Ein Unternehmen

von ThyssenKrupp ThyssenKrupp Aufzugswerke

Elevator

Operating Manual

Brake control 2
OPERATING MANUAL

Printer’s imprint

All rights reserved

 Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH
Postfach 23 03 70, D-70623 Stuttgart

Printed in Germany
The right of reprint or reproduction, even in the case of only partly exploitation, is subject to
express, written permission of THYSSENKRUPP AUFZUGSWERKE GmbH.
Any reproduction, copying or storing in data processing machines in any form or by any
means without prior permission of THYSSENKRUPP AUFZUGSWERKE GmbH is
regarded as infringement of the current Copyright Act and will be prosecuted. Technical
modifications for reasons of improvement of the brake control or for reasons of improving
the safety standard are subject to decisions of THYSSENKRUPP AUFZUGSWERKE
GmbH without prior notice.

The responsibility for the content lies with the editor:

THYSSENKRUPP AUFZUGSWERKE GmbH

Preface

We are pleased that you decided to purchase a quality product from THYSSENKRUPP
Aufzugswerke GmbH.
This operating manual assists you in getting familiar with the connecting control for brake
magnets of lift drives – referred to as brake control below – and with its intended
possibilities of use. Important information concerning safety and hazards help you to safely
use the brake control as intended. The brake control is subject to technical alterations.

ThyssenKrupp Aufzugswerke GmbH 3 Issue 05.06

OPERATING MANUAL

Table of contents :

Brake control 2 PAGE

1. Safety
1.1 Explanation of symbols used 6
1.2 General safety information 7

2. Product description brake control 2

2.1 Description of brake control 2 10
2.2 Technical data of brake control 2 11

3. Transportation and storage 12

4. Mounting and connecting

4.1 Mounting 14
4.2 Connection of brake control 2 15
4.3 Example of connection: pole-changing motor 16
4.4 Example of connection: variable-speed motor 17
4.5 Settings of brake control 2 18

5. Putting into service of brake control 2 19

6. Servicing of brake control 2 20

7. Maintenance
7.1 Replacing of brake control 2 21

8. Annex
8.1 Declaration of conformity 22

ThyssenKrupp Aufzugswerke GmbH 5 Issue 05.06

OPERATING MANUAL 1. SAFETY

1.1 Explanation of symbols used

The following pictographs and designations are used in this operating manual:

Danger
This symbol draws attention to an extreme danger to
life or risk of injury to persons. Disregard of warning
means danger to life !

Danger
This symbol draws attention to an immediate
impending danger to life or risk of injury to persons
caused by electric current.
Warning notices must always be observed !

Warning
This smbol draws attention to an impending danger.
Disregard can cause injury to persons or extensive
damage to property.
Warning notices must always be observed!

Note
This symbol draws attention to important information
and instructions for operation. Disregard can lead to
damages, hazards or failures.

Inspection
This symbol draws attention to inspection sequence.
These inspection notices must be observed in any
case. Disregard can lead to injury to persons or
damage to property.

ThyssenKrupp Aufzugswerke GmbH 6 Issue 05.06

OPERATING MANUAL 1. SAFETY

1.2 General safety information

Information about the operating manual

Knowledge of the basic safety requirements is a prerequisite for the safe use
and the failure-free operation of this component.
This operating manual comprises the most important information how to
safely use the component.
The operating manual and, in particular, the safety information must be
observed by all persons who perform any work on the component. In addition
the rules and requirements concerning the regulations for prevention of
accidents which apply to the installation location must be observed.

Duties of the owner and / or the installer

The owner and / or the installer ensure that only persons are authorized to
work at the component, who
• are familiar with the requirements concerning safe working and prevention
of accidents and who were trained how to use the component;
• have read the safety information and the warning notices in this operating
manual.
Note: Check the compliance of the employees method of working with the
safety requirements in regular intervals.

Duties of the employees

Persons who are authorized to perform work at the component are obliged
• to observe the requirements concerning safe working and prevention of
accidents;
• to read the safety information and the warning notices in this operating
manual prior to start working.

Training of the employees

Only trained and instructed, technically competent persons shall perform
work at the component.
The competence of the employees must be clearly defined for all tasks
concerning putting into service, operation, maintenance and repair work.

Organizational measures
The owner or the installer must provide the necessary personal protective
gear. All existing safety devices must be checked regularly in accordance
with the maintenance plan.

ThyssenKrupp Aufzugswerke GmbH 7 Issue 05.06

OPERATING MANUAL 1. SAFETY

Informal information about safety measures

• The operating manual must always be available at the location of the
installation.
• In addition to the operating manual the general and local regulations for
the prevention of accidents and environmental regulations must be made
available and observed.
• Clearly and easily visible statutory safety instructions must be made
available for the users.
• See to it that all information concerning safety and hazards is always
visibly and legibly made available on the machine.

