A company of ThyssenKrupp Elevator

ThyssenKrupp Aufzugswerke

TW63

W191

TW130

TW160

W263B

W332B

Operating Manual

Explosion-proof Machines Supplement to Operating Manuals: TW63; W191; TW130; TW160; W263B; 332B

OPERATING MANUAL

Imprint All rights reserved © Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH Postfach 23 03 70, D-70623 Stuttgart Printed in Germany This operating manual – including excerpts – may only be reprinted or otherwise copied with the express approval in writing of THYSSENKRUPP AUFZUGSWERKE GmbH. Any form of duplication, dissemination or storage on data media in any form that is not authorised by THYSSENKRUPP AUFZUGSWERKE GmbH represents a violation of prevailing copyright law and shall lead to legal proceedings. We expressly reserve the right to make changes of a technical nature for the purpose of improving the Ex version on the drives described or enhancing the safety standard - even without a separate announcement.

Issuing party responsible for the content: THYSSENKRUPP AUFZUGSWERKE GmbH

Preface We are very glad that you have decided in favour of a quality product made by the ThyssenKrupp Aufzugswerke company. This supplementary operating manual helps you to comply with the additional safety and protection regulations during the installation, operation and maintenance of systems with partial and full explosion protection. It applies exclusively in conjunction with the operating manual for the special drive type. Important safety and hazard warnings help you to operate the drive with explosion protection safely and in line with accepted technical principles. The right to make changes of a technical nature is reserved.

ThyssenKrupp Aufzugswerke GmbH

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OPERATING MANUAL

Table of contents Ex version drives

PAGE

Introduction

6

1. Safety 1.1 1.2

Explanation of the symbols used General safety instructions

7 8

2. Transport and storage 2.1

Transport and storage of the gear drive

12

3. Product description 3.1 3.2 3.3 3.4 3.5

Description of the Ex version drive Technical data Key for designations according to EU Directive Brake monitoring switch on full Ex drives Type plate for the full Ex version gear drive

13 15 16 17 20

4. Setting up and connecting 4.1 4.2

Setting up the machine in the machine room Notes on connecting

21 27

5. Commissioning 5.1

Commissioning the drive

29

6. Maintenance 6.1

Maintenance of the drive

31

7. Repairs 7.1

Repairing the drive

34

Appendix

as of page 35

Declarations of conformity Test certificates Certificates

ThyssenKrupp Aufzugswerke GmbH

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OPERATING MANUAL

Explosion-proof components Additional operating manual for drives the comply with the requirements of the Directive 94/9/EC. As a supplement to the operating manuals for the drives: TW63; W191; TW130; TW160; W263B; W332B this booklet contains important measures, regulations, as well as information where implementation and compliance are a prerequisite for meeting the fundamental safety and health requirements of the Directive 94/9/EC.

Basic principles of explosion protection: Directive 94/9/EC specifies the explosion protection for devices and protection systems. It is restricted to the manufacture and marketing of safe products that are to be deployed in zones where there is a danger of explosion. The supplementary Directive 1999/92/EC is addressed to the operators of installations in areas where there is a danger of explosion and it regulates the safety of persons during installation, operation and maintenance. The above directives are the basis of the ATEX guidelines.

ThyssenKrupp Aufzugswerke GmbH

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OPERATING MANUAL

1.1

1.SAFETY

Explanation of the symbols used 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 are to be followed without fail. They contribute to preventing personal injury or damage to property. Explosion protection This symbol indicates important information and measures in environment where there is a danger of explosion. Nonobservance can lead to death or severe injury!

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OPERATING MANUAL

1.2

1. SAFETY

General safety instructions The safety instructions serve to protect persons and property against injury of damage and dangers that result from improper use, incorrect operation, inadequate maintenance or other inappropriate actions in the area where there is a danger of explosion. This operating manual contains important supplementary details and measures, as well as regulations, where the implementation and adherence are requirements for ensuring protection in line with Directive 94/9/EC. It may only be used in conjunction with the operating manual delivered with the drive. All laws and regulation for elevator systems as well as accident prevention regulations must be known and complied with. Personnel requirements All work on the drives may only be executed by skilled, trained personnel. For work on explosion-proof drives, additional training and knowledge regarding explosion protection are required. For example, personnel must be familiar with the relevant regulations and rules for the installation, handling and operation of explosion-proof installations. Verification of the required training and corresponding experience must be provided. Note: the work is to be checked regularly by a person responsible who is familiar with the local circumstances and the installation and has the corresponding technical knowledge of explosion protection. 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. General safety instructions for operation in the Ex zone: Only assemblies or devices that are approved for Ex operation may be installed and operated. The drive, motor and additional electrical equipment may only be operated in the Ex-protected area if the described requirements, regulations and measures are complied with. NB: in the case of an explosive gas mixture or dust concentration in conjunction with hot surfaces, open live connections, friction of moving parts, switching, grinding and impact sparks, severe or even fatal injury can occur. Dust deposits: to reduce the risk of dust explosions, the installation operator must ensure that a possible dust deposit does not exceed a maximum thickness of 5 mm in accordance with EN50281-1-2.

