Product Manual TWJ-ASW series (Meal elevator)
NingBo Hosting Elevator Co., LTD
Version No.: SD2013-04-20-
Contents Chapter I…………….… Instructions for use and aintenance Chapter II …………… The installation dia!ra of ain parts Chapter III ……………… Coissionin! instruction anual
Chapter I Instructions for use and aintenance 1 !eneral r"les This anual is applica"le to the use of car!o elevators of ASW-JSW control s#ste produced "# the factor#. $.$ The noral %or&in! conditions of the car!o elevator control s#ste shall confor to relevant provisions of J'$-*+++. $.* In order to ensure the safe operation of car!o elevators, proper aintenance ana!eent s#ste ust "e esta"lished, %ith the reuireents as follo%s a) Conduct inspection and aintenance on the safet# circuit and electrical control coponents %ee&l#/ ") Conduct detailed inspection, ad0ustent and repair on iportant echanical and electrical euipent uarterl#/ c) Conduct the test on the car!o elevator control s#ste annuall#, chec& the %or&in! conditions of all the echanical and electrical safet# circuits and the insulation resistance values, and replace the seriousl# daa!ed devices/ d) When the elevator is out of service for ore than seven da#s, it can onl# "e used after the detailed inspection/ $. Ta&e a !ood record of the operation conditions of the car!o elevator control s#ste. The user unit needs the %ell trained and ualified personnel to operate the elevator control s#ste, the elevator "ase station &e# and eer!enc# &e# need those personnel $.1
for safe&eepin!. The door to%ards the achine roo shall "e loc&ed. As for the incopletel# closed shaft %a#, the users shall ta&e correspondin! easures to avoid the intentionall# or unintentional entr# of irrelevant personnel.
2 #nstr"$tions %or o&eration 2.1
're&aration %or start-"& a) Confir that all the operation s%itches are placed in noral positions/ ") Close the po%er s%itch of the achine roo distri"ution "o2/ c) Place the control ca"inet po%er s%itch at 34. 2.2 (&eration an) o&erating a* Hall $all $) If the car!o elevator is in stand"# state on the floor %ith de"ris, the porters shall anuall# open the landin! doors/ *) If the car!o elevator is in stand"# state on other floors, after the porters press the call "utton, the elevator iediatel# starts operatin! in response to the call elevator %ith the porters on/ ) When the car reaches the lasted recorded call la#er station in a certain direction, it %ill chan!e the direction in response to the call elevator in the reverse direction/ +* "toati$all ret"rn to te +ase station /o&tional*
2.3
2.4
2.
$) Accordin! to users5 reuireents, a certain floor can "e set as the "ase station, !enerall# the first floor/ *) After the car!o elevator in response to the last call coand, if there is no call si!nals %ithin the set tie, the elevator %ill autoaticall# return to the "ase station, %ithout openin! the door/ ) In the process of returnin! to "ase, if soeone calls the elevator, the elevator %ill stop at the nearest floor, %ithout openin! the door. $* (verloa) &rote$tion If the car!o elevator is detected in the overload state, the "u66er in the car rin!s, and the car!o elevator cannot "e started. )* 'assing $ie $) When the car!o elevator reaches the call floor of the porters, the passin! chie on the car top shall rin!, reindin! the porters of the arrival of the car!o elevator. e* Straigt travel servi$e $) In the strai!ht travel state, the car!o elevator onl# shall not response to the porters to call the floor si!nals. *) 3ther states of the strai!ht travel service are the sae as those of the driver5s operation. (vera"l o&eration a) The achine roo eer!enc# electric operation $) 4o atter the car!o elevator operation is in %hat &ind of operation ode (noral operation and self-learnin! operation), the car!o elevator shall "e stopped iediatel# after the action of the eer!enc# electric s%itch/ *) The eer!enc# electric operation speed is +.7s, after the action of the eer!enc# electric operation s%itch, press the up%ard or do%n%ard "utton on the eer!enc# electric operation "o2, the car!o elevator shall ta&e up%ard or do%n%ard operation/ ) The eer!enc# electric operation %ill a&e the !overnor s%itch, the upper and lo%er liit s%itch and the safet# !ear electrical s%itch fail to %or&/ 1) When the car!o elevator s%itches the eer!enc# electric operation ode to the noral operation ode, the elevator can ta&e noral operation. Te elevator sa%et &rote$tion %a$ilities a* Sa%et $ir$"it å $) 8urin! the elevator operation process, if the safet# circuit is disconnected, the elevator door is opened or the safet# s%itch acts, an eer!enc# stop shall "e caused/ *) The safet# circuit recovers, and the elevator %ill ta&e the correction operation. +* Sloing )on )evi$e /o&tional* The slo%in! do%n device installation is to prevent that the elevator is too fast to cause sta!!ered state %hen the car!o elevator stops at the station, as for the car!o elevator stoppin! at the floor %ith the elevator speed at $.+7s, it can also prevent the overturn situation of car!oes. 'ro$essing o% serio"s $on)itions
