Operating manual - TW160 drive

thyssenkrupp Aufzugswerke

Operating manual TW160 drive

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Contact your thyssenkrupp Aufzugswerke sales partner for details of colours for your specific products.

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To improve readability, a gender-specific form of address has not been used. Gender-specific pronouns therefore refer to both men and women.

Issued by

thyssenkrupp Aufzugswerke GmbH

Bernhäuser Strasse 45

73765 Neuhausen a. d. F.

Germany

Tel.: +49 7158/12-0

E-mail: [email protected]

Internet: www.thyssenkrupp-elevator-eli.de

Operating manual Table of Contents

TW160 drive

thyssenkrupp Aufzugswerke Version 03/2019

Table of Contents

1 About these instructions ................................................... 7

1.1 Guide to layout ................................................................................ 7

2 Safety .................................................................................. 8

2.1 Warning notes ................................................................................. 8

2.2 Safety requirements ........................................................................ 9

2.3 Warranty and liability ......................................................................10

2.4 Dangers in handling the product ....................................................11

2.5 International occupational health and safety regulations ................12

2.6 Personal protective equipment .......................................................13

3 Product Description ......................................................... 14

3.1 Standards and legal requirements ..............................................14

3.2 Description .....................................................................................15

3.3 Version with emergency brake - NBS .............................................16

3.4 Version for traction sheave in the shaft SA9 ..................................17

3.5 Version for vapour-proof partition wall SA4 ....................................18

3.6 Special versions SA2 / SA3 / SA3.1 / SA11 / SA12/SA15 ..............19

3.7 Version with safeguard measures complying with EN81-77 ...........20

3.8 Functional description ....................................................................20

4 Technology ....................................................................... 22

4.1 Technical data ................................................................................22

4.2 Dimensions of machine ..................................................................27

4.3 Type plate ......................................................................................31

4.4 Motor data ......................................................................................31

4.5 Machine base frame .......................................................................31

4.6 Machine base frame dimension sheets ..........................................41

4.7 Encoder ..........................................................................................50

5 Transportation and storage ............................................ 51

5.1 Packaging ......................................................................................51

5.2 Transport ........................................................................................52

5.3 Checking the delivery .....................................................................54

5.4 Packaging materials .......................................................................54

5.5 Ambient conditions .........................................................................54

5.6 Standstill maintenance ...................................................................55


TW160 drive


6 Installation ........................................................................ 56

6.1 Setting up the machine base frame ................................................56

6.2 Aligning the machine ......................................................................56

6.3 Installation (frame with rope pulley) ................................................57

6.4 Mounting the rope guard ................................................................59

6.5 Mounting the rope guard complying with EN81-77 .........................60

6.6 Mounting the shift protection complying with EN81-77 ...................61

6.7 Connecting motors .........................................................................62

7 Commissioning ................................................................ 65

7.1 Work steps .....................................................................................65

7.2 Emergency operation .....................................................................66

8 Servicing and Maintenance............................................. 68

8.1 Maintenance period ........................................................................68

8.2 Maintenance measures ..................................................................68

8.3 Lubrication ......................................................................................69

8.4 Checking the backlash ...................................................................71

8.5 Replacing the brake shoes .............................................................73

8.6 Setting and checking the brake shoe stroke and armature base

plate ...............................................................................................74

8.7 Braking deceleration setting ...........................................................77

8.8 Brake readjustment in the event of brake lining wear .....................77

8.9 Replacing the traction sheave ........................................................78

8.10 Replacing the motor .......................................................................80

8.11 Replacing the Encoder ...................................................................83

8.12 Check for escaping grease / oil ......................................................86

8.13 Check of the brake linkage .............................................................88

9 Special versions (optional) ............................................. 89

9.1 Overview of special versions ..........................................................89

9.2 Brake monitoring circuit ..................................................................90

10 Appendix ........................................................................... 94

10.1 Blocking clamp ...............................................................................94

10.2 Tightening torques ..........................................................................95

10.3 Manufacturer specifications for Wachendorf ..................................96

10.4 Manufacturer specifications for Centaflex coupling ......................102

10.5 Manufacturer information Radio Energie ......................................104


TW160 drive


10.6 Manufacturer specifications for Bernstein switch .........................105

10.7 Details regarding ABV, ESV, EU-BD as well as shaft

calculations ..................................................................................111

Operating manual About these instructions

TW160 drive

thyssenkrupp Aufzugswerke 7 Version 03/2019

1 About these instructions

1.1 Guide to layout

Sequence of actions involving several steps

First action.

Second action.

Interim result (optional)

Third action.

Final action step with end marker.

Result of action (optional)

Course of action with independent steps

Action step.

Action step.

Action step.

Information

Information must always be read and observed.

Reference

Chapter 2

List

Superordinate item of a list

Subordinate item of a list

Subordinate item of a list

Superordinate item of a list

Operating manual Safety

TW160 drive


2 Safety

2.1 Warning notes

Warning notes are intended for the protection of persons and property.

Warning notes must be read and observed by every person who works on the

product.

Warning notes precede activities that pose a hazard for people and the product.

2.1.1 Structure

SIGNAL WORD AND SIGNAL COLOUR

Type and source of danger!

Consequences if danger disregarded.

Measures to avert the danger.

2.1.2 Indications of danger to persons

DANGER

Danger with a high degree of risk!

If ignored, leads to death or serious injury.

Read and observe warning.

WARNING

Danger with a medium degree of risk!

If ignored, may lead to death or serious injury.


CAUTION

Danger with a low degree of risk!

If ignored, may lead to minor or moderate injury.


2.1.3 Indication of possible damage to property

NOTE

Hazard with possible damage to property!

If ignored, may lead to product function impairments or function loss.



TW160 drive


2.2 Safety requirements

This document contains important information for safe operation of the product.

Keep this document and all other applicable documents at the location of use for

the entire working life of the product.

2.2.1 Area of applicability

This document applies only to the product described here.

Other applicable documents

International occupational health and safety regulations

2.2.2 Basic requirements for safety

All existing safety devices are to be tested regularly in accordance with the

maintenance schedule.

This document, in particular the chapter entitled “Safety", together with the

warning notes and all other applicable documents must be observed by all

persons who work with the product.

Supplementary to this document, the rules at the location of use with regard to

environmental protection, and the regulations of work safety and accident

prevention must be observed.

All safety and hazard notices on the installation must be kept in legible condition.

Safety information and instructions required by law must be displayed to users in

plain view.

A requirement for safe handling and non-disruptive operation of this product is

knowledge of the fundamental safety regulations.

2.2.3 Obligations of the operating company and installation firm

Only deploy trained and instructed qualified personnel.

Provide personnel with the required personal protective equipment.

Check personnel at regular intervals to ensure that they follow safety-conscious

work practices and comply with national provisions.

Make all other applicable documents as well as this document available to

personnel.

2.2.4 Duties of personnel

Clearly establish all areas of responsibility prior to any activity.

Always wear the personal protective equipment made available to you.


TW160 drive


2.3 Warranty and liability

The 'General Terms of Sale and Delivery' of thyssenkrupp Aufzugswerke GmbH apply.

The product is configured in the factory and delivered ready for operation.

Warranty and liability claims in the event of injury or damage to property will be invalidated if attributable to at least one of the following causes:

Improper use that is not in line with the intended purpose of the product.

Chapter 2.3.1

Improper installation, commissioning, operation and maintenance of the product

Operation of the product with defective or inoperative safety devices, guards or

protection devices

Noncompliance with the information and instructions in the operating manual in

respect of transport, storage, installation, assembly, commissioning, operation

and maintenance

Structural modification to the product without agreement or approval

Modification to product features without agreement or approval

Deficient monitoring of parts that are subject to wear

Repairs that are carried out improperly

Cases of catastrophe due to third-party interference or force majeure

Use on non-approved auxiliary materials and operating fluids

2.3.1 Use in line with intended purpose

The product has been constructed using state-of-the-art technology and in line with the recognised technical safety regulations. It may only be used in accordance with its intended purpose and when the technical safety devices are in satisfactory condition. Any other or additional form of use shall be regarded as non-compliant with the intended use. thyssenkrupp Aufzugswerke GmbH shall not be liable for any damage arising from such use and any damage arising due to operator errors.

To comply with the intended use of the product:

Use the product only as a drive for elevators.

Read and comply with the document, in particular the chapter entitled “Safety",

together with the warning notes and all other applicable documents.

Follow the commissioning instructions, observe the installation description and

maintain the required inspection and maintenance work.


TW160 drive


2.4 Dangers in handling the product

The traction sheave and handwinding wheel of the TW160 are designed without

safety covers. This means that the drive may only be operated in a closed room.

It must be ensured when persons are in the vicinity of the machine that there is

adequate safety clearance to all revolving parts (marked in yellow).

With the vertical version, do not place any objects (e.g. tools etc.) on the

handwinding wheel, as there is a risk of injury as a result of parts being thrown.

In the event of improper use, there is a risk of personal injury or to the life of the

user or third parties, or impairment on the subassembly or other assets can

arise. Malfunctions that can impair safety must be rectified immediately.

When working on the drive, it must be de-energised before work is started, and

the system must be secured against inadvertent switching on.

A sign indicating that maintenance work is under way on the drive must be

attached in the area of the main switch.

Emergency brake, NBS: if an emergency brake NBS is fitted, the sequence and

procedure for emergency rescue change. This also applies to testing and setting

up procedures. Follow the instructions in the separately supplied operating

manual.

It must be ensured that a fault generated by the encoder, the brake or the brake

activation is detected by the elevator control or frequency inverter. The control

system must immediately place the elevator in a safe state.

The elevator system must be fitted with a safety device complying with EN81 or

that detects unintended elevator car movement with the door opened and

initiates suitable measures.


TW160 drive


2.5 International occupational health and safety regulations

Table 2.5-1

International rules for occupational health and safety can also be found in various languages on our ELI web platform and can be downloaded at: http://www.thyssenkrupp-elevator-eli.de/nc/de/downloads.html


TW160 drive


2.6 Personal protective equipment

Danger Cause (examples) Risks Remedy Equipment

Unprotected shaft Fall

Safety harness

WARNING: Do not walk underneath suspended loads!

Falling tool

Transport of heavy load

Sharp-pointed objects

Head injury

Head protection

WARNING: Do not walk underneath suspended loads!

Falling tool

Transport of heavy load


Danger of crushing in the foot area

Cut or stab injury in the foot area

Foot protection

Sharp objects

Mechanical parts


Caustic substances

Danger of crushing in the hand area

Cut or stab injury in the hand area

Acid / alkali burns

Hand protection

Severe noise pollution Noise damage

Ear protection

Flying parts

Flying particles

Laser beams

Optical beams

Eye injury

Loss of sight/blinding

Eye protection

Electrical voltage Electric shock

Enable source of energy

Table 2.6-1

Operating manual Product Description

TW160 drive


3 Product Description

3.1 Standards and legal requirements

EN81-1:2010-06 and EN81-20/50

The TW160 machines comply with the European standard EN81-1:2010-06 and EN81-20/50

The drive is part of the protection device according to DIN EN81-1:2010-06 / 9.11 and EN81-20/50/5.6.7.


