Operation manual Track System TRUMPF 95 - Gerriets

gerriets

Operation manual Track System TRUMPF 95 - Gerriets

E

Operation Manual

Track System TRUMPF 95

Technic


1-4 Contents

1

2

3

4

2

Introduction

System Installation

System Operation

Safety Instructions

Contents Page

1.1 General Instructions 3

1.2 Approved Use of System 3

1.3 Unapproved Use of System – Safety Risks 3

1.4 Technical Data 4

1.5 Further Information 4

1.6 System Options 4

1.7 Safety Instructions 5

2.1 Installation 5

2.2 Preparation 5

2.2.1 Delivery of System 5

2.2.2 System Design 5 - 6

2.3 Track Mounting 7 - 29

2.3.1 System Parts Mounting 7 - 9

• Walk-Along System 10 - 15

• Side Cord Operation 16 - 19

• Top Cord Operation 20 - 23

• Double Top Cord Operation 24 - 28

• Motors 28 - 30

2.3.2 Rope Attachment 31

2.3.3 Rope Operation Test 31

2.3.4 Curtain Attachment 31

2.3.5 Curtain Operation Test 31

2.3.6 Motor Installation 32

2.3.7 System Operation 32

3.1 Operator Instructions 33

3.2 Instruction of Untrained Persons Working Area 33

3.3 Maintenance 33

3.4 System Modifications 33

4.1 Safety Risks of Approved Uses 34

Operation Manual / TRUMPF 95

Information

All information subject to change or

technical modification without notice.

(Updated 05/2010)


1 Introduction

1.1 General Instructions

Applications

Operation Manual

1.2 Approved Use of System

1.3 Unapproved Use of System

TRUMPF 95 is a track system for medium- and heavy-duty applications.

A top groove on track allows easy mounting of all accessories.

Installation options:

• Direct ceiling mounting.

• Hook clamp installation for use on truss and pipe battens.

• Wall mount bracket installation.

Perfect for stage and studio. Allows complex configurations such as curves and

switching points.

During events and on stage, there are always people in the curtain area. Operators of a

TRUMPF 95 track system must know and follow the special safety regulations for each

production. Possible risks during a production must be understood and guidelines put in

place to minimize accidents.

Please pay attention to following safety standards:

• BGV C1 / GUV-V C1

• BGI 810-0

• BGI 810-2

• DIN 56950

• DIN 60204-1

This operation manual is included in the delivery of the TRUMPF 95 track system. It

includes all necessary instructions to assemble and to operate the track system safely

and to prevent accidents or damage.

TRUMPF 95 is approved for supporting and moving curtains and light-weight scenery

within the maximum load capacity of the track and the associated components. Do not

exceed load rating of track and runners.

The track system load capacity refers to textile curtains applications. For light-weight

scenery applications, specific runners must be used.

TRUMPF 95 is not approved for supporting or moving (flying) people. Unapproved use

can result in serious injury or death.

Operation Manual / TRUMPF 95

3


1 Introduction

1.4 Technical Data

1.5 Further Information

1.6 System Options

4

Load Capacity

Track weight: 900 g/m

Track section length: 6,00 m

Maximum distance between hanging points: 2 m

Minimum curve radius: 500 mm

Wheels: ball bearing

Load weight

[kg]

100

90

80

70

60

50

40

30

20

10

0

Verify the load capacity and stability of the ceiling structure and all attachment

accessories.

System Design The load capacity of the overall TRUMPF 95 system is determined by the system’s

weakest link. Do not load any component up to the maximum load capacity as there is a

risk of overloading hanging points.

The track system should be designed with the load capacity of the hanging points:

The track system’s load (point load or uniform distributed load) is secured by the

hanging points.

The center hanging points’ weight load is higher than the weight load of the hanging

points at the end of the track.

The load capacity of the hanging points depend on the mounting nuts used. Replacing a

standard camlock nut with an adjustable nut or a HD nut can increase the load capacity.

If you still need a higher load capacity, or a replacement is not possible, you must

reduce the distance between the hanging points.

To define the maximum hanging point distance for a given load weight, see the diagram

in chapter 1.4.

You can find further information, such as load capacity, dimensions and weight of all

track system parts in chapter “2.3 Track Mounting”, in the Gerriets Technic manual and

on our website www.gerriets.com.

Manual or motor operation and control systems:

camlock nut:

standard

Art. 3115 0091

adjustable nut

Art. 3115 0071

HD adjustable nut

Art. 3115 0061

0,00 0,50 1,00 1,50 2,00 (max.)

hanging point distance [m]

• ROPE-DRIVE: Manual operation with a continuous loop hemp rope Ø 22 mm.

• HAND-DRIVE: manual operation with hand crank.

• FRICTION-DRIVE: motor operation without rope.

Motor moves via drive wheel along the track.

• TRAC-DRIVE: Motor operation with continuous loop rope.

• G-FRAME 54 control unit.

• G-FRAME 54 frequency controller.

• Hand held remote control.

Track switch, 2 positions, manual or motor operation, available with switch controller.

Track switch, 3 positions, manual or motor operation, available with switch controller.

Operation Manual / TRUMPF 95


2 System Installation

1.7 Safety Instructions The operator is responsible for the system operation. Your TRUMPF 95 track system,

delivered by Gerriets and installed properly, should pose no safety risk. However, with

any mechanical moving equipment, risk of accident or injury is possible.

