surface of the ribbons that may cause ribbon storage problems. White lithium grease can then be reapplied in these areas. Gearmotors, Motors, and Gearboxes The gearmotors, motors, and gearboxes are appropriately sized to provide years of trouble free performance when the specified load limits are not exceeded and proper, scheduled maintenance inspections are performed. Limit Switches The extended and retracted limit switches should be inspected periodically to insure that the switch arms are activated at the proper point. If a limit switch fails, the unit will not operate in the associated direction.
Do not adjust the limits outside of the factory settings. Setting the retracted limit less than the factory setting, or the fully extended limit greater than the factor setting will cause damage to the unit.
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Retracted Limit Switch
Extended Limit Switch Figure 5-1
Limit Switches
Fuses Most of the models are internally protected with a 3AB style, ceramic, time delay, ¼” diameter by 1-¼” long fuse. See table 5-1 for fuse specification, and table 5-2 for associated Will-Burt fuse part numbers; “*” denotes customer installed breaker – see wiring diagram for details. REPLACEMENT FUSE
Model 2-10 Model 3-12 Model 4-15 Model 6-20 Model 12-25 Model 12-25 HD Model 18-30
230VAC N/A 5A 5A 20A 20A 30A 30A
120VAC 5A 5A 10A 20A N/A N/A N/A
Table 5-2 Will-Burt Part Number 221022 221023 221024 221025 221026 Table 5-2 TP-4857301-E
12VDC 15A 15A 30A * 80A N/A N/A N/A
24VDC 10A 10A 20A * 40A * 100A * 200A N/A
Fuses
Description FUSE; 5 AMP; 250V; SLO-BLO 3AB FUSE; 10 AMP; 250V; SLO-BLO 3AB FUSE; 15 AMP; 250V; SLO-BLO 3AB FUSE; 30 AMP; 250V; SLO-BLO 3AB FUSE; 20 AMP; 250V; SLO-BLO 3AB Fuse Part Numbers 5-2
Installation, Operation, And Maintenance Manual
CHAPTER 6
OPTIONAL EQUIPMENT
*Same for 12-25 Standard and Heavy Duty
Table 6-1 shows the different options available for each Ribbon Lift model. Option Payload Cable Management System DMX Control – Fleenor Design Dynamic Guy System Column Cover Trailer Hitch Carrier Heavy Duty
Model 2-10
Model 3-12
Model 4-15
Model 6-20
Model 12-25*
Model 18-30
*Same for 12-25 Standard and Heavy Duty
Table 6-1
Option Availability per Model
Cable Management Mounting Plate Column Cover Bellows Dynamic Guy System
Figure 6-1 Optional Equipment
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Cable Management Storage Tray
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Payload Cable Management System Description – A Ribbon Lift with the payload cable management option is shown in Figure 6-1. The payload cable management option is a fully integrated system that allows users to provide power and signal controls to their payload through the column center. Ribbon Lift units fitted with a payload cable management option will have a storage tray assembly bolted to the bottom of the unit and a mounting bracket on top of the payload plate as shown in Figure 6-1. The tray assembly houses a coil of flexible conduit containing cables (e.g. power, signal) that can be connected to the payload from the base of the unit. The conduit is fed through the center of the column and extends and retracts with the column. This system eliminates the need for high maintenance, noise inducing slip rings and unsightly cabling on the exterior of the unit. Maintenance - The payload cable management option was designed for virtually maintenancefree operation. For initial installation and scheduled maintenance, verify that the conduit fittings are secure and that two screws mounted in the conduit-mounting bracket prohibit the payload conduit fitting from rotating. Typically, the customer specified cabling is installed at the factory prior to shipment. However, the user can install cables using the following procedure: 1. Retract the column to 12-14 inches (305-356mm) above the top plate 2. Remove the enclosure wrap by unbolting the latches 3. Note the orientation of the outer tray with respect to the base (mark with white marker if necessary). 4. Disconnect the conduit from the base, and the conduit fitting from the payload end of the conduit (Figure 6-2). 5. Remove the screws that hold the tray and note the orientation of the inner tray with respect to the outer tray (use white marker if necessary). 6. Note the spiral orientation of the conduit coil in the plastic pan. 7. Pull the conduit out of the base assembly and the payload end of the conduit out of the center of the column. 