Professional Documents
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Zatop Sm160 30b 40b Ingles
Zatop Sm160 30b 40b Ingles
30B-40B
Gearless permanent magnet synchronous motor
Content
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Structure of the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Requirements placed on the personnel / due diligence . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Operational area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Disposal / recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 General mounting advises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Patent situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Mounting the drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Fastening the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Fastening rope protection clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 EMC directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.4 Absolute encoder connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 Brake connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.5.1 Triggering of the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 First-time start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Drive approval test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.1 Half load test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.2 Testing the brake according EN 81-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.4 Pull out of safety gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.5 Emergency evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.5.1 Manual emergency evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.5.2 Electrical emergency evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.2 Dimension sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.3 EC-Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.4 Operating instructions brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.5 EC-Declaration of conformity of the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.6 EC type-examination certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.7 Type-examination certificate (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.7.1 Statement concerning ESV-type-examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.8 Calculation of tripping speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.9 Shaft calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1 General information
1.1 Application
The ZAtop is designed as a gearless drive for traction sheave rope elevators.
No other drive applications are permitted without the disengagin by the ZIEHL-ABEGG SE
company!
1.5 Copyright
The copyright to this operation instructions is held by ZIEHL-ABEGG SE, Künzelsau. This operation
instructions must not be wholly or partly reproduced for competitive purposes, used in any unauthor-
ised way or made available to third parties without our agreement.
2 Safety instructions
2.1 General
ZIEHL-ABEGG SE electric motors are not ready-to-use products and may only be operated after
having been installed into machines or plants and established their safety, depending on the applica-
tion, by protective grating, barriers, constructive devices or other adequate measures (see also
DIN EN ISO 13857)!
Installation, connection to the power supply and commissioning may only be performed by qualified
service personnel! The relevant regulations must be observed!
Planners, manufacturers and operators of system parts or entire systems are responsible for the
correct and safe mounting and a reliable operation.
2.2 Pictographs
Safety instructions are highlighted with warning triangles and are depicted according to the degree of
hazard as follows.
Danger!
General hazardous area. Death or severe injury or significant property damage can occur if the
corresponding precautions are not taken!
Warning!
Middle or slight bodilies harm is possible if the corresponding precautions are not taken!
Caution!
CAUTION! Material damage is possible if the corresponding precautions are not taken.
Danger!
Danger by dangerous, electric voltage! Death or severe injury can occur if the corresponding
precautions are not taken!
Information
Important additional information and advice for user.
Warning!
Danger by hot surface! Slight bodily harm is possible if the corresponding precautions are not taken!
Danger!
" The motor has casted eyelets or threads to suit eyebolts. The eyelets are for the transport of the
motor including sheave and brake only. Do not lift higher loads with these eyelets for example a
socket, ropes, etc. Use adequate hoists. Danger to life!
Warning!
" Dependent on the working conditions the surface temperature can be very high. Danger of burns!
" The motor is only to be operated within the ranges specified on the type plate!
" Use the motor only as intended and only for the specified tasks in the purchase order!
" When the motor current is off, it can not develop any electric torque. When opening the
brakes the lift will accelerate uncontrolled! Therefore it is recommended to short-circuit the
motor windings, when the motor current is off. This induces a speed dependent braking
torque similar to the friction of a worm gearbox. The short-circuit has to be made by main
contacts of the contactors, because the current is approx. rated current. In any case do not
short-circuit the windings, while the motor wires still carry current.
" Safety features, for example the brake release monitoring, may not be dismantled, circumvented or
made inoperative!
" A temperature sensor is installed into the winding as motor protection and must be connected!
3 Product overview
3.1 Operational area
The ZAtop, a permanent magnet inner-rotor synchronous motor, offers all benefits which a modern
elevator motor asks for:
• simple installation
• best controllability
• lowest noise level
• highest travel comfort
• compact design
Due to the very compact design the ZAtop is ideal for machine roomless elevators. Of course the
certified brakes provide maximum security and are approved as a safety device for ascending car
overspeed protection. Protected through registered design and patents application pending one can
for the very first time build a new dimension of machine roomless elevators.
3.2 Transport
" ZIEHL-ABEGG SE electric motors are packed by the manufacturer for the types of transport and
storage agreed upon.
