REF: KALEA-A2.

COV
PREP: PRHP 09/04

PICKERINGS

TECHNICAL TRAINING

PROGRAMME

PLATFORM LIFT - TYPE A2

INSPECTION PROCEDURE

SAFETY WHEN WORKING ON THE EQUIPMENT

When the pulpit cover is removed, live electrical equipment is exposed. Ensure that
the system is electrically isolated before working on items where contact with the
exposed electrical equipment is possible.
When any of the back panels are removed, be aware of the potential trapping points
between the platform and back panel-mounting frame.
Before entering the shallow pit, always ensure the pit prop is locked in the set
position.
For lifts incorporating variable speed inverter drives, capacitors remain charged to a
potentially lethal voltage after the AC supply has been disconnected. Ensure the AC
supply has been isolated for at least ten minutes before working on electrical parts of
the drive.
You are also referred to the LEIA Lift Safety: Site Handbook.
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CONTENTS

Section Page No

1. OVERVIEW OF THE KALEA PLATFORM LIFT - TYPE A2

Extracts from the Specification ........................................................................ 1

2. EMERGENCY PROCEDURES

2.1 Manual opening of the Landing Doors ....................................................... 2

2.2 Release of Passengers from the Lift .......................................................... 3

3. INSPECTION PROCEDURE

Accessing Components ................................................................................... 4

Component Inspection ..................................................................................... 6

4. ILLUSTRATIONS ....................................................................................... 12

5. ELECTRICAL CIRCUIT DIAGRAMS & PARTS LIST ................................ 19

6. SPRINT AUTOMATIC DOOR OPERATOR MANUAL

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1. OVERVIEW OF THE KALEA PLATFORM LIFT - TYPE A

SPECIFICATION

Maximum Load 400 kg/4 persons

Travel Up to 9 meters.

Speed 0.15 m/s maximum.

Electrical Supply 1-phase, 230V A.C.

Drive System Belt driven rotating bronze nut which runs up and down
steel wormed screw. Secondary safety nut to hold the load
should the drive nut fail. Drive motor positioned behind platform.
Motor is inverter driven from single phase supply.

Control System Constant pressure push button. PLC based control system
mounted on the platform under pulpit cover.

Landing Doors Steel hinged type with manual opening and mechanical closing
operation as standard. Powered operation and remote control
optional. Electromechanical interlocking system operated by
retiring ramp.

Alarm System Primary system is a sounder attached to the platform, supplied

from automatically charged batteries. A second voltage free
contact is provided on the alarm push button for the option to
operate a remote alarm.

Emergency
Lowering Secondary drive system supplied by automatically recharged
batteries. Emergency lowering is activated by simultaneous
operation of the push button and key switch at the bottom floor
landing entrance.
Emergency drive only becomes functional when main power
supply is lost.

Platform
Overload Overload protection fitted as standard. Upon exceeding the
rated load the overload indicator illuminates and the lift is
prevented from starting.

Pit prop Prior to entering the pit, the platform prop is set and the door
lock kept released, by a turning special key at the landing
entrance. A green indicator illuminates to when the prop is set.
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2. EMERGENCY PROCEDURES

2.1 MANUAL OPENING OF THE LANDING DOORS

To gain emergency access into the well (shaft) or lift platform, the unlocking
key for the landing doors must be used. In the interest of safety, use of the
key should be limited to an authorised person(s), who has been instructed
in and is familiar with the correct procedure.

IF IT IS NECESSARY TO OPEN THE LANDING DOOR TO DETERMINE

THE POSITION OF THE PLATFORM OR TO RELEASE THE
PASSENGERS FROM THE PLATFORM, EXTREME CARE MUST BE
TAKEN TO AVOID FALLING INTO THE LIFT WELL (SHAFT).

DO NOT LEAVE LANDING DOORS OPEN UNLESS THE ENTRANCE IS

ADEQUATELY AND SECURELY PROTECTED TO PREVENT ANY
PERSON ACCIDENTALLY FALLING INTO THE WELL (SHAFT).

