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XL30D truss manual
WWW.PROLYTE.COM
PROLYTE USER MANUAL
FOR XL30D TRUSS
Part 2 of 2
PART 2 NOT TO BE USED IN ISOLATION - ONLY TO BE USED IN CONJUNCTION WITH
PART 1: GENERAL TRUSS MANUAL
ARTICLE CODE:
READ THIS MANUAL CAREFULLY AND UNDERSTAND ALL OF ITS CONTENTS PRIOR TO
ASSEMBLY AND LOADING OF PROLYTE TRUSS.
1
CONTENTS
1. PREFACE
3
2. SCOPE
3
3. IDENTIFICATION
3
4. ASSEMBLY
4
5. DISASSEMBLY
4
6. TECHNICAL SPECIFICATIONS
4
7. TOOLING LIST
4
8. SLINGING TRUSSES
5
APPENDIX A: LOADING TABLES
6
APPENDIX B: STRUCTURAL DATA TRUSSES
7
APPENDIX C: DECLARATION OF CONFORMITY, CE
8
PROLYTE GROUP© 2014
Prolyte User Manual for XL30D Truss
Read this manual carefully and understand all of its contents prior to assembly and loading of
Prolyte truss. Prolyte has made every effort to ensure the accuracy of this manual; no liability
will be accepted for errors. Prolyte reserves the right to change or alter its products or manuals
without prior notice.
No part of this manual may be reproduced in any form or by any means without prior written
permission. PROLYTE GROUP - phone +31 (0)594 85 15 15 - fax +31 (0)594 85 15 16
WWW.PROLYTE.COM
2
VERSION 1.0 - APRIL 2014
XL30D truss manual
1. PREFACE
Read this manual carefully and understand all of its contents before you
assemble and load the truss. Part 2 shall be read in conjunction with Part 1,
“General Truss Manual”. Part 2 supersedes Part 1 in the case of conflicts.
This preface explains how to interpret the symbols and text styles in this
manual.
This manual has been written for all users of Prolyte trusses. Please ensure
that you read and understand this manual completely before using the trusses.
This manual should be accessible to everyone assembling, disassembling, or
using the trusses. Save this manual for later use. Prolyte can send you an
additional manual on request, or you can download it from the Prolyte website.
DANGER
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL
RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS TO BE
LIMITED TO THE MOST EXTREME SITUATIONS.
WARNING
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD
RESULT IN DEATH OR SERIOUS INJURY.
CAUTION
This manual has been written for all the users of Prolyte Truss elements. Make
sure that you read and understand this manual completely before using the
Truss elements. This manual should be accessible for everyone assembling,
disassembling or using the Truss elements. Save this manual for later use. At
request, we can send you an additional manual or you can download it from
the Prolyte website. (www.prolyte.com)
For health and safety reasons people assembling, disassembling, transporting
and maintaining truss elements should wear adequate Personal Protection
Equipment (PPE) like - but not limited to - gloves, sound protection, hard hats
and safety shoes. The noise levels during assembly and disassembly can
exceed 80dB. Elements weighing 20kg or more shall be carried by at least
2 persons. Artists, performers or people who have to be on the stage or in
the vicinity of 50cm shall be instructed and informed about correct use and
possible dangers before use.
2. SCOPE
Prolyte XL30D trusses are structural elements with incorporated 3 phase
power rail, designed to be repeatedly assembled and disassembled in order to
carry loads in temporary or permanent installations. The 3 phase power track
is suitable for 240V, 16 amp per phase. Depending on the application, Prolyte
trusses can be considered to be lifting accessories or construction products.
If used as lifting accessories, trusses are subject to the European Machinery
Directive 2006/42/EC. A declaration of conformity can be found in Appendix
C. If trusses are used as construction products in temporary or permanent
constructions they are subject to the European Construction Products Directive
305/2011/EC. A declaration of performance can be found in Appendix C.
3. IDENTIFICATION
All Prolyte trusses have an embossed logo on their couplers and identification
stickers. These should never be removed. XL30D trusses are distinguished by
the number of embossed rings on the coupler receiver (see figure 1) and the
identification sticker on the product and the technical specifications.
