Operating Instruction ZETATOP SM160

ZETATOPSM 160

Compact gearless permanent magnet synchronousmotor

Operating Instructions

A-TBA09_01-GB 1024 Part.-No. 01006161-GB

english

Content

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 Structure of the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.4 Requirements placed on the personnel / due diligence . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 Operational area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 General installation advises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 Patent situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.3 Mounting the drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.4 Fastening the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.5 Changing the traction sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.6 Fastening bearing anges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.7 Fastening rope protection clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.2 EMC directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.1 Safety instructions commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.2 Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.3 Encoder connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.4 Encoder change ECN1313/ERN1387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.5 Brake connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.6 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.7 First-time start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.8 Drive approval test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.9 Pull out of the trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.10 Emergency evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7 Faults and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8 Service & maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118.1 General notes on maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118.2 Inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128.3 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Operating Instructions ZETATOP – model series SM 160

A-TBA09_01-GB 1024 Part.-No. 01006161-GB1/37

9 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129.2 Dimension sheet A-M-6382 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149.3 Operating instructions brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159.4 Declaration of conformity of the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219.5 Type-examination certicate of the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239.6 Calculation of tripping speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279.7 Shaft calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Operating Instructions ZETATOP – model series SM 160

A-TBA09_01-GB 1024 Part.-No. 01006161-GB2/37

1 General information

1.1 ApplicationThe ZETATOP is designed as a gearless drive for friction driven rope elevators.No other drive applications are permitted without the prior permission by the Ziehl-Abeggcompany!The ZETATOP, a permanent magnet inner-rotor synchronous motor, offers all benets which a modernelevator motor asks for: simple installation, best controlability, lowest noise level, highest travelcomfort and compact design.Due to the very compact design the ZETATOP is ideal for machine roomless elevators.Of course the certied brakes provide maximum security and are approved as a safety device forascending car overspeed protection.Protected through registered design and patents application pending one can for the very rst timebuild a new dimension of machine roomless elevators.

1.2 Structure of the operating instructionsThis manual is part of the drive and must always be kept in its vicinity for reference at all times. Allpersons involved in installation, operation, maintenance or repair of the drive must have read andunderstood this manual. Ziehl-Abegg takes no resposibility for damage or disruption caused bydisregard of this manual.

1.3 Target groupThe operating instructions address persons entrusted with planning, installation, commissioning andmaintenance and servicing and who have the corresponding qualications and skills for their job.

1.4 Exclusion of liabilityZiehl-Abegg AG is not liable for damage due to misuse, improper use or as a consequence ofunauthorized repairs or modications.

1.5 CopyrightThe copyright to this manual is held by Ziehl-Abegg AG, Künzelsau. This manual must not be whollyor partly reproduced for competitive purposes, used in any unauthorised way or made available tothird parties without our agreement.

2 Safety information

2.1 GeneralZiehl-Abegg electric motors are not ready-to-use products and may only be operated after havingbeen installed into machines or plants and established their safety, depending on the application, byprotective grating, barriers, constructive devices or other adequate measures (see also DIN EN 294)!The assembly, repair and electric installation is only allowed to be carried out by qualied personnel,following the relevant regulations.Planners, manufacturers and operators of system parts or entire systems are responsible for thecorrect and safe installation and a reliable operation.

2.2 PictographsSafety instructions are highlighted with warning triangles and are depicted according to the degree ofhazard as follows.

Warning!Hazardous area. Death or severe injury or signicant property damage can occur if thecorresponding precautions are not taken!

Attention!Slight bodily harm is possible if the corresponding precautions are not taken!

Operating Instructions ZETATOP – model series SM 160 General information

A-TBA09_01-GB 1024 Part.-No. 01006161-GB3/37

CAUTION!Caution!Material damage is possible if the corresponding precautions are not taken!

Voltage!Warning about hazardous voltage

InformationImportant information and advice for user.

2.3 General safety instructions

Voltage!When the motor shaft is turning, voltage will be induced and applied to the motor terminal!

Warning!The motor has casted eyelets or threads to suit eyebolts. The eyelets are for the transport of the motorincluding sheave and brake only. Do not lift higher loads with these eyelets for example a socket,ropes, etc. Use adequate hoists. Danger of life!

