ThyssenKrupp DAF 330 User manual

ThyssenKruppAufzugswerke
OperatingManual

DriveDAF330

OPERATING INSTRUCTIONS
ThyssenKrupp Aufzugswerke GmbH
Imprint
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©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 MANUAL
ThyssenKrupp Aufzugswerke GmbH
Table of contents
COMPACT Gearless®DAF 330 PAGE
1. Safety
1.1 Explanation of symbols used 6
1.2 General safety information 7
1.3 Emergency operation „release after safety gear oper.“ 10
2. Product description
2.1 Description of DAF 330 12
2.2 Functional description 13
2.3 Technical data 14
2.4 Lubrication 16
2.5 Name plate 17
2.6 Motor types 18
2.7 Motor connection 18
2.8 Pulse generator 18
2.9 Terminal diagrams motor / temperature monitoring 21
2.10 Motor data 23
2.11 Machine frame 24
3. Transportation and storage 27
4. Mounting of machine in machine room 29
5. Putting into service 30
6. Servicing 31
7. Maintenance
7.1 Replacing of brake shoes 32
7.2 Checking and adjusting of brake shoe stroke 33
7.3 Adjusting of braking deceleration 34
7.4 Adjusting of brake test switch 35
7.5 Replacing of traction sheave 36
7.6 Replacing of pulse generator 37
7.7 Checking for escaping grease / oil 39
8. Special versions (optional)
8.1 Additional pulse generator extension 40
8.2 SA3 safety contact 40
9. Annex
9.1 Tightening torque – mechanical strength 41
9.2 Additional parts 42
9.3 Connecting cable for pulse generator 45
Type examination certificate of braking device
Declaration of conformity
9.4 Changes compared to previous version 51
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ThyssenKrupp Aufzugswerke GmbH
1.1 Explanation of symbols used
The following pictographs and designations are used in this operating manual:
Danger
This symbol draws attention to an extreme danger to
life or risk of injury to persons. Disregard of warning
means danger to life !
Danger
This symbol draws attention to an immediate
impending danger to life or risk of injury to persons
caused by electric current.
Warning notices must always be observed!
Warning
This symbol draws attention to an impending danger.
Disregard can cause injury to persons or extensive
damage to property.
Warning notices must always be observed!
Note
This symbol draws attention to important information
and instructions for operation. Disregard can lead to
damages, hazards or failures.
Inspection
This symbol draws attention to inspection sequence.
These inspection notices must be observed in any
case. Disregard can lead to injury to persons or
damage to property.
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1.2 General safety information
Information about the operating manual
Knowledge of the basic safety requirements is a prerequisite for the safe use
and the failure-free operation of this component.
This operating manual comprises the most important information how to
safely use the component.
The operating manual and, in particular, the safety information must be
observed by all persons who perform any work on the component.
In addition the rules and requirements concerning the regulations for
prevention of accidents which apply to the installation location must be
observed.
Duties of the owner and / or the installer
The owner and / or the installer ensure that only persons are authorized to
work at the component, who
•are familiar with the requirements concerning safe working and prevention
of accidents and who were trained how to use the component;
•have read the safety information and the warning notices in this operating
manual.
Note: Check the compliance of the employees method of working with the
safety requirements in regular intervals.
Duties of the employees
Persons who are authorized to perform work at the component are obliged
•to observe the requirements concerning safe working and prevention of
accidents;
•to read the safety information and the warning notices in this operating
manual prior to start working.
Training of the employees
Only trained and instructed, technically competent persons shall perform
work at the component.
The competence of the employees must be clearly defined for all tasks
concerning putting into service, operation, maintenance and repair work.
Organizational measures
The owner or the installer must provide the necessary personal protective
gear. All existing safety devices must be checked regularly in accordance
with the maintenance plan.
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Informal information about safety measures
•The operating manual must always be available at the location of the
installation.
•In addition to the operating manual the general and local regulations for
the prevention of accidents and environmental regulations must be made
available and observed.
•Clearly and easily visible statutory safety instructions must be made
available for the users.
•See to it that all information concerning safety and hazards is always
visibly and legibly made available on the machine.
Use as intended
DAF 330 was designed in accordance with the state of the art and the
recognized safety regulations. DAF 330 shall only
•be used for its intended purpose
•be used exclusively if safe operation is ensured.
DAF 330 drive shall exclusively be used as drive for lifts.
Any other use or any use exceeding the scope of the above definitions is
regarded as use outside of the intended purpose. THYSSENKRUPP
