Prolyft 2012 brochure by Prolyte

233

234

Contents INTrODUCTION 236 ProLyft hoists 241 controllers 244 accessories 247 theatre products 251 pilewindWINCH 254 performerfly winch 255 powerfly winch 256 protrac 257

236

Simplicity in motion ProLyft designs and manufactures a broad range of

speed or load of the movement is only limited by your

ultra-safe, lightweight and compact lifting systems,

imagination. The life of technicians and operators is

all supported by a worldwide network of Service

made easy by simple solutions that work flawless

Points and backed by a Lifetime Warranty.

and movements that can be reproduced with

In addition, ProLyft offers a number of essential

accuracy, day-by-day. Control solutions enhance safe

accessories to add to the utility and application of the

operation, generate more movement possibilities and

hoists and controllers.

give designers the space to create.

Drive and control solutions from ProLyft make

Prolyte is able to cover a broad spectrum of drive and

productions happen, on stage, on tour, in theatres or

control solutions within the entertainment market due

sports arenas. They ensure safe object or performer

to employees with an open ear for customer

movements and protect performers in their daily

demands and the ability to translate ideas into

work. Whether up, down, left or right, the direction,

standard or customized solutions.

237

application

Definition A hoist, as used within the entertainment and events industry, can be defined as an electrically-driven lifting device, whereby the main (special) lifting chain is the load bearing element, as used for lifting, holding and lowering of loads, either suspended above persons or not.

Application Electrical hoists, as used within the entertainment and events industry, are commonly used for lifting or holding loads above persons. These loads can be truss constructions, set pieces, lighting or sound equipment, or any technical equipment or decoration used in the design of the event. Since lifting and holding loads above persons incurs higher levels of risk to the persons under the load, extra safety measures often are required.

Standards / DIRECTIVES / CODE-OF-PRACTICE EN-ISO-12100-1

Safety of machinery - Basic concepts, general principles for design Part 1: Basic terminology, methodology (ISO 12100-1:2003)

EN-ISO-12100-2

Safety of machinery - Basic concepts, general principles for design Part 2: Technical principles (ISO 12100-2:2003)

EN-14492-1/2

Cranes - Power driven winches and hoists - Part 1: Power driven winches

EN-60204-32

Safety of machinery - Electrical equipment of machines Part 32: Requirements for hoisting machines (IEC 44/543/CDV)

ASME-B30.16

Overhead Hoists (Underhung)

FEM-9.511 (06.1986)

Rules for the design of series lifting equipment; Classification of mechanisms

FEM-9.671 (10.1988)

Rules for the design of series lifting equipment; Chain qualities, selection criteria and requirements

FEM-9.755 (06.1993)

Measure for achieving safe working periods for motorized serial hoist units (S.W.P.)

FEM-9.756 (08.2004)

Hand-operated and power driven hoists for special purposes.

FEM 9.683 (10.1995)

Selection of lifting and travel motors.

BGV-C1/GUV-V C1

Veranstaltungs- und Productionsstatten fur szenische Darstellung

EN-818-7

Short link chain for lifting purposes - Safety Part 7: Fine tolerance hoist chain, Grade T (Types T, DAT and DT)

Machine directive 2006/42/EC

Electromechanical Directive EMC 89/336/EEC

BS-7905-1

Lifting equipment for performance, broadcast and similar applications - Specification for the design and manufacture of above stage equipment (excluding trusses and towers)

DIN-56950

Veranstaltungstechnik - Maschinentechnische Einrichtungen - Sicherheitstechnische Anforderungen und Prüfung

ISO-13849-1

Safety of machinery - Safety-related parts of control systems Part 1: General principles for design

IEC-62061

Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems

CWA 15902-1 (european code-of-practice)

lifting and load-bearing equipment for stage and other production areas within the enterainment industry

NPR-8020-10 (dutch code-of-practice)

lifting equipment for stages and other production areas within the entertainment industry “safety factors”

238

Photo: JSA. Russia.

Do: • I nspect your hoist on a regular basis, and keep a written record of all inspection and maintenance. •C ertify your hoist at least once a year at a ProLyft Service Point to enhance the life expectancy of your hoist and retain the Lifetime Warranty. • S tore your hoist properly and protect it from adverse environmental conditions. •M ake a proper risk assessment before using a “standard” hoist to its maximum WLL. If not determined as safe, additional measures must be taken. A minimum requirement is that the WLL should be reduced by 50%. • U se limit switches in case of limited travel height or a blocked travel path. • U se designated and approved lifting chain only. • R econnect the dead-end of the chain to the hoist to reduce the dropheight of the chain in case of an involuntary chain drop. • P rotect your hoist against water and dust. • L ift grids or loads on multiple hoists should only with hoists of similar loading capacity and lifting speed. • Check the chain visually before each lifting job.