PROCEDURE – LOWEST FLOOR

1. LOCATE AND HAVE READY THE DOOR UNLOCKING KEY.

2. SWITCH OFF THE ELECTRICAL POWER SUPPLY TO THE LIFT AT
THE ISOLATING SWITCH.
3. LOCATE THE LOCK RELEASE ACCESS HOLE IN THE DOOR
FRAME. Remove the protection screw plug with the socket key
provided.
4. INSERT THE KEY IN THE ACCESS HOLE TO ENGAGE THE
TRIANGULAR PIN. ROTATE THE KEY CLOCKWISE OR ANTI-
CLOCKWISE UNTIL IT STOPS (ACCORDING TO THE DOOR
TYPE) TO DISENGAGE THE LOCK. WHILST HOLDING THE KEY
IN THIS POSITION PULL ON THE DOOR TO OPEN.

Note: For lifts fitted with fire rated doors, there is no hole in the frame to
access the lock with an EN81 key as described above. Instead, there is a
small Torx screw in the door panel. Removing this allows a screwdriver
or similar to be pushed in until it reaches the chamfered surface at the
end of the lock pin, which is then opened by applying a ‘lever’ action.

PROCEDURE – OTHER DOORS

INSERT THE KEY IN THE ACCESS HOLE TO ENGAGE THE TRIANGULAR

PIN. ROTATE THE KEY CLOCKWISE OR ANTI-CLOCKWISE UNTIL IT
STOPS (ACCORDING TO THE DOOR TYPE) TO DISENGAGE THE LOCK.
WHILST HOLDING THE KEY IN THIS POSITION PULL ON THE DOOR TO
OPEN.
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2.2 RELEASE OF PASSENGERS FROM THE LIFT

This procedure must be used only in the case of an emergency and only by
authorised persons who have had instructions in its use. It is dangerous for any
other person to attempt to do so.
Note: the emergency drive system will only operate when the lift electrical
supply is isolated.

PROCEDURE
1. LOCATE THE KEY FOR THE EMERGENCY LOWERING KEY SWITCH.

2. REASSURE PASSENGERS TRAPPED IN THE WELL that their release

is being attended to and warn them that the lift is about to be moved and
therefore to stand clear of the doors and remain in the well until instructed
to leave.

3. CHECK THAT ALL LANDING DOORS ARE CLOSED AND LOCKED.

4. SWITCH OFF THE ISOLATOR (positioned at the bottom floor entrance)

5. LOCATE THE EMERGENCY LOWERING KEY SWITCH AND PUSH

BUTTON AT THE BOTTOM FLOOR ENTRANCE (see Fig.1). INSERT
THE KEY INTO THE KEY SWITCH. ACTIVATE EMERGENCY
LOWERING BY SIMULTANEOUSLY OPERATING THE KEY SWITCH
AND APPLYING CONSTANT PRESSURE ON THE PUSH BUTTON. AN
INTERMITTENT BLEEPING SOUND IS EMITTED WHEN THE LIFT IS
MOVING UNDER EMERGENCY CONTROL.

6. UPON THE PLATFORM REACHING FLOOR LEVEL, STOP THE

LOWERING PROCEDURE IMMEDIATELY BY RELEASING THE PUSH
BUTTON AND KEY SWITCH. BE CAREFUL NOT TO ALLOW THE
PLATFORM TO PASS THE FLOOR LEVEL.

7. UNLOCK THE LANDING DOOR (see Section 2.1) using the emergency
unlocking key and manually open the door to release the passengers.
WARNING - IF THE PLATFORM IS NOT EXACTLY AT FLOOR LEVEL,
CARE MUST BE TAKEN TO PROTECT THE PASSENGERS WHEN
LEAVING THE WELL.

8. AFTER RELEASING THE PASSENGERS, CLOSE LANDING DOOR

AND CHECK IT IS SECURELY SHUT.

9. LEAVE THE POWER SUPPLY SWITCHED OFF AND PLACE "OUT OF

SERVICE" NOTICES AT EACH ENTRANCE.

