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PMC145

PMC145 (machine room version )

Operating
manual

Drive
PMC145

Drive
PMC145
-

machine
room
version

ThyssenKrupp Aufzugswerke
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Copyright by ThyssenKrupp Aufzugswerke GmbH

Note on industrial property rights ISO 16016


Printed in Germany
This document including excerpts may only be reprinted or otherwise copied
with the express approval in writing of ThyssenKrupp Aufzugswerke GmbH.

Any duplication, dissemination or storage on data media unauthorised by


ThyssenKrupp Aufzugswerke GmbH is an infringement of copyright and shall give
rise to prosecution.

Right to make changes of a technical nature reserved


We expressly reserve the right to make changes of a technical nature for the
purpose of improving our products or enhancing the safety standard - even without
a separate announcement.

Colouring

The colouring of the components used in our documentation is used only for the
documentation.
Enquire about colours for your products from your ThyssenKrupp Aufzugswerke
Sales Partner.

Issued by
ThyssenKrupp Aufzugswerke GmbH
Bernhuser Strasse 45
73765 Neuhausen a. d. F.
Germany

E-mail: Eli.elevator.plant.de@thyssenkrupp.com
Internet: www.thyssenkrupp-elevator-eli.de
OPERATING MANUAL PMC145

Table of contents

PMC145 drives PAGE


1. Safety 6
1.1 Symbols 6
1.2 Safety instructions 7
2. Product description 10
2.1 Description 10
2.1.1 PMC145 12
2.1.2 PMC145 MR version 13
2.2 Functional description 14
3. Technology 15
3.1 Dimensions 15
3.1.1 PMC145 S XS 15
3.1.2 PMC145 M XM 16
3.1.3 PMC145 L XL 17
3.2 Ambient conditions 18
3.3 Pulse generator 19
3.4 Traction sheave 20
3.5 Brake 21
3.6 General technical data 22
3.7 Electrical data for brake 23
4. Transport and storage 24
5. Mounting the machine 26
5.1 PMC145 27
5.1.2 PMC145 MR version 28
5.2 Electrical wiring diagram
PMC145 and MR version 30
5.3 Wiring 30
6. Commissioning 31
7. Maintenance / service 32
7.1 Maintenance 32
7.2 Lubrication 32
7.3 Testing the brake 33
7.4 Checking for escaping grease / oil 35
8. Appendix 36
8.1 Tightening torques 36
8.2 Documents 37
9. Changes 71

ThyssenKrupp Aufzugswerke GmbH 5 12-2011


OPERATING MANUAL PMC145 SAFETY

1. Safety

1.1 Symbols

The following pictograms and designations are used in this operating manual:

Danger
This symbol indicates extreme danger to life and the
health of persons. Nonobservance can lead to death
or severe injury!

Danger
This symbol indicates an immediate danger to the life
and health of persons due to electrical current.
Hazard warnings must always be observed!

Warning
This symbol warns against imminent danger.
Nonobservance can lead to bodily injury or extensive
damage to property.
Warnings must always be observed!

Note
This symbol indicates important information and
operating instructions. Nonobservance can lead to
damage, danger or malfunctions.

Check
Test steps are specified with this symbol.
The test instructions marked in this way must be
followed without fail. They contribute to preventing
personal injury or damage to property.

ThyssenKrupp Aufzugswerke GmbH 6 12-2011


OPERATING MANUAL PMC145 SAFETY

1.2 Safety instructions

Notes regarding the operating manual


A requirement for safe handling and non-disruptive operation of this drive is
knowledge of the fundamental safety regulations.
This operating manual contains the most important information that is
required to operate the drive.
The operating manual, in particular the safety instructions, is to be complied
with by all persons that work on this drive.
Furthermore, the rules and regulations covering accident prevention that
apply to the usage site are to be complied with.

Obligations of the operator and/or of the installation firm


The operator or installation firm undertakes only to allow persons to work on
the drive who
are familiar with the regulations regarding work safety and accident
prevention and have been instructed in handling the drive
have read the chapter on safety and the warnings in this operating
manual.
Note: Check the safety awareness of the personnel at regular intervals.

Obligations on the part of personnel


Persons assigned to work on subassemblies undertake before starting work
to
observe the regulations regarding work safety and accident prevention.
read the chapter on safety and the warnings in this operating manual.

Training of the personnel


Only trained and instructed qualified personnel may work on the drive.
The responsibility of the personnel is to be clearly defined for all tasks
involving commissioning, operation, maintenance and repair.

Organisational measures
The required personal protective equipment is to be provided by the operator
or installation firm, as the case may be. All existing safety devices are to be
checked regularly in accordance with the maintenance plan.

ThyssenKrupp Aufzugswerke GmbH 7 12-2011


OPERATING MANUAL PMC145 SAFETY

Informal notes on the safety measures


The operating manual is to be kept permanently at the usage site of the
installation.
Complementary to the operating manual, the generally applicable and
local regulations for accident prevention and environmental protection are
to be provided and complied with.
Legally prescribed safety instructions are to be provided for the users at
clearly visible positions.
Keep all safety and hazard warnings on the installation in a legible
condition.

Use in line with intended purpose


Our products have been constructed using state-of-the-art technology and in
line with the recognised technical safety regulations. They must only be
deployed in line with the intended purpose and
used when all the technical safety features are in perfect condition.
The sole purpose of use is to drive elevators.
Any other or additional form of use shall be regarded as non-compliant with
the intended use. THYSSENKRUPP AUFZUGSWERKE GmbH shall not be
liable for any damage arising from such use and any damage arising due to
operator errors.
Proper use in line with the intended purpose also includes
observance of all instructions in the operating manual and
adherence to commissioning instructions, system description and
inspection and maintenance work.

Warranty and liability


As a general principle, the "General Terms of Sale and Delivery" of
THYSSENKRUPP AUFZUGSWERKE GmbH apply.
Warranty and liability claims in the event of personal injury and damage to
property shall be excluded if they arise due to any of the following causes:
improper use that is not in line with the intended purpose of the drive
incorrect installation, commissioning and maintenance of the drive
operation of the machine with defective and/or
non-operative safety and protective devices
Nonobservance of the instructions in the operating manual with regard to
Transport, storage, installation, commissioning, operation and
maintenance
Customer constructional alterations to the machine
Changes to the drive ratios (power output etc.) performed by the operator
Deficient monitoring of parts that are subject to wear
Repairs that are carried out improperly
Cases of catastrophe due to third-party interference and force majeure.

ThyssenKrupp Aufzugswerke GmbH 8 12-2011


OPERATING MANUAL PMC145 SAFETY

Constructional changes to the machine performed by the operator


The machine is set in the factory and delivered ready for operation.
In event of changes being made to the machine, all warranty on the part of
THYSSENKRUPP AUFZUGSWERKE GmbH is cancelled.

Risks in handling the machine


The drive must only be operated in a closed machine room or secured shaft
and only with cover and rope guard on the traction sheave. It is not suitable
for operation in explosive or aggressive atmosphere. Use in tropical regions
is possible only after special measures have been taken.
When working on the drive, it must be de-energised before work is started,
and the system must be secured against inadvertent switching on.
It must be ensured that persons in the machine room keep a safe distance
from all rotating parts.

In the event of improper use of the drive, there is a risk of personal injury or
to the life of the user or third parties, or impairment on the assembly or other
assets can arise. Malfunctions that can diminish safety are to be rectified
immediately.

Note: When connecting and working on the drive brake, please follow the
manufacturer's instructions.

Important:
Suitable measures must be taken by the manufacturer of the elevator
installation:
a) to be able to operate the brake in emergencies (power failure)
b) to be able to carry out and individual check of the two brake circuits

ThyssenKrupp Aufzugswerke GmbH 9 12-2011


OPERATING MANUAL PMC145 PRODUCT DESCRIPTION

2. Product description

2.1 Description

Product key

PMC145 XM 105

Main designation for PMC145 drives


PM Permanent magnet

Machine type
C Compact

Machine size
145

Machine length (drive output)


S, M, Machine length of the three basic types
L (1 m/s)
X Prefix X: extension of the basic type
S 450 kg / 1 m/s
M 630 kg / 1 m/s
L 1000 kg / 1 m/s
XS 450 kg / 1.6 m/s
XM 630 kg / 1.6 m/s
XL 1000 kg / 1.6 m/s

Generation of the machine


1.. 1st digit designates the machine generation

(1st of the drives described


here)

Winding variant
.05 2nd and 3rd digit for the electrical version

PMC145 MR version : (MR= machine room)


Same as PMC145 but with
these differences: rope protection cover, cover for brakes as well as
brakes with manual release.
Cable lengths (motor, brake, and pulse
generator)

ThyssenKrupp Aufzugswerke GmbH 10 12-2011


OPERATING MANUAL PMC145 PRODUCT DESCRIPTION

Overview of versions

Machine type Rated Traction


Suspension load
Rated speed
sheave
)

Q [kg] v [m/s] DT [mm]


PMC145 M 102 400
1:1 1 1.2
PMC145 L 101 630
PMC145 S 103 1
450
PMC145 XS 106 1,6
240
PMC145 M 102 1
2:1 630
PMC145 XM 105 1,6 1.75
PMC145 L 101 1
1000
PMC145 XL 104 1,6

Table 2.1

Please also consult the details on the type plate of the drive.

ThyssenKrupp Aufzugswerke GmbH 11 12-2011


OPERATING MANUAL PMC145 PRODUCT DESCRIPTION

2.1.1 PMC145

1
3
4
2
5

6
Fig. 2.3
Fig. 2.1

11

10
Fig. 2.4
12
Fig. 2.2

Version without brake release lever

1 Cover of pulse generator and 2 Connection for motor and posistor


brakes (cable fitted at the factory)
3 Motor unit 4 Rope guard plate
5 Pressure plate 6 Traction sheave diameter =
240 mm
7 Type plate (both sides) 8 Plug connector for brake cable
Cables are enclosed loose
10 Brakes Mayr Duplostop
11 Pulse generator ECN413 with cable
12 Mount for drive 4 x M16 connection to baseplate
Table 2.2

ThyssenKrupp Aufzugswerke GmbH 12 12-2011


OPERATING MANUAL PMC145 PRODUCT DESCRIPTION

2.1.2 PMC145 machine room version

Illustrated difference to PMC145

Fig. 2.8 1 Fig. 2.9 2


3

Fig. 2.10 Fig. 2.11

1 Rope guard plate 2 Brake covers


3 Brake actuating lever

Table 2.4

ThyssenKrupp Aufzugswerke GmbH 13 12-2011


OPERATING MANUAL PMC145 PRODUCT DESCRIPTION

2.2 Functional description

Machine:
the PMC 145 machine series consists of a frequency-controlled, permanently-
excited synchronous motor in a standardised structural shape IM B3 or IM B5
(depending on version), a pulse generator, a brake and a shaft with associated
mountings that can absorb the load from the ropes.
It is offered in 3 construction sizes with different motor outputs and in 3
construction versions:

Version:
the traction sheave is arranged as floating on one motor side. The brake is located
on the opposite motor side. The traction sheave is attached to the end of the motor
shaft on the conical shaft end and secured in place by a screw-connected plate.
The use of microencapsulated screws and special locking washers ensures that the
traction sheave is additionally secured against unwanted detachment. This version
of the machine corresponds to the standardised structural shape IM B3.

Machine room version:


On this version, the brake is equipped with manual release levers, the rope cover
has been modified and the brakes are covered.

All machines are configured for single wrap. A rope guard holds the ropes in the
groove profiles and prevents intrusion into the rope entry points.

