PEGA_Industrial_Lift_(IL_1118_VFC_DL)_Manual.pdf

PEGA-HOIST 2012

OPERATING AND INSTRUCTIONAL MANUAL

INDUSTRIAL LIFT PEGA IL 1118 VFC DL

READ AND UNDERSTAND THIS HANDBOOK BEFORE

OPERATING OR SERVICING THIS EQUIPMENT

This handbook is only applicable if the manufacturing number indicated below corresponds to the manufacturing number stamped on the identification nameplate of the equipment.

YOUR LIFTHOIST HAS

Manufacturing No.: 03/12 Production Year: 2012

P0704

INDUSTRIAL LIFT PEGA IL 1118 VFC

FOREWORD

This product was designed and manufactured to meet strict quality and safety standard. This manual is intended to provide advice and instructions to the operator and qualified service personal so that he can safely control the situations which can occur when the product is used, and can carry out the required service and maintenance on the product. All installations should comply with local Safety Regulations and site practice.

This manual contains important information about servicing.

As a result it should be kept in the vicinity of the unit.

A requirement of fault-free operation and fulfillment of any rights to claim under guarantee is that the information in the Instruction Handbook is adhered to.

Please read the Instruction Handbook carefully before you start to work with the unit.

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 here in are subject to change without notice.

CONTENTS

TECHNICAL DESCRIPTION

A

TECHNICAL DATA & SPECIFICATIONS

B

IMPORTANT SAFETY INSTRUCTIONS

C

OPERATING INSTRUCTIONS

D

SERVICE AND MAINTENANCE

E

ELECTRIC TROUBLESHOOTING

F

FOUNDATION

G

PROJECTING HOIST MAST

H

PREPARATION BEFORE INSTALLATION

I

INSTALLATION

K

TECHNICAL DESCRIPTION A 0

General ...……………………………………. A 1

Regulations ………………………………….. A 1

Foundation slab.…………………………….. A 2

Base frame …………………………………... A 3

Hoist mast …………………………………… A 3

Wall tie ………………………………………. A 4

Car …………………………………………… A 5

Drive unit ………………………………….... A 6

Cable guiding device ……………………….. A 7

Control system ……………………………… A 8

Landing equipment ………………………… A 9

Safety equipment …………………………… A 10

Safety components …………………………. A 11

Terminal and final stop switches ………….. A 12

A 1

GENERAL

Company Pega Hoist is a manufacturer of passenger/material hoists, permanent and special elevators.

Complete hoist assembly derives from standard proven components.

The hoist car starts from sizes 3’-4.9” x 2’-6.7” to 13’-1.5” x 4’-11.1” with payload from 660 lb to 7100 lb. Additional sizes are atypical with the std. supporting framework.

Drive units are conceived as assemblies in sizes according to the number of motors being used from one to three motors. The permanently installed hoists have the motors equipped with centrifugal brakes which are being used for emergency car lowering.

There are three different types of the mast made – flat, rectangular 650 x 250mm and square

650 x 650 mm. For anchoring the masts to the structure there were several wall ties developed.

Individual types differ from each other by length, the car size, speed and payload. Especially with the permanent hoist there the wall ties could be used length wise to the hoists center line or perpendicular to the hoist center line.

REGULATIONS

The hoist and its mechanical and electrical components are designed and dimensioned to conform to operating conditions on construction sites and fulfill demands according to EN 81 and ASME 17.1. The hoist and its components have been thoroughly tested and conform to one or several of the following international/national standards: IEC, CEE, EN, DIN, UL, CSA, SS etc.

Necessary documents such as operator´s manual, wiring diagrams, circuit diagrams and spare parts lists are delivered with the hoist.

A 2

P0701

BUILDING EDGE = ATTACH LINE

7'-8.2" (2,343)

.1

(2 ,4

)CENTER OF THE MAST

.7

(3

3'-10.1" (1,171)

FOUNDATION SLAB

Hoist is to be installed on the foundation slab which should be at the same level as the ground around next to the building according to the drawing below ( the hoist will serve two floors and will be attached to the building from outside). The slab must be sufficient to bear the load. The pit will be made by using the enclosure and building side. Using the ladder mounted on the mast will allow the pit access.

A 3

P0304

P0305

BASE FRAME

Lower part of the mast sections is mounted onto the base frame which carries all the vertical loads from the mast tower to the concrete slab. It’s anchored to the pit’s floor by special M24 bolts.

HOIST MAST

The mast 650 x 250mm is used for this project. The mast is constructed of tubes and frames of high tensile steel and fabricated in length of 1508 mm.

Each section is provided with one bolted racks module 8 and the section are bolted together with bolts and nuts.

A 4

ANCHOR

WALL TIE

WASHERS

P0293

WALL TIE

Special short wall tie is located on the rear side of the mast opposite of the car. It’s attached to the mast by clamps. The other side of it is anchored into the concrete. Due to the fact that sometimes the walls are slightly uneven it’s possible to rectify it by adding shims between the wall and the tie. The set of shims is supplied with each wall tie.

A 5

P0597

CAR

The car is made from carrying frame and it’s own cage. The cage is attached to the frame by eight bolts.

Located on the main beams are the guide rollers which allow the car to move on the mast tower.

The safety device is located at the upper portion of the main beams above the ceiling and the drive unit is connected thru the load pins. The roof is designed so it could be walked on during the installation and is surrounded by a railing.

The car has one two part vertically opening door and when opened the tilt ramp comes down.

When the door is closing the ramp will retract automatically.

A 6

P0307

DRIVE UNIT

The compact machinery assembly contains two drive units. For the hoists with larger payload was developed special gear train utilizing the idle pinions (additional gears) to transfer the power onto the rack and it is also used on this hoist. Each drive unit has an electromagnetic centrifugal brake on it’s end.

In case of power blackout or some other failure it’s possible to lower the car to the nearest floor by pulling the lever inside. This lowering is done thru the centrifugal brake which safely controls the speed. The drive unit is connected to the car by load pins. The connection between car and drive unit means that the hoist is prepared for an overload sensing system.

