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Operating ManualMachine TW63

Thys

senK

rupp

ThyssenKrupp AufzugswerkeA company ofThyssenKrupp

Elevator

OPERATING MANUAL

ThyssenKrupp Aufzugswerke GmbH 3 Issue 01.2005

Printer’s imprint

All rights reserved Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH

P.O. box 23 03 70, D-70623 Stuttgart

Printed in Germany, January 2005The right of reprint or reproduction, even in the case of only partly exploitation, is subject toexpress, written permission of THYSSENKRUPP AUFZUGSWERKE GmbH.Any reproduction, copying or storing in data processing machines in any form or by anymeans without prior permission of THYSSENKRUPP AUFZUGSWERKE GmbH isregarded as infringement of the current Copyright Act and will be prosecuted. Technicalmodifications for reasons of improvement of TW 63 or for reasons of improving the safetystandard of TW 63 are subject to decisions of THYSSENKRUPP AUFZUGSWERKEGmbH without prior notice.

The responsibility for the content lies with the editor:THYSSENKRUPP AUFZUGSWERKE GmbH

Preface

We are pleased that you decided to purchase a quality product fromTHYSSENKRUPP AUFZUGSWERKE GmbH.This operating manual assists you in getting familiar with the drive for moving cars – theTW 63 machine which is referred to as TW 63 below – and with its intended possibilities ofuse. Important information concerning safety and hazards helps you to safely use theTW 63 as intended. TW 63 is subject to technical alterations.

OPERATING MANUAL


Table of content :Machine TW63 PAGE1. Safety

1.1 Explanation of symbols used 61.2 General safety information 7

2. Product description2.1 Description of machine TW63 102.2 Functional description 112.3 Dimensions 142.4 Technical data 172.5 Name plate 182.6 Lubrication 192.7 Motor types 212.8 Connection von Windenmotoren 222.9 Terminal diagram for VVVF motors 23

and magnetic clamps2.10 Connection of motors acc. to BV 6531 - 21 242.11 Connection of motors acc. to BV 6531 - 22 252.12 Connection of VFD motors 262.13 Motor data – phase-shift controlled motors (A4) 272.14 Motor data – VVVF motors (A4) 282.15 Motor data - phase-shift controlled motors (A4) 292.16 Motor data – special motors (B5) 302.17 Machine frame 31

3. Transportation and storage 404. Mounting of machine in machine room 43

4.1 Mounting of rope guards for traction sheave 445. Putting into service 45

5.1 Emergency operation 466. Servicing 47

6.1 Checking of backlash 487. Maintenance

7.1 Replacing of brake shoes 497.2 Adjusting of braking deceleration 507.3 Adjusting of brake shoe stroke / armature base plate 517.4 Replacing - Montage of traction sheave 527.5 Replacing - Montage of motor 53

8. Special versions (optional)8.1 Special versions 548.2 SA3 Brake monitoring TCM 558.3 SA3 Brake monitoring BRC 57

9. Annex9.1 Tightening torque – mechanical strength 599.2 Flexible coupling for B5 motors 619.3 Pulse generators 639.4 Manufacturer’s information pulse generator page 1 - 4 659.5 Manufacturer’s information – product information 699.6 Blocking clamp 70

OPERATING MANUAL 1. SAFETY


1.1 Explanation of symbols used

The following pictographs and designations are used in this operating manual:

DangerThis symbol draws attention to an extreme danger tolife or risk of injury to persons. Disregard of warningmeans danger to life !

DangerThis symbol draws attention to an immediateimpending danger to life or risk of injury to personscaused by electric current.Warning notices must always be observed!

WarningThis symbol draws attention to an impending danger.Disregard can cause injury to persons or extensivedamage to property.Warning notices must always be observed!

NoteThis symbol draws attention to important informationand instructions for operation. Disregard can lead todamages, hazards or failures.

InspectionThis symbol draws attention to inspection sequence.These inspection notices must be observed in anycase. Disregard can lead to injury to persons ordamage to property.



1.2 General safety information

Information about the operating manualKnowledge of the basic safety requirements is a prerequisite for the safe useand the failure-free operation of this component.This operating manual comprises the most important information how tosafely use the component.The operating manual and, in particular, the safety information must beobserved by all persons who perform any work on the component.In addition the rules and requirements concerning the regulations forprevention of accidents which apply to the installation location must beobserved.

Duties of the owner and / or the installerThe owner and / or the installer ensure that only persons are authorized towork at the component, who• are familiar with the requirements concerning safe working and prevention

of accidents and who were trained how to use the component;• have read the safety information and the warning notices in this operating

manual.Note: Check the compliance of the employees method of working with thesafety requirements in regular intervals.

Duties of the employeesPersons who are authorized to perform work at the component are obliged• to observe the requirements concerning safe working and prevention of

accidents;• to read the safety information and the warning notices in this operating

manual prior to start working.

Training of the employeesOnly trained and instructed, technically competent persons shall performwork at the component.The competence of the employees must be clearly defined for all tasksconcerning putting into service, operation, maintenance and repair work.

Organizational measuresThe owner or the installer must provide the necessary personal protectivegear. All existing safety devices must be checked regularly in accordancewith the maintenance plan.



Informal information about safety measures• The operating manual must always be available at the location of the

installation.• In addition to the operating manual the general and local regulations for

the prevention of accidents and environmental regulations must be madeavailable and observed.

• Clearly and easily visible statutory safety instructions must be madeavailable for the users.

• See to it that all information concerning safety and hazards is alwaysvisibly and legibly made available on the machine.

Use as intendedTW 63 was designed in accordance with the state of the art and therecognized safety regulations. TW 63 shall only• be used for its intended purpose• be used exclusively if safe operation is ensured.

TW 63 drive shall exclusively be used as drive for lifts.Any other use or any use exceeding the scope of the above definitions isregarded as use outside of the intended purpose. THYSSENKRUPPAUFZUGSWERKE GmbH cannot be hold liable for any damages resultingfrom this and for any damages which are caused by any errors ofprocedure. Use within the scope of its intended purpose also comprises

• observance of all information of the operating manual• fulfilment of the instructions applying to putting into service, installation

description and inspection and repair work.

Guarantee and liabilityThe „General sales and delivery terms“ of THYSSENKRUPPAUFZUGSWERKE GmbH apply generally.Any claims for guarantee and liability are excluded in the case of injury topersons or damage to property resulting from one or several of the causesbelow:• use of TW 63 outside the scope of its intended purpose• inexpert mounting, putting into service, operating and maintaining of TW 63• operating the TW 63 with defective and/or non-operative safety and

protective devices• disregard of instructions of operating manual that apply to

transportation, storage, mounting, putting into service, operating andmaintaining of TW 63



• unauthorized constructional modifications of TW 63• unauthorized modification of drive (performance etc.)• unsatisfactory supervision of parts which are subject to wear• inexpert repair work• catastrophes caused by outside influence and Act of God.

Constructional modifications of machine TW 63TW 63 is adjusted at the factory and is delivered ready for work.Attention : oil necessary for putting TW 63 into service has been filled in atthe factory already ! Please check oil-level glass prior to initial startup ofTW 63. (See chapter 2.6 fig. 7 / 9).In the case of any modifications of the machineTHYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable.

Use of TW 63 and possible hazardsThe traction sheave and the handwheel of TW 63 are designed withoutprotective cover and shall only be used within a closed room. See to it thatthe necessary safety distance to all revolving parts (marked yellow) isobserved by persons working in the machine room.Note: do not place any objects (such as tools etc.) on the handwheel of TW63 V since there is the danger of injury caused by flinging parts.

In the case of incorrect use there will be danger to life of the user or thirdparties resp. impairment of the component or material property. Failureswhich possibly impair the correct functioning shall be eliminated immediately.

