Operation Manual: Temporarily Installed Suspended Access Equipment

Temporarily Installed
Suspended Access Equipment
OPERATION MANUAL
For ZLP Series

Temporarily Installed Suspended Platform
INSTALLATION OPERATION
MAINTENANCE
NOTE: READ OPERATION MANUAL CAREFULLY BEFORE OPERATING
TEMPORARILY INSTALLED SUSPENDED ACCESS EQUIPMENT
Content
1. Brief Description……………………………………………………………. 1
2. Main Parameters……………………………………………………………. 1
3. Main Structure and Operation Principle………………………………….. 4
3.1 Suspension Mechanism……………………………………………………… 5
3.2 Suspended Platform…………………………………………………………. 7
3.3 Hoist…………………………………………………………………………... 8
3.4 Safety Lock…………………………………………………………………... 8
3.5 Electric Control System…………………………………………………….. 9
3.6 Steel Rope……………………………………………………………………. 11
4. Installations and Adjustment……………………………………………. … 12
4.1 The Preparation before Installation……………………………………….. 12
4.2 Installation of Suspension Mechanism……………………………………... 12
4.3 Installation of Suspended Platform………………………………………… 13
4.4 Installation of Hoists, Safety Locks and Electric Control Box……………. 13
4.5 Adjustment of Rotating Direction of the Motor…………………………… 14
4.6 Connection Between Suspended Platform and Suspension Mechanism…. 14
4.7 Special Notice………………………………………………………………… 14
5. Operation……………………………………………………………………. 15
5.1 Checking and Adjusting after Installation…………………………………. 15
5.2 Operation Procedure………………………………………………………… 16
5.3 Safety Operation Regulations………………………………………………. 17
6. Common Failures and Troubleshooting…………………………………… 19
7. Maintenance………………………………………………………………… 20
7.1 Daily Maintenance…………………………………………………………... 21
7.2 Daily Check …………………………………………………………………. 21
7.3 Check Periodically…………………………………………………………... 21
8. Storage, Packing and Transportation……………………………………… 22
9. Documents and Tool………………………………………………………… 22
9.1 Documents attached…………………………………………………………. 22
9.2 Tools………………………………………………………………………….. 22
10. Attached Table and Figure…………………………………………………. 22
Operation Manual for ZLP Series Temporarily Installed Suspended Access Equipment
1. Brief Description
ZLP series temporarily installed suspended access equipment is ideal equipment
for building facade construction, decoration, cleaning and maintenance. And it is also
widely used in elevator installing, ship building and repairing, or in other works such
as big-size tank, bridge, embankment and chimney.
It is easy for operation, flexible for moving, reliable in safety. Besides, it is not
necessary to build scaffolding in the construction, the efficiency will be promoted and
the cost will be reduced. Therefore, ZLP series versatile knock-down platforms
provides workers safer, easier and more efficient platform access.
ZLP series temporarily installed suspended access equipments are conforming to
the national standard GB19155-2003.
2. Main Parameters
Model description
Z L P 500/630/800
Main parameter or rated capacity (kg)

Identity Symbol: P --- Climbing Type
Suspended Platform
Decoration Machinery
Table 1: Main Parameters for ZLP500
Item Parameters
Rated capacity 500 kg
Rated speed 9.6 m/min
Platform length 4 m~5m
Steel rope 4T31
Hoist model LTD5
Rated lifting force 5 KN
Model YEJ90L-4
Hoist Power 1.1 KW
Motor Phase 3 Phase
Speed 1420 r/m
Brake force moment 15 Nm
Configuration Anti-tilting
Permission force of impact 30 KN
Safety lock
Locking Cable Distance ＜100mm
Locking Cable Angle 3°～8°
Suspension Front beam overhang 1.3-1.7 m
mechanism Height adjustment 1.365 -1.925 m
1
Lifting part (including Steel Platform 400 kg

hoist, safety lock and
Weight electric control system) Aluminum platform 290 kg
Suspension mechanism 310kg

Counter weight 750 kg
Item Parameters
Platform length 6m
Steel rope 4T31
Hoist model LTD6.3
Rated lifting force 6.3 kN
Model YEJ90L-4
Hoist Power 1.5kW
Motor Phase 3 phase
Speed 1420 r/m
Permission force of impact 30 kN
Safety lock


2
Item Parameters
Platform length 7.5 m
Steel rope 6*19W+IWS-8.6
Hoist model LTD8
Rated lifting force 8 kN
Model YEJ100L1-4
Hoist Power 2.2 kW
Motor Phase 3 Phase
Speed 1420 r/m
Permission force of impact 30 kN
Safety lock


Notes: The voltage and frequency of home country is 380V, 50Hz. If your voltage
and frequency are different, we will note here ___V ___Hz.
3
3. Main Structure and Operation Principle

ZLP series temporarily installed suspended access equipment consists of the
components as below: hoists, safety locks, electric control system, suspended platform,
suspension mechanism, counter weight, steel rope, etc (see figure 1 as below).
Figure 1: Temporarily Installed Suspended Access Equipment
3.1 Suspension Mechanism

The suspension mechanism is the heavy-duty steel frame structure fixed on the
4
top of the building as the supporting equipment. It is mobile, adaptable and easy to
erect and dismantle.
3.1.1 The suspension mechanism (see figure 2 as below) consists of front beam (1),
middle beam (4), rear beam (5), front base (2), rear base (6), upper column (8), tommy
bar (3), counter weight (7) and reinforce steel rope (9) etc. The tommy bar is mounted
on the front and rear base; the front and rear beams will be fixed through the tommy
bar, the middle beam is fixed between the front and rear beam. The upper column is
mounted on the tommy bar for fixing the reinforced steel rope and counter weight will
be placed on the rear base. For details of structure, see attached figure 1: suspension
mechanism on page 23.
Figure 2: Suspension Mechanism

