AS-04.07.005_NMX_encoder

NMX Maintenance instruction

REPLACING THE BRAKES OF HOISTING MACHINES NMX07 AND NMX11

1075426.wmf

1080060.pdf

© 2011 KONE Corporation Maintenance instruction NMX 2013-03-15 (A) AS-04.08.039

All rights reserved. This document is intended to be used by people who are familiar with elevator maintenance and have received proper training on methods and safety as specified by KONE.

© 2011 KONE Corporation All rights reserved.

AS-04.08.039 (A) 2013-03-15


TABLE OF CONTENTS 1

ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Purpose of this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Audience of this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Symbols used in this document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

NMX07 AND NMX11 HOISTING MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3

SAFETY AND MAINTENANCE TARGETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Maintenance method safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Environmental Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Customer experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

REPLACING THE NMX07 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.3 Disconnecting the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 4.4 Removing the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.5 Installing the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.6 Checking and adjusting the brake air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.7 One-sided electrical braking test (with 0% load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.8 Replacing the second brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.9 Connecting the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.10 Finalizing the replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5

REPLACING THE NMX11 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Disconnecting the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Removing the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Installing the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Checking and adjusting the brake air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 One-sided electrical braking test (with 0% load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 Replacing the second brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Connecting the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 Finalizing the replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7

FEEDBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42


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2 2 2 2 4 6 6 7 8 8

25 25 25 27 29 31 35 37 38 38 40

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1

ABOUT THIS DOCUMENT

1.1

Purpose of this document This instruction describes replacing the brakes of NMX07 and NMX11 hoisting machines. Magnetic encoder is used in illustrations but the method is essentially the same for machines with optical encoder.

1.2

Audience of this document The main audience of this instruction are maintenance operatives who do maintenance work and their supervisors and line managers.

1.3

Symbols used in this document Symbol

Description Remove the screw.

Loosen the screw. Do not remove it.


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Symbol

Description Tighten the screw to hand-tightness.

Tighten the screw fully.

Unplug.

Plug in.

Do not dispose of.


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1.4

Related Documents – AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and autowalks – AS-01.01.190 Environmental excellence-Maintenance – AS-01.03.101 On-site Maintenance Safety Manual – AM-01.03.001 Preventing falls from height when working on elevators, escalators and building doors – AS-01.05.007 Maintenance tool catalog – AS-04.08.092 User instruction for electrical brake opening tool KM872759G01

NMX07 AND NMX11 HOISTING MACHINES

OPTIONAL : BARCODE

2

1077761.wmf

1077858.wmf

NMX07 with example of machine data plate


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1075209.wmf 1075210.wmf

NMX07 with magnetic encoder

NMX11 with magnetic encoder

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1077233.wmf

NMX07 with optical encoder


NMX11 with optical encoder

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3

SAFETY AND MAINTENANCE TARGETS – Maintenance work must only be carried out by competent and qualified personnel. – Refer to AS-01.03.101 On-site Maintenance Safety Manual for general safety precautions and personal safety issues. – Take time to familiarise yourself with the elevator. – Ensure you have adequate information to do the work and fully understand all the possible effects of your actions. - IF IN DOUBT - ASK. – Talk to your supervisor if you have any doubts about the working method or safety related issues. – Any local variations to the method must be supported by a local method statement and risk assessment.

3.1

Maintenance method safety Note the following safety items when working with brakes of NMX07 and NMX11 hoisting machines: – General KONE safety regulations must be followed during the work. All normal safety measures required in elevator maintenance must be implemented. Local safety regulations must also be followed. – Refer to AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and autowalks. The Take 5 safety initiative is designed for installation, servicing, maintenance and modernisation work done on the elevators. – Never replace more than one brake at a time. Check that the first brake has correct air gap and the fixing bolts are tightened to correct torque before starting the work on the second brake. – In machine-room-less elevators, check that the elevator car roof withstands the weight of one brake in the position where you will store it, combined with your own weight and weight of tools laid on the roof. Keep the brake units on landing until you are ready to install them. Do not store brake units on the elevator car roof. The heaviest brake unit model weighs approximately 40 kg. – When working on the elevator car roof at a height from where returning safely to the landing is not possible in case of a elevator fault, a second maintenance technician is needed. – In machine-room-less elevators, blocking device must be engaged before any starting any work on the brakes. Exact design of the blocking device depends on the elevator.