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OPERATING MANUAL

1. SAFETY

Ambient conditions: it must be ensured that the drive is adequately ventilated and that there is no external heat transfer. If additional protective hoods are deployed, a risk analysis must verify that no ignition sources can arise, e.g. impact sparks due to grinding. In shaft areas with aggressive chemical vapours and gas, protection is to be provided and precautions taken against electrochemical corrosion. The entire area of the drive is to be checked to ensure that no ignition sources can arise, e.g. impact sparks due to grinding. Important safety instructions for assembly, maintenance and repair tasks for explosion-proof installations: Due to the special hazardous situation that makes explosion protection necessary, special regulations apply and additional precautionary measures are to be taken, even for maintenance, installation and repair work. This includes strict adherence to a work approval system. Work approval system: All work to be carried out in the area where there is a danger of explosion or in its vicinity that could lead to an explosion is to be approved before the work starts by the operator or a person responsible in writing in the form of an 'approval note'. The approval of work in writing should contain the following details: day, work area, persons involved, point of contact responsible, forecast duration of the measures, as well as a short description of the protection measures to be taken. If an activity lasts a number of days, a new approval note is to be issued for each additional day. Before the start of installation, maintenance or repair work, an approval note is to be obtained for the area concerned. It is to be ensured that all the required protection measures have been taken and that in the work area the presence of dangerous explosive atmosphere can be excluded. This is to be ensured for entire duration of the work and, if required, also beyond. After completion of the work, the safety of the installation is to be checked before start-up. The explosion protection measures required for normal operation must be effective once again. All those involved must be notified regarding completion of the work. It is recommended that you use a specially designed checklist. Additional safety rules for the Ex zone: Smoking is strictly prohibited in the entire area around the elevator. In the entire area, activities where heat, electrostatic charge, sparking or fire can occur are strictly prohibited! If drilling, welding or other activities involving sparking are to be carried out during installation or maintenance, an 'approval note' is to be obtained (see 'Work approval system'). As the explosive gases usually accumulate in the shaft pit, special protection measures are to be taken here.

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OPERATING MANUAL

1. SAFETY

During installation, maintenance and repair work, gas detectors are to be set up to draw attention - acoustically or visually - to dangerous gas concentrations. Before running a safety gear test, it is to be clarified and agreed with the operator that there are no explosive gas in the shaft. If required, ventilate the shaft. This also applies if terminal boxes, control cabinets or other closed containers with electrical components have to be opened during installation or maintenance work in the influenced area. NB: due to the increased safety risk in the areas where there is a danger of explosion, the warnings, notes on hazards and safety instructions in this operating manual are to be given special attention! Compliance with the safety regulations is to be checked regularly. Note: the sources of danger and measures listed in this manual are only examples; no claim is made with regard to their completeness.

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OPERATING MANUAL

2.1

2. TRANSPORT AND STORAGE

Transport and storage of the gear drive Packaging: You will find details of the packaging in the operating manual of the drive. In the case of drives with Ex-protected motors, the drive motor and the gear are usually delivered separately. Transport: Transport must be effected in compliance with the safety regulations and observing the centre of gravity of the transported goods. 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 goods themselves. • Pay attention to protruding parts! Danger of injury and damage! Crane transport: • Do not walk underneath suspended loads! • Use transport hangers or lifting lugs to mount the transportation chain or rope. • Do not lift by the housing! • After transport, remove the transport hangers. Pay attention to the icons on the packaging or elsewhere.

Top

Fragile goods

Protect against water

Protect against heat

Hand hooks prohibited

Attach here

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OPERATING MANUAL

2. TRANSPORT AND STORAGE

Dimensions and weight The weight data is specified on the packaging on a label below the transport hangers. Please refer to the delivery note for the dimensions. You will approximate details in the operating manual of the drives in chapter 4 'Technical data'. 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 stored carefully in a protected location. On covering, attention is to be paid to ensuring that no condensation can form and that no moisture can penetrate. To prevent contact corrosion in the bearings, the drive shaft is to be turned a number of time approx. every 3 months with the brake opened. • 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 in line with regulations.

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OPERATING MANUAL

3.1

3. PRODUCT DESCRIPTION

Description of the Ex version drive Note: this operating manual only describes the machines produced by ThyssenKrupp Aufzugswerke. It is intended as a supplement to the manual for drives with explosion protection delivered with the drive. Versions The various versions are: Partial Ex version Full Ex version

Partial Ex version (TW130, TW160, W263B, W332B) In the case of partial Ex elevator drives, the gear and motor are in the machine room, spatially separated from the shaft by a protective wall. The drive in the pulley room that involves a danger of explosion has an extended driven shaft on the gear. The wall duct in the pulley room is vapour-proof. The explosion protection for the elevator is therefore restricted to only the pulley room and shaft area. The devices in the machine room have no explosion protection. Wall ducts for lines that lead into the area where there is a danger of explosion are to be sealed in line with regulations (e.g. sand trap etc.). Note: any gases that might enter the machine room are to be removed by means of suitable ventilation measures. Without this, the corresponding protection cannot be ensured. The maximum gap width in the area of the shaft seal at the wall duct must not exceed 0.4 mm. To prevent an accumulation of gas in the machine room, the ventilation must not be shut down. After an interruption in the ventilation, the machine room is to be thoroughly ventilated before switching on the drive!

Full Ex version (TW63, W191, TW130, TW160, W263B, W332B) All devices in the machine room must be equipped with the prescribed explosion protection. On the elevator drive, this concerns: the motor, ventilation blower, brake magnets, pulse generator, switches, control system, terminal boxes as well as all electrical connections. In the entire area where there is a danger of explosion, protection measures are to be taken to prevent spark formation, electrostatic charge and ignitable temperatures.

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OPERATING MANUAL

3. PRODUCT DESCRIPTION

Brake monitoring: Motor movements when the brake is partially or fully closed must be prevented. Alongside premature wear, a malfunction of the brakes can lead to their heating up to ignition temperature. In the case of full Ex version drives, this means monitoring of the mechanical 2-circuit shoe brakes is required. The scope of delivery of the machines includes brake monitoring switches. These check the position (opened / closed) of the individual brake blocks. In the event of deviations from the specified position, the drive is to be shut down immediately by means of the corresponding signal processing. For further details on the technical data, please refer to the manufacturer specifications in the Annex and the description in chap. 3.4. Motor data: connection and performance data for full Ex motors can be found on the type plate of the motor or in the enclosed operating manual of the manufacturer.

