Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ThyssenKrupp
Elevator
ThyssenKrupp Aufzugswerke
ThyssenKrupp
Operating Manual
Mini gearless DAF270
OPERATING MANUAL
Imprint
All rights reserved
Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH
P.O. box 23 03 70, D-70623 Stuttgart
Printed in Germany, June 2004
The copyright of this documentation rests with THYSSENKRUPP AUFZUGSWERKE
GmbH. This documentation or extracts of it shall not be copied, distributed or used for the
purpose of competition.
Any reprint, copying or storing in data processing machines in any form or by any means
without prior permission of THYSSENKRUPP AUFZUGSWERKE GmbH is regarded as
infringement 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 GMBH
without prior notice.
Preface
We are pleased that you decided to purchase a quality product from THYSSENKRUPP
AUFZUGSWERKE GmbH.
This operating manual assists you in getting familiar with the drive for moving cars - the
Mini gearless DAF270 (which is referred to as DAF270 below) - and its intended
possibilities of use. Important information concerning safety and hazards helps you to
safely use the DAF270.
DAF270 is subject to technical alterations.
Issue 06.2004
OPERATING MANUAL
Table of contents
Mini gearless DAF270
PAGE
1. Safety
1.1 Explanation of symbols used
1.2 General safety information
6
7
10
3. Product description
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Description of DAF270
Functional description
Technical data - machine
Technical data - brake
Pulse encoder
Dimensions
Machine frame
Lubrication
Name plate
12
14
17
20
21
22
25
27
28
4. Mounting of machine
4.1
4.2
4.3
4.4
4.5
Mounting of machine
Motor connection
Connection of magnetic brake
Connection of encoder
Schematic diagram
30
32
33
39
40
41
6. Servicing
6.1 Servicing of machine
6.2 Drive brake test
42
43
7. Maintenance
7.1
7.2
7.3
7.4
7.5
47
49
51
51
52
8. Annex
8.1
8.2
8.3
8.4
8.5
8.6
55
56
61
66
70
72
Issue 06.2004
OPERATING MANUAL
1.1
1. SAFETY
Issue 06.2004
OPERATING MANUAL
1.2
1. SAFETY
Issue 06.2004
OPERATING MANUAL
1. SAFETY
Use as intended
DAF270 is designed in accordance with the state of the art and the
recognized 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 is
regarded as use outside of the intended purpose. THYSSENKRUPP
AUFZUGSWERKE cannot be hold liable for any damages resulting from this
and 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.
Issue 06.2004
OPERATING MANUAL
1. SAFETY
Issue 06.2004
OPERATING MANUAL
2.
Top
Keep dry
Do not expose to
heat
Fasten here
10
Issue 06.2004
OPERATING MANUAL
Unpacking
Information
Intermediate storage
Environmental conditions
Information
Surrounding at the final site of the machine (humidity, temperature) shall
comply with the requirements for machine rooms. (Between +5 and +40
C according to EN81).
Relative humidity of air shall not exceed 70%.
11
Issue 06.2004
OPERATING MANUAL
3.1
3. PRODUCT DESCRIPTION
2
1
Fig. 1
7
Part designation
Disc on motor shaft
Cheese head screw
M12x 50
Traction sheave
Ventilation opening
Casted housing
Thread for fastening M16
Motor terminal box
Bearing bracket
12
Pos.
9
10
11
12
13
14
15
16
Part designation
Transport hole
Cover plate for brake
Encoder
Brake terminal box
Encoder connection
Electromagnetic brake
Cable duct thermal contact
Cable duct motor connection
Issue 06.2004
OPERATING MANUAL
3. PRODUCT DESCRIPTION
10
11
12
13
Fig. 2
7
16
15
14
Versions:
The following versions are available:
1. Various drive capacities
2. Motors with electrical rating for inverters with sinusoidal mains
regeneration 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
ThyssenKrupp Aufzugswerke GmbH
13
Issue 06.2004
OPERATING MANUAL
3.2
3. PRODUCT DESCRIPTION
Functional description
Machine: DAF270 consists of a frequency-controlled permanent-magnet
synchronous motor.
DAF270 has two different power ranges, which are differentiated by the letter
behind the type designation:
DAF270 M (medium) for the standard and DAF270 L (large) for the higher
power range. The external housing dimensions differ in size. See chapter 3.6
Dimensions.
