GMV SPA FLUID DYNAMIC EQUIPMENTS AND LIFT COMPONENTS
UNI EN ISO 9001 Certified Company
2.00
ENG
ü ü
* 1 0 9 9 1 4 5 8 EN *
SELL TECH WORK CUST USER
English ORIGINAL INSTRUCTIONS
MI GREENLIFT
INSTALLATION MANUAL
GREEN LIFT FLUITRONIC SYSTEM
FOR SYSTEMS: q GLF MR q GLF MRL MC q GLF MRL T q REDUCED HEADROOM (TR) q REDUCED PIT (FR)
q REDUCED HEADROOM AND PIT (TFR)
SYSTEM N° INSTALLER
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INDICE 0 GENERAL INFORMATIONS 5
0.1 INTRODUCTION 5 0.1.1 DEFINITIONS 5 0.1.2 MAIN STANDARDS OF REFERENCE 5 0.1.3 TERMS AND SYMBOLS USED 6 0.1.4 DOCUMENTS RELATED WITH INSTALLATION 6
0.2 SAFETY PRECAUTION DURING INSTALLATION 6 0.3 PRELIMINARY OPERATIONS 7
0.3.1 INSTALLATION PROCEDURES 7 0.3.2 DIMENSIONS CONFORMITY 7 0.3.3 MATERIALS OFF LOADING AND STORAGE 7 0.3.4 SCAFFOLDING 7
1 WELL MATERIAL 8 1.1 ANCHORING 8
1.1.1 PLUMBING 8 1.1.2 BRACKETS 8
1.1.2.1 FIXING WITH ANCHORS 9 1.1.2.2 FIXING WITH HALFEN 9 1.1.2.3 FIXING IN WALL 9 1.1.2.4 OTHER FIXINGS 9
1.2 BOLTS, SCREWS AND ANCHORS 10 1.2.1 ANCHORS AND HALFEN 10 1.2.2 TIGHTENING TORQUES 10 1.2.3 TIGHTENING TORQUES FOR OTHER SYSTEMS BOLTS 10
1.3 GUIDE RAILS 11 1.4 ELEMENTS ON THE PIT BOTTOM 11
1.4.1 PISTON PEDESTAL 11 1.4.2 GUIDE BRACKETS OF THE PISTON 11
2 HYDRAULIC MATERIAL 12 2.1 PISTON 12
2.1.1 INTRODUCTION OF PISTON IN THE WELL 12 2.1.1.1 INTRODUCTION INTO A WELL WITH OPEN ROOF 12 2.1.1.2 INTRODUCTION FROM A LIFT-DOOR 12
2.1.2 POSITIONING OF PISTON INTO THE WELL 12 2.1.3 PISTON INSTALLATION 13
2.1.3.1 INSTALLATION FO THE GUIDE BRACKETS FOR THE PISTON 13 2.2 HYDRAULIC POWER UNIT 14
2.2.1 POSITIONING OF THE POWER UNIT IN THE MACHINE ROOM 14 2.3 MRL HYDRAULIC POWER UNIT 14
2.3.1 INTRODUCTION OF HYDRAULIC POWER UNIT IN THE PIT 14 2.3.2 FIXING OF THE MRLT POWER UNIT TO THE GUIDES 14 2.3.3 CONNECTION OF HYDRAULIC PIPES 14 2.3.4 HYDRAULIC POWER UNIT FIRST FILLING 15
2.4 HYDRAULIC POWER UNIT FINAL FILLING 15 3 SLING AND ROPES 16 3.1 INSTALLATION 16
3.1.1 OIL PIPE 16 3.1.2 DRIVING LEVERS OF THE SAFETY DEVICES 16
3.2 ROPES 16 3.2.1 PLACING ROPES 16 3.2.2 ROPING OF THE SYSTEM 16 3.2.3 TENSIONING OF THE SYSTEM 17
3.3 TESTS 17 3.3.1.1 TESTS FOR STANDARD SYSTEMS 17 3.3.1.2 TESTS FOR SYSTEMS WITH HEADROOM AND/OR PIT REDUCED 17
4 CAR AND DOOR OPERATOR 17 5 LANDING DOORS 18 6 ELECTRICAL MATERIAL 18 6.1 WELL AND MACHINERY ROOM 18
6.1.1 INSTALLATION OF THE CONTROL PANEL OUTSIDE THE WELL 18 6.1.2 INSTALLATION OF THE CONTROL PANEL INSIDE THE WELL 18 6.1.3 WELL ELECTRICAL LINES 18
6.2 ELECTRICAL CONNECTIONS 18 6.2.1 CONNECTION OF THE FINAL LIMIT SWITCH 19
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6.2.2 CONNECTIONS OF THE ELECTRICAL SWITCHES AND WELL INFO 19 6.2.3 CONNECTIONS OF THE CAR AND CAR DOOR OPERATOR 19
6.2.3.1 CAR PUSH-BUTTON STATION 19 6.2.3.2 CONNECTIONS ON THE CAR ROOF 19 6.2.3.3 DOOR OPERATOR AND DOOR SWITCH 19
6.2.4 CONNECTIONS OF THE LANDING DOORS 19 6.2.4.1 PUSH-BUTTON PANELS 19 6.2.4.2 SAFETY SWITCHES 19
6.2.5 CONNECTION OF THE WELL LIGHTING 19 6.2.6 CONNECTIOS OF THE DEVICES 19
7 SAFETY DEVICES AND SIGNS 20 7.1 SAFETY DEVICES 20 7.2 NOTICES, MARKINGS AND OPERATING INSTRUCTION 21 8 ADJUSTMENTS 22 8.1 LUBRICATION AND TOPPING UP 22 9 EXAMINATIONS AND TESTS 22 10 FINAL OPERATIONS 22 10.1 ADVICES 22 10.2 FINAL OPERATIONS 22
REV
14.03.2018 2.00 First issue (update to EN81-20) DT GG DT AM
ENG
All rights reserved. Any kind of reproduction, even partial, of this document is forbidden without written permission from GMV Spa GMV Spa reserves the right to alter the product or this document, partially or entirely without any prior notice in the event of any technical, construction or production improvements. The drawings, descriptions and technical characteristics given in this document are purely for indication purposes. For any data that is not given in this document, reference should be made to the documentation attached to each component. To guarantee the constant safety of the product, only original parts or spares should be used, unless they are approved by GMV Spa beforehand. GMV Spa accepts no responsibility in the event the instructions given herein are not adhered to.
