Synrowinch 400, 500

SW400
SW500
SW500M
Hoist for suspended platforms
Operating and maintenance manual
Prior to using this hoist, all persons concerned must have read
and understood this manual.
PLUMETTAZ SA
Zone industrielle “En Vannel C”
CH-1880 BEX
Switzerland
Tel. + 41-24 463 06 06
Fax +41-24 463 06 07
Internet: http://www.plumettaz.ch
598.069-E V2.0
SW400 SW500 (M) / Operating and maintenance manual 2/25
Contents
1 Introduction 3
2 Description 3
3 Integration of the winch in the platform 4
3.1 MECHANICAL ATTACHMENT OF THE WINCH TO THE PLATFORM 5
3.1.1 Attachment to the platform floor 1 6
3.1.2 Lateral attachment 2 6
3.1.3 Protections and cowling 6
3.2 LIFTING LIMIT 7
3.3 CONNECTION AND FUNCTION OF THE ELECTRIC ELEMENTS 7
3.3.1 Connection box 7
3.3.2 Switches and control elements 8
3.3.3 Stop programmer (optinal) 9
3.3.4 Electric power elements 9
3.3.5 Electric diagram 9
3.3.6 Service mode 10
3.3.7 Installation mode 10
4 Operating instructions 11
4.1 USER’S COMPETENCE LEVEL 11
4.2 APPLICATION LIMITS 11
4.3 INADEQUATE USE 11
4.4 STEEL-ROPES 11
4.4.1 Installing the steel-ropes 12
5 Safety prescriptions 13
5.1 IN CASE OF SAFETY BLOCKAGE 13
5.1.1 Rope rupture 13
5.1.2 Stop due to the mechanical tilt limiter 13
5.1.3 Manual interlocking of the block stop. 14
5.2 EMERGENCY DESCENT 14
5.3 MANUAL LIFTING 14
5.4 EMERGENCIES 15
6 Technical data 15
7 Inspections and check-ups 16
8 Setting and adjustment. 17
8.1 BLOCK STOP SWITCHES 17
8.2 ADJUSTMENT OF THE LAYERING ARM STOPS 18
8.3 OVERLOAD SETTING 19
8.4 CABLE TENSION 19
9 Maintenance 20
9.1 INSTRUCTION OF HANDLING 20
9.1.1 Transport measurements 20
9.1.2 Lifting point 21
9.2 MAINTENANCE INSTRUCTIONS 22
9.2.1 Winch 22
9.2.2 Electrical motor 22
9.2.3 Centrifugal brake 23
9.2.4 Layering arms poulies 24
9.2.5 Safety block 24
10 Identifying of troubleshooting 25
© 2004 by PLUMETTAZ SA CH-1880 Bex Emission : JPR Approbation : MC Date :19.05.2004 598.069-E Version : 2.0
1 Introduction
This document deals exclusively with the Syncrowinch Type SW400, SW500 and
SW500M; the documents concerning the additional equipment are attached
hereto.
This hoist was designed for the lifting and lowering of suspended maintenance
platforms (SAE, Suspended Access Equipement), for permanent, (BMU,
Building Maintenance Unit), and/or temporary application (TSP, Temporary
Suspended Platforms) and complies with the European Norm EN 1808 for built-
in platform winches.
This manual is one part of the Synchrowinch machine and must be
handed out to the final user of the SAE.
A detailed description of the machine is to be found in the document Technical
Description.
For any technical problems, warranty inquiries or spare parts orders, you are
kindly requested to indicate the serial number and machine number marked on
the SW identification plate (see arrows).
2 Description
The Syncrowinch machine is set up of :
• A winch with two drums - each coiling one steel-rope - providing for hoisting and rope storage. The winch is driven by
an electric motor.
• Two rope layering arms, with a built-in overload sensor system.
• A safety block
• A frame holding the various elements together.
3 Integration of the winch in the platform

