ZIEHL-ABEGG ZAS0 User manual

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Content
1 General information ........................................................ 4
1.1 Application .......................................................... 4
1.2 Structure of the operating instructions ..................................... 4
1.3 Target group ......................................................... 4
1.4 Exclusion of liability ................................................... 4
1.5 Copyright ........................................................... 4
2 Safety instructions ......................................................... 4
2.1 eneral ............................................................ 4
2.2 Pictographs ......................................................... 4
2.3 eneral safety instructions .............................................. 5
2.4 Requirements placed on the personnel / due diligence ........................ 5
2.5 Safety instructions for certain operating phases .............................. 6
2.5.1 Mounting ..................................................... 6
2.5.2 Normal operation ............................................... 6
2.5.3 Maintenance and repair ........................................... 6
2.6 Notes on special types of danger ......................................... 7
2.6.1 Electrical energy ................................................ 7
2.6.2 as, dust, steam and smoke ....................................... 7
2.6.3 Oils, greases and other chemical substances ............................ 7
3 Product overview .......................................................... 7
3.1 As-delivered state ..................................................... 7
3.2 Transport ........................................................... 7
3.2.1 eneral . ..................................................... 7
3.2.2 Transport by forklift truck .......................................... 8
3.2.3 Crane transport, lifting the drive: ..................................... 8
3.3 Storage ............................................................. 8
3.4 Disposal / recycling ................................................... 8
4 Mechanical installation .....................................................
4.1 eneral mounting advises .............................................. 8
4.2 Mounting the drive unit ................................................. 9
4.3 Fastening the traction sheave ........................................... 10
4.4 Fastening rope protection clamp ......................................... 10
4.5 Oil filling ............................................................ 11
4.6 Setting the operating brake ............................................. 11
4.7 Setting the brake release monitoring of the operating brake .................... 14
4.8 Micro switch of the brake release monitoring ................................ 14
4.9 Adjusting the safety brake .............................................. 14
4.10 Hand wheel ......................................................... 14
5 Electrical installation ....................................................... 15
5.1 Safety precautions .................................................... 15
5.2 EMC directive ........................................................ 15
5.3 Motor connection ..................................................... 15
5.4 Connection impulse encoder ............................................ 16
5.5 Connection operating brake ............................................. 17
5.6 Connection safety brake (SB/SBE) ........................................ 18
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6 Start-up .................................................................. 19
6.1 Operating conditions ................................................... 19
6.2 First-time start-up ..................................................... 19
6.3 Operation ........................................................... 19
6.4 Drive approval test .................................................... 19
6.5 Pull out of safety gear ................................................. 20
6.6 Emergency evacuation ................................................. 21
6.6.1 Manual emergency evacuation ...................................... 21
6.6.2 Electrical emergency evacuation .................................... 22
7 Faults, causes and remedies ................................................. 22
7.1 eneral ............................................................ 22
7.2 Possible faults on the gearbox ........................................... 22
7.3 Possible faults on the motor ............................................. 23
7.4 Possible faults on the operating brake ..................................... 23
7.5 Possible faults on the safety brake ........................................ 23
Service & maintenance ..................................................... 24
8.1 eneral notes on maintenance .......................................... 24
8.1.1 Cable clamp .................................................. 24
8.2 Inspection intervals .................................................... 25
8.2.1 Oil change .................................................... 26
8.2.2 Oil table ..................................................... 27
8.2.3 Oil quality .................................................... 27
8.2.4 Maintenance of the operating brake .................................. 28
8.2.5 Maintenance of the safety brake ..................................... 28
8.3 Spare parts .......................................................... 29
8.3.1 Replacement of the traction sheave .................................. 31
8.3.1.1 Required tools for the replacement of the traction sheave: .......... 31
8.3.1.2 Dismounting the traction sheave ............................ 31
8.3.1.3 Mounting the traction sheave .............................. 32
8.4 Tightening torques and strength values .................................... 34
9 Enclosure ................................................................ 35
9.1 Technical data ....................................................... 35
9.1.1 Technical data gear ............................................. 35
9.1.2 Protection class ................................................ 35
9.2 Dimension sheets ..................................................... 36
9.3EC(8Declaration of conformity . . . ......................................... 37
9.4 Safety brake ......................................................... 39
9.4.1 SB – safety brake ............................................... 39
9.4.1.1 Operating Instructions SB ................................. 39
9.4.1.2 (8Geclaration of conformity SB ............................ 44
9.4.1.3 E8 type-examination certificate SB . ......................... 45
9.4.2 SBE – safety brake reinforced ...................................... 52
9.4.2.1 Operating Instructions SBE ................................ 52
9.4.2.2 E8Geclaration of conformity SBE ........................... 57
9.4.2.3 E8 type-examination certificate SBE . ........................ 58
9.4.32YHUYLHZW\SHH[DPLQDWLRQFHUWL¿FDWH ............................ 66
9.5 Calculation traction sheave shaft ......................................... 67
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1 General information
1.1 Application
The drives are built according to the state of the art and recognised safety rules and are delivered safe
for operation. Unauthorised modifications that impair the operating safety are not permitted. This also
applies to protective devices which are fitted for touch protection.
