Hydraulic Residential Elevator

INSTALLATION MANuAL

Thank you for your purchase of a Federal Elevator Hydraulic Residential Elevator. We appreciate and value your continued affiliation with us and we are proud to list your company as one of our recommended Dealers.

This manual will provide you with instructions on how to properly install one of our Panorama or Renaissance models in a home. Upon your job going to contract, we will issue a special number which begins with F-. Please refer to this number when communicating with us so that we can collect the project’s corresponding files. Federal Elevator will provide you with an Installation Package with your shipment which will include General Layout and Electrical Schematics that are specific to your job. Those materials along with this Manual will be of help during your installation.

Please pay close attention to any safety messages and notes in sections following. These are indicated with symbols ( ) and bold text and contain important information that will ensure your safety and will ease the installation process.

Should you have any questions during the installation, please contact us at (905) 458-4015 or at 1-888-785-5438 ext. 228 for Technical Support.

September 2015

PAGE 1 of 48

Table Of Contents

SECTION 1 – SafETy aNd MaTErIalS rEquIrEd

2 Safety2 recommended P.P.E.2 Mechanical Safety 2 Electrical Safety 3 recommended Tools and Materials required

SECTION 2 – INSTallaTION

4 Pre-Installation Site Check4 Installation Procedure4 rail Bracket Installation5 rail Installation7 Installation of Cylinder, Sling assembly and

related Equipment7 Cable Installation8 Pum p unit and Controller Installation 8 Cab Installation 10 accordion door Installation10 Bifold Gate Installation 10 2-Speed door Installation 10 Cab Electrical 10 Travel Cable Installation 11 Switch Mounting 11 Hoistway and Hall Station Wiring11 Tapehead Mounting/Magnet Installation 11 Tapehead Magnet and Valve adjustment12 Interlock Installation12 uninterrupted Power Supply (uPS) Installation13 finalizing The Installation

SECTION 3 – adjuSTMENTS aNd TrOuBlESHOOTING

14 Tapehead Magnet and Valve adjustment quick Guide15 Troubleshooting Procedures15 quick Guide15 quick fix Guide for Typical Problems 16 residential Controller PlC Inputs & Outputs21 Maintenance Guideline

aPPENdICES

23 appendix 1 – residential 3" X 5" rule

24 appendix 2 – Temporary Operation Start up Procedure

25 appendix 3 – Main and auxiliary disconnect and Motor Connection

26 appendix 4 – residential Exploded View – accordion doors

27 appendix 4a – residential Exploded View – Bifold doors

28 appendix 5 – Infrared Curtain assembly

29 appendix 6 – Two Speed door Installation

30 appendix 7 – Tapehead Mounting

31 appendix 7a – four Stop Magnet Placement

32 appendix 7B – Three Stop Magnet Placement

33 appendix 7C – Two Stop Magnet Placement

34 appendix 8 – Hoistway Prewiring drawing

35 appendix 9 – Blain Valve adjustment Sheet

47 Notes

PAGE 2 of 48

SECTION 1 – Safety and Materials RequiredSafETy

WarNING: always pay very close attention to this symbol. It indicates important safety information for preventing serious injury/bodily harm or equipment damage.

Always use proper safety procedures when working on any installation lift. Ensure that your Personal Protective Equipment (P.P.E.) is appropriate for the type of job that you are doing and that it fits correctly.

It is very important for you to keep in mind the 3"x 5" rule during the initial stages of design. aSME a17.1 rule 5.3.1.4.2 States: The clearance between the hoistway doors or gates and the hoistway edge of the landing sill shall not exceed 3 inches (76mm). The distance between the hoistway face of the landing door or gate and the car door or gate shall not exceed 5 inches. This rule must be strictly adhered to as it will prevent having an area between the hall door and elevator door that could potentially be an area that a small child, person, or animal could fit and be subject to injury or death. Please refer to Appendix 1 – Residential 3" x 5" Rule.

NOTE: Some door hinges and door handles may interfere with this rule due to size. Ensure that they will not impede with this rule before you begin installation of the elevator.

NOTE: Please refer to detail a on Page 2 of the General layout which indicates interlock mounting and running clearance dimensions.

rECOMMENdEd P.P.E.:

■ Steel toe boots – CSA/UL approved – Soles resistant to shock

■ Hard hat – Class A

■ Eye/face protection – CSA/UL approved

■ Work gloves

■ Hearing protection

■ Personal fall arrest equipment – with at least basic training

■ Respiratory protection

MECHaNICal SafETy

alWayS adHErE TO THE fOllOWING rECOMMENdaTIONS durING INSTallaTIONS:

■ Watch out for any moving parts

■ Do not wear shorts or tank tops, long sleeve shirts and pants are recommended

■ Jewelry and loose clothing shall not to be worn when working

■ Always shore the lift before working in the pit

■ There should always be two people present to complete the installation

■ Never try to lift a cylinder or any other heavy object alone

■ Tie off your personal fall arrest equipment when over 6 ft.

■ Make sure to provide proper barricades as per local building jurisdictions at every hall entry prior to the installation of doors with working interlocks

ElECTrICal SafETy

alWayS adHErE TO THE fOllOWING rECOMMENdaTIONS durING INSTallaTION:

■ Before working on any electrical circuits remove all metal object and electrical components you are carrying, i.e. cell phones, jewelry, tools, keys, etc.

■ Use a proper circuit tester in good working condition

■ Always take the time to check each circuit before performing any work

■ Assume that all electrical circuits are lIVE unless tested to prove otherwise

■ Make sure that you are not standing or kneeling on metal or wet surfaces

■ Use fuse pullers to install and remove fuses

■ When exiting the site, ensure that you use proper lock-out and tag out procedures so that the elevator is inoperable when the mechanic is not on-site.

Always work in a safe manner and be aware of your surroundings.

YOU ARE RESPONSIBLE FOR YOUR OWN SAFETY!

PAGE 3 of 48

rECOMMENdEd TOOlS aNd MaTErIalS rEquIrEd

Federal Elevator recommends that you have the following tools and materials available for use during every installation:

STaNdard MECHaNICS TOOl KIT:

■ Screwdrivers:

■ Phillips - #1, #2, #3■ Slotted – ¹⁄₈" (for wiring controller), ³⁄₁₆", ¼"■ Robertson - #1, #2

■ Set of open wrenches – ⁵⁄₁₆" to ¾"

■ Set of socket wrenches (deep and shallow) – ⁵⁄₁₆" to ¾"

■ Exactor knife

■ Locking pliers – small, medium

■ Set of allen keys – Metric and SAE

■ 10" Files - (File Rail joints)

■ Center Punch

■ Hammers

■ Tape measure – Metric / SAE

■ Pry bars – Small, Large

■ Flashlight

■ Carpenters pencils

■ Permanent markers

■ 2 Plumb bobs and lines

■ Chalk line

■ Levels – 4', 2'

■ Extension cords – 50' to 100'

■ Chain hoist or come along – min. ½ ton capacity

■ ½" reversible hand drill

■ Hammer drill

■ Electric grinder

■ Drill bits – Carbide, masonry

■ Hacksaw with fine and coarse blades

■ Chisels

■ Temporary light for shaft

■ Funnel for Oil reservoir

■ Digital multimeter

■ Alligator clips

■ Emery paper- Fine

■ Fuse puller

■ Wire Strippers

■ Wire Ties

■ Rags c/w cleaning solvents

■ Temporary Up + Down Buttons

■ Scaffolding and/or Ladders

■ Safety harness equipment (Fall Arrest)

■ Safety Boots, Safety helmet, safety glasses and gloves

MaTErIalS rEquIrEd:

■ Wall Anchors to suit project construction

■ 32 Grade Hydraulic Oil - Min. 20 gal.

■ Electrical Tape

■ ½" Aluminum Flex

■ ¹⁄₈" Aluminum flex

■ Marr Connectors

■ Butt Connectors

■ ½" + ¹⁄₈" electrical connectors

■ TEW stranded wire 10 ga. + 18 ga. – This is dependent on electrical codes

■ Multi-wire cable (wiring for call buttons and interlocks)

■ Wire Ties

PAGE 4 of 48

SECTION 2 – InstallationdElIVEry Of MaTErIal

aCCEPTING THE lIfT

Federal Elevator has taken every care to ensure that the equipment leaves the factory in excellent condition. Upon receipt of the material, inspect all components in the presence of the shipping company. Ensure that there is no damage to the equipment, wrapping or the crating.

NOTE: any damages to the equipment, wrapping or crating should be reported to the carrier immediately and an email sent to us as soon as possible listing all of the damages. It is your responsibility to file freight claims against the carrier for damages to equipment during shipping.

uNPaCKING THE lIfT

Once the lift has been inspected and accepted, an inventory of all parts must be completed. We recommend that you compare all components in the shipment against the shipping list, which can be found in the Installation Package that states the F number. Should there be any discrepancies between the shipping list and the shipment, please call 1-905-458-4015 and let us know immediately.

WarNING: Ensure that two (2) people are available to unpack the lift. failure to do so may result is serious bodily harm and/or damage to equipment.

PrE-INSTallaTION SITE CHECK

Below are a list of site checks and dimensions that shall be done prior to beginning any installation. If any of these requirements are not met, notify the site super immediately. If any dimensions on site are different from those on the drawings, contact Federal Elevator to confirm whether alterations need to be made.

SITE CHECK

Prior to installation, the site must be inspected to ensure that it is ready for you to begin the process. Please check the following:

SHafT

■ Check that the shaft is square and plumb

■ Confirm the finished shaft length and width with original dimensions given by customer and Federal Elevator drawings

■ Confirm the number of floors served

■ Ensure rail bracket supports are exposed (if the supports are covered by dry wall, the drywall must be cut out so as to allow the bracket to sit against the supports)

■ Make sure support dimensions are the same as bracket spacing on drawings

■ Pit floor must be smooth and level where the pit steel sits

■ Check: pit dimension, floor to floor dimension and total travel dimension

■ Check overhead

■ Ensure no other equipment, or piping are in the shaft, unless they pertain to the elevator

MaCHINE rOOM

■ Confirm that the machine room is in the right location and on the right floor

■ Ensure that there is a min. clearance of 3'3" in front of any live circuits, as well as a min. clear height of 7'0" – Or as per any Local Codes

■ Make sure that main disconnect switch (fused, 3 pole with auxiliary contact) is live with fuses in place

■ Usually 220 V - single phase, or as per drawing

■ Check that 120VAC – 15 Amp fused disconnect is live

■ Ensure G.F.I. receptacle is installed and working

■ Verify that the light switch and light are working

INSTallaTION PrOCEdurE

WarNING: Because of the close tolerances required with this equipment, the placement of the guide rail brackets is CrITICal as there is no adjustment once the rails are attached. Therefore you should plumb the rail brackets as accurately as possible before the installation of the guide rails.

WarNING: It is advisable to have more than one person on site during the start-up stage.

raIl BraCKET INSTallaTION

1. It is very seldom that you come across a plumb and square shaft so the mechanic must first establish the “tightest point” in the shaft. The tightest point is found by dropping a plumb line from the top landing (from the top landing sill on the rail wall side) to the pit and taking measurements from the landing sill to the plumb line at each landing. The smallest distance to this plumb line will be your tightest point.

NOTE: Ensure the plumb bob is perfectly still and not touching the pit floor.

2. Once the tightest point is found, it is time to mark the center line of the rails. Refer to the plan view of the General Layout (page 1 of 4) for this dimension.

PAGE 5 of 48

NOTE: This dimension is not a constant and will vary from job to job depending on the size of the lift.

3. Drop a chalk line from the top of the shaft to the pit floor. Ensure that your chalk line intersects the center line marking made from the tightest point. Check that your measurement at the top and bottom is not smaller than the tightest point measurement. Once the weight of the chalk line stops moving, “snap” the chalk line and confirm you have a clear mark all the way up the shaft.

4. Using this center line mark, make your way up the scaffolding/ladder and mark the vertical rail support locations as shown in the General Layout (page 3 of 4).

NOTE: These vertical dimensions do not have to be exact, they can be moved up or down in case of an obstruction to a maximum of 80" (2032 mm).

5. Using a 4' carpenters level, mark the hole locations as seen in Figures 1 or 2 (see page 1 of 4 of the General Layout drawings to determine what size Distance Between Guide rails (D.B.G.) your installation requires).

NOTE: Ensure that the marks are level by using the bubble indicators on the level.

figure 1 – 30" d.B.G. rail bracket fastening dimensions

figure 2 – 27" d.B.G. rail bracket fastening dimensions

6. Once your holes are marked, begin to drill holes for anchors, through bolts, or lag bolts (depending on the construction of the elevator support wall).

7. ALWAYS begin the installation of the brackets with the top bracket. Center the bracket with the chalk line mark and level it off. Tighten the four (4) Through bolts or anchors and drop a plumb line to the pit on each of the rail bracket legs, 5 ½" from the wall, see Figure 3

NOTE: for extended rail brackets refer to General layout (page 3 of 4) for centerline dimensions. These centerline dimensions are very critical).

With the two (2) plumb lines hanging, continue to install the remaining rail brackets. Ensure that you keep the rail bracket leg centerline dimension constant or within ¼". Use the plumb lines to as a guide to keep the rail brackets in line.

figure 3 - rail Bracket leg Centerline

NOTE: Make sure that your rail brackets are perfectly level and all bolts are tightened. Shimming may be needed in order to keep your leg centerlines constant.

raIl INSTallaTION

1. You must install the pit steel before the installation of the rails can begin.

2. Ensure that the floor is clean and level before installing the pit steel. If not, use the rails shims provided and shim level underneath pit steel.