Attention!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 dened on the type plate!• Use the motor only in the authorised fashion and only for the tasks specied in the 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 shortcircuitthe motor windings, when the motor current is off. This induces a speed dependingbraking torque similar to the friction of a worm gearbox. The short circuit has to be madeby main contacts of the contactors, because the current is approx. rated current. In anycase do not short-circuit the windings, while the motor wires still lead current.

• Safety components, e. g. the brake release monitoring, may neither be disassembled nor by-passed or disabled!

• Temperature sensor installed into the winding serve as motor protection and must be con-nected!

2.4 Requirements placed on the personnel / due diligence• The assembly, repair and electric installation is only allowed to be carried out by qualied

personnel, following the relevant regulations.• Planners, manufacturers and operators of system parts or entire systems are responsible for the

correct and safe installation and a reliable operation.

Operating Instructions ZETATOP – model series SM 160 Safety information

A-TBA09_01-GB 1024 Part.-No. 01006161-GB4/37

3 Product overview

3.1 Operational areaThe ZETATOP, a permanent magnet inner-rotor synchronous motor, offers all benets which a modernelevator motor asks for:

• simple installation• best controlability• lowest noise level• highest travel comfort• compact design

Due to the very compact design the ZETATOP is ideal for machine roomless elevators. Of course thecertied brakes provide maximum security and are approved as a safety device for ascending caroverspeed protection. Protected through registered design and patents application pending one canfor the very rst time build a new dimension of machine roomless elevators.

3.2 Transport• Ziehl-Abegg 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 only 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 shockloads.• 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 nal installation.• Avoid extreme heat or cold (storage temperature -20 °C until +60 °C).• Avoid high humidity that may cause condensation.• Avoid aggressive conditions (e. g. 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. Takecare if the bearing makes untypical noises)

4 Mounting

4.1 General installation advisesMounting, electrical connection and commissioning are only to be performed by trained servicepersonnel. Adhere to all machinery-related requirements and specications supplied by the systemmanufacturer or machine builder.

CAUTION!Caution!When working at or in the lift the motor and especially the brakes have to be covered and protectedagainst dust and chips.

Any violation will result in a loss of guarantee on our motors and accessories!The following general rules apply:

The rope pull must be vertical to the motor foot.The angle of wrap at the driving sheave must be at least 150°.A lateral rope pull is not admissible!

Operating Instructions ZETATOP – model series SM 160 Product overview

A-TBA09_01-GB 1024 Part.-No. 01006161-GB5/37

• If the sheave should offer more grooves than the actual number of ropes, the ropes must beapplied on the sheave either centred or towards the motor side.

• Do not install distorted.• Do not apply any force (levering, bending). Above all, do not expose the rotor to any heavy

mechanical shocks.• Carry out the electrical connection in accordance with the enclosed circuit diagram.• Before starting installation, the drive must be checked for transport damage, especially the

cables have to be checked.• No welding must be done on the drive. The drive must not be used as an earthing point for

welding. Magnets and bearings could be destroyed.• The cooling-airow around the motor must not be obstructed.• Keep at least 70 mm space between the brake and the wall (axial direction) to make access to

the encoder possible.

4.2 Patent situationPlease pay attention to the patent situation concerning the use of elevator machines in theshaft. When using the ZETATOP according to our installation examples there are no problemswith patents. In doubt please contact Ziehl-Abegg.

• When installing the motor in the elevator shaft,the motor can be placed in the shaft head, withthe motor axle parallel to the nearest wall.

• The motor must not be hanged over the cabin.• The motor should be fastened at the framework, Halfen cast-in channals or girders. The drive

must not be placed of fastened onto all four guide rails.• If the girder that supports the motor is fastened at one wall, the motor has to be installed on top

of the girder. A hanging motor is not permissible!

4.3 Mounting the drive unit• On the bottom side of the socket are 4 threads.• The motor has to be xed with 4 screws M16 - 8.8 at the mounting plate. Tightening

torque M16 - 8.8: 195 Nm• Screw-in depth at least 1.5 times of screw size. (min. 24 mm, max. 32 mm)• Fasten the screws crosswise in at least two stept to the required tightening torque.• The permissible unevenness for the mounting surface is 0,3 mm.• The mounting surface has to be rigid and robust enough to withstand the forces.• For the installation, rubber buffer should be used to absorb the vibration.