10. CALL OUT THE LIFT SERVICE TECHNICIAN to check the lift before
being put back into service
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3. INSPECTION PROCEDURE

Accessing Components

The majority of components are accessible following removal of the pulpit cover
and central column of the back panels. Gate locks are accessed following removal
of the access panels corresponding to the position of the lock. The emergency
drive system is accessible following removal of the hood from the uppermost back
panels

Removal of the central

back panels The central back panels are secured by M5 socket
screws (4 per panel. See Fig.2). Removal of these
panels provides access to: drive screw, guides and
rollers, limit switch ramps, lock actuating arms and pit
prop.

Removal of the
pulpit cover Switch off the electrical supply to the lift. Two ‘Torx’
headed screws secure the pulpit cover at the top (see
Figs.3, 4 & 5).
A tool (Torx T25) to remove these is included in the
emergency tool kit provided with the lift. Following
removal of the screws, lift the bottom of the cover out
from behind the skirting plate. Put the cover in a safe
place.
The control panel is now accessible and can be isolated
by the mains switch S1 (see Fig.6).

Accessing
components behind
the control panel Access to: drive system and screw, retiring ramp and
limit switches is possible by the means described below.

Before entering the pit, ensure there are no passengers

on the platform and the entrance is suitably guarded.
With the platform positioned at an upper floor, use the
actuating key to engage the pit prop, indicated by
illumination of the green indicator at the bottom landing
entrance (see Fig.7 & 8). When the prop is set, a contact
in the safety circuit opens to isolate the lift from operation.
Note: To avoid accidental resetting of the prop and
setting of the door lock by a third party, remove the
activating key before entering the pit.
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Operate the pit stop switch and enter the lift pit.
Remove the lowest central back panel via the four
socket screws. Remove the panel from the pit and place
it in a safe place.

Exit the pit and reset the stop switch. Engage the
actuating key and turn it until the pit prop is fully
retracted. Close the landing door and call the lift down
to floor level.

The light diffuser requires removing before the control

panel cabinet can be opened. This is achieved by
removing the two fixing screws and then unclipping the
diffuser from under the push button panel (see Fig.6).

Hinged strips on either side secure the control panel

cabinet. This is to allow the cabinet to be swung open
from either the left or right hand side, depending on the
position of the lift entrance. Remove the fixing screws
from one hinge only (see Fig.9). The cabinet can then
be opened and with the bottom back panel removed the
components behind accessed.
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Component Inspection

The frequency of these checks depends on the usage and age of the lift.

Platform Check the function of the platform light. A time-out facility

switches off the light following a period of lift inactivity. The
light should switch on upon opening the landing door.
Isolate the lift main supply and check that the light remains
illuminated by the emergency supply.

Note:
The controller PLC monitors the state of the 24 Volts
supply and prevents the lift from operating should this
voltage level reduce below 22V. In such a case, a low
battery warning (pulsing sound) is emitted and the
overload indicator illuminated. If the platform is in
travel when this occurs, it is allowed to continue to the
next floor and then prevented from restarting.

It has been found that when the lift has been switched
off for some time and the emergency batteries have
become discharged, that upon power up the drain on
the 24V d c, caused by the load of the platform light
and simultaneous charging of the batteries, reduces
the 24 Volts supply sufficiently to prevent the lift from
operating. In such cases the platform light tube should
be detached and the batteries allowed to charge for
several hours. Following this period, the light tube
should be reinstated and the lift operationally tested
and put back into service.
The customer should be advised to leave the lift
permanently switched on.

Check the function of platform push buttons:

Check emergency alarm system. Check function of alarm
push button, the platform sounder should operate and if
fitted, the remote alarm should also sound (customer
option).
When fitted with automatic door openers (option), check
that operation of the call buttons also opens the doors.

Check function of ON/OFF key switch (option) and

emergency stop switch. Stop switch should remain in the
off position until it is rotated to reset it.

Check the pulpit cover, side panels and handrails are

secure.
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Check operation of the safety bar behind the handrail/push

button station and that the floor safety edge operates on all
three sides. When tripped, these devices should stop travel
in the up direction only. Travel is then only possible in the
down direction.

Check the stability and ride quality of the platform, which

should run smoothly between guide rails. Report any
excessive vibration. The VF drive should produce soft
starting and stopping.

Check the platform floor covering for wear and damage.

