COMPLETE LIFTS

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MistRaL MRL

MistRaL 630

INSTALLATION INSTRUCTIONS

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INSTALLATION MANUAL

MistRaL MRL

1. SUPPORTING BEAM
23
22 2. BEAMS BRACKETS
21
1 3. CAR SLING GUIDE RAILS 896216
2 20
4. COUNTER WEIGHT GUIDE RAIL 50505
3
5. COUNTER WEIGHTS ROPE ATTACHEMENT
4
6. COUNTER WEIGHT FRAME
19
7. COUNTER WEIGHT FILLERS
18
5 8. RIGID SCREEN

6 9. BUFFER
17 10. OIL COLLECTOR
11. CAR SLING BUFFER SUPPORT
12. OVER SPEED GOVERNOR ROPE TENSION DEVICE
7
13. COUNTER WEIGHT BUFFER SUPPORT
14. CAR FRAMES ROPES ATTACHMENT
16
15. GUIDE BRACKET
16. LOAD MEASURING DEVICE
15
MECHANICAL EMERGENCY RELEASE SYSTEM
17.
(MANOEUVRE)
18. LANDING DOOR
19. CONTROLLER CABINET

8
14 20. BRAKE RESISTANCE
21. INVERTER CABINET
22. TRACTION SHEAVE
23. MACHINE

10

11

12 13

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TABLE OF CONTENTS

TABLE OF CONTENTS ...2

1 FOREWORD............................................................................................................................................. 4

2 GENERAL DATA...................................................................................................................................... 4

3 INSTALLATION........................................................................................................................................ 5
3.1 INSTALLATION OF DOORS IN THE SHAFT ................................................................................... 5
3.2 INSTALLATION OF GUIDE RAIL BRACKETS ................................................................................. 7
3.3 INSTALLATION OF GUIDE RAILS BASE PLATE (OPTIONAL) ...................................................... 9
3.4 INSTALLATION OF GUIDE RAILS ................................................................................................. 10
3.5 INSTALLATION OF TRACTION MACHINE .................................................................................... 12
3.6 INSTALLATION OF BUFFERS FOR CAR FRAME AND COUNTERWEIGHT FRAME................. 21
3.7 INSTALLATION OF COUNTERWEIGHTS FRAME ....................................................................... 22
3.8 INSTALLATION OF CAR FRAME ................................................................................................... 23
3.9 INSTALLATION OF CAR FRAMES UPPER JOINING BEAM ....................................................... 24
3.10 PROJECTION ASSEMBLY ............................................................................................................. 25
3.11 FIXING THE FRONT JOINING BEAM, ON THE CAR FRAMES PROJECTION........................... 26
3.12 ASSEMBLY OF SAFETY GEARS TRIPPING SYSTEM................................................................. 27
3.13 INSTALLATION OF CARS LIFTING BEAM-SPEED GOVERNOR-BUFFERS PLATE ................ 28
3.14 CONNECTING SPEED GOVERNOR TO SAFETY GEARS TRIPPING SYSTEM........................ 29
3.15 INSTALLING CARS FRAME BUTTRESSES ................................................................................. 30
3.16 INSTALLATION OF ROPES ATTACHMENTS ............................................................................... 31
3.17 INSTALLATION OF CARS FRAME CAM....................................................................................... 32
3.18 DETERMINATION OF WIRE ROPES LENGTH ............................................................................ 33
3.19 INSTALLATION OF ELECTRONIC OVERLOAD............................................................................ 34
3.20 INSTALLATION OF SPEED GOVERNORS ROPE AND TENSION DEVICES ............................. 35
3.21 FIXING OF THE CAR PLATFORM ................................................................................................. 36
4 MAINTENANCE...................................................................................................................................... 37
4.1 TRACTION ROPES AND HITCHES ............................................................................................... 37
4.2 BRAKE............................................................................................................................................. 37
4.3 SPEED GOVERNOR....................................................................................................................... 37
4.4 BUFFERS ........................................................................................................................................ 38
4.5 ALARM DEVICE AND EMERGENCY STOPS................................................................................ 38
4.6 CAR AND ACCESS TO THE CAR .................................................................................................. 38
4.7 COUNTERWEIGHT INSPECTION.................................................................................................. 39
4.8 ELECTRIC SAFETY CIRCUITS ...................................................................................................... 39
4.9 SIGNALING OR OPERATIONS ...................................................................................................... 39
4.10 SHAFT ............................................................................................................................................. 40
4.11 GUIDES ........................................................................................................................................... 40
4.12 MAINTENANCE OF GEARBOX...................................................................................................... 41
5 INSTRUCTIONS INSTALLING EMERGENCY RELEASE BASE INSIDE THE CONTROL CABINET 42