The machine has no automatic interlock.

Temperature monitoring
Motor: a temperature sensor is built into the winding of the stator to monitor the
motor temperature. It is connected via the motor supply line installed at the factory.

Note: for signal evaluation of the temperature sensor, it is to be connected by the


customer to a posistor triggering device.

ThyssenKrupp Aufzugswerke GmbH 14 12-2011


3.
3.1

Fig. 3.1
Typenschild Maschine Typenschild Bremse ZB machine PMC145 S
Machine type plate Brake type plate
ZB machine PMC145 XS
Dimensions
OPERATING MANUAL

Technology

ThyssenKrupp Aufzugswerke GmbH


3.1.1 PMC145 S (450 kg, 1.0 m/s)

Bemerkungen / Remarks:

15
1) Anzugsdrehmoment
Tightening torque
PMC145

a) Befestigung Maschine auf Rahmen - Gewinde M16 / 30 tief


Einschraubtiefe M16 - min. 20 (Festigkeitsklasse 8.8)
Mounting of machine on base frame - thread M16 / 30 deep
Screw-in depth M16 - min. 20 (hardness class 8.8)

b) Anheben Maschine mit Ringschrauben - M12


Raising the machine with eyebolts - M12

S = Schwerpunkt
Centre of gravity

G = Gesamtgewicht
Total weight
PMC145 XS (450 kg, 1.6 m/s)

ZB machine PMC145 S/XS


AY machine PMC145 S/XS

Data sheet ZB machine PMC145 S/XS

12-2011
TECHNOLOGY
3.1.2

Fig. 3.2
OPERATING MANUAL

ThyssenKrupp Aufzugswerke GmbH


PMC145 M (630 kg, 1.0 m/s)
PMC145 XM (630 kg, 1.6 m/s)

Bemerkungen / Remarks:

16
1) Anzugsdrehmoment
Tightening torque
PMC145

a) Befestigung Maschine auf Rahmen - Gewinde M16 / 35 tief


Einschraubtiefe M16 - min. 20 (Festigkeitsklasse 8.8)
Mounting of machine on base frame - thread M16 / 35 deep
Screw-in depth M16 - min. 20 (hardness class 8.8)

b) Anheben Maschine mit Ringschrauben - M12


Typenschild Bremse Raising the machine with eyebolts - M12
Brake type plate
S = Schwerpunkt
Centre of gravity

G = Gesamtgewicht
Typenschild Maschine Total weight
Machine type plate

ZB machine PMC145 M/XM


AY machine PMC145 M/XM
ZB machine PMC145 M
ZB machine PMC145 XM
Data sheet ZB machine PMC145 S/XM

12-2011
TECHNOLOGY
3.1.3

Fig. 3.3
OPERATING MANUAL

ThyssenKrupp Aufzugswerke GmbH


PMC145 L (1000 kg, 1.0 m/s)
PMC145 XL (1000 kg, 1.6 m/s)

Bemerkungen / Remarks:

17
1) Anzugsdrehmoment
Tightening torque

a) Befestigung Maschine auf Rahmen - Gewinde M16 / 30 tief


PMC145

Einschraubtiefe M16 - min. 20 (Festigkeitsklasse 8.8)


Mounting of machine on base frame - thread M16 / 30 deep
Screw-in depth M16 - min. 20 (hardness class 8.8)

b) Anheben Maschine mit Ringschrauben - M12


Raising the machine with eyebolts - M12

S = Schwerpunkt
Typenschild Bremse Centre of gravity
Brake type plate
G = Gesamtgewicht
Total weight
Typenschild Maschine
Machine type plate

ZB machine PMC145 SL/L/XL


ZB machine PMC145 L AY machine PMC145 SL/L/XL
ZB machine PMC145 XL

Data sheet ZB machine PMC145 SL/L//XL

12-2011
TECHNOLOGY
OPERATING MANUAL PMC145 TECHNOLOGY

3.2 Ambient conditions

The machine is configured for the following ambient conditions:


Air humidity up to 95% (no dewfall).
Temperatures between 0 C and + 45 C.
Height without derating: 1000 m amsl.
A minor dust and/or salt content of the air is permitted (harbour towns).
For safety, the brake system stops the elevator under the following conditions:
Air humidity up to 99% (no dewfall).
Temperatures between - 30 C and + 70 C.

NB: at temperatures around and below freezing point, dewfall can lead to a drop in
the braking torque of the brake.
In the event of longer standstills, there is a danger that the friction linings rust and
seize on the friction surfaces.
The corresponding countermeasures (e.g. air conditioning unit) are to be
implemented by the operator of the assembly.

In the case of synchronous machines, the max. current must not exceed the value
on the type plate.

ThyssenKrupp Aufzugswerke GmbH 18 12-2011


OPERATING MANUAL PMC145 TECHNOLOGY

3.3 Pulse generator

A sealed single-turn absolute pulse generator with sinusoidal output signal is built
onto the end of the rotor shaft to regulate and control the drives.
It is connected to the control system via a shielded connection line firmly connected
to the pulse generator with Sub-D connectors.

The line shield is placed on the connector and pulse generator housing.

Assembly instructions:
The pulse generator is attached to the brake by the pulse generator bracket.
The washers enclosed with the pulse generator are designed with twist protection.

Mounting of pulse generator


with detent edged washer
as twist protection

Pulse generator bracket

Pulse generator

Mount
Pulse generator bracket
Fig. 3.6

Other documents, see Appendix for pulse generator


Disassembly
Pin assignment
Dimensions

Note:
The pulse generator fitted as standard is specially geared to the drive and must not
be changed.

ThyssenKrupp Aufzugswerke GmbH 19 12-2011


OPERATING MANUAL PMC145 TECHNOLOGY

3.4 Traction sheave


The one-part version of the traction sheave (rim and hub) is in a floating
arrangement on the conical shaft end of the drive shaft, secured with a disc. For
safety reasons, microencapsulated screws and locking washers are used to mount
the disc.

The groove flanks are hardened as standard [50 HRc]

Machine type Unit PMC145 S / XS PMC145 M / XM PMC145 L / XL

Diameter - DT [mm] 240


Rim width - B [mm] 75 100 135
Rope diameter - d [mm] 6
1)
Number of grooves - z max. 6 max. 8 max. 11
3) 4)
Groove clearance - GC [mm] 12 10
2)
Version Seat groove
1)
Vee groove angle - [] 75 - 100
Material EN-GJS 600-3
1)
dependent on consignment
2)
Version in accordance with a factory standard 60 300 50 00 0 with hardened groove flanks (min.
50 HRc).
3)
NC91 - standard
4)
MO61- standard

Table 3.7

ThyssenKrupp Aufzugswerke GmbH 20 12-2011


OPERATING MANUAL PMC145 TECHNOLOGY

3.5 Brake
The electromagnetically operated dual-circuit brake is fitted to the BS bearing
bracket.
Special securing screws with rounded hexagon socket screws (Torx) and a
securing pin are used, preventing unwanted loosening of the screwed connections.
The brake (test status ABV 766/1) meets the requirements for the protective device
that prevents overspeed in the upward moving elevator car in accordance with
EN81, section 9.10.
It consists of two adjacently arranged disc brakes (parallel arrangement) with a
joint brake rotor and has a direct effect on the driven shaft.
When de-energised, the anchor disc of each brake is pressed by means of elastic
force onto the brake rotor. The force shifts the brake rotor on the gear teeth of the
motor shaft and presses the second lining side against the fixed bearing surface of
the PMC145 bearing bracket.
The braking torque of a brake circuit is configured in such a way that the loaded
elevator car is brought to a halt from its rated speed and safely held in place. A
calculation-based check and single-circuit check are to be carried out during
project planning or before commissioning.
It is not possible to set the braking torque or air gap.
The brake may only be adjusted in the manufacturer's plant. In the event of any
modification, the function of the brake is no longer ensured.
The brake contains a connection cable with the corresponding multiple connectors
(on the MR version without multiple connectors) for connection of the brake to the
brake control and evaluation of the brake monitoring.

Machine type Unit PMC145 S / XS PMC145 M / XM PMC145 L / XL


Manufacturer Mayr
ROBA-duplostop RSR ...
Brake type
200 400
Braking torque [Nm] 2x250 2x350 2x550

Table 3.8

Brake release
The regular electrical release takes place on applying current to the brake.
Applying voltage to the two separately connected brake magnet coils (series
connection of the brakes) draws in the armature base plates and releases the joint
brake rotor of the brake.
A manual brake release is only fitted on the MR version.
See Appendix, Mayr brakes

ThyssenKrupp Aufzugswerke GmbH 21 12-2011


OPERATING MANUAL PMC145 TECHNOLOGY

Warning!
On connecting the brakes, the manufacturer of the elevator system must
implement suitable measures that enable inspection of the brake (separately for
each brake circuit) and emergency rescue (also in the event of a power failure).
Note!
The brakes of PMC 145 machine are intended for static application as a parking
brake. Dynamic braking is restricted to emergency and inspection braking.
During normal operation, the wear on brake linings is negligible. Under no
circumstances does the brake replace safety systems for downward operation.
Brake monitoring
A microswitch is fitted for monitoring the brake function of each brake circuit. This
reports the current position of the brake (released / closed) by means of a
corresponding signal.

The brakes with mechanical brake release lever have an additional wear
monitoring switch.

The switches are fitted, set and provided with safety coating varnish at the plant.
The customer must evaluate the monitoring signals.

3.6 General technical data

Designation Unit Technical data


Machine PMC145
Version S XS M XM L XL
Weight (including traction sheave) [kg] 154 174 185 205 242 263
Mass moments of inertia [kgm2] 0,22 0,29 0,29 0,33 0,42 0,46
(including traction sheave)
Airborne noise level [dB(A)] < 54
Momentum grade G 2.5
Type of protection IP21

Table 3.9

ThyssenKrupp Aufzugswerke GmbH 22 12-2011


OPERATING MANUAL PMC145 TECHNOLOGY

3.7 Electrical data for brake

Version without manual release for deployment of the machine in installations


without machine room

Designation Unit Electrical data for brake


Machine PMC145
Version S / XS M / XM L / XL
Manufacturer Mayr
ROBA-duplostop RSR ...
Type
200 400
Electrical ventilation 1 solenoid per brake circuit (series connection)
Overexcitation: 2 x 103.5 = 207
Operating voltage [VDC]
Stop: 2 x 72 = 144
Energy consumption -
[W] 2 x 151 2 x 158 2 x 181
overexcitation
Energy consumption - stop [W] 2 x 72 2 x 76 2 x 89
[c/h] 120 180
Operating mode S5 [%
duty 50
cycle]

Table 3.10

Version with manual release for deployment of the machine in installations


with machine room

Designation Unit Electrical data for brake


Machine PMC145
Version S / XS M / XM L / XL
Manufacturer Mayr
ROBA-duplostop RSR ...
Type
200 400
Electrical ventilation 1 solenoid per brake circuit (series connection)
Overexcitation: 2 x 90 = 180
Operating voltage [VDC]
Stop: 2 x 45 = 90
Energy consumption -
[W] 2 x 264 2 x 348 2 x 344
overexcitation
Energy consumption - stop [W] 2 x 66 2 x 87 2 x 86
[c/h] 120 180
Operating mode S5 [%
duty 50
cycle]

Table 3.11

ThyssenKrupp Aufzugswerke GmbH 23 12-2011


OPERATING MANUAL PMC145 TRANSPORT

4. Transport and storage

Packaging:
The machine will be shipped on a pallet, optionally package in foil.