Pit area and

Platform underside Before entering the pit, ensure there are no passengers on
the platform, the entrance is suitably guarded, the pit prop
has been set by operation of the activating key at the
landing entrance (the green indicator illuminates when the
prop is set, see Figs.7 & 8), the pit area is adequately
illuminated and operation of pit stop switch immobilises lift.
Note: To avoid accidental resetting of the prop and
setting of the door lock by a third party, remove the
activating key before entering the pit.

Ensure that the pit area is clean, dry and free of debris.

Remove excess oil/ grease from the bottom of the guides.

Check the condition of the underside of the platform and

the security of fixings.

Check the condition of the floor safety edge and

switches. The safety edge switches are shown in Figs.10
& 11.

After exiting the pit area, reset the pit prop and door
lock with the activating key (the green indicator should
extinguish).

Trailing Cables Check security and condition of trailing cables paying

close attention for signs of wear and snagging damage.
Ensure trailing cables hang clear of any possible
snagging/chaffing points.

Guides and Guide

Rollers/Pads Check the condition and security of the guide rails,
guide rollers and pads. Reduce excessive side play
between platform and guides (see Fig.21).
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Drive Nut and

Worm Screw Check condition and security of the worm screw. For
long travel applications the screw is supplied in two or
more sections. Check security of the screw joint and
locking pins. Ensure there is a film of grease on the
screw surface, lubricate as necessary with Gleitmo 805
grease. Note: application of too much lubricant
results in grease being expelled by the drive nut
and consequential contamination of components.

Check the nut for wear as illustrated in Figs.12 & 13.

The wear template is normally found clipped to a
mounting rail on the control panel.
After checking nut wear, remember to remove the
template and return it to its storage position.

Check the function of the nut wear limit switch, which

when operated, should stop the lift in both directions of
travel. Under normal conditions, there should be a small
gap (approx. 0.5mm) between the limit roller and top of
the actuating disk, (see Fig.13).

Motor and Drive Check the condition and security of motor and fixings.

Run the lift and listen for any unusual sounds from the
motor.

Check the drive belt for wear, damage and correct

tension, adjust/replace as found necessary.
To adjust the drive belt tension, slacken the four motor
mounting screws. The tension is then adjusted by the
jacking screw seen positioned to the left side of the
motor pulley in Figs.14. Re-tighten the mounting
screws.

Check the brake is lifting correctly and promptly stops

travel when the push button is released.

Whilst travelling in the down direction, press and hold

the brake release push button (S85) situated on the
controller next to the emergency drive push buttons
(S71 & S72) (see Fig.6). While keeping this button
pressed, release the down push button. The brake will
remain lifted but the platform should still come to a stop
without descending much further. Also, with the lift
stationary, press the brake release button, the lift should
not descend.
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Limit Switches
and Ramps Referring to Figs.15 & 16. S2 is the final limit and is
common for both directions of travel. Check the switch
and its operating ramps are secure. The limit should trip
10mm after floor level.
When tripped the final limit cuts the main supply to the
lift. This puts the alarm system and platform light on to
emergency battery supply.

The shaft switches are shown in Fig.16. S70 is an

inductive type switch, which counts the floor position
and also stops the lift at floor level in both directions of
travel. The switch is operated as it encounters metal
plates placed in close proximity (indicated by
illumination of the switch LED). Upon the platform
entering the desired floor, the switch encounters the
plate initiating the stop signal to the VF drive, and the lift
speed ramps down to a soft stop.
The clearance between switch and plate should be set
to 3-5mm.

Switch S75 is the down limit. It prevents the lift from

over-travelling at the bottom floor, on both normal and
emergency drive.

Check the inductor switch (S70) stops the platform

level. If not, adjust stop plates as necessary.

Check condition and security of all limit switches, ramps

and plates.

Emergency Drive The emergency drive rotates the main screw, which
causes the platform to move up or down (at reduced
speed) depending on the direction of rotation. The
supply for this drive is via the emergency batteries and
is only active when the main power supply is off.

The emergency drive and drive screw mountings are

accessible following removal of the shaft panel hood
(see Fig.22)

Check security of the drive screw bearing and fixings

and emergency drive assembly.

Check condition and security of the drive motor cables.