OPERATING MANUAL 2. PRODUCT DESCRIPTION


2.1 Description of machine TW 63

The machine consists of:

1 Real value generator 9 Rope guard2 Handwheel / flywheel 10 Machine frame (optional)3 Separately driven fan (optional) 11 Name plate4 Motor 12 Gear housing5 Armature base plate 13 Rope guard carrier6 Brake shoe 14 Brake monitoring switch7 Traction sheave 15 Motor terminal box8 Washer on traction sheave shaft 16 Brake magnet

Versions:

The following machine versions are available: gear with speed reduction,traction sheave version, motor version, generator version,

1 2 3 4

5

6

7

89

15

14

13

12

11

9

10

Fig. 1 Design of TW63 V(vertical motor mounting)



2.2 Functional description

The machine TW63 is designed as drive for use in lifts.

The gear (machine) is a single-stage, anti-friction bearing worm gear. Thehousing is a monobloc design with an end plate integrated on one side andan integrated dual-circuit brake. The worm teeth are oil-submersed inoperation. A overhung traction sheave is used.

Drive version is subject to motor mounting: the power is transmitted from athree-phase motor which is vertically mounted onto the gear or a three-phasemotor which is horizontally flanged to the gear drive on the wormshaft to theworm-wheel, the traction-sheave shaft up to the traction sheave.

The following constructional sizes of drive motors are available:A4 (standard version): one-piece worm and rotor shaft.B5: worm shaft and rotor shaft are linked with a flexible coupling (SA14).

Drive typesDependent on the respective arrangement of motor, pulse generator,flywheel rim, etc. the drive can be used for• pole-changing (AC2)• phase-shift-controlled (ACVV) or• frequency-controlled (VVVF)installations.

Fig. 2Design of TW63 H (horizontal motor mounting)

78 6 15

4

2

3

59

10

9

12

16



Brake:The dual-circuit brake shoe is spring-operated. Two independently actingbrake shoes press the brake lining to the brake disc at a preset spring force.The braking force is rated in such a way that one shoe will be capable ofstopping the car loaded with full rated load.Electrically operated magnetic clamps cause the brake to be released.If operated manually, the accompanying brake release lever must be appliedto the cast-on recesses of the brake shoe ends. By pressing in direction ofthe machine (see fig. 2 in arrow direction) the brake shoes will be expanded,thus releasing the brake.

Traction sheave:Overhung one-piece version fastened on drive shaft by taper;Groove form: seat and V-groove;Hardened groove flanks as a standard (50 HRc).

Diameter - ∅ DT mm 450 510 590 675Rim width mm 132 96Max. grooves – z ∗ d 8 ∗ ∅ 8

7 ∗ ∅ 10/118 ∗ ∅ 87 ∗ ∅ 10/116 ∗ ∅ 12

8 ∗ ∅ 87 ∗ ∅ 10/116 ∗ ∅ 12

6 ∗ ∅ 85 ∗ ∅ 10/114 ∗ ∅ 12

Material Specially alloyed EN-GJL 250 (HB 190 to 230)

1 Brake shoe2 Brake release lever

Fig. 3

2

1



SA Special versions TW 63 (optional)

(Additional parts for special applications)

SA3 Brake test switches for checking the brake shoes(open-closed) and wear of brake lining.

Note: check and re-set the setting of the brake test switchesafter every brake setting.For description of setting see SA3 brake monitoring

SA 9 with extended traction sheave shaft for separating drive and well.The traction sheave shaft is supported by a bearing.

SA 12 with additional terminal box for terminal connection of brakerelease magnets for motors without terminal box acc. to BV6531.

SA 14 with flexible coupling for motors of constructional type B5 acc. toBV 6530-05 for compensating possible misalignment in the case ofmotor shafts with double bearings.For description see annex 9.2 coupling from Centaflex

SA 15 with magnetic clamps for brake in (Ex) sG4 versionSA3 and SA12 are not possible in combination with SA15.

Note: for detailed description of special versions see 8.1



2.3 Dimensions

TW 63 V of constructional size A4 (vertical motor mounting)

Comment:1) pole-changing (AC2)2) phase-shift-controlled (ACVV)3) frequency-controlled (VVVF)

Terminal box for motor andbrake release magnet

Fig. 4Gravity center

Name plate shaft

Oil level glass

Separately driven fan

Handwheel

Transport aid

Name plate motor

Rope guard

Flywheel 1)(∅ acc. to order)

Oil drain



TW 63 V, SA9 dimensions (with outside bearing and extended traction sheave shaft)

Machine with outside bearing:For machines with additional bearing for extended traction sheave shaft(SA9) 2 compensating supports are mounted below the machine at thefactory (see above fig.). Therefore the traction sheave shaft has two staticallydetermined bearing points.

Fig. 5

1

3

4

2

Comment:1) Centre self-aligning bearing2) Centre bearing box3) Vertical motor mounting4) Horizontal motor mounting

Mac

hine

fram

e di

men

sion

with

horiz

onta

l rop

e de

partu

re

1

372

±1 3

)42

2 ±1

4)

260

3)31

0 4)

1 Comp. support2 Traction sheave3 Outside bearing4 Tractions sheave shaft



TW63 H: (horizontal motor mounting)

Comment:1) to 3) for motors of constructional size A4, see standard version for vertical

motor position.4) With motors of constructional size B5 (SA14)5) Illustrated as left-hand version, right-hand version mirror-inverted to A - A

Fig. 6

Gravity center

Transport aid (to be removed aftertransport)

Brake release lever (loose, variableoperating position)

Oil drain

Oil level glass

Opening for oil filling



2.4 Technical data

Designed for use in installations with rated load up to 630 kg andvrated 1.6 m/s or rated load up to 1000 kg and vrated 1.0 m/s (suspension 1:1)

Axle distance: 155 mm

Permissible load of traction sheave shaft:for standard version max. 43 kNfor SA 9 (extended wheel shaft) max. 41 kN

Brake magnet connection:With machine TW63 the two magnets

Connection magnetic clamp: are connected in series.

Rated voltage: 50 V Power supplyRated current: 1.1 A for high-speed exit.: 200 VProtection class: IP65 for withstand voltage: 100 V

Magnetic clamp rating : 2* 2500 NMax. braking torque : approx. 2* 90 NmBrake disc ∅ : 200 mm

Motor connection:For terminal connection diagram of motor and magnetic clamps see coverinside of motor terminal block.Note: for details about standard motors see chapter 2.6

Weight:Standard version: motor of constructional size A4

Machine (without motor and traction sheave) 250 kgMachine SA 9 (without motor and traction sheave) 290 kgMachine (with motor and traction sheave) approx. 370 kgMachine SA 9 (with motor and traction sheave) approx. 410 kgTraction sheave acc. to order 450–675mm ∅ approx.50 -70 kg

Noise levelAirborne noise of standard machine version with motor of constructional sizeA4 in normal operation (measured in machine room at a distance of 1 m):With integrated fan: approx. 65 dB(A);with separately driven fan: approx. 67 dB(A)

Oil filling:Vertical mounting 11 litres synthetic gear oil SM1Horizontal mounting 9 litres synthetic gear oil SM1Supply by THYSSENKRUPP AUFZUGSWERKE GmbH



2.5 Name plate of machine TW 63

To be differentiated acc. to customer

1. THYSSENKRUPP AUFZUGSWERKE GmbH

2. Lift Equip



2.6 Lubrication of TW 63

Lubricator Oil change interval Motorlage Filling quantitySynthetic gear oil SM1 First time after 4 years,

then every 8 yearsVertical = 11 litresHorizontal = 9 litres

Oil changing• See to it that the gear has heated up to working temperature prior to

changing oil.• Discharge gear oil by removing the cap on the oil drain pipe.• Collect waste oil in the tank provided for this purpose.• After discharging the gear close the oil drain by means of sealing tape and

cap.• Fill the recommended oil quantity into top opening of gear box (red cap,

see fig. 8 or 9).• Check the oil level by means of oil level glass (see fig.7 or 9 pos.2 below).

