ThyssenKrupp NBS User manual

ThyssenKruppAufzugswerke

Operatingmanual

EmergencybrakesystemNBS
For:TW45C,TW 3,TW130,TW1 0


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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

OPERATING MANUAL NBS
ThyssenKrupp Aufzugswerke GmbH
Table of Contents
Emergency brake system NBS PAGE
1. Safety
1.1 Symbols 6
1.2 Safety instructions 7
2. Product description
2.1 Emergency brake system NBS 10
2.2 Operation principle of the NBS 13
2.3 Placing the emergency brake system out of operation 17
2.4 NBS control unit 19
2.5 Speed governor connection 22
2.6 Releasing the NBS emergency brake mechanically 24
3. Technical data
3.1 Mounting the NBS TW45C 25
3.2 Mounting the NBS, TW63 28
3.3 Mounting the NBS, TW130 29
3.4 Mounting the NBS, TW160 30
3.5 Connecting the NBS emergency brake 31
4. Transport and storage 36
5. Assembly
5.1 Installation instructions 38
5.2 Terminal connecting information 38
6. Commissioning / maintenance
6.1 Commissioning 39
6.2 Maintenance 40
6.3 Emergency rescue for drives with NBS 41
7. Repairs
7.1 Replacing the NBS emergency brake 43
7.2 Replacing the brake test switch 46
8. Appendix
8.1 Tightening torques and tightness values 47
8.2 Changes 48
8.3 Appendices: type test certificate
and brake manufacturer specifications 48
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OPERATING MANUAL NBS 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!
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
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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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 installation site must be complied with.
Obligations of the operator and/or of the installation company
The operator or installation firm undertakes only to allow persons to work on
the product who are familiar with the regulations regarding work safety and
accident prevention and have been instructed in handling the product.
They must also 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.
Obligations on the part of personnel
Persons assigned to work on subassemblies undertake before starting work
to
die comply with the regulations regarding work safety and accident
prevention.
They must also have 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 maintenance schedule.
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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 NBS emergency brake has been constructed using state-of-the-art
technology and in line with the recognised technical safety regulations.
The NBS emergency brake may only be deployed when it is in perfect
working order with regard to safety.
The exclusive intended purpose of the NBS emergency brake is to protect
the elevator car against overspeed as it is moving upwards.
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
compliance with all instructions in the operating manual and
compliance with the commissioning instructions, the installation description
as well as performance of 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 NBS
emergency brake
Installation, commissioning, operation and maintenance of the NBS
emergency brake that is not in line with accepted technical principles
Operation of the NBS emergency brake with defective and/or malfunctioning
safety and protection devices
Nonobservance of the instructions in the operating manual with regard to
transport, storage, installation, commissioning, setting, operation and
maintenance of the NBS emergency brake
Customer constructional alterations to the NBS emergency brake
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Changing, exceeding the specified ratings
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 NBS emergency brake
The components of the NBS emergency brake are assembled and tested in
the plant. In event of changes being made to the assembly, all warranty on
the part of THYSSENKRUPP AUFZUGSWERKE GmbH is cancelled
Dangers in handling the NBS emergency brake
The internal electronic circuit of the NBS emergency brake is connected to
mains voltage. Before intervention in the control system, required for
example with the safety catch activated or during a brake test, the power
supply to the drive is to be disconnected before starting work and the
installation is to be secured against inadvertent activation.
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 of the assembly or other assets can
arise.
Malfunctions that can impair safety must be rectified immediately.
Make sure that the brake release screws (screw head marked in red) have
been removed from the NBS emergency brake before beginning operation of
the elevator, as otherwise the brake will not function in an emergency.
No persons may be transported (except emergency rescue) with the
brake release screws screwed in!
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2. Product description
2.1 Emergency brake system NBS
1 Elevator control 5 NBS emergency brake
2 NBS control unit 6 NBS cover
3 NBS brake trigger switch 7 Brake release lever, show
brake
4 Terminal box, NBS connection 8 Motor TW63, horizontal
The NBS emergency brake system that is mounted as an option on
ThyssenKrupp elevator gears serves as an additional protection device
against overspeed for the elevator car as it moves upwards. It complies with
the applicable regulations of EN81.
Fig. 2.1
1
2
3
4
5
6
7
8
Fig.: right-hand version of NBS emergency brake
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Structure
The NBS emergency brake system consists of:
A type-approved electromagnetic disc brake.
This is mounted directly on the traction sheave or worm drive shaft. It is
located on the opposite side of the traction sheave.
The mounting position of the NBS emergency brake is defined with regard to
the direction of view of the motor towards the gear (arrangement of NBS
emergency brake on left or right). see Fig. 2.1.
An extended traction sheave or worm drive shaft for mounting the brake
on the gear and the necessary additional bore hole in the bearing bracket.
