Installation Requirements For Rotomat PDF

Hänel Büro- und Lagersysteme
Installation Requirements for the Owner/Operator

Hänel Rotomat
Erection of Carousels without Powered Auxiliary Equipment
2010-01-01 (RT) INST-RO-REQ-O.en.odt

Hänel Rotomat
Contents
Note:
A separate table of contents is provided at the beginning of each chapter containing multiple subchapters.
Chapter Subject Page

0. Guide 3
1. Basic information 7
2. Personnel requirements 9
3. Safety instructions 11
4. Preparing the installation location 13
5. Preparing for installation 15
6. Disposal instructions 40
Keyword index 42
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Hänel Rotomat
0. Guide
Contents
This section contains basic information about this manual. Follow the instructions in order to prevent errors when preparing to install the
Hänel Rotomat. It is particularly important that you note the meaning of the symbols for the safety instructions and follow the
corresponding instructions exactly. By doing so, you prevent possible accidents and the associated risk of injuries and property damage.
Target group of this document, "Installation Requirements"
This document, entitled "Installation Requirements", is intended for trained technicians employed by the customer or owner/operator.
These must be specialists who are trained for and experienced in executing the respective tasks.
Table of contents
In addition to the main table of contents, any chapter containing multiple subchapters has a separate table of contents located at its
beginning.
Classification of the signal words and colours used
Meaning of the signal words and colours used:
Signal word and colour Meaning
(Warning sign) DANGER High risk of danger
• Safety instruction Safety alert symbol with the keyword "DANGER".
• Preventive measure High risk, warning of fatal injuries in the event that
instructions/requirements are not observed.
White text on red background.
A specific symbol to explain the danger appears in the box to the
left.
(Warning sign) WARNING Moderate risk of danger
• Safety instruction Safety alert symbol with the keyword "WARNING".
• Preventive measure Moderate risk, warning of possible severe to fatal injuries in the
event that instructions/requirements are not observed.
Black text on orange background.
left.
(Warning sign) CAUTION Low risk of danger
• Safety instruction Safety alert symbol with the keyword "CAUTION".
• Preventive measure Low risk, warning of possible minor to moderate injuries in the
event that instructions/requirements are not observed.
Black text on yellow background.
left.
CAUTION Property damage
• Safety instruction Keyword "CAUTION".
• Preventive measure Warning of property damage (with level of severity specified) in
the event that instructions/requirements are not observed.
Black text on yellow background.
(Mandatory SAFETY INSTRUCTION Safety instruction
instruction sign) • Instruction text Keyword "SAFETY INSTRUCTION".
Instruction for safe work.
White text on green background.
A specific mandatory instruction symbol may appear which
explains the specific safety measure.
3
Hänel Rotomat
0. Guide (continued)
Symbols and signal words used

Symbol Meaning
Danger!
Notes with this symbol and the keyword
"Danger!" warn you of possible severe injuries of
a general nature, possibly including fatal injuries.
Danger!
"Danger!" warn you of a hazard caused by
falling.
Danger!
"Danger!" warn you of a
hazard caused by suspended loads, particularly
unintended revolving of the carriers.
Danger!
"Danger!" warn you of a hazard caused by
electrical current.
Danger!
This symbol informs you of the following:
• Climbing into the access point is strictly
prohibited for any and all personnel
• Climbing into the service opening and sitting
or standing inside the carousel is prohibited
for untrained or unauthorised persons.
Secure the main switch(es)!

This symbol informs you that, before beginning a
task, you must switch off the main switch and
secure it from being switched on again using a
padlock.
4
Hänel Rotomat
0. Guide (continued)
Symbols and signal words used (continued)

Symbol Meaning
Wear fall protection equipment!
This symbol informs you that, before beginning
a task at great heights, you must put on fall
protection equipment as personal safety
equipment (PSE).
Wear a safety helmet!

This symbol informs you that when hazards
from falling parts exist, you must wear a helmet
as personal safety equipment.
Disposal
This symbol indicates that applicable national
laws and regulations for the disposal of
recyclable materials must be followed.
Information symbol
This symbol indicates particularly important
information for installation intended to help you
avoid making errors or causing damage;
this information may include tips to help make
the installation easier.
Signal words are "Important!", "Instruction",
"Information" or "Tip"; of these, instructions
given under the signal word "Important!" must
be followed especially carefully.
5
Hänel Rotomat
1. Basic information
Contents
This chapter provides basic information about the Hänel Rotomat.
Manufacturer (see type plate)
Hänel Büro- und Lagersysteme Hänel Büro- und Lagersysteme
P.O. Box 11 61 Bafflestrasse 21
D-74173 Bad Friedrichshall, CH-9450 Altstätten / SG,
Germany Switzerland
Phone: +49 (0) 7136 27725 Phone: +41 (0) 717573080
Fax: +49 (0) 7136 27741 Fax: +41 (0) 717573085
Internet: www.haenel.de Internet: www.haenel.ch
Scope of validity of the Installation Requirements

These Installation Instructions are valid for carousels of the
following series:
Type: Hänel Rotomat /100, /115, /125 in versions 200, 300-800,
860 and 900 up to unit height of 4 m (196.90 in),
model years 1993 and later
Drives: 1 or 2
Number of access points: unlimited
Date of issue of the Installation Requirements:
January 2010
Keep in an accessible place as a complete
document
• These Installation Requirements are a part of the carousel and
must be stored in an accessible location at all times, even after
the installation work is completed.
• Pages may never be removed from these Installation
Requirements. If the Installation Requirements or any of its
pages are lost or missing, particularly the section entitled
"Safety instructions", they must be replaced immediately.
Copyright
This documentation contains information that is protected by
copyright. It may not, in whole or in part, be photocopied,
duplicated, translated or stored to any electronic medium without
prior consent.
All other rights reserved.
Change service
This documentation is not subject to the change service of the
manufacturer. Changes to this documentation may be made
without further notification.
7
Hänel Rotomat
1. Basic information (continued)
Purpose of this manual

