MERDİVEN MANUEL

8/8/2019 MERDVEN MANUEL

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W-BT ESCALATOR INSTALLATION GUIDE BOOK

HYUNDAI ELEVATOR CO., LTD. - 1 -

1. GENERAL

1.1 INSTALLATION PROCEDURE

TRUSS FIRST RUNNING

PIT & WELL INSTALLATION TEST & STEPWAY CHECK & LEVELING INSTALLATION

JOBSITE

ARRIVAL

TRUSS JOINT & (INTERMEDIATE SUPPORT

AXLE CHAIN SUPPORT BEAM EXTRUSION

JOINT INSTALLATION) INSTALLATION

OUTER DECK HANDRAIL FRAME HANDRAIL SKIRT PANEL

INSTALLATION INSTALLATION INSTALLATION INSTALLATION

GLASS GUIDE STRIP

INSTALLATION INSTALLATION

SWITCH ADJUSTMENT

& SECOND NEWEL SKIRT

RUNNING TEST INSTALLATION

TEST

RUNNING

INNER DECK

INSTALLATION

Figure 1.1 Escalator installation procedures


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1.2 ESCALATOR MAJOR COMPONENTS

Figure 1.2 Escalator major components


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Figure 1.3 Escalator section1.3 BALUSTRADE DIMENSION

Figure 1.4 Sample balustrade part dimension drawing


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For actual job site dimension, refer to the balustrade parts dimension drawing

which is contained in each escalator shipment package.

Figure 1.5 section dimension of escalator


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2. PIT & WELL WAY CHECK

Check the job site to install escalator by referring layout drawing and actual site

dimension such as rise, wellway length, pit depth, base plate size, etc.

Figure 2-1 Typical Truss and Wellway Layout

Figure 2-2 Typical Layout Check Check the Base Plate location and Welding condition.

Prearrange below with the General Contractor before starting installation ;

Temporary Power Supply.

Storage Area.

Access to the building for Truss & Overhead support for hoisting Truss assembly.


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3. TRUSS JOINING & HOISTING

3.1 TRUSS JOINING

Join truss by aligning and bolting "match holes" which is already drilled from our factory.

Make sure that shim plate shall not be slipped out while joining truss.

Figure 3-1 Truss joining3.2 AXLE CHAIN ASSEMBLY

Join the axle chain by joining lower part of chain first and then upper part of

chain by using chain block with some force.

NOTICE: Always use brand-new split pin. Never use even once used split pin.

Figure 3-2 Step chain jointing Figure 3-3 Truss moving


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3.3 TRUSS HOISTING & LEVELING

Hoist truss horizontally to prevent twist or damage of truss.

Adjust truss angle, floor finish line of building and floor plate with maintaining the

horizontal level at 4 (four) parts such as support angle, floor plate, W.P.(Working point)and

step by using truss-leveling bolt.

Insert shim between base plate and support angle, then weld base plate by using angle to

fix truss as shown on Figure 3-5.

NOTICE: Weld angle after installing Intermediate support beam, if Intermediatesupport beam is required.

Figure 3-4 Floor leveling Figure 3-5 Truss base plate work

NOTICE : Handrail will be worn out or slanted, if there are level differencebetween left and right hand side of Truss after truss installation.

4. INTERMEDIATE SUPPORT BEAM WORK

Install intermediate support beam to prevent from sagging of Truss, if intermediate

support beam is shown on layout drawing.

Weld and install support beam. (Figure 4-1)


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Figure 4-1 Intermediate support beam work

5. TRUSS WIRING, FIRST RUNNING TEST & STEP INSTALLATION

5.1 TRUSS WIRING

Connect the cables in the upper truss to the cables (or junction box) in the lower truss.

Test all the pre-installed safety switches and emergency stop switch.

5.2 FIRST RUNNING TEST

Do the first running test.

5.3 STEP INSTALLATION

NOTICE : Step installation or step removal can only be done at the inclinationpart of escalator.

Figure 5-1 Step Installation & removal


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6. PANEL SUPPORT EXTRUSION INSTALLATION

NOTICE: Adjust length [X] of mounting clamp assembly. (Figure 6-1) Install Panel Support Extrusion from the lower part.

Adjust length [A] of panel support extrusion by bolting. (Figure 6-2)

Check whether panel support extrusion is horizontal or not and then adjust it to be leveled

by using machinist level.

