520 frame synchronous ac manual - imperial electric lubrication ... brown/ green 1 sensor up ... 525...

1 DOCUMENT 520 08132009 PDF

520 Frame Synchronous AC Motor Manual


TABLE OF CONTENTS

Receiving - Handling – Storage…………..…………………………. 3 Extended Storage…………………………………………………….… 3 Inspection - Installation……………………………………………….. 4 Motor - Encoder Connections…………………………………..……. 5 Encoder Mounting and Dismounting……………………………….. 6 Brake Connections…………………………………………………….. 7 Brake Adjustments…………………………………………………….. 8 Brake Switch Adjustments…………………………………..……….. 13 Periodic Brake Lubrication Procedure………………….….………. 14 Machine Lubrication (Bearings)…………………………….……….. 17 Maintenance……………………………………………………………… 18 Contact Information......……………………………………….……….. 19 Warranty Information………………………………………………….. 20


Receipt:

• Upon delivery, report any significant damage to shipper and to manufacturer.

• Check that motor nameplate information matches your order. Sample nameplate shown below:

Handling:

• If possible, lift motor as single unit. • Anchor lifting slings to the eye bolts provided on motor. • Use spreader bars for balancing to prevent damage.

Storage:

• Store in a warm, dry and clean location. • Protect the motor from dust and dirt – particularly construction

dust which can penetrate the motor.

Extended Storage:

The brake drum, sheave and various other parts are protected with a rust inhibiting membrane before shipping.


Extended Storage (Continued): If the motor is stored beyond 30 days: • Store in a dry, dirt free area. • Periodically check motor’s exterior for rust. If necessary,

remove any rust with a fine abrasive paper before using. • Do not allow oil or solvents to come in contact with the sheave

grooves, brake linings or brake drum.

Commissioning:

Commissioning the motor includes the pre-installation inspection, installation and start up.

Inspection:

If the motor has been stored for an extended period of time the following checks need to be performed before any electrical connections can be made: • Condensation on the motor. If the there is any evidence of

condensation, contact the manufacturer for drying instructions before proceeding.

• Insulation resistance. Use a megohmmeter to confirm insulation resistance between the motor phases and the ground terminal. There should be a minimum of 100M ohms@ 500VDC for 60 seconds.

Installation:

1. Provide structural support consistent with loading on gearless

motor feet or base pads. 2. Provide a level foundation with bolts well anchored and matched

to motor base or base holes. 3. Remove any rust, dirt or oil from brake drum surface before

allowing brake linings to contact the brake drum. 4. Remove any rust, dirt or oil from all motor surfaces. 5. Carefully check brake settings and solenoid parameters. Refer

to the brake adjustment instructions for specific values.


Installation (Continued):

6. Manually release brakes and turn the drive sheave by hand to confirm smooth operation and no mechanical interference.

7. Make motor connections according to all applicable national and local electrical codes, observing all safety precautions.

Motor Connections:

Verify that intended connection comply with motor characteristics as indicated on the motor nameplate.

Phase Connections:

Phase Output

U Phase 1 V Phase 2 W Phase 3

Ground Green/Yellow

Encoder Connections:

520 series motors use a Heidenhain™ ECN1313 encoder. Pins on cable connector are male. Optional Imperial 12 meter [39.4ft.] cable available

[p/n 0850424].

Pinout and general specifications:

Pin Signal Color7 Up (Power Supply Voltage) Brown/ Green 1 Sensor Up Black 10 OV White/Green 4 Sensor OV White 11 Inside Shield No Designation 15 A+ Green/Black 16 A‐ Yellow/Black 12 B+ Blue/Black 13 B‐ Red/Black 14 Data Grey 17 Data Pink 8 Clock Violet 9 Clock Yellow


ECN1313 Encoder Information

Criteria Description

Data Interface EnDat

Positions Per Revolution 8192 (13bit)

Incremental Signals 1Vpp

Line Count 2048

Power Supply 5V ±5%

Max. Current Consumption w/o Load 150 mA

Max Cable Length 150M [492ft.]

Encoder Mounting Instructions:

• Any prying or hammering can be damage the encoder.


Pressing the encoder out during dismounting:

The encoder must be locked to the shaft for proper motor performance.

