SUZHOU TORIN DRIVE EQUIPMENT CO., LTD.

Transcription

1 Overhead Geared Elevator Traction Machine IGD20 Geared Machine Complete Operation and Service Manual SUZHOU TORIN DRIVE EQUIPMENT CO., LTD. Manual No. TDII-003-IGD20

2 Overhead Geared Elevator Traction Machine Contents Limited Liability and Warranty... 1 Safety Precautions... 1 Product Specific Warnings... 2 Arrival of the Equipment... 3 Application... 3 Machine Overview... 5 Installation... 6 Adjustments... 9 Brake Torque Adjustment... 9 Brake Stroke Adjustment Brake Synchronous Adjustment Maintenance Brake Stroke Check Brake Lining Wear Check Lubricating Check Replacement Encoder Replacement Brake Switch Replacement Motor Replacement Brake Replacement Brake Lining Replacement Sheave replacement Ring Gear Replacement Bearing Replacement O-Rings and Seal Replacement Troubleshooting chart Traction Machine Assembly Brake Assembly Mechanical Dimensions Manual No. TDII-003-IGD20

3 Limited Liability and Warranty The manufacturer shall NOT be liable for any loss of profit, indirect, incidental or consequential damages of any kind including, but not limited to, personal injury, labor cost, downtime, etc. The manufacturer warranty shall cover 12 months from the date of installation or 24 months from the date of shipment whatever comes first. The limited warranty does not apply to normal wear and tear items or any machines that have been subjected to misuse, misapplication, improper installation, improper modification/adjustment/repair or inadequate maintenance, etc. Safety Precautions Please read this page BEFORE any work is performed on Elevator Equipment. Important! The procedures contained in this manual are intended for the use of qualified elevator personnel. In the interest of your personal safety and the safety of others, do NOT attempt ANY procedure that you are NOT qualified to perform. All procedures must be done in accordance with the applicable rules in the latest edition of the EN81 and any governing local codes. Terms in This Manual CAUTION statements identify conditions that could result in damage to the equipment or other property if improper procedures are followed. WARNING statements identify conditions that could result in personal injury if improper procedures are followed. General Safety Specific warnings and cautions are found where they apply, and DO NOT appear in this summary. Electrical Safety All wiring must be in accordance to local governing code and standards. Manual No. TDII-003-IGD20 1

4 Use the Proper Fuse To avoid fire hazards, use only a fuse of the correct type, voltage, and current rating as specified in the parts list for the product. Electrical Hazards Electric shocks can cause personal injury or loss of life. Circuit breakers, switches and fuses may NOT disconnect all power to the equipment. Always refer to the wiring diagrams. Please verify if the AC supply is grounded or not, high voltage will be present at many points. Printed Circuit Cards When printed circuit cards are involved, do NOT remove connections or cards from the equipment while power is applied. This can damage equipment. Always store and ship printed circuit cards in separate static bags. Mainline Disconnect Unless otherwise suggested, always turn OFF, Lock and Tag out the mainline disconnect to remove power from the equipment. Test Equipment Safety Always refer to manufacturers instruction book for proper test equipment operation and adjustments. Buzzer type continuity testers can damage electronic components. Connection of devices such as voltmeters on certain low level analog circuits may degrade electronic system performance. Always use a voltmeter with a minimum impedance of 1M Ohm/Volt. A digital voltmeter is recommended. When Power Is On Dangerous voltages exist at several points in some products. To avoid personal injury, do NOT touch exposed electrical connections or components while power is ON. Product Specific Warnings The IGD20 Machine MUST be balanced during hoisting. See Hoisting Method in the Installation section for proper lifting procedures. result in severe injury and equipment damage. Hang the elevator car before removing ANY bolts. Failure to do so may Manual No. TDII-003-IGD20 2

5 Arrival of the Equipment Receiving Upon arrival of the machine, make a visual check for any external damage immediately upon their arrival on site. If any damage incurred in transit is found, make a notice of claim in the presence of the forwarder. If necessary, do not put these machines into operation. Hoisting See Hoisting Method in the Installation section for proper lifting procedures. Storing During storage in a warehouse or on the elevator job site, precautions should be taken to protect the machine from dust, dirt, moisture, and temperature extremes. Application Overview The IGD20 Machine is a geared machine designed for elevators. Its worm and gear configuration allows speeds up to1.75 m/s(maximum), and an elevator capacity of up to 884 KG with 1:1 roping. The maximum capacity is 1768 KG with 2:1 roping. The IGD20 machine uses a drum brake with dual brake solenoids. The qualified elevator personnel can adjust the compression length of the spring to control the brake torque. Codes and Standards These machines are designed to comply with National Code. The motors are designed with insulation class F minimum. Environmental Specifications Operating ambient temperature: 0 to 50 Storage temperature: 0 to 60 Humidity: relative humidity of 10% to 95% non-condensing Altitude: Up to 1000m above sea level without de-rating Specifications Induction motors: 380V / 50Hz / 4 poles / 3-phase Brake coils: 110VDC / 1A Maximum full load mass: 4,500 KG Sheave diameter: 530 mm Up to 5 x 13mm Ropes Manual No. TDII-003-IGD20 3

