Modernisation of a Seven-Floor Traction Passenger Lift in Croydon

Equipment: Seven-Floor Traction Passenger Lift (600kg, 8 Person Capacity)
Project Date: August 2024

Introduction

Omni Lift Services Ltd was commissioned to modernise a seven-floor traction passenger lift in a multi-story building located in Croydon. The project aimed to enhance the lift's performance, reliability, and safety by replacing the old geared machine with new gearless. 

Background

The existing lift was equipped with an older geared machine that had become inefficient and less reliable over time. To ensure uninterrupted service and compliance with current safety standards, the client sought a comprehensive upgrade involving the installation of a new gearless machine and associated system enhancements.

Challenges

• Logistical Constraints: Transporting heavy machinery to the top floor of a seven-story building required meticulous planning due to limited access.
• Safety Compliance: Upgrading to a gearless machine necessitated modifications to the control system to meet the latest safety regulations.
• Technical Integration: Ensuring seamless integration of new equipment with the existing infrastructure and control systems.

Work Done

1. Transportation of New Machine: Safely transported the new gearless machine to the top floor using specialised equipment and logistics planning.
2. Scaffolding Installation: Erected fixed scaffolding at the top of the lift shaft by a specialised scaffolding engineer to provide secure access to the lift machine area.
3. Securing Lift Components: Propped the lift car in the pit and suspended the counterweight using lifting eyes and rail clamps to ensure safety during the replacement process.
4. Machine Replacement: Removed the existing geared machine and installed a new gearless machine from the same manufacturer for compatibility and performance enhancement.
5. Disposal of Old Machine: Disposed of the old geared machine in compliance with environmental regulations.
6. Rope Replacement: Supplied and fitted new main lift ropes using 10mm Pfeifer Drako 250T ropes (five ropes at 25 meters each) and replaced rope wedge anchors.

Electrical and Control System Enhancements

1. Wiring Installation: Ran new wiring to the lift machine, brake, and encoder to accommodate the new gearless system.
2. Drive Unit Replacement: Replaced the drive unit with a new one and performed panel modifications, which included:
   • Installing a new inline filter, brake resistor, and contactors (MC, MC1, and BR).
   • Implementing new wiring and relays for brake monitoring switches (BM1, BM2).
   • Updating software on the Almega control system and programming inputs for brake switch monitoring.
3. System Tuning: Carried out an autotune of the new lift machine, input desired parameters, and performed an encoder offset to calibrate the system.