AM-01.01.250 A

KONE MonoSpace® 3.0 Installation Instruction

KONE MONOSPACE®, RELEASE 3.0

1075531.wmf

KONE MonoSpace® Installation 2013-03-18 (B) AM-01.01.250 Instruction3.0

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AM-01.01.250 (B) 2013-03-18


Copyright ©2012 KONE Corporation All rights reserved.

No part of the contents of this document may be copied, reproduced or transmitted in any form or by any means, or translated into another language or format, in whole or part, without prior written permission of KONE Corporation. Authorization Notice This publication is for informational purposes only. All persons participating in the installation and/or maintenance of KONE equipment and using these instructions must be qualified to perform such work, are required to have received equipment specific training as specified by KONE and must have KONE Corporation's authorization to install and maintain KONE equipment. DISCLAIMER OF WARRANTIES AND LIABILITIES KONE reserves the right at any time to alter the product design, specifications and procedures reflected in this document. NO STATEMENT CONTAINED IN THIS DOCUMENT IS TO BE CONSTRUED AS A WARRANTY OR CONDITION, EXPRESS OR IMPLIED, AS TO ANY PRODUCT, SPECIFICATION OR PROCEDURE, ITS MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OR QUALITY, OR AS A MODIFICATION OR REPRESENTATION OF THE TERMS OF ANY PURCHASE AGREEMENT. KONE DISCLAIMS ANY LIABILITY RESULTING FROM OR IN CONNECTION WITH THE USE OR DISCLOSURE OF INFORMATION IN THIS DOCUMENT. KONE HAS NO LIABILITY FOR TYPOGRAPHICAL OR OTHER ERRORS OR OMISSIONS CONTAINED IN THIS DOCUMENT OR ANYONE'S INTERPRETATION OF THE INSTRUCTIONS. THE USER OF THIS DOCUMENT ASSUMES ALL RISKS ASSOCIATED WITH THE USE OR DISCLOSURE OF THIS DOCUMENT. Confidentiality Notice This proprietary and confidential document is provided to you only for purposes of installing and/or maintaining KONE products and it may not be used or its contents disclosed for any other purpose without KONE's prior written permission. Neither this document nor its contents may be copied or disclosed to third parties for any reason. KONE reserves the right to prosecute any breach of this obligation. Trademark Notice "KONE, MonoSpace, MiniSpace, EcoDisc, TranSys, Alta, KoneXion, KONE ECO3000 and all other product names are trademarks or registered trademarks of KONE Corporation in various countries."

Copyright ©2012 KONE Corporation All rights reserved.

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TABLE OF CONTENTS 1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.1 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.2 Related and supplementary documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.3 Daily installation order guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.4 Customer experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1.5 Step numbering in the pictures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1.6 Explanation for quality requirement table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Recommended working postures and ergonomic methods . . . . . . . . . . . . . . . . . . . 2.3 Installation method safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Danger and personal protection signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

SITE REQUIREMENTS AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3.1 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4

OFFLOADING AND DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.1 Offloading and distributing materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.2 Offloading and transporting landing doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5

INSTALLING MAN RIDING HOIST AND OVERSPEED GOVERNOR . . . . . . . . . . . . . . . . 5.1 Man riding hoist parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Work positioning equipment or restraint system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Safety checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Routing the man riding hoist rope and cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Installing overspeed governor hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Fixing the man riding hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 Lowering the man riding hoist hook to the pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Pit ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 Testing the hoist equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

PLUMBING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 6.1 Elevator shaft plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 6.2 Plumbing table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7

MECHANICAL INSTALLATION IN THE PIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Guide rail preparing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Installing dividing beams (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Guide rail brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Installing first guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Installing and aligning the first length of car guide rails (H  3500) . . . . . . . . . . . . . . 7.6 Installing counterweight buffer, OSG tension weight and OSG rope. . . . . . . . . . . . . 7.7 Installing counterweight frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Installing car buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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21 21 25 26 28

45 46 48 49 49 50 51 52 53 53 54

58 59 61 61 63 66 67 69 71

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8

CAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 8.1 Contents of car packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 8.2 Installing uprights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 8.3 Installing bottom beam (skewed type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 8.4 Installing bottom beam (parallel type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 8.5 Installing car floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 8.6 Connecting ASGT rope to safety gear linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 8.7 Initial loading of counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 8.8 Installing car walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 8.9 Installing top beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 8.10 Installing car top balustrade and car roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 8.11 Tensioning overspeed governor rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

9

ATTACHING HOIST TO CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Installing swivel balustrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Attaching hoist and automatic safety gear trigger . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 Testing ASGT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 Using ASGT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

CAR INTERIOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 10.1 Installing ceiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 10.2 Mirrors and handrails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 10.3 Skirting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 10.4 Installing seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 10.5 Installing buffer rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 10.6 Installing tenant directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

11

INSTALLING REST OF GUIDE RAILS AND BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Preparing for guide rail installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Installing third ring of guide rail brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Preparing oil buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 Finalizing car installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Installing guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

123 124 125 128 129 131

12

MECHANICAL INSTALLATION IN TOP OF ELEVATOR SHAFT . . . . . . . . . . . . . . . . . . . 12.1 Installing overspeed governor to final position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 Installing counterweight overspeed governor and tension weight . . . . . . . . . . . . . . 12.3 Removing the extension rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 Car sill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 Installing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6 Installing rope hitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 Parking plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 Filing and checking the guide rail joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133 134 135 136 137 137 145 146 147


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104 105 107 108 109

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13

LANDING DOOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Installation order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 Installing landing sill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3 Installing uprights and top parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4 Installing door panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 Top track settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 Installing panels and strips (front type version only) . . . . . . . . . . . . . . . . . . . . . . . . 13.7 Installing landing toe guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 149 150 154 158 162 163 167

14

CAR FRONT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 Installing car front walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2 Finalizing car front installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 Installing ceiling for steel roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168 169 171 172

15

INSTALLING CAR DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 Unpacking and transporting the door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 Installation of Low duty door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3 Installation of Mid and High duty door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4 Installing finger protection list (window / glass doors) . . . . . . . . . . . . . . . . . . . . . . . 15.5 Door panel buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 Door panel fixings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7 Door panel guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 Installation of door panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9 Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10 Railing settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11 Emergency opening for car door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12 Electrification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13 Car door lock and contact measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

178 179 180 182 184 184 185 186 187 189 194 197 198 200

16

KONE SIGNALIZATION SYSTEM (KSS) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 16.1 Hall indicator (KSH) and landing call station (KSL) . . . . . . . . . . . . . . . . . . . . . . . . . 16.2 Installing COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3 Hall display (KSJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 203 204 205

17

INSTALLING MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 17.1 Installing wall type MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 17.2 Installing door type MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

18

IDE300 (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

19

ELECTRIFICATION AT TOP OF THE ELEVATOR SHAFT (KDL16S) . . . . . . . . . . . . . . . 19.1 Overview (KDL16S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2 Opening drive covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.3 Installing SEP and drive panels, brake resistor and trunkings (KDL16S) . . . . . . . . 19.4 Connecting machine cables (KDL16S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5 Cabling: MAP - drive, SEP - drive (KDL16S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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210 212 213 214 216 217

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20

ELECTRIFICATION AT TOP OF THE ELEVATOR SHAFT (KDM40) . . . . . . . . . . . . . . . . 20.1 Overview (KDM40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2 Installing SEP and drive panels, KDA module, brake resistor and trunkings (KDM40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3 Machine cables (KDM40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4 Cabling: MAP - KDA module, SEP - KDA module (KDM40) . . . . . . . . . . . . . . . . . . 20.5 Cabling: KDA - drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222 225 226 227

21

CABLES: SEP-MAP, MAIN SUPPLY, KRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 Installing load weighing sensor, OSG cables and topmost lighting unit . . . . . . . . . 21.2 Wiring between SEP and MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 Connecting main supply cable to MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 Group connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

228 229 230 231 231 233

22

INSTALLING TRAVELLING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 22.1 Installing travelling cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

23

ELEVATOR SHAFT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 Shaft lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 Installing shaft wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3 Wiring at the landings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.4 Installing segmented shaft network (if 16 served floors / group elevator) . . . . . . . . 23.5 Installing support channel (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

237 238 239 240 241 242

24

ELECTRIFICATION IN THE PIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1 Installing components under car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.2 Installing electrification under the car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.3 Installing pit electrification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4 Installing pit toe guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

243 244 245 246 247

25

CAR ELECTRIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 Magnet switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 Installing car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3 Installing electrification on the car roof (sliding guide shoes) . . . . . . . . . . . . . . . . . 25.4 Installing electrification on the car roof (roller guide shoes) . . . . . . . . . . . . . . . . . . 25.5 Install the provision for lift announcer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.6 Install the intercom socket on the car roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.7 Installing curtain of light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.8 Installing ramps and magnets (driving up). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.9 Wiring of door operator and curtain of light (or photo cell) . . . . . . . . . . . . . . . . . . . 25.10 Installing car emergency light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

248 249 250 252 253 254 254 255 260 261 261


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26

FINALIZING LANDING DOORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1 Uprights on slampost side (fire rated EI30/EI60/EI120-W doors) . . . . . . . . . . . . . . 26.2 Uprights on non-slampost side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.3 Fire trims (frame version only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.4 Corner angles and wall gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 Top extension panel fire insulation (front version only) . . . . . . . . . . . . . . . . . . . . . . 26.6 Carpet profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.7 Quality check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

262 263 264 267 270 270 271 271

27

ROPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 Lubrication of suspension ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 Roping principle (skewed car sling). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 Roping principle (parallel car sling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5 Roping in the pit (skewed sling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.6 Roping in the pit (parallel sling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.7 Attaching compensation chain under the car (optional) . . . . . . . . . . . . . . . . . . . . . 27.8 Opening brakes for roping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.9 Roping at top of the elevator shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.10 Shortening the ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.11 Attaching compensation chain to counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.12 Moving OSG rope in the large groove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.13 Installing brake release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.14 Testing manual brake release operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.15 Dismantling man riding hoist from car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.16 Finalizing car installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

272 273 275 276 277 278 279 279 280 281 282 284 284 285 287 288 289

28

COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.3 Final steps of commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.4 Fine adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

293 294 296 298 299

29

COMMISSIONING OF THE CAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 Layout of drive 10 electronic assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2 Layout of AMD drive 2 electronic assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3 Testing factory adjusted door operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.4 Adjusting closing force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.5 LEDs, drive 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.6 DIP-switches, drive 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.7 LEDs, drive 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.8 DIP-switches, drive 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.9 Commissioning of curtain of light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300 301 302 304 305 306 307 307 309 310


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30

FINAL STEPS AND ELEVATOR SHAFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.1 Correction of parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.2 Checking the levelling accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.3 Volume adjustment (audible feedback) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.4 Group locking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.5 Emergency lighting battery and KONE remote monitoring . . . . . . . . . . . . . . . . . . . 30.6 Emergency battery drive (EBD-A) test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.7 Testing the compensation chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.8 Elevator shaft cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

312 313 313 314 314 315 316 317 317

31

SAFETY INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 31.1 Safety inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

32

MEASURING RIDE COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

33

HANDOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 33.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 33.2 QD-181.212, Quality control in installation – maintenance handover for KONE MonoSpace elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

34

FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1 Fault finding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.2 Normal run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.3 Faults in drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

36

FEEDBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

321 321 322 323

APPENDIX A. KDL drive related issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 APPENDIX B. Balancing factors and loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 APPENDIX C. Electrification panels, introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 APPENDIX D. Elevator shaft wiring with trunking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 APPENDIX F. Energy efficiency class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 APPENDIX G. Ceiling types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 APPENDIX H. Installing car floor, BB 1600 x DD 1400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 APPENDIX I.

Delivery above lowest floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

APPENDIX J.

Synchronization, parallel sling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371


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1

GENERAL The single and flexible man installation method described in this instruction is designed to ensure an efficient, trouble-free installation, whilst maintaining safe working practices. This is a general instruction which can be used for MonoSpace® release 3.0 elevators. Some of the components may differ from those that are described in this instruction. In these cases refer to the delivery documents or component level AM instructions. Follow this instruction. If it is necessary to deviate from the method a carefully designed, risk assessed, method statement must first be obtained from your front line management. All installation tasks must be controlled and verified during installation by filling in the QD-181.211 which is used as a checklist before: – commissioning – safety inspection – handover to maintenance and customer

1.1

Abbreviations

1.1.1

General

Abbreviation FFL CL DBG A B C D

Term finished floor level central line distance between guide rails marking of entrance e.g. A-door/side marking of entrance e.g. B-door/side marking of entrance e.g. C-door/side marking of entrance e.g. D-door/side

C2

usually main door, always MAP side opposite main door

C1

D2

B1

D1

B2 A


Definition

1078299.wmf

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1.1.2

Elevator shaft and car

NOTE: For more information on following cases, see AM-01.01.256: - low pit devices - low headroom, SH  3320 mm - small car, BB  900 mm or DD  1000 mm

Abbreviation Term elevator shaft SH headroom height

Unit

Definition

mm

PH

pit depth

mm

WW

elevator shaft width

mm

WD

elevator shaft depth

mm

H HF

travel height floor to floor distance

mm mm

the vertical distance between the finished floor at the highest level served and the roof of the elevator shaft that part of the elevator shaft located under the lowest landing level served by the elevator the horizontal distance between the inner surfaces of the elevator shaft walls measured parallel to the car width the horizontal distance between the inner surfaces of the elevator shaft walls measured parallel to the car depth sum of interfloor distances given as a minimum

car clear height car clear width car clear depth toe guard height

mm mm mm mm

car and landing door sills

car CH BB DD NE


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Elevator shaft vertical dimensions Front doors

HH HF HH

PH

PH 1007040.wmf


H

HA

HF

HR

H

HB

CH

HH

CH

SH

SH

HA HB HB

Frame doors

1007041.wmf

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1.1.3

Landing/front and frame door

Elevator shaft horizontal dimensions, front door

1007043.wmf

Abbreviation LW LW1 LD LR HR HA HB LL HH

Term from clear opening to elevator shaft wall from clear opening to elevator shaft wall side wall depth door raw opening width door raw opening height front door lintel height front door extension height door clear opening width door clear opening height


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Unit mm mm mm mm mm mm mm mm mm

Definition

front door case LR=WW

AM-01.01.250 (B) 2013-03-18


Elevator shaft horizontal dimensions, frame door

1007042.wmf

Abbreviation FW FW1 FD LR HR LL HH 1.1.4

Term front wall width front wall width front wall depth door raw opening width door raw opening height door clear opening width door clear opening height

Unit mm mm mm mm mm mm mm

Definition

LR=WW-2*FW or WW-(FW+FW1)

Additional abbreviations MAP = maintenance access panel SEP = shaft electrification panel


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1.2

Related and supplementary documents In addition to this manual, you can find safety, quality, process and product-related information in the following documents: Elevator level: – AM-01.01.256, KONE MonoSpace, Release 3.0: Small car, low pit and low headroom solutions and FuRe – Shaft vane diagrams, layout drawings, wiring diagrams – AS-01.01.030 Rescue instruction for KONE MonoSpace type elevator Safety: – AM-01.03.001 Preventing falls from height when working on elevators, escalators and building doors – AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and autowalks – AM-01.03.003 Take 2 - double security safety practice when using hoists for man riding purposes – AM-01.03.010 Safe working in elevator shaft and machine room areas – AM-01.05.016 Installing light entrance protection (LEP) – Man riding hoist manual Quality & Environment: – – – – – –

QD-181.211 Quality Document - KONE MonoSpace Elevators QD-181.212 Quality control in installation - maintenance handover AM-01.01.190 Environmental excellence - Installation AM-01.01.257, Visual inspection - quality control of the car interior and landings AM-01.05.014 DT-5 user instructions AS-12.02.001 Instruction for handling electrostatic-discharge-sensitive-devices on site

Productivity: – AM-01.01.260 5S guide book - Eliminating unnecessary actions in elevator installation – AM-01.01.261 5S advanced instructions - Eliminating unnecessary actions in elevator installation Car & Sling: – – – – –

AM-06.06.030 Hermes Car AM-06.12.010 Global accessories, suspended ceilings and lighting AM-07.04.040 Progressive type safety gear AQ32 AM-07.04.042 Progressive type safety gear CSGB-01 AM-08.06.002 Roller guides; RG80, RG100, RG125 and RG200

Ropes: – AM-09.01.006 Lubrication of suspension ropes – AS-01.01.010 Lubricant recommendation instruction


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Doors: – – – – – – – – – – – – –

AM-03.12.064 Automatic landing door (AMDLY) AM-03.12.066 Automatic landing door (AMDL) AM-03.12.067 Automatic car door AMDC AM-03.12.094 KES201 landing door AM-03.17.011 Formula systems slimscreen curtain of light FCU 0735 and FZU 1047 3D (for automatic car door AMD) AM-03.35.020 Electrical installation, commissioning, troubleshooting instruction, AMD drive 2 + car door operator AM-03.35.023 Fine tuning of AMD drive 2 car door operator AM-03.35.024 Advanced modular door, Drive 1.5 car door operator electronic AM-03.35.027 Electrical Installation, Commissioning and Troubleshooting Instruction AMD Drive 10 Car Door Operator AM-03.90.111 ReNova slim car door AMDSC3 AM-03.90.112 ReNova slim car door AMDSC4 AM-03.90.113 ReNova slim car door AMDSC6 AM-03.90.121 ReNova slim landing door

Machinery: – AM-04.05.056 Hoisting Machine NMX07 / NMX11 Electrification & Commissioning: – AM-10.60.028 Elevator shaft bundle (cables and connection boxes without trunking) – AM-11.65.038 ECB-1 single line ReGenerative unit – AM-11.65.042 KDM drive for MonoSpace® and MonoSpace® Special: Installation, commissioning and safety inspection – AM-11.65.045 Machine-Room-Less Elevators with KDL16S drive, Installing, Commissioning and Safety Inspection – AM-12.20.005 KONE Signalisation System (KSS) installation – AM-12.20.017 KONE Polaris™ 500 and 800 Destination Control Systems (DCS) – AM-13.20.018 KONE IDE300™ - Integration of doors and elevator – AM-13.25.007 KONE remote monitoring (KRM) for elevators – 994525D01 KDM Parameter list (delivered with drive) – 994525D02 KDM Diagnostic Code List – 994525D03 KDM Parameter Guide – 972483D01 KDL16 Parameter Table (delivered with drive) – 972484D01 KDL16 Parameter Guide – 972485D01 KDL16 Diagnostic Codes – 813138 Global LCE Fault Codes – 812281 F2K Remote Control Boards – 813131 User Interface Menu Instructions for LCE – 818442 PIN Code Feature – 827328 Configuration switch instruction – TC05115W3-EN KONE Site Reference Pocket Book for LCE Electrification


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Product-related maintenance instructions and spare parts lists: Elevator level: – AS-01.01.039 General fault finding – AS-01.01.076 Fault finding instruction for KONE MonoSpace 3.0 Doors: – – – –

AS-03.12.036 Maintenance instruction for AMD doors ASG-03.12.036 Preventive maintenance instruction for AMD doors AR-03.12.037 Spare parts manual for AMD car door AR-03.12.076 Spare parts manual for AMD landing door

Machinery: – AS-04.06.005 Replacing NMX07 and NMX11 hoisting machine in machine-room-less elevator – AR-04.06.015 Spare parts NMX07 – AR-04.06.016 Spare Parts NMX11 – ASG-04.06.003 Preventive maintenance for NMX07 and NMX11 machines – AS-04.07.005 Replacing encoders of NMX07 and NMX11 – AS-04.08.039 Replacing the brakes of hoisting machines NMX07 and NMX11 – AS-04.08.092 User instruction for electrical brake opening tool KM872759G01 Car & Sling: – AS-07.03.016 Repairing Hermes car sling Ropes: – AS-01.01.010 Lubricant recommendation instruction – AS-09.01.005 Semi-automatic relubrication for suspension ropes: maintenance instructions – AS-09.05.001 Lubricating the suspension ropes Electrification: – AS-10.22.006 Repair instruction for KONE MonoSpace®, MonoSpace® 1.6 m/s and TranSys™ shaft electrification panels – AR-10.22.006 Spare parts manual for KONE MonoSpace electrification – AS-11.65.040 Repair instruction for KDM drive system in KONE MonoSpace Special – AR-11.65.040 Spare parts manual for KDM drive system – AS-11.65.052 Repairing KDL16S – AR-11.65.034 Spare parts manual for KDL16 drives


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1.3

Daily installation order guide

Elevator shaft Door type

Car interior

1.3.1

Elevator 5 floors, 12 m travel, single side entrances AMDL1 or AMDL2, frame non fire rated, installation with expander bolts for guide rails and landing doors One handrail and one mirror

Prerequisites to meet the schedule Complete on time / error free delivery Installation site fulfilling the 5 Site Absolutes Fitter has installed 5-8 units prior. Working within allocated working hours.

Single man schedule The table below indicates phases of the installation. Day 1

2

3

Action Arrival at site, transporting tools, receiving delivery. Installing man riding hoist, installing overspeed governor. Setting the lasers. Plumbing and establishing plumbing table. Installing first guide rail brackets and pit ladder, preparing counterweight frame. Installing and aligning first lengths of guide rails and brackets. Installing buffers and counterweight frame. Installing sling and installing overspeed governor. Installing car and initial loading of the counterweight. Waste material handling. Installing automatic safety gear trigger. Attaching man riding hoist to car and installing third ring of guide rail brackets. Installing car interior. Installing working light to the car roof. Installing and aligning guide rails and brackets to intermediate floors. Installing topmost floor lengths of guide rails and brackets. Transferring the overspeed governor to its final position and setting the rope to final length. Installing car sill. Installing machine and rope fixings. Installing landing door sill brackets.


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Day 4

5

6

7

1.3.2

Action Installing landing doors. Installing car front wall and car door. Installing last landing door. Installing trunking and elevator shaft lighting. Waste material handling. Installing MAP, SEP and drive panels. Installing elevator shaft top wiring and brake lever. Installing travelling cables, elevator shaft wiring and signalization. Installing car wiring and setting positioning system and ramps. Installing pit wiring. Waste material handling. Installing car electrification and car operating panel. Placing filler weights inside the car for balancing operations, roping. Closing the brake, re-checking the brake lever operation, safety checks, commissioning and removal of tools. Balancing and final steps. Cleaning down the elevator shaft and disposal of waste materials. Safety inspection (assistance with test weights).

Flexible man schedule The table below indicates in which phases of the installation two men are required and when the installation can be undertaking by a single man. Day 1

Action Arrival at site, transporting tools, receiving delivery. Installing the man riding hoist, installing the overspeed governor. Setting the plumbing jig. Cleaning guide rails and mounting fish plates. Plumbing and establishing plumbing table. Installing first guide rail brackets and pit ladder, preparing counterweight frame. Installing and aligning first lengths of guide rails and brackets. Installing buffers and counterweight frame. Installing sling and installing overspeed governor for single man working.


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Task split fitter 1 / 2 1 2 1 2 2 1 2 1 1

2

1

2

AM-01.01.250 (B) 2013-03-18


Day 2

3

4

5

6

7

Action Installing the car and initial loading of the counterweight. Waste material handling. Installing the automatic safety gear trigger. Attaching the man riding hoist to car and installing the third ring of guide rail brackets. Installing the car interior. Installing and aligning guide rails and brackets to intermediate floors. Preparing the car and counterweight guide rail brackets. Preparing machine and landing door brackets Installing top most floor lengths of guide rails and brackets. Transferring the overspeed governor to final position and setting the rope to final length. Installing the pulley beam and car sill. Installing the machine and rope fixings. Installing the landing door sill brackets. Installing the trunking and elevator shaft lighting Installing the landing doors, not finally adjusted. Installing the car front wall and car door. Installing the last landing door. Waste material handling. Final adjustment of the landing doors. Installing the MAP, SEP and drive panels. Installing the elevator shaft top wiring and brake lever. Installing the travelling cables, shaft wiring and signalization. Installing car wiring and setting positioning system and ramps. Installing the pit wiring. Waste material handling. Installing the car electrification and car operating panel. Placing filler weights inside the car for balancing operations, roping. Closing of the brake and re-check of the brake lever operation, safety checks, commissioning and removal of tools. Balancing and final steps. Cleaning down the elevator shaft and disposal of waste materials. Safety inspection (assistance with test weights).


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Task split fitter 1 / 2 1 2 1 1 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

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1.4

Customer experience The focus of your work must always be customer satisfaction. To reach and exceed the customers’ expectations, be polite, constructive and co-operative, and communicate clearly. Remember that for customers, you represent KONE, so ensure that you handle or at least communicate all customer requests and feedback to the correct persons. For more information on how to deliver best-in-class customer experiences through behavior and communication, see the KONE Ambassador program in KONE intranet (search for Ambassador) or contact your supervisor.

1.5

Step numbering in the pictures 1. When reading this instruction, note that the numbers in the pictures refer to the step numbers.

1. Xxxxxxxxxx 2. Xxxxxx 3. Xxxxxxxx 2

3 1

1082830.wmf


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1.6

Explanation for quality requirement table

Quality Requirements:

Required mandatory outcomes upon completion of the chapter.

MAIN hazards identified. Other hazards are described within each chapter.

!!! CAUTION - issues that affect reliability !!!

SORT STABILIZE SHINE STANDARDIZE SUSTAIN Method tools needed:

5S

This area highlights the negative effects of failing to meet the quality requirements.

Reminder of 5S standards.

Tools from the installation kit. Hand tools needed: Tools from the tool kit. 5S Installation Progress Report Progressive reminder to complete this document. QD-181.211 Progressive reminder to complete this document.


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2

SAFETY When you are working on your own ensure that: – someone in authority knows where you are – regular checks are made to ensure your safety If you have any doubts about Single Man Working on your specific job site, discuss them with your supervisor. Where required, discuss method statements and risk assessments with your supervisor and colleagues before starting work. Work safely and follow local codes and agreed practices. Certain components are from their characteristics, weight and size not suitable to be installed by Single Man Working methods. These components are highlighted in the installation chapter section, as an example car glass rear wall.

2.1

General safety The words WARNING and CAUTION are used to highlight possible hazardous situations to persons or equipment as follows:

WARNING: This is to warn about serious safety hazards.

CAUTION: This is to warn about damage to equipment which may also involve a safety hazard.

2.1.1

Safety instructions Following safety instructions should be referred to in conjunction with this installation instruction: – AM-01.03.001 Preventing falls from height when working on elevators, escalators and building doors – AM-01.03.002 Take 5 - Electrical safety when working on elevators – AM-01.03.003 Take 2 - Double security safety practice when using hoists for man riding purposes – AM-01.03.010 Safe working in elevator shaft and machine room areas – Man riding hoist manual


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NOTE: Installation work must only be carried out by competent and qualified personnel.

2.1.2

Double security safety practise when using hoists for man riding purposes Refer to AM-01.03.003 - Take 2 Double security safety practice when using hoists for man riding purposes. To ensure your and your co-workers personal safety you must always be protected from falling by two independent devices. It is not permitted to drive or to be on top of the suspended platform without double security: 1. Safety gear The safety gear must be connected to the overspeed governor and automatic safety gear trigger. 2. Man riding hoist The man riding hoist must be correctly attached to the car sling using the fittings provided with the hoist. It is not permitted to disconnect the man riding hoist or remove the hook from the car until it has been double secured: 1. Safety gear The car must be secured on the safety gear using the automatic safety gear trigger. 2. Chains The parking chain(s) must secure the car to the agreed anchorage point in the shaft.

2.1.3

Electrical working safety Familiarise yourself with the safety instruction AM-01.03.002 and follow it at all times. Refer to AM-01.03.002 "Take 5 - Electrical Safety when Working on Elevators". The following 5 steps must be taken in the specified order unless there are essential reasons for doing otherwise: 1. 2. 3. 4.

Disconnect the power supply completely. Secure it against re-connection. Verify that the installation is de-energised. Check requirements for earthing in special circumstances.  (This operation may only be carried out by qualified personnel in co-operation with the person responsible for the building electrification who must ensure that the technique can be safely employed in this situation.) 5. Provide protection against adjacent live parts.


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2.1.4

General safety precautions Safety precautions Follow your national lift codes and other safety related regulations. The local safety codes and rules must be obeyed at all times. Follow this instruction. Do not skip any step, otherwise there may be a potentially dangerous situation which you have not considered. ENSURE THAT ELECTRICAL EQUIPMENT AND CONDUCTORS ARE SAFELY DE-ENERGISED BEFORE WORKING ON THEM. A locking off system for main electric supply isolator or other system (for example fuse removal, locking and tagging system, etc.) must be agreed with main contractor before installation commences. Do not connect or disconnect any connectors when the power is ON.

Note In case of conflict between the code and this instruction, rely on your code. Refer to your local procedures for the type of entrance protection required. Warning signs highlight possible hazards. (See page 28.)

Personal safety equipment must be Refer to the list of Personal safety items on available and used as required. page 28. Use only approved manual handling techniques. Do not work at different levels within the same / adjacent elevator shaft enclosures. The rust protection must be removed from Refer to page 59 for specific safety notes. the rails. Otherwise, the safety gear will not operate correctly. Prevent falls from height: 1. Identify all possible fall hazards. 2. Remove the fall hazards, if possible. 3. If it is not possible to remove a fall hazard, then reduce the risk of fall using fall prevention methods. 4. If it is not possible to protect against a fall hazard using fall prevention methods, then use fall arrest equipment but only when verified through specific risk assessment. The provision of suitable rescue equipment, instruction and training must be available to ensure the timely rescue in case of a fall. Refer to AM-01.03.001.


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Safety precautions CAUTION: Safety harnesses with lanyards.  When your safety harness is not secured to a life line or other approved anchorage point, ensure the lanyard does not cause a catching or tripping hazard.

Note If applicable, safety harnesses must be used in accordance with your national codes.

Always position the car at a safe level relative to landing before accessing or egressing. NEVER WORK UNDER A SUSPENDED LOAD! Ensure that the lifting equipment is correctly rated for the task and in good condition. Always use the hoist in accordance with Additional safeguards ensure that there is your local regulations. no unwanted movement of the car due to hoist control or other failure. Refer to AM-01.03.003 Take 2 - safe working when using hoists for man riding purposes. Take care handling waste materials in accordance with your local regulations.


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2.2

Recommended working postures and ergonomic methods These recommended working postures and ergonomic methods has been identified to contribute a better workplace and your well-being.

Working height Adjust height of working to enable your hands to be within the vertical area of chest and belt buckle.

Working distance Adjust working distance to enable the object to be within length of forearms.

Lifting Focus on the lift, even if the lifted object is light! 1. Go close to the lifted object 2. Use your legs 3. Keep your back untwisted and straight 4. Keep both feet on the same lane

Carrying 1. Keep the lifted object as close to the body as possible 2. Keep your back untwisted and straight

Loading of transport cart Slide the component onto the KONE transport cart instead of lifting it. Moving heavy objects without a handle If the object doesn't contain a handle, push/ slide the object instead of pulling.

NOTE: If work is being carried out by kneeling, with bent back/legs or with hands elevated above chest or object is further than length of forearms, ensure to limit time of exposure and alternate the working postures. Make sure that the working area is un-obstructed and not hindering you.


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2.3

Installation method safety Special feature The car is used as the working platform.

Note Do not drive on the car roof until the balustrade is fitted and the safety gear is connected. The man riding hoist is used to move the car during the initial stages of the installation.

The man riding hoist is positioned on the car roof and an additional securing rope is attached to the overspeed governor lifting eye. The man riding hoist and overspeed governor are suspended from lifting eyes in top of the elevator shaft. The elevator’s own overspeed governor Refer to AM-01.03.003 Take 2. and safety gear are used during installation. The automatic safety gear trigger engages the safety gear automatically in the event of hoist rope failure or manually when it is necessary to secure the car. The parking chain is used to secure the car to a car guide rail bracket whenever the hoist hook is disconnected from the car or when you are working under the car in the pit. Always keep the chain as tight as possible.

1078317.wmf

When working from the car roof you must always park the car using both the parking chain and the safety gear before disconnecting the hoist hook. Emergency descent from the car roof.

Guide rails are lifted using the car.


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At certain times the hoist hook is removed from the car whilst it is still used as a working platform. During these operations the safety gear must be engaged and the parking chain must be used. If there is a power failure on site, it is always possible to move the car to a lower landing level using the brake releasing lever. For emergency descent refer to the man riding hoist handbook. Guide rails are fitted in the conventional way using the sliding clamp to lift each rail.

AM-01.01.250 (B) 2013-03-18


Special feature Blocking device

Note

After roping, whenever working on the traction or suspension elements the blocking device must be used.

WARNING: The blocking device is not strong enough on its own to support the weight of the car. In situations where the car is not supported by the ropes it must be secured using the parking chain and safety gear.

When moving the car on manual brake release, do not let it overspeed. Check speed indication LEDs on LOP-CB board. Do not leave the brake open. (Try to limit the motor rotation to 1 second intervals.) If you are working on your own, ensure that someone in charge knows where you are and that regular checks are made to ensure your safety. If you have any doubts about single man working on a specific site, discuss with your supervisor.


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2.4

Danger and personal protection signs Danger signs Danger Electric shock

Sign

Danger Risk of falling

Sign

Danger Magnetic field

Risk of fire

Corrosion Dermatological risk

Entry prohibited

General hazard warning

Suspended load

Pinching hazard

Sign

Safety gloves, overall, safety shoes with ankle protection, safety helmet, safety goggles, dust mask, hearing protection and safety harness are provided for your personal protection. USE THEM AS REQUIRED. Personal protection signs Mandatory Sign Safety helmet

Mandatory Overall

Sign

Mandatory Dust mask

Hearing protection

Safety shoes with ankle protection

Safety gloves Rubber gloves

Fall prevention equipment

Safety goggles

Fall prevention measures

Man riding hoist mandatory inspection

First aid kit


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Sign

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3

SITE REQUIREMENTS AND TOOLS THE FIVE SITE ABSOLUTES 1. The elevator shaft is clean and dry before installation work starts. 2. The shaft is constructed according to KONE layout drawings and the shaft openings are sealed for safety. 3. The lifting eyes and the ventilation ducts specified by KONE are in place. 4. 3-phase power supply for elevator and installation hoisting is provided. 5. A 30 m2 storage space is provided on the ground floor close to the shaft and the access ways to the shaft are clear.

