TAC50 20technical 20information PDF

TECHNICAL INFORMATION
TAC50t TECHNICAL INFORMATION
WARNING
The following procedures are intended for
the use of qualified and authorized
personnel ONLY. In the interest of your
personal safety and the safety of others, do
NOT attempt ANY procedure that you are
NOT qualified and authorized to perform.
These Procedures must be done in accordance with the applicable rules of the latest
edition of the National Electrical Code; the latest edition of ANSI A17.1, Safety Code
for Elevators; and any governing local codes.
All drawings and information herein are the proprietary property of ThyssenKrupp
Elevator Manufacturing, Inc. and are loaned subject to return on demand and must not
be made public or copied, nor used, directly or indirectly, in any manner detrimental
to the interest of ThyssenKrupp Elevator Manufacturing, Inc.
Every attempt has been made to ensure that this manual is as accurate and up-to-date
as possible. However, ThyssenKrupp Elevator Manufacturing, Inc. assumes no liability
for consequences resulting from any error or omission. Please report any problems
with this manual to the Technical Publications Department.
PLEASE CHECK THE CHANGE

INFORMATION SECTION OF THIS
MANUAL
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-A Printed in USA August, 2002
INTRODUCTION
The TAC50t TECHNICAL INFORMATION PROCEDURES begin at the bottom of the line that precedes the revised text
are divided into two sections: TECHNICAL INFORMATION— and will end at the bottom of the last line of the revision. The
VARIABLE VOLTAGE, VARIABLE FREQUENCY DRIVE, ‘‘Change Bar’’ will be removed should the page be revised
TECHNICAL INFORMATION—SCR DRIVE and TECHNICAL again so that only the latest revisions will be so marked.
INFORMATION—PWM DRIVE.
Engineering changes occur between manual revisions.
Pages are identified as follows: Please check the CHANGE INFORMATION Section for these
changes. The TECHNICAL INFORMATION section should be
Introductory Pages: Section Number (3), followed by a dash kept current by incorporating revisions as they are received.
and a sequential capital letter as the page ‘‘number’’. Exam-
ple: 3-A. Each Procedure should be read carefully and completely
before starting that Procedure. Special attention should be
TECHNICAL INFORMATION—VVVF DRIVE: Section Number given to all CAUTIONS and WARNINGS. Refer to SAFETY
(3) followed by a V (VVVF), a dash and a sequential page num- SUMMARY for explanation. Procedures should be followed in
ber. Example: 3V-1. the order in which they are written.
TECHNICAL INFORMATION—SCR DRIVE: Section Number All Test Equipment, Supplies and Parts should be on hand
(3) followed by an S (SCR), a dash and a sequential page num- prior to starting the TECHNICAL INFORMATION Procedures.
ber. Example: 3S-1. These should be maintained in or near the machine room for
future use.
Figures and Tables are identified in sequential order, that is,
Table 1...etc. If a new subsection begins (for example, SCR ALL Standard Safety Precautions should be followed on the
Drive), numbering is started over. job site. Refer to SAFETY SUMMARY for Safety Precautions
pertaining to TAC50t equipment.
Text Revisions are designated with a ‘‘Change Bar’’—a
black mark in the left margin beside the revision. The mark will
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-B Printed in USA August, 2002
SAFETY SUMMARY
This page should be read BEFORE any work is Always lock out and tag out the Mainline Disconnect when
performed on TAC50t Equipment. power has been removed from equipment. Refer to the
ThyssenKrupp Elevator Employees’ Safety and Accident
Specific warnings and cautions will be found throughout the Prevention Program Manual for the required procedure.
manual where they apply and do NOT appear in this sum-
mary. Always lock out the Main Line Disconnect when power has
been removed from equipment.
All installation wiring must be in accordance with the National

Terms in This Manual Electric Code and be consistent with all state and local codes.
CAUTION statements identify conditions that could result in

damage to the equipment or other property if improper proce-
dures are followed. Test Equipment Safety
WARNING statements identify conditions that could result in Always refer to manufacturers’ instruction book for proper
personal injury if improper procedures are followed. operation and adjustments of test equipment.
Meggering or buzzer type continuity testers can damage elec-

tronic components. Connection of devices such as voltmeters
Use the Proper Fuse on certain low level analog circuits may degrade performance
of an electronic system. Always use a voltmeter having a mini-
To avoid fire hazard, use only a fuse of the correct type, volt- mum impedance of 1M Ohm/Volt. A digital voltmeter is rec-
age rating and current rating as specified in the parts list for ommended.
your product.
When Servicing With Power On

Other Electrical Safety Information
Dangerous voltages exist at several points in this product. To
Electric shocks can cause personal injury or loss of life. Circuit avoid personal injury, do NOT touch exposed connections or
breakers, switches and fuses may NOT disconnect all power components while power is ON.
to the equipment. Always refer to the wiring diagrams.
Whether the AC supply is grounded or not, high voltage to Refer to the ThyssenKrupp Elevator Employees’ Safety and
ground will be present at many points. Accident Prevention Program Manual and the Elevator
Industry Field Employees’ Safety Handbook for safety
Do NOT remove connections or printed circuit cards from the information on installation and service of electrical
equipment while power is applied. This can damage equip- equipment.
ment.
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-C Printed in USA August, 2002
STATIC PROTECTION GUIDELINES
IMPORTANT! Read this page before performing work with electronic cards.
Modern elevator control systems use a number of electronic S Extra care should be used when handling indi-
cards to control various functions of the elevator. These cards vidual, discrete components such as EPROMS
have components that are sensitive to static electricity. Dam- which do not have circuit card traces and com-
age to some electronic components will result from a rather ponents for suppression.
small discharge of static.
Immediate and long-term operation of an electronic- based

system depends upon the proper handling and shipping of its SHIPPING:
cards. For this reason, the Factory bases warranty decisions S Any card returned to the factory MUST be
on the guidelines below. packaged in a static bag designed for the card.
S Any card returned to the factory MUST be
packaged in a shipping carton designed for the
card.
HANDLING:
S ‘‘Peanuts’’ and styrofoam are unacceptable
S Cards shipped from the factory in separate
packing materials.
static bags must remain in the bags until time
for installation.
NOTE: Refer to the Parts Manual to order extra static bags and
S Wear an anti-static wrist strap with ground shipping cartons for each card.
wire. Acceptable straps may be purchased
from the 3-M Company (Charge-Guardt, No.
2066) or Radio Shack.
S Cards MUST NOT be placed on ANY surface
Failure to adhere to these guidelines
without adequate static protection. will VOID card warranty!
S Handle Cards only by their edges after dis-
charging your body to ground. Components,
traces or connectors MUST NOT be touched.
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-D Printed in USA August, 2002
CONTENTS
Page Page
RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . 7-1 Quantum Quiet AC/DC Drive Assembly, 230V, 40-60HP
GROUP CONTROLLER . . . . . . . . . . . . . . . . . . . 7-1 NON-REGENERATIVE . . . . . . . . . . . . . . . . . . . . . . 7A-21
CAR CONTROLLER (FRONT) - SCR, MG, AND
HARDWARE AND SOFTWARE VECTOR VVVF DRIVES . . Quantum Quiet AC/DC Drive Assembly, 460V
7-1 NON-REGENERATIVE . . . . . . . . . . . . . . . . . . . . . . 7A-23
CAR CONTROLLER (REAR) - HARDWARE AND SOFT-
WARE VECTOR VVVF DRIVES . . . . . . . . . . . . . . 7-2 CAR CONTROLLER REAR - DSD 412 SCR DRIVE
CAR CONTROLLER (REAR) - MG DRIVE . . . . . . 7-2 (190 Amp Small Frame Shown) . . . . . . . . . . . . . . 7A-28
CAR CONTROLLER (REAR) - SCR DRIVE . . . . . 7-3
MISCELLANEOUS - SCR, MG, AND HARDWARE AND CAR CONTROLLER REAR - DSD 412 SCR DRIVE
SOFTWARE VECTOR VVVF DRIVES . . . . . . . . . 7-3 (300 Amp Large Frame Shown) . . . . . . . . . . . . . . 7A-29
VVVF QUANTUM DRIVE (Rear Controller)
..................................... 7-4 DSD 412 SCR DRIVE . . . . . . . . . . . . . . . . . . . . . . . 7A-32
VVVF QUANTUM DRIVE (Front Controller)
..................................... 7-5 BRAKE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . 7A-33
APPENDIX A APPENDIX B
REPLACEMENT PARTS CARD CONFIGURATION
GROUP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . 7A-1 CPU CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
CAR CONTROLLER FRONT - VVVF, SCR DRIVES CARD JUMPER CONFIGURATIONS . . . . . . . . . . . . 7B-3
........................................ 7A-3
CAR CONTROLLER VVVF, SCR - POWER SUPPLY PANEL . . APPENDIX C

7A-6 BRAKE ADJUSTMENT
CAR CONTROLLER REAR PANEL ASSEMBLY—VVVF QUAN- GD-1 GEARED MACHINE . . . . . . . . . . . . . . . . . . . . 7C-1
TUM QUIET AC/DC DRIVE 60, 80 & 120 HP REGENERATIVE
7A-11 GD300 GEARED MACHINES . . . . . . . . . . . . . . . . . 7C-9
QUANTUM QUIET AC/DC DRIVE—60 HP REGENERATIVE . G3 GEARLESS MACHINE . . . . . . . . . . . . . . . . . . . 7C-17

7A-13
G4/G5 GEARLESS MACHINE . . . . . . . . . . . . . . . . . 7C-25
VVVF QUANTUM QUIET DRIVE—80 AND 120 HP REGEN-
ERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-15
APPENDIX D
Quantum Quiet AC/DC Drive Assembly, 230V RAKE TORQUE VALUES
NON-REGENERATIVE . . . . . . . . . . . . . . . . . . . . . . 7A-18
GEARED MACHINES . . . . . . . . . . . . . . . . . . . . . . . 7D-1
Quantum Quiet AC/DC Drive Assembly, 230V, 10-30HP OBTAINING TORQUE VALUES . . . . . . . . . . . . . 7D-1
NON-REGENERATIVE . . . . . . . . . . . . . . . . . . . . . . 7A-19
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-E Printed in USA August, 2002
CONTENTS (continued)
Page Page
APPENDIX E APPENDIX G
RAKE TORQUE VALUES SAFETY DEVICE VERIFICATION
CARD REPLACEMENT PROCEDURES . . . . . . . . 7E-1 AND TEST
S CPU Card . . . . . . . . . . . . . . . . . . . . . . . . . 7E-1 GOVERNOR OVERSPEED TEST . . . . . . . . . . . . 7G-1
S DSP Card . . . . . . . . . . . . . . . . . . . . . . . . . 7E-1 CAR SAFETY TEST . . . . . . . . . . . . . . . . . . . . . . 7G-1
S PMI Card . . . . . . . . . . . . . . . . . . . . . . . . . . 7E-1 COUNTERWEIGHT SAFETY TEST . . . . . . . . . . . 7G-2
S Load Weigher Control Card . . . . . . . . . . . . 7E-2 CAR BUFFER TEST . . . . . . . . . . . . . . . . . . . . . . 7G-3
S Magnetek SCR Drive Main CPU Card . . . . 7E-2 COUNTERWEIGHT BUFFER TEST . . . . . . . . . . . 7G-4
S Digital Current Regulator Card . . . . . . . . . 7E-2 GATE AND LOCKS CAR VELOCITY CLAMP TEST 7G-4
S Generic Software on the CPU and DSP Boards
.................................. 7E-2
S Job Eproms on the CPU Boards . . . . . . . . 7E-2 APPENDIX H
DOOR AND OPTION ADJUSTMENTS
APPENDIX F
SOFTWARE REVISION TABLES
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-F Printed in USA August, 2002
ILLUSTRATIONS
Figure Page Figure Page
APPENDIX B 4 Torque Wrench & Adaptor on Brake . . . . . . 7C-7

CARD CONFIGURATION 5 GD-300 Machine Assembly . . . . . . . . . . . . . 7C-9
6 GD-300 Brake Assembly . . . . . . . . . . . . . . . 7C-10
1 CPU Card . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2
7 GD-300 Brake Solenoid Assembly . . . . . . . 7C-11
2 DSP Card . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-3
8 Torque Wrench & Adaptor on Brake . . . . . . 7C-15
3 PMI Card . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-4
9 G3 Gearless Machine . . . . . . . . . . . . . . . . . 7C-17
10 G3 Brake Assembly . . . . . . . . . . . . . . . . . . . 7C-18
APPENDIX C
11 G3 Brake Solenoid Assembly . . . . . . . . . . . 7C-20
BRAKE ADJUSTMENT
12 G4/G5 Gearless Machine . . . . . . . . . . . . . . . 7C-25
1 GD-1 Machine Assembly . . . . . . . . . . . . . . . 7C-1 13 G4/G5 Brake Assembly . . . . . . . . . . . . . . . . 7C-26
2 GD-1 Brake Assembly . . . . . . . . . . . . . . . . . 7C-2 14 G4/G5 Brake Solenoid Assembly . . . . . . . . 7C-28
3 GD-1 Brake Solenoid Assembly . . . . . . . . . 7C-3
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-G Printed in USA August, 2002
TABLES
Table Page Table Page
APPENDIX B APPENDIX G
CARD CONFIGURATION SAFETY DEVICE VERIFICATION
AND TEST
1 CPU Card Configuration . . . . . . . . . . . . . . . 7B-1
1 ThyssenKrupp Car Buffer Strike Speeds . . . 7G-3
APPENDIX D 2 ThyssenKrupp Counterweight Buffer Strike Speeds
RAKE TORQUE VALUES ................................... 7G-4
1 Required Torque (Part 1) ............... 7D-1 APPENDIX H

2 Required Torque (Part 2) ............... 7D-2 DOOR AND OPTION ADJUSTMENTS
3 Required Torque (Part 3) ............... 7D-3
4 Required Torque (Part 4) ............... 7D-4 1 Door Adjustments . . . . . . . . . . . . . . . . . . . . 7H-1
5 Required Torque (Part 5) ............... 7D-5 2 Emergency Operation Adjustments . . . . . . . 7H-2
6 Required Torque (Part 6) ............... 7D-6 3 Signal Fixture Adjustments . . . . . . . . . . . . . 7H-3
7 Required Torque (Part 7) ............... 7D-7 4 Miscellaneous Adjustments . . . . . . . . . . . . 7H-3
8 Required Torque (Part 8) ............... 7D-8 5 Security Operation Adjustments . . . . . . . . . 7H-4
6 Inconspicuous Riser Operation Adjustments
APPENDIX F ................................... 7H-5
SOFTWARE REVISION TABLES
1 TAC50t Software Kit . . . . . . . . . . . . . . . . . . 7F-1
2 TAC50t Software Change Descriptions . . . 7F-1
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-H Printed in USA August, 2002
TECHNICAL INFORMATION RECOMMENDED SPARE PARTS
RECOMMENDED SPARE PARTS
GROUP CONTROLLER
PART NO. PRINT NO. QTY DESCRIPTION
9853297 132278 1 box / 10 cars Fuse, 6A, 250V (F1, F3) (Box of 10)
9853285 132591 1 box / 20 cars Fuse, 1A, 250V (F2) (Box of 10)
6300CN5 1 Card, PMI
6300JC2 1 Card, CPU, Enhanced *
9853534 690AC1 2 Relay, 3PDT, 24 VDC
9780191 409AE9 5 per car Fuse, Subminiature, 2A, 125V
9853250 409AE7 5 per car** Fuse, Subminiature, 1A, 125V
518AG4 2 / 10 cars Module, Input, 24 VDC
518AL1 2 / 10 cars** Module, Input, 48 VDC
518AH1 2 / 10 cars Module, Input, 115 VAC, 110 VDC
518AJ1 2 / 10 cars Module, Output, 24 VDC, 48 VDC
518AM1 2 / 10 cars** Module, Output, 110 VDC
518AK1 2 / 10 cars Module, Output, 115 VAC
CAR CONTROLLER (FRONT) - SCR, MG, AND

HARDWARE AND SOFTWARE VECTOR VVVF DRIVES
9853110 298AA1 2 / 10 cars Contactor, 4P, 120 VAC

9853121 297AC1 5 / 10 cars Auxiliary Contact, 1P, NC
9853133 297AD1 5 / 10 cars Auxiliary Contact, 2P, NO; 2P, NC
9853522 690AB1 2 Relay, 3PDT, 120 VAC
9853558 690AE1 2 Relay, 3PDT, 110 VDC
6300DE33 1** Card, DSP (SCR)
6300DE35 1** Card, DSP (VVVF, MG)
6300ET1 1** Card,Regulator, Low Armature Voltage < 360V (MG)
6300ET2 1** Card Regulator, High Armature Voltage > 361V (MG)
9811096 141095 1 box / 10 cars Fuse, 2A, 250V (Box of 10)
9802277 132276 1 box / 10 cars Fuse, 3A, 250V (Box of 10)
9853303 132658 1 box Fuse, 3.2A, 250V, SLO-BLO (Box of 10)
9853315 132590 1 box** Fuse, 6.25A, 250V SLO-BLO (Box of 10)
409AK5 1 box Fuse, 5A, 250V
409AH1 1 box Fuse, 1.8A
270AB20 1** Circuit Breaker, 3 Phase, 20A (CB1)
804AC1 25 Transient Suppressor Assembly
9853224 409AA2 5 Fuse, Subminiature, 1/8A, 125V
409AA3 5 Fuse, Subminiature, 1/8A, 125V
409AA5 5 Fuse, Subminiature, 1/2A, 125V
409AA13 5 Fuse, Subminiature, 4A, 125V
890AB1 2 Varistor, MOV, 250V, 15J, 2000A
9719234 33021 1 Kit, Encoder, +5V Regulator
* See Technical Information, Appendix B for Group CPU jumper position information.
** As required-job specific.
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-1 Printed in USA August, 2002
CAR CONTROLLER (REAR) - HARDWARE AND SOFTWARE VECTOR VVVF DRIVES

9853492 672BX1 1 Power Supply, +24V @3A (PS2)

672BH1 1 Power Supply, ±15V @1.5A (PS4)
9718278 297AH2 1 Contact, Auxiliary, 10A, 120V
9718291 804AN2 1 Suppressor, Surge
804AV1 1 Suppressor, 3 Phase
9853510 689AA1 2 Rectifier (DB1, DB2, BB1, BB3, HLB)
9716853 6300LR2 1 Card, Digital Current Regulator
9718941 690AN1 1 Relay, Solid State
9716993 409BB20 1** Fuse, 20A, 1000V (F6)
9717183 409BB30 1** Fuse, 30A, 1000V (F6)
9717353 409BB40 1** Fuse, 40A, 1000V (F6)
9719179 804AP1 5 Transorb, Suppressor Transient
850AN1 5 Suppressor, RC Network, 120V
9717080 409AV1 3 / 10 cars** Fuse, 40A, 500V
9717158 409AV2 3 / 10 cars** Fuse, 50A, 500V
9717195 409AV3 3 / 10 cars** Fuse, 80A, 500V
9717365 409AV4 3 / 10 cars** Fuse, 100A, 500V
409AV5 3 / 10 cars** Fuse, 150A, 500V
9717110 409AX1 3 / 10 cars** Fuse, 50A, 700V
9717160 409AX2 3 / 10 cars** Fuse, 70A, 700V
9717201 409AX3 3 / 10 cars** Fuse, 100A, 700V
9718473 409AG1 3 / 10 cars** Fuse, 250V, 15A
9718620 409AF10 3 / 10 cars** Fuse, 600V, 10A
9718643 409AF6 3 / 10 cars** Fuse, 600V, 6.25A
9718485 409AG17 3 / 10 cars** Fuse, 250V, 17.5A
9718655 409AF1 3 / 10 cars** Fuse, 600V, 8A
9718515 409AG25 3 / 10 cars** Fuse, 250V, 25A
9718539 409AG30 3 / 10 cars** Fuse, 250V, 30A
9718667 409AF15 3 / 10 cars** Fuse, 600V, 15A
9718965 409AJ2 3 / 10 cars** Fuse, 8A, 250V
CAR CONTROLLER (REAR) - MG DRIVE

9714881 6300AF5 1 Card, RTG

6300EE1 1 Card, Motor Field Regulator
850AN1 2 Suppressor RC
** As required—job specific.
CAR CONTROLLER (REAR) - SCR DRIVE

46S02975-0502 1 Main CPU PCB

05P00090-0293 1 Power Supply
46S03207-0010 1 Parallel / Serial Card
46S03012-0010 1 Field Control PCB
46S02976-0032 1** Armature Inverface 50, 100, 190HP
46S03088-0012 1** Armature Inverface 300HP
9718023 05P00017-0155 3 / 10 cars** Fuse, AC Line, (51A SCR Drive)
9718072 05P00017-0178 3 / 10 cars** Fuse, Armature, (51A SCR Drive)
MISCELLANEOUS - SCR, MG, AND HARDWARE AND SOFTWARE VECTOR VVVF DRIVES
1 Sensor Assy, Loadweigher

6300DN 1 Loadweigher Control Card
373AA2 1 / 20 cars Encoder, 2048 Pulses / Revolution, Motor Velocity
9716180 309AD1 2 Coupling, Flexible Encoder
373AR1 1 / 20 cars Encoder, 1024 Pulses / Revolution, Governor Position
9718473 409AG1 3 / 10 cars** Fuse, 250V, 15A, FLA, FLB, FLC
9718620 409AF10 3 / 10 cars** Fuse, 600V, 10A, FLA FLB, FLC
9718643 409AF6 3 / 10 cars** Fuse, 600V, 6.25A, FLA FLB, FLC
9718485 409AG17 3 / 10 cars** Fuse, 250V, 17.5A, FLA, FLB, FLC
9718655 409AF1 3 / 10 cars** Fuse, 600V, 8A, FLA, FLB, FLC
9718667 409AF15 3 / 10 cars** Fuse, 600V, 15A, FLA, FLB, FLC
6006AB5 Terminal Transducer (NCNT/NDET)
6006AB6 Terminal Transducer (NCNT/Only)
6006AA Position Transducer (LU/LD/DZ/DEZ)
** As required—job specific.
VVVF QUANTUM DRIVE (Rear Controller)

PART NO. PRINT NO. QTY. DESCRIPTION
9719180 378AE1 1 Fan, AC, Muffin 100 CFM w/finger guard

378AH1 1 Fan, AC, Flange Type, 220 CFM
9755196 238AW1 4 Capacitor, 2000 MFD, 450 WVDC
9893453 6300FM3 1 Digital Current Regulator Board
9755391 6300FN1 *** Bus Clamp Board (1 per 40HP, 3 per 60HP, and 6 per 60HP
Regenerative)
9755597 6300GC1 1 Regenerative Control Board (60HP Regenerative)
9755329 6300EM1 *** Bus Voltage Indicator Board (1 per 30HP - 60HP and 60HP Regenerative)
9818534 699AV2 2 Resistor 3.6K Ohm (R1, R2)
9818546 699AV4 1 Resistor, 50 Ohm, 100 Watt (RSS)
9755202 241AV1 3 Capacitor, 1.0 MFD, 1200 Volts (Bus Filter) (7.5 - 20 HP)
9853492 672AC1 1 Power Supply, +24 VDC, 3A (PS2)
672BJ1 1 Power Supply, 15V @ 1.5A (PS4)
672BN3 1 Power Supply, 15V, 5V (PS5)
844AD1 1 Thermostat, 120_ F
844AC1 1 Thermostat, 160_ F
9719120 344AN1 1 Diode Module, 3 phase, 50 Amps
9755238 344AN2 1 Diode Module, 3 phase, 100 Amps
9755275 344AY1 1 Diode Module, 3 phase, 150 Amps
9756590 155BM1 1 IGBT, 6-Pack, 50 A, 1200V (7.5HP - 10 HP, 3 phase)
9756607 155BM2 1 IGBT, 6-Pack, 75A, 1200V (15HP, 3 phase)
9756619 155BN1 1 IGBT, 6-Pack, 100A 1200V (20HP, 3 phase)
9756541 155BH1 1 IGBT, Dual-Pack, 75A, 1200V (7.5 - 20HP, QSR/QSS)
9756553 155BH2 1 IGBT, Dual-Pack, 100A, 1200V (30 HP-QSR/QSS)
9756565 155BJ1 3 IGBT, Dual-Pack, 150A, 1200V (30-HP-3 phase)
9756565 155BJ1 1 IGBT, Dual-Pack, 150A, 1200V (40 HP-QSR/QSS)
9756577 155BK1 3 IGBT, Dual-Pack, 200A, 1200V (40 HP-3 PHASE)
9756577 155BK1 1 IGBT, Dual-Pack, 200A, 1200V, (60HP - 60HP Regenerative, QSR/QSS)
9756589 155BL1 3 IGBT, Dual-Pack, 300A, 1200V (60HP)
9756589 155BL1 6 IGBT, Dual-Pack, 300A, 1200V (60HP Regen)
9755830 6300FK1 *** Inverter Interface Board-Dual (1 per 30HP - 60HP and 2 per 60HP
Regenerative)
9835647 6300FL1 1 Inverter Interface Board-6 Pack (7.5HP - 20 HP)
9893465 6300FV1 1 QSS/QSR Interface Board
9755470 6300FP1 1 QSS/QSR Snubber Board (7.5HP - 20 HP)
9718473 409AG1 3 Fuse, 250V, 15A, FLA, FLB, FLC
9718620 409AF10 3 Fuse, 600V, 10A, FLA, FLB, FLC
9718643 409AF6 3 Fuse, 600V, 6.25A, FLA, FLB, FLC
9718485 409AG17 3 Fuse, 250V, 17.5A, FLA, FLB, FLC
409BD2 3 Fuse, 20A, 500V Semiconductor (FU1 - 3) (7.5 HP)
409BD3 3 Fuse, 20A, 500V Semiconductor (FU1 - 3) (10 HP)
9717080 409AV1 3 Fuse, 40A, 500V Semiconductor (FU1 - 3) (15 HP)
409AV5 3 Fuse, 150A, 500V Semiconductor (FU1 - 3) (60 HP and 60 HP
Regenerative)
9716993 409BB20 1 Fuse, 20A, 1000V (FU6)
9717183 409BB30 1 Fuse, 30A, 1000V (FU6)
9719179 409BB40 1 Fuse, 40A, 1000V (FU6)
*** Variable per Drive HP. See Description of part for amounts.
VVVF QUANTUM DRIVE (Front Controller)

