Motala MC2000 Assembly Instructions Manual
MOTALA HISSAR AB
mc200501
Luxorgatan 1
Box 4029
591 04 Motala
SWEDEN
Tel: +46 (0)141-23 70 50
LOW SPEED LIFT
MC2000
2-6 landings
Automatic/manual doors
Assembly Instruction Manual
Release 2.02 2011-10-20
Safety regulations 3
Wordlist 4
ols 5
To
Preparations before assembly 6
Use the layout drawing for erection site check 6
Lift material 6
Lift well construction planning 6
Assembly 7
Introduction 7
General information on how to erect modules 7
Construction of precision gauge blocks 7
Lift well assembly according to layout drawing. 9
Installation of electric cables and wires 23
Guide rails 24
Driving shafts, gear and motor 27
Connecting pit functions 29
Connecting control panel wiring 30
Connecting drive command box 30
Door panel and removal of work platform 31
Commencing with drive command box 32
Chain jointing rod 32
Platform 33
Fixing lift well 35
Sills 35
Fixing plates 36
Travelling flex cable, panel plate, overload unit and control panel 37
Cancelling drive command box 41
Ceiling 41
Commencing from platform control panel 42
43
Lock arms 43
Highspeed contact and magnet 43
Lubrication 44
Cover plates 45
Finishing work 47
Final inspection and own inspection 47
Layout drawing 48
Checklist 49
Approvals and version history 50
Attachments
MOTALA HISSAR AB
Luxorgatan 1
Box 4029
59104 Motala
SWEDEN
Tel: +46 (0)141-23 70 50
MC2000 – Assembly Instruction Manual
mc200501
Introduction
This assembly instruction manual shows you
how to erect Motala Hissar MC2000 with 2-6
landings and manual or automatic doors.
The texts
and the illustrations of the manual
show an MC2000 with 2 landings, but are also
valid for lifts with several landings. Note that the
manual also describes the assembly of equipment that is not found in all lifts.
MC2000 can be delivered with straight or
adja-cent two-way entrances. For power
supply, see the current electrical diagram.
The assembly instructions are based on
equip-ment and tools that were accessible
when the manual was written. Because of
continuous product development we reserve
the right to al-terations without further notice.
Safety regulations
Important!
For your own safety and for the safety of others,
follow the existing safety regulations.
Warning! Risc to get jammed! Do not work in
the pit without necissary pre-actions, use the pit
prop, use the stop button, switch off the power!
3
MC2000 – Assembly Instruction Manual
Wordlist
Adjacent lift Lift with door or doors on sides B or D.
Chain joint For connecting the chain between the guide rail sections and
tween the chain and the jointing rod.
be
Clamp coupling For jointing the driving shaft.
Corner profile 100x40 Non-drive side corner.
Corner profile 250x40 Drive side corner.
Door front (With door frame, lock etc).
Drive command box For temporary driving.
Drive command panel Plate with control buttons, attached to the panel shelf and
he panel plate.
t
Drive side The side where the guide rails are placed. This is the wider
ide if you look at the door frame. Can be on the B or D side
s
FF Finished floor.
Glass module Glass module on the long and short sides.
Jointing rod 12x12 mm square rod for adjusting the chain tension.
Jointing sleeve U-section to be put between two corner profiles.
Lift well module Isolamine. Product and expression for 25 to 35 mm thick iso-
lated steel modules.
Non-drive side E.g. side B if the guide rails are on side D.
Panel plate The plate to which the panel shelf and the control panel are
ached.
att
Panel shelf Steel shelf with electric equipment, attached to the panel
ate.
pl
Passage contact Contact which straps across the lock contact when the lift is
the landing zone.
in
Platform Floor frame, floor plate
Pit prop (in the pit) Yellow safety bar that can be raised.
Safety gear test equipment. Attached below the gripping lever. Remote-released by a
ord in the control panel.
c
Side A The side where the motor and gear are placed.
