INSTALLATION GUIDE CONTROLLER HT06 SUMMARY CHAPTER DESCRIPTION “INTRODUCTION STARTUP OPERATIONS AUTOTUNE EMERGENCY OPERATION FAULTS STORAGE FAULT CODES. REALTIME INFOS. PROGRAMMING THE CONTROLLER HT06 LAYOUT LEGEND OF COMPONENTS: LEGEND OF TERMINALS It Sjoleol olor] jor|no]| INSULATION TESTS. Teyuel Rann pled Ho dec we jun Ve UNpee polite: IO6 Quick wer manvel—Losteciled 18 July 208\ s aM uy Asko Asconicti SpA. 4. INTRODUCTION To install the AsKo controller it is necessary to follows strictly the attached schomatic. ‘The schematic is divided in two parts: the first represents the internal circuits, the second all the connections that must be made during the installation. The terminals on the controller are divided by locations (safety chain, car, door operator, shaftiloors etc) 2. STARTUP OPERATIONS * Execute all the connections as shown in the page 01 of the second part of the circuit diagrams Gonnect ULS and DLS of the HT06 to OV Connect INS of the terminals with OV Gonneet 1 and 2 of the safety chain Connect between 2 and 5 of the safety chain the ALT inspection button Connect 5 and 8 of the safety chain Connect 8 with 10 of the safety chain de Gulch vier manuel Los! uly 2008 2GEARLESS TRACTION MACHINE | Pett:t Number:] PRODUCT MANUAL ___| page 1 of 24 OPERATION INSTRUCTIONS Date:08-6-12 GETM GEARLESS TRACTION MACHINE OPERATING INSTRUCTIONS (GETM1. 9-100A21) oe i yaa vitPart: Numbers} Page 2 of 22 Date:08-6-12 GEARLESS TRACTION MACHINE, PRODUCT MANUAL. OPERATION INSTRUCTIONS Contents General-usage to intended purpose— Type code~ Technical dat Product description- Earthing- 40. Operation and maintenance- General Maintenance intervals- 42, Brake~ Adjusting the bral Electrical connection~ Start-up ~~ Maintenance General instruction: Trouble shooting- 43. Dimension outline 44. connection diagram-Part:1 Number: Page 3 of 22 Date:08-6-12 GEARLESS TRACTION MACHINE PRODUCT MANUAL. OPERATION INSTRUCTIONS 4. Purpose Only qualified personnel are allowed to perform any panning, Installation oF maintenance work. The personnel must be trained for the job and must be familiar with the instalation, assembly, commissioning and operation ofthe product. Sufficient knowledge in lit construction is essential The Low Voltage Directive (LV) applies to lit motors, in consideration of amenciment Marking, Lift motors do not fall under the scope of Machinery Directive (MD). The LVD covers the respective Taquifements of the Machinery directive, Within the meaning of the MD, li motors are not machines but components to he built info machines. Their commissioning is prohibited until the requirements of the directive are satisfied by or upon integration of the motor into the final product. The regulations concerning operation, maintenance and inspection in accordance with the applicable safety regulations in it construction such as EN 81 “Safely rules for the construction and inetallaion of fits’, Part 1Electrc fifi", the “Technical rules for Its" and other relevant regulations shall be strictly observed. ‘The operator is responsible forthe proper installation ofthe motor with regard to safety requirements as wall as for its inspection and maintenance as specified inthe applicable regulations No liability can be ‘assumed for any damage caused by improper handling of any other acts which are not in conformity with these operating instructions and thus deter form the qualities of the product. Tn thie manual, the following pictograms are used to mark warning and important notes These pictograms must be observed. & (anger) means that death or serious injury to persons or serious damage to property will ‘cour unless the appropriate precautions are taken. 1s damage to property Qowasning means that death or serious injury to persons of ser may occur unless the appropriate precautions are taken: ® (Caution) means that injuries to persons or damage to property may occur unless the appropriate precautions are taken. ‘The three-phase lft motors are intended for use in an enclosed, lockable machine room to which only qualified personnel and personnel authorized by the client have ao75s8- &. 