• Enter date of next oil change in name plate on cover of oil-level glass.See fig. 1 pos. 11.

• Never mix different types of oil.• Avoid entry of oil into groundwater.• Dispose of waste oil as well as cleaning cloths or rags dirtied with oil and

fat in accordance with the local requirements.• Only use lubricators recommended by THYSSENKRUPP

AUFZUGSWERKE GmbH.

Note: For any damages caused by lubricators which were not recommendedTHYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable.

Fig. 7

Opening for oil filling

Fig. 8

Oil level glass

Oil drain



Horizontal motor position

Fig. 9

1 2 3

1 Opening for oil filling2 Oil level glass3 Oil drain



2.7 Motor types

The following motors are available for machine TW63:

Constructional size A41. Pole-changing motors (AC2) constructional size A4

Range of ratings: 5.0; 6.8 KWForced ventilationMotor data see 2.13

2. Frequency-controlled motors (VVVF) constructional size A4 Range of ratings: 5.7; 11.0; 16.0 KW

Integrated ventilationMotor data see 2.15

3. Phase-shift-controlled motors (ACVV) constructional size A4Range of ratings: 6.8 KWForced ventilationMotor data see 2.14

Constructional size B5Gear and motor are connected by means of flexible coupling (SA14) inaccordance with BV 6530-06

4. Pole-changing motors (AC2)Range of ratings: > 6.8 KWForced ventilation

5. Phase-shift controlled motors (ACVV) constructional size B5Range of ratings: > 6.8 KWForced ventilationMotor data see 2.16

6. Special motorsData and version acc. to customer specification

Flywheel rim:Pole-changing motors (AC2) are equipped with a flywheel rim in accordancewith order specification.

Hand wheel:Controlled A4 motors (ACVV / VVVF) are equipped with a plastic handwheelof 270 mm dia. and B5 motors are equipped with a hand wheel ofdia. 360 mm (Siemens motor dia 270 mm)



General motor data:a) with vertical motor mounting:Protection class: IP 21Insulation class: FProtective motor switch 6 posistors (3 with frequency-controlled motors)

b) with horizontal motor mounting:Protection class: IP 20Insulation class: FProtective motor switch 6 posistors (3 with frequency-controlled motors)

Data of forced ventilation: (if available)Mains voltage: 230 VMains frequency: 50 HzPower: 0.1 KVACurrency: 0.44 ASpeed: 2000 1/minCapacitor: 2 µF

2.8 Connection

How to connect the motor:When you connect the motor observe the terminal diagram enclosed in themotor terminal box and/or the circuit diagram of this operating manual as wellas the respective building codes.

Motors with pulse generators:For connection and technical data concerning connection of the pulsegenerator see chapters 9.3 – 9.5.



2.9 Terminal diagram for VVVF motorsand magnetic clamps

for frequency-controlled motors

Anschlußplan = terminal diagram = schema de branchementAnschlußkasten Motor / terminal box motor / Boite a bornes de monteur

ACHTUNG! ATTENTION! An den Klemmen der Kaltleiter keine Spannung größer als 2.,V anlegen! Do not apply more than 2.5V at the terminals of the PTC thermistors! Ne pas mettre tension plus que 2,5V aux bornes des condukteurs a froid!

Anschlußkasten BremseTerminal box solenoidsboite a bornes de electrofrein

KlemmenleisteTerminal stripReglette de raccordementDEE 132 / 140

KaltleiterPTC-thermistorsconducteursa froid

N BM

Magnetic clampconnection

Motor connection

Fig. 10



2.10 Connection of motors acc. to BV 6531 – 21

for three-phase pole-changing motors

Make contact in winding

Starting capacitor for fan

Disconnector



2.11 Connection of motors acc. to BV 6531 – 22

for phase-shift-controlled three-phase motorswith DC brake winding

Disconnector

Make contact in winding

Starting capacitor forfan

Low-speed winding asDC winding orswitched in series tobrake circuit



2.12 Connection of VFD motors

for special motors of constructional size B5

Star connection

Brake magnet wiring in separateterminal box of shaft (SA12)

ϑ = Kaltleiter PTC thermistors Conducteurs à froidAchtung! Attention!An die Klemmen der Kaltleiter keine Spannunggrößer als 2,5V anlegenDo not apply more than 2,5V at the terminals of thethermistors.Ne pas mettre tension plus que 2,5V aux bornesdes conducteurs à froid

BremswicklungBrake windingBobinage au freinSchaltung abhängigvon derWicklungsausführung.

Schaltung nach Angabeam Leistungsschild.Connection as stated onthe rating plate.Branchement suivantindication sur la plaqueindicatrice.

DeltaTriangle

Frem

dbel

üftu

ngFo

rced

ven

tilat

ion

Vent

ilatio

n fo

rcèe

Hohe Drehzahl Zum RegelgerätHigh speed To the controlGrand vitesse device Vers l`appareil de règlage

DrehzahlgeberSpeed controlTransmetteur de vitesse

3 * UK 16



2.13 Motor data - pole-changing motors (AC2)

Constructional size A4Motor type: LNLA 132 LN-20Y LNLA 132 LP-20Y

Synchronous speed: [1/min] 1500 1500Rated speed: (asyn.) [1/min] 1380 / 275 1380 / 275Moment of inertia: (J1.) [kgm²] 0.043 0.043Moment of : (JM.) [kgm²] 0,047 0,057Moment of : (JH.) [kgm²] 0,010 0,010Moment of : (Js.) [kgm²] see right-hand table see right-hand table

S 5 operating data with 180 F/h, 40 % ED

Power: (PN.) [KW) 5,0 6,8Rated torque: [Nm] 35 47Starting torque: [Nm] 80 / 60 106 / 80Rated current: [A] 12.8 / 9 16.2 / 11.9Permissible starting current: [A] 48.0 / 12.0 60 / 16Rated voltage – motor: [V] 400 400Rated frequency: [Hz] 50 50Generator marks:: -- --Weight: (rotor / stator) [kg] 12.55 / 30 14.9 / 36Length: (motor incl. flywheel rim) [mm] 446 446

Moment of inertiaflywheel rim

∅ JS

mm kgm2

330 0,342

360 0,515

370 0,590

380 0,657

400 0,815

410 0,957

430 1,127



2.14 Motor data – phase-shift-controlled motors (ACVV)

Constructional size A4Motor type: LNLA 132 LS-20Y

Synchronous speed: (1/min) 1500Rated speed: (asyn.) (1/min) 1370Moment of inertia: (J1) (kgm²) 0.043Moment of; (JM) (kgm²) 0,057Moment of; (JH) (kgm²) 0,010Moment of; (Jges.) (kgm²) 0,110


Power: (KW) 6.8Rated torque: (Nm) 47Starting torque: (Nm) 113Rated current: (A) 16.3Permissible starting current: (A) 57Rated voltage – motor: (V) 400Rated frequency: (Hz) 50Generator marks: 2 x 64Weight: (rotor / stator) (kg) 14.9 / 36Length: (motor incl. handwheel) (mm) 459



