thyssen (maquina mini gearless daf-270)
TRANSCRIPT
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Operating ManualMini gearlessDAF270
ThyssenKrupp
ThyssenKrupp AufzugswerkeA company of
ThyssenKrupp
Elevator
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OPERATING MANUAL
ThyssenKrupp Aufzugswerke GmbH 3 Issue 06.2004
Imprint
All rights reserved
Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbHP.O. box 23 03 70, D-70623 Stuttgart
Printed in Germany, June 2004The copyright of this documentation rests with THYSSENKRUPP AUFZUGSWERKEGmbH. This documentation or extracts of it shall not be copied, distributed or used for thepurpose of competition.
Any reprint, copying or storing in data processing machines in any form or by any meanswithout prior permission of THYSSENKRUPP AUFZUGSWERKE GmbH is regarded asinfringement of the current Copyright Act and will be prosecuted.
Technical modifications for reasons of improvement or higher standard of Mini gearless
DAF270 are subject to decisions of THYSSENKRUPP AUFZUGSWERKE GMBHwithout prior notice.
The responsibility for the content lies with the editor:THYSSENKRUPP AUFZUGSWERKE GmbH
Preface
We are pleased that you decided to purchase a quality product from THYSSENKRUPPAUFZUGSWERKE GmbH.This operating manual assists you in getting familiar with the drive for moving cars - theMini gearlessDAF270 (which is referred to as DAF270 below) - and its intendedpossibilities of use. Important information concerning safety and hazards helps you tosafely use the DAF270.DAF270 is subject to technical alterations.
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OPERATING MANUAL
ThyssenKrupp Aufzugswerke GmbH 5 Issue 06.2004
Table of contents
Mini gearlessDAF270 PAGE
1. Safety
1.1 Explanation of symbols used 61.2 General safety information 7
2. Transportation and storage 10
3. Product description
3.1 Description of DAF270 123.2 Functional description 143.3 Technical data - machine 173.4 Technical data - brake 203.5 Pulse encoder 213.6 Dimensions 223.7 Machine frame 253.8 Lubrication 273.9 Name plate 28
4. Mounting of machine
4.1 Mounting of machine 304.2 Motor connection 32
4.3 Connection of magnetic brake 334.4 Connection of encoder 394.5 Schematic diagram 40
5. Putting into service
5.1 Putting machine into service 41
6. Servicing
6.1 Servicing of machine 426.2 Drive brake test 43
7. Maintenance
7.1 Replacing of traction sheave 477.2 Replacing of pulse encoder 497.3 Replacing of brake monitoring switch 517.4 Silencing of brakes 517.5 Replacing of brakes 52
8. Annex
8.1 Tightening torque mechanical strength 558.2 Manufacturer's instructions for pulse encoder 568.3 Manufacturer's instructions for magnetic brake 618.4 Type test examination certificate for brake 66
8.5 Declaration of conformity for brake 708.6 Type examination certificate for
calculation of traction sheave shaft 72
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OPERATING MANUAL 1. SAFETY
ThyssenKrupp Aufzugswerke GmbH 6 Issue 06.2004
1.1 Explanation of symbols used
The following pictographs and designations are used in this operating manual:
Danger
This symbol draws attention to an extreme danger tolife or risk of injury to persons.Disregard of warning means danger to life!
DangerThis symbol draws attention to an immediateimpending danger to life or risk of injury to persons
caused by electric current.Warnings must always be observed!
Warning
This symbol draws attention to an impending danger.Disregard can cause injury to persons or extensivedamage to property.Warnings must always be observed!
Note
This symbol draws attention to important informationand instructions for operation. Disregard can lead todamages, hazards or failures.
Inspection
This symbol draws attention to the proper inspectionsequence.These inspection notices must be observed in anycase. Disregard can lead to injury to persons ordamage to property.
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OPERATING MANUAL 1. SAFETY
ThyssenKrupp Aufzugswerke GmbH 7 Issue 06.2004
1.2 General safety information
Information on the operating manual
Knowledge of the basic safety requirements is a prerequisite for the safe useand fail-free operation of this component.This operating manual comprises the most important information how tosafely use the component.The operating manual and, in particular, the safety information must beobserved by all persons who perform any work on the component.In addition the rules and requirements concerning the regulations forprevention of accidents which apply to the installation location must beobserved.
Duties of the owner and / or the installer
The owner and / or the installer ensure that only persons are authorized towork at the component, who
are familiar with the requirements concerning safe working and preventionof accidents and who were trained how to use the component.
have read the safety information and the warning notices in this operatingmanual.
Note:check the compliance of the employees method of working with thesafety requirements in regular intervals.
Duties of the employees
Persons who are authorized to perform work at the component are obliged
to observe the requirements concerning safe working and prevention ofaccidents;
to read the safety information and the warning notices in this operatingmanual prior to start working.
Training of the employees
Only trained and instructed, technically competent persons shall performwork at the component.The competence of the employees must be clearly defined for all tasksconcerning putting into service, operation, maintenance and repair work.
Organizational measures
The owner or the installer must provide the necessary personal protective
gear. All existing safety devices must be checked regularly in accordancewith the maintenance plan.
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OPERATING MANUAL 1. SAFETY
ThyssenKrupp Aufzugswerke GmbH 8 Issue 06.2004
Informal information about safety measures
The operating manual must always be available at the location of theinstallation.
The general and local regulations for the prevention of accidents and
environmental regulations must also be made available and observed. Clearly and easily visible statutory safety instructions must be made
available for the users.
See to it that all information concerning safety and hazards is alwaysvisibly and legibly made available on the machine.
Use as intended
DAF270 is designed in accordance with the state of the art and therecognized safety regulations. DAF270 shall only
be used for its intended purpose be used only if safe operation is ensured
DAF270 shall exclusively be used as drive for lifts.Any other use or any use exceeding the scope of above definitions isregarded as use outside of the intended purpose. THYSSENKRUPPAUFZUGSWERKE cannot be hold liable for any damages resulting from thisand for any damages which are caused by any errors of procedure.Use within the scope of its intended purpose also comprises
observance of all information of the operating manual
fulfilment of the instructions applying to putting into service, installation
description and inspection and repair work.
Guarantee and liability
The "General Conditions and Terms of Sale" of THYSSENKRUPPAUFZUGSWERKE GmbH apply generally.Any claims for guarantee and liability are excluded in the case of injury topersons or damage to property resulting from one or several of the causesbelow:
use of DAF270 outside the scope of its intended purpose
inexpert mounting, putting into service, operating and maintaining ofDAF270
use of DAF270 with defective and/or non-operative safety andprotective devices
disregard of the instructions in the operating manual that apply totransportation, storage, mounting, putting into service, operation andmaintenance of DAF270
unauthorized constructional modifications of DAF270
unauthorized modification of drive (rating etc.)
unsatisfactory supervision of parts that are subject to wear inexpert repair work
catastrophes caused by outside influences and Act of God
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OPERATING MANUAL 1. SAFETY
ThyssenKrupp Aufzugswerke GmbH 9 Issue 06.2004
Constructional modifications at DAF270
DAF270 is adjusted at the factory and delivered ready for work.
