Elevator Installation and Assembly Procedure PDF Download

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Document Category Engineering
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Assembly Instructions
LE
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/N
SH
RA
CK
&
PINION
ELEVATOR
SH
hoists with square mast
Load capacity>
1000 kg (2200 lbs) LE
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M
O
R
I G
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A
L
Edition 04.2015
Assemby Instructions

Table of Contents
LiE
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1
Table of Contents
ML009GB
Edition 04.2015
2 / 58
1
Table of Contents
2
2
Introduction
5
2.1
Assembly personnel
5
3
Guide
6
3.1
Warnings
6
4
Obligatory warn
ing
instructions
7
4.1
Electric shock
7
4.2
Crushing by car
7
4.3
Falling tools and parts
7
4.4
Secure machine against being switched on
7
4.5
Fall and trip hazard
8
4.6
Impact injuries
8
4.7
Suspended loads
8
4.8
Prevent access for unauthorised persons
8
5
Technical Data
9
5.1
Tests before delivery
9
5.2
Transport / storage
9
5.3
Operating and environmental conditions
10
5.4
Dimensions of the Machine
10
5.5
Speeds
11
5.6
Lifting height
11
5.7
Load capacity
11
5.8
Mast.
11
5.8.1
Mast 650 x 250
11
5.8.2
Mast 650 x 650
12
5.9
Acoustic emissions
12
5.10
Cable guide
12
5.11
Tightening torques
13
5.11.1
Mechanical fittings without tightening-torque control
13
5.11.2
Mechanical screw
connections with torque control
13
5.11.3
Electrical screw
connections without torque control (metal screw
connections)
13
5.11.1
Assembly torque fischer”
bolt anchor FAZ II……………………………………. 13
5 .12
Assembly geometry
14
5.13
Anchoring forces
14
5.14
Foundation
14
5.14.1
Load-bearing capacity of the foundation
14
5.14.2
Hoists with basin/underrun section
14
5.15
Requirements of the installation site
15
5.15.1
Foundation
15
5.15.2
Foundation – steel construction
15
5.15.3
Soil pressure
15
5.15.4
Tolerances for the “support plates” on site
15
5.15.5
Tolerances for vertical deviation
15
5.15.6
Electrical connection
15
6
Transport
17
6 .1
Safety notes………………………………………………………………………………………. 1 7
6.2
Loading and unloading the machine
18
7
Lifti g Parts of the Machine
19

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Table of Contents
7 .1
Lifting the machine
19
7 .2
Double doors of the enclosure
19
7.3
Enclosure
20
7.4
Mast section
20
8
Control Elements for Assembly
21
8.1
Assembly control
21
9
Assembly
23
9.1
Assembly personnel
23
9 .2
Safety notes
23
9.2.1
Installation and Connecting
23
9.2.2
Transporting material.
24
9.3
Assembly procedure
25
9.4
Assembling the base unit.
26
9.4.1
Assembling the mast bracket
26
9.4.2
Classification of the mast brackets
27
9.4.3
Provisional electrical connection
29
9.4.4
Extending the mast sections
30
9.4.5
Commissioning the lubrication device
32
9.4.6
Install the buffer support
33
9.4.7
Installing the cable guides
34
9.4.8
Installing the cable holder on the mast sections
34
9.4.9
Assembling the central feeder
35
9.4.10
Assembling the cable carriage
36
9 .4 .11
Electrical connection
38
9.4.12
Limit switch bar at the ground station
.40
9.4.13
Limit switch bar at the top landing (mast end)
.41
9.4.14
Limit switch bar at the landings
41
9.5
Base enclosure
42
9.6
Landing doors
45
9.7
Programming the landing level positions
.46
9.7.1
Single/Automatic control
.46
9.7.2
Selective/Collective control.
48
9.8
Check after assembly/ before commissioning
51
9 .9
Checking the bolted connections
51
10
Dismantling (disassembly)
52
11
Disposal of the machine
53
12
Notes and comments
54
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Assembly Instruction

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Introduction
ML009GB
Edition 04.2015

Table of Contents
2 2.1
LE
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Introduction
These assembly instructions describe the general assembly of a GEDA
hoist on a square mast.
The description and
image
representations used relate to a machine
type and possibly only have a schematic character to your machine
type.
The function and operation is not affected by this.
Individual technical specifications and dimensions for your machine are
given in the
product-specific documents:

Assembly drawings (V-2155-502-4-014&026)

Operating
Manual (V-2155-502-4-806)

Wiring
diagram
(V-2155-502-A-021)
These documents are included in the scope of delivery
of your hoist.
Assembly personnel
The machine shall only be assembled, operated and
maintained
by
authorised
persons who
can
be guaranteed to act properly on the
basis of their training or knowledge and
practical experience, and
who are aware of the hazards. These
persons must be appointed
to the tasks of installation, dismantling and
maintenance
by the
operating company.
Edition 04.2015
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Assembly Instruction

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Obligatory warning instructions
3
Guide
You will come across a series of illustrations and symbols while reading
this manual which are intended to help you navigate through and
understand this manual. The different meanings are explained below.
Text display
Meaning
Bold
type
Emphasises particularly important
words/passages