20 20
85
1000
SW500M 1380
SW400/500 1370
135.5
94
170.5
472
124
1626 166
160m
0m
or
9
528 f
or
335
3 f
46
70
518
230
3.1 Mechanical attachment of the winch to the platform

The winch is fastened at the end of the platform on three points :
- 1 Two flanges hold the « feet » of the frame to the platform floor.
- 2 A lateral attachment plate fastens the upper part of the frame to the platform structure.
All the attachment accessories (screws included) are originally furnished with the SW400; attachment with other components is
strictly prohibited !
1 2
1
2 3
max 13mm
4 3
3.1.1 Attachment to the platform floor 1

The two flanges bear all the vertical load, each flange has two sets of screws, washer and nuts.
The frame must rest on the full length of its feet.
The fixing screws must traverse the platform through a hole of max. 13mm diameter, with a minimal full material of 50mm
diameter, the thickness must be at minimum of 15mm and maximum 20mm.
The minimal resistance of the material must be comparable to that of aluminium.
Total load borne by the two flanges :
Total load in normal working conditions SW400 Fn400=4’320N SW500 Fn500=5’570N
In exceptional emergency situation (rope rupture) SW400 Fn400 max=10’000N SW500 Fn500 max=12’000N
3.1.2 Lateral attachment 2

This attachment point (two bolting) is subjected to a maximal load when the safety block activates an emergency
stop in case of platform over-tilt.
This maximal load is SW400 Fl-400 = 1’500N SW500 Fl-500 = 1’900N.
Characteristics of the attachment points :

1 Galvanized hexagon head screw ISO 4017 M10x45 quality 8.8
2 Steel washer DIN433 10.5/18x1.6
3 Torque prevailing nut DIN6926 ISO 7043 M10 Resistance grade 8
Tightening moment of the bolted joint Mt =40Nm
3.1.3 Protections and cowling

It is the platform manufacturer’s concern to adapt the necessary safety protections for the platform users.
All moving parts and the steel-rope trough must remain inaccessible but visible from inside the platform and from the top of the
winch.
The outer part of the winch must be completely hooded and shock resistant.
However, these protections must allow access to the maintenance and control elements.
From inside the platform:

• The rope attachment of the inner drum
• The end-of-rope switch, for controls
• The inner rope layering arm and the overload sensor system
From outside the platform:

• The outer rope attachment
• The rope layering arm pulleys
Recommendations:
Do not cover the overload alarm
Protect the terminal box from direct water splashes; the motor casing, however, should remain free for heat exchange.
3.2 Lifting limit

The SW is fitted with a lifting limit sensor and an ultimate lifting limit sensor, however the sensor plate fitted on the steel-ropes is
not included in the basic equipment.
It must be adapted to the position of the sensor rod by the platform manufacturer.
95mm 94mm 65mm
3.3 Connection and function of the electric elements

The Syncrowinch is fitted with the norm required electrical sensor elements and a motor brake.
These components are wired and connected to the connection box.
For the connection use the plug provided with the machine.
3.3.1 Connection box
Connector
Terminal Box
Overload alarm
Cable seal
3.3.2 Switches and control elements
Pos. Element Switch type Category EN 1808 Function
1 Overload sensor 1 8.3.5.3 • In service, must be sensed going

up, down or standing still. Must impede
any movement except descent until
overload is suppressed.
8.3.5.7 • Ringing alarm
2 Slack rope sensor 1 B 8.9.2.8 Main power contactor switched off
Roller plunger
3 Slack rope sensor 2 Slow action B 8.9.2.8 Main power contactor switched off
1x NO 1x NC
4 End-of-rope sensor 1 8.6.2.3 Winch power supply turned off
5 Cable tension sensor No norm According to mode

requirements
6 Lifting limit switch B 8.3.10.1 Lifting impeded, descent possible
7 Ultimate lifting limit switch Roller lever 1 8.3.10.5 Winch power supply turned off
Slow action 1x NO 1x NO
6
Lifting limit switch
7
Ultimate lifting limit switch
2
3 Slack rope 1 + anti-tilt detection
Slack rope detection 2
8 5
Automatic stop device Cable tension detection
1
Overload detection device
Service brake
Electrical motor 1 kW 1500rpm
End of steel wire rope 1 detector

