C5_5__Attachment_4_-_Shasta_Dam_Job_Manuals.pdf

PDF 8 MB Posted Mar 11, 2026

Attached to: Northern California Area Office (NCAO) Troubleshoo
Solicitation number: 140R2026Q0050
Issued by: Department of the Interior Bureau of Reclamation

About this file

Written by GovTribe AI · Mar 11, 2026

This file is a technical manual and job documentation package for gearless elevator equipment and hydraulic brake systems installed at Shasta Dam. The primary contents include installation and operation manuals for the Imperial Electric Company's 908 OB Frame Synchronous AC Motor (Model 908EAG098K702), complete with engineering drawings, electrical schematics, and component specifications. The elevator system is rated for 10,000 lbs. capacity with 500 feet per minute velocity, operating on 480V/60Hz three-phase power with 388 volts and 129 amps at rated load. The documentation covers a 2:1 rope configuration with a 30-inch sheave and 11/16-inch cable specifications, with estimated suspended loads of 56,293 lbs.

The file also contains comprehensive operating manuals for the KTR-STOP S-80-F B-30 hydraulic brake system (identifying numbers M734339 and M734340) and a Werthenbach Hydraulik-Antriebstechnik hydraulic power unit (Order 4500860437). These manuals detail assembly, commissioning, maintenance, and troubleshooting procedures for the dual hydraulic systems (System A and System B) that control the brake operations. The documentation includes motor lubrication specifications (SKF LGEP2 grease at prescribed intervals), encoder information (Heidenhain ECN113 with EnDat interface), brake pad maintenance protocols, and hydraulic fluid specifications. All materials emphasize critical safety protocols regarding air-gap establishment, pressure management, and operational procedures necessary for proper elevator brake system functionality and safety compliance.

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Other files

File	Type	Posted
Sol_140R2026Q0050_Amd_0001.pdf	PDF	Mar 18, 2026
C5_5__Attachment_2_-_Wage_Determination.pdf	PDF	Mar 11, 2026
C5_5__140R2026Q0050_Combined_Synopsis_Solicitation.pdf	PDF	Mar 11, 2026
C5_5__Attachment_1_-_Photos.pdf	PDF	Mar 11, 2026
Sol_140R2026Q0050.pdf	PDF	Mar 11, 2026
C5_5__Attachment_3_-_Elevator.jpg	JPG image	Mar 11, 2026

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Akron, Ohio

Customer: MCE – ARMSTRONG ELEVATOR

Customer order number : SHASTA DAM

Imperial order number: MPEG11663

Car Number: SE1

Frame Size: AGR-908OB Live Load: 10,000 lbs.

F.P.M.: 500 Sheave Dia.: 30.0” with (18) “U” Grooves

Cable Dia.: 11/16 in. Cable Qty.: 6 Roping: 2:1 Wrap: DOUBLE

Encoder: Heidenhain ECN113, Absolute, EnDat interface, 2048 lines

Motor Model Number: 908EAG098K702

Machine outline drawing: 3-2100-0026

Installation & Operation manual: 900 Frame Synchronous AC Manual

Gearless Elevator Motor Data

Installation, Operation

& Maintenance

22.36 [567.9]

Ø40.00 [Ø1016.0]

16.00 [406.4]

7.00 [177.8]

59.00 [1498.6]

ROPE DROP

EXISTING

SECONDARY SHEAVE

6-11/16"-EHS

(Outer Tensile grade Min 1570 N/mm²)

Avg Breaking load: 32800 lbs.

Avg Wt/ft : 0.69 lb/ft

Preferred rope Manufactures Bethlehem, Gustav Wolf, Drako, Messilot, IPH

FRAME 908

MACHINE

14200 LBS

26.02 [661.0]

20.00 [508.0]

21.50 [546.1]

24.50 [622.3]

49.65 [1261.0]

2" FILLET WELD

WELD ISOLATION PLATES

TO EXTRA PLATES

.41 [10.3]

OFFSET

HYDRAULIC BRAKE

CONTROLLER

1.76 [44.7]

26.55 [674.5]

2.00 [50.8]

ISOLATION PAD

BY IMPERIAL

1.00 [25.4]

ISOLATION PLATE

64.64 [1641.9]

60.35 [1532.8]

59.52 [1511.7]

1.00 [25.4]

20.00 [508.0]

.50 [12.7]

13.00 [330.2]

1.67 [42.3]

13.00 [330.2]

BOLT EXTRA ISOPLATES

TO MACHINE BEAMS

USING 3/4-10 GRADE 8

THREADED ROD

AS SHOWN

(PLATES AND HARDWARE

PROVIDED BY ARMSTRONG)

22.00 [558.9]

1.37 [34.8]2.00

[50.8]

The Driving Force in Motion

IMPERIAL

ELECTRIC D

THIRD ANGLE PROJECTION

UNLESS OTHERWISE NOTED.

MUST BE HELD WITHIN:

ALL DIMENSIONS

ARMSTRONG ELEV SHASTA DAM MPEG11663

908 OB 98.0 127.3 388 129 908EAG098K702

This rating table is for 45 % CW

Rated Load Lbs.

Feet per Min.

Sheave Diameter

Inches

Rated Torque Ft-Lb.

Acceleration Torque Ft-Lb.

Total Torque Ft-Lb.

Motor Frame

Hp. RPM Rated

Rated Motor Volts

Rated Amps

Peak Amps

Peak Drive Volts

10000 500 30.0 4042 8090 12133 908OB 98.0 127.3 34.0 388 129 388 463

SHASTA DAM

10,000 LBS

2:1

500 FPM

45%

428' EST.

321°

ROPES 7-3/4"

56293 lbs EST.

PE1

SHEET (1-2)

NOTE:

THE STATIC LOADS SHOWN IN DRAWING

ARE BASED ON A 56293 LBS SUSPENDED LOAD +14200 Lbs

MOTOR, BASE WT

LOADS ARE STATIC NEED TO DOUBLE FOR IMPACT

CAR CAPACITY = 10,000 lbs.

CAR WEIGHT = 15,300 lbs.

CWT. WEIGHT = 19800 lbs. (45%) HOIST ROPE WT = 5175 lbs.(6-11/16"-0.69 lb/ft) COMP ROPE WT = 3250 lbs.(9-5/8"-0.58 lb/ft) TRAVEL CABLE WT = 868 lbs COMP SHEAVE WT= 1900 lbs EST SUSPENDED LOAD: 56,293 lbs

RESULTANT SHEAVE SHAFT LOAD

(2:1) ON MOTOR : 56,293 lbs

MOTOR SHEAVE SHAFT LOAD : 120,000 (MAX)

ELEVATOR SE-1

NOTE

ELEVATOR

PE1-RIGHT HAND SWING

AutoCAD SHX Text 3/4"-10 Thread

AutoCAD SHX Text 0.750"

AutoCAD SHX Text D

AutoCAD SHX Text

AutoCAD SHX Text A

AutoCAD SHX Text B

AutoCAD SHX Text

AutoCAD SHX Text C

AutoCAD SHX Text D

AutoCAD SHX Text

AutoCAD SHX Text This print is the property of The

AutoCAD SHX Text lender for inspection and/or approval.

