Pro Lyft 2017 Brochure

User Manual: ProLyft-2017-brochure

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Aetos hoists
Controllers
Rigging gear

ProLyft is a
Prolyte Group brand

205

Photo by Promontaje

206

Contents
INTRODUCTION 206
AETOS CHAINHOISTS 208
CHAINHOIST ACCESSORIES 211
AETOS BASIC CONTROLLER 215
AETOS PRO CONTROLLER 216
THUJA NETWORK 218
AETOS + 219
AUXO 215
MANUAL CHAIN HOISTS 221
PROTRAC 223

207

INTRODUCTION

Photo: Perinic Sistemi D.O.O, Voice of Croatia

Get Ready for the Next Level
When Simplicity in Motion is the ultimate goal, there is always
a next level to meet. ProLyft invites you to take that level further
with a product range that is fit to meet the future.

ProLyft products
Lifting, drive and control solutions from ProLyft make

Made for entertainment

productions happen, on stage, on tour, in theatres or sports

ProLyft Aetos hoists are designed to meet the increasingly

arenas. They ensure safe object or performer movements

exacting demands of the entertainment market. These fool proof

and protect performers in their daily work. Whether up, down,

hoists are designed to withstand rigorous transportation and

left or right, the direction, speed or load of the movement is

rough handling, and can be serviced just about anywhere –

only limited by your imagination. ProLyft is able to cover a

even if it is 12 metres above the stage!

broad spectrum of lifting, drive and control solutions within

ProLyft Aetos controllers for electric chain hoists are designed

the entertainment market due to employees with an open ear

to meet the increasingly exacting demands of the entertainment

for customer demands and the ability to translate ideas into

market. The controllers are designed in accordance with the

standard or customized solutions.

latest standards, using a user-friendly layout, reducing the risk
of operator failures, in either simple or complex lifting situations.

208

Photo: ProLyft Service Point training at Prolyte Asia Pacific

The Unique ProLyft Program
ProLyft sustains a unique service programme on its complete
hoist range, developed to offer maximum service and support
for all hoist owners. This program encompasses:
• Installed network of trained and certified Service Points.
• Lifetime warranty.
• Individual identification - RFID tag on every hoist for easy,
web-enabled, track and trace functions.
• ProLyft Service database – automatic reminders for
re-certification.
• Test certificates worldwide online available for owners of
every hoist.

209

AETOS CHAINHOISTS

Photo: © Prolyte Group

THE PROLYFT AETOS RANGE
The Aetos range is fully equipped to meet future demands in lifting
equipment and offers clever features and carefully engineered product
attributes. It comprises standard 250kg, 500kg and 1000kg hoists and
controls.

Optimised Chain Feeding:
• Specially designed disentangle plate for optimal and jam-free chain feeding
• 90% reduction of locking chains.
• Jam-free steel chain guide.
• Disentangle plate insert softer than the chain.
• Chain bag bracket with integrated dead end of chain attachment.

EASY TO SERVICE:
• Easy replaceable disentangle plate insert.
• Easy access to chain guide and load wheel.
• Easy mounting of optional second brake.
• Easy replacement of electronic circuit board.
• Covers equipped with safety steel and captive bolts.
• All electronic components integrated on 1 circuit board.
• Adjustable clutch.

EXTENDED LIFE, REDUCED MAINTENANCE
ProLyft Aetos electrical chain hoists have been carefully engineered for the
entertainment industry; specifically designed to endure daily use, extending the typical life expectancy of the hoist and chain.

210

DESIGN:
• Damage reducing housing design.
• Hand grips integrated in covers.
• Replaceable smooth bumpers on covers.
• Through and through coloured plastic covers.

AETOS 250 KG HOIST

358
213
191
135

388
381

Limit switches on all hoists:
• Both “direct control” and “low voltage control” hoists are equipped with limit switches
as standard.
• The limit switches are activated by a foam chain stop.
• Prevents hoists from being overloaded when running against the stop.
• Adding or positioning a foam chain stop to set a limit takes less than
a minute.

112

AETOS 500 KG HOIST

437
255
230
160

415
405

PREPARED FOR D8+, CATEGORY A AND BGV-C1 USE:
• The clutch overload protection device is mounted outside the
drive train.
• Easy mounting of the second brake.
• Proper load capacity marking supplied with second brake.
• Limit switches available in direct control and low voltage control
versions.
• Prepared for double end limit switches.
• Output shaft for rotary limit switch or encoder connection.

