ESC&AWK Installation Manual

Installation Manual of Automatic Escalator
Installation Manual
of Automatic Escalator-CE-11-EN
Page 1 of 1
Table of content
1.
General provisions ................................................................................................3
2.
Preparation before installation..............................................................................7
3.
Measurement for the construction dimension.........................................................7
4.
Lifting, transportation, assembly and positioning ..................................................9
5.
Check and adjustment for the driving system ....................................................... 13
6.
Check and adjustment for the step ....................................................................... 16
7.
The adjustment and test of comb.......................................................................... 19
8.
Disassembly of step refer to figure 21.................................................................. 20
9.
Deflection protection of step................................................................................ 20
10.
Front edge plate .............................................................................................. 21
11.
Installation and adjustment of balustrade system ............................................. 22
12.
Lighting and warning mark of steps................................................................. 27
13.
Supporting system of escalator ........................................................................ 28
14.
Control system and electrical components ....................................................... 29
15.
Debugging....................................................................................................... 30
16.
Test Run .......................................................................................................... 33
17.
Inspection........................................................................................................ 33
18.
Delivery for Use .............................................................................................. 33
19.
Installation schedule........................................................................................ 34
20.
Installation tools.............................................................................................. 35
21.
High strength bolt installation ......................................................................... 36
22.
Lubrication drawing ........................................................................................ 36
23.
Installation drawing of balustrade system........................................................ 36
Page 2 of 2
1.
General provisions
This manual is applied for the installation of escalator .

1.1.
The installation method applied in this manual is general method, please

refer to the detail installation requirement described in this manual. If the
construction dimension &requirement are not conforming with the
requirement of KONL, please contact our technical department for further
discussion.
1.2.
Installation procedure
See figure 1
Page 3 of 3
Measuring
positioning
construction
again,
lifting
Level adjustment on the upside
Level adjustment on the downside
Power into control box
Cleaning each part and lubricating
Steps test run
Checking traction machine driving system
Checking the rail system
Checking tension of the chains for the steps
Installing the balustrades
Page 4 of 4
and
Handrail test run
Checking tension of the handrail
Installing the front-edge plate on upside and

downside
Installing and checking steps
Checking the safety device
Commissioning
Adjusting speed between handrail and steps
Adjusting mesh between steps and comb
Adjusting clearance between steps and skirting
Adjusting the stopping distances unloaded
Page 5 of 5
Adjusting the stopping distances loaded
Commissioning
Available for each safety device
Checking insulation capability
Checking safety device
Cleaning and lubricating again
Moving one hour for each downward and upward
Self-checking for installation
Acceptance inspection
Turn over for use
Figure1 installation procedure of escalator

Page 6 of 6
1.3.
The commissioning after installation should be performed by skilled

installation personnel
1.4.
The electrical system should be assembled and commissioned before

shipment
2.
Preparation before installation
2.1. Installation personnel

The installation team generally composes 4 people, including one qualified
installation locksmith and one electrician.
2.2. Pieces mount check and verification before installation
Before installation, the installation responsible of the client must check the
amount, verify all the parts, pieces and documents with package, and
understands the technical installation parameter of escalator width, rising height,
angle of inclination etc. Recheck if the construction dimension including pit
length, width, rise height, upper and bottom supporting point horizontal distance
are in accordance with construction drawing requirement. The lower pit should
not have leakage of water, the interior wall is horizontal or vertical, no concave
and convex surfaces. Any deviations should be informed to the related
department and make corrective actions.
2.3. The safety rule to be followed by installation personnel
During installation, falseworks are required in the 2 sides of escalator in order to
facilitate the installation of 2 sides. The hamlet is to be worn; safety belt and tool
bag must be well fastened. 2 people are required during working related with
electricity; the power switch must be guarded by designated people. The power
must be turned off in case people enter into the structure and make internal
adjustment. The designated people for the guard of the power switch should not
leave in order to avoid suddenness; the warning panels of No entry shall be
put in the upper and lower entrance. During test run, installation personnel must
check if there are forgotten tool or other sundries inside the structure, the test
run can be only carried out after these checking without problem. During lifting
of the escalator, the centre of gravity must be paid attention, and avoid reel or
great swing, and put in the required position. In additional avoid deformation of
the structure.
2.4.
The lighting for installation should be provided by the user, and with less
than 36V safety voltage, at least 3 lighting points are required, the power
need to be available both in the machine room and installation site to
ensure the normal use of installation.
2.5.
Gas cutting and welding must be performed by qualified personnel, and

fire-fighting measures must be available.
3.
Measurement for the construction dimension