6 Designed for 180 starts per hour at 40% elevator duty cycle and 1:1 roping Incremental encoder: 1024 pulse per revolution Estimated weight: 625 KG Detailed Machine Specifications Model Number IGD20-51P7-13mm IGD20-61P7-13mm IGD20-80P5-13mm IGD20-80P6-13mm IGD20-80P7-13mm IGD20-81P0-13mm IGD20-81P5-13mm IGD20-81P7-13mm Motor (Kw) Elevator Capacity Elevator Speed (Kg) (m/s) Pole # Gear Ratio Motor Voltage 47:2 47:2 41:1 41:1 41:1 41:1 53:2 47:2 (VAC) Current (A) Motor speed Sheave Spec (mm) (RPM) Diameter Rope# Φ Pitch Manual No. TDII-003-IGD20 4

7 Machine Overview The following is a list of major components of the IGD20 Machine. Along with a description of their functions, there is an overview of some of the critical adjustments and maintenance information. See Installation and Maintenance in detail. Brake Solenoid It is an independent electrically controlled solenoid that, when, energized removes pressure applied by the brake shoes to the brake drum. Brake Switch Is installed in the brake system, its function is to give feedback of the acting of brake to the inverter. Brake Arms The mechanical arms that are used, to press the brake shoes against the brake drum. Each arm operates independently. Brake Spring The spring s function is to, supply the necessary force to the brake shoes when the brake is de-energized. The spring creates friction between the brake shoe and the brake drum to hold the suspended load. The spring works in compression, and the length of spring is determined by the force required to hold the load. Brake Lining they are used to provide friction between the brake drum and the brake arm. Brake The electromechanical device that is used to prevent the elevator from moving when the car is at rest. Motor The part of the hoist motor assembly used to provide the necessary torque and speed to move the elevator when in operation. Brake Drum The smooth surfaced drum connected to the worm shaft. When the brake is energized the brake shoes are released from the brake drum.. Encoder Is a device that is directly coupled to the armature shaft of the hoist motor. Its function is to give the motor speed feedback to the elevator inverter drive and controller. Brake Solenoid Brake Spring Brake Spring Brake Arm Brake Lining Manual No. TDII-003-IGD20 5

8 Brake Manual Release Motor Encoder Brake Drum Figure1 IGD20 Machine Assembly Recommended Hoisting Method Installation Figure2 IGD20 Machine Recommended Hoisting Method Manual No. TDII-003-IGD20 6

9 Motor Connection Use the job wiring diagrams with the motor configuration information to connect the motor to the controller. Inverter drive output reactor: it is strongly recommended that a load reactor be installed between the inverter and motor to filter out high transient peak voltages that may damage the motor windings. Before operating the machine, refer to the appropriate Product Manual and verify that the drive parameters for the job are set correctly. Motor Connection Connect the motor cable (U, V, W, and grounding) to three phase AC reactor then to frequency inverter output terminal, and check the short-circuiting between the windings and the ground before connection. Brake Connection The power terminal of brake is BK+ (positive pole) and BK-(negative pole). There are two micro switches installed in the brake, their function is to give feed back on the action of the brake. Users can connect it according to their control system requests. Manual No. TDII-003-IGD20 7

10 Incremental Encoder Connection (Optional Accessory) These machines may be supplied with Nemicon s SBH T Incremental Optical Encoder. The incremental resolution is 1024 pulses per revolution. The field personnel can connect the encoder to the inverter by following the figure below for proper encoder signals: A and B and +V and GND (+V and GND is the encoder power supply is 12V). Manual No. TDII-003-IGD20 8

11 Brake Torque Adjustment Adjustments Generally, the brake stroke has been adjusted in the factory and does not need to be re-adjusted any more. Adjustment of the brake MUST be complete before anyone is allowed to ride on the platform. Preparation 1. Verify that any required Compensation Chains or Rope Assemblies have been installed. 2. On construction jobs, verify that hoist way barricades are in place to prevent unauthorized access. Required Tools & Materials: Open end wrench: 18mm Torque wrench Loctite 271 Adjust Procedure Steps 1. Remove the elevator from service. 2. Check the length of the compressed spring.the scale should show the measurement data per the motor power of the machine, otherwise the length must be readjusted. Motor Power Kw Spring and Washer length mm Measurement data mm Compressed Spring measurement Measurement data Manual No. TDII-003-IGD20 9

