ThyssenKrupp DAF290 User manual

ThyssenKrupp Aufzugswerke
Operating Manual
Drive DAF290
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Legal information
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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 media unauthorised by
ThyssenKrupp 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
Tel.: [phone]
E-mail: [e-mail]
Internet: www.thyssenkrupp-elevator-eli.de
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OPERATING MANUAL DAF290
ThyssenKrupp Aufzugswerke GmbH
Table of Contents
Drive DAF290 PAGE
1. Safety
1.1 Symbols 6
1.2 Safety instructions 7
2. Product Description
2.1 Description 10
2.2 Functional description 11
3. Technical Data
3.1 Dimensions 12
3.2 Machine base frame - optional - 13
3.3 Lubrication 14
3.4 Encoder 14
4. Transportation and Storage 15
5. Machine Setup 17
5.1 Commissioning 18
5.2 Terminal connecting plans 19
6.Servicing 21
7. Maintenance
7.1 Replacing brake shoes 22
7.2 Checking and setting brake shoe stroke 23
7.3 Setting braking deceleration 24
7.4 Setting the brake test switch 25
7.5 Traction sheave replacement 26
7.6 Replacing the encoder 27
7.7 Checking for escaping grease/oil 28
7.8 Emergency measure “Releasing the car from the engaged
position (safety gear)” 29
8. Special Versions (SA) (Optional)
8.1 Mounting an additional encoder 31
9. Appendix
9.1 Tightening torques – tightness values 32
9.2 Accessory parts 33
9.3 Changes 36
Type test certificate
Declaration of conformity
Drawing, line assembly, CPI pulse encoder
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OPERATING MANUAL DAF290 SAFETY
ThyssenKrupp Aufzugswerke GmbH
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.
Test/Check
Test steps are specified with this symbol.
The test instructions marked in this way should be
followed without fail. They contribute to preventing
personal injury or damage to property.
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OPERATING MANUAL DAF290 SAFETY
ThyssenKrupp Aufzugswerke GmbH
1.2 Safety instructions
Notes regarding the operating manual
A requirement for safe handling and non-disruptive operation of this
subassembly 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, must be complied
with by all persons who work on this assembly.
Furthermore, the rules and regulations covering accident prevention that
apply to the installation site must be complied with.
Obligations of the operator and/or of the installation company
The operator and/or installation company undertakes only to allow persons to
work on the subassembly who
•are familiar with the regulations regarding work safety and accident
prevention and have been instructed in handling the subassembly.
•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 subassemblies 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 personnel
Only trained and instructed qualified personnel may work on the assembly.
The responsibility of the personnel must be clearly defined for all tasks
involving commissioning, operation, servicing and repair.
Organisational measures
The required personal safety equipment must be provided by the operator or
installation company, as the case may be. All existing safety devices are to
be tested regularly in accordance with the servicing schedule.
Informal notes on the safety measures
•The operating manual is to be kept permanently at the usage site of the
installation.
•In addition to the operating manual the generally applicable and the local
regulations pertaining to accident prevention and environmental
protection must be provided and complied with.
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OPERATING MANUAL DAF290 SAFETY
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•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 DAF290 has been constructed using state-of-the-art technology and in
line with the recognised technical safety regulations. The DAF290 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 DAF290 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 initial operation instructions, system description and
inspection and servicing 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 DAF290
•Installation, commissioning, operation and servicing of the DAF290 that is
not in line with accepted technical principles
•Operation of the DAF290 machine with defective and/or malfunctioning
safety and protection devices
•Nonobservance of the instructions in the operating manual with regard to
transport, storage, assembly, commissioning, operation and servicing of
the DAF290
•Constructional changes to the DAF290 performed by the operator
•Changes to the drive ratios (power output, etc.) performed by the
operating company
•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.
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OPERATING MANUAL DAF290 SAFETY
ThyssenKrupp Aufzugswerke GmbH
Constructional changes to the DAF290 machine
The DAF290 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 DAF290
The DAF290 may only be operated in an enclosed machine room and only
with the cover and rope guard fitted on the traction sheave and deflecting
rope pulley.
Before mounting the handwinding wheel, the power to the drive must be
disconnected and the installation secured against inadvertent activation.
Remove the handwinding wheel before reconnection.
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 subassembly or other assets
can arise. Malfunctions that can impair safety must be rectified immediately.
