Operating Manual Compact...

ThyssenKrupp Aufzugswerke

A company of ThyssenKrupp

Elevator

Operating Manual Compact gearless® SC300

OPERATING INSTRUCTIONS

ThyssenKrupp Aufzugswerke GmbH 3

Imprint

All rights reserved © Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH

Postfach 23 03 70, D-70623 Stuttgart Printed in Germany These operating instructions may – even in extract form – only be reprinted or otherwise copied with the express written approval of THYSSENKRUPP AUFZUGSWERKE GmbH. All copying, distribution or saving in any form on data storage media which is not authorised by THYSSENKRUPP AUFZUGSWERKE GmbH constitutes a copyright infringement and will result in prosecution. We expressly reserve the right to carry out technical alterations which lead to an improvement of our products or increase the safety standard – also without special prior notice. The issuer responsible for the content: THYSSENKRUPP AUFZUGSWERKE GmbH

Preface

We are delighted that you have decided upon a quality product from the company THYSSENKRUPP AUFZUGSWERKE GmbH. These operating instructions will help you to get to know our products and to benefit from their intended applications. Important safety and hazard instructions will help you to operate our products safely and properly. Subject to technical alterations.

OPERATING INSTRUCTIONS 1. CONTENTS AND SAFETY

ThyssenKrupp Aufzugswerke GmbH

Table of contents

Compact gearless® SC300 PAGE

1. Safety 1.1 Explanation of the symbols used 6 1.2 Safety instructions 7 1.3 Emergency measure "Releasing the car from the engaged

position (safety gear)" 10

2. Product description 2.1 Description 12 2.2 Functional description 13

3. Technology 3.1 Technical data 16 3.2 Dimensions of machine 17 3.3 Dimensions of machine base frame 18 3.4 Motor data 24 3.5 Type plate 24 3.6 Pulse generator 25

4. Transport and storage 26

5. Mounting the machine 5.1 Machine setup 28 5.2 Aligning the machine and machine base frame 28 5.3 Mounting the rope pulley 29 5.4 Connecting the machine 30

6. Commissioning 32

7. Maintenance / service 7.1 Maintenance 33 7.2 Lubrication 34 7.3 Testing the brakes 36 7.4 Setting the brake test switch 38 7.5 Replacing the brakes 39 7.6 Replacing the traction sheave 40 7.7 Replacing the pulse generator 41 7.8 Checking for escaping grease / oil 43

8. Appendix 8.1 Tightening torques - tightness values 45 8.2 Accessory parts 46 Manufacturer specifications for pulse generator from page 49

onwards Type test certificate Declaration of conformity

5



1.1 Explanation of the symbols used 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 are to be followed without fail. They contribute to preventing personal injury or damage to property.

6



1.2 General safety instructions

Notes regarding the operating manual A requirement for safe handling and non-disruptive operation this assembly is knowledge of the fundamental safety regulations. This operating manual contains the most important information that is required to operate the assembly safely. The operating manual, in particular the safety instructions, is to be complied with by all persons that work on this assembly. 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 and / or installation firm undertakes only to allow persons to work on the assembly who • are familiar with the regulations regarding work safety and accident prevention and have

been instructed in handling the assembly. • have read the chapter on safety and the warnings in this operating manual. Note: Check at regular intervals that the personnel work with a heightened awareness with regard to safety.

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

Training of the personnel Only trained and instructed qualified personnel may work on the assembly. 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 device are to be checked regularly in accordance with the maintenance plan.

7



Informal notes on the safety measures • The operating manual is to be kept permanently at the usage site 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 The SC300 has been constructed using state-of-the-art technology and in line with the recognised technical safety regulations. The SC300 may only be • deployed in line with the intended purpose and • used when all the technical safety features are in perfect condition. The exclusive intended purpose of the SC300 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 in the operating manual and • Adherence to the commissioning instructions, the installation description as well as the

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 in line with the intended purpose of the SC300 • Installation, commissioning, operation and maintenance of the SC300 that is not in line with

accepted technical principles • Operation of the SC300 with defective and/or

non-operative safety and protective devices • Nonobservance of the instructions in the operating manual with regard to

Transport, storage, installation, commissioning, operation and maintenance of the SC300 • Constructional changes to the SC300 performed by the operator • Changes to the drive ratios (power output etc.) performed by the operator • Deficient monitoring of parts that are subject to wear • Repairs that are carried out improperly • Case of catastrophe due to third-party interference and force majeure

8



Constructional changes to the SC300 performed by the operator The SC300 is set at the plant and delivered ready for operation. If changes are made to the machine, the entire warranty of THYSSENKRUPP AUFZUGSWERKE GmbH shall become null and void

Dangers in handling the SC300 The SC300 may only be operated in an enclosed machine room and only with the cover and rope guard on the traction sheave. When working on the drive, the power is to be switched off before starting work and the installation secured against inadvertent activation. It must be ensured when persons are in the machine room that there is adequate safety clearance to all revolving (marked in yellow) parts. In the event of improper use, there 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.

General warnings for working on electrical components Do not work on live devices, components or cables! When an installation is switched off it is to be secured against unauthorised reactivation! Attention: Residual voltage can still be expected on bare wires and energised parts after they have been switched off! Electronic and other components remain energised even after the removal of fuses. Work may only be performed on the device after a waiting time of 5 minutes or as soon as the intermediate circuit voltage has reduced to a residual voltage of less than 60 V! This is to be tested by using a measuring instrument.

