HI-15081-1_TE__1_TESI_Operations_Manual.pdf

Tower Elevator Systems, Inc.

www.towerelevators.com

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Operation Manual

Industrial Rack and Pinion Elevator

Trac-Cab TC5K-SPV Special Purpose Vehicle

Inclined Rack and Pinion Elevator

United States Army Oahu, Hawaii

Schofield Barracks Bldg 1580 East Range

This System Is Designed For Use by Trained and Authorized Personnel Only

This is Not a Public Access Elevator

Operation Manual – Trac-Cab TC5K-SPV Industrial Rack and Pinion Elevator System

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NOTICES

Abstract This Operation Manual contains basic information and instructions for Normal and Emergency Operation and fault troubleshooting of the TESI TRAC-CAB Industrial Rack and Pinion Elevator System.

Applicable Specifications This equipment meets or exceeds the ASME A-17.1 Safety Code for Elevators and Escalators.

Disclaimer This manual must not be relied upon for complete information and instruction in the safe use of the elevator equipment. Proper training and knowledge of elevator systems usage, OSHA and other safety rules, including electrical and fall protection must be a part of a qualified users training program.

Tower Elevator Systems, Inc. will not be liable in any event for direct, indirect, or consequential damages arising from the use of this Manual. We reserve the right to revise this Manual without the obligation to notify any person or organization. It is the responsibility of the owner/user to insure safe use of the equipment, including maintaining current documentation.

Warranty Program TESI warrants all components to be free of defects in material and workmanship for a period of (1) years from the date of initial installation, provided a dated Final Inspection and Testing Report proof of proper installation by a TESI authorized representative, is forwarded to TESI.

Warranty Conditions This warranty does not apply to products that have been abused, misused, or modified.

Normal wear and tear is not covered under warranty.

TESI reserves the right as final authority in determining whether the product should be repaired or replaced. Defective parts or products that can be shipped must be returned freight prepaid to receive warranty repair or replacement. Should a TESI authorized technician be called out for warranty repair, and it is discovered the repair is not covered under the warranty for reasons stated above; the customer is responsible for payment for repairs.

This is the only warranty. TESI makes no implied warranties, including any warranty of merchantability or fitness for a particular purpose. All warranties are limited to the duration of the expressed warranty period as set forth. TESI’s maximum liability hereunder is limited to the purchase price of the product. In no event shall TESI be liable for any consequential, indirect or special damages of any nature arising from the sale or use of the product.

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SAFETY WARNINGS

Elevator systems equipment contains potentially dangerous high voltage electrical circuits and moving parts. Dangers exist that can only be recognized and avoided with proper training. Compliance with the OSHA and other safety regulations and proper inspection, maintenance, and repair of the equipment is imperative.

Use of the equipment should be limited to properly trained and authorized persons.

Although Tower Elevator Systems, Inc. has incorporated practical safety precautions and features in the equipment, extreme care must be taken at all times to insure personal safety when you operate or service this equipment. Observe all Safety and instructional signage.

Signage Legend

DANGER – This means the hazard will kill or seriously injure you.

WARNING – This means the hazard could kill or seriously injure you.

INSTRUCTIONS – Owner policy and posted instructions must be followed.

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IMPORTANT INFORMATION

WARNING

Multiple Control Points Be aware the system can be controlled remotely from the Ground Control Station via an authorized technician login at the Ground Display Panel. Access to the Ground Control Station must be limited to authorized personnel included in your Access and Emergency Rescue Plan.

Storms, Earthquakes In case of severe storms, hurricanes, or earthquakes, all vital parts of the elevator system must be inspected and tested by a qualified inspector prior to returning the system to service.

DANGER

Fire In case of fire do not use the elevator. If you are on the elevator when fire is reported, exit as soon as possible at the nearest landing and follow the site Evacuation Plan.

Electric Shock The elevator is powered by 480 Volt 3 Phase and 100A that is supplied by others. In some circumstances devices may have multi-source power circuit feeds or be provided power by a Battery Backup, even when the main system power is disconnected. Lock Out / Tag Out System Power and observe safety procedures prior to servicing this equipment. Only authorized and trained personnel are allowed to service this equipment.

LOCK-OUT TAG-OUT PROCEDURE

Announce lock-out to others Lock and tag power in the OFF position Put key in your pocket Notice others before restart Remove lock and tag Turn power back on Announce power is ON

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TABLE OF CONTENTS

NOTICES

SAFETY WARNINGS

Signage Legend

IMPORTANT INFORMATION

TABLE OF CONTENTS

INTRODUCTION

About TESI

JOB DETAIL

ELECTRICAL SERVICE

ELEVATOR SYSTEM CONFIGURATION

SYSTEM OVERVIEW

TRAC-CAB MAIN COMPONENTS & CODE ITEMS:

Special Purpose Vehicle Trailer Tractor 1 Tractor 2 Tunnel Hoistway and Control Station

SYSTEM ZONES and VEHICLE MOVEMENT Loading Zones Landings Tunnel / Hoistway Vehicle Movement Remote Vehicle Movement—Upper Loading Zone Remote Vehicle Movement—Mid Loading Zone Remote Vehicle Movement—Lower Loading Zone Manual Vehicle Operation

ELEVATOR OPERATION INSTRUCTIONS

Operation Policies Operation Modes:

