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A company

of ThyssenKrupp

Elevator

ThyssenKrupp Aufzugswerke

A company of ThyssenKrupp Elevator ThyssenKrupp Aufzugswerke Operating Manual Machine TW45B
A company of ThyssenKrupp Elevator ThyssenKrupp Aufzugswerke Operating Manual Machine TW45B

Operating Manual

Machine TW45B

11.10.2007
11.10.2007

Ein Unternehmen

von ThyssenKrupp

Elevator

ThyssenKrupp Aufzugswerke

Anlageblatt zur Betriebsanleitung Maschine TW45B Appendix to instruction manual machine TW45B

Annexe aux instructions de service machine TW45B

Betrifft:

Änderung an den Bremsen 2x50Nm

Subject:

Modification of brakes 2x50Nm

Objet:

Modification des freines 2x50Nm

Anschluss TCM / TCI Steuerungen Connection TCM / TCI controls Raccordement manœuvres TCM / TCI

Bremsansteuerung bei nicht TCM / TCI Brake control if not TCM / TCI Commande de frein en cas de non TCM / TCI

TCM / TCI Bremsansteuerung bei nicht TCM / TCI Brake control if not TCM / TCI
TCM / TCI Bremsansteuerung bei nicht TCM / TCI Brake control if not TCM / TCI
TCM / TCI Bremsansteuerung bei nicht TCM / TCI Brake control if not TCM / TCI

Betrifft:

Neuer Bremslüfthebel für Bremse 2x50Nm

Subject:

New brake release lever for brake 2x50Nm

Objet:

Nouveau levier de desserrage de frein pour frein 2x50Nm

Nouveau levier de desserra ge de frein pour frein 2x50Nm Vor Einsatz des Bremslüfthebels Anlage ausschalten,

Vor Einsatz des Bremslüfthebels Anlage ausschalten, Antrieb elektrisch stillsetzen Before use of the brake release lever switch off installation, stop drive electrically Avant l’usage du levier de desserrage de frein désactiver l’installation, arrêter l’entraînement électriquement

Bremslüfthebel spreizen Spread brake release lever Écarter levier de desserrage de frein

an der Maschine (Bremsen) einbauen install at the machine (brakes) monter à la machine (freines)

at the machine (brakes) monter à la machine (freines) Rändelschraube festziehen Tighten knurled thumb screw

Rändelschraube festziehen Tighten knurled thumb screw Serrer vis moletée

Beide Bremslüfthebel sind angebracht Both brake release levers are fixed Tous les deux leviers de desserrage de frein sont fixés

an den Bremsen fixieren attach to the brakes fixer aux freines

Bremsen fixieren attach to the brakes fixer aux freines Bremslüfthebel fixiert Fixed brake release lever Levier

Bremslüfthebel fixiert Fixed brake release lever Levier de desserrage de frein fixé

brake release lever Levier de desserrage de frein fixé Beide Bremslüfthebel gleichmäßig in Richtung Handrad
brake release lever Levier de desserrage de frein fixé Beide Bremslüfthebel gleichmäßig in Richtung Handrad

Beide Bremslüfthebel gleichmäßig in Richtung Handrad ziehen Pull both brake release levers equally to the handwinding wheel Tirer régulièrement tous les deux leviers de desserrage de frein vers le volant de dépannage

leviers de desserrage de frein vers le volant de dépannage einzelne Bremse lüften release single brake

einzelne Bremse lüften release single brake desserer frein séparément

de frein vers le volant de dépannage einzelne Bremse lüften release single brake desserer frein séparément
de frein vers le volant de dépannage einzelne Bremse lüften release single brake desserer frein séparément

Bremshebel müssen nach Benützung entfernt werden Brake levers must be removed after utilization. Enlever les leviers de frein après Iutilisation. После окончания работы тормозные рычаги нужно убрать.

après Iutilisation. После окончания работы тормозные рычаги нужно убрать .

Anlageblatt zur Betriebsanleitung Maschine TW45B Appendix to instruction manual machine TW45B Annexe aux instructions de service machine TW45B

Betrifft: Änderung Bremslüfthebel und el. Anschluss der Bremsen. Subject: Modification of brake release lever and electrical connection of brakes Objet: Modification du levier de desserrage de frein et raccordement électrique des freines

Folgende Kapitel sind durch das Anlageblatt betroffen:

The appendix refers to the following chapters:

L’annexe fait référence aux chapitres suivants:

2.2

4.2

5.1

5.2

7.3

7.4

OPERATING INSTRUCTIONS

Imprint

All rights reserved

© Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH Postfach 23 03 70, D-70623 Stuttgart

Printed in Germany These operating instructions may – even in extract form – only be reprinted or otherwise copied with the express written approval of THYSSENKRUPP AUFZUGSWERKE GmbH. All copying, distribution or saving in any form on data storage media which is not authorised by THYSSENKRUPP AUFZUGSWERKE GmbH constitutes a copyright infringement and will result in prosecution. We expressly reserve the right to carry out technical alterations which lead to an improvement of our products or increase the safety standard – also without special prior notice.

The issuer responsible for the content:

THYSSENKRUPP AUFZUGSWERKE GmbH

Preface

We are delighted that you have decided upon a quality product from the company THYSSENKRUPP AUFZUGSWERKE GmbH. These operating instructions will help you to get to know our products and to benefit from their intended applications. Important safety and hazard instructions will help you to operate our products safely and properly. Subject to technical alterations.

OPERATING MANUAL

Table of contents :

Machine TW45B

PAGE

1. Safety

1.1 Explanation of symbols used

10

1.2 General safety information

11

2. Product description

2.1 Description of machine TW45B

14

2.2 Functional description

15

2.3 Dimensions

18

2.4 Technical data

24

2.5 Machine frame

28

2.6 Name plate

34

2.7 Lubrication

35

3. Transport and storage

37

4. Mounting of machine in machine room

40

4.1 Mounting of rope guard

42

4.2 Connection

43

5. Putting into service

5.1 Putting machine into service

46

5.2 Emergency operation

47

5.2.1 Drive for machine-room-less installation without

emergency braking system NBS

5.2.2 Drive with emergency braking system NBS

5.2.3 Drive for machine in shaft with emergency braking system

5.2.4 (Optional) brake release levers for manual release

6. Servicing

6.1 Servicing of machine

50

6.2 Checking of drive brake

51

6.3 Checking of flank clearence

54

6.4 Checking of escaping grease / oil

55

7. Maintenance

7.1 Replacing of traction sheave - installation

57

7.2 Replacing of motor – installation

58

7.3 Replacing of brake with machine room version (TWR)

59

7.4 Replacing of brake with shaft version (MRL)

61

8. Annex

8.1

Tightening torque – mechanical strength

63

8.2

Blocking clamp Manufacturer’s instruction brake / coupling Single-disk brake – Mayr (TWR) Double-disk brake – Warner (MRL) Encoder Manufacturer’s instruction sheets 1-3 - encoder Manufacturer’s instruction – product supplement - encoder Manufacturer’s instruction - motors

65

OPERATING MANUAL

TW45B

1. SAFETY

1.1 Explanation of symbols used

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

and designations are used in this operating manual: Danger This symbol draws attention to an extreme

Danger

This symbol draws attention to an extreme danger to life or risk of injury to persons. Disregard of warning means danger to life !

Danger This symbol draws attention to an immediate impending danger to life or risk of injury This symbol draws attention to an immediate impending danger to life or risk of injury to persons caused by electric current. Warnings must always be observed!

Warning

This symbol draws attention to an impending danger. Disregard can cause injury to persons or extensive damage to property. Warnings must always be observed!electric current. Warnings must always be observed! Warning Note This symbol draws attention to important information

damage to property. Warnings must always be observed! Note This symbol draws attention to important information

Note

This symbol draws attention to important information and instructions for operation. Disregard can lead to damages, hazards or failures.