List 1
Denotes lists

List 2
Denotes lists
(brackets)
Item
numbers

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6 / 58
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Guide
4 4.1
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Obligatory warning instructions
Electric shock A Electric shock
Components remain live even after activation of the
EMERGENCY
STOP, or switching off the
machine at
the
main switch.
Applies to all work on electrical parts.
Interrupt the mains supply upstream
of the
main switch.
DANGER
4.2
Crushing
by car A Danger to life
Car creates a crush hazard.
Never remain
inside the enclosure during operation.
W
hen working
inside the enclosure, activate the
setting
mechanism, switch off the main switch and secure from
switching on.
4.3
Falling tools and
parts
Ai Danger to life
Falling tools/parts
Secure tools/parts against falling when working.
4.4
Secure machine against being switched on
DANGER
DANGER
e
A Danger to life
Due to the machine being switched on during
maintenance/servicing tasks or if there is a defect.
Secure the
main switch with a padlock against switching
on.
DANGER
I
t
/C
t
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Assembly Instruction

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4.5
Fall and
trip
hazard
Technical Data
A
]W
ARNING
Fall and trip
hazard
Look out for steps and objects on the ground when
entering/exiting the
car.
4.6 4.7 4.8
Impact injuries ,,_

] CAUTIO
N
F
Impact injuries
Ill
Always wear a safety helmet when working
if there is an
impact hazard.
0 Suspended loads
A
A
]W
ARNING
Danger to life
Raised
load.
Do
not stand
under suspended loads.
Do
not stand on a suspended load.
Only lift loads at the suspension points.
Only use suitable
lifting gear.
Prevent access for unauthorised
persons
/A
] W
ARNING
Danger to life
Access only for authorised individuals.
No
access for unauthorised individuals.
uctions
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ML009GB
Edition 04.2015

Obligatory warning instructions
5
Technical Data
LED/AN
SH
r:jj=
The values given
are standard values and
can
deviate depending
on the machine.
For the exact data and values, refer to the assembly drawings and
operating
manual for the machine.
5.1
Tests before delivery
The following checks have been carried out prior to delivery:

ATEX
check by an external test centre (for explosion protected
machine).

Dynamic drop test of safety gear with 125%
of the
max. payload.

Electrical tests according to EN
60204.

Function tests.
5.2
Transport/ storage
r:jj=
The values given
are standard values and
can deviate depending
on the machine.
Temperature range:
minimum
-4 °F
(- 20
°C)
maximum
104 °F
(40 °C)
Air humidity (relative):

Store in dry
rooms.

No jolts or vibrations.

No abrasive, corrosive substances.

The machine must be protected against pest damage (insects,
rodents etc.).

The machine must be cleaned and
inspected for damage before
transport/storage.
Reference Doc : V-2155-502-A-505 (Field Preservation
Procedure)
80%
RH
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Assembly Instruction

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Technical Data
5.3
Operating and environmental conditions
@=
The values given are standard values and
can
deviate depending
on the machine.
The
machine must only be operated when the following
operating and
environmental conditions are satisfied:
Temperature range
minimum
-4 “F
(-20°C)
maximum
104 °F
(40 °C)
W
ind
speed
Assembly:
28 mph (45 km/h)
Observe the
height-dependent change
in wind speed.
It may be necessary
to cease/prohibit operation of the machine under
extreme weather conditions (e.g. thunder storm
or sand and snow
storms), even if the operating and environmental conditions fall within
the
bounds of those stated.
Here, the operating company must provide appropriate regulations.
Atmosphere at the place of use
The atmospheric composition on-site must be suitable for people to
remain for longer periods in the area. In particular, reduction in the
oxygen concentration as a result of displacement or consumption must
be
prevented. The legal limit values for pollutant
concentrations/aerosols and dust in the workplace must not be
exceeded.
Operating
production systems I transporting
materials:
Ensure no
concentrations of aggressive / corrosive substances or dusts
are allowed to build up when operating the production plant or
transporting materials using the hoist. If this cannot be excluded with
absolute certainty inspect the corrosion protection of the
hoist as well as
the functional reliability of the electrical components at regular intervals
and
replace, if necessary.
Height
Up to a maximum
of 3280 ft (1000 m) above sea level.
The technical data, such as e.g. the load capacity, is only ensured up to
this assembly site elevation. (Motor heating)
5.4
Dimensions of the Machine
Dimensions (W
xLxH):
refer to assembly drawing
(V-2155-502­
A-014)
10
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Edition 04.2015

Technical Data
5.5
Speeds
Assembly
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approx. 40 ft/min (12
m/Min.)
5.6
Lifting height
Lifting height
5. 7
Load capacity
refer to assembly drawing
(V-2155-502-A-014)
(jjj=
The values given are standard values and can deviate depending
on the machine.
Assembly
Ladder in the car
5.8
Mast
1100 lbs (500
kg)
max. 330
lbs (150
kg)
(jjj=
Masts for offshore applications feature additional safety elements.
(jjj=
The vertical inclination of the mast must be a
max. 0.2° (max. 2 mm
every
3 m
mast length).
Check inclination during and following
installation using
appropriate means.
During assembly, make sure that the car door and landing-level
door are correctly aligned (Refer to Chapter 9.6)
5.8.1
Mast 650 x 250
W
eight: 302 lbs (137 kg)
Tightening torque for the mast
connection 258 lbf ft (350 Nm)
(4 bolts M
24 x 260-8.
8 with
washers and
collar nuts M
24)
(jjj=
For anchoring distances, refer
to the assembly drawing for
the machine
2’1 9/16″
X
9 13/16″
(650 x 250 mm)
1,
1

>
4’11
6/16″
(1508 mm)
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Assembly Instruction

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5.8.2
Mast 650 x 650
W
eight: 343 lbs (155 kg)
Tightening torque for the mast
connection 258 lbf ft (350 Nm)
(4 bolts M
24 x 260–8.8 with
washers and collar nuts M
24)
(G
por anchoring distances, refer
to the assembly drawing for
the machine (V-2155-502­
A-014)

)
Technical Data
4’11
1/16″
(1508 mm)
2’1 9/16″
X
2’1 9/16”
(650 x 650
mm)
LI
5.9
Acoustic emissions
Noise level LW
A:
5.1 0
Cable guide
@=
For the distances of the cable guides, refer to the assembly
drawing for the machine.