3.1

Site requirements Before installation can start, ensure that the following things have been done: – – – – – –

–

– – – –

The site must be 100 % ready. Transport routes must be defined and agreed as close as possible to the elevator shaft. Elevator shaft tolerances must be checked by the supervisor. Delivery must be complete and on site. Installation start date must be agreed with the customer. When starting the installation and the wall mounted MAP is delivered, ask the builder to finalise the wall at the location of the MAP. This ensures that the wall mounted MAP can be installed without re-adjustment. A locking off system for main electric supply isolator, or other system (for example fuse removal, locking and tagging system, etc.), must be agreed with main contractor before installation commences. Refer to AM-01.03.002 Take 5. Installation tools must be available on site. Recommended hand tools must be available. Personal safety equipment must be available. The site inspection should take place minimum one week before the installation is scheduled to start, in accordance to the delivery process milestones “835”.


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Note Where required, the elevator shaft lighting can be lowered from the top floor and temporarily secured to the entrance protection horizontal stands. If the lifting eye is screw type, the lifting eye must be securely fastened to avoid untightening.

3 WD

Requirement Adequate lighting and 3 -phase power supply must be temporary or permanent positioned for both the elevator and the man riding hoist according to the layout drawing. Lifting eyes must be positioned in the top of the elevator shaft according to the layout drawing and marked with the safe working loads. Right handed elevator: 1. Lifting eye for man riding hoist (2000 kg) 2. Lifting eye for machine (1500 kg) 3. Lifting eye for overspeed governor (1500 kg) • front side if skewed sling • rear side if parallel sling 4. Lifting eye for KDM drive (if applicable, 1500 kg)

1

2 4

3 WW

1077488.wmf

Typical lifting eye construction: Maximum diameter of hook section 18 mm.

!

max 65 1078300.wmf

Finished floor marks must be on each landing. For group elevators setting out reference lines must be marked on the lowest common floor area. Elevator shaft and pit must be cleaned and The elevator shaft must be watertight. pit waterproofed. C-inserts (if used) must be correctly positioned and cleaned. Suitable material storage areas must be Materials should be stored within 20 metres agreed with builder, adjacent to the elevator or close range from the elevator shaft. shaft. Suitable storage area must be provided for installation tools. Clear, unobstructed access routes to at least one entrance, at or next to the ground floor, for long or bulky items, (guide rails, car components, doors and so on), must be defined and clear of obstructions.


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Requirement Note ALL landings must be protected with full height entrance protection according to the local safety codes and regulations. Fit temporary barriers around the top and bottom landing entrances wherever temporary protection is removed or landing doors must remain open. The entrance protection must be imperforate. See AM-01.05.016, Installing light entrance protection (LEP). The bars must be secured so that they cannot be moved unintentionally 1078840.wmf horizontally or vertically. Elevator shaft dimensions and tolerances must be in accordance with layout drawings. Suitable provision for disposal of waste According to the local requirements. materials must be available. Appropriate fixing points for safety harnesses must be available.


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3.2

Pcs. 2 or 3

Tools MonoSpace® tools Tool Pcs. Tool Support bars 1 Automatic safety gear trigger Drawing number: 716161 Drawing number: 803140G01 1 Brake wire rope bracket: 3 support bars are needed if plumbing jig Drawing number: 803144G01 1 Brake wire rope: is used. Drawing number: 772277G01

1082712.wmf

1007069.wmf

1

Rope fixing plate Drawing number: 803146

1

Telescopic pipe, Bahco AP-5M Drawing number: KM823588H04

1027222.wmf

1

Parking chain 2 m, 1500 kg Drawing number: 266828

1010242.wmf

2

Plumbing supports (pit) Drawing number: 716177G01

2

Guide rail securing to car roof Drawing number: 773444G01 Guide rail lifting pocket Drawing number: 762396G01

1007070.wmf

1007072.wmf

1

Guide rail lifting clamp for guide rails T70, T82, T89

2 Drawing number: 716165G01

1007079.wmf P17000195.wmf


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Pcs. 1

MonoSpace® tools Tool Pcs. Tool Counterweight guide rail positioning tool 1 Unwinding device Drawing number: 716175G01 Drawing number: 504610G01

1007076.wmf

1

Hoist test bracket, max. load 2000 kg Drawing number: 716157G01

1

Counterweight guide rail alignment tool Drawing number: 716180G01

2

Eyebolt RUD RS-M8 Drawing number: 934990

1007084.wmf

4


1007074.wmf

1031357.wmf

1 1 1

1031357.wmf

Hoisting chains: Extension chain 1.5 m, 500 kg Drawing number: 266827 Shortenable chain 2 x 1.5 m, 500 kg Drawing number: 266826 Car/door installation chain 2 x 0.5 m, 500 kg Drawing number: 266825

4

1031357.wmf

3

1007078.wmf



Shackle 12 mm tap, 1500 kg Drawing number: 754257

1007081.wmf

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Pcs. 1

MonoSpace® tools Tool Pcs. Tool Rope grip for rope reeler securing, 9 mm 1 Shackle for car roof rope reeler securing, Drawing number: 754257 8 mm tap, 350 kg Drawing number: 754257

1007083.wmf

1

1007082.wmf

Plumbing jig (optional, see APPENDIX E. Plumbing jig) Drawing number: 754257

2

1007071.wmf

Pcs. 1

Plumbing weight (optional, if plumbing jig is used) Drawing number: 50077610G01

1080362.wmf

Other installation tools Tool Pcs. Tool Guide rail transportation tool 1 Swivel balustrade Drawing number: KM971149G01 or 2 sets in case of TTC (1 set = 2 balustrade parts, upper and lower). 2 Drawing number: KM50026878G02

1060909.wmf


1078014.wmf

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Pcs. 1

Other installation tools Pcs. Tool 1 Manual chain hoist, capacity 500 kg (Yale compact 500 or equivalent).

Tool Man riding hoist + pulleys, 750 kg / 1000 kg capacity.

See hoist equipment parts on page 46.

A = 289 mm H = 190 mm

1007086.wmf

1

Overspeed governor extension rope Drawing number: 772277G05

1033403.wmf

1 set

Machine transporting wheels Drawing number: 715802

1

Elastic grip L=1m

1031365.wmf

1007090.wmf

1

Site trolley Drawing number: 589519

1

Overspeed governor hanger kit including: – OSG hanger assembly – Pulley bracket assembly – Climbing rope Drawing number 823588G01

1078301.wmf

1010244.wmf


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Pcs. 1

Other installation tools Tool Pcs. Tool Battery tool 2 Transportation tool (used with Cable (Drawing number: 859326) and transportation wheels and axle) Drawing number: 854900D01 9V battery (supplied locally) Used with construction-time power supply.

4x

1078366.wmf

1039959-1.wmf

1

Rope clamp Drawing number: KM839679G01

2

Hilti PMP34 / PMP45 point laser

1078890.wmf

1060910.wmf

1

Carpenters ruler

2

Levelling plate

PMP 34

HILTI

+30

+20

+10

Laser alignment tool Drawing number: 50077847G01

+10

1

+20

Target plate +30

2

M8x50

1048308.wmf

1080768.wmf


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Pcs. 1

Tool Work stool Drawing number: 265173

Other installation tools Pcs. Tool 1 Telescopic ramps Drawing number: KM966635

1073236.wmf

1077935.wmf

1

Rope socket 6-8 Drawing number: KM971423G01

1

Electrostatic discharge (ESD) kit Needed to protect the components from damage if any PC boards are replaced. (KM857505)

1060911.wmf

1072347.wmf

2

Installation jig Drawing number: KM756128 Included in AMD door delivery

2

1082413.wmf

1073260.wmf


Plate for ramps Drawing number: KM50077171

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3.2.1

Hand tools (recommended) Tool

Carpenter’s pencil Tape measure, L 3.0 m Multimeter, protected against high voltage Hammer drilling machine, with dust collector Cordless drilling machine; with adjustable torque for car and landing doors and car installation. One extra accumulator (battery), bit cassette including Phillips head and flat heads in different sizes, drill bit cassette (sizes 1.5 - 10 mm). Phillips head bit 150 - 200 mm. Tool for concrete inserts Spanners: U end and ring end. Sizes 10, 11, 12, 13, 15, 16, 17, 18, 19 mm. Min. thickness for 16 - 19 mm spanners is 5 mm. Ratchet 1/2" drive Extension L 200 mm 1/2" Sockets (deep) 1/2", 13, 15, 16, 17, 18, 19 mm Carpenter’s hammer, 6 Oz. rubber handle, “shock absorbent” Vice grip/polie grip: L 150 mm and L 250 mm Engineers squares: 300 x 150 - 200 mm and 750 x 350 mm Side cutter, isolated handles (L 170 mm) File for guide rail joints, normal model Knife Disc cutter, disc > 125 mm Engineers square, adjustable block width 30 mm Pulling rope to pull the man riding hoist rope (plastic, 70 m, Ø6...8 mm) Allen keys, set 3 - 12 mm 2 G-clamps

Tool Lockable tool box for the normal hand tools Carpenter’s ruler Plastic tuning screw driver Adjustable spanner, L 200 - (250) mm Drill bits: 6 mm (light fitting, pit stop switches) 8 mm (trunking) 10 mm (pit ladder, travelling cable wall fixing) 12 mm L (150) (Hilti, for cutting through reinforcing bars) Crow bar, L 500- 700 mm Screwdrivers: Flat headed 5 mm L 200 mm. Electrical, isolated 2.5-3 mm head L150-200mm Phillips head: Standard size L 200 mm. Ratchet 1/4" drive small model Extension 1/4", L 40 - 150 mm Sockets 1/4" drive, 10, 11, 12, 13 mm Sledge hammer, 1000 gram Hammer side flat, end drop forged Magnetic spirit levels, lengths 700 and 1500 mm Rivet pliers, replaceable head to cover the different rivet sizes Long nose pliers, medium model (L 170 mm) Rope cutting pliers, 8 mm Hacksaw, standard model 4 pcs plumbing weights, max. 10 kg/each (diameter max. 40 mm, length max. 300 mm) Sheet metal cutters, professional quality for 0.6...1.5 mm steel sheet 2 vacuum handles, capacity 40 - 80 kg

1007097.wmf

1010245.wmf


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3.2.2

Installation blister pack KM50091308G02

Item M10 x 50 bolt

Material in installation blister Reason Pcs. Car guide rail fish plates (standard 1 type) are thicker than before. M10 bolt from the CWT guide rail joint is not long enough to permit the method of leaning back the topmost car guide rail at machine installation.

– 5 x 70 wood screw – plastic wall plug – 20 mm plastic tube, 35 mm long

CWT screen secured to shaft wall for 4 TAKE 2 method of guiding hoist rope tension weight.

CWT edge trim, 50 mm long

Required to be installed to the guide rail clips of the lowest guide rail brackets.

4

M12 x 80 expander fixings

– 2 x fixings to install a tethering anchor bracket – 2 x fixings for the hoist test – 1 x fixing to hold temporarily bracket for rail jointing – 1 x fixing to hold temporarily bracket for ladder securing

6

– 8 x 50 coach screw – M8 mudguard washer – plastic plug

M10 M12

35

WARNING: Use M12 anchor bolts only in concrete! If other wall material exists, locally source suitable fixings. Consult your local support function. Required to temporarily fix pit ladder 2 to the lowest floor sill area. NOTE: Required due to the safety codes of various frontlines. 1082610.wmf


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4

OFFLOADING AND DISTRIBUTION

CAUTION: For personal safety and to prevent any damage to the components: – Keep the working areas clear and unobstructed. – Never go under any suspended load. – Use correct manual lifting techniques. – Wear gloves to protect your hands. – Always wear a helmet. – Wear safety harness and fix it to an approved fixing point while working in areas where there is risk of injury from falling. – Wear goggles and dust masks as necessary. – Use hearing protection as necessary. – When using the telescopic ramps ensure they are parallel and cannot slip off leading edge. Introduce yourself to the person responsible for the site. Familiarise yourself with the site facilities, the local rules, safety requirements and site management procedures.

4.1

Offloading and distributing materials

NOTE: The 150 kg (300 kg / pair) maximum WLL (working load limit) marking of the telescopic ramps is based on single axle trolley usage. On specific tested method steps, where a twin axle assembly is used (such as machine transport), the load is more evenly distributed across the ramps. In such cases the WLL is increased to 380 kg / pair of ramps. Always follow the designated method description. WLL 300 kg / pair of ramps

WLL 380 kg / pair of ramps

1078918.wmf


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1078916.wmf

AM-01.01.250 (B) 2013-03-18


1. Fix the transportation wheels to machine package while unloading. 2. Use wooden blocks to tilt machine box when removing the wheels.

1060912.wmf

1060914.wmf

Offload the material to the destinated storage area. Arrange the materials to ensure easy access to each component in the installation order.

NOTE: Car floor is at the oppposite side of the packing list. NOTE: A number at top of each crate indicates the installation order. Place the machine box so that the side with the holes is downwards. When offloading the machine from the vehicle, put it into vertical position and use a forklift to place machine onto the axle and wheels. Push the machine into the storage area. Remove the axle and wheels and leave the crate in upright position on two pieces of wood. The female end of the guide rail bundle is marked with tape. Locate the bundle so that the male side faces the elevator shaft. Handle the bundle carefully so as not to damage ends. Put the guide rail bundle on a higher stable working level to achieve a good working height of 1.0 m. It is important that the tools and materials are positioned according to the installation order to achieve and maintain a controlled installation environment throughout the installation. Do not open the packages until you are ready to install the equipment. Check against the material documentation that the delivery is complete. Position the tools and materials to correct levels before the installation starts.


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Mono3 - Unloading order

Copyright ©2012 KONE Corporation

All rights reserved.

xxxxxxxx (Draft -) 2012-05-24 Copyright © 2012 KONE Corporation All rights reserved.

Compiled by: Information Product Author / Ville Malmiala Checked by: Global Installation Support / Solution Manager, Global Packing / Konsti Ville Approved by: Global Installation Support / Anssi Venho

KONE MonoSpace® 3.0

Installation Instruction

1079322.pdf

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Package group 100 200

Group header Installation requisites Guide rails and shaft beams

300

Doors

400

Machine room

500

Shaft and machine room Car Car sling and frame

600 700

Package label 110 120 210 220 230 311 312 330 331 410 420 430 510 440 / 540 610 710 720 730

A Topmost landing – Long tool box – Hand tools – Man riding hoist top pulley – Elevator shaft lighting (if applicable) – Overspeed governor and rope – Parking plate – Rope suspension, counterweight side B Entrance level / Storage area – Smaller tool box – Man riding hoist, ASGT – Working stool – Counterweight guide alignment tools – Guide rails and brackets – Counterweight, filler weights – Car sling, car – Machine – Car door and landing doors – SEP, MAP, drive panel, COP – Elevator shaft electrification – Pit ladder – Ropes – Wiring material

Package label text Installation requisites Overspeed governor Guide rails Guide rail fixings Shaft beams Frame / Fronts Door panels Door operator Railing Machine Ropes Shaft electrification panel Shaft equipment Wiring Car Car sling Counterweight frame Filler weights

A

B

1007099.wmf


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4.2

Offloading and transporting landing doors 1. Keep the area on the side of the crate with the identification label “OPEN THIS SIDE” unobstructed. 2. Always transport parts of door one at a time. 3. The top tracks will be stored in the shaft mechanics box. 4. Open the narrow side of the card board box marked “Open this side” by cutting the vertical edges of the side. This is to gain access to the door panels. 5. Remove the top wooden support to access to the sills. 6. When extracting the door panels, do not break the two wooden rings around them. Slide the door panels out the opening. 7. When the panels are stored into the car or at the landing, ensure that the guide shoes are facing up in order to not damage them.

a31294e4.wmf


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5

INSTALLING MAN RIDING HOIST AND OVERSPEED GOVERNOR

Quality Requirements: Man riding hoist and accessories – inspected and certified (inspection period validity to meet local code) – ONLY TRAINED PERSONS TO USE THE HOIST! – lifting hook in shaft tested Car overspeed governor – installed to temporary position – check data label to ensure correct type and tripping speed – ensure correct tripping direction – ensure the rope is on the small pulley

1075605.wmf

!!! CAUTION - issues that affect reliability !!! N/A

NOTE: Check carefully that the OSG rope is correctly on the groove and UNDERNEATH the internal rope guard!

5S

SORT STABILIZE SHINE STANDARDIZE SUSTAIN

Method tools needed: Man riding hoist test bracket, overspeed governor hanger, telescopic pole, site trolley, man riding hoist + rope + accessories + hoist test plate (fuse plate) Hand tools needed: Pencil, tape measure, hammer drill, hammer, 2 x spanner (19 mm), pulling rope 5S Installation Progress Report N/A QD-181.211 QD 1 completed


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5.1

Man riding hoist parts

NOTE: The man riding hoist type described in this instruction is Tirak X750.

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14.1 14.2 15 16

Item Diverter pulley including the safety rope Electric hoist Tension weight Manual rope reeler for maximum 60 m rope. Minimum rope length = 2 x elevator shaft height. Safety pin no. 2. 6 mm Electric supply extension cable for main power supply, 45 m, 5 x 1.5 mm2 Pendant controller Extension cable for the pendant control Car adapter for the hoist Car adapter for the hook Adapter axle Split pin 6.3 x 40 Diverter pulley Ø160 mm Safety pin 5 x 32 mm for diverting pulley Safety pin no. 2. 6 mm Tension weight pulley Ø130 mm Tension spring (guide for rope)


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Greifzug component no. 33009 57497 30158 12056 16537

53877 53887 72415 63496 53997 63656 12056 20205 8363

AM-01.01.250 (B) 2013-03-18


14.1

7. 1.

13.

8. 6. 2.

5. 9. 12.

16. 3.

11.

15. 4. 11. 10.

14.2.

P17000140.wmf


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5.2

Work positioning equipment or restraint system

NOTE: For more information, see AM-01.03.001 Preventing falls from height when working on elevators, escalators and building doors. Work positioning or restraint systems are systems of personal protection designed to secure the user in a safe position where it is not possible to fall. The restraint may also be used as an additional measure to prevent fall when working close to or leaning over the basic entrance protection, for example, when installing components at the top of an elevator shaft. The area around the fall hazard must be segregated to prevent risks to others. Work positioning system CAUTION: Work positioning or restraint systems must not be used to arrest a fall.

1072131.wmf

NOTE: Wall fixings are located with KM50091308G02 (Blister - Installation hardware). Use these fixings only in concrete! If other wall material exists, consult your local support function to source suitable fixings.

Typical equipment includes: – Body belt. NOTE: A full body harness is sometimes used but is less suitable for low level anchor point. – Adjustable lanyard (without shock absorber). Keep the lanyard as short as possible and take extreme care that the lanyard cannot be damaged by sharp edges. – Suitable fixing point. The anchorage point strength requirements vary, but they must be capable of supporting around double the maximum pull force of a person and be in accordance with local regulations.

KONE methods do not support the use of work positioning or restraint systems as primary fall prevention systems. This system is suitable as additional protection to the primary protection or where there is a limited risk of injury. They are only to be used where no other better solution is possible, subject to site specific risk assessment. (for example, existing elevator with no car top balustrade).


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5.3

Safety checks Make the following safety checks. Item Lifting equipment and suspension eyes.

Hoist and lifting equipment. Plugs and cables. Emergency stop button and limit switches (if applicable). Safety harnesses and ropes.

5.4

Requirement Must be load marked, tested and in good condition according to local requirements. Must be tested according to local requirements. Must be in good condition. Must prevent movement of hoist when contacts are open. Must be inspected and in good condition. When used, they must always be securely attached to approved fixing points.

Risk Falling loads.

Electric shock. Uncontrolled movement of hoist/car. Falling.

Transporting 1. Use site trolley to transport the man riding hoist.

SMW06.wmf

1060916.wmf

1060917.wmf


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5.5

Routing the man riding hoist rope and cable

WARNING: When there is a risk of falling wear a tethering system when working at unguarded landing entrances. Always install the hoist from the lowest landing level. For more information, see AM-01.03.001. 1. Lower the power supply cable from the topmost landing to the pit. Connect to hoist. Check the operation of the hoist safety functions. 2. Drive out the hoist rope and pull it to the top floor using the lifting rope. 1 = rope entry, 2 = rope exit If the hoist motor does not run, reverse two phases in the plug by rotating the phase changer* in the plug housing 3. Pull the hoist rope to the topmost landing. Allow 8 metres of slack to reach the elevator shaft ceiling. Loop the hoisting rope through the pulley.

1072131.wmf

*

1

2


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P17000199.wmf

P17000107.wmf

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5.6

Installing overspeed governor hanger

WARNING: Check the correct orientation for the overspeed governor. The rope guard must face the shaft wall.

NOTE: The counterweight overspeed governor (if any) must have higher tripping speed than the car overspeed governor.

*

~4 m

~4 m

1. Route the pulling rope through the hanger. Tighten the lower hook to maintain in correct position. *) Make a loop at the rope end to enable pulling the rope back to the landing. 2. Lift the hanger to the lifting eye.

1079201.wmf


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3. 4. 5. 6.

Pass the rope over the small groove of the OSG. Check the tripping direction. Secure rope ends together and lower to the pit. Check that ropes do not get entangled. Pull the overspeed governor to hanger. The rope guard must face the wall. Remove the pulling rope. It is needed for car floor installation.

1078306.wmf

5.7

Fixing the man riding hoist rope 1. Attach the securing rope of the hoist diverting pulley to machine lifting eye. Use telescopic pole and adaptor bracket. Strengthen adaptor bracket: 1 = M6 flange nuts from car bolt delivery, 2 = M6 x 40 bolt, provided locally. 2. Fit hoist rope over the diverting pulley. Attach the pulley to the hoist suspension eye.

1

2

1078319.wmf


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5.8

Lowering the man riding hoist hook to the pit 1. Drive out the hoist rope and lower the hook to the pit. 2. Clip the hoist hook over the suspension bar on the hoist. 3. Fit the car parking chain (capacity 1500 kg) to the underside of the hoist and drive the hoist into the elevator shaft

1009514.wmf

P17000146.wmf

5.9

Pit ladder 1. When using the ladder, ensure the suitable angle between the ladder and the pit floor. 2. Secure the pit ladder for installation time use according to method A or B. Install the CWT guide rail bracket while entrance protection is fitted. 3. Fix the pit ladder wall fixing bracket to the machine side wall. 4. Fix the securing strap is to the wall to prevent unwanted removal of the ladder.

1m

A

PH

B

PH /3 1078313.wmf


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5.10

Testing the hoist equipment If the lifting eye or suspension element for the man riding hoist diverter pulley has not been tested and certified, perform and record the test. The test ensures that the hoist equipment will take the maximum load hoisted during the installation.

WARNING: No one is allowed to be in the elevator shaft during this test.  WARNING: The hoist can be used for material transportation after test. Do not use the hoist for man riding.

1. Install the hoist test bracket on the side wall of the elevator shaft. NOTE: Fixings* are located with KM50091308G02 (Blister - Installation hardware). Use these fixings only in concrete! If other wall material exists, locally source suitable fixings 2. CAUTION: If "double" adapter is used, use direct line pulling to prevent hoist damage. 3. Attach the dynamometer or test plate (breaking strength 1500 kg or 2000 kg, supplied locally) between the hoist and the hoist test bracket. Shorten the parking chain to 300 mm. NOTE: Select the chain capacity according to the hoist capacity. 4. Drive the hoist slowly upwards until the hoist ropes are almost under tension. Take up the tension smoothly. Sudden loadings may damage the equipment. 5. Run continuously until the load limit of the hoist is reached or the test plate breaks. Motor power supply is automatically disconnected. Drive the hoist downwards to reset it. 6. Write your name and test date on the test plate and store it. Fix it to the tested lifting point after guide rail installation. 2

1010613.wmf

1082349.wmf


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6

PLUMBING

Quality Requirements: – – – –

plumbing table is completed dimensions in the pit are similar to those in layout drawings lasers are positioned on the pit floor according to the plumbing table laser tools are calibrated, clean and batteries checked

1075617.wmf


5S


Method tools needed: Pit ladder, lasers Hand tools needed: Tape measure, pencil, spirit level 5S Installation Progress Report N/A QD-181.211 QD 2 completed


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6.1

Elevator shaft plumbing 1. Place laser tools on the pit floor to the LL dimension. Check the accuracy of the laser beams by measuring dimension LL at second landing. See layout drawings. 2. Measure dimensions at each landing and fill in the plumbing table. For nominal dimensions see layout drawings. Store plumbing table with other elevator documentation. 3. Mark the landing door centre line (A) below the lowest landing LL

A1

LL

A2

!

Plumbing table A5

x1

A6 A3

x1

A1

x2

A4

6.2

(A)

1051761.wmf

1048316.wmf

LL

A2

x2 1051760.wmf


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Elevator number:

Measured by:

Date:

Position SH (headroom height) H (travel height) PH (pit depth) WW (elevator shaft width) WD (elevator shaft depth) x1 (vertical straightness of pit wall) x2 (vertical straightness of pit wall)

A1

A2

Measured (mm)

A3

A4

A5

A6

LL

Nominal dimension Level 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16


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7

MECHANICAL INSTALLATION IN THE PIT

Quality Requirements: Pit ladder – installed correctly (ensure that length meets local code) Guide rail brackets (first 2 rounds) – installed according to the layout drawings – level in all planes Guide rails – clean, not rusty – checked for straightness – installed correct way up – installed according to the layout drawings – vertically aligned, parallel to each other, maximum DBG deviation of -0 mm, +1 mm – edge trim fitted to car guide clips of lowest bracket – all remaining guide rails placed in pit (if enough space) Buffers (car and counterweight) – installed according to the layout drawings – buffer top fixing installed 125 mm below the buffer plate (if polyurethane buffer) – installed level to each other (if dual buffers) – oil level checked (if oil buffers) Counterweight frame – CWT shoes aligned and not twisted Dividing beams (if applicable) Overspeed governor tension weight – installed to correct height, minimum distance from bottom of weight to pit floor is 195 mm – adjusted to ensure the slack rope switch operates

!!! CAUTION - issues that affect reliability !!! Incorrectly installed guide rails causes: – ride comfort issues (noise / vibration) – drive faults / failures – levelling accuracy problems – premature shoe liner wear (car / counterweight) Incorrectly adjusted counterweight shoes causes: – ride comfort issues (noise / vibration) – drive faults / failures – premature shoe liner wear Incorrectly adjusted OSG tension weight causes: – safety circuit break due to rope stretch – noise / vibration from rope rubbing guard Incorrectly adjusted buffer bracket height causes: – contact with oil collectors if top bracket too high


1075519.wmf

SORT STABILIZE SHINE STANDARDIZE SUSTAIN Method tools needed: Man riding hoist + accessories, guide rail transportation tools, guide rail lifting clamp, Hilti RA laser kit, guide rail alignment and DBG tools, machine transport wheel + axle sets, work stool, timber pieces Hand tools needed: G-clamp, hammer drill, hammer, ratchet + sockets (18, 19 mm), spanner (13, 15, 18, 19 mm), small crowbar or podger spanner (19 mm), tape measure, pencil, spirit level 5S Installation Progress Report

5S

Lift pit equipment installed, Counterweight installed, Guide rails installed = 25% QD-181.211 QD 3 completed

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7.1

Guide rail preparing

WARNING: The guide rail bundle may fall down when metal straps are opened. Open the middle strap first and then the outer straps.

WARNING: Remove the rust protection from the guide rails, otherwise the safety gear will not operate correctly.

NOTE: Before drilling in the pit area, check any water proofing that may be affected and limitations to drilling depths.

4 3 2 1

3

Travelling height > 3.5 m: 1. First guide rails (L = 5 m) 2. Intermediate guide rails (L = 5 m) 3. Second topmost guide rails (L = depends on the shaft height) 4. Topmost guide rails (L = 2.5 m)

2 1

Travelling height  3.5 m: 1. First guide rails (L = 2.5 m) 2. Intermediate guide rails (L = depends on the shaft height) 3. Topmost guide rails (L = 2.5 m)

1078541.wmf

1078540.wmf

NOTE: Identify the topmost guide rail on the machine side according to the machine fixing holes.

NOTE: After lowest guide rail installation (car / CWT rails): Due to difficult drilling angle, it is recommended to first install only the car guide rails, then the CWT rails. This offers clear drilling capability.

1078546.wmf


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1. Use guide rail transportation tool to transport the car guide rails (T70-T89). 2. Clean the guide rails and fish plates thoroughly. Fix the fish plates and jointing pieces. Check that the Z-type fish plates are installed the correct way according to the car sling bottom pulley beam type (skewed / parallel) and synchronization bar location (rear / front). NOTE: The topmost fish plate on combination bracket side must always be installed the same way to enable the machine installation. 3. Check the guide rail straightness. Use a string or a plumb wire. 4. Adjust the DBG at the alignment tool*. Set the counterweight guide rail positioning tool** to the correct length. Refer to the layout drawings. max 5mm

max 5mm

max 2.5mm

max 2.5mm

*

**

A

A 1078394.wmf

A = synchronization bar


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7.2

Installing dividing beams (if applicable) 1. Install the first two dividing beams before car installation. Align using the lasers. See layout drawings. 2. Install the rest of the dividing beams after car installation. Align using the lasers and car top balustrade uprights.

1

2

1010422.wmf

7.3

Guide rail brackets The table on the following page describes the different types of the guide rail brackets and extensions for guide rail brackets.

A

L 1082429.wmf

L = distance from back of the guide rail to the elevator shaft wall A = distance between the fixing holes in the bracket / extension


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Combination / car single bracket CWT single bracket A = 170 mm

Car single bracket (25
*

* **

** 1079043.wmf

*) if 187  L < 240 97  L < 306 **) if 240  L < 375, extension plate and 6 fixing bolts Extension (for combination / car Extension (for CWT single single bracket) bracket) A = 440 mm

0 23

** 5 11

*

1079042.wmf

*** 1079046.wmf

1079037.wmf

*) 25  L < 45 **) 45  L < 65 ***) 65  L < 85 Car single bracket (50
0 23

*

** 5 11

*

** 1082430.wmf

1079044.wmf

*) if 375  L < 490 *) if 306  L < 421 **) if 490  L < 655 **) if 421  L < 530 Two topmost combination and CWT single side brackets have isolated clips.

*) 50  L < 80 **) 80 L < 97 Car single bracket (85
*

*** *

**

**** **

1079047.wmf

1079050.wmf

*) 85  L < 125 **) 125  L < 165 *) topmost CWT single bracket for concrete shaft (anchor bolts) **) topmost CWT single bracket for steel shaft (C-channel/T-bolts) ***) 165  L < 205 ****) 205  L < 245


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7.4

Installing first guide rails

WARNING: When using hoist in 2:1 mode, do not stand directly under the load.

CAUTION:  Counterweight filler weight may hit the combination bracket fixing bolts.  Minimize the length of the threaded studs if the combination bracket is adjusted close to minimum.   1080264.wmf

NOTE: Dimension A, see previous page. Dimension X, see table below.

CWT guide rail HT60 T70

X (mm) CWT bracket (DBG + 152) - A / 2 - 20 (DBG + 182) - A / 2 - 20

X (mm) CWT bracket with extension (DBG + 152) - A / 2 - 80 (DBG + 182) - A / 2 - 80

NOTE: If delivery is one or more floors above the lowest floor, see APPENDIX I. Delivery above lowest floor. This provides method steps how to hoist the components down to the lowest floor.


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1. Place lasers as close to the side walls as possible, to the centre of the guide rail line. 2. Measure, mark out and drill the guide rail bracket fixing holes. See layout drawings. 3. Fix the guide rail brackets.

* X

A/2 A

X

* A

A A/2

A

1075556.wmf

4. Hoist the car guide rails to the shaft. Use a chain as a weight at the lifting clamp to help the clamp slide back down. 5. Fix the car guide rails. Fit edge trims (delivered in installation blister) at the lowest car guide rail brackets (to prevent guide rail lifting during preliminary safety gear check). Do not fit edge trims to any other than lowest car guide rail clips. 6. Align the bracket using shims* if wall inclination is poor.

* 5

6

4

1075560.wmf


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7. Position the laser level plates. Measure distances A, B, C, D and E. See layout drawings and plumbing table. 8. Tap the pointed screws lightly with a hammer so that they dig into the concrete. 9. Place the lasers on top of the plates and turn them ON. Level the plate observing that the laser beam point is centred in the lens. 10.Adjust the guide rails (laser beams in the centre of the targets). 11.Check DBG and parallelism. Maximum deviation in DBG is -0 mm, +1 mm.

234

B

E =

E =

D

31

C(31+DBG+31) A 1077355.wmf

12.Fix and align the first counterweight guide rails.

1077481.wmf


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7.5

Installing and aligning the first length of car guide rails (H  3500) 1. Temporarily fix the counterweight guide rail bracket to the side wall. Secure the first car guide rail against the bracket. 2. Lift the intermediate guide rail using man riding hoist and join the guide rails (working from the landing). Align and finalise the guide rail joint. 3. Install and align the guide rails.

1040042.wmf


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7.6

Installing counterweight buffer, OSG tension weight and OSG rope 1. Install polyurethane buffer to the combination bracket side guide rail. Fix the striker plate. Drill the fixing holes for the oil buffer. Store the buffer to the pit. 2. Place timber pieces (located in sling package) beside the buffer. 3. Hoist the remaining guide rails onto the front side of the elevator shaft. Store some of the guide rails to the second floor if the space is insufficient in the pit.

80

1078795.wmf

4. Install and adjust the overspeed governor tension weight. Check that the slack rope switch (*) triggers in lower position.

*

150 195 1077698.wmf


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~25

5. Connect the overspeed governor rope to the anchorage. Use extension rope to be able to adjust rope length later from the car roof. *) Use BG-M6 type iron grips. Refer to KM181743.

