thyssen лебедка daf-270

7/23/2019
THYSSEN (Maquina Mini Gearless DAF-270)
Operating Manual
Mini gearless® DAF270
A company of
ThyssenKrupp
Elevator
ThyssenKrupp Aufzugswerke
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THYSSEN (Maquina Mini Gearless DAF-270)
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.
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 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.
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
Table of contents
Mini gearless® DAF270
PAGE
1. Safety
1.1
1.2
Explanation of symbols used
General safety information
2. Transportation and storage
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
Mounting of machine
Motor connection
4.3 Connection
Connection of
of encoder
magnetic brake
4.4
4.5 Schematic diagram
30
32
33
39
40
5. Putting into service
5.1
Putting machine into service
41
6. Servicing
6.1
6.2
Servicing of machine
Drive brake test
42
43
7. Maintenance
7.1
7.2
7.3
7.4
7.5
Replacing of traction sheave
Replacing of pulse encoder
Replacing of brake monitoring switch
Silencing of brakes
Replacing of brakes
47
49
51
51
52
8. Annex
8.1
8.2
8.3
8.4
8.5
8.6
Tightening torque – mechanical strength
Manufacturer's instructions for pulse encoder
Manufacturer's instructions for magnetic brake
Type test examination certificate for brake
Declaration of conformity for brake
Type examination certificate for
calculation of traction sheave shaft
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61
66
70
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OPERATING MANUAL
1.1
1. SAFETY
Explanation of symbols used
The following pictographs and designations are used in this operating manual:
Danger
This symbol draws attention to an extreme danger to
life or risk of injury to persons.
Disregard of warning means danger to life!
Danger
This symbol draws attention to an immediate
impending danger to life or risk of injury to persons
caused
bymust
electric
current.
Warnings
always
be observed!
Warning
This symbol draws attention to an impending danger.
Disregard can cause injury to persons or extensive
damage to property.
Warnings must always be observed!
Note
This
symbol draws
toDisregard
important can
information
and instructions
for attention
operation.
lead to
damages, hazards or failures.
Inspection
This symbol draws attention to the proper inspection
sequence.
These inspection notices must be observed in any
case. Disregard can lead to injury to persons or
damage to property.
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
1.2
1. SAFETY
General safety information
Information on the operating manual
Knowledge of the basic safety requirements is a prerequisite for the safe use
and fail-free operation of this component.
This operating manual comprises the most important information how to
safely use the component.
The operating manual and, in particular, the safety information must be
observed by all persons who perform any work on the component.
In addition the rules and requirements concerning the regulations for
prevention of accidents which apply to the installation location must be
observed.
Duties of the owner and / or the installer
The owner and / or the installer ensure that only persons are authorized to
work at the component, who
• are familiar with the requirements concerning safe working and prevention
of accidents and who were trained how to use the component.
• have read the safety information and the warning notices in this operating
manual.
Note: check the compliance of the employees method of working with the
safety 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 of
accidents;
• to read the safety information and the warning notices in this operating
manual prior to start working.
Training of the employees
Only trained and instructed, technically competent persons shall perform
work at the component.
The competence of the employees must be clearly defined for all tasks
concerning putting into service, operation, maintenance and repair work.
Organizational measures
The owner or the installer must provide the necessary personal protective
gear.
All maintenance
existing safety
devices must be checked regularly in accordance
with the
plan.
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OPERATING MANUAL
1. SAFETY
Informal information about safety measures
•
•
•
•
The operating manual must always be available at the location of the
installation.
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 always
visibly and legibly made available on the machine.
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.
Guarantee and liability
The "General Conditions and Terms of Sale" of THYSSENKRUPP
AUFZUGSWERKE GmbH apply generally.
Any claims for guarantee and liability are excluded in the case of injury to
persons or damage to property resulting from one or several of the causes
below:
• use of DAF270 outside the scope of its intended purpose
• inexpert mounting, putting into service, operating and maintaining of
DAF270
• use of DAF270 with defective and/or non-operative safety and
protective devices
• disregard of the instructions in the operating manual that apply to
transportation, storage, mounting, putting into service, operation and
maintenance 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
Constructional modifications at DAF270
DAF270 is adjusted at the factory and delivered ready for work.
In the case of any modifications of the machine THYSSENKRUPP
AUFZUGSWERKE GmbH cannot be hold liable.
Use of DAF270 and possible hazards
DAF270 shall only be operated in a closed machine room, provided with
cover and rope guard at the traction sheave or installed in a machine frame
in the headroom. The owner of the installation must verify that the drive is
accessible 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 switching
on.