12 3. Go to Step 4 only if the length is out of the range. Otherwise the brake torque is good. 4. Loosen the Spring Adjustment Locknut by open end wrench (18mm), then adjust the spring adjustment washer slowly to ensure the length is in range. Spring adjustment washer Spring adjustment locknut 5. If the length is too long, tighten the washer clockwise to reduce it. If the length is too short, loosen the washer counter-clockwise to increase the length. 6. Re-measure and reconfirm that the value of length is good. 7. Also measure the brake torque by torque wrench. To do this remove the encoder cover from the motor shaft, tighten a bolt M12 into the motor shaft, and install the torque wrench on the bolt to measure the torque, if motor power <=7.5KW,make sure the torque >=80Nm;if motor power <=11KW,the torque >=120Nm. For information regarding how to remove the encoder cover, please refer to Encoder Replacement section Page Then apply red Loctite 271 between the bolt and luck nut for anti-vibration purpose. Manual No. TDII-003-IGD20 10

13 Brake Stroke Adjustment does not need to be re-adjusted any more. Generally, the brake stroke has been adjusted in the factory and Required Tools & Materials: Open End Wrench: 18mm Feeler gauges Adjustment Procedure: If the brake stroke is too small, the brake drum and brake shoe maybe rubbing and causing an abnormal noise when it runs. Generally, brake stroke has been tested and set at the factory and there is no need for any readjustment. 1. Loosen the stroke adjustment locknut, verify that the hit cap and the stroke adjustment bolt just make contact when the brake s power is on, and screw the stroke adjustment bolt into the direction of the brake solenoid. Hit Cap Stroke adjustment locknut Stroke adjustment bolt 2. Measure the gap at the bottom of the brake shoe and the drum, as shown in the below picture, verify it is mm with feeler gauges, and make sure the gap is about uniform from top to bottom. If the gap of the top is too big, tighten the bolt clockwise to reduce it. If the gap is too small, loose the bolt counter-clockwise to increase the gap. Brake drum Feeler gauges Brake Lining 3. Tighten the Locknut M12 up then apply Loctite 271 between the locknut and the bolt. Manual No. TDII-003-IGD20 11

14 Brake Synchronous Adjustment This step should be performed when the condition of the brake torque is as per the machines rated requirement. Required Tools & Materials: Open End Wrench: 18mm Adjustment Procedure: 1. If one brake arm opens slower than the other brake arm, loose the spring adjustment nut and locknut. 2. If one brake arm opens faster than the other brake arm, tighten the nut. 3. After adjustment, verify the brake torque again to make sure it is according to Brake torque adjustment requirement of the machine. Maintenance Only qualified personnel are allowed to perform any maintenance work. The person who performs the maintenance work must be very careful as some work must be performed when the machine is running. Brake Stroke Check Please pay attention to the value of brake stroke during the course of routine maintenance. If the brake stroke is too short, the power of the solenoid can not push the brake arm to obtain/shorten the big gap, the brake must be disabled. Generally, the brake stroke has been adjusted in the factory and does not need to be readjusted in the field. Suggested check cycle Every 3 months after install on the first 6 months. Every 1 year thereafter. Benchmark Criteria The gap at the bottom of the brake Shoe and the brake drum should be 0.1~0.5mm. Manual No. TDII-003-IGD20 12

15 Brake Lining Wear Check function correctly. If the brake lining wear is more than 2 mm, the brake will not Suggested check cycle Every 1 year Benchmark Criteria The brake lining wear must be less than2mm. Use a steel ruler to measure the thickness of the brake shoe, the thickness must be more than 6mm. Otherwise replace the brake lining or replace the whole brake assembly. Brake lining Lubricating Check The oil type we recommend is Shell Omala 460 or Kunlun 34# (equal to 460) elevator oil or other type of synthetic oils which have similar performance. Change of oil depends on the cleaning and ageing degree. Check the oil color, smell and cleaning degree and confirm whether oil needs to be changed. If oil turns black and has foul smell, it should be changed. Use filter paper to check oil when it is hot (due to the elevator running) and watch the metal corpuscle/debris if any on the filter paper to confirm whether needs to change the oil.. The oil volume of the IGD20 machine is 8L. The oil level should be at scale mark. If too little, the lubrication will be not enough for smooth functioning of the machine. If too much, the oil will be leak out. If the machine is stored for more than 1 year, the oil should be changed before use. When using mineral oil, the first oil change should be done after the new machine runs 400 hours. When using synthetic oil, it should be done after 700 hours running. After that it should be done as per the machines running pattern, change mineral oil every hours (at most months) and synthetic oil every hours (at most than months). Manual No. TDII-003-IGD20 13