Cable guides must be installed depending on the expected wind
pressure

W
hen installing the
cable guides, care must be taken to ensure that
the cable carriage is not located inside a cable guide when the
car
has stopped at a landing. Install cable guides accordingly.
ructions
12
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Technical Data
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5.11
Tightening torques
(ifr’
Only bolts with a strength of 8.8 and greater must be used.
t
I
t
ith.
t ti
ht
I fitti
M
h
ec
amca
r
Ings wl
OU
1g
ening-o
rque con
ro
All details refer to bolts
in strength class 8.8
Tightening torque
Tightening torque
M8
18
lbf ft
25 Nm
M
16
159
lbf ft
210
Nm
M
10
36
lbf ft
49 Nm
M
18
221
lbf ft
300
Nm
M
12
63
lbf ft
86 Nm
M
20
313
lbf ft
425
Nm
M
14
100
lbf ft
135 Nm
M
24
524
lbf ft
710
Nm
5.11.1
5.11.2
Mechanical screw
connections with torque control
Mast elements to each other
258
lbf ft (350
Nm) I Tightening torque
Bolts 4 x M
24 x 260 – 8.8 with washers and collar nuts M
24
Mast bracket with the mast
For the tightening torque, refer to para.5.11.1
Mast elements to one
another
693 Nm
(dry!)
I Tightening torque
Bolts 4 x M
24 x 260–8.8
each with 2 x Nordlock washers
and 1 x nut M
24
Mast tie to the mast
For the tightening torque, refer to para.5.11.1
5.11.3
Electrical screw
connections without torque control (metal
screw
connections)
Tightening torque
Tightening torque
M4
0.88 lbf ft
1.2
Nm
M
12
11
lbf ft
15.5
Nm
M5
1.4
7 lbf ft
2 Nm
M
16
22
lbf ft
30 Nm
M6
2.21 lbfft
3 Nm
M
20
38
lbf ft
52 Nm
M8
4.42 lbf ft
6 Nm
M
24
59
lbf ft
80 Nm
M
10
7.37Ibfft
10
Nm
M
30
110
lbf ft
150 Nm
5.11.1
Assembly torque fischer
bolt anchor FAZ
II
Bolt anchor type
I Assembly torque
FAZ
1110
33 lbf ft
45
Nm
FAZ
1112
44.25 lbf ft
60
Nm
FAZ
1116
81
lbf ft
110
Nm
FAZ
1124
199 lbf ft
270
Nm
Edition 04.2015
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Assembly Instruction

Technical Data
5.12
Assembly geometry
Assembly geometry->
refer to the assembly drawing for the
machine.
5.13
Anchoring forces
@=’
The anchoring
forces and anchoring
distances are given
in
the
assembly drawing
for the machine.
@=’
Existing
anchoring
points on site must be able to safely absorb
the reaction forces of the
hoist.
5.14
Foundation
The foundation must safely transfer any existing
loads into the subsoil.
Therefore, before beginning
installation task, determine the following
points.

Proof of the
load capacity of the foundation

Verification of the
load-bearing capacity of the subsoil
Since the
load-bearing capacity of the subsoil is often very
difficult to
estimate, a specialist subsoil investigator should be called on if there is
even the slightest doubt, in particular for high/complicated
superstructures.
The following points must be taken into account when assessing the
subsoil:

Maximum
permissible soil pressure

Predicted settlement

Predicted groundwater levels

Predicted thawing and frost processes

Construction activities expected in direct proximity to the installation
site
Steel plates and concrete can be used as load-distributing base
supports. The foundation must be horizontal to erect the
mast.
5.14.1
Load-bearing capacity of the foundation
Do not install the hoist before the
load-bearing capacity has attained the
requisite 75%. This value
is generally reached after 6-7 days. If the
foundation is laid in frost conditions, the
necessary
measures for these
conditions must be carried out (e.g. insulation of the foundation).
5.14.2 ructions
14
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Edition 04.2015
Hoists with basin/underrun section
The basin/
underrun section must be provided on site and must
be established
in accordance with the
respective applicable
standards/directives for hoists.
Draining of the
basin/
underrun section must be ensured.

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Technical Data
5.15
5.15.1
5.15.2
5.15.3
5.15.4
Requirements of the installation site
Foundation

The foundation
must be
horizontal and
have sufficient load
bearing
capacity.

Depending on the
assembly height, steel sheeting
or concrete, for
example, can be
used as load distributing
base supports.

Sealing of the subsoil must be carried out in accordance with the
ground
load.

The total weight of the
hoist and
mast sections are transferred to the
foundation via the foot section support.