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OPERATING MANUAL

3.2

3. PRODUCT DESCRIPTION

Technical data: 3.2.1 Gear drive: general technical data can be found in the operating manual of the drive. Supplementary details that concern explosion protection can be found in this manual. EX version markings for ThyssenKrupp gear drives Ambient temperature: independently of advanced temperature limits of the allocated categories (II2G and II2D), the drives may only be deployed at ambient temperatures of +5°C to 40°C. Ambient conditions: it must be ensured that the gear is adequately ventilated and that there is no external heat transfer. Full EX machine CE

II

2

GD

c,k

IIC

T4

IIC

T4

Traction sheave unit, partial Ex version CE

II

2

GD

c

Note: explanations of the designations can be found in chapter 3.3 3.2.2 Motor data: connection, performance data and protection type of full Ex protected motors can be found on the type plate of the motor or in the enclosed operating manual of the manufacturer. 3.2.3 Brake magnets in Ex-protected version: see manufacturer specifications in the Annex. 3.2.4 Brake monitoring switch in Ex-protected version: see manufacturer specifications in the Annex.

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OPERATING MANUAL

3.3

3. PRODUCT DESCRIPTION

Markings of the machines in accordance with Directive 94/9/EC In accordance with Directive 94/9/EC, the types of protection are linked to the device groups, categories, Ex atmospheres as well as the minimum protection types and temperature classes. Example: electrical equipment in the protection type 'protection by constructional safety' II

CE marking Marking for prevention of explosions Device group II: Other than mining Category 2: for zones 1, 2, 21, 22 3: for zones 2, 22 Ex atmosphere G: gas D: flammable dust Type of protection p: overpressure encapsulation d: pressure-proof encapsulation e: increased safety n: type of protection n nA: type of protection n; A: non-sparking electrical equipment c: protection by constructional safety k: liquid immersion Explosives group II Limit gap width A: d ≥ 0.9 mm B: 0.9 mm >d ≥ 0.5 mm C: 0.5 mm >d Temperature class Limit temperature T1: max. 450 °C T2: max. 300 °C T3: max. 200 °C T4: max. 135 °C T5: max. 100 °C T6: max. 85 °C

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2

G

c

IIC

T4

OPERATING MANUAL

3.4

3. PRODUCT DESCRIPTION

Brake monitoring switches with full Ex drives The scope of delivery of the full Ex equipment includes monitoring of the mechanical dual circuit shoe brake with explosion-proof switches. Function: a switch checks the position (opened / closed) of each brake block. Further, the brake lining is monitored to detect separation or whether it is missing. In the event of failure or malfunction of a brake circuit, the control system of the elevator must switch off the drive immediately. This measure is required for full Ex operation, as operation with partially closed brake can lead to the brake heating up to ignition temperature. The brake monitoring must be connected before commissioning. Its proper function must be checked, see chapter 4.2. NB: operation without the brake monitoring circuit connected and functioning is prohibited! Installation: The brake test switches are to be attached to the gear drive using the enclosed bracket, in the same way as the brake monitoring SA3 (see machine manual). See also example in Fig. 1 for TW160. The connection lines of the brake test switch on the switch side are connected ex works. The manufacturer specifications on Ex-protected switches are available in the Annex. Note: before beginning with the brake test switch setting, the brake block lift setting must be checked. If this does not correspond to the required setting values, the brake block lift is to be set first. You will find a description in the operating manual of the drive.

Fig. 1

Fitting the brake switches TW160

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OPERATING MANUAL

3. PRODUCT DESCRIPTION

Setting the brake test switches on full Ex drives: Requirements: • To set the test switches, the brake must be closed; the brake blocks must make contact with the brake disc. • To determine the switching point exactly, a continuity checker must be connected. • The setting and/or inspection must be carried out before connecting the switch to the control system or, on checking the switch the installation must be without power. Setting the switches: • Loosen the lock nut of the setting screw. • Unscrew the setting screw until it makes contact with the operating cam. • Unscrew the setting screw further until a change in the switching state from opened to closed can be detected on the continuity checker. • • •

Unscrew the screw another ¼ revolution (≙ 0.3 mm) towards the switch. Secure this setting by tightening the lock nut. Repeat the setting procedure on the second switch.

NB: the switch has two switch contacts: Break contact and connection lines Make contact and connection lines

brown / blue grey / black

Function of the brake test switch Brake closed

=

make contact closed

Brake opened

=

make contact opened

=

break contact opened

Wear check if brake lining is lost

12 BU blue

brown BN 11 grey

GY 23

24 BK black

Note: the switch setting must be checked regularly and adjusted if required. Check interval for switch setting: With controlled drives (frequency controller; ACVV) once a year. With non-controlled drives (AC2) every six months

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OPERATING MANUAL

3. PRODUCT DESCRIPTION

2

1

Fig. 2 8

7

6

5

4

3

Switch assembly TW160 1

Brake blocks

5

Switch tappet

2

Gear box

6

Setting screw

3

Switch

7

Securing bolt

4

Securing bracket

8

Lock nut

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OPERATING MANUAL

3.5

3. PRODUCT DESCRIPTION

Type plate for the full Ex version machine 1. Type plate on the machine

2. Type plate for the traction sheave unit on partial Ex version SA4 (partial Ex) only for the machines TW130, TW160, W263B, W332B

Note: the type plate must remain clearly legible after installation. It must not be painted over or otherwise rendered illegible. The key for Ex designations can be found in chapter 3.3.

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OPERATING MANUAL

4.1

4. SETTING UP THE MACHINE

Setting up the machine in the machine room Installation • •

• •

Before assembly work commences, the following points must be ensured without fail: The conditions stated in the chapter 'Safety' must be met. The details on the type plates of the drive and brake magnets must match the regulations for the area of application on site (protection type, device group, category, zone, temperature class, maximum surface temperature). The drive unit is to be checked for visible damage, e.g. caused by transport or storage. There must be no explosive atmosphere in the entire assembly area. Oils, acids, gases, vapours, emissions of rays etc. are to be kept way from the assembly area or shut off for the assembly period.

•

The assembly area is to be secured by appropriate measures (setting up a gas detector; installation devices secured against unauthorised activation).

