PMC-Gearless

PMC145

PMC145 (machine room version )

Operating manual Drive PMC145 Drive PMC145 machine room version

ThyssenKrupp Aufzugswerke

Legal information All rights reserved © Copyright by ThyssenKrupp ThyssenKrupp Aufzugswerke GmbH Note on industrial property rights ISO 16016 Printed in Germany This document – including excerpts – may only be reprinted or otherwise copied with the express approval in writing of ThyssenKrupp Aufzugswerke GmbH. Any duplication, dissemination or storage on data dat a media unauthorised by ThyssenKrupp Aufzugswerke Aufzugswerke GmbH is an infringement of copyright and shall give rise to prosecution. Right to make changes of a technical nature reserved We expressly reserve the right to make changes of a technical nature for the purpose of improving our products or enhancing the safety standard - even without a separate announcement. Colouring The colouring of the components used in our documentation is used only for the documentation. Enquire about colours for your products from your ThyssenKrupp Aufzugswerke Sales Partner. Issued by ThyssenKrupp Aufzugswerke GmbH Bernhäuser Strasse 45 73765 Neuhausen a. d. F. Germany E-mail: Internet:

[email protected] www.thyssenkrupp-elevator-eli.de

OPERATING MANUAL

PMC145

Table of contents PMC145 drives

PAGE 6 6 7

1.

Safety 1.1 Symbols 1.2 Safety instructions

2.

Product description 2.1 Description 2.1.1 PMC145 2.1.2 PMC145 MR version 2.2 Functional description

10 10 12 13 14

3.

Technology

3.1 Dimensions 3.1.1 PMC145 S XS 3.1.2 PMC145 M XM 3.1.3 PMC145 L XL 3.2 Ambient conditions 3.3 Pulse generator 3.4 Traction sheave 3.5 Brake 3.6 General technical data 3.7 Electrical data for brake

15 15 15 16 17 18 19 20 21 22 23

4.

Transport and storage

24

5.

Mounting the machine 5.1 PMC145 5.1.2 PMC145 MR version 5.2 Electrical wiring diagram PMC145 and MR version 5.3 Wiring

26 27 28 30 30

6.

Commissioning

31

7.

Maintenance / service 7.1 Maintenance 7.2 Lubrication 7.3 Testing the brake 7.4 Checking for escaping grease / oil

32 32 32 33 35

8.

Appendix 8.1 Tightening torques 8.2 Documents

36 36 37

9.

Changes

71

ThyssenKrupp Aufzugswerke GmbH

5

12-2011

OPERATING MANUAL 1.

Safety

1.1

Symbols

PMC145

SAFETY

The following pictograms and designations are used in this operating manual: Danger This symbol indicates extreme danger to life and the health of persons. Nonobservance can lead to death or severe injury! Danger This symbol indicates an immediate danger to the life and health of persons due to electrical current. Hazard warnings must always be observed! Warning This symbol warns against imminent danger. Nonobservance can lead to bodily injury or extensive damage to property. Warnings must always be observed! Note This symbol indicates important information and operating instructions. Nonobservance can lead to damage, danger or malfunctions. Check Test steps are specified with this symbol. The test instructions marked in this way must be followed without fail. They contribute to preventing personal injury or damage to property.


6

12-2011

OPERATING MANUAL 1.2

PMC145

SAFETY

Safety instructions

Notes regarding the operating manual A requirement for safe handling and non-disruptive operation of this drive is knowledge of the fundamental safety regulations. This operating manual contains the most important information that is required to operate the drive. The operating manual, in particular the safety instructions, is to be complied with by all persons that work on this drive. Furthermore, the rules and regulations covering accident prevention that apply to the usage site are to be complied with.

Obligations of the operator and/or of the installation firm The operator or installation firm undertakes only to allow persons to work on the drive who are familiar with the regulations regarding regarding work safety and accident prevention and have been instructed in handling the drive have read the chapter on safety and the warnings warnings in this operating manual. Note: Check Note: Check the safety awareness of the personnel at regular intervals. •

•

Obligations on the part of personnel Persons assigned to work on subassemblies undertake before starting work to observe the regulations regarding work work safety and accident prevention. read the chapter chapter on safety safety and the warnings in this operating manual. manual.

• •

Training of the personnel Only trained and instructed qualified personnel may work on the drive. The responsibility of the personnel is to be clearly defined for all tasks involving commissioning, operation, maintenance and repair. Organisational measures The required personal protective equipment is to be provided by the operator or installation firm, as the case may be. All existing safety devices are to be checked regularly in accordance with the maintenance plan.


7

12-2011

OPERATING MANUAL

PMC145

SAFETY

Informal notes on the safety measures •

•

•

•

The operating operating manual manual is to be kept permanently at the usage site of of the installation. Complementary to the operating manual, the generally applicable and local regulations for accident prevention and environmental protection are to be provided and complied with. Legally prescribed safety instructions are to be provided for the users at clearly visible positions. Keep all safety and hazard warnings on the installation in a legible condition.

Use in line with intended purpose Our products have been constructed using state-of-the-art technology and in line with the recognised technical safety regulations. They must only be deployed in line with the intended purpose and used when all the technical technical safety features are in perfect condition. The sole purpose of use is to drive elevators. Any other or additional form of use shall be regarded as non-compliant with the intended use. THYSSENKRUPP AUFZUGSWERKE GmbH shall not be liable for any damage arising from such use and any damage arising due to operator errors. Proper use in line with the intended purpose also includes observance of all instructions instructions in the operating operating manual and adherence to commissioning commissioning instructions, instructions, system description and inspection and maintenance work. • •

• •

Warranty and liability As a general principle, the "General Terms of Sale and Delivery" of THYSSENKRUPP AUFZUGSWERKE GmbH apply. Warranty and liability claims in the event of personal injury and damage to property shall be excluded if they arise due to any of the following causes: improper use that is not not in line with with the intended intended purpose of the drive drive incorrect installation, installation, commissioning and maintenance maintenance of the drive operation of the machine with defective defective and/or and/or non-operative safety and protective devices Nonobservance of the instructions instructions in the operating manual manual with regard regard to Transport, storage, installation, commissioning, operation and maintenance Customer constructional alterations to the machine Changes to the drive ratios (power output output etc.) performed by the operator operator Deficient monitoring of parts that are subject to wear Repairs that are are carried carried out out improperly improperly Cases of of catastrophe due to third-party interference and force majeure.

• • •

•

• • • • •


8

12-2011

OPERATING MANUAL

PMC145

SAFETY

Constructional changes to the machine performed by the operator The machine is set in the factory and delivered ready for operation. In event of changes being made to the machine, all warranty on the part of THYSSENKRUPP AUFZUGSWERKE GmbH is cancelled.

Risks in handling the machine The drive must only be operated in a closed machine room or secured shaft and only with cover and rope guard on the traction sheave. It is not suitable for operation in explosive or aggressive atmosphere. Use in tropical regions is possible only after special measures have been taken. When working on the drive, it must be de-energised before work is started, and the system must be secured against inadvertent switching on. It must be ensured that persons in the machine room keep a safe distance from all rotating parts. In the event of improper use of the drive, there t here is a risk of personal injury or to the life of the user or third parties, or impairment on the assembly or other assets can arise. Malfunctions that can diminish safety are to be rectified immediately. Note: When Note: When connecting and working on the drive brake, please follow the manufacturer's instructions. Important: Suitable measures must be taken by the manufacturer of the elevator installation: a) to a) to be able to operate the brake in emergencies (power failure) b) to b) to be able to carry out and individual check of the two brake circuits


9

12-2011

OPERATING MANUAL PMC145 2.

Product description

2.1

Description

PRODUCT DESCRIPTION

Product key PMC145 XM 105

Main designation for PMC145 drives PM Permanent magnet Machine type C Compact

Machine size 145 Machine length (drive output) S, M, Machine length of the three basic types L (1 m/s) X Prefix X: extension of the basic type S 450 kg / 1 m/s M 630 kg / 1 m/s L 1000 kg / 1 m/s XS 450 kg / 1.6 m/s XM 630 kg / 1.6 m/s XL 1000 kg / 1.6 m/s Generation of the machine 1.. 1st digit designates the machine generation (1st of the drives described here) Winding variant .05 2nd and 3rd digit for the electrical version

PMC145 MR version : (MR= machine room) Same as PMC145 but with these differences: rope protection cover, cover for brakes as well as brakes with manual release. Cable lengths (motor, brake, and pulse generator)


10

12-2011

OPERATING MANUAL PMC145

PRODUCT DESCRIPTION

Overview of versions

Machine type

PMC145 M 102 PMC145 L 101 PMC145 S 103 PMC145 XS 106 PMC145 M 102 PMC145 XM 105 PMC145 L 101 PMC145 XL 104

Suspension

Rated load

Q [kg] 400 630

1:1

450 2:1

630 1000

Rated speed

Traction ) sheave

v [m/s]

DT [mm]

1 ÷ 1.2 1 1,6 1 1,6 ÷ 1.75 1 1,6

240

Table 2.1 Please also consult the details on the type plate of the drive.


11

12-2011

OPERATING MANUAL PMC145

PRODUCT DESCRIPTION

2.1.1 PMC145

1

3 4 2 5

6 Fig. 2.3 Fig. 2.1 7 8

11

10

Fig. 2.4

12 Fig. 2.2 Version without brake release lever 1 Cover of pulse generator and brakes 3 Motor unit 5 Pressure plate

2 Connection for motor and posistor (cable fitted at the factory) 4 Rope guard plate 6 Traction sheave diameter = 240 mm 7 Type plate (both sides) 8 Plug connector for brake cable Cables are enclosed loose 10 Brakes Mayr Duplostop 11 Pulse generator ECN413 with cable 12 Mount for drive drive 4 x M16 connection to baseplate baseplate Table 2.2 ThyssenKrupp Aufzugswerke GmbH

12

12-2011

OPERATING MANUAL PMC145 2.1.2

PRODUCT DESCRIPTION

PMC145 machine room version Illustrated difference to PMC145

Fig. 2.8

1

Fig. 2.9

2 3

Fig. 2.10

Fig. 2.11

1 Rope guard plate 3 Brake actuating lever

2 Brake covers

Table 2.4


13

12-2011

OPERATING MANUAL PMC145 2.2

PRODUCT DESCRIPTION

Functional description Machine: the PMC 145 machine series consists of a frequency-controlled, permanentlyexcited synchronous motor in a standardised structural shape IM B3 or IM B5 (depending on version), a pulse generator, a brake and a shaft with associated mountings that can absorb the load from the ropes. It is offered in 3 construction sizes with different motor outputs and in 3 construction versions: Version: the traction sheave is arranged as floating on one motor side. The brake is located on the opposite motor side. The traction sheave is attached to the end of the motor shaft on the conical shaft end and secured in place by a screw-connected plate. The use of microencapsulated screws and special locking washers ensures that the traction sheave is additionally secured against unwanted detachment. This version of the machine corresponds to the standardised structural shape IM B3. Machine room version: On this version, the brake is equipped with manual release levers, the rope cover has been modified and the brakes are covered. All machines are configured for single wrap. A rope guard holds the ropes in the groove profiles and prevents intrusion into the rope entry points. The machine has no automatic interlock.