4.4 Fastening the brakeThe drive will be delivered with the mounted brake.Brake xation in accordance with the brake operating instructions.When replacing the brakes, rst screw in the central locking screw/air screw.

An exchange of the brake can be carried out only with special centering tool. Please, they turnin case of a braking exchange to the hotline of the Ziehl-Abegg AG.

Operating Instructions ZETATOP – model series SM 160 Mounting

A-TBA09_01-GB 1024 Part.-No. 01006161-GB6/37

4.5 Changing the traction sheave

Warning!At wrong assembling the traction sheave can remove itself.

Disassembling:• Interrupt the electrical circuit of the installation and secure it against switching-on, secure the

elevator car and the counterweight.• Release the traction sheave and put down the ropes.• Secure sheave to prevent that it jumps off the shaft!• Remove the screws and the washers of the traction sheave 3 x (M10 x 40) and insert the screws

at external hole diameter of the plate• Put a distance plate with a thickness of 5 - 8 mm between the shaft end and plate.• Remove the traction sheave from the cone of the motor shaft by uniformly tightening the screws.

Mounting:• Traction sheave and input shaft must be cleaned.• Insert the key into the motor shaft.• Add the traction sheave to the conical motor shaft (please observe the position of the key).• Put the plate at the traction sheave and fasten it with the three screws and washers with a torque

wrench at the inner hole circle of the plate. Fasten screws in three torque steps (20, 40 &68 Nm), one after another, by turns in circle until no more rotary motion of the screws isrecognizeable. Tightening torque M10 - 10.9: 68 Nm

• Use glue for screws Loctite 243 or a similar product.• The washers DIN 6796 must always be used.

4.6 Fastening bearing anges

The assembling and disassembling of the magnet rotor and the bearing ange must only be carriedout by qualied personnel and with special devices or in the factory.Tightening torque M12 - 8.8: 79 Nm

4.7 Fastening rope protection clamp• The drive unit is equipped with two rope-protection-clamps.• Each of the two protection clamps will be fastened at the bearing ange with two screws M8 x 16

and washers. Tightening torque M8 - 8.8: 23 Nm• Through the longholes in the clamp the required rope direction can be adjusted.• The rope protection clamps must be fastened in a distance of 2 - 3 mm to the ropes.• On installations with rope pull upwards a protection must be installed to prevent foreign

bodies to enter between rope and traction sheave.

5 Installation

5.1 Safety precautionsMounting, electrical connection and commissioning are only to be performed by trained servicepersonnel. Adhere to all machinery-related requirements and specications supplied by the systemmanufacturer or machine builder.

5.2 EMC directiveThe adherence to the EMC directive 2004/108/EC only pertains to this product if controllers testedand recommended by Ziehl-Abegg are used, which have been installed in accordance with thecorresponding controller description and in line with the EMC. If the product is integrated unprofes-sionally into a system or complemented by and operated with components (e. g. regulators andcontrollers) which have not been recommended, the operator of the complete system alone shall beresponsible for adhering to the EMC directive 2004/108/EC.

Operating Instructions ZETATOP – model series SM 160 Installation

A-TBA09_01-GB 1024 Part.-No. 01006161-GB7/37

6 Start-up

6.1 Safety instructions commissioningThe drive must not be connected to the mains supply without a controller!A shielded motor cable has been connected. The shielding must be attached to the controller.The maximummotor cable length is 25 m.

6.2 Motor connection• Connect to the motor terminal box depending on the motor cable as follows:

PE U V Wgreen/yellow black brown blue *green/yellow black brown grey **green/yellow 1 2 3

* DIN VDE 0243: 1990-01** DIN VDE 0293-308: 2003-01

• If no other agreement was met, the encoder offset is is set to 0. To do that, connect the directcurrent 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 tothe 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 resistorcontroller! The admissible tet voltage of PTC resistors is max. 2,5 V DC.

• The controller has to ensure that the motor contactors are only switched when current is turnedoff. With switching the contactors under load, especially with speed 0, the contactors can bedemaged.