The drives exclusive be used for the intended purpose and in a perfectly safe condition. The exclusive
intended purpose of the ZAS is for driving cable lifts. Any other use above and beyond this will be
considered as improper use. ZIEHL-ABE SE will not be liable for any damages resulting from this
or damage resulting from improper use. The intended use also includes observing all the instructions
in this manual and following the start-up instructions, the machine description and performing all the
necessary inspection and maintenance work.
1.2 Structure of the operating instructions
This manual is part of the drive and must always be kept in its vicinity for reference at all times. All
persons involved in mounting, operation, maintenance or repair of the drive must have read and
understood this manual. ZIEHL-ABE SE takes no responsibility for damage or disruption caused
by disregard of this manual.
1.3 Target group
The operating instructions address persons entrusted with planning, installation, commissioning and
maintenance and servicing and who have the corresponding qualifications and skills for their job.
1.4 Exclusion of liability
ZIEHL-ABE SE is not liable for damage due to misuse, improper use or as a consequence of
unauthorized repairs or modifications.
1.5 Copyright
The copyright to this operation instructions is held by ZIEHL-ABE SE, Künzelsau. This operation
instructions must not be wholly or partly reproduced for competitive purposes, used in any unauthor-
ised way or made available to third parties without our agreement.
2 Safety instructions
2.1 General
ZIEHL-ABE SE electric motors are not ready-to-use products and may only be operated after
having been installed into machines or plants and established their safety, depending on the applica-
tion, by protective grating, barriers, constructive devices or other adequate measures (see also
DIN EN 294)!
Installation, connection to the power supply and commissioning may only be performed by qualified
service personnel ! The relevant regulations must be observed!
Planners, manufacturers and operators of system parts or entire systems are responsible for the
correct and safe mounting and a reliable operation.
2.2 Pictographs
Safety instructions are highlighted with warning triangles and are depicted according to the degree of
hazard as follows.
Danger!
eneral hazardous area. Death or severe injury or significant property damage can occur if the
corresponding precautions are not taken!
Warning!
Middle or slight bodily harm is possible if the corresponding precautions are not taken!
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CAUTION!
Caution!
Material damage is possible if the corresponding precautions are not taken.
Danger!
Danger by dangerous, electric voltage! Death or severe injury can occur if the corresponding
precautions are not taken!
Information
Important additional information and advice for user.
Warning!
Danger by hot surface! Slight bodily harm is possible if the corresponding precautions are not taken!
2.3 General safety instructions
Information
"The drive must only be used in a technically perfect condition for the purpose for which it was
intended under consideration for safety and dangers in accordance with the operating manual.
Faults which could impair the safety especially must be eliminated immediately.
"The rules and regulations for the prevention of accidents applicable for the application site must
be observed additionally.
Danger!
"The drive has special attachments. The attachments provided are designed exclusively for
transporting the drive including brake and traction sheave. Do not lift other loads such as bolted
on bases, machine frames, cables lying on top, etc. with the attachments provided. Suitable
lifting gear must be used. Risk of death!
Danger!
Dependent on the workingconditions the surface temperature can be very high. Danger of burns!
"The elevator machine is only to be operated within the ranges dened on the motor type plate!
"Use the machine only in the authorised fashion and only for the tasks and flow media specified in
the order!
"Safety features, for example the brake release monitoring, may not be dismantled, circumvented
or made inoperative!
"A temperature sensor is installed into the winding as motor protection and must be connected!
Danger!
"The traction sheave and hand wheel of the drive are designed without safety covers and may
only be used in a closed room!
"Makes sure that you keep a safe distance away from all rotating (marked yellow) parts when you
are in the machine room.
2.4 Requirements placed on the personnel / due diligence
"Always keep the operating manual close at hand at the application site of the lift.
