Gearless Xaf: Installation and Maintenance
Gearless Xaf: Installation and Maintenance
Gearless Xaf: Installation and Maintenance
Gearless XAF
A.C. Drive for lifts
These symbols appear in this document whenever it is important to take special precautions during installation,
operation, maintenance or servicing of the motors.
It is essential that electric motors are installed by experienced, qualified and authorised personnel.
In accordance with the main requirements of EEC Directives, the safety of people, animals and property should be ensured when
fitting the motors into machines.
The following preliminary precautions must be taken before working on any stationary device:
• Mains voltage disconnected and no residual voltage present
• Careful examination of the causes of the stoppage (jammed transmission - loss of phase
- cut-out due to thermal protection - lack of lubrication, etc)
Even when not supplied with power, there is voltage at the terminals of a rotating synchronous motor with
magnets.
Accordingly, before carrying out any work check carefully that the motor is not rotating.
Assembly or maintenance of the rotor must not be carried out by people with pacemakers or any other implanted
medical electronic device.
The motor rotor contains a powerful magnetic field. When the rotor is separated from the motor, its field may affect
pacemakers or disturb digital devices such as watches, mobile phones, etc.
Dear Customer,
You have just acquired a LEROY-SOMER motor.
This motor benefits from the experience of one of the largest manufacturers in the world, using state-of-the-art technologies –
automation, specially selected materials and rigorous quality control. As a result, the regulatory authorities have awarded our
motor factories ISO 9001, Edition 2000 international certification from the DNV. Similarly, our environmental approach has
enabled us to obtain ISO 14001: 2004.
Products for particular applications or those designed to operate in specific environments are also approved or certified by the
following organisations: CETIM, LCIE, DNV, ISSEP, INERIS, CTICM, UL, BSRIA, TUV, CCC and GOST, which check their
technical performance against the various standards or recommendations.
We thank you for making this choice, and would ask you to read the contents of this manual.
By observing a few essential rules, you will ensure problem-free operation for many years.
LEROY-SOMER MOTORS
CE conformity
Our motors conform to standard EN 60034 (IEC 34), and therefore to the Low Voltage Directive 73/23/EEC modified by
Directive 93/68, which is demonstrated by their marking with the symbol
MOTEURS LEROY-SOMER
USINE
conform to the harmonized standard EN 60 034 (IEC 34) and thus meet the
essential requirements of Low Voltage Directive 73-23 EEC of 19th February 1973 modified
by Directive 93-68 EEC of 22nd July 1993.
The components thus defined also meet the essential requirements of the
Electromagnetic Compatibility Directive 89-336 EEC of 3rd May 1989 modified by Directives
92-31 EEC of 28th April 1992 and 93-68 EEC of 22nd July 1993,if they are used within certain
voltage limits (IEC 34).
The components defined above must not be installed unless the machine in which
they are incorporated has been declared as conforming to the relevant directives.
N.B. : When components are powered by specially adapted electronic converters and/or
servo-controlled by electronic control-command devices, they must be installed by a
professional person. This person must take responsibility for complying with the regulations
concerning electromagnetic compatibility in the country where the machine is used.
Declaration made by At
On
Quality Director
MOTEURS LEROY-SOMER Signature
MOTEURS LEROY-SOMER (SIEGE SOCIAL BD MARCELLIN LEROY - 16015 ANGOULEME CEDEX) SOCIETE ANONYME AU CAPITAL DE 411 800 000 F - RCS ANGOULEME B 338 567 258 - SIRET 338 567 258 00011
NOTE:
LEROY-SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest
technological developments. The information contained in this document may therefore be changed without notice.
Copyright 2003: LEROY-SOMER MOTORS
This document is the property of LEROY-SOMER.
It may not be reproduced in any form without prior authorization.
All brands and models have been registered and patents applied for.
