ThyssenKrupp DAB450 User manual

ThyssenKrupp Aufzugswerke
Operating Manual
Drive DAB450

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Contact your ThyssenKrupp Aufzugswerke sales partner for details of colours for your
specific products.
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To improve readability, a gender-specific form of address has not been used. Gender-
specific pronouns therefore refer to both men and women.
Issued by
ThyssenKrupp Aufzugswerke GmbH
Bernhäuser Strasse 45
73765 Neuhausen a. d. F.
Germany
Tel.: [phone]
E-mail: [email protected]
Internet: www.thyssenkrupp-elevator-eli.de

OPERATING MANUAL DAB450
Table of contents
DAB450 drive PAGE
1. Safety
1.1 Symbols 6
1.2 Safety instructions 7
2. Product description
2.1 Description 10
2.2 Functional description 11
2.3 Protection devices earthquake 12
3. Technology
3.1 Technical data 15
3.2 Dimensions of machine 16
3.3 Dimensions of machine base frame (optional) 17
3.4 Encoder 20
4. Transport and storage 23
5. Mounting the machine
5.1 Machine setup 26
5.2 Aligning the machine base frame 26
5.3 Connecting the machine 27
5.4 Connecting the motor 28
5.5 Connecting the brake magnet 30
5.6 Connecting the brake test switches 31
5.7 Connecting the manual operation limit switch 32
5.8 Connecting the encoder 33
6. Commissioning 35
7. Maintenance / service
7.1 Maintenance 36
7.2 Lubrication 37
7.3 Testing the brakes 39
7.4 Testing the release mechanism of the brakes 40
7.5 Replacing brake shoes 41
7.6 Setting braking deceleration 43
7.7 Setting the brake test switch 45
7.8 Replacing and setting the encoder 47
7.9 Replacing the rope pulley 49
7.10 Checking for escaping grease / oil 50
7.11 Emergency measures 51
7.12 Wear parts 56
8. Special Versions
8.1 Climate-protected version 57
8.2 Accessory parts 57
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OPERATING MANUAL DAB450
9. Appendix
9.1 Tightening torques 61
Type test certificate for braking device
Declaration of conformity for braking device
Certification complying with US standard
Type test certificate in accordance with EN 81-1 –A3
Operating manual for SIKO magnet sensor
ThyssenKrupp Aufzugswerke GmbH

OPERATING MANUAL DAB450 SAFETY
1. Safety
1.1 Symbols
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 physical 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.
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OPERATING MANUAL DAB450 SAFETY
1.2 Safety instructions
Notes regarding the operating manual
A requirement for safe handling and non-disruptive operation of 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.
For countries in which CSA regulations apply, the regulations listed below are
to be taken into account:
The applicable regulations of the latest version of the National Electrical
Code, Article 620, the latest version of the ASME A17.1, Safety Code for
Elevators, and the applicable regional regulations must be observed and/or
complied with when carrying out the measures and following the instructions
described in this manual.
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 the safety awareness of the personnel at regular intervals.
Obligations on the part of 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.
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OPERATING MANUAL DAB450 SAFETY
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.
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 DAB450 has been constructed using state-of-the-art technology and in
line with the recognised technical safety regulations. The DAB450 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 DAB450 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.
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OPERATING MANUAL DAB450 SAFETY
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 DAB450
•Installation, commissioning, operation and maintenance of the DAB450
that is not in line with accepted technical principles
•Operation of the DAB450 with defective and/or
non-operative safety and protection devices
•Nonobservance of the instructions in the operating manual with regard to
transport, storage, installation, commissioning, operation and maintenance
of the DAB450
•Constructional changes to the DAB450 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
•Cases of catastrophe due to third-party interference and force majeure.
Constructional changes to the DAB450 performed by the operator
The parts installed in and attached to the DAB450 are mounted and set at
the plant.
If changes are made to the machine, this renders the entire warranty of
THYSSENKRUPP AUFZUGSWERKE GmbH
Dangers in handling the DAB450
The DAB450 may only be operated in an enclosed machine room and only
with the screen fitted.
Before mounting the manual drive, the power to the drive must be
disconnected and the installation secured against inadvertent activation.
Remove the manual drive before reconnection and screw on the cover plate.
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.
