17 ALBERTO SASSI S.p.A.

- OWNERS HANDBOOK GEARLESS G-400

1. Safety rules
Read carefully the owners handbook before carrying out any interventions on the
machine. The book contains important information useful to avoid damages to people, to
the product and/or to other related products.

ATTENTION!
Only qualified and well-trained personell should work on the units to avoid
any personal injury or damage to machinery.

The present owners handbook for Gearless motor G-400 has to be considered part of the
machine and anyone who will operate on the machine must refer to it.
Skilled personel must read, comprehend and follow what specified in the
handbook before carrying out any intervention.

ATTENTION Risk of injuries for people due to electric current!

This device is operated by electric current. Read carefully the

installation and operative instructions as well as the safety regulations
present in this handbook.
To avoid fire or electric shocks protect the device against rain or
splashing water
Do not touch the device with wet hands.
Before carrying out any maintenance or repair operation, switch off the
mains switch in control panel. Do not disconnect the terminals while
the brake is energized.

Motor G400 must be operated with an inverter and a resolver (i.e. Pulse generator)

Do not connect the motor directly to the mains! Feeding must be provided
by a suitable electronic converter.

The motor generates a braking torque when the winding is closed as short circuit.
The torque is proportioned to the rotary speed and the voltage present in the
windings is equal more or less to the nominal voltage.

Therefore, for safety reasons, the use of a device in the control panel
to short circuit the motor phases anytime when the machine is not
fed is strictly recommended. This device prevents the sudden and
uncontrolled acceleration of the opening transistors of the brake.
Refer to chapter 5.1 motor .

Do not short circuit motor phases when the motor is fed!

The motor and the converter could seriously get damaged thus
compromising the operation!

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18 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400

The assembled motor, with sheave and brake, is

heavy.
Handle with care and by means of suitable
means: use the eye bolt near the sheave and
that positioned beside the brake.

The hooks are designed to support the weight of

the machine complete with brake and sheave.
Do not use them to lift other loads.

The machine could generate

strong magnetic fields, Picture 1. Handling example for motor
therefore people with pace
G-400
makers or similar have to
keep away!
Carefully clean the installation
enviroment to avoid iron dust to
deposit over motor or brake.

WARNINGS:
9 Technical data and information supplied (data plates and technical
specifications) must be followed. Provide a correct control to supply the nominal
feeding voltage indicated in motor plate.
9 Check the condition of the device before connecting the machine to the mains or
before operating it. In case of defects or malfunctions do not install the machine.
9 Do not store machine for long time. Keep it in its packing in clean an dry
environments avoiding changes in temperature.
Should the machine be stored for a long time before operating it, release the
brake and turn the shaft by hands checking motor bearings.
In case of strange noise contact After Sales Service of Alberto Sassi SpA.

2. Scope of supply
G-400 is a machine without traction elements (gearless) for lifting units with ropes. G-400
machine is a fully versatile unit very compact and easy to use which can be installed in
installations without machine room (roomless). The overhung sheave (projecting) facilitates
the positioning of the ropes and maintenance operations if necessary.
Gearless type G-400 is a synchronous motor with permanent magnets with internal rotor.
Used with an inverter has to be considered as an evolved traction unit featuring high
comfort, less interferences and installation advantages.
G-400 is supplied with the sheave indicated in the catalogue of Alberto Sassi S.p.A. and a
brake with high safety features since it is certified as safety device against the uncontrolled
movement of tha cabin in upwards direction (refer to the specific Owners handbook)
G-400 can be installed in installation with roping 1:1 and 2:1 as well.
Any other use is allowed without specific authorization of Alberto Sassi S.p.A.

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 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400 19

3. Unit conditions

3.1. Different mechanical configurations

According to the required specifications the machine is supplied with two different options:
with natural ventilation or with forced ventilation with two air conveyors to be fixed over the
rips and the cover of terminal box with cooling fans.

Picture 2. Standard machine, casing with fins, natural Picture 3. Machine with fans and air conveyors
ventilation.

3.2. Protection degree

The standard version of Motor G-400, without forced ventilation, has a protection degree IP
21, that is protection against foreign bodies with diameter larger than 12.5mm and vertical
dripping water. In case of motor with forced ventilation, the protection degree is IP20.
Since the machine is part of complete system, suitable protection measures must be
adopted according to final installation site and to personell who will operate on it. Minimum
safety requirements specified by the general rule must be attended.

Designers, manufacturers and fitters of parts of the complete system or complete

installation are responsible for correct and safe installation of the gearless
machine.

3.3. Working temperature and thermal class

According to section 0.3.15 of EN 81-1:2008 room temperature must range between +5C
and +40C. Motor is made up of high quality materials and is class F, that is maximum
working temperature allowed by components is 155C.