See to it that the safety distance to all revolving parts (marked yellow) is
observed 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 eliminated
immediately.
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
2.
2. TRANSPORT AND STORAGE
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 a
special pallet screwed below the machine frame.
Remove these transport contrivances before you install the machine on
site.
Transport:
Machine and frame must be perfectly horizontal and the safety precautions
observed .
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 and
not to the machine.
Pay attention to projecting parts! There is the risk of injury to persons or
damage!
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 motor
housing!
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 to
heat
Do not use handheld
grippers
Fasten here
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OPERATING MANUAL
2. TRANSPORT AND STORAGE
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 during
transport.
Information
•
•
Immediately document the damage noticed (drawing, photograph,
description of damage).
Immediately send the respective documents to THYSSENKRUPP
AUFZUGSWERKE GmbH.
Unpacking
Information
•
•
Dispose packing equipment in accordance with the environmental
standards or make it available for further use.
Special transport aids and transport contrivances remain at the
customer.
Intermediate storage
•
•
•
Even if the component is not mounted directly after delivery, it should be
stored in dry places and protected with humidity-proof covering.
Do not store the component in the open air. Parts without surface coating
lack long-time preservation.
Open ventilation opening.
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%.
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OPERATING MANUAL
3.1
3. PRODUCT DESCRIPTION
Description of Mini gearless DAF270
5
4
9
9
3
2
1
Fig. 1
7
6
Represented without rope guard and covering
DAF270 consists of:
Pos.
1
Part designation
Pos.
Part designation
9
Transport hole
2
Disc on motor shaft
Cheese head screw
M12x 50
10
Cover plate for brake
3
Traction sheave
11
Encoder
4
Ventilation opening
12
Brake terminal box
5
Casted housing
13
Encoder connection
6
7
Thread for fastening M16
Motor terminal box
14
15
Electromagnetic brake
Cable duct thermal contact
8
Bearing bracket
16
Cable duct motor connection
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OPERATING MANUAL
3. PRODUCT DESCRIPTION
DAF270 rear view
9
5
8
9
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
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OPERATING MANUAL
3.2
3. PRODUCT DESCRIPTION
Functional description
Machine:
DAF270
synchronous
motor.consists of a frequency-controlled permanent-magnet
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
frontare
self-aligning
the rear rolling bearing of the bearing
bracket
sealed andbearing
life-timeand
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
is designed for thermal class F but used according to thermal
classmachine
B.
DAF270 has a self-ventilated motor (without auxiliary forced ventilation)
Operating temperature (max. 130°C ± 5°C) 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.
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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.
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OPERATING MANUAL
3. PRODUCT DESCRIPTION
Machine frame: the drive DAF270 is designed for installation in the
headroom, but can also be utilized for installation in the machine room. The
machine frame necessary for installation of the machine in the headroom is
delivered optionally.
The drive is delivered completely pre-assembled.
For details concerning machine frame and installation see separate
documents for frame.
LiftEquip: LiftEquip customers obtain a project planning form with design
data 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 the
headroom easier, is optionally available.
Please contact LiftEquip, if interested.
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OPERATING MANUAL
3.3
3. PRODUCT DESCRIPTION
Technical data machine
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
10 x 8
7 x 10
Max. groove number – z x d
Groove form traction sheave
Seat or V-groove
Material traction sheave
Max. brake torque acc. test
certificate Mbr
Type test certificate No. of brake
8 x 10
1)
EN-GJL 300 (HB 190 to 300)
2x1700
[Nm]
2x1700
2x1250
ABV 591
Moment of inertia gearless
[kgm²]
Moment of inertia traction sheave
[kgm²]
0.53
1,50
2,45
Moment of inertia machine
[kgm²]
2.63
3,60
5,35
[kN]
43.5
57
57
[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
Permissible shaft load at traction
2.10
2,90
Ftzul
sheave
Weight machine (incl. traction
sheave)
1) Hardened groove flanks are used (min. 50 HRc).