8. Remove the tray assembly and lift the inner tray out of the outer tray. 9. Carefully remove the conduit out of the outer tray (do not kink or crush the conduit), straighten it out and pull the necessary cables through. Leave at least 12” (305mm) of cable exposed at each end. 10. Position the conduit back in the outer tray in the same spiral orientation it was in prior to removal. Re-insert the inner tray while carefully pulling about 3 feet (0.9m) of conduit through the center hole of the inner tray, and about 18 inches (457mm) of conduit through the outer slot of the inner tray. 11. Reconnect the conduit to the base assembly. Use a cord to pull the conduit up through the center of the column, and secure the payload end of the conduit using fittings previously removed. 12. The payload conduit fitting must be prohibited from rotating by inserting two screws in the conduit mounting bracket and engaging the outside of the fitting. Restricting the TP-4857301-E
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conduit from rotating at the payload fitting allows the conduit’s residual memory to assist in re-coiling of the conduit in the outer tray during retraction. 13. Reinstall the tray assembly to the unit with the fasteners previously removed. Verify that all holes properly line up with the bottom plate. Reinstall the enclosure wrap. 14. Test by extending and retracting the column slowly in incremental steps.
Conduit Mounting Bracket
Conduit Fitting
Enclosure Wrap not shown See Figure 2-1
Base Assembly
Inner Tray Center Hole Inner Tray Outer Slot
Inner Tray Flexible Conduit Outer Tray
Figure 6-2 Cable Management Kit TP-4857301-E
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DMX Control – Fleenor Design DMX Features 1. 2. 3. 4. 5. 6. 7.
Precise and repeatable position control Position retention after power down - no need to perform a homing routine Adjustable soft limits (extended and retracted) Programmable position and speed control Built-in redundant safety systems Easy to change DMX address Unit can be controlled by either DMX or hand-held pendant
DMX Specifications 1. Position is accurate to 0.5% of maximum stroke 2. Three channel control a. Position adjust b. Unused c. Speed (variable from zero to maximum speed) d. Enable/Disable (above 50% of full range enabled, below 50% disabled) 3. Following controls are mounted in an easy access location on the unit: a. DMX address selector switch b. Standard mushroom-style emergency stop (E-stop) button c. DMX In and DMX Out d. Pendant/DMX control switch 4. Safety Equipment a. DMX controlled Enable/Disable function b. E-stop button c. Command conflicts not possible between DMX and pendant inputs d. Programmable soft limits to restrict travel e. Hard limits to protect equipment
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DMX Set Up 1. Apply appropriate power to the unit. 2. Make sure the E-stop button is in the Up position. 3. To set the software retracted limit, disconnect the DMX cable from the unit and set the Pendant/DMX selector switch to ‘pendant’ control. Using the pendant, adjust the Ribbon Lift to the retracted position desired (make sure this is greater than the fully retracted limit) and push the DMX limit toggle switch down (away from the center of the Ribbon Lift). 4. To set the software extended limit, use the pendant to run the Ribbon Lift to the extended position desired and push the DMX limit toggle switch up (towards the center of the Ribbon Lift). 5. Turn the Pendant/DMX selector switch to ‘DMX’. 6. Plug in the DMX cable. 7. Adjust the DMX address selector switch to the desired address. 8. The DMX system uses 4 channels a. Channel 1 – Position adjust – The higher the number, the higher the position. b. Channel 2 – Unused c. Channel 3 – Speed adjust – High command is high speed. d. Channel 4 – Enable mode – must be above 50% command for the unit to operate DMX IN
Pendant/DMX Selector Switch
DMX OUT DMX Limit Toggle Switch
DMX Address Selector Switch Pendant Control Receptacle
E-Stop
Figure 6-3 Cable Management
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Dynamic Guy System Description - Figure 6-1 shows a Ribbon Lift with an optional dynamic guy system. The guy system is a set of three guy cables anchored to the outer edge of the base and to the payload plate. The guy cables automatically extend and retract with the column, maintaining tension throughout the column stroke. This system provides additional stability to the column. Maintenance - The guy system should be inspected for proper tension before operation. There should be tension on all three cables throughout the column stroke.