AUFZUGSWERKE cannot be hold liable for any damages resulting from
this and for any damages which are caused by any errors of procedure.
Use within the scope of its intended purpose also comprises
•observance of all information of the operating manual
•fulfilment of the instructions applying to putting into service, installation
description and inspection and repair work.
Guarantee and liability
The „General sales and delivery terms“ of THYSSENKRUPP
AUFZUGSWERKE apply generally.
Any claims for guarantee and liability are excluded in the case of injury to
persons or damage to property resulting from one or several of the causes
below:
•use of DAF 330 outside the scope of its intended purpose
•inexpert mounting, putting into service, operating and maintaining of
DAF 330
•operating the DAF 330 with defective and/or non-operative safety and
protective devices
•disregard of instructions of operating manual that apply to
transportation, storage, mounting, putting into service, operating and
maintaining of DAF 330
•unauthorized constructional modifications of DAF 330
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•unauthorized modification of drive (performance etc.)
•unsatisfactory supervision of parts which are subject to wear
•inexpert repair work
•catastrophes caused by outside influence and Act of God.
Constructional modifications of machine DAF 330
DAF 330 is adjusted at the factory and is delivered ready for work.
In the case of any modifications of the machine THYSSENKRUPP
AUFZUGSWERKE cannot be hold liable.
Use of DAF 330 and possible hazards
DAF 330 shall only be operated in a closed machine room and only if a rope
guard is mounted on traction sheave and on deflection pulley. Switch off
power supply and secure installation against unintended switching on before
you install the handwheel. Remove handwheel before you put installation
into service again.
See to it that the necessary safety distance to all revolving parts (marked
yellow) is observed by persons working in the machine room.
In the case of incorrect use there will be danger to life for the user or third
parties resp. impairment of the component or material property. Failures
which possibly impair the correct functioning shall be eliminated immediately.
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1.3 Emergency operation ″
″″
″release after safety gear
operation″
″″
″
If safety gear operation is effected on car or counterweight side the traction of
the traction sheave may be insufficient for moving the car, the ropes may slip.
The following measures are necessary:
•Disconnect drive and control.
•Remove traction sheave cover and/or rope fixing beam above traction
sheave.
•Place hydraulic jack in location hole of machine frame on tension side of
lowered traction sheave.
•Bolt pressure arm with centering pin down to end face of traction sheave.
Use thread close to jack (see fig. 2)
•Nest nib of blocking clamp in snap ring groove below the brake disk and
screw to traction sheave in next thread above thrust piece (see fig. 1).
•Tighten 3 pressure screws and clamp ropes by means of thrust piece.
•Operate brake release lever on brake magnet and move traction sheave
into desired direction until the grip wedge is released by pushing the lever
upwards and downwards. (See to it that the drain valve is closed and the
centering pin of the thrust piece shall rest on the groove of the lever).
•Remove the blocking clamp and install the rope fixing bracket in
accordance with the instructions after disengagement.
Installation of blocking clamp
Note: if the travel of the hydraulic jack or the travel of the traction sheave is
not enough for releasing the car, it shall be maintained in its position with the
rope clamp. The recess of the rope clamp shall rest on the machine frame
and the other rope clamp side on the welded-on bracket on the inside of the
frame.
Lower hydraulic jack, re-adjust thrust piece on next fastening thread on
traction sheave above hydraulic jack. Re-adjust blocking clamp if the travel is
insufficient.
Fig. 1
1 Nib
2 Thrust piece
3 Pressure screw
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1
2
3
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Repeat above procedure until the car is released. See to it that the rope
clamp does not clamp the ropes during disengagement operation since
otherwise there is the risk that the rope clamp gets between ropes and
traction sheave.
Attention: prior to restoring the lift to service make sure that the cause of the
failure has been eliminated and check lift for correct functioning.
How to mount the jack on the traction sheave
Note: for further illustrations of the accessory tools mentioned in above
description of disengagement procedure see chapter 9.2 additional parts.
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1 Thrust piece
2 Rope fixing
beam
3 Centering pin
4 Hydraulic jack
5 Lever
6 Drain valve
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1 2
3
4
5
6
Fig. 2
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ThyssenKrupp Aufzugswerke GmbH 
2.1 Description machine DAF 330
The machine consists of:
Pos.
Part designation Pos Part designation
1 Brake release magnet 7 Casing
2 Brake release lever 8 Motor and name plate
3 Forced ventilation 9 Traction- brake- sheave
4 Brake shoes 10 Disk on motor shaft
5 Terminal box 11 Rope fixing beam
6 Bearing bracket 12 Brake spring
5