3% (Danger) » The instructions given in this manual or any ‘other instructions supplied must always be observed to avoid dangers or damage. * Check the proper functioning of the motor and the brake after installing the machine. = Repairs may only be carried out by the manufacturer or an authorized repair agency, unauthorized opening and tampering may lead to injuries to persons and property. ray (Warning) + The machines are not designed for direct connection fo the three-phase system ut are to be operated via an electronic frequency converter, Direct connection to the system may destroy the motor. Issued by: Approved by “This set supersede the same date:2, Type code ‘The type code of the machine is composed of series type cade and machine type code, 4. Series type code: include corporation code. sort code—GETM( from” Gearless Elevator Traction Machine” the first capital letter), max axes load code Cunit: t) and product series structural characteristic code. Such a: GEARLESS TRACTION MACHINE | Part:I PRODUCT MANUAL Numbers Page 4 of 22 OPERATION INSTRUCTIONS Date:08-6-12 “High surface temperatures may occur on the external parts of the machine. Therefore no temperature-sersitive parts may contact these parts or be attached to them, Protection against accidental contact should be provided, If required, * The twin shoe brake Is designed only as a holding brake for a limited number of emergency braking operations. It must not be used as a working brake. High voltages occur at the terminal connections during the operation of synchronous motors. xr om) IO For example: XT GETM1.9 or GETM1.9—Gearless Elevator Traction Machine axes loat |__.. product series structural characteristic code. Expressed by a capital letter or nothing. (See table 2) Machine's max axes load. By two numbers. (see table 1) — Sort code—GETM Corporation code. Expressed by two capital letter "XT" (XIZI TRUST) st fix DZD-Brake Table 1 Max axes load code Max axes load (t) a Code He 15 - aS tere i 1.9 1.9 _ ae 3.0 of 3.0 ee L tes 1 5.5 PS: there will be more code as the development of the products. Issued by: [Arnot ‘This sheet versed th same dt:GEARLESS TRACTION MACHINE PRODUCT MANUAL ‘Number:1 Page 5 of 22 Date:08-6-12 OPERATION INSTRUCTION: Table 2 product series structural characteristic code = aie aaa Fit Fix DZD-Brake Fix Fix DZD-Brake | ST-Brake for MRL | dishing-Brake | Shaft-Brake characteristic ; code [God A B ce D 2) machine type code: include series type code.main parameter coce(made up of rated speed code and rated load code) . product structural characteristic code and brake voltage rating code four parts. Such as: [eee LOCOLOO |__ Brake voltage rating code: number 1 to 4. 4-DC2V, 2-DC4ABV; 3—DC110V; 4—other- Product structural characteristic code: number “1” and "2", 1—fithandwheel_ 2—no handwheel Rated load code: arabie numerals (see table 4) ————— Main parameter code:made up of four characters. Rated speed code: rated speed X100 (see table 3) For example: XT GETM3.0-175D11 or GETM3.0-176D11 Gearless Elevator Traction Machine with handwheel and DZD brake. Made by Xizi Trust. ‘Axes load= 3t rated speed= 1.75m/s rated load=1000kg brake voltage rating=DC24v Table 3 rated speed code 1 Rated speed | 95 | gg | 4.0 | 15-475 | 175 | 20 | 2025 | 25 (mis) ce (ier Code | 060 | 063 | 100 | 175 | 175 | 200 | 50 | 260 [ Ps: there will be more code as the development of the products. [ssw apo This set np ese dtGEARLESS TRACTION MACHINE Parisi 3. Technical data Traction sheave: o 400 mm or # 450 mm Drive motor: synchronous motor ‘Number of pole pairs: 10,12,16 Thermal class: F Degree of protection: IP 40 Overioad capability: 2.5 fold Winding protection: triple PTC 150°C Machine ‘Typical number of carrying ropes and diameter: 4-o8mm, 6-210mm, 8-010mm Type GETM1.9-100A1 | Duty load (Kg) a Roping _| Rated speed (m/s) eH 4.0 | Rated torque _ (Nm) 486 Permissible load (Kg) 1850 Rated voltage (V) 290 Startup current (A) 22 motor | Rated current (A) 10.6 Rated power (kW) 43 Rated frequence (Hz) 18 Startup degree (Fh) 240 Brake 21-500 Brake = Rated voltage pe2av sheave | Traction sheave dia. (mm) | 420 | a PRODUCT MANUAL ‘Number:1 a Page 6 of 22 “| OPERATION INSTRUCTIONS _ | Pate:08-6-12 Table4 rated load code Rated loadikg) | 630 | 00 | e00 | 1000 [1150 | 1360 [1600 Code a |B | c¢ D E F GC | Ps:_ there will be more code as the development of the products: Issued by: Approved by: ‘This sheet supersede the same date:GEARLESS TRACTION MACHINE | Part: PRODUCT MANUAL Numbers] — Page 7 of 22 OPERATION INSTRUCTIONS _ | Pate:08-6-12 Number of rope 4 Rope dla (mm) 08 [ space betwoon of rope 2 Angle of notch (B) 7 96 weight (Kg) 320 ‘This document covers machines for elevator duty loads of 250 to 1600 kg _ and elevator speed of 1.0 to 2.5mis, There will be five configurations of the machine for this duty range. Machine 1.0mis 1.0mis 1.75mis 1.76m/s, 2.6m/s type A00kg 1000kg 1000kg 1600kg 1600kg Elevator } Duty Range | 250-400kg | 680-1000kg | @80-1000kg | 1000~1600kg | 1000~1600kg (kg) Elevator | Speed 1.0 1.0 1.54.78 1.61.78 20-26 Range (mis) i | 1.0m/s 400kg Duty Limits 450kg: ‘© Maximum Empty Car Weight = 650kg © Maximum Rise without compensation = 30m 1.0m/s 1000kg Duty Limits 100kg: Maximum Empty Car Weight=1600kg © Maximum Rise without compensation = 30m. © Maxlinum Rise =50m 1.76mis 1000kg Duly Limits 1100kg: © Maximum Empty Car Weight = 1600kg © Maximum Rise without compensation = 30m © Maximum Rise 4.75mis 1600kg Duty Limits 1600 © Maximum Empty Car Weight =2200kg © Maximum Rise without compensation © Maximum Rise =105m 2.5mis 16009 Duty Limits 1600 50m\ GEARLESS TRACTION MACHINE | Partst PRODUCT MANUAL, Number: 1 Page 8 of 22 ees e Date:08-6-12 * Maximum Empty Car Weight =2200kg ‘® Maximum Rise without compensation = 50m © Maximum Rise = 105m Brake monitoring contacts: Load ability of contacts: 110 VAC Ito 3A Mechanical life of contacts: § x 10° switching operations Degree of protection: IP 40 The table is applicable for an overall shaft efficiency of approx. 