1080212.wmf


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7.7

Installing counterweight frame

NOTE: Do not install the buffer spacer yet. It will be installed during the roping. 1. Use long bolts (M8x50) and nuts to fix the transport wheels. 2. Counterweight with a safety gear: Hoist the safety gear to the centre of the pit floor on top of the wood blocks (from car sling package) for stability. Hoist and fix the counterweight frame on top of the safety gear.

M8x50

1080772.wmf


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3. Loosen the guide rail clips from the counterweight single side guide rail brackets. Remove the shaft side clips. Lean the guide rail against the shaft rear wall. 4. If solid counterweight guide rail: • hoist the counterweight frame to the shaft • secure the frame to the guide rail on the combination bracket side • hoist the single side counterweight guide rail to the frame. Use a chain between the hoist and the guide rail lifting clamp. • secure the guide rail to the frame with a cable tie and a G-clamp 5. If hollow type guide rail: • hoist the frame onto the timber pieces. The car side of the counterweight frame is marked with a yellow sticker. Leave sufficient angle to insert the rail • secure the frame to the combination guide rail with a cable tie • insert the loose guide rail to the counterweight frame 6. Push the assembly back until the rail enters the rail clips. Fix the shaft side guide rail clips. 7. Mark lowest combination bracket height to an upright (for initial loading. The laser target plate will be positioned to the thin metal filler height later). 3

3

5

7 6 6 4

1080667.wmf


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7.8

Installing car buffers

4x M12x40

125*

1. Install the car buffers, both clamps on the lower part. Align and adjust the height. See layout drawings. *) Minimum required distance to ensure clearance to oil collector during buffer testing.

4x M12x110

120


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8

CAR INSTALLATION

Quality Requirements: HANDLE MATERIALS CAREFULLY TO AVOID DAMAGE! Car sling – installed and aligned – safety gears adjusted and connected to overspeed governor rope Car – platform installed level to sling beam – car walls installed in correct position (D1, D2 etc.) – rear and side walls aligned with platform (top edges level to each other) – all panel gaps even – no rattling noise during knock & feel test – all protective plastic paper removed from joints etc. – car roof and roof stiffener installed – car top balustrade and kick plate installed – inspect for any sharp edges Counterweight frame – initially loaded (pay attention to the special filler weight location!) Counterweight screen – temporary installed to shaft wall Automatic Safety Gear Trigger rope – connected to safety gear linkage

1077033.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed car sling and car causes: – misalignment of other components (walls, roof, doors) which affects visual appearance and causes noise / vibration Incorrectly adjusted car shoes causes: – ride comfort problems (noise / vibration) – drive faults / failures – premature shoe liner wear Incorrectly adjusted safety gear causes: – noise / vibration – damage to guide rails causing noise / vibration – premature wear of safety gear components – premature shoe liner wear


5S


Method tools needed: Man riding hoist + accessories, work stool, site trolley, OSG extension rope, rope clamp, ASGT rope Hand tools needed: Tape measure, spanner (10, 17 mm), 2 x spanner (13, 19 mm), ratchet + sockets (10, 13, 17, 19 mm),  2 x G-clamps, large size square, long nose pliers, insulating tape, vacuum lifting handles, allen key (8 mm), battery drill / driver 5S Installation Progress Report N/A QD-181.211 QD 4 commenced

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8.1

Contents of car packages In the car package on top of the car floor, is the individual order bound layout of the car package. Refer to this layout drawing when installing the car walls and the car interior.

COP

1080825.wmf

NOTE: If delivery is one or more floors above the lowest floor, see APPENDIX I. Delivery above lowest floor. This provides method steps how to hoist the car components down to the lowest floor.


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8.2

Installing uprights

NOTE: If car sling with roller guide shoes: Uprights are delivered with sliding guide shoes at the top end. They will be replaced with the roller guides later.

NOTE: Before installing uprights with SLG20 guide shoes: * Ensure the shoe liner (A) is not protruding beyond the edge of housing (B) by more than 0.5 mm.

B

A

B

A

*

*

1080149.wmf


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NOTE: If car has a COP with back box, check that the car floor diagonal bracket in corresponding location is different*. 1. Check the car buffer alignment. Shim as necessary. 2. Hoist the uprights on top of the buffers and secure to the guide rails with cable ties. Machine side upright is marked. 3. Install the safety gear levers and OSG rope anchorage. Use cable tie to secure the assembly from bending until it is connected to synchronisation bar.

1

2.3

2.2

*

3

2.1

1075481.wmf


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8.3

Installing bottom beam (skewed type)

WARNING: Use this method only when unloading the beam from the pallet. Do not let the pulleys hit the ground. WARNING: Never work under suspended load. Work from the landing when hoisting the bottom beam to the shaft

NOTE: Check that the bottom beam is installed the right way. Machine side of the beam is marked. NOTE: The stopper bolts* are pre-set at factory, do not adjust them at site. 1. Secure the site trolley to pallet. 2. Use a piece of wood under the bottom beam to rotate the beam end to site trolley.

*

1079144.wmf


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3. Transport the beam close to the shaft entrance. Non-machine end will enter the shaft first. 4. Attach the adjustable chain so that the chain at the machine end of the beam is 150 mm longer. *) Machine side of the beam is marked.

* >X

X

*

1078446.wmf

5. Hoist the bottom beam between the uprights. Fit one fixing bolt on the machine side before lowering the other end of the beam. 6. Push the upright against the guide rail with G-clamp. Fix the bottom beam. Check the alignment. Check that the uprights are parallel to each other. 7. Tighten the car floor diagonal supports roughly to final position.

6 5 7 6

6

=

=


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1075482.wmf

AM-01.01.250 (B) 2013-03-18


8. If the rear side pulley interferes with plumbing laser beam, lower the pulley down. Fix the pulley to final position after guide rail installation.

1076218.pdf 1076223.pdf 1080286.wmf

9. Adjust the gap between the sliding side of the safety gear and guide rail to 3 mm. Use the keeper plate of the single guide rail bracket as a gauge.

3

3

10.Store the following items in the pit to be installed later: • travelling cable hanger • compensation chain hanger (if applicable) • bolts to fix the platform to the bottom beam (M12, 4 pcs)


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8.4

Installing bottom beam (parallel type)

WARNING: Use this method only when unloading the beam from the pallet. Do not let the pulleys hit the ground. WARNING: Never work under suspended load. Work from the landing when hoisting the bottom beam to the shaft. 1. Use site trolley to transport the pulley beam close to the elevator shaft.

1082435.wmf

2. Hoist the bottom beam between the uprights (pulleys on A side). Keep the bottom beam level to ease installation to uprights. NOTE: Machine side of the bottom beam is marked. 3. Fix the bottom beam. Check the alignment. Use G-clamp to push the upright against the guide rail. 4. Tighten the car floor diagonal supports roughly to final position.

=

=


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1080751.wmf

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5. Adjust the gap between the sliding side of the safety gear and guide rail to 3 mm. Use the keeper plate of the single guide rail bracket as a gauge.

3

3

6. Store the following items in the pit to be installed later: • travelling cable hanger • compensation chain hanger (if applicable) • bolts to fix the platform to the bottom beam (M12, 4 pcs)


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8.5

Installing car floor

WARNING: Do not remove the lifting equipment or step onto the floor before securing the floor to the sling.

NOTE: Because of the different orientation at the packaging, the 1600 mm x 1400 mm size floor can not be installed using the standard method. For more information, see APPENDIX H. Installing car floor, BB 1600 x DD 1400. 1. Install the transport wheels to the car floor while unpacking. 2. Use a chain to keep platform close to the package when lifting to upright position. 3. Transport the car floor close to the shaft entrance.

2

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4. Small cars with parallel pulley beam: Install the car sill brackets before hoisting the floor to the shaft. The pulley beam may obstruct access behind the platform front edge.

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5. Fix brackets to the centre of front and rear edges of the floor. 6. Fit upper fixing bolts to both sides of the car floor. The bolts guide the floor to the correct position. 7. Fix and route a pull rope to control the floor movement.

6 7 5

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8. Hoist the car floor to the shaft. Lower it onto the bottom beam.

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9. Fix the diagonal supports hand tight, front ones first. 9.1 In cases with COP back box, the diagonal bracket is different. The diagonal may interfere with plumbing laser. Leave the diagonal to hang beside the upright (tighten slightly). Fix after the guide rail installation. 10.Secure the floor to the uprights hand tight. 11. Check the alignment. Adjust from diagonal support top fixings. Finally tighten all the bolts. 12. Connect the safety gear levers to the synchronisation bar. 12.1 Parallel type pulley beam, synchronization bar on rear side NOTE: If parallel type pulley beam and synchronization bar on the front side of the car platform, see APPENDIX J. Synchronization, parallel sling.

10

11 11

11

9.1

12

9

12.1

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8.6

Connecting ASGT rope to safety gear linkage 1. Connect the automatic safety gear trigger rope to the safety gear linkage on machine side. Secure the rope so that you have access to it later from the car roof. 2. Slide the upright securing cable ties up just below the top beam fixing holes.

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8.7

Initial loading of counterweight

WARNING: Do not install all the filler weights at this stage.  WARNING: If filler weights are delivered one or more floors higher than the lowest floor, DO NOT INSTALL the filler weights at this stage. They will be transported within the car and installed after guide rail installation. For more information, see APPENDIX I. Delivery above lowest floor.  WARNING: In case of lead filler weights, wear safety gloves and a respirator mask.

CAUTION: Install the adapter plates to counterweight frame always if delivered (DBG  525). These plates enable the use of double chain method when lifting the CWT frame for initial loading. Remove the plates from the CWT frame after installation and store them to the lowest combination bracket. Initial load filler weights are always delivered without paint marks. Balancing load filler weights should always be delivered with paint marks. If no paint marks are visible on the balancing load, use following calculation to assist: Load x Bal% / 2 = weight of painted fillers Load = elevator load, Bal% = Balancing factor percentage General rules: – split filler weights are always 10 kg – full size filler weights are always 25 kg – balancing load calculated sum will always be rounded up to next FULL SIZE filler weight, not split weight. Example: – 630 kg car with a Balancing factor percentage of 42.1% – 4 x split filler weights (40 kg) were delivered to site 630 kg x 42.1% / 2 = 132.615 kg 132.615 kg - 40 kg (split filler weights) = 92.615 kg This figure is rounded up to next full size filler weight = 100 kg TOTAL: 100 kg (full size) + 40 kg (split) = 140 kg of painted filler weights If in doubt, contact your local support function.


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5

A

B 2x

4

3

1x

2 1

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1. Bottom filler type 2 (inside the counterweight bottom beam, concrete) 2. Bottom filler type 1 (steel) A = fillers with yellow paint marking (CWT single guide rail bracket side) B = fillers with green paint marking (combination bracket side) 3. Basement filler weight (steel) 4. Standard filler weight (steel, concrete or lead) 5. Top filler weight (steel or concrete)


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1. Lift the counterweight frame up using hoist so that bottom of the frame is at the car floor height during loading. Use shortenable chain (and 2 x 0.5 m chain) for lifting. 2. Install all filler weights without paint mark to the counterweight frame: • install the bottom fillers to the counterweight bottom beam (type 1 or type 2) • place one thin metal filler to the bottom the correct way up *) slot towards the car at the combination bracket side • place two thin metal fillers to the marked height (lowest combination bracket height) • all the steel filler weights except one must be below the concrete filler weights • secure the fillers with the clamps NOTE: Do NOT move car / CWT until securing clamps are fitted. 3. Store remaining filler weights on landing so that they can not tilt and fall down. 4. Check that the counterweight pulley is secured. Remove the CWT front plate for roping. 5. Install the counterweight screen temporarily to the side or rear wall (fixings from installation blister). The screen is used to guide the man riding hoist rope tension weight.

1 5

1

35

4

* 230

4

3


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8.8

Installing car walls

CAUTION: In case of 3D laminate walls, do not use vacuum handles for transportation. Textured surface enables air to enter between the protective surface and the vacuum handle. This causes failure of the gripping capacity of the vacuum tool. CAUTION: Do not damage the wall panel fixing hooks. Transport the panels with hooks facing upwards. If panel with hooks at both edges, use pieces of wood under the panel

NOTE: In case of glass rear wall, the installation order of the wall panels is different. For more information, see section 8.8.3 Installing car walls, glass rear wall. NOTE: Use lifting eyes (RUD RS-M6) and hoist to manoeuvre the big car wall panels (weight > 25 kg).

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8.8.1

Installing car walls, single entrance car 1. Car with steel roof: Insert a bolt at each side wall panel at the centre hole of the top edge (not at the top beam area). Rear wall panel fixings will be inserted from inside the car after car roof is in place. 1. Car with plywood roof: Insert a bolt at each side wall panel at the centre hole of the top edge (not at the top beam area). 2. Install and align the balustrade brackets. Note the fixing holes: A = use lower fixing holes if car roof is 30 mm thick B = use upper fixing holes if car roof is 16 mm thick 3. Lift wall panel D1 to position. Secure it temporarily with a G-clamp and a timber piece. 4. Install the remaining wall panels in following order: D2, C2, C1, B1, B2. 5. Install the rear wall panel stiffener (if applicable).

C2

C1

D2

B1

D1

B2

1 2

A

B A B A

3 3

5

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8.8.2

Installing car walls, through type car 1. Insert a bolt at each side wall panel at the centre hole of the top edge (not at the top beam area). 2. Install and align the balustrade brackets. Note the fixing holes: A = use lower fixing holes if car roof is 30 mm thick B = use upper fixing holes if car roof is 16 mm thick 3. Lift wall panel D1 to position. Secure it temporarily with a G-clamp and a timber piece. 4. Lift and install the wall panel D2. 5. Install the B wall panels the same way. 6. Place the counterweight guide rail positioning tool over the bolts on top of the wall panels to maintain walls in upright position. Remove the G-clamps and timber pieces.

3 1

6

C D2

B1

D1

B2

3

B A B A

4 5

2

A

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8.8.3

Installing car walls, glass rear wall

NOTE: Glass rear wall is not suitable to be installed by Single Man Working methods. NOTE: Installation order of the wall panels is C, D, B. NOTE: If side wall panel weight is > 25 kg, use hoist for installation. 1. Open the car package completely to expose the glass wall edges. 2. Install side spine parts. NOTE: Do not insert the M8 Allen bolts on wheels side yet. 3. Raise the wheels side of the wall panel. Install the transportation tools / wheels.  The adapter brackets and fixing bolts are delivered with the walls. 4. Drill holes to two timber pieces (from the car package, under platform). Fix them as diagonal supports with M6 bolts. 5. Turn the wall panel to upright position and transport it close to the elevator shaft.

M8 M6

2

2

4

4

3


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6. Hoist the top end of the wall panel slightly up. Place wooden blocks under the wall panel. Remove the top end transportation wheels. 7. Hoist the wall panel slightly up. Remove the bottom end transportation wheels.

M8

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8. Hoist the wall panel to final position and fix it to the car platform. Do not remove the hoist suspension until the wall panel is secured with a long timber piece (from sling crate). 9. Install the D2 and D1 wall panels. 10.Remove the temporary diagonal support. Install the B1 and B2 wall panels.

C D2

B1

D1

B2 A

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8.8.4

Installing car wall with full height, flush mounted COP back box

NOTE: If DD > 1800 mm, there are 3 wall panels on the side walls (B1, BX, B2). 1. Install the COP back box brackets to the B1 (or BX if applicable) and B2 wall panels with self drilling screws. The brackets are delivered with the COP. 2. Lift the wall panel B1 to position. Secure temporarily with a G-clamp and a timber piece. 3. Install the back box to the wall panel. Fix it to the brackets with self drilling screws from inside the car. Remove the G-clamp. 4. Lift the wall panel B2 to position. Fix the back box to the brackets with self drilling screws. 5. Check the back box dimensions at top and bottom. If the gap is too tight for the COP, push the wall panels apart from each other to widen the gap. 6. Fix the back box to the platform with one self drilling screw. 7. After car roof installation: Install the upper car wall stiffener between the wall panels B1 and BX. Install the lower one from the pit when access under the car is available.

C1

C2 D2

B1

D1

COP B2 A

2 2

4

3 3

1 1

7

6


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8.8.5

Installing car walls, horizontal wall panels

NOTE: To identify wall panels, check a label on the rear side of panels. The label identifies the individual panels (for example C1) and their proper orientation (arrow points upward).  NOTE: Check that the platform rear groove is level with the side groove. If the deviation is noticeable with your finger (1 mm or more) shim with steel band from the package material etc.   NOTE: Remove protective film from visual lists. Peel back protective film from wall panel edges by a few centimeters to identify pattern and to aid in later removal.  NOTE: If wall pattern is the triangle pattern, it must be aligned from panel to panel.

1. Install the corner profiles. At the rear side of the car, slightly loosen one of the platform bolts to insert the pole. The other bolt is found in the blister. 2. Install the stiffener for the rear wall if car width 1200 mm). 3. Install the wall panels, starting from the rear wall. For more information on walls with COP back box, see following sections. • Install the rubber profile on the edge of the platform groove (to keep wall panel tight in the groove). • In correct installation sequence (see illustration), identify the next panel. Install an aluminium profile in its top groove. Insert two bolts into the profile (four in rear wall if car width 1200 mm). Place the panel in the car. • Fix the bolts in the profile to the corner poles (and stiffener if applicable). • Check the corner profile alignment (in rear wall use the gauge tool provided. The gap between wall panel and corner pole is 10 mm for the first three panels, 13 mm for the top panel). • At end of the rear wall installation, install visual lists for the rear corners. Visual list nuts are tightened in sequence with side wall installation. 4. Slide the car roof fixing bolts into the wall top profiles. For number and location of bolts, see roof panels. Install the wall top profiles and the balustrade brackets. Note the fixing holes: A = use lower fixing holes if car roof is 30 mm thick B = use upper fixing holes if car roof is 16 mm thick


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C D

B

D4

C4

D3

C3

B4 B3

D2.2 C2

A

B2.1 D1

C1 B1

1

2 1

1

13

3

10

1 A

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4

4 B A B A

3 3

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Installing COP back box, non full height 1. Fix back box to wall panel surface using self drilling screws. 2. Fix back box to aluminium profiles using self drilling screws. Installing COP back box, full height 1. Install the wall panels next to the rear wall as described in previous section. 2. Fix COP back box and COP visual list to aluminium profiles using self drilling screws. Position lower end of COP visual list to car floor height 3. Install the first panel of the remaining wall section. Insert an extra bolt for the COP stiffener into the aluminium profile. 4. Install the COP stiffener into the platform groove and position it in contact with the COP back box side surface. Fix the stiffener to aluminium profile. 5. Install the rest of the wall panels. 6. Fix back box and COP visual list to aluminium profiles using self drilling screws. Position lower end of COP visual list to car floor height. 7. Fix the COP back box to the platform with one self drilling screw.

2 6

1

2 6

2 6

3

4 7


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Car with glass rear wall 1. Install the glass rear wall the same way as for the car with the vertical panels. See 8.8.3 Installing car walls, glass rear wall. 2. Install the visual list. 3. Install the side wall panels the normal way.

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8.9

Installing top beam 1. Remove the blocking device temporarily if pre-assembled. 2. Install the top beam. The machine side of the beam is marked. NOTE: If plywood roof, check that the hinge* locating holes are at the rear (C) side. Failure to comply will prevent correct closing and locking of the ceiling! NOTE: If plywood roof, the hinges* are delivered in a separate blister. 3. Check that the top beam flange is flush with the top edge of the wall panels.

* 2 2 1

3

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8.10

Installing car top balustrade and car roof

WARNING: If plywood roof, do not enter the car roof until the front stiffener is installed.

1076989.wmf

CAUTION: Use only short screws delivered with the car to install components on the plywood. 1. Prepare the balustrades for the installation. If telescopic handrail and mid-rail are not factory preset, set lengths: Rear = BB - 120, Sides = DD - 40.

BB

DD

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2. Protect the wall panels from scratching with cardboard. 3. Install the rear side car top balustrade (height = 1100 mm during the installation). NOTE: In case of through type car, install the rear uprights of the balustrade.

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4. Hoist the rear roof panel onto place working on the work stool at front side of the car. Shorten the manual chain hoist to tilt the panel to correct angle when lowering it down. Remove the chain at the rear edge of the roof panel later. Use a second chain for the front roof section. Plywood roof: Check that the roof panel is installed the right way up. The top beam fixing nuts belong to the bottom side of the panel. 5. Hoist the man riding hoist rope reeler to the roof. 6. Install the side balustrades.

1. 2.

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7. Fit the front roof panel onto place. Use cardboard to protect the front edge of the roof panel against chain touching. 8. Fix the car roof panels, front stiffener, kick plates and car top balustrade supports loosely. 9. Check the wall panel top edge alignment with the roof panel edge. Adjust if needed. 10. Check the wall panel alignment visually from the landing. 11. Finally tighten all the bolts. 12. Install the additional uprights (if any) to the side balustrades.

12

9

x4


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8.11

Tensioning overspeed governor rope

*

1. Lift the overspeed governor tension weight up using a rope clamp and a lift rope. Secure to the balustrade. 2. Remove slack from the rope. Tight the iron grip to secure the rope.  Maximum distance* from the car roof to the topmost rope grip is 700 mm. 3. Secure the rope coil to the balustrade. Leave slack to enable the safety gear operation.

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9

ATTACHING HOIST TO CAR

Quality Requirements: Swivel balustrade – installed at front of car (and rear if TTC) Man riding hoist – inspected and certified (inspection period validity to meet local code) – ONLY TRAINED PERSONS TO USE THE HOIST! Automatic safety gear trigger – installed, adjusted and tested together with the car safety gear to ensure correct operation TAKE 2 – full compliance with all aspects of TAKE 2

1077209.wmf


5S


Method tools needed: Man riding hoist + ASGT + accessories, swivel balustrade Hand tools needed: Spanner (10, 13, 18, 19 mm), 2 x spanner (24 mm) 5S Installation Progress Report N/A QD-181.211 N/A


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9.1

Installing swivel balustrade If through type car, two swivel balustrades are required. The swivel balustrade: – is used on the car roof during the elevator installation. – is installed to the car top balustrade immediately after installing the car top balustrade. – provides a physical barrier to protect the fitter from falling from the front side or rear side (C doors) of the car while working on the car top with the swivel balustrade closed, before the landing doors are installed. – removes the need for using personal protective equipment such as fall restraint or fall arrest systems on the car roof. – prevents unauthorized persons to access the car roof during the installation. – is removed from the balustrade after the elevator installation is completed. – is installed at the 1100mm height and 550mm height. – is an installation tool. Access and egress to and from the car top must be done with the car top level with the landing. The swivel balustrade must be aligned with the landing entrance protection opening. No unprotected gap is permitted at the side of the car when the entrance protection is opened. If the gap between the landing and car top platform is greater than 300 mm (or less if required by local legislation) then additional fall preventive measures must be used. When moving the car, the swivel balustrade must be locked in horizontal position. Balustrade locks in closed position with a catch. The swivel balustrade is designed to complement the existing car roof balustrade.


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1

2

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* *) Turn the square tube so that the handle screw will remain under the pole to avoid interference with the top most balustrade.


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9.2

Attaching hoist and automatic safety gear trigger

WARNING: The ASGT rope must be tight. Check that the safety gear arm has not moved. No slack is permitted. 1. Attach the man riding hoist on the opposite side of the machine. The securing ring of the hoist axle bar must be on the car top connection side. NOTE: If BB < 900 mm, installation hoist adapter plates* to sling corner modules are delivered. For more information, see AM-01.01.256. 2. Position the hoist rope tension weight to the CWT screen edge when car is on the buffer. 3. Drive the car upwards to fully compress the ASGT gas springs. 4. Fit the rope between the ASGT and safety gear arm. Adjust the rope tension. 5. Whenever the hoist rope is slack, secure the hoist to prevent it falling.

*

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9.3

Testing ASGT

WARNING:  It is essential that the rust protection is removed from the rails. Otherwise, the safety gear will not operate correctly. Test the operation of the automatic safety gear trigger and safety gear each day before commencing work from the car top. 1. Drive the car approximately 500 mm above the buffer. Open the latch release to engage the safety gear. The safety gear must engage. 2. Drive the car downwards to ensure that the safety gear has engaged fully. Drive the car downwards until the man riding hoist rope is slack. 3. Press the upper part of the ASGT down. 4. Ensure that the latch release has engaged to the pin. The automatic safety gear trigger must be latched. 5. Drive the car upwards. 6. Check the safety gear marks on the guide rails. The marks should be at the same height and of the same depth and length. 7. If the marks are not equal the safety gear must be adjusted.

4

1

2 3

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9.4

Using ASGT 1. Open the latch release to engage the safety gear. The safety gear must engage. 2. Drive the car downwards to ensure that the safety gear has engaged. Drive the car downwards until the man riding hoist rope is slack. 3. Press the upper part of the ASGT down. 4. Ensure that the latch release has engaged to the pin. The automatic safety gear trigger must be latched. 5. Secure the car with the parking chain. 6. Detach the hoist hook from the safety gear trigger. 7. Perform the required operation. 8. Re-attach the hoist hook to the safety gear trigger.

4

2 3 1

5 6 8

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10

CAR INTERIOR INSTALLATION

Quality Requirements: HANDLE MATERIALS CAREFULLY TO AVOID DAMAGE! Car ceiling (plywood version) – installed ensuring all panels are aligned – all panel gaps even – no rattling noise during knock & feel test – all protective plastic paper removed from joints etc. – ensure lighting cables etc. are routed to avoid visibility and damage – inspect for any sharp edges Car accessories (hand rail, skirting, mirror...) – installed to correct location – no rattling noise during knock & feel test – all protective plastic paper removed from joints etc. – inspect for any sharp edges and de-burr if necessary NOTE: See also AM-01.01.257, Visual inspection - quality control of the car interior and landings.

1077273.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed interior components causes: – misalignment which affects visual appearance and causes noise / vibration

5S


Method tools needed: N/A Hand tools needed: Allen keys, spanner (10, 13 mm), Phillips screwdriver,  ratchet + socket (13 mm), knife, battery drill / driver, vacuum handles, rivet pliers 5S Installation Progress Report Lift Car Built QD-181.211 QD 4 completed


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10.1

Installing ceiling

10.1.1

Unpacking – – – –

10.1.2

Handle parts with care, avoid scratching the parts! Be sure not to lose any parts! After unpacking store parts indoors, if possible! Remove stainless steel protection tapes (before installation) on the areas where they might disturb installation or will be visible after installation!

Installing ceiling side panels 1. Install the end plates to the underside of the car sling top beam. 2. If no fan: Install the grill covers to the top side of the top beam using self drilling screws.

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3. Fix the ceiling side bars to the roof. For panel alternatives see APPENDIX G.

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4. Install the gap closing trims to the wall panels. Check that they do not affect the lock operation. 5. Fix the ceiling locks and ceiling hinge brackets to the roof panels (if not pre-fixed at the factory). Ensure that the fixing bolts are in the end of the slotted holes.

NOTE: Check that the distance between the ceiling hinge brackets match the distance between the hinges in the ceiling. Ensure the lock levers are towards the side walls.

4

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10.1.3

Installing ceiling to steel roof

NOTE: Do not install the ceiling for the steel roof at this phase. To prevent interference the ceiling will be installed after car front wall installation.

10.1.4

Installing ceiling to plywood roof

NOTE: Note that the pictures are viewed from inside the car. 1. Loosen the pre-assembled hinge part screws slightly and slide the ceiling in position. Tighten the hinge part screws. 2. Hang the ceiling plate from the hinges. Tighten the hinges. Bend the safety clips in the ceiling panel by hand.

N

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3. Fix the end parts using screws and pins. 4. Fix the fluorescent tube lighting assembly. 5. Route and connect the lighting cable. – Ensure that the cable cannot be seen from inside the car after closing the ceiling. – Ensure that the power is OFF. Do not connect or disconnect any connectors when the power is ON. 6. Turn the ceiling in position and secure with screw (inside ceiling).

P

Q

R

S

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10.2

Mirrors and handrails

10.2.1

Transporting mirror

NOTE: Mirror package MUST be opened inside the car to reduce handling risk.  NOTE: Check that the car and landing are level. Use ramps as a bridge for the site trolley. 1. 2. 3. 4.

Transport the mirror package to the car using the site trolley. Place the package so that the marker arrows are pointing to top and front. Lean the package against the side wall. Open the package. Full width, partial height mirror: Protect the side walls with cardboard before lifting the mirror to position.

4

3

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10.2.2

Installing mirror

NOTE: Six fixings when mirror height is over 1500 mm, otherwise four. NOTE: NEVER remove the tape film before the mirror is on the car wall. 1. Remove the car wall protective film from the mirror area. 2. Fix the conical fixing pieces (if not pre-assembled) to car wall pre-drilled holes with rivets.

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3. Use vacuum handles to lift the mirror on to the fixing pieces.

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4. Remove the adhesive tapes and push the mirror to the wall.

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10.2.3

Installing handrail 1. Assemble the handrail if necessary. Check the handedness from the fixing points at the car wall panels. The securing screws must be at the bottom side of the handrail. 2. Remove the car wall protective film from the handrail leg area. 3. Screw the handrail fixing screws in position and tighten them. 4. Place the handrail onto the screws. Secure the handrail with retaining screws. Use a 3 mm allen key. 5. If handrail with the floor support legs: – Fix the legs to the handrail loosely – Push the handrail against fixing screws and secure with retaining screws – Adjust legs against the car floor and secure with retaining screws. Fix to the floor with screws provided.

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10.3

Skirting

1. Fix the fixing clips using self tapping screws or blind rivet (50 mm above finished floor line, minimum 4 pieces per wall). 2. Place the skirting in position. 3. Ensure that the side skirting profiles are against the front walls.

50

4. Fix the corner pieces.

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10.4

Installing seat 1. Fix the seat to the holes in the car wall using bolts. 2. Fix the seat surface with tape provided.

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10.5

Installing buffer rail 1. Screw or rivet the fixing pieces to the wall. 2. Hang the profile from the fixing pieces. Check the alignment. 3. Secure the profile to the wall using screws (minimum 2 pcs). 4. Push the buffer insert in its position.

3 1

=

=

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10.6

Installing tenant directory 1. Fix the tenant directory to the holes in the car wall using screws.

5

=

=

5

=

==

5

=

=

1500

=

5

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11

INSTALLING REST OF GUIDE RAILS AND BRACKETS

Quality Requirements: Laser tools – position checked for accuracy Guide rail brackets – level in all planes – install ‘isolated’ car guide rail clips to 2 topmost guide rail brackets Guide rails – adjusted to correct accuracy – vertically aligned, parallel to each other, maximum DBG deviation of -0 mm, +1 mm Car shoe adjustment – ensure car shoe DBG gap is 1mm each shoe NOTE: Topmost CWT guide rail on combination side is not installed during this phase. NOTE: Drive and SEP brackets must be installed during the guide rail bracket installation. 1076760.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed guide rails causes: – ride comfort issues (noise / vibration) – drive faults / failures – levelling accuracy problems – premature shoe liner wear (car / counterweight) Incorrectly adjusted guide shoes causes: – ride comfort issues (noise / vibration)

5S


Method tools needed: Man riding hoist + ASGT + accessories, Hilti RA laser kit, guide rail alignment and DBG tools, guide rail lifting pockets + securing chains, guide rail lifting clamp Hand tools needed: Tape measure, pencil, hammer drill, hammer, spanner (15, 17, 18, 19 mm), ratchet + sockets (18, 19 mm), spirit level, small crowbar or podger spanner 5S Installation Progress Report Guide Rails Installed (Through to 100%) QD-181.211 QD 5 completed


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11.1

Preparing for guide rail installation

NOTE: Lifting pockets are not needed if the travel is 12 m or less. 1. Install the lifting pockets.  If small car (no access behind the platform front edge), use M8 bolts and self drilling screws. Protect the car floor surface with a timber piece. 2. Install the securing chains. Select the fixing method according the roof type and car size.

M6x30

M8

1078645.wmf

3. Position the lasers to correct position using the target plates. The target plate must be positioned to the same height as the thin metal fillers.

1077356.wmf


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11.2

Installing third ring of guide rail brackets Drilling dimensions

B

A

B

X

A 1079274.wmf

A, see section 7.3 Guide rail brackets. B, measure from lower guide rail bracket. X, see table below. CWT guide rail HT60 T70

X (mm) CWT bracket (DBG + 152) - A / 2 - 20 (DBG + 182) - A / 2 - 20

X (mm) CWT bracket with extension (DBG + 152) - A / 2 - 80 (DBG + 182) - A / 2 - 80

NOTE: Use oil collector to protect the car guide shoe from dust when drilling.

1080191.wmf


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1. Install the third ring of the guide rail brackets. 2. Align the guide rails. 3. Adjust the gap between car guide rails and car guide shoes to 1 mm. Shim as necessary. CAUTION: Do not remove guide shoe until securing the upright to the guide rail bracket.

1

1

1

1mm

1mm

3

2 3

1076762.wmf


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4. Move the laser plumbing tools up to the third bracket height. Use plumbing supports. *If limited space between shaft wall and COP back box, use outer aligning point at the target tool. NOTE: If shaft height is < 10 m, leave the lasers in the pit. Move laser tools up to shorter distance if laser accuracy is affected.

*

1078649.wmf


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11.3

Preparing oil buffers

WARNING: Do not stand or lean above buffers when releasing from locked state. 1. Position the car to have safe access to the pit. Engage the safety gear. 2. Release lock down screw and allow the buffer to rise to fully open state. Buffer will rise approximately 150 mm in first 2 seconds and a further 50 mm in approximately 10 minutes. NOTE: Opening the oil filling screw on top of the buffer speeds up the operation.

1082726.wmf

3. Check the oil level of the buffers by loosening the lower oil level plug. If the oil spills out, the oil level is OK. Add more oil if necessary.

11.3.1

Filling oil to buffer 1. 2. 3. 4.

Open the sealing screw on top of the buffer using the tool attached to the buffer. Loosen the upper oil level plug. Pour oil to the buffer until oil starts to spill out from the oil level plug. Tighten the plug. Wait 10 minutes. Check the oil level by loosening the lower oil level plug. If the oil spills out, the oil level is OK. 5. Repeat as many times as necessary.