4

11
10
8

3
6
1

7
9
2
12
Fig.3
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Versions
The following versions are available:
1. Lift speed;
2. Electrical rating for current regeneration;
3. Groove profiles of traction sheave;
4. Machine frame versions;
5. Additional safety devices;
6. Additionally mounted generator
Special versions, for details see 8.1
2.2 Functional description
Machine:DAF 330 consists of a frequency-controlled motor of constructional
size B3 (DIN IEC 34).
Note:it is designed for 2 : 1 suspension with single or double rope wrap.
Dependent on motor type and controller the actual braking energy can be
a) supplied to resistors (for motor data see 2.10)
b) regenerated sinusoidally to the mains (see 2.10/2.11)
Motor shaft and rope pulleys are equipped with life-time lubricated roller
bearings. The traction sheave and the integrated brake disk are pressed and
screwed onto the conical end of the motor shaft. The screws are secured
against unintentional unscrewing by means of Loctite (type 241).
The gearless machine does not have a self-locking device.
Brake: an electromagnetically operated outside dual-circuit shoe brake is
mounted on the motor casing. Two independently operating brake shoes with
preset spring resistance press the brake lining onto the brake disk.
The braking force is adjusted in such a way that one braking shoe can stop
the car loaded with full loading capacity.
Electrically operated brake test switches monitor the position of the brake
shoes and the wear of the brake linings: in the case of malfunction or
reaching of preset wear limit the drive will be disconnected.
An electrically operated dual expanding magnet is used for releasing the
brake (one electromagnet for each brake shoe).
A brake release lever is mounted on the dual expanding magnet for manually
releasing and simultaneously operating both brake shoes.
Machine frame: in the as-delivered condition the machine frame necessary
for mounting the machine is a completely pre-assembled unit (incl. mounted
rope pulley in the case of double wrap). (For details concerning machine
frame and its dimensions see 2.12)
Additional parts:additional parts necessary for operation, servicing and
trouble-shooting such as blocking clamp, rope grip, handwheel and hydraulic
lever are delivered optionally.
Note: for description of use as intended see chapter 9.2
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2.3 Technical data machine
Dimensions machine DAF 330
Permissible axle load of motor shaft: . max. 85 kN to 217min-1.
max. 75 kN to 260 min-1
Braking moment: max. 3000 Nm
Moment of inertia (mot.+ traction sheave) / (counterpulley)12 kgm² / 1.5 kgm²
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Fig. 4
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OPERATING MANUAL 2. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 
Traction sheave with integrated brake disk
440 mm rim diameter / 540 mm brake disk diameter
10 mm rope diameter
Number of grooves with
a) double wrap = 12 non-hardened semicircular grooves
b) single wrap = 6 - 8 seat or V-grooves for rope Ø 10 mm with hardened groove
flanks
Select the groove form (wedge angle with V-grooves or undercut angle with
seat grooves) in accordance with the necessary traction.
Weight :
Weight of machine incl. traction sheave 750 kp
Weight of machine incl. frame and rope pulley 1050 kp
Technical data dual expanding magnet:
Power supply
Retentive current: (with UH= 90V) 1.3 A
Pick up current: (with UA= 50V) 2.4 A
Rated retentive voltage: 100 V
Fast excitation: 180 V
Protection class: IP65
Series-connected coils with DAF 330.
Technical data forced ventilation:
Operating voltage: 400 – 460 V
Mains frequency: 50 / 60 Hz
Rated output: 0.27 kW
Current: 0.42 A
Air quantity: 600 m³/h
Noise level: 68 dB(A)
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OPERATING MANUAL 2. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 
2.4 Lubrication DAF 330
The machine does not require lubrication.
•The roller bearings of the motor shaft are provided with life-time
