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ZIPPO Lifts - installation & operating instructions type 21XX of 74 Version 02.2007

2-post lifts Types 2130, 2135, 2140, 2160

(H387), (H383), (H388), (H389)

Installation and Operating Instructions

Title page

ZIPPO Lifts GmbH · Heinrich-Hertz-Straße 21 · D-77656 Offenburg · Germany Tel. 0049 - (0)781 - 601 - 0 · Fax 0049 - (0)781 - 601 - 33 · E-Mail [email protected]

Version 02.2007


Documentation Data: 2-post lift type 2130 (H387), 2135 (H383),

2140 (H388), 2160 (H389) First edition 01.2006 Change of 06.2007


TABLE OF CONTENTS


WORKS CERTIFICATE 2130 4 WORKS CERTIFICATE 2135 5 WORKS CERTIFICATE 2140 6 WORKS CERTIFICATE 2160 7 Confirmation in accordance with §5 section 4 of the Accident Prevention Regulations for ”Electrical Appliances and Equipment” (BGV A2)) 8 Application Range and Appropriate Use 9 Safety Instructions 10 Product Description 17 Technical Data 18 Datasheet Type 2130 (H387) 19 Datasheet Type 2135 (H383) 20 Datasheet Type 2140 (H388) 21 Datasheet Type 2160 (H389) 22 Transport-Storage-Unpacking-Scope of Delivery 23 Important Information! 24 Notification of Damages in Transport 25 Foundation Plan and Power Supply (Customer) 26 Foundation 26 Floor fixing for lifts up to 4 to 27 Foundation work for lifts up to 4 to 28 Floor fixing for lifts starting from 4 to 29 Foundation work for lifts starting from 4 to 30 The most important designations according to the new concrete standard B 4710-1 31 Power supply 32 Fixing Specifications & Power Values 33 Assembly and Commissioning 34 Assembly 2nd Control Panel 36 Assembly wire link 36 Assembly of the Lifting Arms and the Arm Locking Device 37 Mechanical Synchronization 37 Operation of the Lifts in Practice 37 Description of the main board SGMX9 39 Preparation for the Initial Installation / Positioning of Lifting Carriages 39 Switches on the main board for EL lifts 40 Activation / Diagnostic Functions / Printed Circuit Board 41 Potentiometer Test 42 Malfunction Indication 42 Operating Modes 44 Circuit Diagram 47 Circuit Diagram with 2 Control Panels 48 Initial operation 50 Fault Finding / Problem Solving 51 Emergency Lowering 52 Control of the Safety Devices (Load Nut Failure) 53 Functionality of the Safety Lock Device 53 Testing of the Load Nut Wear 53 Safety Lock Device (blocks lifting after load nut failure) 54 Load bearing nut testing 55 New Safety Nut Measure for 2130-40 (H387, H383, H388) 56 Maintenance 57 Supply of Spare Parts 58 Declaration of Conformity 59 Warranty Card - Garantiekarte - Carte de garantie 63 Information for practising the visual and functional check 64 Spare parts 67 Certificates 69


WORKS CERTIFICATE 2130 Herewith it is certified that the supplied vehicle lift, according to our type description, corresponds to the title and tested construction sample. It was manufactured to the regulations of technology and can be used without alterations for its purpose to the regulations of the BGG945/BGR500.

ZIPPO Lifts GmbH - Offenburg, 07.02.2006 (Frank von der Crone)

DATASHEET

Manufacturer: ZIPPO Lifts GmbH D-77656 Offenburg

Type: 2130 (H387)

Serial - No.:

Year of construction:

Day of initial operation: .........................................................




DATASHEET


Type: 2135 (H383)

Serial - No.:






DATASHEET


Type: 2140 (H388)

Serial - No.:






DATASHEET


Type: 2160 (H389)

Serial - No.:




Confirmation in accordance with §5 section 4 of the Accident Prevention Regulations for ”Electrical Appliances and Equipment” (BGV A2)) It is herewith certified that the electrical equipment / the electrical appliances / the electrical installation of the machine or plant

Two-post vehicle lift type 2130 (H387), 2135 (H383), 2140 (H388), 2160 (H389) (Accurate details about type and location of installation)

Serial no. _________ corresponds to the regulations for Accident Prevention for ”Electrical equipment and electrical appliances” (BGV A2)

This confirmation serves exclusively the purpose of the owner’s / user’s exemption from the testing of the electrical equipment / the electrical appliances / the electrical installation before its initial operational use (§5 section 1,4 of the BGV A2). This confirmation does not include any guarantees under Civil Law, nor does it serve to cover liabilities.

Manufacturer or Installer of the equipment / appliances:

ZIPPO Lifts GmbH Heinrich-Hertz-Straße 21 D - 77656 OFFENBURG

Offenburg, 07.02.06 -------------------------------------------------------------------------- ---------------------------------------------------------------------- place and date (Frank von der Crone/CEO)


Application Range and Appropriate Use

The 2-Post lift has been tested for functionality and longevity. It is most economical and safe. It is up to you to make use of these advantages. This is best achieved through correct handling, good maintenance and good care of the lift. Please read the operating instructions carefully. It contains all necessary data and shows how easy it is to keep your lift in good working order. The lift is designed to lift motorised vehicles; it is not meant to transport persons. If the lift is used in car body shops, i.e. in rooms where solvents are used, please be aware of the danger of explosion. The standard engine is not protected against explosions. The lift is exclusively designed for lifting passenger cars or vehicles where the total weight does not exceed the maximum permitted carrying capacity of the lift and where stipulated acceptance points lie within the acceptance area of the lift. Your lift has been furnished with a safety device which guarantees safe operation when handled in accordance with the instructions. During installation and operation please pay attention to the functioning of the safety device and check this after each failure. Please make sure that a function test is carried out after each failure. Your vehicle lift should only be maintained and repaired by manufacturer trained specialists who possess the relevant certificate. Only original spare parts should be used. If other spare parts are used, the CE-conformity will be null and void. According to the regulations about the operation of vehicle lifts, lifting gear must be subjected to a safety test by an expert after one year at the latest. This test must be entered into the test report book. Please note, that only manufacturer trained specialists who are certified by the manufacturer as lift experts can test your lift and confirm its good functioning.


Safety Instructions

General Safety Instructions Owner’s Responsibility: The vehicle lift is constructed and built to legal standard and further technical specifications. It therefore corresponds to current technology and guarantees the highest degree of safety in operation. Please note, that the machine is only safe in action when all necessary measures have been met. It is the responsibility of the vehicle lift owner to plan and check that the regulations are adhered to. The owner is responsible for the following safety aspects: - The vehicle lift must only be used for its intended purpose - The vehicle lift must be kept in good functioning condition and

especially the safety equipment must be checked regularly to ensure that it is functioning reliably.

- Operating, maintenance and repair staff must be supplied with the necessary protective gear and it is essential that this is worn.

- The operating instructions must be kept in a legible condition and must be available where the machine is used.

- Only qualified and authorised personnel should operate, maintain and repair the machine.

- The personnel must be regularly informed about relevant operational safety and environmental protection issues and must know the operating instructions and above all the safety regulations contained therein.

- Any safety labels and warnings attached to the vehicle lift must not be removed and must be legible.


Basic Safety Measures during Normal Operation: The vehicle lift may only be operated by authorised personnel who has received special training, knows the operating instructions and is able to adhere to them. Before switching on the lift, the following must be checked and ensured: - that only authorised persons are present in the working area of

the lift. - that nobody can be injured when the lift is set in motion. - Before each use, the lift must be checked for visible damages

and it must be ensured that it is only operated in good condition.

- Faults must immediately be reported to the responsible member of staff

- Before starting to operate the machine it must be checked and secured that all safety equipment is in good functioning condition.

- Inspection and maintenance intervals stipulated in the operating instructions must be observed.

Basic Safety Measures during Maintenance and Repair: Before maintenance or repair work is carried out, the working area of the lift must be made inaccessible for unauthorised persons. A sign should show clearly that maintenance or repair work is in progress! Before maintenance or repair work is carried out, unplug the power supply or, if this is not possible, switch off at the main switch and secure it with a padlock. The key to this padlock should be kept by the person who carries out the maintenance or repair work. If heavy machine parts are to be exchanged, the load bearing equipment and buffer should be appropriate and in good condition. Any lubricants, coolants or cleaning agents which might endanger the environment, should be disposed of properly.


Electrical Work: Repair work on the electrical system of the lift should only be carried out by a qualified electrician. Electrical installations should be checked regularly. Loose connections should be tightened. Damaged leads / cables must be exchanged immediately. Keep housing of electrical installations closed at all times. Access is only permitted to authorised persons in charge of the key / tools. Housing of electrical installations must never be cleaned with a hose pipe.

Protection of the Environment: During all work with and on the vehicle lift the statutory regulations regarding the avoidance of waste and proper waste disposal must be adhered to. In particular during installation, repair and maintenance work, water contaminating materials must not be allowed to seep into the soil or into the sewage system. These include:

grease and oils oils for hydraulic systems coolants detergents containing solvents

Such materials must be kept, transported and collected in suitable containers and disposed of.


Practical Safety Instructions and Signs: The following operating instructions contain practical safety instructions in order to draw attention to any unavoidable remaining risks which might occur while the vehicle lift is in operation. Such remaining risks endanger

• people • products • the environment

The signs used in the operating instructions are there mainly to draw attention to the safety directions.