Do NOT • Run the chain in or out the hoist when the hoist rests on its sides as this will damage the brake. • Use the end-stop on the chain (and therefore the slip clutch) as travel limit. • Use damaged lifting chains. • Use hoists outdoors without proper protection for environmental influences, such as rain or dust. • Lift loads under an angle as loads may exceed the maximum WLL due to a shift in the of point gravity. (This can have a significant impact on the flown truss structure and the roof construction.) • Use motor bridles, since this will cause the loading per hoist to fluctuate in an unpredictable manner. • Move loads above people without taking appropriate safety measures • Modify the hoist other than through an official ProLyft Service Point; otherwise, product liability shifts from the manufacturer to the person or company responsible for the modification.

239

ProLyft hoists

Photo: De la Mar, Amsterdam, The Netherlands

Worldwide service network ProLyft has established an extensive network of worldwide

with a RFID tag for positive identification, and all hoist owners

Service Points, unique among hoist manufacturers. All Ser-

have free access to this database. Automatic reminders are sent

vice Points are fully equipped and staffed by comprehensively

to hoist owners on a yearly basis, in order to make sure that the

trained personnel. All Service Points are certified to perform

hoists are re-certified in time. If the hoist is tested at regular

any required maintenance or repair jobs on ProLyft hoists. Each

intervals at one of the ProLyft Service Points, the Lifetime War-

Service Point maintains an inventory of spare parts as well as a

ranty remains in effect.

stock of standard hoists. All technical and sales personnel are re-trained on a yearly basis to ensure a consistently high level

What makes ProLyft hoists unique?

of service expertise.

High Quality: Complies with all applicable European and American safety standards. All parts are forged and machined,

Certification

making them stronger, more durable and with higher tolerances.

Only authorized ProLyft Service Points can certify your hoist on

All metal parts zinc plated

annual basis to secure the Lifetime Warranty for each ProLyft

Security: IP54 protection. Integrated phase-loss protection.

hoist. All ProLyft service points are accredited and certified to

User friendliness: Lightweight, compact and symmetrical hoists.

test your hoist and issue certification.

Magnetic oil refilling plug in gearbox for easy detection of excessive wear. Easy repair and service access.

Free Access

Silent operation: Five-pocket load wheel for smooth operation.

All ProLyft hoist owners can easily track hoists that are regis-

Oil-based gear box, very low noise level (68 dB). Internal one-

tered in the ProLyft service database. Each hoist is equipped

piece nylon chain guide for quiet chain handling.

240

ProLyft 500 kg / 1000 kg / 2000 kg

PLE-11 / PLE-12 / PLE-13

PLE-13

PLE-21 / PLE-22 / PLE-23

Direct Control Hoist:

ProLyft 2000 kg

Low Voltage Control Hoist:

ProLyft 500 kg / 1000 kg / 2000 kg

Standard features Direct control hoist • C-Form 16 A-4p powerplug and cable with strain relief • Multiple voltage motor • Chain bag for 30 m and up to 80 m chain • Jam-free chain guide • Internal, sealed clutch • Integrated handgrips • Standard swivel hook on upper and lower chain • Zinc plated load chain • Phase failure contactor • AC brake Options • Double brake • Build in encoder for positioning system • External load cell system • 8 m/minute lifting speed (for 500 kg hoist only)

ProLyft 500 kg / 1000 kg / 2000 kg

Standard features LOW VOLTAGE control hoist • C-Form 16 A-4p powerplug and cable with strain relief • C-Form 10 A-4p control plug and cable with strain relief • Multiple voltage motor • Chain bag for 30 m and up to 80 m chain • Jam-free chain guide • Internal, sealed clutch • Integrated handgrips • Standard swivel hook on body and lift chain • Zinc plated load chain • Adjustable limit switch (max. 70 m lift) • AC brake • 115 V control circuit Options • 24 V or 48 V control circuit • Double brake • External Load cell system • Smart limit (to operate LV hoist as direct control) • 8 m/minute lifting speed (for 500 kg hoist only)

241

ProLyft 500 kg / 1000 kg / 2000 kg

480 297

245

216

Side view

480

217

260

Direct control hoist

Low voltage control hoist

Front view

All measurements are for the direct control and low voltage hoist: A: 500 / 1000 kg MIN. 411 mm - 2000 kg MIN. 478 mm B: 500 / 1000 kg MIN. 469 mm - 2000 kg MIN. 542 mm C: 500 / 1000 kg 194 mm - 2000 kg 216 mm D: 500 / 1000 kg 120 mm - 2000 kg 98 mm

Benefits: • Compact measurements & symmetrical design • Lightweight housing, 35 kg • Powder-coated sturdy housing • Five-pocket load wheel for smooth operation • Multiple disk brake for reliable operation • All forged and machined for greater strength and durability with higher tolerances • Accurate and robust all-steel limit switches • Internal one-piece metal chain guide • Oil-based gear box for very low noise level (68 dB) • Magnetic gearbox oil plug for easy detection of excessive wear • Easy repair and service access • Grade 80 chain complies to FEM classification 2 m • 300 starts per hour • Easy and secure mounting of chain bag