1082511.wmf


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11.4

Finalizing car installation 1. Fix the floor to the bottom beam. Remove the buffer extensions one at a time to access the fixing bolts. NOTE: Safety space MUST be maintained at ALL times! 2. Adjust the gap between car guide rails and car guide shoes to 1 mm. Remove the shims as necessary. 3. Tighten all the lowest wall fixing bolts.

1mm

1mm

2

3 1

1077617.wmf

2

4. Check the roller guide (if applicable) alignment and that the plastic glider firmly touches the guide rail. *) No gap. **) Shim as necessary

*

**


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**

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5. If parallel sling: Fix the pulley beam to the car floor.

1082772.wmf


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11.5

Installing guide rails

  CAUTION: If the car is not on the pit buffers, it must be secured on the safety gear and the parking chain whenever the hoist hook is removed. Keep the chain tightened. 1078317.wmf

NOTE: Due to difficult drilling angle, it is recommended to first install only the car guide rails, then the CWT rails. This offers clear drilling capability

NOTE: If KDL16S drive: Fix the C-profiles to the drive fixing brackets according to the DD dimension (car depth). Install fixings (travelling cable hanger etc) to brackets before installing. Install the drive and SEP panel fixing brackets at the same time as the guide rail brackets (below the machine location).

2500

DD 1200-2100 1100-1199 1000-1099 900-999

1082449.wmf


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1. Install and align the remaining car guide rails: • Drill fixing holes also for counterweight guide rail brackets when driving up. • Transport the guide rails in lifting pockets. Use sliding clamp and hoist for lifting. • Use angle irons of the counterweight guide rail brackets to ease car guide rail guiding. • Do not rest the car on safety gear during the alignment. • Move the laser plumbing tools upwards in maximum 10 m intervals. • Two topmost combination and CWT single brackets have isolated clips. • Topmost fish plate (if Z-type) on machine side car guide rail must be installed the right way to enable guide rail pivoting when installing the machine. 2. Install and align the remaining counterweight guide rails. Temporarily remove the short one (next to the machine). It will be reinstalled after the machine installation.

*

*

*

1076844.wmf

*) Note the use of the isolated guide rail clips: – topmost combination bracket = isolated car clips – second topmost combination bracket = isolated car and CWT clips – topmost and second topmost CWT brackets = isolated CWT clips


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12

MECHANICAL INSTALLATION IN TOP OF ELEVATOR SHAFT

Quality Requirements: Car overspeed governor – moved to final position – plumb and aligned – ensure correct tripping direction – ensure rope is still fitted to the small pulley Counterweight overspeed governor (if any) – installed and roped Car sill – position / accuracy checked – level in all planes Machine – lifting hook in shaft tested – no metal to metal contact between machine and bedplate / guide rail – bedplate securing plate corners are bent to secure to fixing bolts Rope hitches – installed correctly to ensure rope alignment to pulleys – all lock nuts must be tightened Parking plate – installed in alignment with the blocking device Guide rail joints – joints checked for correct alignment – joints dressed / filed with a surform file (do NOT use a grinder!)

1077306.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed OSG (car / CWT) causes: – contact between rope and guard leading to noise / vibration and premature rope wear Incorrectly installed / adjusted car sill causes: – misalignment with door operator railing, car front walls – door running problems (noise / vibration and premature shoe wear) Incorrectly installed machine causes: – noise / vibration if metal to metal contact exists by machine touching bed plate / guide rail – noise / vibration if contact exists by machine touching shaft wall Incorrectly installed rope hitches causes: – misalignment of ropes to pulleys Incorrectly adjusted / dressed guide rail joints causes: – poor ride comfort – noise / vibration – premature shoe liner wear (car / counterweight)


5S


Method tools needed: Man riding hoist + ASGT + accessories, Hilti RA laser kit, guide rail alignment and DBG tools, manual chain hoist, pulling rope, hoist test plate, machine transport wheel + axle sets, site trolley, telescopic ramps, 2 x shackle (12 mm) Hand tools needed: Tape measure, pencil, hammer drill, hammer, spanner (10, 15, 17, 18, 19 mm), ratchet + sockets (18, 19, 24 mm), spirit level, small crowbar or podger spanner, battery drill / driver, 2 x G-clamp, pliers 5S Installation Progress Report Lift Machine Installed QD-181.211 N/A

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12.1

Installing overspeed governor to final position 1. Engage the safety gear by activating the ASGT. 2. Transfer the overspeed governor to final position. *) Use cable tie at balustrade height to position the tension weight back to correct height. 3. Check the overspeed governor rope tension. Adjust as necessary.

*

*

1078615.wmf


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12.2

Installing counterweight overspeed governor and tension weight 1. Install the counterweight overspeed governor. For correct position, see layout drawings. 2. Install the tension weight. A = right handed elevator B = left handed elevator 3. Attach the rope to the safety gear lever.

A B

1079675.wmf


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12.3

Removing the extension rope 1. Drive the car to the pit. Engage the safety gear by activating the ASGT. 2. Remove the extension rope. Use a timber block to keep the tension weight in position. 3. Temporarily remove the fixing from the safety gear linkage and rotate down to suitable working height to attach the overspeed governor rope to the anchorage. 4. Rotate up and reinsert fixing. 5. Check that: • the overspeed governor rope is tensioned • the overspeed governor arm is horizontally level • the minimum distance between the tension weight and the pit floor is 120 mm.

3

2

4


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12.4

Car sill 1. Place the car front wall panels temporarily into position. 2. Install the sill base brackets, X = 115...315 mm. A = side opening, B = centre opening *) Third bracket in the middle if LL > 950 mm. 3. Install and align the sill steel profile (not aluminium profile yet). Centre opening door: centrally. Side opening door: the sill profile overlaps LL 45 mm on the slam post side.

32

X

X

*

M8

A

B

M8 1078910.wmf

12.5

Installing machine

WARNING: The brakes do not need to be adjusted. Do not attempt to adjust the brakes. They will get damaged.

NOTE: Do NOT install the manual brake release cable before roping. Machine brakes are opened for roping using temporary bolts at the brake release levers.


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12.5.1

Transporting

WARNING: The safe working load of the hoist depends on the size, the configuration and the angles formed by the hoist rope and the horizontal.  When the car is positioned near the suspension point the hoist rope angle becomes less than 45 degrees, the hoist ropes become over tightened and the safe working load is reduced (the smaller the angle from horizontal, the greater the stress on the hoist ropes).  Ensure that the hoist rope angles are greater than 45 degrees. Angles approaching 30 degrees are considered extremely hazardous and must be avoided.

45° 1069611.wmf

NOTE: The 150 kg (300 kg / pair) maximum WLL (working load limit) of the telescopic ramps is based on single axle trolley usage. On specific tested method steps, where a twin axle assembly is used (such as machine transport), the load is more evenly distributed across the ramps. In such cases the WLL is increased to 380 kg / pair of ramps. Always follow the designated method description. WLL 300 kg / pair of ramps

WLL 380 kg / pair of ramps

1078918.wmf


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1. Transport the machine to the topmost floor, near the shaft. If the hoist rope angle is critical, raise the car floor level using pallets or equivalent to reach the landing. 2. Open the machine crate. Remove all the loose components from the crate.

45°

1075262.wmf


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12.5.2

Preparations for machine installation 1. Mark the topmost guide rail bracket position. Remove the guide rail bracket. 2. Fix the manual chain hoist to machine lifting eye. Test the lifting eye using a test bracket (breaking strength 600 kg, supplied locally). Write your name and test date on the test plate and store it to the tested lifting point. 3. Clean the machined surfaces of the bed plate. Fix the bed plate to the car guide rail. *) Use M12 lifting eye and manual chain hoist. 4. Measure and record the guide rail position at the second topmost guide rail bracket. Remove the isolated clips.

1

3

*

X min NMX07 640 NMX11 820

2

X

4 NMX11

X

NMX07

3

13 1075263.wmf


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5. Attach the pull rope to ease the guide rail pivoting and lifting. 6. If T89 guide rail and deep elevator shaft: route another pull rope round the lifting eye. Use shackle if necessary. 7. Loosen the topmost guide rail joint. Remove three fixing bolts. Replace one M12 fixing bolt temporarily with M10 x 50 mm bolt (from installation blister). 8. Fix short counterweight guide rail (included in delivery) to ease the re-aligning. Z-type fish plate: Turn the fish plate if installed the wrong way for machine installation. 9. Pivot the guide rail against the counterweight guide rail bracket.

T89

6

7

M10

9 M12

8 5

8


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12.5.3

Machine lifting

WARNING: Operate the hoists from landing. No one is allowed to be in the elevator shaft while lifting the machine.

NOTE: Narrow cars (BB < 900 mm): For more information, see AM-01.01.256.  Steel roof: Remove the car roof front kick plate temporarily. Secure the telescopic ramps to the car sling top beam with M8 bolts.  Plywood roof: Secure the telescopic ramps to the car sling top beam using plates for ramps and timber blocks.  Clamp G-clamps to the ends of the ramps to limit machine movement and prevent any damage to the car roof. 

1082423.wmf


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1. Drive the car to a suitable height. 2. Engage the safety gear by activating the ASGT and secure the car with parking chain. 3. While machine on the landing, attach the adjustable chain (length 600 mm) between the man riding hoist and machine lifting plate. Attach manual chain hoist hook to the machine lifting plate. 4. Move the machine crate to the car roof. 5. Use manual chain hoist for machine lifting and man riding hoist for guiding. Raise machine slightly and remove the crate. 6. Adjust the adjustable chain to its maximum length (1.5 m) to be able to release the man riding hoist hook after hoisting the machine up. 7. Hoist the machine above its final position.

3

4 6 7

2

1075265.wmf


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12.5.4

Finalising machine installation 1. 2. 3. 4.

Pull the car guide rail back to position. Re-install the guide rail joint bolts handtight. Attach the man riding hoist hook to the ASGT. Drive the car up to suitable working height. Lower the machine onto the bed plate. Check the isolation pad alignment. Check that there is no mechanical contact with machine body and fixings. NOTE: There must be a gap (minimum 2 mm) between the bedplate and machine body after the roping. 5. Fix the machine to the guide rail. 6. Install the topmost bracket. Align and tighten the guide rail joint. 7. Install the last counterweight guide rail. NOTE: If HT type guide rail, loosen the guide rail clips below the joint temporarily.

5 1 6

7

4

6 1075266.wmf


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12.6

Installing rope hitches 1. Check that the rope bottle threads are fitted with equal length. Lock the nuts by tightening them against each other. Check that the lock nut is not leaning against the split pin. 2. Install the rope hitches. Store the rope bottle wedges on the car roof. NOTE: If car DD < 985, the car side rope hitch must be installed closer to the guide rail line. Select the correct fixing holes according to the car guide rail size.

DD < 985, T70

DD < 985, T82

1077672.wmf


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12.7

Parking plate

It is absolutely forbidden to secure the car on the blocking device of the car unless it is roped and minimum half load has been installed in the counterweight. 1. Install the parking plate. 2. Secure the parking pin with a cable tie so that it cannot engage to the parking plate accidentally.

1077705.wmf


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12.8

Filing and checking the guide rail joints

WARNING: Take care that hands do not impact Z-type fish plates when filing joints. 1. Check all the fish plate joints using a 1.5 m long spirit level. Shim using pieces of metal strap from packing as necessary. 2. Dress the joints using a surform file. Use oil collectors to protect guide shoes from dust. 3. When installation is completed, dress safety gear marks on the guide rail blades (if any).

1080204.wmf


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13

LANDING DOOR INSTALLATION

Quality Requirements: HANDLE MATERIALS CAREFULLY TO AVOID DAMAGE! FFL mark – exists at all floors (by builder) – transferred into the elevator shaft for future reference Landing doors – installed and aligned at all landings • reference to FFL mark • sill level in both planes • running clearance with car sill checked • railing plumb and aligned • lock contact gap adjusted • lock roller distance from coupler checked • correct gaps around doors (max 6 mm) • if glass doors, finger protection must be installed – no rattling noise during knock & feel test – all protective plastic paper removed from joints etc. – inspect for any sharp edges and de-burr if necessary Closing weight / spring – closes doors from any point of door travel Landing toe guards – installed at each landing – fixed securely in vertical plane (to prevent obstruction to landing door rollers) NOTE: See also AM-01.01.257, Visual inspection - quality control of the car interior and landings.

!!! CAUTION - issues that affect reliability !!! Landing door NOT installed to FFL mark causes: – dissatisfaction of the builder! – potential rework door running problems (noise / vibration) premature shoe wear misalignment with car sill (running clearance) misalignment with car coupler (lock rollers must drop when the car coupler is fully open) – premature roller wear – lock contact failure (crash stopping of elevator) – poor visual appearance Incorrectly adjusted locks causes: – intermittent faults Incorrectly adjusted door gaps causes: – potential damage to door panel surfaces Incorrectly removed plastic paper causes: – noise during door travel – damage to door panel surface (scratching)


SORT STABILIZE SHINE STANDARDIZE SUSTAIN Method tools needed: Man riding hoist 

5S

Incorrectly adjusted sills / railings causes: – – – –

1076676.wmf

Hand tools needed: Tape measure, pencil, hammer drill, hammer, spanner (13, 15, 19 mm), ratchet + sockets (13, 15, 19 mm), square, spirit level, allen keys, Phillips screwdriver, battery drill / driver, 2 x door setting jig tool 5S Installation Progress Report Doors and Frames Installed (Through to 75%) QD-181.211 QD 6 commenced

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13.1

Installation order

NOTE: These instructions are for KES 201 doors.

Start the installation from the topmost floor. Install the last landing doors and car doors in following order: 1. lowest landing door 2. car front wall and car door 3. second lowest landing door

NOTE: The topmost (or second topmost) landing doors have MAP cable entry openings(*).

A

B

For more information on positioning the doors, see technical specification section of the side binder.

* NOTE: It is strongly recommended to transport the door components directly from A = front type door the crate to the shaft. B = frame type door


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13.2

Installing landing sill Sill bracket types L brackets 0...120  80

H=170

FFL

X= 50...75 X= 25...70

X

Box brackets (200 mm)

0...40

FFL

X= 120...170

X

1010145.wmf

80

H=250

*

120...170

FFL

X= 70...120 X= 120...170


X

 80

H=200

X= 120...170

X= 70...120

 80 40...120

H=120

FFL

X= 70...120

Box brackets (250 mm)  *) additional stiffening plates

1010144.wmf

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x

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13.2.1

Installing landing sill brackets 1. Cross measure the car door opening. 2. Mark the dimension LL to the car sill, elevator shaft wall and car roof front edge. 3. Remove the car front wall panels.

1079154.wmf

< 80

FFL

B

4. Measure, mark and drill the wall fixing holes. For dimension H, see table above. Frame 150 package 11 and front: X = LL / 2 - 75 Frame 120 package 15: X = LL / 2 - 100 5. Install and align the brackets. The middle bracket (A) is only required if LL > 900 mm. B = 47 mm (centre opening door) or 45 mm (side opening door) below FFL.

A 1076702.wmf


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13.2.2

Installing grout guard (optional) 1. Bend and install the sill grout guard. Keep resting area on the ground as short as possible. 2. Seal with tape and plastic film.

1. Nail anchor D6 2. Self drilling screw 2

2

1 1


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Installing sill profile 1. 2. 3. 4.

Check that the nylon washers (A) are fitted. Slide the sill onto the brackets. Draw a marking line to profile 22.5 mm (25 mm if Frame 120) from upright fixing profile. Align the landing sill marking with the car sill LL marking. Adjust the sill gap to 30 mm.

30

13.2.3

A

1076706.wmf

Frame 150

Frame 120

1078908.wmf


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13.3

Installing uprights and top parts

NOTE: For frameless door installation, see AM-03.12.065. Remove the protection plastic from the fixing points and corners before installation. Work from the car roof. At lowest landing, work from inside the car.

13.3.1

Installing uprights and lintel 1. Install the uprights and lintel. Check the alignment.

= = 1076710.wmf


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2. Fire rated doors: Install the sheet metal fire trim. Shape according to the shaft wall. Do not fix nail anchors yet. Note: If door with DMAP, cut off part of the fire trim for cable routing.

1076711.wmf

3. Fix the door frame to the wall. Align and check the cross-measures. Do not fully tighten.

1076714.wmf


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13.3.2

Installing lock and top track 1. Install the emergency opening device (B) and the top track stiffener (A, only if side opening door). 2. Fit two M8 mushroom bolts loosely at a distance of LL + 150 mm (Frame 150 or front) or LL + 120 (Frame 120). Hang the top track. Insert the opening lever (B) to the slot. 3. Fit rest of the M8 mushroom bolts loosely. 4. Install the screws (C) centrally to the slots. Tighten the mushroom bolts. 5. Fix the top track to the stiffener (A). 6. Check the lock release mechanism operation with emergency opening key.

B

M6

C

A

M8 B A

M8

M8

M6

1076727.wmf

B b 1033717.wmf

C

A

A a31294a3.wmf

1078266.wmf


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13.3.3

Checking door unit alignment

NOTE: Do not fit the carpet profile at this stage. 1. Check the door unit alignment. X = car sill line. 2. Tighten the wall fixings.

X 60 HH+254

= =

30

1079168.wmf

13.3.4

Installing support beam (for extended front type doors) 1. Install the support beam. 2. Check the alignment. 1

1

4

2

1007319.wmf


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13.4

Installing door panels

NOTE: Check the LL at sill level before door adjustments. Accepted tolerance is +1 mm.

13.4.1

Installing panels 1. Front type doors: Install the side extension panels. See chapter 13.6.1. 2. Fix the door panels to the hangers (from the side if smoke labyrinths*). 3. Place jigs under the door panel. Shim up the gap between the panel and the hanger.

*

5mm

1076757.wmf

4. Install the self adhesive buffers to door panel edge (centre opening door ) or to the slampost (side opening door). Note: Surface must be dry and clean. The glue will not bond at temperatures below 0° C.

Buffer1


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13.4.2

Installing finger protection list (window / glass doors)


max. 6 mm

0...1 mm

25

max. 6 mm

1. Clean the area and fit the self-gluing protection list on the side post. In side opening doors fit the self-gluing protection list also between the door panels.

0...1 mm

1079320.wmf

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13.4.3

Installing closing spring / closing weight 1. Side opening door (LL = 700 - 900 mm): • Install the closing spring fixing bracket. • Route and connect the closing rope. • Install the closing spring cover. 2. Side opening door (LL = 600, 650, 1000 or 1100 mm): • Slide the closing weight into the tube. • Route and connect the closing rope. 3. Centre opening door: • Route and connect the closing rope.

HH = 2100 a31294a8.wmf

side_weight2

HH = 2000 a31294a7.wmf

a31294e6.wmf


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13.4.4

Aligning door panels

5mm

1. Loosen M10 bolts. Adjust the door panel position and alignment. Use shims as required.

1010108.wmf

2. Adjust the door panel position. 1 = buffer.

1

3mm

3mm

1 1010112.wmf

3. Adjust the door panel position. 1 = adjusting shim. 4. Check that the anti-tip rollers are finger tight (A) against the rail profile. 5. Check the door function: door panels move smoothly and freely, door does not make any abnormal noise, closing weight closes the door from any open position.

1

5 mm 5 mm 5 mm 5 mm 1010114.wmf

1010113.wmf

A


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A

0.3 mm

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13.5

Top track settings

1. Centre opening 2. Side opening 3. Lock hook buffer 4. Door contact 5. Lock contact 6. End buffer

4 3

5

5

1

3 2

2

2

6

6 1007325.wmf

1

2 > 10

3

3

> 10

1. Centre opening measurements 2. Side opening measurements

3

2

2

1010116.wmf

Railing 1

190


110* 77**

162 (376)

10

2 3

155

1. Centre lock holder 2. Landing sill line 3. Car sill line

13

13

30

* Open ** Pressed

1

20

(NH / 2)

85

HH

Railing 1. Landing door lock and contacts. Standard. Protection class IP20.

1. Check the lock function. The lock hook must rest on the buffer in closed position. The lock gap must be 1-2 mm when the hangers are closed and lean against the end buffer. Check the contact functions. Check that the lock gap does not break the door contact function. Note: The door lock is not adjustable. 2. Check the lock roller clearance to the coupler at all landings. Nominal clearance = 13 mm, minimum clearance = 8 mm. If not correct, check that the car is plumb and aligned in back to front direction or re-align the door. Re-check clearance after door operator installation.

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13.6

Installing panels and strips (front type version only)

13.6.1

Installing side extension panel 1. Slide the side extension panel into position. 2. Fix the panel to the door frame. To fulfil EN81, fix 2 self-drilling screws at the bottom. Check that there is no visible gap on landing side. 3. Align the panel to the door frame. Drill and fix the support brackets in the shaft. 4. Install the panel extension on the flooring with the nail anchors.

2

1

1. No gap 2. Front panel 3. Upright 4. Self drilling screws

2 4

3

1 2

3 1010120.wmf

1060880.wmf


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13.6.2

Installing top extension panel 1. 2. 3. 4.

Install the joining strip to the lintel with self drilling screws. Lift in the top extension panel from the landing side. Fix the panel to the joining strip and side extension panels. Fix the panel to the shaft wall using support brackets. Check that the panel is plumb.

3

1

4

2

4

3

1010121.wmf

1. Joining strip 2. Top extension panel 3. Lintel 4. Side extension panel


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13.6.3

Installing backing strips

75

75

75

1

2

100

100

150 75

100

75

100

1. Check that the wall surface is smooth and clean. If the wall is not smooth, overbend the cover strip slightly to ensure a firm pressure to the panels. 2. Cut the backing strips to fit. Check that the backing strip is tight against the wall. Fix to the door with self drilling screws.

3

100

75

100

4 1010126.wmf

1. Front 2. Extended front 3. Front MAP 4. Backing strip


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13.6.4

Installing cover strips (front type version only) 1. Fit the top cover strip over the backing strip. Use wooden block and hammer if necessary. Wooden block must cover the cover strip width and be minimum 300 mm long to avoid possible dents. 2. Cut the side cover strips (from lower part) to fit in the door opening. 3. Fit the side cover strips over the backing strips. If extended front type door, fit the upper side cover strip first. 4. Secure the side cover strip with the locking screws on side panel.

1

1. Top cover strip 2. Side cover strip 3. Upper side cover strip

3

2 NOTE: Top cover strip for controller cabinet. 1007335.wmf

B B A

A A

A

A-A

B-B 1007334.wmf


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13.7

Installing landing toe guards

NOTE: Do not install the landing toe guards for topmost and lowest landings yet. They will be installed after electrification. 1. Install the toe guard to the sill. Use the special screws provided.

1078267.wmf

2. If the toe guard overlaps the top track of the next landing door, cut it and secure to the door fixings. If this is not possible, manufacture new toe guard locally.

1

  1 = Shortened toe guard 2 = Self tapping screw 3 = Timber insert

2 3 1007469.wmf


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14

CAR FRONT INSTALLATION

Quality Requirements: HANDLE MATERIALS CAREFULLY TO AVOID DAMAGE! Car front – front wall panels and lintel installed – aligned and dimensions checked for accurate LL dimension – diagonal reference (equal corner to corner size: cross measurement) – height from sill to lintel checked – correct number of fixings used • lintel = minimum 1 fixing per 100 mm • front wall panels = minimum 3 fixings at top & bottom • stiffeners MUST have fixing screws installed – no rattling noise during knock & feel test – all protective plastic paper removed from joints etc. Door operator brackets – installed according to instruction Car ceiling (steel version) – installed ensuring all panels are aligned – all panel gaps even – no rattling noise during knock & feel test – all protective plastic paper removed from joints etc. – ensure lighting cables etc. are routed to avoid visibility and damage – inspect for any sharp edges

1077317.wmf


5S

Incorrectly installed car front wall causes: – poor visual appearance – noise / vibration – misalignment with car doors – misalignment with landing doors – unnecessary stress forces to car

Method tools needed: Man riding hoist 

Incorrectly installed door operator brackets causes: – misalignment of door operator with car sill which affects car door running – misalignment of running clearance between car coupler and landing lock rollers and landing sills – door running problems (noise / vibration) Incorrectly adjusted ceiling panels cause: – poor visual appearance – noise / vibration



Hand tools needed: Tape measure, 2 x spanner (10, 13 mm), ratchet + sockets (10, 13 mm), square, spirit level 5S Installation Progress Report N/A QD-181.211 QD 6 continued

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14.1

Installing car front walls

NOTE: Fix the front wall panels and lintel with bolts at equal distances (maximum distance between two bolts is 100 mm). Fit a bolt through each stiffener (if any). 1. Turn the roof front stiffener the right way up (if installed upside down). 2. Install the front wall panels.  NOTE: ensure that the panels are pulled completely down on the hooks. 3. Install the lintel and the door operator brackets. For bracket types, see next page. Adjust the lintel height (HH) according to the finished car floor level. NOTE: Move only the lintel, not car front wall panels. 4. Install the jamb mounted destination indicator (JM-DIN, if applicable). For more information, see AM-12.20.017.

3

<1 00 <1 00

HH

!

3

HH+362

2

3

2

4 1075498.wmf


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Table 1: Operator fixing brackets Side opening AMDC-2, bracket 602335

HH+362

HH+362

Centre opening AMDC-1, bracket 602334

1072048.wmf

1072047.wmf

AMDC-1 (35 mm car return), bracket 601191 (35 mm)

67

2 HH+293

1

KES600 KES800

LL - 100

1072049.wmf

AMDC-2 (35 mm car return), bracket 601166 (35 mm)

1

4 11 LL - 100 LL - 3

HH+245

2

KES600 KES800

1072050.wmf

1 = car door sill line, 2 = suspension screw


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14.2

Finalizing car front installation 1. Install the sill profile. Centre opening door: to the centre. Side opening door: 11.5 mm from the end of the steel profile on slam post side.

11.5mm

1011146.wmf

2. Install the slam post and compensative lintel. 3. Check that the car door entrance is square and in plumb. 4. Install the carpet profile.

1079289.wmf


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14.3

Installing ceiling for steel roof

WARNING: Do not install the security ropes at this phase. To prevent tripping hazard and to protect the release equipment from damage, install the security ropes after roping.

14.3.1

Installing ceiling 1. Cut and fix the plastic finger protection lists (if applicable) to the ceiling panel with screws or rivets (not to the hinge area). 2. Fix the lighting unit (if applicable ) to the ceiling using double sided tape and a rivet.

1082801.wmf

2. Hang the ceiling and secure in position immediately using M6 bolts.

1077277.wmf


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NOTE: Check that the distance between the ceiling lock brackets match the distance between the locks in the side panels.

1077729.wmf

3. Route and connect the lighting cable. – Ensure that the cable cannot be seen from inside the car after closing the ceiling. – Ensure that the power is OFF. Do not connect or disconnect any connectors when the power is ON. – In two panel ceilings, ensure that the cable does not obstruct opening the ceiling.

1080645.wmf


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4. Install the inductive loop cable if applicable. – Fix the cable with self-adhesive cable tie bases. Do NOT tighten the cable ties yet. – Adjust cable length to make both ends equal. – Route the cable through to the roof. Tighten the cable ties.

1082289.wmf

5. Install the telescopic ladder (if applicable) to the ceiling panel.

1082797.wmf


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14.3.2

Closing the ceiling

WARNING! Wear protective gloves when opening or closing the ceiling panels. Panels may have sharp edges.

1. Turn the latch of ceiling locks into lock position (towards the hinge of the ceiling panel) by hand or using a screw driver.

1074882.wmf

2. Close the ceiling by pushing it upwards until you hear click sound (the lock engages).

NOTE: Check that the ceiling is locked properly by carefully pushing up and pulling down the ceiling. 1074883.wmf


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3. Multi-panel ceilings: Check that the ceiling panels align each other perfectly. If necessary re-open the ceiling panels and adjust the ceiling hinges (and locks).

25

= (25-28)

3

= (25-28)*

?

?

25

25 1077281.wmf

*) With CL181 ceiling the dimension is approximately 40mm


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14.3.3

Opening the ceiling 1. Insert a screw driver in the gap between the wall and ceiling. Turn the latch into open position (towards front of the ceiling).

1074884.wmf

2. Push up the ceiling to release the lock.

1074885.wmf

3. Lower down the ceiling carefully. – While lowering, ensure that the loose cable on top of ceiling is not tightened (to avoid damaging the cable or ceiling). – Remove the safety wire from quick fix.

1074886.wmf


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15

INSTALLING CAR DOORS

Quality Requirements: HANDLE MATERIALS CAREFULLY TO AVOID DAMAGE! Car door operator – height from sill FFL to lintel checked – vertically aligned and plumb – level, parallel to sill Car doors – aligned to car front and to each other – correct gap around doors (max 6 mm) – no rattling noise during knock & feel test – all protective plastic paper removed from joints etc. – lock contact gap adjusted – if glass doors, finger protection must be installed Coupler – clearance between landing lock rollers and car door coupler checked (13 mm each side) Emergency opening device – rope length adjusted Electrification – routed to avoid cable damage or tripping hazards

1077323.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed car door operator causes: – misalignment of door operator with car sill which affects car door running – misalignment of running clearance between car coupler and landing lock rollers and landing sills – door running problems (noise / vibration) Incorrectly installed car doors causes: – poor visual appearance – lock contact failure (crash stopping of elevator) Incorrectly removed plastic paper causes: – noise during door travel – damage to door panel surface (scratching) Incorrectly adjusted coupler causes: – impact / damage of landing lock rollers (crash stopping of elevator) Incorrectly installed emergency opening device causes: – cable too tight = potential break of car door lock during travel – cable too slack = potential snagging of cable on landing doors during travel Incorrectly installed electrification causes: – tripping hazards during maintenance – cables under strain can cause unnecessary disconnections


5S


Method tools needed: Man riding hoist, site trolley  Hand tools needed: Allen keys, spirit level, small crowbar, tape measure, spanner (13, 15 mm), 2 x door jig, square, pliers, battery drill / driver  5S Installation Progress Report N/A QD-181.211 QD 6 continued

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NOTE: These instructions are for AMDV car doors. For AMDLY type of door, see AM-03.12.086.

15.1

Unpacking and transporting the door operator Step 1

2

Action Unpack the door operator from the packing just before transporting to the car front. Use site trolley to transport the operator. Be careful not to twist the mechanics.

Note Use proper lifting techniques and gloves to protect your hands.

1010352.wmf


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15.2

Installation of Low duty door operator

1 2

1078775.wmf

1. Car sill line 2. Suspension screw Step 1

2 3

Action Install the fixing brackets to the side posts. Ensure that the brackets are: – in plumb* – at correct height (HH+362 mm) – at correct distance (67 mm) from the car door sill line Attach the suspension screws to the brackets. Hang up the operator unit on the suspension screws, trough the key holes on the operator back side.


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Note Bracket alternatives, see section 14.1. *The car door entrance must also be in plumb.

The suspension screws should be set 5...8 mm unscrewed.

AM-01.01.250 (B) 2013-03-18


HH + 254


30

1009901.wmf

Step 4 5 6 7

Action Attach the lower fixing screws hand tightened. Control the horizontal position of the operator. Tighten all fixing screws. Control the vertical position of the railing.


181 (376)

Note Bracket alternatives, see section 14.1. Control the horizontal position of the operator. Re-adjust the fixing brackets in plumb.

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15.3

Installation of Mid and High duty door operator

1

X

2

1078782.wmf

1. Car sill line 2. Suspension screw Step 1

2 3

Action Install the fixing brackets to the side posts. Ensure that the brackets are: – in plumb* – at correct height (HH+362 mm) – at correct distance (67 mm) from the car door sill line Attach the suspension screws to the brackets. Hang up the operator unit on the suspension screws, trough the key holes on the operator back side.


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Note Bracket alternatives, see section 14.1. *The car door entrance must also be in plumb.

The suspension screws should be set 5...8 mm unscrewed.

AM-01.01.250 (B) 2013-03-18


HH + 290 *

31

HH + 190


1009903.wmf

* When panel 4 (full glass) and panel 6 Step 4 5 6 7

Action Attach the lower and the top fixing screws hand tightened. Control the horizontal position of the operator. Tighten all fixing screws. Control the vertical position of the railing.

Note Top fixing screw only when drive 2. Adjust from the adjustable fixing brackets. Use T-handed Hexagon key. Re-adjust the fixing brackets in plumb.

Do not drive the car with installed operator before the door panels are installed. Move the car with care as the vanes or the coupler not get stuck and damaged.


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15.4

Installing finger protection list (window / glass doors)

15.5

25

0...1 mm

max. 6 mm

max. 6 mm

1. Clean the area and fit the self-gluing protection list on the side post. In side opening doors fit the self-gluing protection list also between the door panels.

0...1 mm

1079320.wmf

Door panel buffers Step 1

Action

Note The glue will not bond at temperatures below 0° C.

Panel L & 1

40

40

40

Fit a self-adhesive buffer, 40 mm from the top and 40 mm from the bottom on the leading panel edge.

1009904.wmf


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15.6

Door panel fixings

1

2

3

4

100990

Step 1

Action Cover plate on window, glass and full glass panels must be removed before the fixings can be reached.


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f

Note 1. Railing 1 / panel L 2. Railing 2/ panel L 3. Railing 1 / panel 3 4. Railing 2 / panel 3 / 4 / 6

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15.7

Door panel guides

1. Panel L 2. Panel 3 / 4 / 6

1

2

1009906.wmf

Step 1 2 3

Action Note Installation of panel guides for hidden sill is described in the door panel installation. Cover plate on window, glass and full glass panels must be removed before the fixings can be reached. After final door adjustment must the full glass panel guides be secured by 2 dowels.


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15.8

Installation of door panels

15.8.1

Suspension of door panel

3.

4.

5.

5 mm 1009966.wmf

Step 1 2 3 4 5 6 15.8.2

Action

Note Close the door. Hangers in closed position. Put in the door panel under the hanger. From the side if air seal labyrinths. Fit the door panel to the hanger. Untightened screw joints. Place two jigs under the door panel for 5 mm gap. Shim up the gap between door panel and hanger. Tighten the screw joints slightly and remove the jigs.

Vertical adjustment of the door panel Step 1 2

3

Action Open the door. Hangers in open position. Adjust the door panel vertically against side post or door panel. – Adjust rear or front top fixing shim package. Adjust the end buffer in order to get door panels in line with the wall (See page 194).