Information and support :
FLUID DYNAMIC EQUIPMENTS AND LIFT COMPONENTS
UNI EN ISO 9001 CERTIFIED COMPANY
GMV SPA VIA DON GNOCCHI, 10 - 20016 PERO - MILANO (ITALY) - TEL. +39 02 33930.1 - FAX +39 02 3390379 - E-MAIL: [email protected] VIA PER BIANDRATE, 110/112 – 28100 NOVARA (ITALY) – TEL. +39 0321 677 611 – FAX +39 0321 677690 - E-MAIL: [email protected]
Please visit www.gmv.it to check for
any updated versions of this document or further information about GMV products
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MAIN DATA OF THE SYSTEM
P K
GMV PK N° SYSTEM REF.
S/N OF THE CONTROL PANEL
SYSTEM TYPE
GLF �
MR �
MC �
MRL �
MRL2
WELL TYPE
�
STD EN81-20 �
REDUCED HEADROOM TR EN81-21
�
REDUCED PIT FR EN81-21
�
REDUCED PIT AND HEADROOM TFR EN81-21
MANOEUVRE
�
AUTOMATIC PUSH BUTTON (APB)
�
HOLD TO RUN
�
DOWN COLLECTIVE
�
FULL COLLECTIVE
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0 GENERAL INFORMATIONS
0.1 INTRODUCTION
0.1.1 DEFINITIONS
The definitions are used in this manual as indicated in the following standards and regulations EN81-20 e EN81-50 Safety regulations for the construction and installation of lifts UNI EN ISO 14798 Lifts (elevators), escalators and mobile walkways
– Risks assessment and reduction methodology UNI EN ISO 7010 Graphic symbols: Safety signs and colours EN12016 e EN12015 Electromagnetic compatibility CEI EN 61439-1 Low voltage switchgear and control gear assemblies (LV control panels)
0.1.2 MAIN STANDARDS OF REFERENCE
For anything that is not expressly given in this manual, reference should be made to the local standards and regulations in force, observing in particular:
Directive 2006/42/CE Machine Directive – in relation to machines, and amending Directive 95/16/CE (recast) Directive 2014/33/UE Lifts Directive - on the harmonisation of the laws of the Member States relating to lifts and safety
components for lifts Directive 2014/35/CE Low Voltage Directive – on the harmonisation of the laws of the Member States relating to the
making available on the market of electrical equipment designed for use within certain voltage limits Directive 2004/108/CE Electromagnetic Compatibility Directive (EMC) – approximation of laws in member States
regarding electromagnetic compatibility, and repealing Directive 89/336/CEE
Rules EN-81 complete series Safety regulations for the construction and installation of lifts Refer to the complete series and, in particular to:
EN 81-20 Safety rules for the construction and installation of lifts – Lift for the transport of persons and goods - Part 20: Passengers and goods passenger lifts
EN 81-50 Safety rules for the construction and installation of lifts – Examinations and tests - Part 50: Design rules, calculations, examinations and tests of lift components
EN 81-41 Safety regulations for the construction and installation of lifts – Special lifts for the transport of persons and goods – Part 41: Vertical lifting platforms for use by persons with impaired mobility
EN 81-58 Safety regulations for the construction and installation of lifts – Examinations and tests – Part 58: Landing door fire resistance test
EN 81-70 Safety regulations for the construction and installation of lifts – Particular applications for lifts for the transport of persons and goods - Part 70: Accessibility to lifts for persons, including persons with disabilities
CEI EN 60439-1 Low voltage switchgear and control gear assemblies (LV control panels) Part 1: Type tested assemblies (AS) and partially type tested assemblies (ANS)
EN 12015 Electromagnetic compatibility – Product family standard for lifts, escalators and moving walkways – Emission
EN 12016 Electromagnetic compatibility – Product family standard for lifts, escalators and moving walkways – Immunity
EN 12183 Manual wheelchairs: Requirements and test methods EN 12184 Electrically powered wheelchairs, scooters and their chargers
― Requirements and test methods UNI EN 12385-3 Steel wire ropes – Safety – Part 3: Information for their use and maintenance UNI EN 12385-5 Steel wire ropes – Safety – Part 5: Stranded ropes for lifts UNI EN 13015 Maintenance for lifts and escalators: Rules for maintenance instructions EN 13411-6+A1 Terminations for steel wire ropes – Safety
– Part 6: Asymmetric wedge sockets EN 13411-7+A1 Terminations for steel wire ropes – Safety
– Part 7: Asymmetric wedge sockets UNI EN ISO 7010 Graphic symbols – Safety signs and colours – Registered safety signs UNI EN ISO 13857 Machine safety – Safety distance to avoid access to dangerous areas with arms or legs UNI EN ISO 14121-1 Machine safety – Risks assessment – Part 1: Principles UNI EN ISO 12100 Safety of machinery - General principles for design - Risk assessment and risk reduction UNI EN ISO 14798 Lifts (elevators), escalators and mobile walkways
– Risks assessment and reduction methodology
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0.1.3 TERMS AND SYMBOLS USED
NOTE Gives information of particular importance.