160,9

123,9

AETOS 1000 KG HOIST*
533
523

540
304
263
196

STANDARD FEATURES OF THE AETOS RANGE:
• Available in a 250kg, 500kg and a 1000kg hoist body.
• Fixed speed of 4m/min.
• Available in “direct control” and “low voltage control” versions.
• CEE form plug 16Amp 4pin and cable with strain relief for power
connection.
• CEE form plug 10Amp 4pin and cable with strain relief for low voltage
control (optional).
• Equipped with limit switches on all hoists, both direct control and low
voltage control.
• End limit switches are activated by chain stop for 100% repeatable
accuracy and easy of use.
• External limit switches can be used for hoists used above a grid or
false ceiling.
• Multiple voltage motor, suitable for worldwide use.
• Chain bags for 30m up to 80m available.
• 5-pocket load wheel.
• Zinc-plated load chain.
• 100% sealed aluminium transmission house without oil plugs.
• Standard swivel hook on hoist body and hoist chain.
• IP 55 protection.

192

146

* Can be converted to a double reeved 2000kg hoist

211

AETOS CHAINHOISTS

Technical specifications
Load capacity

250 kg

500 kg

1000 kg

2000 kg

Lifting speed

4m/min

2m/min

Operating voltage

230/400V - 50Hz

208/460V - 60Hz

Protection Class

IP 55

Motorpower at 50Hz

0,25 kW

0,33 kW

0,66 kW

Current consumption at
full load

0,75 Amp @ 400V

0,82 Amp @ 400V

1,46 Amp @ 400V

1,3 Amp @ 230V

1,42 Amp @ 230V

2,53 Amp @ 230V

FEM Class

1Am

FEM Duty factor

50%

Starts per hour

300

Noise Level

60 dBA

Load Wheel

5 pocket

Load Chain EN 818-7

4,0 x 12,2mm

5,0 x 15,1mm

7,1 x 20,5 mm

Falls of chain

Weight of Chain

0,35 kg

0,53 kg

1,1 kg

Weight of Body

18 kg

28 kg

47 kg

Type of Control

DC and LVC

Limit switches

single up/low limitswitches on DC
and LVC

Type of Power Connector

CEE 16A-4p (red)

Type of LVC Connector

CEE 10A-4p (yellow)

Low Voltage Control
Voltage

24V

Easily Adaptable:
• Covers 180 degree rotatable for motor-up use.
• Easy mounting of optional second brake.
• Brake shaft and electronics prepared for second brake.
• Output shaft prepared for rotary limit switch or encoder connection.
• All hoists can be double reeved.
• Swivelling chain bag bracket for motor-down and motor-up use.
• Multiple voltage motor.

212

AETOS ACCESSORIES

Photo: PROmontaje,

AETOS ACCESSORIES RANGE
A complementary range of accesories, to adapt your hoists to all types of
use. Sturdy chainbags, with a perfect fit and reinforced bottom, to keep the
chain secured in the bag, from 22 to 80m chain lenght.

Swivelling chain bag brackets for motor-down or motor-up use. For all
hoists types. High grade zinc plated chain to complement your hoists.
Available in several lenghts and loading types.

PLA-10-004

PLA-10-013

PLA-10-009

Chainbag max 22mtr, 4.0x12.2mm chain

Chainbag max 30mtr, 5.0x15.1mm chain

Chainbag max 65mtr, 7.1x20.5mm chain

PAE-S-BR250

PAE-S-BR500

PAE-S-BR1000

BRACKET CHAINBAG ASSY AETOS 250

BRACKET CHAINBAG ASSY AETOS 500

BRACKET CHAINBAG ASSY AETOS 1000

213

AETOS ACCESSORIES

PLS-10-002

PLS-12-002

PLS-11-002

Chain 4X12,2mm/m (250Kg hoists)

Chain 5,0x15,1mm/m (500Kg hoists)

Chain 7,1x20,5mm/m (1000Kg hoists)

PLA-10-006

QUIK LINK 4MM,ELV.FOR CHAINBAG.

Quick connection link to connect the chainbag safely to the chainbag bracket.