Total weight of the
hoist must be calculated complete with anchor
points and cable guides.
For the
payload of the
machine, refer to the Technical Data in the
instruction manual
Foundation – steel construction
The tolerance of the foundation for the steel construction
is:
Foot section mast:
+/- 1 mm
Foot section buffer:
+/- 2 mm
Soil pressure
For the
individual technical data for your machine, refer to the
project­
specific documentation.
Tolerances for the “support
plates” on site
@=
The data is only applicable for anchoring
“Type 1”, refer to
Chapter 9.4.2. For Type 2-4, do not refer to this chapter.
The
bolting surfaces on the wall brackets (scope of delivery
from
the
works/ on site) must ensure the following tolerances:
Parallelism
+/-3
mm
to the vertical reference line.
In order to align the
mast, use space plates to compensate.
5.15.5
5.15.6
Tolerances for vertical deviation
The tolerance for the vertical deviation for the
position of the wall
bracket (scope of delivery
from
the works/ on site):
Because the
connection to the mast using
clamps is carried out directly
on the
mast tube
(variable), GEDA
has allowed a deviation of +/­
30 mm.
Electrical connection
Refer to the
machine operating
instructions.
The cables provided
by the
customer must be designed such that:

they correspond
to the
connected
load of the machine.

no
interference voltages or interference frequencies occur.
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Assembly Instruction

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Transport

the
response behaviour of the safety equipment meets the
relevant
legal requirements.
Determination of the
cross-section of the cable required must be carried
out taking
into consideration the manner of routing. Country-specific
regulations must be observed.
W
ARNING
The equipotential bonding for the
hoist must be
connected to the
primary
equipotential bonding of the
building!
The
hoist must be factored into the
lightning protection
concept of the
operation.
Note for machines with frequency converter
W
ARNING
Electric shock
The frequency converter can prevent correct function or
lead to malfunctions in the “type A” residual current
device.
In the event of defects e.g. in the wiring, this can
lead
to electric shocks.
This product can cause a direct current in the protective earthing
conductor. At those places where a residual current device (RCD) or
a residual current monitor (RCM) is used for protection in the event of
direct or indirect contact, then only an
RCD
or RCM
of Type
B is
permitted on the
power supply end of this product.
If the
installation guidelines include
a “residual current device” (residual
current circuit breaker), then you must use a “Type
B” residual current
circuit breaker (all-current sensitive) for three-phase frequency
converters.
Select a residual current circuit breaker with the following features:

Filtering of high-frequency currents.

A
delay that prevents triggering
caused by interference capacities
which may be charged at switch-on.
This delay is not possible on 30 mA
residual current circuit breakers.
In this case, select a residual current circuit breaker that is resistant
to accidental triggering, for example a residual current circuit breaker
with enhanced immunity to interference (super-immune).
If several machines with frequency converters are operated from
a mains connection, then one
residual current device (residual current
circuit breaker) must be used for each machine with a frequency
converter.
16 / 58
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Edition 04.2015

Transport
6
Transport
6.1
Safety notes

Immediately report transport damage and/or missing
parts to the
supplier.

W
ear a safety helmet, safety shoes and safety gloves during
transport
tasks!

Only use appropriate, standardised and
tested
lifting
gear,
forklifts, cranes) and sling gear (round slings, lifting straps, sling
ropes, chains) for transport
at the assembly site.

During transportation, the car must be empty.

Only lift the machine
using the
necessary
parts and at the specified
suspension points.

W
hen selecting
hoisting equipment, always take into account the
maximum
suspended
loads!

Avoid tipping or dropping the machine/forklift at all costs.

Ensure that stable balance is maintained when transporting with
forklift trucks. Use appropriate means to secure the machine against
slipping/falling. Only transport the machine
at walking
pace.

No
persons must remain in the area below
or on the
raised
machine/parts of the machine.

Only load and transport equipment that has been carefully
disassembled, packaged and
lashed.

Always ensure that the machine
is transported without being
knocked
or jolted. Make sure that the
machine
is firm
during
transportation. Support the car before lashing down for
transportation.

The machine
must only be transported / installed on foundations with
a sufficient load capacity.

The
load
must be accordingly secured when transporting over steep
inclines/slopes.

Observe the
pictograms on the packaging.

Label dismantled parts to prevent any mix-up when reassembling.
Edition 04.2015
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Assembly Instruction

Transport 6.2
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Loading
and
unloading
the machine
The machine sections/components are loaded and unloaded using
a forklift truck.
Forklift
tines must be the
correct length or appropriate underlays
must be provided.
Forklift take-up points (1) are mounted on the base unit.
Exemplary
figure
Exemplary
figure
18 / 58
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Edition 04.2015

Lifting Parts of the
Machine
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7
Lifting
Parts of the Machine
@=’
Appropriate aids are installed
for the transportation and
lifting
of
the
parts. These are indicated
by red
paint and
must be removed
before commissioning.
7.1
Lifting the machine
Hoisting equipment (1) is attached to the
mast to lift the machine
using
a crane.

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r
e hoist must be suspended
vertically!

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7.2
Double doors of the enclosure
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7.3
Enclosure
Pre-assembled max. 220 lbs (100 k
)
Lifting
Parts of the Machine
Exemplary
figure
As a slinging point, two eyebolts (1) are installed on the
upper side
of
the enclosure.
Use the
hoist sling, chain or rope and
lift the enclosure.
7 .4
Mast section
Mast 650 x 250;
Mast 650 x 650;
ructions
302 lbs (137 kg)
343 lbs ( 155 kg)
20 I 58
ML009GB
Edition 04.2015

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Control Elements for Assembly
LEE/AN
SH
8
Control Elements for Assembly
8.1
Assembly control
(Use exclusively for maintenance and
assembly personnel)
On the car roof
1=
EMERGENCY
STOP
2 = Test lubrication
pump
3 = EMERGENCY
mode
switch (assembly/
maintenance switch)
OFF = normal mode/ car
control unit is active
ON
= Assembly control on
the
car roof is active
4 = UP
button
5 = DOW
N
button
For example, explosion-protected machine
6 = Maintenance switch
To switch off the
voltage to carry
out tasks in the
switch
box
Cir’
For a machine without Ex-protection, the assembly control is
connected
in
the switch
box on the car roof or on the underside
of this switch
box.
The power must be switched off
at the maintenance switch
(6)
when working at the switch
box.