Your ProLyft 1000 kg hoist can easily be converted into a 2000 kg hoist by using the PLS-13-002 upgrade set. Technical specifications for direct and low voltage hoist Load capacity

500 kg

1000 kg

2000 kg

lifting speed 50 Hz standard m/min

Operating voltage

400 v-3P-50 Hz / 230 v-3p-60 Hz

Protection class

IP 54*

Motor power at 50Hz

0,75 kW

Power consumption at operation

1,9 A

FEM CLASS

FEM Duty factor

50%

Starts per hour

300

Noice level

68 dB

Load wheel

5-pocket

Load chain EN-818-7

7,1 x 20,5 mm

Falls of chain

Weight of chain per meter lift

1,1 kg

2,2 kg

Weight of body

35 kg

35 Kg

37 kg

Type of control

direct

Type of connector

CEE 16 A-4p

Low voltage control

115 V

Suspension with swivelhook

standard

* IP 55 available as option

242

235

A B

297

332

217 C

235

ProLyft 250 kg

100

20,6

150

19,8

320

All measurements are in mm.

Your ProLyft 250/226 kg hoist can easily be converted into a 500/452 kg hoist by using the PLS-13-001 upgrade set. Technical specifications - ProLyft PLE-10/20 PLE-10-001

PLE-20-001

Load capacity

250 kg

226 kg

lifting speed 50Hz standard m/min

Operating voltage

400 v-3P-50 Hz / 460 v-3p-60 Hz

220 v-1P-50 Hz / 110 v-1P-50 Hz

Single phase operation

n/a

yes

Protection class

IP 54*

Motor power at 50Hz

0,16 kW

Power consumption at operation

0,7 A

FEM CLASS

1 Am

FEM Duty factor

50%

Starts per hour

300

Noice level

55 dB

Load wheel

10-pocket

Load chain EN 818-7

3,9 x 11,9

Falls of chain

Weight of chain per meter lift

0,34 kg

Weight of body

11 kg

Type of control

direct

low voltage

Type of connector

CEE 16 A-4p

CEE 16 A-3p

Low voltage control

n/a

48 v only

Suspension with swivelhook

n/a

* IP 55 available as option

Benefits • Compact measurements (fits into H30V truss) • Symmetrical design • Lightweight housing • Durable black coating on housing • Power outlet on top side • 10-pocket chain wheel for smooth and silent operation • Closed, non-adjustable electrical brake for reliability • All machined parts for greater strength and durability compared to powder-pressed parts • Internal one-piece guide • Grade 80 chain • 300 starts per hour • Safe and easy mounting of chain bag

Standard features 250 kg hoist • Direct control (48 V) • CEE 16A-4p plug and cable with strain relief • Multiple voltage motor • Chain bag for 22 m chain • Jam-free chain guide • Internal, sealed clutch • Standard swivel hook on lift chain • Zinc plated load chain • 10-pocket load wheel Options • Low voltage control (48 V) • Single-phase version • Double brake

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controllers

PLE-30-010 for direct control

PLE-30-020 for direct control

PLE-40-010 for low voltage control

PLE-40-020 for low voltage control

1-way control

2-way control

Including high voltage contactors and emergency stop button, 1 x CEE 16A-5p plug and power cable and 1 x CEE 16 A-4p plug and power cable.

Including high voltage contactors and emergency stop button, 1 x CEE 16A-5p plug and power cable and 2 x CEE 16 A-4p plug and power cable.

Premium quality manual controllers, competitively priced Prolyte offers a range of high quality yet affordable hoists controllers. Whether 1-way or 2-way, each controller offers safe and reliable performance in the most demanding, high-pressure applications. LED indicators maintain visual control when needed, and compact size makes for easy handling. Pricing is highly competitive.

All ProLyft control units are prepared for SOCAPEX connector mounting on the back side.

Remote control PLE-30-043U

Remote control for basic and modular range controllers, incl. 10 m. extension cable.

Multi-channel controllers The ProLyft rack-mount multi-channel controllers are developed specifically for the control of the PLE series chain hoists. Each is available in direct or low voltage control version, and in standard 4-, 8- or 12-channel configurations in a 19”rack housing. The controllers allow you to operate the hoists individually or simultaneously with one single-run button. For larger applications, the controllers can be interconnected to serve a system up to 64 channels. All pre-selected hoists are activated by one button for optimum safety and ease of use.

basic range

PLE 30-044 direct control (400-415 V-3ph-50 Hz)

PLE 30-083 direct control (400-415 V-3ph-50 Hz)

PLE 30-123 direct control (400-415 V-3ph-50 Hz)

PLE 40-043 low voltage control (400-415V-3ph-50Hz)

PLE 40-083 low voltage control (400-415 V-3ph-50 Hz)

PLE 40-123 low voltage control (400-415 V-3ph-50 Hz)