PLA-10-008

QUIK LINK 6MM,ELV.FOR CHAINBAG.

Quick connection link to connect the chainbag safely to the chainbag bracket.

PLA-31-05

PLA-32-05

PLA-33-05

PLA-34-01

Control Cable Low Voltage Hoists

Powercable 32A/400V/5p

Mutli cable, 16p. HARTING

6A, CEE 4p. To be used for low voltage controlled hoists. Available in several lenghts.

Mains cable 32A, CEE 5p. To be used to
connect your controls to the power system.
Available in several lenghts.

To be used to connect up to 4 hoists - in
combination with the 4-way break-out or
break-in. Available in several lenghts.

Break-in Cee-form to Harting, Direct
Control
Adapter to connect a multi cable to 4 motor
cables . 4 x 4p. Male CEE connector to
female HARTING connector.

PLA-34-02

PLA-34-04

PLA-35-05

PLA-36-05

Break-out Harting to Cee-form, Direct
Control
Adapter to connect 4 motor cables to a
multi cable. Male HARTING connector to 4 x
4p. female CEE conector.

Break-out Harting to Cee-form, Low
Voltage Control
Adapter to connect 4 motor cables to a
multi cable. Male HARTING connector to 4
x 4p. female CEE conector. For low voltage
hoists.

Powercable 16A/400V/3p

Powercable 16A/400V/5p

Motor cable 16A, CEE 3p. To be used for
direct controlled single phase hoists. Available in several lenghts.

Mains cable 16A, CEE 5p. To be used to
connect your controls to the power system.
Available in several lenghts.

214

AETOS AS THE STARTING POINT
Aetos hoists and controllers make it possible to create the best and most
affordable solution for every lifting situation. Standard Aetos hoists and
controls are fit to cover your average lifting situation, they are designed
with an understanding of the requirements of entertainment rigging, making them easy and intuitive to operate.
The system offers power and control connections which are commonly
used within the entertainment sector worldwide and are easy to adapt to
special power requirements.
The control system offers added safety through a clear overview of selected hoists during operation, while an optional remote control guarantees
an overview of the lifting situation from the best possible viewpoint.

REMOTE CONTROL
All Aetos remote controls have an ergonomic design to make them easy to
handle and operate.
The Aetos 1-channel remote control can be used as a remote up/down in
combination with the Aetos Pro controllers, or as a pickle on a single Auxo
hoist.
The Aetos 24-channel remote control brings all of the functionality of the
Pro controllers to the remote control, including possibilities for both left
and right hand operation.
All remote controls connect to the hoists or controllers using the Thuja
Network connection (7p XLR), indicators on the front panel show errors,
selections and availability.

Low voltage setup

215

AETOS ACCESSORIES

PLA-40-001

PAE-A-FC500

PAE-A-FC1000

Flightcase 250kg hoist

Flightcase 500kg hoist

Flightcase 1000kg hoist

PLA-50-003

PLA-50-007

Raincover 1000kg hoist single reeved

Raincover 1000kg hoist double reeved

216

AETOS BASIC CONTROLLER

Photo: © Prolyte Group

PROLYFT AETOS CONTROLLERS
ProLyft Aetos controllers have been engineered with an understanding
of the needs of rigging operators. The front panel layout and the
functionality of the buttons have been carefully designed to meet

the demands of daily practice in lifting, where any selection mistake can
create an overload situation.

AETOS BASIC CONTROLLERS
Aetos Basic controllers are designed for applications that do not require
advanced technology, offering a safe, simple, robust and effective control
solution.
Available models

• 4- and 8-channel version.
• Direct Control and Low Voltage Control version.
• 400Volt and 230V version.
Specifications
• Robust rotating up/down selection switches per channel.
• Main circuit breaker per 4-channels.
• LED phase indication.
• E-stop at SIL2 level.
• Illuminated start button.
• 32Amp/400V CEE form 5pin mains connector.
• Mains connector with phase inversion insert.
• Harting 16pin output connector(s).
• 19-inch rack mountable housing.
• No link function.
Article codes:
PAE-C4DC-00
PAE-C4LV-00
PAE-C8DC-00
PAE-C8LV-00
PAE-C4DC-01
PAE-C4LV-01
PAE-C8DC-01
PAE-C8LV-01