The machine has a monobloc housing with integrated bearing bracket on one
side.
The drive shaft with rolling bearings is made of tempering steel.
The front self-aligning bearing and the rear rolling bearing of the bearing
bracket 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 the
drives 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 thermal
class 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 drive
is 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 with
detent 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 the
motor 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 pressed
against the brake lining of the rotor. The rotor is pushed and the second rotor
lining acts on the rigid bearing surface of the brake or the bearing bracket.
14
Issue 06.2004
OPERATING MANUAL
3. PRODUCT DESCRIPTION
The two rotors are rigidly connected to the motor shaft through interlocked
holes and a hub.
Brake release: the voltage-fed brake magnet coils attract the armature discs
and release the brake rotors.
The brakes cannot be released manually.
The brake torque of each brake circuit permits to stop the car loaded with
rated load at rated speed. The brake torque cannot be adjusted.
Note: the brakes of DAF270 are designed for use as holding brake. Any
dynamic braking is restricted to emergency and test braking. Normal use will
not lead to any noticeable wear on the lining.
This drive brake can in no way replace the safety braking system used for
downward operation.
Attention: the manufacturer of the lift installation must provide proper
measures 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 brake
position (released/closed) of each brake. Any failure is signaled to the
control. The machine must be shutdown or a further run prevented if the drive
either runs at zero speed with one brake circuit open or starts with one brake
circuit closed.
For terminal diagram see chapter 4.3 and adjusting of brake test switch
chapter 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 case
of overspeed if the braking device of the DAF270 is utilized as ascending
car overspeed protection means. The requirements including range of use
and conditions set out in the annex of type test certificate No. ABV 591 of
01-08-08 must be complied with. See chapter 8.4.
Real value generator: DAF270 is a synchronous machine excited by a
permanent magnet. In energized state the absolute rotor position is supplied
by a sine-cosine-wave absolute position encoder. Speed and shaft position
are 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 of
installation shall comply with the requirements for machine rooms and thus
be 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, the
braking torque of the disc brake can be reduced due to condensation.
In case of a longer standstill, the friction linings can rust at the friction
surfaces.
Corresponding counter measures are to be made by the owner of the
component.
15
Issue 06.2004
OPERATING MANUAL
3. PRODUCT DESCRIPTION
English
Note: an installation frame, which makes delivery of the frame into the
headroom easier, is optionally available.
Please contact LiftEquip, if interested.
16
Issue 06.2004
OPERATING MANUAL
3.3
3. PRODUCT DESCRIPTION
DAF270
Version
M 0xx
L 0xx
[mm]
320
440
490
[mm]
145
132
150
10 x 8
7 x 10
Seat or V-groove
8 x 10
1)
[Nm]
2x1700
2x1250
ABV 591
[kgm]
[kgm]
0.53
1,50
2,45
[kgm]
2.63
3,60
5,35
[kN]
43.5
57
57
[kg]
550
570
740
[kg]
35
55
65
[kg]
400 - 650
[kg]
400 - 600
2.10
2,90
sheave)
17
Issue 06.2004
IA
Starting current
kg
1600
CPI26.
CPI32
65
45
2200
0.94
83
14.50
330
24
87
1175
10.7
440
1600
CPI50R
90
68
2200
0.95
88
23.20
350
30
139
1050
15.3
440
1.6
1600
CPI48
90
78
2200
0.94
86
23.20
305
35
139
1025
14.9
440
1.6
1600
CPI48
90
78
2200
0.95
87
25.30
330
35
152
1025
16.3
440
1.75
1600
CPI48.
2)
CPI60
100
89
2200
0.96
90
29.00
320
38
174
1000
18.2
440
2.0
18
1) The rated output indicated only applies to unbalanced installations under S5 operation (240 F/h, 50% Ed) with max. MA!
Inverter type
(assigned as standard)
Imax.zul.
MA
Starting torque
cos
Power factor
Nm
Efficiency (100%PN)
Hz
fStator
Stator frequency
IN
Rated current
min
U,eff
nRot
Speed
-1
Nm
kW
mm
Effective voltage
MN
PN
Rated torque
Rated output
1)
DT
1)
1.0
2:1
m/s
2:1
2:1
Elevator speed
2:1
2:1
Issue 06.2004
1000
CPI15
49
34
2200
0.94
79
10.00
330
18
60
1175
7.4
320
1.0
1:1
M008
Suspension
M 002
M 005
M 002
M 000
TYP DAF270
M 001
3. PRODUCT DESCRIPTION
OPERATING MANUAL
IA
Starting current
kg
2000
CPI50R,
CPI100R
100
75
2750
0,96
82
26
430
235
156
1375
22,5
490
2000
CPI26E
490
1,0
2:1
L009
19
1) The rated output only applies to unbalanced S5 operation (240 F/h, 50% Ed) at max. MA!
