Hollister-Whitney Elevator Corporation
Contents
1. T ba Symbol designating Symbol designating an 153 an action that might A action that might be dan gerous to human safety Symbol designating an elec A trical action that might be dangerous to human safety 2 1 Precautions and restrictions on use 21 Restrictions on use TA forthe brake to comply with directive 95 16 EC the installer must observe the general conditions for installations and use as defined in the EC type certificate ref ABV 769 of 14th October 2005 drawn up by the TOV Munich including the mandatory use of a speed limiting device in compliance with EN 81 1 paragraphs 9 9 and 9 10 10 This brake is designed to work in dry conditions Friction faces must be kept completely clean of i grease or abrasive dust which might deteriorate their performances If maximum rotation speeds are exceeded the guar antee is no longer valid This brake must not be dismantled This brake may only be used in a horizontal axis The customer must be careful not to alter the fac torySet airgap and the working clearance of the brake and the hand lever Ti This brake is designed for a maximum ambient tem 25 perature of 40 C insulation class 155 C The maximum temperature in continual use is 100 Ti This brake is designed for static applications Any p 1c dynamic braking is restricted to emergency braking and test braking This brake2. W Hollister Whitney Elevator Corporation Hollister W r Fax 217 222 Hollister Whitney Elevator Corporation Repair and Maintenance Manual Warner Brakes GL100 GL115 GL130 and GL170 Gearless Machines Bulletin 1159 Page 1 of 17 Hollister Whitney Elevator Corporation NOTE The Warner Brake is no longer supplied on OEM GL Machines All Current Manufacture GL Machines are supplied with MAYR BRAKES If it is necessary to replace your Warner Brake a Mayr Brake of equivalent Size will be substituted BEFORE PERFORMING ANY MAINTENANCE ON THE MACHINE BRAKES TAKE ALL THE NECESSARY SAFETY PRECAUTIONS TO IMMOBILIZE THE CAR AND COUNTERWEIGHT TO PREVENT ANY UNINTENDED MOVEMENT DURING THE MAINTENANCE PERIOD THAT MAY RESULT IN INJURY OR DEATH READ THE ENTIRE BRAKE REPLACEMENT PROCEDURE BEFORE BEGINNING ANY OF THE STEPS OUTLINED BELOW CONTACT HOLLISTER WHITNEY WITH ANY QUESTIONS PRIOR TO BEGINNING THE BRAKE REPLACEMENT BEFORE OPENING ANY ELECTRICAL ENCLOSURES ON THE MACHINE REMOVE ALL ELECTRICITY FROM THE MACHINE AND BRAKES TO PREVENT ELECTRICAL SHOCK THAT MAY RESULT IN INJURY OR DEATH DURING THE MAINTENANCE PERIOD Table of Contents L Checking Brakes IL Basic Service a Brake Adjustments b Brake Switch Adjustments i Procedure 1 Warner Manual Brake Release Adjustment Brake Removal Warmer Brake Disassembly amp Cleaning Brake Install Mayr Warner Manual o equipped Bulletin 1159 Page 2 of 17
3. 5 2 Grounding To be compliant with VDE 580 the customer must ground the brake see Fig 1 G rounding screw and safety washer supplied WARNER ELECTRIC EUROPE Rue Champfleur B P 20095 F 49182 St Barth lemy d Anjou Cedex SM381gb rev 10 07 sE 6 Spare parts Part Partnumber Freton pads BT 712 095538 Microswitch BT 787000455 7 Tools Tools Function Feeler gauge Iargap amp microswhch adjustment Open jawed spanner 1E mm ATF largap adjustment Torque wrench measurement range gt 50 Wn wit open ended spanner atachement 18 mm AJF Airgap adjustment Open jawed spanner 8 mm ATF Microswitch adjustment Maimeter Wotage checking 8 Troubleshooting Fau Tause Remedy Brake does not release Supply voltage too low Power supply is interrupted Airgap too large Wom friction pads Collis damaged Airgap too small Overexcitation time too short Check and adjust supply voltage Reconnect power supply check the adjustment of micraswitch Re adjust the airgap chapter 4 1 Replace pads Replace the brake Re adjust the airgap chapter 4 1 Increase overexcitation time Brake does not engage Voltage present at switch off position Grease on friction faces Hand release lever actuated Check the microswitch s adjustment and the customer s power supply Clean the disc and replace the brake Release the lever Nuisance braking Holding