Transport:
Transport must be effected in compliance with the safety regulations and
observing the centre of gravity of the drive.

Fork-lift truck transport:


In the case of transport with a fork lift, the forks used must be long
enough to prevent the transported goods from tipping over.
Always pick up the transport pallet with the forks, not the motor itself.
Pay attention to protruding parts! Danger of injury and damage!

Crane transport:
Do not walk underneath suspended loads!
Use 3 M12 ring bolts to attach transport chains or ropes to the motor.

After transport, remove the Fig. 4.1


wooden transport protection slats.
Pay attention to the icons on the packaging or elsewhere.

Top Fragile goods Protect against


water

Protect against heat Hand hooks Attach here


prohibited

ThyssenKrupp Aufzugswerke GmbH 24 12-2011


OPERATING MANUAL PMC145 TRANSPORT

Dimensions and weight


The weight data is specified on the packaging of the drive on a label.
See table 3.9.
Please refer to the delivery note for the dimensions.

Check on acceptance by the recipient


The delivered parts and their packaging are to be checked for completeness,
damage or other conspicuous features.

Reporting and documenting damage in transit


On delivery, make sure that no damage in transit has occurred.

Information
Any damage that is determined is to be documented immediately
(sketch, photo, description of the damage).
Forward the corresponding documents without delay to
THYSSENKRUPP AUFZUGSWERKE GmbH.

Unpacking
Information
Dispose of packaging materials in an environmentally compatible
manner or reuse them.
Specific transport aids and shipping braces remain with the customer.

Intermediate storage
If the assembly is not installed immediately after delivery, it must be
covered and stored carefully in a protected location.
Attention is to be paid to ensuring that no condensation forms on the
cover and that no moisture can penetrate.
The assembly must not be stored outdoors. Bare parts have no long-term
preservation.

Ambient conditions
Information
The environment at the final location (moisture, temperature) must
correspond to normal indoor climate conditions for machine rooms.
(According to EN 81. between +5 and +40 C)
The relative air humidity must not exceed 70%.

ThyssenKrupp Aufzugswerke GmbH 25 12-2011


OPERATING MANUAL PMC145 MOUNTING THE MACHINE

5. Setting up the machine

Setting up
The drive is set up depending on customer requirements

Aligning the drive


The machine is to be set up according to the plan of installation. The rope
departure from the traction sheave and deflecting pulley is to be aligned
plumb according to the drawing on the elevator car rope pulley or the
counterweight pulley.
With load applied to the ropes, the machine should be aligned horizontally on
its installation surface. Irregularities are to be balanced out by inserting shims
under the support.

Mounting the drive


Raising the drives, see Fig. 3.1-3.3 after comment b)
Mounting the drives, see Fig. 3.1-3.3 after comment 1) and a).

Note: the brake is to be protected against coarse dust and liquids of any
type. It may only be operated with the protection fitted above the brake at the
plant.
After completion of the setting up procedures, the securing bolts are to be
tightened with the prescribed torque. See Appendix

ThyssenKrupp Aufzugswerke GmbH 26 12-2011


OPERATING MANUAL PMC145 MOUNTING THE MACHINE

5.1 PMC145

Electrical connection:

Connection of the brakes using the supplied cables (power and test
switch, see Fig. 5.3 and 5.4)
The motor connection cable (power and PTC thermistor) is
connected at the factory.
The absolute pulse generator is connected at the plant

Connection
motor / PTC thermistor

Connection
Brakes

Left brake
Connection
Pulse generator

Clamps for screen,


Fig. 5.0 brake lines

ThyssenKrupp Aufzugswerke GmbH 27 12-2011


OPERATING MANUAL PMC145 MOUNTING THE MACHINE

5.1.2 PMC145 (machine room version)

Electrical connection :
Connection of the brakes using the supplied cable (power and test
switch, see Fig. 5.3 and 5.4.1)
The motor connection cable (power and PTC thermistor) is
connected at the factory.
The absolute pulse generator is connected at the plant.

Switch for wear monitoring

Switch for brake monitoring


Fig. 5.1

Manual release lever

Connection
Brakes

Fig. 5.2

ThyssenKrupp Aufzugswerke GmbH 28 12-2011


OPERATING MANUAL PMC145 MOUNTING THE MACHINE

Brake connection at the drive:

Label left brake

Fig. 5.3

Connection lines at control system:

Brake output

PMC145 MR version PMC145

Motor PTC
thermistor

Motor power

Screen

Fig. 5.4.1
Strain relief

Brake test switch


Fig. 5.4

Do not apply voltage greater than 2.5 V at the PTC thermistor. Adhere to the
internal resistance of the measurement devices!

ThyssenKrupp Aufzugswerke GmbH 29 12-2011


OPERATING MANUAL PMC145 MOUNTING THE MACHINE

5.2 Electrical wiring diagram for PMC145

Fig. 5.5

5.2.1 Electrical wiring diagram for PMC145 (machine room version)

Fig. 5.6

5.3 Wiring

Pay attention to the following when routing the control, pulse generator and
motor cables:

The pulse generator cable is to be routed as far as possible away from the
motor cable, but at least over 200 mm.

The control line should not be routed parallel to the motor cable either.

ThyssenKrupp Aufzugswerke GmbH 30 12-2011


OPERATING MANUAL PMC145 COMMISSIONING

6. Commissioning the machine

Before commissioning the machine, the following points should be checked


and carried out:

Safety, auxiliary and installation tools removed from the danger zone
Setup and alignment of machine, frame and rope departure checked
Mounting of machine and frame (if present) checked
Bolts tightened and secured with the prescribed torque (see table
'Tightening torques')
Protective cover fitted
Function of safety shutdown devices checked
Power connections, earthing of motor and brake magnet connected,
checked and secured
Special add-on components (optional) checked
Attach the direction arrow (Up / Down) above traction sheave and clearly
visible according to the direction of travel
Check the brake function
Brake test carried out with each individual brake circuit

ThyssenKrupp Aufzugswerke GmbH 31 12-2011


OPERATING MANUAL PMC145 MAINTENANCE

7. Maintenance
7.1 Maintenance of the machine

Maintenance period: maintenance of the machine should take place within


the framework of central maintenance of the elevator, at least once a year.
Note: commissioning and maintenance work may only be carried out by
trained and instructed qualified personnel.
All laws and regulations for elevator systems as well as accident prevention
regulations must be known and complied with.

Check braking deceleration of the magnetic brakes with each


brake circuit individually
Check groove profile on the traction sheave for damage and wear
Check secure seating of bolts of the traction sheave mount
Check motor bearings for wear (noise, backlash)

Check that electrical connections are in good condition, i.e.


undamaged; check that they are securely attached and safe
Check that protective and safety devices are present, functioning
and correctly set
Check the seals on the shaft in the area of the brake
(grease and/or oil escaping)

Table 7.1

NB: during maintenance and inspections, no voltage may be applied to the


brake!
Comply with the instructions in the Appendix 'Brake'

7.2 Lubrication

The bearings have lifetime lubrication, which means that the drive requires
no other lubrication.


ThyssenKrupp Aufzugswerke GmbH 32 12-2011


OPERATING MANUAL PMC145 MAINTENANCE

7.3 Testing the brake


Test interval: once a year within the framework of the central
maintenance of the elevator

Test the braking deceleration at each brake circuit.

Note: before beginning the test, the following preparations are required:
Signs indicating that maintenance work is under way must be attached to
the elevator at all landing doors.
All doors are to be locked properly.
Ensure that there is no one in the elevator car.
The elevator car must be located at least two floors below the top landing.
For the individual test of the brake circuits, the brake magnet coils must be
connected separately to the excitation / retentive voltage (see table in
chapter 8).
Manual release levers are mounted on the machine room version.
See chapter 8.

In order to be able to test a brake circuit separately, the other brake must
be opened.
NB: If the elevator begins to move after releasing a brake circuit or does
not noticeably decelerate during the brake operation, the system is to be
switched off immediately and the brake is to be closed.

The dual brake function is not ensured. Check the brake!

Activate the measuring device.


Test sequence: test the braking deceleration on each brake circuit
Initiate a normal run (brake to be tested is opened)
After the rated speed has been reached, trigger an emergency stop (brake
to be tested closes)
Determine the deceleration value for the 1st brake circuit with the
measuring device.
Compare the measurement result with the standard value
Disconnect the permanent power supply of the continuously opened 2nd
brake circuit and connect to the 1st brake circuit.
Connect the measuring device to the 2nd brake circuit.
Repeat the test operation on the 2nd brake circuit.

Deceleration values:
The minimum deceleration value for one brake circuit is approx. 0.4 m/s
The minimum deceleration value for both brake circuits is approx. 1.0 m/s

ThyssenKrupp Aufzugswerke GmbH 33 12-2011


OPERATING MANUAL PMC145 MAINTENANCE

NB: after completion of the individual brake test, the original state of the
circuit (operation of both brakes simultaneously) is to be re-established.
Testing of both brake circuits
Following an individual test, run a brake test with both brake circuits by
triggering emergency braking.
The deceleration value here must be significantly greater than the values
determined in the individual tests!

Check for wear:


Use a feeler gauge to check the air gap between the spool and armature
base plate with the brake closed (coils without current).
Repeat the operation at various positions of the circumference.

Table for brake air gap


See chapter 8.

Once the limit air gap is reached (see chapter 8), the complete brake
must be replaced. Repairs can only be carried out at the plant.

Air gap

Fig. 7.1

PCM version without brake release lever

ThyssenKrupp Aufzugswerke GmbH 34 12-2011


OPERATING MANUAL PMC145 MAINTENANCE

7.4 Checking for escaping grease / oil


Examine the area around the bearing bracket, disc brake and brake linings
(brake rotor) for traces of oil.

You cannot see the inner brake disc.


This means that a precise examination of the gap between the bearing
bracket and inner brake body is important; it should also be checked for
traces of oil.

Contamination level Procedure


No escaping oil determined Check regularly within the Every 3 months
framework of maintenance (6 months if
elevator used
infrequently,
< 50 000 runs
per year)
If escaping oil is determined Clean the drive and, if Repair after
or oil is escaping from the necessary, the brake, and 4 weeks at the
brake disc / brake linings carry out short-term repairs latest
Before continuing operation
until modification, run a brake
test. If the braking effect is
inadequate, shut down the
installation.

PMC
Dual-circuit
Grease disc brake

Brake rotor Fig. 7.5 Bearing bracket


Fig. 7.4 Bearing bracket

ThyssenKrupp Aufzugswerke GmbH 35 12-2011


OPERATING MANUAL PMC145 APPENDIX

8. Appendix
8.1 Tightening torques

NB: during work on the machine or parts replacement, care must be taken to
ensure that the prescribed bolt tightness and tightening torques are complied
with.
Non-microencapsulated bolts / screws are to be secured against unwanted
loosening during installation using Loctite 241 or a similar means of securing
bolts / screws.
To comply with the prescribed torques, all bolt and screw connections are to
be tightened using a torque wrench!

The following table applies to all mounts.


Slotted pan head tapping screws DIN 912 ISO 4762
Hexagon screws DIN 931 / 933 ISO 4014 / 4017

Dimensions Tightening torque MA (Nm)


Tightness 8.8 10.9 12.9
M4 2.6
M5 5.3
M6 9.0 12 15
M8 23 30 35
M10 45 60 75
M12 75 110 130
M16 190 270 320
M20 370 520 620
M24 640 900 1100

Table 8.1
Please bear in mind that individual mounting parts are to be tightened with a
tightening torque that deviates from that specified in the above table.
The applicable values are listed on the previous page or in the corresponding
chapter of this manual.