"The rules for accident protection and environmental protection must be observed and made
familiar to personnel. The same applies for the provision of personal safety equipment.
"This operating manual and especially the chapter "Safety instructions" must have been read
and understood before beginning work on the drive.
"The personnel may not wear long hair loose, loose clothing or jewellery. There is a danger of
injury for example by being caught or pulled in by rotating parts.
"Always keep the safety instructions at, on or near to the drive in a legible condition.
"In case of changes in the drive that are relevant to safety, it must be shut down immediately and
the responsible department/person informed.
"Do not make any changes, additions and conversions to the drive which could impair the safety
without the supplier's permission. This also applies for the installation and setting of safety
devices and welding of supporting parts.
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"Spare parts must always meet the technical requirements specified by the manufacturer. This is
always guaranteed in the case of original spare parts.
"Keep the prescribed intervals or intervals specified in the operating manual for periodic inspec-
tions.
"Workshop equipment suitable for the work is necessary for carrying out maintenance measures.
"Work on the drive may only be performed by reliable, trained or instructed personnel. The
responsibilities for the operation, set-up, maintenance and repair must be clearly allocated.
Observe the legally admissible minimum age.
"Work on electrical equipment of the drive may only be performed by a qualified electrician or an
instructed person under the control and supervision of a qualified electrician in accordance with
electrical engineering rules.
"Installation, connection to the power supply and commissioning may only be performed by
qualified service personnel ! The relevant regulations must be observed!
"Planners, manufacturers and operators of system parts or entire systems are responsible for the
correct and safe mounting and a reliable operation.
2.5 Safety instructions for certain operating phases
2.5.1 Mounting
"Always wear personal safety equipment for installation work because sharp-edged parts can
cause cutting wounds among other things.
2.5.2 Normal operation
"Refrain from working in any way which is detrimental to safety.
"Take measures to ensure that the drive is only operated in a safe, perfect working order.
"Only operate the drive when all the protective devices and safety-related devices are available
and working properly.
"Shut down and secure the lift immediately in the event of malfunctions!
Always have faults eliminated immediately.
2.5.3 Maintenance and repair
"Cordon off the maintenance area widely insofar as necessary.
"Switch off the machine completely and secure it against switching back on unexpectedly for
maintenance and repair work.
"Single parts and larger sub-assemblies must be fastened and secured carefully to lifting gear so
that they do not pose a threat. Only suitable and technically perfect lifting gear and load handling
devices with a suitable load capacity may be used. Do not stand or work underneath suspended
loads.
"When performing overhead installation work, use the climbing aids and work platforms provided
or others with approved safety. Wear fall protection when performing maintenance work at a
great height.
"Keep all handles, steps, railings, podiums, platforms and ladders free from dirt, snow and ice.
"Clean oil, fuel or care agents from the drive and especially the connections and screwed joints
before beginning maintenance or repairs. Do not use aggressive cleaning agents.
"Before cleaning the drive with water or other cleaning agents, close all openings which may not
be penetrated by water, steam and cleaning agents for safety and functional reasons. Electric
motors and switch cabinets are especially at risk.
"After cleaning the closed openings are opened completely.
"Re-tighten screw connections that were loosened during maintenance and repair work, if
necessary with a torque wrench, see chapter “Maintenance and Service – Torques and Strength
Values.”
"Make sure that operating and auxiliary materials are disposed of in a safe and environmentally
friendly way.
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2.6 Notes on special types of danger
2.6.1 Electrical energy
"Only use original fuses with the specified fuse rating. Switch off the drive/machine immediately
in case of faults in the electrical energy.
"The electrical equipment of the drive must be inspected regularly. Defects such as loose
connections or charred cables must be repaired immediately.
"The main switch must be operated to turn on the power to the drive.
2.6.2 Gas, dust, steam and smoke
"Only perform welding, cutting and grinding work in or on the lift when it is expressly permitted
(danger of fire and explosion).
"Dust and inflammable materials must be cleaned from the drive and especially the brakes and it
must be covered with suitable material and sufficient ventilation provided before welding, cutting
and grinding.
" Observe the national regulations, where necessary, for working in confined spaces.
2.6.3 Oils, greases and other chemical substances
"Observe the safety regulations applicable for the product when handling oils, greases and other
chemical substances.
"Handle hot operating and auxiliary media with care (danger of burning or scalding).
3 Product overview
3.1 As-delivered state
"The scope of the delivery is listed in the delivery documents. Check for completeness upon
receipt.