9



1.3 Emergency measure "Releasing the car from the engaged position (safety gear)"

If the safety gear on the elevator car or counterweight has triggered, it can occur that the driving force of the traction sheave is insufficient to move the elevator from this position; the ropes slip through.

Perform the following measures in this case: • Switch off the drive and control system. • Remove the traction sheave cover above the traction sheave. • Release the hydraulic cylinder on the pull side of the traction sheave and place it in the

mounting borehole in the machine base frame. • Screw the pressure arm with centring pin facing downwards onto the front of the traction

sheave. Here, use the thread near the cylinder (see Fig. 1.2). • Engage the blocking clamp with lug in the ring groove under the brake disc and bolt in the

next thread above the pressure arm on the traction sheave (see Fig. 1.1). • Tighten the 3 pressure screws to clamp the ropes with the pressure piece. • Operate the release lever on the brake magnet and pump the cylinder to move the

traction sheave in the desired direction until the safety gear lock is released. (The drain valve must be closed; the centring pin of the pressure arm must be located in the groove of the cylinder)

• After the pulling operation has been completed, remove the blocking clamp and mount the rope fixing beam as well as the traction sheave cover according to instructions.

Note: if the path of the hydraulic cylinder or the traction sheave movement is not enough to free the elevator car, secure it by applying the rope clamp. The rope clamp is to be mounted in the drilled hole in the machine base frame (below the rope departure on the traction sheave) on the ropes, see Fig. 8.6. Lower the hydraulic cylinder, reset the pressure arm to the next securing thread on the traction sheave above the hydraulic cylinder. If there is not an adequate path for the blocking clamp, reset this too. Then repeat the procedure described until the elevator car is free. The rope clamp is to be released from the ropes using the cylinder during the pulling operation, as it otherwise blocks the pulling operation.

1 Ring groove 2 Lug 3 Pressure piece 4 Set bolts

Fig. 1.1

1

3

4

2

Mounting the blocking clamp

10



After completing the measure, remove the auxiliary tools and mount the protective devices (rope fixing beam / protective hood). NB: before reconnection of the installation, ensure that the cause of the malfunction has been remedied and that the installation is in proper working order. Fitting the cylinder on the traction sheave

NB: you will find more illustrations of the additional tools required for the process in chapter 8

1 Pressure arm 2 Centring pin 3 Hydraulic cylinder 4 Lever 5 Drain valve

1

2

3

4

5

Fig. 1.2

11

OPERATING MANUAL 2. PRODUCT DESCRIPTION


2.1 Description

Illustration without rope guard and cover The SC300 consists of:

Item Part designation Item Part designation 1 Disc on motor shaft 9 Pressure springs 2 Brake block 10 Tightening screw 3 Brake magnet 11 Monitoring switch 4 Brake magnet connection 12 Groove profile traction sheave 5 Brake release lever 13 Brake disc 6 Pressure piece 14 Brake lining 7 Brake test switch 15 Brake block pin 8 Setting screw for 7 16 Machine base frame

5 4

11

10

8

3

6

1

7

9

2

12

Fig. 2.1

13

14

16

15

12



Versions The following versions can be supplied: 1. Elevator speeds, see type plate; 2. Groove profiles and number of ropes on the traction sheave 3. Machine base frame variants (depending on suspension and gap between the ropes on the

rope departure, ASL) 4. Safety-relevant accessory parts

2.2 Functional description

Machine: the SC300 consists of a frequency-controlled, permanently excited synchronous motor in design B3 (DIN IEC 34-7). It is divided into two performance ranges that differ with regard to the designation in the Appendix on the type designation. The specification SC300 S (small) stands for the lower power output, SC300 M (medium) for the higher power output. The outer casing dimensions are the same. The housing is designed in as a monoblock with a one-sided integrated bearing bracket. The drive shaft is mounted on roller bearings and is made of tempering steel. The front self-aligning bearing behind the traction sheave can be relubricated via a lubrication nipple. Surplus grease is drained off through an overflow pipe during lubrication. The rear self-aligning bearing in the bearing bracket is sealed and has lifetime lubrication. The SC300 can be operated either with 1 : 1 or 2 : 1 suspension, with single (180°) or double rope wrap. The rope departure is fitted vertically facing downwards. Depending on the motor type and control device, the braking energy that occurs can be: a) directed to resistors (only with type SC300 S) b) returned sinusoidally to the mains system The machine is configured for thermal class F and is used according to class B. The SC300 machine has its own ventilation (it has no additional forced ventilation). The operating temperature (max. 130°C ± 5°C) is monitored by a bimetal thermostat. In the event of overheating, it switches the drive off. Once the thermal contact closes when the motor cools down, the drive is ready for operation again. The overhung traction sheave with integrated brake disc is presses onto the conical end of the motor shaft and additionally secured with a disc screwed onto the front. The screws are microencapsulated to prevent inadvertent loosening and are seated on detent edged washers. The gearless machine has no automatic interlock. Brake: an electromagnetically actuated dual-circuit outer shoe brake in installed at the motor casing. Two independently acting brake blocks press the brake lining with preset spring force onto the brake disc cast on the traction sheave. The braking force is configured in such a way that one of the brake blocks is sufficient to bring an elevator car loaded with full weight to a standstill.