4-way controller basic

8-way controller basic

12-way controller basic

• Pre-selection facility with LED indication

• Output: 1 x Harting 16p connector for

• Output: 2 x Harting 16p connector for

•O utput: 3 x Harting 16p connector for

hoist connection

• Input power: 100 cm power cable with

hoist connection • Input power: 100 cm power cable with

1 x CEE 32 A-5p with phase reverse plug • Link input/output with 4p. Hirschmann connector

1 x CEE 32 A-5p with phase reverse plug • Link input/output with Neutrik Powercon connector

1 x CEE 32 A-5p with phase reverse plug • Link input/output with 4p. Hirschmann connector

• Short circuit protection for power and control

• Emergency stop button

• 19”3U rack housing

• 19”4U rack housing

• All A-class components

More control options, Including computerized hoist controls available on request. Please contact cs@prolyte.com for additional information.

244

low voltage control

Motor cable

Control Cable (yellow)

5 m.

PLA-30-05

5 m.

PLA-31-05

10 m.

PLA-30-10

10 m.

PLA-31-10

20 m.

PLA-30-20

20 m.

PLA-31-20

Break-out PLA-34-004

Low voltage control PLE-40-043

PLA-30-05

PLE-40-083

PLA-30-10

PLE-40-123

PLA-30-20 Power cable 5 m.

PLA-32-05

10 m.

PLA-32-10

20 m.

PLA-32-20

245

direct voltage control

Motor cable 5 m.

PLA-30-05

10 m.

PLA-30-10

20 m.

PLA-30-20

Break-out PL A-34-02

Direct control PLE-30-044 PLE-30-083 PLE-30-123 Power cable

246

5 m.

PLA-32-05

10 m.

PLA-32-10

20 m.

PLA-32-20

ACCESSORIES

PLA-34-04

PLA-33-05/10/20/25

front / back side

Break-out Harting 16p. connector male 4x 16 A-4p female and 4 x 115 V-4p male, for low voltage control

Multi cable 16p connector, 5,10, 20, 25 m

PLA-40-001

PLA-40-012

PLA-40-010

Flight case for 2 x 250 kg hoist

Flight case for 1 x 500, 1000 or 2000 kg direct control hoist

Flight case for 1 x 500, 1000 or 2000 kg low voltage control hoist

PLA-30-05/10/20/25/30/40/50

PLA-31-05/10/20/25

PLA-32-05/10/20/25

PLA-35-05/10/20/25

Motor power cable

Low voltage motor control cable,

Mains power cable

Motor power cable single phase

16 A-4p, 5,10, 20, 25, 30, 40, 50 m

115 V-4p, 5,10, 20, 25 m

32 A-5p, 5, 10, 20, 25 m

16 A-3p, 5, 10, 20, 25 m

PLA-34-02

PLA-35-001U

PLA-10-004

PLA-10-001 *

Break-out Harting 16p. connector male 4 x 16 A-4p female, for direct controlt

Link cable length 1 m for controller

Chain bag for a 250 kg hoist, max. 22 m chain length

max. 30 m chain length max. 45 m chain length

PLA-10-007 Chain bag for a 250 kg hoist, max. 40 m chain length

PLA-10-009 *

PLA-10-002 *

PLA-10-012 *

max. 65 m chain length max. 80 m chain length * Chain bag for 500, 1000 or 2000 kg

247

options / spare parts

PLA-55-004

PLA-56-005

Double brake kit for 500, 1000, 2000 kg hoist. For assembly instructions we refer to the manual. Also available for 250 kg hoist.

Lug. Fixed suspension point for 500, 1000, 2000 kg hoist, cross mounted

PLS-13-001

PLS-13-002

PLS-913JG3AS

Upgrade set. To upgrade your 250/226 kg hoist to a 500/452 kg hoist by double reefing the chain

Upgrade set. To upgrade your 500 kg hoist to a 1000 kg hoist or a 1000 kg to a 2000 kg hoist by double reefing the chain

Standard swivel upper hook assembly

PLA-55-016

PLA-55-025

PLA-50-003

PLA-50-007

Limit switch for 500, 1000, 2000 kg hoist

Smart limit. Converts a low voltage hoist into a direct controlled hoists with limit switches

Rain cover for 500, 1000, 2000 kg hoist

Rain cover for 2000 kg hoist

PLA-10-006

PLA-10-008

PLS-75JG6K

PLS-20428K

Quick-link to mount chain bag to bracket, 3,5 mm for 250 kg hoist

Quick-link to mount chain bag to bracket, 6 mm for 500, 1000 and 2000 kg hoist

Chain stop kit for 500/1000/2000 kg hoist, to mount on dead end of chain

Chain stop kit for 250 kg hoist

248

ACCESSORIES

Quality and safety assured All ProLyft rigging hardware products are manufactured to the highest quality standards, and are fully tested and certified to comply with the latest regulations and standards. ProLyft uses only the very best available materials and components to assure safe and flawless performance. Choose from a variety of safe and user-friendly rigging materials for slinging trusses, making bridles or providing guy wires where needed. Each piece of ProLyft rigging equipment offers the extra margin of robust quality makes it “rigger-proof”. rigging hardware ProLyft supplies a wide range of standard rigging hardware, from steel wire ropes, soft steels and shackles to chain clutches, ratchet straps and round slings. All steel wire ropes are available in 1- or 2-tonne versions, either sleeved or black steel. All steel wire ropes are colour coded to length and have a turn back loop with tapered ending and inspection eye. Each steel is marked with the ProLyft logo, a certification number and WLL.