"Be on the alert for any damage to the packaging or the drive.
"Report any damage due to transport to your shipping agent.
"Transport damages are not covered by the ZIEHL-ABE SE guarantee!
3.2 Transport
3.2.1 General
Information
The instructions in the chapter "Safety instructions" must be observed!
"ZIEHL-ABE SE drives are packed by the manufacturer for the types of transport and storage
agreed upon.
"Transport the elevator machine either with the original packing or at the casted eyelets or
eyebolts using adequate hoists.
"Transport motor without any additional load and taking the centre of gravity into account!
"The threads in the shaft ends are not to suit eyebolts to transport the motor.
"Avoid excessive vibration and shocks.
Warning!
"Transport must be carried out under consideration of the safety regulations and the centre of
gravity of the drive.
"Only use lifting gear and load handling devices with sufficient load capacity for transport.
"Transport the drive with reasonable caution. This will avoid injury to persons and damage to the
drive. Bumping the free shaft ends can cause damage to the drive!
Danger!
"The gearbox is filled with oil. Transport and store the drive only in a vertical position!
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3.2.2 Transport by forklift truck
CAUTION!
Caution
"Always grip the transport pallet and never the drive itself when transporting by forklift truck.
Secure the load against tipping.
Warning!
"Beware of protruding or overhanging parts: There is a danger of injury and damage.
3.2.3 Crane transport, lifting the drive:
Danger!
"Never step underneath suspended loads.
"Secure the drive without frame by a rope to the attachments provided. For drives fitted to the
machine frame, fasten the transport rope to the frame.
CAUTION!
Caution!
"Make sure that the hand wheel is not damaged during transport. Ropes or chains may not be
lying on the the hand wheel during transport.
3.3 Storage
"Store the drive in a weather-protected place in the vertical position on a vibration-free wooden
base and cover it over.
"Protect it against dirt and weather influences until its final installation.
"Make sure that the traction sheave is not engaged.
Caution
"Cover the drive especially carefully when it is stored outdoors. Make sure that neither moisture
nor foreign materials can settle on the drive!
"Extreme heat or cold (storage temperature -20 °C to +60 °C) must be avoided!
"High humidity which can lead to condensation must be avoided.
"Avoid aggressive conditions (for example salt spray)!
"Avoid excessive storage times (maximum one year)
"Check the motor bearing for correct function before installing the elevator machine. (Ease the
brakes and move the rotor by hand. Take care if the bearing makes untypical noises)
3.4 Disposal / recycling
Disposal must be carried out professionally and environmentally friendly in accordance with the legal
stipulations.
4 Mechanical installation
4.1 General mounting advises
Installation, electrical connection and start-up only to be performed by trained service personnel.
Observe the machine-related conditions and specifications of the system manufacturer or machine
builder. Damages due to improper use are excluded from the liability.
CAUTION!
Caution!
"When working at or in the lift, the drive and especially the brakes have to be covered and
protected against dust and chips.
Any violation will result in a loss of guarantee on our elevator machine and accessories!
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The following general rules apply:
"The rope pull may be vertical or horizontal.
"At lateral (horizontal) rope pull, the motor housing must be supported on the side. The
fixings scews of the motor must not be loaded with shearing force!
"If the traction sheave should offer more grooves than the actual number of ropes, the ropes
must be applied on the sheave either centred or towards the motor side.
OK OK
"Do not install distorted.
"Do not apply any force (levering, bending). Above all, do not expose the rotor to any heavy
mechanical shocks.
"Carry out the electrical connection in accordance with the enclosed wiring diagram.
"Before starting installation, the drive must be checked for transport damage, especially the
cables have to be checked.
"No welding must be carried out on the drive. The drive must not be used as an earthing point for
welding. Magnets and bearings could be destroyed.
"The cooling-airflow around the motor must not be obstructed.
"To allow the accessibility to the safety brake, hand wheel and impulse encoder when necessary,
make sure the drive is installed far enough away from the wall.
4.2 Mounting the drive unit
"Install the drive according to the machine drawing.
"There are 4 through borings at the base
"The elevator machine has to be fixed with 4 screws M16 - 8.8 at the mounting plate.
Tightening torque M16 - . : 195 Nm
"Fasten the screws crosswise in at least two steps to the required tightening torque.
"The permissible unevenness for the mounting surface is 0.3 mm.
"The mounting surface has to be rigid and robust enough to withstand the forces.