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Control Elements for Assembly
@
Arter switching
on the main
switch, a green control light must
illuminate on the car control which
indicates that it is
ready for
service.
Assembly control connected
1 = EMERGENCY
STOP
4 = UP
button
5 = DOW
N
button
6 = Button EMERGENCY
STOP
release
(Before the command to move, press
and
hold until the ascent or descent
has finished.)
7 =slow/ fast selector switch
22 I 58
ML009GB
Edition 04.2015

Assembly 9 9.1
LEE/AN
SH
Assembly WARNING
A
The machine
must be assembled
in
accordance
with the assembly instructions and
under
supervision
by an authorised
person specified
by
the contractor!
Assembly personnel
The
machine
shall only be assembled, operated and
maintained by
authorised persons who
can
be guaranteed to act properly on the
basis
of their training or knowledge and practical experience, and who
are
aware of the
hazards. These persons must be appointed to the tasks of
installation, dismantling and
maintenance by the
operating company.
9.2
Safety notes
9.2.1
Installation and Connecting

Precautionary
measures stipulated
by the
company for avoiding fires,
explosions, dust, gas, steam
and
smoke (during welding, burning
and
grinding work) must be observed.

Welding, burning and grinding work on the
machine must only be
carried out following consultation with and approval from
GEDA.

The torques specified must be adhered to. Use a calibrated torque
wrench.

Appropriate lifting gear must be used when working with heavy parts.

Adhere to the minimum
requirements for thoroughfares, paths and
emergency exits.

Provide sufficient space to open doors and covers.

Observe the reduced load capacity of the car during assembly.

Observe the clearances for the mast brackets and cable guides.

Avoid mixing up/incorrect re-assembly of dismantled parts. Label
parts.

In the event of wind velocities>
28 mph (45 km/h), bring the car
down to the ground and cease operation.
Edition 04.2015
23 / 58
Assembly Instruction

LE
E
/
SH
Assembly

National accident prevention regulations from
the
industrial safety
authorities and all applicable laws and guidelines must be complied
with.

During
assembly, never do the following from
inside the
car:

reach or lean
into the travel path during travel.

allow
parts to project into the travel path during ascent/descent.

stand
on the
load.

exit the car to climb onto the mast or the
building.

Cordon off/identify
the assembly/hazard area.

No one
is allowed to stand
under the assembly/hazard area.

At loading points > 6.6 ft. (2 m) protection to prevent persons from
falling must be provided.

Safety rails on-site may only be removed once the landing-level
safety doors have been
installed.

When assembling
the
mast using
mas sections, the
projecting
mast may be moved out over the
last mast anchor by a max. 15
ft
(4.5 m)! (Upper edge of the trolley to the mast attachment point).

Make sure that the masonry/concrete and steel construction
is
capable of absorbing the
anchoring forces. A
construction expert
must check to ensure the anchoring wall is suitable for anchoring
forces of this kind. The inspection results will determine whether
plugs/dowels or through
bolts must be used.

The hoist may only be operated once all landing
level safety doors
have been fully installed and checked.
Assembly Instruction
24/ 58
Edition 04.2015
9.2.2
Transporting material

The operator is responsible for correct loading and unloading and for
correctly securing the
load.

Use appropriate lifting gear for loading
and
unloading. Only use lifting
gear that is designed for the weight of the load.

Never drive the
lifting gear into the
car.

Secure load with fastenings so that any movement is impossible
during transport.

Distribute the
load evenly and centrally in the car.

Observe the maximum
permissible
load capacity.

Never cover doors, control panels, emergency call system, first aid
kits or warning notices with the
load. They must remain accessible at
all times.

At loading points ;::: 6.6 ft. (2 m) protection to prevent persons from
falling
must be provided.

Material must not project into the travel path of the machine.

W
hen transporting material, this must not lead to a concentration of
abrasive/corrosive substances. If this cannot be safely excluded,
then the corrosion protection and/or the functional reliability of the
electrical components must be
inspected at regular intervals and, if
necessary, replaced.

Assembly
LE
E
/
SH

The generation/accumulation of (explosive) fine
particulate matter
must be prevented/removed immediately.

Unauthorised persons must be kept away during
installation of the
landing level safety doors. Unsecured building areas must be
secured against access.
9.3
Assembly procedure
The
installation plan shows the
basic assembly stages and their
chronological sequence. However, installation is always based on the
detailed instructions in this manual and the approved installation
drawings. Depending on the work equipment available / number of
installation engineers, work may be carried out in parallel or the
sequence of the
installation steps may be changed. If the sequence is
changed, the amended
installation plan must be checked by the
operating company to ensure that it is sensible and that there are no
potential hazards and must be subsequently approved.
Assembly schematic GEDA
SH
Base unit with basic mast
Install base unit with base mast and attach with bolts
(base mast comprises 3 mast sections)
Check the alignment of the base unit using a plumb line
Install the
1st Anchorage
Assembling
/ checking
limit switch
bar/ Emergency limit switch
bottom
AN
Electrical connection
Temporary
connection of the car
Connect assembly control (no Ex-protection)
Extension of the mast up to half the assembly height

Assembly of the mast brackets
Installation of the cable guides
Installation of the central feeder ( > half the assembly height)
Install the buffer support
Electrical connection
Install the ground-station switch box
Mains connection at the ground-station switch box
Routing the travelling cab
le across the cable carriage
Extension of the mast up to the maximum
assembly height.
Assembling
/ checking
limit switch
bar / Emergency limit switch top
Insta
ll the enc
los
ure
Assembly
of
the
enclosure
pane
ls
Assembly
of
the steps
and
lan
ding
Assembly
of the encl
os
ure
door
Install
the lan
dina lev
el safety
doors.
Electrica
l connecti
on
lan
ding(s) / basin
Conn
ecting
the
landin
g
call
boxes
Conne
ct the con
nections In the basin
I
(I
I{
fl

24/ 58
ML009GB
Edition 04.2015

LE
D
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Assembly
26/ 58
9.4
Assembling
the
base
unit
(ff’=’
The
machine must be installed and deployed
only vertically! The
alignment of the
base unit differs for each
machine, refer to the
drawings supplied.