ThyssenKrupp Aufzugswerke GmbH 36 12-2011


OPERATING MANUAL PMC145 APPENDIX

8.2 Documents

Verification of the calculation of a traction sheave shaft

Manufacturer specifications for pulse generator


Certificates
Technical data

Manufacturer specifications for brake


with and without brake release lever
Certificates
Technical data

ThyssenKrupp Aufzugswerke GmbH 37 12-2011


DR. JOHANNES HEIDENHAIN GmbH
Postfach 1260 .0-83292 Traunreut-"'(08669)
31-0 .~ (08669) 5061

Die Singleturn-Absolutdrehgeber der Baureihe ECN 413


The Absolute Single turn Rotary Encoders of the EGN 413 Series

Identnummer Varianten
Basic part number Variant

01,02,
586 645 10 -12,
22 -24

erfllen die grundlegenden Vorschriften folgender EG Richtlinien:


comply with the regulations of the following EC Directive:

EMV-Richtlinie 89/336/EWG
EMC Directive 89/336/EEC

Die bereinstimmung mit den Vorschriften der oben genannten Richtlinie wird durch die Einhaltung
folgender Normen nachgewiesen:
This product complies with these regulations by meeting the following standards:

DIN EN 55022, Klasse B


DIN EN 61000-6-1
DIN EN 61000-6-2
DIN EN 61000-6-3
DIN EN 61000-6-4

Traunreut, 05.02.2007 HEIDENHAIN ,GmbH

1(/
Israel
Qualittsbeauftragter
Quality Officer

Diese Erklrung bescheinigt die bereinstimmung mit den genannten Richtlinien, beinhaltet jedoch keine
Beschaffenheitsgarantie. Die Sicherheitshinweise der mitgelieferten Produktdokumentationen sind zu beachten.
This declaration certifies thai this product complies with the above guidelines. It is not, however, a guarantee of quality.
Please comply with the safety instructions in the accompanying documentation.

20884902
Montage DIN EN 100 015 1
Assembly CECC 00015 1
Montage
Montaggio
2. 0 I
Montaje

1.
SW3/4
Montageanleitung
3. SW4
5.
Mounting Instructions
M5 x 20 DIN 6912 8.8 Md = 5 + 0.5 Nm Instructions de montage
Md = 5 + 0.5 Nm Istruzioni di montaggio
Mehrfachverwendung max. 3x.
For multiple use, max. 3x. Instrucciones de montaje
Utilisation rpte 3x max.
Riutilizzo max 3x. 4. Im Lieferumfang enthalten Fleckbeschichtung
Uso mltiple mx. 3 veces. 2x M5 2x Sperrkantscheibe SKM5 Included in delivery Patch coating
Contenu dans la fourniture Enduit autofreinant
Md = 5 0,5 Nm
Standard di fornitura Rivestimento
(nicht im Lieferumfang enthalten) Elementos suministrados Recubrimiento tintado

M5 x 50 DIN 6912 8.8


ID 202 264-36
ECN 413 EnDat01
2/2007

Demontage
Disassembly
Dmontage M10 DR. JOHANNES HEIDENHAIN GmbH WELLA1:65B, KUPPA1:66A,
Smontaggio Abdrckgewinde Dr.-Johannes-Heidenhain-Strae 5 ANELA1:16S15, BELEA1:58
Desmontaje Back-off thread 83301 Traunreut, Germany
Filetage de dgagement { +49 (86 69) 31-0
Brugola per estrazione | +49 (86 69) 50 61
1. rosca de expulsin E-Mail: info@heidenhain.de
SW3/4
Technical support | +49 (86 69) 31-10 00
Measuring systems { +49 (86 69) 31-31 04
E-Mail: service.ms-support@heidenhain.de
2. TNC support { +49 (86 69) 31-31 01
E-Mail: service.nc-support@heidenhain.de
2x M5 NC programming { +49 (86 69) 31-31 03
E-Mail: service.nc-pgm@heidenhain.de
3. 4. 5. PLC programming { +49 (86 69) 31-31 02
E-Mail: service.plc@heidenhain.de
Lathe controls { +49 (7 11) 95 28 03-0
360
E-Mail: service.hsf@heidenhain.de
lsen
Loosen M5 www.heidenhain.de
dvisser M10
svitare M10
aflojar SW4
M10 Schraube nur soweit eindrehen, bis sich die Konusverbindung lst.
Turn the M10 screw only far enough in to release the taper shaft.
Ne tourner la vis M10 que jusqu'e0 ce que l'attache du cne se desserre.
Ruotare la brugola M10 fino al distacco della sede conica dell'albero.
Ve 00
Apretar el tornillo M10 slo hasta que la conexin cnica se suelte. 619 091-91 12 2/2007 E Printed in Germany nderungen vorbehalten
Subject to change without notice Sous rserve de modifications Con riserva di modifiche Sujeto a modificaciones
ECN 413 EnDat01 16.850.1
Mae in mm Kabelschirm mit Gehuse verbunden
Dimensions in mm Cable shield connected to housing
Cotes en mm 0.3 A 1 2 3 4 5 6 7 8 Blindage du cble reli au botier
Dimensioni in mm
Dimensiones en mm 9 10 11 12 13 14 15 Collegare lo schermo del cavo alla carcassa
Pantalla del cable conectada a carcasa

4 12 2 10 1 9 3 11 5 13 8 15 6
UP Sensor 0V Sensor
A+ A B+ B DATA DATA CLOCK CLOCK 1)
UP 0V
1.5

62 +10

86
72
br/gn bl gn/sw ge/sw bl/sw rt/sw gr rs vio ge
BN/GN BL GN/BK YL/BK BL/BK RD/BK GY PK VI YL
A = Lagerung
Bearing Nichtverwendete Pins oder Litzen drfen nicht belegt werden! 1) Innenschirm
Roulement Vacant pins or wires must not be used! Internal shield
Cuscinetto Les plots ou fils non utiliss ne doivent pas tre raccords! Blindage interne
Rodamiento I pin o i fili inutilizzati non devono essere occupati! Schermo interno
No conectar los pins o hilos no utilizados! Blindaje interno
k = Kundenseitige Anschlussmae
Required mating dimensions
Conditions requises pour le montage
Quote per il montaggio
Cotas de montaje requeridas

RS-485
max. Cable length [m]

CLOCK

fc = 1
CLOCK > 100 mm > 100 mm > 200 mm
T T
Schirm auf Gehuse
UP = 3.6 ... 14 V Strquellen
Shield on housing
(max. 160 mA) M Noise sources
Blindage sur boter
am Gert, at encoder, sur l'appareil, integrato, en el aparato. Sources parasites
Schermo sulla carcassa
Origine del disturbo
Blindaje a carcasa
Fuentes de interferencias
EN 50 178/4.98; 5.2.9.5 300 1 000 2 000
IEC 364-4-41: 1992; 411(PELV/SELV)
CLOCK frequency [kHz]
(siehe, see, voir, vedi, vase
HEIDENHAIN D 231 929) (C
(F)

R1 R2
RS-485 360 el.
T 40 C T 10 C
(40 F) (14 F)
DATA A 0.8 ... 1.2 VSS
0
DATA ( 1 VSS)
90 el. 6 mm R1 20 mm R2 75 mm
30 ... 80 C
A B (22 ... 176 F)
0
B
ECN 413
Absoluter Singleturn-Drehgeber / Absolute singleturn encoder
einseitig offene Hohlwelle / Blind hollow shaft
Version Thyssen

155 16.850.1 22


720.3

58
83

151

6

4.4

6.9
21
5.4
A= Lagerung Kundenwelle
B= Lagerung Geber
k= Kundenseitige Anschlussmae 16.850.1
m= Messpunkt Arbeitstemperatur
= Selbstsichernde Schraube M5 x 50 0.3 A
DIN 6912 SW4
= Abdrckgewinde M6
= Abdrckgewinde M10
= Verschlussschraube SW3 und 4

A= Bearing of mating shaft 1.5


62 +10

B= Bearing of encoder
86
72

k= Required mating dimensions


m= Measuring point for operating tem-
perature
= Self-tightening screw M5 x 50
DIN 6912 width A/F 4
= Back-off thread M6
= Back-off thread M10
= Screw plug sizes 3 and 4

Elektrischer Anschluss / Electrical Connection

4 12 2 10 1 9 3 11 5 13 8 15 6
1)
5V 5V 0V 0V A+ A B+ B DATA DATA CLOCK CLOCK
UP sensor UN sensor

br/gn bl ws/gn ws gn/sw ge/sw bl/sw rt/sw gr rs vio ge


BN/GN BL WH/GN WH GN/BK YL/BK BL/BK RD/BK GY PK VI YL
1)
Die Sensorleitung ist intern mit der Versorgungsleitung verbunden. Innenschirm / Internal shield
The sensor line is connected internally with the power supply. Auenschirm auf Gehuse / External shield on housing
Nicht verwendete Pins oder Litzen drfen nicht belegt werden!
Vacant pins or wires must not be used!
ECN 413

Absolute Positionswerte EnDat 2.2


Absolute position values

Bestellbezeichnung / Ordering designation EnDat 01

Positionen/U / Positions per revolution 8 192 (13 bit) / 8192 (13 bits)

Code / Code Dual / Pure binary

Elektr. zul. Drehzahl / bei Genauigkeit 1 500 min1/ 1 LSB; 12000 min1/ 50 LSB
Elec. permissible speed / at accuracy 1500 rpm/ 1 LSB; 12000 rpm/ 50 LSB

Rechenzeit tcal / Calculation time tcal 5 s

Inkrementalsignale / Incremental signals 1 VSS1) / 1 VPP1)

Strichzahlen / Line counts 2 048

Grenzfrequenz 3 dB / Cutoff frequency 3 dB 400 kHz

Systemgenauigkeit / System accuracy 20

Spannungsversorgung / Power supply 3,6 bis 14 V / 3.6 to 14 V


Stromaufnahme / Current consumption 160 mA (ohne Last / without load)

Elektrischer Anschluss Kabel 5 m, mit Sub-D-Stecker (Stift), 15-polig


Electrical connection Cable 5 m, with D-sub connector (male), 15-pin

Welle / Shaft Konuswelle 9,25 mm, Konus 1/10 / Taper shaft 9.25 mm, taper 1:10
2) 2)
Mech. zul. Drehzahl n / Mech. perm. speed n 12 000 min1 / 12 000 rpm

Trgheitsmoment Rotor / Moment of inertia of rotor 2,6 106 kgm2

Vibration 55 bis 2000 Hz / Vibration 55 to 2000 Hz 300 m/s2 (EN / IEC 60068-2-6)
Schock 6 ms/2 ms / Shock 6 ms/2 ms 1 000 m/s2/ 2000 m/s2 (EN / IEC 60068-2-27)

Max. Arbeitstemperatur2) 100 C


Max. operating temperature2)

Min. Arbeitstemperatur Kabel fest verlegt: 40 C / Flange socket or fixed cable: 40 C


Min. operating temperature Kabel bewegt: 10 C / Moving cable: 10 C

Schutzart EN 60529 / Protection IEC 60 529 IP 67 am Gehuse; IP 64 am Welleneingang / IP 67 at housing; IP 64 at shaft inlet

Masse / Weight ca. 0,3 kg/0.3 kg


1)
eingeschrnkte Toleranzen: Signalgre 0,8 bis 1,2 VSS
2)
Zusammenhang zwischen Arbeitstemperatur und Drehzahl bzw. Versorgungsspannung siehe Katalog Drehgeber
1)
Restricted tolerances: Signal amplitude 0.8 to 1.2 VPP
2)
For the correlation between the operating temperature and the shaft speed or supply voltage, see Rotary Encoders catalog

DR. JOHANNES HEIDENHAIN GmbH


Dr.-Johannes-Heidenhain-Strae 5
83301 Traunreut, Germany
{ +49 (86 69) 31-0
| +49 (86 69) 50 61
E-Mail: info@heidenhain.de
www.heidenhain.de
Mb 1108 2/2007 nderungen vorbehalten/Subject to change without notice
Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Please read these Operational Instructions carefully and follow them accordingly!
Ignoring these Instructions can lead to lethal accidents, malfunctions, brake failure and damage to other parts.