This manual contains instructions for the specialists employed by
the owner/operator. The instructions are provided to prepare them
for installing the carousel for the customer or owner/operator in
order to guarantee a smooth installation process. In this way,
extra costs caused by delays can be avoided.
Auxiliary equipment
Installation without powered auxiliary equipment (such as a raised
working platform or forklift) is possible only for types /100, /115, /
125 in versions 200, 300 - 800, 860 and 900 up to a unit height of
4 m (196.90 in).
DANGER
The applicable safety instructions must be
followed throughout the entire installation
period. For further information, refer to
Chapter 3, "Safety instructions".
The installation area must be sufficiently
cordoned off to prevent risk of accident and
access by third parties.
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Hänel Rotomat
2. Personnel requirements
Contents
Overview of the qualifications required of the installation
personnel.
Installation personnel
The requirements of Hänel installation personnel and Hänel
representatives apply:
• The installation personnel must have completed a qualifying
examination, or comparable examination in the country of use,
in the field of mechanical or electrical engineering.
• They must follow the installation instructions.
• They must have sufficient knowledge of the language of the
country of use.
• They must be adequately suited to the tasks described here,
and trained in the use and handling of the respective devices.
• They must be able to provide evidence of having received
adequate training in all matters related to technical support of
the carousel and its safe handling, as well as regular annual
follow-up training, from the manufacturer.
Furthermore, the owner/operator is responsible for the auxiliary
personnel they employ. Thus the auxiliary personnel is likewise
required to:
• Follow the installation instructions.
• Have sufficient knowledge of the language of the country of
use.
• Be adequately suited to the tasks described here, and trained
in the use and handling of the respective devices.
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Hänel Rotomat
3. Safety instructions
Contents
This chapter provides important instructions intended to protect
the installation personnel employed by the owner/operator,
the Rotomat itself, and (where applicable) third parties from injury
or damage.
Important notes before beginning work
These "Installation Requirements for the Owner/Operator" are
fundamental to safe and trouble-free installation of the Hänel
Rotomat, and require careful and thorough compliance.
Hänel factory installers are obligated to verify this before
installation begins.
Safety during installation

DANGER
These safety instructions, and those in the
"Safety" chapter of the Hänel Rotomat
Operating Manual, must be observed and
followed at all times to prevent hazards to
your health.
Personal safety equipment
The following personal safety equipment is required:
• Fall protection equipment whenever working at great heights.
The respective laws and regulations of the country of use
apply.
• Protective gloves as protection against burns on hot drives
and injuries from corners and edges.
• Safety shoes and a safety helmet to protect against falling
parts.
Selecting permitted fall protection equipment Important!
For all work at great heights, only the following type of fall Outside Europe, the corresponding laws,
protection equipment is permitted: standards and accident prevention
regulations for fall protection apply.
• The safety harness must conform to EN 361. A safety belt in
accordance with EN 358 is not suitable as fall arrest
equipment!
• The safety harness must have a travelling fall arrester in
accordance with EN 353-2 and a deceleration device in
accordance with EN 355. The deceleration device is
mandatory when using a safety harness.
• The fastener (safety rope) between the safety harness and
the carousel or building must conform to EN 354 and be
twice as long as the carousel.
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Hänel Rotomat
3. Safety instructions (continued)
Safety during installation (continued)

Safety of the installation area
The installation area must be sufficiently cordoned off to prevent
risk of accident and access by third parties.
Parts lifted using lifting gear must always be secured against
falling down or falling over.
DANGER
Risk of fatal injury from being crushed or from
falling objects
• Never climb into the carousel through the
access point.
• It is forbidden to ride in the carriers at any
time.
SAFETY INSTRUCTION
Fire protection
In accordance with locally applicable building codes, necessary
fire protection measures must be clarified with the respective
regional fire protection authority.
Modifications to the Rotomat DANGER
Modifications are permitted only after a specialised safety Unauthorised modifications of the carousel
concept is created and approved by the Hänel factory. cause substantial risk of injury, including fatal
This applies both to modifications carried out by companies injury.
associated with Hänel and to those carried out by independent
representatives or other companies. • Any modification without the proper
approval is prohibited.
Unauthorised modifications shall have the following
consequences:
- All safety warranties and certifications shall be rendered null
and void.
- Hänel shall no longer be deemed the manufacturer of the unit,
and all warranty claims against Hänel shall be rendered null and
void.
- In accordance with 2006/42/EC, a new safety assessment
process and safety concept for conformity assessment may have
to be created in all parts. This would then have to take place
under the sole responsibility and at the sole risk of the company
carrying out the modification, and without the detailed knowledge
of the manufacturer.
WARNING
Hazard from overload of the carousel • After loading a carrier, check to make sure that the
The load of the carriers and the carousel are not total weight of the stored articles does not exceed the
monitored automatically. Overloaded containers can permitted maximum.
cause one-sided loads or overloads of the carousel or • The owner/operator is responsible for monitoring the
falling of stored articles. correct load.
• Refer to the type plate for the permitted load per
carrier and for the entire carousel.
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Hänel Rotomat
4. Preparing the installation location
Contents
This chapter describes how to select and prepare the installation
location according to the following list of conditions to be verified.

