Maintenance Manual of the Escalator - irsalift.com fileInstallation, Commissioning, Operation and Maintenance Manual of the Escalator ZHEJIANG MEILUN COMPLETE ELEVATOR CO., LTD September,

Installation, Commissioning, Operation and

Maintenance Manual of the Escalator

ZHEJIANG MEILUN COMPLETE ELEVATOR CO., LTD

September, 2012

Contents I．Overview⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1 II. Product Introduction⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 2

Chapter I Mechanical part ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯2 1. Product type⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯2 2. Specifications and Technical Index of the Main Types ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯2 3. Main Mechanisms and Operating Principles ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯2

Chapter II Electrical part ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯13 1. Instructions of Escalator Electrical Principles⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯13 2. Instructions of Escalator Maintenance ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯13 3. Lighting Circuit of Escalator ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ ⋯13

4 Escalator Safety Devices⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯14

5. Instructions of Escalator Oil-way Principles⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯22 III. Instructions for Escalator Installation and Commission⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯23

(I) Lifting, Transportation, Assembly of the Escalator and Putting it in Place⋯⋯23 (II) Inspection and Adjustment of the Driving System⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯27 (III) Checking and Adjusting of Stairs⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯28 (IV) Adjustment of Comb Plate and Operation Test (as figure 4-18)⋯⋯⋯⋯⋯⋯⋯⋯⋯31 (V) Dischargement of the Stair ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯32 (VI) Collapse Protection⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯32 (VII) Front Plate⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯33 (VIII) Installment and Adjustment of Handrail System ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯33 (IX) Bearing of Escalator ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯39

(X) Escalator Control and Electrical Components ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯40 (XI) Commission ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯41

IV. Care and Maintenance of the Escalator⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯49 (I) Pre-maintenance Safety Precautions⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯49 (II) Routine Maintenance⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯49 (III) Items and Contents of Heavy, Medium and Minor Repair Check ⋯⋯⋯⋯⋯⋯49 (IV) Maintenance Operation and Adjustment ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯50

1. Electrical System Maintenance⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯50 2. Cleaning and Maintenance of the Machine Room⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯50 3. Care and Maintenance of the Main Machine⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯51

4. Care and Maintenance of the Main Drive⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯51

5. Check and Adjustment of the Drive Chain ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯51 6. Check and Adjustment of the Braking Length⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯52 7. Inspection and Replacement of the Lubricating Oil in Reduction Gearbox ⋯52 8. Dismounting, Installation and Adjustment of the Stair⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯53 9. Replacement of the Decorative Tread⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯53 10. Lubrication of the Stair Axle Sleeve⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯54 11. The Changing of the Accessory Wheel⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯54 12. Changing of the Stair Nylon Gear⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯54 13. Maintenance of the Hand Strap Device⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯54 14. The Check and Adjustment of the Dragging Chain’s Tension and of Travel

Switches ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯56 15. Check and Adjustment of Meshing between the Stair and the Combs⋯⋯⋯⋯⋯57 (V) The Common Failures of the Escalator and Their Troubleshooting Methods⋯

⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯58 V. Safe Operation and Use of the Escalator ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯59 VI. Emergency Rescue Plan of Escalator⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯61 VII. Emergency Rescue Method of Component Failure of Escalator⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯62

VIII. Emergency Rescue Method of Being Clamped in Escalator⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯64 Appendix I Operation Instruction of Examining and Adjusting the Brake ⋯⋯⋯⋯⋯⋯⋯66

General Structure and Operating Principle of the Brake⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯67 Appendix II Operation Instruction of Examining and Adjusting the Auxiliary Brake⋯⋯

⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯77 Table 1：Explanatory Table of Safety Switch Failures⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯81 Table 2：Explanatory Table of Monitor Wafer (MCTC-PES-E1) Faults⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯83 Table 3：Safety Monitoring Board (ES) 11 / A) Error Description Table⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯84

Installation, Commissioning, Operation and Maintenance Manual of the Escalator

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I. Overview FSL series escalators, combined by a chain conveyor with special structures and two

replacement conveyors of special structures, can be used as continuous conveying machinery up and down for the people between different floors of the building.

The escalator is the electric drive equipment with circular movement steps which transports the passengers upward or downward in a slope, mainly used for continuous conveying of people up and down between different floors of the building. It is driven by electricity, and it can transport large amounts of passengers continuously in a certain direction, which is usually used in the places with concentrated stream of people such as the public places, shops, railway stations, airports, docks, edifices and subway stations which need to convey large numbers of people in a relatively short time.

The design and manufacturing of this series escalators accord with national standard GB16899-2011 “Safety rules for the construction and installation of Escalator and Moving Walk”, and all the products have compact structures, light weights, stable operation, good comfort, large conveying capacity, uniform transport traffic, convenient installation and maintenance and so on. The escalator can either run forward or reverse with continuous operation, meeting the needs of the passengers going up and down.


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Ⅱ. Product Introduction

Chapter I Mechanical Part

1. Product Types Product types of this escalator are mainly:

1). Ordinary escalators (SWE), which adopt the aluminum handrail brackets and chain drives, with the inclination of 23.2°, 27.3°, 30°and 35°respectively, and the step widths of 1000, 800 and 600mm. 2). Slim escalators(SDS)，which adopt stainless handrail brackets and chain drives, with the inclination of 23.2°, 27.3°, 30°and 35°respectively, and the step widths of 1000, 800 and 600mm.

Type Inclination Escalator code Step width

FSL series escalators

23.2° FSL23.2

1000, 800 and 600mm

27.3° FSL27.3

30° FSL30

35° FSL35

2. Specifications and Technical Index of Main Types

Product type

FSL23.2, FSL27.3, FSL30, FSL35

Inclination 23.2°, 27.3°, 30°, 35°

Lifting height

≤17.5M

Step width 600mm 800mm 1000mm

Operation speed

0.5m/s 0.65m/s 0.5m/s 0.65m/s 0.5m/s 0.65m/s

Maximum capacity

3600 people/h

4400 people/h

4800 people/h

5900 people/h

6000 people/h

7300 people/h

3. Main Structures and Operating Principles These series escalators are composed of metal frames, traction devices, drive

devices, handrail drive devices, escalator way guide, step drive chains, steps, handrail devices, comb comb plates, electric control systems, and automatic lubrication systems, as shown in Figure 1-1.


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Figure 1-1 Overall schematic of the escalator

(1) Steps (2) traction devices (3) drive devices (4) escalator way guide (5) metal truss, (6) comb

comb plates (7) handrail devices (8) electric control system (9) safety protection system (10)

automatic lubrication system

3.1. Metal Truss： The role of the metal truss role is to install and support each component of the

escalator, bear various loads and connect two floors of different heights in the building. The end drive, the middle drive of the escalator way, the drive device, the tension device, the guide rail system and the handrail system are installed in the inner and top of the metal structures, which are general welded with angle steel, and rectangular steel. There are two kinds of trusses: the overall welding truss and the fission welding truss.

Fission trusses can be generally divided into two and three segments. When it is of two segments, it can separate the truss according to the lifting height, while it id of three segments, it is namely, the upper platform, the middle truss and the lower platform. Among them, the upper and lower platforms are relatively standard, but due to the different rated speeds, the horizontal sections of the escalator involved are different, affecting the straight line length between the upper platform and the lower platform. The middle truss length will be varied according to the lifting height.

To ensure the escalator is under good working condition, the truss has adequate stiffness, with allowable deflection of 1 ‰ of the

Figure 1-2 Center support


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distance between the upper and lower supporting points of the escalator. When necessary, the escalator truss should be set with intermediate support, which not only acts as a support, but can also adjust itself with the expansion and shrinkage of the truss.

The maximum deflection of this skeleton, according to the passenger load calculation or real measurement, is not more than 1/1000 of supporting distance L, which is in full line with the specified requirement of “GB16899”. 3.2. Traction Device

The traction device is composed of drive sprockets, drive chains, main drive sprockets, and step chains, which is the major component of the power transmission of escalators. The quality directly affects the smooth operation and noise levels of escalators. Step chain’s drive device is installed at the end of the horizontal straight section, i.e. the so-called end drive type. The used step chains of traction devices are sleeve roller chains, consisting of links, small shafts and sleeves and etc. At a certain number of links, which is, at a certain section length, it can be disassembled. The step chains are supported by the permanent lubricated supporting wheels and the step wheels of the step chains can run smoothly on the sprockets of the guide rail system, drive devices and tensioning devices. The step chains also make the uniform load distribution to prevent premature wear and tear of the guide rail system, and especially two traction chains which are connected by the step shaft in the backward area guarantee the overall operation stability of the step chains. The traction chains should be selected corresponding to the lifting height of the escalator. The bearing pressure of chain pins is an important factor to extend the service life of step chains. 3.3. Drive Device

Figure 1-3 Truss diagram of the escalator


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Figure1-4 One structure form of the upper structure of the end driven escalators

1-handrail 2-traction sprockets 3-contrrol cabinet 4-drive unit 5-steps 6-traction chains 7 -hold-down

device of the handrail 8-handrail drive wheel 9-upper drive shaft 10-drive chain 11 drive sprockets

This series escalator adopts vertical traction machine with advantages of compact

structure, smooth operation and the reliability, which can also adopt horizontal traction machine according to customer’s need. The drive device is equipped with power-off brake, thus it can stop the escalator and maintain a stable state when the escalator fails or has normal downtime.

The role of drive device is to pass on the power to the step system and handrail system. As the escalator is used to carry people and often used in concentrated stream of people, especially escalators serving the public transportation systems with long running time, so the drive device has the following features: 1) all parts and components are under detailed calculation with higher strength and stiffness to ensure the adequate reliability of the machine under short-term overload. 2) Parts with high wear resistance

to ensure the machine work for a long time in several years. 3) Drive device with compact structure is convenient for assembly, disassembly and maintenance. The drive device is usually consists of the motor, the reducer, the brake, the drive chain, and the main drive shaft.

Seen from Figure 1-4, it is known that the motor drives the main drive shaft through the chain and the main shaft is equipped with

Figure 1-5 Main drive shaft


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two traction sprockets, two handrail-drive wheels, the drive sprocket, and the emergency brake, etc. The traction chain is equipped with a series of steps which are driven by the traction sprockets of the main shaft. The handrail-drive wheels of the main shaft drive the handrail through the handrail chains, and the handrail hold-down device is designed to increase the friction between the handrail and handrail drive wheel to prevent slippage.

The driver is mainly composed of the motor, the worm and gear reducer, the chain sprocket, the brake, etc. Generally the vertical driver is adopted, as the advantages are: compact structure, small area occupation, light weight, easy to maintenance; low noise, little vibration, good balance, and big bearing capacity. The escalator of small lifting height can be driven by one driver and the escalator of medium lifting height can be driven by two drivers.

The brake is an important part depending on the friction between the friction pair to make the mechanism stop. One side of the friction pair is connected to the fixed frame of the mechanism, and the other is connected to the drive part of the mechanism. When the mechanism is started, the brake pulls two sides of the friction surface apart, and the mechanism starts operation. When the mechanism needs to be stopped, the brake makes two sides of the friction surface contact and compressed, and at this point, the friction surface generates enough friction torque to consume kinetic energy and make the mechanism slow down until it stop. 3.4. Handrail Device

It is driven by curve belt compacted friction, and the handrail has a certain wrap angle and gains enough friction drive force through the tensioning belt compacted on the outside of the handrail to realize the synchronization operation between the handrail and the steps.

The handrail device is composed of the handrail drive device, the baseboard, the apron board, the internal and external cover plates, the handrail and the handrail guide rail system.

1）Handrail drive device： As shown in Figure 1-4, the handrail drive device is driven directly by the handrail

drive chains without intermediate shaft, and the drive wheel edge of the handrail has oil resistant rubber friction layer to increase the friction so as to improve the friction and ensure the synchronization operation between the handrail and steps. To make the handrail get enough friction, the belt compact device is additionally equipped under the handrail drive wheels. The tensioning degree of the belt compact device can be adjusted by the tension spring and the adjustable nuts in order to ensure the normal work of the


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handrail, as shown in the figure.

Figure 1-6 Tensioning and pressing device of handrail

1 locknut 2 adjusting nut 3 tensioning screw 4 nut 5 fixed support 6 friction wheel

7 pressing belt wheels 8 pull rod 9 handrail 10 adjusting nut 11 spring

2）Handrail guide rail: Handrail drive device drives the round handrail guide and the handrail of the guide rail to realize the synchronous circulating operation between the handrail and steps. This escalator adopts cold-drawn metal rails and rolling bearing of nylon roller to make up the handrail guide rail system. 3）Baseboard: it uses transparent and specially made 10 mm thick toughened glass,

and it supports within the clamping components. It is fixed by the bolt on the even distributed handrail supporting with stainless steel plate covers on the inside and outside of the glass. 4）Apron plate: It is assembled by stainless steel panels and C-shaped reinforcing

ribs through welded bolts to make a whole, which is the separator between the running steps and the fixed parts to protect the security of passengers during the escalator taking. Its unilateral clearance to the step is not less than 4 mm, and the clearance sum of two sides is less than 7 mm. 5）Handrail: Handrail is composed of a variety of materials, mainly are synthetic

rubbers, cotton fabric, and steel wires or steel strips, etc. The standard color of the handrail is black, which can be offered with a variety of colors according to customer requirements in accordance with the color card of the handrail. 6）Handrail: Handrails of the escalator are set at both sides of the step, acting as the

protection and decoration. 3.5 Step Way Guide Rail

This step way guide rail system includes all guide rails, returning rails, guide rail supports, steering wall, etc.


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According to the motion requirements and the force analysis of the step, special galvanized cold-drawn guide rails of different cross sections have been used on different working sections respectively, which not only simplifies the structure and reduces the weight, and also possesses the advantages of stable and reliable operation as well as convenient installation and adjustment. 1) Guide rails and returning rails: the inclined straight line section is the main

working section of the escalator, and is also the longest part in the step way. The running steps and the returning rails of this section are cold-formed steels with light weight, large relative rigidity and high manufacturing precision, and convenient in assembly and adjustment. Such guide rail reduces the vibrated operation, curve operation and shaking operation of steps, which prolongs the service life of the steps and the roller. At the same time, it reduces the smooth turning radius between the upper platform guide and lower platform guide, reduces the pressure of step wheels and step sprockets on the guide rail, reduces the vertical acceleration, and also prolongs the service life of the guide rail system.

