MC 450 Instruction manual

USER'S MANUAL

MC 450 MAST CLIMBING WORK PLATFORM

ORIGINAL INSTRUCTION MANUAL This manual is assigned to:

Part No. 707520-009_C

Issue: 07-2016

MC 450-001

Serial No.

Alimak Hek MC 450

Year of manufacture:

Alimak Hek Vertical Access Equipment (Changshu) Co. Ltd Building #12, Ma Qiao Industrial Square Changshu Economic Development Zone Changshu 215513 Jiangshu Province, PRC Phone: +86 (0)512 5229 6800 Fax: +86 (0)512 5229 6900 Company Registration No: Place of Registration:

320581400008972 Changshu, China

www.alimakhek.cn

Alimak Hek MC 450

II

FOREWORD FOREWORD

This machine is provided with a rack and pinion drive.

The platform can be configured to the shape of the facade.

This machine can be quickly moved and is easy to transport.

Every care has been taken in the construction of the mast climbing work platform to ensure that all safety aspects have been considered.

This machine can be fitted with one or two masts and must be anchored (see section 3 in safety). The mast, which consists of separate elements, can easily be adjusted in height to match the height of the building work. The mast is easy to assemble from the platform.

Depending on the application area, a choice can be made from different platform lengths, platform widths and permissible loading. The information included in this manual refers to the basic machine in the standard version, as delivered by Alimak Hek VAE.

Read this manual carefully before assembling, disassembling, using or maintaining the machine.

III

Alimak Hek MC 450

CONTENTS CONTENTS FORWARD CONTENTS LIST OF ILLUSTRATIONS MEANING OF THE SYMBOLS USED 1. TECHNICAL DETAILS 1.1. General 1.2. Electrical installation 1.3. Base frame 1.4. Drive unit 1.5. Platform construction 1.5.1. Single mast machine 1.5.2. Twin mast machine 1.6. Wall reaction force 2.

3.

4.

5.

6.

IV I

COMPONENT DESCRIPTION 2.1. General description SAFETY 3.1. General 3.2. Safety prior to use 3.3. Safety in use 3.4. Safety after use 3.5. Built-in and additional safety features TRANSPORT 4.1. Repositioning on the building site 4.2. Repositioning with a crane CONTROL COMPONENT 5.1. Power supply socket for the drive unit 5.2. Platform Control Box ASSEMBLY AND ANCHORING 6.1. Preparation for assembly 6.2. Basic requirement for electric AC supply 6.3. Ground support 6.4. Positioning the mast climbing work platform 6.4.1. Mast climbing work platform on a base frame 6.4.2. Mast climbing work platform with two masts on base frames

Ⅲ Ⅳ Ⅴ Ⅵ 1-1 1-1 1-3 1-5 1-5 1-6 1-8 2-1 2-1 3-1 3-1 3-1 3-1 3-3 3-3

6.5. Assembly of cable drum and cable basket 6.6. Assembly of the mast 6.7. Anchoring of the mast 6.8. Adjusting the platform width 6.9. Checking and adjusting lower striker plate 6.10. Adjusting the leveling system 6.11. Checking items before the first use after completing the installation of the machine.

6-10

7. OPERATION 7.1. General 7.2. Preparation 7.3. Testing 7.4. Brake test 7.5. Operation from the platform 7.6. Operation in an emergency situation 7.7. Drop test 7.8. Resetting the safety device

7-1 7-1 7-2 7-2 7-3 7-3 7-4 7-5 7-7

8.

8-1

DISASSEMBLY AND TRANSPORT

9. 4-1 4-2 4-3 5-1 5-1 5-2 6-1 6-2 6-3

6-11 6-14 6-16 6-17 6-18 6-20

MAINTENANCE 9.1. General 9.2. Maintenance intervals 9.3. Leveling safety mechanism check 9.4. The motor brake 9.4.1. Brake adjustment 9.4.2. Adjustment of air gap 9.5. Reject limits pinion and rack drive, steel rack rollers and guide rollers 9.6 When it is in the case of grand maintenance or large-scale adjustment

9-1 9-1 9-2 9-3 9-3 9-4 9-5 9-6

10. TROUBLESHOOTING

10-1

11. MACHINE DISPOSAL

11-1

6-4 6-5 6-6

6-8

Alimak Hek MC 450

9-7

CONTENTS

LIST OF ILLUSTRATIONS Fig. 1 Dimensions Fig. 1-1 Mast element Fig. 1-2 Platform element Fig. 1-3 Fence Fig. 1-4 End fence Fig. 1-5 Corner post Fig. 1-6 Base frame Fig. 1-7 Drive unit Fig. 1-8 Reaction force

Ⅱ 1-2 1-2 1-2 1-2 1-2 1-4 1-4 1-10

Fig. 2-1 Basic set MC 450 Fig. 2-2 Entrance door

2-1 2-2

Fig. 4-1 Transport MC 450 Fig. 4-2 lifting the mast

4-1 4-3

Fig. 5-1 Power supply socket drive unit Fig. 5-2 Control Box-exterior Fig. 5-3 Up and Down push button

5-1 5-2 5-2

Fig. 6-1 Position machine Fig. 6-2 Preparation before assembly Fig. 6-3 Ground support &base frame Fig. 6-4 Distance to the facade Fig. 6-5 Base frame Fig. 6-6 Fence Fig. 6-7 Stair Fig. 6-8 Gate safety switch Fig. 6-9 Base frame Fig. 6-10 Stair Fig. 6-11 Fence Fig. 6-12 Gate safety switch Fig. 6-13 Cable arm Fig. 6-14 Cable guide Fig. 6-15 Cable drum Fig. 6-15 Cable basket Fig. 6-17 Main switch Fig. 6-18 Key switch “BY PASS” Fig. 6-19 Lifting the mast section Fig. 6-20 Assembly of the mast Fig. 6-21 Orange top mast element Fig. 6-22 Mast cover Fig. 6-23 Tie-in Fig. 6-24 Platform extension Fig. 6-25 Adjusting lower strike plate Fig. 6-26 Right drive unit Fig. 6-27 Left drive unit Fig. 6-28 Adjusting the mechanical leveling system

6-1 6-2 6-3 6-5 6-6 6-7 6-7 6-7 6-8 6-9 6-9 6-9 6-10 6-10 6-10 6-10 6-11 6-12 6-12 6-12 6-13 6-14 6-15 6-16 6-17 6-18 6-19 6-19

Fig. 7-1 Main switch Fig. 7-2 Emergency push-button Fig. 7-3 Push button Control Box Fig. 7-4 Brake lever drive unit Fig. 7-5 Push buttons Fig. 7-6 Brake lever drive unit

7-2 7-2 7-3 7-3 7-3 7-4

Fig. 8-1 Securing extension Fig. 8-2 Bundle platform elements

8-2 8-3

Fig. 9-1 Brake level drive unit Fig. 9-2 Brake Fig. 9-3 Fiction disk Fig. 9-4 Air gap adjustment Fig. 9-5 Rack and pinion

9-3 9-4 9-4 9-5 9-6

Alimak Hek MC 450

V

SYMBOLS MEANING OF THE SYMBOLS USED

WARNING Failing to (exactly) comply with the working or operating instructions may lead to serious injury, fatal accident, severe mechanical damage or operating losses.

During use, no person may stand under the machine.

Danger: High voltage.

Danger of falling objects.

VI

Alimak Hek MC 450

Fig.1 Dimensions

Alimak Hek MC 450 SM Sup睡r • 7595-061 C

VII

TECHNICAL DETAILS

1. TECHNICAL DETAILS 1.1 General Description

Single

Twin

Platform length (m)

4.2-10.2

7.0-30.2

Platform width (m)

1.2-2.2

1.2-2.2

Distance between mast centers (m) ]

See section 1.5

See section 1.5

Vertical travel speed (m/s)

0.13(50Hz)/0.16(60Hz)

0.13(50Hz)/0.16(60Hz)

Loading capacity (Kg)

See section 1.6

See section 1.6

Max. rated load on the platform extension (Kg)

240

240

Distance between cable guides (m)

6

6

Maximal lifting height (m) A

200

200

Tie distance (m) B

8-10

8-10

Height of first tie-in for the base frame (m) C

3

3

Height of second tie-in for the base frame(m)D

8-10

8-10

Top overhang (m) E

4.5

4.5

Height from the ground to the work platform in its lowest position for access (m) F Height platform including fence 1.1m (m) G

0.35

0.35

2.07

2.07

Height platform to deck (m) H

0.97

0.97

Height fence 1.1 m to upper side mast cover (m) I

0.89

0.89

Noise level Emission sound pressure level at workstations is less than 70 dB (A) The sound power level emitted by the machinery at workstations is less than 80 dB (A) Note: The MC 450 can be used indoors and outdoors. The details are based on standard applications. In special situations, it may be possible to deviate from these. This may only be done with the prior written approval of Alimak Hek. Top mast For all mast positions of machine configurations it is mandatory to use the orange top mast.

