GE AR LE S S G 100- G 200- G 300- G 400- G 500 - RE V.

10 - 11/2015

LIBRETTO USO E MANUTENZIONE

G-100

OWNERS HANDBOOK
BETRIEBS UND WARTUNGSANLEITUNG
NOTICE DUTILISATION ET DENTRETIEN
MANUAL DE USO Y MANTENIMIENTO

G-200
GEARLESS REV.10 -11/15

G-300

G-400

G-100/G-200/
G-300/G-400/G-500
Motore Gearless sincrono
a magneti permanenti
Gearless synchronous motor
with permanent magnets
Permanentmagnet erregter
Synchronmachine
Moteur gearlss synchrone

G-500

aimants permanent
ALBERTO SASSI S.p.A. (GRUPPO SASSI HOLDING)
U ffi ci e Stabilimento - O ffices a n d Fa c to r y
Bro undWerk - Bureaux et Usine -Oficina- y Fbrica:
Via G. Rossa, 1 - Loc. Crespellano 40053 Valsamoggia (BO)
Italy - Tel. +39 051 6720202 - Fax +39 051 6720244
h t t p : / w w w. s a s s i . i t - e - m a i l : s a s s i @ s a s s i . i t

Motor gearless sincrono

con imanes permanentes

REV.10

La presente pubblicazione stata redatta per i gearless conformi alle norme

EN 81-1: 1998 + A3: 2009. Stabilimento in Loc. Crespellano - Valsamoggia (BO)
The present publication has been written for gearless complying with
EN 81-1: 1998 + A3: 2009 standards. Factory in Loc. Crespellano - Valsamoggia (Bologna) Italy
Diese Verffentlichung wurde fr gearless verfasst, die der Europischen Norm
EN 81-1: 1998 + A3: 2009 entsprechen. Werk in Loc. Crespellano - Valsamoggia (Bologna) Italy
La prsent ouvrage a t rdig pour des gearless conformes aux normes
EN 81-1: 1998 + A3: 2009. Etablissement de Loc. Crespellano - Valsamoggia (Bologna) Italy
Esta publicacin ha sido elaborada para gearless que cumplan con la norma
EN 81-1: 1998 + A3: 2009. Fabrica Loc. Crespellano - Valsamoggia (Boloa) Italy

Tutti i diritti di riproduzione del presente catalogo sono riservati alla:
ALBERTO SASSI S.p.A.

Il testo ed il sistema di numerazione non possono essere usati in altri
stampati, ristampati o tradotti, n integralmente n parzialmente, senza
lautorizzazione scritta della ALBERTO SASSI S.p.A.

PER LA ESATTA INTERPRETAZIONE DELLE PRESENTI ISTRUZIONI VALE
IL TESTO LETTERALE ESPRESSO IN LINGUA ITALIANA

N.B.: le descrizioni ed immagini fornite nella presente pubblicazione non
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che riterr opportune in qualsiasi momento.

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VERBINDLICH.

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rservs : ALBERTO SASSI S.p.A.

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INTERPRTATION CORRECTE DE CES INSTRUCTIONS: SEUL FAIT FOI LE TEXTE
LITTRAIRE EN LANGUE ITALIENNE

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CORRECT INTERPRETATION OF THE PRESENT INSTRUCTIONS: ONLY LITERAL
TEXT EXPRESSED IN ITALIAN LANGUAGE IS DEEMED AUTHENTIC.

Note: the descriptions and illustrations supplied here do not express or
imply a warranty.

ALBERTO SASSI S.p.A. reserves the right to make any modifications it
retains neces-sary at any time.

Todos los derechos de reproduccin de este manual son propiedad de:
ALBERTO SASSI S.p.A.

Prohibido utilizar el texto y el sistema de numeracin en impresos o
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CONSIDERA AUTNTICO EL TEXTO LITERARIO EN ITALIANO.

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no son vinculantes.

ALBERTO SASSI S.p.A. se reserva el derecho de realizar cualquier modificacin que considere oportuna en cualquier momento.

All rights reserved by ALBERTO SASSI S.p.A.

Copyright ALBERTO SASSI S.p.A.

