Prysmian Draka CITEBK065P143A User manual

Draka CSR d.6,5 mm PU Coated Rope
User Manual
Version 1022
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Important! Please read first!
WARRANTY AND SAFETY INFORMATION
This user manual is meant to serve as a
general guideline for use of DRAKA CSR
d.6,5 mm Elevator Rope.
Please contact your rope supplier for
technical assistance.
Customers are encouraged to adapt
these guidelines to the specific
requirements of their elevator models.
Elevator manufacturers and installers are
fully responsible for design, testing, and
usage of elevators.
All conditions of the conformity or type
certificates issued by the notified body
and local laws and regulations must be
fulfilled to ensure safe operation of the
elevator.
Certification documents are available
from your rope supplier upon request.

1
Product description 2
Special handling instructions 3
Keep away from certain chemicals 3
Protection from the elements 4
Avoid all contact with dirt and lubricants 5
Transporting and moving reels 6
Handling rope on a reel 7
Usage and maintenance 8
Deflection sheave alignment and sheave groove information 8
Friction factors 9
Installation 10
Tensioning and checking for torsion 11
Listen for noise during operation 12
Operating temperatures and exposure to sunlight 13
Humidity and condensation 14
Discard criteria 15
Warranty 20
Table of Contents

2
Draka EHC’s Coated Steel Rope (CSR) is a unique
product that offers several advantages in
elevator operation. It is smaller in diameter
and offers better traction than comparable
uncoated steel ropes.
SAP Code: CITEBK065P143A
Description: DRAKA CSR d.6,5 mm 7x7+7x19W
sZ 2450 N/mm2
Every Draka CSR d. 6,5 mm rope is uniquely
marked to be traceable to its point and
time of manufacture. This number must be
reported in the working certificate to ensure
a match between the rope and the document.
Product description
SPECIFICATIONS AND TRACEABILITY
SPECIFICATIONS FOR
DRAKA CSR D.6,5 mm
Specification
Diameter (nominal) 6,5 mm
Wire rope diameter 5,0 mm
Wire rope construction Warrington
7x7+7x19
with IWRC
Wire tensile (nominal) 2.450 N/mm2
strength
Minimum Breaking Load 28 kN
Weight (kg/m) 0,12
Metallic cross-section 12,6 mm2

3
Exposure to certain chemicals may damage
PU-coated ropes. The extent of damage
depends upon the substance and the
concentration, temperature and duration of
exposure.
Exposure will cause a gradual degradation
of the rope. In extreme cases, it can cause
disintegration of the coating.
Chemical substances to avoid include, but are
not limited to:
• Aromatic hydrocarbons such as benzene
and toluene
• Concentrated acid and alkaline
solutions
• Solvents such as ethanol, aliphatic esters,
propanol, acetone, and ketones. Some
organic solvents such as dimethyl sulfoxide,
dimethylformamide and tetrahydrofuran
can dissolve the coating
• Extended contact with hot water can cause
slow degradation of the coating
• Lubricants such as oils and greases can
cause severe reduction of the rope’s traction
capabilities.
Special handling instructions
KEEP AWAY FROM SPECIFIC CHEMICALS

4
Special handling instructions
PROTECTION FROM THE ELEMENTS
The rope must be stored in a protected
environment that is dry, clean and
temperature-controlled. Most importantly, the
rope must not be exposed to the environment
(e.g. rain, direct sun exposure, dust, dirt, etc.).
When storing, find a location where the rope
will not be exposed to direct sunlight. For
instance, if a window permits direct sunlight
to shine on the cable, the window should be
blocked or shaded.
Long-term storage temperature must be kept
within a range of -10°C to +50°C.
During short-term exposure, such as
transportation, temperatures between
-25°C and 80°C can be tolerated. Note that
temperatures above 80°C can cause a slow
degradation of the coating.
Avoid contact with heat sources, as high
temperatures can melt the coating and cause
irreversible damage.
DO NOT perform welding or grinding work in
proximity of the product as sparks will cause
damage to the coating.

5
Coated ropes are very sensitive to lubricants
and oil substances in general.
Therefore, it is essential that the rollers in the
cutting machine counter are free of lubricants
and debris that they have picked up from
cutting standard wire ropes.
Additionally, the operator’s gloves must
be clean and clear of grease or lubricants. Dirty
rollers and gloves will transfer contaminants to
the coating that may damage the rope.
If the rope becomes contaminated, use these
steps to clean the rope:
• Remove dirt by rubbing the coating with a
dry, clean cloth.
• If this is ineffective, use a clean cloth to
apply pure water or a solution of mild soap
in water. Remove any soap residue with
pure water.
• If contamination is still present, pour
isopropanol (isopropyl alcohol) onto a
clean cloth and use the cloth to
remove the dirt/lubricant. Use a minimal
amount of solvent. Heavy or long-term
contact with isopropanol will damage the
coating.
Special handling instructions
AVOID ALL CONTACT WITH DIRT AND LUBRICANTS