2.15 Motor data – VVVF motors (frequency-controlled VVVF)

Constructional size A4Motor type: DEE 132 K 005 DEE 132 M 003 DEE 140 S 009

Speed range: (1/min) 1300-1450 1451-1700 1250-1450 1451-1650 1250-1400 1401-1650Moment of : (J1) (kgm²) 0,056 0,056 0,056Moment of : (JM) (kgm²) 0,027 0,042 0,065Moment of : (JH) (kgm²) 0,010 0,010 0,010Moment of : (Jges.) (kgm²) 0,093 0,108 0,131


Power: (KW) 5,7 11.0 16.0Torque range: (Nm) 43,5-34,0 34,0-32,0 84,0-72,5 72,4-63,7 122-109 109-92,6Current: (A) 15.5 26.5 38.5Permissible starting torque: (Nm) 80 65 170 150 240 220Permissible starting current: (A) 25 48 67Sinusoidal voltage – motor: (V) 340 340 330

Generator marks: VN <1.5 m/s / VN ≥1.5 m/s 1024 / 4096 1024 / 4096 1024 / 4096Weight: (kg) 22 38 47

Length: (motor incl. handwheel) (mm) 459 459 459



2.16 Motor data – ThyssenKrupp/Siemens special motors

Constructional size B5 (with hand wheel Ø 360mm 270mm)Ausführung ACVV VVVVFSchutzart: IP21 IP54Motor type: LNLA 160 LS-20C 1LA6- 166-4AA-11Z

Synchronous speed: (1/min) 1500Rated speed: (asyn.) (1/min) 1350 1250 - 1500Moment of : (J1.) (kgm²) 0,054 0,054Moment of : (JM.) (kgm²) 0,135 0,055Moment of : (JH.) (kgm²) 0,0292 0,010Permissible mass moment of inertia: (Jges.) (kgm²) 0,218 0,119

S 5 operating data with 240 F/h, 50 % ED 180 F/h, 40 % ED 240 F/h, 50 % ED

Power: (KW) 10.0 13,0Rated torque: (Nm) 70 100 - 83Starting torque: (Nm) 170 170Rated current: (A) 23 32Permissible starting current: (A) 80 47Rated voltage – motor: (V) 400 330Rated frequency: (Hz) 50 max. 50Generator marks: 2 x 64 4096Weight: (kg) 157 114Length: (motor incl. handwheel) (mm) 627 589



2.17 Machine frame TW63 (optional)

Standardized versions:The machine frames for TW 63 described below are designed for mounting inthe machine room above the well.

1.Without deflection pulley: for direct rope departure car – counterweight or2:1 suspension. See fig. 11

2.With deflection pulley: standard frame incl. deflection pulley ∅ 450 mmfor defined rope distance as left-hand or right-hand version (to be determinedby position of deflection pulley). See fig. 12

3.With deflection pulley: frame with order-specific deflection pulley(∅ 360/ ∅ 450/ ∅ 540 mm) as left-hand or right-hand version (to bedetermined by position of deflection pulley). See fig. 13

4. With 2 pulleys: standardized version for machine room below beside thewell. See table version 4, representation in fig. 14. Machine frame with boltedsheating, trapezoidal supports and rope coverings incl. two diverter pulleys.Left-hand and right-hand frame versions dependent on pulley supports.Designed for use with well wall thickness of 180 – 320 mm by means ofadjustable support.Non-changeable rope and pulley distance measures.Rope pulley data:. Ø 400 mm for ropes of 4 x Ø 10Range of use:Installations with 1:1 suspension – Q`≤ 450 kg for F`≤ 900 kg andvrated ≤ 1.6 m/sInstallations with 2:1 suspension – Q` ≤ 1050 kg with F`≤ 1500 kg andvrated ≤ 1.0 m/s

Note: frames 2. and 3. are designed for housing deflection pulleys withsupports. For arrangement and dimensions see fig. 12/13 and tables ofversions 2/3.

MountingPlace machine frame on insulation elements for prevention of structure-bornenoise. Different types of insulation elements are available which differdependent on the way of mounting:

a) Rubber block 100 x 100 x 50 high without baseShall be used for mounting the machine on a machine room without plasterfloor or directly on the plaster floor.

b) Rubber block like a) but with additional base 140 x 140 x 80 mm high.Shall be used for mounting the machine frame on plaster floor, base casteddirectly in plaster floor. (coating ≤ 60 mm)



Mounting of frameLoosely screw frames which are delivered as pre-fabricated parts together inthe machine room. See to it that the brackets with additional drilled holes (2holes) and pulley support are mounted on the correct side. Mount deflectionpulley and axle on the pulley support and secure.Place frame on insulation elements as shown in plan of installation and align.Place machine on frame by means of hoist; traction sheave shall be mountedon the side of deflection pulley. Laterally shift machine on frame until thenecessary ASL measure is reached (parallel rope distance on ropedeparture). Screw machine to frame. Parallelly align traction sheave anddeflection pulley. Level uneven base by placing enclosed bearing elementsunder. See to it that you do not strain the housing. Tighten screws withrequired torque. Note that rope departure is aligned towards rope pulley oncar or fastening on car and counterweight.

Attention: in the case of lateral or diagonal rope departure secure the gearhousing on the machine frame against dislocating by means of stoppersfastened with set screws.

Explanation code designations:ASL = Parallel rope distance on rope departureDT = Diameter of traction sheaveSR = Diameter of deflection pulleyα = Angle of wrap on traction sheaveX1 = Distance 1 between rope departure and outer edge of frameX2 = Distance 2 between rope departure and outer edge of frameY1 = Vertical axle distance between traction sheave and deflection

pulleyY2 = Vertical distance between centre deflection pulley and support

baseZ1 = Distance 1 between rope departure centre and outer edge of

frame

1 – 6) see explanations in representation of version 1 (fig. 11).



Data machine frame version 1

Illustration see fig.11

Weight machine frame: approx. 80 kg

Arrangement maschineleft-hand version 4) 5)

Arangement machineright-hand version 4) 5)

Traction sheave∅ DT(mm) Measure x1 Measure x2 Measure x1 Measure x2

450 96,5 386,5 386,5 96,5510 66,5 338,5 338,5 66,5590 94,5 230,5 230,5 94,5675 120 120

Arrangement maschineleft-hand version 6)

Arrangement maschineleft-hand version 6)

Traction sheave∅ DT(mm) Measure x1 Measure x2 Measure x1 Measure x2

450 136,5 328,5 340,5 124,5510 106,5 298,5 310,5 66,5590 66,5 258,5 202,5 122,5675 92,0 148,0 160,0 80,0

Note: left-hand or right-hand version means that the machine 5) (right-handversion – position of traction sheave with view from motor onto machine) isdisplaced into mentioned direction up to last possible row of mounting holes.Measures x1 or x2 indicate the distance between rope departure and outeredge of frame dependent on traction sheave ∅ .