TW160 drive


3.2 Description

3.2.1 Standard version


TW160 drive


Item Designation Item Designation

1 Driving gear 2 Traction sheave (standard version)

3 Motor (version V3F, frequency controller)

4 Operational brake

5 Actual-value sensor (type WDG100)

6 Handwinding wheel

7 Rope guard (adjustable) 8 Oil drain (3/4")

9 Oil filling hole with cover 10 Oil level monitor (dipstick) and ventilation

11 Traction sheave mount 12 Brake release lever (mounted)

13 Motor terminal box with connection

14 Mounting surface for machine base frame

15 Internal ventilator for motor cooling

16 Air vents for motor

17 Inspection opening with cover for gear teeth check

Fig. 3.2-1

3.3 Version with emergency brake - NBS


1 Disc brake, emergency brake system

2 Cover plate for brake

3 Socket wrench for manual release 4 Screws for manual release (screw head marked in red)

5 Brake test switch with connection line

6 Connection line, brake voltage

7 Protective cover for brake

Fig. 3.3-1

file://///taes-sfs-01/tkaw/Service/PK/Produktkatalog/TAW--DSF/TW160_22001_ger.dsf


TW160 drive


3.4 Version for traction sheave in the shaft SA9


1 TW160 machine SA9 2 Traction sheave shaft, SA4/9 version

3 External bearing (bearing housing with self-aligning bearing on adapter sleeve)

4 Traction sheave, SA4/9 version

5 Compensating support (for statically defined machine mounting)

6 Mounting surfaces for machine base frame

Fig. 3.4-1

TW160_23001_GER

file://///taes-sfs-01/tkaw/Service/PK/Produktkatalog/TAW--DSF/TW160_23001_ger.dsf


TW160 drive


3.5 Version for vapour-proof partition wall SA4


1 TW160 machine SA4 2 Traction sheave shaft, SA4/9 version

3 External bearing (bearing housing with self-aligning bearing on adapter sleeve)

4 Traction sheave, SA4/9 version

5 Compensating support (for statically defined machine mounting)

6 Mounting surfaces for machine base frame

7 Partition wall with seal for TW160 machine base frame SA4

Fig. 3.5-1

TW160_24001_GER


TW160 drive


3.6 Special versions SA2 / SA3 / SA3.1 / SA11 / SA12/SA15


1 Brake monitoring SA3 / 3.1 and/or brake test switches for SA15

2 Handwinding wheel, on gear side - SA2

3 Oil drain, side - SA11 5 Additional terminal box - SA12 for intermediate terminal connection of the magnetic clamps

Fig. 3.6-1


TW160 drive


3.7 Version with safeguard measures complying with EN81-77

Installation in the machine room, with earthquake safeguard complying with EN81-77.


1 Traction sheave (D640/D720/D800)

2 Earthquake safeguard complying with EN81-77

Fig. 3.7-1

3.8 Functional description

The TW 160 machine consists of a worm gear (gear drive) with flange-connected motor.

Power transmission takes place on motors of the IMB9 model series (flanged-on design with 1 bearing) via a rigid connection between the motor and worm shaft via worm wheel, traction sheave shaft to the traction sheave.

In the case of motors of the IMB5 model series (flanged-on design with 2 bearings), a

flexible coupling (SA14) is required between the motor and gear drive.

Brake

The dual-circuit outside shoe brake is spring actuated. Two independently acting brake shoe press the brake lining with preset spring force onto the brake disc.

The braking force is configured in such a way that one of the brake shoes is sufficient to bring an elevator car loaded with full weight to a standstill.

The brake is released by electrically operated magnetic clamps with armature base plate.

For manual operation, a brake release lever is fitted.

Gear housing

The TW160 has a monobloc housing with two fitted and screw-connected bearing brackets. The motor flange is cast onto the housing.

The right-hand or left-hand version of the traction sheave is created with the

corresponding installation of the bearing brackets in the housing.

The gear housing is cast from EN-GJL 250.


TW160 drive


Drive motor

Flange-mounted type B9 and IMB5 three-phase motors are used.

The motor shaft-worm shaft connection is established in the type B9 versions using a bolted rigid coupling and in the type IMB5 versions using a flexible coupling.

Emergency braking device NBS

An additional protection device that works as an emergency brake in the event of overspeed upwards is optional.

Traction sheave

The one-part traction sheaves are fastened overhung on the drive shaft by using a cone (1:15) and a mounting plate including 3 screws (M16-8.8 microencapsulated with locking washer). Chapter 8.8

Actual-value sensor

The actual-value sensor is located before the handwinding wheel, mounted on the motor shaft. Chapter 4.7

Ambient conditions

In order to ensure the function of the product as intended, it is presupposed that

the mean temperature at the final usage site is kept between +5°C and +40°C.

Air humidity must not exceed an annual average of 70% (no dewfall and no

freezing).

Safeguard measures complying with EN81-77

The additional safeguard measures complying with EN81-77 are available as options.

Operating manual Technology

TW160 drive


4 Technology

4.1 Technical data

name unit technical data

manufacturer ThyssenKrupp Elevator

gear type TW160

axle distance mm 225

ratios 50:1 / 42:1 / 35:1 / 57:2 / 51:2 / 45:2 / 41:3

oil filling l approx. 16.5

synthetic gear oil

(polyalkyleneglycol with additives)

designation SM1

circumfer. backlash ° 0.015 - 0.06

weight kg approx. 540

TW160_30101_ENG

type of oil

Table 4.1-1

4.1.1 Load data - traction sheave shaft

The load values Ftperm set out below represent the limit value of the permissible radial load on the traction sheave shaft calculated from the overall masses present at the installation.

Traction sheave shaft - standard version: Ft 97 kN

Traction sheave shaft - emergency brake (NBS): Ft 97 kN

Traction sheave shaft - SA 4/9 (with external bearing): Ft 77 kN

4.1.2 Mass moment of inertia

The value for the mass moment of inertia includes the driving gear with brake disc and coupling element as well as a proportion for the traction sheave.

Mass moment of inertia: Jrot = 0.158 kg/m²

It does not include the mass moment of inertia for the motor with handwinding wheel or flywheel rim hub as well as the flywheel rim for AC2 versions.

The value for the mass moment of inertia of the motor can be taken in the case of:

Standardised versions in accordance with product catalogue "Elevator motors"

custom-order motors from the motor lists (e.g. Siemens, Koncar etc.)

Additional flywheel masses

In the case of machines with pole-changing motor versions (AC2), additional flywheel masses are required on the motor shaft depending on the installation data.

The additional flywheel mass consists of a flywheel rim hub and a bolted flywheel rim.


TW160 drive


Unit

mm 330 360 370 380 400 410 430 455 480 510

0.285 0,458 0.533 0,600 0.758 0,900 1,070 1.435 1,750 2,280

0,342 0,515 0,590 0,657 0,815 0,957 1,127 1,492 1,807 2,337

TW63_30707_ENG

Designation Mass moment of inertia Jrot [kgm2]

Flywheel rim0.057 0.057

Total

kgm2hub

Flywheel rim

0.057

Table 4.1-2

4.1.3 Brake data

Redundant electromagnetic dual-circuit outside shoe brake on the motor / worm shaft integrated in the gear or motor flange. The electric release of the brake circuit takes place via magnetic clamps. The magnetic clamps are available in standard and in explosion-proof versions.

A coupling is integrated on the brake disc for connecting the motor and worm shafts; depending on the motor type used, this coupling may be rigid (for the B9 type) or flexible (for the IMB5 type).

Unit

Nm

mm

mm

N

A

m1) Version for explosion protection TW160_30201_ENG

II 2 D Ex mb IIIC T95°C Db 1)

Type approval codewithout on standard version

IBExU17ATEX1137 X 1)

Connection cable length 1.7 1.5 1)

Rated current 1.8 / 1.79 1)

Monitoring devices Brake test switches

Manual release Brake release lever (mounted)

Protection type, magnetic clamps

IP65 (standard version)

II 2 G Ex mb IIC T5 Gb 1)

Nominal force - magnetic clamps 5000

Operating voltage VDC180 - overexcitation

90 - holding voltage

Brake disc diameter 275

Air gap 0.3

Air gap setting possible

Electrical release 1 magnetic clamp per brake circuit

(2 magnetic clamps connected in series)

Braking torque max. 2 x 245

Braking torque setting possible

DesignDual-circuit outside brake shoe

with brake disc made of EN-GJL 250

Brake linings Asbestos-free

Designation Technical data

Manufacturer thyssenkrupp Aufzugswerke

Type TW160

Table 4.1-3


TW160 drive



TW160 drive


4.1.4 Emergency brake

More detailed information as well as technical information for setting up and operation of machines with NBS emergency brake can be found in a separate operating manual. These are delivered with drives with emergency brake system equipment.

The part number for the German instructions is: 65 990 01 86 0

The part number for the English instructions is: 65 990 02 86 0

The part number for the French instructions is: 9710 000 9229

4.1.5 Traction sheave

Different versions of traction sheave are used, depending on the location of the machine.

Standard version: traction sheave position in the machine room

Special version SA4/9 - vapour-proof partition wall in the machine room / traction

sheave position in the shaft

The traction sheaves for the standard versions differ from the SA4/9 versions in the dimensional assignment of traction sheave middle to cone and rim width. The use of SA4/9 versions in machines for the machine room - and vice versa - is not possible.

unit

mm 640 720 800 640 720 800

mm

°

kg 140 160 190 130 150 180

1) Version in accordance w ith product description groove profiles w ith hardened groove flanks (min. 50 HRc).

2) With minimum groove clearance - RAmin in accordance w ith product description groove profiles

TW160_30301_ENG

technical dataname

machine version

diameter - DT

max. number of grooves - z x d 2)

10 x 10 9 x 10

9 x 11/12 8 x 11/12

8 x 13 / 8 x 1/2"

standard SA 4/9

160180rim width - B

groove type

weight

seat / vee groove 1)

material

depends on project specs 1)

special alloyed EN-GJL 250

7 x 13 / 7 x 1/2"

7 x 14/15 6 x 14/15

7 x 16 / 7 x 5/8"

vee groove angle

6 x 16 / 6 x 5/8"

Table 4.1-4


TW160 drive


4.1.6 Weight data

ZB machine TW160 1) 540 x x x x x x

accessories for SA9 60 x x

accessories for NBS 150 x x

traction sheave D720 2), 3) 160 x x x x x x

motor DTE180 4) 225 x x x

ZB machine complete 700 760 850 925 985 10751) without motor 2) weight for traction sheave D640 approx. 140 kg and D800 approx. 190 kg3) weight for traction sheaves - SA9 minus 10 kg4) weight for other motor versions see chapter - motor versions TW160_30708_ENG

name unit weight2)

kg

machine version

with motor DTE180 without motor

Table 4.1-5

The weight data for the type IMB5/V1 motor can be taken in the case of:

Normalised versions in accordance with a factory standard (see notes on factory

standards in the chapter - Type IMB5/V1 motors)

custom-order motors from the motor lists (e.g. Siemens, Koncar etc.)

In the case of pole-changing version machines (AC2), the weight data are increased to include the values of the additional flywheel masses.

Unit

330 360 370 380 400 410 430 455 480 510

kg 14 20 22 24 28 31 35 42 48 57

TW63_30709_ENG

Designation Weight m [kg]

mmFlywheel rim

Table 4.1-6

4.1.7 Acoustic specifications

The airborne noise levels in the machine room at a distance of 1 m for the standard

version of the machine during operation at normal rating are: 74 dB(A)

The specified electrical data apply to the following site conditions:

Maximum altitude 1000 m amsl

Maximum temperature + 40° C at maximum 50% air humidity

Max. relative air humidity 70% at 20 °C

If the conditions stated above are exceeded, the deratings in accordance with VDE0530 apply.


TW160 drive


4.2 Dimensions of machine

4.2.1 Standard version


1 Additionally for SA1 2 Pictured: traction sheave position right / left mirror-inverted to A-A

Fig. 4.2-1


TW160 drive


4.2.2 Version with emergency brake - NBS

Fig. 4.2-2

file://///taes-sfs-01/tkaw/Service/PK/Produktkatalog/TAW--DSF/TW160_30902_GER.dsf


TW160 drive


4.2.3 Version for traction sheave in the shaft (SA9)


1 Centre, rolling bearing 2 Centre, bearing housing

Fig. 4.2-3


TW160 drive


4.2.4 Version for vapour-proof partition wall SA4 (Partial Ex)


1 Centre, rolling bearing 2 Centre, bearing housing

Fig. 4.2-4


TW160 drive


4.2.5 Special versions SA2/SA11/SA12

Fig. 4.2-5

4.3 Type plate

The current type and the technical data are specified on the type plate of the product.

4.4 Motor data

The technical data can be found on the type plate.

4.5 Machine base frame

The machine base frames with and without rope pulley described below are intended for installation of the machine in the machine room above the shaft.


TW160 drive


4.5.1 Assembly, machine base frame TW160 - 62 340 01 10 0

Machine base frame version without rope pulley for use in:

Installations with 1:1 rope suspension and direct rope departure for an elevator

car - counterweight rope distance ASL (DT + 100) mm depending on the

traction sheave diameter

Installations with 2:1 or 4:1 rope suspension


1 TW 160 machine 2 TW160 machine base frame

3 Insulation elements 4 Mounting parts for machine / base frame

Fig. 4.5-1

The complete machine base frame comprises the following components:

Machine base frame made from welded rolled profiles

Hole pattern for machine mounting as per order, depending on DT and ASL

Technical data

Weight of machine base frame: approx. 150 kg

Project planning dimensions

Project planning dimensions, see dimension sheet

TW160_31010_GER


TW160 drive



Machine base frame in version with rope pulley on supports depending on the pulley hub position in left-hand or right-hand configuration for use with:

Installations with 1:1 rope suspension and elevator car - counterweight rope

distance ASL = 795 1400 mm in conjunction with traction sheaves dia. 640,

720 and 800 mm

The versions D450-7/8x10. D540-7/8x13 and D640 (for rope pulleys, see factory standard 60 720 12 00 0) are used for the rope pulley. The rope pulleys have maintenance-free rolling bearings.


