Unit 5 - Escalator Technology - Steps PDF

Unit 5 - Escalator Technology - Steps A Escalator Step When looking up the escalator, you are facing the front of the step. The length of the step is measured from both ends of the step tread (front and rear) and the width is from both sides of the step. The step frames, tread...

Unit 5 - Escalator Technology - Steps A Escalator Step When looking up the escalator, you are facing the front of the step. The length of the step is measured from both ends of the step tread (front and rear) and the width is from both sides of the step. The step frames, treads, and riser excluding their attachment or inserts (demarcations) are a die-cast aluminum design and form the Step Unit Assembly. The Step Unit Assembly is preassembled before it is installed in the escalator truss. This design allows for step removal without disturbing the balustrades or disassembling any part of the chains. The steps are the interconnecting members of both step chains. Step Demarcation Line Step Plate Step Riser Axle Slot Frame Yoke Step Wheel Fig 1 - Step Standard Escalator Step Width Size Step Capacity Applications Low volume and space is Small 600 mm One passenger limited. Shopping malls, One passenger plus departmental stores. Medium 800 mm one package or one Cater to low/normal piece of luggage. traffic. Large airports, train Two passengers; one stations and some retail Large 1000 mm may walk past another. usage. Cater for heavy traffic. Escalator Technology – Unit 3 1 Unit 5 - Escalator Technology - Steps Depth y1 Height x1 Width z1 Fig 2 - Step According to SS626:2017, the step height x1 shall not exceed 0.24m. If escalators are permitted to use as an emergency exit when out of service, the step height shall not exceed 0.21m. The step depth y1 shall not be less than 0.38m. For escalator and passenger conveyors the nominal width z1 shall be not less than 0.58m and not exceed 1.10m. For passenger conveyors with an angle of inclination up to and including 6º, larger widths are permitted. The step construction does not have to correspond to the drawing, only the indicated dimensions have to be observed. A-1 Checking and Inspection of Escalator Steps All the checking and inspection are conducted with the power supply switched off.  Condition and alignment of step and step riser.  Step rollers and wheels condition and lubrication.  Step run-in (or cleat) guide condition and lubrication.  Stand on steps and check the play of the steps in both the direction of and perpendicular to the direction of travel. Escalator Technology – Unit 3 2 Unit 5 - Escalator Technology - Steps A-2 Operational Test The operational test is conduct with the escalator running continuously in the up and down direction. Inspect, observe and note any defects including abnormal noise and vibrations.  Note the smoothness and quietness of the ride.  Check the step alignment, clearance to skirting and note any step skew.  Check rubbing of step roller’s side with the track. B Calculation - Example Consider an escalator travel at a standard 0.5 m/sec on a standard 30° incline and is 10 m along the incline. An escalator step is 1 m wide and 0.4 m depth from front to back so a fresh step rolls out at the top of the escalator (a) Calculate the height in the vertical plane? H = (sin 30) x 10 = 5 m in the vertical plane (b) Calculate how many second a fresh step is roll out at the top of the escalator? 0.4 m / 0.5 m/sec = (0.8m/sec) per step (c) If every step carries one person, calculate the maximum capacity of the escalator in an hour? (3600 sec/hr) / (0.8 m/sec) per step = 4,500 people (d) If 30 people would take 20 seconds to rise a height in the vertical plane and the average person has a mass of 80 kg, calculate the power required to lift 30 people where g is the acceleration due to gravity = 9.81? Power = (mass x g x {height x people}) / time = (80 x 9.81 x {5 x 30}) / 20 = 5,886 W = 5,886 / 1000 = 5.89 kW. Escalator Technology – Unit 3 3 Unit 5 - Escalator Technology - Steps C Escalator Step Dismantling Much of the escalator maintenance works are done in the inner part of the escalator. As such, the following procedures must be observed at all times during testing and maintenance.  Never switch ON the escalator when somebody is standing on it.  Both upper and lower machinery pits area must be barricaded before commencing of any work.  Always switch on the maintenance control and operate the escalator with the maintenance button when the steps have been removed for inspection purposes.  For proper and complete inspection of escalator, a minimum of at least 3 consecutive steps must be removed.  Never reverse the direction of the escalator by means of the key switches or maintenance buttons until the steps have come to a standstill.  Ensure that sufficient level of lighting is available at all times while inspecting and testing on the escalator. An inspection lamp with proper extension cord shall be available at all times. C-1 Escalator Steps Dismantling and Assembly Procedures Step Removal and Fixing 1. Wear the proper Personal Protection Equipment (PPE) 2. Barricade the UPPER and LOWER PLATFORM area of the escalator and place an ‘Under Maintenance’ signage. Escalator Technology – Unit 3 4 Unit 5 - Escalator Technology - Steps 3. Remove the FLOOR PLATE on the lower side of the escalator. Eye Bolt 4. Remove the screw on the floor plate and replace it with an EYE BOLT to lift the floor plate. 