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

1. Safety rules

Read this operators manual before carrying out any operation on the unit. It contains important information
for preventing injury to people, and damage to the product or any other products related to it.
WARNING!
To prevent all risk of injury, or damage to the unit, only skilled, trained staff may do work
on the device.
This operators manual for the gearless motor type G is an integral part of the unit and
must be referred to for all procedures on or involving the unit.
All skilled personnel working on the unit during installation and maintenance must read, understand
and comply with the information provided in this manual.
WARNING! Electric shock hazard!
This device is operated by electric current. Always comply with the safety precautions and
assembly procedure instructions provided in this document.
To avoid the risk of fire or electric shocks, never expose this device to rain or splashing
water. Do not touch the device with wet hands.
Before doing any work on the device, disconnect the power supply by breaking the contact
of the master switch on the control panel. Never disconnect the device terminals when
the motor is powered up.
To operate, the motor requires an inverter and a resolver (e.g. an encoder).
Do not connect the motor directly to the electrical mains!
The power supply must be provided by a suitable electronic converter.
The motor naturally develops a braking torque when the winding short-circuits with no power to the
machine. Torque depends on rotation speed and is independent from the control panel and the winding.
This short-circuit torque, depending on the type of installation and out of balance
loads, contributes to decreasing the natural acceleration of the machine if the brake
is opened, but it may not be enough to limit cabin speed.
Therefore, in order to increase safety, the control panel must be set up with a device
to short-circuit the motor phases when the machine is not powered. This precaution
alone, however, is not sufficient to ensure cabin speed control with the brake open!
Read paragraph 5.1 Motor.
Do not short-circuit the motor phases while the motor is powered
The motor and the converter connected to it may be seriously damaged, thus compromising their operation!!
IMPORTANT SAFETY WARNINGS
The technical data and information supplied (the rating data and technical information) must be

complied with. A suitable drive device, capable of supplying the rated power supply voltage stated

on the motor nameplate, must be provided.
Check the condition of the device before connecting to the electrical power source, or operating it.

In the event of defects or malfunctions, the device must not be installed.
The unit should not be stored in a warehouse for lengthy periods of time.
Keep it in its original packaging, in a dry place without excessive variations in temperature.

In the event of lengthy storage, before putting the unit into operation check the motor bearings by

releasing the brake and turning the shaft by hand.

If abnormal noise is heard, contact the Alberto Sassi SpA after-sales service.

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English

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

Strong magnetic fields may occur in the vicinity of the unit. People with pacemakers and
similar devices must not approach it!
Take care to keep the place of installation clean to prevent iron dust from depositing on
the motor or brake.

1.1. Handling

The assembled motor unit, including the sheave and brake, is quite heavy. Handle it with care and with
suitable equipments.
For G-200 T1 and G-300 use the eye-ring fixed to the tie rod close to the pulley and that fixed close to the
brake, (drw 1a). For G-500 use the hook present in the casing on pulley side and the two hooks in the casing
on brake side; use the three lifting belts supplied with the machine (drw. 1b).
For G-400 use the two hooks in the casing pulley side and the two hooks in the casing brake side (Drw. 1c).
For G-100 and G-200 TC use the two eye bolt fixed to the machine body (drw. 1d).
The hooks are designed to support the weight of the unit complete with brake and sheave.
Do not use them for transporting additional loads!
Drw. 1b
handling
of gearless
G-500.

Drw. 1a
handling
of gearless
G-200 T1
and G300.

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

The unit is fitted with a sheave according to the Alberto Sassi

SpA catalogue range and a brake which guarantees a high
level of safety because it is certified as safety device against
the overspeed in upwards direction and as protection device
against the unintended movement of the cabin (see relative
Operators Manual).
G-200 / G-300 / G-400 / G-500 can be installed in installations
with suspension 1:1 and 2:1 as well.
G-500 can be installed in installations with suspension 4:1 too.
G-100 is suitable for installation with suspension 2:1 ropes
direction downward (drw. 1e).
No other applications are permitted without the prior
authorisation of Alberto Sassi SpA.

