Tkaw-Manual-Ba Atr Dab450 2017 03 en

Operating Manual
Drive DAB450
ThyssenKrupp Aufzugswerke
Legal information
All rights reserved

© Copyright by ThyssenKrupp Aufzugswerke GmbH
Note on industrial property rights ISO 16016
Printed in Germany
This document – including excerpts – may only be reprinted or otherwise copied with the
express approval in writing of ThyssenKrupp Aufzugswerke GmbH.
Any duplication, dissemination or storage on data media unauthorised by ThyssenKrupp
Aufzugswerke GmbH is an infringement of copyright and shall give rise to prosecution.
Subject to change without notice
We expressly reserve the right to make changes of a technical nature for the purpose of
improving our products or enhancing the safety standard - even without a separate
announcement.
Choice of colours
The choice of colours used in our documents for the components is solely for illustration
purposes in the documentation.
Contact your ThyssenKrupp Aufzugswerke sales partner for details of colours for your
specific products.
Form of address
To improve readability, a gender-specific form of address has not been used. Gender-
specific pronouns therefore refer to both men and women.
Issued by
ThyssenKrupp Aufzugswerke GmbH
Bernhäuser Strasse 45
73765 Neuhausen a. d. F.
Germany
Tel.: +49 7158/12-0
E-mail: [email protected]
Internet: www.thyssenkrupp-elevator-eli.de
OPERATING MANUAL DAB450
Table of contents
DAB450 drive PAGE

1. Safety
1.1 Symbols 6
1.2 Safety instructions 7
2. Product description
2.1 Description 10
2.2 Functional description 11
2.3 Protection devices earthquake 12
3. Technology
3.1 Technical data 15
3.2 Dimensions of machine 16
3.3 Dimensions of machine base frame (optional) 17
3.4 Encoder 20
4. Transport and storage 23

5. Mounting the machine
5.1 Machine setup 26
5.2 Aligning the machine base frame 26
5.3 Connecting the machine 27
5.4 Connecting the motor 28
5.5 Connecting the brake magnet 30
5.6 Connecting the brake test switches 31
5.7 Connecting the manual operation limit switch 32
5.8 Connecting the encoder 33
6. Commissioning 35
7. Maintenance / service
7.1 Maintenance 36
7.2 Lubrication 37
7.3 Testing the brakes 39
7.4 Testing the release mechanism of the brakes 40
7.5 Replacing brake shoes 41
7.6 Setting braking deceleration 43
7.7 Setting the brake test switch 45
7.8 Replacing and setting the encoder 47
7.9 Replacing the rope pulley 49
7.10 Checking for escaping grease / oil 50
7.11 Emergency measures 51
7.12 Wear parts 56
8. Special Versions
8.1 Climate-protected version 57
8.2 Accessory parts 57
OPERATING MANUAL DAB450
9. Appendix
9.1 Tightening torques 61
Type test certificate for braking device
Declaration of conformity for braking device
Certification complying with US standard
Type test certificate in accordance with EN 81-1 –A3
Operating manual for SIKO magnet sensor

OPERATING MANUAL DAB450 SAFETY
1. Safety
1.1 Symbols
The following pictograms and designations are used in this operating manual:
Danger
This symbol indicates extreme danger to life and the
health of persons. Nonobservance can lead to death
or severe injury!
Danger
This symbol indicates an immediate danger to the life
and health of persons due to electrical current.
Hazard warnings must always be observed!
Warning
This symbol warns against imminent danger.
Nonobservance can lead to physical injury or
extensive damage to property.
Warnings must always be observed!
Note
This symbol indicates important information and
operating instructions. Nonobservance can lead to
damage, danger or malfunctions.
Check
Test steps are specified with this symbol.
The test instructions marked in this way must be
followed without fail. They contribute to preventing
personal injury or damage to property.
ThyssenKrupp Aufzugswerke GmbH 6 Version 03/2017

1.2 Safety instructions
Notes regarding the operating manual

A requirement for safe handling and non-disruptive operation of this
assembly is knowledge of the fundamental safety regulations.
This operating manual contains the most important information that is
required to operate the assembly safely.
The operating manual, in particular the safety instructions, is to be complied
with by all persons that work on this assembly.
Furthermore, the rules and regulations covering accident prevention that
apply to the usage site are to be complied with.
For countries in which CSA regulations apply, the regulations listed below are
to be taken into account:
The applicable regulations of the latest version of the National Electrical
Code, Article 620, the latest version of the ASME A17.1, Safety Code for
Elevators, and the applicable regional regulations must be observed and/or
complied with when carrying out the measures and following the instructions
described in this manual.
Obligations of the operator and/or of the installation firm

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

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

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

Organisational measures
The required personal protective equipment is to be provided by the operator

or installation firm, as the case may be. All existing safety devices are to be
checked regularly in accordance with the maintenance plan.
Informal notes on the safety measures
• The operating manual is to be kept permanently at the usage site of the
installation.
• Complementary to the operating manual, the generally applicable and
local regulations for accident prevention and environmental protection are
to be provided and complied with.
• Legally prescribed safety instructions are to be provided for the users at
clearly visible positions.
• Keep all safety and hazard warnings on the installation in a legible
condition.
Use in line with intended purpose
The DAB450 has been constructed using state-of-the-art technology and in
line with the recognised technical safety regulations. The DAB450 may only
be
• deployed in line with the intended purpose and
• used when all the technical safety features are in perfect condition
The exclusive intended purpose of the DAB450 is to drive elevators.
Any other or additional form of use shall be regarded as non-compliant with
the intended use. THYSSENKRUPP AUFZUGSWERKE GmbH shall not be
liable for any damage arising from such use and any damage arising due to
operator errors. Proper use in line with the intended purpose also includes
• Observance of all instructions in the operating manual and
• Adherence to the commissioning instructions, the installation description
as well as the inspection and maintenance work.

Warranty and liability

As a general principle, the "General Terms of Sale and Delivery" of
THYSSENKRUPP AUFZUGSWERKE GmbH apply
Warranty and liability claims in the event of personal injury and damage to
property shall be excluded if they arise due to any of the following causes:
• Improper use that is not in line with the intended purpose of the DAB450
• Installation, commissioning, operation and maintenance of the DAB450
that is not in line with accepted technical principles
• Operation of the DAB450 with defective and/or

non-operative safety and protection devices
• Nonobservance of the instructions in the operating manual with regard to
transport, storage, installation, commissioning, operation and maintenance
of the DAB450
• Constructional changes to the DAB450 performed by the operator
• Changes to the drive ratios / power output etc. performed by the operator
• Deficient monitoring of parts that are subject to wear
• Repairs that are carried out improperly
• Cases of catastrophe due to third-party interference and force majeure.
Constructional changes to the DAB450 performed by the operator

The parts installed in and attached to the DAB450 are mounted and set at
the plant.
If changes are made to the machine, this renders the entire warranty of
THYSSENKRUPP AUFZUGSWERKE GmbH
Dangers in handling the DAB450

The DAB450 may only be operated in an enclosed machine room and only
with the screen fitted.
Before mounting the manual drive, the power to the drive must be
disconnected and the installation secured against inadvertent activation.
Remove the manual drive before reconnection and screw on the cover plate.
It must be ensured when persons are in the machine room that there is
adequate safety clearance to all revolving (marked in yellow) parts.
In the event of improper use, there is a risk of personal injury or to the life of
the user or third parties, or impairment on the assembly or other assets can
arise.
Malfunctions that can diminish safety are to be rectified immediately.