1 - RECEIPT.............................................................................................................................................................. 5
2 - STORAGE............................................................................................................................................................ 5
2.1 - Storage location.................................................................................................................................................. 5
2.2 - Prolonged storage (> 3 months).......................................................................................................................... 6
3 - ENVIRONMENT................................................................................................................................................... 6
4 - COMMISSIONING............................................................................................................................................... 6
4.1 - Mechanical installation........................................................................................................................................ 6
4.1.1 - Cleaning.............................................................................................................................................................................. 7
4.1.2 - Mechanical installation......................................................................................................................................................... 7
4.1.3 - With deflection sheave......................................................................................................................................................... 7
4.2 - Electrical installation........................................................................................................................................... 8
4.2.1 - Wiring the motor and the thermal probe............................................................................................................................... 8
4.2.2 - Wiring the brakes and microswitches................................................................................................................................... 8
4.2.3 - Wiring the motor with «external connection box» option...................................................................................................... 9
4.2.4 - Encoder wiring..................................................................................................................................................................... 9
4.3 - Commissioning................................................................................................................................................... 9
4.4 - Maximum rated power........................................................................................................................................ 9
5 - MAINTENANCE/SERVICING........................................................................................................................... 10
5.1 - After one month’s operation.............................................................................................................................. 10
5.2 - Every year......................................................................................................................................................... 10
5.3 - Every 3 years.................................................................................................................................................... 10
IEC60034-1
Fig. 1: Nameplate
Encoder
cable
- Release the brake by supplying it with power (section 4.2.2) Place a support on the
- Remove the protective varnish from the sheave grooves side of the front foot
PE
thermal probe
It is the responsibility of the user to connect the 4 pin connector installed on the brake :
motor in accordance with the current legislation and 2 WAGO 731-604/019-000 connectors are located on the
regulations in the country of use. This is particularly motor back face (brake). Shield cable fixation bracket is
important as regards the size of the cables, the type and located downside each connector.
size of fuses, the earth or ground connection, powering
down, acknowledging insulation faults and protection
against overcurrents. 1 2 3 4 1 2 3 4
This table is given for information only, and must
under no circumstances be used in place of the current
standards.
The recommended cross-sections are given for a single-
wire cable, with a maximum length of 10 m. Above this,
line drops due to the cable length must be taken into
account.
Brake A Brake B
Particular care must be taken to tighten the nuts on the 1 2 1 2
terminals. (Incorrect tightening may lead to the connections
being damaged by overheating: see diagram Fig. 6)
- Connect the power cables to terminals U1, V1 and W1, in
accordance with IEC 600034-1. 3 4 3 4
11 1
12
10 16 13 2
9
14 3
8 15 17 4
7 6 5
1 6 11
9
1
Motor Bearings 4
Fig. 7:
2103202.A DE NDE Fixing the encoder
Type : 21320E 6217 2RS C0
MOBILITH SHC220
7.1.1 - Dismantling the encoder
Grease :
60 g - Undo (2 turns with a SW2 spanner) the fixing screw on the
Regreasing encoder casing (Ref. 1 fig. 7) in the support piece.
interval 3 YEARS - Undo the encoder plug (SW4 spanner or screwdriver).
- Undo (SW4 spanner) the central encoder fixing screw
(Ref. 3 fig. 7) on the motor shaft.
6 - BRAKE AND MICROSWITCH - Remove the encoder from its support (depending on the
ADJUSTMENT PROCEDURE model).
- Tighten the small M2.5 chc screw (Ref. 1 fig. 7) (SW2 torque 8 - Replacing the brake and
wrench or screwdriver) on the encoder casing to a torque of
1.25 Nm 0/-0.2 Nm.
microswitches
- Retighten the encoder plug (SW4 spanner or screwdriver).
- If necessary, phase the encoder (see drive manual) This operation must be made by an agreed
Leroy-Somer Service Center.
7.2 - Replacing the sheave 9 - ORDERING SPARE PARTS
7.2.1 - Removing the sheave
To ensure optimum after-sales service, the following
Secure the load before any work is carried out on information must be provided with each spare parts order:
the motor. Check that no torque is applied to the rotor. - Type and serial number of the motor
and for each spare part:
- Loosen the SKF nut - Name and (or) reference number of the part
- Remove the SKF nut - Quantity ordered.
- An extracting plate is to be manufactured according to the For instant identification, please give the reference of the
here-below drawing (measure the diameters on the sheave). document used for the order (drawing or manual number).
Insert 3 screws, 3 nuts on the extraction plate (Fig. 10) The type and serial number can be found on the nameplate
- Remove the sheave. WARNING, the sheave may fall. of the motor.