CH CONTROLLER AE 4 WAY BASIC 400-3 DC
CH CONTROLLER AE 4 WAY BASIC 400-3 LV
CH CONTROLLER AE 8 WAY BASIC 400-3 DC
CH CONTROLLER AE 8 WAY BASIC 400-3 LV
CH CONTROLLER AE 4 WAY BASIC 230-3 DC
CH CONTROLLER AE 4 WAY BASIC 230-3 LV
CH CONTROLLER AE 8 WAY BASIC 230-3 DC
CH CONTROLLER AE 8 WAY BASIC 230-3 LV

217

AETOS PRO CONTROLLER

Photo: Promontaje

THE AETOS PRO CONTROLLER RANGE
The Aetos Pro controllers are designed for:
• Professional rental companies, demanding a flexible control system to
facilitate the frequent change of lifting configurations, offering both easy
operation and a clear overview of the selected and operated hoists.
• Permanent installations, where controllers are centralised and operated
remotely; and where there is a growing demand for multiple remotes
and E-stops.
• Use with touch screen remotes, enabling you to create groups of hoists
or patch your hoists to any control position.

SPECIFICATIONS
Front panel:
• Sealed front panel with integrated buttons.
• Hoist selection switches to select the group of hoists to operate.
• Group up/down switch.
• Bump function within a selected group.
• Single deselect button for easy clearing of the previous selection.
• Emergency stop at SIL2 level.
Back panel and housing:
• 32Amp/400V CEE form 5pin mains connector with 1,5m powercord.
• Automatic phase order detection.
• Main breaker on back panel, per 4-channels.
• Modular power packs per 4 channels, easily interchangeable.
• Harting 16pin output connector(s).
• 9-inch rack mountable housing.
AVAILABLE MODELS:
• 4-, 8- and 12-channel version.
• Direct Control and Low Voltage Control version.
• 400Volt and 230Volt version.

218

With special LED indicators:
• LED indicators for “power”, “breaker trip” and “operational”.

• LED indicators to show the selection per switch.
• LED output automatically adjusts to light conditions:
· Bright in the sun.
· Soft in the darkness of a stage.

PAE-C4DC-10
CH CONTROLLER AE 4 WAY 7P-BUS 400-3 DC
PAE-C4LV-10
CH CONTROLLER AE 4 WAY 7P-BUS 400-3 LV
PAE-C8DC-10
CH CONTROLLER AE 8 WAY 7P-BUS 400-3 DC
PAE-C8LV-10
CH CONTROLLER AE 8 WAY 7P-BUS 400-3 LV
PAE-C12DC-10
CH CONTROLLER AE 12 WAY 7P-BUS 400-3 DC
PAE-C12LV-10
CH CONTROLLER AE 12 WAY 7P-BUS 400-3 LV
PAE-C4DC-11
CH CONTROLLER AE 4 WAY 7P-BUS 230-3 DC*
* Other 230V options follow the same article coding as the 400V

REMOTE CONTROL:
The unique Aetos remote control has 24 channels. Its ergonomic design
makes it easy to handle and operate. The up and down buttons are situated on both the left and right sides of the panel to facilitate both left and
right handed operation. The remote control connects to the controller using
the Thuja network connection (7pin XLR). Indicators on the front panel
show errors, selections and availability.
PAE-C24R-10

CH REMOTE AE 24 CHANNEL 7P-BUS

PAE-A-FC19IN4U
Controller ﬂightcase 19-inch 4HE

219

THUJA NETWORK

Photo: © Prolyte Group

INTRODUCING THE PROLYFT THUJA NETWORK SYSTEM
In conjunction with the Aetos range of electric chain hoist controllers,
ProLyft introduces the Thuja network. Thuja is a digital data network for
controlling lifting equipment in the entertainment industry; safe enough for
lifting above people, simple enough for touring use.
The Thuja network will enable far-reaching possibilities for future control
solutions.
The Thuja network allows links between Aetos controllers, creating an
extended system, offering the ability to connect remote controls, read
feedback from hoists and connect extra E-stops.
To prevent interference with other data networks used in the industry, and
to minimize the risk of unsafe network communication, the Thuja network
uses standard cat5 cables with 7-pin XLR connectors.
AETOS PRO CONTROLLERS
• Thuja network connection “Link in” / “Link out” by 7pin XLR’s
on front panel to:
· Link controllers (up to 99).
· Connect remotes.
• The order of linking will automatically number the
controllers on the remote.
• Emergency stop in a linked configuration at SIL2 level.