AutoCAD SHX Text

APPR.

AutoCAD SHX Text

REV.

AutoCAD SHX Text

ECN NO.

AutoCAD SHX Text

DATE

AutoCAD SHX Text

DRWN. BY:

AutoCAD SHX Text

DATE:

AutoCAD SHX Text

DESCRIPTION:

AutoCAD SHX Text

THE IMPERIAL ELECTRIC COMPANY

AutoCAD SHX Text Akron, Ohio 44306

AutoCAD SHX Text

DRWG. #

AutoCAD SHX Text

SCALE:

AutoCAD SHX Text

CHK. BY:

AutoCAD SHX Text

REV.

AutoCAD SHX Text

DRWG. SIZE

AutoCAD SHX Text A

AutoCAD SHX Text B

AutoCAD SHX Text C

AutoCAD SHX Text It is subject to return upon request.

AutoCAD SHX Text loaned to the vendor, customer, or

AutoCAD SHX Text Imperial Electric Company, and is

AutoCAD SHX Text X.XX %%p.010 [0.254]

AutoCAD SHX Text X.X %%p.015 [0.381]

AutoCAD SHX Text

AutoCAD SHX Text X%%d %%p1%%d

AutoCAD SHX Text X.XXX %%p.005 [0.127]

AutoCAD SHX Text

AutoCAD SHX Text 3-2100-0026

AutoCAD SHX Text 06-28-20

AutoCAD SHX Text

NONE

AutoCAD SHX Text

AC GEARLESS 908OB FRM , 11/16" CABLE

AutoCAD SHX Text

30" SHEAVE 16 U GROOVES - RH SWING

AutoCAD SHX Text C

AutoCAD SHX Text

MOTOR MODEL

AutoCAD SHX Text

FRAME HP RPM VOLTS AMPS

AutoCAD SHX Text

CUSTOMER NAME

AutoCAD SHX Text

CUSTOMER ORDER NO.

AutoCAD SHX Text

IMPERIAL ELEC. ORDER NO.

AutoCAD SHX Text 06-28-20

AutoCAD SHX Text A

AutoCAD SHX Text

SHEAVE SHAFT

AutoCAD SHX Text

LOAD (MAX.)

AutoCAD SHX Text

MTR WEIGHT

AutoCAD SHX Text

(LBS.)

AutoCAD SHX Text

AutoCAD SHX Text 14200 lbs

AutoCAD SHX Text

(MAX LBS./FOOT)

AutoCAD SHX Text

120,000 LBS

AutoCAD SHX Text

FRAME

AutoCAD SHX Text

SIZE

AutoCAD SHX Text

908OB

AutoCAD SHX Text

(LBS.)

AutoCAD SHX Text 0 lbs

AutoCAD SHX Text

BASE WEIGHT

AutoCAD SHX Text

CUSTOMER JOB DATA

AutoCAD SHX Text

JOB NAME

AutoCAD SHX Text

RATED LOAD

AutoCAD SHX Text

ROPING

AutoCAD SHX Text

VEL.(FT/MIN)

AutoCAD SHX Text

% CWT.

AutoCAD SHX Text

TRAVEL

AutoCAD SHX Text

WRAP ANGLE

AutoCAD SHX Text

COMPENSATION

AutoCAD SHX Text

SUSPENDED LOAD

AutoCAD SHX Text CAR No.

AutoCAD SHX Text 07-26-20

AutoCAD SHX Text B

AutoCAD SHX Text

AutoCAD SHX Text 11-17-20

AutoCAD SHX Text C

AutoCAD SHX Text

90°

48.69 [1236.8]

17.93 [455.5] 41.24

[1047.4]

90°

40.74 [1034.9]

1.75 [44.4]

64.64 [1641.7]

60.00 [1524.0]

ROPE DROP

HYDRAULIC BRAKE

CONTROLLER

HYDRAULIC BRAKE

CONTROLLER

TERMINAL BOX

20.00 [508.0]

21.50 [546.1]

24.50 [622.3]

26.02 [661.0]

8.63 [219.1]

.41 [10.3]

OFFSET

The Driving Force in Motion

IMPERIAL

ELECTRIC D

THIRD ANGLE PROJECTION

UNLESS OTHERWISE NOTED.

MUST BE HELD WITHIN:

ALL DIMENSIONS

ARMSTRONG ELEV SHASTA DAM MPEG11663

908 OB 98.0 127.3 388 129 908EAG098K702

This rating table is for 45 % CW

Rated Load Lbs.

Feet per Min.

Sheave Diameter

Inches

Rated Torque Ft-Lb.

Acceleration Torque Ft-Lb.

Total Torque Ft-Lb.

Motor Frame

Hp. RPM Rated

Rated Motor Volts

Rated Amps

Peak Amps

Peak Drive Volts

10000 500 30.0 4042 8090 12133 908OB 98.0 127.3 34.0 388 129 388 463

SHASTA DAM

10,000 LBS

2:1

500 FPM

45%

602' EST.

321°

ROPE 9-5/8" OR EXISTING

56293 lbs EST.

PE1

SHEET (2-2)

NOTE:

THE STATIC LOADS SHOWN IN DRAWING

ARE BASED ON A 56293 LBS SUSPENDED LOAD +14200 Lbs

MOTOR, BASE WT

LOADS ARE STATIC NEED TO DOUBLE FOR IMPACT

CAR CAPACITY = 10,000 lbs.

CAR WEIGHT = 15,300 lbs.

RESULTANT SHEAVE SHAFT LOAD

(2:1) ON MOTOR : 56,293 lbs

MOTOR SHEAVE SHAFT LOAD : 120,000 (MAX)

ELEVATOR PE-1

NOTE

ELEVATOR

PE1-RIGHT HAND SWING

AutoCAD SHX Text D

AutoCAD SHX Text

AutoCAD SHX Text A

AutoCAD SHX Text B

AutoCAD SHX Text

AutoCAD SHX Text C

AutoCAD SHX Text D

AutoCAD SHX Text

AutoCAD SHX Text This print is the property of The

AutoCAD SHX Text lender for inspection and/or approval.

AutoCAD SHX Text

APPR.

AutoCAD SHX Text

REV.

AutoCAD SHX Text

ECN NO.

AutoCAD SHX Text

DATE

AutoCAD SHX Text

DRWN. BY:

AutoCAD SHX Text

DATE:

AutoCAD SHX Text

DESCRIPTION:

AutoCAD SHX Text

THE IMPERIAL ELECTRIC COMPANY

AutoCAD SHX Text Akron, Ohio 44306

AutoCAD SHX Text

DRWG. #

AutoCAD SHX Text

SCALE:

AutoCAD SHX Text

CHK. BY:

AutoCAD SHX Text

REV.

AutoCAD SHX Text

DRWG. SIZE

AutoCAD SHX Text A

AutoCAD SHX Text B

AutoCAD SHX Text C

AutoCAD SHX Text It is subject to return upon request.