OPERATING MANUAL DAB450 PRODUCT DESCRIPTION
2. Product description
2.1 Description
1 2 3
4
14
6
13
12
11 9
10
Fig. 2.1
1 Brake magnet 8 Transport/Machine base frame

2 transport eyebolt 9 Traction sheave
3 transport eyebolt / hanger 10 Type plate
4 cover grate 11 brake test switch
5 Brake connection box 12 Mounting for manual drive
6 Brake shoe 13 Motor terminal box
7 Spring plate 14 Brake release lever

Versions
The following versions can be supplied:

1. Elevator speed
2. Version for current regeneration
3. Diameter of traction sheave ∅ 600 / 660 mm
4. Machine base frame versions
5. Accessory parts for maintenance / emergency operation
6. Additional encoder mounting
Special versions, see description in chapter 8
2.2 Functional description
Machine: the DAB450 consists of a frequency-controlled motor similar in

design to B3 (DIN IN 60034) in protection type IP21. It is firmly bolted to a
transport frame (optional: machine base frame).
Depending on the customer, the rope drive is intended for operation with
single or double rope wrap and operation with 1 : 1 or 2 : 1 suspension.
Speed measurement takes place via a no-contact, inductive pulse encoder
(API). This is connected to the built-in electronic evaluation system (square
wave pulse) by means of a plug-in connection (pulse encoder connector).
Mounting for an optionally available second encoder (GWA) is prepared.
Depending on the motor type and control device, the braking energy that is
created is fed back sinusoidally into the network.
The engine shaft and rope pulley are equipped with roller bearings.
There is a possibility to lubricate all bearings.
The traction sheave and brake disc are doubly supported by bearings and
consist of one cast part.
The gearless machine has no automatic interlock.

Brake: an electromagnetically actuated, type-approved, dual-circuit outer
shoe brake is mounted at the pedestal bearing.
Two brake shoes acting independently of each other press the brake lining
onto the brake disc with pre-adjusted spring force.
The braking force is configured in such a way that one of the brake shoes is
sufficient to bring a loaded elevator car to a standstill.
The position of the brake shoes and wear on the brake linings is checked by
a brake monitoring circuit. If there is a malfunction or the set wear limit is
reached, the drive is switched off.
The brake is released by a separate electromagnet for each brake shoe with
integrated overvoltage protection.
For manual operation, an external brake release lever is fitted. It can be used
to operate one brake shoe or both brake shoes simultaneously.

The DAB450 is self-ventilating. It is configured for thermal class F and

used up to class B.
A triple posistor built into the motor winding monitors the operating
temperature (shutdown temperature 130 °C ± 5 °C)
The maximum sound pressure level is 70 dB(A)
Machine base frame: the gearless is delivered with a mounted machine
base frame as a unit. (With double wrap, including built-in rope pulley)
More details on the machine base frame and its dimensions can be found in
chapter 3
Accessories: the accessories necessary for the operation, maintenance
work and removal of malfunctions such as the hoist, hydraulic cylinder, rope
clamps for the traction sheave and counterroller as well as a manual drive
are delivered as options.
If a number of the same machines are set up in one machine room, only one
of each accessory part is required for each room.
Note: a description of specified use of the accessories is provided in
chapter 9
The machine type complies with the European standard EN81-1:1998

+A3:2009 as well as EN81-20/50:2014 and also the specifications of ASME
A17.1. They comply with the European standard EN60034. Approval for the
North American region (CSA and ASME A17.5) is also available.
2.3 Protection devices for deployment in an earthquake region of

category 1 complying with EN81-77 - optional - (only for delivery with
machine base frame)
Fig. 2-2: DAB external rotor gearless with earthquake protection devices
(the version DAB450S/L is shown)
1 DAB450 external rotor gearless 2 DW-R machine base frame

3 Earthquake protection for traction 4 Earthquake protection for rope
sheave pulley
5 Shift protection 6 Intrusion protection on rope pulley
The protection devices consist of a traction sheave cover, rope holder on the rope
pulley as well as shift protection on the machine base frame. The earthquake
protection device is standardised with traction sheave diameter DT = 600/660 mm and
rope pulley diameter = 600.
The intrusion protection meets the requirements from EN81-1/ 9.7 and EN81-20/5.5.7.
Fig. 2-3: Components for earthquake protection on the traction sheave
The traction sheave cover is suitable for SW application as well as DW application.

Rope departures of 0° to 75° to the horizontal can be covered.
The earthquake protection on the traction sheave of the DAB450 is adequately

dimensioned and can be used up to and including earthquake category 3 complying
with EN81-77
Fig. 2-4: Components for earthquake protection on the rope pulley

1 DW-R machine base frame 2 DW rope pulley, diameter 600 mm

3 SW rope holder 4 SW cross strut
5 DW rope guard
The earthquake protection on the rope pulley consists of up to 3 different holding-down

clamps.
The holding-down clamps on the DAB450 rope pulley can be used for the ASL range of
900 - 1500 mm.
All holding-down clamps are adjustable.
The earthquake protection on the rope pulley of the DAB450 is adequately
dimensioned and can be used up to and including earthquake category 3 complying
with EN81-77
Fig. 2-5: Components for earthquake protection on the shift protection on the
machine base frame
Description of items for Fig. 2-5

1 Shift protection adapter 2 DW-R machine base frame
The shift protection ensures that the drive with machine base frame does not change
its position in the event of an earthquake.
The earthquake protection against shifting of the DAB450 is adequately dimensioned
and can be used up to and including earthquake category 1 complying with EN81-77
In the case of deployment of the machine in earthquake categories 2 and 3, additional
safeguard measures in accordance with EN81-77 are necessary.

OPERATING MANUAL DAB450 TECHNOLOGY
3. Technology
3.1 Technical data
Rating
The rating of the DAB450 can be found on the type plate
Torques DAB450 S DAB450 L

Braking torque (with lifting magnet type GH100 011) maximum 4,250 Nm
minimum 3,680 Nm
per brake shoe
Traction sheave with integrated brake disc
600 / 660 mm rim diameter and 680 mm brake disk diameter
Weight: DAB450 S DAB450 L

Machine 2 300 kg 2 650 kg
Machine weight, including frame and rope pulley 3 200 kg 3 500 kg
Rope pulley (DW) diameter 600 270 kg
Technical data for lifting magnet, see type plate for lifting magnets
Note:
The coils of the lifting magnets are connected in series.
Other technical data can be found on the type plate.

3.2 Dimensions of machine
Fig. 3-1
1 Mounting of machine (pedestal 2 Mount of protective hood on
bearing AS and BS) on machine machine base frame
base frame

3.3 Dimensions of machine base frame (optional)

right-hand design
Fig. 3-2
1 Min. clearance for lifting 2 Vertical measurement to overall

centre of gravity
3 Vertical measurement traction 4 Project planning dimension x1
sheave to rope pulley depending on traction sheave
"standard (special size)" diameter DT:
DT = 600 mm → x1 = 250 mm
DT = 660 mm → x1 = 220 mm
5 ASL

Fig. 3-3
1 Overall centre of gravity

Side view of machine base frame
Fig. 3.4
1 Min. clearance for brake release

lever
When aligning the grooves of the traction sheave to the rope pulley, the
grooves must be arranged with an offset of half the distance from one
groove centre to the next.
Example: groove clearance 18 mm offset = 9 mm

3.4 Encoder
A magnetic tape is mounted in the pedestal bearing AS for the regulation and
control of the DAB450. The signals are read with a magnet sensor.
The connection is made via connector.
Installation instructions, see chapter 5
Technical data
SIKO magnetic tape with evaluation unit with 25600 pulses per revolution
(see table)
Encoder for DAB450S/L

Encoder type SIKO: magnetic tape MB100 with MSK110TH-SK20
Magnet sensor with integrated
MSK110TH-SK20
evaluation unit
Supply voltage UB 5 V DC +/- 10%
Two square wave signals offset by 90°
Output tracks
and their inverse signals
Output RS 422
Maximum speed of movement,
25 m/s
magnetic tape
Pulses / revolution 25600
Operating temperature range - 10...+ 70 °C
Type of protection (sensor) IP 67
Approx. 100 mm free connection line with 12-pin
Connection
round plug
DAB450 31401 ENG
Table 3.4.1
Fig. 3.5

1 Magnet sensor MSK110TH with 2 Magnetic tape MB100

integrated electronic evaluation system
3 Coupling connector of the sensor with
pin contacts
Fig. 3.6.1
Fig. 3.6.2
2. Optional encoder
(relevant to additional safety monitoring)
Technical data
Same execution as standard encoder (see Table 3.4.1).