Side B The side placed clockwise next to side A.
Side C The side opposite side A.
Side D The side placed clockwise next to side C.
Slide Flat bar iron with sliding guide shoes where the chain is fas-
tened.
Turning case Cut plastic case where the chain changes direction.
Two-entrance lift. Lift with doors on side A and side C.
Two-metre fixing plate angles. Fixings for the large cover plate above the guide rails.
Work platforms Occasional platforms for building lift wells.
4
MC2000 – Assembly Instruction Manual
Tools
Tools/Equipment with item numbers can be ordered from Motala Hissar AB.
Equipment
Sets of dimension sticks, 1480 mm, 1081
m, 1181 mm.
m
Work platforms, standard set. 705658 For lift well construction. For about three
Drive command box complete with 25 m
ble.
ca
Winch or telpher, min. approx 100 kg. 705867 For lifting guide rails.
Lifting eye bolt with lock, see ill 6 on
page 25.
Fastening rod (telescopic) 705824 For suspending the winch in the well top.
Chain fixing tool. 701268 To prevent the chain from sliding during as-
Glue sprayer. 101428
Structural glue. 100510 Gluing of platform floors.
Grease and lubricating substances. Lubrication of guide rails and lock arms.
Lifting tool (suction cups), 2 pieces 101423 For glass and lift well modules.
Working place illumination
Spirit-level, short, approx, 500 mm
MH item
numbe
705827 For lift well construction, outside dimensions:
705868 For driving the lift during assembly and test-
705826 For lifting guide rails.
r
Notes
depth 1560mm x width 1150 mm/1250mm.
rs. Extra equipment to be ordered
floo
ing.
sembly.
Spirit-level, long, approx, 2000 mm
Measure tape/folding rule, plumb.
Measuring instruments
Tools for electric installation
Jigg saw with long blade “120mm”. For cutting lift well modules “35mm thick”.
Wire shears For cutting wires and wire covers.
Electric screw driver with extender and bits,
pe ph2.
ty
Ratchet with extender and sleeves 13 mm
nd 17 mm.
a
Ring-open-end spanners 7-17 mm.
Plate shears
Riveting tongs
Drill, diameter 3.3, 4.2, 6 and 12 mm For pop rivets and making holes in jointing
ods for drive chains.
r
Hand tools: multi-purpose pliers, screwdrivers, socket wrenches etc.
Hack saw For sawing the joint rod of the drive chain.
Crowbar
5
MC2000 – Assembly Instruction Manual
2
A
D
B
Preparations before assembly
Use the layout drawing for erection site check
Measurments
There is an example under the heading “Layout
awing” on page 48. (The measurments in the
dr
picture are taken from that example.)
Check that the pit:
• has the correct measurments
• is even and level
• is painted.
C
1590
Check the lifting heights (FF-FF). Check that
the floors are completed, i.e. have the correct
height.
Use the plumblines to measure the openings of
e joists. Also check that the diagonal meas-
th
ures of the openings are equal.
Check that the erection space is at least 30 mm
the maximum height of the lift.
above
Check the wall opening dimensions in front of
e door sections according to the layout draw-
th
ing.
Free space for doors
Check the space available for opening doors,
king the inclination of the floors into consider-
ta
ation. Are the doors hung correctly - right or
ft?
le
Free space for the pit prop
Check the space available for the pit prop. See
e layout drawing.
th
Power supply
Check that there is power supply for the lift, the
llumination and the telephone. Compare with
i
the electrical diagram and the layout drawing.
Other facts
Go through and make sure what parts of the lift
e to be powder coated or just primed consid-
ar
ering the framing of joists, walls etc. at the erection site. See the object description enclosed
h the delivery of the lift. Also check the plac-
wit
ing of glass modules, if any.
60
1280
mc20050
Lift material
Check at arrival
Check the number of packages against the
gnment note and the equipment against
consi
the packing list.