16 For good results, we recommend using mineral oil the first time. But please note that it is prohibited to mix mineral oil and synthetic oil. When changing the mineral oil to synthetic oil please follow the below steps: 1. Take the rope off from the drive sheave when machine stops running and drain the mineral oil away. 2. According to machine oil volume, pour kerosene into geared box. After running the machine at high speed for few minutes, drain the kerosene away. Repeat this step 2 or 3 times. 3. Pour the synthetic oil as per requirement. 4. Run the elevator at high speed in upwards and downwards direction for about 10 minutes (Check if there is smoke through the oil window). 5. Put on the rope and load 25% of rated load on cabin. 6. Run the elevator in upwards and downwards direction for about 10 minutes and check the gear box to see if it sends up smoke. When changing the synthetic oil to mineral oil, please follow the same steps as noted above. Replacement The maintenance personnel who does the replacement work, must make sure that the machine is powered off and the elevator is secured and will not move unexpectedly. Only qualified personnel are allowed to perform the replacement work. Please refer to the troubleshooting procedure first and make sure that the component is actually bad before performing this replacement procedure. Encoder Replacement Required Tools & Materials: Philips head screw driver Inner hexagon spanner (6mm) Clean cloth Straight head screw driver 1.Method to removing the encoder 1. Remove the encoder shield by Philips head screw driver. 2. Remove the encoder cable by straight head screw driver. 3. Remove the broken encoder. Manual No. TDII-003-IGD20 14

17 2.Method to assembly 1. Clean the motor shaft with clean colth, then slip the encoder on to the shaft. 2. Tighten the bolt into the motor through the reed, fasten the encoder with bolt 3. Connect the encoder and the transducer with cable, and fix the encoder shield by screw. Brake Switch Replacement Please refer to the troubleshooting procedure first and make sure that the switch is actually bad before performing this replacement procedure. Required Tools & Materials: Brake switch Philips screw driver Loctite 290 Multimeter Straight head screw driver Open end wrench(7mm) Feeler gauges:1mm 1. Method to Disassemble 1. Loosen the bolts and the washers in the brake terminal box by the Philips head screw driver, and remove the terminal box cover. 2. Remove the brake switch cable which is to be replaced from the brake terminal by straight head screw driver. 3. Loosen the composite slot screw M4x10 by philips head screw driver, then remove the broken switch. 2. Method to assembly 1. Clean the switch bracket component installing surface, if it is not clean. 2. Install the brake switch and the switch bracket component on the brake surface by composite slot screw M4x10. Manual No. TDII-003-IGD20 15

18 3. Reconnect the new brake switch cable. 4. Verify with multimeter that the brake switch is functioning. 3. Brake switch adjustment 1. Loosen the adjustment bolts by Philips head screw driver and open end wrench(7mm), and adjust the position of the brake switch on the slot of the switch bracket component. 2. Place a 1mm feeler gauges between the hit cap and the brake switch, and adjust the switch slowly, when the switch is active (makes the click noise), tighten the ajustment bolts and locknut, and remove the feeler gauges. 3. Apply Loctite 290 between the screw heads and the switch body. Motor Replacement Please refer to the troubleshooting procedure first and make sure that the motor is actually bad before performing this replacement procedure. Required Tools & Materials: Hoisting equipment Open end wrench: 24mm Arm Puller Clean cloth Lubricating oil Torque Wrench 1. Method to Disassemble 1. Remove the elevator from service. 2. Remove the encoder from the motor; refer to the Encoder Replacement on Page Remove the power cable from the terminal box. 4. Install a hoist and rigging over the motor, and hoist the motor until pressure is applied to the rigging. 5. Remove the Bolts (4) M12x45 and washers. Manual No. TDII-003-IGD20 16

19 6. Remove the motor away from the traction machine. 7. Place a big enough block on the ground below the motor, and lower the motor on the block. 8. Fix the arm puller on the shaft joint, and remove the shaft joint, put away the keyway C12/C16 until the assembly of the new motor. 2. Method to Assembly 1. Clean the motor shaft with clean cloth. Put the keyway on the shaft and apply some lubricating oil. 2. Press the shaft joint into the motor shaft with a hydraulic pressing machine (A special machine used for inserting the shaft joint into the motor shaft). 3. Apply some lubricating oil on the rubber coupling, hoist the motor and keep it at a flat level, make the position of the shaft joint s keyway and the position of the brake drum s keyway 180-degree from each other. 4. Tighten the bolts (4) M12x45 and washers to 50-70Nm. 5. Turn the motor and measure the run out of the brake drum it should be within 0.5mm. Brake Replacement Please refer to the troubleshooting procedure first and make sure that the brake is actually bad before performing this replacement procedure. Required Tools & Materials: Hex Wrench (6mm) 1. Method to Disassemble 1. Remove the elevator from the service. 2. Remove the brake cable and the brake switch cable from the brake terminal box. 3. Loosen the adjustment nuts, then loosen the brake fix bolts(4), and remove the broken brake. Adjustment Nuts Brake fix bolts Manual No. TDII-003-IGD20 17