2.6
a) When the follo%in! three serious cases occur, it can "e used onl# after "ein! strictl# chec&ed, restored and identified "# relevant departents. $) The elevator has severe top hittin!, pit suattin! or car rollin!/ *) 9ire occurs/ ) :arthua&e occurs. +* "les an) ste&s %or release o% te $argoes tra&&e) in te $argo elevator /&ro$essing o)e*: In case of the car!o elevator failure, proptl# notif# the elevator repair departent, "efore the arrival of the professional repair personnel, as for sudden po%er outa!e, the trained rescue personnel shall release the trapped passen!ers accordin! to different situations "ased on the follo%in! steps. $) Cut off the ain po%er of the car!o elevator achine roo, and han! the dia!ra of the ;under repair
prevention of de"ris trippin!, especiall# a&in! the car!oes ove on the roller. 8on5t use a %heel too sall to a&e it stuc& in the !ap "et%een the car and the landin! door, %hich a# a&e the landin! door daa!ed. The car!oes ust "e evenl# distri"uted on the floor of the elevator car and fi2ed, to avoid internal oveent in the process of ovin!. Copare the %ei!ht of the car!oes to "e transitted, and chec& the a2iu load capacit# of #our car!o elevator. 3verload a# cause dan!er to the load (car!oes) and the elevator itself. $* Te elevator "ses te &reventive eas"res taen + &artiall $lose) sa%t a When the shaft %a# is partiall# closed, there ust "e a "affle or "arrier to prevent users fro "ein! hurt "# euipent durin! the operation. These "arriers or "affles ust "e &ept in !ood conditions in all circustances, in accordance %ith national re!ulations. If these "arriers are ade of !lass, special attention shall "e paid to the. When there is a need to clean up this &ind of !lass, due to safet#, listen to advice fro the repair copan#. )* 7atters nee) te intervention %ro ee$"tives To ensure the full aintenance of the car!o elevator device, the elevator o%ner has statutor# responsi"ilities. Therefore, "efore the elevator is put into noral operation, the repair copan# shall forulate the repair plan, %hich is e2treel# iportant. The car!o elevator device ust "e liited to intended use. The ventilation device shall "e installed, to a&e the environent of the shaft %a#, achine roo and the control ca"inet no ore than the euipent operation conditions7teperature (if there are no different specifications in the "oo&let, !enerall# "et%een =℃ and 1+℃). The car!o elevator docuents ust "e stored in the appropriate place, to ensure that the specified personnel in need can ta&e free access. >nder eer!enc# situations and repair %or&, ensure that the safet# path%a#s reuired for "uildin!s and facilities are availa"le. Measures (such as loc&up) shall "e ta&en to onl# allo% specified personnel to ta&e access to the achine, preventin! an# in and out. At an# tie, there is a need to ensure enou!h li!htin! in the achine roo, achine area, shaft %a# or the path%a#s. All the roos, shaft %a# and copartents shall not "e used for other purposes (used for %arehouse, %irin!, etc.). A ualified repair copan# ust "e entrusted to carr# out the repair, to ensure the safet# of the coplete device. 'eneral repair instructions can "e found in correspondin! elevator docuents in the anual. Peranentl# ensure that the car!o elevator provides service for users. 8urin! the use, ensure that the counication lines of the car are sooth for %or&. Conduct the inspection accordin! to the local re!ulations. If there are no re!ulations a"out this device, it shall "e chec&ed "# the ualified repair copan#. As the car!o elevator stops usin! for a period of tie, a ualified repair copan# shall clean it up and lu"ricate it, replace the daa!ed parts, chec& the safet# parts, and then put it into noral operation. As for an# a"noral eer!enc# found in the use of the elevator, it shall "e reported to the repair copan#. 3ther%ise, an# chan!e in the "uildin!s and
facilities that a# affect the car!o elevator shall "e reported as %ell. e* eserve) )o$"ents All the preservation %or& of ;use and aintenance anual of the car!o elevator<, special personnel shall "e arran!ed to "e responsi"le for safe&eepin! the docuents. %* 8se o% te eergen$ "nlo$ing e As for each landin! door, the trian!le &e# can "e used to unloc& fro outside/ As for this t#pe of &e#, it shall onl# "e su"itted to a person in char!e of ana!eent. In order to avoid that the &e# cannot "e loc&ed effectivel# a!ain after "ein! unloc&ed so as to cause accidents, these &e#s shall "e provided %ith detailed instructions %ith iportant easures to "e ta&en. After the eer!enc# unloc&in!, alon! %ith close of the landin! door, loc&in! device shall not "e &ept in the unloc&ed position.