In the case of any modifications of the machine THYSSENKRUPPAUFZUGSWERKE GmbH cannot be hold liable.
Use of DAF270 and possible hazards
DAF270 shall only be operated in a closed machine room, provided withcover and rope guard at the traction sheave or installed in a machine framein the headroom. The owner of the installation must verify that the drive isaccessible to trained experts only.Works at the drive shall only be performed with the drive disconnected from
power supply and the installation protected against unintentional switchingon.
See to it that the safety distance to all revolving parts (marked yellow) isobserved by persons working in the machine room / headroom.Inexpert handling can cause danger to life for the user or third parties resp.impairment of the component or material property.Failures which possibly impair the correct functioning are to be eliminatedimmediately.
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OPERATING MANUAL 2. TRANSPORT AND STORAGE
ThyssenKrupp Aufzugswerke GmbH 10 Issue 06.2004
2. Transport and storage
Packing:DAF270 is delivered:
a) without machine frame; assembled on a wooden pallet and wrapped in foil.
b) machine and frame assembled and wrapped in foil; wooden edges or aspecial pallet screwed below the machine frame.Remove these transport contrivances before you install the machine onsite.
Transport:Machine and frame must be perfectly horizontal and the safety precautionsobserved.
Transport by means of fork lift:
The forks must be of proper length to prevent the machine from tilting.
See to it that the forks are attached to the frame or transport pallet andnot to the machine.
Pay attention to projecting parts! There is the risk of injury to persons ordamage!
Transport by crane:
Do not stay below suspended loads!
Fasten transport chains or ropes at the machine frame.See to it that the machine is perfectly horizontal.
Fasten at transport aid and secure against tilting. Do not lift the motorhousing!
Remove transport aids after transport.
Note the pictographs fastened on the packing or other visible places.
Top Handle with care Keep dry
Do not expose toheat
Do not use handheldgrippers
Fasten here
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OPERATING MANUAL 2. TRANSPORT AND STORAGE
ThyssenKrupp Aufzugswerke GmbH 11 Issue 06.2004
Dimensions and weight
The weight is indicated on a sticker on the packing of the machine.For dimensions see delivery note.For rough data see chapter 3.3 Technical Data
Examination by customer on receipt of goods
Examine the delivered parts for completeness, damage or anything strange.
Report and document transport damage
After receipt of goods make sure that there is no damage caused duringtransport.
Information
Immediately document the damage noticed (drawing, photograph,description of damage).
Immediately send the respective documents to THYSSENKRUPPAUFZUGSWERKE GmbH.
Unpacking
Information
Dispose packing equipment in accordance with the environmentalstandards or make it available for further use.
Special transport aids and transport contrivances remain at thecustomer.
Intermediate storage
Even if the component is not mounted directly after delivery, it should bestored in dry places and protected with humidity-proof covering.
Do not store the component in the open air. Parts without surface coatinglack long-time preservation.
Open ventilation opening.
Environmental conditions
Information
Surrounding at the final site of the machine (humidity, temperature) shallcomply with the requirements for machine rooms. (Between +5 and +40C according to EN81).Relative humidity of air shall not exceed 70%.
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 12 Issue 06.2004
3.1 Description of Mini gearless DAF270
Represented without rope guard and covering
DAF270consists of:
Pos. Part designation Pos. Part designation
1 Disc on motor shaft 9 Transport hole
2 Cheese head screw
M12x 5010 Cover plate for brake
3 Traction sheave 11 Encoder
4 Ventilation opening 12 Brake terminal box
5 Casted housing 13 Encoder connection
6 Thread for fastening M16 14 Electromagnetic brake7 Motor terminal box 15 Cable duct thermal contact
8 Bearing bracket 16 Cable duct motor connection
3
1
7 6
54
2
Fig. 1
9
9
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 13 Issue 06.2004
DAF270 rear view
Versions:
The following versions are available:
1.Various drive capacities
2.Motors with electrical rating for inverters with sinusoidal mainsregeneration or braking operation through resistors
3.Various traction sheave diameters
4.Various groove profiles and rope number at traction sheave available
5.(Optional) machine frame variants dependent on dimensions
6.Various types of brake
10
11
12
13
1415
5 8
9
Fig. 2
7
9
16
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 14 Issue 06.2004
3.2 Functional description
Machine:DAF270 consists of a frequency-controlled permanent-magnetsynchronous motor.
DAF270 has two different power ranges, which are differentiated by the letterbehind the type designation:DAF270 M (medium) for the standard and DAF270 L (large) for the higherpower range. The external housing dimensions differ in size. See chapter 3.6Dimensions.
The machine has a monobloc housing with integrated bearing bracket on oneside.The drive shaft with rolling bearings is made of tempering steel.
The front self-aligning bearing and the rear rolling bearing of the bearingbracket are sealed and life-time lubricated.
DAF270 is designed for 1 : 1 and 2 : 1 suspension with single wrap(max.180) and downward rope departure.(The motor terminal box is accessible from below.) In all other cases, turn thedrives and adjust the mounting position to the respective access.
Motor:dependent on motor type and controller the braking energy can be:a)supplied to resistors;
b)regenerated sinusoidally to the mains. (Only for motors 350V)
The machine is designed for thermal class F but used according to thermalclass B.
DAF270 has a self-ventilated motor (without auxiliary forced ventilation)
Operating temperature (max. 130C 5C) is monitored by a posistor.Evaluation by means of a frequency inverter. In case of overheating the driveis de-energized through the inverter.
Traction sheave:the single-block (rim and nub) overhung traction sheave is
attached onto the conical end of the motor shaft and secured against falling
down by screw-connected disc on the front side. The micro-encapsulated
screws are protected against unintensional working loose and provided withdetent edged washers placed under.
The groove flanks are hardened as standard (50 HRc).
For further data see chapter 3.3 Technical Data.
The gearless machine does not have a self-locking device.
Brake:an electromagnetically operated, dual-circuit brake is attached to themotor housing. It consists of two independently operating brake shoes(tandem), which act onto the motor shaft.The spring-applied armature disk of the respective magnetic brake is pressedagainst the brake lining of the rotor. The rotor is pushed and the second rotorlining acts on the rigid bearing surface of the brake or the bearing bracket.
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 15 Issue 06.2004
The two rotors are rigidly connected to the motor shaft through interlockedholes and a hub.Brake release:the voltage-fed brake magnet coils attract the armature discsand release the brake rotors.
The brakes cannot be released manually.The brake torque of each brake circuit permits to stop the car loaded withrated load at rated speed. The brake torque cannot be adjusted.