220

PTH-7PXLR-0.3

THUJA NETWORK CABLE 7P-XLR 0,3M

Thuja network cable to connect lifting control equipment.

AETOS +

STEP UP TO A NEXT LEVEL
The ProLyft Aetos+ range is an extension to your standard Aetos products
with helpful accessories for load measuring and positioning. Creating the
possibility to safely suspend loads above people, protect your lift against
overloading and to provide more essential information to the operator,
thereby adding safety in your lifting application.
Load cells, geared limit switches and encoders work as simple add-ons
to the existing systems. These add-ons are wired to a separate smart
control interface, making the system very cost-efficient and easy to up- or
downscale for each lifting application.
GROUP PROTECTION
Connecting the control interface in a position between the remote control
and the hoist controller, each add-on is automatically connected to the
corresponding hoist, thereby also creating group protection. Crossing any
limit of one of the selected hoists will stop the complete selected group.
AETOS SYSTEM INTEGRATION
Aetos+ accessories fully integrate with all Aetos hoists and Pro controllers:
• Independent from the type of control, direct or low voltage control
• Independent from the load capacity
• Independent from the amount of controlled channels

Due to these options the system offers ultimate flexibility, parts of
the installation can be upgraded without losing control over the
non-upgraded part.
LOAD MONITORING
The load monitoring interface is positioned in between the remote control
panel and the hoist controller. The load monitor reads the
load cells and connects the load data to the corresponding hoist.
Additional functions of the load monitoring interface are:
• Hoist and chain length selection to detect self weight of hoists
• Motor up or motor down selection
• Overload level switch-off setting
• Overload level warning setting
• Peak hold display
Hoists can always be lowered when an overload is detected.
The connection of the hoist to the hoist controller remains unchanged and
is identical to the Aetos range, for either Direct Control or Low Voltage
Control.

Low voltage setup

221

AUXO

AUXO, MADE FOR ENTERTAINMENT
The ProLyft Auxo range provides out-of-the-box solutions for simple to
complex situations, answering the daily needs for safe rigging. The Auxo
system is based on the Aetos hoist bodies, but offers a total new approach
to lifting and control solutions, stepping away from control systems as we
know and opening a world of new possibilities.
THUJA NETWORK
Thuja is a digital data network for controlling lifting equipment in the entertainment industry; safe enough for lifting above persons, simple enough
for touring applications.
All hoists are connected via the Thuja network using a cat5 cable with
7-pin XLR data connection. You can daisy chain from one hoist to another.
Like this all hoist are connected with an individual address, either by self
addressing or by patching, based on the unique hoist numbers.
OPERATING THE AUXO
The Auxo hoist can be operated with:
• A stand alone 1-channel remote control
• A 24-channel remote control in a group of maximum 24 hoists
• A touch screen controller in a set of maximum 999 hoists

222

INTEGRATED COMPONENTS
All Auxo hoists are standard equipped with:
• Load read-out
• Hook position read-out
• Phase order detection, up is always up
• Overload log and overload protection
• Motor up / motor down detection
• Registration of running hours and loaded hours
• Maintenance advice based on running/loading hours
POWER AND EMERGENCY STOP
Each hoist has its own emergency stop relay, power for the hoist may be
taken from any power outlet available. In this set up you can:
• Combine power for the hoists with power for the lighting department
• Take power from the nearest wall outlet
• Daisy chain power from one hoist to another

MANUAL CHAIN HOISTS

Photo: © Prolyte Group

PRODUCT FEATURES: PHC-500ST AND PHC-1000ST
• Available in 500 and 1000 kg load capacity versions.
• Standard lifting chain lengths: 10, 15, 20, 25m.
(The hand chain is always two times the length of the load chain).
• Hand chain guide prevents toppling or jamming of the hand chain.
• High quality bearings to ensure smooth operation.
• Robust, black powder coated housing.
• Zinc plated and/or yellow chromatized brake parts and guide rollers.

• Zinc plated load chain and hand chain.
• Rotating hooks on housing and chain.
CHAIN BAG
The manual chain hoist can be equipped with standard chain bags fitting
the chain or oversized chain bags that can also be used to transport the
manual hoist.
E

F
H

A min.

