AM-09.11.006 en F.1 Main [PDF]

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KONE Traction Elevator Installation Instruction

ROPE REPLACEMENT FOR LOW AND MID RISE ELEVATORS KONE © AM-09.11.006 All (F) 2009 rights 2011-09-12 Traction KONE reserved. Corporation Elevator

1053665.wmf

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AM-09.11.006 (F) 2011-09-12

KONE Traction Elevator Installation Instruction

Confidentiality Notice This proprietary and confidential KONE document is provided to you only for purposes of reroping elevators using RPD tool and it may not be used or its contents disclosed for any other purpose without KONE's prior written permission. Neither this document nor its contents may be copied or disclosed to third parties for any reason. KONE reserves the right to prosecute any breach of this obligation. Authorization Notice This publication is for informational purposes only. All persons participating in the installation and/or maintenance of KONE equipment and using these instructions must be qualified to perform such work, are required to have received equipment specific training as specified by KONE and must have KONE Corporation's authorization to install and maintain KONE equipment. DISCLAIMER OF WARRANTIES AND LIABILITIES KONE reserves the right at any time to alter the product design, specifications and procedures reflected in this document. NO STATEMENT CONTAINED IN THIS DOCUMENT IS TO BE CONSTRUED AS A WARRANTY OR CONDITION, EXPRESS OR IMPLIED, AS TO ANY PRODUCT, SPECIFICATION OR PROCEDURE, ITS MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OR QUALITY, OR AS A MODIFICATION OR REPRESENTATION OF THE TERMS OF ANY PURCHASE AGREEMENT. KONE DISCLAIMS ANY LIABILITY RESULTING FROM OR IN CONNECTION WITH THE USE OR DISCLOSURE OF INFORMATION IN THIS DOCUMENT. KONE HAS NO LIABILITY FOR TYPOGRAPHICAL OR OTHER ERRORS OR OMISSIONS CONTAINED IN THIS DOCUMENT OR ANYONE'S INTERPRETATION OF THE INSTRUCTIONS. THE USER OF THIS DOCUMENT ASSUMES ALL RISKS ASSOCIATED WITH THE USE OR DISCLOSURE OF THIS DOCUMENT. Trademark Notice "KONE, MonoSpace, MiniSpace, EcoDisc, TranSys, Alta, KoneXion, KONE ECO3000 and all other product names are trademarks or registered trademarks of KONE Corporation in various countries."

Copyright Notice Copyright © 2009 KONE Corporation All rights reserved. No part of the contents of this document may be copied, reproduced or transmitted in any form or by any means, or translated into another language or format, in whole or part, without prior written permission of KONE Corporation.

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LIST OF CONTENTS 1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1 Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.1 General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.2 Installation method safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.3 Personal safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.4 Protecting work areas with safety fences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.5 Floor protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.6 Public safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.7 Elevator safety items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3

SITE REQUIREMENTS AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.1 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4

ROPE REPLACEMENT PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.1 Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.2 Measuring the counterweight overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.3 Checking and adjusting rope guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.4 Putting RPD and tools on car roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.5 Positioning RPD for rope replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.6 Securing car and counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.7 Friction test before use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5

ROPE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.1 Rope weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.2 Reducing rope friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.3 Rope replacement schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6

ROPE REPLACEMENT 1:1 (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 6.1 Replacing ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 6.2 Securing new rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7

ROPE REPLACEMENT 2:1 (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 7.1 Replacing ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 7.2 Securing new rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8

ROPE REPLACEMENT 2:1 (MONOSPACE) AND 4:1 (TRANSYS) . . . . . . . . . . . . 39 8.1 Replacing ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 8.2 Securing new rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

9

ROPE REPLACEMENT 2:1 (PU/PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 9.1 Replacing ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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9.2

Securing new rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

10

ROPE REPLACEMENT 1:1 (PU/PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 10.1 Replacing ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 10.2 Securing new rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

11

RELEASING THE CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

12

REMOVING RPD FROM SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

13

FINALIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

14 APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 APPENDIX A. Rope inspection criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 APPENDIX B. Checking operation of the rope pulling device. . . . . . . . . . . . . . . . . . . . . . 56 APPENDIX C. Making rope joint with the crimping tool . . . . . . . . . . . . . . . . . . . . . . . . . . 57 APPENDIX D. Installing friction releasers (PU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 APPENDIX E. Working from scaffolding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 APPENDIX F. Site survey before rope replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 APPENDIX G.Rope pulling device inspection before use . . . . . . . . . . . . . . . . . . . . . . . . 65 APPENDIX H. Site survey after rope replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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1

GENERAL This document describes rope replacement methods for low and mid rise elevators using the rope pulling device (RPD). The device assists in the pulling and feeding of rope during this procedure, so that the work is safer and not so physically demanding. The use of the device reduces the need for manpower to a maximum of 2 fitters per replacement. If the machine is being replaced at the same time as the rope replacement, take care to calculate the rope length based on the position of the new machine and on the diameter of its traction sheave. As a proactive measure, the counterweight pulley assembly including the bearings must be replaced along with the ropes.

WARNING These methods can be used provided that: • Maximum travel height is 200 m. • Diameter of suspension ropes is 8, 10 or 13 mm. • Service drive is available. • The rope fixings permit adjustments in the rope length, or can be replaced so as to permit adjustments. • Ropes are in suitable physical condition for this method. • Power supply is available to power rope pulling device, for example, power supply on top of car may be used. • A site survey has been previously made to evaluate the site conditions and safety when using the method and tools, including the rating and position of lifting and hanging points used, the weight of the elevator components lifted and the tooling needs.

WARNING RPD is intended to be used only for rope replacement using the methods described. Never use the device for other purposes. Use of grinder for rope cutting is not allowed as it involves hot works.

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1.1

Related documents Safety and product related information is contained in the following documents. It is mandatory to follow the AM safety instructions and safety related information during the rope replacement. • AM-01.03.001 Use of Fall Arrest Systems on Elevator Construction And Modernization Sites • AM-09.06.002 Rope Handling During Installation • AS-09.06.002 Rope Faults And Criteria for Replacement • AM-01.05.012 Rope Pulling Device Handbook • AS-08.03.004 Replacing counterweight pulley

2

SAFETY Related safety instructions: • AM-01.03.001, Use of fall prevention systems when working on elevators and escalators • Site safety audit Take time to familiarise yourself with the elevator. This is particularly important when working on other manufacturer’s equipment where the level of training and information available may vary. Ensure you have adequate information to do the work and fully understand all the possible effects of your actions. - IF IN DOUBT - ASK. Talk to your supervisor if you have any doubts about the working method or safety related issues. Any local variations to the method must be supported by a local method statement and risk assessment.

2.1

General safety • Introduce yourself to site agent or person responsible for the building. • Ensure that the site safety audit has been carried out. • When working in buildings that are occupied, ensure therefore that your work cannot cause a safety hazard to other people in the building. • Place warning and information signs as required. • Use barriers whenever necessary. • Take care that the communication between fitters and between the fitters and other building users is effective.

