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CS6 ATEX lifting tables for Zone 2 – flexible and interchangeable
Maluk hydraulic scissor lifts for the EX-Zone 2
Six hydraulic double scissor lifts for the hazardous area. With flexible platform extensions and complete assembly by maluk.
An industrial engineer needed six hydraulic lifting tables for use in an ATEX Zone 2 area that is prone to explosions. The lifting tables needed to be integrated into an existing production facility and enable reliable operation around the clock.
The task was clear: the platforms must be lowered by 450 mm so that pallets can be transported in the facility. Subsequently, the lifting tables are moved back up and serve as work platforms for people and aluminum roller scaffolds in a standstill state. No passenger transport is planned.
In addition to the requirements for explosion protection, the customer had one special request: The six lifting tables should be as flexible as possible and interchangeable with each other.
Our solution consists of six hydraulic double scissor lifts with a lifting capacity of 500 kg each and a platform size of 5,900 × 850 mm. Three of the lifts were additionally equipped with a 500 mm high base frame.
Especially practical: Although only two lifting tables require a wider platform, we have prepared all six for mounting additional platform extenders. This way, the extenders can also be attached to another lifting table if necessary.
The entire facility was built for the ATEX requirements Ex II 3G IIA T2, Zone 2 Designed. The installation, commissioning and on-site training are also included in the scope of services provided by maluk.
Technical data of the ATEX lifting tables
Number: 6 hydraulic lifting tables
Lift capacity: 500 kg per lifting table
Platform: 5.900 × 850 mm, tear plate
Profit increase: 450 mm
Building height: 3 × 550 mm and 3 × 1,050 mm including substructure
Construction: Hydraulic double scissor
Lift and lowering time: approximately 20 seconds each time
Motor power: approx. 0.75 kW
Operating voltage: 400 V / 50 Hz
ATEX classification: Ex II 3G IIA T2 for Zone 2
Hydraulic unit: external, outside the ATEX zone
Surface: RAL 1007, Narcissus Yellow
Special features: folding bellows, ATEX end switches, preparation for platform extensions and additional steel substructures
Assembly on weekends – so that production can continue
In an industrial plant that operates 24 hours a day, the installation of new machines is particularly demanding. Long downtime should be avoided as much as possible.
Therefore, the assembly of the six ATEX lifting tables was deliberately scheduled for the weekend.
maluk takes over the assembly, commissioning, and training directly at the customer's premises.
After the lifting tables are fixed to the concrete floor, the hydraulic and electrical connections are made, the functions are checked, and the operating personnel are trained.
Thanks to the weekend assembly, the work can take place outside the regular production processes. This keeps the disruption to the ongoing operations to a minimum.
Six ATEX special lifting tables with a sophisticated concept
This project shows that not only load capacity, platform size and lifting height are important factors when choosing individual lifting tables.
The real challenge lay in planning six lifting tables with different installation heights, ATEX requirements and flexible uses so that they could be integrated into the existing system as easily as possible.
The uniform lifting table structures, the platform extension brackets that can be screwed on, and the additional substructures resulted in a solution that also offers advantages during maintenance and in the event of possible malfunctions.
From technical planning to production, assembly and commissioning – all from a single source at maluk.
load
500 kg
Platform
5,900 x 850 mm
Hub
450 mm
Six lifting tables with pre-assembled platform spreaders
Six lifting tables with pre-assembled platform spreaders
An important goal in the planning was to ensure the maximum possible interchangeability of the lifting tables.
In normal operation, only two of the six units require a wider platform. Nevertheless, we have prepared all six lifting tables structurally so that the supplied side extensions can be bolted on.
For example, if one of the two wider lifting tables fails, another suitable lifting table can take its place. The platform extension is accordingly modified accordingly.
This means that the customer does not have to keep a separate replacement lifting table ready for every installation situation. This simplifies maintenance work and increases flexibility in the event of a breakdown.
The yellow sheet metal platforms provide a sturdy surface for the intended working area.
Two building heights thanks to additional steel substructures
Although the six lifting tables are largely identical in design, two different working heights are required in the facility.
Three lifting tables have a build height of 550 mm. The other three are mounted on an additionally fabricated steel base that is 500 mm high, thus reaching a total build height of 1,050 mm.
Instead of designing two completely different lifting table variants, we opted for a uniform basic concept with additional sub-structures.
This has a major advantage: The actual lifting tables remain largely identical in design and can be easily exchanged with each other, taking into account the specific installation situation.
The stable double-scissor design allows a cutting height of 450 mm in all six versions.
ATEX version with bellows and end position monitoring
The lifting tables are used in an area classified as ATEX Zone 2. Accordingly, explosion protection had to be taken into account already during the design phase.
The execution was carried out in accordance with the project-specific requirements Ex II 3G IIA T2. These include suitable ATEX end switches for the upper and lower end positions, as well as the corresponding technical documentation.
The platforms were additionally equipped with a rotating pleated bellows that covers the area between the platform and the base frame and serves as a bottom run protection in the intended safety concept.
Other features include maintenance supports, an overpressure valve and an adjustable bottom check valve. Since the lifting tables are also used as stationary work platforms when raised, the unintentional lowering must be prevented by the overall system.
The necessary protective measures were adapted to the specific installation situation and the intended use.
External hydraulic units and integration into the system control
The control system for the six lifting tables was also adapted to the existing production facility.
The hydraulic units and the electrical control components are located outside the explosive hazard zone. Within the ATEX zone, appropriate control elements for on, off and emergency stop are provided.
Through the electrical interfaces, the lifting tables can be integrated into the overall system control. The end switches report the upper and lower end positions.
The six lifting tables can be operated simultaneously. An exactly synchronized operation is not required for the intended work process. Additionally, manual operation is provided.
Before delivery, the hydraulic and electrical functions are tested.
Do you need an ATEX hub table?
Feel free to call us anytime for advice!
Ing. Lukas Hornbogner, lifting table expert: +43 650 58 11 056 or by email: lukas@maluk.at
FAQ ATEX Hubtisch
Frequently asked questions about the hub table in the EX-Zone
An ATEX lifting table is a lifting table designed specifically for use in hazardous areas. Depending on the location of use, electrical and mechanical components must meet different requirements for explosion protection. The design depends on the existing ATEX zone, the gas or dust group, and the permissible surface temperature.
Suitable devices of the II group, category 3G are provided for the ATEX zone 2. The suitability depends additionally on other characteristics of the existing explosive atmosphere. In this project, the design for Ex II 3G IIA T2 was determined and documented accordingly.
Yes, provided that the design is suitable and the modification has been technically approved. For this project, all six lifting tables were prepared for screw-on platform extenders. This allows the extenders to be converted to other suitable lifting tables if necessary.
The external arrangement allows the electric motor, hydraulic unit, and certain electrical control components to be operated outside the hazardous area. This simplifies the design of these components. The remaining components within the zone must still comply with the respective ATEX requirements.
Yes. In this project, maluk takes on the complete assembly, commissioning, and training of the operating personnel. To minimize disruption to ongoing operations, assembly was scheduled for the weekend. Assembly work can also be adapted to the customer’s operational requirements for other special lift table projects.