Alimak Hek MC 450

1-1

TECHNICAL DETAILS

Fig.1-1

Mast element

Fig.1-2

Platform elements

Fig.1-4

End fence

Fig.1-5 Corner post

Fig.1-3 Fences

1-2

Alimak Hek MC 450

TECHNICAL DETAILS Part

Figure

Part

L x W x H(mm)

Weight(Kg)

Weight 78[kg] 99/100 78

l x b x h [mm]

Mast element 1-1 450x450x1508 Platform Mast element 800x1200x500 element 1-2 150 500x500x1508 800(checkerplate/ply wood) Platform element 800x1200x500 Platform element 1-2 80 1500x1200x500 1500(checkerplate/ply wood) Fence 800 1-3 770x30x1109 (with mesh/open) Platform Fence 1500 (with element 1-3 150 1500x1580x500 1470x30x1109 mesh/open) End fence 1-4 2184x30x1109 (with mesh/open) Corner post 1-5 70x30x1274

No. of

Bolt/locking pin Other other Dimensions M16x210mm Module 5 φ37(Class 8.8) Module Max. 5platform extension 800mmx1000mm platform φ37(Class 8.8) Max. Max. platform extension extension 1500mmx1000mm façade side … … mm* 1000

No. of Pin Pins dim. bolts/locking pins 4 (bolt) 34 (lockingΦ37 pin) Φ 37

99.6 132/133

33 (locking pin)

11.5/6.8

…

120 22/13.3

…3

58/43

…

…

3.24

…

…

Φ 37

…

Max. …platform extension … side façade 1000 mm* …

Plug-in fence 770x30x1212 12.64 --- be possible. ----- with prior written Note: With supplied telescopic extensions. Other configurations may This may only be done 80 approvalPlug-in of Alimak Hek. For minimum area required for installation, drawing (GAfence 150 1470x30x1212 17.7 --- please --- refer to the General Arrangement --drawing). End fence 2184x30x1109 55 ------Corner post

1.2

70x30x1274

3.24

---

---

---

Electrical installation

Number of motors Rated power mast climbing work platform

Single Maximumofstarting Number motorscurrent

1

Rated power mast climbing work platform

4kw

Power consumption (based on S3-25%)

Maximum starting current

± 58.8

Power consumption (based Power consumption (based on on S1)S3-25%)

5.12kw

Single

Twin

1

2

4kW

58A 2

2x4kw 5.4 kVA ± 117.6

5.12x2kw 400 Vac

Supply voltage

5.4 x 2 kVA 6.8 x 2 kVA

380-440V

Minimum supply voltage Minimum power supply Phases

Supply Phasesfrequency (depending on the national conditions regarding to power supply) Supply (depending Fuse atfrequency building site (slow) on the national conditions 32A regarding to power supply)

Control voltage

380Vac 3 + N + Pe 7.6kVA

14.4kVA

50 Hz 3+N+Pe

3+N+Pe

3250Hz/60Hz A 230Vac

Fuse and type atfrequency building site (slow) Control voltage

Power Controlsupply voltage(to machine)

116A

6.8kVA

Supply voltage

2x4kW

Twin

50 Hz 32A/GV2-ME32C

Up to 50 m

5G 6 mm²

Up to 125 m

5G 6 mm²

Control voltage frequency

5G 6mm², 0.41 kg/m

Machine cable / 5G 6 mm², 0.41 kg/m Power supply (to machine) weight Up to 125m 5G 6 mm², 0.41 kg/m

Single phase outlet (other versions available)

230VAC 5G 6mm²

Up to 50 m

5G50Hz/60Hz 6mm²

50~120 m

5G 5G 6mm² 6mm²

Up to 120 m

5G 6mm²

220V/16A

230 V / 16A

Single phase outlet

Alimak Hek MC 450

1-3

TECHNICAL DETAILS

Fig. 1-6 Base frame

Fig. 1-7 Drive unit

1-4

Alimak Hek MC 450

TECHNICAL DETAILS 1.3 Base frame

Dimension A (mm)

1200

Dimension B (mm)

565

Dimension C (mm)

1346

Dimension D (mm)

623.4

Dimension E (mm)

823

Weight (Kg)

150

1.4 Drive unit

Dimension A (mm)

1192

Dimension B (mm)

1280

Dimension C (mm)

2938

Weight (Kg)

775

Alimak Hek MC 450

1-5

TECHNICAL DETAILS 1.5 Platform construction

Symmetrical platform construction Drive unit: 1.2 m = A Element 800: 0.8 m = B Element 1500: 1.5 m = C A-symmetrical configurations may be possible. This may only be done with prior written approval of Alimak Hek. 1.5.1 Single mast machine The payload must be equally distributed on the platform.

Platform length(m) 4.2

C

A

C

Maximum Payload (Kg) 2500

Configuration Weight (Kg) 1380

5.8

B

C

A

C

B

2250

1624

7.2

C

C

A

C

C

2000

1731

8.8

B

C

C

A

C

C

B

1750

1975

10.2

C

C

C

A

C

C

C

1500

2083

Note: The weight of the surface on the platform extension part is not included in the maximal payload and configuration weight. The information above applies to double sides fencing, all mesh wired.

1-6

Alimak Hek MC 450

TECHNICAL DETAILS 1.5.2 Twin mast machine

The payload must be equally distributed on the platform.

Platform length 7.0

B

A

C

C

A

B

Max. payload( Kg) 4500

8.4

C

A

C

C

A

C

4500

2594

C

A

C

C

C

A

C

4500

2770

B

C

A

C

C

C

A

C

B

4340

3014

3900

3473

3750

3648

9.9 11.5 15.9

C

C

A

C

C

C

C

C

A

C

C

17.4

C

C

A

C

C

C

C

C

C

A

C

C

Config. weight (Kg) 2487

19.0

B

C

C

A

C

C

C

C

C

C

A

C

C

B

3590

3892

20.4

C

C

A

C

C

C

C

C

C

C

C

A

C

C

3450

4000

22.0

B

C

C

A

C

C

C

C

C

C

C

C

A

C

C

B

3290

4244

23.4

C

C

A

C

C

C

C

C

C

C

C

C

C

A

C

C

3150

4351

25.0

B

C

C

A

C

C

C

C

C

C

C

C

C

C

A

C

C

B

2990

4595

26.4

C

C

C

A

C

C

C

C

C

C

C

C

C

C

A

C

C

C

2850

4703

28.0

B C

C

C

A

C

C

C

C

C

C

C

C

C

C

A

C

C

C

B

2690

4946

29.4

C C

C

C

A

C

C

C

C

C

C

C

C

C

C

A

C

C

C

C

2550

5054

30.2

C C

C

C

A

C

B

C

C

C

C

C

C

C

C

C

A

C

C

C

2500

5176

C

Note: The weight of the surface on the platform extension part is not included in the maximal payload and configuration weight. The information above applies to double sides fencing, all mesh wired. 10,9

2400 kg / P15 2600 kg / P15 2900 kg / P16 3000 kg / P20 3200 kg / P22 1500 kg / P13

Alimak Hek MC 450

1-7

TECHNICAL DETAILS 1.6 Wall Reaction forces

Note: End of the tube should have an additional clamp and bolts show as this image. 665190-014 Fig. 1-8 Reaction forces

Mast tie in drawing No.

SINGLE

665190-014

TWIN

665190-014

Lmin

Lmax

Bmin

Bmax

1450

500 750

800 1350

1450

500 750

800 1350

700 700

Pmax In Out of service(kN) service (kN) 29.2 12.5 34.1 15.8 27.3 38.5

12.5 15.8

Note: This moment calculation and the in service wind are according to EN1495. The machine is also consider the weather protection, unbalance load, and safety device activated condition. This out of service wind load is according to EN1495, and the mast height is 200m.

