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A company

of ThyssenKrupp
Elevator
ThyssenKrupp Aufzugswerke

Operating Manual
Machine TW45B
Ein Unternehmen
von ThyssenKrupp ThyssenKrupp Aufzugswerke
Elevator

Anlageblatt zur Betriebsanleitung Maschine TW45B


Appendix to instruction manual machine TW45B
Annexe auxÄnderung
Betrifft: instructions
an de
denservice
Bremsenmachine
2x50NmTW45B
11.10.2007
Subject: Modification of brakes 2x50Nm
Objet: Modification des freines 2x50Nm

Anschluss TCM / TCI Steuerungen Bremsansteuerung bei nicht TCM / TCI


Connection TCM / TCI controls Brake control if not TCM / TCI
Raccordement manœuvres TCM / TCI Commande de frein en cas de non 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

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
an der Maschine an den Bremsen fixieren
Bremslüfthebel spreizen (Bremsen) einbauen attach to the brakes
Spread brake release lever install at the machine fixer aux freines
Écarter levier de desserrage (brakes)
de frein monter à la machine
(freines)

Beide Bremslüfthebel sind


Rändelschraube festziehen angebracht Bremslüfthebel fixiert
Both brake release levers are
Tighten knurled thumb fixed
Fixed brake release lever
screw Tous les deux leviers de Levier de desserrage de
Serrer vis moletée desserrage de frein sont fixés frein fixé

Beide Bremslüfthebel gleichmäßig in Richtung Handrad ziehen einzelne Bremse lüften


Pull both brake release levers equally to the handwinding wheel release single brake
Tirer régulièrement tous les deux leviers de desserrage de frein vers desserer frein
le volant de dépannage 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.
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.

ThyssenKrupp Aufzugswerke GmbH


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 65
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
ThyssenKrupp Aufzugswerke GmbH
9 Version 05/2009
OPERATING MANUAL TW45B 1. SAFETY

1.1 Explanation of symbols used

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

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 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!

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

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.

ThyssenKrupp Aufzugswerke GmbH


10 Version 05/2009
OPERATING MANUAL TW45B 1. SAFETY

1.2 General safety information

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.

ThyssenKrupp Aufzugswerke GmbH


11 Version 05/2009
OPERATING MANUAL TW45B 1. SAFETY

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.)

ThyssenKrupp Aufzugswerke GmbH


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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 before you start operation.

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.

Emergency brake NBS: 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 release. 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.

ThyssenKrupp Aufzugswerke GmbH


13 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

2.1 Description of machine TW45B

1
2

12

4
11

10 5

4 6

8
7
7

Fig. 1

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

ThyssenKrupp Aufzugswerke GmbH


14 Version 05/2009
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.

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.

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.

ThyssenKrupp Aufzugswerke GmbH


15 Version 05/2009
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.

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.

ThyssenKrupp Aufzugswerke GmbH


16 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

Note: 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 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.

ThyssenKrupp Aufzugswerke GmbH


17 Version 05/2009
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

Motor connection Oil drain

Pulse generator
200

Fig. 3

approx. 991

Manual release mounting

ThyssenKrupp Aufzugswerke GmbH


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OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

TW45B horizontal motor position


(version for machine in machine room (TWR) with NBS)

B =115

NBS mounting

119

Fig. 4

392

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

ThyssenKrupp Aufzugswerke GmbH


19 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

TW45B (TWR) vertical motor position

Brake release lever

Oil level
gauge glass

Oil drain

Fig. 5 Fig. 6

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

ThyssenKrupp Aufzugswerke GmbH


20 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

Fig. 7

Fig. 8

ThyssenKrupp Aufzugswerke GmbH


21 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

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

∅DT / 2 742,8
155 kproj = 438

285

100
200
27

1) 200
1) Thread M16 x 25 deep

Fig. 9

Fig. 10

Version for machine in shaft (MRL) without rope guard

ThyssenKrupp Aufzugswerke GmbH


22 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

TW45B version for machine in shaft (MRL) rear view

1)

1)
1)

1)

393

1)

1)