Drw. 1e

3. Condition of the unit

3.1. Protection degree

In the basic version, the Gearless motor has IP 21 protection, meaning that it is protected against the entrance of foreign bodies more than 12.5 mm in diameter, and against vertically dripping water.
For the protection degree of the safety brake, please refer to the specific Operators handbook.
Since the motor is part of a larger system, suitable protection measures must be taken on the basis of the
final place of installation and the staff who have access to the unit, while still complying with the minimum
requirements of general safety regulations.
Designers, manufactures and peple mounting the system or the complete installation are responsible
for the correct and safety installation of the machine.

3.2. Operating temperature and thermal class

In accordance with point 0.3.15 of the EN 81-1:2008 standard, the ambient temperature is considered to
be between +5C and +40C. The motor is built from high-quality materials, and is in class F, meaning a
maximum permitted operating temperature for the components of 155C.
Drw. 1d
handling
of gearless
G-100 and
G-200 TC

Drw. 1c
handling
of gearless
G-400.

WARNING!
The motor contains high-performance permanent magnets having a maximum duty
temperature of 150C. If the temperature exceeds this value, the magnets might suffer
a permanent reduction in or loss of their magnetic properties, impairing the motors
performance.
Never exceed this limit!
To prevent the motors limit operating temperature from being reached, the winding incorporates three
temperature control thermistors tripped at 130C. Take care to connect the thermistors to the control panel
and monitor the temperature of the winding in the control circuit.

2. Scope of supply

The motor type G has been designed as a gearless traction unit for rope elevator systems.
It is a particularly versatile, compact, user-friendly unit, allowing it to be used even in roomless systems
and where space is limited. The projecting sheave simplifies the fitting of the ropes and any maintenance
work (G-100 and G-200 TC excluded).
The gearless type G is a synchronous motor with permanent magnets with internal rotor, and in combination with an inverter it provides a modern traction system with high comfort levels, low sensitivity to
interference, and easy installation.

English

18

REV 10 - 11/15

3.3. Motor data plates

The data plate present in the machine shows the

performances of the machine according to the real
use of the installation. These data are necessary for
setting the inverter which controls the machine.
Example in figure 2.

REV 10 - 11/15

Drw 2. Data plate of gearless

machines.

19

English

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

Data

Abbrevation

Machine type

TYPE

Motor

MOTOR

Serial number

SERIAL NR

4. Installation

Unit

The motors condition and performance must be verified upon receival. No defects detected subsequently
will be covered by the warranty.
Any damage caused in transit, or missing motor components, must be reported to Alberto Sassi SpA
immediately.
Welding on the unit is forbidden. Using the motor as mass point for electric arc welding is also forbidden.

Type of service
Max starting per hours

STS/h

% of intermittance (Cycle duration factor)

CDF %

Number of poles

No. POLES

Nominal voltage, star connection

Vn

Frequency regulation, high speed

Hz

Voltage at full load

Power factor

Cos

Mechanical power of the shaft

Pout

kW

Torque at full load

Nm

Setting speed

rpm

Insulation class

ISOL CLASS

Protection degree

IP

Actual out of balance load

OUT OF BAL. LOAD

Kg

Nominal frequence

fn

Hz

of traction sheave

Dp

mm

Peripheric speed of the traction sheave

SHEAVE SPEED

m/s

Order number by the customer

ORDER N

Installation code by the customer

LIFT N

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

The units electrical connections must be made by qualified staff. To connect the motor, refer to and comply
with the terminal board diagram provided in Figure 5 of this manual.
In order to operate, the motor must receive three-phase power from the inverter, and direct current power
to the brake. It is essential to connect the safety components (thermistors, brake micro switches, etc.) to the
control circuit.
The control panel must contain the device needed to short circuit the motor whenever
the unit is not powered up, and this device must be permanently connected. See points
1 Safety Regulations and 5.1 Motor.
To operate effectively, the unit must be fixed to an extremely rigid structure, such as a
rugged motor mounting plate, with permissible unevenness for the mounting surface
lower than 0,25 mm. Suitable vibration-damping supports must be installed between
this structure and the structure of the unit itself. For the fitting of G-100/G-200/G-300,
utilize screws M16 class 8.8 and a tightening torque of 205 Nm; for G-500 screws M30 class
8.8 and tightening torque of 1370Nm; for G-400 screws M24 class 8.8 and torque 690Nm.
The lift cabin should also be isolated from vibrations by means of springs or dampers in
the rope fixing area.
In case the traction sheave has more grooves than the effective number of ropes to be used, take care to
position the ropes in the grooves close to the motor (drw. 3a and 3b).

