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Operation - Manual - Gondola ZLP PDF
Operation - Manual - Gondola ZLP PDF
Brief description
The temporarily installed suspended access equipment is multipurpose and highly efficient
construction machinery applicable to work at heights. It is a substitute of traditional scaffold used for
exterior wall construction, decoration, cleaning and maintenance of high-rising buildings, such as
mortaring, decorating walls with mosaic, painting, fixing windows and cleaning etc. It is also ideal for
applications such as installation of elevators, the welding of seagoing ship in ship building industry,
cleaning of oil-based paint, big –size tanks, high chimneys, bridges and large dams.
This equipment is accord with the national standard GB19155-2003, it is easy in operation and
maintenance.
1
Main technical parameters
Item Model and parameters
ZLP800 ZLP630 ZLP500
Rated load 800 kg 630 kg 500 kg
Ascend speed 8~10 m/min 9~11 m/min 9~11 m/min
Suspended platform size (2.5m×3) ×0.69 (2m×3) ×0.69 (2.5m×2) ×0.69
( L×W)
Wire rope 4×25Fi+PP-8.6 or 4×25Fi+PP-8.3 or
4×31SW+PP-8.6 4×31SW+FC-8.3
Hoist model LTD 8.0 LTD 6.3 LTD 6.3
Rated lifting force 8KN 6.3KN 5 KN
Power 1.8 KW 1.5 KW 1.5 KW
Hoist
Electric Voltage AC220V,240V,380V,415V and etc.
motor Braking 15 N.m
torque
Type LST30/LST20/LSG20
Steel rope angle 3°~8°
adjusting range (°)
Safety lock Allowable compact ≤20KN
force
Rope lock distance ≤100m
Diameter of steel rope 8.6mm 8.3mm 8.3mm
Suspension Height adjustment 1.15m~1.75m
Mechanism 1.1~1.6m (should reduce the load on the suspended
Front beam extent
platform when extent is 1.5m or more)
Suspended platform
(including hoist, safety 610Kg (steel) 480Kg (steel) 410Kg (steel)
lock, electric control 450Kg (aluminum) 360Kg (aluminum) 300Kg (aluminum)
box)
Machine
Suspension mechanism 2×175Kg
weight
Balance weight 1000Kg 900Kg 750Kg
Whole machine weight 2000Kg (steel) 1790Kg (steel) 1570Kg (steel)
(not including wire rope 1830Kg(aluminum) 1650Kg(aluminum) 1450Kg(aluminum)
and cable)
The voltage and frequency of the motor can be manufactured to meet the needs of the
buyer’s requirements.
2
3.1 Suspension mechanism
The suspended mechanism is the heavy-duty steel frame structure erected at top of working profile as
the supporting equipment, bearing the rated and the load of the platform. Each suspended access
equipment take two sets of suspension mechanism. The force applied by the suspension mechanism on the
building or supporting structure shall meet relevant loading requirements of building structure.
(See figure 2)
1. Front beam 2. Front support 3. Tommy bar 4. Middle beam 5. Rear beam
6. Coupling sleeve 7. Rear support 8. Balance weight 9. Upper column
10. Reinforce wire rope 11. Turnbuckle
3.1.1
The suspension mechanism consists of front beam, middle beam, rear beam, front seat, rear seat, upper
column, balance weight, reinforce wire rope and tommy bar etc. To meet the requirement of working
condition, the front and rear beam as well as the height of suspension mechanism is adjustable within
certain range. Moreover, rollers are equipped to the base so that the suspension mechanism can be moved.
For the details of structure, see attached figure1: suspension mechanism
3.1.2 The configuration of the suspension mechanism shall meet the following in equation:
K=G*b/ (F*a)>=2
K------------------anti-upset safely coefficient
G------------------mass of the balance weight and rear seat (kg)
a-------------------extent of the front beam (m)
F-------------------Total mass of the platform, hoist, and electric system. Safety lock, wire rope and
rated load, plus wind pressure (kg)
b-------------------distance between the front seat and rear seat (m)
When the extent (a) of the front beam is 1.5m or more, the load on the suspended platform should be
reduced.
