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ZIPPO Lifts - installation & operating instructions type
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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
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Documentation Data: 2-post lift type 2130 (H387), 2135
(H383),
2140 (H388), 2160 (H389) First edition 01.2006 Change of
06.2007
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TABLE OF CONTENTS
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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
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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:
.........................................................
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WORKS CERTIFICATE 2135 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, 07.024.2006 (Frank von der
Crone)
DATASHEET
Manufacturer: ZIPPO Lifts GmbH D-77656 Offenburg
Type: 2135 (H383)
Serial - No.:
Year of construction:
Day of initial operation:
.........................................................
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WORKS CERTIFICATE 2140 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, 18.04.2006 (Frank von der
Crone)
DATASHEET
Manufacturer: ZIPPO Lifts GmbH D-77656 Offenburg
Type: 2140 (H388)
Serial - No.:
Year of construction:
Day of initial operation:
.........................................................
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WORKS CERTIFICATE 2160 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, 18.04.2006 (Frank von der
Crone)
DATASHEET
Manufacturer: ZIPPO Lifts GmbH D-77656 Offenburg
Type: 2160 (H389)
Serial - No.:
Year of construction:
Day of initial operation:
.........................................................
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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)
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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.
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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).
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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
With long 3- part lifting arms min: 680mm max 1680mm
With long 3- part lifting arms min: 830mm max 1800mm
Lifting arm locking device:
Automatic locking of lifting arms
Automatic locking of lifting arms
Automatic locking of lifting arms
Automatic locking of lifting arms
Supporting pads
Rotary plate d=138mm pick up height: min: 80mm max: 110mm
Rotary plate d=138mm pick up height: min: 80mm max: 110mm
Rotary plate d=138mm pick up height: min: 88mm max: 115mm
Rotary plate d=140mm pick up height: min: 115mm max: 145mm
Spindle lifting nut system:
Electronic monitoring with potentiometer
Electronic monitoring with potentiometer
Electronic monitoring with potentiometer
Electronic monitoring with potentiometer
Operating panel:
1 control panel 1 air supply, 2 socket 240V
2 control panel 2 air supply, 4 socket 240V
2 control panel 2 air supply, 4 socket 240V
2 control panel 2 air supply, 4 socket 240V
Drive: Power: Connection value: Fuse protection:
2 alternating current motors 2x3 kW 400V AC 50 Hz 20 A
2 alternating current motors 2x3 kW 400V AC 50 Hz 20 A
2 alternating current motors 2x3 kW 400V AC 50 Hz 20 A
2 alternating current motors 2x3 kW 400V AC 50 Hz 25 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!
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Datasheet Type 2130 (H387)
We
rese
rve
the
right
to a
lter t
he c
onst
ruct
ion
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Datasheet Type 2135 (H383)
We
rese
rve
the
right
to a
lter t
he c
onst
ruct
ion
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Datasheet Type 2140 (H388)
We
rese
rve
the
right
to a
lter t
he c
onst
ruct
ion
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Datasheet Type 2160 (H389)
We reserve the right to alter the construction!
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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.
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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.
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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
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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.
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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
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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
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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
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ZIPPO Lifts - installation & operating instructions type
21XX Page 31 of 74 Version 02.2007
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!
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ZIPPO Lifts - installation & operating instructions type
21XX Page 32 of 74 Version 02.2007
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
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ZIPPO Lifts - installation & operating instructions type
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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
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ZIPPO Lifts - installation & operating instructions type
21XX Page 34 of 74 Version 02.2007
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
For example:
Anc
horin
g de
pth
Acc
ordi
ng to
m
anuf
actu
rer
Leng
th in
di
rect
ion
of tr
avel
wid
th in
dire
ctio
n of
trav
el
Min
. thi
ckne
ss
with
out f
loor
co
verin
g
Qua
lity
of
conc
rete
B
471
0-1
Anc
horin
g de
pth
see
man
ufac
ture
r
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
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ZIPPO Lifts - installation & operating instructions type
21XX Page 35 of 74 Version 02.2007
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)
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ZIPPO Lifts - installation & operating instructions type
21XX Page 36 of 74 Version 02.2007
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.
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ZIPPO Lifts - installation & operating instructions type
21XX Page 37 of 74 Version 02.2007
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
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ZIPPO Lifts - installation & operating instructions type
21XX Page 38 of 74 Version 02.2007
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.
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ZIPPO Lifts - installation & operating instructions type
21XX Page 39 of 74 Version 02.2007
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.
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ZIPPO Lifts - installation & operating instructions type
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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.
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ZIPPO Lifts - installation & operating instructions type
21XX Page 41 of 74 Version 02.2007
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
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ZIPPO Lifts - installation & operating instructions type
21XX Page 42 of 74 Version 02.2007
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.
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ZIPPO Lifts - installation & operating instructions type
21XX Page 43 of 74 Version 02.2007
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.
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ZIPPO Lifts - installation & operating instructions type
21XX Page 44 of 74 Version 02.2007
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
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ZIPPO Lifts - installation & operating instructions type
21XX Page 45 of 74 Version 02.2007
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.
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ZIPPO Lifts - installation & operating instructions type
21XX Page 46 of 74 Version 02.2007
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.
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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.
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Circuit Diagram
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Circuit Diagram with 2 Control Panels
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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.
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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
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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
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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!
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Safety Lock Device (blocks lifting after load nut failure)
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Load bearing nut testing
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New Safety Nut Measure for 2130-40 (H387, H383, H388)
Safety nut
Spindle
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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
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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:
________________________________________________________
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Declaration of Conformity
ZIPPO Lifts GmbH Heinrich-Hertz-Straße 21 D - 77656
OFFENBURG
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)
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ZIPPO Lifts GmbH Heinrich-Hertz-Straße 21 D - 77656
OFFENBURG
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
Signature: (Frank von der Crone)
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