3.4. Warranties

The information and technical data in this Operators Manual are up to date at the time of
publication and may be subject to amendment without previous notice.
No complaints may be made with regard to motors already sold on the basis of new revisions and/or
editions of this Operators Manual.
No liability will be accepted for faults or defects in the event that:
The installation and general use conditions described in this Operators Manual have been ignored;
The motor has been used improperly, or has been used for an application other than that specified
by Alberto Sassi SpA (intended uses and performance data provided in the catalogue) without prior
agreement of the different applications;
The motor has been modified with alteration of its original components, without agreeing the
procedures with Alberto Sassi SpA;
The motor has been used in conditions other than those considered suitable;
The motor has been handled without due care and attention.
Visible damage must be reported to the Alberto Sassi SpA after-sales service immediately upon receival.

no

ok

-
-

3.5. Packaging

The machines are supplied to the customer wrapped in a VCI plastic film (Volatile corrosion inhibitor) inside
each box. The VCI prevents corrosion and oxidation during transport or storage.

English

20

REV 10 - 11/15

Drw 3a

Drw 3b

Before first use, check that:

The safety devices are installed and operational (see Safety Regulations section);
There are no obstacles in the path of the moving parts;
The motor is earthed by means of the conductor provided;
The cable screens have been correctly connected to prevent all emissions or electromagnetic
interference (EMC);
Check that the entire system has been earthed correctly;
Installation, mounting position and the connections have been carried out correctly;
The plant data correspond to the data on the units data plate.
REV 10 - 11/15

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ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

5. Start-up
5.1. Motor

Connecting the motor directly to the electrical mains is forbidden!

The power supply must be provided by a suitable electronic converter.
Make sure that the motor casing has been earthed using the terminal provided
(PE on the terminal board shown in drw 5).
In order to operate, the gearless type G requires an inverter and an angular position transducer (e.g. an
encoder). The encoder is supplied with the motor, already assembled on the drive shaft.
For information about the encoder, refer to point 5.2 Encoder.
Normal inverters are capable of effectively controlling stopping of the unit and the power supply current.
Users are advised to use this function, and not to open the motor contactors (required by point 12.7.3 of the
EN 81-1:1998+A3:2009 standard) unless the current level is zero (except in emergencies).
Otherwise there is a risk of damage to both the contactors (DC current with zero speed has to be cut off with
AC contactors) and the inverter (overcurrent on the free-wheeling diodes).
However, from the control system side it must be ensured that the contactors have switched completely,
as required by the relevant standards.
To raise the plants overall safety level, it is compulsory to use the braking torque generated
by the motor by short-circuiting its phases whenever it is not in operation.
IMPORTANT! This short-circuit torque may not be enough to limit cabin speed if the brake
is open. Provide the control panel with a suitable device.
Drawing 4 shows a possible connection diagram for the
motor phases, which ensures that no short-circuits are
created when the motor is powered up.
Whenever the motor is stopped by opening the two
contactors K1 and K2, this connection short-circuits the
phases by means of contactor K3. A suitable electronic or
mechanical interlock must be provided between the two
contactors K2 and K3 (dotted line) to prevent the closure
of K3 until K2 is definitely open.

Take care to comply with the cycle direction of the power supply phases U, V and W at
the inputs and outputs of the contactors fitted between the inverter and the motor.
The G motor has been tested with regard to electromagnetic emissions (EMC compatibility)
Herefollows the certificates complying with norms UNI EN12015 and 12016

The connections between the motor and the inverter

must be made in accordance with the phases U, V, and W
and must not be changed. Otherwise, the motor might
accelerate out of control. However, if the phase cycle
order is not complied with, this error can generally be
compensated by means of the inverter control software.
Refer to the technical information for the inverter used
for more information.
To feed the motor use a shield cable to limit the disturbances caused by the inverter.