Wiring diagram motor

Operating Instructions ZETATOP – model series SM 160 Start-up

A-TBA09_01-GB 1024 Part.-No. 01006161-GB8/37

6.3 Encoder connection

CAUTION!Caution!Never touch the connetion pins at the encoder or encoder cable. The electronic may be destroyed bystatic discharge.

• The encoder has to be connected to the frequency inverter.• The encoder contains components that may be damaged by electrostatic discharge. The body

of the person touching them must rst be discharged, for example, by touching a conductive,earthed object, (e.g. bright metal parts of a control panel), immediately beforehand.

• A screened cable must be used for the encoder connection. It is recommended to use a Ziehl-Abegg encoder-cable which garanties a sufcient screen connection.

• The encoder must not be detached mechanically in order not to lose the factory settings. If theencoder has been detached, the new encoder-offset has to be determined with the frequency-inverter. Please see the inverter manual for this procedure.

Contacts SV120 round connector at encoder ECN113 and ECN1313 (Ziehl_Abegg standard)

Pin SignalA DATAB DATA inversC Up SensorD UpE 0 V unF Track B (sine)G Clock inversH ClockJ 0 V sensorK Track A (cosine)L Track A invers (cosine invers)M Track B invers (sine invers)

6.4 Encoder change ECN1313/ERN1387

Further information:Please also see mounting instructions of the Encoder.

Disassembling:• Loosen the clamping bolt of the encoder (Hexagon key SW2) at the outer clamping-ring.• Turn out small cap on encoder back side (slot or hexagon). Remove cap and cable cover.• Open the central bolt M5 x 50 1 - 2 turns (360° - 720°).• Screw the draw off screw M10 (not included) into the thread on the encoder back side and press

the encoder off the ange.• Turn out draw off screw M10 rst and than central bolt M5. Remove encoder.

Mounting:

CAUTION!Caution!Never touch the connetion pins at the encoder or encoder cable. The electronic may be destroyed bystatic discharge.

• Attach encoder.• Fasten central boltM5 x 50. Tightening torque M5 - 8.8: 5,5 Nm• Put on cable cover and fasten cap on the back side of the encoder.• Tighten the clamping bolt of the encoder (Hexagon key SW2) at the outer clamping ring.

Max. tightening torque SW2: 1,2 Nm• Determine the encoder offset again in accordance with the frequency inverter description.• If a different encoder system is installed, please contact Ziehl-Abegg.


A-TBA09_01-GB 1024 Part.-No. 01006161-GB9/37

6.5 Brake connection• Please also refer to the operating instructions of the brake.• The brake is designed for static applications only. Any dynamic braking must be re-

stricted to emergency braking and test braking. At static use, there is no brake wear.Therefore the brake is almost maintenance free.

• Release of the brakes: Electrical release of the brakes with a supply by accumulators/-UPS. A mechanical release of the brakes is not possible.

• Dimension the supply and the wiring adequate for the 24 V brake. Brake current about 3,5 A percircuit!

• The terminal box for the brake may be removed from the motor and mounted on site for a betterattainability.

• The brake is only allowed to be supplied with power when fastened to the motor and after havingconntected the protective conductor of the motor at the control and the motor side.

• The brakes have to be protected against over voltage from switching by varistors. The brakesare supplied with varistors ex factory.

• The brake release monitoring has to be evaluated, otherwise the type certicate is notfullled! The change of state of both brake circuits has to be monitored separated.

• The brake release monitoring is realized by micro-switches. Please assure with adequate wiring,that the contact-current is at least 10 mA to keep the contacts clean.

• After a long storage period, the brake disks may stick to the magnet plate. Then the motor willnot move even if the brake is released. In this case, please demount the brake from the motorand separate the brake disk and the magnet plate with care (e. g. by using a rubber mallet)

Activating the brakesIs is recommended to switch the brake through two contactors, one is switching the AC-side and theother is switching the DC-side. In normal operation the contactor on the AC-side has to be switchedby the brake relay of the inverter.This will remarkably reduce the mechanical noise. Additionally thecontactor on the DC-side should be switched by the motor contactors for a quick turn off and fastclosing of the brake at an emergency stop.