20 2. Method to Assembly 1. Install the new brake onto the reduction box, and fix it with the bolts and washers, but do not tighten it completely. 2. Adjust the position of the brake, make the axes of the solenoid, the spring threaded stud and the stroke adjustment bolt in the same axes, and tighten the bolts, make the position of the brake relatively fix. 3. For the brake adjustment process please refer to this manual s on Page Brake Lining Replacement Please refer to the troubleshooting procedure first and make sure that the brake lining is actually bad before performing this replacement procedure.if the brake lining wears more than 2mm, it must be replaced or replace the whole brake arm assembly. Required Tools & Materials: Open end wrench: 18mm Hammer Retainer pliers 1. Method to Disassemble 1. Remove the elevator from service. 2. Remove the spring adjustment nut & washer, the brake spring, and the spring bolt. 3. Remove the set screws and washers, and install the M6 bolt into the end of the brake arm pivot pin. 4. Remove the brake arm pins by pulling on the bolt installed in step (3) by using the retainer pliers. 5. Hoist and remove the brake arm, and move it away from the machine. NOTE: This brake arm is not heavy enough to require rigging and can be removed by a hand. 6. Remove the circlip, then remove the pin with a hammer and a bolt, use the bolt head to prop the pin, then hammer the bolt s other side to get the pin out of the hole. 7. Remove the worn out brake lining. 2. Method to Assembly 1. Clean the brake arm and new brake lining with clean cloth. 2. Install in pressure spring into the hole of the brake arm, and fix the brake show (with brake lining) with the pin and the circlip. Manual No. TDII-003-IGD20 18

21 3. Install the brake arm assembly into the reduction box with the brake arm pivot pin, and fix it with the bolt M6x12 and washers. 4. Install the spring threaded stud, the brake spring, the spring adjustment nut, and the adjustment washer. 5. About the brake adjustment please refer to this manual s on Page Sheave replacement Please refer to the troubleshooting procedure first and make sure that the sheave is actually bad before performing this replacement procedure Required Tools & Materials: Hoisting equipment Torque wrench Dial meter Open end wrench: 18mm and 38mm A Spacer/ Pipe Clean cloth 1. Method to Disassemble 1. Remove the elevator from service. 2. Loosen the Nut M16 in the Stop Lever by the open spanner, and turn the stop lever (rope gripper) about 90 along the direction of the arrow. 3. Remove the ropes from the drive sheave. 4. Install a 1/2-ton hoist and rigging over the sheave. 5. Hoist the sheave until pressure is applied to the rigging. 6. Remove the three (3) drive sheave retaining bolts by open end wrench (18mm), and remove the drive sheave retainer. 7. Place the spacer (1 ¾ section 3 pipe or similar material) over the end of the output shaft. 8. Replace the drive sheave retainer: use three (3) of the long drive sheave carrier bolts, and Manual No. TDII-003-IGD20 19

22 put these bolts through the outer set of holes that line up with the threaded holes in the sheave. 9. Equally tighten the three (3) bolts in the drive sheave retainer until tight. Repeat this process until the sheave is pulled off of the output shaft and the sheave carrier. NOTE: The output shaft and sheave carrier are tapered. Once the sheave is moved a small amount, it can be removed by hand Drive Sheave Drive Sheave Retainer Drive Sheave Carrier Bolts Drive Sheave Retaining BOLTS Keyway Spacer Output Shaft 2. Method to Assembly 1. Ensure the replacement sheave keyway is also in the same position of the removed sheave. This will make it easier to line up the drive sheave and the output shaft keyways. 2. Hoist the replacement sheave into place. 3. Replace the drive sheave retainer and align the three (3) inner holes in the out shaft. 4. Insert, thread, and hand tighten the three (3) drive sheave retaining bolts. 5. Tighten the three (3) drive sheave retaining bolts to 50~70Nm. Manual No. TDII-003-IGD20 20

23 6. Clean the rope groove of the drive sheave-this will be used as an indicator surface. 7. Attach a dial meter to the machine, over the drive sheave, between the 12 o clock and the 1 o clock position. Set the indicator to measure the side of the cleaned rope groove. See below figure. Dial meter Drive Sheave 8. With the dial meter, check for sheave grove run out(it should be 0.2mm),by rotating the drive sheave clockwise one (1) complete revolution. 9. Hang the ropes on the drive sheave. 10. Release the safety and the governor. 11. Turn ON the mainline that was disconnected. 12. With the weight now on the drive sheave, run the car down a few landings & then back up. 13. Reinstall the two (2) rope retainers. Ring Gear Replacement Please refer to the troubleshooting procedure first and make sure that the component is actually bad before performing this replacement procedure. Required Tools & Materials: Pneumatic wrench Box end wrench (24mm) Hammer Dial indicator Color ink Hoisting equipment Clean cloth 1. Method of replacement 1. Remove the sheave; please refer to this manual s Sheave Replacement Method to Manual No. TDII-003-IGD20 21

24 Disassemble on page Loosen the Plug Cock, drain the oil. Oiling window hoods Plug Cock 3. Take apart the pin form the top housing and the bottom housing with hammer, and loosen the bolts from the spindle through cover and the bolts from the bearing gland. Spindle Through-Cover The Bearing Gland 4. Loosen the bolts and washers. 5. Hoist the top housing with hoisting equipment. Manual No. TDII-003-IGD20 22

