ZIEHL-ABEGG ZA top Series User manual

Art.-Nr. 01013509-GBA-TIA21_08-GB 2021/21 Index 001
ZA top
SM225.60B
SM250.45B
Replacement of the brake
Assembly instructions
Store for future use!

Content
1 General information ........................................................ 3
1.1 Structure o the assembly instructions ..................................... 3
1.2 Target group ......................................................... 3
1.3 Exclusion o liability ................................................... 3
1.4 Copyright ........................................................... 3
2 Safety instructions ......................................................... 3
2.1 General ............................................................ 3
2.2 Pictographs ......................................................... 3
2.3 Requirements placed on the personnel / due diligence ........................ 3
2.4 General sa ety instructions .............................................. 4
3 Safety precautions ......................................................... 4
4 Versions of the brake ....................................................... 4
Scope of delivery ..........................................................
6 Required tool/equipment .................................................... 6
6.1 Tools: .............................................................. 6
6.2 Equipment: .......................................................... 6
7 Dismounting the brake ..................................................... 7
8 Mounting the brake ........................................................ 10
9 Functional test on microswitch/inductive proximity switch for release monitor ........ 1
10 Adjustment of the microswitch/inductive proximity switch for release monitor ........ 16
11 Disposal / recycling ........................................................ 16
Assembly instructions – model series ZAtop
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1 General information
1.1 Structure of the assembly instructions
"
The assembly instruction does not replace the original operating instructions o the motor or
requency inverter!
"
The original operating instructions has to be always available!
1.2 Target group
The assembly instructions address persons entrusted with planning, installation, commissioning and
maintenance and servicing and who have the corresponding qualifications and skills or their job.
1.3 Exclusion of liability
ZIEHL-ABEGG SE is not liable or damage due to misuse, incorrect use, improper use or as a
consequence o unauthorized repairs or modifications.
1.4 Copyright
This assembly instructions contains in ormation protected by copyright.ZIEHL-ABEGG SEThe assem-
bly instructions may be neither completely nor partially photocopied, reproduced, translated or put on
a data medium without prior explicit consent rom. In ringements are liable or damages.
2 Safety instructions
2.1 General
ZIEHL-ABEGG SE spare parts are not ready-to-use products and may only be operated when they
have been installed on an elevator machine and their sa ety has been assured using guard grilles,
barriers, structural attachments or other appropriate measures, depending on the application (see
also DIN EN ISO 13857)!
2.2 Pictographs
Sa ety instructions are highlighted with warning triangles and are depicted according to the degree o
hazard as ollows.
Danger!
General hazardous area. Death or severe injury or significant property damage can occur i the
corresponding precautions are not taken!
Information
Important additional in ormation and advice or user.
2.3 Requirements placed on the personnel / due diligence
Danger!
"
Installation, connection to the power supply and commissioning may only be per ormed by qualified
service personnel! The relevant regulations must be observed!
"
Persons entrusted with the planning, installation, commissioning and maintenance and servicing in
connection with the elevator machine must have the corresponding qualifications and skills or
these jobs. Based on their training, knowledge and experience as well as knowledge o the relevant
standards, they must be able to judge the work trans erred to them and be able to recognize
possible hazards.
"
In addition, they must be knowledgeable about the sa ety regulations, EU directives, rules or the
prevention o accidents and the corresponding national as well as regional and in-house
regulations. Personnel undergoing training, instruction, or on apprenticeship may only work on the
elevator machine under the supervision o an experienced person. This also applies to personnel in
general training.
"
Comply with the legal minimum age.
Assembly instructions – model series ZAtop General in ormation
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2.4 General safety instructions
Danger!
"
The elevator machine has attachment points: integrally cast eyelets or screwed-on eye bolts, eye
plates or steel cable loops. The attachment points are designed exclusively or transporting the
elevator machine including brake and traction sheave. Do not li t other loads such as bolted on
components, ropes lying on top, etc. with the attachment points. Suitable li ting gear must be used.
Danger!
Warning of hand injuries!
"
Risk o injury rom reaching into the rope guard.
"
Do not carry out any activities during operation.