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• When two or more persons are working on the same elevator, one person should be in charge of control and access keys and safe and appropriate car movements. When the car must be moved, the responsible person must inform the other(s) of the intended car movements beforehand. • Agree the appropriate safety measures with the building owner or his representative. • Report any defects or other dangerous conditions to your supervisor. • Ensure that ALL DOORS (machine room, pit, access and inspection doors) are locked at all times when unoccupied by authorised personnel. • Cover any unused holes in the machine room floor with steel plates. • Install temporary screens in common elevator shafts and machine rooms, where adjacent elevators are running and there is no dividing screen at the level you are working. • In machine rooms where adjacent elevators are running ensure that all work areas are protected with barriers. • Liaise with the building owner or his representative in cases where there are elevator groups where adjacent elevators are running and passenger traffic in the lobby area may interfere with your work. Ensure that all work areas are protected with barriers and that access routes for other building users are safe. • Know the rules applicable to the building (location of fire fighting equipment emergency exits, etc.). • If you suspect that hazardous materials are present, stop the work. Inform your supervisor who will arrange for a specialist to check the installation. Disposal of hazardous material is always a specialist’s job. Never attempt to do this yourself. • Hot work is not usually necessary and should be avoided wherever possible by applying tools and methods that do not cause risk of fire. If hot work cannot be avoided, local work procedures for the necessary routines and equipment must be followed. • When using cleaning fluids and other solvents, ensure that the area is well ventilated and that fumes cannot become a nuisance or hazard to other building users. Use only approved cleaning fluids and follow the manufacturers instructions.

2.2

Installation method safety Ensure that a site survey and risk assessment have been made to ensure the safety of the method, tools, lifting points, etc., in accordance with local regulations. Check that the ropes are in suitable condition to safely perform the pulling by RPD (pulling force = 24 kN, 240 kg). See Appendix A. Ensure that all open landings or openings are fitted with secure imperforate barriers or have hoarding erected for protection. Never leave an open void unprotected and unguarded. Do not work on scaffolding before it is stabilized. Refer to Appendix: Working with scaffolding. If you cannot reach the top of the shaft from the car roof, you must not use ladders or similar tools to do any work, refer to the site survey. When handling the ropes, ensure that the cut or free rope end do not cause injuries or damages.

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2.3

Personal safety Safety gloves, overall, safety shoes with ankle protection, safety helmet, safety goggles, dust mask, hearing protection and fall protection equipment are provided for your personal protection. USE THEM AS REQUIRED.

Mandatory Safety helmet

Hearing protection Safety harness and associated equipment

Sign

Personal protection signs Mandatory Sign Overall

Safety shoes with ankle protection Safety goggles

Mandatory Dust mask

Sign

Safety gloves Rubber gloves First aid kit

• Ensure that tools and other equipment are in a serviceable condition. Take special care to check the condition of electric cables, plugs and sockets. • Whenever there is a possibility of falling any distance and there is a risk of injury an adequate fall prevention system must be used. Refer to AM-01.03.001. • Lock and tag all power supplies and verify that they are safely de-energised, before starting any electrical work. • Avoid working in a building that is otherwise unoccupied. If you are working alone, ensure that a responsible person periodically monitors your welfare. • Before riding on the car roof, check that required safety space is available at the elevator shaft top and the inspection drive and stop buttons operate correctly. • If buffers are to be replaced, do this also before riding on the car roof. • Do not work under suspended loads. • Do not work at different levels in the same elevator shaft. • When working in common shafts and it is not possible to switch off adjacent elevators. Ensure adequate fall protection system is in place and use temporary sheeting between the running lifts and the lift having the rope replacement. • Use correct manual lifting techniques. Use hoist for all heavy components. The words WARNING and CAUTION are used to highlight possible hazardous situations to persons or equipment as follows: WARNING CAUTION

This is to warn about serious safety hazards. This is to warn about damage to equipment which may also involve a safety hazard.

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KONE Traction Elevator Installation Instruction

2.4

Protecting work areas with safety fences Entrance protection must be: • Lockable • Openable without key from inside • Imperforate or at minimum preventing contact with exposed elevator machinery

No work at the landing. Closed landing door.

2.5

Work on the car roof. Closed landing door or car at landing and fence closing the landing door area.

Floor protection Cut floor protection boards to required size and place them in position, fix them by using hazard warning tape (yellow & black). Areas to be protected agreed with building owner. Flooring outside landing entrances and route from bottom floor entrance to building entrance must be protected to avoid damaging existing floor materials.

2.6

Public safety • • • •

Keep the working area closed to the public at all times. Keep the area outside the working area clean. Store materials in designated storage areas. Not on landings or in working area. In residential buildings keep to the agreed daily working schedules to avoid unnecessary disturbance to residents. • When transporting material into the elevator shaft, use additional safety fences or guarding, if there is a danger that outsiders can enter the working zone in front of the access landing level.

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2.7

Elevator safety items The following list includes items checked during the site survey, ensure that all of them have been checked. • Follow all of the safety rules and instructions concerning general work with elevators. • Always assess the risks of the selected methods according to local conditions and company rules. Local risk assessment has to be made if there are deviations. • Use the correct manual lifting techniques. • Do not work at different levels in the elevator shaft at the same time. • When the ropes are slack or removed the car must always be securely held by two different supports. A secured safety gear and parking chain are to be used. The parking chain is attached between reliable fixing point in the shaft and car sling. • Be careful when opening screws and nuts, for example, when adjusting or removing rope guards, to prevent items falling into the pulley housings or into the pulley grooves. • Check that the counterweight guide rails are strong enough to keep the counterweight in position. • Check that the car guide rail brackets are strong enough to hold the car, men and tools securely in position when parking chains are attached on both sides and the safety gear is engaged. If they are not, check if guide rail clamps can be used. • Check that the overspeed governor, safety gear and its synchronising elements are fully operative. • Check that the guide rails are clean. • Check the operation of all safety devices. • Check that the area around the rope path is free from sharp edges or components which could damage the rope when it is slack. • Check that the car roof is strong enough to carry two men with tools and, where applicable, is able to carry the rope weight too. • Check that there is sufficient headroom when the counterweight is on the compressed buffer: The safe height = 1.0 m + (0.035 x velocity2) m. • Determine the car weight. The maximum weight of the car, travelling cable and compensation ropes or chains must not exceed the load rating of the weakest lifting or supporting component. Select hoisting equipment accordingly. • Estimate the counterweight mass. The pit prop must be rated to support the maximum weight of the counterweight. • Maximum travel: The selected method and rope lifting tools must be selected so that the lifted or supported rope weight is within the limits of the load rating of the tools. • Maximum headroom: Do not stand on a ladder to reach the slab from the car roof. Use pull ropes instead. • When working at the top of the shaft ensure that you have sufficient space to safely exit from the car roof. It is recommended that the maximum height from the landing level to the top of the door operator should not exceed 1.5 m.

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3

SITE REQUIREMENTS AND TOOLS

3.1

Site requirements • Site specific method statement must be completed, including site specific risk assessment. • Transportation of equipment must be planned. • A suitable secure material storage area must be agreed with the building owner. • Clear and unobstructed access routes must be defined. • Adequate lighting must be arranged, temporary or permanent. • Adequate power supply available, temporary or permanent. • Rope guards’ clearances can be adjusted to 5 mm. • Rope bottles using wedges should be in use to anchor the ropes. If not, the existing rope fixings should be changed, so as to permit rope adjustments. Never re-use babbitted rope anchorages. • Adequate lifting points should be available, or temporary solutions possible. • Floor protection material available. • Tools and equipment available. • Before commencing the rope replacement work the site survey and safety check list must be filled.

