ZIEHL-ABEGG ZA top SM160.40B/S User manual

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Original operating instructions
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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
3 Product overview .......................................................... 6
3.1 Operational area ...................................................... 6
3.2 Transport ........................................................... 6
3.3 Storage ............................................................. 6
3.4 Disposal / recycling ................................................... 6
4 Mechanical installation ..................................................... 6
4.1 eneral mounting advises .............................................. 6
4.2 Patent situation ....................................................... 7
4.3 Mounting the drive unit ................................................. 7
4.4 Fastening the brake ................................................... 7
4.5 Fastening rope protection clamp ......................................... 8
Electrical installation ....................................................... 8
5.1 Safety precautions .................................................... 8
5.2 EMC directive ........................................................ 8
5.3 Motor connection ..................................................... 8
5.4 Absolute encoder connection ............................................ 9
5.5 Brake connection ..................................................... 10
5.5.1 Triggering of the brakes .......................................... 11
6 Start-up .................................................................. 11
6.1 Operating conditions ................................................... 11
6.2 First-time start-up ..................................................... 11
6.3 Drive approval test .................................................... 12
6.3.1 Half load test .................................................. 12
6.3.2 Testing the brake according EN 81-1 ................................. 12
6.4 Pull out of safety gear ................................................. 13
6.5 Emergency evacuation ................................................. 14
6.5.1 Manual emergency evacuation ...................................... 14
6.5.2 Electrical emergency evacuation .................................... 14
7 Faults and remedy ......................................................... 1
8 Service and maintenance ................................................... 1
8.1 eneral notes on maintenance .......................................... 15
8.2 Inspection intervals .................................................... 16
8.2.1 Checking the air gap ............................................. 16
Original operating instructions
ZAtop – model series SM160.30B/40B
A-TBA12_01- B  Part.-No. 01008166- B (EU-BD 845)
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8.3 Spare parts .......................................................... 16
8.3.1 Replacement of the absolute encoder ECN1313/ERN1387 .................. 17
8.3.1.1 Required tool for the replacement of the absolute encoder: .......... 17
8.3.1.2 Dismounting the absolute encoder ........................... 17
8.3.1.3 Mounting the absolute encoder ............................. 18
8.3.2 Replacement of the brake ......................................... 19
8.3.2.1 Required tool for the replacement of the brake: .................. 20
8.3.2.2 Dismounting the brake ................................... 20
8.3.2.3 Mounting the brake ..................................... 23
8.3.2.4 Check the micro switches for the release monitoring .............. 25
8.3.2.5 Adjusting the micro switches for the release monitoring ............ 26
8.3.3 Replacement of the traction sheave .................................. 27
8.3.3.1 Required tools for the replacement of the traction sheave: .......... 27
8.3.3.2 Dismounting the traction sheave ............................ 27
8.3.3.3 Mounting the traction sheave .............................. 28
8.3.4 Fastening bearing brackets ........................................ 29
9 Enclosure ................................................................ 29
9.1 Technical data ....................................................... 29
9.2 Dimension sheets ..................................................... 30
9.3 ECEU eclaration of conformity ............................................ 34
9.4 Operating instructions brake ............................................. 35
9.5 EU eclaration of conformity of the brake .................................. 50
9.6 EU type-examination certificate . . . . . ..................................... 52
9.16WDWHPHQW RQ W\SH H[DPLQDWLRQ FHUWLILFDWHV ............. 59
9.8 Calculation of tripping speed ............................................ 59
9.9 Shaft calculation ...................................................... 60
Original operating instructions
ZAtop – model series SM160.30B/40B
A-TBA12_01- B  Part.-No. 01008166- B (EU-BD 845)
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1 General information
1.1 Application
The ZAtop is designed as a gearless drive for traction sheave rope elevators.
No other drive applications are permitted without the disengagin by the ZIEHL-ABEGG SE
company!
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. 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 ISO 13857)!
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 bodilies harm is possible if the corresponding precautions are not taken!
CAUTION!
Caution!
Material damage is possible if the corresponding precautions are not taken.
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ZAtop – model series SM160.30B/40B eneral information
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Compliance with the following instructions is mandatory to ensure the functionality and safety of the
product. If the following instructions given especially but not limited for general safety, transport,
storage, mounting, operating conditions, start-up, maintenance, repair, cleaning and disposal / recy-
cling are not observed, the product may not operate safely and may cause a hazard to the life and
limb of users and third parties.