CERTIFICATE NR

G-300 T1

1001-11-CDC

G-300 T0 - G-200

1002-11-CDC

G-500

12CDC020

G-100

ECM-2015-001

G-400

ECM-2015-002

CERTIFYING BODY
L.E.M. srl

ENTE CERTIFICAZIONE MACCHINE

5.2. Encoder

Supply power to the motor by means of a screened cable earthed at both ending sides.
The motor power supply cable must not be longer than 10 metres .
Otherwise, check the voltage drops along the cable.

22

MACHINE

Three 130 PTC thermistors (blue-blue terminals) have been included in the motor winding to monitor the
temperature. Users are urged to connect and process this monitoring signal to protect the working
life of the unit.
Use appropriate breaking equipment to function in association with the signal provided by the PTC.
The maximum measurement voltage is 2.5 V. The typical response times of PTC sensors are 5 10 seconds.
Drawing 5 shows the diagram of the terminal box of the motor to carry out the electrical connections.
Left side refers to the connection for power feeding of the machine, while right side refers to the connections
to control the signals of thermoresistors and thermocontacts. The fan is optional.

Drawing 4. Connection plan for motor phases of

gearless type G when the motor is not electrically fed.

English

Drawing 5. Connection plan of terminal box for motor type G

REV 10 - 11/15

The encoder is the digital electronic device that supplies the motor control system with information about
the rotors angular position. It must be installed, and must be compatible with the software installed on
the inverter. Refer to the manual of your converter for guidance on whether an absolute or incremental
encoder should be installed.
The encoder is factory-mounted on the drive shaft. The connection must be stable: this is required to retain
the rotor synchronisation acquired by the electronic converter during the initial tuning operations over time.
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ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

The rotor must be re-aligned by the inverter whenever the encoder is mounted on the shaft or tampered
with in any way. Refer to the manual of your converter for instructions for this procedure.
The encoder is a digital position measurement instrument used during operation of the
unit. It is a rather delicate device, and specifically:
all kinds of mechanical shock must be avoided to avoid reducing the measurement precision;
a screened cable must be used to prevent interference and disturbance on the signal;
the encoder is sensitive to electrostatic discharges. Before handling the device, touch
a metal object connected to ground to disperse any electrical charge on your body.
Do not disconnect the encoder under load.

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

At this point the new encoder can be fitted, by following the above procedure in reverse. Check that the
new encoder is equipped with the new centering washer. After fixing the new encoder, it is important
to repeat the recognition of the rotor synchronisation, following the relative procedure described in the
manual of the inverter used.

Unless otherwise specified the encoder fitted to the machine is an absolute encoder. Refer to the manual
of your converter for guidance on choosing the type of encoder.
For information about the alternatives, users may also consult the encoder area of our site www.sassi.it.

5.2.1 Encoder Heidenhein EnDat ECN 1313 (Absolute)
The ECN 1313 Encoder is an absolute encoder with EnDat interface. It is a bidirectional digital communications interface capable of reading and updating the information of the encoder. For additional information,
users are advised to refer to the encoder manual.
The standard encoder is supplied with a 10meter cable. Each ending part is equipped with a 12pin Minitek
connector. One part is already inserted in the encoder, while the other has to be connected to the inverter. If the
Minitek connector is not used, remove it by connecting the wires to the inverter according to the following table.

Pin

Signal

Wire color Pin

Signal

Wire color

1a
2a
3a
4a
5a
6a

DATA/
A+
0V Sensor
B+
CLOCK/
Up Sensor

Blue
Red
Black
Brown
Pink
Grey

Up
CLOCK
B0V
ADATA

Grey-Pink
Green
White
Red-Blue
Purple
Yellow

1b
2b
3b
4b
5b
6b

Drw 6. Fitting encoder to motor shaft

(from Owners handbook by Heidenhain)

Drw. 7. Fitting encoder to motor shaft (from

Owners handbook by Heidenhain)

Please follow the instructions of drawing 8 to connect the cable (the operation had been already carried out
in workshop)

(not wired side)

In case the conductors are not used, these must be isolated. The Up Sensor power supply is connected
internally to the main power.