3. The pit steel must be inline with the rail bracket legs. This is done by using the plumb lines, see Figure 4. The pit steel is to be secured to the floor after the installation of the car frame and fixing of the guide rails.

figure 4 - Pit Steel

4. Once the pit steel is set into place, you may begin to stack the rails.

NOTE: confirm that the faces of the rails are clean prior to installation.

5. The first set of rails that should be stacked will have a ½" hole in at approx. 60" high from pit floor. These holes are for the bottom dead stops.

NOTE: rails ends are “tongue and groove”, please verify that one of the rails is “male” end down and the other is “female” end down.

PAGE 6 of 48

6. Place the rails in the center of the rail bracket legs and pit steel brackets and tighten rail clips by hand, center the rail with the plumb line by eye. Begin by making sure that you have the proper D.B.G. between the rail faces (see General Layout for this dimension), shims may be needed to achieve this dimension.

7. Using a level, level out the front and side faces of the rail. Always remember to keep your rail centerline (5 ½" or as per drawing, see Figure 3). Once everything is level and at the required dimension, tighten the rails to the brackets using the rail clips.

8. With the first rails stack in place, the fish plates can be installed. Always remember to keep the machined face of the fish plate against the rail. Tighten the eight (8), four (4) per fish plate, bolts by hand. With the fish plate in place, the next set of rails can be stacked.

9. Gently bring the next rail down onto the stacked rail until the tongue and groove match up. Insert the remaining eight (8), four (4) per fish plate, bolts (M12 x 2") into each fish plate and tighten by hand.

10. Follow steps 1 to 9 until the rails are completely stacked.

NOTE: Ensure that all fish plate bolts, rail clips and rail bracket bolts are tight. Check that all rail joints are mated properly. If necessary, file the rail joints to ensure a smooth transition.

NOTE: Do NOT use a grinder to file the rail joins.

INSTallaTION Of CylINdEr, SlING aSSEMBly aNd rElaTEd EquIPMENT

1. After the installation of the rails it is time to move onto the cylinder assembly.

2. The vertical drawings in the General Layout will indicate the dimension for both the pillar (3" x 3" Steel tubing) and the cylinder to wall bracket. Anchor the pillar bracket onto the wall with the appropriate fastening hardware. On top of the pit steel you will see welded square angles where the pedestal sits into place.

3. Place the pillar bracket onto the pillar and tighten bolts (see Figures 5 and 6).

4. Sit the cylinder pillar cup into place. Federal Elevator has installed a decal which indicates the direction of the cup to avoid any confusion. The plate of the cup has a diagonal cut which faces towards the back wall and to the right. (see Figure 5).

figure 5 - Cylinder and Pedestal assembly

figure 6 - Pit Steel assembly

5. Prior to lifting the cylinder, and for ease of installation, we suggest installing the flow control valve, bleeder and drain elbow ahead of time on the floor. Use high grade Teflon tape to ensure a secure and leak free fitting.

NOTE: refer to figures 7, 8 and 9 to determine the correct direction of the valve restricted flow. Please ensure attention has been paid to this detail.

figure 7 - flow Control Valve a

figure 8 - flow Control Valve B figure 9 - flow Control Valve C

PAGE 7 of 48

6. Lift cylinder using a chain hoist or come along (min.½ ton) and place into cylinder cup.

7. Install the cylinder bracket provided ensuring that the clamp is approximately 12" (305mm) below the cylinder head and pushed as far as you can to the right (see Figure 10).

figure 10 - Cylinder Bracket Set-up

8. The sheave assembly can now be mounted to the top of the cylinder. The cylinder top plate is attached to the underside of the sheave and must be removed and fastened to the cylinder head with the ¾" bolt provided in cylinder. The cylinder top plate is also marked with a decal which points towards the back of wall. Slide the sheave between the rails and drop it onto the top cylinder. There are four ½" hex bolts holding the plate to the sheave. Fasten them together and tighten all bolts.

NOTE: That this assembly is installed so that the cylinder is offset towards the back wall and to the right.

9. The next step is to plumb the cylinder. The sheave has been designed with slots at each end of the plates that allow it to be moved ½" in either direction. If necessary, loosen bolts and shift the top of cylinder over to achieve your level. Adjust the pillar bracket as necessary to plumb the shaft. Once this is complete and you are satisfied the cylinder is level tighten up the cylinder wall bracket and the sheave plate.

10. With your scaffolding or ladder still in place, slide the two ³⁄₈" wire ropes through the sheave so both loose ends are at the bottom of shaft. The sling assembly can now be installed onto the rails. For shipping purposes these slings were fastened together.

11. Disassemble sling uprights by removing the four ½" x ¼" bolts in the top horizontal and bottom safety channel. Remove the two ¼" bolts from the plank cross braces. Lay a couple of cinder blocks or pieces of wood on the pit floor to be used as temporary sling supports inside the shaft.

12. The finished sling will have to be located at the under travel distance below the lowest landing. The top of the platform should be approximately 1"- 1 ½" (25-38mm) below the finished floor of the lowest landing (see Figure 11).

figure 11 - Sling Set-up

13. Insert both sling uprights onto the rail with the sling planks resting on the wood/blocks. Tighten the top horizontal sling channel to sling uprights by hand and proceed to do the same for the bottom with the bottom safety assembly.

14. Place a level across the sling planks and ensure that they are level to one another. Shim if necessary. Once this is done tighten all eight ½" bolts and attach sling cross braces together to ensure that the distance between the legs is constant.

NOTE: The guide shoes should have a clearance of ¹⁄₃₂" between each guide and rail face.

CaBlE INSTallaTION

1. During the installation of the sheave, your ropes had been passed through the sheave while the scaffolding or ladder was in place. It is now time to fasten both ends of the ³⁄₈" steel cable into the wedge sockets.

NOTE: federal Elevator pistons are not required to be raised out of the cylinder prior to roping.

2. We suggest roping the wedge sockets on the dead end hitch side (Pit Steel) first. Ideally, manually thread yours bolts on the shackle rod halfway up so it provides maximum adjustment in either direction once the ropes become taunt should adjustment be required.

3. Remove cotter pin from wedge and remove from wedge socket. Pass your first rope down through the long side of the socket and loop the cable back up towards the short side of the socket. At the same time, insert the wedge back up through the socket pulling an excess of 18"–24" (457-610mm) cable past the top of the socket.

4. With the rope clips provided, fasten the excess rope to the stationary rope together. Ensure the cotter pins are placed into the shackles and that your rope clips are fastened properly (Refer to Figure 12).

NOTE: remember, ‘you never saddle a dead horse’.

PAGE 8 of 48

figure 12 – Wedge Socket

5. Review your wedge sockets position so that they are not twisted and running parallel to one another to avoid any further twisting. You will later need to trim down the excess length but this is done once you are satisfied of the final adjustments after running the lift is complete.

6. Proceed with the next rope following the same steps (See General Layout).

7. Now it is time to fasten the rope to the wedge sockets on the car sling assembly. Make sure that the first rope you fastened is aligned correctly with the opposing end.

8. Follow the same steps as earlier and pull the ropes as taut as possible. This will lessen the platform from dropping down too far into the pit once tension is applied.

9. Fasten your clips onto the rope and provide same excess of rope as you did at the pit steel.

10. Roping is now complete and you can proceed in the machine room to install the pump unit and controller.

PuMP uNIT aNd CONTrOllEr INSTallaTION

1. Install the hydraulic power unit and fix the controller to the machine room wall (Please refer to the General Layout).

2. Verify that the electrical supply is as required by the specifications and is compatible with the supplied equipment meeting all local requirements.

3. Read the electrical schematics provided before connecting motor and other equipment to the power supply (Electrical Schematics are included in your Installation package). (Refer to appendix 3 – Main and auxiliary disconnect and Motor Conection)

4. Once all connections are made and ready electrically, review the appendix 2 Temporary Operation Start up Procedure for up and down direction.

5. Connect the hydraulic hose line or piping (to suit local code requirements) to the tank unit. It is recommended with all our hydraulic fittings that Teflon tape be used or an equivalent caliber of pipe dope (hard piping). Be careful not to block passage of oil with excess Teflon tape.

6. Fill the tank with Grade 32 hydraulic oil making sure the oil will cover the pump/motor unit completely.

7. Dry any excess spillage and inspect tank for any potential leaks. Check oil level again after the oil is pumped to the hydraulic cylinder.

Note: The typical amount of oil required is 15 gallons, this will however, depend upon travel and the size of the tank.

Completed Machine room

CaB INSTallaTION

With the slings and cables installed and elevator running, it is now time to begin installing the cab.

NOTE: It is essential to follow the steps given to ensure proper installation.

appendix 4 – residential Exploded View – accordion doors and appendix 4a – residential Exploded View – Bifold doors are good points of reference to help you understand the way the cab and parts of the residential elevator will fit together.

1. Begin by raising the lift approx. 6" to get some tension on the cables.

2. Remove the tape off of the bottom sling channel to expose the pivot plate. Unscrew the ¼" nuts on the ¼"-20 x 6" eye bolt and bring the bottom ¼" nut all the way to the bottom of the eye bolt and bring the top ¼" nut down so that all of your thread is up in the air, and tighten by hand.

PAGE 9 of 48

3. Pass the ½" threaded rod through the large slot on the pivot plate. On the front face of the safety block, there are a total of 3 bolts. There are two ¼" bolts and one ⁵⁄₁₆" bolt. Unscrew the ⁵⁄₁₆" x 1" bolt and pass it through the hole in the pivot plate. With the bolt through the pivot plate hole, re-screw it back into its original place. Screw the bolt in half way and then place the smaller pivot plate slot onto the knurled roller. Tighten the 5/16" bolt all the way and then loosen it off a couple of turns so that the pivot plate pivots freely but is not too loose that it may slide off.

4. With the springs compressed and the plate in the normal position there should be a gap of around ¹⁄₁₆" between the knurled roller and the face of the guide rail, this should be the same for both sides. See Figures 13 and 14 for clarification and final assembly views.

figure 13 – Safety Block attachment

figure 14 - Safety Block assembly

5. With the safeties in working order, you must install the platform onto the slings. Place the platform in the center of the two slings and 1 ¼" from the floor landing, or as per drawing sheet 1 of 4 of General Layout. The platform must be placed at a distance of 10" from the floor to the platform, or as per drawing ¾ of the General Layout. This dimension can be larger, but can not be smaller.

NOTE: This dimension is critical to ensure that the lift will not hit the rail brackets on the way up or down.

6. Make sure platform is level in both directions, if needed, use shims provided to make level. With the platform in place and level, insert the four ⅜" x 1 ½" bolts and tighten them by hand.

Platform Installed

7. Ride the elevator to each landing and check the dimensions from the landing to the platform edge. If the tightest point was found at the beginning of the installation, this will be the landing where your running clearance will be set. With the clearances all set and the platform level, the bolts can be tightened.

8. Take the lift for another ride up and down the shaft to check clearances at every bracket and landing.

9. With the platform set, the cab installation can begin.

NOTE: do not remove (if provided) cab wall shims around perimeter of platform. These are designed to suit floor to sill allowance.

10. The control wall must be mounted onto the platform first. Before placing the control wall onto the platform, a few things need to be done. Firstly, all of the switches and cab wiring must be uncoiled from around the car station box and passed over the top of the control wall so that it lies on the front face.

11. The Safety Switch (the side of the switch will be marked ‘Safety Switch’) which is attached to the bottom of the car station box must be passed behind the slings along with the travel cable.

12. You must then uncoil the travel cable and make sure there are no kinks in it. Pass the end in between the cylinder and the left guide rail (when facing the slings). As you pass the travel cable through, walk the control wall into place. There are two holes at the bottom of the walls for ¼" bolts to pass through. In your hardware package we have provided two ½" x 6" threaded rods. These are passed through the vertical tabs which are welded onto the top of the control wall, and they attach to the horizontal tabs welded to the slings. Use ½" locks, flats and nuts to fix these together.

13. Using your level, make sure that the control wall is completely plumb before continuing to the next wall.

14. After control wall is secured and leveled, mount back walls and fasten to control wall using the ¼" bolts provided. Position side wall in place and fasten to back wall using ¼" hardware. The ceiling can now be placed on cab walls. Pre drilled holes have already been provided in the ceiling. Use ¼" bolts to fasten into place. Once the ceiling is secured, the car door can be installed.

PAGE 10 of 48

aCCOrdION dOOr INSTallaTION

1. Accordion gate can be slid through the accordion car gate track (previously mounted on the cab ceiling).

2. Bolt the car gate shroud onto control wall face where holes have been provided. Once secure, fasten accordion gate to car gate shroud.

NOTE: a car gate shroud is not provided for platforms over 36", the gate is fastened directly to the back of the return wall. On all return walls federal Elevator has provided ¼" x 3" lag Bolts for fastening.

3. If applicable, mount automatic car gate operator to ceiling. You will find holes predrilled in ceiling where operator was mounted in our plant.

4. Locate into position and secure with wood screws.

5. Attach arm from accordion gate leading edge to gate operator. There will be two countersunk machine screws that attach to operator when cover has been removed.