1-8

Alimak Hek MC 450

COMPONENTS 2.

COMPONENT DESCRIPTION

2.1 General description

The basic set of the mast climbing work platform with rack and pinion drive consists of the following 5 main parts: 

Drive unit



Mast



Platform elements and fences



Base frame



Control system

End fence

Fence

Fence with Control Box

Drive unit

Entrance/ Exit gate Mast

Stairs Fig.2-1

Alimak Hek MC 450

Basic set MC 450

2-1

COMPONENTS

The drive unit moves up and down the mast with the aid of guide rollers. The drive unit, operated by one electric motor, is moved along the mast by means of the pinion. For the mast climbing work platform with two masts, the motors are controlled by the leveling system. Much consideration has been given to simple and safe assembly and disassembly. A crane on the platform (optional) ensures that the mast elements can be positioned quickly and safely. The platform can be adjusted to suit the required working situation with the use of separate platform elements. The width of the platform can be adjusted by means of extensions. (The platform extension can only be pulled out on the ground and any operation concerning the platform extension in the air is not allowed.) The gate (Fig. 2-2) is both the entrance and exit with the interlock. The machine cannot be operated unless the gate has been closed completely. All electrical connections, which must be disconnected for transport purposes, are made by means of plugs and sockets. The main electrical installation is mounted in the Control Box on the platform. The simple construction ensures that only a minimum of maintenance is required. The mast elements, the base frame, the drive unit, the cable guides and various other components are protected from corrosion by an appropriate surface treatment.

2-2

Alimak Hek MC 450

2

1. Cam 2. Limit switch Fig. 2-2 Entrance/Exit gate

1

SAFETY 3.

SAFETY No changes or modifications may be made to the machine. The ground surface must be sufficiently stable to support the weight of the machine and the mast. The mast must ALWAYS be anchored in accordance with the instructions. For all mast positions of machine configurations it is mandatory to use the orange top mast.

3.2 Safety prior to use

-

The base frame must be effectively supported. The working area around the machine must be free from obstacles. The machine must be securely anchored at the specified intervals. In areas where the effects of any item will significantly increases the wind area or wind speed, it is not allowed to use the platform.

3.1 General The machine is constructed to be safe, both during assembly and in use. The machine is thus provided with the following built-in and additional safety features: -

The motor brake works automatically if the supply voltage fails.

-

If the TOP limit switch fails to operate, so that the mast climbing work platform continues to rise, an additional main limit switch is operated.

-

If the LOWER limit switch fails to operate, so that the mast climbing work platform continues to descend, an additional main limit switch is operated.

-

In case of an emergency situation the machine is also fitted with an over-speed safety device.

3.3 Safety in use

Alimak Hek MC 450

There must be no obstructions in the path of the machine.

During use, no person should stand under the machine.

3-1

SAFETY Material must never extend beyond the outer limits of the platform. Items which may roll must be properly secured. Materials must never be stacked against the fence. If work must be carried on close to high voltage cables, a minimum safety distance of 15 m must be maintained. If overhead structure exist, 2.5 m must be maintained.

-

-

-

When materials and/or tools with a large surface will be used contact your supplier in connection with wind sensitivity. -

-

-

-

-

-

-

3-2

The adequate site lighting shall be provided to illuminate the platform over the full height of travel of the machine. In order to ensure that no person unintentionally walks under the platform, the mast climbing work platform must be surrounded with suitable fence. The machine may only be used for the purpose for which it was designed, that is, the vertical transportation of persons and materials with a maximum weight within the design limits of the particular construction. Loads (materials, persons, etc.) must be distributed in accordance with the loading diagram. Operations on the mast climbing work platform may only be carried out by persons with adequate knowledge and qualifications to do so. Inspection and maintenance must be carried out as given in this instruction manual. During assembly and maintenance, the mast climbing work platform may not be used for other purposes.

-

-

-

-

Keep hatches in the base of the drive unit clear. From the platform it must be possible to get, to the emergency descent controls via the hatches. The competence and sense of responsibility of the operator or engineer are essential to the efficient use of the platform. Local safety laws and regulations must always be followed. Technical personnel must be in a position to deal with any difficulty encountered in every possible situation during assembly and disassembly. The operating personnel must be familiar with those situations which can occur during use. If operating or technical personnel report errors or dangers or are not aware of the safety regulations, the owner or the person responsible must be informed immediately. For machines with two masts, there must always be two persons present on the platform during use. This in case of making a possible emergency descent. The working area must be kept free from obstacles (building materials, dirt, snow, etc.). Fences must never be removed during normal use. The platform must only be entered and/ or loaded when it is in its lowest position. The same rule applies to leaving the platform. When electrical storms are expected, work on the platform must be stopped in time to avoid the danger of lightning strikes. The power supply must be switched off and the connector withdrawn from the supply socket. Platform extensions on telescopic supports may only be used to carry personnel. Such personnel may only stand on these extensions when the machine is stationary.

Alimak Hek MC 450

SAFETY - If erecting two adjacent platforms there must be a clear gap between the ends of the platforms of at least 0.5 meter.

-

-

3.4 Safety after use - Transport on public roads must only be done with a truck intended for the purpose. - The platform must be placed in the lowest position and the main switch must be secured.

-

In the event of a power failure it is possible for the platform to make an emergency descent by manually releasing the motor brakes. Audio Visual Warning. When descent of the platform up to a distance of 2.5 meters from the ground, a buzzer will sound and a light will flash underneath the platform. The mast climbing work platform can only be moved on the base frame when the platform (without decks) is in the lowest position.

3.5 Built-in and additional safety features The MC 450 mast climbing work platform is provided with the following in-built and additional safety features: -

-

Phase control relay in the Control Box. "Emergency stop" push button on the Control Box. Monitoring limit switches. Leveling system for machines with two masts. Lock the platform if one side drops more than the other during an emergency stop. In the event of a power failure the motor brake is operated automatically to prevent the platform descending unexpectedly.

Alimak Hek MC 450

3-3

TRANSPORT 4.

TRANSPORT Transportation on the base frame over the public roads is not permitted. The national valid traffic regulations must be observed. Because of its limited dimensions, the basic implementation of the machine can be transported with a normal lorry. Ensure that, during transport, all securing devices are properly fitted and that the machine is lowered onto the buffers. Disassemble the machine before transporting it as described in chapter 8.

For transport, all fences, steps and mast protection must be removed. For transportation, secure the machine carefully to the loading platform of the transport vehicle. The machine can be loaded and unloaded from the transport vehicle using a crane mounted on the vehicle, a crane on the building site or a fork-lift truck. See figure 4-1 for loading and unloading points. Set the machine down carefully to avoid damage. See figure 4-1. A. Lifting point by crane B. Support points for the fork of a forklift truck

A

B Fig.4-1

Transport MC 450

B

4-1 Alimak Hek MC 450

TRANSPORT 4.1 Repositioning on the building site

Ensure that trees, power cables etc., cannot be touched.

Once on the building site, the mast climbing work platform can be moved in the lowest position on its base frame. When the circumstances are not as above, contact your supplier. If it is not possible to install the first tie in at 3m. Outriggers can be used. Details about the special application ,please contact Alimak Hek VAE to get fully information. Note: The outriggers referred to are an accessory designed by Alimak Hek VAE and are available on request.

Outriggers layout

4-2 Alimak Hek MC 450

TRANSPORT 4.2 Repositioning with a crane Only the single drive unit can be moved. At the building site the mast climbing work platform can be repositioned with a crane. A crane with sufficient lifting height can be used to lift the mast. A maximum of 6 mast sections can be assembled lying on the ground before being lifted to the mast top and assembled. For details, please refer to Fig.4-2. The total transport weight can be calculated on the undermentioned way. Fig. 4-2 lifting the mast

Item

Weight (kg)

No. of drive units No. of base frames No. of platform elements 800 No. of platform elements 1500 No. of mast elements No. of fences 800 No. of fences 1500 No. of end fences No. of corner posts

x 775 x 150 x 99 x 132 x 78 x 11.5 x 22 x 58 x3.24

Total transport weight

= = = = = = = = =

=

4-3 Alimak Hek MC 450

+ Kg

CONTROL COMPONENTS 5.