Use as intended
The brake control is designed in accordance with the state of the art and the
recognized safety regulations. The brake control shall only
• be used for its intended purpose
• be used only if safe operation is ensured
The brake control shall exclusively be used for connecting magnetic brakes
of lift drives. Any other use or any use exceeding the scope of the above
definitions is regarded as use outside of the intended purpose.
THYSSENKRUPP AUFZUGSWERKE cannot be hold liable for any damages
resulting from this and for any damages which are caused by any errors of
procedure.
Use within the scope of its intended purpose also comprises
• observance of all information of the operating manual
• fulfilment of the instructions applying to putting into service, installation
description and inspection and repair work.

Guarantee and liability

The „General Conditions and Terms of Sale“ of THYSSENKRUPP
AUFZUGSWERKE GmbH apply generally.
Any claims for guarantee and liability are excluded in the case of injury to
persons or damage to property resulting from one or several of the causes
below:
• use of the brake control outside the scope of its intended purpose
• inexpert mounting, putting into service, operating and maintaining of the
brake control
• operating the brake control with defective and/or non-operative safety and
protective devices
• disregard of instructions of operating manual that apply to transportation,
storage, mounting, putting into service, operating and maintaining of the
brake control
• unauthorized constructional modifications of the brake control
• change of ratings or overrating
• unsatisfactory supervision of parts which are subject to wear

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OPERATING MANUAL 1. SAFETY

• inexpert repair work

• catastrophes caused by outside influence and Act of God.

Constructional modifications of the brake control

The brake control components are factory-assembled and assessed.
In the case of any modifications of the component THYSSENKRUPP
AUFZUGSWERKE GmbH cannot be hold liable.

Use of brake control and possible hazards

The internal electronic circuit of the brake control is current-currying. The
component is provided with a transparent cover as a safety-precaution
aganst contacting the current-carrying elements.
The brake control shall only be operated with the protective cover installed.
In the case of settings, such as changing of the jumper settings, disconnect
the drive before you start working and secure the installation against
unintentional connection.
Install the protective cover on the brake control before re-operation
starts.

In the case of incorrect adjustment and use there will be danger to life for the
user or third parties resp. impairment of the component or material property.
Failures which possibly impair the correct functioning are to be eliminated
immediately.

ThyssenKrupp Aufzugswerke GmbH 9 Issue 05.06

OPERATING MANUAL 2. PRODUCT DESCRIPTION

2.1 Description brake control 2

Fig. 1

Brake control 2 is designed for activating brake magnets of lift drives at low
rated currents of 0.25 – 1.25A

Configuration
Brake control 2 consists of control board, mains filter and terminals.
The components are mounted on a steel elbow and have a plexiglass cover
as a safety precaution against contacting current-carrying elements.

Mode of operation
A semi-controlled rectifier bridge generates the DC voltage for the brake
magnets. The rectifier bridge is controlled via phase control component.
A free-wheeling diode and a varistor suppressor circuit are provided at the
output of the rectifier bridge.
For compliance with the required EMC limit values an integrated mains filter
is used.

Voltage of 180 V DC is present at output of terminal 10 – and terminal 20 + if

mains voltage (230 V AC) is applied.
The output voltage will be reduced to approx. 90 V DC (withstand voltage)
after approx. 1 second if terminals 10 and 22 are connected.

ThyssenKrupp Aufzugswerke GmbH 10 Issue 05.06

OPERATING MANUAL 2. PRODUCT DESCRIPTION

2.2 Technical data brake control 2

Part. No.: 65 100 27 68 0

Rated supply voltage: 230 V AC
Mains-side fuse 230V F3,15A
(Visible type fuse on board)
Supply voltage frequency: 50 Hz
)
Output voltage (withstand v.)* 90 V DC ± 5% factory-set
)
Overexcitation voltage * 180 V DC ± 3%
Output current: max. 2,5 A
Switch-on duration: 100 % ED
Protection class: IP00
Ambient temperature range: 0° to 50°C
Relative humidity: max. 70 %
Max. site altitude above sea level: 2000 m without derating
derating of 1 % per 100m
above 2000 m to 3500 m
EMC test: compliance with requirements of
EN 12015 and EN 12016
Fitting position: screw in drilled holes provided on
mounting elbow; see chapter 4.1 fig. 2
Dimensions L * B * H: 180 mm * 120 mm * 103 mm
Fastening: see fig. 2
Weight: 1.1 kg

*) the voltage values indicated apply to the rated supply voltage

of the brake magnets.