Fig. 11

1) Thread M16 x 25 deep

ThyssenKrupp Aufzugswerke GmbH


23 Version 05/2009
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


vrat 1,0 ≤ vn ≤ 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

ThyssenKrupp Aufzugswerke GmbH


24 Version 05/2009
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 2 surface disc brake in
radial armature base plate tandem arrangement
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
[W] 83 with retentive voltage 65 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 without
brake circuit
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)

ThyssenKrupp Aufzugswerke GmbH


25 Version 05/2009
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 [Nm] 70 70 ⇒ 63 88
torque
Allowable starting [A] 20 32
current:
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 WDG100-38-1024/4096 TTL
(standard)
Real value generator WDG100-38-1024 HTL
(special) WDG100-38-1024 sine/cosine
1
) For use in the shaft (MRL)

The electrical data applies to the following environmental conditions:


• max. altitude 1000 m above sea level
• max. temperature + 40 °C at max. 50% air humidity
• max. relative humidity 70 % at 20 °C
If the conditions listed above are exceeded, derating as set out in VDE0530
applies.

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).

ThyssenKrupp Aufzugswerke GmbH


26 Version 05/2009
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 [mm] 7 ∗∅ 8 7 ∗∅ 8 5*∅ 8
–z∗d 6 ∗ ∅ 10 6 ∗ ∅ 10
6 * ∅ 11 6 * ∅ 11
5 * ∅ 12
Groove type/ [°] acc. to order
undercut angle:
Weight: [kg] 45 55 30
Material: specially alloyed EN-GJL 250
(HB 190 to 230)

Note: Emergency braking system NBS see separate operating


manual NBS.

ThyssenKrupp Aufzugswerke GmbH


27 Version 05/2009
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

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)

ThyssenKrupp Aufzugswerke GmbH


28 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

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
X1 = distance 1 between rope departure and outer edge of frame
X2 = distance 2 between rope departure and outer edge of frame
With frame model 2 fig. 13
X1 = distance 1 between axle center of rope pulley and bearing surface
of frame support at machine frame
X2 = distance 2 between rope departure and outer edge of frame
support

Y1 = vertical axle distance between traction sheave and deflection


pulley
Y2 = vertical distance between deflection pulley center and support
bearing
Z1 = 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)

ThyssenKrupp Aufzugswerke GmbH


29 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

Data machine frame model 1

Shown in fig. 12

Traction Arrangement of machine


sheave left right
diameter
x1 min x1 max x2 min x2 max
DT
440 [mm] 52 342 52 342

520 [mm] 52 262 52 262

Weight: machine frame 1 without supports and deflection pulley


approx. 50 kg

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.
x1 or x2 is the distance between rope departure and outer edge of machine
frame dependent on the traction sheave ∅.

ThyssenKrupp Aufzugswerke GmbH


30 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

Data machine frame model 2


Shown in fig. 13

Rope distance measurements (ASL) and angle of wrap α


(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


diameter
Maximum angle of wrap
DT
ASLmin [mm] and αmax [°]
[mm]
With deflection pulley ∅SR [mm]
360 450
ASLmin αmax ASLmin αmax
440 582 167 566 168
520 662 167 616 170

Traction sheave Maximum rope distance car – counterweight and


diameter
Minimum angle of wrap
DT
ASLmax [mm] and αmin [°]
[mm]
with deflection pulley ∅SR [mm]
360 450
ASLmax αmin ASLmax αmin
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


incl. deflection pulley ∅ 450 approx.170 kg

ThyssenKrupp Aufzugswerke GmbH


31 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

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

ThyssenKrupp Aufzugswerke GmbH


32 Version 05/2009
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

ThyssenKrupp Aufzugswerke GmbH


33 Version 05/2009
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):

2. Name plate of gear (Lift Equip)

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)

ThyssenKrupp Aufzugswerke GmbH


34 Version 05/2009
OPERATING MANUAL TW45B 2. PRODUCT DESCRIPTION

2.7 Lubrication

Lubricator Oil change interval Motor position Quantity


Synthetic gear oil SM1 First change after 4 years, Vertical approx. 5.5 liter
TRIBOL 800 / ISO460 thereafter at a period of 8 horizontal approx. 5,5 liter
years

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.
Version with vertical motor position Version with horizontal motor position
ventilation ventilation
oil charging hole oil charging hole

Fig. 14 Oil drain Oil level gauge Fig. 15 Oil level gauge

ThyssenKrupp Aufzugswerke GmbH


35 Version 05/2009
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
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.