Temperature monitoring Motor: a Motor: a temperature sensor is built into the winding of the stator to monitor the motor temperature. It is connected via the motor supply line installed at the factory. f actory. Note: for Note: for signal evaluation of the temperature sensor, it is to be connected by the customer to a posistor triggering device.


14

12-2011

OPERATING MANUAL 3.

PMC145

TECHNOLOGY

Technology

3.1 Dimensions 3.1.1 PMC145 S (450 kg, 1.0 m/s)

PMC145 XS (450 kg, 1.6 m/s)

S S X X / / S S 5 5 4 4 1 1 C C M M P P e e n n i i h h c c a a m m B Y Z A

S S X 5 5 4 4 1 1 C C M M P P e e n n i i h h c c a a m m B B Z Z

: s k r a m e R / n e g n u k r e m e B

t n e e m u o q r o m t h g e r i n d n s e g t u z h g n i A T ) 1

p f e e i e t 0 d 3 ) 0 3 / 8 . 6 8 / ) 1 e 6 8 . M s 1 8 s e a M s l d s d k a n s a l i c t i e r w s e h e k t s e G g i n - t e d s n e m r e F a a r h ( f ( m h 0 e 0 a 2 s R . a 2 . n b n f i u m n i a o m e n 6 e i n 6 i 1 h 1 h c M c M s e a a f h t m e M i f p t e g b o d n u g u a i n r n g i i h t t n w s c u e e s r f n e i o c S B E M ) a

2 1 M - 2 1 n M e b u t s a r l o h b c e s y g e n i h t R i t i w m e n e i n h i y t h c i c a t v s m k a r a n e u g M h f p r o n t e e g n w e r b i e s h t c n h i n a S e A R = C ) b S

S X / S 5 4 1 C M P e n i h c a m B Z t e e h s a t a D

t h c i w t e h g i g t m e a w s l a e t G o = T G

e s m e e r t a B l p d l i e h p c t y s n e e k p r y a T B

e n i h e c t s l a a p M e p d l i y h t c e s i n n h e c p y a T M

Fig. 3.1


15

12-2011

OPERATING MANUAL 3.1.2

PMC145

TECHNOLOGY

PMC145 M (630 kg, 1.0 m/s) PMC145 XM (630 kg, 1.6 m/s)


t n e e m u o q r m o h t g e r i n d n s e g t u z h g n i A T ) 1

p f e e i e t 5 d 3 ) 5 3 / 8 . ) 6 8 / 8 1 e 6 . M s 1 8 s M s e a l d s d k a n s a l i c e i r s w t e h e k t s G g - e i n - t e d r n s e m a e F a r h ( m f ( h 0 e 0 a 2 s 2 R . a . n b n f i u m n i a o m e n 6 e i n 6 1 i h h 1 c M c M s e a a f h t e m M i t f p e g b o d n u g u a n i r n g i i h t t n w s c u e e s r f n e i o c S B E M ) a

2 1 M - 2 1 n M e b u t s a r l o h b c e s y g e n i h t R i t i w m e n e i n h i y t h c i c a t v s m k a r a n e u g M h f p r o n t e g e n w e r b i e s h t c n h i n a S e A R = C ) b S

e s m e e r t a B l p d l i e h p c y t s n e e k p r y a T B

M M X X / / M M 5 5 4 4 1 1 C C M M P P e e n n i i h h c c a a m m B Y Z A

M X / S 5 4 1 C M P e n i h c a m B Z t e e h s a t a D

t h c i w t e h g i g t m e w a l s a e t G o = T G


M M X 5 5 4 4 1 1 C C M M P P e e n i n i h h c c a a m m B B Z Z

Fig. 3.2


16

12-2011

OPERATING MANUAL 3.1.3

PMC145

TECHNOLOGY

PMC145 L (1000 kg, 1.0 m/s) PMC145 XL (1000 kg, 1.6 m/s)


t n e e m u o q r o m h t g e r i n d n s e g t u h z i g n A T ) 1

p f e e i e t 0 d 0 3 ) 3 / 8 . ) 6 8 / 8 1 e 6 . M s 1 8 s M s e l a d s d k a n s a l i c t i e r s w e h e k t s e G g - n i - t e d r n s e a e F m a r h ( f m ( h 0 e 0 a 2 s 2 R . a . n b n f i i u a m n o m e - e n 6 n 6 i i 1 h 1 h c M c M s e a h a f t m e M i f p t e g b o d n u g u a n i r n g h t i i t n w s c s u e e r f i n o c e S B E M ) a

2 1 M - 2 1 n M e b u t s a r l o h b c e s y g e n i t R h i t i w m e n e i n h i h c c a s m a e M h n t e g n b i e s h i n a R A ) b

L L X X / / L / / L L L S S 5 5 4 4 1 1 C C M M P P e e n i n i h h c c a a m m B Y Z A

y t i t v k a n r u g f p r o e e w r h t c n e S C = S

L X / / L / L S 5 4 1 C M P e n i h c a m B Z t e e h s a t a D

t h c i w t e h g i g t m e a w s l a e t G o = T G

e s m e e r t a B l p d l i e h p c t y s n e e k p a y r T B


L L X 5 5 4 4 1 1 C C M M P P e e n n i i h h c c a a m m B B Z Z

Fig. 3.3


17

12-2011


PMC145

TECHNOLOGY

Ambient conditions The machine is configured for the following ambient conditions: • Air humidity up to 95% (no dewfall). • Temperatur Temp eratures es between bet ween 0 °C and + 45 °C. • Height without derating: 1000 m amsl. • A minor dust and/or salt content of the air is permitted (harbour towns). • For safety, the brake system stops the elevator under the following conditions: • Air humidity up to 99% (no dewfall). • Temperatures between - 30 °C and + 70 °C. NB: at NB: at temperatures around and below freezing point, dewfall can lead to a drop in the braking torque of the brake. In the event of longer standstills, there is a danger that the friction f riction linings rust and seize on the friction surfaces. The corresponding countermeasures (e.g. air conditioning unit) are to be implemented by the operator of the assembly. In the case of synchronous machines, machines, the max. current must not exceed the value on the type plate.


18

12-2011


PMC145

TECHNOLOGY

Pulse generator A sealed single-turn absolute pulse generator with sinusoidal output signal is built onto the end of the rotor shaft to t o regulate and control the drives. It is connected to the control system via a shielded connection line firmly connected to the pulse generator with Sub-D connectors. The line shield is placed on the connector and pulse generator housing. Assembly instructions: The pulse generator is attached to the brake by the pulse generator bracket. The washers enclosed with the pulse generator are designed with twist protection. Mounting of pulse generator with detent edged washer as twist protection Pulse generator bracket Pulse generator Mount Pulse generator bracket Fig. 3.6

Other documents, see Appendix for pulse generator • Disassembly •

Pin assignment

• Dimensions Note: The pulse generator fitted as standard is specially geared to the drive and must not be changed.


19

12-2011


PMC145

TECHNOLOGY

Traction sheave The one-part version of the traction sheave (rim and hub) is in a floating f loating arrangement on the conical shaft end of the drive shaft, secured with a disc. For safety reasons, microencapsulated screws and locking washers are used to mount the disc. The groove flanks are hardened as standard [≥ [≥50 HRc] Machine type

Unit

Diameter - DT Rim width - B

[mm] [mm]

Rope diameter - d Number of grooves - z

PMC145 S / XS

PMC145 M / XM

PMC145 L / XL

75

240 100

135

[mm] 1)

Groove clearance - GC

6 max. 6

3)

[mm]

12 10

Version Vee groove angle - β

[°] [°]

max. 11

4)

Seat groove 75 - 100

Material 1)

max. 8 2)

1)

EN-GJS 600-3

dependent on consignment

2)

Version in accordance with a factory standard 60 300 50 00 0 with hardened groove flanks (min. 50 HRc).

3) 4)

NC91 - standard MO61- standard

Table 3.7


20

12-2011


PMC145

TECHNOLOGY

Brake The electromagnetically operated dual-circuit brake is fitted to t o the BS bearing bracket. Special securing screws with rounded hexagon socket screws (Torx) and a securing pin are used, preventing unwanted loosening of the screwed connections. The brake (test status ABV 766/1) meets the requirements for the protective device that prevents overspeed in the upward moving elevator car in accordance with EN81, section 9.10. It consists of two adjacently arranged disc brakes (parallel arrangement) with a joint brake rotor and has a direct effect on the driven driven shaft. When de-energised, the anchor disc of each brake is pressed by means of elastic force onto the brake rotor. The force shifts the brake rotor on the t he gear teeth of the motor shaft and presses the second lining side against the fixed bearing surface of the PMC145 bearing bracket. The braking torque of a brake circuit is configured in such a way that the loaded elevator car is brought to a halt from its rated speed and safely held in place. A calculation-based check and single-circuit check are to be carried out during project planning or before commissioning. It is not possible to set the braking torque or air gap. The brake may only be adjusted in the manufacturer's plant. In the event of any modification, the function of the brake is no longer ensured. The brake contains a connection cable with the corresponding multiple connectors (on the MR version without multiple connectors) for connection of the brake to the brake control and evaluation of the brake monitoring. Machine type

Unit

PMC145 S / XS

Manufacturer Brake type Braking torque

200 2x250

[Nm]

PMC145 M / XM

PMC145 L / XL

Mayr ROBA-duplostop RSR ... 400 2x350

2x550

Table 3.8 Brake release The regular electrical release takes place on applying current to the brake. Applying voltage to the two separately connected brake magnet coils (series connection of the brakes) draws in the t he armature base plates and releases the joint brake rotor of the brake. A manual brake release is only fitted on the MR version. See Appendix, Mayr brakes


21

12-2011

OPERATING MANUAL

PMC145

TECHNOLOGY

Warning! On connecting the brakes, the manufacturer of the elevator system must implement suitable measures that enable inspection of the brake (separately for each brake circuit) and emergency rescue (also in the event of a power failure). Note! The brakes of PMC 145 machine are intended for static application as a parking brake. Dynamic braking is restricted to t o emergency and inspection braking. During normal operation, the wear on brake linings is negligible. Under no circumstances does the brake replace safety systems for downward operation. Brake monitoring A microswitch is fitted for monitoring the brake function of each brake circuit. This reports the current position of the brake (released / closed) by means of a corresponding signal. The brakes with mechanical brake release lever have an additional wear monitoring switch. The switches are fitted, set and provided with safety coating varnish at the plant. The customer must evaluate the monitoring signals. 3.6

General technical data Designation Machine Version Weight (including traction sheave)

Unit

[kg]