13



The position of the brake blocks and wear on the brake linings is monitored by the test switch. In the event of a malfunction or if the set wear limit is reached, a signal is issued. The brake is released by electrically operated double-vane magnets (each brake block has its own solenoid.) For manual operation, a brake release lever is fitted to the double-vane magnet. This releases both brake blocks simultaneously when operated. Brake test switch: the switch shown in Fig. 2.1, item 7, monitors each brake circuit and its switching state separately by means of a built-in light emitting diode. If a brake circuit does not close when the drive is at a standstill or does not open when the drive starts up, the elevator machine must be shut down and/or any new travel prevented. Terminal connecting plan, see chapter 5 'Setting the brake test switch', see chapter 7. If the braking device of the SC300 is to be used as a protective device against overspeed for the upward moving elevator car, the brake must be triggered in the event of overspeed via the electric safety device of the speed governor or a device with a similar high level of safety that is also subject to type approval. In the connection, the requirements, range of application and conditions stated in the Appendix of Type Test Certificate No. ABV 700 dated 1.10.2002 are to be complied with, see chapter 8. Actual-value sensor: the SC300 is designed as a permanently excited synchronous machine. Once the voltage has been switched on, a sine-cosine encoder delivers the absolute rotor displacement position. High-resolution sine-cosine tracks pick up the speed and angular position. Machine base frame: a machine base frame that is required for setting up the machine (with double wrap including built-in rope pulley mounted on roller bearings) is delivered as an option with the drive, fully mounted as a unit. (For more details regarding the machine base frame and its dimensions, see chapter 3.)

14



Accessories: the accessories required for operation, maintenance work and the removal of malfunctions such as the blocking clamp for the traction sheave, rope clamp, handwinding wheel and hydraulic cylinder are supplied as options. Note: adescription of specified use is provided in chapter 8

15

OPERATING MANUAL 3. TECHNOLOGY


3.1 Technical data

Thyssen Compact gearless® SC300 S SC300 M

Diameter of traction sheave DT [mm] 410 440

Diameter of brake disc [mm] 540 Max. braking torque according to test certificate [Nm] 1800 3000

Moment of inertia of gearless® [kgm²] 4.70 6.15 Permitted shaft load on the traction sheave

[kN] 90 120 Permitted axle load on the rope pulley

[kN] 90

Diameter of rope pulley [mm] 400

Rim width of the traction sheave [mm] 155 183

Groove data of traction sheave DW z x d 10 x D 10 12 x D10

Groove data of traction sheave SW Groove flanks hardened

z x d 6 to 8 x D 10

Groove form on traction sheave Semicircular, seat or vee groove Material specification for traction sheave EN-GJL 300 (HB 190 to 300) Weight of machine [kg] 565 665

Weight of the traction sheave [kg] 95 110

Weight of machine base frame SW [kg] 195

Weight of machine base frame DW [kg] 320 to 370 SW = single wrap; DW = double wrap Double-vane magnet

Power supply SC300 S SC300 M

Holding current (at UH = 50 V) [A] 0.86 1.00

Pick-up current (at UA = 95 V) [A] 1.56 1.90

Rated retentive voltage [V] 100 100

for rapid excitation [V] 180 180

Type of protection IP65 On the SC300, the two magnet coils are connected in series.

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3.2 Dimensions

Dimensions of Compact gearless ®SC300 S Deviating values for (SC300 M) in parenthesis

∅ 41

0 (∅

440)

880 (

891)

115 (118)

Fig. 3.1

17



3.3 Dimensions of machine base frame (optional)

The machine base frames of the SC300 are intended for installation in the machine room above the shaft. They have no rope anchorage. Their structure differs as follows: • Base frame with single rope wrap (with and without deflecting rope pulley), in the rest of

the text referred to as SW (single wrap) • Base frame with double rope wrap, in the rest of the text referred to as DW (double wrap)

The DW base frame includes a deflecting rope pulley mounted on roller bearings. On all base frames, the traction sheave is fitted with a cover. This protects the rope entry and at the same time functions as a rope guard. Its mounting is secured by a switch. If the cover is removed, the drive switches off automatically.

Fig. 3.2

Fig. 3.3

Illustration of left-hand design

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Base frame versions: DW machine base frames differ with regard to the arrangement of the rope pulley in the base frame, in right-hand design (R) and left-hand design (L). The definition results from the arrangement of the rope pulley in relation to the traction sheave looking towards the traction sheave in front of the motor (see illustration in Fig. 3.6). Decisive for the base frame length is the parallel distance between the ropes on the rope departure (ASL). This is made according to customer specifications depending on the order within the maximum values that can be supplied. In order to keep the overall height as low as possible, the machine base frames are divided into 2 ASL ranges with different base frame heights. Dimension range for gap between the ropes on the rope departure, ASL, depending on base frame height:

Base frame height Gap between the ropes on the rope departure

Fig.

615 mm 650 mm ≤ ASL < 900 mm 14

715 mm 900 mm ≤ ASL ≤ 1250 mm 14 Rope pulley data: (only applies to rope pulley in the machine base frame with double wrap) D = 400 mm Number of grooves and rope diameter according to the traction sheave optionally: 14 semicircular grooves for 10 mm rope diameter (max. 7 ropes) 14 semicircular grooves for 12 mm rope diameter (max. 7 ropes) 12 semicircular grooves for 13 mm rope diameter (max. 6 ropes) The roller bearings of the rope pulley have permanent lubrication.