ThyssenKrupp Aufzugswerke GmbH


36 Version 05/2009
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.

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 !

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.

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.

Fig. 17
Vertical motor position

ThyssenKrupp Aufzugswerke GmbH


37 Version 05/2009
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

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

Top Handle with care Keep dry

Do not expose to Do not use hand- Fasten here


heat held grippers

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.

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38 Version 05/2009
OPERATING MANUAL TW45B 3. TRANSPORT AND STORAGE

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)

ThyssenKrupp Aufzugswerke GmbH


39 Version 05/2009
OPERATING MANUAL TW45B 4. MOUNTING OF MACHINE

4. Mounting of machine in machine room

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 8.1

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.

ThyssenKrupp Aufzugswerke GmbH


40 Version 05/2009
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.

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).

ThyssenKrupp Aufzugswerke GmbH


41 Version 05/2009
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 torque is correct.
Tightening torque see table 8.1 in annex.

1
2

max. 1 - 2 mm
Fig. 19 Fig. 20
1 Rope guard support
2 Rope guard support

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.

ThyssenKrupp Aufzugswerke GmbH


42 Version 05/2009
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.
1 2 3 4

Fig. 21
9 8 7

1 W2
2 U2
3 Earth connection
4 V2
5 Posistor-temperature sensor
6 Posistor-temperature sensor
7 W1
8 V1
9 U1

ThyssenKrupp Aufzugswerke GmbH


43 Version 05/2009
OPERATING MANUAL TW45B 4. MOUNTING OF MACHINE

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 8.2.1

ThyssenKrupp Aufzugswerke GmbH


44 Version 05/2009
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 PHOENIX
connector at the connecting line.
The two magnet coils are to be connected to Coil C Coil D
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

The brake operates on a direct current


supply.
Polarity does not affect the way the brake
operates.
Correct coil voltage acc. to name plate.
Attention: verify that connecting voltage is 6000
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

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.
Fig. 22
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.

Emergency braking system NBS (optional) :


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

ThyssenKrupp Aufzugswerke GmbH


45 Version 05/2009
OPERATING MANUAL TW45B 5. PUTTING INTO SERVICE

5.1 Putting into service

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 8.1
Only use ThyssenKrupp Aufzugswerke mounting parts and components for
installation and repairs. In case of disregard ThyssenKrupp Aufzugswerke
GmbH cannot be hold liable.

ThyssenKrupp Aufzugswerke GmbH


46 Version 05/2009
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).

Attention: 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.
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.

ThyssenKrupp Aufzugswerke GmbH


47 Version 05/2009
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

ThyssenKrupp Aufzugswerke GmbH


48 Version 05/2009
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

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

ThyssenKrupp Aufzugswerke GmbH


49 Version 05/2009
OPERATING MANUAL TW45B 6. SERVICING

6.1 Servicing of 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) 6.2
(max. 0.6 mm per air gap with Warner brake)
• 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 6.3
worm wheel; 0.05 mm to 0,12 mm at 20° C (max. 1.5 mm)

• 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 2.5
fastening with machine mounted on machine

• Check grooves of rope pulleys for damage and wear

• Check electrical connections for correct functioning and test for 4.2
safety

• 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

ThyssenKrupp Aufzugswerke GmbH


50 Version 05/2009
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.

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.

ThyssenKrupp Aufzugswerke GmbH


51 Version 05/2009
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 ➾run direction up;
Car loaded with rated load ➾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 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 is to be removed, and the original condition
established (operation of both brakes).

ThyssenKrupp Aufzugswerke GmbH


52 Version 05/2009
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)

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 VN 1,0 m/s ≥ 1,25 m, with VN 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 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.

ThyssenKrupp Aufzugswerke GmbH


53 Version 05/2009
OPERATING MANUAL TW45B 6. SERVICING

6.3 Checking of flank clearance

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!