The sign points to danger for persons (peril of death or injuries)

This sign points to danger for machines, materials and the environment.

Danger – general sign

This sign is a reminder that the power supply to the housing must be switched off and locked so that it is secured against accidental switching on.

The most important aim of the safety instructions is to prevent injury to people. The respective applied sign cannot replace the text of the safety instructions. The text must always be read in full.

This sign does not relate to safety but gives information which should lead to a better understanding of the machine processes.


General Safety Instructions for Vehicle Lifts:

The vehicle lift must only be used for lifting vehicles in accordance with the technical data.

Only trained personnel may operate the system.

Safety devices must not be replaced.

Necessary repair work may only be carried out by instructed customer service personnel. Unauthorised alterations of the equipment exclude any liability by the manufacturer for any resulting damages.

Work on electrical installations may only be carried out by electricians.

The vehicle lift must not be operated in environments liable to explosions.


General Vehicle Lift Safety Instructions:

An uneven distribution of load on the front and back pick-up platforms should not exceed the listed ratio of the types: 1730 - 1730 CH and 1731 at a capacity of 3000 kg 3 to 2 and 2 to 3 and of types: 1735, 1735FL at a capacity of 3500 kg 2 to 1 and 1 to 2 The vehicle must always rest on all 4 supporting pads.

The vehicle must be picked up at the points stipulated by the manufacturer.

The vehicle and the lift must be observed during all vertical movements.

While the lift is operated, the danger area must be kept free. Travelling on or climbingup on the lift is not permitted. Persons under the age of 18 must not operate the lift.

The safety devices must not be changed in their position or function.

Repairs should only be carried out by authorised specialists.

The statutory accident prevention rules must be adhered to.

No work must be carried out on the vehicle during vertical movements.

The nominal load shown on the lift must not be exceeded.

After a brief lifting of the vehicle it should be checked that all lifting arms are securely bolted. If necessary, the vehicle should be lowered again and by a slight swinging movement of the lifting arm the bolt should slip into place.

During assembly and dismantling of vehicle parts the shift of the centre of gravity must be taken into account

Take care when vehicles are loaded! (other total weight and weight displacement)

If electrical welding on the vehicle or on the lift have to be done, please turn the main switch on position O


If the safety instructions are not observed there is a danger of injury!

Remaining Risks:

During vertical movements of the lift, no person is permitted to stand underneath a lifted vehicle or in the danger area. If this prohibition is not adhered to, there may be the danger of injury. The operator must be expressly instructed to activate the up and down switch only if no person is standing in the danger area.

The foot protection corresponds to statutory regulations, but this does not exclude all imaginable possibilities of injury, but only those which are probable according to experience. The operator must be instructed to activate the up and down switch only if no person is standing in the danger area. Before each use, the protective device of the lift must be checked for its perfect functionality.

If a vehicle has been picked up correctly onto the lift according to instructions, there will be no danger of accidents. If, however, the vehicle has not been picked up according to instructions, there is the danger of injury. Special care must be taken with loaded vehicles or in cases of shift of centre of gravity through mounting or dismantling of heavy parts. The operator has to be instructed to check the correct pick up of the vehicle before work commences.


Product Description This lift consists mainly of two equal lift columns which are driven by an electric motor: the control column with integrated base plate and the auxiliary column with an integrated base plate. There is no mechanical connection between the lift columns. Each of the columns contains lifting spindles and a lifting carriage with the load pick up devices. The two electrical motors drive the lifting spindles by means of a stable and low-noise ribbed V-belt. Integrated thermo-sensors in the motor coil winder act as an overload monitor. The various types of nuts are located on the spindles: -supporting nuts with safety nuts- which are connected with the two lifting carriages and, depending on the direction of the drive, carry out the up or down movements. The two lifting carriages are guided by six ball bearings in each column. The necessary synchronisation of the carriage is guaranteed by an electronic synchronisation control. In the event that the two carriages are not synchronic (for example, due to one-sided load, insufficient lubrication, etc.) the deviation will be adjusted by the synchronization control within a distance of approx. 10 mm. This is done by stopping the advanced carriage until the carriage which is lagging behind is at the same level again. This process can possibly be observed several times during the lifting. The drive is activated with the double push button on the control panel according to the movement symbols indicated; it is switched off via potentiometer in the upper and lower end position. After releasing the button it returns to position “0” automatically and the movement of the lift is stopped in each position of the load pick up device. The lift is equipped with safety devices like, for example, the protection against break of the supporting nut which will transfer the load to a free running safety nut in case of a worn thread. In this process a mechanical safety system is started, which prevents a restart. There is also an arm locking device which locks the lifting arms in their swinging movement after a stroke distance of approx. 15 mm from the basic position in order to avoid that the lifted vehicle slips of the load pick up device. The foot protection is activated via the potentiometer which stops the lowering of the load pick up device automatically in the danger area (200mm above the platform base). By pressing the button ”SENKEN” (down) again, the load pick up device can be brought back into base position. This lowering in the danger area will activate a warning signal tone. The thermo-sensor in the drive motors causes the motors to switch off when they are too hot and indicates when the lift can be used again after a drop of temperature (after approx. 10-15 minutes). An easily assembled pipe bend which is placed above the control column to the auxiliary column leads all electrical cables (power supply, monitoring and control cables) safely. The lifting arms are, depending on the type, single or double telescopic-like adjustable to the required working length. The long single telescopic lifting arms in drive on direction in the back and the short single or double telescopic lifting arms in drive on direction in the front. This ensures that the doors are free on both sides. The vehicle to be raised is to be placed in such a way that the front door hinges are in the area of the lift columns, so that a large door opening angle is created. The aim should be to direct the motor side of the vehicle towards the short lifting arms (centre of gravity of the vehicle should be at the centre of the lift if possible).


Technical Data Type 2130 (H 387) Type 21 35 (H383) Type2140 (H388) Type 2160 (H 389) Lifting arms:

With short 3- part lifting arms min: 420mm max: 880mm ------------------- and long 2- part lifting arms min: 830mm max 1340mm

With long 3- part lifting arms min: 650mm max 1330mm



Lifting arm locking device:

Automatic locking of lifting arms




Supporting pads

Rotary plate d=138mm pick up height: min: 80mm max: 110mm




Spindle lifting nut system:

Electronic monitoring with potentiometer




Operating panel:

1 control panel 1 air supply, 2 socket 240V




Drive: Power: Connection value: Fuse protection:

2 alternating current motors 2x3 kW 400V AC 50 Hz 20 A




Lifting height: 2005 mm

2005 mm

2005 mm

1905 mm

Lifting time: 35sec 35 sec 35 sec 45 sec Weight: 620kg 650kg 750kg 1000kg Capacity:

3.000 kg

3.500 kg

4.000 kg

6.000 kg

ED-operation: S3 S3 S3 S3 Sound pressure level:

78 dB(A)

78 dB(A)

78 dB(A)

78 dB(A)

We reserve the right to alterations of construction!


Datasheet Type 2130 (H387)

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We reserve the right to alter the construction!


Transport-Storage-Unpacking-Scope of Delivery Transport and Storage The packed lift should only be lifted at the appropriate points. Gripping the lift from below with a fork-lift truck can lead to costly repairs. The lift should not be stored outside. The lift should only be unpacked at its installation place. It has to be taken care, that the column isn't knocked or dropped, otherwise the spindle might become deformed and a smooth run is not guaranteed any more. Unpacking When the lift and the accompanying packages are unpacked, possible damages of transport should be noted and the carrier as well as ZIPPO Lifts GmbH should be informed immediately (see enclosed notification form). The individual parts must be laid out in such a way that nothing can be lost when the packing material is disposed of.


Important Information!

for our lift end customers in case of Damages in transit

Delivery Please check the goods immediately after delivery in the presence of the carrier. If the goods show damages of transport, the carrier must not be given a blank receipt. If necessary, note the damage on the haulage documents. Claim for damages: In order to ensure a quick and unproblematic claim settlement of the damage, each damage in transit must be reported immediately to the ZIPPO Lifts GmbH and the customer service partner after the damage has been noticed. The notification can be made by telephone, in writing or by fax / e-mail and must contain the following: No. of assignment on the ZIPPO Lifts GmbH-delivery note and date of delivery Type of lift and serial number Exact description of the damage

(If necessary, use the back side of this information sheet.) Rectifying damages and settlement The company ZIPPO Lifts GmbH- can only deal with transport damages if a damage claim, as described above, has been made. Repairs or deliveries of spare parts as well as the financial settlement of transport damages are handled by your ZIPPO Lifts service partner.


Notification of Damages in Transport On the lift Type: _____________________________________

Serial no.: _____________________________________

Delivered with Delivery note no.: _____________________________________

By Company: _____________________________________

Date: _____________________________________

The following damage was noticed: on delivery

during unpacking

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

(Accurate description of the damage)

The packing was damaged

not damaged

_________________________________ _________________________________

Place / Date Customer


F o u n d a t i o n P l a n a n d P o w e r S u p p l y ( C u s t o m e r ) Minimum foundation requirement: The surface of the base must be level and horizontal for all lifts. The subsoil must comply with the general building ground regulations (DIN 1054). For lifts which are installed outdoors, the foundation must be frost resistant. If the lift is not to be installed on solid ground, an engineer engaged in statical calculations must examine each case individually. The lifts are anchored with dowels.