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3.2

Tools Rope pulling device (RPD) and transportation box Pcs. 1

Tool Rope pulling device Weight: approximately 60 kg

Figure

1055293.wmf

1

Transporting box, 31431 KM50037403 Dimensions: 845 x 520 x 560 mm Weight with RPD: 110 kg

NOTE! When the transport box cover is turned upside down, it serves as an unwinding device for rope reels that weigh under 30 kg.

1060033.wmf

Electrification unit, control pendant and power cables (2 pcs.)

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KONE Traction Elevator Installation Instruction

Figure

Crimping tool, KM50037404 IKH 7378

Sleeves for support bearings Drawing number: 936105 KM936105H01 for 8-10 mm ropes, 9 mm KM936105H02 for 13 mm ropes, 12 mm

9 mm

8

Tool

12 mm

Pcs. 1

9 mm sleeves installed in place 1058638.wmf

25 of each size

Rope joint Drawing number: 935406 KM935406H01 for 8 mm rope (yellow) KM935406H02 for 10 mm rope (green) KM935406H03 for 13 mm rope (red)

1

Ratched spanner 30 mm IKH 2230

1063251.wmf

• Service book • AM-01.05.012 • AM-09.11.006 1063185.wmf

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KONE Traction Elevator Installation Instruction

Tool box and content Pcs. 1

Tool Box for rope collector and pipes, 46794 KM50037405 Dimensions: 645 x 645 x 215 mm Weight with content: 25 kg

1

Reeling device Drawing number: 928397 Use plastic bag in the device Pipes for reeling and unwinding device KM937232G01 for 2 m pipe KM937232G02 for 3 m pipe Drawing number: 937232 Positioning rope, KM975729G01 Drawing number: 975729

Figure

1058658.wmf

2

1

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KONE Traction Elevator Installation Instruction

Additional tools (delivered locally) Pcs. 1 or 2

2 1 1 2 1

1 1

Tool Hoisting equipment Capacity rated to car weight. Supplied locally. Lifting and manoeuvring chain length in accordance with the needed lifting height and weight. Hoisting chains: Capacity rated to car weight. Chain Extension chain Shortenable chain Car securing chain Capacity rated to car weight. Chain hoist, capacity 500 kg For suspending rope pulling device.

Figure

1007087.wmf

1007078.wmf

1007070.wmf

Chain or fabric line with protection For hanging RPD from hoist (500 kg). Rope cutter, 8 - 13 mm, KM278691 Baudat HCS22

1058871.wmf

3

Friction releaser, KM926559G01 Drawing number: 926559

1051623.wmf

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KONE Traction Elevator Installation Instruction

Pcs.

1 or 2

Always use a wrap cable tie to secure the grip. Pit prop, KM1355865 or KM50020169 Rated for counterweight weight. Supplied locally.

Figure

1011816.wmf

1051621.wmf

2

Tool Rope grip, KM276452 To secure the rope to be changed, to prevent it from falling (in MonoSpace 2:1 and Transys 4:1 elevators).

G-clamp For securing the counterweight prop. 1007097.wmf

1

Unwinding device Drawing number: 504610G01

1007076.wmf

1

Working stool, KM265173, ATT-75

1007089.wmf

Scaffolding or work platform, if needed Height enabling reach to counterweight rope hitch / diverter. Protective covering for landing area Locally delivered.

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KONE Traction Elevator Installation Instruction

Pcs.

Tool Barriers and entrance protection

Figure

In accordance with local codes and requirements. NOTE! Barriers must be secured.

Protective sheeting to segregate elevator from other elevators in common elevator shaft, if needed. Normal hand tool set

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KONE Traction Elevator Installation Instruction

4

ROPE REPLACEMENT PREPARATIONS WARNING The following chapters give a description of general and specific rope replacement procedures for PT, PU, PS, MonoSpace and TranSys elevators. Due to the varied nature of the elevators it is essential to pre-plan the roping operation, communication rules and individual personnel responsibilities in each individual case. The rope replacement is to be carried out by authorised persons only.

4.1

Safety procedures • Check that there is no-one inside the car or in the lift well during the rope replacement. • Disconnect the landing calls using the interface, if possible, so that the rope inspection will not be interrupted and to avoid trapping passengers in the elevator. • Before going to the car roof, push the car roof stop button down. Turn the inspection drive unit to inspection drive before releasing the stop button. • Before commencing the rope replacement work fill in the “Site survey before rope replacement”-list. Refer to appendix. • After commencing the rope replacement work fill in the "Site survey after rope replacement"-list. Refer to appendix.

4.2

Measuring the counterweight overtravel Step 1

Action Take the car to the topmost floor.

2

Check that the car is at floor level on the topmost floor. Place warning and information signs at every landing. Place entrance protections at top and bottom landings.

3

Note Transport all tools and roping material to the topmost floor.

Ensure that the floors are protected from possible damages from oil in the ropes.

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KONE Traction Elevator Installation Instruction

Step 4

5

6

Action Go to bottom floor, exit lift and give car call to topmost floor. Ensure the car is at floor level. Press pit stop button.

Note

Place barrier in front of door. Place door holding device to ensure the door will not close while you are in the pit.

Close doors and call the elevator. Ensure the elevator does not move. Open doors and enter pit. Check if there are any extension pieces of the counterweight buffer stored in the pit or machine room. Re-install the extension pieces, if any.

1063252.wmf

7

8

9

Measure and record the existing overtravel measurement (A). Check the correct overtravel measurement (B) from the layout drawings. The car must be lifted to measurement X = B - A + rope stretch + safety gear functional measurement, so that it hangs on the safety gear. If no layout drawing is available, check with your supervisor, he will define the correct measurement (see AM09.13.003 and site survey form). Write down the overtravel (B) on the elevator shaft wall or counterweight screen. This is to help maintenance technician. Exit pit and release stop button.

© 2009 KONE Corporation All rights reserved.

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Remove door holding device and close the door.

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KONE Traction Elevator Installation Instruction

4.3

Checking and adjusting rope guards Step 1

Action Check and adjust the clearances of the rope guards in the shaft and in the machine room. All rope guards should be 4-5 mm from the rope. The space must be close enough so that the ropes do not fall off from the pulleys and the joint passes the guards without getting stuck.

Note

Check that all guards are secure. Remove the guards if they cannot be adjusted. If there are pulleys on the counterweight, drive the car to meet the counterweight.

If there are pulleys under the car, drive the car near to the lowest landing. Go to the pit to check the clearances on the car pulley rope guards.

Use the work stool to reach pulleys. NOTE! Ensure you cannot be trapped in the pit. Use door holding device to keep the door open. If there are pulleys at the top of the shaft, drive the car to the top and check the rope guard clearances.

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1051588.wmf

If it is necessary to go to the headroom, ensure that there is always someone on the landing monitoring the work in the shaft.

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KONE Traction Elevator Installation Instruction

4.4

Putting RPD and tools on car roof WARNING There is a high stored energy in the tensioned springs (A). If the central bolt (B) is opened unintentionally it may release the spring (A) and shoot it with a high speed. When turning the spring adjustment nut (C) ensure that the central bolt (B) does not rotate. When replacing or turning the disks, always: • Release the spring tension by opening the spring adjustment nut (C) and securing screw (F) first. • When re-assembling, add thread locker Loctite 248 to the threads of the central bolt (B) and disk fixing bolts (E). Note that during the normal operation of the rope pulling device the central bolts (B) are rotating with the disks.

