Bi-Directional Progressive Safety Gear

Bi-Directional Progressive Safety Gear (PRO 2000-A, PRO 2000-B, PRO 5000) Installation and Operation Instructions

PRO 2000-A PRO 2000-B PRO5000 PRODUCT PRO2000-A PRO2000-B PRO5000 Speed, P+Q, [m/s] [kg] 1 2400 1,2 2200 1,6 2000 1 4000 1.2 3330 1.6 2800 2 2250 2.5 1850 1 5000 1.2 4400 1.6 3400 2 3100 2.5 2500 Thickness of the head rail, [mm] 5, 9, 10, 12, 14, 16 9, 10, 12, 14, 16 12, 14, 16, 18, 20 2

Bi-Directional Progressive Safety Gear PRO 2000-А The safety gear produce with mechanism( the part which is connecting the block of safety gear to the cabin), or without mechanism. Attention!!! In case when safety gear is produced without mechanism, mounting dimensions for the mechanism of the safety gear should be made strictly according to the dimensions which has showed in the figures A and B-B. The safety gear can be used with 5 mm, 9 mm and 16 mm guide rails. 3

The safety gear produce with mechanism( the part which is connecting the block of safety gear to the cabin), or without mechanism. Attention In case when safety gear is produced without mechanism, mounting dimensions for the mechanism of the safety gear should be made strictly according to the dimensions which has showed in the figures A and B-B. The safety gear can be used with 5 mm, 9 mm and 16 mm guide rails. A square tube 25х25х2 mm or pipe is recommended to be used as synchronizer of safety gears. Attention!!! This items must be specified by customers: The speed of the Elevator P+Q The thickness of the rail head and rail type The safety gear will be completed according to these data and cannot be used on the elevators with other different data s. 5

Bi-Directional Progressive Safety Gear PRO 5000 The safety gear produce with mechanism (the part which is connecting the block of safety gear to the cabin), or without mechanism. Attention In case when safety gear is produced without mechanism, mounting dimensions for the mechanism of the safety gear should be made strictly according to the dimensions which has showed in the figures A and B-B. The safety gear can be used with 5 mm, 9 mm and 16 mm guide rails. 6

A square tube 25х25х2 mm or pipe is recommended to be used as synchronizer of safety gears. Attention!!! This items must be specified by customers: The speed of the Elevator P+Q The thickness of the rail head and rail type The safety gear will be completed according to these data and cannot be used on the elevators with other different data s. 1. Description and Principle of Operation All of the safety gears (PRO2000, PRO2000S, PRO5000) are Bi-Directional and Progressive. The Safety Gear consists of: Mechanism (the part which is connecting the block of safety gear to the cabin) Figure 1 (it may not be included), the block of the safety gear Figure 2, the set of pads Figure 3 ( for 7

safety gear PRO2000-A one set of pads, for safety gear PRO2000-B and PRO5000 two sets of pads ), roller Figure 4, the lever of activation Figure 5, interrupter switch Figure 6, the square of the synchronizer Figure 7, mounting plate Figure 8, mounting plate with for centralizing Figure 9, screw (М8х50) Figure 10, nut М8 Figure 11, spring Figure 12, the support ring Figure 13 4 pcs, mounting bolts Figure 14 4 pcs ( М12х45-PRO2000-A/B, M14x45-PRO5000), the control lever of the roller Figure 15, levers Figure 16, spring Figure 17, shim Figure 18 While moving of the elevator cabin down or up and activation of over speed governor (OG), the rope which is attached to the lever ( Figure 5) stops. Therefore the lever ( Figure 5 ) raises the lever ( Figure 15 ), which in turn raises the lever ( Figure 4 ) in the groove of the safety gear block (Figure 3). At primary stage the lever ( Figure 4) moving up according the figure groove of the safety gear block ( Figure 2), chooses the clearance to guide rail. At secondary stage, being in the contact with guide rail, the lever ( Figure 4) continues its moving in the groove of safety gear block ( Figure 2). Therefore the safety gear block ( Figure 2) starts moving in the grooves of the safety gear ( Figure 1) and selects the clearance between the set of pads ( Figure 3 ) and the rail guide. At the third stage, when the pads ( Figure 3 ) make contact with guide, starts the braking process. The rail guide is placed between the pads ( Figure 3 ) and the lever ( Figure 4 ). The required braking force and the deceleration speed is ensured as due to the unique shape of the pad, as the copper insert, which is located in the upper part of the groove of the safety gear block ( Figure 2 ). When the roller ( Figure 4) is in the up position (there is a yellow copper part inside the block) the copper part does not allow the roller to jam, and provides a roll which creates a constant force pressure of the roller to the rail guide. Synchronization of two safety gears is ensured by the fact, that the lever ( Figure 15 ) is connected to the square of the synchronizer (Figure 7 ). At the moment when the lever ( Figure 15 ) rises, it turns and square synchronizer ( Figure 7 ), which passes through the synchronizer rotational movement of the second safety gear. There is a lug with the groove on the tube of the synchronizer, which includes a roller switch ( Figure 6 ). When the tube of the synchronizer is rotated, it presses the roller switch and it starts working. During operation of the safety gears the square synchronizer (Figure 7) spread the levers (Figure 16), which are connected by a spring (Figure 17). At the moment removing of the cabin from the safety gears the spring ( Figure 17 ) tightens the levers (Figure 16). These springs, act on the square of the synchronizer (Figure 7) and return it to its original position. The roller switch ( Figure 6 ) is in the groove on the lug and the synchronizer returns the switch to its original position. 2. The Installation of Safety Gear Please, before the installation verify that the safety gear meets the required source data: The speed, P+Q, the width of the rail guide and the type of the rail guide. The working surfaces of the rail guides should be free of dirt. The installation of the safety gear in case when it is supplied without mechanism ( Figure 1. ) 8