A brake flange for mounting the brake on the gear housing, including set of
seals.
The emergency brake system (NBS) control unit for activation of the
electromagnetic disc brake and connection to the elevator control system.
The circuit for activation of the brake is type-approved and meets the
requirements of EN81-A3.
A monitoring switch mounted on the magnetic brake to monitor the position
of the brake (opened / closed).
An additional safety switch on the speed governor that initiates the brake
operation when the rated speed is exceeded.
The required cable connections for signal forwarding and energy supply.
A schematic overview for connection of the emergency brake system can be
found in Fig. 2.1.
Function principle
Opening: triggered by the run command, the NBS emergency brake system
- which is closed with spring force - opens shortly in front of the shoe brake
fitted on the gear and by opening the shoe brake releases the drive. The
switch state of the NBS emergency brake is indicated when opened by the
indicator lamp on the control unit lighting up.
Closing in the normal mode:
On stopping from a travel movement, the drive switches off first. The
mechanical shoe brake responds and closes the NBS emergency brake
system after a preset delay time.
Closing in the event of emergency stop or power failure:
In all 3 cases, the drive brake and NBS emergency brake respond without a
delay.
(UCM – uncontrolled car movement complying with EN81-A3)
Closing in an emergency situation:
If the speed governor responds to overspeed, the drive switches off and the
drive brake closes. At the same time, the NBS emergency brake is operated
by means of the additional switch on the speed governor.
If the elevator car leaves the door zone with an open door, bridging of the
safety circuit is cancelled by the safety module for the function 'levelling
operation with open door' and / or 'relevelling'. The open safety circuit means
that the NBS contactors drop out and the emergency brake is operated
without delay.
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In both cases, the power supply to the electromagnets that hold the disc
brake open while the elevator is moving is switched off. The NBS emergency
brake closes and brakes the drive on the traction sheave or worm drive shaft.
2.1.1 Measures after activation of the NBS emergency brake
Determine what caused the brake to respond.
a) At overspeed, the switches on the speed
governor must be operated (open).
Check the function and operability of the drive and drive brake; reset the
switches and governor to their operating positions. (Engage the locking
spring on the speed governor in the middle position).
b) In the event of an emergency stop or power failure, the switches are in the
operating position (closed).
c) In the case of UCM, the installation was shut down with a UCM error. The
elevator control system must store this error. A restart may only be
possible by manual intervention of maintenance personnel.
If the installation is defective or without current, initiate rescue.
To move the elevator car in order to achieve this, the NBS emergency brake
must be put out of operation.
Proceed as described in chapter 6.3 and comply with the specified safety
instructions.
Determine and, if possible, rectify the cause of the overspeed to exclude a
repetition of the malfunction.
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2.1.2 Deployment limits and precautions
•To guarantee conformity of the brake in accordance with EU Directive
95/16/EC, the conditions of installation and use must be complied with.
For compliance with the permitted travel speed, the use of a speed
governor complying with EN81-1, Section 9.9, is mandatory. See type test
certificate in the Appendix, chapter 8. The associated ABV no. can be
found in the technical data of the drive.
•According to the manufacturer specifications, the NBS emergency brake
system is only permitted for dry operation. Oil, grease and abrasion dust
are to be kept away from the brake, as otherwise the performance
characteristics can change.
•Elevator operation with the brake release screws screwed in is not
possible. Screwing in the screws puts the NBS emergency brake system
out of operation. At the same time, the brake monitoring interrupts the
safety chain.
•The operator must ensure that the setting of the air gap made at the plant
is not changed, thus ensuring faultless release of the brake.
•The NBS emergency brake system is intended for static application as a
parking brake. Dynamic braking is restricted to emergency braking when
the elevator is moving upwards.
Under no circumstances does the brake replace safety systems for
downward operation.
•Any changes to the brake without express approval by the manufacturer
or their representatives lead to loss of warranty entitlements and an
exclusion of liability relevant to conformity.
2.2 Function principle of the NBS emergency brake
2.2.1 Indicators in the circuit diagram
2.2.1.1 Location indicators
+TS Elevator control system in the machine room
+T Speed governor in the machine room
+M Drive
+NBS Accessory NBS emergency brake control system
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2.2.1.2 Interface indicators
(A)
NBS contactor release monitoring: run may only be initiated if the contactors
+NBS-K77.1, +NBS-K77.2 and +NBS-K77.5 dropped out before the start of
the run.
(contactor contact chain closed)
(B)
Run signal to NBS: the signal must be applied during the entire run.
(C)
Run enable from NBS: a driving motion (run) is only permitted if the
contactors +NBS-K77.1, +NBS-K77.2, +NBS-K77.3 and +NBS-K77.5 have
picked up. (Contactor contact chain closed)
2.2.2 Initial situation
The elevator is at a standstill. The service brake brakes the drive firmly.