PHC-500ST

PHC-1000ST-1010

D
D

PHC-500ST

350 21

145 140 80

240

PHC-1000ST

380 28

158 155 87

270

Manual Chain Hoists 500kg and 1000kg

load capacity

Chain size

lift per 1m hand chain overhaul

pull on hand chain at WLL

Weight

PHC-500ST-1010

500kg

5x15mm

26mm

210N

20kg

PHC-500ST-1515

500kg

5x15mm

26mm

210N

27kg

PHC-500ST-2020

500kg

5x15mm

26mm

210N

35kg

PHC-500ST-2525

500kg

5x15mm

26mm

210N

43kg

PHC-1000ST-1010

1000kg

6x18mm

24mm

240N

27kg

PHC-1000ST-1515

1000kg

6x18mm

24mm

240N

37kg

PHC-1000ST-2020

1000kg

6x18mm

24mm

240N

47kg

PHC-1000ST-2525

1000kg

6x18mm

24mm

240N

57kg

223

MANUAL CHAIN HOISTS

QUALITY IN 2 VERSIONS
The manual chain hoists are available in a standard version and in a
version with a rotatable hand chain guide. Both versions offer a 1000kg
and a 500kg SWL capacity. These premium quality, basic hoists offer
different chain lengths on both versions, optional black powder coating and
a high quality zinc plated chain.
OPERATES FROM ANY POSITION
Using the rotatable hand chain guide the operator can work from any
position, being able to follow and operate from any work position. This
allows the operator to stand and work outside the danger zone near the
load. The rotatable hand chain guide makes this hoist type specifically
suited for tower and roof system applications, where the hoist is used in
an inverted position.

PRODUCT FEATURES: PHC-500RHG AND PHC-1000RHG SERIES
• Available in 500 and 1000 kg load capacity versions.
• 360 degree rotating hand chain guide.
• High quality and easy serviceable brake system.
• Zinc plated and/or yellow chromatized brake parts and guide rollers.
• Zinc plated load chain and hand chain.
• Chain guide and gearbox almost completely closed for
maximum protection.
• Rotating hooks on house and chain.
• Available chain length: The RHG series hand chain hoist can be
supplied with any preferred amount of load and hand chain. Used in
combination with most of the MPT towers the hoist will be configured
with 15m load chain and 3m hand chain (PHC-500RHG-0315).

E
I

F
K

N
PHC-500RHG-0315

PHC-1000RHG-0315

Manual Chain Hoists 500kg and 1000kg rotating hand chain guide

PHC-500RHG

300

17 133

148 148 139

206 24

61 87 110

PHC-1000RHG

335

22 156

175 167 164

242 24

70 97 125

load capacity

Chain size

lift per 1m hand chain overhaul

pull on hand chain at WLL

Weight

PHC-500RHG-0315

500kg

5x15mm

33mm

210N

15kg

PHC-1000RHG-0315

1000kg

6x18mm

20mm

300N

25kg

224

PROTRAC

Photo: Royal Opera House, London, UK

READY FOR THE FUTURE
The rapid evolution of contemporary theater productions has placed new
demands on existing fly-bar systems. Important recent developments
include higher loading requirements, a growth in the scope of productions, and the introduction of mechanically operated fly-bar systems. The
demands placed by new production techniques have made many fly-bar
systems no longer suitable for the job.
Developed to fill this gap, ProTrac* is a substantially upgraded fly-bar
system with several extra options and a high loading capacity. Additionally,
because ProTrac is a lightweight system (low inherent weight), it allows a
higher net loading capacity for your winches or drives.

SYSTEM DESCRIPTION
ProTrac consists of a rectangular upper profile of extruded aluminium
combined with a lower round aluminium tube or profile. Three types of
lower profile can be connected to the upper profile:

ACCIDENTS AVOIDED
Compared to commonly used conventional fly-bars or steel ladder beams,
ProTrac dramatically reduces the horizontal bending that results from
applying loads to the fly-bar.
ProTrac has practically NO lateral flex: horizontal bending is less than 2 cm
over 24 m of length when full load is applied. Nearby fly-bars will not be
blocked and, more importantly, potential accidents due to the blocking of
the flyway can be prevented.
Further, ProTrac can be furnished with yellow end-caps to enhance
visibility of the fly-bar, thus providing an extra safety margin for
technicians and actors when working on stage.