" Transport the motor(s) either with the original packing or at the casted eyelets or eyebolts using
adequate hoists.
" Transport motor without any additional load and taking the centre of gravity into account!
" The threads in the shaft ends are not to suit eyebolts to transport the motor.
" Avoid excessive vibration and shocks.
" Check packing and motor for possible damage and report the forwarding agency about any
damages caused by transport. Shipping damages are not covered by our guarantee!
3.3 Storage
" Store the motor in the original packaging in a dry area protected from the weather or protect it from
dirt and weather until final mounting.
" Extreme heat or cold (storage temperature -20 °C to +60 °C) must be avoided!
" High humidity which can lead to condensation must be avoided.
" Avoid aggressive conditions (for example salt spray)!
" Avoid excessive storage times (we recommend max. one year) and check motor bearing for correct
function before installing the motor. (Ease the brakes and move the rotor by hand. Take care if the
bearing makes untypical noises)
4 Mechanical installation
4.1 General mounting advises
" Mounting, electrical connection and commissioning are only to be performed by trained service
personnel. Adhere to all machinery-related requirements and specifications supplied by the system
manufacturer or machine builder.
Caution!
CAUTION! " When working at or in the lift, the drive and especially the brakes have to be covered and protected
against dust and chips.
Any violation will result in a loss of guarantee on the motors and accessories!
The following general rules apply:
" The rope pull may be vertical or horizontal.
" At lateral (horizontal) rope pull, the motor housing must be supported on the side. The
fixings scews of the motor must not be loaded with shearing force!
" If the traction sheave should offer more grooves than the actual number of ropes, the ropes must
be applied on the sheave either centred or towards the motor side.
5 Electrical installation
5.1 Safety precautions
Mounting, electrical connection and commissioning are only to be performed by trained service
personnel. Adhere to all machinery-related requirements and specifications supplied by the system
manufacturer or machine builder.
CAUTION! " The drive must not be connected to the mains supply without a controller!
" The motor is permitted to be used at frequency inverters with a maximum DC-link voltage of
< 750 V DC!
" A screened motor cable has to be used. The screen has to be connected on both ends. The
maximum motor cable length is 25 m.
" Connect to the motor terminal box depending on the motor cable as follows:
PE U V W
green/yellow black brown blue *
green/yellow black brown grey **
green/yellow 1 2 3
" If no other agreement was met, the absolute encoder offset is set to 0 To do that, connect the direct
current with U to + and V and W to -.
" The motor connection lines U, V and W have to be connected on the motor and inverter side to the
correct phases and must not be changed. Otherwise the motor may speed up uncontrolled.
" The motor is protected by PTC-resistors. The connection has to be made via a PTC resistor
controller! The admissible test voltage of PTC resistors is maximum 2.5 V DC.
Danger!
The levers for hand release must be removed after brake hand release action.
The contacts from K3 must close before the contact from K4 and are only permitted to open after the
contact from K4 has opened.
6 Start-up
6.1 Operating conditions
" The drive must be installed in a not free accessible machine room or a closed hoistway.
" Be aware of the protection class specified on the name plate.
" Do not operate the motor in an explosive atmosphere.
" The ambient temperature may be within 0 °C and +40 °C.
" Maximum permissible humidity 95 %, not wet.
" Reduced cooling when installed 1000 m above sea level. Therefore, the torque by 1 % per 100 m
must be reduced or the duty cycle time of 1.5 % per 100 m.
" Please contact ZIEHL-ABEGG SE in case of orders deviating from the corresponding application
conditions.
Attention!
The measures for emergency evacuation described below may only be performed by instructed
persons for maintenance of the lift or qualified personnel of lift companies.
When the brakes are released manually, the lift moves in the direction of the greater weight. If there is
a balance between the cabin and the counterweight, the cabin must be made heavier by suitable
means.
To reduce the acceleration of the lift, we recommend to short-circuit the motor for the evacuation. The
short-circuit is generated by the motor contactors.
The short-circuit generates a speed-dependent braking torque. The maximum braking torque is
achieved at lower speeds.
Depending on the system type and weight ratios, it is possible that due to the short-circuit
generated braking torque is not sufficient to limit the lift speed. So the speed must be
monitored closely during evacuation and evacuation interrupted if necessary.