•

For the assembly period, an "inspection permit" or "fire permit" must have been issued by the operator. For work flame or spark formation or dangerous heating, a "lighting permit" is to be obtained from the operator for the day of assembly. For more detailed explanations, see "Important safety instructions for assembly work on explosion-proof installations" in chapter 1.2. Setting up the W263B and W332B in the partial Ex version

•

• •

• •

• • •

Set up the drive unit according to the plan of installation. Align the rope departure to the car and counterweight. Secure without tension and warping on the machine base frame, drive unit, on machine room floor or concrete foundation. NB: when setting up the partial Ex version of the drive, do not place any insulation or rubber elements under the drive, as the seal of the wall duct is impaired in the event of vibration movements. Ensure that the driven shaft has an exact horizontal alignment. The offset from the gear to the outside bearing may be a maximum of ± 1 mm. Use suitable measures to align the wall duct to the driven shaft. The dimension of the gap between the driven shaft and gland on the sealing plate should be the same around the entire circumference. No metal parts may make contact in the area around the seal! The graphited cord seal is pretensioned with a spring. If an air gap forms between the drive shaft and graphited cord, this may be a maximum of 0.4 mm. The air gap is to be checked using a feeler gauge. The frame of the wall duct is to be walled in and sealed. Non-shrinking material must be used. The relevant regulations for explosion protection are to be complied with. Once the wall has dried, the central location of the sealing bush to the wheel shaft and the sealing effect of the graphited cord are to be checked once again with the traction sheave subjected to load (carrier cables applied). If required, minor deviations from the central location can be corrected by moving the sealing plate at the frame mount of the wall duct. The screwed connection of the bearing bracket to the wall frame must be tight and even. The surrounding seal must not have any interruptions or be damaged. The frame of the wall duct is to be joined as permanently elastic in accordance with the Ex regulations. The elasticity and effectiveness of the seal are to be checked before commissioning.

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OPERATING MANUAL

4. SETTING UP THE MACHINE

Diagram: sketch of function principle of the gear drives W263B/W332B with wall bearing SA4 4

3

5

2

1

12

Fig. 3

11

10

9

8

1

Console

7

Pedestal support

2

Outside bearing

8

Gear drive

3

Friction pulley

9

Driven shaft

4

Sealing plate

10

Masonry

5

Frame

11

Gland

6

Oil drain

12

Rope guard

ThyssenKrupp Aufzugswerke GmbH

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7

6

OPERATING MANUAL

4. SETTING UP THE MACHINE

Wall bearing for partial Ex drives W263B and W332B Section A-D

1 2

3

4 5 6 7 8 11

11

9 5

4

2 10

Fig. 4 1 2 3 4 5 6

Bearing bracket screwed connection Seal Sealing plate Locking ring Disc Bush

ThyssenKrupp Aufzugswerke GmbH

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7 8 9 10 11 -

Pressure springs Driven shaft Gland with graphited cord Wall frame Reinforcing spar

OPERATING MANUAL

4. SETTING UP THE MACHINE

Setting up the partial Ex versions of TW130 and TW160 machines The machine, outside bearing and wall bearing on the above drives are mounted on a machine base frame. The frame and drive unit can be delivered separately. • Mount the machine with wall bearing and outside bearing on the machine base frame. NB: on setting up the partial Ex drive version, no insulation or rubber elements may be used! • Align the drive unit and secure the frame to the base with dowels. Ensure that the unit is mounted without tension or warping and that the driven shaft is in an exact horizontal position. • The machine base frame has not been machined in the support area of the compensating support and pedestal bearings. The support height of the pedestal bearing support is set approx. 1 mm higher in relation to the compensating support. This dimension has been deliberately selected to enable manufacturing tolerances to be balanced out by placing shims under the compensating supports. The shim thickness is to be geared in such a way that the pedestal bearing and shaft are precisely aligned horizontally (maximum offset ± 0.5 mm). If these are out of line, this leads to a poorly sealed bearing and premature wear of the twin-lip seals on the pedestal bearing. • The wall opening for the driven shaft duct is closed off by a sealing plate. Seals that surround the sealing plate edge and driven shaft duct ensure a vapour-proof closure against the frame and outer bearing housing. The screwed connection of the plate and frame must be tight and even all round. • The frame with wall duct are to be walled in and sealed in line with the Ex regulations. Nonshrinking material must be used. • Once the wall has dried, the seal on the driven shaft duct is to be checked again with the traction sheave subjected to load (carrier cables applied). Check the seal between the frame and sealing plate. The seal must be without interruption and must not be damaged. • No metal parts may make contact in the area around the seal of the shaft duct! • The frame of the wall duct is to be joined as permanently elastic in accordance with the Ex regulations. The elasticity and effectiveness of the seal are to be checked before commissioning. NB: on setting up the drive, ensure that the ventilation (intake and exhaust air) is not obstructed. The cooling blower should not draw in its own heated exhaust air or that of neighbouring devices.

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OPERATING MANUAL

4. SETTING UP THE MACHINE

Diagram: TW160 on machine base frame with wall bearing SA4 2

4

3

5

1

6

Fig. 5

10 1 2 3 4 5

9

4

8

Gear drive Sealing plate Seal Machine base frame Friction pulley

6 7 8 9 10

7 Seal Wallplug fixture Outside bearing Driven shaft Compensating support

The partition wall and wall duct must be vapour-proof. Note: the design of the illustrated frame also corresponds to the frame of the TW130, whereby the dimensions are to be matched to the dimensions of the TW130. Dimensions of the vapour-proof TW130 version can be found in the operating manual for the machine with special version SA4. Detail for Fig. 5 ThyssenKrupp Aufzugswerke GmbH

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OPERATING MANUAL

4. SETTING UP THE MACHINE

1

2

3

5

4

Fig. 6 10

5

9

8

7

1

Sealing plate

6

Groove nut

2

Seal

7

Safety plate

3

Bearing housing

8

Adapter sleeve

4

Self-aligning bearings

9

Integral collar

5

Seal

10

Driven shaft

6

Setting the full Ex version of the machine In contrast to the partial Ex version (setup in the machine room with vapour-proof wall duct), the drive is located in the area of the shaft where there is a danger of explosion. This means that all the technical devices of the installation must be fitted with the required explosion protection. NB: all of the possibilities and influences that lead to ignition, ignitable heating or spark formation are to be inhibited by suitable measures.