Weight machine frame incl. deflection pulley ∅ 450 :approx. 170 kg

Angle of wrap α (°)Traction sheave∅ DT(mm)

Rope distancecar – counterweight

ASL(mm)

Motorlagevertikal

Motorlagehorizontal

450 745 155 155510 775 158 158590 775 164 164

Comments see version 1 fig. 11


Weight machine frame incl. deflection pulley ∅ 360 approx.170 kgincl. deflection pulley ∅ 450 approx.200 kgincl. deflection pulley ∅ 540 approx.230 kg

Rope distance measures and angle of wrap

Minimum rope distance car – counterweightand maximum angle of wrap

ASLmin (mm) and αmax (°)

With deflection pulley ∅ SR (mm)

Traction sheave∅ DT (mm)

∅ 360 ∅ 450 ∅ 540ASLmin αmax ASLmin αmax ASLmin αmax

450 622 166 566 169 566 168510 652 168 664 166 664 164590 760 166 704 170 704 168675 802 169 815 168 883 160



Maximum rope distance car – counterweightand minimum angle of wrap

ASLmax (mm) and αmin (°)With deflection pulley SR (mm)

Traction sheave∅ DT (mm)

∅ 360 ∅ 450 ∅ 540ASLmax αmin ASLmax αmin ASLmax αmin

450 1098 137 1042 137 1042 133510 1128 139 1072 139 1072 135590 1100 146 1044 145 1044 142675 1143 149 1087 147 1087 145

Intermediate values for ASL in modular dimension of 68 mm

Project planning dimensions

Deflectionpulley

SR (mm)

Measurex1

(mm)

Measurex2

(mm)

Measurey1

(mm)

Measurey1

(mm)

Measurez1

(mm)360 130 61 700 190 245450 231 116 655 235 255540 276 116 575 315 255


Machine frame with 2 pulleys for drive arranged below - beside

Weight of machine frame incl. two rope pulleys ∅ 400 approx. 210 kg

Traction sheave - ∅ DT(mm)

Angle of wrap α(°)

450 187510 191590 197675 203



Version 1 Machine frame TW63 without deflection pulley

Comments:1) Version with motor of constructional size A42) Version with motor of constructional size B53) Additional insulation elements with load of traction sheave shaft P > 38 kN4) Vertical motor position5) Horizontal motor position – right-hand machine mounting6) Horizontal motor position – left-hand machine mounting

Fig. 11

Rubber block

Base

Machine arranged onleft-hand right-hand side



Version 2 Machine frame TW63 with deflection pulley

Left-hand version is illustrated (mirror-inverted right-hand version)


Fig. 12



Version 3 Machine frame TW63 with deflection pulley

Right-hand version is illustrated (mirror-inverted left-hand version)


Fig. 13



Version 4 Machine frame TW63 with 2 deflection pulleysand drive arranged below beside

Comments see version 1 fig. 11.Fig. 14

Left-hand frame mounting Right-hand frame mounting

View A

OPERATING MANUAL 3. TRANSPORTATION


3. Transportation and storage

Packaging:In the as-delivered condition the TW 63 is mounted on a special pallet.Dependent on the order volume machine frame, supports and deflectionpulley are enclosed. In the case of delivery by sea the machine incl.additional parts are wrapped in seaworthy packing.

Transportation:Transportation shall be subject to observation of the safety requirements andthe gravity centre of the machine.

Attention: machine is filled with oil. It shall be transported and stored inupright position only.

Transportation by means of fork lift:• In the case of transportation by means of fork lift see to it that the fork is

attached to the pallet and not to the machine.• Pay attention to projecting parts! There is the risk of injury to persons or

damage to property!

Transportation by means of crane:• Do not stay below suspended loads!• Fasten machine without frame on motor by means of a rope as shown in

the figure below. See to it that the ventilation grid cannot be damaged.• Wrap rope around motor of machine without frame and secure to crane

as shown in figure below !• Secure machine against sliding and turning over.

Rope fastening: wrap transport rope under terminal box and ventilationopening around motor in the case of machine without machine frame.See figure.

Transport aid

Fig 15



Note the pictographs fastened on the packing or on other visible places.

Top Handle with care Keep dry

Do not expose toheat

Do not use hand-held grippers

Fasten here

Dimensions and weightThe weight is indicated on a sticker on the packing placed below thetransport rail.For dimensions see delivery note.For rough data see chapter 2.3 Technical data.

Examination by customer on receipt of goodsExamine the delivered parts for completeness, damage or anything strange.

Report and document transportation damagesAfter receipt of goods make sure that there is no damage caused duringtransportation.

Information

• Immediately document the damages noticed (drawing, photograph,description of the damage).

• Send the respective reports immediately to THYSSENKRUPPAUFZUGSWERKE GmbH

UnpackingInformation

• Dispose packing equipment in accordance with the environmentalrequirements or make it available for further use.

• Special transport aids and transport contrivances shall not be sentback to THYSSENKRUPP AUFZUGSWERKE GmbH but remain atthe customer.



Intermediate storage

• If the component is not mounted directly after delivery carefully store itat a sheltered place and see to it that it is provided with a humidity-proofcovering.

• Do not store the component in the open air. Parts without surface coatinglack long-time preservation.

Environmental conditions

InformationSurroundings at the final site of the machine (humidity, temperature) shallcomply with the requirements for machine and pulley rooms acc. to thestandards in force. (Between +5° and + 40 °C acc. to EN 81).

OPERATING MANUAL 4. MOUNTING OF MACHINE


4. Mounting of machine in machine room

Dependent on the order volume the TW63 machine is delivered includingmachine frame and deflection pulley. Dependent on the customerrequirements the frame is mounted on supports, brackets, concrete socle oris casted directly in plaster floor on the machine room floor.To make installation and mounting of the frame supports easier, drawing andparts list of the frame are enclosed.

Attention: mount the frame acc. to drawing and fasten by enclosedelements. Observe indicated strength and respective torque. See data inchapter 9.1

In order to better comply with the requirements concerning noise reduction /structure-borne noise transmission insert the insulation elements deliveredbetween frame support and floor.

The number of rubber elements depends on the overall weight load. Theindividual rubber elements should be loaded at between 7000 and 12 000 N /rubber element.(For position and arrangement of the rubber elements see layout drawing).Note: on arranging the rubber elements observe that the overall gravitycentre shall lie within the rubber elements ( the same applies if the car issuspended from the deflection pulley side).If cast plaster floor is used as supporting surface for the machine frame seeto it that the thickness of the coating shall be ≤ 60 mm. Insert insulationelements with wooden base (80 mm). The base part shall also be cast.For mounting and machine frame data see chapter 2.16 – 2.17.

Aligning of machinePlace the machine in accordance with the layout drawing. Align the ropedeparture of the traction sheave acc. to the drawing so that it is in vertical linewith the car fastening resp. with the rope pulley and the counterweight. If theropes are tensioned the machine shall be horizontally aligned and mountedon its supporting surface on the rubber elements. Level uneven position byplacing metal or wooden plates underneath.

SA9 traction sheave in well, machine with extended traction sheave shaftand pedestal bearing.

Attention: when placing a gear with outside bearing see to it that the following points are observed by all means

• Mount and fasten the colums in accordance with the requirements• Horizontally align the worm wheel shaft• Exactly align the bearings of the machine and the outside bearings

OPERATING MANUAL 4. MOUNTING OF MACHINE


4.1 Mounting of rope guards for traction sheave

Screw the rope guards to the rope guard brackets by means of the enclosedscrews. Turn the rope guard brackets in such a way that the distancebetween rope and rope guards is as small as possible on the side of thetraction sheave where the ropes enter and leave. (1 -2 mm)

In the case of diagonal rope departure adapt the position of the ropeguards to the changed rope departure direction.

Note: first align, then tighten the fastening screws of the rope guard bracketson the machine with pre-set torque.For tightening torques see table in annex of operating manual.

(W191 illustrated)

1 Rope guard bracket2 Rope guard

Attention:If the ropes are entering the traction sheave at any angle above thehorizontal up to a maximum of 90° (example: machine arranged onbottom/top beside) an additional provision is necessary to avoid theintroduction of objects between ropes and pulleys.If the ropes enter the traction sheave at a protected area within the machineframe, the function "protection against bodily injury " is not necessary.