4.1 Ambient conditions and hazardous materials 13
4.2 Safety 13
4.1 Ambient conditions and hazardous materials
Ambient conditions DANGER

The carousels must be protected from humidity, moisture, and There is a risk of fatal injury if the carousel is
weather forces such as wind and snow. They are not intended for operated in hazardous environments.
outdoor operation.
• The carousel must not be operated
The carousels are not intended for use in explosive, aggressive unless all conditions are properly met.
or corrosive environments.
Explosion hazard DANGER
Hot surfaces or sparks may develop in the carousel, for example There is a risk of fatal injury if you do not
from self-heating of drive parts or damage to interior parts from comply with these instructions.
improperly stored articles. Therefore, no potentially explosive
materials may be stored or handled in the carousel. • Do not store any explosive materials
inside the Rotomat.
Hazardous materials WARNING
The storage of hazardous materials in the carousel or the There is a substantial health risk if you do not
surrounding area is not permitted at any time. Examples of comply with these instructions.
hazardous materials include:
• Do not store any hazardous materials
• Irritants and other materials hazardous to the health inside the Rotomat!
• Flammable materials
• Explosive materials
4.2 Safety
You must follow any applicable special regulations of your country while preparing for installation.
Before beginning work, the installer must obtain information from the customer or owner/operator about the special operating and safety
instructions, as well as new or revised regulations.
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Hänel Rotomat
5. Preparing for installation
Contents
This chapter describes the preparations to be made by the
owner/operator for proper installation of the Rotomat.
The following instructions must be followed exactly to ensure safe
and correct installation. Careful and thorough preparation can
prevent extra costs caused by delays and provides many other
benefits.

5.1 Preparing the installation area 16
5.2 Mains power supply 21
5.3 Determining weights 25
5.4 Auxiliary personnel 26
5.5 Mechanical auxiliary equipment 28
5.6 Installation situations and auxiliary equipment, examples 29
5.7 Transport 30
5.8 Examples: How to use auxiliary equipment during installation 33
5.9 Ladders and scaffolding 36
5.10 Providing a service access door 37
5.11 Additional instructions 38
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Hänel Rotomat
5.1 Preparing the installation area
An adequately sized installation area must be made available WARNING

which is clear and free of obstacles. This section provides
information about the general characteristics of the area and Risk of accident for third parties!
about openings and recessed pits. • For the entire duration of the installation
work, block off the installation area so
Dimensions that is inaccessible to unauthorised
The installation area needs to be at least large enough for a persons (third parties).
side part of the Rotomat - its largest single part - to be laid flat
on the ground. In addition to the dimensions of the side part,
sufficient space must remain for handling the side parts and
other parts.
The dimensions of the side part of the carousel are as follows:
Height: See carousel height in order confirmation
Depth: See carousel depth in order confirmation
Width: 206 mm (8.10 in)
Carousel type Width
Rotomat 100 206 mm (8.10 in)
Rotomat 115 206 mm (8.10 in)
Rotomat 125 206 mm (8.10 in)
The dimensions for the holes in the ceiling must be 100 mm
(3.9 in) more than the unit depth and unit width.
Accessibility
The carousel must be accessible using the installation auxiliary
equipment at least on its front or rear side, but also on one or two
other sides wherever possible.
Service doors
Depending on the carousel height, there are one or two standard
service doors on the front of the carousel.
With regard to installation and the pivoting radius when opening
the doors, refer to the document "Power Supply and Foundation
Plan" and the safety instructions for the service doors in the
Carousel Operating Manual.
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Hänel Rotomat
5.1 Preparing the installation area (continued)
Accessibility (continued) Note

Emergency operation If this is not possible, a crank with a universal
When a carousel is erected with its side against a wall or in a joint must be used, which is available as an
room niche, for types /100 to /125, there must be a clearance of optional accessory.
approximately 16 cm (6.30 in) between the wall and the drive
side(s) to allow for emergency operation using a crank.
Securing the ceiling hole above the access level Information
After the side parts are erected and before installation of the The access level is the level from which the
carousel continues, the ceiling hole must be covered by the side parts of the carousel are brought to the
owner/operator with a removable, stable floor made of boards installation location.
that will not slip or shift out of place.
For ceiling holes that are enclosed on at least one side by a
perpendicular wall, the owner/operator must also attach
immovable supports for the floor made of boards to the wall.
Important!
The ceiling hole must be adequately sized:
Min. unit depth + 100 mm (3.9 in)
Min. unit width + 100 mm (3.9 in)
Important!
For work conducted at heights above 3.5 m
(137.8 in), scaffolding must also be provided
(see Chapter 5.5).
DANGER
Floor made of boards, There is a substantial risk of injury, including
secured from slipping fatal injury, from falling.
or shifting out of place
• After installation, the gap between the
carousel and the ceiling hole must be
If necessary: properly sealed by the owner/operator.
Additional wall
support
Fig. 1: Floor made of boards
17
Hänel Rotomat
Installation in a recessed pit

Also refer to Section 5.5 and the Installation Requirements for
"Erection of Carousels using Powered Auxiliary Equipment".
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Hänel Rotomat
Height and width of the area

The following heights and widths of the area are required for
set-up and installation of the individual carousel parts:
A Standard installation Important
For standard installation or if, for space reasons, The customer's building must have an
carousel parts have to be erected or conveyed to the appropriate mounting option
top using a chain block, the room height must be at (such as a steel girder) for the chain block.
least D = 30 mm (1.20 in) above the carousel height More space will be required above the
(see Fig. 2). carousel corresponding to the version of the
mount provided by the owner/operator.
B Room height < carousel height + 3 cm SAFETY INSTRUCTION
(1.2 in) Set up the side parts manually.
Building dimensions less than those specified under A: • For this process, adequate safety can be provided only by a
carousels with a height < 3 m (118.1 in) can be non-slip substrate and the correct number of auxiliary
installed even at a room height of D=1 cm (0.40 in) personnel; see Chapter 5.4.
greater than the carousel height, but this requires the
floor and ceiling surfaces to be absolutely level and
parallel.
C Rotomat with divided side parts
For carousels with divided side parts (such as
carousels with 2 access points): room height approx.
D=13 cm (5.12 in) above the unit height.
D Niche installation Note
Carousels can be installed in a corner or niche. This must be specified when placing the
The carousel can be installed in front of the corner or order.
niche, then pushed to its final location. For carousels
taller than 3 m (118.1 in), suitable hardwood beams Important!
must be provided for moving the carousel. Final location on a pedestal:
Room height at final location as specified in Section B. The carousel cannot be pushed into this
position.
The carousel must be installed at its location
under conditions A-C above.
D = 1 cm
D = 13 cm
D = 3 cm
Fig. 2: Room height: standard Fig. 3: Room height for divided side parts Fig. 4: Room height for niche installation
19
Hänel Rotomat
Checking the floor characteristics

