Wurtec 30-10001669 User manual
6200 Brent Drive | Toledo, Ohio 43611
30-10001669
RAIL STRAIGHTNESS TESTER
Rev. 0 - 1/27/16 | Release - 1/27/16
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Table of Contents
Important Warnings……………………………………………………………………………………………………...3
Description .........................................................................................................................................................4
Features and Functions.....................................................................................................................................5
Set Up..................................................................................................................................................................9
1. Rail Set Up ...............................................................................................................................................9
2. Rail Straightness Tester Set Up.............................................................................................................9
a. Rail End Clamp...............................................................................................................................10
c. Rail End Clamp (with Spool Assembly) .......................................................................................11
d. Steel Wire Installation....................................................................................................................11
Testing and Operation.....................................................................................................................................13
Troubleshooting...............................................................................................................................................14
Replacement Parts.......................................................................................................................................14
Bill of Materials.................................................................................................................................................15
Rail End Clamp 30-10001686...........................................................................................................................15
Exploded View..........................................................................................................................................15
Parts List...................................................................................................................................................15
Sensor Block 30-10001673..............................................................................................................................16
Exploded View..........................................................................................................................................16
Parts List...................................................................................................................................................16
Rail End Clamp 30-10001698...........................................................................................................................17
Exploded View..........................................................................................................................................17
Parts List...................................................................................................................................................18
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WARNING!
CAUTION!
The equipment covered in this manual should only be installed, used, and serviced by qualified personnel
trained in proper work and safety procedures. This manual is intended to assist such trained individuals in
the installation and use of this equipment and is not intended as a substitute for proper training and experi-
ence.
This document or any other information regarding this equipment is not intended to cover all of the possible
situations which may be encountered while using the equipment described herein. Should specific situations
arise which are not covered by the information provided, or should the user desire further details, the specifics
should be directed to Wurtec, Inc.
Note: In the effort of continuous product improvement, Wurtec, Inc. reserves the right to modify the design
and specifications of this product at any time without notice.
Always place guide rails on stable, secure support devices. Avoid placing any parts of your body underneath
the guide rails. Falling rails can cause serious bodily harm. Always wear proper safety equipment.
Overview:
The purpose of this manual is to provide the user with detailed instructions on the proper use of the Rail
Straightness Tester. This includes:
Hazards associated with use of this product;
Explanations of the Features and Functions of this product;
Installation and Proper Use instructions;
A Troubleshooting Guide.
After reading this manual, the reader will be able to set up elevator guide rails in a manner that allows for ac-
curate straightness testing. The reader will be able to install this product onto a guide rail and use it to deter-
mine whether the rail is “straight” within a specified tolerance. Also, the reader will have a clear understand-
ing of how to transfer this product quickly onto another rail in order to test multiple rails.
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DESCRIPTION:
The Rail Straightness Tester is designed to provide a quick, accurate method for measuring the
straightness of an elevator guide rail. It comes in a compact portable case, and is composed of
three (3) sections:
(2) Rail End Clamps (one with the wire spool assembly, which should contain approximately
100’of Ø.015 steel wire)
Sensor Block
4-1/2” Diagonal Cutters are also included in the kit, for cutting the steel wire.
(2) Saw Horses or other support devices capable of supporting a
guide rail in a stable manner.
Rail End Clamp
Sensor Block
Rail End Clamp
with Spool
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FEATURES AND FUNCTIONS:
The Rail Straightness Tester uses an electrical system to determine the straightness of a rail within (4)
tolerance zones. A steel wire runs the length of the rail and connects the sections of the Rail Straightness
Tester. If the wire touches the edge of any of the target holes, it completes the electrical circuit which
activates a light and beeper device. This alert tells you that the rail has exceeded its straightness tolerance.
The (4) straightness tolerance zones are:
Rail Straightness Designation Tolerance As Shown on Target
BE+ ±0.5mm 1mm
BE ±1mm 2mm
B ±1.5mm 3mm
(For Reference Only) ±2mm 4mm
Below is a representation of the sizes of each of the tolerance zone holes and the wire that runs along the
rail and through the target.
The target contains 4 pairs of holes with a path in-between. The pairs include:
one for the actual measurement (the smaller of the two)
one for visual inspection of wire location relative to the target hole
If the wire touches the edge of the smaller target hole and closes the circuit to set off the alert system,
switch the target to the larger hole to visually inspect which direction the rail is out-of-tolerance.
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Use this hole when measuring
rail straightness
Use this hole for visual inspection
Visual
Inspection
Hole
Music Wire
Use this Hole when
Measuring Rail Straight-
The geometric form of the rails measured
by the Rail Straightness Tester is
represented by the following Geometric
Dimensioning & Tolerancing control
symbols:
(Note: This example shows the BE+
(±0.5mm) tolerance zone)
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The Rail Straightness Tester is designed for
quick and easy transition between rails so
that multiple rails can be measured
efficiently. The handles by the wire spool
allow you to relieve tension on the wire
when transitioning between rails.