NOTE: all elevators with accordion gates MuST have an Infrared light Curtain installed running along the entrance of the cab. refer to Appendix 5 for Infrared Curtain Assembly.

BIfOld GaTE INSTallaTION

Similar to the Accordion door, the bifold door has been predrilled into the track and prepared for final installation. Refer to `appendix 4a – residential Exploded View – Bifold doors.

2-SPEEd dOOr INSTallaTION

Refer to appendix 6 for 2-Speed door Installation which has instructions and diagram which will help you with installation of the 2 speed doors.

Note: you must ensure that the cab is square and plumb and that all bolts are tight before moving onto the cab electrical part of the installation.

CaB ElECTrICal

Before any other components are installed, make sure to install the ‘Safety Switch’. This switch should have been passed back behind the bottom.

TraVEl CaBlE INSTallaTION

1. With the cab built and plumb, run the lift up on temporary controls so that you can get underneath the lift and Install the travel cable and hanger.

2. The travel cable hanger is usually placed on the wall opposite the rail wall (if it cannot be placed on this wall, place it on any other wall where there is no risk of interference).

3. The height of the travel cable hanger is based on your travel and is installed using the following calculation:

Equation 1 - Travel cable hanger location

4. Once height is determined, mount the travel cable hanger using the 4 holes provided.

5. After travel cable hanger has been attached, pass the travel cable through the slings onto the sling cross braces, (See Figure 15).

figure 15 – View from under the cab, notice the way the travel cable hangs from cab.

6. Pass the travel cable into the slots of the hanger and replace the cover.

7. To get a proper hang, bring the elevator to the bottom floor and make sure the cable does not hit the floor and is not pulled. Once this has been confirmed, take the lift to the top floor and make sure that the travel cable is not pulling.

8. Ensure that when you are traveling up the shaft, the cable has a nice loop with no kinks.

NOTE: Your elevator may be equipped with a flat or round travel cable.

NOTE: The travel cable hanging could be done as the next step after installing the control wall on the platform.

TraVEl2

+ 1 fOOT (305MM)

PAGE 11 of 48

SWITCH MOuNTING

1. Switch mounting brackets are already placed in the proper location for you. All switches and switch brackets are marked with stickers for easy installation. Straighten out all switch cables (switches should be on ceiling) and separate each switch. The switch brackets are located either on the cab wall or on the top inside of the slings.

2. Simply match the switch to the marking on the bracket and tighten the switch onto the bracket. Make sure to secure the loose switch cable so that it does not get caught on anything.

HOISTWay aNd Hall STaTION WIrING

Please refer to appendix 8 Hoistway Prewiring drawing or Electrical Schematics for all hoistway and Hall Station wiring connections.

TaPEHEad MOuNTING/MaGNET INSTallaTION

1. Locate an area as close to the rail as possible that can accommodate the footprint of the unit for the entire length of the shaft. Refer to appendix 7 Tapehead Mounting.

2. Mount the top clamp retainer so the center of the tube correspond to where you want the center of the tape to be located. Mount it high so that the sensor unit will not hit the top clamp at the furthest extent of up overtravel.

3. Mount the bottom clamp retainer so the center of the tube is plumb with the top retainer tube. Mount it low enough so the sensor unit will not hit the bottom clamp at the furthest extent of down overtravel.

4. Drill a ⅜" clearance hole in the center of the tape about 2" from the end. Install the top clamp on this end of the tape with 3 at ⅜" bolts. There will be about 1" of extra tape; bend it slightly to clear the threaded rod.

5. Install the top clamp into the top clamp retainer tube with a washer and two hex nuts as shown. For now, have the hex nuts at the end of the threaded rod. Carefully unroll the tape and let it hang.

NOTE: you can save some time by sliding the sensor up the tape and tying it off at the top of this point.

6. Install the bottom clamp into the bottom clamp retainer tube with washers, spring and hex nuts as shown. For now, have the hex nuts about 1" from the end of the threaded rod. Put a wedge of scrap material between the clamp and the clamp retainer to compress the spring about ½". Refer to appendixes 7 Tapehead Mounting, 7a four Stop Magnet Placement, 7B Three Stop Magnet Placement, and 7C Two Stop Magnet Placement.

7. Pull the tape tight. Mark the tape to correspond to the center hole of the clamp, and drill a ⅜" clearance hole. Cut the tape at least 2" beyond the hole.

8. Remove the wedge and adjust the top clamp so the spring is compressed about ¾". Tape should be hanging straight. Tighten all nuts and bolts.

TaPEHEad MaGNET aNd ValVE adjuSTMENT

NOTE: The valve should be adjusted completely before applying the magnets to the steel tape.

1. Before loading the car, make sure that it moves smoothly in the down direction by using the emergency lowering valve.

2. Start by adjusting the relief valve and make sure that you have the correct operation pressure and that the car can move up in the rated load speed.

3. Adjust the bypass following the appendix 9 Blain Valve adjustment Sheet provided with your Installation Package.

4. Adjust the high speed for both directions, before adjusting the slow speed.

5. Federal Elevator has mounted 4 LED’s (marked A,B,C,D) to show the situation of the coils (A,B,C,D). The proper LED energizes when the related coil energizes. For example, if the elevator is moving ion the high speed in the up direction, both LED’s A & B are energized, the same for coils A & B. If the elevator is moving high speed in the down direction, both LED’s C & D are energized, the same for coils C & D.

6. Please refer to appendix 9 Blain Valve adjustment Sheet for more details about the valve and the coil function.

7. It is best to perform the speed adjustment before operating the automatic however, by removing the jumper between terminals (A & B) and the jumper between terminal (C & D) the elevator can travel up and down (temporarily) in slow speed.

8. If a top of the car inspection station provided, you can use it instead of temporary operation to mount the magnets. Please note that another adjustment is required after turning the operation into automatic. This adjustment includes the acceleration and deceleration in both directions (up and down). The up levelling speed also needs to be adjusted.

9. After the high and slow speed are adjusted properly in both directions, you can start applying the magnets. Refer to the tapehead magnet drawings for their placement (Refer to appendixes 7 Tapehead Mounting, 7a four Stop Magnet Placement, 7B Three Stop Magnet Placement, and 7C Two Stop Magnet Placement).

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10. After magnets have been mounted, level the car at each floor and ensure that all of the sensors (LD/LDZ, HDZ and LU) are energized while the elevator is level.

11. Refer to appendixes 7 Tapehead Mounting, 7a four Stop Magnet Placement, 7B Three Stop Magnet Placement, and 7C Two Stop Magnet Placement to confirm proper magnet location.

12. When the elevator is ready to be turned onto automatic, it is time to do the second valve adjustment for the acceleration, deceleration and the final leveling speed if applicable.

13. To check the valve and tapehead magnet adjustment, start by sending the elevator to the intermediate floor.

INTErlOCK INSTallaTION

1. Remove cover plate, from the lock.

2. Mark a line 72" (1823mm) from the floor ( NOTE: this dimension could change depending on door height), this is to the center of the lock. Mark another line at approximately ⅜" (9.5mm) from the door in its closed position to the front face of the lock base.

3. The door keeper is to be installed ¹⁄₈" (3mm) from the bottom of the locking mechanism in the energized position (at its maximum vertical height).

4. Mount the lock cover plate.

figure 16 – locked position figure 17 – unlocked position

figure 18 – Cover plate figure 19 – door keeper

Once all shaft and hall station cables are run into the controller, refer to the Electrical Schematics for all wiring information.

uNINTErruPTEd POWEr SuPPly (uPS) INSTallaTION

To install the UPS in your controller, please ensure that all power is turned off. Refer to Figures 20 and 21 and the important notes following.

figure 20 – Close up of the back of uPS figure 21 – Top of uPS

NOTE: The uPS is to be connected only afTEr the elevator is in working order and in automatic operation with all of the wiring complete.

NOTE: Be sure to test the uPS before connecting it to the controller to ensure that it gives the required voltage.

NOTE: Never use the Bypass plugs in the uPS. We have placed a large red X in Figure 20 to help you understand which are the bypass plugs.

NOTE: Keep plug and receptacle connected unless an external mounted uPS back-up is available.

NOTE: Never plug the uPS into the wall, only plug it into the controller.

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fINalIzING THE INSTallaTION

Once installation has been completed, we recommend going through the following steps to ensure that the elevator is in safe working order:

1. Ensure all temporary operation buttons and jumpers have been removed from the controller.

NOTE: This step is crucial, please complete first.

2. Run the elevator to ensure smooth operation.

3. Test all safety features to be certain that they are in good working operation: Door switches, hall door interlocks, slack rope switch, pit switch, top of car stop switch, in car stop switch and any other safety device applicable to the elevator.

4. Double check all safety circuits and switches to ensure safe operation.

5. Ensure that the home owner is provided with a demonstration on how to run the elevator and given any keys required.

6. Provide the home owner with the Owner’s Manual and fill in your contact information

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SECTION 3 – Adjustments and Troubleshooting

TaPEHEad MaGNET aNd ValVE adjuSTMENT quICK GuIdE

The LCD is an optional part that can be added to the PLC, enabling the user to change a memory location value or to monitor and troubleshoot a problem. The screen will display a message specifically describing the nature of the fault. (See Figure 22).

Values which could be controlled by the elevator user include the following:

1. Changing the door opening time (A minimum of 1 second and maximum of 20 seconds).

2. Changing the power door (slide or swing), same for the car gate operator. Or turning the power door off at a selected floor without changing the wiring.

3. Changing the maximum tripping time for the low oil timer; a minimum of 30 seconds, and a maximum of 180 seconds.

figure 22 - lCd

Apply and adjust the magnets as shown in the Appendices 6, 6A, 6B and 6C.

To check the level and tapehead magnet adjustment, begin by sending the elevator to the intermediate floor, below are some possible problems and their source of the problem.

1. If you experience the elevator stopping above the level in both directions – Try moving the door zone magnet down.

2. If you experience the elevator stopping below the level in both directions. – Try moving the door zone magnet up.

3. If you experience the elevator stopping above the level when it goes in the up direction, but below the level when it goes in the down direction. Try the following:■ Decrease the slow speed in both directions.■ Ensure that all of the sensors (LD, LU, DZH, & DZL) are

energized when the elevator is level with the floor.

If the above does not work, refer to the Appendices 6, 6A, 6B and 6C.

4. If the elevator stops above the floor in the up direction and stops level with the floor in the down direction. Try the following:■ Decrease the leveling speed in the up direction.■ Decrease the low speed in the up direction.■ Decrease the setting of the pump delay timer if LCD

screen provided.

5. If the elevator stops level in the up direction and below level in the down direction. Try the following:■ Move the door zone magnet up, the elevator will stop

level in the down direction but above the floor in the up direction. Go back to step 4 and also make sure that the down direction slow speed is not high.

6. If the elevator is stopping below the floor in the up direction and stops level in the down direction. Try the following:■ Increase the leveling speed in the up direction.■ Increase the low speed in the up direction.■ Increase the setting of the pump delay timer if LCD

screen provided.

7. If the elevator will stop level in the up direction and above the level in the down direction. Try the following:■ By moving the door zone magnet down the elevator will

stop level in the down direction but below the floor in the up direction. Go back and do step 6.

8. If the elevator stops below the floor in the up direction & above the floor in the down direction, try the following:■ The door zone magnet is too long.■ The slow speed is too low in both directions.

9. For final adjustment, you may need to adjust the acceleration & the deceleration. This may affect the leveling (within ¹/8"), but by readjusting the slow speed you can get the elevator to stop level.

For the top and the bottom floor, use the same procedure which was used for the intermediate floor.

NOTE: The PlC will not allow the elevator to move in the slow speed more than 10 sec, within this time the elevator should reach the floor level.

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TrOuBlESHOOTING PrOCEdurES

quICK GuIdE

1. Access machine room.

2. Locate the elevator and inspect for any damages to the equipment.

3. Inspect each call station for damage and they are in the off position (if key required).

4. Test the elevator hall doors and ensure that they are all closed and locked

5. With the proper meter, determine that the main line voltage is correct and check the main fuses.

6. Check the position of the motor overload device if in the off position; look for poor connections at control or motor, or a failure in any of the main contactors.

7. Test all fuses in the controller with the proper meter. If any fuses are open, check the wiring print to determine the cause and location of the circuit and switches.

8. Test the hoistway circuit to determine if any switches are open with the proper meter (do not under any circumstances jump out any part of these circuits with a jumper wire or by any other tool).

9. If the elevator will go down but not up check the ‘UP’ terminal switch.

10. If the elevator will go up but not down check the ‘DN’ terminal switch and down coil.

11. Call Federal Elevator Systems Inc. (1-905-458-4015) if none of the above rectifies the problem.

quICK fIX GuIdE fOr TyPICal PrOBlEMS

The elevator moves in the down direction but will not move or accept calls in the up direction

■ Check if the power relay has de-energized

■ Check if the overload has tripped

■ Check if the phase protection relay has tripped (if applicable)

■ Check if the low oil timer has tripped

Motor turning but no pressure:

■ Confirm the up coils are energized. If yes, check the voltage and compare it with the rated voltage on the coils.

■ Confirm that the motor is turning freely in the right direction (clockwise).

■ Adjust the Bypass and the relief as per the appendix 9 Blain Valve adjustment Sheet.

■ Confirm the valve up adjustments are correct.

down coils energizes but elevator not moving:

■ Confirm that the shut-off valve is open.