A Load carrying capacity Note
A structural engineering check of the load carrying capacity of For the loads and force distribution of the
the substrate, at both the installation and the erection location of specific carousel type, refer to the Power
the carousel, must be carried out by the owner/operator. Supply and Foundation Plan.
The force distribution extends in the area of the side parts,
as these are the load-carrying elements of the carousel.
B Level tolerances DANGER
The floor at the erection location of the carousel must be flat, Poor quality substrates cause a substantial
solid (i.e. rigid) and level as determined by a spirit level. risk of injury, including fatal injury.
In accordance with EN 18202, Table 3: "Level tolerances",
Row 1, distance between measuring points 4 m (39.4 in), Erection of the carousel is not permitted
the unevenness of the floor may not exceed 20 mm (0.79 in). under the following conditions:
• On floating or cast plaster floor
DANGER (due to its insufficient load carrying
Poor quality substrates cause a substantial capacity)
risk of injury, including fatal injury. • On magnesium oxychloride cement
• Installation cannot be approved if there is (due to corrosion of the housing)
an apparent structural flaw in the • If the level tolerances of the floor are
foundation. exceeded.
Check the
evenness of the
floor using a level.
Side support
surfaces must
be rigid!
Fig. 5: Checking the floor characteristics
20
Hänel Rotomat
5.2 Mains power supply
DANGER
If work on the electrical equipment is not
carried out properly, there is a risk of fatal
injury!
• Therefore, these tasks may be performed
by qualified electricians only.
Electrical connection of the carousel Note
You must provide an electrical connection for the operation of the The standard cable gland of the connecting
Rotomat, and an additional connection for the tools required for cable with a cross-section of 5 x 2.5 mm² or
installing the carousel, such as electric screwdrivers etc. 5 x 4 mm² with earth wire (for units with
For more information, also refer to the Power Supply and frequency converter, 2 earth wires) is on the
Foundation Plan and the section below on the mains power rear side of the carousel.
supply connection/wire cross-sections.
Before the carousel is installed, the electrical connection to the DANGER
carousel must be installed by an in-house electrician employed
by the owner/operator; likewise, the connection in the carousel is There is a risk of fatal injury when working on
to be routed with supervision of the installer by an in-house the live electrical system!
electrician employed by the owner/operator. • The mains power supply cable must be
de-energised until the installer gives the
clearance.
Cable gland Important!
The standard cable gland of the connecting cable is located on Any deviations must be specified when
the rear of the carousel, at the bottom of the left side part. placing the order and described in the order
confirmation.
Connection variants
Depending on the carousel versions, the following connection
variants exist:
A Type /100, /115, /125
Wiring cabinet below the access opening
Fig. 6: Wiring cabinet below access point, 1 drive Fig. 7: Wiring cabinet below access point, 2 drives
21
Hänel Rotomat
5.2 Mains power supply (continued)
Connection variants (continued)
B Type /100, /115, /125

Wiring cabinet above the access opening
Fig. 8: Wiring cabinet above access point, 1 drive Fig. 9: Wiring cabinet above access point, 2 drives
22
Hänel Rotomat
Electrical connection values Note

The following is an overview of the nominal current values for the For carousels with 2 drive motors,
electrical connection depending on the motor power. multiply the nominal current listed in the
table by a factor of 2.
Electrical connection values - 50 Hz mains power (Number of drive motors according to order
supply confirmation)
Nominal mains current (A)

Motor power
230 V 400 V 415 V
1 x 0.7 / 0.9 kW, 3 PH 6.9 4.0 3.9
1 x 0.9 / 1.3 kW, 3 PH 9.5 5.5 5.3
1 x 1.1 / 1.5 kW, 3 PH 7.5 4.3 4.2
Electrical connection values - 60 Hz mains power

supply

Motor power
208 V 220 V 240 V 440 V 460 V 480 V
1 x 0.9 / 1.3 kW, 3 PH 7.6 7.2 6.6 3.6 3.4 3.3
1 x 1.1 / 1.5 kW, 3 PH 8.4 8.0 7.5 4.0 3.8 3.7
1 x 1.15 / 1.6 kW, 3 PH 8.6 8.1 8.0 4.2 4.0 4.0
Electrical connection values - 50/60 Hz mains power supply with frequency converter

Motor power
120 V 1 PH 230 V 1 PH 208 V 3 PH 400 V 3 PH 480 V 3 PH
1 x 1.1 kW 17.6 12.0 7.1 4.8 4.0
1 x 1.5 kW 20.5 13.1 8.0 5.1 4.2
2 x 1.1 kW 31.6 23.0 14.1 9.4 7.2
2 x 1.5 kW --- --- 16.1 10.1 8.5
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Hänel Rotomat