4. Hollister Whitney Elevator Corporation L CHECKING BRAKES While it may be Inconvenient to Check Brakes especially on Machine Room less applications MRL S Inconvenience is NOT an excuse Brakes should and MUST be checked On Gearless Machines the Main Service Brake and the Emergency Brake can be the same type of Brake and can have same Pick Voltage the same Hold Voltage etc Be sure all Brake Switches are Operational and NEVER ignore a Brake or Brake Switch Failure or worse an Unintended Motion Fault FIND THE CAUSE of the Fault or Failure Brake Failure Some Possible Causes 1 Dirt or Dust in the Air Gap of the Brake Dirt or Dust in the Air Gap may cause the brake to not fully open when picked and this in turn can cause the Brake to drag on the Rotor cause premature wear on the Brake Pad and ultimately wear out the Brake Pad Use Compressed Air to blow the Dust and Dirt out of the Air Gap The Brake should be Disassembled and Cleaned once a year See Section II e 2 The Brake Pick Voltage may be set too low Check the Pick Voltage when the Brake is hot The Voltage to Pick a Cold Brake is different than the Voltage to Pick a Hot Brake If the Brake does not fully Pick it may cause Excessive Lining Wear and eventual Failure of the Brake 3 The Brake Hold Voltage may be set too low If the Brake Hold Voltage is set too low the Brake may relax or even fall out after the initial Pick If the Brake relaxes or falls
5. in case of large temperature variation any risk of sticking from the friction material able to hindrance the start of the drive Data for customer friction disc Material steel 150 to 250 HV or cast iron thickness of the friction disc 15 mm 0 0 1 roughness of the friction faces Ra lt 3 2 Protection dry phosphatizing or Nitriding Geometric tolerances J Pulley axis TEF Data for mounting pins Material steel min 900 N mm2 diameter 25h8 roughness Ra lt 0 8 Protection dry phosphatizing or Nitriding u 01 Support ans Pulley axis WARNER ELECTRIC EUROPE Rue Champfleur B P 20095 F 49182 St Barth lemy d Anjou Cedex SM381gb rev 10 07 m 3 3 1 Hand lever configuration According to the hand lever side of actuation the custo mer must fit the pins for limitation of the hand lever travel in the selected position Dimension of the pin out of the magnet 6 max see Fig 7 Release right 3 3 2 Installation The brake is delivered pre assembled with pre set microswitches and airgaps Engage the brake armature attracted under voltage or with hand release on his disc Hand release Connecting bar Conduit box Counter nut Mounting pins A Friction disc Screws for airgap adjustment Fig 4 Mountthe mounting pins then the connecting bar and tighten with the indicated torque for the locknuts T5
6. previously noted Reassemble Brake Coil Assembly to the Caliper Guide and complete Electrical Connections e Adjust Brake as Necessary for 0 01 Air Gap Brake Replacement Mayr See Bulletin 1158 Section II and IV at hutp www hollisterwhitney com tech support g Warner Brake Service Manual See Following Document Bulletin 1159 Page 16 of 17 Hollister Whitney Elevator Corporation THIS SPACE INTENTIONALLY BLANK Bulletin 1159 Page 17 of 17 MANNEN i SM381gb rev 10 07 Electrically Released Brakes ERS VAR11 01 FT 3600 N EC type certificate ABV 769 According to drawing 1 12 106881 WARNER ELECTRIC EUROPE Rue Champfleur B P 20095 F 49182 St Barth lemy d Anjou Cedex Warner T l 33 0 2 41 21 24 24 Fax 33 0 2 41 21 24 00 Electric www warerelectric eu com We WARNER ELECTRIC EUROPE 7 ue Champfleur B P 11095 F 49182 St Barth lemy d Anjou Cedex declare thatthe brakes made in our factory from St Barth lemy d Anjou and hereafter designated ERS VAR1I 01 Fully comply with directive 95 16 EC on Lifts and are intended far incorporation into an installation or for assembly with other equipment with he aim of constituting a machine subject ta the application of directive 98 37 EC and the directive on Elecvomagnetic Compatibility 89 336 modified Compliance withthe basic requirements ofthe Low Voltage Directive 73 23 modifed is guaranteed by our full compliance with the f