If no adequate fixed subsoil with the necessary concrete strength class is existent, a foundation with the concrete quality C20/25 with reinforcement must be created.

Foundation Since the ZIPPO Lifts 2 post lifts are planned as “base frame free” lifts, the subsoil / the foundation is critical. The entire load (dead weight of the columns and weight to be lifted) are transferred to the foundation through the anchor bolts. Before installing the lift, it is essential to gain certainty about the available subsoil (see supplement floor fixing for lifts and BGG 945). When installing the lift on a suspended floor, the floor's suitability must be verified by a building expert. Only after checking the available subsoil, a decision can be made about the corresponding fixing system! The penetration depths of the anchors have to be followed (see instructions of the anchor manufacturers), since otherwise the safety of persons working below the lift may be compromised. The correct length (L) of the active part of the anchor bolt is obtained by adding the measurements ,,h" + thickness of the floorcover and height of the lies and the height of the installation base. Drill size and the tightening torque are in accordance to the bolt manufacturers instructions. To achieve a perfect installation, the concrete floor should be level and horizontal (min. C20/25, frost proof) with the corresponding load capacity.


Floor fixing for lifts up to 4 to B = floor thickness (21 cm)

h = anchoring depth of dowels in C20/25

s = thickness of ground covering until concrete

C20/25

t = thickness of component

g = threaded length

L = length of dowels

x = according to the indications of manufacturer

Length of dowels: L = h + s + t + g

Depending on the type of anchoring, use appropriately-sized washers for 21+1 mm drill holes in the base plate!

Subject to change without prior notice!

Measures in mm


Foundation work for lifts up to 4 to The foundation must be frost-protected and on grown earth! Single foundation Reinforcement

2130/2135/2140 X=384.3cm Y=256.8cm

Floor plate C20/25 thickness; d=>21 cm

necessary. aSX = 2,57 cm²/m lower reinforcement BST 500

necessary. aSX,Y = 3,77 cm²/m upper reinforcement BST 500 M Column fitting 2130-2135: for ex. Hilti HVA/HAS-M12x110 Liebig chemical anchor BLS 20/125 Column fitting 2140: for ex. Hilti HVA/HAS-M16x125 Liebig chemical anchor BLS 25/150 Important: Always follow the assembly Instructions and keep to the min, anchoring depths specified by the dowel manufacturers! Tests on existing concrete floor are necessary for anchoring!

Underground Permissible sigma B = 200 kN/m² C 20/25, BST 500 M Concrete f loor > 2,0 cm

Permissible sigma B = 150 kN/m² C 20/25, BST 500 M Concrete floor > 2,0 cm

120


Floor fixing for lifts starting from 4 to

B = floor thickness (21 cm)

h = anchoring depth of dowels in C20/25

s = thickness of ground covering until concrete

C20/25

t = thickness of component

g = threaded length

L = length of dowels

x = according to the indications of manufacturer

Length of dowels: L = h + s + t + g

Depending on the type of anchoring, use appropriately-sized washers for 21+1 mm drill holes in the base plate! Subject to change without prior notice!

Measures in mm


Foundation work for lifts starting from 4 to The foundation must be frost-protected and on grown earth! Single foundation Reinforcement

2160 depending upon setting up width X = from 398 cm to 433 cm Y = from 218 cm to 253 cm

Floor plate C20/25 thickness; d=>21 cm necessary. aSX = 2,57 cm²/m lower reinforcement BST 500 M

necessary. aSX,Y = 3,77 cm²/m upper reinforcement BST 500 M

Column fitting 2160: for ex. Hilti HVA/HAS- M16x125 Liebig chemical anchor BLS 25/150 Important: Always follow the assembly instructions and keep to the minimum anchoring depths specified by the dowel manufacturers! Tests on existing concrete floor are necessary for anchoring!


The most important designations according to the new concrete standard B 4710-1 Exposition classes (environmental classes)

X0 no corrosion risk, no frost;

XC1

XC2 corrosion caused by carbonation

XC3

XC4

X0 non-reinforced concrete, concrete in buildings with < 30% air humidity

XC1 concrete in buildings (flat, office), kitchen, bathroom, laundry;

foundations in the ground water

XC2 interiors with high air humidity, laundries, cattle sheds, indoor swimming

pools, not oppressive ground water, water pressure less than 2 m

XC3 water pressure height 2 to 10 m; seal concrete buildings

(in former times: WU)

XF1 Rain and frost strain for curved ( > 5 %) and vertical surfaces, all

backings with frost

XF2 concrete in case of frost and thawing agent (salt) for curved (< 5%) and

horizontal surfaces

XF3 rain and frost strain for horizontal surfaces; hydraulic engineerings

XF4 concrete in case of frost and thawing agents (salt) for horizontal surfaces

(in former times: FTB)

Concrete strength classes

The new strength classes are to be compared roughly as follows:

C8/10…………… B 8/B 80 C12/15…………. B 15/B 160 C16/20…………. B 20/B 225 C20/25…………. B 25


Power supply Electrical connections:

A lift operated by electrical power must have a fixed device at an easily accessible place, so that the lift can be safeguarded against unauthorised used when it is no longer in legitimate use (lockable switch to power supply).

Drive power: 2x 3 kW (without 230 V sockets) Power supply: 3 Ph, N, PE - 400 V 50 Hz Cable: 5x 2,52 mm Safety valve: 3x 20 A slow for type (2130-H387,2135-H383,2140-H388) (on site) 3x 25 A slow for type (2160-H389) Air plug: A permanent connection for air supply which can be turned off must be installed in a place which is easily accessible from the lift.

The supply cables can be lead directly to the column head of the control column or through a power channel in the foundation directly under the base plate of the control column.

Danger


Fixing Specifications & Power Values

Lifts: Type: Manufacturer:

Description of type: Piece:

Torque during anchoring:

Individual foundations foundation dimensions:

Concrete floor (hall floor) foundation characteristics

Power values

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Important: All securtites “slowly acting”

ZIPPO2130 ZIPPO2135

H387 H383

chemical anchor Hilti HVA/HAS-M12x110 (12 Pcs.) Liebig BLS 20/125/.. (12 Pcs.)

40 Nm 80 Nm

120cm 100cm 21 cm C 20/25 11,5cm 15 cm

400 V/ 50 Hz/ 3x20 A

ZIPPO2140 H 388 chemical anchor Hilti HVA/HAS-M16x125 (12 Pcs.) Liebig BLS 25/150/.. (12 Pcs.)

80 Nm 180Nm

120cm 100cm 21 cm C 20/25 13cm 15 cm

400 V/ 50 Hz/ 3x20 A

ZIPPO2160 H 389 chemical anchor Hilti HVA/HAS-M16x125 (12 Pcs.) Liebig BLS 25/150/.. (12 Pcs.)

80 Nm 180Nm

150cm 150cm 21 cm C 20/25 13cm 15cm

400 V/ 50 Hz/ 3x25 A

ZIPPO 8125 K H333 Fischer GM-10 (8 Pcs.) 150cm 200cm 15 cm C 20/25 400 V/ 50 Hz/ 3x20 A

ZIPPO8132 DSF

H398

Fischer GM-10 (8 Pcs.) Hilti HVA/HAS-M12x110 (8 Pcs.)

40 Nm

250cm 150cm 21 cm C 20/25 11,5cm 400 VI 50 Hz/ 3x20 A

The installation of the lifts is only admissible and will only be carried out if the minimum requirements of the fundaments indicated are fulfilled at the place of installation. The respective anchor manufacturers´ instructions must be followed! Subject to technical change without prior notice! Date 21.04.2006


Assembly and Commissioning Precondition for a correct installation is a level and horizontal concrete with a corresponding load capacity (minimum C20/25). First of all the posts are set up at their positions. The distance dimensions of the posts base plates are to be taken from the corresponding drawing.

In accordance with EN 1493 there must be a safety margin of minimum 500 mm between the lift columns and any other obstacle (wall, etc) and, similarly, between any lifted load and another obstacle.

After renewed checking of the set-up situation, the base plate is doweled through the existing drilled holes (the base plates must lie on with their entire surface!). Twelve anchor bolts M12 or M12 are needed which are to be chosen according chapter “Foundation”. Other anchor bolts can also be used that have been approved for the concrete by the building supervisory authorities. Dowels are not supplied.

Securely screw the base plates of the main column and the slave column. Torque of the screws see page 33.

The lift columns should be vertical; in no way they should lean inward. A slight outward lean (up to 10 mm) is desirable. If necessary, extra shims have to be placed between the column base plates and the floor for leveling purposes.

At the slave post are the connection cables to the main post. These cables are connected with the main post by an on site installed empty overhead conduit. When installing the cables it is important to ensure that the wires are not mixed up! Before commencing the electrical work, carefully read and observe the instructions regarding initial installation (following pages)! For further questions, ZIPPO Lifts-Service is available.

The electrical installation of the lift must be carried out by an electrical engineer and according to the enclosed circuit diagram and the VDE regulations 0100. The lift should operate in accordance with the travel direction symbols when the main drive switch is activated. If necessary, change the direction of turn by swapping around the 2 phases.

Important: Protective conductor checks must be carried out after initial installation, after repairs, after alterations to the installation, as well as prescribed according to the VDE regulations 0100!