Mains power supply connection and wire Note
cross-sections Enquire with your local energy supplier as to
Unless another mains power supply at the location of use of the the specific mains power supply connection
carousel is specified when placing the order and in the order requirements for your region.
confirmation, the electrical components are designed for
operation with a TN-S power system in accordance with
IEC 60364-1 (separate neutral and earth wires in the entire
power system): The connection contains
For three-phase drive:
3 outer conductors
1 neutral conductor
1 earth wire
For carousel versions with frequency converter:
additional separate earth wire
For alternating current drive (with frequency converter only)
1 outer conductor
1 neutral conductor
2 earth wires
Note:
The mains supply voltage and the customer-side fuse
protection of the mains power line → must conform to the
specifications on the type plate.
Wiring installation by the owner/operator
→ in accordance with IEC 60364-4-43,
IEC 60364-4-473 and
IEC 60364-5-52 and
customer employs a residual current circuit breaker in
accordance with EN 50178 or IEC 755.
Selection of the wire cross-section
→ in accordance with DIN VDE 02984 (VDE 0298 Part 4):
Table A.1 in A2 method of installation and Table 13.5.1 of
NFPA 79 (NFPA = National Fire Protection Association).
For carousels equipped with frequency converter: Note
If the customer employs a residual current circuit breaker at For carousel versions with frequency
the installation site, → a "universal, time-delayed residual converter, an additional separate earth
current circuit breaker (Type B)" is required in accordance with wire is required in accordance with
EN 50178 or IEC 755. EN 50178.
Safeguarding the wiring installation Caution!
Wiring installations may only be safeguarded as follows The regulations of the respective national or
(all values are maximum values): local electricity providers apply.
Connection Wire cross-section Safety device on Connection value Wire cross-section Safety device on
value according in accordance with: the mains side according to in accordance with: the mains side
to type plate type plate
VDE 0298-4 NFPA 79 VDE 0298-4 NFPA 79
Table A.1 Table 13.5.1 Table A.1 Table 13.5.1
AC up to Three-phase
(2 loaded wires) current up to
(3 loaded wires)
- 15 A AWG 14 (2.08 mm2) 15 A - 10 A 5 x 1.5 mm2 AWG 16 (1.30 mm2) 10 A
- 16 A 3 x 1.5 mm2 16 A - 15 A AWG 14 (2.08 mm2) 15 A
- 20 A 3 x 2.5 mm2 AWG 12 (3.30 mm2) 20 A - 20 A 5 x 2.5 mm2 AWG 12 (3.30 mm2) 20 A
- 25 A 3 x 4.0 mm2 25 A - 25 A 5 x 4.0 mm2 25 A
- 30 A AWG 10 (5.26 mm2) 30 A - 30 A - A 5 x 6.0 mm2 AWG 10 (5.26 mm2) 30 A
- 34 A 3 x 6.0 mm2 34 A
- 43 A 3 x 10.0 mm2 AWG 8 (8.367 mm2) 43 A
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Hänel Rotomat
5.3 Determining weights
Selecting installation aids according to weights

Refer to the order confirmation for the total weight of the carousel.
So that the correct installation aids are selected and/or provided,
you must determine the weight of the heaviest part of the
carousel. Refer to the following tables for the side part weight in
kg/lbs according to the type, row distance and height.
Refer to Chapter 5.5 for the minimum load capacity of lifting gear.
Side part weights in kg and lbs:

Carousel height in (m)
Carousel 2.5 3.0 3.5 4.0
type Carousel height in (in)
98.4 118.1 137.8 157.5
/100/178 228/503 264/582 312/688 348/767
/100/203 216/476 252/556 288/635 324/714
/100/230 204/450 240/529 276/609 312/688
/100/254 204/450 240/529 264/582 300/662
/100/280 192/423 228/503 252/556 288/635
/100/305 192/423 216/476 252/556 276/609
/100/330 180/397 216/476 240/529 276/609
/100/356 180/397 204/450 228/503 264/582
/100/381 180/397 204/450 228/503 264/582
/100/406 168/370 192/423 228/503 252/556
/100/432 168/370 192/423 216/476 252/556
/100/457 168/370 192/423 216/476 240/529
/115/203 228/503 276/609 312/688 360/794
/115/230 216/476 252/556 300/662 336/741
/115/254 204/450 240/529 288/635 324/714
/115/280 204/450 240/529 276/609 300/662
/115/305 192/423 228/503 264/582 300/662
/115/330 192/423 216/476 252/556 288/635
/115/356 180/397 216/476 252/556 276/609
/115/381 180/397 216/476 240/529 276/609
/115/406 180/397 204/450 240/529 264/582
/115/432 180/397 204/450 228/503 264/582
/115/457 180/397 204/450 228/503 252/556
/125/254 240/529 276/609 324/714 372/820
/125/280 228/503 264/582 312/688 348/767
/125/305 216/476 264/582 300/662 336/741
/125/330 204/450 252/556 288/635 324/714
/125/356 204/450 240/529 276/609 312/688
/125/381 192/423 228/503 276/609 300/741
/125/406 192/423 228/503 264/582 300/741
/125/432 192/423 216/476 264/582 288/635
/125/457 192/423 216/476 252/556 288/635
25
Hänel Rotomat
5.4 Auxiliary personnel
Selecting and providing auxiliary personnel Note

The owner/operator or customer must, at no charge, provide The auxiliary personnel provided must be
suitable auxiliary personnel for unloading, transport and sufficiently qualified for the work.
erection of housing parts. If the number of auxiliary personnel The responsible installer assigns them their
and auxiliary equipment provided does not meet the task and the tools and equipment they need.
requirements listed below, the installation may take longer or
may not be able to be carried out at all for safety reasons. Hänel shall not be held liable for the auxiliary
personnel or their level of qualification.
The information is valid for standard carousels with a ground-
level transport route of approx. 50 m (164 ft) and facilities for
unloading using a high-lift truck or loading ramp.
SAFETY INSTRUCTION
Auxiliary personnel must be equipped with
personal safety equipment (e.g. safety shoes,
safety helmet, work gloves etc.) and wear
them if necessary. For further information,
refer to Chapter 3 on "Safety instructions" and
the corresponding information in the
supporting documents.
Required auxiliary personnel and outlays
Depending on the height of the carousel and the available
auxiliary equipment, 2 to 4 auxiliary personnel are required.
The hours listed here are based on standard conditions and may
vary depending on the circumstances of each case.
If the route to the installation location is difficult, more helpers
may need to be provided.
If more than 2 carousels are delivered at the same time, increase
the number of helpers by 2 for each additional carousel.
Properties of the lifting gear Important!
Load capacity / lifting gear: at least 2.5 t (5,513 lbs) The lifting capacity (load capacity) of the lifting
Fork length / high-lift truck: 1500 to 1800 mm (70.0 / 59.0 in) gear must apply even at the minimum lifting
Note the minimum lifting height. height!
A Unloading the carousel