All hoist’s drive units are controlled by the inverter and advantages are:

- better (softer) riding comfort when starting and stopping

- better stopping accuracy

- less brake wear

- hoist speed can be reduced during installation and inspection procedures

A 7 located at the base station From RM1 switchboard

P0290

To cable trolley

From cable trolley arm To cable

To RM2 switchboard located at the car´s roof

Junction box

Cable arm

Cable guide

Cable trolley

Cable

CABLE GUIDING DEVICE

Cable trolley is most used solution to supply power to the car and it’s also on this unit. The advantages of the cable trolley are:

- The cable is tensioned all the time to avoid looping.

- Allows reaching bigger heights.

- The trolley cable is a bit longer than half of the total travel height.

First there is the junction box installed in the middle of the mast tower to which the fixed cable is connected from the base station. The trolley cable is also connected here and it goes thru the cable trolley to the cable arm on the car. The cable trolley is located below the car when at base station and when at the car is at the last floor the cable trolley is just below the junction box.

U-shaped guides with special rubber springs are attached to the hoist mast. These cable guides guide the power cable in the right distance from the hoist mast all the way.

A 8

PIT LIGHT

SWITCHBOARD RM1

CALL BOX "*1"

CALL BOX "2"

CAR TOP INSPECTION STATION

SWITCHBOARD RM2

CONTROL PANEL

SWITCHBOARD RM3

PIT STOP SWITCH

P0706

CONTROL SYSTEM

Can Open system is used for communication and it’s divided according to the locations listed below.

The car: In it is the floor selection control panel. Here is a set up for connecting the communication panel (the end user may connect his own communication). The

RM2 electrical cabinet is located on the car’s roof where the inverter and most of controls are located. Further there is a cabinet which controls the hoist in the inspection mode.

The pit: Located here is a box with a light, receptacle and the stop button.

Main floor: The RM1 cabinet is installed at the main floor where the power and communication cables are brought in from the site. Also located here is a main On-Off switch and a call box.

Upper floor: The call box is mounted here.

A 9

P0705

LANDING EQUIPMENT

The door is mounted to the side of the ceiling construction in the shaft. The doors made by

PEGA-HOIST model WP are going to be used. These doors have mechanical lock with electrical safety control and are activated by an ARC retiring cam located on the car.

A 10

SAFETY EQUIPMENT

SAFETY DEVICE

The lift has a unique safety device which smoothly stops the car on the mast in case the normal traveling speed is exceeded.

The safety device fitted in conjunction with the drive unit has a pinion engaging in the rack.

The device is actuated by a centrifugal weight. When the centrifugal weight activates the safety device the brake cone is screwed against a brake lining inside the safety housing. The lift is brought to a smooth stop and simultaneously the power to the drive motors is cut off.

OVERLOAD PROTECTION

The car has a overload safety feature which won’t allow the hoist to operate and the indicator on the panel will light up. It will be necessary to remove a part of the load to continue the operation.

A 11

P0467

SAFETY COMPONENTS

Automatic stop at top and bottom landing

At top and bottom landing, limit cams are mounted on the mast. These cams activate the limit switches, which automatically stops the car. The functions for the Up and Down limit switches are backed up by a final limit switch with its own cams on the mast at top and bottom landing. This switch cuts the power supply and stops the car should the normal limit switch not function.

Below the bottom landing level close to the lift mast buffers are located. These buffers are designed to stop a descending car beyond its normal limit of travel.

Safety hooks

To prevent the car from climbing off the mast during erection or dismantling and the pinions disengaging from the rack in case a back up roller or guide roller on the car comes off, safety hooks are mounted on the car frame. The safety hooks are placed on the car and on the trolley preventing the car from falling off the mast should the drive pinion run off the top rack.

Safety details on machinery plate

On the machinery and safety device plates retainers keep the pinion of the machinery and the safety device constantly engaged with the rack on the lift mast and in case a back up roller or guide roller on the car comes off.

A 12

P0466

MAST SECTION

BASE FRAME

BUFFER

LOWER BUFFER

This buffer is designed to stop a descending car beyond its normal limit of travel

TERMINAL AND FINAL STOPPING SWITCHES

No. Description Type pcs

1. Upper and lower limit switch Schmersal TVH335-01/01z 1

2. Emergency switch in the car Schmersal T4VH335-02z 1

3. Trap door lock Schmersal TR236-11z 1

4. Trap door switch Schmersal T1R 236-11z 1

5. Safety device Schmersal Z1R236-02z 1

6.

Car door Electromagnetic locking unit

Schmersal AV415-22ZPKFE24

7. Inductive sensor – hoist position Telemechanique XS630B1MAL5 1

8. Inductive sensor – mast end Telemechanique XS630B1MAL2 1

9. Brake release Schmersal TR236-11z 1

A 13

THIS PAGE LEFT INTENTIONALLY BLANK

TECHNICAL DATA & SPECIFICATIONS B 0

Technical data sheet….……………………... B 1

Dimensions…………………………………… B 2

Location of landing door …………………… B 4

Tightening torque…………………………… B 5

B 1

P0704

TECHNICAL DATA SHEET – PEGA IL 1118 VFC DL

CAPACITY

Payload capacity 2500 lb

Passengers 15

Speed 100 fpm

Net lifting height 117’-8”

Tie spacing 16’-1”

7’-5”

10’-10”

Overhang 0

ELECTRICAL DATA

Power supply 480V 3Ph 60Hz

Power supply fuses 50 A

Rated power 22 kW

Starting current 38 A

Running current 29 A

Power consumption 22 kVA

WEIGHTS

Car 3970 lb

Motor trolley 1380 lb

Mast section 275 lb

OTHERS

Temperature range 0°C - 50°C

Sound noise level max 70dB

Place of installation: El Segundo, California, USA

The lift PEGA IL 1118 VFC DL will be used by authorized personnel for special purpose of transporting passengers and material between two floor levels.