Immediately discontinue use and service unit if guy wires loose tension at any point in the column travel. Death or serious injury could occur. Heavy Duty Description – The heavy duty option provides approximately twice the lifting capacity of a single motor unit. Two motors are electrically synchronized via the drive controller, and are actuated using a single pendant (Figure 6-4).
Dual Motors And Gearboxes
Figure 6-4 Model 12-25 Heavy Duty Option (body wrap and motor covers not shown) Maintenance - The motors and gearboxes are appropriately sized to provide years of trouble free performance when the specified load limits are not exceeded and proper, scheduled maintenance inspections are performed.
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Column Cover Description – The column cover as shown in figure 6-1 is a bellows that provides a weather resistant casing for the column, and increases its service life when subjected to water and other contaminants such as dirt and sand. Additionally, the column cover offers safety improvements, reducing the possibility of injury from the edges of the ribbon and pinch points. If a less industrial look is needed for an application, the column cover will hide the stainless steel ribbons and may improve the unit’s presentation. Maintenance - The column cover should be inspected for uniformity prior to extension. During column extension, the cover may deform slightly. To inspect the column, the cover can be released by removing the retaining ring at the bottom of the column. Normal maintenance of the cover involves wiping the disk segments with a damp cloth when the cover is near the fully compressed state. Trailer Hitch Carrier Description – The trailer hitch carrier option provides a method of transporting the Ribbon Lift on the back of vehicles (Figure 6-5). The design also provides flexibility by allowing the carrier to be quickly dismounted from one vehicle and mounted to another vehicle with a standard floor jack. The carrier mounts into a standard 2-inch square receiver hitch. The unit can be securely bolted to the carrier using the anchor holes in the bottom of the mounting feet, and the corresponding holes in the carrier. Mounting hardware is included with the carrier. For the carrier option Will-Burt also recommends the column cover option to minimize contamination in field applications.
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Figure 6-5
Trailer hitch carrier option
The Ribbon Lift should always be in the fully retracted position while the vehicle is being operated. Maintenance – Periodically check the tightness and condition of the bolts securing the unit to the carrier.
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CHAPTER 7
TROUBLESHOOTING
Use Table 7-1 to assist in identifying the cause or causes of a malfunction you may encounter in a Ribbon Lift product. NOTE: Table 7-1 is intended as an aid for diagnostics purpose only. procedures, contact Will-Burt.
For detailed repair
Disconnect electrical power before servicing the unit. Exercise caution if unit must be on for test or maintenance procedures. Failure to do so may result in injury or death from electrical shock or moving parts. Symptom
Cause No electrical power to the unit Improper input power
Unit will not operate
Pendant control not properly connected to base Limit switch improperly activated Gearmotor failure Drive controller failure
Unit will extend but not retract
Unit will retract but not extend
Column doesn’t stop where required
Excessive noise during operation Ribbon tabs not fully engaged
Check limit switch activation Contact Will-Burt for a replacement Contact Will-Burt for a replacement
Retraction limit switch improperly activated
Check retracted limit switch activation
Retraction limit switch failure
Contact Will-Burt for a replacement
Extended limit switch improperly activated Extended limit switch improperly activated Improper limit switch adjustment Limit switch failure Drive sprocket teeth disengaging from ribbon, or ribbon tabs engaging Ribbon tabs not fully engaged Possible damage to a ribbon
Table 7-1
TP-4857301-E
Recommended Action Verify proper voltage is supplied to the unit Verify proper voltage is supplied to the unit Verify that pendant control plug is properly connected to the base
Check extended limit switch activation Contact Will-Burt for a replacement Adjust appropriate limit switch Contact Will-Burt for a replacement Noise should diminish with continued operation Contact Will-Burt Contact Will-Burt
Troubleshooting Chart
7-1