6 INSTRUCTIONS FOR INSTALLING DIVIDING PLATE INSIDE THE CONTROL CABINET .............. 43
7 EMERGENCY RELEASE INSTRUCTIONS FOR THE LIFT USER ...................................................... 44

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1 FOREWORD
1.1 This handbook is intended to assist the lift engineer during the installation, use and maintenance of the lift,
to let the engineer know how to correctly install and service the lift complying with the technical requirements
demanded by the Lit Rules.

1.2 The handbook will chronologically follow all operations, starting from the preliminary inspection at the site to
the operational tests and finally to the programmed maintenance works. It is divided into three main sections:
installation use and maintenance.

1.3 he lift owner is responsible for ensuring the pursuance of the Law Rules and of the operational standards
contained in this handbook.

All information contained in this handbook is the property of KLEEMANN; and it is forbidden to divulge or
to copy, even in part, this information without the written authority of KLEEMANN.
It is forbidden to use this handbook for purposes not strictly related to the installation, use and
maintenance of the lift.

This handbook must be considered as an integral part of the lift, it must be kept in good condition and in a
locked location next to the control panel.

For the sake of product safety, modifications and/or the use of spare parts not purchased from
KLEEMANN should be avoided.

KLEEMANN accepts no responsibility for any operation work not in compliance with the instructions
contained in this handbook.

KLEEMANN reserves the right to make any modifications it retains necessary at any time.

2 GENERAL DATA
2.1 MistRaL MRL is a traction lift WITHOUT MACHINE ROOM, with EC type test certificate issued by TUV
SUDDEUTSCHLAND, designed for buildings up to 45m lift travel, having a pay load ranging from 450Kg up to
630Kg at a speed up to 1,0 m/s.
2.2 The car and landing doors are power operated, central or side opening, ranging from 700 and 900mm clear
width or semi automatic landing doors with automatic folding cabin doors, according to the type.

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3 INSTALLATION
3.1 INSTALLATION OF DOORS IN THE SHAFT
At first the centerline of all landing doors needs to be located. A plumb line must be used (suspended from
the last landing) in order to determine the exact position of landing doors.

A B

= =
= =

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For more details please refer

to doors installation manuals
that can be found inside the
packaging.
Doors can be either side or
central opening.

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3.2 INSTALLATION OF GUIDE RAIL BRACKETS

Afterwards we describe an indicating assembly method of MistRaLs mechanical parts. The dimensions
L1, A, L2, for each order seperately, are given from KLEEMANNs Technical Department.

Indicating dimensions: L1=200 mm

Max A=2000 mm

L2=1325 mm

In case you are going to use a scaffold install it as in the drawing below.
L2

headroom
A
A

Shaft Width
Car Travel

200 350
200
A

Shaft Depth
200
A

pit

Scaffold Plan
L1

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For easier installation use only a wall bracket to make holes in the wall, fix the metallic wads and replace
the wall bracket with a fully assembly bracket. Pay attention so as to use washers where the holes are oval
shaped.

In situations where the shaft walls exceed normal tolerances and there may be a problem with the
alignment of the guide rails, the bracket sets may be provided with fillers which are placed between the bracket
back and the shaft wall (see above figure). It should be noted that these fillers are optional and that 2 fillers of
thickness 4mm and one piece of 2mm are provided per bracket set (total thickness 10mm).

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3.3 INSTALLATION OF GUIDE RAILS BASE PLATE (OPTIONAL)

This option is offered in order to avoid

drilling the pit floor to secure the buffer
supports and the overspeed governors
tensioning device.