PART NO. PRINT NO. QTY. DESCRIPTION
9853522 690AB1 2 Relay, 3 PDT, 120 VAC

9853558 690AE1 2 Relay, 3 PDT, 110 VDC
9853534 690AC1 2 Relay, 3 PDT, 24 VDC
6300DE35 1 Card, DSP
9843991 6300JC2 1 Card, CPU, 16 MHZ
9853285 132591 1 box Fuse, 1A, 250V
9811096 141095 1 box Fuse, 2A, 250V
9802277 132276 1 box Fuse, 3A, 250V
409AK5 1 box Fuse, 5A, 250V
9853297 132278 1 box Fuse, 6A, 250V
9853303 132658 1 box Fuse, 3.2 A, 250V, slo-blow
9853315 132590 1 box Fuse, 6.25A, 250V slo-blow
409AH1 1 box Fuse, 1.8A, 250V
9804420 804AC1 2 Transient suppressor assy
9853224 409AA2 5 Fuse, Subminiture, 1/8A, 25V (Loadweigher)
409AA3 5 Fuse, Subminiture, 1/4A, 125V (DSP)
409AA5 5 Fuse, Subminiture, 1/2A, 125V
9853250 409AA7 5 Fuse, Subminiture, 1A, 125V (PMI)
409AA9 5 Fuse, Subminiture, 2A, 125V
409AA13 5 Fuse, Subminiture, 4A, 125V
890AB1 2 Varistor,mov, 250V, 15J, 2000A
9719350 518AG4 2 Module, Input, 24 VDC
9719374 518AJ1 2 Module, Output, 24VDC, 48 VDC
9809820 518AL1 2 Module, Input, 48 VDC
9719362 518AH1 2 Module, Input, 115 VAC, 110 VDC
9852931 518AM1 2 Module, Output, 110 VDC
9719349 518AK1 2 Module, Output, 115 VAC
*** Variable per Drive HP. See Description of part for amounts.
This page
intentionally
left blank.
ENIL THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-6 Printed in USA NIL

TECHNICAL INFORMATION REPLACEMENT PARTS
APPENDIX A—REPLACEMENT PARTS
GROUP CONTROLLER
2 OFF ON OFF ON
1
3 F1
2A
F2
2A
F3
CPU I/O
17
4
6 FLB
T2
5 __A
8
11
9
12 10
13
18
14
15
16
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7A-1 Printed in USA August, 2002
GROUP CONTROLLER (continued)

ITEM PART NO. PRINT NO. DESCRIPTION
1 171DB6 Switch, Rotary, 2 Pos. w/Contact Block (I/O)

171DB7 Switch, Rotary, 2 Pos. w/Contact Block (CPU)
2 9853273 132284 Fuse Holder, Panel Mount
3 9853297 132278 Fuse, 250V, 6A (F1, F3) (Box of 10)
141095 Fuse, 250V, 2A (F2) (Box of 10)
4 2106AB12 Cage, Card Assembly
5 6300KB1 Motherboard (Backplane)
6 9863000 6300CN5 Card, PMI
7 9843991 6300JC2 Card, CPU, Enhanced * 16mhz
8 9853200 378AL1 Fan, Card Cage
9 9724370 112386 Diode, 3A 1000 V
10 9955185 834AM20 Block, Terminal, 20 Position
11 672BF2 Power Supply, +5 V, 12V @ 35A, PS1
12 9853534 690AC1 Relay, 3PDT, 24 VDC
13 9853560 770AC1 Socket, Relay
14 9758343 65834 Diode Assembly, Relay 1A, 200V
15 412AD1 Fuse Holder Assembly: FHS
412AV1 Fuse Holder, Panel Mount
9853315 132590 Fusetron, 6.2A 250V
16 684AD5 Rail, Mounting Relay/Terminal, 187mm (11.3I)
17 672BB2 Power Supply, International, 200-230/117 VAC
672BB3 Power Supply, International, 380-415/117 VAC
9781096 874BY1 Transformer, 200-415V/117V, .75kva
9718643 409AF6 Fuse, 6.25A 600V (200-220 V Primary)
9877605 409AF3 Fuse, 3A 600V (380-415 V Primary)
71345 Fuse Block 600V 30A
18 9853194 378AA1 Fan, 19I Rack Mount
The following items are not shown in the illustration:

9853467 661AA8 Plug, 16 pin PMI, Labeled 1-16
661AA13 Plug, 16 pin PMI, Labeled 17-32
711BB1 Retainer, PMI Modules
9822136 132138 Shunt, Header
132823 Cable, RS-232, 10’ 25 Pin Male D-Shell / 25 Pin Male D-Shell
220AJ1 Cable, Serial Communications, 4 #22 Twisted Shielded Pairs
220AJ2 Cable, Serial Communications, 3 #22 Twisted Shielded Pairs
9846256 462DB1 Harness, Diagnostics Port, 10 Pin CPU Plug / 25 Pin Female (J3 to RS232)
9853250 409AA7 Fuse, PMI, Subminiature, 125V, 1A
9780191 409AA9 Fuse, PMI, Subminiature, 125V, 2A
9719350 518AG4 Module, PMI, Input, 24 VDC
9809820 518AL1 Module, PMI, Input, 48 VDC
9719362 518AH1 Module, PMI, Input, 115 VAC, 110 VDC
9719374 518AJ2 Module, PMI, Output, 24 VDC, 5-60 VDC
9852931 518AM1 Module, PMI, Output, 110 VDC
9719349 518AK1 Module, PMI, Output, 115 VAC
661AA10 Plug, 10 Pin, CPU
699AK201 Resistor, 121 ohm 1/4w
9954715 834AN12 Terminal Block, Grounding, 12 Position
9954806 834AP1 Lug, Terminal Block Grounding (#10 - #4 AWG Wire)
687BR1 Receptacle, GFCI, 125V, 16A
CAR CONTROLLER FRONT - VVVF, SCR DRIVES
1
3
2
4
5
6
7
8
9
10
11
12
13
14
15
22
16
23
17
18 24
19 25
20
21
26
120 HP Drive ONLY
27
CAR CONTROLLER FRONT - VVVF, SCR DRIVES (continued)

1 171DB4 Switch, Assembly, AUTO
171DB6 Switch, Assembly, I/O
171DB7 Switch, Assembly, CPU
171DB8 Switch, Assembly, DOOR
2 171DB1 Switch, Push Button, UP, w/contact block
171DB3 Switch, Push Button, DOWN, w/contact block
3 270AD10 Circuit Breaker, 3 Phase, 10A: CB1
270AD15 Circuit Breaker, 3 Phase, 15A: CB1
4 412AV1 Fuse Holder, Panel Mount
5 9853285 132591 Fuse, 250V, 1A (Box of 10) (F10)
9802277 132276 Fuse, 250V, 3A (Box of 10) (F5, F12)
9811096 141095 Fuse, 250V, 2A (Box of 10) (F2, F11)
9853297 132278 Fuse, 250V, 6A (Box of 10) (F1, F4, F9)
9853303 132658 Fuse, 250V, 3.2A, SLO-BLO (Box of 10) (F6, F7, F8)
9853315 132590 Fuse, 250V, 6.2A, SLO-BLO (Box of 10) (F6, F7, F8)
409AK5 Fuse, 250V, 5A (F3)
9733668 132667 Fuse, 250V, .25A (F14)
9853285 132591 Fuse, 250V, 1A (F14)
141289 Fuse, 250V, 2.5A (F14)
6 9843991 6300JC2 Card, CPU, 16 MHz
7 2106AB9 Card Cage, 24I
8 6300KB1 Car / Group Motherboard, 24I
9 6300CL2 Backplane, P2
10 9841349 6300DE33 Card, DSP—SCR
9881141 6300DE34 Card, DSP—MG
9731817 6300DE35 Card, DSP—VVVF (Software Vector)
11 9881967 6300ET1 Card, Regulator, Low Armature Voltage < 360V (MG)
6300ET2 Card, Regulator, High Armature Voltage >361V (MG)
12 9863000 6300CN5 PMI Card
13 9853560 770AC1 Socket, Relay
14 9853534 690AC1 Relay, 3PDT, 24 VDC
9853522 690AB1 Relay, 3PDT, 120 VAC
15 684AD6 Rail, Relay/Contactor Mounting, 35I Lg.
16 9724370 112386 Diode, 1000V, 3A
17 9755615 804AC1 Suppressor, Transient Assembly, 220V
18 890AB1 Varistor, MOV, 250V, 15J, 2000A
19 9853110 298AA1 Contactor, 4P, 120 VAC
20 9853121 297AC1 Auxiliary Contact, 1P, N/C
9853133 297AD1 Auxiliary Contact, 2P, N/O; 2P, N/C
21 9720807 297AE1 Contactor, Auxiliary Contact, 4 N.O.
9852815 297AF1 Contactor, Auxiliary Contact, 4 N.C.
22 9955185 834AM20 Block Terminal, 20 Position, Low Voltage
23 9983764 65168 Block Terminal, 20 Position, High Voltage
24 672BF2 Power Supply Assembly, +5V, 12VDC @ 20A (PS1)
672BX1 Power Supply Assembly, +24V, 4.3A, 100W (PS2, PS6)
672BY1 Power Supply Assembly, +24V, 6.3A, 150W (PS3)
672CC1 Power Supply Assembly, +48V, 3.2A, 150W (PS3)
672BH1 Power Supply Assembly, 15V @ 1.5A (PS4)
25 874DF1 Transformer T1—3.75 KVA, 60hz 230/460 VAC, 3 Phase
9853674 874BG1 Transformer T1—3.75 KVA, 50/60hz, 230/460 VAC, 3 Phase
874AW1 Transformer T1—4.75 KVA, 50/60hz, 230/460 VAC, 3 Phase
874DH1 Transformer T1—6.75 KVA, 50/60hz, 230/460 VAC, 3 Phase
874BX1 Transformer T1—3.75 KVA, 50/60hz, 200/400 VAC, 3 Phase
874CR1 Transformer T1—4.75 KVA, 50/60hz, 200/400 VAC, 3 Phase
874CT1 Transformer T1—6.75 KVA, 50/60hz, 200/400 VAC, 3 Phase
874DG1 Transformer T1—3.75 KVA, 50/60hz, 220 VAC, 3 Phase
874CY1 Transformer T1—3.75 KVA, 50/60hz, 575 VAC, 3 Phase
874DD1 Transformer T1—4.75 KVA, 50/60hz, 575 VAC, 3 Phase
874DE1 Transformer T1—6.75 KVA, 50/60hz, 575 VAC, 3 Phase
26 378AH1 Fan, Flange Type, (120 HP Drive Only)
27 799AD1 Filter, 6I Fan, (120 HP Drive Only)
CAR CONTROLLER FRONT - VVVF, SCR DRIVES (continued)


28 9822136 132138 Shunt, Header
29 132823 Cable, RS-232, CPU to FAST
30 462DB1 Harness, Diagnostic Tool, 25 Pin D-Shell to 10 Pin Connector
31 9834849 220CB1 Cable Assembly, S/W DSP to CR
32 220AJ1 Cable, Serial, #22 Shielded
33 9853200 378AL1 Fan, Card Cage
34 9840746 ECA-126 Card, Extender (Prototek, Inc.)
35 9853467 661AA8 Plug, Terminal Strip, 16 Position (PMI)
36 9846244 462DA1 Harness, Card Cage
37 9846256 462DB1 Harness, Diagnostics Tool
38 661AA10 Plug, Terminal Strip, CPU
39 661AG12 Plug, Terminal Strip, 12 position (DSP)
40 9853224 409AA2 Fuse, Subminiature, 125V, 1/8A
41 *409AA3 Fuse, Subminiature, 125V, 1/4A
42 *409AA5 Fuse, Subminiature, 125V, 1/2A
43 9853250 409AA7 Fuse, Subminiature, 125V, 1A
46 9719350 518AG4 Module, Input, 24 VDC
9809820 518AL1 Module, Input, 48 VDC
9719362 518AH1 Module, Input, 115 VAC, 110 VDC
47 9719374 518AJ2 Module, Output, 24 VDC, 48 VDC
9852931 518AM1 Module, Output, 110 VDC
9719349 518AK1 Module, Output, 115 VAC
48 874CD1 Transformer--5 KVA, Isolation
874CE1 Transformer--7.5 KVA, Isolation
874CF1 Transformer--10 KVA, Isolation
874AL1 Transformer--15 KVA, Isolation
874AM1 Transformer--20 KVA, Isolation
874AN1 Transformer--27 KVA, Isolation
874AP1 Transformer--34 KVA, Isolation
874AR1 Transformer--40 KVA, Isolation
874AT1 Transformer--51 KVA, Isolation
874AV1 Transformer--63 KVA, Isolation
874BH1 Transformer--75 KVA, Isolation
874BJ1 Transformer--93 KVA, Isolation
874BK1 Transformer--112.5 KVA, Isolation
49 9878270 690AJ2 Relay, RPR, 220V
50 9719234 33021 Kit, Encoder, +5V Regulator
51 804AC3 Supressor, Transient Assembly, 30V
52 119268 Connector Housing Plug
53 9737984 690BW1 Voltage Monitor, 230V
690BW2 Voltage Monitor, 440V
CAR CONTROLLER VVVF, SCR - POWER SUPPLY PANEL
13
5
14
3
14
11
10
12
2
14
8
6
7
4
1
15
14
CAR CONTROLLER VVVF, SCR - POWER SUPPLY PANEL (continued)

1 672BF2 Power Supply Assembly, +5V, 12VDC @ 20A (PS1)
2 672BX1 Power Supply Assembly, +24V, 4.3A (PS2)
672BY1 Power Supply Assembly, +24V, 6.3A (PS3)
672CC1 Power Supply Assembly, +48V, 3.2A (PS3)
4 672BH1 Power Supply Assembly, +15V, 1.5A (PS4)
672BY1 Power Supply Assembly, +24V, 6.3A (PS6)
672CC1 Power Supply Assembly, +48V, 3.2A (PS6)
6 412AN2 Bolck, Fuse, Multipostion, 250V
7 409BC56 Fuse, MDL, 7A, 250V
8 65168 Block, Terminal
9 9781213 116AB1 Battery, DSP, 12V, TBAT
10 9719880 890AF1 Varistor, MOV, 150V, 80 J, (Used with PS3 and PS6)
11 804AB2 Supressor, Zener, 25V, 5W, (Used with PS3 and PS6)
12 115283 Diode, 1000V, 6A, DVL+
13 9718400 146381 Resistor, 75 Ohm, 75W, RCD, (Counterweight Derail)
14 44882 Standoff, 3/8I x 7/16I Lg
15 786BP1 Standoff, Blocking, PCB
CAR CONTROLLER REAR PANEL ASSEMBLY—VVVF QUANTUM QUITE

AC/DC DRIVE 7.5-60 HP NON-REGENERATIVE
16
14 15
17
Refer to Page for

Drive Unit Assembly
5
Refer to Page for
Brake Controller Assembly
4
Refer to Page 7A-6 for
2 Power Supply Assemblies
3 13
12 10
8
9
6 11
7
18
CAR CONTROLLER REAR PANEL ASSEMBLY—VVVF QUANTUM QUIET

AC/DC DRIVE 7.5-60 HP NON-REGENERATIVE (continued)
1 708AT2 Resistor, 15 Ohm 1000W (230V Drive)

9718175 708AT1 Resistor, 60 Ohm, 1000W (460V Drive)
2 9755214 298AH7 Contactor, 3 p, (7.5 HP, <9 FLA)
9718187 298AH1 Contactor, 3 p, (7.5,10,15 HP, <18 FLA)
9718205 298AH2 Contactor, 3 p, (18 - 26 FLA, 7.5 HP)
9718217 298AH3 Contactor, 3 p, (15 HP, <26 FLA )
9718229 298AH4 Contactor, 3 p, (15, 20 HP, 26 - 38 FLA)
9720790 298AH9 Contactor, 3 p, (30, 40 HP, 37.1 - 42 FLA)
9755226 298AH8 Contactor, 3 p, (40, 60 HP, 42.1 - 80.0 FLA)
9834618 298AH10 Contactor, 3 p, (40, 60 HP, <72 FLA)
9834620 298AH11 Contactor, 3 p, (40, 60 HP, 72-160 FLA)
3 9718278 297AH2 Contact, Auxiliary, 120V, 10A (298AH1, 2, 3, 4)
9774737 297AH4 Contact, Auxiliary, (C1, C2) (298AH8, 10, 11)
4 9804420 804AC1 Suppressor, Surge, (C1, C2)
5 486AR22 Choke, 3 Phase, L1 (230V 7.5, 10 HP)
486AR25 Choke, 3 Phase, L1 (230V 15 HP)
486AD6 Choke, 3 Phase, L1 (460V 7.5 HP)
486AD7 Choke, 3 Phase, L1 (460V 10 HP)
6 71345 Fuseblock, 1 Pole 600V, FSP1, FSP2
7 9718643 409AF6 Fuse, 600V, 6.25A, FSP1, FSP2
8 9954958 71389 Fuseblock, 3 Pole 250V, (230V Input) FLA, FLB, FLC
9951106 101908 Fuseblock, 3 Pole 600V, (460V Input) FLA, FLB, FLC
9 9718473 409AG1 Fuse, 250V, 15A, FLA, FLB, FLC (T1=3.75KVA, 200-240V Input)
(T1=4.75KVA, 220-240V Input)
9718485 409AG17 Fuse, 250V, 17.5A, FLA, FLB, FLC (T1=4.75KVA, 200-208V Input)
9718515 409AG25 Fuse, 250V, 25A, FLA, FLB, FLC (T1=6.75KVA, 200-240V Input)
409AF5 Fuse, 600V, 5A, FLA, FLB, FLC (T1=3.75KVA, 550-600V Input)
9718643 409AF6 Fuse, 600V, 6.25A, FLA, FLB, FLC (T1=3.75KVA, 440-480V Input)
(T1=4.75KVA, 550-600V Input)
9718655 409AF1 Fuse, 600V, 8A, FLA, FLB, FLC (T1=4.75KVA, 440-480V Input)
(T1=6.75KVA, 550-600V Input)
(T1=6.75KVA, 440-480V Input)
(T1=9.75KVA, 440-480V Input)

AC/DC DRIVE 7.5-60 HP NON-REGENERATIVE (continued)
10 834BL3 Terminal Block, 3 Pole, 50A
12 9853510 689AA1 Rectifier, BD, BB1, BB2, BB3, BB4, HLB, SBD
13 9744435 128074 Resistor, Adj., 250 Ohm, 200W (Freight Doors Only, R3DR, R4DR)
700898 Rod, Threaded, 10-24 x 11.25I Lg
75781 Washer, Mica
75778 Washer, Centering
700393 Washer, Flat, #10 , .190
701032 Nut, #10, .190 Z
14 378AL1 Fan, Muffin (60 HP)
15 422AA1 Grille, Fan, Muffin (60 HP)
16 412AM3 Fuse, Block, 3 Pos., Clip Type, 700V, 30A, FU1, FU2, FU3, (7.5, 10HP)
9755846 412AT1 Fuse, Block Stud Type, FU1, FU2, FU3, (15-60 HP)
17 409BT4 Fuse, 50A, 250V, FU1, FU2, FU3, (230V 7.5, 10HP Drive)
409BT7 Fuse, 80A, 250V, FU1, FU2, FU3, (230V 15HP Drive)
409BD2 Fuse, 20A, 500V, FU1, FU2, FU3, (460V 7.5HP Drive)
409BD3 Fuse, 30A, 500V, FU1, FU2, FU3, (460V 10HP Drive)
9721848 409AX4 Fuse, 40A, 700V, FU1, FU2, FU3, (460V 15HP Drive)
18 9852194 378AA1 Fan, 19I Rack Mount
708AJ13 Resistor, Adj., 50 Ohm, 420W, RSBR (B44 W/Sheave Brake)
718AB1 Rod, Threaded, 10-24 x 12.5I Lg (B44 W/Sheave Brake)
75781 Washer, Mica (B44 W/Sheave Brake)
75778 Washer, Centering (B44 W/Sheave Brake)
700393 Washer, Flat, #10 , .190 (B44 W/Sheave Brake)
701032 Nut, #10, .190 Z (B44 W/Sheave Brake)
238AH1 Capacitor, 1200 Mfd, 250 VDC (HD-86 Door Operator Only)
141230 Clamp, Mounting, 2I (HD-86 Door Operator Only)
141814 Resistor, Adj., 10K, 25W (HD-86 Door Operator Only)
196VA1 Bracket, Capacitor Mounting, (HD-86 Door Operator Only)
9954715 834AN12 Terminal Block, Grounding, 12 Position
9954806 834AP1 Lug, Terminal Block Grounding (#10 - #4 AWG Wire)
687BR1 Receptacle, Duplex, 120V GFCI
287AE1 Face Plate, Receptacle, Duplex GFCI
788AH9 Door Module VMP, 1/2 Dr, Smart Tech
788AH11 Door Module VMP, 1/2 Dr, Manual Freight
6300LV1 Brake Regulator - 2 AMP
412AY1 Fuse Block Modular, 40HP, 230V (3 per Controller)
412AY2 Fuse Block Modular, 60HP, 230V (3 per Controller)