A

A B

E B

Step 1

C

F 1063187.wmf

Action Move the car to hang the chain hoist from the point at the top of the shaft defined by the site survey. For example, from a point in the shaft roof, a support beam, or a chain suspended from the machine room.

© 2009 KONE Corporation All rights reserved.

C

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Note WARNING! Ensure that you have located the correct point and you are using the chain hoist defined in the site survey and rated for the lifting load.

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KONE Traction Elevator Installation Instruction

Step 2

Action Move the car to be able to hang the RPD positioning rope from points at the top of the shaft, defined in the site survey. For example, from a point in the shaft roof, a support beam, or a chain suspended from the machine room.

Note

In MonoSpace and PU elevators it can be suspended from a horizontal rope anchorage beam, or pulley beam.

3

4 5

If you need to drive the car up to reach the hanging point, ensure that you maintain safe access height to the landing. If this is not possible ensure that there is always someone on the landing monitoring the work in the shaft. Fix the positioning rope and the hoist for hanging the RPD in the defined hanging point. Re-position the car so that the car roof is level with the landing floor. Put the RPD electrification box on the car roof and connect all cables.

1055060.wmf

Ensure that the cabling cannot become a tripping hazard.

6

Check the operation of the device. See Appendix or follow the instructions in RPD Handbook (AM-01.05.012). Check the operation of: • direction buttons • emergency stop button • safety switches of the finger protection guard

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If the emergency stop button is pressed down when RPD is running, RPD does not start after releasing stop button. Drive must be resetted: Switch power OFF, wait 10 seconds, switch power ON.

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KONE Traction Elevator Installation Instruction

Step 7

Action Ensure that the central bolt (B) is tighten and safely in place by measuring the distance between the bolt head and the plastic wedge of the RPD body. Maximum distance is 180 mm. If it is more than 180 mm the central bolt has loosened. If the central bolt is loose: • release the spring tension by opening the spring adjustment nut (C) • open the securing screw (F) • carefully open and remove the central bolt (B) • add thread locker Loctite 248 to the threads of the central bolt (B) • re-tighten the central bolt in place (tightening torque is 120Nm) • tighten the securing screw (F)

Note

≤ 180

C

B

F ≤ 180

When turning the spring adjustment nut (C) ensure that the central bolt (B) does not rotate. Note that during the normal operation of the rope pulling device the central bolts (B) are rotating with the disks.

80 ≤1 1063193.wmf

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KONE Traction Elevator Installation Instruction

Note There are 2 different sleeves for 3 different rope sizes: • 9 mm for 8 mm and 10 mm ropes • 12 mm for 13 mm rope 12 mm

Action Install the correct sleeves, according to the suspension rope dimensions. If during rope replacement you pull the rope on only one side of the RPD, put sleeves only to the bearings on that side. Clean the surfaces between sleeves and bearings before each rope replacement work.

9 mm

Step 8

1058640.wmf

NOTE! The RPD can be driven along the positioning rope with both types of sleeves.

1053437.wmf

9

Put positioning rope to the RPD and fix the collar (A) to the pipe coupling. Tighten the RPD disks. Tighten the nuts with the wrench, until the spring is fully compressed.

A

1053438.wmf

30

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KONE Traction Elevator Installation Instruction

Step 10

Action Drive the rope pulling device up the positioning rope into the shaft and onto the car roof.

Note

Control the movement to prevent sudden swings that may damage the device and other equipment, or cause injury.

1053442.wmf

11

12

Once the device is on the car roof, detach positioning rope from lifting sling. Lift the required tools and material to the car roof. For example: • securing chains • manual chain hoist(s), for hoisting car • chain hoist (500 kg), for suspending RPD • rope grip • rope cutter • crimping tool • rope joints • hand tools (wrenches, etc.)

1053429.wmf

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KONE Traction Elevator Installation Instruction

4.5

Positioning RPD for rope replacement Step 1

2

3 4

4.6

Action Attach the chain hoist (500 kg) to a point above the RPD working position near the counterweight ropes, as defined in the site survey. It can be the same point used to take the RPD onto the car roof, for example, a rope anchorage beam, or a guide rail bracket, or a chain lowered from the machine room. Raise RPD to the correct operating height. Either using the chain hoist or by running it up the positioning rope. (The positioning rope may be fixed to the same position as the chain hoist.)

Note Ensure that you have located the correct point defined in the site survey, it must be strong enough to support the weights. Ropes must run through the RPD as straight as possible. See Rope replacement schematics for RPD position in rope system.

Hang RPD from chain hoist (500 kg). Release positioning rope from RPD by opening the tightening bolts of the disk springs. Remove the positioning rope from the hanging point.

Check that it is in the correct position.

Securing car and counterweight Step 1

Action Position the car so that you are at a good height to operate the RPD and you can reach all necessary roping elements (refer to the site survey). WARNING! Ensure that you have safe access to the landing. Use stool to enter and exit the shaft, if needed.

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Note This can be about 600 mm above the topmost landing sill, or even higher (like, for example, in MonoSpace elevators). Do not drive too high. When working at the top of the shaft, ensure you have sufficient space to safely exit from the car roof. Recommended maximum height from landing level to top of the door operator is 1.5 m.

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KONE Traction Elevator Installation Instruction

Step 2

3

Action Go to pit and place the pit prop(s) under the counterweight. Choose the pit props according to counterweight weight. Ensure that the pit props are tightened against the counterweight, so as to stop any down movement. Props should be vertically aligned and centre to the frame.

Note

WARNING! Ensure that counterweight guide rails are firmly secured so that the counterweight remains between rails while ropes are slack. Lower the counterweight on the pit props by opening the elevator brake. 1057547.wmf

4

Mark the position of the car on the side of the wall or door post (M1). From M1 measure upwards: • + 50 mm for safety reaction distance • + 30 mm for rope slack • + rope stretch (see table)

M2 M1

Mark the final position (M2). 1051591.wmf

5

Secure the hoist chains to the car sling crosshead. Ensure that the sling or any dedicated lifting points in the sling, are safe for hanging the car weight (refer to the site survey). Hang the car from the manual hoist.

6 7 8

Hoist the car to measured position (M2), so that ropes become slack. Activate safety gear by pulling the safety gear rope. Lower car to the safety gear.

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Refer to 4.2 Measuring the counterweight overtravel, step 7.

Ensure that car is positioned correctly, if not re-position car.

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KONE Traction Elevator Installation Instruction

Step 9

Action Secure the car to the guide rail brackets with two safety chains according to the car weight.

Note

The brackets must be strong enough, if not another securing point needs to be available (refer to the site survey). Keep the chain as tight as possible.

4.7

Friction test before use The device drive parameters have been set to provide enough torque needed in the roping operations. If there is enough friction the drive stops the motor when the preset load limit is reached.

Perform the test standing on the landing, to avoid risk of injury if the tested rope snaps. Step 1 2 3

Action Set the device in roping position and anchor with chain. Put one old rope to the device. Tighten the RPD disks. Tighten the nuts (C) with the wrench, until the spring is fully compressed. Then loosen the nuts (C) three rounds. WARNING!When turning the spring adjustment nut (C) ensure that the central bolt (B) does not rotate.