Wiring diagram brake


A-TBA09_01-GB 1024 Part.-No. 01006161-GB10/37

6.6 Operating conditions• The drive must be installed in a building or a closed hoistway.• Be aware of the protection class specied on the type 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 bedewed.• Reduced motor output when installed 1000 m above sea level.• Please contact Ziehl-Abegg in case of orders deviating from the corresponding application

conditions.

6.7 First-time start-upBefore rst-time start-up, check the following:

• Installation and electrical connection have been properly completed.• Safety devices are installed.• All leftover installation materials and other foreign materials have been removed.• Protective conductor has been connected.• Motor protection correctly connected and operative.• Cable entries closed.• Installation, mounting position and accessories are o.k.• Connected load corresponds to the data on the name plate.

6.8 Drive approval testHalf load testDue to the short circuit of the motor while the VVVF is inactive, the motor will create a speeddepending braking torque. This braking torque will be produced already at a very low speed.If the car with half load does not move when the brakes are opened, the short circuit wiring should bedeactivated. After that the test should be repeated.After testing the short circuit wiring must be activated again.

Half load test (alternative):If deactivating of the short circuit wiring is not possible or not desired, the testing of 50 % balance canbe made as follows:With half load the motor current has to be measured in up and down direction. Mostly this is possibleat the VVVF. (Please see operating instructions of your VVVF). The measured currents should notdivert by more than 10 %.

Testing the brake according EN 81-1When testing the brakes, the short circuit wiring has to be deactivated to only test the effect of thebrake.It is recommended to perform the tests when the car position is about in the middle of the shaft.

OverloadThe test shall be carried out whilst the car is descending at rated speed with 125 % of the rated loadand interrupting the supply to the motor and the brake.

Failure of one brake circuit:The test shall be carried out whilst the car is descending at rated speed with rated load.To simulate the failure of one brake circuit, the single brake circuits have to be released independentfrom the safety circuit. This state must not be permanently, it has to be done by a key button orequivalent. While using this function the safety circuit should always be opened.While performing this test the elevator has to be observed. If there should be no visible deceleration,the open brake circuit has to be closed immediately! The elevator has to be put out of service and thebrake to be checked!As an example, please also see our wiring diagram SV024. The information on processes andsections of the circuitry must be regarded as such without further implications. Their adaptation toother applications must be investigated. Ziehl-Abegg does not guarantee their suitability in suchcircumstances.If the circuitry is made corresponding SV024: Press one of the key buttons at nominal speed until theelevator stops. Repeat the test by pressing the other key button to test the second brake circuit.


A-TBA09_01-GB 1024 Part.-No. 01006161-GB11/37

Testing the microswitchesThe microswitches have to be single tested. According to their use as a make or brake contact onemicroswitchcontact at a time has to be opened or short circuit.On a wrong or lacking signal, a travel must not be started.

6.9 Pull out of the trapIf the car loaded with the nominal load enters the trap due to a malfunction or during the TÜVcertication, it is possible that the trap device is seated rather rmly. In such a case, it is entirelypossible that the drive torque is no longer sufcient to pull the car out of the trap.With gearless drives in machine rooms, a handwheel does not make any sense because there is nogear reduction. That is because due to the low moment arm of force, only slight force can be applied.A handwheel could even present a hazard, as even with only a slight imbalance in the installation, it isno longer possible to stop the elevator with the handwheel.With gearless drives in the shaft, the motor is usually not accessible. A handwheel is unnecessary insuch a layout.In both cases with gearless drives, applicable is: One must fall back on a chain hoist or similar if thedrive torque is insufcient or if there is a lack of drive on the rope. It makes sense to keep a suitablechain hoist ready during the TÜV inspection.

NoteNote that an overload in the car leads to an increase in the motor torque. 25 % overload results in150 % of the required motor torque! As regulated drives are normally designed for a maximum torqueof ca. 170 - 200 %, only slight reserves are available during such special cases.For that reason it is recommended, just as described in EN 81-1 Appendix D.2 j), to perform a TÜVtrap inspection in the door area so that the car can be unloaded there to relieve the drive.