1. Front beam 2. Front base 3. Tommy bar 4. Middle beam
5. Rear beam 6. Rear base 7. Counter weight 8. Upper column
9. Reinforcing steel rope 10. Turnbuckle
3.1.2 The configuration of the suspension mechanism shall meet the following
formula:
G *b
n 2
F*a
n------- Safety coefficient against overturning;
G------ Weight of counter weight in kg;
a------- Front beam overhang in m;
F------- Total weight in Kg of the platform, hoists, electric control system,
safety lock, steel rope and rated load, plus wind pressure;
b------- Distance in m between the front base and rear base.
Table 4: The Relation between Permissible Load and the variables as Working Height,
Front Beam Overhang, Distance between the Front Base and Rear Base
5
Counter Working Front beam Distance between

Model Permissible load
weight Height overhang front and rear base
1.3 m 4.6 m 500 kg
50 m 1.5 m 4.6 m 500 kg
1.7 m 4.4 m 400 kg
1.3 m 4.6 m 500 kg
100 m 1.5 m 4.6 m 500 kg
1.7 m 4.4 m 350 kg
ZLP500 750 kg
1.3 m 4.6 m 500 kg
120 m 1.5 m 4.6 m 500 kg
1.7 m 4.4 m 300 kg
1.3 m 4.6 m 500 kg
150 m 1.5 m 4.6 m 450 kg
1.7 m 4.4 m 250 kg

1.3 m 4.6 m 630 kg
50 m 1.5 m 4.6 m 630 kg
1.7 m 4.4 m 550 kg
1.3 m 4.6 m 630 kg
100 m 1.5 m 4.6 m 630 kg
1.7 m 4.4 m 500 kg
ZLP630 900 kg
1.3 m 4.6 m 630 kg
120 m 1.5 m 4.6 m 630 kg
1.7 m 4.4 m 450 kg
1.3 m 4.6 m 630 kg
150 m 1.5 m 4.6 m 630 kg
1.7 m 4.4 m 400 kg
6

1.3 m 4.6 m 800 kg
50 m 1.5 m 4.6 m 800 kg
1.7 m 4.4 m 550 kg
1.3 m 4.6 m 800 kg
100 m 1.5 m 4.6 m 700 kg
1.7 m 4.4 m 460 kg
ZLP800 1000 kg
1.3 m 4.6 m 800 kg
120 m 1.5 m 4.6 m 680 kg
1.7 m 4.4 m 440 kg
1.3 m 4.6 m 800 kg
150 m 1.5 m 4.6 m 630 kg
1.7 m 4.4 m 400 kg
3.2 Suspended Platform

Suspended platform is the workplace at heights for the workers. A modular
system gives you the flexibility you need to mix and match sections to achieve
different lengths. With caster wheel fitted underneath, the platform is easy to move.
Suspended platform (see figure 3 as below) consists of high and low balustrades,
bottom plate and mounting frame for hoist. The mounting frames are fixed on the both
ends of the platform and the hoists & safety locks should be fixed on the frame.
Figure 3: Suspended Platform
3.3 Hoist
The hoist is the powered unit for the platform with the climbing structure.
3.3.1 The hoist for ZLP series suspended platform is LTD5, LTD6.3 and LTD8. It
7
consists of electromagnetic brake motor, centrifugal speed limiter and dual speed
reduction system ， “α” cable-guiding system(LTD5 and LTD6.3) and “S” (LTD8)
cable-guiding system. The hoist is driven by the electromagnetic brake three-phase
asynchronous motor through the worm gear and a pair of reduced gears. The
suspended platform will be moved upward and downward with the movement of the
hoist.
3.3.2 The hoist is provided with automatic rope feeding function and operators just
need to insert steel rope into the inlet of the hoist.
3.3.3 The electromagnetic brake of hoist motor is able to be auto-engaged to produce
braking torque that stops and supports the suspended platform. In the event of power
failure or emergency, the manual descending device can be used to prompt the
suspended platform to slide downwards at even speed.
Figure 4: LTD 5 and LTD6.3 Hoist Figure 5: LSB30 II Safety Lock
3.4 Safety Lock

Model LSB30 II anti-tilting safety lock is the safety-protecting device for the
suspended platform. When the working steel rope is broken or the suspended platform
is inclined to certain angle, the safety lock will be actuated to lock the safety steel rope
to prevent the suspended platform from falling down.
3.4.1 The anti-tilting safety lock consists of parts as rope clip, sleeve plate, torsion
spring, bracket, swing arm and roller. It is so arranged that the working steel rope is
put against the roller on the swing arm to make the rope clip open and allow the
smooth pass of safety steel rope. If the suspended platform tilts to its limits or working
steel rope break, the pressure on the swing arm of safety lock will reduce or impair.
The safety rope clip swiftly closes and locks safety steel rope to prevent suspended
platform from dropping or tilting by the friction as that in between torsion spring, rope
clip and steel rope. When anti-tilting safety lock is applied, the tilt angle of suspended
platform should be 3 ~8.
3.4.2 The safety lock is marked by factory for the first time. After the first marking is
8
effective, the professional technician should conduct maintenance and service at an

interval of 6 months and remark at the end of 6 months.
3.5 Electric Control System

The electric control system consists of electric control box, electromagnetic
braking motor and handle switch etc. The up and down movement of suspended
platform is controlled by two electromagnetic braking motors (see figure 6 as below).
Left limit switch

Right limit switch
Power indicator light Starting button
Left motor Right motor
Handle switch
Emergency
stop button
Up and down button
Universal switch
Power cable
Figure 6: Electric Control System
The electric control box is used for the control of the up and down movement of
the suspended platform. The main elements are mounted onto an isolated plate and the
universal switch, power indicator light, starting button and emergency stop button are
fixed on the panel.
3.5.1 The schematic diagram and wiring diagram see attached figure on page 30 and
page 31.
3.5.2 The main electric elements see table 3 next page.
Table 3: List of Electric Elements
Code Name Specifications Remarks
9
KM1,2,3 AC contactor CJX1-22/22 36V
DZ47LE-32
QF1 Power leakage breaker 3-phase, 4-wire
In=25A(20A) I△n=30ma
QF2 Miniature circuit breaker DZ47-60 In=2A Single-phase
TC Control transformer BK-100 380V/36V
FR Thermal overload relay JR36-20/3 5A
QC Universal switch LW5D-16/3 Customized
SB1 Starting button LA19-11
SB3,4 Control button LA19-11
SB2 Control button COB61
STP Emergency stop button LAY3 Self-lock
U1,2 Rectifier for brake Integrated with motor
HL Power indicator light ND1-25 36V