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OPERATING MANUAL DAB450 PRODUCT DESCRIPTION
2. Product description
2.1 Description
1
Brake magnet
8
Transport/Machine base frame
2
transport eyebolt
9
Traction sheave
3
transport eyebolt / hanger
10
Type plate
4
cover grate
11
brake test switch
5
Brake connection box
12
Mounting for manual drive
6
Brake shoe
13
Motor terminal box
7
Spring plate
14
Brake release lever
Fig. 2.1
7
2
3
8
5
6
1
4
9
10
11
13
12
14
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OPERATING MANUAL DAB450 PRODUCT DESCRIPTION
Versions
The following versions can be supplied:
1. Elevator speed
2. Version for current regeneration
3. Diameter of traction sheave ∅600 / 660 mm
4. Machine base frame versions
5. Accessory parts for maintenance / emergency operation
6. Additional encoder mounting
Special versions, see description in chapter 8
2.2 Functional description
Machine: the DAB450 consists of a frequency-controlled motor similar in
design to B3 (DIN IN 60034) in protection type IP21. It is firmly bolted to a
transport frame (optional: machine base frame).
Depending on the customer, the rope drive is intended for operation with
single or double rope wrap and operation with 1 : 1 or 2 : 1 suspension.
Speed measurement takes place via a no-contact, inductive pulse encoder
(API). This is connected to the built-in electronic evaluation system (square
wave pulse) by means of a plug-in connection (pulse encoder connector).
Mounting for an optionally available second encoder (GWA) is prepared.
Depending on the motor type and control device, the braking energy that is
created is fed back sinusoidally into the network.
The engine shaft and rope pulley are equipped with roller bearings.
There is a possibility to lubricate all bearings.
The traction sheave and brake disc are doubly supported by bearings and
consist of one cast part.
The gearless machine has no automatic interlock.
Brake: an electromagnetically actuated, type-approved, dual-circuit outer
shoe brake is mounted at the pedestal bearing.
Two brake shoes acting independently of each other press the brake lining
onto the brake disc with pre-adjusted spring force.
The braking force is configured in such a way that one of the brake shoes is
sufficient to bring a loaded elevator car to a standstill.
The position of the brake shoes and wear on the brake linings is checked by
a brake monitoring circuit. If there is a malfunction or the set wear limit is
reached, the drive is switched off.
The brake is released by a separate electromagnet for each brake shoe with
integrated overvoltage protection.
For manual operation, an external brake release lever is fitted. It can be used
to operate one brake shoe or both brake shoes simultaneously.
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OPERATING MANUAL DAB450 PRODUCT DESCRIPTION
The DAB450 is self-ventilating. It is configured for thermal class F and
used up to class B.
A triple posistor built into the motor winding monitors the operating
temperature (shutdown temperature 130 °C ± 5 °C)
The maximum sound pressure level is 70 dB(A)
Machine base frame: the gearless is delivered with a mounted machine
base frame as a unit. (With double wrap, including built-in rope pulley)
More details on the machine base frame and its dimensions can be found in
chapter 3
Accessories: the accessories necessary for the operation, maintenance
work and removal of malfunctions such as the hoist, hydraulic cylinder, rope
clamps for the traction sheave and counterroller as well as a manual drive
are delivered as options.
If a number of the same machines are set up in one machine room, only one
of each accessory part is required for each room.
Note: a description of specified use of the accessories is provided in
chapter 9
The machine typecomplies with the European standard EN81-1:1998
+A3:2009 as well as EN81-20/50:2014 and also the specifications ofASME
A17.1. They comply with the European standard EN60034. Approval for the
North American region (CSA and ASME A17.5) isalso available.
2.3 Protection devices for deployment in an earthquake region of
category 1 complying with EN81-77 - optional - (only for delivery with
machine base frame)
Fig. 2-2: DAB external rotor gearless with earthquake protection devices
(the version DAB450S/L is shown)
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OPERATING MANUAL DAB450 PRODUCT DESCRIPTION
1
DAB450 external rotor gearless
2
DW-R machine base frame
3
Earthquake protection for traction
sheave
4
Earthquake protection for rope
pulley
5
Shift protection
6
Intrusion protection on rope pulley
The protection devices consist of a traction sheave cover, rope holder on the rope
pulley as well as shift protection on the machine base frame. The earthquake
protection device is standardised with traction sheave diameter DT = 600/660 mm and
rope pulley diameter = 600.
The intrusion protection meets the requirements from EN81-1/ 9.7 and EN81-20/5.5.7.
Fig. 2-3: Components for earthquake protection on the traction sheave
The traction sheave cover issuitable for SWapplication as well as DWapplication.