CONTROL COMPONENTS

5.1 Power supply socket for the drive unit The power supply cable for the electrical supply between the building site connection and the mast climbing work platform must be connected to the socket on the Control Box.

Fig. 5-1 Power supply socket Control Box

5-1 Alimak Hek MC 450

CONTROL COMPONENTS 1

5.2 Platform Control Box The door of the control box is secured with two quick-release fastener. The control box is provided with the following push buttons at the outside (Fig. 5.2): 1. 2. 3. 4. 5. 6. 7. 8. 9.

Emergency stop Buzzer Power supply light Safety OK light By pass Alarm Socket Service mode Main switch

3

2

4

2 5

7

8

9

6

Fig.5-2 Control box- exterior

The Up and Down switch can be found at the left side of the Control Box (fig. 5-3). When the Emergency push-button is pressed, it is locked in the depressed position. It can be unlocked by turning it clockwise. Note: The main switch can be secured with a padlock to prevent unauthorized use of the platform.

Fig.5-3 Up and Down push-button

2 1

5-2 Alimak Hek MC 450

ASSEMBLY AND ANCHORING 6.

ASSEMBLY AND ANCHORING

Definition left and right in relation to positioning: Left-hand: Viewed from the step side, the machine is fitted to the left-hand side. Right-hand: Viewed from the step side, the machine is fitted to the right-hand side.

Fig. 6-1 Position machine

If assembly work must be interrupted, this must be done in such a way that, when the work is restarted it is clear what stage had been reached when work was stopped. For this reason always complete a part of the assembly, for example, assemble collect or secure all the components for a connection, complete a ground support or completely assemble a tie-in before stopping work. ☆☆ While the mast is being mounted, no more than two persons with a single mast machine or four persons with a twin mast machine, may be on the platform, so that no more than 75% of the lifting capacity is used. (This is only applicable during erection and dismantling.) The assembly must always be followed by a test run, as described in section 7.3. Until the test has been performed, the platform may not be used for any purpose other than transporting its own mast elements and anchoring components. Where any non-standard configurations are required, these shall be agreed between Alimak Hek and the customer. The loading of the mast climbing work platform must be planned so that when, in the assembly situation, the maximum height of the mast above the last tie-in is reached, the material load on the platform is a minimum. In the process of assembly, the distance between the first tie-in and the base frame should not exceed 3 meters; and the assembly for next step cannot start only if the first tie-in has been assembled completely. During normal operation, erection and dismantling, there is a mast detection limit switch used for detecting whether the drive unit is contacted with mast rack. If not, the mast detection limit switch will be activated and the platform will stop moving. Top mast For all mast positions of machine configurations it is mandatory to use the orange top mast.

6-1 Alimak Hek MC 450

ASSEMBLY AND ANCHORING 6.1 Preparation for assembly Ensure that the site where the mast climbing work platform will be assembled accords with the national requirements and that permission has been obtained from the relevant authorities for the assembly. -

Ensure that a suitable power supply, good lighting, lifting equipment and tools are available.

-

Ensure that the building site is easily accessible to the vehicle which will deliver the mast climbing work platform.

-

Prepare the site with suitable support and anchoring facilities.

-

Ensure that the position where the mast climbing work platform will stand has good drainage.

-

Plan the positioning of the mast climbing work platform so that where the mast needs to be anchored, it can be so anchored with the standard material.

-

The components of the mast climbing work platform mast should be placed as close as possible to the place where it will be assembled.

-

The electrical power supply connection must be placed as close to the mast climbing work platform as possible so as to reduce the voltage drop to a minimum. If the voltage reduction is too great the machine may not function properly.

6-2 Alimak Hek MC 450

Fig. 6-2 Preparation before assembly

ASSEMBLY AND ANCHORING

6.2   



 

Basic requirement for electric AC supplies Voltage Steady-state voltage: 0,9 ... 1,1 of nominal voltage Frequency 0,99...1,01of nominal frequency continuously 0,98 ... 1,02 short time Harmonics Harmonic distortion not to exceed 10 % of the total r.m.s. voltage between live conductors for the sum of the second to fifth harmonic. An additional 2 % of the total r.m.s. voltage between live conductors for the sum of the sixth to 30th harmonic is permissible. Voltage unbalance Neither the voltage of the negative sequence component nor the voltage of the zero sequence component in three-phase supplies shall exceed 2 % of the positive sequence component. Voltage interruption Supply interrupted or at zero voltage for not more than 3 ms at any random time in the supply cycle. There shall be more than 1 s between successive interruptions. Voltage dips Voltage dips shall not exceed 20 % of the peak voltage of the supply for more than one cycle. There shall be more than 1 s between successive dips.

Humidity/Environment  

MC 450 electrical equipment can be capable of operating correctly when the relative humidity does not exceed 50 % at a maximum temperature of +40 °C. Higher relative humidity is permitted at lower temperatures (for example, 90 % at 20 °C). ALWAYS follow the user instruction manual to perform the installation.

Altitude 

MC 450 electrical equipment can be capable of operating correctly at altitudes up to 1 000 m above mean sea-level.

Transportation and storage 

MC 450 Electrical equipment can be designed to withstand, or suitable precautions can be taken to protect against, the effects of transportation and storage temperatures within a range of -25 °C to +55 °C and for periods not exceeding 24 h at up to +70 °C. A special agreement can be necessary between Alimak Hek and the Client.

Alimak Hek MC 450

6-3

ASSEMBLY AND ANCHORING 6.3 Ground support Before the position for the mast climbing work platform is prepared, a check must be made to ensure that the distance between the mast and the working surface can be spanned by the standard anchoring material. 1. Ensure that the forces are spread over as large an area as possible.

2. The soil must be able to withstand a ground pressure of at least 2 kg/cm². If this requirement is not met, soil improvement must be carried out such that the ground satisfies this minimum requirement.

3. The ground support must be flat and centrally loaded with a minimum ground support of 400x400 mm. When a center jack is used, this is not required up to a height of 100 m.

Ground support

4. The ground support must be durable and of such a quality that the load can be transferred without plastic deformation.

5. If the machine is installed on a concrete foundation or on a hard road surface, the installation must be provided with wooden packing underneath the jack to prevent slipping.

6-4

Fig.6-3

Alimak Hek MC 450

Ground support & base frame

ASSEMBLY AND ANCHORING 6.4 Positioning the mast climbing work platform

665190-014 Fig. 6-4 Distance to the facade

Mast tie in drawing No. Single

665190-014

Twin

665190-014

Lmin

Lmax

Bmin

Bmax

1450

500 750

800 1350

1450

500 750

800 1350

700 700

Alimak Hek MC 450

6-5

ASSEMBLY AND ANCHORING 6.4.1 Mast climbing work platform with single mast on a base frame

1. Position the distance between the mast center and the facade; ensure that the base frame is parallel to the facade. . the base frame. 2. Place 3. Level the machine using the jacks; ensure that the mast is vertical in both directions by checking with a spirit level (with a length of at least 1m) placed against two adjacent sides of the mast. Place ground support under the machine to provide optimum load spreading and stability unless, as per paragraph 6.3.3, a 5th center jack is used and the machine configuration height is not exceeding 100m.

Ground support

4. Assemble the platform components sequentially on both sides until the desired length is attained. The platform may not exceed the maximum length (see section1.5).

Fig. 6-5 Base frame

6-6

Alimak Hek MC 450

ASSEMBLY AND ANCHORING

5. The width of the platform can be adjusted to fit the form of the facade. 6. Place the stairs and secure them with bolts and nuts. 7. Place the fence and secure it with bolts and nuts. 8. Place the gate and the cam for the gate safety switch and connect it to the Junction Box. And the machine can only be operated when the gate is closed. 9. Place the Control Box in designated location and fix it.

Fig. 6-6 Fence

the

10. Connect the control cable and the electrical power supply cable. Secure the cables to the underside of the platform neatly so that they do not hang down. 11. Place the first tie-in at the height of maximum 3 meters from the base frame (see section 6.6.5).

Fig. 6-7 Stair

12. Assemble the rest of the mast element and tie-ins. Lift the mast sections and fix them with tie-ins with the tie distance between 8 to 10 meters from the base frame. (see section 1.1). 13. Assembly the cable arm and cable guide if using this accessory (see section 6.5).