19



Dimensions when mounted on SW machine base frame

Fig. 3.4

20



Location and arrangement of the isolation elements under the SW machine base frame

Number and location of isolation elements

[kN] G1 G2 G3 G4 to 40 1 1 1 1

Static total load

on all isolation elements to 53 1 1 2 2

Fig. 3.5

G1 G2

G3 G4

21



Dimensions when mounted on DW machine base frame

1 Overall height y1 2 Vertical distance between rope pulley and traction sheave y2

3 1250 mm≥ASL≥ 650 mm

y1 y2 Standard ASL range 1576 685 900 to 1250 mm 1676 785 650 to 899 mm

ASL = parallel gap between the ropes on the rope departure

Fig. 3.6

2

1

3

22



Location and arrangement of the isolation elements under the DW machine base frame

Number and location of isolation elements

[kN] G1 G2 G3 G4 to 40 1 1 1 1 Static total load on all

isolation elements to 53 1 1 2 2

Fig. 3.7 G3

G1 G2

G3

23



3.4 Motor data The technical data can be found on the type plate. In the case of synchronous machines, the max. current must not exceed the value on the type plate.

3.5 Name plate The current type and the technical data are specified on the type plate of product. Version 1. THYSSENKRUPP AUFZUGSWERKE

2. LiftEquip

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3.6 Pulse generator

A sealed incremental hollow shaft pulse generator with sinusoidal output signal is fitted to the end of the rotor shaft to regulate and control the SC300. The connection to the control system is via a 7-m long shielded connection line with 15-pin Sub-D connector (RS485) and UNC screwed connection that is firmly connected to the pulse generator. The line shield is placed on the connector and pulse generator housing. Connection, assembly instructions and drawing, see chapter 8. Technical data for TTL type pulse generator: Sealed hollow shaft anchoring pulse generator with 2 signals offset by 90° and a reference mark. Number of marks (Z) 2048 impulses / revolution Supply voltage 5 ± 5% V Output driver RS 485 / sine Output signal: analogue / serial 1 Vss, limit frequency (-3 dB) ≥ 200 kHz /

RS485 EnDat Operating temperature range - 20...+ 100 °C Storage temperature range - 30...+ 80 °C Permissible relative air humidity 100% max. operating current at 5 V 150 MA Type of protection IP 64 Connection and assembly instructions: The connector housing is to be connected to the reference potential. If the pulse generator connection is to be extended, use HEIDENHAIN original cables. Note: the pulse generator fitted as standard is specially geared to ThyssenKrupp converters. If another converter is used, a pulse generator with adapted connection values must be used. Other details regarding the connection assignment at the 15-pin Sub-D connector and instructions for assembly and wiring can be found in chapter 8.

25

OPERATING MANUAL 4. TRANSPORT AND STORAGE


4. Transport and storage Packaging: The SC300 is shipped as follows: a) Machine ready-mounted on machine base frame, base frame and machine in seal-wrapped

in foil. To provide protection during transport, wooden wedges are screwed underneath the machine base frame. These are to be removed before setup at the place of destination.

b) Machine without machine base frame, bolted onto wooden pallet, seal-wrapped in foil. Transport: Transport must be effected in compliance with the safety regulations and observing the centre of gravity of the machine and base frame. Fork-lift truck transport: • In the case of transport with a fork lift, the forks used must be long enough to prevent the

transported goods from tipping over. • Always pick up the base frame and/or transport pallet, not the machine itself, with the

forks. • Pay attention to protruding parts! Danger of injury and damage! Crane transport: • Do not walk underneath suspended loads! • Transportation chains or ropes are to be secured in the 4 corner drilled holes of the

machine base frame. Pay attention to the centre of gravity! • In the case of delivery without a base frame, attach to the transport support and secure

against tilting. Do not lift by the motor casing! • After transport, remove the 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

26

OPERATING MANUAL 4. TRANSPORT AND STORAGE


Dimensions and weight The weight data are specified on the packaging on a label on the machine. Please refer to the delivery note for the dimensions. Approximate specifications, see chapter 3 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 is to be documented immediately (sketch, photo, description of the damage).

• Forward the corresponding documents without delay to THYSSENKRUPP AUFZUGSWERKE GmbH.

Unpacking

Information

• Dispose of packaging materials in an environmentally compatible manner or reuse them.

• Specific transport aids and shipping braces remain with the customer. Intermediate storage

• If the assembly is not installed immediately after delivery, it must be stored carefully in a protected location. On covering, attention is to be paid to ensuring no condensation can form and that no moisture can penetrate.

• The assembly must not be stored 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%.

27

OPERATING MANUAL 5. MOUNTING THE MACHINE


5.1 Machine setup

The Compact gearless® SC300 is delivered fully mounted and aligned with an optional machine base frame (with double wrap, including rope pulley). The base frame is set up depending on the customer on the machine room floor or directly in a cement floor. In order to comply with regulations for noise abatement and sound transmission, isolation elements are to be inserted between the frame supports and the ground. These differ according to the type of mounting: a) Rubber block 100 x 100 x 50 high without base

For mounting the machine on the machine room floor without a cement floor or directly surface mounted on the cement floor.

b) Rubber block same as a) however with an additional base 140 x 140 x 80 mm high, for mounting on a cement floor, support cast in cement floor (coating thickness ≤ 60 mm). The support is also to be cemented in place.