Figure 1: Embossed rings
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD
RESULT IN MINOR OR MODERATE INJURY.
NOTICE
ADDRESSES PRACTICES NOT RELATED TO PERSONAL INJURY
XL30D has one embossed ring.
3000
290
239
239
SAFETY
INSTRUCTIONS
IS USED FOR LISTS OF STEPS, PROCEDURES OR INSTRUCTIONS THAT
MIGHT OTHERWISE CLUTTER UP A DANGER, WARNING OR CAUTION
NOTIFICATION NOTE THAT EQUIVALENT PHRASES, SUCH AS SAFE
OPERATION PROCEDURES OR SAFE SHUT DOWN PROCEDURE, CAN BE
USED IN PLACE OF THE WORDS “SAFETY INSTRUCTIONS.”
Prolyte truss XL30D Technical specifications
Prolyte X30D-truss can be recognized by the CCS6 ® couplers with the
Prolyte-logo at the ends The X30D truss is of triangular shape type:
• 239 (w) x 239mm (h) (centre to centre)
• 290mm (w) x 258mm (h) (outside main chords)
• Top Main chords: 51x2 mm
• Bottom Main chord: custom extrusion with 3 phase Live track
• Diagonals: 16x2 mm
Dimensions can differ +/- 3mm
3
XL30D truss manual
4. ASSEMBLY
WARNING
R-Clips (CCS6-605)
M8 nut (BM-M8-SN)
MAKE SURE YOU USE PROLYTE ORIGINAL PINS AND COUPLERS
1. Inspect the trusses and coupler parts as described in part 1.
2.Put the conical couplers (CCS6-600) into the conical tube-ends of the
truss the wide side of the truss-pinhole points should outward or upward.
See figure 11.
3.Fix the coupler with the tapered steel truss pins (CCS6-603 for repeated
assembly) or (CCS6-604 for longer periods of assembled use).
4.Slightly manoeuvre the truss-sections towards each other. Make sure the
main chord with power track points downwards at all times
5.Use a red copper hammer of 750gr to hammer the pins in place. This
prevents wear on the pins and dents on the truss. Make sure truss pins
are hammered in firmly in order to avoid unwanted deflection.
6.Lock the truss pins in place with the R-clips (CCS6-605) or the M8 selflocking nuts (BM-M8-SN).
7. Check if all connections are made before lifting
DANGER
CONNECTING THE POWER TRACK TO THE MAIN POWER SUPPLY SHALL BE
PERFORMED BY A CERTIFIED ELECTRICAL ENGINEER ONLY
WARNING
CONNECTING LAMPS TO THE POWER TRACK SHALL BE PERFORMED BY A
CERTIFIED ELECTRICAL ENGINEER ONLY
WARNING
MAKE SURE EACH TRUSS ELEMENT HAS PROPER GROUNDING. THIS SHALL
BE PERFORMED BY A CERTIFIED ELECTRICAL ENGINEER ONLY
8.Connect lamps or other electrical elements by means of appropriate
connection systems only. Consult your supplier of these components in
order to confirm if appropriate. Each phase of the power track is suitable
to be loaded with 240V-50hz-16amps
4
Conical coupler (CCS-600)
Spigot
(CCS6-603)
Spigot with thread
(CCS6-604)
5. DISASSEMBLY
WARNING
DISCONNECT THE WHOLE STRUCTURE FROM THE MAIN POWER SUPPLY
BEFORE LOWERING THE TRUSSES OR DISASSEMBLING THE TRUSSES.
1.Disconnect the whole structure from the main power supply before
lowering the trusses or disassembling the trusses.
2. Remove the load from the truss and place the truss on the ground.
3.When the span is resting on the ground, the R-clips or M8-selflocking
nuts can be removed.
4.Manoeuvre the truss a little if needed to release tension from the
coupling parts.
5.Undo the steel truss pins as much as possible in one strike with a red
copper hammer.
NOTICE
NEVER USE SHARP TOOLS SUCH AS SCREWDRIVERS TO DISENGAGE
TRUSS-PINS FROM THE COUPLERS. A TRUSS-PIN IN OPPOSITE DIRECTION
WILL DO
6. TECHNICAL SPECIFICATIONS
For loading tables of trusses, see appendix A.