Disregard can lead to damages, hazards or failures. Inspection This symbol draws attention to inspection

Inspection

This symbol draws attention to inspection sequence. These inspection notices must be observed in any case. Disregard can lead to injury to persons or damage to property.

OPERATING MANUAL

TW45B

1. SAFETY

1.2 General safety information

M ANUAL TW45B 1. S AFETY 1.2 General safety information Notes on the operating manual Persons
M ANUAL TW45B 1. S AFETY 1.2 General safety information Notes on the operating manual Persons

Notes on the operating manual

Persons who perform work on the component must know the basic safety precautions to ensure safe use and failure-free operation of this component. This operating manual comprises the most important instructions how to safely use the component. The operating manual and, in particular, the safety instructions must be observed by all persons who perform any work on the component. In addition the rules and requirements concerning the regulations for prevention of accidents which apply to the installation location must be observed.

Duties of the owner and / or the installer

The owner and / or the installer ensure that work on the component shall only be performed by trained and qualified persons who

observe the accident prevention regulations;

have read the safety information and the warning notices in this operating manual. Note: Check whether these instructions are observed in regular intervals.

Duties of the employees

Persons who perform work on the component must

observe the accident prevention regulations and safety precautions;

read the safety information and the warning notices in this operating manual prior before they start working.

Training of the employees

Work on this component shall not be performed by other than trained and qualified persons. These persons shall not perform any work other than the instructions given for putting into service, operation, maintenance and repair work.

Organizational measures

The owner or the installer must provide the necessary personal protective gear. All existing safety devices must be checked regularly in accordance with the maintenance plan.

OPERATING MANUAL

TW45B

1. SAFETY

O PERATING M ANUAL TW45B 1. S AFETY Informal information about safety measures • The operating
O PERATING M ANUAL TW45B 1. S AFETY Informal information about safety measures • The operating

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 made available and observed.

Clearly and easily visible statutory safety instructions must be made available for the users.

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

Use as intended

TW45B is exclusively designed in accordance with the state of the art and the recognized safety regulations. TW45B shall only

be used for its intended purpose

be used exclusively if safe operation is ensured. TW45B drive shall exclusively be used as drive for lifts. Any other use or any use exceeding the scope of the above definitions is regarded as use outside of the intended purpose. THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable for any damages resulting from this and for any damages which are caused by any errors of procedure. 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 liability

The „General sales and delivery terms“ of THYSSENKRUPP AUFZUGSWERKE GmbH apply generally. Any claims for guarantee and liability are excluded in the case of injury to persons or damage to property resulting from one or several of the causes below:

use of TW45B outside the scope of its intended purpose

inexpert mounting, putting into service, operating and maintaining of

TW45B

operating the TW45B with defective and/or non-operative safety and protective devices

disregard of and instructions of the operating manual that apply to transportation, storage, mounting, putting into service, operating and maintaining of TW45B

unanauthorized constructional modifications of TW45B

unauthorized modification of drive (performance etc.)

OPERATING MANUAL

TW45B

1. SAFETY

unsatisfactory supervision of parts which are subject to wear

inexpert repair work

catastrophes caused by outside influence and Act of God.

Modifications of machine TW45B

TW45B is delivered factory-adjusted, pre-assembled and ready for operation. In the case of any modifications of the machine THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable. Attention : the machine is delivered with oil filled in ! Please check oil level using gauge glass modifications of the machine THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable. Attention : before you start before you start operation.

oil level using gauge glass before you start operation. Use of TW45B and possible hazards Traction
oil level using gauge glass before you start operation. Use of TW45B and possible hazards Traction

Use of TW45B and possible hazards

Traction sheave and handwheel of TW45 B do not have any protective cover. The drive shall only be operated in a closed machine room. See to it that the necessary safety distance to all revolving parts (marked yellow) is observed by persons working in the machine room. Note: danger of injury caused by objects (such as tools etc.) placed on the handwheel.

In case of inexpert use there will be the risk of damage to the user or third parties or impairment of the component or material property. Failures which may affect safe operation must be eliminated immediately.

Attention: works on the handwheel shall only be performed with the power supply switched off and the drive protected against unintentional switching on (e.g. by locking of key-operated switch or removing of power supply fuses). A warning sign to that effect must be provided at the control cabinet when performing works at the drive.Attention:

Emergency brake NBS: installation sequence is different with emergency brake mounted on. The same applies to testing and installation sequence is different with emergency brake mounted on. The same applies to testing and setting. Observe notes in enclosed operating manual.

Attention: the model for placement in the shaft (MRL) is delivered without manual releaseAttention: the model for placement in the shaft . Handwheel operation is only possible using proper . Handwheel operation is only possible using proper electrical accessories which are not part of the supply schedule. The manufacturer of the lift installation must provide proper measures:

a) to be able to operate the brake in cases of emergency (power failure).

b) to be able to lift the car when the safety gear is engaged. (For example

rope device at car or counterweight.)

c) to be able to check the two brake circuits separately.

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

2.1 Description of machine TW45B

12

11

10

4

9

8

7

Fig. 1

2.1 Description of machine TW45B 12 11 10 4 9 8 7 Fig. 1 1 2

1

2

3

4

5

6

7

Figure: TW45B, vertical motor position, machine in machine room

Machine TW45B (vertical motor position) consists of:

1

Handwinding wheel

7

Rope guard

2

Real value generator

8

Rope guard support

3

Motor

9

Gear

4

Transport eyebolt

10

Disk brake

5

Traction sheave

11

Brake release lever

6

Disk at traction sheave shaft

12

Motor connection

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Versions:

Two versions are available:

a) Vertical and horizontal motor position for machine in machine room (TWR)

b) Horizontal motor position for machine in shaft (MRL)

Compared to version with machine in machine room (TWR) the model of the machine for use in shaft (MRL) is equipped with two-surface disc brakes in tandem arrangement with higher braking torque but without mounted-on brake release levers and handwinding wheel.

mounted-on brake release levers and handwinding wheel. The following versions are available: Drive rating Gear

The following versions are available:

Drive rating Gear ratio Traction sheave version Traction sheave in left-hand and right-hand design with horizontal motor position (seen from motor to gear) Encoder version

An optionally mounted emergency braking system NBS prevents overspeed in upwards direction. It has an additional disk brake acting on the traction sheave shaft. Note: It is not possible to retrofit an existing machine with an NBS emergency braking system !

2.2 Functional description

Machine TW45B is designed for driving lift cars with rated load 450 kg and speed 1,0 v 1,25 m/s.

with rated load 450 kg and speed 1,0 ≤ v ≤ 1,25 m/s. The gear (shaft)

The gear (shaft) consists of a single-stage worm gear in monoblock housing with separated AS/BS bearing brackets. A flexible coupling transmits the power from motor to gear. A dual-circuit disc brake is installed between motor and gear. An overhung traction sheave is used. Tooth system operating in synthetic oil.

Attention: the gear can be considered self-locking for ratio > 25.5. Observe that this does not apply to lower ratio.

Different designs of drives are used dependent on the position of the flanged three-phase motor. The drive transmits power to the worm shaft and from there to the worm wheel, traction sheave shaft and traction sheave.

TW45B has flange-mounted motors (250 mm) in B5 / V1 design. Integrated posistors protect the motor against thermal overload. The thermal motor monitoring is connected in the motor terminal box. Details see chapter 2.4.

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Drive type:

TW45B is available with frequency-controlled three-phase motor only. An encoder for speed monitoring is available optionally. It is mounted on the motor shaft. Technical data and manufacturer’s instrutions for available encoder versions see chapters 8.3 – 8.5 A mounted-on handwinding wheel is available with drives models with machine in machine room (TWR).