First, place the base plate at the

bottom of the pit. Then, place the first pair of
guides as explained in the next paragraph.
Fasten the plate onto the guides using the
base plates brackets (common for both the car
guides and for the counterweight guides).
Next, assemble the base for the tensioning
device and in the end assemble the buffer
supports as shown in the figure.

When the pit depth is bigger than

1500mm, an extra support for the car slings
buffer support is provided. The support is
fastened with clips on the main rails as shown
in the drawing.

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3.4 INSTALLATION OF GUIDE RAILS

Put the cut guides last in the top of the shaft. Pay attention if they are male or female and that they must
touch the floor, unless a guide rails base plate is used. Distances of the first and the last bracket are:

Without guide rails base plate With guide rails base plate
st
Distance of 1 bracket from floor 200 mm 600mm
Distance of last bracket from top of well 1325 mm

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Once plumb lines are set and the guides are installed, brackets for aligning the guide rails (jigs), are used
in order to establish that the DBG distance is steady and equal to 1000 mm throughout the well. Two sets of
brackets are given.

Place the bracket the way shown in the next figure at the
bottom end of a guide. Make sure there is no gap between the
bracket and the guide. Using the magnetic level, which is also
provided, make sure that the bracket is horizontal. Repeat the
procedure at the top end of the same guide. Then, we can make the
proper corrections that may be needed. The same must be done at
all guides.

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3.5 INSTALLATION OF TRACTION MACHINE

3.5.1 Installation of brackets to headroom

In order to install the traction machine we use the free space left at the top of the shaft after the guide rails
installation.

Shaft Width Two different mounts

need to be fixed. These are
fixed on the concrete shaft
walls using special 12x120
min 1000
expansion bolts that are
supplied along with the
max 160

mounts. Dimensions L1, L2,

L5
L3

L3, L4, L5, and L6 for each

L4

L6
order seperately, are given
Lifting Beam/Hook from KLEEMANNs Technical

Headroom
max Load 800Kg
Department

Attention: The mounts

175 are not positioned at the
same height.

Shaft Depth

Lifting Beam/Hook
max Load 800Kg
max 160
L1

168 L2
Headroom

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3.5.2 Installation of motor and pushcart

To install the motor the following steps can be followed:

Place the main crossbeam to the side of the brackets leaving a minimum space of 650 mm for the motor
to pass through. Secure it using bolts.

Shaft Width

min 650

Remove the last part of the scaffold and create a level as it is indicated in the drawing
min 800

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Move the traction machine and all items concerning the pushcart to the top landing. Assembly the
pushcart as indicated in the drawing. The assembly must be done at the top landing, otherwise the scaffold will
disrupt the pushcarts lifting procedure. Place the machine on the pushcart and secure it using clips.

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Shaft Width

min 100
Shaft Depth

Lift the motor directly through the scaffold and place it on the top of the pushcart as it is indicated in the
above drawings.

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Place the motor in position making adjustments with the nuts of the upper part of the pushcart. When the
motor is in place move the main cross beam under the motor base, place all the necessary bolts and remove the
pushcart from the shaft.

NUT ADJUSTING THE NUT ADJUSTING

MACHINE IN CROSS AXIS THE MACHINE IN
LONGITUDINAL AXIS

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800

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Isolation between motor base and brackets is provided and is placed as follows:

Fasten the nuts until the rubbers are compressed; the rubber of 15mm must be compressed to 12mm and
the rubber of 8mm must be compressed to 5mm. Secure the system placing a second nut in every bolt.