There is no run command.
Safety switch +T-S102.1 is closed. The operating mode selector switch
+NBS-S77 is open in the switch position "normal mode".
The brake magnet +M-Y78 has no current. The NBS emergency brake thus
also brakes the drive firmly. The closed monitoring switch +M-S78 means
there is control voltage 24 V = at relay +NBS-K77.4. Relay +NBS-K77.4 has
picked up. Indicator lamp +NBS-H77 does not light up.
The power supply +NBS-G77.2 provides the control voltage of 24 V.
The die 230V AC is provided as mains voltage at the input of the NBS control
system terminal X2:L.
This mains voltage also supplies the module from generation of the brake DC
voltage G77.1 via make contacts of the NBS contactors.
Contactors +NBS-K77.1 +NBS-K77.2, +NBS-K77.5 have dropped out without
voltage. Contactor +NBS-K77.3 receives no voltage from the elevator control
system and has therefore also dropped out.
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2.2.3 Initiating a run
Before initiating the run, the elevator control system checks whether the NBS
contactor release monitoring is closed. If the NBS contactor release
monitoring is closed and the elevator control system has met all the other
conditions for initiation of a run (safety circuit closed), a run can be initiated
by the elevator control system.
Initiation of a run is signalled by the elevator control system to the NBS
emergency brake control system in that the elevator control system applies a
voltage of 230 V~ to contactor coil +NBS-K77.3. Contactor +NBS-K77.3
picks up.
If the contactor +NBS-K77.3 picks up, this makes contactors +NBS-K77.11
and +NBS-K77.2 pick up as long as the safety circuit of the elevator control
system is closed. This connects the brake magnet +M-Y78 to the brake
voltage output of the component ROBA switch +NBS-G77.1:5-6. This
enables the brake activation voltage (207V DC) and after a time set in the
component +NBS-G77.1 it is reduced to a brake retentive voltage
(104 V DC). This releases the NBS emergency brake and holds it open.
The time up to switching over to retentive voltage is specified by resistor
R77.2 on +NBS-G77.1. The value 1M Ohm sets approx. 1.2 seconds.
On release of the NBS emergency brake, monitoring switch +M-S78 is
opened. This causes relay +NBS-K77.4 to drop out and contactor +NBS-
K77.5 picks up. Indicator lamp H77 shows that the NBS emergency brake
has been released.
+NBS-K77.5 checks the brake test switch for each run.
If the NBS emergency brake is not released, contactor +NBS-K77.5 is also
without current and has dropped out. The contactor contact chain between
+NBS-X2:14 and +NBS-X2:15 is then interrupted. The elevator control
system must ensure that the drive is no longer moved under the closed NBS
emergency brake. If the NBS emergency brake engages while the elevator is
moving, interrupting the contactor contact chain withdraws the run enable by
the NBS emergency brake control system, which means the elevator control
system must immediately trigger an emergency stop.
If the contactor contact chain between +NBS-X2:14 and +NBS-X2:15 is
closed, the NBS emergency brake control system enables the run. Following
run enable from the NBS emergency brake control system, the elevator
control system can start the run.
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2.2.4 End of run
A run is normally terminated after a regulated delay in that the direction of
travel and run signal are switched off by the elevator control system. The run
ends immediately (emergency stop) if the safety chain is interrupted in the
event of a malfunction.
At the end of the run, the power supply to contactor coil +NBS-K77.3 must be
cut immediately by the elevator control system. Contactor +NBS-K77.3 drops
out. The delayed auxiliary switch block of the contactor +NBS-K77.3 drops
out after the set time.
As long as safety switch +T-S102.1 and the safety circuit of the elevator
system are closed, the NBS emergency brake should open without delay and
close with a delay. The delay of the auxiliary switch block +NBS-K77.3, which
can be set from 0.1 to 30 seconds, should be set in such a way that the NBS
emergency brake only engages when the drive is at a standstill and the
service brake firmly brakes the drive.
As soon as contactors +NBS-K77.1 and +NBS-K77.2 are without voltage and
have therefore dropped out, the brake magnet +M-Y78 is disconnected from
the brake voltage. The NBS emergency brake engages. The initial situation is
reached once again.
The dropping out of the NBS contactors K77.1, K77.2, K77.3 must be
checked by the elevator control system for each run or at the latest during a
change of direction. This contactor chain is available for the check at
terminals X2:11 and X2:12.
2.2.5 Emergency braking
The NBS emergency brake is activated via an additional safety switch
+T-S102.1 at the speed governor of the elevator at overspeed independently
of the direction of rotation of the drive.
The safety shutdown of the drive at overspeed takes place via the regular
safety switch (e.g. +T-S102) of the speed governor. This safety switch is part
of the safety circuit of the elevator control system.