Manual release of the brake is finished when a floor is reached. Now the lift door can be opened with
a triangular key.
The lift manufacturer's safety instructions have priority!
Danger!
The levers for hand release must be removed after brake hand release action.
A brake with a mechanical hand release system is available optionally. The hand release
system cannot be fitted later. The complete brake must be replaced to retrofit the hand release
system.
To check the brake wear or to check the treaction sheave, the following instructions have to be
referred:
It is not possible to adjust the brakes. The brakes cannot be readjusted. Replace the both brake rotors
when the maximum air gap has been reached.
The brake wear has to be checked with the brake closed, therefore:
" Make sure that all moving parts have stopped, secure them mechanically if required!
" Make sure that the elevator can not be moved from any other person than the one who does the
check!
Note: All fixing screws on the housing, brakes and traction sheave are marked with locking varnish.
That means a loosened screw is optically visible. If a screw does get turned, it must be tightened
using the prescribed tightening torque, the old locking varnish needs to be removed and marking has
to be made again.
1. The airgap has to be checked 3 times at the circumfence. The maximum value of the three has to
be taken into account.
2. If the maximum value of the air gap is exceeded on one of the magnets, it must be changed the
brake rotor and the O-ring.
Maximum admissible air gap after wear: 0.9 mm!
1. Unscrew the clamping screw (1) with an allen wrench SW 2 The position of the clamping screw
can diversify.
2. Removethecover of the encoder (2) with an allen wrench SW 4
3. Unscrew the central fixing screw (3) with an allen wrench SW 4 for 1 - 2 revolutions. The absolute
encoder can be turned now.
4. Tighten the screw M10 x 25 (4) with the fitting tool until the absolute encoder is loose. Due to the
tightening the screw is pressing onto the central fixing screw (3) and pulls the absolute encoder
off the drive shaft.
5. Screw out the screw M10 x 25 (4) as well as the central fixing screw.
6. Screw the screw M10 x 25 (4) onto the absolute encoder again. Take the absolute encoder from
the motor shaft with the support of the screw.
Caution!
Due the electrostatic discharge the absolute encoder can be destroyed! Do not touch the pins of the encoder
cable as well as the electronics of the absolute encoder!
Risk of death!
Incorrect mounting of the brake can have influence on the braking action!
The brake bodies are mounted on the opposite side of the power take off. (see arrow)
A brake with a mechanical hand release system is available optionally. The hand release
system cannot be fitted later. The complete brake must be replaced to retrofit the hand release
system.
1. Dismount the absolute encoder (see chapter "Replacement of the absolute encoder").
2. Disconnect the electrical connection (1) of both brakes.
3. Carefully remove strain reliefs (2) of all connecting cables with wire cutters.
4. Cut off varistors (3).
5. Feed all connecting cables (4) out of the terminal box (5) and the terminal box plate (6).
6. Unscrew adapter shaft (8) from the motor shaft with wrench (9) and screw wrench SW 32
7. Screw assembly shaft (10) onto the motor shaft using SW 17 allen wrench.
Torque: 60 Nm
8. Loosen the four hexagon head screws (11) on the brake always alternately with a turn.
SM160.30B - SW 13
SM160.40B - SW 16
9. Take off the brake body (12).
ATTENTION! Weight of the brake body:
SM160.30B approx. 22 kg
SM160.40B approx. 30 kg
10. Remove the brake rotor (13) from the toothed motor shaft (14). The brake rotor may only be
removed manually.
ATTENTION! Do not work with screwdrivers to loosen the brake rotor!
The friction lining can be damaged by the screwdrivers! Brake discs with damaged friction linings
may not be mounted any more!
11. Loosen the hexagon head screw (15) with screw wrench SW 16 and remove the cover plate (16)
of the micro switch. The parts are reused.
1. Fasten the cover plate (16) of the micro switch with the hexagon head screw (15) and a screw
wrench SW 16
2. Grease the O-ring (example given Vaseline) and place it in the nut (17) of the brake rotor (13).
3. Ensure that the friction disk of the rotor and the braking surface (18) from the flansh bearing
bracket of the motor is free of dirt and grease.
4. Push the brake rotor (13) onto the toothed motor shaft (14) with slight pressure.
ATTENTION! It must be noted that:
SM160.30B: The installation direction is insignificant because the brake rotor (13) is symmetrical.