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3.2

Tools Description Electrical brake opening tool (KM872759G01) with adapter cable (KM873577G05)

Illustration / Note

1074375.wmf

Torque wrench, 50 - 100 Nm

1070299.wmf

Chain hoist, minimum capacity 250 kg

Standard maintenance tools Feeler gauges, 0.1 mm, 0.2 mm and 0.35 mm

Multimeter (CAT III compliant). NOTE: To prevent short circuits and arcing, the maximum length of bare metal probe tips is 4 mm. (CAT III, IEC/ EN 61010-031) 1068841.wmf

Fluke 179 (or equivalent) with 1000 V insulated test probes and at least 100 mm long leads.


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3.3

Environmental Issues Hazardous waste material must be taken care of according to the local regulations and KONE Environmental Strategy. Refer to AS-01.01.190 Environmental excellence-Maintenance.

3.4

Customer experience The focus of your work must always be customer satisfaction. To reach and exceed the customers’ expectations, be polite, constructive and co-operative, and communicate clearly. Remember that for customers, you represent KONE, so ensure that you handle or at least communicate all customer requests and feedback to the correct persons. For more information on how to deliver best-in-class customer experiences through behavior and communication, see the KONE Ambassador program in KONE intranet (search for Ambassador) or contact your supervisor.


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NMX07 Maintenance instruction

4

REPLACING THE NMX07 BRAKES

1075426.wmf

4.1

Tools – – – – – –

4.2

electrical brake opening tool KM872759G01 with adapter cable (KM873577G05) torque wrench, range 50 – 100 Nm chain hoist, minimum capacity 250 kg standard maintenance tools (see AS-01.05.007) feeler gauges (0.1 mm, 0.2 mm and 0.35 mm) Multimeter (CAT III compliant). NOTE: To prevent short circuits and arcing, the maximum length of bare metal probe tips is 4 mm. (CAT III, IEC/EN 61010-031) Fluke 179 (or equivalent) with 1000 V insulated test probes and at least 100 mm long leads.

Safety measures The following safety measures must be carried out before the actual work: Step Action 1 Check that the elevator car and car roof are empty. 2 Drive the elevator car to the topmost floor. 3 Take the elevator out of use.


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Illustration/Note

Put "Under maintenance" signs to all landings. Disable landing calls and door operation. Prevent unauthorized access to the working area. Use safety fences where needed.

AS-04.08.039 (A) 2013-03-15


Step Action 4 Install a chain hoist to an adequate and verified lifting point in the ceiling or other point above the hoisting machine. 5 If needed, move the elevator car to a suitable working level.

Illustration/Note Minimum capacity 250 kg.

6

De-energize the drive module and verify the de-energized state.

Refer to drive specific instructions and AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and autowalks.

7

Connect the electrical brake opening tool. If needed, engage the blocking pin.

Refer to AS-04.08.092.

8

NOTE! Elevator car roof will be used as working platform if the hoisting machine is in the elevator shaft.

NOTE! Blocking device must be used if the hoisting machine is in the elevator shaft. Exact design of the blocking device depends on the elevator.

1076555.pdf


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4.3

Disconnecting the brakes

1079585.wmf

1075428.wm

* 1079584.wmf

1075431.wmf

NOTE! Write down the result of measurement. (*)


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1079632.wmf


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4.4

Removing the brake

WARNING! Never work on more than one brake at a time! The first brake must pass the one-sided brake test before starting the work on the second brake!