Side plate, in the curve section, forms a component with the related guide rails and returning rails on the same side fixing on the plate. This component is then assembled into the fixed part of the metal structure of escalator as a whole when it finishes the assembly on special tooling, which can accurately control the dimension between the guide rails.

The guide bracket supporting each guide rail (guide bracket diagram) uses cold drawn or cold rolled material. The average clearance between the guide rail side and the main wheel side of steps at the upper and lower horizontal sections of the working branch is less than 0.5 mm in order to make sure steps can go through the comb successfully. The clearance of other sections is less than 1 mm. 2) Steering wall: when the traction chain tracts the sprocket and the tensioning

chain of at the tensioning end to steer through drive end, steps main wheel is already in no need of the guide rail and returning rail, thus this place will be the terminal of the guide rail and the returning rail. The guide rail terminal is not allowed to exceed the sprocket center line. But when the auxiliary wheel goes through the drive end and tension end, it still needs steering guide. When the terminal steering guide of this auxiliary is made as a whole, it is the steering wall.


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Figure 1-7 Guide brackets and guide rails Figure 1-8 Steering wall

3.6 Steps: It is the direct component to carry passengers, which is a four-wheel vehicle with

special structures, being sub-assembly type or integral assembly type. It is connected to the step chain through the step main shaft. As the number of the step is large and steps are moving parts, so the performance and quality of the escalator depends largely on the quality and performance of steps.

These series escalators provide aluminum alloy steps and stainless steel steps for selection. The groove depth of the step surface is larger than 10 mm, the groove width is 5-7 mm, and the tooth top width is 2.5-5 mm which is of the equal pitch tooth shape, and the role is except for preventing slippery, and also making steps go through the upper part and entry successfully which can be embedded into the comb tooth, ensuring the passengers safety going up and down. The circular surface of step kick plate is designed to ensure the uniform clearance between the two steps during the operation at the inclined section. The kick plate is made with tooth sockets whose requirement is same with that of the kick plate, which can make the teeth of the following steps embed into the tooth socket of the previous step kick plate. The distance between the tooth crests of the step and the kick plate is not bigger than 6mm. 3.7 Comb Teeth, Comb and Floor Plates:

In every escalator entrance, it should be furnished with comb teeth and comb in order to ensure passenger safety during the transition. The tooth on the comb should mesh with the tooth on the style. Even though the passengers’ shoes and items are relatively static on the step, they could also be smoothly transited to the floor plate. Once the step running is hindered by some item, the comb is lifted or displaced to stop the escalator from running. Combs can adopt aluminum alloy castings or engineering plastic injection moldings.

The floor plate is not only the escalator passengers’ entrance, but also the cover


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plate of the upper and lower platform maintenance rooms, which is made of steel plate, and has reinforced ribs welded on the back. The floor plate surface is paved with wear-resisting and slippery preventing material. 3.8 Tensioning Device：

The tensioning device is composed of the step sprocket, the shaft, the tensioning vehicle and step chain spring, etc.

Figure 1-9 The tensioning device Figure1-10 Structure diagram of spring tensioning device

1) The role of the tensioning device： a. Make the traction chain of the escalator obtain necessary tension in order to ensure

the normal operation of the escalator. b. Compensate the elongation of traction chain in the operation. c. Tract the chain and steps to transit from one branch to another, being the steering

role. d. Supply the necessary components for the guide, such as the steering wall installed on

the tensioning device. 2) The structure of the tensioning device：

The escalator uses the spring tensioning device, and both ends of the sprocket shaft of this structure formed tensioning device are installed within the sliders. The slider can slide in the fixed chute, and the tension of the tension spring can be adjusted by the nut to ensure the step chain is in good working condition during the escalator running. When the volume chain ruptures or elongates, the wheel on the tensioning vehicle guides precisely to produce displacement, making its safety device (volume chain rupture protection device) work and the escalator stop running immediately. 3.9 Working Principles of the Escalator

The escalator transmission is divided into the passenger lifting motion of steps and the synchronous movement of handrails.

1) Step motion The host small sprocket drives the main shaft through double-row sleeve roller


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chain, and the step sprocket mounted on the drive main shaft drive the step chain. The tension vehicle with the roller can be adjusted horizontally in the frame guide rail to adjust the step number. The tensioning device makes the step chain of closed loop movement have certain tension force though adjusting the pressure spring, making the step hanging on the chain realize uniform motion.

In order to reduce the vibration and the noise during step motion, the main and auxiliary step wheels of steps both adopt rolling bearings with plug-in polyurethane rollers. 2) Handrail motion When the main shaft is driven for rotation, the double-row sprocket fixed on its

axis drives the handrail sprocket through the double-row chain, and adjusts the tension force of the handrail and the tensioning belt to obtain adequate friction driving force at the same time. Besides, the slide between the handrail and the drive friction wheel is small, thus it’s easy to guarantee the make the handrail and the step have the synchronous speed, and the error to realize that is 0 ~ + 2%. 3.10 Automatic Lubrication System

The escalator’s mechanical structure need to use a variety of chains and to ensure these chains have low vibration and low noise during the operation and extend the service life of the chains and sprockets, it is very important to lubricate the chains. Automatic lubrication system is composed of the lubrication pump, the oil filter, the oil, the brush and the piping, which is set on the horizontal section of the metal frame. The electrical control part lubricates moving parts such as the step, the main drive chain, and the handrail drive chains on a regular time and regular quantity. 3.11 Electrical Control System

Electrical control system is composed of the control cabinet, the junction box, the control button, the handrail lighting (configured according to the customer), the step clearance lighting, the safety switch and the connecting cable, etc. The control cabinet is set on the horizontal section end of the metal frame, and the junction box is installed at the lower horizontal ends, which is basically to realize the intermediate connection between the safety switches at the lower part. The main role of the safety switch is to ensure the absolute safety of passengers, and once the malfunction of the escalator occurs, the escalator will stop running immediately. And the fault display will show the code of the failure parts, and when the maintenance personnel troubleshoots the fault according to the fault display parts, the escalator can restart for normal operation. The location layouts of the safety switch are shown in the figure below, and for details please see the electrical principle descriptions.


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Figure1-11 Location layout schematic of safety switches 1. Lower aprons protection (left and right)

2. Speed detection device of the handrail (left and right)

3. Lower step missing detection switch

4. lower entrance protection(left and right)

5. Comb comb plate protection (left and right)

6. Detection switch of the lower maintenance cover plate

7. Upper aprons protection (left and right)

8. Upper entrance protection (left and right)

9. Detection switch of the upper maintenance cover plate

10. Comb comb plate protection (left and right)

11. Detecting switch of the drive speed testing

12. Drive chain rupture protection

13. Sagging protection of the upper step

14. Upper step missing detecting switch

15. Sagging protection of the lower step

16. Step chain rupture protection (left and right)

1

2

3

4

5

6

7 8

9

10

11

12 13

14

15

16


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Chapter II Electric Part

1. Instructions of Escalator Electrical Principles In upper and lower machine rooms, there are control box and coupling box on

which there are emergency stop switch, overhaul switcher and overhaul socket. The main power switch is also installed on control box. The key switch, emergency stop switch and trouble indicator are installed on upper and lower handrail cover plates of escalator. When the escalator runs normally, the main power switch should be set as “ON” and the upper and lower overhaul switchers should be set as “Normal”. When all the switches in safety circuit are normal, operating personnel puts the key switch at up (down) running position. At this time, the bell rings to alert passengers to look out. Then the key switch resets and the bell stops ringing. And PC machine outputs signal to make KZD band-type brake contactor, KS upward (KX downward) running contactor and KQD star starting contactor pull in. And the escalator starts upward (or downward) running. Later on, KQD releases, KYX triangle running contactor pulls in and the escalator runs normal.

2. Instructions of Escalator Maintenance When the short-circuit plug of overhaul socket on control cabinet is pulled out, the

escalator is in the state of overhaul and cannot run normally. When you plug overhaul plug in overhaul socket and press upward or downward button on the panel of handheld overhaul box, the escalator can run in inching on the condition that all the switches are in safety circuit are normal. In the same way, when you pull out short-circuit plug of overhaul socket on coupling box, the escalator is in the state of overhaul and cannot run normally. When you press upward or downward button on the panel of handheld overhaul box, the escalator can run in inching on the condition that all the switches are in safety circuit are normal. What should be noticed is that when the short-circuit plugs of overhaul socket on both control cabinet and coupling box are pulled out, the escalator neither runs in inspection or runs normally. 3. Lighting Circuit of Escalator 3.1. Step lighting of up and down horizontal segments


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In the process of step forming ladder or ladder disappearing, it may be danger for passengers to step between two steps at the transition point of up and down horizontal and curve segments of ladder way. In order to avoid the above situation, two fluorescent lamps should be installed under up and down horizontal segments of step. So, seeing the light when they pass this place, passengers can

timely adjust their standing position on step to ensure their safety. 3.2. Safety lighting

Both upper and down machine rooms of escalator are installed safety lighting AC36V. And upper control cabinet and lower coupling box are both installed socket AC36V and AC220V to supply power for safety lighting and overhaul.

4. Escalator Safety Devices

Fault and security issues due to the escalator can be solved by functions like auto-alarm, auto-display and auto-trouble analysis of the escalator safety analysis, which Ensure the safety of the passengers from the maximum limit.

4.1. Service Brake

Service brake is installed on high-speed motor shaft, it can make the escalator stop by doing uniformly retarded motion and keep the stopped state in the process of stopping the service. At stop time, the band-type brake is normally closed, that is in the braking state. When continuous electricity going through band-type coil, it is open, the escalator starts running. After the outage of band-type circuit, band-type brake applies the brake immediately.

4.2. Auxiliary Brake

When actuating unit and actuating spindle are connected by the drive chain, once the chain breaks, the two lose connection. At this time, even if the safety switch cuts off the power supply and the motor stops running, it cannot stop the escalator ladder. Especially when loading up, the escalator ladder will suddenly do countermotions and speed down, which will lead to passenger’s hurt. Therefore, install a brake on actuating spindle, drive the spindle by mechanical method, that is we can prevent the above situation from happening if the whole escalator stops running. The brake is called

Green Flourescent light

Figure 2-1 Stair interval lighting between up and down horizontal sections


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auxiliary brake.

Auxiliary brake is installed in the following situations

1） The service brake isn’t connected with step, step or tape drive wheels through axle, gear, multiple row of chains, two or more than two single chains;

2） The service brake isn’t using electromechanical brake;

3） Lift height is above 6m;

4） Public traffic type escalator.

The function of auxiliary brake should be under the action of braking force, on-load escalator stops under the obvious deceleration and keeps an idle state. Don’t need to ensure the braking length of the service brake. The action of the auxiliary brake should be able to cut off the control circuit in emergency. The auxiliary brake is mechanistic, applying the brake by principle of friction through mechanical structure.

The auxiliary brake works in any of the following situations.

1） Before the speed going beyond 40% of the nominal speed;

2） When the ladder way suddenly alter its prescribed direction.

4.3. Handrail Entrance Safety Device to Prevent Foreign Bodies

To prevent foreign bodies entering the handrail passageway and to avoid children’s hands being clamped here, an elastic software ring safety device to prevent foreign bodies is installed below the entrance of the handrail end. The device can become deformed when receiving the effect parallel to the handrail’s motor direction. The device has a ferrule installed at the handrail entrance where handrail can get through, and an elastomer bumper is installed inside the ferrule to form the outer element. The

bumper has dowels, which can touch the switches installed in the entrance. When dowels touch the switches, escalator stops and send out alarm signal. When ferrule bumper touches with objects which stop at the same time, the inherent elasticity of the bumper make dowels away from switches to restart the escalator.

4.4. Skirting Safety Device and Skirt deflector

Step and skirting clearance safety switches are installed on the upper and lower

Figure 2-2 Skirt panel protective equipment


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sides of the escalator, when escalator is in normal operation, step and skirting keep some interval, 3.5mm for one side and 7mm for the sum of both sides. To ensure the safety of the passenger when taking the escalator, install C-shape steel on the back of the skirting, and install safety switches at the place with a certain distance to C-shape steel. When foreign bodies enters the gap between the step and skirting, skirting becomes deformed, and C-shape steel moves with it to a certain position, then touches safety switches to let them work, thus the safety switches cut off the safety circuit, and the escalator stops the service.

To decrease the resistance between the step and skirting, add skirt skirt deflector for the escalator.

4.5. Drive Chain Scission Protection Switch

Drive chain protection switch is installed on the upside of the escalator, when the drive chain breaks or is too long, touch the protection switch, then it operates and cuts off the safety circuit; meanwhile, the electromagnet pulls in, and drives ratchet device to make it grab the chain, then escalator stops the service. (The protective device can only be used to promote escalator that is above 6m and public traffic type escalator.)

4.6. Elongation or Break Protection Switch of Step Chain

Except the mechanistic protective device that is used to prevent the break of traction chain, escalator installs switches at the tensioning spring end, when traction chain becomes too long due to abrasion or other reasons, it will touch the switch, cut off the power supply and stop the escalator.

4.7. Safety Switch of Abnormal Comb Safety switches of abnormal comb are installed in front of skewback under comb

on both sides of escalator. The comb teeth will move forward when passengers’ umbrella tip, high-heeled shoes or other foreign matters insert it. When it moves to a certain distance, the skewback under comb will touch safety switch which will cut off safety circuit to stop the escalator. 4.8. Safety Switch of Step Sinking

Up and down curve segments of ladder way of escalator are installed with switches of step sinking. On minor axle of step, an angle gear is installed, and the metal structure is installed an upright tube which is connected with a hexagonal axle under which there is a switch. When the step is damaged and sinks, the angle gear touches the upright tube, and the hexagonal axle turns to strike the switch. And then the safety switch moves to cut off safety circuit to stop the escalator.


