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YOUR MACHINE HAS:
Manufacturing No.: Year: Part No. 9023 767 - 1041995 - 01 - 27
If the bottom right corner of this book is cut, the book is only valid for illustrative use!
This manual is only applicable if the manufacturing number indicated below corresponds to the manufacturing number stamped on the identificationsign of the equipment. Where there is a conflict contact Your ALIMAK representative.
Operator’s Manual forSCANDO MINI,
U-600 & ALICOMPermanent Lifts
Photographs and drawings are illustrative only and do not necessarily show the design of the products on the market at any given point in time.The products must be used in conformity with applicable practice and safety regulations. Specifications of the products and equipment
presented herein are subject to change without notice.
FOREWORDThis product is designed and manufactured to meet strict qualityand safety standards. This manual is intended to provide adviceand instructions to the operator and qualified service personnelso that he can safely control the situations which can occur whenthe product is used, and can carry out the required service andmaintenance on the product.
This manual shall always be available in the box intended forthis purpose on the machine.
Potential risk for user or equipment are indicated in the followingway, in this book:
WARNING! Information with these symbolsand headings indicates the possibility of per-sonal injury.
IMPORTANT: Information with these headings indicate thepossibility of damage to the equipment.
CONTENTS
CDEF
IMPORTANT SAFETY INSTRUCTIONS
OPERATING INSTRUCTIONS
SERVICE AND MAINTENANCE
ELECTRIC TROUBLESHOOTING
IMPORTANT SAFETY INSTRUCTIONS
Safety instructions ..........................................
ALIMAK 31275
C 1
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ALIMAK 31276
Important Safety InstructionsGeneralOver the years serious accidents have occurred during theerection and dismantling of rack and pinion lifts. Common tothese accidents has been the ”human factor”, i.e. non adherenceto proper safety procedures and common sense.
This document affects those personnel involved with the erection,dismantling and servicing of such equipment.
Some examples:
Leaning over the safety railing on the car roof while the lift ismoving upwards can cause you to be struck by a tie or a cableguide.
Incomplete installation of mast bolts can cause separation of themast sections, leading to the fall of the car with subsequent lossof life or serious injuries.
Avoid the risk of accidents by carefully studying these instruc-tions regularly. Think clearly! Do not rush the work and alwayscheck to make certain that the work is being done properly.SAFETY FIRST!
Safety instructions
Local Safety Regulations
– All local regulations shall apply.
Weather Conditions
– Lifts must not be erected or dismantled in wind speedsexceeding 15 m/sec. (33 mph) or as governed by localregulations where more stringent.
Preparation
– The Instruction Manual is to be carefully studied beforework begins.
– The site of erection/dismantling must be made secure fromfalling objects by barricading or roping off the area.
– No admittance to the lift car during erection or dismantlingby unauthorized personnel.
Safety Equipment and Protective Clothing.
– Prescribed safety equipment and clothing such as hard hat,safety shoes, safety belt, etc. shall be used.
– Loose fitting clothes such as scarves must not be used asthey might become entangled in moving parts.
C 1
ALIMAK 31277
General
– Read all Warning and Instruction Signs.
– Keep the work area clean. Any oil spillage must be removedimmediately to avoid the risk of slipping.
– During erection, dismantling or lifeway inspection, the liftmust always be operated from the car roof. When workingfrom the car roof take precautions to avoid being struck bymast ties, cable guides, landings, structure openings, etc.while lift is moving.
– When the control equipment on the car roof is to be left ontemporarily during installation/dismantling or service, themain switch in the control panel of the lift car as well as thefinal limit switch must be switched off and locked in orderto ensure no accidental moving of the car.
– Under no circumstances shall the lift be driven if there isa person within the ground enclosure, on the mast or tie.
– Complete each item of work before starting a new one ortaking a break. This is especially important when boltingmast sections and installing ties.
Mast and Mast Tie
– The maximum tie distance, prescribed on the applicableArrangement drawing or in Manual, must not be exceeded.
– Bolted joints shall always be tightened to the required torqueas prescribed by the Manual.
– If any structural damage or severe corrosion is seen on suchitems as mast sections or mast ties, the lift must be immedia-tely taken out of service and the extent of the damage bedetermined and corrective action taken before the lift is putinto service again.
Electrical Power
– Work performed on electrical equipment must be carried outby competent personnel, trained for such work. The powersupply must be switched off and locked before work isperformed.
Spare Parts
– Unauthorized spare parts are not to be used. Only “AlimakGenuine Spare Parts” are to be installed.
C 2
Always lock the main ”ON/OFF” switchwith a padlock to prevent unintentionaloperation while service/inspection workis carried out.
The main ”ON/OFF” switch must be inthe ”OFF” position before the paneldoor can be opened.
OPERATING INSTRUCTIONS
Instruction for use ..........................................Operating instructions ...................................If the lift does not start...................................If the lift suddenly stops .................................Manual cranking ............................................
ALIMAK 31278
D 1D 2D 3D 3D 5
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ALIMAK 31279
D 1Instructions for useInstructions to the user/operator on how the equipment is to behandled are presented below. These instructions will also befound on a plate in the lift car.
Note that the user/operator is responsible for ensuring that thedaily ”Safety Inspection” has been carried out BEFORE thelift is put into service.
Prior to any use of this lift perform safety procedures below, aswell as any required maintenance and lubrication specified in theOperator’s Manual.