Manufacturers name: PEGA HOIST Ltd.

Manufacturers address: Fáblovka 547, CZ – 533 52 Pardubice

Country of manufacture: Czech Republic

DIMENSIONS

Internal car width 4’-11”

Internal car length 5’-10.8”

Internal car height 7’-3”

Door opening width 56”

Door opening height 80”

B 2

.7

(3

2'-1.6"(650)

.2

(2

,3

1.2"(30)

7'-0.4" (2,143)

BUILDING EDGE = ATTACH LINE

3'-6.2"(1071.5)

P0702

MAST SECTION

BASE FRAME

BASE STATION

CAR

DIMENSIONS

B 3

FRONT VIEW

P0703

.6

(3 .1

6'-1.1" (1,856)

DOOR OPENING

56" (1,432)

(2

.2

(2

.0

D O

O R

O P

E N

IN

G

A

BB

A

4'-11" (1,500)

.1

(1 .8

.8

(1

.8

CUT B-B

5'-10.8" (1.800)

(2

.2

6'-1.1" (1.858)

CUT A-A

B 4

3,5" (90)

LANDING SILL

CAR FLOOR FRAME

P0716

LOWER PART OF CAR DOOR

LOCATION OF LANDING DOOR

B 5

TIGHTENING TORQUE

The chart applies to galvanized bolt and nut of strength class 8.8 - dry surface.

Dimension Spanner size Nm Torque Lbf x ft

M 6 10mm 10 7 M 8 13mm 24 18 M 10 17mm 47 35 M 12 19mm 81 60 M 14 22mm 128 95 M 16 24mm 198 146 M 20 30mm 386 285 M 24 36mm 668 493

1/4" UNC 7/16" 11 8

3/8" UNC 9/16" 39 29

1/2 UNC 3/4 94 69

5/8 UNC 15/16 186 137

3/4 UNC 1 1/8 327 241

1" UNC 1 1/2 783 577

1 1/4" UNC 1 7/8 1549 1142

Bolted mast joints

Bolted diameter M 24 x 240 Bolted quality 8.8 Tightening torque 300 Nm

IMPORTANT SAFETY INSTRUCTIONS C 0

IMPORTANT SAFETY INSTRUCTIONS

DURING THE ASSEMBLY……………….. C 1

CHECK LIST PRIOR TO USE...………….. C 2

MAST AND WALL TIE……………………. C 2

ELECTRICAL POWER……………………. C 2

SPARE PARTS……………………………… C 2

C 1

IMPORTANT SAFETY INSTRUCTIONS DURING THE

ASSEMBLY

Over the years a serious accidents have occurred during the erection and dismantling of rack pinion hoists. Common to these accidents has been the "human factor", i.e. no adherence to proper safety procedures and common sense.

This document affects that personnel involved with the erection and servicing of such equipment.

Some examples:

Leaning over the safety railing on the cage roof while the hoist is moving upwards can cause you to be struck by a tie-in or a cable guide.

Incomplete installation of mast bolts can cause separation of the mast sections, leading to the fall off the cage with subsequent loss of life or serious injuries.

Avoid the risk of accidents by carefully studying these instructions regularly. Think clearly! Do not rush the work and always check to make certain that the work is being done properly. SAFETY FIRST!

Local Safety Regulations

- All local regulations shall apply.

Preparation

- The instructions manual is to be carefully studied before work begins.

- The site of erections must be made secure from falling objects by barricading or roping off the area.

- No admittance to the hoist cage during erection or dismantling by 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 as they might become entangled in moving parts.

C 2

CHECK LIST PRIOR TO USE

- Make sure that all the hoist’s components are installed

- That main and all other shut off switches are functional

- Make sure that all the doors are closing, locking and opening properly

- Check the cable guides

- Check all the limit cams and limit switch functions

- Do the drop test procedure to make sure the safety device functions properly

MAST AND WALL TIE

- It’s necessary to adhere to wall tie distances because the anchoring is possible only at the ceiling levels and the proper distances are shown in the section „H“

- Bolted joints shall always be tightened to the required torque as prescribed in the section

„B“.

ELECTRICAL POWER

- Work performed on electrical equipment must be carried out by competent personnel trained for such work. The power supply must be switched off and locked before work is performed.

SPARE PARTS

- Unauthorized spare parts are not to be used. Only “PEGA Genuine Spare Parts" are to be installed.

C 3

OPERATING INSTRUCTIONS D 0

Information about electrical equipment …………………………………… D 1

Location of switchboards …………………... D 2

Phase failure relay ………………………….. D 4

Frequency invertor …………………………. D 4

The overload sensing device

BRIDGEBOY ………………………………. D 5

Description of control ………………………. D 8

Emergency procedures ……………………... D 16

Pit Access ……………………………………. D 17

Hands free telephone programming guide… D 18

D 1

INFORMATION ABOUT ELECTRICAL EQUIPMENT

The electrical equipment consists of many parts and components. Their specifications and workout complies with the relevant local codes and expectations. They have also been designed and fabricated to correspond and respect local conditions at the place of elevator final installation. The components have been thoroughly tested and conform to international / national standards.

In order to meet the requirements of the customer and conform to the applicable lift regulation, and code, the electrical equipment is designed specifically for each order.

Necessary documents, such as wiring diagrams, circuit diagrams and parts lists are an important part of the lift delivery.

Work performed on electrical equipment must be carried out by competent personnel trained for such work. The power supply must be switched off and locked before work is performed.