SoftSteel® The SoftSteel has a normal outside webbing for soft slings, but instead of the polyamide core the SoftSteel has a core of steel wires. As flexible as a normal soft sling, the steel wires within the SoftSteel have a much better fire resistance. The SoftSteel can be used in circumstances where the normal soft slings are not allowed. The outside webbing is black, including a grey identification label and a cleverly hidden inspection window to inspect the steel wires within the SoftSteel. Available with a WLL of 2000 kg, the SoftSteel complies with all CE regulations and is BGV C1 approved.

249

Rigging hardware

SW-10-L050-EE/C WLL 1000 kg, 10 mm

SW-10-L050-EE/B WLL 1000 kg, 10 mm

SW-14-L050-EE/C WLL 2000 kg, 10 mm

SW-10-L050-EE WLL 1000 kg, 10 mm SW-14-L050-EE WLL 2000 kg, 14 mm

Steel wire rope sleeved

Steel wire rope black

Steel wire rope

Available in lengths from L050-L1000, colour coded

RS-1T-100 / RS-2T-100 / RS-3T-100

SS-2T-100

Roundsling L100, WLL 1000 kg, 2000 kg, 3000 kg, black

Soft steel L100, WLL 2000 kg, black

RI-SH1T-EB WLL 1 ton - RI-SH2T-EB WLL 2 ton RI-SH3,2T-EB WLL 3,25 ton RI-SH4,7T-EB WLL 4,7 ton

Available in different lenghts

Available in the following lengths: L 050, L100, L200, L300

Shackle pin type

1600 kg

750 kg

RI-O-RING-3T

BM-M12-EB

RI-SH1T WLL 1 ton - RI-SH2T WLL 2 ton

Top ring WLL 3 ton

Lifting eye M12 thread

RI-SH3,2T WLL 3,25 ton - RI-SH4,7T WLL 4,7 ton Shackle bolt type

CH-07-150CHH

CH-07-200HCSH

CH-10-200CRH

Shortening chain

Shortening chain with spanner

Shortening chain

Length 1,5 m, WLL 1,5 ton

Length 2 m, WLL 1,5 ton

Length 2 m, WLL 3 ton

250

ACC - 40D/V - LIFT

Lifting bracket WLL 500 kg

Lifting bracket WLL 1000 kg

lifting brackets ProLyft lifting brackets are the ideal solutions for permanent or semi‑ permanent installations, where the suspension point must be reliable, stable and part of the overall truss design. The lifting brackets are made of a special extruded aluminium profile. ProLyft has two types of lifting brackets in several sizes to mount on your truss: the WLL 500 kg and 1000 kg.

The lifting eye is limiting the load bearing capacity. The lifting bracket can also be mounted on the bottom chords of the truss by simply bolting the lifting eye at the other side of the profile. For proper use of brackets and lifting eyes, please refer to the Black Book “Technical Matters”.

Lifting Bracket Measurements

ACC-20D/V-LIFT WLL 250 kg

106

190

ACC-30D/V-LIFT WLL 500 kg

134

239

ACC-30D/V-LIFT WLL 1000 kg

134

239

ACC-40D/V-LIFT WLL 500 kg

134

339

ACC-40D/V-LIFT WLL 1000 kg

134

339

ACC-36R-LIFT WLL 500 kg

134

207

ACC-36R-LIFT WLL 1000 kg

134

207

ACC-36V-LIFT WLL 500 kg

134

299

ACC-36V-LIFT WLL 1000 kg

134

299

ACC-52V/SV-LIFT WLL 1000 kg

134

470

251

Rigging hardware

TOOL - HAM - 500 / TOOL - HAM - 750

RA - 2T - 200HH

RA - 1T - 150OE

Copper hammer.

Ratchet L200, WLL 2000 kg (hook-hook)

Ratchet L150,WLL 1000 kg (open end)

Also available in the following lengths:

L400, L600, L750, L1100

RA - 5T - 200HH Ratchet L200, WLL 5000 kg (hook-hook) Also available in the following lengths: L400, L600, L750, L1100

252

theatre products

Photo: Helsingor Theatre

Prolyte on stage Prolyte manufactures a range of products that, over the years,

All Prolyte products are distinguished by precision

have demonstrated proven advantages in arts and entertainment

engineering, high quality, and uncompromising safety standards.

venues, including theatres and auditoria of all types and sizes.