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Check operation of the emergency drive in both

directions of travel via push buttons S71 & S72 on the
control panel (see Fig.6). CAUTION: When driving the
lift down via S71 do not allow the platform to over-
travel the bottom floor and buffer out, as this will
cause damage to the emergency drive unit!

Check operation of the emergency drive button and key

switch at the bottom landing entrance (see Fig.1). The
lift will travel in either direction depending on the
position of the key switch. Check the platform stops
level at the bottom floor (stops via S75 limit switch. See
Fig.12).

Check condition of the emergency batteries. The

minimum voltage should be 24V D.C. If the level is
between 20 – 22V, check the charger unit.
It is recommended that the batteries be replaced
every three years.

Landing Doors
and Locks Check the security, condition and function of the door
electrical interlock contacts. Ensure the lift stops/will not
start when contacts are open.

The door locks are operated by a remote retiring ramp

and lock arm, via Bowden cables. The bottom floor lock
has two operating cables; one for retiring ramp
operation and the second for unlocking via the pit prop
actuating key.

Check the security, condition and function the retiring

ramp, lock actuating arms and rollers, operating cables
and door locks. When in the locked position, the lock
pin must protrude from the door frame by a minimum of
7mm. The locks are accessed following removal of the
cover plate (see Fig.17). The lock actuating cable(s) is
adjusted at the lock, (see Fig.18 & 19).

The correct setting for the lock actuating arm is shown

in Fig.20.

With the door locked, check the door movement. If it is

excessive enough to open the interlock contacts and
stop the lift, reduce the amount of movement via
adjusting the slotted plate in the door lock pin aperture.

Check the function of the pre-lock contacts by manually

unlocking while the lift is in travel.
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Check the security, condition and operation of the

doors. Lubricate hinges as found necessary and adjust
door closers as required via the damping screw at the
side of the unit (exposed following removal of the clip-on
plastic cover).

For automatic doors, refer to the door operator manual

for maintenance and adjustment instructions. Note:
door open delay time is controlled and adjusted at
the door operator, not on the main controller.

Refitting the back

panels Refit all back panels ensuring that they and all fixing
screws are secure. Note: prior to refitting back
panels, check that the trailing cables are hanging
correctly and clear of snagging/chaffing points.

General Ensure that any greasy marks produced during

servicing activities are cleaned from all surfaces.
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4. ILLUSTRATIONS

Fig.1 Emergency Lowering station at Fig.2 Central Back Panel fixings (4 per
bottom floor entrance panel)

Fig.4 After removing fixing screws, tilt

and lift out Pulpit Cover

Fig.3 Platform and Pulpit

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Fig 5. Pulpit Cover removed exposing Fig.6. Controller Components

Controller

Fig.7. Pit Prop Actuating Key and Prop Fig.8 Pit Prop, Door Lock operating
Set Indicator arm and Final Limit operating Ramp
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Fig.9 Controller Cabinet Hinge Fixings Fig.10 Platform Safety Edge Switches

Fig.11 Platform Safety Edge Switch and Fixings

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Fig.12 Controller Cabinet open – Drive, limits and R. Ramp exposed. Picture
shows use of Template provided for checking Drive Nut wear

Fig.13 Nut wear switch setting and Wear check point (with template)
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Fig.14 Drive unit with Belt Tension Screw highlighted

Fig.16. S75 – Down Limit, S70 -

Inductor Switch and Stop Plate
Fig.15 Switch S2 - Final Limit
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Fig.17 Cover Plate above entrance – remove to access Door Lock

Fig.18 Door Lock and Landing Wiring Terminals

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Fig.19 Lock and Adjustment points for Operating Cables

Fig.20. Setting the Door Lock Roller Fig.21. Platform Guide Roller and Side
to Side Adjustment Screw
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Fig.22 Emergency Drive Unit

5. ELECTRICAL CIRCUIT DIAGRAMS & PARTS LIST

Note: these diagrams are typical and for example purposes only. You should
always refer to the drawings specific to the job!

