Installation and Debugging of Hydraulic Elevators

Hydraulic elevators are widely used in the industrial and commercial sectors, undertaking the important task of vertical cargo transportation. The two most important parts of a hydraulic elevator are the mechanical structure and the electrical control system. The mechanical structure is like the body, and the electrical control system is the soul of the hydraulic system. The power source of a hydraulic elevator consists of a power main controller and a hydraulic system. The correct installation and precise debugging of its circuit and hydraulic system play a decisive role in the safe and efficient operation of the cargo lift.

Main Controller Installation:

1.Install the main controller in a dry, well-ventilated location that is convenient for operation and maintenance. Fix the main controller to the wall or a special support with expansion bolts to ensure it is firm and does not shake.   

2.Internal Inspection: Check whether the wiring terminals are tightened. If they are loose, retighten them.

3.Power Supply Connection: Connect the three-phase power supply to ensure the correct phase sequence. Use a multimeter to measure the power supply voltage, which should be within the rated voltage range of the cargo lift. Firmly connect the power cord to the power input terminal of the control cabinet and provide good insulation protection.

Sensor Installation:

Install limit switches on the guide rails of the cargo lift. The limit switches are used to control the accurate leveling of the cargo lift on each floor. The installation position should be precisely adjusted according to the leveling height of each floor to ensure that the sensing distance is within the specified range. The limit switch is installed at the upper limit position of the guide rail to prevent the cargo lift from running over the limit. It should be installed firmly and act sensitively.

LOP/COP Installation:

Install the Lop/Cop at an appropriate position near the entrance and exit of the elevator on each floor, and the height should be convenient for personnel operation. The Lop/Cop should be installed vertically and smoothly and fixed to the wall with screws. Connect the wires between the Lop/Cop and the main controller to ensure that the functions of the buttons are normal, such as the up, down, door open, and door close buttons operate flexibly and the signal transmission is accurate.

Wiring and Connection Selection of Cables:

Select appropriate specifications of wires and cables according to the load and transmission distance of the electrical system of the cargo lift. Generally, copper core cables are used for power lines, and the cross-sectional area is determined according to the motor power. Multicore copper core wires are used for control lines to ensure stable signal transmission.

Follow the principle of separating strong and weak currents and avoiding crossovers for wiring. The power lines and control lines are separately routed through pipes, and the pipe materials are generally PVC pipes.

When wiring, first strip off an appropriate length of the insulation layer at the end of the wires and cables to expose the conductors. Insert the conductors into the wiring terminals and use a screwdriver to tighten the terminal screws to ensure good contact and no looseness. Mark the wire numbers for the wires connected to each wiring terminal to facilitate future maintenance and troubleshooting.

Hydraulic System Installation Steps

Pump Station Installation:

Place the pump station in an appropriate position, generally close to the oil cylinder for easy pipeline connection.

Connect the oil pipes using methods such as threaded connection. When using fethreaded connection., ensure that the seals are installed correctly, tighten the connection nuts or bolts to the specified torque to prevent oil leakage. During the connection process, pay attention to keeping the inside of the oil pipes clean to avoid impurities from entering.

Fix the oil pipes to the structural frame of the cargo lift with pipe clamps. At the bends of the oil pipes, appropriately increase the number of pipe clamps to ensure that the oil pipes are firmly fixed and there is no vibration or displacement during operation.

Slowly pour clean hydraulic oil into the oil tank through a filter to reach the specified oil level. During the oil filling process, pay attention to keeping the oil clean and prevent impurities from mixing in. After the oil filling is completed, start the hydraulic pump for a short trial run to check whether there is any leakage in the system and whether the oil level is normal. If necessary, replenish the hydraulic oil to the specified oil level.

Debugging Steps Circuit System Debugging

Insulation Test:

Use a megohmmeter to measure the insulation resistance of each electrical circuit in the control cabinet, the motor windings, wires, and cables, etc. Check whether the wires and cables are damaged or damp, and whether the electrical components have poor insulation.

Connect the power supply and use a phase sequence meter to check whether the power supply phase sequence is correct. If the phase sequence is wrong, it will cause the motor to rotate in the opposite direction, affecting the normal operation of the cargo lift. If the phase sequence is incorrect, adjust the positions of any two phases of the power supply incoming line to make the phase sequence correct.

Operate each control switch in the control cabinet to test various control functions of the elevator, such as up, down, door open, door close, and floor selection. Check whether the signal transmission between the button box, call box, and control cabinet is normal, and whether each electrical component acts accurately and sensitively. For problems found during the test, such as buttons not responding or signals malfunctioning, troubleshoot and repair them in a timely manner.

Safety Circuit Test:

Test the functions of the safety circuit of the cargo lift one by one, including the emergency stop button, light curtain stop, door open power-off, etc. Press the emergency stop button, and the cargo lift should stop running immediately; check the door open power-off to ensure that the elevator can only run after the door is closed in place, and the door will not open accidentally during operation. If there is a fault in the safety circuit, the fault must be eliminated before proceeding to the next step of debugging.

Start the pump station and make the car of the cargo lift slowly rise and fall without load for several times. Observe whether the pump station is working normally, whether there is any abnormal noise and vibration; check whether the oil cylinder is running smoothly; check whether there is any leakage at the connections of the oil pipes. If any problems are found, stop the machine in a timely manner for troubleshooting, such as adjusting the pressure of the hydraulic pump, removing the air in the pipeline, and tightening the oil pipe joints.

Overall Debugging

Leveling Accuracy Debugging:

Under no-load and full-load conditions of the cargo lift, run it to each floor several times and measure the height difference between the car sill and the landing door sill, that is, the leveling accuracy. If the leveling accuracy does not meet the requirements, adjust the position of the stop limit switch for calibration.

Conduct a comprehensive calibration of all safety devices of the cargo lift again, including the upper travel protection, door open power-off, overload stop protection, emergency stop, etc. The overload protection device should act reliably when the rated load is exceeded to make the cargo lift stop running. For problems found in the safety devices during the calibration process, repair or replace them in a timely manner to ensure that the safety performance of the cargo lift meets the standards.

Stability Test:

Let the cargo lift run continuously several times at the normal operating speed under the full-load condition, and observe the overall running stability of the cargo lift. Check whether there is any looseness or deformation of each component, and whether the electrical system and hydraulic system are working normally, and whether there are phenomena such as overheating and abnormal noise. If any stability problems are found, tighten, adjust or repair the relevant components.

Comprehensive Performance Evaluation:

After completing the above debugging items, conduct a comprehensive evaluation of the comprehensive performance of the cargo lift. Check whether the cargo lift meets the various technical indicators required by the design.