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N
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THYSSEN (Maquina Mini Gearless DAF-270)
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THYSSEN (Maquina Mini Gearless DAF-270)
4
0
0
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
3.4
3. PRODUCT DESCRIPTION
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 40°C
Max. temperature at full load
40°C
100°C
100°C
-1
250 min
-1
Maximum speed
250 min
Air gap (stroke per brake
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
6m
Weight (incl. accessories)
approx. 84 kg
approx. 84 kg
Type test certificate number
ABV 591
ABV 591
circuit)
Release monitoring
(per brake circuit)
Switching voltage
Switching capacity
Operating distance at setting
screw
ThyssenKrupp Aufzugswerke GmbH
1 x microswitch
24 VDC
10 ÷ 100 mA
0.15 mm
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
3.5
3. PRODUCT DESCRIPTION
Pulse encoder
DAF270
is controlled
by output
meanssignals
of an enclosed
encoder with
sine-wave
mountedincremental
on the rear hollow
end of shaft
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:
- 20...+ 100 °C
- 30...+ 80 °C
Permissible
Max. on-loadrelative
currenthumidity:
with 5 V
Protection class: IP 64
100
150
%
mA
Connection and installation instructions:
Connect connector box and reference potential.
Should longer cables be required only use original cables from
HEIDENHAIN.
Note:
the build-on pulse
encoder
is another
standardtype
andof
specially
to use
with ThyssenKrupp
inverter.
Use of
inverteradapted
necessitates
a
pulse 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 on
installation and wiring see manufacturer's instructions in chapter 8.2.
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OPERATING MANUAL
3.6
3. PRODUCT DESCRIPTION
Dimensions
Dimensions DAF270 M 0xx
M20 x 28 deep
0
5
5
550
Brake connection
0
4
=
T
D
6
4
3
Center of
gravity
Fig. 3
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
3. PRODUCT DESCRIPTION
Dimensions DAF270 L 0xx
M20 x 28 deep
0
5
5
550
Brake connection
0
9
4
=
T
D
6
4
3
Center of
gravity
Fig. 4
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
3. PRODUCT DESCRIPTION
Dimensions DAF270 M 008 (Tepper variant 1 : 1)
M20 x 28 deep
550
0
5
5
Brake connection
0
2
3
=
t
D
6
4
3
Fig. 5
ThyssenKrupp Aufzugswerke GmbH
Center of gravity
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
3.7
Machine frame
3. PRODUCT DESCRIPTION
(optional)
The
for DAF270 is designed for machine-room-less elevators
to
bemachine
placed inframe
the headroom.
The frame from ThyssenKrupp Aufzugswerke is intended for 2:1 suspension.
The drive, terminal rope anchorages and the overspeed governor are also
accomodated in the frame. The drive is attached at two profiles and
supported by elastic elements. The frame is supported at the support points
of the profile ends in the headroom.
Fig. 6
Machine frame with mounted drive, overspeed governor and terminal rope
anchorages for headroom installation
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THYSSEN (Maquina Mini Gearless DAF-270)
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
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
3.8
3. PRODUCT DESCRIPTION
Lubrication DAF270
DAF270
has lifetime-lubricated rolling bearings. The bearings do not require
lubrication.
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
3.9
3. PRODUCT DESCRIPTION
Name plate DAF270
Version
1. THYSSENKRUPP AUFZUGSWERKE GmbH
A
B
C
D
E
F
1
B3
2
120 kN
3
4
5
6
G
Line
1
1
2
2
2
3
3
4
4
4
4
4
4
4
4
4
5
6
H
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
ThyssenKrupp Aufzugswerke GmbH
I
J
K
L
M
N
O
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 ∅
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
3. PRODUCT DESCRIPTION
2. LiftEquip
A
B
C
D
E
F
G
1
2
3
4
5
6
8
H
Line
1
1
2
2
2
2
3
3
I
Column
A
D
A
B
C
D
A
D
4
4
4
4
4
4
4
4
5
6
ThyssenKrupp Aufzugswerke GmbH
E
F
G
H
J
K
L
M
J
K
L
M
N
O
P
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 ∅
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THYSSEN (Maquina Mini Gearless DAF-270)
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.
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
4. MOUNTING OF MACHINE
How to align the machine on the frame:
The machine is delivered aligned. After disassembly of drive or displacing of
machine (due to exchanged traction sheave, for example) verify that the
machine is properly aligned and re-align, if required.
Note: when the machine is completely installed, tighten the fastening screws
with the pre-set torque. See chapter 8.1.
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THYSSEN (Maquina Mini Gearless DAF-270)
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
Motor terminal diagram:
for frequency-controlled motors
Th
Th
U
V
W
Grd.
Fig. 8
Fig. 9
Temperature monitoring motor
Connect terminal connection "Th" (thermistor) and PTC tripping device (or
frequency inverter connection provided for that purpose.
Voltage applied shall not exceed 2.5 V.