Check that nothing is damaged or missing.
Placing
Transport the material to the erection site and
ace it on the appropriate floor. Use the
pl
“checklist”. See example under the heading on
page 49. The door frames are marked on the
bottom side of the profile with an 0, I, II, III or IIII,
dependi
ng for which floor they are intended.
Lift well construction planning
• Where do glass module sections start and
end, if any? The first lift well module might
have to be adjusted so that the glass modules are at the right height above the correct
sts higher up in the lift well. See the lay-
joi
out drawing.
• Where are the channels for lock wires and
es? (These channels can be found in
cabl
adjacent lifts and in two-entrance lifts.)
6
MC2000 – Assembly Instruction Manual
100
100
100
100
mc200553
mc200552
8
Assembly
Introduction
This section contains general information on
o construct so called precision gauge
how t
blocks and how to erect lift well modules and
glass modules.
General information on how to erect modules
Lift well modules
Generally, each module is assembled with four
ews in the corner profiles. The screws are
scr
placed about 100 mm from the upper and lower
edges.
For a nicer look, the screws can be exchanged
pop rivets (4 mm).
by
Glass modules
Glass modules are to be placed with the bevelled window moulding on the outside of the lift
. (The flush side on the inside.)
well
The modules are generally put together so that
each modul
e is fastened with four screws in the
corner profiles. You need to pre-drill 3,2mm.
The screws in the splice between two modules
placed about 8 mm from the lower edge of
are
the upper module so that the screw also goes
through the male profile of the lower module.
Construction of precision gauge blocks
For glass modules, precision gauge blocks are
used at joist passages and in the pit so that the
glass surfaces are placed at the proper height
according to the layout drawing. Note that the
measurements in the layout drawing apply to
cutting measurements of the precision gauge
blocks. Example: see the heading “Layout
drawing” on page 48
7
MC2000 – Assembly Instruction Manual
1
2
2
1
1
4
1. Cut the lift well modules with a jigg saw.
Protect the surface with insulating tape or
something similar.
2. Remove the sharp edges.
3. Turn the U-profile with notch 1 towards the
side of the lift well. Note that the top U-
out
profile looks different.
Finish (top clearance of lift well)
Use female section 2 of a lift well module.
Joist passage
Use female section 2 of a lift well module.
Pit
For glass modules, for example.
Use male section 4 of a lift well module.
8
MC2000 – Assembly Instruction Manual
mc200505
2
1
3
4
C
A
D
B
100
100
mc200506
8
5
7
6
Lift well assembly according to
layout drawing.
Bottom part of the lift well, landing 0
1. Erect the broad corner profile on side C of
the lift well. Note that the broad profile must
be placed against side D.
2. Erect the thin corner profile.
3. Place a U-profile (35 mm) on the bottom
de, “female side”, at the bottom of the
si
lowest lift well module/glass module. The
notches (ends) of the U-profile should be
turned towards the outside of the lift well.
4. Place three lift well modules/glass modules
ween the corner profiles. Turn the “male
bet
side” upwards. The modules must not
reach the very bottom of the corner profiles. Leave a millimetre or two so that,
ater, you will be able to align the whole
l
side C vertically.
5. Place a short dimension stick between the
ner profiles. Check that the base is
cor
level.
6. If necessary, adjust with a metal shim under the corner profiles. The shim must be
aced under the corner profile and the
pl
module. Note! When plumbing, always
start at the “highest point” of the pit.
7. Fasten the modules in the corner profile by
taching one screw at the top and one at
at
the bottom of each side about 100 mm
from the edges. Use a dimension stick.
(For placing of screws, see the heading
“General information on module assembly”
on page 7).
8. Align vertically by means of a long spirit-
vel.
le
9. Fasten the modules and the corner profiles
th screws.
wi
9
MC2000 – Assembly Instruction Manual
10
mc200508
14
10. Place a U-profile (25 mm) under the lift well
module/glass module on side D. Turn the
notch of the U-profile towards the outside
of the lift well.