The number of rubber elements and their arrangement is based on the total load and the base frame type. You will find guide values for SW and DW base frames in chapter 3 The required individual load should be between 7000 and 12 000 N / per element. On arrangement of the supports, it is to be taken into account that the overall centre of gravity lies within the rubber elements. You will find the versions and dimensions of the machine base frames in chapter 3

5.2 Aligning the machine and machine base frame

The machine is to be set up according to the plan of installation. When aligning the machine and base frame, pay attention to the following: • The axle alignment of the traction sheave and rope pulley must be exactly parallel. • The machine is to be aligned on the frame by moving the parallel dimension of the gap (ASL)

of the outgoing ropes • The rope departure from the traction sheave and deflecting pulley is to be aligned plumb

according to the plan of installation 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 frame support. Rope arrangement: the outermost rope coming from the elevator car rope pulley must be arranged on the 1st groove of the traction sheave on the brake disc side if all the grooves of the traction sheave are used. In the case of a base frame with rope pulley and single wrap (SW), the grooves of the traction sheave and rope pulley must be exactly aligned. (Check the groove alignment with a tensioned cord.) In the case of double wrap (DW), the grooves of the traction sheave and rope pulley must be offset by half the groove gap dimension (Ra) in relation to one another. Ra = distance from rope middle to rope middle The middle offset "M" corresponds to Ra/2 (see Fig. 15) With standard grooves, M = rope groove diameter + 4 mm

28



After changing the machine location or after replacing the traction sheave or rope pulley, check the alignment and, if required, correct it. Setting: the location of the axles and/or the dimension of the gap and the groove alignment can be changed by loosening the securing bolts of the machine on the base frame and adjusting the lateral stop screws on the machine foot. Note: after completion of the setting up procedures, the securing bolts are to be tightened with the prescribed torque. See chapter 8.

5.3 Mounting the rope pulley When mounting the rope rollers in the machine base frame, attention must be paid to ensuring that the clearance between the pulley support and side contact of the rope pulley is adhered to. The installation takes place depending on the bearing design. a) In the case of rope pulleys with deep groove ball bearings, the enclosed spacer washers are

to be bonded around the sides of mounting borehole (centered) before installation. They prevent the rope pulley from scuffing the pulley support. The rope pulley carriers must be mounted in such a way that the clearance is a maximum of 1 mm (0.5 mm per side).

b) In the case of rope pulleys with cylindrical roller bearings, the inner ring of the bearing protrudes from the side of the rope pulley. This means that no spacer rings are required. The clearance between the rope pulley and carrier may be a maximum of 1 mm (0.5 mm per side).

For installation, raise the rope pulley with lifting gear until the drilled holes of the rope pulley carrier and rope pulley are aligned. Insert the pulley shaft with the slanted side into the drilled hole until the axle bracket groove is flush with the fastening panel. Insert the axle holder into the groove and bolt it onto the rope pulley carrier. Fit the rope support. After hanging up the ropes, the rope support is to be mounted via the base frame rope pulley on the machine base frame or on the pulley supports. The distance "s" ± 1 mm is to be adhered to between the rope support and cable. The distance can be adjusted by changing the number of square washers between the rope support and base.

Rope ∅ Distance "s" 10 8 12 9 13 10

29



5.4 Connecting the machine On connecting the motor, not only the safety instructions in this operating manual but also chapter 1.2 of the enclosed terminal connecting plan in the motor terminal box and/or the terminal connecting plan and regional building codes are to be complied with.

Terminal plan:

Do not apply a voltage greater than 2.5 V at the terminals of the posistor. Adhere to the internal resistance of the measurement devices!

The terminal diagram is printed on the inside of the cover.

Th Th

Th Th

Fig. 5.2

U V W PE

30



Terminal connecting plan for double-vane magnet

Terminal connecting plan for brake test switch

Switching state Lamp indicator on the switch 24 V = 1 = brake open Off 2 = brake closed On 3 = with 0.3 mm wear Off

A = Output Illuminated display "On" A = 0 V

1 +

2 −

PE

Button 1

−

blue black

brown

A +

Button 2

black blue brown

− +

31

OPERATING MANUAL 6. COMMISSIONING


6. Commissioning

Before commissioning the machine, the following points should be checked: • Remove safety, auxiliary and installation tools from the danger zone • Check setup and alignment of machine, base frame and rope departure • Mounting of the machine and base frame checked • Tighten and secure the bolts with the prescribed torque, see table 'Tightening torques' in

chapter 8 • Check the brake block lift and setting, chapter 7 • Check the setting and function of the brake test switch, chapter 7 • Run brake tests, each with one block, chapter 7 • Check the function of the handbrake release • Rope protection cover fitted, function of safety shutdown device on removing the traction

sheave hood checked • Power connections, earthing of motor, forced ventilation and brake magnet connected and

checked • Mount and check special add-on components (optional) • Attach the direction arrow (Up / Down) according to the direction of travel in a clearly

visible position above the traction sheave on the brake vane magnet (the label is enclosed with a brief description in the brochure sleeve tied to the drive)

NB: if the drive is to be operated with a brake control circuit as a substitute for an emergency braking device (safety gear) in the upward direction, we would line to expressly point out that the elevator system may only be put into operation with a functioning brake monitoring system! Under no circumstances may the feedback cable or brake test switch be disconnected to put the installation into operation without a brake test switch by resetting the non-volatile memory (EPROM). Ignoring this instruction can endanger persons.