Note: for SA9 (traction sheave in well) rope guard is not provided byTHYSSENKRUPP AUFZUGSWERKE GmbH.

max. 1 - 2 mm

2

1

2

1

Fig. 16 Fig. 17

OPERATING MANUAL 5. PUTTING INTO SERVICE


5. Putting into service

Prior to putting the machine into service first check whether the followingworks were carried out:

• Safety, accessory and installation tools are removed from danger zone• Check mounting of machine, frame, base and rope departure• Oil drain is assembled and closed with cap• Check gear oil level• Fastening of machine and frame is checked• In the case of lateral or diagonal rope departure secure gear housing

against displacing by means of stops and set screws.• Screws are tightened and secured with pre-set torque (see table with

tightening torques in 9.1)• Brake shoe stroke and adjustment are checked• With SA3 adjustment and function of brake test switches are checked• Brake test with one brake shoe each is carried out• Functioning of manual brake release is checked• Rope guards are mounted and distance to traction sheave is adjusted• Supply terminals and earthing of motor, forced ventilation and brake

release magnet are connected and secured• Direction arrow (up/down) for the respective travel direction is clearly

visibly glued on the motor near the handwinding wheel

Note: in case that traction sheave and rope pulley are delivered as separateparts install see to it that they will be correctly installed.If the machine is delivered disassembled for reasons of weight, transportationor space, re-assemble the dismantled parts to the original condition andobserve the respective torque when screwing the fastening parts (see tabletightening torque 9.1)

Any warranty obligation on parts is subject to use of original mounting andfastening parts from ThyssenKrupp Aufzugswerke GmbH.

OPERATING MANUAL 5. PUTTING INTO SERVICE

ThyssenKrupp Aufzugswerke 46 Issue 01.2005

5.1 Emergency operation

TW 63 is equipped with handwheel and accompanying brake release leverfor emergency operation.The brake release lever shall be applied to the cast-on recesses of the brakeshoe ends (see fig. 3A). By pressing the levers the brake shoes will beexpanded, thus releasing the brake.In the case of emergency rescuing of trapped passengers also turn thehandwheel, if necessary, in order to move the car to the nearest landing.Depending on the load the car can start moving quickly as soon as the brakeis released. Immediately stop moving the handwheel and regulate the speedof the car by pressing the brake release lever accordingly.

Attention: if the handwheel is used for servicing and maintenance works(e.g. "safety gear operation") see to it that the person performing the workstands on a safe working area. Note that there is the danger of injury ifelectric recall is operated at the same time.

Fig. 3A

2

1 Brake shoe2 Brake release lever

1

OPERATING MANUAL 6. SERVICING


6. Servicing

Maintenance interval: maintenance of the machine should at least becarried out once a year, preferably in the course of the general liftmaintenance.Note: installation and maintenance works shall only be carried out by trainedand instructed, technically competent personnel.They shall be familiar with all directives and requirements for lift installationsas well as with the requirements for the prevention of accidents and theyshall observe them accordingly.

For further information concerning proceeding, adjustment and data see chapter: ⇓

• Check oil level and fill in oil, if necessary 2.6• Change oil (observe date of oil change) 2.6

• Check brake shoes for wear, residual brake lining shall be at least 3 mm

7.3

• Check brake adjustment, brake stroke shall be 0.3 mm + 0.1 mm 7.3

• Check armature base plate for pre-tension and movability 7.2• Check brake deceleration 7.3

• Check worm teeth for wear• Check backlash between worm shaft and worm wheel

(0.04 mm to 0.12 mm with 20° C.)6.1

• Check groove profile on traction sheave for damage and wear• Check screws of traction sheave fastening for correct tightening 9.1

• Check grooves on rope pulleys for damage and wear

• Check electrical supplies for correct working and safety

• Check provision and correct adjustment of protective and safetyequipment

Notes on lubrication (oil change, quantity, maintenance interval) seechapter 2.6.

OPERATING MANUAL 6. SERVICING


6.1 Checking of flank clearence

The backlash of the worm gear (between worm wheel and worm shaft)increases due to wear.As soon as the wear limit (backlash) of 1.5 mm is reached safe operation ofthe machine is no longer ensured.Replace the machine.

Possibilities of measuring:• Remove load from machine (by unroping the traction sheave)• Perform measurement with the brake engaged• Apply stop to traction sheave, e.g. screw clamp• Determine measuring radius (M) and mark measuring point

(radius ( r ) = 130 mm for TW 63)• Attach dial gauge and magnet holder to machine casing and adjust to

measuring point (M).• Manually move the traction sheave until the hand of the dial gauge starts

moving.• Move traction sheave to and fro until a stop is felt.The tooth flank of the

worm wheel is to be loaded with approx. 20 - 50 N.• Read dial gauge deflection (ME).• Calculate backlash acc. to the equation below.• Perform measurement at three different points at least!

M = measuring radiusME = measured resultr = radius – worm wheelall dimensions in mm

Backlash = ME * r M

Dial gauge

Traction sheave

Worm wheel

Fig. 18

OPERATING MANUAL 7. MAINTENANCE


7.1 Replacing of brake shoes

Note: if the residual lining thickness is 3mm or less, or if the linings aredamaged (e. g. glazing etc.) the brake linings shall be replaced.

• Before you start working secure counterweight and car and switch offpower supply.

• Unscrew and remove nuts on tension spring.• Remove pin lock bolt and brake shoe pin.• Remove one brake shoe, then mount armature base plate on new brake

shoe. Slightly grease sliding surface between armature base plate andarmature screw.

• Check movability of armature base plate, re-adjust, if necessary. It shouldbe possible that the armature base plate can be moved on the bolt at lowresistance.

• Secure adjustment by tightening the lock nut.• Mount the pre-assembled brake shoe, do not tighten nuts on tension

spring.Attention: see to it that the thread of the brake shoe bolt projects, sinceotherwise it cannot be removed any more.

• Pre-tension brake tension springs to max. 13.5 mm. (approx. 11 turns ofcounternuts)

• Adjust brake shoe stroke by changing the armature base plate bolt onbrake shoe. Measure brake shoe stroke 0.3 mm + 0.1 mm to centre ofbrake disk.

• Replace and adjust second brake shoe in the same way.• After replacement of the brake shoes is finished, run car under emergency

electrical operation and check whether both shoes of the brake aredisengaged uniformly.

• Check stroke travel and deceleration and re-adjust, if necessary.

Fig: 19 Brake shoe adjustment, illustrated without motor and traction sheave

1 Worm shaft2 Brake disk3 Magnetic clamp4 Cover ring5 Armature base plate6 Armature base plate

screws7 Brake shoe8 Dial gauge9 Tension screws

1 2 3

4

5

6

7

Stroke 0.3 + 0.1

8

9



7.2 Adjusting of braking deceleration

Only adjust brake with one acting brake shoe each while moving the carloaded with rated load downwards (full – down) or the empty car upwards(empty – up) in accordance with the deceleration values stated in thetable below.Adjust the brake shoe torque by pre-tensioning the brake springs for eachlift type individually and at both brake shoes evenly.

Machine withflywheel masse

Machine withhandwinding wheel

≤ ≤ ≤ ≤ > v m/s 0.63 1.25 0.63 1.25 1.25

- a full-down) m/s² 0.2 0.3 0.3 0.4 0.50- a (empty-up) m/s² 0.4 0.5 0.5 0.6 0.75

Table: brake deceleration values

1 Brake shoe bolt 7 Washer2 Safety screw incl. washer 8 Counternuts3 Oil vent 9 Anchor bolt4 Inspection opening 10 Armature base plate5 Brake shoe 11 Cover ring6 Rubber disk 12 Magnetic clamp

12

1

11

10

8

9

8

7

6

5

2 3 4 2 1

Fig. 20



7.3 Adjusting of brake shoe stroke / armature base plate

Before first startup and during regular inspection check the working stroke ofthe brake shoes as well as the pre-tension and the movability of the armaturebase plates.