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OPERATING MANUAL

4.2

4. SETTING UP THE MACHINE

Notes on connecting NB: work in the area where there is a danger of explosion may only be commenced after an "approval note" (permission in writing) has been granted (you will find more details in chapter 1.2 'General safety'). • In the case of connections of devices in the area where there is a danger of explosion, the valid national or international regulations are to be observed in each case. • The work may only be carried out on the installation when it is without power and has been secured against reactivation. • Before opening connection and terminal boxes, check that the installation is without voltage and secured against unauthorised activation. • The mains frequency and voltage must correspond to the connection values of the drive. The voltage tolerance specified on the type plate of the motor must not be exceeded. • The cable type and width of connection and positive earths as well as the equipotential bonding must comply with the setup regulations. • Interconnect the devices consistently with safe positive earth connections of adequate width. • Use the cable termination fittings assigned accordingly for the connection. The connection must be made in such a way that a permanently safe electrical connection is maintained (no protruding wire ends). • There must be no foreign bodies, dirt or moisture in the connection and terminal boxes. They must comply with the required explosion protection and are to be sealed to ensure they are dustproof and waterproof. • A separate connection box that complies with the explosion protection regulations is to be used for additional connecting parts. No additional connecting parts may be fitted in the existing terminal boxes. • Cable entries must be approved for the Ex zone concerned with an EC - Type Test Certificate and secured against loosening of their own accord. • Cable entry openings that are not required are to be closed off with special dustproof and waterproof stoppers approved and certified for the Ex use case. They are to be secured against loosening of their own accord. • For all connections, attentions is to be paid to strain relief. • Intermediate clampings of connections must be fitted in explosion-proof terminal boxes in the case of full Ex protection. • The drive (gear and motor) is to be earthed consistently according to the VDE regulations with adequate width (min. 16 mm²). In the case of full Ex protection, observe the notes and specifications in the enclosed operating manual of the motor manufacturer!

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OPERATING MANUAL

4. SETTING UP THE MACHINE

Temperature monitoring: in the case of explosion protection, temperature-monitoring sensors in the motor winding and at other dangerous points where overheating can occur must be connected to an electronic evaluation system that is approved for the required protection in each case and must bear a mark of conformity. It must be ensured here that the drive motor shuts down immediately if the overheating protection is triggered. It is to be ensured that the ventilation blower continues to run even after the drives has been shut down! (coasting) The purpose of this measure is to prevent heat accumulation after the cooling blower is deactivated. The proper functioning of the protection measures is to be checked regularly.

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OPERATING MANUAL

5.1

5. COMMISSIONING

Commissioning the drive Before commissioning and when carrying out regular maintenance work, adherence to the safety regulations is to be checked. Inspection points before commissioning • The room where the drive is set up must conform with the conditions and regulations for elevator rooms. • The machinery space, drive (gear and motor) must be adequately ventilated. There must not be any external heat transfer. • The intake and exhaust air ducts must not be obstructed. • Housing ventilation ducts and any condensation drains must be open and free of impurities. • Before commissioning, it must be checked whether the installation has been performed in line with regulations and secured with suitable screwed connections. • Before commissioning, the oil level at the gears is to be checked; if necessary, top up or drain the surplus amount. Overflowing oil can create sources of danger! • The oil gauge, drain plug as well as ventilation plug must be freely accessible at any time. • Temperature-monitoring sensors in the motor winding and at other points where there is a danger of overheating must be connected to the electronic evaluation system. The proper function must be checked. • The temperature of the drive is to be checked, whereby the determined values must not exceed the permitted temperature class on the type plate. • Drive and driven elements such as the traction sheave, rope run-in and run-out must be fitted with guards preventing accidental contact. • The entire area of the drive is to be checked to ensure that no ignition sources can arise, e.g. impact sparks due to grinding or friction. Run-in operation for drives with "full Ex protection" On commissioning drives with full Ex protection, these are to be run in with the loads specified below. During the run-in operation, check the surface temperature of the gear. NB: during the run-in operation, no explosive atmosphere may be present! Procedure: 24-hour run-in operation (operating time ≤ 40%) with the following load a) 1/3 of the rated load b) 2/3 of the rated load Note: during run-in operation, the installation is to be monitored continuously!

ThyssenKrupp Aufzugswerke GmbH

29

OPERATING MANUAL

5. COMMISSIONING

Check of the surface temperature: The maximum surface temperature specified on the type plate is based on measurements under normal environmental and setup conditions. Even slight changes in these conditions (e.g. narrow installation conditions) can have a significant influence on the temperature development. Immediately after commissioning and repeated at yearly intervals, a temperature measurement is to be carried out at the gear box casing and the bearings. The measurement is to be performed with an ex-protected temperature measurement device. The highest surface temperatures normally occur on the cover of the rear worm shaft bearing (see Fig. 7). The maximum surface temperature must not exceed a difference value of 50 K compared to the ambient temperature. With a higher difference value, the drive must be shut down immediately. In this case, make sure that you consult ThyssenKrupp Aufzugswerke.

Measuring point

Fig. 7 Illustration of W332B

ThyssenKrupp Aufzugswerke GmbH

30

OPERATING MANUAL

6.1

6. MAINTENANCE

Maintenance of the drive Note: this chapter refers exclusively to additional maintenance work that only concerns the Ex versions. It supplements the details provided for each drive in the special operating manual. All laws and regulation for elevator systems as well as accident prevention regulations must be known and complied with. Maintenance period: on account of the higher operating risk in the case of Ex installations, maintenance of the machine should be carried more frequently than in the case of operation under normal conditions. The frequency is indicated in the lubricating instructions in this chapter (at least once per year within the framework of the central maintenance). Due to the special hazardous situation that makes explosion protection necessary, special regulations apply and additional precautionary measures are to be taken, even for maintenance and assembly work. Before starting maintenance work, chapter 1.2 "General safety instructions" must be read. This chapter contains important safety instructions for assembly and maintenance work on explosion-proof installations. During maintenance work, gas detectors are to be set up to draw attention - acoustically or visually - to dangerous gas concentrations. If required, ventilate the machine room. This also applies if distributor terminal boxes, control cabinets or other closed containers with electrical components have to be opened during installation or maintenance work in the area where there is a danger of explosion. If components are to be replaced, a check must be run before installation as to whether they meet the requirements and comply with the regulations for the area where there is a danger of explosion. It must be checked whether all the components are consistently earthed with adequate width in line with regulations. Supply lines for connections must be sealed using suitable measures in accordance with the explosion protection regulations. Only cable entries that are approved by EC - Type Test Certificate for the Ex area concern may be used. They are to be secured against loosening of their own accord. Unused openings are to be sealed off with certified and approved stoppers.