Part names:
Reference Name
1 Sheave
2 Complete brake
3 Encoder support
Fig. 10:
Removing the sheave 4 Encoder kit
Option CDF brake motor power supply
7.2.2 - Refitting the sheave
- Clean all the parts and check they are in good condition.
- Place the key on the shaft
- Bring the sheave close to the cone
- Fit a spacer washer (2mm thickness)
- Tighten the SKF brake nut according to the here-below table
(step 1) 1 2 3 4
- remove the nut and the spacer washer
- Fit the SKF lock washer
- Tighten the SKF brake nut according to the here-below table
(step 2)
- Lock the lock nut with the washer.
Step 1 Step 2
XAF Nut Size Socket Size
(Nm ± 10%) (Nm ± 10%)
2 370 95 KM 14 TMFS 14
3 640 160 KM 18 TMFS 18
4 860 215 KM 18 TMFS 18
6 1120 280 KM 18 TMFS 18
M
A
N
U
A
L
SOMMAIRE
1 Technical specifications 3-4-5-6-7
2 Precautions and restrictions on use 8
2.1 Restrictions on use 8
2.2 Precautions and safety measures 8
3 Installation 8
3.1 Transport - storage 8
3.2 Handling 8
3.3 Mounting 9
3.4 Demounting 9-10
4 Maintenance 10
4.1 Adjusting the airgap 10
4.2 Adjusting the microswitch 11
5 Electrical connection 11
5.1 Important recommendations 11
5.2 Electric connection 12
6 Spare parts 13
7 Tools 13
8 Troubleshooting 13
WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM411gb - rev 09/12 2/13
1 Technical specifications
Motor flange
Braking
circuit A
Braking
circuit B Front disc, smalll
emboss on brake
side
O-Ring in disc
Fig. 1a Fig. 2a
Encoder
mount
Fig. 1b Fig. 2b
O-Rings in
disc
WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM411gb - rev 09/12 3/13
ERS VAR09 SZ 1000/800
Encoder
mount
Fig. 1c Fig. 2c
O-Rings in
disc ERS VAR09 SZ 1700/1200
Motor flange
Rear disc, heel on fixing
flange side
Encoder
Magnet B mount
Magnet A
Fig. 1d Fig. 2d
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Table 1
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Symbol designating Symbol designating an Symbol designating an elec-
an action that might action that might be dan- trical action that might be
damage the brake gerous to human safety dangerous to human safety
WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM411gb - rev 09/12 8/13
3.3 Mounting - Make all electrical connections permanent.
Specifications for the customer’s friction face: VAR09 SZ1700/1200 (Fig. 1d)
Material: Steel (150 to 250 HV) or Lamellar graphite cast iron
Roughness ≤ Ra 3,2 - Put the O-rings into the discs.
Protection: Phosphatizing dry or nitriding
- Engage the front disc on the customer’s shaft as
Geometrical tolerances: illustrated in Fig. 1, the boss on the brake side.
0,1 Customer’s shaft axis
0,1 - Engager l’inducteur A.
The brakes are delivered pre-assembled with pre-set micros- - Engage the rear disc on thecustomer’s shaft as
witches and airgaps. Fixing screws are supplied separately. illustrated, with the boss on the customer fixing
flange side.
ERS VAR07 SZ300/300 (Fig. 1a)
- Engage magnet B, repositioning magnet A using the
- Put the O-ring into the disc. fixing screws.
- Slide the disc (small emboss on brake side) - Switch on the current to magnets A and B.
- Engage magnet, energize magnet. - Line the brake up with the customer fixing flange, using
the fixing screws.
NOTE: Secure the fixing screws using the safety washer.
NOTE: Secure the fixing screws using the safety washer
- Put in position and tighten the fixing screws of magnet, supplied.
(star sequence tightening, first to initial torque,
final setting torque after, see Table 2). The supply of - Tighten the fixing screws, (star sequence tightening,
current to the brake should be switched on throughout first to initial torque, final setting torque after, see Table
this operation. 2). The supply of current to the brakes should be
switched on throughout this operation.
- Make all electrical connections permanent.
- Make all the permanent electrical connections.