How to proceed:

1. Check armature base plate for movability:After a long time of use the rubber disk between armature base plate andbrake shoe (fig. 16 pos. 6) may sink and, consequently, the pre-tension of thearmature base plate may be too low.To restore the pre-tension re-adjust the counternuts between brake shoe andarmature base plate. The pretension is correct if the armature base plateslightly clings on the anchor bolt and can be turned.

2. Check stroke :Align dial gauge to brake shoes and measure on the level of the brake diskcentre. Release brake shoes by operating the drive and check stroke ofbrake shoe. Stroke travel shall be 0.3 mm + 0.1 mm.

Re-adjust: unscrew counternuts (fig. 20 pos. 8) and re-adjust armature baseplate by means of hexagon socket screw key in the case of deviations.Secure adjustment.

Note: release brakes and see to it that both brake shoes work with the samestroke.

3. Adjust pre-tension of springs:Correct adjustment of pre-tension is only possible in the course of adjustingthe braking deceleration (see 7.2) Do not exceed the maximum pre-tensionvalue of 13,5 mm.

Note: if brake test switches are provided (SA3) check or re-adjust them aftere every brake adjustment.

See brake monitoring SA3 chapter 8.2



7.4 Replacing of traction sheave

Disassembly:

• Switch off power supply, secure car and counterweight,.• Remove load from traction sheave by discarding ropes.• Secure traction sheave with rope or chain to hoist.• Unscrew screws on fastening disk of traction sheave and loosely screw

them in outer hole circle of disk into traction sheave hub(see fig. 21 pos. 2 below)

• Place spacer (5 – 10 mm thick and somewhat smaller than diameter ofdrilled hub holes) between shaft end and disk.

• Remove traction sheave from shaft by alternately and uniformly tighteningthe screws

Assembly:• Clean shaft end and drilled hole of traction sheave; never make any

dimensional changes in featherkey, groove, shaft or drilled holes.Check contact surfaces for damage.

• Do not grease or oil shaft and drilled hole.• Fit new traction sheave to conical shaft end of worm wheel shaft.• Bring position of featherkey and groove in line.• Slide traction sheave on worm wheel shaft.• Screw disk with new (micro-encapsulated) screws and detent edged

rings in inner hole circle of disk. Tighten screws alternately anduniformly.

Attention danger: if the traction sheave is assembled incorrectly it can workloose.

• See to it that screws are tightened and check tightening torque 100 Nm !See table 9.1 in annex.

Fig. 21

1

2

3

4

1 Traction sheave2 Hole for forcing screw3 Fastening disk4 Fastening screw

2



7.5 Replacing of motor

Note: with motors of constructional size A4 the rotor is shrink-fit to themotor shaft. Therefore the rotor can only be replaced together with theworm shaft. This is why the motor shall be replaced at the factory.The following description of motor change only applies to motors ofconstructional size B5 (SA14)

Disassembly :Switch off power supply, secure car and counterweight.Fasten motor to hoist and secure.Disconnect electrical terminals and lines from motor (motor and magneticclamp terminals).Remove nuts on motor, brake and coupling disk.For assembly of flexible coupling see annex 9.2.Carefully remove motor from studs and place it on the floor.

Assembly :Compare motor data of the two motors.Fasten spare motor to hoist and secure.Lift motor by means of hoist and bring motor coupling and brake disk intoline. See to it that the mounting holes and the screws are aligned to eachother.Mount motor and coupling unit to shaft and then screw coupling to brakedisk. Screw on nuts and tighten uniformly in accordance with the requiredtorque (see table of tightening torque in annex).

Note: for assembly of flexible coupling SA14 see chapter 9.2.

OPERATING MANUAL 8. SPECIAL VERSIONS


8.1 SA Special versions (optional)

(Additional parts for special applications)

Survey:

SA 3 with brake monitoring switches

SA 9 traction sheave in well (with extended traction sheave shaft)

SA 12 with additional terminal box for brake release magnets for motorswithout terminal box

SA 14 with flexible coupling for motors of constructional size B5

SA 15 with brake release magnets in ex (sG4) version

SA3 Brake monitoring switches for monitoring the brake shoes(open-closed) and the wear of brake lining.Note: check and, if necessary, re-adjust existing brake monitoring switchesevery time you adjust the brake.See 8.2 SA3 adjustment description of brake monitoring switches

SA9 With extended traction sheave shaft if the traction sheave is arrangeddirectly in the well. The traction sheave shaft is supported by a bearing. Themachine is fastened on pedestal supports for compensating the shaft loadand the forces acting on the bearings.

SA12 Additional terminal box for intermediate terminals of brake release magnets(for motors without terminal box acc. to BV 65 31)

SA14 For motors of constructional size B5 possible misalignments between brakedisk and motor coupling are compensated by means of a flexible coupling.For description of coupling see annex 9.2 flexible coupling for motors ofconstructional size B5

SA15 Brake release magnets in ex-(sG4) version(not possible in combination with SA3 and SA12)



8.2 SA3 Brake monitoring TCM

Version for TCM controls

The brake monitoring is designed for monitoring the brake shoes.It prevents motor motions if the brake is partly or fully closed. It helps todetect possible brake lining wear at an early stage.Switches (sensors) are used to monitor whether the brake shoes areclosed, open or worn-out. For better evaluation the run signal - deviatedfrom W/W1 contactor - is used.

Failure is displayed via light-emitting diodes on the sensors and the brakemonitoring switches in the control cabinet. If a Teleservice device isconnected the error will be indicated on the display.

Mounting:1. Manufacture 2 cables (0.3*0.75mm² with PVC sheath) if they are not part

of the supply schedule for direct connection of sensors to control andconnect sensors.

2. The (micro-encapsulated) hexagon screws to be adjusted as well as thecounternuts have been pre-assembled on the brake shoes at the factory.The plunger on the switch shall be opposite but not in contact to theadjusting screw.

Adjusting :Adjust brake shoe stroke prior to setting the sensors! For description seechapter 7.3

3. Switch on electrical emergency operation and lift control.4. Turn adjusting screw towards switch until LED flickers.5. Slowly turn screw back until LED will just go out.6. Then turn screw back by one fourth of rotation (equivalent to approx.

0.3mm) towards the switch and lock it.LED flickers constantly.

7. Supply motor with power, then release and close brakes and check at thesame time that switching of the sensors changes between engaged anddisengaged brake.



Fig. 22 Brake test switches mounted on machine

Fig. 23 Adjustment of test switch on hexagon screw

1 Spring clamp2 Brake shoe3 Adjusting screw4 Test switch (sensor)5 Plunger

1 2 3 4 5



8.3 SA3 Brake monitoring BRC

Version for third-party and older controls ( not TCM ! )

The brake monitoring BRC is a retrofit electronic device designed for monitoring of brakeshoes. The signals sent from the sensors are evaluated and transmitted to the secondarycontrol electronics. The device automatically switches off if the set sensor value isreached.

Light-emitting diodes on the sensors and the BRC brake monitoring switches are providedfor failure display. If a Teleservice device is connected the error will be indicated ondisplay.

Fig. 24 Terminal connection diagram for brake monitoring BRC applies to third-party and older controls (not TCM)

Connections :L1 a.N for mains 230 VW for make contact to W contactorB1 sensor 1 with voltage supply 24V/0VB2 sensor 2 with voltage supply 24V/0VK1 make contact for evaluation (e.g.connection to safety circuit)Teles. for connection to THYSSENKRUPP Teleservice device

(remote monitoring of lift)

Sensor mounted onmachine, adjusted torespective integrally castsurface of brake shoe

Cable length acc. to order(standard length approx. 5 m)cable 3*0.75 mm² with PVCsheath

Teles. K1Failure display

L1 N WBrake monitoring BRC

Make contactTravel contactor

Connection K1 interrupter contactTeleservice in safety circuit



Fig. 25 Terminal connection diagram for sensors

Brown

Black B1 Blue 0V Blue 0V

Black B2

Brown 24V

OPERATING MANUAL 9. ANNEX


9.1 Tightening torques- strength

Attention: to be strictly observed when performing work on the machine orreplacing parts!