Deviations from the following requirements may therefore lead both to the loss of the statutory material
defect liability rights and to the liability of the buyer for the product that has become unsafe due to the
deviation from the specifications.

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
Danger!
When the motor shaft is turning, voltage will be induced and applied to the connection terminals!
Danger!
"
The motor has casted eyelets or threads to suit eyebolts. The eyelets are for the transport of the
motor including sheave and brake only. Do not lift higher loads with these eyelets for example a
socket, ropes, etc. Use adequate hoists. Danger to life!
Warning!
"
Dependent on the working conditions the surface temperature can be very high. Danger of burns!
"
The motor is only to be operated within the ranges specified on the type plate!
"
Use the motor only as intended and only for the specified tasks in the purchase order!
"
When the motor current is off, it can not develop any electric torque. When opening the
brakes the lift will accelerate uncontrolled! Therefore it is recommended to short-circuit the
motor windings, when the motor current is off. This induces a speed dependent braking
torque similar to the friction of a worm gearbox. The short-circuit has to be made by main
contacts of the contactors, because the current is approx. rated current. In any case do not
short-circuit the windings, while the motor wires still carry current.
"
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!
2.4 Requirements placed on the personnel / due diligence
"
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.
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ZAtop – model series SM160.30B/40B Safety instructions
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Danger!
Danger by dangerous, electric voltage! Death or severe injury can occur if the corresponding
precautions are not taken!

3 Product overview
3.1 Operational area
The ZAtop, a permanent magnet inner-rotor synchronous motor, offers all benefits which a modern
elevator motor asks for:
•simple installation
•best controllability
•lowest noise level
•highest travel comfort
•compact design
Due to the very compact design the ZAtop is ideal for machine roomless elevators. Of course the
certified brakes provide maximum security and are approved as a safety device for ascending car
overspeed protection. Protected through registered design and patents application pending one can
for the very first time build a new dimension of machine roomless elevators.
3.2 Transport
"
ZIEHL-ABE SE electric motors are packed by the manufacturer for the types of transport and
storage agreed upon.
"
Transport the motor(s) 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.
"
Check packing and motor for possible damage and report the forwarding agency about any
damages caused by transport. Shipping damages are not covered by our guarantee!
3.3 Storage
"
Store the motor in the original packaging in a dry area protected from the weather or protect it from
dirt and weather until final mounting.
"
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 (we recommend max. one year) and check motor bearing for correct
function before installing the motor. (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
"
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.
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 the motors and accessories!
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.
Product overview
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"
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.
"
Keep at least 290 mm space between the brake and the wall (axial direction) to make access to the
encoder possible.
4.2 Patent situation
Pleasepayattention to the patent situation concerning the use of elevator machines in the
shaft. When using the ZAtop according to our installation examples there are no problems with
patents. In doubt please contact ZIEHL-ABEGG SE.
"
When installing the motor in the elevator shaft, the motor can be placed in the shaft head, with the
motor axle parallel to the nearest wall.
"
The motor must not be hanged over the cabin.
"
The motor should be fastened at the framework, Halfen cast-in channals or girders. The drive must
not be placed of fastened onto all four guide rails.
"
If the girder that supports the motor is fastened at one wall, the motor has to be installed on top of
the girder. A hanging motor is not permissible!
4.3 Mounting the drive unit
"
On the bottom side of the socket are 4 threads.
"
The motor has to be fixed with 4 screws M16 - 8.8 at the mounting plate.
Tightening torque M16 - 8.8: 19 Nm
"
Screw-in depth at least 1.5 times of screw size. (minimum 24 mm, maximum 32 mm)
"
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.
4.4 Fastening the brake
The drive will be delivered with the mounted brake.
Brake fixation in accordance with the brake operating instructions.
Information
An exchange of the brake can be carried out only with special centering tool. Please contact
the ZIEHL-ABEGG SE customer service in case of a brake exchange!
Mechanical installation
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ZAtop – model series SM160.30B/40B

4. Fastening rope protection clamp
"
The drive unit is equipped with two rope protection clamps.
"
Each of the two protection clamps will be fastened at the housing with two screws M8 x 16 and
washers.
Tightening torque M8 - 8.8: 23 Nm
"
Through the longholes in the clamp the required distance to the ropes can be adjusted.