1074902.wmf

1077825.wmf

NOTE! Loosen just enough to get the shim plates out.


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1075439.wmf

 CAUTION!  Beware of the tilting brake.  Remove in the order shown in the picture.

1074919.wmf

1074920.wmf

1075450.wmf


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* 1077830.wmf 1075454.wmf

4.5

Installing the brake

WARNING! Never work on more than one brake at a time. The first brake must pass the one-sided brake test before starting the work on the second brake.

* 1075454.wmf

1077830.wmf


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1079597.wmf

WARNING!  Use dry, clean cloth. Do not use solvents!

1075450.wmf

1075457.wmf

107492



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NOTE! Keep the brake unit vertically aligned. Tighten little by little all screws to avoid tilting the brake.

1075456.wmf

1075995.wmf

NOTE!  New shim plates are included in the spare part pack. Start with 2.2 mm thickness.


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A

B 1074939.wmf


1074906.wmf

WARNING! Tightening torque = 60 – 70 Nm. Do not overtighten the bolts. Tighten little by little all screws to avoid tilting the brake.


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4.6

Checking and adjusting the brake air gap


1079603.wmf 1074940

1079601.wmf

NOTE! Refer to AS-04.08.092 and drive specific instructions for detailed instruction on how to connect, use and disconnect the electrical brake opening tool.  Open and close the brake five times using electrical brake opening tool.

NOTE!  Brake air gap must be 0.2 – 0.35 mm everywhere. Gap should not vary more than 0.1 mm in the whole brake pad area. Adjust by adding or removing shim plates, if needed (Step 4).

1074941 wmf


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 Remove or add shim plates based  on the measurements in step 3.

1

3

2

A

B

1075458.wmf

WARNING! Tightening torque = 60 – 70 Nm. Do not overtighten the bolts. Tighten little by little all screws to avoid tilting the brake. After adjusting, check the brake air gap again (Step 3).  Perform one-sided brake test. See section 4.7.

4.7

One-sided electrical braking test (with 0% load) During one sided brake test the performance of each brake unit of the hoisting machine is tested individually and independently. Each brake alone must be able to hold the empty elevator car in position.


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Step Action 1 Note the position of the car before the test.

2 3

Machine-room-less elevators: Go to the landing. Open the brake on one side fully. WARNING! Open only one brake at a time!

4

5 6

4.8

Illustration/Note Do one of the following: – Note the exact position of the blocking pin in the slot (machine-room-less elevators). – Use tape to mark the car position relative to the landing door. – Use tape to mark the position traction sheave (in machine room).

Use the electrical brake opening tool. WARNING! Before removing electrical covers, ensure that the power is switched off.

WARNING! If the brake release cable is too tight, when one brake is opened, there is a risk of opening simultaneously the other brake! Wait about one minute with one of the There must not be visible movement of brakes open. Check for movement of the the elevator car (tape marks or blocking elevator car. pin). Brake system must pass the test before the elevator is put back in service. Close the brake. Use the electrical brake opening tool. Disconnect the brakes from the electrical brake opening tool.

Replacing the second brake NOTE! When the first brake has been replaced and it has passed the one-sided brake test, you can replace the second brake using the same methods. The illustrations in previous sections show the right hand brake but the procedures are valid for left side brake as well. Step 1 2 3

Action Remove the brake. Install the brake. Check and adjust the air gap.


Illustration/Note Refer to section 4.4 Removing the brake. Refer to section 4.5 Installing the brake. Refer to section 4.6 Checking and adjusting the brake air gap.

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Step Action 4 Perform the one-sided braking test.

4.9

Illustration/Note Perform the test for both brakes. Refer to section 4.7 One-sided electrical braking test (with 0% load).