Note: the brakes of DAF270 are designed for use as holding brake. Anydynamic braking is restricted to emergency and test braking. Normal use willnot lead to any noticeable wear on the lining.This drive brake can in no way replace the safety braking system used fordownward operation.
Attention:the manufacturer of the lift installation must provide propermeasures for brake connection to ensure that the brake can be tested and
emergency rescue performed (even in case of power failure).
Brake monitoring:A separate control switch monitors the momentary brakeposition (released/closed) of each brake. Any failure is signaled to thecontrol. The machine must be shutdown or a further run prevented if the driveeither runs at zero speed with one brake circuit open or starts with one brakecircuit closed.For terminal diagram see chapter 4.3 and adjusting of brake test switchchapter 7.3.
An electrical safety device of the overspeed governor or a type-tested safety
device of the same safety level shall initiate the releasing of the brake in caseof overspeed if the braking device of the DAF270 is utilized as ascendingcar overspeed protection means.The requirements including range of useand conditions set out in the annex of type test certificate No. ABV 591of01-08-08must be complied with. See chapter 8.4.
Real value generator: DAF270 is a synchronous machine excited by apermanent magnet. In energized state the absolute rotor position is suppliedby a sine-cosine-wave absolute position encoder. Speed and shaft positionare detected by high-resolution sine-cosine-wave tracks.For description of encoder and technical data see chapter 3.5 and
manufacturer's instructions in chapter 8.2.
Environmental conditions: the ambient temperature at the site ofinstallation shall comply with the requirements for machine rooms and thusbe maintained between +5 and +40 C (in accordance with EN 81).The relative humidity of air shall not exceed 70%
Attention:in case of temperatures over or under the freezing point, thebraking torque of the disc brake can be reduced due to condensation.In case of a longer standstill, the friction linings can rust at the frictionsurfaces.Corresponding counter measures are to be made by the owner of the
component.
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 16 Issue 06.2004
Machine frame:the drive DAF270 is designed for installation in theheadroom, but can also be utilized for installation in the machine room. Themachine frame necessary for installation of the machine in the headroom isdelivered optionally.
The drive is delivered completely pre-assembled.For details concerning machine frame and installation see separatedocuments for frame.
LiftEquip: LiftEquip customers obtain a project planning form with designdata and installation instructions for the machine frame.
Material number of the project planning form:
German 9720 000 6756
English 9720 000 6778
Note:an installation frame,which makes delivery of the frame into theheadroom easier, is optionally available.Please contact LiftEquip, if interested.
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 17 Issue 06.2004
3.3 Technical data machine
1) Hardened groove flanks are used (min. 50 HRc).
Thyssen Compact gearless DAF270
Version M 0xx L 0xx
Diameter traction sheave - DT [mm] 320 440 490
Rim width traction sheave - B [mm] 145 132 150
Max. groove number z x d 10 x 8 7 x 10 8 x 10
Groove form traction sheave Seat or V-groove1)
Material traction sheave EN-GJL 300 (HB 190 to 300)
2x1700Max. brake torque acc. test
certificate Mbr[Nm]
2x12502x1700
Type test certificate No. of brake ABV 591
Moment of inertia gearless [kgm] 2.10 2,90
Moment of inertia traction sheave [kgm] 0.53 1,50 2,45
Moment of inertia machine [kgm] 2.63 3,60 5,35
Permissible shaft load at traction
sheave Ftzul[kN] 43.5 57 57
Weight machine (incl. traction
sheave)
[kg] 550 570 740
Weight traction sheave [kg] 35 55 65
Weight machine frame TK [kg] 400 - 650
Weight machine frame LE [kg] 400 - 600
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OPERA
TING
MANUAL
3.PRODUC
TDESCRIPTION
ThyssenKruppAufzugswerkeGmbH
18
Issue06.2004
TYPDA
F270
M0
00
M0
01
M0
02
M0
02
M0
05
M008
Suspension
r
2:1
2:1
2:1
2:1
2:1
1:1
Elevatorspeed
v
m/s
1.0
1.6
1.6
1.75
2.0
1.0
Traction
sheavediameter
DT
mm
440
440
440
440
440
320
Ratedo
utput1)
PN
1)
kW
10.7
15.3
14.9
16.3
18.2
7.4
Ratedtorque
MN
Nm
1175
1050
1025
1025
1000
1175
Speed
nRot
min-1
87
139
139
152
174
60
Ratedc
urrent
IN
A
24
30
35
35
38
18
Effectivevoltage
U,eff
V
330
350
305
330
320
330
Statorfrequency
fStator
Hz
14.50
23.20
23.20
25.30
29.00
10.00
Efficiency(100%PN)
%
83
88
86
87
90
79
Powerfactor
cos
0.94
0.95
0.94
0.95
0.96
0.94
Starting
torque
MA
Nm
2200
2200
2200
2200
2200
2200
Starting
current
IA
A
45
68
78
78
89
34
Max.pe
rmissiblecurrent
Imax.
zul.
A
65
90
90
90
100
49
Inverter
type
(assignedasstandard)
CPI26.
CPI32
C
PI50R
CPI48
CPI48
CPI48.
CPI602)
CPI15
Ratedlo
ad(guidevalue)
Q
kg
1600
1600
1600
1600
1600
1000
1)Theratedoutputindicatedonlyappliestounbalancedinstalla
tionsunderS5operation(240F/h,50%Ed)withmax.M
A!
2)2)Withcurrentlimitationto100A!
Pulseen
coderdataseechapter3.5
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OPERA
TING
MANUAL
3.PRODUC
TDESCRIPTION
ThyssenKruppAufzugswerkeGmbH
19
Issue06.2004
TYPDAF270
L007
L009
Suspension
r
2:1
2:1
Elevatorspeed
v
m/s
2,0
1,0
Tractio
nsheavediameter
D
T
mm
490
490
Ratedoutput1)
PN
1)
kW
22,5
Ratedtorque
M
N
Nm
1375
Speed
nRot
min-1
156
Ratedcurrent
IN
A
235
Effectivevoltage
U,eff
V
430
Statorfrequency
fStator
Hz
26
Efficien
cy(100%PN)
%
82
Power
factor
cos
0,96
Startingtorque
M
A
Nm
2750
Startingcurrent
IA
A
75
Max.p
ermissiblecurrent
Imax.zul.
A
100
Inverte
rtype
(assign
edasstandard)
CPI50R,
CPI100R
C
PI26E
Ratedload(guidevalue)
Q
kg
2000
2000
1)The
ratedoutputonlyappliesto
unbalancedS5operation(2
40F/h,50%
Ed)atmax.MA!