SM160.40B: The stepped brake rotor collar (19) must face away from the machine wall.
5. Make sure that the gear teeth engage easily.
6. O-ring may not be damaged.
7. Push the brake body (12) onto the assembly shaft (10).
ATTENTION! Weight of the brake body:
SM160.30B approx. 22 kg
SM160.40B approx. 30 kg
8. Fasten the brake body evenly all round in steps with four hexagon head screws (11) and washers.
SM160.30B - SW 13 - torque: 36 Nm
SM160.40B - SW 16 - torque: 48 Nm
9. Endue the hexagon head screws (11) with locking varnish.
10. Release assembly shaft (10) loosen with an allen wrench SW 17 and take it off the motor shaft.
11. Provide threadlocker Loctite 243 or a similar product to the thread of the adapter shaft (8).
12. Screw the adapter shaft (8) onto the motor shaft with wrench (9) and screw wrench SW 32
Tightening torque: 60 Nm
13. Remove the wrench (9).
14. Insert the connecting cables (4) of the solenoids and the release monitoring as shown in the
picture in the terminal box area (6) and connection box (5).
15. Connect the magnet coils and the release monitoring according to the wiring diagram(20) in the
top cover of the connection box(5).
16. Please make sure that the varistors (3) match the brake voltage:
brake voltage 207 V - varistor K250
brake voltage 24 V - varistor K30
17. Fit strain reliefs (2).
18. Mount the absolute encoder (see chapter "Replacement of the absolute encoder").
The adjusting is only necessary if the micro switches are not working correctly.
The micro switches are on the side of the brake body (see arrows).
WARNING! Ensure that you select the appropriate micro switch for the magnet to be adjusted.
Requirements:
• Release the traction sheave and put the ropes off the traction sheave.
• Secure the traction sheave so that it does not jump off the drive shaft.
The traction sheave is mounted on the power take-off side of the motor (see arrow).
1. Undo the fixing screws (1) of the rope guards (2) with a screw wrench SW 13 and remove the
rope guards (2).
2. Release the fixing screws M10 x 40 (3) of the traction sheave (4) with an allen wrench SW 8 and
remove the fixing plate (5).
1. Clean the traction sheave (4) and the motor shaft (8). Both parts have to be free of dirt and
grease.
2. The parallel key (7) has to be available.
3. Put traction sheave (4) on drive shaft (8). The bores for screws M10 must point outwards.
Observe the position of the groove for the parallel key.
4. Screw front plate (5) to the drive shaft (8) at the inner circle of holes using three screws
M10 x 40 (3). Apply threadlocker Loctite 243 or a similar product to the fixing screws.
Do not forget washers!
5. Tighten the fixing screws (3) with a torque wrench with an allen screw SW 8 uniformly in two
steps:
- Tightening torque step 1: 50 Nm
- Tightening torque step 2: 68 Nm
6. Coat the fastening screws (3) with sealing varnish.
7. Fit rope guards (2) with screw wrench SW 13
The mounting and dismounting of the magnet rotor and the flange bearing bracket must only be
carried out by qualified personnel and with special devices in the factory.
9 Enclosure
9.1 Technical data
Motor type 160.30B 160.40B
Suspension 2:1 2:1 2:1 2:1 2:1 2:1
typical payload* 675 525 450 1000 750 630 kg
Rated torque 195 260 Nm
Maximum torque 335 450 Nm
permissible radial load 1900 2500 kg
Rated brake torque 2 x 225 2 x 300 Nm
Speed 1.6 1.6 1.6 1.6 1.6 1.6 m/s
Total weight 182 187 192 178 180 182 kg
Traction sheave
- Diameter 160 210 240 160 210 240 mm
- Width 101 76 76 140 101 88 mm
- Rope diameter 4 6-7 6-7 4 6-7 6-7 mm
- Number of grooves 12 5 5 16 8 9
Protection class
Customer Service
phone +49 7940 16-308
fax +49 7940 16-249
[email protected]
Headquarters
ZIEHL-ABEGG SE
Heinz-Ziehl-Straße · 74653 Künzelsau
Germany
phone +49 7940 16-0 · fax +49 7940 16-249
[email protected] · www.ziehl-abegg.com