ThyssenKrupp Aufzugswerke GmbH

31

OPERATING MANUAL

6. MAINTENANCE

You will find additional details on the procedure, settings and data in the operating manual of each drive type. • All bearings are to be checked annually with regard to heat development or bearing damage (temperature, noise, etc.). • Check the alignment of the wall duct to the driven shaft; if they are out of line, correct. • Check the effectiveness of the seal between the wall duct and partition wall; if required, replace the seals. • In the case of a wall duct with sealing plate, check that the distance between the duct opening and the driven shaft is even and check the gap width (max. gap width 0.4 mm). • Check the elasticity and effectiveness of the seal of the frame join at the wall duct. • Check the effectiveness of the seals and secure seating of screwed connections and cable bushings. • Check that the rope guard is present and that the correct distance is set to the cables on the traction sheave. • Check the brake block lift and brake function. • Check the function of the brake test switches. • Check the oil level; top up if necessary. • Change the oil at the prescribed intervals. Only use approved oil! • Replenish the outside bearing grease filling (type F1*). • Check the proper ventilation of the drive, machine room and shaft. • Check that electrical connections are securely seated and in good condition; check the cable routing and safety. • Check that the components are properly earthed. • Check that protective and safety devices are present, functioning and correctly set. • Clean the cooling air paths of the ventilation; remove dust deposits in the area of the drive. • As a preventive measure, check the entire area of the drive for possible ignition sources, e.g. impact sparks that can arise if parts make contact and grind. • Skilled personnel must check the operational safety of the drive with regard to explosion protection after every 20 000 hours of operation. Overhaul if required.

Partial Ex Partial Ex Partial Ex Partial Ex

Full Ex

Other points to be checked are listed with descriptions in chapter 5.1 'Commissioning'.

ThyssenKrupp Aufzugswerke GmbH

32

OPERATING MANUAL

6. MAINTENANCE

Lubricating instructions for full and partial Ex installations: -Ex V

V

V

V

In the case of partial Ex installations, the lubricating instructions in the operating manual for the drive applies. Gear drive type / Lubricant * Replacement interval Filling lubrication point amount TW63 Synthetic gear oil SM1 * For the first time after 2 years then every 4 years W191 Mineral gear oil For the first time after Refer to the details in the M1 * 2 years, separate then every 2 years operating TW130 Synthetic gear oil SM1 * For the first time after manual for 2 years, each gear then every 4 years drive type TW160 Synthetic gear oil SM1 * For the first time after

V

W263B

Mineral gear oil M1 *

V

W332B

Mineral gear oil M1 *

V

V T

Rolling bearings of motors (except for bearings with service life lubrication) Gear drive outside bearing with rolling bearing

**

Multipurpose grease F1*

2 years, then every 3 years For the first time after 2 years, then every 2 years For the first time after 2 years, then every 2 years **

2 times a year

V = full Ex protection; T = partial Ex protection version * **

Can be obtained through ThyssenKrupp Aufzugswerke GmbH Comply with the operating manual of the motor manufacturer

NB: if lubricants such as oils and greases other than those specified in the operating manual are used, this can lead to unforeseen heat (danger of fire), inadequate lubrication, premature wear and destruction of the assembly. ThyssenKrupp Aufzugswerke GmbH shall not be liable in this case!

ThyssenKrupp Aufzugswerke GmbH

33

OPERATING MANUAL

7.1

7. REPAIRS

Repairing the drive Note: a description of the repair work for the topics listed below can be found in the operating manual for each drive type: • • • • •

Brake block replacement Braking deceleration setting Brake block lift Traction sheave replacement Motor extension replacement

When working on explosion-proof installations, the following must be observed: The same regulations and conditions as for installation and maintenance also apply to repair work. For this reason, comply with the safety instructions listed in chapter 1.2. Only assemblies or devices that are approved for Ex operation may be installed and operated. This must be documented by a certificate. Before starting to install replacement parts, the details on the type plates must be checked to ensure the parts are permitted for the case concerned. All the components that are used and fitted must comply with the specifications in the declaration of conformity and Ex regulations. Only original components may be used. Installation may only be carried out when these conditions have been met. With the full Ex version, attention should be paid to ensuring that parts to be replaced and their connections correspond to the required atmosphere, protection type and temperature class, see overview in chapter 3.3. Repairs to explosion-proof components, e.g. motors, may only be carried out in compliance with the corresponding regulations "Regulations regarding electrical installations in rooms where there is a danger of explosion", or they must be repaired by the manufacturer. After the repair has been completed, they are to be fitted with an additional sign indicating the date, repair firm, type of repair and mark of the expert.

ThyssenKrupp Aufzugswerke GmbH

34

OPERATING MANUAL

Appendix

Declarations of conformity Manufacturer specifications for brake monitoring switch Type test certificate for brake monitoring switch Declaration of conformity for brake monitoring switch Manufacturer specifications for Ex brake magnets Type approval for Ex magnets

ThyssenKrupp Aufzugswerke GmbH

35

EG-Konformitätserklärung EC Declaration of Conformity im Sinne der EG- Maschinenrichtlinie 98/37/EG; Anhang II C und Explosionsschutzrichtlinie 94/9/EG According to the EC-Machinery Directive 98/37/EC; Annex II C and ATEX Manufaturer Directive 94/9/EC Hiermit erklären wir, dass das nachfolgend aufgeführte elektrische Bertiebsmittel aufgrund der Konzipierung und Bauart der o.g. Richtlinien entspricht. We hereby declare that the following electrical equipment conforms to the above mentioned machinery directives.