D 2

LOCATION OF SWITCHBOARDS

Main controls:

Cabinet RM 1 – on outside is: Cable glance for power cable

Cable glance for trailing cable

Cable glance for telephone line

Cable glance for connection of alarm bell

Plugs for floors

Plug for PIT light

Plug for PIT stop panel inside is: Main on-off switch for the lift

Control buttons for DROP TEST

Cabinet RM 2 – on outside is: Main on-off switch for the RM2

Plug for motor encoder

Plug for connection of the self-lubrication

Plug for connection of the car panel

Plug for connection of the Inspection panel

Plug for connection of the RM3 junction box

Cable glance for connection of the over-weighting pins

Cable glance for connection of brake resistor

Cable glance for connection of motors

Cable glance for connection of trailing cable inside is: Variable frequency invertor (VFC/VFD)

Mode switch selector

Overload device

Junction box RM3: Cable glance for door lock

Cable glance for connection of retiring cam

Cable glances for limit switches

Cable glance for car light

Car top inspection station : El. outlet 110V/15A

Controls for ride up/down

Button - enable

Stop button

Light switch

Inspection switch

PIT light : Light

El. outlet 110V/15A

PIT stop switch Stop button

Pit light switch

Car control panel: Floor buttons

Stop button

Alarm button

Light switch

D 3

PIT LIGHT

SWITCHBOARD RM1

CALL BOX "*1"

CALL BOX "2"

CAR TOP INSPECTION STATION

SWITCHBOARD RM2

CONTROL PANEL

SWITCHBOARD RM3

PIT STOP SWITCH

P0706

Display

Overload indicator

Emergency phone

Hall station: Lift call

Connection for limit switch

D 4

PHASE FAILURE RELAY

The electrical equipment is protected by a wrong sequence indicator / relay phase, which means that the lift can only be driven when correct phase sequence is connected.

FREQUENCY INVERTOR

NXP DRIVE INVERTERS

Technical data

D 5

THE OVERLOAD SENSING DEVICE BRIDGEBOY

Signaling of the status of overload:

Color LED indicator on overload evaluation unit Bridgeboy

- green – load lower than maximum load

- red – load higher than allowed maximum or faulty load pins or their cable

- make sure that load pins are connected in parallel

DRIVE UNIT

Load gauge

D 6

SOLUTIONS TO THE OVERLOAD SIGNAL

1. Check the voltage (Vm) between common test point (-) and point 8(+)

This voltage is proportional to the hoist.

The Vm is approx. 3V with empty car.

Vm with full load is 10V and may never be negative

2. Check the voltage(Vs) between common test point (-) and the point SP1(+)

The Vs is normally 10V (+/- 1V). If Vm is greater than Vs than the car is overloaded.

3. Remove a part of the load until the LED becomes green. The Vm has to be slightly lower than Vs.

4. The voltage between point 3(-) and point 4 (+) should be approx. 8V.

5. Check the voltage between point 1(+) and point 2(-) and it will be about 3mV with empty car and must increase to about 8 mV with full load.

6. In the case that the weight in the hoist is lesser then allowed max. weight and the unit signals overload it’s possible to adjust it with SP1 pot by turning it clockwise until lit stops signaling overload.

D 7

Terminal assignment of input and output of overload evaluation unit

D 8

PIT LIGHT

SWITCHBOARD RM1

CALL BOX "*1"

CALL BOX "2"

CAR TOP INSPECTION STATION

SWITCHBOARD RM2

CONTROL PANEL

SWITCHBOARD RM3

PIT STOP SWITCH

P0706

DESCRIPTION OF CONTROL

D 9

PRESS BUTTON BELLOW

TO USE EMERGENCY TELEPHONE,

DIALING WILL OCCUR

LIGHT ON INDICATES

YOUR CALL RECEIVED

P0707

*1

MAXIMUM CAPACITY

15 PERSONS OR 2,500 lbs

PE G A

OVER

LOAD

AUTOMATICALY

LIGHT

ON OFF

Description of control elements on the switchboard RM1

1. Main switch

Is located inside RM1 cabinet and by turning it OFF it will cut the power to the hoist.

At this time there will power supplied only to the receptacle in the pit, on the roof top and to the lights in the shaft.

2. Alarm bell

When “alarm bell” button is pressed the alarm bell will sound off.

3. Button DROP/RESET – inside the switchboard

To be used during testing of the safety device

4. Button “UP” – inside the switchboard

To be activated by putting the mode key switch in the position DROP TEST

Description of control elements on the car control panel

D 10

1. Landing buttons with numbers „1*“, „2“, after pressing one the indicator lights up as confirmation that the order has been received, after arriving at the selected floor the indicator lamp goes off and the car and landing door will unlock.

2. Button “ALARM”

By pressing it will activate the bell at the RM1 cabinet.

3. Button ”STOP”

By pressing it the hoist will stop and erase the previous floor selection.

4. Switch “LIGHT”

Switch on/off the car lights

5. Display

Indicating the direction of car travel and the present location. In case of some problem it will display an error code.

6. Signal light “OVERLOAD”

If the payload is too high the signal light will be ON and the hoist won’t operate.

Description of control elements in the switchboard RM2

Operating mode switch – three position key

It is located inside the switchboard RM2

Operation modes:

- 1. mode – OPERATION

- 2. mode – PROGRAM

- 3. mode – DROP TEST

Description of control elements on the hall station

1. Call button

By pressing the hoist will come and the light will be on indicating that the hoist is coming.

*1 2

A G PE PE G A

D 11

Description of the control elements on car top inspection panel

1. Button ”UP”

By containing continuous pressure “UP” the hoist goes up in slow speed (65ft/min)

If the car stops in the landing zone the door can be opened. Together with pressing the button UP also press the button ENABLE. It’s the safety feature so the hoist isn’t activated by accidentally.

2. Button “DOWN”

By containing continuous pressure “DOWN” the hoist goes down in slow speed

(65ft/min). Together with pressing the button DOWN also press the button ENABLE.

If the car stops in the landing zone the door can be opened.

3. CENTRAL STOP

It stops the hoist.

4. Button “ENABLE”

Confirming button for the hoist travel

5. Normal-Inspection switch

By turning it puts the hoist in the INSPECTION mode and turns the light ON at the roof.

MAIN INFORMATION ABOUT THE LIFT CONTROL

The lift has to be operated by instructed personnel only!

The three position mode switch is located in the RM2 situated at the car roof top. These basic modes are: operation, program and drop test.