Brake Connections: 520 series motors are provided with dual circuit, electrically

released brakes. These brakes are also provided with a manual released handle. Connect the brake and micro switch as shown in the elevator controller document/drawing package.


522 Motor: Motor Brake Pick Voltage: 93 VDC for 1 second maximum. Hold Voltage: 40 VDC Coil Resistance (per coil) Cold: 36 (±6%) Ω Hot: 44Ω 525 Motor: Motor Brake Pick Voltage: 155 VDC for 1 second maximum. Hold Voltage: 53 VDC Coil Resistance (per coil) Cold: 29 (±6%) Ω Hot: 38Ω Brake Adjustments:

NOTICE: Do not leave manual release handle assembled to solenoid.

Remove handle from solenoid and store for easy access.

Brake adjustments and proper clearance are critical to elevator and machine performance. Damage due to improper brake adjustments is not covered under warranty.

• All brake adjustments are made before the motors are shipped.

• Brake torque specifications set per table below:

Brake Torque / Per Side 522 1250 Ft.lbs. 525 2335 Ft.lbs.


Brake Adjustments Procedure:

The brake supplied with the motor is adjusted at the factory but it may be necessary to set up or adjust the brake in the field. The following procedure will outline the correct steps to adjust brakes:

Figure 1 shows the location of the bolts and / or nuts used during the adjustment procedure.

Figure 1: Complete Motor

Brake arm clearance adjustment bolt

Brake spring compression nut

“Heel / Toe” adjustment bolt

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Brake Adjustments Procedure (Continued):

1. Remove all electrical power to the solenoid and motor. Check to make sure the brake pads on both sides are pressed against the brake drum with no gaps.

Notice:

The manual release handle MUST BE REMOVED when adjusting the brakes and during normal motor operation.

2. On both sides of the brake - loosen the brake arm clearance

bolts (1 each side) until the bolts are not touching the solenoid plungers. See figure 2.

Figure 2

3. On both sides of the brake, loosen the lower brake shoe “heel /

toe” adjustment bolt. See figure 3.

Figure 3

Loosen lock nut before turning bolt.

Brake arm clearance bolt.

Loosen lock nut before adjusting “heel/toe” clearance.

“Heel / toe” adjustment bolt

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4. Loosen the outside lock nut located against the brake spring compression nut. Tighten or loosen the brake spring compression nut to achieve the required holding force. A measurement from the brake arm to the spacer’s outer edge is supplied by the factory (decal located on the brake arm) and must be re-established to maintain the specified holding force shown in the Brake Torque table on page 9. See figure 4.

Figure 4

5. Adjust the “heel / toe” adjustment bolt on both sides. Use a

shim to establish a 0.004” – 0.005” gap between the brake shoe and the bolt. Retighten the lock nut to prevent movement while maintaining the established gap. See figure 5.

Figure 5

Lock nut Spring compression nut

Outer edge of spacer Brake arm

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6. Ensure both left and right plunger arms are pushed towards the center of the solenoid. Turn the brake arm clearance bolts until they both are touching the solenoid plungers. See figure 6.

Figure 6

7. Apply power to the brake solenoid to lift both brakes shoes off

the drum. Check the gap between the brake pad and the brake drum with a 0.004” – 0.005” thick shim (see figure 7). Gap adjustment is obtained by turning the brake arm clearance bolt against the solenoid plunger (see figure 6). If the clearance between the brake pad and the brake drum is not even from top to bottom then adjust it with the heel / toe bolt (see figure 5).

Figure 7

Solenoid

Plunger

Brake arm clearance bolt

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8. Cycle the brake solenoid off and on to ensure it is working properly. Recheck the gap between brake pad and brake drum to ensure that it is not dragging on either side. If the brake clearances are acceptable, then tighten the lock nuts on the heel / toe adjustment bolt and the brake arm clearance bolt to prevent any future movement.

9. Store the manual brake release handle for easy access. Adjustments for brake Switch:

The brake switches are mounted on a bracket attached to the

either side of the brake solenoid as shown in the picture below. Adjustments are made by loosening the hex nut and sliding the switch into the proper position so that the switch is activated by the opening and closing of the brake arm.