Coupling:

Worm wheel and rotor shaft of motor are connected through a flexible, maintenance-free coupling. The coupling half connected to the gear has a sprocket, which transmits the drive movement to the brake rotor of the disc brake.

the drive movement to the brake rotor of the disc brake. Brake: Note: the brakes of

Brake:

Note: the brakes of the TW45B machine are intended for static applications as holding brakes. Any dynamic braking is restricted to emergency and test braking. Normal use will not lead to any noticeable wear of lining. These brakes can in no way replace the safety braking systems required for downwards travelling cars. Function:

Two different operational brake designs are used with TW45B.

a) A two-surface disc brake with radial armature base plate designed for version with machine in machine room (TWR). Two independently operating radial armature base plates press onto the brake lining of the rotor. The disc moves on the hub, forces the friction lining onto the gear housing and is thus stopped.

b) A two-surface disk brake with two brake rotors in tandem arrangement for version with machine in shaft (MRL). Two independently operating armature base plates with preset spring resistance press onto the brake lining of the rotors. The two discs move on the coupling hub, force the friction lining onto the bearing cover and armature base plate and are thus stopped. The torque of the two spring-operated brakes has been adjusted at the factory and shall not be re-adjusted. The braking force is adjusted in such a way that one brake shoe con stop the car loaded with full loading capacity. The disc brakes are released through electrically-operated magnetic clamps.

Manual release of brake is only possible with machine in machine room (TWR). The brake release levers at transition motor-gear (fig. 1, pos. 11) must be operated. When the brake release levers are pressed, the armature base plate and the rotor are separated. (fig. 25, pos. 5) The rotor is connected to the motor and the worm shaft through a toothing system; the brake is released. Tooth system for vertical motor position Drawing and important manufacturer’s instructions related to installation and details see chapter 8.2.1.

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Note: TW45B machine for placement in shaft (MRL) does not have mounted- on brake release levers. TW45B machine for placement in shaft (MRL) does not have mounted- on brake release levers. Manual release of the brake is not possible!

Emergency braking system NBS:

The optional NBS emergency braking system protects the elevator car travelling upwards from overspeed. Description and details of the emergency braking system see operating manual NBS.

Traction sheave:

The one-piece (rim and hub) traction sheave is fixed using a cone and a mounting plate overhanging the shaft drive. Further details see chapter 2.4 Technical data.

Pulse generator:

An overview of pulse encoders used incl. technical data see chapter 8.3 and manufacturer’s instructions in chapters 8.4 – 8.5.

Environmental conditions:

Surrounding at the final site of the drive (humidity, temperature) shall comply with the requirements for machine rooms (between +5°and +40°C according to EN81.) Relative humidity of air shall not exceed 70%.

Attention: the torque of the two-surface disc brake can intensively drop by dewing in case of the torque of the two-surface disc brake can intensively drop by dewing in case of temperature around or under the freezing point. There is the danger that friction linings seize up at the friction surfaces in case of standstill for longer time. The user of the assembly must provide proper counter measures.

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

2.3

Dimensions

TW45B vertical motor position (version for machine in machine room (TWR) with NBS)

Manual release operational brake Fig. 2 Oil drain Motor connection
Manual release
operational brake
Fig. 2
Oil drain
Motor connection
Pulse generator Fig. 3 approx. 991 200
Pulse generator
Fig. 3
approx. 991
200

Manual release mounting

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

TW45B horizontal motor position (version for machine in machine room (TWR) with NBS)

Fig. 4

B =115

for machine in machine room (TWR) with NBS) Fig. 4 B =115 119 392 NBS mounting
119
119
392
392

NBS mounting

room (TWR) with NBS) Fig. 4 B =115 119 392 NBS mounting Version for machine in

Version for machine in machine room (TWR) incl. rope guard acc. to EN81

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

TW45B (TWR) vertical motor position

Brake release lever Fig. 5
Brake release lever
Fig. 5
Oil level gauge glass Oil drain
Oil level
gauge glass
Oil drain

Fig. 6

Version for machine in machine room (TWR) incl. rope guard acc. to EN81

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Fig. 7

Fig. 8

O PERATING M ANUAL TW45B 2. P RODUCT D ESCRIPTION Fig. 7 Fig. 8 ThyssenKrupp Aufzugswerke
O PERATING M ANUAL TW45B 2. P RODUCT D ESCRIPTION Fig. 7 Fig. 8 ThyssenKrupp Aufzugswerke

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

TW45B version for machine in shaft (MRL) without handwinding wheel and

mechanical brake release ∅∅∅∅DT / 2 742,8 kproj = 438 155 285 100 200 1)
mechanical brake release
∅∅∅∅DT / 2
742,8
kproj = 438
155
285
100 200
1) 200
1) Thread M16 x 25 deep
27

Fig. 9

Fig. 10

100 200 1) 200 1) Thread M16 x 25 deep 27 Fig. 9 Fig. 10 Version

Version for machine in shaft (MRL) without rope guard

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

TW45B version for machine in shaft (MRL) rear view

393 1) 1) Fig. 11 1) Thread M16 x 25 deep 1) 1) 1) 1)
393
1)
1)
Fig. 11
1) Thread M16 x 25 deep
1)
1)
1)
1)

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

2.4 Technical data

Gear unit:

Gear type:

 

TW45B

Manufacturer:

 

ThyssenKrupp Aufzugswerke GmbH

Application:

 

Machine room

Shaft

(TWR)

(MRL)

Axle distance:

[mm]

 

120

Gear ratio:

 

46:1; 32:1

40:3

Oil filling:

[liter]

approx. 5,5

Type of oil:

 

Synthetic gear oil (polyalkylenglycol)

Sort of oil:

 

SM1 (TRIBOL 800 / ISO 460)

Circumferential

[°]

0,03 ÷ 0,07

backlash:

Weight (machine)

[kg]

approx. 105

Designed for use in installations with rated load of 450 kg and v rat 1,0 v n 1,25 m/s

Permissible radial load of traction sheave: max. 26 kN

Mass moment of inertia:

component

gear

motor

hand wheel

total

J1 [kgm²]

0.0045

0.018

0.01

0.0325

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Operational brake:

Application:

 

Machine room (TWR)

 

Shaft (MRL)

 

Manufacturer:

   

Mayr / Mauerstetten

 

Warner & Turco

Type:

   

ROBASTOP RSZ 60

 

ERS VAR09 SZ 50/50

Braking torque :

[Nm]

 

2 x 30

 

2 x 50

Adjustment of torque

   

not possible

 

Type:

 

2 surface disc brake with radial armature base plate

surface disc brake in tandem arrangement

2

Brake linings

   

asbestos-free

 

Brake disc :

[mm]

 

131

 

150

Operating voltage:

[VDC]

180

with overexcitation

90

per magnet with overex.

[VDC]

90

with retentive voltage

45

per magnet with retent.

Performance data:

[W]

332

with overexcitation

196 with overexcitation 65 with retentive voltage

[W]

83 with retentive voltage

Brake monitoring:

   

without

 

Air gap:

[mm]

 

0,4 ± 0,05

 

0,25 ± 0,05

 

Max. after wear

[mm]

 

1,7

 

je Spalt

0,6

Adjustment of air gap:

   

not possible

 

Electrical release

   

1 magnetic clamp

1

magnetic clamp per

 

brake circuit (series connection)

 

Manual release:

 

1 brake release lever per brake circuit

 

without

Protection class:

   

IP54

Weight:

[kg]

 

approx. 15

 
 

Weight:

Standard version of TW45B

 

Machine (with motor and traction sheave 360)

 

[kg]

200

 

Machine (with motor and traction sheave 440)

 

[kg]

215

Machine (with motor and traction sheave 520)

 

[kg]

225

Version with NBS (to be added)

 

[kg]

40

Sound level:

Airborne sound level in machine room at a distance of 1 m under operation at normal rating: 65 dB(A)

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Motor data:

VVVF three-phase motor in B5 design The following motor operational specifications apply to the use of TAW frequency converters of type CPI10; CPI15/15E; CPI26E.