"
Only per orm maintenance work on the drive when stopped!
"
I the elevator machine is not energised, no electric torque is available. Releasing the brakes can
cause uncontrolled acceleration o the elevator.
We recommend short-circuiting the windings o the de-energised elevator machine to generate a
brake torque dependent on the speed.
In the event o a short-circuit, a short-circuit current o at least the level o the rated current is
flowing.
The windings may not be short-circuited when the elevator machine is energised.
3 Safety precautions
Danger!
In case sa ety precautions are not taken:
✓Can it lead to death or severe injury or significant property damage!
✓Brake mal unction may result!
On installed drives, be ore replacement o the brake, ollowing sa ety measures have to be taken:
"
Counterweight has to rest on the bu er.
"
Cabin has to be suspended.
✓Thereby the ropes are unburdened!
4 Versions of the brake
Figure 4-01 Figure 4-02 - Brake with a mechanical hand release system
A brake with a mechanical hand release system is available optionally. The hand release
system cannot be fitted later. The complete brake must be replaced to retrofit the hand release
system.
Assembly instructions – model series ZAtop Sa ety precautions
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Scope of delivery
•Brake
•Brake assembly kit (optional):
Brake assembly kit 207 VDC - Article number 70029992
Brake assembly kit 24 VDC - Article number 70029993
Figure 5-01
Figure 5-02 - Brake bodies 1 in version with hand release
Assembly instructions – model series ZAtop Scope o delivery
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Pos. Count Designation
4 2 varistor
82Cover
11 3 Socket cap screw M16 x 190
13 1 Brake body 2
On the design with levers for hand release, the following parts are
supplied loose:(see Figure 5-02)
13A - 2 x 4 Steel ball
13B - 2 x Connection piece
13C - 2 x Axial needle roller and cage assembly
13D - 2 x Adjusting nut
13E - 2 x Set screw
14 1 Brake rotor 2
15 3 Socket cap screw M16 x 110
16 1 Brake body 1
The following parts are pre-assembled on the design with levers for
hand release:(see Figure 5-02)
16A - 2 x Tension washer
16B - 2 x Hexagon head bolt M12 x 200
16C - 2 x Adjusting nut
17 1 Brake rotor 1
18 2 O-ring
21 2 Hand release rod
22 4 Wire-end sleeves
23 1 Micro-active cloth
24 1 Feeler gauges, 13-part
25 1 Anti tamper paint 20 ml
26 1 Technical vaseline 50 g
27 1 Quick cleaner LOCTITE® 7063 400 ml
The corresponding brake assembly kits, item 4 and items 22 to item 27, are available as an option and
are supplied in a separate olding box:
Assembly kit brake 207 Vdc - Article number 70029992
Assembly kit brake 24 Vdc - Article number 70029993
6 Required tool/equipment
6.1 Tools:
•ZIEHL-ABEGG tool set article number 70027450
•Wire cutter
•Cable stripper
•Crimper
•Slotted screwdriver 0.6 x 3.5
•Screw wrench size 13
•Allen wrench size 14
•Torque wrench or a tightening torque o 200 Nm with allen wrench size 14
•Torque wrench or tightening torque 23 Nm, size 13
•Li ting eye bolt M12
6.2 Equipment:
•Bearing grease
•Threadlocker LOCTITE® 243
Assembly instructions – model series ZAtop Required tool/equipment
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7 Dismounting the brake
During the mounting as well as the dismounting also the operating manual o the brake has to be
observed.
Risk of death!
When dismounting the brake make sure that the cabin and the counterweight are
mechanically secured against movement!
Attention!
"
Due the electrostatic discharge the absolute encoder can be destroyed! Do not touch the pins o the encoder
cable as well as the electronics o the absolute encoder!
"
You must discharge your own body be ore touching. This can be done, or example, by touching a conductive,
earthed object ( or example bare metal switch cabinet parts) immediately be ore.
