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

Functional test

All units with two or more chain strands must be inspected before every
operation for twisted or kinked chains. Chains on 2-strand units may become
twisted if the bottom block is rolled over. It a strand is twisted disconnect it
from the hoist and re-thread it correctly. In some cases it may be necessary to
remove the last link.
Before initial operation lubricate the unloaded chain and test all hoist functions
under a no-load condition.

8.7. MAINTENANCE LOAD HOOK

Inspect the hooks for deformation, damage, surface cracks, wear and signs
of corrosion as required but at least annually. Adverse working conditions
may dictate shorter periods. Hooks that do not fulfill all requirements must be
replaced immediately. Welding on hooks to compensate for wear or damage
is not permissible. Hooks must be replaced when the mouth of the hook has
opened more than 10% (Fig. 18) or the nominal value of other dimensions has
decreased by 5% due to wear. Nominal dimensions and wear limits are shown
in table 5.

2-strand design

•

Remove the chain anchor bolt.

•

The chain anchor bolt is situated next to the disentangle plate. First
unscrew the four cylinder screws of the chain anchor. Then tap out the
anchor bolt with a drift.

•

Attention: Do not damage anchor bolt or bore.

•

Pull the load chain through the chain hook and remove the chain end
stop.

•

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.

•

Guide the new chain through the double reeved hook by pulling they old
chain manually through the hook block.

•

See the 1-strand instructions for positioning the end-stops.

Fitting the chain anchor bolt

Inspect the chain anchor bolt ( Fig. 17) for flaws, cracks or burrs. Enter the
last link of the new load chain end into the slot in the underside of the chain
anchor.

Attention: The chain must not be twisted.

Now enter the chain anchor bolt through the side bore.
Attention: Move the last chain link back and forth while entering the chain
anchor bolt to ensure that the chain is not trapped or damaged by the anchor
bolt.
Finally the chain anchor is screwed with the housing again.
Fastening torque for the locking screws: M6 = 10 Nm / M8 = 25 Nm
Functional fixed after 60 minutes.
Curing time at room temperature 24 hours.

Attention: Screws should be used only one time.

2-strand design

• Remove the chain anchor bolt.
• The chain anchor bolt is situated next to the

disentangle plate. First unscrew the four cylinder screws
of the chain anchor. Then tap out the anchor bolt with a

drift.

• Attention: Do not damage anchor bolt or bore.
• Pull the load chain through the chain hook and remove

the chain end stop.

• 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.

• Guide the new chain through the double reeved hook by

pulling they old chain manually through the hook block.

• See the 1-strand instructions for positioning the end-

stops.

Fitting the chain anchor bolt

Inspect the chain anchor bolt (Fig. 17) for flaws, cracks or
burrs. Enter the last link of the new load chain end into the

slot in the underside of the chain anchor.
Attention: The chain must not be twisted.
Now enter the chain anchor bolt through the side bore.
Attention: Move the last chain link back and forth while

entering the chain anchor bolt to ensure that the chain is
not trapped or damaged by the anchor bolt.
Finally the chain anchor is screwed with the housing
again.
Fastening torque for the locking screws: M6

10 Nm

25 Nm
Functional fixed after 60 minutes.
Curing time at room temperature 24 hours.

Attention: Screws should be used only one time.

Functional test

All units with two or more chain strands must be
inspected before every operation for twisted or kinked

chains.  Chains  on  2-strand  units  may become twisted  if
the bottom block is rolled over. It a strand  is twisted
disconnect  it from the hoist and re-thread it correctly.  In
some cases it may be necessary to remove the last link.

Before initial operation lubricate the unloaded chain and
test all hoist functions under a no-load condition.

8.7. MAINTENANCE LOAD HOOK

Inspect the hooks for deformation, damage, surface

cracks, wear and signs of corrosion  as required  but at
least annually.  Adverse  working conditions may  dictate
shorter periods. Hooks  that  do not  fulfill all requirements
must be replaced immediately. Welding  on hooks  to

compensate  for  wear  or  damage  is not  permissible.
Hooks  must  be replaced  when  the  mouth  of  the hook
has  opened more  than 10% (Fig.  15) or the  nominal
value  of other dimensions  has decreased  by 5% due to

wear. Nominal dimensions and wear limits are shown in
the following table.

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

Fixing screws

Chain anchor

Anchor bolt

Fig. 17

Fig. 18

Inspection

Hook

width

Hook

height

Hook

opening

Dim.

PAE-250

housing hook

Nominal

size [mm]

15,0

22,1

38,0

PAE-250

housing hook

Minimum

size [mm]

14,2

21,0

41,8

PAE-250

chain hook

Nominal

size [mm]

14,0

17,0

24,0

PAE-250

chain hook

Minimum

size [mm]

13,3

16,2

26,4

PAE-500

Nominal

size [mm]

15,0

22,1

38,0

PAE-500

Minimum

size [mm]

14,2

21,0

41,8

PAE-1000

Nominal

size [mm]

22,0

30,0

35,0

PAE-1000

Minimum

size [mm]

20,9

28,5

38,5

Table 5

2-strand design

• Remove the chain anchor bolt.
• The chain anchor bolt is situated next to the

disentangle plate. First unscrew the four cylinder screws
of the chain anchor. Then tap out the anchor bolt with a

drift.

• Attention: Do not damage anchor bolt or bore.
• Pull the load chain through the chain hook and remove

the chain end stop.

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

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

• Guide the new chain through the double reeved hook by

pulling they old chain manually through the hook block.

• See the 1-strand instructions for positioning the end-

stops.

Fitting the chain anchor bolt

Inspect the chain anchor bolt (Fig. 17) for flaws, cracks or
burrs. Enter the last link of the new load chain end into the

slot in the underside of the chain anchor.
Attention: The chain must not be twisted.
Now enter the chain anchor bolt through the side bore.
Attention: Move the last chain link back and forth while

10 Nm

25 Nm
Functional fixed after 60 minutes.
Curing time at room temperature 24 hours.

Attention: Screws should be used only one time.

Functional test

All units with two or more chain strands must be
inspected before every operation for twisted or kinked

Before initial operation lubricate the unloaded chain and
test all hoist functions under a no-load condition.

8.7. MAINTENANCE LOAD HOOK

Inspect the hooks for deformation, damage, surface

wear. Nominal dimensions and wear limits are shown in
the following table.

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

The Unique ProLyft Program

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

Easily Adaptable:

AETOS

Range