Contents:
Page 1: - Contents Page 11: - Installation: Design with Toothed Motor Shaft
- Declaration of Conformity - Installation: Hub Design
- Safety and Guideline Signs - Hand Release
- TV (German Technical Inspectorate) Certification - Braking Torque Adjustment
- Noise Damping
Page 2: - Safety Regulations
Page 12: - Release Monitoring
Page 3: - Safety Regulations
Page 13: - Wear Monitoring
Page 4: - Brake Illustrations
Page 14: - Electrical Connection (Operation with Nominal
Page 5: - Brake Illustrations Voltage)

Page 6: - Parts List Page 15: - Electrical Connection (Operation with Overexcitation)

Page 7: - Table 1: Technical Data Page 16: - Brake Inspection (Customer-side after Installation)
- Table 2: Technical Data - Dual Circuit Brake Functional Inspection
- Maintenance
Page 8: - Table 3: Technical Data - Disposal
- Malfunctions / Breakdowns
Page 9: - Table 4: Switching Times
- Torque-Time Diagram

Page 10: - Design


- Function
- State of Delivery
- Application
- Installation Conditions

Declaration of Conformity
A conformity evaluation for the applicable EU directives has been carried out for this product. The conformity evaluation is set out in
writing in a separate document and can be requested if required. It is forbidden to start use of the product until you have ensured that all
applicable EU directives and directives for the machine or system into which the product has been installed have been fulfilled.
Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion. This statement is
based on the ATEX directive.

Safety and Guideline Signs TV (German Technical Inspectorate)


Certification
Danger! License number: ABV 766/2
Danger of injury to personnel and
damage to machines.

Please Observe!
Guidelines on important points.

29/03/2010 TK/HW/GC/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0


Eichenstrae 1 Fax: 08341 / 804-421
87665 Mauerstetten http://www.mayr.de
Page 1 of 16 Germany eMail: info@mayr.de
Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Safety Regulations
These Safety Regulations are user hints only and may not be complete!

Guidelines for Electromagnetic Compatibility


Danger! (EMC)
Danger of death! Do not touch voltage-
carrying cables and components. In accordance with the EMC directives 2004/108/EC, the
individual components produce no emissions. However,
functional components e.g. mains-side energisation of the
brakes with rectifiers, phase demodulators, ROBA-switch
To prevent injury or damage, only professionals and
devices or similar controls can produce disturbance which lies
specialists should work on the devices.
above the allowed limit values. For this reason it is important to
read the Installation and Operational Instructions very carefully
Danger! and to keep to the EMC directives.
This warning applies if:
Device Conditions
 the electromagnetic brake is used incorrectly.
 the electromagnetic brake is modified. Please Observe!
When dimensioning the brakes, please
 the relevant standards for safety and / or installation remember that installation situations,
conditions are ignored. braking torque fluctuations, permitted
friction work, run-in behaviour and wear as well as general
Please Observe! ambient conditions can all affect the given values. These
Before product installation and initial factors should therefore be carefully assessed, and
operation, please read the Installation and alignments made accordingly.
Operational Instructions carefully and
observe the Safety Regulations. Incorrect operation can
cause injury or damage. Please Observe!
At the time these Installation and Operational Instructions go  Mounting dimensions and connecting dimensions must be
to print, the electromagnetic brakes accord with the known adjusted according to the size of the brake at the place of
technical specifications and are operationally safe at the time installation.
of delivery.  The magnetic coils are designed for a duty cycle of 100 %.
However, a duty cycle > 60 % leads to increases in
Please Observe! temperature which cause premature aging of the noise
damping and therefore an increase in switching noises.
 Only specialists who are trained in the transport, The max. permitted switching frequency is 240 1/h. On
installation, operation, maintenance and general operation overexcited brakes, the switching frequency must not
of these devices and who are aware of the relevant exceed 180 1/h.
standards should be allowed to carry out this work. These values apply for an intermittent duty S3 60%.
 Technical data and specifications (Type tags and The permitted surface temperature on the brake flange
documentation) must be followed. must not exceed 80 C at a max. ambient temperature of
 The correct connection voltage must be connected 45 C.
according to the Type tag. The overexcitation time span should be c. 600 ms on sizes
 Never loosen electrical connections or carry out 200 to 400 and c. 1 s for sizes 600 to 1000.
installations, maintenance or repairs while the voltage  The brakes are only designed for dry running.
connection is energised! The torque is lost if the friction surfaces come into contact
 Cable connections must not be placed under mechanical with oil, grease, water or similar substances.
strain.  The braking torque is dependent on the present run-in
condition of the brakes.
 Check electrical components for signs of damage before
putting them into operation. Never bring them into contact  Manufacturer-side corrosion protection of the metallic
with water or other fluids. surface is provided. The surface is rough sawn and not
machined (milled material).
 The braking torque is lost if the friction lining and / or the
friction surface come into contact with oil or grease.
Protection Class I
Please Observe!
This protection can only be guaranteed if the basic insulation is
Please ensure that the brake is clean and
intact and if all conductive parts are connected to the PE
oil-free, as both brake circuits have an
conductor of the permanent installation. Should the basic
effect on the same linings. Special sealing
insulation fail, the contact voltage cannot remain (VDE 0580).
measures, among other precautions, may be necessary - in
particular in gear applications!
Ambient Temperature 0 C up to +45 C
Danger!
Appointed Use At temperatures of around or under freezing point, condensation
This safety brake is intended for use in electrically operated can strongly reduce the torque. During longer downtimes, the
elevators and goods elevators according to EC 81-1/1998. friction linings can stick to the friction surfaces. The user is
The safety brake corresponds to DIN EN 81, Part 1 [Sections responsible for taking appropriate counter measures.
12.4.2.1 (2nd Paragraph), 12.4.2.2, and 12.4.2.5] in its general
design and its mode of operation. Insulation Material Class F (+155 C)
The effectiveness of the mechanical dual circuit system can be
tested at the place of operation (requirement acc. TRA 102). The magnetic coil and the casting compound are suitable for
use up to a maximum operating temperature of +155 C.

29/03/2010 TK/HW/GC/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0


Eichenstrae 1 Fax: 08341 / 804-421
87665 Mauerstetten http://www.mayr.de
Page 2 of 16 Germany eMail: info@mayr.de
Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Safety Regulations
These Safety Regulations are user hints only and may not be complete!

Brake Storage Please Observe the Following Standards:


 Store the brakes in a horizontal position, in dry rooms and DIN EN ISO
dust and vibration-free. 12100-1 and 2 Machine Safety
 Relative air humidity < 60 %. DIN EN 61000-6-4 Noise emission
 Temperature without major fluctuations within a range from EN12016 Interference resistance (for elevators,
20 up to +60 C. escalators and moving walkways)
 Do not store in direct sunlight or UV light. EN 60204 Electrical machine equipment
 Do not store aggressive, corrosive substances (solvents /
acids / lyes / salts etc.) near to the brakes.
For longer storage of more than 2 years, special measures are Liability
required (please contact the manufacturers).
 The information, guidelines and technical data in these
documents were up to date at the time of printing.
Handling
Demands on previously delivered brakes are not valid.
Before installation, the brake must be inspected and found to be
 Liability for damage and operational malfunctions will not
in proper condition. The brake function must be inspected both
be taken if
once installation has taken place as well as after longer system
downtimes, in order to prevent the drive starting up against - the Installation and Operational Instructions are ignored or
possibly seized linings. neglected.
- the brakes are used inappropriately.
User-implemented Protective Measures: - the brakes are modified.
 Please cover moving parts to protect against injury through - the brakes are worked on unprofessionally.
seizure and catapulted objects.
- the brakes are handled or operated incorrectly.
 Place a cover on the magnetic part to protect against injury
through high temperatures.
 Protect against electric shocks by installing a conductive Guarantee
connection between the magnetic component and the PE
conductor on the permanent installation (Protection Class I)  The guarantee conditions correspond with the
and by carrying out a standardised inspection of the Chr. Mayr GmbH + Co. KG delivery conditions.
continuous PE conductor connection to all contactable  Mistakes or deficiencies are to be reported to mayr at
metal parts. once!
 Protect against highly inductive switch-off peaks by
installing varistors, spark quenching units or similar devices
according to VDE 0580/2000-07, Paragraph 4.6, to prevent Conformity Markings
damage to the coil insulations or switch contact The product confirms to the CE according to the low voltage
consumption in extreme conditions (this protection is directive 2006/95/EC
contained in mayr rectifiers).
 Install additional protective measures against corrosion if
the brake is subject to extreme ambient conditions or is Identification
installed in open air conditions, unprotected from the
weather. mayr components are clearly marked and described on the
 Take precautions against freeze-up of the armature disk Type tag:
and the rotor in high humidity and at low temperatures.

Regulations, Standards and Directives Used: Manufacturer


DIN VDE 0580 Electromagnetic devices and components,
general directives
mayr
2006/95/EC Low voltage directive Name/Type
2004/108/EC EMC directive
95/16/EC Elevator directive Article number
EN 81-1 Safety regulations for construction and
installation of elevators and small goods
Serial number
elevators
BGV C1 (previously VGB 70) Safety regulations for
theatre stage technical systems

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

14 1 1.1 2 1.1 1 14
Air gap "b"

3
8

Left Right
brake brake

Customer-side
shaft

+0,12
Air gap "a" 0,45 -0,02

Fig. 1 Fig. 2a

Air gap "b"

16

10 12 6 11 10 6 12 11 15
Fig. 3

4 5 2

1
+0,2
Air gap "a" 0,45 -0,05

Fig. 4 Fig. 2b

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

7.1

Release Release

Fig. 5

7.6 7.3 7.4 1 7.2


7.1
3
7.5
2 Adjustment dimension
1,6 +0,2 for Size 200
2,0 +0,2 for Sizes 400 - 1000
Fig. 6