(Referring to attached table1)
3
3.2.1 The suspended platform, welded with profiled steel pipes. The parts can be jointed with bolts and
nuts. The length of the standard section is 2.5m or 2m.
3.2.2 The balustrade on the working side is 970mm high and the balustrade on the back side is 1120mm
high. The floor has anti-slip strips.
For details of structure, see attached figure 2: suspended platform. (Page 18)
3.3 Hoist
3.3.1 The hoists for ZLP800 (A) consists of electromagnetic brake motor, centrifugal speed limiter and
dual speed reduction system and pulling rope system etc.
The hoists adopts type“S”crawling and rising mechanism.
For details of structure, see attached figure3: hoist (A) for ZLP800(A) and attached figure4: hoist (B) for
ZLP800 (B).
3.3.2 The hoist for ZLP800 (B) /ZLP630 /ZLP500 consist of electromagnetic brake motor, centrifugal
speed limiter and dual speed reduction system and pulling rope system ect.
The hoist adopts type (a) crawling and rising mechanism.
For details of the structure, see attached Figure 3: Hoist for ZLP500/ZLP630/ZLP 800(B) ( page 19)
3.3.3 The hoist is provided with automatic rope feeding function, and operators just need to insert wire
ropes into the inlet of the hoist. (See figure 3)
3.3.4 The electromagnetic brake of the 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 fork of
manual descending unit(inside the handle of hoist)can be used to plug in the fork hole of electromagnetic
brake (inside the motor hood) to raise fork and open brake so as to prompt the suspended platform to slide
downwards at even speed (See figure 4)
3.3.5 The cooling of hoist is by the lubrication of gear oil, which should be replaced at an interval of
6-12months pursuant to practical situation. The No.18dual-curve gear oil is recommended to use, and the
oil volume of hoist is 1.2libers for ZLP800, and 2liters for ZLP630 or ZLP500.If used in extreme cold
winter, the No80W/90 general vehicle gear oil is the best.
Figure 3 Figure 4
3.4 Safety lock
Safety lock is a separate mechanical unit that can automatically lock safety wire rope when the working
wire rope is broken or the suspended platform tilts to its limits.
There are two kinds of safety locks. Anti-proof safety lock or centrifugal speed-limit safety lock should be
used according to different shape suspended platform.
4
3.4.1 The tilt-proof safety lock ( see figure 5) consists of parts as rope clip, sleeve plate, torsion spring,
bracket, swing arm and roller. It is so arranged that the working wire rope is put against the roller on the
swing arm to make the rope clip open and allow the smooth pass of safety wire rope. If the suspended
platform tilts to its limits or working wire rope break, the pressure on the swing arm of safety lock will
reduce or impair. The safety rope clip swiftly closes and locks safety wire rope to prevent suspended
platform from dropping or tilting by the friction as that in between torsion spring, rope clip and wire rope.
When anti-tilting safety lock is applied, the tilt angle of suspended platform should be 3 degree-8 degree,
the model ZLP800, ZLP630 and ZLP500 take two anti-tilting safety lock.
Figure 5 Figure 6
3.4.2 The centrifugal speed-limit safety lock (see figure 6) is based on the principle of centrifugal
speed-limit. When centrifugal safety lock is applied, the safety wire rope is led through the rope sheave,
which is connected with the centrifugal speed-limit. When the suspended platform’s downward movement
speed exceeds the limits, the kicker of centrifugal speed limit triggers the clamping device and locks the
safety wire rope within 20cm distance to stop the operation of platform.(the single suspension point access
equipment usually takes this type safety lock)
3.4.3The safety lock is marked by factory for the first time. After the first marking is effective, the
professional technician should conduct maintenance and service at an interval of 12months and remark at
the end of 12 months.(For the safety locks operating in the dusts, corrosive materials and adhesive
materials, the overhaul and second marking are required on 6 months basis)
5
Figure 7
1. Left upper limit switch 2. Handle switch 3. Left motor 4. Right motor
5. Emergency stop 6. Power cable 7. Upward button 8. Downward button
9. Turning switch 10. Right upper limit switch
Special notice:
The wire ropes should be replaced in any one of the situations below:
a. The loosening, twisting, untwisting, or any other deformation and distortion.
b. The wire rope should be rejected when the wire breaking number within the range of “ab” spacing
reaches5 (see figure 9).