3 #nstr"$tions %or re&air an) aintenan$e 3.1
Notes a) ?euireents for repair personnel $) 9ailiar %ith the principle, structure, and the operation ethod of the elevator %ith the use of the control s#ste/ *) 9ailiar %ith the structures and action processes of the ain parts, especiall# failiar %ith the application ethod for the freuenc# conversion device/ ) 9ailiar %ith control pro!ra flo%/ 1) With s&illed a"ilit# in fault 0ud!ent, anal#sis, and eliination/ ) With safe operation &no%led!e. ") The elevator shall not "e allo%ed to carr# car!oes at repair, the ain po%er s%itch and the entrance hall at each la#er shall "e han!ed %ith the "ill"oard of ;under repair, no s%itchin!-on (use)<. c) At repair, a host shall "e deterined to "e responsi"le for the coand (usuall# underta&en "# personnel %ith hi!h technolo!#), and other coordinators ust o"e# the dispatch. d) At repair, the elevator can onl# "e placed in the ;overhaul< state, and correspondin! s%itches shall "e disconnected %hen the car does not need to run. $) In the achine roo, the ain po%er s%itch shall "e disconnected/ *) In the pit, the eer!enc# stop s%itch of the pit "o2 shall "e disconnected. e) It is strictl# for"idden to seal safet# circuit and the loc& circuit %ith short-circuit ethod for operation. f) @efore liftin! the car %ith the anual "arrin! %heel, cut off the ain po%er s%itch. !) The li!htin! lap adopts B safet# lap %ith shield. h) It is strictl# for"idden to lean to%ards the %or& in the car or at the car top outside the landin! door, %or& %ith one foot on the shaft %a# side or the car !round sill and the other on an# fulcru in the shaft %a#, and %or& %ithin the counter%ei!ht operation scope, if %or& ust "e ta&en in the place, it shall "e carried out on condition that the special person is in char!e of the car out-of-service s%itch. i) 8urin! the repair, if the drive circuit %irin! has "een disconnected, ensure the
sae seuence at the recover#, and ta&e coissionin! to o"serve %hether the traction achine turns correctl#. 0) After the repair, all s%itches shall "e restored to the ori!inal position, fill in the repair records, for use of the elevator deliver# acceptance. 3.2 Sa%et o&erating &ro$e)"res a) @efore startin! the noral use of the car!o elevator, the porters shall $) @efore openin! the landin! door to enter to the car, note %hether the car is stopped at the la#er/ *) @efore "e!innin! the %or& ever# da#, operate the car!o elevator up%ard and do%n%ard for several ties, to see %hether there is a"noral phenoenon/ ) The landin! door shall not "e opened "# hand outside, and the elevator cannot "e started %hen the landin! door and car door are not full# closed/ 1) 4ote %hether the levelin! accurac# has si!nificant chan!es/ ) Clean the dirt inside the car, and for"id %ater cleanin!. ") At noral operation, notes for porters $) After the handlin!, par& the car in the "ase station, disconnect the po%er s%itch inside the car, and close the landin! door/ *) The car carr#in! capacit# shall not e2ceed the rated load of the car!o elevator/ ) Inflaa"le, e2plosive and other dan!erous car!oes are not allo%ed to deliver, in special cases, the# shall "e approved "# relevant departents, and safet# protection easures shall "e ta&en/ 1) 8on5t ta&e the overhaul speed for noral operation under the condition that the landin! door and the sei-car door are open. ) 4o aterials shall "e placed at the car top/ ) The load shall "e securel# ounted in the iddle of the car, to avoid dupin! in operation/ c) When the car!o elevator has the follo%in! faults, press the alar "utton for alar, and proptl# notif# the repair personnel/ $) After the landin! door and the sei-car door are closed, fail to start the operation/ *) There are si!nificant chan!es in operatin! speed/ ) The travel direction is opposite to the coand direction/ 1) The levelin! la#er, speed s%itchin!, call and indicator la#er si!nals fail to %or& and out of control/ ) There are a"noral noises, lar!e vi"ration and shoc&/ ) It surpasses the end station position and continues to run/ ) The alfunction of safet# !ears/ D) There is electrical stunnin! %hen contactin! %ith an# etal part/ E) The electrical coponents are overheated and eit scorchin! odor. d) After the use of the car!o elevator, the porters shall par& the car in the "ase station, and disconnect all the s%itches on the operation panel, and close the landin! door. e) As for the sudden stop or out of control durin! the elevator operation, proptl# notif# the repair personnel, hold the traction achine "# hand to a&e the car
3.3
enter the open door area, open the landin! door "# hand to assist the porters to ta&e the car!oes out. e&air an) aintenan$e o% i&ortant &arts a* Tra$tion a$ine 1* Tra$tion seave a) Feep the traction rope !roove clean, and it is not allo%ed to add lu"rication oil to the rope !roove/ ") When the %ear de!rees of rope !rooves are inconsistent, the# shall "e replaced tiel# %hen the a2iu !ap has reached ore than $7$+ of the traction %ire rope diaeter or serious unevenness affects the use/ c) When the !ap "et%een the traction rope and rope !roove "otto is less than or eual to $, or the depth of sei-circle !roove rope %ear %ith incisions to%ards the incision is less than *, it shall "e loaded or replaced. The thic&ness of %heel flan!e "elo% the loaded rope %heel rear incision shall "e no less than the traction rope diaeter. 