1 Machine TW160 2 Upper section, machine base frame

3 Pedestal bearing for rope pulley 4 Rope pulley

5 Upper section, machine base frame

6 Supports for insulation elements

7 Insulation elements

Fig. 4.5-2

TW160_31001_GER


TW160 drive





Pedestal bearing (bolted) for the rope pulley holder with axle; version based on

the rope pulley used

Rope pulley D450, 540 or 640

Supports (6 pcs. bolted) for mounting the insulation elements.

It is possible through appropriate mounting of the bolted supports to position the

pulley hub on the right or left in the machine base frame.

Technical data

Weight of machine base frame

m

TW160_31007_ENG

weight incl. rope pulley

420D450

D640

rope pulley version [mm]

550

D540 kg 470

Table 4.5-1




Machine base frame version with rope pulley on concrete foundations - depending on whether the rope pulley position is on the left or right for use in:

Installations with 1:1 rope suspension and elevator car - counterweight rope

distance ASL = 795 1400 mm in conjunction with traction sheaves dia. 640,

720 and 800 mm

The versions D450-7/8x10. D540-7/8x13 and D640 (for rope pulleys, see factory

standard 60 720 12 00 0) are used for the rope pulley. The rope pulleys have

maintenance-free rolling bearings.


TW160 drive



1 Machine TW160 2 Machine base frame

3 Pedestal bearing for rope pulley 4 Rope pulley

5 Rope pulley 6 Foundations (supplied by customer)

7 Insulation elements

Fig. 4.5-3




Pedestal bearing (bolted) for the rope pulley holder with axle; version based on

the rope pulley used

Rope pulley D450, 540 or 640

By mounting the bolted pedestal bearing accordingly, it is possible to position the pulley hub on the right or left in the machine base frame.

TW160_31011_GER


TW160 drive


Technical data

Weight of machine base frame

m

TW160_31008_ENG

weight incl. rope pulley

340D450

D640

rope pulley version [mm]

470

D540 kg 390

Table 4.5-2




TW160 drive



Machine base frame for "Partial Ex" installations with vapour-proof wall duct (SA4) in a version without a rope pulley for use in:

Installations with 1:1 rope suspension and direct rope departure for an elevator

car - counterweight rope distance ASL (DT + 100) mm depending on the

traction sheave dia. DT used.

Installations with 2:1 or 4:1 rope suspension

TW160_31012_GER


TW160 drive



1 TW160 machine - SA4 2 Compensating supports

3 Pedestal bearing housing (external bearing)

4 Base frame

5 Frame yoke 6 Sealing plate

7 Rope guard 8 Mounting parts for machine / base frame

9 Mounting parts for machine base frame

10 Vapour-proof partition wall (supplied by customer)

11 Machine room floor

Fig. 4.5-4

The machine base frame consists of a base frame with welded bearing bracket and a frame yoke for holding the rope guards and the bolted sealing plate. The hole pattern for mounting the machine and the position of the frame yoke are dependent on the traction sheave diameter - DT and the traction sheave position - left or right.

It is possible for the customer to provide a vapour-proof enclosure of the entire machine base frame by using side plates on the base frame and by using the profile section of the frame yoke (U140).

The base frame is bolted to the machine room floor with heavy-load anchors (6 pieces supplied). The arrangement is sealed against the machine room floor by the customer.

Technical data

Weight of machine base frame: approx. 350 kg

4.5.5 Mounting parts, TW160 base-frame-mounted machine

A set of bolting elements (4 x M20-8.8) is available (AY mounting parts 62 340 03 98 0) for mounting the TW160 machine on the standardised machine base frame with / without rope pulley.

A reinforced mounting (6 x M20-8.8 / 2 x M16-8.8) is used (assembly, mounting parts 62 340 03 98 0) is used for individual applications of the TW160 machine with horizontal or vertically upward rope departure - except for the special versions SA4/9.


TW160 drive


4.5.6 Version with earthquake safeguard complying with EN81-77

Optional components are available for the TW160 O SR and TW160 M SR base frames; these meet the requirements for protection devices complying with EN81-77.


1 W160 machine 2 Rope guard complying with EN81-77 for traction sheave

3 TW160 M SR machine base frame

4 Rope guard complying with EN81-77 for rope pulley dia. D450, D540, D640

5 Shift protection complying with EN81-77

Fig. 4.5-5

The safeguard measures are only suitable for machine base frames with locations in the machine room.

The protection device consists of a change rope guard for rope pulleys dia. D450, D540 or D640 which prevent the ropes departing from the grooves.



2 Rope guard complying with EN81-77 for rope pulley dia. D450, D540, D640

3 Rope pulley dia. D640

Fig. 4.5-6


TW160 drive


The safeguard measures also consist of shift protection devices that prevent the machine from changing its position


1 Shift protection complying with EN81-77


Fig. 4.5-7

In the case of deployment of the machine in earthquake categories 2 and 3, additional safeguard measures in accordance with EN81-77 are necessary.


TW160 drive


4.6 Machine base frame dimension sheets

4.6.1 Version without rope pulley


1 Machine with traction sheave position - left

2 Machine with traction sheave position - right

S Centre of gravity

Fig. 4.6-1


TW160 drive


Project planning dimensions:

Project planning dimension L dependent on traction sheave diameter DT and traction sheave position - left or right - of the machine.

640

720

800

TW160_31002_ENG

traction sheave version

DT

project planning dimension L

mm

295 200

240

280

255

215

traction sheave position

left right

unit

Table 4.6-1

Position and number of insulation elements depending on the static shaft load

90 2 2 2 2 1 1

75 2 2 1 1 1 1

60 2 2 1 1 1 1

30 1 1 - - 1 1

TW160_31004_ENG

Ft [kN]

III

number of isolation elements

IV V VIposition for

isolation elementI II

static

shaft load

Table 4.6-2


TW160 drive


4.6.2 Version with rope pulley / machine base frame with supports

Version with rope pulley position on left


1 With rope pulley D540 2 With rope pulley D640

3 With rope pulley D450 4 Machine with traction sheave position - left


S Centre of gravity, machine base frame

Fig. 4.6-2

TW160_31102_GER

185

250


TW160 drive


Version with rope pulley position on right






Fig. 4.6-3

TW160_31103_GER


TW160 drive



Project planning dimension L dependent on traction sheave diameter DT and traction sheave position - left or right - of the machine

TW160_31005_ENG

955

1400

ASLmax

800

traction sheave version rope distance elevator car - counterweight

DT

640

720 mm

795

ASLmin

875

Table 4.6-3


and rope pulley and traction sheave positions

I II III IV I II III IV I II III IV I II III IV

90 2 4 1 2 3 4 2 2 4 3 2 2 4 2 2 1

75 2 4 1 2 3 3 1 2 3 3 2 1 4 2 2 1

60 2 3 1 2 2 3 1 1 3 2 1 1 3 2 2 1

30 2 2 1 2 2 2 1 1 2 1 1 1 2 1 1 1

TW160_31006_ENG

position for

isolation element


static

shaft load

Ft [kN]

800 1000 1200 1400

rope distance elevator car - counterweight ASL [mm]

Table 4.6-4


TW160 drive


4.6.3 Version with rope pulley / machine base frame on concrete foundation

Version with rope pulley position on left






Fig. 4.6-4

TW160_31104_GER

185

250


TW160 drive


Version with rope pulley position on right






Fig. 4.6-5

TW160_31105_GER


TW160 drive



Project planning dimension L dependent on traction sheave diameter DT and

traction sheave position - left or right - of the machine

TW160_31005_ENG

955

1400

ASLmax

800

traction sheave version rope distance elevator car - counterweight

DT

640

720 mm

795

ASLmin

875

Table 4.6-5


and rope pulley and traction sheave positions

I II III IV V VI VII VIII I II III IV V VI VII VIII

90 1 1 - 2 1 2 1 1 1 1 1 1 1 2 1 1

75 1 1 - 1 1 1 1 1 1 1 1 1 1 1 1 1

60 1 1 - 1 - 1 1 1 1 1 - 1 1 1 1 1

30 1 1 - - - - 1 1 1 1 - - - - 1 1

I II III IV V VI VII VIII I II III IV V VI VII VIII

90 1 1 1 1 2 1 1 1 1 1 2 - 2 1 1 1

75 1 1 1 1 1 1 1 1 1 1 1 - 2 1 1 1

60 1 1 1 - 1 1 1 1 1 1 1 - 1 - 1 1

30 1 1 - - - - 1 1 1 1 - - - - 1 1

TW160_31009_ENG


static

shaft load

Ft [kN]

isolation element 1200 1400

isolation element 800

position for rope distance elevator car - counterweight ASL [mm]

rope distance elevator car - counterweight ASL [mm]


1000

static

shaft load

Ft [kN]

Table 4.6-6


TW160 drive


4.6.4 Version with vapour-proof partition wall (SA4)


1 Machine with traction sheave position - left


S Centre of gravity

Fig. 4.6-6


TW160 drive


4.7 Encoder

The installation and connection are described in Chapter 10 external operating manual in the Appendix

Encoders are distinguished by type depending on the control system deployed.

The following encoders are available for the TW160.

Encoder type Pulses Use

1024

4096

4096 LiftEquip for ships' elevators

4096 LiftEquip for CT inverter E300

1024 tk Brazil 1)

HTL 1024 External controls and/or inverters

Sine, cosine 1024 External controls and/or inverters

1) Version with adapted connector for tk Brazil

MOTOREN_34300_ENG

TTL

tkAW inverters and third-party inverters

Table 4.7-1

Operating manual Transportation and storage

TW160 drive


5 Transportation and storage

5.1 Packaging

The packaging varies depending on the version of the drive that is delivered. The illustration shows the standard version.

Standard version: special pallet 1680 x 850 mm

Special versions SA4/SA9: special pallet 1700 x 1240 mm

Version with emergency brake system: special pallet 1680 x 1100 mm

Wooden blocks are placed under the gear housing and the gear housing is bolted onto the pallet.

For the special versions SA4 and SA9, the compensating supports are packaged separately and secured to the pallet.

Fig. 5.1-1

Further packaging depends on the order and is country-specific (air/sea/land freight).

1. Refer to the delivery note for the dimensions and weight.

2. Observe the symbols attached to the packaging or in visible locations.

3. Dispose of used packing material in an environmentally responsible manner.

4. Consult the technical data for the approximate details. Chapter4.1

Specific transport equipment and shipping braces remain with the customer


TW160 drive


5.2 Transport

NOTICE

Improper transport!

Damage and possibly loss of function of the machine.

Do not place heavy objects on the assembly when packaged.

Protect it against impacts and falling.

Protect it against water and extreme temperatures .

Comply with safety regulations.

Pay attention to the centre of gravity of the product.

Do not lift the machine by the motor or pedestal bearings.

Always lift the machine by both transport hangers.

NB: machine is filled with oil. It may only be transported and stored upright.

5.2.1 Transport by fork lift

WARNING

Protruding or tilting parts

Falling transported goods can lead to severe crushing injuries or cuts and

possibly fatal injuries.

When effecting transport with a fork lift, use adequately long forks

to prevent tipping over.

Always pick up at the frame or transport pallet with the forks, not

the machine itself.

During transport, keep a safe distance to persons.


TW160 drive


5.2.2 Crane transport

WARNING

Suspended load!

Falling transported goods can lead to severe crushing injuries and possibly fatal injuries.

Do not walk underneath suspended loads.

Only use tested and adequately dimensioned lifting gear.

The specified means of transport are only configured for

transportation of the machine, the installed brake and traction

sheave. Do not use them to transport any other loads.

On the version with emergency brake system (NBS), the transport hanger is mounted the other way around, as here the centre of gravity is on the other side of the machine.


1 Transport hanger

Fig. 5.2-1

Attach the rope with a closed transport hook on the transport hanger.

1


TW160 drive


5.3 Checking the delivery

WARNING

Severe transport damage to the product.

Can lead to a malfunction of the product and thus to death or serious injury.