WARNING!
Permanent magnets with high performances are present in the motor whose
maximum working temperature is 150C. Should temperature exceeds this
value, magnets could reduce or loose their permanent magnetic feautures, thus
affecting machine s performances. Do not exceed this value!

Three safety thermistors to check the temperature are inserted in the winding; they operate
as soon as a temperature of 130C is reached. IMPORTANT: connect the thermistors to
the control panel and constantly check the temperature of the winding in the
control circuit.

3.4. Motor data plate

The plate attached to the motor shows the nominal performances. Picture 4 and 5 show an
example.

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20 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400

Picture 4. Example of the data plate present in Picture 5. Example of the data plate present in
machine G-400 with nominal data of the motor machine G-400 with data related to the type of
installation

The plate shows:

Specification Abbreviation Unit
Machine type TYPE
Mechanical power of the shaft POWER KW
Nominal torque Mn Rated Torque Nm
Nominal speed (revolutions per minute) rpm rpm
Nominal voltage, star connection V V
Nominal voltage In Rated Current A
Number of poles No. Poles
Nominal frequence Freq. Hz
Protection degree IP
Insulation class ISOL CLASS
Power factor Cos
Moment of inertia of the motor J rotor Kg m2
Max starting per hours (starts/h) Sts/h
Intermitting factor (Cycling Duration Factor) CDF%

3.5. Warranties
Information and technical data contained in the present handbook were at the time of
printing on the latest state and can vary without previous notice. Claims on motors
already supplied cannot be accepted on the basis of updated revision or issues of the
present handbook.
Liabilty for damages and breakdowns is not taken over with :
Ignoring the installation and operating instructions indicated in the present
handbook;
Improper use of the motor or in case the motor is used in a way different from what
specified by Alberto Sassi SpA (purposes and performances in catalogue) without
prior agreement;
Arbitrary modification of the motor components without approval from Alberto Sassi
SpA;
Inappropriate working of the motor;
Inappropriate handling.
Defects are to be advised immediately after detection to After Sales Service of Alberto
Sassi SpA.

4. Installation
Delivery status and performances must be checked on machine arrival. Any defect detected
afterwards will not be covered by warranty.
Any damage occurred during transport or any missing part must be immediately
communicated to Alberto Sassi SpA.

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 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400 21

Welded joints are strictly forbidden. Do not use the motor as mass point for electric-arc
welding.

Electric connections have to be carried out by skilled personell. To connect the motor, follow
the plans of the terminal box indicated in picture 7a and 7b.
Supply motor with three phase feeding by means of an inverter and DC current to the
brake.
We recommend to connect safety components (thermistors, microswitchs of the
brake Ecc ) to control circuit.

Provide the control panel with a suitable device to short circuit the
motor every time when the machine is not fed. The device must be
permanentely connected. See chapter 1 Safety rules and and 5.1
Motor)

In case of cooling fans provide the suitable AC current (monophase, 220/240 V 50 Hz)

To reach the best running condition,the machine must be fixed to a very rigid structure, for
example a solid plate having planarity deviations lower than 0.25mm. Place silent blocks
between the rigid structure and the supporting structure. Use screws M20 class 8.8 and
tigheting torque of 400Nm. The free length of the threaded part is 40 mm, use a bolt whose
length is suitable to the present frame.
We also recommend to insulate the cabin from the transmission of vibrations using springs
or silent blocks where the ropes are to be fixed.

Before first start check that:

9 Safety devices are installed and operative (see chapter Safety rules);
9 Moving parts are not hindered by any obstacle;
9 Machine is earthed by means of a ground wire;
9 Shields of wires had been properly connected;
9 Installation, mounting position and connections had been carried out in a proper
way;
9 Installation data correspond to data present in motor plate.

5. Start-up

5.1. Motor

Do not connect motor directly to the mains! Feeding must be provided by a

proper electronic converter.
IMPORTANT: earth motor casing by means of the specific terminal
(PE in terminal box showed in picture 7a and 7b, color yellow-
green)

Motor G-400 requires an inverter and a resolver (i.e. pulse generator) for its operation.
The pulse generator supplied with the motor is already fitted to motor shaft. Specific
information over the pulse generator are present in chapter 5.2 Pulse generator.
Before final installation check that the pulse generator is positioned in the correct way.

Common inverters are able to control machines stop and feeding voltage. Use them and do
not open the terminal blocks of the motor (foreseen by chapter 12.7.3 of standard EN 81-
1:2008)when machine is fed (unless emergency cases). Should this occur the terminal
blocks (DC current at null speed to be interrupted by counters in AC) and the inverter
(overcurrent in diods of free-wheeling) can be damaged.
Assure that the terminal blocks have completely changed over as indicated by present
standards.

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22 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400

To increase the safety degree of the complete system, the braking

torque generated by the motor when the phases are short circuited
anytime motor is not working, must be used!
Provide the control panel with a suitable device.