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Befo
re commissioning the hoist (also
for assembly), the first mast
bracket must be positioned.
9.4.1
Assembling
the
mast bracket
(ff’=’
Because the mast brackets are designed for each location of
installation, for the exact data, refer to the assembly drawings of
the machine.
(ff’=’
With higher structures, the gear racks must be manually lubricated
during assembly!

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(ff’=’
The vertical and
rectangular alignment of the mast must be
checked and, if necessary, corrected.
(ff’=’
The vertical inclination of the mast must be a
max. 0.2° (max. 2 mm
every
3 m
mast length).
Check inclination
during and
following
installation using

9.4.2
Assembly
appropriate means.
During
assembly, make sure that the car door and
landing-level
door are correctly aligned. (Refer to Chapter 9.6)

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650
X 650
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650
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650×250
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650 x 650
E E o o uo cu o o ci. a. c
uctions
28/ 58
ML009GB
Edition 04.2015

Assembly
9.4.3
Provisional electrical connection

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ARNING
A
A
qualified
electrician
must connect the supply cable
and carry out the subsequent safety inspection
in
accordance with EN
60204/IEC
204!

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WARNING
A
To
operate the hoist during
assembly, the
Emergency stop circuit for the landing
level doors
must be temporarily bridged
in
the switch
box using
a wire jumper.
(Refer to the wiring
diagram
for the machine).
This task must be carried
out by a qualified
electrician.

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Assembly 9.4.4 @
LE
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Extending the mast sections
Align
the mast sections vertically using
a spirit level/plumb
line.
This must also
be checked when attaching
each
anchor.
The mast sections are lifted and
positioned on the
mast using a crane.
Attachment of other mast sections is carried out from
the car roof.
WARNING
A

Fitters must always wear personal safety equipment
(e.g. fall arrester and safety belt) when working on the
car roof.

Operation
is with the
assembly control.

The
load bearing capacity during assembly is max .
1100 lbs (500 kg)

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30 / 58
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Assembly
Tightening torque
258 lbf ft
(350
Nm), width across flats 1 7 /16″
(36 mm)

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ARNING
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KHQassembling
the mast using
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(ir’
With
higher structures, the gear racks must be manually lubricated
during
assembly!

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The gear racks must be lubricated
manually prior to the initial
commissioning!
GLWLRQ
31 / 58
VVHPEO,QVWUXFWLRQ

Assembly 9.4.5
LE
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/
SH
Commissioning the lubrication device
So that no grease escapes during transportation, for Ex-protected
hoists a film
is placed over the
grease tank.
(ij=
The film
must be removed
before initial commissioning
(before
installation)!
The
lubrication device is located on the
roof of the car.

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Assembly
9.4.6
Install the buffer support
A Danger to life
Car creates a crush hazard.
W
hen working
inside the
enclosure, activate the
setting
mechanism, switch off the
main switch and
secure from
switching
on.

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Assembly 9.4.7
LEE
/
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Installing the cable guides
The cable guides ensure trouble-free transport of the cable to the
cable
carriage. Cable guides must be installed depending on the expected
wind pressure.
(if=’
For the distances
betw
een the cable guides, refer to the assembly
drawing
for the machine.
Cable guide

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9.4.8
Installing the cable holder on the mast sections

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Assembly
9.4.9
Assembling the central feeder

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Assemble the central feeder so
that the lower part of the cable
attachment is
located slightly higher than
half the assembly
height.
@=
The cable holder for the travelling cable is
installed
in
the mast
section
below
the switch
box for the central feeder.
DVW[
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WARNING

Damage to the cable carriage
KFDEOHFDUULDJHmust always be positioned
below
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VVHPEO,QVWUXFWLRQ

Assembly
LE
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SH
9.4.10
Assembling the cable carriage
CAUTION
A
Damage
to the cable and
cable
carriage.
During assembly, make sure that the
cable
length is still
sufficient when raising the
car onto the
buffer.
The
cable
carriage
is installed when the
car is stationary
at the
ground
station. There is the
option of modifying
the
cable
carriage
so that it is
on the
left side
instead of the
right side.
The
housing of the cable roller (1) is attached flexible on the
bracket (2)
so that the
cable roller automatically aligns itself.

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Assembly

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Cable assembly for
explosion-protected
non-explosion
machine
protected machine
r:jj=
The cable carriage is available in
different designs (travelling cable
to left
or right).
r:jj=
The cable must be installed so that the side with the cable
identification is located
on the outside of the cable pulley/ cable
carriage.
Cable identification
GLWLRQ
37 / 58
VVHPEO,QVWUXFWLRQ

Assembly 9.4.11
LiE
D
AN
SH
Electrical connection
Power supply must be from
the central feeder above half the assembly
height.
A Electric shock
W
ork on the electrical installations must only be
carried out by
qualified electricians or instructed persons, in accordance with the
accepted rules of electrical engineering.
A
qualified electrician must carry
out the subsequent safety check in
accordance with EN
60204/IEC
204!