Connecting the brakes

1079601.wmf


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1075459.wmf

1074963.wmf

NOTE!  Adjust according to the value measured before disconnecting the cable. (*) NOTE! The brake lever should be horizontally aligned, and have at least 5 mm of free movement when the brake is normally closed. Move the brake lever on the brake by hand. It should move easily at least 5 mm (X). Adjust if needed (*).

x

* 4.10

1077372.wmf

Finalizing the replacement Step Action 1 Disengage the blocking pin, if machineroom-less elevator.


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Illustration/Note

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Step Action 2 Remove the chain hoist from the machine room or shaft ceiling. 3 Test the operation of the manual brake releasing device. 4 Put the elevator back to use. 5

Illustration/Note

Enable landing calls and door operation. Remove safety fences, if needed.

Remove the "Under maintenance" signs.


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5

REPLACING THE NMX11 BRAKES

1080060.pdf

5.1

Tools – – – – – –

5.2

electrical brake opening tool KM872759G01 with adapter cable (KM873577G05) torque wrench, range 50 – 100 Nm chain hoist, minimum capacity 250 kg standard maintenance tools (see AS-01.05.007) feeler gauges (0.1 mm, 0.2 mm and 0.35 mm) Multimeter (CAT III compliant). NOTE: To prevent short circuits and arcing, the maximum length of bare metal probe tips is 4 mm. (CAT III, IEC/EN 61010-031) Fluke 179 (or equivalent) with 1000 V insulated test probes and at least 100 mm long leads.

Safety measures The following safety measures must be carried out before the actual work: Step Action 1 Check that the elevator car and car roof are empty. 2 Drive the elevator car to the topmost floor. 3 Take the elevator out of use.


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Illustration/Note

Put "Under maintenance" signs to all landings. Disable landing calls and door operation. Prevent unauthorized access to the working area. Use safety fences where needed.

AS-04.08.039 (A) 2013-03-15


Step Action 4 Install a chain hoist to an adequate and verified lifting point in the ceiling or other point above the hoisting machine. 5 If needed, move the elevator car to a suitable working level.

Illustration/Note Minimum capacity 250 kg.

6

De-energize the drive module and verify the de-energized state.

Refer to drive specific instructions and AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and autowalks.

7

Connect the electrical brake opening tool. If needed, engage the blocking pin.

Refer to AS-04.08.092.

8

NOTE! Elevator car roof will be used as working platform if the hoisting machine is in the elevator shaft.

NOTE! Blocking device must be used if the hoisting machine is in the elevator shaft. Exact design of the blocking device depends on the elevator.

1076555.pdf


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5.3

Disconnecting the brakes

1079661.wmf

1079654.wmf

* 1079665.wmf

1079676.wmf

NOTE! Write down the result of measurement. (*)


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1079673.wmf


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5.4

Removing the brake

WARNING! Never work on more than one brake at a time! The first brake must pass the one-sided brake test before starting the work on the second brake!

1080054.wmf

1079682.wmf

NOTE! Loosen just enough to get the shim plates out.


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1080029.wmf

3 4

2

1080033.wmf

1

1080035.wmf


 CAUTION!  Beware of the tilting brake.  Remove in the order shown in the picture.

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* 1080038.wmf

1080037.wmf

5.5

Installing the brake


*

1080038.wmf

1080037.wmf


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1079597.wmf


1080036.wmf

1080040.wmf

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* NOTE! Keep the brake unit vertically aligned. Tighten little by little all screws to avoid tilting the brake.

*

1080048.wmf

1080045.wmf



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1080046.wmf


*

WARNING! Tightening torque = 60 – 70 Nm. Do not overtighten the bolts. Tighten little by little all screws to avoid tilting the brake.


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5.6

Checking and adjusting the brake air gap


1080 1080055.wmf

1079603.wmf

NOTE! Refer to AS-04.08.092 and drive specific instructions for detailed instruction on how to connect, use and disconnect the electrical brake opening tool.  Open and close the brake five times using electrical brake opening tool.

NOTE!  Brake air gap must be 0.2 – 0.35 mm everywhere. Gap should not vary more than 0.1 mm in the whole brake pad area.