Dial gauge
Traction sheave

Worm wheel

Fig. 23

M = measuring radius Flank clearance = ME * r


ME = measured result M
r = radius – worm wheel
all dimensions in mm

ThyssenKrupp Aufzugswerke GmbH


54 Version 05/2009
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 Every 3 months
framework of maintenance (6 months if
elevator used
infrequently, <
50 000 runs per
year)
If a large amount of Clean the drive and, if Repair after 4
escaping oil is determined necessary, the brake and weeks at the
or oil is escaping from the carry out short-term repairs latest
brake disc / brake linings Before continuing operation
until modification, run a brake
test. If the braking effect is
inadequate, shut down the
installation.

ThyssenKrupp Aufzugswerke GmbH


55 Version 05/2009
OPERATING MANUAL TW45B 6. MAINTENANCE/ SERVICE



Diagram of the horizontal version

 Shaft sealing
 Bearing cover ring












 ÖL


  Fett

 
 Armature base
 plates
 Brake discs
 Fig. 6.4.1

ThyssenKrupp Aufzugswerke GmbH


56 Version 05/2009
OPERATING MANUAL TW45B 7. MAINTENANCE

7.1 Replacing of traction sheave - installation

Disassembly:
• 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:
• 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 !
1 2 3 4

1 Fastening screws
2 Forcing screw / hole
3 Traction sheave
4 Mounting disk
5 Rope guard plate

Fig. 24
5 2 5
• Remove securing devices at traction sheave with lifting device
• Replace ropes
• Mount and align rope guard plates
• Remove securing devices at car and counterweight

ThyssenKrupp Aufzugswerke GmbH


57 Version 05/2009
OPERATING MANUAL TW45B 7. MAINTENANCE

7.2 Replacing of motor – installation


a) version for machine in machine room (TWR) with Mayr brake

Disassembly :
• Switch off power supply, secure car and counterweight.
• Secure motor with lifting device.
• Disconnect electrical terminals and connecting lines to motor.
(Motor, encoder and brake connections)
• Remove mounting nuts at housing flange; carefully remove motor from
coupling; put motor down.
• Loosen set screw (fig. 25, pos.5); remove coupling half (fig. 25 pos. 2 –
hub 2) from motor shaft end using pull-off device.

Assembly:
• Make sure that replacement motor is available; compare motor data.
• Warm up coupling half to temperature of approx. 200°C and push
shaft end on replacement motor. Secure with set screw.
See to it that the coupling half claws project the shaft end. The claw
bottom must be at the level of the shaft end.
• Secure replacement motor with lifting device.
• Lift motor with lifting device and bring motor, coupling and housing
flange in line.
• Turn motor shaft and bring slightly greasy coupling halves in line.
(Tooth in line with gap). The flexible gear ring (fig. 25 pos. 3) must be
between the two coupling halves.)
• Connect motor and gear coupling.
• Turn motor and bring mounting holes and threaded bolts at gear flange
in line.
• Push on motor, until the motor face is adjacent to gear flange or flange
ring.
• Screw motor to gear flange with nuts and tighten uniformly in several
operations. Observe tightening torque. (See table with tightening
torques 8.1 in annex)
• Inter-connect lines and terminal box at motor; connect electrical
connections acc. to terminal plan in chapter 4.2.
• Inter-connect brake connection, encoder connection and control.
• Check braking system for correct functioning before startup.

Note: see installation and connection instructions of brake manufacturer in


chapter 8.2.

b) Version for machine in shaft (MRL) with Warner brake


To replace the motor repeat above steps and see fig. 27.
Remove set screw (fig. 27, pos.2) before you remove the coupling half.

ThyssenKrupp Aufzugswerke GmbH


58 Version 05/2009
OPERATING MANUAL TW45B 7. MAINTENANCE

7.3 Replacing of brake with machine room version


(TWR)

Measure

Fig. 25
Air gap

1 Hub 1 11 Cheese-head screw (4x)


2 Hub 2 12 Pressure spring (4x)
3 Gear ring 13 Pressure spring (4x)
4 Set screw 14 Release lever 1
5 Set screw 15 Release lever 2
6 O ring 16 Cheese-head screw (4x)
7 Coil carrier with magnet coil 17 Cheese-head screw (2x)
8 Two-piece armat.base plate 18 Damping elements (6x)
9 Rotor 19 Connect. cable appr. 1m long
10 Socket (4x) 20 Screw

Replacing of dual-circuit disk brake (Mayr)