Left Right
brake brake

6 13 6 9
Fig. 7

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Parts List
(Only use mayr original parts)
Item Name
1 Coil carrier assembly (inc. magnetic coils)
1.1 Connection cable 2-wire;
Connection coil blue/brown
2 Armature disk
3 Rotor
4 Distance bolts
Hexagon head screw, strength 8.8. DIN 931:
For Size 200 (100 Nm / 150 Nm / 200 Nm design): M8x100
For Size 200 (250 Nm/ 280 Nm design): M8x110
For Size 400 (210 Nm / 275 Nm / 350 Nm / 420 Nm design): M10x110
5 For Size 400 (375 Nm / 450 Nm design): M10x110
For Size 400 (550 Nm / 600 Nm design): M10x120
For Size 600 (all designs): M12x120
For Size 800 (all designs): M12x130
For Size 1000 (all designs): M16x130
6 Release monitoring assembly
6.1 Microswitch inc. adapter plate (Fig. 10; page 12)
6.2 Cap screw (Fig. 10; page 12)
6.3 Hexagon nut (Fig. 10; page 12)
6.4 Hexagon head screw (Fig. 10; page 12)
6.5 Spring washer (Fig. 10; page 12)
7 Hand release assembly
7.1 Hand release lever
7.2 Steel ball
7.3 Thrust spring
7.4 Cap screw
7.5 Hexagon nut
7.6 Washer
O-ring NBR 70 (not included in delivery):
For Size 200 (all designs): D48x3
For Size 400 (210 Nm / 270 Nm / 350 Nm / 420 Nm design): D55x3
For Size 400 (375 Nm / 450 Nm / 550 Nm / 600 Nm design): D60x3
8 For Size 600 (all designs): D60x3
For Size 800 (650 Nm / 850 Nm design): D67x3
For Size 800 (950 Nm design): D76x3
For Size 1000 (920 Nm / 1050 Nm design): D76x3
For Size 1000 (1200 Nm design): D82x3
9 Wear monitoring assembly
9.1 Microswitch inc. adapter plate (Fig. 11; page 13)
9.2 Cap screw (Fig. 11; page 13)
9.3 Hexagon nut (Fig. 11; page 13)
9.4 Hexagon head screw (Fig. 11; page 13)
9.5 Spring washer (Fig. 11; page 13)
10 Cable clamp D6 for coil cable
11 Cable clamp D6 for microswitch cable
12 Cap screw M4x8
13 Cable tie
14 Type tag (on the side of the coil carriers)
15 Hub
16 O-ring

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Table 1: Technical Data (independent of Type and Size)


+0,20
Nominal air gap 1) "a" braked (Fig. 2) 0,45 0,05 mm
2)
Limit air gap "a" for nominal torque (Fig. 2) 0,9 mm
Inspection air gap "b" on released brake (Fig. 2) min. 0,25 mm
Protection (coil/casting compound): IP54
Protection (mechanical): IP10
Protection (switch): IP67
Ambient temperature: 0 C to +45 C
Duty cycle: 60 %
1)
Measured in the armature disk (2) area, middle, vertical centre axis.
2)
The nominal torque is given up to the limit air gap (0,9 mm).

Danger!
The tension ability of the brake is larger, but the rotor (3) must be replaced at the latest when the air gap reaches
0,9 mm, also due to the brake noise behaviour. On brakes with reduced braking torque, with hand release and / or
operating with overexcitation, unpermittedly high wear on the rotor (3) wear will not be noticed via the brake switching
behaviour. As the magnetic coil is capable in this constellation of achieving a very large armature disk (2) tension path,
unpermittedly high wear on the rotor (3) leads to relaxation of the thrust springs, which in turn causes a drop in braking
torque. In extreme cases, the armature disks (2) may even contact the shoulder screws or the adjusting screw on the
hand release (air gap 1,6 mm) which would lead to the braking torque being lost.
We therefore recommend an additional wear monitoring device (see page 14) for brakes with reduced braking torque,
with hand release and/or operation with overexcitation.
Brakes with reduced braking torque are
For Size 200: 100 Nm and 150 Nm design For Size 600: 500 Nm design
For Size 400, short: 210 Nm, 270 Nm, and 350 Nm design For Size 800: 650 Nm design
For Size 400, long: 375 Nm and 450 Nm design For Size 1000: 920 Nm design

Table 2: Technical Data


Nominal torque Overexcitation Nominal
3)
voltage Nominal voltage capacity Inductivity Rotor thickness
Size minimal 1,5 to 2 x U Nom U Nom P (20 C) (207 V coil) in new condition
100 Nm
150 Nm No 24/104/180/207 V DC 2 x 74 W 85,5 H 18 0.05 mm
200 200 Nm
250 Nm
Yes 24/104/180/207 V DC 2 x 74 W 85,5 H 18 0.05 mm
280 Nm
210 Nm
400 270 Nm
No 24/104/180/207 V DC 2 x 93 W 50 H 18 0.05 mm
Short version 350 Nm
420 Nm
375 Nm
No 24/104/180/207 V DC 2 x 92 W 18 0.05 mm
400 450 Nm
Long version 550 Nm
Yes 24/104/180/207 V DC 2 x 92 W 18 0.05 mm
600 Nm
500 Nm
No 24/104/180/207 V DC 2 x 86 W 64,6 H 18 0.05 mm
600 600 Nm
700 Nm Yes 24/104/180/207 V DC 2 x 86 W 64,6 H 18 0.05 mm
600
800 Nm Yes 24/104/180/207 V DC 2 x 96 W 64,6 H 20 0.05 mm
Long version
650 Nm
No 24/104/180/207 V DC 2 x 118 W 20 0.05 mm
800 850 Nm
950 Nm Yes 24/104/180/207 V DC 2 x 118 W 20 0.05 mm
920 Nm
No 24/104/180/207 V DC 2 x 121 W 20 0.05 mm
1000 1050 Nm
1200 Nm Yes 24/104/180/207 V DC 2 x 121 W 20 0.05 mm
3)
The braking torque (nominal torque) is the torque effective in the shaft train on slipping brakes, with a sliding speed of 1 m/s referring to
the medium friction radius.

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Table 3: Technical Data

Inspected max.
Inspected max. friction work Tightening
speed in on EMERGENCY torque Release
Nominal the elevator area as STOP fixing force per
torque Max. a prototype- per braking screw braking Release
Size minimal speed inspected brake circuit 4) Item 5 circuit angle Mass
100 Nm 100 N
150 Nm 1200 rpm 810 rpm 20000 J 24 Nm 150 N 13 24 kg
200 200 Nm 200 N
250 Nm 230 N
1200 rpm 810 rpm 20000 J 24 Nm 13 27 kg
280 Nm 260 N
210 Nm 200 N
400
270 Nm 230 N
Short 1000 rpm 710 rpm 30000 J 48 Nm 15 36,6 kg
version 350 Nm 300 N
420 Nm 400 N
375 Nm 325 N
400 1000 rpm 1000 rpm 30000 J 48 Nm 15 40,7 kg
450 Nm 390 N
Long
version 550 Nm
1000 rpm 1000 rpm 30000 J 48 Nm 470 N 15 43,5 kg
600 Nm
500 Nm 390 N
600 600 Nm 800 rpm 500 rpm 35000 J 83 Nm 470 N 15 51,6 kg
700 Nm 540 N
600
Long 800 Nm 800 rpm 500 rpm 35000 J 83 Nm 620 N 15 61,9 kg
version
650 Nm 320 N
800 850 Nm 600 rpm 400 rpm 40000 J 83 Nm 420 N 15 66,5 kg
950 Nm 460 N
920 Nm 410 N
1000 1050 Nm 500 rpm 400 rpm 45000 J 200 Nm 470 N 15 83 kg
1200 Nm 530 N
4)
Max. 3 movements one after the other with a 5-minute break each time

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Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Table 4: Switching Times [ms]


Nominal
torque Tightening Tightening t2 Drop-out t11 Drop-out t1 Drop-out t11 Drop-out t1
Size minimal t2 on overexcitation AC AC DC DC
100 Nm 140 600 950 90 190
150 Nm 180 350 800 55 145
200 200 Nm 195 280 670 38 115
250 Nm
115 150 400 20 90
280 Nm
210 Nm 240 800 1200 100 250
400 275 Nm 310 270 800 40 170
Short version 350 Nm 350 235 675 30 145
420 Nm 450 190 400 25 125
375 Nm 295 385 700 36 160
400 450 Nm 320 200 870 30 140
Long version 550 Nm
165 150 550 15 100
600 Nm
500 Nm 300 500 900 60 220
600 600 Nm 390 350 790 42 180
700 Nm 230 240 650 34 160
600
800 Nm 260 200 960 38 230
Long version
650 Nm 300 540 1070 60 240
800 850 Nm 450 400 950 45 210
950 Nm 240 250 850 35 180
920 Nm 360 530 1250 70 260
1000 1050 Nm 490 400 1100 55 220
1200 Nm 260 250 900 35 180

Please Observe!
 The use of varistors for spark quenching increases the DC-side switching times.
 At temperatures of around or under freezing point, condensation can strongly reduce the braking torque.
The user is responsible for taking appropriate counter measures.
The customer is responsible for providing a protective cover against contamination caused by construction sites.

Torque-Time Diagram
M M4 Key:
M1 = Switching torque
M2 M2 = Nominal torque (characteristic torque)
M4 = Transmittable torque
M1 M6 = Load torque
M6 t1 = Connection time
t11 = Response delay on connection
0,1 M2
t2 = Separation time
t t21 = Response delay on separation
t4 = Slipping time + t11
t11 t21

P t1 t2

ON t4

OFF
t

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Design Installation Conditions



The ROBA -duplostop is a spring applied, electromagnetically  The eccentricity of the shaft end in relation to the fixing
releasing dual circuit brake. holes may not exceed 0,3 mm.
It is used for installation in a gearless elevator and serves as a  The position tolerance of the threaded holes for the cap
brake assembly on the drive sheave shaft and as part of the screws (5) must not exceed 0,3 mm.
protective assembly against excessive upward-moving cage
 The axial run out deviation of the screw-on surface to the
speeds.
shaft must not exceed the permitted axial run out tolerance
of 0,063 mm in the area of the friction surface.
Measuring procedure acc. DIN 42955.
Larger deviations can lead to a drop in torque, to
Function continuous slipping on the rotor (3) and to overheating.
ROBA-duplostop brakes are spring applied, electromagnetic  The toothed motor shaft should be designed according to
safety brakes. the information given in the applicable Assembly Drawing.
The O-ring groove must be inserted before the shaft is
Spring applied function: splined. The O-ring groove must be free of burrs.
In de-energised condition, thrust springs press against the
armature disks (2). The rotor (3) with the friction linings is
therefore held between the armature disks (2) and the machine Please Observe!
screw-on surface. The dimensions on the assembly drawings
The motor shaft is braked by the rotor (3). are manufacturer-side recommendations.
Electromagnetic:
Due to the magnetic force of the coils in the coil carriers (1), the  On hub designs the hub bore (15) tolerances and the shaft
armature disk (2) is attracted against the spring force to the coil must be selected so that the hub toothing (15) is not
carrier (1). widened. Widening of the toothing leads to the rotor (3)
The brake is released and the shaft can rotate freely. jamming on the hub (15) and therefore to brake
Safety brake function: malfunctions.
The ROBA-duplostop brakes reliably and safely in the event of Recommended hub - shaft tolerance H7/k6.
a power switch-off, a power failure or an EMERGENCY STOP. If the hub (15) is heated for better joining, the O-ring (16)
must be removed beforehand and re-mounted after hub
installation.
The max. permitted joining temperature of 200 C mu st not
State of Delivery be exceeded.
 Dimensioning of the key connection according to the
The brake bodies are partly assembled with coil carriers (1),
requirements shaft diameter, transmittable torque and
armature disks (2), distance bolts (4), hand release (option,
operating conditions must be carried out. For this, the
dependent on Type) and adjusted microswitches (option,
corresponding user data must be known or the customer
dependent on Type). The rotor (3) and the hexagon head screws
must carry out the dimensioning according to the valid
(5) for securing the brake are included loose in delivery.
calculation basis DIN 6892.
Please check state of delivery! For the calculation, a hub quality of Re = 300 N/mm2
should be used.
The length of the key should lie over the entire hub (15).
 For the dimensioning of the key connections, the permitted
Application tensions common in machine construction must be
considered.
 ROBA-duplostop for use as holding brakes with
occasional EMERGENCY STOP braking actions.  The mounting dimensions and the screw-on surface s with
depth K + 2 mm (K = screw projection) acc. Catalogue or
 The max. permitted speeds and friction work, see
applicable Assembly Drawing must be given (Fig. 8).
Table 3, must be observed.
 The rotor and brake surfaces must be oil and grease-free.
A suitable counter friction surface (steel or cast iron) must
be used. Sharp-edged interruptions on the friction surfaces
must be avoided. Recommended surface quality in the area
Motor shaft of the friction surface Ra = 1,6 m.
In particular customer-side mounting surfaces made of
central axis
grey cast iron are to be rubbed down additionally with
Mounting A fine sandpaper (grain 200 400), or ideally with a
Ra 1,6

surface sander.
 Please abstain from using cleaning agents containing
solvents, as they could affect the friction material.
0,063 A  During longer downtimes, we recommend the use of
suitable corrosion protection measures for the mounting
s