The lower profile connects to the upper profile with stud bolts.
Suspension points for the ProTrac components slide into the slot of the
upper profile and are easily fixed, due to a lock and load system. ProTrac is
a modular system.
ProTrac is a modular system. Variable lengths can be connected via internal tubes, which are bolted into place. The connection of two lower profiles
is placed under 45 degrees to guarantee flawless runner travel. ProTrac’s
profiles are black anodised and are furnished with rubber caps at the ends.
The upper profile can be fitted with extra drilled holes of 50 mm (spaced
500 mm) to provide fittings for integrated electrical sockets.

EASY INSTALLATION
The ProTrac system is very flexible, allowing components of several
different lengths to be easily combined and connected.
ProTrac can replace conventional fly-bars in theatres or other venues
without any alteration of the existing installation. There is no need to make
adjustments to the suspension cables or the complete fly-bar system: the
steel wires of the existing system can simply be connected to the
adjustable suspension points of the ProTrac components.
Calculation methods used for ProTrac comply with DIN 56921.

1
2
3

Tube with slot profile 48,3 mm
Tube with slot profile 48,3 mm,
with integrated rail fiting for Helm 100 runner
Tube with slot profile 60 mm,
with integrated rail fiting for Helm 100 runner

ADVANTAGES
• High loading capacity. Max. Point load of 350 kg on 4,5 m span possible
• High Safety Factor: ProTrac has a Safety factor of 5 (on permanent
deformation) and 10 (on failure)
• Reduced horizontal bending. The lateral flex is less than 2 cm over 24 m
length if full load is applied, nearby fly-bars will not be blocked
• Very low inherent weight: ProTrac is 20 to 25% lighter than steel ladder
beams, which offers extra load capacity for your scenery
• Modular and flexible: ProTrac can be used in all theatres or other
venues, without any adjustments or changes to the
structural components
• Compact build height: ProTrac has a build height of only 306 mm
• Black stays black: ProTrac is anodised black
• Enhanced safety; End-caps available in several colours

*ProTrac is a patented system

225

DO NOT
• Exceed the maximum allowable load given
• Cantilever the ProTrac more as stated
in the structural report
• Use damaged parts or suspension equipment

• Only use pre-tensioned steel wires for the suspension of fly-bars
• Check the actual load on the fly-bar before the first movement
• Check the suspension of the load to the fly-bar before the first movement
• Make sure the fly path of loads or set pieces is not blocked
• Make sure you use the right type of sheave for your steel wires
• Only use tested and certified hardware
• Keep a written logbook

Front view

Example:
Winch / Hoist capacity 750 kg.
Length of ProTrac = 24 m.
Self weight ProTrac = 216 kg.
Free loading capacity =
750 kg - 216 kg = 534 kg.
Point loads: 2 x point loads of 267 kg.
Max. Uniformly distributed load =
534/24 = 22,3 kg/m1.

500

2500-4500 (adjustable)

500

250

302

250

2500-4500 (adjustable)

149

2500-4500 (adjustable)

97,5

Connector view

• The given allowable loading is for the complete ProTrac system, and is equal for
48,3 mm or 60 mm lower tube.
• The allowable loading is given for the ProTrac only. In a complete system winch
capacity and total length also have to be taken in account.
• The total weight of 2 point loads in 2 adjacent fields should not exceed the maximum allowable capacity of the suspension cable points.
TECHNICAL SPECIFICATIONS PROTRAC
TYPES

UPPER PROFILE

LOWER PROFILE 48,3 mm LOWER PROFILE 48,3 mm LOWER PROFILE 60 mm +
1 + HELM 100
2 HELM 100
3

Alloy

EN AW 6082 T6 F28

EN AW 6082 T6 F31

EN AW 6005 F26

Profiles

60 diam.

48,3 diam.

60 diam.

Coupling system

bolts

Self weight

6,088 kg/m

1,944 kg/m

1,921 kg/m

2,534 kg/m

lx in mm4

6581770

133896

116630

222400

Wx in mm3

90437

5760

4160

7963

ly in mm

1074310

145635

160570

289000

Wy in mm3

36575

6350

6648

9999

Fig 1. Slide in lock and load block in
upper profile.