Before commissioning, ensure that there is no severe damage to the product.

1. Check the completeness of the delivery.

2. Compare the order and delivery documents.

3. Check the packaging for damage and any other conspicuous anomalies.

In the case of damage

1. Do not commission a damaged product.

2. Any damage that is determined is to be documented immediately by means of a

sketch, photo or description of the damage.

3. Report damage to the manufacturer.

5.4 Packaging materials

Specific transport equipment and shipping braces remain with the customer.

Dispose of packaging materials in an environmentally compatible manner.

5.5 Ambient conditions

5.5.1 Intermediate storage

Bare parts have no long-term preservation.

The product may be exposed to a maximum relative air humidity of 60% (at 20

°C).

Store the product carefully in a protected location.

Protect it against the formation of condensation and moisture.

Protect against dirt in the machine.

5.5.2 During operation

The environment at the final location must correspond to normal indoor climate

conditions for elevator machines and pulley rooms (in accordance with EN81,

between + 5 °C and + 40 °C).


TW160 drive


5.6 Standstill maintenance

If the drive is not installed for a longer period, the following measures are to be carried out annually:

1. Release the operational brake manually by means of the brake release lever

and (if present) the emergency break manually by releasing the emergency

release screws.

2. Turn the traction sheave disc by means of the handwheel at the motor by 3

revolutions in both directions.

3. Depending on the storage conditions, replace the corrosion protection of the

bare parts (for example with Rivolta KSP 317 corrosion protection wax).

Operating manual Installation

TW160 drive


6 Installation

6.1 Setting up the machine base frame

The base frame is set up depending on the customer on supports, beams, a concrete pedestal or directly cast in the machine room floor.

For reducing noise and sound transmission, we offer insulation elements, which can be inserted between the frame supports and the ground. These differ according to the type of mounting:

Rubber block 100 x 100 x 50 without packing.

For mounting the drive on the machine room floor without a cement floor or

directly surface-mounted on the cement floor.

Rubber block 100 x 100 x 50 with additional packing 140 x 140 x 80 mm

For installation on cement floor, packing cast into cement floor

(thickness ≤ 60 mm). The packing component must be cast in when installing

the cement floor.

The number and arrangement of rubber elements is based on the total load and distance between the rope departures (ASL) dimension. The required individual load should be between 7 KN and 12 KN per element.

When arranging the supports, the overall centre of gravity must lie within the rubber elements.

The arrangement under the machine base frame should be such that the stress and/or buffering of the insulation elements (maximum difference 3 - 5 mm) is as even as possible.

6.2 Aligning the machine

The machine is to be set up according to the general arrangement drawing. The rope departure from the traction sheave is to be aligned plumb to the elevator car mounting or the elevator car rope pulley and the counterweight according to the drawing. With load applied to the ropes, the machine should be aligned vertically on its installation surface. Irregularities are to be balanced out by inserting shims under the floor support.

SA4, SA9 traction sheave in the shaft, machine with extended traction sheave shaft and pedestal bearing.

Important: On setting up a gear drive with pedestal bearing, it must be ensured without fail that

the compensating supports are mounted and secured according to instructions

the traction sheave shaft is aligned horizontally

the bearings of the machine and the outside bearing are exactly aligned


TW160 drive


Installation of the compensating support for SA4/SA9

Fig. 6.2-1

Screw the supplied compensating supports onto the housing of the machine

from below with 6 x M16x90 bolts and nuts as well as 2 x M16x40 washers

(tightening torque 190 Nm).

6.3 Installation (frame with rope pulley)

Fig. 6.3-1

86

0(

be

i/a

t D

p=

54

0)

(b

ei/

at

Dp

=4

50

/64

0)

96

0

54

0(

be

i/a

t D

p=

54

0)

(b

ei/

at

Dp

=6

40

)5

87

(b

ei/

at

Dp

=4

50

)6

60

8-9-10-11-12Ma = 190 Nm

Dp

1 2

3

1640( )

11

05

()

34

5

3 55( bei /at Dp=540)

( bei /at Dp=450)310

( bei /at Dp=640)4051010

4-5-6-7Ma = 370 Nm

A

1 A

Lage der Seilrolle - rechts

position of rope pulley - right hand

Lage der Seilrolle - links

position of rope pulley - left hand


TW160 drive


1. Bolt together the delivered base frame in the machine room.

2. Make sure that the supports are mounted with additional drilled holes (2

holes) and pulley support on the correct side.

3. Mount and secure the deflecting pulley with axle on the pulley supports.

4. Set up and align the frame on the insulation elements according to the

general arrangement drawing.

5. Use lifting gear to place the machine on the base frame; the traction sheave

must be on the deflecting pulley side

6. Balance out uneven surfaces by inserting the enclosed shims.

7. Bolt the machine onto the frame, whereby the machine housing must not be

tensioned. (Balancing by means of the supplied shims)

8. Align the rope grooves of the traction sheave and deflecting pulley in parallel.

9. Tighten the screws with the prescribed tightening torque. Chapter 10.2

10. Plumb the rope departure on the rope pulley at the elevator car and/or

mounting on the car and counterweight.

With a horizontal rope departure, the gear housing on the machine base frame is to

be secured against shifting by means of car steady plates.

NOTE

Hazard with possible damage to property!

May lead to product function impairments or function loss.

With a side or oblique rope departure, the gear housing on the machine

base frame is to be secured against shifting by means of car steady

plates with set screws.

The arrangement of the suspension ropes in the suspension plates, on

the traction sheave as well as the rope pulleys must be as symmetrical as

possible.

The versions can be found in the general arrangement drawing.


TW160 drive


6.4 Mounting the rope guard

1. Use the enclosed screws to bolt the rope guard onto the rope guard carrier.

2. Pivot the rope guard carrier to set the guard in such a way that the gap between

the rope and guard on the rope run-in and run-out side of the traction sheave is

as small as possible. (1 -2 mm)

3. With inclined pulling, adapt the location of the rope guard carrier by remounting

the changed rope pull direction.

Tighten the securing bolts of the rope guard carrier on the gear drive after alignment with the prescribed tightening torque. Chapter 10.2


1 Rope guard carrier 2 Rope guard

Fig. 6.4-1

CAUTION

Danger with a low degree of risk!

May lead to minor or moderate injury.

For machines with rope run-in direction from 0 - 90°above horizontal (e.g. machine arrangement down/up beside), an additional rope guard is required to prevent foreign bodies penetrating between the rope and grooves.

If the rope run-in zone is protected within the machine base frame, the function "protection against injury" is not required.

For SA9 traction sheave in the shaft, no rope guard is fitted at the plant.

1

2 1

2

max. 1-2 mm


TW160 drive


6.5 Mounting the rope guard complying with EN81-77

1. Use the enclosed screws to bolt the rope guard onto the rope guard carrier.

2. Set the rope guard by pivoting or remounting in such a way that the clearance

between the rope and hoop guard does not exceed a maximum of 2 mm over

the entire width of the traction sheave.

3. To align the rope guard, push the enclosed shims between the rope guard

carrier and rope guard.

4. The rope guards on the rope run-in and rope departure positions must not be

mounted more than 15° away from the rope run-in and rope departure

positions.

5. If the angle between the rope run-in and rope departure positions is greater

than 90°, mount a third rope guard in such a way that the angle between all

rope guards is not more than 90°.

6. With inclined pulling, adapt the location of the rope guard carrier by remounting

the changed rope pull direction.

Tighten the securing bolts of the rope guard carrier on the gear drive after alignment with the prescribed tightening torque.


1 Rope guard carrier 2 Rope guard, long

3 Rope guard, long 4 Rope guard, small

Fig. 6.5-1

For machines with rope run-in direction from 0 - 90°above horizontal (e.g. machine arrangement down/up beside), an additional rope guard is required to prevent foreign bodies penetrating between the rope and grooves.

If the rope run-in zone is protected within the machine base frame, the function "protection against injury" is not required.

The rope guards on the rope pulley are to be mounted according to the same specifications.

max. 2 mm


TW160 drive


6.6 Mounting the shift protection complying with EN81-77

1. Secure each of the shift protection devices with 2 tie bolts (Hilti HST M16/25 or

Fischer M16/25 FAZII) at the installation site.

2. Secure the shift protection devices to the bare concrete.

3. Before drilling, ensure that no reinforcing steel at the positions of the holes

hinders the drilling.

If this is the case, use one of the alternative holes that are already on the shift

protection device.

The fastening materials are included in the scope of supply. The installation instructions of the manufacturers are to be strictly complied with!

4. Align the shift protection in such a way that the rubber elements of the shift

protection devices do not touch the machine base frame.

5. Set the clearance to a maximum of 5 mm.

The shift protection is configured for the following machine insulations:

Insulation elements without underlay for machine room without floor pavement.

Insulation elements with underlay for machine room with floor pavement (≤ 60

mm high); underlay made from Multiplex laminated wood 140 x 140/80 / mm

high.

Fig. 6.6-1


1 Shift protection 2 Machine base frame

3 Tie bolts 4 Alternative holes

Fig. 6.6-2

max. 5 mm


TW160 drive


6.7 Connecting motors

On connecting the motor, the enclosed terminal connecting plan in the motor terminal box and/or the wiring diagram in this operating manual and corresponding building codes are to be complied with.

6.7.1 Terminal connecting plan for motor and magnetic clamps

Comply with the documents supplied with the motor and the information in the terminal strip.

Terminal connecting plan of DTE / DTL motors

An intermediate connection is set up for the brake in the terminal box of the motor.

Fig. 6.7-1 DTE motor


TW160 drive


Terminal connecting plan for Motorlift motors

Fig. 6.7-2


TW160 drive


6.7.2 Wiring diagram DTE132/140/180, motorlift CMRFL1 und motors made by

EMOD


1 Motor 2 Posistor

3 Encoder 4 Brake (intermediate terminal connection)

Fig. 6.7-3 Survey diagram for DTE 132/140/180 motors

6.7.3 Wiring diagram DTL


1 Motor 2 Posistor

3 Encoder 4 Brake (intermediate terminal connection)

5 Forced ventilation (only for DTL180)

Fig. 6.7-4 Survey diagram for DTL180 motors

41 2 3

Motoren_34211_GER

5

Operating manual Commissioning

TW160 drive


7 Commissioning

7.1 Work steps

For assembly, use only original construction and mounting parts from thyssenkrupp Aufzugswerke GmbH, as otherwise no warranty can be provided.

Before commissioning the machine, the following points must be checked and carried out:

OK Work step

1. Remove safety, auxiliary and installation tools from the danger

zone.

2. Check setup and alignment of machine, base frame, rope

departure and base.

3. Check the oil drain pipe is seated securely and leak-tight.

(Machine is filled with oil at the plant)

4. Check the gear oil level. 8.3.3

5. Check the secure mounting of the machine and base frame.

6. With a side or oblique rope departure, the gear housing is

secured against moving with end stops and set screws.

7. Make sure that the bolts are tightened with the prescribed

torque and secured. 10.2

8. Check the brake shoe stroke and setting 8.6

9. With SA3, SA3.1 and SA15 , check the setting and function of

the brake test switches. 9.2

10. Conduct a brake test with one brake shoe in each case. 8.7

11. Check the function and setting of the handbrake release 7.2

12. Fit the rope guard and set the distance to the traction sheave. 6.4 resp. 6.5

13. Check whether the power connections and earthing of the

motor, forced ventilation and brake magnet are connected and secured.

14. Stick the direction arrow (Up / Down) clearly visible on the

motor near the handwinding wheel according to the direction of travel.

Table 7.1-1


TW160 drive


If the traction sheave and rope pulley are delivered separately, they are to be mounted properly.

If the machine was dismantled due to weight, transport or space, removed parts are to be reassembled to their original state and the mounting parts tightened with the corresponding tightening torque. Chapter 10.2.

7.2 Emergency operation

The TW160 is equipped for emergency operation with a handwinding wheel and a brake release lever.

The brake release lever and pressure piece with pressure rod are mounted on the brake shoes with notched impact pins. On the version with vertical motor position, the brake release lever is additionally secured in the rest position with a retaining clip. The brake lever is set in the operation position approx. 5 - 10° above the horizontal as shown in the following illustration:

Operation position Rest position

Fig. 7.2-1

Emergency rescue of trapped persons

1. Open the brake by moving the brake release lever into the operation position

and actuate the lever against the pressure rod until the brake shoes are

released.