OPERATION

If the mode switch is in position “operation” the hoist can be controlled from the main panel in the car and call boxes at each floor.

To call the hoist press the call box button at the floor and it’s confirmed by been lit.

D 12

In the car press the desired floor button and that button becomes lit. During the ride the panel will display the floor number of the floors traveled thru and direction of the travel. One floor selection will always be accepted by the elevator, regardless whether it was called/set from the car or from a floor call station. All other calls will be ignored from the moment of call confirmation upto completion of the order, i.e. coming to stop at the desired landing and unlocking the doors there. Another call (order) will be accepted by the elevator logically only after full completion of the previous call (order) i.e. unlocking of the doors at the landing of previous call.

When the hoist will stop at the certain floor the door lock will be released, than the retiring cam unlocks the landing door and it can be opened.

When the next floor selection is made the retiring cam retracts, locks the landing door, the car door will lock and the hoist starts to move.

For emergency stopping there are pull/push buttons located at control panel in the car.

If the elevator for whichever reason stops in between landings, e.g by pressing STOP button, (while pressing and holding the STOP button - an error message E4 would appear on the car display). Restraing the reason of stoppage (e.g. releasing the STOP button) an E3 eror message will appear on the car display, and the VFD display will show error E3.6 – car stopped between the landigs. Having pressed desired destination button, the elevator will complete its journey to the re-called landing.

If the hoist is turned on and the floors aren’t programmed the display on the panel will show

E3 and on the inverter E 3.5. In this case we have to program the floors first – see chapter programming.

INSPECTION

By turning the INSPECTION switch at the car top inspection station the elevator can be operated only from the roof by available buttons.

It will be necessary to press the ENABLE button together with the button UP or DOWN.

The stop buttons are also functional. To return to the normal operation turn the switch to a position NORMAL.

The elevator will automatically stop while reach (through its OPS switch) onto its upper resp.

lower operations limit cam. Adjument of the operation switch on the operations cam, is such that the car stops approx. 5 cm (2 inches) lower than is the normal/automatic operations car stoppage level (set by software).

If the car stops within +-150 mm the door will open.

Inspection Operation With Open Door Circuits.

Switches Car Door Bypass and Hoist way door bypass are located in the electrical box RM2.

These switches are possible to be used in the inspection regime / operations. Thy effectively bridge / jump the door switches (e.g. during the elevator erection). The Jumpers shall not be

D 13 used to bypass hoist way door or car door contacts. These switches do operate in the inspection regime only. The switches have position BYPASS and OFF. If the switch CAR

DOOR BYPASS is in the position BYPASS the car door contacts are bridged / jumped , therefore there is a chance to drive the elevator in the inspection regime with door opened or disconnected. If the switch HOISTWAY DOOR BYPASS is in position BYPASS the contacts of the landing doors are bridged / jumped and therefore it is possible to drive the elevator in the Inspection regime with the landing doors opened or disconnected. For each of the switches if in OFF position, the elevator operates normally in all regimes.

PROGRAM MODE

With the selector being in „PROGRAM“mode.

The display shows the number of the floor being programmed. If none are programmed it will

“1” will show on the display.

In this mode by pressing 1 and 2 the elevator drives up to these programmed floors.

1. Zeroing – see below “Deleting of all programmed floors”.

The elevator is controlled by buttons of the controller 1 and 2 in the car.

By pressing and holding of the button 2 the elevator travels up, pressing and holding the button 1 the elevator travels down. When pressing and holding button 1 or 2 for longer than 5 seconds, the elevator accelerates (when traveling in between the floors), for a fine manual approach to a landing during programming, press the relevant button for less than 5 seconds.

It is necessary to travel with the elevator some 3 feet (1m) using button 2. Then we travel down by button 1 up to a complete final stop The button 1 must be pressed for a maximum 5 seconds, so the elevator does not accelerates, as the approach to the cam must be in the slow speed (the elevator will stop at the bottom operating cam).

2. If the elevator stopped on the operations cam and the position of the car does not correspond with the landing 1, it is necessary to move the cam along the mast tower exactly for the difference distance between sill of the car and sill of the landing, of course in the right direction. Having moved the cam, it is necessary to check all by slow speed approach onto the moved cam again. If the car and landing door sills are aligned after stop on the cam the operations cam is adjusted and set correctly and this position then defines landing 1. Therefore landing 1 does not have to be programmed, it is automatically set by the position of the operations cam.

3. The car display will be showing number of the programmed floor (1). Using the buttons 1 and 2 we will travel and set car position of landing 2 (again aligned door sills). The car display will show number 2.

4. As long as the car and landing door sills are fine-aligned, the programmed floor car position can be entered by pressing button 3. If the button 3 is pressed, its light is on during saving of the floor position, after the floor light turns off, the level of floor 3 has been saved successfully. Then it is possible to go on with other floor programming.

D 14

In case there only two landings of an elevator, there is no 3 button on the car control panel, then to save the programmed floor 1 or 2 then press ENTER button on the inverter display in the 1.21.1 parameter. When ENTER is pressed the display will show STORING and when display clears the programmed floor is stored.

5. By using buttons 1 or 2 travel to the next programmed floor. The car display will show number of the next floor.

6. Please repeat the procedure as per the point 4 above.

7. After completion of programming of all floors, switch the regime switch in the RM2

el. box into the “OPERATION” position.

D 15

Deleting of all programmed floors.

- The elevator must be in the 1st floor

- Regime switch in the RM2 must be in position “PROGRAM”

- By pressing 1 the car will move down till it stops by itself. (the elevator will stop at the bottom by operating cam).

- Select parameter 2.10.4

- Select the option Reset Floor and press ENTER. Wait till the display shows No

Action.

- Now move the hoist up by pressing button 2 about 1 meter lenght.

- The floor positions are erased.

- As a feed back of successful deletion turn the mode switch in the RM2 to a position ”OPERATION” to make sure there is no reaction when floor button is pushed. And the car display shows E3, the VFD display shows E3:5 – All the floors aren´t programmed.