Grease the pick-up bolts thoroughly. After fitting the lifting arms, check that the catch interlocks with the toothing of the lifting arm.

When the lift has been lubricated at the column according to the lubrication schedule and its operation has been checked (according to BGG 945) by a qualified engineer, then commissioning can begin.

Securing of the pick-up devices (e.g. lifting arms) against being inhinged unintentionally:

Secure the eye bearing with a hexagonal safety screw on the pick-up bolt so that there remains a gap of 1 to 2 mm between the eye and the screw head.

Attention: The self-securing screws only reach complete turning security after 24 hours.

The guide brackets for the tensioning belt have sufficient distance from the columns so that the tensioning belt does not get penned in and damaged. The guide brackets may need to be adjusted The spindles must be oiled and the spindle oilers at the lifting carriage are to be filled with ZIPPO Spindle Oil using the observation holes on the columns (order no: 21.30.041)


Attention! Before mounting the cover, assembly two washers to the thread bolt in order to avoid that the drive belt rubs against the cover.

If the flexible cover causes “buzzing“ noises during the lifting operation, it has to be lubricated with industrial grease on the back.

Test the upper and lower limit and the security stop by means of a test-drive or program them again respectively. After a functional check of the lift by a technical expert according to BGG945, the lift can be commissioned.

The results of the check must be recorded in the check book.


Assembly 2nd Control Panel

The auxiliary posts of the type family 21.. are equipped with a cover plate to which a second control panel with two plug sockets and an air connection can be mounted. In order to mount it the perforated part of the cover plate of the auxiliary post has to be quarried out and burred. The installation of the second control panel has to be carried out in accordance with the circuit diagram by an electrical specialist according to local VDE guidelines. In this case the supply has to take place at the auxiliary post! Now the control panel can be hinged into the recess at the auxiliary post and screwed with the cover plate (like at the main post).

Assembly wire link According to the following representation, first, the screws and washers of the motor holder have to be unscrewed. With respect to 2130-40 (H383/H387/H388), now the angle support is fixed to the main and auxiliary post as represented. Concerning the 2160 (H389), the angle support is screwed by means of the M8 hexagonal screw with the motor holder at the intended thread.

If a control panel is planned at the auxiliary post, the cables for the main switch, the supply, the potentiometers and sockets must be pushed through the pipe of the wire link altogether, starting from the auxiliary post. Then the two halves of the motor cover have to be mounted. Finally, the halves of the motor cover are fixed with pipe clips at the pipe of the wire link.

auxiliary post main post


Assembly of the Lifting Arms and the Arm Locking Device After fitting the lifting arms it is important that the tooth system of the catch latches and unlatches easily. The threaded bolt at the catch has to be adjusted in such a way that the catch is at least 2mm above the tooth system if the carriage is completely lowered.

Mechanical Synchronization The brake pad which is installed in the motor holding plate has to be pretensioned with a hexagon head screw so that the spindle at the big belt pulley can rotate with approximately 12 Nm torque (series 2130-40, H387/H383/H388) and 20 Nm (series 2160, H389) with assembled lifting arms. This approximates the power that is needed to rotate it by one hand.

Operation of the Lifts in Practice First, put the main switch in position „Ein“ (on). By using the control switch, the lift is moved according to the directions indicated by the arrows. After releasing the control switch, it returns automatically to the “Stop” position. Operation of the lift is only permitted to authorized and instructed persons! According to the accident prevention regulations, persons under the age of 18 are not allowed to operate the lift. Persons are neither allowed to travel on the lift nor in the vehicle to be lifted. See also operating instruction at the lift. In case of malfunction of the lift, the lift has to be directly decommissioned and secured against unauthorized use. Furthermore, the ZIPPO customer service or your supplier has to be informed. See also operating instructions at the control post! Before operating the lift, check that no persons are in the danger area, that no objects lean against the vehicle and that no objects are located below it. Attention: Some vehicles need higher pick-up supports. Therefore we offer accessories like a set of spacers in order to provide a secure pick up in special cases as well. Approach your supplier for further information. The gross vehicle weight rating must not exceed the permissible lifting capacity and load distribution.


Original ZIPPO Lifts accessories must be used as pick-up supports (parts tested for type examination). Logs of wood or other tools for pick-up are prohibited due to risk of accident. The vehicle should be positioned and lifted up so that its centre of gravity is in the middle between the posts. When demounting heavy parts of the vehicle, the shift of the gravity centre must be taken into account in order to avoid a crash of the picked up vehicle. The lift is only to be used according to its purpose as a vehicle lift. Other fields of application do not correspond to the designated purpose of use. The use as a lifting tool in order to lift heavy components like motors and other car parts is prohibited. The lifting arms are equipped with automatic arm locking devices which latch the lifting arms in their swivelling movement after a short lifting distance and release them again at a lifting height of 15mm during the lowering.

In order to assure a secure pick-up of the vehicle it must be lifted at the 4 points stipulated by the vehicle manufacturer. After a short lifting distance check the vehicle once again for secure pick-up.


Description of the main board SGMX9 Overview: The lift is equipped with an electronic control board. The upper and lower limits can be adjusted to required circumstances. The stored data can be adjusted to required circumstances. The stored data is permanent and will not be lost when there is no power. Attention! If the Jumper is placed in the bridge position the values will be lost.

During the first installation of the lift, it is necessary to check the adjustment of the upper and lower limits. If necessary, they have to be adjusted.

Required adjustments during installation: Adjustment of lower and upper limits, synchronization of both carriages, adjustment of the safety stop when lowering at a height of min. 200 mm above the ground.

Safety stop: When lowering the lift, the carriages stop at the programmed point. After pushing the down button again, the carriages continue to the lower limit. You can hear the warning noise during this operation.

Attention! During programming the lift, the automatic limits do not work - danger of collision in the upper and lower limits -. Take care of approx. 15 mm overrun.

Initial installation: Due to different local conditions and individual wishes, the different limits must be programmed.

Standard adjustments should be: The lower limit: Between the lowest point of the lifting arm and the ground, there should be at least 10 mm of space. The upper limit: Between the base plate and the lowest point of the lifting arm, there should be a maximum difference of 1900 mm. Safety stop: There should be a minimum of 200 mm between the lowest point of the lifting arm and the ground.

Preparation for the Initial Installation / Positioning of Lifting Carriages During the initial installation of the lifting carriages, or after repair, the lifting carriages have to be positioned approx. 10 mm higher than normally in their lowest position due to overrun. The lowering of the carriages can be done by means of the button up/down either individually or carefully together. Notice: The potentiometers are protected against mechanical damages by means of an electrical end stop. Therefore it is possible, that the lower limit cannot be reached by using the motor. In this case, after loosening the holder of the distance transmitter, the distance transmitter has to be pushed out of the toothing mesh. Now the carriage can be lowered by turning the pulley on top of the column. When reaching the intended lower limit of the carriage, turn the distance transmitter pinion clockwise (seen from above) until it reaches the mechanical stop. Then turn it back half a turn. The pinion will return to the locked position by exercising light pressure and the M6 safety screw of the distance transmitter holder has to be tightened. Make sure there is an undamaged spring washer under the screw head.


Switches on the main board for EL lifts

Switch on the electronic board for initial installations and programming

Switch position: Function: 0 Normal drive mode 1 Lower limit of carriage 2 Synchronization of carriages 3 Upper limit of carriage 4 Operating mode master column only 5 Operating mode slave column only 6 Security stop and acoustic signal when further lowering of the carriages 7 Potentiometer test mode 8* Connection, signal and EEPROM test mode 9 PC-operation mode in connection with PC-diagnosis software

*If you encounter any fault during these test modes, this fault will be stored on the EEPROM . The main board cannot be adjusted to normal mode in this case. If normal drive mode is selected, and a fault occurs during test mode, both red and green LED's flash. To overcome this situation, change defective parts or run test mode again. Programming (Initial installation of the potentiometer already done) Step:

Switch position:

Enter button:

Function:

A

4

push

operating mode master column only lower the carriage that approx. 10 mm are left between the lowest point of the pick-up device and 15 mm for overrun

B 5 push operating mode slave column only (as step A) C

1

push push

set lower limit after success of step A and B save mode

D

2

push push

synchronisation of carriages save mode

E

0

push

normal operation mode (both LED are red) move both carriages upward until maximum height of 1900 mm - possibly

F

3

push push

set upper limit after success of step E. save mode

G

0

push

normal operation mode (both LED are red) lower lift to a min. 200 mm above ground in order to set safety stop

H

6

push push

set safety stop after success of step G save mode

I

0

push

normal operation mode (both LED are red) programming finished. Caution! How to activate the control unit / successfully diagnosis test (switch position 8 necessary (see it later)

* If the above disconnecting point is not reached, continue in individual drive with position 4 and 5 Attention: No end stops !

push = both LED are green push = both LED are flashing


Important notice:

If you encounter big differences in voltage or any other problems, it might happen that the main board is shut down automatically for safety purpose. In this case the lift cannot be operated. In many cases, the main board can be reactivated by turning the main switch on and off.