6
Maximum care must be paid in the operation
of movement and handling of the rope
coils due to the delicate nature of the rope
surface.
All sharp edges must be avoided and suitable
hanging points must be used to move the
reels properly in the warehouse.
Forklift forks can seriously damage the
surface of the rope. DO NOT let the forks
touch the exposed rope in any way. The
preferred method of movement is to place a
rod through the hub of the reel and use the
forks to lift the rod.
Transporting and moving reels
TAKE SPECIAL CARE WHEN USING FORKLIFTS

7
Handling rope on a reel
AVOID KINKING, LOOPING AND PLACING TORSION INTO THE ROPE
When uncoiling the rope:
DO NOT let the rope loop or kink.
DO NOT uncoil the rope on dirty or rough
surfaces, as this can irreparably damage
the rope coating.
DO NOT introduce torsion into the rope.
Torsion can be avoided by allowing the
reel to rotate as the rope is payed off. Do
not drag the rope from a standing reel.
DO NOT drag the rope over sharp edges
or rough surfaces. Use a smooth rotating
drum to prevent damaging the rope.
DO NOT use metallic strips to secure
coiled ropes. The sharp edges will dam-
age the surface of the rope. The use of
plastic strips is mandatory.
Plastic strips

8
Elevators must be designed with the properties
of DRAKA CSR d.6,5 mm elevator rope in mind
to obtain all its benefits. The following
recommendations are general guidelines.
Please contact your supplier of DRAKA CSR
d.6,5 mm ropes for further support.
During elevator design, reduce deflection
angles of the ropes entering sheaves to the
absolute minimum. It is recommended to
carefully check alignment of all elevator
components during installation with
appropriate tools such as laser gauges.
Additionally, all sheaves must be in the same
plane. The rope cannot be rotated during
travel.
Both traction and deflection sheaves must
have semi-circular grooves. Worn or otherwise
unsuitable sheaves can damage the rope.
Usage and maintenance
DEFLECTION SHEAVE ALIGNMENT AND SHEAVE GROOVE INFORMATION

9
Prysmian Group recommends using the
following values for the friction factor fas
a guideline for elevator design. Please note
that these are friction factor values fand not
friction coefficient μ.
• Car loading condition
(EN81-50 art. 5.11.2.2.1): f= 0.25
• Emergency braking condition
(EN81-50 art. 5.11.2.2.2): f= 0.25
• Car stalled condition
(EN81-50 art. 5.11.2.2.3): f= 0.75
The values for fgiven above are based on
laboratory test results. It is mandatory to
perform traction tests during prototyping
of elevator models and for each individual
installation before putting it into operation.
Note that traction of new ropes tends to
increase during the first elevator movements.
Please note that the main concern of the
EN81-20 art. 5.5.3.b condition for emergency
stops is to ensure sufficient deceleration.
Elastomer coated elevator ropes have
significantly higher friction factors compared
to bare steel wire ropes. In some cases, this
can lead to very high decelerations during
emergency stops.
We recommend to use a wrapping angle of
at least 120°for the traction sheave. Please
contact your rope supplier in case your elevator
design requires wrapping angles less than 120°.
The electrically-isolating nature of the coating
can cause electrostatic charging during
elevator usage. Electrical grounding of the
steel rope core is recommended, particularly if
plastic deflection sheaves are used.
Usage and maintenance
FRICTION FACTORS
30° ≤ y ≤ 60°
Ø 6,5 mm
Surface roughness
Ra = 1,6 µm
Groove radius
3,3 mm ≤ r ≤ 3,6 mm

10
During rope installation, do not pull the rope
over sharp objects or edges. Avoid twisting/
rotating the rope around its axis. Twisting
can lead to a build-up of excess strand or wire
length inside the rope. This can cause reduced
rope life.
Remove all greases and oils (such as
corrosion protection) from the traction
sheave before rope installation. Contamination
of the rope with lubricants such as greases
and oils can cause severe reduction of
traction capabilities and rope slip over the
traction sheave.
The sheaves should not be painted.
Avoid rope contact with lubricated elevator
parts such as guide rails.
DO NOT use contaminated gear (such as greasy
gloves) during rope handling.
Usage and maintenance
INSTALLATION

11
Rope terminations should be compliant with
DRAKA CSR d.6,5 mm elevator ropes and fulfill
all relevant safety regulations.
Ropes must be installed with equal tensions
(±10%). Tensions must be re-checked after a
few trips and corrected if necessary.
After initial tensioning, run the elevator
up and down to allow for the tension to be
spread along the complete length of the
rope. Check the rope tensions again, adjust as
necessary, and make another complete trip
of the elevator. Repeat until tensions fall with
the 10% difference.
Immediately after installation, rope torsions
should be checked during inspection mode.
Rope torsion can be best observed by
attaching to the ropes small “flags” made
from sticky tape. During elevator movement,
ropes should not rotate for more than one
full turn for a moving distance of 20 metres
of rope. Excessive rope torsions/rotation
during movement is usually caused by
misalignments and will reduce the life of the
rope.
Usage and maintenance
TENSIONING AND CHECKING FOR TORSION
Preferred
assembly
Rope tensioning is an iterative process -
Repeat until all ropes have equal tension