Limit switch
SL1,2 JLXK1-111(YBLX-K1/111)
(or travel switch)
XP1,2
10-core plug P32K11Q
XS1,2
XP3, XS3 15-core plug P32K9Q
HA Alarm bell UC-4 36V 55mm
YB1,2 Electromagnetic brake Integrated with motor
FU1,2 Fuse 2A
3.5.3 The principle of electric control is as below:

a. Power supply: the power supply adopts 3-phase and 5-wire system in which the
5-core cable is going through L1 power socket to control box, which is powered
on by 3-phase leakage breaker. L4, L5 and L6 are 3-phase power line (see attached
figure on page 30). The users should connect power in 3-phase 5-wire system.
b. Control circuit: the control circuit is controlled by 36V power transformed from
control transformer TC (see attached figure on page 30), which is easy to control.
It can be controlled in electric control box and handle switch. The motor can run
simultaneously and independently, which is governed by turning universal switch
on the panel of the control box. When universal switch is turned to one side, the
single motor running is realized; when handling universal switch in the middle
position, both motors run simultaneously.
10
c. Circuit of motor brake: the motor brake is installed inside the hood of motor; the
voltage is rectified to DC 99V power via half-wave rectifier module.
d. Emergency stop and overloading protecting circuit: the power is transmitted to
motor via general contactor KM1, motor control contactor KM2, KM3 and
thermal relay FR1, FR2 and motor socket (see attached figure on page 30). If in
any abnormal situation, emergency stop can be executed to ensure safety. That is
to press the emergency stop button on the panel of electric control box so that the
general contactor KM1 loses power, the motor is power off and the suspended
platform stops. Thermal relay can be power-off automatically in case of the motor
overloading.
e. Limit switch and alarm circuit: upper limit stopper is set on the upper working area
of the suspended platform. When the limit switch (or travel switch) actuates the
limit, the motors will stop running and the suspended platform will stop
simultaneously. By the same time, the alarm bell will ring.
3.5.4 Special notice:
a. If the limit switch is contacted with the top limit stopper, it is necessary to make
the suspended platform move downward before pressing the starting button and
control button.
b. If the power supply is off during operation, it is necessary to position the manual
descending device by two operators together and then make the suspended
platform moved downward to the ground smoothly.
c. To facilitate the work, L4 and L6 in the electric control box are offered to supply
power to lighting and hand-held tools. However, the use of big power consumers
such as welding machines and iodine lamps is prohibited so as to prevent the
circuit and elements from damage.
3.6 Steel Rope

3.6.1 The steel rope used in hoists for the equipment is special galvanized steel rope.
The structure for ZLP500 and ZLP630 is 4T31/25, diameter is 8.3mm/8.6mm.
The structure for ZLP800 is 6*19W+IWS, diameter is 8.6mm
3.6.2 The maintenance and inspection of steel rope
The steel rope should be kept and maintained in a proper way to prevent
corrosion and pollution, and the steel ropes should be regularly inspected for
deformation and breakage. The rejection of steel rope is as per the specification of
GB5972.
3.6.3 Special notice:
The steel rope must be the steel rope designated by our company.
The steel rope should be replaced in any one of the situations below:
a. The loosening, twisting, untwisting, or any other deformation and distortion.
b. The steel rope should be rejected when the rope breaking number within the range
of ab spacing reaches 5 (see figure 7 as below). When any corrosion or abrasion on
the surface of steel rope, the standard for rejection is reduced further. The
percentage of reduction is that the maximum allowable breaking numbers 5 times
11
the percentage of the corrosion or abrasion on the surface of steel rope to make
deduction.
Figure 7: Steel Rope
c. Obvious corrosion on the steel rope, that is, the concave pit on the surface and the
steel rope is loose.
d. The nominal diameter of steel rope is reduced by 6%, even if there is no twist
breakage.
e. When the abrasion of outer rim of steel rope up to 40% of diameter.
f. The damage or accumulation incurred by the heat or electric arc.
4. Installations and Adjustment

4.1 The Preparation before Installation
Prior to installation, please check up the number of parts as shown in the packing
list. Check the condition of each and all the parts and components.
4.2 Installation of Suspension Mechanism

See attached figure 1: suspension mechanism (page 23) and use the special
installing tool ─ pinch bar if necessary.
4.2.1 Insert the tommy bars into the front base and rear base respectively. Adjust the
height of the tommy bars and tighten the bolts to form the front base and rear base.
(The height of which should be adjusted with the 1.365~1.925 m range according to
the height of parapet).
4.2.2 Lead the front and rear beams into sleeve on front or rear base, position the
middle beam between the front and rear beams and tighten the bolts and nuts.
4.2.3 Mount the working steel rope and safety steel rope onto the coupling sleeve of
the front beam. Make sure that the ends of the ropes must be clamped well (see
section)
4.2.4 Adjust the front beam overhang and fix the upper column with tommy bar with
the bolts and make sure that it is not askew.
4.2.5 Adjust the distance between the front and rear bases. Adjust the three beams to
make sure that the three beams should be in the same straight line. Care must be taken
that the height different between the three beams must not larger than 10 cm.
Moreover, it is only allowed that the front is higher than the rear.
4.2.6 Fix the coupling sleeve on the tommy bar of the rear base. Lead one end of the
reinforcing steel rope (7m long) into the coupling sleeve of front beam and tighten the
rope clamp (see section 4.7.3). Lead the reinforcing steel rope to the rope sheave on
12
upper column and the other end through the hole of the close side of the turnbuckle,
tighten the rope clamp. Adjust the screw bar of the turnbuckle and tighten the
reinforcing steel rope to raise one end of front beam about 3cm.
4.2.7 Place the suspension mechanism to its working position with the reach of front
hanger plate out of the working wall space about 60cm. The distance between two
front hanger plates of suspension mechanism should be larger than the length of the
suspended platform, but not beyond 30cm.
4.2.8 Place the counter weight onto the poles of the rear holder and fix them with bolts
and slowly release the steel ropes.
4.3 Installation of Suspended Platform