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3.5.3 Installation of brackets in case of pockets

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3.6 INSTALLATION OF BUFFERS FOR CAR FRAME AND COUNTERWEIGHT FRAME

Shaft Width

280

380

dbg=400
Shaft Depth

DBG=1000
Installation with the guide rails
placed in the right side of the shaft
58

338
470

Shaft Width

280
380
dbg=400

Shaft Depth

Installation with the guide rails

DBG=1000

placed in the left side of the shaft

58
364

470

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3.7 INSTALLATION OF COUNTERWEIGHTS FRAME

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3.8 INSTALLATION OF CAR FRAME

3.8.1 SIDE BEAMS

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3.9 INSTALLATION OF CAR FRAMES UPPER JOINING BEAM

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3.10 PROJECTION ASSEMBLY

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3.11 FIXING THE FRONT JOINING BEAM, ON THE CAR FRAMES PROJECTION

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3.12 ASSEMBLY OF SAFETY GEARS TRIPPING SYSTEM

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3.13 INSTALLATION OF CARS LIFTING BEAM-SPEED GOVERNOR-BUFFERS PLATE

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3.14 CONNECTING SPEED GOVERNOR TO SAFETY GEARS TRIPPING SYSTEM

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3.15 INSTALLING CARS FRAME BUTTRESSES

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3.16 INSTALLATION OF ROPES ATTACHMENTS

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3.17 INSTALLATION OF CARS FRAME CAM

Always the cars frame cam is installed opposite to the cars frame lifting beam.

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3.18 DETERMINATION OF WIRE ROPES LENGTH

Bring the counterweights frame to such a position so as to barely touch (not full contact) the elastic buffer
Lift the car frame up and level it with the highest landings floor. Fix the rope sockets on the car frame.

LOWER LEVEL

0
max 100

0
UPPER LEVEL
0

max 100

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3.19 INSTALLATION OF ELECTRONIC OVERLOAD

In order to avoid overloading the lift with more passangers than permitted, an electronic overload device is
installed on the wire ropes (Micelect ILC2 T3 / 10mm). It is positioned behind the slings upper joinong beam, as
shown bellow. A quick installation guide of the device is given with the dosier which is given with the product.

ELECTRONIC
OVERLOAD

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3.20 INSTALLATION OF SPEED GOVERNORS ROPE AND TENSION DEVICES

dbg=400

dbg=400
DBG=1000

DBG=1000
364

338

470 470

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3.21 FIXING OF THE CAR PLATFORM

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4 MAINTENANCE
4.1 TRACTION ROPES AND HITCHES

The following examinations and tests are to be carried out on the traction ropes and traction rope hitches
during the commissioning and maintenance inspections.

4.1.1 Upon commissioning as well as in periodic inspections, check the state of the ropes in their entirety. To do
so, count the fractured wires.

A fractured cord or its wire equivalent, in a one-meter length of rope, requires that all the ropes be
replaced. In order to find fractured threads, pass a cotton rag along the rope. Threads fractured due to wear
(abrasion) must be detected visually.

4.1.2 Check the state of the counterweight and car hitches; in particular, check that the nuts of the rope hitches
are securely fastened.
4.1.3 Check the lubrication of the ropes. Make sure that the grease on the rope does not impede its inspection.

4.2 BRAKE
The following examinations and tests are to be carried out on the machine and brake during the
commissioning and maintenance inspections.

4.2.1 Check the wear of the grooves in the sheave.

If the ropes slide excessively, causing an imprecise landing, replace the sheave.

4.2.2 Check the wear of the break lining: the lining should be replaced before there is metal contact between
the brake shoes and the brake drum. The lining should be fire proof.

4.2.3 Check that the adjustment screws and nuts, the brake shoes and drum do not show any signs of wear or
corrosion, which might cause a malfunction.

4.2.4 Check that the brake springs are free from corrosion, fractures and fractured spires and do not run the risk
of coming out of their seats.

4.2.5 There should not be any oil between the surfaces of the brake, or on the brake shoe or the brake drum.

4.2.6 The machine and the brake should be checked every three months.

4.3 SPEED GOVERNOR

The following examinations and tests are to be carried out on the speed governor during the
commissioning and maintenance inspections.

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4.3.1 Check that the speed governor functions reliably and safely. The bearings should be checked and
lubricated every year.

4.3.2 Check that the rope of the tension devices remains tense and that the slack rope switch works properly.

4.3.3 Check that there is no excessive lengthening of the governor rope, which might trigger the safety contact
in the tension device. If there is, shorten the rope.

