Prolyte PRO LYFT AETOS PAE-1000DC Series Operating And Maintenance Manual Download

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1. GENERAL INFORMATION

Attention

: All users must read these operating

instructions carefully prior to the initial operation. These
instructions are intended to acquaint the user with the
hoist controller and enable him/her to use it to the full
extent of its intended capabilities.

The operating instructions contain important information
on how to handle the hoist controller in a safe, correct and
economic way. Acting in accordance with these
instructions helps to avoid dangers, reduce repair costs

and downtime and to increase the reliability and lifetime of
the hoist controller.
Anyone involved in doing any of the following work with
the hoist controller must read the operating instructions

and act accordingly:

• Operation, including preparation, trouble shooting and

cleaning

• Maintenance, inspection, repair

• Transport

Apart from the operating instructions and the accident
prevention act valid for the respective country and area

where the hoist controller is used, also the commonly
accepted regulations for safe and professional work must
be adhered to.
The user is responsible for the proper and professional

instruction of the operating personnel.

Suitable for entertainment use

The

PRO

LYFT AETOS hoist controllers are specially

designed for use in the Entertainment industry. They must
only control electric chain hoists that are suitable for use
in the Entertainment industry.

Combining the hoist controller with different type of
electric chain hoists might lead to unwanted, unexpected
or dangerous situations.
The

PRO

LYFT AETOS hoist controllers are not designed

to control hoists suspending or lifting loads above people.

Read the manual of the electric chain hoists before
starting to operate them with the hoist controller.

Regulations

The accident prevention act and/or safety regulations of
the respective country for using manual and electric chain
hoists must be strictly adhered:

• Europe:

• Machine Directive 2006/42/EG
• Safety of Machinery NEN 12100:2010
• Germany: BGV D6, BGV D8

Additional regulations are in effect for lifting or suspending
loads over people.
Germany: SQ P2
The Netherlands: NPR8020-10

United Kingd

om: BS7950-1

Maintenance/Repair

In order to ensure correct operation, not only the

operating instructions, but also the conditions for
inspection and maintenance must be complied with. If
defects are found or abnormal noise is to be heard stop

using the hoist controller immediately.

Attention:

Before starting to work on electrical

components the power-supply is to be cut off.

2. INCORRECT OPERATION

•

Do not

exceed the rated power capacity per controlled

channel.

•

Do not

lift stuck or jammed loads.

•

Do not

shortly and frequently actuate the up/down

switch.

• Do not

control hoists if the movement of the load is not

visible from the operating position.

• Do not

control hoists if you are skilled for lifting loads

• Do not

use cables with damaged strain reliefs and/or

isolation.

• Do not

use any input- or output cables that are not

suitable for the supplied voltage and / or current.

• Do not

use the Thuja data connection (link in, link out)

with other network devices unless these devices are
specified to be suitable for use in the Thuja data
network.

• Do not

connect the controller to a mains connection that

is not properly fused.

• Do not

use the controller without proper grounding.

• Do not

connect more then one hoist on a single

channel.

3. ELECTRIC CONNECTIONS

All electric connections must be used with respect for the
specified voltages and maximum power consumption.

Power input:

The power input connector is a 5pin CEEform connector
suitable for 3 phase 32Amp / 400Volt. 3 Phases, neutral
and ground.

Depending on the type of controller it can be plugged in to
either a 3 phase 400V or a 3 phase 230V mains
connections.

Make sure the mains connection is fused at maximum
32Amps per phase. It is advised to use circuit breakers
with a C or D characteristic.

Make sure the mains connection is properly grounded.
Improper grousing might lead to dangerous with the

risk

of electric shock.

Maximum power consumption per hoist.

Each hoist channel is capable of switching an electric
chain hoist with maximum power consumption of 1,5kW.

Power output to the hoists

For each 4 hoist channels there is a Harting 16 output
connector.

Make sure the cables (and each individual wire of the
cable) connected to the output connector are suitable for
minimum 10Amps at 400V per wire.

To avoid voltage drops longer cables should have bigger
wire diameters.

page

AETOS

Range

AETOS

Range

Replace the load chain

1-strand design

•

Disassemble chain hook.

•

Unscrew both cylinder screws and separate the housing halves. Remove
the foam stopper.

• Remove the dead of the chain from the chain bag bracket. Remove the

chain end stop, by removing the 2 screws, remove the foam stop washer
and remove the foam stopper.

•

Fitting the new chain.

• Cut the second to last link open on the loose end of the load chain to

form a C. Remove the last link and connect the new chain. The new chain
must be fitted so that the welds on the standing links face towards the
chain guide and away from the load sheave. Operate the hoist in the
lowering direction (DOWN-button) to feed the chain through the hoist.