ATTENTION A warning that the described operation could cause damage to the system or physical injury, even serious, if the safety rules are not observed.
NOTE Correct work. To make installation operations is possible
The normal use of the lift is possible
NOTA Wrong work. To make installation operations is NOT possible
The normal use of the lift is NOT possible
ABBREVIAZIONI
MRL Machine Room Less (Control panel inside well) TR Reduced headroom FR Reduced pit MRL2 Machine Room Less (Control panel outside well) TFR Reduced headroom and pit
0.1.4 DOCUMENTS RELATED WITH INSTALLATION
This is the documentation to be used for the installation of a complete lift:
LIFT PROJECT DRAWING
INSTRUCTION AND DIAGRAMS OF THE HYDRAULIC PART AND RUPTURE VALVE
INSTRUCTION RELATED TO THE SAFETY GEAR
INSTRUCTION RELATED TO SLING AND ROPES
INSTRUCTION RELATED TO THE CAR
INSTRUCTION RELATED TO DOOR OPERATOR, CAR AND LANDING DOORS
INSTRUCTION AND DIAGRAMS OF THE ELECTRICAL PART AND THE CONTROL PANEL
INSTRUCTION RELATED TO
ADDITIONAL OR OPTIONAL COMPONENTS
THIS MANUAL
All the documentation for a correct and safe installation of the lift, must be stored by the installation responsible. Please remember that this documentation is considered part of the plant and must be complete, well stored
and unabridged in every part. In order to maintain the readability, the documentation shouldn’t be damaged and shouldn’t have missing
parts. Moreover, do not tear or deteriorate sheets during consulting.
0.2 SAFETY PRECAUTION DURING INSTALLATION
During installation and maintenance, it is compulsory to observe the applicable national safety standards for the workplaces
ATTENTION - Before beginning any of the installation operations, ALWAYS check that all the mechanical and electrical safety devices are, turned on and in perfect working order.
Sx I ngombr o Tela i - Fr ames D x
Vano - Well
Sx
Van
o - W
ell
Muro
-Gu
ida -
Wall
-Gui
de
Inter
no C
abin
a - In
side
Car
luce por te -cl ear ent ranceI ngombr o Tela i - Fr ames
Int er no C abina - I nside Car
Dtg -
Dbg
Dx
Mur
o-Guid
a - W
all-G
uide
Vano - Well
Foss
a - P
itTe
stat
a - H
eadr
oom
Ingo
mbro
tela
i-Fra
mes
Heig
htluc
e po
rte-o
peni
ng d
oors
>150
>130
>100
Cors
a - T
rave
l
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0.3 PRELIMINARY OPERATIONS
0.3.1 INSTALLATION PROCEDURES
Before the installation please verify the following items: q Adequate lighting in the lift well. q Cleaning conditions of the well and the pit waterproofing. q The electrical equipment must be adequately grounded (otherwise stop the installation until the ground
wire is correctly connected) q The entrance to the well are closed q Verify that is possible to introduce the piston, the components into the well and also the adequate lifting
devices. q The accesses to the machine room can be safely used in any moment (EN81-20 §5.2.2.5), both in the
prefab machine room and in the machine room cabinet. q The accesses to the machine room should be adequately lighted (EN81-20 §5.2.2). Particularly as
concerns the machine room cabinet, the lighting in the working area, limited by the open swing panels and by a chain, should comply with EN81-20 §5.2.1.4.2.
q The cabinet can be positioned according to the LIFT PROJECT DRAWING in an environment protected against bad weather.
q Prepare a material storage area near the well, easily accessible by the installation personnel and protected against bad weather.
q Verify that all grooves and the holes for the electrical cable are free, accessible and smooth. q Verify there is an air vent in the lift well.