25 6. Place two stands approximately 300mm apart in an area of the machine room with enough clearance to work the output shaft and ring gear. 7. Hoist the output shaft assembly from the bottom housing, and lower onto 610mm stands. 8. Place some protective material between the ring gear and the stands. 9. With the assembly resting on the stands, remove the output shaft sling, and set the sheave side of the output shaft pointing down. Hoisting equipment 10. Remove the nuts, washers and bolts that secure the ring gear to the gear flange. NOTE: Note the position of the ring gear bolts, washers and nuts. The new material is to be installed in the same position. 11. Contact the building engineer to turn off the machine room smoke detectors. 12. Check the mating surface of the new gear and the gear flange for any debris that may hinder a flush fit. 13. With a gloved hand, set the new gear (with the mating side down on the gear flange), and gently move the new gear until it drops onto the gear flange. 14. Once the gear is sitting flush, align the holes to match the gear flange (drift pins or an existing bolt can be used for alignment). 15. Allow the gear to cool completely, then adjust the hole from the flange side up. See below figure. Manual No. TDII-003-IGD20 23

26 Adjust the holes from the flange side up 16. Insert and tighten the bolts, washers, and lock nuts. NOTE: It may be necessary to use the lock nut to pull the bolt through; turn the lock until the bolt head is flat on the gear surface. Do not hammer the bolts. 17. Torque the lock nuts to 108 Nm Hoist the output shaft assembly into the bottom housing. 2. Method to Adjustment 1. Tighten the bottom housing and the bearing gland with the bolts; tighten the bottom housing and the spindle through-cover with the bolts. 2. Install the magnetic base of the dial meter to the gear case. 3. Pull the drive sheave in one direction, and then zero the dial meter. 4. Push the drive sheave in the opposite direction, and read the amount of gear movement. NOTE: The displacement for a machine should be 0.12~0.2mm. Manual No. TDII-003-IGD20 24

27 5. If the displacement does not reach the requirement, turn the bearing gland or the spindle through-cover (the position of twelve (12) holes), repeatedly adjusted to meet the requirements straight. 6. Spray or paint layout color on three (3) teeth (equally spaced around the sheave), and allow it to dry completely. 7. Place the car on inspection Operation. Turn on the mainline disconnect. 8. Run the machine in one direction until the color is marking of the worm and the pattern can be seen. 9. Repeat Step 12, but run the machine in the opposite direction. 10. Survey the gear pattern carefully. Contact Area Layout Color Dye 11. Make sure that the contact area account for 30% of the direction of the gear s width, and for 55% of the direction of the gear s height. If the contact area is to left, increase the shims of the left side cover, or reduce the shims of the right side cover. If the contact area is to right, reduce the shims of the left side cover, or increase the shims of the right side cover. Repeatedly adjust to meet the requirements straight. 12. Clean the junction surface of the bottom housing and the top housing with clean cloth, daub the sealant around the surface of the bottom housing. Sealant 13. Hoist the top housing onto the bottom housing with the hoisting equipment, then tighten them with Bolts, Nuts. Manual No. TDII-003-IGD20 25

28 14. Tighten the bolts to fasten the spindle through-cover, and tighten the Bolts to fasten the bearing gland. See below figure. 15. Put the Pin into the case and the case cover, and inject elevator oil into the case, fit on the oiling window hoods, and tighten it with bolt. 16. Install the sheave; refer to this manual s Sheave Replacement Method to Assemble on Page Connect the mainline and test the machine. Bearing Replacement Please refer to the troubleshooting procedure first and make sure that the component is actually bad before performing this replacement procedure. The bearing replacement work must be done on the ground, so the machine must be lifted and moved out of hoist way to perform the bearing replacement work. Required Tools & Materials: Hoisting equipment Bearing heater Open end wrench: 18mm and 24mm Arm puller 3#general purpose lithium lubricating grease Manual No. TDII-003-IGD20 26

29 1. Output shaft bearing replacement 1. The step about hoisting the output shaft assembly from the bottom housing can be done by refer ring this manual s Ring Gear Replacement --Method of replacement Step 1~8. 2. Withdraw the spindle through-cover assembly. NOTE: Don t damage the seal in the output shaft bearing cover assembly. 3. Remove the bearing with the arm puller. 4. Place the new bearing in or on the bearing heater. And heat it to about 80±15 degree C. 5. With a gloved hand, quickly slide the heated bearing fully onto the output shaft. 6. When the bearing has cooled completely, spread grease outside the ring worm on the inside lane of the bearing. 7. Apply right amount of 3# General purpose lithium lubricating grease on the seal of the output shaft bearing cover assembly, and install it to the output shaft. 8. Replace the bearing in the bearing gland with the same method, please refer to steps 3~7. 9. Hoist the output shaft assembly into the bottom housing, and adjust the backlash by referring to this manual s Ring Gear Replacement part 2 Backlash Adjustment. 2. Worm Gear Bearing Replacement 1. Remove the brake system; refer to this manual s Brake Replacement Page 17 and Brake Lining Replacement Method to Disassemble steps 1~6. 2. Remove the motor refer to this manual s Motor Replacement Method to Disassemble. 3. Loosen the Plug Cock, drain the oil. 4. Loosen the Bolt and the washer that tighten the worm shaft front cover, with the M18 mm open end wrench, and remove the worm shaft front cover. 5. Remove the brake drum and put away the keyway. 6. Loosen the Bolts and the washers that tighten the worm shaft through cover with the M18mm open end wrench, and remove the worm shaft through cover assembly. 7. Loosen the bolts and the washers from the worm shaft back cover assembly, and remove it. 8. Turn the shaft sheave by hand to remove the worm shaft assembly from the bottom housing. 9. Install an arm puller on the bearing, and remove the bearing. The front bearing and the back bearing is same and can be removed the same way. Manual No. TDII-003-IGD20 27