OPERATING MANUAL DAB450 TRANSPORT AND STORAGE
4. Transport and storage
Packaging:
Shipping takes place depending on the drive and order (transport frame,
machine base frame), optionally covered with foil.
Other packaging types can deviate from this on a country-specific basis
(air / sea /truck freight).
Transportation:
Transport must be effected in compliance with the safety regulations and
observing the centre of gravity of the machine and base frame.
 The machine may only be moved with the transport hanger mounted.
 Only secure the machine on the transport hanger and eyelets specifically
designed for the purpose. For horizontal transport and to enable
manoeuvring with limited space available, additional transport eyebolts
are fitted.
 Pay attention to protruding parts! Danger of injury and damage!
Crane transport:
 Do not walk underneath suspended loads!
 Transportation chains or ropes may only
be attached to the transport hanger and the
eyes specifically designed for the purpose.
 Do not lift by the motor or pedestal bearings!
Fig. 4.1
1 Transport hanger

Pay attention to the icons on the packaging or elsewhere.
Top Fragile goods Protect Protect Hand hooks Attach here

against against heat prohibited
water
Dimensions and weight

The weight data are specified on the packaging on a label on the machine.
Please refer to the delivery note for the dimensions.
Check on acceptance by the recipient

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

On delivery, make sure that no damage in transit has occurred.
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
Dispose of packaging materials in an environmentally compatible manner or

reuse them.
Specific transport aids and shipping braces remain with the customer.

Intermediate storage
If the assembly is not installed immediately after delivery, it must be covered
and stored carefully in a dry, weather-protected location. On covering,
attention is to be paid to ensuring that no condensation can form and that no
moisture or dirt can penetrate.
Bare parts have no long-term preservation.
Standstill maintenance
To prevent contact corrosion in the bearings, the drive shaft is to be turned a
number of times approx. every 3 months with the brake opened in both
directions
.Execution
1. Remove protective hood (hammer back).
DANGER
The brake release lever races upwards on deactivating and/or
engaging the brake!
Severe injury to the face or upper body.
Hold the brake release lever tightly.
2. Insert brake release lever and pull downwards.
3. Turn the brake drum alternately in both directions, 5 times in one direction, 5.5 times
in the other. In doing so, make sure that the brake drum is at a different position to
hat before turning.
4. Carry out a visual inspection for contamination, corrosion and damage.
5. Rework these points if necessary.

Re-establishing the original state
1. Close the brake (brake shoes applied).
2. Refit the protective hood
3. Sign the maintenance plan.
Ambient conditions
The environment at the final location (moisture, temperature) must
correspond to normal indoor climate conditions for machine rooms.
(In accordance with EN 81, between +5 °C and +40 °C)
The relative air humidity must not exceed 70%.

OPERATING MANUAL DAB450 MOUNTING THE MACHINE
5. Mounting the machine
5.1 Machine setup
The DAB450 machine is delivered fully mounted and aligned on the machine
base frame (with double wrap including rope pulley).
Note: The equipment attached for transport such as transport hangers and
eyes in Fig. 3.2, chapter 3, are to be removed before assembly of the screen
and/or before commissioning.
The base frame is set up depending on the installation on the machine room
floor or directly in a cement floor.
In order to comply with regulations for noise abatement and sound
transmission, isolation elements are to be inserted between the frame
supports and the ground. These differ according to the type of mounting:
a) Rubber block 100 x 100 x 50 high without support
for mounting the machine on the machine room floor without a cement
floor or directly surface mounted on the cement floor.
b) Rubber block same as a) however with an additional base 140 x 140 x
80 mm high, for mounting on a cement floor, support cast in cement floor.
(Coating thickness ≤ 60 mm) The support is also to be cemented in place.
The number of rubber elements is based on the total load.
The required individual load on the supports should be between 7000 and
12,000 N per support.
On arrangement of the supports, it is to be taken into account that the overall
centre of gravity lies within the rubber elements.
You will find the versions and dimensions of the machine base frames in
Chapter 3
5.2 Aligning the machine base frame
The machine is to be set up according to the plan of installation. The rope
departure from the traction sheave and deflecting pulley is to be aligned
plumb according to the drawing on the elevator car rope pulley or the
counterweight pulley. With load applied to the ropes, the machine should be
aligned horizontally on its installation surface. Irregularities are to be
balanced out by inserting shims under the support.
Rope arrangement: The arrangement of the carrier cables in the suspension

plate, on the traction sheave as well as the cable rollers should be as
symmetrical as possible.
Alignment of the machine on the base frame: the machine is aligned on

the base frame in such a way that the axle alignment of traction sheave and
counterroller are exactly parallel. The lateral location of the rope grooves
must be offset by half of the groove gap dimension. The parallel dimension of
the gap (ASL) of the outgoing ropes is to be complied with. (See Fig. 3.3-3.5
in chapter 3)

Adjusting: the machine and base frame have been aligned at the plant and
fixed with spring-type straight pins. The location of the axles and/or the
distance cannot be changed.
The lateral location of the rope grooves can be set at the setting screws
beside the pulley shaft. Use the screws to set the desired groove offset, then
turn each screw back by ¼ revolution so that the mounting is free.
Note: after completion of the installation work, the securing bolts are to be
tightened with the prescribed torque. See chapter 9
1
1 Setting screws
2 Rope pulley DW
3 Pulley shaft
4 Axle bracket
5 Machine base frame
5 4 3 2
Fig. 5.1
5.3 Connecting the machine
Wiring diagram DAB450

Standard version
Fig. 5.2

CSA version
Fig. 5.3
1 Motor 2 Actual-value sensor

3 Brake 4 Safety switch for emergency
evacuation
5 Motor winding 6 Temperature monitoring, motor
7 Lifting magnets for brake circuits 1+2 8 Monitoring switch for brake circuit 1
9 Monitoring switch for brake circuit 2
5.4 Connecting the motor
1. Standard version
Terminal plan
The terminal diagram is

printed on the inside of the
terminal block cover.
Fig. 5.4
Fig.: motor terminal box

Do not apply a voltage greater than 2.5 V at the terminals of the

posistor. Adhere to the internal resistance of the measurement devices!
Cable
Terminal max. motor Cable Cable type Outer
Machine Cable cross-
version gland
area current 1) type (as an example) diameter
section
[mm] [A] [mm²] [mm²] [mm]
2) Lapp Unitronic
M16x1.5 5-9 1.5 2x1.5 7.5
LiYCY
50 10 4G10 21.3
DAB450S/L M40x1.5 19 -27.3
68 16 4G16 Lapp Ölflex 24.1
88.5 25 4G25 Classic 100SY 29.4
M50x1.5 27 - 35
110 35 4G35 32.4
1) Motor current ILhm acc. to TLD design (if available) otherwise IN acc. to tables for electrical data
2) Temperature monitoring DAB450_31404_ENG
Table 5.1
2. CSA version
For machines in range of application USA and Canada according to A17.1, one bore
D50.2 mm and D22.1 mm respectively are provided in the motor terminal box for installing
corresponding conduits
22 mm
50 mm
Fig. 5.5

5.5 Connecting the brake magnet
Standard version
Fig. 5.6
1 BM coil 1 2 BM coil 2
3 Lifting magnet for brake circuit 1 4 Lifting magnet for brake circuit 2
CSA version
Fig. 5.7
1 BM coil 1 2 BM coil 2
3 Lifting magnet for brake circuit 1 4 Lifting magnet for brake circuit 2

Note: a check of the brake magnets connected in series is only possible with
A triggering of both magnets. (If one coil is defective, neither of the coils works.)
1 Terminal BM3 3 2 1
2 Terminal BM1
Fig. 5.8 3 Terminal BM2
5.6 Connecting the brake test switches
1. Standard version
Button 1 Button 2
blue black
black blue
brown brown
0V A + + 0V A
Fig. 5.9
Functional description, see chapter 7 (Setting the brake test switches).