88 %. It lists a standard selection of machines. The lif and project data will be adapted to the actual site conditions and may deviate from the above values. 4, Product description The lift machines, series GETM, have been developed in line with the trend towards geartess lifts based on our experience in drive construction. “The compact flat-ype gearless lft machines are distinguished by their high efficiency, extremely low noise and the excellent operating characteristics of the three-phase synchronous motor. a (Warning) All our gearless lift machines are designed solely for use with electronic frequency converters. ‘Owing to the frequency converter supply, the starting currents of the motors are low, which makes it possible to install lit systems even in case of weak power systems. “The synchronous motor has been designed for various rated torques, based on soveral overall wwiathe, it can also be supplied for several rated speeds, which can then be further adapted to individual customer requirements. ‘The permanentfeld flattype synchronous motor comprises @ stator , a rotor and a machine base ‘The frame carries the wound stator core, against its inner surface, and envelops the core to form a potlike enclosure. The magnet ring comprising 10/12 /16 poles rotates within this enclosure. The magnet ring is centered on and fastened to the rotor_to transmi the motor torque. The traction sheave of spheroidal cast iron possesses a frictional and positive connection to the rotor. It Is optimized for different groove dimensions and carries the rotor brake drum for the external opposed shoe brake, The rotor with its shaft is arranged in the stator frame. It is carried in a sturdy ball bearing in the main bearing head and in a locating ball bearing at the other end. The traction sheave shaft is optimally designed for the high loads to be carried and has high fatigue strength. ‘The drive-specific measuring system Is arranged within the center of the machine behind the shaft. Itis connected using a signal plug connector. The electrical connection of the motor is made in terminal box where the temperature monitoring device is also connected. The brake system comprises a twin shoe brake with a centrally arranged brake magnet, The brake system is connected to the supply voltage via a control unit which is included in the scope of supply. The electrical connection is made in the control cabinet, The terminals for the brake monitoring Issued by: Approved by: ‘This sheet supersede the same de:GEARLESS TRACTION MACHINE PRODUCT MANUAL Numbers! Page 8 of 22 Date:08-6-12 OPERATION INSTRUCTIONS © Maximum Emply Car Weight =2200kg © Maximum Rise without compensation = 50m © Maximum Rise = 105m Brake monitoring contacts: Load ability of contacts: 110 VAC /to 3A, Mechanical life of contacts: 5x 10° switching operations Degree of protection: IP 40 ‘The table is applicable for an overall shalt efficiency of approx. 88 %. It lists a standard selection of machines, The lift and project data will be adapted to the actual site conditions and may deviate from the above values. 4, Product description The lift machines, series GETM, have been developed in line with the trend towards gearless lifts based on our experience in drive construction. The compact flat-type gearless lift machines are distinguished by their high efficiency, extremely low noise and the excellent operating characteristics of the three-phase synchronous motor. a (Warning) Alt our gearless lift machines are designed solely for use with electronic frequency converters, ‘Owing to the frequency converter supply, the starting currants of the motors are low, which makes it possible to install lift systems even in case of weak power systems, The synchronous motor has been designed for various rated torques, based on several overall widths, It can also be supplied for several rated speeds, which can then be further adapted to individual customer requirements. ‘The permanent base “The frame carries the wound stator core, against