Prolyte stands at the forefront of industry standardisation and

Many of these products offer perfect solutions for the theatrical

forthcoming regulations, a position that is reflected in our

environment, ranging from trusses and stage elements to hoists,

innovative, safe and user-friendly products.

and fly-bar systems and motorised flying systems.

253

Pilewindwinch

PILEWINDWinch Affordable winches PileWindWinches provide an affordable alternative for situations where accurate positioning and speed matter less, like non-performance situations or maintenance bars. The PileWindWinch wraps its steel wire in a multi-layer fashion on the winch drum. The wire runs through a narrow gap that is barely wider than the steel wire itself.

Operator panels Manual up/down/speed Local (single axe) control; up/down/e-stop/speed adjust, key switch/reset. Central (multi axe) control; winch selection switchboard with an attached single axe controller to execute the moves. Position control Local (single axe); able to teach-in and select 5 positions with an attached single axe controller to execute the moves. Central (multi axe); LCD screen control with teach-in and select of 5 positions per winch. To be combined in 20 cues. Positioning can be speed or time synchronized. Moves are executed with an attached single axe controller.

Modular design The drums are modular and can be easily adapted to the thickness of the wire and the number of steel wires. The winches can be equipped with several control options. PileWindWinches are standard available for loads up to 750kg at speeds of 4 to 16m/min. Standard lifting heights are 5-27m. Principle of PileWind: Speed, Power and Position will vary Based on the principle of a pile wind, the speed will decline when the wire is unrolled and the pile gets smaller. As a result the speed difference can be up to 50% for a 20m pile wind winch with a 10mm steel cable. The change in diameter of the pile also influences the available torque and the accuracy of the winch. Therefore, the mentioned speed always refers to the maximum speed.

SPECIFICATIONS PILE WIND WINCH Available versions: Standard lifting capacity 70-750kg. Fixed speed 4m/min, variable speed 0-4, 0-8, 0-16m/min. Lifting height 5 or 27 m. Drum for 2 to 10 steel wires, 4 â&#x20AC;&#x201C; 10mm diameter. Drum for rope or bungee on request. Specifications: Minimum safety factor on the steel wires: 10. 3 phase a-synchronous motors, 400V. Double brake, or single brake with self-braking gearbox (depending on type). Vario speed based on closed-loop invertors Vario speed types are standard equipped with over speed protection Safety factor on gearbox: 2. Limit switches. All winches according to BGV-D8+ and SIL2. Options: Optional low noise (theatre) brakes. Overload and underload protection. SIL3/BGV-C1 E-stop. Incremental encoders with battery backup. Absolute encoders. Load visualization.

selection table (more options available) front/motorplate

sideplate

max. Pile diameter(mm)

pile diameter (mm)

lifting height*** 4mm

5mm

WLL (kg) 6mm

m1- 0,25KW

m2 - 0,25 KW

m3 - 0,35 KW

m4 - 1,1 KW

m5 - 2.2 KW

m6 - 2,2 KW

4 m/min fixed/ variable

16 m/min variable

300

250

110

244

522

278

456

1240

300

178

382

204

333

907

400

350

173

371

198

323

881

400

151

324

173

283

769

*** no less then 2 cables per winch must be used to ensure a safety factor of 10

254

PerformerFly winch

PerformerFly Multipurpose Winch PerformerFly is a multi-functional truss winch (PPFW 5540) that can be fully integrated in any H40V truss configuration to provide a flexible solution for rental companies or touring sets. With its speed of 4 m/second and acceleration of 4 m/second², this winch offers the full scope of movement possibilities. In addition, the smooth start and stop control affords precise travel positioning and safe operation. In combination with a railing system (also available as an integral component in an H40 truss), the options for flexible fly solutions are almost endless. This type of winch is specially developed to be used for performer flying. Integral safety and control systems, including location of the second brake and spindle end switches in addition to the regular SIL3 requirements, ensure safe operation for performer and technician. The PPFW 5540 can be delivered with different types of drums to accommodate 4, 5 or 6 mm steel wire using one or two cables. Depending on the application, the drum has a capacity of 20-75 m length. As an option, the PPFW 5540 can be mounted with a fleet angle correction unit.

Specification PerformerFly Winch PPFW 5540 - as standard integrated in H40 truss frame: • Lifting capacity: 125/250 kg • Self-weight: 275 kg • Local control/connection box • Motor: 7,5 kW servo drive • Method: double wire PowerFly with zero fleet compensation • Wire: 4, 5 or 6 mm 7x19 KSR • Lifting speed: 4 m/second (SWL 125 kg) • Lifting speed: 3 m/second (SWL 250 kg) • Maximum acceleration: 4 m/second² • Travel length: 20 - 75 m • Drum diameter: 180 mm • Cross-wire detection and cross-wire prevention rollers • SIL 3 double encoder • Hard wired double safety end switches LL, L, H, HH • Double brakes on the drum including manual release • Static weight measurement by load cells

Specification PerformerFly Traveler PTS03-01-150 - also available as an integral component in an H40 truss frame: • Self-weight: approx. 300 kg • Motor assembly • Tooth belt drive • Motor: 3 kW single brake • Speed: 2 m/second • Acceleration: 2 m/second² • Abs + incremental encoder • 2x heavy-duty carrier SWL 260 kg • 1x heavy-duty single-track rail • Travel distance: up to 25 m • Accuracy within 1 mm

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PowerFly winch

Photo: De la Mar, Amsterdam, The Netherlands

PowerFly Winch The modular PowerFly winches can be built to practically any specification to meet application requirements. Based on a standard concept, all components can be selected and assembled to fit the needs of the customer.