Note / Illustration

B

C 3x

B

B

C C 4

1063194.wmf

1063188.wmf

Drive up with slow speed until there is no slack rope left.

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KONE Traction Elevator Installation Instruction

Step 5

Action Continue driving up with slow speed.

Note / Illustration *) Tightening torque of the central bolt (B) is 120 Nm.

If the drive stops the motor there is enough friction to go on with the work. If the rope continues to slip from the disks, tighten both discs half a turn and repeat the test. If the rope continues to slip, even after the springs have been fully tightened, check for the cause, e.g. the disks may be too worn, or the rope contaminated with machinery oil, etc. Correct the fault before continuing with the work. See AM-01.05.012 RPD Handbook. If the surface of the disks is too worn on one side, so that there is no friction, but it is still usable on the other side, you should turn the disks around to use the surface which is not worn. For more information on how to remove and install the disks refer to AM01.05.012 RPD Handbook. 6

*)

1058642.wmf

NOTE! All disks should be turned at the same time, so that all disk sides marked A should face all disks marked A, or all disk sides marked B should face B.

If RPD swings a lot during the friction test, secure the lower end of RPD to the guide rails. This keeps RPD steady when pulling ropes and brings more power to pulling.

1074536.wmf

7

Start replacing the rope. Follow the appropriate method according to the elevator type.

See following chapters.

NOTE! Remember to repeat this test for all ropes before cutting.

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KONE Traction Elevator Installation Instruction

5

ROPE REPLACEMENT To ensure a correct and safe installation, it is important that you understand the roping system.

5.1

Rope weight The maximum acceptable lifting load for one fitter is 25 kg (refer to local code, for example, in Holland it is 23 kg). When dealing with ropes (either new or old), no fitter should repeatedly lift or carry manually more than 25 kg. To have an idea of the weight of the ropes, depending on their dimensions and length, see the estimates in the table. Remember that the core material influences the rope weight (steel core ropes are heavier than fibre core ropes).

Table 1: Estimation of rope weights

Nominal diameter (mm)

Approximate mass (kg/100 m)

8 10 13

21,5 - 28,0 34,0 - 43,0 57,9 - 75,0

Number of rope loops equal to 23 kg (inside the reeling device) * 50 30 20

* Number of rope loops equal to 23 kg (inside the reeling device) = 23 / (π x D x M) π = 3.14...

D = diameter of reeling device [m] = 0.5 m M = mass of one metre of rope [kg/m]

5.2

Reducing rope friction Use friction releaser or a split plastic tube on traction sheave or diverting pulley grooves.

1074539.wmf

For more information on friction releaser, see APPENDIX D. Installing friction releasers (PU).

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KONE Traction Elevator Installation Instruction

5.3

Rope replacement schematics NOTE! The replacement procedure is made for one rope at a time. Ensure that you have located the correct rope before starting the replacement.

1:1 PT

M

1055321.wmf

M

2:1 PT

M

1055339.wmf

Single wrap

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Double wrap

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KONE Traction Elevator Installation Instruction

M

M

2:1 MonoSpace

2:1 PS, PU

M

M

4:1 TranSys

© 2009 KONE Corporation All rights reserved.

1:1 PS, PU

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1055055.wmf

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KONE Traction Elevator Installation Instruction

6

ROPE REPLACEMENT 1:1 (PT) NOTE! For rope replacement preparations see chapter 4.

6.1

Replacing ropes Step 1 2

Action Build scaffolding in the pit in order to reach the top of the counterweight. Guide the first old rope between the RPD disks. Tighten the RPD disks. Tighten the nuts with the wrench, until the spring is fully compressed.

Note

1053448.wmf

30

3 4

5

Perform the friction test. Cut the rope on the RPD from the car rope anchorage. Ensure that you have the correct rope. Place the new rope on the unwinding device in the topmost landing and direct it through the pipe to the car top.

See chapter 4.7.

1055056.wmf

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KONE Traction Elevator Installation Instruction

Step 6

Action Join the old rope and the new rope using a joint and the crimping tool.

Note

See Appendix C on how to make the joint. 7

8

Cut or loosen the rope on the counterweight anchor and direct it through the pipe to the reeling in the landing. Fix the pipe. Drive the RPD to pull the new rope through the machine room and lower the old rope down to the reeling device. NOTE! Reduce drive speed when the joint is passing the RPD, to prevent it from jamming.

9

NOTE! Stop the procedure and remove the old rope from the reeling device if it is full and before containing 25 kg of old rope. (See estimate table on page 30.) Tie the old rope and place it so as not to leak any oil or dirt on the floor. Stop pulling the rope when enough new rope as reached the counterweight anchorage.

1053647.wmf

© 2009 KONE Corporation All rights reserved.

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KONE Traction Elevator Installation Instruction

6.2

Securing new rope Step 1

2

3

4 5 6

Action Go to the pit. Cut the new rope to the correct length and attach the new rope to the counterweight anchor. On the car side, pull end of new rope from pipe and fix it to the bottle on the car rope anchorage. Use the RPD to pull the new rope up towards the car anchorage, so that it is tight on the counterweight. Release collecting pipe from the car anchorage.

Note

There should be no rope slack on the counterweight side. You should have enough rope to fix to the rope anchorage and make final adjustments, if needed

Fix rope end to the rope bottle on the car side. Release rope from RPD. Repeat the rope replacement procedure for the other ropes.

1010517.wmf

© 2009 KONE Corporation All rights reserved.

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KONE Traction Elevator Installation Instruction

7

ROPE REPLACEMENT 2:1 (PT) NOTE! As a proactive measure, the counterweight pulley assembly including the bearings must be replaced along with the ropes. NOTE! For rope replacement preparations see chapter 4.

7.1

Replacing ropes Step 1

Action Guide the first rope between the RPD disks on both sides. Ensure that it is the same rope on both sides. Tighten the RPD disks. Tighten the nuts with the wrench, until the spring is fully compressed.

Note

1053478.wmf

2 3 4

Drive rope towards the counterweight anchorage to perform the friction test. Drive all rope slack to car side. Cut the same rope on car side near the rope bottles and take it from the pulley. Remove the old rope from bottle.

See chapter 4.7

1053660.wmf

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KONE Traction Elevator Installation Instruction

Step 5

6

7

8

9 10

11

Action Route the pipe from the unwinding device in the landing and fix it near the car side ropes. Pull enough new rope through it to be able to join it with the old rope. Join the old rope and the new rope using a joint and the crimping tool.

Note

See Appendix C on how to make the joint. Drive briefly in slow speed towards the counterweight rope bottle. This way you are able to re-check that you have chosen the correct rope and that you are able to pull it. Cut the rope from the counterweight anchor and direct it through the pipe to the reeling device in the landing. Fix the pipe from the rope reeling device to the RPD. Start pulling rope using the RPD. NOTE! Stop the procedure and remove the old rope from the reeling device if it is full and before containing 25 kg of old rope. (See estimate table on page 30.) Tie the old rope and place it so as not to leak any oil or dirt on the floor. Stop pulling new rope before the reel is empty and when you have enough new rope on both ends to fix to both rope anchorages.

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1053637.wmf

WARNING! Ensure that you are pulling rope to the correct direction. Otherwise the rope may fall from the pulling device to the shaft

NOTE! Reduce drive speed when the joint is passing the RPD, to prevent it from jamming.