• Fitting chain hook and chain end stop.
• Slide the foam stoppers over the loose ends of the load chain and refit

chain hook, foam stop washer and chain end stop. The chain end stop
must be fitted so that the length over foam stopper and chain end stop
towards the end of the chain is 60cm.

• Connect dead end of the chain to the chain bag bracket.

• Attention: Install new hex. nuts with clamping part.

• Before initial operation lubricate the unloaded chain and test all hoist

functions under no-load condition.

8.5. REGULAR INSPECTIONS, SERVICE AND TESTING

According to prevailing national/international occupational safety and health
regulations, hoisting equipment must be inspected at least annually by a
competent person. Adverse working conditions may dictate shorter inspection
periods.
The commissioning and inspection details can be noted on the test certificate
delivered with the hoist or in chapter 8.4 of this manual. Repairs may only be
carried out by ProLyft Service Points that use original ProLyft spare parts.
The inspection must determine that all safety devices are present and fully
operational and cover the condition of the hoist, lifting gear, accessories and
supporting constructions.
If required by the Occupational Health and Safety Organization, the results of
the adequate inspections and competent performance of repairs have to be
substantiated. If the electric hoist (with capacity of 1 t and up) is installed in a
carriage, or if the load is moved in one or several directions, the installation is
considered as crane and inspections have to be carried out in accordance with
BGV D6-Cranes.

8.6. LOAD CHAIN

The load chains are case-hardened and carry the designations 4x 12,2 DAT
(250kg), 5x 15,1 DAT(500kg) and 7,1 x20,5 DAT (1000kg).
The AETOS electric hoists are specially designed to use this type of chain. For
this reason only chains that have been approved by the manufacturer may be
used in the AETOS hoists.

Lubricating the load chain

The load chain is to be lubricated before initial operation and every month,
however, latest after 50 operating hours. Adverse working conditions,
e.g. excessive dust or continued heavy duty can dictate shorter periods
between lubrication.
•

Before the chain is lubricated it must be cleaned. Flame cleaning is
forbidden. Use only cleansing methods and agents that do not corrode
the chain material. Avoid cleansing methods that can lead to hydrogen
brittleness, e.g. spraying or dipping chain in caustic solvents. Also avoid
surface treatments that can hide cracks and flaws or other surface
damage.

•

The chain must be lubricated in a no-load condition so that lubricant can
enter between the links, e.g. by dipping in oil.

•

Either motor oil of the viscosity 100, e.g. Shell Tonna T68 or Rocol
DRY PTFE Spray can be used to lubricate the chain. For very dusty
applications use a dry lubricant.

Inspecting the load chain for wear

Load chains must be inspected every 3 months or the latest after 200
operating hours. Visually inspect the chain over its full length for deformation,
cracks, flaws, elongation, wear or corrosive pitting. Link chains must be
replaced when the nominal thickness (d: Fig. 16) on any part of the chain
has been reduced by more than 10% or when the pitch t is elongated by
more than 5% or over 11 pitches (11 x t) by 2%. Nominal dimensions and
wear limits are shown in the following table 4. Chains that do not fulfill all
requirements must be replaced immediately.

LINK CHAINS A= 4 X 12,2 DAT / B = 5 X 15,1 DAT / C = 7,1 X 20,5 DAT

Inspection

Dim.

Nominal Value [mm]

Wear Limit [mm]

Length over
11 pitches

11 x t

134,2

166,1

225,5

136,9

169,4

230,0

Length of 1
pitch

12,2

15,1

20,5

12,8

15,9

21,5

Diameter

7,1

Mean
thickness

d1 +
d2
2

7,1

3,6

4,5

6,4

8.5. REGULAR INSPECTIONS, SERVICE AND TESTING

dictate shorter inspection periods.
The commissioning and inspection details can be
noted on the test certificate delivered with the hoist or in
chapter 8.4

of this manual. Repairs may only be carried

out by

PRO

LYFT Service Points that use original

PRO

LYFT spare parts.

The inspection must determine that all safety devices
are present and fully operational and cover the condition

of the hoist, lifting gear, accessories and supporting
constructions.
If required by the Occupational Health and Safety
Organization, the results of the adequate inspections and

competent performance of repairs have to be
substantiated. If the electric hoist (with capacity of 1 t
and up) is installed in a carriage, or if the load is moved
in one or several directions, the installation is considered

as crane and inspections have to be carried out in
accordance with BGV D6-Cranes.

8.6. LOAD CHAIN

The load chains are case-hardened and carry the
designations 4x 12,2 DAT (250kg), 5x 15,1 DAT(500kg)
and 7,1 x20,5 DAT (1000kg).
The AETOS electric hoists are specially designed to use

this type of chain. For this reason only chains that have
been approved by the manufacturer may be used in the
AETOS hoists.