2

1

1. Cam 2. Limit switch Fig. 6-8 Gate safety switch

Alimak Hek MC 450

6-7

ASSEMBLY AND ANCHORING

6.4.2 Mast climbing work platform with two masts on base frames One drive unit must be adjusted for ‘left’ and the other for ‘right’. 1. Check that the left-hand machine is adjusted for ‘left’ and the right-hand machine for ‘right’. 2. Position the base frames parallel to the facade and with a separation to allow for the required distance between the masts. 3. Level the machine using the jacks. Ensure that the mast is vertical in both directions by checking with a spirit level (with a length of at least 1m) placed against two adjacent sides of the mast. Place ground support under the machine to provide optimum load spreading and stability unless, as per paragraph 6.3.3, a 5th center jack is used and the machine configuration height is not exceeding 100m 4. Assemble the platform element from left to right and connect the drive unit and platform element, two platform elements together with the locking pins until the desired length is attained. The platform may not exceed the maximum length (see section 1.5). Besides, the fixed lower deck connection cannot be removed when the decks are fitted so has to be removed before decks are connected as a twin machine. Note: in the process, the leveling system may be fully locked by locking pins. For details, please refer to the “adjusting the leveling system” part in section 6.10.

6-8

Ground support

Fig. 6-9 Base frame

Alimak Hek MC 450

ASSEMBLY AND ANCHORING 5. Install the first tie-in at the height of maximum 3 meters to each of the ground (see section 6.6.5) 6. Assemble the rest of the mast sections and tie-ins for each of the base frame. Lift the mast section and fix them with the tie-in with the distance between 8 to 10 meters from the base frame (see section 1.1). 7. The width of the platform can be adjusted to fit the form of the facade.

Fig.6-10 Stair

8. Place the stairs and secure them with bolts and nuts. 9. Place the fence and secure it with bolts and nuts. 10. Place the gate and the cam for the gate safety switch and connect it to the Juction Box. The machine can be operated when the gate is closed.

11. Connect the control cable and the electrical power supply cable. Secure the cables to the underside of the platform neatly so that they do not hang down.

Fig. 6-11 Fence

12. Adjusting the leveling system (see section 6.9). 13. Assembly the cable arm and cable guide if using this accessory (see section 6.5).

1 2 1. Cam 2. Limit switch

Fig. 6-12 Gate safety switch

Alimak Hek MC 450

6-9

ASSEMBLY AND ANCHORING

6.5 Assembly of cable drum and cable basket We recommend to use cable drum with cable guide and cable arm for maximum lifting height from 50 to 120m. For maximum lifting height less than 50m, we recommend to use cable basket without cable arm and cable guide. 6.5.1 Assembly of cable drum 1. Both the single and twin machine will be equipped with the cable arm and cable guide;

Fig. 6-13 Cable arm

2. For the position of assembly for the cable arm, please refer to Fig. 6-13. Besides, the cable arm is connected to the platform with locking pins; 3. The cable guide is mounted to the mast element with bolts and nuts. For the position of the cable guide, please make sure that the cable arm is in line with the central point of the cable guide and cable drum(Fig.6-14). Fig. 6-14 Cable guide

4. Cable drum should be installed as Fig 6-15. It can be assembled in the bracket which is easy to mount to the baseframe by bolts and nuts. Note: Distance H should be more than 1600mm and the bottom striker plate need to be adjust accordingly. 6.5.2 Assembly of cable Basket Cable basket can be installed as Fig.6-16: directly under the control box.

Fig. 6-15 Cable drum

Basket

Fig.6-16 Cable basket

6-10

Alimak Hek MC 450

ASSEMBLY AND ANCHORING

6.6 Assembly of the mast If work has to be stopped, always complete the sequence being worked . on. Tighten all the bolts used for the last attachment and switch off and secure the main switch so that the machine cannot be operated.

As the assembly proceeds, place the tie-in tubes, tie-ins and cable guides as described in section 6.5. Note that the power supply consists of 3 x 230 V + neutral + safety earth.

The mast(s) must always be assembled parallel to the facade. In winds of strengths above 12.7 m/s (6 Beaufort) the machine may not be assembled. Mast height h/m

h≤70

Verticality deviation/mm

≤1/1000 height of the mast

70 ＜h ≤100

100＜ h ≤150

150 ＜h ≤200

＞200

≤70

≤90

≤110

≤130

Table: Verticality deviation for installation

1. Connect the power supply to the machine. 2. Set the main switch in position “On”. Fig.6-17 Main switch

6-11 Alimak Hek MC 450

ASSEMBLY AND ANCHORING 3. When the mast climbing work platform is delivered it is on the buffers. In order to lift the mast climbing work platform from the buffers, insert the corresponding key onto the BY PASS key switch and turn the key clockwise. To raise the platform, also press the UP button at the same time. For a two-mast construction, check that the lower striker plates and the leveling system switches are properly adjusted. (See section 6.9)

1 Fig. 6-18 Key switch “BY PASS”

4. The mast climbing work platform is raised and lowered by pressing the UP and DOWN push buttons. When the push-button is released, the mast climbing work platform stops. In addition, an emergency stop pushbutton is provided. When this button is pushed, the power of the motors will be shut off.

5. Use a fork-lift truck or crane to raise the mast elements onto the platform. Ensure that the maximum loading permitted during assembly is not exceeded.

6. Stand on the platform and place a mast element on the last element assembled using a crane if needed. Secure the mast element with four bolts, washers and nuts. Tighten the bolts to the specified torque value of 125 Nm.

Fig. 6-19 Lifting the mast section

Fig. 6-20 Assembly of the mast

6-12

Alimak Hek MC 450

ASSEMBLY AND ANCHORING 7. Raise the platform towards the top of the mast element and repeat the procedure until another element must be assembled. Plan the procedure so that, when a tie-in must be fitted, the loading of material and mast elements is a minimum. 8. Ensure that tie-ins are placed at the specified intervals. 9. Repeat this working method until the mast has reached the required height. The last element assembled must always be the orange top mast element. The maximum specified height must not be exceeded. 10. If a crane is available on the building site, the mast can be more quickly assembled (lift 6 masts at a time). Up to six mast elements can be assembled on the ground and then Fig. 6-21 Orange top mast element raised into position with the crane. 11. The mast must not extend too far above the uppermost tie-in. To achieve good stability, it is always better to place a tie-in as close to the top of the mast as possible. 12. Assemble the mast guard panels on top of the drive unit. Secure with bolts provided. And please note the SERVICE is to be switched off. 13. The assembly is now complete. The assembly must now be tested as described in paragraph 7.3.

Fig. 6-22 Mast cover

6-13 Alimak Hek MC 450

ASSEMBLY AND ANCHORING 6.7 Anchoring the mast If work must be stopped, always complete the current sequence before stopping. Tighten all the bolts for the latest fixture and secure the main switch so that the mast climbing work platform cannot be operated.

Before starting to fix any tie-ins, ensure that the base frame is level. The wall must be of such a quality that it can accept the forces applied to it via the tie-ins.

The platform extensions and the tieins must not come into contact during raising and lowering. The tie-in forces must be approved by the owner or the person responsible for the building to which the machine will be anchored. 1. Check that the mast is vertical with a spirit level at least one meter long. Recheck as each tie-in is secured. 2. The mast must be anchored to the building at the distances specified in the table in section1.1. 3. The tie-ins are assembled from mast adapters, horizontal tie-in tubes and a support tube. 4. The horizontal tie-in tubes and the support tubes can be supplied in various lengths.

6-14 Alimak Hek MC 450

ASSEMBLY AND ANCHORING 5.

Fixing the tie-ins: -

-

-

-

6. -

-

-

-

Anchoring is carried out using bolt couplings, nut and bolt fastenings and washers. If conditions make it necessary, use may be made of other approved attachment materials which are suitable for the forces present. (Consult your Alimak Hek representative.) Cemented-in tie-ins must be allowed to become fully secure (the cement must have time to harden) before the mast climbing work platform is assembled. The cement or concrete used must be in accord with the specifications. If chemical anchors or expansion bolts (M16. Class 8.8) are used, these must be approved and must be able to withstand the forces involved. Specifications for these types of bolts are available from Alimak Hek VAE. Permission to use them must be obtained from the local authorities. Securing the tie-ins: Secure the mast adapters to the mast with four bolts and nuts (85 Nm). Fix the wall plates to the building. Secure the horizontal tie-in tubes between the mast adapters and the wall plates. Tighten the horizontal tie-in tube couplings to the correct torque value. Use the adjustment construction to set the mast vertical and parallel to the building. Fix the support tube.