AC/DC DRIVE 60, 80 & 120 HP REGENERATIVE
11
12
13
4
10
1
2 10
3
9 7 9
8
5
6
14
60 HP REGENERATIVE 80-120 HP REGENERATIVE

AC/DC DRIVE 60, 80 & 120 HP REGENERATIVE (continued)
1 9755226 298AH8 Contactor, 3 Phase, 60HP, C1, C2 (with EN-81)
9834618 298AH10 Contactor, 3 Phase, 80HP, C1
9834620 298AH11 Contactor, 3 Phase, 120HP, C1
2 9774737 297AH4 Contact, Auxiliary, (C1, C2) (60-80 HP)
9834631 297AH5 Contact, Auxiliary, (C1) (120 HP)
3 9804420 804AC1 Surge Suppressor, C1
4 486AD10 Choke, 3 Phase, L1 (60HP)
486AD11 Choke, 3 Phase, L1 (80HP)
486AD12 Choke, 3 Phase, L1 (120 HP)
5 9954958 71389 Fuseblock, 3 Pole 250V, FLA-C (<250V Input)
9951106 101908 Fuseblock, 3 Pole 600V, FLA-C (251-600V Input)
(T1=4.75KVA, 220-240V Input)
(T1=4.75KVA, 550-600V Input)
(T1=6.75KVA, 550-600V Input)
(T1=6.75KVA, 440-480V Input)
(T1=9.75KVA, 440-480V Input)
7 834BL3 Terminal Block, 3 Pole, 50A (TB20, TB30)
8 834BL12 Terminal Block, 12 Pole, 50A (TB25)
9 9853510 689AA1 Rectifier-- BB3, BB4, HLB, SBD
10 9744435 128074 Resistor, Adj.--250 Ohm, 200W (Freight Doors Only) (R3DR, R4DR)
75781 Washer, Mica
700393 Washer, Flat, #10 , .190
701032 Nut, #10, .190 Z
11 9755846 412AT1 Fuse Block, Modular, FU1, FU2, FU3
12 9721885 409AX8 Fuse, Semiconductor, 150A, 700V, FU1, FU2, FU3 (60 HP Drive)
9721897 409AX9 Fuse, Semiconductor, 200A, 700V, FU1, FU2, FU3 (80 HP Drive)
9721899 409AX10 Fuse, Semiconductor, 300A, 700V, FU1, FU2, FU3 (120 HP Drive)
13 9755615 804AV1 Suppressor, Surge, FU1, FU2, FU3
14 9853194 378AA1 Fan, 120V, Rack Mount, 60, 80 HP Drive
378AJ1 Fan, 120V, Rack Mount, 120 HP Drive
708AJ13 Resistor, Adj., 50 Ohm, 420W, RSBR (B44 W/Sheave Brake)
718AB1 Rod, Threaded, 10-24 x 12.5I Lg
75781 Washer, Mica
700393 Washer, Flat, #10 , .190
701032 Nut, #10, .190 Z
238AH1 Capacitor, 1200 Mfd, 250 VDC (HD-86 Door Operator Only)
141230 Clamp, Mounting, 2I (HD-86 Door Operator Only)
141814 Resistor, Adj., 10K, 25W (HD-86 Door Operator Only)
196VA1 Bracket, Capacitor Mounting, (HD-86 Door Operator Only)
QUANTUM QUIET AC/DC DRIVE—60 HP REGENERATIVE
2 31 32 10 8 9 3 4 5
36
33
35
27
6
28 7
30
34 11
20
23
12
29
13
25 14
15
24
16
17
18
26 22 21 19
QUANTUM QUIET AC/DC DRIVE—60 HP REGENERATIVE (continued)

1 834AM4 Terminal Block, 4 Position
2 9834941 844AC1 Thermostat, 160 F, TS2
9834953 844AD1 Thermostat, 120 F, TS1
3 9755603 736AN1 Sensor, Current, 200A, LEM3&4
4 155CX1 IGBT, dual-pack, 300 A, 1200V
5 472BG15 Thermstrate Pad, Heatsink
6 155CW1 IGBT, dual-pack, 200 A, 1200V
7 472BG14 Thermstrate Pad, Heatsink
8 6300FK2 Inverter Interface Board - dual
9 6300FV2 QSS/QSR Interface Board
10 786AP1 Standoff, #6-32 Male/Female, 1.0I Lg
786AT1 Standoff, #6-32 Male, 1.0I Lg
11 9818546 699AV4 Resistor, 50 OHM, 100W (RSS)
12 9818534 699AV2 Resistor, 3.6K OHM, 100W (R1, R2)
13 9755196 238AW1 Capacitor, 2000 MFD, 450 WVDC
14 396CJ2 FS, Screw, CSH, .250-28 x .500 ZV
15 700405 FS, Washer, LWHR, .250 Z
16 196TT2 Bracket, Capacitor
17 596AX1 Mount, Capacitor, Dual, Plastic
18 207AG4 Bus Bar, Capacitor, wide
19 207AP1 Bus Bar, Negative, Cap. Bank
20 781AX1 Spacer, Copper, .750 O.D. x .875 Lg
21 207AR1 Bus Bar, Positive, Cap. Bank
22 786AH1 Standoff, 1/4I
23 9755391 6300FN1 Bus Clamp Board
24 451AR3 Guard, Plastic, Bus Bar
25 9755470 6300FP1 QSS/QSR Snubber Board
26 9755329 6300EM2 Bus Voltage Indicator Board
27 9834837 220BG2 Cable Assembly, Flat, 34 Conductor, 8I Lg (CR/IIB & RCB/IIB)
28 9834849 220CB1 Cable Assembly, (CR - DSP)
29 6300LR2 Current Regulator Board, AC/DC
30 9834825 220BG1 Cable Assembly, Flat, 34 Conductor, 4I Lg (CR/RCB)
31 9755597 6300GC1 Regenerative Control Board
32 451AT1 Guard, Plastic, High Voltage (RCB Guard)
33 207BJ1 Bus Bar, Positive, IGBT
34 207BH1 Bus Bar, Negative, IGBT
35 165PT1 Shield, Electric Noise
36 786AH3 Standoff, Locking, 1 1/4” RCB Guard
9834886 462EW1 Harness, IGBT/IIB (Not Shown)
241BE4 Capacitor, 1.0 MFD, 1200V (Not Shown)
9719180 378AE1 Fan, Tube Axial, 100 CFM w/Finger Guard
9834874 462EF1 Harness, Regen Control to 3 Phase
166AC1 Catch, Cover, Spring Draw
9869499 804BH1 ZNR Assmebly, 670VDC, (+ to - Diode Bridge)
9819733 804BJ1 ZNR Assembly, 560VDC, (QSS, C1 to C2E1)
9834898 462EX1 Harness, CR to Current Sensor 18I

221AJ1 Cable Clamp, Nylon, Hinged
VVVF QUANTUM QUIET DRIVE—80 AND 120 HP REGENERATIVE
5 6
4 7
3
2 8
1
48
49
47 9
46
45 10
43 12 11
44
15
42 16
29
41 17
13
40 14 28
39
50
38 18
51 27
19
37
30 20
36
35 24 21
25
34 33 32 31 26 22
VIEW A--A
23
QUANTUM QUIET AC DRIVE-80 AND 120 HP REGENERATIVE (continued)

1 9834850 220CE1 Harness Assy, 14 Conductor Ribbon. 3I (SPS to Inverter Interface Board)
2 207AX1 Bus Bar, Negative, IGBT, 80HP
207AX2 Bus Bar, Negative, IGBT, 120HP
3 9834941 844AC1 Thermostat, 160F, TS2
4 9834953 844AD1 Thermostat, 120F, TS1
5 834AM4 Terminal Block, 4 Pos., TB1 (for thermostat connections)
6 9755603 736AN1 Sensor, Current, 200A, LEM 1 thru 4, 80HP
736AT1 Sensor, Current, 300A, LEM 1 thru 4, 120HP
7 155CE1 IGBT, Single, 400A, 1200V, R, S, T, U, V, W, QSS, 80HP
472BG9 Thermstrate Pad, IGBT, 80HP
155CD1 IGBT, Single, 600A, 1200V, R, S, T, U, V, W, QSS, 120HP
472BG10 Thermstrate Pad, IGBT, 120HP
8 207BC1 Bus Bar, Center
9 207BB1 Bus Bar, Positive, RST, 80HP
207BB2 Bus Bar, Positive, RST, 120HP
10 166AC1 Catch, Cover, Spring, Draw
11 6300HC2 Inverter Interface Board
12 6300HD3 Inverter Snubber Board, 80HP
6300HD4 Inverter Snubber Board, 120HP
13 6300HG3 QSS/QSR Interface Board
14 6300HJ3 QSS/QSR Snubber Board
15 9755329 6300EM2 Bus Voltage Indicator Board
16 207AY1 Bus Bar, Capacitor, Narrow
17 207AG5 Bus Bar, Capacitor, Wide
18 834BL3 Terminal Block, 3 Pole, 50A, FLA-C (TB20) & BM1-3 (TB30)
19 9951103 101908 Fuseblock, 3 Pole, 600 V
20 9842860 122860 Fuse, 2 A, 600 V, BF1-3 (AC Motor Blower)
(T1=4.75KVA, 220-240V Input)
(T1=4.75KVA, 550-600V Input)
(T1=6.75KVA, 550-600V Input)
(T1=6.75KVA, 440-480V Input)
(T1=9.75KVA, 440-480V Input)
23 834BL12 Terminal Block, 12 Pole, 50A (TB25)
24 9804420 804AC1 Surge, Suppressor, C1
25 9834618 298AH10 Contactor, 3 Phase, C1, 80HP
9834620 298AH11 Contactor, 3 Phase, C1, 120HP
26 9774737 297AH4 Contact, Aux., C1, 80HP
9834631 297AH5 Contact, Aux., C1, 120HP
27 9755196 238AW1 Capacitor, 2000MFD, 450WVDC
28 596AX1 Mount, Capacitor, Dual, Plastic
29 196LC1 Bracket, Capacitor
30 9853510 689AA1 Rectifier, Full-wave, 35A, DB1, DB2, BD
31 9719180 378AE1 Fan, AC, Muffin, 100CFM, 4I
378AH1 Fan, AC, 220CFM, 6I
32 442AA1 Finger Guard, 4I
442AD1 Finger Guard, 6I
QUANTUM QUIET AC DRIVE-80 AND 120 HP REGENERATIVE (continued)

33 141936 Hinge, Lift-off, RH

141935 Hinge, Lift-off, LH
34 165LA1 Shield, Elect. Noise, CR, RCB
35 9834898 462EX1 Harness, CR/RCB to Current Sensor
36 9834825 220BG1 Cable Assembly, Flat, 34 Conductor, 4.25I Lg (CR/SPS; RCB/SPS)
37 221AJ1 Cable Clamp, Nylon, Hinged
38 6300LR2 Current Regulator Board
39 132221 Standoff, 5/8I (Mount CR, RCB, SPS)
40 9834849 220CB1 Cable Assembly, (CR/DSP)
41 462EX1 Cable Assembly, Flat, 34 Conductor, 9I Lg (CR/RCB)
42 220CE2 Harness Assy, 14 conductor ribbon, 7I lg (SPS to QSS/QSR Interface Board)
43 6300GC2 Regenerative Control Board
44 786AH3 Standoff, Locking, PCB, 11/4I (For mtg. RCB guard)
45 451AT1 Guard, Plastic, High Voltage (RCB guard)
46 462EF2 Harness, Regen Control to 3 Phase, 80HP
462EF3 Harness, Regen Control to 3 Phase, 120HP
47 6300HE1 Switching Power Supply
48 412AY1 Fuseblock, Modular, Stud-type (For FU1 - 3), 80HP
412AY2 Fuseblock, Modular, Stud-type (For FU1 - 3), 120HP
49 9721897 409AX9 Fuse, 200A, 700V, Semicond., FU1-3, 80HP
9721903 409AX10 Fuse, 300A, 700V, Semicond., FU1-3, 120HP
50 9744435 128074 Resistor, Adj., 250 Ohm, 200W (Freight Doors Only) (R3DR, R4DR)
75781 Washer, Mica
700393 Washer, Flat, #10, .190
701032 Nut, #10, .190 Z
51 708AJ13 Resistor, Adj., 50 Ohm, 420W, RSBR (B44 W/Sheave Brake)
75781 Washer, Mica
700393 Washer, Flat, #10, .190
701032 Nut, #10, .190 Z
9755615 804AV1 Suppressor Assembly, 80HP
804AV3 Suppressor Assembly, 120HP
207BA1 Bus Bar,Positive, UVW, 80HP
207BA2 Bus Bar,Positive, UVW, 120HP
781AX2 Spacer, Copper, .750 O.D., .875 Lg
900CR1 Wire Assembly, 9.5I (From U,V,W+ bus bar to cap Assembly)
900CR2 Wire Assembly, 12.5I (From negative bus bar to cap Assembly)
900CR3 Wire Assembly, 18I (From negative bus bar to cap Assembly)
900CR4 Wire Assembly, 15.5I (From negative bus bar to cap Assembly)
900CE5 Wire Assembly (From R,S,T to L1; from U,V,W to C1)
9818546 699AV4 Resistor, 50 OHM, 100 W, RSS1, RSS2
9834886 462EW1 Harness, IGBT/IIB
900CT1 Wire Assy, 14 Ga (RSS1/2 to QSS/QSR Snubber Board)
900AC138 Wire Assy., 18 Ga., (R1-2 to CAP-, R2-2 to CAP+)
9818534 699AV2 Resistor, 3.6K OHM, 100 W, R1, R2
900AD60 Wire Assy, 14 Ga., #8 Ring (Ground wire, drive door/side)
900AD66 Wire Assy, 14 Ga., #8 Ring to strip (Gnd, rear panel to gnd term)
900AD89 Wire Assy, 14 Ga., #8 Ring to.250 ring (Gnd, heat sink to side)
221AB1 Tie wrap anchor
462FR1 Harness, fan
9718400 146381 Resistor, Adj. 75OHM, 25W, RCD (for Cwt Derail option)
119268 Connector Housing Plug, J1
Quantum Quiet AC/DC Drive Assembly, 230V

NON-REGENERATIVE
3
6 4
5
1 2109AM1 Drive Ass’y Quantum AC/DC, 7.5/10HP

2109AM2 Drive Ass’y Quantum AC/DC, 15HP
2109AM5 Drive Ass’y Quantum AC/DC,40HP
2 166AC1 Spring, Draw Catch
3 462HF1 Cable, Power Supply
4 672BM3 Power Supply
5 462HE1 Cable, Control Supply
6 378AH1 Fan, 6I, 120VAC
7 442AD1 Grille, Wire Fan, 6I
Quantum Quiet AC/DC Drive Assembly, 230V, 10-30HP

NON-REGENERATIVE
12
11
10
13
14
6 15
7
5
4
2
16
1
17
18
24
9 23
19
21 22
25
20 9
26
Current Regulator 2 to Controller DSP
2109AM, Quantum Quiet AC/DC Assembly, 230V, 10-30HP NON-REGENERATIVE (continued)

1 141787 Standoff, Current Regulator

2 6300LR21 Current Regulator PCB
3 9834837 220BG2 Cable , Flat, 34 Conductor , 7.5-30HP (Current Regulator to Interface)
4 9834850 220CE1 Cable, Flat, 14 Conductor , 30HP (QSS/QSR to Inverter Snubber)
5 9834886 462EW1 IGBT/IIB Harness
6 6300FP2 QSS/QSR Snubber Board, 230V
7 804BK1 ZNR Assembly, 7.5/10HP
804BK2 ZNR Assembly, 15HP
804BK3 ZNR Assembly, 20/30HP
8 6300FV2 QSS/QSR Incerter Interface Card
9 786BJ1 Standoff, Locking, PCB, M4 X .875 LG., 7.5/10HP
786BJ2 Standoff, Locking, PCB, M4 X 1.00 LG., 15/20HP
786BJ3 Standoff, Locking, PCB, M4 X 1.125 LG., 30HP
10 9834941 844AC1 Thermostat, 160_F
11 9834953 844AD1 Thermostat, 120_F
12 141675 Jumper, 2 Position
13 344BT1 Diode Module, 3–phase Bridge, 60A, 800V, 7.5/10HP
344BV1 Diode Module, 3–phase Bridge, 100A, 800V, 15HP
344BW1 Diode Module, 3–phase Bridge, 150A, 800V, 20/30HP
14 472BG3 Heatsink Thermostat Pad
15 6300LG1 Bus Voltage Indicator PCB
16 9818534 699AV2 Resistor, 3.6K Ohm, 100W
17 9818546 699AV4 Resistor, 50 Ohm, 100W
18 238BT1 Capacitor Elec., 3600µF, 450VDC
19 155CN1 IGBT Dual, QSS/QSR 400A, 600V
20 6300LH2 Current Sensor Ass’y, 150A Board, 7.5-20HP
6300LH3 Current Sensor Ass’y, 200A Board, 30HP
21 155CJ1 IGBT, 6-pack,100A, 600V, 7.5/10HP
155CK1 IGBT, 6-pack, 150A, 600V, 15HP
155CL1 IGBT, 6-pack, 200A, 600V, 20HP
155CM1 IGBT, 6-pack, 300A, 600V, 30HP
22 472BG11 Heatsink Thermostat Pad for 155CJ1, 7.5/10HP
472BG12 Heatsink Thermostat Pad for 155CL1 & 155CK1, 15/20HP
472BG7 Heatsink Thermostat Pad for 155CM1, 30HP
23 241BD1 Capacitor, Film, 600V, IGBT Snub. 2.0µF, 7.5-15HP
241BD2 Capacitor, Film, 600V, IGBT Snub. 3.3µF, 20HP
241BD3 Capacitor, Film, 600V, IGBT Snub. 4.7µF, 30HP
24 6300LF1 Inverter Interface PCB, 6-pack
25 9834898 462EX1 Harness, AC/DC Current Reg., to Current Sensor
26 9834849 220CB1 Cable Current Regulator to T5 DSP, Car, Rear Panel
Quantum Quiet AC/DC Drive Assembly, 230V, 40-60HP

NON-REGENERATIVE
9
10
12 13 15
8
11 14
7 16
6
5 17
19
20 21
24
25 22
23
2109AM, Quantum Quiet AC/DC Assembly, 230V, 40-60HP NON-REGENERATIVE (continued)

1 9834849 220CB1 Cable, CR to DSP

2 6300LR21 Current Regulator PCB
4 9834837 220BG2 Cable , Flat, 34 Conductor , 7.5-30HP (Current Regulator to Interface)
5 6300FK2 Inverter Interface Board
7 9834850 220CE1 Cable, Flat, 14 Conductor , 30HP (QSS/QSR to Inverter Snubber)
8 9834953 844AD1 Thermostat, 120_F, TS1
9 9834941 844AC1 Thermostat, 160_F, TS2
10 141675 Jumper Strip, 2 Position
11 207BK1 Bus Bar Bridge, AC/DC
12 344BX1 Diode Module, Dual Bridge, 100A, 800V, 40HP (3 Per Drive)
344BY1 Diode Module, Dual Bridge, 160A, 800V, 60HP (3 Per Drive)
13 472BG6 Heatsink Thermostat Pad (For Diode Module,.BX1 &BY1)
14 804BK2 ZNR Assembly, 40HP
804BK3 ZNR Assembly, 60HP
15 6300LG1 Bus Voltage Indicator Board
16 9818546 699AV4 Resistor, 50 Ohm, 100W
18 141787 Standoff, .375 (Current Regulator)
19 238BT1 Capacitor Elec., 3600µF, 450VDC
20 155CN1 IGBT, Dual, 400A, 600V, 40HP
155CP1 IGBT, Dual, 600A, 600V (U, V, W & QSS/QSR), 60HP
21 472BG14 Heatsink Thermostat Pad (For IGBT, 155CN1), 40HP
472BG15 Heatsink Thermostat Pad (For IGBT, 155CP1), 60HP
22 9755603 736AN1 Sensor, Current, 200A, 40HP
736AT1 Sensor, Current, 300A, 60HP
23 9834898 462EX1 Harness, Current Regulator, to Current Sensor
25 241BD2 Capacitor Film, 600V, IGBT, Snub, 3.3µF, 40HP
241BD3 Capacitor Film, 600V, IGBT, Snub, 4.7µF, 60HP
Quantum Quiet AC/DC Drive Assembly, 460V

NON-REGENERATIVE
7 2
3
6 4
5
1 2109AL1 Drive Assembly Quantum AC/DC, 7.5/10HP

2109AL2 Drive Assembly Quantum AC/DC, 15HP
2 166AC1 Spring, Draw Catch
3 462HF1 Cable, Power Supply
4 672BM3 Power Supply
5 462HE1 Cable, Control Supply
6 378AH1 Fan, 6I, 120VAC
7 442AD1 Grille, Wire Fan, 6I
2109AL, Quantum Quiet AC/DC Assembly, 460V, 10-30HP NON-REGENERATIVE (continued)
11
10
7 8
6 12 13
4
14
3
1 2
15
16
17
18
23 19
22
7
20 7
21
24

1 141787 Standoff, Current Regulator

2 6300LR2 AC/DC Current Regulator 2 PCB - CCF
3 9834837 220BG2 Cable , Flat, 34 Conductor (Current Regulator to Interface)
4 9834850 220CE1 Cable, Flat, 14 Conductor (QSS/QSR to Inverter Snubber)
6 804BH2 ZNR Ass’y (Diode Module Assy.)
7 786BJ1 Standoff, Locking, PCB, M4 X .875 LG., 7.5/10HP
786BJ2 Standoff, Locking, PCB, M4 X 1.00 LG., 15/20HP
786BJ3 Standoff, Locking, PCB, M4 X 1.125 LG., 30HP
8 6300FP1 QSS/QSR Snubber Board, 460V
11 141675 Jumper, 2 Position
12 9719120 344AN1 Diode Module, 3–phase Bridge, 60A, 1600V, 7.5-20HP
9755238 344AN2 Diode Module, Dual Bridge, 100A, 1600V, 30HP
13 9779280 472BG3 Heatsink Thermostat Pad for AN1 & AN2
14 6300LG1 Bus Voltage Indicator PCB
16 9818546 699AV4 Resistor, 50 Ohm, 100W
17 9755196 238AW1 Capacitor, 2000µF, 450VDC
18 155CY1 IGBT, 6-pack, 50A, 1200V, 7.5/10HP
155CR1 IGBT, 6-pack, 75A, 1200V, 15HP
155CT1 IGBT, 6-pack, 100A, 1200V, 20HP
155CV1 IGBT, 6-pack, 150A, 1200V, 30HP
19 472BG11 Heatsink Thermostat Pad, 7.5/10HP
472BG12 Heatsink Thermostat Pad, 15/20HP
472BG7 Heatsink Thermostat Pad, 30HP
20 6300LH1 Current Sensor Ass’y, 50A, 7.5-15HP
6300LH2 Current Sensor Ass’y, 150A, 20/30HP
21 6300LF1 Inverter Interface PCB, 6-pack
23 9834849 220CB1 Cable Current Regulator to T5 DSP, Car, Rear Panel
24
10
11
9
13
12
8 14
15
7
3
16
17
18
1
19 20
23
22 21
24

1 9834849 220CB1 Cable, Current Regulator to T5 DSP, Rear Panel

2 6300LR2 AC/DC Current Regulator 2 Board 2
4 141787 Standoff, .375
5 9843837 220BG2 Cable, Flat, 34 Conductor, (Current Regulator to Inverter Interface PCB)
6 6300FK2 Inverter Interface Board
8 9834850 220CE1 Cable, Flat 14 Conductor
11 141675 Jumper Strip, 2 Position
12 9755275 344AY1 Diode Module, Dual Bridge, 150A, 1600V
13 9779346 472BG6 Heatsink Thermostat Pad (For Diode Module)
14 9869499 804BH1 ZNR Assembly, 60HP
15 6300LG1 Bus Voltage Indicator Board
16 9818546 699AV4 Resistor, 50 Ohm, 100W
18 9755196 238AW1 Capacitor Elec., 2000µF, 450VDC
19 155CW1 IGBT, Dual, 200A, 1200V, 40HP
155CX1 IGBT, Dual, 300A, 1200V, 60HP
20 472BG14 Heatsink Thermostat Pad, 40HP (For IGBT pin.)
472BG15 Heatsink Thermostat Pad, 60HP (For IGBT pin.)
21 9755603 736AN1 Current Sensor, 200A, 60HP
6300LH2 Current Sensor Ass’y, 300A, 40HP
24 241BE2 Capacitor Film, 600V, IGBT, Snub, 1.5µF, 40HP
241BE3 Capacitor Film, 600V, IGBT, Snub, 2.0µF, 60HP
CAR CONTROLLER REAR - DSD 412 SCR DRIVE

(190 Amp Small Frame Shown)
18 19 20 21 22
1 23 24 25
3 4
17 DSD 412 SCR Drive
(See Page 7A-32)
16 15
Digital Brake Current
Regulator Board
40 (See page 7A-33)
14 13 5
7
8
12
9
41
10 11
CAR CONTROLLER REAR - DSD 412 SCR DRIVE

(300 Amp Large Frame Shown)
18 19 20 21 22
1 23 24 25
3 4
16 15
DSD 412 SCR Drive

(See Page 7A-32)
Digital Brake Current

40 Regulator Board
(See page 7A-33)
14 13 5
7
8
12
9
41
10 11
DSD 412 SCR DRIVE
26
39
32
29
37
33
38
35
30
28
36
27
31
34
CAR CONTROLLER REAR - DSD 412 SCR DRIVE (continued)