(UNIT: mm)

Figure 6-1 adjustment

Mark joint line of inner & outer deck and glass panel. (Figure 6-2)

Figure 6-2 Marking joint line of inner & outer deck and glass panel

NOTICE: If the level of mounting clamp is all different, glass lining-up work will not beeasy. Moreover, glass will be shaken and frictional resistance of inner surface of handrail will

be increased.

800TYPE1000

TYP

E

1200

TYPEFOR 588 STEPFOR 606

STEP

[X] 427.5 436.5 536 636

(UNIT: mm)

ESCALATOR

DEGREE[A] [B] [C]

30 477 220 903


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Figure 6-3 Panel support extrusion installation


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7. OUTER DECK INSTALLATION

Install a splice plate into the upper end of the lower curve deck. (Figure 7-2)

NOTICE: In case of parallel installation, the outer deck at the middle part shall beassembled first. Fasten bolts securely and finish all outer deck installation works

before taking next step.

NOTICE: Overall clearance between the tops and bottoms at the joint of two units ofescalators shall be same.

Figure 7-1 Outer deck installation

Figure 7-2 Outer deck splicing Figure 7-3 Mounting clamp


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8. GLASS PANEL INSTALLATION

573

1380

2121

11

22

22

2

2

23

233

3

909.

7

909.

7

Figure 8-1 Glass panel installation

2mm

2 GLASS

1 GLASS

PANEL SUPPORT

GLASS JOINT LINE

SHIM (3mm)

EXTRUSION JOINT

*REMOVE AFTER GLASS SETTING

Figure 8-2 3mm shims between glasses Figure 8-3 Glass panel section

NOTICE: Install a Glass vertically. Adjust high and low, left and right side width ofhandrail return guide.

Assemble a Glass accurately starting from bottom curve by setting the W.P. as standard.

Adjust 3mm gap for top and bottom part of joint of adjacent glasses by pre-assembling

variable glass.

Check whether Glass is being installed vertically or not by using machinist level.

Assemble top curve glass finally and then inspect vertical & horizontal level once more.

Readjust it by using mounting clamp, if required.

NOTICE: Two pieces of roughly 1/8" (3mm) thick padding will maintain space of panelsuntil all the glasses are installed and then shims will be removed. Leave 1/8"(3mm)

gap between each panels.

NOTICE: Maintain 3mm space between glasses. In case of 3mm gap is not maintainedthen handrail tension will be affected.


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9. HANDRAIL FRAME INSTALLATION

9.1 NEWEL HANDRAIL FRAME

Remove joint bars from the ends of the plastic handrail return guides and bolt them onto

the lower ends of the handrail newel guides.

Slip the lower newel guide onto the newel panel, and insert the joint block (with four holes)

to connect the newel with the panel support extrusion.

Drill holes into the newel to align with the holes in the joint block, and insert the

connecting bolts

Figure 9-1 Newel frame assembly

Figure 9-2 Newel frame fixed


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9.2 HANDRAIL FRAME

Inspect the gripper to make sure that it is fully seated on the panels.

Install lower curve handrail guide on the gripper.

Figure 9-3 Handrail frame assembly Install upper curve handrail guide on the gripper.

The holes for the splice block for the last piece must also be drilled. Carefully measure and

cut the last handrail guide piece to the required length.

Figure 9-4 Cut the variable Handrail frameNOTICE: Cut 30-40mm surplus part of variable handrail frame as shown on Figure 9-4while assembling variable handrail frame.

NOTICE: Readjust glass installation condition, if cutting part is out of the range of30 - 40mm.


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9.3 GUIDE STRIP INSTALLATION (ONLY FOR ALUMINIUM FRAME)

NOTICE: Do not splice Handrail Guide Strips.

Figure 9-5 Guide strip installation Figure 9-6 Trimming ends of guide strip

10. HANDRAIL & RETURN GUIDE INSTALLATION

10.1 PRELIMINARY SETUP

Figure 10-1 Return guide installation Figure 10-2 Do not handrail bent

Figure 10-3 Section of return guide


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NOTICE : Thoroughly clean debris, especially along the path of the handrail,inside of aluminum and plastic handrail guides.

NOTICE : Upper curve handrail return guide shall not be getting resistance.10.2 HANDRAIL INSTALLATION & ADJUSTMENT

1) Handrail guide system Confirm the return guide is located so there is enough clearance for the handrail under

the guide and between the guide and truss.