ThyssenKrupp Aufzugswerke GmbH 11 Issue 05.06

OPERATING MANUAL 3. TRANSPORTATION AND STORAGE

3. Transportation and storage

Packaging of brake control 2:

The brake control is delivered packed in a carton.
Transportation:
Transportation shall be subject to observation of the safety requirements.

• Mind the risk of damage !

• Do not put any heavy objects onto the packed component.
• The assembly is not impact-proof and must be protected against
dropping.
• The component shall not be exposed to moisture or humidity.
• Remove packing material after transportation.

Note the pictographs fastened on the packing or on other visible places:

Top Handle with care Keep dry

Do not expose to Do not use hand- Fasten here

heat held grippers

Dimensions and weight

Approx. weight of brake control 1.1 kg, packing not included.
For dimensions see delivery note.
For rough data see chapter 2.3. „Technical data“ of the operating manual.

Examination by customer on receipt of goods

Examine the delivered parts for completeness, damage or anything strange.

Report and document shipping damage

After receipt of goods make sure that there is no damage caused during
transport.

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OPERATING MANUAL 3. TRANSPORTATION AND STORAGE

Information
• Immediately document the damage noticed (drawing, photograph,
description of damage).
• Send the respective documents immediately to ThyssenKrupp
Aufzugswerke GmbH.

Unpacking
Information
• Dispose packing equipment in accordance with environmental
standards or make it available for further use.
• Special transport aids and transport contrivances shall not be sent
back to THYSSENKRUPP AUFZUGSWERKE GMBH but remain at
the customer.

Intermediate storage
• If the assembly is not mounted directly after delivery, carefully store it at
a sheltered place and see to it that it is provided with a humidity-proof
covering.
• Do not store the assembly in the open air. Parts without surface coating
lack long-time preservation. Oxidized connections and contacts impair
the correct functioning of the device.

Environmental conditions
Information
Storage: the ambient temperature during storage is assumed to be
maintained between 0 °C to + 50°C.
Maximum relative humidity of air shall not exceed 90 % (no moisture or
icing)
Operation: the ambient temperature at the final site of the machine shall
be maintained between 0 °C to + 50 °C and the relative humidity of air
shall not exceed 70 % (no moisture, no icing).

Thyssen Aufzugswerke GmbH 13 Issue 05.06

OPERATING MANUAL 4. MOUNTING AND INSTALLATION

4.1 Mounting

How to mount brake control 2

Screw the brake control 2 in the drilled holes on the side of the supporting
elbow of the control cabinet.
You can also use the drilled holes in front of the distance piece optionally.

Dimensions- fastenings:
103
85

6
30
Drilled holes Ø
43
10

120

174
180

Fig. 2

ThyssenKrupp Aufzugswerke GmbH 14 Issue 05.06

OPERATING MANUAL 4. MOUNTING AND INSTALLATION

4.2 Connection of brake control 2

How to connect
Attention: Before you start connecting the brake control, read the safety
information of chapter 1.2, in particular section „Use of brake control and
possible hazards“.

Mains voltage of brake control 2

Connect mains voltage 230 V AC to terminals L and N,
and protective conductor to terminal PE.

Brake magnet connection

Run contactors (see terminal diagrams 1 or 2) are provided for connecting
the brake magnets which are connected in series to terminals
10 – and 20 +.
On closing the run contactors terminal 22 will activate the saver circuit, which
will be active after approx. 1 second.

Designation of brake control 2 terminals

16 22 10 4 20 L N PE
Fig. 3
Examples of connection see figures 4 and 5

ThyssenKrupp Aufzugswerke GmbH 15 Issue 05.06

OPERATING MANUAL 4. MOUNTING AND INSTALLATION

4.3 Example of connection: pole-changing motor

65 100 27 68 0 (D 6.48 – N 006)
prevent temporary discontinuous operation when changing over from fast to slow operation.
2 dropout delayed, inductive contactors K02, K03 must be used for double disconnection to

Mains filter

Fig. 4 Pole-changing motor

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OPERATING MANUAL 4. MOUNTING AND INSTALLATION

4.4 Example for connection: variable-speed motor

65 100 27 68 0 (D 6.48 – N 006)
An additional relay contact K01 (e.g. from run contactor) is required for

Mains filter
disconnection.

Fig. 5 Variable-speed motor

ThyssenKrupp Aufzugswerke GmbH 17 Issue 05.06

OPERATING MANUAL 4. MOUNTING AND INSTALLATION

4.5 Settings of brake control 2

The rated output voltage (withstand voltage) can be changed through

potentiometer. The factory-set and sealed withstand voltage of 90 V shall not be
changed.