Carousel type Carousel Number of Number of Approx. time
height installers helpers required
in m (in) (in hrs.)
/100, /115, 2 (78.7) 2 2 1.0
/125 3 (118.1) 2 2 1.0
4 (167.5) 2 2 1.5
B Transport to the erection location

Carousel type Carousel Number of Number of Number of Approx. time
height installers helpers helpers* required
in m (in) Normal transport Difficult (in hrs.)
route transport route
(e.g. with step)
/100, /115, 2 (78.7) 2 2 4 1.5
/125 3 (118.1) 2 2 6 2.0
4 (167.5) 2 4 6 2.5
26
Hänel Rotomat
5.4 Auxiliary personnel (continued)
C Erecting the side parts and installing the housing

in m (in) (in hrs.)
/100, /115, 2 (78.7) 2 2 2.0
/125 3 (118.1) 2 4 2.5
4 (167.5) 2 4 3.0
D Final installation of the housing and electrical installation

in m (in) (in hrs.)
/100, /115, 2 (78.7) 2 None 2.0
/125 3 (118.1) 2 2.5
4 (167.5) 2 3.0
E Carrier installation
in m (in) (in hrs.)
/100, /115, 2 (78.7) 2 None* 2.0
/125 3 (118.1) 2 2.5
4 (167.5) 2 3.0
* If the carriers still need to be transported to the carousel: 2 helpers
27
Hänel Rotomat
5.5 Mechanical auxiliary equipment
Selecting and providing mechanical auxiliary

equipment
As the owner/operator, you must provide free of charge
mechanical auxiliary equipment that conforms to accident
prevention regulations and safety instructions for unloading,
transport and erection of carousel parts.
Difficult transport routes Note
For difficult transport routes such as installations in upper floors, Hänel shall assume no liability for auxiliary
recessed pits/shafts or tight installation spaces for carousels equipment.
taller than 3 m [118.1 in] (see Chapter 5.1), powered auxiliary The auxiliary equipment must be in proper
equipment such as a goods hoist, forklift, chain block or crane condition and have valid inspection stickers.
must be used (see "Rotomat Installation Requirements for the
Owner/Operator for Erection of Carousels using Powered
Auxiliary Equipment").
DANGER
Risk of fatal injury from overturning or falling
of heavy parts!
• When using auxiliary equipment, prevent
risks to your health by following the
accident prevention regulations and safety
instructions.
• For more information, refer to the safety
instructions in this manual and the
Rotomat Operating Manual.
Properties of the lifting gear Important!
Select the lifting gear according to the following parameters: The lifting capacity (load capacity) of the
A Minimum lifting capacity or minimum load capacity lifting gear must apply even at the minimum
lifting height!
• According to the max. weight of the individual carousel parts
(see Chapter 5.3, "Determining weights")
B Minimum lifting height
• According to the following table
Auxiliary equipment Minimum lifting height Properties / Notes

Platform truck Minimum lifting capacity 1 t [2300 lbs]
Ladders E.g. step ladders - no simple ladder.
Chain block Approx. 0.5 m [19.7 in] Minimum lifting capacity 1.5 t [3308 lbs]
above the carousel height The owner/operator must ensure that the lifting gear is fastened such that it withstands the load
capacities.
Goods hoist • Dimensions:
Side part of the carousel, the largest single part
(see Chapter 5.1, "Preparing the installation area")
Installation For setup inside the carousel, with levels at intervals of approx. 2.5 m [98.4 in] and which can
scaffolding, fixed be disassembled level-by-level from above.
• Dimensions:
Width: outside width of the carousel minus 500 mm [19.7 in]
Depth: approx. 2/3 of the carousel depth
The floor of each level must have a door through which components can be
passed.The maximum component size for this purpose is approximately the
carousel depth x carousel width x 115 mm [4.53 in]
28
Hänel Rotomat
5.6 Installation situations and auxiliary equipment, examples
Examples: Installation situation and minimum required auxiliary equipment
Installation situation Auxiliary equipment

Carousels in offices • Step ladders
• Scaffolding
• Chain block for tight installation spaces
and carousel heights over 3 m [118.1 in]
Carousels through multiple • Step ladders
storeys
• Goods hoist
• Chain block
Fig. 10: Examples of mechanical auxiliary equipment
29
Hänel Rotomat
5.7 Transport
Providing the auxiliary equipment

The Rotomat is delivered disassembled.
Ensure that all required auxiliary personnel and auxiliary
equipment (see Chapters 5.4 to 5.5) are available when the
Rotomat is delivered.
Erection location
Survey the conditions at the erection location and make any
necessary adjustments for the transport of carousel parts there.
This will ensure that is possible to carry on with the rest of the
installation process quickly and efficiently.
Safety precautions
For further information, refer to the safety instructions in Chapter 3
and the relevant instructions in the supporting documents.
DANGER SAFETY INSTRUCTION
There is a substantial risk of injury, including Wear a safety helmet!
fatal injury, from falling heavy parts.
When there is a danger from falling parts,
• The parts must be secured from falling
• a helmet must be worn as personal
during transport, for example using a safety
catch or stop mechanisms for lifting belts. safety equipment.
DANGER
There is a substantial risk of injury, including
fatal injury, to third parties - especially
unauthorised persons - in the danger zone of
the transport path.
• Watch out for third parties during transport.
• Ensure that no third parties - especially
unauthorised persons - are in the danger
zone of the transport path.
Transport using mechanical auxiliary equipment DANGER
Ensure the following: Risk of accident when transporting carousel
• A sufficient number of helpers is present. parts over stairs!
• As many helpers as are necessary are employed for each • Avoid using stairs when transporting
transport step. parts of the carousel. It is better to have
• Safety instructions are followed during transport. the carousel parts brought to the upper
storeys from the outside by the
owner/operator, for example using a
lorry-mounted crane, and passed to the
inside through a window or door.
WARNING
There is a substantial risk of injury from
tipping of heavy parts!
• The side parts must be secured from
tipping over during transport.
Fig. 11: Transport example
30
Hänel Rotomat
5.7 Transport (continued)
For taller carousels, auxiliary supports are supplied by the