Strength DIN / Tight.- ISO torque

Nm

Handwheel on hubCheese head screw M 8*12 8.8 4762 20Lock washer S8

Hub on shaftCheese head screw M 12 * 35 microencapsul. 8.8 4762 75Detent edged disk SK M12Dowel pin 6 *18 8752 9

Pulse generator on motor casingCheese head screw M 6 *12 8.8 4762 9

Motor bearing cover on motor casingCheese head screw M 6 *12 8.8 4762 9

Motor casing on gear box casingCheese head screw M 12 * 35 8.8 4762 75

Brake disk on worm shaft (only with A4 motors)Shaft nut M 55 * 2 8.8 600

Bearing cover on inside box casingCheese head screw M 12 * 35 microencapsul. 8.8 4762 75

Disk on conic. end of worm wheel shaftCheese head screw M16 * 40 microencapsul. 8.8 4762 100Detent edged disk SK M16

Bearing bracket on casingCheese head screw M 10 * 30 microencapsul. 8.8 4762 40

Bearing cover on bearing bracketHexagon nut M10 * 30 8.8 4017 40Detent edged disk SK M10

Disk on bearing – worm wheel shaftCheese head screw M 10 * 30 microencapsul. 8.8 4762 40



th ISO torqueNm

Locking screw on brake shoe boltsCheese head screw M6 * 12 8.8 4762 9Detent edged disk SK M6

Brake release magnet on casingHexagon screw M16 * 120 8.8 4014 150

Machine on machine frame versions 1 - 3 / 4Hexagon screw M20 * 90Washer 21Hexagon nut M20Lock nut M20

8.8

8

4014734940327967

190 / 350

Tightening torques for screwing the fastening partson the machine frame

Hexagon screw M 6 * 20 8.8 4017 9

Hexagon screw M10 * 16 8.8 4017 40

Hexagon screw M12 * 35 8.8 4017 75

Hexagon screw M16 * 25 8.8 4017 190

Hexagon screw M16 * 40 8.8 4017 190

Hexagon screw M16 * 80 8.8 4017 190

Detent edged disk SK M10



Note: install screws, washers, detent edged disks, nuts and lock nuts acc. tothe information of enclosed drawings and tighten with the torque specified.

Note: only use micro-encapsulated screws once, then replace.

Any warranty obligation on parts is subject to use of original mounting andfastening parts from ThyssenKrupp Aufzugswerke GmbH.



.

9.2 Annex Flexible coupling for B5 motors sheet 1

Design for TW63



TW63

9.2 Annex Flexible coupling for B5 motors sheet 2



9.3 Pulse Generators

Versions: the following pulse generators are available for TW63

Type classification dependent on the control used1.TTL for THYSSENKRUPP control CPI

for v < 1.5 m/s with 1024 pulses part No. 00 990 13 03 0for v ≥ 1.5 m/s with 4096 pulses part No. 00 990 14 03 0Use cable of 10 m length, SUB-D 9 tab and locking lever acc. to DIN46342 for connection.

Connector assignment Electrical data:Connection Pin Colour Supply voltage 5 V DCMinus 7 white Power consumpt.: max. 60 mAPlus 9 brown Output: push-pullChannel A 2 green Max load.: 40 mAChannel B 3 yellow Level with 20 mA: H >3,6 VDCZero pulse 5 grey L < 1.2 VDCChannel A inv. 1 red Max. pulse frequency: 200 kHzChannel B inv. 4 black Terminal protector: noZero pulse inv. 6 lilacShield 8+casing black

Please note manufacturer’s information in chapters 9.5 – 9.5

2.HTL for third-party controls or converterswith 2 x 64 pulses part No. 00 990 12 03 0Use cable of 10 m length insulated with end sleeves for connection..Connector assignment Electrical data:Connection Pin Colour Supply voltage 15V DCChannel A 6 grey Power consumpt. +15V: ≥ 90 mAChannel B 5 pink Power consumpt. -15V: ≥ 10 mAChannel C 3 green Output: A Channel 64 I/UMass 4 yellow B Channel 64 I/UPlus 15 V 1 brown C Channel 128 I/UMinus 15 V 2 whiteShield open




3.HTL for third-party controls or converterswith 1024 pulses part No. 00 990 16 03 0Use cable of 10 m length insulated with end sleeves for connection.

Connector assignment Electrical data:Connection Colour Supply voltage 15V DCChannel A green Power consumpt.: max.60 mAChannel B yellow Channels: A, B, N, ABN inv.Channel N grey Output: HTL- differential driverChannel A inv. red Load: max. 40 mAChannel B inv. black Level: with 20 mAChannel N inv. lilac H > UB – 2,5 VDCMass yellow L > 2,5 VDCPlus 15 V brown Pulse frequency: max. 200 kHzMinus white Terminal protector: yesShield strand Early warn. output: NPN OC, 10 mAEarly warning output:pink Umax. = 30 VDC

Cable length: max. 100 m


4.HTL for third-party controls or converterswith 1024 pulses part No. 00 990 19 03 0Use cable of 10 m length insulated with end sleeves for connection.

Connector assignment Electrical data:Connection Colour Supply voltage: 5V DCChannel +A green Power consumpt.: max. 100 mAChannel +B grey without loadChannel +N black Channels /output: sine, cos., NChannel - A yellow Output load : min 120 OhmChannel - B pink Termin. resistor between + andChannel - N lilac - outputs.Plus 5 V brown Level: 1 Vss +/- 25 %Minus white Max. frequency (-3dB): 100 kHzShield strand Terminal protector: no

Early warning output: conductive inoperating stateCable length: max. 150m with <260pF/mGeneral design:

acc. to DIN VDE 0160




9.4 Pulse Generator Manufacturer’s Instruction Sheet 1

Part No.: 00 990 12 03 0 with 2 x 64 pulses



9.4 Pulse Generator Manufacturer’s Instruction Sheet 2

Part No. 00 990 13 03 0 with 1024 pulsesPart No. 00 990 14 03 0 with 1024 pulses



9.4 Pulse Generator Manufacturer’s Information Sheet 3

Part No. 00 990 16 03 0 with 1024 pulses



9.4 Pulse Generator Manufacturer’s Information Sheet 4

Part No.: 00 990 19 03 0 with 1024 pulses



9.5 Pulse Generator Manufacturer’s InstructionProduct Information



9.6 Blocking clamp

Every machine is equipped with a blocking clamp suitable for the respectivetraction sheave (rim width and design)

Use of blocking clamp:Use the blocking clamp during assembly works on the car or on thecounterweight in order to avoid movements by slip of ropes on tractionsheave or during works for which the traction of the installation is notsufficient (for example for safety gear operation).

Note: Tighten the blocking clamp by means of the screw connection in sucha way that slip of ropes on traction sheave is impossible.

Mounting the blocking clamp to the traction sheave (illustration without ropes)

1 Traction sheave groove2 Rope3 Pressure plate4 Washer5 Hexagon nut6 Spacer7 Clamp clip

Attention: After terminating mounting works disassemble blocking clamp,since otherwise there is the risk of damage to the installation.

1

2

3

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ThyssenKrupp Aufzugswerke GmbHA company of ThyssenKrupp ElevatorBernhäuser Strasse 4573765 Neuhausen a. d. F.GermanyTel.: +49 7158/12-0Fax: +49 7158/12-2585E-Mail: info@tke-aufzuege-de.thyssenkrupp.comwww.thyssenkrupp-aufzuege.com 62

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