     

Machine room (TWR)

 

Application

   

Shaft (MRL)

 

Manufacturer:

   

Siemens AG

 

Type:

   

1LA7130-4AA19Z

1LA7133-4AA19Z

Voltage / frequency:

[V/Hz]

 

340 / 42

 

S5 – operational data

   

180 c/h – 50%ED

 

Speed range:

[1/min]

1000

1249

1250

1800

1250

1415

Rating:

[kW]

4,2 5,2

 

5,2

 

7

Torque range for speed:

[Nm]

 

40

40

28

52 46

[1/min]

1000

1249

1250

1800

1250

1415

Rated current:

[A]

 

12,5

 

16,5

Allowable starting torque

[Nm]

 

70

70

63

 

88

Allowable starting current:

[A]

 

20

 

32

Efficiency:

   

0,84

 

0,82

Design:

   

IMB5/V1

 

Protection class:

   

IP54

Ventilation:

   

Integrated ventilator

 

Handwinding wheel:

[mm]

 

270 (plastic)

 

without 1 )

kproj. ( see fig. 2 + 7)

[mm]

 

485

Weight:

[kg]

 

50

 

60

Real value generator (standard)

   

WDG100-38-1024/4096 TTL

 

Real value generator (special)

   

WDG100-38-1024 HTL WDG100-38-1024 sine/cosine

 

1 ) For use in the shaft (MRL)

 

The electrical data applies to the following environmental conditions:

max. altitude

max. temperature

max. relative humidity

If the conditions listed above are exceeded, derating as set out in VDE0530 applies.

1000 m above sea level + 40 °C at max. 50% air humidity 70 % at 20 °C

The connecting cable at the real value generator is 10 m long. A connector is provided at the cable end of the standard generator (1024 TTL).

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Motor connection:

Motor connection see chapter 4.2. The terminal diagram is imprinted or enclosed at the inside of the terminal block .

Traction sheave:

The monobloc traction sheaves overhanging the shaft drive are fixed using a cone. Groove type: seat or V-grooves Hardened groove flanks as standard (50 HRc)

Application:

   

Machine room

 

Shaft

Diameter - DT

[mm]

 

440

 

520

360

Rim width:

[mm]

 

115

 

77

Max. grooves – z d

[mm]

7

∗ ∅

8

7

∗ ∅

8

5 *

8

6

∗ ∅ 10

6

∗ ∅ 10

 
 

6

* 11

6

* 11

 

5

* 12

Groove type/ undercut angle:

[°]

 

acc. to order

 

Weight:

[kg]

 

45

 

55

30

Material:

   

specially alloyed EN-GJL 250 (HB 190 to 230)

 
specially alloyed EN-GJL 250 (HB 190 to 230)   Note: Emergency braking system NBS see separate

Note: Emergency braking system NBS see separate operating manual NBS.

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

2.5 Machine frame TW45B

(optional)

The machine base frame consists of brackets of plate edge construction with two welded face plates.

It is designed for use with machines with horizontal motor position.

A hole grid in the machine frame allows the machines with vertical motor

position to be moved in increments for customer-specific arrangement.

Standard models for machines in machine room and in shaft:

1. With deflection pulley, for direct rope departure to be used in:

a) installations with 1:1 rope suspension for car – counterweight rope distance ASL 620 mm and car – traction sheave rope distance

520 mm

b) installations with 2:1 rope suspension. See tables model 1, shown in fig. 12.

The frame is installed using impact soundproof elements.

2. With deflection pulley, frame with deflection pulley 360 or

450 mm and variable rope distance in left-hand or right-hand design

used for installations with 1:1 rope suspension and ASL : 608 ASL 833 mm. (depending on position of deflection pulley. See tables model 2, shown in fig. 13

of deflection pulley. See tables model 2 , shown in fig. 13 Note: frames 2 have

Note: frames 2 have supports to house the deflection pulleys. Arrangement and dimensions shown in fig. 13 and table for model 2.

Installation Machine frames are installed in the machine room using soundproof elements. These elements differ depending on the installation:

a) Isolation elements 100 x 100 x 50 mm high without base. (60 309 01 14 0) To be used for installation of machine directly on the machine room floor without plaster floor or directly on the plaster floor.

b) Isolation elements as above, but with base 140 x 140 x 80 mm high. (60 300 04 37 0) To be used for installation of machine on plaster floor, base casted in plaster floor. (covering thickness 60 mm)

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

O PERATING M ANUAL TW45B 2. P RODUCT D ESCRIPTION Frame mounting (frame without deflection pulley)

Frame mounting (frame without deflection pulley)

Screw the frame delivered disassembled together in the machine room. See to it that the supports with additional (two) bore holes and the rope pulley are mounted on the proper side. (The side where the deflection pulley is to be arranged.)

Mount and secure deflection pulley and axle to pulley support.

Arrange and align frame on isolation elements in accordance with layout drawing.

Tighten the fastening screws with the pre-set torque.

Mount machine on frame using hoist, the traction sheave must be at the deflection pulley side.

Laterally move machine on frame until the required ASL measure (rope distance car - counterweight at rope departure) is reached.

Screw machine and frame together. Observe not to distort the machine housing. To ensure that the base is perfectly horizontal put enclosed metal plates under, if required.

Align the rope grooves of the traction sheave so that they are in parallel line to the rope grooves of the deflection pulley.

Tighten the fastening screws with the pre-set torque. See chapter 8.1.

Align the rope departure so that it is in vertical line with the rope pulley at the car and/or the fastening at the car or counterweight. Attention: in case of lateral or diagonal rope departure the gear box casing is to be secured against shifting using plates bolted to the machine frame.

Explanation of abbreviations:

ASL =

parallel distance of ropes at rope departure (fig. 13)

DT

=

diameter of traction sheave

SR

=

diameter of deflection pulley

α

=

angle of wrap at traction sheave

With frame model 1, fig. 12

X

X

With frame model 2 fig. 13

X

1

2

1

X

Y

Y

Z

2

1

2

1

=

=

distance 1 between rope departure and outer edge of frame distance 2 between rope departure and outer edge of frame

distance 1 between rope departure and outer edge of frame distance 2 between rope departure and

=

distance 1 between axle center of rope pulley and bearing surface

=

of frame support at machine frame distance 2 between rope departure and outer edge of frame support

=

vertical axle distance between traction sheave and deflection

=

pulley vertical distance between deflection pulley center and support

=

bearing distance 1 between center of rope departure and outer edge frame support at deflection pulley side

1) – 2)

See remarks representation fig. 1 (fig. 12)

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Data machine frame model 1

Shown in fig. 12

Traction

   

Arrangement of machine

 

sheave

 

left

right

diameter

         

DT

x 1 min

x 1 max

x 2 min

x 2 max

440

[mm]

52

342

52

342

520

[mm]

52

262

52

262

Weight: machine frame 1 without supports and deflection pulley approx. 50 kg

frame 1 without supports and deflection pulley approx. 50 kg Note: left or right means that

Note: left or right means that the machine 1) in right-hand design (traction sheave seen from motor towards machine) can be moved in respective direction to outer mounting holes in the frame. x 1 or x 2 is the distance between rope departure and outer edge of machine frame dependent on the traction sheave .