4
3.3.3 Stop programmer (optinal)
Not included in basic equipment (available on option)

Option N°1 Wired sensor with magnetic ring and attachments.
Option N°2 Counter with 6 programmable pre-settings.
3.3.4 Electric power elements
Motor
Voltage: 230 / 400V
Frequency: 50Hz
Power: 1kW
Nominal current: 4 / 2.3A
Protection: IP 54
Electromagnetic brake
Connection voltage: 230 VAC
Voltage on bobbin: 195 VDC
Built-in rectifier in terminal box
3.3.5 Electric diagram
3.3.6 Service mode

Defined by the requirements of the platform manufacturer.
3.3.7 Installation mode

When installing or removing a platform, the operator will be able to use the motor to wind or unwind the steel-ropes of the
winch.
When steel-ropes are under tension, the layering arms pivot until they touch the rope tension sensor (Position N°5), and the
motor will start rotating.
A rotating knob should permit to select this mode, and the direction of the motor rotation.
This mode may only be operational when the descent limit is activated, it must also be operational when the slack rope sensors
(pos 2 and/or 3) are activated.
4 Operating instructions
It is obligatory to install the SW400 or 500 by pairs on a suspended platform (one on each side); the four steel-rope ends are
fixed to the building structure.
For single point suspended platform, only the ”SW 500 M” type is adapted.
4.1 User’s competence level

Description of action Level of instruction and minimum subject knowledge
Normal operation of the machine Qualified operator (person having been instructed on how to operate and
control this equipment)
Installation Qualified installer
Safety controls Qualified operator
Weekly control Qualified installer
Half-yearly control Qualified installer
Test travels Qualified installer
Electrical connections and controls Qualified electrician
Maintenance Qualified personnel
4.2 Application limits

• Steel-rope of less than 6.3mm diameter
• The maximal rope storage capacity of the drums must be observed
• Do not exceed the maximum load
• Minimum ambient temperature –10°C, maximum +55°C
4.3 Inadequate use

• Partial removal or removal of machine components
• Any working position other than vertical (steel-ropes exiting upwards)
• Operating in explosive or corrosive atmosphere, highly magnetic fields, ….
• Any usage not described in the introduction is prohibited
• The installation of an SW combined with a machine of another manufacturer or type
• It is obligatory to replace all damaged components by parts originating from Plumettaz SA
• Using another type of steel-rope
4.4 Steel-ropes
Steel-rope type: Steel-rope of 6.5mm diameter 0/+3%, original parts from 6x19, steel core, galvanized,
Minimal rupture load 24’000N
A good winding quality and optimal function of the safety block can only be guaranteed when an original steel-rope
furnished by Plumettaz is being used.
Criteria for steel-rope replacement : The steel-rope must be changed when following damages are observed during a
check-up or when starting an operation :
Steel-rope diameter under 6.3mm
One ruptured strand
More than 10 broken wires over a length corresponding to 30 times the diameter
Large spots of corrosion on the surface or inside
Rope deformation such as rope basket, kink, bend, ...
We recommend:
• Keep the steel-rope certificates
• Do not grease the steel-ropes
• Register the number of service hours
4.4.1 Installing the steel-ropes

When handling steel-rope, protective gloves must be worn.
Self locking attach of rope

It is made up of two half parts tightening the rope, one sliding compared to the other. The system is self locking when a force of
traction is applied on the rope.
Procedure of installation
1- Preparing the steel-rope: the 4 platform ropes must be of the same length. To facilitate the introduction of the steel-rope in
the SW, its ends must be sharpened to points over a length of approx. once its diameter.
(for more information about the rope end finishing, consult the handbook “Service and workshop information” N° 598.074)
2- Introduce the steel-rope into the safety block, then through the layering arms.
3- Then with one hand push back the mobile Key and then introduce the steel-rope through the opening of the drum shaft and
into the “Quick fix” attachment
4- Beware that the end of the rope comes out of the attachment at least of 5 times the diameter. By applying a traction on the
rope one controls the self-locking of the system.
Uninstall the rope.