Figure 9
When any corrosion or abrasion on the surface of wire rope, the standard for rejection is reduced further.
The percentage of reduction is that the maximum allowable breaking number5 times the percentage of the
corrosion or abrasion on the surface and the wire rope is loose.
c. Obvious corrosion on the wire rope, that is .the concave pit on the surface and the wire rope is loose.
d. The nominal diameter of wire rope is reduced by 6%, even if there is no twist breakage.
e. When the abrasion of outer rim of wire rope to 40% of diameter.
f. The damage or accumulation incurred by the heat or electric arc.
4. Installation
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4.1The 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
8
Figure 10
1. Hoisting-mounting frame 2. Pin shaft 3. Safety lock 4. Upper limit stopper 5. Electric control
box 7. Working wire rope 8. Pin locking 9. Heavy hammer
For ZLP630 or ZLP500, install the hoists on the hoist-mounting frame, fix with bolts, nuts, handles and
locking pins (see figure 11). Install safety lock on the bracket of the hoist-mounting frame, fix and tighten
with bolts.
Figure 11
9
1. Hoisting-mounting frame 2. Pin shaft 3. Safety lock 4. Upper limit stopper
5. Electric control box 6. Working wire rope 7. Bolt M10×120 8. Pin locking
9. Nut 10.Heavy hammer
4.4.2 Install and hang the electric control box in the middle of balustrade of the suspended platform.
4.4.3 Insert motor plug and handle switch plug. Install the upper limit travel switch to the right position of
safety lock. Power plug should be inserting into the power socket and power cable should be connected
based on three-phases and five-wire system
Figure 12
1. Inner hexagon screw 2. Electromagnectic disc 3. Hollow screw 4. Spring
5. Armature 6. Friction disc 7. Motor cover
and electromagnetic disc should be within the range of 0.5-0.6mm, its structure is shown in figure9. First
loosen the inner hexagon screw 1 on the electromagnetic disc2, and then turn hollow screw 3 to adjust
spacing around, and finally retighten inner hexagon screw1. 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.
5.1.3 Rope passing inspection
Turn the turning switch on the panel of electric control box to the hoist ready for the rope passing. The
working wire rope will insert into the upper hole of hoist after passing between the limiting wheel and
retainer ring of safety lock. Start upward button, the hoist will wind automatically to finish the rope
passing and positioning of wire rope (During rope passing, close attention should be paid to any abnormal
condition , if any ,stop passing immediately). After the working wire rope is positioned, the safety lock
will be opened automatically to insert the safety wire rope from the upper end hole of safety lock. (The
operating procedure on the other side of hoist is the same)
5.1.4 After the wire ropes at both two sides are passed, raise and level the suspended platform to the level l
meter above the ground surface. Mount heavy hammer on safety wire rope 15cm off the ground.
5.1.5 The redundant wore ropes should be handles with care; they should be packed to prevent damage.
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5.2 Test run
5.2.1 The user should prepare a safety rope to be fixed independently on the attachment over the operating
area. The operator should wear safety helmet and safety strap according to related
regulations, fasten the safety strap knuckle on the safety rope.
5.2.2 Check the condition of locking rope, the detailed procedure is as follows: turn the turning switch on
the panel of the electric control box to the middle, and raise the suspended platform 1~2cm and stop, and
then turn the turning switch to another side to make suspended platform tilt. When the suspended platform
tilts to 3°~8, the safety lock will lock the safety wire rope. When raising the lower end of suspended
platform to the leveling condition, safety lock will be reset automatically, and the safety wire rope will be
in free condition in safety lock. (The left and right safety lock should be checked as per the procedures
above).