4.3.1 Put the bottom plate flat on the ground, mount the high and low balustrades, and
place the bolts and nuts (also square shims for aluminum platform) in position without
tightening them for the time being.
4.3.2 Install the caster wheel on the hoist-mounting frame. Fix the hoist-mounting
frame of at the ends of suspended platform; place the bolts and nuts (also square shims
for aluminum platform) in position without tightening them for the time being.
4.3.3 Check that the installation of above parts is correct, make sure that the high
balustrade in the same line and also the low balustrade.
4.3.4 Tighten the bolts connecting the balustrades and bottom plate, as well as the
bolts connecting the balustrades together. Tighten the bolts connecting the balustrades
and the hoist-mounting frame. Fix the support pulley at the one side of the low
balustrade.
4.4 Installation of Hoists, Safety Locks and Electric Control Box

4.4.1 Fix the hoists on the hoist-mounting frame with pins and M10 bolts: insert the
pin into the hole at the low end of the hoist and at the mount frame, insert the M10
bolt into the two holes at the high end of the hoist and at the mount frame.
4.4.2 Install safety lock on the bracket of the hoist-mounting frame and tighten with
bolts. Fix the limit switch onto the right position of the safety lock.
4.4.3 Install and hang the electric control box in the middle of high balustrade of the
suspended platform.
4.4.4 Insert motor plug and handle switch plug into the power socket of the electric
control box. Power plug should be inserted and power cable should be connected
based on three-phase five-wire system.
4.5 Adjustment of Rotating Direction of the Motor

Turn on the power supply. Turn the universal switch to one side, press the start
button and then press the control button “up”. The rotating direction of the motor
should run in clockwise. If not, exchange the two wires. Turn the universal switch to
the other side to check the rotating direction of the other motor. Make sure that
rotating directions of the motors are correct.
4.6 Connection between Suspended Platform and Suspension

13
Mechanism
4.6.1 Rope passing of the hoist
Turn the universal switch to the side where the hoist is prepared for rope passing.
Insert the working steel rope into the inlet of the hoist after passing between the
limiting wheel and the roller of safety lock. And then press the upward button, the
hoist will wind automatically to finish the rope passing and positioning of steel rope.
4.6.2 Rope passing of the safety lock
Make the suspended platform rise up until the arm of the safety lock cannot be
rose, and then insert the safety steel rope into upper inlet of safety lock.
4.6.3 Place heavy hammer
After the complete of the connection of the working steel rope and safety steel rope,
hang the heavy hammer onto the other ends of the ropes.
4.7 Special Notice

4.7.1 The distance between the two suspension mechanisms should be the same with
the distance of the two suspension points of the platform, with the error of not larger
than 10 cm.
4.7.2 The suggested front beam overhang should be 1.3 m; the suggested distance
between the front and rear should be 4.6 m. The counter weight should be placed on
the two rear beams on the average basis and fixed with the bolts.
4.7.3 The fixing method at the end of steel rope should be in accordance with the
requirements of the standard GB5976-86 (see figure 8 as below). U bolt is fixed on the
rear portion of steel ropes; clamp is fixed on the working section of steel ropes, which
cannot be mixed up. The steel rope clamp cannot be alternately arranged on the steel
rope, and the correct clamping method is as follows:
Figure 8: The Correct Clamping Method

a. Quantity of the clamps: 3 pieces (at least);
b. Arrangement of the clamps (see figure 8 above);
c. The distance between the clamps is 60 mm;
d. Tightening of the clamp: the first clamp should be close to the rope ring and
tightened. Care must be taken that it is not allowed to damage the steel rope when
tightening, and then make the second and third clamps. It is necessary to make the
clamps tightened again after the steel rope is loaded one or two times.
4.7.4 Care must be taken that the steel ropes must not be damaged, deformed or
twisted.
4.7.5 The hoist must be fixed with the pins and bolts.
14
4.7.6 Make sure that the plugs of the two motors and the control button be inserted
into the sockets of the control box correctly.
4.7.7 The power supply, connected with the control box, should have the null and
earth lines and the control box should be ground contacted reliably.
4.7.8 Make sure that the connection of the steel rope with the hoist is in normal,
otherwise, stop connection for check.
4.7.9 The remaining steel rope should be placed in order and bounded well.
4.7.10 The four heavy hammers must be hung onto the lower ends of the working steel
rope and safety steel rope respectively.
5. Operation
5.1 Checking and Adjusting after Installation
5.1.1 Check if the connections are correct, the steel ropes are not damaged, the
clamping are correct, the nuts are tightened, and the front beam overhang is in
accordance with the standard. Make sure that the moment of force of the stability of
the suspension mechanism is over two times of the overturning moment.
5.1.2 Check if the wiring is correct. The voltage of power should be within the range
of ___V5%. After the power is connected, push the testing button on the power
leakage breaker, and power leakage breaker should work swiftly. Close the door of
electric control box, and inspect if handle switch, universal switch and motor is
normal.
5.1.3 Checking electromagnetic brake:
a. The spacing between the armatures
and the electromagnetic disk should
be within 0.8-1.0 mm (see figure 9).
First, loose inner hexagon screw (1),
15
then adjust the spacing by turning