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KONE Traction Elevator Installation Instruction

7.2

Securing new rope Step 1

2

3

4 5 6

Action On the car side, pull the end of the new rope from the pipe and fix it to bottle on the rope anchorage. Drive the rope through the RPD towards the counterweight side, so that it is tight on the car side. Release collecting pipe from RPD.

Note

There should be no rope slack on the car side. You should have enough rope to fix to the rope anchorage and make final adjustments, if needed.

Fix rope end to the rope bottle on the counterweight side. Release rope from RPD. Repeat the rope replacement procedure for the other ropes.

1010517.wmf

© 2009 KONE Corporation All rights reserved.

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KONE Traction Elevator Installation Instruction

8

ROPE REPLACEMENT 2:1 (MONOSPACE) AND 4:1 (TRANSYS) NOTE! As a proactive measure, the counterweight pulley assembly including the bearings must be replaced along with the ropes. NOTE! For rope replacement preparations see chapter 4.

8.1

Replacing ropes Step 1

Action Guide the first rope between the RPD disks on both sides. Tighten the RPD disks. Tighten the nuts with the wrench, until the spring is fully compressed.

2

Drive rope towards the counterweight anchorage to perform the friction test. Fix a rope grip on the other side to a secure place (for example, to guide rail bracket or rope anchorage).

3

Note

1053478.wmf

See chapter 4.7.

NOTE! If you use fabric slings, remember to use protection to prevent possible cuts to the sling. Secure the rope to be replaced with the rope grip. This prevents the rope from falling down the shaft towards the car pulleys.

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KONE Traction Elevator Installation Instruction

Step 4 5

6

7

8

9

Action Cut rope on car side anchorage and remove old rope from bottle. Route the pipe from the unwinding device in the landing. Fix the pipe to the rope bottle frame on the car side, or to another place, just as long as the new rope is fed perpendicular to the pulley beneath the car.

Note

Pull enough rope through the pipe to be able to join it with the old rope. Join the old rope and the new rope using a joint and the crimping tool.

See Appendix C on how to make the joint. Release rope from rope grip. Make sure the ropes are routed so that there is no possibility of tangled ropes. Cut rope over the RPD on the counterweight anchorage side and direct it through the pipe to the reeling device in the landing. Fix the pipe to the RPD. Start pulling rope using the RPD. 1053653.wmf

NOTE! Stop the procedure and remove the old rope from the reeling device if it is full and before containing 25 kg of old rope. (See estimate table on page 30.) Tie the old rope and place it so as not to leak any oil or dirt on the floor.

© 2009 KONE Corporation All rights reserved.

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WARNING! Ensure that you are pulling the rope to the correct direction. Otherwise the rope may fall from the pulling device to the shaft

AM-09.11.006 (F) 2011-09-12

KONE Traction Elevator Installation Instruction

Step 10

Action Stop pulling new rope before the reel is empty and when you have enough new rope on both ends to fix to both rope anchorages.

Note NOTE! Reduce drive speed when the joint is passing the RPD, to prevent it from jamming.

4:1

2:1 M

M

1065914.wmf

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KONE Traction Elevator Installation Instruction

8.2

Securing new rope Step 1

Action On the car side, pull end of new rope from pipe and fix it to the bottle on the car rope anchorage.

2

Drive the rope through the RPD towards the counterweight side, so that it is tight on the car side. Release collecting pipe from RPD.

3

4 5 6

Note Ensure that you have the rope secure during the procedure, so that it does not fall to the car pulleys. Secure it using the rope grip. There should be no rope slack on the car side. You should have enough rope to fix to the rope anchorage and make final adjustments, if needed

Fix rope end to the rope bottle on the counterweight side. Release rope from RPD. Repeat the rope replacement procedure for the other ropes.

1010517.wmf

© 2009 KONE Corporation All rights reserved.

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KONE Traction Elevator Installation Instruction

9

ROPE REPLACEMENT 2:1 (PU/PS) NOTE! As a proactive measure, the counterweight pulley assembly including the bearings must be replaced along with the ropes. NOTE! For rope replacement preparations see chapter 4.

9.1

Replacing ropes In PU elevators the frictional holding of the roping system should be tested to guarantee that the old rope will not run out from the reel in the landing during replacement, because of the weight of the rope on the opposite side.

Step 1

2

Action Due to high friction in PU roping system, friction releaser should be installed in the traction sheave before starting the rope replacement. Put one old rope between the RPD disks (on the same side that you installed the sleeves to the bearings).

Note See Appendix Installing friction releasers.

Tighten the disks. Tighten the nuts with the wrench, until the spring is fully compressed.

1053448.wmf

3 4 5 6 7

Drive rope towards the counterweight See chapter 4.7. anchorage to perform the friction test. Cut rope over the RPD on the counterweight anchorage side and direct it through the pipe to the reeling device in the landing. Fix the pipe from the rope reeling device to the RPD. Fix rope grip to the car on the car side and secure the rope with the rope grip. This prevents the rope from falling towards the car pulleys. Cut rope on car side and remove old rope from bottle.

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KONE Traction Elevator Installation Instruction

Step 8

9

10

11

12

Action Route the pipe from the unwinding device in the landing Fix the pipe to the rope bottle frame on the car side, or to another place, just as long as the new rope is fed perpendicular to the pulley beneath the car. Direct the new rope along the pipe and through the rope bottle.

Note

Pull enough rope to be able to join it with the old rope. Join the old rope and the new rope using a joint and the crimping tool.

See Appendix C on how to make the joint. Release rope from rope grip. Make sure the ropes are routed so that there is no possibility of tangled ropes. Start pulling rope using the RPD. NOTE! Stop the procedure and remove the old rope from the reeling device if it is full and before containing 25 kg of old rope. (See estimate table on page 30.) Tie the old rope and place it so as not to leak any oil or dirt on the floor. Stop pulling new rope before the reel is empty. Make sure that the joint is out of the roping system and rope has been fully replaced. Ensure that the end of new rope does not fall into the shaft.

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1053652.wmf

WARNING! Ensure that you are pulling the rope to the correct direction. Otherwise the rope may fall from the pulling device to the shaft

NOTE! Reduce drive speed when the joint is passing the RPD, to prevent it from jamming.

AM-09.11.006 (F) 2011-09-12

KONE Traction Elevator Installation Instruction

9.2

Securing new rope Step 1

Action On the car side, pull end of new rope from pipe and fix it to the rope bottle.

2

Drive the rope through the RPD towards the counterweight side, so that it is tight on the car side. Release collecting pipe from RPD.

3

4 5 6 7

Note Ensure that you have the rope secure during the procedure, so that it does not fall to the car pulleys. If diverting pulleys are under the car secure it using the rope grip. There should be no rope slack on that side. You should have enough rope to fix to the rope anchorage and make final adjustments, if needed.

Fix rope end to the rope bottle on the counterweight side. Release rope from RPD. Repeat the rope replacement procedure for the other ropes. Remove the friction releasers from the machine traction sheave.

1010517.wmf

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KONE Traction Elevator Installation Instruction

10

ROPE REPLACEMENT 1:1 (PU/PS) NOTE! For rope replacement preparations see chapter 4.

10.1

Replacing ropes Step 1 2

Action Build scaffolding in the pit in order to reach the top of the counterweight. Locate one old rope and guide the first rope between the RPD disks on both sides.

Note

Tighten the RPD disks. Tighten the nuts with the wrench, until the spring is fully compressed.

1053478.wmf

3 4 5 6

Drive rope towards the counterweight anchorage to perform the friction test. Cut this rope over the car anchorage. Put new rope from the unwinding device in the landing through the pipe. Join the old rope and the new rope using a joint and the crimping tool.

© 2009 KONE Corporation All rights reserved.

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See chapter 4.7.

See Appendix C on how to make the joint.

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KONE Traction Elevator Installation Instruction

Step 7 8

9

10

Action Fix the pipe from the rope unwinding device to the RPD. Cut the same rope over the counterweight anchorage and direct it through the pipe to the reeling device in the lower landing. Start pulling rope using the RPD. NOTE! Stop the procedure and remove the old rope from the reeling device if it is full and before containing 25 kg of old rope. (See estimate table on page 30.) Tie the old rope and place it so as not to leak any oil or dirt on the floor. Stop pulling new rope before the reel is empty. Make sure that the joint is out of the roping system and rope has been fully replaced. Ensure that the end of new rope does not fall into the shaft.

© 2009 KONE Corporation All rights reserved.

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Note

Reduce drive speed when the joint is passing the RPD, to prevent it from jamming.

AM-09.11.006 (F) 2011-09-12

KONE Traction Elevator Installation Instruction

10.2

Securing new rope Step 1

2

3 4 5

Action On the car side, pull the end of the new rope from the pipe and fix it to the rope bottle. Drive the rope through the RPD towards the counterweight side, so that it is tight on the car side. Fix rope end to the rope bottle on the counterweight side. Release rope from RPD. Repeat the rope replacement procedure for the other ropes.

Note

There should be no rope slack on that side.

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11

RELEASING THE CAR Step 1 2

3 4 5

Action Check that all ropes are properly placed on the pulleys. Check that there is no slack in any of the ropes. If there is slack, unload the slack ropes and re-fix them again. Remove securing chains from the car. Lift car from safety gear using the manual chain hoist. Lower car to the ropes and check car location against overtravel target marker tape (M2), it should be approx. 50 mm *) below the marker M2. If not, raise the car again and readjust the rope length.

Note

This is a quick check procedure to ensure that the rope length will be correct when completing the re-roping.

M2 *)

M1

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6 7

Remove scaffolding. Remove pit props from under the counterweight.

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12

REMOVING RPD FROM SHAFT Step 1

Action Lower RPD to the car roof, either:

Note

By using the positioning rope • fix it to the same place used to raise the RPD • put the rope to the RPD • drive the device slightly up to take it from the chain hoist • drive the device down onto the car roof

2

3

Or by using the chain hoist (500 kg) to lower it to the roof (and then putting the positioning rope to the RPD). Attach the positioning rope to the same point at the top of the shaft that was used to move the device into the shaft.

If you need to drive the car up to reach the hanging point and you lose access to the landing, ensure that there is always someone on the landing monitoring your work.

Drive car down so that the car roof is level with the topmost landing floor.

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Step 4

5 6

Action Raise RPD up on the positioning rope and drive it out from the shaft and into the landing. Help to direct it manually.

Note

Control the movement to prevent sudden swings that may damage the device and other equipment, or cause injury. Remove positioning rope from inside the shaft and from RPD. Remove all tools and working material from the car roof to the landing.

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13

FINALIZING Step 1

2

3

Action Drive the car up and down two to three times before checking and equalizing the rope tensions. Check the overtravel. If necessary readjust rope length. Record the final over travel to "Site survey after rope replacement"-list. See appendix. Check for slack in the ropes. Adjust the ropes on the car side so, that they are equally tensioned. Rough adjustment: Loosen the wedge of the rope with the most compressed spring.

Note

Before moving the car on inspection drive re-check the overtravels and safety spaces.

Fine adjustment: Loosen tension of the most compressed spring(s). Using screw driver and hammer knock the wedge up a little. Check the change in rope tension. Or use the nuts of the anchor screws.

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Step 4

5

6

7

8

Action Re-adjust the clearance in the rope guards to its original value, if it used to be less than 4-5 mm. With the car on the topmost landing, go to the pit to check the distance between the counterweight and the buffer. Clean elevator shaft and all working areas (including car roof, machine room and landings).

Note

CAUTION! Do not use non-approved cleaning fluids. WARNING! If using cleaning fluids, ensure the area is well ventilated and follow the instructions delivered with the cleaner.

Dispose of old ropes and materials according to KONE environmental policy, local laws, rules, regulations and procedures. Fill in the "Site survey after rope replacement"-list. Return it to your supervisor. See appendix.

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14

APPROVALS AND VERSION HISTORY Compiled by:

Information Product Author / Hannu Tormanen

Checked by:

R&D / Antti Mertala

Approved by:

Global Installation Support / Anssi Venho

Translation approved by: /

Issue -.2 A

B

C D E

F

Date Description of Change Ref CR 2007-10-10 Issue for piloting. 2007-11-02 Issue for piloting. Safety statements added on pages 10 and 23. 2008-07-28 Second issue for piloting. Changes in tool list. Changes to rope replacement 1:1 (PT). Added method for rope replacement 1:1 (PU/PS). Other minor changes. 2009-01-21 Thread locker and warning of the spring tension added, other minor changes. Appendices F, G, and H added. 2009-03-19 Tools section updated. 2009-08-10 Rope pulling device packing changed. Other minor changes. 2011-05-10 Requirement for replacing counterweight diverter pulley and bearing and reference to AS-08.03.004 added. Other minor changes. 2011-09-12 KM numbers added to tools, collars updated

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Approved by Anssi Venho Anssi Venho Anssi Venho

Anssi Venho

Anssi Venho Anssi Venho Anssi Venho

Anssi Venho

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KONE Traction Elevator Installation Instruction

APPENDIX A. Rope inspection criteria This method must not be used if any of the following conditions exist: • • • • • •

The rope diameter has reduced to less than 94% of its nominal diameter Any wires are corroded to less than 80% of their normal cross sectional area The outer wires are worn flat to less than 50% of their normal cross sectional area Any strand has broken Any strand has more than 5 wire breaks in one lay length The rope is otherwise damaged, kinked or birdcaged

Reference document AS-09.06.002 - Rope faults and criteria for replacement.

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APPENDIX B. Checking operation of the rope pulling device Checks should be made always before using the machine, to ensure that the machine works correctly and that there are no safety risks for those operating the machine. Perform a quick visual check after using the machine.

Step 1 2

Action Check visually the condition of the device and all its components. After connecting all the cables, connect device to power supply.

Note / Illustration For example, look for damage in the electric cables.

The green light should be on in the electrification box. (Make sure that both RPD shields are closed.)

3

4

5

Check the operation of the direction buttons (1) in low and high speed. Try to drive in both directions. The rope pulling device should operate NOTE!Make sure both shields are fully closed and emergency STOP button released. Check the operation of the emergency stop button (2). Push the stop button down and try to push the drive buttons (1), one at a time. The device should not operate. Check the operation of the safety switches of the shields. Open the shield on one side and push one drive button at a time, the device should not operate. Repeat test on the other side. Open both and try again to drive the device.

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APPENDIX C. Making rope joint with the crimping tool NOTE! The crimping tool is a commercial tool normally used for electrical cable shoe crimping. The sizes 25, 35, and 70 refer to standard electrical cable shoe sizes.