1.Fix the block of the safety gear to existing housing by means of 4 bolts ( Figure 14) М12х45 (PRO2000-A/B), or by means of 4 bolts ( Figure 14 ) М14х45 (PRO5000). Therefore it is necessary to insert 4 rings ( Figure13 ) in the grooves of the safety gear. It is necessary to fix the block of the safety gear to the corps by means of mounting plates ( Figure 8 and 9 ). If necessary, between the corps and mounting plates ( Figure 8 and 9 ) can be installed the shim ( Figure 18 ). These shims are used in order to avoid the clamping of the safety gear block ( Figure 2 ) by means of mounting plates ( Figure 8 and 9 ), and to allow the safety gear block to move freely in the grooves of the safety gear. Attention!!! The mounting plate with focus ( Figure 9 ) should be placed on the opposite side of the synchronizer. 2. Fix the spring ( Figure 12) to the mounting plate ( Figure 9 ) by means of bolt М8х50 ( Figure 10 ), nut М8 (Figure 11 ). Attention!!! After tightening the bolts ( Figure 14 ) the safety gear block in assembly ( Figure 2 ) should freely move in the grooves on the corps ( Figure 1 ). The bolt with spring ( Figure 10 and 12 ) needs to be set straight. 1.The block of safety gear will be shifted according to the grooves on the corps in the direction of the spring compression until it stops, If the force is removed the safety gear block ( Figure 2 ) should return to its original position under the action of the spring ( Figure 12 ). 2. To install the safety gear corps in assembly with block to the elevator and to fix according to the technical documentation. 3. To put the safety gear on the Elevator according to the guide, observe the following recommendations: 9

- The clearance from the end face of the rail guide until the surface A on the safety gear should be 5-7 mm. - The clearance from the pads of the safety gear until the rail guide should be 1,5 mm. - It is not allowed to skew the safety gear relative to the rail guide. The surface А on the safety gear must be strictly parallel to the end face of the rail guide. The surfaces B and C on the safety gear must be strictly parallel to the side surfaces of the rail guide 4. The safety gears should be connected by means of synchronizer. In place of mounting the synchronizer to the safety gear there must not be the any gap. The synchronization of 2 safety gears will be better, if their connection will be as rigid as possible. The installation of the safety gear in case when it is produced with the block (Figure 1). Attention!!! It is necessary to make sure that the safety gear block ( Figure 2 ) freely moves in the grooves on the corps ( Figure 1 ). The block of safety gear will be shifted according to the grooves on the corps in the direction of the spring compression until it stops, If the force is removed the safety gear block ( Figure 2 ) should return to its original position under the action of the spring ( Figure 12 ). 2. To install the safety gear corps in assembly with block to the elevator and to fix according to the technical documentation. 10