2. CSA version
Button 1 Button 2
12 24 23 11
11 23 24 12
Fig. 5.10
Functional description, see chapter 7 (Setting the brake test switches).
5.7 Connecting the manual operation limit switch

Limit switch
22 14
21 13
Fig. 5.11
The manual drive limit switch must be connected in the safety circuit.
See installation terminal plan.

5.8 Connecting the encoder
The connection is made at the 12-pin round plug or with connecting line, see
also Fig. 5.12
Fig. 5.12

Encoder connecting line –Optional-
Fig. 5.13

OPERATING MANUAL DAB450 COMMISSIONING
6. Commissioning
Before commissioning the machine, the following points should be checked

and carried out:
• Safety, auxiliary and installation tools removed from the danger zone
• Setup and alignment of machine, frame and rope departure checked
• Mounting of the machine and base frame checked
• Bolts tightened and secured with the prescribed torque (see table
'Tightening torques', chapter 9)
• Brake shoe stroke and setting checked
• Setting and function of the brake test switch checked
• Brake test carried out with one brake shoe in each case
• Brake release with lever function checked
• Protective cover fitted
• Function of safety switch on the cover plate of the hand drive mounting
checked
• Distance of the pulse encoder in weight-loaded state of the traction
sheave checked
• Power connections, grounding of motor, lifting magnet, test switches and
pulse generator connections according to legal regulations and safety
instructions
• Special add-on components (optional) properly mounted and function
checked
• Direction arrow (Up / Down) attached on the pedestal bearing and clearly
visible according to the direction of travel

OPERATING MANUAL DAB450 MAINTENANCE / SERVICE
7. Maintenance / service
7.1 Maintenance
Maintenance period: maintenance of the machine should take place within

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

chapters: 
 Check the brake shoes for wear; the remaining lining 7

thickness must be at least 3 mm
 Check the brake setting; the shoe stroke should be 0.5 mm 7
 Check the braking deceleration 7
 Check the function of the brake test switches 7
 Check the pressure roller for ease of movement, damage 7.4.1
and wear, and replace if necessary
 Check groove profile on the traction sheave for damage and
wear
 On the double wrap rope pulley (if present), check the
grooves for damage and wear
 Check motor bearings for wear (noise, backlash)
 Lubricate the roller bearings on the motor shaft with the 7
motor running
 Lubricate the roller bearings on the rope pulley DW 7
(if present) on the roller axle
 Check that electrical connections are in proper and
adequate condition and check that they are securely
attached
 Check the function and setting of the safety switches
(handwinding wheel cover, rotor safety cover) 7
 Check that protective and safety devices are present and
correctly set

7.2 Lubrication
Lubrication volume for roller bearings on gearless axle and

roller bearings of the rope pulley
Yearly lubrication quantity 200 g See Fig.

Roller bearings on the gearless per lubrication nipple 7.2.1
axle
Yearly lubrication quantity 200 g See Fig.
Roller bearings of the rope 7.2.2
pulley
e.g. multipurpose grease F1 Code no. 60 300 27 90 0
cartridge 400 gr
e.g. multipurpose grease F1, can be obtained through

THYSSENKRUPP AUFZUGSWERKE GmbH

Relubrication
3 3
1
2
Lubricate "on both sides"!

1 2 1
Fig. 7.2.1
Machine 3
3
1
1 Lubrication nipple 2
2 Overflow opening
3 Setting screw for the 4
position of the rope pulley
4 Axle bracket Fig. 7.2.2
Rope pulley
The pulley shaft has a thread Rp ¼" for the grease outlet pipe on both sides;
this is required where a tensioner device for compensating rope is used.
When relubricating:
To distribute the grease filling uniformly in the bearing, observe the following:
a) Grease filling: Add in several partial quantities during operation. (min. 3 or
several parts)
b) Operate the drive for at least 3 minutes between the individual filling
operations
Note:
Lubricant must be refilled when the machine is running in order to ensure

that distribution in the bearing is uniform!
Filling of uncontrolled lubricant quantities without redistribution through
bearing rotary movements may cause damage to the bearing and sealing
systems!
Use the specified lubricating grease only.
If other greases are used the:
 Lubricating ability may degrade.
 Grease ducts may harden.
 Bearings may become damaged.
THYSSENKRUPP AUFZUGSWERKE GmbH will not be held liable for

damage resulting from the use of non-approved lubricants

7.3 Testing the brakes

Prior to initial operation and with the monitoring system running, the work
stroke of the brake shoes must be checked.
When opening the brakes, ensure that both brake shoes are operating with
the same stroke.
1 2 3 4 Setting the brake shoe stroke:

With the solenoid actuated, the air gap between
brake disc and brake lining should be 0.5 mm
5 (see the cast-in value at the brake shoes)
 Actuate brake magnet, check air gap with feeler
gauge.
6  Correct the setting by turning the adjusting screw
(pos. 8) at the brake shoe until the feeler gauge
at 0.5 mm can be pushed through the air gap
level with the cast-in arrow at the brake shoe
without resistance.
0.5 mm stroke
 Secure this setting by tightening the counter nut
and repeat this procedure at the second brake
shoe.
7
Fig. 7.3
1 Brake disc
5 8
2 Brake actuating lever
3 Compression spring
4 Spring plate
5 Setting nut for braking force
6 Brake shoes
7 Brake shoe pin
8 Adjusting screw for shoe stroke
A Fig. 7.4
NB: after a brake adjustment, the deceleration and the brake test switch
must be checked and/or adjusted.
See chapter 7

7.4 Testing the release mechanism of the brakes
During the annual maintenance, the functional capability as well as ease of

movement are to be checked in accordance with the following instructions.
Procedure:
1. Switch off the system!
2. Inspection of the pressure rollers
It must be possible to turn the pressure rollers (Fig. 7.4.1) by hand.
They must neither be difficult to move nor have noticeable play backlash.
There must be no abrasion at the pressure rollers and setting screws.
The pressure rollers (Fig. 7.4.1) can only be turned / moved when the
anchor rod on the brake magnet (Fig. 7.4.2) is pressed downwards.
Fig. 7.4.1 Brake actuating lever Pressure roller Setting screw

3. Check of the brake actuating lever

It must be possible to push the anchor rods coming up out of the two
brake magnets with your thumb (see Fig. 7.4.2) and they must have
buffering, easy moving characteristics when operation involves
jolting.
Anchor rod
Brake magnet
Fig. 7.4.2
 If a defect occurs with regard to points 2. or 3., in general both

accessory brake actuating levers (see Fig. 7.4.1) are to be replaced!
The replacement is to be requested through ThyssenKrupp Aufzugswerke.
See replacement kit no. 6144 000 9209
7.5 Replacing brake shoes
Note: With a remaining lining thickness less than or equal to 3 mm, or if the
brake linings have become unusable and the required deceleration is not
achieved, the brake linings have to be replaced.
In order to achieve the same braking effect after replacing the shoes, it is
necessary to measure and note down the setting of the initial spring tension
before removal. See Fig. 7.4, dimension "A"

Caution: Before starting work, the counterweight and elevator car must be
secured against uncontrolled movement. The power supply to the installation
must be switched off. No torque may be acting on the traction sheave.
1.) Disassembling brake shoes:
 Unscrew the nut at the spring collar and remove disc and compression
spring.
 Remove the locking ring at the brake shoe pin.
 Remove brake shoe and refit the adjusting screw for brake actuating
lever and test switch actuation at approx. the same distances on the new
brake shoe.
 Install new brake shoe on machine.
 Reseat or bed in the lining to 75% contact area of the lining surface.
 Align the brake shoe laterally. The adjusting screw for brake shoe stroke
should be aligned to the middle of the roller at the brake actuating lever.
If offset, disassemble brake shoe and align to the roller centre by
rearranging the spacer washers at the shoe bearing. (Washer thickness
1 mm.)
 Screw compression spring and spring collar with nut onto guide bolt until
the brake lining is against the brake disc.
 Tighten the nuts to the setting dimension (the noted value of the setting
used so far). See also chapter 7.6 "Setting the braking deceleration".
Caution: The test switch screw must not touch the switch contact, or only
very lightly, because otherwise the switch will be damaged.
2.) Setting the brake shoe stroke
With the solenoid actuated, the air gap between brake disc and brake
lining should be 0.5 mm
 Set stroke as described in chapter 7
 Change and set the second brake shoe in the same manner.
3.) Setting braking deceleration
Set the deceleration as described in chapter 7.
4.) Setting the brake test switches
Make the setting of the brake test switches at the brake shoes as
described in chapter 7.
5.) Checking the settings at the replaced shoes
 After replacement, operate with electrical recall and observe whether
both brake shoes open evenly.
Important: After every brake block change, the block stroke, braking
deceleration, setting and operation of the test switches must be checked and
corrected if necessary.