Semi-Automatic Operation Normal Operation Mode Gaining SPV Access Loading/Unloading Equipment Adjusting the Passenger Seats Preparing for Vehicle Travel Loading Zone Slow Speed Entering the Tunnel Voltage Drop Transfer Switch Rock Sensors Exiting the Tunnel Local Access Control Stations Installing and Removing the Cargo Trailer Semi-Automatic Operation - Landing and Car Door Interlocks Power Loss

SPV OPERATING STATION LEGEND – OS1

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Semi-Automatic Operation – Main Screen General LED Indicators on Human Machine Interface VMI Power AMP

SAFETY FEATURES

3D Graphic and Safety Overview LED Strobes on Passenger Cab Alarm Tones Hoistway Safety Laser Scanner How to Recover from a Triggered Laser (Tunnel Breach) Smart-Reel Cable Management System Dual UPS System

EMERGENCY OPERATION

Self-Rescue Up Pass-Through Cab Safety PLC E-Stop Function Emergency Rescue Lowering Emergency Lowering Operation Emergency Lowering With Electric Interlocks Description of Emergency Lowering Mechanism Fireman’s Service Cab Lighting Emergency Communications

ADMINISTRATION AND INSPECTION (Car and Ground) Mode Key Switch Operation: Passenger Cab

TOUCHPANEL INTERFACE - MAIN SYSTEM MENU

Sub-System Status Screens Sub-System: Door Interlock Screen Sub-System: Safety System Screen (E-Stops) Sub-System: Mode Screen VMI – Voice Message Information Screen Restricted Access Log In Instructions Machine Control - OS1 Cab Technician Mode Machine Control - CP1 Ground Station

INSPECTION MODE:

Alarm Sub-System: Alarm Selector Screen Drive System Status Screen VFD Fault Screen Drive Fault Details Overtravel Fault Screen Overspeed Fault Screen Rescue Lowering Fault Screen Lowering Fault Details How to recover from Rescue Lowering Hydraulic Timer Expired Fault Screen Brake Monitor Smart-Reel Condition Fault Rock Sensor / Collision Fault Screen

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Safety Laser Scanner Screen Alarm Logger Screen Start-Up and Commissioning Screen Special Drive Screen Special Drive Alarms (Special Drive Parameters) Screen Brake Test Screen Brake Test Sequence Description Testing the Safety and Speed Governor Safety Brake Test Step by Step Instructions Floor Positioning Screen Sound and Light Screen Gearing Setup

DUAL DRIVE AND SAFETY FUNCTIONAL & DESIGN OVERVIEW

TESI RACK AND PINION SAFETY OVERVIEW

Reference ASME A17.1 2007 Mounting of the Safety System Overspeed Governor:

Safety Device Redundant Fail-Safe Parking Brakes:

Safety Rated Industrial PLC Controller Drive System Design Summary

SYSTEM TROUBLESHOOTING

TESI TRAC-CAB Industrial Elevator Control System Safety PLC System Passivation Cold Boot – Power Cycle Procedure Safety PLC E-Stop Function Recovering from Power Failure Absolute Rotary Encoder Personnel Safety Bars (Collision Detection System) How to reset personnel safety bars (manual reset device)

QUICK CHECK PROBLEM SOLVER

Drive and Wheel Alignment Techniques

INSPECTION, MAINTENANCE, AND REPAIR

Additional Inspection and Maintenance Safety Brake Certification Recommended Hydraulic Oil Changing the Rescue Lowering Hydraulic Oil Filter Cartridge Recommended Hydraulic Oil Filter Rack and Gear Lubrication Recommended Lubricant

RACK AND PINION GEAR INSPECTION PROCEDURE:

DUAL DRIVE AND SAFETY SYSTEM

Review of Rack and Pinion Design SEW Eurodrive KAF97 – 10hp Gearmotors – 2 Required Temporiti S.r.L. Elevator Safety Brakes – 2 Required

SYSTEM FUNCTION TESTING CHECKLIST

APPENDIX DOCUMENTS

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Appendix A – Applicable Safety Code Appendix B – ETL Data Label Appendix C – Step by Step Operational Sequence Detail Appendix D – Factory Acceptance & Testing Documents Appendix E – Training Plan Appendix F – Signage Appendix G – Smart-UPS Operation Manual by APC

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INTRODUCTION

The Trac-Cab TC5K-SPV is a Rack and Pinion Industrial Elevator designed and engineered for industrial applications in harsh environments. The Code classification for the TC5K-SPV system is a permanently installed Rack and Pinion Special Purpose Personnel elevator as defined by Part IV, Part 5.1 and Part 5.7 of the A17.1-2007 Elevator Code.

The machine travels up and down the elevator hoistway located inside the water supply access tunnel using dual pinion gear drives and safeties, driven by a variable speed electric drive system. The dual pinions each have a fully redundant integral automatic fail-safe brake system for maximum safety. The dual pinion gears engage a Rack and Rail system engineered to meet the Elevator Code requirements. The Rack and Rail runs the length of the hoistway providing precision tracking and positive engagement.

TESI has developed our product line with Safety and Technology as the driving factor using off-the-shelf industry proven components whenever possible. The core components of the Trac-Cab Drive System are the Siemens based Fail-Safe “Programmable Logic Controller” (PLC) controller, the “Variable Frequency Drive” (VFD) speed controller and the dual Gearmotors with, continuous duty integral Fail-Safe drive brakes. The Active Drive System is autonomously backed up by an independently actuated, mechanically set, Dual Fail-Safe Rack and Pinion Safety device, which is continuously monitored by the Safety PLC elevator controller. This design exceeds the functionality commonly found in the marketplace and meets all Code requirements for performance and safety.