If the additional safety switch +T-S102.1 is opened, contactors +NBS-K77.1
and +NBS-K77.2 are without voltage and drop out. This disconnects the
brake magnet +M-Y78 without delay from the brake voltage so that the NBS
emergency brake engages and brakes immediately.
Each opening of the safety circuit also leads to contactors +NBS-K77.1 and
+NBS-K77.2 dropping out and to undelayed engaging of the NBS emergency
brake.
The door safety circuit is usually bridged by a safety module on levelling at
the landing or relevelling. The bridging is permitted complying with EN81 in a
defined door zone and at a speed lower than 0.8 m/s.
To comply with the requirements of EN81-A3, the permitted length of the
door zone has to be calculated. It is only on leaving the door zone with an
open elevator car or landing door that contactors +NBS-K77.1 and +NBS-
K77.2 drop out and the emergency brake engages to brake the elevator car.
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Where contactors +NBS-K77.1, +NBS-K77.2 and +NBS-K77.5 drop out, the
contactor contact chain between +NBS-X1:14 and +NBS-X1:15 is
interrupted. The elevator control system must immediately switch off the drive
if the contactor contact chain between +NBS-X2:14 and +NBS-X2:15 is
interrupted.
2.3 Placing the NBS emergency brake out of operation
As monitoring of the NBS emergency brake is integrated in the safety chain
of the elevator control system, special measures are required to open the
NBS emergency brake and/or put it out of operation in certain situations such
as emergency rescue, safety gear test, brake test etc.
NB: the work described here may only be performed by qualified personnel.
It must not be performed by the elevator attendant, as in the event of
malfunctions only trained and qualified personnel are able to recognise the
causes and the associated dangers involved in the removal of the
malfunction and reconnection.
2.3.1 Opening the NBS emergency brake with power supplied to installation
(after activation of the brake as a safety device as a result of overspeed or in
the case of UCM)
Check the function and operability of the drive brake and drive. Perform a
visual inspection to see whether there are any discernible faults or if any
safety devices are broken / disconnected. Reset the switches and speed
governor to their operating positions.
a) With functioning drive brake: set switch on the control unit of the NBS to
"Open". This electrically releases the NBS emergency brake. Run
emergency rescue with manual release of the drive brake (same as for drives
without NBS).
b) If the drive brake is defective: move the elevator car by briefly opening and
closing the switch on the control unit.
c) With triggered safety gear: pull the elevator car out of the safety gear with
recall. Rest of procedure as described at a).
Note: driving the elevator car with the motor is not possible when the NBS
brake switch is opened. (See type test certificate in Appendix.)
NB: every time the NBS emergency brake is activated, the cause of activation
of the emergency braking device is to be determined before reconnection of
the drive and, if possible, rectified.
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2.3.2 Manual release with installation without power
To manually release the NBS emergency brake, the brake release screws
specifically designed for the purpose (screw head marked red) and their
washers are to be fully screwed into the brake housing. An illustration and
important notes for each drive type can be found in chapter 2.6
NB: the release screws are to be removed from the brake housing before
reconnection of the elevator. A safety circuit means that it is not possible to
move the elevator car with motor drive with a manual released NBS
emergency brake.
2.3.3 Bridging the safety switches for test and adjustment work NB:
intervention in the control system of the elevator system described below
means that essential parts of the safety monitoring are put out of operation.
While this setting is made, no persons may be transported. Bridging the
safety switches is exclusively intended for adjustment and testing purposes,
for example a safety gear test. After completion of the measures, the secure
operating mode is to be established.
The connection terminals in the control unit of the NBS emergency brake are
to be bridged according to installation plan / wiring diagram / drawing.
Emergency bridging to shut down the NBS control system in special cases.
Overall view, see chapter 3.5
After intervention in the control system, the drive can be operated in switch
position "Open" in the unsecured state with opened emergency brake. No
transport of persons with the safety device bridged or brake release
screws mounted!
See also warnings on the NBS control unit!
IMPORTANT INFORMATION
The "EN81-A3-conform" designation (see illustration) only applies to each of the
type-approved components that are marked! The component is part of the protection
device in accordance with DIN EN81-1 chapter 9.11 or DIN EN81-2 chapter 9.13.
The "EN81-A3-conform" designation is not valid for the entire elevator
system!
In the case of frequency converters with the "EN81-A3-conform" designation, there
is the possibility to integrate an internal speed monitoring system (not type-
approved) for the overall system.
Fig.: "EN81-A3-conform" designation
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2.4 NBS control unit
NBS control unit in the operating mode
Fig. 2.4
1
2
3
1 Indicator lamp
2 Operating mode selector switch
3 Device panel
4 Housing cover
4
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2.4.1 NBS control unit with opened housing cover
Fig. 2.4.1
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