Page 7 of 7
3.1.
The recheck of the constructing dimension must be completed before the

escalator put into installation position. The construction requirement and
dimension must be strictly rechecked as per the construction drawing of
Zhejiang Kangli Elevator Group.
3.2.
The upper and lower horizontal supporting points must be rechecked, the
horizontal distance for the angle of inclination, and step dimension,
embedded parts as well as the level degree of 2 horizontal supporting
point must conform to the construction drawing requirement.
3.3.
The rising height of H must be rechecked strictly as per the installation

drawing requirement of H+/-5mm. Vertical distance H is the distance
between the final decoration surface of the upper and lower floor. H can
be measured by the method of plumb line from upper floor, and identify
the vertical distance measuring point. If actual H is not conformed to the
construction height r, installation team must find and take necessary
actions in time. Please Refer to figure 2.
Final
surface
decoration
Passenger conveyor width /2
Final
surface
Upper center point
decoration
inner surface of
Support beam
Lower center point

inner surface of pin
Figure 2 construction measurement

3.4.
Identify the central point 0,0, in the net space of upper and lower
supporting beam, and make the installation mark. And also make the
mark for the upper and lower supporting beam centre(width of
escalator/2)A.B, AB, measure the horizontal distance L of 3 points , and
check if it conforms to the construction drawing dimension requirement,
meanwhile, step width 170mm of supporting beams shall also conform to
the construction drawing requirement to ensure the horizontal distance in
the width is correct during the installation of escalator, the allowable
construction deviations shall be less than requirement of construction
dimension requirement.Please refer to figure 2.
3.5.
The interior surface of upper and lower supporting beams must be kept
horizontal and vertical, no concave-convex is allowed. Please refer to
figure 2.
Page 8 of 8
3.6.
The construction for the escalator with pit shall conform to the
requirement of 3.3, 3.4, and 3.5, and recheck the length, width and
height of the pit as per construction drawing; the symmetry line of pit
shall be consistent with the central line of upper and lower support beam.
No visible deflection, concave-convex and leakage of water are allowed.
The length, width and height shall conform to the construction drawing
requirement.
3.7.
Recheck if embedded plates on the step surface of lower and upper

supporting beams have been put, the distance between the upper
surface of the embattled plate and the final decoration surface of the floor
shall be 135+/-5mm. embedded plate shall be horizontal, and the edge
shall be even with pit and support beam, it shall not exceed the outsider
of the support beam, and also positioned without deflection.
4.
Lifting, transportation, assembly and positioning
4.1.
Lifting and positioning of escalator must be performed by qualified team,

the transportation tool must also conform to the transportation
requirement. Whole unit transportation is generally used, while in some
special condition or high rising height escalator, the truss might be too
large, therefore the escalator can not be entered into the clients building,
the escalator could be fabricated or transported by separated parts, this
condition shall be confirmed by the end user and manufacturer.
4.2.
The specialised rope tools for the lifting of upper and lower part are
provided together with escalator, they are in the 4 corner of upper and
lower structure, lifting shall be performed in this rising position, and
should not change to other lifting position freely. Refer to figure 3.
Figure 3-1 correct lift method

4.3.
Figure 3-2 incorrect lift method
If the structure is made by several separated parts, the combined

structure shall be used, one lifting position shall be in the lug of the
Page 9 of 9
escalator, and another end shall be connected steadily with connecting

surface of the structure and avoid deflection of the structure.
4.4.
The transportation of separated structure shall depend on the fission

structure, generally it will be divided into 2 parts namely, lower part, and
middle &upper part. the upper and middle part shall not be separated
except the structure is too large to transport. The middle parts can be
made by several parts if its too long, while in any case, the client shall
confirm the separated parts when they place the order. Refer to figure 4.
Figure 4-1 unit transport
figure 4-2 separated transport
4.5.
The additional support is needed for the superposition of fission style

transportation, the support can be in the 2 sides of escalator, while the
horizontal connection beam must be set in the upper part of additional
support, it can support the weight of the each separated structure, it must
be stable. Wood shall be put between structure and supporting beam to
avoid the movement during transportation. Refer to figure 4-2.
4.6.
Assembly
4.6.1. When the separated structures are transported to site, the next step
is assembly which shall be performed as per figure 5. The
positioning pin shall approaches the positioning hole first, and then
enter it slowly. The step rail connecting part must be paid more
attention in order to avoid bending, collision and then fix the
connecting screws.
Figure 5 assembly
4.6.2. Recheck the perpendicular and level of connection, might be
adjusted by the means of adjustable washer. The allowable gap for
Page 10 of 10
the connection shall less than 0.05mm, and sidesteps less than
0.05mm as well.
4.6.3. After fitting of the step rail, install the step traction chain, and adjust
tension properly.
4.7.
When move escalator horizontally, sleeper, roller be well put under the
upper and lower support point, and move it slowly in the horizontal
direction. Refer to figure 6, 7, and 8.
Figure 6 horizontal movement method
Figure 7 horizontal movement method
Figure 8 incorrect horizontal movement method

4.8. Positioning of escalator
Move escalator to installation position in the horizontal direction, and then lift
and put to the upper and lower support beam. Refer to figure 9, which is
construction style with pit.
Page 11 of 11
Figure 9
4.8.1. Before putting the whole escalator on upper and lower support
beam, lift firstly the upper part, safety rope must be fixed and pulled
properly before lifting. During lifting of upper part, release slowly the
safety rope, which led the upper part slowly upward, and then move
the lower part toward. Refer to figure 10.
Figure 10 upper lifting

4.8.2. The height of escalator and final positioning
Have the escalator be above upper and lower supporting beam, the upper and
lower part of escalator shall in horizontal style, lay down slowly, put escalator on
upper supporting beam, and also make the centre of escalator be consistent
with construction centre line. Refer to figure 11. The distance between multiple
escalators shall be even. The gap between upper and lower part, and the gap
between upper and lower supporting beam shall be consistent, put installation
padding plate when positioning, install the adjusting screw, the rubber shall be
under the plate. Refer to figure 12.
Page 12 of 12
Figure 11
Figure 12
4.9.
Horizontal adjustment of escalator