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 20 Issue 06.2004
3.4 Technical data operating brake
Type: ERS VAR09
SZ1700 / 1250
ERS VAR09
SZ1700 / 1700
Manufacturer Warner & Tourco Warner & Tourco
Brake torque 2 x 1250 Nm 2 x 1700 Nm
Version Dual-surface disc brake
asbestos-free brake
linings
Dual-surface disc brake
asbestos-free brake
linings
Operating voltage
(one brake circuit)
Without overexcitation
207 VDC voltage
103.5 VDC overexcitation
52 VDC withstand voltage
Rated output
(one brake circuit)
Without overexcitation
123 W with voltage
applied
232 W with overexcitation
59 W with withstand
voltage
Maximum ambient temperature 40C 40C
Max. temperature at full load 100C 100C
Maximum speed 250 min-1
250 min-1
Air gap (stroke per brake
circuit)
0.35 + 0.05/-0.1 mm 0.35 + 0.05/-0.1 mm
Maximum air gap in case of
wear
0.6 mm 0.7 mm
Operating time ED 60 % ED 60 %
Length of connecting line 10 m 6 m
Weight (incl. accessories) approx. 84 kg approx. 84 kg
Type test certificate number ABV 591 ABV 591
Release monitoring
(per brake circuit)
1 x microswitch
Switching voltage 24 VDC
Switching capacity 10 100 mA
Operating distance at setting
screw
0.15 mm
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 21 Issue 06.2004
3.5 Pulse encoder
DAF270 is controlled by means of an enclosed incremental hollow shaftencoder with sine-wave output signals mounted on the rear end of the rotorshaft.Connection to control by means of permanently connected shieldedconnecting cable of 10 m length with 15-pole sub D connector (RS485) andUNC screwing.The cable shield is connected-up to connector and encoder housing.Connection, installation and drawing see chapters 7.2 and 8.2
Technical data for TTL encoder:
Enclosed hollow shaft encoder with 2 signals with 90 phase shift andreference mark.
Number of increments (Z): 2048 pulses/revolution
Supply voltage: 5 5% V
Output driver: RS 485 / sine
Output signals: analog / serial 1Vss, max. frequency (-3dB) >/= 200kHz /
RS485 EnDat
Working temperature range: - 20...+ 100 C
Storage temperature range: - 30...+ 80 C
Permissible relative humidity: 100 %Max. on-load current with 5 V 150 mA
Protection class: IP 64
Connection and installation instructions:
Connect connector box and reference potential.Should longer cables be required only use original cables fromHEIDENHAIN.
Note:the build-on pulse encoder is standard and specially adapted to usewith ThyssenKrupp inverter. Use of another type of inverter necessitates apulse encoder adapted to the respective connected load.
Use of a second encoder is not provided with DAF270 machine.
Connection assignment at 15-pole Sub-D connector and instructions oninstallation and wiring see manufacturer's instructions in chapter 8.2.
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 22 Issue 06.2004
3.6 Dimensions
Dimensions DAF270 M 0xx
Fig. 3
M20 x 28 deep
550
346
DT=44
0
550
Center ofgravity
Brake connection
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 23 Issue 06.2004
Dimensions DAF270 L 0xx
Fig. 4
550
550
DT
=490
346
Brake connection
Center ofgravity
M20 x 28 deep
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 24 Issue 06.2004
Dimensions DAF270 M 008 (Tepper variant 1 : 1)
M20 x 28 deep
550
550
Center of gravity
Brake connection
346
Dt=320
Fig. 5
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 25 Issue 06.2004
3.7 Machine frame (optional)
The machine frame for DAF270 is designed for machine-room-less elevatorsto be placed in the headroom.
The frame from ThyssenKrupp Aufzugswerke is intended for 2:1 suspension.The drive, terminal rope anchorages and the overspeed governor are alsoaccomodated in the frame. The drive is attached at two profiles andsupported by elastic elements. The frame is supported at the support pointsof the profile ends in the headroom.
Machine frame with mounted drive, overspeed governor and terminal ropeanchorages for headroom installation
Fig. 6
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 26 Issue 06.2004
The shaft dimensions and the parallel distance of the ropes at the point ofrope departure (ASL) (tailor-made acc. to customer specifications inaccordance with available versions) define the frame design and dimensions.
DAF270 with frame from LiftEquip for headroom installation.
Fig. 7
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 27 Issue 06.2004
3.8 Lubrication DAF270
DAF270 has lifetime-lubricated rolling bearings. The bearings do not requirelubrication.
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 28 Issue 06.2004
3.9 Name plate DAF270
Version
1. THYSSENKRUPP AUFZUGSWERKE GmbH
A B C D E F
G H I J K L M N O
Line Column Meaning
1 A-D Machine type1 E-F Serial No. / year of construction
2 A Design
2 B Protection class
2 D-F Insulation class
3 A-E Mode of operation
3 F Weight of machine [ kg ]
4 G Rated output [ kW ]
4 H Motor speed [ U / Min.]
4 I Voltage [ V ] (star connection)4 J Power strength [ A ]
4 K Efficiency
4 L Starting torque [ Nm ]
4 M Power consumption [ A ]
4 N
4 O Frequency [ Hz ]
5 A-F Operating force brake magnet [Nm]
6 A-F Traction sheave ; max. number of
ropes; rope
1
2
3
4
5
6
120 kNB3
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OPERATING MANUAL 3. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 29 Issue 06.2004
2. LiftEquip
A B C D E F G
H I J K L M N O P
Line Column Content
1 A Machine type
1 D Serial No. / year of construction
2 A Design
2 B Protection class2 C Insulation class
2 D Maximum axle load [ kN ]
3 A Mode of operation
3 D Weight of machine [ kg ]
4 E Rated output [ kW ]
4 F Motor speed [ U / min.]
4 G Voltage [ V ] (star connection)
4 H Strength of current [ A ]
4 J Efficiency4 K Starting torque [ Nm ]
4 L Power consumption [ A ]
4 M Frequency [ Hz ]
5 Note on further data
6 Traction sheave ; max. number of
ropes; rope
1
2
3
4
5
6 8
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 30 Issue 06.2004
4.1 Mounting of machine
AssemblyDAF270 is designed for headroom installation, but may also be used in themachine room provided that the proper means are made available.
1.) Delivered without machine frame:Delivery of a frame-less drive necessitates the need to make proper assemblyand fastening means available. The drive may be attached at the side threadholes dependent on the rope departure direction. Dimensions see chapter 3.6 .See to it that the motor connection box is accessible.To comply with the requirements for noise reduction / structure-borne noisetransmission isolation elements shall be inserted between drive fastening and
support.The tensile force resulting from lateral or diagonal rope departure must beconsidered and the drive supported properly.
2.) Delivered with machine frame (optional):Optionally DAF270 is delivered assembled and aligned on the machine frame.The frame is assembled in the headroom of the elevator installation inaccordance with the customer's specifications.The number of rubber elements and their arrangement depends on theoverall weight load and the possible supports.
The necessary or permissible individual load depends on the characteristicvalues of the isolation element.The rubber elements are to be arranged in such a way that the load isdistributed equally.