Technical data PMC145 S XS M 154 174 185

XM 205

L 242

XL 263

0,33

0,42

0,46

Mass moments of inertia (including traction sheave)

[kgm2]

0,22

Airborne noise level Momentum grade Type of protection

[dB(A)]

< 54 G 2.5 IP21

0,29

0,29

Table 3.9


22

12-2011


PMC145

TECHNOLOGY

Electrical data for brake without manual release for deployment of the machine in installations Version without manual without machine without machine room Designation Machine Version Manufacturer

Unit

Type Electrical ventilation Operating voltage Energy consumption overexcitation Energy consumption - stop Operating mode S5

[VDC]

Electrical data for brake PMC145 S / XS M / XM L / XL Mayr ROBA-duplostop RSR ... 200 400 1 solenoid per brake circuit (series connection) Overexcitation: 2 x 103.5 = 207 Stop: 2 x 72 = 144

[W]

2 x 151

2 x 158

2 x 181

[W] [c/h] [% duty cycle]

2 x 72 120

2 x 76

2 x 89 180

50

Table 3.10

with manual release for deployment of the machine in installations Version with manual with machine with machine room Designation Machine Version Manufacturer

Unit

Type Electrical ventilation Operating voltage Energy consumption overexcitation Energy consumption - stop Operating mode S5

[VDC]

Electrical data for brake PMC145 S / XS M / XM L / XL Mayr ROBA-duplostop RSR ... 200 400 1 solenoid per brake circuit (series connection) Overexcitation: 2 x 90 = 180 Stop: 2 x 45 = 90

[W]

2 x 264

2 x 348

2 x 344

[W] [c/h] [% duty cycle]

2 x 66 120

2 x 87

2 x 86 180

50

Table 3.11


23

12-2011

OPERATING MANUAL 4.

PMC145

TRANSPORT

Transport and storage Packaging: The machine will be shipped on a pallet, optionally package in foil. Transport: Transport must be effected in compliance with the safety regulations and observing the centre of gravity of the drive. Fork-lift truck transport: In the case of transport transport with a fork lift, the forks used used must must be long enough to prevent the transported goods from tipping over. Always pick up the transport pallet with the forks, not the motor itself. Pay attention to protruding parts! Danger of injury injury and damage!

•

• •

Crane transport: Do not walk underneath suspended loads! Use 3 M12 ring bolts to attach transport chains chains or ropes to the motor. • •

After transport, remove the Fig. 4.1 wooden transport protection slats. Pay attention to the icons on the packaging or elsewhere.

•

Top

Fragile goods

Protect against water

Protect against heat

Hand hooks prohibited

Attach here


24

12-2011

OPERATING MANUAL

PMC145

TRANSPORT

Dimensions and weight The weight data is specified on the packaging of the drive on a label. See table 3.9. Please refer to the delivery note for the dimensions. Check on acceptance by the recipient The delivered parts and their packaging are to be checked for completeness, damage or other conspicuous features. Reporting and documenting damage in transit On delivery, make sure that no damage in transit has occurred. Information •

•

Any damage that is determined determined is to be documented documented immediately (sketch, photo, description of the damage). Forward the corresponding documents without delay delay to THYSSENKRUPP AUFZUGSWERKE GmbH.

Unpacking Information •

•

Dispose of packaging materials in an environmentally environmentally compatible compatible manner or reuse them. Specific transport aids aids and shipping shipping braces remain with the customer.

Intermediate storage •

•

If the assembly is not installed immediately after delivery, delivery, it must be covered and stored carefully in a protected location. Attention is to be paid to ensuring that no condensation forms on the cover and that no moisture can penetrate. The assembly must not be stored outdoors. outdoors. Bare parts have no long-term preservation.

Ambient conditions Information The environment at the final location (moisture, temperature) must correspond to normal indoor climate conditions for machine rooms. (According to EN 81. between +5° and +40° C) The relative air humidity must not exceed 70%.


25

12-2011

OPERATING MANUAL 5.

PMC145

MOUNTING THE MACHINE

Setting up the machine Setting up The drive is set up depending on customer requirements Aligning the drive The machine is to be set up according to the plan of installation. The rope departure from the traction sheave and deflecting pulley is to be aligned plumb according to the drawing on the elevator car rope pulley or the counterweight pulley. With load applied to the ropes, the machine should be aligned horizontally on its installation surface. Irregularities are to be balanced out by inserting shims under the support. Mounting the drive Raising the drives, see Fig. 3.1-3.3 after comment b) Mounting the drives, see Fig. 3.1-3.3 after comment 1) and a).

Note: the Note: the brake is to be protected against coarse dust and liquids of any type. It may only be operated with the protection fitted above the brake at the plant. After completion of the setting up procedures, the securing bolts are to be tightened with the prescribed torque. See Appendix


26

12-2011

OPERATING MANUAL

5.1

PMC145


PMC145 Electrical connection: •

Connection of the brakes using the supplied cables (power and test switch, see Fig. 5.3 and 5.4)

cable (power and PTC thermistor) is The motor connection cable (power connected at the factory.

generator is connected at the plant The absolute pulse generator is

•

•

Connection motor / PTC thermistor

Connection Brakes Left brake

Connection Pulse generator

Clamps for screen, brake lines

Fig. 5.0


27

12-2011

OPERATING MANUAL

PMC145


5.1.2 PMC145 (machine room version) Electrical connection : •

Connection of the brakes using the supplied cable (power and test switch, see Fig. 5.3 and 5.4.1)

cable (power and PTC thermistor) is The motor connection cable (power connected at the factory.

generator is connected at the plant. The absolute pulse generator is

•

•

Switch for wear monitoring

Switch for brake monitoring Fig. 5.1

Manual release lever

Connection Brakes Fig. 5.2


28

12-2011

OPERATING MANUAL

PMC145


Brake connection at the drive:

Label left brake Fig. 5.3 Connection lines at control system:

Brake output version PMC145 MR version

PMC145 Motor PTC thermistor Motor power

Screen Fig. 5.4.1 Strain relief

Brake test switch Fig. 5.4

Do not apply voltage greater than 2.5 V at the PTC thermistor. Adhere to t o the internal resistance of the measurement devices!


29

12-2011


PMC145


Electrical wiring diagram for diagram for PMC145

Fig. 5.5 5.2.1

Electrical wiring diagram for diagram for PMC145 (machine room version)

Fig. 5.6 5.3

Wiring Pay attention to the following when routing the control, pulse generator and motor cables: cable is to be routed as far as possible away from the The pulse generator cable is motor cable, cable, but at least over 200 mm. mm. The control line should not be routed parallel to the motor cable either.


30

12-2011

OPERATING MANUAL 6.

PMC145

COMMISSIONING

Commissioning the machine

Before commissioning the machine, the following points should be checked and carried out: •

Safety, auxiliary auxiliary and installation tools removed from the danger danger zone zone

•

Setup and alignment of machine, frame and rope departure checked checked

•

Mounting of of machine machine and frame (if present) checked checked

•

Bolts tightened and secured secured with the prescribed prescribed torque (see table 'Tightening torques')

•

Protective cover fitted

•

Function of safety shutdown devices checked

•

• •

Power connections, connections, earthing of motor and brake magnet connected, connected, checked and secured Special add-on components (optional) checked Attach the direction direction arrow (Up / Down) above traction sheave sheave and clearly visible according to the direction of travel

•

Check the brake function

•

Brake test carried out with each individual brake circuit


31

12-2011

OPERATING MANUAL

PMC145

7.

Maintenance

7.1

Maintenance of the machine

MAINTENANCE

Maintenance period: maintenance period: maintenance of the machine should take place within the framework of central maintenance of the elevator, at least once a year. Note: commissioning Note: commissioning and maintenance work may only be carried out by trained and instructed qualified personnel. All laws and regulations for elevator systems as well as accident prevention regulations must be known and complied with.

•

• • •

•

•

•

Check braking deceleration of the magnetic brakes with each brake circuit individually Check groove profile on the the traction sheave for damage damage and wear Check secure seating of bolts of the traction traction sheave sheave mount Check motor bearings for wear (noise, backlash) Check that electrical connections are in good condition, i.e. undamaged; check that they are securely attached and safe Check that protective and safety devices are present, functioning and correctly set Check the seals seals on the shaft in the area of of the brake (grease and/or oil escaping)

Table 7.1

NB: during NB: during maintenance and inspections, no voltage may be applied to the brake! Comply with the instructions in the Appendix 'Brake'

7.2

Lubrication The bearings have lifetime lubrication, which means that the drive requires no other lubrication.


32

12-2011


PMC145

MAINTENANCE

Testing the brake Test interval: once a year within the framework of the central maintenance of the elevator Test the braking deceleration at each brake circuit. Note: before Note: before beginning the test, the following preparations are required: •

• • •

Signs indicating that maintenance work is under way must be attached attached to the elevator at all landing doors. All doors are to be locked properly. Ensure that there is no one in the elevator car. The elevator car must be located at at least two floors below the top landing. landing. For the individual test of the brake circuits, the brake magnet coils must be connected separately to the excitation / retentive voltage (see table in chapter 8). Manual release levers are mounted on the machine room version. See chapter 8. In order to be able to test a brake circuit separately, the other brake must be opened. NB: If NB: If the elevator begins to move after releasing a brake circuit or does not noticeably decelerate during the brake operation, the system is to be switched off immediately and the brake is to be closed. closed . The dual brake function is not ensured. Check the brake!

Activate the measuring device. Test sequence: test the braking braking deceleration on each brake circuit • •

•

• •

• •

Initiate a normal run (brake to be tested is opened) After the rated speed has has been reached, reached, trigger an emergency stop (brake to be tested closes) Determine the deceleration value value for the 1st brake circuit with the measuring device. Compare the the measurement measurement result with the standard value Disconnect the permanent power power supply of the continuously continuously opened opened 2nd brake circuit and connect to the 1st brake circuit. Connect the measuring device to the 2nd brake circuit. Repeat the test operation operation on the 2nd brake circuit.

Deceleration values: minimum deceleration value for one brake one brake circuit is approx. 0.4 m/s² The minimum deceleration both brake circuits is approx. 1.0 m/s² The minimum deceleration value for both brake


33

12-2011

OPERATING MANUAL

PMC145

MAINTENANCE

NB: after NB: after completion of the individual brake test, the original state of the t he circuit (operation of both brakes simultaneously) is to be re-established. Testing of both brake circuits circuits by Following an individual test, run a brake test with both brake circuits by triggering emergency braking. The deceleration value here must be significantly greater than the values determined in the individual tests! Check for wear: Use a feeler gauge to check the air gap between the spool and armature base plate with the brake closed (coils without current). Repeat the operation at various positions of the circumference. Table for brake air gap See chapter 8. Once the limit air gap is reached (see chapter 8), the complete brake must be replaced. Repairs can only be carried out at the plant.