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Data machine frame model 2

Shown in fig. 13

Rope distance measurements (ASL) and angle of wrap αααα (Intermediate results for ASL measurements can be adjusted in increments of 40 mm in accordance with the mounting holes in frame)

Traction sheave

Minimum rope distance car – counterweight and Maximum angle of wrap ASL min [mm] and α max [°]

diameter

DT

[mm]

With deflection pulley SR [mm]

 

360

 

450

 

ASL min

α

max

ASL min

α

max

440

582

167

566

168

520

662

167

616

170

Traction sheave

Maximum rope distance car – counterweight and Minimum angle of wrap ASL max [mm] and α min [°]

diameter

DT

[mm]

 

with deflection pulley SR [mm]

 

360

 

450

 

ASL max

α

min

ASL max

α min

440

832

149

776

150

520

832

154

776

157

Project planning dimensions see fig. 13

Deflection

Measure

Measure

Measure

Measure

Measure

pulley

x1

x2

y1

y2

z1

SR

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

360

130

61

645

190

245

450

231

116

600

235

255

Weight:machine frame model 2 incl. deflection pulley 360 approx .140 kg

450 approx.170 kg

incl. deflection pulley

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Model 1 Machine frame TW45B without deflection pulley Fig.12
Model 1
Machine frame TW45B without deflection pulley
Fig.12

Remarks:

1) Machine with horizontal motor position / traction sheave right 2) Machine with horizontal motor position / traction sheave left 3) Machine with vertical motor position / traction sheave right 4) Machine with vertical motor position / traction sheave left

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

Model 2

Machine frame TW45B with deflection pulley

Shown with rope pulley position in right-hand design (left-hand design mirror-inverted)

Fig. 13

Explanation of remarks see version 1 fig. 12

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

2.6 Name plate of TW45B

The current model and the technical data are stated on the nameplate of the product.

1. Name plate of gear (ThyssenKrupp Aufzugswerke):

product. 1. Name plate of gear (ThyssenKrupp Aufzugswerke): 2. Name plate of gear (Lift Equip) 3.

2. Name plate of gear (Lift Equip)

Aufzugswerke): 2. Name plate of gear (Lift Equip) 3. Name plate of motor (laterally fastened at

3. Name plate of motor

(laterally fastened at the motor)

4. Name plate of operational brake:

(With vertical motor position fastened at motor flange below brake covering)

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

2.7

Lubrication

Lubricator

Oil change interval

Motor position

Quantity

Synthetic gear oil SM1 TRIBOL 800 / ISO460

First change after 4 years, thereafter at a period of 8 years

Vertical

approx. 5.5 liter approx. 5,5 liter

horizontal

approx. 5.5 liter approx. 5,5 liter horizontal Oil change • Before you change oil run the

Oil change

Before you change oil run the gear until it is warmed to working temperature (at least 35°C).

Discharge gear oil by the plug at the oil drain.

Attention, there is the risk of scalding !

Discharge waste oil in collecting pan provided.

Close oil drain after discharging the gear oil filler cap and sealing tape.

Pour in recommended quantity of lubricator in the special filling hole at the gear housing (remove vent screw, see figs. 14 to 16).

Check oil level at oil gauge.

Note date of next oil change in name plate at gear housing.

Never mix different sorts of oil.

Oil must not be allowed to flow in the groundwater.

Waste oil and oily, dirty and greasy cleaning cloths must be disposed of in accordance with the local requirements.

Only use types of grease recommended by THYSSENKRUPP AUFZUGSWERKE for refill.

Note: For any damages caused by lubricators not recommended THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable. For any damages caused by lubricators not recommended THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable.

Version with vertical motor position

ventilation oil charging hole

vertical motor position ventilation oil charging hole Fig. 14 Oil drain Oil level gauge Version with

Fig. 14

Oil drain

Oil level gauge

Version with horizontal motor position

Oil level gauge Version with horizontal motor position ventilation oil charging hole Fig. 15 Oil level

ventilation oil charging hole

Fig. 15

Oil level gauge

OPERATING MANUAL

TW45B

2. PRODUCT DESCRIPTION

TW45 version with horizontal motor position (Figure: version with machine in shaft (MRL) without brake release lever)

1

Fig. 16
Fig. 16
in shaft (MRL) without brake release lever) 1 Fig. 16 2 1 Oil charging hole /

2

1

Oil charging hole / ventilation

2

Oil drain

Note: the correct oil level is even with the center of the oil gauge. The gear is properly lubricated when it leaves the factory. Please observe during transport or any changes at the oil charging hole.

OPERATING MANUAL

TW45B

3. TRANSPORT AND STORAGE

3. Transport and storage

Packing:

TW45B without frame is delivered securely mounted to a Europallet. The traction sheave is enclosed. Machines with frames are delivered with frame disassembled. Optionally the machine may be delivered completely assembled and aligned.

For transport by sea, machine and accessories are shipped in seaworthy crates.

machine and accessories are shipped in seaworthy crates. Transport: The safety precautions are to be observed

Transport:

The safety precautions are to be observed and the machine and frame must be perfectly horizontal, both in cross and lengthwise direction.

Attention: machine is filled with oil. Make sure that it is always transported and stored in vertical position.

Transport by forklifts:

Always lift the machine, not transport pallet ! Secure machine against tilting.

Pay attention to projecting parts. Risk of injury to persons or damage to property !

parts. Risk of injury to persons or damage to property ! Transport by crane: • Do

Transport by crane:

Do not stay below suspended loads!

Lift machine without frame using transport eyebolts and rope. Hook bolts on the shaft are not suitable for handling the machine !

Secure transport rope at frame in case of machine assembled on machine frame.

Protect the machine against tilting.

Fig. 17

frame. • Protect the machine against tilting. Fig. 17 Rope fastening: fasten transport rope at eyebolts

Rope fastening: fasten transport rope at eyebolts in case of machine without machine frame. See fig. 17 or 18

Use transport eyebolts below motor with vertical motor position.

Protect handwinding wheel against damage. Ropes and chains shall not be adjacent to handwinding wheel during transport.

Vertical motor position

OPERATING MANUAL

TW45B

3. TRANSPORT AND STORAGE

Use transport eyebolts at motor and gear box housing with motor in horizontal position.

Protect handwinding wheel against damage. Ropes or chaines shall not be close to handwinding wheel during transport.

Fig. 18

Motoranordnung horizontal Horizontal motor position
Motoranordnung horizontal
Horizontal motor position

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

Top Handle with care Keep dry Do not expose to heat Do not use hand-
Top
Handle with care
Keep dry
Do not expose to
heat
Do not use hand-
held grippers
Fasten here
to heat Do not use hand- held grippers Fasten here Dimensions and weight The weight is

Dimensions and weight

The weight is indicated on a sticker on the packing. For dimensions see delivery note. For rough data see 2.3 Technical data

Examination by customer on receipt of goods

Examine the delivered parts for completeness, damage or anything strange.

Report and document shipping damage

After receipt of goods make sure that there is no damage caused during transport.

OPERATING MANUAL

TW45B

3. TRANSPORT AND STORAGE

O PERATING M ANUAL TW45B 3. T RANSPORT A ND S TORAGE Information • Immediately document
O PERATING M ANUAL TW45B 3. T RANSPORT A ND S TORAGE Information • Immediately document
O PERATING M ANUAL TW45B 3. T RANSPORT A ND S TORAGE Information • Immediately document
O PERATING M ANUAL TW45B 3. T RANSPORT A ND S TORAGE Information • Immediately document
O PERATING M ANUAL TW45B 3. T RANSPORT A ND S TORAGE Information • Immediately document

Information

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

Send the respective documents immediately to THYSSENKRUPP AUFZUGSWERKE GmbH.

Unpacking

Information

Dispose packing equipment in accordance with the environmental standards or make it available for further use.