■ Check the setting of the flow control valve.

■ Confirm that the valve down adjustments are correct.

■ Confirm that the safety block is not engaged.

■ Confirm that the adjustment of the low pressure switch is correct.

■ Check the voltage and compare it with the rated voltage on the coils.

Elevator is missing the bottom floor (sitting in the pit):

■ The slow speed may be set too high.

■ It may be missing some or all of the door zone signals (Possible reasons: short magnet, wrong location or polarity of the magnet, wrong location of the switches or the cams which may be causing the switch to not engage mechanically).

■ It could be that it is missing the floor limit signals.

■ It may be missing the slowdown limit signals.

■ The final limit switch may be located in the wrong place.

Elevator is missing a floor:

■ It could be missing one or more of the door zone signals.

■ It could be missing the floor limit (position) signals.

■ It could be missing the slowdown limit signals.

Elevator is missing the top floor:

■ The pump delay adjustment could be too high. While Federal Elevator will pre-set the pump delay in the factory before shipping, the setting could have changed. Confirm that it is set to 0.2 seconds, this could be adjusted from the LCD screen.

■ The valve leveling speed could be set too high during the pump delay timing, lower the levelling speed.

■ The elevator could be missing some or all of the door zone signals, go back and check that they are in the right location.

■ Could be missing the floor limit (position) signals.

■ Could be missing the slowdown limit signals.

■ Final limit cam could be installed in the wrong area.

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Elevator is bouncing in the up direction:

■ There could be mechanical resistance due to a mechanical issue.

■ Valve may require pressure adjustment.

■ Ensure that the motor data plate and the power supply match and that they pump mechanical specification is suitable.

■ The up acceleration could be set too low.

■ There may not be enough oil in the tank.

■ Rails may need to be lubricated with oil.

Elevator is bouncing in the down direction:

■ There could be mechanical resistance due to a mechanical issue.

■ Valve may require better adjustment in the down direction.

■ Low pressure switch may need adjustment.

■ There could be air in the cylinder, bleed the cylinder to see if this fixes the problem.

■ Rails may need to be lubricated with oil.

Elevator is stuck between floors:

■ One or more of the electromechanical safety contact is open (for example: door contact, gate contact, safety switch contact or low pressure switch contact).

■ A fuse could be blown.

NOTE: the monitoring from the PlC software may cause the elevator to stop at any position for example: the low oil timer or the overload is enabled however, after a few seconds, the controller will register an automatic call to the bottom floor to allow exit from the elevator. Elevator may shutdown at the bottom floor level and needs to reset the PCL to re-operate. If the problem comes back, then some parts are not functioning will and may require replacement.

door interlock unlocking Solenoid not energizing:

■ No power to the Solenoid – It may be missing some or all of the door zone or the position signals. There may be no power from the 24V feeding fuse (F24) or the fuse could be blown. The software may not be permitting the Solenoid to energize due to illegal signals (For example: a jumper detected or 2 position signals at the same time).

■ The door interlock unlocking the Solenoid has power but it is buzzing – Possible voltage drop in the wiring: Federal Elevator supplies permanent duty 24VdC Solenoid with momentarily operation of 12 seconds (this is adjustable). Check your shaft connection.

rESIdENTIal CONTrOllEr PlC INPuTS & OuTPuTS

This section explains the basic function of the inputs and outputs for the Federal Elevator Residential Controller.

GENEral INfOrMaTION

The Federal Elevator Residential Controller (GR) is a controller system designed by Federal Elevator to operate both hydraulic units (1 to 4 coil valve) and electric drum units. The operation of the elevator can be either automatic or constant pressure.

The controller has been designed to operate up to 4 stops with 2 automatic car gate operators, 4 automatic hall door operators as well as electric strikes. However, it is possible to provide customized controller options beyond our standard.

Federal Elevator always saves the required default setting data on the PLC during the testing stage in our factory. Changing this data on site is possible by using the LCD screen tool which is provided initially to the dealer on their first order (See Figure 22). This tool is removable and can be used on any Federal Elevator PLC controller. Care must be taken when changing the data parameters using this tool as any mistake will result in an elevator shutdown situation. For example, if the job is installed with a 4 coil valve but the data parameters have been accidently set up for a 2 coil valve, then the PLC will receive signals from the B and C coils causing the redundancy to trip in less than 1 second. The same is true if the job is installed with a 2 coil valve but the data parameters have been accidently set up for a 4 coil valve.

INPuT SuMMary

X0

This input energizes when the elevator is at the 3rd Floor Limit (position) area. It activates the 3rd floor reading and setting even when the elevator is moving. This signal is monitored by the General Sensor Monitoring Timer in the PLC.

When the elevator is moving and passing this floor, this signal should not energize for more than 7 seconds or the PLC will stop the elevator. If the elevator is slowing down at this floor, it should arrive at the floor level within 5 seconds or the PLC will stop it automatically from the slowdown monitoring timer. If the elevator starts moving from this floor, the position signal should de-energize within 10 seconds (this includes the pump bypass time) otherwise the start monitoring timer in the PLC will stop the elevator.

X1

This input energizes when the elevator is at the 2nd floor Limit (position) area. It activates the 2nd floor reading and setting even when the elevator is moving. This signal is monitored by the General Sensor Monitoring Timer in the PLC. When the elevator is moving and passing this floor, this signal should

PAGE 17 of 48

not energize for more than 7 seconds or the PLC will stop the elevator. If the elevator is slowing down at this floor, it should arrive at the floor level within 5 seconds or the PLC will stop it automatically from the slowdown monitoring timer. If the elevator starts moving from this floor, the position signal should de-energize within 10 seconds (this includes the pump bypass time) otherwise the start monitoring timer in the PLC will stop the elevator.

X6

This input energizes when the elevator is at the 1st Floor Limit (position) area. It activates the 1st floor reading and setting even when the elevator is moving. This signal is monitored by the General Sensor Monitoring Timer in the PLC.

If the elevator is slowing down at this floor, it should arrive at the floor level within 5 seconds or the PLC will stop it automatically from the slowdown monitoring timer. If the elevator starts moving from this floor, the position signal should de-energize within 10 seconds (this includes the pump bypass time) otherwise the start monitoring timer in the PLC will stop the elevator.

X7

This input energizes when the elevator is at the Top Floor Limit (position) area. It activates the 4th floor reading and setting even when the elevator is moving. This signal is monitored by the General Sensor Monitoring Timer in the PLC.

If the elevator is slowing down at this floor, it should arrive at the floor level within 5 seconds or the PLC will stop it automatically from the slowdown monitoring timer. If the elevator starts moving from this floor, the position signal should de-energize within 10 seconds (this includes the pump bypass time) otherwise the start monitoring timer in the PLC will stop the elevator.

X2 & X3

Main Door Zone Signals operated from the related door zone relays.

X4 & X5:

Auxiliary Door Zone Signals and Level Correction Signals.

The main door zone signals and the auxiliary door zone signals have multi-functions. In order to activate any opening command after the elevator has performed a complete stop you need a floor signal and at least one of the auxiliary door zone signals.

The opening command controls the opening of any car or hall door in addition to the electrical strike and electrical interlock. The LEVEL CORRECTION could be performed after the elevator makes a complete stop and the floor signal is active. Both of the main door zone signals and at least one of the auxiliary door zone signals are required.

When the elevator enters the designated floor area, it uses the position magnet to slow down. If that position signal is not working for any reason, the elevator will slowdown from the auxiliary door zone signals (UL or DL). Then it will stops when both (UL & DL) ENERGIZE at the same time.

Once the elevator stops, missing any of the main door zone signals or the position signal will cause the elevator to:

■ Deactivate any opening command

■ Deactivate any re-leveling or level correction command

■ Register an automatic call to the bottom floor

Sequence for Inputs X4 and X5:

a. When the elevator arrives at the required floor level it slows down in order to perform the complete stop. The slowdown could be either from the floor position or the Door Zone magnet when one of the Auxiliary Door Zone signal (X4 or X5) are energized. The maximum slow down time is from 5 to 10 seconds. If the elevator does not reach the floor level within this time, it will stop automatically.

In this case:

1. If the elevator is more than 2" away from the floor level, it will travel to the bottom floor to reset.

2. If the elevator is less than 2" away from the floor level, it will re-level as mentioned in section C below.

NOTE: the up maximum slow down timer is different from the down maximum slow down timer and both are adjustable by using the lCd screen. federal Elevator has saved the default settings at 10 seconds for both directions.

IMPOrTaNT EXaMPlE:

question: What would happen if you register a call to all available floors with the following conditions?

■ Elevator is at the bottom level

■ Door Zone magnets are mounted on all floors

■ Position magnet is mounted only at the bottom floor

answer: The elevator will travel, slow down and stop at each floor with the Door Zone magnets working as a counter. The power doors (hall or car) will not open. The EMI interlock solenoid or the electric strike will not energize and the elevator will not perform the re-leveling even though it is stopped at the floor level. This explains the floor counter operation from the Door Zone magnet signal.

PAGE 18 of 48

IMPOrTaNT EXaMPlE:

question: What would happen if you register a call to all available floors with the following conditions?

■ Elevator is at the bottom level

■ Door Zone magnet is only mounted at the bottom floor

■ Position magnets are mounted on all floors

answer: The elevator will travel and slow down when the proper position magnet energizes. Since the maximum slow speed time is limited, the elevator will stop level by adjusting the maximum slow down timers (T55 for the Up direction and T54 for the Down direction in the PLC software). This should be done at 50-60% of the full cab load and only after finishing all valve adjustments. Note that no power doors (car of hall) will open. The EMI interlock solenoid or the electric strike will not energize and the elevator will not perform the re-leveling function.

NOTE: It is recommended to have all magnet mounted as shown in the related drawing. refer to Appendixes 7 Tapehead Mounting, 7A Four Stop Magnet Placement, 7B Three Stop Magnet Placement, and 7C Two Stop Magnet Placement.

B. Inputs X2, X3, X4, X5 and only one of the position signals should be energized when the elevator is at the floor level.

C. If only X4(or X5) is de-energized but X3, X4 and only one of the position signals still on, the elevator will perform the re-leveling and it will stop when X2, X3, X4 and X5 are all energized.

Additional Information:

1. The re-leveling starts only after the elevator stops.

2. When the safety circuit is made, the re-leveling will start and continue up to a maximum of 20 attempts. If the elevator level cannot be corrected, it will travel to the bottom floor to reset.

3. If any of the door contacts are opened or if the stop push button in the car station is turned to the off position, the number of the re-leveling is unlimited

4. For a Hydraulic elevator: the maximum re-leveling time is 10 sec followed by 1 second interval to check if any contacts are welded. If so, the elevator will shut down.

5. For the Drum Unit: the maximum re-leveling time is 1 second followed by 5 second interval to allow the drive to reset to zero and to check if any contacts are welded.

X10, X11, X16 & X17:

During the automatic operation, all the above inputs are to be energized in order for the elevator to start. Jumping the safety in the controller may cause the software to trip the operation for 1 hour from the time the jumper is removed. Re-cycle the power to reset.

X16

Signal from the final limit switch.

This signal energizes when all the safety contacts before the terminal (FINAL) are energized.

X17

Signal from the hall door contact switch.

This signal energizes when all the hall door contacts are made in addition to all the safety contact before the terminal (FINAL) are energized.

If some contacts of the safety circuit are open (e.g. pit switch and or the 1st floor hall door contact) jumping the safety between terminal LOW AND E-CT will cause input X17 to energize without input X16. This will stop the elevator from the PLC. Reset to re operate.

X10 aNd X11

These signals may be either from the 2nd set of the hall door contact switches or the signal from the car gate operator contact. This signal energizes when all the safety contacts are made up.

If some contacts of the safety circuit are open (e.g. pit switch and/or the 1st floor hall door contact), jumping the safety between terminal + and terminal E-L will cause inputs X10 & X11 to energize without inputs X16 & X17. This will stop the elevator from the PLC. Reset to re operate.

Inputs X10 & X11 should always have the same state (either both on or both off) otherwise the PLC will stop the operation

The inputs X10 & X11 have 4 possibilities as shown:

SIGNALS G GX Redundancy

INPUTS X10 X11

POSSIBILITIES 1 ON ON OK 2 ON OFF Will Trip 3 OFF ON OK 4 OFF OFF Will Trip

X12 & X13:

a – Hydraulic controller

In hydraulic controller, signals X12 & X13 are operated from the up contactors. Both U & UX contactors should be in the same position. Therefore, both inputs X12 & X13 are to be energized or de-energized at the same time. Please note if both contactors U & UX fail in the energized or de-energized position at the same time the PLC will detect this failure.

B – Drum controller

This is the exact same operation as the hydraulic controller but the names of the contactors (relays) are UD and UDX. The contactors UD and UDX energize in both directions of travel.

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NOTE: If both of the contactors u & uX (or ud & udX) are energized manually, the PlC will detect the wrong signals and shut the elevator down.

X14

Power Supply Signal

Input X14 is required to be energized in order for the elevator to move up but it is not required for the elevator to move down.

X15

Call Common Signal

Input X15 is required to be energized in order to operate in automatic mode. It is activated from the temporary/automatic key switch (Located on the PC board, see electrical schematic) when this key switch is turned to automatic.

X20, X21, X22 & X23

Floor Call Signals (1st floor, 2nd floor, 3rd floor and 4th floor respectively).