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When above faults occur, fault codes can be shown by seven segments code for examination and maintenance. For details about fault code, see attached table: Explanatory table of faults. 4.9. Fault Protection of Handrail Deviation 4.9.1. Action principle Under left and right handrail beside the inflection point on the lower part of escalator, there is a handrail speed detector fixed with a sensor (See Figure 2-3). If the tachometer wheel is plastic, the induction device should be irony; if the tachometer wheel is irony, the induction device should be a hole. The size of the section of induction device should be closed to the section of inductive head of sensor. The mounting distance is required to be 1mm≤L3=L4≤4mm. Sensor 3 /4 should be set to measure the speed of left and right handrail.

Rotating passively by the driving of handrail, tachometer wheel has a linear speed which is basically the same as speed of handrail. A sensor is installed on tachometer wheel and on non-running part is fixed Sensor 3/4 whose induction tip is opposite to the sensor. When tachometer wheel rotates along with handrail, Sensor 3/4 outputs pulse signals (tachometer wheel outputs one pulse signal every time when it rotates one circle) shown in Figure 1. The revolving speed of tachometer wheel can be measured by measuring the radius, and the speed of handrail can be further calculated. Compared with the speed of ladder, when the speed of handrail continues to be slower than the ladder for 85% for 15seconds, the power of escalator or its safety circuit should be cut off to stop the escalator. In this way, the handrail is protected by speed measurement.

Figure 2-3 Installation instruction of tacho-generator of handrail

4.9.2. Testing method On the condition that the escalator runs normally, when the running speed of escalator is reduced by hand or the output signal of tacho-generator is dismantled (The

Signal:


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speed of left handrail is F1 and the speed of right handrail is F2), the system will cut off the power of escalator or its safety circuit to stop escalator after 15 seconds for the speed fault of handrail. Thus the handrail is protected by speed measurement. When the left handrail is under the protection of speed measurement, the safety monitoring panel of escalator will show the fault “ERR5”; when the right handrail is under the protection of speed measurement, the safety monitoring panel of escalator will show the fault “ERR06”. After the fault is removed, the power can be cut or hand reset.

4.10. Over Speed and Direction Reversal Protector 4.10.1. Installing the detection sensor of speed and moving direction of escalator The installation method of sensor: the center of induction surface of a sensor is

opposite to the center of driving chain sprocket teeth, while the edge of another sensor is opposite to center shaft of adjacent sprocket teeth (See Figure 2-4); mounting distance: 3mm≤LA=LB≤5mm

Figure 2-4 Arrangement Figure of main engine detection sensor

4.10.2. Detection principle 4.10.2.1. Over speed protection function

By Sensor A and Sensor B, the speed of driving chain sprocket can be measured which can judge whether the escalator over speeds and execute over speed protection function. When driving station works and driving chain sprocket rotates, the sensor outputs am pulse every time when each sprocket tooth intercepts sensor. The running speed of escalator can be worked out by measuring the pulse interval. As speed measurement channels, Sensor A and Sensor B can separately measure 1.2 times and 1.4 times over speed and protect it by setting a certain pulse period or frequency threshold.

4.10.2.2. Anti-reversal function When the two sensors are installed correctly, the phase position of Senor A can be

advanced of that of Sensor B and there is overlap of pulses of two sensors. At this time,


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the actual running direction of escalator can be measured by the judgment of logic sequence of two sensors and the reversal running can be prevented.

4.10.3. Testing method 4.10.3.1. Testing method of over speed protection function In safety monitoring panel of escalator (F0-01), you can reduce set value of sensor

pulse (20% and 40%) and determine that the escalator over speeds by comparing actual running speed of escalator with set value. Then you should cut off power of safety circuit of escalator to make it stop running at once. When escalator is under over speed protection, safety monitoring panel of escalator will show fault “ERR01” (over speeding for1.2 times) or “ERR02” (over speeding for 1.4 times). This measuring ability can function in both normal and overhaul running states, and the fault can be removed by hand reset.

4.10.3.2. Testing method of direction reversal function If Sensor A and Sensor B enter the opposite signal of safety monitoring panel of

escalator before start, the safety monitoring panel will judge it as logical error after start and cut off the power of safety circuit of escalator to make it stop running at once. The safety monitoring panel of escalator will show the fault “ERR03”. This measuring ability can function in both normal and overhaul running state, and the fault can be removed by hand reset.

4.11. Stop Switch and Key Switch Installed on the end plate of up and down skirtings, a red urgent stop switch and a

key switch can be turned on as required direction; installed at the conspicuous place on control box and coupling box of upper and lower machine rooms, stop switches are easy to operate. In an emergency, you should press the stop switch to stop the escalator. The switch is for the personnel who work on installation and maintenance in the truss to use in an emergency. 4.12. Motor Overload Protection

When there is too much electric current due to overload or for other reasons, the thermo relay will automatically turn off and cut off all power supplies of electromotor. When the fault is removed, thermo relay will reset.

4.13. Phase Protection When the power phase is wrongly connected or comes away, phase sequence

protection switch will motion and the escalator will cannot move. 4.14. Yellow Border of Step Step is the important part to transport passengers. For the sake of passengers’ safety,

there is a yellow border on each step to notify passengers to stand in the area except


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yellow border. 4.15. Step Missing Protector 4.15.1. The installation method of detection sensor Each machine room has a detection sensor which is installed on the section of long

edge of kick-plate opposite to the step (as shown in Figure 2-5/6). And the mounting distance: 3mm≤L5=L6≤5mm.

Figure 2-5 Schematic Figure of detecting points of sensor

Figure 2-6 Schematic Figure of installation position of sensor

4.15.2. Detection principle The sensor detecting missing step is Sensor 5 /6. Whether there is any step missing

can be detected by installing Sensor 5 /6 at the rotation end of step in upper/lower machine rooms. Whether the step is missing can also be detected by calculating the pulse of Sensor A/B between adjacent pulses of Sensor 5/6 and the signal of Sensor A /B.

When the step passes, Sensor 5/6 receives the signal and outputs a pulse. Suppose the interval of two adjacent pulses of the same Sensor is T and in the interval T, the pulse counting of Sensor A or B is X. If there is no step missing, the value of X in the interval of T is within certain threshold value whatever step speed. If the value of X exceeds threshold value, there will be step missing fault and the escalator will in a safe

The beam which is detected

Stair

Stair


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state after emergency stop. 4.16. Overhaul Cover plate Opening Detection Device In the process of escalator’s normal running, if up and down overhaul cover plates

are opened, the detector switch installed under the cover plate will cut off the power of safety circuit of escalator to stop walkway at once. When the escalator is in overhaul state, the detector switch does not work.

4.17. Protection Function of Stopping Distance Overhang There is the case when the escalator cannot stop due to fault of brake. When

stopping distance is longer than the maximum allowable distance for 1.2 times, the safety monitoring panel will judge that there is a fault of stopping distance overhang whose fault code is “ERR04”. After the fault is removed, the escalator can return to normal by hand reset.

4.18. Brake Loosing Fault Protector 4.18.1 Action principle The detector switches are installed under brake coil of service brake (See Figure

2-7)

Figure 2-7 Figure of brake loosing fault protector The detector switches detect the motion of brake arms of two sides of brake. The

switching signals are connected to X6 and X7 of system safety monitoring panel and numbers of terminal are 10 and 11 (please refer to electrical schematic Figure). When there is a brake loosing fault, which is brake arms’ not opening after the start of escalator with detector’s not motioning the system safety monitoring panel cannot receive signal of brake opening. At this time, the power of escalator or its safety circuit will be cut off to stop the escalator, so the brake loosing fault protection is realized.

4.18.2 Testing method Before or when the moving walk runs, if the signal line of detector switch is

removed (terminal number is 10 or 11) or the connection of band-type brake coil is removed (terminal number is U32), the band-type brake won’t open. At this time, the


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system safety monitoring panel cannot receive signal of brake opening and cut off the power of escalator or its safety circuit to stop the escalator. And the system safety monitoring panel will report the fault “ERR09”. After the fault is removed, the escalator can return to normal by hand reset.

4.19 Hand Turning Detection Protector When the detachable hand turning gear is installed, the detection protector will

work and cut off power of safety circuit to prevent the escalator starting. 5. Instructions of Escalator Oil-way Principles

5.1. The Function of Automatic Oiling When the cumulative running time of escalator is up to 12 hours, automatic oiling

device will work for 300 seconds and then stop automatically. 5.2. The Function of Manual Oiling

When the escalator needs oil, it can also be oiled manually besides automatic oiling. When oiling manually, you should turn on the key switch for 6 seconds in the running state of escalator. And the oiling device will automatically stop after working for 300 seconds.


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Ⅲ. Instructions for Escalator Installation and

Commission Escalator assembled in the factory can be transported to field in complete machine

or in segmentation to be installed. In segmented shipment, you should take apart the completely assembled ladder way of escalator at the detachable place along the traction chain, and temporarily joint step and traction chain on the metal structure of this segmentation solidly. When they are transported to installation site, you should first join metal structures together into a whole, and then connect traction chain. There are several kinds of the installation of handrail system: Taking apart and transport them to the site to be assembled, after trial assembly in the factory; Transporting parts and components to the site to be assembled; transporting complete machine assembled in the factory to the installation site. (I). Lifting, Transportation, Assembly of the Escalator and Putting it in Place

1. Lifting and taking in place of escalator should be performed by specialized personnel, and transport machine has to meet the transportation requirement of escalator. The general way of transportation is entire transportation, and disassembling transportation is supplied on special occasions or when the whole machine cannot be into the building with higher lifting of escalator and too long truss.

2. The escalator is equipped with wire rope kit for lifting which lies at quadrangle of truss. You should crane at the handle position when lifting, and cannot change the position at will. See Figures

Figure 4-1 Correct way of lifting Figure 4-2 Wrong way of lifting

3. If applying the way of taking truss apart, you should use composite truss. And the end of lifting is still at the handle position, while the other end should be lifted at the joint end of truss without deformation of truss.

4. The fission transport of truss is decided by fission structure. In general, the lower part is viewed as an independent part, and the middle and upper parts are viewed as a whole part. Only when the truss is too long to be transported, the middle part and


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the upper one can be divided. See Figure

Figure 4-3 Mode of whole transport Figure 4-4 Mode of fission transport

5. During fission transport, auxiliary support frame should be set at two sides of

the truss. And on the upper part of auxiliary support frame, there should be firm horizontal connection beam which can bear total weight of fission truss. And there should be wooden parts between truss and supporting beam, to avoid the movement during transport. See Figure 6. Combination and assembling

6.1 When the fission truss of escalator is transported at the installation site, it needs to be assembled to be a whole. Combination and assembling should be carried according to Figure4-5. The joint part cannot be collided for fear that rail joint becomes curve. And then bolts at the joint part should be fastened.

Figure 4-5 Combination and assembling

6.2 When combining and assembling, you should also check the verticality and

horizontal of truss juncture and adjust them by adjusting shim. The juncture of step guide track shall be closed. The part gap at lay-up shall be shorter than 0.05mm, and the protrusion at lay-up shall also be lower than 0.05mm. 6.3 After step guide track is connected, step drag chain should be connected, so the tension is adjusted preliminarily.

7. When the entire escalator moves horizontally on the ground, sleeper, roller or rolling log have to be filled on the origin of force of escalator, and the movement should be slow. See Figure 4-6 and Figure 4-7:


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8. Putting the escalator in place 8.1 The escalator has to be lifted on upper and lower bearing beams when

horizontally moving. See Figure 4-8.

8.2 Before the whole escalator is lifted on bearing beams, the upper part should be

firstly lifted with the lower part being attached to safety cable. With the upper part being lifted gradually, the safety cable on the lower part is loosed accordingly. So the upper part goes up slowly and the lower part moves forward slowly. See Figure 4-9

Figure 4-6 Horizontal movement way of escalator

Figure 4-7 Horizontal movement way of escalator

Figure 4-8 Putting the escalator in place


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8.3 The height before escalator is in place and the final place The escalator has to be higher than upper and lower bearing beams and be slowly

put down in horizontality. So escalator lies on upper and lower bearing beams and the center of escalator should be basically the same as center line of civil construction. See Figure 4-10. Several paratactic escalators should be uniformly put in place. The gaps between escalator and bearing beams should be the same. Installation filler plates should be put under the escalator when it is being put in place, and the adjusting bolt rubber sheet should be put under the steel plate. See Figure 4-11

9. Horizontal adjustment of escalator 9.1 The upper and lower steps of escalator should be a little higher than final grade

level of upper and lower floor, to avoid water flowing into rack when the floor is washed. To adjust the height, adjusting filler iron can be put under the installation filler plates of upper and lower parts of escalator, and the filler iron should be welded with embedded iron plate of upper and lower bearing beams.

9.2 After the heights of upper and lower parts of escalator and upper and lower floors are adjusted, the levelness of upper and lower parts should be adjusted. And the horizontal measurement of upper and lower parts should be between 200×200 angle steels of truss, and the levelness middle parts of step transverse plane can also be measured. Longitudinal levelness is measured on both sides of girders of upper and lower truss of escalator (when the comb plates of upper and lower parts are not

Figure 4-9 Lifting the upper part

Figure 4-10 The height before escalator is lifted


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installed). Longitudinal levelness of middle parts can also be measured, and the levelness of escalator should be less than 0.5mm.

9.3 After both horizontal and longitudinal levelness are adjusted, adjusting bolt should be fastened. And all the fasteners should be checked to ensure that all of them are fastened.

(II). Inspection and Adjustment of the Driving System 1. First debug the whole escalator and then have a pilot run. after the assay was

approved it can leave factory. Due to the transportation, first discharge the handrail system and then transport it to the site for installment. And other assembly units must work after check and adjustment.