Figure 7-01 Figure 7-02
1. Remove cover rom connection box (1).
2. Disconnect the electrical connection (2) o both brake bodies.
3. Care ully remove strain relie s (3) o all connecting cables with wire cutters.
4. Cut o varistors (4).
Figure 7-03 Figure 7-04
5. Feed all connecting cables (5) out o the terminal box.
6. Remove the cable ties at the brake cables.
7. Unscrew the hexagon head bolt M8 x 16 - 8.8 (6) using a size 13 spanner and remove the fixing
plate (7) with terminal box.
8. Remove the covers (8).
Assembly instructions – model series ZAtop Dismounting the brake
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Figure 7-05 Figure 7-06
9. Dismounting absolute encoder (9), see "Replacement o the absolute encoder A-TIA17_02-..."
10. Caution: Due to the great weight o the brake body, we recommend you to secure and change
the brake body by using an eye bolt M12 (10) and appropriate li ting gear.
11. Completely unscrew one o the socket cap screws M16 x 190 (11) with a size 14 socket head
wrench
12. Replace the socket cap screw M16 x 190 (11) with a threaded bolt M16 (12) rom the
ZIEHL-ABEGG toolkit, article number 70027450.
Figure 7-07 Figure 7-08
13. Fasten the threaded bolt M16 (12) by hand.
14. Replace the two remaining socket cap screws M16 x 190 (11) in turn with a threaded bolt M16 (12)
rom the ZIEHL-ABEGG toolkit, article number 70027450.
15. Fasten the threaded bolts M16 (12) by hand.
Figure 7-09 Figure 7-10
16. Secure the brake body 2 (13) to the eye bolt (10) using suitable li ting gear and remove.
ATTENTION! Weight of brake body approx. 0 kg!
17. Detach the brake rotor 2 (14) rom the toothed hub. The brake rotor may only be detached by
hand.
ATTENTION! Do not use screwdrivers to release the brake rotor.
The screwdrivers damage the riction lining. Damaged riction linings may not be re-fitted!
Assembly instructions – model series ZAtop Dismounting the brake
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Figure 7-11 Figure 7-12
18. Caution: Due to the great weight o the brake body, we recommend you to secure and change
the brake body by using an eye bolt M12 (10) and appropriate li ting gear.
19. Completely unscrew the 3 socket cap screws M16 x 110 (15) gradually in turn with a size 14
socket head wrench.
20. Secure the brake body 1 (16) to the eye bolt (10) using suitable li ting gear and remove.
ATTENTION! Weight of brake body approx. 0 kg!
Figure 7-13 Figure 7-14
21. Detach the brake rotor 1 (17) rom the toothed hub. The brake rotor may only be detached by
hand.
ATTENTION! Do not use screwdrivers to release the brake rotor.
The screwdrivers damage the riction lining. Damaged riction linings may not be re-fitted!
22. Remove the o-ring (18) rom the toothed hub (19).
Assembly instructions – model series ZAtop Dismounting the brake
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8 Mounting the brake
During the mounting as well as the dismounting also the operating manual o the brake has to be
observed.
Risk of death!
Incorrect mounting can have a detrimental impact on the braking action.
Attention!
"
Never touch the connection contacts on the position absolute encoder or on the cable! The electronics can be
destroyed by static electricity.
"
You must discharge your own body be ore touching. This can be done, or example, by touching a conductive,
earthed object ( or example bare metal switch cabinet parts) immediately be ore.
Figure 8-01 Figure 8-02
1. Make sure that the brake sur ace (20) on the motor housing and the toothed hub (19) on the drive
sha t are ree o dirt and grease. Clean with a micro active cloth (23) and LOCTITE® 7063 (27)
rapid cleaner rom the “Brake assembly kit” (article number 70029992/70029993).
2. Lightly grease the first o-ring (18) with technical Vaseline (26) and insert in the machine wall side
groove in the toothed hub (19).
Figure 8-03 Figure 8-04
3. Make sure that the riction lining o brake rotor 1 (17) is ree o dirt and grease. Clean with a micro
active cloth (23) and LOCTITE® 7063 (27) rapid cleaner rom the “Brake assembly kit” (article
number 70029992/70029993).
4. Slide brake rotor 1 (17) over the o-ring (18) onto the toothed hub (19) by hand exerting only light
pressure.
ATTENTION! Make sure that the long rotor collar is acing away rom the machine wall.