Note

1009967.wmf


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Positioning of door panel

CL

CL 2...3

2...4

1...2

7.5

1009968.wmf

Centre opening Step 1

Side opening Action

Note

Close the door. Hangers in closed position must be on the buffer. The hanger plates must touch the buffer little before the door panel lists touch each other.

2

3

Slow and middle panel Push the door panel against the lintel cover plate and then back of 1...2 mm. Fast panel (centre opening) Adjust both panels against each other. Ensure the panel front edges are positioned in respect of the door centre line as shown in the figures above. Fast panel (side opening) Adjust the panel against the slam post. Ensure that rubber trim list seals the gap between door panel and car front wall. With panel 6 doors ensure that the air seal labyrinth is not touching the front wall (must be 3...5 mm gap to ensure proper closing of door panels).

1009969.wmf

3...5 3...5 1009970.wmf

Ensure that the labyrinths has a free space of 3...5 mm and not touch each other.

3...5

15.8.3

1009971.wmf

4

Tighten the upper panel screw joints, but not final.


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15.8.4

Adjustment of door panel running clearance

1-2 5 mm 5 mm

5 mm

3-4 5 mm

1009972.wmf

Step 1 2 3 4

Action Close the door. Check that the gap between panels or side post is 5 mm and even. Open the door. Check that the gap between panels or side post is 5 mm and even.

15.9

Coupler

15.9.1

Standard coupler, railing 1

Note Hangers in closed position. Adjust the panel rear top fixing and/or rear bottom guide. Hangers in open position. Adjust the panel front top fixing and/or front bottom guide.

Coupler with vane length 300 mm (NH 300) is pre-assembled in the factory. Coupler with vane length 400 mm (NH 400), the vane package has to be installed at site. For more information, see AM-03.12.067.


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15.9.2

Standard coupler with lock, railing 1 Coupler with vane length 300 mm (NH 300) is pre-assembled in the factory. Coupler with vane length 400 mm (NH 400), the vane package has to be installed at site. For more information, see AM-03.12.067.

15.9.3

Standard coupler, railing 2

1. Symmetric vane 2. Asymmetric vane

A

B 1 A

2 1009976.wmf

Step 1

Action Install the vanes to the coupler using M6X20 (DIN7984) bolts.

2

Ensure the coupler function.


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Note The cuts (A) at the vane ends must be turned outwards. The vane and the plastic part it is fixed on must be at same level (B). Do not use any other screws to fix the vanes than mentioned!

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15.9.4

Coupler with lock, railing 2

1 2 2

1

18.5 1009977.wmf

1. Countersunk screw M8X35 (DIN7991) 2. Hexagon socket screw M8X30 (DIN7984), schnorr lock washer M8 Step 1

Action Install the coupler finger tight to the hanger plate by 4 screws.


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Note The hanger plate on the drive belt side. Do not use any other screws than mentioned.

AM-01.01.250 (B) 2013-03-18


2 3

4

1009978.wmf

Step 2

4

Action Slip the synchronization rope into the rope guide at the back of the coupler. Connect the coupler to the drive belt fixing. Remove the locking screw.

5

Ensure the coupler function.

3


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Note Valid for centre opening doors only (AMDL-1/3/5).

Store the screw in the upper corner of the coupler.

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15.9.5

Door stiffener Panel 1

Panel 3 / 4 / 6

1 A

A B

A

B

B

2

1. Motor 2. Coupler vane 3. Gap

3 1

2

1009979.wmf

Step 1

2

Action Fix the stiffer between hanger plate and door panel. Ensure that the coupler vanes are hanging straight. To prevent changing in the door panel adjustments, tighten the upper screw first. Check that there is a gap between coupler vanes and motor (also transformer and electronic box).


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Note Valid only for railing 2 and standard panels.

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15.10 Railing settings 15.10.1 Anti-tip rollers Railing 1

Railing 2

1

A

A

Plastic roller

Rubber roller

2

0.15 mm

1009980.wmf

Steel roller 11 0m m

1 1009981.wmf

1. End buffer Step 1

2

3

Action Rubber/plastic roller Check that the anti-tip rollers are slightly pressed (finger tight, A) against the rail profile. Steel roller Check that there is a space of 0.15 mm between roller and rail. If needed, loosen the nut and adjust the eccentric roller using the T-handled hexagon key. Adjust the end buffer in order to get the door panels in line with the front wall (= door opening).


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Note Finger tight (A): the roller can be turned by one finger.

If LL dimension is small; the coupler vanes must be in open position and the end buffer must be loosen.

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15.10.2 Door contacts Railing 1, protection class IP20 Centre opening 3 mm

Side opening

3 mm

3 mm

1009982.wmf

Railing 2, protection class IP20 Centre opening

Side opening

1009983.wmf

Step 1

Action Make sure the function of the door contacts.


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Note Adjust the contact bridge if needed.

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15.10.3 Coupler / Lock rollers

CL

190

CL

190

84

10

20

30

110* 77

13

1 2 1009984.wmf

HH

3 4

155

Railing 1

13**

1 Landing sill line 2 Car sill line 3 Dimension when coupler is open 4 Dimension when coupler is pressed

CL = Centre line / slampost line * 108 when car door lock ** 11 when car door lock

CL

190 84

13

1

110 77

Step 1 2

2

1009985.wmf

HH

1 Landing sill line 2 Car sill line 3 Dimension when coupler is open 4 Dimension when coupler is pressed

10 ****

20

30

167***

Railing 2

13

3 4

CL

190

CL = Centre line / slampost line *** when panel 4 (full glass) and panel 6 **** 8 when hidden sill

Action Check that the coupler opens and closes properly. Pull the drive belt manually until coupler is fully open. Secure the drive belt with a cable tie.

Note

1079312.wmf

3

Check the lock roller clearance to the coupler at all landings. – Nominal clearance = 13 mm – Minimum clearance = 8 mm


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Adjust the landing door lock roller position if needed (only railing 2). (Arrows show the adjustability)

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15.11 Emergency opening for car door lock

1

2

2

1009987-1.wmf

1009986-1.wmf

Railing 1

Standard Railing 2

Step 1

Action Fix the rope guide (1) on the door panel stiffener.

2

Fix the rope fixing plate (2) to the door panel stiffener. Fix the rope end at the fixing plate with a rope clamp. Ensure the emergency opening function. Glue the label approximately in the middle of the door panel.

3 4 5


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Glass

Note Only needed if curtain of light. 2 self taping screws 4.2x13 (pre-drill 3,5 mm holes) 2 self taping screws 4.2x13 (pre-drill 3,5 mm holes)

Not glass panels.

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15.12 Electrification 15.12.1 Cable connections, drive 10

D1 D2

3

1

MIN

S1 1 2 3 4

1077696.wmf

Step 1

2

3

X1

Check that the S1 DIP switches are ON position: – speed selection is in maximum – open force limiter is in operation – curtain of light is in operation


2

MAX

3

4

SP0

OFF ON OFF ON

SP1

OFF OFF ON ON

OFL +24 V

1077707.wmf

7

Action Position the door operator in a suitable working height when standing on the landing. Check that the door power supply from the MAP is switched OFF. Connect: – door contact cable (1) to D2 and the separate earth wire to the earth screw (2). – supply cable (3) to D1. – control cable (7) to X1. – photocell cables (8) to X15 and X16. Fix the cables using cable ties.


1

ON

2

SPEED

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Note

For door contact cable, a separate earthing is required only for countries with special regulations. See project delivery documents for the wiring diagram. CAUTION: Do not connect +24 V from the door operator to the +24 V EXT supplied from elevator control. For more information on DIP switches, see chapter 29.6.

AM-01.01.250 (B) 2013-03-18


15.12.2 Cable connections, drive 2

X9 X19

2

1

X4

X5 X6

D1 D2

X2 X1

4 X15 X16 X17 X18

2

3

4

D1

X2

7

D1

D2

X1

D2

6

8

6 5 1 To the car electrification unit 5 Door contact cable Step 1 2 3 4 5

6 7 8

1009989.wmf

2 Trafo unit 6 Supply cable

3 Separate earth screws 7 Control cable

Action Ensure that the door power supply from the MAP is switched OFF! Connect the door contact cable (5) to the Molex plug D2. Connect the supply cable (6) to the Molex plug D1. Connect the control cable (7) to the Phoenix plugs X1, X2. Connect the safety device cables (if any) to the Phoenix plugs X15, X16, X17, X18. Connect the emergency drive cable (if any) to the Phoenix plug X5. Route the cables to the car electrification unit. Fix the cables using cable ties (8).


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4 Motor unit 8 Cable ties Note

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15.13 Car door lock and contact measurements 15.13.1 Car door lock and contacts for railing 1 Standard protection class IP20

>10

2

>10

3

3

3

2

1009994.wmf


Side opening

Action Check the lock function. – Ensure that the lock hook overlaps the lock beak properly in closed position. – The lock gap should be 1...2 mm when the hangers are fully closed and leans against the end buffer. – Check the contact functions.


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Note The lock is not adjustable!

Ensure that the lock gap do not brake the door contact function.

AM-01.01.250 (B) 2013-03-18


15.13.2 Car door lock and contacts for railing 2 Standard protection class IP20

>10

2

3

3

>10

3

2

1009995.wmf


Side opening

Action Check the lock function. – The lock hook must rest on the lock hook buffer in closed position. – The lock gap should be 1...2 mm when the hangers are fully closed and leans against the end buffer. – Check the contact functions.


201 (376)

Note The lock is not adjustable! Not valid when “Optional”

Ensure that the lock gap do not brake the door contact function.

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16

KONE SIGNALIZATION SYSTEM (KSS) INSTALLATION

Quality Requirements: Landing signalization – aligned to frame / wall, position according to layout drawings – cable routing clear of obstruction, provide slack for future maintenance purposes – plugs properly inserted into sockets and not under strain COP – flush and securely installed – take care not to damage the car wall when installing COP – cable routing clear of obstruction, provide slack for future maintenance purposes – plugs properly inserted into sockets and not under strain NOTE: See also AM-01.01.257, Visual inspection - quality control of the car interior and landings.

!!! CAUTION - issues that affect reliability !!! Incorrectly installed signalization causes: – poor visual appearance – plugs not inserted correctly to sockets can cause unnecessary disconnections / failures of unit – cables under strain can cause unnecessary disconnections (doors, car, travelling past guide brackets etc.) – incorrectly routed / secured cables can be damaged by moving parts – failing to provide sufficient slack for future maintenance purposes can lead to damage to the cables / unit

5S


Method tools needed: Man riding hoist, work stool Hand tools needed: Battery drill / driver, Phillips screwdriver, hammer drill, hammer, side cutters, allen keys, tape measure 5S Installation Progress Report N/A QD-181.211 N/A


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NOTE: For signalization devices not described in this chapter, see AM-12.20.005.

16.1

Hall indicator (KSH) and landing call station (KSL) Step 1 2 3 4 5

Action Note Fix the mounting bracket to wall or door frame with screws. Route and connect the cable to the unit. Slide the device to the mounting bracket. Secure using allen screw. Attach the braille tag (if applicable) to the recess at the landing call station.

1078607.wmf


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16.2

Installing COP Step 1 2 3 4

Action Route and connect COP cables. Fix the limit bracket below COP. Lift the COP in position. Secure in position using screw.

Note

*) Be careful not to scratch the wall.

*)

1078608.wmf


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16.3

Hall display (KSJ) Step 1 2 3 4 5

Action Remove the cover. Connect the cables. Insert the unit in the car wall cut out. Secure using screws. Re-fix the cover.

Note

1079083.wmf


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17

INSTALLING MAP

Quality Requirements: MAP (maintenance access panel) – wall type = aligned to wall, position according to layout drawing – frame type = aligned to frame – door operation checked – locks operation checked with key – no rattling noise during knock & feel test – all protective plastic paper removed from joints etc. – inspect for any sharp edges and de-burr if necessary – install fire protection (if needed)

1076668.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed / aligned MAP causes: – MAP door lock operation failure

5S


Method tools needed: Man riding hoist Hand tools needed: Battery drill / driver, Phillips screwdriver, hammer drill, hammer, side cutters, tape measure, spirit level, ratchet + socket (19 mm, wall MAP) 5S Installation Progress Report N/A QD-181.211 N/A


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17.1

Installing wall type MAP 1. Install the MAP (1 = surface mounted, 2 = flush mounted). 2. Route the cables to the elevator shaft. Check that the cables are clear of all moving parts of the elevator.

1

2

1007410.wmf


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17.2

Installing door type MAP

NOTE: Use gloves, protect your arms and use dustmask when handling rockwool. 1. 2. 3. 4.

Install the MAP body. Fire rated doors: Fit rockwool pieces to top and bottom consoles. Install the components inside the MAP body. Route the cables to the elevator shaft. Check that the cables are clear of all moving parts of the elevator. 5. Fire rated front type doors: Install the fire protection plates.

55

1076552.wmf


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18

IDE300 (OPTIONAL) 1. Install and connect the components for IDE300 (integration of doors and elevator) if any. For more information, see AM-13.20.018.


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19

ELECTRIFICATION AT TOP OF THE ELEVATOR SHAFT (KDL16S)

Quality Requirements: SEP, drive, THD filter, trunkings, external braking resistor (if any) – installed to correct position according to layout drawings Accessories (EBD etc.) – installed to correct position according to layout drawings Cables between shaft top components – routed and connected, free of obstruction – encoder cable routed separately (not grouped with machine cables) – plugs properly inserted into sockets – all ‘screw type’ cable terminations tightened, ensure no loose cable strands – earthings checked – cable grounding / shields to be correctly clamped – ensure no damage has occurred during installation

NOTE: Ensure that all covers are closed after installation. 1076397.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed shaft top electrification causes: – equipment (SEP, drive etc.) not installed to layout drawing position will interfere with required running clearance from ropes or car – accessories (EBD etc.) not installed to layout drawing position will interfere with required safety spaces, running clearances Incorrectly installed shaft top cabling causes: – incorrectly routed encoder cable can cause poor encoder reference feedback due to magnetic field disturbances from machine cables. This leads to poor ride comfort and drive faults – plugs not inserted correctly to sockets can cause unnecessary disconnections – earthing / shield clamps not used correctly will NOT provide the required grounding to remove signal interference – loose ‘screw type’ terminals cause unnecessary disconnections


5S


Method tools needed: Man riding hoist Hand tools needed: Tape measure, spirit level, pencil, hammer drill, hammer, side cutters, 2 x spanner (10 mm), ratchet + socket (19 mm, EBD), spanner (17, 19 mm), allen keys, spanner (7 mm), 2 x spanner (8 mm), TORX screwdriver (T10), electrical terminal screwdriver, multigrip pliers 5S Installation Progress Report Lift Controller Installed QD-181.211 QD 7 commenced

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WARNING: During electrification work the power must be off. Ensure that the power to the main supply cable cannot be turned on. Remove fuses and lock the main switches. Notice the separate lighting supplies. For more information, see AM-01.03.002.

CAUTION: When drilling above drive, SEP or MAP, protect the panels from dust.

CAUTION: If there is a danger of condensed water, on the wire or cable surface, to enter electrical components or connectors in the elevator shaft, form a loop before the cable entry or connector. This cable loop method is recommended for all installations and mandatory in wet/humid operating conditions.

CAUTION: When installing the machine cables ensure the following things: Encoder and thermistor cables must be o 90 separated from motor supply and brake control cables. Otherwise there might be disturbances >100mm in the encoder signals. These cables can cross each other at an angle 2 1 3 of 90 degrees. If these cables are routed 4 parallel, the minimum clearance between two 1082766.wmf cable groups must be 100 mm. 1 = encoder cable, 2 = brake control cable, 3 = motor cable, 4 = thermistor cable

NOTE: Leave sufficient cable length to allow the SEP and drive panels to be moved from behind the ropes to the maintenance position.

NOTE: For more information on ECB-1 Single Line Regenerative Unit, see AM-11.65.038.


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19.1

Overview (KDL16S)

12

8 9

1

2 6 3

10

4 5

11 7 1. Machine 2. Drive panel 3. THD filter 4. Maintenance access panel (MAP) 5. Shaft electrification panel (SEP) 6. Fuse box (F290:2) 7. Fuse box (F290:1)

8. Overspeed governor (OSG) contact 9. Load weighing device (LWD) at rope terminal 10. Elevator shaft lighting 11. ECB-1 single line ReGenerative unit OR External braking resistor 12. Emergency battery drive (EBD)

NOTE: In case of bigger THD filter, install the fuse box (F290:2) to the shaft wall.


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19.2

Opening drive covers

WARNING: The covers must be closed when switching the power on. 1. Removing the cover plate.

1076584.pdf

2. Opening the slide deck. Keep the slide deck closed during the drive module installation to prevent damaging the internal components.

1075530.wmf 1075532.wmf


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1075533.wmf

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19.3

Installing SEP and drive panels, brake resistor and trunkings (KDL16S)

NOTE: For exact location of the components, see delivery documents. 1. Install the drive panel to the back plate. 2. Install the drive panel, SEP and travelling cable hanger.

1079311.wmf


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3. Install the metal plate trunkings. 4. Install the 2 m piece of trunking beside the drive panel. 5. Install the emergency battery drive unit (EBD) and THD filter. *) Install the external braking resistor (optional, only if rated speed is 1.6 m/s or above). CAUTION: Ensure that there is a minimum 10 mm clearance between the EBD and the car door operator.

EBD

!

4

THD

*

5

1076579.wmf


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19.4

Connecting machine cables (KDL16S)

WARNING: Ensure that the power supply is safely locked off. For more information, see AM-01.03.002.

XMEN5 XT1 U,V,W

XBR4 XBRE2

PE

1076539.wmf

Cable Thermistor cable Machine supply cable Brake cable Encoder cable External braking resistor cable


216 (376)

To drive XT1 U, V, W, PE XBR4 XMEN5 XBRE2

AM-01.01.250 (B) 2013-03-18


19.5

Cabling: MAP - drive, SEP - drive (KDL16S)

XLG1 XBAT1 XL1 XS3

XL6

T1,T2,T3 PE T1,T2, T3,PE X4 XM14 XD1

1076370.wmf

*) THD filter Cable Supply cable Load weighing cable Cable Safety chain cable Battery backup cable LCE cable


From MAP T1, T2, T3, PE XL6

To drive T1, T2, T3, PE XLG1

From SEP

To drive

XD1 XM14 X4

217 (376)

XS3 XBAT1 XL1

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20

ELECTRIFICATION AT TOP OF THE ELEVATOR SHAFT (KDM40)

Quality Requirements: SEP, drive, KDA module, THD filter, trunkings – installed to correct position according to layout drawings Accessories (EBD etc.) – installed to correct position according to layout drawings Cables between shaft top components – routed and connected, free of obstruction – encoder cable routed separately (not grouped with machine cables) – plugs properly inserted into sockets – all ‘screw type’ cable terminations tightened, ensure no loose cable strands – earthings checked – cable grounding / shields to be correctly clamped – ensure no damage has occurred during installation

NOTE: Ensure that all covers are closed after installation. 1078933.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed shaft top electrification causes: – equipment (SEP, drive etc.) not installed to layout drawing position will interfere with required running clearance from ropes or car – accessories (EBD etc.) not installed to layout drawing position will interfere with required safety spaces, running clearances Incorrectly installed shaft top cabling causes: – incorrectly routed encoder cable can cause poor encoder reference feedback due to magnetic field disturbances from machine cables. This leads to poor ride comfort and drive faults – plugs not inserted correctly to sockets can cause unnecessary disconnections – earthing / shield clamps not used correctly will NOT provide the required grounding to remove signal interference – loose ‘screw type’ terminals cause unnecessary disconnections


5S


Method tools needed: Man riding hoist, manual chain hoist (500 kg) Hand tools needed: Tape measure, spirit level, pencil, hammer drill, hammer, side cutters, 2 x spanner (10 mm), ratchet + socket (19 mm, EBD), spanner (17, 19 mm), allen keys, spanner (7 mm), 2 x spanner (8 mm), electrical terminal screwdriver, multigrip pliers 5S Installation Progress Report Lift Controller Installed QD-181.211 QD 7 commenced

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WARNING: During electrification work the power must be off. Ensure that the power to the main supply cable cannot be turned on. Remove fuses and lock the main switches. Notice the separate lighting supplies. For more information, see AM-01.03.002.

WARNING: RISK OF ELECTRIC SHOCK If the yellow DANGER led does not illuminate, when the main power is ON, do not open the drive module. Switch OFF the main switch (220). Lock and tag. Wait for 5 minutes. Continue the work with special caution! Add a warning sign on the cover of the module. Inform your supervisor.  > 50 VDC Inverter drives usually remain energized for about 5 minutes after the power has been disconnected.   DO NOT work on the drive, or hoisting motor until you have verified that this energy has been discharged.  Test equipment must be set to the 1000 VDC range. The test equipment must be checked before and after the test to ensure that it functions correctly.

CAUTION: When drilling above drive, SEP or MAP, protect the panels from dust.

CAUTION: If there is a danger of condensed water, on the wire or cable surface, to enter electrical components or connectors in the elevator shaft, form a loop before the cable entry or connector. This cable loop method is recommended for all installations and mandatory in wet/humid operating conditions.


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CAUTION: When installing the machine cables ensure the following things: Encoder and thermistor cables must be o 90 separated from motor supply and brake control cables. Otherwise there might be disturbances >100mm in the encoder signals. These cables can cross each other at an angle 2 1 3 of 90 degrees. If these cables are routed 4 parallel, the minimum clearance between two 1082766.wmf cable groups must be 100 mm. 1 = encoder cable, 2 = brake control cable, 3 = motor cable, 4 = thermistor cable

NOTE: Leave sufficient cable length to allow the SEP and drive panels to be moved from behind the ropes to the maintenance position.


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20.1

Overview (KDM40) 1. Machine 2. Drive panel 3. KDA module 4. Shaft electrification panel, (SEP) 5. Maintenance access panel (MAP) 6. Car 7. Customer cables: – main supply cable – lighting supply (if applicable) 8. Travelling cables 9. Motor supply 10. Motor connections – brake supply – thermistors – encoder 11. Shaft bundle 12. Maintenance access panel connections 13. Elevator shaft lighting

10

1

9 13

2

12

3

5

4 7

12 6

8 11

1077237.wmf


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20.2

Installing SEP and drive panels, KDA module, brake resistor and trunkings (KDM40)

NOTE: For exact location of the components, see delivery documents. 1. Install the drive panel, KDA module and SEP panel. Wall fixing (option 1): Use drilling template when drilling fixing holes for the drive and KDA module. Check the free space for cooling above (200 mm) and on the right hand side (50 mm) of the drive module.

1

1

1

1

2

2

2

2

1077213.wmf


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Fixing with brackets (option 2): NOTE: The amount (one or two) of extension pieces depends on distance between the car and the shaft wall. Adjust the wall fixing brackets so that panels are reachable from the car roof. Check the running clearance between the car and the panels. Check the free space for cooling above (200 mm) and on the right hand side (50 mm) of the drive module.

1080284.wmf


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2. Install the metal plate trunkings. 3. Install the 2 m piece of trunking beside the drive panel. 4. Install the emergency battery drive unit. CAUTION: Ensure that there is a minimum 10 mm clearance between the EBD and the car door operator.

EBD

!

2

3

1077229.wmf


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20.3

Machine cables (KDM40)

WARNING: Ensure that the power supply is safely locked off. See AM-01.03.002.

C U V W

U V W

A

V U W

U

XMEN5

V W

U,V,W PE

B

XBR1 XBR2 XT1 1077218.wmf

Cable To drive / KDA module Thermistor cable XT1 Machine supply cable (note phases, A = right handed, B = left handed) U, V, W, PE Brake cable XBR1, XBR2 Encoder cable XMEN5 Use delivered adapter rings at machine supply cable entry (C). Do not tighten the entry nuts outside the drive panel, use tightening tool inside the drive panel. Check that all connections are clean and clamps are secure.


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20.4

Cabling: MAP - KDA module, SEP - KDA module (KDM40)

XL5 XW1 XD5 XLG1 L1,L2,L3 PE XBAT1

XL6

XD1

T1,T2, T3,PE X4 XM14 XD1

1077227.wmf

Cable Supply cable Speed information cable LWD cable Cable Safety chain cable Battery backup cable LCE cable


From MAP T1, T2, T3, PE XL6 XL5

To KDA module L1, L2, L3, PE XLG1 XW1

From SEP

To KDA module

XD1 XM14 X4

226 (376)

XD5 XBAT1 XD1

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20.5

Cabling: KDA - drive module

X4 XMEN1

X6 X7

L1,L2,L3 X8 1 X20 PE

5

2

6

4 3 1077228.wmf

Cable

From KDA module Power supply cable 1 201/1,3,5,PE Signal cable 2 KDA/XD4 3 DCBG/XEIN1 4 DCBG/XRS1 DCBG/XAP1 Main contactor control 5 KDA 201:1/13 and XRD/1 DC link charge 6 KDA F298/1 and 3 NOTE: KDA ends of cables are pre-connected


No.

227 (376)

To Drive L1,L2,L3,PE 367 I/O board/X4 367 I/O board/XMEN1 367 I/O board/X6 367 I/O board/X7 367 I/O board/X8 385/X20

AM-01.01.250 (B) 2013-03-18


21

CABLES: SEP-MAP, MAIN SUPPLY, KRM

Quality Requirements: Cables – routed and connected according to the AM, free of obstruction – plugs properly inserted into sockets – all ‘screw clamp’ type cable terminations must be checked for correct tightness – all ‘screw type’ cable terminations tightened, ensure no loose cable strands – earthings checked – cable grounding / shields to be correctly clamped – check for evidence of damage

1076669.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed / routed cables causes: – obstruction for moving parts (doors, car etc.) – obstruction for MAP interface users – plugs not inserted correctly to sockets can cause unnecessary disconnections – damaged cables can cause intermittent faults – loose ‘screw type’ terminals cause unnecessary disconnections

5S


Method tools needed: Man riding hoist Hand tools needed: Tape measure, spirit level, pencil, hammer drill, hammer, side cutters, electrical terminal screwdriver 5S Installation Progress Report N/A QD-181.211 N/A


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21.1

Installing load weighing sensor, OSG cables and topmost lighting unit

NOTE: The LCEVTC board is always used in case of VDI_A (energy efficiency class A): 1. Route fix and connect the load weighing sensor cable (140) and overspeed governor cable (127). Leave minimum 100 mm space between the cables when they are parallel to each other. 2. Install the topmost (halogen) lighting unit. Route and connect the lighting cable (157). Note: In high headroom situations, light unit must be accessible from the car top.

Standard case

VDI-A case

KDL16S XLG1

LCEVTC KDM XW1

MAP 1079279.wmf

Cable LWD cable LWD cable (in case of VDI-A)

From Load weighing device Load weighing device / VTC board

OSG cable Lighting cable

Overspeed governor Shaft light


229 (376)

To MAP / LOP-CB / XL4 KDA module / XW1 (KDM) KDL16S drive / XLG1 MAP / LOP-230 / XLH6 MAP / H157

AM-01.01.250 (B) 2013-03-18


21.2

Wiring between SEP and MAP 1. Route and connect cables between the SEP and the MAP. Tie excess cables (coming from bottom of the MAP) behind the toe guard of the topmost landing door.

XM5 X1 XL1 LCEREC

**

XL1

*

274

XM5 LCECPU

XM3 XH2

LCE230

XM7 T1,T2 XLH2 XLH1 XLH8

1076583.wmf

From SEP LCEREC / X1 LCEREC / XM5 LCECPU / XL1 LCEADO / XM5 LCEADO / XM3, XH2 LCEADO / XM7, earthing terminal


To MAP 220 / T1, T2 LOP230 / XLH1 LOP-CB / XL1 LOP230 / XLH2 LOP230 / XLH8 274

230 (376)

*) Place plastic bush over the cable entry **) IVC (in case of VDI) Segmented shaft module

AM-01.01.250 (B) 2013-03-18


21.3

Connecting main supply cable to MAP

WARNING: Do not connect or disconnect any connectors when the power is on. 1. Check that the main switch is switched and locked off. 2. Route and connect the main supply cable. 3. Lock off the main switch (220).

1076590.wmf

21.4

Options

21.4.1

Remote alarm connections 1. Connect the remote alarm output cable to LCERAL / XM30 in the MAP. 2. Check the required alarm method. Set the required alarm transfer delay using potentiometer S2. 3. If required, inhibit the remote alarm by setting switch S1 to OFF position. 4. Test and reset. S1 = Alarm ON/OFF switch S2 = Alarm delay time potentiometer S3 = Reset alarm

NOTE: For more information on remote alarm options, see delivery documents.


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21.4.2

Connections to LCEOPT board (SEP) 1. Route and connect all the cables to the LCEOPT board in SEP.

External input FID fire detection External FRD firemen’s drive External OSS out of service switch

Connector Note For the correct pins, see Remove the jumpers circuit diagrams. when connecting the cables. Potential free only.

External output FRD firemen’s drive return FRD firemen’s drive service EPD emergency power drive mode EPD emergency power drive running EPD emergency power drive returned OSS out of service indication DAL-GP disturbance alarm Cables from landings FRD firemen’s drive switch


Connector X1 X2 X3 X3 X4 X5 Connector

Note X5 Remove the jumpers For the correct pins, see when connecting the cable. circuit diagrams.

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21.5

Group connections

21.5.1

LEDs on LCEGTW board (SEP)

LED

Normal status LIFT 24 V OK 24 VDC supply from elevator is OK On GROUP 24 V OK 24 VDC supply from other elevator is OK On LIFT FAIL Communication towards elevator CPU is not working properly Off GROUP FAIL Communication towards other elevator is not working properly Off


Function when LED is on

233 (376)

Colour Green Green Red Red

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21.5.2

Group elevator wiring (with segmented shaft power supply) 1. Switch the power off in each SEP. 2. Connect the group cables (XG1A-XG1B, XG3A-XG3B) and the end resistors. For order of the SEP panels, see delivery documents. 3. Switch the power on in each SEP. 4. Check that GROUP 24 V OK LEDs are lit.

LCECPU561 XG3B

XG3B

XG3B

XG3A

XG3A

XG3A

XG1A

XG1A XG1B

XG1B

LCEGTWO

1078878.wmf


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22

INSTALLING TRAVELLING CABLES

Quality Requirements: Travelling cables – installed according to instruction (400 mm loop) – cable markings (text) towards shaft wall – plugs properly inserted into sockets, cable terminations tightened, earthings checked – cables not under strain – excess travelling cable to be correctly stored under the car, NOT tied to the travelling cable loop

* 1010388.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed travelling cables causes: – excessive strain to cables and unnecessary disconnections – incorrect running loop / height can cause potential snagging and damage to the travelling cables on guide brackets and by rubbing on the shaft wall – incorrect running loop (text towards car) can cause broken wires inside the travelling cables

5S


Method tools needed: Man riding hoist, unwinding tool Hand tools needed: Phillips screwdriver, side cutters 5S Installation Progress Report N/A QD-181.211 N/A


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22.1

Installing travelling cables 1. Connect travelling cables to the SEP (marking XC = SEP side connectors). 2. Fasten the travelling cables to the hanger. Writing* on the cable must face the shaft wall. 3. Lower the travelling cables to the pit as a loop. Move them over the car sill and further to the other side of the car. Ensure that the cables do not get twisted. 4. Secure the cables temporarily to the car top balustrade.

XC11 XC12

LCECPU

1007445.wmf

XC3 XC4 XC1

LCEADO*

* 1010388.wmf 1078883.wmf


236 (376)

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23

ELEVATOR SHAFT WIRING

Quality Requirements: Elevator shaft lighting – installed according to layout drawing Shaft bundle – installed and connected – ensure LCEFCB jumper is set correctly (single entrance or TTC) – ensure end of line resistor is in place Landing toe guards – installed at each landing – fixed securely in vertical plane (to prevent obstruction to car door coupler)

1076670.wmf


5S

Incorrectly installed shaft lighting causes: – inadequate lighting levels


Incorrectly installed shaft bundle causes: – plugs not inserted correctly to sockets or cables under strain can cause unnecessary disconnections

Method tools needed: Man riding hoist, telescopic support pole from plumbing jig

Incorrectly installed landing toe guards causes: – interference / damage to the car door coupler

Hand tools needed: Tape measure, pencil, spirit level, hammer drill, hammer, pliers, Phillips screwdriver, battery drill / driver, side cutters 5S Installation Progress Report N/A QD-181.211 N/A


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WARNING: During electrification work the power must be off. Ensure that the power to the main supply cable cannot be turned on. Remove fuses and lock the main switches. Notice the separate lighting supplies.

NOTE: This section describes the shaft wiring without trunking. For more information on elevator shaft wiring with trunking, see APPENDIX D. Elevator shaft wiring with trunking.

23.1

Shaft lighting

CAUTION: Check the clearance from the end of the car pulley to the wall. Install the lights in vertical position if there is a risk of colliding.

6m

1027379.wmf


238 (376)

max. 0.5m

1078679.wmf

max. 0.5m

6m

6m

mm

6m

2 50

0.5m

6m

0.5m

2m

max. 0.5m

max 0.5m

1. Install the elevator shaft lighting. Install the light units to horizontal position (if possible) with the lamps pointing downwards. Install the lowest light unit to vertical position. Note: In high headroom situations, topmost light unit must be accessible from the car top. 2. Drill holes for signalling cable and door lock cable fixings at each landing.

1081064.wmf

AM-01.01.250 (B) 2013-03-18


23.2

Installing shaft wiring

NOTE: For more information on elevator shaft wiring without trunking, see AM-10.60.028. For more information on elevator shaft wiring with trunking, see APPENDIX D. For more information on segmented shaft network, see section 23.4. For the correct location of the shaft bundle, see the elevator layout drawings. 1. Install the connection and protection boxes. Do not drill through the holes on the box. Fix the flat cables with wall plugs between the connection and protection boxes. 2. Connect the safety chain wires to MAP and signalization and alarm bell cables to SEP.