Install the newel return guide as following handrail adjusting guide. (Figure 10-4)

Line up disconnected part of return guide and adjusting guide. Mark and cut

adjusting guide 12mm below the point where guides over lap.

Install handrail on remaining adjusting guide.

Temporarily connect guides with Inner splice bar. Install outer splicing bar on return

guide, and tighten bolts. The outer splice bar on the adjusting guide is not installed until

step mentioned below, so that the inner splice bar is free to move while the

adjusting guide is adjusted.

700mm below splice, lift adjusting guide and handrail up toward top of balustrade. On

inner splice bar, mark end of adjusting guide. Release handrail and adjusting

guide. (Figure 10-4)

700mm below splice, push adjusting guide and handrail down away from balustrade.

On inner splice bar, mark end of adjusting guide. Release handrail and adjusting

guide. (Figure 10-4)

Find the midpoint of tension marks made by push adjusting guide up and down.

Adjust adjusting guide that the end of adjusting guide is located at midpoint of

tension marks. Attach outer splice bar on adjusting guide and tighten bolts.

Figure 10-4 Handrail tension adjustment


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2) Installation of handrail systemHandrail system is subassembly with circular moving handrail, which is supported for

holding by passenger. Because of limit of transportation, subassemblies of handrail system are

not convenience to install on the escalator (except special). Handrail system assembling is

divided to two times to finished. in the first time, debuggingchecking and remove to park are

finished in workshop, the second installation will be finished on building site, which is a

systemic engineering. See the appendix installation drawing.

Handrail system are composed of handrail driverguide panelhandrailhandrail entry

deviceskirt panelinner and outer deck and top and bottom turning parts.

The handrail in the handrail system is a motional parts for holding by passenger, which

speed should be accordance with speed of stepand should be ahead of step for 0-2.0%,

Which can be done by adjusting handrail drivers.

Handrail driving system is a subassembly to drive handrail to move circularly (Figure

10-5).

Figure 10-5 Handrail drive

1Tension screw 2Press tape 3Friction wheel 4Handrail

5Tension rod 6Screw 7Locknut 8Nut 9Press spring

Handrail are drove by friction wheel (3) with rubber tire, tension of handrail (4) may bedone by adjusting the nut 8 on the tension rod, and press handrail with press tape (4), tension

of press tape is adjusted with tension screw.

Tension force of handrail and press tape should be proper, and friction wheel will drive

handrail normally, at this time, it will take more strength to stop handrail. Tension of press tape

are kept continuously by spring (9), while operating tension rod (5), it must be done to removed

inner deck and skirt panel, and loose screw 6, release locknut (7), and adjust tension rod with

nut (8). While finished adjusting it must be remembered to tighten the locknut (7).


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11. SKIRT PANEL INSTALLATION

Install the lower curve skirt section onto the skirt support angle on the lower truss.

Check the skirt face is vertical to the steps. Both sides' gap between skirt panel and step

shall be within 4mm.

If the skirt is not vertical to the steps, loosen bolt with holding the skirt support angle.

Readjust it as required.

Figure 11-1 Skirt panel installation

1200TYPE:506.5

1000TYPE:405

800TYPE:304.5

SKIRTSUPPORTANGLE

SKIRTPLATETRUSS

CHORD

Figure 11-2 Skirt panel installation


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12. SECOND RUNNING TEST & SWITCH ADJUSTMENT

NOTICE : Remove dust on surface of track and dust in the machine room first and thendo second running test to prevent from breakage of step.

Adjust upper & lower skirt switch gap.

Check handrail running condition, skirt panel & step interference. Combplate & step guide roller adjustment

The teeth of the comb section "A"-"A" must mesh correctly with the cleats of the step

tread. If comb needs adjustment, see Figure 12-1.

The step guide rollers guide steps running smoothly without knocking. Adjust the rollers

or the skirt panels, if necessary.

There shall be clearance of 0.20.3mm between rollers and steps.

The top of the step guide rollers must be 5 2mm below from the top of the step tread.

Adjust rollers, if necessary.

Teeth of the combfinger shall be engaged with the grooves of the step tread byapproximately 6mm depth. Raise or lower the combplate, if necessary.

Figure 12-1 Combplate adjustment

Figure 12-2 Step guide roller adjustment


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13. INNER DECK INSTALLATION

Figure 13-1 Inner deck installation

Figure 13-2 Inner deck installation


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14. NEWEL SKIRT INSTALLATION

Figure 14-1 Top newel dimension

Figure 14-2 Bottom newel dimension


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1. Part Name

1) Skirt Panel

2) Inner Deck3) Outer Deck4) Handrail Frame5) Newel Skirt(Inner, Outer Side)6) Floor Plate7) M4 Screw (dish head)

2. Structure


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PartNo.