To replace brake proceed as follows:
• Remove motor as described in chapter 7.2
• Disconnect connecting cable (19)
• Remove screws (16), remove release levers (14) and (15)
• Remove gear ring (3)
• Remove screws (11), pull off brake

ThyssenKrupp Aufzugswerke GmbH


59 Version 05/2009
OPERATING MANUAL TW45B 7. MAINTENANCE

• Loosen set screw (4), remove hub with rotor (9) from worm shaft
• Put hub 1 of new brake with mounted rotor onto worm shaft end
(note mounting direction)
Attention: mechanical impacts onto the worm shaft will damage the rolling
bearings.
• To assemble brake, repeat steps in reverse order
• Mount motor with mounted hub at drive, connect connections
See to it that:
• Tightening torque of screws fig. 25 pos. 11 : 22 Nm
• Tightening torque of screws fig. 25 pos. 16 : 6 Nm
• Secure screws (16) with Loctite 213
• Check air gap
• Check brake release (the rotor must be able to be turned in an energized
condition of the brake free of brake torque using the handwinding wheel,
fig. 26 pos. 2)
Note: the emergency braking device NBS must be released during testing.
Screw release screws at NBS in. See operating manual NBS.
Air gap check: put a feeler gauge between armature disc (3) and magnet
coil carrier (4) and check air gap (7). Repeat several times at the
circumference.
The brake magnets must be de-energized. (Brake de-energized).
The air gap of new linings should be 0.35-0.45 mm.
See 6.2 Checking of drive brake

1 2 3 4 5 6

1 Gear housing
2 Rotor with brake linings
3 Armature disk
4 Magnet coil carrier
5 Brake release lever
6 Motor flange
7 Air gap

Fig. 26

ThyssenKrupp Aufzugswerke GmbH


60 Version 05/2009
OPERATING MANUAL TW45B 7. MAINTENANCE

7.4 Replacing of brake with shaft version (MRL)


Brake (from Warner) without brake release levers and 2 rotors

Air gap at coil carriers

7 8 9 10 11 12 13 14 15 16

6
5
4

3
2

Fig. 27

22 21 20 19 18 17

1 Motor shaft 12 Rotor 2


2 Set screw 13 Bearing cover
3 Coupling half 14 Cheese-head screw (4x)
4 Armature disk D 15 Shaft sealing ring
5 Magnet coil carrier D 16 Gear housing
6 Cheese-head screw (3x) 17 O ring (3x)
7 Motor flange 18 Worm shaft
8 Flange ring 19 Brake connection
9 Rotor 1 20 Retaining washer
10 Magnet coil carrier C 21 Coupling hub
11 Armature disc C 22 Flexible gear ring

ThyssenKrupp Aufzugswerke GmbH


61 Version 05/2009
OPERATING MANUAL TW45B 7. MAINTENANCE

Do not perform any work at the brake without observing the instructions of
the manufacturer in chapter 8.2.2.

Note: when the air gap reaches the maximum value (0.6 mm/gap) or the
brake is defective, it must be completely replaced.

Disassembly:
• Switch off power supply and secure drive against unintentional switching
on; secure car and counterweight
• Disconnect brake and motor connections; remove motor
• Remove flexible coupling
• Remove retaining washer at worm shaft front (pos. 20)
• Secure brake package using enclosed lockings screws. The respective
mounting holes are in the hole circle of the fastening screws.
Attention: before you loosen the fastening screws, secure brake unit with
enclosed two screws M6 x 80 K8 with red screw head.
Highly pre-tensioned pressure springs are installed between armature base
plate and coil carrier. These parts may burst in case the brake unit is not
secured.
• Unscrew cheese-head screws pos. 6.
• Remove secured brake unit incl. coupling hub from worm shaft (pos. 18)
using pull-off device screw-connected to front coupling hub by two M5
screws.

Assembly:
• Pull new brake unit up onto worm shaft. Align borings with the brake
energized (electrically released).
• Bring fastening screws and thread in bearing cover in line and loosely
screw.
• Screw-connect coupling hub and worm shaft using retaining washer
pos. 20, cheese-head screw M12 x 25 8.8 and retaining ring. (75 Nm)
• Lock fastening screws pos. 6 with Loctite 243 and tighten with required
tightening torque. (9 Nm)
• Remove locking screws for brake assembly.
• Put flexible gear ring in coupling hub.
• Mount motor to gear housing; bring motor coupling and brake in line by
turning the motor shaft.
• Tighten motor fastening screws, connect brake and motor.
Check air gap between magnet coil carrier and armature base plates. Repeat
several times at the circumference.