Air gap

Fig. 7.1 PCM version without brake release lever


34

12-2011


PMC145

MAINTENANCE

Checking for escaping grease / oil Examine the area around the bearing bracket, disc brake and brake linings (brake rotor) for traces of oil. You cannot see the inner brake disc. This means that a precise examination of the gap between the bearing bracket and inner brake body is important; it should also be checked for traces of oil. Contamination level No escaping oil determined

Procedure Check regularly within the framework of maintenance

If escaping oil is determined or oil is escaping from the brake disc / brake linings

Clean the drive and, if necessary, the brake, and carry out short-term repairs Before continuing operation until modification, run a brake test. If the braking effect is inadequate, shut down the installation.

Every 3 months (6 months if elevator used infrequently, < 50 000 runs per year) Repair after 4 weeks at the latest

PMC Dual-circuit disc brake

Grease

Fig. 7.4

Bearing bracket


Brake rotor

35

Fig. 7.5

Bearing bracket

12-2011

OPERATING MANUAL 8.

Appendix

8.1

Tightening torques

PMC145

APPENDIX

NB: during work on the machine or parts replacement, care must be taken to ensure that the prescribed bolt tightness and tightening torques are complied with. Non-microencapsulated bolts / screws are to be secured against unwanted Non-microencapsulated loosening during installation using Loctite 241 or a similar means of securing bolts / screws. To comply with the prescribed torques, all bolt and screw connections are to be tightened using a torque wrench! The following table applies to all mounts. Slotted pan pan head head tapping tapping screws DIN 912 ISO 4762 4762 Hexagon screws DIN 931 / 933 933 ISO 4014 4014 / 4017 Dimensions

Tightening torque MA (Nm)

Tightness

8.8

10.9

12.9

M4

2.6

M5

5.3

M6

9.0

12

15

M8

23

30

35

M10

45

60

75

M12

75

110

130

M16

190

270

320

M20

370

520

620

M24

640

900

1100 Table 8.1

Please bear in mind that individual mounting parts are to be tightened with a tightening torque that deviates from that specified in the above table. The applicable values are listed on the previous page or in the corresponding chapter of this manual.


36

12-2011


PMC145

APPENDIX

Documents Verification of the calculation of a traction sheave shaft Manufacturer specifications for pulse generator Certificates Technical data Manufacturer specifications for brake with and without brake release lever Certificates Technical data


37

12-2011

         

    







 





           

      

           

                   

  

  

     

   

              

       

        

   

    

            

 

  







                                                                       

                      

     

                                                    

                                     

  



              

 













                           



      





















  

 

 









































 

 

 

 

  



 

       

 

 

 

         

                                            

   

                   

  

   

      

                                     

                 

  

               

 

          



 

    















         

 

 

  

  

 

  

   

   

   

   

 

 

       

ECN 413 • Absoluter Singleturn-Drehgeber / Absolute singleturn encoder • einseitig offene Hohlwelle / Blind hollow shaft • Version Thyssen





 



 

     

 

 





 

Lagerung Kundenwelle Lagerung Geber Kundenseitige Anschlussmaße Messpunkt Arbeitstemperatur Selbstsichernde Schraube M5 x 50 DIN 6912 SW4 Á = Abdrückgewinde M6 Â = Abdrückgewinde M10 M10 Verschlussschraube hlussschraube SW3 und 4 Ã = Versc

À= Á= Â= Ã=

  



A= B= k= m= À=

A= B= k= m=







  

Bearing of mating shaft Bearing of encoder Required mating dimensions Measuring point for operating temperature Self-tightening Self-tighten ing screw M5 x 50 DIN 6912 width A/F 4 Back-off thread M6 Back-off thread M10 Screw plug sizes 3 and 4



  

 

 



 

 

Elektrischer Anschluss / Electrical Connection

4

12

2

10

1

9

3

11

5

13

5V UP

5V sensor

0V UN

0V sensor

A+

A–

B+

B–

DATA

DATA

br/gn BN/GN

bl BL

ws/gn WH/GN

ws WH

gn/sw GN/BK

ge/sw YL/BK

bl/sw BL/BK

rt/sw RD/BK

gr GY

rs PK

Die Sensorleitung ist intern mit der Versorgungsleitung verbunden. The sensor line is connected internally with the power supply.

Nicht verwendete Pins oder Litzen dürfen nicht belegt werden! Vacant pins or wires must not be used!

1)

8

15

CLOCK CLOCK

vio VI

6 1)

ge YL

Innenschirm / Internal shield Außenschirm auf Gehäuse / External shield on housing

ECN 413 Absolute Positionswerte Absolute position values

EnDat 2.2

Bestellbezeichnung / Ordering designation

EnDat 01

Positionen/U / Positions per revolution

8 192 (13 (13 bit) / 8192 (13 bits)

Code / Code

Dual / Pure binary

Elektr. zul. Drehzahl / bei Genauigkeit

† 1 1500 500

min m in–1 /± 1 LSB; † 12 12000 000 min min–1 /± 50 50 LSB LSB

Elec. permissible speed / at accuracy

† 1500

rpm/± 1 LSB; † 12000 rpm/± 50 LSB

Rechenzeit tcal / Calculation time t cal cal

† 5

Inkrementalsignale / Incremental signals

» 1 VSS

Strichzahlen / / Line counts Strichzahlen

2048

Grenzfrequenz –3 dB / Cutoff frequency –3 dB

‡ 400 kHz

Systemgenauigkeit / System accuracy

± 20“

Spannungsversorgung / Power supply Stromaufnahme / Current consumption

3,6 bis 14 V / 3.6 to 14 V † 160 mA (ohne Last / without load)

Elektrischer Anschluss Electrical connection

Kabel 5 m, mit Sub-D-Stecker (Stift), 15-polig

Welle / Shaft

Konuswelle ¬ 9,25 mm, Konus 1/10 / Taper shaft ¬ 9.25 mm, taper 1:10

µs µs 1)

1) / » 1 V PP PP

Cable 5 m, with D-sub connector (male), 15-pin

2)

2)

min–1 / † 12 000 rpm

Mech. zul. Drehzahl n / Mech. perm. speed n speed n

† 12000

Trägheitsmoment Rotor / Moment of inertia of rotor

2,6 · 10–6 kg kgm m2

Vibration 55 bis 2000 Hz / Vibration 55 55 to 2000 Hz Schock 6 ms/2 ms / Shock 6 ms/2 ms

†

2)

300 m/s2 (EN / IEC 60068-2-6) 60068-2-6) † 1 1000 000 m/s m/s2 / † 2 2000 000 m/s m/s2 (EN / IEC 60068-2-27) 60068-2-27)

Max. Arbeitstemperatur 2) Max. operating temperature

100 °C

Min. Arbeitstemperatur Min. operating temperature

Kabel fest verlegt: –40 °C / Flange socket or ﬁxed cable: –40 °C Kabel bewegt: –10 °C / Moving cable: –10 °C

Schutzart EN 60529 / Protection IEC IEC 60 529

IP 67 am Gehäuse; IP 64 am Welleneingang / IP 67 at housing; IP 64 at shaft inlet

Masse / Weight

ca. 0,3 kg/0.3 kg

1) eingeschränkte Toleranzen: Signalgröße 0,8 bis 1,2 VSS 2) Zusammenhang zwischen Arbeitstemperatur und Drehzahl 1) Restricted tolerances: Signal amplitude 0.8 to 1.2 V PP PP 2)

bzw. Versorgungsspannung siehe Katalog Drehgeber bzw.

For the correlation between the operating temperature and the shaft speed or supply voltage, see Rotary see Rotary Encoders catalog

       

              



Mb 1108 · 2/2007 · Änderungen vorbehalten/ Subject to change without notice

Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Please read these Operational Instructions I nstructions carefully and follow them accordingly! Ignoring these Instructions can lead to lethal accidents, malfunctions, brake failure and damage to other parts.

Contents: Page 1: - Contents - Declaration of Conformity - Safety and Guideline Signs - TÜV (German Technical Inspectorate) Certification Page 2: - Safety Regulations Page 3: - Safety Regulations Page 4: - Brake Illustrations

Page 11: - Installation: Design with Toothed Motor Shaft - Installation: Hub Design - Hand Release - Braking Torque Adjustment - Noise Damping Page 12: 12: - Release Monitoring Page 13: - Wear Monitoring

Page 5: - Brake Illustrations

Page 14: - Electrical Connection (Operation with Nominal Voltage)

Page 6: - Parts List

Page 15: - Electrical Connection (Operation with Overexcitation)

Page 7: - Table 1: Technical Data - Table 2: Technical Data

Page 16: - Brake Inspection (Customer-side after Installation) - Dual Circuit Brake Functional I nspection - Maintenance - Disposal - Malfunctions / Breakdowns

Page 8: - Table 3: Technical Data Page 9: - Table 4: Switching Times - Torque-Time Diagram Page 10: 10: - Design - Function - State of Delivery - Application - Installation Conditions

Declaration of Conformity A conformity evaluation for the applicable EU directives has been carried out for this product. The conformity evaluation is set out in writing in a separate document and can be requested if required. It is forbidden to start use of the product until you have ensured that all applicable EU directives and directives for the machine or system into which the product has been installed have been fulfilled. Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion. This statement is based on the ATEX directive.

Safety and Guideline Signs Danger! Danger of injury to personnel and damage to machines.

TÜV (German Technical Inspectorate) Certification License number: ABV 766/2

Please Observe! Guidelines on important points.

29/03/2010 TK/HW/GC/SU

Page 1 of 16

Chr. Mayr GmbH + Co. KG Eichenstraße 1 87665 Mauerstetten Germany

Tel.: 08341 / 804-0 Fax: 08341 / 804-421 http://www.mayr.de eMail: [email protected]

Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Safety Regulations These Safety Regulations are user hints only and may not be complete! Guidelines for Electromagnetic Compatibility (EMC)

Danger! Danger of death! Do not touch voltagecarrying cables and components.

In accordance with the EMC directives 2004/108/EC, the individual components produce no emissions. However, However, functional components e.g. mains-side energisation of the brakes with rectifiers, phase demodulators, ROBA ® -switch devices or similar controls can produce disturbance which lies above the allowed limit values. For this reason it is important to read the Installation and Operational Instructions very carefully and to keep to the EMC directives.

To prevent injury or damage, only professionals and specialists should work on the devices. Danger! This warning applies if: the electromagnetic brake is used incorrectly.   the electromagnetic brake is modified. the relevant standards for safety and / or installation  conditions are ignored.

Device Conditions

Please Observe! Before product installation and initial operation, please read the Installation and Operational Instructions carefully and observe the Safety Regulations. Incorrect operation can cause injury or damage. At the time these Installation and Operational Instructions go to print, the electromagnetic brakes accord with the known technical specifications and are operationally safe at the tim e of delivery. Please Observe! Only specialists who are trained in the transport,  installation, operation, maintenance and general operation of these devices and who are aware of the relevant standards should be allowed to carry out this work. Technical data and specifications (Type tags and  documentation) must be followed. The correct connection voltage must be connected  according to the Type tag. Never loosen electrical connections or carry out  installations, maintenance or repairs while the voltage connection is energised!  Cable connections must not be placed under mechanical strain. Check electrical components for signs of damage before  putting them into operation. Never bring them into contact with water or other fluids.  The braking torque is lost if the friction lining and / or the friction surface come into contact with oil or grease. Please Observe! Please ensure that the brake is clean and oil-free, as both brake circuits have an effect on the same linings. Special sealing measures, among other precautions, may be necessary - in particular in gear applications!