1 77052 Terminal Block, 3 Pos. 175A

2 834BB1 Terminal Block, 1 Pos., TFG
3 9837061 298AL3 Contactor, 3 Pole; 1 M / 101 - 239 FLA
298AL4 Contactor, 3 Pole; 1 M / 240 - 300 FLA
9844510 298AL5 Contactor, 3 Pole; 1 M / 0 - 100 FLA
4 297AJ1 Contact Block, Aux., 2 Pole INO, INC, 1 M
5 196WE1 Bracket, Resistor Mounting, 2 Pos. (R3DR, R4DR, Freight Doors)
6 9744435 128074 Resistor, Adj., 250 Ohm, 200W (Freight Doors Only) (R3DR, R4DR)
9735641 700898 Rod, Threaded, 10-24 x 11.25I Lg
9760131 75781 Washer, Mica
9760039 75778 Washer, Centering
700393 Washer, Flat, #10, .190
701032 Nut, #10, .190 Z
7 708AJ13 Resistor, Adj., 50 Ohm, 420W, RSBR (B44 W/Sheave Brake)
9760131 75781 Washer, Mica
9760039 75778 Washer, Centering
700393 Washer, Flat, #10 , .190
701032 Nut, #10, .190 Z
8 221AB1 Tie Wrap Anchor
(T1=4.75KVA, 220-240V Input)
(T1=4.75KVA, 550-600V Input)
(T1=6.75KVA, 550-600V Input)
(T1=6.75KVA, 440-480V Input)
(T1=9.75KVA, 440-480V Input)
12 9853510 689AA1 Rectifier, Full Wave : BD, BB1, BB2, HLB, BB3, BB4, SBD
119268 Connector Housing Plug
13 298AA2 Contactor, 4 Pole 24VDC: MFP
14 9804420 804AC1 Suppressor, Transient, Assembly
15 412AT1 FuseBlock, Modular, Stud Type (FLD1)
16 9717158 409AV2 Fuse, Semiconductor, 500V, 50A (FLD1)
17 486AB2 Inductor, 4mH. 80 Amp (0-80A Armature)
486AB3 Inductor, 4mH. 140 Amp (81-140A Armature)
486AB4 Inductor, 4mH. 188 Amp (141-188A Armature)
486AB5 Inductor, 4mH. 240 Amp (189-240 Amp Armature)
486AB6 Inductor, 4mH. 300 Amp (241-300 Amp Armature)
18 701032 FS, Nut, NHK .190(10) Z
19 718AB2 Threaded Rod, #10-24 X 18.000 LG
20 512AB1 MICA Insulation Washer (300W)
21 399AD1 Center Washer (300W)
CAR CONTROLLER REAR - DSD 412 SCR DRIVE (continued)

22 700393 Washer, Flat, #10, .190

23 708AH1 Resistor, 250 Ohm, 300W (HRG)
24 708AG3 Resistor, 1.9 Ohms, 25 Amps (Dynamic Braking)
708AG4 Resistor, 3.5 Ohms, 14.1 Amps (Dynamic Braking)
708AG5 Resistor, 8.5 Ohms, 9.2 Amps (Dynamic Braking)
25 820AK1 Terminal, Lug .250
77152 Terminal, Lug .375
26 46S02975-0502 Drive Control Board
27 46S02976-0032 Armature Interface Board, 50, 100, 190HP Drive
46S03088-0012 Armature Interface Board, 300HP Drive
28 46S03577-1003 Cube I.D. PCB, (Arm. Interface Board) 2-3HP Drive
46S03577-1007 Cube I.D. PCB, (Arm. Interface Board) 5-7.5HP Drive
46S03577-1015 Cube I.D. PCB, (Arm. Interface Board) 10-15HP Drive
29 05P0090-0293 Power Supply Board
30 46S03020-0020 Snubber Board, 50A
46S03020-0030 Snubber Board, 100A
31 05P00050-0409 SCR Module, 50A
05P00050-0410 SCR Module, 100A
05P00050-0412 SCR Module, 190A
46S03214-0010 SCR Module, 300A
32 05P00016-0048 Fan, 50A, 100A
05P00016-0012 Fan,190A
05P00016-0008 Fan, 300A
33 05P00217-0014 Current Transducer, 50A
05P00217-0013 Current Transducer, 100A
34 05P00050-0442 Field Power Module (SCR/Diode Bridge)
35 05P00218-0023 Thermistor
36 46S03207-0010 Parallel/Serial Board
37 9718023 05P0017-0155 AC Line Fuse, 50A
9718035 05P0017-0166 AC Line Fuse, 100A
9718047 05P0017-0220 AC Line Fuse, 190A
9718059 05P0017-0234 AC Line Fuse, 300A
38 9718072 05P00017-0178 Armature Fuse, 50A
9718084 05P00017-0179 Armature Fuse, 100A
9718096 05P00017-0366 Armature Fuse, 190A
9718151 05P00017-0235 Armature Fuse, 300A
39 46S03594-0010 Field Interface Board, 0.2-40A
40 238AD1 Capacitor, 90mfd, 500V
41 409AD1 Fuse, 30A, 600 V
42 708AJ9 Resistor, 10 Ohm, 420W (RSP1, RSP2) (not shown)
43 708AJ12 Resistor, 25 Ohm, 420W (RSP1, RSP2) (not shown)
44 708AD1 Resistor, 5K Ohm, 200W (not shown)
45 297AJ2 Aux. Contact Block, 2 Pole (B44,not shown)
46 9718400 146381 Resistor, Adj., 75 Ohm, 25W (RCD1) (not shown)
47 9853157 220BJ1 Cable Assembly, 63I, Encoder (not shown)
48 220AL2 Ribbon Cable Assembly, 72I (not shown)
49 462DK3 Harness, DSP To SCR Drive, (66I, 2 Shielded Pr. ) (not shown)
BRAKE REGULATOR
1 6300LV1 Digital Brake Current Regulator Board, 2A

2 6300LV2 Digital Brake Current Regulator Board, 10A
3 409BG4 Fuse, PCB, 3A, 250V, (F1-4)
4 412BA3 Fuse Block, 3 Pos., 30A, 600V
5 409BW23 Fuse, 12A, 600V
6 155DB1 IGBT, 50A, 1200V
7 966AV5 Resistor, 100W, MCR
8 241BG9 Capacitor, 2.5Mfd, 850V
9 344BT1 Diode Module, 3 Phase, 60A, 800V
3 1 2 4 5
8
3
9
Digital Brake Current Digital Brake Current

Regulator Board 2A Regulator Board 10A
This page
intentionally
left blank.
ENIL THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7A-34 Printed in USA NIL

TECHNICAL INFORMATION CARD CONFIGURATIONS
CPU CARD
HEADER SHUNT
CAR GROUP DUPLEX
CONFIGURATION CONFIGURATION CONFIGURATION
E2 - E3 E2 - E3 E2 - E3
E5 - E6 E5 - E6 E5 - E6
E8 - E9 E8 - E9 E8 - E9
E11 - E12 E11 - E12 E11 - E12
E14 - E15 E14 - E15 E14 - E15
E17 - E18 E17 - E18 E17 - E18
E20 - E21 E20 - E21 E20 - E21
E23 - E24 E23 - E24 E23 - E24
E26 - E27 E26 - E27 E26 - E27
E30 - E31 E30 - E31 E30 - E31
E33 - E34 E33 - E34 E33 - E34
E48 - E49 E48 - E49 E48 - E49
] E55 - E69 ] E55 - E69 ] E55 - E69
] E57 - E68 ] E57 - E68 ] E57 - E68
E73 - E74 E73 - E74 E73 - E74
E83 - E84 E83 - E84 E83 - E84
E86 - E87 E86 - E87 E86 - E87
E88 - E89 E88 - E89 E88 - E89
E91 - E92 E91 - E92 E91 - E92
E93 - E94 E93 - E94 E97 - E98
E97 - E98 E97 - E98 E99 - E100
E99 - E100 E99 - E100 E101 - E102
E101 - E102 E101 - E102 E105 - E106
E105 - E106 E105 - E106 E107 - E112
E107 - E112 E107 - E112 E123 - E124
E123 - E124
Table 1 - CPU Card Configuration
] Wire wrapped jumper required ONLY for close landing control with two sets of leveling sensors.
(continued)
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7B-1 Printed in USA August, 2002
Figure 1 - CPU Card
CARD JUMPER CONFIGURATIONS
GND1
1
JP2
Installed = Optical NTSD

Removed = Mechanical NTSD
Installed = ETSD
Removed = ETSL
JP1
GND2
GND3
Figure 2 - DSP Card
JP1
1
4
2
1
JP3
1 Jumpers 1 & 2
Installed for TAC50,
PMI 1
8
JP2
I/O CARD JUMPERS OUTPUT JUMPERS

BOARD NO. ADDRESS REQUIRED ENABLE REQUIRED
1 20H JP1-3 Modules 1-8 *JP2-3
2 28H JP1-1, JP1-3 Modules 9-16 *JP2-4
3 30H JP1-2, JP1-3 Modules 17-24 *JP2-5
4 38H JP1-1, JP1-2, JP1-3 Modules 25-32 *JP2-6
5 40H JP1-4 Modules 33-40 JP2-7
6 48H JP1-1, JP1-4 Modules 41-48 JP2-8
7 50H JP1-2, JP1-4 * DO NOT Install on Board 1.
8 58H JP1-1, JP1-2, JP1-4
9 60H JP1-3, JP1-4
10 68H JP1-1, JP1-3, JP1-4
11 70H JP1-2, JP1-3, JP1-4
12 78H JP1-1, JP1-2, JP1-3, JP1-4
Figure 3 - PMI Card
TECHNICAL INFORMATION GD-1 BRAKE ADJUSTMENT
APPENDIX C—BRAKE ADJUSTMENT

GD-1 GEARED MACHINE
WARNING WARNING
Routine maintenance of the machine brake Adjustment of the brake MUST be complete
must be performed AT LEAST annually. See before anyone is allowed to ride on the
the Service Manual. platform.
Required Tools & Materials: Summary of Steps

S Pliers: Retainer Ring & Adjustable Slip Joint (90 degrees ) S The major steps in adjusting the brake are:
S Bearing Oil (Print #70305) S (1) preparation; (2) brake disassembly, cleaning, and
S Flint Paper (Grade 240 or finer) lubrication; (3) brake reassembly and preliminary adjust-
ments; and (4) final adjustment.
S Degreaser (biodegradable, non-polluting)
S 1/4 ” Flat Screwdriver
S Tape Measure PREPARATION
S Allen Wrenches 1. Verify that any required Compensation Chains or Rope
S Wire Brush Assemblies have been installed.
S 1/4 ” x 20 Bolt 2. On construction jobs, verify that hoistway barricades are
S Torque Wrench & Adaptor in place to prevent unauthorized access.
S Feeler Gauges 3. Learn the names of the brake parts. See Figures 1, 2, &
S Open End Wrenches 3.
Figure 1 - GD-1 Machine Assembly
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7C-1 Printed in USA August, 2002
Stroke Adjustment Bolt
Solenoid Pin Stroke Adjustment

Brake Solenoid
Locknut
Brake Spring
Spring Adjustment Nut
Spring Bolt
Brake Switch
Stop Adjustment Nut Stop Adjustment Nut
Stop Adjustment Locknut Stop Adjustment Locknut

Falt Washer Flat Washer
Brake Adjustment Bolt Brake Adjustment

Bolt Locknut
Brake Arm
Detail “A”
Figure 2 - GD-1 Brake Assembly
E2000, 2002 THYSSENKRUPP ELEVATOR MANFACTURING, INC. 7C-2 Printed in USA August, 2002
DISASSEMBLY, CLEANING, & LUBRICATION

REMOVE & CLEAN THE BRAKE ARM ASSEMBLIES
CAUTION 1. a. Remove the retainer rings from the brake arm pins on
the gear housing side.
Take care that NO grit or other contaminants
come in contact with these parts. b. Install a ¼I x 20 bolt in the brake arm pins.
c. Remove the brake arm pins, pin bushings, and link
bars by pulling on the bolt installed in the previous
PRELIMINARY SETUP
step.
1. a. Tie off (or land in the pit) the platform or the counter-
weight - whichever is heavier. d. Remove the brake arms and the solenoid pin.
b. Manually trip the governor jaws. NOTES:
S Record the number and position of the shim washers for
2. Turn OFF and LOCK the mainline disconnect.
reassembly.
3. Remove the spring adjustment nut & washer, the brake
spring, and the spring bolt. S The brake arm pins can be removed in only one direction:
toward the motor.
4. Clean the threads of the spring bolt with a wire brush, and
lubricate them with grease. 2. Lightly sand, thoroughly wash, and coat with bearing oil
the following parts:
5. a. Measure and record the uncompressed brake spring brake arm pins, solenoid pin, link bars, shim
length. washers, retainer rings, and brake arm bores.
b. Verify that the brake spring diameter is 2¾I. 3. Ensure that the brake linings are tightly riveted to the
6. a. Disconnect the brake wiring from the junction box brake shoe assemblies, the rivets are recessed a mini-
(mounted on the motor). mum of 1/16I within the brake linings, and that the brake
b. Remove the flex-conduit from the junction box. linings are a minimum of 1/8I thick.
7. On the sheave side:
REMOVE AND CLEAN THE SOLENOID
a. Measure and record the length of the brake adjust- (see Figure 3)
ment bolt that extends past the brake adjustment
locknut. 1. a. Remove the brake solenoid from the brake arm.
b. Remove the stop adjustment nuts and flatwasher NOTE: Take car that the dust seal is not damaged.
from the brake adjustment bolt. b. Remove the front plate of the brake solenoid.
8. On the gear side: c. Remove the solenoid sleeve and plunger.
a. Loosen the brake adjustment bolt locknut. NOTE: Verify that both pin bushings are present.
b. Remove the brake adjustment bolt from the machine 2. If the solenoid plunger is coated with a factory- applied
housing by turning it counter clockwise. dry lubrication (black coating), wipe it with a clean, dry,
cloth; if no coating is present, replace the plunger.
3. Store the plunger to prevent any damage or contamina-
tion.
4. Thoroughly clean the inside of the solenoid sleeve and
front plate assembly.
Figure 3 - GD-1 Brake Solenoid Assembly
REASSEMBLY AND ADJUSTMENT d. With power disconnected from the Brake Solenoid,
run the car on Inspection speed with the brake col-
BRAKE REASSEMBLY lapsed on the brake drum for about 1 minute.
1. a. Reassemble the Brake Solenoid. See Figure 3. e. Land the Counterweights on the buffers.
f. Remove the Spring Adjustment nut and washer, the
NOTE: Be careful not to pinch the solenoid wiring.
Brake Spring and Spring bolt, and verify that 90%
b. Assemble the Brake Solenoid to the Brake Arm it was contact is made.
removed from. g. If 90% is not made, or if the linings are not burnished
c. Insert the Solenoid Pin and verify that the Brake Sole- slightly, repeat steps (a) through (f).
noid Plunger moves freely in the Solenoid Assembly.
2. a. Install the Brake Arms with the Shim Washers in their CAUTION
original position. See Figure 2, Detail A-A. DO NOT run the car with the brake collapsed
b. Reconnect the Flex Conduit and the Brake Wiring. for over 1 minute--Brake Drum will overheat.
c. Verify that the Brake Arms will move freely.
7. a. Install the Brake Adjustment Bolt from the gear side.
3. Verify that the Brake Shoes are centered horizontally on See Figure 2.
the Brake Drum (the shim washers may need to be
b. Tighten the Stop Adjustment nut on the end of the
moved).
Brake Adjustment Bolt to obtain the dimension
4. Using a .002I feeler gauge, check for shoe-to-drum con- recorded earlier (Preliminary Setup step 7).
tact on both sides of the brake shoe--at the top, the cen-
c. Install the Stop Adjustment locknut and tighten.
ter, and the bottom of the drum:
a. Place the feeler gauge on the edge of the Brake Drum, PRELIMINARY SHOE ADJUSTMENT
push one of the Brake Arms against the drum, and
1. Ensure that the Solenoid Pin contacts the center of the
verify that the gauge cannot be pulled out.
Stroke Adjustment bolt.
b. Place the feeler gauge on the opposite edge of the
drum, and repeat step (a). 2. a. Turn the Brake Adjustment Bolt by hand counterclock-
c. Repeat steps (a) and (b) at the other Brake Arm. wise until the Brake Shoe on the sheave side just
touches the Brake Drum.
5. If the Brake Shoe does not make 90% contact, sand in the
shoes as follows: b. Hold the Brake Adjustment bolt and temporarily
tighten the Adjustment Bolt locknut.
3. On the gear side, pull the Brake Arm back against the flat
WARNING washer and turn the Coupling Nut until shoe- to-drum
If the job was shipped prior to 1984, or if clearance is .020I.
there is any question of whether the brake 4. Hold the Coupling Nut and tighten the Stop Adjustment
linings are ASBESTOS, replace the linings locknut.
before sanding.
5. a. Loosen the Brake Adjustment Bolt locknut.
a. Remove the Spring Bolt, the Brake Spring, and the b. Turn the Brake Adjustment Bolt clockwise until the
Spring Adjustment washer and nut. Brake Shoe (on the gear side) clears the Brake Drum
b. Place adhesive-backed sandpaper (approx. 80 grit) by .008I.
around the entire surface of the Brake Drum. c. Hold the Brake Adjustment bolt and tighten the
Adjustment Bolt locknut.
c. Hold one Brake Arm against the drum and rotate the
drum back and forth. 6. Tighten the Brake Spring Adjustment nut until the Brake
Spring is compressed to 1/2I less than its uncom-
d. If 90% contact is not made, repeat step (c).
pressed length.
e. Repeat steps (b) through (d) for the other Brake Arm.
f. Remove the sandpaper from the Brake Drum.
6. a. Install the Brake Spring bolt, washer, and adjustment
nut.
b. Tighten the Spring Adjustment nut until the Brake
Spring is compressed to 1/2I less than its uncom-
pressed length.
c. Reset the Governor Jaws.
7. Tighten the Brake Spring Adjustment nut until the Brake NOTE: In the following step, be ready to quickly tighten the
Spring is compressed to 1/2 ” less than its uncom- Brake Spring adjustment nut, or press on the Brake Arm
pressed length. assemblies to prevent excessive movement.
8. a. Push the Solenoid Plunger completely back into the 7. Slowly loosen the Spring Adjustment Nut and repeat step
Brake Solenoid assembly. 6 until the car no longer comes to a stop; then tighten the
a. Adjust the Stroke Adjustment Bolt to 1/4 ” between Brake Spring by turning the Brake Adjustment nut clock-
the Solenoid Plunger and the Stroke Adjustment Bolt. wise one turn.
b. Hold the Stroke Adjustment bolt and tighten the 8. a. Measure the compressed Brake Spring length.
b. Subtract the compressed spring length from the
c. Verify that the Solenoid Pin Retainer does not restrict uncompressed length (as recorded from Preliminary
the movement of the Solenoid Pin. Setup step 5).
FINAL SHOE ADJUSTMENT 9. Increase the spring tension by the amount calculated in
step 8.
1. Turn ON the Mainline Disconnect.
NOTE: This adjustment ensures that the brake will hold 50%
2. Electrically energize the brake. of capacity, the maximum load for a construction platform
(plus a safety factor).
3. If the Brake Arms do not contact the stops, de- energize
the brake and adjust the Stroke Adjustment bolt for a full For Use by Contractors (Temporary Car) or for Final Adjust-
pick. ment
1. Verify proper Counterweighting by placing a balanced

FINAL ADJUSTMENT load on the elevator with the car in the center of the hoist-
way.
NOTE: To make the final adjustments to the GD-1 brake, you
must be able to run the platform from the controller. NOTE: When the brake is manually opened, the car should
NOT drift.
BRAKE SPRING TENSION ADJUSTMENT
2. With the balanced load still on the car, measure and
record the system friction with the torque wrench and
For Construction Platform
adaptor as follows:
1. Verify proper Counterweighting. a. Place the car and counterweight in the middle of the
hoistway, shackle-to-shackle.
2. Position the platform at the bottom terminal landing.
b. Turn OFF and LOCK the Mainline Disconnect, and
3. Tighten the Spring Adjustment nut until the spring is fully manually open the brake.
compressed; then turn it counter-clockwise 1 turn. c. Connect the torque wrench and adaptor to the brake
as shown in Figure 4.
d. Set the torque wrench indicator to zero.
WARNING
e. Verify that the System Friction is the same in both
Do NOT load the platform beyond 50% of the directions by rotating the brake drum in both direc-
contract capacity. Weights should be added tions, and record the value.
100 lbs. at a time to prevent accidental loss
of traction. NOTE: This System Friction value should be added to the
required torque, because the System Friction will decrease
with usage. See Appendix D - Brake Torque Values for a
4. Place 50% of the capacity load on the platform. table of torque requirements.
5. Turn OFF and LOCK the Mainline Disconnect.
3. With the balanced load still on the elevator, monitor the
6. Pry open the Brake Arms to allow the Brake Drum to rotate loop current while:
about an inch, and release the Brake Arms so that they a. Running the elevator DOWN from the top landing;
close on a moving drum; then verify that the brake stops (continued)
the car.
b. Running the elevator UP form the bottom landing; BRAKE ARM ADJUSTMENT
c. Verify that the car is heaviest at the BOTTOM.
NOTE: Proper counterweighting is essential to determine
where the car is the heaviest. 2. Position the platform at the bottom terminal landing, and
remove the load.
CAUTION 3. Run the platform up and down and adjust the Stroke
A properly counterweighted and Adjustment Bolt so that when the brake picks, the Brake
compensated car MUST be heaviest Arms will gently contact the Stop Adjustment Nuts.
at the BOTTOM.
4. If either of the Brake Shoes drags the Drum while the car
is running, adjust the shoe-to-drum clearance with the
4. Position the platform at the bottom terminal landing. Stroke Adjustment Bolt.
5. Tighten the Spring Adjustment nut until the spring is fully 5. Run the car up and down until the Brake Solenoid assem-
compressed; then turn it counterclockwise 1 turn. bly reaches normal operating temperature.
6. Weights should be added 100 lbs. at a time to prevent 6. Run the car to the top floor and turn OFF and LOCK the
accidental loss of traction. Mainline Disconnect.
7. Place 125% of the capacity load on the car. 7. Drift the car up to land the counterweights.
8. Turn OFF and LOCK the Mainline Disconnect. 8. Place the Controller on Inspection and turn ON the Main-
line Disconnect.
9. Pry open the Brake Arms to allow the Brake Drum to rotate
about an inch, and release the Brake Arms so that they 9. a. a. Electrically energize the brake and verify with a
close on a moving drum; verify that the brake stops the feeler gauge that the brake shoes clear the brake
car. drum by a minimum of .005”.
b. Rotate the brake drum by hand as far as possible to
NOTE: In the following step, be ready to quickly tighten the verify that the clearance remains a minimum of .005”.
Brake Spring adjustment nut, or press on the Brake Arm
assemblies to prevent excessive movement. c. If the clearance is less than .005”, adjust the Stop
Adjustment bolt to obtain a minimum of .005” and
10. Slowly loosen the Spring Adjustment Nut and repeat step retighten all locknuts.
6 until the car no longer comes to a stop; then tighten the
Brake Spring by turning the Brake Adjustment nut clock-
wise one turn. WARNING
11. 10. Tighten the Brake Adjustment nut 1/2 turn. The Brake Pick Voltage is set in relationship
to the Spring Pressure. If the Spring Pressure
is increased, the Pick Voltage must be
CAUTION verified to ensure proper brake operation.
The Maximum Brake Spring length is 4
inches--IF the brake spring is MORE THAN 4
inches long, tighten it to 4 inches.
NOTE: The brake is now set to hold 125% of capacity, which

is the minimum allowed by code. Brake Spring tension should
NOT require additional adjustment unless the capacity of the
elevator changes.
TORQUE VERIFICATION
1. Position the platform at the top terminal landing.
3. Connect the torque wrench and adaptor to the brake as

shown in Figure 4.
4. Set the torque wrench to ZERO, and pull up on the wrench

in the direction corresponding to an up- moving car.
5. Verify that the brake is set to hold at least one half of the
value shown in the torque tables (see Appendix D), PLUS
the value recorded in Final Adjustment (Temporary Car),
step 2, (half-- because the torque adaptor doubles the
length of the wrench).
6. Record the brake adjustments on the Brake Adjustment

Record Sheet.
Figure 4 - Torque Wrench & Adaptor on Brake
This page
intentionally
left blank.
ENIL THYSSENKRUPP ELEVATOR MANFACTURING, INC. 7C-8 Printed in USA NIL

TECHNICAL INFORMATION GD300 BRAKE ADJUSTMENT
BRAKE ADJUSTMENT
GD300 GEARED MACHINES
WARNING WARNING
Required Tools & Materials: Summary of Steps