Design and dimension of the machine frame in accordance with thecustomer's specifications.
Note:prior to start setting the machine into operation remove the plastic coverof the ventilation hole underside the housing. (Fig. 1 pos. 4)
How to align the machine frameThe machine shall be assembled or installed in accordance with the layoutdrawing.Align the rope departure of traction sheave and deflection pulley inaccordance with the drawing so that it is in vertical line with the car ropepulley or the counterweight pulley. When the ropes are tensioned, themachine shall be arranged horizontally aligned at the base plate. Use metalplates to ensure that the base is perfectly horizontal.
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 31 Issue 06.2004
How to align the machine on the frame:The machine is delivered aligned. After disassembly of drive or displacing ofmachine (due to exchanged traction sheave, for example) verify that themachine is properly aligned and re-align, if required.
Note:when the machine is completely installed, tighten the fastening screwswith the pre-set torque. See chapter 8.1.
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 32 Issue 06.2004
4.2 Motor connection
Observe terminal diagram at the cover of the motor connection box orterminal diagram.Adhere to fig. 8. Verify that the safety instructions and the respective localbuilding regulations are complied with.Motor connection data of respective motor type see 3.3
Motor terminal diagram:for frequency-controlled motors
Temperature monitoring motor
Connect terminal connection "Th" (thermistor) and PTC tripping device (orfrequency inverter connection provided for that purpose.Voltage applied shall not exceed 2.5 V.
Fig. 8 Fig. 9
ThTh
Grd.
U
V
W
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 33 Issue 06.2004
4.3 Brake connection
Description and important instructions see chapter 3.4 and manufacturer's
instructions in chapter 8.3
Brake and encoder connection
3
7
4
2 1
5
6
8 9 10
11
12
1 Brake housing 7 Conn. PTC resistors motor
2 Brake test switch D 8 Encoder connection
3 Brake voltage connection 9 Fastening bow
4 Brake test switch 10 Bearing bracket
5 Terminal box 11 Cover plate brake
6 Brake test switch C 12 Encoder
Fig. 10
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 34 Issue 06.2004
Connection of brake:
Voltage supply of release coils and control switches
The brake release coils are located in the connection box (fig. 10 pos. 5) atthe front brake side.Connect four-conductor cable - cores 1; 2 (terminals 1; 2) = brake coil D andcores 3;4 (terminals 3; 4) = brake coil C - and brake circuit.
Connection of screened six-core cable from connection box (cores 1;2(terminal 6; 7) = temperature monitoring brake) and motor temperaturemonitoring with evaluator to be made by the customer. The voltage appliedshall not exceed 2.5 V.
Cores 3; 4 (terminals 8; 9) = brake monitoring D;and 5; 6 (terminals 10; 11) = brake monitoring C,must be connected to the brake monitoring.
Note:it is recommended to adhere to the instructions and recommendationsof the brake manufacturer as the performance of the brake in service mainlydepends on the circuit selected. See chapter 8.3.
Terminal
Connection
11
10
Brake monitoring D
9
8
Brake monitoring C
7
6
Thermal monitoring
brake
5 Series connection Th
4
3
Brake connection
brake D
2
1
Brake connection
brake C
Fig. 11
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 35 Issue 06.2004
For operating voltage of magnet coils (direct current acc. toDIN IECE038) see name plate at the brake body.Connection and corresponding type of brake see table Technical datachapter 3.4.
When the brake ERS VAR09 SZ1700 / 1700 is connected, make sure thatthe necessary overexitation is always maintained. Disregard may affect safeand quick operation! No overexcitation possible with brake type ERS VAR09SZ1700 / 1250.
Note:when disconnecting the brake coils alternative power supply isrecommended. Direct power supply necessitates protection of the coilsagainst the risk of transient overvoltage acc. to VDE 0580.Details on connection of connector plugs at the brake line ends see fig. 14and chapter 8.3, Manufacturer's instructions (Warner) point 5.2.1.
Miniature fuse:the fuses in the power supply lines are to be adapted to thecustomer's power supply.
Connection temperature monitoring brake:
The PTC thermistor detectors are series-connected (core grey/grey) at thefactory at the brake terminal box (terminal 5-7) via a screened cable. Seeterminal assignment and connections at terminal box (fig. 11) and connectionassignment for conductor in fig. 14.Terminals "Th" are to be connected to a PTC thermistor tripping device bythe customer. The voltage applied shall not exceed 2.5V.
See to itthat the distance to all revolving parts is observed by persons layingconnecting cables.Corresponding counter measures are to be made.Do not use the same cable duct for connecting lines used for temperaturemonitoring and brake test and motor connection line.
Connection release monitoring brakes:
Microswitches are attached at the coil body of the magnet brake. A pre-setand pre-assembled switch per brake circuit each monitors the brakecondition (opened/closed). The setting shall not be changed.
When replacing make sure that the switch setting is in accordance with theinstructions in chapter 7.3.Check the switches for proper setting and correct function.
Connection release monitoring switch
1
2
4
Input connectionbrown
Break contactconnection black
Make contactconnection blue
Fig. 12
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 36 Issue 06.2004
The switch connections are connected at the terminal box (fig. 11) viaa 6-core screened cable (fig. 14) for signal processing.
The connection at the customer is made as break contact.
An evaluation of the signal of both switch conditions must be made
by the customer!
Switching current range min. 10 mA to max. 100 mA at 24 VDC.
Further details see chapter 8.3 Manufacturer's instructions.
After connecting check brake and monitoring switches for correct functioning.
Note:an appropriate access to the brake and microswitches for theinspection, adjustment or replacement works must be possible.
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 37 Issue 06.2004
Magnetic brake with release monitoring
1 Contact extension for release monitoring C
2 Bearing bracket
3 Brake lining
4 Brake coil body C
5 Brake disc D
6 Anchor disc D
7 Brake coil body D
8 Cheese head screw (switch fastening)
9 Setting screw brake release C
10 Brake release switch C (release monitoring)
11 Eyebolt
12 Terminal box
4
1
Fi . 13
65
Air gap
2
3
7
8
9
10
11
12
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 38 Issue 06.2004
Connectionsideterm
inalbox
atbrake
Adernendhlsen
Adernendhlsen
PPHOENIX
conductor
Connecting cables magnetic brake
1 2 3 4PHOENIXconductor
6.
503
503
Brakecoil
connection
1 2 3
Core1
4
Core2
5 6 7
Core3
8
Core4
9
Core5
10Core6
Switch
C
Switch
D
6.
503
10000or6000
15
703
12+3
6.
6.8
120
3
Scree
ning
Fig. 14
Atthec
ustomer
Brake
monitoringandthermisto
rconnection
6.8
Thermis
to
Magnet
CandD
CoilD
CoilC
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 39 Issue 06.2004
4.4 Encoder connection
The encoder at the rear shaft end is screw-connected to the brake housing
by means of a fastening bracket. See fig. 10.Connection to control by means of a 10 m long connecting cable with15-pole sub-D connector.Pin assignment of connector see chapter 8.2 Manufacturer's instructions.Description and technical data for encoder connection see chapter 3.5.