Push back the mobile key, if necessary to free the key strike a light blow with a plastic hammer
We recommend :
When installing a steel-rope, follow the current rules to uncoil the storage drum; do not pull it over sharp edges.
More than 3 spires must always remain on the drum before the rope attachment; less than 3 spires will trigger the electric
sensor.
It is the platform manufacturer’s concern to designate the steel-rope anchoring point on the building.
5 Safety prescriptions
5.1 In case of safety blockage
Beware ! If the safety block sets in during normal service, an anomaly of the machine or the steel-ropes must be suspected. This
is an emergency situation !
5.1.1 Rope rupture

If a steel-rope ruptures inside or outside the SW, the safety stop will set in and block on the second rope.
In such a case, the platform may not be moved in any way before its occupants have left it.
After such an incident, the machine must be checked over by the Plumettaz customer service.
5.1.2 Stop due to the mechanical tilt limiter

If the electric tilt limiter does not work, the platform tilt will be limited to maximum 14° by the locking in of the lower winch
safety block.
To emerge from such a situation with total security, the operator will have to raise the lower winch manually (§5.3).
Beware, manual lowering of the upper winch will not release the opposite safety block !
5.1.3 Manual interlocking of the block stop.

For the single point suspended platform, the block stop is equipped with a manual release of the safety brake.
Normal function position
By turning a quarter the handle you release the safety brake
To emerge from such a situation with total security, the operator will have to raise the lower winch manually (§5.3).
5.2 Emergency descent

In case of power failure, the platform can be lowered manually.
To this effect, proceed by releasing the electromagnetic brake with the manual brake lever.
To ensure a platform descent in horizontal position, the left and right brakes must be activated simultaneously. The operator will
control the horizontal position visually, however, a tilting beyond approx. 10° will activate the tilt limiting system. (see §5.1.2)
The speed is limited by the centrifugal brake.
After usage, put the brake lever back in place.
5.3 Manual lifting

As for an emergency descent, a short lifting can also be operated without motor.
• Remove the cap at the back of the motor and introduce the manual steering wheel
• Introduce the brake lever into the caliper
• Then turn the steering wheel (ccw) and release the brake simultaneously
After use, put all parts back in place.
5.4 Emergencies
Causes that trigger off the safety block
Fall of the platform on the side of the Safety block locks in on the second
Rupture of the suspension rope ruptured rope rope
Fall of the platform to approximately.

Faulty motor drive 12° Safety block locks in
Faulty speed reducer, mechanical Platform tilt to approximately 12° Safety block locks in
blocking
Faulty electrical tilt sensor Platform tilt to approximately 12° Safety block locks in
Causes that trigger off the upper lifting limit and ultimate lifting limit
Sensor plate triggers off the lifting

Platform stops in high position limit Platform stops
Sensor plate triggers off the ultimate Platform stops, winch power supply
Faulty lifting limit lifting limit switched off
Causes that trigger off a emergency descent
Motor driven lifting and descent

Electric power failure impossible Emergency descent
Stop in high position in case of Sensor plate triggers off the lifiting Manual emergency descent up to the
ultimate lifting limit detection limit safety loop OK
6 Technical data
Maximal service load (WLL) : SW400 = 4’000 N SW 500 = 5’000N
Service travel : max. 160 m
Steel-rope diameter : 6.5 mm 0/+3%
Weight of winch without steel-rope : 85 kg
Weight of steel-rope, 6.5mm diameter : 15 kg/100m
Standard motor : 3x 400V 50Hz / 1.0kW / 1500 min-1
Average lifting speed : 8.8 m/min
Speeds going up (0-160m / 50 Hz) : 7.2 – 9.9 m/min
Speeds going up (0-160m / 60 Hz) : 8.6 – 12.6 m/min
Quadrant Drive reduction ratio (speed reducer) : 110
Apparent drive reduction : 219
7 Inspections and check-ups