AutoCAD SHX Text loaned to the vendor, customer, or

AutoCAD SHX Text Imperial Electric Company, and is

AutoCAD SHX Text X.XX %%p.010 [0.254]

AutoCAD SHX Text X.X %%p.015 [0.381]

AutoCAD SHX Text

AutoCAD SHX Text X%%d %%p1%%d

AutoCAD SHX Text X.XXX %%p.005 [0.127]

AutoCAD SHX Text

AutoCAD SHX Text 3-2100-0026

AutoCAD SHX Text 06-28-20

AutoCAD SHX Text

NONE

AutoCAD SHX Text

AC GEARLESS 908OB FRM , 11/16" CABLE

AutoCAD SHX Text

30" SHEAVE 16 U GROOVES - RH SWING

AutoCAD SHX Text C

AutoCAD SHX Text

MOTOR MODEL

AutoCAD SHX Text

FRAME HP RPM VOLTS AMPS

AutoCAD SHX Text

CUSTOMER NAME

AutoCAD SHX Text

CUSTOMER ORDER NO.

AutoCAD SHX Text

IMPERIAL ELEC. ORDER NO.

AutoCAD SHX Text 06-28-20

AutoCAD SHX Text A

AutoCAD SHX Text

SHEAVE SHAFT

AutoCAD SHX Text

LOAD (MAX.)

AutoCAD SHX Text

MTR WEIGHT

AutoCAD SHX Text

(LBS.)

AutoCAD SHX Text

AutoCAD SHX Text 14200 lbs

AutoCAD SHX Text

(MAX LBS./FOOT)

AutoCAD SHX Text

120,000 LBS

AutoCAD SHX Text

FRAME

AutoCAD SHX Text

SIZE

AutoCAD SHX Text

908OB

AutoCAD SHX Text

(LBS.)

AutoCAD SHX Text 0 lbs

AutoCAD SHX Text

BASE WEIGHT

AutoCAD SHX Text

CUSTOMER JOB DATA

AutoCAD SHX Text

JOB NAME

AutoCAD SHX Text

RATED LOAD

AutoCAD SHX Text

ROPING

AutoCAD SHX Text

VEL.(FT/MIN)

AutoCAD SHX Text

% CWT.

AutoCAD SHX Text

TRAVEL

AutoCAD SHX Text

WRAP ANGLE

AutoCAD SHX Text

COMPENSATION

AutoCAD SHX Text

SUSPENDED LOAD

AutoCAD SHX Text CAR No.

AutoCAD SHX Text 07-26-20

AutoCAD SHX Text B

AutoCAD SHX Text

AutoCAD SHX Text 11-17-20

AutoCAD SHX Text C

AutoCAD SHX Text

Page

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

Original 797112-1

F.Heissenberg +

Date

Replaced by

Titel- / Deckblatt

Modification

0 76

Appr Replacement of

8 93

&EPC2/1

11.02.2020

Name

+ Dokumentenart

Project name/description Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191

+49 05207-99161-0

Number of pages

33758

25.06.2018

Edit date

797112-1

Created on

KTR drawing No.

Machine categorie

KTR_Cover_Sheet_new

F.Heissenberg

Zur Brinke 14

Customer discription

Phone.

Machine type

Company / customer

29.06.2020 by (short name)

KTR Brake Systems

Schloß Holte-Stukenbrock

AC 480V / 60Hz / 5A

AC 115 V / 60Hz

Main voltage

Control voltage

Cabinet protection claas

Customer fuse rating Type : C / 10A

KTR discription

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

&BAA/1

Original 797112-1

F.Heissenberg +

Date

Replaced by

Artikelsummenstückliste : LAPP.1119904 -

SIE.3RT2015-1AK61

Modification

0 76

Appr Replacement of

8 93

+ESK&ETL/1

29.06.2020

Name

+ Dokumentenart

Summarized parts list KTR_Article_Total_List_ENG v2

DesignationOrder number Unit priceType numberSupplier Quantity

LAPP

2ÖLFLEX® CLASSIC 110Power and control cables1119904

SAC-5P-15,0-PUR/M12FRSensor/actuator cable1402146 0049900000082

PLC-RPT-120UC/21-21AURelay Module2900342 4800000340468

PT 2,5-TWINFeed-through terminal block3209549 48000004202584

3RV2011-1FA15CIRCUIT-BREAKER SCREW CONNECTION 5A3RV2011-1FA15 2 480000030026

Ventilstecker - freie LeitungsendenValve plug form A to M12 male straight, 3-pole7000-18041-2360500 6

Phoenix Contact

PT 2,5-TWIN-PEGround modular terminal block3209565 48000004204114

Siemens

3RT2015-1AK61CONTACTOR, AC-3, 3KW/400V, 1NO, AC110V 50HZ, 120V 60HZ3RT20151AK61 2

ADOAA050MSS0005H04Socket, AC, 1/2" connector, Free from halogenE11248 4

Murrelektronik GmbH

ÖLFLEX® CLASSIC 110Power and control cables1119105 2 ifm electronic gmbh

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

+&EPC2/1

Original 797112-1

F.Heissenberg +

Date

Replaced by

ESK

Junction Box

Modification

0 76

Appr Replacement of

8 93

=HYDA&EFS/1

29.06.2020

Name

+ Dokumentenart

3R V2

=HYDB-F1

3RT2

SIEMENS=HYDB-K1

-X

=HYDA-K2

=HYDA-K3

=HYDA-K4

3R V2

=HYDA-F1

3RT2

SIEMENS=HYDA-K1

-X

=HYDA-K2

=HYDA-K3

=HYDA-K4

Normal Brake E-Brake

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

=&ETL/1

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDA

ESK

Grid / Hydraulic Power

Modification

0 76

Appr Replacement of

8 93

26.06.2020

Name

+ Dokumentenart

480V/60Hz AC Grid Power IN Customer Fuse C 10A

Customer Side

2.2

U1 V1 W

-M1 480V/60Hz AC 0,75kW(1Hp)