2* 7otor a) Al%a#s &eep the electric otor clean and coolin! fan %or& norall#/ ") The insulation of the otor shall confor to the reuireents/ c) The sound of the otor shall "e noral. +* Brae $) The action shall "e fle2i"le and relia"le. Gu"ricate the pins often and &eep the %or&in! surface of "ra&e shoes and "ra&e drus clean, %hich shall not "e splashed %ith oil stains. *) At "ra&in!, the "ra&e shoes on "oth sides shall fit %ith the %or&in! surface of "ra&e drus closel# and evenl#. At "ra&e-releasin!, the "ra&e shoes on "oth sides shall leave the "ra&e drus5 %or&in! surface at the sae tie. The !ap "et%een the shall "e no !reater than +., and %hen the !ap is too lar!e, it need appropriate ad0ustent. ) The "ra&e "and shall have no !reas# dirt. The fastener rivets shall "e "uried in "ra&in! "and to prevent the contact %ith the "ra&e drus. It can a&e appropriate ad0ustent %hen "ra&in! "and %ear results in the a"noral "ra&in! %ith noises. If the %ear is so serious that the rivets e2pose out of the surface of "ra&e "and, or the %ear aount is ore than $71 of the "ra&e "and5s thic&ness, the "ra&e "and shall "e replaced. 1) There shall "e no loose in the %irin! of the electroa!netic coils, %ith !ood insulation. Teperature rise shall "e no ore than D+℃. $* (vers&ee) governor $) With fle2i"le and relia"le action, the rotatin! part shall "e oiled for once a onth, %ith cleanin! and oil chan!e for once a #ear (the overspeed !overnor has "een ad0usted "efore the deliver#, and has "een sealed, and the use units shall not disconnect it for ad0ustent ar"itraril#)/ *) The tension of the tensionin! device shall "e consistent, %ith fle2i"le rotation, and the rope sheave and !uide device shall "e oiled %ee&l#, %ith cleanin! and oil chan!e for once #ear/
) Al%a#s chec& the rope clapin! 0a%, and reove forei!n "odies, to ensure relia"le action. When the overspeed !overnor rope e2tension e2ceeds the prescri"ed scope and cuts the control circuit, it shall "e truncated. )* Sa%et gear $) The action is sensitive and relia"le, and the rotatin! rod part shall "e chec&ed %ee&l#, to ensure that it is fle2i"le %ithout "loc&in! phenoenon, and the pull force and liftin! hei!ht confor to the reuireents/ *) 3il the rotatin! part for once onthl#, the !ap "et%een the %ed!e and the !uide rail %or&in! surface shall "e eual at *H, %ith fle2i"le and relia"le action, coated %ith vaseline for anti rust and lu"rication. e* Sei-$ar )oor, lan)ing )oor an) elevator $ar $) If the han!er rollers of the sei-car door and landin! door %ear, causin! the openin! and closin! doors difficult or even cannot %or& norall#, the# shall "e replaced/ *) The door !uide rail shall "e %iped re!ularl# and seared %ith a sall aount of !rease, a&in! the door ni"le and fle2i"le, under sooth operation, if the door slider %ear affects the use, it shall "e replaced tiel#/ ) Wee&l# inspection a) :nsure that the action of each safet# s%itch of the door openin! and closin! echanis is accurate/ ") Safet# contact pad acts fle2i"l# and relia"l#, and the collision force shall "e less than 4/ c) The loc&in! hoo&, loc&in! ar and ova"le contacts of the landin! door loc&s act fle2i"l#, %ith the d#naic and static contacts in ali!nent, eshin! for at least , to prevent the eer!ence of virtual connection and adhesion phenoena/ d) If the landin! door lin&a!e traction device is loose, ad0ust it tiel# for tensionin!/ 1) Monthl# inspection a) As for the sei-car door safet# s%itch, ensure that the elevator shall not "e started %hen the sei-car door is not closed ti!htl#/ ") The landin! door at each la#er 8on5t open the door "# hand outside the landin! door (e2cept for trian!ular &e#s)/ c) As for the rope head plate overload and full-load s%itch, ensure the accurate action. ) uarterl# inspection a) As for landin! door echanis, the anual s%itch action shall "e fle2i"le and relia"le/ ") Chec& %hether the car %all is loose. f) Traction %ire rope $) Chec& and ad0ust the rope head co"ined nut %ee&l#, to a&e the traction rope tension unifor/ *) When the traction %ire rope %ear reaches the provisions in Ta"le $, it shall "e replaced "# a ne% one/
Ta"le $ Standards for replaceents of the elevator traction %ire rope Percenta!e of the %ire surface %ear or corrosion part over 4o. of "ro&en %ires %ithin a pitch DH$+
the diaeter () +
$+
$
*+
*
K+
$
$
$*
$$
E
D
8iaeter of the %ire rope ()
4ote $. If the percenta!e of the %ire surface %ear or corrosion part over the diaeter is 6ero, "ut the nu"er of "ro&en %ires has reaches the nu"ers in correspondin! coluns of the ta"le, the %ire rope shall "e replaced/ 4ote *. If the percenta!e of the %ire surface %ear or corrosion part over the diaeter reaches +, the %ire rope shall "e replaced even if there are no "ro&en %ires/ 4ote . If the percenta!e of the %ire surface %ear or corrosion part over the diaeter has "een reached, the %ire rope shall not "e replaced as the correspondin! nu"er of "ro&en %ires has not "een reached/ 4ote 1. If the %ire rope has "ro&en strands, it shall "e replaced.
) When the traction %ire rope stretches overl#, it shall "e truncated. When the traction %ire rope has dirt or sand and other forei!n "odies on the surface, it shall "e %iped up proptl# %ith &erosene. !) 'uide rail and !uide shoe $) The car !uide rails and counter%ei!ht rails shall aintain !ood lu"rication, chec& the oil level of the oil "o2 at the autoatic lu"ricatin! device onthl#, and refill it tiel#/ *) When the %or&in! surface of !uide rails are daa!ed due to the safet# !ear %or&, or there are pits, "urrs, scratches and others found on it, it shall "e polished sooth tiel#/ ) When the !uide shoe liner %ears $ at %or&, it shall "e replaced. If the liner %ears seriousl# %ithin a onth, it shall "e chec&ed at shutdo%n, and ta&es operation after the repair/ 1) Carefull# chec& the connection "olts of the !uide rail connection plate and the !uide rail frae annuall#, reti!hten all the fastenin! "olts, and re-cali"rate the si6e and verticalit# of the !uide rail end face. h) Copensation chain (optional) $) When the copensation chain !enerates lar!e noises durin! the operation, chec& and sear the erasure oil. i) :lectrical euipent $) The safet# contact s%itches of the car!o elevator electrical safet# devices shall "e fle2i"le and relia"le, chec& the for once onthl#, %ipe the surface dirt, verif# the contact relia"ilit# of contacts, tri the ones under a"lation soothl#, and replace the if serious/ *) The liit s%itch shall "e sensitive and relia"le, and an overrun test shall "e