hollow screw (4). Finally, tighten
inner hexagon screw (1).
b. Power on to check the operation
of electromagnetic armature, the
armature must separate with friction
disc completely after being absorbed,
and no clog after power is off. The
armature should press the spring
disc completely under the force of
spring.
Figure 9: Electromagnetic Brake
1. Inner hexagon screw 2. Electromagnetic disk
3. Armature 4. Hollow screw 5. Motor cover
6. Spring 7. Friction disk
5.1.4 Checking safety lock: move the suspended platform upward about 1-2 m and
make its one end inclined about 3°～8°, the safety lock should be actuated to lock
the safety steel rope.
5.1.5 Make the suspended platform upward and downward 3-5 times for about 3-5 m
travel and check:
a. The noise of the hoist should be normal and the electromagnetic brake will be
actuated reliably.
b. Press emergency stop button or pull the limit switch, the suspended platform will
stop moving immediately.
c. Make the suspended platform horizontal, if necessary.
5.1.6 Checking manually descending: move the suspended platform upward for about
3-5 m and stop it. Pull the manual descending device, the suspended platform can
move downward smoothly.
5.1.7 Adjustment of the upper limit stopper: move the suspended platform upward to
the highest position. Fix the limit stopper and adjust the location of the limit switch
and make sure that the limit switch will be actuated normally.
5.1.8 Rated load testing: The rated load should be evenly distributed on the working
platform. In the operating process no abnormal sound, and when stopping no sliding
movement. The safety lock should lock the safety steel rope flexibly and reliably
when the platform is in tilting.
5.2 Operation Procedure

5.2.1 Turn on the power supply.
5.2.2 Press the starting button.
5.2.3 Double hoists operation: turn universal switch to the middle position and press
the control button.
5.2.4 Single hoist operation: turn universal switch to the side of the operating hoist
and press the control button.
5.2.5 After the work completed, cut off the power supply and make sure the control
box is locked.
16
5.3 Safety Operation Regulations

The suspended access equipment is special equipment operated at the certain
height, so it is very important to pay more attention to the safety operation. After
installation, it is necessary to follow the procedures of 5.1 last page for checking and
adjusting. Besides, the following safety operation regulations should be followed:
5.3.1 The suspended access equipment should only be operated and maintained by
qualified personnel with adequate technical training.
5.3.2 The operators should read the operation manual and check the equipment
carefully before operation strictly follow the safety regulations and “Daily Check
Items” (see section 7.2) during the operation and maintenance of the equipment.
5.3.3 The operators should wear safety helmets and should be fastened with rope
lifeline with the self-lock device. Moreover, the rope lifeline should be fixed
independently on the attachment over the operating area.
5.3.4 It is not allowed to use the equipment overloaded or with troubles (the rated
weight including the weight of operators). The load should be evenly distributed on
the platform. The loaded weight must be decreased as the working height, the front
beam overhang or the distance between the front and rear holders change.
Furthermore, the loaded weight must be decreased further if the wind force is stronger.
Make sure that the moment of force of the stability of the suspension mechanism is
over two times of the overturning moment.
5.3.5 It is not suggested to install the platform over the rated length or use the two
platforms together. And it is also not allowed to assembly the suspended platform with
the parts and elements from different manufactories.
5.3.6 The limit switch, emergency stop button, electromagnetic brake and manual
descending device should be sensitive and reliable.
a. When the platform is in its normal operation, it is prohibited to manually break the
motors or safety lock, so as to prevent any accident from happening.
b. The emergency stop button is the self-lock one, it is necessary to be rotated in
clockwise to make the button out when reset.
c. It is necessary to press the starting button to move the platform after the limit
switch or the emergency stop button is pressed.
d. When the limit switch is activated, the operation of platform will automatically
halt and the alarm bell will ring. Under this circumstances, lower the platform
promptly to have the limit switch be away from the limit stopper.
5.3.7 During operation of platform, the operator should keep an eye on the platform’s
operation condition and promptly shoot any hidden trouble possibly leading to
accidents.
5.3.8 The platform should be adjusted promptly if it is tilting and the height difference
of two ends should be no higher than 15cm. And otherwise, it will affect the operation
of the safety lock.
5.3.9 It is not allowed to use ladders, boxes, or other tools to obtain increased height.
Never use additional extensions to exceed the permissible length of the platform.
5.3.10 It is not allowed to make use the platform as the elevator for people or goods
17
and also it is not allowed to mount any hanging device in the platform.
5.3.11 Once the hoist is blocked during operation, it is not allowed to move the
platform forcedly. Fix the platform first and make sure it is safety, then check and
eliminate the troubles.
5.3.12 In case of working steel rope breakage during operation, the personnel in the
platform should keep calm and leave the platform under the prerequisite of ensured
safety. After maintenance and repair personnel enters the platform, the first thing to do
is to take anti-dropping measures by having the clamp of safety steel rope hold the
platform or by fastening the platform with the steel rope secured on the building roof.
Then, pull the replacing steel rope through the hoist, and press the up button to have
the platform move upward. If the suspended access equipment works normally,
release the safety lock cautiously, detach the fixing steel rope and lower the platform
down to the ground. It will not be put into operation again until it passes the stringent
inspection.
5.3.13 In case of power break during operation shut down the power first. If it is
necessary to have the suspended platform lowered back onto the ground, operate
manual descending device to have the platform lowered smoothly onto the ground.
5.3.14 Site environment:
a. No high voltage line within the 10 meters;
b. It is not allowed to use the equipment in thunderstorm, fog or the wind of grade 5
(wind speed 8.3m/s) or higher;
c. Make sure that the welding spark will not affect or damage the steel rope;
d. Temperature required: -20℃~+40℃;
e. Error of the voltage:±5%.
5.3.15 The suspended access equipment should avoid contacting corrosive gas and
liquid. If there is no alternative available, anti-corrosion and segregation measures
should be taken in its operation.
5.3.16 Cut off the power supply, lock the control box and clean the equipment after
completion of the operation. It is not allowed any foreign, dirty matter or water
entering into the motor, safety lock, electromagnetic brake and control box.
5.3.17 The working steel rope and safety steel rope should not be bent and should be
prevented from the contamination of mortar and other foreign materials. They should
be replaced as required by the operation manual in case of cracking, breaking, peeling,
distortion, flossing and corrosion. The safety steel rope should be prevented from
contacting grease or oil.
5.3.18 The safety lock should be checked and its moving parts should be lubricated
regularly during its service life and it should not be dismantled without authorization.
5.3.19 Special attention should be paid to mark limit effective of the safety lock.
When the steel rope is removed from platform, it should be winded to form a bundle
and be stored properly.
18
6. Common Failures and Troubleshooting