We believe that our machines offer several advantages over other systems commonly found in the marketplace. Some of our unique features are especially relevant on industrial elevators. These include the Dual Drive and Safety System, the Hydraulic Rescue Lowering system, the Safety PLC based UL Listed Elevator Controller and the Optional Smart-Reel Cable Management system (applicable for machines over 100ft tall). These systems have been developed to address specific challenges common to tall outdoor rack and pinion elevator design. In addition, all rail components are solid structural members, welded and hot dip galvanized. This is a significant advantage over systems that utilize tubular members, which are very prone to rusting from the inside out. Internal rusting of the structural members, introduces a safety concern because the deterioration cannot be inspected and can unknowingly weaken key parts of the system over time. This hazard is eliminated with our design.

The Trac-Cab system operation is directed by the TESI UL Classified Elevator Control system based on software logic developed by TESI, running on the Siemens Fail-Safe PLC and a network of Siemens logic controllers and sensors. The operator interface utilizes Touchpanel graphical displays to provide operation status information and system administration functions. All user-initiated automatic elevator control functions are accomplished via industrial lighted push buttons for long life and improved operational functionality. The operator interface includes an integral alarm bell meeting

TESI Operations Manual TC5K-SPV 100914tl.doc Page 10 of 128 the A17.1 Elevator Code emergency signaling requirements. The operator interface also contains one of the system Emergency Stop buttons.

The TC5K-SPV is a semi-automatic elevator that may be directed to any floor from the cab-based operator station. There are no fixed call stations due to the shared use hoistway and personnel safety concerns. All input sensor data is continuously compared against expected tolerances resulting in fail-safe operation. This technology not only provides for maximum control and flexibility of the elevator system, but also eliminates many complex landing position switches, leveling devices, slow down switches, and other sensors that are commonly found on cable traction drive elevators.

The intelligent control system also monitors drive and system parameters to provide active feedback for system function status. Any anomalies, alarms or system faults are displayed in plain text to the operator or technician via the graphical touch screen interface. This information is available at both the Cab and Ground station HMI (Human Machine Interface). The interface is protected by pass-code input, which restricts access to all administration and technical operations. All operational and system administration functions are accomplished directly from the system touch panel; no need to configure and connect a laptop.

Per the Elevator Code, the system can be operated in Inspection Mode. TESI has provided technician inspection control from the cab operating panel and ground operation station, allowing authorized technician access from the ground and cab stations upon secure log in.

In short, the Trac-Cab is a rugged, flexible, and technologically advanced industrial elevator system that is designed and engineered for long life and trouble free service.

About TESI

Tower Elevator Systems, Inc. is a Licensed and Insured, US based manufacturer of Industrial Rack and Pinion Elevator systems. TESI manufactures elevator systems at our production facility in Austin, TX. The fabrication and quality processes have been developed to insure consistency and code compliance. TESI manufacturing procedures are AWS (American Welding Society) Code Compliant and our Plant is subject to frequent quality inspections by both our Customers and Suppliers. The facility is equipped with an 80-foot tall testing tower, allowing full function, load and speed testing of our systems prior to shipment.

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ELECTRICAL SERVICE

Electrical Service 480 VAC 3P 60 Hz:

Min 60 amp service required - Reuse Existing 200 AMP service with appropriate circuit protection.

Telco Service:

Emergency Communications

Standard PSTN Phone Line (service to terminate at Elevator Control)

JOB DETAIL

Customer Starcom Builders / US Army - Schofield Elevator

Application Incline Elevator Repair - Water Supply Access Tunnel

Location US Army Schofield Barracks Building 1580 East Range, Oahu HI

TESI Model Number TC5K-SPV

TESI Job Number 11-1020-STARCOM

Customer JOB / PO Num Job: W9128A-09-D-0013, Task Order 0003 / Starcom PO #1112-1

Project ID Schofield Elevator

Environment: Indoor - Underground- No Climate Control

Electrical Classification Unclassified Electrical Area

Code Design Reference ASME A17.1 v2007 - Section 4, 5.1 & 5.7

Elevator Classification Special Purpose Inclined Rack and Pinion Elevator

Freight Loading Personnel Carrier (1,000 lb.) with Cargo Trailer (4,000 lb.)

Drive System TESI Dual Drive Dual Safety - 10 HP SEW KAF97

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ELEVATOR SYSTEM CONFIGURATION

Capacity (Rated Load) 1,000 Lbs. Personnel - 4,000lbs Cargo

Cab Size 3'-8" W x 8' L x 4' H (nominal)

Cab Configuration Dual Door - Single Part Horizontal Slide

Cab Door Interlock Solenoid Interlock

Speed 110 fpm (nominal)

Height 1,200 ft. travel (nominal)

Landings 3 Stops – Upper, Mid, Lower

Landing Door Type Upper Landing - Single Part Swing - Other Custom Doors and Gates

Landing Interlock Type Solenoid Interlock

Special Hoistway Protection Dual Safety Laser Scanners (top and bottom) to protect against personnel entering the tunnel while the car is moving.

