WITTUR servogearless WSG-S1.5 User manual

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WITTUR Holding GmbH
Rohrbachstraße 26-30 • -85259 Wiedenzhausen, Germany
Tel. [phone] • Fax [phone]
http://www.wittur.com, E-mail: [e-mail]
servogearless
Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 1
Subject to changes without notice ! Subject to changes without notice !
EN
Gearless Lift Machines
WSG-S1.5
Reprinting, translation or reproduction in any form -
whether in part or in full - requires the prior written
permission of WITTUR Holding GmbH.
Wittur Holding GmbH reserves the right to make
changes in the information and pictures contained in
these operating instructions without prior notice.

Offenburger Str. 3
-01189 resden
Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.wittur-edrives.de
Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 2
Subject to changes without notice ! Subject to changes without notice !
EN
These operating instructions are
applicable to lift machines:
WSG - S1.5 - ....
WITTUR Electric rives GmbH reserves the right to correct or
change the contents of this manual and these product details
without prior notice. We expressly reserve the right to make
technical changes which improve the lift machines or their
safety standards without prior notice. No liability can be
accepted for damage, injuries or expense arising therefrom.
We cannot guarantee the correctness and completeness of the
details.

Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 3
Subject to changes without notice ! Subject to changes without notice !
EN
Contents
1. General information............................................................................................................................4
1.1. About this operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2. Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3. Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4. Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2. Safety instructions...............................................................................................................................4
2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2. Format of the safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.3. Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Product description ............................................................................................................................6
4. Transport and storage ........................................................................................................................7
5. Installation ..........................................................................................................................................8
5.1. Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.2. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5.2.2. Motor connection / Winding protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5.2.3. Speed/Position measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.2.4. Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
6. Commissioning ..................................................................................................................................17
7. Operation and maintenance ..........................................................................................................18
7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
7.2. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
7.3. Regreasing the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.4. Replacing the traction sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.5. Emergency evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
7.6. Testing the brake system to EN 81-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
7.7. Replacing the measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.8. Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
8. Type code.............................................................................................................................................24
9. Technical data ....................................................................................................................................25
10. Dimension drawing............................................................................................................................26
11. Accessories..........................................................................................................................................27
11.1. Connecting cable for measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
11.2. Cable set for motor and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
11.3. Brake manual release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
11.4. Rope guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
12. Spare parts .........................................................................................................................................31
Annex
EU eclaration of Conformity
Calculation of the traction sheave shaft
Traction sheave shaft
Calculation of the traction sheave shaft (traction sheave: 160 mm)
Traction sheave shaft (traction sheave: 160 mm)
EU type-examination certificate EU-B 975
Brake operating instructions

Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 4
Subject to changes without notice ! Subject to changes without notice !
EN
1. General information
2. Safety instructions
2.1. General
WSG-S1 lift machines are not ready-to-use products; they may only be operated after they have been installed
in lift systems and their safe operation has been ensured by taking the appropriate measures.
WSG-S1 lift machines are intended for use in an enclosed, lockable operating area to which only qualified
personnel and personnel authorised by the customer have access.
1.1. About this operating manual
The purpose of this operating manual is to ensure that any work on WSG-S1 lift machines is carried out safely.
Please regard it as part of the product and keep it within easy reach.
All persons working on or with WSG-S1 lift machines must have read and understood this operating manual.
1.2. Intended use
WSG-S1 lift machines are intended for use as gearless drives for rope lifts. They may only be used for their
intended purpose and with all safety devices in proper working order.
They may only be operated under the conditions described in this manual and with due regard to their perform-
ance limits.
1.3. Scope of delivery
The WSG-S1 lift machines are customised to meet individual requirements. The exact scope of delivery can be
found in the accompanying documentation.
1.4. Warranty and liability
Our "Conditions of Sale and elivery" shall apply for all our supplies and services.
Any warranty claims must be made immediately upon discovery of the deficiency or defect.
We do not accept any warranty or liability claims for personal injury or property damage resulting from one or
more of the following causes
• Improper use of the WSG-S1 lift machine
• Improper installation, commissioning, operation or maintenance
• Operation of the WSG-S1 with defective and/or inoperative safety or protective devices
• Non-compliance with the instructions contained in the operating manual or other documentation supplied
• Unauthorised construction modifications to the WSG-S1
• Insufficient monitoring of parts subject to wear
• Repairs carried out improperly
• Emergencies caused by external forces or force majeure

Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 5
Subject to changes without notice ! Subject to changes without notice !
EN
Qualified personnel
Only qualified personnel are authorised to perform any planning, installation or maintenance work, and this
must be done in accordance with the relevant instructions. The personnel must be trained for the job and must
be familiar with the installation, assembly, commissioning and operation of the product.
2.2. Format of the safety instructions
The safety instructions contained in this operating manual are presented in a standardised format.
They comprise a danger symbol + signal word + instruction text. The danger symbol indicates the type of dan -
ger, the signal word specifies the severity of the danger, and the instruction text describes the danger and
explains how to avoid it.
Danger symbols
Signalworte
•DANGE Serious injuries or death will result
•WA NING Serious injuries or death may result.
•CAUTION Minor to moderate injuries may result.
•NOTICE Property damage may result.
•Information Points out useful information.
2.3. Safety precautions
• 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 authorised repair agency. Unauthorised opening
and tampering may result in injuries to persons and property.
• The machines are not designed for direct connection to the three-phase system but are to be operated via an
electronic frequency converter. irect connection to the mains may damage the motor beyond repair.
• High surface temperatures may occur on the external parts of the machine. Therefore, no temperature-sensi -
tive parts may be in contact with these parts or attached to them. Protection against accidental contact
should be provided, if required.
• The EU type-examined fail-safe brakes provided are designed only for a limited number of emergency brak-
ing operations. They must not be used as working brakes.
• If the motor is not energised, no torque is produced. This may result in uncontrolled acceleration of the lift,
if the brakes are released. Therefore, the motor winding should be short-circuited to produce a speed-depen -
dent braking torque while the motor is not supplied with current. (Use the main contacts for short-circuiting
as rated motor current may be flowing.) The motor must never be short-circuited while it is energised.
• High voltages are present at the terminal connections during the operation of synchronous motors.
Risk of electric shock Property damage
General danger Information

1 2 3 5 7 46 8 11 910 12 13 14 15 16 17
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Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 6
Subject to changes without notice ! Subject to changes without notice !
EN
The compact gearless WSG-S1 synchronous lift machines are designed for traction sheave lifts. They are distin-
guished by their high efficiency, extremely low noise and excellent operating characteristics.
The machines can be supplied for several rated speeds, which can be further adapted to meet individual cus -
tomer requirements. The machine comprises a frame, the synchronous motor, the traction sheave, and the
type tested safety brake, which can be used to prevent uncontrolled upward movement of the car.
The nameplate of the lift machine is on the motor frame.
3. Product description
Type code of lift
machine
Rated voltage Rated speed
Rated torque
Serial no.
Rated frequency
Weight
rive-Code
Item Part WSG-S1.5
1 Bolts (3x) M8x30 - 10.9
2 Lock washers (3x) NL 8- IN 25201
3 Pressure disc
4 Bolts (2x) IN 912 - M8x20
5 Rope slip-off guard
6 Washers (2x) IN 125 - A 8,4
7 Traction sheave
8 Frame
9 Brake BFK 464-22S
10 Bolts (6x) IN 912 M 10 x 110
11 Locking ring
12 Plug-in shaft
13 Screws (3x) IN 912 - M 4x10
14 Clamping sleeve
15 Screws (4x) IN 912 - M 6x25
16 Measuring system
17 Cylinder-head screw IN 912 M 5x50

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Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 7
Subject to changes without notice ! Subject to changes without notice !
EN
4. Transport and storage
• The lift machines leave the factory in perfect condition after being tested.
• Make a visual check for any external damage immediately upon their arrival on site. If any damage is found
to have occurred in transit, make a notice of claim in the presence of the carrier. If appropriate, do not put
these machines into operation.
• Observe the relevant safety regulations and take the centre of gravity into account when handling the lift
machines.
• Check that the eyebolts are tightly fitted before using them.
• o not expose the motor to any shocks or impact.
Storage
• Store the motors only in closed, dry, dust-free, well-ventilated and vibration-free rooms (storage tempera -
ture: -20°C to 60°C). o not store lift machines in the open air. Bright parts are not sufficiently preserved to
withstand extended periods of exposure.
• Avoid excessive storage periods (recommendation: max. one year).
• After prolonged storage (>3 months), rotate the motor in both directions at a low speed (< 20 min-1) to
allow the grease to distribute evenly in the bearings.
• Measure the insulation resistance before initial operation of the machine. If the value has dropped below
1kper volt of rated voltage, the winding needs to be dried (insulation meter voltage: 1,000 V C).
• This can be done, for instance, with hot air, in a drying oven, or by applying a C voltage to the motor con-
nections. Make sure that the voltage selected does not exceed the values shown in the figure " rying the
winding". Let the temperature rise to about 70 – 80°C and maintain it for several hours.
WA NING The eyebolts are designed for the specified machine weight, i.e. additional loads must not be
applied. anger of breakage!
Drying the winding
Unpacking
• ispose of the packaging material in an environmentally friendly manner or reuse it.
• Any special transport aids or shipping braces are left with the customer.