ta&en ever# ten da#s, rel#in! on %hether it can "e relia"l# disconnected/ ) Control ca"inet/ a) Chec& %hether the indicator li!hts on the icrocoputer panel %or& norall#. ") Chec& %hether the ca"inet %irin! is relia"le and the rela# %or&s norall#, %ith focus on the relia"ilit# of the "ra&e contactor and door loc& rela# contacts, and replace the contacts %ith flae fusion. c) Clean the control ca"inet %ell. d) :er!enc# rescue device ($) Conduct char!e and dischar!e of the "atter# for once ever# si2 onths, and chec& %hether the eer!enc# rescue %or&s norall# 3perate the car!o elevator to the iddle floor and then out of the levelin!-in 6one, turn off the ain po%er s%itch, press the eer!enc# anual "ra&e-releasin! "utton and the au2iliar# "ra&ereleasin! "utton, and operate the elevator to the levelin! device %ith the anual eer!enc# evacuation device. (*) The "atter# !enerall# has #ears of service life at eer!enc# rescue. 1) 9reuenc# conversion device (optional) a) The po%er suppl# ust "e off (399)/ Pa# attention to the aintenance and inspection/ After the po%er is off, the capacitor %ill dischar!e po%er still, and the operation can "e started after the converter control panel li!ht is off/ ") 8ail# inspection 4ote %hether the freuenc# conversion device has a"noral sound, sell and "rea&a!e, if a"noral, the place and de!ree shall "e deterined. 9reuentl# clear the dust and forei!n "odies on the control ca"inet and at the vent, to aintain the noral operation of the freuenc# conversion device. c) ?e!ular repair The service life of freuenc# conversion devices varies due to different environent and the tie. As for continuous use %ithin the peritted scope, the electrol#tic capacitor shall "e replaced for ever# #ears !enerall#, and the coolin! fan shall "e replaced for ever# #ears.
4 S"ar o% l"+ri$ating oil Ta"le * Suar# of lu"ricatin! oil No.
$ *
Nae
'uide a2le 3verspeed !overnor sheave shaft Safet# !ear %ed!e
Nae o% l"+ri$ating oil
7aintenan$e
'rease
Monthl# refuelin!
*L en!ine oil
?efuelin! for ever# $ da#s
Baseline
Appl#in! oil uarterl#
1
'uide rail and !uide shoe
The door slider of anual landin! door
'rease
'rease
Monthl# inspection and refillin!
9reuent inspection
Part II The installation dia!ra of ain parts 3verspeed !overnor (euipped %ith safet# !ear) Machine supportin! "ea Traction achine
3verspeed !overnor "ea
@earin! seat
'uidin! %heel
'as&et plate
9i!ure I Scheatic dia!ra of la#out of ain parts in achine roo
3verspeed !overnor hole position of car
Control ca"inet
Main po%er
Machine roo door
9i!ure II Scheatic dia!ra of la#out of achine roo floor slot
Pulley coponents
Top "ea 8oor !uide rail (Aluinu allo#)
@alance %ei!ht coponents
Pulley coponents Protective cover of chain of trian!ulation A-+$ door s%itch
Nandle location Nood
coponents
Top "ea
Support of door poc&et connection
3rientation "all clip
Goc&
4ote $. Pull the hood after installation has "een finished and chec& if orientation "all clip is installe) in &la$e . *. Chec& if the s%itch of sin!le plate connected %ith closin! clearance around 2 after closin! hood. >pper door . Chec& if A-+$ s%itch contact is st"$ %hen liftin! the hood up%ards. plate
9i!ure III Scheatic8oor dia!ra 0a" of hood in car inlet (@alance %ei!ht is on left and installed s#etricall# on ri!ht) A-+$ door s%itch coponents Go%er "ea 8oor !uide rail
Go%er door plate
9i!ure IB Structural dia!ra of landin! door (This fi!ure is the scheatic dia!ra of lever liit ca, %hile for !u#ed liit ca, the door liit, door loc& oves do%n%ards to "e near the door closin! location)
9i!ure B Structural dia!ra of /integral* car
9i!ure BI Structural dia!ra of /%rae* car
Giit s%itch coponents
Side frae of ceilin!
Connection support
Safet# !ear
Gevelin! inductor device Nood on car inlet
9i!ure BII Installation scheatic dia!ra of levelin! inductor and liit s%itch
Tension sprin! support :lectroa!netis valve
Tension sprin!
Gever
Support
Giit ca
9i!ure BIII Structural dia!ra of lever liit ca Installation ethod $. When the elevator starts up, electroa!netis valve suc&s to a&e the liit ca vertical. Then liit ca surface contacts %ith the "alls of door loc& *. Measure the installation si6e of loc&, the residual loc&s can "e installed "ased on this si6e directl# . Startup elevator and coission it. Jud!ent points if the loc& installed correctl# shall "ase on the follo%in! standards $. :levator can stop in levelin! in noral operation/ *. The elevator can "e started up norall# after levelin!. ?e!ulation ethod please refer to the electrical principle dia!ra for echanical re!ulation and electrical part. $. If elevator does not open at the levelin!, it eans the loc& s%itch is turned off and the distance "et%een the ipact "all and elevator ca. So the door "all location shall "e coissioned at that tie. *. When elevator stops in levelin!, the landin! door does not open, it eans the door "all is too a%a# fro the elevator ca. . When elevator operates norall#, "ut the electroa!net does not attract at soe
level %hile attract in other levels, it eans that there is soethin! %ron! %ith the circuit and #our door loop is not closed.