There are also dowel rods and a magnet
which holds the assembly together in (2)
pieces so that it can be transferred to
another rail with two hands.
—— 1mm
—— 1mm
Dowel Pin
Receiver Hole
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Magnet
When the Rail Straightness Tester is not in
use, there are pairs of holes on the spool
where you can tie the wire until the
next use.
Tie your wire around any of these
hole pairs when not in use.
RailNOT toScale
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SET UP: Rail Set Up
Place the rail you wish to test on (2) saw
horses. The saw horses should be placed
in the following manner,
see Figure 1.
For example, if you have a 5m rail, the
saw horse spacing would be, see Figure 2
This set up minimizes the deflection of the
rails due to gravity, which in turn allows for
a more accurate measurement of
straightness.
Figure 1
Ensure that the rail is
free from any physical
deformities, dirt, or
other foreign objects.
! IMPORTANT !
Figure 2
Rail Straightness Tester Set Up
a. Rail End Clamp
i. Rotate the Cam Handle counterclock-
wise to spread open the plates of the
Rail End Clamp so that the opening is
wide enough to fit over the rail.
ii. Place the Rail End Clamp on the nose
of the rail, at one end of the rail.
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iii. While the Cam Handle is in the per-
pendicular position relative to the Eye
Bolt, rotate the handle clockwise so
that it tightens the plates snugly onto
the nose of the rail. When you extend
the Cam Handle, it should loosen the
blocks from the rail. Return the handle
to the perpendicular, tightened
position.
b. Sensor Block
i. Place the sensor block onto the nose of
the rail. The electrical enclosure should
be on the same side as the Cam Handle
on the Rail End Clamp. There is a
magnet recessed into the aluminum
block which will hold the Sensor Block
on the rail.
Magnet
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ii. Rotate the Target to your desired
straightness tolerance. Your chosen
target hole should align with the hole
through the Sensor Backing.
Align Target with
Hole
C. Rail End Clamp with Spool
Assembly)
i. Follow the installation steps from the
first Rail End Clamp, except on the
opposite end of the rail.
D. Steel Wire Installation
i. Locate the end of the wire on the
spool and thread it between the han-
dles and along the groove on the Rail
End Clamp.
ii. Continue threading the wire through
the Target and Sensor Backing, and
along the groove of the other Rail End
Clamp.
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iii. Turn the Thumb Screw on the back of the
Rail End Clamp counterclockwise to
loosen, and wrap the wire a few times
around the neck of the screw.
iv. Turn the Thumb Screw clockwise to
tighten it and hold the wire in place.
v. Squeeze the handle to a mid-rotation po-
sition, at a point where the wire is below
the horizontal level of the groove on the
Rail End Clamp.
vi. While in this position, rotate the knob on
the side of the spool counterclockwise to
loosen the wire spool. Rotate the spool to
reel in any excess wire.
vii. Tighten the knob to lock the spool in
place.
viii.Release the handle to tighten the wire.
Wrap the wire
around the screw
Bottom of Groove Wire
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TESTING AND OPERATION:
1. Slide the Sensor Block up next to the Rail End
Clamp with the wire spool. Make sure the wire
is in the proper target hole.
2. Set the switch on the electrical enclosure to
“ON”.
3. Test the system by intentionally moving the
wire so that it touches the edge of the target
and activates the alert system. Refer to the
Troubleshooting section if the alert system
does not activate.
4. Slide the Sensor Block along the rail.
If the alert system is activated at any time,
the rail is out-of-tolerance. Visually inspect
the rail for physical deformities or foreign ob-
jects. Also, rotate the target to the visual in-
spection hole and check which direction the
rail is out-of-tolerance. Mark the location of
the non-conformity on the rail.
5. You can determine that a rail is within toler-
ance once you have reached the other end of
the rail with the Sensor Block without
activating the alert system.
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Symptom(s) Recommended Action
The visual/audio alert system is not
functioning properly.
Check the connection on the back side of the Sensor Backing. The
ring terminal should be tightly fastened between the hex nut and
Sensor Backing.
Remove the screws on the cover of the electrical enclosure. Check
or replace the battery.
The wire is kinked, frayed, or otherwise
unsuitable for accurate measurement. Cut off the section of wire with undesirable characteristics with the 4-
1/2” Diagonal Cutters provided in the kit. Thread a new section of
wire from the spool.
Part No. Description
Battery CR2032 3V Lithium Coin Cell Battery
Steel Wire PC30-100 Malin-7 Ø.015” 30 Lb. Test X 100’
REPLACEMENTPARTS
TROUBLESHOOTING:
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BILL OF MATERIALS:
Rail End Clamp 30-10001686
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Sensor Block 30-10001673
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Rail End Clamp 30-10001698
Parts List
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Table of contents