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THYSSEN (Maquina Mini Gearless DAF-270)
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
7
9
10
11
6
12
5
4
3
2
Fig. 10
1
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
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
4. MOUNTING OF MACHINE
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) at
the front brake side.
Connect four-conductor cable - cores 1; 2 (terminals 1; 2) = brake coil D and
cores 3;4 (terminals 3; 4) = brake coil C - and brake circuit.
l
a
in
m
r
e
T
n
o
ti
c
e
n
n
o
C
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 the instructions
and recommendations
of the brake
manufacturertoasadhere
the performance
of the brake
in service mainly
depends on the circuit selected. See chapter 8.3.
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OPERATING MANUAL
4. MOUNTING OF MACHINE
For operating voltage of magnet coils (direct current acc. to
DIN IECE038) see name plate at the brake body.
Connection and corresponding type of brake see table Technical data
chapter 3.4.
When the brake ERS VAR09 SZ1700 / 1700 is connected, make sure that
the necessary overexitation is always maintained. Disregard may affect safe
and quick operation! No overexcitation possible with brake type ERS VAR09
SZ1700 / 1250.
Note: when disconnecting the brake coils alternative power supply is
recommended. Direct power supply necessitates protection of the coils
against the risk of transient overvoltage acc. to VDE 0580.
Details on connection of connector plugs at the brake line ends see fig. 14
and 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 the
customer's power supply.
Connection temperature monitoring brake:
The PTC thermistor detectors are series-connected (core grey/grey) at the
factory at the brake terminal box (terminal 5-7) via a screened cable. See
terminal assignment and connections at terminal box (fig. 11) and connection
assignment for conductor in fig. 14.
Terminals "Th" are to be connected to a PTC thermistor tripping device by
the customer. The voltage applied shall not exceed 2.5V.
See to it that the distance to all revolving parts is observed by persons laying
connecting cables.
Corresponding counter measures are to be made.
Do not use the same cable duct for connecting lines used for temperature
monitoring and brake test and motor connection line.
Connection release monitoring brakes:
Microswitches are attached at the coil body of the magnet brake. A pre-set
and pre-assembled switch per brake circuit each monitors the brake
condition (opened/closed). The setting shall not be changed.
When replacing make sure that the switch setting is in accordance with the
instructions in chapter 7.3.
Check the switches for proper setting and correct function.
Connection release monitoring switch
Input connection
brown
2
Break contact
connection black
4
Make contact
connection blue
1
Fig. 12
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THYSSEN (Maquina Mini Gearless DAF-270)
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.
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
4. MOUNTING OF MACHINE
Magnetic brake with release monitoring
Air gap
4
5
6
7
3
2
8
9
1
10
11
12
Fi . 13
1
2
3
4
5
6
7
8
9
10
11
12
Contact extension for release monitoring C
Bearing bracket
Brake lining
Brake coil body C
Brake disc D
Anchor disc D
Brake coil body D
Cheese head screw (switch fastening)
Setting screw brake release C
Brake release switch C (release monitoring)
Eyebolt
Terminal box
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OPERATING MANUAL
4. MOUNTING OF MACHINE
Connecting cables magnetic brake
to
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c
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±
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n
r
e
d
A
rm
e
t
e
id
s
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t
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n
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C
Fig. 14
ThyssenKrupp Aufzugswerke GmbH
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D
h
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it
w
S
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7
4
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8
5
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C
9
6
re
o
C
0
1
3
±
0
5
6.8
±
0
0
0
6
r
o
0
0
0
0
1
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1 2 3
P
1 2 3 4
±
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5
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T
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±
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±
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7
e
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a
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b
t
a
.
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THYSSEN (Maquina Mini Gearless DAF-270)
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.
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
4.5
4. MOUNTING OF MACHINE
Schematic diagram DAF270
h
c
it
w
s
l
o
rt
n
o
C
e
k
a
r
B
e
r
u
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W
M
+
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
5.1
5. PUTTING INTO SERVICE
Putting DAF 270 into service
Before you start putting the machine into service the following points are to
be 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 tightening
torques in 8.1)
Check supply terminals, earthing of motor and brakes for connection and
test
Check thermal monitoring of motor and brake for connection to
connection PTC thermistor tripping device (not part of the supply
schedule)
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 removed
from 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 power
failure) for proper functioning (not part of supply schedule)
Check rope guard cover or rope support for proper mounting and
distance (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 an
emergency braking system (safety gear) against overspeed in upwards
direction, 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 by
disconnecting the check-back or brake test switches and resetting the nonvolatile memory (EPROM).