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Pre-assemble stairs and pedestal.
@
since there are different designs of stairs with pedestal, this
drawing is used only as an example.
Refer to the assembly drawing for the machine.
42 I 58
ML009GB
Edition 04.2015

Assembly
>
Assemble base enclosure in accordance with the assembly drawing
for the machine (V-2155-502-A-014&026).

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drawings are
only examples. Refer to the assembly drawing
for the machine.
GLWLRQ
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VVHPEO,QVWUXFWLRQ

Assembly
LE
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/
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Assembly
9.6
Landing
doors
Protection to prevent persons from
falling must be provided at all
loading
and unloading points with heights above 6.6 ft (2 m).
Only landing
level doors, in combination with a platform
that ensure
safe transfer to the building, are permitted for the tested and approved
GEDA
hoists.
(G
g
ecause the landing
doors with
landing
level enclosure are
constructed for each location of assembly, the drawing
is only an
example.
Refer to the assembly drawing for the machine
(V-
2155-502-014&026).

In
order to ensure sufficient stability
of the
landing enclosure, it is
normally necessary
to
install additional bracing on site.
The
GEDA
landing level door is tested and approved in conjunction with
the
GEDA
hoist and it conforms to these requirements.

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VWUXFWXUHLQDFFRUGDQFHZLWKWKHDVVHPEOGUDZLQJ

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ZLWKWKHZLULQJGLDJUDP
([DPSOHV
(G
e
following
clearances must be observed
according to the
standard for hoists betw
een the approach
plate of the landing
level
door and
the door sill
of the hoist (also
refer to the assembly
drawing):
– EN81:
min. 25 mm
I max. 35 mm
-A
SME
A17.1: min. 1″
(25 mm)/ max. 1 ¼” (32 mm)

Make sure that the car door and
landing
level door are correctly
aligned
(refer to the assembly drawing).
Make sure that the plate of the retiring
cam
reliably touches the
contact on the landing
level door.

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Assembly
LE
E
/
SH
9.7 9.7.1
Program
m
ing
the
landing
level positions
Single/Automatic control
After assembling the mast sections and
landing level safety doors
(basin doors), the precise stop position must be determined and entered
for all the upper landings.
(it=’
The
landing
level positions must also
be programmed
after
replacing
the
PLC
control or after retrofitting
landings!
At the
lowest landing
level (ground station), the
car is stopped by the
limit switch approach bar that is already installed. This landing
level
position must be checked and, if necessary, adjusted.
(it=’
The
lowest landing
level (ground
station) cannot be
programmed!

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URRIRIWKHFDU
DANGER
A Electric shock

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URJUDPPLQJMXPSHU
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(it=’
The
programming jumper remain
pressed
until all landing
level
positions are programmed!
46 / 58
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Assembly
*) = Enable button

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 RUDOW
N
 

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UDOW
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XWWRQEHIRUHWKHHQDEOHEXWWRQ

The car floor and sill of the landing
level safety
door must be at
exactly the same
level.
l
0 0
Move to landing
level position

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PDLQWHQDQFHFRQWUROWRWKHSRVLWLRQ
MANUAL/ON.

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XWWRQ  WRSRVLWLRQWKH
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G
por control using the enable
button (5), simultaneously press
the UP
or DOW
N
button with the
enable button and
keep
pressed.

RUDSSUR[7 seconds, press KH
GLUHFWEXWWRQV  WREHSURJUDPPHGDW
A
KLFKWKHFDULVSRVLWLRQHG
$IWHUVHFRQGVWKHIODVKIUHTXHQFRIWKH
7
]
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– (
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@
[

4
@
3

2

1 V
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VVHPEO,QVWUXFWLRQ

Assembly
LE
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/
SH

VHWKHmaintenance control RPRYHWKH
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HSHDWWKH
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Cir’
This
programming
must be carried
out at all higher landing
levels!
When all the landing
levels
have been
programmed, remove the
programming jumper.

XUQ
WKH
NHVZLWFKRQWKHPDLQWHQDQFHFRQWUROWROPERATION/OFF
QG
UHPRYHWKH
NH
Function check

UHVVWKHGLUHFWEXWWRQ  
7KHFDUDXWRPDWLFDOOPRYHVWRWKH
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VHOHFWHGDQGVWRSVWKHUH
Check

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,VWKHIORRURIWKHFDUDWWKHVDPH
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Cir’
Carry out a function check at each
landing.
9. 7 .2
Selective/Collective control
IWHUDVVHPEOLQJWKHPDVWVHFWLRQVDQGODQGLQJOHYHOVDIHWGRRUV
EDVLQGRRUV WKHSUHFLVHVWRSSRVLWLRQPXVWEHGHWHUPLQHGDQGHQWHUHG
IRUDOOWKHXSSHUODQGLQJV
Cir’
The landing
level positions must also
be programmed after
replacing the
PLC
control or after retrofitting
landings!
WWKH
ORZHVWODQGLQJOHYHO JURXQGVWDWLRQ WKH
FDULVVWRSSHGEWKH
OLPLWVZLWFKDSSURDFKEDUWKDWLVDOUHDGLQVWDOOHG7KLVODQGLQJ
OHYHO
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Cir’
The lowest landing
level (ground
station) cannot be programmed!

SHQWKHVZLWFKFDELQHWRQWKH
URRIRIWKHFDU
A Electric shock
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HQJLQHHULQJ

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SURJUDPPLQJSXVKERWKSURJUDPPLQJ
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DANGER
48 / 58
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Assembly
(G
o
update
individual landing
positions, only press the
programming jumper 251 (1a)!