"
The rope protection clamps must be fastened in a distance of 2 - 3 mm to the ropes.
"
On installations with rope pull upwards a protection must be installed to prevent foreign
bodies to entering between rope and traction sheave.
Electrical installation
.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.
.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.
.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
< 7 0 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 2 m.
"
Connect to the motor terminal box depending on the motor cable as follows:
PE U V W
green/yellow black brown blue *
green/yellow black brown grey **
green/yellow 1 2 3
* DIN VDE 0243: 1990-01
** DIN VDE 0293-308: 2003-01
"
If no other agreement was met, the absolute encoder offset is set to 0 To do that, connect the direct
current with U to + and V and W to -.
"
The motor connection lines U, V and W have to be connected on the motor and inverter side to the
correct phases and must not be changed. Otherwise the motor may speed up uncontrolled.
"
The motor is protected by PTC-resistors. The connection has to be made via a PTC resistor
controller! The admissible test voltage of PTC resistors is maximum 2.5 V DC.
Electrical installation
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ZAtop – model series SM160.30B/40B

Wiring diagram Motor
.4 Absolute encoder connection
Caution!
Never touch the connection contacts on the position absolute encoder or on the cable! The electronics can be
destroyed by static electricity.
"
The absolute encoder must be connected to the frequency inverter.
"
The absolute encoder contains components that may be damaged by electrostatic discharge. The
body of the person touching them must first be discharged, for example, by touching a conductive,
earthed object, (e.g. bright metal parts of a control panel), immediately beforehand.
"
A shielded cable must be used for the encoder connection. It is recommended to use a ZIEHL-
ABE SE cable which guarantees a sufficient shield connection.
"
The absolute encoder must not be detached mechanically in order not to lose the factory settings. If
the absolute encoder has been detached, the new encoder-offset has to be determined with the
frequency inverter. Please see the inverter operation instructions for this procedure.
Contacts SV120 round connector at absolute encoder ECN1313 (ZIEHL-ABEGG SE standard)
Pin Signal Description
A DATA Data line for communication with the absolute encoder
B DATA / Data line inverse
C 5 V Sensor Up Sensor cable for encoder voltage (5 V positive)
D 5 V Up Controlled +5 V voltage supply (positive)
E 0 V Un round voltage supply absolute encoder (negative)
F B+ (sine) Analog track B (sine)
CLOCK / Clock signal invers
H CLOCK Clock signal for serial transfer
J 0 V Sensor Un Sensor cable for encoder voltage (negative)
K A+ (cosine) Analog track A (cosine)
L A- (cosine inverse) Analog track A invers (cosine invers)
M B- inverse (sine inverse) Analog track B invers (sine invers)
Electrical installation
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ZAtop – model series SM160.30B/40B

. Brake connection
"
Please also refer to the operating instructions of the brake.
SM160.30B Brake type ROBA-twinstop (RTW), Size 2 0, 2 x 22 Nm
SM160.40B Brake type ROBA-twinstop (RTW), Size 3 0, 2 x 300 Nm
"
The brake is designed for static applications only. Any dynamic braking must be restricted
to emergency braking and test braking. At static use, there is no brake wear. Therefore the
brake is almost maintenance free.
"
Open the brakes:
If exist, Electrical release of the brakes with a supply by accumulators/UPS is possible.
Mechanical release of the brakes is possible. Hand release version is available as an option.
Retrofitting the hand release is not possible.
"
Dimension the supply and the wiring adequate for the 24 V brake. Brake current about 3,4 A per
circuit!
"
The brake circuits can be opened mechanically. They are separated from each other.
"
The terminal box for the brake may be removed from the motor and mounted on site for a better
attainability.
"
The brake is only allowed to be supplied with power when fastened to the motor and after having
connected the protective conductor of the motor at the control and the motor side.
"
The brakes have to be protected against over voltage from switching by varistors. The brakes are
supplied with varistors ex factory.
"
The brake release monitoring has to be evaluated; otherwise the type certificate is not
fulfilled! The change of state of both brake circuits have to be monitored separately.
"
The brake release monitoring is realized by micro-switches. Please assure with adequate wiring,
that the contact-current is at least 10 mA to keep the contacts clean.
"
After a long storage period, the brake rotor may stick to the bearing bracket. Then the motor will not
move even if the brake is released. In this case, please demount the brake from the motor and
separate the brake rotor and the bearing bracket with care.
Danger!