11. Place three lift well modules/glass modules
de D. Turn the “male side” upwards.
on si
The modules must not reach the very bottom of the corner profiles. Leave a millimetre or two so that, later, you will be able to
ign the whole side C vertically.
al
12. Fasten the modules in the corner profile by
f
astening one screw at the top and one at
the bottom about 100 mm from the edges.
Note! The screw heads in the corner profile
of the driving side must be placed at least 6
mm from the corner profile to leave room
for the guide rail flange.
13. Align horizontally by means of a spirit-level.
14. If necessary, use metal shims.
10
MC2000 – Assembly Instruction Manual
mc200509
15 17
16
C
D
A
B
18
20
In this example, the lift well side B has glass
modules. The first glass module must not be in
close contact with the pit but should be placed
a little higher up. For measurments, see the layout drawing.
15. Using the male section of a lift well module,
truct a precision gauge block and
cons
place it in close contact with the pit. See
the heading “Construction of precision
gauge blocks” on page 7.
16. Install the U-profile with the notch turned
wards the outside of the lift well.
to
17. Fit the precision gauge block.
18. Place a glass module on top of the preci-
sion gauge block. Turn the “male side” upwards and the level glass side towards the
ift well. Check with a spirit-level that the
l
upper edge of the glass module is horizontal.
19. If necessary, adjust with a metal shim be-
tween the precision gauge block and the
t.
pi
20. Fasten the glass module with a screw in
e longitudinal bottom corner profile. See
th
the heading “Glass module” on page 7.
11
MC2000 – Assembly Instruction Manual
mc200511
22
A
D
C
B
mc200512
23
B
D
C
A
21. Fit three glass modules.
22. Fasten the tops of the glass modules in the
ner profile with a screw through the two
cor
modules.
23. Set up the door frame. Start at the bottom.
Check
is laterally vertical. If necessary, adjust with
metal shims.
with a spirit-level that the door frame
12
MC2000 – Assembly Instruction Manual
mc200513
25
24
A
B
C
D
mc200514
26
24. Use a long dimension stick to check the
correct distance between sides A and C of
the lift well. Fasten the door frame with
screws at the very bottom of the modules
on sides B and D.
25. Move the dimension stick upwards and fasten the door frame with screws in the upper
es of sides B and D.
modul
26. Check with a spirit-level and straighten the
frame vertically against sides A and C.
door
27. Secure the remaining screws in the modules.
13
MC2000 – Assembly Instruction Manual
mc200519A
mc20051
Placing the lift well in the pit
1. Adjust the placing of the lift well in the pit
and chec
k that the lift well can pass freely
upwards through the joists.
2. Measure and adjust the diagonal measurements of the lift well.
Erecting the work platform, landing 0.
1. Erect the work platform in the two predrilled holes of the door frame. Unfold the
platform and set up two adjustable legs in
the back edge of the platform.
14
MC2000 – Assembly Instruction Manual
mc200517
2
mc200518
11
mc200518
2
2
2. Attach the lock pins.
3. Set up the platform floor.
Construction of lift well for remaining floors (1-4)
Corner profiles, side C
1. Fasten a screw in each corner profile of
de C so that half the jointing sleeve de-
si
scends into the profile.
2. Attach the jointing sleeves.
15
MC2000 – Assembly Instruction Manual
mc200519
3. Erect the corner profiles onto the jointing
sleeves
16
MC2000 – Assembly Instruction Manual
mc200521mc200521
7
In this example side C is also fitted with glass
modules and therefore a precision gauge block
is needed for the joist passage and a second
one is needed as a finish at the well top.
4. Construct precision gauge blocks, see the
ng “Construction of precision gauge
headi
blocks”, on page 7.