Power Dual 10 HP

Main Drive Gear Ratio 27.91 : 1

Volt Gen GB Ratio 40 : 1

Pinion 6 in PD - Match Existing Gear Rack Mesh

Gear Rack Use Existing - 1.5" Face Gear Rack

Counterweight N/A

Elevator Control Semi-Automatic - 3 Stop with Local Access Control at Upper and Lower Landings

Speed Control VFD (Variable Frequency Drive)

Overspeed Safety Dual Rack and Pinion Overspeed Safety

Emergency Lowering Yes, TESI Hydraulic Lowering

Cable Management Powered Smart-Reel on Car with Mid-Point Articulation Slip Ring

Controls Package TESI Custom Controls for Inclined Elevator with Onboard Touchpanel

Rock Detection & Clearing Per Specification Section 5.5.2

Voice Message Information Per Specification Section 5.5.3

Onboard Lighting Provide Onboard Floodlights per Specification Section 5.5.3

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SYSTEM OVERVIEW

TESI Trac-Cab Rack and Pinion Industrial Freight Elevator

3d Drawing of the Special Purpose Incline Rack and Pinion Elevator

This unique system is comprised of (4) separate, but articulated hinge connected, wheeled units riding on rail track in an approximately 1,300’ long below ground incline tunnel. There are two 10 HP Rack and Pinion type Tractor Drives, a 1,000 lb. Rated Load (4) person Personnel Cab, and a 4,000 lb. Rated Load Cargo Trailer.

The system is designed to allow technicians to service water pump equipment located in large rooms at the bottom of the tunnel. In effect, the system is a hybrid combination of Special Purpose Personnel Elevator and a cargo mine type train. Although the system is referred to as an elevator, we think Special Purpose Vehicle, SPV is a more accurate description, as elevators do not commonly have cargo trailers. The whole of the tunnel and rooms are referred to as hoistway and are protected as such.

Although the 1,300’ long tunnel is on a 30 degree incline, the Upper and Lower Landings are flat floor open rooms. To perform their duties the technicians use chain hoists to load and unload heavy pump equipment onto the cargo trailer in the Landings and then travel to another Landing. The tunnel is lighted and actively ventilated and not considered a confined space.

There is a third Loading Zone at the Mid Landing for electrical equipment, not pumps.

To maintain personnel and equipment safety there are numerous innovative High Technology devices plus an intuitive easy to use control system, utilizing both touch screen and VMI audio “The Talking Elevator” technology. Both the hardware

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Design and construction shall be of manufacture’s standard industrial duty fabrication processes suitable for long life in harsh environments. System components shall be of corrosion resistant materials and finishes as appropriate to the environment and application. Materials and finishing shall be dictated by function, application and exposure of components per manufacturer’s recommended standard design process.

Materials and finishes may include, but are not limited to, hot dip galvanized carbon steel, aluminum, stainless steel, composites, powder coated steel, zinc electroplating, and other industrial duty finish processes.

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TRAC-CAB MAIN COMPONENTS & CODE ITEMS:

Special Purpose Vehicle

1. Passenger Cab - Designation: Passenger Cab Location: Mounted to the Tractor Backbone & Rail System Function: Provides enclosed housing for riders. Includes cab door, cab lighting, an operator station, seating, emergency egress hatches, emergency power supply, a fire extinguisher and applicable safety and information signage.

2. Cab Door - Designation: Cab Doors (2) Location: Passenger Cab, on each long side of the cab Function: Provides safe entrance and exit to the elevator car when the car is at a particular landing area. Cab doors are electrically monitored and mechanically locked;

meaning that the elevator will not operate in normal or inspection mode when a cab door is open.

Doors are specially designed to wrap around the car roof to allow easier loading and unloading.

3. Spring Motor Door Closers – Designation: Door Assist Location: Passenger Cab Function: The spring motor door function is to allow the door to be constantly managed while opening and closing. This prevents the door from slamming open or closed when located on the decline.

4. Emergency Egress Hatch and Path - Designation: Exit Hatch (2) Location: Passenger Cab, on each short side of the cab.

Function: Provides Emergency Exit through the Passenger Cab if it is stranded in the tunnel, blocking passage. Personnel can open one hatch, traverse the cab and then open the second hatch to escape to the unobstructed portion of the tunnel. Hatch is electrically monitored and must be closed for the elevator to run in automatic operation.

The Egress path has a tread plate for safety. The exit hatches can be operated from both inside and outside of the car.

5. Adjustable Folding Seats - Designation: Cab Seats (2) Location: Passenger Cab Function: Provides seating passengers during duration of travel. Adjustable so that passengers can tilt the seat when the SPV is traveling on the decline portion of the tunnel.

6. Interior Car Light - Designation: Cab Light Location: Mounted in the Elevator Cab Function: Provides Code Required Car lighting Mode: On / Auto – In “AUTO” mode the light is activated upon a “change-of-state” (i.e. door open or elevator call) of the elevator system and remains on for

TESI Operations Manual TC5K-SPV 100914tl.doc Page 16 of 128 a specific time period. After the light “times out”, it will remain off until the elevator is to be used again. The “ON” mode will keep the light on as long as the switch is in the “ON” position. Battery Back Up is provided for Emergency Lighting per Code.

7. Passenger Cab Operator Station - Designation: OS1 Location: Recess Mounted in the Cab Wall Function: OS1 provides the main elevator user interface for all system operations. It is connected to CP1 via the traveling cable and the Siemens ProfiSafe Network. OS1 features a touch panel display for easy operation and industrial lighted push buttons for trouble free operation in rugged environments.

8. Hands Free Emergency Communications - Designation: Auto-dialing Phone Location: Passenger Cab Operator Station Function: Provides a HELP button that will autodial up to five pre-programmed phone numbers when pressed. It will continue to dial until a connection is made.