4.9.1. The surface of upper and lower pallet shall be a little higher than
that of upper and lower floor final surface, in order to avoid the
cleaning water enter into the escalator. The height can be adjusted
by stow-plate under the upper and lower part, adjustable washer is
used below the stow-plate, stow-plate shall be welded together the
embedded plates of upper and lower support beams.
4.9.2. The level will be adjusted after adjustment of upper and lower part
and the height between upper and lower floor surface, the level
degree of upper and lower part shall be within 200x200 angle iron of
structure, or measure the level degree of upper, middle and lower
step transverse plane. Longitudinal level degree is measured in the
main beams of 2 sides of escalator structure upper and lower part
(front-edge plate not installed yet), or measure the level degree of
upper, middle and lower step longitudinal plane, tolerance for the
level degree is less than 0.5 mm.
4.9.3. After completion of transverse and longitudinal level degree
adjustment, tighten adjusting screw, and check if all the tighten
pieces are well fixed and no loose.
5.
Check and adjustment for the driving system

Page 13 of 13
5.1.
The whole escalator will get commissioning and test run, and shipped
after approval of check out certificate. Due to the reason of transportation,
balustrade system is disassembled and installed at site; all the other
parts shall not be tested run until proper adjustment and inspection.
5.2.
Traction machine
Refer to figure 13
Traction machine is located in the upper machine room. Motor 9 drives reducer
10 through coupling device 8, reducer brings along main shaft through chain
wheel 11 and driving chain 12, so that drive the step. There is a mechanical and
electrical belt brake, the gap between brake wheel and belt shall be less than
0.7 when braking belt is open, and brake works well for open and close. If the
brake is closed, the motor shall be not started. The brake for driving system
must have enough brake torque, and the brake distance of upward and
downward shall be adjusted to 0.20~ 1.00 m as per unloaded and loaded.
5.3.
Tension device shall be with suitable tension, and also equipped with
step chain broken and extension protection device. The tension shall be
adjusted by adjust the length of compression spring as per actual
situation of work. Refer to figure 14-1 and figure 14-2.
1. brake motor
2. brake belt
3. brake spring
4. fly wheel
5. eccentric tighten block
6. vemier
7. vent hole
8. coupler
9. motor
10.reducer
11.chain wheel
12.driving wheel
Figure 13 Driving system

Distance of horizontally
travelling of steps
800mm
H6000mm
Length of tension spring

compressed
H4000mm
145mm
4000<H<6000mm
140mm
H=6000mm
135mm
Page 14 of 14
Distance of horizontally
travelling of steps
1000mm
H=4000~7000mm
Length of tension spring

compressed
H4000mm
145mm
4000<H<6000mm
140mm
H=6000mm
135mm
6000<H<7000mm
130mm
Figure 14-1
zoom in A
Compression spring
Tension wheel
Compression spring
Chain fracture point
Figure 14-2 Tension device

5.4.
Driving system
5.4.1. Driving system includes traction machine, control panel, balustrade
drive, step traction chain etc. Front edge plate will be demounted
before make inspection to driving system. To facility maintenance,
control panel may be taken out of machine room after demounting
screw. Refer to figure 15.
Page 15 of 15
Figure 15 Driving system

1.control box
2.driving aix
5.4.2. Check tension of all chains. tension of the double chain of traction
machine output shaft , firstly release foot screw of traction machine,
adjust screw to make traction machine backward and out, the cam
may adjust the tension of double chain, the tension shall not be too
loose or too tight, sagging of chain shall be less than 15mm, and
also effect main drive chain safety device(if available).The chain
tension for balustrade shaft can be adjusted by adjusting screw
which are positioned on the side plate of main shaft, and its sagging
shall be less than 10mm, the adjustment can be done after demount
3 steps and chain cover, at mean time check the parallel of chain
and cam.
6.
Check and adjustment for the step
Step is the moving part where passenger stands. Refer to figure 16.
Step is connected by 2 special trolley chains, trolleys outer band is made up of
polyurethane, inner band uses trolley bearings which can avoid the noise during
the mesh between trolley and chain wheel. There is one outward pin in every 3chain cycle, this pin is used to connect step shaft. Steps are fixed with step
shaft through one nylon sleeve; Side positioning is fixed by clamp.
A step
B step wheel
C guide block
Page 16 of 16
Figure 16 step
6.1.
Step is the part that runs in cycles, nylon guide block. If step guide blocks
are worn, steps will impact step guide rail, step will also cause attrition
with skirt panel, therefore regular check of guide block shall be taken to
find out the worn situation, at least 3 guide blocks shall be demounted
and measured, its nominal thickness is 7-0.2mm. Refer to figure 17. if the
worn thickness of guide block reach to maximum value of 1.2 mm, the
guide block need to be changed. Other guide block shall be checked at
random in the lower machine room. In the 2 sides of steps, the gap
between skirt panel and step guide block shall be less than 0.4 mm each
side, skirt panel or moved steps could be adjusted if necessary.
Figure 17 guide block