2.1 Installation

2.2 Preparation

2.2.1 Delivery of System

2.2.2 System Design

For further information see table 4.1.

The installation should be done by certified technicians only. All installers must follow

the operation instructions.

Not following the operation instructions can damage the system. Gerriets GmbH is not

liable for these damages.

Please check immediately that the delivery slip matches the parts received to the

images in chapter “2.3 Track Mounting” to verify that the shipment is complete.

For designing your custom track system, please note the following points:

When you determine the track system length you must include the curtain stacking

space (length of each runner and master runner) and length of the needed

components such as end stops, return pulley, head pulley and motors at the ends

of the track system.

Stacking space calculation for each side of curtain:

Number of runners (approx. 4-5 runners per meter) x lengths of each runner

+ length of master runner

+ lengths of head and return pulleys

+ length of end stop (+ motor)

These questions help you to define the correct number and type of hanging points.

Track: what kind of load (point load or uniform distribute load) is appropriate?

• Which system position/application bears the highest load capacity (open curtain,

scenery attached to 1 or to 2 scenery carriers)?

• If considering a span width of less than 2 m: Which is the highest possible load

capacity weight for the most stressed hanging points? Regard your system as a

multi-span girder. The spans next to the center hanging point are loaded with the

maximum load capacity. Multiply the span load weight times 1.375. The result is the

approx. maximum load capacity of the center hanging point.

For further questions please contact our customer service team.

q

or

P

l l

q

or

P

P = Point load q = Uniform distributed load I = Distance between spans

• Does the value exceed the maximum load capacity?

• Use the diagram in chapter 1.4 to verify the maximum span width.

The distance between the track end hanging points and the end of the track should be

as short as possible.

The maximum load capacity of the track system (see diagram in chapter 1.4) or its

components (chapter 2.3.1) must not be exceeded. In addition, pay attention to the load

capacity of each single component. The load capacity of all parts is specified in chapter

2.3.1”System Parts Mounting”.

Operation Manual / TRUMPF 95

5


2 System Installation

2.2.2 System Design The track system’s load capacity is lower at the joint of two track sections. Place the

hanging points less than 100 mm away from the joints/splice points.

6

Ensure that TRUMPF 95 is mounted to a stable structure.

Plan the track configuration including the maximum weight load and define where

accessory parts, such as hang points or rope guides, are mounted in top groove of the

track.

Depending on the site of operation different safety regulations may apply.

Track sections can be mounted directly to the ceiling structure or preassembled on the

floor.

The installation location should be secured as to prevent objects from overhead from

falling down.

Please see the system parts mounting instructions in the following chapter.

Operation Manual / TRUMPF 95


2 System Installation

2.3.1 TRUMPF 95: System Parts Mounting

The following pages include drawings and descriptions of the TRUMPF 95 track system as well as mounting instructions and useful tips.

Depending on which mounting nut you select, three load capacities are given. These values always refer as following:

• Standard camlock nut (3115 0091) – lowest load capacity.

• Adjustable nut (3115 0071).

• HD adjustable nut (3115 0061) – highest load capacity.

In case the measurements in your copy can not be read clearly, please use the TECHNIC manual or go to www.gerriets.com.

Track Mounting

Art-No 3115 1011 (1012/1021/1022)

Art-No 3115 0011

Art-No 3110 9115

Track, Straight

With groove on top of track for accessories mounting.

• Weight: 900 g/m.

If you shorten a track section, the cut must be straight

and at a right angle. Deburr the cut edge to ensure a

precise joint connection of the track sections.

Track Splice

Connects two track sections.

• Weight: 260 g.

Joint Pin

• Ø 2,5 mm x 20 mm.

For precise track section connection (included in standard

delivery).

Track sections are centered by 2 joint pins and friction-locked

connected with a track splice.

Before connecting the track sections, slide required

camlock nuts (3115 0071/3115/0061) into top groove

of track.

Operation Manual / TRUMPF 95

7


2 System Installation

2.3.1 TRUMPF 95: System Parts Mounting

Art-No 3115 0091

8

Camlock Nut

For accessories mounting. Premounted to all accessories

(M8 x 20 mm screw).

• Weight: 10 g.

• Load capacity in the groove: 45 kg.

• Place the camlock nut where needed in the track groove.

• Loosen screw until almost removed.

• Tighten screw until noticeable resistance. Keep on tightening.

The camlock nut should turn 90° and securely fit into the top

groove of the track.

• Double-check if camlock nut is turned 90° in the

groove of track.

• If the camlock nut is not in the required position

(compare image) repeat the steps above.

Operation Manual / TRUMPF 95


2 System Installation

2.3.1 TRUMPF 95: System Parts Mounting

Art-No 3115 0071

Art-No 3115 0061

Art-No 3115 0011

Adjustable nut

• Positioned in top groove of the track.

• With hole to accept M8 bolt.

• Load capacity in groove: 60 kg.

HD adjustable nut

• For heavy-duty applications. Only for straight applications.

With hole to accept M8 bolt for track mounting.

• Weight: 72 kg.

• Load capacity in groove: 80 kg.

Slide HD adjustable nut in groove of track and secure it at the

desired position by tightening the screws.

End Stop

With hole to attach the curtain camlock nut mounted.

• Weight: 130 g.

