Hörrmann IBS Instructions for Adjustment and Operation

1 Safety

⚠️ Safety

If the instructions are not followed, this could result in injury or damage to the product.

• Read and follow the instructions carefully.
• Observe the instructions for the dock leveller and the control 560 T/V.
• Keep these instructions accessible at all times.
• Only allow persons to work on the product who have been authorised and instructed by the operator. This applies to fitters, maintenance personnel, and operators.

2 Description

The IBS (Intermediate Stop) is a semi-automatic system that provides an intermediate stop when extending and retracting the telescopic lip. The equipment is suitable for Hörmann telescopic lip dock levellers equipped with the 560 T/V control system.

3 Electrical Connection

Refer to the control documentation for details on electrical connection.

4 Adjustment

Ensure the following conditions are met when performing adjustment work:

• The working area is cordoned off.
• The control is secured against unauthorised operation.
• The dock leveller is undamaged and in proper working order.
• Cables are not kinked, squeezed, or damaged.
• The dock leveller is secured using the maintenance support.

Dimensions and Legend

The diagram illustrates the components and measurements for the IBS system:

• 1, 2: Sensors for intermediate stop
• 3: Sensor for platform position
• X: Position of the sensor holder
• Y: Intermediate stop of extension range
• NL: Dock leveller length (refer to data label)

[Diagram showing the dock leveller mechanism with labeled components 1, 2, 3, X, Y, NL]

4.1 Intermediate Stop

Procedure:

1. Measure the required extension range (Y) for the intermediate stop of the telescopic lip. The factory setting for the intermediate stop is an extension range of 100 mm. The maximum extension range (Ymax) is the distance between the front edge of the platform and the front edge buffer.
2. Determine the position X for the sensor holder using the table "Determination of position X".

Determination of position X

The formula for determining position X is: Position X = extension range Y + table value

* See data label

If the length of the dock leveller differs, use the following formula: X = Y + NL – L – type-dependent value

Type-dependent values:

• HTL2 / HRT 60 kN: 800
• HTL2 100 kN: 1010
• HTL2 ISO: 950
• HTLV4: 795

The sensor holder is fastened using a magnet. To change the position, move the sensor holder.

[Diagram showing the sensor holder being repositioned on the platform beam, with arrows indicating movement and measurement from the rear rail.]

Reposition the sensor holder. Measure the distance from the inside of the rear rail of the platform.

4.2 Platform Position

The IBS system is installed at the factory to ensure the platform is aligned horizontally in the intermediate stop. Chamfered alignment is also possible.

[Diagram showing the sensor being loosened and shifted within the holder.]

Loosen the sensor. Shift the sensor in the holder.

Adjustment for horizontal position (factory setting)

The values below correspond to the sensor position on the scale of the holder:

* Dock leveller in installation height > 750 mm

5 Operation and Functional Progress

Note the brief instructions.

⚠️ WARNING: Danger of injury and damage when driving over the dock leveller in the intermediate stop. The platform can only be loaded to a limited extent in the intermediate stop. The warning lamp flashes. Do not drive over the dock leveller in the intermediate stop.

5.1 Before the Loading Process

1. Press the "Extend lip" button. Keep the button pressed. The platform lifts. The lip extends to the preset length. The platform lowers. The warning lamp flashes. It is possible to access the dock leveller, e.g., to open vehicle doors.
2. Press the "Lift platform" button. Keep the button pressed until the platform is above the level of the loading surface. The warning light goes out.
3. Press the "Extend lip" button within the next second. Press and hold the button until the lip is extended as far as needed and no further.
4. Release the button. The lip is lowered to the loading surface after approximately one second.

To correct the lip: In order to retract the lip again, use the "Retract lip" button.

5.2 After the Loading Process

1. Press the "Return" or "Retract lip" button once (1x). The platform lifts. The lip retracts to the preset length. The platform lowers. The warning lamp flashes. It is possible to access the dock leveller, e.g., to close vehicle doors.
2. Press the "Return" or "Retract lip" button once (1x). The dock leveller will automatically move into the home position.

6 Maintenance

6.1 Checking and Maintenance

Perform a function check as part of the maintenance of the dock leveller.

6.2 Malfunctions and Troubleshooting

All 3 sensors must be set and switched correctly to ensure trouble-free operation of the IBS system.

[Diagram showing sensor holder positions for sensors 1, 2, and 3.]

The sensor holder for sensors 1 and 2 must be at the bottom of the platform beam. Sensor 3 must be able to detect the bolt of the hose clamp.

Troubleshooting Steps:

• Check whether the sensor switches properly. Hold a metal object in front of the sensor. When the sensor switches, the sensor LED lights up.
• If the sensor switches: Correct the position of the sensor.
• If the sensor does not switch: Perform the following measures:
  • Remove any contamination.
  • Check the connections. Correct if necessary.
  • Check the components for damages. Replace defective components.
  • Fasten loosely hanging cables.