6.2.
Adjustment of step and comb plates engagement
Refer to figure 18.
3comb
figure 18 step and comb plates engagement

1.guide plate 2. comb plate safety point 3. comb 4 surface of tread
6.2.1. Comb plates are located in the entrance and exits of escalator,
which are fixed in the front part of comb by screw and engaged with
Page 17 of 17
teeth alveolus of step, which led each step engages with comb plate
and pass through smoothly.
6.2.2. Guide plates are in the 2 sides of comb plate; comb plate safety
devices are in its rear. When objects are stuck in the mesh between
the step and comb plate, the comb will be moved backward, switch
off the main power switch, therefore escalator is stopped.
6.2.3. Check and adjust the match between 2 ends of comb plate and
guide block, each side gap shall be less than 0.4mm, no obstacle is
allowed when comb moves backward, it needs to adjust the
adjusting bolts which are in the 2 sides of guide block, sufficient
lubrication is needed in the guide sleeve.
6.2.4. Check for the mesh of step and comb plate refers to figure 19.The
mesh depth of the comb into the groove of the tread shall be at least
6mm,the gap between the surface of tread and root of comb plate
shall be less than 4mm.
1.guide plate 2.shirting plate 3.comb plate 4.step

Figure 19 Check for the mesh of step and comb plate
6.2.5. The broken point is preserved during design and fabrication, to
avoid attaint step heavily. Comb plates need to be changed in case
deflection were found.
6.2.6. It needs to check the mesh between comb and step. To check if
steps can pass through step guide wheel without side push force, if
no side force, it means probably side guide blocks are already worn
or need to adjust step guide wheel.
Page 18 of 18
7.
The adjustment and test of comb

Please refer to figure 20.
7.1.
Before check upper and lower comb plate, it needs to demount frontedge plate firstly. When 100kg horizontal forces on the centre of comb,
comb safety device start to function, and escalator is stopped.
1.comb plate 2. comb 3. abnormal objects protection switch

Figure 20 adjust of the comb plate and protection switch
7.2.
a.
b.
c.
d.
e.
In some cases, if no spring force measure devices at site to know the

performance force of adjusted comb, but it still need to check the free
movement of comb plate, the following items need to be checked:
Demount 2 pieces of comb plate
Put one screw in the step gap of left and right side of comb plate
Turn flywheel on the motor,release the brake
Combs can move smoothly through resistance, and also can switch on or off.
Move step backward by hand through flywheel, combs shall be back to
normal, and then reset by hand.
7.3. Check and adjustment for Comb plate safety device

There are 2 switches on each comb plate (one in upper and another in lower
part), switches shall be cling with adjusting block without gap. The distance for
Page 19 of 19
switch on and off is 2~3.5mm, if at lease one switch is on, the escalator cannot
run.
8.
Disassembly of step (refer to figure 21)
8.1.
The demounting to the steps shall be performed in the lower machine

room, spot move the step which will be demounted to the designated
position, maintenance control switch must be operated by designated
person, 3 steps (for check) shall be marked by red paints.
8.2.
Mark the position of step sleeve on shaft by mark pin, release clamping
screw, push clamp and step sleeve to step chain, move step backward
and lift and carry it out at the turning entrance.
6 6
1. step chain 2.direction change arm 3.step 4.comb 5.comb plate

Figure 21 disassembly of step
8.3.
Remounting of steps shall follow the reverse order. Before fasten screw,
aim step at the mark on the shaft, fix screw, run carefully and slowly
lower steps, and check the mesh situation of steps and combs.
9.
Deflection protection of step
9.1.
In order to avoid long term running causes fatigue deformation or even

step broken and hurt other parts, there is one step safety device
respectively at the upper and lower of escalator. refer to figure 22, In
case of step deflection or break, safety devices stops the running of
escalator by cutting safety cycle power.
9.2.
The vertical height of switch bar can be adjusted, the normal distance
between switch bar top and step arc toe plate is 5+/-0.5mm.
Page 20 of 20
1Deflection protect switch 2step 3Arc step 4Sub step wheel

5Sub step rail6Step wheel 7Step rail 8Step chain
9Comb plate
figure 22
10.
Front edge plate
10.1. There is a preserved cover plate on the upper and lower machine room.
There is a sliding-proof on the cover plate (design is different as per
client request), the front-edge plate is divided into 2 parts in order to
facility installation and repair.
10.2. Before demounting front-edge plate, use special tool to insert into
preserved hole, lift front-edge plate and demount it. Refer to figure 23.
1cover(tiny) 2cover(large) 3Cover hook 4Adjustable support bolt

figure 23 front edge plate
Page 21 of 21
11.
Installation and adjustment of balustrade system
11.1. Balustrades are the combined system for passengers to support by hand
and with handrail for cycle.
11.2. Due to limitation of transportation, whole balustrade system cannot be
assembled with escalator as a whole for shipment (its possible for some
case). The balustrade systems assembly will be carried out in 2 steps:
workshop assembly, commissioning, check, demounting and package as
1st step, the 2nd step will be competed on site, this is a schematised
assembly project. Refer to installation drawing in the appendix.
11.3. Balustrade system composes handrail drive, bracket, handrail, handrail
entry guard, skirt panel, interior profile, and balustrade decking and
upper and lower turn parts.
11.4. Handrail is the moving part in the balustrade for passengers to support
by hand, its moving speed is identical with steps, its speed is required
faster than 0-2.0% of steps, which is achieved through adjustment of
handrail driving parts.
11.5. Balustrade driving system
Refer to figure 24 . It is the driving system of balustrade for recycle.
Figure 24 driving system for balustrade