Operation Manual / TRUMPF 95

9


2 System Installation

2.3.1 TRUMPF 95: Walk-Along Track / Overview

Walk-Along Track

Mounting Considerations

List of parts for sample system

below

10

Track system without motor operation. Manual opening and

closing of the curtain.

The basic track system to move a curtain/scenery along a

track.

Please note height measurements of all components for

system design and installation.

Please calculate length of each runner and master runner for

stacking space.

Art-No Article

3115 1012 Track, straight, clear anodized

3100 8011 Hook clamp

31150021 End stop

3100 0061 HD runner with overlap arm

3100 0021 2-wheel runner, black

3100 0031 4-wheel runner

3115 0021

3100 8011

Operation Manual / TRUMPF 95

3100 0061


2 System Installation

3115 1012

3100 0031

End view

140

109

43

34

90

3100 0021

Side view

40

25

Operation Manual / TRUMPF 95

47

50

11


2 System Installation

2.3.1 TRUMPF 95: Walk-Along Track / System Parts Mounting

Art-No 3100 0031

Art-No 3100 0011

Art-No 3100 0021

Art-No 3115 0031

Art-No 3100 8021 / 3100 8022

12

4-Wheel Runner

Curtain attachment via tie line, carabiners up to 60/6, shackles

or curtain hooks.

• Load capacity: 20 kg.

• Weight: 110 g.

4+4 Master Runner

• Load capacity: 20 kg.

• Weight: 180 g.

2-Wheel Runner

With 360° swivel for curtain attachment via tie line, carabiners,

up to 60/6, shackles or curtain hooks.

• Load capacity: 10 kg.

• Weight: 50 g.

Center Overlap Bracket

For parallel track sections overlap at center (2 to 3 brackets per

overlap). With 12.5 hole to accept hook clamp 3115 8011.

Mounted via 2 camlock nuts (included in delivery).

• Weight: 210 g.

• Load capacity (hook clamp mounting): 80 kg.

Ceiling Mounting Plate

For track systems without cord operation.

For direct ceiling mounting of tracks. With hole to accept M6

bolt (screw and anchor not included).

Distance: every 1-2 m, depending on weight load.

• Weight: 185 g.

• Load capacity: 50 kg.

• For defining the distance between mounting plates,

use load capacity table in chapter 1.4!

• Verify that the ceiling structure and all attachment

accessories such as bolts or anchors are stable

(we recommend using M6 screws in combination

with metal anchors).

• Screw ceiling mounting plate to ceiling.

• Squeeze both plates to the track and tighten

the M4 nuts!

Operation Manual / TRUMPF 95


2 System Installation

2.3.1 TRUMPF 95: Walk-Along Track / System Parts Mounting

Art-No 3100 8011

Art-No 3110 8011

Art-No 3115 8021

Art-No 3100 8061 / 3100 8062

Art-No 3115 8071 / 3115 8072

Art-No 3115 8061 / 3115 8062

Hook Clamp, Direct

With attachment kit for direct track mounting (camlock nut and

M8 bolt).

• For pipe battens installation, pipe Ø 48 mm to Ø 60 mm.

• Load capacity: a / b / c *

• Weight: 605 g.

Hook Clamp, Suspension

With attachment kit for mounting directly to suspension

brackets or center overlap brackets.

• For pipe diameter 48-60 mm.

• Load capacity: 45 kg.

For mounting a double track system with center overlap

via hook clamps, off-set mounting plate 3115 8021 is

necessary to align the hook clamps.

Off-Set Mounting Plate

For suspension of a double track with hook clamps (not in

overlap area).

• Load capacity: 45 kg.

Wall Mount Bracket 150 **

With attachment kit for direct track or suspension mounting.

• Wall distance adjustable.

• Length: 150 mm.

• Weight: 465 mm.

• Load capacity: 45 kg.

For use on a walk-along system. If used on a side cord or

top cord system, different attachment kits must be used.

Please note when ordering.

Wall Mount Bracket 250 **

See 3100 8061, with arm length 250 mm.

• Weight 624 g.

• Load capacity: 45 kg.

Wall Mount Bracket 380 **

See 3100 8061, but arm length 380 mm.

• Weight: 1.106 g.

• Load capacity: 30 kg.

Operation Manual / TRUMPF 95

*

The load capacity of a suspension

point depends on the mounting nut

type:

a = Standard camlock nut: 45 kg

b = Adjustable nut: 60 kg

c = HD adjustable nut: 80 kg

**

Mount the wall mount bracket

securely to the wall with 2 bolts.

Make sure there is sufficient structure

on or behind wall when bolting.

The wall mount bracket must be

securely fastened to the wall before

the track is connected.

13


2 System Installation

2.3.1 TRUMPF 95: Walk-Along Track / HD Carrier Options

Art-No 3100 0051

Art-No 3100 0071

Art-No 3100 0101

Art-No 3100 0061

14

HD Runner

4 top load bearing and 4 side stabilizing wheels.

With fall protection (in case of load bearing wheels failure).

• Load capacity bis 35 kg. ***

• Weight: 720 g.

HD Scenery Carrier

Technical details: see 3100 0051, but with swivel attachment.

• Weight: 640 g.

• Swivel with M8 bolt for scenery atttachment.

HD Scenery Carrier with Scenery Attachment

Technical details see 3100 0071.

Attachment plates. With 2 holes to accept countersunk bolt,

1 hole to accept 8 mm bolt. For scenery thickness 8-60 mm.