Bezeichnung des Betriebsmittels: Name of the component:

EEx 14 ...

Beschreibung des Betriebsmittels:

Positionsschalter, EX-geprüft II 2G EEx d IIC T6 II 2D IP65 T80°C Position switch , EX-proof II 2G EEx d IIC T6 II 2D IP65 T 80°C

Description of the component:

14 .. ....

Einschlägige EG-Richtlinien: Relevant EC directives:

98/37/EG 1998 (Maschinenrichtlinie) 73/23/EWG 1973 (Niederspannungsrichtlinie) 94/9/EG 1994 (Explosionsschutzrichtlinie) (ATEX)

Angewandte harmonisierte Normen: Harmonized standards:

EN 60947-5-1 EN 50014 : 2000 EN 50018 : 2000 EN 50281-1-1 : 1998

Prüfschein/Test certificate:

PTB 03 ATEX 1070 X

Anbringung der CE-Kennzeichnung: Application of the CE mark

2003

Ort und Datum der Ausstellung: Place and date of issue:

Löhne, 17. November 2003

Rechtsverbindliche Unterschrift: Legally binding signature:

i. V. Ralf Twellmann (Technischer Leiter/Technical Director)

6

Ex switchgear Safety switches Position switches with safety function EEx/EExM 14 range

ø 4,3 8,4

20 22

4

50

50

9

1. 1.3 1.3.1

ø7

30

Features

• Thermoplastic enclosure • Double-insulated X • II 2G EEx d IIC T6 II 2D IP65 T80°C • Slow action A, change-over contact, double break, suitable for safety applications in combination with positive linked actuator • Snap action, change-over contact, single break; change-over contact, double break • Available with overlapping contacts • Suitable for in-line mounting • Pre-wired cable • IP 67

Info

Version for equipment category 3D (dust-Ex zone 22) available Ordering suffix: -3D

Approvals

EC Type test certificate: EEx 14: PTB 03 ATEX 1070 X EExM 14: PTB 03 ATEX 1069 X EExM 14 1Ö/1S: PTB 00 ATEX 1006 X

Info

• With overlapping contacts, ordering suffix 1Ö/1S UE • With cable on side, ordering suffix -s

Note

The switch must be protected from mechanical damage.

Cable length

Always specify cable length • 1 metre long ordering suffix • 2 metres long ordering suffix • 5 metres long ordering suffix • 10 metres long ordering suffix Other lengths on request

Actuators Plunger

Plunger

with watertight collar W

56

17,7

8,5

ø 10 ø 10

16

with front mounting F

-1m -2m -5m -10m

1. 1.3 1.3.1

Ex switchgear Safety switches Position switches with safety function EEx/EExM 14 range Actuators

Ball plunger

Ball plunger KU

with watertight collar WKU

with front mounting FKU

Roller plunger

Roller plunger R

with watertight collar WR

with front mounting FR

Spring rod

Long spring wire (Cat’s whisker) TL

with rounded steel tip TF

with plastic rod TK

8

ø7

73

157

81

44

ø 1,6

ø7

Roller lever

Roller lever D

Long roller lever DL

Vertical actuation

Ball plunger at front VKU

Roller plunger at front VR

Adjustable-length roller lever DS

57

1. 1.3 1.3.1

Ex switchgear Safety switches Position switches with safety function EEx/EExM 14 range

ø 10

Features

• Actuating speed with actuating angle 0° to switch axis 0.5 m/s • With slow action suitable for safety application

Info

Version for equipment category 3D (dust-Ex zone 22) available Ordering suffix: -3D

Contacts/ Switch travel

Change-over 4 BK contact

1 BU

2 BN

Snap action

0 1,5

EExM 14

2 Öffner

Slow action

EEx 14 2Ö

58

Ordering details

5,5

1 NO 1 NC

Snap action 1-4 1-2

8,5

Plunger

An EEx/EExM 14 range position switch with plunger with snap action and change-over contact: EExM 14

Slow action

0

3

1,5 EExM 14 1Ö/1S

BK 23 BN 11

1 NO 1 NC

EEx 14

2,8

5,5

24 BK 12 BU

23-24 11-12

Anwendung / Applications: Die Positionsschalter der Reihe EEx 14 ... entsprechen den Europäischen Normen für den Explosionsschutz EN 50014 und EN 50018 / EN 50281 und sind daher für den Einsatz in explosionsgefährdeten Bereichen der Zone 1 und 2 sowie Zone 21 und 22 nach DIN EN 60079-14 und DIN EN 50281-1-2 vorgesehen. The position switches of series EEx 14 … comply with the European standards for explosion protection EN 50014 and EN 50018 / EN 50281 and therefore are designed for the explosive areas of zone 1 and 2 as well as zone 21 and 22 as per DIN EN 60079-14 and DIN EN 50281-1-2.

Montage und Anschluss / Installation and connection: Die Positionsschalter EEx 14 ... sind kunststoff gekapselt. Der Positionsschalter ist so anzubringen bzw. zu errichten, dass sein Gehäuse hinreichend vor mechanischer Beschädigung geschützt ist. Die Anschlussleitung dieses Schalters muss fest und so verlegt werden, dass sie ebenso vor mechanischer Beschädigung geschützt ist. Umbauten und Veränderungen am Schalter, die den Explosionsschutz beeinträchtigen, sind nicht gestattet. Ferner gelten für das Errichten von elektrischen Betriebsmitteln in explosionsgefährdeten Bereichen die DIN EN 60079-14 und DIN EN 50281-1-2. The position switches EEx 14 ... are protectively insulated by a plastic housing. The position switch has to be fitted or mounted so that its housing is protected against mechanical damages. The connection of this switch has to be fixed and laid in a way that it is protected against mechanical damages as well. Reconstruction and alterations at the switch - which might affect the explosion protection are not allowed. Furthermore DIN EN 60079-14 DIN EN 50281-1-2 have to be applied for the installation of electrical equipment in explosive areas. "X" = Zulassungsbedingungen / Approval requirements

Hinweis / Note: Zu beachten ist ferner die PTB-Prüfbescheinigung und die darin enthaltenen besonderen Bedingungen. Moreover the PTB test certificate and the enclosed special conditions have to be observed.