S Pliers: Retainer Ring & Adjustable Slip Joint (90 degrees )
The major steps in adjusting the brake are:
S Bearing Oil (Print #70305)
S Flint Paper (Grade 240 or finer) (1) preparation; (2) brake disassembly, cleaning, and lubrica-
tion; (3) brake reassembly and preliminary adjustments; and
S Degreaser (biodegradable, non-polluting)
(4) final adjustment.
S Tape Measure
S Feeler Gauges PREPARATION
S Wire Brush
1. Verify that any required Compensation Chains or Rope
S Torque Wrench & Adaptor Assemblies have been installed.
S .002 & .005 shims
S Open End Wrenches 2. On construction jobs, verify that hoistway barricades are
in place to prevent unauthorized access.
S Adjustment of the brake MUST be complete before anyone
is allowed to ride on the platform.
3. Learn the names of the brake parts. See Figures 1, 2, & 3.
Figure 1 - GD-300 Machine Assembly
Figure 2 - GD-300 Brake Assembly
DISASSEMBLY, CLEANING, & LUBRICATION c. On a 16I brake, remove the safety wire and the 3 bolts
in the front support.
CAUTION 2. a. Remove the brake arm pins and the brake arms from
the base.
Take care that NO grit or other contaminants
come in contact with these parts. b. Remove the solenoid pin.
NOTE: Record the number and position of the shim washers
PRELIMINARY SETUP
for reassembly.
1. a. Tie off (or land in the pit) the platform or the counter- 3. Lightly sand, thoroughly wash, and coat with bearing oil
weight - whichever is heavier. the following parts:
b. Manually trip the governor jaws. brake arm pins, solenoid pin, shim washers,
retainer rings, and brake arm bores.
2. Turn OFF and LOCK the mainline disconnect.
4. Ensure that the brake linings are tightly riveted to the
3. Remove the spring adjustment nut & washer, the brake brake shoe assemblies, the rivets are recessed a mini-
spring, and the spring bolt. mum of 1/16I within the brake linings, and that the brake
linings are a minimum of 1/8I thick.
4. Clean the threads of the spring bolt with a wire brush, and
lubricate them with grease. 5. Clean out the oil holes (if provided) at each end of the
brake arm assembly for oiling of the brake arm pins.
5. a. Measure and record the uncompressed brake spring
length. REMOVE AND CLEAN THE SOLENOID
b. Verify that the brake spring diameter is 2¾I or
21/16I. 1. a. Remove the brake solenoid from the brake arm.
NOTE: Take car that the dust seal is not damaged.
6. a. Disconnect the brake wiring from the junction box
b. Remove the front plate of the brake solenoid.
(mounted on the motor).
c. Remove the solenoid sleeve and plunger.
b. Remove the flex-conduit from the junction box.
NOTE: Verify that both pin bushings are present.
7. a. Loosen the locknut on each stop adjustment bolt.
2. If the solenoid plunger is coated with a factory- applied
b. Back the stop adjustment bolts away from the brake
dry lubrication (black coating), wipe it with a clean, dry,
arms so that the brake arms can be moved away from
cloth; if no coating is present, replace the plunger (see
the brake drum.
Figure 3).
REMOVE & CLEAN THE BRAKE ARM ASSEMBLIES 3. Store the plunger to prevent any damage or contamina-
tion.
1. a. On a 12I brake, remove the safety wire and 3 bolts
that lock the brake arm pins in place. 4. Thoroughly clean the inside of the solenoid sleeve and
b. On a 16I brake, remove the retainer rings and loosen front plate assembly.
the set screws in the front support.
Figure 3 - GD-300 Brake Solenoid Assembly
REASSEMBLY AND ADJUSTMENT

BRAKE REASSEMBLY
WARNING
If the job was shipped prior to 1984, or if
1. a. Reassemble the Brake Solenoid. See Figure 3.
there is any question of whether the brake
NOTE: Be careful not to pinch the solenoid wiring. linings are ASBESTOS, replace the linings
b. Assemble the Brake Solenoid to the Brake Arm it was before sanding.
removed from.
c. Insert the Solenoid Pin and verify that the Brake Sole- a. Remove the Spring Bolt, the Brake Spring, and the
noid Plunger moves freely in the Solenoid Assembly. Spring Adjustment washer and nut.
b. Place adhesive-backed sandpaper (approx. 80 grit)
2. a. Install the Brake Arms with the Shim Washers in their around the entire surface of the Brake Drum.
original position. See Figure 2. c. Hold one Brake Arm against the drum and rotate the
b. On 16I brakes, replace the retainer rings, 3 bolts, and drum back and forth.
safety wire (where applicable); then tighten the set d. If 90% contact is not made, repeat step (c).
screws in the front support.
e. Repeat steps (b) through (d) for the other Brake Arm.
c. On 12I brakes, replace the 3 bolts and the safety wire
f. Remove the sandpaper from the Brake Drum.
(where applicable) in the front support.
NOTE: Position the flats on the brake arm pins up and toward 12. a. Install the Brake Spring bolt, washer, and adjustment
the gear case. nut.
d. Reconnect the Flex Conduit and the Brake Wiring. b. Tighten the Spring Adjustment nut until the Brake
Spring is compressed to:
e. Verify that the Brake Arms will move freely.
1) If the spring outside diameter is 23/4I - tighten it
3. Verify that the Brake Shoes are centered horizontally on to 1/2I less than its uncompressed length.
the Brake Drum (the shim washers may need to be
moved). 2) If the spring outside diameter is 21/16I - tighten
it to 11/4I less than its uncompressed length.
4. Using a .002 feeler gauge, check for shoe-to-drum con-
c. Reset the Governor Jaws.
tact on both sides of the brake shoe - at the top, the cen-
ter, and the bottom of the drum: d. With power disconnected from the Brake Solenoid,
run the car on Inspection speed with the brake col-
a. Place the feeler gauge on the edge of the Brake Drum,
lapsed on the brake drum for about 1 minute.
verify that the gauge cannot be pulled out. e. Remove the Spring Adjustment nut and washer, the
Brake Spring and Spring bolt, and verify that 90%
contact is made.
drum, and repeat step (a).
f. If 90% is not made, or if the linings are not burnished
c. Repeat steps (a) and (b) at the other Brake Arm.
slightly, repeat steps (a) through (f).
NOTES:
S If the contact is 90% or more, proceed to Preliminary Shoe CAUTION
Adjustment. DO NOT run the car with the brake collapsed
S If the contact area is less than 90%, do steps 5 through 10. for over 1 minute--Brake Drum will overheat.
5. Loosen the bolts that hold the base of the brake assembly
to the machine bedplate.
6. Using a feeler gauge, square the shoes to the brake drum
by rotating the base as required.
7. Shim the bolts that hold the base to the machine bed-
plate.
8. Retighten the bolts that hold the base to the machine
bedplate.
9. Check that the brake shoes are still centered on the brake
drum; if not, reposition the shims on the brake pins.
10. Check that the brake shoes still make proper contact with
the brake drum; if not, repeat steps 5 through 9.
11. If the Brake Shoe does not make full contact after repeat-
ing steps 5 - 9, sand in the shoes as follows:
PRELIMINARY SHOE ADJUSTMENT FINAL ADJUSTMENT

1. Ensure that the Solenoid Pin contacts the center of the NOTE: To make the final adjustments, you must be able to run
Stroke Adjustment bolt. the platform from the controller.
2. Land the Counterweights on the buffers. BRAKE SPRING TENSION ADJUSTMENT
3. Loosen the Spring Adjustment nut until the Brake Arms For Construction Platform
will move freely.
1. Verify proper counterweighting.
4. a. Push one of the Brake Arms away from the Brake Drum.
a. While checking with a feeler gauge, adjust the Stop 2. Position the platform at the bottom terminal landing.
Adjustment bolt on this side for a minimum brake
shoe-to-drum clearance of .005”. 3. Tighten the Spring Adjustment nut until the spring is fully
b. Hold the Stop Adjustment bolt and tighten the Stop compressed; then turn the nut counterclockwise 1 turn.
c. Verify that the shoe-to-drum clearance is still .005”. WARNING
5. Repeat step 3 for the other Brake Arm. Do NOT load the platform beyond 50% of the
contract capacity. Weights should be added
6. If the outside diameter of the Brake Spring is 2#%”, 100 lbs. at a time to prevent accidental loss
of traction.
tighten the Spring Adjustment Nut until the Brake Spring
is compressed to 1/2 ” less than its uncompressed
length. 4. Place 50% of the capacity load on the platform.
7. If the outside diameter of the Brake Spring is 2-os”, 5. Turn OFF and LOCK the Mainline Disconnect.
tighten the Spring Adjustment nut until the Brake Spring
is compressed to 1 1/4 ” less than its uncompressed 6. Pry open the Brake Arms to allow the Brake Drum to rotate
length. about an inch, and release the Brake Arms so that they
close on a moving drum; verify that the brake stops the
8. a. Push the Solenoid Plunger completely back into the car.
Brake Solenoid assembly.
b. Adjust the Stroke Adjustment bolt to 1/4 ” between NOTE: In the following step, be ready to quickly tighten the
the Solenoid Plunger and the Stroke Adjustment bolt. Brake Spring adjustment nut, or press on the Brake Arm
c. Hold the Stroke Adjustment bolt and tighten the assemblies to prevent excessive movement.
7. Slowly loosen the Spring Adjustment Nut and repeat step
FINAL SHOE ADJUSTMENT 6 until the car no longer comes to a stop; then tighten the
1. Turn ON the Mainline Disconnect. wise one turn.
2. Electrically energize the brake. 8. a. Measure the compressed Brake Spring length.
b. Subtract the compressed spring length from the
3. If the Brake Arms do not contact the stops, de- energize uncompressed length (as recorded in preliminary
the brake and adjust the Stroke Adjustment bolt for a full setup step 5).
pick.
9. Increase the spring tension by the amount calculated in
step 8.
NOTE: This adjustment ensures that the brake will hold 50%
of capacity, the maximum load for a construction platform
(plus a safety factor).
For Use by Contractors (Temporary Car)

or for Final Adjustment
1. Verify proper Counterweighting by placing a balanced 4. Position the platform at or near the bottom terminal land-
load on the elevator and the car in the center of the hoist- ing.
way.
5. Tighten the Spring Adjustment nut until the spring is fully
NOTE: When the brake is manually opened, the car should compressed; then turn the nut counterclockwise 1 turn.
NOT drift.
2. With the balanced load still on the car, measure and WARNING
record the system friction with the torque wrench and Weights should be added 100 lbs. at a time
adaptor as follows: to prevent loss of traction.
a. Place the car and counterweight in the middle of the
hoistway, shackle-to-shackle.
6. Place 125% of the capacity load on the car.
b. Turn OFF and LOCK the Mainline Disconnect, and
manualy open the brake. 7. Turn OFF and LOCK the Mainline Disconnect.
c. Connect the torque wrench and adaptor to the brake
as shown in Figure 4. 8. Pry open the Brake Arms to allow the Brake Drum to rotate
d. Set the torque wrench indicator to zero. about an inch, and release the Brake Arms so that they
close on a moving drum; verify that the brake stops the
e. Verify that the System Friction is the same in both
car.
directions by rotating the brake drum in both direc-
tions, and record the value.
NOTE: In the following step, be ready to quickly tighten the
Brake Spring adjustment nut, or press on the Brake Arm
NOTE: This System Friction value should be added to the
assemblies to prevent excessive movement.
required torque, because the System Friction will decrease
with usage. See Appendix D - Brake Torque Values for a
9. Slowly loosen the Spring Adjustment Nut and repeat step
table of torque requirements.
8 until the car no longer comes to a stop; then tighten the
3. With the balanced load still on the elevator, monitor the
wise one turn.
loop current while:
a. Running the elevator DOWN from the top landing; 10. 10. Tighten the Brake Adjustment nut 1/2 turn.
b. Running the elevator UP from the bottom landing;
CAUTION
NOTE: Proper counterweighting is essential to determine Maximum Brake Spring length is 4 inches--IF
where the car is the heaviest. the brake spring length is MORE THAN 4
inches, tighten the spring to 4 inches.
CAUTION
A properly counterweighted and is the minimum allowable by code. The Brake Spring Tension
compensated car MUST be heaviest at the should NOT require additional adjustment unless the capacity
BOTTOM. of the elevator changes.
BRAKE ARM ADJUSTMENT TORQUE VERIFICATION
1. Turn ON the Mainline Disconnect. 1. Position the platform at the top terminal landing.
2. Position the platform at the bottom terminal landing and 2. Turn OFF and LOCK the Mainline Disconnect.
remove the load.
3. Connect the torque wrench and adaptor to the brake as
3. Run the platform up and down and adjust the Stroke shown in Figure 4.
Adjustment Bolt so that when the brake picks, the Brake
Arms will gently contact the Stop Adjustment bolts. 4. Set the torque wrench to ZERO, and pull up on the wrench
in the direction corresponding to an up- moving car.
4. If either of the Brake Shoes drags the Drum while the car
is running, adjust the shoe-to-drum clearance with the 5. Verify that the brake is set to hold at least one half of the
Stroke Adjustment bolt. value shown in the torque tables (see Appendix D), PLUS
the value recorded in Final Adjustment (Temporary Car),
5. Run the car up and down until the Brake Solenoid assem- step 2, (half-- because the torque adaptor doubles the
bly reaches normal operating temperature. length of the wrench).
6. Run the car to the top floor and turn OFF and LOCK the 6. Record the brake adjustments on the Brake Adjustment
Mainline Disconnect. Record Sheet.
7. Drift the car up to land the counterweights.
8. Place the Controller on ‘‘Inspection‘‘ and turn ON the

Mainline Disconnect.
9. a. Electrically energize the brake and verify with a feeler

gauge that the brake shoes clear the brake drum by a
minimum of .005”.
a. Rotate the brake drum by hand as far as possible to
verify that the clearance remains a minimum of .005”.
b. If the clearance is less than .005”, adjust the Stop
Adjustment bolt to obtain a minimum of .005” and
retighten all locknuts.
WARNING
The Brake Pick Voltage is set in relationship
with the Spring Pressure. If the Spring
Pressure is increased, the Pick Voltage must
be verified to ensure proper brake operation.
Figure 4 - Torque Wrench & Adaptor on Brake
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intentionally
left blank.
ENIL THYSSENKRUPP ELEVATOR MANFACTURING, INC. 7C-16 Printed in USA NIL

TECHNICAL INFORMATION G-3 BRAKE ADJUSTMENT
BRAKE ADJUSTMENT
G3 GEARLESS MACHINE
WARNING WARNING
Required Tools & Materials: Summary of Steps:

S Ball and Roller Bearing Grease (#70313)
(1) preparation; (2) disassembly, cleaning, and lubrication;
S Flint Paper (Grade 240 or finer)
(3) brake reassembly and preliminary adjustment; and (4)
S Degreaser (biodegradable, non-polluting) final adjustment.
S Tape Measure 1. Verify that any required Compensation Chains or Rope
Assemblies have been installed.
S Feeler Gauges
S Wire Brush 2. On construction jobs, verify that hoistway barricades are
S Hammer & Punch in place to prevent unauthorized access.
S Pliers: Retainer Ring, Needle Nose, & Adj. Slip-Joint
S Open End Wrenches
Figure 1 - G3 Gearless Machine
Figure 2 - G3 Brake Assembly

5. Ensure that the Brake Linings are tightly riveted to the
Brake Shoe assemblies, the rivets are recessed a mini-
CAUTION mum of -os” within the brake linings, and that the brake
Take care that NO grit or contaminants come linings are a minimum of -ra” thick.
in contact with these parts.
6. Lightly sand, thoroughly wash, and coat with bearing oil
PRELIMINARY SETUP
Brake Shoe Pins, Retainer Rings, and Brake Shoe bores.
1. a. Tie off (or land in the pit) the Platform or Counter-
weight, whichever is heaviest. 7. Check that each Brake Arm will pivot freely on its pin by
rocking the arm back and forth.
b. Manually trip the Governor Jaws.
NOTE: There is usually NO problem, but if resistance is felt in
2. Turn OFF and LOCK the Mainline Disconnect. step 7: remove, clean, and lubricate the Brake Arms, and the
Brake Arm Pins and bores; then reassemble.
3. Remove the End Caps of the Armature Shaft bearings and
inspect the bearings for lubrication. 8. Verify that the Brake Arm Pin has not backed out on the
machine side and that the Pin retainer is in place.
NOTE: If lubrication is needed, use Ball & Roller Bearing
grease (Do NOT overfill). REMOVE AND CLEAN THE SOLENOID
4. Replace the Bearing End Caps. 1. a. Remove the Brake Bracket Cap or Brake Switch
Assembly.
5. Remove the Spring Adjustment locknuts and washers
and the Brake Springs to allow the Brake Arms to move b. Raise and lay back the Brake Levers.
fully away from the drum. c. Remove the Solenoid Plunger.
6. Clean the threads of the Spring Bolt with a wire brush and 2. If the Solenoid Plunger is coated with a factory- applied
lubricate them with grease. dry lubricant (black coating), wipe it with a clean, dry
cloth. If NOT, replace the plunger.
REMOVE AND CLEAN THE BRAKE SHOE ASSEMBLIES
3. Store the Solenoid Plunger to prevent any damage or
1. Verify that the Spring Rod locknuts holding the Spring contamination.
Rods to the Brake Magnet assembly are tight. See Figure
2. 4. Thoroughly clean the inside of the Solenoid Sleeve and
End Pole.
2. Mark the Brake Shoe parts for reassembly to their original
Brake Arm. 5. a. Remove the Retainer Rings that hold the Brake Lever
Pins, and remove the Retainer Springs and Washers,
3. If present, remove the allen-head Set Screw (through the the Retainer, and the pins.
hole in the brake shoe assembly) that locks the Brake b. Remove the Brake Levers.
Shoe Pins to the Brake Arm. c. Lightly sand, thoroughly wash, and coat with bearing
oil the following parts:
4. a. Remove the Retainer Rings that hold the Brake Shoe
Pins. Brake Lever Pins, Retainer Rings, Retainer Springs,
b. Slide the pins out and remove the Brake Shoe assem- the Retainer, and Brake Lever bores.
bly from the Brake Arm.
Figure 3 - G3 Brake Solenoid Assembly

BRAKE REASSEMBLY 5. Loosen the locknut holding the Brake Adjustment bolt;
then back the bolt out five turns.
1. a. Verify that grease fittings work properly.
b. Install the Brake Levers (make sure Retainer Rings are 6. Using a .002 feeler gauge, check for shoe-to-drum con-
locked in the grooves of the Brake Lever pins). See tact on both sides of the brake shoe--at the top, the cen-
Figure 3, Detail A-A. ter, and at the bottom of the drum:
c. Verify that the Solenoid Yoke bolt is tight. a. Place the feeler gauge on the edge of the Brake Drum,
d. Install the Solenoid Plunger so that the Brake Levers
verify that the gauge cannot be pulled out.
are between Solenoid Plunger and Solenoid Yoke.
e. Verify that the Solenoid Plunger moves freely in the
drum, and repeat step (a).
Solenoid Assembly.
c. Repeat steps (a) and (b) at the other Brake Arm.
f. Lubricate the Brake Lever Pins through the grease fit-
tings at each end of the pins with Ball and Roller Bear-
7. If the Brake Shoes do not make 90% contact, they must
ing Grease.
be sanded BEFORE Final Adjustment.
NOTE: Wipe away any excess grease from around the end of
8. Install the Brake Springs, Washers, and Adjustment nuts.
the pins.
2. Assemble the Brake Shoes to the Brake Arms, and verify

that the Retainer Rings are locked in the grooves of the
pins and the allen-head set screws are tight.
3. Wipe the Brake Drum and Brake Shoes with a clean, dry
cloth.
4. Loosen the locknut holding the Stop Adjustment bolt;

then back the bolt out three turns.
PRELIMINARY SHOE ADJUSTMENT BRAKE SPRING TENSION ADJUSTMENT

1. Turn the Brake Adjustment bolts clockwise until the Brake
Levers are level. Do NOT tighten the locknut (temporary
1. Verify proper counterweighting.
adjustment).
2. Position the platform at the bottom terminal landing.
2. On each side, tighten the Stop Adjustment bolt until it just
contacts the Shoe Assembly.
3. Tighten each Spring Adjustment nut until both springs
are fully compressed; then turn each nut counter-clock-
3. Hold the Stop Adjustment bolt and tighten the locknut.
wise 1 turn.
4. Tighten each brake spring to a length of 6 1/2 ”.
WARNING
FINAL SHOE ADJUSTMENT
Do NOT load the platform beyond 50% of the
1. Turn ON the Mainline Disconnect. contract capacity. Weights should be added
100 lbs. at a time to prevent loss of traction.
2. Electrically energize the brake.
4. Place 50% of the capacity load on the platform.
3. If the pick is not enough to clear the drum, de- energize
the brake and turn the Brake Adjustment bolts until both 5. Turn OFF and LOCK the Mainline Disconnect.
shoes clear the Brake Drum surface by .005”.
NOTES:
CAUTION
S The Brake Lever Arms must be in contact with the Solenoid
Yoke to ensure lifting of the Brake Arms at the same time During step 6, monitor the Drive Sheave and
that the brake is energized. verify that it does NOT begin to slip through
the brake.
S The Stop Adjustment bolt may be adjusted to equalize
shoe-to-drum clearance from top to bottom of the shoe;
however, do not vary the Stop Adjustment bolt more than 6. Reduce tension on one of the Brake Springs until the shoe
-ra turn (either way) from the setting obtained in Prelimi- clears the Brake Drum surface.
nary Shoe Adjustment, Step 2.
7. Reduce tension on the fully compressed Brake Spring
until the Drive Sheave just begins to slip through the
4. Verify that the push-point on the Brake Lever Arm is cen-
Brake Shoes when the ropes are kicked.
tered on the Brake Adjustment bolt.
8. Measure and record the compressed Brake Spring
5. Electrically energize the brake and verify that each shoe
length.
clears the brake drum by a minimum of .005”.
9. Tighten the Spring Adjustment Nut on the other spring
6. Hold the Brake Adjustment bolt and tighten the locknut.
until it is fully compressed.
7. Reset the Governor Jaws.
10. Reduce tension on the Brake Spring adjusted in step 7
until the Brake Shoe does NOT contact the Brake Drum
Surface.
FINAL ADJUSTMENT
11. Reduce tension on the fully compressed Spring until the
NOTE: To do the final adjustment, you must be able to run the
Drive Sheave just begins to slip through the Brake Shoes
platform from the controller.
when the ropes are kicked.
12. Adjust the other Brake Spring to the compressed length

that was recorded in step 8.
13. Tighten the Brake Spring Adjustment locknuts.