0.3.2 DIMENSIONS CONFORMITY
Perform the following check before starting the installation of the plant, verify that the measures are according with the project drawing, particularly pay attention to: q Width of the well (distance between the side panels). q Length of the well (distance between front and rear panel). q Depth of the pit. q Travel height. q Height of the headroom. q Verticality of the well. q Length of the piston. q Length of the piston-pedestal q Car frame DBG (distance between guides). q Distance between well and Machine room. q Recesses for the landing doors q Indicate the level of the finished floor, inside the lift well, at each landing station.
0.3.3 MATERIALS OFF LOADING AND STORAGE
q Using the packing list as reference verify that all materials received are those ordered and are complete. q Check the condition of all components and materials upon reception at the building yard, to verify if any
damage occurred during transport; immediately inform GMV Spa in case any part is missing or in case of damage.
q Store the electrical and electronic components in a cool and dry place in their original packages q If, for any reason, it were not possible to install the plant immediately, periodically check the stored
components to prevent possible damages due to a prolonged storage in bad conditions. q Check if the documentation related to the plant is enclosed. q Pay particular attention when off-loading the pistons and the guide rails q Do not off load the pistons by throwing them on the floor, make them roll on blocks.
0.3.4 SCAFFOLDING
Use regular scaffolding for the installation. The scaffolding must have work landing at each landing station, at least at 0,5 m under the floor level of the landing station.
WARNING The scaffolding, if entirely or partly composed by metal structures, should be grounded and comply with the safety standards.
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1 WELL MATERIAL
NOTE The following parts are inside the sling package :
- The oil collecting tray - The beam of pit bottom - The guide-brackets of the piston (included in the standard
supply)
1.1 ANCHORING
1.1.1 PLUMBING
For a correct plumbing, refer to the following instructions and to the images Lower the plumb lines for
the doors and for the guide rails to verify if the plan and vertical dimensions of the well comply with the project drawing and highlight possible structural differences in the panels plumbing.
Set the control templates to verify the distance between guides.
1.1.2 BRACKETS
If not contrary to the specific instructions of the materials supplied, for a correct and safe installation of the brackets please refer to the following procedure:
df
L [mm]
do [mm]
h(min) [mm]
hef min [mm]
M10 90 10 80 60 M12 100 12 95 70 M16 145 16 135 85
DTG = dimension show on layout DAG = dimension show on layout
Y <= dimension show on layout
G S Pd Ps
T82/A T82/B 68,25 10 5/10 = Pd
T90/A T90/B 75 10 5/10 = Pd
T125/B 82 10 5/10 = Pd
Set the brackets on the well panels taking the plumbing as reference.
Drill the wall and install the brackets starting from the bottom with the supplied fixing material (dowels and bolts).
Mount the brackets taking as a reference the positions indicated on the project drawing of the plant. Mount the counter-bracket using the related fixing material.
A
A // B // C // D
B CD
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SM DAG X M SM10 DAG X M (min) (max) (min) (max)
130 170 210 ~110
170 210 250 ~110 190 230 275 150 210 250 290 ~110 230 270 315 150 250 290 330 ~110 270 310 355 150 290 330 370 ~110 310 350 395 150 330 370 410 ~110 350 370 435 150
ST/UN – HA/UN ST – ST/D – ST10 SM – SM10
T82 T90
T125
1.1.2.1 FIXING WITH ANCHORS
1.1.2.2 FIXING WITH HALFEN
1.1.2.3 FIXING IN WALL
Make some holes, sufficiently wide to insert the brackets in the wall, in the position, showed on the layout, where you should fix them.
Install the guides in the correct position as shown on the layout fixing them temporarily to the well or to the scaffolding Place the brackets in the holes fixing them to the guides using their counter-brackets, paying attention to
leave a distance for adjustment. Fix the brackets in the wall using pieces of bricks and cement paying attention to do not move the guide from
their position. When the cement become dry verify that the guides are parallel and in the position shown on layout. If the
guides are not in the needed position move them to the correct placement.
1.1.2.4 OTHER FIXINGS
If you have another type of fixing, please refer to the instructions of the manufacturer.