1.tension blot 2.compression spring 3.pressing chain
4.friction wheel 5.belt 6 blot 7.tension bar 8.anti-loose nut 9.nut
11.5.1. Handrail is driven by friction wheel 4 with rubber wheel hub,
degree of tightness for handrail 5 can be adjusted by nut 8 on the
tension bolt 7, and also pressed tightly by pressing chain, the degree
of tightness depends on pressing bolt 1.
11.5.2. The friction wheel will drive handrail into normal running when
tightness is suitable between handrails and pressing chains, at that
Page 22 of 22
time handrail can not be stopped until by big force of people.

Tightness relies on spring 2. The inclined profile and interior profile
need to be demounted when handle tension bolt 7.Release loose
proof nut 8, and use another nut 9 to adjust tension bolt, dont forget
to refasten loose proof nut 8.
11.5.3. Handrail chain broken safety device is installed in the bottom of
each side of handrail, refer to figure 25, when handrail is too long or
broken, it will touch the bar of safety device, and protection switch
will operate and stop the escalator. When any one of handrail chain
broken, safety switch is cut off, the power will be cut off, therefore
escalator will be stopped.
11.5.4. In the upper and lower entrance of handrail, there are finger
protection safety device (refer to figure 26), when foreign bodies or
childrens finger enter into the entrance of handrail, and touch safety
switch, escalator will be stopped. For the guide pieces of handrail,
when foreign bodies enter the entrance from R direction, baffle will
be moved and guide piece will press to switch 4, i.e., power is cut off
and escalator is stopped. Moving plate can open one distance of
30mm, which will not trap the finger and avoid accident. After solving
the fault, handrail guide piece will reset under the operation of spring
3.
Figure 25 chain broken safety device

1. switch 2.bar 3.balustrade belt
Page 23 of 23
Figure 26 finger protection switch

1. bottom plate 2.guide block 3.spring 4.switch
11.6. Balustrade (refer to figure 27)

11.6.1. Interior panels are made up of tempered glass which is fixed
within glass clamp; handrail guide rail and support are installed on
the upper part of tempered glass.
11.6.2. Balustrades are pre-assembled in the truss in the workshop, as
per different requirement, it can be 2 types of with or without lighting,
tempered glass can be replaced by some other material, which has
sufficient strength.
11.6.3. Tempered glass is main support part of balustrade, which is
installed in the glass clamp with liner. Installation of glass shall be
started from the lower side, it maybe start from the first block of
standard glass (1800mm). And then start to install upper and lower
R section after positioning of first one. And the balance of straight
section will be installed as per order, interleave shall be put between
glasses which led one less than 4 mm gap. There is one
compensatory section glass in each side, they are installed after
installation of straight section. Upper R section glass will be installed
after installation of compensatory section glass. During installation of
glasses, the perpendicular shall be inspected, maximum allowed
deviation is 3mm, and also the distance between the centres of each
glass shall be achieved to ensure the centre distance of handrail.
11.6.4. After installation of glasses of both sides, its time to install
handrail pulley blocks in the handrail turning section, each pulley
shall be very agile without obstacle, which may effect the running of
Page 24 of 24
handrail or cause friction heat etc. Pulley blocks are installed in the
groove of handrail bracket.
11.6.5. Handrail bracket is installed on the glasses, and filled with U type
glass wedge. The connection face of handrail shall be very rigorous
and even without convexes, scratches or other phenomena, which
affect appearance. Thin type must be stuck firstly by use of doubleface glue, and then add some French chalk on it, and finally install
handrail bracket.
with light
without light
Figure 27 Balustrades
1.belt
6ctighten piece
2Belt rail
7Shirting panel
3Belt frame
8 C-part
4a.light cover panel
9 step
4b.light cover panel
10 outer decorating panel
5Toughened glass
11 truss upper bar
6ainner panel
12 vibration protecting mat
6bouter cover panel 13 building surface
Page 25 of 25
slender
11.6.6. Handrail guide rail is the part of direction-guide, installed on the

handrail bracket, the linearity shall be checked, connection face shall
be rigorous and even, angled, and not cause any scathe to the
handrail.
11.6.7. Check all the moving components or pieces related with handrail,
they must be put in right position and turning smoothly which is
required when put handrail into guide rail, and then adjust the
tightness and running condition as per 11.5, the operation speed of
handrail shall be adjusted as per 11.4.
11.6.8. Handrails are power driven by friction, due to big amount of
moving or guiding components, every step shall be checked
carefully to ensure that the running of handrail is normal.
11.7.
Shirting Panel
11.7.1. Shirting panels are installed in the 2 sides of lower part of

balustrade, they are made generally by flowered stainless steel ,one
side gap between shirting panel with steps shall be less than 4mm,
the lump sum of 2 sides gap shall be less than 7mm.
11.7.2. In order to avoid sudries in the gap which affect normal operation
of escalator, especially to avoid the rubber overshoes of passengers
were trapped in the gap between skirt panels and steps, the skirt
panel safety device must be installed(refer to figure 28). The Switch
3 will be on in case of deformation of shirting panel, and stop
escalator.
figure 28
1. shirting plate 2.step 3.switch
11.8. Interior profile and balustrade decking
11.8.1. After normal operation of handrail, install the interior profile first
and finally install balustrade decking
11.8.2. The installation and disassembly of interior profile and balustrade
decking refer to figure 29, move 300mm of interior profile towards
Page 26 of 26
upper machine room and then remove it, the installation shall be as
per reverse order.
Figure 29 inner profile and decking installation