The levers for hand release must be removed after brake hand release action.
Wiring diagram brake
Electrical installation
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ZAtop – model series SM160.30B/40B

. .1 Triggering of the brakes
It is recommended to switch the brake through two contactors, one is switching the AC-side (K4) and
the other is switching the DC-side (K3).
To reduce noises during brake disconnect the brakes should be switched to the alternating current
side (K4), while normal operation. The brakes are switched-off slower and thus quieter through the
rectifier.
To ensure instantaneous brake application in emergencies, during inspection drives and return rides,
use a second contactor (K3), which disconnects the brakes from the direct current side. Integrate this
contactor into the safety circuit.
CAUTION!
Caution!
Brakes, which are connected to the direct current side, must be protected against excess voltage from
the switching actions by using corresponding varistors!
Due to the high operating current, master contactors must be used to switch the brakes!
Simplified diagram for brake activation
The contacts from K3 must close before the contact from K4 and are only permitted to open after the
contact from K4 has opened.
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 cooling when installed 1000 m above sea level. Therefore, the torque by 1 % per 100 m
must be reduced or the duty cycle time of 1.5 % per 100 m.
"
Please contact ZIEHL-ABE SE in case of orders deviating from the corresponding application
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.
"
All leftover installation materials and other foreign materials have been removed.
"
The protective earth is connected.
"
Motor protection correctly connected and operative.
"
Cable entries closed.
"
Mounting, installation position and accessories are o.k.
"
Connection data corresponds to the data on the name plate.
Start-up
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ZAtop – model series SM160.30B/40B

6.3 Drive approval test
6.3.1 Half load test
Due to the short-circuit of the motor while the VVVF is inactive, the motor will create a speed depend-
ing braking torque. This braking torque will be produced already at a very low speed.
If the car with half load does not move when the brakes are opened, the short-circuit wiring should be
deactivated. After that the test should be repeated.
After testing the short-circuit wiring must be activated again.
Half load test (alternative):
If deactivating of the short-circuit wiring is not possible or not desired, the testing of 50 % balance can
be made as follows:
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 %.
6.3.2 Testing the brake according EN 81-1
"
When testing the brakes, the short-circuit wiring has to be deactivated to only test the effect of the
brake.
"
It is recommended to perform the tests when the car position is about in the middle of the shaft.
1. 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.
2. Failure of one brake circuit:
The test shall be carried out whilst the car is descending at rated speed with rated load.
To simulate the failure of one brake circuit, the brake circuits have to be released separated from each
other, also if the safety circuit is open. The brake circuits can be released mechanically or electrically.
This state must not be permanently, it has to be done by a key button or equivalent. While using this
function the safety circuit should always be opened.
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!
As an example take a look at simplified diagram. The diagram is to be understood analogously. Their
adaptation to other applications must be investigated. ZIEHL-ABE does not guarantee their
suitability in such circumstances.
If the circuitry is made corresponding simplified diagram:
Press one of the key buttons at nominal speed until the elevator stops. Repeat the test by pressing
the other key button to test the second brake circuit.
3. Testing the micro switches
The micro switches have to be single tested. According to their use as a normely open or normaly
closed contact one micro switch contact at a time has to be opened or close.
If there is a wrong or missing micro switch signal, a travel must not be started.
Start-up
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Simplified diagram for brake activation
1 Voltage supply
2 Button two c rcu t test
3 / 4 “Open brake” button
6.4 Pull out of safety gear
If the car loaded with the nominal load enters the trap due to a malfunction or during the TÜV
certification, it is possible that the trap device is seated rather firmly. In such a case, it is entirely
possible that the drive torque is no longer sufficient to pull the car out of the trap.
With gearless drives in machine rooms, a handwheel does not make any sense because there is no
gear reduction. That is because due to the low moment arm of force, only slight force can be applied. A
handwheel could even present a hazard, as even with only a slight imbalance in the installation, it is
no longer possible to stop the elevator with the handwheel.
With gearless drives in the shaft, the motor is usually not accessible. A handwheel is unnecessary in
such a layout.
In both cases with gearless drives, applicable is: One must fall back on a chain hoist or similar if the
drive torque is insufficient or if there is a lack of drive on the rope. It makes sense to keep a suitable
chain hoist ready during the TÜV 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.
Start-up
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6. Emergency evacuation
Attention!
The measures for emergency evacuation described below may only be performed by instructed
persons for maintenance of the lift or qualified personnel of lift companies.
