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Installation, Operation & Maintenance Manual

The Mat Mover

No.’s 91101-100, 91101-150, 91102-200, 91102-250

INST00276059

08-19-2009

22'-0"

(CENTER TO CENTER)

FIGURE C

FRONT VIEW

SIDE VIEW

FLANGE BEARING

REED DEVICE

EIGHT (8) VANE

TRIAC

MOTION SENSOR

ROTARY COUNTING

(SHAFT MOUNTED)

TERMINAL BLOCK MODULE

Summary of Contents for 91101-100

Page 1: ... Mat Mover No s 91101 100 91101 150 91102 200 91102 250 2009 PORTER ATHLETIC INC ALL RIGHTS RESERVED INST00276059 08 19 2009 22 0 CENTER TO CENTER FIGURE C FRONT VIEW SIDE VIEW FLANGE BEARING REED DEVICE EIGHT 8 VANE TRIAC MOTION SENSOR ROTARY COUNTING SHAFT MOUNTED TERMINAL BLOCK MODULE ...

Page 2: ...herwise documented and signed by an officer of Porter Athletic Inc NAME OF PROJECT NAME OF DEALER NAME OF INSTALLATION COMPANY PHONE PHONE Porter Order Number _________________________ Date of Scheduled Shipment _________________________ Date of Substantial Completion _________________________ The gymnasium equipment for this project has been custom fabricated according to the Owner s Architect s ...

Page 3: ...f Wall Mounted Hoists 10 7 Upper Limit Actuator Setting 11 8 Mounting the Control Box 12 15 9 Wiring the Complete Mat Mover System 16 17 10 Operational Check Procedure 17 18 11 Operational Check Procedure Trouble Shooting Guide 19 12 Assembling the Load Bar 19 20 13 Cable Attachment to Load Bar and Drum 20 14 Initial Hoisting of Load Bar 20 21 15 Setting the Lower Limits 21 16 Installing Cable Sta...

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Page 5: ...m we suggest that your equipment be numbered and a file maintained of its location name of manufacturer model num ber date of purchase and maintenance performed This will be useful when ordering replacement parts and keeping track of maintenance Defective equipment should be marked DO NOT USE until replacement or repairs are completed Inspections should be performed periodically depending upon the...

Page 6: ...has witnessed the proper operation of the unit and is sanctioned by the facility as being responsible for the operation of the Mat Mover 2 The key switch which controls the Mat Mover must be flush mounted on the wall of a location which is in full view of the operator and not directly beneath the equipment 3 Always make sure the area below the Mat Mover is clear of all individuals when raising or ...

Page 7: ...ers will be timed out disengaging the system for approximately 60 seconds If the key switch is actuated before the 60 second time limit a new 60 second time out clock will be started The sys tem must be inspected to determine the cause of the one unit not running or the reed device being by passed before the watchdog timers allow the system to run consistently The reed device also ensures the load...

Page 8: ...e load bar contact both bars ensuring the load is level If the load bar is not level contact your Porter dealer immediately This may be an indicator of an uneven cable wind 10 Make certain the audible motion alarm beeper operates any time the Mat Mover system is engaged If the alarm system is not working contact Por ter or your Porter dealer immediately This system has been designed to provide a s...

Page 9: ...rchitect structural engineer is mandatory IMPORTANT An architect or structural engineer must give written approval for the support design and any structural modifications including the steel specifications before the unit may be installed The same critical approval applies to wall mounted units The wall to which the Mat Mover attaches must be capable of supporting load of unit as indicated Approva...

Page 10: ...50 and 91102 250 2 ORIENTATION OF DRUMS The drums must be in line along their longitudinal axis The upper actuator arm which activates the upper limit switch will not function unless the drum orientation is as shown Refer to Figure A for correct orientation Figure B illustrates the incorrect drum orientation ...

Page 11: ...Step 4 if units are wall mounted The exact location of anchoring is included on the custom installation print provided with each product Four 4 high strength eighteen inch 18 long rods are provided to suspend each hoist frame from the structural A typical installation is shown in Figure C FIGURE C ...

Page 12: ... through 3 verified the units can now be put in place Secure four 4 5 8 diameter high strength rods provided to the structural steel on centers indicated in Figure C With the four 4 rods suspended lift the unit in place as shown If a lift is available the task of hoisting the unit in place is easy Lay two 2 2 x 4 s across the lift s platform side rails Place the unit on the 2 x 4 s and use the hyd...

Page 13: ...he unit Do not use the level on the top cover The top cover plate may be slightly distorted giving an inaccurate reading Be sure to check for levelness in each direction utilizing the two 2 angles of the frame weldment as a base A one inch 1 space between the top cover of the hoist unit and the overhead structure is required to provide wiring access by the electrician again refer to Figure F Repea...

Page 14: ...y the load bar pushing up the actuator bar in turn activating the limit switch To install the upper limit actuator bar unfasten the full thread bolt from the top of the actuator bar Apply a small amount of grease to the top 4 of the bar Slide the actuator bar through the tube located on the end plate between the drum and limit switch Place the whisker spring of the limit switch through the opening...