Attention: check brake for correct functiong before it is released for lift
operation.

ThyssenKrupp Aufzugswerke GmbH


62 Version 05/2009
OPERATING MANUAL TW45B 8. ANNEX

8.1 Tightening torque – Strength

Attention: verify that screw strength and tightening torque in below table are
observed when work is performed on the machine or parts exchanged.
Secure non-microencapsulated screws against unintentional working loose
by placing washers under and seal with Loctite 243 or the like.
Observe tightening torque and tighten screws using torque wrenches !
The values given apply to the following applications described below. For
motor and connection see instructions of the manufacturer in chapter 8.6.
Below table applies to the remaining fastenings without specification.
DIN/ Tightening
Stren- ISO torque
gth
[Nm]

Disk on worm wheel shaft


Cheese-head screw M16 * 40 micro-encapsulated 8.8 4762 75
Detent edged washer SK M16

Motor at gear flange


Locking screw M12 * 25 8.8 938
Lock washer S12
Counternut M12 75

Brake housing at gear flange


Cheese-head screw M8 * 75 (fig. 24, pos.11) 8.8 4762 22

Release lever at brake housing


Cheese-head screw M5 * 12 (fig. 24, pos.16) 8.8 4762 6

Handwinding wheel at motor shaft


Lock washer S12
Cheese-head screw M12 * 35 8.8 4762 75
Clamping sleeve 4 * 10 1481

Bearing bracket at housing


Cheese-head screw M10 * 30 micro-encapsulated 8.8 40

Pulse encoder at ventilation grid


Clips nut M4
Cheese-head screw M4 * 8 8.8 84
Lock washer S4

ThyssenKrupp Aufzugswerke GmbH


63 Version 05/2009
OPERATING MANUAL TW45B 8. ANNEX

Cheese-head screws ISO 4762 (DIN 912)


Hexagon bolts ISO 4014 / 4017 (DIN 931 / 933)

Dimension Tightening torque MA (Nm)


Strength 8.8 10.9 12.9
M4 2,6
M5 5,3
M6 9 12 15
M8 23 30 35
M10 45 60 75
M12 75 110 130
M16 190 270 320
M20 370 520 620
M24 640 900 1100

Note: use micro-encapsulated screws once only.

Only use mounting parts and components from ThyssenKrupp


Aufzugswerke GmbH. In case of disregard ThyssenKrupp
Aufzugswerke GmbH cannot be hold liable.

ThyssenKrupp Aufzugswerke GmbH


64 Version 05/2009
OPERATING MANUAL TW45B 8. ANNEX

8.2 Blocking clamp

Each machine is equipped with a blocking clamp corresponding to the


respective traction sheave (rim width and design)

Use of blocking clamp:


Use the rope clamp to secure the ropes and prevent rope slip or secure
the car / counterweight (release from safety gear operation).

Note: install the two-piece rope clamp on the ropes. Clamp and tighten
clamp screwing accordingly.

4 5

3 6

2 7

Fig. 28
Rope clamp mounting at traction sheave

1 Traction sheave
2 Ropes
3 Pressure piece
4 Washer
5 Hexagon nut
6 Spacer
7 Clamp clip

Attention: remove blocking clamp when installation works are terminated.


Disregard will damage the installation.

ThyssenKrupp Aufzugswerke GmbH


65 Version 05/2009
6000
Overview: the following encoders are available for TW45B
1. 1024 - (standard version) / 4096 - TTL (optional)
for v < 1.5 m/s with 1024 pulses material number 9950 000 6021
for v ≥ 1.5 m/s with 4096 pulses material number 9950 000 6022
Use cable of 10 m length, SUB-D 9 tab and locking lever acc. to
DIN 46342 for connection

Connector assignment Electrical data:


Connection Pin Colour Power supply: 5 V DC
Minus 7 white Power consumpt.: max. 60 mA
Plus 9 brown Output: push-pull
Channel A 2 green Load: max. 40 mA
Channel B 3 yellow Signal level at 20 mA:
H > 3.6 VDC
Zero pulse 5 grey L < 1.2 VDC
Channel A inv. 1 red Pulse frequency: max. 200 kHz
Channel B inv. 4 black Circuit protection: no
Zero pulse inv. 6 violet
Shield 8+housing black

Please note instructions of the manufacturer in chapters 8.4 – 8.5

2. 1024 HTL (optional)-


with 1024 pulses material number 00 990 16 03 0
Connection by insulated cable of 10 m length with end sleeves.