Troubles Analysis of causes Troubleshooting Remarks
Suspended 1. Motor electromagnetic brake
1. Replace electromagnetic
platform slides fails. See 5.1.3
brake.
down in static 2. The spacing between brake and
2. Adjust the space.
condition armature is over too big.
Press emergency stop button
or pull the limit switch to
The main contact point of AC
stop the moving of the
contactor disengages.
platform, replace the
Suspended
contactor.
platform cannot
stop in ascending
or pull the limit switch to
Control button fails. stop the moving of the
platform, replace the control
button.
The main contact point of AC or pull the limit switch to
contactor disengages or the control stop the moving of the
button fails. platform, replace the
contactor or control button.
The electromagnetic brake is out of
order: 1. Adjust the space. If it is
1. The space between the can’t be done, replace the
Suspended
electromagnetic disk and the brake disk.
platform cannot
armature is too big. 2. Check if the space between
stop in descending
2. Too small contact area between the friction disk and the
See 5.1.3
the friction disk and the armature is
armature. well-distributed; otherwise,
3. Slipping between the friction replace the disk or the
disk and the armature because armature.
of the water or oil. 3. Clean.
4. The steel rope is slipping in the 4. Repair the hoist.
hoist.
1. Check to see if any
Suspended
Power supply is abnormal: leakage, and take
platform cannot
1. Leakage breaker disengages. preventive measures.
ascend and
2. Phase lacking. 2. Check if the 3-phase power
descend
is normal and reconnect.
19
Failure of control line:

1. Control transformer or control 1. Replace.
button damaged. 2. Wait 3-5 minutes before
2. Thermal overload relay breaks restarting or replacing the
or damages. thermal overload relay.
3. Universal switch not in good 3. Replace.
contact.
It is not
allowed to
The steel rope is blocked in the Fix the platform and examine
restart the
hoist. & repair hoist.
platform
forcedly
1. Adjust the spacing of
motor brake.
1. Sensitivity difference in motor
2. Check the rope pressing
brake.
device of hoist or replace
Suspended 2. Difference in motor rotating
rope pressing device or
platform tilt speed, and hoist rope pulling.
replace motor with incorrect
rotating speed.
Uneven in the load of suspended Adjust the load of suspended
platform. platform.
Input
The electromagnetic brake is not voltage:
actuated: 1. Replace the rectifier. AC220 V
Hoist cannot 1. Rectifier damaged. 2. Check and adjust. and output
actuate suspended 2. No input voltage. voltage:
platform DC99 V
Low voltage of the power supply. Check and adjust the voltage.
Damage of hoist. Check and repair the hoist.
Abnormal noise of Operation lacking phases. Check the power supply.

the motor or the Lower or higher voltage. Adjust the voltage.
motor is hot Bearing damaged. Replace.
Oil dust on the safety steel rope Clean or replace the steel
Safety lock slip or
Problem wit rope clip. Replace the clip.
locking angle is too Replace by
Replace torsion spring of
big Sluggish motion in safety lock. manufactory
safety lock.
7. Maintenance
The daily maintenance and check, before operation of the equipment, will be
done by the operators and check periodically by the qualified personnel. The
maintenance and the check should be recorded.
20
7.1 Daily Maintenance

7.1.1 Safety lock
a. Cleaning the surface;
b. Cleaning the surface of the steel rope and clear out the rust;
c. Prevent the water and dirty matter from entering the lock.
7.1.2 Hoist
a. Cleaning the surface;
b. Cleaning the surface of the electromagnetic brake and the end cover of the
motor by removing the cover of the motor;
c. Cleaning the surface of the steel rope and clear out the rust;
d. Prevent the water and dirty matter from entering the hoist and motor.
7.2 Daily Check

a. Reliability of the safety lock;
b. Emergency stop and limit switch;
c. Reliability of the electromagnetic brake;
d. Sensitive of the manual descending device;
e. Steel rope, rope clamp and connections;
f. Making the suspended platform move upward and downward 3-5 times with
the travel of about 3-5 meters;
g. Following the “Daily Check Items” (see attached table 2), check two times
every day (morning and afternoon). It is not allowed to use the suspended
platform with any troubles.
7.3 Check Periodically

The safety lock must be re-calibrated in six month from the date of the delivery
by the manufacturer; and the hoist must be checked by the qualified person.
Generally, the equipment should be checked at an interval of 2 months depending on
the application condition and the working period. After the end of use of entire
machine, a thorough keeping and examination should be done.
7.3.1 Hoist:
a. Replace the oil in the gear reducer: No. 32 machine oil (LTD8), No. 18
hyperbola gear oil (LTD5 and LTD6.3), quantity: 0.8 kg; first replace in 20-30
days, then replace in one or two months intervals. Check the wear-out
condition of the worm and gear.
b. Clearing out the dirty matter by removing the cover of the hoist; cleaning the
gear and replace the grease; check the wear-out condition of the bearing
assembly, guide roller, steel ring and press pan.
c. Cleaning the electromagnetic by removing it; check the wear-out condition of
the armature and the brake disk. Replace if the armature is deformed or the
thickness of the brake disk is less than 10 mm.
7.3.2 Safety lock: check if the arm action of the lock and the rotation of the roller are
sensitive.
21
7.3.3 Electric control box: the isolated resistance should be less than 2MΩ; check the
electric elements and the connecting wire; replace the elements, if necessary, based on
the diagram; check the system condition with power on.
7.3.4 Check if the working steel rope and safety steel rope are in good condition.
7.3.5 Check if the suspended platform and the suspension mechanism are deformed or
damaged; if there is any crack and fracture in welding of the structure. Repair or reject
if necessary.
8. Storage, Packing and Transportation