5.2.3 Zero load testing: No abnormal sound in hoist, the operation of electromagnetic brake is flexible and
reliable. Press “emergency stop” button, the suspended platform should stop operation.
5.2.4 Manual descending inspection: Take the fork out of the hoist handle, and plug (insert) it into the fork
hole inside of motor hood to rise up, the suspended platform should be moving smoothly at the even speed
no greater than 1.5 times rated speed.
5.2.5 Adjustment of the upper limit stopper: ascend the suspended platform to the working height; adjust
the upper limit stopper and angle of swing arm of the upper limit switch.
5.2.6 Rated load testing: the rated load should be evenly distributed on the working platform. The
operation process no abnormal sound and when stopping no sliding movement. The safety lock should
lock the safety wire rope flexibly and reliably when the platform is tilting.
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required by relevant regulations.
6.3 The platform must be protectively grounded and the load applied on the platform should be roughly
distributed in a even way. It is prohibited to have the platform overloaded or to operate the platform with
the hoists or safety lock with the trouble.
6.4 When the platform is in its normal operation, it is prohibited to manually brake the motors or safety
lock, so as to prevent and accident from happening.
6.5 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.
6.6 When the limit switch is activated, the operation of platform will automatically halted and the buzzer
will signal the alarm. Under the circumstances, lower the platform promptly to have the limit switch be
away from the stopper.
6.7 The platform should be adjusted promptly if it is tilting and the height drop of two ends should be no
higher than 15cm.
6.8 In case of power break during operation, shut down the power first. If it is needed to have the
suspended platform lowered back onto the ground, use same method of ‘5.2.4 manual descending
inspection’ to operate the electromagnetic brakes at the same time to have the platform lowered smoothly
onto the ground.
6.9 The working wire rope and safety wire rope should not be bent and should be prevent 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 wire rope
should be prevented from contacting grease or oil.
6.10 In case of working wire rope breakage during operation, the personnel in the platform should keep
calm and composed and leave the platform under the prerequisite of ensured safety. After maintenance and
repair personnel enter the platform, the first thing to do is to take anti-dropping measures by having the
clamp of safety wire rope hold the platform fast or by fastening the platform with the wire rope secured on
the building roof. Then, pull the replacing wire rope through the hoist, 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 wire rope and lower the platform down to the ground. It will not be put into
operation again until it passes the stringent inspection.
6.11 The operation of suspended access equipment should meet relevant regulations regarding work
performed at heights. The equipment should not used under such weather conditions as thunder, rain, fog
and wind of Grade 5 (wind speed 8.3m/s) or higher.
6.12 The suspended access equipment should not be used in the area within 10m away from high-voltage
power cables.
6.13 Never use additional equipment, i.e. ladders, boxes, to obtain increased height in the suspended
platform. Never use additional extensions to exceed the permissible length of the platform. Ensure that all
the materials and equipment are safety stored within the confines of the platform.
6.14 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.
6.15 The safety 1ock should be checked and its moving parts should be lubricated regularly during its
service life and it should not be dismantled without authorization. Special attention should be paid to the
labeled service of the safety lock..
6.16. When the suspended platform is stored in the open air, measures should be taken to prevent
the rainwater from entering into the hoist, safety lock and electric control box.
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6.17 When the wire rope is removed from platform, it should be winded to form a bundle and stored
promptly.
6.18 The suspended access equipment should be stored in a dry and well ventilated warehouse free of
corrosive gases.
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Trouble condition Trouble analysis Troubleshooting
Working wire rope Welding problem at end of rope 1. Grind welding part
can’t go through 2. Remark end of wire rope
hoist
Hoist can’t actuate 1. Power voltage is too low 1. check and adjust voltage
suspended platform 2. Damage of hoist 2. Examine and adjust hoist
3. Brake doesn’t open or open 3. Adjust spacing and check if brake
incompletely work properly
Motor noise or 1. Operation lacking phases 1. Check power supply
abnormal in heat 2. Voltage is too low or high 2. Check power voltage
radiation 3. Bearing is damaged 3. Replace
Safety lock slip or 1. Oil dust on the safety wire rope 1. Clean or replace wire rope
locking angle is too 2. Abrasion of rope clip 2. Replace rope clip
big 3. Sluggish motion in safety lock 3. Replace torsion spring of safety lock
8. Maintenance of products
Careful maintenance and management on the suspended access equipment should be executed. Strict
executions of responsibilities can not only keep the performance of whole machine but also guarantee
personnel safety and extend service life.