AVAILABLE VERSIONS ARE: • Lifting capacity of 100 - 2000 kg • Fixed or variable speed up to 4 m/s • Drums for 1-7 wires, from 2-14 mm wire diameter • Drum can accommodate either wire rope, fibre rope or bungee cord • Lifting height variable depending on application The winches are standard supplied with an asynchronous motor; specific outside dimensions or dynamic behaviour may require a servo motor. Based on the safety regulations and standards applicable in the specific use, each winch can be equipped with the following features: • limit switches • absolute or incremental encoders • single or double brakes • slack-wire detection • cross-wire detection • load cells

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This modularity not only offers application-specific winches, it also minimizes end cost as no unnecessary or oversized components are used. All winches can be equipped with a fleet angle correction unit when needed.

Specification PowerFly Winch as shown PFW75-12-5000: • Lifting capacity: 500 kg net • 4 wires • Lifting speed: 0-2 m/second • Maximum acceleration: 2 m/second² • Lifting height: 15 m • Cross-wire detection and cross wire prevention rollers • Slack-wire detection • Hard-wired double safety end switches LL, L, H, HH • SIL 3 double encoder • Accuracy within 1 mm • Static weight measurement by load cells

ProTrac

Photo: Royal Opera House, London, UK

Ready for the future The rapid evolution of contemporary theater productions has placed new demands on existing fly-bar systems. Important recent developments include higher loading requirements, a growth in the scope of productions, and the introduction of mechanically operated fly-bar systems. The demands placed by new production techniques have made many fly-bar systems no longer suitable for the job. Developed to fill this gap, ProTrac* is a substantially upgraded fly-bar system with several extra options and a high loading capacity. Additionally, because ProTrac is a lightweight system (low inherent weight), it allows a higher net loading capacity for your winches or drives.

System Description ProTrac consists of a rectangular upper profile of extruded aluminium combined with a lower round aluminium tube or profile. Three types of lower profile can be connected to the upper profile:

Accidents avoided Compared to commonly used conventional fly-bars or steel ladder beams, ProTrac dramatically reduces the horizontal bending that results from applying loads to the fly-bar. ProTrac has practically NO lateral flex: horizontal bending is less than 2 cm over 24 m of length when full load is applied. Nearby fly-bars will not be blocked and, more importantly, potential accidents due to the blocking of the flyway can be prevented. Further, ProTrac can be furnished with yellow end-caps to enhance visibility of the fly-bar, thus providing an extra safety margin for technicians and actors when working on stage.

The lower profile connects to the upper profile with stud bolts. Suspension points for the ProTrac components slide into the slot of the upper profile and are easily fixed, due to a lock and load system. ProTrac is a modular system. ProTrac is a modular system. Variable lengths can be connected via internal tubes, which are bolted into place. The connection of two lower profiles is placed under 45 degrees to guarantee flawless runner travel. ProTrac’s profiles are black anodised and are furnished with rubber caps at the ends. The upper profile can be fitted with extra drilled holes of 50 mm (spaced 500 mm) to provide fittings for integrated electrical sockets.

Easy installation The ProTrac system is very flexible, allowing components of several different lengths to be easily combined and connected. ProTrac can replace conventional fly-bars in theatres or other venues without any alteration of the existing installation. There is no need to make adjustments to the suspension cables or the complete fly-bar system: the steel wires of the existing system can simply be connected to the adjustable suspension points of the ProTrac components. Calculation methods used for ProTrac comply with DIN 56921.

1 Tube with slot profile 48,3 mm 2 Tube with slot profile 48,3 mm, with integrated rail fiting for Helm 100 runner 3 Tube with slot profile 60 mm, with integrated rail fiting for Helm 100 runner

Advantages • High loading capacity. Max. Point load of 350 kg on 4,5 m span possible • High Safety Factor: ProTrac has a Safety factor of 5 (on permanent deformation) and 10 (on failure) • Reduced horizontal bending. The lateral flex is less than 2 cm over 24 m length if full load is applied, nearby fly-bars will not be blocked • Very low inherent weight: ProTrac is 20 to 25% lighter than steel ladder beams, which offers extra load capacity for your scenery • Modular and flexible: ProTrac can be used in all theatres or other venues, without any adjustments or changes to the structural components • Compact build height: ProTrac has a build height of only 306 mm • Black stays black: ProTrac is anodised black • Enhanced safety; End-caps available in several colours