30 Brake drum Worm shaft through cover Arm Puller Back bearing Front bearing 10. Place the new bearings in the heater, and heat bearings to 80±15 degrees c, then quickly slide the hot bearing fully onto the worm shaft. NOTE: Do not wear gloves when performing steps11 and Install the bearing cup of the front bearing into the front bearing bore of the bottom housing, and apply some 3# general purpose lithium lubricating grease on it. 12. Turn the shaft sheave by hand to install the worm shaft assembly into the bottom housing, and install the bearing cup of the back bearing into the back bearing bore of the bottom housing with 3# general purpose lithium lubricating grease. 13. Install the worm shaft back cover assembly and some shims into the corresponding hole, and screw two bolts and washers on the cross, do not tighten it too much. 14. Install the protecting pipe/spacer into the worm shaft motor side, place the seal into the worm shaft through cover, and smear some 3#general purpose lithium lubricating grease in it. Place the bearing and washer in the worm shaft motor side, and remove the protecting pipe/spacer, tighten the worm shaft through-cover with the Bolts and washers. 15. Tighten the worm shaft back cover with the blots and washers. 16. Cover the brake drum into the worm shaft, then install the worm shaft front cover assembly, tighten it with bolt and washer, and press the brake drum into the position, note the position of the keyway to install motor conveniently. 17. Measure the travel movement of the brake drum by moving the drum in the forward and backward direction with dial meter, the radial movement should be no more than 0.1mm,the axial gap should be 0.03~0.08mm. Adjust the quantity of the shims in the cover of worm shaft on the back side until they meet the standard. 18. Loosen the bolts and washers to remove the worm shaft back cover, install the seal, and apply some 3#general purpose lithium lubricating grease. Place the assured shims to the back bearing bore, tighten it with bolts and washers. 19. Loosen the bolt to open the oil windows lid, then fill in about 9L elevator oil. 20. Install the motor; refer to this manual s Motor replacement Method of Assembly. 21. Connect the mainline and test the machine. Manual No. TDII-003-IGD20 28

31 O-Rings and Seal Replacement Please refer to the troubleshooting procedure first and make sure that the component is actually bad before performing this replacement procedure. If the position where the bearing is installed leaks oil, then the O-Rings and Seal must be examined and replaced. Required Tools & Materials: Open end wrench: 18mm and 24mm 3#general purpose lithium lubricating grease 1. Method of replacement (on the Output shaft) 1. If oil leaked on the bearing cover: a) Loosen the bolts and washers and remove the bearing gland, and then remove the old O-Ring. b) Apply some 3#general purpose lithium lubricating grease into the new O-Ring, and install it onto the bearing gland. c) Tighten the Bolts and washers. 2. If oil leaked on the main shaft bearing cover: a) Remove the sheave, refer to this manual s Sheave Replacement Method to Disassemble. b) Loosen the bolts and washers and remove the spindle through cover, then remove the old O-Ring. Spindle through cover Seal O-Ring c) Remove the bearing cup from the cover, examine the seal and replace it with new one if it is damaged. d) Apply some 3#general purpose lithium lubricating grease on the new O-Ring, and install it onto the spindle through cover. e) Tighten the bolts and washers. f) Install the sheave, refer to this manual s Sheave Replacement Method to Assembly. Manual No. TDII-003-IGD20 29

32 2. Method to Replacement (on the Worm Shaft) 1. If oil leaked on the worm shaft s back cover: a) Loosen the bolts and washers, remove the worm shaft back cover, and then remove the old O-Ring. b) Apply some 3#general purpose lithium lubricating grease on the new O-Ring, and install the O-ring on the worm shaft back cover. c) Tighten the bolts and washers. 2. If oil leaked on the worm shaft through cover: a) Remove the motor; please refer to this manual s Bearing Replacement Worm shaft bearing replacement steps 1-6. Seal Worm shaft through cover O-Ring b) Examine the seal and replace it with new one if it is damaged. c) Apply some 3#general purpose lithium lubricating grease on the new O-Ring, and install the O-Ring on the worm shaft through cover. d) Install the bearing, please refer to this manual s Bearing Replacement Worm shaft bearing replacement step13~21. Manual No. TDII-003-IGD20 30