"For the installation, insulating elements should be used to absorb the vibration.
"Align the rope pull of the traction sheave perpendicularly to the cabin fixture or the cabin cable
pulley and the counterweight according to the machine drawing.
"The drive should stand vertically aligned on its base with loaded cables. Compensate for any
unevenness by placing plates underneath the bottom.
Information
"For the arrangement of the insulation elements it must be considered that the total centre of
gravity is within the insulation elements (even when the cabin is suspended on the deflector
roller side.
CAUTION!
Caution!
"If a frame is provided, this must be installed with the enclosed fastening parts according to the
drawing. The strength specifications and the corresponding tightening torques must be
observed.
Warning!
"The drive must be fixed at all four fastening points provided.
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4.3 Fastening the traction sheave
The drive will be delivered with the mounted traction sheave.
The traction sheave with conical hub sits directly on the main axle of the gearbox.
CAUTION!
Caution!
"It is not permitted to knock or hammer on the traction sheave because this could damage the
roller bearings, locking rings or shaft rings.
4.4 Fastening rope protection clamp
The drive is delivered with fitted cable protection brackets (1) and cable protection supports.
Picture 4.4.1: Driving disk with front hand guard
1 Cable protection bracket
3 Cable protection support
Picture 4.4.2: Driving disk with rear hand guard
1 Cable protection bracket
2 Hex socket screw and hex nut
"Set these by swinging the cable protection brackets (1) so that the distance between the cable
and the cable protection bracket on the cable in and cable out side of the driving disk is as small
as possible (1 - 2 mm).
"Set fastening screws (2) and cable protection brackets (1) with a SW 13 open-ended wrench.
"In case of inclined pull, adjust the position of the cable protection brackets (1) to the changed
cable pull direction by suitable installation of the cable protection supports (3) on the gearbox
housing.
CAUTION!
Caution!
"For machines with cable direction of 0-90° over the horizontal (example: machine arrangement
bottom or top opposite), an additional cable protection is necessary which prevents penetration
of foreign bodies between the cable and the groove.
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4.5 Oil filling
Information
The drive is delivered with an oil filling. Check the oil level with the dipstick (1) before start-up.
Picture 4.5.1: earbox housing with dipstick and oil drain screw.
1 Oil dipstick
2 Oil drain screw
"In order to be able to pull out the oil dipstick vertically upwards, the free space above the
machine must be as high as the oil dipstick is long (ZAS0 = 281 mm).
CAUTION!
Caution!
"For gear machines made by ZIEHL-ABE SE only synthetic oils containing active ingredients
for increased corrosion protection and ageing resistance as well as reduced wear in the mixed
friction area in accordance with DIN 51517-3 (DIN 51517-3 - CLP P ISO V 460) are
permissible.
"Never mix synthetic oil with mineral oil!
The synthetic oils have a greater application temperature range than mineral oils and contribute
additionally to higher efficiency of the gearbox. These oils are suitable for an application temperature
range of -20 °C to +80 °C.
See the oil table in the chapter "Maintenance and service – oil change".
4.6 Setting the operating brake
The brake is set in the factory to the maximum spring pre-tension (see table "Setting the spring pre-
tension"). However, you should check the values on site according to the following points.
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Setting the brake and bleeding distance:
Picture 4.6.1: Test dimension rubber ring
1 Rubber ring
2 Anchor plate
3 Washer
4 uts
5 Magnet housing
Picture 4.6.2: Setting the spring pre-tension
9 Brake spring
Picture 4.6.3: Adjusting the brake
6 Brake lever
8 uts
10 uts
Picture 4.6.4: Setting the spring pre-tension
L Spring length
Picture 4.6.5: Adjusting the brake
7 Brake liner
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"Pre-tension the rubber ring (1) between the anchor plate (2) and the disk (3) to 3 mm.
"Lock the nuts (4).
" Connect the brake lever (6) to the amature plate (2).
"Install the brake lever according to the chapter "Maintenance and service – maintenance of the
operating brake".
"The distance between the magnet housing (5) and the anchor plate (2) must be at least 0.5 mm
and 1 mm at the maximum.
"Lock the nut (8).
"Set the brake spring (9) so that a brake liner (7) safely decelerates the cabin at full downward
load (recommended value: approx. 1 floor distance).
"Pre-tension the brake spring (9) to dimension "L" with engaged brake at the maximum (see
table below and picture 4.6.4).
The dimension "L" indicates the distance between the end of the eye bolt (A) and the disk (B).