XLH4 XLH7 XH11 XH12

1076661.wmf

Cable Landing door contact (P122) / landing door lock contact Tension weight contact / stop switch in the pit Alarm bell cable Signalling cable (LCEFCB)


239 (376)

To SEP / LOP230 / XLH7 SEP / LOP230 / XLH4 MAP / LCECPU / XH11 MAP / LCECPU / XH12

AM-01.01.250 (B) 2013-03-18


23.3

Wiring at the landings 1. Connect the landing door lock cables (E) and DOM contact cables (F, optional). D = dual entrance connection. 2. Connect the signalization cables. Leave 100 mm free cable ends at the landing side. 3. Connect optional devices** (alarm bell, fireman’s drive, key switch, locking of landing calls, potential free contact, water sensor contact). 4. Secure signalling cable (at 1 m distances) and any extra cable lengths** to the flat cable. 5. If more than 8 floors, connect another flat cable(s)*. 6. Through type elevator: Check jumper X1 position. Left (A) = front side door, right (B) = rear side door.

F

E

E

D

** * X1

A

B 1076665.wmf


240 (376)

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23.4

Installing segmented shaft network (if 16 served floors / group elevator)

NOTE: Segmented shaft network is used when there are more than 16 served floors (including rear side served floors with through-type car). It feeds operating power for the chain of FCB boards and signalization devices. Note that the control cabinet feeds power to the first 16 served floors. 1. Split shaft network so that number of served floors in each segment is about equal. No segment can have more than 16 served floors. 2. Connect the termination resistor (TX+ / TX-) in the lowest shaft network module. 3. Connect the termination resistor to the lowest LCEFCB/FOB board.

262:1/2

N

20 19

LCEFCB/LCEFOB

11 10 2 XS1

1

XS2 TX+ TX-

XS2 1077302.wmf


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23.5

Installing support channel (optional) 1. If elevator with dividing beams or steel elevator shaft, use support channels to install the shaft wiring components.

1068996.wmf


1068886.wmf

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24

ELECTRIFICATION IN THE PIT

Quality Requirements: Travelling cable – not twisted – cable markings (text) towards shaft wall – installed according to instruction (400 mm loop) – loops hang freely at the correct height (car on buffers) • outer loop = 150 mm from pit floor • inner loop = 100 mm from outer loop Pit wiring – electrification cables routed to avoid cable damage or tripping hazards – stop switch(es) must be installed to correct position (within easy reach of lowest floor and pit) Pit toe guard (side opening door cases) – installed to comply with EN81:1 clause 5.7.3.3 b (code reason = in cases where distance from car toe guard to front wall exceeds 150 mm) – also in rear side for TTC cases 1076648.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly installed travelling cables causes: – excessive strain to cables and unnecessary disconnections – incorrect running loop / height can cause potential snagging and damage to the travelling cables on guide brackets and by rubbing on the shaft wall – incorrect running loop (text towards car) can cause broken wires inside the travelling cables Incorrectly installed pit wiring causes: – plugs not inserted correctly to sockets can cause unnecessary disconnections – incorrectly routed / secured cables in the pit can cause potential tripping hazards and damaged to the cables

5S


Method tools needed: Man riding hoist + ASGT Hand tools needed: Tape measure, spanner (19 mm), pencil, hammer drill, hammer, sprit level, Phillips screwdriver, side cutters, battery drill / driver 5S Installation Progress Report Shaft Wiring Complete

WARNING: If Fire Fighting elevator, ensure that the pit electrification height is according to local code requirements QD-181.211 to prevent water ingress. IP Rating of enclosures must be in N/A accordance with local codes, check delivery documentation.


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24.1

Installing components under car 1. Position the car to have safe access to the pit. Engage the safety gear. 2. Install the travelling cable hanger. 3. Install the compensation chain hanger (if applicable). NOTE: Select the fixing point so that the minimum loop for the chain will be 610 mm. 4. Install the ballast weights (if applicable). For position and number of weights, see layout drawings. NOTE: If no ballast weights, remove the clamp bolts from the ballast weight channels. 5. Adjust the car safety gear switch.

D2

B1

D1

B2 4

3


2

1082212.wmf

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24.2

Installing electrification under the car

=

=

1. Position the car so that there is safe access to the pit. Engage the safety gear. 2. Fix the travelling cables to the hanger under the car. Adjust the travelling cable loops according to the distance between the car and the car buffers.

400mm

100mm 150mm 1010076-1.wmf

1027312.wmf

3. Fasten the excess cable length (if any) to the car floor. 4. Lift the safety gear switch cable to car roof. Use car bottom alarm button as lift rope. 5. Install the car bottom alarm button.

1080317.wmf


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24.3

Installing pit electrification

WARNING: Check that the car is safely locked off and can not move.

NOTE: For more information on elevator shaft wiring with trunking, see APPENDIX D. Elevator shaft wiring with trunking. 1. Install a 500 mm piece of trunking (*). 2. Install the lowest shaft lighting unit, lighting switch, pit stop switch and intercom socket. The pit stop switch must be reachable from the pit and from the landing. 3. Connect the pit cables (OSG tension weight contact, pit stop switch, shaft lighting, intercom socket, oil buffer contacts (if any) and any additional pit devices). 4. Check that an end connector is connected to the XS2 in the lowest board.

*

<0.6m

XS2

1076649.wmf


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24.4

Installing pit toe guard 1. Install the pit toe guard (also for C-side if through type car). The lower end of the toe guard must touch the pit floor.


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25

CAR ELECTRIFICATION

Quality Requirements: Car electrification – electrification routed to avoid cable damage or tripping hazards – plugs properly inserted into sockets, earthings checked COL (curtain of light) – installed and aligned – RX unit NOT installed to slam post side on side opening doors Limit switch ramps – positioned to activate the final limit switch 40...60 mm beyond terminal floor and break contact BEFORE car or CWT contacts buffer 1082290.wmf

Magnets – correctly positioned – edge of position switch horizontally within 5...10 mm of face of magnet

!!! CAUTION - issues that affect reliability !!! Incorrectly installed car wiring / electrification causes: – plugs not inserted correctly to sockets can cause unnecessary disconnections – incorrectly routed / secured cables on the car can cause potential tripping hazards and the cables can be damaged leading to exposed hazardous voltages and potentially hazardous short circuit situations Incorrectly installed COL causes: – unwanted activation failures from misaligned units – COL RX (receiver unit) installed to slam post side will cause unwanted activation from light sources on landings Incorrectly adjusted limit switch ramps causes: – unwanted crash stopping from slight overtravel – car / CWT striking buffers

5S


Method tools needed: Man riding hoist + ASGT Hand tools needed: Battery drill / driver, Phillips screwdriver, side cutters, 2 x spanner (8, 10, 13 mm), spanner (19 mm), pliers, allen keys, tape measure, spirit level, hacksaw (if required to cut door operator bracket) 5S Installation Progress Report Lift Car Wired QD-181.211 QD 7 continued

Incorrectly adjusted magnets / switches causes: – poor levelling accuracy – unwanted re-levelling activations – loss of elevator position / crash stopping drive faults


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25.1

Magnet switches

NOTE: Clear the unnecessary tools and materials from the car roof. Check the location and number of the car roof devices in the delivery documents. The main principle is shown in the picture below. Switch 61:U and 61:N Car position switches 30 Door zone switch, front side

Magnet strip and number 120 mm magnet for each level

Magnet fixing Single car guide rail Machine side car guide rail

B30 Door zone switch, rear side

270 mm magnet for each front door 270 mm magnet for each rear door

77:U Deceleration switch upwards 77:N Deceleration switch, downwards 77:S Synchronisation switch (if 77:N is not between two lowest floors or if 77:U is not between two topmost floors)

80 mm magnet at the top part of the elevator shaft 80 mm magnet at the bottom part of the elevator shaft 80 mm magnet between the lowest and second lowest floor, 80 mm magnet between the topmost and second topmost floor

1. 2. 3. 4. 5. 6.

Shaft bundle Trap door contact (option) Car top connection box Door operator Photo cell amplifier / COL amplifier Travelling cable

Separate bracket on the counterweight guide rail Single car guide rail Machine side car guide rail Separate bracket on the counterweight guide rail

B30 77:S 2 30

61:U, 61:N 77:U CAUTION: Note the positions of 77:U and 77:N to ensure the clearance for the safety gear passing the magnets.

77:N 3

4

5

6

1

1077566.wmf

NOTE: This is view of right handed elevator with skewed sling. In left handed elevator all positions will be mirrored. In case of parallel sling the 51 will be on the rear side of the car guide rail line.


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25.2

Installing car top connection box

CAUTION: Use only short screws delivered with the car to install components on the plywood roof. 1. Secure the travelling cables to the kick plate. Length of the larger cable inside the car top connection box is 440 mm, smaller cable 380 mm from the kick plate. 2. Install the car top connection box on front side of the car, opposite to the machine. Do not drill any through holes on the plywood roof. 3. Connect the travelling cables, see markings on the plugs. Connect earth wires to the earth bar, check the connection tightness.

LCECCB XT3 XT1

XT4

XT2

1078752.wmf


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25.2.1

Connectors on LCECCB board LCECCB board

XB1 - Final limit switch 51 XB2 - Safety gear contact 52 XB3 - Inspection station 42 XB4 - Rear door button B41 XB5 - Safety lock 63 XB6 - Trap door 57 XB7 - Door contact front side 87 XB8 - Door contact rear side B87 XB11 - Insulation test XB12 - Inspection station 24 VDC signals 42 XB13 - 230 VAC plug 45 XB14 - Car light 44 XB15 - Car ventilation 43 XB16 - Front door power supply XB17 - Rear door power supply XB18 - To Car Operating Panel XB21 - Door zone switch front side 30 XB22 - Car position switch upwards 61:U XB23 - Car position switch downwards 61:N XB24 - Door zone switch rear side B30 XB25 - Deceleration switch, upwards 77:U XB26 - Deceleration switch, downwards 77:N XB27 - Synchronisation switch 77:S XB28 - Door operator front side 84 XB29 - Photocell front side 90 XB30 - Door operator rear side B84 XB31 - Photocell rear side B90 XB32 - Battery 227 XB33 - KoneXion XB34 - Emergency lighting for car roof XB35 - Alarm bell 65 XT1, XT2, XT3, XT4 - Travelling cables


P1

XB21

30 XB22

61U

FAIL

24V OK

L3

L1

XB1 L8

L11

L2

BATTERY FUSE F2 OK

L12

INSULATION TEST

XB23

61N

BATTERY OK

L13

51 XB11 XB2 XB12

XB24

B30

L14

77U

L15

77N

L16

77S

L17

24 V

XB25

XB3

XB13

230 V

XB26

45

XB27 XB28

52 42

LIGHT

42 230V XB14

44

XB4 XB15 B41

84

A DOOR

FAN

43

XB29

XB5 XB16

90

A PHOTOCELL

63

DOOR A

XB30

230V XB6

XB17

B84

B DOOR

DOOR B 230V

XB31

57

B90

XB7

B PHOTOCELL XB32

LCECCB

227

BATTERY XB34

713713 H05

44:2

EM. LIGHT XB35

XB8 XB18

65

ALARM BELL XT1

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87

XT3

XT4

B87

COP XT2

XB33

XB9

KONEXION 1010458.wmf

AM-01.01.250 (B) 2013-03-18


25.3

Installing electrification on the car roof (sliding guide shoes)

CAUTION: Handle the switches with care.

NOTE: To prevent tripping hazard, route the cables along the kick plates and inside the car sling top beam. Tie them using cable ties. 1. Install the switches and oil lubricators (1). Connect the cables. 2. Set the distance between the 61:U and 61:N to 130 mm to ensure the correct levelling. 3. Route and connect the safety gear contact, car bottom alarm button, COP, trap door contact (if any), blocking device and all other possible safety chain cables. 4. Route and connect the ventilation, car lighting and all the optional cables. 5. Install the KRM equipment. For more information, see AM-13.25.007. 6. Route and connect the cable of the second COP (if any) to the normal COP.

61:U 77:U

B30 77:S

130

61:N

min. 10mm

1

77:N 51 30 1077554.wmf


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25.4

Installing electrification on the car roof (roller guide shoes)

CAUTION: Handle the switches with care.

NOTE: To prevent tripping hazard, route the cables along the kick plates and inside the car sling top beam. Tie them using cable ties. 1. 2. 3. 4.

Replace the car sling sliding guide shoes (remove fixing bolts) with the roller guide shoes. Install the switches. Connect the cables. Set the distance between the 61:U and 61:N to 130 mm to ensure the correct levelling. Route and connect the safety gear contact, car bottom alarm button, COP, trap door contact (if any), blocking device and all other possible safety chain cables. 5. Route and connect the ventilation, car lighting and all the optional cables. 6. Install the KRM equipment. For more information, see AM-13.25.007. 7. Route and connect the cable of the second COP (if any) to the normal COP.

B30 77:S

30 77:N 61:U 51

77:U

min. 10mm

61:N 1080714.wmf


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8. Check the roller guide (if applicable) alignment and that the plastic glider firmly touches the guide rail. *) No gap. **) Shim as necessary

*

**

25.5

**

1082448.wmf

Install the provision for lift announcer

CAUTION: Use only short screws delivered with the car to install components on the plywood roof. 1. Install the LCEOPT board in plastic box on the car roof. For more information, see delivery documents. 2. Route and connect the cable from COP to LCEOPT board.

25.6

Install the intercom socket on the car roof

CAUTION: Use only short screws delivered with the car to install components on the plywood roof. 1. Install the intercom socket to the car roof. 2. Route and connect the cable to XB9 on the LCECCB board at the car top connection box. For more information, see delivery documents.


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25.7

Installing curtain of light For more information on installing curtain of light, see AM-03.17.011.

25.7.1

Fixing curtain of light

CAUTION: Side opening doors: Install the transmitter TX at the slam post side. Otherwise the car or lobby lighting may interfere and cause a fault operation in the curtain.

Action Fix both detector parts (the transmitter TX and the receiver RX) to the opposite ends of the sill. Railing 1:

Note For railing type 2 when LL=700, 750 or 850 mm, cut off a piece from the fixing bracket.

HH+254

Step 1

5 94.5

2 0 +1 L L

CL

1

TX 1064076.wmf

1. Buffer 2. Fixing for side opening door


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Step Action Railing 2, centre opening door:

LL=900...1100

5

LL=700...850

Note

64.5

LL+8 / LL+15

+8 LL

LL

CL

5 +1

CL

1011159.wmf

Railing 2, side opening door:

LL=900...1100 9

LL=700...850

5

CL

64.5

LL+5

1011160.wmf


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Step 2

Action Adjust the detectors in vertical position in both directions.

Note

HL= 2100mm

6mm

HL= 2000mm

1011161.wmf

1

1027471.wmf

1041530.wmf

4

Check the running clearance of the detectors at each landing. Inspect the running clearance visually at top and bottom of the shaft.


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Minimum running clearance: – 10 mm to landing door – 25 mm to wall

AM-01.01.250 (B) 2013-03-18


25.7.2

Routing the cables of the curtain of light

Centre opening door

2

1. Cable tie 2. Cable behind the operator

1

1011168.wmf

Step 1

Action Route the cables to the car roof.

2

Fix the cables properly using cable ties. Fixing accessories are supplied in the plastic bag.


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Note Avoid tight bends and sharp edges. Do not over tighten the cable fixings. Ensure that cables do not hit any moving objects (for example door panels, landing doors)

AM-01.01.250 (B) 2013-03-18


25.7.3

Connecting the cables Step 1

Action Connect the cables direct to the terminals in the door operator board.

Note 1. Drive 1 2. Drive 2 3. Car 4. Transmitter 5. Receiver

45 44

X15

46 49 47

X16

48

1

X16

X15

2 3 4

5 X15

TX

X16

RX 101119

2

Set the DIP switches. 1. Receiver lens 2. Pos. 1. Overconnection of single beam 3. Pos. 2. Set this to ON

1 3 2

on

off

on

off 1011174.wmf


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25.8

Installing ramps and magnets (driving up)

NOTE: For correct locations of ramps and magnets, see shaft vane diagrams. 1. Fit the limit switch ramps. The switch must start to operate 40...60 mm below the lowest floor and 40...60 mm above the top floor. Electrical contacts must break before the buffer. 2. Place magnets for 61:N, 61:U and 30 (B30).  A = floor level, B = bottom ends at the same level 3. Place magnets for 77:U and 77:N (white mark of the lower magnet upwards, upper magnet downwards). The magnet must be minimum 100 mm from a bolt or guide rail clip. Raise/lower as necessary, horizontally in front of the switch (narrow detection area). 4. Optional: Place magnets for 77:S, dummy floors (floor to floor distance > 5 m) and 61 magnets for each 5 metre (at equal distances).

1

77:S B30

3

2

4

77:S

*

**

77:U

30

61:N

**

B

5...10 mm

77:S

77:N

*

=

A

=

61:U

1077731.wmf


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25.9

Wiring of door operator and curtain of light (or photo cell) Step 1

Action Connect the cables on the operator and route the cables outside of the kick plates to the car top connection box. Secure the cables with cable ties.

Note Refer to the layout drawing.

25.10 Installing car emergency light 1. Install the car emergency light to the car lintel. 2. Route and connect the cable to the car top connection box.

1080611.wmf


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26

FINALIZING LANDING DOORS

Quality Requirements: NOTE: These instructions are for installing KES 201 landing doors. Fire proofing materials – installed Carpet profile – installed and aligned, no tripping hazards Quality check performed – inspect for any sharp edges and de-burr if necessary – no scratches or dents – no abnormal noises, normal noise level at 1 m distance from moving door: • normal = max 55 dB(A) • impulse (e.g. reopening) = max 60 dB(A)

!!! CAUTION - issues that affect reliability !!! Incorrectly installed fire proofing materials causes: – contact with doors causing damage to fire proofing materials and doors Incorrectly installed carpet profiles causes: – tripping hazards – contact with doors which prevents smooth running Scratches or dents to doors causes: – poor visual appearance – handover rejection by the customer

5S


Method tools needed: Man riding hoist Hand tools needed: 2 x spanner (8 mm), spanner (15, 16 mm), hammer drill, hammer, battery drill / driver, metal cutting shears, tape measure, spirit level 5S Installation Progress Report Doors and Frames Installed 100% QD-181.211 QD 6 completed


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26.1

Uprights on slampost side (fire rated EI30/EI60/EI120-W doors)

2 4

1 3

5 6 4

Step 1 2

3

Action Install the 4 M5 bolts (1) to the slampost stiffener brackets (2) using the nut (3). Fit the insulation material (4) on the stiffener brackets.

Note

Always use gloves, protect your arms and wear dust masks when handling the insulation material.

Secure the insulation material with big washers and nuts (5)(6).


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26.2

Uprights on non-slampost side

26.2.1

Frame door (fire rated EI30/EI60/W)

Step 1 2 3

4

Action Cut the small 150mm wide hard rockwool plate into 4 pieces of 50 x 150mm strips (2). Fit the strips evenly devided into the upright. Apply 4 springs (3) to the hard rockwool (1).

Slide the hard rockwool plate under the top track bracket and over the strips.


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Note Always use gloves, protect your arms and wear dust masks when handling the rockwool. The spring height has to match the 4 pieces of strips in the upright. Shorten the hard rock wool plate so that it fits into the upright.

AM-01.01.250 (B) 2013-03-18


26.2.2

Frame door (fire rated EI120)

A

B

el120_h.wmf

Step 1

Action Install 2 insulation material blocks in the upright.

2

Apply 4 springs to the blocks.


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Note The blocks have to be installed with the expanding seal (A) positioned like in the picture and the thin layer (B) in the centre part of the upright. Apply 2 springs for each block.

AM-01.01.250 (B) 2013-03-18


26.2.3

Front door (fire rated EI30/EI60)

Step 1 2

3 4 5 6

Action Note Install the brackets (1) to the upright flange. Cut the small 150 mm wide hard Always use gloves, protect your arms rockwool plate into 4 pieces of 50 x 150 and wear dust masks when handling the mm strips (2). rockwool. Fit the strips evenly devided into the upright. Apply 4 springs (3) to the hard rockwool The spring height has to match the 4 plate (4). pieces of strips in the upright. Slide the hard rockwool plate under the Shorten the hard rock wool plate so that top track bracket and over the strips. it fits into the upright. Bend the brackets (1) to keep the hard rockwool plate in position.


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26.3

Fire trims (frame version only)

26.3.1

Sheet metal Step 1 2

3

Action Fix the vertical fire trims (*) to the door frame using self-drilling screws. Bend the straight fire trim back against the wall to close the wall gap. The fire trims must overlap the rockwool on the “non slampost” side. Fix the fire trims to the wall using nail anchors.

* 26.3.2

Note

The corner cut out in the fire trim is for the top track bracket. The trim edge holds the rockwool in position.

*

1007501.wmf

Installing fire trims of the lowest landing door Step Action 1 Engage the safety gear before entering the pit. 2 Remove the car buffers and lower the upper fixings temporarily. 3 Drive the car downwards close to the buffer bases.

Note

1082371.wmf

4 5 6

Install the fire trims starting from the top of the door. Raise the car. Reinstall the buffers. Install the lowest part of the fire trims to the door working from the work stool and the landing.


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26.3.3

Soft adhesive

el120_d.wmf

Step 1 2

Action Open the package and cut 1.5 m long stripe. Cut the remaining part in half.

Note

1 .5

m

=

= el120_f.wmf


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Step 3

Action Clean the wall surface from the dust.

4

Glue the short stripe horizontally on the top of the door and the wall. Glue the long stripes vertically to the both side of the door.

5

Note

ei120_c.wmf

6 7 8

Install 3 flat brackets to both uprights with self drilling screws. Bend them against the wall. Fix them to the wall with anchor nails.

el120_e.wmf


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26.4

Corner angles and wall gaps 1.

2.

2.

a1125dl.wmf

Step 1

2

26.5

Action Note Fit the front side extension panel corner Only for front version. angles to the shaft wall using nail Match the slots in the corner angles and anchors. the holes in the side extension panel. Fix the corner angles to the side panels using self drilling screws. Fill the wall gaps of the frame and front version doors with the soft rock wool blocks to comply with required fire ratings.

Top extension panel fire insulation (front version only) Always use gloves, protect your arms and wear dust masks when handling the rockwool. 2.

Step 1 2 3

3.

2.

Action Note Cut holes in the hard rockwool plate for the top fixing profiles. Fasten the hard rockwool panel to the horizontal beam using annealing wire and washers. Fill the top pocket with two soft rockwool slabs.


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26.6

Carpet profile

a31265xc

Step 1 2

3

26.7

Action Clip the carpet profile over to the landing sill. Use silicone or other suitable filler to close the gaps between the floor and the carpet profile. If needed, knock the uprights evenly to close the gap between the uprights and the carpet profile.

Note Do not fit this before the floor finish is installed as the profile is not removable. Use extra screws to fix the carpet profile to the landing floor if the floor is exceptionally curved.

Quality check Step 1

2

3

Action Check the operation and appearance of all doors. For more detailed door quality information refer to the AMD Maintenance Standard AS-03.12.036. Make sure there are no dents, scratches or abnormal noises. Normal noise level: from door: 1 metre from landing: 1 metre speed level: 1 (normal) Door moving: max. 55 dB(A) Impulse (e.g. reopening): max. 60 dB(A) Ensure the emergency key works properly.


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Note

AM-01.01.250 (B) 2013-03-18


27

ROPING

Quality Requirements: Ropes – lubrication level checked – rope lengths and equal tensioning checked – lock nuts tightened, split pins installed – lock nuts not leaning against split pins – rope guards adjusted – rope labels retained and stored in the MAP for future reference Compensation chains (if any) – chain length checked – no twists, runs free of obstructions Manual brake release cable – routed to prevent obstructions and contact with car or landing doors – correct type and number of fixings used – bending radius > 100 mm – adjusted to ensure brake operation Car ceiling – suspended ceiling safety ropes must be correctly installed and secured

1077505.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly lubricated / tensioned ropes causes: – extremely premature rope wear / replacement – extremely premature machine sheave wear / replacement Incorrectly adjusted rope terminations causes: – noise, vibration and poor ride comfort Incorrectly adjusted rope guards causes: – gap too small = rope(s) rubbing guard , noise / vibration, poor ride comfort and premature rope wear / replacement – gap too big = potential loss of rope from pulley! Incorrectly installed car toe guard causes: – can cause interference / damage to the landing lock rollers Incorrectly installed / adjusted brake release cable causes: – obstruction with moving parts / damage to cable – adjusted too slack = unable to manually operate brakes – adjusted too tight = potential brake malfunctions


5S


Method tools needed: Man riding hoist + ASGT, unwinding tool, work stool, 2 x telescopic support pole from plumbing jig, pulling rope, brake opening bolts (temporary, with delivery), telescopic pole, site trolley, rope clamp Hand tools needed: Tape measure, 2 x spanner (8, 13, 19 mm), spanner (10, 17, 18 mm), side cutters, knife, ratchet + socket (13 mm), allen key (6 mm), spirit level, hammer drill, battery drill / driver, insulating tape, pliers, 2 x G-clamps 5S Installation Progress Report Roping Complete QD-181.211 QD 7 commenced

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27.1

Lubrication of suspension ropes Elevator suspension ropes are lubricated completely during the manufacturing process. However, long storage and installation times may reduce the effectiveness of lubricant applied in manufacturing of the suspension ropes. Hence, re-lubrication already before commissioning of the elevator may be required to guarantee the full service life of ropes, machinery traction sheave and other rope pulleys. There are five reasons for rope lubrication: 1. 2. 3. 4. 5.

To protect the rope core from deteriorating. To prevent friction between the wires, strands and core. To guard against corrosion. To optimise the position in traction sheave to get best friction. To prevent damaging (wearing) of the traction sheave.

NOTE: It is essential to use correct amount of lubricant, because too little may not protect the rope and too much can result in serious problems. (Frequent light application has given the best results).

WARNING : Overspeed governor ropes must NOT be lubricated.


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27.1.1

Determining the lubrication need

CAUTION: No definite time-dependent interval can be given for lubrication. Lubrication need must be checked during new equipment installation because rope storage and installation times can be relatively long. Correctly lubricated rope should stick lightly to the glove when grabbing it by hand. The lubrication of the suspension ropes is required if: – – – –

the ropes are dry or the lubricant has become stiff there is red dust on the ropes or on the floor there is metal dust under sheave or pulleys the grooves of the pulleys are dry (no lubrication film on fingertip when wiping)

CAUTION:  If the ropes get dirty during the roping:  - Do not clean them with any chemical cleaner, solvent or diluent. - Clean them gently using a brush or rag moistured with rope lubricant.

27.1.2

Lubricants For more information on acceptable lubricants, see AS-01.01.010 - Lubricant recommendation instruction.

27.1.3

Lubricating ropes For more information on lubricating the ropes, see AM-09.01.006.


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27.2

Roping principle (skewed car sling)

NMX07 4 5

NMX11 1

4

1

5 6

1 4

5

3

1

31

2

23

6

4

12 4

21 43

12 34

2

12 34

5

1 32 4 5

12 34 5

1 1

2

5


4

1

31

34 5

6

1 32 4 65

12 34 56

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1075348.wmf

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27.3

Roping principle (parallel car sling)

NMX07 3 4 5

NMX11

1

3 1

4

1

5 6

21

1 4

5

3

3

21 43

1 32

12 3

2

12 3

12 3

12 34

31

6

4

12 4

2

34

5

1 1 1

2

5

12

1 32 4 5

12 34 5

4

1

31

34 5

6

21 43 5 6

12 34 56 1079981.wmf


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27.4

Preparations

500

1. Ensure the access to the pit and to the car roof. 2. If skewed bottom pulley beam: Make a pull rope loop round the car. Note the routing between the car guide rails. Lower the rope ends from the car roof, tie them together in the pit. Tidy the rope tails with tape. 3. If skewed bottom pulley beam: Use G-clamp for rope guiding.

1075349.wmf

4. Place the remaining counterweight filler weights: •onto the top beam at the car roof (check that the load is on the top beam) OR •inside the car (protect the car interior from any damage).

1077713.wmf


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27.5

Roping in the pit (skewed sling) 1. Pull the suspension rope round the car. Fix the rope to the pull rope with cable ties. 2. Release the rope from behind the G-clamps. Secure the rope to the hand rail. Leave approximately 1.5 m free rope end to ease rope end fixing at top of the shaft. 3. Repeat for the other ropes. Check that each rope end is equally long. 4. Route the suspension ropes round the diverting pulleys below the car. 5. Adjust the rope guards. Ensure that the ropes remain in correct order.

2

1

2

3mm

5

5

4 1075358.wmf


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27.6

Roping in the pit (parallel sling) 1. Secure the rope end to the car top balustrade. Leave approximately 1.5 m free rope end to ease rope end fixing at top of the shaft. 2. Lower the rope as a loop between the car and the landing door. Secure to the balustrade. Repeat for all the ropes. 3. Route the suspension ropes round the diverting pulleys below the car. 4. Adjust the rope guards. Ensure that the ropes remain in correct order.

2

3mm

4

1

2 3

27.7

4

1080930.wmf

Attaching compensation chain under the car (optional) 1. Attach the compensation chain (if applicable). Expose minimum one free link of the chain.

1078749.wmf


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27.8

Opening brakes for roping 1. Fit the threaded bar (included in delivery) between the brake release lever and support. 2. Tighten the nut (1) until the brake opens. Repeat for the other brake. CAUTION: Do not try to open the brake using any other tools than the long screw (included in the delivery).

1 1078871.wmf 1080167.wmf

NOTE: Brake opens before the brake release lever touches the limiter pin. An air gap of 0.05 - 0.10 mm is enough to open the brake. Check the air gap using a feeler gauge while opening the brake.


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27.9

Roping at top of the elevator shaft 1. Fix the car side rope end. The rope ends must be equally long. Fit the rope grips. Tape the rope ends. Check that the lock nuts are not leaning against the split pins. 2. Route the rope loop round the traction sheave. Lower the loop down to the counterweight. 3. Fix the counterweight side rope end. 4. Make a rope guide tool. Drop the tool down to the pit. 5. Route the rope loop round the CWT pulley. Ensure that the ropes remain in correct order. 6. Install the CWT pulley cover plate. Remove the pulley securing cable ties.

1

4

3

1200

1

5 2

6

2 1075359.wmf


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27.10 Shortening the ropes

WARNING: Check that the car is heavier than the counterweight. Remove filler weights one at a time from the counterweight frame to allow car to drive down. 1. Mark and loosen the ASGT rope grips* to prevent safety gear engaging when driving down. Lift the counterweight frame 1350 mm above the pit floor. 2. Install the buffer spacer. 3. Install the oil buffer (if applicable). 4. Lower the counterweight frame slowly onto the telescopic pipes. **In case of deep pit, extend the telescopic pipe length to 2000 mm. Lock with M12 bolts. 1 = piece of fabric, 2 = cable tie, 3 = G-clamp, 4 = timber piece 5. Secure the car with the parking chain. 6. Measure the distance X between the counterweight buffer and the buffer spacer.

4

* 1 2

2

3

**

4

3


=

=

6

2000

1

X

1

1077717.wmf

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7. Calculate the distance Y (from the car sill to the landing sill or between top tracks**). Y=X-A-B-C  A = overtravel: 85 mm (see layout) B = rope stretch: • 3.75 mm per rope meter (fibre core F819 S-FE) • 2 mm per rope meter (PAWO F3) • 1.83 mm per rope meter (PAWO F7S) C = spring compression: 20 mm 8. Connect the ASGT rope. Adjust rope grips according to marking. 9. Position the car according to calculation Y (car sill below the topmost landing sill). 10.Shorten the ropes at the counterweight side rope fixing one at a time. Do not remove the rope fixings. 11.Fit the rope grips. Cut and tape the rope ends. Check that the lock nuts are not leaning against the split pins.

**

Y

*

1033741.wmf

Y

1007524.wmf

1033401.wmf

12.Remove the telescopic pipes below the counterweight. 13.Install the counterweight oil lubricators.

1078369.wmf

14.Remove the man riding hoist tension weight.


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27.11 Attaching compensation chain to counterweight

 200

1. Cut the compensation chain to correct length. 2. Install the chain to the counterweight. For correct fixing point, see layout drawings. Check that the distance from chain to the pit floor is minimum 200 mm. Check that the chain is not twisted. Check that the loop is minimum 610 mm.

1079216.wmf

27.12 Moving OSG rope in the large groove 1. Fit the overspeed governor rope in the large groove. Wear gloves.

1078686.wmf


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27.13 Installing brake release cable

WARNING: Cable cover must be free to follow the brake release lever movement without jamming. Minimum cable bend radius is 100 mm. Maximum bending angle is 90 degrees. Maximum amount of bends is 3 pieces. For more information, see drawing 856426 (included in delivery).

1. NMX07 machine: Remove the metal sleeve* from the manual brake release cable. NMX11 machine: Do not remove the metal sleeve* from the manual brake release cable. 2. Connect the cable to the machine. Locate the nuts at cable end to middle of the threaded bar to have adjustment tolerance in both directions. NMX07

NMX11

NMX07

NMX11

1 1081654.wmf


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3. Route the cable and pull the slack to the lever end. 4. Mark cable sleeve at position of lever handle sleeve socket. 5. Pull out minimum 300 mm of the wire rope towards the machine end so as not to damage the wire rope. 6. Peel back 50 mm of the outer coating and cut the sleeve. 7. Push and pull the slack to the lever end. Cut and peel back the wire rope end. Route the brake release cable into the lever. Note that tightening clamp area and brake cable must have metal contact surfaces for sufficient friction. 8. Adjust the cable tension. The brake levers must be in the centre position.

8

90º

r > 100 mm

~100 mm

7

~50 m 0m ~5

5

6 1080609.wmf


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27.14 Testing manual brake release operation

WARNING: The speed can increase fast when you open the brake. When the traction sheave starts to move, stop it by letting the brakes close every 0.5 - 1.0 second to avoid the elevator accelerate to over speed. 1. 2. 3. 4.

Pull the lever to brake open position. The cable must release the machine brake. The car should move and stop immediately when the lever is released. The lever must return to the brake closed position by itself. Store the lever inside the MAP.

1076094.wmf

1079301.wmf


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27.15 Dismantling man riding hoist from car

WARNING: The car top balustrade must be set according to the layout drawing / EN81-1. 1. Secure the diverting pulley securing rope to second topmost guide rail bracket. Tie the gate of the diverter pulley hook open. 2. Locate the car roof approximately 400 mm above the topmost landing. 3. Close the machine brakes. Roll the hoist rope on the reeler. 4. Connect the hoist hook to the hoist body. Drive the hoist out on the landing. 5. Remove the diverting pulley and securing rope. Work from the landing.