6. .1 Manual emergency evacuation
In case of power failure or failure of the recovery control, emergency rescue is only possible by
releasing the brakes manually. The picture shows how the levers must be actuated for hand release.
Manual lifting of the brake
The levers for hand release can be inserted with an offset of 90° in every position and can be actuated
±25° on both sides.
possible insertion positions of the levers for hand release
When the brakes are released manually, the lift moves in the direction of the greater weight. If there is
a balance between the cabin and the counterweight, the cabin must be made heavier by suitable
means.
To reduce the acceleration of the lift, we recommend to short-circuit the motor for the evacuation. The
short-circuit is generated by the motor contactors.
The short-circuit generates a speed-dependent braking torque. The maximum braking torque is
achieved at lower speeds.
Depending on the system type and weight ratios, it is possible that due to the short-circuit
generated braking torque is not sufficient to limit the lift speed. So the speed must be
monitored closely during evacuation and evacuation interrupted if necessary.
Manual release of the brake is finished when a floor is reached. Now the lift door can be opened with
a triangular key.
The lift manufacturer's safety instructions have priority!
Danger!
The levers for hand release must be removed after brake hand release action.
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.
6. .2 Electrical emergency evacuation
The electrical emergency evacuation is described in the operation instructions of the control, the
inverter and, if available, an evacuation unit with UPS.
Start-up
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7 Faults and remedy
Failure Causes Adjustment
Running noise Bearing defective Contact customer service
VVVF-settings wrong Check VVVF settings
Absolute encoder defective Change absolute encoder
Excessive tempera-
ture / Temperature
protection trips
Motor surface covered Remove cover from motor or mount with
more distance to motor.
Ambient temperature higher than 40 °C Enhance shaft ventilation
VVVF-settings wrong Check VVVF settings
Motor will not start Motor phases connected incorrect Check motor connection
VVVF defective Check VVVF
Brake does not release See brake faults
Brake switching
noises
Brake is switched on the DC-side Change brake wiring to AC-switching at nor-
mal operation. Add overvoltage protection.
Air gap of brake too big Replacement of the brake rotors
Brake does not re-
lease
Power supply too low. The voltage at the
brake is to low.
Check power supply, change wiring (and
transformer) size
Brake control wrong / defective Check brake wiring
Brake coil defective Replace brake (Special tools necessary!
Contact ZIEHL-ABE SE customer serv-
ice)
Brake worn out Replace brake rotors (Special tools neces-
sary! Contact ZIEHL-ABE SE customer
service)
Brake release moni-
toring does not
switch
Micro switches defective Replace the micro switch
Contacts dirty Switch micro switches with a higher contact
current, at least 10 mA or change micro-
switches
8 Service and maintenance
8.1 General notes on maintenance
"
Observe the safety-at-work regulations!
"
Disassembling the machine can only be done with special devices!
Caution, strong magnetic force!
"
Never use a high-pressure cleaner (e. g. a steam jet cleaner) for cleaning the motor!
"
Take note of abnormal operating noise.
"
The bearings have a lifetime lubrication. There is no possibility to relubricate. Maintenance is not
necessary for the bearings.
To check the brake wear or to check the treaction sheave, the following instructions have to be
referred:
It is not possible to adjust the brakes. The brakes cannot be readjusted. Replace the both brake rotors
when the maximum air gap has been reached.
The brake wear has to be checked with the brake closed, therefore:
"
Make sure that all moving parts have stopped, secure them mechanically if required!
"
Make sure that the elevator can not be moved from any other person than the one who does the
check!
Faults and remedy
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8.2 Inspection intervals
During commissioning or
after the first 3 months
every year
Distance of the rope protection clamp X X
Checking the air gap of the brake X X
Visual inspection of the fixing screws on the housing,
brakes and traction sheave. The locking varnish must
be free of damage.
XX
Check the traction sheave if worn out X
Check the microswitch X
Note: All fixing screws on the housing, brakes and traction sheave are marked with locking varnish.
That means a loosened screw is optically visible. If a screw does get turned, it must be tightened
using the prescribed tightening torque, the old locking varnish needs to be removed and marking has
to be made again.
8.2.1 Checking the air gap
1. The airgap has to be checked 3 times at the circumfence. The maximum value of the three has to
be taken into account.