X

Adjust by adding or removing shim plates, if needed (Step 4).

1080051


f

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 Remove or add shim plates based  on the measurements in step 3.

*

*

*

1080052.wmf

*

WARNING! Tightening torque = 60 – 70 Nm. Do not overtighten the bolts. Tighten little by little all screws to avoid tilting the brake. After adjusting, check the brake air gap again (Step 3).  Perform one-sided brake test. See section 5.7.

5.7

One-sided electrical braking test (with 0% load) During one sided brake test the performance of each brake unit of the hoisting machine is tested individually and independently. Each brake alone must be able to hold the empty elevator car in position.


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Step Action 1 Note the position of the car before the test.

2 3

Machine-room-less elevators: Go to the landing. Open the brake on one side fully. WARNING! Open only one brake at a time!

4

5 6

5.8

Illustration/Note Do one of the following: – Note the exact position of the blocking pin in the slot (machine-room-less elevators). – Use tape to mark the car position relative to the landing door. – Use tape to mark the position traction sheave (in machine room).

Use the electrical brake opening tool. WARNING! Before removing electrical covers, ensure that the power is switched off.

WARNING! If the brake release cable is too tight, when one brake is opened, there is a risk of opening simultaneously the other brake! Wait about one minute with one of the There must not be visible movement of brakes open. Check for movement of the the elevator car (tape marks or blocking elevator car. pin). Brake system must pass the test before the elevator is put back in service. Close the brake. Use the electrical brake opening tool. Disconnect the brakes from the electrical brake opening tool.

Replacing the second brake NOTE! When the first brake has been replaced and it has passed the one-sided brake test, you can replace the second brake using the same methods. The illustrations in previous sections show the right hand brake but the procedures are valid for left side brake as well. Step 1 2 3

Action Remove the brake. Install the brake. Check and adjust the air gap.


Illustration/Note Refer to section 5.4 Removing the brake. Refer to section 5.5 Installing the brake. Refer to section 5.6 Checking and adjusting the brake air gap.

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Step Action 4 Perform the one-sided braking test.

5.9

Illustration/Note Refer to section 5.7 One-sided electrical braking test (with 0% load).

Connecting the brakes

1080050.wmf

1080055.wmf


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*

1077950.pdf

NOTE!  Adjust according to the value measured before disconnecting the cable. (*) NOTE! The brake lever should be horizontally aligned, and have at least 5 mm of free movement when the brake is normally closed. Move the brake lever on the brake by hand. It should move easily at least 5 mm (X). Adjust if needed (*).

x

* © 2011 KONE Corporation All rights reserved.

1077372.wmf

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5.10

Finalizing the replacement Step Action 1 Disengage the blocking pin, if machineroom-less elevator. 2 Remove the chain hoist from the machine room or shaft ceiling. 3 Test the operation of the manual brake releasing device. 4 Put the elevator back to use. 5

Illustration/Note

Enable landing calls and door operation. Remove safety fences, if needed.

Remove the "Under maintenance" signs.


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6

APPROVALS AND VERSION HISTORY Compiled by:

Information Product Author / Janne Kaskimies

Checked by:

KTO Maintenance Method Specialist / Jukka Lindberg KTO Component Manager / Pasi Lehtimäki

Approved by:

SEB Maintenance Method Director / Werner Ettrich

Translation approved by: /

Issue Date Description of Change Ref CR Approved by 2012-02-03 First issue. Seppo Valliovuo A 2013-03-15 Updated the sequence for replacing both W. Ettrich brakes. Updated air gap criteria. Added use of blocking device to "Maintenance method safety" section. Updated multimeter details in "Tools" section. Added taping the traction sheave to "One-sided electrical braking test" section for elevators with machine room. Added checking the brake lever alignment and movement after installing the brake.


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KONE Corporation KONE Technical Documentation P.O. Box 679 FI-05801 Hyvinkää, Finland


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AS-04.07.005_NMX_encoder

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