Inverter type
(assigned as standard)
Imax.zul.
MA
Starting torque
cos
Power factor
Nm
Efficiency (100%PN)
Hz
fStator
Stator frequency
IN
Rated current
min
U,eff
nRot
Speed
-1
Nm
kW
mm
Effective voltage
MN
PN
Rated torque
Rated output
1)
DT
1)
Elevator speed
2,0
2:1
Suspension
m/s
L 007
TYP DAF270
OPERATING MANUAL
Issue 06.2004
3. PRODUCT DESCRIPTION
OPERATING MANUAL
3.4
3. PRODUCT DESCRIPTION
Type:
ERS VAR09
SZ1700 / 1250
ERS VAR09
SZ1700 / 1700
Manufacturer
Brake torque
2 x 1250 Nm
2 x 1700 Nm
Version
Operating voltage
(one brake circuit)
Rated output
(one brake circuit)
40C
100C
100C
Maximum speed
250 min
0.35 + 0.05/-0.1 mm
0.35 + 0.05/-0.1 mm
circuit)
Maximum air gap in case of
wear
0.6 mm
0.7 mm
Operating time
Length of connecting line
ED 60 %
ED 60 %
10 m
6m
approx. 84 kg
approx. 84 kg
ABV 591
ABV 591
-1
Release monitoring
(per brake circuit)
Switching voltage
Switching capacity
Operating distance at setting
screw
250 min
-1
1 x microswitch
24 VDC
10 100 mA
0.15 mm
20
Issue 06.2004
OPERATING MANUAL
3.5
3. PRODUCT DESCRIPTION
Pulse encoder
DAF270 is controlled by means of an enclosed incremental hollow shaft
encoder with sine-wave output signals mounted on the rear end of the rotor
shaft.
Connection to control by means of permanently connected shielded
connecting cable of 10 m length with 15-pole sub D connector (RS485) and
UNC 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 and
reference 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:
Storage temperature range:
Permissible relative humidity:
Max. on-load current with 5 V
Protection class: IP 64
- 20...+ 100
- 30...+ 80
100
150
C
C
%
mA
21
Issue 06.2004
OPERATING MANUAL
3.6
3. PRODUCT DESCRIPTION
Dimensions
Dimensions DAF270 M 0xx
550
M20 x 28 deep
550
346
DT=440
Brake connection
Center of
gravity
Fig. 3
22
Issue 06.2004
OPERATING MANUAL
3. PRODUCT DESCRIPTION
550
M20 x 28 deep
550
346
DT = 490
Brake connection
Center of
gravity
Fig. 4
23
Issue 06.2004
OPERATING MANUAL
3. PRODUCT DESCRIPTION
M20 x 28 deep
550
550
346
Dt = 320
Brake connection
Fig. 5
Center of gravity
24
Issue 06.2004
OPERATING MANUAL
3.7
Machine frame
3. PRODUCT DESCRIPTION
(optional)
Fig. 6
Machine frame with mounted drive, overspeed governor and terminal rope
anchorages for headroom installation
25
Issue 06.2004
OPERATING MANUAL
3. PRODUCT DESCRIPTION
The shaft dimensions and the parallel distance of the ropes at the point of
rope departure (ASL) (tailor-made acc. to customer specifications in
accordance with available versions) define the frame design and dimensions.
DAF270 with frame from LiftEquip for headroom installation.
Fig. 7
26
Issue 06.2004
OPERATING MANUAL
3.8
3. PRODUCT DESCRIPTION
Lubrication DAF270
DAF270 has lifetime-lubricated rolling bearings. The bearings do not require
lubrication.