The equipment should be stored in the dry and ventilating storehouse to prevent
it from rusting. It is necessary to make the maintenance if it is stored for one-year
period. The hoist, safety lock and the electric control box should be packed separately.
The steel ropes should be bounded and packed for transportation. Care must be taken
that the bottom plate of the platform, balustrades, mount frame for hoist and the
suspension mechanism should not be deformed when loading and transportation.
9. Documents and Tool

9.1 Documents attached
a. Packing list one copy
b. Operation manual one copy
c. Quality inspection certificate one copy
9.2 Tools
Pinch bar one piece
10. Attached Table and Figure

Attached figure 1: Suspension Mechanism
Attached Figure 2:LTD5& LTD6.3 Hoist Structural Diagram
Attached Figure 3: LTD5& LTD6.3Hoist Exploded View
Attached Figure 4: LTD8 Hoist (A)
Attached Figure 5: LTD8 Hoist (B)
Attached Figure 6: Electric Control Schematic Diagram
Attached Figure 7: Electric Wiring Diagram
Attached Table 1: List of Fragile Parts
Attached Table 2: Daily Check Items
22
Attached figure 1: Suspension Mechanism
23
Attached Figure 2: LTD5 &LTD6.3 Hoist Structural Diagram
24
41
40
42
43
27
28
26
25
32
33
29
34
31
30
24
16
17
35
36
18
19
37
38
39
15
20
21
1
22
4
23
5
6
11
10
12
13
14
Attached Figure 3: LTD5 &LTD6.3 Hoist Exploded View
25
Attached Figure 4: LTD8 Hoist (A)
26
Attached Figure 5: LTD8 Hoist (B)
27
Components of LTD5 (See Attached Figure 2 & 3)
No. Name Specification Quantity No. Name Specification Quantity

1 Rope inlet pipe ZLP5008.1-12 1 23 Screw M6×30 4
2 Box ZLP5008.1-4 1 24 Bolt M8×35 4
O-shape gasket
3 Base plate of rope guide ZLP5008.4-2 1 25 35510460 1
sealing
Centrifugal
4 Rope guide ZLP5008.4-1 1 26 1
Speed limiter
5 Cover of Rope guide ZLP5008.4-3 1 27 Gasket sealing B47×25×7 1
6 Gasket sealing B230×200×15 1 28 Shield ring GB893.1-86-37 1
7 Driving disc ZLP5008.1-11 1 29 Bearing #6005-2Z 1
8 Steel belt assembly ZLP5008.1-8 1 30 Worm ZLP500B.1-1 1
9 Bearing #6304-Z 1 31 Nut M8 4
10 Wire pressing unit 1 32 Pinion shaft ZLP500B.1-7 1
11 Cover ZLP5008.1-5 1 33 Bearing #6007 1
12 Bolt M10×90 2 34 Sleeve ZLP500B.1-9 1
13 Washer Ф6 3 35 Bearing #6207 1
O-shape gasket
14 Screw M6×35 3 36 35513600 1
sealing
15 Shield ring GB894.2-86-18 1 37 Front cover ZLP500B.1-11 1
16 Screw M6×70 3 38 Washer Ф6 4
17 Washer Ф6 3 39 Screw M6×30 4
18 Rope outlet pipe ZLP5008.1-13 1 40 Bearing #6303-2Z 1
19 Shield ring GB894.2-86-18 1 41 Shield ring GB893.1-86-37 1
20 Screw M6×45 2 42 Sealing cover ZLP500B.2-2 1
21 Bearing #6304 1 43 Worm-wheel ZLP500B.1-10 1
22 Screw M6×25 4
28
Components of LTD6.3 (See Attached Figure 2 & 3)
No. Name Specification Quantity No. Name Specification Quantity

1 Rope inlet pipe ZLP6308.1-12 1 23 Screw M6×30 4
2 Box ZLP6308.1-4 1 24 Bolt M8×35 4
Base plate of O-shape gasket
3 ZLP6308.4-2 1 25 35510460 1
rope guide sealing
Centrifugal
4 Rope guide ZLP6308.4-1 1 26 1
speed limiter
5 Cover of Rope guide ZLP6308.4-3 1 27 Gasket sealing B47×25×7 1
6 Gasket sealing B230×200×15 1 28 Shield ring GB893.1-86-37 1
7 Driving disc ZLP6308.1-11 1 29 Bearing #6005-2Z 1
8 Steel belt assembly ZLP6308.1-8 1 30 Worm ZLP6308.1-1 1
9 Bearing #16304-Z 1 31 Nut M8 4
10 Wire pressing unit 1 32 Pinion shaft ZLP6308.1-7 1
11 Cover ZLP6308.1-5 1 33 Bearing #6007 1
12 Bolt M10×90 2 34 Sleeve ZLP6308.1-9 1
13 Washer Ф6 3 35 Bearing #6207 1
O-shape gasket
14 Screw M6×35 3 36 35513600 1
sealing
15 Shield ring GB894.2-86-18 1 37 Front cover ZLP6308B.1-11 1
16 Screw M6×70 3 38 Washer Ф6 4
17 Washer Ф6 3 39 Screw M6×30 4
18 Rope outlet pipe ZLP6308.1-13 1 40 Bearing #10003-2Z 1
19 Shield ring GB894.2-86-18 1 41 Shield ring GB893.1-86-37 1
20 Screw M6×45 2 42 Sealing cover ZLP6308B.2-2 1
21 Bearing #10004 1 43 Worm-wheel ZLP6308B.1-10 1
22 Screw M6×25 4
Components of LTD8
Please see details in the attached figure4 and figure5.
29
1
QF2 96 47
L1 L2 L3 N TC
FR2 FR1
380V 36V HL HA
PE
QF1 10
22
1.5
SB1
17 18
L4 L5 L6 KM1 95
STP 11 20
SL1 SL2 KM1
KM1 SB3
L9 KM2
13 KM3 7
L8
SB2
L7
KM3
21 KM2 8
30
KM2 KM3 3 5
SB4
KM2 KM3
U V W
QC 4 6
YB1
M1
U1 U2
U5 V5 W5 U4 V4 W4 FU1
QC contact diagram
FR2 FR1
contact left middle right
1U 1V 1W 1,2 -
2U 2V 2W
3,4 -