The routing maintenance includes routine keeping, inspection, regular examination and repairing.
The routing keeping and inspection before and after operation should be conducted by operators, the
routine inspection and regular examination and repairing should be done by professional personnel.
8.1 Routine keeping: Unless in connection with the replacement of parts and components, the operators
should implement oiling, cleaning and keeping, as well as the inspection and adjustment of
electromagnetic brake spacing. Clear the stains from the wire rope and remove the rusts to it maximum.
8.2 Routine inspection: Each day prior to use, the operator should check the machine according to terms
5.3 above mentioned, in particular, the safety lock, hoist and wire rope. The program to be repairs should
be finished in time.
8.3 Regular inspection: The user should work out clear regulation according to the application condition
and working time (1~2 months in general), after the end of use of entire machine, a thorough keeping and
examination should be done. Professional maintenance personnel should check the abrasion of parts. The
fragile parts and damaged parts should be replaced or dismantled for cleaning and replacing grease and
lubricants etc. The wiring of electric control box should be inspected; the wire should have no failure and
the entire machine have no leakage.
If the user follows the keeping, use and maintenance regulations, the hoist should be overhauled after the
use of one year. When used in the harsh environment of dust and corrosive materials, the maintenance
cycles should be reduced correspondingly.
8.4 The marking cycle of safety lock after being shipped out of factory is 12 months. After the termination
of marking cycle, the users submit application to distributors or manufacturers to have it to be serviced and
maintained by professional and remarked. (For the safety lock using in the dusts, corrosive and adhesive
environment, and the remarking cycle of safety lock should be reduced).
The rejection of wire rope is as described before; the wire rope up to the rejection standard should be
rejected.
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9. Handing and storage
The products should be stored in dry and ventilating warehouse without corrosive gas to avoid corrosion.
If storage is over one year, a second maintenance should be conducted.
Attached table 1: Relation between working height, extent of front beam and
permissible load.
Model Balance Working Extent Distance Permissible load
weight height of front between front (kg)
(kg) (m) beam and rear base Steel Aluminum
(m) (m)
ZLP800 1000 50 1.5 4.6 800 800
1.7 4.4 570 730
100 1.3 4.6 800 800
1.5 4.6 750 800
1.7 4.4 510 670
120 1.3 4.6 800 800
1.5 4.6 730 800
1.7 4.4 490 650
150 1.3 4.6 800 800
1.5 4.6 690 800
15
1.7 4.4 450 610
ZLP630 900 50 1.5 4.6 630 630
1.7 4.4 540 630
100 1.3 4.6 630 630
1.5 4.6 630 630
1.7 4.4 480 610
120 1.3 4.6 630 630
1.5 4.6 630 630
1.7 4.4 450 580
150 1.3 4.6 630 630
1.5 4.6 630 630