They are usually operated from the car or the hall push buttons.

NOTE: If the temporary/automatic key switch not in the automatic position, call will not be registered even if a jumper had been used directly to the above mentioned terminals.

X100, X101, X102 & X103:

a – Hydraulic

The inputs X100, X101, X102 and X103 are operated from the valve terminals A, B, C and D in order to monitor the valve. Inputs X100, X101, X102 and X103 should have the same state as the outputs Y100, Y101, Y102 and Y103.

NOTE: If the up coil valve signals are operated from the PlC without the contactors u & uX, the PlC will stop the operation after 1 sec even if the inputs X100 & X101 match the signals from the outputs y100 & y101.

B – Drum

X101: Drive is running

X102: Signal from the drive (failure)

X104, X105, X106 & X107:

They energize when terminals W1, W2, W3 & W4 are energized. If any electrical strikes are powered by use of a jumper, the elevator will stop the operation

X110:

Door open push button signal.

X111:

Signal from the temporary operation.

If it is on, the elevator will not accept to register an automatic call even if a jumper used from terminal PLC directly to the call inputs X20 thru X23

OuTPuTS SuMMary

y0 and y1:

Hydraulic drum

Y0 Up moving command Up – Down moving command

Y1 AUX Up moving command AUX Up – Down moving command

Both outputs should have the same state causing the 2 related contactors or relays to energize otherwise the elevator will stop after 1 second. the related monitoring inputs should energize within 1 second. Also, the other related outputs and inputs should energize within 1 second (see inputs X100 thru X103 and outputs Y100 thru Y103).

y2

High Speed: Not used in the standard application

y3

Slow Speed: Not used in the standard application

y4, y5, y6 & y7

Call Register Light.

Energizes when a call is permitted to be registered. If the power is turned off and the UPS is still turned on, a call can be registered in the down direction to a lower level only.

y10, y11, y12 & y13

Position Indicator outputs that illustrates the elevators position in the hoistway.

The digital position indicator is flashing when the elevator is travelling and solid when the elevator is at the floor level.

y14

1st Car Gate Operator Open Relay Command

y15

2nd Car Gate Operator Open Relay Command

When the elevator stops at a floor level and the signal is sent to the automatic car gate operator to open, the GR1 relay (operated from Y14) and the GR2 relay (operated from Y15) will energize according to PLC pre-setting. The relays GR1 & GR2 are used in the related car power door operator to open the door.

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Example: You purchase an elevator with 2 openings having sliding doors. The first opening is for floors 1, 2 & 4 while the second opening is for floor 1, 3 & 4.

When the elevator arrives to a floor and stops at the floor level, the open command is initiated depending on the designated floor.

■ The relays will be in the following states:

■ At the 1st floor both of the relays GR1 & GR2 will energize.

■ At the 2nd floor only the GR1 relay will energize.

■ At the 3rd floor only the GR2 relay will energize.

■ At the 4th floor both of the relays GR1 & GR2 will energize.

y16

Automatic Car Light.

When it energizes, the related AL relay in the car station energizes to TURN OFF the light. In order for the Y16 to energize and turn off the light: the elevator should time up to 5 min (300 sec) in normal operation and all the safety contacts are made. No software monitoring or software safety is activated, the elevator is at the door zone with all the required door zone signals are on, no call registered.

y17

Level correction, Re-leveling Enabled.

If the elevator stops within 2" (50mm) above or below the designated floor level, the elevator will automatically correct itself. Y17 energizes to activate the RLVL & RLVLX relays to operate the level correction. This requires the elevator to be in automatic operation and it is designed to allow for the car and hall door contacts to be open. The same applies for the car stop push button or switch.

y100, y101, y102 & y103

Hydraulic: Valve terminals A, B, C & D.

A: Up slow speed coilB: Up high speed coilC: Down high speed coilD: Down slow speed coil

Drum: Up & Down command.

y104, y105, y106 & y107

EMI Interlock or Electric Strike Terminals.

Energizes at the designated floor with only one output energized at each time. These will activate the door open command. The PLC is designed so that placing jumpers on any of the above terminals will cause the opening command and the elevator to shut down.

COMMON INPuTS aNd OuTPuTS durING auTOMaTIC OPEraTION (2 STOP)

1. When the elevator is at the first floor level with all doors closed, the inputs X2, X3, X4, X5, X6, X10, X11, X14, X15, X16, X17 are illuminated.

The output Y10 is also illuminated.

2. Pushing the 1st floor hall call push button will energize X20 momentarily and energize the 1st floor hall door Interlock solenoid (input X104 energizes and outputs Y104, Y14 & Y4 energize). This will also cause the hall door contacts to open (Inputs X17 will drop) and the automatic car gate contact, if applicable, will open (Inputs X10 & X11 will drop).

3. Close the hall door and wait for the car door to close fully. All the inputs and the outputs will go back to normal. See item 1 above.

4. Pushing the second floor call will cause the input X21 to energize momentarily and the output Y5 to latch. The outputs Y0 & Y1 energize to operate the up contactors. The outputs Y100 & Y101 will also energize to operate the A & B coils.

5. Inputs X12 & X13 will energize right away or within 1 sec. If not, the elevator call will be cancelled.

6. Inputs X100 & X101 will energize right away or within 1 sec. If not, the elevator call will be cancelled.

7. The elevator starts moving (or it will shut down within 5 sec)

8. The DL signal will de-energize (input X5)

9. The DZL signal will de-energize (input X3)

10. The DZH signal will de-energize (input X2)

11. The UL signal will de-energize (input X4)

12. The P1 signal will de-energize (input X6)

13. If any of the above signals remain energized within 5 sec from the time the elevator starts moving, the elevator will shut down and the LCD screen will indicate a tape head failure.

14. Between floors the output Y10 will be turned off and the output Y11 will start flashing

15. The elevator will start to enter the 2nd floor area, input X1 will energize causing the elevator to slow down. Output Y11 will latch and output Y101 and input X101 will de-energize. This will be followed by inputs X5, X3, X2 & X4 energizing. The elevator now is at the 2nd floor level. The output Y100 and the input X100 will de-energize after a 0.4 second pump delay. The outputs Y0 & Y1 will de-energize causing the elevator to stop level

PAGE 21 of 48

16. The output Y105 and input X105 will energize while the inputs X10, X11, X17 and output Y5 will de-energize. If an automatic car gate operator is installed then output Y14 and/or Y15 will energize.

17. After few seconds, outputs Y14, Y15 and Y105 as well as input X106 will de-energize. The car door will start to close and the interlock will engage.

18. At this point, your inputs will be: X1, X2, X3, X4, X5 in addition to X10, X11, X14, X15, X16 and X17.

COMMON INPuTS aNd OuTPuTS durING auTOMaTIC OPEraTION (3 STOPS)

1. When the elevator is at the first floor level with all doors closed, the inputs X2, X3, X4, X5, X6, X10, X11, X14, X15, X16, X17 are illuminated. The output Y10 is also illuminated.

2. Pushing the 3rd floor hall call push button will energize X22 momentarily and output Y6 will energize. The elevator will start moving up with Y11 flashing.

3. As the elevator enters the 2nd floor area, the input X1 and output Y11 will energize. Because a 3rd floor call was placed, the elevator will continue passed the 2nd floor call. When passing the 2nd floor, the inputs X2, X3, X4 and X5 will energize. When the elevator is passed the 2nd floor the inputs will de-energize in the flowing order: X5, X3, X2, X4 and X1.

4. As the elevator approaches the 3rd floor area, the input X0 energizes causing the elevator to slow down. Output Y12 energizes, output Y101 de-energizes and input X101 de-energizes initiating the slowdown speed.

5. X5, X3, X2 and X4 will energize when the elevator has reached the floor.

6. The output Y100 and Input X100 will de-energize after a 0.4 second pump delay. The output Y0 and Y1 will de-energize causing the elevator to stop.

MaINTENaNCE GuIdElINE

The schedule for maintenance on this unit is to be arranged by the local service company; however, it is recommended that the following inspections and adjustments (if required) be carried out at regular intervals not exceeding 90 days.

NOTE: Please check all local codes or authorities to ensure that you are following the correct guidelines, regulations and codes while performing your elevator maintenance.

CHECK THE MaCHINE rOOM fOr THE fOllOWING:

Check the tank unit for the following:

1. That there is no oil leakage around the control valve

2. That there is no oil leakage around the hydraulic hose joints

3. Check the minimum oil level when elevator is at the top floor

4. That the oil tank is clean and dry

5. Check expiry date of hose line

Check the controller for the following:

1. Loose terminal connections

2. Burnt or frayed wiring

3. Excessive dust buildup

4. Loose relays and bases

5. Ensure that the controller is clean of any debris

6. Ensure that the emergency battery has not exceeded its expiry date

INSPECT THE SHafT fOr THE fOllOWING:

Check the shaft for the following:

1. That the guide rail brackets, rails and clips are secure

2. That the guide rail fish plates are secure

3. Ensure that all limit switches are secure

4. Check lights and outlets to ensure that they are functioning

5. That all piping and fittings are secure

6. That the pit is clean and dry

7. That the hoisting ropes are undamaged

8. That rope attachments and rope clips are secure

PAGE 22 of 48

9. That the guide rails are sufficiently lubricated

Inspect the hydraulic cylinder for the following:

1. Ensure that there are no scratches to piston

2. That the wiper seal is not leaking excessive oil

3. If applicable, ensure that the oil return hose is connected

4. Check that the cylinder and pillar brackets are secure

Inspect the piston follower for the following (if applicable):

1. That the piston sheave guide shoes are secured

2. That there is sufficient lubrication to the guide shoes

3. That the piston sheave is level

TESTING THE SafETy dEVICES – THIS SHOuld BE COMPlETEd ON EaCH SErVICE Call

Inspect the top of car for the following:

1. That all attachments are secure

2. That travel cables are hanging properly

3. That conduits and piping are not damaged

4. That the car top is clean and dry

5. If applicable, check top of car inspection station to ensure that the light works and you can run on top of car inspection

Inspect the door frames for the following:

1. That all frames are secure and not damaged

2. That door interlocks are attached firmly

3. That door hinges are lubricated

4. That the door view panel is intact

5. That door gibs are secured

6. That the spring door closer is attached firmly to slow door

Inspect each landing entrance for the following:

1. That the button face plate is secure

2. That call buttons are operating as normal

Inspect the inside of the car for the following:

1. That lights are working

2. That the face plate secure

3. That all indicator lights and buttons are functioning

4. That all walls and handrails are secured

5. If applicable, that the telephone is working

6. Disconnect power to test that the emergency light works

7. Check floor level stops for accuracy

PAGE 23 of 48

aPPENdIX 1 – rESIdENTIal 3" X 5" rulE

APPENDICES

PAGE 24 of 48

aPPENdIX 2 - TEMPOrary OPEraTION STarT uP PrOCEdurE

During temporary operation: some fuses may be not mounted to the sockets by Federal before shipping!! Only after completing all the connections to the controller, the above fuses should be mounted with the power OFF (including the POWER PACK) in order to start the automatic operation.

The PLC protection cover is to be removed before placing the elevator in service in order to allow the air to ventilate the PLC.

During installation: the TEMPORARY – AUTOMATIC switch (where applicable) should be in the temporary position and is not to be turned into automatic until all of the temporary jumpers are removed.

■ Before making any connections, make sure that:

a. There is enough starting power for the motor and the controller.b. And that the 110V (+ or - 5%) AC volts from a separate disconnect switch.

■ Connect the ground wire from the main switch to the ground of the proper terminal in the controller (10 AWG).

■ Both the main disconnect switch and the 110V disconnect switch are OFF:

a. Connect the wires from the main switch to the terminals of the proper contactor (see sticker in the controller).b. Connect the wires from the 110V disconnect switch to the proper terminals in the controller; making sure that AC2 (or N)

is the neutral (use the white wire), and that AC1 (or H) is the (HOT-LIVE) line (use the black wire).c. Connect the wires from the proper terminals in the controller into the auxiliary contact in the main disconnect switch

(and remove the jumper).d. Turn the 110V power on to ensure that you have the correct voltage between AC1 and AC2 (or H and N).e. Turn the main power on to ensure that you have the correct voltage between (L1 & L2), (L1 & L3), and (L2 & L3).

PAGE 25 of 48

aPPENdIX 3 – MaIN aNd auXIlIary dISCONNECTS aNd MOTOr CONNECTION

PAGE 26 of 48

aPPENdIX 4 – rESIdENTIal EXPlOdEd VIEW – aCCOrdION dOOrS

PAGE 27 of 48

aPPENdIX 4a – rESIdENTIal EXPlOdEd VIEW – BIfOld dOOrS

PAGE 28 of 48

aPPENdIX 5 – INfrarEd CurTaIN aSSEMBly

PAGE 29 of 48

aPPENdIX 6 – TWO SPEEd dOOr INSTallaTION

INSTALLATION ILLUSTRATION 500297( FOR TWO SPEED HALL ENTRANCE )

AVT Beckett Elevator Ltd.Beckett Elevator Ltd.