5. Make sure that the gear teeth engage easily.
6. O-ring may not be damaged.
7. Lightly grease the second o-ring (18) with technical Vaseline (26) and insert in the remaining ree
groove in the toothed hub (19).
Assembly instructions – model series ZAtop Mounting the brake
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Figure 8-05 Figure 8-06
8. Caution: Due to the great weight o the brake body, we recommend you to secure and change
the brake body by using an eye bolt M12 (10) and appropriate li ting gear.
9. Slide brake body 1 (16) over the threaded bolts up to the motor housing
ATTENTION! Weight of brake body approx. 0 kg!
10. Design with hand release:
Slide brake body 1 (16) with the pre-assembled hand release components - tension
discs (16A)/hexagon head bolts (16B)/adjusting nuts (16C) - over the threaded bolts up to
the motor housing
ATTENTION! Weight of brake body approx. 0 kg!
Figure 8-07 Figure 8-08
11. Screw on brake body 1 (16) by hand with the socket cap screws M16 x 110 (15)
12. Uni ormly asten the 3 socket cap screws M16 x 110 (15) gradually in turn using a torque wrench
with size 14 socket head wrench.
Tightening torque: 200 Nm
13. Endue the socket cap screws with anti tamper paint (25).
14. Make sure that the riction lining o brake rotor 2 (14) is ree o dirt and grease. Clean with a micro
active cloth (23) and LOCTITE® 7063 (27) rapid cleaner rom the “Brake assembly kit” (article
number 70029992/70029993).
15. Slide the brake rotor 2 (14) with the O-ring (18) onto the toothed hub (19) by hand by exerting
light pressure.
ATTENTION! Make sure that the long rotor collar is acing towards the brake body 1.
16. Make sure that the gear teeth engage easily.
17. O-ring may not be damaged.
Assembly instructions – model series ZAtop Mounting the brake
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Figure 8-09
18. Slide on the brake body 2 (13).
Figure 8-10 Figure 8-11
19. Individually unscrew the threaded bolts M16 (12).
20. Replace each o the threaded bolts M16 (12) with a socket cap screw M16 x 190 (11).
21. Screw on brake body 2 (13) by hand with the socket cap screws M16 x 190 (11)
22. Uni ormly asten the 3 socket cap screws M16 x 190 (11) gradually in turn using a torque wrench
with size 14 socket head wrench.
Tightening torque: 200 Nm
23. Endue the socket cap screws with anti tamper paint (25).
24. Unscrew the li ting eye bolt M12 (10).
Assembly instructions – model series ZAtop Mounting the brake
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Figure 8-12 Figure 8-13
25. Check the air gap "A" between the coil carrier and armature disk when de-energised:
Air gap: 0.40 mm ≤ "A" ≤ 0.60 mm
See brake operating instructions in the appendix to the original operating instructions.
✓If the air gaps are outside the tolerance, please contact our customer service.
26. On the brake design with hand release system, lightly grease
2 x 4 steel balls (13A) (with bearing grease) and insert in the counterbores in the brake
body 2 spool carrier (13).
27. Slide the two connecting pieces (13B) onto the hexagon head bolts (16B) with the counterbores
first.
28. Lightly grease the axial needle cages (13C) with bearing grease and attach to the centring collar
o the adjusting nuts (13D) and then screw the adjusting nuts (13D) onto the hexagon head
bolts (16B) with the axial needle cages (13C) first until they are in contact with the connecting
pieces (13B).
Figure 8-14 Figure 8-15
29. Adjust the hand release system:
Slide the adjusting plate 1.8 mm (24) between an adjusting nut (16C) and armature
disk (14).
30. Screw the adjusting nut (13D) onto the hexagon head bolt (16B) until the adjusting plate
clamps 1.8 mm (24) and then turn back until the adjusting plate (24) can be removed. The
hexagon head bolt (16B) can be held in place using the slot on the end o the screw.
31. Coat the threaded pin (13E) with LOCTITE® 243, screw into the adjusting nut (13D) with
tightening torque 4 Nm and thus clamp the adjusting nut (13D) on the hexagon head bolt (16B).
