ZIEHL-ABEGG ZA top SM200.15D User manual

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Content
1 General .................................................................. 3
1.1 Structure of the assembly instructions ..................................... 3
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Exclusion of liability ................................................... 3
1.4 Copyright ........................................................... 3
2 Safety instructions ......................................................... 3
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................. 3
2.2 ictographs . . . . . . . . . . . . . . . . . . . . . . . . ................................. 3
2.3 Requirements placed on the personnel / due diligence . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Versions of the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Scope of delivery ..........................................................
Tools required ............................................................ 7
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2 RTW 250 - ZAtop SM200.15D . . . . . . . . . . ................................. 7
6.3 RTW 350 - ZAtop SM200.23D . . . . . . . . . . ................................. 7
6.4 RTW 450 - ZAtop SM200.30D . . . . . . . . . . ................................. 7
6.5 RTW 800 - ZAtop SM200.40E and SM200.45E . . . . . . ........................ 7
6.6 Required aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 Dismounting the brake . . . . . . . . . . . . . . . . . . . . ................................. 8
8 Mounting the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 11
9 Functional test on microswitch/inductive proximity switch for release monitor . . . . . . . . 15
10 Adjustment of the microswitch/inductive proximity switch for release monitor . . . . . . . . 15
11 Disposal / Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly instructions – model series ZAtop
A-TIA39_01-GB 2023/39 Index 002 art.-No. 01013520-GB
2/16

1 General
1.1 Structure of the assembly instructions
"
"
The assembly instructions does not replace the original operating instructions of the elevator
machine or frequency 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 for their job.
1.3 Exclusion of liability
ZIEHL-ABEGG SE is not liable for damage due to misuse, incorrect use, improper use or as a
consequence of unauthorized repairs or modifications.
1.4 Copyright
This assembly instructions contains information 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 from. Infringements are liable for 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 safety 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
Safety instructions are highlighted with warning triangles and are depicted according to the degree of
hazard as follows.
Danger!
General hazardous area. Death or severe injury or significant property damage can occur if the
corresponding precautions are not taken!
Information
Important additional information and advice for user.
2.3 Requirements placed on the personnel / due diligence
Danger!
"
"
Installation, connection to the power supply and commissioning may only be performed by qualified
service personnel! The relevant regulations must be observed!
"
"
ersons entrusted with the planning, installation, commissioning and maintenance and servicing in
connection with the elevator machine must have the corresponding qualifications and skills for
these jobs. Based on their training, knowledge and experience as well as knowledge of the relevant
standards, they must be able to judge the work transferred to them and be able to recognize
possible hazards.
"
"
In addition, they must be knowledgeable about the safety regulations, EU directives, rules for the
prevention of accidents and the corresponding national as well as regional and in-house
regulations. ersonnel undergoing training, instruction, or on apprenticeship may only work on the
elevator machine under the supervision of an experienced person. This also applies to personnel in
general training.
"
"
Comply with the legal minimum age.
Assembly instructions – model series ZAtop General
A-TIA39_01-GB 2023/39 Index 002 art.-No. 01013520-GB
3/16

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 for transporting the
elevator machine including brake and traction sheave. Do not lift other loads such as bolted on
components, ropes lying on top, etc. with the attachment points. Suitable lifting gear must be used.
Danger!
Warning of hand injuries!
"
"
Risk of injury from reaching into the rope guard.
Danger!
"
"
If the elevator machine is not energised, no electric torque is available. Releasing the brakes can
cause uncontrolled acceleration of the elevator.
We recommend short-circuiting the windings of the de-energised elevator machine to generate a
brake torque dependent on the speed.
In the event of a short-circuit, a short-circuit current of at least the level of the rated current is
flowing.
The windings may not be short-circuited when the elevator machine is energised.
3 Safety precautions
Danger!
In case safety precautions are not taken:
✓Can it lead to death or severe injury or significant property damage!
✓Brake malfunction may result!
On installed drives, before replacement of the brake, following safety measures have to be taken:
"
"
Counterweight has to rest on the buffer.
"
"
Cabin has to be suspended.
✓Thereby the ropes are unburdened!