7. 7 This brake may only be used in a horizontal ais 4c The customer must be careful not to alter the work ing Clearance of the brake and the hand lever 4 Maintenance 4 1 Adjusting the airgap AA Check the airgap at each maintenance inspection Tsp Reminder This brake is intended fora static appli c cation as a safety brake Any dynamic braking is restricted to emergency and test braking Normal use will not lead to any noticeable wear on the lining The airgap adjustment must be reset before A LA the max airgap is reached This to ate any functional problems because of the hand release travel Slide two feeler gauges 0 3 mm thick in the airgap avoiding the dampers between the armature and the magnet Fig 5 Energize magnet Tighten the airgap adjusting screws H M12 18 A F until you reach contact with a torque of 2 Nm Tighten the counter nut 18 A F with a torque of 40 Nm 4 Nmin holding the screw to avoid it rotating WARNER ELECTRIC EUROPE Rue Champfleur B P 20095 F 49182 St Barth lemy d Anjou Cedex SM381gb rev 10 07 a Checking airgap area see Fig 6 Checkin ap Fig 6 42 Adjusting the microswitch Remove the conduit boxto reach the airgap Slide a feeler gauge 0 10 mm thick near the screw between the face of the magnet and the moving armature Switch on the current and t
8. as shown in Figure 1 The air gap should be 0 015 If the air gap does not measure 0 015 loosen the lock nuts B and use the adjustment screws to set the air gap to 0 015 To REDUCE the air gap turn the screws INTO the housing To INCREASE the air gap turn the screws OUT of the housing Both screws must be adjusted to keep the air gap equal on both sides of the brake After the air gap is set re tighten the lock nuts B Figure 1 Bulletin 1159 Page 4 of 17 Hollister Whitney Elevator Corporation Brake switch adjustments When the brake switch is clamped on the rotor de energized the brake switch should NOT be actuated To adjust the switch clamp the brake on the rotor de energize and follow the appropriate procedure below i Warner Tools required 8mm wrench or adjustable wrench Referring to Figure 2 loosen the lock nut A Adjust screw B ZN until the switch is barely actuated by pin C Once the switch is actuated turn screw B back OUT by 1 6 of a turn so the switch is no longer actuated Re tighten lock nut A and test the brake and switch operation Figure 2 cover removed for clarity Bulletin 1159 Page 5 of 17 Hollister Whitney Elevator Corporation Manual brake release adjustments if so equipped Tools required 3 8 wrench or adjustable wrench Leave the manual brake release handle in the at rest With the b
9. can in no way replace the safety braking system used during lift descent Tim When connecting the conduits on the conduit box see Fig 4 the customer must avoid any restraint able to prevent the sel floating of the brake 22 Pres d n measures ZA During maintenance make sure that the mecha nism to be braked by the brake is stopped and that there is no risk of it accidentally starting up All inter vention have to be made by qualified personnel owning this manual JR Any modification made to the brake without the L express authorisation of a representative of Wamer Electric in the same way than any use out of the contrac tual specifications accepted by W amer Electric will result in the warranty being invalidated and Wamer Electric will no longer be liable in any way with regard to conformity When switching on DC side the coil must be protected against voltage transients This brake is delivered in standard packaging that will keep itintact for a period of 6 months during ground air or sea transport towards neighbouring continents without crossing the tropics 3 2 Handling TE Avoid any impact to the brake so that its perform 4c ance is not impaired o gt Never lift the brake by its cables 33 Installation mounting TE In case of long storage check the brakes before t t setting the drives in order to avoid
10. ighten the adjusting screw H M5 8 A F in contact with the microswitch until you reach the trip point Fig 7 Check that itfunctions correctly by switching the power on and off several times ensuring the microswitch is activated correctly Microswitch detection screw Detection screw Airgap stroke measure Microswitch Operation microswitch Current range 10 mA min to 100 mA max at 24 VDC Maximum electrical lifetime of the microswitch ensure only by switching under resistive load Microswitch Red 5 Electrical connection Brake ERS VAR 11 01 operates on a direct current sup ply Polarity does not affect the way the brake operates 5 1 Important recommendations FA All works on the electrical connections have to be made with power off T5 ake sure thatthe nominal supply voltage is always 4c maintained A lack of power results in a reduction to the maximum airgap Jp Emergency braking for emergency braking the D switching 0 FF must be connected on DC current side in order to obtain short engaging time of the brake Service braking for service braking the switching O FF and the switching ON must be connected on AC current side in order to obtain silent switching The connecting wires must be thick enough to help prevent sudden drops in voltage between the source and the brake Tolerances on the supply voltage at the brake terminals 5 10 NF C 79 300