Lubricating the load chain

The load chain is to be lubricated before initial operation
and every month, however, latest after 50 operating
hours. Adverse working conditions,

e.g. excessive dust or continued heavy duty can dictate
shorter periods between lubrication.
• Before the chain is lubricated it must be cleaned. Flame

cleaning is forbidden. Use only cleansing methods and

agents that do not corrode the chain material. Avoid
cleansing methods that can lead to hydrogen
brittleness, e.g. spraying or dipping chain in caustic
solvents. Also avoid surface treatments that can hide

cracks and flaws or other surface damage.

• The chain must be lubricated in a no-load condition so

that lubricant can enter between the links, e.g. by
dipping in oil.

• Either motor oil of the viscosity 100, e.g. Shell Tonna

T68 or Rocol DRY PTFE Spray can be used to
lubricate the chain. For very dusty applications use a
dry lubricant.

Inspecting the load chain for wear

Load chains must be inspected every 3 months or the
latest after 200 operating hours.
Visually inspect the chain over its full length for
deformation, cracks, flaws, elongation, wear or corrosive

pitting.

Link chains must be replaced when the nominal thickness

d on any part of the chain has been reduced by more
than 10% or when the pitch t is elongated by more than
5% or over 11 pitches (11 x t) by 2%. Nominal
dimensions and wear limits are shown in the following

table 2. Chains that do not fulfill all requirements must
be replaced immediately.

Replace the load chain

1-strand design

• Disassemble

chain hook.

• Unscrew both cylinder screws and separate the housing

halves. Remove the foam stopper.

• Remove the dead of the chain from the chain bag

bracket. Remove the chain end stop, by removing the 2

screws, remove the foam stop washer and remove the
foam stopper.

• Fitting the new chain
• Cut the second to last link open on the loose end of

the load chain to form a C. Remove the last link and
connect the new chain. The new chain must be fitted
so that the welds on the standing links face towards the
chain guide and away from the load sheave. Operate

the hoist in the lowering direction (DOWN-button) to
feed the chain through the hoist.

• Fitting chain hook and chain end stop.
• Slide the foam stoppers over the loose ends of the load

chain and refit chain hook, foam stop washer and chain
end stop. The chain end stop must be fitted so that the
length over foam stopper and chain end stop towards
the end of the chain is 60cm.

• Connect dead end of the chain to the chain bag bracket.
• Attention: Install new hex. nuts with clamping part.
• Before initial operation lubricate the unloaded chain and

test all hoist functions under no-load condition.

WWW.PROLYTE.COM

INTRODUCING THE PROLYFT AETOS RANGE

When Simplicity in Motion is the ultimate goal, there’s always a next level to
meet. ProLyft invites you to take that level further with a product range that is fit
to meet the future

Get Ready for the Next Level

ProLyft AETOS is the brand new ProLyft hoist range. The AETOS range is fully
equipped to meet future demands in lifting equipment and offers clever features
and carefully engineered product attributes. The AETOS range comprises of a
standard 500kg and 1000kg hoist and will be expanded in the near future.

The Unique ProLyft Program

ProLyft sustains a unique service programme on its complete hoist range,
developed to offer maximum service and support for all hoist owners.
This program encompasses:
• Installed network of trained and certified Service Points
• Lifetime warranty
• Individual identification - easy web-enabled track and trace functions
• ProLyft Service database – automatic reminders for re-certification
• Test certificates worldwide available for owners of every hoist

Standard Features of the AETOS Range:

• Available in a 500kg and a 1000kg hoist body
• Fixed speed of 4m/min
• Red CEE form plug 16Amp 4pin and cable with strain relief

for power connection

• Yellow CEE form plug 16Amp 4pin and cable with strain relief

for low voltage control (optional)

• Equipped with limit switches on all hoists
• End limit switches are activated by chain stop for 100% repeatable accuracy

and easy of use

• External limit switches can be used for hoists used above a grid or false ceiling
• Multiple voltage motor
• Chain bags for 30mtr up to 80mtr available
• 5-pocket load wheel
• Zinc-plated load chain
• 100% sealed aluminium transmission house without oil plugs
• Standard swivel hook on hoist body and hoist chain
• IP 55 protection

Easily Adaptable:

• Covers 180 degree rotatable for motor-up use
• Easy mounting of optional second brake
• Brake shaft and electronics prepared for second brake
• Output shaft prepared for rotary limit switch or encoder connection
• All hoists can be double reeved
• Swivelling chain bag bracket for motor-down and motor-up use
• Multiple voltage motor

AETOS

Range

Fig. 16

Table 4

Inspection

Dim.

Nominal Value [mm]

Wear Limit [mm]

Length over

11 pitches

11 x t

134,2 166,1 225,5 136,9 169,4 230,0