Part Name RemarkPartNo.

Part Name Remark

1 Direction Indicator Option 10 M5 Nut

2 Fixing Panel See Note 1 11 Newel Skirt(inner)

3 Acrylic Panel See Note 1 12 Sensor For Autostart Option

4 Newel Skirt(outer) 13 M5 Screw

5 Strip 14 Fixing Screw (ST2.9*9.5

6 Inlet Guard See Note 2 15 M5 Nut

7 Stud Bolt 16 Connect Panel

8 Spring 17 Fixing Screw (ST4.2*9.5

9 Plain Washer

Note1. Fixing panel ( 2 ) and Acrylic ( 3 ) are installed as part of direction indicator( 1 ).2.Use Inlet Guard ( 6 ) according to Handrail Frame ( Aluminum Alloy Type or Stainless

Steel Type ).

3. Installation and Adjustment* The Sequence of Installation

1) Check Parts before installation

Install the Inner Deck, Outer Deck, Skirt Paneland Handrail Frame.Note: Please refer to related dimensions inattached drawing when installing the parts aboveand adjust in time if the measured dimensions arenot matched.


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4) Install Screw (M5 and M4)M5 Screw (Pan Head) : Part No.7

M4 Screw (Dish Head) : Part No.13 in StructuredrawingNote: Do not fasten M4 Screw now, wait till thefinal installation and adjustment is over andfasten it at that time.

5) Install Handrail Inlet Guard (Part No. 6)(1) Split the top of the Inlet Guard by some

degrees (but not too much), put in theHandrail, then install the Inlet GuardAccording to the Arrow in the picture.(2) Stud Bolt, Spring and Plain Washer(Part No.7,8,9) are needed when installingthe Inlet Guard. Take care whether theseparts go loose when installing.

2) Install the Outer Newel SkirtPart No. 4 3) Install the Outer Deck ( Part No.11 )If the direction indicator is equipped, install itfirst and connect the related wiring, then installthe outer deck.Note: The arrow displayed in the DirectionIndicator panel indicates Escalator running

direction.

If the escalator is equipped with sensor forautostart, please install it first and connect relatedwiring before installing the Outer Deck.Note: Install the Inner Newel Skirt after fixingSpecial Nut on the skirt panel and fasten it

with Dish Head Nut(M4).


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6) Fasten the Handrail Guard andinstall the connecting parts (PartNo. 9,10,16)Install Sequence: Newel SkirtPlain WasherNutConnect Panel

(For Switch Operation)

Nut

Enlarged A

7 Install the Inner Deck(Part No.2)

First overlap the two decks byabout 15mm in the directionindicated by Arrow 1, then pushthe deck in the direction indicatedby Arrow 2 with considerableforce till the two decks are alignedto each other.

Note: Make sure the relatedwiring is connected before

installing. If possible, wiring in thispart should be connected in asocket way for the convenience ofinstallation and maintenance.

8) Ajustment and Test Run(1) Please refer to related dimensions ininstallation drawing and installation site. Adjust

the relative position of the parts and finally fastenall the Screws.(2) Start the escalator, check if Direction Indicator(Part No.1) and Sensor for Autostart (Part No.12)are normally working.(3) After installation, check if the Inlet Rubberinterferes with Handrail, if yes, adjust in time.


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5. Requirements of Packing, Transportation, and StorageTop, Bottom, Left and Right Newel Skirt should be packed in a carton after separately packedwith vinyl. The carton should be labeled a packing list, and stabilize the parts inside in case ofpossible damage during transportation.

Escalator Balustrade Installation DimensionsW-BT Model ( 30 and 35 degree)

SIZE

2 Flat Steps 3 Flat Steps

TOP BOTTOM TOP BOTTOM

30degree 35degree 30degree 35degree 30degree 35degree 30degree 35degree

a 804 1131 601 601

Dimensions [a, b, c, d, e ](of 2 Flat Steps) +

407

b 1195 1321.5 990.4 990.8

c 1219 1345.9 1015 1015

d 1413.6 1541.1 1209.5 1210.4

e 236.4 236.4 236.4 236.4


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Brief Newel Assy Install Instruction

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