D 16

DROP TEST

TO BE CARRIED OUT BY TRAINED SERVICE PERSONNEL.

A drop test with full load shall be carried out for each next installation and then at least every

6 months - or in accordance with local safety regulations.

If the safety device begins to trip or if noise occurs in the safety device during operation, the lift must be taken out of operation immediately and the local PEGA representative be notified for action.

WARNING:

NO ONE IS ALLOWED IN THE LIFT CAR DURING A DROP TEST. BEFORE

STARTING A DROP TEST, MAKE SURE THAT BRAKES FUNCTION

DROP TEST is necessary to carry from the main floor (*1). Regime switch in the RM2 el.

box switch in to the “DROP TEST” position. At this moment the drop test control buttons in

RM1 el. box are activated and the car is ready for the following procedure:

1. Load the car with the code requested weights (load).

2. At the main floor, in RM1 press and hold the “UP” button. Travel with the elevator approx. 6m (18ft) up (approx. 18 seconds). Stop and check if all is ok.

3. Then press and hold the button “DROP/RESET” (in RM1) this will release the motor brakes and the car will start falling until the safety device (over speed governor) will not come on.

6. Check visually the car and then press the “UP” button. The car will travel up and will automatically stop in approx. 0.5m (2ft).

7. Then press and hold the “DROP / RESET” button. The car will automatically travel down, and will stop in the main floor (*1).

8. Reset the safety device according to the instructions placed on the car roof (drive unit).

9. Turn the switch key into the position “OPERATION”

If you don't succeed with the drop test, contact nearest PEGA representative.

Drop Test can be performed by qualified technician only.

D 17

EMERGENCY PROCEDURES

ALARM BUTTON

In the case of emergency persons stuck in the lift can use the bell which will alarm the main floor and cage roof.

BRAKE RELEASE

BY USING THE BRAKE LEVER THE CAR CAN LOWERED TO THE NEAREST

LEVEL AND PERSONS MAY EXIT.

This situation may occur even after power failure.

In the short time failure it’s possible to select desired level and continue. If the power isn’t available for longer period it will be necessary to get the persons out by doing the following:

1) Brake the safety glass to get the key of lever hand brake and triangular key

2) Unlock and remove the lock on the brake lever.

3) By pulling on the brake lever bring the car to the closest lower floor.

4) Using the triangular key to open the door.

5) The person hearing the alarm can open the doors.

TRAP DOOR TRIANGULAR KEY

CAR DOOR TRIANGULAR KEY

LEVER HAND BRAKE

DIRECTION

OF MOTION

P0502

LEVER HAND BRAKE KEY

It is forbidden to pull the brake lever down again after it was restored automatically.

During the car lowering watch thru the window to make sure that the car doors are lined up with the landing doors awhile stopping.

If during lowering the car goes too far nothing will happen it will stop on the buffer. It will activate the emergency and operating switches. After the power is restored the switches must be deactivated in the INSPECTION mode by going up.

This should be done by authorized personnel only.

WARNING:

THE LANDING DOOR OPENING MAY CREATE POTENTIAL HAZARD OF

FALLING IN TO THE SHAFT. ENSURE THAT THE DOOR IS LOCKED AFTER

CLOSING.

D 18

PIT ACCESS

- Park the car in the second floor (2)

- Turn OFF the main switch in the RM1.

- Before going into the pit switch ON by key switch the LIGHT on the switchboard

RM1

- Using the key open the lower landing door.

- The ladder mounted on the mast can be used to enter the pit.

- Safety feature: push the CENTRAL STOP placed in the pit.

D 19

HANDS FREE TELEPHONE PROFRAMMING GUIDE

Telephone : ET901

D 20

D 21

SERVICE AND MAINTENANCE E 0

SERVICE AND MAINTENANCE............... E 1

SCHEDULE.................................................... E 2

WEAR CHECK.............................................. E 4

ADJUSTMENT OF THE HOIST................. E 8

INSTRUCTIONS FOR CHANGING THE

PINIONS.......................................................... E 14

CENTRIFUGAL BRAKE SUCO E 15

LUBRICATION DIAGRAM......................... E 17

STORAGE E 20

E 1

SERVICE AND MAINTENANCE

In order to avoid unnecessary breakdowns, those responsible for the service and maintenance of this equipment must regularly ensure that all scheduled maintenance work according to the maintenance program below is carried out at the recommended intervals.

Adjustments and replacement as a result of checks, must be carried out by trained/authorized service personnel. Only PEGA Genuine Spare Parts must be used.

WARNING!

IF THE HOIST IS TO BE SERVICED TURN THE INSPECTION SWITCH IN THE

CAR TO THE POSITION “ON” AND THE TOGGLE SWITCH AT THE RM2 ALSO

HAS TO BE “ON”. AFTER THAT THE HOIST CAN BE OPERATED FROM THE

ROOF.

WHEN LEAVING THE CAR WITHOUT HAVING COMPLETED

THE SERVICE WORK OR TO CARRY OUT SERVICE, THE

FINAL LIMIT SWITCH MUST BE SWITCHED OFF, LOCKED

AND PROVIDED WITH A WARNING SIGN.

SERVICE INTERVALS

Intervals based on operating time shall be followed in the first instance. If the lift is used only periodically, the first applicable intervals to be reached shall be followed.

CHECKLISTS

Checklists with room for notes on maintenance executed will be found at the end of this manual. Use them!

E 2

SERVICE AND MAINTENANCE SCHEDULE

Interval – 40 operating hours

Parts_______________________Instructions________________________________________

1. Sign plates Check that all signs are in position according to the spare parts manual, hours and last instruction and that they are legible. Check also that the documentation is according to the manuals available in the documentation box.

Interval – 80 operating hours

Parts_______________________Instructions________________________________________

2. Safety device Check with the user/users if the safety device has been tripping without cause or 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. Gear boxes Check that oil level and refill if necessary. Leaking seals must be replaced by trained/authorized personnel.