5.2.2. Encoder Heidenhain EnDat ERN 1387 (Incremental sin/cos)
Encoder ERN 1387 is an synusoidal incremental encoder, with an analogical absolute synusoidal track that
can be used as additional information by the inverter. For additional information, users are advised to refer
to the encoder manual.
The standard encoder is supplied with a 10meter cable. Each ending part is equipped with a 14 pin Minitek
connector. One part is already inserted in the encoder, while the other has to be connected to the inverter. If the
Minitek connector is not used, remove it by connecting the wires to the inverter according to the following table.

Pin

Signal

Wire color Pin

Signal

Wire color

1a
2a
3a
4a
5a
6a
7a

CA-

Black
Violett
Green
White
Grey
-

Up
D+
B+
R0V
A+
C+

Grey-Pink
Pink
Brown
Yellow
Red-Blue
Red
Blue

R+
BD-

1b
2b
3b
4b
5b
6b
7b

(not wired side)

In case the conductors are not used, these must be isolated. The Up Sensor power supply is connected
internally with the main power

5.2.3. Replacing Encoder ECN 1313 / ERN 1387
switch off mains switch and disconnect the cable,
remove the cover (drw. 6),
undo the stud bolt (drw. 6),
remove the fixing screw (drw 7),
remove the encoder by hand together with its centering washer.

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24

REV 10 - 11/15

Drw. 8

5.3. Brake

Consult the enclosed documentation concerning the brake. It describes all its functions and the operations
to be carried out to work on the system in safety. The brake is already assembled to the unit and already preadjusted in the factory. However, after installation users are still advised to check that it operates correctly,
without excessive noise and without slipping. Since braking of the unit is generally controlled by the inverter
which controls the supply of power to the motor, the brake produces only a static torque during stops at the
floors. This means that in these conditions there is no wear of the brake, and no maintenance is required.
Dynamic braking only occurs in emergencies and during any tests on the installation.
The supervision of brake release provided by the microswitches MUST be checked, as
otherwise the certification becomes null and void.
The two braking circuits must be monitored separately and independently.
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ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

6. Maintenance

Follow all safety procedures for suspended loads to prevent the sheave from falling down
after the removal of flange for sheave.

6.1. Replacement of the traction sheave

WARNING!
Before carrying out the procedures described here, make the elevator plant safe.
Place signs to warn of Work in Progress on the plant. Secure all suspended loads.
In the event of incorrect installation, the sheave may come off the unit shaft!!

If excessive wear is noted on the sheave, contact the Alberto Sassi SpA after-sales service to replace the
sheave. The sheave replacement procedure is described below.
The following instructions refer to the mounting and disassembly of traction sheave in geareless
G-200 T1/300/400/500. In G-100 and G-200 TC the traction sheave is integral to the motor body therefore
its replacement could be more difficult; in this case contact after sales departement of Alberto Sassi S.p.A.

6.1.1. Disassembly - disc pulley

After breaking the master power supply switch contact and securing all suspended loads, the ropes can
be removed from the sheave and work on the sheave can begin.
Remove the plastic guard over the pulley ring-nut, undo the four M10 screws (6 screws M12 for G-500) and
remove the M12 stud bolt. Unscrew the ring-nut which keeps the pulley fixed to the cone. Do not lose the
steel washer underneath the ring-nut.
To remove the pulley from the shaft cone, there are two M10 threaded extraction holes in the outside
edges of the pulley, to which a driver tool can be fitted for this operation. The driver can be ordered to the
Alberto Sassi SpA after-sales service (code number 30000052P0).
When the screws are screwed into the extraction holes, the pulley is removed from the drive shaft cone.


6.1.2. Disassembly - band sheave (G-400 - G-500)
In case of band sheave (for G-400 and G-500 only) please refer to the following instructions:

English

1) Unfit the
selflocking
nuts M14 of
the fixing
bolts (light
arrows)
and the
nuts M16
of the fitted
pins (dark
arrows).

2) Undo the
fixing bolts
by means
of a socket
wrench 22.

3) Extract
the fitted
pins by
means of
a hammer
taking
care not to
damage the
threadings.

4) To extract
the sheave,
just screw 3
of the M14
bolts in the
related
threaded
holes
positioned
at 120 in
the sheave.