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OPERATING MANUAL 4. MOUNTING OF MACHINE
ThyssenKrupp Aufzugswerke GmbH 40 Issue 06.2004
4.5 Schematic diagram DAF270
Winding
Temperature
monitoring
Brakemagnet
Controlswitch
En
coder
Motor
Brake
Temperature
monitoring
+M
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OPERATING MANUAL 5. PUTTING INTO SERVICE
ThyssenKrupp Aufzugswerke GmbH 41 Issue 06.2004
5.1 Putting DAF 270 into service
Before you start putting the machine into service the following points are tobe checked and/or the following works performed:
Check mounting and aligning of machine, frame and rope departure
Check fastening of machine and frame
Tighten screws and secure with pre-set torque (see table tighteningtorques in 8.1)
Check supply terminals, earthing of motor and brakes for connection andtest
Check thermal monitoring of motor and brake for connection to
connection PTC thermistor tripping device (not part of the supplyschedule)
Check brake and encoder for correct connection to control
Check lower release hole of drive for removal of plastic cover
Check whether safety, accessory and installations tools are removedfrom the danger zone
Check armature base plate and brake connection (chapter 6.2 c)
Check brake control switches for proper connection and functioning(chapter 7.3)
Perform brake test with one acting brake shoe each (chapter 6.2)
Check brake release (for emergency rescue even in case of powerfailure) for proper functioning (not part of supply schedule)
Check rope guard cover or rope support for proper mounting anddistance (max. 2mm) (not part of the supply schedule of machine frame)
Check special mountings (optional) for correct mounting and functioning
Attention:if the drive is operated by a brake control circuit instead of anemergency braking system (safety gear) against overspeed in upwardsdirection, it must be observed that the elevator installation shall only be put
into service with the brake monitoring faultlessly functioning!Never put the installation into service without brake test switches bydisconnecting the check-back or brake test switches and resetting the non-volatile memory (EPROM).Disregard may cause danger to life of persons.
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OPERATING MANUAL 6. SERVICING
ThyssenKrupp Aufzugswerke GmbH 42 Issue 06.2004
6.1 Servicing of DAF270
Servicing interval:servicing of the machine should be carried out at leastonce a year, preferably in the course of the general elevator servicing.
Note:installation and servicing works shall only be carried out by trained andqualified personnel.These persons must know and observe the respective regulations andrequirements for elevator installations as well as the accident preventionregulations.
Further information concerning proceeding, adjustment and data seechapters:
Check armature base plate - air gap between armature discand brake coil body for wear of brakes
6.2
Check brake deceleration 6.2
Check brake control switches for proper functioning 7.3
Check screw-connections and fastenings for propertightening (tightening torque)
8.1
Check grooves of traction sheave and drive fastening forproper tightening; re-tighten, if required.
7.4
Check groove profiles for damage and wear
Check electrical connections for correct working, soundcondition and proper fastening
Check motor bearings for wear (noise, backlash)
Check protective and safety equipment; test forcorrect working
Check protective and safety equipment; check danger andinstruction signs; check signs for proper affixing and visibility
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OPERATING MANUAL 6. SERVICING
ThyssenKrupp Aufzugswerke GmbH 43 Issue 06.2004
6.2 Drive brake test
Inspection interval:inspection of the brake shall be carried before initial
operation, after exchange of brake and once a year in the course of thegeneral elevator servicing.
a)The brake deceleration is tested for each brake circuit individually.
Note:before testing:
Inspection signs must be made available at the landing doors.
Close the doors acc. to the rules.
Make sure that the car is empty.
While testing the brake circuit with the empty car moving upwards the carmust be at least 2 landings below the upper-most landing.
While testing the brake circuit with the fully loaded car moving downwardthe car must be at least 2 landings above the lower-most landing.
The single circuits are tested by applying below voltage at the single brakecoils:
Brake type SZ1700/1700with excitation / withstand voltage 104 / 52 VDC
Brake type SZ1700/1200 with operating voltage 207 VDC
While testing the brake circuit, the brake of the 2. brake circuit must bereleased during the braking operation (even in case of emergency stop).Withstand voltage must be applied at the magnet coil of the 2. brakecircuit.Disable release monitoring of the brakes until the respective brake circuitis tested.
Attention:should the elevator move after release of one brake circuit or failto decelerate sensibly during the braking operation, switchthe continuouslyenergised coil off immediately.The dual circuit braking function is not guaranteed. Check brake!
Testing with deceleration measure:Check brake deceleration at each brake circuit individually.
Testing may be performed while moving the empty car upwards or the fullyloaded car downwards.
Connect deceleration measure
Activate normal run (brake to be tested is released)
Activate emergency stop as soon as rated speed is reached (brake to betested closes). While testing the brake circuits individually, the motor coilsshould be de-energized. Motor braking may lead to wrong test results.
Determine deceleration for 1. brake circuit using a measuring device
Compare measurement and reference value
Remove continuous voltage supply at continuously open 2. brake circuitand connect to 1. brake circuit.
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OPERATING MANUAL 6. SERVICING
ThyssenKrupp Aufzugswerke GmbH 44 Issue 06.2004
Repeat test at 2. brake circuit.
Deceleration values:
Minimum deceleration for onebrake circuit 0.4 m/s
Minimum deceleration for bothbrake circuits 1.0 m/s
Attention:after testing the brake, remove the continuous control voltage atthe 2. brake ciruit and establish the original condition (both brakes acting atthe same time). Enable the release control switches at the brakes again.
Simple testing of braking deceleration without measuring device:
(this inspection method only applies to travel heights 7mand control pointobservable from brake operation point.)
Inspection sequence:
The details described in a are to be observed.
Provide terminal for continuous power supply at brake circuit of the 2.brake coil.Move the fully loaded car at least two landings above the bottom-mostlanding.
Mark ropes at the height of the control point.The control point shall be easily visible from the brake operation position.(Marking at bracket height, for example).
Move the car upwards to the nearest landing. While testing, apply continuous control voltage at 2.brake.
Note: voltage must be present even with the main switch disabled. If not,both brakes will become effective.
Move fully loaded car downwards at normal speed. Observe control pointand ropes from brake operation position.
Switch off main switch as soon as marking reaches the control point.
Measure distance between marking and control point. This distancecorresponds approximately to the stopping distance of the tested brake
circuit. Remove continous operating voltage and apply at tested brake coil.
Compare stopping distance result and reference value.
Stopping distance The max. stopping distance for single brake circuit shall not exceed:1.8 m for installations with VN1.0 m/s; 3.5 m for installations with VN1,6 m/s;5.0 m for installations with VN2.0 m/s.