Page 15: ...hitect Ideally the control box is to be located mid point between the two hoist units on the closest wall and a minimum of 12 0 above the finished floor On wall mounted Mat Mover units the control panel must be clear of the load bar travel area see Figure J Once the location has been selected mark the four 4 anchor locations on the wall to match the four 4 holes on the back of the control box Do n...

Page 16: ... switch and control panel locations The key switch location is to be within clear view of all hoisting operations but not beneath the equipment Remember the wrestling mats may total 45 in length so a wall adjacent to the Mat Mover is ideal The control panel may be centered between the two hoist units for minimum wire run Note however on wall mounted units the control panel should not be mounted on...

Page 17: ...f travel The phasing must be corrected before any changes are made at the keyswitch terminal Proper phasing can be identified by matching motor direction of travel with the limit switch operation for that direction of travel For example if the motor is turning the cable drum in the UP direction and the UP limit stops that direction of travel the unit is phased properly The same logic applies to th...

Page 18: ...Page 14 FIGURE J POWER SOURCE ...

Page 19: ...Page 15 FIGURE K BEFORE ...

Page 20: ...or travel direction identification 10 5 During the check procedure all references made to actuating a limit switch are to be done manually to ensure the unit is phased properly preventing all limits from being put in an override situation and causing personal injury and or structural damage Manually actuate all limits with a broom stick or other similar extension taking precaution that hands limbs...

Page 21: ... power source and at control panel To correct phasing switch wires L1 and L2 at control panel or junction box After switching wires turn power ON at both the power source and control panel and repeat Step 10 5 10 7 If the installer is not on site at this time switch the circuit breakers off and leave the keys with the appropriate personnel informing same the unit cannot be operated until the limit...

Page 22: ...witch 11 6 If the steps checked correctly for corresponding light and function go to Step 7 If the lights did not correspond to the function turn the unit off and disconnect the power at the power supply circuit breaker Check all field wiring for proper connections Do not change internal wiring of the motors or control panel The wiring logic of each unit was tested at the factory If the cause cann...

Page 23: ... 4 long Grade 8 bolts must be used at this connection The 5 16 cables must now be secured to each drum by means of the cable block and two 2 5 16 x 1 3 4 long machine bolts provided for each drum Note that the barrel end of the cable terminates at the drum and must be installed in line with the drum rotation ensuring the cable rotation does not wind the initial cable wrap 180 against the barrel en...

Page 24: ...S Each hoist has a lower limit switch located on the underside of the frame weldment see Figure O With the center section of the load bar elevated 3 3 off the floor move the limit switch assembly on the adjustment rod until the whisker arm engages the hoist cable and the switch opens clicks At this point the hoist should not lower when the key switch is actuated Make certain there is a minimum of ...

Page 25: ...ensuring the cable does not uncoil around the drum should the mat be inadvertently lowered onto an obstacle bleachers extended ball cart etc The straps are to be installed on each cable drum with the load bar in the DOWN position making certain the strap does not impede the payout or take up of the cable see accompanying photo The cable stay straps are to secure the initial cable windings only Loa...

Page 26: ...to run consistently The reed device also ensures the load bar stays within approximately 3 of level during the operation cycle If one unit operates winds faster the unit will automatically shut off The operator simply needs to turn the key to OFF and then turn the key back in the corresponding direction the hoist was moving If the alignment adjustment is signif icant one unit will raise or lower i...

Page 27: ...peration and maintenance of this equipment Point out safety concerns and the operations maintenance information contained in this manual ensuring the individual is clear in understanding the tremendous forces developed by the Mat Mover system and the necessity of having only trained authorized personnel operate this equipment ...

Page 28: ...d is the cable attachment at the load bar or pulley These connections must be made with Grade 8 bolts and nylock nuts a lock nut may be substituted 3 PULLEY AT LOAD BAR If Applicable It is advisable to disassemble the pulley check the sheave bearing and shaft for excessive wear and replace with a factory replacement pulley if necessary There is a grease fitting on the sheave Use a standard high te...

Page 29: ...y question of structural integrity Replace covers ensuring all screws are tight to eliminate any vibration noise 6 SLING The mat sling is to be checked for signs of tearing or loosening at the seams Check stitching on all straps The sling may be cleaned with a mild solution of soap cleaner and water or power foam sold by Rigmar Industries of Elk Grove Village Illinois 1 800 323 0779 7 CONTRACT MAI...

Page 30: ...rection of motor travel Incoming power source wires to be reversed switch L1A with L2A at the control panel DO NOT reverse wires at electric motor or ANY location this will override the limit switch controls 3 Unit will not go up Misaligned actuator bar One or both upper limit actuator bars are lodged in the UP position Pull bar in DOWN position which will release the limit switch Lubricate the ba...

Page 31: ...after actuating both down limit switches one or both down limit switches require adjustment 6 Motor overload relay in Mat Mover control panel keeps tripping Incorrect voltage Wire not terminated properly or broken Contact the electrician or consult the factory 7 Pulleys at load bar are squeaking Pulleys require lubrication Contact your Porter dealer The load bar will need to be supported or lowere...

Page 32: ...ER NOTES THIS WARNING IS GIVEN IN COMPLIANCE WITH CALIFORNIA S PROPOSITION 65 WARNING This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING This product can expose you to Titanium Dioxide which is known to the State of California to cause cancer For more information go to www p65warnings ca gov E ...

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