its inner surface, and envelops the core to form a potlike enclosure. The magnet ring comprising 10 /12 /16 poles rotates within this enclosure. The magnet ring is centered on and fastened to the rotor to transmit the motor torque. The traction sheave of spheroidal cast iron possesses a fiictional and positive connection to the rotor. it is optimized for different groove dimensions and carries the rotor brake drum for the external opposed shoe brake. “The rotor with its shaft is arranged In the stator frame. It is carried in a sturdy ball bearing in the main bearing head and in a locating ball bearing at the other end. The traction sheave shaft is optimally designed for the high loads to be carried and has high fatigue strength. The drive-specific measuring system is arranged within the center of the machine behind the shaft. Itis connected using a signal plug connector. ‘The electrical connection of the motor is made in terminal box where the temperature monitoring Id flat-type synchronous motor comprises a stator , a rotor and a machine device is also connected. The brake system comprises a twin shoe brake with a centrally arranged brake magnet. The brake sysiem is connected to the supply voltage via @ control unit which is included in the scope of supply. The electrical connection Is made in the control cabinet. The terminals for the brake monitoring Issued by: Approved by: ‘This sheet supersede the same diteParts] Number:l Page 9 of 22 Date:08-6-12 mien GEARLESS TRACTION MACHINE PRODUCT MANUAL OPERATION INSTRUCTIONS contacts are accommodated in a separate erminai box on the machine. “Tho brake can be released manually. if required, by operating the manual release fever. The braking torque can be adjusted to the specific needs, if necessary PY adjusting the two brake springs “The two ropes slip-off guards are used 10 prevent the ropes dap from the sheave groove. 5. Nameplates ‘The nameplate ofthe tit machine is on the motor frame. Example: daupeuy Carloss Traction lachine Series Type GETHS. 0 Rated RPK 95. x/nin Yotor Type GEMS. 0-100823 Pole 12 P Rated Poter «5 Frequmoy 20 Te Rated Vel 200 Y Rated Torque 550 Na foted ment 13 A Duty 240 P/h Insolation lass F Dinof Steare 400° mm Protectit ke Serial WO, 0506180 Date 06.03.27 6. Scope of supply «Lift machine GETM according 10 of order the specification (on shipping pallet) « Complete operating instructions + Delivary note 7. Transport and storage “The lt machines leave the factory In 2 faulloss condition after being tested. Make a visual check for any external damage immediately uPo” {heir arrival on site. If any damag> incurred in transit is found, make a notice of claim in the presence ofthe forwarder. necessary, do not put these machines into ‘operation. & (Danger) the eyebotts are designed for the specified machine weight, Le. itis not permitted to suspend additional loads. store the motors only in closed. ON dustfree, well ventilated and vibration- free room. ‘The time of reserve does not exceed 6 months, Once be ‘exceeded, you should inspect it No liability is assumed for any damage yesulling from improper handling of the machine. Approved by:GEARLESS TRACTION MACHI Part:1 PRODUCT MANUAL Numbers! __} Page 10 of 22 OPERATION INSTRUCTIONS | Pate:08-6-12 8, Installation 8.1 General Check the permissible base frame or foundation loads by calculation before installing the lift machine. & (Warning) the base frame must be sufficiently rigid to accommodate the bending and torsional forces occuring over the whole load range Place the machine on a plane surface with a permissible deviation from planeness not exceeding 0.1mm. Install the machine only In an enclosed machine room and take care to observe the relevant safety precautions. & (Danger) Fasten the machine on the frame with four M10 bolts of strength class 12,9(bolt tightening torque 860 N-m) Lift machines are generally provided with rope slip-off guards. After putting the ropes in place, adjust them so that the distance between the rope and the rope slip-off guard does not exceed 1.Smim. 8.2 Degree of protection Lift machines are designed with degree of protection IP 40, Make sure that the cable entries to the terminal boxes are sealed properly when making the electrical installation. 