Appointed Appointed Use This safety brake is intended for use in electrically operated elevators and goods elevators according to EC 81-1/1998. The safety brake corresponds to DIN EN 81, Part 1 [Sections 12.4.2.1 (2nd Paragraph), 12.4.2.2, and 12.4.2.5] in its general design and its mode of operation. The effectiveness of the mechanical dual circuit system can be tested at the place of operation (requirement acc. TRA 102).

29/03/2010 TK/HW/GC/SU

Page 2 of 16

Please Observe! When dimensioning the brakes, please remember that installation situations, braking torque fluctuations, permitted friction work, run-in behaviour and wear as well as general ambient conditions can all affect the given values. These factors should therefore be carefully assessed, and alignments made accordingly. Please Observe!  Mounting dimensions and connecting dimensions must be adjusted according to the size of the brake at the place of installation. The magnetic coils are designed for a duty cycle of 100 %.  However, However, a duty cycle > 60 % leads to increases in temperature which cause premature aging of the noise damping and therefore an increase in switching noises. The max. permitted switching frequency is 240 1/h. On overexcited brakes, the switching frequency must not exceed 180 1/h. These values apply for an intermittent duty S3 60%. The permitted surface temperature on the brake f lange must not exceed excee d 80 °C at a max. ambient tem perature of 45 °C. The overexcitation time span should be c. 600 ms on sizes 200 to 400 and c. 1 s for sizes 600 to 1000. The brakes are only designed for dry running.  The torque is lost if the friction surfaces come into contact with oil, grease, water or similar substances. The braking torque is dependent on the present run-in  condition of the brakes.  Manufacturer-side Manufacturer-side corrosion protection of the metallic surface is provided. The surface is rough sawn and not machined (milled material).

Protection Class I This protection can only be guaranteed if t he basic insulation is intact and if all conductive parts are connected to the PE conductor of the permanent installation. Should the basic insulation fail, the contact voltage cannot remain (VDE 0580).

Ambient Ambie nt Tempera Tem perature ture 0 °C up u p to t o +45 +4 5 °C Danger! At temperatures of around or under freezing point, condensation can strongly reduce the torque. During longer downtimes, the friction linings can stick to the friction surfaces. The user is responsible for taking appropriate counter measures.

Insulation Insulat ion Material Ma terial Class F (+155 °C) The magnetic coil and the casting compound are suitable for use up to a maximum operating temperature of +155 °C.



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Safety Regulations These Safety Regulations are user hints only and may not be complete! Brake Storage

Please Observe the Following Standards:

Store the brakes in a horizontal position, in dry rooms and dust and vibration-free. vibration-free.  Relative air humidity < 60 %.  Temperature without major fluctuations within a range from – 20 °up to +60° +6 0°C. C.  Do not store in direct sunlight or UV light.  Do not store aggressive, corrosive substances (solvents / acids / lyes / salts etc.) near to the brakes. For longer storage of more than 2 years, special measures are required (please contact the m anufacturers).

DIN EN ISO 12100-1 and 2 Machine Safety DIN EN 61000-6-4 Noise emission EN12016 Interference resistance (for elevators, escalators and moving m oving walkways) EN 60204 Electrical machine equipment



Liability 

Handling Before installation, the brake must be inspected and found to be in proper condition. The brake function must be inspected both once installation has taken place as well as after longer system downtimes, in order to prevent the drive starting up against possibly seized linings.



User-implemented Protective Measures:   







Please cover moving parts to protect against injury through seizure and catapulted objects. Place a cover on the magnetic part to protect against injury through high temperatures. Protect against electric shocks by installing a conductive connection between the magnetic component and the PE conductor on the permanent installation (Protection Class I) and by carrying out a standardised inspection of the continuous PE conductor connection to all contactable metal parts. Protect against highly inductive switch-off peaks by installing varistors, spark quenching units or similar devices according to VDE 0580/2000-07, Paragraph 4.6, to prevent damage to the coil insulations or switch contact consumption in extreme conditions (this protection is contained in mayr ® rectifiers). Install additional protective measures against corrosion if the brake is subject to extreme ambient conditions or is installed in open air conditions, unprotected from the weather. Take precautions against freeze-up of the armature disk and the rotor in high humidity and at low temperatures.

The information, guidelines and technical data in these documents were up to date at the time of printing. Demands on previously delivered brakes are not valid. Liability for damage and operational malfunctions will not be taken if - the Installation and Operational Instructions are ignored or neglected. - the brakes are used inappropriately. - the brakes are modified. - the brakes are worked on unprofessionally. - the brakes are handled or operated incorrectly.

Guarantee  

The guarantee conditions correspond with the Chr. Mayr GmbH + Co. KG delivery conditions. Mistakes or deficiencies are to be reported to mayr ® at once!

Conformity Markings The product confirms to the CE according to the low voltage directive 2006/95/EC

Identification ®

mayr components are clearly marked and described on the

Type tag:

Regulations, Standards and Directives Used: DIN VDE 0580 2006/95/EC 2004/108/EC 95/16/EC EN 81-1 BGV C1

Electromagnetic devices and components, general directives Low voltage directive EMC directive Elevator directive Safety regulations for construction and installation of elevators and small goods elevators (previously (previously VGB 70) Safety regulations for theatre stage technical systems

29/03/2010 TK/HW/GC/SU

Page 3 of 16


Manufacturer

mayr ® Name/Type Article number Serial number


Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 14

1

1.1

2

1. 1

1 14 Air gap "b"

3 8 Left brake

Right brake

Customer-side shaft

2

Air gap "a" 0,45

+0,12 -0,02

Fig. 1

Fig. 2a Air gap "b"

3 16

10

12

6

11

10

6

12

11

15

Fig. 3

4

5

2

1 Air gap "a" 0,45

+0,2 -0,05

Fig. 4 29/03/2010 TK/HW/GC/SU

Page 4 of 16

Fig. 2b Chr. Mayr GmbH + Co. KG Eichenstraße 1 87665 Mauerstetten Germany


Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 7.1

Release

Release Rel ease

Fig. 5

7.6 7.3

7. 4

1 7 .2 7.1

3

7.5

2 Fig. 6

Left brake

Adjustment dimension 1,6 +0,2 for Size 200 2,0 +0,2 for Sizes 400 - 1000

Right brake

6

13

6

9

Fig. 7 29/03/2010 TK/HW/GC/SU

Page 5 of 16



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Parts List (Only use mayr ® original parts )

Item 1 1.1 2 3 4

5

6 6.1 6.2 6.3 6.4 6.5 7 7.1 7.2 7.3 7.4 7.5 7.6

8

9 9.1 9.2 9.3 9.4 9.5 10 11 12 13 14 15 16

Name Coil carrier assembly (inc. magnetic coils) Connection cable 2-wire; Connection coil blue/brown Armature disk Rotor Distance bolts Hexagon head screw, strength 8.8. DIN 931: For Size 200 (100 Nm / 150 Nm / 200 Nm design): For Size 200 (250 Nm/ 280 Nm design): For Size 400 (210 Nm / 275 Nm / 350 Nm / 420 Nm design): For Size 400 (375 Nm / 450 Nm design): For Size 400 (550 Nm / 600 Nm design): For Size 600 (all designs): For Size 800 (all designs): For Size 1000 (all designs):

M8x100 M8x110 M10x110 M10x110 M10x120 M12x120 M12x130 M16x130

Release monitoring assembly Microswitch Microswitch inc. adapter plate (Fig. 10; page 12) Cap screw (Fig. 10; page 12) Hexagon nut (Fig. 10; page 12) Hexagon head screw (Fig. 10; page 12) Spring washer (Fig. 10; page 12) Hand release assembly Hand release lever Steel ball Thrust spring Cap screw Hexagon nut Washer O-ring NBR 70 (not included in delivery): For Size 200 (all designs): For Size 400 (210 Nm / 270 Nm / 350 Nm / 420 Nm design): For Size 400 (375 Nm / 450 Nm / 550 Nm / 600 Nm design): For Size 600 (all designs): For Size 800 (650 Nm / 850 Nm design): For Size 800 (950 Nm design): For Size 1000 (920 Nm / 1050 Nm design): For Size 1000 (1200 Nm design):

D48x3 D55x3 D60x3 D60x3 D67x3 D76x3 D76x3 D82x3

Wear monitoring assembly Microswitch Microswitch inc. adapter plate (Fig. 11; page 13) Cap screw (Fig. 11; page 13) Hexagon nut (Fig. 11; page 13) Hexagon head screw (Fig. 11; page 13) Spring washer (Fig. 11; page 13) Cable clamp D6 for coil cable Cable clamp D6 for microswitch cable Cap screw M4x8 Cable tie Type tag (on the side of the coil carriers) Hub O-ring

29/03/2010 TK/HW/GC/SU

Page 6 of 16



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Table 1: Technical Data (independent of Type and Size) Nominal air gap 1) "a" braked (Fig. 2)

0,45

+0,20

− 0,05

mm

Limit air gap 2) "a" for nominal torque (Fig. 2) 0,9 mm Inspection air gap "b" on released brake (Fig. 2) min. 0,25 mm Protection (coil/casting compound): IP54 Protection (mechanical): IP10 Protection (switch): IP67 Ambient temperature: 0 °C to t o +45 +4 5 °C Duty cycle: 60 % 1) Measured in the armature disk disk (2) area, middle, vertical centre axis. axis. 2) The nominal torque is given up to the limit air gap (0,9 mm). Danger! The tension ability of the brake is larger, but the rotor (3) must be replaced at the latest when the air gap reaches 0,9 mm, also due to the brake noise behaviour. On brakes with reduced braking torque, with hand release and / or operating with overexcitation, overexcitation, unpermittedly high wear on the rotor (3) wear will not be noticed via the brake switching behaviour. As the magnetic coil is capable in this constellation of achieving a very large armature disk (2) tension path, unpermittedly high wear on the rotor (3) leads to relaxation of the t hrust springs, which in turn causes a drop in braking torque. In extreme cases, the armature disks (2) may even contact the shoulder screws or the adjusting screw on t he hand release (air gap 1,6 mm) which would lead to the braking torque being lost. We therefore recommend an additional wear monitoring device (see page 14) for brakes with reduced braking torque, with hand release and/or operation with overexcitation. Brakes with reduced braking torque are For Size 200: 100 Nm and 150 Nm design For Size 400, short: 210 Nm, 270 Nm, and 350 Nm design For Size 400, long: 375 Nm and 450 Nm design