2. The handwinding wheel might also have to be moved to bring the elevator car

into the nearest landing.

3. Depending on the load, the elevator car can begin to move quickly after

opening the brake.

4. Immediately let go of the handwinding wheel and control the speed of the

elevator car by pressing the brake release lever with varying degrees of force.

5. Following the rescue operation, put the brake release lever back in the rest

position.

5°-10°


TW160 drive


CAUTION

Abrasion injuries

If the handwinding wheel is used for installation and maintenance purposes (e.g. pulling out of the safety gear), the person performing the operation must ensure they have a firm and safe stance.

There is also a risk of injury when simultaneously operating electrical recall.

Pay special attention.

Operating manual Servicing and Maintenance

TW160 drive


8 Servicing and Maintenance

8.1 Maintenance period

Maintenance of the machine should take place within the framework of central maintenance of the elevator, at least once a year.

8.2 Maintenance measures

OK Work step

1. Check the oil level and top up if necessary.

Chap. 8.3.3

2. Change the oil when the change date is reached. Chap. 8.3.2

3. Re-lubricate the pedestal bearings. Chap. 8.3.1

4. Check the brake shoes for wear; the remaining lining

thickness must be at least 3 mm.

Chap. 8.5

5. Check the brake setting; the shoe stroke should be

0.3 + 0.1 mm.

Chap. 8.6

6. Check the braking deceleration.

Chap. 8.7

7. Check the backlash between the worm shaft and worm

wheel.

Chap. 8.6

8. Check the groove profile on the traction sheave for damage

and wear.

9. Check that the bolts of the traction sheave mount are

securely seated.

Chap. 10.2

10. Check rope pulley grooves for damage and wear.

11. Check proper and adequate condition and safety of

electrical connections.

12. Check that protective and safety devices are present and

correctly set.

Table 8.2-1


TW160 drive


8.3 Lubrication

NOTICE

Bearing damage!

Damage to the bearings due to unsuitable lubricant

Use only the specified lubricant

8.3.1 Outside bearing

On delivery, the initial filling took place at the plant.

Rolling bearing grease F1 multipurpose grease can be obtained from thyssenkrupp Aufzugswerke GmbH.

Part number Designation Amount of grease

60 300 27 900 AY multipurpose grease F1 cartridge 400 gr

Annually:

110 g re-lubrication

SAP 8.3-1

8.3.2 Gear

On delivery, the initial filling took place at the plant.

Synthetic gear oil SM1 can be obtained from thyssenkrupp Aufzugswerke GmbH.

Lubricant Replacement interval Motor position = filling

amount

Synthetic gear oil SM1 For the first time after 3 years

then every 6 years 17 litres

Table 8.3-1

Never mix different types of oil.

Do not let any oil seep through to the groundwater.

Dispose of old oil as well as cloths contaminated with oil and grease according to

prevailing regional regulations.

Only use lubricants approved by THYSSENKRUPP AUFZUGSWERKE GmbH

oil change

1. Before the oil change, run the gear until it reaches operating temperature (at

least 35°C).

2. Discharge the gear oil by removing the cap on the oil drain pipe and collect the

old oil in a container specifically designed for the purpose.


TW160 drive


WARNING

Risk of scalding!

Caution: hot oil represents a risk of scalding!

Be particularly careful.

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

4. Fill the machine with the prescribed oil quantity through the upper opening on

the gear housing (fill opening cap, see Fig. 3.2-1

5. Check the level with the oil dipstick (see Fig. 8.3-1).

Only rest the oil dipstick, do not screw in.

6. Enter the date for the next oil change in the type plate on the gear housing.


1 Oil filling hole see Fig. 3.2-1 item 9

2 Oil dip stick

3 Oil drain

Fig. 8.3-1

8.3.3 Checking the oil level

Only place the oil dip stick (red cap) in position to check the oil level; do not screw in. The oil level should be between the two markings.

2

1

3


TW160 drive


8.4 Checking the backlash

If the running performance deteriorates, this might have been caused by excessive backlash in the worm gear toothing.

Wear on the worm wheel gear teeth changes the existing tooth thickness and this can be determined using the following measurement of the backlash.

WARNING

Deformation and/or breakage of the teeth on the worm wheel or worm shaft due to excessive backlash.

The braking effect deteriorates.

Measure the backlash at least every 3 years and/or if running performance deteriorates (noises, jolting, etc.)

When a wear limit value (backlash) of 1.5 mm is reached, the gear drive must be replaced.

Measurement possibility:

1. Take load off the ropes: move the counterweight onto the buffers and lift the

elevator car with lifting gear.

The traction sheave must be free to move.

2. Run the measuring operation with the operational brake closed.

3. Release the emergency brake, if present.

4. Fit a measuring attachment to the traction sheave; e.g. screw clamp.

5. Specify the measured radius (M).

6. Mark the measuring point.

The radius (r) for the TW160 = 186 mm.

7. Attach a dial gauge with magnet stator at the gear drive housing and align to

the measuring point (M).

8. Turn the traction sheave by hand until the dial gauge pointer moves.

9. Move the traction sheave back and forth until resistance is felt in both

directions.

10. Read off the movement of the dial gauge.

11. Use the formula below to calculate the backlash.


TW160 drive


Fig. 8.4-1

M = measured radius

ME = measurement result

r = radius - worm wheel All dimensions in mm

Backlash = ME * r M

Dial gauge

Traction sheave

Worm wheel


TW160 drive


8.5 Replacing the brake shoes

With a remaining lining thickness of ≤ 3 mm, or if the linings are damaged (e.g. glazing), the brake shoes and brake linings must be replaced.

8.5.1 Disassembly

1. Switch off the installation power supply.

2. Secure the car and counterweight before starting work.

3. Loosen the two nuts on the bolt on which the compression springs for the pre-

tension are located.

4. Undo the two M8 bolts that hold the brake shoe pin in place.

5. Push the cover ring over the magnetic clamp and armature base plate

6. Undo the lock nuts on the armature screw and turn the armature screw together

with the armature base plate slightly back to enlarge the gap between the

magnetic clamp and armature base plate.

7. Screw one of the M8 screws into the front of the brake shoe bolt and pull it out of

the housing.

8. Remove the bolt, including compression springs and spring plates.

9. Remove the brake shoe.


TW160 drive


8.5.2 Installation

1. Mount the armature base plate with armature screw onto a new brake shoe

2. If required, lightly grease the sliding surface between the armature base plate

and armature screw.

3. Secure setting of the armature base plate pre-tension by tightening the lock

nuts.

4. Install the pre-assembled brake shoes; do not tighten the nuts on the

compression springs.

5. Refit the pin and locking screws.

6. Pre-tension the compression springs by approx. 20.5 mm and secure the

setting with the lock nuts.

7. Set the brake shoe stroke by adjusting the armature base plate screw on the

brake shoe. The brake shoe stroke should be 0.3 mm + 0.1 mm, measured to

the middle of the brake disc.

8. Push the cover ring over the gap between magnetic clamp and armature base

plate.

9. After replacement of the brake shoes, run the lift with electrical recall and

observe whether the both brake shoes open uniformly.

10. Set the operation position of the brake release lever with 5-10° above the

horizontal.

8.6 Setting and checking the brake shoe stroke and armature base

plate


TW160 drive



1 Magnetic clamp 2 Armature base plate

3 Working stroke of shoes 0.3 mm + 0.1 mm on the middle of the brake disc

4 Brake disc

5 Brake release lever Pressure piece with pressure rod

6 Rubber disc

7 Washer 8 Hexagon nut

9 Lock nut 10 Armature screw

11 Cover ring

Fig. 8.6-1

Before first commissioning and during monitoring, the working stroke of the brake shoes, the pretension of the brake springs and movement of the armature base plates are to be checked.


TW160 drive


Sequence:

Check ease of movement of the armature base plate

1. After a longer period of use, it can occur that the rubber disc settles between

the armature base plate and brake shoe (Fig. 8.6-1, item 6). This means that

the pretension of the armature base plate becomes insufficient.

To restore the pretension, the lock nuts (Fig. 8.6-1, Item 8) between the brake

shoe and armature base plate must be adjusted.

2. Correct pretension is achieved when the armature base plate can be turned on

the armature screw despite light suction.

Check the stroke.

1. Align a dial gauge on the brake shoe at the height of the centre of the brake disc.

2. Switch the drive to operate the brake shoes while checking the stroke of the

brake shoes. The path should be 0.3 mm + 0.1 mm.

Adjust the stroke

1. In the event of deviations, loosen the lock nuts (Fig. 8.6-1, Item 9)

2. Adjust the anchor bolt with an Allen key. On opening the brakes, make sure that

both brake shoes work with the same stroke.

3. Then secure the settings with the lock nut

Set the initial tension of the springs

A correct setting of the initial tension is only possible within the framework of a deceleration measurement. In doing so, do not exceed the maximum initial tension distance of 20.4 mm.

If brake test switches (SA3,SA3.1 and SA15) are present, these must be checked or adjusted after brake adjusting. Chapter 9.2.2


TW160 drive


8.7 Braking deceleration setting

The brake adjustment is to be carried out only with one effective brake shoe with the elevator car loaded with the rated load on a descending run (full down) or with an empty elevator car on an ascending run (empty up) according to the deceleration values in the table below.

The braking torque must be set on uniformly on both brake shoes by pre-tensioning the brake spring depending on the installation.

Braking deceleration Machine with

flywheel mass

Machine with handwinding

wheel

v in m/s 0.63 1.25 0.63 1.25 1.25

a in m/s2 (full down) 0.2 0.3 0.3 0.4 0.50

a in m/s2 (empty up) 0.4 0.5 0.5 0.6 0.75

Table 8.7-1

If brake test switches SA3 / SA3.1 are present, these must be checked or adjusted after brake adjusting. See chapter 9.2

8.8 Brake readjustment in the event of brake lining wear

With wear on the brake linings, the stroke of the brake shoes increases compared with the reference state (0.3 mm + 0.1 mm). As of a limit value of 0.6 mm, the following settings on the brake are to be checked and, if required, corrected:

1. Armature base plate pre-tension: check and, if required, adjustment of the pre-tension

2. Stroke of the brake shoes: setting to reference value 0.3 mm +0.1 mm to middle of brake disc

3. Pre-tension of the compression springs: setting of the reference value to a maximum of 20.5 mm, as well as check of the deceleration Chapter 8.5.2

4. Setting for brake test switches

5. Operation position of the brake release lever: setting to 5 - 10° above the horizontal. For readjustment, the lock nut on the pressure rod must be released and the rod in the pressure piece adjusted. Subsequently secure the setting by tightening the lock nut.

Operation position Rest position

5°-10°


TW160 drive


8.9 Replacing the traction sheave

8.9.1 Disassembly



3. Take the load off the traction sheave and disengage the ropes.

4. Use a rope or chain to secure the traction sheave on the lifting gear.

5. Undo the 3 screws on the mounting plate for the traction sheave and loosely

screw them in the outer circle of holes of the traction sheave into the traction

sheave hub (see Fig. 8.9-1, Item 2).

6. Place a spacer (approx. 5 – 10 mm thick, smaller than inner diameter of hub)

between the shaft end and the sheave.

7. By tightening the screws diagonally and evenly, remove the traction sheave

from the shaft.

WARNING

Falling traction sheave!

The traction sheave can suddenly come loose.

Secure the traction sheave with chains or ropes.

For the SA9, the worm wheel shaft must be supported (self-aligning bearing!) before removing the outside bearing.

8.9.2 Installation

DANGER

Traction sheave not resting properly on cone (is loose)!

Traction sheave tumbles and can come loose. Elevator car can crash.

Do not change the dimension of the feather key, groove, cone

shaft or traction sheave bore hole under any circumstances.

Avoid damage and contamination of the traction sheave.

Ensure correct installation.

The cone of the traction sheave and shaft must be free of grease,

oil and paint, and must be undamaged

In the case of traction sheave replacement, the new bolts that are supplied must be used.

Ensure bolts are secure and tightening torque is correct!


TW160 drive


1. Place the new traction sheave on the conical shaft end of the worm wheel shaft.

6. Align the locations of the feather key and groove in relation to one another.

7. Push the traction sheave onto the worm wheel shaft.

8. Screw on a disc with the supplied screws (microencapsulated) and detent edged

washers on the inner circle of holes of the sheave. Tighten the screws evenly

and alternately.

DANGER

Insecure threaded connection!