2

"X"

"X"

Maßzeichnung /Dimensional drawing:

4,3

50

8,2

9

8,5

Ø10

20 4 22

16

30

Wichtiger Hinweis: Die hier beschriebenen Produkte wurden entwickelt, um als Teil einer Gesamtanlage oder Maschine sicherheitsgerichtete Funktionen zu übernehmen. Ein komplettes sicherheitsgerichtetes System enthält in der Regel Sensoren, Auswerteeinheiten, Meldegeräte und Konzepte für sichere Abschaltungen. Es liegt im Verantwortungsbereich des Herstellers einer Anlage oder Maschine, die korrekte Gesamtfunktion sicherzustellen. steute übernimmt keine Haftung für Empfehlungen, die durch diese Beschreibung gegeben oder impliziert werden. Aufgrund dieser Beschreibung können keine neuen, über die allgemeinen steute-Lieferbedingungen hinausgehenden Garantie-, Gewährleistungs- oder Haftungsansprüche abgeleitet werden.

Important note: The described products have been developed in order to assume safety functions as a part of an entire plant or machine. A complete safety system normally covers sensors, monitoring modules, indicator switches and concepts for safe disconnection. The responsibility taken by the manufacturer of a plant or machine implies to secure the correct general function. Moreover steute does not assume any liability for recommendations made or implied by this description. From this description new claims for guarantee, warranty or liability cannot be derived beyond the general terms and conditions of delivery.

3

Technische Daten / Technical data: Explosionsschutz: Explosion protection:

II 2G EEx d IIC T6 II 2D IP65 T80°C

Prüfschein/Test certificate: PTB 03 ATEX 1070 X Aufbau: Design:

EN 50014 : 2000 EN 50018 : 2000 EN 50281-1-1 : 1998 nach / acc. EN 60947-5-1

Schaltsystem: Switching system:

Tastkontakt 1 Öffner + 1 Schließer bzw. 2 Öffner Öffnerkontakt zwangsgeführt gem. EN 60947-5-1 Slow action contact 1 normally closed + 1 normally open or 2 NC, positive guided normally closed contact as per EN 60947-5-1

Schutzart: Protection class:

IP 67

Anschluss: Connection:

4- bzw. 2-adrige PVC-Leitung H05 VV-F 0,75 mm² 4- resp. 2-core PVC conductor H05 VV-F 0.75 mm²

Zul. elektrische Belastung: 250 V AC -6 A (AC-15) Perm. electrical load: 220 V DC -0,25 A (DC-13) 24 V DC - 4 A (DC-13) 250V AC - 3 A (AC-15) *) Temperaturklasse: Temperature class:

T6 bzw. T5 T6 or T5

Zulässige Umgebungstemperaturen:

T6 = -20 °C bis +65 °C (bis zu dieser Temperatur am Einbauort bleibt die Oberflächentemperatur des Positionsschalters unter 80 °C) T5 = -20 °C bis +90 °C bei max. elektr. Belastung von 250 V/3A AC 15, mit spez. temperaturbeständiger Anschlussleitung (der Positionsschalter ist für eine Temperaturbeständigkeit von 90 °C ausgelegt) T6 = -20 °C to +65 °C (up to this temperature at site of installation the surface temperature of the position switch remains below 80 °C) T5 = -20 °C to +90 °C at max. electr. load of 250 V/3A AC 15, with special heat-resistant connection (the precision limit switch is designed for a heat resistance of 90 °C)

Permissible ambient temperature:

*)

für Umgebungstemperatur > 65 °C / for ambient temperature > 65 °C 4

Schaltbild u. Farbcodierung/Switching circuit and color coding: 1Ö/1S

(BN) 11

12 (BU)

(BN) 23

24 (BK)

(BU)

(BN)

2Ö

1S

1Ö

(BU)

(BN)

Typenschlüssel-bzw. Bezeichnung: type code / type identification

EEx 14

*

Betätigung actuation

Typ.-Bezeichnung type identification

Typenschlüssel EEx 14 type code EEx 14 1

2

3

4

Type type

5

Kontakt Betätigung contact actuation `00 0 1Ö/1S `01 Stößel 5 2Ö 9 1Ö oder / or 1S `02 W `03 KU `04 WKU `05 ST `06 WST `07 K `08 WK `09 R 10 WR 21 D 22 23 DL 14 = EEx 14 24 25 DD 27 DF 28 29 DS Artikel-Nr.: 32 TL

6

7

Kennung identification 3 EX - Einsatz 4 Goldkontakte 9 SPEZIAL

8 fortlaufende Nummer consecutive number

3 EX insert 4 gold platet contacts 9 SPECIAL

52 53 ST (AZ) 54 SB 55 RT/RTM (Handtaster) 56 RV 57 RW 58 RSSA 59 RFV

Part.No.:

33

61 V

EEx 14 R 14.0.09.3.01

34 TF

62 VKU

35 36 37 38 44 47 48 49 50 51

63 VR 66 AZ

TK TFL F FKU FR

5

(BN) 11

12 (BU)

(BK) 21

22 (BK)

Nr. 60 000 21 86 0

Ein Unternehmen von ThyssenKrupp Elevator Bernhäuser Strasse 45 73765 Neuhausen a. d. F. Deutschland Tel.: +49 7158/12-0 Fax: +49 7158/12-2585 E-Mail: [email protected] www.thyssenkrupp-aufzuege.de

Issue 06/2007

ThyssenKrupp Aufzugswerke GmbH