PAGE 30 of 48

aPPENdIX 7 TaPEHEad MOuNTING

PAGE 31 of 48

aPPENdIX 7a fOur STOP MaGNET PlaCEMENT

PAGE 32 of 48

aPPENdIX 7B THrEE STOP MaGNET PlaCEMENT

PAGE 33 of 48

aPPENdIX 7C TWO STOP MaGNET PlaCEMENT

PAGE 34 of 48

aPPENdIX 8 HOISTWay PrEWIrING draWING

PAGE 35 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

34 268 10

Z1

139

372210

337

,5

54

EV 100

¾“ EV 1 ½“ & 2“ EV 2 ½“ EV

EN ISO 9001

2 ½“ EV¾“ EV 1 ½“ EV

EV 100 EV 100

GmbH

Pfaffenstrasse 1 Tel. 07131 2821-0Boellinger Hoefe Fax 07131 48521674078 Heilbronn http://www.blain.deGermany e-mail:info@blain.de

B44

EN 81-2

Z1

120

559

5490

T P

Z120 5513

3 x M6

10 100

1521

,563

,5

9929

118,

5Z

26 216

Z1

2978

5411

026

5570

8943

,529

180

8550 53,5 41

18938

3 x M10

Z

101

P T

Z1

EV 100

P T

Z

63 210110 130

62Z1

3 x M10

3415

165

75

2919

8

Simple Responsive Adjustment Self Cleaning Pilot Line Filters Temperature and Pressure Compensation Self Cleaning Main Line Filter (Z-T) Solenoid with Connecting Cables Built-in Turbulence Suppressors Pressure Gauge and Shut Off Cock 70 HRc Rockwell Hardened Bore Surfaces Self Closing Manual Lowering 100% Continuous Duty Solenoids

Technical Data: ¾“ EV 1 ½“ & 2“ EV 2 ½“ EV

Flow Range: l/min 10-125 (2-33 USgpm) 30-800 (8-208 USgpm) 500-1530 (130-400 USgpm)Pressure Range: bar 5-100 (74-1500 psi) 3-100 (44-1500 psi) 3-68 (44-1000 psi)Press. Range CSA: bar 5-100 (74-1500 psi) 3-70 (44-1030 psi) 3-47 (44-690 psi)Burst Pressure Z: bar 575 (8450 psi) 505 (7420 psi) 340 (5000 psi)Pressure Drop P–Z: bar 6 (88 psi) at 125 lpm 4 (58 psi) at 800 lpm 4 (58 psi) at 1530 lpmWeight: kg 5 (11 lbs) 10 (22 lbs) 14 (31 lbs)Oil Viscosity: 25-60 cSt. at 40°C (104°F). Max. Oil Temperature: 70°C (158°F)Solenoids AC: 24 V/1.8 A, 42 V/1.0 A, 110 V/0.43 A, 230 V/0.18 A, 50/60 Hz. Insulation Class, AC and DC: IP 68 Solenoids DC: 12 V/2.0 A, 24 V/1.1 A, 42 V/0.5 A, 48 V/0.6 A, 80 V/0.3 A, 110 V/0.25 A, 196 V/0.14 A.

DescriptionAvailable port sizes are ¾“, 1 ½“, 2“ and 2 ½“ pipe threads, depending on flow. EV 100‘s start on less than minimum load and can be used for across the line or wye-delta starting. According to customers‘ information, valves are factory adjusted ready for operation and very simple to readjust if so desired. The patented up levelling system combined with compensated pilot control ensure stability of elevator operation and accuracy of stopping independent of wide temperature variations.EV 100 valves include the following features essential to efficient installation and trouble free service:

The BLAIN EV 100 program includes the widest range of options offered to the elevator industry for high performance passenger service. Easy to install, EV 100‘s are smooth, reliable and precise in operation throughout extreme load and temperature variations.

Elevator Control Valves

Manufacturer of the Highest Quality:Control Valves for ElevatorsTank Heaters - Hand PumpsPipe Rupture Valves - Ball Valves

PAGE 36 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

BLAIN HYDRAULICS 2

B44

EV 100

EV 10

EV 1

EV 0

EN 81-2

Optional EquipmentEN Emergency Power SolenoidCSA CSA SolenoidsKS Slack Rope ValveBV Main Shut-Off ValveHP Hand Pump

DH High Pressure SwitchDL Low Pressure SwitchCX Pressure Compensated DownMX Auxiliary Down

Up Up to 0.16 m/s (32 fpm). 1 Up Speed. Up Start is smooth and adjustable. Up Stop is by de-energising the pump-motor.Down Up to 1.0 m/s (200 fpm). 1 Full Speed and 1 Levelling Speed. All down functions are smooth and adjustable.

¾" 1 ½" and 2" EV 2 ½"

Up Up to 0.16 m/s (32 fpm). 1 Up Speed. Up to 0.4 m/s (80 fpm) by overtravelling and levelling back down. Up Start is smooth and adjustable. Up Stop is smooth and exact through valve operation whereby the pump must run approx. ½ sec. longer through a time relay.Down Up to 1.0 m/s (200 fpm). 1 Full Speed and 1 Levelling Speed. All down functions are smooth and adjustable.

EV Control ValveTypes

USA Patent No. 4,637,495Pats & Pats Pend: France, Germany,Italy, Japan, Switzerland & U.K.

USA Patent No. 4,637,495Pats & Pats Pend: France, Germany,Italy, Japan, Switzerland & U.K.

Up Up to 1.0 m/s (200 fpm). 1 Full Speed and 1 Levelling Speed. Up Start and Slow Down are smooth and adjustable. Up Levelling speed is adjustable. Up Stop is by de-energising the pump-motor.Down Up to 1.0 m/s (200 fpm). 1 Full Speed and 1 Levelling Speed. All down functions are smooth and adjustable.

Up Up to 1.0 m/s (200 fpm). 1 Full Speed and 1 Levelling Speed. All 'up' functions are smooth and adjustable. Up Levelling speed is adjustable. Up Stop is smooth and exact through valve operation whereby the pump must run approx. ½ sec. longer through a time relay.Down Up to 1.0 m/s (200 fpm). 1 Full Speed and 1 Levelling Speed. All down functions are smooth and adjustable.

USA Patent No. 4,601,366Pats & Pats Pend: France, Germany,Italy, Japan, Switzerland & U.K.

USA Patent No. 4,601,366Pats & Pats Pend: France, Germany,Italy, Japan, Switzerland & U.K.

PAGE 37 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

BLAIN HYDRAULICS 3

EV 1

EV 10

EV 100

EV 0

Adjustments UP

1. By Pass: When the pump is started, the unloaded car should remain stationary at the floor for a period of 1 to 2 seconds before starting upwards. The length of this delay is determined by the setting of adjustment 1. 'In' (clockwise) shortens the delay, 'out' (c-clockwise) lengthens the delay.

2. Up Acceleration: With the pump running, the car will accelerate according to the setting of adjustment 2. 'In' (clockwise) provides a softer acceleration, 'out' (c-clockwise) a quicker acceleration.Up Stop: The pump-motor is de-energised. There is no adjustment.Alternative Up Stop with Over-travel: The motor is de-energised at floor level. Through the flywheelaction of the pump-motor drive the car will travel to just above floor level. In overtravelling the floor, down levelling solenoid D is energised, lowering the car smoothly back down to floor level where D is de-energised.

S Relief Valve: 'In' (clockwise) produces a higher, 'out' (c-clockwise) a lower maximum pressure setting. After turning 'out', open manual lowering H for an instant.Important: When testing relief valve, do not close ball valve sharply.

1. By Pass: When the pump is started and solenoid A energised, the unloaded car should remain stationary at the floor for a period of 1 to 2 seconds before starting upwards. The length of this delay is determined by the setting of adjustment 1. 'In' (clockwise) shortens the delay, 'out' (c-clockwise) lengthens the delay.

2. Up Acceleration: With the pump running and solenoid A energised as in 1, the car will accelerate according to the setting of adjustment 2. 'In' (clockwise) provides a softer acceleration, 'out' (c-clockwise) a quicker acceleration.

5. Up Stop: At floor level, solenoid A is de-energised. Through a time relay the pump should run approx. ½ second longer to allow the car to stop smoothly by valve operation according to the setting of adjustment 5. 'In' (clockwise) provides a softer stop, 'out' (c-clockwise) a quicker stop.Alternative Up Stop: At relatively higher speeds, the car will travel to just above floor level. In overtravelling the floor, down levelling solenoid D is energised, lowering the car smoothly back down to floor level where D is de-energised.

S Relief Valve: 'In' (clockwise) produces a higher, 'out' (c-clockwise) a lower maximum pressure setting. After turning 'out', open manual lowering H for an instant.Important: When testing relief valve, do not close ball valve sharply.

1. By Pass: When the pump is started and solenoid B energised, the unloaded car should remain stationary at the floor for a period of 1 to 2 seconds before starting upwards. The length of this delay is determined by the setting of adjustment 1. 'In' (clockwise) shortens the delay, 'out' (c-clockwise) lengthens the delay.

2. Up Acceleration: With the pump running and solenoid B energised as in 1, the car will accelerate according to the setting of adjustment 2. 'In' (clockwise) provides a softer acceleration, 'out' (c-clockwise) a quicker acceleration.

3. Up Deceleration: When solenoid B is de-energised, the car will decelerate according to the setting of adjustment 3. 'In' (clockwise) provides a softer deceleration, 'out' (c-clockwise) a quicker deceleration.

4. Up Levelling: With solenoid B de-energised as in 3, the car will proceed at its levelling speed according to the setting of adjustment 4. 'In' (clockwise) provides a slower, 'out' (c-clockwise) a faster up levelling.Up stop: The pump-motor is de-energised. There is no adjustment.

S Relief Valve: 'In' (clockwise) produces a higher, 'out' (c-clockwise) a lower maximum pressure setting. After turning 'out', open manual lowering H for an instant.Important: When testing relief valve, do not close ball valve sharply.

1. By Pass: When the pump is started, and solenoids A and B energised, the unloaded car should remain stationary at the floor for a period of 1 to 2 seconds before starting upwards. The length of this delay is determined by the setting of adjustment 1. 'In' (clockwise) shortens the delay, 'out' (c-clockwise) lengthens the delay.

2. Up Acceleration: With the pump running and solenoids A and B energised as in 1, the car will accelerate according to the setting of adjustment 2. 'In' (clockwise) provides a softer acceleration, 'out' (c-clockwise) a quicker acceleration.

3. Up Deceleration: When solenoid B is de-energised, whilst solenoid A remains energised, the car will decelerate according to the setting of adjustment 3. 'In' (clockwise) provides a softer deceleration, 'out' (c-clockwise) a quicker deceleration.

4. Up Levelling: With solenoid A energised and solenoid B de-energised as in 3., the car will proceed at its levelling speed according to the setting of adjustment 4. 'In' (clockwise) provides a slower, 'out' (c-clockwise) a faster up levelling.

5. Up Stop: At floor level, solenoid A is de-energised with solenoid B remaining de-energised. Through a time relay the pump should run approx. ½ second longer to allow the car to stop smoothly by valve operation according to the setting of adjustment 5. 'In' (clockwise) provides a softer stop, 'out' (c-clockwise) a quicker stop.

S Relief Valve: 'In' (clockwise) produces a higher, 'out' (c-clockwise) a lower maximum pressure setting. After turning 'out', open manual lowering H for an instant.Important: When testing relief valve, do not close ball valve sharply.

Valves are already adjusted and tested. Check electrical operation before changing valve settings. Test that the correct solenoid is energised, by removing nut and raising solenoid slighty to feel pull.Nominal Settings: Adjustments 1 & 4 approx. level with flange faces. Up to two turns in either direction may then be necessary.Adjustments 2, 3 & 5 all the way 'in' (clockwise) then two turns 'out' (c-clockwise). A small final adjustment may be necessary.

Warning: Only qualified personell should adjust or service valves. Unauthorised manipulation may result in injury, loss of life or damage to equipment. Prior to servicing internal parts, ensure that the electrical power is switched off and residual pressure in the valve is reduced to zero.

PAGE 38 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

5

D C B A

4BLAIN HYDRAULICS

V

X

Y W

U

8 9 7 4 1 2

TP

Z1

Z

Z1

Z1

6

H

3

S

M1

M1

D C A BS

5

2

1

349

68

D C B A

68

9 7 4

3

5

2

S

1

KS

Positions of Adjustments EV 100 1½", 2", 2½"

Adjustments UP1 By Pass2 Up Acceleration3 Up Deceleration4 Up Levelling Speed5 Up StopAdjustments DOWN6 Down Acceleration7 Down Full Speed8 Down Deceleration9 Down Levelling Speed

Adjustments DOWN

Valve Types Elements Omitted EV 0 A, B, W, 3, 4 & 5EV 1 B, W, 3 & 4EV 10 A & 5EV 100 as shown

Control ElementsA Solenoid (Up Stop)B Solenoid (Up Deceleration)C Solenoid (Down Deceleration)D Solenoid (Down Stop)H Manual LoweringS Relief ValveU By Pass ValveV Check ValveW Levelling Valve (Up)X Full Speed Valve (Down)Y Levelling Valve (Down)

KS Option

Valves are already adjusted and tested. Check electrical operation before changing valve settings. Test that the correct solenoid is energised, by removing nut and raising solenoid slightly to feel pull.Nominal Settings: Adjustments 7 & 9 approx. level with flange face. Two turns in either direction may then be necessary. Adjustments 6 & 8 turn all the way 'in' (clockwise), then 1.5 turns 'out' (c-clockwise). One final turn in either direction may be necessary.