6Ainner panel 6Bouter cover 6Ctighten piece 7Shirting panel
8C-part 9Step 10Outer decoration panel 11Truss upper bar
12Vibration protection mat 13Building surface
12.
Lighting and warning mark of steps

See figure30
12.1. In view of the safety of passengers, green fluorescent lamps are installed
under steps which in level on the upside and downside, in order that
passengers can see the moving steps, avoiding the risk of trapping
between combs and steps when both landings. Once defacing,
displacing in time must be available.
12.2. Yellow markings may be brushed on the sides of the steps, indicating
passengers tread only within the scope of 1(see figure 30-2), not allowed
treading on yellow marking (see 2 in figure30-2).
Page 27 of 27
Green light
Figure 30-1
Figure 30-2
1. safety area
13.
2.yellow edge
Supporting system of escalator
13.1. All parts of escalator are installed on the supporting truss, supplied by
whole unit when the height is not to high and separated unit connecting
by bolts when the height is high, which are wedded by profiled bar.
13.2. Ensuring escalator properly operation, the truss shall be sufficiently rigid
and breakage-resistant, its deflection shall not exceed 1/1000 of the span.
Upper and lower parts are supported on the concrete beam of upper and
lower floor, which shall be fixed after level adjustment. (See figure31)
Figure 31 supporting
1glue
2Screw lock
4Rubber mat
figure 32 middle supporting
3Nylon plate
5.Steel plate
Page 28 of 28
13.3. When rise more than 6m, thus the span and flexibility increased, the
middle supporting must be setting (see figure32). Due to spring in the
middle supporting, it can react stretch supporting on the truss, and adjust
automatically following expansion and contraction of the truss.
13.4. In order to reduce vibration transfer when the truss expanding or contract,
supporting connect is placed between construction and escalator, sliding
between nylon-blocks, under which rubber gasket is plus. The clearance
between construction and construction is sealed with puddle. One side of
it is applied with this supporting connect at least.
14.
Control system and electrical components
14.1. All the control components are placed in the control box located in upper
machine room. The control box can be taken out of machine room after
loosening the bolts in order to be easy to be operated. Refer to figure
33.The operating handle is joined with main switch in view of safety.
When inspecting and maintaining escalator, the control box can be
opened up and maintained only after turning the handle to cut off power
of the main switch. The component with no.2 is inspection outlet placed
for inspecting escalator.
1handle
2socket
3socket
4Light switch
Figure 33 control box

14.2. An intended reversal of direction of escalator can be realized by turning
directional conversion key-switch by operator.
On both upside and downside of skirting, directional conversion key-switch,
which can be turned according to the need of up and down, and emergency
stop button with red placed conspicuous and easily accessible. If occurring
some emergency, escalator shall be stopped immediately by pressing
emergency stop button.
Page 29 of 29
The position of the button
Figure 34 direction control and emergency spot button

14.3. Due to more safety devices placed different parts here and there, once
occurring faults, inspecting in time is necessary to resume properly
operation. In view of the need of customers, one fault indicator is placed
in control box, which can help to save time and obviate fault as soon as
possible. There are two numeral tubes and one fault explain band on the
fault indicator. When the number on numeral tubes is as same as it on
band, it indicates going wrong here, immediately inspecting can be
obtained. After obviating fault, numeral tubes display d0, indicating
properly operation is ok.
15.
Debugging
15.1. Mechanical part debugging

15.1.1. After finishing escalator installation, clearing field, both inside and
outside of escalator is available. Only if every safety device in order,
every rotating parts obtaining enough lubricating, such as traction
machine, driver, transmission system, steps guide rail, chains etc.,
escalator can work. Travelling up and down one week, checking
again if any exceptional thing occurring, then decide whether
escalator can work continuously. During escalator working
continuously, adjusting for operating performance, accelerated
starting, decelerated braking and steady operating is necessary.
15.1.2. All pallet tread shall move into comb smoothly, clearances
between them shall be in accordance with 6.2.4.
15.1.3. Friction between pallet tread and skirting is forbidden; clearances
between them shall be in accordance with 11.7.1. (Excluding the
step guide block)
15.1.4. When two consecutive steps meshing, there shall not be friction.
Page 30 of 30
15.1.5. At rated frequency and at rated voltage, the speed, measured

under no load in the direction of movement of the steps, is permitted
to deviate from the rated speed by a maximum of 5%, the speed in
the direction of movement calculation is then:
V=s/t
Where
v-------speed of up or down movement, m/s;
s-------measured distance, m;
t--------time corresponding the moving up or down distance, s.
15.1.6. Handrail shall move at a speed with tolerance of 0~2% of the
speed of the steps. Accordance with calculation of 15.1.5, the speed
of handrail and pallet under no load are measured individually, each
once both up and down. Then speed tolerance of moving up or down
calculation is then:
v=(v1-v)/v100%
Where
v------speed tolerance from handrail and steps;