32

OPERATING MANUAL 7. MAINTENANCE / SERVICE


7.1 Maintenance

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

More details on the sequence, settings and data can be found in chapters:

• Check the brake blocks for wear; the remaining lining thickness must be

at least 3 mm 7

• Check the brake setting; the block stroke should be 0.3 mm 7 • Check the braking deceleration 7 • Check the function of the brake test switches 7 • The grease filling of the front engine shaft bearing is to be topped up with

the prescribed amount of grease 7

• Check groove profile on the traction sheave for damage and wear

• Check that the screws securing the traction sheave and drive are securely seated; tighten if required

8

• On the rope pulley (if present), check the grooves for damage and wear

• Check motor bearings for wear (noise, play)

• Check that electrical connections are in proper and adequate condition, i.e. undamaged; check that they are securely attached

• Check that protective and safety devices are present, functioning and correctly set

• Check the seals on the shaft in the area of the brake 7

33



7.2 Lubrication SC300

Lubrication quantity on the front bearing (AS) of the motor shaft

Yearly lubrication quantity SC300 M

100 gr

Yearly lubrication quantity SC300 S

75 gr

See Fig. 7.1

e.g. multipurpose grease F1 cartridge 400 gr

Code no. 60 300 27 90 0

The lubricator is positioned on the drive side on the traction sheave. See Fig. 7.1. The SC300 does not need any other relubrication. • The second motor shaft rolling bearing has lifetime lubrication. • The rolling bearings for the machine base frame rope pulley also have lifetime lubrication e.g. multipurpose grease F1, can be obtained through THYSSENKRUPP AUFZUGSWERKE GmbH

34



Relubrication When relubricating: To distribute the grease filling uniformly in the bearing, observe the following:

a) Grease filling: add in several partial quantities during operation

(min. 3 or several parts). b) Operate the drive for at least 3 minutes between the individual filling operations.

Note:

Lubricant must be refilled when the machine is running in order to ensure that distribution in the bearing is uniform! Filling of uncontrolled lubricant quantities without redistribution through bearing rotary movements may cause damage to the bearing and sealing systems! Use the specified lubricating grease only. If other greases are used the:

• Lubricating ability may degrade. • Grease ducts may harden. • Bearings may become damaged.

THYSSENKRUPP AUFZUGSWERKE GmbH will not be held liable for damage resulting from the use of non-approved lubricants.

Lubrication nipple

Fig. 7.1 Traction sheave with lubrication nipple

35



7.3 Testing the brake

Prior to initial operation and with the monitoring system running, the work stroke of the brake blocks must be checked. On opening the brakes, make sure that both brake blocks work with the same stroke.

Setting the brake block stroke: The air gap between the brake disc and brake lining should be 0.3 mm with the magnet operated (see value cast on the brake block) • Actuate brake magnet, check air gap with feeler gauge. • Correct the setting by twisting the nuts on the setting

screw at the brake block until the feeler gauge set at 0.3 mm can be pushed through the air gap at the same height of the arrow cast in the brake block without resistance.

• Secure this setting by tightening the counter nut and repeat this procedure at the second brake block.

NB: after a brake adjustment, the deceleration and the brake test switch must be checked and/or adjusted. see chapter 7.

Fig.: 7.2 Brake adjusting

1

5

3 4 2

6

7

8

9

11

10

0.3 mm stroke 1 Brake vane magnet 2 Manual release lever 3 Adjusting screw for block stroke 4 Adjusting screw for test switch 5 Pressure spring 6 Clamping screw for pressure spring 7 Switch for protective hood 8 Brake blocks 9 Working stroke of blocks 0.3 mm 10 Brake block pin 11 Brake disc

36



The braking torque must be set on uniformly on both brake blocks by pretensioning the brake spring depending on the installation. The brake adjustment for the SC300 is to be carried out only with one effective brake block with the elevator car loaded with the rated load on a descending run (full down) according to the value specified in the table below.

In a brake test, the braking distance (sa) with one braking block should be below the specified value.

Speed [v] [m/s] 1.0 – 1.2 1.6 – 1.75 2.0 – 2.5 3.0 – 3.5 Braking distance [sa] [m] ≤ 1.5 ≤ 5 ≤ 10 ≤ 15

Important: In the case of repeated braking, the brake disc heats up, which causes braking behaviour and setting values to change. It is recommended, therefore, to have a sufficiently long cooling down phase between tests. Setting the braking force (contact pressure of the brake block) The braking force setting is made by changing the pressure spring pretension. The system-specific deceleration is set by turning the pressure spring clamping screw at the brake block. Secure this setting with the counter nut on the brake block. Repeat the setting procedure on the second brake block. NB: the maximum pretension path for a brake block on version SC300 S = 15 mm, on version SC300 M = 27 mm (Corresponds approximately to the following number of screw revolutions: 7.5 for S, 13.5 for M). The brake were set to these values on shipment ex works. The maximum value in each case must not be exceeded. If the maximum value is exceeded, this can impair the brake function. Caution: When setting, the test switch screw must not touch the switch contact, or only very lightly, because otherwise the switch will be damaged.

Note: Brake test switches must be checked or readjusted after adjusting the brake. See 'Setting the brake test switch', chapter 7

37



7.4 Setting the brake test switch

NB: Before starting to set the sensor, the brake block stroke setting must have been carried out! For description, see chapter 7

Setting: 1. Switch on the emergency operation switch and elevator control system. 2. Adjust the setting screw (Fig. 7.3 item 1) towards the switch until the LED lights up. 3. Slowly turn the screw back until the LED goes out. 4. Adjust the setting screw by ¼ revolution (corresponds to around 0.3 mm) towards the

switch and tighten the nut. LED lights up continuously.