4.3.4 Check that the threads of the governor rope are not damaged. If they are, replace the rope. One way to
check their state is to see if there is a fractured cord, or its wire equivalent, in one meter of rope. In order
to detect fractured cords or threads, pass a cotton rag along the rope. Occasionally, there may be threads
fractured because of wear (abrasion), which must be detected visually.

4.3.5 Check frequently that the over speed contact (governor contact) works properly.

4.3.6 Check the ropes hitches and the pulley groove. Clean them of any particles to ensure the correct
operation of the governor.

4.4 BUFFERS
The following examinations and tests are to be carried out on the buffers during maintenance inspections.

4.4.1 Check that there are buffers, and check their state.

4.5 ALARM DEVICE AND EMERGENCY STOPS

The following examinations and tests are to be carried out on the alarm device during maintenance
inspections.
4.5.1 Check that it works, and that it can be heard from outside.

4.5.2 Check that all of the alarm, emergency and rescue systems of the lift work properly (emergency lights,
telephone, etc.)

4.6 CAR AND ACCESS TO THE CAR

The following examinations and tests are to be carried out on the car and access to the car during
maintenance inspections.

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4.6.1 Check the general state of the car and its frame.

4.6.2 Check that the car is lit at all times

4.6.3 Check that the stops switch on the car roof works properly.

4.6.4 The distance between the car and the landing door must not exceed 20 mm, except with simultaneous
automatic doors, where it can be up to 30mm.

4.6.5 Check that the car and the landing doors have toe guards.

4.6.6 If the lift has a car door, check that the lift does not start if the door is open and that, once started, it stops
when the door opens.

4.6.7 If the lift has a car door, check that it opens freely and that it is sensitive to obstacles.

4.6.8 If the lift has a car door, check the door contact closing.

4.6.9 If the lift has a car door, check that the panels slide correctly and check the state of the guide shoes. If
they are worn replace them.

4.6.10 Check that the there is a load plate inside the car.

4.6.11 Check that the floor call buttons, as well as the car pushbuttons (floor selection, door-open) work properly.
4.6.12 Check the correct operation of the two-way means of communication (car outside)

4.7 COUNTERWEIGHT INSPECTION

The following examinations and tests are to be carried out on the counter weight during maintenance
inspections.

4.7.1 Check the state of the counterweight frame, especially the nuts, locknuts, guide shoe supports, etc.

4.7.2 Check the rope clamps, nuts, locknuts and safety pins of the rope sockets.

4.8 ELECTRIC SAFETY CIRCUITS

The following examinations and tests are to be carried out on the electric safety circuits during
maintenance checks.

4.8.1 Check that the ground wires that join the door frames, locks, motors casing, and controller box are in good
working order and are connected to a ground or to the metal guides.

4.8.2 Check that a grounding of the safety circuit conductors causes the lift to stop.

4.8.3 Check the good working order of all the safety devices. Make sure that they cause the lift to stop
completely.

4.8.4 Check the good working of the rescue systems, if the lift has them.

4.8.5 If necessary, check the currents and voltages.

4.9 SIGNALING OR OPERATIONS

The following examinations and tests are to be carried out on the signaling or operations that affect safety
during maintenance inspections.

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4.9.1 In the case of closed shafts with blind, non-automatic landing doors, there should be a light to indicate that
the car is on the other side of the door. Check that this light works on every floor.

4.9.2 Check that the delay works, so that priority is given to calls from inside the car over calls from outside.

4.9.3 Check that final limit switches, different from those that cause the normal stop on the end floors, cause the
final safety stop at the ends of the travel.

Check that the final safety switches work properly, and that the car fits in the guides in such a way that its
movement is not hindered.

Check that the car is properly leveled on all the floors, whether empty or with a maximum load.

4.9.4 Check the state of the relays and contactors, and check how they react if a phase fails or if phases are
reserved.

4.10 SHAFT

The following examinations and tests are to be carried out on the shaft during maintenance inspections.

4.10.1 Check that there are no water leaks in the pit or combustible substances that might cause a malfunction of
the lift. Ensure that the pit is clean, dry and free from waste.