1. Check that all emergency stop switches and the final limitswitch are working.
Make test runs with each one of the switches in ”Off”-position.
2. Check all electrical interlocks by making test runs with: a) Ground landing door open. d) With car trap door open.b) Car entrance door open. e) Each landing door open.c) Car exit door open.
The lift must not start. Be sure to check only one switchat a time.
3. Check all mechanical interlocks by making test runs and atthe same time try to open the doors.
Car and landing doors must remain locked until the carstops at the landing.
4. Check the condition and function of all springs on all cableguides.
5. Check function of limit switches by making test runs.
Also check fastening of all limit ramps and switches.
6. In case of storms, tornados, hurricanes or earthquakes, allvital parts of the lift must be inspected and tested by anexpert or authorized local inspector prior to use of the lift.
7. Lift installed outdoors must not be used when wind velocitiesexceed 20 m/sec. (For USA and Canada 40 mph).
8. Where icing can take place, the lift should be parked at theground landing upon completion of work. If the mast or powercable are covered with ice, remove ice before using lift.
9. Equipment and materials not associated with the lift shall notbe attached to the lift in any manner.
SAFETY INSTRUCTIONS
Operating instructionsControl equipment with pushbuttons1. Visually check that the liftway is free from any obstacles.
Keep this constantly under observation.
2. Switch on the main ON/OFF switch at the ground landing.
3. Make sure that the maximum permissible load, according tothe information on the load plates in the lift, is not exceeded.
4. Close the landing doors and the lift car doors fully.
5. Depress the button with the symbol for the desired directionof travel. The lift will now start.
6. Depress the ”STOP” button at the desired landing. The liftwill stop. At top and bottom landings the lift car will stop automatic-ally due to the limit cams in the mast.
Stop next landing equipment
If the lift is provided with ”Stop next landing equipment”,depress the button with the symbol for this function just be-fore you have reached the desired landing. The lift car willthen stop automatically at the level at the landing.
Automatic floor call system
If an ”automatic floor call system” is provided with onebutton for each landing, the button for required landing ispushed. The lift car then automatically stops at the selectedlanding.
When carrying out service and inspection workWhen it is necessary to operate the lift from the car roof, inorder to carry out service and inspection work, the switch in theelectric cabinet in the lift car shall be set in the ”Inspection”position. The switch then breaks the self-holding function of the”Up” and ”Down” buttons and the landing control circuits. Thismeans that the lift will stop as soon as the pushbutton isreleased and that the lift can only be operated from the lift car.
ALIMAK 31280
D 2
ON
OFF
If the lift does not start – check:– that the main ON/OFF switches at the ground landing and
on car is in the ”ON” position and that the lift is suppliedwith electric power.
– that no ”Emergency Stop Button” is in the depressed posi-tion.
– that the final limit switch on the machinery or safety plate isin the ”ON” position. If the final limit switch is activated –see heading ”Manual cranking”.
– that the roof trapdoor and car doors are fully closed.
– that all the landing doors are fully closed.
– that the ”Normal/Inspection” switch in the electric cabinet inthe car is in the ”Normal” position.
– that no circuit breaker for control power has tripped out.
If the lift still does not start, see the instructions in the section”Electric troubleshooting”.
If the lift suddenly stops:If the lift has stopped between landings due to a power failureor any other electric failure, such as blown fuses, tripped motor,overload protector, etc., it can be manually lowered to the nextlower landing for unloading.
Only slide the lift short distances at very low speed in order notto exceed the normal operating speed of the lift. If excess speedoccurs, the lift’s safety device will automatically trip and stopthe lift. The safety device must then be reset before the lift canslide again.
Sliding
1. First check applicable items on previous page.
2. Switch off the main ON/OFF switch on the electricalcabinet on the car roof.
ALIMAK 31281
D 3
ON
OFF
ALIMAK 31282
3. Lift the brake lifter on the motor (motors) to allow the car toslide down to the next landing.
I M P O RTA N T: Only slide short distances with maximum1/3 of normal operating speed.
Stop at least 1 minute every 20 meters(65 ft) so that the brake has time to coold o w n .
When the brake becomes overheated it be-comes damaged leading to a deteriorationof the brake function.
4. If sliding of the car is not possible – stay in the car and callfor assistance.
WARNING! Do not leave the car – waitfor qualified assistance.
Centrifugal brake
The lift can be provided with a centrifugal brake to prevent acci-dental tripping of the safety device when going down by gravity.
The motor brake can be released mechanically by a lever in thecar to allow the car to move down. When doing so, the centrifugalbrake keeps the preset speed which is lower than the trippingspeed.
The centrifugal brake tends to become overheated when descen-ding long distances by gravity – stop therefore at least 10minutes every 200 m (650 ft) and let the brake cool down.
Manual crankingIf, due to heavy load and poor brake function, the lift has beendriven against the final limit cam at the bottom landing so thatthe power to the driving unit has been cut off, the car can becranked back manually to the normal landing level.
Motor brakes should be checked by trained/authorized servicepersonnel, before the lift is put back into service.
CrankingTo be carried out by trained service personnel.
WARNING! The power must always be cut off bymeans of the main On/Off-switch on the electriccabinet on the lift car roof before cranking may becarried out.
D 4
Brake release lifter
ON
OFF
ALIMAK 31283
D 51. Remove the inspection cover on the intermediate flange of
the brake motor which is most easily accessible, when thereare several brake motors.
2. If there is more than one brake motor, lift the brake lifter onthe other brake motors and insert the wedge so that thebrake or brakes is/are released.
IMPORTANT: Use no more than moderate force wheninserting the wedge. If excessive force isused when inserting the wedge, the effectmay be the opposite due to overturningthe magnet housing and locking thebrake disc.
3. Insert the cranking lever from the lift tool kit, in the highestaccessible hole on the coupling inside the intermediateflange.
4. Pull the lever downwards and lift the motor brake at thesame time. The lift car will move upwards.
Reapply the brake between each turn of the crank.
Note that cranking can be carried out against one appliedbrake if the lift car is unloaded.
WARNING! Remove the wedge/wedges and toolswhen the cranking is finished.
Cranking motor coupling
SERVICE AND MAINTENANCE
Service and maintenance ...............................Adjustment and wear limits ..........................Drop test ..........................................................Lubrication diagram ......................................
ALIMAK 31284
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Service and maintenance In order to avoid unnecessary breakdowns, those responsible forthe service and maintenance of this equipment must regularlyensure that all scheduled maintenance work according to themaintenance programme below is carried out at the recommen-ded intervals.
Adjustments and replacement as a result of checks, must becarried out by trained/authorized servicepersonnel. Only ALIMAK Genuine Spare Parts must be used.
WARNING! Before carrying out any servicework, the ”Normal/Inspection” switch in theelectric cabinet on lift car must be placed in the”Inspection” position.
When leaving the car without having completedthe service work or to carry out service, themain switch must be switched off, locked andprovided with a warning sign.
Service intervalsIntervals based on operating time shall be followed in the firstinstance. If the lift is used only periodically, the first applicableinterval to be reached shall be followed.
ChecklistChecklist, with room for notes on maintenance executed, willbe found at the end of this manual. Use them!
Service and maintenance scheduleSee the appendix at the end of this manual for tightening torques.
ALIMAK 31285
Interval Part Instructions
40 operating 1. Sign plates/ Check that all signs are in position according to the spare parts manual, andhours or at least instruction that they are legible. Check also that the documentation according to theevery 2nd month manuals documentation box is available.
2. Safety device Check with the user/users if the safety device has been tripping without causeor if noise can be heard from the device during operation. For further details,see the instructions for checking wear on the safety device under the heading”Adjustment and wear limits”.
3. Worm gears Check the oil level and refill if necessary. Leaking seals shall be replaced bytrained/authorized service personnel.
4. Counter roller(s) Check that all screw joints are properly tightened.at the rear of the machinery plate and safety hooks and guide rollers on the lift carframe.
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ALIMAK 31286
Interval Part Instructions
5. Attachment of Check that all screw joints are properly tightened. machinery plate
6. Electric motor Check that the car stops within acceptable limits, specified later in thisbrakes chapter. See also the special instruction for checking the brake torque with a
spring balance.
7. Brake pads Check the play between the electro-magnet armature and the rotating brakedisc according to instructions later in this chapter.
8. Lift cable(s) Check the cable for wear and to ensure that no kinks occur. Check also theattachment of the cable in the cable support arm on the lift car and the fixturein the lift mast – where a cable guiding device and trolley is furnished.Check that the cable is marked ”ALIMAK”.
9. Cable basket, Clean the cable basket. If the cable guide device is of a type for power andwhere applicable control cables which has been taped together, check the tape and, if neces-
sary, reinforce it along the entire length of the cable.
10. Interlocks Check the function of all mechanical and electrical interlocks on all landingsand on the lift car. See the instruction under ”Safety Instructions”.
11. Car floor and Clean car floor and roof. roof
12. Lubricating See the instructions in the “Lubrication diagram”. Also check rack for possible damages, misalignment and attachment, whenlubricating.
120 operating 21. Lift mast Check visually that all screw joints of all racks and mast joints are properlyhours or at least tightened. Also check the screw joints for attaching the mast in the baseevery 6 months frame.
22. Mast ties Check that all screw joints in all mast ties are properly tightened.Also check attachment to structure.
23. Limit switches Check attachment and function.and cams, andfinal limit switchwith associatedcams
24. Cable guides Check the cable guides with regard to attachment, function and installationin the mast in relation to the cable support arm on the lift car.
25. Cable trolley, Check that the cable trolley does not come in contact with the buffer frame atwhere applicable the ground landing and that the trolley is parallel to the mast tubes. Check
also the function, attachment and wear on the guide and cable rollers and thatthe cable wheel on the trolley runs smoothly.
26. Base slab/pit Remove all debris, which may have fallen on/into the base (or pit).
27. Gates on lift Check the function, attachment and wear on rollers. Check to ensure thatcar and rubber absorbers are in place.enclosures
28. Buffers for lift Check that the buffers are in position and in a proper condition.car
29. Signal equipment Check the function of the control device, alarm signal, lighting, automaticand lighting stop at landings and, where applicable, voice communication system.
30. Emergency Switch off the main ON/OFF switch in the lift car and check to ensure thatlighting the emergency light function.
Switch on the main ON/OFF switch and check that the LED on the batterycharger is lighted.
Interval Part Instructions
31. Rack and pinion Check the wear on the rack and pinion according to the instructions underthe heading ”Adjustment and wear limits”.
32. Worm gear Check the wear according to the instructions under the heading ”Adjustmentwear limits”.
33. Enclosures Check that there is nothing in the vicinity of the landing which can be usedas a ladder or can reduce the correct height of the enclosure in any way.Point out any infringements and risks of injuries to the site manager.
34. Scaffolding Check that the distance from the lift car to landings, scaffolding,adjacent to lift balconies, windows or any other location where persons may find
themselves, are not less than regulations dictate.Point out any infringements and risks of injuries to the site manager.
35. Guide rollers Check wear and bearing play of the lift car guide rollers. Adjustment andreplacement, when required shall be carried out by trained/authorized servicepersonnel.
36. Safety device Test the safety device according to the instructions under the heading ”Drop test”.
37. Centrifugal brake Check that the sliding speed does not exceed the normal operating speedwith more than 15% by using a tachometer. Also check the brake linings.Change linings when they are worn down to 3 mm (.12”).
38. Electric motor(s) If necessary, clean the cooling flanges of the electric motor(s).
39. Lubricating See the instructions in the “Lubrication diagram”.
40. Contactors Check the condition of the contact points in the contactors.
400 operating 45. Lubricating See the instructions in the “Lubrication diagram”.hours or at leastevery 6 months
1000 operating 50. Shaft couplings Check any play in the coupling between the motor and the worm gear withhours or at least the aid of the cranking lever. If play occurs, service must be carried out byonce a year trained/authorized personnel.
51. Electric wiring Check all wires, sealing glands and connections.
52. Motor overload Check that the motor overload protector is set with the rated current on theprotector data plate for the electric motor.
53. Deformations/ Inspect the equipment visually in its entirety for deformation/mechanicalmechanical damage to mast tubes/beams, diagonal ties in the mast sections, mast ties,damage doors, protective rails, floors, etc.
This inspection and any actions which may be necessary after the inspectionmust be performed by trained/authorized service personnel.
54. Corrosion, Inspect the equipment in its entirety for corrosion and wear on loadbearingdamage and force-absorbing components with the aid of an ultrasonic thicknessand wear measuring instrument. This inspection and any actions which may need to be
taken after the inspection must be performed by trained/authorized servicepersonnel.
A method for internal corrosion protection of the mast tubes is available,please contact your ALIMAK representative.
55. Lift mast/ Check that all screw joints of all racks and mast joints are properly tightened.guide rail Also check the screw joints for attaching the mast in the base.
ALIMAK 31287
E 3
Adjustment and wear limitsCar stopping positionIf the distance between actual stopping positions empty/fullyloaded car exceeds 110 mm (4.3 in.), the brakes must be checkedby trained/authorized service personnel.
Inspection of brake padsCheck with the aid of a feeler gauge.
Changing the brake pads
The pads (10) must be replaced before the gap between armature(5) and rotating disc (8) is less than 0.3 mm.
1. Remove protective screen (1).
2. Measure and make a note of the position of the adjustingsleeve so as to make sure that it is refitted in the sameposition after the pads have been changed. Note, however,that the brake will have to be applied a number of timesbefore it starts to work normally.
3. Unscrew and remove adjusting sleeve (6) and take out brakespring (7).
4. Slacken nuts (12) and run them back as far as the end of thebolts.
5. Slide end plate (2) back as far as the nuts.
6. Slide electromagnet housing (4) back against the end plate.
7. Fit new pads (10). There is a special tool which makes thisoperation easier. See fig.
8. Push electromagnet housing (4) back along the bolts so thatarmature (5) comes up against the new pads (10).
9. Push back end plate (2) and tighten nuts (12).
10. Refit brake spring (7) and screw in adjusting sleeve (6) tothe position according to point 2 above.
11. Operate the brake a few times to check that it is workingproperly.
12. Fit protective screen (1).
If the brake cannot be released, check:
– that the rectifier is in order and energized.
– that the brake contactor is in order.
– the voltage via the magnet coil (nom. 195V D.C.).
– the resistance of the coil (nom. about 450 Ohm for brakeBXLF 50 and about 348 Ohm for BXLF 100 at 20°C).
Replace electromagnet housing with coil if the coil turns out tobe detective.
ALIMAK 31288
Normally 40 mm (1.57”)– empty car
Maximum 70 mm (2.75”)– with pay-load
40
70
Pliers for brake padsPart No. 3000 272-499
Sill
Min. 0.3 mm
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1. Protective screen2. End bracket3. Magnet coil4. Electromagnet housing5. Armature6. Adjusting sleeve7. Brake spring8. Rotating brake disc9. Compression spring
10. Brake pad11. Bolt12. Nut13.14. Spacer15.16. Cable clip for magnet coil17. Fixed brake disc18. Fan screen19. Key20.21.22. Stop screw23. Fan24. Cone25. Circlip26. Tube27. Carrier28. Spacer29. Screw
ALIMAK 31289
E 5
Checking brake torque
WARNING! Before checking the brake torque,the power supply must be switched off and locked.At least one brake must be applied during the test.
If the machinery is of single motor design the liftcar must be brought down to rest on the buffersprings before checking is allowed to take place.
This test is carried out by means of using a lever and a springbalance.
Fit the cranking lever according to the figure.
Release the brake and turn the lever up and down to determinethe total cog play. Then turn the lever upwards, reapply thebrake and fit the spring balance.
Pull down and read value on the spring balance when the brakestarts to slide.
Electromagnetic disc brake size BXLF 100:Shall have a torque of 100 Nm (88.5 lbf x ft) ± 25%.
Electromagnetic disc brake size BXLF 50:Shall have a torque of 50 Nm (37 lbf x ft) ± 25%.
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ALIMAK 31290
BXLF 50 = 10 kpBXLF 100 = 20 kp
500 mm
121 mm
Guide rollerAdjustment of guide rollersAlways adjust the rollers in pair, in other words the correspond-ing rollers on both sides of the mast tubes/guide rail shall beadjusted at the same time.
Carry out the adjustment by freeing the fixing screw on theroller and turning the eccentric shaft, which is provided with aspanner grip, until the correct play is obtained. Then tighten thefixing screw.
NOTE: The roller play shall always be adjusted with the lift carempty (unloaded).
Wear limitsMeasure with sliding caliper.
Dimensions New roller Worn-out roller(mm) (mm)
A Ø 74 min. Ø 68(Ø 2.91”) (min. Ø 2.68”)
B 7 min. 4(.27”) (min. .157”)
Note that the ”wearing” on the roller face must be equal – allaround.
Measure with sliding caliper.
Dimensions New roller Worn-out roller(mm) (mm)
D Ø 72 min. Ø 68(Ø 2.83”) (min. Ø 2.68”)
Note that the ”wearing” on the roller face must be equal – allaround.
ALIMAK 31291
E 7
A
B
D
0.5
mm
(.02
”)
0.5 mm(.02”)
RackMeasure the wear with the Alimak rack gauge part No. 9019 645.If the gauge reaches the bottom, the rack must be replaced.
Note: Only for racks manufactured after Jan. 1986.
Alternativ
Measure with a dia. 18 mm (.709”) gauge rod and sliding caliper.
PinionCheck the wear with a sliding caliper.
Mast tubes
Checking of wear and corrosion of the mast sections is carriedout by means of Alimak testing equipment for ultrasonicsounding, Part No. 3001 991-301. The bottom mast section isthoroughly checked.
New mast tubes (t) = 4.2 mm nom. (.165”)
Max. worn out mast tubes (t) = 3.1 mm (.122”) – approx. 25%reduction of wall thickness.
Note that wear/corrosion on the mast sections have an effect onmax. allowed overhang (free top) and max. allowed mast heightas follows:
Reduction of original Reduction of overhang Reduction of mastwall thickness in % of the lift mast in % height in %
10% 15% 20%15% 20% 30%20% 20% 40%25% 25% 50%more than 25% Mast section should be scrapped
U600 guide rail
Check the wear with a sliding caliper.
New guide flange (t) = 8.0 mm nom. (.315”)
Max. worn out guide flange (t) = 7.0 mm (.275”) – approx. 15%reduction of wall thickness.
ALIMAK 31292
(.7087”)Ø 18 mm
Max. worn cog 35.8 mm (1.409”)
New cog 37.1mm (1.461”)
Max
. wor
n co
g67
.9 m
m (
2.67
3”)
E 8New rack
Max. worn rack
Worm gear
WARNING: Before checking can be carried outthe power supply must be switched off in a safetyway.
Dismantle the inspection plug on the gear housing and checkthe wearing of the worm wheel.
Place the guage with the end marked 100% perpendicular and inthe centre of one of the cogs. If the groove enters the cog, theworm wheel is worn out.
If not – turn the guage and check if it is more/less 50%.
A BGear ratio New cog Max. worn cog Gauge
mm (in.) mm (in.) Part No.
10 : 1 3.9 (.153) 2.9 (.114) 9030 153 - 10114 : 1 3.8 (.149) 2.8 (.110) 9030 153 - 102
16.5 : 1 4.8 (.189) 3.8 (.149) 9030 153 - 10320 : 1 4.3 (.169) 3.3 (.130) 9030 153 - 104
10.25 : 1 3.6 (.142) 2.6 (.102) 9030 153 - 10720.5 : 1 4.0 (.157) 3.0 (.118) 9030 153 - 10825.5 : 1 2.8 (.110) 2.3 (.090) 9030 153 - 10929.5 : 1 2.3 (.090) 1.8 (.071) 9030 153 - 110
ALIMAK 31293
Inspection plug
Gauge
50% worn cog Max. worn cog
E 9
Measuring the radial play of the rotating shaft on thesafety device1. Clamp a support (A) on the rack with the aid of a C-clamp –
about 1 mm (.039”) above the safety device pinion.
2. Measure the play with a feeler gauge.
3. Lift the pinion with the aid of the cranking lever from thelift tool kit or some other suitable instrument and measurethe play again.
Note that the pinion may not be turned but must remain inprecisely the same position during both measurements.
4. The difference between the two measured values is the radialplay in the safety device shaft.
5. If the radial play is greater than 0.6 mm (.024”), the safetydevice must be replaced.
IMPORTANT! Test has to be done before lubrication.
ALIMAK 31294
A
E 10
Drop test To be carried out by trained service personnel. A drop test must be carried out at every new installation and inaccordance with local safety regulations. Thereafter a drop testmust be carried out at least every 6 months without load andonce a year with full load.
If the safety device begins to trip or if noise occurs in the safetydevice during operation, the lift must be taken out of operationimmediately and the local ALIMAK representative be notified foraction.
WARNING: No one is allowed in the lift car duringa drop test. Before starting a drop test, make surethat the brakes function properly according to theinstructions in the chapter titled: “Service andMaintenance”.
Electrically powered lifts
1. Set the “Normal/Inspection” switch in the electric cabinetin the lift car into the “Inspection” position.
2. Connect the ALIMAK drop test cable to the terminal blockmarked “Drop test” in the electric cabinet on the car.
3. Attach the cable to the car adjacent to the electric cabinet andlower the pushbutton box to the bottom landing via the rooftrap door. At the same time, check that the cable is sus-pended in such a way that it cannot be crushed or beobstructed when the drop test is carried out.
4. Load the car with full load. Switch on the main ON/OFFswitch and run the car from the ground level up about 10meters (33 feet) by means of the Up-button on the push-button box on the testing cable.
5. Depress the button marked with an arrow symbol andmaintain it in the depressed position. This releases the motorbrake(s) and the lift car will drop until it reaches the trippingspeed and the safety device is actuated.
Release the pushbutton immediately if the safety devicedoes not come into function and stop the lift – at least3 meters (10 feet) above the ground level. The brake(s)are applied when the pushbutton is released.
If so, start the test from item 4 again.
6. Run the car up to the next higher landing.
ALIMAK 31295
E 11
ALIMAK 31296
7. Remove the test cable and then try to start the car in theupward direction.
The microswitch in the safety device shall, when the safetydevice has been actuated, prevent the lift from starting whenthe test cable has been removed. In other words, it must notbe possible to start the lift.
8. Reset the safety device according to instructions later in thischapter.
9. Reset the “Normal/Inspection” switch in the electric cabinetto the “Normal” position.
Note that if the lift is provided with centrifugal brake(s), theweights in the centrifugal brake(s) must be blocked with ablocking tool as illustrated, before the drop test can becarried out.
Don’t forget to remove the blocking tool(s) before takingthe lift into normal operation.
If you don’t succeed with the drop test, contact nearestALIMAK representative.
Calculating the safety device stopping distance
The safety device stopping distance can be measured betweenthe end face of the safety device and the end of the indicating pin– measure ”L”, see figure.
Multiply measure ”L” with factor 188.5 for safety device typeGF.
IMPORTANT! The safety device must be exchanged ifmeasure ”L” is more than 8 mm (.31 in.).
E 12
Blocking tool
L
Resetting the safety device
If the safety device trips during normal operation, a careful checkmust be made of the motor brake(s), transmissions, pinion, rackand all guide and counter rollers by personnel specially trainedfor this purpose, before the safety device may be reset. The causeof the tripping must be determined and rectified.
The safety device may be reset after a drop test, without havingto carry out the checks listed above.
IMPORTANT: Exchange intervals, see sign on safety device!
The safety device must ALWAYS be resetat the normal lower landing level.
Resetting
1. Switch off the car main ON/OFF switch.
2. Unscrew the screws (1) and remove the cover (2).
3. Unscrew the screws (3).
4. Use the sleeve (5) and the cranking lever (4) to back off thenut (7) until the end of the pin (6) is on a level with the endsurface of the safety device.
5. Install the screws (3) and the cover (2) with the screws (1).
6. Remove the protective cover (9).
7. Tighten the screw (8) by hand as far as possible and then afurther 30° with aid of the sleeve and the cranking lever(4) – in the direction indicated by the arrow on the cover.
8. Reinstall the protective cover (9).
9. Switch on the car main ON/OFF switch and run the carabout 20 cm (approx. 8 in.) upward on the lift mast to resetthe centrifugal weight of the safety device in the neutralposition.
10. Make a test run.
WARNING: From a safety pointof view the safety device mustnever be dismantled more than isnecessary to reset it as describedabove. For this reason the safetydevice is sealed.
ALIMAK 31297
Tighteningtorque 20 Nm
E 13
ALIMAK 31298
Lubrication diagramThe oil in the worm gears shall be changed after the first 25 operating hours.
INTERVAL POS. LUBRICATING POINT LUBRICANT VOLUME INSTRUCTIONS
40 operating hours 1 Worm gear Check the oil level andor at least every refill – if necessary.2nd month 2 Rack Alilube Lubricate during lowering
Part No. 3001 396-201 and take lift out of opera-tion for 2–3 hours to permitthe spray to congeal.
Lubricator for rack Grease acc. to sign Check grease level and– where applicable on lubricator. refill – if necessary.
3 Safety device Grease Grease nipples.
120 operating hours 4 Cable guiding device Ali-low-fric compound Grease trailing cable(s) andor at least every 6 Part No. 9052 045-000 slide surfaces on trolleymonth and car cable bracket. Do
not grease mast tubes/guides – the cable trolleymay get stuck.
5 Landings doors, interlocks Grease Grease bearings and slideand ramps surfaces.
6 Car doors, gate interlocks Grease Grease slide surfaces andand ramps bearings.
7 Guide rollers on car Grease
8 Operating lever for motor SAE 10–30 oil Lubricate bearings andbrake and Teleflex cable slide surfaces.
Roof trapdoor and electric SAE 10–30 oilcabinet hinges
400 operating hours 10 Worm gear Alioil HD 1.5 l Change oil.or at least every 6 (0.4 US gal.)month
The lubricating oil grades indicated above have been used when the equipment is delivered from the factory. Only oil recommendedby ALIMAK shall be used. If for some reason this is not possible, please contact ALIMAK or ALIMAK Representative for advice.
Oil recommendations for ALIMAK gear boxes
Extreme cold conditions Normal conditions Extreme warm conditions
ALIOIL ARCTIC ALIOIL HD ALIOIL TROPICPart No. 9041 979-000 Part No. 9040 996-000 Part No. 9041 980-000
Alioil Arctic, HD (Heavy Duty) and Tropic can be mixed.
If changing to other oil, the gear box and air filter must first be carefully cleaned.
E 14
ALIMAK 30814
1 2 3
4 5 6:1
6:2
7 8 10
E 15
TROUBLESHOOTING
Electric troubleshooting .................................Tone frequency – Signal equipment..............
ALIMAK 31299
F 1F 4
F 0
ALIMAK 31300
F 1Electric troubleshootingAdvice concerning procedures for troubleshooting
All forms of troubleshooting require adapting the procedure tothe function and structure of the equipment in question and toother conditions which may be local in nature. For example, theerection site, maintenance, previous operational disturbances, etc.
The main principles for all forms of troubleshooting in electricsystems are presented below. Troubleshooting is carried outwith the aid of a test lamp or voltmeter. We recommend avoltmeter – preferably a universal instrument – for rapid andreliable troubleshooting.
WARNING: Danger! High voltage. Work on theelectric equipment in the machinery may only becarried out by an authorized electrician or autho-rized service personnel.
1. Use the circuit diagram. This diagram is located in a boxintended for this purpose in the car. This shows how theelectric equipment should function, and how it is built andconnected.
1a. Check that the stopping circuit is not broken, in other wordsthat thermal relays and phase failure relays have not beenactuated and that the limit switches for the safety device,roof trap doors etc. have their contacts closed. Make surethat stop bottons, including bottons on landings, are not inthe depressed position. When the stopping circuit is unbroken,the main contactor, if any, shall be in the ”ON” position.
1b. Check that the end position switches for ”Up” and ”Down”respectively function as intended.
2. Connect the voltmeter/test lamp between the zero terminaland the terminal as indicated on the circuit diagram, andcheck that power is supplied where it should be supplied. Gothrough each terminal, one by one, and work methodicallyso that the circuits which function correctly can be eliminatedand the fault can be localized.
3. Begin at the botton landing by checking that power is suppliedon all three phases of the incoming main voltage.
4. Check that the outgoing lift cable receives power when themain switch is switched on.
5. Now begin troubleshooting in the lift car by checking thatthe power reaches the car.
6. Check in the equipment cabinet to ensure that power occurson all three phases of the incoming cable from the groundlanding.
7. Check that the ”Up” and ”Down” pulses from the pushbottons and control devices reaches theelectric cabinet in the car in the intended manner.
8. Make a trial run and check that the coil on the relevant contactor (Up, Down) receives powerand that it is actuated.
Check also that the brake contactor is actuated and that the brake coil is energized so that thebrake releases.
9. If the fault does not occur in the lift operating system but in its lighting or signal system, carryout fault-tracing in a manner similar to that described above, in other words check the circuitsmethodically one by one until you have narrowed down the fault and localized it.
Experience shows that certain fault causes have symptoms which, in turn, may indicate the causeand the probable location of the fault:
Example:
Symptom Probable cause Probable fault location
a) Control fuses blow Short-circuit, equipment Damaged control cable, dama-immediately. grounded. ged pushbutton, limit switch
etc. located ”outside”, usuallyon landing.
b) Fuse blows after a short Equipment partially grounded, Damp or water in limit switch,time. overload. connection box, door lock,
etc due to damaged electricinstallation. Improperly con-nected new equipment.
c) Lift stops or cannot be Limit switch in stopping circuit Stop pushbutton depressed,started. has tripped/been actuated, door open, thermal relay ac-
blown fuse. tuated due to overload or care-less operation, open trapdoor,
* switch in safety device ac-tuated, power failure fromsupplying network. See alsoa) and b) above.
d) Lift does not come when Broken stopping circuit. Door not fully closed, emer-called for. gency stop button depressed.
e) Lift stops and can be restar- Switch actuated in the stopping Door switch too close to theted, but then stops again. circuit. cam.
* The switch is set the factory and may not be adjusted.
ALIMAK 31301
F 2
Example:
Main principles for electric troubleshooting in stop circuit– control voltage 110V/50Hz or 127V/60Hz.
ALIMAK 31302
F 3
1. Switch on the main ON/OFF switch and close the gate/doors.
2. Check that the final switch is in the ”ON” position.
3. Obtain the circuit diagrams and lists which are kept in the cabinet used for this purpose in the lift car.
4. Then test with a voltmeter or test lamp between the zero terminal and the terminals in the electric cabinet asdescribed below:
Test Result Conclusion
Between the zero terminal and last no reaction fault located in stopping circuitterminal in stopping circuit.
Terminal 322 according to diagramin example above.
Then test each terminal in the stopping circuit systematically, beginning from the transformer.
between zero terminal and terminal 301 reaction the circuit is intact to and incl. terminal 301between zero terminal and terminal 304 reaction the circuit is intact to and incl. terminal 304between zero terminal and terminal 314 reaction the circuit is intact to and incl. terminal 314between zero terminal and terminal 316 reaction the circuit is intact to and incl. terminal 316between zero terminal and terminal 318 reaction the circuit is intact to and incl. terminal 318between zero terminal and terminal 320 no reaction the circuit is not intact to and incl. terminal
320
Probable fault location: element C11. TheReason diagram indicates that C11 is a slack rope– an foreign object between the switch and the cam. switch, located on the car roof.– unbalanced counterweight wire ropes.– a loosened wire rope.
Action
Check the mechanical function and connection of the switch. Adjust the counterweight wire ropes, if necessary.
The terminal numbers listedbelow apply to this diagramonly. The procedure for testingother electric equipment withother terminal numbers iscarried out in a correspondingmanner as described below.
Tone frequency – Signal equipment
This equipment is used for transmitting control signals to the liftcar via the power supply cable.
The equipment can send 3 signals, A, B and C, from the groundlanding to the lift car. An emergency signal can also be sentfrom the lift car to the ground landing.
The signals usually have the following significance: A = Up, B= Down and C = Stop at next landing. Audible tones areemitted from the units when transmission takes place. Thesetones are built up of three sub-tones, which are sent withdifferent internal sequences depending on which of the signalsA, B or C is actuated. The emergency signal tone consists ofone single tone only.
The emergency signal is independent of the network and,consequently, also function in the case of a power failure.
Other external alarm equipment can be connected, if so desired,to the terminal marked ”EMRG”.
ALIMAK 31303
F 4
If a fault occurs, check the following:
1. That the transmitter and receiver are supplied with power.The LED marked ”PWR” shall be lighted. If not, check thefuse protection and the supply voltage (12V AC or DC).Spare fuses will be found in the tone transmitter.
2. That the transmitter receives control signals. LED:s A, Band C are actuated when the inputs receive 110 – 127V AC.
3. That the output signal on the ground/earth cable connectionis about 1 – 2V AC during transmission.
4. That the receiver actuates the LED:s and relay output switchagree with the transmitter’s input signal.
5. That the circuit between the transmitter and receiver is notbroken. Disconnect the lift cable’s protective ground fromthe transmitter. Measure the resistance between the dis-connected lift cable’s protective ground and its terminalscrew. The measuring instrument shall indicate ”short-circuit”.
6. That the protective ground between the transmitter andreceiver is not connected to ground. Disconnect the liftcable’s protective ground from both the transmitter and thereceiver. Measure the resistance between the lift cable’sprotective ground and its terminal screw. The measuringinstrument shall indicate ”open” circuit.
Check that the final limit switch is grounded to the electriccabinet’s ground bar with its own conductor.
7. That the emergency transmitter in the receiver actuates the”EMRG” relay in the tone transmitter.
Check that the emergency signal is approx. 7V AC on theterminal screw.
Instructions for replacing a defective electronics board:
1. Lift off the contact strip from the circuit board.
2. Dismount the cover.
3. Remove the circuit board.
4. Insert the new circuit board and connect the contact strip.
ALIMAK 31304
F 5
Items refer to the Service and Maintenance Instructions in the manual.
Name of company Machine type Serial No.
Site Inspector Month Year
Inspection Date Remark Taken care of
....................... date
Check List
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
20
21
22
23
24
25
26
27
28
29
30
31
Item
Inspection Date Remark Taken care of
........................ date
32
33
34
35
36
37
38
39
40
41
42
43
44
45
50
51
52
53
54
55
56
57
58
59
60
61
62
63
Place Date Year Signature/ 19
Item
ALIMAK 31305
Tightening torqueRecommendations according to the chart on the following pageapplies in general except for:
ALIMAK Mast bolt, dim. 1 ”UNC
– Torque : 300 Nm (220 lbf x ft)
– Spanner size : 1 1/2”
ALIMAK Mast bolt, dim. M 20
– Torque : 160 Nm (120 lbf x ft)
– Spanner size : 30 mm
ALIMAK Scaffold clamp Ø 48 mm
– Torque : 80 Nm (60 lbf x ft)
– Spanner size : 23 mm
ALIMAK Scaffold clamp Ø 76 mm
– Torque : 150 Nm (110 lbf x ft)
– Spanner size : 28 mm
ALIMAK Scaffold clamp Ø 76 mm
– Torque : 220 Nm (163 lbf x ft)
– Spanner size : 24 or 27 mm
ALIMAK U-bolt, dim. M 12
– Torque : 90 Nm (67 lbf x ft)
– Spanner size : 19 mm
Appendix
50
100
ALIMAK 31306
Recommended torquesThe chart applies to galvanized screw and nut of strength class8.8 – dry surface.
Dimension Spanner size TorqueNm lbf x ft
M 6M 8M 10M 12M 14M 16M 20M 24
1/4” UNC3/8” UNC1/2” UNC5/8” UNC3/4” UNC1” UNC1 1/4” UNC
10 mm13 mm17 mm19 mm22 mm24 mm 30 mm36 mm
7/16”9/16”3/4”
15/16”1 1/8”1 1/2”1 7/8”
718356095146285493
829691372415771142
10244781128198386668
1139941863277831549
Additional copies...
...can be ordered using the ordering form below.
ALIMAK ABTechnical Document Dept.
P.O. Box 30614S - 931 03 Skellefteå
Sweden
Send. . . . . . . . . . . . . . . . . . . . pcs Technical Description Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . pcs Data sheet No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . pcs Operator’s Manual Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . pcs Installation Manual Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . pcs Spare Parts Manual Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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* Kindly state the invoicing address if other than customer.