Special transport aids and transport contrivances shall not be sent back to THYSSENKRUPP AUFZUGSWERKE GmbH but remain at the customer.

Intermediate storage

Even if the component is not mounted directly after delivery, it should be stored in dry places and protected with humidity-proof covering.

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

Note: do not damage surface coating and preservation ! Mechanical (scratches), chemical (acids, alkalines) or thermal (sparks, welding beads, heat) damages may cause corrosion and thus failure of surface protection.

Environmental conditions

Information

Surrounding at the final site of the machine (humidity, temperature) shall comply with the requirements for machine rooms. (Between +5°and +40° C according to EN 81)

OPERATING MANUAL

TW45B

4. MOUNTING OF MACHINE

4. Mounting of machine in machine room

O F M ACHINE 4. Mounting of machine in machine room General installation instructions: Installation shall
O F M ACHINE 4. Mounting of machine in machine room General installation instructions: Installation shall

General installation instructions:

Installation shall only be performed by trained and competent persons. Utmost care must be taken. ThyssenKrupp Aufzugswerke GmbH cannnot be hold liable for any damage caused by inexpert installation. Sufficient free area around the drive must be ensured for installation, maintenance and cleaning works. Sufficient lifting devices must be provided for installation works. Attention: do not perform any welding works at the drive. The drive is not suitable as connection to earth. Gear teething or bearing parts may be impaired. Attention: use all mountings available. Mounting are subjected to respective design. Ensure that air supply for cooling the drive is not affected. It must be possible to check the oil level. Place of installation / base:

Ensure that the place of installation is perfectly horizontal, with max. tolerance of 0.5 mm. The base must also be perfectly horizontal both in cross and lengthwise, verify that it is stable enough for the forces acting on the base.

Installation (machine delivered without frame or disassembled):

Remove packing, arrange machine on base. Remove surface coating at worm wheel shaft, connection and traction sheave bores. Attention: do not touch shaft sealing ring when performing any cleaning works ! Ensure proper ventilation. Do not smoke. Mount traction sheave to machine. (See chapter 7.1) Secure traction sheave by tightening the screws using torque wrench. Note tightening torque (75Nm). See chapter 8.1arrange machine on base. Remove surface coating at worm wheel shaft, connection and traction sheave bores.

Machines with machine frame and rope pulley are mounted in accordance with customer’s specification on supports, brackets, base or directly casted in plaster floor. Installation and mounting of frame supports see enclosed drawing and parts list. Attention: Mount frame in accordance with drawing using enclosed mounting elements. Observe strength and respective tightening torque. See details in chapter 8.1 In order to comply with the requirements concerning noise reduction / structure-borne noise transmission insert the isolation elements delivered between frame support and floor.casted in plaster floor. Installation and mounting of frame supports see enclosed drawing and parts list.

OPERATING MANUAL

TW45B

4. MOUNTING OF MACHINE

The number of isolation elements depends on the overall weight load. The individual isolation element should be loaded between 7000 and 12 000 N / isolation element. Arrange the isolation elements in accordance with layout drawing.

the isolation elements in accordance with layout drawing. Note: arrange the isolation elements in such a

Note: arrange the isolation elements in such a way that the load is distributed equally (the same applies to car suspended at rope pulley side). When the machine is mounted on plaster floor, coating thickness shall be 60 mm. Use isolation elements with base (80 mm high). The base part shall also be cast.

How to arrange the machine Arrange the machine in accordance with the layout drawing. Align the rope departure of the traction sheave acc. to the drawing so that it is in vertical line with the car mounting or the car rope pulley and the counterweight. When the ropes are tensioned, the machine must be arranged horizontally aligned at the base plate. Use metal plates to ensure that the base is perfectly horizontal. After roping mount the rope guards (chapter 4.1).

OPERATING MANUAL

TW45B

4. MOUNTING OF MACHINE

4.1 Mounting of rope guard

Connect rope guard and rope guard support using enclosed screws. Turn the rope guard supports in such a way that the distance between rope and rope guards is as small as possible on the side of the traction sheave where the ropes enter and leave. (1 - 2 mm)

In case of diagonal rope departure re-adapt position of rope guards to changed rope direction.

Note: align rope guards; then tighten the fastening screws at rope guard support; verify that tightening align rope guards; then tighten the fastening screws at rope guard support; verify that tightening torque is correct. Tightening torque see table 8.1 in annex.

1 2 max. 1 - 2 mm Fig. 19
1
2
max. 1 - 2 mm
Fig. 19

1

Rope guard support

2

Rope guard support

1

2

19 1 Rope guard support 2 Rope guard support 1 2 Fig. 20 Attention: If the

Fig. 20

Rope guard support 2 Rope guard support 1 2 Fig. 20 Attention: If the ropes enter

Attention:

If the ropes enter the traction sheave at any angle above the horizontal up to

a maximum of 90°(e.g. machine arranged on bottom / top beside) an

additional rope guard is required to avoid the penetration of objects between

ropes and pulleys.

If the ropes enter the traction sheave at a protected area within the machine frame, function „protection against bodily injury“ is not necessary.

OPERATING MANUAL

TW45B

4. MOUNTING OF MACHINE

4.2

Connection

Motor connection:

Observe terminal diagram at the cover of the motor connection box or terminal diagram in operating manual as well as the respective local requirements. Motor connection data see chapter 2.4 Technical data. Observe instructions of manufacturer in annex, chapter 8.6.

Fig. 21

1

2

3

4

of manufacturer in annex, chapter 8.6. Fig. 21 1 2 3 4 9 8 7 5

9

8

7

5

6

1

W2

2

U2

3

Earth connection

4

V2

5

Posistor-temperature sensor

6

Posistor-temperature sensor

7

W1

8

V1

9

U1

OPERATING MANUAL

TW45B

4. MOUNTING OF MACHINE

O PERATING M ANUAL TW45B 4. M OUNTING O F M ACHINE 30 V! 30 V!
30 V! 30 V! 30 V!
30 V!
30 V!
30 V!

Pulse encoder connection:

Connection and encoder data for encoder connection see chapters 8.3 – 8.5.

Posistor- temperature sensor (motor – thermal element) connection:

To evaluate the posistor temperature sensor integrated in the motor a control unit (motor protection device) is required. This unit is to be connected to terminals in fig. 21, pos. 5 and 6.

Holding brake for machine in machine room version (TWR), make Mayr:

The connecting line (approx. 1 m long) of the holding brake leaves the gear box at the gear flange side opposite the brake release levers. The magnet coils of the disc brake are to be connected to the black connecting line. The brake operates on a direct current supply. Polarity of the connecting coils (brown/blue) does not affect the way the brake operates. The coil voltage is indicated on the name plate. Attention: there is the risk of wear when operating the brake at lower than intended connection voltage. Further details see chapters 2.4 and 8.2.1coils (brown/blue) does not affect the way the brake operates. The coil voltage is indicated on

OPERATING MANUAL

TW45B

4. MOUNTING OF MACHINE

Holding brake for machine in shaft (MRL) make Warner:

A 6 m long 4-core connecting line with socket at the line end is enclosed. This connector is to be connected to the connector at the connecting line. The two magnet coils are to be connected to the terminal block at the opposite line end. The line cores are identified each. Cores 1 and 2 for magnetic coil C Cores 3 and 4 for magnetic coil D See fig. 26, pos. 19

Connector PHOENIX Coil C Coil D 6000 Fig. 22
Connector PHOENIX
Coil C
Coil D
6000
Fig. 22

The brake operates on a direct current supply. Polarity does not affect the way the brake operates. Correct coil voltage acc. to name plate. The brake operates on a direct current Attention: verify that connecting voltage is correct. When operating Attention: verify that connecting voltage is correct. When operating the brake at lower than intended voltage the brake may fail to open completely. This may cause wear. Further details see chapters 2.4 and 8.2.2

may cause wear. Further details see chapters 2.4 and 8.2.2 Note: there are two outputs for

Note: there are two outputs for the brake coil connection to be able to operate each braking circuit individually. This is required for inspection by notified bodies (each brake circuit is tested separately or releasing the brakes step by step in cases of emergency such as rescue of passengers.