Collision "o% 'uidin! sheave coponents
Connected %ith %ire pull rope in iddle
Mova"le collision "o%
Support
9i!ure IO Structural dia!ra of !u#ed collision "o%
Counter%ei!ht !au!e
*-M$* "olt
(9i2ed ethod of iron e2pansion)
*-M$* "olt
(9i2ed ethod of %all scre%) 9i!ure O Scheatic dia!ra of fi2ed ethod of counter%ei!ht support
Car !uide rail support
Safet# pin "oard
Counter%ei!ht !uide rail support Counter%ei!ht tension sheave (connection support is plate-castin!)
8-A-$ "uffer
Car side tension sheave /Conne$tion s"&&ort is L-sa&e) s"&&ort*
Giit device Gevelin! inductor device
9i!ure OI Structural dia!ra of elevator shaft %a#
Part III Coissionin! instruction anual 1. !eneral r"les This instruction is applica"le to the TWJ car!o elevator, e2cludin! construction lifter and all 0ac&in! euipent in ine. $.+ 'eneral rules $.$ The installation and coissionin! standards shall "e consistent %ith relevant re!ulations of JG135-2000 Cargo elevator. $.* To ensure safet# of elevator installation and coissionin! as %ell as elevator operation ualit# and perforance, it shall "e consistent %ith the follo%in! reuireents $.*.$ The personnel in char!e of elevator installation and coissionin! shall "e trained professionall#, failiar %ith elevator structure and ain part functions, relevant standard &no%led!e of elevator and pass the e2aination and issued %ith the certificate "# relevant departent. The technician in char!e of electrical installation and coissionin! shall "e trained %ith technician technolo!#, "e failiar %ith electrical operation, pass e2aination and issued %ith ualified certificate "# supervision authorities. $.*.* ?ead and aster the !eneral standard of product and technolo!ical standards of installation, electrical principle and relevant technical aterials, etc. "efore installation and coissionin!. $. This instruction has re!ulated the !eneral rules of procedure for the installation ualified %ith the a"ove conditions and our copan#5s elevator5s installed and coissioned "# the technician. :levator coissionin! shall not onl# "e consistent %ith desi!n reuireents and standards, "ut also inspect or test safet# protective perforance of echanical and electrical parts. $.1 Installation and coissionin! standards of ain parts of elevator $.1.$ Please refer to the General Standard Process of Elevator Installation for the procedure of elevator installation and the installation and coissionin! standards of each part.
2. 're&aration +e%ore elevator $oissioning *.$.$ :lectrical %irin! in achine roo, shaft %a#, car, etc. shall "e acc oplished. *.$.* :ach echanical part, especiall# echanical safet# part shall "e installed copletel#. *.$. Illuination and d#naic po%er and %irin! shall "e prepared. *.$.1 8ra%in!s and !roundin! %ires needed in the coissionin! shall "e prepared. *.$. :lectrician tools such as ultieter, apere eter, etc. needed in the coissionin! shall "e prepared. *.$. Chec& and clean all the installed parts thorou!hl#. S%eep and scru" all electrical echanical devices to &eep the clean. *.$. Chec& the in0ected lu"ricant. Chec& if the lu"ricatin! part clean and &eep sufficient lu"ricant. 3il level hei!ht shall "ase on oil level indication line.
3. Coissioning ste&s o% elevator .$ 9ocus on inspections "efore po%er suppl# %hen preparation %or& is accoplished and "efore closin! the a0or po%er s%itch. .$.$ Chec& if %irin! "et%een each electrical and echanical part in achine roo correct.
.$.* Chec& if %irin! fro control panel in achine roo and each part of car to each floor of shaft %a# correct. .$. Chec& if %irin! fro control ca"inet to operation ca"inet correct. .$.1 Chec& if each %irin! terinal in control panel loose and chec& if each rela# and %irin! of contactor loose. Ti!hten the un%ired thu"scre%. .* Traction achine operates %ith no-load after "ein! char!ed %ith po%er .*.$ Chec& phase after "ein! char!ed %ith po%er %ithout pushin! the traction %ire. a. Chec& if the direction contactor consistent %ith the rotation direction of traction sheave. ". Chec& if traction achine operates for%ards and "ac&%ards norall#, for e2aple, if there is noise in decelerator, if there is a"noral noise, heatin!, a2ial driftin!, radial run out, etc. in the "earin! or if the# are consistent %ith reuireents. c. @ra&e clearance re!ulation. The clearance shall not "e "i!!er than +.. . Traction %ire rope ..$ The car shall "e lifted %ith anual-operated hoist (rated %ei!ht of hoist shall "e "i!!er than the car %ei!ht). When traction %ire rope connects the car %ith counter%ei!ht and then the shaft %a# scaffold can "e reoved. .1 Trial operation .1.$ Chec& and verif# if the si6e "et%een relevant parts consistent %ith the one re!ulated in the installation and la#out dra%in!s %ith the aintenance speed one floor "# one floor/ if it is, the person %ith rich installation e2perience shall chec& if the installed parts in shaft %a# ipactin! %ith each other on car roof and operate the elevator up%ards and do%n%ards slo%l# for t%ice and then chec& and verif# the ites listed as follo%s one floor "# one floor a. Clearance of elevator hall door in each floor shall eet the appointed value re!ulated in civil en!ineerin! plane. ". :ach safet# protective s%itch shall "e relia"le. . Install and re!ulate the safet# protective s%itch. ..$ The safet# protective s%itch shall "e re!ulated in accordance %ith re!ulations in General Standard Process of Elevator Installation. ..* The liit s%itch and other action si6es on terinal station shall "e re!ulated in accordance %ith the reuireents listed in the follo%in! ta"le Installation si6e of each s%itch 4ae
Si6e
?ear&
++
$.+7s elevator
++
+.7s elevator
9orced reducer s%itch >pper and lo%er space s%itch
+～+
>pper and lo%er liit s%itch
+～$++
.. ?e!ulate and chec& doors in each floor. The elevator shall not operate if there is an# door in an# floor is not closed or closed ti!htl#. Chec& if the loc& relia"le. . Coissionin! of control si!nal