Assembly instructions – model series ZAtop Safety precautions
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4 Versions of the brake
Figure 4-01 - Brake without a mechanical hand release system
Figure 4-02 - Brake with a mechanical hand release systemFigure 4-03 - Brake with hand release for bowden cable
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 Versions of the brake
A-TIA39_01-GB 2023/39 Index 002 art.-No. 01013520-GB
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5 Scope of delivery
•
Brake
•
Tool kit for brake exchange and encoder exchange - Article number 70030741 (optionally available)
•
Assembly kit brake - Article number 70029992 (optionally available)
Figure 5-01- Delivery parts
Figure 5-02 - additional delivery parts brake with manual release system
Pos. Count Designation
42Varistor
13 1 Wrench encoder adapter
15 1 Assembly aid for ZAtop SM160, SM200 bis SM250
17 4 RTW 250 - ZAtop SM200.15D
Hexagon head screw M8 x 110 - 10.9 with washer
RTW 350 - ZAtop SM200.23/B
Hexagon head screw M10 x 110 - 8.8 with washer
RTW 450 - ZAtop SM200.30/B
Hexagon head screw M12 x 120 - 8.8 with washer
RTW 800 - ZAtop SM200.40E
Hexagon head screw M12 x 130 - 10.9 with washer
RTW 800 - ZAtop SM200.45E
Hexagon head screw M12 x 130 - 10.9 with washer
18 1 Brake body
19 1 Brake rotor
20 1 O-ring
Assembly instructions – model series ZAtop Scope of delivery
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Pos. Count Designation
21 1 Hand release lever set
21A - Hand release lever set for hand-operated version
21B - Hand release lever set for bowden cable
25 4 Wire-end sleeves
26 1 Micro-active cloth
27 1 Feeler gauges, 13-part
28 1 Anti tamper paint 20 ml
29 1 Technical vaseline 50 g
30 1 Quick cleaner LOCTITE
®
7063
TM
400 ml
The tool set for brake replacement and encoder replacement (article number 70030741) osition 13
and osition 15 is available as an option and is supplied in a case.
The assembly kit brake (article number 70029992), including position 4 and position 25 to position 30
is optionally available and supplied in a separate folding box.
Tools required
.1 General
•
Wire cutter
•
Cable stripper
•
Crimper
•
Slotted screwdriver 0.6 x 3.5
•
Allen wrench size 17
•
screw wrench size 32
•
Torque wrench for tightening torque 60 Nm, size 32
.2 RTW 250 - ZAtop SM200.15D
•
Lifting eye bolt M10
•
Allen wrench size 5
•
Screw wrench size 13
•
Torque wrench for a tightening torque of 9.5 Nm with allen wrench size 5
•
Torque wrench for tightening torque 32 Nm, size 13
.3 RTW 350 - ZAtop SM200.23D
•
Lifting eye bolt M10
•
Allen wrench size 5
•
Screw wrench size 16
•
Torque wrench for a tightening torque of 9.5 Nm with allen wrench size 5
•
Torque wrench for tightening torque 48 Nm, size 16
.4 RTW 450 - ZAtop SM200.30D
•
Lifting eye bolt M10
•
Allen wrench size 5
•
Screw wrench size 18
•
Torque wrench for a tightening torque of 9.5 Nm with allen wrench size 5
•
Torque wrench for tightening torque 74 Nm, size 18
.5 RTW 800 - ZAtop SM200.40E and SM200.45E
•
Lifting eye bolt M12
•
Allen wrench size 5
•
Screw wrench size 18
•
Torque wrench for a tightening torque of 9.5 Nm with allen wrench size 5
•
Torque wrench for tightening torque 109 Nm, size 18
. Required aids
•
Threadlocker LOCTITE
®
243
TM
or similar product
Assembly instructions – model series ZAtop Tools required
A-TIA39_01-GB 2023/39 Index 002 art.-No. 01013520-GB
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7 Dismounting the brake
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!
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!
"
"
You must discharge your own body before touching. This can be done, for example, by touching a conductive,
earthed object (for example bare metal switch cabinet parts) immediately before.
Figure 7-01 Figure 7-02
1. Remove cover from connection box (1).
2. Disconnect the electrical connection (2) of both brakes.
3. Carefully remove strain reliefs (3) of all connecting cables with wire cutters.
4. Cut off varistors (4).
Figure 7-03 Figure 7-04
5. Feed all connecting cables (5) out of the terminal box.
6. On the ZAtop SM200.40E and SM200.45E, unscrew the wire rope loop (10).
7. Unscrew the two cylinder head screws M6 (6) with washers (7) with allen key size 5 and remove
the cover plate (11).
Assembly instructions – model series ZAtop Dismounting the brake
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Figure 7-05
8. Remove the absolute encoder (12), see assembly instructions "Replacement of the absolute
encoder - A-TIA17_02-..."
Figure 7-06 Figure 7-07
9. Using the tightening wrench (13) and a wrench size 32, unscrew the adaptor shaft for the absolute
encoder (14) from the drive shaft.
Figure 7-08 Figure 7-09
10. Attach the assembly aid (15). Screw the M20 cylinder head screw of the assembly aid (15) hand
tight into the drive shaft using a allen key, size 17.
11. ATTENTION! Due to the heavy weight of the brake body, we recommend securing the brake
using an lifting eye bolt (16) and the corresponding lifting gear.