2. If the maximum value of the air gap is exceeded on one of the magnets, it must be changed the
brake rotor and the O-ring.
Maximum admissible air gap after wear: 0.9 mm!
8.3 Spare parts
Spare parts and accessories not supplied by ZIEHL-ABE SE have not been tested or approved by
us. These parts may be lower in function or quality and therefore can reduce functionality or safety of
the installation. ZIEHL-ABE SE will assume no liability or guarantee for damages caused by spare
parts that are not approved.
Available spare parts:
•Absolute encoder
•Brake (complete)
•Brake rotor & O-rings
•Micro switch for Brake
•Traction sheave
•Rope guard
Service and maintenance
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8.3.1 Replacement of the absolute encoder ECN1313/ERN1387
The absolute encoder is mounted on the motor drive shaft opposite the power take off side (see
arrow).
8.3.1.1 Required tool for the replacement of the absolute encoder:
•Wire cutter
•Allen wrench SW 2
•Allen wrench SW 4
•Torque key for a tightening torque of 5.2 Nm with Allen key SW 4
•Screw M10 x 25 (included in toolkit, article 70027450)
8.3.1.2 Dismounting the absolute encoder
1. Unscrew the clamping screw (1) with an allen wrench SW 2 The position of the clamping screw
can diversify.
2. Removethecover of the encoder (2) with an allen wrench SW 4
3. Unscrew the central fixing screw (3) with an allen wrench SW 4 for 1 - 2 revolutions. The absolute
encoder can be turned now.
Service and maintenance
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4. Tighten the screw M10 x 25 (4) with the fitting tool until the absolute encoder is loose. Due to the
tightening the screw is pressing onto the central fixing screw (3) and pulls the absolute encoder
off the drive shaft.
5. Screw out the screw M10 x 25 (4) as well as the central fixing screw.
6. Screw the screw M10 x 25 (4) onto the absolute encoder again. Take the absolute encoder from
the motor shaft with the support of the screw.
Caution!
Due the electrostatic discharge the absolute encoder can be destroyed! Do not touch the pins of the encoder
cable as well as the electronics of the absolute encoder!
8.3.1.3 Mounting the absolute encoder
Caution!
Never touch the connection contacts on the position absolute encoder or on the cable! The electronics can be
destroyed by static electricity.
Service and maintenance
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1. The brakes are used to centre the absolute encoder.
2. Attach the absolute encoder to the drive shaft.
3. Provide threadlocker Loctite 243 (5) or similar threadlocker material to the thread of the central
fixing screw (3).
4. Tighten the central fixing screw (3) with an allen wrench SW 4
Tightening torque: .2 Nm
5. Fix the cover of the encoder (2) with an allen wrench SW 4
6. Adjust the cable outlet by turning the absolute encoder and tighten the clamping screw (1) with an
allen key SW 2 The position of the clamping screw can diversify.
Tightening torque: 1.2 Nm
7. Carry out the alignment of the absolute encoder corresponding to the operation instructions of the
frequency inverter.
8.3.2 Replacement of the brake
(SM160.40B illustrated)
During the mounting as well as the dismounting also the operating manual of 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!
Risk of death!
Incorrect mounting of the brake can have influence on the braking action!
The brake bodies are mounted on the opposite side of the power take off. (see arrow)
Service and maintenance
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Brake with 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.
8.3.2.1 Required tool for the replacement of the brake:
•ZIEHL-ABE toolkit article 70027450
•Tool for replacing the absolute encoder (see chapter "Replacement of the absolute encoder")
•Wire cutter
•Cable stripper
•Crimper
•Slotted screwdriver 0.6 x 3.5
•Allen key SW 17
•screw wrench SW 10
•screw wrench SW 13 (SM160.30B)
•screw wrench SW 16 (SM160.40B)
•screw wrench SW 32
•Torque wrench for tightening torque 36 Nm with screw wrench SW 13 (SM160.30B)
•Torque wrench for tightening torque 48 Nm with screw wrench SW 16 (SM160.40B)
•Wrench (included in toolkit, article 70027450)
•Assembly shaft (included in toolkit, article 70027450)
8.3.2.2 Dismounting the brake
1. Dismount the absolute encoder (see chapter "Replacement of the absolute encoder").
2. Disconnect the electrical connection (1) of both brakes.
3. Carefully remove strain reliefs (2) of all connecting cables with wire cutters.
4. Cut off varistors (3).
Service and maintenance
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