For Use by Contractors (Temporary Car) 3. Verify proper Counterweighting by placing a balanced
or for Final Adjustment load on the elevator and the car in the center of the hoist-
way.
NOTE: When the brake is manually opened, the car should

WARNING NOT drift.
If the job was shipped prior to 1984, or if
there is any question of whether the brake 4. With the balanced load still on the elevator, monitor the
linings are ASBESTOS, replace the linings loop current while:
before sanding. a. Running the elevator DOWN from the top landing;
b. Running the elevator UP from the bottom landing;
1. If the shoes do not make 90% contact, sand in the shoes c. Verify that the car is heaviest at the BOTTOM.
as follows:
a. Run the empty car to the top landing and land the NOTE: Proper counterweighting is essential to determine
counterweights on the buffers. where the car is the heaviest.
b. Remove the spring adjustment locknuts and washers,
and the brake springs, to allow the brake arms to CAUTION
move fully away from the drum.
A properly counterweighted and
c. Place adhesive-backed sandpaper (approx. 80 grit) compensated car MUST be heaviest at the
around the entire surface of the brake drum.
BOTTOM.
d. Hold one brake arm against the drum and run the car
on Inspection DOWN about 1 revolution.
5. Position the empty platform at the top terminal landing
e. Allow the car to drift back up and land the counter-
and verify that the brake holds.
weights on the buffers.
f. If 90% contact is not made, repeat steps (d) and (e). 6. Tighten the Spring adjustment nut on one side of the
g. Repeat steps (d) through (f) for the other Brake Arm. machine until the Brake Spring is fully compressed.
h. Remove the sandpaper from the Brake Drum.
2. a. Install the Brake Springs, washers, and adjustment
nuts. CAUTION
b. Tighten the Spring Adjustment nuts until the Brake
Springs are compressed to 6 1/2 ”. During step 8, monitor the Drive Sheave to
verify that it does NOT begin to slip through
c. With power disconnected from the Brake Solenoid, the brake.
run the car with the brake collapsed on the brake drum
for about 1 minute.
d. Remove the Spring Adjustment nuts and washers and 8. Reduce tension on the Brake Spring that was NOT
the Brake Springs, and verify that 90% contact is adjusted in step 6 until the shoe clears the Brake Drum
made. surface.
e. If 90% is not made, or if the linings are not burnished
9. Reduce tension on the fully compressed Brake Spring
slightly, repeat steps (a) through (d).
until the Drive Sheave just begins to slip through the
Brake Shoes when the ropes are kicked.
CAUTION
DO NOT run the car with the brake collapsed 10. Tighten the Adjustment Nut 1/2 turn.
for over 1 minute--Brake Drum will overheat.
11. Measure and record the length of the compressed spring.
(continued)
BRAKE SPRING TENSION ADJUSTMENT BRAKE ARM ADJUSTMENT

(continued)
12. Tighten the Spring Adjustment nut on the other Brake
Spring until it is fully compressed. 2. Position the platform at the bottom terminal landing and
remove the load.
13. Reduce tension on the Brake Spring adjusted in step 6
until the Brake Shoe clears the Brake Drum surface. 3. Run the platform up and down and verify a shoe- to-drum
clearance of .003 to .004” on each side.
14. Reduce tension on the fully compressed Spring until the
Drive Sheave just begins to slip through the Brake Shoes 4. Hold the Brake Adjustment bolt and tighten the locknut.
when the ropes are kicked.
5. Run the platform and verify that both Brake Levers are
15. Tighten the Adjustment Nut 1/2 turn. contacted by the Solenoid Yoke at the same time the
brake is energized.
16. Adjust the other Brake Spring to the compressed length
that was recorded in step 11. 6. Run the car up and down until the Brake Solenoid assem-
bly warms up to normal operating temperature.
7. Run the car up to the top floor and turn OFF and LOCK
18. Position the platform at or near the bottom terminal land- the Mainline Disconnect.
ing.
8. Drift the car up to land the counterweights.
19. Tighten the Spring Adjustment nuts equally until one of
the springs is fully compressed; then turn both adjust- 9. Place the Controller on ‘‘Inspection’’ and turn ON the
ment nuts counterclockwise one turn. Mainline Disconnect.
10. a. Electrically energize the brake and verify with a feeler

WARNING gauge that the brake shoes clear the brake drum by
Weights should be added 100 lbs. at a time a minimum of .003”.
to prevent loss of traction. b. If the clearance is less than .003”, adjust the Brake
Adjustment bolt and the Stop Adjustment bolt to
obtain a minimum of .003” and retighten all locknuts.
20. Place 125% of the capacity load on the car.
NOTES:
21. Turn OFF and LOCK the Mainline Disconnect. S Failure to activate both Brake Levers at exactly the same
time will result in uneven wear of the Brake Magnet Guide
22. Turn each Adjustment Nut 1/2 turn counterclockwise Bushing.
until the Drive Sheave slips through the Brake when the
S The machine must be checked periodically for grease leak-
ropes are kicked; then turn each Adjustment Nut 1/2 turn
ing from bearing seals onto the Drive Sheave; if grease is
clockwise.
found, it must be cleaned off IMMEDIATELY so as not to
contaminate the Brake Shoes, Drum, or Tachometer
23. Tighten the Spring Adjustment locknuts.
Wheel.
is the minimum allowed by code. Brake Spring Tension should WARNING
NOT require additional adjustment unless the capacity of the
elevator changes. The Brake Pick Voltage is set in relation to
the Spring Pressure: If the Spring Pressure is
increased, the Pick Voltage must be verified
to ensure proper brake operation.
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intentionally
left blank.
E2000, 2001 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7C-24 Printed in USA January, 2001
TECHNICAL INFORMATION G4/G5 BRAKE ADJUSTMENT
BRAKE ADJUSTMENT
G4/G5 GEARLESS MACHINE
WARNING WARNING
Required Tools & Materials: Summary of Steps:

S Ball and Roller Bearing Grease (#70313)
(1) preparation; (2) disassembly, cleaning, and lubrication;
S Flint Paper (Grade 240 or finer)
(3) brake reassembly and preliminary adjustment; and (4)
S Degreaser (biodegradable, non-polluting) final adjustment.
S Tape Measure 1. Verify that any required Compensation Chains or Rope
Assemblies have been installed.
S Feeler Gauges
S Wire Brush 2. On construction jobs, verify that hoistway barricades are
S Hammer & Punch in place to prevent unauthorized access.
S Pliers: Retainer Ring, Needle Nose, & Adj. Slip-Joint
S Open End Wrenches
Figure 1 - G4/G5 Gearless Machine
Figure 2 - G4/G5 Brake Assembly

7. Measure and record the length of each uncompressed
Brake Spring.
CAUTION
Take care that NO grit or contaminants come 8. Clean the threads on the Spring Rod with a wire brush and
in contact with these parts. lubricate them with grease.
REMOVE AND CLEAN THE BRAKE SHOE ASSEMBLIES

PRELIMINARY SETUP
1. Verify that the Spring Rod locknuts holding the Spring
1. a. Tie off (or land in the pit) the Platform or the Counter- Rods to the Brake Magnet assembly are tight. See Figure
weight, whichever is heavier. 2.
b. Manually trip the Governor Jaws.
2. Mark the Brake Shoe parts for reassembly to their original
2. Turn OFF and LOCK the Mainline Disconnect. Brake Arm.
3. Check for Pedestal to Sheave Alignment: 3. If present, remove the allen-head Set Screw (through the
a. Remove the End Caps of the Armature Shaft Bear- hole in the brake shoe assembly) that locks the Brake
ings. Shoe Pins to the Brake Arm.
b. Hold a level (such as a straight edge) that will span the 4. a. Remove the Retainer Rings that hold the Brake Shoe
width of the Drive Sheave horizontally across the Pins.
machine surface of the bearing housing.
b. Slide the pins out and remove the Brake Shoe assem-
c. On both sides, measure the distance from the straight bly from the Brake Arm.
edge to each outer edge of the sheave.
5. Ensure that the Brake Linings are tightly riveted to the
NOTE: If the distance on each side between the straight edge Brake Shoe assemblies, the rivets are recessed a mini-
and the sheave varies more than -%}{”, continue with steps mum of 1/16 I within the brake linings, and that the brake
(d) through (g). linings are a minimum of 1/8 I thick.
d. Remove the Taper Pins and loosen the pedestal bolts
holding the pedestal to the bedplate. Lightly sand, thoroughly wash, and coat with bearing oil
e. Move the pedestal as required to equalize the dis-
tance on each side of the sheave as measured in step 6. Brake Shoe Pins, Retainer Rings, and Brake Shoe bores.
(c).
f. Retighten the pedestal mounting bolts and drill and 7. Check that each Brake Arm will pivot freely on its pin by
ream a new hole for the taper pin on each side. rocking the arm back and forth.
g. Install new taper pins.
NOTE: There is usually NO problem, but if resistance is felt in
4. Inspect the bearings for lubrication. step 7: remove, clean, and lubricate the Brake Arms, and the
Brake Arm Pins and bores; then reassemble.
NOTE: If lubrication is needed, use Ball and Roller Bearing
Grease (Do NOT overfill). 8. Verify that the Brake Arm Pin has not backed out on the
machine side and that the Pin retainer is in place.
5. Replace the Bearing End Caps.
6. Remove the Spring Adjustment Locknuts, Nuts, Wash-

ers, and the Brake Springs to allow the Brake Arms to
move fully away from the Brake Drum.
DISASSEMBLY & CLEANING

(continued)
REMOVE AND CLEAN THE SOLENOID SOLENOID PLUNGER AIR GAP ADJUSTMENT
1. a. Remove the Cotter Pins that secure the Brake Levers 1. Verify that there are an equal number of shims on each
to the Solenoid Plungers. side of the Solenoid Plunger.
b. Loosen the allen-head Set Screws that lock the Brake
Lever Pins to the Brake Levers. 2. Install the Solenoid Plungers with no clearance between
the Plunger, Plunger Cushion, and the Solenoid Housing.
c. Remove the Retainer Rings that hold the Brake Lever
pins and remove the pins.
3. Add shims equally to to each plunger until the Solenoid
d. Remove the Brake Levers. Plungers bottom out on each other.
e. Lightly sand, thoroughly wash, and coat with bearing
oil the Brake Lever Pins, Retainer Rings, and Brake 4. With the Plungers bottomed out on each other, push one
Lever bores. Plunger firmly against the Solenoid Housing.
f. Remove the socket-head Shoulder Bolt.
5. Measure the distance between Solenoid Housing and the
g. Remove the Solenoid Plungers.
Plunger Cushion and add .1 inch.
2. If the Solenoid Plungers are coated with a factory- applied
6. Remove shims to equal half of the amount calculated in
dry lubricant (black coating), wipe them with a clean, dry
step 5 from both Plungers to ensure a .1” air gap with
cloth. If NOT, replace both plungers.
both plungers pushed in fully.
3. Store the Solenoid Plungers to prevent any damage or
contamination.
4. Thoroughly clean the inside of the Solenoid Sleeve.
Figure 3 - G4/G5 Brake Solenoid Assembly

BRAKE REASSEMBLY PRELIMINARY SHOE ADJUSTMENT
1. a. Install the Solenoid Plungers in the Solenoid Sleeve. 1. a. Turn the Spring Rod locknuts 3 turns AWAY from the
b. Connect the Solenoid Plungers to the Brake Levers Solenoid to equalize spring tension.
and install the Cotter Pins. b. Tighten each Spring Rod locknut at the same time so
c. Install the socket-head Shoulder Bolt. that the Spring Rod does not move.
d. Verify that the Solenoid Plungers move freely in the
2. On each side, tighten the Stop Adjustment bolt until it
Solenoid Sleeve.
contacts slight resistance with the Shoe Assembly.
e. Verify that the grease fittings work properly.
f. Install the Brake Lever Pins (make sure the flat on the 3. Hold the Stop Adjustment bolt and tighten the locknut.
brake lever pins faces outward toward the set screw).
g. Tighten the allen-head Set Screws and install the 4. On both sides of the brake, check the point where the
Retainer Rings (make sure the Retainer Rings are Brake Lever and the Brake Arm Plate meet and determine
locked in the grooves of the pins). if the surfaces are squarely flush with one another and
that the Brake Levers are in a vertical position (shim as
h. Lubricate the Brake Lever Pins through the grease fit-
required). See Figure 2.
tings at each end of the pins with Ball & Roller Bearing
Grease.
NOTE: The Brake Levers should remain in a vertical position
NOTE: Wipe away any excess grease from around the end of throughout the remainder of the procedure.
the pins.
5. While holding the Plunger Cushion firmly against the
2. Assemble the Brake Shoes to the Brake Arms with the Plunger Plate, move the Plunger Stud to adjust the dis-
shim washers in their original positions (make sure the tance between the solenoid Assembly and the Plunger
Retainer rings are locked in the grooves of the pins). Cushion to .3I (“.05I).
3. Verify that the Brake Shoe linings are centered on the
6. Verify that the Spring Rod clears either side of the throat
drum surface; if not, shim as necessary.
in the Brake Arm by at least -os”.
4. Wipe the Brake Drum and Brake Shoes with a clean, dry
FINAL SHOE ADJUSTMENT
cloth.
5. Loosen the locknut holding the Stop Adjustment bolt;
then back the screw out three turns.
2. Electrically energize the brake.
6. Using a .002 feeler gauge, check for shoe-to-drum con-
3. If the pick is not enough to clear the drum, de- energize
tact on both sides of the brake shoe--at the top, the cen-
the brake and tighten the Brake Lever locknuts until both
ter, and at the bottom of the drum:
shoes clear the Brake Drum surface.
a. Place the feeler gauge on the edge of the Brake Drum,
push one of the Brake Arms against the drum, and NOTE: The Solenoid Plungers should be pulled in fully to the
verify that the gauge cannot be pulled out. Solenoid Assembly.
drum, and repeat step (a). 4. Adjust the Stop Adjustment bolt as required for equal
c. Repeat steps (a) and (b) at the other Brake Arm. shoe-to-drum clearance from top to bottom.
7. If the brake shoes do not make 90% contact, they must NOTE: Do not exceed 1/8I in or out.
be sanded BEFORE Final Adjustment.
5. Hold the Stop Adjustment bolt and tighten the locknut.
8. Install the Brake Springs, Washers, and Adjustments
nuts. 6. Reset the Governor Jaws.
FINAL ADJUSTMENT
NOTE: To do the final adjustment, you must be able to run the BRAKE SPRING TENSION ADJUSTMENT
platform from the controller.
For Use by Contractors (Temporary Car)
or for Final Adjustment
WARNING
1. Verify proper counterweighting. If the job was shipped prior to 1984, or if
there is any question of whether the brake
2. Position the platform at the bottom terminal landing. linings are ASBESTOS, replace the linings
before sanding.
3. Tighten each Spring Adjustment nut until the springs are
fully compressed; then turn each nut counter-clockwise
1 turn. 1. If the shoes do not make 90% contact, sand in the shoes
as follows:
a. Run the empty car to the top landing and land the
CAUTION counterweights on the buffers.
Weights should be added 100 lbs. at a time b. Remove the spring adjustment locknuts and washers,
to prevent loss of traction. Do NOT load the and the brake springs, to allow the brake arms to
platform to more than 50% of the contract move fully away from the drum.
capacity. c. Place adhesive-backed sandpaper (approx. 80 grit)
around the entire surface of the brake drum.
d. Hold one brake arm against the drum and run the car
4. Place 50% of the capacity load on the platform. on Inspection DOWN about 1 revolution.
e. Allow the car to drift back up and land the counter-
5. Turn OFF and LOCK the Mainline Disconnect. weights on the buffers.
f. If 90% contact is not made, repeat steps (d) and (e).
g. Repeat steps (d) through (f) for the other Brake Arm.
CAUTION
h. Remove the sandpaper from the Brake Drum.
During step 6, monitor the Drive Sheave and 2. a. Install the Brake Springs, washers, and adjustment
verify that it does NOT begin to slip through nuts.
the Brake.
b. Tighten the Spring Adjustment nuts until the Brake
Springs are compressed to 6 1/2 ”.
6. Reduce tension on the Brake Springs equally, 1/2 turn c. With power disconnected from the Brake Solenoid,
at a time, until the Drive Sheave just begins to slip through run the car with the brake collapsed on the brake drum
the Brake Shoes when the ropes are kicked. for about 1 minute.
d. Remove the Spring Adjustment nuts and washers and
7. a. Measure the compressed Brake Spring length. the Brake Springs, and verify that 90% contact is
b. Subtract the compressed spring length from the made.
uncompressed length (as recorded from preliminary e. If 90% is not made, or if the linings are not burnished
setup step 7). slightly, repeat steps (a) through (d).
(continued)
8. Increase the spring tension by the amount calculated in
step 7.
CAUTION
9. Tighten the Brake Spring Adjustment locknuts. DO NOT run the car with the brake collapsed
for over 1 minute--Brake Drum will overheat.
10. a. Turn the Spring Rod locknuts 3 turns AWAY from the
Solenoid to equalize spring tension.
b. Tighten the Spring Rod locknut at the same time so
that the Spring Rod does not move.
FINAL ADJUSTMENT (continued)

3. Verify proper Counterweighting by placing a balanced 12. a. Turn the Spring Rod locknuts 3 turns AWAY from the
load on the elevator and the car in the center of the hoist- Solenoid to equalize spring tension.
way. b. Tighten each Spring Rod locknut at the same time so
that the Spring Rod does not move.
NOTE: When the brake is manually opened, the car should
NOT drift. NOTE: The brake is now set to hold 125% of capacity, which
is the minimum allowed by code. Brake Spring Tension should
4. With the balanced load still on the elevator, monitor the NOT require additional adjustment unless the capacity of the
loop current while: elevator is changed.
a. Running the elevator DOWN from the top landing;
b. Running the elevator UP from the bottom landing; BRAKE ARM ADJUSTMENT
NOTE: Proper counterweighting is essential to determine
2. Position the platform at the bottom terminal landing and
where the car is the heaviest.
remove the load.
CAUTION 3. Run the platform up and down until the Brake Solenoid
assembly warms up to normal operating temperature,
A properly counterweighted and and adjust the Brake Lever locknuts to produce a shoe-
compensated car MUST be heaviest at the to-drum clearance of .003” to .004”.
BOTTOM.
4. Tighten the Brake Lever Locknuts so that the Brake lever
5. Position the platform at the bottom terminal landing. is captured between the nuts.
6. Tighten each Spring Adjustment nut until the springs are NOTE: The machine must be checked periodically for grease
fully compressed; then turn each nut counter-clockwise leaking from the bearing seals onto the inside of the Drive
1 turn. Sheave; if grease is found, it must be cleaned off IMMEDI-
ATELY so as not to contaminate the Brake Shoes, Brake Drum,
or Tachometer Wheel.
CAUTION
Weights should be added 100 lbs. at a time
to prevent loss of traction. WARNING
The Brake Pick Voltage is set in relation to
7. Place 125% of the capacity load on the car. the Spring Pressure: If the Spring Pressure is
increased, the Pick Voltage must be verified
8. Turn OFF and LOCK the Mainline Disconnect. to ensure proper brake operation.
CAUTION
During step 9, monitor the Drive sheave and
verify that it does NOT begin to slip through
the brake.
9. Reduce tension on the Brake Springs equally, 1/2 turn

at a time, until the Drive Sheave just begins to slip through
the Brake Shoes when the ropes are kicked.
10. On each side, tighten the Brake Spring Adjustment Nut

1/2 turn.
11. Tighten the Spring Adjustment locknuts.
This page
intentionally
left blank.
E2000, 2001 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7C-32 Printed in USA January, 2001
TECHNICAL INFORMATION BRAKE TORQUE VALUES
APPENDIX D—BRAKE TORQUE VALUES
GEARED MACHINES
OBTAINING TORQUE VALUES S Percent Counterweight (value MUST be exact) (from job
layout)
This section provides a brake torque value table (Table 1,
parts 1 through 7) from which brake torque may be NOTES:
determined. However, in order to use the table, several values S Some non-standard duties and all gearless elevators
must be known: require the use of test weights only.
S Car Capacity (from job data or crosshead) S Some non-standard duty elevators require that Field
S Drive Sheave Diameter (measure from outside to outside Operations be contacted for the appropriate torque value.
or obtain value from job layout) S Until further notice, the brake torque duty table applies only
S Gear Ratio (from machine nameplate) to geared equipment by Thyssen.
S Roping Ratio (from job layout)
CAPACITY SHEAVE GEAR PERCENT TORQUE TORQUE

(pounds) DIAMETER RATIO COUNTERWEIGHT 1:1 ROPING 2:1 ROPING
(inches)
1000 24 D-69 40% 40.44 32.47

1000 30 D-69 40% 44.43 34.46
1000 24 T-73 40% 47.10 35.80
1000 30 T-73 40% 52.75 38.63
1000 25 S-57 40% 34.55 29.53
1000 25 D-65 40% 42.13 33.31
1200 24 D-69 40% 43.05 33.78

1200 30 D-69 40% 47.69 36.09
1200 24 T-73 40% 50.80 37.65
1200 30 T-73 40% 57.38 40.94
1200 25 S-57 40% 36.20 30.35
1200 25 D-65 40% 45.01 34.76
1200 24 S-69 40% 33.78 29.14
1200 24 D-87 40% 39.21 31.86
1200 30 S-59 40% 38.06 31.28
1200 30 D-87 40% 42.89 33.70
1200 24 S-59 40% 35.35 29.92
1200 30 S-69 40% 36.09 30.30
1200 22 D-87 40% 37.99 31.24
1500 25 S-57 40% 38.66 31.58

1500 25 S-65 45% 44.53 34.52
1500 33 T-73 40% 68.29 46.40
1500 36 T-73 40% 72.27 48.39
Table 1 - Required Torque (Part 1)
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7D-1 Printed in USA August, 2002

(inches)
1500 30 S-59 40% 40.92 32.71

1500 36 D-73 40% 56.35 40.42
1500 30 D-87 40% 46.77 35.64
1500 30 T-73 40% 64.31 44.41
1500 30 D-69 40% 52.58 38.54
1500 24 T-73 45% 50.18 37.34
1500 24 S-69 40% 35.73 30.12
1500 24 D-87 40% 42.32 33.41
1500 30 S-59 40% 40.92 32.71
1500 24 D-69 40% 46.96 35.73
1500 30 S-69 40% 38.54 31.52
1500 24 S-59 40% 37.64 31.07
1500 22 D-87 40% 40.83 32.67
2000 25 D-65 40% 56.55 40.53

2000 33 T-73 40% 81.01 52.75
2000 36 T-73 40% 86.14 55.32
2000 24 S-69 40% 38.99 31.75
2000 30 D-87 40% 53.24 38.87
2000 30 S-69 40% 42.62 33.56
2000 30 S-59 40% 45.69 35.09
2000 36 D-73 40% 65.60 45.05
2000 24 D-69 40% 53.49 38.99
2000 30 T-73 40% 75.87 50.18
2000 30 D-69 45% 53.49 38.99
2000 36 T-91 40% 73.95 49.23
2000 36 T-73 40% 86.14 55.32
2000 30 S-59 40% 45.69 35.09
2000 24 S-59 40% 41.45 32.97
2000 30 S-69 40% 42.62 33.56
2000 30 D-69 40% 60.73 42.62
2000 22 D-87 40% 45.57 35.04
2100 25 S-57 40% 43.60 34.05

2100 25 D-65 40% 57.99 41.25
2100 33 T-73 40% 83.55 54.02
2100 36 T-73 45% 75.97 50.24
2500 25 S-57 40% 46.89 35.69

2500 25 D-65 45% 55.75 40.13
2500 33 T-73 40% 93.72 59.11
2500 36 T-73 40% 100.01 62.26
2500 39 T-73 40% 106.31 65.40
2500 24 S-69 40% 42.25 33.38
2500 30 D-87 40% 59.70 42.10
2500 30 D-69 40% 68.88 46.69
2500 22 D-87 40% 50.31 37.41
2500 36 D-73 40% 74.84 49.67

(inches)
2500 24 D-69 45% 52.76 38.63

2500 30 T-73 45% 74.59 49.54
2500 30 D-73 40% 66.45 45.48
2500 36 T-91 45% 72.71 48.61
2500 36 T-73 40% 100.01 62.26
2500 39 T-73 40% 106.31 65.40
2500 24 D-87 40% 52.66 38.58
2500 30 S-59 40% 50.45 37.48
2500 24 D-69 40% 60.01 42.25
2500 24 S-59 40% 45.26 34.88
2500 30 D-69 40% 68.88 46.69
2500 22 D-87 40% 50.31 37.41
3000 25 D-65 45% 61.36 42.93

3000 33 T-73 45% 89.48 56.99
3000 36 T-73 40% 113.88 69.19
3000 39 T-73 40% 121.33 72.92
3000 25 S-73 40% 45.19 34.85
3000 30 D-87 40% 66.17 45.33
3000 30 D-69 40% 77.04 50.77
3000 25 D-105 45% 47.32 35.91
3000 36 D-73 45% 71.76 48.13
3000 25 D-73 40% 65.88 45.19
3000 30 T-73 40% 98.99 61.74
3000 30 D-73 40% 74.16 49.33
3000 25 T-73 40% 86.57 55.54
3000 25 T-73 45% 73.73 49.11
3000 30 T-73 45% 83.58 54.04
3000 36 T-73 40% 113.88 69.19
3000 39 T-73 40% 121.33 72.92
3000 26 T-73 45% 75.70 50.10
3000 24 S-69 40% 45.51 35.01
3000 24 D-87 40% 57.83 41.17
3000 30 S-59 40% 55.22 39.86
3000 25 S-73 40% 45.19 34.85
3000 24 D-69 40% 66.53 45.51
3000 30 D-87 40% 66.17 45.33
3000 30 S-73 40% 49.33 36.91
3000 30 D-69 40% 77.04 50.77
3000 36 D-73 40% 84.09 54.29
3500 25 S-57 40% 55.11 39.81