For Size 600: For Size 800: For Size 1000:

500 Nm design 650 Nm design 920 Nm design

Table 2: Technical Data Nominal torque 3)

Size

200

400 Short version

400 Long version

600 600 Long version 800

1000 3)

minimal 100 Nm 150 Nm 200 Nm 250 Nm 280 Nm 210 Nm 270 Nm 350 Nm 420 Nm 375 Nm 450 Nm 550 Nm 600 Nm 500 Nm 600 Nm 700 Nm 800 Nm 650 Nm 850 Nm 950 Nm 920 Nm 1050 Nm 1200 Nm

Overexcitation voltage 1,5 to 2 x U Nom

Nominal voltage U Nom

Nominal capacity P (20 ( 20 °C)

Inductivity (207 V – coil)

Rotor thickness in new condition

No

24/104/180/207 V DC

2 x 74 W

85,5 H

18 –0.05 mm

Yes

24/104/180/207 V DC

2 x 74 W

85,5 H

18 –0.05 mm

No

24/104/180/207 V DC

2 x 93 W

50 H

18 –0.05 mm

No

24/104/180/207 V DC

2 x 92 W

18 –0.05 mm

Yes

24/104/180/207 V DC

2 x 92 W

18 –0.05 mm

No

24/104/180/207 V DC

2 x 86 W

64,6 H

18 –0.05 mm

Yes

24/104/180/207 V DC

2 x 86 W

64,6 H

18 –0.05 mm

Yes

24/104/180/207 V DC

2 x 96 W

64,6 H

20 –0.05 mm

No

24/104/180/207 V DC

2 x 118 W

20 –0.05 mm

Yes

24/104/180/207 V DC

2 x 118 W

20 –0.05 mm

No

24/104/180/207 V DC

2 x 121 W

20 –0.05 mm

Yes

24/104/180/207 V DC

2 x 121 W

20 –0.05 mm

The braking torque (nominal torque) is the torque effective in the shaft train on slipping brakes, with a sliding speed of 1 m/s referring to the medium friction radius.

29/03/2010 TK/HW/GC/SU

Page 7 of 16



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Table 3: Technical Data

Size

200

400 Short version

400 Long version

600 600 Long version 800

1000 4)

Nominal torque minimal 100 Nm 150 Nm 200 Nm 250 Nm 280 Nm 210 Nm 270 Nm 350 Nm 420 Nm 375 Nm 450 Nm 550 Nm 600 Nm 500 Nm 600 Nm 700 Nm 800 Nm 650 Nm 850 Nm 950 Nm 920 Nm 1050 Nm 1200 Nm

Max. speed

Inspected max. Inspected max. friction work speed in on EMERGENCY the elevator area as STOP a prototypeper braking inspected brake circuit 4)

Tightening torque fixing screw Item 5

Release force per braking circuit 100 N 150 N 200 N 230 N 260 N 200 N 230 N 300 N 400 N 325 N 390 N

Page 8 of 16

Mass

13 °

24 kg

13 °

27 kg

15 °

36,6 kg

15 °

40,7 kg

1200 rpm

810 rpm

20000 J

24 Nm

1200 rpm

810 rpm

20000 J

24 Nm

1000 rpm

710 rpm

30000 J

48 Nm

1000 rpm

1000 rpm

30000 J

48 Nm

1000 1000 rpm rpm

1000 1000 rpm rpm

3000 300000 J

48 Nm

470 470 N

15 °

43,5 43,5 kg

800 rpm

500 rpm

35000 J

83 Nm

390 N 470 N 540 N

15 °

51,6 kg

800 800 rpm rpm

500 500 rpm rpm

3500 350000 J

83 Nm

620 620 N

15 °

61,9 61,9 kg

15 °

66,5 kg

15 °

83 kg

600 rpm

400 rpm

40000 J

83 Nm

500 rpm

400 rpm

45000 J

200 Nm

320 N 420 N 460 N 410 N 470 N 530 N

Max. 3 movements one after the other with a 5-minute break each time

29/03/2010 TK/HW/GC/SU

Release angle



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Table 4: Switching Times [ms] Nominal torque minimal 100 Nm 150 Nm 200 Nm 250 Nm 280 Nm 210 Nm 275 Nm 350 Nm 420 Nm 375 Nm 450 Nm 550 Nm 600 Nm 500 Nm 600 Nm 700 Nm

Size

200

400 Short version

400 Long version

600

Tightening t2 140 180 195

Tightening t2 on overexcitation – – –

Drop-out t11 AC 600 350 280

Drop-out t1 AC 950 800 670

Drop-out t11 DC 90 55 38

Drop-out t1 DC 190 145 115

–

115

150

400

20

90

240 310 350 450 295 320

– – – – – –

800 270 235 190 385 200

1200 800 675 400 700 870

100 40 30 25 36 30

250 170 145 125 160 140

–

165

150

550

15

100

300 390 –

– – 230

500 350 240

900 790 650

60 42 34

220 180 160

800 Nm

–

260

200

960

38

230

650 Nm 850 Nm 950 Nm 920 Nm 1050 Nm 1200 Nm

300 450 – 360 490 –

– – 240 – – 260

540 400 250 530 400 250

1070 950 850 1250 1100 900

60 45 35 70 55 35

240 210 180 260 220 180

600 Long version 800

1000

Please Observe!  The use of varistors for spark quenching increases the DC-side switching times. 

At temperatures of around or under freezing point, condensation can strongly reduce the braking torque. The user is responsible for taking appropriate counter measures. The customer is responsible for providing a protective cover against contamination caused by construction sites.

Torque-Time Diagram

M

Key:

M4

M2 M1 M6 0,1 M2 t t21

t11 P

OFF 29/03/2010 TK/HW/GC/SU

Page 9 of 16

= Switching torque = Nominal torque (characteristic (characteristic torque) = Transmittable torque torque = Load torque = Connection time = Response delay on connection = Separation time = Response delay on separation separation = Slipping Slipping time + t11

t2

t1

ON

M1 M2 M4 M6 t1 t11 t2 t21 t4

t4 t Chr. Mayr GmbH + Co. KG Eichenstraße 1 87665 Mauerstetten Germany


Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Design

Installation Conditions

The ROBA ® -duplostop ® is a spring applied, electromagnetically releasing dual circuit brake. It is used for installation in a gearless elevator and serves as a brake assembly on the drive sheave shaft and as part of the protective assembly against excessive upward-moving upward-moving cage speeds.

  

Function ROBA ® -duplostop ® brakes are spring applied, electromagnetic safety brakes. Spring applied function: In de-energised condition, thrust springs press against the armature disks (2). The rotor (3) with the friction linings is therefore held between the armature disks (2) and the machine screw-on screw-on surface. The motor shaft is braked by the rotor (3). Electromagnetic: Due to the magnetic force of the coils in the coil carriers (1), the armature disk (2) is attracted against the spring force to the coil carrier (1). The brake is released and the shaft can rotate freely. Safety brake function: The ROBA ® -duplostop ® brakes reliably and safely in the event of a power switch-off, a power failure or an EMERGENCY STOP.



Please Observe! The dimensions on the assembly drawings are manufacturer-side recommendations. 

State of Delivery The brake bodies are partly assembled with coil carriers (1), armature disks (2), distance bolts (4), hand release (option, dependent on Type) and adjusted microswitches (option, dependent on Type). The rotor (3) and the hexagon head screws (5) for securing the brake are included loose in delivery.

 

ROBA ® -duplostop ® for use as holding brakes with occasional EMERGENCY STOP braking actions. The max. permitted speeds and friction work, see Table 3, must be observed.

Dimensioning of the key connection according to the requirements shaft diameter, transmittable torque and operating conditions must be carried out. For this, the corresponding user data must be known or the customer must carry out the dimensioning according to the valid calculation basis DIN 6892. For the calculation, a hub quality of Re = 300 N/mm2 should be used. The length of the key should lie over the entire hub (15).



For the dimensioning of the key connections, the permitted tensions common in machine construction must be considered.



The mounting dimensions and the screw-on surface s with depth K + 2 mm (K = screw projection) acc. Catalogue or applicable Assembly Drawing Drawing must be given (Fig. 8).



The rotor and brake surfaces must be oil and grease-free. A suitable counter friction surface (steel or cast iron) must be used. Sharp-edged interruptions on the friction surfaces must be avoided. Recommended surface quality in the area of the friction surface Ra = 1,6 µm. In particular customer-side mounting surfaces made of grey cast iron are to be rubbed down additionally with fine sandpaper (grain ≈ 200 – 400), or ideally with a sander. Please abstain from using cleaning agents containing solvents, as they could affect the friction material. During longer downtimes, we recommend the use of suitable corrosion protection measures for the mounting surface (e.g. zinc-phosphate coating) until initial operation.

Motor shaft central axis Mounting surface

Ø 0,3 s

6 , 1 a R

A 

0,063 A

s

On hub designs the hub bore (15) tolerances and the shaft must be selected so that the hub t oothing (15) is not widened. Widening of the toothing leads to the rotor (3) jamming on the hub (15) and therefore therefore to brake malfunctions. Recommended hub - shaft tolerance H7/k6. If the hub (15) is heated for better joining, the O-ring (16) must be removed beforehand and re-mounted after hub installation. The max. permitted joining temperature of 200 °C mu st not be exceeded.



Please check state of delivery!

Application

The eccentricity of the shaft end in relation to the fixing holes may not exceed 0,3 mm. The position tolerance of the threaded holes for the cap screws (5) must not exceed 0,3 mm. The axial run out deviation of the screw-on screw-on surface to the shaft must not exceed the permitted axial run out tolerance of 0,063 mm in the area of the friction surface. Measuring procedure acc. DIN 42955. Larger deviations can lead to a drop in torque, to continuous slipping on the rotor (3) and to overheating. The toothed motor shaft should be designed according to the information given in the applicable Assembly Drawing. Drawing. The O-ring groove must be inserted before the shaft is splined. The O-ring groove must be free of burrs.



K

Fig. 8 29/03/2010 TK/HW/GC/SU

Page 10 of 16



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Installation: Design with toothed motor shaft (Figs. 1 - 2a and 3 - 8) 1.

2.

3.

4.

5.

Hand release (7)

Insert the O-ring (8, slightly slightly greased, greased, acc. Parts List with with NBR 70 material (provided by customer) into the motor shaft groove. Please use NLGI Class 2 grease with a basic oil viscosity of 220 mm2 /s at 40 °C, e.g. Mobilgrease HP222. Push the rotor (3) onto the motor shaft by hand using using light pressure. Please ensure that the rotor collar Ø 90 for Size 200, Ø 110 for Size 600, Ø 124 for Size 800 and Ø 135 for Size 1000 is facing in the direction of the machine wall. The installation direction is immaterial for Size 400 because the rotor (3) is symmetrical. On special designs, the rotor collar must be aligned acc. the applicable Assembly Drawing. Drawing. Check that the toothing moves m oves easily. Do not damage the O-ring. Secure the left brake body body using using hexagon hexagon head head screws screws (Item 5, 4 pcs.) all round step-wise evenly (we recommend that you secure the screws using Loctite 243). Tighten the hexagon head screws using a torque wrench and observe the tightening torque acc. Table 3. Then repeat this procedure with the right brake body. Check air gap "a" = 0,45 00,,20 05 mm The nominal air gap must be given in the middle of the armature disk (2) area, vertical centre axis (Fig. 1). Check air gap "b" > 0,25 mm in energised state on the rotor (3) (Fig. 2). The inspection air gap must be given.