9. Industrial Telephone - Designation: Telephone handset Location: Passenger Cab Operator Station Function: Provides rugged communication method for riders in the Passenger Cab. It allows optimum function in a noisy environment, including the Vehicle Movement Alarm sounding, persons speaking in background or the noise of other equipment working.

10. Backup Power Supply - Designation: UPS (2) Location: Located under seats in the Passenger Cab Function: Provides emergency power to the hydraulic emergency rescue system, as well as the communication system.

11. LED Floodlight - Designation: Floodlight Location: Front and rear roof of Passenger Cab Function: Provides visual indication that the vehicle is in the tunnel.

12. Flashing LED Beacons - Designation: Strobes Location: Roof of Passenger Cab Function: Four colored LED strobes to communicate conditions to the personnel in the area of the SPV.

13. Personnel Safety Bars - Designation: Personnel Safety Bar Location: Passenger Cab Front and Rear, Cargo Trailer Rear Function: Deactivates/stops the car in the event that someone or something is located in the tracks.

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14. Trailer Pintle Hitch - Designation: Pintle Hitch Location: Passenger Cab Function: Together with the Towing Eye on the trailer, allows cargo trailer to be easily removed so that the SPV can be used without it.

15. Elevator Guide Wheels - Designation: Guide Wheels & Axles Location: Mounted to the Backbone and Roll on all surfaces of the Rail Track.

Function: Provide Alignment and Tracking for the Cab on the Rail.

Load bearing wheels are Stainless Steel with double stacked (4 each wheel) precision sealed ball bearings that require no lubrication.

Alignment & Backing wheels are Poly Tread over Aluminum Hub with double stacked (4 each wheel) precision sealed ball bearings that require no lubrication.

Trailer

16. Weld-On D-Ring Tie Down - Designation: Tie Downs Location: Trailer Function: Provides a tie-down point to secure cargo and equipment in the trailer.

17. Towing Eye - Designation: Towing Eye Location: Trailer Function: Together with the Pintle Hook on the passenger cab, allows cargo trailer to be easily removed so that the SPV can be used without it.

18. Rock Sensor Assembly - Designation: Rock Sensor Location: Front and Rear of Tractor Drives and Rear of Trailer Function: Detects the presence of an obstruction on the rack. All obstructions should be cleared so that the pinion is not damaged.

19. Personnel Safety Bar – [See description above]

20. Elevator Guide Wheels - [See description above]

Tractor 1

21. Drive System - Designation: Drive System Location: Mounted on each tractor Function: A variable speed electrically powered dual drive train that transfers electrical power to mechanical movement via the gearmotors and pinion drive gears.

The pinion gears are positively connected to the rack providing the elevator lift.

22. Hydraulic Emergency Rescue System -

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Designation: Rescue Lowering Location: Mounted on Tractor 1 and integral with the drive system Function: The Rescue Lowering System will allow a stranded rider to lower the cab under a controlled gravity descent in the case of a power unit malfunction or power loss to the system. Lowering speed is regulated to a controlled and safe speed by the hydraulic speed governor.

23. Rack and Pinion Safety - Designation: Dual Independent Safety Brake System (2) Location: Mounted on each tractor Function: In the event of an Overspeed condition, the Safety Brake system will engage to slow and stop the car independently.

24. Overspeed Volt Generator & Right Angle Gearbox - Designation:

Location: Tractor 1 Function: Provides electrical signal proportional to vehicle speed that is input to the Overspeed Governor System to detect an overspeed condition.

25. Variable Frequency Drive - Designation: VFD Location: Tractor 1 Function: Controls the operation of the main drive motors allowing variable speed settings, speed ramps, dynamic braking and overload sensing.

26. Braking Resistor - Designation: Braking Resister Location: Mounted on Tractor 1 Function: Provides means to dissipate heat and energy produced as a by-product of lowering the car under a controlled speed via dynamic braking of the

VFD.

27. Traveling Cable Management System – Smart-Reel Managing Traveling Power, Control and Communications Cable Designation: Smart-Reel Location: Mounted on front end of Tractor 1 Function: Provides a means to tension and manage the traveling power, control and communications cable that is linked between the CP1 cabinet and the traveling car.

28. Cable Management Roller Arm Designation: Roller Arm Location: Mounted on front end of Tractor 1 Function: The cable management roller arm guides the cable from the smart reel to the tunnel floor. This keeps the cable aligned during pay out / take up. The roller arm has square grooves it to keep the cable centered while in use.

29. Fiber Optic Rotary Joint - Designation: Rotary Joint Location: Inside the Smart-Reel, mounted on Tractor 1

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Function: Provides fiber optic cable management, as part of the travel cable management system.

30. Traveling Power, Control and Communications Cable - Designation: Control Cable Location: Inside the Cable management System, mounted on Tractor 1 Function: Provides an electrical link for power, control and communications between the CP1 Elevator Controller cabinet and the Passenger cab.

31. Pinion - Designation: Drive Pinions Location: Tractors 1 & 2 Function: The Pinion Gears on the Tractor Drive system engage the Gear Rack and move the elevator up and down the hoistway, converting the rotary motion of a motor to linear motion.

32. Rock Sensor Assembly - [See description above]

33. Personnel Safety Bar - [See description above]

34. Elevator Guide Wheels - [See description above]

Tractor 2

35. Drive System – [See description above]

36. Rack and Pinion Safety - [See description above]

37. Power Distribution - Designation: PD1 Location: Mounted on Tractor 2 Function: Where the main power comes into the car and distributes to other parts of the system.