Rope departures of0° to75° to the horizontal canbe covered.
The earthquake protection on the traction sheave of the DAB450 is adequately
dimensioned and can be used up toand including earthquake category 3 complying
with EN81-77
Fig. 2-4: Components for earthquake protection on the rope pulley
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OPERATING MANUAL DAB450 PRODUCT DESCRIPTION
1
DW-R machine base frame
2
DW rope pulley, diameter 600 mm
3
SW rope holder
4
SW cross strut
5
DW rope guard
The earthquake protection on the rope pulley consists of up to 3 different holding-down
clamps.
The holding-down clamps on the DAB450 rope pulley can be used for the ASL range of
900 - 1500 mm.
All holding-down clamps are adjustable.
The earthquake protection on the rope pulley of the DAB450 is adequately
dimensioned and can be used up to and including earthquake category 3 complying
with EN81-77
Fig. 2-5: Components for earthquake protection on the shift protection on the
machine base frame
Description of items for Fig. 2-5
1
Shift protection adapter
2
DW-R machine base frame
The shift protection ensures that the drive with machine base frame does not change
its position in the event of an earthquake.
The earthquake protection against shifting of the DAB450 is adequately dimensioned
and can be used up to and including earthquake category 1 complying with EN81-77
In the case of deployment of the machine in earthquake categories 2 and 3, additional
safeguard measures in accordance with EN81-77 are necessary.
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OPERATING MANUAL DAB450 TECHNOLOGY
3. Technology
3.1 Technical data
Rating
The rating of the DAB450 can be found on the type plate
Torques DAB450 S DAB450 L
Braking torque (with lifting magnet type GH100 011) maximum 4,250 Nm
minimum 3,680 Nm
per brake shoe
Traction sheave with integrated brake disc
600 / 660 mm rim diameter and 680 mm brake disk diameter
Weight: DAB450 S DAB450 L
Machine 2 300 kg 2 650 kg
Machine weight, including frame and rope pulley 3 200 kg 3 500 kg
Rope pulley (DW) diameter 600 270 kg
Technical data for lifting magnet, see type plate for lifting magnets
Note:
The coils of the lifting magnets are connected in series.
Other technical data can be found on the type plate.
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OPERATING MANUAL DAB450 TECHNOLOGY
3.2 Dimensions of machine
Fig. 3-1
1
Mounting of machine (pedestal
bearing AS and BS) on machine
base frame
2
Mount of protective hood on
machine base frame
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OPERATING MANUAL DAB450 TECHNOLOGY
3.3 Dimensions of machine base frame (optional)
right-hand design
Fig. 3-2
1
Min. clearance for lifting
2
Vertical measurement to overall
centre of gravity
3
Vertical measurement traction
sheave to rope pulley
"standard (special size)"
4
Project planning dimension x1
depending on traction sheave
diameter DT:
DT = 600 mm →x1 = 250 mm
DT = 660 mm →x1 = 220 mm
5
ASL
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OPERATING MANUAL DAB450 TECHNOLOGY
Fig. 3-3
1
Overall centre of gravity
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OPERATING MANUAL DAB450 TECHNOLOGY
Side view of machine base frame
1
Min. clearance for brake release
lever
When aligning the grooves ofthe traction sheave to the rope pulley, the
grooves must be arranged with an offset of half the distance from one
groove centre to the next.
Example:groove clearance 18 mm offset = 9 mm
Fig. 3.4
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OPERATING MANUAL DAB450 TECHNOLOGY
3.4 Encoder
A magnetic tape is mounted in the pedestal bearing AS for the regulation and
control of the DAB450. The signals are read with a magnet sensor.
The connection is made via connector.
Installation instructions, see chapter 5
Technical data
SIKO magnetic tape with evaluation unit with 25600 pulses per revolution
(see table)
Encoder for
Encoder type
Magnet sensor with integrated
evaluation unit
Supply voltage UB
Output tracks
Output
Maximum speed of movement,
magnetic tape
Pulses / revolution
Operating temperature range
Type of protection (sensor)
Connection
DAB450 31401 ENG
DAB450S/L
25600
25 m/s
- 10...+ 70 °C
Approx. 100 mm free connection line with 12-pin
round plug
IP 67
5 V DC +/- 10%
SIKO: magnetic tape MB100 with MSK110TH-SK20
Two square wave signals offset by 90°
and their inverse signals
MSK110TH-SK20
RS 422
Table 3.4.1
Fig. 3.5
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