ERS VAR09 SZ600/500, SZ600/600 et SZ1000/800
(Fig. 1b and Fig. 1c) Taille 300 500 600 800 1200
Vis fixation 6xM8 6xM10 6xM10 8xM10 8xM12
- Put the O-rings into the discs. Cs approche (Nm) 9 30 30 30 50
Cs ± 10 % (Nm) 22 64 64 64 111
- Engage the front disc on the customer’s shaft, the boss Hexagone de manoeuvre
13 21 21 21 21
on the brake side. des vis de réglage (mm)
NOTE: Secure the fixing screws using the safety washer. 3.4 Demounting
- Put in position and tighten the fixing screws of magnet ERS VAR07 SZ300/300
A, (star sequence tightening, first to initial torque,
final setting torque after, see Table 2). The supply of - The car must be stopped by another system than the
current to the brake should be switched on throughout brake.
this operation.
- Do not energise the brake.
- Engage the rear disc on the customer’s shaft, with the
boss on the customer fixing flange side. - Untight the fixing screws (star sequence, several turns,
the brake must stay straight).
- Engage magnet B, energize magnet B.
- Unmount the magnet.
NOTE: Secure the fixing screws using the safety washer.
- Remove the disc.
- Put in position and tighten the fixing screws of magnet
B, (star sequence tightening, first to initial torque, - Change the fixing screws.
final setting torque after, see Table 2). The supply of
current to the brake should be switched on throughout
this operation.
WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM411gb - rev 09/12 9/13
ERS VAR09 Position of feeler gauges on each braking
circuit for airgap adjustment VAR07 SZ300
- Remove the front disc. Position of feeler gauges per magnet for airgap
adjustment VAR09 SZ600/500, SZ600/600
4 Maintenance
on the magnet).
WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM411gb - rev 09/12 10/13
4.2 Adjusting the microswitch ERS VAR09 SZ 1700/1200
Black
"NC"
Slide a shim thickness 0,20mm, near screw in the corres- Brown
ponding airgap. Switch on the current and tighten (the
M4 adjusting screw 7 A/F for ERS VAR09 or the M5 Adjusting screw
for microswitch
adjusting screw 8 A/F for ERS VAR07) in contact with
the microswitch until you reach the actuation point. Then Airgap
turn the screw in the opposite direction until the micros-
witch does not actuate. Check, by 3 successive energisings
of the brake, that the microswitch does not actuate with the
shim thickness of 0.20mm.
Then slide a shim thickness 0.178mm or 0.007” and check Microswitch Fig. 5c
that the adjustment is stable (the microswitch actuates), by
3 successive energizings of the brake, see Fig. 5a for
VAR07 and Fig. 5b or Fig. 5c for VAR09. Operation microswitch
5 Electrical connection
Connector
Brakes ERS VAR07 and ERS VAR09 operate on a direct
Fig. 5a current supply.
The brakes are equipped with a plug connector WAGO (fig. 6a) or with two plug connectors WAGO (fig. 6b).
1 2 3 4 1 2 3 4
Fig. 6b
WARNING: in the event of connection in series of the magnets, the values of tension to be applied between terminals 1
and 3 with motor side, must be adapted.
WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM411gb - rev 09/12 12/13
6 Spare parts
Part
Friction disc Thank you to join to your request for spare part, the reference and the part number of the brake
Microswitch (see example below).
O-ring in the disc
7 Tools
Tools Function
Airgap adjustment shims Airgap and microswitch adjustment
Open jawed spanner 13 mm A/F (VAR07) and 21 mm A/F (VAR09) Airgap adjustment
Torque wrench (measurement range > 140 Nm) with hexagonal socket
6/flat (M8 VAR07 SZ300) Airgap adjustment
8/flat (M10 BVAR09 SZ600 et SZ 1000)
10/flat (M12 VAR09 SZ1700)
Open jawed spanner 7 mm A/F Microswitch adjustment
Multimeter Voltage checking
Troubleshooting
Fault Cause Remedy
Brake does not • Power supply is too low • Adjust power supply
release • Power supply is interrupted • Reconnect power supply, check the adjustement of
microswitch
• Airgap too large • Re-adjust the airgap (chapter 4.1)
• Worn disc • Change disc and readjust the airgap
• Coil is damaged • Replace the brake
• Airgap too small • Re-adjust the airgap (chapter 4.1)
Brake does not • Voltage present at switch off position • Check the microswitch’s adjustment and the customer’s
brake • Grease on friction faces power supply
• Clean the friction faces, change the disc
WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM411gb - rev 09/12 13/13
notes