Disregard may cause danger to life of persons.
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THYSSEN (Maquina Mini Gearless DAF-270)
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:
•
Check armature base plate - air gap between armature disc
and 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 proper
tightening (tightening torque)
8.1
•
Check grooves of traction sheave and drive fastening for
proper tightening; re-tighten, if required.
7.4
•
Check groove profiles for damage and wear
•
Check electrical connections for correct working, sound
condition and proper fastening
•
Check motor bearings for wear (noise, backlash)
•
Check protective and safety equipment; test for
correct working
•
Check protective and safety equipment; check danger and
instruction signs; check signs for proper affixing and visibility
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OPERATING MANUAL
6.2
6. SERVICING
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 the
general 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 car
must be at least 2 landings below the upper-most landing.
•
While testing the brake circuit with the fully loaded car moving downward
the car must be at least 2 landings above the lower-most landing.
•
The single circuits are tested by applying below voltage at the single brake
coils:
Brake type SZ1700/1700 with 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 be
released during the braking operation (even in case of emergency stop).
Withstand voltage must be applied at the magnet coil of the 2. brake
circuit.
Disable release monitoring of the brakes until the respective brake circuit
is tested.
Attention: should the elevator move after release of one brake circuit or fail
to decelerate sensibly during the braking operation, switch the continuously
energised 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 fully
loaded 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 be
tested closes). While testing the brake circuits individually, the motor coils
should 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 circuit
and connect to 1. brake circuit.
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OPERATING MANUAL
•
6. SERVICING
Repeat test at 2. brake circuit.
Deceleration values:
Minimum deceleration for one brake circuit
0.4 m/s²
Minimum deceleration for both brake circuits
1.0 m/s²
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
observable from brake operation point.)
7m and control 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 V N 1.0 m/s; 3.5 m for installations with VN 1,6 m/s;
5.0 m for installations with V N 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).
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OPERATING MANUAL
6. SERVICING
b) Testing of both brake circuits
When a brake circuit is tested individually, activate emergency stop operation
and 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. The
second 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 the
distance between the screwhead and the support is approx. 1-3 mm.
Attach dial gauge and holder at the brake and vertically align the dial gauge
towards the screwhead. (See fig. 15)
Energize brake circuit to be tested shortly several times and read screw
stroke at dial gauge. (The stroke corresponds to the airgap at the front
brake).
Afterwards remove screws and reposit.
Replace brake as soon as the max. limit air gap is reached. Repairs to
be performed at the factory!
Discription of brake replacement see chapter 7.5.
Note: the electro magnet may fail to attract the armature base plate properly
and without delay if the air gap is too large. This means that the brake opens
delayed or fails to open.
Never tighten the red screws (fig.15, pos. 11). Remove the screws before
operation is started. In case of disregard the brakes cannot be closed!
Table air gap brake
Rated torque
Rated air gap
Limit air gap
Typ
for 2 brake
circuits
Braked
complete
Braked
complete
1250
2500 Nm
0.35 mm
1700
3400 Nm
0.35 mm
Rated air gap
Limit air gap
ThyssenKrupp Aufzugswerke GmbH
± 0,1
± 0,1
max. 0.6 mm
max. 0.7 mm
brake closed (at zero current), new lining
brake closed (at zero current), worn off lining
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OPERATING MANUAL
6. SERVICING
Representation: checking of stroke movement of anchor plates (release
gap) at non-accessible brake C.
6
5
7
8
10
4
11
12
9
3
2
8
1
Fig. 15
9
14
13
11
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
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
7.1
7. MAINTENANCE
Replacing of traction sheave
➂
➄
➄
➃
➂
➁
➀
⑨
View rotated 90°
➇
Fig. 16
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
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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
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
7.2
7. MAINTENANCE
Replacing of pulse encoder
1
2
3
4
6
5
4
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
Technical data, see chapter 2.8
Manufacturer's instructions
chapter 8.3
Disassembly:
•
Switch off power supply
•
Remove connector plug of encoder connection on control.
•
Unscrew clamp bolt at female encoder component using hexagon socket
wrench 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
•
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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
7
5
6
1
Fig. 18
1
Hexagon socket screw
2
Fixing strap
3
Brake housing
4
Encoder
5
6
Shaft end
Connecting line
7
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.