3~ M

Hydraulic Power Unit A

-X2 1 2 3 PE1

-X1 1 2 3 PE1

1/ L1

2/ T1

-K1 /2.4

3/ L2

4/ T2

5/ L3

6/ T3

1/ L1

2/ T1

3/ L2

4/ T2

5/ L3

6/ T3

-F1 3,5...5A

I>I> I>

/4 .9

300/500 V 4X1.5

ÖLFLEX® CLASSIC 110

-W1

1 2 3 GNYE

1L1 / =HYDB/1.9

1L2 / =HYDB/1.9

1L3 / =HYDB/1.9

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDA

ESK

Controls

Modification

0 76

Appr Replacement of

8 93

29.06.2020

Name

+ Dokumentenart

115V/60Hz AC permanent supply max current 5A

Customer Side

HPU A Motor Control

A potential distribution

-X1 4 5

-K2 /3.1

-K3 /3.6

-K4 /3.7

A1 A2

-K1

AC-3, 3KW/400V, 1S, AC 110V 50HZ, 120V 60HZ

1/L1 2/T1 /1.4 3/L2 4/T2 /1.4 5/L3 6/T3 /1.4

6 7 8 9 10

115VAC_HYDA / 3.0

0VAC_HYDA / 3.0

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDA

ESK

HPU Valves / Sensors

Modification

0 76

Appr Replacement of

8 93

26.06.2020

Name

+ Dokumentenart

Pressure Switch

Oil Level Oil Temp

14 1.5

Electronic Pressure Switch IFM efector 500

PY 9920

-X2 4 5 6 7 8 9PE2

Hydraulic Power Unit A -S2

1.5

1 2 2

A1 A2

-K2

12 11

/2.5

22 21

/4.6

300 V AC

4x0,34

5 m

PUR

-W5

A1 A2

-K3

12 11

/2.5

22 21

/4.7

A1 A2

-K4

12 11

/2.4

22 21

/4.8

BK WH BU 300/500 V

5G0.75

ÖLFLEX® CLASSIC 110

-W6

1 2 3

-S1

1 5 24

115VAC_HYDA/2.8

0VAC_HYDA/2.8

115VAC-HYDA / 5.2

0VAC-HYDA / 5.2

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDA

ESK

Customer Signals

Modification

0 76

Appr Replacement of

8 93

26.06.2020

Name

+ Dokumentenart

115VAC

from customer

Customer Side

Hydraulic Pressure Switch

Oil Level

Oil Temp

Motor Protection

13.713.813.6 max. 30V AC/DC max. 50mA max. 30V AC/DC max. 50mA max. 30V AC/DC max. 50mA max. 30V AC/DC max. 50mA

Brake open/close

115VAC

from customer not used not used

17 18 19 20 21 22

Hydraulic Power Unit A

-X1 11 12 15 16PE2 PE3

3x0,75 5 m

PVC-JZ

-W2

21 3x0,75 5 m

PVC-JZ

-W3 x1 x2

PE-Y1

1.3 x1 x2

PE-Y2

1.5

GNYE GNYE

-K2 /3.1

-K3 /3.6

-K4 /3.7

23 24 25 x1 x2

PE-Y3

1.6

13 14 PE4

3x0,75 5 m

PVC-JZ

-W4

2 GNYE1

13NO

14NO

-F1 /1.0

PE PE PE

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDA

ESK

Hydraulic Brake

Modification

0 76

Appr Replacement of

8 93

=HYDB/1

29.06.2020

Name

+ Dokumentenart

Brake Position Sensor

Pad WearReleased

Customer Side max: 30V AC/DC - 0,1A

Pressure Switch Customer max. 250V AC max. 0,1A

/A C

Sw itc hi ng s ig na l o ut pu t 8 5.

..2

0V /A

Electronic Pressure Switch IFM efector 500

PY 9920

Please note this is only a connection example !

The example connection is customer supply, it’s not supplied by KTR !

Connection example

Brake

-X1 26

-S1 1 4 2 5 3

SAC-5P-15,0-PUR/M12FR

-W7

BN BK WH GY BU

28 29 30 31 32 33 PE3

300 V AC

4x0,34

PUR

-W8

BN BK WH BU

-S3

1 5 24

A1 A2

-K

-0VAC-HYDA/3.8

-115VAC-HYDA/3.8

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

=HYDA/5

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDB

ESK

Grid / Hydraulic Power

Modification

0 76

Appr Replacement of

8 93

26.06.2020

Name

+ Dokumentenart

480V/60Hz AC Grid Power IN Customer Fuse C 10A

Customer Side

3.2

U1 V1 W

-M1 480V/60Hz AC 0,75kW(1Hp)

3~ M

Hydraulic Power Unit B

-X2 1 2 3 PE1

-X1 1 2 3 PE1

1/ L1

2/ T1

-K1 /2.4

3/ L2

4/ T2

5/ L3

6/ T3

1/ L1

2/ T1

3/ L2

4/ T2

5/ L3

6/ T3

-F1 3,5...5A

I>I> I>

/4 .9

300/500 V 4X1.5

ÖLFLEX® CLASSIC 110

-W1

GNYE1 2 3

1L1 / =HYDA/1.9

1L2 / =HYDA/1.9

1L3 / =HYDA/1.9

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDB

ESK

Controls

Modification

0 76

Appr Replacement of

8 93

29.06.2020

Name

+ Dokumentenart

115V/60Hz AC permanent supply max current 5A

Customer Side

HPU B Motor Control

B potential distribution

-X1 4 5

-K2 /3.1

-K3 /3.6

-K4 /3.7

A1 A2

-K1

AC-3, 3KW/400V, 1S, AC 110V 50HZ, 120V 60HZ

1/L1 2/T1 /1.4 3/L2 4/T2 /1.4 5/L3 6/T3 /1.4

6 7 8 9 10

115VAC_HYDB / 3.0

0VAC_HYDB / 3.0

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDB

ESK

HPU Valves / Sensors

Modification

0 76

Appr Replacement of

8 93

26.06.2020

Name

+ Dokumentenart

Pressure Switch

Oil Level Oil Temp

1.6

Electronic Pressure Switch IFM efector 500

PY 9920

-X2 4 5 6 7 8 9PE2

Hydraulic Power Unit B

300 V AC

4x0,34

5 m

PUR

-W5

A1 A2

-K2

12 11

/2.5

22 21

/4.6

-S2 1.6

1 2 2

A1 A2

-K3

12 11

/2.5

22 21

/4.7

A1 A2

-K4

12 11

/2.4

22 21

/4.8

BK WH BU 300/500 V

5G0.75

ÖLFLEX® CLASSIC 110

-W6

1 2 3

-S1

1 5 24

115VAC_HYDB/2.8

0VAC_HYDB/2.8 0VAC_HYDB / 5.2

115VAC_HYDB / 5.2

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDB

ESK

Customer Signals

Modification

0 76

Appr Replacement of

8 93

26.06.2020

Name

+ Dokumentenart

Customer Side

Hydraulic Pressure Switch

Motor Protection

Oil Level

Oil Temp

20.6 20.8 20.7 max. 30V AC/DC max. 50mA max. 30V AC/DC max. 50mA max. 30V AC/DC max. 50mA max. 30V AC/DC max. 50mA

115VAC

from customer

115VAC

from customer

Brake open/close not used not used

17 18 19 20 21 22

Hydraulic Power Unit B

-X1 11 12 15 16PE2 PE3

3x0,75 5 m

PVC-JZ

-W2

21 3x0,75 5 m

PVC-JZ

-W3 x1 x2

PE-Y1

1.3 x1 x2

PE-Y2

1.5

GNYE GNYE

-K2 /3.1

23 24 25 x1 x2

PE-Y3

1.6

13 14

3x0,75 5 m

PVC-JZ

-W4

2 GNYE1

PE4

-K3 /3.6

-K4 /3.7

13NO

14NO

-F1 /1.0

PE PE PE

Circuit diagram hydraulic unit with quick-start-2-stage and lowering for article no. 470000766694 / 470000775191 Ed.

Original 797112-1

F.Heissenberg +

Date

Replaced by

HYDB

ESK

Hydraulic Brake

Modification

0 76

Appr Replacement of

8 93

29.06.2020

Name

+ Dokumentenart

Brake Position Sensor

Pad WearReleased

Customer Side max: 30V AC/DC - 0,1A

Pressure Switch Customer

/A C

Sw itc hi ng s ig na l o ut pu t 8 5.