26

REV 10 - 11/15

5) To extract the flange for sheave unscrew the screws

of the ring nut. Just undo it without removing because
it could be useful in case the detachment of the shaft is
strong or difficult (conical coupling).

6) Position the extractor tool (code 30000052M0) in

such a way that the central tie rod acts on the shaft
and the external tie rods on the flange for sheave,
then screw the M20 nuts of the tie rods till the flange
detaches from the conical. coupling.

6.1.3. Assembly - disc pulley

Fit the tang into the seat provided after checking and after cleaning the mating cone to remove any dirt.
Fit the new sheave onto the cone, aligning it as required by the tang.
The sheave is secured by means of a special M55 x 2 (M75x2 for G-500) ring-nut, secured by four high-strength
M10 screws (6 screws M12 very high resistance for G-500).
A steel shim (recovered during the dismantling procedure) must be fitted between the ring-nut and the sheave
to prevent the fixing screws from deforming the cast iron surface of the sheave hub.
A recess is provided in the ring-nut and in the steel shim, and must be aligned with one of the holes used
for extracting the sheave.
The M12 stud bolt (recovered during the dismantling procedures) must be screwed into this hole.
The screws must be tightened in sequence and not alternatevely, with a tightening torque of 40 Nm (80
Nm for G-500) to ensure that the ring-nut will not become loose (repeat tightening to the specified torque
several times). For additional safety, Loctite 243 should be applied to the four M10 screws (six screws M12
for G-500) to ensure that they remain tightened over time.

6.1.4. Assembly - band sheave (G-400 - G-500)
In case of band sheave (for G-400 and G-500 only) proceed in the following way:
Before mounting check that the space between shaft and sheaves cone is not dirty.
The sheave has four fixing holes for bolts M14 (B in drawing 10).
The calibrated bolts have k6 tolerance.
Couple flange and sheave and bore the pins (17mm H7 tolerance).
See A in drawing 9. Insert the fixing ring (drw. 10a) to avoid the tightning of the dowel directly to the cast iron.
Screw the ring nut checking that any of the dowels is positioned over the key slot.
Apply a drop of Loctite 243 and tighten the dowel crosswise with 80Nm (use a torque wrench).

REV 10 - 11/15

27

English

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

ALBERTO SASSI S.p.A.

Owners handbook gearless G-100/200/300/400/500

TRANSLATION FROM ORIGINAL ITALIAN TEXT

7. Accessories

7.1. Connection cables

To simplify the installers job, pre-cabling of the unit can be requested when placing the order.
The cable is available in the standard sizes of 7-10-15-20 -30-40 metres.
The cabling consists of four cables.

One screened to supply power to the motor,

one not screened to control the thermorsistors and, if present, the fan.
One not screened to supply power to the brake

One not screened for the signals of the brake microswitches

The cables supplied are chosen according to the tables of norm UNEL 35012-70.
We assume to have laid a multipolar cable pvc or EPR-insulated over an open air gangway.
IMPORTANT: check the power failure for each installation.
Drw. 10

Drw. 10 a

The following table shows the tightening torques required:

Nuts and bolts
to fix the flange
to the sheave

Tightening torque
of bolts for flange

4 bolts M14x50

135Nm

2 pins M16x55

205Nm

6.2. Flange for bearing

6.3. Ropes guard

Screws to tighten
the ring nut to
the slow shaft

Tightening torque
of the screws for ring
nut

6 screws M12 (G-500)

4 screws M10 (G-400)

80Nm
40 Nm

Do not dismantle or reassemble the flange for bearing or the rotor. To carry out these operation in the
correct way specific tools are required.
In the event that the bearings need replacement, contact the Alberto Sassi SpA after-sales service.

ROPES GUARD

The motor is fitted with guards to prevent the

ropes from slipping off the sheave and against
foreign bodies.
There are holes in the flange to which the rope
guards must be fixed.
Protection against foreign bodies is provided by
two anti-intrusion bars fastened to the motor
shield by means of M8 screws after they have
been adjusted to the diameter of the sheave and
the ropes fitted.

ANTI
INTRUSION
BARS

Drw. 11

English

28

REV 10 - 11/15

REV 10 - 11/15

29

English