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OPERATING MANUAL
7.3
7. MAINTENANCE
Replacing of brake monitoring switch
•
•
•
•
Secure car and counterweight
Switch off power supply and protect installation against unintentional
switching on
Disconnect defective switch at connection box (fig. 11) and replace
Mount new switch at brake coil body, fig. 13, pos. 10, and connect to
terminal box
Setting and checking of brake monitoring switch:
•
Screw in setting screw M4 for switch operation by two to three screw
turns. The switching contact of the brake monitoring switch shall not
touch the setting screw
•
Apply operating voltage at brake circuit to be set
•
Set distance between switching contact and setting screw to 0.15 mm
using a feeler gauge
•
Unscrew setting screw until the contact of the microswitch reaches the
switching point
•
Remove feeler gauge; disconnect operating voltage
•
Check microswitch for correct functioning by switching the brakes on and
off 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 the
noise dampening is subject to a certain aging dependent on the application
or operational conditions (switching frequency, torque adjustment, natural
drive vibration).
The brake must be completely exchanged, if the noise behaviour of the brake
rises to an inadmissible level.
An exchange of the damping elements is only possible at the manufacturer.
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OPERATING MANUAL
7.5
7. MAINTENANCE
Replacing of brakes
4
6
5
7
5
3
6
7
8
2
1
9
10
11
12
Air gap
Air gap
Fig. 19
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
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OPERATING MANUAL
7. MAINTENANCE
Replacing of dual-circuit disc brake (Warner)
Note: for safety reasons, the brake must be completely replaced as soon as
the 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 unintentional
switching on
Rest counterweight on buffer; secure car
Remove cover plate at brake
Disconnect or unplug connecting cables between brake monitoring
switch, PTC thermistor and brake connections at brake.
Remove terminal connection between encoder and motor shaft. Remove
fixing
strap at
brake
housing
instructions
see
chapter
7.2. and encoder at the same time. Assembly
Attention! Prior to continue disassembly screw in enclosed red hexagon
sockets (M8x150). In case of disregard the brake parts will be separated
by spring force.
•
Screw transport eyebolts (M12) into side threads at the brake housing
circumference. 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 up
drive (240°C). Non-defective pushing off is not possible, therefore. Re-use if
toothing 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 is
mounted the right way round; hub collar backwards!)
Align new brake towards toothed sleeve using lifting device. Observe
position of connection box (marking at bearing bracket).
Before you start mounting the brake, connect the brake coils and make
sure that the brake is open. In case of disregard, the brake rotor blocks
and 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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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
airchapter
gap of rear
in
6.2) brake at bearing bracket using a dial gauge. (See description
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.
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OPERATING MANUAL
8.1
8. ANNEX
Tightening torque - mechanical strength
Attention:
screw strength
and tightening
performing observe
any workrequired
on the machine
or exchanging
parts. torque when
Non-microencapsulated screws must be secured against unintentional
working 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
Strength
Tightening torque MA [Nm]
8.8
10.9
12.9
M4
2,8
4,1
4,8
M5
5,5
8,1
9,5
M6
M8
9,6
23
14
34
16
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
Attaching encoder on brake
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Clamping bolt
M4 x 4
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2,5 Nm
1,0 Nm
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OPERATING MANUAL
8.2
8. ANNEX
Manufacturer's instruction for pulse encoder
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
8. ANNEX
Mounting dimensions
4 x M4
7
h
0
3
∅
Installation
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OPERATING MANUAL
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8. ANNEX
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THYSSEN (Maquina Mini Gearless DAF-270)
OPERATING MANUAL
8. ANNEX
∅
87
45
SW3 (2X))
Md = 2,5
± 0,5Nm
10 000 mm
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OPERATING MANUAL
8. ANNEX
Pin assignment
15-pole sub-D connector (pin)
Data
Clock
Contact
Color
Green
Yellow
Blue
Red
Black
Black
Black
Black
nicht
Not Assigned
belegt
Gray
Red
Purple
Yellow
Inside
Screen
Contact
Color
Brown
White
Green
Green
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Blue
White
White
Black
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OPERATING MANUAL
8.3
8. ANNEX
Manufacturer’s instructions - Brake
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8. ANNEX
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8. ANNEX
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8. ANNEX
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8. ANNEX
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8.4.
8. ANNEX
Type test examination certificate for brake
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OPERATING MANUAL
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8. ANNEX
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8. ANNEX
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8. ANNEX
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8.5.
8. ANNEX
Declaration of conformity for brake
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8. ANNEX
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OPERATING MANUAL
8.6
8. ANNEX
Type examination certificate for
calculation of traction sheave shaft
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