Death or severe physical injury due to parts coming loose.

When mounting the traction sheave, care must be taken to ensure that the prescribed bolt / screw strength of 10.9 and tightening torques of 250 Nm are complied with Chapter 10.2.

m Designation Item Designation

1 Traction sheave 2 Hole for pressure screw (3x)

3 Securing bolt (3x) 4 Mounting plate

Fig. 8.9-1

1

4

2

3


TW160 drive


8.10 Replacing the motor

Order a motor with clutch hub

8.10.1 Disassembly



3. Attach and secure the motor to the lifting gear.

4. Unplug the electrical connections.

5. Disconnect the lines from the motor (motor and magnetic clamp connection).

6. Remove the 4 axial screws for the flexible coupling and/or 4 nuts on the rigid

coupling. In the case of the flexible coupling, the elastomer part of the coupling

remains screw-connected to the brake disc.

7. In the case of the rigid coupling, the spacer washers remain between the clutch

hub and brake disc.Remove the nuts on the flange between the motor and gear

Structural shape IMB5 with flexible coupling.

chapter 10.4.

Structural shape IMB9 with rigid coupling

Carefully pull off the motor from the studs and place on the floor.

Both structural shapes

8. If the replacement motor was delivered without a handwinding wheel and

encoder or flywheel rim, remove these and use them for the new motor.

Installation instructions for encoder and handwinding wheel in Cap.8.11


TW160 drive


8.10.2 Installation

1. Compare the motor data of both motors.

2. Attach and secure the replacement motor to the lifting gear.

3. Raise the motor using the lifting gear and align the motor coupling to the brake

disc.

4. Push the motor into the gear flange and tighten the nuts.

Structural shape IMB5 with flexible coupling

Fig. 8.10-1

Mount the 4 radial screws between the coupling element and clutch hub in

line with °Chapter 10.4


TW160 drive


Structural shape IMB9 with rigid coupling

Fig. 8.10-2

Check the dimension 95 +/- 0.5 at the spacer washers.

Fit the nuts to mount the clutch hub onto the brake disc. ( Chapter 10.2)

Both structural shapes

5. Plug in the electrical connections, see Chapter 6.3


TW160 drive


8.11 Replacing the Encoder

To replace the encoder, the handwinding wheel must be removed first. Depending on the motor use, there are three ways to fasten the handwinding wheel.


1 Handwinding wheel 2 Locking washer

3 Flat countersunk nib bolt 4 Stud

5 Actual-value sensor 6 Motor

7 Encoder connection cable 8 Cable ties

9 Encoder mount

Fig. 8.11-1

8.11.1 Disassembly

Preparatory measures

1. Before starting work, switch off the power to the installation and secure against reactivation.

2. Unplug the encoder connection cable at the frequency inverter

8

9

1

2

4

3

5 6 7


TW160 drive


Handwinding wheel hub with feather key and disc screw-connected on the shaft

end

1. Remove the locking washer on the handwinding wheel by removing the

middle flat countersunk nib bolt M8 x 20.

2. Pull the handwinding wheel off the motor shaft.

3. Remove the feather key for fixation of the handwinding wheel.

Handwinding wheel hub pinned on the shaft end with adapter sleeve

1. Remove the bolt mounting of the handwinding wheel to the hub.

2. Pull the handwinding wheel off the hub.

3. Support the motor shaft; drive out the spring-type straight pin with a drift

punch; pull off the hub

Handwinding wheel hub with axial adapter sleeve (Motorlift motors)

1. Remove the screw in the middle of the handwinding wheel.

2. Pull the handwinding wheel and hub off together.

Encoder

1. Use an Allen key (2 mm) to loosen the two studs on the collar of the encoder

inner ring (do not remove).

2. Unscrew the slotted pan head tapping screw at the bracket of the encoder

mount.

3. Remove the cable ties holding back the cables.

4. Pull the encoder off the end of the motor shaft.

5. Check that the technical data of the new encoder match.

8.11.2 Installation

Encoder

1. Fit the encoder mount of the removed encoder onto the new encoder.

2. Push the new encoder onto the clean shaft end of the motor until it makes

contact with the shaft collar.

The mounting collar must point towards the shaft end.

3. Screw on the encoder mount at the motor.

4. Secure the encoder inner ring by tightening the stud on the motor shaft.


TW160 drive


Handwinding wheel hub with feather key and cover screw-connected on the

shaft end

There are two feather key grooves in the handwinding wheel borehole. When pushing on the handwinding wheel, use the groove that matches one of the three cast-on reinforcement ribs in the inside of the handwinding wheel (reduces unbalanced mass at the handwinding wheel)

1. Insert the feather key in the groove.

2. Push the handwinding wheel onto the shaft end.

3. Mount the locking washer on the new handwinding wheel.

4. Use the flat countersunk nib bolt to secure it in the motor shaft borehole.

Handwinding wheel hub pinned on the shaft end with adapter sleeve

1. Push the hub onto the shaft end.

2. Align to the borehole.

3. Support the shaft end.

4. Mount the adapter sleeve 8x45 DIN 1481.

5. Push the handwinding wheel onto the hub.

6. Secure with Allen screws M8x16 DIN 7984.

Handwinding wheel hub with axial adapter sleeve (Motorlift motors)

1. Push the handwinding wheel and hub together onto the shaft end, pushing

the borehole in the hub onto the adapter sleeve.

2. Attach the screw in the middle of the handwinding wheel.

Concluding work

1. Secure the connection line to the motor with cable ties.

2. Connect the encoder connection cable to the frequency inverter.

3. Switch on the installation and perform a teach-in run for adjustment.


TW160 drive


8.12 Check for escaping grease / oil

DANGER

Loss of the brake function!

Can lead to the elevator car falling.

Grease or oil must never come into contact with the brake disc or other components of the brake.

Replace brake linings that are contaminated with oil.

Examine the area around the bearing cover, brake drum and brake linings

for traces of oil.

Degree of soiling Procedure

No escaping oil / grease

determined

Check regularly within the

framework of maintenance

Every 3 months

(6 months in case of

reduced frequency,

< 50,000 runs per year)

If a small amount of escaping

oil / grease is determined

Clean and check regularly within

the framework of maintenance

Every 3 months

(6 months in case of

reduced frequency,

< 50,000 runs per year)

If a large amount of escaping

oil / grease is determined or

brake disc/brake linings

already fouled with oil / grease

present

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.

If necessary, check on a daily

basis whether oil / bold is still

escaping. If this is the case: shut

down the installation.

Repair after 4 weeks at

the latest

Table 8.12-1

NOTE

Use of incorrect cleaning agent!

Damage to the break

For cleaning work on the brake, only use the cleaning agent isopropanol (isopropyl alcohol).

Only carry out cleaning work on the brake surfaces.


TW160 drive



1 Brake drum 2 Bearing cover

3 Shaft sealing ring 4

Fig. 8.12-1

2

1

1

3


TW160 drive


8.13 Check of the brake linkage

The brake linkages could chafe against the cast edge of the brake shoe.

In the process, material could be removed and the braking effect impaired.

Make sure that the brake linkages are "free" and unable to chafe.

Item Designation

1 Break the cast edge at the brake shoe (debur or radius)

2 Examine the brake release pressure rod for traces of chafing; grease if necessary

Fig. 8.13-1

If necessary, debur the cast edge with a file so that there is no longer a sharp edge at this position and the brake linkages do not get stuck. If necessary, twist, align or grease the brake linkage.

1

2

Operating manual Special versions (optional)

TW160 drive


9 Special versions (optional)

9.1 Overview of special versions

Overview:

SA 1 reinforced mounting parts for horizontal or inclined pulling

SA2 extended worm shaft for handwinding wheel on gear drive

SA 3* with brake monitoring (light barrier sensor)

SA 3.1*with brake monitoring (microswitch)

SA 4 with wall bearing and extended worm drive shaft

SA 9 Traction sheave position in the shaft (extended drive shaft with pedestal bearing and machine on compensating supports for statically defined mounting / mounting of the drive shaft

SA11 with side oil drain

SA12 for drive with frequency inverter

SA14 with flexible coupling for motors in design B5

SA15 Gear, magnetic clamps and brake test switches* in full Ex version; motor and encoder in full Ex version

The special versions marked with * are delivered separately due to the risk of damage.

Explanation:

SA3 Brake test switch (light barrier sensor) to check the brake shoe position (opened-closed) and the brake lining wear.

Note: After adjusting the brake, the setting of the brake test switches must be checked and readjusted if necessary.

Description of setting, see 8.2.2 SA3 brake monitoring circuit

SA3.1 Brake test switch (microswitch) to check the brake shoe position (opened- closed) and the brake lining wear.

SA 4 Version for vapour-proof partition wall with extended drive shaft for spatial separation of drive and shaft. A sealing bearing bracket in the partition wall achieves partial Ex protection. The drive shaft is supported here by a bearing.

SA 9 Traction sheave position in the shaft (extended drive shaft) with arrangement of the traction sheave directly in the shaft. The drive shaft is supported here by a bearing.

SA11 Oil drain pipe with angled pipe leading away from the machine to the side.

SA12 Additional terminal box to connect the brake magnets if there is no possibility in the motor terminal box.

SA14 With the motor shaft double-supported by bearings (model series IMB5), any alignment irregularities are balanced out with the help of a flexible coupling. Description, see Chapter 10 Flexible coupling.

SA15 Gear, magnetic clamps and brake test switch in full Ex version; motor and encoder in full Ex version


TW160 drive


More detailed information as well as technical information for setting up and operation of full or partial Ex drives can be found in separate operating instructions. These are delivered with drives with Ex equipment.

Part number for the German instructions: 60 000 20 86 0 Part number for the English instructions: 60 000 21 86 0

9.2 Brake monitoring circuit

The brake monitoring circuit checks the brake shoes.

It prevents motor movements when the brake is partially or fully closed and

enables detection of any brake lining wear at an early stage.

Switches (sensors SA3 or microswitches SA3.1/SA15) are used to check

whether the brake shoes are closed, open, or worn.

The travel signal - derived from the W/W1 contactor - is used for the evaluation.

It is indicated by means of light emitting diodes

on the sensors (SA3 only).

on the brake monitoring in the control cabinet and/or by deactivation of the

drive.

If a Teleservice device is connected, the fault is shown on the display.

9.2.1 Installation

Switch mounting SA3 / SA3.1 on machine TW160

7 4

3 2 2 1

8

9


TW160 drive



1 Tightening screw for compression spring

2 Brake shoes

3 Adjusting screw 4 Test switch (sensor)

5 Brake release lever 6 Pressure rod

7 Motor 8 Compression spring

9 Gear drive

Fig. 9.2-1

1. If not included in the scope of supply, make 2 lines (3 x 0.75 mm² for SA3 and 2

x 0.75 mm² for SA3.1 with PVC sheaths) for direct connection of the switches to

the control system and connect the switches.

2. Mount the hexagon screws (microencapsulated) with lock nut to be adjusted on

the brake shoes (pre-assembled at the plant). The switch tappet on the sensor

must be opposite the setting screw, but should not make contact with it.

9.2.2 Setting SA3

Before starting to set the sensor; the stroke of the brake shoes must be adjusted! Description, see chapter 8.6

1. Switch on the emergency operation switch and elevator control system.

2. Adjust the setting screw for the switch.

3. The LED lights up.

4. Turn back the screw slowly.

5. The LED goes out.

6. Move the adjusting screw by ¼ turns (corresponds to approx. 0.3 mm) in the

direction of the switch and secure with a lock nut.

7. LED lights up continuously.

8. Open and close the brakes by switching the motor

9. In doing so, check that the sensors switch between open and closed brake.

9.2.3 Setting SA3.1

The break contact with contacts 11 and 12 is used to monitor the position of the brake shoes. With the brake open, the switch is closed.

The make contact closes contacts 23 / 24 only when the wear limit of the brake linings has been reached and the brake is closed. The contacts must be switched in such a way that when one contact of both switches closes the drive is prevented from starting up.

With a correctly set brake test switch, all switch contacts must be interrupted with a closed brake.

Before starting to set the sensor; the stroke of the brake shoes must be adjusted! Description, see chapter 8.6


TW160 drive


1. Connect the continuity test device to contacts 11 and 12 of the break contact.

The adjusting screw must not touch the control tappet.

2. In home position of the drive (brake magnet without current) unscrew the

adjusting screw for the brake test from the brake shoe in direction control tappet

until opening of the contact is indicated by a signal interruption at the continuity

test device.