Inspections must be recorded in a control book.
Controls must always take place on both platform winches. The 2 machines must behave in identical manner.
Safety check-up: Before any operation and daily

Weekly check-up: Weekly or after every 20 hours’ service
Half-yearly check-up: Every 6 months or after every 400 hours’ service
Check-up
Position
half-yearly
Controlled element Procedure
weekly
Safety
1. Whole SW and accessories Visual check-up • • •
2. Winch mechanism Motor driven lifting and descent • •
Rope coiling Visual check-up of the correct rope coiling on the drums
Motor The layering arms must move from stop to stop
3. Emergency descent Proceed as in § 5.2. Check the functioning of the speed limiter and • •
Centrifugal brake and service brake the service brake.
4. Controlling drive (QD speed reducer) When functioning normally, the Quadrant Drive reverses easily. • •
Easy to check by operating an emergency descent.
5. Visual check-up the steel-ropes and See § 4.4 •
their endings
6. Electric power supply (Wires and Visual check-up of the electric wires •
sockets) Check-up of the socket-plug connections
7. Layering arms Moving freely from stop to stop. Check the lost motion of the •
pivots. If necessary, adjust stops as in §4.4.2
8. Layering arm pulley Measure groove depth, max. 12mm •
9. Safety block mechanism Place platform on ground. Remove protections. •
Activate the slack rope sensor lever, check the shutting of the jaws,
the spring, the oxidation of the half-moon-shaped jaw guidance (if
needed, lightly oil the friction surfaces).
Block the jaws by pulling the steel-ropes by hand.
Blockage in case of mechanical platform tilting.
Check the wear of the sensing roller bushes.
Block entry guidance cylinder
Visual check-up of the shock absorbers (compression) and the
traversing screws.
10. Switches and emergency stop Check switch function and attachments •
11. End-of-rope sensor Uncoil steel-rope completely and then check sensor mechanism •
and switch
12. Rope attachment Visual check-up of attachment, end-of-rope loop and screw •
tightening, as per §4.4.1
Place attachment into its lodging
13. Overload sensor With 125% of the nominal load, the ringing overload alarm must •
set in and any lifting movement become impossible, whereas
descent remain possible
14. Lifting limit sensor Press the sensor rod until it touches the lifting limit. Lifting must •
become impossible, descent remain possible.
Sensor rod must move easily. Check rod, bushes and spring.
15. Ultimate lifting limit sensor Press the sensor rod until it touches the ultimate lifting limit. •
Electric power supply cut on winch.
16. Structure of winches and attachment Visual check-up of the attachment points •
8 Setting and adjustment.

8.1 Block Stop switches
Adjustment of the points of commutations by adjustment of the cams
8.2 Adjustment of the layering arm stops

The scavenging stroke of the layering arms is limited by adjustable stops. See adjustment settings on drawing.
Underload 6mm
The adjustment is facilitated by using the hold of adjustment P590.116
8.3 Overload setting

The works’ setting is calibrated to WLL = 400kg for the SW400 and 500kg for the SW500
1 Loosen the locking screws
2 Push back the rear stop of the spring
3 Load the platform until the desired nominal load is reached. The alarm will start ringing.
4 Adjust the rear spring stop by pressing it until the overload alarm stops ringing.
5 Unload the platform partially.
6 To check, load again as in point 3 : the overload alarm should not set it.
7 Overload by 50 to 100kg : the overload alarm must set it and starting up must be impossible.
8.4 Cable tension

The adjustment of the cam makes it possible to regulate the preload of rolling up
No tension
Under tension
9 Maintenance
No particular maintenance is needed on the SW, when operating in non-aggressive climates
All repairs and check-ups must be done by Plumettaz SA, or an official agent of the company.
9.1 Instruction of handling