The hand release is completely assembled manufacturerside. The brake is released when both hand release levers are moved simultaneously (7.1), see Fig. 5. By lifting the hand release levers (7.1) up from the steel balls (7.2), both cap screws (7.4) incl. washers (7.6) together with the armature disk (2) are pulled against the coil carrier (1) (Fig. 9). After this, the rotor (3) is free and the brake is released. Danger! Operate the hand release carefully. Existing loads are put into motion when the hand release is activated.

7.6 7.3

7. 4

1 7. 2 7.1

3

7.5

+ −

Installation: Hub design (Figs. 1 and 2b - 8) 1.

(Option dependent on Type for release using a Bowden cable)

Mount the hub (15) with the O-ring inserted (Item (Item 16 /O/ Oring must be lightly lig htly greased) greased) onto the shaft and bring it into the correct position (the length of the key should cover the entire hub) and secure it axially e.g. using a locking ring).

2. Push the rotor rotor (3) over the O-ring (16) (16) onto the hub (15) (15) by hand using light pressure. Please ensure that the direction of the rotor collar is aligned acc. the applicable Assembly Drawing. Check that the toothing moves easily. Do not damage the O-ring.

2 Fig. 9

Adjustment dimension 1,6 +0,2 for Size 200 2,0 +0,2 for Sizes 400 - 1000

Braking Torque Adjustment Adjustment ROBA ® -duplostop ® brakes are delivered adjusted to the braking torque required on order.

Noise damping

3. Secure the left brake body using hexagon hexagon head screws screws (Item 5, 4 pcs.) all round step-wise evenly (we recommend that you secure the screws using Loctite 243). Tighten the hexagon head screws using a torque wrench and observe the tightening torque acc. Table 3. Then repeat this procedure with the right brake body. 4. Check air gap "a" = 0,45 00,,20 05 mm The nominal air gap must be given in the middle armature disk (2) area, vertical centre axis (Fig. 1). + −

Please Observe! The noise damping used here was set and adjusted manufacturer-sid m anufacturer-side. e. However, However, this component is subject to aging dependent on the application or operational conditions (torque adjustment, switching frequency, ambient conditions, system vibrations etc.) and must be readjusted or replaced as a routine measure or if the switching noise becomes t oo loud. This must only be carried out by qualified and authorised specialist personnel, and should therefore be undertaken in the place of manufacture.

5. Check air gap "b" > 0,25 mm in energised state on the rotor (3) (Fig. 2). The inspection air gap must be given.

29/03/2010 TK/HW/GC/SU

Page 11 of 16



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Manufacturer-side Adjustment and Functional Inspection of the Microswitches (6.1), see Fig. 10:

Release Monitoring (6) Fig. 10 (Option, dependent on Type) ROBA ® -duplostop ® brakes are delivered with one release monitoring (6) per brake circuit. The microswitches (6.1) emit a signal for every brake condition change "signal brake opened or brake closed“ On initial operation: Connection as NO contact (black and blue strands). The customer is responsible for a signal evaluation of both conditions. From the point at which the brake is energised, a time span of three times the separation time must pass before the microswitch signal on the release monitoring is evaluated. Wiring Diagram:

2 COM Contact Black connection

NC Contact Grey Gr ey con onne nect ctio ion n Connection when brake closed

1 4 NO Contact blue connection Connection when brake released

Re-adjustment is possible via the hexagon head screws (6.4) and the hexagon nuts (6.3). If this proves necessary, please contact the manufacturers.

Function When the magnetic m agnetic coils are energised in the coil carriers (1), the armature disks (2) are attracted to the coil carrier (1), the microswitches (6.1) emit a signal and the brake is released.

2

6.5 6.3 6.4 6.1 6.2 1

Brake mounted and secured with the nominal torque. Danger! Brake must not be energised.

1.

Turn the hexagon head screw screw (6.4) (6.4) in the direction direction of the microswitch (6.1) up to the microswitch tappet. 2. Tighten the hexagon hexagon nut (6.3), so that the hexagon hexagon head head screw (6.4) is placed under pre-tension by the spring washer (6.5). 3. Put a feeler gauge 0,12 0,12 mm (loose sensor plate) between the switch tappet and the hexagon head screw (6.4). 4. Connect the inspection or measurement device (diode inspection) to the NO contact black/blue. 5. Turn the hexagon head screw screw (6.4) (6.4) in the direction direction of the switch (6.1) up to signal "ON", turn "ON", turn it back to the signal "OFF" and "OFF" and counter the hexagon head screw (6.4) with the hexagon nut (6.3). 6. Energise brake  Signal "ON" De-energise De-energise brake  Signal "OFF", "OFF", Re-adjust if necessary and repeat the inspection. 7. Remove the feeler gauge 0,12 mm. 8. Inspection with feeler gauge 0,16 mm Energised  Signal "ON" De-energised  Signal "ON" 9. Remove the feeler gauge 0,16 mm. 10. Repeat inspection with feeler gauge 0,12 mm Energised  Signal "ON" De-energised  Signal "OFF" 11. Put the feeler gauge gauge 0,20 mm between the armature disk (2) and the coil carrier (1) in the microswitch (6.1) area and then energise the brake. The signal must be "ON". 12. Paint items 6.2, 6.3 and 6.4 6.4 with sealing sealing lacquer.

Customer-side Inspection after Mounting onto the Elevator Machine The customer-side contact is an NO contact. Please inspect the release monitoring of both circuits: Brake de-energised  Signal "OFF", Brake energised  Signal "ON"

Fig. 10

Table 5: Microswitch Specifications (6.1) Characteristic values for measurement:

250 V~ / 3 A

10 mA DC-12 Minimum switching capacity: 12 V, 10 Recommended switching capacity: for maximum lifetime and reliability

24 V, 10...50 mA DC-12 DC-13 with free-wheeling diode!

Usage category acc. IEC 60947-5-1: DC-12 (resistance load), DC-13 (inductive load)

29/03/2010 TK/HW/GC/SU

Page 12 of 16



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Manufacturer-side Adjustment of the Microswitch (9.1)

Wear Monitoring (9) Figs. 7 and 11 (Option, dependent on Type) Only one microswitch for wear monitoring (9) is required per ROBA ® -duplostop ® , which is mounted onto the right brake (Figs. 7 and 11). The ROBA ® -duplostop ® brake is brake is delivered with manufacturerside adjusted wear monitoring (9).

Danger! The brake is screwed onto the installation device to the tightening torque (see Table 3) and the coil is de-energised. 1.

Function Due to wear on the rotor, (3) the air gap "a" between the coil carrier (1) and the armature disk increases (2). Once the maximum air gap (limit air gap) of 0,9 mm has been reached (Table 1), the m icroswitch contact (9.1) switches over and emits a signal. The rotor (3) must be replaced.

2.

The customer is responsible for signal evaluation.

4. 5.

Wiring Diagram:

2 COM Contact Black connection

3.

NC Contact Grey Gre y conn onnect ection ion Connection when wear limit is reached

1

6. 7.

Connect the inspection or measurement device (diode inspection) to the NC contact black/grey. Turn the hexagon head screw screw (9.4) (9.4) in the direction direction of the microswitch (9.1) until it switches, and apply pre-tension via the spring washer (9.5) using the hexagon nut (9.3). Hold the hexagon nut (9.3) and turn the hexagon hexagon head screw (9.4) back until the microswitch contact (9.1) switches over again. Mark the position of the hexagon hexagon head screw (9.4) (marker (marker pen). Hold the hexagon head screw screw (9.3) (9.3) and turn the hexagon head screw (9.4) approx. 0,6 – 0,7 turns back in the direction of the microswitch (9.1). Counter the hexagon hexagon head screw (9.4) with with the hexagon nut (9.3) and mark the position using red securing lacquer. Mount the Wear Monitoring guideline sign.

4 NO Contact blue connection Connection when wear limit is not yet reached

Before replacing the rotor (3) • Clean the brake and remove abraded particles using compressed air. • Do not inhale brake dust. • Measure the rotor thickness "new" (see Table 2).

Right brake 9.5

2

9.3

6

9.4

1

Replacing the rotor (3) Replace the rotor by following the Brake Installation instructions backwards.

9.1

Danger! The drive brake must be load-free on hoist drives. Otherwise there is a danger of load crashes!

9.2 Fig. 11

Table 6: Microswitch Specifications (9.1) Characteristic values for measurement:

250 V~ / 3 A

Minimum switching capacity: 12 V, 10 mA DC-12 24 V, 10...50 mA Recommended switching DC-12 capacity: DC-13 with free-wheeling for maximum lifetime diode! and reliability Usage category acc. IEC 60947-5-1: DC-12 (resistance load), DC-13 (inductive load)

29/03/2010 TK/HW/GC/SU

Page 13 of 16



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Electrical Connection for Operation with Nominal Voltage (Without Overexcitation) DC current is necessary for operation of the brake. The coil voltage is indicated on the Type tag (14) as well as on the brake body and is designed according to the DIN IEC 60038 (± 10 % tolerance). Operation must take place via DC voltage with a low ripple content, e.g. via a bridge rectifier or with another suitable DC supply. Dependent on the brake equipment, the connection possibilities can vary. Please follow the exact connections according to the Wiring Diagram. The m anufacturer and the user must observe the applicable directives and standards (e.g. DIN EN 60204-1 and DIN VDE 0580). Their observance must be guaranteed and double-checked!

Magnetic Field Removal AC-side Switching max.

230V~ 2,5A–

1/025.000.6 [U– = 0,9×U~] Brückengleichrichter Bridge rectifier

SDC

IN

1

Earthing Connection

2

3

OUT

4

5

6

The power circuit is interrupted before the rectifier. The magnetic field slowly reduces. This delays the rise in braking torque. When switching times are not important, please switch ACside, as no protective measures are necessary for coil and switching contacts.

S1 Coil

The brake is designed for Protection Class I. This protection covers not only the basic insulation, but also the connection of all conductive parts to the PE conductor on the fixed installation. If the basic insulation fails, no contact voltage will remain. Please carry out a standardized inspection of the PE conductor connections to all contactable metal parts!

Supply Voltage Requirements In order to minimise noise development of the released brake, it must only be operated via DC current with low ripple content. AC current operation can take place using a bridge rectifier or another suitable DC power supply. Supplies whose output voltages have a high ripple content (e.g. a half-wave half-wave rectifier, a switch-mode mains adaptor, ...) are not suitable for operation of the brake.

