Instruction manual and installation guide Traction sheave brake TSB 2000-1 TSB 2000-2
Content Traction sheave brake Page 1. Safety 2 1.1 Explanation of symbols 2 1.2. General safety instructions 3 2. Product specification 6 2.1 Specification of the traction sheave brake 6 2.1.1 Technical data 6 2.1.2 Capacity data 7 2.1.3 Operating conditions 8 2.2 Structure 8 2.3 List of components 9 2.4 The type plate data 11 2.5 Functional description of the traction sheave brake 12 2.6 Maintenance and inspection 13 3. Transportation and storage 14 4. Operating conditions for the traction sheave brake 14 5. Installation of the traction sheave brake 15 6. Electrical connection of the traction sheave brake 15 7. Disposal of hydraulic oil 16 8. Illustration of the traction sheave brake 17 Traction sheave brake TSB2000-1 17 Traction sheave brake TSB2000-2 18 9. EU type examination certification 19 9.1 Appendix to EU type examination certification 20-22 1
1. Safety 1.1 Explanation of symbols The following symbols and terms are used in this instruction manual: Danger This symbol warns of extreme danger. Disregard of this warning is life-threatening. Danger This symbol warns of immediate danger by electric shock. Hazard warnings must be obeyed at all times! Warning This symbol warns of possible danger. Disregard may cause bodily harm/personal injury or extensive material damage. Hazard warnings must be observed at all times! Notice This symbol points out important information and instructions for use. Disregard may cause damage, hazard or disturbances. Check This symbol indicates test procedures These test procedure have to be executed when indicated. They contribute to preventing damage to persons or material. 2
1.2 General safety instructions Reference to operating instructions A knowledge of the basic safety instructions is vital for the safe and trouble free usage of the brake. This instruction manual provides important instructions for the safe use of the brake. These instructions have to be observed by all persons working with this brake. In addition, the local rules and regulations for accident prevention must be observed. Commitment of the user and/or the assembling company The user or installer is obliged to allow only persons who are familiar with the regulations for occupational safety and accident preventions and who are trained to use the brake have read the chapter on safety regulations and the warning. to actually work with the brake. Advice: Check that the staff are conforming with the safety regulations from time to time Obligation of the staff Persons who work with this assembly commit themselves before starting work to. obey the regulations for occupational safeties and accident prevention read the safety instructions and warnings in this instruction manual Training of the staff Only trained and skilled people are allowed to work with the brake. The responsibility of the staff has to be clearly specified for all tasks during commissioning, operation, maintenance and repair. Measure of organisation The personal safety equipment necessary must be provided by the user or installer. All safety instructions have to be checked regularly according to the maintenance plan. 3
Informal notice on safety measures. the manual has to be stored near the elevator in addition to the manual, the relevant official regulations for accident prevention and environmental protection have to be provided legal safety regulations of must be indicated to the user keep all safety and danger instructions close to the equipment in a legibile condition Usage according to the definition Exclusive usage of the traction sheave brake as safety equipment for traction sheave lifts with a maximum brake torque according to the calculated proof (see appendix to the examination report) in connection with a type certificated safety device to check the speed of the elevator. The Traction sheave brake has to be installed in the immediate vicinity of the traction sheave and is used to prevent overspeed during the upward movement caused by a technical disturbance or failure of parts in the drive system. It is not intended to be used as an operating brake. It is also not intended for any other usage.. the SAV Schmidt Aufzugsplanung und Vertrieb is not responsible/ is not liable for any damages which arise from mistakes of process, Correct usage according to the definition also includes compliance with the instructions in the manual and observing the commissioning regulations, the description of the equipment as well as inspection and maintenance. 4