12
Ropes should be silent while running over
sheaves. Noise can be a sign of excessive
deflection angles as the rope enters the sheave
and could indicate dirt inside the sheave
grooves.
Carefully check for misalignment to see if
all ropes are running through the grooves
correctly and if terminations are properly
positioned.
Usage and maintenance
LISTEN FOR NOISE DURING OPERATION

13
The recommended temperature range during
elevator operation is 0°C to 40°C. However,
the rope may withstand temperatures that are
above or below the threshold for a short period
of time, such as when they are being shipped.
The rope should not be used in environments
with temperatures higher than 60 °C or
below -10°C. Using the rope outside of the
recommended temperature range may lead to
a reduction in the life of the ropes.
When used in external panoramic elevators,
the glass should be surface laminated with a
PVB film interlayer to protect the rope against
UV rays. As an alternative, apply an adhesive
anti-UV film to the glass. It is necessary that at
least 98% of UV radiation be blocked.
Usage and maintenance
OPERATING TEMPERATURES AND EXPOSURE TO SUNLIGHT
Outside
panoramic
elevator
Inside
panoramic
elevator
98% UV
reflectance

14
DRAKA CSR d.6,5 mm elevator ropes operate
best in environments that do not permit
condensation (the formation of moisture) on
the ropes.
Avoid placement in areas where there are wide
differences in ambient temperatures, such as
sunlit areas that rapidly cool in the evening).
Adequate airflow in the hoistway (creating a
chimney effect with lower and upper venting)
is a good way of decreasing condensation. The
best way is to make sure that the hoistway is
climate-controlled.
Usage and maintenance
HUMIDITY AND CONDENSATION
Airflow

15
DRAKA CSR d.6,5 mm elevator ropes are
almost maintenance-free and must not be
lubricated. Check for discard criteria at regular
inspection intervals specified by the elevator
manufacturer. The discard criteria are part of
the conformity examination certificates issued
by the notified body. During elevator inspection,
check also for surface contamination of ropes,
confirm or adjust rope tensions for equality,
and verify traction capability.
If one or more of the discard criteria is
reached, ALL ropes in the installation must
be replaced. It is forbidden to exchange
individual ropes.
Discard criteria
REPLACE ALL ROPES IF DISCARD CRITERIA IS REACHED FOR ONE

16
Coated steel ropes have to be replaced when
the maximum number of trips or lifetime
in years (from TÜV SÜD examination of
conformity certificate CA561) is reached OR
when one of the other discard criteria described
below occurs.
DISCARD CRITERION
Suspension 1:1 1:1 2:1 2:1
With extra pulley No Yes No Yes
Maximum number 3 1,5 1 0,75
of trips (millions)
Number of bends of 1 2 3 4
rope parts with the
highest level of wear
Maximum number 10 10 10 10
of years until
replacement of
the ropes
The ropes have to be discarded after reaching
a determined value of time or trips (it depends
which case occurs first). Every change of
direction shall be counted as one complete trip.
Discard criteria
DEPENDS ON NUMBER OF TRIPS, NUMBER OF YEARS OR VISIBLE DAMAGE

17
Discard criteria
DEPENDS ON NUMBER OF TRIPS, NUMBER OF YEARS OR VISIBLE DAMAGE
In addition, the ropes must be regularly
inspected over the whole length and discarded:
• in case of positional displacement of the
steel rope inside the plastic sheathing
• in case of recognizable ingress of
moisture into the plastic sheathing,
• in case of deformation of the plastic
sheathing (e.g., blistering, crease, necking),
• in case of deformations caused by
persistent torsions of the ropes,
• in case of coating cracks clearly visible at
straight rope sections under tension that
extend to the inner steel rope with a number
greater than 3 over a length of 10 cm,
• in case of plastic sheathing damage with
large separation of the coating from the rope
of a length greater than 1,5 cm,
• in case of escaping steel wire through the
plastic sheathing with a number greater
than three over a length of 100 cm, and
• in case of wire rope strand breakage.
All ropes in the elevator installation have to be
exchanged at the same time even when above
discard criteria are reached only for one or more
individual ropes. It is not allowed to exchange
individual ropes.
Discard criteria
INSPECTION

18
Ropes have to be discarded in case of
deformation of the plastic sheathing.
Ropes have to be discarded in case of coating
cracks clearly visible at straight rope sections
under tension that extend to the inner steel
rope with a number greater than three over a
length of 10 cm.
Discard criteria
EXAMPLES