0,3
surface (e.g. zinc-phosphate coating) until initial operation.
s

Fig. 8

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Installation: Design with toothed motor shaft Hand release (7)


(Figs. 1 - 2a and 3 - 8) (Option dependent on Type for release using a Bowden
cable)
1. Insert the O-ring (8, slightly greased, acc. Parts List with
NBR 70 material (provided by customer) into the motor The hand release is completely assembled manufacturer-
shaft groove. Please use NLGI Class 2 grease with a basic side.
oil viscosity of 220 mm2/s at 40 C, e.g. Mobilgrease The brake is released when both hand release levers are moved
HP222. simultaneously (7.1), see Fig. 5.
2. Push the rotor (3) onto the motor shaft by hand using light By lifting the hand release levers (7.1) up from the steel balls
pressure. (7.2), both cap screws (7.4) incl. washers (7.6) together with the
Please ensure that the rotor collar armature disk (2) are pulled against the coil carrier (1) (Fig. 9).
90 for Size 200, After this, the rotor (3) is free and the brake is released.
110 for Size 600,
124 for Size 800 and Danger!
135 for Size 1000 is facing in the direction of the machine
Operate the hand release carefully.
wall.
Existing loads are put into motion when the
The installation direction is immaterial for Size 400 because
hand release is activated.
the rotor (3) is symmetrical.
On special designs, the rotor collar must be aligned acc.
the applicable Assembly Drawing.
Check that the toothing moves easily.
Do not damage the O-ring. 7.6 7.3 7.4 1 7.2
3. Secure the left brake body using hexagon head screws
(Item 5, 4 pcs.) all round step-wise evenly (we recommend
that you secure the screws using Loctite 243). 7.1
Tighten the hexagon head screws using a torque
wrench and observe the tightening torque acc. Table 3. 3
Then repeat this procedure with the right brake body. 7.5
+0,20
4. Check air gap "a" = 0,45 0,05 mm
The nominal air gap must be given in the middle of the 2 Adjustment dimension
armature disk (2) area, vertical centre axis (Fig. 1).
1,6 +0,2 for Size 200
5. Check air gap "b" > 0,25 mm in energised state on the
rotor (3) (Fig. 2). 2,0 +0,2 for Sizes 400 - 1000
The inspection air gap must be given. Fig. 9

Installation: Hub design (Figs. 1 and 2b - 8)


Braking Torque Adjustment
1. Mount the hub (15) with the O-ring inserted (Item 16 / O-
ring must be lightly greased) onto the shaft and bring it ROBA-duplostop brakes are delivered adjusted to the
into the correct position (the length of the key should cover braking torque required on order.
the entire hub) and secure it axially e.g. using a locking
ring).
2. Push the rotor (3) over the O-ring (16) onto the hub (15) by
hand using light pressure.
Noise damping
Please ensure that the direction of the rotor collar is aligned Please Observe!
acc. the applicable Assembly Drawing.
Check that the toothing moves easily. The noise damping used here was set and
Do not damage the O-ring. adjusted manufacturer-side.
However, this component is subject to
3. Secure the left brake body using hexagon head screws aging dependent on the application or
(Item 5, 4 pcs.) all round step-wise evenly (we recommend operational conditions (torque adjustment,
that you secure the screws using Loctite 243). switching frequency, ambient conditions,
Tighten the hexagon head screws using a torque system vibrations etc.) and must be re-
wrench and observe the tightening torque acc. Table 3. adjusted or replaced as a routine measure
Then repeat this procedure with the right brake body. or if the switching noise becomes too loud.
+0,20
This must only be carried out by qualified
4. Check air gap "a" = 0,45 0,05 mm and authorised specialist personnel, and
The nominal air gap must be given in the middle armature should therefore be undertaken in the place
disk (2) area, vertical centre axis (Fig. 1). of manufacture.

5. Check air gap "b" > 0,25 mm in energised state on the


rotor (3) (Fig. 2).
The inspection air gap must be given.

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Release Monitoring (6) Fig. 10 Manufacturer-side Adjustment and Functional


(Option, dependent on Type) Inspection of the Microswitches (6.1), see Fig. 10:
Brake mounted and secured with the nominal torque.
ROBA-duplostop brakes are delivered with one release
monitoring (6) per brake circuit.
The microswitches (6.1) emit a signal for every brake condition
change "signal brake opened or brake closed Danger!
On initial operation: Brake must not be energised.
Connection as NO contact (black and blue strands).
The customer is responsible for a signal evaluation of both
conditions. 1. Turn the hexagon head screw (6.4) in the direction of the
From the point at which the brake is energised, a time span of microswitch (6.1) up to the microswitch tappet.
three times the separation time must pass before the 2. Tighten the hexagon nut (6.3), so that the hexagon head
microswitch signal on the release monitoring is evaluated. screw (6.4) is placed under pre-tension by the spring
washer (6.5).
Wiring Diagram: 3. Put a feeler gauge 0,12 mm (loose sensor plate) between
NC Contact the switch tappet and the hexagon head screw (6.4).
Grey connection 4. Connect the inspection or measurement device (diode
Connection when inspection) to the NO contact black/blue.
2 brake closed
5. Turn the hexagon head screw (6.4) in the direction of the
COM Contact 1
Black connection
switch (6.1) up to signal "ON", turn it back to the signal
4 "OFF" and counter the hexagon head screw (6.4) with the
NO Contact
blue connection
hexagon nut (6.3).
Connection when 6. Energise brake  Signal "ON"
brake released
De-energise brake  Signal "OFF",
Re-adjust if necessary and repeat the inspection.
Re-adjustment is possible via the hexagon head screws (6.4)
and the hexagon nuts (6.3). 7. Remove the feeler gauge 0,12 mm.
If this proves necessary, please contact the manufacturers. 8. Inspection with feeler gauge 0,16 mm
Energised  Signal "ON"
De-energised  Signal "ON"
Function 9. Remove the feeler gauge 0,16 mm.
10. Repeat inspection with feeler gauge 0,12 mm
When the magnetic coils are energised in the coil carriers (1),
Energised  Signal "ON"
the armature disks (2) are attracted to the coil carrier (1), the
microswitches (6.1) emit a signal and the brake is released. De-energised  Signal "OFF"
11. Put the feeler gauge 0,20 mm between the armature disk
(2) and the coil carrier (1) in the microswitch (6.1) area and
then energise the brake. The signal must be "ON".
2 6.5 6.3 6.4 6.1 6.2 1 12. Paint items 6.2, 6.3 and 6.4 with sealing lacquer.

Customer-side Inspection after Mounting onto the


Elevator Machine
The customer-side contact is an NO contact.
Please inspect the release monitoring of both circuits:
Brake de-energised  Signal "OFF",
Brake energised  Signal "ON"

Table 5:
Microswitch Specifications (6.1)
Fig. 10
Characteristic values for 250 V~ / 3 A
measurement:

Minimum switching capacity: 12 V, 10 mA DC-12

Recommended switching 24 V, 10...50 mA


capacity: DC-12
for maximum lifetime DC-13 with free-wheeling
and reliability diode!

Usage category acc. IEC 60947-5-1:


DC-12 (resistance load), DC-13 (inductive load)

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Wear Monitoring (9) Figs. 7 and 11 Manufacturer-side Adjustment of the


(Option, dependent on Type) Microswitch (9.1)
Only one microswitch for wear monitoring (9) is required per
ROBA-duplostop, which is mounted onto the right brake Danger!
(Figs. 7 and 11). The brake is screwed onto the installation
The ROBA-duplostop brake is delivered with manufacturer- device to the tightening torque (see
side adjusted wear monitoring (9). Table 3) and the coil is de-energised.

1. Connect the inspection or measurement device (diode


Function inspection) to the NC contact black/grey.
Due to wear on the rotor, (3) the air gap "a" between the coil 2. Turn the hexagon head screw (9.4) in the direction of the
carrier (1) and the armature disk increases (2). microswitch (9.1) until it switches, and apply pre-tension via
Once the maximum air gap (limit air gap) of 0,9 mm has been the spring washer (9.5) using the hexagon nut (9.3).
reached (Table 1), the microswitch contact (9.1) switches over 3. Hold the hexagon nut (9.3) and turn the hexagon head
and emits a signal. screw (9.4) back until the microswitch contact (9.1) switches
The rotor (3) must be replaced. over again.
The customer is responsible for signal evaluation. 4. Mark the position of the hexagon head screw (9.4) (marker
pen).
5. Hold the hexagon head screw (9.3) and turn the hexagon
Wiring Diagram: head screw (9.4) approx. 0,6 0,7 turns back in the
NC Contact direction of the microswitch (9.1).
Grey connection 6. Counter the hexagon head screw (9.4) with the hexagon nut
Connection when (9.3) and mark the position using red securing lacquer.
2 wear limit is reached
7. Mount the Wear Monitoring guideline sign.
COM Contact 1
Black c onnection 4
NO Contact
blue connection Right brake
Connection when
wear limit is not yet reached

9.5
Before replacing the rotor (3) 2
Clean the brake and remove abraded particles using
compressed air.
9.3
Do not inhale brake dust. 6
Measure the rotor thickness "new" (see Table 2).
9.4
1
Replacing the rotor (3)
Replace the rotor by following the Brake Installation
instructions backwards. 9.1
Danger!
The drive brake must be load-free 9.2
on hoist drives.
Otherwise there is a danger of load
crashes! Fig. 11

Table 6:
Microswitch Specifications (9.1)
Characteristic values for 250 V~ / 3 A
measurement:

Minimum switching capacity: 12 V, 10 mA DC-12

Recommended switching 24 V, 10...50 mA


capacity: DC-12
for maximum lifetime DC-13 with free-wheeling
and reliability diode!
Usage category acc. IEC 60947-5-1:
DC-12 (resistance load), DC-13 (inductive load)

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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Electrical Connection for Operation Magnetic Field Removal


with Nominal Voltage (Without Overexcitation) AC-side Switching
DC current is necessary for operation of the brake. The coil max.
voltage is indicated on the Type tag (14) as well as on the brake 230V~ The power circuit is interrupted
body and is designed according to the DIN IEC 60038 ( 10 % 2,5A before the rectifier. The
1/025.000.6 magnetic field slowly reduces.
tolerance). Operation must take place via DC voltage with a low [U = 0,9U~]
ripple content, e.g. via a bridge rectifier or with another suitable Brckengleichrichter This delays the rise in braking
DC supply. Dependent on the brake equipment, the connection Bridge rectifier torque.
possibilities can vary. Please follow the exact connections IN SDC OUT
according to the Wiring Diagram. The manufacturer and the user When switching times are not
must observe the applicable directives and standards (e.g. DIN important, please switch AC-
EN 60204-1 and DIN VDE 0580). Their observance must be 1 2 3 4 5 6
side, as no protective
guaranteed and double-checked! measures are necessary for
coil and switching contacts.
Earthing Connection S1
Coil
The brake is designed for Protection Class I. This protection
covers not only the basic insulation, but also the connection of
all conductive parts to the PE conductor on the fixed installation. F1
If the basic insulation fails, no contact voltage will remain.
Please carry out a standardized inspection of the PE conductor N L F1: external fuse
connections to all contactable metal parts!