11. ke Shoe Plate and Coil Assembly Bulletin 1159 Page 11 of 17 Hollister Whitney Elevator Corporation 1 Hollister Whitney Parkwa Fax 2 Clamp Brake Coil Assembly shut with 2 C Clamps Unbolt the Brake Release Lever Note this bolt is under some spring pressure Care should be taken when releasing Take note of small parts and ball bearings Bulletin 1159 Page 12 of 17 Hollister Whitney Elevator Corporation 1 Hollister Whi Quincy Ph Release C Clamps evenly and remove Brake Shoe Plate from Coil Assembly Bulletin 1159 Page 13 of 17 Hollister Whitney Elevator Corporation 1 Ho Whitn y IL Fax 217 222 0493 Remove Compression Springs 8 Compression Washers 8 Brake Lever Spring and Plastic Brake Shield Bulletin 1159 Page 14 of 17 Hollister Whitney Elevator Corporation 1 Hollister Whitney Parkwa Fax 217 2 Using Brake Cleaner Scouring Pad and Putty Knife as necessary clean faces of Brake Shoe Plate and Coil Assembly and clean Guide Pins and Holes When Clean and Dry reassemble taking care not to forget the Compression Washer under each Compression Spring Bulletin 1159 Page 15 of 17 ter Whitney Elevator Corporation To reassemble the Brake Lever use the 18mm Socket to help compress the Brake Lever Bolt to get the nut started Use Medium Strength Threadlocker on all Bolted Connections Retighten Brake Lever Bolt to the Air Gap
12. ollowing Standards NFC 79300 and VDE O580 B 65 Drawn up in St Barth lemy d Anjou uly 2002 E PRAT General Managing Director CONTENTS w Q 1 Technical specifications 2 4 Maintenance 4 2 Precautions and restrictions on use 3 41 Adjusting the airgap 4 21 Restrictions on use 3 42 Adjusting the microswitch 5 22 Precautions and safety measures 3 5 Electrical connection 5 3 installation 3 51 Important recommendations 5 3 1 Transport storage 3 52 Grounding 5 32 Handling 3 6 Spareparts 6 33 Installation mounting 34 7 Tools 6 3 3 1 Hand lever configuration 4 8 Troubleshooting 6 3 3 2 Installation 4 1 Technical specifications Hand release Grounding screw M5 count Rr Stes PS for airgap rae nuts adjustment Airgap Holes for mounting pins Customer s friction disc Fig 1 Fig 2 Tabie 1 Warner Electric Part Number ERS VARII O1 Tangential force of braking N 1800 to 3600 according version Maximum linear speed outside disc m s 8 Nominal airgap mm 0 3 0 1 0 Maximum airgap after wear mm 06 Overexcitation voltage voc a8 103 207 Holding voltage voc 24 52 103 Resistance Ohm 144 608 210 Power overexcitation wW 160 176 204 Power holding w 40 445 51 Cyclic duration factor ED 60 Weight kg 143 Maximum force on the hand lever N 1000 WARNER ELECTRIC EUROPE Rue Champfeur B P 20085 F 49182 St Barth lemy d Anjou Cedex SM381gb rev10 07 26 damage the brake
13. out it may cause Excessive Lining Wear and eventual Failure of the brake 4 The Manual Release Arm may not be adjusted properly Check for at least 1 4 of an inch of movement in both directions when the Brake is Not Energized If this Arm is set too tight the proper pressure on the Brake Pads may not be achieved If the proper Brake Pad pressure is not applied the brake may not be able to Hold the Car To Test Connect the Manual Release to the Emergency Brake ONLY With the Car at the Top Landing with the Doors Closed open the Emergency Brake and make sure the Main Service Brake holds the car Then with the Car at the Bottom Landing put 125 load in the Car and Open the Emergency Brake and make sure the Main Service Brake holds the car Repeat the test with the Manual Release connected only to the Main Service Brake Bulletin 1159 Page 3 of 17 Hollister Whitney Elevator Corporation IL BASIC SERVICE a Brake adjustments Tools required 3 4 wrench or adjustable wrench and 0 0 The air gap on the brakes is preset from the factory at 0 01 After burnishing the air gap must be re verified and adjusted as necessary to ensure proper brake operation Before you check or adjust the brake air gap clamp the brake on the rotor de energize All adjustments and measurements will be made with the brake clamped on the rotor de energized Check the air gap at location A on both sides of the brake