Attention: the drive is designed for installation in shaft and does not have any brake release levers. Please observe that the owner of the lift installation must ensure that the brake may be released step by step in case of power failure.Attention:

Emergency braking system NBS (optional) :

Description and details of emergency braking system see enclosed operating manual of NBS (if required).

OPERATING MANUAL

TW45B

5. PUTTING INTO SERVICE

5.1 Putting into service

5. P UTTING I NTO S ERVICE 5.1 Putting into service Before you start putting the

Before you start putting the machine into service the following works are to be performed:

Check fastening of machine, traction sheave and frame

Check whether rope guard is mounted and distance to traction sheave adjusted

Check installation of machine, frame, base and rope departure

Secure gear housing against moving in case of lateral or diagonal rope departure

Tighten screws and secure with pre-set tightening torque (see table tightening torque 8.1)

Check gear oil level

Plastic plug in oil filling hole at gear housing removed and ventilation screw inserted and closed. Plastic plug at front side of housing removed and oil drain screw inserted and closed at height of traction sheave shaft (figures 14 to 16).

Check supply terminals, earthing of motor, ventilation and brake magnets for correct connection and fusing

Check connection (voltage, frequency) for compliance with manufacturer’s instructions

Check monitoring devices (pulse generator, thermal element) for connection and correct functioning

Check holding brake and emergency brake NBS (if available) for correct connection and functioning

Check manual release of brake(s) for correct functioning (does not apply to machine in shaft)

Check brake ventilation (for emergency evacuation, see chapter 1.2) mounted by the customer for correct functioning in case of machine in shaft (MRL)

Visibly glue direction arrows (up/down) for respective travel direction at motor (adjacent to handwinding wheel)

Remove safety, accessory and installation tools from danger zone

Note: mount disassembled traction sheave using enclosed micro- encapsulated screws. See chapter 7.1 In case the machine is disassembled for reasons of weight, transport or space, re-assemble in original assembly condition and tighten fastening elements with respective tightening torque. See table tightening torque 8.1Note:

Only use ThyssenKrupp Aufzugswerke mounting parts and components for installation and repairs. In case of disregard ThyssenKrupp Aufzugswerke GmbH cannot be hold liable.

OPERATING MANUAL

TW45B

5. PUTTING INTO SERVICE

5.2 Emergency operation

5.2.1 Drive with machine in machine room (TWR) without emergency braking system NBS:

TW45B with machine in machine room is equipped with a handwinding wheel and two brake release levers (one lever for each brake circuit). When operating both brake release levers at the same time, the disc brake opens. To rescue passengers trapped in the car, it may be necessary to move the car to the nearest landing by handwheel mechanism. When the car is opened, the car may start suddenly dependent on the load. Immediately stop turning the handwinding wheel and move the car by carefully releasing the brake release levers (galloping brake).machine room (TWR) without emergency braking system NBS: Attention: persons operating the handwinding wheel (e. g.

Attention: persons operating the handwinding wheel (e. g. "lifting the car from the moment of safety persons operating the handwinding wheel (e. g. "lifting the car from the moment of safety gear operation"), must work on a secure platform. There is the risk of injury to persons when operating emergency operation control at the same time.

5.2.2 Drive with emergency braking system NBS:

Note that emergency operation proceeding changes with emergency braking system NBS mounted on. Note that emergency operation proceeding changes Observe instructions in operating manual NBS! Material No. of operating Observe instructions in operating manual NBS! Material No. of operating manual NBS: 65 990 01 86 0 Proceeding with emergency braking system see chapters 1.3 and 2.2!

5.2.3 Drive with machine in shaft and emergency braking system (machine- room-less variant without brake release levers attached and (optionally available) brake release levers

Corresponding counter measures are to be made by manufacturer of the elevator installation to be able to rescue passengers in the case of power failure. Please note the following points:

Carefully open the electrically operated brake

Start car with weight of car / counterweight balanced and note that static friction of guides and automatic interlock of worm gear are to be overcome

Check moving speed with the brakes open to avoid the risk of safety devices against overspeed being activated.

Further details on proceeding not possible as brake operation is subjected to respective design and version of elevator installation.

OPERATING MANUAL

TW45B

5. PUTTING INTO SERVICE

5.2.4 Optionally available brake release levers for manual release operation for drives equipped with tandem disc brakes from Warner (machine-room-less variant). Use of the lever mechanism necessitates the need of directly accessible drives. (e.g. machine in shaft pit)

1. Release of single brake: (e. g. manual brake test with one brake circuit active) Attach the narrow end pieces of the two brake release levers between armature base plate and magnet coil carrier of brake. See fig. 23. Tighten both levers in direction of motor.

Fig. 23

See fig. 23. Tighten both levers in direction of motor. Fig. 23 ThyssenKrupp Aufzugswerke GmbH 48

OPERATING MANUAL

TW45B

5. PUTTING INTO SERVICE

2. Release of both brakes: (e. g. in case of emergency rescue)

Attach the two narrow end pieces of the release levers between armature disc plate and magnet coil carriers at the brake. See fig. 24 Tighten both levers in direction of motor. When operating both brake release levers at the same time, the two disc brakes open. Details on emergency rescue of trapped persons see proceeding in chapter 5.2.1.

Fig. 24

of trapped persons see proceeding in chapter 5.2.1. Fig. 24 Attention: remove brake release levers before
of trapped persons see proceeding in chapter 5.2.1. Fig. 24 Attention: remove brake release levers before

Attention: remove brake release levers before the machine is switched on. Never start operation with the brake release levers attached!

OPERATING MANUAL

TW45B

6. SERVICING

6.1 Servicing of machine

M ANUAL TW45B 6. S ERVICING 6.1 Servicing of machine Servicing interval: servicing of the machine

Servicing interval: servicing of the machine should be carried out at least once a year, preferably in the course of the general lift servicing.

Note: installation and servicing works shall only be carried out by trained and qualified personnel.

These persons must know and observe the respective regulations and requirements for lift installations as well as the accident prevention regulations.

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

 

⇓⇓⇓⇓

Check oil level and re-fill, if required

2.7

Change oil at the end of oil change interval

2.7

Clean ventilation screw and opening at gear housing

2.7

Check gear and bearings for leakage

 

Check brake and air gap (max. 1.7 mm with Mayr brake) (max. 0.6 mm per air gap with Warner brake)

6.2

Check holding brake and manual release for correct functioning

6.2

Check brake deceleration

6.2

Check worm toothing for wear

 

Check circumferential flank clearance between worm shaft and worm wheel; 0.05 mm to 0,12 mm at 20°C (max. 1.5 mm)

6.3

Check traction sheave groove profile for damage and wear

 

Check screws of traction sheave fastening for correct tightening

7.1

8.1

Check machine, supports and rope pulley supports for correct fastening with machine mounted on machine

2.5

Check grooves of rope pulleys for damage and wear

 

Check electrical connections for correct functioning and test for safety

4.2

Check protective and safety equipment and test for correct functioning and adjustment

 

Notes on lubrication (oil change, quantity, oil change interval) see chapter 2.7

OPERATING MANUAL

TW45B

6. SERVICING

6.2 Checking of drive brake

Inspection interval: once a year in the course of the general lift servicing

1.) Functional test of holding brake

electrical test:

power supply off

brake closed

power supply on

brake released

mechanical test (only possible in case of machine in machine room (TWR):

press both release levers

brake released

press each release lever separately

brake closed

When the brake opens, the armature disc moves away from the friction disc, and the air gap is closed. See fig. 24 / 26

2.) Inspection of wearing condition:

Wear at the friction linings of the rotor is caused by improper setting or defects. When wearing limit is reached, replace friction linings or disc brake. Inspection of wearing condition by checking the air gap:

The maximum permissible air gap is:

1.7 mm

for Mayr brake (TWR version)

2 x 0.6 mm

for Warner brake (MRL version)

Description of the inspection sequence see 7.2

3.) Inspection of deceleration

a) Test of one single brake circuit. To check the brake circuits for

correct operation each brake circuit must be inspected separately. The brake shall be checked with one brake circuit effective only.

shall be checked with one brake circuit effective only. Note: holding brake of lifts equipped with

Note: holding brake of lifts equipped with an emergency braking system NBS can only be checked with the emergency braking system NBS out of service ! Description see operating manual Emergency braking system NBS.