5. Do note down the sequence how the floor plate is removed so that they can be placed back easily after work. Floor Plate Escalator Technology – Unit 3 5 Unit 5 - Escalator Technology - Steps 6. Before you enter into the pit, activate the E-STOP switch and connect the remote control on the inspection jack E-Stop Inspection Jack 7. Plug in the Remote Control on the inspection jack on the pit control box. Remote Control 8. Enter into the pit and switch ON the light Screw Rod Toe Guard or Apron Escalator Technology – Unit 3 6 Unit 5 - Escalator Technology - Steps 9. Inside the escalator pit, remove the TOE GUARD or APRON which protects the workers working in the escalator pit from the moving steps. 10. Use a correct size Philip screwdriver to remove the screw and place them in somewhere that has no issue of losing them. 11. Remove the rod. 12. Deactivate the E-STOP Switch on the pit control box. E-Stop 13. Check that all the SAFETY SWITCHES are not activated. Safety Switch 14. Shout ‘Up’ or ‘Down’ before moving the escalator using the remote control. Check and alert everybody before moving the escalator. Escalator Technology – Unit 3 7 Unit 5 - Escalator Technology - Steps 15. Before using the remote control, ensure you deactivate the E-Stop of the pit control box and run either direction and bring the step to be removed at a comfortable level. Comfortable Level 16. Once comfortable position is reached, activate the E-STOP Switch of the remote control and control box. 17. Total isolation must be done for safety before continues the dismantling work. 18. Loosen the two Allen Screws located on each end of the axle. Allen Screw Escalator Technology – Unit 3 8 Unit 5 - Escalator Technology - Steps 19. Shift the each Bush Retainers away by tapping it away from the axle slot with soft mallet or hammer plus a plunger on both side. AXLE SLOT BUSH RETAINER 20. Before the bush retainers of both side are fully out of the axle slot of the step, remember to hold the step to prevent it from falling out suddenly. Step is out of the axle 21. Tilt the step slightly at an angle before it can be slide out from its runway. To remove the roller from the runway, take out one roller first, tilt slightly and slide out the second roller to remove. Open slot on the curve track Escalator Technology – Unit 3 9 Unit 5 - Escalator Technology - Steps 22. Remove the step and stack them in proper order. Carry out the next removal of step unit by repeating from 12 to 21 once more. Second step First step Escalator Technology – Unit 3 10 Unit 5 - Escalator Technology - Steps Replacing the Step Roller 1. Once the step is removed from the escalator, we will arrange them in proper order so that they can be replaced in sequence. Second step First step 2. Position the STEP to expose the STEP ROLLERS. Step Roller 3. Select the proper tool to remove the Bearing Retaining Screw. Proper tool – Hexagonal Key Escalator Technology – Unit 3 11 Unit 5 - Escalator Technology - Steps 4. Place the Hexagonal Key onto the Bearing Retaining Screw. Hexagonal Key Bearing Retaining Screw 5. Remove Bearing Retaining Screw and place it in a suitable location so that you will not lose it. Bearing Retaining Screw Escalator Technology – Unit 3 12 Unit 5 - Escalator Technology - Steps 6. Removed the old roller and fix a brand new roller. Hexagonal New Step Key roller 7. Place back the STEP and get ready for fixing back. Fixing the Step 1. Check that the E-STOP Switch on the pit control box and remote control are activated to prevent running of the escalator. E-Stop Switch Escalator Technology – Unit 3 13 Unit 5 - Escalator Technology - Steps 2. Access into the escalator pit. 3. Slide down one side of the step roller into the opening on the curve track and insert the other side of the step roller in position. 4. Insert the bush retainers into the axle slot Escalator Technology – Unit 3 14 Unit 5 - Escalator Technology - Steps 5. Align the step in the centre by measuring the gap from both side of the rollers to the edge gap. 6. Move the Bush Retainers and tighten the Allen Screw so that the bush won’t come out. 7. Check by hand that both the BUSH RETAINER and ALLEN SCREW are snugly in position. Escalator Technology – Unit 3 15 Unit 5 - Escalator Technology - Steps 8. Deactivate the E-STOP Switch. 9. Run the escalator for few rounds to observe for any abnormal noise and vibration. This is to further ensure that the step is fixed properly. 10. Continue to replace another step with the same procedure. 11. Once all the steps are replaced, turn selector switch to ‘Normal’ operation 12. Place back the rod and toe guard or apron 13. Switch off the light before you are out of the pit. 14. Place back the platform cover and ensure it is secured. 15. After place back the platform cover, run the escalator with Key Switch in ‘Normal’ operation to make sure everything is in working order. 16. Remove the barricade. 17. Perform housekeeping of the area of work. Escalator Technology – Unit 3 16