ZAtop SM200.15D, SM200.23D and SM200.30D:Screw in eye bolt M10 (16)
ZAtop SM200.40E and SM200.45E: Screw in eye bolt M12 (16)
Assembly instructions – model series ZAtop Dismounting the brake
A-TIA39_01-GB 2023/39 Index 002 art.-No. 01013520-GB
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12. Completely unscrew the four hexagon head screws (17) alternately diagonally using a wrench.
RTW 250 - ZAtop SM200.15D:
loosen hexagon head screws M8 x 110 - 10.9 (17), wrench size 13
RTW 350 - ZAtop SM200.23D:
loosen hexagon head screws M10 x 110 - 8.8 (17), wrench size 1
RTW 450 - ZAtop SM200.30D:
loosen hexagon head screws M12 x 120 - 8.8 (17), wrench size 18
RTW 800 - ZAtop SM200.40E and SM200.45E:
loosen hexagon head screws M12 x 130 - 10.9 (17), wrench size 18
13. Remove the two other hexagon head screws (17) alternately with ½ turns each.
Figure 7-10 Figure 7-11
14. Detach the brake body (18).
ATTENTION! Observe the weight of the brake body:
RTW 250 - ZAtop SM200.15D approx. 30 kg
RTW 350 - ZAtop SM200.23D approx. 3 kg
RTW 450 - ZAtop SM200.30D approx. 45 kg
RTW 800 - ZAtop SM200.40E and SM200.45E approx. 71 kg
15. Detach the brake rotor (19) from the toothed hub. The brake rotor (19) may only be detached by
hand.
ATTENTION! Do not use screwdrivers to release the brake rotor.
The screwdrivers damage the friction lining. Damaged friction linings may not be re-fitted!
Figure 7-12
16. Remove the o-ring (20) from the toothed hub (21).
Assembly instructions – model series ZAtop Dismounting the brake
A-TIA39_01-GB 2023/39 Index 002 art.-No. 01013520-GB
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8 Mounting the brake
During the mounting as well as the dismounting also the operating manual of the brake has to be
observed.
Risk of death!
Incorrect mounting of the brake can have influence to the braking action!
Caution!
"
"
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 before touching. This can be done, for example, by touching a conductive,
earthed object (for example bare metal switch cabinet parts) immediately before.
Figure 8-01 Figure 8-02
1. Ensure that the friction lining of the brake rotor (19), the braking surface (22) on the flange bearing
bracket and the toothed hub (21) on the drive shaft are free of dirt and grease. erform cleaning
with a micro-active cloth and quick cleaner LOCTITE
®
7063
TM
.
2. Lightly grease the o-ring (20) with technical vaseline and insert into the groove in the hub (21).
3. Slide the brake rotor (19) manually over the O-ring (20) onto the toothed hub (21) with slight
pressure.
ATTENTION!Make sure that the rotor collar is facing towards the machine wall.
4. Make sure that the gear teeth engage easily.
5. O-ring may not be damaged.
Figure 8-03 Figure 8-04
6. ATTENTION! Due to the heavy weight of the brake body (18), we recommend securing the brake
using an lifting eye bolt (16) and the corresponding lifting gear.
ZAtop SM200.15D, SM200.23D and SM200.30D:Screw in eye bolt M10 (16)
ZAtop SM200.40E and SM200.45E: Screw in eye bolt M12 (16)
7. osition the brake body (18) on the bearing bracket.
ATTENTION! Observe the weight of the brake body:
RTW 250 - ZAtop SM200.15D approx. 30 kg
RTW 350 - ZAtop SM200.23D approx. 3 kg
Assembly instructions – model series ZAtop Mounting the brake
A-TIA39_01-GB 2023/39 Index 002 art.-No. 01013520-GB
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RTW 450 - ZAtop SM200.30D approx. 45 kg
RTW 800 - ZAtop SM200.40E and SM200.45E approx. 71 kg
Figure 8-05 Figure 8-06
8. Slightly screw on the brake body (18) with the 4 hexagon head bolts (17).
Do not forget the washers!
9. Tighten the 4 hexagon screws (17) with the specified pre-tightening torque in the order 1. to 4..
RTW 250 - ZAtop SM200.15D:
Hexagon head screws M8 x 110 - 10.9 (17), torque wrench size 13
Pre-Tightening torque: 10 Nm
RTW 350 - ZAtop SM200.23D:
Hexagon head screws M10 x 110 - 8.8 (17), torque wrench size 1
Pre-Tightening torque: 1 Nm
RTW 450 - SM200.30D:
Hexagon head screws M12 x 120 - 8.8 (17), torque wrench size 18
Pre-Tightening torque: 25 Nm
RTW 800 - ZAtop SM200.40E and SM200.45E:
Hexagon head screws M12 x 130 - 10.9 (17), torque wrench size 18
Pre-Tightening torque: 3 Nm
10. Tighten the 4 hexagon screws (17) with the specified tightening torque in the order 1. to 4..
RTW 250 - ZAtop SM200.15D: Tightening torque: 32 Nm
RTW 350 - ZAtop SM200.23D: Tightening torque: 48 Nm
RTW 450 - SM200.30D: Tightening torque: 74 Nm
RTW 800 - ZAtop SM200.40E and SM200.45E: Tightening torque: 109 Nm
11. Endue the hexagon head screws (17) with anti tamper paint.
12. Unscrew lifting eye bolt (16).
13. Unscrew the M20 cylinder head screw of the assembly aid (15) with an allen key size 17 from the
drive shaft. Remove the assembly aid (15).
Figure 8-07 Figure 8-08
14. rovide threadlocker LOCTITE
®
243
TM
or a similar product to the thread of the adapter shaft (14).
15. Screw the adapter shaft (14) onto the drive shaft with wrench (13) and torque wrench size 32.
Tightening torque: 0 Nm
Assembly instructions – model series ZAtop Mounting the brake
A-TIA39_01-GB 2023/39 Index 002 art.-No. 01013520-GB
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Figure 8-09
16. Check the air gap "A" between the coil carrier and armature disc with the feeler gauge
when de-energised.
ZAtop SM200.15D, SM200.23D and SM200.30D:
Air gap 0.3 mm ≤ "A" ≤ 0.5 mm
ZAtop SM200.40E and SM200.45E:
Air gap 0.4 mm ≤ "A" ≤ 0. mm
This air gap must be present in the area of the horizontal central axis of both armature
discs (23).
See the brake operating instructions in the appendix to the original operating instructions.
17. Check the air gap "B" > 0.2 mm between the brake rotor and armature disc with the feeler
gauge when energised.
The test air gap must be present.
See the brake operating instructions in the appendix at the original operating instructions.
✓If the air gaps are outside the tolerance, please contact our customer service.
Figure 8-10 Figure 8-11
Figure 8-12 Figure 8-13
Assembly instructions – model series ZAtop Mounting the brake
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18. Fix the cover plate (11 ) with the two cylinder head screws M6 x 12 - 8.8 (6) with torque wrench
with allen wrench size 5 and washers (7).
Tightening torque: 9.5 Nm
19. On the ZAtop SM200.40E and SM200.45E, screw the wire rope loop (10).
20. Bundle the connection cables (5) of the magnet coils and the release monitoring and lead it into
the terminal box (1).
21. Connect the magnet coils, the release monitoring and the varistors (4) according to the connec-
tion diagram (24) in the top cover of the terminal box (1).
22. Fit strain reliefs (3).
23. Close the terminal box cover (1).
24. erform brake test (see chapter "Brake operating instructions - brake test" in the appendix at the
original operating instructions).
Figure 8-14
25. Mount the absolute encoder (12), see assembly instructions "Replacement of the absolute
encoder - A-TIA17_02-..."
26. Carry out the alignment of the absolute encoder (12) corresponding to the original operation
instructions of the frequency inverter.
Brake design with hand release lever
Figure 8-15 Figure 8-16
27. Mount the hand release lever (21A or 21B) and secure with a retaining ring (31).
Assembly instructions – model series ZAtop Mounting the brake
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9 Functional test on microswitch/inductive proximity switch for re-
lease monitor
After mounting of the brake, a functional test must be performed on the micro switches/inductive
proximity switches (see chapter "Brake operating instructions - release monitor" at the original operat-
ing instructions).
If the function is not available, please check the causes that may prevent the actuation of 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 of release monitor with micro switches or inductive
proximity switches" in the appendix at the original operating instructions).
10 Adjustment of the microswitch/inductive proximity switch for re-
lease monitor
Figure 10-01 Figure 10-02
Adjustment of the microswitches/inductive proximity switches is only necessary if they are not working
correctly.
The microswitches/inductive proximity switches are located on the left side of 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 of the release monitor with microswitches/inductive proximity switches, see “Assembly
and adjustment of 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 professionally and environmentally friendly in accordance with the legal
stipulations.
Assembly instructions – model series ZAtop Functional test on microswitch/inductive proximity switch for release
monitor
A-TIA39_01-GB 2023/39 Index 002 art.-No. 01013520-GB
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© by Ziehl-Abegg - - 01013520-GB - 2023/39 - - Subject to technical changes
Customer Service
phone [phone]
fax [phone]
[email protected]
Headquarters
ZIEHL-ABEGG SE
Heinz-Ziehl-Straße · 74653 Künzelsau
Germany
phone [phone] · fax [phone]
[email protected] · www.ziehl-abegg.com