5. Set up no more than 3 or 4 modules.
6. Align and fasten side C with screws in the
way as you did for landing 0.
same
Corner profiles, side A
7. Push the two corner profiles into the door
ame. For length, see the checklist. (The
fr
corner profiles ascend through the joists so
that the door frame of landing 1 can be
placed on top of these profiles.)
17
MC2000 – Assembly Instruction Manual
A
B
C
D
A
B
D
C
8. Measure and cut the lift well module with a
jigg saw if necessary. The module should
end a few millimetres below the upper ends
of the corner profiles.
9. Assemble the module/modules.
10. Use a short dimension stick and fasten the
modul
of the corner profiles.
11. Use a spirit-level and fasten the remaining
s
e with two screws in the upper edges
crews in lift well wall A.
12. Erect the modules on sides B and D. Use a
ong dimension stick and fasten the mod-
l
ules with two screws in the upper edges of
he corner profiles. Use a spirit-level and
t
fasten the remaining screws in lift well walls
B and D.
18
MC2000 – Assembly Instruction Manual
mc200548
13
mc200545
13. Note! For adjacent lifts and two-entrance
lifts, remember that you need a channel for
cables and wires in the lift well walls. The
retiring ramp is always on the same side as
the motor and the gear, see “Layout drawing” on page 48.
14. Install the modules on sides B and D.
15. Cut the modules about 2 mm shorter than
e corner profiles.
th
16. Set up the U-profiles.
17. Fasten the sides with screws just as you
d on the previous floor.
di
19
MC2000 – Assembly Instruction Manual
mc200525
18. Install the door frame in the two foremost
corner profiles.
19. Unfold and fit the door frame against the
modul
es of sides B and D. Use a glazier’s
lifting tool with suction cups.
20
MC2000 – Assembly Instruction Manual
mc200526
Erecting the work platform, landings 1-4
1. Erect the work platform in the two preilled holes of the door frame. Unfold the
dr
platform and set it up in the two adjustable
legs in the back edge of the platform.
2. Attach the lock pins.
3. Install the platform floor.
21
MC2000 – Assembly Instruction Manual
2
1
3
Finishing the upper part of the lift well
Straightening of sides B and D
1. Place the dimension stick on a level with
he upper edge of the door frame.
t
2. Fasten a screw in the upper part of the
frame and another screw on the same
door
level on side C.
3. Align side A with a spirit-level and fasten
t
he remaining screws.
4. Align and fasten the other side in the same
.
way
5. Erect the remaining modules on side C and
sec
ure them with screws. Use a short di-
mension stick.
In order to place the last lift well modules/glass
es on side C in case of minimal roof
modul
space.
• Unfasten the module screws temporarily.
• Pull the corner profiles apart so that the
module
ner profiles.
• Fasten the modules with screws.
s can be placed in between the cor-
22
MC2000 – Assembly Instruction Manual
127:
Installation of electric cables and wires
Pull all the cables to the control panel, i.e. the
e from the pit and the cables from all the
cabl
door frames.
The illustrations show the standard installation,
e. the control panel is installed on the door
i.
frame on the top floor at the same place as the
motor and the gear.
If the control panel is placed on another floor on
side the lift, cables for the hand wheel
or out
contact 28: must be installed; the motor cable
and the brake cable to the control panel. (The
hand wheel contact is effected by the hand
wheel tool for emergency control of the lift.)
Also see on page 28.
Top landing
1. Route the cable for the safety gear contact
127: to the control panel (to be installed
later) with cable tie
2. .Temporarily fasten the upper end limit
U (marked with an arrow in the photo)
62:
and pull the cable through the door frame
to the control panel.
3. Note where the cables from the door
ames enter the channel so that you do not
fr
screw or drill through them by mistake. Try
to keep the cables in the centre of the door
frame profile and the corner profile.