The potentiometer connections P1 and P2 are not marked on the lift. The location of the components corresponds to this drawing. The wiring of the potentiometer connections must be carried out according to the colour scheme of the plan at hand. Incorrect wiring damages the potentiometers! When fitting a new EEPROM or circuit board or in the event of any unrecoverable interruption to the control sequence, carrying out the following steps can help! To activate EEPROM: 1. Main switch off 2. Place jumper in bridge position 3. Main switch on, diodes flash green / orange 4. Wait three seconds 5. Main switch off 6. Remove the jumper (place in non-bridge position) 7. Main switch on 8. Activate control; see: Activation of the diagnostic function 9. Reinstall limits and stop position (see above)

Activation / Diagnostic Functions / Printed Circuit Board

INSTRUCTION: The lift should be positioned in the middle in order to enable the necessary up and down movements of the test.

Activation of the diagnostic function by turning the code switch to position 8, and pressing the "enter" button. Subsequently, both LEDs will flash red / green and the buzzer will sound intermittently. The control requires the button “up” to be pressed.

Press the AUF (up) button. LED1 will show red. LED2 goes out. The safety circuit is checked. If this is all correct, LED1 goes out - LED2 shows red and the electronic relays for upward movement are activated. The lift goes up – both LEDs show red.

Press the AUF (up) button until the lift stops automatically. Release the button - both LEDs flash orange / green.

Press the AB (down) button, LED1 shows orange - LED2 goes out. The safety circuit is checked. If this contains no faults LED1 goes out- LED2 shows orange and the relays for downward movement are activated. The lift moves downwards - both LEDs shows orange.


Press the AB (down) button until the lift stops automatically. Release the button - both LEDs flash green.

Place the code switch in position 0 - press the enter button once - both LEDs show green - test okay – activation of the PC circuit board successful.

If the test runs successfully, a corresponding entry is registered with EEPROM. The lift can only be used normally in position "0" after the successful completion of this test.

If a fault occurs during the test the lift cannot be used in the position "0". A rerun of the test is only possible after cutting the mains voltage and repeating the above mentioned procedure.

Potentiometer Test Test the potentiometer against values in the relevant value range. Description: Activation of this operating mode by turning the code switch to position 7 and pressing the enter button. If the value of the main column potentiometer is in the relevant range, LED1 will flash green. If the value is greater than 97% it will flash red. If it is less than 3%, it will flash orange. If the value of the auxiliary column potentiometer is in the relevant range, LED2 will flash green. If the value is greater than 97% it will flash red. If it is less than 3%, it will flash orange.

Malfunction Indication Position 0: Normal operation Both LEDs show green if no buttons are pressed. If the “Aufwärts” (up) buttons are pressed, both LEDs show red. If the “Abwärts” (down) buttons are pressed, both LEDs show orange. The following faults are possible: PROBLEM: Both LEDs show red REASON: A fault has occurred in EEPROM SOLUTION: The parameters must be reset through the jumpers, and then the control must be aligned. If this does not solve the problem the control must be replaced. PROBLEM: Both LEDs flash orange / green at the same time REASON: The control mechanism must be initialized. SOLUTION: code switch in position 8 and carry out alignment. PROBLEM: One or both LEDs flash red / green alternately REASON: The minimum speed felt below the value SOLUTION: Turn the control off and on. If the fault occurs again, check the mechanics. PROBLEM: One or both LEDs flash red REASON: The upper limit of that particular column has been reached SOLUTION: The carriage of this column can only be moved in downward direction. PROBLEM: One or both LEDs flash orange REASON: The lower limit of that particular column has been reached SOLUTION: The carriage of this column can only be moved in upward direction PROBLEM: During the downward movement both motors stop suddenly, both LEDs,

however, show orange. REASON: The stop position is reached. SOLUTION: Release the button and push it again. PROBLEM: During the downward movement the alarm sounds REASON: The height is below the stop position SOLUTION: It is normal for the buzzer to sound during downward movement below the stop position.


PROBLEM: One of the motors stops a short moment during the movement, the corresponding LED shows green REASON: The control restores the synchronization of the columns SOLUTION: This behavior is normal PROBLEM: One or both LEDs flash red and the alarm buzzer sounds REASON: The upper limit of the corresponding column has been exceeded. SOLUTION: The lift must be realigned. Further operation is not possible. PROBLEM: One or both LEDs flash orange and the alarm buzzer sounds REASON: The lower limit of the corresponding column has been exceeded. SOLUTION: The lift must be realigned. Further operation is not possible. PROBLEM: Both LEDs flash alternately orange / red and the alarm sounds REASON: The maximum allowed tilt between the columns has been exceeded. SOLUTION: The lift must be realigned. Further operation is not possible. PROBLEM: After switching on, the buzzer gives three short sounds REASON: The internal real time clock is not set correctly SOLUTION: The clock must be set using the PC - configuration software. PROBLEM: LED1 is out. LED2 shows red REASON: The control has detected a defect in its programmable memory. SOLUTION: If the fault occurs again after a disconnection of the power supply, replace the EEPROM or the control circuit board. PROBLEM: Both LEDs flash alternately orange / green REASON: The parameters are not in the order: “LOWER LIMIT < STOP POSITION < UPPER LIMIT” SOLUTION: Realignment of the limits and the stop position according to the above mentioned rule


Operating Modes Position 4: Operating the main column directly 1. Turn the code switch to position 4 and press enter. The LEDs go out briefly while the button is pressed and flash green after release). 2. By pressing the “Hoch” (up) button, the carriage goes up. LED1 flashes red. 3. By pressing the “Runter” (down) button the carriage goes down. LED1 flashes orange. BEWARE: There is no control of the programmed limits. Position 5: Operating the auxiliary column directly 1. Turn the code switch to position 5 and press enter. The LEDs go out briefly while the button is pressed and flash green after release. 2. By pressing the “Hoch” (up) button, the carriage goes up. LED2 flashes red. 3. By pressing the “Runter” (down) button the carriage goes down. LED2 flashes orange. BEWARE: There is no control of the programmed limits. Position 1: Lower limits 1. Drive the motors by means of position 4 and position 5 to the desired lower limit. 2. Turn the code switch to position 1 and press enter. The LEDs go out briefly while the button is pressed and show green after release. 3. By pressing “enter” again the limits are programmed. The LEDs flash green alternately. 4. A further pressing of “enter” reconnects to point 2. The following faults are possible: PROBLEM: After carrying out point 3, both LEDs show red. REASON: The parameters could not be programmed into EEPROM so as to be secure against failure of the current. SOLUTION: Repeat alignment. If the problem occurs again, the control must be replaced. In this situation, press the “enter” button to return to point 2. Position 3: Upper limits 1. Drive the motors by means of position 4 and position 5 to the desired upper limit. 2. Turn the code switch to position 3 and press “enter”. The LEDs go out briefly while the button is pressed and show green after release). 3. By pressing “enter” again the limits are programmed. The LEDs flash green alternately. 4. A further pressing of “enter” reconnects to point 2. The following faults are possible: PROBLEM: After carrying out point 3, both LEDs show red. REASON: The parameters could not be programmed into EEPROM so as to be secure against failure of the current. SOLUTION: Repeat alignment. If the problem occurs again, the control must be replaced. In this situation, press the “enter” button to return to point 2. Position 6: Stop position 1. Drive the motors by means of position 4 and 5 to the desired stop position. 2. Turn the code switch to position 6 and press “enter”. The LEDs go out briefly while the button is pressed and show green after release. 3. By pressing “enter” again the stops are programmed. The LEDs flash green alternately. 4. A further pressing of “enter” reconnects to point 2. The following faults are possible: PROBLEM: After carrying out point 3, both LEDs show red. REASON: The parameters could not be programmed into EEPROM so as to be secure against failure of the current. SOLUTION: Repeat alignment. If the problem occurs again, the control must be replaced. In this situation, press the “enter” button to return to point 2.


Position 2 : Column difference 1. Align the motors with position 4 and position 5 as desired (height difference = 0). 2. Turn the code switch to position 2 and press “enter”. The LEDs go out briefly while the button is pressed and show green after release. 3. By pressing “enter” again the stops are programmed. The LEDs flash green alternately. 4. A further pressing of “enter” reconnects to point 2. PROBLEM: After carrying out point 3, both LEDs show red. REASON: The parameters could not be programmed into EEPROM so as to be secure against failure of the current. SOLUTION: Repeat alignment. If the problem occurs again, the control must be replaced. In this situation, press the “enter” button to return to point 2. Position 7 : Testing the potentiometer 1. Turn the code switch to position 7 and press “enter”. The LEDs go out briefly while the button is pressed. LED flashes orange – the corresponding potentiometer is in the non-permitted zone 0-3% LED flashes green – the corresponding potentiometer is in the permitted zone 3-97% LED flashes red – the corresponding potentiometer is in the non-permitted zone 97-100% Position 8 : Initialising the control 1. Turn the code switch to position 8 and press “enter”. The LEDs flash red / green and the buzzer sounds intermittently after pressing the button. 2. Press the up button and hold it pressed until the lift cuts out automatically. 3. LED1 shows red, LED2 is out. The relays for upward travel are activated. The lift must not move. The following faults are possible: PROBLEM: After carrying out point 2, LED1 flashes red. REASON: The lift has moved although the safety relay has not switched on. SOLUTION: Turn the control off and on. Repeat the test, check the wiring, and if necessary replace the control. 4. LED1 is out, LED2 shows red, only the safety relay is activated, the lift must not move. PROBLEM: After carrying out point 4, LED2 flashes red. REASON: The lift has moved although only the safety relay has switched on. SOLUTION: Turn the control off and on. Repeat the test, check the wiring, and if necessary replace the control. 5. LED1 and LED2 show red, the safety relay and the relays are activated for up. The lift must move upwards. PROBLEM: After carrying out point 5, LED1 and LED2 flash red. REASON: The lift has not moved although the safety relays and direction relays have switched on. SOLUTION: Turn the control off and on. Repeat the test, check the wiring, and if necessary replace the control. 6. Both LEDs show green. Release the “up” button. 7. The LEDs flash orange / green and the buzzer sounds intermittently after pressing the button. 8. Press “down” button and hold it until the lift switches off automatically. 9. LED1 shows orange, LED2 is out and the relays are activated for downward. The lift must not move. The following faults are possible: PROBLEM: After carrying out point 9, LED1 flashes orange. REASON: The lift has moved although the safety relay has not switched on. SOLUTION: Turn the control off and on. Repeat the test, check the wiring, and if necessary replace the control. 10. LED1 is out, LED2 shows orange, only the safety relay is activated. The lift must not travel. PROBLEM: After carrying out point 10, LED2 flashes orange. REASON: The lift has moved although only the safety relay has switched on. SOLUTION: Turn the control off and on. Repeat the test, check the wiring, and if necessary replace the control.


