WITTUR WSG-18 Series User manual

Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
Seite/page 1
Datum/date 14.02.2006
Stand/version 0.17
Änderungen vorbehalten! Subject to changes without notice!
MADE BY
SAD GmbH
A MEMBER OF WITTUR
Reprinting, translation or reproduction in any form -
whether in part or in full - requires the prior written
permission of WITTUR AG.
Wittur AG reserves the right to make changes in the
information and pictures contained in these operating
instructions without prior notice.
WITTUR AG
Rohrbachstraße 26-30 • D-85259 Wiedenzhausen, Germany
Tel. [phone] • Fax [phone]
http://www.wittur.com, E-mail: [email protected]
58 00 000 0250 ba_wxg18_e17 14.02.2006
English
Gearless Lift Machines
WSG-18.1
WSG-18.2
WSG-18.3
WLG-18.A
WLG-18.B
WLG-18.C
liftgearless

Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
Seite/page 2
Datum/date 14.02.2006
Stand/version 0.17
Änderungen vorbehalten! Subject to changes without notice!
MADE BY
SAD GmbH
A MEMBER OF WITTUR
These operating instructions are
applicable to lift machines:
WSG-18. ....
WLG -18. ....
System Antriebstechnik Dresden 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 stan-
dards without prior notice. No liability can be accept-
ed for damage, injuries or expense arising therefrom.
We cannot guarantee the correctness and complete-
ness of the details.
Offenburger Strasse 3
01189 Dresden
Tel. [phone]
Fax [phone]
[email protected]
www.sadgmbh.de

Änderungen vorbehalten! Subject to changes without notice!
MADE BY
SAD GmbH
A MEMBER OF WITTUR
Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
1. General safety instructions..................................................................................................................4
2. Product description ...............................................................................................................................6
3. Nameplate................................................................................................................................................6
4. Scope of supply ......................................................................................................................................8
5. Transport and storage...........................................................................................................................8
6. Installation...............................................................................................................................................9
7. Electrical connection...........................................................................................................................10
7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
7.2. Motor connection / Winding protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
7.3. Speed/Position measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
7.3.2. Measuring system ERN 1387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
7.3.1. Measuring system ECN 1313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
7.3.3. Measuring system ROD 426 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
7.4. Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
8. Commissioning.....................................................................................................................................17
9. Operation and maintenance .............................................................................................................18
9.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
9.2. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
9.3. Lubricating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
9.4. Fan filter mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
9.5. Replacing the traction sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
9.6. Emergency evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
9.7. Testing the brake system to EN 81-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
9.8. Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
9.9. Replacing the measuring system (ECN / ERN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
9.10. Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
10. Type code.............................................................................................................................................27
11. Technical data WSG-18 ...................................................................................................................28
12. Dimension drawing WSG-18..........................................................................................................29
13. Technical data WLG-18 ...................................................................................................................30
14. Dimension drawing WLG-18 ..........................................................................................................31
15. Accessories..........................................................................................................................................32
15.1. Connecting cable for measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
15.2. Rope clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
15.3. Return motion device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
15.4. Cable set for motor and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
16. Spare parts..........................................................................................................................................35
17. EC type-examination certificate....................................................................................................36
Seite/page 3
Datum/date 14.02.2006
Stand/version 0.17
Contents