7. TOOLING LIST
Red copper hammer +/- 750gr Wrench, size 13mm socket Spanner, size 13
: To fit the steel conical pins CCS6-603
and CCS6-604
: To tighten bolts of the CCS6-604
: To tighten bolts of the CCS6-604
XL30D truss manual
8. SLINGING TRUSSES
Prolyte advises slinging trusses as shown below. Trusses shall be suspended
in node points or within 100mm from a node point in order to maintain the
loadbearing capacity.
TRIANGULAR TRUSS
APEX UP
1 SLING BASKET
TRIANGULAR TRUSS
APEX DOWN
1 SLING WRAP
DANGER
MAKE SURE THAT THE LOAD BEARING PARTS OF THE SUSPENSION
EQUIPMENT ARE FIRE RETARDANT AT ALL TIMES.
NOTICE
ECCENTRIC SLINGING SHALL BE CHECKED CASE BY CASE BY A
STRUCTURAL ENGINEER.
5
XL30D truss manual
APPENDIX A: LOADING TABLES
WARNING
CAUTION
TRUSSES SHOULD ONLY BE USED IN THE ORIENTATION SHOWN AND
WITHIN THE LIMITS STATED UNDERNEATH THE LOADING TABLE
UNLESS PROVEN DIFFERENTLY BY A STRUCTURAL ENGINEER, HEAVY
LOADS SHALL BE SUSPENDED FROM THE NODE POINTS ONLY. THE POWER
RAIL CAN BE LOADED WITH 10KG/M1 MAX. THE TOTAL LOAD SHALL NOT
EXCEED THE OVERALL LOAD AS STATED IN THE LOADING TABLES
XL30D - Allowable Loading
MAXIMUM ALLOWABLE POINT LOADS
Uniformly Distributed
Load
UDL
SPAN
Centre Point Load
CPL
DEFLECTION
Single Load Third Points
Load per Point
Single Load Fourth Points
Load per Point
Single Load Fifth Points
Load per Point
TPL
QPL
FPL
DEFLECTION
SPAN
m
ft
kg/m
lbs/ft
mm
inch
kgs
lbs
mm
inch
kgs
lbs
kgs
lbs
kgs
lbs
3
9.8
189.5
127.5
0.4
236.8
522.6
0.4
156.6
345.6
0.5
124.8
275.4
0.5
102.9
227.2
total weight
0.5
4
13.1
110.2
74.2
0.6
186.9
412.6
0.8
126.5
279.3
1.0
102.9
227.1
0.9
80.5
177.7
1.0
5
16.4
70.7
47.6
1.0
152.8
337.2
1.2
105.1
232.0
1.5
83.7
184.8
1.4
65.4
144.3
1.5
6
19.7
48.4
32.6
1.4
127.6
281.7
1.7
89.0
196.3
2.2
69.0
152.3
2.0
54.4
120.1
2.2
7
23.0
34.7
23.4
1.9
108.2
238.8
2.3
76.2
168.2
2.9
57.9
127.8
2.7
46.0
101.5
2.9
8
26.2
25.7
17.3
2.5
92.5
204.2
3.0
65.8
145.2
3.8
49.2
108.5
3.6
39.2
86.6
3.8
9
29.5
19.4
13.1
3.2
79.5
175.6
3.8
57.1
126.0
4.9
42.0
92.7
4.5
33.7
74.3
4.9
10
32.8
14.9
10.1
3.9
68.5
151.2
4.7
49.6
109.4
6.0
36.0
79.4
5.6
29.0
64.0
6.0
11
36.1
11.6
7.8
4.7
58.9
130.0
5.7
43.1
95.0
7.3
30.8
68.0
6.7
24.9
55.0
7.3
12
39.4
9.0
6.1
5.6
50.4
111.3
6.8
37.3
82.3
8.6
26.3
58.0
8.0
21.3
47.1
8.6
1 inch = 25,4 mm | 1m = 3.28 ft | 1 lbs = 0,453 kg
• Loading figures only valid for static loads and spans with two supporting points
• Spans must be supported at each end
• If dynamic loads or wind loads are involved, or more supporting points are applied, contact a
structural engineer or Prolyte Customer Service
• L oading figures are based on German DIN standards; to comply with BS 7905-2 / ANSI E1.2-2006
/ CWA 15902-2, the loading data must be multiplied by 0.85
• The self-weight of the trusses has already been taken into account
• For spans longer than indicated and with a different loading setup use the KYLo program
• ProlyteStructures can create custom‑made pieces on request
• Loading tables triangle truss only valid for apex-up or apex-down
6
Mark approval certificate
No. 2238/04.