11. LED1 and LED2 show orange, the safety relay and the relays are activated for down. The lift must travel downwards. PROBLEM: After carrying out point 11, LED1 and LED2 flash orange REASON: The lift has not moved although the safety relays and direction relays have switched on. SOLUTION: Turn the control off and on. Repeat the test, check the wiring, and if necessary replace the control. 12. Both LEDs flash green. Release the down button, the test is complete, the control can be switched to position 0 again. NOTE: If the test under point 8 is not carried out completely then the lift can no longer be used

in position 0.


Circuit Diagram


Circuit Diagram with 2 Control Panels


Initial operation According to BGR 500 the initial operation must be done by a specialist in the presence of the owner/user. The specialist is obliged to instruct the owner/user concerning the use of the lift and to point out the dangers through wrong operation, the safety indications according to the current law and the behaviour in case of faults. It must be certified by the specialist in the enclosed check book. Drive the vehicle into the middle between the two columns. Swivel the lifting arms under the vehicle and position them under the points stipulated by the vehicle manufacturer. Take care that the vehicle is evenly placed on all 4 lifting pads. In cases where our standard turntables are not suitable for the safe pick-up of a vehicle (i.e. off-road vehicle), we recommend the wide range of accessories for special purposes. Please observe the operational safety regulations.

Raising The vehicle doors must be kept closed. Press the button”up” and observe the vehicle and the lift. When the vehicle wheels have lost contact with the floor (after a height of approx. 30 cm), the lifting process must be interrupted and the rubber turntables under the vehicle must be checked for safe positioning. Equally important is a visual inspection of the arm locking devices. The lifting process can be continued only after checking that the automatic toothed segments of the arm locking device are firmly anchored on each lifting arm / lifting carriage. Check that nobody is present in the danger area. Press the ”up” button until the vehicle has been lifted to the desired working height. When the lift has reached the upper limit, it stops automatically. During the raising process neither persons nor objects must be present in the working area. Avoid jerky raising actions.

Lowering Check the danger area. During the lowering process neither persons nor objects must be present in the working area of the lift or on the lifting platform. Press the button ”down”, observe the vehicle and the lift until the required height or the danger area of approx. 200 mm above the lift base position has been reached. At this height the lift stops automatically. If the button ”down” is pressed again, the lift can be driven back into its base position. During this lowering process in the danger area a warning signal tone is audible. If one of the lifting carriages advances, resulting in a tilt of the vehicle, a synchronization control decelerates the advancing motor until the lifting carriage which is lagging behind has reached the same level. During a working process the lift can undergo several alignments. Jerky lowering by tipping the lowering key must be avoided because this might cause extreme oscillation of the lift. When the lower limit has been reached the lift stops automatically and the lock of the arm locking device is released automatically. The lifting arms which are positioned under the vehicle loading points must be pushed together and swivelled back into their base position. Drive the vehicle out of the lift.

Note: The process described for the initial operation applies to each lifting and lowering process of the vehicle.


Fault Finding / Problem Solving If unusual faults occur at the lift, directly switch off the power supply, decommission it, secure it against unauthorised use and inform ZIPPO Lifts customer service. All repairs only must be be carried out by trained and qualified specialists.

As a general rule, the customer service should always be notified when faults occur!

Noises during lifting and lowering movements: Cause: Inadequate lubrication, worn spindle bearings, loose ribbed V-belt Solution: Lubricate spindles, check spindle bearings and renew them if necessary, tighten (replace) ribbed V-belt. Lift does not switch electrically anymore Solution: Check the load current switching elements as well as the motor on its function. Check the main switch, control circuit, micro-fuse as well as continuity check of the thermal switch in the engine coil. Lift does not lift the picked-up load, or the engine "hums" Check whether the permissible capacity of the lift is not exceeded. Check lubrication between load nut and spindle. Check electrical line for the electric motor, whether existing tension rests against all three phases, check protective contacts, check wedge rib belts. Lifting carriage and/or lift only raises approx. 100 mm. Solution: Examine the safety device, load nut is probably worn and the safety lock device switches off the lift mechanically, that means the mechanical safety lock device has began to work. Decommission the lift immediately, secure against unauthorized use and inform ZIPPO customer service. Arm locking device does not function. Solution: Examine the locking parts, examine the pressure springs, examine the locking rods for perfect fit and/or intactness. The lower and upper limits are not reached Solution: (see "positioning of the lifting carriages") If the control malfunctioned (see also page “emergency lowering”) 1. Turn the main switch to position “0” 2. Remove the cover of the control box and proceed in accordance with emergency lowering In cases of failure, which go beyond the mentioned points, the ZIPPO customer service has to be consulted. Repairs of ZIPPO lifts may be implemented only by authorized customer services. Only original "ZIPPO spare parts" should be used. If other parts are used the model homologation expires. - If the lifting carriages have an excessive overrun after disconnection 1. Test mechanical synchronization, if brake pads are worn out. There is a bore in the brake pad guide. If the lower edge of the brake pad can be seen, a new brake pad has to be assembled. 2. Preload hexagon screws with a tightening torque of 1,2 Nm, secure with safety nut Brake pad Brake pad worn out

Notice


Emergency Lowering Important: During the emergency lowering procedure the automatic end limits are switched off. Driving the

lift to the mechanical end points may cause damages. Notes: The procedure described below for the emergency lowering of the lift must only be undertaken

by authorised, trained personnel. A second person has to watch the procedure from outside the operating area to ensure the safety of the operator and vehicle.

The emergency lowering procedure must be terminated immediately, if any danger arises. Restarting the emergency lowering procedure is only allowed after removing the cause of danger. Just one lowering of the lift is permissible, whereas contact with the floor of the load pick-up device has to be avoided. Implementation of the emergency lowering procedure Emergency lowering using the motors might be necessary if the electronic control fail. If other elements fail, then the lift has to be lowered manually (by turning the bolt on the large pulley, just with dead-voltage lift). The main switch must be on the “0” position. According to the picture both contactors can be switched mechanical from 0 to 1 for a one-time emergency lowering. In case of not synchronized lifting arms, it is possible to synchronize the lifting arms by switching only one of the contactors from 0 to 1. All movements are to be done in small steps with caution. Operating the contactors – moving directions of the locking Through mechanical locking of the contactors, the emergency lowering can be carried out. Warning: No automatic end limits When reaching the maximum necessary lower position of the load pick-up device, the emergency lowering is to be stopped immediately. The lift can be used again, only after removing of all defects by authorised personnel. K1-contactor main column motor 1 up K2-contactor main column motor 1 down K3-contactor slave column motor 2 up K4-contactor slave column motor 2 down. It`s possible to use different contactors. ABB contactors Color: Black Condor contactors Color: Gray

K3 “up” slave column motor 2

K1 “up” main column motor 1

K2 “down” main column motor 1

K4 “down” slave column motor 2


Control of the Safety Devices (Load Nut Failure)

Functionality of the Safety Lock Device Your lift is equipped with a safety lock device that stops the operating lift once a load nut has failed. For explanation of the function of the safety lock device, please consider the following drawing. Fig. 2 and 3 show the position of the load nut and the safety nut, respectively, with the angled safety catch between the two nuts on the driving angles. These load carrying elements are enclosed within the lifting carriage and cannot be accessed from outside. When running the lift in normal operation, there is a safety clearance between safety nut and carriage which allows the safety nut to run unloaded. If the thread of the load nut is worn, the carriage falls on the so far unloaded safety nut and activates the safety lock which presses against the back wall of the column (see fig. 3). If the lift is on the safety nut, it can be lowered. If the carriage is moved upwards again, the safety lock catches on the bar on the back wall of the lift and stops the lift from rising. The locking mechanism must be disconnected not at all. If the lift stops about 10 mm above the ground level during an upward movement, the supporting elements are defect. After activation of the safety lock device the lift must not be used anymore before reparation of qualified personnel. Load nut failures can only be repaired by qualified lift engineers! To prevent load nut failure, the following check should be carried out periodically:

Testing of the Load Nut Wear With check nut “trapezoidal thread Tr45x6", available as special accessory (Art. No. 00.21.66). 1. Remove the tensioning belt, until the safety nut in the carriage can be seen. 2. Push the carriage upwards with the corresponding lever and hold it. 3. Put the check nut on the spindle; turn to the left, until the check nut is flush with the load nut. 4. Lower the carriage again 5. Measure the gap between the load nut and the check nut with a feeler gauge or vernier caliper. If the wear is more than 1mm, the load nut has to be replaced!