3. Continue unscrewing the adjusting screw a further approx. 1/4 revolution.

4. Secure this setting by tightening the lock nut.

5. Repeat the setting procedure at the second brake test switch.

Checking setting:

Open and close the brakes by switching the motor. Observe whether the switch at the contacts corresponds to the procedure described above.

Push the feeler gauge between adjusting screw and control tappet. Select the thickness of the feeler so that contact 23/24 is closed.

When one of the contacts is closed, it must no longer be possible to start up the drive.

Terminal connecting diagram - brake test switch

SA3 - version


1 Button 1 2 Button 2

3 A (black) 4 - (blue)

5 + (brown)

Fig. 9.2-2


TW160 drive


SA3.1 - version


1 Button 1 2 Button 2

Fig. 9.2-3

9.2.4 switch mounting SA15 (Full-EX)

Fig. 9.2-4

The switch mounting for SA15 is described in the operating manual 'Explosion protection for machines (ATEX)'.

Schaltwege EIN AUS

Schaltbild

0

1,5

3

5,5mm

11

-12

23-2

4

12 (BU)(BN) 11

(GY) 23 24 (BK)

Operating manual Appendix

TW160 drive


10 Appendix

10.1 Blocking clamp

NOTE

Leaving the blocking clamp fitted after completion of the installation work!

Can damage the installation.

Remove the blocking clamp after completion of the installation work.

A blocking clamp that matches the traction sheave (rim width and design) is part of each machine

Deployment of the blocking clamp:

During installation work on the elevator car or counterweight to prevent

movement due to slipping ropes.

In the case of work where the rope traction of the system is insufficient, e.g.

removing from the safety gear, use the blocking clamp.

The blocking clamp is to be tensioned via the screwed connection until it is excluded that ropes will slip.


1 Traction sheave 2 Pressure piece

3 Hexagon nut 4 washer

5 Clamp clip

Fig. 10.1-1

Operating manual Appendix

TW160 drive


10.2 Tightening torques

DANGER

Insecure threaded connection!

Death or severe physical injury due to parts coming loose.

When working on the machine or in the case of parts replacement, comply with the prescribed bolt tightness and tightening torques.

Only use suitable tools (torque wrench).

Non-microencapsulated bolts / screws are to be secured against unwanted loosening during installation using detent edged washers or Loctite 243 and a similar means of securing bolts / screws.

Microencapsulated screws are to be replaced after they have been used once.

The tightening torques given here apply for screwed connections without specifications at the corresponding location.

If in the drawing or elsewhere in the document other tightening torques are predefined for the particular bolt size, these have to be observed!

The values listed below apply to screwed connections with regular threads (not fine threads):

Hexagon socket bolts DIN 912 ISO 4762

Hexagon head bolts DIN 931/933 ISO 4014/4017

Tightness 8.8 10.9 12.9

Dimensions Tightening torque MA (Nm)

M4 2.6 - -

M5 5.3 - -

M6 9.0 12 15

M8 20 30 35

M10 40 60 75

M12 75 105 130

M14 120 170 205

M16 190 265 320

M20 370 520 620

M24 640 900 1080

M30 1300 1800 2150

Table 10.2-1

For assembly, use only original construction and mounting parts from thyssenkrupp Aufzugswerke GmbH, as otherwise no warranty can be provided.

Hohlwellen - Drehgeber WDG 100H

Maßzeichnung WDG 100 H, Angaben in mm

Ausgangsschaltung 5 VDC: I05

Bestell-Nr.: WDG 100H-XX-YYYY-ABN-I05-K3-D56

YYYY = XX = Hohlwellendurchmesser: 30, 38 mm

Empfohlene Wellenanpassung:für Hohlwellendurchmesser D (XX) = 38: 38m6 (k6, j6)für Hohlwellendurchmesser D (XX) = 30: 30m6 (k6, j6)Max. Rundlaufabweichung der Antriebswelle: 0,05 mm

Thyssen-Sachnummer: 9950 000 6021 für 1024 Striche9950 000 6022 für 4096 Striche

Impulszahl = 1024, 2048, 4096

Impulsfolge bei Blick auf Nabe, Drehung im Uhrzeigersinn.

18.08.2016/Angaben ohne Gewähr Irrtümer und Änderungen vorbehalten.

Elektrische Daten:

Versorgung: 4,75 ... 5,5 VDCStromaufnahme: max. 70 mAKanäle: A, B,N und

ABN inv.Ausgang: GegentaktBelastung: max. 40 mAPegel: bei 20 mA

H > 2,5 VDCL < 1,2 VDC

Impulsfrequenz: max. 200 kHzAnschlussschutz: nein

A

A

B

B

N

N

0° 360°90°

Spezifikationen

Mechanische DatenGehäuse

- Flansch: Aluminium- Rückseite: Aluminium- Durchmesser: 100 mm- Tiefe: 42 mm- Befestigung: über Hohlwelle mit

2 Gewindestiften M4

Hohlwelle

- Material: Edelstahl- Durchmesser: 30, 38 mm- Belastung am max. 200 N radial Wellenende: max. 100 N axial- Anlaufmoment: 1,5 NcmBefestigung: 2 x M4, DIN 913

Lager - Typ: 2 Präzisionskugellager

10- Lebensdauer: 3 x 10 U bei 100%

Lagerlast11

4 x 10 U bei 40%12

3 x 10 U bei 20%Drehzahl: max. 3.500 U/minGewicht: ca. 720 gAnschluss: radialer Kabelabgang

mit 10m Kabel undkonfektioniertem, metallisiertem 9-pol.SubD-Stecker mitRändelschraube UNC 4-40

Elektrische Daten Allgemeine Auslegung: gem. DIN VDE 0160

Versorgung/Ausgänge: ® AusgangsschaltungKabellänge: max. 100 m

OptikLichtquelle: IR - LEDLebensdauer: typ. 100.000 Std.Abtastung: differentiell

Genauigkeit in % einer Periodendauer des Signals A

Phasenversatz: 90° + 4,2%Impuls-/Pausen -verhältnis: 50% + 4,2%

Umwelt - Daten

bei geerdetem Gehäuse und gegen imEingebauten Zustand berührbare Teile.

ESD (EN 61000-4-2): 8 kVBurst (EN 61000-4-4) 2 kVSchutzart (EN 60529): IP 54Vibration (IEC 68-2-6): 50m/s² (10-2000 Hz)Stoß (IEC 60068-2-27): 1000m/s² (6 ms)Arbeitstemperatur: -20 - +80°CLagertemperatur -30 - +80°C

WD

G

5 V

Signal

Masse

Ausw

ert

ung

Schirm

26ET3126LS32A,B,N

A,B,N

1kW

1kW

100

W

3

11

15°

37

42

63

+0,03

40

2 x GewindestiftM 4 x 4 DIN 913

+0,05

SteckerbelegungFunktion Pin FarbeMinus 7 weißPlus 9 braunA 2 grünA inv. 1 rotB 3 gelbB inv. 4 schwarzN 5 grauN inv. 6 violettSchirm 8 Litze + Gebergehäuse

+ Steckergehäuse

31

,8

25

UN

C 4

/40

46,5

39,5

5

15,4

1 2

3 4

5

6 7

8 9

Wachendorff Automation GmbH & Co. KGIndustriestrasse 7D-65366 GeisenheimTel.: +49 (0) 67 22 / 99 65 - 25Fax: +49 (0) 67 22 / 99 65 - 70www.wachendorff-automation.de

WDG100H-xx-yyyy-ABN-I05-K3-D56-zzzxx = Ø 25, 25.4, 28, 30, 38, 40, 42, 45yyyy = PPR = 1024, 2048, 4096zzz = 130 = 13m, 200 = 20m, blank = 10m

Technical SupportGermany:Tel.: +49 (0) 67 22 / 99 65 131Fax: +49 (0) 67 22 / 99 65 70email: [email protected]

Other countries, please contact your distributor.Autres pays, veuillez contacter votre distributeur.Otros paises, rogamos contacten a su distribuidor.Per gli altri paesi si prega di contattare il vostrodistributore.

18.08.2016

SUBD99-pin

7

9

2

5

1

4

6

8

WH

BN

GN

YE

GY

-

RD

BK

VT

Litze, Flex, Toron,

Cordón,Cavetto

3

Kabel, cable, Câble,Cable, cavo

K3

1 2 3 4 5

6 7 8 9

Steckergehäuse/Schirmmit Gebergehäuse leitendverbunden

Connector housing/shieldelectrically connected toencoder housing

Bôtier de connexion/Ecran avec boîtier d’ementteur liés de manière conductrice

Caja de conector/Pantallsconectada en conductancia com caja de transmisor

scatola prese/Schemo conscatola transmettitore collegata da condure

31,8

25

UN

C 4

/40

46,5

39,5

5

15,4

1 2

3 4

5

6 7

8 9

4,2

4,2

TTL / RS422

Wachendorff Automation GmbH & Co. KGIndustriestraße 7 • D-65366 GeisenheimTel.: +49(0)6722/99 65 -25Fax: +49(0)6722/99 65-70eMail: [email protected]

D56

Hollow shaft Encoder WDG 100H

Dimensional drawing WDG 100H Dimensional specifications, in mm.

Output circuit: 5 VDC: R05

Order-No.: WDG 100H-38-1024-AB-R05-K3-J66-100

Suggested shaft adjustment:about hollow shaft diameter 38mm: 38m6 (k6, j6)Max. concentricity deviation of motor shaft: 0,05 mm

Thyssen-No.: 9950 001 1304

View from shaft end, rotating clockwise.

19.05.14/Specifications without engagement, subject to errors and

Electrical data:

Power supply: 4,75 ... 5,5 VDCCurrent consumption: max. 70 mA Channels: A, B and

AB inv. Output: push-pullLoad: max. 40 mA Signal level: bei 20 mA

H > 2,5 VDCL < 1,2 VDC

Pulse frequency: max. 200 kHzCircuit protection: no

Specifications

: 38 mm

ca. 720 g

Electrical Data General Layout: DIN VDE 0160

Supply / Output: ® Output circuitCable lenght: max. 100 m

in % einer Periodendauer des Signals A

.

Mechanical Data

Housing

- Servo flange: Aluminium- Housing: Aluminium,- Depth: 42 mm- Attachment: about Hollow-shaft with

2 set screw M4Hollow shaft

- Material: Stainless steel- Diameter:- Loading on shaft- max. 200 N radial end: max. 100 N axial- Starting torque: approx.1.5 Ncm at

ambient temperaturAttachment: 2 x Hub M4, DIN 913

Bearings

- Type: 2 precision ball bearings

10- Service life: 3 x 10 revs. at 100%

of full rated shaft load11

4 x 10 revs. at 40%12

3 x 10 revs. at 20%Speed: max. 3.500 r.p.m.Weight:Connection: radial with 10 m

shielded cable withconnector(7-pol. Phönix terminal)

Optics

Light source: IR - LEDService life: typ. 100.000 hrs.Scanning: differential

Accuracy

Quadratue phasing: 90° + 7,5% Pulse on/off ratio: 50% + 7%

Environmental Data

Measured mounted and housing grounded

ESD (DIN EN 61000-4-2): 8 kV Burst (DIN EN 61000-4-4): 2 kVProtection rating (EN 60529): IP54Vibration 50m/s² (10-2000 Hz)(DIN EN 60068-2-6): Shock 1000m/s² (6 ms)(DIN EN 60068-2-27): Operating temperature: -20°C to +80°CStorage temperature: -30°C to +80°C

2 x set screwM 4 x 4 DIN 913

WD

G

5 V

Signal

Ground

Eva

lua

tion

Shield

26ET3126LS32A,B

A,B

1kW

1kW

10

0W

Wachendorff Automation GmbH & Co. KGIndustriestrasse 7D-65366 GeisenheimTel.: +49 (0) 67 22 / 99 65 - 25Fax: +49 (0) 67 22 / 99 65 - 70www.wachendorff.de

3

11

15°

37

42

63

+0,03

40

+0,05

10

01

00

00

100

R05A

A

B

B

Pin arrangemant:Function Pin Colour

Negative 6 whitePositiv 7 brownA 5 greenA inv. 4 greyB 3 yellowB inv. 2 pinkShield 6 braiding

Cable connection, 10 m shielded cable

Hohlwellen - Drehgeber WDG 100H

Maßzeichnung WDG 100 H, Angaben in mm

Ausgangsschaltung 10-30 VDC: I24

Bestell-Nr.: WDG 100H-XX-1024-ABN-I24-K3-C07

Impulszahl: 1024 I/UXX = Hohlwellendurchmesser: 38 mm (28,40,42)*Thyssen-Sachnummer: 0099016030*ohne Sachnummer

Impulsfolge bei Blick auf Nabe, Drehung im Uhrzeigersinn.