factory.
If no supports have been attached at the factory, you must use
the Hänel transport cart or attach stable wooden supports as a
tilt protection device.
Unloading the carousel parts from the truck DANGER
For safety reasons, the lorry must be unloaded towards the back, There is a substantial risk of injury, including
and the unloading process must be carried out under the fatal injury, from falling heavy parts.
co-ordination of the installers responsible for the setup.
• Secure lifting belts using stop
mechanisms to keep them from slipping
or shifting out of place.
• Fasten the cables and belts to the
rectangular tube welded between the two
main guides only.
Transport to the erection location DANGER
Ensure the following: Risk of accident when transporting carousel
• Safety instructions are followed during transport. parts over stairs!
• Third parties are not in the danger zone of the mechanical • Avoid using stairs when transporting
auxiliary equipment. parts of the carousel. It is better to have
• The mechanical auxiliary equipment has the required load the carousel parts brought to the upper
capacity. storeys from the outside by the
owner/operator, for example using a
lorry-mounted crane, and passed to the
inside through a window or door.
Fig. 12: Examples: Transport using mechanical auxiliary equipment
Fig. 13: Examples: Transport, negative example - carousel part not secured, risk of accident!
31
Hänel Rotomat
5.7 Transport (continued)
Examples: Transport using powered auxiliary equipment for difficult transport routes e.g. steps
Follow these instructions when bringing carousel parts to upper floors of the owner/operator's facility through a window or door, for
example using a truck-mounted crane or lift truck. They will help you to avoid using the stairs to transport the carousel parts.
DANGER
There is a substantial risk of injury, including
fatal injury, from falling heavy parts.
• Secure lifting belts using stop
mechanisms to keep them from slipping
or shifting out of place.
• Fasten the cables and belts to the
rectangular tube welded between the two
main guides only.
SAFETY INSTRUCTION
Wear a safety helmet!
safety equipment.
Fig. 14: Transport using high-lift truck/wall opening
Fig. 15: Transport using high-lift truck/window
32
Hänel Rotomat
5.8 Examples: How to use auxiliary equipment during installation
A) Handling the side parts

The cables and belts may be fastened only to the rectangular
tube welded between the two main guides only.
Supports
When the side parts are erected manually, they must be secured
against a stable part using supports.
Refer also to Fig. 16.
Supports
33
Hänel Rotomat
5.8 Examples: How to use auxiliary equipment during installation (continued)
B) Handling the headpiece

The following is an example of installation using scaffolding. Note
Other adequate installation types are
permissible.

There is a substantial risk of injury, including Wear a safety helmet!
fatal injury, from falling of the headpiece.
• The headpiece must be secured from • a helmet must be worn as personal
falling during transport (for example, using safety equipment.
a safety catch or safety cables between
the part and lifting gear).
Bringing the headpiece to the installation position

Step Task Important note/illustration
1 Bring the headpiece to the installation position
manually or using a chain block, for example
(see Fig. 17).
2 Attach the headpiece and screw it onto the side parts.

The illustration shows an example of the installation
situation using scaffolding (Fig. 17).
Fig. 17: Example: Attaching the headpiece using scaffolding
For more information, refer to the instructions in the

chapter on "Installing the headpiece" in the Hänel
installation instructions for the Rotomat.
34
Hänel Rotomat
5.8 Examples: How to use auxiliary equipment during installation (continued)
C) Example: Erecting the side parts using a chain block

To erect the side parts using a chain block, use a hook and
safety catch.
Otherwise, there is a substantial risk of injury, Wear a safety helmet!
including fatal injury, from falling of the panels.
• The side parts must be secured from
falling while being erected (for example,
using a safety catch or safety cables safety equipment.
between the part and lifting gear).
Erecting the side parts

Step Task Important note/illustration
Erect the side part at the installation position using the
chain block.
Fig. 18: Erecting the side part using a chain block (examples)
35
Hänel Rotomat
5.9 Ladders and scaffolding
Using ladders and scaffolding

Safety precautions
For further information, refer to the safety instructions in
Chapter 3 and the relevant instructions in the supporting
documents.
DANGER
There is a danger of falling when using
ladders and scaffolding.
• At great heights, ladders and scaffolding
may not be used without fall protection
equipment.
DANGER
There is a danger of falling when using unsafe
ladders and scaffolding.
When working on the Rotomat, only safety
ladders may be used!
• Check the condition of the devices before
using them.
• Damaged or incomplete auxiliary
equipment must be repaired before use,
or else it may not be used for installation.
Fig. 19: Use safety ladders only!
Wear fall
protection!
Fig. 20: Safety step ladder Fig. 21: Scaffolding
36
Hänel Rotomat
5.10 Providing a service access door
Fulfilling the service requirements at the customer's location

For maintenance tasks that are necessary after the carousel is
put into service, access must be provided by means of the
service doors; refer to the Power Supply and Foundation Plan.
Ensure that the necessary access is guaranteed, and that for
working heights of 2 m (78.7 in) or more, the customer has
provided auxiliary equipment such as a safety ladder or
scaffolding. Ensure that safe and unobstructed access is
possible using the respective auxiliary equipment.
There is a danger of falling when using Wear a safety helmet!
ladders and lifting platforms.
• At great heights or for carousels that
extend over several floors, scaffolding and
lifting platforms may not be used without safety equipment.
fall protection equipment.
• Fastening anchors with corresponding
load capacity must be provided by the
owner/operator.
Important!
The bottom edge of the top service access
door must be at least 2 m (6.57 ft) above the
access level of the Rotomat, and there must
be a clear view into it from the access point.
If it is anticipated that the safety clearance
will be smaller or there will be no clear view,
this must be specified when placing the
order.
In that case, a safety switch and an additiona
l main switch are installed on the top service
access door.
Fig. 22: Example: Rotomat service access door
37
Hänel Rotomat
5.11 Additional instructions
These Installation Requirements are based on our terms of

delivery and the standard technical design of our carousels.
Deviations from these, if technically feasible, require a surcharge.
38
Hänel Rotomat
6. Disposal instructions
Disposing of the packaging material