27
Issue 06.2004
OPERATING MANUAL
3.9
3. PRODUCT DESCRIPTION
1
2
3
B3
120 kN
4
5
6
G
Line
1
1
2
2
2
3
3
4
4
4
4
4
4
4
4
4
5
6
Column
A-D
E-F
A
B
D-F
A-E
F
G
H
I
J
K
L
M
N
O
A-F
A-F
Meaning
Machine type
Serial No. / year of construction
Design
Protection class
Insulation class
Mode of operation
Weight of machine [ kg ]
Rated output [ kW ]
Motor speed [ U / Min.]
Voltage [ V ] (star connection)
Power strength [ A ]
Efficiency
Starting torque [ Nm ]
Power consumption [ A ]
Frequency [ Hz ]
Operating force brake magnet [Nm]
Traction sheave ; max. number of
ropes; rope
28
Issue 06.2004
OPERATING MANUAL
3. PRODUCT DESCRIPTION
2. LiftEquip
A
1
2
3
4
5
6
Line
1
1
2
2
2
2
3
3
Column
A
D
A
B
C
D
A
D
4
4
4
4
4
4
4
4
5
6
E
F
G
H
J
K
L
M
Content
Machine type
Serial No. / year of construction
Design
Protection class
Insulation class
Maximum axle load [ kN ]
Mode of operation
Weight of machine [ kg ]
Rated output [ kW ]
Motor speed [ U / min.]
Voltage [ V ] (star connection)
Strength of current [ A ]
Efficiency
Starting torque [ Nm ]
Power consumption [ A ]
Frequency [ Hz ]
Note on further data
Traction sheave ; max. number of
ropes; rope
29
Issue 06.2004
OPERATING MANUAL
4.1
4. MOUNTING OF MACHINE
Mounting of machine
Assembly
DAF270 is designed for headroom installation, but may also be used in the
machine 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 assembly
and fastening means available. The drive may be attached at the side thread
holes 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 noise
transmission isolation elements shall be inserted between drive fastening and
support.
The tensile force resulting from lateral or diagonal rope departure must be
considered 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 in
accordance with the customer's specifications.
The number of rubber elements and their arrangement depends on the
overall weight load and the possible supports.
The necessary or permissible individual load depends on the characteristic
values of the isolation element.
The rubber elements are to be arranged in such a way that the load is
distributed equally.
Design and dimension of the machine frame in accordance with the
customer's specifications.
Note: prior to start setting the machine into operation remove the plastic cover
of the ventilation hole underside the housing. (Fig. 1 pos. 4)
How to align the machine frame
The machine shall be assembled or installed in accordance with the layout
drawing.
Align the rope departure of traction sheave and deflection pulley in
accordance with the drawing so that it is in vertical line with the car rope
pulley or the counterweight pulley. When the ropes are tensioned, the
machine shall be arranged horizontally aligned at the base plate. Use metal
plates to ensure that the base is perfectly horizontal.
30
Issue 06.2004
OPERATING MANUAL
4. MOUNTING OF MACHINE
31
Issue 06.2004
OPERATING MANUAL
4.2
4. MOUNTING OF MACHINE
Motor connection
Observe terminal diagram at the cover of the motor connection box or
terminal diagram.
Adhere to fig. 8. Verify that the safety instructions and the respective local
building regulations are complied with.
Motor connection data of respective motor type see 3.3
Th
Th
U
V
W
Grd.
Fig. 8
Fig. 9
32
Issue 06.2004
OPERATING MANUAL
4.3
4. MOUNTING OF MACHINE
Brake connection
Description and important instructions see chapter 3.4 and manufacturer's
instructions in chapter 8.3
Brake and encoder connection
8
10
11
12
5
4
Fig. 10
Brake housing
Encoder connection
Fastening bow
10
Bearing bracket
Terminal box
11
12
Encoder
33
Issue 06.2004
OPERATING MANUAL
4. MOUNTING OF MACHINE
Connection of brake:
Connection
Terminal
11 Brake monitoring D
10
9 Brake monitoring C
8
7 Thermal monitoring
6 brake
5 Series connection Th
4 Brake connection
3 brake D
2 Brake connection
1 brake C
Fig. 11
Connection of screened six-core cable from connection box (cores 1;2
(terminal 6; 7) = temperature monitoring brake) and motor temperature
monitoring with evaluator to be made by the customer. The voltage applied
shall 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 recommendations
of the brake manufacturer as the performance of the brake in service mainly
depends on the circuit selected. See chapter 8.3.