• Weight: 1.009 g.

Scenery Attachment

• If necessary, separate clamping plates from scenery carrier by

removing M5 bolt.

• Attach scenery or scenery frame to clamping plates. Use an

end-to-end M8 bolt for attaching the scenery and wood

screws for positioning the scenery between the clamping

plates.

HD Runner with Overlap Arm

HD runner for up to 35 kg weight load.

For single track systems with center overlap.

• Weight: 815 g.

Operation Manual / TRUMPF 95

***

Depending on the distance between

suspension points and the mounting

nut type, the weight load must be

below the given runner/carrier load

capacity. Please see diagram in

chapter 1.4.

x1

x2

x1

top view

x1 = 17,5 cm, x2 = 35 cm


2 System Installation

2.3.1 TRUMPF 95: Cord Operation / Accessories

Art-No 3115 0051

Art-No 3197 0001

Art-No 3115 0041

Art-No 4104 1182

Return Pulley

Returns rope at the end of the track.

Mounted via two camlock nuts (standard delivery)

• For use with rope up to Ø 8 mm.

• Weight: 825 g.

Return and Tensioning Pulley

Return pulley with automatic tensioning of operating rope.

Mounted via 3 camlock nuts (included in standard delivery).

• For use with rope up to Ø 8 mm.

• Tensioning distance: 140 mm.

• Weight: 1250 g.

Head Pulley

Diverts operation cord to floor pulley.

Mounted via 1 camlock nut (standard delivery).

• For use with rope up to max. Ø 8 mm.

Note: Always install 2 suspension points in head

pulley area to reduce stress.

Polyester Rope Ø 8 mm

• Standard rope.

• Works for manual operation.

• Color: black (also available in white).

• Tensile strength: approx. 1163 daN.

• Non-stretch.

Operation Manual / TRUMPF 95

15


2 System Installation

2.3.1 TRUMPF 95: Side Cord Operation / Overview

Side Cord Operation

Important

List of parts for Sample System

Below

16

Side cord operation is suitable for low clearance applications.

Side cord operation systems are lower and narrower than top

cord systems.

Side cord operation is a basic cord guide system that is

economical and easy to install.

Side cord operation is only for straight, single track applications

up to 12 m long.

A curtain center overlap up to 35 cm is possible by using

overlap arms.

Art-No Article

3115 1012 Track, straight, clear anodized

3115 8041 Track suspension bracket

3115 0041 Head pulley

3115 0051 Return pulley

3115 4021 Rope guide

3115 0021 End stop

3115 4012 HD master runner

3100 0021 2-wheel runner, black

3100 0031 4-wheel runner

4104 1182 Polyester rope Ø 8 mm

3100 7071 Floor pulley 180

3115 0051

3115 0021

3100 0021

Operation Manual / TRUMPF 95

3115 1012

3115 4012


2 System Installation

3115 4021

3115 8041

3100 0031

End view

109

105

34

90

181

92

Side view

96

Operation Manual / TRUMPF 95

40

3115 0041

4104 1182

25

3100 7071

47

131

50 80

17


2 System Installation

2.3.1 TRUMPF 95: Side Cord Operation / System Parts Mounting

Art-No 3115 4011

Art-No 3115 4012

Art-No 3115 4012

18

HD Master Runner, Side Cord

Curtain attachment via tie line, carabiners up to 60/6, shackles

or curtain hooks.

• Load capacity: 35 kg. ***

• Weight: 835 g.

HD Master Runner with Overlap Arm

Technical Details: 3115 4011.

For single track system with curtain center overlap.

• Weight: 954 g.

Side Cord Guide

Guides returning rope.

With camlock (included in standard delivery).

Mounting distance: approx. 2.5 m.

• For use with rope up to Ø 8 mm.

• Weight: 75 g.

Operation Manual / TRUMPF 95

***

Depending on the distance between

suspension points and the mounting

nut type, the weight load must be

below the given runner/carrier load

capacity. Please see diagram in

chapter 1.4.


2 System Installation

2.3.1 TRUMPF 95: Side Cord Operation / System Parts Mounting

Art-No 3115 8041

Side Cord Track Suspension Bracket

Camlock mounting (included in standard delivery) every 1-2 m,

depending on weight load.

With hole to accept M12 bolt for structure or hook clamp

3100 8011 mounting or 2 Ø 7 mm holes for structure

mounting.

• Weight: 135 g.

• Load capacity: a / b / c. *

For defining the distance between suspension points, use

table in chapter 1.4.

Operation Manual / TRUMPF 95

64,5

41

80,7

*

The load capacity of a suspension

point depends on the mounting nut

type:

a = Standard camlock nut: 45 kg

b = Adjustable nut: 60 kg

c = HD adjustable nut: 80 kg

19


2 System Installation

2.3 TRUMPF 95: Top Cord Operation / System Parts Mounting

Top Cord Operation

Important

20

3115 1032

For straight and curved track systems of any length.

Rope moves along the top side of the track. No cord sag.

Installation without suspension is not possible.

A track system for curved or very long track configurations.