Horizontal Sections

6. Down Acceleration: When solenoids C and D are energised, the car will accelerate downwards according to the setting of adjustment 6. 'In' (clockwise) provides a softer down acceleration, 'out' (c-clockwise) a quicker acceleration.

7. Down Speed: With solenoids C and D energised as in 6 above, the full down speed of the car is according to the setting of adjustment 7. 'In' (clockwise) provides a slower down speed, 'out' (c-clockwise) a faster down speed.

8. Down Deceleration: When solenoid C is de-energised whilst solenoid D remains energised, the car will decelerate according to the setting of adjustment 8. 'In' (clockwise) provides a softer deceleration, 'out' (c-clockwise) a quicker deceleration. Attention: Do not close all the way in! Closing adjustment 8 completely (clockwise) may cause the car to fall on the buffers.

9. Down Levelling: With solenoid C de-energised and solenoid D energised as in 8 above, the car will proceed at its down levelling speed according to the setting of adjustment 9. 'In' (clockwise) provides a slower, 'out' (c-clockwise) a faster down levelling speed.Down Stop: When solenoid D is de-energised with solenoid C remaining de-energised, the car will stop according to the setting of adjustment 8 and no further adjustment will be required.

KS Slack Rope Valve: Solenoids C and D must be de-energised! The KS is adjusted with a 3 mm Allan Key by turning the screw K 'in' for higher pressure and 'out' for lower pressure. With K turned all the way 'in', then half a turn back out, the unloaded car should descend when Manual Lowering H is opened. Should the car not descend, K must be backed off until the car just begins to descend, then backed off a further half turn to ensure that with cold oil, the car can be lowered as required.

Warning: Only qualified personnel should adjust or service valves. Unauthorised manipulation may result in injury, loss of life or damage to equipment. Prior to servicing internal parts, ensure that the electrical controller is switched off and residual pressure in the valve is reduced to zero.

Vertical Section

M1 Second pressure gauge connection, ½"Z1 Pressure switch connection, ¼"

Important: Length of ¾“ thread on pump connections should not be longer than 17 mm!

PAGE 39 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

5BLAIN HYDRAULICS

EV 0

EV 1

EV 10

7

DHDL

RSES

8

XF

HP

V1

U

9 H

Y KS

D C6

M

S2

EV 100

B

3

A

5

BV

W4

EN

6

898

7

2

1

5

5

A

C

D

C D

6

898

7

2

1

C D

6

898

7

2

1

3

B

45

A

C D

6

898

7

2

1

4

3

B

7

DHDL

RSES

8

XF

HP

V1

U

9 H

Y KS

D C6

M

S2

B

3

BV

W4

EN

7

DHDL

RSES

8

XF

HP

V1

U

9 H

Y KS

D C6

M

S2

A

5

BV

EN

7

DHDL

RSES

8

XF

HP

V1

U

9 H

Y KS

D C6

M

S2

BV

EN

EV

Z1

Z1

Z1

Z1

Elevator ValvesControl Elements

A Solenoid (Up Stop) U By Pass ValveB Solenoid (Up Deceleration) V Check ValveC Solenoid (Down Deceleration) W Levelling Valve (Up)D Solenoid (Down Stop) X Full Speed Valve (Down)H Manual Lowering Y Levelling Valve (Down)S Relief Valve F Filter Hydraulic Circuit Electrical Sequence

Adjustments UP1 By Pass2 Up Acceleration3 Up Deceleration4 Up Levelling Speed5 Up Stop

Adjustments DOWN6 Down Acceleration7 Down Full Speed8 Down Deceleration9 Down Levelling Speed

MO

TOR

MO

TOR

MO

TOR

MO

TOR

PAGE 40 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

US gpm.US gpm. 5 10 15 20 25 30 35

20 40 60 80 100 120 140

50 100 150 200 250 300 350 400 20 40 60 80 100 120 140 160 180 200

200 400 600 800 1000 1200 1400 1600 100 200 300 400 500 600 700

1

1

7

S

01 02 03 04

06

05 0 1 2 3 4 5

6

8 9

10

UF

MM

M

DR

MO

DF

DN

DK

DG

DS

MMAD

AR

M

MO

AN

AS

AH

AF

3+5+6

2

S

H

8

FS

FS

Y

XXD

SMMS SESF SZ SO

EV

HO

UD UOU 1E EO FO1F

W6 VF FO 4F FS 4E EO

FO 7F

9F

7O7EF UOXO

4

56

3

8

9

H

A+B

C+D

6 mar 11 BLAIN HYDRAULICS Designers and Builders of High Quality Valves for Hydraulic Elevators Printed in Germany

EO9E

KS

1 ½" & 2" 2 ½"¾" US gpm.

l/min. l/min. l/min.

SK

97

4

C+D A+B ¾" 1 ½" 2 ½"FO 26x2P 47x2.5P 58x3P *EO 9x2P 9x2P 9x2PUO 26x2V 39.34x2.62V 58x3VWO 5.28x1.78V 5.28x1.78V 5.28x1.78VVO 23x2,5V 42x3V 60x3V **7O 5.28x1.78P 9x2P 9x2PXO 13x2V 30x3V 47x3VHO 5.28x1.78V 5.28x1.78V 5.28x1.78VSO 5.28x1.78P 5.28x1.78P 5.28x1.78PMO 26x2P 26x2P 26x2P

O-Ring: V - Viton P - Perbunan

50

40

30

20

10

0

700

600

500

400

300

200

100

50

40

30

20

10

0

700

600

500

400

300

200

100

50

40

30

20

10

0

700

600

500

400

300

200

100

FD

2

VO WO W

bar psi psi barbar psi

V

D C A B

5

12

68 3 9 7

D C AB

H SH S 5

1

2

49 7

468

3

D C AB

5

1

2

4

3

H S

9 7

68

{

Pos. No. Item FS Lock Screw - Flange FO O-Ring - Flange 1F Flange - By Pass EO 0-Ring - Adjustment 1E Adjustment - By Pass UO 0-Ring - By Pass Valve U By Pass Valve UD Noise Suppressor UF Spring - By Pass 2 Adjustment - Up Acceleration 3 Adjustment - Up Deceleration EO 0-Ring - Adjustment 4E Adjustment - Up Levelling 4F Flange - Check Valve FO 0-Ring - Flange VF Spring - Check Valve W Up-Levelling Valve WO 0-Ring - Up Levelling Valve VO Seal - Check Valve V Check Valve W6 Screw - Check Valve 3 Adjustment - Up Stop 3 Adjustment - Down Acceleration 7F Flange - Down Valve FO 0-Ring - Flange 7O 0-Ring - Adjustment 7E Adjustment - Down Valve UO 0-Ring - Down Valve XO Seal - Down Valve X Down Valve XD Noise Suppressor F Main Filter 8 Adjustment - Down Deceleration EO 0-Ring - Adjustment 9E Adjustment - Down Levelling 9F Spring - Down Valve Y Down Levelling Valve H Manual Lowering - Self Closing HO Seal - Manual Lowering SE Adjustment - Screw SM Hexagonal MS Grub Screw SO 0-Ring - Nipple SZ Nipple SF Spring SK Piston MM Nut - Solenoid AD Collar - Solenoid M Coil - Solenoid (indicate voltage) AR Tube - Solenoid 'Up' MO 0-Ring - Solenoid AN Needle - 'Up' AF Spring - Solenoid 'Up' AH Seat Housing - 'Up' AS Seat - Solenoid Up' MM Nut - Solenoid M Coil - Solenoid (indicate voltage) DR Tube - Solenoid 'Down' MO 0-Ring - Solenoid DF Spring - Solenoid 'Down' DN Needle - 'Down' DK Core - Solenoid DG Seat Housing with Screen-'Down' FD Filter Solenoid DS Seat - Solenoid 'Down'Some parts occur more than once in different positions of the valve.

EV Spare Parts List

Stat

ic p

ress

ure

with

em

pty

car.

Stat

ic p

ress

ure

with

em

pty

car.

Stat

ic p

ress

ure

with

em

pty

car.

Stat

ic p

ress

ure

with

em

pty

car.

Adjustments

In case of down leakage, replace and test in the following order: DS & DN , XO , VO , WO , FO + HO .

Flow Valves

F Do not remove!

Solenoid Valves0-Ring-SizeNo.

* FO by 4F 2½" is 67x2.5P** 90 Shore

Flow Guide Selection Charts

To order EV 100, state pump flow, empty car pressure (or flow guide size) and solenoid voltage.Example order: EV 100, 380lpm, 18 bar (empty), 110 AC ≡ EV 100/4/110AC

Taper threads: Do not exceed 8 turns of piping into the valve connections.

PAGE 41 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEETKVEN ISO 9001

GmbH

Pfaffenstrasse 1 Tel. 07131 2821-0Boellinger Hoefe Fax 07131 48521674078 Heilbronn http://www.blain.deGermany e-mail:info@blain.de

EN 81-2

KV2S

P

Z

T3.2 kg

KV2P

P

Z

T2.5 kg

KV1S

P

Z

T2.3 kg

P

Z

T1.8 kg

B44

KV1P

KV 1/2" solenoid valves are designed for small hydraulic lifts operating at speeds up to 0.16 m/s (32 fpm) depending on the valve selected. The smooth and accurate ride characteristics of the KV2S valve which includes 'soft stop' in both directions, render it highly suitable for quality home lifts and lifts for the handicapped.

Flow Range: 5-80 l/min. (1.3-20 gpm) - see fl ow pressure charts on page 6 Pressure Range: 3-100 bar (45-1500 psi)Oil Viscosity: 25-60 mm²/sec. at 40°C (15-35 cSt. at 120°F) Burst Pressure: 500 bar (7500 psi)Solenoids AC: 24 V/1.8 A, 42 V/1.0 A, 110 V/0.5 A, 230 V/0.18 A, 50/60 Hz Max. Oil Temperature: 70°C (158°F) Solenoids DC: 12 V/2.1 A, 24 V/1.1 A, 42 V/0.6 A, 80 V/0.3 A, 125 V/0.25 A, 196 V/0.14 A.Ports: P Pump, Z Cylinder and T Tank all G1/2"Insulation Class, AC and DC: IP 68

Control Valves for Small Lifts

Speeds max. (EN code)

Up One up speed, 0.16 m/s (32 fpm) max. Up start has built-in damping. Up stop has no damping (pump stops).Down One down speed, 0.16 m/s (32 fpm) max. Down start has adjustable damping. Down speed is adjustable. Down stop has built-in damping.

Up One up speed 0.16 m/s (32 fpm) max. with soft stop, or 0.4 m/s (80 fpm) max. with overtravel and releveling. Up start has built-in damping. Up stop has adjustable damping (delayed pump stop required).Down One down speed, 0.16 (32 fpm) max. Down start has adjustable damping. Down speed is adjustable. Down stop has built-in damping.

Up One up speed, 0.16 m/s (32 fpm) max. Up start has built-in damping. Up stop has no damping (pump stops).Down Two down speeds, 1 m/s (200 fpm) max. Down start has adjustable damping. Fast down speed and leveling speeds are adjustable. Slow down and stop have built-in damping.

Up One up speed, 0.16 m/s (32 fpm) max. with soft stop, or 0.4 m/s (80 fpm) max. with overtravel and releveling. Up start has built-in damping. Up stop has adjustable damping (delayed pump stop required).Down Two down speeds, 1 m/s (200 fpm) max. Down start has adjustable damping. Fast down speed and leveling speeds are adjustable. Slow down and stop have built-in damping.

Manufacturers of the Highest Quality:Control Valves for ElevatorsTank Heaters - Hand PumpsPipe Rupture Valves - Ball Valves

PAGE 42 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

BLAIN HYDRAULICS 2

EN ISO 9001

B44

EN 81-2

9

7 9 S 1

C6 D

KV2P

5

KV1P

D6

S 1

1S

KV1S

AD6

9

5

AC6 D

7 9 S 1

KV2S

H

H

H

H

DL

V

DH HP

BV

ES RS FEND

6

H KS

Y

9

U

1

S

M

H

DL

V

DH HP

BV

ES RS FEND

6

H KS

Y

9

U

1

S

M

A

5

DL

V

DH HP

BV

ES RS FEND

6

H KS

Y

9

U

1

S

M

C

X

7

DL

V

DH HP

BV

ES RS FEND

6

H KS

Y

9

U

1

S

M

A

5

C

X

7

D6

9

1

A

D5

5 6

9

1

C D6

7

911

A

C D

6

7

91

55

1

Electrical SequenceHydraulic Circuit

Alternative Overtravel

Mot

orM

otor

Mot

or

Alternative Overtravel

Mot

or

For Options:BV, EN, HP, KS,DH, DL and HAsee page 4.

Control Elements

A Solenoid ‘Up StopʼC Solenoid ‘Down DecelerationʼD Solenoid ‘Down StopʼU Bypass ValveH Manual LoweringHA Manual Down Speed Adjuster

Adjustments DOWN

6 Down Acceleration7 Down Full Speed 9 Down Leveling SpeedDown Deceleration built-in

Adjustments UP

1 Bypass5 Up Soft StopUp Acceleration built-in

V Check ValveX Down ValveY Down Level ValveF Main FilterS Relief Valve

3 mm socket key

3 mm socket key

3 mm socket key

3 mm socket key

PAGE 43 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

KV1P

KV1S

KV2P

KV2S

3BLAIN HYDRAULICS

Adjustments UP

1. Up Bypass: When the pump is started, the unloaded car should remain stationary at the fl oor for a period of about 1 second before starting upwards. The length of this delay is according to the setting of adjustment 1.'In' (clockwise) shortens the delay, 'out' (c-clockwise) lengthens the delay.Up Stop: At fl oor level, the pump-motor is de-energized. The stop may be abrupt depending on load and speed of approach. No adjustment possible.