Fig. 6-23 Tie-in

Pivoted tube coupler for tube dia. 48mm: - Torque: 85Nm - Spanner size: 24mm Pivoted tube coupler for tube dia. 60mm: -Torque: 100Nm -Spanner size: 1”

Note: For the anchoring of the tie-in, please refer to Fig. 6-23 Tie-in.

6-15 Alimak Hek MC 450

ASSEMBLY AND ANCHORING 6.8 Adjusting the platform width

The planks used for adjusting the platform width must in every case be secured in every direction.

The platform widening and the mast anchor must not come into contact when the platform is raised and lowered.

The platform extension can only be pulled out on the ground and any operation concerning the platform extension in the air is not allowed. For the distance between mast center and the facade, please refer to 6.4. The platform extension must be in accordance with specification EN1495: 1997+A2: 2009. The platform extension must be fabricated from a non-slip, easily cleaned material. The extension must be self-draining. The width of any openings or gaps in the floor must be sufficiently narrow that a ball with a diameter of 15 mm will not pass through. The platform extension must be able to withstand a static load of 200 kg on a square area of 0.1x0.1 m on the least favorable part of the floor surface without causing any permanent distortion.

1. Pull out the extensions and secure them with bolts under the platform. 2. Cover the extensions with planks and secure. 3. Fix the fence to the extensions. Fig. 6-24 Platform extension

6-16 Alimak Hek MC 450

ASSEMBLY AND ANCHORING 6.9 Checking and adjusting striker plates

For a two-mast construction, the striker plates must be checked and if necessary, adjusted to keep the platform level. . For the lower and main striker plate. 1. Lower the highest placed unit until the limit switch just touches the lower striker plates. 2. Use the other unit to level the platform. 3. Check that the lower limit switch just touches the lower striker plate for this unit. 4. If the lower striker plate does not touch the limit switch, adjust the position of the striker plate until it just touches the limit switch. 5. Main striker plate position is mounted as Fig.6-25-1. 6. AVW striker plate position is mounted as Fig.6-25-1. 7. Check the adjustment.

1. Lower striker plate 2. Main striker plate 3. 2.5 meter striker plate

For the top striker plate. 1. Drive the machine to the preset altitude. 2. Check and mount the top striker plate. 3. Use the other unit to level the platform. 4. Check that the top limit switch just touches the top striker plate for this unit. 5. If the top striker plate does not touch the limit switch, adjust the position of the striker plate until it just touches the limit switch. 6. Main striker plate is mounted as Fig.6-25-2. 7. Check the adjustment.

1. Main striker plate 2. Top striker plate Fig. 6-25-2 Adjusting striker plates

6-17 Alimak Hek MC 450

ASSEMBLY AND ANCHORING 6.10 Adjusting the levelling system MC 450 is supplied with a control levelling system, both electrical, which keeps the platform levelled during normal service operation upwards and downwards, and mechanical, for controlling the levelling during emergency descent with manual brake release. Both lower deck module hinges at the end of central span must be connected to the levelling rods present in the bottom part of drive unit, with suitable accessories provided. Note: Use the hold buttons as show in fig 7.5 to raise or lower machine to remove fixed link before connecting to levelling system.

Central span

Wing

Right drive unit

Left drive unit

Fig. 6-26 Left drive unit

Wing

Central span

Connection between the platform and leveling system

6-18 Alimak Hek MC 450

Fig. 6-27 Right drive unit

ASSEMBLY AND ANCHORING

Adjustment of the mechanical levelling system

1

1. Place a spirit level on the centre line of the central span. Manually move the platform to its horizontal position and fix one of the two drive units. 2. Adjust the bowed wire by means of screw A connecting to the levelling box, so that the space between the lever B and the levelling rod C is about 1 mm when the hand released lever is pulled and brake released.

WARNING! The operation 2 must be made.

3. If the space in such condition is too small it will be not possible to release the brakes.

Push

4. Push the lever B by hand permitting the ring to touch the levelling rod C. Loose the screw grain fixing the biconic cam and slide it to touch the ring of lever B. Fix the cam in such position. The same adjustment must be made for the other drive unit. Note that the cam D must be placed to the left side of the ring in the left drive unit and to the right side in the right one. If, while in operation, the levelling rods are adjusted correctly as described above the platform will remain constantly level and at the most will present a difference in height of about 2 or 3 degrees before the automatic levelling device comes into action.

Push

Fig. 6-28 Adjusting the mechanical leveling system

6-19 Alimak Hek MC 450

ASSEMBLY AND ANCHORING

6.11 Checking items before the first use after completing the installation of the machine.

1. Up and Down limit switch (functional) 2. Door limit switch (functional) 3. Mast section limit switch (functional) 4. Leveling system (functional) 5. Safety device (functional) 6. Manual release (functional) 7. Emergency stop (functional) 8. Running the platform with one time rated load 9. Drop test with one time rated load

6-20

Alimak Hek MC 450

OPERATION 7.

OPERATION Operation instructions

7.1 General Material may never extend beyond the edges of the platform. Items which can roll must be properly secured. The load may never be supported against the fence.

The use of relevant personal protective equipment such as hard hats, protective shoes, eye protection.

No person may stand under the machine while it is in use.

Each day before the mast climbing work platform is taken into use, the user shall check the operating devices, brakes and emergency stops shall be checked. The condition of all trailing cables, travel limit switches, guardrails, structural connecting mast ties, cables and information plates shall also be checked. Keep the work platform clean from waste, building materials and of debris, snow etc. Before any work is commenced, the operator shall visually check the extensions and any timber or other packing on the ground shall be visually checked to ensure that it is in good order. Ensure that tools and other objects do not project outside the perimeter of the mast climbing work platform. During the work the operator shall carefully follow the operation instructions. At the end of the work period the platform shall be brought into the "off" position and it shall be isolated to prevent unauthorized operation. In the event of a fault with the mast climbing work platform, which can jeopardize safety, the operator shall immediately immobilize the mast climbing work platform and notify a responsible person. In case of emergency the operator must follow the relevant instruction in the user manual.

Note: The maximum reaction force (for instance caused by tools) of the platform with regard to the facade amounts for a single mast machine 500 N and for a twin mast machine 800 N.

During rising or descending no person may stand on the platform extensions.

The maximum allowable wind speed during erection and dismantling as well as in and out of service is shown as follow.

In service

Maximum wind speed Erection 12.7m/s(6 Beaufort) Normal

Tied MC 450

15.5m/s

Operation procedure requirements

7-1 Alimak Hek MC 450

OPERATION 7.2 Preparation

Before the mast climbing work platform is used, it must be visually inspected (daily if used every day) in accordance with national regulations and/or national training. Details of the check recommended by Alimak Hek can be found at page 9-2 and further.

. 7.3 Testing 1.Test the platform function and check the following: 1. all limit switches, striker plates and safety devices and ensure that everything is properly adjusted.

Fig.7-1 Main switch

2. that the path of the platform is not obstructed. 3. the functioning of all the push buttons on the Control Box.

4. the free movement of the power supply cable. Fig.7-2 Emergency push-button

7-2

Alimak Hek MC 450

OPERATION

7.4 Operation from the platform UP (fig. 7-5,): If this push-button is pressed, the platform is raised. When the push-button is released, the platform stops immediately. DOWN (fig. 7-5,): If this push-button is pressed, the platform is lowered. When the push-button is released, the platform stops immediately. STOP LEFT MOTOR: If this push-button is pressed, meanwhile press “up”or “down” button, right platform will go up or down STOP RIGHT MOTOR: If this push-button is pressed, meanwhile press “up” or “down” button, Left platform will go up or down

Fig. 7-3 Push-buttons Control Box

EMERGENCY (fig. 7-3,): When this push-button is pressed, all the function of the machine will stop. Fig. 7-4 Brake lever drive unit

1 ○ 7.5 Brake test 2 ○ The brake test must be carried out daily. 3 ○ 1. Lift the platform by 1 meter and then stop, and check if the working platform descend or not by activating the brake lever. 2. If the platform does not descend, the mast climbing work platform must not be used. Please consult the service engineer.