Supply Voltage Requirements  Low-noise switching; however, the brake engagement time
is longer (c. 6-10 times longer than with DC-side switching). Use
In order to minimise noise development of the released brake, it for non-critical brake times.
must only be operated via DC current with low ripple content. AC
current operation can take place using a bridge rectifier or
another suitable DC power supply. Supplies whose output DC-side Switching
voltages have a high ripple content (e.g. a half-wave rectifier, a
max.
switch-mode mains adaptor, ...) are not suitable for operation of 230V~ The power circuit is interrupted
the brake. 2,5A between the rectifier and the
1/025.000.6 coil as well as mains-side. The
[U = 0,9U~]
Device Fuses Brckengleichrichter magnetic field reduces
Bridge rectifier extremely quickly. This causes
To protect against damage from short circuits, please add a quick rise in braking torque.
suitable device fuses to the mains cable. IN SDC OUT

When switching DC-side, high


Switching Behaviour voltage peaks are produced in
1 2 3 4 5 6
the coil, which lead to wear on
The operational behaviour of a brake is to a large extent
the contacts from sparks and
dependent on the switching mode used. Furthermore, the
to destruction of the insulation.
switching times are influenced by the temperature and the air S1
Coil
gap between the armature disk (2) and the coil carrier (1)
(dependent on the wear condition of the linings).
F1

Magnetic Field Build-up N L F1: external fuse

When the voltage is switched on, a magnetic field is built up in


the brake coil, which attracts the armature disk (2) to the coil  Short brake engagement times (e.g. for EMERGENCY
carrier (1) and releases the brake. STOP); however, louder switching noises.

Protective Circuit
When using DC-side switching, the coil must be protected by a
suitable protective circuit according to VDE 0580, which is
integrated in mayr rectifiers. To protect the switching contact
from consumption when using DC-side switching, additional
protective measures are necessary (e.g. series connection of
switching contacts). The switching contacts used should have a
minimum contact opening of 3 mm and should be suitable for
inductive load switching. Please make sure on selection that the
rated voltage and the rated operation current are sufficient.
Depending on the application, the switching contact can also be
protected by other protective circuits (e.g. mayr spark
quenching unit), although this may of course then alter the
switching time.

29/03/2010 TK/HW/GC/SU Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-0


Eichenstrae 1 Fax: 08341 / 804-421
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Page 14 of 16 Germany eMail: info@mayr.de
Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Electrical Connection for Operation Magnetic Field Removal


with Overexcitation AC-side Switching
DC current is necessary for operation of the brake. The coil The power circuit is
voltage is indicated on the Type tag (14) as well as on the brake ROBA -switch
R R interrupted before the
body and is designed according to the DIN IEC 60038 ( 10 % 20/017.000.2
U = 0,45U~ Imax = 1,8A
rectifier. The magnetic field
tolerance). The brake may only be operated with overexcitation 200 - 500V~ t: 0,05-2sec
slowly reduces. This delays
(e.g. with a ROBA-switch fast acting rectifier or phase 200 - 300V~ R: 0-10M the rise in braking torque.
demodulator). Dependent on the brake equipment, the IN S DC

OUT
+

connection possibilities can vary. Please follow the exact 1 2 3 4 5 6 7 8 When switching times are not
connections according to the Wiring Diagram. The manufacturer important, please switch AC-
and the user must observe the applicable directives and 1 2 3 4 5 6 7 8 side, as no protective
standards (e.g. DIN EN 60204-1 and DIN VDE 0580). measures are necessary for
Their observance must be guaranteed and double-checked! coil and switching contacts.
S1
Coil
Earthing Connection
The brake is designed for Protection Class I. This protection
F1
covers not only the basic insulation, but also the connection of
all conductive parts to the PE conductor on the fixed installation.
N L F1: External fuse
If the basic insulation fails, no contact voltage will remain.
Please carry out a standardized inspection of the PE conductor
connections to all contactable metal parts! Low-noise switching; however, the brake engagement time
is longer (c. 6-10 times longer than with DC-side switching). Use
Device Fuses for non-critical brake times.
To protect against damage from short circuits, please add
suitable device fuses to the mains cable.
DC-side Switching
Switching Behaviour The power circuit is
The operational behaviour of a brake is to a large extent ROBA -switch
R R
interrupted between the
20/017.000.2
dependent on the switching mode used. Furthermore, the U = 0,45U~ Imax = 1,8A
rectifier and the coil as well
switching times are influenced by the temperature and the air 200 - 500V~ t: 0,05-2sec
as mains-side. The magnetic
gap between the armature disk (2) and the coil carrier (1)
200 - 300V~ R: 0-10M field reduces extremely
+

(dependent on the wear condition of the linings).


IN S DC OUT quickly. This causes a quick
1 2 3 4 5 6 7 8 rise in braking torque.

1 2 3 4 5 6 7 8 When switching DC-side,


Magnetic Field Build-up high voltage peaks are
When the voltage is switched on, a magnetic field is built up in produced in the coil, which
S1
the brake coil, which attracts the armature disk (2) to the coil Coil lead to wear on the contacts
carrier (1) and releases the brake. from sparks and to
destruction of the insulation.
F1
Field Build-up with Normal Excitation
If we energise the magnetic coil with nominal voltage, the coil N L F1: External fuse
voltage does not immediately reach its nominal value. The coil
inductivity causes the current to increase slowly as an Short brake engagement times (e.g. for EMERGENCY
exponential function. Accordingly, the build-up of the magnetic STOP); however, louder switching noises.
field takes place more slowly and the braking torque drop
(curve 1) is also delayed.

Field Build-up with Overexcitation Protective Circuit


A quicker and safer drop in braking torque is achieved if the coil When using DC-side switching, the coil must be protected by a
is temporarily placed under a higher voltage than the nominal suitable protective circuit according to VDE 0580, which is
voltage, as the current then increases more quickly. Once the integrated in mayr rectifiers. To protect the switching contact
brake is released, it is possible to switch over to the nominal from consumption when using DC-side switching, additional
voltage (curve 2). The effective capacity may however not be protective measures are necessary (e.g. series connection of
larger than the nominal capacity of the coil. switching contacts). The switching contacts used should have a
The ROBA-switch fast acting rectifier works on this principle, minimum contact opening of 3 mm and should be suitable for
which is obligatory for safe operation of this brake. inductive load switching. Please make sure on selection that the
rated voltage and the rated operation current are sufficient.
Current path Braking torque path Depending on the application, the switching contact can also be
I
2 M protected by other protective circuits (e.g. mayr spark
Mnom quenching unit), although this may of course then alter the
switching times.
Inom
1 2 1

t t

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Eichenstrae 1 Fax: 08341 / 804-421
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Installation and Operational Instructions for ROBA-duplostop
Type 8010._ _ _ _ _ Sizes 200 to 1000 (B.8010.GB)

Brake Inspection Maintenance


(Customer-side after mounting Installation onto
ROBA-duplostop brakes are mainly maintenance-free.
Elevator Machine) The friction linings are robust and wear-resistant. This ensures a
 Individual air gap inspection particularly long service lifetime.
(Nominal air gap "a" and air gap "b" on both brake circuits However, the friction linings are subject to functional wear on
acc. Table 1 and Fig. 2). frequent use of EMERGENCY STOP. Therefore, the following
inspections are to be carried out at regular inspection intervals:
 Braking torque inspection:
Please compare the requested braking torque with the  Braking torque or retardation inspection
torque stated on the Type Tag. (individual brake circuits). (TV interval)
 Release function inspection  Inspection of air gap braked
(Battery operated to guarantee emergency escape for (both brake circuits) (TV interval)
passengers during a power failure).  Inspection of toothing backlash, toothed shaft on motor to
the rotor (3) or hub (15) to the rotor (3)
 Switching function inspection
Max. permitted toothing backlash 0,5. (TV interv al)
Energised brake Signal "ON" (NO contact)
De-energised brake Signal "OFF" (NO contact)
Danger!
To inspect the rotor (3) wear condition,
please measure the air gap "a" acc. Table 1
Dual Circuit Brake Functional Inspection and Fig. 2.
If the brake limit air gap has been reached
The ROBA-duplostop brake is equipped with a double safety
(redundant) brake system. (0,9 mm), meaning that the friction linings are worn
This means that, should one circuit fail, the braking effect is down, the rotor (3) must be replaced.
maintained. Please follow the Installation section backwards to dismantle
the brake (page 11).
Danger!
Should the elevator begin to move after
release of one brake circuit or should it fail to
react to the braking procedure, the energised
coil must be switched off immediately! Disposal
The dual circuit function is not guaranteed.
Our electromagnetic brake components must be disposed of
Shut down the elevator, de-install and inspect the brake.
separately as they consist of different materials. Please observe
the relevant authority regulations. Code numbers may vary
The individual circuit inspection is carried out by energising the
according to the dismantling process (metal, plastic and cable).
individual circuits with nominal voltage.
Electronic components
Inspection left brake circuit: (Rectifier / ROBA-switch / Microswitch):
1. Energise the right brake circuit.
Products which have not been dismantled can be disposed of
2. Trigger an EMERGENCY STOP with the left brake circuit under the Code 160214 (mixed materials) or Components under
and inspect the stopping distance according to the elevator Code. No. 160216, or can be disposed of by a certified disposal
regulations. firm.
3. De-energise the right brake circuit.
Brake bodies made of steel pads with coil / cable
and all other steel components:
Inspection right brake circuit: Steel scrap (Code No. 160117)
1. Energise the left brake circuit.
2. Trigger an EMERGENCY STOP with the right brake circuit Aluminium components:
and inspect the stopping distance according to the elevator Non-ferrous metals (Code No. 160118)
regulations. Brake rotor (steel or aluminium pads with friction linings):
3. De-energise the left brake circuit. Brake linings (Code No. 160112)
Seals, O-rings, V-seals, elastomers, terminal boxes (PVC):
Inspection both circuits: Plastic (Code No. 160119)
Energise both braking circuits with nominal voltage.
Trigger an EMERGENCY STOP and inspect the stopping
distance according to the elevator regulations. The stopping
distance must be much shorter than the stopping distance for an
individual circuit.

Malfunctions / Breakdowns:

Malfunctions Possible Causes Solutions

Incorrect voltage on rectifier Apply correct voltage


Rectifier failure Replace rectifier
Brake does not release
Air gap too large (worn rotor) Replace rotor
Coil interruption Replace brake
Brake does not release Solution as above
Release monitoring does not switch Defective microswitch Replace the microswitch (manufacturer-
side)

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OPERATING MANUAL PMC145 CHANGES

9. Changes

Changes
Version
Chapter
12/2011 Electrical data for brake 3

ThyssenKrupp Aufzugswerke GmbH 71 12-2011 


ThyssenKrupp Aufzugswerke GmbH
Nr. 9710 000 9265

Bernhuser Strae 45
Issue 12/2011

73765 Neuhausen a. d. F.
Deutschland
e-Mail: Eli.elevator.plant.de@thyssenkrupp.com
Internet: www.thyssenkrupp-elevator-eli.de