ORVHWKHVZLWFKFDELQHW
Position:
SHUDWLRQ
3URJUDP
WKH
8SGDWHWKH
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ODQGLQJ
OHYHO
SRVLWLRQV
SRVLWLRQV
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PDFKLQHV
(ii=
The
programming jumpers remain
pressed
until all landing
level
positions are programmed!
Move to landing
level position

RWDWHWKHNHVZLWFK  RQWKH
PDLQWHQDQFHFRQWUROWRWKH
SRVLWLRQ
MANUAL/ON.

KHJUHHQFRQWUROOLJKW  IODVKHV
RQWKHFDUFRQWURO

UHVVWKHUP
XWWRQ  RUDOW
N
XWWRQ  WRSRVLWLRQWKHFDULQIURQW
RIDODQGLQJ
OHYHOGRRU
&
por control using
the enable
button (5), simultaneously press
the
UP
or DOW
N
button with the
enable button and
keep
pressed.
0 ·[+]
R>@

(QDEOHEXWWRQ

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 RUDOW
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GLWLRQ
49 / 58
VVHPEO,QVWUXFWLRQ

Assembly
LE
E
/N
SH
@=
The car floor and
sill
of the
landing
level safety door must be at
exactly the same
level.

RUDSSUR[7 seconds, press KH
GLUHFWEXWWRQV  WREHSURJUDPPHGDW
ZKLFKWKHFDULVSRVLWLRQHG
$IWHUVHFRQGVWKHIODVKIUHTXHQFRIWKH
FRQWUROOLJKW  ZLOOFKDQJHIRUDSSUR[
VHFRQGVWRFRQILUP
WKHHQWU
O
@

[: 0

@
@El

1l
@
4

z
@
1

VHWKHmaintenance control RPRYHWKH
FDUWRWKH
QH[WODQGLQJ
OHYHOVDIHWGRRUDQGSRVLWLRQ
LWH[DFWO

HSHDWWKH
ODQGLQJ
SURJUDPPLQJ
@=
This programming
must be carried
out at all higher landing
levels!

ywhen all the landing
levels
have been
programmed, remove the
programming jumpers.

XUQ
WKHNHVZLWFKRQWKH
PDLQWHQDQFHFRQWUROWROPERATION/OFF
QG
UHPRYHWKH
NH
Function check

UHVVWKHGLUHFWEXWWRQ  
7KHFDUDXWRPDWLFDOOPRYHVWRWKH
ODQGLQJVHOHFWHGDQGVWRSVWKHUH
Check

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ODQGLQJ
‡
,VWKHIORRURIWKHFDUDWWKHVDPHOHYHODVWKHVLOORIWKH
ODQGLQJ
OHYHO
VDIHWGRRU
@=
Carry out a function check at each
landing.

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Assembly
9.8
Check after assembly/ before commissioning

Check to ensure that
— the
gear rack is adequately lubricated with grease
– all assembly aids have been
removed from
the machine
– the wire jumpers installed in the ground-station switch box for
assembly have been
removed
– the specified tests have been carried out
– there is no oil leakage at the gear motor
– the
supply cable has a sufficient cross section
– the
cables are correctly connected
– the direction of motor rotation agrees with the UP/D
OW
N button
movements
– the
length of travelling cable
is sufficient for the assembly height.­
the danger zone at the
lower loading
point is cordoned off.
– plates/notices are present and
legible (see technical data).

Carry
out a test run with loaded
car and carry
out a function check of
the brake.

Check that the
control in the car and call buttons at the stop positions
function correctly.

Check to make sure that the
EMERGENCY
STOP
buttons stop the
hoist (ground station, landings, basin)

Check to make sure that the
landing level and car doors open and
close correctly.

The travelling cable, mains supply and control lines must not indicate
and damage.

Carry
out a drop test to check the function of the safety gear. (See
operating manual)

Give handover report
and documentation to the operator/user.

Give the key for the ground station switch box to an authorised and
instructed person.
9.9
Checking the bolted connections
@=
After approx. 20 journ
eys, the
bolted connection must be checked.

The following bolted connections must be checked:

Anchoring the mast and
buffer base plate in the foundation

Bolted connections of the
1st Mast to the mast base plate

Bolted connection of all masts to one another

Bolted connection of the mast connection to the
mast

Bolted connection of the telescopic tubes / wall brackets / wall
plates

Cable guides
Edition 04.2015
51 / 58
Assembly Instruction

LE
D
A
SH
Disposal of the machine
10
Dismantling (disassembly)

The machine must be disassembled
under supervision of an
authorised
person specified
by the contractor!
@=
The same
regulations and
safety
instructions for assembly are
applicable for disassembly.
Disassembly is generally carried out in reverse order to installation; in
addition, also observe:

Disassemble the
landing safety doors first.

Before removing the mast brackets, check whether all mast
connection bolts are engaged.

The car must be stopped so that impact of the mast section to be
removed is located above the
upper edge of the carriage.

Only release the mast brackets when there are no more mast
sections above the anchor point.

Always intermittently unload the car.
52/ 58
ML009GB
Edition 04.2015

Dismantling (disassembly)
LE
E
/N
SH
11
Disposal of the
machine
Correctly disassemble the
machine
at the end
of the
service life and
dispose of it in an environmentally friendly way according
to
national
provisions.
C]j=’
It is
prohibited to use parts
from
a machine that is
being
disposed
of in
other machines or to assemble such
parts
to produce a new
machine.
During
disposal of the machine components, observ
e:

Drain and dispose of oil/grease in an eco-friendly way.

Recycle metal parts.

Recycle plastic parts.
Recommendation:
Contact the
manufacturer or commission a specialist company to
handle disposal requirements in accordance with regulations.
Edition 04.2015
53/ 58
Assembly Instruction

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