Test report No. 2237/04.
TUV certification only valid for
loading table above.
XL30D truss manual
APPENDIX B: STRUCTURAL DATA
TRUSSES
The data mentioned is based on calculations according to Eurocode EN 1999
and calculated with a safety factor of 1.5 on the load side.
WARNING
Trusses and structures from assembled trusses shall be calculated based on
the structural data provided.
WARNING
NEVER MIX STRUCTURAL DATA FROM DIFFERENT STANDARDS WITHOUT
KNOWING THEIR RESPECTIVE SAFETY PRINCIPLE
NEVER EXCEED THE MENTIONED STRUCTURAL CAPACITY
Technical Specifications - XL30D Series
Type
Triangular (D)
Alloy
EN AW 6082 T6
Main Tubes (Chords)
51 x 2 mm
Braces
16 x 2 mm
Coupling System
CCS6
Type
Allowable Normal Force in Main Chord:
XL30D
12.44
kN
Allowable Normal Force in Diagonals:
6.94
kN
Surface area complete truss:
10.26
cm²
Moment of Inertia Y-axis:
993.87
cm4
Moment of inertia Z-axis:
773.70
cm4
Allowable bending moment Y-axis:
2.46
kNm
Allowable bending moment Z-axis:
3.82
kNm
Allowable shear force Z-axis:
8.50
kN
Allowable shear force Y-axis:
4.90
kN
7
XL30D truss manual
APPENDIX C: DECLARATION
OF CONFORMITY, CE
CE-DECLARATION OF CONFORMITY FOR MACHINERY
(Directive 2006/42/EEC Annex I)
Prolyte Group bv,
Industriepark 31,
9351 PA Leek, The Netherlands,
Herewith declares that:
Prolyte Aluminium trusses E15V, E20L, E20D, E20V, H20LB, X/H30L, XL30D, XU30D, X/H30D, X/H30V,
X/H40L, X/H40D, X/H40V, H40R, S40T, S36R/V, S36PRA-D/F, B52T, C52T, H52V, S52SV/V/F, S66R/V/RV/
VV, S100SV, B100RV, S100F, B100CW, D75T, M145RV, SP2, SP3, SP4, AO2, AO3, AO4, MX2, MX3, MX4
Litepro2, Litepro3, Litepro4.
• are in compliance with the Machinery Directive 2006/42/EEC annex I
• the following harmonized standards have been applied (or parts/clauses of):
EN 292-1, EN 292-2, EN 294, EN 349
• the following national technical standards and specifications have been used (or parts/clauses of): DIN 18000-1, DIN 4113- all parts , BGV C1 / GUV 6.15, BS 7905-2, CWA 15902-2,
EN 10002-1, EN 1990, EN 1999 all parts, EN 30042:1994, ISO 3834-1 / 3, EN 292-1 / 2, EN 754 all
parts, EN 755 all parts, EN 515, EN 573, EN 10204:2004
Leek, The Netherlands 28-08-2012
M. Hendriks
Technical Director
8
XL30D truss manual
9
XL30D truss manual
Prolyte Group HQ
Leek, Netherlands
[email protected]
WWW.PROLYTE.COM
10
Prolyte Products UK Ltd
Wakefield, England
[email protected]
Prolyte Products GmbH
Emsdetten, Germany
[email protected]
FACEBOOK.COM/PROLYTEGROUP
Prolyte Products RO SRL
Slatina, Romania
[email protected]
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