..$ :lectrical control pro!ra shall "e consistent %ith reuireents of electrical principle dra%in!s a. Chec& if each coand in each floor valid/ ". Chec& if po%er s%itch functional/ c. Chec& if indications of each floor correct. d. Chec& if "uttons of each floor and the stop s%itch valid. (Pa# attention to the safet# of vice-contact connected %ith AC**+B) . Installation of floor operation ca"inet ..$ The operation ca"inet is set up "eside the station hall of each floor of the car!o elevator. It shall "e &ept vertical durin! installation and %ired "ased on electrical principle dra%in!s. Pa# attention to the positive pole and ne!ative pole displa#ed on the panel. .D Traction achine .D.$ When each rope score is a"raded and sun&en differentl# to "e $7$+ diaeter of traction rope a%a# or "e sun&en seriousl# to further affect the application, the rope score shall "e repaired or the sheave shall "e replaced. .D.* 3il volue in decelerator shall "e &ept %ithin the oil level scope appointed in oil fi!ure or oil %indo% %hen environental teperature is in - QCH=1+QC .D. The "ra&e shall %or& fle2i"l# and relia"l#. The pivot shall "e lu"ricated %ith en!ineer oil. 8urin! the "ra&in!, the elevator !ates on "oth sides shall "e closel# ti!htened to the %or&in! surface of "ra&e sheaves. 8urin! the !ate liftin!, the elevator !ates on "oth sides shall leave "ra&in! sheaves surfaces at the sae tie and the clearance shall not "e "i!!er than +.. .E 'uide rail and shoe !uide .E.$ The !uide rail shall "e painted or in0ected %ith lu"ricatin! oil ever# %ee&. It is referred to use lu"ricatin! oil appointed in Ta"le $. Ta"le $ 4o.
Gu"ricatin! part
3peration
4o. of oiled parts
3il cate!or#
3iled
3il replaceent
period
period
L+ !ear oil in $
*
r e c u d e ?
Tan&
9ill oil after openin! the reducer cover
$
@earin!
3iled the "earin! %ith oil cup %ith oil !un
*
@ra&e
0oint of "ra&in! ar
1-
%ith oiler 1
suer
Feep oil
ne% achine and
L*+ !ear oil in
pointer
$* onths for the
%inter
3iled on each rotator#
onths for the
Motor
3iled on "oth ends of otor "earin!s
*
Calciu "ase lu"ricatin! oil L*+-+ en!ine oil Githiu "ase !rease
!eneral achine $ da#s
$* onths
* da#s
$ onth
$ #ear
.E.* The shoe !uide shall "e replaced %hen clearance "et%een !uide rail roof and shoe !uide roof e2ceeds . .E. When !uide rail operation surface is daa!ed or coarse due to safet# !ear "ra&in!, it shall "e polished in tie. .$+ 3verspeed !overnor (set up %hen load is ore than *+&!)
If overspeed !overnor is reuested to confi!ure "ased on user5s need, it shall ensure the action is fle2i"le and relia"le. The rotator# pin shall "e refueled once ever# %ee& and cleaned once ever# #ear. .$$ Safet# !ear (set up %hen load is ore than *+&!) .$$.$ Chec& rotator# rod re!ularl# and it shall "e fle2i"le %ithout "ein! stuc&. refuel echanical oil to lu"ricate the rotator# part ever# onth. .$$.* Safet# lin&a!e s%itch %hich is non-reset shall "e relia"le. The control circuit shall "e cut off to force the elevator to stop %hen the safet# !ear %or&s. .$* :lectrical euipent .$*.$ Safet# protective s%itch shall "e fle2i"le, relia"le and chec&ed once onthl#. .$*.* The space s%itch and liit s%itch shall "e sensitive and relia"le and there shall "e soe residual for the collision "o% after it is pressed. .$*. Control panel is 8C $$+B, AC **+B and three-phase AC D+B ain circuit. It shall "e distin!uished durin! the aintenance in case of short circuit or daa!in! electrical coponents. .$*.1 When replacin! the fuse, the fusin! current and this loop shall "e atched. The rated current of coon control circuit fuse shall "e consistent %ith the one of the po%er of this loop. The rated current of otor loop fuse shall "e *.H ties of the one of this otor. .$*. When there is an# fault in electrical control s#ste, it shall "e found out and eliinated in different phases "ased on the electrical principle dra%in!s. .$ :levator aintenance .$.$ Install aintenance s%itch and up%ard and do%n%ard aintenance operation "uttons on the control panel. When it needs to "e aintained, pull the s%itch to the aintenance position %hen autoatic operation lin& is invalid. :levator operation relies on aintenance "utton. To eet the aintenance deand, the elevator can stop at an# position in the shaft %a# %hen the elevator is in ;Inchin!< status. .$.* If the elevator does not operate %hen operate the up%ard or do%n%ard "utton, chec& input status of icrocoputer or chec& safet# loop. If the closin! indicator on panel does not li!ht, it can "e confired that the door of the car or the one of soe floor does not closed causin! door interloc&in! s%itch does not %or& and causin! a"noral operation. It shall "e inspected and eliinated one floor "# one floor. 3n the contrar#, the fault is caused "# other echanical or electrical fault, %hich shall "e inspected and eliinated carefull#. .$1 9ast operation of elevator .$1.$ In the achine roo, s%itch the elevator to autoatic operation %hen it is operated to the iddle floor slo%l#. 3pen odd nu"er coand in control ca"inet, the elevator %ill onl# run at the sin!ular floor. 3"serve elevator operation, Gevelin! si!nal and traction achine, etc. to see if it can stop at levelin! or shuts do%n norall#. If not, re!ulate it. .$1.* After the elevator operates at the sin!ular floor norall#, !ive even nu"er coand to let the elevator run the even nu"er floors. 3"serve elevator operation, levelin! si!nal, traction achine, etc. to see if it starts, stops at the levelin! or shuts do%n norall#. If not, please re!ulate it. Then a&e the elevator operate in the shaft %a# at a full 0ourne#. Measure if the operation tie is sufficient. .$1. Pa# attention to speed feed"ac& to chec& and confir the elevator can operation "ased on the speed re!ulated in the contract.