..2

0V /A

Connection example

Please note this is only a connection example !

The example connection is customer supply, it’s not supplied by KTR !

max. 250V AC max. 0,1A

Electronic Pressure Switch IFM efector 500

PY 9920

Brake

-X1 26

-S1 1 4 2 5 3

SAC-5P-15,0-PUR/M12FR

-W7

BN BK WH GY BU

28 29 30 PE3

300 V AC

4x0,34

PUR

-W8

BN BK WH BU

-S3

1 5 24

31 32 33

A1 A2

-K

-0VAC_HYDB/3.8

-115VAC_HYDB/3.8

900 OB Frame Synchronous ACPM

Document 908 OB Frame 6/23/15 Page 1

900 OB Frame AC Permanent Magnet Gearless Machine

Document 908 OB Frame 6/23/15 Page 2

Guarantee and Limitation of Warranties We guarantee that the apparatus manufactured by us will deliver its rated output as indicated on the nameplate, provided such apparatus is properly cared for, operated under normal conditions, and with competent supervision.

We agree to correct by repair or replacement at our option and at our own expense, F.O.B. our factory (buyer to pay freight one way) any defects in apparatus, which may develop under normal and proper use within twelve months after date of shipment. Warranties are contingent upon inspection proving the claims and the buyer giving us immediate written notice of such defects, and provided further that during said period the apparatus is properly cared for, operated under normal conditions, and with competent supervision. The correction of such defects by repair or replacement by us shall constitute a fulfillment of all of our obligations to the buyer. When the apparatus or goods are sold by the original buyer, the maximum guarantee period shall be limited to twelve months from the date of shipment from our factory.

Imperial Electric Company makes no warranty of any kind; expressed or implied, except as above stated.

Warranties of fitness for purpose and merchantability are specifically excluded. The materials sold hereunder shall be of Imperial Electric’s standard quality, and buyer assumes all risk and liability whatsoever resulting from the use of such materials, whether used singly or in combination with other goods or apparatus. Imperial Electric neither assumes nor authorizes any person to assume for it any other liability in connection with the sale or use of the apparatus or goods sold hereunder, and there are no oral agreements or warranties collateral to or affecting this agreement

No Liability for Consequential Damage We are not liable for consequential damage in case of any failure to meet the conditions of our guarantee or the terms of our quotation or your purchase order.

Returns Before returning material to our factory, authorization must be obtained from the factory or nearest district office or representative.

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

Contact Information Imperial Electric Company 1503 Exeter Road Akron, Ohio 44306

Phone: 330 734 3600 Fax: 330 734 3601 www.imperialelectric.com

For service-related inquiries, email: dlimperialelevatorserviceteam@nidec-ise.com

Document 908 OB Frame 6/23/15 Page 3

Table of Contents

Receiving, Handling, and Hoisting----------------------------------------------------------------------------4 - 5

Storage and Extended Storage--------------------------------------------------------------------------------6

Establishing the Air-Gap----------------------------------------------------------------------------------------7

Commissioning----------------------------------------------------------------------------------------------------8

Inspection ---------------------------------------------------------------------------------------------------------8

Machine Positioning--------------------------------------------------------------------------------------------8

Electrical Connections------------------------------------------------------------------------------------------8

Motor AC Connections-----------------------------------------------------------------------------------------8

Encoder Connections-------------------------------------------------------------------------------------------9

Brake Maintenance and Troubleshooting---------------------------------------------------------------10

Brake Inspection------------------------------------------------------------------------------------------------10

Encoder Replacement-----------------------------------------------------------------------------------------11 - 12

Machine Lubrication-------------------------------------------------------------------------------------------13

Periodic Lubrication Process Details----------------------------------------------------------------------14

Document 908 OB Frame 6/23/15 Page 4

Receiving

Upon delivery, examine the machine and report any significant damage to the shipper and to Imperial Electric immediately. Verify that the motor nameplate data matches your order. A sample nameplate is shown below. If the machine has gotten wet during delivery, contact the carrier and Imperial Electric.

Handling and Hoisting

The 908 OB frame machine is a very heavy machine. This machine, as shown below weighs

14,000 lbs. The holes in the frame of this machine are not for lifting this machine. The only approved lifting points for this machine are the on the machine base

Approved lift points

Document 908 OB Frame 6/23/15 Page 5

The only way to lift this machine is at the lift hooks located on the machine base, using a lifting device, and lifting straps qualified for a load of this weight. In the example shown below, we are using a properly rated fork lift, then lifting and suspending the motor using appropriately rated and rigged straps.

Do not lift using the holes in the stator frame! These are used during machine assembly only!

Do not use to lift machine!

It cannot be stressed enough; you must use extreme caution and care when lifting this machine.

Remember, this machine weighs 14,000 lbs!

Document 908 OB Frame 6/23/15 Page 6

Storage and Extended Storage

Storage

• Store in a warm, dry, clean location.

• Protect the machine from weather conditions that can cause condensation.

• Protect the machine from dust, dirt, and metal shavings. Certain metal dusts and shavings can be attracted to the machine by the magnets.

Construction or cement dust can possibly penetrate the machine; keep it in a clean, dry place.

Extended Storage

The brake rotor, sheave, and various other parts are protected with a rust inhibiting membrane before shipping. If the motor is stored beyond thirty days:

• Store in a dry, dirt free area.

• Periodically check the machine exterior for rust.

• If necessary, remove any rust with a fine abrasive paper.

• Do not allow oil or solvents to come in contact with the sheave grooves, brake linings, or brake rotor.

• Place the machine in a sealed enclosure with a dehydrating desiccant package sized for the enclosure and humidity level.

Document 908 OB Frame 6/23/15 Page 7

Important! This following section is extremely important!

This motor cannot be energized until an Imperial Electric qualified technician has confirmed that the Air-

Gap between this motor’s rotor and stator has been properly established! Failure to properly establish this air-gap could result in damage to the rotor magnets!

How do we make sure we have the proper air-gap?

It begins with the machine being perfectly level on its mount, some shimming may be needed.

Remove the rear cover plate by threading lifting eyes into the upper threaded holes and using a hoist.

The air-gap between the rotor and the stator.

A precision plastic gauge of

1.5mm (.06 inch) thickness, is then inserted in the air-gap around the complete outside diameter of the rotor.

This air-gap of 1.5mm must exist at every point on the

OD of the rotor and ID of the stator.

For best results, the machine rotor should be turned by hand and the air-gap rechecked at every point on the stator ID to insure a consistent gap.

Once again, this air-gap is so important that it must be established and confirmed by an Imperial qualified technician during placement and setup of the machine.

Move the rotor manually by grabbing the sheave with a gloved hand and pulling.

See page 2 for Imperial Electric contact information

Document 908 OB Frame 6/23/15 Page 8

Commissioning

Commissioning the machine includes a pre-installation inspection, machine positioning, and electrical connections.

Adjustments, if required, are described in the Suntes brake manual.

Inspection

Inspect the machine carefully before installing, especially if it has been stored for thirty days or more.