38. Potential Transformer - Designation: 480VAC to 120 VAC Transformer Location: Mounted on Tractor 2 in PD1 Cabinet Function: Transforms 480 VAC 3P Power for local use at 120 VAC 1P for controls, lighting, etc. on the moving vehicle.

39. Absolute Position Encoder - Designation: Encoder Location: Mounted on Trailer 2 Function: Maintains position information when power is removed from the system. The position of the encoder is available immediately on applying power. The relationship between the encoder value and the physical position of the controlled machinery is set at assembly; the system does not generally need to return to a calibration point to maintain position accuracy.

40. Pinion - [See description above]

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41. Elevator Guide Wheels - [See description above]

Tunnel Hoistway and Control Station

42. Elevator Controller - Designation: CP1 Location: Mounted in the Control Equipment Room at Surface Level Function: Main Elevator Controller. Provides Central Point of System Power, Network and Communication circuit distribution, elevator hoist control and digital serial network connected to the remote call stations. Also, contains elevator ground administration and control position.

43. Main Power Disconnect - Designation: Disconnect Location: In the equipment control room near CP1 Function: Provides Code Required Main Power Disconnect to the Elevator System.

Main System Power Lock-Out / Tag-Out should be done at this location during service.

44. Hoistway Access Door / Upper Landing Safety Gate - Designation: Upper Landing Gate & Doors Location: Entrance to Pit / Hoistway Enclosure Function: Provides personnel access to Hoistway and Special Purpose Vehicle for use and maintenance

45. Mid Landing Safety Gate - Designation: Mid Landing Gate Location: At the entrance to the switch gear room at the Mid Landing in the tunnel Function: Provides personnel access to and from Hoistway and Special Purpose Vehicle for use and maintenance

46. Local Access Control Stations - Designation: Local Access Control Stations Location: Top, Mid and Lower Landings Function: Provides means via keyed access by trained personnel to jog the SPV forward, back and stop for cargo positioning. Also allows emergency E-Stop functions.

47. Gear Rack and Rail - Designation: Rack and Rail Location: Mounted in the Elevator Hoistway Function: An integrated system providing the main structural guide for the elevator to track up and down the hoistway. The Rail System is mounted to the building structure.

The Gear Rack is mounted to the Rail System. The Pinion Gears on the Tractor Drive system engage the Gear Rack and move the elevator up and down the hoistway.

48. Safety Laser Scanners - Designation: Safety Laser Scanner (2) Location: Top and bottom of hoistway Function: Safety system that monitors each end of the travel tunnel to detect intrusions. If an intrusion is detected, an alarm will sound and the SPV will stop until it is reset.

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49. Spring Buffer Assembly - Designation: Spring Buffer (2) Location: Mounted at the upper and lower end points of the hoistway Function: A spring buffer assembly providing shock absorption impact protection should the elevator car travel into the restricted areas.

50. Midpoint Articulation Fixture - Designation: Midpoint Transition Location: Mounted at the hoistway’s midpoint, approximately 600’ down the tunnel Function: Anchors one end of the travel cable at the midpoint of the tunnel. It flips direction as the SPV travels from one end of the tunnel to the other.

51. Travel Cable Overload Switch – Designation: Cable Overload Protection Location: Midpoint Cable Transition Function: Consists of tension switch that reports an over-tension of the cable if the cable is entangled and pulled by the traveling car. It consists of a safety switch that when activated will trigger an emergency stop of the SPV prior to cable damage.

Operator must evaluate cause of over-tension and correct it. The safety switch must be manually reset and the fault acknowledged at the Drive System Status Screen on any system HMI to return the system to service.

52. Upper and Lower Normal Terminal Stopping Limits and Actuation Cams - Designation: Normal Terminal Stopping Switches Location: Cams are mounted to the SPV and switches are mounted to the rail.

Function: Provides device-based normal terminal stopping at the Top and Bottom of the normal travel path in the hoistway. The limit switch is mechanically activated when it makes physical contact with the actuation cam – a trapezoidal piece of metal mounted on the SPV. The switches are mounted to the rail system in the hoistway at the Upper Landing Normal Terminal Stop and at the Lower Landing Normal Terminal Stop.

53. Upper and Lower Final Terminal Stopping Limits and Actuation Cams - Designation: Overtravel Switches - Final Terminal Stopping - Per A17.1 Part 2.25.2 Location: Cams are mounted to the SPV and switches are mounted to the rail.

Function: Provides hard wired device-based overtravel stopping at the Top and Bottom of the Overtravel Runby area in the hoistway. Switches are mounted to the rail system in the hoistway above the Upper Landing and below the Lower Landing. The limit switch is mechanically activated when it makes physical contact with the actuation cam

– a trapezoidal piece of metal mounted on the SPV. Upon actuation the car can be driven off the switch in the opposite direction of travel using Inspection Control.

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SYSTEM ZONES AND VEHICLE MOVEMENT

Loading Zones There are three: one located within the Upper Landing, one within the Lower Landing and third is at the Mid Landing, in the incline portion of the tunnel.

The Top Loading Zone is adjacent to the large exterior access equipment loading door referred to as Upper Safety Barricade within the Upper Landing. The Lower Loading Zone shares space with the Lower Landing adjacent to the pump room at the bottom of the tunnel. The Mid Loading Zone which shares space with the Mid Landing serves the equipment room located there. No hoists are available at the Mid Landing.