Picture 6 shows a possible connection

plan for motor phases. It assures the
absence of short circuits when motor is
fed.
Anytime the motor stops and opens
two remote control switchs K1 and
K2, this connection short circuits the
phases through switch K3.
A suitable interblock between switch K2
and K3 ( section lining ) must be present
to prevent the closing of switches K3 until
K2 is safely opened.

Connection wires between motor an

inverter must be connected following
phases U, V and W and must not be
changed. On the contrary motor could run
faster without control. By the way should
the cycles of the phases are not
respected, the control software of the
inverter can solve this problem.
Refer to Techincal features of the inverter
implemented to aquire more information.

Picture 6. Example for connection of motor phases of G-

400 machine to brake motor when not fed

To reduce the interferences which could occur due to the inverter, a shield wire to feed the
motor must be used.

Feed the motor with a shield wire, earthed at both ending parts.
If possible, limit the Maximum length of the feeding wire to 10 m.
On the contrary check that voltage drops along the wire do not
occur.

Motor G-400 had been tested with regards to electromagnetic emissions (EMC
compatibility) and obtained compatibility certification nr. 172-08-CDC (issued by L.E.M SrL
Laboratory EMC UNI EN ISO 17025 http://www.lem-emc.it/) which complies with
International Standard EN 12015:2005 and EN 12016:2005.

Three thermistors PTC to check temperature are inserted in motor winding. Connect and
use this control signal to safeguard machine life! Use proper release devices to control
the signal of PTC. Maximum measure voltage is 2.5V. Typical response times of PTC devices
are 5 10 seconds.
Picture 7a and 7b show the plans for motor terminal box of G-400 L1 and G-400 L2 to
carry out electric connections.

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 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400 23

Drw 7a. Connection plan of terminal box for motor G400 L1 .

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24 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400

Drw 7b. Connection plan of terminal box for motor G400 L2.

5.2. Encoder
The encoder is the digital electronic device which informs the motor control about the
angular position of the rotor. It must be present and must be compatible with the
software installed to the inverter. To choose the most suitable encoder type (absolute,
sinusoidal incremental) please refer to the handbook of the converter implemented.
Encoder is delivered mounted to motor shaft, and we recommend not to change the
connection between encoder and motor shaft to avoid change to their relative centering
Connection must be stable: in this way the phase of rotor aquired by the electronic
converter during tuning starting operations is kept during time.

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 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400 25

Everytime encoder is mounted to the shaft or in case of any intervention, rotor

alignement by the inverter must be repeated. Refer to the instructions of the
converter used.

Encoder works as digital controller for the position during machine

operation. It must be handled with care:
Avoid any mechanical shock to avoid interferences to
measurement;
Use a shield wire to avoid interferences and noises of the signal;
The pulse generator is sensitive to electrostatic shocks. Before
handling it, touch a metal mass earthed to disperse charge, which
could be present in the body.

Normally the machine is provided with Encoder Heidenhain ECN 413, but other types of
encoder can be mounted. To choose the right type please refer to the handbook of your
converter.
For further information regarding the possible encoder types, please refer to the Encoder
section present in our web site. www.sassi.it .

5.2.1 Encoder Haidenhain EnDat ECN 413

The encoder ECN 113 is an absolute-type encoder with EnDat interface. It is a
bidirectional digital communication interface, able to read and update the information
contained in the encoder. For further information, please refer to the handbook of the
encoder.
The encoder must be connected to the inverter according to the specification in chart 1.

Chart 1. Match between connector/color of the wires of pulse generator ECN 413
with signals transmitted by the inverter
Pin Signal Colour Notes
1 Up sensor Blue
2 n.c. Black
3 n.c. Red
4 0V White
5 n.c. Green
6 n.c. Brown
7 Up Brown/green
8 CLOCK Violet
_________
9 CLOCK Yellow

10 0 V Un White/green
11 Internal shield
12 B+ Blue/Black
13 B Red/black
14 DATA Grey
15 A+ Green/black
16 A yellow/black
________
17 DATA Pink

The pins and the free items must not be used, but must be insulated as well. The feeding of
the sensor is connected inside to the main feeding.

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26 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400

5.2.2 Replacement of the encoder ECN413

In case of replacement of the encoder, please contact After Sales Service of Alberto Sassi
SpA.

Picture 9 Disassembly of encoder ECN

413 from motor shaft (from Heidenhain
catalog)

Picture 8 Mounting of encoder ECN413 to the motor shaft (from

Heidenhain catalog)

To dismantle the device, please follow the following steps.