4 ○

1. 2. 3. 4.

UP button Down button STOP LEFT MOTOR button STOP RIGHT MOTOR button

Fig. 7-5 Push-buttons

Alimak Hek MC 450

7-3

OPERATION 7.6 Operation in an emergency situation

In an emergency, for example in the event of a power failure, the platform can always be lowered. - Using the troubleshooting analysis in chapter 10, try to solve the problem. If the problem cannot be solved it is possible 1. to make an emergency descent to the first escape possibility in the following way. 2. . 1. Open the panel in the platform. 2. The motor has a lever which permits the brake to be released 3. 3. When this lever is operated, the platform will begin to descend. For a two-mast construction, the brakes must be released by two persons simultaneously so a clear system must be agreed between them. 4. For a two-mast construction, take the opportunity during the stop situation the set the platform level with the aid of the brake release mechanisms. If the platform becomes excessively inclined, the leveling safety system will come into operation. In this event, external help will be required. Note: Please don’t pull the lever in case that the machine travel so fast that the safety device will be activated. 5. After a maximum descent of 5 m, stop the platform for 2 minutes before repeating the process.

7-4

Alimak Hek MC 450

Fig. 7-6 Brake lever drive unit

OPERATION 7.7 Drop test To be carried out by trained service personnel. A drop test with full load shall be carried out for each new installation and then at least twice a year – or in accordance with local safety regulations. DANGER! Brake malfunction hazard No one is allowed in the platform during a drop test. Will cause severe bodily injury or death. Note: The tripping speed of the safety device is 0.5m/s. If the safety device begins to trip, or if noise occurs in the safety device during operation, the machine must be taken out of service immediately and the local ALIMAK HEK representative should be notified for action.

Drop test instruction 1. Test runs the platform in upward and downward direction to ensure that the brakes have sufficient brake torque. 2. Connect the ALIMAK HEK drop test cable to the terminal block marked “Drop test” in the electric cabinet in the Control Box. 3. Attach the cable to the platform adjacent to the electric cabinet and lower the push-button box to the bottom landing. At the same time, check that the cable is suspended in such a way that it cannot be crushed or be obstructed when the drop test is carried out. 4. Load the platform with prescribed load. Switch on the main ON/OFF switch and run the machine from the ground level up minimum 3 meters or 2 pcs. mast sections, by means of the “Up” button on the pushbutton box on the testing cable.

Alimak Hek MC 450

Remote drop test equipment at ground landing connected on terminal inside the platform control box.

7-5

OPERATION 5. Press the button on the drop test push-button box marked with an arrow symbol and maintain it in the depressed position. This releases the motor brake(s) and the platform will drop until it reaches the tripping speed and the safety device is actuated. 6. Run the platform upwards minimum 0.2 m. with the drop test push-button box to release the mechanism of the safety device. Then take the platform down to the normal lower landing by inching little by little with the drop test device. Be careful so that the safety device is not activated again. 7. Remove the test cable and then try to start the machine in the upward direction. The microswitch in the safety device shall, when the safety device has been actuated, prevent the machine from starting when the test cable has been removed. In other words, it must not be possible to start the platform. 8. Reset the safety device according to instructions later in this chapter. If you don’t succeed with the drop test, contact the nearest ALIMAK HEK representative. Calculating the safety device stopping distance The safety device stopping distance can be measured between the end face of the safety device and the end of the indicating pin– measure “L”, see figure. Safety device type： SAJ50 Lmax=10mm IMPORTANT! The safety device must be exchanged if measure “L” exceeds the value stated on the safety’s sign.

7-6

Alimak Hek MC 450

OPERATION

7.8 Resetting the safety device If the safety device trips during normal operation, a careful check must be made of the motor brake(s), transmissions, pinion, rack and all guide and counter rollers only by trained/authorized service personnel, before the safety device can be reset. The cause of the tripping must be determined and rectified. The safety device may be reset after a drop test, without having to carry out the checks listed above. Exchange intervals, see sign on safety device！! WARNING! Falling hazard Never reset the safety device by untrained person. Can cause severe injury or death. Resetting 1. Switch off the platform main switch. 2. Unscrew the screws (1) and remove the cover (2). 3. Unscrew the screws (3). 4. Use the sleeve (5) and the cranking lever (4) to back off the nut (7) until the end of the pin (6) is on a level with the end surface of the safety device.(at this time switch on the limit switch electric circuit) 5. Install the screws (3) and the cover (2) with the screws (1). 6. Remove the protective cover (9). 7. Tighten the screw (8) by hand as far as possible and then a further 30°by means of the sleeve and the cranking lever (4) – in the direction indicated by the arrow on the cover, then full back. 8. Reinstall the protective cover (9). 9. Switch on the main switch and run the machine up minimum 20 cm upward to reset the centrifugal weight of the safety device in its neutral position. 10. Make a test run. From a safety point of view the safety device must never be dismantled more than is necessary to reset it as described above. For this reason the safety device is sealed. Alimak Hek MC 450

Tightening torque: 20Nm

7-7

DISASSEMBLY AND TRANSPORT 8.

DISASSEMBLY AND TRANSPORT

Ensure that the maximum loading allowed during assembly is not exceeded.

1

In winds of strength above 12.7 m/s (6 Beaufort), the machine may not be disassembled.

Note: Carry out an inspection of the mast climbing work platform to check it is safe to dismantle. Special attention to ties, mast, platform elements and ground. conditions. Generally speaking, the disassembly of the machine should be carried out top down. 1. Switch service mode to “On”. 2. Remove the mast guards. 3. Disassemble the mast elements above the uppermost tie-in. Before loosening the uppermost tie-in, lower the disassembled elements to the ground. Now disconnect the uppermost tie-in. 4. Together with the disassembly of the mast, the tie-in tubes, the tie-in and the cable guides must be disassembled. 5. If a crane is available on the building site, the mast can be more quickly disassembled. As many as six mast elements can be removed together and lowered to the ground with the crane. The mast elements can be further disassembled on the ground. 6. Repeat this procedure until the mast, with the platform in its lowest position, has been completely disassembled. 7. Release the brakes and allow the platform onto the buffers. 8. Remove platform sections and all accessories.

8-1 Alimak Hek MC 450

DISASSEMBLY AND TRANSPORT

9. Disconnect the electrical supplies. 10. Remove the Control Box. 11. Raise the jack and remove the ground supports.

The transport method depends on the dimensions of the platform and the widths and lengths of vehicles permitted by national regulations. If the machine is too large to be transported in one piece, take the following steps. 12. Disassemble the fences, the gates and the gate posts. 13. Disassemble the platform extensions. Slide in the extensions and secure them.

Fig. 8-1 Securing extension

8-2 Alimak Hek MC 450

DISASSEMBLY AND TRANSPORT

13. Disassemble the platform elements. During the disassembly of the platform elements, care must be taken that the machine remains in balance. Support the platform if necessary. 14. The platform elements can be packed in bundles of four. 15. Slide in the extensions of the base frame and secure them.

Fig.8-2 Bundle platform elements

8-3 Alimak Hek MC 450

MAINTENANCE 9.

MAINTENANCE

9.1 General

The simple robust construction of the machine ensures that maintenance can be kept to a minimum. Sensible use of the machine, regular checks for correct functioning and regular cleaning will result in a minimum requirement for maintenance. This will guarantee a long working life for the mast climbing work platform. Parts must comply with to the technical specification of Alimak Hek VAE. Use only genuine spare parts of Alimak Hek VAE.

Adjustments and replacement as a result of checks, must be carried out by trained /authorized service personnel. Only Alimak Hek Genuine Spare parts must be used.

The frequency and extent of periodic examinations and tests depends on national regulations, manufacturer requirements, operating conditions and the frequency of use. It is normally not necessary to dismantle parts at periodic examinations, unless there are any doubts in relation to reliability and safety.