23
MC2000 – Assembly Instruction Manual
1
2
1
Landing 0, pit
1. Pull the cable with terminal block “control
anel - terminal block pit” through the
p
opening in the door frame. (Length of cable
to the block approx. 0.8 m.)
2. Pull the door lock wire through the same
ing.
open
3. Install “terminal block with the stop button”
and cabe
switch 62:U on the side wall of the driving
side in the lift well. It should be placed in a
position of 100mm from centre nearest
door side, about 50 mm upwards on the
wall.
4. Route the cable for the pit prop into the cor-
ner profile and out where the recess for the
t prop is. The end limit and the pit prop
pi
shall be fitted later.
l for the pit prop and end limit
Guide rails
Lower guide rails
1. Place the lower rails in the lift well. Note the
markings A and C. Side A is always the
side where the motor and the gear are
placed.
24
MC2000 – Assembly Instruction Manual
mc200529
1
2
6
2. Place the guide rails in the very corners
th the mounting brackets turned towards
wi
the lift well wall. Check that the lower end
of the guide rail is on the same level as the
lower edge of the lift well, i.e. take the
shims, if any, into consideration
3. Secure the guide rails with screws. Note!
Use 25
mm screws. Check that you do not
screw through any cable or door lock.
Upper guide rails
1. Install the chain fixing device.
2. Remove the two plate screws (transport
ocking) that keep the chain in place in
l
each guide rail.
3. Erect the adjustable mounti
ng rod between
two of the walls of the lift well.
4. Attach the lifting winch to the mounting rod.
5. Lift the guide rails into the lift well.
6. Install a lifting loop on one of the guide
ils.
ra
7. Lift the guide rail. Check that it is installed
n its correct position, see the marking in
i
the guide rail profile..
25
MC2000 – Assembly Instruction Manual
8. Joint the chains. Lift the guide rail that is to
be jointed high enough above the lower
guide rail so that you can attach the connecting links.
9. Hold the chains in the upper guide rail with
g. two screw drivers and loosen the chain
e.
fixing device at the same time. Lower and
adjust the guide rail. Work carefully and
check that the steering pins enter the top
track properly.
10. Fasten the guide rails in the lift well with
rews. Use 25 mm screws. Check that the
sc
two C-profiles of the guide rails are in a position exactly opposite each other, so that
he lift moves softly past the joint.
t
11. Perform the same operation with the remaining guide rails..
26
MC2000 – Assembly Instruction Manual
mc200530
1
2
mc200531
3
20mm
4
mc200532
7
Driving shafts, gear and motor
1. Carefully push the safety gear shaft into the
sprocket wheel on side A of the lift. Note!
Do not use force!
2. Fasten the lock screw (use a 3 mm socket
ch).
wren
3. Carefully insert the long driving shaft into
si
de A. Check that the shaft reaches the
very bottom of the sprocket wheel bearing
in the turning case. Maximally 20 mm of the
keyway should be seen. Note! Do not use
force!
4. Fasten the lock screw (use a 4 mm socket
ch.)
wren
5. Loosen the four M10 screws (transport po-
sition) on each slide so that the shafts can
ned by hand. (Note! These screws
be tur
will be needed later for platform fitting.)
6. Measure and adjust the chain joints of the
two gui
de rails so that they are at the same
distance from the turning case.
7. Pull the shaft coupling tight crosswise (use
6 mm socket wrench 41 Nm).
a
27
MC2000 – Assembly Instruction Manual
10
9
mc200534
11
mc200535
28:
8. Thread on the test device cord of the safety
gear through the hollow space between the
guide rail and the door frame.
9. Fit the two keyways on the short driving
ft before installing the motor package.
sha
10. Change the oil plug at the top of the gear
or the enclosed plug with vent holes.
f
11. Tie the test device cord of the safety gear
n an empty screw hole on the gear.
i
12. Fasten the hand wheel contact 28: with
rews. The contact must be activated be-
sc
fore the hand wheel tool enters the teeth.
28
Loading...