Connector assignment Electrical data:


Connection Colour Power supply: 10 - 30 V DC
Channel A green Power consump.: max. 60 mA
Channel B yellow Channels: A, B, N, ABN inv.
Channel N grey Output: HTL- differential driver
Channel A inv. red Load: max. 40 mA
Channel B inv. black Signal level: at 20 mA
Channel N inv. violet H > UB – 2,5 VDC
Mass yellow L > 2,5 VDC
Plus 15 V brown Pulse frequency: max. 200 kHz
Minus white Circuit protection:: yes
Shield cord Control output: NPN OC, 10 mA
Control output: rose Umax. = 30 VDC
Cable length: max. 10 m
Longer cables available. Please contact manufacturer.
Please note instructions of the manufacturer in chapters 8.4 – 8.5
3. 1024 – Sine / Cosine - HTL (optional)-
with 1024 pulses material number 00 990 19 03 0
Connection by insulated cable of 10 m length with end sleeves.

Connector assignment Electrical data:


Connection Colour Power supply: 4.75– 5.5 V DC
Channel +A green Power consump.: max. 100 mA
Channel +B grey without load
Channel +N black Channels / output: sine, cosine, N
Channel - A yellow Output load: min 120 Ohm
Channel - B rose Terminal resistor between + and
Channel - N violet - outputs.
Plus 5 V brown Signal level: 1 Vss +/- 25 %
Minus white Max. frequency (-3dB): 100 kHz
Shield cord Circuit protection: no
Control output: conductive when defective
Cable length: max. 150m at <260pF/m
Design acc. to DIN VDE 0160

Please note instructions of the manufacturer in chapters 8.4 – 8.5


Part No. 9950 000 6021 mit 1024 Imp.
Part No. 9950 000 6021 mit 4096 Imp.
Part No. 00 990 16 03 0 with 1024 pulses
Part No. 00 990 19 03 0 mit 1024 Imp.
ThyssenKrupp Aufzugswerke GmbH
Tightening torque specified by the manufacturer (Siemens)

Applies to specified works to be performed at motor and motor connections.

Fig.1

Tightening torque for screwing of electrical connections – junction plate


connections (except for terminal strips)

Thread ∅ M4 M5 M6 M8 M10 M12 M16


min. [Nm] 0,8 1,8 2,7 5,5 9 14 27
max. [Nm] 1,2 2,5 4 8 13 20 40

Fig.2

Tightening torque for metal (I) and plastic (II) screwings

Thread ∅ M12x1,5 M16x1,5 M20x1,5 M32x1,5 M50x1,5


M25x1,5 M40x1,5 M63x1,5
I min. [Nm] 4 5 6 8 10
I max. [Nm] 6 7,5 9 12 14
II min. [Nm] 2 3 4 5 6
II max. [Nm] 3,5 4 5 7 8

Fig.3

Tightening torque for screws at electrical terminal blocks, bearing brackets


and protective conductor screwings

Thread ∅ M4 M5 M6 M8 M10 M12 M16 M20


min. [Nm] 2 3,5 6 16 28 46 110 225
max. [Nm] 3 5 9 24 42 70 165 340

Check the tools for current functioning before you start installation work !

ThyssenKrupp Aufzugswerke GmbH


ThyssenKrupp Aufzugswerke GmbH
Nr. 62 310 03 86 0

Ein Unternehmen von ThyssenKrupp Elevator


Bernhäuser Strasse 45
Issue 05/2009

73765 Neuhausen a. d. F.
Deutschland
Tel.: +49 7158/12-0
Fax: +49 7158/12-2585
E-Mail: info.aufzuege.de@thyssenkrupp.com
www.thyssenkrupp-aufzuege.de