7.6 Setting / checking braking deceleration
Basic setting of the brakes
The braking force (contact pressure of the brake shoe) is executed machine-
specifically and uniformly by means of the initial tension of the brake springs
at the two brake shoes. On delivery, the brake is set ex works as standard
depending on type,
see Table 7.6.1
Machine Initial spring tension distance
DAB450 24 mm (corresponds to approx. 8 revolutions)
Table 7.6.1
If this brake adjustment is changed, the configuration complying with

EN81/A3 is invalid and must be checked!
However, if it is necessary to set the brake subsequently, proceed as follows.
To set the initial tension distance:

tighten the setting nut (Fig. 7.3) by hand as far as possible.
Make sure that the compression spring is seated centrally in the brake shoe;
the compression spring must not touch the side of the brake shoe. Then set
the initial tension distance in accordance with the table/illustration
(corresponding to the turns of the setting nut as a reference value) and lock
the setting nut. (100 - 200 Nm)
DAB450 / braking torque: 4250 Nm

Initial tension
8 revolutions
Initial tension
24 mm
163 mm = length with initial tension
187 mm = free length
Fig. 7.6.1
If the specified number of revolutions is exceeded, this can impair the

brake function.

The brake adjustment for the DAB450 is to be carried out only with one
effective brake shoe with the elevator car loaded with the rated load on a
descending run (full down) according to the values specified in the table
7.6.2.
Brake test Brake shoes Load Deceleration

ON Q=100% 0.4 - 0.6 m/s²
two Q=125%  1.2 m/s²
Table 7.6.2
Before carrying out a brake test, check the braking distance, which
results from the above-mentioned deceleration.
Important: In the case of repeated braking, the brake disc heats up, which
causes braking behaviour and setting values to change. It is recommended,
therefore, to have a sufficiently long cooling down phase between tests.
Caution: When setting, the test switch screw must not touch the switch
contact, or only very lightly, because otherwise the switch will be damaged.
Note: Brake test switches must be checked or readjusted after adjusting the
brake.
See chapter 7.7

7.7 Setting the brake test switch

1.) Standard version
Before setting the brake test switch, the brake shoe stroke must be set! For
description, see Chapter 7.3.
1. Switch on emergency operation switch and elevator control unit.

2. With the brake closed, use a screwdriver to turn back the switch tappet
carefully.
3. Slide a feeler gauge with setting dimension 1.45 mm between the screw and
switch tappet (see Fig. 7.6.1, Pos. 7)
4. Pull back the screwdriver
 LED lights up
5. Unscrew the setting screw from the brake shoe until the LED goes out.
 LED is off
6. Use the nut to secure the setting screw.
7. Repeat the setting procedure at the second brake test switch.
8. Check the LED function by switching the motor (open and close the brakes).
1 2 3
1 Adjusting screw
for shoe stroke
2 brake test
switch
3 LED (display)
4 Brake shoes
5 Adjusting screw
for brake test
6 Switch tappet
7 Insert the 1.45
mm feeler gauge
here
8 6 8 Lock nut
4 5 7
Fig. 7.7.1

2. CSA version
There are two sets of identical brake test switches with the same function to
monitor each brake circuit separately.
The switches each contain a break contact and a make contact.
The break contact with contacts 11 and 12 is used to monitor the position of
the brake shoe. With the brake open, the switch is closed.
The make contact closes contacts 23 / 24 only when the wear limit of the
brake linings has been reached and the brake is closed. The contacts must
be connected so that when a contact of the two switches is closed, operation
of the drive is prevented.
With a correctly set brake test switch, all switch contacts must be interrupted
with a closed brake.
23 11
Brake test switch
in the CSA version
Fig. 7.7.2
Setting: 24 12
Note: Before making the test switch setting, the brake shoe stroke setting
must be made. Description, see chapter 7.3
During the setting up procedures, the drive should be switched off for safety
reasons.
 Connect the continuity test device to contacts 11 and 12 of the break
contact. The adjusting screw must not touch the control tappet.
In home position of the drive (brake magnet without current) unscrew the
adjusting screw for the brake test from the brake shoe in direction control
tappet until opening of the contact is indicated by a signal interruption at the
continuity test device. (≙0.44 mm)
 Continue unscrewing the adjusting screw a further approx. 1/4 revolution.
 Secure this setting by tightening the lock nut.
 Repeat the setting procedure at the second brake test switch.
Check the setting:

switch on the motor to open and close the brakes. Observe whether the
switch at the contacts corresponds to the above described procedure.
Push the feeler gauge between adjusting screw and control tappet.
Select the thickness of the feeler so that contact 23/24 is closed.
When one of the contacts is closed, it must no longer be possible to start up
the drive.

7.8 Replacing and setting the encoder

NB: Make sure that you avoid damaging the magnet sensor! Risk of
destruction!
Replacement of the encoder (magnet sensor)
On the pedestal
bearing AS
Fig. 7.8.1
Fig. 7.8.2
Unplug the encoder connector

from the connecting line. Fig. 7.8.3
Fig. 7.8.4
Remove cover plate for connector
and encoder
Fig. 7.8.5
Undo 2 screws on the magnet sensor
Fig. 7.8.6
Replace magnet sensor with line and
connector,
mount in reverse order.
NB
Mount magnet sensor with the

line facing upwards.
Fig. 7.8.7
Magnet sensor - setting the distance
 When setting the magnet sensor, shut down the drive.
 Loosely screw on the magnet sensor
 Set the distance between gear wheel and encoder to 0.2  0.05 mm
using a distance gauge or foil (not metal).
 Tighten screws on the magnet sensor with
maximum tightening torque 1 Nm
 Screw on covers, plug connector onto connecting line
 Check the operation of the encoder
Comply with the instructions of the magnet sensor manufacturer in the

Appendix

7.9 Replacing the rope pulley
Caution: Before starting work, the counterweight and elevator car must be
secured against uncontrolled movement. The system must be without
current. No tensile force or torque may be acting on the traction sheave and
rope pulley.
Relieve the load on the rope pulley by lifting the ropes with the hoist
(chapter 9); secure the rope arrangement with the blocking clamp.
Remove the rope support on the rope pulley.
Pull the ropes with blocking clamp to the side and tie in place.
Attach the rope pulley to the lifting gear; turn back the setting screw
(chapter 5, Fig. 5.1, Item 1) on the axle bracket side; remove the axle
bracket; slightly raise the rope pulley with the lifting gear and pull out the
axle.
Use the lifting gear to carefully lift the rope pulley out of the machine base
frame and place it down.
Place the new pulley with the lifting gear carefully in the installation position
in the frame. Observe the rope arrangement.
Align the axle borehole of the rope pulley as flush with the mounting
boreholes in the frame. Fit the axle and secure with the axle bracket.
Detach and remove the lifting gear.
Align the rope sequence on the rope pulley according to the arrangement on
the traction sheave.
Lower the hoist to tension the ropes.
Fit the rope support; remove the blocking clamp.
Tighten the side setting screws for the position of the rope pulley above the
axle bracket until the rope pulley is clamped in place. Then turn the setting
screw back by half a revolution (play backlash). Secure this setting with lock
nuts.
(Can be omitted if there are HeliCoil inserts in the threads of the setting
screws)
Check the alignment of the grooves from the traction sheave to the rope
pulley.
The grooves must be
flush with rope arrangement SW.
With double wrap, the grooves must be arranged offset by half the groove
gap dimension (half of the distance from one groove centre to the next).
See chapter 3, "Offset" and example.
If there are deviations, correct the setting by moving rope pulley to the side
over the axle with the setting screws (chapter 5, Fig. 5.1, Item 1).