5. Check the setting: switch on the motor to open and close the brakes. In doing so, check whether the sensors (item 6) indicate the switch between opened and closed brake.

1 Adjusting screw for brake monitoring 2 Brake blocks 3 Adjusting screw for stroke 4 Pressure piece 5 Brake magnet 6 LED – sensor indicator 7 Brake test switch 8 Button tappet (sensor) 9 Adjusting screw for brake spring force

Fig. 7.3

1

3 4

9

8

6

5

2

7

NB: if brake monitoring is used as a substitute for an emergency braking device upwards, consult the instructions in chapter 6!

38



7.5 Brake block replacement

NB: in the event of a remaining lining thickness of less than 3 mm or if the brake linings have become unusable and the required deceleration is not achieved, the brake linings must be replaced. Caution: Before starting work, the counterweight and elevator car must be secured against uncontrolled movement. The power supply to the installation must be switched off. Torque must not act on the traction sheave. 1.) Disassembling brake blocks: • Remove the tightening screw and pressure spring on the brake block; remove the

securing element on the brake block pin. • Remove brake block and refit the adjusting screw for brake magnet and test switch

actuation at approx. the same distances on the new brake block. • Install new brake block on machine. • Reseat or bed in the lining to 75% contact area of the lining surface. • Check the lateral alignment of the brake lining in relation to the brake disc support. In the

case of misalignment, disassemble brake block and align to the brake disc centre by rearranging the spacer washers at the block bearing. (Washer thickness = 1 mm.)

• Fit the pressure spring with screw on the brake block until the brake lining makes contact with the brake disc.

Caution: the test switch screw must not touch the switch contact, or only very lightly, because otherwise the switch will be damaged.

2.) Setting brake block stroke With the solenoid actuated, the air gap between brake disc and brake lining should be 0.3 mm

• Set stroke as described in chapter 7 • Change and set the second brake block in the same manner. • Secure setting by tightening the counter nuts. 3.) Setting braking deceleration Set the deceleration as described in chapter 7. 4.) Setting brake test switch Make the setting of the brake test switch at the brake blocks as described in chapter 7. 5.) Checking the settings at the replaced blocks • After replacement, run the elevator with return and observe whether the both brake

blocks open uniformly. Important: After every brake block change, the block stroke, braking deceleration, setting and operation of the test switches must be checked and corrected if necessary.

39



7.6 Traction sheave replacement

Disassembly: • De-energise the system, secure car and counterweight. • Remove traction sheave cover or rope fixing beam. • Ease load on traction sheave; lay down cables. • Secure traction sheave with lifting gear. • Measure the dimension of the pretensioned brake springs and note down the value. • Relieve pressure on tension springs by unscrewing the screws until the traction sheave is

free. • Unscrew the disc (Fig. 2.1, item 1) on the motor shaft. • Lightly screw in the disc with screws in the outer circle of holes of the disc at the traction

sheave hub. • Place a spacer of approx. 5 to 10 mm thickness between the shaft end and the traction

sheave. The dimension of the spacer must be such that it does not protrude beyond the front shaft face.

• By evenly and alternately tightening the screws, pull the traction sheave off the shaft. Installation: • Clean the shaft end and traction sheave bore hole. The positions of the feather key,

groove, shaft or bore hole must not be changed under any circumstances. • Do not apply grease or oil to the shaft and bore. • Carefully mount new traction sheave with lifting gear on tapered shaft end of the motor

shaft. • Align the locations of the feather key and groove in relation to one another. • Fit traction sheave on motor shaft, taking care with the brake blocks! • Screw disc at inner hole circle onto motor shaft. The revealed face must be aligned to the

traction sheave. • Tighten the screws evenly and alternately clockwise in a number of revolutions to the

prescribed torque, see chapter 8. • Check the lateral alignment of the brake linings in relation to the brake disc support. In

the case of a middle offset, remove the brake block and adjust the spacer washers on the brake block pin to align the linings to the centre of the brake surface. (Washer thickness = 1 mm.)

• Set the press-on force of the springs, brake block stroke to 0.3 mm and the brake test switch.

• Install traction sheave cover or rope fixing beam.

40



7.7 Replacing the pulse generator Illustration, see chapter 8

Disassembly:

• Pull off the plug connector for the pulse generator connection at the control system. • Use a hexagon socket spanner M 2.5 to loosen the clamping bolts at the pulse generator

mounting sleeve (2 screws, item 3). • Unscrew the pulse generator mount from the securing tab on the rear bearing bracket of

the machine (4 x M4). • Grip the pulse generator by the housing and carefully pull it off the shaft end in an axial

direction.

Installation:

• Before mounting the pulse generator, clean the shaft end; do not apply grease. The shaft end must be free of dirt and grease.

• Carefully push the pulse generator with mounting sleeve onto the shaft end in the direction of the arrow using small rotational movements until the securing brackets make contact with the tabs.

• Carefully tighten the clamping bolts (item 3) in the mounting sleeve; the pulse generator must not be tensioned. It must be easy to move the pulse generator housing on the shaft.

• Turn the pulse generator housing until the connection line is in the right position. • Align the bracket drilled holes onto the threaded holes and firmly bolt the pulse generator

onto the securing tab. • Connect the pulse generator connection with the control system.