Using a soft cloth, thoroughly wipe down the machine. Check for and remove any rust, dirt, or oil from machine surfaces. Remove any rust, dirt, or oil from brake disc surfaces.

Check for any evidence of condensation. If condensation has occurred, contact Imperial Electric for drying instructions before proceeding.

Use a megohmmeter to confirm insulation resistance between the motor phases and the ground terminal.

There should be a minimum of 100 megohms @ 500 VDC for 60 seconds.

Machine Positioning

Provide structural support consistent with loading on gearless machine feet or base pads.

Provide a level foundation with bolts well anchored and matched to motor base or base holes.

Carefully check brake settings and clamper parameters. Refer to brake adjustment instructions in separate brake manual for specific values.

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

Electrical Connections

Electrical connections between the elevator controller and the machine must be made in accordance with local and national code requirements. Generally, AC connections, brake connections, and encoder connections are required to be through separate conduits.

Motor AC Connections

Incoming power to the controller and outgoing power to the motor must be in separate grounded conduits.

Verify power to the controller has been shut off at the main disconnect before proceeding with connections.

1. Refer to the power section drawing in the controller job prints.

2. Make connections as shown. Follow any special notes regarding wire sizes.

3. Follow grounding instructions in the controller job prints.

Phase Connections

Phase Output

U Phase 1

V Phase 2

W Phase 3

Ground Green/Yellow

Terminal

Block currently being used on Frame

900 OB. U,

V, and W are clearly marked

Remember! Do not hook up this machine to electricity until you and a qualified Imperial technician have verified the rotor/stator air-gap!

Document 908 OB Frame 6/23/15 Page 9

Pinout and general specifications

Criteria Description

Data Interface EnDat

Positions Per Revolution 8192 (13 bit)

Incremental Signals 1 Vpp

Line Count 2048

Power Supply 5V, +/- 5%

Maximum Current Consumption without load 150 mA

Maximum Cable Length 150 m (492 feet)

Close up of encoder connector pin numbers

ECN 1313

Encoder

The ECN 1313 is a tapered shaft encoder. It is installed in the machine before shipment. Pins on the encoder connector are male. If required, Imperial can provide an optional cable that is 12 meters (39.4 feet) long, part number 0850424.

Should it be necessary to remove or replace the encoder, please refer to the instructions later in this document.

Encoder Connections

Encoder connections must be made with the power off to avoid equipment damage!

Document 908 OB Frame 6/23/15 Page 10

Brake Inspection Brakes must be inspected at regular intervals.

1. Wipe the machine and braking components down with a soft cloth.

2. Check that the brake pads are resting evenly against the braking surface (at least 95% contact).

3. Note that pad thickness is constant across the arc of the pad.

4. Check that no oil or solvents have contaminated the brake pads or braking surface.

5. Check that there is no evidence of the brake dragging or dropping on the braking surface of the moving brake disc.

6. With the elevator arranged so that it will not move, pick the brake and check that there is a continuous gap between the brake pad and the braking surface of no more than .25mm (.010 inch)

7. Listen as the brake is operated. A certain amount of noise is expected as the brake opens and drops. Excessive noise indicates that lubrication and/or adjustment is required. Refer to Brake Troubleshooting.

Brake adjustments and proper clearances are critical to elevator and machine performance. Damage caused by improper brake adjustment is not covered by warranty.

Brake Maintenance & Troubleshooting

Elevator brakes, unlike vehicle brakes, are not designed to routinely bring the elevator to a stop. A properly adjusted elevator brake will drop onto the braking surface immediately after the car has stopped, preventing additional movement and helping to maintain position.

Because they are not routinely pressing against a moving surface, elevator brake shoes wear very slowly.

All aspects of this machine’s brake adjustment and maintenance are covered in the brake manual as a separate addendum to this manual.

Proper maintenance of the elevator brake includes regular inspection, lubrication, and adjustment when required.

Again, please refer to the specific brake manual for your machine for operation and maintenance information.

Document 908 OB Frame 6/23/15 Page 11

Loosen the encoder expansion collar set screw which is located at

6 o’clock in this picture

Use a 2mm hex key. The expansion collar must be free, or the encoder will not come out.

Remove encoder cable protection shield.

Encoder center attachment screw exposed. Remove with 4mm hex key.

Before using the jacking bolt, insert small screw to protect the threads the encoder center bolt uses.

Insert a M5x10 SHCS into the hole that the center attachment screw occupied.

Remove encoder carefully as it is a precision devise.

Remove the thread protection screw as well.

Thread a M6 x 70mm jacking bolt into the encoder. As bolt is threaded it will push encoder off the shaft.

When installing the encoder, make sure the expansion collar screw assembly does not fall out.

Encoder Replacement

Document 908 OB Frame 6/23/15 Page 12

Insert the encoder center screw; use a touch of blue Loctite on the threads

Tighten center screw and the expansion collar screw.

If encoder cable was removed, then carefully plug into its socket. The socket is keyed; it can only go in one way. Make sure to snap the strain relief into its clip.

Attach the strain relief/cable protection shield.

Clip

To install this encoder cable shield, use a wide blade screwdriver or a 4mm Allen

Encoder replacement done!

Encoder Replacement (Continued)

Document 908 OB Frame 6/23/15 Page 13

Periodic lubrication of the 908 frame machine

The 908 frame machine has two machine lube install points. One grease zerk for the outboard bearing and one grease zerk for the stator frame bearing. Each bearing also has a drain tube with overflow catch cup. Do not confuse the machine grease zerks with the brake clamper grease zerks.

Service Lubrication Grease Quantity

Frame 908 OB

Frame End Bearing:

Lubricate every 3000 hours or 6 months

Grease Quantity: 5.7 oz, (161.0g)

Grease Type: SKF LGEP2

Service Lubrication Grease Quantity

Frame 908 OB

Encoder End Bearing:

Lubricate every 3000 hours or 6 months

Grease Quantity: 4.3 oz, (122.0g)

Grease Type: SKF LGEP2

Document 908 OB Frame 6/23/15 Page 14

Elevator Motor Service Periodic Lubrication Process Details

1. Important! Before beginning service lubrication process, place the elevator on Machine Room

Inspection so that it can be locked out and only operated by the Elevator Service Technician working on the machine.

2. Clean off the grease zerk and the grease plug.

3. Using a 17mm socket, remove the drain plug.

4. Inspect the drain plug threads. If the threads have Teflon tape, then remove the old Teflon tape, clean the threads, and apply fresh, new Teflon tape. If the plug does not have Teflon tape, then clean the threads and apply Teflon tape. At the end of this process, when the drain plug is re-inserted, it should have new, clean Teflon tape applied to the threads.

5. With the drain plug removed, add 1/3rd of the above noted quantity of grease based on your machine frame type. To do this, be familiar with the grease gun being used. Know how many pumps per ounce of volume, or how many pumps per gram of weight.

6. Once the first 1/3rd of the grease is added, run the motor a few floors. This helps distribute the small amount of grease that has just been added. The grease drain plug should remain removed while running it these few revolutions. Very little, if any, grease should come out. If a little grease does come out, that is ok. Don’t try and replace it, just wipe it off and continue with this process. The grease drain plug stays out during this whole process of adding grease and does not need reinstalled until all the grease has been added.