7.10 Checking for escaping grease / oil

Check the area around the bearing cover, brake drum, brake linings, shaft,
as well as the lower and/or inner area of the traction sheave for traces of oil.
It is not possible to see the inner area.

This means that a precise examination of the gap between the bearing
bracket and braking surface is important; it should also be checked for traces
of oil.
NOTE
Use of incorrect cleaning agent!
Damage to the break
For cleaning work on the brake, only use the cleaning agent
isopropanol (isopropyl alcohol).
Only carry out cleaning work on the brake surfaces.
Degree of soiling Procedure

No escaping oil / grease Check regularly within the Every 3 months
determined framework of maintenance (6 months in case of
reduced frequency,
< 50,000 runs per
year)
If a small amount of Clean and check regularly Every 3 months
escaping oil / grease is within the framework of (6 months in case of
determined maintenance reduced frequency,
< 50,000 runs per
year)
If a large amount of Clean the drive and, if Repair after 4 weeks
escaping oil / grease is necessary, the brake and carry at the latest
determined or brake out short-term repairs.
disc/brake linings already Before continuing operation
fouled with oil / grease until modification, run a brake
present test. If the braking effect is
inadequate, shut down the
installation.
If necessary, check on a daily
basis whether oil / bold is still
escaping. If this is the case:
shut down the installation.

Grease
Fig. 7.10.1
Traction sheave /
brake drum
Bearing cover
Seal
7.11 Emergency measures
Emergency measures describe possibilities to move the elevator car in the

event of malfunctions or a failed drive for rescue measures or removal of
malfunctions.
Elevator car movement by releasing the shoe brakes
The fork-shaped end of the brake release lever with the two pins is to be
inserted in the drilled holes below the brake magnets. Illustration and
description, see Chapter 9 "Accessory parts"
Carefully pulling the end of the lever downwards opens the shoe brake.
The elevator car now moves downwards or upwards depending on the
weight distribution between the car and counterweight.
Note: watch the speed of movement, as when overspeed is reached the
safety gear or emergency braking device is triggered.
After completion of the release operation, remove the release lever.

Elevator car movement by means of manual drive.

If the weight difference between the car and counterweight is too low,
the elevator does not move even if the brake is opened.
In this case, move the elevator car by means of the manual drive.
Note: two persons are required for elevator car movement with the manual
drive. Limit switch
Remove the cover plate
Fig. 7.11
See also Fig. 2.1
Chapter 2
for the manual drive on the front of the drive. Removing the cover plate
means that the limit switch interrupts the power supply to the drive motor.
With light turning movements, push the manual drive into the mounting
borehole
Fig. 7.12
on the pedestal bearing and secure to the pedestal bearing with screws.
While one person releases the shoe brakes with the brake release lever,
the second person should move the elevator car by turning the handwinding
wheel. An illustration and description of the handwinding wheel can be found
in chapter 9 "Accessory parts".
NB: moving the handwinding wheel can lead to the drive starting up
suddenly. The movement is to be stopped immediately by lifting the release
lever; remove the manual drive; move the elevator car into the next landing
by carefully releasing the brakes.
Do not operate the manual drive with the brake closed.

Before the gearless is switched on, the manual drive must be removed!

7.11.1 Drawing out of the safety gear
If the safety gear on the elevator car or counterweight has triggered, it can
occur that the driving force of the traction sheave is insufficient to move the
elevator; the ropes slip through.
Perform the following measures in this case:
1. Switch off the drive and control system.
2. Remove the safety cover on the rotor of the drive.
3. Use the clamping device to lift the transport carriage of the hoist
downwards onto the machine base frame. Attach the ropes loosely to the
transport carriage. See Fig. 7.11.1+2.
4. Raise the transport carriage slightly and place the hoist on the machine
base frame in such a way that the transport carriage sliding guides lie at
the hoist.
See Fig. 7.11.1+2
5. Bolt the hoist to the machine base frame.
6. Place the transport carriage of the hoist in the start position according to
the pulling direction.
b) Tension upwards, place transport carriage in device downwards.
b) Tension downwards, attach transport carriage in device upwards.
7. Use rope clamps to clamp the ropes to the transport carriage. The rope
clamps on the hoist must be open during pulling. Screw on the guide
stirrup bolts in such a way that the transport carriage can still be moved
up and down.
8. Remove the transport eyebolt, place the lowered hydraulic cylinder on
the pressure side in the hoist.
9. Pump the jack to move the transport carriage in the desired direction until
the ropes on the pull side are tensioned.
(The drain valve on the hydraulic cylinder must be closed)
Open the shoe brake at the drive with the brake release lever and hold
open during the pumping operation.
10. Continue pumping until the grip wedge has loosened or the end of the
lifting path on the hoist is reached.
If the safety gear lock is free, close the brake and remove the hoist.
Otherwise continue the sequence.
11. Use the rope clamps to clamp the ropes to the hoist, then open the rope
clamps on the transport carriage.
12. Lower the hydraulic cylinder, reset the transport carriage.
13. Repeat the pulling operation until the safety gear lock is free.
14. Remove the device; mount the protective device.
15. Switch on the drive and control system.
NB: before reconnection of the installation, ensure that the cause of the
malfunction has been remedied and that the installation is in proper working
order.

Use the clamping device

to clamp the transport
carriage down on the ropes.
Transport
carriage
Rope clamps
Fig. 7.11.1
Raise the transport carriage slightly and clamp onto the ropes. Place the
hoist on the machine base frame in such a way that the transport carriage is
lying with its sliding guides at the device.
Hoist
Rope clamps
Fig. 7.11.2

See also chapter 9 'Accessory parts'
Safety instructions:
 Lifting gear must not be attached to the normal shaft equipment such as
shackles, centre beam etc., as these are not configured for the required
high stresses.
 The supplied hydraulic cylinder must not be replaced by a stronger or
other winching device, as the higher forces can damage the drive.
 For safety reasons, the hydraulic cylinder must not be supported by motor
power.

7.12 Wear parts
Spare parts for worn sleeve bearings
Fig. 7.12.1 1 2 3 Fig. 7.12.2
See also chapter 7.4, Fig. 7.4.1
Accessories, wear parts kit, pressure roller DAB450

No. 9710 000 9418 DE / EN
Designation
1 Pressure roller D52x27-R500,
including 2 sleeve bearing bushes
2 Locking ring DIN 471 20 x 1.2
3 Bolts D20h x 82

OPERATING MANUAL DAB450 SPECIAL VERSIONS
8. Special Versions and accessory parts
8.1 Special Versions
8.1.1 Climate-protected version (optional)
On the climate-protected version, the coils and windings are protected by an

additional immersion-applied coat of paint. Bare surfaces where there is a
risk of rust have a protective coat of paint.
8.2 Accessory parts
For operation of the DAB450, the following optional accessory parts can be
supplied:
9.2.1. Brake release lever
9.2.2. Manual drive
9.2.3. Hoist
9.2.4. Rope clamp for rope pulley / traction sheave
9.2.5. Hydraulic cylinder
Note: the listed parts are necessary for deployment in emergencies or in the
case of maintenance or repair work and at least one of each should be
present in every machine room.
8.2.1. Brake release lever
X
A
Fig. 8.2
Y
Fig. 8.1
Side with one end (Y) to release only one brake shoe.
(brake tests ; TÜV inspection/approval)
Side with two ends (X) Releases both brake shoes.
(to move elevator car without drive; rescue of passengers)
Note: insert the lever into the release borehole (A) until the ring at the end of
the lever disappears in the borehole.