8.3 Ambient conditions The following ambient conditions must be ensured on site: Altitude: max.1000 m ‘Ambient temperature: 0...40°C ‘The deviation between voltage fluctuation and rated voltage does not exceed £7 % There is no corrosive and flammable gas in environment. ‘There are no lubricant and others on the surface of steel wire rope The angle of car and counterweight, the angle ‘of wheel wire rope on the traction, must meet the regulation 9.3.1.b in GB7588- Max.rel.humidity:85% at 20°C(n0 moisture condensation) Install the machine so that ventilation is not obstructed, i.e. sufficient heat dissipation by convection and radiation must be ensured. ‘Connect any separate fans carefully. Take care not to allow the outlet air, also from adjacent units, to be drawn in again directly. In the case of three-phase fans check that the direction of rotation Issued by Approved by: “This cheet supersede the same date: 9GEARLESS TRACTION MACHINE | Pavtst PRODUCT MANUAL Numbers1 _—_| Page 11 of 22 OPERATION INSTRUCTIONS | Pates08-6-12 corresponds with the arrow on the fan housing, The torque and power values indicated in the Technical data apply to the above ambient temperatures and altitudes. 9, Electrical connection 9.4 General Make the electrical connection after having installed the motor. Have this done by @ qualified electrician. Before starting any work on the motors, and particularly before opening any covers of active parts, make sure that the motor and plant have been property isolated. This refers also to any additional or auxiliary cirouits. & (canger) Thos safety rules to be applied are: + Disconnect the fift machine from the power supply. + Lock it against unintentional restarting. + Verify the safe isolation form supply + Earth and short (with voltages above 4,000V) + Safeguard or cover adjacent live parts. Connect the machine €0 that a permanent electrical connection is ensured. There must be no foreign bodies, dir or moisture in the terminal box. Seal the cable entry holes which are not needed a (Warming) The insulation system of the motors is designed such that they can be connected to aconverter with a maximum d.c. link voltage Usa max UP to max. 380 Volt Note: Ung nacis the maximum value of the d.c. link voltage which is only transient and approximately equivalent to the inception voltage of the braking chopper or of the energy recovery unit. 9.2 Motor connection / Winding protection ‘The electrical connection of the motor and the winding is made in a terminal box on top of the machine. ‘The main electric will be consisted of motor, thermostat, limit switch, speed transducer and stralght-low-electlcty (stopping-machine loop). The junction of the main machine, thermostat and limit ewitch are in the junction box. The wire of the speed transducer is inserted into the transducer. “The wire of the brake is in the wire box. The situation of terminal block in the junetion box is as follows. Issued by: Approved by: ‘his sheet supersede the same date:GEARLESS TRACTION MACHINE | Patt:1 Number:1 PRODUCT MANUAL Page io cee. OPERATION INSTRUCTIONS | Da's:08-6-12 9.3 Earthing For safety reasons, itis very important that the motor be properly and carefully earthed, a (Warning) Use the earthing screw provided on the housing! In addition, connect the protective, or earthing conductor in the terminal box. When using shielded power cables, make sure the cable shield metal contacts the motor frame over a large area, This is achieved e.g. by special cable glands provided for shield contact. 10.Operation and maintenance 10.1 General ‘The regulations concerning operation, maintenance and inspection in accordance with the applicable safety regulations in lift construction such as EN 81 "Safety rules for the construction and installation of lifts’, part 1: "Electric lifts’, the “Technical rules for lifts” (TRA 200) and other relevant regulations shall be strictly observed. ‘The operator is responsible for the proper installation of the motor with regard to safely requirements as well as for its inspection and maintenance as specified in the applicable regulations. ‘Maintenance is normally limited to the following: Check the traction sheave. Check the radial shaft sealing rings (no grease should penetrate form the rings, especially at the ND fend as it could contaminate the neighbouring brake surfaces), Inspect and service the emergency twin brake. Clean the motor surface. BQ qvaming) The tt operator is responsible for regular checks of the brake safety components and the traction sheave, and must include these components in his visual inspection schedules.GEARLESS TRACTION MACHINE] Petts PRODUCT MANUAL Number: Page 13 of 22 OPERATION INSTRUCTIONS | Date:08-6-12 40.2 Maintenance intervals The following maintenance activities are recommended to be performed: Check the thickness of the brake linings | Every sixmonths | See section 12.7.2 | Check the bearing noise Every six months ae Check the brake Every six months | See section 10.1 Check the traction sheave for wear Every six months | See section 12 ‘Cheok the traction sheave for tight seating | Every six months | See section 10.3 Check the electrical