3500 25 D-65 45% 66.97 45.73
3500 30 T-73 45% 92.57 58.53
3500 33 T-73 40% 119.15 71.82
3500 36 T-73 40% 127.75 76.13

(inches)
3500 25 S-73 40% 48.40 36.45

3500 30 D-87 40% 72.63 48.57
3500 30 D-69 40% 85.19 54.84
3500 25 D-105 40% 57.73 41.12
3500 36 D-73 40% 93.34 58.92
3500 25 D-73 40% 72.30 48.40
3500 30 T-73 40% 110.54 67.52
3500 30 D-73 40% 81.86 53.18
3500 25 T-73 40% 96.20 60.35
3500 25 T-73 45% 81.22 52.86
3500 26 T-73 45% 83.49 53.99
3500 24 S-69 40% 48.78 36.64
3500 21 S-73 40% 44.58 34.54
3500 24 D-87 40% 63.01 43.75
3500 30 S-59 40% 59.99 42.24
3500 24 D-69 40% 73.05 48.78
3500 30 D-87 40% 72.63 48.57
3500 30 S-73 45% 47.19 35.84
3500 25 D-105 45% 50.79 37.64
4000 25 S-57 40% 59.22 41.86

4000 36 S-73 40% 63.54 44.02
4000 36 D-73 40% 102.58 63.54
4000 26 D-73 40% 80.89 52.70
4000 33 T-73 40% 131.86 78.18
4000 30 D-73 45% 75.87 50.18
4000 36 D-73 40% 102.58 63.54
4000 30 T-73 40% 122.10 73.30
4000 33 T-73 40% 131.86 78.18
4000 36 T-73 40% 141.62 83.06
4000 25 S-73 40% 51.61 38.06
4000 30 D-87 40% 79.10 51.80
4000 30 D-69 45% 78.85 51.67
4000 25 D-105 40% 62.20 43.35
4000 25 D-73 40% 78.72 51.61
4000 25 T-91 45% 76.01 50.26
4000 36 Q-73 40% 180.66 102.58
4000 24 S-69 40% 52.04 38.27
4000 21 S-73 40% 47.27 35.89
4000 24 D-87 40% 68.18 46.34
4000 30 S-59 40% 64.75 44.63
4000 24 D-69 40% 79.57 52.04
4000 30 D-87 40% 79.10 51.80
4000 21 D-105 40% 56.17 40.33
4500 26 S-73 40% 56.04 40.27

4500 25 S-57 45% 55.11 39.81

(inches)
4500 36 S-73 40% 68.16 46.33

4500 36 D-73 40% 111.83 68.16
4500 26 D-73 40% 87.57 56.04
4500 33 T-73 40% 144.58 84.54
4500 30 D-73 45% 81.86 53.18
4500 36 D-73 40% 111.83 68.16
4500 30 T-73 40% 133.66 79.08
4500 33 T-73 40% 144.58 84.54
4500 36 T-73 40% 155.49 90.00
4500 24 S-69 40% 55.30 39.90
4500 30 D-73 40% 97.27 60.89
4500 30 T-73 45% 110.54 67.52
4500 33 Q-73 40% 184.60 104.55
4500 36 Q-73 40% 199.16 111.83
4500 24 S-69 40% 55.30 39.90
4500 24 D-87 40% 73.35 48.93
4500 30 S-73 40% 60.89 42.69
5000 26 S-73 40% 59.37 41.94

5000 25 S-57 40% 67.45 45.97
5000 36 S-73 40% 72.79 48.64
5000 36 D-73 40% 121.08 72.79
5000 26 D-73 45% 79.41 51.95
5000 33 T-73 45% 129.04 76.77
5000 30 D-73 45% 87.86 56.18
5000 36 D-73 40% 121.08 72.79
5000 30 T-73 40% 145.22 84.86
5000 33 T-73 40% 157.29 90.90
5000 36 T-73 40% 169.36 96.93
5000 24 D-69 45% 78.12 51.31
5000 30 D-73 40% 104.98 64.74
5000 30 T-73 45% 119.53 72.02
5000 30 D-73 40% 104.98 64.74
5000 30 Q-73 40% 185.46 104.98
5000 33 Q-73 40% 201.55 113.03
5000 36 Q-73 40% 217.65 121.08
5000 24 S-69 40% 58.56 41.53
5000 24 D-87 40% 78.52 51.51
5000 30 S-73 40% 64.74 44.62
6000 26 S-73 40% 66.05 45.28

6000 25 S-57 45% 64.70 44.60
6000 36 S-73 45% 69.71 47.10
6000 36 D-73 40% 139.57 82.03

(inches)
6000 26 D-73 40% 107.61 66.05

6000 33 T-73 40% 182.72 103.61
6000 30 D-73 40% 120.39 72.45
6000 30 T-73 40% 168.34 96.42
6000 36 T-73 40% 197.10 110.80
6000 25 D-73 40% 104.41 64.45
6000 25 S-73 40% 64.45 44.48
6000 30 Q-73 40% 216.28 120.39
6000 25 S-73 40% 64.45 44.48
6000 25 D-105 40% 80.06 52.28
6000 33 S-73 40% 77.24 50.87
7000 26 S-73 40% 72.73 48.62

7000 26 D-73 40% 120.96 72.73
7000 36 S-73 40% 91.28 57.89
7000 36 D-73 40% 158.06 91.28
7000 26 D-73 40% 120.96 72.73
7000 33 T-73 40% 208.15 116.32
7000 26 T-73 40% 169.19 96.85
7000 30 T-73 40% 191.45 107.98
7000 25 D-73 40% 117.25 70.88
7000 30 D-73 40% 135.80 80.15
7000 26 Q-73 40% 217.42 120.96
7000 25 S-73 40% 70.88 47.69
7000 25 D-105 40% 88.98 56.74
7000 30 S-73 40% 80.15 52.33
7000 30 D-73 45% 111.83 68.16
8000 26 S-73 45% 67.54 46.02

8000 26 D-73 45% 110.57 67.54
8000 36 S-73 40% 100.53 62.51
8000 36 D-73 40% 176.55 100.53
8000 26 D-73 45% 110.57 67.54
8000 33 T-73 40% 233.58 129.04
8000 26 T-73 40% 189.23 106.86
8000 30 T-73 40% 214.57 119.53
8000 33 T-73 45% 188.37 106.43
8000 25 D-73 45% 107.26 65.88
8000 30 D-73 40% 151.21 87.86
8000 25 S-73 40% 77.30 50.90
8000 25 D-105 40% 97.91 61.21
8000 26 S-73 40% 79.41 51.95
8000 25 D-73 40% 130.09 77.30
8000 30 S-73 40% 87.86 56.18
8000 33 S-73 40% 94.19 59.35

(inches)
9000 26 S-73 45% 72.73 48.62

9000 26 D-73 45% 120.96 72.73
9000 30 D-73 45% 135.80 80.15
9000 36 S-73 40% 109.77 67.14
9000 36 D-73 40% 195.05 109.77
9000 26 T-73 40% 209.26 116.88
9000 33 T-73 40% 259.00 141.75
9000 30 T-73 45% 191.45 107.98
9000 33 Q-73 40% 337.17 180.84
9000 26 S-73 40% 86.09 55.29
9000 36 S-73 40% 109.77 67.14
9000 26 D-73 40% 147.67 86.09
9000 30 S-73 40% 95.56 60.03
9000 30 D-73 40% 166.62 95.56
10000 26 S-73 40% 92.76 58.63

10000 26 D-73 40% 161.03 92.76
10000 30 D-73 40% 182.03 103.27
10000 36 D-73 40% 213.54 119.02
10000 33 T-73 40% 284.43 154.47
10000 33 D-73 40% 197.79 111.14
10000 26 T-73 40% 229.29 126.90
10000 26 D-73 45% 131.35 77.92
10000 26 T-73 45% 184.77 104.64
10000 33 Q-73 40% 371.08 197.79
10000 26 T-73 45% 184.77 104.64
10000 36 S-73 40% 119.02 71.76
10000 30 S-73 40% 103.27 63.88
12000 26 D-73 40% 187.74 106.12
12000 30 D-73 40% 212.86 118.68
12000 33 T-73 40% 335.29 179.89
12000 36 T-73 40% 363.54 194.02
12000 26 S-73 40% 106.12 65.31
12000 33 S-73 40% 128.10 76.30
12000 26 T-73 40% 269.36 146.93
14000 26 S-73 40% 119.48 71.99

14000 36 S-73 40% 156.01 90.25
14000 26 D-73 40% 214.45 119.48
14000 26 T-73 40% 309.43 166.97
14000 33 T-73 40% 386.14 205.32
14000 26 Q-73 40% 404.41 214.45
16000 26 S-73 45% 109.09 66.79

16000 36 S-73 40% 174.50 99.50
16000 30 D-73 40% 274.50 149.50
16000 26 T-73 40% 349.50 187.00
16000 26 T-73 40% 349.50 187.00

(inches)
16000 26 S-73 40% 132.83 78.67

16000 33 S-73 40% 162.00 93.25
16000 26 D-73 40% 241.17 132.83
18000 26 S-73 40% 146.19 85.34

18000 36 S-73 45% 156.01 90.25
18000 30 D-73 40% 305.32 164.91
18000 26 T-73 40% 389.57 207.03
18000 26 D-73 40% 267.88 146.19
20000 26 S-73 40% 159.55 92.02

20000 26 D-73 40% 294.59 159.55
20000 30 D-73 40% 336.14 180.32
20000 26 T-73 45% 340.60 182.55
TECHNICAL INFORMATION COMPONENT REPLACEMENT PROCEDURES
APPENDIX E—COMPONENT REPLACEMENT PROCEDURES
CARD REPLACEMENT PROCEDURES 5. Install the DSP card.
CPU Card 6. Verify the DAC ADJ per SCR, VVVF, or MG Section.
1. Turn OFF the mainline disconnect. 7. Turn ON the mainline disconnect.
2. Remove from the defective CPU card: 8. Initialize the NTSD and ETSL/D system:
S Generic software chips U46 and U60. a. Place car on Inspection.
S Job EPROM chips U36 and U63. b. Enter the ETSO command.
S EEPROM chip U22. c. Enter the NTSI command.
d. Cycle power.
3. Install the U46, U60, U36, U63, and U22 chips on the new e. Enter ETST.
CPU card. f. Enter ETSS.
4. Configure the header jumpers on the new CPU card the 9. Set up the NTSD and ETSD/L terminal back-up systems
same as on the defective card. by performing the following procedures in the ADJUST-
MENT section:
5. Install the CPU card. S NTSD and ETSL/D Adjustment
S Terminal Backup Checkpoint & Pattern Check
6. Turn ON the mainline disconnect. S NTSD System Test
S ETSL/D System Test
7. Ensure that the +5V power supply is +5.0V, 0.1V.
PMI Card
NOTE: If the replacement card has never been in a system be-
fore shipping, it may require up to 4 minutes to initialize as op- 1. Turn OFF the mainline disconnect.
posed to 2 minutes for a card that has been in a system.
2. Remove the defective PMI card from the card cage.
DSP Card
3. Remove each fuse and each I/O module from the defec-
1. Turn OFF the mainline disconnect. tive PMI card and install them in the same positions on the
new PMI card.
2. Remove from the defective DSP card:
S DSP software chips U43 and U47. 4. Configure the header jumpers on the new PMI card the
S ETSL/D software chip U70 (if present). same as on the defective card.
3. Install the U43, U47, and U70 (if required) chips on the 5. Install PMI card in card cage and connect all plugs.
new DSP card.
4. Configure the header jumpers on the new DSP card the 6. Turn ON the mainline disconnect.
same as on the defective card.
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7E-1 Printed in USA August, 2002
TECHNICAL INFORMATION COMPONENT REPLACEMENT PROCEDURES
Load Weigher Control Card 12. Press the RESET button to display P-UP message.
1. Turn OFF the mainline disconnect. Digital Current Regulator Card

2. Remove the Load Weigher card from the car top housing.
1. Turn OFF the mainline disconnect.
3. Configure the dip switch on the new card the same as on
the defective card. 2. Remove the defective Digital Current Regulator card, then
install the new card.
4. Install the Load Weigher Control card in the car top hous-
ing.
3. Turn ON the mainline disconnect.
5. Turn ON the mainline disconnect.
6. Place car at bottom landing. Verify the VO=-4V +/- .1V. If
voltage is different, go to Loadweigher setup in the AD-
SOFTWARE REPLACEMENT
JUSTMENTt section.. PROCEDURES
Magnetek SCR Drive—Main CPU Card Generic Software on the CPU and DSP Boards
1. Record all SCR drive parameter values from the SCDU. 1. Turn OFF Mainline Disconnect.
2. Turn OFF the mainline disconnect. 2. Remove the CPU card from the card cage.
3. Remove the Generic Software chips U46 and U60.
3. Remove from the defective CPU card:
4. Install the new U46 and U60 chips.
S DCU software chips U39 and U40
S PCU software chips U13 and U14 5. Re-install the CPU in the card cage.
6. Remove the DSP card
4. Install the U13, U14, U39, and U40 chips on the new CPU
card. 7. Remove the U43 and U47 chips.
8. Install the new DSP chips U43 and U47.
5. Remove the defective Main CPU card and install the new
Main CPU card. 9. Re-install the DSP board
10. Ensure that the controller is on Inspection and turn ON the
6. Turn ON the mainline disconnect. Mainline Disconnect.
7. Move the NVRAM Protect switch on the SCR drive to the 11. Ensure that the controller has powered up properly and
UP (unprotected) position. (Both LEDs are off) run the car on Inspection.
12. Check the NTSD and ETSD tables and do a new Terminal
8. Press the RESET button on the SCR drive main CPU card. System Back-up, if necessary.
(The SCDU should display the P-UP message.)
13. Return car to normal service.
9. Load the SCR parameter values recorded in step 1 into Job Eproms on the CPU Boards
the CPU card with the SCDU.
1. Turn OFF the Mainline Disconnect.
10. Save the parameter values to NVRAM.
2. Remove the CPU card.
a. Press the up or down arrow key until Function 994
(NVRAM ACCESS) is displayed. 3. Remove the Job Eproms U36 and U63 chips.
b. Press the DATA/FCTN key. (Data LED green on) 4. Install the new U36 and U63 chips.
c. Press the up or down arrow key until SAVE is dis- 5. Ensure that the controller is on inspection. Turn ON the
played. (Data Send LED red) Mainline Disconnect.
d. Press the ENT key to save the parameter values.
6. Ensure that the controller has powered up properly, and
11. Move the NVRAM Protect Switch to the DOWN (protect) the car will run on inspection.
position. (The DS1 LED should turn OFF.) 7. Return the Car to normal service.
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7E-2 Printed in USA August, 2002
TECHNICAL INFORMATION SOFTWARE REVISION TABLES
APPENDIX F—SOFTWARE REVISION TABLES

The following charts are designed to show the major changes assume that all versions prior to the retrofit have been
(as they relate to field application) that took place with each replaced and begins with the retrofit software version.
release of Software in the TAC50t System. These charts
Integral Car/Group Du- DSP ETSL/D SCR-PCU SCR-DCU

Loadweigher
plex Software (U46, Software Software software Software
Generic
U60) (U43, U47) (U70) (U52, U53) (U3, U4)
675HE1 675CN19 6757 675GM1 675GL1 675EA1
675HE2 675CN19 675CP7 675GM1 675GL1 675EA1
SOFTWARE
DESCRIPTION
NUMBER
675CN19 S DSP Generic Software Assembly (U43, U47)
675CP7 S IC 87C652 US Program ETSD/L (DSP, U70)
675HE2 S ICG Generic Software TAC50t (U46 , U60)
675EF7 S Job Eprom Software (U36, U63)
675ED7 S Group Job Eprom - When seperate group cabinet is required (U36, U63)
Table 1 - TAC50t Software Kit
SOFTWARE
DESCRIPTION OF CHANGE
NUMBER
675HE1 S Initial release.
S Add new parameter defaults for Quantum Quiet Drive,
S SCR Drive Jobs with instantaneous transfer switch are being bypassed on EP lowering.
S Car does not open doors at the nearest floor after counterweight derailment operation is activated.
675HE2
S Changed the default for SEA from 0 to 4 for electronic safety edges.
S Changed the default for DCC from 6 to 3. The product of DCP and DCC exceeds the default value of AST.
S A car on high priority would not respond to a lower priority service, after a power cycle when the higher priority service is cleared.
Table 2 - TAC50t Software Change Descriptions
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7F-1 Printed in USA August, 2002
TECHNICAL INFORMATION SOFTWARE REVISION TABLES
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intentionally
left blank.
ENIL THYSSEN ELEVATOR 7F-2 Printed in USA NIL

TECHNICAL INFORMATION SAFETY DEVICE VERIFICATION AND TEST
APPENDIX G — SAFETY DEVICE VERIFICATION AND TEST

6. Remove the temporary jumper from V+ and UIN.
IMPORTANT!
NOTE: The actual trip speed may be viewed using the FLTN
command. The corresponding car speed for error 54 is the
After doing the safety tests, verify Load- governor switch trip speed.
weigher operation with the DLW command.
7. Place the car on Inspection, and reset the governor
switch.
GOVERNOR OVERSPEED TEST

CAR SAFETY TEST
NOTE: The OVERSPEED test when enabled will disable the
ETSD/L electronic governor and the OSP overspeed protec- NOTE: When enabled, the OVERSPEED test will disable the
tion. The car will NOT be prevented from decelerating. If the ETSD/L electronic governor and the OSP overspeed protec-
governor switch does NOT activate, the car will stop normally tion. The car will NOT be prevented from decelerating. If the
at the call floor. The system will automatically return to normal governor jaws do NOT set, the car will stop normally at the call
mode (all safety backup system enabled) after completion of floor. The system will automatically return to normal mode (all
the test. safety backup system enabled) after completion of the test.
1. Turn OFF the DOOR DISC switch.
2. Position the car at the bottom floor. CAUTION

Make certain the following items have been
3. Initiate the over-speed test: done before proceeding with the safety test:
a. Enter the TST4 command (the FAST will display: “Run S Safety and governor are free of debris and
OVERSPEED test? (Y/N)”). rails are clean
b. Enter “Y” to enable the test (the FAST will display S All adjacent cars in the hoistway have been
“Enter maximum overspeed allowed:”). positioned at the TOP terminal floor and
c. Enter the governor switch trip speed, plus 10 fpm (the taken out of service.
FAST will display “Enter overspeed acceleration S The top of the car under test has been
rate”). inspected and all loose objects have been
NOTE: Refer to the governor nameplate to determine the car removed.
speed at which the governor overspeed switch should trip. S The inside of the car under test has been
d. Enter the desired acceleration rate from contract to inspected and all loose objects have been
trip speed (the FAST will display “Enter car call to removed.
execute OVERSPEED test”).
NOTE: The overspeed acceleration rate must be less than or
equal to the programmed ACR value. 1. Place a full load on the car, and place the car at the top
floor.
e. Enter a top floor car call.
2. Install a temporary jumper across terminals OVL and GV.
4. After the car reaches top speed, increase the car speed
by connecting a temporary jumper between V+ and UIN. NOTES:
S Do NOT jumper the car Safety Plank switch. The Safety
NOTE: Connecting V+ to UIN will cause the car to accelerate
at the programmed acceleration rate to programmed trip Plank switch MUST be active.
speed; removing the jumper from V+ to UIN will slow car to S Refer to the governor nameplate to determine the car
contract speed. speed at which the safety jaws should set.
5. Verify that the governor switch trips at proper car speed.
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7G-1 Printed in USA August, 2002
3. Initiate the over-speed test: COUNTERWEIGHT SAFETY TEST

a. Enter the TST4 command (the FAST will display “Run
OVERSPEED test? (Y/N)”). NOTE: When enabled, the OVERSPEED test will disable the
b. Enter “Y” to enable the test (the FAST will display ETSD/L electronic governor and the OSP overspeed protec-
“Enter maximum overspeed allowed:”). tion. The car will NOT be prevented from decelerating. If the
governor jaws do NOT set, the car will stop normally at the call
c. Enter the governor safety trip speed plus 10 fpm (the floor. The system will automatically return to normal mode (all
FAST will display: “Enter overspeed acceleration safety backup system enabled) after completion of the test.
rate”).
d. Enter the desired acceleration rate from contract
speed to trip speed. The FAST will display “Enter car
call to execute OVERSPEED test.” CAUTION
e. Enter a bottom terminal floor car call. Make certain the following items have been
done before proceeding with the safety test:
NOTE: The overspeed acceleration rate must be less than or
S Safety and governor are free of debris and
equal to the programmed ACR value.
rails are clean
S All adjacent cars in the hoistway have been
positioned at the TOP terminal floor and
by connecting a temporary jumper between V+ and UIN.
taken out of service.
S The top of the car under test has been
NOTE: Connecting V+ to UIN will cause the car to accelerate
inspected and all loose objects have been
at the programmed acceleration rate to programmed trip
removed.
speed; removing the jumper from V+ to UIN will slow car to
S The inside of the car under test has been
contract speed.
removed.
5. After the safeties set and the car comes to a stop, remove
the temporary jumper at V+ and UIN.
NOTE: The actual trip speed may be viewed by using the FLTN
command. The corresponding car speed for error 54 is the car 1. Place an empty car at the bottom landing.
speed when the safeties set.
2. Install a temporary jumper across terminals OVL and GV.
6. Place the car on Inspection and:
a. Reset the governor jaws. 3. Inhibit the movable jaw of the car governor from engag-
b. Reset the governor switch. ing.
c. Install a temporary jumper across terminals HS and
CS. 4. Inhibit the car safety arm from moving.
d. Remove the temporary jumper from Terminals OVL to
5. Initiate the over-speed test:
GV.
a. Enter the TST4 command (the FAST will display “Run
7. Reset the safeties by running the car UP on Inspection. OVERSPEED test? (Y/N)”).
8. Verify that the car stopped within the acceptable b. Enter “Y” to enable the test (the FAST will display
distance. “Enter maximum overspeed allowed:”).
c. Enter the governor safety trip speed, plus 10 fpm (the
9. Verify there is NO damage to the car or hoistway equip- FAST will display: “Enter overspeed acceleration
ment from the test. rate”).
10. Reset the safety plank switch, and remove the temporary NOTE: Refer to the governor nameplate to determine the car
jumper from Terminals HS to CS. speed at which the safety jaws should set.
d. Enter the desired acceleration rate from contract

speed to trip speed (the FAST will display “Enter car
CAUTION
call to execute OVERSPEED test”).
e. Enter a top terminal floor car call. Make certain the following items have been
done before proceeding with the buffer test:
NOTE: The overspeed acceleration rate must be less than or S All adjacent cars in the hoistway have been
equal to the programmed ACR value. positioned at the TOP terminal floor and
taken out of service
S The top of the car under test has been
by connecting a temporary jumper between V+ and UIN.
NOTE: Connecting V+ to UIN will cause the car to accelerate removed
at the programmed acceleration rate to programmed trip S The inside of the car under test has been
speed; removing the jumper from V+ to UIN will slow car to inspected and all loose objects have been
contract speed. removed
7. After the counterweight safeties set and the car comes to

a stop, remove the temporary jumper at V+ and UIN.
1. Verify the buffers are filled with oil.
NOTE: The actual trip speed may be viewed by using the FLTN
command. The corresponding car speed for error 54 is the car 2. Inhibit the counterweight safeties (if required).
speed when the counterweight safeties set.
3. Place a full load on the car, and move it two or more floors
8. Place the car on Inspection and:
above the bottom terminal floor (to allow for a high-speed
a. Reset the car and counterweight governor jaws. run).
b. Reset the car and counterweight governor switches.
c. Remove the temporary jumper from the car governor
switch.
CAUTION
9. Reset the safeties by running the car down on Inspection. The final limit MUST NOT be jumped out
during the run into the buffer.
10. Verify that the counterweight stopped within the accept-
able distance.
4. Enter the TST3 command (the FAST will display “Run
11. Verify there is NO damage to the car or hoistway equip- BUFFER test? (Y/N)”) and:
ment from the test. a. Enter “Y” to enable the test (for jobs with reduced
12. Remove all temporary inhibitors from the governors and stroke buffers, the FAST will display: “Enter buffer
safeties. strike speed”).
b. For reduced stroke buffers, set the buffer strike speed
to the appropriate rated car strike speed. See Table 1;
CAR BUFFER TEST for modernization jobs, see buffer nameplate (the
FAST will display “Enter car call to execute BUFFER
NOTE: The BUFFER test when enabled disables the NTSD test”).
system, ETSD/L system, and normal limits, and prevents the c. Enter a bottom terminal floor car call.
car from decelerating once it reaches the programmed buffer
strike speed for the given run. The system automatically BUFFER RATED CAR AND CWT.
returns to normal mode (all safety backup system enabled) NAMEPLATE STRIKE SPEED (FPM)
after completion of the test. MAX SPEED (FPM)
288 250
402 350
460 400
575 500
805 700
920 800
1150 1000
Table 1 -Car Buffer Strike Speeds
5. Verify the car strikes the buffer at the correct speed, and: a. Enter “Y” to enable the test. For jobs with reduced
a. Place the car on Inspection. stroke buffers, the FAST will display “Enter buffer
strike speed:”.
b. Set parameter IVE = 10.
b. For reduced stroke buffers, set the buffer strike speed
c. Install a temporary jumper across terminals GV to HS.
to the appropriate rated counterweight strike speed.
See Table 2. For modernization jobs, see buffer
6. Inspect the car and buffer for any possible damage.
nameplate. The FAST will display “Enter car call to
execute BUFFER test”.
7. Run the car UP on inspection until it clears the buffer and
verify that the buffer plunger returns to the fully extended c. Enter a top terminal floor car call.
position within 90 seconds.
6. Verify the counterweight strikes the buffer at the correct
8. Remove the temporary jumper from Terminals HS and speed.
GV; and the test weights from the car.
7. Place car on Inspection, install a temporary jumper
across terminals GV to HS, and set parameter
COUNTERWEIGHT BUFFER TEST IVE = 10.
NOTE: The BUFFER test when enabled disables the NTSD 8. Inspect the counterweight and buffer for any possible
system, ETSD/L system, and normal limits and prevents the damage.
car from decelerating once it reaches the programmed buffer
strike speed for the given run. The system automatically 9. Run the car DOWN on inspection until it clears the buffer,
returns to normal mode (all safety backup system enabled) and verify that the buffer plunger returns to the fully
after completion of the test. extended position within 90 seconds.
10. Remove the temporary jumper from terminals HS and GV.