Safety Lock Device (blocks lifting after load nut failure)


Load bearing nut testing


New Safety Nut Measure for 2130-40 (H387, H383, H388)

Safety nut

Spindle


Maintenance The lubrication of the spindle has to be checked monthly. Check if the wicks are assembled and point into the right direction, possibly lubricate the spindle manually. The brake settings of the synchronization have to be checked monthly and to be adjusted if required. At normal use maintenance on the vehicle lift must be carried out once a year.

At more than average use, i.e. more than 20 lifting sessions per day, we recommend that maintenance is done every six months in order to maintain the safety and the value of the vehicle lift:.

• lubricate spindles, • lubricate lifting arms sections, suspension bolt and arm locking device, • check filling of the spindle oiler system and refill it if necessary, check anti-twist device, • check (or replace) rubber pad of the turntable, • check (or replace) function and condition of the arm locking device, ensure their smooth running • check function of the potentiometer, • check initial tension and conditions of the v-ribbed belts, readjust tension and if necessary replace them, • check all screws, • control of the fixing of anchors by using a torque wrench The exchange of load bearing parts and control components always has to be carried out by a technical expert to ensure that all prescribed setting values, which are necessary for a failure-free operation of the lift, are fulfilled. Otherwise the durability of the exchanged components and the overall functioning is limited.

For statutory inspections we recommend concluding a maintenance contract (safety check and maintenance) with one of our authorized customer service partners. Only he may place the “HAK” inspection plate and register in the check book which bindingly confirms the safety and function of the lift.

Notice

Notice


Supply of Spare Parts Indication of reparation services and purchase of spare parts

Customer service of the manufacturer:

ZIPPO Lifts GmbH Heinrich-Hertz-Straße 21

D-77656 Offenburg Germany

Telefon: 0049 – (0)781 – 601-0 Telefax: 0049 – (0)781 – 601-33

E-Mail: [email protected]

Customer service of the supplier: (Please insert stamp or address) Company: ________________________________________________________ Street: ________________________________________________________ City: ________________________________________________________ Telephone: ________________________________________________________


Declaration of Conformity


EC – Declaration of Conformity For EG – Machine Guidelines 98 / 37 / EC, Appendix II A

For Machine Types listed in Appendix VI

We declare herewith that the vehicle lift of the following detail has been designed, built and installed conforming to the current basic safety and health requirements as stated in the EC – Regulations. If any alterations of the vehicle lift are made which we have not agreed to, this declaration loses its validity. Designation of the lift: 2 - post lift Lift type: 2130 (H387) Machine - No.: Year of Construction: Current EC - Regulations: EC – Machine Guidelines 98 / 37 / EC EC – Guideline EMV 89/336/EEC i.d.F. 93/97/EEC Applied mutually agreed EN 1493 standards: EN 292-1 u. -2; EN 294; EN 349; EN 60204-1; Applied national standards and technical specifications: BGG945/BGR500; DIN 15018-1; BGVA2 DIN 31001 EC-Certificate- No.: 04 205-637/06 Rev.1 Testing institution: 0044 is responsible for keeping the documents in accordance with appendix VI of the EC – Guide Lines (98/37EC). Place: Offenburg Date: 07.02.2006

Signature: (Frank von der Crone)



EC – Declaration of Conformity

For EG – Machine Guidelines 98 / 37 / EC, Appendix II A For Machine Types listed in Appendix VI

We declare herewith that the vehicle lift of the following detail has been designed, built and installed conforming to the current basic safety and health requirements as stated in the EC – Regulations. If any alterations of the vehicle lift are made which we have not agreed to, this declaration loses its validity. Designation of the lift: 2 - post lift Lift type: 2135 (H383) Machine - No.: Year of Construction: Current EC - Regulations: EC – Machine Guidelines 98 / 37 / EC EC – Guideline EMV 89/336/EEC i.d.F. 93/97/EEC Applied mutually agreed EN 1493 standards: EN 292-1 u. -2; EN 294; EN 349; EN 60204-1; Applied national standards and technical specifications: BGG945/BGR500; DIN 15018-1; BGVA2 DIN 31001 EC-Certificate- No.: 04 205-637/06 Rev.1 Testing institution: 0044 is responsible for keeping the documents in accordance with appendix VI of the EC – Guide Lines (98/37EC). Place: Offenburg Date: 07.02.2006






We declare herewith that the vehicle lift of the following detail has been designed, built and installed conforming to the current basic safety and health requirements as stated in the EC – Regulations. If any alterations of the vehicle lift are made which we have not agreed to, this declaration loses its validity. Designation of the lift: 2 - post lift Lift type: 2140 (H388) Machine - No.: Year of Construction: Current EC - Regulations: EC – Machine Guidelines 98 / 37 / EC EC – Guideline EMV 89/336/EEC i.d.F. 93/97/EEC Applied mutually agreed EN 1493 standards: EN 292-1 u. -2; EN 294; EN 349; EN 60204-1; Applied national standards and technical specifications: BGG945/BGR500; DIN 15018-1; BGVA2 DIN 31001 EC-Certificate- No.: 44 205 06-3357 273 001 Testing institution: 0044 is responsible for keeping the documents in accordance with appendix VI of the EC – Guide Lines (98/37EC). Place: Offenburg Date: 07.02.2006






We declare herewith that the vehicle lift of the following detail has been designed, built and installed conforming to the current basic safety and health requirements as stated in the EC – Regulations. If any alterations of the vehicle lift are made which we have not agreed to, this declaration loses its validity. Designation of the lift: 2 - post lift Lift type: 2160 (H389) Machine - No.: Year of Construction: Current EC - Regulations: EC – Machine Guidelines 98 / 37 / EC EC – Guideline EMV 89/336/EEC i.d.F. 93/97/EEC Applied mutually agreed EN 1493 standards: EN 292-1 u. -2; EN 294; EN 349; EN 60204-1; Applied national standards and technical specifications: BGG945/BGR500; DIN 15018-1; BGVA2 DIN 31001 EC-Certificate- No.: 04 205-1184/06 Testing institution: 0044 is responsible for keeping the documents in accordance with appendix VI of the EC – Guide Lines (98/37EC). Place: Offenburg Date: 07.02.2006



Warranty Card - Garantiekarte - Carte de garantie Dear Customer, your decision in favour of a ZIPPO Lifts vehicle lift is well-founded. Being one of the biggest manufacturers specialized in vehicle lifts we have the necessary know-how. Many progressive developments -particularly in view of safety requirements - can be traced back to ZIPPO Lifts GmbH. As result of our advanced technology we render

a full-year guarantee

after take-over of the lift, at the following conditions: During the guarantee-period we remove all defects due to proved machining or material deficiencies. We alternatively repair or replace defective parts. Replaced parts become our property. Guarantee-claims can be approved only in case of immediate notification of the defect. Interventions on the lift of persons non-authorized by ZIPPO Lifts GmbH effect the nullity of the guarantee. Damages due to improper operation or servicing of the lift, use of unsuitable operation-agents, as well as non-observance of the operation instructions are not covered by the guarantee. Furthermore, all damages due to normal wear and tear, wear and tear ilself and breakable plastic accessories are excluded. All service charges originated in other means than guarantee are to be beared by the customer. Sehr geehrter Kunde, aus gutem Grund haben Sie sich für eine ZIPPO Lifts Hebebühne entschieden Als einen der größten Hersteller und Spezialist von Hebebühnen verfügen wir über jahrelange technische Erfahrung Viele richtungsweisende Entwicklungen - Insbesondere für die Sicherheit - sind auf ZIPPO Lifts GmbH zurückzuführen Das Ergebnis unserer ausgereiften Technik ist die Gewährung einer

Garantiezeit von einem ganzen Jahr

ab Übernahmedatum zu nachstehenden Garantie, und Gewährleistungsbedingungen: innerhalb der Garantiezeit beseitigen wir kostenlos alle Mängel, die nachweislich auf Fabrikations- oder Materialfehler zurückzuführen sind, wobei es unserer Wahl überlassen bleibt, ob wir die defekten Teile ausbessern oder durch andere ersetzen. Ausgetauschte Teile gehen in unser Eigentum über, Garantieansprüche können von uns nur dann anerkannt werden, wenn uns der Mangel unverzüglich nach Feststellung gemeldet wird. Eingriffe nicht von uns bevollmächtigter Personen in das Gerät lassen jeden Garantieanspruch erlöschen. Schäden, die durch unsachgemäße Behandlung und Wartung, Verwendung ungeeigneter Betriebsmittel, sowie durch Nichtbeachtung der Bedienungsanleitung entstehen, werden von der Garantie nicht umfaßt. Ausgeschlossen sind auch Schäden, dieinfolge betriebsbedingter Abnutzung auftreten. Verschleißteile, elektrische Sicherungen, sowie zerbrechliche Zubehörteile aus Kunststoff oder Glas sind nicht im Garantieumfang enthalten. Cher Client, de bonnes raisons vous ont amene a porter votre choix sur un pont elevateur ZIPPO Lifts GmbH. En tant qu'un des plus grands fabriquants de ponts elevateurs nous possedons une longue experience technique dans ce domaine. ZIPPO Lifts GmbH - est ä l'origine de nombreuses constructions qui ont marque l'evolution des ponts elevateurs. principalement en ce qui concerne la securite. Le resultat de notre technique eprouve est l'octroi de

une annee de garantie ä partir de la prise en possession, aux conditions suivantes: Pendant la periode de garantie. nous eliminons tout defaut provoque par un vice de fabrication ou une defectuosite de pieces prouves. Nous nous reservons le choix entre la reparation ou le remplacement des pieces defectueuses. Les pieces remplacees deviennent notre propriete. La garantie ne peut etre accordee que si le defaut nous est Signale des sä constatation Toute Intervention sur l'appareil par des personnes non-autorisees par ZIPPO Lifts GmbH - entraine la cessation des droits de garantie. La garantie ne couvre pas des dommages dus ä l'utilisation non.approgriee de l'appareil ou de produits necessaires ä son fonctionnement, ä l'entretien non.approprie ou ä la non - observation de la notice de montage et de fonctionnement. Sont exclus egalement des dommages apparus par suite ä l'usure due au fonctionnement normal de l'appareil, pieces d'usure et accessoires fragiles en matiere plastique. Les frais de deplacement et le temps passe sont ä la Charge du client. si la visite apres-vente n'est pas justifiee par la garantie.