7. Now, add the second 1/3rd of the grease. This is the same process as before, after adding this 2nd

1/3rd of the grease, run the motor a few floors.

8. Now, pump in the third and final 1/3rd of the grease, and once again, run the motor a few floors.

Running the motor a few floors after each addition of the grease, with the grease drain plug out, helps the grease distribute itself and relieve/equalize any air pressure.

9. After the final 1/3rd of the grease has been pumped in, and the motor run a few floors, give one more wipe to the drain plug hole and reinsert the freshly Teflon taped drain plug, tightening it securely.

10. Wipe and clean any grease from the grease zerk and the drain plug.

Important! Do Not Overfill the bearing reservoir by pumping grease until it comes out of the drain hole. This over filling of grease will cause permanent bearing and bearing seal damage. Use only the recommended amount of lubricant called out for your specific machine frame size.

KTR-STOP® S-80-F B-30

(M734430 and M734339)

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

Please observe protection note ISO 16016.

Drawn: 2018-08-07 Shg/Wie Replacing: ---

Verified: Replaced by:

M734339 left-hand version M734340 right-hand version

KTR-STOP

S-80-F B-30

S-80-F B-30 is a spring-actuated brake in a floating calliper design serving to ge-nerate a brake force on a brake disk in order to decelerate a plant’s movement or stop it, respectively, or keep it at standstill.

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

The KTR-STOP® S-80-F B-30 brake was designed to be used as a service and stop brake. For any other applications please consult with KTR.

1 Technical data 3

2 Advice 5

2.1 General advice 5

2.2 Safety and advice symbols 6

2.3 General hazard warnings 6

2.4 Intended use 6

3 Storage, transport and packaging 7

3.1 Storage 7

3.2 Transport and packaging 7

4 Assembly 7

4.1 Components of the brake 7

4.2 Preparation of assembly 10

4.3 Brake pads 10

4.4 Assembly of the brake 10

4.5 Setting/resetting of the centering system 11

4.6 Pressure port of the brake 12

4.7 Start-up of the brake 13

4.8 Setting/Re-setting of the brake 14

4.9 Recommendation of liquids to be used 15

4.10 Disassembly of the brake incl. stand 16

4.11 Spares inventory, customer service addresses 16

4.12 Disposal 16

5 Maintenance 17

5.1 Replacement of brake pads 17

5.2 Maintenance of the brake / replacement of single parts 18

5.3 Maintenance and service 21

6 Accessories - Sensor 22

6.1 Technical Data „State/wear sensor“ 22

6.2 Assembly / start-up 23

Table of contents

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

M734339:

Illustration 1: Dimensional drawing

M734340:

Illustration 2: Dimensional drawing

1 Technical data

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

Table 1: Technical data

Weight [kg] Approx. 165

Width of brake pad [mm] 125

Surface of each brake pad organic [mm ] 28,700

Max. wear of each brake pad [mm] 6

Total brake piston surface - complete brake [cm ] 69

Volume for each brake caliper with 1 mm stroke [cm ] 6.9

Max. operating pressure [bar] 200

Thickness of brake disk [mm] 30

Pressure port G 1/4

Oil bleed G 1/8

Floating range on axles towards mounting surface [mm] 5 off the mounting surface [mm] 10

Operating temperature [°C] -20 to +50

Table 2: Clamping force, loss of preload force, opening pressure and weight

Brake type Clamping force

Fc [kN] Loss of power

Opening pres-sure [bar]

KTR-STOP

S-80-F B-30 80 5.0 170

1) With a stroke of 1 mm (0.5 mm wear of brake pad on each side)

2FF cb

D FzM av bb

Fb Fc Mb z Dav

= Brake power [kN] = Clamping force [kN] = Braking torque [kNm] = Number of brakes with each brake pad = Effective diameter of brake [m]

Dimensions of brake disk

Illustration 3: External assembly of brake

Table 3: Calculation of brake disk up to ØDA = 1000 mm from ØDA = 1000 mm to

ØDA = 1800 mm from ØDA = 1800 mm

DC max. = DA - 305 DC max. = DA - 295 DC max. = DA - 285

Dav = DA - 130 Dav = DA - 120 Dav = DA - 110

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

Connection dimensions of brake 734339 (left-hand version)

Illustration 4: Connection dimensions

Connection dimensions of brake 734340 (right-hand version)

Illustration 5: Connection dimensions

Please read through these operating/assembly instructions carefully before you start up the brake.

Please pay special attention to the safety instructions!

The operating/assembly instructions are part of your product. Please store them carefully.

The copyright for these operating/assembly instructions remains with KTR.

2 Advice

2.1 General advice

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

STOP

Warning of personal injury This symbol indicates notes which may contribute to pre-venting bodily injuries or serious bodily injuries that may result in death.

Warning of product damages venting material or machine damage.

General advice venting adverse results or conditions.

With assembly, operation and maintenance of the brake it has to be made sure that the enti-re drive train is secured against accidental switch-on. You may be seriously hurt by rotating parts. Please make absolutely sure to read through and observe the following safety indica-tions.

All operations on and with the brake have to be performed taking into account "safety first".

Make sure to switch off the power pack before you perform your work on the brake.

Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on or removing the fuse for current supply.

Do not reach into the operating area of the brake as long as it is in operation.

Please secure the brake against accidental contact. Please provide for the necessary protection devices.

Please make sure that the overall brake/hydraulic system is depressurized during maintenance operations.

You may only assemble, operate and maintain the brake if you have carefully read through the operating/assembly instructions and understood them had technical training are authorized by your company

The brake may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications on the brake design are not admissible. We will not assume liability for any damage that may arise. In the interest of further development we reserve the right for technical modifications.

The brake type S-80-F B-30 described in here corresponds to the technical status at the time of printing of these operating/assembly instructions.

2 Advice

2.2 Safety and advice symbols

2.3 General hazard warnings

2.4 Intended use

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

The brake is delivered in preserved condition and can be stored in a closed, dry place during 12 months.

With favourable storage conditions its properties remain unchanged up to 12 months.

If the brake is stored over a longer period exceeding 12 months as well as after each transport the corrosion pro-tection needs to be renewed and the brake has to be applied over the full braking distance in order to prevent the gaskets from sticking together.

The storage rooms must not include any ozone-generating devices like e. g. fluorescent light sources, mercury-vapour lamps or electrical high-voltage appliances.

Humid storage rooms are not suitable.

Please make sure that condensation is not generated. The best relative air humidity is less than 65 %.

In order to avoid any injuries and any kind of damage please always make use of proper transport and lifting equipment.

The brakes are packed differently each depending on size, number and kind of transport. Unless otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR.

The brake is supplied in pre-assembled condition including stand. Before assembly the brake has to be inspected for completeness.

The brake is generally supplied with the transport lock mounted.

The screw plug (component 2.20) and the sensor (component 12) are attached to the brake in bulk.