lubrications.
•Do not lubricate the sintered-metal bushings on the brake shoes
•The roller bearings of the rope pulley are also provided with life-time
lubrication
Should complete/partial re-lubrication still be necessary or bearings be
changed a special grease shall be used only: Petamo GHY 441
(part No.: 270 050 9).
Supplied by THYSSENKRUPP AUFZUGSWERKE .
Note:for any damages caused by lubricators which were not recommended
THYSSENKRUPP AUFZUGSWERKE cannot be hold liable.
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ThyssenKrupp Aufzugswerke GmbH 
2.5 Name plate machine DAF 330
The current model and the technical data are stated on the nameplate of
the product.
1. THYSSEN AUFZUGSWERKE
2. Lift Equip
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ThyssenKrupp Aufzugswerke GmbH 
2.6 Motor types
The standardized THYSSEN motors for machine DAF 330 described below
correspond to constructional size B3 with pulse generator.
They are frequency-controlled.
The following versions are available:
Frequency-controlled THYSSEN motors optionally available for use :
without energy recovery (with resistor)
type DAF 330 - M 001; M 003; M 005;
with energy recovery type DAF 330 - M 002; M 004; M 006;
with rated output of: 25; 20; 17.5/16 KW
For motor data see 2.10 / 2.11
2.7 Motor connection
How to connect the motor:
Note terminal diagram on the inside of the motor terminal box and/or terminal
diagram in chapter 2.9 of this operating manual and the respective building
codes.
2.8 Pulse generator:
DAF 330 is controlled by means of an incremental hollow shaft pulse
generator mounted on the rear end of the rotor shaft. A flange-type socket
has been provided as connection to control.
For notes on installation and drawing see 7.6
Technical data for TTL generator:
Hollow shaft encoder with 2 signals with 90°phase shift and reference mark
Number of increments per rev. (Z): 16384 pulses/revolution
Supply voltage: 4...6 V
Output driver: RS 422
Max. output frequency RS 422: 300 kHz
Push-pull output: 200 kHz
Static radial movement: ±0.5 mm
Static axial movement: ±0.5 mm
Working temperature range: −20...+70 °C
Storage temperature range: −30...+85 °C
Permissible relative humidity: 70 %
Loadless working current with 5 V 120 mA
Protection class: IP 00
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ThyssenKrupp Aufzugswerke GmbH 
SA1 second pulse generator HTL (optional, only applies to additional
safety monitoring)
The second generator is mounted on an extended shaft journal of the motor
shaft behind the first generator.
Technical data SA1 HTL pulse generator (2. generator):
Hollow shaft encoder with 2 signals displaced by 90°and reference mark
Number of increments per rev. (Z):1024 pulses/revolution
Supply voltage: 10...30 V
Output driver: RS 422
Loadless working current with 24 V 100 mA
Protection class: IP 00
All further data are identical with 1. TTL generator.
Contact assignment of generator flange socket for pulse generator
HG 900 E
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K1
__
K1


K2
___
K2


K0
___
K0
Type: number of pulses:
TTL 16 384
HTL 1 024 (SA1)
Fig. 5
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View mating side
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OPERATING MANUAL 2. PRODUCT DESCRIPTION
ThyssenKrupp Aufzugswerke GmbH 
Connection socket on pulse generator
(Make: Stegmann)
TTL HTL
PIN Colour Signal Signal Explanation
5 Volt 24 Volt
RS 422 push-pull
1 black K2 N. C. signal line
2grey Sense + N. C. internal conn. to US
3lilac KO K. O. signal line
4yellow KO N.C. signal line
5white K1 K1 signal line
6brown K1 K1 signal line
7orange N. C. N.C. not reserved
8pink K2 N.C. signal line
9shield shield
10 blue GND GND GND conn. of generator
11 green Sense - GND internal GND connection
12 red US US supply voltage of generator
N. C. = not connected
Do not wire pins / cores designated „N. C.“
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View mating side
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