M X
DAG
X
DAG
M
DAG30mm
DTG
10mmDAG
DTG
DAG
DTG
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1.2 BOLTS, SCREWS AND ANCHORS
1.2.1 ANCHORS AND HALFEN
Type Class Tensile strength
NRk,p [kN] Cut resistance
VRk,s [kN] Minimum distance
[mm]
Min distance from the
edge [mm]
M10 x 90 5.8 9,00 16,65 180 90 M12 x 100 5.8 23,55 26,10 210 105 M16 x 145 5.8 31,00 47,40 255 130
M16 x 50 4.6 31,40 22,60 80 -
1.2.2 TIGHTENING TORQUES
T45/A T50/A
T82/A T82/B
T90/A T90/B T125/B
[Nm] [Nm] [Nm] [Nm]
M10x90 5.8 30 M12x100
5.8 50 M12x100 5.8 50 - -
M12x100 5.8 50 M16x125
5.8 100 M16x125 5.8 100
M16x50 4.6 60 M16x50
4.6 60 M16x50 4.6 60 M16x50
4.6 60
M8 8.8 27
M12 8.8 92
M12 8.8 92 M12
8.8 92
M10 8.8 53 M16
8.8 232 M16 8.8 232
T1
(M10) 21 T2 (M12) 36 T3
(M14) 58 T4 (M16 88
M8 8.8 27 M12
8.8 92 M12 8.8 92 M16
8.8 232
1.2.3 TIGHTENING TORQUES FOR OTHER SYSTEMS BOLTS
Friction coefficient = 0,15
CLASS M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 5.8 0,8 1,83 3,62 6,2 15,2 30 52 83 130 179 254 438 8.8 1,21 2,78 5,5 9,5 23 46 79 127 198 283 402 809
CLASS M27 M30 M32 M36 M38 M41 M46 M50 M55 M60 M65 M70 5.8 649 880 1195 1534 1994 2464 3085 4258 5978 7428 8935 10445 8.8 1201 1628 2216 2840 3697 4554 5712 7888 11075 13785 16572 19359
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1.3 GUIDE RAILS
If not contrary to the specific instructions of the
materials supplied, for a correct and safe installation of the brackets please refer to the following procedure:
1
2
3
Fix the fishplate to the guide-rails segments, on the side with the “male” connection part.
Place the collecting oil tray and the beam, on the bottom of the pit or on the pre-set cement base and level it using a bubble level, complying with the indications of the project drawing.
Install the guide rails starting from the bottom of the pit positioning the “male” part upwards into the groove.
Connect the guide-rails segments using the connection plate
4
5
6
Mount the counter-bracket using the related fixing material
Perform the same procedure to install all guide-rails and brackets.
Check the distances referring to the project drawing and verify the verticality of the guide-rails in comparison to the plumbing and the position template.
7 Tighten all bolts. Clean the guides and lubricate them.
1.4 ELEMENTS ON THE PIT BOTTOM
1.4.1 PISTON PEDESTAL
See sling manual
1.4.2 GUIDE BRACKETS OF THE PISTON
See sling manual
A
A // B // C // D
B CD
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2 HYDRAULIC MATERIAL
If not contrary to the specific instructions of the materials supplied, for a correct and safe installation of the hydraulic material please refer to the following procedure:
2.1 PISTON
2.1.1 INTRODUCTION OF PISTON IN THE WELL
The following situation could occur while inserting the piston in the well: A) Insertion into the well from the open roof. B) Insertion from the lift door.
WARNING The operators are advised to use the safety belts and adequate lifting devices during these operations
2.1.1.1 INTRODUCTION INTO A WELL WITH OPEN ROOF
If the well that will host the lift has an open roof : • Find a crane. • Sling the piston with the two ropes and insert it into the well. • Perform the operations described at paragraph § 2.1.2.
2.1.1.2 INTRODUCTION FROM A LIFT-DOOR
• Position the piston so that the headroom is oriented to the access of the well. • Lift it on two wood blocks and make the ropes pass under it. • Once inside the well the piston will lay on the floor, set a wood board or something else on the laying area
to protect the end. • Verify that inside the well there are the necessary fittings to introduce and correctly fix the piston (cross-
beam, guide-brackets, etc.) • Perform the operations described at paragraph § 2.1.2.
2.1.2 POSITIONING OF PISTON INTO THE WELL
Position the tackle in the position prescribed by the builder into the well and ensure that the ropes and the tackle are fit to support the weight of the piston.
Prepare two ropes or belts with an adequate capacity and minimum length 1.5 m.
Sling the piston with the two ropes as indicated in figure. Hook the four ends of the ropes to the safety hooks of
the tackle. Bind the control ropes at about 50 cm from the lower end
of the cylinder.
The operators in charge of the following actions, must be at least two: an engineer that manages the operations and is responsible for the activities performed (a) and one or more assistants (b) (See figure).
The technician (a) activates the tackle until the lifting ropes are almost tensed, to avoid letting the piston fall into the well.
The operator (b) gathers one end of the rope without binding it or winding it around any part of the body, so that he could let it go in case of danger.
Slowly lift the piston until the lower part rises from its support. The technician (a) gradually lifts the piston from the well while the operator (b), at an adequate distance from
the well, tenses the end part of the piston, and let it slide on the protection, so that it does not damage neither the piston nor the floor, until reaching the sill of the well. Stop the technician (a) to avoid letting the piston fall into the well.
Move the piston held by (b) to the well avoiding traverse.
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2.1.3 PISTON INSTALLATION
WARNING Before to install the piston you must place the pedestal and the guide brackets for the piston. Verify that the dimension of the pedestal is in according with the layout draw.
• Insert the piston into the baseplate of the lower guide-bracket (§ 2.1.3.1) and maintain the lifting ropes slightly tensed.
• Fix and plumb the piston according to the project drawing.
• Pay attention that no foreign matters get into the hole of the central screw, remove the stop bracket.
• Tighten the headroom side fixing screws and the central screw (see figure)
• Verify that all headroom fixing screws have been tightened.