Information for practising the visual and functional check Within the scope of the regular inspection according to chapter 5.4,3 part 2 of the BG-principle Within the scope of the regular inspection the following has to be checked particularly:

1. details of the lifts test object name plate inscription installation and operation instructions

attachment readability completeness

2. extensive operating instructions status readability

3. warning designation status visibility

4. protection against unauthorized usage

status function mobility safety key

5. emergency cutout emergency lowering

status function mobility

6. signalling devices, facilities for communication

status function visibility reliability

7. facilities for stable assembly supports

status function wear deformation corrosion cleft

8. supporting structure clefts deformation corrosion well-running of leads, roller bearing, pivots, telescope, wear between leads, roller bearing, pivots, bearing attachment and safety of removable connections functionality of the closing

9. load pick-up device slip off securing roll off securing holding facilities pivot arm securing

status function

10. steel wire cable cable connections

wear corrosion wire fracture concentrated wire fracture squeezed points loosening of the outside layer distortion

pulley clefts wear burr formation at the pulley correct alignment of the pulleys

cable winding tensioning device safety device against cable slip-off

status function


11. spindle arrangement deformation dirt thread wear notches scoring groove, material application functionality of the cover

load nut thread wear (play) compensating ring storage

status notches scoring

12. hydraulics leak points leak tightness test deaeration

oil supplies status and readability of the advertisement, control of the oil quantity functionality of the cut-off facility if oil need

conduits connections

arrangement damage deformation corrosion

tube tube connections

arrangement damage age brittleness porousness

cylinder arrangement cleft pipe - and flexible tube connection closeness of the collar

piston surface of the piston rod scoring dirt accumulation

filter outside status pressure control valve outside status

leaden seal undamaged 13. pneumatic conduits connections

leakage arrangement damage deformation corrosion

tube tube connections

arrangement damage age brittleness, porousness

cylinder arrangement, cleft, pipe - and tube connections closeness of the collar

piston surface of the piston rod, scoring, dirt accumulation emergency valve outside status, leaden seal undamaged manometer, pressure reducer outside status, effectiveness 14. driving gear (no- traversing) connections between driving gear starting without jerk brakes, self-locking gear, coupling wear

functionality 15. chassis suspension, no- traversing service brakes, fixing brakes wear, functionality Drawbar safety device status, functionality 16. electrical installation wires damage, arrangement, mains lead cleat outside wire protective conductor damage, arrangement


Isolation lift /lifting arrangement lifting arrangement / running gear

dirt, damage, isulating resistance

17. special safety devices emergency stop, slack rope switch, slack chain switch, rope breakage switch chain breakage switch, switch-off safety rail, restart safety lock device, tilting safety device, safety catch, completeness

functionality, arrangement, status deformation, well running of the control element dirt accumulation, status of the pressure spring

These references do not claim for completeness and have to be adjusted to the respective lift to be checked. BGG 945-1 test book for post lifts (up to ZH 1/491) association of industrial employer's liability insurance association technical board " conveyor and load suspension means" of BGZ Juli 2001


Spare parts Seq. No. ZIPPO Part-Nr.: Description:1 21.30.006 Door stop 2130-40 (H387, H383, H388)1 21.60.006 Door stop 2160 (H389)2 21.30.003 Lifting arm safety hexagonal screw (4 pieces)3 21.30.004 Lifting plate complete vertical adjustable (1 set for 1 arm) short 3 21.60.004 Lifting plate complete vertical adjustable (1 set for 1 arm) 4 21.30.021 V-Belt pulley small (motor)5 21.30.020 Belt 2130-40 (H387, H383, H388)5 21.60.020 Belt 21606 21.30.028 Supporting ring (spindle up) 2130-40 (H387, H383, H388) 6 21.60.028 Supporting ring (spindle up) 2160 (H389)7 21.30.048 Cover plate 2130-40 (H387, H383, H388)7 21.60.048 Cover plate 2160 (H389)8 21.30.018 Motor cover left 2130-40 (H387, H383, H388)9 21.30.019 Motor cover right 2130-40 (H387, H383, H388)8 21.60.018 Motor cover left 2160 (H389)9 21.60.019 Motor cover right 2160 (H389)10 21.30.008 Carriage guide rollers laterally (4 piece) 2130-40 (H387, H383, 10 21.60.008 Carriage guide rollers laterally (4 piece) 2160 (H389) 11 21.30.001 Telescopic swing arm asymmetric long 2130 (H387) 12 21.30.002 Telescopic swing arm asymmetric short 2130 (H387) 11 21.60.001 Telescopic swing arm right 2160 (H389)12 21.60.002 Telescopic swing arm left 2160 (H389)13 21.30.034 Lifting nut cpl. (1 set for 1 column) 2130-40 (H387, H383, H388)13 21.60.034 Lifting nut cpl. (1 set for 1 column) 2160 (H389)14 21.30.035 Lifting nut accessory15 21.30.007 Carriage guide rollers rear (2 piece)16 21.30.010 Fitting screw. (1 Set= 2piece) 2130-40 (H387, H383, H388) 16 21.60.010 Fitting screw. (1 Set= 2piece) 216017 21.30.009 Arresting device 2130-40 (H387, H383, H388)17 21.60.009 Arm locking assembly 216018 21.30.045 Drive belt cover cpl. 2130-40 (H387, H383, H388) 18 21.60.045 Drive belt cover cpl. 2160 (H389)19 21.30.025 Lifting spindle 2130-40 (H387, H383, H388)19 21.60.025 Lifting spindle 2160 (H389)20 21.30.005 Carriage cpl. 2130-35 (H387, H383)20 21.40.005 Carriage cpl. 2140 (H388)20 21.60.005 Carriage cpl. 2160 (H389)21 21.30.017 Motor fixing plate 2130-40 (H387, H383, H388)21 21.60.017 Motor fixing plate 2160 (H389)22 21.30.022 V-Belt pulley large 2130-40 (H387, H383, H388) 22 21.60.022 V-Belt pulley large 2160 (H389)23 21.30.036 Control 24 21.30.026 Fixing of the spindle2130-40 (H387, H383, H388) 24 21.60.026 Fixing of the spindle 2160 (H389)25 21.30.027 Spindle bearing up and down cpl.25 21.60.029 Spindle bearing up cpl. 2160 (H389)25 a 21.60.027 Spindle bearing down cpl. 2160 (H389)25 b 21.60.030 Bearing inlay 2160 (H389)26 21.30.030 Potentiometer cpl27 21.30.031 Fixing of the Potentiometer28 21.30.015 Motor with cable 2130-40 (H387, H383, H388)29 21.60.015 Motor with cable 2160 (H389)29 21.30.037 Control circuit board30 21.35.001 Telescopic swing arm (symmetric) 2135 (H383)30 21.40.001 Telescopic swing arm (symmetric) 2140 (H388)31 21.30.023 Synchronization32 21.30.046 Data plate33 21.30.047 Operations instruction sticker


34 21.30.040 Spindle oiler 2130-40 (H387, H383, H388)35 21.60.040 Spindle oiler 2160(H389)35 21.30.041 Spindle oil36 21.30.016 Motor cable auxiliary side 10 m37 21.30.032 Potentiometer-cable operating side; 3 wire38 21.30.033 Potentiometer-cable auxiliary side 10 m ; 3 wire39 21.30.042 Oil sucking cloth40 21.60.003 Securing spring 2160 (H389)41 21.60.031 Grooved ball bearing (spindle down) 2160 (H389) 42 21.60.032 Ground plate43 21.30.014 Brake pad 13 x 22 mm Version June 2007 / subject to change without prior notice!


C e r t i f i c a t e s


Anlage 1 zum Zertifikat Nr.: / Annex 1 to Certificate No. 04 205-640/06 Rev. 1

Aktenzeichen: l File reference 2.4-124/06

Type name: Vehicle lift type: 2130

Capacity: 3000 kg


Control board: SGMX9

Power supply: 400 V, 50 Hz


Capacity: 3500 kg






Capacity: 4000 kg




Drive: electromechanical

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