Points on the circuit diagram shown as encircled numbers refer to terminal blocks
on the control panel.
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REF: KALEA-A2.22
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Electrical part list A2 Electrical part list A2 A2 Siemens PLC IO

Sign Product Producer Type
FO Frequency converter ABB ACS 140
F1 Fuse manoeuvre 230V 4A Merlin Gerin 24308
F2 Fuse manoeuvre 24V 1A Merlin Gerin 24305
F3 Fuse manoeuvre 48V 1A Merlin Gerin 24305
F4 Fuse manoeuvre 12V 10A Littelfuse 3310661
F5 Fuse manoeuvre 12V 1A Littelfuse 3310554
TR1 Transformer 230VAC/24AC 80VA Toroid 5612387
V1 Rectifier brake ABB
L1 Brake ABB
L2 Retiring cam Kronenberg EMT-18
M1 Main motor 3x230/400VAC ABB 2.2kW B14
M2 Emergency lowering motor Valeo 404,319
D3 Charger Mascot 24V 1,3A
PLC PLC Siemens 12/24rc 6EDI 052-1MD00-0BA4
B3 Battery 12V 2Ah Fiamm FG21201
B2 Overload lamp Telemecanique ZB4BV04
H2 Light platform KG Knutsson 2JA 377 182 241
K1 Contactor down Allen Bradley 100-M09NKH31S
K2 Contactor up Allen Bradley 100-M09NKH31S
K3 Main contactor Allen Bradley 100-M09NKH31S
R11 Relay emergency lowering C.O. 351142
R12 Relay emergency lowering C.O. 351142
R13 Relay emergency lowering C.O. 351142
R14 Relay door contact Finder 4052-8048
R15 Relay door contact Finder 4052-8048
S1 Main internal switch Garo 3155200
S2 Limit switch up and down Gycom 41086
S11 Pit prop Telemecanique XCKP102
S14 Emergency stop pit Telemecanique XALK174
S15 Emergency stop platform Telemecanique ZB4BS54
S20 Nut failure switch Telemecanique XCKP518
S23:1-4 Safety edge Telemecanique XCKP118
S26 Emergency drive button outside Telemecanique ZB4BL2
S27 Emergency drive key-switch outside Telemecanique ZB4BG7K (1242A)
S30-34 Doors Kronenberg PZ73-B-DZ21
S40-44 Lock Kronenberg DL1
S50-S54 Platform button 0-4 Telemecanique ZB4BL2
S60-S64 Call button 0-4 Telemecanique ZB4BL2
S70 Inductive landing switch Baumer IFRM 18P1702/L
S71 In lift emergency drive button Merlin Gerin 18035
S72 In lift emergency drive button Merlin Gerin 18035
S75 Limit down Telemecanique ZCP39
S85 Brake release Merlin Gerin 18032
S83 Emergency alarm button
S86 Overload Telemecanique
S90-S94 Key-switch additional stop landings Telemecanique ZB4BG2
S95 Key-switch platform Telemecanique ZB4BG2
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i1m1 Inductive landing switch S70 Modul 1

i2m1 Limit down S75 Modul 1
i3m1 Door R14 Modul 1
i4m1 Lock R15 Modul 1
i5m1 Overload S86 Modul 1
i6m1 Modul 1
i7m1 Emergency drive alarm R13 Modul 1
i8m1 Emergency alarm button S83 Modul 1
i1m2 Platform button 0 S50 Modul 2
i2m2 Call button 0 S60 Modul 2
i3m2 Platform button 1 S51 Modul 2
i4m2 Call button 1 S61 Modul 2
i1m3 Platform button 2 S52 Modul 3
i2m3 Call button 2 S62 Modul 3
i3m3 Platform button 3 S53 Modul 3
i4m3 Call button 3 S63 Modul 3
i1m4 Platform button 4 S54 Modul 4
i2m4 Call button 4 S64 Modul 4
Q1m1 Start down Modul 1
Q2m1 Start up Modul 1
Q3m1 Soft stop Modul 1
Q4m1 Retiring cam Modul 1
Q1m2 Overload lamp Modul 2
Q2m2 Battery Modul 2
Q3m2 Emergency alarm Modul 2
Q4m2 Light platform Modul 2
Q1m3 Alarm relay contact Modul 3
Q2m3 Automatic door Modul 3