• Verify that the piston is straight and fix it. • Block the piston with the collars on the guide-brackets
(§ 2.1.3.1). • Remove the lifting ropes and move the hook of the
crane out of the working area. • In case of multi-stage piston perform the seams
according to the indications contained in the packaging and wait until 4 hours before filling with oil.
2.1.3.1 INSTALLATION FO THE GUIDE BRACKETS FOR THE PISTON
WARNING To install the guide brackets for the piston refer to the sling manual
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2.2 HYDRAULIC POWER UNIT
2.2.1 POSITIONING OF THE POWER UNIT IN THE MACHINE ROOM
The GL system, apart from a standard machine room, can also be supplied with different types of machine room cabinet. For all cabinets the open swing panels do not define a sufficiently wide working area. Therefore it is necessary to define the working area with the safety chains supplied. If necessary, assemble the panels following the instructions of the supplied cabinet.
2.3 MRL HYDRAULIC POWER UNIT
2.3.1 INTRODUCTION OF HYDRAULIC POWER UNIT IN THE PIT
WARNING The insertion of the hydraulic power unit in the pit is made from the lift door and with the oil tank empty. The operators are advised to use the safety belts and adequate lifting devices during these operations.
Fix the oil collection tank to the guides according to the project drawing and as shown in the figure.
Place the tackle in the position prescribed by the builder into the well and ensure that the ropes and the tackle are fit to support the weight of the hydraulic power unit.
Prepare two ropes or belts with an adequate capacity and minimum length 1,5 m.
Sling the hydraulic power unit fixing the two ropes to the rings, as showed in figure. Hook the four ends of the ropes to the safety hooks of the tackle. Bind the control ropes at one of the handles of the hydraulic power unit. The operators in charge of the following actions, must be at least two: an engineer that
manages the operations and is responsible for the activities performed (A) and one assistant (B) see figure.
The technician (A) activates the tackle until the lifting ropes are almost tensed, to avoid letting the power unit fall into the pit.
The operator (B) gathers one end of the control rope without binding it or winding it around any part of the body, so that he could let it go in case of danger.
Slowly lift the hydraulic power unit until the lower part rises from the floor. The technician (A) gradually lifts the hydraulic power unit from the well while the
operator (B), at an adequate distance from the well, tenses the hydraulic power unit, and let it slide, so that it does not damage neither the hydraulic power unit nor the floor, until reaching the sill of the well.
Stop the technician (A) to avoid letting the hydraulic power unit fall into the well.
Move the power unit held by (B) to the well avoiding traverse.
Place the hydraulic power unit to its correct position and maintain the lifting ropes slightly tensed.
Place the hydraulic power unit according to the project drawing on the oil collecting tank previously fixed to the guides.
Remove the lifting ropes and move the hook of the crane out of the working area.
2.3.2 FIXING OF THE MRLT POWER UNIT TO THE GUIDES
Fix the tank to the guides following the instructions of its manual.
2.3.3 CONNECTION OF HYDRAULIC PIPES
Connect fittings and piping following the instructions of the manuals of the hydraulic components supplied.
WARNING Ensure that there is no dirty inside the tube. These impurities could damage the sealing of the piston and of the valve block and inhibit the correct operation of the plant.
òò
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2.3.4 HYDRAULIC POWER UNIT FIRST FILLING
For a correct and safe filling, refer to the instructions of the manual of the supplied power unit.
NOTE The necessary quantity of fluid/oil is showed in the technical data of the system (see the flow chart or the LAYOUT DRAWING and if necessary look for the kind of fluid/oil to use into the lift technical data).
NOTE Use only clean and new oil to fill the tank, and verify that there is no water into the oil. Otherwise it becomes turbid and opaque.
If the power unit has a submerged motor, use the necessary quantity of fluid to cover the engine and the pump. If the power unit has a dry motor, , use the necessary quantity of fluid to cover the pump filter.
WARNING Interrupt the filling operations and install the sling and the control panel.
2.4 HYDRAULIC POWER UNIT FINAL FILLING
Ended the installation of the electrical connections, start again with the filling following the instructions of the hydraulic power unit.
WARNING During the final filling operation it is necessary to control that the oil never reaches the minimum level. In this case, immediately stop the motor and top it up. The motor (if submerged) must always be covered by oil to avoid burning.
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3 SLING AND ROPES
For assembly, refer to the instructions of the manual of the supplied sling.
3.1 INSTALLATION
3.1.1 OIL PIPE
Connect the valve to the piston and the pipe to the piston valve, following the installation instructions of the hydraulic material.
Rotate the piston until to have no interferences between valve, pipe, ropes and car frame.
3.1.2 DRIVING LEVERS OF THE SAFETY DEVICES
WARNING Lever and plate shall be free to move.
3.2 ROPES
3.2.1 PLACING ROPES
Place the middle of the ropes into the pulley groove without to connect the
ends to the fixings rope. Do not remove the safety protection.