33 Troubleshooting chart The proper maintenance of the geared machines requires adequately trained qualified personnel and proper tools. Faults Possible causes Possible solutions a. Incorrect inverter wiring Verify the inverter wiring to make sure it is done correctly. b. Incorrect inverter parameters Verify the inverter parameters. Motor not working c. Incorrect encoder wiring Verify the encoder wiring is correct. d. Bad encoder alignment Verify if the inverter alignment procedure is performed correctly. e. Loose encoder mounting Tighten the encoder mounting screws f. Bad encoder Replace the encoder. g. Bad brakes Verify the brake operations Abnormal noise or vibration h. Bad motor contactor Replace motor contactor. a. Brake friction noise a. Verify brake control currents. b. Verify brake strokes. b. Bad grounding Verify that earth ground is good. c. Bad inverter parameters Make sure inverter parameters are correct d. Bad encoder feedbacks Check grounding and shielding. e. Bad bearing Replace the machine or bearing. Electrical shocks a. Bad grounding Make sure that ground is solid. b. Bad humidity level Make sure the humidity is within the specs. c. Broken cable insulation Replace the cable. a. Oil or grease on brake disk Remove the oil and change the brake lining. Brake not working Brake switch Not working Motor is too hot b. Incorrect brake stroke Readjust the brake stroke to factory standard c. Brake lining wear out to much Check the brake lining thickness and readjust the brake stroke or replace the brake d. Bad brake coils Replace the brake assembly e. Incorrect counterweight percentage Verify counterweight percentage f. Noise absorber height is too big Reduce the absorber height a. Bad wiring Verify brake wiring b. The position of brake switch not installed correctly Readjust the brake switch position c. Bad brake switch Replace the switch a. Elevator is overloaded Verify elevator loading and duty cycle b. In correct counterweight percentage Verify counterweight percentage Manual No. TDII-003-IGD20 31

34 Traction Machine Assembly No. Torin Drive Part No. Description 1 FYJ The housing bottom 2 FYJ The housing cover 3 GB/T879 Pin 4 FYJ Worm wheel cover 5 GB/T5782 Bolt M18X50 6 GB/T93 Washer 18 7 FYJ Plate 8 GB/T5783 Bolt M6X16 9 GB/T5782 Bolt M20X GB/T93 Washer GB/T6170 Nut M20 12 FYJ Worm wheel 13 FYJ Worm wheel flange 14 GB/T93 Washer GB/T6171 Nut M20 16 GB/T28 Bolt M12 17 GB/T297 Bearing 18 FYJ Worm wheel through-cover 19 FYJ Key 20 FYJ Key Manual No. TDII-003-IGD20 32

35 No. Torin Drive Part No. Description 21 FYJ Main shaft 22 Oil seal 23 GB/T1235 O ring 24 FYJ Oil seal 25 FYJ Paper washer 26 FYJ Worm cover 27 QB-3-1 Plug Cock 28 QB-3-2 Paper 29 FYJ Paper washer 30 GB/T1235 O ring 31 FYJ Worm through-cover 32 GB/T5783 Bolt M12X40 33 FYJ Worm 34 FYJ Key 35 Oil seal 36 GB/T91 pin Manual No. TDII-003-IGD20 33

36 Brake Assembly No. Torin Drive Part No. Description 1 FYJ Brake arm 2 FYJ Brake lining 4 YJ Brake spring 5 FYJU Spring cover 6 GB/T6171 Nut M12 7 FYJ Bolt 8 FYJ Limited bolt 9 FYJ Hit cap 10 J2.2J-12 Sping 11 J2.2J-10 Copper shaft 12 FYJ Brake box 13 J2.2J-16 Release plate 14 J2.2J-18 Plate 15 GB/T65 Bolt M5X16 16 J2.2J-17 O ring 17 FYJ Paper washer 18 J2.2J-15 Coil box 19 FYJ Circle plate 20 FYJ Coil box 21 J2.2J-20 Release spanner 22 GB/T68 Bolt M3 23 Junction 24 GB/T68 Bolt M3 25 Junction box 26 Release circle 27 GB/T6170 Nut M10 28 GB/T97.1 Washer 10 Manual No. TDII-003-IGD20 34

37 29 GB/T93 Washer GB/T5782 Bolt M10X YJ240B Switch bracket 32 Bolt M4X10 33 Microswitch 34 Bolt M3X15 35 FYJ Nut M3 36 FYJ Plate 37 GB/T6173 Nut M12 38 GB/T869 Rivet Manual No. TDII-003-IGD20 35

38 Mechanical Dimensions Manual No. TDII-003-IGD20 36

39 Suzhou Torin Drive Equipment Co., LTD Address:Changshu New &HighTechIndustrial Park, CEDZ, Jiangsu, China Post No.: Tel: / / / Fax: / torindrive.com torindrive.com Website:http// Torin Drive International Mumbai, India Phone: (022) Fax: (022) Manual No. TDII-003-IGD20 37