Fig 2. Connection of upper to lower profile by
means of stud bolts which are fastened
with a self locking nut.

MAXIMUM DYNAMIC LOADS
SPAN

MAXIMUM ALLOWABLE POINT LOADS

DISTRUBUTED
Load

kg/m

lbs/ft

lbs

2,5

8,2

462,3

311,1

577,9

1275,4

433,4

956,6

288,9

637,7

239,8

529,3

2,7

8,9

396,1

266,5

534,7

1180,0

401,0

885,0

267,3

590,0

221,9

489,7
455,6

2,9

9,5

343,0

230,8

497,4

1097,7

373,0

823,3

248,7

548,9

206,4

3,1

10,2

299,9

201,8

464,9

1026,0

348,7

769,5

232,4

513,0

192,9

425,8

3,3

10,8

264,4

177,9

436,3

962,9

327,2

722,2

218,1

481,4

181,1

399,6

3,5

11,5

234,8

158,0

410,9

907,0

308,2

680,2

205,5

453,5

170,5

376,4

3,7

12,1

209,9

141,2

388,3

857,0

291,2

642,8

194,2

428,5

161,2

355,7

3,9

12,8

188,7

127,0

368,0

812,1

276,0

609,1

184,0

406,1

152,7

337,0

4,1

13,4

170,5

114,8

349,6

771,6

262,2

578,7

174,8

385,8

145,1

320,2

4,3

14,1

154,9

104,2

332,9

734,8

249,7

551,1

166,5

367,4

138,2

304,9

4,5

14,8

141,2

95,0

317,7

701,2

238,3

525,9

158,9

350,6

131,9

291,0

226

Fig 3. The 60 mm lower profile with integrated
rail profile fit for Helm 100 runners for
48H & 60H.

Fig 4. A completely assembled section
of ProTrac.

Photo: Prolyte Campus at TSD Group, Argentina

227

PROLYTE CAMPUS

Photo: TSD Group,

access to this knowledge base for all our customers and users.
Transferring knowledge and creating a dialogue with technicians
worldwide, finding their needs and sharing experiences is a
valuable base for creating solutions that work and help you

Prolyte Campus

grow your business.

Prolyte Campus is a Prolyte Group initiative to support its

available. Providing the tools and training to use the Prolyte

What does the Prolyte Campus
offer?

Group products safely and in compliance with applicable

Sharing knowledge is the pivoting point, in whatever way

standards and regulations will help you perform better. Prolyte

is needed to get the message across. As a start the Prolyte

Campus offers a complete program of learning activities to

Campus will offer a mix of online, printed and seminar based

create awareness on the safe use of Prolyte products.

means of knowledge transfer. Existing activities, like the

customers with the best and most up-to-date knowledge

BlackBook, How to video’s, Rigging Courses and Seminar
Providing the knowledge to let your business grow

possibilities, will be continued. New initiatives, like web based

As a manufacturer Prolyte Group always feels the responsibility

learning content and networking opportunities will be developed.

to supply knowledge as integrated part of its products.

Prolyte users will be encouraged to share their experience and

Creating the awareness that safe working practices are key

daily practice skills.

to responsible ownership is one of our goals. Placing all our

www.prolyte.com/prolytecampus

training initiatives under one umbrella is a means to facilitate

228

Photo: Prolyte Campus at Rolight, The Netherlands

BlackBook
The ultimate reference guide for our industries riggers, trussing
and staging technicians, the BlackBook offers renowned
technical background information and practical tips and
tricks. Completely up-to-date with the latest developments in
regulations and product design, this book is a must read for all
technicians in the live industry.
www.prolyte.com/brochures

Safety is our driving force
Prolyte Group products comply with strict international
standards and regulations. The manufacturing and welding of
our products is a very precise and reliable process, we work
exhaustively to ensure our procedures and protocols conform

Helping
you build
great
things

to applicable standards and endeavour to be one step ahead
of new and future regulations and standards. All products are
manufactured to EN1090-3 EXC3, the highest execution class,
as certified by two independent notified bodies. All our loading
tables and structural calculations are in compliance with EC9.

229

Prolyte Group
www.prolyte.com

230

∙

sales@prolyte.com

facebook.com/Prolytegroup

∙

 +31 594 851 515
instagram.com/prolytegroup

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