Kabelbelegung

Funktion FarbePlus braunA grünB gelbN grauA inv. rotB inv. schwarzN inv. ViolettMinus weißSchirm Litze

18.08.2016/Angaben ohne Gewähr Irrtümer und Änderungen vorbehalten.

Spezifikationen

Mechanische DatenGehäuse

- Flansch: Aluminium- Rückseite: Aluminium- Durchmesser: 100 mm- Tiefe: 42 mm- Befestigung: über Hohlwelle mit

2 Gewindestiften M4

Hohlwelle

- Material: Edelstahl- Durchmesser: 38 mm- Belastung am max. 200 N radial Wellenende: max. 100 N axial- Anlaufmoment: 1,5 NcmBefestigung: 2 x M4, DIN 913

Lager - Typ: 2 Präzisionskugellager

10- Lebensdauer: 3 x 10 U bei 100%

Lagerlast11

4 x 10 U bei 40%12

3 x 10 U bei 20%Drehzahl: max. 3.500 U/minGewicht: ca. 720 gAnschluss: radialer Kabelabgang

mit 10m Kabel mitAderendhülsen

Elektrische Daten Allgemeine Auslegung: gem. DIN VDE 0160

Versorgung/Ausgänge: ® AusgangsschaltungKabellänge: max. 100 m

OptikLichtquelle: IR - LEDLebensdauer: typ. 100.000 Std.Abtastung: differentiell

Genauigkeit in % einer Periodendauer des Signals A

Phasenversatz: 90° + 7,5%Impuls-/Pausen -verhältnis: 50% + 7%

Umwelt - Datenbei geerdetem Gehäuse und gegen im eingebauten Zustand berührbare Teile.

ESD (EN 61000-4-2): 8 kVBurst (EN 61000-4-4)- auf Versorgung: 2 kVSchutzart (EN 60529): IP 54Vibration (IEC 68-2-6): 50m/s² (10-2000 Hz)Stoß (IEC 68-2-27): 1000m/s² (11 ms)Betriebstemperatur: -10 - +70°CLagertemperatur -30 - +80°C

Elektrische Daten:

Versorgung: 10 - 30 VDCStromaufnahme: max. 60 mAKanäle: A, B, N, ABN inv.Ausgang: HTL-

DifferentialtreiberBelastung: max. 40 mAPegel: bei 20 mA

H > U - 2,5 VDCB

L < 2,5 VDCImpulsfrequenz: max. 200 kHzAnschlussschutz: neinFrühwarn- Ausgang: NPN OC, 10 mA

U = 30 VDCmax

Kabellänge: max. 100 m

A

A

B

B

N

N

0° 360°90°

WD

G

Schirm

Ausw

ert

ung

Masse

Signal

10-30 V

A,B,N

A,B,N

Wachendorff Automation GmbH & Co. KGIndustriestrasse 7D-65366 GeisenheimTel.: +49 (0) 67 22 / 99 65 - 25Fax: +49 (0) 67 22 / 99 65 - 70www.wachendorff-automation.de

WDG100H-xx-yyyy-ABN-I24-K3-C07xx = Ø 28, 38, 40, 42mmyyyy = PPR 1024, 4096

Technical SupportGermany:Tel.: +49 (0) 67 22 / 99 65 131Fax: +49 (0) 67 22 / 99 65 70email: [email protected]

Other countries, please contact your distributor.Autres pays, veuillez contacter votre distributeur.Otros paises, rogamos contacten a su distribuidor.Per gli altri paesi si prega di contattare il vostrodistributore.

18.08.2016

Steckergehäuse/Schirmmit Gebergehäuse leitendverbunden (Nicht S7, K1, K2, K3)

Connector housing/shieldelectrically connected toencoder housing (not S7, K1, K2, K3)

Bôtier de connexion/Ecran avec boîtier d’ementteur liés de manière conductrice (No S7, K1, K2, K3)

Caja de conector/Pantallsconectada en conductancia com caja de transmisor(No S7, K1, K2, K3)

scatola prese/Schemo conscatola transmettitore collegata da condure(No S7, K1, K2, K3)

BU:

-

-

-

-

-

-

-

-

-

WH

BN

GN

YE

GY

-

RD

BK

VT

Litze, Flex, Toron,

Cordón,Cavetto

-

Kabel, cable, Câble,Cable, cavo

-

, ,,

-

Wachendorff Automation GmbH & Co. KGIndustriestraße 7 • D-65366 GeisenheimTel.: +49(0)6722/99 65 -25Fax: +49(0)6722/99 65-70eMail: [email protected]

C07

Tachogenerator RE.0444 zu SA 1

Anschlusshinweis

6085103100 / 2620-16

BERNSTEIN AG . Hans-Bernstein-Straße 1 . 32457 Porta Westfalica . www.bernstein.eu

Technical modifications and errors excepted.

The technical datasheet corresponds to the technical state as of 2016-10-24 and will not be removed in case of changes.

Page 1 of 2

Technical Data

Plastic bodied limit switch

Series BI2

Operating symbol

Operating diagram

Description BI2-U1Z W Article number 6085103100

Tolerance:Operating Point ± 0,25 mm;Operating force ± 10 %On Off

Electrical Data

Rated insulation voltage Ui 400 V ACConv. thermal current Ithe 10 A

Rated operational voltage acc. to CCSAUS

UeUe

240 V AC300 V AC

Utilization category AC15 Ue / Ie 240 V / 3 ADirect opening action p acc. to IEC/EN 60947-5-1, annex KShort-circuit protective device Fuse 10 A gGProtection class II (totally insulated)

Fixed positioning with e.g. fixing screw M5

according to the standard DIN EN ISO 4762.

6085103100 / 2620-16

BERNSTEIN AG . Hans-Bernstein-Straße 1 . 32457 Porta Westfalica . www.bernstein.eu

Technical modifications and errors excepted.

The technical datasheet corresponds to the technical state as of 2016-10-24 and will not be removed in case of changes.

Page 2 of 2

Technical Data

Mechanical data

Enclosure Thermoplastic, glass fibre reinforcedCover Thermoplastic, glass fibre reinforcedActuator plunger (Thermoplastic)Ambient air temperature -30 °C ... +80 °CContact type 1 NC, 1 NO (Zb)Mechanical life 10 x 106 operating cyclesSwitching frequency ≤ 100 / min.Assembly 2 x M4 / 2 x M5 / 2 x M3 front mountingConnection 4 screw connections (M3,5)

Conductor cross-sections Solid: 0,5 ... 1,5 mm²Litz wire with ferrules: 0,5 ... 1,5 mm²

Cable entrance 2 x M16 x 1,5Weight ≈ 0,08 kgInstallation position operator definableProtection type IP65 acc. to IEC/EN 60529; DIN VDE 0470 T1

ID for safety engineering

B10d 20 x 106 cycles

Standards

VDE 0660 T100, DIN EN 60947-1, IEC 60947-1VDE 0660 T200, DIN EN 60947-5-1, IEC 60947-5-1DIN EN ISO 13849-1

EU Conformity

acc. to directive 2014/35/EU

Notes

The degree of protection specified (IP code) applies only to a properly closed protective guard and the use of an equivalent cable gland with adequate cable.

Actuation

The push bolt actuator is mainly intended to be actuated along its axis.Side actuation will considerably reduce switch life.

Approvals

CCSAUS A300, Q300CCC

Technische Daten Kontaktloser Taster im Biggy-Gehäuse

Dieses Dokument wird nicht Vertragsgrundlage; die darin enthaltenen Angaben stellen keine Beschreibungen zu erwartender Beschaffenheiten dar, so dass eine Sachmängelhaftung wegen eventueller Abweichungen der tatsächlichen von der hier beschriebenen Beschaffenheit ausgeschlossen ist. Änderungen bleiben vorbehalten.

Ausgabedatum : 29.03.2011 / Blatt 1 von 2 Dokument : 6659381003_de / Stand : 1 / 0152-11

Baureihe OR81

Typbezeichnung OR81GL-DHTN-0005-ALX Artikelnummer 6659381003

Anschlussschema

+ + A

-

not connected

T

-

Schaltweg (Betätigungsrichtung, -kraft in Stößelrichtung)

Befestigungsschraube M5 nach DIN 912

oder DIN EN ISO 4762 Betätigungskraft F ≤ 12N

Bernstein AG, Tieloser Weg 6, D-32457 Porta Westfalica / www.bernstein.eu Vorlage : 0850174277 Orig. 3

Technische Daten Kontaktloser Taster im Biggy-Gehäuse

Kennzeichnende Merkmale nach EN 60947-5-2

Elektrische Daten

Schaltelementfunktion NPN - Schließer Hysterese H ≈ 0,05 mm Bemessungsbetriebsspannung Ue 24 VDC Bemessungsbetriebsspannungsbereich UBB 20,4 – 27,6 VDC Bemessungsisolationsspannung Ui 75 VDC Bemessungsstoßspannungsfestigkeit Uimp 500 VAC Gebrauchskategorie DC 12 Bemessungsbetriebsstrom le 50 mA Kleinster Betriebsstrom Im 1 mA Leerlaufstrom lo ≤ 20 mA Reststrom Ir ≤ 0,2 mA Max. Laststrom 200 mA Art des Kurzschlussschutzes rastend Schaltfrequenz f ≤ 6000 / h Verpolschutz ja Bereitschaftsverzug tv ≤ 4 ms bei UB = 24 VDC B

Einschaltverzug ton < 1 ms Elektromagnetische Verträglichkeit (EMV)

Hochfrequenzbeeinflussungsfestigkeit IEC 61000-4-3 Elektrostatische Entladungsfestigkeit IEC 61000-4-2 Schnelle Transientenfestigkeit (Burst) IEC 61000-4-4 Stoßspannungsfestigkeit (Surge) IEC 61000-4-5 Störaussendung CISPR 11

Mechanische Daten

Gehäuse PA6, rot Deckel PA66, schwarz Stößel Betätigung POM, natur Manschette CR, schwarz Befestigung 2 x M4 / 2 x M5 / 2 x M3 Frontbefestigung Betriebstemperatur 0 °C ... +60°C Lagertemperatur -20 °C ... +80°C Schutzart IP65 Verschmutzungsgrad 3 Anzeigen LED gelb Anschlussart Schraubklemmen (M3,5) Leiterquerschnitte Eindrähtig 0,5 – 1,5mm² oder Litze mit Aderendhülse 0,5 – 1,5mm² Kabeleinführung 2 x M16x1,5 (Kabelverschraubung, Blindkappe)

EG-Konformität

Bemerkungen

Etikett nach Kundenvorgabe zusätzlicher Aufdruck des Fertigungskodes nach Artikelnummer

0099216070

6659381003

Dieses Dokument wird nicht Vertragsgrundlage; die darin enthaltenen Angaben stellen keine Beschreibungen zu erwartender Beschaffenheiten dar, so dass eine Sachmängelhaftung wegen eventueller Abweichungen der tatsächlichen von der hier beschriebenen Beschaffenheit ausgeschlossen ist. Änderungen bleiben vorbehalten.

Ausgabedatum : 29.03.2011 / Blatt 2 von 2 Dokument : 6659381003_de / Stand : 1 / 0152-11

Bernstein AG, Tieloser Weg 6, D-32457 Porta Westfalica / www.bernstein.eu Vorlage : 0850174277 Orig. 3

ABV, ESV, EU-BD and the shaft calculations can be found in the following operating manual:

Document number DE 65 999 01 86 0 EN 65 999 02 86 0 FR 9710 000 9229

ThyssenKrupp Aufzugswerke

Operating Manual Emergency Brake System NBS for: TW45C, TW63; TW130; TW160

thyssenkrupp Aufzugswerke GmbH

Bernhäuser Strasse 45

73765 Neuhausen a. d. F.

Germany

E-mail: [email protected]

Internet: www.thyssenkrupp-elevator-eli.com

Ve

rsio

n 0

3/2

019

No

. 6

2 3

40 0

2 8

6 0

Operating manual - TW160 drive

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Transcript of Operating manual - TW160 drive