OPERATING MANUAL

TW45B

6. SERVICING

Before testing:

Inspection signs must be made available at the landing doors during inspection work at the lift.

Close the doors acc. to the rules.

Make sure that the car is empty.

The car must be at least two landings below respective terminal landing (seen from run direction).

Car empty Car loaded with rated load

run direction up; run direction down.

The single brake circuits are tested by energizing the single brake coils with 90 V / 45 V excitation / withstand voltage. When a single circuit is tested, the brake of the 2. brake circuit must be released during the braking process. Therefore, the magnet coil of the 2. brake circuit is energized with withstand voltage.

Attention: should the lift move after release of one brake circuit or not decelerate sensibly during should the lift move after release of one brake circuit or not decelerate sensibly during the braking process, the energized coil must be switched off immediately. The dual circuit braking function is not guaranteed. Check brake !

Test sequence: inspection of the brake deceleration to be made for each brake circuit individually

Connect deceleration measuring device

Activate normal run (brake to be tested is released)

Activate emergency stop as soon as rated speed is reached (brake to be tested closes)

Determine deceleration for 1. brake circuit using a measuring device

Compare result of the measurement and reference value

Remove continuous voltage supply at continuously open 2. brake circuit and connect to 1. brake circuit.

Connect test terminal at deceleration measuring device to 2. brake circuit.

Repeat test at 2. brake circuit.

Deceleration values:

Minimum deceleration for one brake circuit

0.4 m/s²

Minimum deceleration for both brake circuits

1.0 m/s²

Attention: when the single brake test is terminated, the continuous control voltage at the 2. brake when the single brake test is terminated, the continuous control voltage at the 2. brake is to be removed, and the original condition established (operation of both brakes).

OPERATING MANUAL

TW45B

6. SERVICING

Simple inspection of brake deceleration without measuring device:

(this inspection method only applies to travel heights 7m and control point observable from operation point)

7m and control point observable from operation point) Inspection sequence: • The measures described in

Inspection sequence:

The measures described in „before testing“ are to be observed.

Provide terminal for continuous power supply at brake circuit of the 2. brake coil. The car loaded with max. permissible rated load must be at least two landings above bottom-most.

The ropes shall be marked level at control point height. The control point shall be easily visible from the brake operation position. (Marking at bracket height, for example)

Move the car upwards to nearest landing.

Energize 2. brake with continuous control voltage during inspection process. Note: brake shall not be de-energized when the main switch is switched off, as otherwise both brakes will become effective.

Move car downwards at normal speed. Observe control point and ropes from brake operation position.

Switch off main switch as soon as rope marking reaches the control point.

Measure distance between rope marking and control point. This distance is equivalent to the stopping distance of the tested brake circuit.

Compare determined stopping distance and reference value.

Stopping distance The max. stopping distance for single brake circuit shall not exceed:

In case of installations with V N 1,0 m/s 1,25 m, with V N 1,25 m/s 2,0 m (These values apply for simple inspection only)

Disconnect continuous voltage supply and connect to tested brake coil.

Repeat described sequence with 2. brake circuit.

Attention: when the brake test is terminated, the original condition is to be established (operation of when the brake test is terminated, the original condition is to be established (operation of both brake coils at the same time).

b) Inspection of both brake circuits

When single circuits are inspected, test of both brake circuits follows by activating emergency stop. The deceleration value must considerably exceed the value measured during single inspection!

Remove inspection signs when inspection and service works are terminated.

OPERATING MANUAL

TW45B

6. SERVICING

6.3 Checking of flank clearance

TW45B 6. S ERVICING 6.3 Checking of flank clearance The flank clearance of the worm gear

The flank clearance of the worm gear (between worm wheel and worm shaft)

increases due to wear. As soon as the wear limit (flank clearance) of 1.5 mm is reached safe

operation of the 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 ) = 95 mm for TW 45B)

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. Do not move the worm wheel since this may cause falsified measurement results (bearing clearance).

Read dial gauge deflection (ME).

Calculate flank clearance acc. to the equation below.

Perform measurement at three different points at least!

Fig. 23

Dial gauge Traction sheave Worm wheel
Dial gauge
Traction sheave
Worm wheel

M

= measuring radius

ME

= measured result

r = radius – worm wheel all dimensions in mm

Flank clearance =

ME

*

r

 

M

OPERATING MANUAL

TW45B

6. MAINTENANCE/ SERVICE

6.4 Checking for escaping grease / oil

Examine the areas around the brake disc and armature base plate for traces of oil.

Contamination level

Procedure

No escaping oil determined

Check regularly within the framework of maintenance

Every 3 months (6 months if elevator used infrequently, < 50 000 runs per year)

If a large amount of escaping oil is determined or oil is escaping from the brake disc / brake linings

Clean the drive and, if necessary, the brake and carry out short-term repairs Before continuing operation until modification, run a brake test. If the braking effect is inadequate, shut down the installation.

Repair after 4 weeks at the latest

OPERATING MANUAL

TW45B

6. MAINTENANCE/ SERVICE

Diagram of the horizontal version Shaft sealing Bearing cover ring ÖÖLÖÖLLL FeFettFettFetttt Armature base
Diagram of the horizontal version
Shaft sealing
Bearing cover
ring
ÖÖLÖÖLLL
FeFettFettFetttt
Armature base
plates
Brake discs
Fig. 6.4.1

OPERATING MANUAL

TW45B

7. MAINTENANCE

7.1 Replacing of traction sheave - installation

Disassembly:

7.1 Replacing of traction sheave - installation Disassembly: • Switch off power supply, secure car and

Switch off power supply, secure car and counterweight.

Remove rope guard plates.

Remove load from traction sheave; discard ropes.

Secure traction sheave with lifting device.

Loosen screws on mounting disc of traction sheave; put screws in outer hole circle of disk and loosely screw in traction sheave hub.

Place a washer approx. 5 – 10mm thick between shaft end and disk.

Tlighten screws uniformly and remove traction sheave from motor shaft.

Assembly:

and remove traction sheave from motor shaft. Assembly: • Clean shaft end and traction sheave holes;

Clean shaft end and traction sheave holes; never make any dimensional changes in featherkey, groove, shaft or drilled holes. Check whether the contact surfaces are free from visible damage.

Never grease or oil shaft and holes.

Carefully fit and screw new traction sheave to conical end of motor wheel shaft.

Bring position of featherkey and groove in line.

Push traction sheave on motor shaft.

Screw-connect disk at inner hole circle using enclosed screws (micro-encapsulated) and detent edged washers. Tighten screws uniformly in several operations.

Attention danger: the traction sheave may work loose if assembled improperly.

Observe screw strength 8.8 and tightening torque = 75 Nm !

Fig. 24

1 2 3 4 5 2 5
1
2
3
4
5
2
5

1