.$1.1 If the elevator runs norall# in the top or "otto floors, then chec& the operational ran!e of the upper liit s%itch, lo%er liit s%itch, and ar!inal s%itch to ensure eetin! its safet# standard. (e.!. freuenc# conversion. Chec& the upper7lo%er reducer s%itch to !uarantee eetin! its standard first, then allo% the elevator to shoot upstairs or do%nstairs and o"serve the elevator %hen reachin! top7"otto floor to chec& %hether it shall hit ceilin! or touch !round. If it did, ad0ust the operational ran!e of the up7do%n slo%do%n s%itch.) .$ Test of landin! operation "oard .$.$ There is an operation "oard "# the side of the landin! door ever# floor in car!o elevator. >sers shall find the correspondin! stop "uttons for each landin!. When the deliver# staffs open a landin! door, finish loadin! their !oods and close the door, #ou can see the %ord RcloseR over the operation "oard, indicatin! that the door is %ell closed. Push the "utton of #our tar!et landin!, the elevator shall shoot to%ard the re!istered landin!, stop upon arrival and send out an unloadin! si!nal so that deliver# staffs shall open the landin! door and the %ord ;Close< shall disappear at that tie. After finishin! unloadin! and closin! the landin! door, the car!o elevator shall "e in an unoccupied status and read# for runnin! an#tie. In that case, the elevator shall reach the landin! and !et the !oods if receivin! an instruction fro an# landin!. Chec& the operation "oard, especiall# the stop "utton to see if it %or&s %ell. .$ ?e!ulate "alanced coefficient. Input "alanced load (1*H+ rated load) in car. Clip the traction achine input %ire %ith one clap apere eter and easure current values of up%ard operation and do%n%ard operation of the elevator. ?ecord the current %hen the car and counter%ei!ht runs into each other. If the elevator is in over"alanced status, the record current values of up%ard operation and do%n%ard operation of the elevator shall "e eual (the difference shall not e2ceed $A.). 3ther%ise, add or reduce counter%ei!ht iron on the counter%ei!ht support until the elevator is in over"alanced status. 9i2 the %ei!ht in counter%ei!ht support. .$ Start up and deceleration coissionin! shall "e re!ulated "ased on electrical control principle to a&e the elevator start up soothl# and "ra&e in "alance %ithout clear vi"ration. .$D ?e!ulate the levelin! accurac# :ach floor is installed %ith a levelin! s%itch. The a!net vane is on car roof. After the position is re!ulated and car operates up%ards %ith no-load and stops at each floor, re!ulate the elevator door a little hi!her than the levelin! !round and re!ulate it a little lo%er than the levelin! !round %hen car operates up%ards %ith load to a&e the t%o values siilar. In the sae %a#, the values that the elevator stops hi!her or lo%er than the floor !round shall "e siilar %hen car operates do%n%ards %ith no-load or load. .$E Goadin! trial operation .$E.$ When the car!o elevator is loaded %ith car!o, it shall a"solutel# not e2ceed the rated load/ other%ise there %ill "e slidin!, rushin! or sedientation causin! daa!e to the euipent and car!o. .$E.* 'enerall#, there is no elevator door set up in the car!o elevator, so the loaded car!o shall "e piled firl# and tidil# in case of slidin! or causin! accident or dan!er due to the slidin! car!o in car ipactin! %ith landin! door device and "rac&et and to further affect noral operation seriousl#. .$E. It is not allo%ed to load flaa"le, e2plosive car!o %ith stron! corrosion (e2cept the speciall# desi!ned one) in the coon desi!ned car. If there is an# special circustance, it shall !et approval fro the relevant departents and ta&e safet# easures.
4. Notes )"ring $oissioning 1.$ ;Stop for aintenance< shall "e hun! on the door of each floor durin! the elevator coissionin!. 1.* Turn off the s%itch on correspondin! location %hen car operation aintenance is not needed and turn off the !eneral po%er s%itch %hen in achine roo/ 1. 4otes durin! the operation. If an# of the follo%in! a"noral conditions occurs, the po%er shall "e disconnected and aintainer shall "e infored in tie. 1..$ The elevator operates a!ainst the coand direction/ 1..* There is an# a"noral noise, "i!!er vi"ration and ipact/ 1.. The elevator &eeps operatin! after passin! the terinal location/ 1..1 There is electrical stunnin! %hen contactin! %ith an# etal part/ 1.. The electrical coponents are overheated and eit scorchin! odor.