2. Traction machine

Figure4-12 driving system

Traction machine lies in the upper machine room of the escalator. Through

coupling 8 electromotor drives reducer 10,and through chain wheel 11 and driven chain

1. Braking electrical machine 2. Brake band 3. Tripping spring 4. Flywheel 5. Eccentric clamping piece 6. Oil scale 7. Riser vent 8. Coupling 9. Electrical machine 10. Reduction box 11. Chain wheel 12. Driven chain


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12 reducer casing drives the move of driving principal axis, so that the steps can move. There is electromechanical brake on the top of electromotor. The interval between brake wheel and brake band should not as big as 0.7mm when the brake looses. The switch of brake is in effect. When brake does not loose, electromotor should not work. The brake of drive system should have enough retarding torque. As for the stopping distance, it should be adjusted between 0.2~1.00m depending on that of no-load and load operation..

3. Driving system 3.1 driving system consist of traction machine, control cabinet, handrail drive, step

drag chain and so on. The upper and down comb plates should be discharged for checking. To facilitate maintaining, with bolts discharged, electric control cabinet can be carried out of machine room. As figure 4-13

Figure 4-13 driving system

1. Control cabinet 2. Actuator

3.2 check tension of chains of all kinds of specification, and the tensioning of double row of chain of traction output shaft. First loosen the base pin, so that adjustable bolt pushes out the tractor to the back. Cam can adjust the tensile force of the double row chains, which should keep proper (not too tight and not too loose). The droop of the chains can not bigger than 15mm. And keep protection switch of drive chain in effect. The adjusting bolt on the side plate of principal axis can adjust the chain tension of handrail spindle. Meanwhile keep droop not bigger than 10mm, and this can be done by discharging 3 steps and chain covers. While adjusting the chain tension, it is necessary to check the depth of parallelism of chain and chain wheel.

(III) Checking and Adjustment of Steps Step is a moving part on which passengers stand. Steps are concatenated by two

roller chains with special license. The outer ring of idler wheel is made from


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polyurethane and the inside track has ball bearing. And this avoids noise produced when idler wheel and chain wheel engages. One extending pin roll in every three chain links is used for connecting step axle. The steps are fixed in the step axle with nylon nylon, and its cross range location is through clamp.

Figure 4-14 steps

1. Steps are assembly units for cyclic motion. There are nylon guide pads on the

two sides. If guide pads are frayed, steps will shock step guide rail as well as rub with skirt guard panel. The attrition rate need to be checked regularly, by discharging at least above three guide pads, of which the intended size is 7-0.2mm. As figure 4-14

Figure 4-15 Step guide pad

2. If the abrasion loss reaches maximum 1.2mm, guide pads must be changed. Step guide pads are expected to be checked casually in the lower machine room. On the two sides of the steps, unilateral clearance between skirting and guide pad should not bigger than 0.4mm. When it is necessary skirting needs to be adjusted and biased steps needs to be revised.

3. Checking and adjusting comb tooth centralizer, as figure4-16

A. stair body B. stair wheel C. guide block


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Figure 4-16 Step broach centralizer

3.1 Comb lies in the entrance of the escalator and it is fixed with screw, and in the

front it meshes with step alveolus. And this keeps every step and comb sweeping through.

3.2 There are guide plates on the two sides of comb, and safety switch is in the back of it. When the move gets stuck by foreign matters, the comb moves rearward turning off the switching power supply, then the escalator stops moving.

3.3 Check and adjust the condition that comb and guide plate watch. Make sure that the gap on the two sides of comb is not bigger than 0.4mm. When comb moves backward there is no obstacle. The adjusting bolt needs to be adjusted only. And lubrication should be in good condition in the guide card slot.

3.4 Checking step and comb engage

Figure 4-17 Checking steps, comb engage and guide pulley

Depth of engagement between comb and step step panel should not be as big as

6mm. When cascade tooth engages with comb broach, perpendicular distance from the

1. Guide pad 2. Safety contact of comb plate 3. Comb tooth


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surface of the step to the root of comb broach should not bigger than 4mm. 3.5 When designed and manufactured, comb has scheduled breaking point, in case

that it badly damages steps. Once there is something wrong with comb, it should be changed.

3.6 Check whether every step engages with broach while the escalator are working, as well as whether volume passes step guide pulley without lateral thrust. If there is no yawing force, it is possible that cascade lateral guide block has been wore or guide pulley need to be adjusted.

(IV) Adjustment of Comb and Operation Test (as figure 4-18)

Figure 4-18 Adjustment of teeth panel and protection switch

1. Before checking upper and down teeth panels, the comb plates should be removed first. When there is 100 kilogram horizontal force in the center of teeth panel, foreign matter protection switch of comb tooth should work making the escalator stop.

2. In some cases, for example there is no spring ergograph to measure operating force in the site, but it is needed to keep checking the freelance of the teeth panel. So the following should be done:

a. discharge two comb b. Put a lag spike into the gap of the left and right step in the front of teeth panel c. Pass the flywheel of the turning electromotor (release hand brake disc) d. Teeth panel should be able to move smoothly via resistance, and the on-off

action can be operated.

1. comb panel 2. Teeth panel 3.Foreign matter protection switch of comb


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e. Hand jigger moves step backward, and teeth panel should get back to its normal position. And now switch will reset through hand movement.

(V). Dischargement of the Step 1. Step dischargement should be done in the bottom machine room. Move the step

point to be discharged to designated spot. The control switch must be operated and maintained by specially-assigned person. Three steps (for check) should be marked with red lacquer.

2. mark the position where axle sleeve are in the axle with scratch awl, loosen clamping screw, push clamp and axle sleeve to step chains, retreat steps (as figure 4-19 arrows show) and lift it, and lift it from the guide rail in the opening of turning wall.

Figure 4-19 Dischargement 3. After dischargement reinstall it as the opposite order. Before the bolts are tightened, in the mark the screws need to be tightened. Then operate the bottom step slowly and check the engagement of steps and comb teeth. (VI). Collapse Protection

1. To avoid escalator fatigue deformation, breakage and damage to other components due to long-time running, there are collapse protection devices in the upper and bottom parts of the escalator (as figure 4-20). Once cascade deformation and subsidence and breakage happen, protection switch will cut safety circuit power supply to stop the escalator.

2. Switch rod vertical height of the collapse protector is adjustable. When escalator works well, the vertical dimension while arc kick-plate passes the top of switch rod is 5+0.50mm.

1. Stair chain 2. Turning wall 3. Stair 4. Teeth panel 5. Comb plate 6. Stair accessory

ring


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Figure 4-20 Step collapse protector

1. collapse protection switch 2. step step 3.step arc kick plate 4. step accessory ring 5.step accessory

guide rail 6.step main-wheel 7.step main guide rail 8.step chain 9.comb

(VII) Comb plate

1. In the top and lower machine rooms, cover fashioned in advance overall cover plates, on which there are panel of skid resistance. To make it easy to disassembly and assembly and carry while install and maintain, comb plate is made into two parts.

2. While discharge comb plate, insert special tools into hole of pre-process and then lift up and discharge it. (as figure4-21 )

1. cover plate（small） 2. cover plate（big） 3.Cover plate component 4. Adjustable staybolt

Figure 4-2 Comb plate

(VIII) Installment and Adjustment of Handrail System Handrail system is for passengers holding and there is a handrail for circular motion and a systematic combination of parts. Since the limitation of transportation, the whole parts of rail system device can not be assembled on the whole escalator for leaving factory. Rail system device assembly takes two times to complete: first workshop assembly commission, testing, and removing the packing; the second assembly is done in the final installation site, and this is a systematic assembly engineering. Rail system consists of rail drive, breast board, armrest with gateway protection, skirting, both


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inside and outside cover plates, top and bottom turning ends and other units. the handrail in the handrail system is moving part for passengers toughing, and requires keeping consistent with speed of cascade movement. The rate of movement of the handrail also requires exceeding that of cascade by 0 ~ 2.0% and this is achieved by adjusting the handrail driving part.

1. Handrail driving system In handrail driving system, driven handrail moves circularly.

Figure 4-22 Handrail driving

1. Tensioning screw 2.impact belt 3.friction wheel

4. Handrail 5.tensioning pole 6. Screw

7. Locknut 8. Nut 9. Pressure spring

1.1 Friction wheel 3 with banana tire drives handrail, degree of tightness of

handrail 4 is adjusted by nut 8 on the tensioning lever 5, and can be impacted through the pressure made by band 2 to the armrest 4. Tensioning degree of pressure belt depend on tensioning screw1 to adjust.

1.2 Pressure belt of handrail tensions right, then the friction wheel will drive the armrest with normal operation , at this time a larger manpower can make handrail stop running. Press belt tension is to rely on a spring 9 to maintain continuously. When operating tension rod 5, it is necessary to dismantle inclined cover plate and lower inner decking and loosen screw 6 and locknut 7, meanwhile use another nut 8 to adjust tensioning pole, after that don't forget to tighten locknut7 again.

1.3 In the bottom of each handrail there are handrail tape-break protection switch (see photo)... When the handrail extends overly or at fracture, it will touch the lever of broken belt protection switch , protecting switch action, making escalator stop. As for the handrail broken belt on both sides of the switch, as long as one side of the switching power supplies is cut off, the escalator will stop running. 1.4 On the upper and bottom entrance of handrail, there is equipped with finger protection switch (see photo)... When some foreign body or child's fingers go into the


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entrance of the handrail, hit a protection switch to stop the escalator. both sides of the activity board1 in the finger protection switch can swing. when foreign body follows the direction R, baffle 4 is dragged out of the support of supporting shoe then under the action of the spring after 3, from the supporting block 2 slides down, then activity board open, hit switch 5 at the same time, and cut off power supply so that escalator stops running. Activity shrouding can be opened 30 mm, so as not to clamp hand, and all this can avoid the happening of accident. After trouble is removed, pull stop dog 4 above and forward, restoring its original position

Figure 4-23 Tape-break protection switch of handrail

Figure 4-24 Finger protection switch

1. Activity shrouding 2. Rest pad 3. Spring

4. Stop dog 5. Switch 6. Handrail

2. Handrail device (as figure 4-25)

2.1 The guard board of handrail device is formed by tempered glass without support, which is fixed in the clamping element, and handrail guide rail and the bracket are installed on the upper toughened glass.

2.2 Armrest device is first installed in the factory then installed on the truss. According to different requirements, with and without illumination, toughened glass also can be replaced with other materials with enough strength.

1. Switch 2. Pole 3. Hand strap


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2.3 Toughened glass is the main support of the armrest device, installed inside the glass clamping piece, with a pad. The installation of the glass should be from lower loading, a piece of standard paragraphs glass(1800 mm) can be assembled. After locating another R glass will be pack up. The rest line segment glass, in turn, will be fitted, and between each there will be pad filled, making a maximum 4mm gap between the pieces. On every edge there is a piece of compensation glass, installed after line segment glass is installed. After compensation glass being installed, R section glass will be installed. When installing glass on both sides , the verticality of the glass should be checked, and the tolerance is not more than 3 mm. The guarantee of the center distance between the two glasses will keep up the center distance of the handrail.

2.4 After the glass of both sides installed, handrail pulley belt group in the handrail turning end should be installed. And each pulley should be flexible, not block, so as not to affect the operation of the handrail and frictional heating and phenomenon alike. Armrest pulley belt group is in the handrail bracket slot.

Figure 4-25 Handrail devices

1. h（slim type）and strap 2.Handrail guide rail 3. Handrail stand

4a. Illumination cover plate 4b. Illumination cover plate 5. Tempered glass

6a. Lower inner decking 6b. Lower outer decking 6c. Clamping bar

7. Skirting 8.C-Unit 9.step

10. Outer decorating plate 11.Top chord of truss 12. Crash pad

11.13. Building floor

With lighting (ordinary type)

With lighting (ordinary type) (slim type）


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2.5. Handrail bracket is installed in the upper glass and filled with the u-shaped glass fillet. Handrail bracket joint should be tight and smooth, and prominent phenomenon is not allowed, and the surface is not allowed to appear scratched.

2.6. Handrail guide rail is guiding element of its movement, installed on the handrail bracket. Check the straightness of the installation, and joint should be smooth, closely and chamfering. Don't make the handrail scratches or damages handrail at runtime.

2.7. Check related movement components and parts of the handrail , and make sure it can turn flexibly and the position is right. Only doing this can the handrail be installed into guide rail and cooperation position, and according to 7.5 adjust the tightness and running situation of handrail. And handrail running speed is adjusted according to 7.4.

2.8. The operation of the handrail is driven by friction. Because of many revolving members and guiding elements, before the normal operation of handrail careful check of each link must be done , making two handrails run at a normal state.

3. Skirting 3.1. Skirting are on both sides of the bottom of escalator handrail, usually made of

hair grain stainless steel. The clearance between the unilateral and cascade per side is not greater than 4 mm, and the sum of gap between skirting and steps is not greater than 7 mm.

3.2. To prevent clutter among skirting, affecting the normal operation of escalator, especially to prevent the passengers wearing a rubber shoes foot from clipping into the space between the cascade and coaming, an apron board protection switch (see photo) must be equipped with. Once the skirt plate deformation happens, the micro switch 3 works and makes escalator stop.

Figure 4-26 1. Skirting 2. Step 3. Microswitch


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4. Lower inner decking and Lower outer decking 4.1. Through installation and commission, after normal operation, Handrail can be

fitted with a decking, and the lower inner decking should be in place first, finally lower outer decking will be fitted.

4.2. The installation and unloading of the lower inner decking and lower outer decking (see photo)... After moving the lower inner decking to upper machine room direction for about 300 mm, it can be removed. Reassembling can be fitted in the opposite direction.

5. Step illumination and caution (as figure 4-28) 5.1. In order to consider the safety of the passengers, at the top and bottom rung

horizontal motion segment, to avoid the passengers walk around seams between cascade and escalator, installation manual risk in operation and maintenance, with green fluorescent under the cascade, and the moving cascade is visible all the time.

5.2. Cascade is also with yellow border, and this instructs passengers can only step (shown in figure 4-29) within the scope of the 1 and are not allowed to tread on the yellow frame 2, and once is damaged, the yellow warning strip should be replaced timely.