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Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 8
Subject to changes without notice ! Subject to changes without notice !
EN
5. Installation
5.1. Setting up
• The machines can be used in lift systems with or without a machine room
• The permissible uneveness of the mounting surface is 0.1 mm. The mounting surface must be sufficiently dis -
tortion-resistant and stable to accommodate the forces occurring in the system.
• The rope force can be applied to the lift machine in any direction
• The machine must be mounted on vibration dampers for vibration damping
• No welding work may be performed on the lift machine, nor is it permissible to use the machine as a mass
point for welding work. This might cause irreparable damage to the bearings and magnets.
• If there are more grooves on the traction sheave than the number of ropes used, position the ropes either in
the centre of the traction sheave or towards the motor end.
DANGE Be sure to use calculations to check the base frame or foundation loads before installing the
lift machine.
WA NING Cover the machine and especially the brakes when doing any machining or dust-producing
work in the shaft or machine room.
When using the machine in a shaft, please take into account the patent situation.
• The measuring system is only accessible from the rear side. Therefore, leave enough space between the wall
and the rear side of the machine or ensure that the machine can be moved away from the wall.
Securing the machine
• Fasten the machine using 4 M 20 bolts - strength class 8.8; tightening torque: 395Nm .
• After completing the adjusting work or after a breakdown, tighten all the fastening bolts of the machine,
using the specified torque .
• Lift machines are generally equipped 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 1.5 mm.
• If the lift machine is not installed at the head of the machine room as is usually the case, it may be necessary
to modify the fitting of the rope slip-off guard to fulfill the requirements of EN 81-20 . Optional rope slip-off
guards are available for this purpose.

0,6
0,7
0,8
0,9
1,0
1,1
1,2
0102030405060
Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 9
Subject to changes without notice ! Subject to changes without notice !
EN
Ambient conditions
• The following ambient conditions must be ensured
on site
Altitud: max. 1,000 m a.s.l.
Ambient temperature: -5°C ... 40 °C
Max. rel. humidity: 85% at 20°C
(no moisture condensation)
• Install the machine so that ventilation is not obstruct ,
ed, i.e. sufficient heat dissipation by convection and
radiation must be ensured.
• The torque and power values indicated in the techni cal
data apply to the above ambient temperatures and
altitudes. In the case of a deviating altitude and/or
temperature, the reduction factors k shown in the dia-
gram "Ambient conditions" must be used.
Mpermiss = k * MN
Ppermiss = k * PN
Ambient temperature [°C]
Factor k
Altitude < 1000 m
Altitude < 2000 m
Altitude < 3000 m
5.2. Electrical connection
5.2.1. General
• Before starting any work on the machines, ensure that the lift machine or system is properly isolated.
Before making any electrical connections check that
• the connecting cables are suitable for their specific application and for the relevant voltages and currents.
• sufficiently dimensioned connecting cables, torsion, strain and shear relief, as well as anti-kink protection are
provided
• the protective conductor is connected to the earthing terminal
• there are no foreign bodies, dirt or moisture in the terminal boxes
• cable entries not in use and the terminal box itself are tightly sealed to prevent the ingress of dust or
splash ing water.
CAUTION The insulation system of the motors is designed such that they can be connected to a con-
verter with a maximum C link voltage Ulink max up to max. 700 V C.
Ulink max is the maximum value of the C link voltage which is only transient and approxi -
mately equivalent to the inception voltage of the braking chopper or of the energy recovery
unit.
The maximum permissible rate of voltage rise (dU/dt) at the motor terminals is 4kV/µs. The
overvoltage at the motor terminals must not exceed 1.56 kV. It may be necessary to use
motor current filters or reactors to achieve these values.
WA NING The electrical connection may only be made by a qualified electrician.

M
Pin Signal
1 U1
A
B
C
D
1
2
3
4
2 PE
3 W1
4 V1
A
B
C
Gearless Lift Machine
WSG-S1.5
Operating Instructions
Code GM.8.003649.EN
ate 27.04.2016
Version 0.03
Page 10
Subject to changes without notice ! Subject to changes without notice !
EN
5.2.2. Motor connection / Winding protection
• The electrical connection of the motor and the winding sensors is made in the terminal box, by power con -
nector or by cable (standard length: 5 m).
• The motor cable must be shielded. Ensure that the cable shield contacts the frame over a large area at both
ends.
• The motor phases U1, V1 and W1 must be connected correctly to the corresponding phases of the converter;
they must not be interchanged.
• We recommend using a converter with a switching frequency of 12 kHz.
• The PTC resistor embedded in the winding must be evaluated in an appropriate manner in the control system
or the frequency converter to protect the motor from overheating.
1. Terminal box2. Plug connection
not assigned
not assigned
temperature
sensor
Blick auf die Stiftkontakte
der Anschlussdose (von
außen)
temperature
sensor
As an option, the electrical connection of the
motor and the winding temperature sensors
is made by a rotatable 8-pole power connec-
tor provided on the motor. A type B ST A 078
FR 05 08 0035 000 connector from
"intercontec" can be used, for example, as
the female plug.
WAGO 262
Cable cross-section: ... 4 mm2
Stripping length required: 9-10 mm
Triplet PTC
Type STM-150. S...
Screw plugs 2 xM16 and 1 xM20
2xM16 Cable gland
for cable diameter 5-10 mm
M 20 Cable gland
for cable diameter 7-12 mm