32. Repeat the adjustment o the hand release system on the opposite side.
33. Check the function of the hand release system:
Insert the two hand release bars (21) into the connecting pieces (13B) and move around
4 ° to the left or right.
The required hand release force is around 200 N per lever.
34. The sha t must now rotate reely.
Assembly instructions – model series ZAtop Mounting the brake
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Figure 8-16
35. Mounting absolute encoder (9), see "Replacement o the absolute encoder A-TIA17_02-..."
Figure 8-17 Figure 8-18
36. Tighten the cover hoods (8).
37. Screw on the fixing plate (7) with the terminal box by hand using the hexagon head bolt M8 x 16 -
8.8 (6)
38. Fasten the hexagon head bolt M8 x 16 - 8.8 (6) with a size 13 torque wrench.
Tightening torque: 23 Nm
39. Bundle the connection cables (5) o the magnet coils and the release monitoring and lead it into
the terminal box (1).
Assembly instructions – model series ZAtop Mounting the brake
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Figure 8-19 Figure 8-20
Brake wiring diagram with micro switch
Figure 8-21
1 Brake release monitoring
2Brake
3 Shown with currentless brake
Brake wiring diagram with inductive proximity
switch
Figure 8-22
1 Brake release monitoring
2Brake
3 Minimum strength 2 mA DC
4 Operating oltage range 10 - 30 V DC
5 Shown with currentless brake
40. Connect the magnet coils, the release monitoring and varistors (4) according to the wiring
diagram (28), see Figure 8-21 and Figure 8-22, inside the top cover o the junction box (1).
41. Fit strain relie s (3).
42. Close the cover (1) o the junction box.
43. Per orm brake test (see chapter "Brake operating instructions - brake test" in the appendix at the
original operating instructions).
44. Carry out the alignment o the absolute encoder (9) corresponding to the original operation
instructions o the requency inverter.
9 Functional test on microswitch/inductive proximity switch for re-
lease monitor
A ter mounting o the brake, a unctional test must be per ormed on the micro switches/inductive
proximity switches (see chapter "Brake operating instructions - release monitor" at the original operat-
ing instructions).
I the unction is not available, please check the causes that may prevent the actuation o the micro
switches/inductive proximity switches (see chapter "Brake operating instructions - release monitor" in
the appendix). The micro switches/inductive proximity switches will otherwise have to be readjusted
(see the chapter "Assembly and adjustment o release monitor with micro switches or inductive
proximity switches" in the appendix at the original operating instructions).
Assembly instructions – model series ZAtop Functional test on microswitch/inductive proximity switch or release
monitor
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10 Adjustment of the microswitch/inductive proximity switch for re-
lease monitor
Figure 10-01 Figure 10-02
Adjustment o the microswitches/inductive proximity switches is only necessary i they are not working
correctly.
The microswitches/inductive proximity switches are located on top o the brake (see arrow).
ATTENTION! It must be ensured that the appropriate microswitches/inductive proximity
switches are selected for the magnet to be adjusted.
Adjustment o the release monitor with microswitches/inductive proximity switches, see “Assembly
and adjustment o release monitor with microswitches or inductive proximity switches” chapter in the
appendix at the original operating instructions.
11 Disposal / recycling
Disposal must be carried out pro essionally and environmentally riendly in accordance with the legal
stipulations.
Assembly instructions – model series ZAtop Adjustment o the microswitch/inductive proximity switch or release
monitor
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Assembly instructions – model series ZAtop Adjustment o the microswitch/inductive proximity switch or release
monitor
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Assembly instructions – model series ZAtop Adjustment o the microswitch/inductive proximity switch or release
monitor
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Assembly instructions – model series ZAtop Adjustment o the microswitch/inductive proximity switch or release
monitor
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© by Ziehl-Abegg - - 01013509-GB - 2021/21 - - Subject to technical changes
Customer Service
phone [phone]
ax [phone]
[email protected]
Headquarters
ZIEHL-ABEGG SE
Heinz-Ziehl-Straße · 74653 Künzelsau
Germany
phone [phone] · ax [phone]
[email protected] · www.ziehl-abegg.com