3100 8011

3115 0051

3100 0021

List of parts for sample system below

Art-No Article

Operation Manual / TRUMPF 95

3115 1012 Track, straight, clear anodized

3115 1032 Track curved, without splice, clear anodized

3115 0011 Track splice (not shown) )

3115 0031 Overlap bracket

3115 8031 Track suspension bracket

3100 8011 Hook Clamp

3115 0041 Head pulley

3115 0051 Return pulley

3115 3041 Cord alignment guide

3115 3021 Cord guide, curved track section

3115 3031 Cord guide, straight track section

3115 0021 End stop

3115 3011 Master runner

3100 0021 2-Wheel runner, black

3100 0031 4-Wheel runner

4104 1182 Polyester rope Ø 8 mm

3100 7071 Floor pulley 180

3115 0031

3115 8031

3115 0021

3115 3011

3100 0031


2 System Installation

3115 3031

3115 1012

End view

34

100

216

109

135

207

3115 3041

3115 3021

3115 0041

107

40

Side view

25 44

Operation Manual / TRUMPF 95

153

4104 1182

3100 7071

131

50

21


2 System Installation

2.3.1 TRUMPF 95: Top Cord Operation / System Parts Mounting

Art-No 3115 3011

Art-No 3115 3014

Art-No 3115 3012

Art-No 3115 3015

22

HD Master Runner with Top Cord Rope Attachment

Technical details see: 3100 0052.

• Weight: 847 g.

• Load capacity: 35 kg.

HD Master Runner with Top Cord Rope Attachment and

Limit Switch Arm

For motor driven systems.

In combination with limit switch 3115 7111.

Technical details see: 3115 3011.

• Weight: 1.923 g.

HD Master Runner with Top Cord Rope Attachment and

Overlap Arm

Technical details see 3115 3011.

• Weight: 1.099 g.

HD Master Runner with Top Cord Rope Attachment,

Overlap Arm and Limit Switch Arm

For motor driven systems.

In combination with limit switch 3115 7111.

Technical details see 3115 3011.

• Weight: 1.175 g.

All master runners and carriers also available with scenery carrier bottom part (see TECHNIC manual or go to www.gerriets .com).

For assembly instructions see article no. 3100 0101.

Operation Manual / TRUMPF 95


2 System Installation

2.3.1 TRUMPF 95: Top Cord Operation / System Parts Mounting

Art-No 3115 3041

Art-No 3115 8031

Art-No 3115 3031

Art-No 3115 3031

Top Cord Alignment Guide

• Aligns operating and returning cord to the head pulley.

• With camlock nut

• For use with rope up to Ø 8 mm.

• Weight: 270 g.

Top Cord Track Suspension Bracket

• With hole to accept M12 bolt or hook clamp (3100 8011).

• Camlock mounting every 1-2 m (depending on weight load).

• Weight: 300 g.

• Load capacity with camlock a/b/c. *

To calculate distance between suspension brackets, see

diagram in chapter 1.4.

Top Cord Guide, Straight Sections

• For straight track sections.

• Guides operating and returning rope.

• With camlock nut.

• For use with rope up to Ø 8 mm.

• Weight: 70 g.

Top Cord Guide

Distance between top cord guides:

• Straight sections every 2-3 m.

• Curved sections:

• For 90° curve with R = 500 mm approx. 5 pcs.

• For radius over 500 mm mounting distance approx. 500 mm.

• Camlock nut mounting

• For use with rope up to Ø 8 mm.

• Weight: 175 g.

Operation Manual / TRUMPF 95

*

When mounting the suspension brackets,

ensure that the rope arms can

move smoothly above the track.

The hanging point load capacity depends

on the mounting nut version.

a = standard camlock nut: 45 kg

b = adjustable camlock nut: 60 kg

c = HD Adjustable camlock nut: 60 kg

When mounting the cord guides make

sure that the carrier rope attachment

is not blocked.

23


2 System Installation

2.3.1 TRUMPF 95: Double Top Cord Operation / Overview

List of Parts for Sample System

Below

24

3115 5031

Art-No Article

3115 1012 Track, straight, clear anodized

3115 1042 Track, curved – with splice, clear anodized

3115 0011 Track splice (not shown)

3115 8051 Track suspension bracket

3115 5041 Head pulley

3115 5031 Return pulley

3115 5011 Cord guide, straight track sections

3115 5021 Cord guide, curved track sections

3115 0021 End stop

3115 5062 Master runner with overlap arm

3100 0021 2-wheel runner, black

3100 0031 4-wheel runner

4104 1182 Polyester rope

3100 7071 Floor pulley 180

3115 0021

3115 1012

3115 5011

3100 0021

3100 0031

Operation Manual / TRUMPF 95

3115 8051

3115 5062


2 System Installation

End view

3115 5021

34

153

109

3115 1042

155

220

Side view

92

152

Operation Manual / TRUMPF 95

52

3115 5041

4104 1182

3100 7071

40 25 44 131

120

50

25


2 System Installation

2.3.1 TRUMPF 95: Double Top Cord Operation / Overview

Double Top Cord Operation

26

A further development of the top cord system.

Two independently operating cord systems move two master

runners independently on one track section.

This cord system allows the movement of curtain sections with

different speeds and/or in different directions with one single

track system (image 1).

Several curtain opening options are available. A curtain section

can be opened from right to left and vice versa (image 2).

The curtain moves on the track in a flat or pleated style, if it is

attached between the master carriers of both cords.

A system for applications with different speeds or directions,

such as asymmetrical opening configurations.

Double top cord systems can be equipped with two motors.