Guarantee and liability the SAV General Terms and Conditions apply. Guarantee and liability for injuries to persons or damage to property are excluded if they are due to one or more of the following: Usage of the traction sheave brake that is not in accordance with the regulation Improper assembly, putting into operation, operation and maintenance of the traction sheave brake Usage of the traction sheave brake when the proper working safety- and protective equipment is defect. Non-observance of the instructions in the manual regarding transportation, storage, assembly, putting into operation, operation, maintenance of the traction sheave brake Changes to the traction sheave brake without authorization Improper surveillance of wearing parts Improperly executed repairs Problems caused by external influences or force of nature Design changes at the traction sheave brake The traction sheave brake is adjusted and sealed at the factory. The SAV guarantee is no longer valid if the seal has been removed or tampered with. Danger when using the traction sheave brakes The traction sheave brakes are built according to the state of the art and according to recognized safety rules. Use of the traction sheave brake is only allowed according to the determined conditions of use and in proper and safe working condition. Improper usage may endanger the lives of the user or third parties or, damage may occur to the traction sheave brake or other materials. Disturbances which may influence safety have to be corrected immediately. 5
2. Product specification Manufacturer SAV Schmidt Aufzugsplanung und Vertrieb Nexdorfer Straße 57 D - 03253 Schilda Name Traction sheave brake for lifts to avoid uncontrolled movement of the car in an upward direction 2.1 Specification of the traction sheave brake The traction sheave brake TSB 2000-1 / 2000-2s composes the following parts: 1. Brake disk 2. Brake caliper 3. Brake shoe 4. Hydraulic piston 5. Pressure limiting valve 6. Solenoid valve 7. Hydraulic pump 8. Pump support with clutch 9. Support with roller bearings and torque level 10. Reserve container (oil tank) for 500 ml hydraulic oil 11. Connecting terminal 12. Check lamp 13. Screw for oil check 14. Pressure switch 15. Different connecting conduits 16. Drive flange 17. Type label 2.1.1 Technical data Performance data See technical documentation of the hydraulic pump and the pressure limit valve. Connected loads: U = 230 V alternating current P = 0,02 kw 6
2.1.2 Capacity data Field of use Allowable braking torque during brake acting on the shaft of the traction sheave in an upward direction of the car. Maximum braking torque M bmax = µ x d 1 x p br x A 1 = µ x d 1 x p hydr max x A kolb in Nm TSB 2000-1 = 2170 Nm TSB 2000-2 = 4340 Nm Maximum triggering speed of the overspeed governer and maximum nominal speed Max. triggering speed Max. nominal speed 3,50 m/s 2,50 m/s The maximum triggering speed and the maximum nominal speed have to be calculated based on the above mentioned maximal triggering revolution and nominal revolution of the traction sheave and based on the diameter of the traction sheave and the suspension of the car: D T x π x n v n = ------------- 60 x i v n nominal speed [m/s] DT traction sheave diameter [m] i ratio cabin suspension n revolution [min -1 ] π 3,14 7
2.1.3 Operating conditions 2.1.3.1 The traction sheave brake has to be mounted in the immediate vicinity of the traction sheave. 2.1.3.2 To supervise the upward speed an overspeed governor acc. to DIN EN 81-1, 9.9 or an equivalent type examination certified safety device has to be installed. The actuation of the traction sheave brake has to be initiated by the electrical safety chain of the overspeed governor. 2.1.3.3 The effectiveness of the brake has to be checked electrically. Usage of the lift with activated or a failed brake has to be prevented. 2.1.3.4 The effectiveness of the brake has to be indicated by an optical signal. Only skilled staff may reset of the brake before restarting the lift m 2.2 Structure The support is base for the installation of the traction sheave brake, the carrying shaft is positioned on the support. The brake disk is placed on one side of the carrying shaft, on the opposite side are positioned the pump support and the hydraulic pump. This hydraulic pump is linked with the shaft by a clutch. The brake caliper with the brake shoes is mounted on one side of the torque lever, the other side of the torque lever is used to fix the brake to the frame of the machine. The solenoid valve creates a circuit between pump and oil tank. A duct links the pump with the hydraulic piston of the brake caliper. Between pump and solenoid valve, The pressure created in the duct is regulated by the pressure limit valve and supervised by the pressure switch. The complete hydraulic system is a closed circuit. The drive flange is installed direct to the brake disk and links the traction sheave shaft with the brake. The drive flange is variable according to the gearbox installed. 8