The brake switch is pre-wired at the factory using the “normally open” (NO) terminals on the back side of the switch. The connection can be changed to normally closed by disconnecting the lead on the “normally open” (NO) terminal and connecting it on the “normally closed” (NC) terminal. See photo below:

Common terminal

Normally open terminal

Normally closed terminal

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Periodic Brake Lubrication Procedure

Warning: SKF LGHB 2 grease is the only recommended lubricant for this brake solenoid. The use of any other grease is the sole responsibility of the

user and may void the warranty. Solenoid (Lubrication Schedule - Every 12 months):

1. Remove all electrical power to motor, brakes, controller, etc… 2. Caution should be used to ensure that:

a. If the arms are lifted off the brake drum that the car is immobilized and that each arm is lifted separately.

b. Critical alignment (spring washer orientation) and distances (between the outer edge of the spacer and the brake arm) be recorded to ensure that the performance of the brake be maintained. Reference owner’s manual for details.

3. Lift the brake arm off the brake solenoid push rod. 4. The solenoid has two sides to it. Each side consists of one coil,

plunger assembly, end bracket, etc. Each side mechanically functions totally independent of the other.

5. Remove the plunger cap from the push rod. (The cap is on the terminal end of the push rod that sits against the brake arm).

6. Remove the (6) outer bolts with a 6mm allen wrench. 7. Remove the end bracket with a rubber mallet. A chisel and

hammer may be necessary to separate the bracket from the frame. Caution should be exercised to ensure that damage to either is kept to a minimum. Slide the end bracket over the push rod. This will expose the inside of the solenoid.

Plunger Cap

End Bracket Cylinder Wall

Frame

Plunger Core

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Solenoid (Lubrication Schedule - Every 12 months) Continued:

8. Remove the plunger core by pulling the push rod out of the solenoid.

9. Remove any dust and debris from the outer diameter of the plunger by using emery cloth, degreasers, etc. The plunger needs to be clean.

10. Remove any dust or debris from the inside diameter of the end bracket by using emery cloth, degreasers, etc. The end bracket inside diameter (I.D.) needs to be clean.

11. Remove any dust and debris from the inside diameter of the solenoid coil and cylinder wall with emery cloth, degreasers, etc. Caution should be exercised to ensure that the coil is not damaged in cleaning. Both the inside of the solenoid coil and inner diameter of the cylinder wall needs to be clean.

12. Place the plunger core into the solenoid and again feel the action of the plunger by manually pushing and pulling the push rod by hand. It should move freely…repeat the cleaning procedure until it slides without resistance.

13. Lightly coat the outer diameter of the plunger with SKF LGHB 2 grease.

14. Lightly coat the end bracket inside diameter with SKF LGHB 2 grease. (The part where the plunger shaft passes through the bracket.)

15. Slide the lubricated plunger assembly into solenoid. 16. Reassemble the solenoid by reversing the disassembly

procedure. 17. Before final assembly is complete, ensure the action of the

plunger again by manually pushing and pulling the push rod by hand. Repeat procedure on the other side of the solenoid.

End Bracket (I. D.)

Push Rod

Solenoid Coil

Cylinder Wall

Plunger Core

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Solenoid (Lubrication Schedule - Every 12 months) Continued:

18. Return each brake to their original operating state. 19. Reinstate electrical power to motor. 20. Test unit to ensure that brakes are fully operational.

Brake Rod / Spring Washers Assembly (Lubrication Schedule - Every 12 months):

1. Caution should be used to ensure that: a. If the arms are lifted off the brake drum that the car is

immobilized. b. Critical alignment (spring washer orientation) and distances

(between the outer edge of the spacer and the brake arm) be recorded to ensure that the performance of the brake be maintained. Reference page 13 for details.

2. Loosen and remove the lock nut, the compression nut as well as the spacer. Remove the spring washers noting their orientation with each other. Inspect the brake rod, remove any corrosion and lightly coat the brake rod with SKF LGHB 2 grease to ensure minimal friction between the rod and the washers.

3. Reassemble the brake rod spring/washer assembly by reversing the disassembly procedure.

4. Tighten compression nut until previous recorded clearances are re-established between the outside of the spacer and the brake arm. Tighten lock nut against compression nut.