Figure 4-27

6a. Lower inner decking 6b. Lower outer decking 6c. Clamping bar

7. Skirting 8. C-unit 9. Steps


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Figure 4-28 Step illumination Figure 4-29 Step caution

（IX）. Bearing of Escalator 1. All the components of escalator are installed on the supporting truss, which is

welded together by steel, and is divided into integral and fission parts. at a less height it can supply as a whole, while if height is big, fission structure can be adopted, bolted in the middle. 2. In order to ensure the normal work of the escalator, truss structure must have enough strength and stiffness, and generally its immunity accounts for 1/1000 of its span. Up and down concrete floor bears the lower part of escalator, which is fixed after level calibration. (See figure 4-30)

Figure 4-31 bearing in the middle

1. Puddle 2. Screw fastening 3. Nylon board 4. Rubber blanket 5.steel plate

3. When hoisting height is more than 6 m, its deflection increases accordingly, at

this time intermediate support (see figure 4-31)must be set . Due to the spring loaded in the middle bearing, thus the truss is elastically supported, and it can be adjusted

1. People standing scope 2. Yellow border

Green daylight lamp

Figure 4-30 bearing of escalator


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automatically along with the expansion and contraction of the truss. 4. The bearing connection (as shown in figure 4-30) of escalator and the structure shows, when the escalator truss expands or contracts, nylon boards slide between each other. Underneath there is a rubber mat, to reduce the transmission of vibration, and the clearance between escalators and the buildings will be sealed with cement. At least one ends of escalator use this movable bearing. (X). Escalator Control and Electrical Components

1. All control components are installed in a control box, and located in the upper room. Loosening the bolt can carry electric control cabinetout of rooms, convenient for operation (see photo)... control handle1 are connected to the main switch, and it has certain security. In inspection and repair escalators, only turn the control handle, cutting off the main switch power supply, shall the control cabinetbe opened, and control components be maintained. Number 2 is six core overhaul outlet, set up for repair escalators.

Figure 4-32 Control box

2. The operation and direction of the escalator, is determined by operators turning

direction power supply key. On the lower inner decking at the top and bottom of the escalator device, direction power supply key equipped with automatic escalator can open in accordance with the requirements , and there is a red emergency stop button (see figure /...). , and emergency switch is installed in a marked and easy reach place. In case of emergency, pressing the emergency stop button, escalator stops running immediately.

1. Control handle 2. Six core socket 3. Two core socket 4. Lamp switch


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Figure 4-33 Moving direction and emergency stop button

3. Because there are a lot of escalator safety devices, and they distribute in many

places, in the event of failure, maintenance must be done timely, to resume normal operation of escalator. according to the need of users， in the electric control cabinet key stop box there is a fault display box, and it can save maintenance time, making sure a fastest speed for removal of fault. There are two digital tube and a fault instruction plate (see table 1 and table 2) on the fault display board. When the figures on digital tube and fault illustration plate are the same, it shows there is fault in that position, and problem can be treated quickly. After troubleshooting, digital tube displays 00, saying escalator can be in normal condition. (XI). Commission

1. Commission of the mechanical part 1.1. After finishing installation, clean up the construction scene, the internal, and

external of the escalator. Only run the escalator when all safety protections are working normal, each part and each moving, rotating part such as traction machine, drive, drive system, step rail and chain are having enough lubrication. Run the steps both upward and downward for one round, check for abnormal situations, then the escalator can be ran continuously.

1.2. All the steps should be able to go through the tooth plate, clearance between should conform to the requirement of 2.4. 1.3. The cascade and apron board should not friction, clearance between should conform to the requirement of 7.7.1. 1.4. The two adjacent cascades should not friction during the meshing process. 1.5. When Under rated frequency and voltage, the maximum allowable deviation of the speed and rated speed of an unloaded cascade running along the given direction should be +5%. The speed is calculated according to the formula:

Button installment position


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v=s/t In the formula: v—the speed of escalator going upward or downward， m/ss—the measured running distance， m；t—The time of the upward or downward running corresponding to the distance，s。 1.6. The tolerable deviation of the running speed of Handrail and the cascade is 0~+2% . according to 11.1.5 ， in the same time measure the speed of the unloaded Handrail and the speed of the unloaded cascade running. Measure upward and downward running speed each once. Calculate the speed deviation of upward or downward running handrail and cascade according to the formula: v δ =（v1-v）/v×100%. In the formula： v δ—the speed deviation of upward running handrail and cascade; v1—the speed of upward or downward running handrail ，m/s; v—the speed of upward or downward running cascade，m/s;

1.6.1. Cascade speed are designed speed, handrail running speed is adjustable, when deviation of the handrail and cascade speed deviation exceeds 0 ~ + 2%, can adjust speed of the handrail with handrail drive according to 7.5.

1.7. Braking distance of the escalator, the stopping distance of unloaded escalator when running downwards should be within the following range: Nominal speed Stopping distance

0. 5m/s 0.2~1.00m 0.65m/s 0.3~1.30m 0.75m/s 0.4~1.50m Measurement of stopping distance should start when electric braking device starts

working, deviation of the stopping distance can be done by adjusting the main compression spring of the traction machine brake. 1.8. All running parts of the escalator should be normal, no scratches and abnormal sound, when running unloaded, the operation noise measured on the cascade and 1.0 m above the comb plate should be less than 65 db (A).

2. Commission of electrical part 2.1. Do well the cleaning in the commission site 2.2. After the wiring installation, everything must be checked, especially the safety

circuit connections of all kinds switches .


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2.3 Mechanical and electrical equipment installation can make sure operation . 2.4. Electrical and mechanical parts have had the necessary monomer check,

commission and adjustment. 2.5. There is no block or friction in the whole movement process of the cascade. 2.6. Commission personnel in the commission process must be serious, responsible

and thoughtful, and be rigorous to safety. 2.7. Instruments and measuring tools needed in commission : a）. Multimeter； b）. Tachometer； c）. Tram-egger； d）. Tong-type ammeter； e）. Decibel meter； f）. Second chronograph； g）. Tape, ruler, vernier caliper, vernier depth gauge, line droop, feeler gauge, angle

square and so on 2.8. Protective earthing is in good condition 2.9. Insulation performance is good; the insulation resistance between conductors

and conductors to ground must be bigger than 1000Ω/V, and its value is not less than: a. The power circuit and electrical safety devices 0.5MΩ b. Other circuit (control, lighting, signal, etc.)0.25MΩ When measuring, electronic components should be disconnected 2.10. Due to a lot of safety protection switches, they must be debugged item by

item, and every one is safe and valid. 2.10.1. Safety devices of the escalator: a. Power supply system cut and phase dislocation devices; b. Short circuit of electromotor and overload protection device c. Drive chain protector d. Step chain breaking or extending overly protector e. Working brake f. Brake loosening protector g. Overhang of Stopping distance protector h. Auxiliary brake(hoisting height exceeds 6m) i. Over-speed protective device j. Non-manipulating changeover protector k. Speed fault of handrail protector l. Handrail entrance protector


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m. Comb protector n. Step collapse protector o. Step lose protector p. Opening check of cover plate protector q. Scram button; 2.11. After the commission above, a comprehensive check again is needed, to make

it clear whether it meets the requirement. Function is implemented with reference to the corresponding principle of work. After commission completely according to the above methods and steps, abnormal factors still exist; please contact relevant departments of our company. Do not remove the PLC and change PLC program, causing unnecessary loss.

3. Pilot run 3.1. After the test of mechanical and electrical parts, a pilot run will be done,

before which do cleaning and lubrication again, making all the parts with sufficient lubrication.

3.2. Check that all parts are in normal condition, and then the pilot run can be done. No-load ascending and descending run respectively for 1 hour. Escalators should be running normally, smoothly without noise.

5. Inspection and quarantine After the completion of the commissioning, take self-check. after self-inspection

pass the inspection report, random file and other data to the local administrative department.

4. Place in operation Escalator must have acceptance from local competent department then it can be put

into service, meanwhile conduct completion formalities with the user. By then, the escalator installation completes.


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Assembly Schedule of Escalator

No. Schedule

Process Valid workday

2 3 4 5 6 7

1 Preparing work before installing

2 Retesting civil engineering

3 Jack-up and in position

4 Calibration standard in upper and bottom parts

5 Power supply entering control cabinet

6 Cleaning all parts and lubrication

7 Step pilot run


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8 Inspecting and adjusting all parts

9 Installing handrail device system

10 Ccommission

11 Pilot run

12 Checkout and acceptance

Notes：1. The workday in the table is calculated on the condition that the lifting height of escalator is <=6m. 2. The process arrangement can be adjusted or work parallelly in accordance with physical truth.


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Replacement and Measuring Tool Table

No. Name Specification No. Name Specification

1 Socket spanner 24 Slot type screwdriver 4".6".8".10"

2 Adjustable spanner 8".10".12" 25 Cross screwdriver 4".6".8"

3 Fitter's hammer 1.5pound.2pound 26 Electrician's knife

4 Rubber hammer 2pound 27 Nipper pliers 6"

5 Hacksaw frame 28 Diagonal cutting Nippers

6"

6 Hand vise 2" 29 Wire stripper 8"

7 File File.circle.semicircle.8".10" 30 Buzzer

8 Needle file 31 Test pencil

9 C type dog 2".4".6" 32 Electric soldering iron 35W

10 Retainer pliers 6" 33 Line droop 0.5kg

11 Box spanner 34 Levelling instrument 300mm 0.5/1000

12 Flat chisel 8mm.10mm.12mm 35 Angle square 200mm.300mm

13 Grease gun 36 Depth vernier caliper 300mm

14 Oil gun 37 Vernier caliper 150mm

15 Thread die handle M3~M16 38 Feeler gauge 0.02~2.00


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16 Threading die M3~M16 39 Straight steel ruler 150mm.300mm.500mm

17 Straight shank twist drill Ø2.5~Ø14 40 Steel tap 2m.3m.5m

18 Thread tapping M3~M16 41 Sound Meter

19 Angle abrader Ø120 42 Second chronograph

20 Electric pistol drill Ø1.5~Ø6mm 43 Tong-type ammeter

21 Electric drill Ø3~Ø13mm 44 Tram egger

22 Electric torch 45 Tachometer

23 Lantern ~36V 46 Multimeter


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IV. Care and Maintenance of the Escalator Special person should be assigned to maintain and safeguard the escalator, and the

maintenance personnel must pass through the basic knowledge training of the use of escalator. (I) Pre-maintenance Safety Precautions

1. Set up the safety bar and the "escalator in maintenance" sign; 2. Cut off the power master switch, and hang up on the switch "being repaired, don’t get

through" sign; 3. If the step that needs to be repaired has been removed from the escalator, operations

are allowed only at the assess point, and no one is allowed to stand on the step; 4. Absolutely no escalator belt load start; 5. After the repair and the maintenance, carefully go over the escalator to see if there are

any tools or other things left behind in it, and the escalator can be up and running when there is no remnants.

(II) Routine Maintenance 1. A dust removal with the vacuum cleaner should be conducted every day to the outer

surface of the escalator, step tread and comb plate, and as for the tempered glass, stainless steel inner and outer cover, apron board and aluminum armrest bracket, etc, we usually use the soft cotton cloth to dry clean in order to keep them bright;

2. The sundries and rubbish in the upper and lower horizontal metal skeleton of the escalator should be cleaned every day. As for the way of doing it, cut off the power and uncover the rear panel of comb comb plate to clean all the sundries and rubbish left on the metal frame backplane with the vacuum cleaner;

3. In order to keep good heat dissipation condition of the general rotator, a dust removal should be conducted to the t shell of the traction machine every week, and the method of doing this is the same as above;

4. The handrail is for passengers to hold, so it should be cleaned with wet cloth frequently. If the strap is too dirty, you can sink the cloth in neutral detergent or kitchen cleaner and repeatedly scrub the strap until it is bright. Dissolve fat liquor, gasoline and detergent containing solvent gasoline composition are forbidden to stop the rubber from premature aging and shortening of the handrail life.

5. Regularly clean the foreign matter on the rotary chain of the strap (each time a month). In the process of operation, foreign bodies such as nylon and rubber pulverized, etc will come into being because of the friction between the strap and the handrail bracket. If the bodies are not cleaned in time, the rotary chain bearing would be damaged and unable to rotate, then the strap will be with fever and accelerate wear and tear and the life of it would be shortened.

(III) Items and Contents of Heavy, Medium and Minor Repair Check 1. Heavy repair, the cleaning and adjustment of all the components and the change of the

damaged parts once every three years. After the heavy repair, a full inspection according to the product acceptance criteria shall be carried out.


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2. Medium repair, once every six months, and the main examination contents are: a. Safety control circuit inspection;

b. The adding or changing of the reducer lubricating oil; c. The adjustment of the spring tension of the step chain; d. The adjustment of the tight force of the strap; e. Double row traction chain adjustment;

f. The adjustment of the strap double-row chain; g. Braking force adjustment; h. The adjustment of each safety protection device.

3. Minor repair, once a month, and the main examination contents are: a. Check if there is abnormal vibration and noise in the general rotator, and if the oil

level is normal; b. Check the tension and lubrication conditions of each transmission chain as well

as the riveting situation of the double-row traction chain; c. Check whether the comb is damaged;

d. Check if the main and accessory wheel of the step as well as the lock is damaged and loose;

e. Check the stop button function of the electric system as well as the function of the components.

(IV) Maintenance Operation and Adjustment Set the access switch at the “Maintenance and repair "position in the upper or lower

machine room, and insert the plug of the manual inspection device, then you can hand inching control the up and down driven. When you need to change the moving direction, you need to make sure that the escalator is stopped and then operate the direction.

1. Electrical system maintenance a. Check the connection reliability of each junction and repair them in time; b. Frequently clean the contact of each relay and contactor to ensure the normal

operation of the control circuit; c. Regularly check and adjust the reliability of each protection device of the control

circuit; d. Frequently check and adjust each electronic component according to the line

requirement to keep reasonable working condition. 2. Cleaning and maintenance of the machine room As shown in figure 1, firstly spin away the two sunk screw 2 on back plate 1, and then

file away the back plate 1 with special handle. After that, you can enter the room to do the repair and cleaning job and remove the dust and waste sundry in engine room. You can use the vacuum cleaner to clean the room.