"Lock the nuts (10).
"The optimum setting of the operating brake is reached when the brake opens fully after pre-
tensioning the compression spring and setting the air gap. Complete opening of the operating
brake is indicated by grinding noises audible between the brake liner and the brake disk when
turning the hand wheel. But at the same time no loud knocking noise should be heard when the
anchor plate is attracted by the magnet housing.
"Mark all nuts with sealing varnish.
"Note: The first four steps must only be performed if the brake lever have been changed
completely.
Gear settings
Lift ma-
chine (type)
Spring wire di-
ameter d [mm]
Magnet
size (type)
Spring
length
L
O
[mm]
Dimension L / braking
torque (factory setting)
[mm] / [Nm]
Dimension L / braking
torque (maximum value)
[mm] / [Nm]
ZAS0 4.0 231 72 12 mm / 83 Nm 14 mm / 99 Nm
ZAS1 5.0 231 88 25 mm / 101 Nm 30 mm / 136 Nm
ZAS2 5.5 232 110 30 mm / 139 Nm 35 mm / 174 Nm
ZAS3 7.0 233 115 47 mm / 277 Nm 50 mm / 312 Nm
Table: Setting the spring pre-tension
Warning!
The maximum admissible spring pre-tension may not be exceeded. There is a danger of
material fracture or malfunctioning of the brake!
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4.7 Setting the brake release monitoring of the operating brake
The brake release monitoring is set at the factory. A function check should be performed on site. The
brake release monitoring serves to check the function of the operating brake and not to monitor the
wear of the brake lever with integrated brake liner.
Picture 4.7.1: Brake release monitoring
1 Micro switch
2 Switching plate
3 Setting screw
Picture 4.7.2: Detail brake release monitoring: Setting
screw and micro switch
The brake release monitoring is mounted on the bottom of the brake lever.
"The optimum switching point must be adjusted by the setting screw (3).
Setting the switching point
"The switching point should not be set until the spring pre-tension and the operating brake have
been properly set.
"If the pre-tension is changed or the anchor plate is realigned, the switching point of the brake
release monitoring must also be realigned.
"In the fine adjustment of the setting screw, the screw head should touch the button of the micro
switch but not yet trigger it when there is power to the brake.
4. Micro switch of the brake release monitoring
Picture 4.8.1: Micro switch
2
4
1
Picture 4.8.2: Wiring diagram micro switch
1 black
2 grey
3 blue
The micro switch is protected by the retaining plate against damage due to increasing pressure of the
setting screw.
Warning!
"The setting screw can touch the retaining plate of the micro switch when it is worn. Loss of
braking torque possible!
"Due to wear on the brake liners, the distance between the setting screw and the micro switch
must be checked once a year and readjusted if necessary.
4.9 Adjusting the safety brake
The safety brake is optionally available.
The brake is delivered with preset micro switch and air gap! Further information can be found in the
appendix "safty brake - Operating Manual SB or safty brake - Operating Manual SBE".
4.10 Hand wheel
"Mark a direction arrow (up/down) clearly on the hand wheel according to the direction of travel.
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5 Electrical installation
5.1 Safety precautions
Mounting, electrical connection and commissioning are only to be performed by trained service
personnel. Adhere to all machinery-related requirements and specifications supplied by the system
manufacturer or machine builder.
5.2 EMC directive
The adherence to the EMC Directive 2004/108/EC only pertains to this product if controllers tested
and recommended by ZIEHL-ABE SE are used, which have been installed in accordance with the
corresponding controller description and in line with the EMC. If the product is integrated unprofes-
sionally into a system or complemented by and operated with components (e. g. regulators and
controllers) which have not been recommended, the operator of the complete system alone shall be
responsible for adhering to the EMC Directive 2004/108/EC.
5.3 Motor connection
CAUTION! "The drive must not be connected to the mains supply without a controller!
"The motor is permitted to be used at frequency inverters with a maximum DC-link voltage
of < 750 V DC!
"A screened motor cable has to be used. The screen has to be connected on both ends.
The maximum motor cable length is 25 m.
"There is a wiring diagram in the motor junction box which shows how to connect the motor and
the PTC thermistor.
"The motor is protected by PTC-resistors. The connection has to be made through a PTC resistor
controller unit!
"Make sure that the motor contactors are switched load-free on the control side. The contactor
contacts could be damaged when switching under load, especially at rpm 0. Therefore the
controller enable should always be switched off before or together with the main con-
tactors.