2.3 List of components 2.3.1 Traction sheave brake TSB 2000-1 title quantity 1. torque lever 1 unit 2. carrying shaft 1 unit 3. roller bearing 6208 RS 1 unit 4. pump support 1 unit 5. hydraulic pump 1 unit 6. combined valve solenoid and pressure limiting 1 unit 7. reserve container (oil tank) for 500 ml hydraulic oil 1 unit 8. brake disk 1 unit 9. brake caliper 1 unit 10. brake shoe with assembling kit 2 units 11. pump clutch 1 unit 12. pressure switch 1 unit 13. solenoid coil 220 V/ AC 1 unit 14. internal retaining ring 80 mm 1 unit 15. external retaining ring 40 mm 1 unit 16. feather key 5 x 20 1 unit 17. countersunk bolt M12 x 40 10/9 2 units 18. allen screw M6 x 20 4 units 19. allen screw M6 x 25 4 units 20. countersunk bolt M6 x 15 1 unit 21. nipples 1/2" to 10 2 units 22. nipples 3/8" to 10 2 units 23. nipples M10 to 8 1 unit 24. T-junction 8 mm 1 unit 25. T-junction 10 mm 1 unit 26. elbow 10 mm 1 unit 27. elbow 8 mm 1 unit 28. reduction from 8mm to 10 mm 1 unit 29. pipe bend 10 mm radius 70 mm 1 unit 30. pipe bend 8 mm radius 80 mm 1 unit 31. control switch for oil level 1 unit 32. terminal 7-pole 1 unit 33. warning light 1 unit 34. type label 1 unit 9
2.3.2 Traction sheave brake TSB 2000-2 title quantity 8. torque lever 1 unit 9. carrying shaft 1 unit 10. roller bearing 6208 RS 1 unit 11. pump support 1 unit 12. hydraulic pump 1 unit 13. combined valve solenoid and pressure limiting 1 unit 14. reserve container (oil tank) for 500 ml hydraulic oil 1 unit 35. brake disk 1 unit 36. brake caliper 1 unit 37. brake shoe with assembling kit 2 units 38. pump clutch 1 unit 39. pressure switch 1 unit 40. solenoid coil 220 V/ AC 1 unit 41. internal retaining ring 80 mm 1 unit 42. external retaining ring 40 mm 1 unit 43. feather key 5 x 20 1 unit 44. countersunk bolt M12 x 40 10/9 2 units 45. allen screw M6 x 20 4 units 46. allen screw M6 x 25 4 units 47. countersunk bolt M6 x 15 1 unit 48. nipples 1/2" to 10 2 units 49. nipples 3/8" to 10 2 units 50. nipples M10 to 8 1 unit 51. T-junction 8 mm 1 unit 52. T-junction 10 mm 1 unit 53. elbow 10 mm 1 unit 54. elbow 8 mm 1 unit 55. reduction from 8mm to 10 mm 1 unit 56. pipe bend 10 mm radius 70 mm 1 unit 57. pipe bend 8 mm radius 80 mm 1 unit 58. control switch for oil level 1 unit 59. terminal 7-pole 1 unit 60. warning light 1 unit 61. type label 1 unit 10
2.4 The type plate data The design, the type, the verification sign and the technical data are indicated on the type plate. The type plate is fixed to the side of the traction sheave brake. Type plate 1 2 4 3 5 6 Description 1 traction sheave brake 2 serial number 3 number of the type examination certificate 4 production number 5 date of production 6 preset operating pressure (MPa) 11
2.5 Functional description of the traction sheave brake Purpose The lift must be equipped with a safety device to avoid uncontrolled movement of the car in an upward direction. Function Normal use By connecting the brake to the traction sheave shaft, the rotation is transferred to the brake and the hydraulic pump is actuated. The solenoid valve (type: voltage free closed) is opened, therefore the oil circuit of the oil pump is without pressure. - The brake is not closed. The coil of the solenoid valve has to be activated by the motor contactor. - The pressure of the oil flow is controlled by the pressure switch (closed without pressure). The pressure switch has to be integrated in the safety circuit of the lift. Failure of the lift system If a rotation of the traction sheave shaft occurs when the system is free of current (car in upward movement) the hydraulic pump will create an oil flow which builds up pressure on the brake piston due to the solenoid valve being current free. The brake is closed. The pressure limit valve controls the pressure at the limiting piston. The pressure limit valve is adjusted and sealed at 150 bar max. (depending on technical parameters of the lift system). The pressure switch is adjusted and sealed at max. 10 bar. Thus the brake power created can be controlled. This creates a controlled upward movement of the car. - The break power is controlled linear to the rotation. - With the power on, the brake is inactive without any technical aid, but on standby. Failure of the brake system If a failure of the solenoid valve or of one of the hydraulic components should occur during normal use of the lift and pressure be created at the brake piston, this pressure will be registered by the pressure switch and indicated by the warning light at the traction sheave brake. The lift will be rendered inoperative by the safety circuit. 12