14. rake base holding the entire brake assembly to the housing Refer to Figure 9 Move brake assembly to a work area then remove brake from base See figure 10 Bulletin 1159 Page 9 of 17 Hollister Whitney Elevator Corporation e Warner Brake Disassembly and Cleaning Warner Brakes are prone to dust generation and contamination Prior to disassembly blow out brake with Compressed Air Spray Brake Cleaner into Air Gap and blow dry with Compressed Air If performance of Brake Does Not return to normal proceed with Disassembly and Cleaning Minimum Tools Required 1 4mm 8mm amp 10mm Allen Wrenches 2 Ratchet with 18mm Socket 3 Phillips Head Screw Driver 4 2x 3 C clamps 5 Putty Knife 6 Compressed Air Can 7 Brake Cleaner Spray 8 Nonmetallic Scouring Pads 9 Clean up Cloth or Rags 10 Medium Strength Thread Locker Bulletin 1159 Page 10 of 17 Hollister Whitney Elevator Corporation 1 Hollister Whitney Parkwa Quincy IL Phone 21 Disassembly amp Cleaning Disconnect Brake wires inside Terminal Box on Machine Disconnect Conduit from Terminal Box on Machine Remove 2 Screws from Junction Cover on Brake Remove 3 Bolts from Front of Brake that holds Brake Coil Assembly to Caliper Guide Remove Brake Coil Assembly to a convenient work table It may be convenient to remove the Conduit and Junction Cover from the Brake Coil Assembly at this time Measure and Note the Air Gap between the Bra
15. rake release handle un actuated adjust nut cable but not tight enough to actuate the manual release arm on the brake Once the slack has been removed tighten the jam nut B against the adjustment nut Figure 19 Actuate the manual brake release handle to ensure the brake opens manually and returns to the clamped position when the handle is returned to the at rest position Bulletin 1159 Page 6 of 17 Hollister Whitney Elevator Corporation ister Whitney Parkwa F Quincy IL d Brake Removal BEFORE PERFORMING ANY MAINTENANCE ON THE MACHINE BRAKES TAKE ALL THE NECESSARY SAFETY PRECAUTIONS TO IMMOBILIZE THE CAR AND COUNTERWEIGHT TO PREVENT ANY UNINTENDED MOVEMENT DURING THE MAINTENANCE PERIOD THAT MAY RESULT IN INJURY OR DEATH BEFORE PERFORMING ANY MAINTENANCE ON THE MACHINE BRAKES REMOVE ALL ELECTRICITY FROM THE MACHINE AND BRAKES TO PREVENT ANY UNINTENDED MOVEMENT THAT MAY RESULT IN INJURY OR DEATH DURING THE Tools required Flat small screwdriver for terminal blocks pliers or flat large screwdriver for conduit nut 3 16 hex key 3 8 hex key 3 8 wrench 11 16 wrench or adjustable wrench hammer and punch Before removing the old brake from the machine verify the new brake is the same model and voltage as the brake that is being replaced If the new brake is different than the brake being replaced contact Hollister Whitney For machines equipped with the Hollister Whitney man
16. ual brake release cable begin by removing jam nut A nut B and washer C Then loosen nut D Refer to Figure 5 Figure 5 Bulletin 1159 Page 7 of 17 Hollister Whitney Elevator Corporation 1 Hollister Whitne Quincy IL Once the manual brake release cable hardware has been removed and loosened slide the brake release cable out of the brake Refer to Figure 6 Figure 6 manual brake release cable removed After the manual brake release cable has been completely removed it is time to disconnect the electrical wires to the brake BEFORE REMOVING ANY WIRES FROM THE ELECTRICAL ENCLOSURE WRITE DOWN THE WIRE COLORS AND TERMINAL BLOCK DESIGNATIONS FOR FUTURE REFERENCE THIS INFORMATION WILL BE NECESSARY WHEN CONNECTING THE WIRES FOR THE NEW BRAKE After writing down the wire colors and terminal block designations remove the proper brake wires from the terminal blocks and remove the conduit nut A Refer to Figure 7 Bulletin 1159 Page 8 of 17 Hollister Whitney Elevator Corporation 1 Hollister Whitn Quincy IL ne 21 Once the wires have been removed from the electrical enclosure Loosen do not remove the 3 brake retaining bolts A on the front of the brake itself 1 bolt may be behind tag as shown in Figure 8 This will allow for removal of brake without having to energize the brake Bolt behind tag Figure After the loosening brake bolts remove the 4 bolts in the b
17. voltage too low State of microswitch incorrect Check and adjust the holding voltage Re adjust the microswitch Subject to alteration without prior notice WARNER ELECTRIC EUROPE Rue Champfleur B P 20095 F 49182 St Barth lemy d Anjou Cedex SM381gb rev 10 07 oo
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