Alimak Hek MC 450

9-1

MAINTENANCE 9.2 Maintenance intervals A. Daily maintenance - Tie ins and cable guides - Functioning of all safety items* - connection between mast elements - position of the masts - any loose components - ground supports and the quality of the ground - electrical connections - protective covers (presence and securing) - securing of the platform extension - operation of the limit switches . - no obstacles in the path of the platform - oil leaking from the drive units - functioning of the motor brakes - Close the gates - Place the main switch in position “On” or “Off” (the position depends on the direction of phase rotation of the power supply) - Check that the EMERGENCY stop (Fig. 7-3, item 1) on the Control Box is switched off (the push-button must be pulled out). B. Weekly maintenance - Grease the rack and pinion. If these are heavily contaminated with sand or grit they must be cleaned first. Specification for grease: - Alimak hek-rack and pinion grease. - Clean the platform and the drive unit. - Carry out the checks detailed in section 7.2. - Visually inspect the rack and pinion drive. C. Monthly maintenance - Inspect the guide rollers (visual inspection of security devices, gaskets and bearings). - Check that all mast bolts are tightened with the correct torque. - Check that all tie-ins are secure and re-secure any loose parts. - Check the functioning of all limit switches. - Grease the jacks. - Grease the drive unit pressure rollers.

D. Quarterly maintenance - Check the motor brake. - Check the play in the guide rollers. - Check the rack and pinion (visual). - For a mast climbing work platform with twin masts, check the operation of the leveling device (see section 9.3).

9-2

Alimak Hek MC 450

MAINTENANCE E. Annual maintenance - Check the rack fixing bolts. - General inspection of paintwork, corrosion and welds. - Grease the moving parts and reinstall the mechanism. - Check all welds of the mast climbing work platform. F. Biennial maintenance - Change the oil in the drive unit reduction gearbox. Lubricant specification for motors: Synthetic VG 220 5.1L - Re-grease the bearing of the reduction gearboxes. G. Maintenance during storage of the machine - Inspect the machine in its entirety. - Check all vital parts and replace any which have become damaged. - Clean and grease the rack and pinion drive. - Inspect the mast elements (with the racks) and check that all separate connection pieces are in order. - Check the lowest mast bolts for corrosion and replace them if necessary. - Cover the machine with a tarpaulin; in every case, cover the Control Box and the limit switches. - For long-term storage, please consult your Alimak Hek representative.

9.3 Leveling system safety mechanism check 1. Raise the platform by two meters. 2. Operate the brake release mechanism on one drive unit. The leveling safety mechanism must now operate. 3. Set the platform back in the horizontal position with the ‘UP’ pushbutton. 4. Repeat the previous step for the other unit. 5. If the leveling safety mechanism (twin machine only) does not function correctly, the mast climbing work platform must not be used! Consult your service engineer. 9.4 The motor brake The motor has a built-in electromagnetic brake. This brake functions according to the ‘normally ON’ principle, that is, when the motor has no power supply the brake is active and the motor shaft will be braked. (n = 0 rev. / min). The braking effect is achieved by friction between a disc and the brake must be used ‘dry’ (not greased).

Alimak Hek MC 450

Fig.9-1 Brake lever drive unit

9-3

MAINTENANCE 9.4.1 Brake adjustment

1 Stator 2 Armature 3 Friction Disc 4 Splined Hub 5 Flange 6 Hollow Screw 7 Spring Z air gap

Fig. 9-2 Brake

Inspection of friction disc 1. Remove motor cover and if mounted remove seal. 2. Measure the thickness L of friction disc using a calliper gauge. If L is less than 6.4mm, friction disc must be replaced.

WARNING! Disconnect the brake, and release any load before working on the brake. The platform must be brought down to rest on the buffer before checking is allowed to take place.

9-4

Alimak Hek MC 450

Fig. 9-3 Friction disk

MAINTENANCE

9.4.2 Adjustment of air gap The nominal air gap z will be larger by wearing. Please readjust before it becomes max to guarantee sufficient braking torque for the brakes. When the thickness of friction braking plate achieves the allowed minimum value, the friction braking plate shall be changed. The noise generated by brake is related to the air gap. If the product is used in quite-low-noise environment, please readjust the clearance within its maximum range. Normal air gap Min. air gap Max. air gap (mm) (mm) (mm) 0.3 0.25 0.4 Measure the air gap “z” between armature plate and stator using a feeler gauge. Compare the measured air gap to the maximum permissible air gap = 0.4 mm. If air gap  0.4 mm, adjust it to nominal air gap = 0.3 mm, according to the following instructions: 1. Unbolt the screws (10). 2. Screw the threaded sleeves (9) into the stator by using a spanner. 1/6 revolution counterclockwise (looking from the stator) reduces the air gap by approx. 0.15 mm. 3. Tighten the screws (10) at the recommended 4. Check the air gaps s close to the screws using a feeler gauge: the nominal value of air gap must be z = 0.3 mm. 5. If the difference between the measured air gap and 0.3 mm is too large (and anyway it should be always less than 0.4 mm), repeat the adjustment.

Fig. 9-4 Air gap adjustment

Stator

Hand release

Hand release play

Armature

Check the play 1.8mm for hand release mechanism acc. to sketch. Note: The armature shall be activated when the play adjusted.

Alimak Hek MC 450

9-5

MAINTENANCE 9.5 Reject limits rack, pinion and guide rollers

Reject limits pinion and rack drive Pitch circle pinion

115mm

Number of teeth

23

Module

5

Dimension A, nom.

38.5mm

Dimension A, min.

37.7mm

Dimension B, nom.

39.9mm

Dimension B, min.

38mm

Meas. Pin C

φ8 x 50mm

A

B

Fig. 9-5 Rack and pinion

Guide roller Measure with sliding caliper. Dimensio New roller ns (mm) A Ø 74 （Ø 2.91 in.）

Worn-out roller (mm) minimum Ø 68 （min. Ø 2.68 in.） B minimum 2 (min. .08 in.) Guide rollers for mast tube dia. 60mm are zinc plated (Aimak LOGO on roller face marked silver).

Note that the “wear” on the roller face must be equal – all around.

9-6

C

Alimak Hek MC 450

MAINTENANCE

9.6 When it is in the case of grand maintenance or large-scale adjustment, please note:

1. The machine have to be delivered to Alimak Hek VAE or your local Alimak hek dealer for any grand maintenance or adjustment 2. Do design check according to 6.1.1 EN1495 1997 + A2 2009

3. Do practical test according to 6.1.2 EN1495 1997 + A2 2009

Alimak Hek MC 450

9-7

TROUBLESHOOTING 10. TROUBLESHOOTING

The following table gives an indication of the methods to be employed in the event of a fault. Description Current too high when rising

Solution Avoid a too high voltage drop. Only contact the machine to a stable power supply and see to it that the cable diameter of the power supply cable corresponds with the actual cable length.

Current too high when descending

Avoid a too high voltage drop. Only contact the machine to a stable power supply and see to it that the cable diameter of the power supply cable corresponds with the actual cable length. Ensure that the generator set has sufficient capacity.

Difference current too high

Press the UP button while manually releasing the brakes. When the problem does not occur now, the brake of one of the motors is not electrically lifted. This may be caused by a sticking brake or the lacking of the control current on the brake. Check the motors on damage and oil leakage. If you find any damage or leakage, take the machine out of operation and contact your dealer.

Supply voltage too high

Apply the correct voltage. If necessary, use a transformer.

Supply voltage too low

Apply the correct voltage. If necessary, use a transformer.

In all cases not covered by the above troubleshooting tables, an electrician must be consulted.

Alimak Hek MC 450

10-1

MACHINE DISPOSAL 11.

MACHINE DISPOSAL

General After a number of years of reliable service the life of every machine inevitably comes to an end. The machine must then be disposed of in an as environmentally friendly manner as possible. Amongst others, the following possibilities present themselves: -

Part exchange for a new machine. Disposal by a recycling facility. Demolition.

Discarding the machine Drain the oil out of the reduction gearbox and dispose of this via an authorized facility. Remove any usable parts. Dispose of the remainder via waste disposal facility.

11-1

Alimak Hek MC 450

1 Alimak Hek Vertical Access Equipment (Changshu) Co. Ltd Building #12, Ma Qiao Industrial Square Changshu Economic Development Zone Changshu 215513 Jiangshu Province, PRC Phone: +86 (0)512 5229 6800 Fax: +86 (0)512 5229 6900 Company Registration No: Place of Registration: www.alimakhek.cn

320581400008972 Changshu, China