Geschwindigkeit Speed 1 1

Geschwindigkeit Speed 2 2

1 left and right curtain section

2 left and right curtain section

3 one curtain section

Operation Manual / TRUMPF 95


2 System Installation

2.3.1 TRUMPF 95: Double Top Cord Operation / System Parts Mounting

Art-No 3115 5061

Art-No 3115 5064

Art-No 3115 5032

Art-No 3115 5065

Art-No 3115 5041

Art-No 3115 5031

HD Master Runner with Top Cord Rope Attachment

See 3115 3011, but rope attachment for double top cord

operation.

• Weight: 886 g.

HD Master Runner with Top Cord Rope Attachment and

Limit Switch Arm

Technical details see 3115 5061.

For motor driven applications in combination with limit switch.

3115 7111.

• Weight: 962 g.

HD Master Runner with Top Cord Rope Attachment and

Overlap Arm

Technical details see 3115 5061.

• Weight: 1.305 g.

HD Master Runner with Top Cord Rope Attachment,

Overlap Arm and Limit Switch Arm

Technical details see 3115 5061.

• Weight: 1.381 g.

Head Pulley, Double Cord

Diverts operating and returning ropes to floor.

Camlock nut mounted (included in standard delivery).

• For use with rope up to max. Ø 8 mm.

• Ø Groove base: 25 mm.

• Weight: 1.035 g.

Note: Always install 2 suspension points in head

pulley area to reduce stress.

Return Pulley, Double Cord

• Returns ropes at end of track.

• Ball bearing.

• With camlock nut.

• For use with rope up to Ø 8 mm.

• Ø Groove base: 25 mm.

• Weight: 542 g.

Operation Manual / TRUMPF 95

27


2 System Installation

2.3.1 TRUMPF 95: Double Top Cord Operation / System Parts Mounting

Art-No 3115 5011

Art-No 3115 5021

Art-No 3115 8051

28

Double Top Cord Guide

• For straight track sections.

• Guides operating and returning cords.

• With camlock nut.

• For use with rope up to Ø 8 mm.

• Weight: 190 g.

Double Top Cord Guide, Curved Sections

• Guides operating and returning cords.

• With camlock nut.

• For use with rope up to Ø 8 mm.

• Ø Groove base: 25 mm.

• Weight: 397 g.

Double Top Cord Guide, Suspension Bracket

For ceiling or hook clamp 3100 8011 mounting.

• Spacer with camlock nut.

• With hole to accept M12 bolt.

• Weight: 227 g.

• Load capacity with camlock: a/b/c. *

2.3.1 TRUMPF 95: Manual System Operation: Components and Accessories

Art-No 3100 7071

Art-No 3110 7081

Art-No 3100 7061

Adjustable Floor Pulley 180

• Rope tensioning by height adjustable pulley.

• With Ø 10 mm holes for bolting to the floor.

• For use with rope up to Ø 8 mm.

• Tensioning distance: 180 mm.

• Weight: 1395 g.

Adjustable Floor Pulley 350

Technical details: 3110 7071 except tension adjustment

350 mm.

• Weight: 3.600 g.

Stirrup Floor Pulley

With foot stirrup and Ø 10 mm holes for bolting to the floor.

• Tensioning by foot pressure.

• For use with rope up to Ø 8 mm.

• Weight: 1.205 g.

Operation Manual / TRUMPF 95

*

The load capacity of a suspension

point depends on the mounting nut

type:

a = Standard camlock nut: 45 kg

b = Adjustable nut: 60 kg

c = HD adjustable nut: 80 kg


2 System Installation

2.3.1 TRUMPF 95: Manual System Operation: Components and Accessories

Art-No 3110 7011

Art-No 3100 7091

Art-No 3100 7101

Art-No 3100 7051

Art-No 4305 0301

Self Tensioning Floor Pulley

• With Ø 10m mm holes for bolting to floor.

• For use with rope up to Ø 8 mm.

• Weight: 12.445 g.

Hand-Drive Hand Crank Wall Pulley

• Manual operation for rope up to Ø 8 mm.

• Automatic rope tensioning by pressure springs.

• With Ø 12.5 mm holes for wall mounting.

• Weight: 6985 g.

• The continuous loop rope is operated by a hand crank.

ROPE-DRIVE Track Mounted Pulley

• Manual operation via continuous loop Ø 22 mm hemp rope.

• Automatic tensioning by pressure springs.

• For use with operating rope up to Ø 8 mm.

Track mounting with TRAC-DRIVE mounting bracket

3115 9011.

• Weight: 13.020 g.

• The hemp rope (yellow) is applied to the pulley in the upper

part of the casing with a 180° angle of wrap. The

rope pulley is on the same axis as the double pulley for the

operation rope.

To avoid slipping the hemp rope must be tensioned.

Therefore, calculate the precise mounting height of your

system before ordering the spliced continuous loop rope.

Hemp Rope Adjustable Floor Pulley 350

• For use with rope Ø 22 mm.

• Tension adjustment: 350 mm.

• With Ø 8.5 mm holes for bolting to the floor.

• Weight: 9455 g.

Hemp Rope

• Ø 22 mm.

• Continuous loop.

• Length depending on system height.

Operation Manual / TRUMPF 95

29


2 System Installation

2.3.1 TRUMPF 95: Motor Operation

30

For installation and operation see the corresponding motor operation manual.