The technician crew load and unload the water pump and electrical equipment onto and off the cargo trailer while the vehicle is positioned in these Loading Zones in a Safe State, either by hand, or by using overhead hoists and dolly carts.

This activity falls outside the normal passenger elevator application anticipated by the ASME A17.1 Code and requires special design to allow function and maintain safety.

During these loading activities the personnel are exposed to the un-barricaded vehicle equipment and travel track, so any unexpected movement would place them in harm’s way and must be prevented.

Landings There are three Landings suitable for non-crew passenger entry and exit of the vehicle.

The Upper Landing is in the flat section at the upper terminus end of the vehicle travel just beyond the Upper Loading Zone and has an interlocked landing door for access into the control room building. The Lower Landing is in the flat section of travel at the bottom of the tunnel and is collocated with the Lower Loading Zone. There is no landing door for the Lower Landing as this area must be kept open to allow loading and unloading of large pump equipment and maneuvering of the dolly cart.

It would be undesirable to cage in the Lower Landing area as it could potentially trap persons there in the event of an equipment malfunction and prevent entry of rescue persons. With the programmed Safe State and other safeguards, it is safe to work around this machine without barricades.

The Mid Landing is located in the incline portion of the tunnel and has a standard type Special Purpose Personnel expanded metal interlocked landing door. It also serves as a Loading Zone for the electrical equipment.

The vehicles normal parking position is at the Upper Landing and it should be left there after each use, making it available for control room access.

At the mid landing; the landing door is directly adjacent to the vehicle door allowing safe passage into and out of the vehicle. Neither the vehicle nor landing doors will open unless the controller detects the vehicle properly stopped at the landing.

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At both the Upper and Lower Landings, the vehicle doors can be opened while the vehicle is in the Landing area and completely stopped.

Tunnel / Hoistway This is the incline portion of the vehicle travel path connecting between the upper and lower Loading Zone areas. The tunnel is roughly 9’ in diameter and contains water pipes, electrical conduits, tunnel lighting, rail tracks, and a personnel stairway located directly between the vehicle travel rail tracks.

To protect unauthorized personnel entry into this area, the tunnel is equipped with controller monitored Laser Scanner barricades positioned at the upper and lower terminus points of the incline tunnel. Any personnel passing through these scanners will trip the barricade and cause the controller to immediately stop the vehicle. A Laser Screen breach initiates a latch type "Fault Condition" that will not reset automatically, but requires the operator to confirm the travel path and tunnel are clear before re-initializing the system to allow reset and continued vehicle use.

The Laser Screens are ignored when the vehicle is in Emergency Bypass Mode operation to allow faster passage and to eliminate issues of smoke possibly triggering the barricades.

Vehicle Movement In normal operating mode the vehicle cannot be remotely called from another landing like a standard building elevator because you cannot see the vehicle from other landings and could place unprotected workers at risk of being run over by the vehicle.

The equipment is dedicated to the crew using it and is under their direct control.

Controller operation is Semi-Automatic from the vehicle operator panel only. Vehicle movement is full speed inside the tunnel and slow speed while approaching and in the Loading Zone areas.

Remote Vehicle Movement—Upper Loading Zone While in the Top Loading Zone the vehicle may be remotely moved using the following procedure. No personnel can be in the Upper Loading Zone and the Safety Barricade must be closed. Then the keyed Local Access Control Station may be used to move the vehicle in either direction at slow speed.

Remote Vehicle Movement—Mid Loading Zone While at the Mid Loading Zone the vehicle may be remotely moved using the following procedure. No personnel can be in the Hoistway and the Mid Landing Safety Barricade must be closed. Then the keyed Local Access Control Station may be used to move the vehicle in either direction at slow speed. This is the preferred method of moving the vehicle; however, the manual method may be used.

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Remote Vehicle Movement—Lower Loading Zone No remote movement is allowed at the Lower Loading Zone. The Operator should park the vehicle with the Cargo Trailer in the Loading Zone before exiting. Otherwise the Operator must re-enter the vehicle and go to manual control via the HMI touch panel.

The Operator shall be required to acknowledge that he has inspected the area for personnel via pushbutton on the HMI panel. During this acknowledgment, the audio and visual warnings shall occur. After the Operator has pressed the acknowledgment pushbutton, the vehicle movement screen will appear on the HMI panel. The Operator will press and hold a pushbutton for the direction they wish the vehicle to move. If the vehicle is moved into the Laser Scanner barricade, the vehicle will immediately stop; the same as if a person had entered in the laser scanner barricade.

Manual Vehicle Operation The vehicle may be placed into manual mode by the Operator any time the vehicle is not in motion. This is to allow the vehicle to be positioned manually, whether performing maintenance in the tunnel or to move the vehicle while it is in a Loading Zone.

Manual operation is only available through the Touch Screen Terminal located in the vehicle on the Control Panel. The Operator may switch to manual operation in order to take the vehicle to locations other the Landings or Loading Zones. Slow speeds are still maintained outside of the tunnel. Constant pressure is required upon the Terminal Screen in the direction requested in order to maintain travel.

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Operator Interface Main Screen

ELEVATOR OPERATION INSTRUCTIONS

TESI Trac-Cab Elevator Control System

Operation Policies

Normal and Emergency Operation training must be completed and documented prior to use of this equipment.

Misuse of this equipment could result in personal injury or property damage.

Note that the owner / site operator must confirm that all required safety inspections and maintenance procedures are performed according to all signage and the System Operation Manual.

Operation Modes:

Semi-Automatic Operation –Set-Point Landing Stops from within the vehicle only with controlled reduced speed entry into the loading zones.