5. Test unit to ensure that the brakes are fully operational.

Spring Washers

Brake Rod

Compression Nut

Lock Nut

Spacer

Brake Arm

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Brake Arm Assembly (Lubrication Schedule - Every 3 months):

1. Spray a two second burst of a penetrating lubricant into the lubricating hole or in earlier models, spray a three second burst into the gap between the brake arm and the shaft. (The brake arm shaft was factory lubricated during its assembly and under normal conditions should only require a minimal amount of additional lubrication.)

2. Spray a two second burst of a penetrating lubricant into the gap between the brake shoe and the brake shoe shaft. IMPORTANT NOTE: Caution should be taken not to allow any lubricant spray to make contact with any part of the brake drum or the lining of the brake shoe assembly as braking friction will be greatly reduced.

Machine Lubrication (Bearings):

Warning:

SKF LGEP 2 grease is the only recommended bearing lubricant for this motor. The use of any other grease is the sole responsibility of the

user and may void the warranty.

Although both sheave and encoder end bearings are pre- lubricated at the factory, they do require periodic lubrication.

Warning: Damage due to improper bearing lubrication is not covered under

warranty.

Lubricating Hole

Brake Arm Shaft

Brake Shoe Shaft

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Machine Lubrication (Bearings) Continued: 522 & 525 Encoder End Bearing: Re-lube every 3000 hours or 6 months. Grease Quantity: 0.50 oz, (15.3g)

Grease Type: SKF LGEP2

522 & 525 Sheave End Bearing: Re-lube every 3000 hours or 6 months. Grease Quantity: 1.77 oz, (55g)

Grease Type: SKF LGEP2

1. Remove motor from service. 2. Pre- clean grease fitting and drain plug areas. 3. Remove grease drain plug. 4. Add grease though fitting - only use specified amount.

Warning:

Do not over fill bearing reservoir by pumping grease until it comes out the drain hole. This will cause permanent bearing damage.

5. Clean fitting and drain plug area’s and restore plug.

Maintenance:

Periodic maintenance is critical to machine operation.

• Inspect visually. Check for wear, debris, lubrication leakage and any evidence of heating or abnormal operation.

• Check for proper brake operation. • Check groove wear and cable tension. • Lubricate machine per instructions

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Contact Information: Imperial Electric Company ®

A Kinetek Company® 1503 Exeter Road Akron, Ohio 44306

330.734.3600 Direct 330.734.6301 Fax www.imperialelectric.com

Warning and Disclaimer:

Although every effort has been made to make this document as complete and accurate as possible, Imperial Electric Company and the document authors, publishers, distributors, and representatives have neither liability nor responsibility for any loss or damage arising from information contained in this document or from informational errors or omissions.

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RETURNS: Before returning material to our factory, authorization must be obtained from the factory or nearest district office or representative. GUARANTEE AND LIMITATION OF WARRANTIES We guarantee that the apparatus manufactured by us will deliver its rated output as indicated on the nameplate, provided such apparatus is properly cared for, operated under normal conditions, and with competent supervision. We agree to correct by repair or replacement at our option and at our own expense, F.O.B. our factory (buyer to pay freight one way) any defects in apparatus, which may develop under normal and proper use within twelve months after date of shipment. Warranties are contingent upon inspection proving the claims and the buyer giving us immediate written notice of such defects, and provided further that during said period the apparatus is properly cared for, operated under normal conditions, and with competent supervision. The correction of such defects by repair or replacement by us shall constitute a fulfillment of all of our obligations to the buyer. When the apparatus or goods are sold by the original buyer, the maximum guarantee period shall be limited to twelve months from the date of shipment from our factory. Imperial Electric Company makes no warranty of any kind; expressed or implied, except as above stated. Warranties of fitness for purpose and merchantability are specifically excluded. The materials sold hereunder shall be of Imperial Electric’s standard quality, and buyer assumes all risk and liability whatsoever resulting from the use of such materials, whether used singly or in combination with other goods or apparatus. Imperial Electric neither assumes nor authorizes any person to assume for it any other liability in connection with the sale or use of the apparatus or goods sold hereunder, and there are no oral agreements or warranties collateral to or affecting this agreement. NO LIABILITY FOR CONSEQUENTIAL DAMAGE We are not liable for consequential damage in case of any failure to meet the conditions of our guarantee or the terms of our quotation or your purchase order.

520 frame synchronous ac manual - imperial electric lubrication ... brown/ green 1 sensor up ... 525...

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