YB2 5,6 -
M2 7,8 -
9,10 -
FU2 11,12 -
XP
XS 1 L6 L4
L1 L2 L3 N
380V
QF1 QF2 TC
36V
L4 L5 L6 N
96 10 1
L7 L8 L9 3 5 L7 L8 L9 3 5
18 L7 L8 L9 18
7
8
KM1 KM2 KM3
95 L4 L5 L6 17 95 U V W 4 21 6 95 U V W 4 13 6
U4 V4 W4 95 U5 V5 W5 47
HA
FR1 FR2
22 96
1U 1V 1W 47 2U 2V 2W 96
L1 L2 L3 N PE 1U 1V 1W 3 4 17 18 21 13 U4 V4 W4 U5 V5 W5 5 6 2U 2V 2W 11 10 20 22 96
AC380V 17 11
1 2 13 21 1 2
22 20 1 2 22 20
3 4 5 3 4 5
XS1 6 7 8 XS3 3 4 XS2 6 7 8

3 5 5
9 10 1W 9 10 2W
18
1U 1V 2U 2V
4 6
XP1 XP2 XP3 Ground contact

Panel of control box
1U 1V 1W 2U 2V 2W 17 10
SB1 HL
3,4 5,6 18 96
22 22 10
STP
20 11 11
17 20 18 18
SB4 SB3
21 13
22 22 13 U V W
Motor SL2 Motor SL1 SL2
Wiring Wiring QC
20 11 18
Box Box U5 V5 W5
17 20 21 U4 V4 W4
31
No. Item Installation part
1 Steel rope Working and safety steel rope
2 Braking friction disc Electromagnetic Brake of Motor
3 Armature Electromagnetic Brake of Motor
4 Rectifier module Junction box of Motor
5 Centrifugal speed limiter Hoist
6 Rope pressing unit Hoist
7 Rope guide Hoist
8 Steel belt assembly Hoist
9 Rope inlet pipe Hoist
10 Rope outlet pipe Hoist
11 Sleeve plate Safety lock
12 Rope clip Safety lock
Attached Table 1: List of Fragile Parts
32
Item Contents Result Marks Item Contents Result Marks
Any damage (broken,

deformation, slacking Connections with the mount frame
Hoist
or bending)
Dirty with oil Oil leakage

Steel rope
Any abnormal noise when the

Rust and wear-out platform is moving upward and
Suspended
downward for 3-5 m in 3 times
platform
Clamp slacking movement Horizontal level
Counter weight lose or
Plug and socket connection
Suspended damage
mechanism Connections Electric cable
Location Indicating lamp of the power supply
Connections Electric Actuation of the universal switch

Suspended control
Tube damaged or rust Actuation of the AC contactor
platform box
Crack in welding Actuation of the limit switch
Lock rope is reliable if
Actuation of the emergency stop
Safety lock inclined
Sensitive in action Comments and suggestions:
Spacing
Electro- Blocked or not

-magnetic Brake reliable
brake Slipping down
manually
Note: 1. The “Result” column: “√”means good and “× ” means trouble.
2. If the “Result” column is trouble, “Marks” column: “☆” means to be repaired immediately;
“Δ” means to be repaired at the definite period; and “О” means to be rejected.
3. The movement of the suspended platform should be checked after the completion of the above items
Equipment No. Checked by: Date:
Attached Table 2: Daily Check Items
33

Operation Manual: Temporarily Installed Suspended Access Equipment

Uploaded by

Copyright:

Available Formats

Operation Manual: Temporarily Installed Suspended Access Equipment

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation Manual: Temporarily Installed Suspended Access Equipment

Uploaded by

Copyright:

Available Formats

Temporarily Installed

Suspended Access Equipment

For ZLP Series

Main parameter or rated capacity (kg)

Lifting part (including Steel Platform 400 kg

Suspension mechanism 310kg

Table 2: Main Parameters for ZLP630

Lifting part (including Steel Platform 450 kg

Suspension mechanism 310kg

Table 3: Main Parameters for ZLP800

Lifting part (including Steel Platform 600 kg

Suspension mechanism 310kg

3. Main Structure and Operation Principle

Figure 1: Temporarily Installed Suspended Access Equipment

3.1 Suspension Mechanism

Figure 2: Suspension Mechanism

Counter Working Front beam Distance between

Counter Working Front beam Distance between

Counter Working Front beam Distance between

3.2 Suspended Platform

Figure 3: Suspended Platform

Figure 4: LTD 5 and LTD6.3 Hoist Figure 5: LSB30 II Safety Lock

3.4 Safety Lock

effective, the professional technician should conduct maintenance and service at an

3.5 Electric Control System

Left limit switch

Power indicator light Starting button

Left motor Right motor

Figure 6: Electric Control System

Table 3: List of Electric Elements

Code Name Specifications Remarks

KM1,2,3 AC contactor CJX1-22/22 36V

QF2 Miniature circuit breaker DZ47-60 In=2A Single-phase

TC Control transformer BK-100 380V/36V

FR Thermal overload relay JR36-20/3 5A

QC Universal switch LW5D-16/3 Customized

SB1 Starting button LA19-11

SB3,4 Control button LA19-11

SB2 Control button COB61

STP Emergency stop button LAY3 Self-lock

U1,2 Rectifier for brake Integrated with motor

HL Power indicator light ND1-25 36V

HA Alarm bell UC-4 36V 55mm

YB1,2 Electromagnetic brake Integrated with motor

3.5.3 The principle of electric control is as below:

3.6 Steel Rope

Figure 7: Steel Rope

4. Installations and Adjustment

4.2 Installation of Suspension Mechanism

4.3 Installation of Suspended Platform

4.4 Installation of Hoists, Safety Locks and Electric Control Box

4.5 Adjustment of Rotating Direction of the Motor

4.6 Connection between Suspended Platform and Suspension

4.7 Special Notice

Figure 8: The Correct Clamping Method

then adjust the spacing by turning

5.2 Operation Procedure

5.3 Safety Operation Regulations