9.1.1 Transport measurements
472mm
518mm
1335mm
9.1.2 Lifting point
9.2 Maintenance instructions

9.2.1 Winch
Speed reducer
No maintenance on the speed reducer, it was lifetime lubricated in the works.
The bearings are tight and lifetime lubricated
Control of the bearings clearance
• No maintenance on the electromagnetic brake, when operating in normal conditions; brake must be absolutely oil or
grease free. The friction plate lost motion adjustment is definitive.
9.2.2 Electrical motor

No maintenance on the motor. However, must be cleaned if very dirty
Control the oxidation of the terminals
9.2.3 Centrifugal brake

No maintenance on the centrifugal brake, when operating in normal conditions; brake must be absolutely oil or grease free.
State if stored motionless with the bad weather.
CAUTION Never start the motor with a mounted centrifugal brake without the drum
9.2.4 Layering arms poulies

Wear of the layering arm pulleys.
max depth 12 mm
9 mm
used min dia 128 mm

original dia 133.5mm
9.2.5 Safety block

State requiring a disassembling and cleaning
10 Identifying of troubleshooting
Defect / break-down Possible cause Remedy
Lifting / descent impossible Electric power supply failure Check electric power supply and electric safety
Motor is no longer running devices
Emergency stop or safety switch turned Check position of safety switches
on
Check if mechanical release is possible
Impossible to release the service brake Have the electric power supply of the brake, and
the rectifying bridge checked by an electrician.
Deficient motor cooling Let motor cool down and remove any covering
Motor overheating object.
Overload Check overload setting
Speed reducer overheating Mechanical defect in the speed reducer Change speed reducer
Bad coiling Faulty adjustment of the layering arms Adjust the stop screws

Synrowinch 400, 500

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SW400

Operating and maintenance manual

3 Integration of the winch in the platform

3.1 Mechanical attachment of the winch to the platform

3.1.1 Attachment to the platform floor 1

3.1.2 Lateral attachment 2

Characteristics of the attachment points :

Tightening moment of the bolted joint Mt =40Nm

3.1.3 Protections and cowling

From inside the platform:

From outside the platform:

3.2 Lifting limit

3.3 Connection and function of the electric elements

3.3.1 Connection box

3.3.2 Switches and control elements

Pos. Element Switch type Category EN 1808 Function

1 Overload sensor 1 8.3.5.3 • In service, must be sensed going

4 End-of-rope sensor 1 8.6.2.3 Winch power supply turned off

5 Cable tension sensor No norm According to mode

6 Lifting limit switch B 8.3.10.1 Lifting impeded, descent possible

Electrical motor 1 kW 1500rpm

End of steel wire rope 1 detector

3.3.3 Stop programmer (optinal)

Not included in basic equipment (available on option)

3.3.4 Electric power elements

3.3.5 Electric diagram

3.3.6 Service mode

3.3.7 Installation mode

4.1 User’s competence level

Installation Qualified installer

Safety controls Qualified operator

Weekly control Qualified installer

Half-yearly control Qualified installer

Test travels Qualified installer

Electrical connections and controls Qualified electrician

Maintenance Qualified personnel

4.2 Application limits

4.3 Inadequate use

Rope deformation such as rope basket, kink, bend, ...

4.4.1 Installing the steel-ropes

Self locking attach of rope

Uninstall the rope.

5.1.1 Rope rupture

5.1.2 Stop due to the mechanical tilt limiter

5.1.3 Manual interlocking of the block stop.

Normal function position

By turning a quarter the handle you release the safety brake

5.2 Emergency descent

5.3 Manual lifting

Fall of the platform to approximately.

Sensor plate triggers off the lifting

Causes that trigger off a emergency descent

Motor driven lifting and descent

7 Inspections and check-ups

Safety check-up: Before any operation and daily

8 Setting and adjustment.

8.2 Adjustment of the layering arm stops

The adjustment is facilitated by using the hold of adjustment P590.116

8.3 Overload setting

8.4 Cable tension

9.1 Instruction of handling

9.1.2 Lifting point

9.2 Maintenance instructions

Control of the bearings clearance