On operating the lever, the ring should engage on the inside of the borehole
to prevent slipping.
8.2.2. Manual drive
1 2 3
Manual drive
1 Pinion
2 Securing bolt
3 Handwinding wheel
Fig. 8.3
Important:
The manual drive must be fitted before switching on the motor!
No motor operation with the manual drive fitted

8.2.3. Hoist
1 5
1
5
8
2
3
5
6
4 7
Fig. 8.5
Fig.8.4
Transport carriage
Hoist
1 Transport eyebolt 5 Sliding guides

2 Transport carriage 6 Guide bracket
3 Rope clamp - transport carriage 7 Guide bolts
4 Rope clamp - hoist 8 Push plate for lifting device
Deployment:
for raising the elevator car or counterweight out of the safety gear
Application description, see 7.11.1 Emergency measures / Releasing the car

from the engaged position (safety gear)

8.2.4. Rope clamp (for rope pulley)
Fig. 8.6 Rope clamp
Deployment:
a) Rope locking; it prevents rope movements in the direction of the support.
b) To hold the elevator car / counterweight in place at the rope departure of
the counterroller.
Remove the screws on the rope clamp;
Apply the rope clamp halves to the support on the machine base frame at the
traction sheave rope departure on the ropes. Screw together and tighten the
pressure screws to clamp the ropes.
NB: before commissioning the drive, remove the rope clamp!
8.2.5. Hydraulic cylinder
1 Press the lifting device upwards:

Close drain valve, Item 3, on the lifting device.
Pump at lever, Item 2, with pressure cylinder
2 to move the transport carriage in the desired
direction.
1 Pressure cylinder
2 Lever
3 3 Drain valve
Lower the lifting device: connect the oval end

of the lever (Item 2) via the drain plug (Item 3);
turn to the left to open the valve on the lifting
Fig. 8.7 device.
Before starting to pump, close the valve (turn
to the right)
Deployment:
The hydraulic cylinder serves to lift the car out of the engaged safety gear
Application description, see chapter 7.11.1 "Releasing the car from the
engaged position (safety gear)"

OPERATING MANUAL DAB450 APPENDIX
9. Appendix
9.1 Tightening Torques
DANGER
Insecure threaded connection!
Death or severe physical injury due to parts coming loose.
 When working on the machine or in the case of parts replacement,
comply with the prescribed bolt tightness and tightening torques.
 Only use suitable tools (torque wrench).
 Non-microencapsulated bolts / screws are to be secured against

unwanted loosening during installation using detent edged washers or
Loctite 243 and a similar means of securing bolts / screws.
 Microencapsulated screws are to be replaced after they have been

used once.
The tightening torques given here apply for screwed connections without
specifications at the corresponding location.
If in the drawing or elsewhere in the document other tightening torques are predefined
for the particular bolt size, these have to be observed!
The values listed below apply to screwed connections with regular threads (not fine threads):
Allen screws DIN 912 ISO 4762
Hexagon head bolts DIN 931/933 ISO 4014/4017
Tightness 8.8 10.9 12.9

Screw / bolt size Tightening torque (Nm)
M4 2.6 - -
M5 5.3 - -
M6 9.0 12 15
M8 20 30 35
M10 40 60 75
M12 75 105 130
M14 120 170 205
M16 190 265 320
M20 370 520 620
M24 640 900 1080
M30 1300 1800 2150
Tab. 9-1
For assembly, use only original construction and mounting parts from ThyssenKrupp
Aufzugswerke GmbH, as otherwise no warranty can be provided.

User Information e.g. MSK110TH-0023
version number
type of unit
MSK110TH Magnetic sensor 3. Installation

MB100 Magnetic strip
For mounting, the degree of protection specified
must be observed. If necessary, protect the unit
against environmental influences such as sprayed
MSK110TH water, dust, knocks, extreme temperatures.
3.1 Mounting the magnetic strip
The mounting surface / measuring track must be
flat. Buckles or bumps will lead to measuring in-
accuracies.
For technical reasons the strip should be min.
MB10 56mm longer than the actual measuring distance.
0
Attention! To guarantee optimal adhesion oil,
grease dust etc. must be removed by using clean-
sing agents which evaporate without leaving re-
ENGLISH sidues. Suitable cleansing agents are eg. ketones
(acetone) or alcohols; Messrs. Loctite and 3M can
Exemplary sensor illustrations are valid for all sen- both supply such cleansing liquid. Make sure that
sor types unless described separately. the surface to be glued is dry and apply the strip
with maximum pressure. Glueing should preferably
1. Warranty information be undertaken at temperatures between 20°C to
• In order to carry out installation correctly, we 30°C and in dry atmosphere.
strongly recommend this document is read very
Advice! When applying long pieces of magnetic
carefully. This will ensure your own safety and
strip do not immediately remove the complete
the operating reliability of the device.
protective foil, but rather peel back a short part
• Your device has been quality controlled, tested from the end sufficient to fix the strip. Now align
and is ready for use. Please observe all warnings the strip. As the protective strip is then peeled
and information which are marked either directly back and out press the tape firmly onto the moun-
on the device or specified in this document. ting surface. A wall paper roller wheel could be
• Warranty can only be claimed for components used to assist in applying pressure onto the mag-
supplied by SIKO GmbH. If the system is used netic strip when fixing it in position.
together with other products, there is no warranty
for the complete system. Mounting steps (see fig. 1)
• Repairs should be carried out only at our works. • Clean mounting surface (1) carefully.
If any information is missing or unclear, please • Remove protective foil (2) from the adhesive
contact the SIKO sales staff. side of the magnetic strip (3).
• Stick down the magnetic strip (4).
2. Identification
• Clean surface of magnetic strip carefully.
Magnetic strip: identification by printing on the
strip. • Remove protective foil (6) from adhesive tape on
the cover strip (5).
NNNN 0100 O
• Fix cover strip (both ends should slightly over-
0
0
1
reference point
pole pitch: 1mm lap).
accuracy: 0.01mm • Also fix cover strip’s ends to avoid unintenti-
serial number
onal peeling.
Magnetic sensor: Please check the particular type
of unit and type number from the identification
plate. Type number and the corresponding version
are indicated in the delivery documentation.
MSK110TH + MB100 Datum 24.09.2009 Art.Nr. 85210 Änd. Stand 271/09 5

Attention! The tolerance and gap measures must
be observed over the whole measuring length.
The max. gap without cover strip is 0,4mm. When
using cover strip, the gap is reduced by the thick-
ness of cover strip including its adhesive tape.
Sensor must not touch the magnetic strip.
LINEAR application MSK1000 with MB100:
Fig. 1: Mounting of the magnetic strip
Travel direction
Attention! Do not expose the system to magne- Signal
A before B
0.1mm ... 0.4mm