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OPERATING MANUAL DAF290 PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH
2. Product Description
2.1 Description
1 Brake magnet 7 Housing
2 Brake release lever 8 Name plate
3 Forced ventilation 9 Traction sheave
4 Brake shoe 10 Disc on motor shaft
5 Terminal box 11 Rope fixing beam
6 Bearing bracket 12 Brake spring
Versions
The following versions can be supplied:
1. Groove profiles of the traction sheave
2. Machine base frame versions
3. Safety-relevant accessory parts
4. Additional encoder mounting
Special versions, see Appendix
5
4
11
10
8
3
6
1
7
9
2
12
Fig. 2.1
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OPERATING MANUAL DAF290 PRODUCT DESCRIPTION
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2.2 Functional description
Machine: The DAF290 consists of a frequency-controlled motor with
structural shape B3 (DIN IEC 34).
Note: It is design for operated with 2 : 1- suspension with single or double
rope wrap.
The motor shaft and rope pulley are equipped with rolling bearings with life-
time lubrication. The traction sheave with integrated brake disc is press-fitted
on the tapered end of the motor shaft and screwed on. The screws are
secured with Loctite (type 241) against accidental release.
The gearless machine has no automatic interlock.
Rule for using the drive:
-Voltage at the motor terminals (conductor-conductor) < 1200 V.
-Rise time of the measured voltage (10-90%)
at the motor terminals > 100 ns.
Brake: An electromagnetically actuated dual-circuit outer shoe brake in
installed at the motor casing. 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 designed such that one brake shoe is able to bring the
elevator car with full loading capacity to a halt.
The position of the brake shoes and the wear of the brake linings is
monitored by test switches. In case of malfunction, or when the preset wear
limit has been reached, the test switches switch the drive off.
The brakes are released by means of an electrically actuated double-vane
magnet.
(Each brake shoe has its own electromagnet)
Both brake shoes are actuated at the same time via the installed brake
release lever.
Machine base frame: The machine base frame required to erect the
machine is manufactured and delivered to suit the order. For further
information on the machine base frame and its dimensions, see order
drawings.
Accessories: Accessories required for operation, servicing work and the
elimination of malfunctions, such as blocking clamp, rope grip, handwinding
wheel and hydraulic jack, can be delivered as options.
Note: A description of use in line with the intended purpose is provided in the
Appendix
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OPERATING MANUAL DAF290 TECHNOLOGY
ThyssenKrupp Aufzugswerke GmbH
3. Technical Data
3.1 Dimensions
Permissible axle load of the motor shaft: max. 60 kN
Braking torque: max. 1600 Nm
Moment of inertia (mot. + tract. sh.) / (rope pulley) 7 kgm² / 1.5 kgm²
Fig. 3.1
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OPERATING MANUAL DAF290 TECHNOLOGY
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Traction sheave with integrally cast brake disc
360 mm rim diameter / 480 mm brake disc diameter
8 mm rope diameter
Number of grooves in version
a) double wrap = 14 semicircular grooves, unhardened
b) single wrap = 5 - 9 seat or vee grooves with hardened groove flanks
The groove form (wedge angle with vee grooves, or undercut angle of the
seat grooves) must be selected according to the required driving force.
Weight:
Machine weight incl. traction sheave 750 kp
Machine weight incl. frame and rope pulley 1050 kp
Technical data of double-vane magnet:
Power supply
Holding current: (at U
H
= 90V) 1.3 A
Pick-up current (at U
A
= 50V) 2.4 A
Rated retentive voltage: 100 V
for field forcing device: 180 V
Type of protection: IP65
With the DAF 290, both coils are connected in series.
Technical data of forced ventilation:
Operating voltage: 400 - 460 V
Mains frequency: 50 / 60 Hz
Nominal power: 0.27 kW
Current: 0.42 A
Air volume: 600 m³/h
Noise level: 68 dB(A)
3.2 Machine base frame - optional -
The machine base frame is manufactured and delivered depending on the
order. See corresponding order drawings. The machine base frames are
intended for installation in the machine room above the shaft.
The rope run-in and departure on the traction sheave and rope pulley must
be fitted with protective covers. The cover on the traction sheave must be
secured by a switch. The drive shuts down automatically if the rope guard on
the traction sheave is removed while work is being carried out on the
machine.
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OPERATING MANUAL DAF290 TECHNOLOGY
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3.3 Lubrication
The bearings of the DAF290 are provided with life-time lubrication; the drive
therefore requires no further lubrication.

However, if a repair to the bearing is required, the following grease type and
quantities must be added:
AS (output side) 280g
Petamo GHY 441 special grease
Art. no. 270 050 9
Bearing
complete filling
BS 30g
Petamo GHY 441 special grease
Art. no. 270 050 9
Bearing
complete filling
Available from THYSSENKRUPP AUFZUGSWERKE GmbH
Note: THYSSENKRUPP AUFZUGSWERKE GmbH shall not be liable for
losses caused by the use of non-approved lubricants.