cables Every six months | See section 9 ‘Check the rope slip-off guard Every six months | See section 8.1. Clean the external machine surfaces Asrequirad | See section 12.7.5 10.3 Repairs, : Repairs other than those described in these operating instructions are not permitted to be performed by the lift filer/maintenance technician for liability reasons. The proper maintenance of the gearless lift machines requires adequately trained specialist personnel and specific devices and auxiliaries. (eet 411, Encoder 44.1 General ? . ‘The machine is equipped with a encoder from Heidenhain GmbH.'We recommend the use of an appropriate cable set to connect the measuring system fo the converter system Cable sets can be supplied as accessories.GEARLESS TRACTION MACHINE Part:} ‘ PRODUCT MANUAL Number:1 uf Page 14 of 22 “81” | OPERATION INSTRUCTIONS — | Date:08-6-12 11.2 Measuring system ERN 1387, Periods per rotation: 2048 Operating voltage: 5V Data interface: yr EnDal = - Encoder | Shielded XE CONNECTOR PIN type cable 1 2)3 4 5 6 |7 8 9 10 | 14 12 13 B. 2+ | 2- | At | A- | OV | Bt | SV | Sin-| Sin+ | Cos+ | Cos- ERN1387 12 i a 5a 4b | 4a | 6b | 2a | 5b | 3b | 1b |1a | 7b 2b ba ECN 1313 Periods per rotation: 8192 Operating voltage: 5V Data interface: ssi or EnDal Encoder | Shielded XE CONNECTOR PIN type cable | 1 [2] 3 [4] 5 |] a] 12 43 | 14 | 18 Fee 7 - 3 | DATA : ECN1313. 42 5V | OV | At | A. B+ | B. CLOCK+ | CLOCK- | DATS DATA- 6a | 3a | 2a | Sb] 4a | 3b-| 2b | ba eb- | ta | ERN 1321 Periods per rotation: 4096 Operating voltage: 5V Data interface: ssi or EnDal Encoder | Shielded XE CONNECTOR PIN. + aus A | type cable 4 2 3 4 5 6 7 8 9 ov | +5V A A B B- Zz Ze BRN1321 8 Eco fa 2a 6b 6a 5b Sa 4b 4a 41.3 Installation of Encoder ‘The conicity, which is on the axle of the Encoder, Is connected with rotor shaft by bolt. The details steps as follows: Open the back-cover of the Encoder, then put shaft collar into, connect by the bolt. Approved by: ‘This sheet supersede the same datoGEARLESS TRACTION MACHINE *) Pavtsd PRODUCT MANUAL, ‘Number:1 an Page 15 of 22 Date:08-6-12 OPERATION INSTRUCTIONS NOTE: The bolt must be tightened, or else, will cause the error of speed Encoder. Then, tighten the small bolt of speed Encoder by hexangular spanner not to make speed Encoder shake, After confirmation, insert the wire of speed Encoder into insert, the put ferrule onto the cover of the cover plate, then cover it, twist the bolt. NOTE: Contact ferrule and cover plate closely, or else it maybe cause the disturbance, 12. Brake 42.4 General & (Waring) Brakes are safety devices! Only qualified personnel are allowed to perform any assembly, adjust. “The braking torque data listed in our documents are based on a friction coefficient of the friction lining of =0.42. This value applies to the following operating conditions: Protect the friction surfaces from oil or grease, rain, splash water, snow and ice. Ensure that the brake linings do not come into contact with solvent-containing media, Radial run out of the brake drum, including form deviations of max 0.02 mm.. Deformation of the brake drum resulting from the application force of the brake shoes max.0.1 mm Brake drum surface with a surface roughness of not less than Ra = 3.2mm Brake drum steady-state temperature: max. 180°C Brake linings must be properly bedded-in, the carrying surface percentage must be at least 60%. 12.2 Assembly Before use this manual, please reading the schema, and realize each part's name. (tools: 13# spanner, 8# spanner(2), multimeter, plug gauge) Machine tool oe Issued by: Approved by ‘This sheet supersede the seme date D .- GEARLESS TRACTION MACHINE | Pavtsl PRODUCT MANUAL Number: Page 16 of 22 OPERATION INSTRUCTIONS | Pate-08-6-12 Friction surface 2, bolt 3, cover board 4, MB nut S. MB bolt 6, microswitch Z,base 8 MB bolt ax Turn bolt) to connect base(7) and cover board(3), end fiting brake on machine frame. Adjust IMB bol(8) to make friction surface(1) cling on rotor surface, adjust bolt(2) to make the clearance between base(7) and cover board(3) to 0.2mm. & (Warning)slacken bott(2) before adjust. b. tutn on DC110V power, turn bolt(8) to adjust the clearance between friction surface and rotor surface from 0.10mm to 0.1mm, then turn off power, and turn bolt(2) to cling machine frame, and adjust the clearance between base(8) and cover board(3) from 0.3mm to 0.5mm, & (Waming)make the clearance between base and cover board equably. Turn on power again, and used plug gauge to check the clearance between ftiction surface and rotor surface, it should be 0.10mm~0. 15mm. x ifs right, then tighten bolt(8), $0 the adjusting is finished. d, ifits not fitthe require, do step "b’ again. a (Warning)which bolt has to be adjusted according to purpose. 