Step 1

Action Choose the correct joint according to the dimension of the rope.

Note NOTE! Joints are colour coded:

WARNING! Use only the joints supplied and referred below.

2

8 mm (yellow) - drawing number: 935406H01 10 mm (green) - drawing number: 935406H02 13 mm (red) - drawing number: 935406H03 Choose the correct teeth in the crimping tool (with the correct markings for the rope dimension). Rope dimension - Tool markings 8 mm - 25/25 10 mm - 35/35 13 mm - 70/70

35 25 25 35

NOTE! You can check the dimension of the rope from the marking left on the joint.

ο10 ο8

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3

Cut both rope ends straight. NOTE! If rope end has been finished by welding, cut 100 mm from the end of the rope.

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If needed, use plastic tape to make sure that the strands of the rope do not open. The tape should not go into the joint.

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KONE Traction Elevator Installation Instruction

Step 4

Action Slide the rope into the rope joint.

Note Twist the rope and the rope joint to the direction that tightens the strands. This makes it easier to slide the joint over the rope end.

5

Make sure that rope is deep enough in the joint

You can see the rope through the sight hole in the joint.

6

Use crimping tool to crimp the rope joint to the ropes.

Make at least 4 crimps per side.

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APPENDIX D. Installing friction releasers (PU) WARNING Friction releasers should only be installed to the traction sheave of PU elevators. Do not use them for any other purpose in any other elevator type. NOTE! For PS elevators, no friction releasers are needed, if the machine room is less than 10 meters from the shaft roof.

Step 1

Action After the ropes are loosened, slide the bars of the releaser above and below the ropes to the defined place on traction sheave.

Note

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2

Lock the bars in position using the pins and screws, so that the releaser is adjusted to the width of the traction sheave.

3

Tighten the screws (A) below the traction sheave rim. Tighten the screws (B) against the traction sheave rim.

4

Install another releaser to opposite side of traction sheave if needed.

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APPENDIX E. Working from scaffolding

E.1

Introduction The purpose of this instruction is to ensure your safety and the safety of others who may be affected by your work when it is necessary for you to work from ladders, fixed scaffolds or scaffold platforms. Where this instruction is in conflict with your local regulations you must follow your local codes and practices.

E.2

General principles Safety regulations require safe access to be provided and maintained to any place of work, and that the place be kept safe for any person working there. Guard rails and toe boards or other effective means are required at any place where a person is liable to fall more than one metre. They may also be necessary at lower heights where a person may fall onto sharp or otherwise dangerous surfaces.

When working on scaffolding or other working platforms in the elevator shaft you must ensure that they have been erected in accordance with your local regulations, have been inspected and tagged by a competent person, are inspected at regular intervals and that records have been kept. Some national regulations require that the scaffolding is installed by a qualified person. In situations where it is necessary to modify the scaffolding this must be done by a qualified or otherwise competent person. Do not make alterations to the scaffolding yourself unless you are trained and authorised to do so. Ensure that you have sufficient scaffolding material to avoid the risk of having to move planking from the platforms. This is one of the most common causes of scaffolding accidents. Fixed scaffolding must be designed by a qualified person whenever an approved predefined scaffolding system is not used. Both solutions must be constructed according to local regulations. Scaffolding must be erected, moved, dismantled and altered by trained, authorised employees under the supervision of a competent person. Scaffolding must be inspected by a qualified person who is responsible for keeping written records of the inspections. It is strongly recommended to use a tagging system to indicate the safe condition of the scaffolding. A competent person must inspect the scaffolding for visible defects before each shift and after any occurrence that might affect the structural integrity of the scaffolding. It is not necessary to document these inspections. A fall prevention system must be used when there is risk of injury from a fall. Scaffolding must never be used as a hoisting structure.

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E.3

General scaffolding The scaffold must always be assembled according to the product specific assembly instructions provided by the supplier. Materials and tools must not be unnecessarily stored on the scaffold platform. The scaffolding must be used only for the purpose it was designed for. For safety reasons the scaffold must be assembled in a logical order. The assembly must proceed so that the previous level is ready before starting to installation at the next level. Each level of the scaffold must be braced according to the instructions of the scaffolding manufacturer before starting to install the next section or level. Install the handrails immediately after you have completed each platform level. The manufacturers instruction must be followed when assembling the working platforms and handrails. The gaps in the working platform must not exceed 30 mm. The working platforms must be equipped with kick boards to prevent risk from falling tools or materials. The scaffold must not be taken into use before it is completed. Under no circumstances may anyone work on the scaffold while it is under construction.

E.4

Taking into use The supervisor is responsible for ensuring the inspection of each scaffold before it is taken into use. The inspection can be done by the supervisor or the fitter. Scaffolds must not be used before they are completely ready and inspected. The inspection must be recorded on the scaffold card that is to be fixed to the scaffolding. Following your local codes and procedures. NOTE! Even if a non KONE employee (for example the renting company or representative of the builder) has already made an inspection of the scaffold the KONE responsible person must inspect the scaffold before it is taken into use. The condition of the scaffold must be inspected weekly as a minimum. These weekly inspections must include the same safety items as the inspection before taking into use and must also be recorded on the scaffold inspection record card. If it is necessary to move the scaffolding, the security of the working platforms must be ensured before movement. Never move scaffolding while people, tools or materials are on them.

E.5

Dismantling The scaffold must also be dismantled in a logical sequence. The dismantling must proceed so

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that the upper level is completely dismantled before starting to dismantle the next lower one. The anchorages and braces must be dismantled from each section or level before starting to dismantle the next section or level. To prevent falling the lower handrail must be dismantled before the upper. The working platform is dismantled after these. No other personnel is permitted to work from the scaffold during dismantling. If necessary place barriers and warning notices to prevent access to the scaffolding. The dismantled parts must not be dropped down.

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AM-09.11.006 (E) 2011-05-10

páíÉ=ëìêîÉó=~ÑíÉê=êçéÉ=êÉéä~ÅÉãÉåí= ^ééÉåÇáñ=e= bäÉî~íçê=åìãÄÉêW=|||||||||||||||||||||||||||||||||=oma=pÉêá~ä=kç=|||||||||||||||||||||||||||||||||||||||= = páíÉW=|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||= = All checks must be verified in OK column before leaving the site. Any defect must be rectified before leaving. The inspection must be carried out and a copy of correctly filled inspection sheet returned to your supervisor. Non-compliance leads always to disciplinary actions.

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lîÉêíê~îÉä= lîÉêíê~îÉä=ÅçêêÉÅí=~ÅÅçêÇáåÖ=íç=íÜÉ=ÉäÉî~íçê=ä~óçìí=Çê~ïáåÖëK=jÉ~ëìêÉãÉåí=_=Ñêçã=Çê~ïáåÖë=áë=ã~êâÉÇ= çå=íÜÉ=ÉäÉî~íçê=ëÜ~Ñí=ï~ääK=lîÉêíê~îÉäW=||||||||||||||||=

= `çããÉåíëW=|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||= = fåëéÉÅíÉÇ=ÄóW=|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||= = páÖå~íìêÉW=||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||= = mçëáíáçå=L=Åçãé~åóW||||||||||||||||||||||||||||||=||||||||||||||||||||||||||||a~íÉW=|||||||||||||||||||||||||= AM-09.11.006 (E) 2011-05-10