3.2.2 ROPING OF THE SYSTEM
For a correct and safe roping of the system, if not differently indicated in the manual of the supplied sling, refer to the following procedure:
Pass one of the rope end into the wedge socket termination. Fix the rope with the supplied clamps. Hook the wedge socket termination to the fixed connection element of the ropes
on the bottom pit bar. Pass the other end of the rope into the wedge socket termination and fix it with the clamps. Hook the second wedge socket termination to the ropes connection on the car frame. Repeat the same procedure for all ropes. Move the plate under the rope fixings to the horizontal position with the car
empty. The rope fixings shall to touch the plate but not make noise during the travel of the lift.
Fixing of the releasing rope Fixing ropes in pit Fixing ropes on car frame
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3.2.3 TENSIONING OF THE SYSTEM
For a correct and safe tensioning of the lift please refer to the following procedure: • Fix the maintenance keyboard to the car frame post. • Position the bottom of the car or a provisory plan on the car frame and fix it with bolts. • Load the car bottom with at least 200 kg. • Raise the car frame unwinding the flexible cable. • Once reached half of the travel, fix the flexible cable with the bracket to the guides and unwind the cable
portion remaining into the well, so that it can follow the upward and downward travel without rolling up. • Send the piston to the up stroke and compare the measures with the project drawing. Measure the upper
extra-travel of the car and adjust the ropes in compliance with this length. • Move the car to the lowest station and compare the measures with the project drawing. • Install the ropes releasing device.
NOTA Asymmetric wedge socket UNI EN 13411-6
X Max = 75% Y
NOTA Symmetric wedge socket UNI EN 13411-7
X Max = 40% Y
3.3 TESTS
3.3.1.1 TESTS FOR STANDARD SYSTEMS
þ
• Verify that distance between spring and car frame is the one indicated to plan • Verify that distance between shoes is according with the one indicated to plan • Verify that the buffers are perfectly perpendicular and corresponding to the pedestals under the
car frame.
3.3.1.2 TESTS FOR SYSTEMS WITH HEADROOM AND/OR PIT REDUCED
WARNING Before to move the lift is compulsory to install the car stop mechanical device.
NOTE To make easy the installation, the car stop mechanical device (LCSMD) should be assembled after the sling.
4 CAR AND DOOR OPERATOR
For the installation refer to the instructions of the manual of the supplied car. If necessary, install panels, roof and cabin doors after the landing doors and the electrical material.
WARNING Do not remove the protection film from the exposed side of angles, uprights, roof, panels and accessories until specified, since the film preserves their integrity. WARNING The sill shall be flush. WARNING Protect the covering floor (for example using a cardboard) to preserve its integrity during the assembly
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5 LANDING DOORS
For the installation refer to the instructions of the manual of the supplied doors
WARNING If the emergency devices (remote push-button) are placed inside the upright verify that the door with the above devices is installed at the correct floor (normally the lower landing floor).
6 ELECTRICAL MATERIAL
For a correct and safe installation, follow the instructions of the ELECTICAL PART MANUAL and the WIRING DIAGRAMS, paying attention to the following:
6.1 WELL AND MACHINERY ROOM
6.1.1 INSTALLATION OF THE CONTROL PANEL OUTSIDE THE WELL
WARNING The distance between the upper side of the control panel and the floor level of the machine room should be minor or equal of 2000mm.
Hang the control panel to the guide rails in the cabinet (MRL-MC), or fix it, in the machine room (MR) or on the side of the floor door (MRL2), with dowels or bolts provided, following the instructions of the panel supplied.
6.1.2 INSTALLATION OF THE CONTROL PANEL INSIDE THE WELL
WARNING To prevent any damage or injury, before moving the lift for all requested actions, always verify that the door of the control panel is closed.
Fix the control panel to the guide rails in the well with the supplied T-clips and bolts, following the specific instructions of the materials supplied
6.1.3 WELL ELECTRICAL LINES
Perform the electrical connections complying with the WIRING DIAGRAMS and with the ELECTRICAL PART MANUAL.
Install, following the instructions of the ELECTRICAL PART MANUAL supplied:
The trunks; The connection cables, used to make easy the connections on the car
roof and in the machine room; The flexible cables, used to take all electrical lines from control panel
to the car roof.
WARNING The flexible cables should be fixed (A) to the wall in the upper middle part of the well, in a position such as they do not touch (B) the car and (C) the pit. WARNING Do NOT cut the exceeding cables
6.2 ELECTRICAL CONNECTIONS
The connection operations are extremely easy: the devices are wired at the manufacturer and the outputs are joined to the connectors.
To perform the connections it is enough to match the connectors with the same initial. If you need to move the system, following the procedure shown in the installation manual of the control
panel, it necessary to connect at first the power unit and after the main power complying with the WIRING DIAGRAMS, the ELECTRICAL PART MANUAL and the POWER UNIT/DISTRIBUTOR MANUAL.
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6.2.1 CONNECTION OF THE FINAL LIMIT SWITCH
6.2.2 CONNECTIONS OF THE ELECTRICAL SWITCHES AND WELL INFO
Install switches and magnets respecting the instructions of the WIRING DIAGRAMS and with the ELECTRICAL PART MANUAL.