4k bolt); fit the brake on machine frame and control the clearance between friction surface and rotor surface. 2, bolt(2): Control the base’s(7) station. 12.3 Adjusting Work state: tum off brake power, microswitch is normal close; turn on brake power, microswitch is normal open. adjusting: Connect the cable of micro switch to touchpen of multimeter. Tum on brake power Adjusting bolt(S) fo press the actuating button of microswiteh while it act. And the microswitch is normal close. Tum off brake power, and used muifimeter to chack the state of microswitch, if's normal close, then the adjusting is finished, and tock the nut(4). a (Warning)Keep the bolt(S) still when lock the nut(4). tf microswitch is normal open, then adjust bol(6) to make it turn to normal close, and do step “b,o,d" several times,.. a (Werning)its important to check the state of microswitch after locked nut(4)»_ and compare to normal state. Tse Approved by [rst sper i tePari:1 Number:1 _| Page 17 of 22 Date:08-6-12 GEARLESS TRACTION MACHINE PRODUCT MANUAL OPERATION INSTRUCTIONS. 12.4 Electrical connection 12.4.1 General ‘All work on the braking system may only be carried out by qualified personnel, Ensure thal the system is disconnected from power when making electrical connections. & (Warning) Note the details stated on the rating plate, in the wiring ciagram provided in the motor terminal box or in the operating manual. ‘When carrying out any connection work, always make sure that: = The connecting cables comply with the type of installation and with the voltages and currents, occurring. + Sufficiently dimensioned connecting cables, forsionel, shear and strain relief as well as antikink: protection for the connecting cables are provided. «The protective conductor (only for protection class 1) has been connected to the earth terminal. + There are no foreign bodies, dirt or moisture in the motor terminal box. Cable entties not used and the terminal box itself are sealed to prevent the ingress of dust or water. 12.4.2 Monitoring the brakes ‘The switching state and wear of the brakes are monitored by means of dust ~ proof micro switches «with gold contacts. The contacts are designed as a contacts, ie. the contact is opened Ifthe armature ig attracted (brake released). On demand it is possible to change the contacts of micro switch on position n.o. contact. 12.6 Start ~ up % (Danger) Make sure that the functional test of the brake is only carried out when the motor is at rest, Has been disconnected from the supply and is secured against inadvertent restarting ‘After making the electrical connection of the braking system, perform a functional test to check the {ree running of the brake drum by turning the motor shaft (with the braking system energized and the motor de-energized). After installing the brake, make sure that any covers and protection devices are installed. a (Warning) Surface temperatures of > 100°C may occur in the braking system. For this reason, no temperature — sensitive parts such as normal cables or electronic components may be routed to ‘or fixed to the braking system. Provide appropriate protection against accidental contact, if necessary. If the motor shaft needs to be tumed during adjusting work release the braking system electro magnetically or if necessary by means of manual release, sued by: Approved by: “This sheet supersede the seme date: ;GEARLESS TRACTION MACHINE | Part:1 PRODUCT MANUAL ‘Number: Page 18 of 22 Date:08-6-12 OPERATION INSTRUCTIONS. 12.6 Maintenance £ (Danger) when doing any inspection or maintenance work, make sure that no inadvertent starting of the motor is possible ‘no load moment is acting on the brake drum or on the motor ‘after completion of the inspection and maintenance work, the interlocking preventing inadvertent starting of the motor is cancelled all surfaces providing friction are free from oil or grease, itis not possible to clean an oily or greasy brake lining, 412.7 General instructions When doing inspection or maintenance work, also check the following Tight seating of all bolt and screw connections Condition, setting and operating readiness of all switches: Cleanness and easy running of all bearings Condition and cleanness of the ffiction surface and the brake linings 12.8 Trouble shooting Fault Possible cause Remedy Braking system does not | Braking torque set too large Check and adjust dimer release Braking system not energized Check electrical connection —_| Voltage applied at excitation | Check supply voltage to winding too low excitation winding Brake shoes mechanically blocked | Remove mechanical blocking Overexcitation rectifier defective | Replace rectifier Braking