1033388.wmf

1033386.wmf

6. Check that the gap between car guide rails and car guide shoes is 1 mm

1mm

1mm


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27.16 Finalizing car installation 1. 2. 3. 4. 5. 6. 7.

Install the car fans. Connect to the car top connection box. Check the car balance. Relocate the ballast weights as necessary. Remove the removable clamps and sliders of the roller guide shoes. Adjust the car top balustrade height according to the local code and layout drawings. Secure the OSG resetting stick to the balustrade with cable ties. Install the document holder to the balustrade. Glue yellow and black tape to the balustrades at the overspeed governor rope area.

x4

1077506.wmf

1080718.wmf

0 20

1078759.wmf


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27.16.1 Installing security ropes

WARNING: Risk of ceiling falling down from lock side. It is mandatory to install the security wires. Install them properly. 1. Route the wires through the holes. *) Emergency opening wire releases the ceiling lock from the car roof (roof with trap door). **) Security wire prevents free fall of the ceiling.

*)

**)

1077278.wmf

2. Fix the emergency opening wires: • route the wire • pull the wire so that the lock latch starts to turn • tighten the wire lock and cut off the extra wire

GACL18nt.wmf


1077279.wmf

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3. Connect the security wire to the ceiling. *) The wire rope extension is required for one-panel ceiling only.

*)

1077482.wmf

4. Lift up and lock the ceiling. See chapter closing the ceiling. 5. Check that the emergency opening works: • Open the locks by pulling two emergency opening wires in the car roof corners.

1077350.wmf


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• Pull the security wire in the centre to release the locking and gently lower the ceiling down.

1077280.wmf

6. Close the ceiling. See chapter closing the ceiling. 7. Fix safety rope to ceiling.

1079188.wmf

8. Fix the spring pins.

1077483.wmf


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28

COMMISSIONING

Quality Requirements: Prerequisites – shaft components, machine, car, doors and ropes installed – car and shaft electrification (including signalization) installed – magnets installed accurately according to shaft diagram – man riding hoist removed from car – car and CWT balanced – electrification panel covers closed – OSG installed to final position – safety gear and OSG operation checked Commissioning for inspection drive – terminals, connections, earthings, cable routings checked – construction time power supply connected (if required, KDL16S) – LON protocol performed – drive parameters, dip switches set – motor direction, encoder polarity checked – safety chain checked, RDF and inspection Commissioning for rated speed – LWD adjusted – shaft setup performed – levelling accuracy checked Final steps – car and CWT balanced – CWT screen installed to final position – oil collectors installed – car toe guard fixed securely in vertical plane (to prevent obstruction to landing door rollers) Fine adjusting – elevator running to optimum performance


Poor adjustment of parameters and fine tuning causes: – elevator fails to run to optimum performance – poor ride quality – possibility of drive faults and break downs NOTE: In case of PC board replacement Incorrect storage / handling of PC boards can cause: – component / board damage – component / board failure For more information, see AS-12.02.001.

  

NOTE: If required by your frontline local code, the following tests MUST be performed and verified BEFORE the power is switched on! – Earth Continuity (max value = 0.5 ) – Insulation Resistance to Earth (min value = 1 M)

SORT STABILIZE SHINE STANDARDIZE SUSTAIN Method tools needed: N/A Hand tools needed: Construction time power supply tool (battery & lead), electrical terminal screwdriver, multimeter, spanner (7 mm), 2 x spanner (19), TORX screwdriver (T10), Phillips screwdriver, multigrip pliers, allen keys, thin screwdriver for adjusting potentiometers (LWD), test weights 5S Installation Progress Report

5S

Roping Complete QD-181.211 QD 7.1 commenced


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28.1

Prerequisites

28.1.1

Health and safety at work Mandatory Observe the requirements of your national Elevator Regulation Code.

Note In case of conflict between the Code and the present commissioning instructions, rely on your Code. Be extremely careful when working with the There are high voltages: – in the main circuit capacitors (>500 VDC) electric components and their enclosures. Refer to AM-01.03.002 Take 5. and on the inverter board – in the safety chain and inside the shaft electrification panel (230-400 VAC) Inverter drives remain energised for about 5 minutes after the power has been disconnected. DO NOT work on the drive, hoisting motor or braking resistors until you have verified that this energy has been discharged. Test equipment must be set to the 1000 V DC range. The test equipment must be checked before and after the test to ensure it functions correctly. While the LED DANGER is ON on the inverter board, there are high voltages in the drive module. When making electrical connections in the Car light is not controlled by the main elevator shaft or in the car, the power must switch 220 in maintenance access panel. be turned OFF from the main switch (220) This circuit has its own switch. and car light supply (262) in maintenance Refer to AM-01.03.002 Take 5. access panel. No personnel are permitted in the elevator shaft during this phase.


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28.1.2

Prerequisites and preparations Before starting the commissioning, check that the following basic things have been done: Item

Done

Elevator shaft installation. Machine installation. Car installation. Car and landing door installation. Rope installation. Car and elevator shaft electrification including the signalling devices. The positioning magnets are installed accurately according to the shaft diagram. The man riding hoist is removed from the car. Car and counterweight are balanced. Covers of the electrification panels are placed. Overspeed governor is installed to the final position. Safety gear and overspeed governor operation checked.

WARNING: The elevator first run must always be made from the MAP with the car positioned so that there is access to the car roof from the MAP level.

WARNING: No people are allowed to be on car roof.

CAUTION: The hoist must be removed from the car, the parking plate must be in position and the parking bolt must be retracted.

WARNING: If it is necessary to reroute the cables remember safe operation method. 1. Check that the drive DANGER LED (D1) is illuminated. 2. Switch the power OFF from the main switch (220) 3. Wait at least 5 minutes before touching the cables. 4. Check that the drive DANGER LED (D1) is NOT illuminated. 5. If possible measure from connectors that the voltage is on safe level.


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28.2

Commissioning

WARNING: The tests for earth continuity and insulation resistance must be performed BEFORE the power is switched on for the first time! Perform the commissioning for inspection drive and commissioning for rated speed according to the drive type: Drive type KDL16S

KDM40

Instruction AM-11.65.045, Machine-room-less Elevators with KDL16S Drive, Installing, Commissioning and Safety Inspection  Use motor setup type value from motor data plate. AM-11.65.042, KDM drive system for MonoSpace® and MonoSpace® Special: installation, commissioning and safety inspection  CAUTION: Do not use the motor setup type value defined on the NMX motor data plate.

3mm

NOTE: The remaining counterweight filler weights will be loaded to counterweight during the commissioning. Refer to relevant commissioning instruction. NOTE: For more information on the balancing load, see APPENDIX B. NOTE: Check the safety gear gap (3 mm) after commissioning. NOTE: Check the adjustment of the rope guards (Car & CWT).

1080607.wmf


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1. Place all the remaining filler weights to the counterweight, split filler weights to top. 2. Fit the counterweight clamps. NOTE: Do NOT move car / CWT until securing clamps are fitted. 3. Make a cutout for a compensation chain to the counterweight screen if necessary. 4. Install the counterweight screen to final position. The top edge height from the pit floor must be 2500 mm. 5. Fill in the counterweight over travel sticker. Attach the sticker to the counterweight screen for maintenance purposes. 6. Fit the oil collectors to the guide rails.

OK

NO

140 1077272.wmf

7. Install the car toe guard working from the lowest landing. Align vertically with the front edge of the car sill. A = toe guard support, AMDC1 B = toe guard support, AMDC2

A


B

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28.3

Final steps of commissioning

28.3.1

Balancing the car and counterweight

WARNING: No one is allowed to be on the car roof or in the elevator shaft.

CAUTION: Be careful while releasing the brakes. Do not let the car overspeed.

NOTE: If final car interior is added later: Add an equivalent weight in the car for balancing purposes. After the car interior has been installed, remove unnecessary weights from the car and readjust the offset and gain settings on the load weighing device. Add test weights into the car according to the balancing load (normal or adaptive). Drive car and counterweight to the same height in the elevator shaft. Open the brake. Observe the speed/direction LEDs. The car must not move. Repeat the test with the car a little higher and a little lower ensuring the car and counterweight are balanced. Add or remove filler weights as necessary. 5. Check that the rope tensions are equal at both rope anchorages. The rope clips must not rub each other or the ropes. The lock nuts must not lean against the split pins.

max 3mm

1. 2. 3. 4.

1007537-1.wmf

1076096.wmf


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28.3.2

Adjusting slack rope switch 1. Check the 3 mm distance. 2. Adjust the switch position. 3. Connect the cable to XLH3 on LOP-230 board in the MAP.

1 ~0 .5

3

2

1080328.wmf

28.4

Fine adjusting Perform the fine adjusting according to the drive type: Drive type KDL16S KDM40

Instruction AM-11.65.045, Machine-room-less Elevators with KDL16S Drive, Installing, Commissioning and Safety Inspection AM-11.65.042, KDM drive system for MonoSpace® and MonoSpace® Special: installation, commissioning and safety inspection


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29

COMMISSIONING OF THE CAR DOOR

Quality Requirements: Car doors – running smoothly with no noise – closing quietly, no slam closing – operating speed and door open dwell time according to customer requirements – closing force correctly adjusted Curtain of light (COL) – operating correctly – correctly aligned – RX unit NOT installed to slam post side on side opening doors

1077323.wmf

!!! CAUTION - issues that affect reliability !!! Incorrectly adjusted door parameters causes: – doors fail to run to optimum performance – increased probability of customer dissatisfaction – increased probability of door drive faults, break downs etc. – door closing torque too low = possibly unable to close doors – door closing torque too high = non compliance with local code requirements Incorrectly installed / adjusted COL causes: – unwanted activation failures from misaligned units – COL RX (receiver unit) installed to slam post side will cause unwanted activation from light sources on landings


5S


Method tools needed: N/A Hand tools needed: Multimeter, allen keys, Phillips screwdriver, door force gauge 5S Installation Progress Report N/A QD-181.211 QD 8 commenced

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29.1

Layout of drive 10 electronic assembly

NOTE: For X1 connector, use terminal EXT GND on the door electronic assembly as the reference when measuring the control signal voltage. EXT GND terminal must be connected to the elevator control signal ground (-/24 V for TMS or EPB and so on). The internal ground of the drive 10 board is connected to protective earth.

1. Test Drive Buttons 5

2. Reference switch 3. DIP switches S1 and S2 4. Closing force rotary switch

1

5. LEDs 6. Learn button Plug description: X1 = Standard I/O

4

X3 = Transformer secundary winding S10

X4 = Motor X5 = Battery supply

6

X10 = Motor encoder X15 = Photo cell receiver (curtain of light) X16 = Photo cell transmitter (curtain of light)

5

2

3

X40 = Test drive button

X16

X15 1077697.wmf


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29.2

Layout of AMD drive 2 electronic assembly

1

2 X4

X5 X40

X6

X9

3

X10

X19

X15 X16 X17 X18

X1

X2

4

P02000343.wmf

1. Test Drive Buttons 2. Encoder 3. Motor 4. Reference switch


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Plug description: X1 = Standard I/O X2 = Extended I/O X4 = Motor X5 = Battery supply X6 = Transformer secondary winding X9 = Transformer primary winding X10 = Motor encoder X15 = Photo cell 1 (curtain of light) X16 = Photo cell 2 X17 = Mechanical safety edge 1 X18 = Mechanical safety edge 2 X19 = Board line in X40 = Test drive button


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29.3

Testing factory adjusted door operation

CAUTION: Door operators which are delivered directly from the factory are pre-adjusted: the learning phase is already completed and the closing force potentiometer has been adjusted.

NOTE: At power up - in normal drive, if the door is not at the reference switch (close end position) it will move at low speed until the close end position is found.  After finding the reference switch (close end position) the door will move at normal speed.

Step 1 2

3

Action Note Switch on the inspection drive on the car roof. Switch on the power. Check that the doors open and close The test drive buttons operate only when when the test drive buttons are the elevator is in inspection mode (LED pressed. SD/ X1 lit). Check that the panels do not touch If necessary, the speed and closing force each other or rattle and that the car settings can be fine tuned. door operates smoothly. Switch the elevator to Normal Mode As the control panel controls the and close the landing doors. reopening, the elevator must be in the Normal Mode. Drive the car to the landing level. Check that the safety devices (open button, photocells) reopen the door.

1077701.wmf 1077700.wmf


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29.4

Adjusting closing force Step 1

2

3

4

Action Open and close the door manually and check that there are no mechanical obstructions. Drive the door with the CLOSE button (or close command) to the close  direction. Put a force measuring device between the closing door panels (centre  opening) or between the door panel and slam post (side opening). Do not attempt to measure the force of a moving door, stop it first. Adjust the closing force if necessary using the potentiometer.

Note The test drive buttons only function when the Service Drive input (SERV. DRIVE/X1) is set.

The maximum closing force is 150 N. For centre opening door, the measuring device will show half of the actual close force. For side opening door measuring device will show the actual closing force.

CLOSE FORCE 1077706.wmf

Closing force increases when turning the close force potentiometer clockwise.


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29.5

LEDs, drive 10

45 +24V PC1 44 IN

X15

46 GND

Protective device LEDs Name LED illuminated if +24 V The power of the photo cell is on PC.1 IN Photo cell not interrupted

1077709.wmf

GND GND EXT 17

CLOSE

16

OPEN

10

OPEN END

30

REOP IN

31 REOP NC

X1

32

REOP NO

SD

SERV DRIVE

14

OPEN BUTT

41 PC OUT 9 CLOSE END +24V EXT

Lift interface LEDs Name CLOSE OPEN OPEN END REOPEN SERVICE DRIVE OPEN BUTTON PC OUT CLOSE END +24 V EXTERN

LED illuminated if CLOSE Command is on OPEN Command is on Door is in open end position Reopen NO (Normally Open) contact is closed = reopen request is activated Elevator Inspection drive is active Door open button is pressed Beam of photo cell is not interrupted Door is in close end position External +24 VDC available

GND GND EXT 1077708.wmf

Name POWER STATE WATCH DOG

Miscellaneous LEDs LED illuminated if Power of the board is on (24 VAC) Light: During start up and learning Flashes if a fault is detected Blinking or light: microcontroller defect

1077710.wmf

Reference switch

Doors are closed.

1078565.wmf


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29.6

DIP-switches, drive 10 On

MIN

S1

SPEED

1

2

3

MAX

S1/1 S1/2 S1/3

4

ON

1 2 3 4

SP0

OFF ON OFF ON

SP1

OFF OFF ON ON

S1/4

Open force limiter in operation 24 V COL supply on

+24 V

S2 1 2

ON

S2/2 REOP OPEN BUTT.

Default settings

Speed selection, binary coded

OFL

S2/1

Off

Reopen IN “30” connected to GND EXT Open Button breaks contact to +24 V EXT

Open force limiter not in use

On Off Off

24 V COL supply off 1 second after commands removed in close end position Reopen IN “30” potential free

Off

Open Button makes contact to GND EXT

Off

On

1082264.wmf

NOTE: When expanded I/O board is used with D10, set S1/4 on.

29.7

LEDs, drive 2

45 X15 44 46

+24V

49 X16 47 48

+24V

38

X17 G X18

39 G

PC 1 IN GND

PC 2 IN GND

Protective device LEDs Name LED illuminated if PC.1 IN Photo Cell 1 not interrupted PC.2 IN Photo Cell 2 not interrupted M.SE.1 IN Mechanical Safety Edge 1 not pressed M.SE.2 IN Mechanical Safety Edge 2 not pressed

MSE 1 IN GND MSE 2 IN GND


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GND

17 16 10 30 31 X1 32 SD 14 41 27 GND

28 29 11 X2 9 13 40

EXT. CLOSE OPEN OPEN END REOP. IN REOP. NC REOP. NO SERV. DRIVE OPEN BUTT. PC. OUT LIMIT IN +24V EXT. EXT. SP 0 SP 1 NUD GING CLOSE END SE. OUT POS. OUT

LED LO (H23) OFF OFF ON ON

Lift interface LEDs Name CLOSE OPEN OPEN END REOPEN SERVICE DRIVE OPEN BUTTON PC OUT LIMIT IN +24V EXTERN SPEED 0 SPEED 1 NUDGING CLOSE END SE OUT POS. OUT

Voltage selection LEDs LED HI (H22) Line voltage selected OFF Line voltage selected = 400V range ON Line voltage selected = 230V range ON Line voltage selected = 115V range OFF Not used

Name 5 V POWER WATCH DOG STATUS 24 V POWER


LED illuminated if Close Command ON Open Command ON Door is in open end position Reopen NO contact closed Elevator Service Drive is active Open Button is pressed Beams of PC1 and PC2 are not interrupted Limited open command ON External +24 VDC available Speed level 0 is selected Speed level 1 is selected Nudging command on Door is in close end position Mechanical safety edges 1 and 2 are not obstructed Door open > 800 mm

Miscellaneous LEDs LED illuminated if Board powered (5 V) Blinking or light: µP-defect Light: During start up and learning Flashes if a fault is detected Power Supply for door protective devices is on

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29.8

DIP-switches, drive 2 Example

Switch S1/1

S1 ON

1

PC 1

S1/2

2

PC 2

3 4

MSE 1

5

SP 0 OFF ON OFFON

6

SP 1 OFFOFF ON ON

7

OFL

8

RAIL 1

SPEED MAX 1 2 3 4

S1/3

MIN

MSE2

P02000349.wmf

S1/4 S1/5 S1/6 S1/7 S1/8

Example S2 ON

1

REOP

2

OPEN BUTT.


Switch S2/1 S2/2

ON OFF Photo Cell 1 Photo Cell 1 enabled disabled Photo Cell 2 Photo Cell 2 enabled disabled Mechanical safety Mechanical safety edge 1 edge 1 disabled enabled Mechanical safety Mechanical safety edge 2 edge 2 disabled enabled Speed selection, binary coded, see the figure Open force limitation active Drive attached to railing 1 (ADV railing)

ON Reopen IN “30” connected to GND Open Button brake contact to +24V

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No open force limitation Drive attached to railing 2 CAUTION: Do not use this for railing 1. The railing and belt can be damaged.

OFF Reopen IN “30” potential free Open Button makes contact to GND

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29.9

Commissioning of curtain of light Step 1

Action 2D curtain of light: Check that the red LED in the receiver at about 1700 mm height is lit when the beams are obstructed. 3D curtain of light: Check that the red LED at about 1900 mm height in receiver is lit when the beams are obstructed or when the 3D sensor (in either receiver or transmitter edge) is detecting an obstruction. The red LED in transmitter will only be on when the 3D sensors of the transmitter edge are detecting an obstruction.

29.9.1

Note 2D/3D curtain of light: It is also possible to measure the signal line change from GND to 24V if any obstruction is detected. On the heavy duty operator beam obstruction is indicated by a green LED on the PC1 input (number 44).

Fault finding If LEDs are OFF, but doors do not close Step 1 2

3

Action Check cables and supply. Check that the signal output is not disconnected from the door operator or maintenance access panel. Check that the door operator or maintenance access is responding the signals by connecting the signal input to GND. The doors should close.


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Note

If the doors do not close the problem lies within the control system.

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If LED in receiver is ON but doors do not close Step 1 2 3 4

Action Note Check that the 24 V supply is present on the transmitter unit. Check that the curtain beams are not obstructed. Check that the filters are not dirty. Check that the distance between the units is not greater than the maximum specified.

If doors attempt to close and then re-open (3D curtain of light) Step 1

2

Action Note Check that the 3D sensors are not detecting any obstruction caused by: – landing doors during door closure – opposing slam or landing entrance – the installation bracket Observe the LEDs in transmitter and Both LEDs lit: problem in transmitter. Receiver LED lit: problem in receiver. receiver units during door closure to find out which side is causing problem. Transmitter problem: Turn switch 2 in the transmitter unit dip switch to OFF position to disable the 3D function. If the doors now close correctly, turn switch 2 to ON position and turn switch 1 to OFF position to reduce its 3D. Receiver problem: Turn switch 2 in the receiver unit dip switch to OFF position to disable the 3D function. If the doors now close correctly, turn switch 2 to ON position and turn switch 1 to OFF position to reduce its 3D.

If none of the previous possibilities resolves the problem, substitution of both units is necessary.


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30

FINAL STEPS AND ELEVATOR SHAFT CLEANING

Quality Requirements:

Final steps and elevator shaft cleaning – levelling accuracy checked – emergency battery drive function checked – complete installation cleaned and waste removed Guide rail lubrication – oil lubricators must be filled with the correct oil (supplied) – oil lubricators must be adjusted to ensure • correct contact with guide rail surfaces • correct oil flow distribution

!!! CAUTION - issues that affect reliability !!! Failure to perform shaft cleaning causes: – poor ride comfort as dirt contaminates the guide rail oil – smooth operation of doors is affected by dirt collecting on / in the sills / railings – possible slip and trip hazards Failure to lubricate the guide rails causes: – ride comfort issues (noise / vibration) – drive faults / failures – premature shoe liner wear

5S


Method tools needed: Safety barrier Hand tools needed: Tape measure, Phillips screwdriver, 2 x spanner (19 mm), brush, vacuum cleaner 5S Installation Progress Report Commissioning + testing completed QD-181.211 QD 7.1 and 8 completed


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30.1

Correction of parameter settings

Before driving on the car roof, change the parameter 1_71.

Step 1

30.2

Action Check the setting of the parameter 1_71. The setting of parameter 1_71 MUST BE 0. Otherwise the car drives too high on inspection drive. Inspection drive stops latest at the terminal floor level.

Note If the value of parameter 1_71 is something else than 0, change it to 0.

Checking the levelling accuracy Step 1 2

Action Drive in the car to each floor from both directions. Measure the difference between the car and landing sill levels at each landing.


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30.2.1

Adjustment of the levelling if necessary Step 1 2

3 4 5 6

30.3

Volume adjustment (audible feedback) Step 1 2

3

4 5

30.4

Action If levelling needs adjustment, drive to the topmost floor and go to the car roof. Check that the distance between the If this distance is correct, but the elevator 61:U and 61:N switches is 130 mm. is relevelling, adjust this distance to 125 mm and repeat the setup. This setting defines the normal stopping point. Drive on the car roof and correct the magnet positions. Leave the car roof and repeat setup if any adjustment was made. Re check the levelling accuracy by driving to each floor on normal drive. Repeat checking, if needed.

Action Note Select the main menu "7" at the User-Interface. Select the submenu for the volume 7_80 Button Buzzer Volume adjustment. 7_81 Button Buzzer Volume, Main Floor 7_82 Gong Volume 7_83 Gong Volume, Main Floor Adjust the parameter value of the The value range is from 0 (OFF) to 10 submenu with up and down keys of the (MAX). user interface. Press ACCEPT. Stores the new values. Switch the power off and on. This action transfer the new values to the signalisation devices.

Group locking function LMC function (Locking of Multiple Car calls) allows the locking of multiple car calls using the key switch(es) on the KSS car operating panel. The locking groups are configured using the car operating panel and User Interface. For more information refer to 812232.


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30.4.1

LMC configuration Step 1 2 3 4

5

6 7 8 9 30.4.2

Resetting the LMC configuration Step 1 2

3

30.5

Action Note Drive the car to the floor where the maintenance access panel is located. Turn the elevator to RDF. Set the LMC setup mode parameter Value 1: setting the locking group 1 Value 2: setting the locking group 2 (1_5) to 1 (or 2). Configure the locking group by pushing To remove the locked call from the the car call buttons. The collars of the locking group push the button again. The buttons light up. collar lights down. Store the locking group configuration by The value of the LMC setup mode pushing one of the door open buttons parameter (1_5) changes back to 0 on the car operating panel. automatically. Set the locking type parameter (1_45) to 1 or 3 to enable car calls locking. Switch the power OFF. Turn the RDF OFF. Switch the power ON and verify the locking operation.

Action Turn the elevator to RDF. Set the LMC setup mode parameter (1_5) to 100, 101 or 102 to reset the locking groups. Turn the RDF OFF.

Note Value 100: reset all the groups Value 101: reset only the first group Value 102: reset only the second group

Emergency lighting battery and KONE remote monitoring Step 1

2

Action Connect the emergency lighting battery plug “227 Battery” in the car roof electrification unit.

Note If the elevator main switch is switched off disconnect the emergency lighting battery temporarily to prevent unnecessary discharging. Note that landing calls do not operate when the battery is disconnected. Make settings for KONE remote monitoring (KRM) according to AM-13.25.007.


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30.6

Emergency battery drive (EBD-A) test Step 1

2 3 4

Action Note Enable EBD-A mode in maintenance access panel. Action Display Push MENU button until number 1 1 __ __ shows on the MENU display. Push ACCEPT button. Number 1 1 _1 __ shows on the SUBMENU display. Push ^ - button until number 87 shows 1 87 __ on the SUBMENU display. Push ACCEPT button once. A blinking 1 87 _0, where 0 is blinking number 0 shows on the VALUE display. Push ^ - button until number 1 shows 1 87 _1, where 1 is blinking on the VALUE display instead of 0. Push ACCEPT button to confirm the 1 87 _1, where all the numbers are selection, all the numbers are steady. steady Switch the power OFF. This action restores the setting. Switch the power ON. Run the elevator in normal mode. When the elevator is between floors, Do not switch OFF 220. switch OFF the main supply to the riser. After 10 seconds EBD-A should start to supply power to the control panel, the car should drive to the nearest floor level CAUTION: After the EBD-A has and the doors open. operated wait 20 minutes before After 4 seconds doors should be running the elevator. completely open and EBD-A switched This is to ensure a proper cooling of OFF. the internal components and to prevent possible failures.


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30.7

Testing the compensation chain Step 1

Action Test drive the elevator rapidly up and down. If the compensation chain hits the wall of the car or swings strongly during the drive. Reduce the dimension L slightly.

Note

1033259.wmf

30.8

Elevator shaft cleaning Step 1 2 3 4 5 6 7

Action Clean the headroom. Clean the brackets and guide rails. Clean the doors and landings. Clean the car roof. Clean the car interior. Clean the pit. Handle the waste (according to regulations.)


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31

SAFETY INSPECTION

Quality Requirements: Safety inspection – all safety systems checked – relevant documentation compiled and stored in the Site Project binder, copies sent to local KONE branch office • Safety inspection • Test Sheets • QD-181.211


5S


Method tools needed: Safety barrier Hand tools needed: Multimeter, insulation resistance meter, handheld tachometer, allen keys, Phillips screwdriver, tape measure, testweights,2 x spanner (19 mm), pencil 5S Installation Progress Report Commissioning + testing completed QD-181.211 QD 7.1 and 8 completed

31.1

Safety inspection Perform the safety inspection according to the drive type: Drive type KDL16S KDM40

Instruction AM-11.65.045, Machine-room-less Elevators with KDL16S Drive, Installing, Commissioning and Safety Inspection AM-11.65.042, KDM drive system for MonoSpace® and MonoSpace® Special: installation, commissioning and safety inspection

NOTE: Check that all safety gear marks are removed from the guide rails after safety inspection.


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32

MEASURING RIDE COMFORT Switch off the car fan and landing gong. Make DT-5 measurements in car during a quiet time, avoiding background construction noise. For more information on using DT-5 and RC troubleshooting instructions, see AM-01.05.014. In cases where IQE < 1 cannot be fulfilled despite following the troubleshooting instruction in AM-01.05.014 please contact global field support team.


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33

HANDOVER

33.1

Prerequisites Before the handover procedure can take place: – the safety inspection must have been completed and passed – the QD-181.211 (Installation Quality Document ) must have been completed and available The safety inspection also covers issues described in EN81 Annex D, which gives mandatory actions from a code point of view, where EN regulations apply. It is also important to verify that some of the issues in the handover form have already been checked during the safety inspection.

33.2

QD-181.212, Quality control in installation – maintenance handover for KONE MonoSpace elevators In the QD-181.212 there is a list of items that are assessed during the handover procedure. Local practices determine whether it is necessary to specifically examine all the different points on the list. However, both the installation and maintenance representatives must be positive that the items listed are in an acceptable condition. The purpose of the form is that its subscribers know that the installation meets KONE quality standards.


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34

FAULT FINDING Refer to APPENDIX for LCE fault codes and for drive fault codes.

34.1

Fault finding procedure If the elevator does not run correctly follow this procedure. Step 1 2 3 4

34.1.1

Action Note Check the normal run. Investigate the LEDs in the user Refer to the table on page 345. interface. Check the fault in drive system. Perform the setup drive. (Set the elevator to setup mode, refer to page 327.) Check the load weighing set up and balancing.

Operation of the elevator during the setup drive Step Action / Function 1 Start the setup drive. 2 Elevator starts to move upwards.

3

Elevator makes a setup drive.

4

Setup is ready if the floor counting is correct.


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Note If elevator does not start to move upwards check the position of the car and status of magnetic switches. If elevator does not make the setup drive check the polarity of encoder and motor. Check the motor parameters. If the floor counting is not correct, magnetic stripes are in the wrong position or too close to the switches.

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34.2

Normal run The following table shows the LED sequence when the elevator is working properly. LEDs 9 SPEED> 0.1 m/s 8 START PERMIT

7 MAIN CONTACTOR

Explanation Speed of the elevator is more than 0.1 m/s. Indicates that both main contactors (pos. 201:1 and 201:2) and both auxiliary main contactors (pos. 201:3 and 201:4) have released after previous drive. If the LED stays active after drive, either of the contactors is stuck open and further drives are not possible. Indicates that both drive and LCECPU control have given main contactor activation command.

6 SHAFT DOOR CONTACT

Indicates that all landing doors are closed.

5 CAR DOOR CONTACT

Indicates that car doors are closed.

4 CLOSE DOOR COMMAND

Indicates that LCE gives Close Door command.

3 DRIVE NEED

Indicates that the controller has recognised a need for drive. This can be a given call or specially given command for parking drive, fireman’s operation etc.

2 V3F OK

Communication between the drive unit and CPU is OK.

1 SAFETY INPUT

Indicates that safety circuit is OK.


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Note

LED is off when both main contactors and both auxiliary main contactors are released and start permit input on XD1/3 connector (LCEADO pos. 379) is 0 V. Main relay triac on LCEADO (pos. 379) should open and both main contactors should energise. Input XH2/3 SHAFT DOOR CONTACT (pos. 379 LCEADO) has voltage. Input X1/7 CAR DOOR CONTACT (pos. 379 LCEADO). Command is active during the drive, and it disappears after the doors are closed and the elevator is not active, i.e. there are no active calls. If the LED does not light when a call from car operating panel or landing button is given, either the button is faulty, the connection between button and controller is faulty or controller is faulty. Switch the power OFF for 10 seconds and try again. Check the parameter 1_95. Input X1/5 ‘STOP CONTACT’ (pos. 379 LCEADO) has voltage.

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34.3

Faults in drive system

34.3.1

Checks Make the following checks before the drive can be operated. Step Action 1 Check the motor parameters. 2 3 4

34.3.2

Note The motor parameters should be according to the motor type. Check that motor, brake, encoder, resolver and thermistors are connected. Check the connections to the main circuit board. Check the travelling cable connections.

Drive control After the MODE command is given, drive performs the following supervisions: 1. 2. 3. 4. 5.

34.3.3

DC Link voltage must be over 400 VDC. The braking resistor must be connected. The thermistor must be connected. The resistance of the NTC sensor must be >1500 ohm. Current sensor must not give overcurrent information.

Start, up or down If the supervisions are OK, the MAIN CONTACTOR ENABLE signal is sent to LCE: 1. MBE signal. IGBT will be activated. 2. Brake command. Brake opens. 3. Speed signal. Speed is dependant on type of MODE command.

34.3.4

Crash stopping of the drive Faults for crash stopping of the drive may be the following: 1. 2. 3. 4.

Missing or incorrect encoder signal. Check from the LCE. Wrong polarities of motor or encoder. LED should be lit in down direction. Wrong parameters. Set the default parameter values. Supervisions, as described before.


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35

APPROVALS AND VERSION HISTORY Compiled by:

Information Product Author / Tiina Halonen

Checked by:

Global Installation Support / Richard Baker

Approved by:

Global Installation Support / Hakan Barneman

Issue Date Description of Change Ref CR Approved by 2012-05-28 First issue. Hakan Barneman A 2012-10-16 Issue for piloting. For changes see Hakan Barneman change bars. B 2013-03-18 Updated. For changes see change bars. Hakan Barneman


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36

FEEDBACK Click one of the star buttons in the PDF version to rate the document and report errors or suggest improvements. This opens your default e-mail client. Users of printed documents can send feedback directly to [email protected]. Excellent

Good

Average

Acceptable

Insufficient


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APPENDIX A. KDL DRIVE RELATED ISSUES A.1

Returning the initial settings, KDL16S This is recommended when you do not know the status of the settings of the DCBL board. Step 1 2 3

A.2

Action Set Parameter lock (6_95) parameter to 0. Set Default parameters (6_98) parameter to 1. Wait at least 15 seconds.

Note

Value changes automatically back to 0.

How to use Real time display function This chapter is a general instruction describing how to activate and use Real time display function. The Real time display function is a build in feature which measures / shows the different drive module signals on the LCE user interface. The RealTimeDisplay monitor selection (6_75) parameter activates a function that enables for example: observing of the elevator speed, direction of the car movement, position of the car and motor current in real time. For more details see drive parameter list 972483D01. Step 1 2 3 4

5

Action Note Select RealTimeDisplay monitor selection (6_75). Select any of the elevator functions that See parameter list. you want to see (1...209). Return to floor display by pressing the Menu-button. Activate the Real time display by pressing Select/Accept-button. You can now use Select/Accept-button to change display to show floor, real time or speed display. De-activate the Real time display by Press Menu-button. returning to floor display.


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A.3

Reading detailed fault codes The sub fault codes of the drive are describing the faults in detail. The numbering of the sub fault codes is divided to the following categories: – – – –

1000-series, the elevator is locked (driving is prevented). 2000-series, driving of the elevator is stopped by a machine brake. 3000-series, warnings indicated in advance (before a device or equipment break down). 6000-series, diagnostic information. All sub codes in this category DO NOT indicate a fault. They are for getting additional information.

How to read the sub fault codes

This example describes how to read sub codes 118_6010 and 118_6011. 1. Enter error log. 1.

SELECT 2. ACCEPT

2. Push ACCEPT  (a row of figures starts to scroll).

118 Shaft Setup 118

2021

Setup started at wrong position

2023

Setup stopped because 77:U/N active at same time

6010

Reports minimum 61:U/N overlap

floor

overlap mm

1021405


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f

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APPENDIX B. BALANCING FACTORS AND LOADS Some elevators use adaptive balancing where the balancing load is less than the traditional 50% of rated load. The balancing load varies depending on speed, rated load and travel. The weight difference must be compensated with the balancing (6_10) parameter of the drive, load weighing device GAIN value and using a matching balancing test load during commissioning. To determine whether an elevator uses adaptive balancing, see the layout drawings (car balancing factor %). If an elevator with adaptive balancing is already in operation, the MAP has a sticker that states the car balancing factor. For more information on the car balancing factors and loads used with adaptive balancing, see the layout drawings and following tables.

xx% 40 41 42 43 44 45 MENU

SELECT

xx%

46 47

ACCEPT

48

6_10=xx NOTE:

49 50

1073186.wmf

Figure B1.

Adaptive balancing in layout drawings (left) and sticker in MAP (right)


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B.1

Car balancing factors [balancing (6_10) parameter values] The tables below list the car balancing factors for backup purposes. If available, always check the car balancing factor from the layout drawings. Table 2: Car balancing factors for speed 1.0 m/s (Q = rated load)

Q [kg] / Travel [m]

0 ...5,0

5,001 ...10,0

10,001 ...15,0

15,001 ...20,0

20,001 ...25,0

25,001 ...30,0

30,001 ...35,0

35,001 ...40,0

40,001 ...45,0

45,001 ...50,0

50,001 ...55,0

240

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

320

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

400

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

450

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

480

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

630

40,0 %

42,1 %

44,3 %

46,5 %

48,1 %

49,2 %

42,5 %

43,2 %

43,8 %

44,5 %

45,1 %

680

43,8 %

45,8 %

47,7 %

48,7 %

49,7 %

44,1 %

44,5 %

44,9 %

45,3 %

45,7 %

46,1 %

800

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

900

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,6 %

40,0 %

40,0 %

40,0 %

1000

40,0 %

40,0 %

40,0 %

41,0 %

42,6 %

44,3 %

40,0 %

40,0 %

40,0 %

40,0 %

40,1 %

1150

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %


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Table 3: Car balancing factors for speed 1.6 m/s (Q = rated load) Q [kg] / Travel [m]

0 ...5,0

5,001 ...10,0

10,001 ...15,0

15,001 ...20,0

20,001 ...25,0

25,001 ...30,0

30,001 ...35,0

35,001 ...40,0

240

n/a

n/a

n/a

n/a

n/a

n/a

n/a

n/a

320

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

400

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

450

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

480

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

630

41,6 %

41,6 %

41,7 %

41,8 %

41,9 %

43,1 %

42,3 %

42,5 %

680

45,9 %

46,0 %

46,1 %

46,3 %

46,4 %

46,5 %

46,6 %

46,7 %

800

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

900

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

1000

41,7 %

41,8 %

41,8 %

42,0 %

42,1 %

42,1 %

42,2 %

42,3 %

1150

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

Q [kg] / Travel [m]

40,001 ...45,0

45,001 ...50,0

50,001 ...55,0

55,001 ...60,0

60,001 ...65,0

65,001 ...70,0

70,001 ...75,0

240

n/a

n/a

n/a

n/a

n/a

n/a

n/a

320

40,0 %

40,0 %

40,0 %

40,0 %

41,0 %

44,7 %

47,7 %

400

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

450

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

480

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

630

42,6 %

42,7 %

42,8 %

43,0 %

43,1 %

43,2 %

43,4 %

680

46,9 %

47,0 %

47,1 %

47,2 %

47,3 %

47,4 %

47,5 %

800

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

900

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

1000

42,4 %

42,5 %

42,6 %

44,3 %

44,9 %

45,5 %

46,0 %

1150

40,0 %

40,0 %

40,0 %

40,0 %

40,1 %

40,1 %

40,2 %


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Table 4: Car balancing factors for speed 1.75 m/s (Q = rated load) Q [kg] / Travel [m]

0 ...5,0

5,001 ...10,0

10,001 ...15,0

15,001 ...20,0

20,001 ...25,0

25,001 ...30,0

30,001 ...35,0

35,001 ...40,0

240

n/a

n/a

n/a

n/a

n/a

n/a

n/a

n/a

320

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

400

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

450

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

480

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

630

43,0 %

43,1 %

43,2 %

43,3 %

43,4 %

43,7 %

43,8 %

43,9 %

680

47,3 %

47,3 %

47,4 %

47,7 %

47,8 %

47,9 %

48,0 %

48,1 %

800

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

900

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

1000

43,1 %

43,1 %

43,2 %

43,3 %

43,4 %

43,5 %

43,6 %

43,7 %

1150

40,6 %

40,6 %

40,7 %

40,8 %

40,9 %

40,9 %

41,0 %

41,1 %

Q [kg] / Travel [m]

40,001 ...45,0

45,001 ...50,0

50,001 ...55,0

55,001 ...60,0

60,001 ...65,0

65,001 ...70,0

70,001 ...75,0

240

n/a

n/a

n/a

n/a

n/a

n/a

n/a

320

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

400

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

450

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

480

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

630

44,0 %

44,2 %

44,3 %

44,4 %

44,5 %

44,7 %

44,9 %

680

48,2 %

48,3 %

48,3 %

48,4 %

48,4 %

48,5 %

48,6 %

800

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

900

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

40,0 %

1000

43,8 %

43,9 %

44,0 %

44,1 %

44,2 %

44,3 %

44,4 %

1150

41,2 %

41,2 %

41,3 %

41,4 %

41,5 %

41,5 %

41,6 %


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B.2

Balancing loads The following tables list the balancing loads (rounded to nearest 25 kg) you place in the elevator car for testing the car and counterweight balancing. Table 5: Balancing loads for speed 1.0 m/s (Q = rated speed)

Q [kg] / Travel [m]

0 ...5,0

5,001 ...10,0

10,001 ...15,0

15,001 ...20,0

20,001 ...25,0

25,001 ...30,0

30,001 ...35,0

35,001 ...40,0

40,001 ...45,0

45,001 ...50,0

50,001 ...55,0

240

100

100

100

100

100

100

100

100

100

100

100

320

125

125

125

125

125

125

125

125

125

125

125

400

150

150

150

150

150

150

150

150

150

150

150

450

175

175

175

175

175

175

175

175

175

175

175

480

200

200

200

200

200

200

200

200

200

200

200

630

250

275

275

300

300

300

275

275

275

275

275

680

300

300

325

325

350

300

300

300

300

300

325

800

325

325

325

325

325

325

325

325

325

325

325

900

350

350

350

350

350

350

350

375

350

350

350

1000

400

400

400

400

425

450

400

400

400

400

400

1150

450

450

450

450

450

450

450

450

450

450

450


332 (376)

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Table 6: Balancing loads for speed 1.6 m/s (Q = rated speed) Q [kg] / Travel [m]

0 ...5,0

5,001 ...10,0

10,001 ...15,0

15,001 ...20,0

20,001 ...25,0

25,001 ...30,0

30,001 ...35,0

35,001 ...40,0

240

n/a

n/a

n/a

n/a

n/a

n/a

n/a

n/a

320

125

125

125

125

125

125

125

125

400

150

150

150

150

150

150

150

150

450

175

175

175

175

175

175

175

175

480

200

200

200

200

200

200

200

200

630

250

250

275

275

275

275

275

275

680

300

325

325

325

325

325

325

325

800

325

325

325

325

325

325

325

325

900

350

350

350

350

350

350

350

350

1000

425

425

425

425

425

425

425

425

1150

450

450

450

450

450

450

450

450

Q [kg] / Travel [m]

40,001 ...45,0

45,001 ...50,0

50,001 ...55,0

55,001 ...60,0

60,001 ...65,0

65,001 ...70,0

70,001 ...75,0

240

n/a

n/a

n/a

n/a

n/a

n/a

n/a

320

125

125

125

125

125

150

150

400

150

150

150

150

150

150

150

450

175

175

175

175

175

175

175

480

200

200

200

200

200

200

200

630

275

275

275

275

275

275

275

680

325

325

325

325

325

325

325

800

325

325

325

325

325

325

325

900

350

350

350

350

350

350

350

1000

425

425

425

450

450

450

450

1150

450

450

450

450

450

450

450


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Table 7: Balancing loads for speed 1.75 m/s (Q = rated speed) Q [kg] / Travel [m]

0 ...5,0

5,001 ...10,0

10,001 ...15,0

15,001 ...20,0

20,001 ...25,0

25,001 ...30,0

30,001 ...35,0

35,001 ...40,0

240

n/a

n/a

n/a

n/a

n/a

n/a

n/a

n/a

320

125

125

125

125

125

125

125

125

400

150

150

150

150

150

150

150

150

450

175

175

175

175

175

175

175

175

480

200

200

200

200

200

200

200

200

630

275

275

275

275

275

275

275

275

680

325

325

325

325

325

325

325

325

800

325

325

325

325

325

325

325

325

900

350

350

350

350

350

350

350

350

1000

425

425

425

425

425

425

425

425

1150

475

475

475

475

475

475

475

475

Q [kg] / Travel [m]

40,001 ...45,0

45,001 ...50,0

50,001 ...55,0

55,001 ...60,0

60,001 ...65,0

65,001 ...70,0

70,001 ...75,0

240

n/a

n/a

n/a

n/a

n/a

n/a

n/a

320

125

125

125

125

125

125

125

400

150

150

150

150

150

150

150

450

175

175

175

175

175

175

175

480

200

200

200

200

200

200

200

630

275

275

275

275

275

275

275

680

325

325

325

325

325

325

325

800

325

325

325

325

325

325

325

900

350

350

350

350

350

350

350

1000

450

450

450

450

450

450

450

1150

475

475

475

475

475

475

475


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APPENDIX C. ELECTRIFICATION PANELS, INTRODUCTION C.1

KDL16S drive module (KM51004000V001, V002)

3

4

1

5

D1 2

1076282.wmf

Pos 1 2 3 4 5

Name Slide deck Bottom cover plate Braking resistor assembly Module fan, 2 pcs Contactor board (CO16)

LED DANGER (D1)


Number

Colour Red

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Status ON

KM50014767 KM964619G24 Indication meaning DC-link is charged.

AM-01.01.250 (B) 2013-03-18


C.2

KDM drive module KR6 / KR7

1

2 3 4 5 1066396.wmf

1 2 3 4 5

Fan I/O board Power supply cable connecting points Earthing clamps PE grounding terminals


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Safe de-energizing method

– Check that the yellow DANGER led is lit. – Disconnect and prevent reconnection of the possible emergency power supplies. – Switch OFF the main switch (220). Lock and tag. – Wait for 5 minutes. – Check that the yellow DANGER led is NOT lit. – Open the cover. Check that there is no voltage (AC) in power supply terminals L1-L2, L1-L3, L2-L3, L1-ground, L2-ground, L3-ground. – Check that there is no voltage (DC) in the intermediate circuit between terminals DC+ and DC-.

L1

L2

L3

U

V

W

DC+


1067199.wmf

L1

DC-

1067127.wmf


> 50 VDC

L2

L3

U

V

W

DC+

DC-

1067126.wmf

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C.3

KDA module

5 4 7

3

6

2

1

1077160.wmf

1 2 3 4 5 6 7

Motion control board (DCBG) Circuit breaker (298) Terminal blocks (PE) Main contactor (201:1) Motor fan control (K219) Main contact control board (MCCB2) Brake control module (BCX08)


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C.4

Panels in the elevator shaft (KDM)

1

7

8

1 7 8

KR6/KR7 drive module KDA module (slim) SEP


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C.5

Shaft electrification panel (SEP) 1. Transformer module 2. LCEREC board 3. LCECPU board 4. LCECAN board 5. LCEKNX or LCEVOI board 6. LCEADO board 7. LCEOPT board 8. LCERAL board 9. LCEGTW board 10. LCEDOMCS board 11. Cover 12. Contactor module

1

2 3, 4, 5

12

6 7 8 9 10 7

11


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1075340.wmf

AM-01.01.250 (B) 2013-03-18


C.6

Maintenance access panel (MAP, door type) 1. Light 2. Maintenance intercom / firemen’s drive (option) 3. Brake release lever 4. LOPCB board 5. Socket (274) 6. Run button (270:RB) 7. RDF switch (270) 8. Car light fuse (290:1) 9. Residual current circuit breaker (236) 10. Shaft light fuse (290:2) 11. Impulse relay (268) 12. Main switch (220:2) 13. Lighting switch (262) 14. LOP230 board

5 6 7 8 9 1

10 11

2 12 13

3 14

4

1078973.wmf


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C.7

Maintenance access panel (MAP, wall type) 1. Light 2. Brake release cam 3. User interface board 4. LOP-230 board 5. RUN button 270:RB 6. RDF switch 270 7. Socket 274 8. Lift well light fuse 290:2 9. Car light fuse 290:1 10. Lighting switch 262 11. Main switch 220 12. Terminal blocks PE 13. ISE option (emergency interphone) 14. BDT option (battery drive tool) 15. ISM or FRD UK option (maintenance intercom/firemen’s drive)


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C.8

User interface The buttons and display in the user interface

XL8

XL1

1

OSG TEST

2 3 4 5 6

XL9

S14

LOP-CB 763603H01

1. User interface 2. Overspeed governor test button 3. Menu display 4. Sub menu display 5. Value display 6. Value setting button 7. Menu button 8. Select/Accept button 9. Up call button 10. Down call button 11. Car call button 12. Inhibit door opening switch 13. Inhibit landing calls switch 14. RS232 mode, always keep the switch in left position 15. RDF up button 16. RDF down button 17. OFFSET 18. GAIN

D22

D26

D25

D24

D23

UP CALL S8

MENU

7 8

S6

SELECT

S10

S5

ACCEPT

S9

CAR CALL S4

S7

DOWN CALL

9 10 11 12 13 14 15

S13 S12 RS232 MODE

SPEED

RDF UP

S11 LOPCB TEST

>0.6 m/s S2 -0 m/s

RDF DW

16

S1 OFFSET R127

>0.6 m/s

TP4 TP3

LWD TP6

SPEED MEASUREMENTS GAIN R146

TP5

17

MOTOR CURRENT TP2

TP1

18 XL2

XL3

XL4

XL5

XL6 1007529.wmf


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Use of the buttons in the user interface

Pos. 7

Button MENU

8

SELECT / ACCEPT

6 11

Arrow buttons CAR CALL

9 10 15 16

UP CALL DOWN CALL RDF UP RDF DW Pos.

Action Push MENU button to select the menu. Refer to the LCE parameter table. Push SELECT / ACCEPT button to select the sub menu. Refer to the LCE parameter table. When MENU display is blank, you can choose the required floor number using arrow buttons and push CAR CALL. You can give landing calls up and down by pushing UP CALL or DOWN CALL. Recall drive up. Recall drive down.

2

Switch INHIBIT DOOR OPENING INHIBIT LANDING CALL OSG TEST

14

RS232

Use this switch to make the overspeed governor test and to release the overspeed governor after testing. Keep this switch always in the left position.

Potentiometers GAIN OFFSET

Description These potentiometers are used to set the load weighing device.

12 13

Pos. 18 17

Measuring point LWD TP5 TP6 Speed TP3 + measurements TP4 Motor current TP1 + TP2 -


Action Use these switches to inhibit door opening and landing calls during test drives to avoid interruption of the test or trapping of passengers.

Polarity

Description

Gain Offset Tachometer voltage

Not used.

Motor current

Use these measuring points for measuring the motor current.

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Use these measuring points for speed measurements.

AM-01.01.250 (B) 2013-03-18


LEDs in the user interface board

LED +24V +5V +12V -12V LCECPUnc RUNNING LIFT IN FAULT EMERGENCY ALARM INSPECTION

Function when LED is ON + 24 V DC control voltage is OK. + 5 V DC control voltage is OK. + 12 V DC control voltage is OK. - 12 V DC control voltage is OK. Indicates that CPU and SW are working. Fault prevents the car driving. Emergency alarm push button pushed in car. Inspection drive from car roof is ON (42:DS).


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Normal status ON ON ON ON Blinking

Colour GREEN GREEN GREEN GREEN YELLOW

OFF OFF

RED RED

OFF

YELLOW

AM-01.01.250 (B) 2013-03-18


LED RESCUE DRIVE CAR COMM OK HOISTWAY COMM. OK +24V CAR&SHAFT OK SPEED > 0.1m/s

START PERMIT

MAIN CONTACTOR SHAFT DOOR CONTACT CAR DOOR CONTACT CLOSE DOOR COMMAND DRIVE NEED V3F OK SAFETY INPUT DRIVE UP 77:U 61:U 30 B30 61:N 77:N 77:S DRIVE DOWN OPEN DOOR COMMAND

Function when LED is ON

Normal status OFF

YELLOW

ON ON

GREEN GREEN

+ 24 V DC car and lift well voltage is OK.

ON

GREEN

The LED is ON when the speed goes over 0.1 m/s while accelerating and goes OFF when the speed goes under 0.3 m/s while decelerating. One of the main contactors (201:1, 201:2) or the dynamic brake contactor (204) has not been released. Input XD1/3 on board 379. LCECPU has given main contactor activation command. Lift well doors are closed. Input XH2/3 on board pos. 379 has voltage. Car doors are closed. Input XC1/7 on board pos. 379 has voltage. Close the door command is given.

ON/OFF

YELLOW

ON/OFF

YELLOW

ON/OFF

YELLOW

ON/OFF

YELLOW

ON/OFF

YELLOW

ON/OFF

YELLOW

Need for driving recognised. Drive unit is able to drive. Safety chain input XC1/5 on board pos. 379 is powered. Drive up command is given to the drive unit. Car is at top floor deceleration area. Car is at about +10 mm... -140 mm from floor level. Car is at door zone of front door. Car is at rear door zone. Car is at about -10 mm... +140 mm from floor level. Car is at bottom floor deceleration area. Car is at terminal floor area. Drive down command is given to the drive unit. Open door command is given.

ON/OFF ON ON

YELLOW GREEN GREEN

ON/OFF ON/OFF ON/OFF

YELLOW YELLOW YELLOW





ON/OFF

YELLOW

Rescue drive from MAP is ON (270). Input XM11/2 on LCECPU pos. 375. Car communication network is working. Lift well communication network is working.


346 (376)

Colour

AM-01.01.250 (B) 2013-03-18


LED PHOTOCELL

OPEN BUTTON

CLOSE FORCE LIMITER DOOR ZONE INDICATOR INHIBIT DOOR OPENING INHIBIT LANDING CALLS SPEED >0.6m/s (D68) SPEED >0.3m/s (D67) SPEED >0.02m/s (D66) SPEED >0.02m/s (D65) SPEED >0.3m/s (D64) SPEED >0.6m/s (D63)

Function when LED is ON

Normal status OFF

YELLOW

OFF

YELLOW

OFF

YELLOW

ON/OFF

GREEN

OFF

YELLOW

OFF

YELLOW

ON/OFF

RED

Car speed more than 0.3 m/s, up direction.

ON/OFF

GREEN

Car speed more than 0.02 m/s, up direction.

ON/OFF

GREEN

Car speed more than 0.02 m/s, down direction. Car speed more than 0.3 m/s, down direction. Car speed more than 0.6 m/s, down direction.

ON/OFF

GREEN

ON/OFF

GREEN

ON/OFF

RED

Photocell LED is ON when there is something between doors. Inputs XB29/2 and XB31/2 on board LCECCB pos. 806. Door open button LED is ON when button is pressed. Input XC10/1 on board LCECOB pos. 32. Door closing force limiter is active. Inputs XB28/8 and XB30/8 on board LCECCB pos. 806. Car is at door zone. Signal is present even if the power supply is switched off. Door opening is inhibited with the switch beside this LED. Landing calls are inhibited with the switch beside this LED. Car speed more than 0.6 m/s, up direction.


347 (376)

Colour

AM-01.01.250 (B) 2013-03-18


C.9

Fuses and LEDs on LOP-230 board Fuse F1 Safety chain 230 V F2 Safety chain, brake and fan supplies F3 Door supply


Size/type 1 A/T (5x20 mm) 6.3 A/T (5x20 mm)

F2 OK

ON

2 A/T (5x20 mm)

F3 OK

ON

348 (376)

LED

Normal

AM-01.01.250 (B) 2013-03-18


C.10

Fuses on LCEREC board Fuse F4 Car and shaft 24 V F5 Control voltage 24 V F6 & F7 Short circuit protection of transformer F8 24 V Car and shaft (optional if > 10 floors)


349 (376)

Size/type 4 A multi fuse 4 A multi fuse 6 A/500 V (10x38 mm) 8 A multi fuse

AM-01.01.250 (B) 2013-03-18


APPENDIX D. ELEVATOR SHAFT WIRING WITH TRUNKING D.1

Trunking and shaft lighting

NOTE: For optimal lighting install the light units to horizontal position (if possible) with the lamps pointing downwards. Install the lowest light unit to vertical position.

max 0.5m

1. Install the trunking and elevator shaft lighting.  CAUTION: Check the clearance from the end of the car pulley to the wall. Install the lights in vertical position if there is a risk of colliding. 2. Drill holes for signalling cable and door lock cable fixings at each landing. open trunking cable entries.

6m

6m

0.5m

1076609.wmf


350 (376)

max. 0.5m

6m

m 0m 5 <2

AM-01.01.250 (B) 2013-03-18


D.2

Installing shaft bundles 1. Install the safety chain and signalling shaft bundles. Keep the safety chain shaft bundles behind the plastic protections of the floor control boards. Secure with the cable ties. 2. Connect the safety chain wires to MA113 P and signalization and alarm bell cables to SEP. 3. Counterweight OSG: Connect the adapter cable to XLH6. 4. Route and connect the landing door lock cables and signalling cables. Leave minimum 100 mm free cable ends at the landing side. 5. Through type elevator: Check jumper X1 position. Left (A) = front side door, right (B) = rear side door.

P122 XLH4 XLH7 XH11 XH12

A

X1 Cable Landing door contact (P122) / landing door lock contact Tension weight contact / stop switch in the pit Alarm bell cable Floor control board cable (LCEFCB)


351 (376)

B 1076606.wmf

To SEP / LOP230 / XLH7 SEP / LOP230 / XLH4 MAP / LCECPU / XH11 MAP / LCECPU / XH12

AM-01.01.250 (B) 2013-03-18


D.3

Installing pit electrification

WARNING: Check that the car is safely locked off and can not move.

XS2

0.6 m

1. Install the lowest shaft lighting unit, lighting switch, pit stop switch and intercom socket. 2. Connect the pit cables (OSG tension weight contact, pit stop switch, shaft lighting, intercom socket, oil buffer contacts (if any) and any additional pit devices). 3. Check that an end connector is connected to the XS2 in the lowest board.

1076671.wmf


352 (376)

AM-01.01.250 (B) 2013-03-18


APPENDIX E. Plumbing jig

E.1

Assembling plumbing jig and hanging the plumb lines Note Ensure that you install the supports in the correct way.

Front door

1500

Step Action 1 Install the plumbing jig supports and telescopic pipes at a min. height of 1500 mm above the topmost landing floor level. Frame door

1007130.wmf

1007131.wmf

WARNING: Do not lean into the elevator shaft or against the safety protection bars.

1007133.wmf

1007132.wmf

1007134.wmf 1007135.wmf


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Step Action 2 Assemble the plumbing jig.

Note

2

1

3

6

4

7

5 YY:

40+DBG+40

50

50

DBG

40

40 LL

X

40 1080398.wmf


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Step Action 3 Place the jig onto the supports.

Note

1009604 wmf

4

Adjust the jig according to the top landing entrance.

5

Lower the plumbing lines.

1009605 wmf

LL

1007139.wmf


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E.2

Aligning the guide rails Step Action 1 Clamp the plumbing gauges onto the guide rails.

Note

Parallelity and DBG direction is adjusted at the guide rail brackets. The guide rail is aligned when: • The plumb wire is touching the pointer on the alignment tool. • The parallelity string line wire aligns with the holes in the alignment tool. • DBG is within the stated tolerance +1mm - 0 mm at the clip level. 1009675.wmf

2

Place the counterweight guide rail positioning tool on the nose of the single car guide rail. Keeping this point, still move the side at the single counterweight guide rail up and down to position the guide rail.

Do not use the positioning tool to force the guide rail into position. This will damage the tool. There should be no tight spot when moving the positioning tool up and down nor too big a gap.

1007162.wmf

1007163.wmf


356 (376)

AM-01.01.250 (B) 2013-03-18


APPENDIX F. ENERGY EFFICIENCY CLASS A The VDI 4707 classification standard defines seven energy efficiency classes. The classes are labelled with the letters from A to G. The highest rating is class A. To reach the class A on the elevator with KDL16 drive, perform the steps in this appendix. Under customer request the energy efficiency rating may be indicated with a sticker on a car operating panel.

For more information on drive 10 car door operator see AM-03.35.027 Electrical installation, commissioning, troubleshooting instruction, AMD drive 10 car door operator. For more information on BMV option see AM-11.65.038 ECB-1 single line ReGenerative unit.

F.1

Stand By Mode option (SBM-F) After 5 minutes from the last run: – control panel and drive are set to energy saving mode. – signalization displays are dimmed. – power to door operator and curtain of light is cut off. Step 1

2

Action Note Set following LCE parameters: OSI / HSL selection (1_96) parameter to 4. OCL selection (1_98) parameter to 0. Car fan saving (1_75) parameter to 4. Car light saving (1_76) parameter to 4. Switch the power OFF. This action saves the parameter Wait at least 15 seconds. settings. Switch the power ON.


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Step 3

Action Note Route and connect the cable (50002012) from SEP panel to the topmost floor control board (LCEFCB).

K4/A1 K4/A2 LCEFCB XF4

XF4

1073853.wmf

4 5 6

F.2

Set Standby mode (6_12) parameter to 1. Set Save (6_99) parameter to 1. Switch the power OFF. Wait at least 15 seconds. Switch the power ON.

This drive parameter activates drive standby mode. Value returns automatically to 0. This action saves the parameter settings.

Standby mode of LOPCB board Standby mode must be deactivated when the elevator is in inspection drive. Standby mode must be activated when the elevator is in normal drive. Step 1

Action Inspection drive: Connect XL1 plugs.

2

Normal drive: Disconnect XL1 plugs.

Note

XL1

LOPCB/XL1

XL1

LOPCB/XL1


LCECPU/XL1

358 (376)

LCECPU/XL1

AM-01.01.250 (B) 2013-03-18


APPENDIX G. CEILING TYPES G.1

Ceiling interface for one panel ceiling (DD = 650 … 1180 mm)

DD-56

DD 650...1180

147

BB-4


359 (376)

1077345.wmf

AM-01.01.250 (B) 2013-03-18


G.2

Ceiling interface for two panel ceiling (DD = 1181 … 2310 mm)

DD-56

DD 1181...2310

147

BB-4


360 (376)

1077346.wmf

AM-01.01.250 (B) 2013-03-18


G.3

Ceiling interface for three panel ceiling (DD = 2311 … 3440 mm)

DD-56

DD 2311...3440

147

BB-4


361 (376)

1077347.wmf

AM-01.01.250 (B) 2013-03-18


G.4

Ceiling interface for four panel ceiling (DD = 3441 … 3500 mm)

DD-56

DD 3441...3500

147

BB-4


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APPENDIX H. INSTALLING CAR FLOOR, BB 1600 X DD 1400

NOTE: Because of the different orientation at the packaging, the BB 1600 mm x DD 1400 mm size floor can not be installed using the standard method.

WARNING: Do not remove the lifting equipment or step onto the floor before securing the floor to the sling. 1. Install the transport wheels to the A side of the car floor while unpacking. 2. Use a chain to keep platform close to the package when lifting to upright position. 3. Transport the car floor close to the shaft entrance.

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4. Fix M12 eyebolts (4 pcs) to the front and rear edges of the car floor. 5. Fit upper fixing bolts to both sides of the car floor. The bolts guide the floor to the correct position. 6. Attach the parking chain and the shortenable chain between the man riding hoist and the eyebolts on the C side. 7. Attach manual chain hoist and 2 x 0.5 m chain between the parking chain loop and the eyebolts on the A side.

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8. Hoist the car floor to the shaft. 9. Use manual chain hoist to rotate the floor to horizontal plane. 10. Use man riding hoist to lower the floor to the bottom beam. 11. Continue installation using the standard method. For more information see section 8.5 Installing car floor.

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APPENDIX I. DELIVERY ABOVE LOWEST FLOOR I.1

Lowering material down to pit

NOTE: The method described below must be used for components which are too large to be manually carried down the stairs. 1. Do NOT continue without agreement / permission from the building owner / representative as the work area to be closed to others may be a fire escape route. Liaise with building owner / representative to agree plan of works. This will ensure the building owner / representative can plan alternative routes if required. 2. Ensure that other building users are protected from fall hazards. Close the work area by: • restricting access to landing • providing barriers around immediate work area. Ensure that any personnel at lower landing are standing clear from the landing entrance.

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3. Transport component in front of landing entrance protection barrier ready for hoisting. 4. Pull hoisting chain(s) onto landing and secure to component. WARNING: Do NOT reach over the barrier. Use a suitable timber piece or equivalent to reach the chain(s). 5. Use a work restraint system. For more information, see AM-01.03.001. 6. Remove entrance protection barrier and hoist the component into the shaft. 7. Replace entrance protection barrier immediately after hoisting of each individual component. For more information on components and hoisting techniques, see section I.2 Hoisting techniques. 8. Lower hoist hand control down to lowest floor. 9. Continue installation as normal. 10.Upon completion of hoisting operations discuss with the building owner / representative to reopen the work area to others.

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I.2

Hoisting techniques Following components can be hoisted using standard hoisting method described earlier in this manual: – – – – –

car guide rails counterweight frame car sling uprights car sling bottom beam / pulley assembly car wall panels

Following components need an enhanced hoisting method, see the following instructions: – counterweight guide rails – car platform – car roof panels Enhanced hoisting method, counterweight guide rails

1. Solid guide rails: use the same method as for the car guide rails. 2. Hollow type guide rails: if height from the landing to the pit is suitable, lower the guide rails down by hand. 3. Hollow type guide rails, height is greater than the guide rail length: • Install the fishplate to top end of the guide rail. • Install the guide rail lifting clamp. NOTE: Use M12 x 60 bolt to increase opening size of clamp. • Tie the pulling rope to the guide rail clamp. • Lower guide rail down by hand and continue lowering by rope. • When hoisting operation is completed replace the original M12 bolt to the tool.

M12x60

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Enhanced hoisting method, car platform

1. Fix brackets to the centre of front and rear edges of the floor. 2. Fit upper fixing bolts to both sides of the car floor. The bolts guide the floor to the correct position. 3. Fix and route a pull rope to control the floor movement. 4. Tie the pull rope to transportation wheels to maintain platform upright in upright position.

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Enhanced hoisting method, car roof panels

1. Use the same method as in the car roof installation. Add RUD type eyebolt and M12 shackle to maintain the roof panel in upright position.

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I.3

Initial loading of the counterweight

NOTE: Perform the initial loading of the counterweight after installing the guide rails. 1. Drive car to the floor where the counterweight filler weights are stored. 2. Use site trolley to transport the weights into the car. NOTE: Place maximum 10 filler weights inside the car at the same time. 3. Drive the car to the lowest landing. Take the weights to the landing. 4. Repeat until all the fillers without the paint mark are transported to lowest landing. 5. Position the car to have access to the pit. 6. Perform the initial loading of the counterweight. For more information on order of filler weights, see 8.7 Initial loading of counterweight.

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APPENDIX J. SYNCHRONIZATION, PARALLEL SLING

NOTE: This method is suitable only for cases with parallel car sling bottom beam and synchronization bar in front side of the car platform. It is needed because the linkage between the overspeed governor rope linkage and synchronization bar cannot be connected until there is a safe access under the car.

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1. Detach the clamp plate from the mid linkage at the car sling bottom beam. 2. Fix the clamp plate to the synchronization bar while the car floor is still outside the shaft. 3. Hoist the car floor onto the sling bottom beam using the standard method. NOTE: Take care not to damage the clamp plate.

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4. Connect the overspeed governor rope to the anchorage. Use extension rope to be able to adjust rope length later from the car roof. *) Use BG-M6 type iron grips. Refer to KM181743. 5. Adjust the gap between the sliding side of the safety gear and guide rail to 3 mm. Use the keeper plate of the single guide rail bracket as a gauge. 6. Connect the safety gear levers to the synchronization bar.

5

3

4

6

3

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*

7. Connect the automatic safety gear trigger rope to the safety gear linkage on machine side. Secure the rope so that you have access to it later from the car roof. 8. Slide the upright securing cable ties up just below the top beam fixing holes. 9. Lift the overspeed governor tension weight up using a rope clamp and a lift rope. Secure to the balustrade. 10.Remove slack from the rope. Tight the iron grip to secure the rope.  Maximum distance* from the car roof to the topmost rope grip is 700 mm. 11.Secure the rope coil to the balustrade. Leave slack to enable the safety gear operation.

8

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7

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12.Attach the man riding hoist and automatic safety gear trigger to the car. Test the function of the ASGT. See section 9 Attaching hoist to car. 13.Drive the car upwards to have access to the pit. 14.Activate the ASGT and lower the car onto the safety gear. 15.Secure the car to the fish plate using M12 shackle and the parking chain.

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16.Enter the pit. 17.Connect the mid linkage to the synchronization bar. 18.Fix the pulley beam to the platform.

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19.Go to the car roof: • release the car from the safety gear • reset the ASGT. 20.Enter the pit: • check the free movement of safety gear and mid-linkage system • adjust if necessary 21.Go to the car roof: • test the operation of safety gear according to TAKE2 22.Continue the installation using the standard method.


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KONE Corporation KONE Training and Documentation P.O. Box 679 FI-05801 Hyvinkää, Finland


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AM-01.01.250 A

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