Components/component assemblies of brake – Type S-80-F B-30 incl. stand

Compo-nent/sub as-sembly

Quantity Description

1 1 Stand

2 1 Caliper with components

3 2 Guide pin

4 2 Disk

5 2 Cap screw

DIN EN ISO 4762

6 2 Centering system outside

7 1 Centering system inside

8 2 Pad retraction set movable side

9 2 Pad retraction set on fixed side

10 2 Brake pad

11 1 Distance plate

12 1 Sensor

Illustration 6: Components of the brake

3 Storage, transport and packaging

3.1 Storage

3.2 Transport and packaging

4 Assembly

4.1 Components of the brake

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

Subassembly 2: Caliper with components nent

Illustration 7: Caliper with components

2.1 1 Brake caliper

2.2 1 Brake piston

2.3 1 Scraper

2.4 1 Gasket

2.5 1 Gasket

2.6 1 Set of disk springs

2.7 1 Setting nut

2.8 1 Centering pin

2.9 1 O-ring

2.10 1 Scraper

2.11 1 Gasket

2.12 1 Gasket

2.13 4 Screw plug VSTI (acc. to

DIN 908)

2.14 2 Pad retainer

2.15 2 Pad retainer

2.16 8 Cap screw

DIN EN ISO 4762 - 10.9

2.17 2 Drain plug (nylon)

2.18 4 DU bushing

2.19 4 Scraper

2.20 1 Screw plug VSTI (acc. to DIN 908)

2.21 1 Drain plug (Nylon)

2.22 1 Hexagon screw

DIN EN ISO 4017

Subassembly 6: Centering system outside

Illustration 8: Centering system outside

6.1 1 Cap screw

DIN EN ISO 4762 - 10.9

6.2 1 Pressure spring

6.3 1 Drain plug

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

Subassembly 7: Centering system inside

Illustration 9: Centering system inside

7.1 1 Hexagon screw

DIN EN ISO 4014

7.2 1 Hexagon nut

DIN EN ISO 4032

Subassembly 8: Pad retraction set movable side

Illustration 10: Pad retraction set of brake caliper

8.1 1 Cap screw

DIN EN ISO 4762 - 10.9

8.2 1 Pressure spring

Subassembly 9: Pad retraction set fixed side

Illustration 11: Pad retraction set

9.1 1 Cap screw

DIN EN ISO 4762 - 10.9

9.2 1 Pressure spring

9.3 1 Sealing plug

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

To ensure the full braking power, the preparation for assembly needs to be carefully per-formed.

The connection plate for the stand as well as the brake disk have to be inspected for dimensional accuracy.

For that purpose investigate the connection dimensions, connection surfaces and tolerances as specified in the drawing (see illustrations 1 to 5 and table 2).

Clean and degrease the brake disk and mounting surfaces. Dirt can easily be removed by means of solvents.

Please observe the manufacturer’s instructions regarding the use of solvents.

KTR supplies brake pads free from asbestos and lead only.

If requested, we will provide you with the corresponding certificates.

The brake pads are each adapted to the application and delivered accordingly.

They can be distinguished as follows:

organic material powder metal

Brake pads are highly sensitive to grease and oil which means that they cannot be cleaned.

Brake pads having such kind of dirt need to be replaced and disposed of.

We would recommend to store the brake pads in their package as long as possible to pro-tect them from any kind of dirt.

Brake pads which have worn off to the wear limit have to be replaced immediately. Make sure to replace by original parts only.

In order to avoid any injuries please always make use of proper lifting equipment.

In order to avoid any damages on the brake, never twist a rope or another lifting tool around damageable components.

Please make sure that the mounting surface is right-angled to the brake disk and the tolerances as per illustra-tion 4 and 5 are observed.

Set the unit in the correct position and fasten the stand with the respective screws. For tightening torque and tightening processes consult with KTR.

Make sure that the brake disk can rotate freely while not touching the housing.

In order to avoid any contact between the brake disk and the brake resulting from thermal expansion, the distance of the brake according to table 2 needs to be observed.

Please make sure that the tolerances of the brake disk do not exceed the figures specified in illustration 4 and 5.

4 Assembly

4.2 Preparation of assembly

4.3 Brake pads

4.4 Assembly of the brake

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

Centering system inside

The internal centering system needs to be reset with initial assembly or after having re-placed brake pads or single parts, respectively. Only in this way it is ensured that the gap between the brake disk and the brake pad on the bottom side is set to the right value and the pad does not touch on any side.

The internal centering system has to be reset regularly with wear of the brake pads. For that purpose repeat the complete chapter Setting/resetting of the internal centering system.

Measure the gap between the brake disk and the brake pad on the bottom side via a feeler gauge.

Set the gap to 0.5 mm (see illustration 12) by screwing the hexagon screw (component 7.1) either upwards or downwards.

Secure the hexagon screw (component 7.1) via the hexagon nut (component 7.2).

Seal the bore via the sealing plug.

Illustration 12: Setting of gap Illustration 13: Setting of centering system

The gap between brake disk and brake pad needs to be 0.5 mm on both sides to ensure the brake power.

Centering system outside

Screw the cap screws (component 6.1) with the spring (component 6.2) in the stand (component 1). The screw depth in the stand must be 60 mm.

The cap screw (component 6.1) must be secured with Loctite.

Seal the bores via the sealing plugs (component 6.3).

4.5 Setting/resetting of the centering system

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

Connect the pressure oil line to one of the pressure ports of the brake (see illustration 14 and 15). For that purpose remove the screw plug beforehand.

The hydraulic lines have to be rinsed before connecting to the brake to prevent any partic-les from getting into the brake. If the lines are not rinsed sufficiently, the gaskets may be damaged and the operation of the brake is no longer ensured.

Mount a miniature measuring coupling with a miniature measuring hose to the venting hole (see illustration 14 and 15), for that purpose the screw plug needs to be removed beforehand. Discharge the end of the miniature measuring hose in a suitable collection container.

The pressure port on top serves for venting the brake. For a wash-up system please make use of the pressure port on top.

It is not recommended to use steel plugs for venting.

Connect the drain line to the brake (see illustration 14 and 15). For that purpose remove the drain plug before-hand.

In order to locate a leakage immediately, it is recommended to use a transparent hose and collection container. Since higher pressures (5 bar at the maximum) are not generated, a pneumatic hose may be used, too. Please regularly inspect the brake for leakages.

Severe leakages have to be removed immediately. Oil which has escaped has to be comple-tely removed, since oil remains may vaporize on hot components and ignite.

Illustration 14: Connections of the drain lines/pressure lines Illustration 15: Pressure port of a brake

Please make sure that the connections and hoses are adapted to the brakes with regard to pressure, flow rate, temperature and liquid.

Moreover, you have to use flexible hydraulic hoses in order to not limit the motions of the brake. Any hoses which are located close to mobile components should be secured or coated accordingly.

4.6 Pressure port of the brake

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

44599 EN

Before start-up and after each operation on the brake the hydraulic system has to be gene-rally vented.

Repeat venting the brake several times a year, since any air in the hydraulic system may affect the operation of the brake and the plant.

Make sure that there is sufficient liquid in the hydraulic system during and after the venting process (recommendation of liquid, see chapter 4.10).

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File details come from the government source that posted it. Updated Mar 11, 2026.