V1-------speed of handrail moving up or down, m/s;
V --------speed of steps moving up or down, m/s.
15.1.6.1. The speed of steps is design speed, and the speed of

handrail is adjustable, when the tolerance exceeding 0~2%, adjustment shall be
done according to 11.5.
15.1.7. The stopping distances for downward moving unloaded escalators
shall be between the following values.
Rated speed
Stopping distance
0.45m/s
0.21.00m
0.5m/s
0.21.00m
0.65m/s
0.3m1.3m
0.75m/s
0.351.50m
The stopping distances shall be measured from the time the electric
stopping device is actuated, and be regulated by adjusting of the main
spring of traction machine.
15.1.8. All running part of escalator shall work properly, without friction
and abnormal noise. When working unloaded, operating noise
measured 1.0m on the top of steps and skirting shall not exceed
65db(A).
15.2. Electrical part debugging
15.2.1. At least one person among debugging persons shall understand
all documents taking with equipment.
15.2.2. Debugging persons shall know well about structure, principle and
operating methods.
Page 31 of 31
15.2.3. Debugging persons shall know well about electrical controlling

principle and operating principle of every safety device.
15.2.4. The ability of skilful fault judging, analysing and excluding fault is
available.
15.2.5. Cleaning at the field (machine room upper and down, within and
out of conveyor) will be done well.
15.2.6. When finishing wires connecting, check shall be necessary,
especially of switch of safety circuit.
15.2.7. Installation of mechanical and electrical part shall be in the
condition of operating.
15.2.8. Each of mechanical and electrical part shall have been checked,
tested and adjusted individually.
15.2.9. Trapping, collision and friction shall be impossible on the whole
travelling of steps.
15.2.10.Debugging persons shall be serious, responsible and circumspect;
in addition safety work must be done well strictly.
15.2.11.Following instruments and measures will be needed (in general

condition):
Multi-meter
Tachometer
Megohm-meter
Forcipate current-meter
Decibel-meter
Stopwatch
Tap measure, ruler, vernier caliper, deepness vernier caliper, plug guage
and goniometer and etc.
15.2.12. Protect earthing shall be well.
15.2.13.The insulation capability shall be well, the resistance of the
insulation between conductors, and between conductors and earth,
shall be greater than 1000/V with a minimum of:
a) 0.5M for power circuits and electrical safety device circuits;

b) 0.25M for other circuits (controls, lighting, signaling, etc.)
When measured, electronic components shall be disconnected.
15.2.14.Traveling direction key-switch shall be in accordance with
traveling direction, and emergency stop button shall be reliable on
action.
Page 32 of 32
15.2.15.As per more safety devices of escalator, each safety device shall
be tested, and proved reliable.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
15.2.15.1. Safety devices of escalator are included as following:

Protection device against power supply shut-off and wrong phase;
Protection device against Motor short and overload;
Driving chain protecting device;
Protection device against breaking or over-stretching of chain of steps;
Operational brake (electro-mechanical);
Auxiliary brake (the rise exceeds 6m);
Protection device against risk of over-speed;
Protection device against unintentional reversal of the direction of travel;
Protection device against breaking of handrail;
Protection device at the point of entry into the balustrade;
Trapping of foreign bodies of teeth safety device;
Steps sagging safety device;
Emergency stop button.
15.2.16.After above debugging, general check shall be done in order to
find whether accord with demand, performance function referring to
relevant principle instruction. In case of abnormal, please contact our
related department. Its forbidden to demount PLC or change PLC
program in order to avoid unnecessary losing.
16.
Test Run
16.1. Test run is performed after mechanical and electrical commissioning, its
necessary to make cleaning and lubrication for all related components
before test run
16.2. Check if all the parts are in normal condition, and then make test run,
upward and downward without load for one hour of each, escalator shall
run normally, stably and without noise.
17.
Inspection
17.1. Self check shall be performed after test run, after satisfactory with self
check, inspection report and document for client etc. shall be prepared
and apply for local bureau in charge for acceptance inspection .
18.
Delivery for Use
18.1. Automatic escalator can not be delivered and used until satisfactory
acceptance inspection by local bureau in charge, at the mean time turn
the conveyor to the client. The whole installation is completed.
Page 33 of 33
19.
Installation schedule
P A S S E N G E R C O N V E Y O R IN S T A L L A T IO N S C H E D U L E
Ite m
E ffe c tiv e W o rk in g D a te
D a te
P ro c e d u re
p re p a ra tio n b e fo re in s ta lla tio n