Danger!
"This connection must be made by a specialist according to the pertinent safety regulations.
"The pertinent installation and operating regulations as well as the normal national and
international regulations must be observed.
"See the data on the rating plate!
"See the circuit!
Information
"Adapt the power cable cross sections to the reference current value.
"Provide strain relief for the connecting leads.
"Always connect the protective earth according to DIN VDE 0100 to the marked PE terminal.
"Use the original seal for connecting the junction box.
"Seal unnecessary openings dust and water tight.
CAUTION!
Caution!
"No voltage greater than 2.5 V may be applied to the PTC thermistor!
"Damp windings can lead to creep currents, sparkovers and disruptive discharges. The insulation
resistance of the stator winding must be at least 1.5 megaohms in 220 V - 1000 V motors,
measured at a winding temperature of 20 °C. The winding must be dried at lower values.
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Mechanical connection conditions
Motor rated current
[A]
Terminal board Thread
up to 10 M6 M20
> 10 - 20 M6 M25
> 20 - 25 M6 M32
> 25 - 35 M6 M32
> 35 - 50 M8 M40
> 50 - 63 M8 M40
> 63 - 80 M8 M50
> 80 - 100 M10 M50
> 100 - 125 M10 M63
> 125 - 160 M12 M63
changing of the direction of rotation by
exchanging of 2 phases
Drehrichtungsänderung durch vertauschen
von 2 Phasen
U1
U1
W1
W2
V2
V1 U2
V1
W1
W2
U2
V2
L1
L3
L2
L1
L2
L3
M38=312-001/002
Picture 5.3.1: Wiring diagram motor
permissible tightening torque for bolts M6: 3 m
permissible tightening torque for bolts M8: 6 m
permissible tightening torque for bolts M10: 10 m
permissible tightening torque for bolts M12: 15,5 m
> 160° C
P1 P2
Thermistor maximum
test voltage 2,5 V
Kaltleiter max.
Prüfspannung 2,5 V
S4=007-041
Picture 5.3.2: Wiring diagram motor circuit breaker
5.4 Connection impulse encoder
CAUTION!
Caution!
"Never touch the connection pins at the impulse encoder or encoder cable. The electronic may be
destroyed by static discharge.
"The impulse encoder contains electrostatically sensitive components You must discharge your
own body before touching them. This can be done, for example, by touching a conductive,
earthed object (e.g. bare metal switch cabinet parts) immediately before.
"Use ZIEHL-ABE SE impulse encoder with cable and suitable connecting plug.
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5.5 Connection operating brake
Connection data with series circuit of 2 magnets.
Excitation Holding
Voltage 196 98 V
output 436 109 W
Current 2,22 1.11 A
"Control of the operating brake with fast-switching rectifier The fast-switching rectifier must be
installed in the switch cabinet.
The operating brake junction box contains a wiring diagram for connecting the operating brake and
the brake release monitoring.
Picture 5.5.1: Wiring diagram operating brake and brake release monitoring
Picture 5.5.2: Circuit example for overexcitement type SLC
1 Connection service brake
2 Rectifier with overexcitement
3 Contacts dependent on the safety circuit, use main
contacts
4 Contacts brake contactor, use main contacts
Picture 5.5.3: Circuit example for overexcitement type Roba-
switch
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5.6 Connection safety brake (SB/SBE)
"The safety brake is operated with direct current. The polarity has no effect on the functionality.
"Control of the safety brake with fast-switching rectifier The fast-switching rectifier must be
installed in the switch cabinet.
"The connection data can be found in the enclosure "Safety Brake – Operating Instructions SB or
Safety Brake – Operating Instructions SBE"
The safety brake junction box (SB/SBE) contains a wiring diagram for connecting the safety brake
(SB/SBE) and the brake bleeding monitor.
Picture 5.6.1: Wiring diagram safety brake and brake
bleeding monitor Picture 5.6.2: Safety brake
1 Connection box safety brake (SB/SBE)
Picture 5.6.3: Circuit example for overexcitement type SLC
1 Connection box safety brake (SB/SBE)
2 Rectifier with overexcitement
3 Contacts dependent on the safety circuit, use main
contacts
4 Contacts brake contactor, use main contacts
Picture 5.6.4: Circuit example for overexcitement type Roba-
switch
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6 Start-up
6.1 Operating conditions
"The drive must be installed in a not free accessible machine room or a closed hoistway.
"Be aware of the protection class specified on the name plate.