6.10 Emergency evacuationEmergency escape should be possible by means of an electrical emergency control. In case of apower failure or in case the electrical emergency control does not work, the emergency escape mustbe possible by means of opening the brakes. The lift will move in direction of the higher load to thenext halt.If only the brakes are released the motorwindings have to be short circuit while evacuating to preventuncontrolled acceleration of the lift.The short circuit generates a speed dependent braking torque which is in most cases sufcient to limitthe elevator speed to a secure proportion.With short circuited windings, the maximum possible evacuation speed will be 30 rpm. Please checkin case, if this speed is suitable for the evacuation.As an alternative and in case of a power failure, the power supply of control and frequency inverter ispossible by means of the evacuation unit EVAC by Ziehl-Abegg.If a Ziehl-Abegg frequency inverter is used, an automatic evacuation is possible with supply by anUPS. With reduced power supply, an evacuation in direction of the higher load can be implemented.


A-TBA09_01-GB 1024 Part.-No. 01006161-GB12/37

7 Faults and remedy

Fault Causes RemedyRunning noise Bearing defective Contact customer service

VVVF-settings wrong Check VVVF settingsEncoder defective Change encoder

Excessive tempera-ture / Temperatureprotection trips

Motor surface covered Remove cover from motor or mount withmore distance to motor.

Ambient temperature higher than 40 °C Enhace shaft ventilationVVVF-settings wrong Check VVVF settings

Motor will not start Motor phases connected incorret Check motor connectionVVVF defective Check VVVFBrake does not release See brake faults

Brake switchingnoises

Brake is switched on the DC-side Change brake wiring to AC-switching at nor-mal operation. Add overvoltage protection

Airgap of brake too big Change the brake disks when worn outBrake does not re-lease

Power supply too low. The voltage at thebrake is to low.

Check power supply, change wiring (andtransformer) size

Brake control wrong / defective Check brake wiringBrake coil defective Change brake (Special tools necessary!

Contact Ziehl-Abegg)Brake worn out Change brake disks (Special tools neces-

sary! Contact Ziehl-Abegg)Brake release moni-toring does notswitch

Micro switches defective Change microswitches or brakeContacts dirty Switch micro switches with a higher contact

current, at least 10 mA or change micro-switches

Operating Instructions ZETATOP – model series SM 160 Faults and remedy

A-TBA09_01-GB 1024 Part.-No. 01006161-GB13/37

8 Service & maintenance

8.1 General notes on maintenance• Observe the safety-at-work regulations!• The machine is allowed to be opened by qualied personnel only who have especially been

trained with regard to this drive.• Never use a high-pressure cleaner (e. g. a steam jet cleaner) for cleaning the motor!• Take note of abnormal operating noise!• The bearings have a lifetime lubrication. There is no possibility to relubricate. Maintenance is not

necessary for the bearings.

To check the brake wear or to check the driving sheave, the following instructions have to be refered:It is not possible to adjust the brakes. The brakes cannot be readjusted. Replace the brake disc whenthe maximum air gap has been reached.

The brake wear has to be check 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!

8.2 Inspection intervals

During commissioning orafter the rst 3 months

every year

Distance of the rope protection clamp X XChecking of the brake-airgap X XVisual inspection of the mounting screws on the hous-ing, brakes and traction sheave. The locking compoundmust be free of damage.

X X

Check traction sheave if worn out X

Note: All mounting screws on the housing, brakes and traction sheave are marked with sealing paint.That means a loosened screw is optically visible. If a screw does get turned, it must be tightenedusing the prescribed tightening torque, the old sealing paint needs to be removed and marking has tobe made again.

8.3 Spare partsSpare parts and accessories not supplied by Ziehl-Abegg have not been tested or approved by us.These parts may be lower in funktion or quality and therefore can reduce functionality or safety of theinstallation. Ziehl-Abegg will assume no liability or guarantee for damages caused by spare parts thatare not approved.