34
Issue 06.2004
OPERATING MANUAL
4. MOUNTING OF MACHINE
Break contact
connection black
Make contact
connection blue
Fig. 12
35
Issue 06.2004
OPERATING MANUAL
4. MOUNTING OF MACHINE
The switch connections are connected at the terminal box (fig. 11) via
a 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 the
inspection, adjustment or replacement works must be possible.
36
Issue 06.2004
OPERATING MANUAL
4. MOUNTING OF MACHINE
2
8
9
10
11
12
Fig. 13
1
2
3
4
5
6
7
8
9
10
11
12
37
Issue 06.2004
Fig. 14
38
6.
Screening
12 + 3
6.8
70 3
10 000 or 6 000 15
50 3
6.
50 3
6.
At the customer
Adernendhlsen
120 3
Adernendhlsen
50 3
10 000 6 000 15
1
2
3
4
1
2
3 Core 1
4 Core 2
5
6
7 Core 3
8 Core 4
9 Core 5
10 Core 6
P PHOENIX
Switch D
Switch C
Thermistor
Magnet C and D
conductor
Coil C
Coil D
PHOENIX conductor
OPERATING MANUAL
4. MOUNTING OF MACHINE
Issue 06.2004
OPERATING MANUAL
4.4
4. MOUNTING OF MACHINE
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 with
15-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.
39
Issue 06.2004
OPERATING MANUAL
+M
Winding
Motor
Temperature
monitoring
Encoder
Brake magnet
Temperature
monitoring
Brake
Control switch
4.5
4. MOUNTING OF MACHINE
40
Issue 06.2004
OPERATING MANUAL
5.1
41
Issue 06.2004
OPERATING MANUAL
6.1
6. SERVICING
Servicing of DAF270
Servicing interval: servicing of the machine should be carried out at least
once a year, preferably in the course of the general elevator servicing.
Note: installation and servicing works shall only be carried out by trained and
qualified personnel.
These persons must know and observe the respective regulations and
requirements for elevator installations as well as the accident prevention
regulations.
Further information concerning proceeding, adjustment and data see
chapters:
6.2
6.2
7.3
8.1
7.4
42
Issue 06.2004
OPERATING MANUAL
6.2
6. SERVICING
43
Issue 06.2004
OPERATING MANUAL
6. SERVICING
0.4 m/s
1.0 m/s
Attention: after testing the brake, remove the continuous control voltage at
the 2. brake ciruit and establish the original condition (both brakes acting at
the 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 7m and control point
observable 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-most
landing.
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 point
and 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 distance
corresponds 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 VN 1.0 m/s; 3.5 m for installations with VN 1,6 m/s;
5.0 m for installations with VN 2.0 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 be
established (operation of both brake coils at the same time and connection of
brake test switch).
ThyssenKrupp Aufzugswerke GmbH
44
Issue 06.2004
OPERATING MANUAL
6. SERVICING
Rated torque
for 2 brake
circuits
1250
2500 Nm
1700
Rated air gap
Limit air gap
3400 Nm
0.35 mm
0,1
max. 0.6 mm
0.35 mm
0,1
max. 0.7 mm
45
Issue 06.2004
OPERATING MANUAL
6. SERVICING
11
12
9
3
8
Fig. 15
9
14
13
11
10 Protecting plate
Dial gauge
13 Encoder
Encoder connection
46
Issue 06.2004
OPERATING MANUAL
7.1
7. MAINTENANCE
View rotated 90
Fig. 16
1
2
3
4
5
6
7
8
9
Traction sheave
Fitting key 25 x 14 x 90 mm
Disc
Detent edged washer SK16
Hexagon socket M 16 x 50 8.8 microencapsulated
Tightening torque = 195 Nm
Motor shaft
Motor housing
Motor connection box
Forcing hole
47
Issue 06.2004
OPERATING MANUAL
7. MAINTENANCE
Remove load from traction sheave; discard ropes; secure traction sheave
with lifting device
Loosen screws on mounting disc of traction sheave; put screws in outer
hole 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 dimensional
changes 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 in
accordance with tightening torque.