(These values only apply to simple testing)
Repeat described testing for 2. brake circuit.
Attention:when the brake is tested, the original switching condition is to beestablished (operation of both brake coils at the same time and connection ofbrake test switch).
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OPERATING MANUAL 6. SERVICING
ThyssenKrupp Aufzugswerke GmbH 45 Issue 06.2004
b) Testing of both brake circuits
When a brake circuit is tested individually, activate emergency stop operationand repeat testing for both brake circuits.
Deceleration must fall below the stopping distance of the single circuit tests !
c) Inspection of wearing condition:
Put a feeler gauge between coil body and armature disk and check air gap.The brake must be closed (coils de-energized).Repeat several times at the circumference.This method only applies to the front brake which is easily accessible. Thesecond brake is mounted recessed in the bearing bracket.
Testing the air gap at the second, recessed mounted brake:Screw the enclosed hexagon screws M8 x 150 (marked red) into
8.4 mm holes at the brake front (see fig.15 pos. 11). Screw in until thedistance between the screwhead and the support is approx. 1-3 mm.Attach dial gauge and holder at the brake and vertically align the dial gaugetowards the screwhead. (See fig. 15)Energize brake circuit to be tested shortly several times and read screwstroke at dial gauge. (The stroke corresponds to the airgap at the frontbrake).Afterwards removescrews and reposit.
Replace brake as soon as the max. limit air gap is reached. Repairs tobe performed at the factory!
Discription of brake replacement see chapter 7.5.
Note:the electro magnet may fail to attract the armature base plate properlyand without delay if the air gap is too large. This means that the brake opensdelayed or fails to open.Never tighten the red screws (fig.15, pos. 11). Remove the screws beforeoperation is started. In case of disregard the brakes cannot be closed!
Table air gap brake
Typ
Rated torque
for 2 brakecircuits
Rated air gap
Brakedcomplete
Limit air gap
Brakedcomplete
1250 2500Nm 0.35 mm
0,1max. 0.6mm
1700 3400Nm 0.35 mm 0,1
max. 0.7mm
Rated air gap brake closed (at zero current), new liningLimit air gap brake closed (at zero current), worn off lining
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OPERATING MANUAL 6. SERVICING
ThyssenKrupp Aufzugswerke GmbH 46 Issue 06.2004
Representation:checking of stroke movement of anchor plates (releasegap) at non-accessible brake C.
1
2
3
4
5
6
7
8
10
13
1 Brake switch connection (6-pole) 8 Detent edged washer SK12
2 Brake connection (4-pole) 9 Hexagon socket M12x200
3 Connection box brake 10 Protecting plate
4 Dial gauge 11 Hexagon socket M8x150
5 Dial gauge holder 12 Brake magnet housing D
6 Transport eyebolt M12 13 Encoder
7 Encoder connection 14 Hexagon socket M12 x 20
Fig. 15
9
11
11
12
14
8
9
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OPERATING MANUAL 7. MAINTENANCE
ThyssenKrupp Aufzugswerke GmbH 47 Issue 06.2004
7.1 Replacing of traction sheave
1 Traction sheave
2 Fitting key 25 x 14 x 90 mm
3 Disc
4 Detent edged washer SK16
5 Hexagon socket M 16 x 50 8.8 microencapsulated
Tightening torque = 195 Nm
6 Motor shaft
7 Motor housing
8 Motor connection box
9 Forcing hole
Installation sequence traction sheave replacement
Disassembly:
Switch off power supply; secure car and counterweight
Remove rope fixing beam
Fig. 16
View rotated 90
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OPERATING MANUAL 7. MAINTENANCE
ThyssenKrupp Aufzugswerke GmbH 48 Issue 06.2004
Remove load from traction sheave; discard ropes; secure traction sheavewith lifting device
Loosen screws on mounting disc of traction sheave; put screws in outerhole circle of disk (fig. 16, pos. 3) and loosely screw in traction sheave hub
(holes pos. 8). Place a washer approx. 5 10mm thick between shaft end and disc.
Tighten screws uniformly and remove traction sheave from motor shaft.
Put traction sheave down using lifting device.
Remove mounting disc from traction sheave
Assembly:
Clean shaft end and traction sheave holes; never make any dimensionalchanges in featherkey, groove, shaft or drilled holes
Never grease or oil shaft and holes
Carefully fit new traction sheave to conical end of motor shaft Bring position of featherkey and groove in line. Push traction sheave on
motor shaft
Assemble traction sheave using already available screws and tighten inaccordance with tightening torque.
Disassemble screws and disc
Check fit cover of traction sheave holes (the pressed on bearing surface ofthe traction sheave must project the front shaft at least 1.5 mm)
Fit and screw disc to motor shaft using new micro-encapsulated screwsand detent edged washers
Tighten fastening screws using torque wrench and bring to required torqueof 195 Nm in several operations.
Replace rope; remove securing devices at car and ropes
Screw on rope fixing beam
Attention: the traction sheave may work loose if assembled improperly.When the traction sheave is to be replaced, enclosed newmicro-encapsulated screws must be used.Observe screw strength and tightening torque!
Note:only use micro-encapsulated screws twice, since otherwise the
adhesive force is no longer effective
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OPERATING MANUAL 7. MAINTENANCE
ThyssenKrupp Aufzugswerke GmbH 49 Issue 06.2004
7.2 Replacing of pulse encoder
Disassembly:
Switch off power supply
Remove connector plug of encoder connection on control.
Unscrew clamp bolt at female encoder component using hexagon socketwrench M2.5 (2 screws pos. 3)
Unscrew encoder and fixing strap at brake (2 x M8)
Carefully remove encoder from shaft end into axial direction
1 Shaft end
2 Mounting elbow
3 Clamp bolt
4 Fastening screw
5 Female component -encoder
6 Encoder housing
Technical data, see chapter 2.8Manufacturer's instructionschapter 8.3
Fig. 17
Push onto orremove fromshaft end
1 2 3
6
5
4
4
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OPERATING MANUAL 7. MAINTENANCE
ThyssenKrupp Aufzugswerke GmbH 50 Issue 06.2004
Assembly:
Clean but do not greaseshaft end before you start mounting theencoder.
The shaft end must be clean and free of grease Carefully turn and push fixing strap and female encoder component onto
shaft end in direction of arrow until the fixing strap is close to the brake
Carefully tighten clamping bolt (pos.3) in the female component withoutdistorting the encoder.The encoder housing must be easy to move on the shaft
Turn encoder housing until the connecting cable is positioned properly.
Align strap holes towards threaded holes of brake; screw-connect fixingstrap at brake
Connect encoder connection to control
Adjust encoder
Attention:when performing test and inspection works never switch the driveon with the encoder unconnected; this can cause damage of electroniccomponents in the encoder.