*ProTrac is a patented system

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ProTrac

Do NOT • Exceed the maximum allowable load given •C antilever the ProTrac more as stated in the structural report • Use damaged parts or suspension equipment

• Only use pre-tensioned steel wires for the suspension of fly-bars • Check the actual load on the fly-bar before the first movement • Check the suspension of the load to the fly-bar before the first movement • Make sure the fly path of loads or set pieces is not blocked • Make sure you use the right type of sheave for your steel wires • Only use tested and certified hardware • Keep a written logbook

Front view

Example: Winch / Hoist capacity 750 kg. Length of ProTrac = 24 m. Self weight ProTrac = 216 kg. Free loading capacity = 750 kg - 216 kg = 534 kg. Point loads: 2 x point loads of 267 kg. Max. Uniformly distributed load = 534/24 = 22,3 kg/m1.

500

2500-4500 (adjustable)

500

250

302

250

2500-4500 (adjustable)

149

2500-4500 (adjustable)

97,5

Connector view

• The given allowable loading is for the complete ProTrac system, and is equal for 48,3 mm or 60 mm lower tube. • The allowable loading is given for the ProTrac only. In a complete system winch capacity and total length also have to be taken in account. • The total weight of 2 point loads in 2 adjacent fields should not exceed the maximum allowable capacity of the suspension cable points. TECHNICAL SPECIFICATIONS ProTrac TYPES

UPPER PROFILE

LOWER PROFILE 48,3 mm LOWER PROFILE 48,3 mm LOWER PROFILE 60 mm + 1 + HELM 100 2 HELM 100 3

Alloy

EN AW 6082 T6 F28

EN AW 6082 T6 F31

EN AW 6005 F26

Profiles

60 diam.

48,3 diam.

60 diam.

Coupling system

bolts

Self weight

6,088 kg/m

1,944 kg/m

1,921 kg/m

2,534 kg/m

lx in mm4

6581770

133896

116630

222400

Wx in mm3

90437

5760

4160

7963

ly in mm

1074310

145635

160570

289000

Wy in mm3

36575

6350

6648

9999

Fig 1. Slide in lock and load block in upper profile.

Fig 2. Connection of upper to lower profile by means of stud bolts which are fastened with a self locking nut.

MAXIMUM DYNAMIC LoadS SPAN

MAXIMUM ALLOWABLE POINT LoadS

DISTRUBUTED Load

kg/m

lbs/ft

lbs

2,5

8,2

462,3

311,1

577,9

1275,4

433,4

956,6

288,9

637,7

239,8

529,3

2,7

8,9

396,1

266,5

534,7

1180,0

401,0

885,0

267,3

590,0

221,9

489,7 455,6

2,9

9,5

343,0

230,8

497,4

1097,7

373,0

823,3

248,7

548,9

206,4

3,1

10,2

299,9

201,8

464,9

1026,0

348,7

769,5

232,4

513,0

192,9

425,8

3,3

10,8

264,4

177,9

436,3

962,9

327,2

722,2

218,1

481,4

181,1

399,6

3,5

11,5

234,8

158,0

410,9

907,0

308,2

680,2

205,5

453,5

170,5

376,4

3,7

12,1

209,9

141,2

388,3

857,0

291,2

642,8

194,2

428,5

161,2

355,7

3,9

12,8

188,7

127,0

368,0

812,1

276,0

609,1

184,0

406,1

152,7

337,0

4,1

13,4

170,5

114,8

349,6

771,6

262,2

578,7

174,8

385,8

145,1

320,2

4,3

14,1

154,9

104,2

332,9

734,8

249,7

551,1

166,5

367,4

138,2

304,9

4,5

14,8

141,2

95,0

317,7

701,2

238,3

525,9

158,9

350,6

131,9

291,0

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Fig 3. The 60 mm lower profile with integrated rail profile fit for Helm 100 runners for 48H & 60H.

Fig 4. A completely assembled section of ProTrac.

Contents introduction 7 Litestructures 13 projects & installations 45 ProlyteStructures 49 StageDex 189 ProLyft 233

Prolyte Group Industriepark 9 9351 PA Leek The Netherlands

T: +31-594 85 15 15 F: +31-594 85 15 16 E: info@prolyte.com W:www.prolyte.com

Prolyte Products UK Ltd. Langthwaite Business Park, South Kirkby Wakefield, West Yorkshire, WF9 3NR United Kingdom

T:+44-1977 659 800 F:+44-1977 659 801 E:info@prolyte.co.uk W:www.prolyte.co.uk

Prolyte Products GmbH Rheiner Strasse 125 D 48282 Emsdetten Germany

T:+49 (0) 2572 954100 F:+49 (0) 2572 954105 E: info@prolyte.eu W:www.prolyte.eu

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