F1

N

L

F1: external fuse

 Low-noise switching; however, the brake engagement time is longer (c. 6-10 times longer than with DC-side switching). switching). Use for non-critical brake times.

DC-side Switching max.

230V~ 2,5A–

1/025.000.6 [U– = 0,9×U~] Brückengleichrichter Bridge rectifier

Device Fuses To protect against damage from short circuits, please add suitable device fuses to the mains cable.

SDC

IN

Switching Behaviour

1

The operational behaviour of a brake is to a large extent dependent on the switching mode used. Furthermore, the switching times are influenced by the temperature and the air gap between the armature disk (2) and the coil carrier (1) (dependent on the wear condition of the linings).

2

3

OUT

4

5

6

S1

The power circuit is interrupted between the rectifier and the coil as well as mains-side. The magnetic field reduces extremely quickly. This causes a quick rise in braking torque. When switching DC-side, high voltage peaks are produced in the coil, which lead to wear on the contacts from sparks and to destruction of the insulation.

Coil

F1

Magnetic Field Build-up

N

When the voltage is switched on, a magnetic field is built up in the brake coil, which attracts the armature disk (2) to the coil carrier (1) and releases the brake.

L

F1: external fuse

 Short brake engagement times (e.g. for EMERGENCY STOP); however, STOP); however, louder switching noises.

Protective Circuit When using DC-side switching, the coil must be protected by a suitable protective circuit according to VDE 0580, which is integrated in mayr ® rectifiers. To protect the switching contact from consumption when using DC-side switching, switching, additional protective measures are necessary (e.g. series connection of switching contacts). The switching contacts used should have a minimum contact opening of 3 mm and should be suitable for inductive load switching. Please make sure on selection that the rated voltage and the rated operation current are sufficient. Depending on the application, the switching contact can also be protected by other protective circuits (e.g. mayr ® spark quenching unit), although this may of course then alter the switching time.

29/03/2010 TK/HW/GC/SU

Page 14 of 16



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Magnetic Field Removal

Electrical Connection for Operation with Overexcitation

AC-side Switching

DC current is necessary for operation of the brake. The coil voltage is indicated on the Type tag (14) as well as on the brake body and is designed according to the DIN IEC 60038 (± 10 % tolerance). The brake may only be operated with overexcitation (e.g. with a with a ROBA ® -switch fast acting rectifier or phase demodulator). demodulator ). Dependent on the brake equipment, the connection possibilities can vary. Please f ollow the exact connections according to the Wiring Diagram. The manufacturer and the user must observe the applicable directives and standards (e.g. DIN EN 60204-1 and DIN VDE 0580). Their observance must be guaranteed and double-checked!

R

The power circuit is interrupted before the rectifier. The magnetic field slowly reduces. This delays the rise in braking torque.

R

ROBA -switch 20/017.000.2

U– = 0,45×U~

Imax = 1,8A –

200- 500V~

t: 0,05-2sec R: 0Ω- 10 10M Ω

200- 300V~ S DC

IN

–

+

OU T

1 2 3 4 5 6 7 8 1

2

3

4

5

6

7

8

S1

Earthing Connection The brake is designed for Protection Class I. This protection covers not only the basic insulation, but also the connection of all conductive parts to the PE conductor on the fixed installation. If the basic insulation fails, no contact voltage will remain. Please carry out a standardized inspection of the PE conductor connections to all contactable metal parts! Device Fuses To protect against damage from short circuits, please add suitable device fuses to the mains cable.

Coil

F1

N

L

DC-side Switching R

20/017.000.2

U– = 0,45×U~

Page 15 of 16

+

OU T

2

3

4

5

6

7

8

S1 Coil

When switching DC-side, high voltage peaks are produced in the coil, which lead to wear on the contacts from sparks and to destruction of the insulation.

F1

N

L

F1: External fuse

⇒ Short brake engagement times (e.g. for EMERGENCY STOP); however, STOP); however, louder switching noises.

Braking torque path M Mnom

29/03/2010 TK/HW/GC/SU

–

1 2 3 4 5 6 7 8

Field Build-up with Overexcitation A quicker and safer drop in braking torque is achieved if the coil is temporarily placed under a higher voltage than the nominal voltage, as the current then increases more quickly. Once the brake is released, it is possible to switch over to the nominal voltage (curve 2). The effective capacity may however not be larger than the nominal capacity of t he coil. The ROBA ® -switch fast acting rectifier works on this principle, which is obligatory for safe operation of this brake.

t

S DC

IN

Field Build-up with Normal Excitation If we energise the magnetic coil with nominal voltage, the coil voltage does not immediately reach its nominal value. The coil inductivity causes the current to increase slowly as an exponential function. Accordingly, Accordingly, the build-up of the magnetic field takes place more slowly and the braking torque drop (curve 1) is also delayed.

2

t: 0,05-2sec R: 0Ω- 10 10M Ω

200- 300V~

1

1

Imax = 1,8A –

200- 500V~

When the voltage is switched on, a magnetic field is built up in the brake coil, which attracts the armature disk (2) to the coil carrier (1) and releases the brake.

Inom

The power circuit is interrupted between the rectifier and the coil as well as mains-side. The magnetic field reduces extremely quickly. This causes a quick rise in braking torque.

R

ROBA -switch

Magnetic Field Build-up

2

F1: External fuse

however, the brake engagement time ⇒ Low-noise switching; however, is longer (c. 6-10 times longer than with DC-side switching). switching). Use for non-critical brake times.

Switching Behaviour The operational behaviour of a brake is to a large extent dependent on the switching mode used. Furthermore, the switching times are influenced by the temperature and the air gap between the armature disk (2) and the coil carrier (1) (dependent on the wear condition of the linings).

Current path I

When switching times are not important, please switch ACside, as no protective measures are necessary for coil and switching contacts.

Protective Circuit When using DC-side switching, the coil must be protected by a suitable protective circuit according to VDE 0580, which is integrated in mayr ® rectifiers. To protect the switching contact from consumption when using DC-side switching, additional protective measures are necessary (e.g. series connection of switching contacts). The switching contacts used should have a minimum contact opening of 3 mm and should be suitable for inductive load switching. Please make sure on selection that the rated voltage and the rated operation current are sufficient. Depending on the application, the switching contact can also be protected by other protective circuits (e.g. mayr ® spark quenching unit), although this may of course then alter the switching times.

1 t



Installation and Operational Instructions for ROBA ® -duplostop ® (B.8010.GB) Type 8010._ _ _ _ _ Sizes 200 to 1000 Brake Inspection

Maintenance

(Customer-side after mounting Installation onto Elevator Machine)

ROBA ® -duplostop ® brakes are mainly maintenance-free. The friction linings are robust and wear-resistant. This ensures a particularly long service lifetime. However, However, the friction linings are subject to functional wear on frequent use of EMERGENCY EMERGENCY STOP. Therefore, the following inspections are to be carried out at regular inspection intervals: intervals: Braking torque or retardation inspection  (individual brake circuits). (TÜV interval) Inspection of air gap braked  (both brake circuits) (TÜV interval) Inspection of toothing backlash, toothed shaft on motor to  the rotor (3) or hub (15) to the rotor (3) Max. permitted permitt ed toothing toothi ng backlash 0,5°. (TÜV interv al)









Individual air gap inspection (Nominal air gap "a" and air gap "b" on both brake circuits acc. Table 1 and Fig. 2). Braking torque inspection: Please compare the requested braking torque with the torque stated on the Type Tag. Release function inspection (Battery operated to guarantee emergency escape for passengers during a power failure). Switching function inspection Energised brake Signal "ON" (NO contact) De-energised brake Signal "OFF" (NO contact)

Dual Circuit Brake Functional Inspection The ROBA The ROBA ® -duplostop ® brake is equipped with a double safety (redundant) brake system. This means that, should one circuit fail, the braking effect is maintained. Danger! Should the elevator begin to move after release of one brake circuit or should it fail to react to the braking procedure, the energised coil must be switched off immediately! The dual circuit function is not guaranteed. Shut down the elevator, de-install and inspect the brake.

Danger! To inspect the rotor (3) wear condition, please measure the air gap "a" acc. Table 1 and Fig. 2. If the brake limit air gap has been reached (0,9 mm), meaning that the friction linings are worn down, the rotor (3) must be replaced. Please follow the Installation section backwards to dismantle the brake (page 11).

Disposal

The individual circuit inspection is carried out by energising the individual circuits with nominal voltage.

Our electromagnetic brake components must be disposed of separately as they consist of different materials. Please observe the relevant authority regulations. Code numbers may vary according to the dismantling process (metal, plastic and cable).

Inspection left brake circuit:

Electronic components (Rectifier / ROBA ® -switch / Microswitch): Microswitch):

1. 2. 3.

Energise the right brake circuit. Trigger an EMERGENCY EMERGENCY STOP with the left left brake brake circuit circuit and inspect the stopping distance according to the elevator regulations. De-energise the right brake circuit.

Inspection right brake circuit: 1. 2. 3.

Energise the left brake circuit. Trigger an EMERGENCY EMERGENCY STOP with the right right brake circuit and inspect the stopping distance according to the elevator regulations. De-energise the left brake circuit.

Inspection both circuits: Energise both braking circuits with nominal voltage. Trigger an EMERGENCY STOP and inspect the stopping distance according to the elevator regulations. The stopping distance must be much shorter than the stopping distance for an individual circuit.

Products which have not been dismantled can be disposed of under the Code 160214 (mixed materials) or Components under Code. No. 160216, or can be disposed of by a certified disposal firm. Brake bodies made of steel pads with coil / cable and all other steel components: Steel scrap (Code No. 160117) Aluminium components: Non-ferrous Non-ferrous metals

(Code No. 160118)

Brake rotor (steel or aluminium pads with friction linings): Brake linings (Code No. 160112) Seals, O-rings, V-seals, elastomers, terminal bo xes (PVC): Plastic (Code No. 160119)

Malfunctions / Breakdowns: Malfunctions

Possible Causes

Solutions

Brake does not release

Incorrect voltage on rectifier Rectifier failure Air gap too large (worn rotor) Coil interruption

Apply correct voltage Replace rectifier Replace rotor Replace brake

Release monitoring does not switch

Brake does not release Defective microswitch

Solution as above Replace the microswitch m icroswitch (manufacturerside)

29/03/2010 TK/HW/GC/SU

Page 16 of 16



OPERATING MANUAL 9.

PMC145

CHANGES

Changes Changes Version Chapter 12/2011

Electrical data for brake


71

3

12-2011

ThyssenKrupp Aufzugswerke GmbH Bernhäuser Straße 45 73765 Neuhausen a. d. F. Deutschland e-Mail: [email protected] Internet: www.thyssenkrupp-elevator-eli.de

1 1 0 2 / 2 1 e u s s I

5 6 2 9 0 0 0 0 1 7 9 . r N

PMC-Gearless

Recommend Documents