Mode of operation: brake control operation can be changed by re-setting

jumper X3.
The following versions are possible:

Jumper (bridge) X3 Mode of operation

1–2 Saver circuit active (180 V for 1 s, afterwards 90V)
2–3 No saver circuit (180V constant voltage)
Both open Saver circuit only (90V constant voltage)

Jumper X3 is set in position 1 – 2 on delivery.

Jumper X5 is also set in position 1 – 2 on delivery; setting shall not be changed.

Position of jumpers X3/X5, LED H1/H3 and visible type fuse E1 on board

X3
H3 3
2
H1 1 321
X5

20

E1 10
22
16

Fig. 6

Thyssen Aufzugswerke GmbH 18 Issue 05.06

OPERATING MANUAL 5. PUTTING INTO SERVICE

5. Putting into service of brake control 2

Note: The brake control is factory-assessed. As a safety precaution, the

brake control must be installed and checked for correct functioning before
the lift is put into service.

Inspection instruction for brake control 2:

• The brake control shall be installed and connected in accordance with the
operating manual.
• Varistor-type suppressor circuits are provided at the terminals of the
brake release magnets *)
• Set jumper X3 acc. to the respective mode of operation.
• Jumper X1 and X5 must be set between 1 – 2.
• Light-emitting diodes H1 and H3 must light up simultaneously with fast-
response brakes.
• After closing of contact element K01B or K01F (see chapters 4.3 and 4.4)
light-emitting diode H3 will be dark after approx. 1 second.
• Check output voltage by means of DC multimeter.

*) observe rated voltage

ThyssenKrupp Aufzugswerke GmbH 19 Issue 05.06

OPERATING MANUAL 6. SERVICING

6.0 Servicing of brake control

Brake control 2 is maintenance-free. However, checking in accordance with

the set mode of operation is recommended by means of the LED indicators
and the brake shoe movements in the course of the annual inspection.
See chapter 5 explaining, among others, the function of the LED indicators.
For position or arrangement of jumpers and LEDs see fig. 6.

ThyssenKrupp Aufzugswerke GmbH 20 Issue 05.06

OPERATING MANUAL 7. MAINTENANCE

7.1 Replacing of brake control 2

Installation instructions
Wiring has to be changed as described below if brake control 2 is to replace older braking
current supplies (BSV):
Note: position and function of the terminals described below see examples of
connection in fig. 4 and 5.

1. Terminal board of motor

Remove bridge between terminal 9 (brake magnet) and terminal N !
- This is very important, since otherwise brake control 2 will be destroyed --
Establish new connection between terminal 9 (brake magnet) and terminal 20
(brake control).
2. Control cabinet
- Connect terminal 4 (BSV) to terminal L (brake control 2)
and terminal 16 (BSV) to terminal N (brake control 2)
- Establish connection between PE (control) and terminal PE (brake control 2).
- Remove connection between terminal 28 (BSV) and terminal R (mains)
Establish connection between terminal 10 / 20 and 22 (brake control 2) acc. to
example of connection 65 100 27 68 0 (D6.48-N 006). See fig. 4 and 5

Please note corrected terminal diagram;

- 2-pole-switching generally applies to the new brake control 2 (semi-controlled bridges
with supply connection L/N/PE).
- This means that an additional earthing contact or auxiliary contact must be provided in
the circuit between terminal 20/brake control and terminal 9 on motor board.
Two dropout delayed/lagging earthing contacts must be used with pole-changing drives
(as shown in example of connection fig. 4), since otherwise temporary discontinuous
operation may occur when changing over from fast to slow operation.
An additional earthing contact (e.g. from run contactor) is required with controlled drive.

Installation instruction:
For installation instruction see chapter 5
(The assembly is factory-assessed)

See examples of connection for pole-changing (fig. 4) and variable-speed motors (fig.5).

ThyssenKrupp Aufzugswerke GmbH 21 Issue 05.06

OPERATING MANUAL 8. ANNEX

ThyssenKrupp Aufzugswerke GmbH 22 Issue 05.06

OPERATING MANUAL 8. ANNEX

Thyssen Aufzugswerke GmbH 23 Issue 05.06

ThyssenKrupp Aufzugswerke GmbH
Nr. 65 000 21 86 0

Ein Unternehmen von ThyssenKrupp Elevator

Bernhäuser Strasse 45
Issue 05/2006

73765 Neuhausen a. d. F.
Deutschland
Tel.: +49 7158/12-0
Fax: +49 7158/12-2585
E-Mail: [email protected]
www.thyssenkrupp-aufzuege.de