If you need to check and adjust upper and lower comb comb plate 4 and the comb safety device, you also need the demolition of medium plate 3.


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Figure 5-1 1) Back plate 2) Screw 3) Medium plate 4) Comb plate

3. Care and maintenance of the main machine a. An oil inspection on reducer should be conducted after the escalator is initially

assembled for a month. When the oil level is less than half the worm in the cabinet, a moderate amount of hyperbolic gear oil should be added (hyperbolic gear oil 22 in Winter, and hyperbolic gear oil 28 in Summer);

b. Patrol the machine room before work at least once a day to scrub the grime, supply the lubricating oil, and monitor if the vibration is normal, if the brake action is sensitive and reliable, if the braking distance is qualified, if the brake belt needs to be changed, and if the temperature rise of the lubricating oil, motor and the brake coil are normal. If there is any abnormal phenomenon, you should immediately stop the machine and find the cause of it, then restart it after the removal of the trouble.

c. Reducer lubricating oil should be changed at each heavy repair, and calcium base grease for the antifriction bearing should be added once a month and cleaned and changed each year.

4. Care and maintenance of the main drive Uncover the bearing shell of the main drive once a year to check the wear pattern of the

bearing. If it is severely worn, you should immediately change it, clean and add calcium base grease.

5. Check and adjustment of the drive chain (as shown in figure 2) Refuel and lubricate all the chains every time when you do the maintenance. Generally, the drape factor of the transmission chain between the drive principal axis and the tractor has been adjusted before delivery. However, the elongation of the chain is relatively large at the beginning of usage. So, after the escalator operated for a period, you should check the drape factor of the drive chain and adjust it. As for the adjustment method, loosen the four fastening screw 2 which fix traction machine 1, and then loosen the locknut 3 with the spanner, adjust tensioning bolt 4 to move the traction machine in order to reach the goal of adjusting transmission chain. The loosening or tensioning of the transmission chain is to check the drape factor of it. Generally, it should be adjusted to 30±5mm, and we should guarantee that the output chain wheel is at the same level with the large chain wheel center.


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After the adjustment, tension the four tensioning bolt 4 and locknut 3. If the chain is too long because of too much wearing, the two chains can be allowed to strike.

Figure 5-2 Driving chain adjustment

6. Check and adjustment of the braking length According to the GB16899-2011 standard, when the step operation speed Vt=0.5m/s, the

stopping distance range of the escalator, no-load and load running down, is between 0.2~1m. In order to ensure the braking distance mentioned above, regular check and adjust to the braking distance of the escalator should be conducted.

The adjustment of the braking length is assured through the braking system of the traction machine. The braking system is bidirectional electromagnetic and mechanical brake (friction type), as in figure 3. When the traction machine is powered on, the electromagnet 6 shove the push rod bolt 5, and separate swing arm 1, hem shoe 2 with braking wheel to get the escalator into working condition. When the power is cut off, the electromagnet 6 will lost its electromagnetic force, and with the force of tripping spring 3, the swing arm 1 and hem shoe 2 will hold the braking wheel and produce braking torque to stop the escalator from operating. The braking length can be controlled through adjusting nut 4 adjusting the size of the tripping spring 3 force.

Figure 5-3 Service brake

7. Inspection and replacement of the lubricating oil in reduction gearbox In order to guarantee the normal work and service life of the general rotator, you should

check the quantity and quality changes of the lubricating oil in reduction gearbox every half a month.

Checking methods and requirements: Unscrew and remove the oil scale on the reducer and check if the oil level is within the

1) Traction machine 2) Fastening screw 3) Locknut 4) Tensioning bolt 5) Drive chain 6) Large chain wheel

1) Swing arm 2) Hem shoe 3) Tripping spring 4) Adjusting nut 5) Adjusting nut 6) Electromagnet

Brake wheel


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scope of the upper and lower scribed line shown on the scale plate, if the oil on scale plate is clean, if it is metamorphic and if there is any characteristic smell. When the oil level is lower than the lower scribed line, you should pour oil from the scale mouth (or the inlet opening above the enclosure). After pouring, wait until the oil level to be stable and check the oil level in the oven to make sure that it is not higher than the upper scribed line. If the oil level is higher than the upper scribed line, you can dump oil from the oil-out to guarantee that the oil level in the oven is between the upper and lower scribed line.

When the oil is muddy or metamorphic, lubricating oil should be changed immediately. As for the changing method, catch the oil-out with lacquer tray, then unscrew the oil plug and let all the lubricating oil in the oven out. Pour in lubricating oil of same brand, and clean the oil chamber all over. When the oil flows over, screw in and tighten it, and then pour in new oil. After that, put back the oil scale and tighten up.

The lubricating oil used in the reduction gearbox can only be Mobil 664, and should generally be changed once 18 months.

8. Dismounting, installation and adjustment of the step The dismounting, installation and adjustment of the step should be conducted under

horizontal section of the metal frame. At this time, open the back and front board according to 2, and loosen the snap ring with socket head wrench. Tap the nylon sleeve slightly to break it away from the step bracket. Then the step will separate with the step axle. The step can be taken out when the step accessory wheel tensioning device opened through maintenance point switch or manual turning. When installing the step, operate in the opposite order.

When the step is reinstalled, the meshing situation of the step step and the comb should be checked. If the step leans to one side, you can loosen the snap ring and adjust the sleeve’s position on the step axle and tighten the ring when it is qualified. As shown in figure 4 and 5.

9. Replacement of the decorative tread The material of the yellow decorative tread on both sides of the step tread is ABS, and the

function of it is to remind the passengers to stand within the yellow safe line to avoid themselves from being hurt. When the steps are operating, there will be friction because sundries may enter. Therefore, when the decorative tread is ruptured or damaged, it should be replaced in time. When changing it, you only need to dismantle the connection nut which connects the step with it and put new decorative tread. Then you need to adjust the tread to

1 2

6

5

3 4

Figure 5-4 Cascade adjusting 7

Figure 5-5 Mounting and dismounting of the stairs

1. Stair axle 2. Stairs 3. Accessory wheel

entrance 4.Tightening device 5. Stair bracket 6. snap ring 7. Nylon sleeve


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make sure that it does not intervene with the kick plate and the tooth of the plate adjacent as well as the comb plate comb teeth. Tighten it with the nut when it is qualified. 10. Lubrication of the step axle sleeve In order to reduce the friction between the axle sleeve and the step when the steps overturn at the upper and lower sides, the lubrication of the sleeve should be done once a month. The lubricant is 10~20 engine oil, and you just need to pour it into the storage tank on the sleeve, see figure 6.

Figure 5-6 Axle sleeve

11. The changing of the accessory wheel The damaged accessory wheel should be changed according to the following method. Use the circlip for shaft installation pliers to dismantle the check ring, remove the damaged accessory wheel and install new wheel, and then put the check ring back (as shown in figure 7).

12. Changing of the step nylon gear When the nylon gear of the step (figure 8) is torn, the step will attack the ladder road

guide and will have friction will the skirt penal. Therefore, when the nylon gear is smaller than 5mm, it must be changed. The checking and change of the gear should be conducted in the lower machine room.

13. Maintenance of the balustrade a. The driving of the handrail The synchro error between the running speed of the strap and that of the step should be lower than 2% (only the strap is allowed to be faster). If the requirements cannot meet, we can meet those requirements by adjusting the pressure device. As shown in figure 9, firstly dismantle the lower outer decking on both the right and left side, and find the position of pull rod 8 and tightening spring 11, loosen the locknut of nut

Storage tank

Figure 5-7 Accessory wheel Figure 5-8 Nylon gear


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10 and adjust its tighten nut to adjust the compression of tightening spring 11 to keep its size within 30~40mm. With that, the pull rod 8 and pressure belt wheel 7 will be driven to tighten the strap-pressing device. The driving power of the strap will be guaranteed through the tightening of the device. After the adjustment, tighten nut 10 and recover the lower outer decking.

Figure 5-9 Tensioning and pressing device of handrail 1 locknut 2 adjusting nut 3 tensioning screw 4 nut 5 fixed support 6 friction wheel 7 pressing belt wheels 8 pull rod 9 handrail 10 adjusting nut 11 spring

b. Tensioning of handrail If the tension of the strap is enough, the strap roller in the side chain pulley block will make the surface of the strap summon up a little. When the escalator moves upward, the strap should not be out of the handrail guide rail. So the strap which is too unbending should be tensioned. The tensioning method is: dismantle the lower outer decking on the left and right sides of the segment, loosen nut 4 and locknut 1, and then adjust adjusting nut 2 to adjust tension screw 3. When the degree of tightness of the strap is moderate, retighten nut 4 and locknut 1, and then recover the cover board (See in figure 9). c. Adjustment of the handrail driving chain The adjustment of the handrail driving chain can be conducted only when one step is dismantled. Run the opening to the position of the drive chain adjusting screw, and then tension the strap driven chain through adjusting the adjusting screw on both sides of the curved section, and the ptosis quantity should be 5~15mm under the condition of no load after tensioning. Tighten the nut when it is adjusted. Pay attention that when adjusting, the tight quantitative of the adjusting screw on both sides should be consistent, or the problems such as the swing of the strap or strap cutting will occur. d. The maintenance of the handrail The handrail will be touched by a lot of people, so carefully daily maintenance should be conducted to make the passengers feel clean and comfortable when using it. Notes: (1) The maintenance of the strap should begin from the exposed parts. After that,

operate the escalator to make sure that the left parts exposes and doing the maintenance according to the same essentials;

(2) Wipe the detergent and polish while the escalator is operating is absolutely


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forbidden to make sure that the liquid will not flow into the machine room. (3) Pay attention that if there is gasoline, alcohol, etc, on the strap, they should be

wiped away immediately, or the strap will be aging; (4) Gasoline and alcohol are flammable items. When using them, it is forbidden to be

close to the kindling. Cleaning

Mild dirt Soak the dash cloth in clean water and twist dry it to scrub the surface of the strap repeatedly, and then dry the strap.

When the bilge is slightly obviously

Use the neutral detergent which is 10 times attenuation to scrub the strap. When the bilge is removed, use clean cloth to wipe away the detergent and then dry the strap.

When there is grease and chewing gum attached

Use some organic solvents (such as alcohol, etc.) to wipe it away, and then clean it with clean water.

Disinfection When disinfection is needed, use the cloth with diluted disinfectant to scrub it slightly

Polishing When the strap is cleaned, stain the cloth with SAH-289 anionic hydroxyl emulsion and smear it on the surface of the strap. Dry-scrub it when the liquid is dried. If you use thick emulsion to wet the strap and leave it behind, the strap will be hardened, so you must pay attention to that.

14. The check and adjustment of the dragging chain’s tension and of travel switches Due to the fact that relative elongation will happen to the dragging chain in the process of long-term use, the dragging chain tensioning gear will be too loose, and then the escalator will not be able to operate steadily and the noise of it may be too loud. What’s more, the safety switch board on the expanding car may withhold the safety switch contact to prevent the escalator from operating. Therefore, the position of the dragging chain tensioning gear and the safety switch board should be adjusted (see figure 10). Adjusting method: Open the lower room back board with the method mentioned in article 2. Loosen the locknut with the wrench and compress the tension spring to around 120 mm through tightening the locknut, and then tighten the nut. At the same time, adjust well the relative location of the switch board and the travel switch contact to make the contact at its center and lock it with the nut. When adjusting, pay attention that the tension of the right and left dragging chain should be uniform. If off tracking happens when the escalator is running, or deflection scratches between the escalator and the upper and lower comb, the tension degree of single dragging chain should be slightly adjusted until the steps are right. After the adjustment, cover up the backboard of the front panel device.


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Figure 5-10 Expanding car 1. Expanding spring; 2. Switch board; 3. Adjusting nut;

4. Locknut; 5. Broken chain protection switch

15. Checking and adjustment of the meshing situation of the steps and the combs In order to ensure the safety of the passengers, combs with same number are installed on the comb plate at the upper and lower entrance of the escalator, and the tooth of the comb is meshed with the step step gullet. The meshing depth is 6mm, and the gap on both sides should be uniform, which is generally 1.9mm. In order to ensure the above requirements, cascade guide wheel is installed on both sides of the comb plate to prevent the steps from off tracking before the steps get into the comb. The maximum side shakes between the cascade guide wheel and the step is 0.5mm. (See figure 5-11) Adjustment method: loosen the nut on the guide wheel shaft with a wrench, then close up the guide pulley as well as the axle to one side of the steps, and guarantee that the side shake between the cascade guide wheel and the step is 0.5mm or less and that the top edge of the cascade guide wheel is 6±1mm than the addendum of the steps, and then tighten the nut. The material of the comb is plastic or aluminium alloy which has a fixed breaking point in order to prevent it from damaging the steps severely. In special cases, comb may clash and be damaged. Therefore, you should change the defective comb in time and adjust the mesh clearance and depth between it and the step step gullet according to the above requirements. Tighten it with the nut when it is confirmed qualified.

Figure 5-11 The adjustment of the steps’ partial wheel device 1) Comb 2) steps 3) partial wheel

1

2

3

45


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(V) The Common Failures of the Escalator and Their Troubleshooting Methods When passengers fall on the escalator or abnormal noise occurs while the escalator is operating, the operating personnel should press the red “STOP” button on the side skirt penal which is at the entrance or the exit of the escalator, and the escalator will stop running immediately. Then, cut off the main power and restart it after the removal of the trouble.

1. Removal of minor trouble. See annexed table one and two. 2. When the troubles occur many times and you can’t find the reason, or you have no

technical ability to remove the trouble even if you know the reason, you should send for someone to repair it and remove the trouble. Don’t operate blindly.

3. Control cabinet should be kept clean, with no dust; no oil dirties inside and outside it. When trouble appears in the electrical system circuit itself, for example the falling off of thread residue, blowout or individual components damage, etc, you can conduct troubleshooting and repair according to the electrical schematic diagram attached with the machine.