"Do not operate the motor in an explosive atmosphere.
"The ambient temperature may be within 0 °C and +40 °C.
"Maximum permissible humidity 95 %, not wet.
"Reduced motor output when installed 1000 m above sea level by 1 % per 100 m.
"Please contact ZIEHL-ABE SE in case of orders deviating from the corresponding applica-
tion conditions.
6.2 First-time start-up
Before first-time start-up, check the following:
"Installation and electrical connection have been properly completed.
"Safety devices are installed.
"Installation waste and foreign bodies have been removed from the danger area.
"The protective earth is connected.
"Motor protection correctly connected and operative.
"Cable entries closed.
"The oil drain opening has been properly sealed.
"Mounting, installation position and accessories are o.k.
"The gearbox housing is secured against moving by stops and set screws in case of lateral or
inclined cable pull.
"Connection data corresponds to the data on the name plate.
Warning!
"Separately delivered traction sheave and/or cable pulley must be installed properly (see chapter
"Maintenance and service – changing the traction sheave").
"If the machine has been dismantled for weight, transport or space reasons, the dismantled parts
must be reassembled in their original state and the fastening parts secured with the appropriate
tightening torque (see chapter "Maintenance and service – tightening torques and strength
values").
6.3 Operation
During operation, the drive must be checked for:
"increased operating temperature
"unusual noises
"possible oil leaks
CAUTION!
Caution!
"If irregularities are discovered during operation, the drive must be shut down immediately and
the cause of the fault determined (see chapter "Faults, causes and remedies").
The fault table lists possible faults, their causes and suggested remedies. If the cause cannot be
found or it is not possible to repair the fault by your own means, please consult the after-sales service.
CAUTION!
Caution!
"If the safety brake (if available) is opened before starting a ride, no further ride may be started.
An appropriate signal must be sent to the lift control by the micro switch on the safety brake.
6.4 Drive approval test
Half load test
The lift must be easily movable in both directions by the hand wheel when the brake is open.
Half load test (alternative):
With half load the motor current has to be measured in up and down direction. Mostly this is possible
at the VVVF. (Please see operating instructions of your VVVF). The measured currents should not
divert by more than 10 %.
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Testing the brake according EN 1-1
It is recommended to perform the tests when the car position is about in the middle of the shaft.
If a safety brake is additionally available, this must be bled for testing the operating brake. This is
possible with the bleeding screws provided.
Overload
The test shall be carried out whilst the car is descending at rated speed with 125 % of the rated load
and interrupting the supply to the motor and the brake.
Caution! To avoid overloading of the gear tooth system, the test load of 125 % may not be applied in
upward direction.
Failure of one brake circuit:
The test shall be carried out whilst the car is descending at rated speed with rated load.
To simulate failure of the brake circuit, it must be possible to keep the brake circuits open mechanically
separately even when opening the safety circuit. A special lever for hand releaser (1) is available for
this.
Picture 6.4.1: Bleeding brake circuits independently of each other
4 Levers for hand release
While performing this test the elevator has to be observed. If there should be no visible deceleration,
the open brake circuit has to be closed immediately! The elevator has to be put out of service and the
brake to be checked!
Testing the safety brake (if available)
As a protective device for the upward moving cabin against overspeeding:
The test is conducted with an empty cabin in upward direction. The operating brake must be kept
mechanically open for this test.
As protection against unintended movement of the cabin (A3):
Please follow the lift manufacturer’s instructions!
Testing the micro switches
According to their use as a make or break contact one microswitchcontact at a time has to be opened
or short circuited.
If there is a wrong or missing micro switch signal, a travel must not be started.
6.5 Pull out of safety gear
If the lift car loaded with rated load is caught by the trap due to a fault or during the TÜV inspection,
the trap device could be fairly tight. In such a case it is quite possible that the drive torque is
insufficient to pull the lift car out of the trap.
A person may assist additionally at the hand wheel.
A block and tackle or similar must be used in case of insufficient drive torque or insufficient drive
capacity of the cables.
It is advisable to have a suitable block and tackle on hand for the TUEV inspection.
Note
Note that an overload in the car leads to an increase in the motor torque. 25 % overload results in
150 % of the required motor torque! As regulated drives are normally designed for a maximum torque
of ca. 170 - 200 %, only slight reserves are available during such special cases.
For that reason it is recommended, just as described in EN 81-1 Appendix D.2 j), to perform a TÜV
trap inspection in the door area so that the car can be unloaded there to relieve the drive.
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