S Relief Valve: 'In' (clockwise) produces a higher, 'out' (c-clockwise) a lower maximum pressure setting. After turning 'out', open manual lowering H for an instant.Important: When testing relief valve, do not close ball valve sharply.

1. Up Bypass: When the pump is started, the unloaded car should remain stationary at the fl oor for a period of about 1 second before starting upwards. The length of this delay is according to the setting of adjustment 1.'In' (clockwise) shortens the delay, 'out' (c-clockwise) lengthens the delay.

5. Up Stop: At fl oor level solenoid A is de-energized. Through a time relay the pump must run approx. 1/2 seconds longer to allow the car to stop smoothly by valve operation according to the setting of adjustment 5. 'In' (clockwise) provides a softer stop, 'out' (c-clockwise) a quicker stop. Pre-adjustment: With solenoid A disconnected and the pump running, 5 should be turned in until the car starts to move up, then slowly backed off again until the car stops.Alternative Up Stop: At relatively higher speeds and with the time relay arrangements as with 'up stop' above, the car may travel to just above fl oor level. In overtravelling the fl oor, down leveling solenoid D is energized, lowering the car smoothly back down to fl oor level where D is de-energized.

S Relief Valve: 'In' (clockwise) produces a higher, 'out' (c-clockwise) a lower maximum pressure setting. After turning 'out', open manual lowering H for an instant.Important: When testing relief valve, do not close ball valve sharply.

1. Up Bypass: When the pump is started, the unloaded car should remain stationary at the fl oor for a period of about 1 second before starting upwards. The length of this delay is according to the setting of adjustment 1.'In' (clockwise) shortens the delay, 'out' (c-clockwise) lengthens the delay.Up Stop: At fl oor level, the pump-motor is de-energized. The stop may be abrupt depending on load and speed of approach. No adjustment possible.

S Relief Valve: 'In' (clockwise) produces a higher, 'out' (c-clockwise) a lower maximum pressure setting. After turning 'out', open manual lowering H for an instant.Important: When testing relief valve, do not close ball valve sharply.

1. Up Bypass: When the pump is started, the unloaded car should remain stationary at the fl oor for a period of about 1 second before starting upwards. The length of this delay is according to the setting of adjustment 1.'In' (clockwise) shortens the delay, 'out' (c-clockwise) lengthens the delay.

5. Up Stop: At fl oor level solenoid A is de-energized. Through a time relay the pump must run approx. 1/2 seconds longer to allow the car to stop smoothly by valve operation according to the setting of adjustment 5. 'In'' (clockwise) provides a softer stop, 'out' (c-clockwise) a quicker stop. Pre-adjustment: With solenoid A disconnected and the pump running, 5 should be turned in until the car starts to move up, then slowly backed off again until the car stops.Alternative Up Stop: At relatively higher speeds and with the time relay arrangements as with 'up stop' above, the car may travel to just above fl oor level. In overtravelling the fl oor, down leveling solenoid D is energized, lowering the car smoothly back down to fl oor level where D is de-energized.

S Relief Valve: 'In' (clockwise) produces a higher, 'out' (c-clockwise) a lower maximum pressure setting. After turning 'out', open manual lowering H for an instant.Important: When testing relief valve, do not close ball valve sharply.

Nominal Settings: Adjustment 1 level with fl ange faces. Adjustment 5 (KV1S & KV2S) level with fl ange faces.

Valves are already tested and adjusted. Check electrical operation before changing valve settings. Test that the correct solenoid is en-ergized by removing nut and raising solenoid slightly to feel pull.

Warning: Only qualifi ed personell should adjust or service valves. Unauthorised manipulation may result in injury, loss of life or damage to equipment. Prior to servicing internal parts, ensure that the electrical power is switched off and residual pressure inthe valve is reduced to zero.

PAGE 44 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

BV HP (H13) EN

90

60

30

44

90°

65

65

DH/DL KS

4BLAIN HYDRAULICS

DH/DL KS

BV HP (H13) EN

HA

Options are shown with KV1P Valve. The same Options can be applied to all other KV Valve types .

KV Example with Options

KV Optional EquipmentBV Ball Valve built inEN Emergency Power SolenoidHP Hand Pump H 13KS Slack Rope ValveDH Pressure Switch 10-100 barDL Pressure Switch 1-10 barCSA CSA SolenoidsHA Manual Down Speed Adj.

KV1P / KV1S6. Down Acceleration: When solenoid D is energized, the car will accelerate downwards according to the setting of adjustment 6.

'In' (clockwise) provides a softer down acceleration, 'out' (c-clockwise) a quicker acceleration. Pre-adjustment: 6 should be turned all the way in and then solenoid D energized. Turn 6 slowly back out until the car accelerates downwards.

9. Down Speed: With solenoid D energized as above, the down speed of the car is according to the setting of adjustment 9. 'In' (clockwise) provides a slower down speed, 'out' (c-clockwise) a faster down speed.

Down Stop: At fl oor level, solenoid D is de-energized causing the car to stop. No adjustment necessary.H Manual Lowering: 'out' (c-clockwise) allows the car to be lowered by hand. Closes automatically on release.

KV2P / KV2S6. Down Acceleration: When solenoids C and D are energized, the car will accelerate downwards according to the setting of

adjustment 6. 'In' (clockwise) provides a softer down acceleration, 'out' (c-clockwise) a quicker acceleration. Pre-adjustment: 6 should be turned all the way in and then solenoid C and D energized. Turn 6 slowly back out until the car accelerates downwards.

7. Down Speed: With solenoids C and D energized as above, the down speed of the car is according to the setting of adjustment 7. 'In' (clockwise) provides a slower down speed, 'out' (c-clockwise) a faster down speed.

Down deceleration: When solenoid C is de-energized whilst solenoid D remains energized, the car will decelerate according to the built-in damping. No further adjustment will be required.

9. Down Leveling: With solenoid C de-energized and solenoid D remaining energized, the car will travel at its down leveling speed according to the setting of adjustment 9. 'In' (clockwise) provides a slower, 'out' (c-clockwise) a faster down leveling speed.

Down Stop: At fl oor level, solenoid D is de-energized causing the car to stop. No adjustment necessary.H Manual Lowering: 'out' (c-clockwise) allows the car to be lowered by hand. Closes automatically on release.KS Slack Rope Valve: Solenoid D must be de-energised! The KS, is adjusted with a 3 mm Allan Key by turning the screw K 'in' for higher pressure and 'out' for lower pressure. With K turned all the way 'in', then half a turn back out, the unloaded car should descend when Manual Lowering H is opened. Should the car not descend, K must be backed off until the car just begins to descend, then backed off a further half turn to ensure that with cold oil, the car can be lowered as required.

Valves are already tested and adjusted. Check electrical operation before changing valves settings. Test that the correct solenoid is energized by removing nut and raising solenoid slightly to feel pull.

KV Nominal Settings: Adjustments 7 & 9, screwheads level with the hexagon heads.

Adjustments DOWN

OptionalSeparate EquipmentRS Pipe Rupture ValveES Pipe Rupture Valve End Switch

PAGE 45 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET

BLAIN HYDRAULICS 5

AD6

Z

T Y U P

1

9

5

KV1P KV1S

F V

Z

L KS H S

KV2P KV2S6 D C A

Z

T P U

1

5

F V X Y

Z

L KS H 7 9 S

KV1P KV1S

7 34,5

50

11140

125

110

65

43

Z

T P

M6

44 15,5G /4"DH - DL

1

36,5

M6

Z

T

P

M6

2565

20

508

1436

M6

KV2P KV2S

7 34,5

50

40

125

110

65

43

Z

T P

M6M6G /4"

DH - DL1

40,6

14048,5

Z

T

P

M6

2565

20

507,

5 10,5

15,5

34

M6

Measurements

Assembly

Adjustments1 Bypass5 Soft Stop ‚Up‘6 Start ‚Down‘7 Speed ‚Down‘9 Levelling ‚Down‘S Relief Valve

ConnectionsP PumpT Tank - returnZ Cylinder

KV1P andKV1S

KV2P andKV2S

Control ElementsA Solenoid ‚Up Stop‘C Solenoid ‚Down Deceleration‘D Solenoid ‚Down Stop‘U Bypass ValveV Check ValveX Down ValveY Down Levelling ValveH Manual LoweringL Gauge Shut Off CockF Main Filter

Important: Length of ½“ thread on pipe connections should not be longer than 14 mm!

PAGE 46 of 48

aPPENdIX 9 BlaIN ValVE adjuSTMENT SHEET KV

6 Jan 11 BLAIN HYDRAULICS Designers and Builders of High Quality Valves for Hydraulic Elevators Printed in Germany

MM

M

DR6

MO

6

DF

N6

DK

DG

S6 AS

AH

AF

AN

MO

AR

M

AD

KV1SKV2S

MMD

DR

MO

DF

DN

DK

DG

S6

M

MMC A

KV2

KV2

5 KV1S, KV2S

S

SESMMSSOSZSFSK

HHO

KS

1

1F1EUF UOU EO

7+9

7ESM9F MSSZ SOYOFIXTXO

Z

FZA V VO

SL KS H 7

D/6 CA

1

5

KV2SKV2P

9 0-Ringe: 9x2 P

Z

DH/DL

0-Ringe: 9x2 P

Z

DH/DL

L KS H S

D/6A

KV1P KV1S

5

91

X / Y

h

bar

l/min

US gpm

psi

5 10 15 20 25 30 35100

90

80

70

60

50

40

30

20

10200

400

600

800

1000

1200

1400

KV1

KV2

10 20 40

80

10 20 30 40 50 60 70 80 90 100 110 120 130140 150

bar

l/min

psi

5 10 15 20 2520

10200

10 20 30 40 50 60 70 80 90 100

100

300

KV1&KV2

US gpm

bar

l/min

US gpm

psi

5 10 15 20 2530

20

10200

400

10 20 30 40 50 60 70 80 90 100

100

300

For pressure-fl ow conditions with-in shaded area, use 3/4" piping to avoid unnecessary power loss.Pump fl ows above 80 l/min. not recommended

Example orderKV2S, 65 l/min, 25 bar (empty), 220WSor: KV2S/80/220WS

Pressure Drop P - Z Insert Selection and Down Flow Chart

Solenoid Valves Adjustments

Parts List

Flow Valves

Stat

ic p

ress

ure

with

em

pty

car.

Lowest Relief Pressure

0-Rings: V - Viton - FKM P - Perbunan - NBR

In case of down leakage, replace and test in the following order:S6, N6, HO, V complete, XO, (2x XO with KV2).

0-Rings: 9x2 P 0-Rings: 9x2 P

Pos. No. Item1 1F Flange - Bypass

1E Adjustment - Bypass EO 0-Ring - Adjustment (3,5x1,5 - P) U Flow Guide - Bypass UO 0-Ring - Bypass (17x1 - V) UF Spring - Bypass 5 5 Adjustment - Up Stop

6 6 Adjustment - Down Acceleration7+9 7E Adjustment - Down Valve

9F Spring - Down Valve YO 0-Ring - Flow Guide (10x1 - V) XO Seal - Flow Guide (5.28x1.78 - V) XT 0-Ring Disc FI Filter - Down Valve X Down Flow Guide (Brass) Y Down Levelling Flow Guide (Steel) - KV2 Y Down Flow Guide (Steel) - KV1

S SE Adjustment Screw - Relief Valve SM Hexagonal - Relief Valve MS Locking Screw SO 0-Ring - Nipple SZ Nipple - Relief Valve SF Spring - Relief Valve SK Piston - Relief Valve

H H Manual Lowering - Self Closing HO Seal - Man. Lowering (0-Ring 5.28x1.78 - V)HA HA Adjustable Manual LoweringKS KS Slack Rope Valve

A MM Nut Solenoid AD Collar Solenoid M Coil Solenoid (indicate voltage) AR Tube Solenoid 'Up' MO 0-Ring Solenoid AN Needle Solenoid 'Up' AF Spring Solenoid 'Up' AH Seat Housing 'Up' AS Seat Solenoid 'Up'C+D M Coil Solenoid (indicate voltage) C DR Tube - Solenoid 'Down', w/o adj. 6 D DR6 Tube Solenoid 'Down', with adj. 6 MO 0-Ring Solenoid DF Spring Solenoid 'Down' C DN Needle Solenoid 'Down' D N6 Needle Solenoid 'Down' (Nipple) C HN Needle Solenoid 'Down' DK Core Solenoid 'Down' DG Seat Housing 'Down'(Solen.D with screen) C S6 Seat Solenoid 'Down' C CO 0-Ring Seat Housing

Z ZA Cylinder Thread Connection V Check Valve VO 0-Ring Check Valve (5,28x1,78 - V) F Main Filter

L L Gauge Shut Off Cock

PAGE 47 of 48

NOTES

PAGE 48 of 48

NOTES

1090 Lorimar Drive Mississauga, ON L5S 2A1

Tel 905.458.4015

Toll 1.888.785.5438

Fax 905.458.0680 www.federalelevator.com