CAUTION
Make certain the following items have been BUFFER RATED CAR AND CWT.
done before proceeding with the buffer test: NAMEPLATE STRIKE SPEED (FPM)
S All adjacent cars in the hoistway have been MAX SPEED (FPM)
positioned at the TOP terminal floor and
288 250
taken out of service
402 350
S The top of the car under test has been 460 400
inspected and all loose objects have been 575 500
removed 805 700
S The inside of the car under test has been 920 800
1150 1000
removed
Table 2 - Counterweight Buffer Strike Speeds
1. Verify that the buffers are filled with oil. GATE AND LOCKS CAR VELOCITY CLAMP TEST
2. Inhibit the car safeties. 1. Place the car on Automatic.
2. Turn the door disconnect ON.

3. Verify that the car is empty, and move it two or more floors
below the top terminal floor (to allow for a high-speed 3. Enable door preopening 3I from the floor by setting FAST
run). parameter PRE to three (3).
4. Position adjacent cars at the top terminal floor and 4. Set parameter GLV to one (1). This will set clamp speed
remove them from service. when the doors open to one (1) fpm.
5. Enter the TST3 command (the FAST will display “Run

BUFFER test? (Y/N)”), and:
5. Run the car to any landing and monitor the car and 8. Run the car in the opposite direction to verify that car
demand velocities on the car diagnostic screen as the car speed clamps in both directions.
levels into the floor.
NOTE: A 980 fault (velocity clamping error) will again be
NOTE: The demand velocity will be at the LVE level, but the car logged.
velocity will clamp to the GLV level or one (1) fpm for this test.
A 980 fault (velocity clamping error) will be logged. 9. For testing purposes, try to set GLV to a value greater than
100. The value should be rejected by the FAST.
6. Increase GLV to a value less than the value of LVE.
10. Set GLV to the default value of 50.
7. Make a one-floor run and check that DSP clamps to the
GLV value. 11. Run the car on automatic to check that car velocity does
not clamp to the GLV value. No 980 faults should be
NOTE: A 980 fault (velocity clamping error) will again be logged.
logged.
This page
intentionally
left blank.
E2000 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7G-6 Printed in USA February, 2000
TECHNICAL INFORMATION DOOR AND OPTION ADJUSTMENTS
APPENDIX H—DOOR AND OPTION ADJUSTMENTS

1. Complete door adjustments per Table 1. 4. Complete miscellaneous adjustments per Table 4.
2. Complete emergency operation adjustments per Table 2. 5. Complete security operation adjustments per Table 5.
3. Complete signal fixtures adjustments per Table 3. 6. Complete inconspicuous riser operation adjustments per
Table 6.
ADJUSTMENT UNIT RANGE DEFAULT

CDT-Car Call Door Time 1/ Sec. 16-200 40
16
DCC-Door Cycle Count 0-20 3
DCP-Door Close Protect Time Sec. 5-20 12
DHT-Door Hold Time Sec. 5-120 10
DOP-Door Open Protect Time Sec. 5-20 13
DOT-Door Opening Device Timeout Sec. 0-120 16
EDT-Electric Eye Door Time Sec. 4-80 16
HDT-Homing Door Time Sec. 0-60 12
LDT-Long Door Time 1/ Sec. 32-200 64
16
NDT-Nudging Door Time Sec. 5-120 12
SDT-Short Door Time 1/ Sec. 4-80 16
16
CONTROL STATUS WORD DEFINITION

CSW, BIT 6 SET-Enable Limited Door Reversal
RESET-Disable Limited Door Reversal
CS1, BIT 7 SET-Disable Rear Door Operation
RESET-Enable Rear Door Operation
CS2, BIT 1 SET-Door Close Button will Cancel Door Open Time
RESET-Door Close Button will NOT Cancel Door Open Time
CS2, BIT 4 SET-Enable Nudging Operation
RESET-Disable Nudging Operation
CS2, BIT 5 SET-Disable Electric Eye Timeout
RESET-Enable Electric Eye Timeout
CS2, BIT 6 SET-Enable Rear Door Limited Door Reversal
RESET-Disable Rear Door Limited Door Reversal
CS2, BIT 8 SET-Door Open Button will Stop the Door during Nudging Operation
RESET-Door Open Button will Reopen Door During Nudging Operation
CS2, BIT 10 SET-Door Will Reopen for at Floor Hall Call
RESET-Door will NOT Reopen for Hall Call
CS2, BIT 11 SET-Door will Reopen for at Floor Hall Call within DRL
RESET-Door will NOT Reopen for Hall Call
Table 1 - Door Adjustments
E2000, 2002 TTHYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7H-1 Printed in USA August, 2002

CDH-CWT Derailment High Collision Zone DPP 10000 + 10000
CDL-CWT Derailment Low Collision Zone DPP 10000 + 10000
DLT-Emergency Power De-Select Landing Timer SEC 10-300 300
EAD-Emergency Power Accel/Decel Derate
EAT-Emergency Power Auto Select Timer FPM/SEC 75-300 180
EDS-Emergency Dispatch Service SEC 0-100 JOB E
ELT-Emergency Power Lower Timer
EPF-Emergency Power Floor SEC 0-60 JOB E
ETD-Emergency Power Top Speed FLOOR 1-FLOORn 1
FAL-Fire Service Alternate Landing FPM 0-TOP SPD TOP SPD
FDT-Fire Door Time FLOOR 1-FLOORn 2
FIR-Fire Service Main Landing SEC 1-20 10
LW3-Loadweigher FLOOR 1-FLOORn 1
LEM-Power Priority Lowering % Cap 0-1000 500
MEF-Massachusetts Medical EM Floor x10 0-1000 500
FLOOR 1-FLOORn 1
SEA-Safety Edge Adjustment 0-5 4
Value Phase 1 Operation Phase 2 Operation

0 active/normal speed active/normal speed
1 inactive/reduced speed active/normal speed
2 active/normal speed inactive/normal speed
3 active/normal speed inactive/reduced speed
4 inactive/reduced speed inactive/normal speed
5 inactive/reduced speed inactive/reduced speed

CSW, BIT 0 SET-Disable Emergency Dispatching
RESET-Enable Emergency Dispatching
CSW, BIT 8 SET-Disable Emergency Power Lowering if Car/Group Communication is
Lost or car is Simplex
RESET-Enable Emergency Power Lowering If Car/Group Communication
is lost or Car is Simplex
CSW, BIT 10 SET-Enable Rear Door Operation on Emergency Power Recall
RESET-Disable Rear Door Operation on Emergency Power Recall
CS1, BIT 9 SET-Enable Rear Door to Open Upon Arrival at Medical Emergency Floor
During Massachusetts Medical Emergency Operation
RESET-Disable Rear Door To Open Upon Arrival at Medical Emergency
Floor During Massachusetts Medical Emergency Operation
Table 2 - Emergency Operation Adjustments
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7H-2 Printed in USA August, 2002

FL1-Flashing Jewel Timer 1/ Sec. 1-48 8
16
FL2-Flickering Jewel Timer 1/ Sec. 1-48 2
16
GCT-Gong Cycle Time 1/ Sec. 0-32 13
16
GOT-Gong OFF Time 1/ Sec. 0-32 6
16
HLD-Hall Lantern Delay 1/ Sec. 0-60 5
16

CSW, BIT 12 SET--Enable Handicap Buzzer at Dummy Floors
RESET--Disable Handicap Buzzer at Dummy Floors
CSW, BIT 13 SET-Car Lanterns activate at DRL
RESET-Car Lanterns activate at DOL
CSW, BIT 14 SET-Hall Lanterns and Gongs operate once for Down
RESET-Hall Lanterns and Gongs operate twice for Down
CS2, BIT 12 SET-Hall Lantern at Lobby delayed until door opening
RESET-Hall Lantern at Lobby at slowdown
CS2, BIT 14 SET-Disable car lantern operation at lobby
RESET-Enable car lantern operation at lobby
Table 3 - Signal Fixture Adjustments

BZH-Bottom Hoistway Access Zone DPP 0 - 4096 2560
LW1-Loadweigher-ByPass operation % CAP x 10 0 -1000 800
LW2-Loadweigher-Dispatch Operation % CAP x 10 0 -1000 400
LW4-Loadweigher-Anti-Nuisance Lbs. 0 -1000 150
TAF-Top Hoistway Access Floor FLOOR 1 - Top Floor Top Floor
TZL-Top Hoistway Access Zone DPP 0 - 7168 6144
AST-Automatic Service Timeout sec. 5 - 180 45
CCD-Car Call Dumping sec. 1 - 128 3
HBT-Handicap Buzzer Time 1/ sec. 0 - 32 12
16
HBF-Handicap Buzzer OFF 1/ sec. 4 -32 8
16
HIF-Hall Independent Floor FLOOR HM1-Homing FLOOR 1-FLOORn 1
Floor 1 FLOOR 1-FLOORn 1
HM2-Homing Floor 2 FLOOR 1-FLOORn 2
LBY-Lobby Floor FLOOR 1-FLOORn 1
LFT-Light-Fan Time sec. 0-600 14
SPC-Start Sequence Protection Counter sec. 0-20 6
TF1-Transfer Floor 1 FLOOR 0-FLOORn 0
TF2-Transfer Floor 2 FLOOR 0-FLOORn 0
Table 4 - Miscellaneous Adjustments

SSA-Security Subset A
SSB-Security Subset B
SFL-Secure Floor Lockout
ADA-Hall Call Assignment Delay-Program A sec. JOB E
ADB-Hall Call Assignment Delay-Program B JOB E
SEC-Security Floor 1 Floor 1--FLOORn 1
SHD- Security Homing Delay sec. 0-60 0
CS3, BIT 0 SET-Emergency Dispatch to unsecured floors only
RESET-Emergency Dispatch to all floors
CS3, BIT 1 SET-Home to security floor during security operation
RESET-Park at last floor serviced during security operation
CS3, BIT 2 SET-Security Floor is rear floor
RESET-Security Floor is front floor
CS3, BIT 3 SET-Independent Service will NOT override security operation & security
operation will NOT override independent service
RESET-Independ. Service can serve all floors while on security
TYPE 8 & 9
CS6 (A), BIT 0 SET-Enable Car Call Lockout block
CS7 (B) RESET-Disable Car Call Lockout block
CS6 (A), BIT 1 SET-Enable Car Call Lockout override block
CS6 (B) RESET-Disable Car Call Lockout override block
CS6 (A), BIT 2 SET-Home to security landing upon activation of security
CS7 (B) RESET-Car will NOT home to security landing upon activation of security
CS6 (A), BIT 3 SET-Shut down upon activation of security
CS7 (B) RESET-Respond to hall calls during security
CS6 (A), BIT 4 SET-Emergency Dispatch to unsecured floors only
CS7 (B) RESET-Emergency Dispatch to all floors
CS6 (A), BIT 5 SET-Independent Service will serve unsecured floors only
CS7 (B) RESET-Independent Service will serve all floors
CS6 (A), BIT 6 SET-Independent Service will activate security override output (SO)
CS7 (B) RESET-Independent Service will NOT activate security override output
(SO)
CS6 (A) , BIT 7 SET-Inconspicuous Riser Operation will override security
CS7 (B) RESET-Inconspicuous Riser Operation will NOT override security
CS6 (A), BIT 8 SET-Hall Lanterns operate only on hall call cancellation
CS6 (B) RESET-Hall Lanterns operate normally
CS6 (A), BIT 15 SET-Enable Program A security operation
RESET-Enable Program B Security operation
Table 5 - Security Operation Adjustments
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7H-4 Printed in USA August, 2002

CS4, BIT 0 SET-Enable Door open push button to operate during inconspicuous
riser operation only at valid floors for the special operation is ON
RESET-Disable door open push button to operate at all valid floors
CS4, BIT 1 SET-Hall lanterns will operate only on hall call cancellation
RESET-Hall lanterns will operate only on car call cancellation
CS4, BIT 2 SET-Car will swing back into group during emergency power
RESET-Car will NOT swing back into group during emergency power
CS4, BIT 3 SET-Car will swing back into group during Code Blue
RESET-Car will NOT swing back into group during Code Blue
CS4, BIT 4 SET-Car will swing back into group during Up Peak
RESET-Car will NOT swing back into group during Up Peak
CS4, BIT 5 SET-Car will swing back into group during Down Peak
RESET-Car will NOT swing back into group during Down Peak
CS4, BIT 6 SET-Car will serve only IR car calls while simultaneously on IR and Inde-
pendent Service
RESET-Car will serve all car calls while simultaneously on IR and Inde-
pendent Service
CS4, BIT 7 SET-Car will serve only group car wile simultaneously on IR and Inde-
pendent Service
RESET-Car will serve all car calls while simultaneously on IR and Inde-
pendent Service
CS4, BIT 8 SET-Car will swing to IR operation if group hall call power is lost
RESET-Car will emergency dispatch if group hall call power is lost
CS4, BIT 9 SET-Car will swing to IR operation if car/group communication is lost
RESET-Car will emergency dispatch if car/group communication is lost
CS4, BIT 10 SET-Activation of IR hall call will NOT activate IR operation
RESET-Activation of IR hall call will activate IR operation
CS4, BIT 11 SET-Car will serve only car calls that have corresponding hall calls while
on group operation
RESET-Car will serve all car calls while on group operation
Table 6 - Inconspicuous Riser Operation Adjustments
This page
intentionally
left blank.
ENIL THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7H-6 Printed in USA NIL

TECHNICAL INFORMATION IGBT REPLACEMENT PROCEDURES
APPENDIX J — IGBT REPLACEMENT PROCEDURES

Required Tools and Materials: Disassembly/Cleaning
S Torque wrench, 10-120 inch pounds
1. Tag and disconnect the wires and bus bars from the dam-
S 4 inch ratchet extension for torque wrench
aged IGBT.
S #2 Phillips socket
S #3 Phillips socket
CAUTION
S #2 Phillips screwdriver
S #3 Phillips screwdriver Do not use the torque wrench for the removal
or replacement of hardware; Using the
S WD-40 Lubricant
torque wrench for removal and replacement
S Alcohol of hardware could damage the torque
S Dow Corning 340 Heat Sink Compound calibration of the wrench!
(Premeasured Syringe)
S Open end wrenches
2. Use a # 3 Phillips to remove the bus bar terminal screws
first in order to relieve forces on the IGBT that may be ap-
plied by the bus bars.
Summary of Steps:
NOTE: It may not be necessary to remove all of the terminal
The major steps in the removal and installation of IGBTs are
screws in a Regenerative Drive if you are only replacing an
(1) preparation, (2) disassembly/cleaning, and (3) re-assem-
IGBT from the Regenerative portion of the drive.
bly.
3. Use a #2 Phillips socket to remove the IGBT mounting
screws.
Preparation
4. Carefully remove the IGBT and heatsink pad from the
1. Turn OFF and lock out the Mainline Disconnect.
heatsink.
WARNING 5. Thoroughly clean the heatsink surface with WD-40 Lubri-

cant where the IGBT is to be reinstalled.
Check the voltage between the +Bus and
–BUS to ensure the capacitor bank is fully 6. Thoroughly remove the cleaning residue with a clean dry
discharged! Voltage remains on the high rag or pad soaked with alcohol.
voltage bus for several minutes after power
has been removed.
CAUTION
2. Ground the work surface, test equipment, work surface, Do not reuse the old heatsink pad when
parts storage and yourself to help prevent electro-static installing new IGBTs.
damage to the IGBTs.
3. Use a work mat, grounded to the controller, to stand on

while performing maintenance actions to help prevent Installation of IGBT
electro-static damage to the devices being installed.
Ground the mat to the controller being repaired. 1. Evenly spread the premeasured thermal grease over the
area on which the IGBT is to be mounted. Insure that the
4. Prior to use, insure that all the tools, parts, and packages entire heat sink surface making contact with the IGBT is
associated directly with this replacement are placed on covered with thermal grease.
the grounded work surface.
2. Install the IGBT with the mounting screws finger tight.
a. Replace any screws with damaged heads or threads
in order to insure a good torque value when later tight-
ening the screws.
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7J-1 Printed in USA August, 2002
TECHNICAL INFORMATION IGBT REPLACEMENT PROCEDURE
3. Loosely reinstall the associated busbars to insure that all ThssenKrupp Powerex 460V Mounting
of the terminal screws can be installed prior to applying Part Numbers Drives Torque (in-lbs)
torque to the IGBTs. Part Numbers
155CY1 PM50RVA120 30
CAUTION 155CR1 PM75CVA120 30
All torque values are in Inch/Pounds. 155CT1 PM100CVA120 30
155CV1 PM150CVA120 30
4. Torque the mounting screws in a cross pattern to the 155CW1 PM200DVA120 50
torque values listed for your particular application. See 155CX1 PM300DVA120 50
Figure 1 and Table 1.
a. Alternate between the screws, evenly torque them to
ThssenKrupp Powerex 230V Mounting
25%, 50%, 75%, and then the final torque values. Part Numbers Drives Torque (in-lbs)
Part Numbers
5. Reattach the wires and components removed during the
Removal steps. 155CJ1 PM100CVA060 30
155CK1 PM150CVA060 30
6. Torque the terminal screws to the torque values listed for
155CL1 PM200CVA060 30
your particular application. See Table 2.
155CM1 PM300CVA060 30
155CN1 PM400DVA060 50
CAUTION
155CP1 PM600DVA060 50
The torque values for the terminals are
different from the torque values listed for the 155DR1 PM600DSA060 30
mounting screws of the IGBTs. All torque
values are in Inch/Pounds. ThssenKrupp Third Generation Mounting
Part Numbers IGBT Torque (in-lbs)
Part Numbers
155BM1 PM50RSA120 20
1 3
155BM2 PM75CSA120 20
155BN1 PM100CSA120 20
155BH1 PM75DSA120 20
155BH2 PM100DSA120 20
155BJ1 PM150DSA120 20
155BK1 PM200DSA120 20
155BL1 PM300DSA120 30
155CE1 PM400HSA120 30
155CD1 PM600HSA120 30
4 2 Table 1 - Torque Values
Temporary Tightening = 1, 2, 3, 4
Final Tightening = 4, 3, 2, 1 Drive Horse 7.5 - 30/30 40/40 60/120-60/

Power Regen Regen 120 Regen
Figure 1 - Four Point Mounting Type IGBT’s IGBT Termi-
nals (includ- 95-100 in/
17-20 in/lbs 26-30 in/lbs
ing DSS/ lbs
DSR)
Table 2 - IGBT Terminal Torque Values
E2000, 2002 THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7J-2 Printed in USA August, 2002

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TECHNICAL INFORMATION

TAC50t TECHNICAL INFORMATION

PLEASE CHECK THE CHANGE

All installation wiring must be in accordance with the National

CAUTION statements identify conditions that could result in

Meggering or buzzer type continuity testers can damage elec-

When Servicing With Power On

STATIC PROTECTION GUIDELINES

Immediate and long-term operation of an electronic- based

CAR CONTROLLER VVVF, SCR - POWER SUPPLY PANEL . . APPENDIX C

QUANTUM QUIET AC/DC DRIVE—60 HP REGENERATIVE . G3 GEARLESS MACHINE . . . . . . . . . . . . . . . . . . . 7C-17

APPENDIX B 4 Torque Wrench & Adaptor on Brake . . . . . . 7C-7

Table Page Table Page

1 Required Torque (Part 1) ............... 7D-1 APPENDIX H

RECOMMENDED SPARE PARTS

CAR CONTROLLER (FRONT) - SCR, MG, AND

9853110 298AA1 2 / 10 cars Contactor, 4P, 120 VAC

CAR CONTROLLER (REAR) - HARDWARE AND SOFTWARE VECTOR VVVF DRIVES

9853492 672BX1 1 Power Supply, +24V @3A (PS2)

CAR CONTROLLER (REAR) - MG DRIVE

9714881 6300AF5 1 Card, RTG

CAR CONTROLLER (REAR) - SCR DRIVE

46S02975-0502 1 Main CPU PCB

1 Sensor Assy, Loadweigher

VVVF QUANTUM DRIVE (Rear Controller)

9719180 378AE1 1 Fan, AC, Muffin 100 CFM w/finger guard

VVVF QUANTUM DRIVE (Front Controller)

9853522 690AB1 2 Relay, 3 PDT, 120 VAC

ENIL THYSSENKRUPP ELEVATOR MANUFACTURING, INC. 7-6 Printed in USA NIL

APPENDIX A—REPLACEMENT PARTS

GROUP CONTROLLER (continued)

1 171DB6 Switch, Rotary, 2 Pos. w/Contact Block (I/O)

The following items are not shown in the illustration:

CAR CONTROLLER FRONT - VVVF, SCR DRIVES

CAR CONTROLLER FRONT - VVVF, SCR DRIVES (continued)

CAR CONTROLLER FRONT - VVVF, SCR DRIVES (continued)

The following items are not shown in the illustration:

CAR CONTROLLER VVVF, SCR - POWER SUPPLY PANEL

CAR CONTROLLER VVVF, SCR - POWER SUPPLY PANEL (continued)

CAR CONTROLLER REAR PANEL ASSEMBLY—VVVF QUANTUM QUITE

Refer to Page for

CAR CONTROLLER REAR PANEL ASSEMBLY—VVVF QUANTUM QUIET

ITEM PART NO. PRINT NO. DESCRIPTION

1 708AT2 Resistor, 15 Ohm 1000W (230V Drive)

CAR CONTROLLER REAR PANEL ASSEMBLY—VVVF QUANTUM QUIET

CAR CONTROLLER REAR PANEL ASSEMBLY—VVVF QUANTUM QUIET

60 HP REGENERATIVE 80-120 HP REGENERATIVE

CAR CONTROLLER REAR PANEL ASSEMBLY—VVVF QUANTUM QUIET

QUANTUM QUIET AC/DC DRIVE—60 HP REGENERATIVE

QUANTUM QUIET AC/DC DRIVE—60 HP REGENERATIVE (continued)

9834898 462EX1 Harness, CR to Current Sensor 18I

VVVF QUANTUM QUIET DRIVE—80 AND 120 HP REGENERATIVE

QUANTUM QUIET AC DRIVE-80 AND 120 HP REGENERATIVE (continued)

QUANTUM QUIET AC DRIVE-80 AND 120 HP REGENERATIVE (continued)

33 141936 Hinge, Lift-off, RH

Quantum Quiet AC/DC Drive Assembly, 230V

ITEM PART NO. PRINT NO. DESCRIPTION

1 2109AM1 Drive Ass’y Quantum AC/DC, 7.5/10HP

Quantum Quiet AC/DC Drive Assembly, 230V, 10-30HP

Current Regulator 2 to Controller DSP

2109AM, Quantum Quiet AC/DC Assembly, 230V, 10-30HP NON-REGENERATIVE (continued)

1 141787 Standoff, Current Regulator