- disconnect the wire;
- remove the cover (drw. 8.1)
- loosen the dowels (drw. 8.4)
- remove the fixing screw (drw. 9.1)
- screw a screw M6x70 inside the encoder, this screw will act as extractor for th conical
shaft (drw. 9.2)
- now you can extract the encoder from ist seating
Later you can assemble a neew encoder following the the instruction in reverse order

IMPORTANT: once assembled the new encoder, repeat the recognition of the rotor
phase, follwing the instructions described in the handbook of the implemented
inverter.

5.3. Brake
Read the specific instructions for the brake. Follow them to carry out the correct
instructions to operate in a safety way.

The brake is already mounted to the machine and had been already adjusted in workshop.
We recommend, however, to check, after installation, that everything runs correctly,
without noise or sliding.
The braking is controlled by the inverter, which controls motor feeding, therefore the brake
generates a static torque during stops at the floor. For this reason the brake is not
subject to wear and any maintenance is required. Dynamic brakes are limited only to
emergency cases and to tests.

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 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400 27

Carry out the supervision of brake release operated by the

microswitchs. On the contrary warranty will expire. The two
braking circuits must be checked separately and independently.

To ensure long lasting life to microswitches which control brake release, we recommend to
cable the connections with special wires and to limit voltage at 10 mA to keep switchs clear.
For brake connections, please refer to the specific Owners handbook.

6. Maintenance

6.1. Replacement of traction sheave

IMPORTANT!
Before carrying out the following operations, remove loads from the
installation. Put the signal work in progress on the installation to make
note of the working operations. Rest the counterweight on a suitable
support.
Sheave could fall from motor shaft if it is positioned uncorrectly!!!

In case of eccessive wear of the sheave, contact After Sales Service of Alberto Sassi S.p.A.
to order a new sheave.

6.1.1. Disassembly
Switch off the mains switch, lay counterweight on a suitable support and remove cables
from the sheave.
Remove the plastic cover present over the ring nut and unscrew 4 screws M10. Untighten
the ring nut which keep the sheave in the cone and take the washer positioned under the
ring nut.
To remove the sheave from the cone use the two threaded holes M10 positioned in the
external part of the sheave to which an extractor could be inserted to carry out this
operation. Ask for the specific extractor (code 30000052P0) to After Sales Service of
Alberto Sassi S.p.A. .
Screw the screws in the extracting holes to remove the sheave from the cone of motor
shaft.

6.1.2. Assembly
Check the tab and clean the conical coupling, then position the tab in its seating. Insert the
new sheave in the cone checking that the tab matches the slot present in the sheave.
The sheave is assembled by means of a special ring nut M55 x 2 tightened by four screws
M10 at high resistance. Between ring nut and sheave place a steel spacer to avoid that the
tightening screws damage the cast iron- surface of the hub of the sheave.
Apply Loctite 243 over the threadings of 4 screws M10.Tighten the screws in sequence (not
in alternating way) with a tightening torque of 50 Nm to avoid unscrewing to the ring nut
(repeat the tightening with the specified torque more times) .

6.2. Flange for the bearing

Do not assemble and disassemble the flange for the bearing or motor rotor, because these
parts require special tools to avoid damages to materials.
Should the replacement of the bearing is needed, contact After Sales Service of Alberto
Sassi S.p.A.

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28 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400

6.3. Ropes guard

Protection elements are positioned over the
motor to avoid that the ropes fall down
from the sheave and foreign bodies
penetrate inside.
In the flange there are threaded holes to
position the ropes guard. In case sheave
has a diameter of 240mm the two bars of
the device are to be tightened directly to
the frontal motor shield. By means of the
nuts present in both bars is possible to
tighten them to the shield using a spanner.
For sheave of larger diameter the bar is
tightened to a splined bracket to allow the
adjusting according to the diameter.
Protection against the penetration of
foreign bodies is reached by means of two
brackets to be tightened to motor shield Picture 10
using screws M8 and two brackets with
bars. They must be tightened to the
previous brackets and adjusted according to the diameter of the sheave and the ropes
used. See picture 10.

7. Accessories

7.1. Side fan

Normally, for specific applications, the ventilation group is positioned on the cover of the
terminal box. Should this configuration exceeds overall dimension, it is possible to position

the fans to the side, and fix them directly to the convey carter

7.2. Connection wires

To help the job of the installator, when ordering the machine, you can ask to wire the
machine.
The wiring harness has standard measures 7 10 15 30 mt.
With the harness the are four cables:

- one shielded wire for power feeding to the motor;

- one not shielded wire to control the thermoresistors and , in case, the fan unit;
- one not shielded wire for brake feeding;
- one not shielded wire to control the signals of the microswitches of the brake

The supplied wires have been selected according to the tables of the Norm UNEL 35012-
70, supposing the laying of a multipolar wire with PVC insulation on a open lead support .

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 ALBERTO SASSI S.p.A. - OWNERS HANDBOOK GEARLESS G-400 29

Picture 11: connection plan for motor G-400 with brake DFXY

Rev. 4