Disassemble screws and disc
Check fit cover of traction sheave holes (the pressed on bearing surface of
the traction sheave must project the front shaft at least 1.5 mm)
Fit and screw disc to motor shaft using new micro-encapsulated screws
and detent edged washers
Tighten fastening screws using torque wrench and bring to required torque
of 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 new microencapsulated 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
48
Issue 06.2004
OPERATING MANUAL
7.2
7. MAINTENANCE
6
5
Push onto or
remove from
shaft end
Fig. 17
1
2
3
4
5
6
Shaft end
Mounting elbow
Clamp bolt
Fastening screw
Female component encoder
Encoder housing
Disassembly:
49
Issue 06.2004
OPERATING MANUAL
7. MAINTENANCE
Assembly:
Clean but do not grease shaft end before you start mounting the
encoder.
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 without
distorting 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 fixing
strap at brake
Connect encoder connection to control
Adjust encoder
Attention: when performing test and inspection works never switch the drive
on with the encoder unconnected; this can cause damage of electronic
components in the encoder.
1
2
3
4
6
1
Fig. 18
Fixing strap
Brake housing
Encoder
Shaft end
Connecting line
Clamping bolt
Note: re-adjust the encoder with the pulse encoder being replaced or the
rotor position changed. Proceeding see operating manual of frequency
inverter.
50
Issue 06.2004
OPERATING MANUAL
7.3
7. MAINTENANCE
7.4
51
Issue 06.2004
OPERATING MANUAL
7.5
7. MAINTENANCE
Replacing of brakes
4
5
6
7
8
2
9
10
11
12
Air gap
Air gap
Fig. 19
1
Motor shaft
Hexagon screw M8 x 40
Motor housing
Encoder
Bearing bracket
10 Fixing strap
Braking rotor
11 Toothed sleeve
12
52
O ring
Issue 06.2004
OPERATING MANUAL
7. MAINTENANCE
53
Issue 06.2004
OPERATING MANUAL
7. MAINTENANCE
Attention: avoid any impact onto the motor shaft as this may cause
deterioration of the rolling bearings. Push rotor manually with a slight
pressure 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 description
in chapter 6.2)
Then unscrew transport eyebolts and reposit. The screws must be available
for 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 of
the cover!)
Mount pulse encoder (see chapter 7.2)
Connect brake magnet coils, brake monitoring switches, thermal
elements 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 in
chapter 6.2.
54
Issue 06.2004
OPERATING MANUAL
8.1
8. ANNEX
Dimension
Strength
10.9
12.9
M4
2,8
4,1
4,8
M5
5,5
8,1
9,5
M6
9,6
14
16
M8
23
34
40
M10
46
67
79
M12
79
115
135
M16
195
290
340
M20
395
560
660
M24
680
970
1150
Clamping bolt
M4 x 4
55
2,5 Nm
1,0 Nm
Issue 06.2004
OPERATING MANUAL
8.2
8. ANNEX
56
Issue 06.2004
OPERATING MANUAL
8. ANNEX
Mounting dimensions
30 h7
4 x M4
Installation
57
Issue 06.2004
OPERATING MANUAL
8. ANNEX
58
Issue 06.2004
OPERATING MANUAL
8. ANNEX
87
45
SW3 (2X))
Md = 2,5
0,5Nm
10 000 mm
59
Issue 06.2004
OPERATING MANUAL
8. ANNEX
Pin assignment
15-pole sub-D connector (pin)
Data
Clock
Contact
Color
Green
Black
Yellow
Black
Blue
Black
Red
Black
nicht
Not Assigned
belegt
Gray
Red
Purple
Yellow
Inside
Screen
Contact
Color
Brown
Green
White
Green
Blue
White
White
Black
60
Issue 06.2004
OPERATING MANUAL
8.3
8. ANNEX
61
Issue 06.2004
OPERATING MANUAL
8. ANNEX
62
Issue 06.2004
OPERATING MANUAL
8. ANNEX
63
Issue 06.2004
OPERATING MANUAL
8. ANNEX
64
Issue 06.2004
OPERATING MANUAL
8. ANNEX
65
Issue 06.2004
OPERATING MANUAL
8.4.
8. ANNEX
66
Issue 06.2004
OPERATING MANUAL
8. ANNEX
67
Issue 06.2004
OPERATING MANUAL
8. ANNEX
68
Issue 06.2004
OPERATING MANUAL
8. ANNEX
69
Issue 06.2004
OPERATING MANUAL
8.5.
8. ANNEX
70
Issue 06.2004
OPERATING MANUAL
8. ANNEX
71
Issue 06.2004
OPERATING MANUAL
8.6
8. ANNEX
72
Issue 06.2004