Dispose of the packaging material in an
environmentally responsible manner.
Our units require effective packaging to protect
them during transport. However, we use only
as much as absolutely necessary.
The packaging material is composed of the following recyclable

materials:
• Wood (untreated)
• Corrugated cardboard/cardboard/paper
• Polyethylene film (transparent)
• Tightening straps: Polypropylene (black)
When disposing of the unit, follow the locally applicable laws and
regulations of the country of use.
In Germany, the packaging can be given to your local recycling
centre.
You can obtain their addresses from your local government.
Disposing of the decommissioned carousel after disassembly

Before being disassembled, the decommissioned carousel must
be completely unloaded and, after removing all carriers,
disconnected from the mains power supply by the
owner/operator. The decommissioned carousel must be
disassembled in the reverse logical order to that described in
these Installation Instructions.
DANGER
The safety instructions of these Installation
Instructions and the Rotomat Operating
Manual must be followed at all times!
When disposing of the unit, follow the locally WARNING

applicable laws and regulations of the country
of use. In Germany, you can give the used Danger to the environment from toxic
parts to a recycling centre or vehicle or scrap substances!
recycling facility. You can obtain their • Components of the carousel contain toxic
addresses from your local government. substances.
If you have specific questions about the
proper disposal of the parts, please contact
your local environmental officer or the Hänel
factory.
Note the list of materials
(see the following page).
39
Hänel Rotomat
6. Disposal instructions (continued)
Materials
Material Use Note
Steel • Frame, cross brackets etc.

• Screws
• Various connecting elements
• Chains
Sheet steel • Housing

• Panelling
Copper • Cables
Plastic, rubber, PVC • Cables

• Seals
• Rollers
Batteries, NiCd/Li batteries • Control system
LCD displays • Control system WARNING

• Indicators
Danger from toxic substances!
• LCD displays contain
highly toxic fluids.
Electronic scrap • Electrical supply

• Control units
• Boards with electronic components
• Light barriers
40
Hänel Rotomat
Keyword index
Keyword Page Keyword Page

Accessibility 16 Hazardous materials 13
Additional instructions 38 Headpiece, handling 34
Ambient conditions 13
Auxiliary equipment, mechanical 28
Auxiliary equipment, powered 28 Installation in a recessed pit 18
Auxiliary personnel 26
Ladders 36
Cable securing device 11 Level tolerances 20

Ceiling holes 17 Lifting gear 28
Checking the erection location 20 Load 12
Checking the substrate 20
Colors and signal words 3
Mains power supply 21
Materials 40
Dimensions 16 Mechanical auxiliary equipment 35
Disposal, decommissioned carousel 39 Modification 12
Disposal, materials 40
Disposal, packaging 39
Document information 7 National regulations 13
Niche installation 19
Electrical connection 21
Electrical connection values 23 Personal safety equipment 11
Personnel requirements 9
Preparing for installation 15
Fall protection equipment 11 Preparing the installation location 13
Fire protection 12
Floor characteristics 20
Room height 19
Guide 3
41
Hänel Rotomat
Keyword index (continued)
Keyword Page Keyword Page

Safety equipment, personal 11 Target group 3
Safety instructions 11 Tight installation spaces 19
Scaffolding 38 Transport 30
Service access 37
Service access 37
Side parts, handling 30 Weights 25
Symbols 4 Wire cross-section 24
42

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Hänel Büro- und Lagersysteme

Installation Requirements for the Owner/Operator

2010-01-01 (RT) INST-RO-REQ-O.en.odt

Chapter Subject Page

Symbols and signal words used

Secure the main switch(es)!

Symbols and signal words used (continued)

Wear a safety helmet!

Scope of validity of the Installation Requirements

1. Basic information (continued)

Purpose of this manual

Safety during installation

3. Safety instructions (continued)

Safety during installation (continued)

4. Preparing the installation location

Chapter Subject Page

4.1 Ambient conditions and hazardous materials

Ambient conditions DANGER

5. Preparing for installation

Chapter Subject Page

5.1 Preparing the installation area

An adequately sized installation area must be made available WARNING

5.1 Preparing the installation area (continued)

Accessibility (continued) Note

Fig. 1: Floor made of boards

5.1 Preparing the installation area (continued)

Installation in a recessed pit

5.1 Preparing the installation area (continued)

Height and width of the area

5.1 Preparing the installation area (continued)

Checking the floor characteristics

Fig. 5: Checking the floor characteristics

5.2 Mains power supply

5.2 Mains power supply (continued)

Connection variants (continued)

B Type /100, /115, /125

5.2 Mains power supply (continued)

Electrical connection values Note

Nominal mains current (A)

Electrical connection values - 60 Hz mains power

Nominal mains current (A)

Nominal mains current (A)

5.2 Mains power supply (continued)

5.3 Determining weights

Selecting installation aids according to weights

Side part weights in kg and lbs:

5.4 Auxiliary personnel

Selecting and providing auxiliary personnel Note

A Unloading the carousel

B Transport to the erection location

5.4 Auxiliary personnel (continued)

C Erecting the side parts and installing the housing

D Final installation of the housing and electrical installation

5.5 Mechanical auxiliary equipment

Selecting and providing mechanical auxiliary

Auxiliary equipment Minimum lifting height Properties / Notes

5.6 Installation situations and auxiliary equipment, examples

Examples: Installation situation and minimum required auxiliary equipment

Installation situation Auxiliary equipment

Fig. 10: Examples of mechanical auxiliary equipment

Providing the auxiliary equipment

Fig. 11: Transport example

5.7 Transport (continued)