2.6 Maintenance and inspection Visual inspection Notice: Only trained and skilled staff are authorised to operate and maintain the system. Operation and maintenance may only be conducted by trained and skilled people. All instructions and regulations for lifts as well as the The brake shoes have to be checked for wear and when the wear mark has been reached they have to be changed. The brake disk has also to be checked for wear. (The system of the brake caliper adjusts the distance between brake disk and brake shoe automatically after each use. The wear of the brake shoes has to be checked. The wear is indicated by grooves in the middle of the shoe and can be checked from outside. The depth of the groove is min. 2 mm. When this dimension has been reached the break shoes have to be changed. All bolted connections have to be checked for firm contact. If necessary, they have to be re-tightened. The hydraulic system has to be checked to see if it is oil tight. If the fitting is not oil tight the system has to be re-tightened. The oil level in the tank has to be checked and refilled, if necessary. Possible maintenance operation Instructions for maintenance are provided in the component documentation Inspection of brake function The function has to be checked as following: The car has to be in one of the lower stops. Then the operational brake has to be released. The pressure limit valve is adjusted to 150 bar max. and sealed. The pressure switch is adjusted to 10 bar max. and sealed. During overspeed of the car in an upward direction the switch of the overspeed governor opens the safety circuit. The solenoid coil of the solenoid valve becomes potential free. The solenoid valve closes. Pressure is created in the brake circuit. The traction sheave brake reduces the speed of the car to a level below the nominal speed -- approx. 0,4 0,6 m/s. (according to DIN EN81-1: The safety equipment for the upward travelling car against overspeed has to verify uncontrolled movement of the car by a minimum of 115 % of the nominal speed and maximum 1,25 x v + 0,25 / v in m/s and to stop the car or to reduce the speed to the speed level according to the design of the buffer of the counter weight.) After the functionality test, the normal condition has to be re-installed. 13
3. Transportation and storage Packing and shipping The traction sheave brake is packed as a complete unit in a cardboard box. Unpacking Dispose the packing material according to environmental regulations or re-use it. Specific transportation aids and fixings remain with the customer. Intermediate storage If the traction sheave brake is not assembled immediately after delivery it has to be stored carefully in a protected place. It has to be covered carefully to protect from humidity. The traction sheave brake must not be stored outdoors, as the uncovered parts do not have long term protection. Environmental conditions Note: The environment at the final place of operation (humidity, temperature) has to be normal room conditions. 4. Operating conditions for the traction sheave brake Traction sheave brakes are only permitted in the approved application field. The only application of the traction sheave brake is the use as a safety device in traction sheave lifts according to the data on the type plate. The traction sheave brake has to be assembled in the immediate vicinity of the traction sheave in order to avoid overspeed of the car travelling upwards due to technical problems or break of the drive mechanism in connection with a type tested safety device to monitor the speed of the lift. The use as an operating brake is not in accordance with the regulation. A different or supplementary use is also not in accordance with the regulations. Traction sheave brakes have to be linked positively with the traction sheave or traction sheave shaft. The verification and stipulated regular inspection of the traction sheave brake has to be conducted by the approved authority. 14
5. Installation of the traction sheave brake The torque lever is joined to the machine frame by a bolted connection using a suitable mounting bracket. The traction sheave shaft and the brake are connected by a bolted connection using an adapter flange. This flange is delivered according to the drive system used. The installation regulations, specific to the drive system can be found in appendix A 5. 6. Electrical connection of the traction sheave brake 15
7. Disposal of hydraulic oil The reserve container for hydraulic oil of the traction sheave brake contains a max. 500 ml hydraulic oil. Sort, Type Hydraulic oil HLP 46 After changing the hydraulic oil, the waste oil has to be disposed of in accordance with the regulations. 16
8. Illustration of the traction sheave brake 8.1 Traction sheave brake TSB2000-1: 17
8.2 Traction sheave brake TSB2000-2: 18
9. EU type examination certification: 19
9.1 Appendix to EU type examination certification 20
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