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V. Safe Operation and Use of the Escalator

The following points should be paid attention to when using the escalator: 1. The escalator is a kind of passenger transportation tools which is mainly used in

shopping center and the airport, so it can’t be used as ordinary steps or emergency exits;

2. Cargos are not allowed to be put between adjacent balustrades or between the balustrade and the adjacent structures;

3. Avoid arrangement which could lead to misuse of the escalator near it; 4. Keep the smooth area not occupied 5. As for the outdoor used escalators, ceiling or enclosure is suggested to be provided; 6. Before turning on the escalator, no foreign bodies is allowed to appear on the

footboard; 7. The escalator should be operated by people who have gone through trainings, and it

should be powered on empty. What’s more, passengers are only allowed after the step or the footboard operated for a round;

8. Passengers, when standing on the running escalator, should face up to the moving direction and hold the handrail;

9. Shopping carts and trolleys are not allowed to be used on the escalator. If the shopping carts (or trolleys) can be used near the escalator, appropriate barriers and warning signs should be set to prevent them from entering the escalator;

10. The kids must be hold by an adult if he/she is taking the escalator; 11. The barefoot person is not allowed to take the escalator, and the escalators are not

allowed to transport heavy objects; 12. If the escalator cannot run when turning on it with the key, you should check it the

power master switch is closed, and if the main switch and maintenance control switch, etc, on the control cabinet is closed. If it cannot still cannot run, you then need to check if the safety circuit is disconnected;

13. When you need to changed the running direction of the escalator, you can conduct the operation of changing the direction when there is no passenger on the step and it is completely stopped;

14. The design of the safety sign should comply with the regulations of GB/T2893.1 and GB2893.3, and the minimum diameter of the sign is 80mm. As in the picture:


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15. Passenger information: 1) Observe the marching direction of escalator, and ensure that it’s on the same direction

of where you want to go. Pay attention to your safety when stepping on and leaving the step. The passengers wearing bifocals should be more careful;

2) Hold tight the strap with one hand, and hold steady the things or the kids that follow; 3) If you are wearing loose dress, you should ensure that the corner and the ribbon of it is

far away from the step and side platens of the escalator; 4) Do not place the bag or the weight you carried on the handrail; 5) Do not step on the escalator with bare feet; 6) Do not ship the goods by escalator; 7) Don’t use the still escalator as steps; 8) If you feel uncomfortable when your take the escalator, please change to the elevator

or please just walk; 9) Stand on the right side so that the passengers who need to pass through can pass you

from the left side; 10) You should not contact the side platens of the escalator with your feet and you should

hold the handrail with one of your hands; 11) Do not place the bag or the weight you carried on the handrail; 12) Do not watch the goods around when you take the escalator to avoid the risks due to

inattention; 13) Do not lean your body on the side platens and/or the handrail; 14) Do not run on the escalator; 15) Do not head out beyond the escalator handrail baffle, and mind your head; 16) Do not sit or lie on the escalator; 17) The adult should ensure that the kids that follow are taking the escalator in the right

way; 18) Quickly leave the escalator exports.

Safety sign: “Small children shall be held firmly”

Safety sign: “Push chairs not permitted” Safety sign: “Dogs shall be carried”

Safety sign: “Use the handrail”


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VI. Emergency Rescue Plan of Escalator 1. Range of application: Emergency operation of escalator 2. Notes: There have to be more than 2 members of emergency rescue team who should have Special Equipment Operator License issued by competent department of special equipment. And rescue workers should ensure their own safety in the rescue. 3. Emergency rescue equipments and tools: Key of elevator landing door, common hardware tools, traction rope clamp, hand-drive block, wire rope sockets, wire rope clip, spanner, hammer and crow bar. 4. Operating procedure: (1) Cut off main power supply of escalator;

(2) Confirm there are no irrelevant personnel or other stuff in the whole range of escalator;

(3) Ensure that there are guarding maintenance personnel and safety warning sign at up (down) entrance. And other staffs are forbidden to get on (off) the escalator;

(4) The escalator should run in the direction that the rescue activity requires; (5) Open upper (lower) cover plate, and put them at a safe place; (6) Install handwheel (except fixed handwheel); (7) One maintenance personnel should open the band-type brake while the other

personnel should compare the moving direction sign of handwheel with the walkway’s running direction that the rescue activity requires and slowly turn handwheel to make the escalator run in the direction that the rescue activity requires till it meets the rescue need or the method of manual operating escalator is given up;

(8) Close the band-type brake gear; (9) Fill in Emergency Rescue Records and report to leading sectors. And the document

should be placed on file.


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VII. Emergency Rescue Method of Component Failure of Escalator 1. Range of application: Step breakage, step chain breakage and brake failure. 2. Notes: This appendix is for reference only, so please make the appropriate emergency rescue plan according to the actual situation; Members of emergency rescue team who should have Special Equipment Operator License issued by competent department of special equipment; There have to be more than 2 rescue workers who should ensure their own safety in the rescue. 3. Emergency rescue equipments and tools: Handwheel or barring gear, cut-off wrench, common hardware tools, lighting fixture, communication equipment, address list of internal emergency organization, safety protection equipment, hand emery wheel/cutting equipment, crow bar and warning sign; 4. General rules Press the scram button or cut off main power of escalator; set warning signs at up and down entrance and offer necessary help and protection to injured people; 5. The breakage of step:

(1) Ensure barring direction and rescue in the opposite direction of barring when the barring does not increase damage; (2) Cut off main power supply of escalator;





(9) Close the band-type brake gear; (10) If the abovementioned method does not work, please refer to the following method: a. Remove or incise the step and truss to complete the rescue; b. Ask for support: when the abovementioned method cannot help to rescue, the leader of

emergency rescue team should report to emergency headquarters and ask for support. (11) Fill in Emergency Rescue Records and report to leading sectors. And the document should be placed on file.


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6. The breakage of drive chain (1) Ensure barring direction and rescue in the opposite direction of barring when the

barring does not increase damage; (2) Cut off main power supply of escalator;






emergency rescue team should report to emergency headquarters and ask for support. (11) Fill in Emergency Rescue Records and report to leading sectors. And the document should be placed on file. 7. Brake failure

There are no casualty accidents when the escalator runs normally. If there are power failure or safety circuit cutoff, the brake may fail and the escalator may slide down which could cause accident when there are more people. At this time, the upper entrance should be immediately blocked to prevent people getting on the escalator and people at the lower entrance should be evacuated at once.


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VIII. Emergency Rescue Method of Being Clamped in Escalator 1. Range of application: when there is a clamp accident (step, skirting, handrail or comb). 2. Notes: This appendix is for reference only, so please make the appropriate emergency rescue plan according to the actual situation; Members of emergency rescue team who should have Special Equipment Operator License issued by competent department of special equipment; There have to be more than 2 rescue workers who should ensure their own safety in the rescue. 3. Emergency rescue equipments and tools: Handwheel or barring gear, cut-off wrench, common hardware tools, lighting fixture, communication equipment, address list of internal emergency organization, safety protection equipment, hand emery wheel/cutting equipment, crow bar and warning sign; 4. General rules

Press the scram button or cut off main power of escalator; set warning signs at up and down entrance; offer necessary help and protection to injured people; call 120 immediately if anybody is injured or may be injured 5. Someone is clamped in step and skirting

(1) If the skirting switches (safety device) functions, the rescue method of opposite barring can be applied; (2) Cut off main power supply of escalator;


(4) Ensure that there are guarding maintenance personnel and safety warning sign at up(down) entrance. And other staffs are forbidden to get on (off) the escalator;




emergency rescue team should report to emergency headquarters and ask for support. (11) Fill in Emergency Rescue Records and report to leading sectors. And the document


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should be placed on file. 6. Someone is clamped in handrail

(1) If a passenger is clamped in the entrance of handrail, the protective device at the entrance of handrail can be removed to release the passenger;

(2) If a passenger is injured when being clamped in the handrail, the injured passenger can be released by prying up the handrail with some equipment;

(3) Remove or incise the part that clamps the passenger to rescue the passenger; (4)Ask for support: when the abovementioned method cannot help to rescue, the leader

of emergency rescue team should report to emergency headquarters and ask for support. 7. Someone is clamped in comb

(1) Remove comb or apply the rescue method of opposite barring; (2) Cut off main power supply of escalator;






emergency rescue team should report to emergency headquarters and ask for support. (11) Fill in Emergency Rescue Records and report to leading sectors. And the document

should be placed on file.


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Appendix I: Operation Instruction of Examining and Adjusting the Brake Basic tools should be prepared in advance: 1. Open spanner: two of specification17; two of specification19; as shown in the following picture: 2. Steel ruler: one of specification 150mm; as shown in the following picture: 3. General filler gauge: one; as shown in the following picture:

4. Flat and cross screwdrivers of specification 3; as shown in the following picture:

5. Multimeter (cam measure voltage and resistance); as shown in the following picture:

6. External pliers of 7 inches; as shown in the following picture:


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General Structure and Operating Principle of the Brake I. The general structure of the brake is shown in the following picture:

Note: This picture shows brake arm opening situation

II. The brief introduction of operating principle of the brake: 1. When magnetic device (also called electromagnet) is cut off of power, brake spring holds down brake wheel inside of the motor of escalator through brake bush on brake arms. So that there is a braking torque which make main engine brake. As shown in the following picture:

2. When magnetic device (also called electromagnet) is charged with nominal voltage, brake arms open by ejector rob overcoming spring force. Consequently, there is clearance between the brake bush on brake arms and the brake wheel inside of the motor of escalator, which makes the motor free rotating. As shown in the following picture:

Brake arms

Brake bush

Brake spring

Locknut

Adjusting nut

Magnetic device

Spanner

Ejector rob


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III. Method of examining and adjusting the brake: (I). The flowchart of examining the brake is following:

Brake arm

Spring force

Magnetic ejector rob

electromagnetic force

Examine whether the thickness of the thinnest place of brake bush is more than 2mm. Specific method is shown in explanation1.

Get contact with Jiali company in Tianjin to replace brake arms.

No

The instruction of replacing brake arms: Specific method is shown in explanation7.

Examine whether ejector robs on two sides of the brake operate normally. Specific method is shown in explanation2.

Get contact with Jiali Company in Tianjin for technical support or replacement.

Yes

NoExamine whether the brake operates normally. Specific method is shown in explanation3.

No

Yes

Examine whether brake circuit board or coil fails. Specific method is shown in explanation4.

Get contact with Jiali Company in Tianjin for replacement of relevant parts.

Yes

Examine whether the output voltage of brake circuit board is normal. Specific method is shown in explanation5.

Yes

Adjust clearance of ejector robs of brake. Specific method is shown in explanation6.


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(II). Specific explanation and operational approach of the flow: 1. Specific method of “Explanation 1”: Step one: Use a steel ruler to measure the length of springs at both sides of the brake and record the length, as shown in the following picture:

Step two: Use an open spanner of specification 19 to remove both sides of brake springs, as shown in the following picture:

Step three: Use a steel ruler to measure whether the thickness of the thinnest place of


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brake bush is more than 2mm. If not, you have to get contact with the manufacturer to replace brake arms, as shown in the following picture:

Note: In the above procedure, the both sides of the brake have to be examined.

2. Specific method of “Explanation 2”: Step one: Reset the magnetic device handle for 30～35 degrees, as shown in the

following picture:

Step two: When the spring is opened, push and pull ejector robs on two sides of the brake operate to examine whether they are flexible. And the sliding distance should be 3～4mm, or you need to get contact with the manufacture for replacement of magnetic device or technical supporting. As shown in the following picture:

Brake bush (Brake shoe)


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3. Specific method of “Explanation 3”: Step one: Reset magnetic device handle for 30～35 degrees as the above method. Step two: Push ejector robs on both sides of magnetic device inward till you cannot push

any more, as shown in the following picture:

Step three: Make magnetic device charged with nominal voltage, and examine whether

ejector robs on two sides of magnetic device both move outward. If one or two sides rob don’t move outward, you need to get contact with the manufacture for replacement of magnetic device or technical supporting. 4. Specific method of “Explanation 4”:

Step one: Open the cover of junction box of magnetic, and then you can see a circuit board. According to main engines of different specifications, the manufacture produces single circuit board and double circuit board. The single circuit board is also called single loop magnetic device, while the double circuit board is also called double loop magnetic device. As shown in the following picture (note: the type of circuit board is different for date of manufacture)

Outwar OutwarInwar Inwar

OutwarOutwar InwarInwar


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Double loop magnetic device Single loop magnetic device Step two: Visually inspect whether there is burn mark and use a multimeter to measure the output voltage of output end of each circuit board (3 plugs) is DC100V±5%. If one side or two sides don’t meet the requirement, it means that circuit board of magnetic device is damaged. You should get contact with the manufacture for the replacement of magnetic circuit board or technical support, as shown in the following picture: (note: circuit boards on two sides of double loop magnetic device both need examining)

Step three: Unplug the output end of circuit board (3 plugs) and use a multimeter to separately examine whether values of two coils resistance meet the requirement of “resistance standard of magnetic device XIZIOTIS of manufacture”. If don’t, it means that coil of magnetic device is damaged. You should get contact with the manufacture for the replacement of magnetic circuit board or technical support, resistance standard and test are shown in the following picture:


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Resistance test single loop magnetic device Resistance test double loop magnetic device Resistance standard of magnetic device XIZIOTIS of manufacture:

Magnetic device type and brake force

Range of standard resistance value of single

coil(Ω)(20 ) Notes

BRA450 450N ‐Ⅰ 560.5～619.5

BRA600 600N‐Ⅱ 627～693

BRA800 800N‐Ⅱ 361～399

BRA1000 1000N‐Ⅱ 313.5～346.5

BRA1500 1500N‐Ⅱ 232.8～257.3 Note: The above values of resistance are all the values in an environment temperature of 20

and the actual value should be conversed according to actual environment temperature. The reduction formula: The actual resistance value=Standard resistance value*(234.5+Actual environment temperature)/254.5

4. Specific method of “Explanation 5”:

For details, please see the second operational approach in “Explanation 4”. If one side or two sides don’t meet the requirement, it means that circuit board of magnetic device is damaged. You should get contact with the manufacture for the replacement of magnetic circuit board or technical support. 5. Specific method of “Explanation 6”:

Step one: Reinstall the spring and adjust the length of spring to the length before it is removed. As shown in the following picture:

Step two: Reset magnetic device handle for about 30～35 degrees as the above method.