Note:re-adjust the encoder with the pulse encoder being replaced or therotor position changed. Proceeding see operating manual of frequencyinverter.
Fig. 18
1 Hexagon socket screw
2 Fixing strap
3 Brake housing
4 Encoder
5 Shaft end6 Connecting line
7 Clamping bolt
1
5
1
4
3
2
6
7
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OPERATING MANUAL 7. MAINTENANCE
ThyssenKrupp Aufzugswerke GmbH 51 Issue 06.2004
7.3 Replacing of brake monitoring switch
Secure car and counterweight
Switch off power supply and protect installation against unintentionalswitching on
Disconnect defective switch at connection box (fig. 11) and replace
Mount new switch at brake coil body, fig. 13, pos. 10, and connect toterminal box
Setting and checking of brake monitoring switch:
Screw in setting screw M4 for switch operation by two to three screwturns. The switching contact of the brake monitoring switch shall nottouch the setting screw
Apply operating voltage at brake circuit to be set
Set distance between switching contact and setting screw to 0.15 mmusing a feeler gauge
Unscrew setting screw until the contact of the microswitch reaches theswitching point
Remove feeler gauge; disconnect operating voltage
Check microswitch for correct functioning by switching the brakes on andoff repeatedly
Seal fastening screws of release monitoring using sealing wax
Put installation into operation
7.4 Silencing of the brakes
The used noise dampening has been adjusted at the factory. However thenoise dampening is subject to a certain aging dependent on the applicationor operational conditions (switching frequency, torque adjustment, naturaldrive vibration).The brake must be completely exchanged, if the noise behaviour of the brakerises to an inadmissible level.An exchange of the damping elements is only possible at the manufacturer.
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OPERATING MANUAL 7. MAINTENANCE
ThyssenKrupp Aufzugswerke GmbH 52 Issue 06.2004
7.5 Replacing of brakes
1 Motor shaft 7 Brake magnet housing
2 Hexagon screw M8 x 40 8 Hexagon screw M12 x 200
3 Motor housing 9 Encoder
4 Bearing bracket 10 Fixing strap
5 Braking rotor 11 Toothed sleeve
6 Armature base plate 12 O ring
Fig. 19
1
2
3
4 5 6
8
9
Air gapAir gap
5
6
7
7
10
11
12
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Replacing of dual-circuit disc brake (Warner)
Note:for safety reasons, the brake must be completely replaced as soon asthe brake is defective or the wear limit reached.Exchange of the brake to be made in the house Warner.
To replace the brake proceed as follows:
Disasssembly:
Switch off power supply and secure installation against unintentionalswitching on
Rest counterweight on buffer; secure car
Remove cover plate at brake
Disconnect or unplug connecting cables between brake monitoringswitch, PTC thermistor and brake connections at brake.Remove terminal connection between encoder and motor shaft. Remove
fixing strap at brake housing and encoder at the same time. Assemblyinstructions see chapter 7.2.
Attention!Prior tocontinue disassembly screw in enclosed red hexagonsockets (M8x150). In case of disregard the brake parts will be separatedby spring force.
Screw transport eyebolts (M12) into side threads at the brake housingcircumference. Fix brakes at lifting device
Mark position of connection box at drive
Remove fastening screws (fig. 19 pos. 8)
Carefully push off brake housing and rotor from toothed sleeve (fig. 19
pos. 11) and place aside Carefully push off rear rotor at bearing bracket (use two screw drives as
lever, if necessary)Note:the toothed sleeve is pushed over the shaft end of the warmed updrive (240C). Non-defective pushing off is not possible, therefore. Re-use iftoothing is free from any visible damage.
Assembly:
Fasten new brake at lifting device
Clean and slightly grease toothed sleeve at motor shaft end
Replace defective O rings at toothed sleeve, if necessary Clean braking surface at bearing bracket of drive using special cleaner
and slightly grease (with DELOTHEN NK1, for example)
Mount front brake rotor to toothed sleeve (make sure that the rotor ismounted the right way round; hub collar backwards!)
Align new brake towards toothed sleeve using lifting device. Observeposition of connection box (marking at bearing bracket).
Before you start mounting the brake, connect the brake coils and makesure that the brake is open. In case of disregard, the brake rotor blocksand the brake housing cannot be moved and aligned while fitting the
screws. Mount brake and second brake rotor; tighten fastening screws and
observe proper tightening torque.
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Attention:avoid any impact onto the motor shaft as this may causedeterioration of the rolling bearings. Push rotor manually with a slightpressure over the toothed sleeve (O ring).Loosen red transport eyebolts at front side of brake (do not unscrew). Check
air gap of rear brake at bearing bracket using a dial gauge. (See descriptionin chapter 6.2)Then unscrew transport eyebolts and reposit. The screws must be availablefor future air gap checking and installation works.
Check air gap at front brake using feler gauge
Mount protective cover at brake housing. Observe tightening torque.(Observe sequence of installation. Disregard may cause deterioration ofthe cover!)
Mount pulse encoder (see chapter 7.2)
Connect brake magnet coils, brake monitoring switches, thermalelements and encoder to control
Remove transport contrivances at car and counterweight When the drive or the brakes are replaced, check the drive brake for
correct functioning before you start operation. See description inchapter 6.2.
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OPERATING MANUAL 8. ANNEX
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8.1 Tightening torque - mechanical strength
Attention: observe required screw strength and tightening torque whenperforming any work on the machine or exchanging parts.Non-microencapsulated screws must be secured against unintentionalworking loose using detent edged washers.
The values specified apply to the applications indicated below:
Hexagon socket screws ISO 4762 (DIN 912)Hexagon bolts ISO 4014 / 4017 (DIN 931 / 933)
To observe the required torque, tighten the screws using a torque
spanner!
Dimension Tightening torque MA[Nm]
Strength 8.8 10.9 12.9
M4 2,8 4,1 4,8
M5 5,5 8,1 9,5
M6 9,6 14 16M8 23 34 40
M10 46 67 79
M12 79 115 135
M16 195 290 340
M20 395 560 660
M24 680 970 1150
Attaching encoder on shaft Clamping bolt 2,5 Nm
Attaching encoder on brake M4 x 4 1,0 Nm
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8.2 Manufacturer's instruction for pulse encoder
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Mounting dimensions
Installation
30h7
4 x M4
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SW3 (2X))Md = 2,5
0,5Nm
10 000 mm
8745
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Pin assignment
nichtbelegt
15-pole sub-D connector (pin)
Data
Color
Color
Contact
Contact
Yellow
BlackBlack Black Black
BlueGray Red Purple Yellow
Red
Black
WhiteWhiteWhite
Green
Green Green
Brown
Inside
Screen
Blue
Not Assigned
Clock
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8.3 Manufacturers instructions - Brake
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8.4. Type test examination certificate for brake
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8.5. Declaration of conformity for brake
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8.6 Type examination certificate forcalculation of traction sheave shaft
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