1
m e a su rin g c o n s tru c tio n a g a in
2
liftin g a n d p o s itio n in g
3
le v e l a d ju s tm e n t o n b o th u p sid e a n d d o w n s id e
4
p o w e r in to c o n tro l b o x
5
c le a n in g a ll p a rts a n d lu b ric a tin g
6
p a lle ts c o m m is s io n in g
7
c h e c k in g a n d a d ju s tin g a ll p a rts
8
in s ta llin g b a lu stra d e
9
1 0 d e b u g g in g
1 1 c o m m is sio n in g
1 2 in s p e c tio n
N o te :1 W o rk in g d a te c a lc u la te d a c c o rd in g to th e ris e < 6 m .
2 P ro c e d u re c a n b e a rra n g e d a c c o rd in g to a c tu a l situ a tio n o r to g e th e r.
Page 34 of 34
20.
Installation tools
Item
Tool
Box wrench
Monkey wrench
Spec
Item
Tool
Spec
24
Flat screwdriver
8 10 12
25
Cross screwdriver
Hammer
1.5lb 2lb
26
Electrician knife
Rubber hammer
2lb
27
Long-nose pliers
Hacksaw
Pliers
29
File
8 10
30
Buzzer
Flat files
31
Test pencil
C mould
2 4 6
32
Electric iron
10
Ring clamp
33
Plumb
11
hexagonal
socket wrench
34
Gradienter
12
Flat chisel
35
Goniometer
13
Butter gun
36
Deep
caliper
14
Oil gun
37
Vernier calliper
15
Screw
bracket
M3-M16
38
Plug guage
16
Screw chaser
M3-M16
39
Steel ruler
17
Twist drill
2.5-14
40
Steel tape
18
Tap
M3-M16
41
Decibel-meter
19
Angle polisher
120
42
Stopwatch
20
Handy drill
1.5-6
43
Forcipate current
meter
21
Electric drill
3-13
44
Megohm-meter
22
Torch
45
Tachometer
23
Handy light
46
Multi-meter
28
8mm
10mm
12mm
chaser
~36V
Page 35 of 35
Diagonal cutting
pliers
Connection cover
cutting pliers
vernier
4 6 8
10
21.
High strength bolt installation
21.1. As per the requirement to the high strength bolt used for the connection
of truss:
21.1.1. The installation of high strength bolt and 6 angle nut must use
special instillation tool, and tighten by torque spanner, before fasten
all bolts(screw and support face) must be lubricated by MOSI.
21.1.2. The grade of high strength bolt is (GB/T128-1991)10.9S steel.
21.2. Inspection requirement for pre-tighten force
21.2.1. After proper connection of separated truss sections, it must
perform the test to check if required pre-tighten has been achieved.
A minimum of 2 bolts each connection face shall be selected and
checked, attention, there are some defects if performed like this, its
better to check all the bolts.
21.2.2. It must use one force-measure spanner to tighen 10 degree more
of each nut whether the bolt is tighten or not. We must consider to
overcome direct friction(this is torque-measure)
21.2.3. If the indicator of force-measure spanner shows that required
torque has been already achieved, and also if nut can not be
screwed down any more, we consider that pre-tighten force has
been already achieved.
21.2.4. High strength bolt, screw and middle support section must be
lubricated, rated torque and measured torque are as follows:
Rated torque
Measured torque
M16
280 Nm
310 Nm
M20
490 Nm
540 Nm
300 Nm
320 Nm
M22
730 Nm
800 Nm
22.
Lubrication drawing
23.
Installation drawing of balustrade system
Page 36 of 36

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Installation Manual of Automatic Escalator

Installation Manual of Automatic Escalator

General provisions ................................................................................................3

Preparation before installation..............................................................................7

Measurement for the construction dimension.........................................................7

Lifting, transportation, assembly and positioning ..................................................9

Check and adjustment for the driving system ....................................................... 13

Check and adjustment for the step ....................................................................... 16

The adjustment and test of comb.......................................................................... 19

Disassembly of step refer to figure 21.................................................................. 20

Deflection protection of step................................................................................ 20

Front edge plate .............................................................................................. 21

Installation and adjustment of balustrade system ............................................. 22

Lighting and warning mark of steps................................................................. 27

Supporting system of escalator ........................................................................ 28

Control system and electrical components ....................................................... 29

Test Run .......................................................................................................... 33

Delivery for Use .............................................................................................. 33

High strength bolt installation ......................................................................... 36

Lubrication drawing ........................................................................................ 36

Installation drawing of balustrade system........................................................ 36

Installation Manual of Automatic Escalator

This manual is applied for the installation of escalator .

The installation method applied in this manual is general method, please

Installation Manual of Automatic Escalator

Level adjustment on the upside

Level adjustment on the downside

Power into control box

Cleaning each part and lubricating

Steps test run

Checking traction machine driving system

Checking the rail system

Checking tension of the chains for the steps

Installing the balustrades

Installation Manual of Automatic Escalator

Handrail test run

Checking tension of the handrail

Installing the front-edge plate on upside and

Installing and checking steps

Checking the safety device

Adjusting speed between handrail and steps

Adjusting mesh between steps and comb

Adjusting clearance between steps and skirting

Adjusting the stopping distances unloaded

Installation Manual of Automatic Escalator

Adjusting the stopping distances loaded

Available for each safety device

Checking insulation capability

Checking safety device

Cleaning and lubricating again

Moving one hour for each downward and upward

Self-checking for installation

Turn over for use

Figure1 installation procedure of escalator

Installation Manual of Automatic Escalator

The commissioning after installation should be performed by skilled

The electrical system should be assembled and commissioned before

Preparation before installation

2.1. Installation personnel

Gas cutting and welding must be performed by qualified personnel, and

Measurement for the construction dimension

Installation Manual of Automatic Escalator

The recheck of the constructing dimension must be completed before the

The rising height of H must be rechecked strictly as per the installation

ESC&AWK Installation Manual

ESC&AWK Installation Manual