4.10.2 The shaft, lift and pit should have enough artificial lighting to perform the inspection properly: check that
the system works.

4.10.3 Check that the pushbutton panel (car roof) works properly and that the lift does not respond to calls from
the floors or from the inside of the car when the revision control device is on.

4.11 GUIDES

The following examinations and tests are to be carried out on the guides during maintenance inspections.

4.11.1 Check the state of the car and counterweight guides, and their stability. Check any possible DBG
variation.
Check the oil level of the automatic greasers and refill if necessary.

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4.12 MAINTENANCE OF GEARBOX

SW 1600
In case of maintenance of gearbox move the car to the top
min 1000
leaving a clear opening in the door of min 800 mm height.

In this position the car must be locked for safety reasons. For
665

775
815
max 160

this purpose the safety bracket must be placed on the main guide rail

1150
440 285
Lifting Beam/Hook
using eight bolts M12 DIN 933 and drilling the guide rail in a position as
min Load 800Kg
it is indicated in the safety bracket (in this position safety chain is cut).
175
To reach the motor use the ladder which is stored in the headroom.

After the maintenance of the gearbox safety axis must not be

interlocked with the safety bracket and the ladder must be stored on its
position.

safety bracket

safety bracket

clear opening
min 800

car door
290

operator
935-65
0
-65
935+0
910

safety axis

last floor level

last floor level

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5 Instructions installing emergency release base inside the control cabinet

The manual emergency release base (assembled with the motor) must be placed in the bottom part of the
control cabinet. The base includes 3 cables, one for interlocking the gears, one for moving the car and one for
releasing the brake. First, remove the cables from the base, place the base in its position using five bolts M6, pass
the ropes from the top of the controller through the openings, and finally connect them to the base.

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6 Instructions for installing dividing plate inside the control cabinet

As soon as the installation of the controller and the manual release system is complete the dividing plate
must be placed. As shown in the drawings, the plate is supported on one side at the manual release system using
a M5 bolt, and on the other side a two-sided tape is used to adhere it to the side of the cabinet.

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7 Emergency release instructions for the lift user

In case of power supply cut-off and passengers being trapped in the lift car please follow the emergency
release procedure instructed below:

1. Ensure that: a) all persons inside the lift car are secure, b) all of the lift landing doors are closed and
locked (this can be done by visual inspection).

2. Report the incident to the responsible for the lift maintenance and ask for the immediate expedition of
authorized personnel on site.

3. Turn off the three-phase mains switch of the lift power supply.

4. Locate the three LEDs situated in the floor controller cabinet: i) the LEVEL INDICATION led, lights
when the cabin door is inside the door unlocking zone, ii) the GEARS ENGAGED led, lights when the gears of
the manual emergency manouvre are engaged and iii) the SAFETY CHAIN CUT OFF led, lights in any case that
the lift safety chain is cut off.

5. Locate the engaging knob in the manual

emergency manouvre system. Turn this knob towards
the direction indicated on it to engage the gears until the
GEARS ENGAGED led lights and no further turning
of the knob is possible.

6. Place the crank supplied with the floor

controller in the point shown below.

7. Pull the safety pin located on the brake

release wheel and pull the crank lever to manually
release the brakes of the machine. While holding the
lever with one hand, turn the crank with the other hand
towards the easier to handle direction. By releasing the
lever, the brakes of the machine are activated again and
the car immediately stops moving. Finish the process
when the led LEVEL INDICATION lights, indicating
that the cabin has already entered the door unlocking
zone, meaning the lift door can open and the trapped
passengers can now evacuate the lift cabin safely.

8. From the top floor, open the landing door

using the safe triangle key and check very carefully in
which floor the car has reached. Secure again the
opened landing door and the control cabinet. Unlock the
landing door of the floor that the car has reached and
evacuate the trapped passengers.

9. In case that you failed to evacuate the

trapped persons inform the lift maintenance responsible
and wait for the authorized personnel to arrive.

10. Before leaving the lift ensure that all landing

doors are closed and locked and the three-phase power
supply switch of the lift is in the switched-off position.

VERSION 5.01/2005