4. Rollers and Check that all screw joints are properly tightened.

safety hook

5. Attachment of Check that all screw joints are properly tightened machinery and safety device plate

6. Electric motor Check that the car stops within acceptable limits specified later in this brakes. Chapter. See also the special instructions for checking the brake torque with a spring balance. Check the play between the electro-magnet armature and the rotating brake disc according to instructions later in this chapter.

7. Hoist cable Check the cable for wear and ensure that no kinks occur. Check also attachment of the cable support arm on the car and the fixture on the mast – where the cable guiding device is supplied.

8. Cable trolley Check the proper function of the cable trolley all the way along the mast and it’s guide rollers are tightened.

9. Doors Check the proper function of the doors.

10. Car floor Clean car floor and roof.

and roof

11. Stopping at floors Check for proper stopping at each floor.

12. Lubricating See the instruction in the “Lubricating diagram”. Also check rack for possible damages, misalignment and attachment, when lubricating.

Interval – 120 operating hours

Parts________________________ Instructions________________________________________

21. Hoist mast Check visually that all screw joints of all racks and mast joints are properly tightened. Also check the screw joints for attaching the mast in the base frame.

22. Mast tie-ins. Check that all screw joints in all mast tie-ins are properly tightened. Also check attachment to structure.

23. Cagle guides Check the cable guides with regard to attachment, function and installation in the mast in relation to the cable support arm on the car.

24. Base slab/ pit Remove all debris (or trash), which may have fallen on/into the base (or pit)

E 3

Interval – 200 operating hours

Parts_______________________Instructions________________________________________

26. Signal equipment Check the function of the control device, alarm signal, lighting.

27. Rack and pinion Check the wear on the rack and pinion according to the instruction under the heading “Adjustment and wear limits”

28. Gear box Check the wear according to the instructions under the heading

“Adjustment and wear limits”

29. Lubricating See the instructions in the “lubricating diagram”.

Interval – 400 operating hours

Parts________________Instructions________________________________________

40. Guide rollers Check the wear and bearing play of the car guide rollers and roller and assemblies- where applicable. Adjustment and replacement, where required, must be carried out by trained/ authorized service personnel.

41. Safety device Test the safety device according to the instructions under the heading “drop test”

42. Electric motor If necessary, clean the cooling fins of the electric motor

43. Lubricating See the instructions in the “lubricating diagram”.

44. Contactors Check the condition of the contact points in the contactors.

Interval – 1000 operating hours

Parts________________Instructions________________________________________

45. Electric wiring Check all wires, seals and connections.

46. Deformations Inspect the equipment visually in its entirety for deformation, mechanical damage to mast tubes, damage gates protective rails, floors etc. This inspection and any actions which may be necessary after the inspection must be performed by trained / authorized service personnel.

47. Corrosion Inspect the equipment in its entirety for corrosion and wear in load damage and wear bearing and force absorbing components with the aid of an ultrasonic thickness measuring instruments. This inspection must be performed by trained / authorized service personnel.

48. Hoist mast Check that all screw joints of all racks and mast joints are properly tightened. Also check the screw joints for attaching the mast in the base frame.

49. Lubricating See the instructions in the “lubricating diagram”.

It’s necessary to remove the safety device after being used for 4 years and send it to

PEGA HOIST for refurbishing or order a new one. The device expiration time is shown on it’s label.

E 4

THE WEAR CHECK

MAXIMAL WEAR OF PARTS

Pinion Check the wear with aid of sliding calipers.

Rack Measure with a dia. 14 mm (.709") gauge rod and sliding caliper.

Guide roller Measure with sliding calipers and radius template

Dimensions New roller Worm-out roller

(mm) (mm) (mm)

A Ø 74 min. 71

B 77 ±3 min. 73,5

C R 40 min. R 38 max. R 42 Note that the roller might be asymmetrically worn.

Measure “X”Number cog of pinion New cog Max. worn cog

12 36,7mm 35,5mm

15 37,1mm 35,8mm

16 37,2mm 35,9mm

E 5

SAFETY DEVICE

WHEN TO SEND THE SAFETY DEVICE TO MANUFACTURER FOR

OVERHAUL?

1. Every 3 years from the manufacturing date.

This date is on the safety device label.

2. When you can hear noises from the device during operation (knocking, squeaking, buzzing…).

3. When the device braking track is longer than 1.2m for PEGA 1 and 1.5m for PEGA 3.

4. When the radial clearance of pinion is bigger than 0.3mm.

E 6

HOW TO MEASURE PINION RADIAL CLEARANCE OF SAFETY DEVICE

1. Clamp a support (A) on the rack with aid of a C-lamp – about 1mm (,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 the hoist tool-kit or some other suitable instrument and measure the play again.

4. The difference between the two measured values in the radial play in the safety device shaft.

5. If the radial play is greater than 0,3 mm (,012”). The safety device must be replaced.

IMPORTANT! Test should be performed before lubrication!

E 7

CHECKING THE WEAR OF ALL GUIDE ROLLERS ON THE HOIST

Besides daily visual roller control it’s necessary that every 40 operating hours or once a month to do a closer check of the roller wear.

Description of the procedure:

Make sure that all M16 & M20 bolts holding the rollers to frame are tight. The tightening torque for M16 is 198Nm, for M20 it’s 386Nm.

All guide rollers are designed as floating meaning they have some play so they can follow the contour of the mast. Therefore the movement on the shaft is OK.

Further it’s necessary to check the wear of the bearings. If the wobble exists place a screwdriver between the roller and press up or down. See picture below.

Check the roller and if the play is excessive replace the bearing or the whole roller assy. The maximum play allowed before changing the bearing is 0.20mm.

The real life expectancy depends on the quality and frequency of the maintenance.

E 8

ADJUSTMENT OF THE HOIST

BACK UP ROLLER ADJUSTMENT

!!! IMPORTANT !!!