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Step three: Push ejector robs on both sides of magnetic device inward till you cannot

push any more, and examine the clearance between two ejector robs is 1～1.5mm, as shown in the following picture:

Step four: If the clearance does not meet the requirement, it is recommended to adjust it

with a filler gauge (insert the filler gauge into the clearance and adjust ejector rob bolts with spanner), till the clearance becomes 1～1.5mm, as shown in the following pictures:

Step fiver: Fix ejector robs of the two sides. The specific method: fix ejector rob bolts by

spanner and screw locknut by another spanner. In the process, ejector rob bolts cannot be reversed, as shown in the following picture:

The clearance between two ejector robs


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The examination after adjusting the brake: 1. After adjusting according to the above procures, you need to examine the clearance of ejector robs again till it meets the requirement of 1.5mm. For examination method, see explanation 2. 2. After manually opening the magnetic device spanner, you should install a motor flywheel or install a handwheel and examine whether the rotating is flexible. As shown in the following picture: 3. Charge magnetic device with nominal voltage, install a motor flywheel or install a handwheel and examine whether the rotating is flexible. If the above examinations don’t meet the requirement, you need to readjust it till it meets the requirement or get contact with the manufacture for technical support.

6. Specific method of “Explanation 7”:

Step one: Remove the circlips for shaft under one or two sides of brake arms axis pin that need replacing by a circlip plier axle, as shown in the following picture:

Step two: Tap brake arms axis pin out from down to up, as shown in the following picture:

Fixed and cannot be reversed Screw locknut

Opening magnetic device spanner


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Step three: Remove brake arms that need replacing and install new brake arms.


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Appendix II: Operation Instruction of Examining and Adjusting the

Auxiliary Brake 1. Structural composition

Figure 1 Figure 2

Figure 3

FFigure


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4

Figure 5

Figure 6 Figure 7 1 principal axis; 2 duplex chain wheel; 3 brake bush; 4 brake disc; 5 stop dog; 6 pressure dish; 7 pawl closing piece; 8 pawl; 9 electromagnet; 10 adjusting bolt; 11 dish spring components; 12 rubber mat; 13 nut; 14 locknut; 15 pressure spring; 16 armatures; 17 normally open contact (safety circuit); 18 normally closed contact The auxiliary brake of escalator is an annular plate brake which functions directly on step drive sprocket (2). Its constitution is shown in Figures 1~7.

As shown in Figure 3, hinged with step drive sprocket (2), brake bush (3) is installed on two sides of brake disc (4) with which is placed. Six stop dogs (5) are installed at outside of brake disc which presses on step drive sprocket through pressure dish (6). The pawl closing piece (7) is driven by one-way electromagnet fixed on the truss. When there is chain breakage, reversion or over speeding for 140%, the stop dog will lock brake disc. Pressed by dish spring, the locked brake disc gradually produces a friction with step drive sprocket by rubber mat (12) and brake bush. Consequently, the escalator stops. The auxiliary brake only works when the


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escalator runs down (toward the tensioning end). 2. Operating mode There two operating modes of auxiliary brake:

(1) The motion after the escalator stops normally The auxiliary brake is an active brake which motions every time when the escalator runs

or stops. When the escalator normally stops running, after the main brake stops the walkway, the pawl stretches to the place of stop dog in about delayed 3S to lock the escalator. When the escalator starts, before the motor is powered on, electromagnets attach together retracting the stop dog to release pawl, so the escalator can start to run normally.

(2) The motion in emergency situations In the following dangerous situations, the pawl moves immediately instead of delaying: A. The drive chain overextends or brakes; B. Over speeding for 140%; C. Direction reversal; D. The step is missing; E. Power failure.

The auxiliary brake acts every time when the escalator runs and stops, but the mechanical part does not provide any braking force. 3. Operating principle As shown in Figure 4, drive principal axis can freely rotates along with brake disc. When electromagnets attach together, armature (16) drives the contact to close normally open contact (17). So the safety circuit is powered on and the drive motor can start.

When there is the above red light, electromagnets release without electricity. Then armature drives the contact to close the normally open contact to cut off the safety circuit. And the pawl stretches out to lock the escalator. The stop dog is blocked by pawl, and the running of brake disc, see Figure 5.

The pawl closing piece (7) in installed on the truss and can adjust longitudinally to make rubber mat cushion the hit in brake process. The escalator is finally in a stationary state due to the friction of brake disc, pressure dish and step drive chain. The contact pressure between brake disc and duplex chain wheel has effect on braking distance, and this contact pressure can be adjusted by 6 dish spring components, see Figure 6 and Figure 7. 4. Requirement and method of adjusting auxiliary brake

(1) For the design 1(11-1) in Figure 6, the maximum tightening torque of dish spring component is 24 N.m;

(2) For the design 2(11-2) in Figure 6, the maximum tightening torque of dish spring component is 48 N.m;

(3) The tightening torque of nut (13) should be adjusted according to identity value on list of installation document;

(4) In regular maintenance inspection and simulated function test, if the braking distance of auxiliary brake deviates from service brake for 30%, it has to be readjusted. As shown in Figure7, adjust the braking distance by adjusting pre-tightening force of dish spring


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components (11) (Eleven steps have to be removed to adjust pre-tightening force of dish spring components), the method is as follows:

A. Remove locknut (14); B. Use nut (13) to adjust pre-tightening force of all 6 dish spring components. In order to

make their numerical values same, you need to use torque spanner when adjusting; If there are no numerical values of pre-tightening force, the motion test of auxiliary brake can be performed. According to the braking distance of auxiliary brake, you can adjust it by generally increasing or reducing pre-tightening force till it meets the requirement;

C. Screw the locknut again.


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Attached Table 1: Explanatory Table of Safety Switch Failures

Failure Display Number

Fault Point Elimination Methods

1

Over speed, slowness, direction reversal, the step is missing, velocity anomaly of handrail and band-type brake is not releasing

According to fault message shown by monitor panel of Programmable electronic safety related systems (PESSRAE), reset by reset switch after the removal of fault.

2 Phase sequence relay and

hot protective relay

Check whether the power supply loses or dislocates phase and whether hot

protective relay moves and reset after removal of fault.

3 Stop switches of upper end plate and control cabinet

Examine whether the upper stop switch moves and reset to remove the fault.

4 Detector switch of opening the

upper cover plate and stop switch of overhaul box

Examine whether detector switch moves when cover plate is opened. Detector

switch does not work when cover plate is opened in overhaul.

5 Switch of upper comb teeth

abnormity

Set switch of upper comb teeth abnormity in left and right to adjust comb and reset

after the removal of fault.

6 Switch of upper entrance

Set switch of upper entrance in left and right to clean away foreign matters at the

entrance of handrail and reset after the removal of fault.

7 Switch of upper step sinking

Examine whether the step is damaged through the switch on upper end of

walkway. Remove the step if it’s damaged and reset after the removal of fault.

8 Switch of drive chain breakageExamine whether the chain is broken and

reset after the removal of fault.

9 Switch of upper skirting

Set switch of upper skirting in left and right to remove foreign matters between

skirting and step and reset after the removal of fault.

11 Detector switch of handwheel Examine whether protective cover of disc


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wheel is opened and reset after the removal of fault.

12 Switch of step chain The switch is set in left and right in the lower machine room. Examine whether

step chain overstretches or breaks

13 Switch of lower comb teeth

abnormity

Set switch of lower comb teeth abnormity in left and right to adjust comb and reset

after removal of fault.

14 Switch of lower entrance

Set switch of lower entrance in left and right to clean away foreign matters at the

entrance of handrail and reset after removal of fault.

15 Switch of lower step sinking

Examine whether the step is damaged through the switch on lower end of

walkway. Remove the step if it’s damaged and reset after the removal of fault.

16 Switch of lower skirting

Set switch of upper skirting in left and right to remove foreign matters between

skirting and step and reset after the removal of fault.

17 Detector switch of opening the

lower cover plate and stop switch of overhaul box

Examine whether detector switch moves when cover plate is opened. Detector

switch does not work when cover plate is opened in overhaul.

18 Stop switches of lower end plate and control cabinet

Examine whether the upper stop switch moves and reset to remove the fault.

19 Safety switch and ground

protection switch FU3

Examine whether protective fuse FU3 moves and replace protective tube to

remove the fault. 0 Normal


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Attached Table 2: Explanatory Table of Monitor Wafer (MCTC-PES-E1) Faults

Failure Display Number

Fault Point Elimination Method

ERR01 Over speeding for1.2 times Manual reset, method: press red STOP button

on manipulator for more than 3 seconds. ERR02 Over speeding for1.4 times Manual reset as above method ERR03 Direction reversal Manual reset as above method ERR04 Over stopping distance Manual reset as above method

ERR05 Slow speed of left handrail Reset by powering on again or reset as

abovementioned method

ERR06 Slow speed of right handrail Reset by powering on again or reset as

abovementioned method`

ERR07 The upper step is missing Manual reset, method: press red STOP button

on manipulator for more than 3 seconds.

ERR08 The lower steps is missing Manual reset, method: press red STOP button

on manipulator for more than 3 seconds. ERR09 Service brake opening fault Manual reset as above method ERR10 Auxiliary brake opening fault Manual reset as above method ERR11 Floor plate switch fault Automatic reset after the removal of fault

ERR12

External signal abnormity 1.There is pulse AB in stop state; 2.There is no pulse AB in 4seconds after start; 3.Signal AB among upper steps is less than set value; 4.Signal AB among lower steps is less than set value; 5.Left handrail pulse is too quick; 6.Right handrail pulse is too quick; 7.Overhaul signals of two loops are not consistent.

Manual reset, method: press red STOP button on manipulator for more than 3 seconds.

Check fault subcode by parameter F2-09 to find the fault reason. If the numerical value of

F2-09 is 7, there is a fault that overhaul signals of two loops are not consistent.

ERR13 Hardware fault of PES signal Manual reset as above method ERR14 EEPROM data fault Manual reset as above method ERR15 Parameter abnormity Manual reset as above method

ERR16 Data check abnormity or

communication mcu abnormity Manual reset as above method


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Attached Table 3: Safety Monitoring Board (ES. 11 / A) Error Description Table Shown Error No.

The error point Elimination method

1 Real-time clock damage

Checking whether there is debris in board Y2, and re-power after cleaning, if there is still a error, please submit it to a manufacturer to deal with it.

2 Redundancy detection error

Checking Whether power supply is 24V and stable, and re-power, if there is still a error, please submit it to a manufacturer to deal with it.

3 Parameter CRC error

Parameter is not setted, please re-set all the parameters, and power-off and then open the power, if there is still a error, please submit it to a manufacturer to deal with it.

4 Fault CRC error Pressing the reset button and re-power.

5 Parameters are not appropriate

Checking whether the parameter settings are reasonable or not.

6 Power supply and voltage error

Checking whether power supply and voltage is 24V.

7 Safety relay error Hardware damage, please submit it to a manufacturer to deal with it.

8 Exceed speed of 120%

Checking whether the parameter settings are correct or not, checking whether escalator is over speed, and checking whether X0, X1 signal are normal or not.

9 Exceed speed of 140%

Checking whether the parameter settings are correct or not, checking whether escalator is over speed, and checking whether X0, X1 signal are normal or not.

10 Low speed 80% Checking whether the parameter settings are correct or not, checking whether escalator is low speed, and checking whether X0, X1 signal are normal or not.

11 AB Reversed connection

Checking whether X0 and X1 reverse connection, and Checking whether installation location of the host speed switch is correct or not.

12 Speed abnormal low

Checking whether the elevator speed drop to below the normal speed, when the main board operation still remain the input.

13 The drive chain is disconnected

Checking whether the switch of broken chain is correct, and checking whether the X15 input signal and X15 opening and closing settings are correct

14 Parking braking Checking whether the stopping distance meets international


85 / 85

distance is too large standard and checking whether X0 and X1 signal shake.

15 Additional brake error

Checking whether the input-output relationship of Y1, Y3 and X11, X12 is wrong.

16 The upper step is missing

Checking whether X2 acts normally or not

17 The lower step is missing

Checking whether X3 acts normally or not

18 Lack of inspected cover board

1.Checking whether X10 or X18 and the corresponding switch is action; 2. Checking whether the switch of inspected cover board is action.

19 The switch error of inspected cover board

1.Checking whether X10 or X18 are not consistent; 2. Checking whether the switch of inspected cover board is action.

20 Working brake can not open

Checking whether the brake switch can not be closed when parking.

21 Working brake can not close

Checking whether the brake switch can not be opened when starting.

22 The left handrail is less speed

1. Checking whether the speed switch of left armrest is normal or not. 2. Checking whether the number of pulses of handrails wheel and perimeter settings are correct or not.

23 The left handrail is over speed

Checking whether the number of pulses of handrails wheel and perimeter settings are correct or not

24 The right handrail is less speed

1. Checking whether the speed switch of right armrest is normal or not. 2. Checking whether the number of pulses of handrails wheel and perimeter settings are correct or not.

25 The right handrail is over speed

Checking whether the number of pulses of handrails wheel and perimeter settings are correct or not

26 Run up and down is inconsistent with requirements

Checking whether the run (X6) and input of uplink and downlink (X7, X8) is normal or not.

27 Slipping when stopping ladder

1.Checking whether X0 and X1 (the main wheel speed switch) shake; 2. Checking whether the escalator slip or not.

28 Two-channel IO is inconsistent

Checking whether there is debris near the input port of the board (note back), re-power after cleaning, if there is still a error, please submit it to a manufacturer to deal with it.

Documents

Maintenance Manual of the Escalator - irsalift.com fileInstallation, Commissioning, Operation and Maintenance Manual of the Escalator ZHEJIANG MEILUN COMPLETE ELEVATOR CO., LTD September,