3. To put the safety gear on the Elevator according to the guide, observe the following recommendations: - The clearance from the end face of the rail guide until the surface A on the safety gear should be 5-7 mm. - The clearance from the pads of the safety gear until the rail guide should be 1,5 mm. - It is not allowed to skew the safety gear relative to the rail guide. The surface А on the safety gear must be strictly parallel to the end face of the rail guide. The surfaces B and C on the safety gear must be strictly parallel to the side surfaces of the rail guide 4. The safety gears should be connected by means of synchronizer. In place of mounting the synchronizer to the safety gear, there must not be the any gap. The synchronization of 2 safety gears will be better, if their connection will be as rigid as possible. 3. Verification of the Serviceability of the Safety Gears During the testing, it is strictly prohibited to be on the roof or in the elevator cabin. 3.1 Testing of an empty cabin while driving down 3.1.1 Make sure that there are no people or foreign objects in the pit of the elevator. 3.1.2 To inspect the safety gears, mechanisms of activation and of synchronization. Everything should be securely fastened. 3.1.3 Verify the correctness of safety gear placing. 3.1.4 Check the simultaneity of the touch rollers and rail guides of the right and left safety gears. 3.1.5 Set an empty cabin in the middle of the lift. 3.1.6 Put down an empty cabin. 3.1.7 To activate the over speed governor, the safety gear must be placed on elevator cabin 3.1.8 To check the reliability of the landing of the cabin on safety gears, unlock the brake on/off input device and to reduce the rope of the over speed governor, the cabin must not crawl down. 11

3.1.9 To lift the cabin and check the simultaneity of the actuation of the safety gears according to the trails on the rail guides. Check the breaking distance according to the trails on the rail guides. It should be at least 40 mm for an empty cabin. The possible removing of the cabin because of the counterweight skip is not the spoilage of the safety gear. Check the shape of the safety gears with a view to find any damage or deformation. 3.2 Testing on full load during the driving down 3.2.1 Place in the cabin the load which will be equal of 1,25 from the capacity of the elevator. The load should be placed evenly throughout the cabin. 3.2.2 Start up the cabin at the nominal speed. 3.2.3 Activate the over speed governor. In this case the cabin should settle on the safety gears. 3.2.4 To check the reliability of the landing of the cabin on safety gears, unlock the brake on/off input device and to reduce the rope of the over speed governor. The cabin must not crawl down. 3.2.5 Lift the cabin and check the simultaneity of the actuation of the safety gears according to the trails on the rail guides. Check the breaking distance according to the trails on the rail guides. It should be at least 60 mm for a full cabin. The possible removing of the cabin because of the counterweight skip is not the spoilage of the safety gear. Check the shape of the safety gears with a view to find any damage or deformation. 3.3 Testing on full load during the driving up 3.3.1 Place in the cabin the load which will be equal of 1,25 from the capacity of the elevator. The load should be placed evenly throughout the cabin. 3.3.2 Start up the cabin at the nominal speed. 3.3.3 Activate the over speed governor. In this case the cabin should settle on the safety gears in this case 3.3.4 Remove the cabin and check the simultaneity of the actuation of the safety gears according to the trails on the rail guides. Check the shape of the safety gears with a view to find any damage or deformation. After every testing,the rail guides should be cleaned from burrs and roughs which could appear in the process of the safety gears work. If the damages and deformations were not found after all the tests, the safety gears are ready for working. 4. The determination of the direction of the safety gears actuation. In neutral working position the lever ( Figure 15 ) is placed in the horizontal direction 12

The lever position while the activation of the safety gear during the cabin driving down The lever position while the activation of the safety gear during the cabin driving up The maximum step of the activation lever of the safety gears in the vertical direction from the neutral position while actuation of the safety gear is 14 mm. Sometimes the elevator cabin can make a spontaneous landing on the safety gears. In such cases it is impossible to know, when moving up or down the cabin landed on safety gears. In order to determine the direction of the motion, when the safety gears were activated, you must perform the following recommendations: 1. Make a mark with paint on the branch of the over speed governor rope in the upper beams of the elevator frame (which is connected with the lever). 2. Also make one more mark on the elevator frame at the opposite to this mark 13

It is recommended to choose the area that will be viewable on the shaft door aperture for making marks. With regard to the marks displacement from each other it is possible to determine the direction of the cabin during safety gears activation If the mark which has been painted on the over speed governor rope, is placed up in comprising with the mark which has been painted on the frame, the cabin was moving down in the moment of safety gears activation. If the mark which has been painted on the over speed governor rope, is placed down in comprising with the mark which has been painted on the frame, the cabin was moving up in the moment of safety gears activation. 5. Maintenance, Control, Repair It is necessary to make sure that there are no damages and deformations on the safety gears after each of their activation and subsequent cabin removal. Further operation of the safety gears is prohibited when: - There are damages or deformations on the safety gears parts. -There is a clearance in the mechanism of synchronization which leads to non-simultaneous actuation of the right and left safety gears - If there is a vertically clearance more than 1mm between safety gear block ( Figure 2 ) and the safety gear corps ( Figure 1 ). The presence of this clearance may indicate the rings deformation or destruction ( Figure 13 ). - There is a skew of the safety gear block in comprising to rail guide. In order to ensure the security and efficiency of safety gears, it is necessary to conduct the routine maintenance in accordance with this user manual. The maintenance and renovation must be performed by trained personnel. At least one time in a 3 months. - Clean the safety gears from pollution; 14