6.2.3 CONNECTIONS OF THE CAR AND CAR DOOR OPERATOR
NOTE Connect the car and the door operator only after the connection of all the other parts.
6.2.3.1 CAR PUSH-BUTTON STATION 6.2.3.2 CONNECTIONS ON THE CAR ROOF
Make the electrical connection of the push-button panels according to the WIRING DIAGRAMS
Connect the cables to the terminals of the box on the car roof complying with the WIRING DIAGRAMS Particularly, pay attention to connect correctly the following terminals:
- The releasing ropes safety electrical switch
- Well sensors - Car lighting
6.2.3.3 DOOR OPERATOR AND DOOR SWITCH
Connect the cable to the terminal of the car roof electrical box complying with the WIRING DIAGRAMS.
6.2.4 CONNECTIONS OF THE LANDING DOORS
6.2.4.1 PUSH-BUTTON PANELS
Perform the electrical connections of the push button complying with the WIRING DIAGRAMS.
6.2.4.2 SAFETY SWITCHES
Perform the electrical connections of the safety switches complying with the WIRING DIAGRAMS.
6.2.5 CONNECTION OF THE WELL LIGHTING
Install the well lighting, referring to the instructions of the MANUAL OF THE ELECTRICAL PART supplied and in accordance with the requirements of the current regulations with particular reference to the EN 81-20.
6.2.6 CONNECTIOS OF THE DEVICES
To determine the installed devices you should refer to the MANUAL OF THE ELECTRICAL PART supplied and perform the electrical connections of the safety switches complying with the WIRING DIAGRAMS
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7 SAFETY DEVICES AND SIGNS
7.1 SAFETY DEVICES
For installation, refer to the instructions in the installation manual of the devices supplied.
× Parts drawn not in the correct position for reasons of visibility.
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7.2 NOTICES, MARKINGS AND OPERATING INSTRUCTION
WARNING All labels, notices, markings and operating instructions shall be readable and easily understandable. They shall be placed in a visible position and written in the language of the country where the lift is installed.
This notices shall be installed as shown in the instructions of the devices supplied.
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8 ADJUSTMENTS
Make the necessary adjustments and settings on the piston and distributor (3010 or NGV). For the operations to be carried out, refer to the instructions of the installation manual of the devices supplied.
8.1 LUBRICATION AND TOPPING UP
The hydraulic power unit does not need to be lubricated since all its components are sunk in oil, but it is necessary to periodically top the oil up. For a correct and safe operation, please refer to the instructions of the tank supplied.
WARNING The oil topping up must be performed by previously trained technicians.
9 EXAMINATIONS AND TESTS
At the end of the installation it’s necessary to proceed with examinations and tests of the lift. Carry out the tests indicated in chapter 6 of the EN81-20 standard, referring the instructions of the system
putting on service manual.
10 FINAL OPERATIONS
10.1 ADVICES
Verify that non authorised personnel should not enter into the machine room (always keep it locked) Verify that all protections are mounted on the power unit (electrical connections covering, tank). Once filled the tank or in case of topping up ensure that no oil stains remain around the hydraulic power unit.
WARNING Never put the hands on the silencer, on the valve unit and on the oil tank, since the temperature of these components can exceed 70°C (danger of burning).
Do not lean on nor sit on the hydraulic power unit. Do not set containers with liquids on the power unit or on the clamp board (danger of short-circuit). Always inform the responsible of the arrival. Before setting the plant out of work, hang the service shields to
every station door. Do not leave components, parts, tools, oil or grease stains on the floor. Pay attention to any contact when operating on rotating devices or on devices that remained under tension.
WARNING Never exclude the safety circuits.
Before moving the lift-car, verify the correct operation of the emergency button on the roof. During the movement tightly support with the post or other parts of the lift-car and in any case not with the ropes. Pay particular attention during the upward travel. At the end of the operations, please verify that all protections have been mounted and lock the machine room.
10.2 FINAL OPERATIONS
At the end of the installation it is necessary to perform a test of the plant, in compliance with the standards in force. • This test is performed by the installer (if qualified by a certified Quality System in compliance with UNI EN
ISO 9000) or by a notified organism according to the Lift Standards If the test gives a positive result, it is necessary to communicate that the installation has been performed, indicating:
- The address of the building. - The speed, the rated load, the travel, the number of stations and the starting type - Name or name of the company of the installer. - Copy of the compliance certificate. - Name of the company in charge of the maintenance of the plant - Name of the individual in charge of the periodical maintenance interventions on the plant
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FLUID DYNAMIC EQUIPMENTS AND LIFT COMPONENTS
GMV SPA VIA DON GNOCCHI, 10 - 20016 PERO – MILANO (ITALY) TEL. +39 02 33930.1 - FAX +39 02 3390379 STRADA PER BIANDRATE, 110/112 - 28100 NOVARA (ITALY) TEL. +39 0321 677611 - FAX +39 0321 677690 HTTP://WWW.GMV.IT - E-MAIL: [email protected]
FILE: GLF-MI-10991458EN-200.DOCX - (J2)