1. General safety instructions
Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
Explanation of symbols used in these instructions
means that death or serious injury to per-
sons or serious damage to property will
occur unless the appropriate precautions
are taken.
means that death or serious injury to per-
sons or serious damage to property may
occur unless the appropriate precautions
are taken.
means that injuries to persons or damage
to property may occur unless the appropri-
ate precautions are taken.
points out important information and
operating instructions. If these are not
observed, damage, hazards or faults may
result.
Intended use
The WxG-18 lift machines have been manufactured in
compliance with the latest state of the art and recog-
nised safety regulations. They may only be used for the
purpose for which they are intended, and with all safety
devices in proper working order.
The WxG-18 may only be used for driving lifts. "Intend-
ed use" also requires that the instructions contained in
the documentation supplied with the machine and the
commissioning instructions be observed, and that the
specified inspection and maintenance work be carried
out.
Warranty and liability
Our "Conditions of Sale and Delivery" shall apply for all
our supplies and services.
We do not accept any warranty or liability claims for per-
sonal injury or property damage resulting from one or
more of the following causes:
• Improper use of the WxG-18 lift machine
• Improper installation, commissioning, operation or
maintenance
• Operation of the WxG-18 with defective and/or inoper-
ative safety or protective devices
• Non-compliance with the instructions contained in the
operating instructions or other documentation sup-
plied
• Unauthorised construction modifications to the WxG-18
• Insufficient monitoring of parts subject to wear
• Repairs carried out improperly
• Emergencies caused by external forces or force majeure
Safety precautions
Only qualified personnel are authorised to perform any
planning, installation or maintenance work, and this
must be done in accordance with the relevant instruc-
tions.
The personnel must be trained for the job and must be
familiar with the installation, assembly, commissioning
and operation of the product.
The WxG-18 lift machines are intended for use in an
enclosed, lockable machine room to which only qualified
personnel and personnel authorised by the customer
have access.
Seite/page 4
Datum/date 14.02.2006
Stand/version 0.17
Änderungen vorbehalten! Subject to changes without notice!
MADE BY
SAD GmbH
A MEMBER OF WITTUR
Danger
Warning
Caution
Note
• The instructions given in this manual or
any other instructions supplied must
always be observed to avoid danger or
damage.
• WxG-18 lift machines are not ready-to-
use products; they may only be operated
after they have been installed in lift sys-
tems and their safe operation has been
ensured by taking the appropriate mea-
sures.
• Check the proper functioning of the
motor and the brake after installing the
machine.
Danger

Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
Seite/page 5
Datum/date 14.02.2006
Stand/version 0.17
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MADE BY
SAD GmbH
A MEMBER OF WITTUR
• Repairs may only be carried out by the
manufacturer or an authorised repair
agency. Unauthorised opening and tam-
pering 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. Direct connection
to the mains may destroy the motor.
• High surface temperatures may occur on
the external parts of the machine. There-
fore, no temperature-sensitive parts may
be in contact with these parts or
attached to them. Protection against
accidental contact should be provided, if
required.
• The EC type-examined fail-safe brakes
provided are designed only for a limited
number of emergency braking operations.
They must not be used as working brakes.
• High voltages are applied at the terminal
connections during the operation of syn-
chronous motors.
Warning

Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
The compact flat-type gearless WxG-18 lift machines are
designed for gearless traction sheave lifts with machine
room. They are intended for operation with a 2:1 or 1:1
suspension and are distinguished by their high efficiency,
extremely low noise and excellent operating characteris-
tics.
The WxG-18 gearless lift machines are designed solely for
use with electronic frequency converters.
The synchronous motor has been designed for various
rated torques, based on a number of overall widths. It
can also be supplied for several rated speeds, which can
then be further adapted to meet individual customer
requirements.
The machine comprises a grey cast iron frame (11), the
three-phase motor, traction sheave (4) and shoe brake
(1).
The shaft is very sturdily designed to accommodate the
high loads acting on the traction sheave. At the D end, it
is supported in a robust self-aligning roller bearing (6).
Six threaded holes (6) are provided on the front end
periphery, permitting a mechanical return motion device
to be fitted in case of an emergency.
The stable D end shield (5) is of spheroidal cast iron. At
the ND end the shaft is also carried in a self-aligning
roller bearing (15) which is preloaded by means of a cup
spring. The bearing is incorporated in ND end shield (13)
of grey cast iron. The two bearings are sealed with inter-
nal and external shaft sealing rings.
A separately driven low-noise fan (10) is mounted on top
of the ND end shield. The terminal box is arranged on
the right-hand side (viewed facing the shaft).
The mounting flange on the ND end shield incorporates
the speed/position measuring system (16).
The brake is connected to a AC- system via a control unit
which is included in the scope of supply. This over-exci-
tation rectifier can be installed, for example, in the con-
trol cabinet. The terminals for the brake monitoring con-
tacts, the motor terminals and the temperature detector
monitoring contacts are accommodated in the terminal
box.
The brake can be released manually, if required, by oper-
ating the manual release lever. The braking torque can
be adapted to the specific needs, if necessary, by adjust-
ing the two brake springs.
No brake lining wear occurs, since in modern drive equip-
ment such brakes are under friction only in an emer-
gency. Normally they are only applied when the machine
is at rest.
Seite/page 6
Datum/date 14.02.2006
Stand/version 0.17
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MADE BY
SAD GmbH
A MEMBER OF WITTUR
2. Product description
3. Nameplate
Type code of
lift machine
Rated current Rated speed
Rated torque
Serial no.
EC type-examination
certificate
Rated frequency Weight
The nameplate of the lift machine is on the motor frame.

Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
Seite/page 7
Datum/date 14.02.2006
Stand/version 0.17
Änderungen vorbehalten! Subject to changes without notice!
MADE BY
SAD GmbH
A MEMBER OF WITTUR
13
15
14
16
12
1110
1 Shoe brake
2 Rope slip-off guard
3,14 Hydraulic-type lubricating
nipple
4 Traction sheave
5 D end shield
6 Self-aligning roller bearing
7 Cheese head bolt
8 Brake hub
9Key
10 Fan
11 Machine frame
12 Rotor
13 ND end shield
15 Self-aligning roller bearing
16 Measuring system
1
3
2
7
6
5
4
9
8
13
15
14
16
12
1110
1
3
2
7
6
5
4
9
8
WLG-18
WSG-18
1 Shoe brake
2 Rope slip-off guard
3,14 Hydraulic-type lubrica-
ting nipple
4 Traction sheave
5 D end shield
6 Self-aligning roller bearing
7 Cheese head bolt
8 Brake hub
9Key
10 Fan
11 Machine frame
12 Rotor
13 ND end shield
15 Self-aligning roller bearing
16 Measuring system
NDE DE
NDE DE

5. Transport and storage
The lift machines leave the factory in perfect condition
after being tested.
Make a visual check for any external damage immediate-
ly upon their arrival on site. If any damage incurred in
transit is found, make a notice of claim in the presence
of the carrier. If necessary, do not put these machines
into operation.
Transport
Observe the relevant safety regulations and
take the centre of gravity into account
when handling the lift machines.
The motor has to be hung up at the 4 carrying rings that
way, that the load angle αis always ≤45° between the
ropes.
The eyebolts are designed for the specified machine
weight, i.e. it is not permitted to suspend additional
loads.
Storage
Store the motors only in closed, dry, dust-free, well-ven-
tilated and vibration-free rooms (storage temperature:
-20°C to 60°C). Do 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 (>3months), rotate the motor in
both directions at a low speed (< 20min-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 < 1kΩ
per volt of rated voltage, the winding needs to be dried
(insulation meter voltage: 1,000VDC).
Unpacking
Dispose of the packaging material in an
environmentally friendly manner or reuse
it.
Any special transport aids or shipping
braces are left with the customer.
Warning
Note
This can be done, for instance, with heated air, in a dry-
ing oven, or by applying a d.c.voltage to the motor con-
nections.
Make sure that the voltage selected does not exceed the
values shown in the figure
"Drying the winding" . Let the
temperature rise to about 70 – 80°C and maintain it for
several hours.
u
v
w
A
I≈65% IN
-
U
Drying the winding
Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
Seite/page 8
Datum/date 14.02.2006
Stand/version 0.17
Änderungen vorbehalten! Subject to changes without notice!
MADE BY
SAD GmbH
A MEMBER OF WITTUR
4. Scope of supply
•Lift machine WSG-18/WLG-18 according to order
specification (on shipping pallet)
•Brake control unit
•Complete operating instructions
•Delivery note
Options:
•Return motion device
•Rope clamp
•Connecting cable for measuring system
•Cable set for motor and brake
Rope slip-off guard

Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
Be sure to check the base frame or founda-
tion loads by calculation before installing
the lift machine.
The lift machine may only be installed if the relevant
safety precautions have been met. The machines can be
used in lift systems with a machine room.
The machines may only be installed, electrically connect-
ed and put into operation by trained specialist personnel.
The system-specific conditions and the requirements of
the system manufacturer or plant constructor must be
met.
Cover the machine and especially the
brakes when doing any machining or dust-
producing work in the shaft or machine
room.
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.
Degree of protection
The lift motors are designed with degree of protection
IP23M / IP125, i.e.
M : during operation
S: at rest.
The traction sheaves are provided with holes for the
cooling air circuit and with external fins for stiffening.
Therefore, take special care.
When making the electrical installation, make sure the
cable connections to the terminal boxes are sealed tight-
ly.
Ambient conditions
The following ambient conditions must be ensured on
site:
Altitude: max. 1,000m a.s.l.
Ambient temperature: - 5...40°C
Max. rel. humidity: 85% at 20°C (no moisture con-
densation)
Install the machine so that ventilation is not obstructed,
i.e. sufficient heat dissipation by convection and radia-
tion must be ensured.
The torque and power values indicated in the Technical
Data apply to the above ambient temperatures and alti-
tudes. In case of a deviating altitude and/or ambient
temperature, the reduction factors k shown in the dia-
gram below must be used.
Mpermiss. = k * MN
Ppermiss. = k * PN
Fastening the machine
The rope force can be applied to the lift
machine in any direction.
The machine or base frame should be
mounted on rubber pads for vibration
damping.
The machine is fastened using 8 M20 bolts (strength
class 8.8; tightening torque: 395Nm).
The permissible uneveness of the mounting surface is
0.1mm. The mounting surface must be sufficiently dis-
tortion-resistant and stable to accommodate the forces
occurring in the system.
After completing the adjusting work, tight-
en the 8 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 dis-
tance between the rope and the rope slip-
off guard does not exceed 1.5mm.
If the machine is not installed in the
machine room "on top" of the shaft, the
installation of the rope slip-off guards may
have to be modified. In this case, optional
rope slip-off guards are available that can
be fitted to the foot area of the machine.
Seite/page 9
Datum/date 14.02.2006
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MADE BY
SAD GmbH
A MEMBER OF WITTUR
6. Installation
Danger
Warning
Note
Note
0,6
0,7
0,8
0,9
1,0
1,1
1,2
0 102030405060
Ambient temperature in °C
Factor k
Altitude < 1000 m
Altitude < 2000 m
Altitude < 3000 m
Danger
Note

Gearless Lift Machine
WSG-18 and WLG-18
Operating Instructions
7.1. General
The electrical connection may only be made
by a qualified electrician.
Before starting any work on the machines,
ensure that the lift machine or system is
properly isolated.
Before making any connections check that
•the connecting cables are suitable for their specific
application and for the relevant voltages and currents.
•the sufficiently dimensioned connecting cables and
torsion, strain and shear relief as well as anti-kink pro-
tection are provided
•the protective conductor (Protection Class I only) is
connected to the earthing terminal
•there are no foreign bodies, dirt or moisture in the ter-
minal boxes
•cable entries not in use and the terminal box itself are
tightly sealed to prevent the ingress of dust or splash
water.
The insulation system of the motors is
designed such that they can be connected
to a converter with a maximum d.c. link
voltage Ulink max up to max. 700 Volt.
Note: Ulink max is 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.
The maximum permissible rate of voltage
rise (dU/dt) at the motor terminals may be
max. 1.3 kV/µs (in accordance with the
specifications of DIN VDE 0530 T1, Supple-
mentary Sheet 2). The overvoltage at the
motor terminals must not exceed 1.3 kV. It
may be necessary to use motor current fil-
ters or reactors to achieve these values.
7.2. Motor connection / Winding protection
The electrical connection of the motor and the winding
monitoring devices is made in the terminal box on top of
the machine.
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 cor-
rectly to the corresponding phases of the converter; they
must not be interchanged.
The thermocouples installed in the winding
such as PTC thermistor detectors and ther-
mostatic switches must be evaluated in the
control system or frequency converter to
protect the motor from overtemperature.
The separately driven fan must be properly
connected and operated. It can be switched
in dependence of temperature by the ther-
mal switch S4, if required (relay must be
used).
Seite/page 10
Datum/date 14.02.2006
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7. Electrical connection
Danger
Note
Cable cross-section required:
The currents specified under the machine
data for the series WLG-18 refer to duty
type S3-60%. This must be taken into
account when selecting the cable cross-
section required. The continuous Ir.m.s.
value required for the selected cable is
approximated from:
Ir.m.s. (cable) ≈≈IN (motor, S3-60%) / 1.28
The following table gives the recommended values for
the current-carrying capacity of PVC cables at a maxi-
mum ambient temperature of 40 °C:
Note
Caution
Cable cross-
section
WSG-18
Permis. max. cur-
rent (r.m.s. value)
WLG-18
Permis. max. current
IN(S3 - 60%)
2,5 mm222,6A 29,2A
4,0 mm229,6A 38,2A
6,0 mm238,3A 49,4A
10,0 mm253,1A 68,6A
16,0 mm271,3A 92,0A
25,0 mm294,0A 121,3A
35,0 mm2117,4A 151,9A
50,0 mm2146,2A 188,7A