Back up rollers are located on the back side of machinery plate unit and their function is to keep the pinions properly engaged to the rack. It’s very important that they are correctly adjusted so the hoist operates properly and extends the life of the gear train. The roller has 2 mm of eccentricity and the adjustment is made with special wrench supplied by Pega Hoist.

By turning the roller eccenter adjust its position so that on the hoist with idle pinions the distance between pinion shaft and top of the rack tooth is 31 mm as shown in the picture below. Then tighten the roller bolt with torque 300 Nm and secure it with a tab washer which is inserted into the groove and than weld to the drive unit plate. This last step is a must otherwise if the roller gets loose the pinion and the rack will wear out prematurely.

E 9

CHECKING AND ADJUSTMENT OF THE MOTOR BRAKE

1. Turn off the main switch.

2. Remove the fan cover and rubber sealing collar of the brake.

3. Vacuum the brake lining dust.

4. Measure the brake disc. If the thickness of the disc is less than 10 mm it’s necessary to replace it. (see the SEW manual)

5. Measure the working air gap A (see following picture). Use a feeler gauge and measure at three points offset by 120° between the pressure plate and the damping plate.

Adjust the air gap to 0.3 mm. (see the SEW manual)

6. Install the rubber sealing collar back in place and re-install the dismantled parts.

Checking the function of the motor brakes.

1. Load the cage with the weight same as the hoist’s payload. Manually release one motor brake and the second brake should stop the fully loaded cage on the way down.

2. This way is to test all brakes.

The lifetime of the brake lining is higher than the lifetime of the hoist. If for any reason the lining wears out faster it’s necessary to look for the cause of the problem elsewhere such as brake coil, rectifier e.t.c. Anytime the brake disc is changed it’s also recommended to change the rectifier.

Motor brakes access

Permanent elevators have, except for their motor brakes, also centrifugal brake on the same motor shaft, that enables a controlled / limited speed decent in power failure, or other non-standard situations. As part of the instructions – check of the motor brake air gap is required. Good access to the motor brake, and its adjustment, is by taking off the motor cover.

In case of need for a part replacement or other action, the centrifugal brake SUCO has to be taken off first. Assembly and disassembly of the motor brake cover and also the SUCO brake is described in the chapter “Centrifugal brakes SUCO”, E 10

20±0,5

P

VIEW P

P0319

SAFETY DEVICE ADJUSTMENT

1. Loosen the four screws (1) of the safety device plate.

2. Loosen the bolts on the eccenters (2 and 3).

3. Turn the eccenter (3) until the distance from the safety hook (4) on the rear plate site is the same as on the upper and lower safety hook (4).

4. Adjust by the adjustment bolt (5) with the nut (6) the rack distance from the safety hook (4) to about 3mm. The spring plates have to be pressed for 20+/- 0,5mm.

5. Tighten the nut (6).

6. Tighten the four bolts (1) of the safety device plate and the bolts (2) with the eccenter

(3). The tightening torque has to be 190 Nm.

GUIDE ROLLER ADJUSTMENT

1. The alignment of the car with the mast is very important – in both directions.

2. Eccentricity is adjusted by the eccentrics on the rollers.

3. Eccentrics of the rollers allow movement of ± 3 mm.

4. The rollers are adjusted by the special roller wrench – PEGA.

5. The only one proper and allowed position of the roller is the centered position with tolerance ± 1 mm.

6. The dimension X and Y have to be the same on each side of the car and the same on the upper and lower trolleys as shown picture P0492.

7. Always check if the bolt M16 x 40 is equipped with the washers Nord Lock. The Nord

E 11

UPPER

ROLLERS

LOWER

ROLLERS

PIPE

MAST

P0492

CAR

M A

S T

P

IP

E

X

MAST SECTION

CAR

YY

XX

M A

S T

P

IP

E

CENTERED POSITION

OF ROLLER 3mm

LEFT END POSITION

OF ROLLER

OF ROLLER 3mm

RIGHT END POSITION

SIDE

ROLLERS

3mm 3mm

3mm

3mm

3mm 3mm

3mm

3mm

3mm

3mm

3mm

3mm

Lock washers have to be fixed in the proper way (as shown next drawing).

8. Tighten the bolt with torque figure 200 Nm.

9. The same alignment procedure with the mast has to be done with the motor trolley in direction from the mast.

E 12

P0493

FLAT STEEL XX

Measuring the distance in the direction X To get an idea about position of the car and mast it’s necessary to check the gap between mast pipe and safety hooks which are located in upper and lower part of the car.

Upper safety hook LowerUpper safety hook

If you want the precise measurement than take a flat steel bar and place it on mast pipes from inside as shown in the picture below. Now you may measure the distance between the bar and the main frame in the upper and lower section.

Guide rollers Guide rollers Pega are specially designed to guide the car on the mast. Part of the roller assembly is eccentric shaft which allows the roller to be adjusted 3 mm in either direction to obtain the correct position of the car toward the mast and ensure equal pressure at the contact points.

E 13

The procedure of adjusting the guide rollers:

1) Adjust the guide rollers on the drive unit together with upper rollers on the car. Make sure that the drive unit is parallel to the mast and the pinions are engaged with the rack the full width.

2) Adjust the main lower rollers so the car is straight in the direction X and measure the car according to the picture above making sure that the measurement don’t differ more than 1 mm .

3) Adjust the side guide rollers so that the distance between the main frame and the mast pipe is equal at upper, lower, left and right position.

Adjustments are to be made on straight mast with car symmetrically loaded which makes lesser pressure on the rollers and easier adjustment. If the change is not clearly visible it’s recommended to move the car up and down few times and check the measurements again.

HOW TO SECURE THE GUIDE ROLLERS

THE Nord Lock Bolt System is used to secure the roller bolts from unscrewing.

The washer has to be fixed in proper way as shown in the drawing No. 00254.

E 14

INSTRUCTIONS FOR CHANGING THE PINIONS

There are two types of pinions on the drive unit:

- motor – are located on the shaft of the SEW gear box

- idle – are seated on the shafts mounted in the plate.

The…