Emergency No Power (Rescue) Lowering:

Cab Recovery via controlled gravity descent

Inspection Mode:

Manual Car Control, for trained and authorized technicians only, accessed via OS1 control station inside the Passenger Cab. Requires “INSP” Mode selection from MODE key switch in Cab.

Ground Administration Mode:

For trained and authorized technicians only, accessed via key code from the administration menu and operated from the ground position touch panel. Requires “INSP” Mode selection from MODE key switch in Cab and Authorized Password.

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Semi-Automatic Operation In normal semi-automatic mode, the elevator control is operated using the standard lighted push buttons in the cab after the drive has acknowledged the appropriate safety checks in the loading zones. The control panel display will show relevant system status information.

Normal Operation Mode

Elevator Ready / Semi-Automatic Operation

Verify the electrical power is ON to the Main Controller.

Confirm all required inspections have been performed.

Insure the car travel path is clear of persons or obstructions.

Test to confirm operation of the emergency signaling system.

Close the car gate and landing door and observe the system status is “ready” on the display panel. If not “ready”, diagnose and correct the indicated faults.

Push the desired Floor Call button to start car movement.

Follow the Audible and Visual Prompts to acknowledge a clear travel path.

Car will move at a reduced speed while in the landing zones.

Car will stop prior to exiting the tunnel area into the destination loading zone.

Follow audible and visual prompts to proceed.

Operator must press and hold flashing destination call button in order to proceed into the active loading zone area and onto final destination location at reduced speed until the normal terminal stop is reached.

Press the Red E-Stop button in the event of any system irregularity. Pressing the E-Stop will immediately stop the car, even if not at a landing. Check the screen for system alarm messages.

Gaining SPV Access To gain loading access to the SPV from the Upper Landing, the exterior loading doors should be opened. Once these doors are open, the expandable steel interlocked gate is exposed, allowing clear view into the work area, but not allowing passage. The operator can visually determine from outside the protected area if the cargo trailer needs to be moved from the Upper Landing parking position to facilitate cargo loading.

If required, to move the vehicle the operator uses his key in the Local Access Control Key Station, located outside the interlocked expandable steel gate, to control the vehicle movement with the key switch with no one in the Loading Zone. An E-Stop is co-located on the Local Access Control Station providing instant use if required. Once the vehicle is in the desired position, the operator can now use the key to secure the system in a Safe State and open the expandable gate to allow loading operations.

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Loading/Unloading Equipment The system remains in a Safe State anytime the expandable gate or any door is open, making it safe for workers to be around the vehicle and cargo trailer.

Positioning the Cargo Trailer for Loading is accomplished via the Key Station, located outside of the expandable gate barricade. The operator using a Key can enable access control for vehicle positioning. Then, using the same key switch can enable the “unlocking mode” to allow the safety gate to be opened. The vehicle will not move in this Safe State mode.

Additionally there is a Local E-Stop at this and all manual vehicle control stations. There is another E-Stop inside the expandable gate in the Loading Zone Area for additional safety.

At the Upper Loading Zone, the operator can use the overhead trolley beam and chain hoist the crew unloads the pump equipment from the truck onto the elevator cargo trailer and secures it with the “D” rings provided all around the trailer

Adjusting the Passenger Seats The personnel carrier is equipped with adjustable seats to allow the passengers to tilt back when the car is on the decline. To allow the seat to decline, pull the knob located at the front of the seat frame. Once this occurs the seat will automatically tilt back to the proper position; release the knob and the seat will lock into the tilted position.

When the car transitions from the decline to the straight landing areas lift up the knob and the seat will return to the upright position. The seats are controlled with gas shocks that will push it back into the upright position.

Preparing for Vehicle Travel All doors, gates, and vehicle door must be closed. The landing door will lock when a landing selection has been made and the vehicle doors will lock before the vehicle moves. Additionally, prior to any vehicle movement the operator in the vehicle is required to "Acknowledge" the pathway is clear of persons. To prompt him to do this there are two warnings, one over the vehicle speakers, announced by the recorded VMI (Voice Message Information System), and also displayed in text form on the vehicle operator panel HMI touch screen.

The VMI audio announces: “Warning – Make Certain All Persons Are Clear ", while the message is displayed in text on the vehicle operator panel touch screen.

After the operator "Acknowledges" the message, by pressing on the touch screen, there is a 5 second delay while the VMI audibly repeats the message again, the Motion Alarm ("Beep-Beep-Beep") vehicle movement alarm sounds, and the Yellow Flashing Light on the vehicle top are activated. After the 5 second delay, vehicle movement control is enabled allowing the vehicle to move.

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Loading Zone Slow Speed Vehicle movement in the upper and lower Loading Zones is Slow Speed. The movement alarm, vehicle headlights, and flashing light are active in the Loading Zones.

Entering the Tunnel The Laser Scanner Barricade is programmed to allow the vehicle pass through without tripping by turning the scanner off as the SPV passes under it. Once the vehicle is beyond the Laser Scanner in the tunnel the vehicle will continue travel at full speed. The audio and visual movement alarms deactivated, but the headlights remain on.

Semi-Automatic travel to all landings is possible by selecting the corresponding button on the Control Panel in the vehicle. The vehicle must be at secured as noted in the section “Preparing for Vehicle Travel” above. Before the car will move, the Operator is presented with both a verbal, as well as an onscreen, safety message, cautioning that all persons and obstructions must be out of the way before proceeding.