Available spare parts:• Traction sheave• Brake (complete)• Microswitch for Brake• Brake disks & O-rings• Encoder• Rope protection clamp

Operating Instructions ZETATOP – model series SM 160 Service & maintenance

A-TBA09_01-GB 1024 Part.-No. 01006161-GB14/37

9 Enclosure

9.1 Technical data

Motor type 160.20 160.30 160.30 160.40 160.40Suspension 2:1 2:1 2:1 2:1 2:1Max. payload* 375 480 375 675 480 kgMax. cabin weight 700 900 950 1100 1200 kgRated torque 105 140 140 185 185 NmMax. torque 180 240 240 320 320 NmMax. permissible radial load 1300 1300 1300 1650 1650 kgRated brake torque 2 x 165 2 x 210 2 x 210 2 x 210 2 x 210 NmMax. Speed 1,6 1,6 1,6 1,6 1,6 m/sTotal weight 130 145 150 157 164 kg

Traction sheave- Diameter 160 160 210 160 210 mm- Width 77 101 76 125 76 mm- Rope diameter 4 4 5 - 7 4 5 - 7 mm- Number of grooves 7 10 6 12 6

Table shows typical data, other values possible.Other rope diameters and groove distances are possible.* Dependent on travel, compensation ropes may be necessary.

Protection class

Component Protection classMotor IP 42Encoder IP 40Brake (electrical) IP 54Brake (mechanical) IP 10Complete machine IP 21

Operating Instructions ZETATOP – model series SM 160 Enclosure

A-TBA09_01-GB 1024 Part.-No. 01006161-GB15/37

9.2 Dimension sheet A-M-6382


A-TBA09_01-GB 1024 Part.-No. 01006161-GB16/37

9.3 Operating instructions brake


A-TBA09_01-GB 1024 Part.-No. 01006161-GB17/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB18/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB19/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB20/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB21/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB22/37

9.4 Declaration of conformity of the brake


A-TBA09_01-GB 1024 Part.-No. 01006161-GB23/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB24/37

9.5 Type-examination certicate of the brake


A-TBA09_01-GB 1024 Part.-No. 01006161-GB25/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB26/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB27/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB28/37

9.6 Calculation of tripping speed

DTS = diameter of the traction sheave (table contains typical sheave diameters, other diameters can berecalculated linear)

DBR = effective brake disk diameterVbsn = maximum rated speed (slip velocity) on the effective brake disk diameter (corresponding to 1.2.2)Vbsmax = maximum trip speed (slip velocity) on the effective brake disk diameter (corresponding to 1.2.1)Vn = maximum rated speed of the elevatorVmax = maximum trip speed of the elevator

Type DTS DBR Vbsn Vbsmax Vn(1:1)

Vmax(1:1)

Vn(2:1)

Vmax(2:1)

[mm] [mm] [m/s] [m/s] [m/s] [m/s] [m/s] [m/s]SM160 160 207 5,65 6,5 4,36 5,02 2,18 2,51SM160 210 207 5,65 6,5 5,73 6,59 2,86 3,29SM200.15B 210 235 3,78 4,35 3,37 3,88 1,68 1,94SM200.15B 240 235 3,78 4,35 3,86 4,44 1,93 2,22SM200.15B 320 235 3,78 4,35 5,14 5,92 2,57 2,96SM700 320 650 8,7 10 4,28 4,92 2,14 2,46SM700 400 650 8,7 10 5,35 6,15 2,68 3,08SM860 480 800 8,7 10 5,22 6,00 2,61 3,00SM860 520 800 8,7 10 5,66 6,50 2,83 3,25SM860 600 800 8,7 10 6,53 7,50 3,26 3,75SM860 680 800 8,7 10 7,4 8,50 3,70 4,25


A-TBA09_01-GB 1024 Part.-No. 01006161-GB29/37

9.7 Shaft calculation


A-TBA09_01-GB 1024 Part.-No. 01006161-GB30/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB31/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB32/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB33/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB34/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB35/37


A-TBA09_01-GB 1024 Part.-No. 01006161-GB36/37

©by

Zieh

l-Abe

gg-1

00-0

1006

161-GB-1

024-C

P-S

ubject

totech

nica

lcha

nges

HOTLINE

%Tel. +49 (0) 7940 16-308Fax +49 (0) 7940 16-249email [email protected]

Ziehl-Abegg AGHeinz-Ziehl-Straße · D-74653 Künzelsau · GermanyTel. +49 (0) 7940 16-308 · Fax +49 (0) 7940 [email protected] · www.ziehl-abegg.com

Operating Instruction ZETATOP SM160

Documents

Transcript of Operating Instruction ZETATOP SM160