Art-No 3170 2031 (2061 / 2121 / 2991)

Art-No 3115 9011

Art-No 3170 1011 (1021 / 1031 / 1041)

Art-No 3170 4371 (4681 / 4951)

Art-No 3115 7111

Art-No 3115 7121

TRAC-DRIVE Motor

• 2-grooved pulley.

• Automatic rope tensioning.

• Different speeds and control functions available.

Track mounting with mounting bracket 3115 9011.

• For use with rope up to Ø 8 mm.

• Weight: 16.490 g.

TRAC-DRIVE Mounting Bracket

• For direct track mounting of TRAC-DRIVE or ROPE-DRIVE.

• With 4 bolts, spacers and washers for mounting

TRAC-DRIVE or ROPE-DRIVE to mounting plate.

• Slide camlock nut at end of track into the groove, place and

tighten it.

Friction Drive Motor

• Motor moves silently via drive wheel along the track.

• Power via festoon cable.

• Different speed and control options available.

• Weight: depending on type 3.500 – 6.000 g.

Drum Motor

• Duty cycle: 40 %.

• 3 x 230 / 400 VAC.

• For rope up to Ø 3 mm.

Limit Switch

• With mounting plate and camlock nut for TRUMPF 95.

Limit Switch Plate with Pulley

• With mounting plate and camlock nut for TRUMPF 95.

• For position “up” for guiding the returning rope.

Operation Manual / TRUMPF 95

Limit switch and limit switch arm can

be mounted to FRICTION-DRIVE motor, a

master carrier or directly to the track.

Limit switch and limit switch arm can

be mounted to FRICTION-DRIVE motor, a

master carrier or directly to the track.


2 System Installation

2.3.2 Rope Attachment

2.3.3 Rope Operation Test

2.3.4 Curtain Attachment

2.3.5 Curtain Operation Test

After assembling all parts, the top cord operation cord can be attached.

1 Attach one end of the rope to a master runner.

2 Guide the other end of the rope through the rope guides over the head pulley to the

floor pulley (or the motor) back up to the head pulley, to the return pulley and back

to starting point. Attach it to the second master runner (if mounted).

3 Loosen the rope at the starting point (master runner), pull the rope tight and clamp it

to the master runner.

4 After the installation, cut off the remaining ends of the rope to ensure a smooth

operation.

5 Check the rope tension latest four weeks after installation. If necessary, adjust the

tension. The different cord guide systems are shown in chapter 2.3 “Track Mounting”.

Before attaching the curtain, the track system operation must be checked.

Please pay attention to the following:

Does the rope run smoothly, or does it rub against system components or other objects?

If yes: change the rope alignment or add additional rope guides.

Do you notice any unusual or loud operation noise?

If yes: Find out the cause and replace defect parts where required.

Do not exceed the maximum load capacity of the track system (see chapter 1.4) and its

components.

Attach the leading edge eyelet/grommet part of the curtain to the master runner’s

attachment hole or the overlap arm. Attach the other end of the curtain to the end stop

at the track end.

There should be a distance of approx. 2 cm between the master runner attachment hole

and the top edge of the curtain. This allows the runners to turn smoothly if stacking the

curtain in the stacking area.

The distance between the bottom edge of the curtain and the floor should be 1-3 cm to

prevent the curtain from brushing over the floor.

Attach decorative objects or scenery between 8 mm and 90 mm thickness via the

scenery carrier bottom part (3100 0101) to the scenery carrier (3100 101) or with a

M12 bolt directly to the scenery carrier.

If using other attachment accessories to attach loads to the track system, verify that you

do not exceed the load capacity and that all parts are in a proper condition.

Check after curtain attachment:

• Does the curtain move smoothly and easily?

• Is there a danger of collision with other objects in the curtain area?

If yes, enlarge the safety distance between curtain and other objects or remove the

obstacles.

• Repeat the test after removing the cause of the collision.

Operation Manual / TRUMPF 95

31


2 System Installation

2.3.6 Motor Installation

2.3.7 Operation

32

If a motor drive is part of your TRUMPF 95 track system, the installation of the track

system and all components must be done by a licensed electrician.

Before operating the system ensure that all safety regulations are followed.

Motors and control units must be operated by qualified personnel only.

The operation manual for motor and controls must be followed.

Operation Manual / TRUMPF 95


3 System Operation

3.1 Operator Instructions

3.2 Instruction of Untrained People in

Working Area

3.3 Maintenance

3.4 System Modifications

To operate the system safely, operators must have a basic knowledge of design and

function of the system.

It is the owner’s responsibility to instruct operators accordingly.

Untrained people who work in the system area must be informed about possible safety

risks and proper procedures.

During operation be aware of unknown or unusual noises. This will help prevent major

damage in the future.

The following should be checked as indicated:

each use quarterly biannually

annually

Unusual noise X

Rope condition X

Rope tension X

Master runner + runner:

Smooth operation

X

Master runner + runner:

Silent operation

Master runner + runner:

X

Sight check of wheels

deformation of casing or

components

X

Runner curtain attachment X

Master runner rope

attachment

X

Rope guides:

smooth operation

X

Hanging points: sight check

and screw connections

X

Track connections X

Staining X

For heavy duty applications shorter maintenance cycles are recommended.

Damaged and defective parts must be replaced.

For product details please see our TECHNIC manual, go to www.gerriets.com or contact

our customer support team.