active side
tic fields. Any direct contact of the magnetic strip
with magnetic fields (eg. adhesive magnets or
other permanent magnets) is to be avoided. Sen-
Direction of
sor movements during power loss are not captured outgoing cable
by the follower electronics.
Mounting examples
Gap sensor/magnetic strip
Mounting with chamfered ends (fig. 2) is not re-
< 1° < 3°
commended unless the strip is installed in a safe
and protected place without environmental influ-
ences. In less protected mounting places the strip
may peel. There we recommend mounting accord.
to fig. 3 and 4.
Mounting in a groove (fig. 5) best protects the
magnetic strip. The groove should be deep enough Maximum alignment error
< 3°
to totally embed the magnetic strip.
Admissable devi-
atoion middle of
tape/sensor:
±2mm
Fig. 2 Fig. 3 Fig. 6: Definition of the counting direction with
magnetic strip and assemblage sensor/magnetic ring,
gap measure, tolerances
4. Electrical connection
• Wiring must only be carried out with power off!
Fig. 4 Fig. 5 • Check all lines and connections before switching
on the equipment!
3.2 Mounting of the magnetic sensor MSK110TH
Interference and distortion
The magnetic sensor MSK110TH can be fastened
All connections are protected against the effects
by using two bolts M3 over the elongated holes.
of interference. The location should be selected
We recommend to use the enclosed fixing screws
to ensure that no capacitive or inductive in-
and washer springs (fastening torque 1Nm).
terferences can affect the sensor or the con-
• Cables should be layed in such a way that there nection lines! Suitable wiring layout and choice
is no danger of damaging. Provide ten-sion relief of cable can minimise the effects of interference
and drag chain or casing, if necessary. (eg. interference caused by SMPS, motors, cyclic
• Observe the correct alignment with regard to controls and contactors).
the counting direction (Fig. 6). This does not
Necessary measures
apply if the counting direction can be reversed
in the electronic interpretation (e.g. in SIKO's • Only screened cable should be used. Wire cross sec-
magnetic-strip displays). tion is to be at least 0,14mm², max. 0,5mm².
• Wiring to the screen and ground (0V) must
be secured to a good point. Ensure that the
6 MSK110TH + MB100 Datum 24.09.2009 Art.Nr. 85210 Änd. Stand 271/09
connection of the screen and earth is made to 5. Commissioning
a large surface area with a sound connection to
Following proper installation and wiring, the
minimise impedance.
measuring system can be commissioned by
• The system should be positioned well away from switching on the supply voltage. After switching
cables with interference; if necessary a protective on, the device initializes itself independently.
screen or metal housing must be provided. The
running of wiring parallel to the mains supply
should be avoided.
6. Output signals
The translation module translates the length
• Contactor coils must be linked with spark sup-
information of the magnetic sensor into incre-
pression.
mental output signals with real-time processing of
Supply voltage the output signals.
The voltages depend on the sensor designs; they Please note that pulses having the width of
are to be taken from the delivery documentation the pulse interval set can occur at standstill of
and the identification plate. the device (caused by the internal interpolation
method).
e.g.: 4,5VDC ... 5,5VDC
Caution! When dimensioning the follow-on elec-
Attention! When connecting sensor and follower tronics please take care that it is adjusted to the
electronics, please do not exceed the max. admis- set pulse interval or counting frequency, respec-
sable cable length. tively.
4.1 Connection note acc. to RS422 standard Signal sequence
Please provide the channels with a 120 Ohm ter-
minating resistor.
7. Maintenance
We recommend cleaning the magnetic strip’s surface
from time to time with a soft rag. This avoids dirt
(dust, chips, humidity ...) sticking to the strip.
4.2 Connection type 8. Trouble shooting

E2X: Connection with 12 pole coupler plug. Below are some typical errors which may occur du-
Pin Signal ring installation and operation:
1 B • Magnetic strip incorrectly mounted (active sur-
2 --- face must be mounted towards the sensor) (see
3 /A chapter 3.1).
4 A • Use of foreign protective strip. Must always be
5 --- non-magnetic.
6 --- • Sensor not or incorrectly connected (pin connec-
tion, see chapter 4.2).
7 ---
8 /B viewing side=
• Tolerance for the gap between magnetic sensor and
plug-in side magnetic strip not observed over the total travel
9 --- plug pin distance. Sensor touches strip (see fig. 6).
10 +UB
• Cable squeezed / interrupted / cut by sharp
11 --- edges.
12 GND
• Sensor’s active side not mounted towards the
magnetic strip (see fig. 6).
• Sensor has not been aligned according to fig 6.
MSK110TH + MB100 Datum 24.09.2009 Art.Nr. 85210 Änd. Stand 271/09 7

SIKO GmbH
Werk / Factory:
Weihermattenweg 2
79256 Buchenbach-Unteribental
Postanschrift / Postal address:
Postfach 1106
79195 Kirchzarten
Telefon/Phone +49 7661 394-0
Telefax/Fax +49 7661 394-388
E-Mail [email protected]
Internet www.siko.de
Service [email protected]
8 MSK110TH + MB100 Datum 24.09.2009 Art.Nr. 85210 Änd. Stand 271/09
No. 61 440 02 86 0
Bernhäuser Straße 45
Version 03/2017
73765 Neuhausen a. d. F.
Germany
E-mail: [email protected]
Internet: www.thyssenkrupp-elevator-eli.de

Tkaw-Manual-Ba Atr Dab450 2017 03 en

Uploaded by

Copyright:

Available Formats

Tkaw-Manual-Ba Atr Dab450 2017 03 en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Tkaw-Manual-Ba Atr Dab450 2017 03 en

Uploaded by

Copyright:

Available Formats

Operating Manual

All rights reserved

DAB450 drive PAGE

4. Transport and storage 23

ThyssenKrupp Aufzugswerke GmbH

ThyssenKrupp Aufzugswerke GmbH 6 Version 03/2017

1.2 Safety instructions

Notes regarding the operating manual

Obligations of the operator and/or of the installation firm

Obligations on the part of personnel

Training of the personnel

ThyssenKrupp Aufzugswerke GmbH 7 Version 03/2017

The required personal protective equipment is to be provided by the operator

ThyssenKrupp Aufzugswerke GmbH 8 Version 03/2017

Warranty and liability

• Operation of the DAB450 with defective and/or

Constructional changes to the DAB450 performed by the operator

Dangers in handling the DAB450

ThyssenKrupp Aufzugswerke GmbH 9 Version 03/2017

1 Brake magnet 8 Transport/Machine base frame

ThyssenKrupp Aufzugswerke GmbH 10 Version 03/2017

The following versions can be supplied:

2.2 Functional description

Machine: the DAB450 consists of a frequency-controlled motor similar in

The gearless machine has no automatic interlock.

ThyssenKrupp Aufzugswerke GmbH 11 Version 03/2017

The DAB450 is self-ventilating. It is configured for thermal class F and

The machine type complies with the European standard EN81-1:1998

2.3 Protection devices for deployment in an earthquake region of

1 DAB450 external rotor gearless 2 DW-R machine base frame

Fig. 2-3: Components for earthquake protection on the traction sheave

The traction sheave cover is suitable for SW application as well as DW application.

The earthquake protection on the traction sheave of the DAB450 is adequately

Fig. 2-4: Components for earthquake protection on the rope pulley

ThyssenKrupp Aufzugswerke GmbH 13 Version 03/2017

1 DW-R machine base frame 2 DW rope pulley, diameter 600 mm

The earthquake protection on the rope pulley consists of up to 3 different holding-down

Description of items for Fig. 2-5

ThyssenKrupp Aufzugswerke GmbH 14 Version 03/2017

3.1 Technical data

Torques DAB450 S DAB450 L

Weight: DAB450 S DAB450 L

Other technical data can be found on the type plate.

ThyssenKrupp Aufzugswerke GmbH 15 Version 03/2017

3.2 Dimensions of machine

ThyssenKrupp Aufzugswerke GmbH 16 Version 03/2017

3.3 Dimensions of machine base frame (optional)

1 Min. clearance for lifting 2 Vertical measurement to overall

ThyssenKrupp Aufzugswerke GmbH 17 Version 03/2017

ThyssenKrupp Aufzugswerke GmbH 18 Version 03/2017

Side view of machine base frame

1 Min. clearance for brake release

Example: groove clearance 18 mm offset = 9 mm

ThyssenKrupp Aufzugswerke GmbH 19 Version 03/2017

Encoder for DAB450S/L

ThyssenKrupp Aufzugswerke GmbH 20 Version 03/2017

1 Magnet sensor MSK110TH with 2 Magnetic tape MB100

(relevant to additional safety monitoring)

Same execution as standard encoder (see Table 3.4.1).