1.7 4.4 420 550
ZLP500 750 50 1.5 4.6 500 500
1.7 4.4 430 500
100 1.3 4.6 500 500
1.5 4.6 500 500
1.7 4.4 370 480
120 1.3 4.6 500 500
1.5 4.6 500 500
1.7 4.4 340 450
150 1.3 4.6 500 500
1.5 4.6 500 500
1.7 4.4 310 420
16
Attached figure 1: Suspension mechanism
1. Front support 2. Front tommy bar 3. Middle beam (70mm×70mm) 4. Upper column
5. Bolt 6. Branch pipe of balance weight 7. Rear support 8.Rear beam
9. rigging screw M20 10. Coupling sleeve 11. Tommy bar 12. Balance weight
13. Cutting sleeve of wire rope 14. Spindle sleeve 15. Wrist 16. Lifting piston
17. Big connecting sleeve 18. Cotter pin 19. Front beam (83mm×83mm)
20. Bolt M14*150 21. Wire rope Y-10 22. Intensive wire rope
17
Attached figure 2: Suspended Platform
18
Attached Figure 3: Hoist for ZLP500/ZLP630/ZLP 800(B)
19
Attached table 2: Parts list of hoist for ZLP500/ ZLP630/ ZLP800(B)
No. Name Quantity No. Name Quantity
1 Rope inlet pipe 1 31 Handle 1
2 Box 1 32 Pin 1
3 Alignment pin 2 33 Screw 2
4 Base plate of rope guide 1 34 Bearing 6004 1
5 Rope guide 1 35 Adjustment washer 1
6 Cover of rope guide 1 36 Screw 2
7 Gasket seal 1 37 Bearing 16007 1
8 Driving disc 1 38 Gasket sealing 1
9 Steel belt assembly 1 39 Washer 4
10 Screw 2 40 Screw 4
11 Bearing 6004 1 41 Front cover 1
12 Wire pressing unit 1 42 Motor 1
13 Cover 1 43 Key 1
14 Washer 3 44 O-shape gasket sealing 1
15 Screw 3 45 Centrifugal speed limiter 1
16 Nut 4 46 Shield ring 1
17 Shield ring 1 47 gasket sealing 1
18 Screw 4 48 Shield ring 1
19 Washer 4 49 Bearing 6005 1
20 Bolt 4 50 Fork 1
21 Washer 4 51 Shield ring 2
22 Rope outlet pipe 1 52 Bearing 6203 1
23 Shield ring 1 53 Shield cover 1
24 Key 1 54 Gasket sealing 1
25 Worm 1 55 Screw 1
26 Shield ring 1 56 Worm-wheel 1
27 Nut 4 57 Adjustment washer 2
28 Pinion shaft 1 58 O-shape gasket sealing 1
29 Bearing 6207 1 59 Plug 1
30 Sleeve 1
20
Attached figure 4: Three Phase Electric control diagram
21
Attached figure 5: Three Phase Wiring terminal board diagram
22
Attached figure 6: Three Phase Power plug-in component diagram
23
Attached table 3: Three Phase Electrical components list
No. Code Item Specification Quantity
1 Qs Power leakage breaker C45ADLE-25/34-30 1
2 KM1, KM2, KM3, AC contactor LC1-1201 AC36V (24V) 3
3 T Control transformer JBK-100 1
AC380V (415V)/ 36V/(24V)
4 SB1 Emergency stop LAY3 1
5 SB4, SB3 Handle switch COB-61 1
6 SB2, SB5 Button switch ZB2-BE101c 2
7 SQ1, SQ2 Upper limit switch LXK3-20S/T 2
8 SA Turning switch LW5-16/3 1
9 VC1, VC2 Brake rectifier module AC 250V 3A 2
10 M1, M2 3-phase braking motor YEJ1001L-4 1.8KW(ZLP800) 2
YEJ90L-4 1.5KW(ZLP630)
YEJ90L-4 1.5KW(ZLP500)
11 L1,L2 Electromagnetic brake 99 VDC Integrated
with motor
12 FR1, FR2 Thermal relay JR16B-20/3D 5A (ZLP800) 2
JR16B-20/3D 3.7A (ZLP630)
JR16B-20/3D 2.8A (ZLP500)
13 Q1 Power socket RSC-215 1
14 Q2 Handle switch power P20 6Q 1
15 Q3, Q4 Motor socket P20 6Q 2
16 D Wiring terminal board UKJ-4, UKJ-2.5 1
17 HA Electric bell AC36V (24V) ZMQ-3522 1
18 1RD, 2RD, 3RD, Fuse 2A 5
4RD, 5RD
19 HL Fuse SB5,SB2-ZB2-BV6 AC6.3V 2
24