System modifications are not allowed without the written consent of Gerriets GmbH.

• Only genuine Gerriets spare parts should be used.

• Unapproved modifications will result in voided warranty and liability.

• Manual copyright:

Fa. Gerriets GmbH

Im Kirchenhürstle 5-7

D 79224 Umkirch

Operation Manual / TRUMPF 95

33


4 Safety Instructions

4.1 Safety Risks Even with approved operation and regular maintenance, safety risks can not be totally

excluded. Please note following risks:

34

Risk Cause Action

Mechanical: collision. Moving curtain/scenery. Operator has clear view of

entire curtain area.

Electrical: person touches

defective component under

voltage.

Insufficient insulation

of cables, control units

(see according operation

manual).

Regular checks/maintenance

by certified

electricians.

Break during operation. Overload, wearing. Do not exceed load capacity.

Regular maintenance.

Objects falling down. Scenery not attached

properly.

Unsecured screw

connections are loose.

Collision with other

structures.

Proper screw connections

and regular checks;

check after collision.

Operation Manual / TRUMPF 95


Business hours

Address

Phone numbers

Fax numbers

Online

Monday - Thursday 8:00 a.m.- 12:00 p.m.

1:00 p.m.- 5:00 p.m.

Friday 8:00 a.m.- 12:00 p.m.

1:00 p.m.- 3:30 p.m.

You can reach our telephone switchboard on weekdays from

8:00 a.m.- 6:00 p.m.

Outside normal business hours, please leave a message and we

will get back to you the next business day.

Shipping address GERRIETS GmbH

Bühnenbedarf

Im Kirchenhürstle 5 - 7

D-79224 Umkirch

Mail address GERRIETS GmbH

Bühnenbedarf

Postfach 1154

D-79220 Umkirch

Telephone switchboard +49 7665 - 960 0

Team 5 Sales +49 7665 - 960 250

• Theatres and stage design

Team 4 Sales +49 7665 - 960 240

• Stage equipment for town halls

• Multi purpose halls

• Schools

• Universities

• Churches

Team 3 Sales +49 7665 - 960 230

• Event technic

• Event furnishing

• Amusement parks

• Movie theatres and TV studios

Team 2 Sales +49 7665 - 960 220

• Trade show equipment and

exhibition stand construction

• Industry clientele

• Ship furnishing

Team 1 Sales +49 7665 - 960 210

• Stage design companies

• Planners and architects

Shipping Department +49 7665 - 960 126

Accounting Department +49 7665 - 960 170

General Inquiry +49 7665 - 960 125

Internet www.gerriets.com

E-mail info@gerriets.com

Commercial register,

Freiburg

Tax number

Operation Manual / TRUMPF 95

HRB-Nr. 2678

142191543

Managing Directors Walter Gerriets

Hannes Gerriets

Bernd Baumeister

DTHG and ITI member

35


Gerriets GmbH

Im Kirchenhürstle 5-7

D-79224 Umkirch

+49 7665 960-0

+49 7665 960-125

info@gerriets.com

Gerriets S. A. R. L.

Rue du Pourquoi Pas

F-68600 Volgelsheim

+33 3 89 22 70 22

+33 3 89 22 70 50

gerriets@gerriets.com

Gerriets International Inc.

130 Winterwood Avenue

Ewing NJ 08638, USA

+1 609 758-9121

+1 609 758-9596

mail@gi-info.com

Gerriets Great Britain Ltd.

18 Verney Road

London SE16 3DH, UK

+44 20 7639 7704

+44 20 7732 5760

general@gerriets.co.uk

Gerriets Handel GmbH

Gorskistraße 8

A-1230 Wien

+43 1 6000 600-0

+43 1 6032 585

verkauf@gerriets.at

Gerriets España S. L.

Pol. Ind. Arroyo Buzanca

Avda. de Las Moreras

Sector S-19 B, Naves 1-2-3

E-28350 Ciempozuelos, Madrid

+34 91 134 5022

+34 91 134 5084

gerriets.spain@gmail.com

Gerriets Italia

Risam for show

Viale Spagna 150 / B

I-20093 Cologno Monzese (MI)

+39 02 2532 113

+39 02 2532 130

info@risamforshow.com

Gerriets Belgique

Distribué par :

Gerriets S. A. R. L.

Rue du Pourquoi Pas

F-68600 Volgelsheim

+33 3 89 22 70 22

+33 3 89 22 70 50

gerriets@gerriets.com

Gerriets Nederland

LevTec BV

Anthony Fokkerweg 3

NL-1059 CM Amsterdam

+31 20-40 82 553

+31 20-40 82 662

info@gerriets.nl

Gerriets Hellas

Stage Art EPE

Stournari 27B

10682 Athens

+30 210 3836 715

+30 210 3811 929

info@gerriets.gr

Gerriets Turkey

Benart Ses Isik-ASC Is Merkezi

Mahmut Sevket Pasa Mahallesi

Piyale Pasa Bulvari

Baran Sk No: 4 Kat: 3 Zemin Kat

TR-34384 Okmeydani-Sisli-Istanbul

+90 212 254 33 43

+90 212 254 33 53

benart@benart.net

Gerriets Korea

4F 449-4 Seongnae-dong

Gangdong-gu, Seoul

Korea 134-030

+82 2 477 7713

+82 2 477 1490

info@gerriets.co.kr

www.gerriets.com

05 / 2010

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