41



NB: do not connect the pulse generator when it is under voltage, as otherwise electronic components in the pulse generator are destroyed. When the pulse generator is not connected, the drive may only be switched on for testing with the rope slack.

1 Connection line 2 Encoder 3 Rear bearing bracket 4 Securing bracket 5 Tab 6 Shaft end 7 Clamping bolts

Note: After replacement of the pulse generator or displacement in relation to the rotor, readjustment of the pulse generator is required. The procedure can be found in the operating manual of the frequency converter.

Fig. 7.4

1

5

6

4

3

2

7

42



7.8 Checking for escaping grease / oil, SC300 Check the areas around the bearing cover, brake drum, brake linings, screwed connection of the grease outlet pipe as well as the lower and/or inner area of the traction sheave for traces of oil. For the check, remove the cover plate above the traction sheave! A small amount of escaping oil means individual drops of oil or traces of oil in the area of the bearing seal. Contamination level Procedure

No escaping oil determined Check regularly within the framework of maintenance

Every 3 months (6 months if elevator used infrequently, < 50 000 runs per year)

If a small amount of escaping oil is determined

Clean and check regularly within the framework of

maintenance

Every 3 months (6 months if elevator used infrequently, < 50 000 runs per year)

If a large amount of escaping oil is determined or oil is escaping from the brake disc / brake linings

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

Repair after 4 weeks at the latest

43



Fett

Bearing cover

Traction sheave / brake drum

Fig. 7.5

Grease outlet pipe

Grease

44

OPERATING MANUAL 8. APPENDIX


8.1 Tightening torques - tightness values

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. Bolts / screws are to be secured against unwanted loosening during installation using detent edged washers. The following values apply for: Allen screws ISO 4762 (DIN 912) Hexagon screws ISO 4014 / 4017 (DIN 931 / 933)

The screws are to be tightened with a torque wrench!

Dimensions Tightening torque MA [Nm]

Tightness 8.8 10.9 12.9

M4 2.6

M5 5.3

M6 9 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

45



8.2 Accessory parts

For operation of the SC300, the following optional accessory parts can be supplied: 1. Handwinding wheel 2. Rope clamp 3. Blocking clamp 4. Pressure arm 5. Hydraulic cylinder Note: the listed parts are necessary for deployment in emergencies or in the case of maintenance and repair work and at least one of each should be present in every machine room. 1. Handwinding wheel

The handwinding wheel is bolted onto the front of the traction sheave. It is used to move the elevator when the weight of the car and counterweight are balanced. The brake is to be vented by hand. NB: no motor operation with handwinding wheel fitted

The handwinding wheel must be removed before switching on the motor!

2. Rope clamp

• Undo the screws on the rope clamp. • Insert the halves of the clamp in the drilled hole on the front of the machine base frame (on

rope departure side of the traction sheave), one half on the left and one on the right of the ropes.

• Align the groove of the halves of the clamp on the ropes. • Place the rope clamp on the frame profile at the bottom. • Clamp the ropes into place by screwing together the halves. Tighten the screws firmly.

Fig. 8.2

Fig. 8.1

46



Deployment: a) Rope locking; it prevents rope movements in the direction of the support. b) To hold the elevator car in position. c) For readjustment on releasing the car from the engaged position (safety gear). 3. Blocking clamp (for traction sheave)

1 Lug 2 Pressure piece 3 Pressure screw 4 Securing bolt

Engage the blocking clamp with lug (item 1) in the ring groove under the brake disc. Screw in the securing bolt on the front of the traction sheave. Tighten the pressure screws to clamp the ropes. Deployment: in the event of slipping ropes. Example: on releasing the car from the engaged position (safety gear).

4 2 3

1

Fig. 8.5

Fig. 8.3

Fig. 8.4

Push the rope clamp into the frame.

47



4. Pressure arm (for hydraulic cylinder) Mounting: screw on the pressure arm as closely as possible, with the pin facing downwards, above the cylinder on the traction sheave. Deployment: The pressure arm is for power transmission from the hydraulic cylinder to the traction sheave

5. Hydraulic cylinder

Mounting: place the cylinder with support in the drilled hole on the base frame on the pull side under the traction sheave. Close the drain plug on the cylinder. Pump the lever with pressure cylinder to move the pressure arm and traction sheave. Make sure that the pin of the pressure arm is lying on the cylinder groove to prevent slipping.

1 Support 2 Drain valve 3 Lever 4 Pressure cylinder with groove

Deployment: The hydraulic cylinder serves to lift the car out of the engaged safety gear Application description, see chapter 1 "Releasing the car from the engaged position (safety gear)" Fitted pressure arm with cylinder. Movement in the direction of the arrow

4

3

2

1 Fig. 8.7

Fig. 8.8

Fig. 8.6

48

Mounting dimensions Installation

∅30

h7

4 x M4

SW3 (2X))Md = 2,5 ± 0,5Nm

7000 mm

∅ 87 45

Pin assignment

nicht belegt

ThyssenKrupp Aufzugswerke GmbH Ein Unternehmen von ThyssenKrupp Elevator Bernhäuser Strasse 45 73765 Neuhausen a. d. F. Deutschland Tel.: +49 7158/12-0 Fax: +49 7158/12-2585 E-Mail: [email protected] www.thyssenkrupp-aufzuege.de Is

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01/

2008

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