3.4 Encoder:
An incremental hollow shaft encoder is installed at the rear rotor shaft end for
controlling the DAF290. The end connection to the control is by means of an
encoder flange socket.
The second encoder is installed on an extended shaft journal of the motor
shaft behind the first encoder. (If retrofitted, the shaft journal must be
replaced.)
Installation instructions, see Appendix
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OPERATING MANUAL DAF290 TRANSPORTATION AND STORAGE
ThyssenKrupp Aufzugswerke GmbH
4. Transportation and Storage
Packaging:
Shipping takes place depending on the order and drive (transport pallet,
transport frame, machine base frame), optionally covered with foil.
Other packaging types can deviate from this on a country-specific basis
(air / sea / truck freight).
Transportation:
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 transportation:
•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 transportation:
•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.
•Do not lift by the housing!
•After transportation, remove the wooden transport protection slats.
Pay attention to the picture symbols on the packaging or elsewhere.
This way up Fragile goods Protect against
water
Protect against heat Hand hooks
prohibited
Attach here
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 details, see Technical Data
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OPERATING MANUAL DAF290 TRANSPORTATION AND STORAGE
ThyssenKrupp Aufzugswerke GmbH
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 equipment 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 that no condensation can form and that no moisture can
penetrate.
•The subassembly 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 °C and +40 °C)
The relative air humidity must not exceed 70%.
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OPERATING MANUAL DAF290 MACHINE SETUP
ThyssenKrupp Aufzugswerke GmbH
5. Setting up the machine
Setup
The DAF290 machine is delivered fully mounted and aligned on the 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, insulation 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 support
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), but 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 is based on the total weight load. 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 the
order drawing.
Aligning the machine base frame
The machine is to be set up according to the plan of installation (drawing).
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.
Rope arrangement
The arrangement of the carrier cables in the suspension plate, on the traction
sheave as well as the cable rollers should be as symmetrical as possible.
Alignment of the machine on the base frame: The machine must be
aligned on the base frame in such a way that the axle alignment of traction
sheave and rope pulley (double wrap) are exactly parallel. The lateral
location of the rope grooves must be offset by half the groove gap dimension
(6 mm). The parallel dimension of the gap (ASL) of the outgoing ropes must
be complied with.
Setting: The location of the axles and/or the dimension of the gap 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 mounting bolts must
be tightened to the prescribed torque. See table in the Appendix
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OPERATING MANUAL DAF290 MACHINE SETUP
ThyssenKrupp Aufzugswerke GmbH
5.1 Commissioning
Before commissioning the machine, the following points should be checked
and carried out:
•Safety, auxiliary and installation tools removed from the danger zone
•Setup and alignment of machine, frame and rope departure checked
•Mounting of the machine and base frame checked
•Bolts tightened and secured to the prescribed torque (see 'Tightening
torques' table in the Appendix)
•Brake shoe stroke and setting checked
•Setting and function of the brake test switches checked
•Brake test carried out with one brake shoe in each case
•Function of handbrake release checked
•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, checked and secured
•Special add-on components (optional), 2nd pulse encoder function
checked
•Direction arrow (Up / Down) corresponding to the direction of travel glued
in a clearly visible position above the traction sheave to the brake vane
magnet
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OPERATING MANUAL DAF290 MACHINE SETUP
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5.2 Terminal connecting plans
Motor connection terminal plan:
The terminal diagram is also printed on the inside of the cover
Note: Observe direction of rotation.
The fan should be connected in such a way that the air flow is taken
in by the fan and blown by the motor.
See arrow direction on the air inlet side of the fan.
Fig. 5.1
Forced ventilation
Terminals for motor, temperature monitoring
and forced ventilation
Interference filter
Fig. 5.2
Fan
Neutral
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OPERATING MANUAL DAF290 MACHINE SETUP
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Terminal connecting plan for double-vane magnet
Terminal connecting plan for brake test switch
Setting the brake test switch, see Chapter 7
Button
2
Button
1
−
−−
−
A
+
++
+
+
++
+
−
−−
−
A
1 2 PE
+−
Double-vane magnet
blue
black
brown
black
blue
brown
Switching state Illuminated display on switch 24V=
1= Brake open Off
2= Brake closed On
3= With 0.3 mm wear Off
A = Output
Illuminated display "On" TM A = 0 V
Fig. 5.3
Fig. 5.4
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