- Check the mount reliability of the safety gear. All the bolts should be tightened. - Visually check the safety gears for the presence of defects or deterioration; - Make sure that the safety gear block ( Figure 2 ) moves freely in a horizontal direction along the grooves on the safety gear corps ( Figure 1 ). - Make sure that the lever of safety gears activation ( Figure 5) moves freely up and down, driving the lever ( Figure 15 ) and the roller ( Figure 4 ) - Make sure that the roller switch ( Figure 6 ) is snugly adjoined to the cam on the synchronizer; - Check the synchronous operation of the left and right safety gear; - Visually make sure for the pads presence ( Figure 3 ). Attention!!! Bi-Directional Progressive Safety Gears are intended for 10 actuations up or down by the full load of the elevator cabin. This number does not include cases of false actuation while installing/setting up/delivery of lift, as well as cases with periodic tests of the Elevator. All the cases of safety gears actuation in conditions of normal elevator work should be recorded according to Annex 1. After reaching 10 actuations to one side (up or down) the safety gears should be replaced! 6. General information 6.1 Completeness of delivery The completeness of delivery includes: 15

- The right safety gear in assembly 1 pc. - The left safety gear in assembly 1 pc - Installation and Operation Instructions 1 pc. - Copy of certificate of conformity 1 pc. 6.2 Labelling An example of the label The label is places on the safety gear. On the label is indicated the following information: - The name of the manufacturer - The safety gear model - The thickness of the rail guide - P+Q, kg - The nominal and maximum speed, m/s. - The serial number of the safety gear. 6.3 The Liability and Warranty This guide is intended for people familiar with the installation and maintenance of elevators. Not allowed: The usage of safety gears not on purpose; The installation of safety gears faulty or not corresponding to the appointment; To make any changes in the safety gears construction without the permission of the manufacturer; «Metroplast» refuses from any liability for defects, which came as a result of disregard of this manual or because of wrong actions from the technical staff side that may influence the performance of the product. 6.4 The Refusal in Warranty Service and the Failure from Liability 16

At the occurrence of one or more reasons that follows the manufacturer can refuse to provide the warranty service: - The usage of the safety gears not on purpose; - The disregard of the installation rules, operation, maintenance and conditions of the transport and storage; - Unskilled persons installation and maintenance of the safety gears - The lack of control over the safety gear details exposed to wear; - Unqualified and / or unauthorized repair; - The usage of non-original spare parts ; 6.5 The Spare Parts It is necessary to use the original spare parts. The disregard of this requirement the product can be removed from warranty service. 6.6 The Transportation and Storage The product comes in carton boxes. The weight of one box is about 11 kg. It is necessary to follow the conditions by the transportation and storage of the product: - Prevent from ingress of moisture and dust to the product; - Prevent the falling and deformation of the product; - Prevent contamination of safety gears and their working parts. - The temperature must be in the room -50 +50 C; - The maximum relative air humidity must be 80 % at 20 C, without the formation of dew or frost; 6.7 Safety Regulations Assemblers and adjusters are responsible for the safety during the safety gears installation and service work. Installation and maintenance must be carried out in a sequence that describes this guide. The personnel performing works on installation and maintenance, must be familiar with this manual. The safety gear requires special attention, because its excellent performance ensures safety usage of the lift. 6. Possible Malfunctions and Their Causes The Malfunction Spontaneous landing of the cabin on safety gears Possible Cause -The clearance between the safety gears pads and the rail guide is less than the required value; -The safety gear is installed with the skew regarding to the rail guide; 17

The cabin is skewing after the actuation on the safety gears The safety gears fail - There is a clearance in the mechanism of synchronization of the right and left safety gears; - The mechanism of synchronization of the right and left safety gears is not rough enough; - There is no possibility of safety gear block movement regarding to the corps; Annex 1 Cases of Safety Gear Actuation Elevator, capacity kg, speed m/s, located at All the data should be written from the label of the safety gear Safety gear (model) The width of the rail guide head P+Q, kg The nominal speed, m/s The max speed, m/s Serial number Date Approximate load, kg Side actuation (up/down) Signature 1 2 3 4 5 6 7 18

8 9 10 11 12 13 14 15 16 17 18 19 20 After reaching 10 actuations to one side (up or down) the safety gears should be replaced! 19