system releases | Braking torque set too large Check and adjust dimension, with delay Voltage applied al excitation | replace brake shoe, if required. winding too low Check supply voltage to coll. Braking system does not | Vollage at excllation winding too | Check excitation winding voltage engage high after switching — off (residual | for residual voltage. voltage) Remove mechanical blocking. Brake shoe mechanically blocked Braking system engages | Coll vollage too high Check supply voltage to coll with delay Switch-off time too short with a.c. | Control with de. side switching __| side switching of the overexctation rectifier. Approved by: This sheet supersede the same date:Partsd Number:1 Page 19 of 22 Date:08-6-12 GEARLESS TRACTION MACHINE PRODUCT MANUAL OPERATION INSTRUCTIONS xa Ee [s [on] ea KT L [Mine GEIM1.S—100A1 | 308 | 358 [408 | 698 | 224/443 |118 [420] 4-918 | 82 | 50 105 | 205 | 265| 60 GEMM1.9- 10042 _|308 | 358 [408 |698|224|443] 0 [420] 4-918 | 82 50 | 103 | 203 | 265 | 60 Issued by: Approved by: “This sheet supersede the same dateBrake Power (Machine) ~4 power leads : Brake frame to ground: Brake Switch #1 — 2 power leads (10 - 20Vde) and 4 switch output: Brake Switch #2~ 2 power leads (10 - 30Vdc) and 4 switch output: Release device Switchi#3—2power leads(10-30Vde)and 1 switch output GEARLESS TRACTION MACHINE — | Parts] PRODUCT MANUAL pembet Poe Page 20 of 22 OPERATION INSTRUCTIONS | Date:08-6-12 14.Connection diagram The electrical interfaces to the machine are as follows: Motor leads — 3 leads: uv, W Motor frame to ground: G Motor PTC thermal protectors — 2 leads: PTC-1-M1, PTC-4-M12 Bt+, B1-B2+,82- BG BS1-in, BS1-out BS2-in,BS2-out BS3-in, BS3-out Connectors or terminal blocks and boxes shall be provided on the machine and brake for all electrical connections. MOTOR CONNECTION BRAKE. CONNECTION Issued by: Approved by: “This sheet supersode the same date:SEARLES TRACTION MACHINE Parl PRODUCT MANUAL. Number:1 w——| Page 21 of 22 OPERATION INSTRUCTIONS _ | Pate-08-6-12 BStin BS2in BStout+BS2out BS3in BS3out BRAKE CONNECTION ee Approved by: ‘This sheet supersede the same date:GEARLESS TRACTION MACHINE | Part: PRODUCT MANUAL Number:1 Pago 22 of 22 Date:08-6-12 MOTOR connection cable BStin stout BS2hn Bszaut < Bt a1 B24 B2- BS3in BS3out 5 brake connection cable Approved by: “This sheet supersede the same date:Machine Components with | Part! Engineering improvement | Numbers] Page | of 2 Adjusting Manual Appen Appendix Adjustment and Maintenance Manual of Lever Device for Disk Brake Notice: 1) Please read this manual carefully before installation, operation and maintenance, in case of tie broken of equipment 2) Every clearance, mandrit and reed of the fever had been adjusted before ex-work, adjusting by customer is not allowed if unnecessary 3) Ifadjustment is required, must be conducted by professional, alther adjust according to stated range —. Main parts of Lever device for disk brake: This device is made up of § main parts, 1, Mandril 2, Bracket 3, Reed = 4 Lit 5. cover 6. back up block 7, hexagon thin nut back up block MS hexagon thin nut Issued by: Approved by: ‘This sheet supersede the same date:Machine Components with | Part:! ‘i ‘Number: Engi eering improvement Page 2 of 2 Adjusting Manual Appendix —y Adjustment and Maintenance 1) Adjust the travel of Lever device for brake: After fixing the bracket with limit switch and reed, you can adjust the position of mandril to change the travel of lever device so as to he sure about the limit switch working reliably. 2) Problem and management during the adjustment and maintenance: 1. Readjusting because of the inadequate travel of mandril Loosen the hexagon nut of mandril, move the lever alittle ahead (Each movement is no more than 0.1mm, otherwise the reed will be distortion, the max. travel of mandril should less than 0.3mm, can measure the travel of mandril with dial indicator, then screw down one of the setscrew, open the brake, check whether the limit switch work reliably (Repeat checking 3-4 times), after insuring the switch work reliably, screw down hexagon nut 2, Over travel of the mandril lead to over travel of the lever, fault to restore of the switch, broken out. Loosen the hexagon nut of mandril and turn the lever , move the lever alitile ahead, then screw down hexagon nut, open the brake, check whether the limit switch work reliably (Repeat in nut checking 3-4 times), after insuring the switch work reliably, screw down hexagon 3, Regular maintenance Is required to be done for the lever device annually, deal with the problem in time. 4. Especially pay attention to the status of reed during the maintenance. Issued by: Approved by: ‘This sheet supersede the same date: