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All rights reserved © Copyright by ThyssenKrupp Aufzugswerke GmbH Note on industrial property rights ISO 16016 Printed in Germany This document – including excerpts – may only be reprinted or otherwise copied with the express approval in writing of ThyssenKrupp Aufzugswerke GmbH. Any duplication, dissemination or storage on data media unauthorised by ThyssenKrupp Aufzugswerke GmbH is an infringement of copyright and shall give rise to prosecution. Right to make changes of a technical nature reserved We expressly reserve the right to make changes of a technical nature for the purpose of improving our products or enhancing the safety standard - even without a separate announcement. Colouring The colouring of the components used in our documentation is used only for the documentation. Enquire about colours for your products from your ThyssenKrupp Aufzugswerke Sales Partner. Issued by ThyssenKrupp Aufzugswerke GmbH Bernhäuser Strasse 45 73765 Neuhausen a. d. F. Germany E-mail: [email protected] Internet: www.thyssenkrupp-elevator-eli.de

OPERATING MANUAL TW45C

ThyssenKrupp Aufzugswerke GmbH

List of contents

Drive TW45C PAGE

1. Safety 1.1 Symbols 6 1.2 Safety instructions 7

2. Product description 2.1 Description 10 2.2 Functional description 11

3. Technology 3.1 Technical data 14 3.2 Dimensions of machine 17 3.3 Dimension sheets of the machine 21 3.4 Machine base frame (optional) 26 3.5 Encoder 27 3.6 Brake 28

4. Transport and storage 29

5. Mounting the machine 5.1 Machine setup 32 5.2 Mounting the rope guard 33 5.3 Connecting the machine 34

6. Commissioning 37 6.1 Emergency operation 38

7. Maintenance / service 7.1 Maintenance 40 7.2 Lubrication 41 7.3 Testing the brake 43 7.4 Replacing the brake 45 7.5 Checking the backlash 47 7.6 Replacing the traction sheave 48 7.7 Motor replacement 49 7.8 Checking for escaping grease / oil 50

8. Appendix 8.1 Tightening torques – tightness values 51 8.2 Blocking clamp 53

9. Changes 54 Manufacturer specifications for brake

Manufacturer specifications for encoder Manufacturer specifications for motor Type test certificate

5 08-2012

OPERATING MANUAL TW45C SAFETY


1. Safety

1.1 Symbols

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

Danger

This symbol indicates extreme danger to life and the health of persons. Nonobservance can lead to death or severe injury!

Danger This symbol indicates an immediate danger to the life and health of persons due to electrical current. Hazard warnings must always be observed!

Warning

This symbol warns against imminent danger. Nonobservance can lead to physical injury or extensive damage to property. Warnings must always be observed!

Note

This symbol indicates important information and operating instructions. Nonobservance can lead to damage, danger or malfunctions.

Test

Test steps are specified with this symbol. The test instructions marked in this way must be followed without fail. They contribute to preventing personal injury or damage to property.

6 08-2012



1.2 Safety instructions

Notes regarding this operating manual

A requirement for safe handling and non-disruptive operation of this assembly is knowledge of the fundamental safety regulations. This operating manual contains the most important information that is required to operate the assembly safely. The operating manual, in particular the safety instructions, is to be complied with by all persons that work on this assembly. Furthermore, the rules and regulations covering accident prevention that apply to the installation site are to be complied with.

Obligations of the operator and/or of the installation firm

The operator and / or installation company undertakes only to allow persons to work on the assembly who

• are familiar with the regulations regarding work safety and accident prevention and have been instructed in handling the assembly.

• have read the chapter on safety and the warnings in this operating manual.

Note: check at regular intervals that the personnel work with a heightened awareness with regard to safety.

Obligations on the part of personnel

Persons assigned to work on subassemblies undertake before starting work to

• observe the regulations regarding work safety and accident prevention.

• read the chapter on safety and the warnings in this operating manual.

Training of the personnel

Only trained and instructed qualified personnel may work on the assembly. The responsibility of the personnel is to be clearly defined for all tasks involving commissioning, operation, maintenance and repair.

Organisational measures

The required personal protective equipment is to be provided by the operator or installation firm, as the case may be. All existing safety devices are to be tested regularly in accordance with the maintenance plan.

7 08-2012



Informal notes on the safety measures

• The operating manual is to be kept permanently at the usage site of the installation.

• Complementary to the operating manual, the generally applicable and local regulations for accident prevention and environmental protection are to be provided and complied with.

• Legally prescribed safety instructions are to be provided for the users at clearly visible positions.

• Keep all safety and hazard warnings on the installation in a legible condition.

Use in line with intended purpose

The TW45C has been constructed using state-of-the-art technology and in line with the recognised technical safety regulations. The TW45C may only be

• deployed in line with the intended purpose and

• used when all the technical safety features are in perfect condition.

The exclusive intended purpose of the TW45C is to drive elevator cars. 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. Proper use in line with the intended purpose also includes

• observance of all instructions in the operating manual and

• adherence to commissioning instructions, system description and inspection and maintenance work.

Warranty and liability

As a general principle, the 'General Terms of Sale and Delivery' of THYSSENKRUPP AUFZUGSWERKE GmbH apply. Warranty and liability claims in the event of personal injury and damage to property shall be excluded if they arise due to any of the following causes:

• Improper use that is not in line with the intended purpose of the TW45C

• Installation, commissioning, operation and maintenance that is not in line with accepted

technical principles for the TW45C

• Operation of the TW45C machine with defective and/or

non-operative safety and protective devices

• Nonobservance of the instructions in the operating manual with regard to

Transport, storage, installation, commissioning, operation and maintenance

of the TW45C

• Constructional changes to the TW45C performed by the operator

• Changes to the drive ratios (power output etc.) performed by the operator

• Deficient monitoring of parts that are subject to wear

8 08-2012



• Repairs that are carried out improperly

• Cases of catastrophe due to third-party interference and force majeure.

Constructional changes to the TW45C

The TW45C is set at the plant and delivered ready for operation. If changes are made to the machine, the entire warranty of THYSSENKRUPP AUFZUGSWERKE GmbH shall become null and void. NB : the oil necessary for operation has been added at the plant! Check this before the first commissioning by looking at the oil gauge glass.

Risks in handling the TW45C

The traction sheave and handwinding wheel of the TW45C 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). Note: 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 assembly or other assets can arise. Malfunctions that can impair safety are to be rectified immediately. NB: work may only be carried out on the drive when it is at a standstill. The drive must be secured against inadvertent starting (for example by locking the key-operated switch or removing fuses in the power supply). 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. NB: the shaft version of the machine (MRL) has no manual release. It can only be operated with suitable electrical additional measures that are not included in the scope of supply. Suitable measures must be taken by the manufacturer of the elevator installation:

a) to be able to operate the brake in emergencies (power failure).

b) to enable the elevator car to be pulled out of the safety gear if the safety gear has triggered.

(for example, by means of a winching device for ropes on the elevator car or counterweight).

c) to enable an individual check of each of the brake circuits.

9 08-2012

OPERATING MANUAL TW45C PRODUCT DESCRIPTION


2. Product description

2.1 Description

1 Handwinding wheel 7 Rope guard plate

2 Encoder 8 Rope guard carrier

3 Motor 9 Gear

4 Transport eyebolt 10 Disc brake

5 Traction sheave 11 Motor terminal box

6 Disc on the traction sheave shaft

Fig. 2.1

Fig.: TW45C in vertical version for installation in the machine room

1

2

3

4

5

11

6

9

8 7

10

7

4

10 08-2012



Versions

The TW45C can be supplied in 2 versions:

a) for installation in the machine room (TWR) in vertical and horizontal version

b) for installation in the shaft (MRL) only in horizontal version No brake release lever and no handwinding wheel are fitted on this version.

The following versions can be supplied:

• Drive output

• Gear ratio

• Traction sheave version

• Traction sheave arrangement for the horizontal version in right-hand and left-hand design (definition as viewed from motor to gear)

• Pulse generator version

As an option, an emergency braking device NBS is fitted. This provides protection against overspeed in an upward direction. It consists of an additional disc brake that affects the traction sheave shaft.

Note: the emergency braking device NBS cannot be retrofitted!

2.2 Functional description

The TW45C machine (ThyssenKrupp Wormgear / Q = 450 kg / generation C).

Machines with worm gear, anti-friction bearings, lubrication with synthetic gear oil for traction elevators.

The TW45C will be available from May 2011 onwards and it differs from the previous version TW45B in that there are modified anti-friction bearings with optimised sealing (hub unit on worm shaft).

Hub-Unit

11 08-2012



The gear (gear drive) consists of a single-stage worm gear mounted on roller bearings. The housing is designed in as a monoblock with two separate flange-connected side bearing brackets. The power transmission from the motor to the gear takes place via a flexible coupling. A dual-circuit disc brake is installed between the motor and gear. The traction sheave is overhung. The worm gear toothing is supplied with synthetic oil during operation by means of flood lubrication.

NB: with gear reductions up to 25.5, the gear has no automatic interlock. With larger gear reductions, the gear can have an automatic interlock.

Depending on the version, the drive comes from a three-phase motor standing vertically on the gear or flange-connected horizontally on the gear to the worm shaft, via worm wheel, traction sheave shaft to the traction sheave.

The drive motors are designed as device category B5 / V1 with an ICE

flange ∅250 mm to accommodate the motor. PTC thermistors are installed in the motor to provide protection against thermal overloads. The connection of the thermal motor monitoring is located in the motor terminal box. More details on the motor can be found in chapter 3. Kind of drive As standard, the TW45C is delivered with a frequency-controlled three-phase motor. A pulse generator for speed monitoring can be supplied as an option. This is fitted on the motor shaft. Technical data and manufacturer specifications of the offered encoder versions can be found in chapter 8. In the case of drives for the machine room (TWR), a handwinding wheel is firmly mounted. Coupling Worm shaft and rotor shaft of the motor are connected by a flexible coupling. This is completely maintenance free. The coupling half connected to the gear is provided with an external spline. This transfers the driving motion to the brake rotor of the disc brake. Brake NB: The brakes of the TW45C are intended for static application as a parking brake. Dynamic braking is restricted to emergency and inspection braking. During normal operation, the wear on the friction linings is negligible. Under no circumstances does the brake replace safety systems for downward operation.

12 08-2012



Emergency braking device NBS

An additional protective device that works as an emergency brake in the event of overspeed upwards is fitted as an option. A description and more detailed information on the emergency brake can be found in a separate operating manual that is supplied with the order for the emergency braking device, NBS. Traction sheave One-part version of the traction sheave (rim and hub) in floating arrangement on the conical shaft end of the drive shaft, secured with a disc. More details can be found in chapter 3, Technical data. Encoder An overview of the encoders deployed with technical details can be found in chapter 8. Ambient conditions The environment at the location of the drive (moisture, temperature) must correspond to normal indoor climate conditions for machine rooms (according to EN 81, between +5° and +40° C). The relative air humidity must not exceed 70%. Further technical details, see type plate on the drive.

13 08-2012

OPERATING MANUAL TW45C TECHNOLOGY


3. Technology

3.1 Technical data

3.1.1 Gear unit

Designation Unit

Manufacturer

Gear type

Axle distance [mm]

Gear ratios

Type of oil

Designation

Backlash [°]

Weight [kg]

1) available from the start of 2013

Oil filling [L]4.0 (horizontal motor position)

5.0 (vertical motor position)

Synthetic gear oil

(polyalkylene glycol with additives)

SM1

Technical data

0.03 - 0.07

approx. 105

ThyssenKrupp Aufzugswerke

TW45C

120

40:3 / 41:2 1)

/ 32:1 / 46:1

Permitted radial load on the traction sheave shaft: max. 30 kN

3.1.2 Weight TW45C in standard version

Machine location m (kg)

Machine room

Headroom Shaft pit

Assembly, winch TW45C 1)

120 x x x x

Assembly, winch TW45C 2)

160 x x

Motor 5.2 kW 50 x x x x x

Motor 7.0 kW 60 x

Traction sheave D590 60

Traction sheave D520 55 x x



Traction sheave D320 30

Assembly, entire machine - 215 225 255 265 195 205 1)

Version without emergency brake 2)

Version with emergency brake, NBS

Table 3.1

Table 3.2

14 08-2012



3.1.3 Noise levels Airborne noise levels in the machine room at a distance of 1 m during operation at normal rating at the TKAW frequency converter:

•approx. 63 dB(A) at motor speed n1 ≤ 1250 rpm



15 08-2012



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

Designation Unit Technical data

Diameter - DT (mm) 320 360 440 520 590

Rim width - B (mm) 102 77 115

Max. number of grooves - z x d

7 x 8 5 x 8 7 x 8 / 6 x10

6 x 11

7 x 8 / 6 x 10 6 x 11 / 5 x 12

Groove type Seat / vee groove 1)

Vee groove angle Depends on project specs 1) Groove clearance -

GC

standardised

7x8-S95-RA14.0

5x8-S85-RA14.5

4x8-K45- RA18.5

Versions 5x8-S90-RA14.5

Weight (kg) 30 25 45 55 60

Material Specially alloyed EN-GJL 250 1)

Version in accordance with a factory standard 60 300 50 00 0 with hardened groove flanks (min. 50 HRc)

Note: details of the emergency brake (NBS) can be found in a separate operating manual that is supplied if the brake is fitted.

Table 3.3

16 08-2012



3.2 Dimensions of machine

Installation in the machine room / vertical motor position

1 Driving gear (vertical motor position / mounting surface - foot)

2 Traction sheave (D360 / D440 / D520 / D590)

3 Motor 4 Operational brake (2x50 Nm)

5 Actual-value sensor 6 Handwinding wheel (D270)

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

9 Oil filling hole and ventilation (R3/4") 10 Oil level monitoring (gauge glass)

11 Traction sheave mount 12 Motor connection (M16x1.5 / M25x1.5)

13 Transport eyebolts 14 Mounting surface machine base frame (foot mounting)

15 Manual release for operational brake (plug-in)

Fig. 3.1

17 08-2012



3.2.1 Installation in the machine room / horizontal motor position

1 Driving gear (horizontal motor position / mounting surface - foot)

2 Traction sheave (D360 / D440 / D520 / D590)

3 Motor 4

5 Actual-value sensor 6 Handwinding wheel (D270)

7 Rope guard (adjustable) 8 Oil drain (R3/4")


11 Traction sheave mount 12 Motor connection (M16x1.5 / M25x1.5)

13 Transport eyebolt 14 Mounting surface machine base frame (foot mounting)

15 Operational brake (2x50 Nm) 16 Manual release for operational brake (plug-in)

Fig. 3.2

18 08-2012



3.2.2 Installation in the headroom

1 Driving gear (horizontal motor position / mounting surface - flange)

2 Traction sheave (D360)

3 Motor 4 Operational brake (2x50 Nm)

5 Actual-value sensor 6 Motor connection (M16x1.5 / M25x1.5)

7 Transport eyebolt 8 Oil drain (R3/4")


11 Traction sheave mount 12 Mounting surfaces of machine base frame (flange fixing)

Fig. 3.4

TW45B_24001_GER

19 08-2012



3.2.3 Installation in the shaft pit

1 Driving gear (horizontal motor position / mounting surface - flange)

2 Traction sheave (D360 / 440 / 520 / 590)

3 Motor (connection box at side) 4 Operational brake (2x50 Nm)

5 Actual-value sensor 6 Motor connection (M16x1.5 / M25x1.5)

7 Transport eyebolt 8 Oil drain (R3/4")


11 Traction sheave mount 12 Mounting surfaces of machine base frame (flange fixing)

13 Handwinding wheel D270 (optional)

Fig. 3.5

20 08-2012



3.3 Dimension sheets of the machine 3.3.1 Version for the machine location in machine room / vertical motor position

1 Traction sheave position on right, mirror-inverted to A-A

2 Screwed connections - machine base frame M16 -8.8

3 with traction sheave diameter = 320 (W=102) / 440 / 520 / 590

4 with traction sheave diameter = 360

5 manual brake release for brake (plug-in)

Fig. 3.6

21 08-2012



3.3.2 Version for location in machine room / motor position horizontal in combination with emergency brake, NBS (optional)


2 Screwed connections - machine base frame M16 -8.8




6 Clearance for manual release of the emergency brake, NBS

Fig. 3.7

22 08-2012



3.3.3 Version for the machine location in headroom


2 Thread M16x25 deep

3 Mounting surfaces - machine base frame

Fig. 3.8

23 08-2012



3.3.4 Version for machine location in the shaft pit (flange fixing)


2 Thread M16x25 deep

3 Mounting surfaces - machine base frame




Fig. 3.9

24 08-2012



3.3.5 Version for machine location in the shaft pit (foot mounting)

Fig. 3.10

25 08-2012



3.4 Machine base frame (optional)

Various machine base frame versions are possible. Consult the general arrangement drawings. Setup The machine base frames are set up with insulation elements (see Chapter 8 Machine insulation) on a machine support in the plant room or directly on the plant room floor.

A rope guard plate above the traction sheave serves as a means of protection in accordance with EN81 item. This is monitored by a safety switch. Assurance is provided in this way that the system has come to a halt if and when the rope cover plate is removed (e.g. for attaching a handwinding wheel or hoist).

A rope guard in accordance with EN81-1/9.7 is in place for the rope pulley.

Selection, number and location of insulation elements: See chapter 8 Machine insulation.

Mounting the base frame

• Loosely bolt together the base frame (delivered as disassembled) in the

machine room. Make sure that the supports are mounted with additional drilled holes and pulley support on the correct side. (The side on which the deflecting pulley is to be located.)

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

• Place and align the base frame on the isolation elements according to the plan of installation.

• Use lifting gear to place the machine on the base frame; the traction sheave must be on the deflecting pulley side.

• Move the machine sideways on the base frame until the required ASL dimension (parallel gap between the ropes at the rope departure) is reached.

• Bolt the machine onto the base frame. The machine housing must not be tensioned. Balance out uneven surfaces by inserting the enclosed shims.

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

• Tighten the screws with the prescribed tightening torque. See chapter 8.

• Plumb the rope departure on the rope pulley at the elevator car and/or mounting on the car and counterweight.

Important: With a side or oblique rope departure, the gear box casing on the machine base frame is to be secured by means of car steady plates with set screws.

26 08-2012



3.5 Encoder

The following hollow shaft encoders are available For installation and connection, see manufacturer's specifications in the Appendix 1. 2x1024 Impulse TTL 2x4096 Impulse TTL

Connection with line and connector, hard-wired.

2. 2x1024 Impulse HTL Connection with line stripped of insulation and wire end sleeves

attached.

3. 2x1024 Impulse sine-cosine Connection with line stripped of insulation and receptacles attached.

27 08-2012



3.6 Brake

Technical data

Designation Unit Technical data

Manufacturer Warner Electric

Type ERS VAR09 SZ50/50

Braking torque (Nm) 2 x 50

Braking torque setting Not possible

Design 2-surface disc brake arranged in

tandem

Brake linings Asbestos-free

Brake disc diameter (mm) 151

Air gap (mm) 0.25 +/- 0.05

Air gap setting Not possible

Electrical ventilation 1 magnetic clamp per brake circuit (series connection)

Operating voltage (VDC) 180 - overexcitation

90 - retentive voltage

Performance data - overexcitation

(W) 196

Performance data - stopping (W) 65

Monitoring devices None

Manual release Manual release lever (not mounted)

optionally possible

Connection cable length (m)

Optionally 1 (with end sleeves / brake circuits connected in series via cables, e.g. in the machine room) or 6 (including connectors / brake circuits externally connected in series, e.g. with MRL)

Type of protection IP54

Weight (kg) approx. 15

Type approval code without (not required)

TW45B_30201_GER

More details, see Appendix chapter 8 Warner

28 08-2012

OPERATING MANUAL TW45C TRANSPORTATION AND STORAGE


4. Transportation and Storage

Packaging Further packaging depends on the order and is country-specific (air/sea/land freight). Transportation Transportation must be effected in compliance with the safety regulations and observing the centre of gravity of the machine.

Important: Machine is filled with oil. It may only be transported and stored in an upright position. Fork-lift truck transport

• For transport, always pick up the transport pallet, not the machine itself, with the forklift. Secure the load against falling over.

• Pay attention to protruding parts. Danger of injury and damage!

Fig. 4.1 Fig. 4.2

Fig. 4.3

The gear housing is bolted onto wooden blocks.

The gear housing is bolted directly onto the pallet.

Special pallet 1200 x 800.

29 08-2012



Crane transport

• Do not walk underneath suspended loads!

• Secure the machine without base frame by rope to the transport eyebolts. Do not secure at the facing threads of shafts!

• In the case of a machine that is mounted on the machine base frame, attach a transport rope to the base frame.

• Secure the machine against slipping and falling over.

In the case of machines without machine base frame, attach a transport rope to the transport eyebolts. See Fig. 4.4 or 4.5 In the case of the vertical version, the transport hooks cast on below the motor are to be used.

Attention should be paid to ensuring that the handwinding wheel is not damaged. Ropes or chains must not make contact with the handwinding wheel during transport.

Lifting - vertical

In the case of the horizontal version, the transport eyebolt cast on the gear is to be used.

Lifting - horizontal Observe wrap Fig. 4.5

Fig. 4.4

30 08-2012



Pay attention to the icons on the packaging or elsewhere.

This way up Fragile goods Protect against water

Protect against heat

Hand hooks prohibited

Attach here

Dimensions and weight

The weight data is specified on the packaging on a label. Please refer to the delivery note for the dimensions. Rough specifications, see chapter 3 'Technical data'.

Check on acceptance by the recipient

The delivered parts and their packaging are to be checked for completeness, damage or other conspicuous features.

Reporting and documenting damage in transit

On delivery, make sure that no damage in transit has occurred.

Any damage that is determined is to be documented immediately (sketch, photo, description of the damage).

Forward the corresponding documents without delay to THYSSENKRUPP AUFZUGSWERKE GmbH.

Unpacking

Dispose of packaging materials in an environmentally compatible manner or reuse them. Specific transport equipment and shipping braces remain with the customer.

Intermediate storage

If the assembly is not installed immediately after delivery, it must be stored carefully in a protected location. On covering, attention is to be paid to ensuring that no condensation can form and that no moisture can penetrate.

The assembly must not be stored outdoors. Bare parts have no long-term preservation.

Ambient conditions

The environment at the final location (moisture, temperature) must correspond to normal indoor climate conditions for machine and pulley rooms and shaft. (According to EN 81 between +5° and +40° C)

31 08-2012

OPERATING MANUAL TW45C MOUNTING THE MACHINE


5. Mounting the machine

5.1 Machine setup The machine is delivered with and without frame depending on order. Mounting parts for machine on machine base frame A set (6231 000 4183) of screw connection elements (M16-8.8) is available for mounting the TW45C machine on the machine base frame TW45B O SR / M SR.

Installation instructions for machine base frame in the machine room In order to comply with regulations for noise abatement and sound transmission, insulation elements are to be inserted between the frame supports and the ground. The machine base frames are set up over impact soundproof elements (rubber block 100 x 100 x 50 mm high) in the machine room. Insulation elements without underlay (60 309 01 14 0) for machine room without floor pavement or setup of the machine base frame directly on floor pavement Insulation elements with underlay (60 300 04 37 0) for machine room with floor pavement

(≤ 60 mm height); underlay made of laminated wood Multiplex 140 x 140 x 80 mm high See Appendix Machine insulation Version, see general arrangement drawings

Aligning the machine The TW45C 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. Remove any irregularities.

32 08-2012



5.2 Mounting the rope guard

Use the enclosed screws to bolt the rope guard onto the rope guard carrier. Pivot the rope guard carrier to set the guard is 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). With inclined pulling, adapt the location of the rope guard carrier by remounting the changed rope pull direction. Note: Tighten the securing bolts of the rope guard carrier on the gear drive after alignment with the prescribed tightening torque. Tightening torques, see table 8

1 Rope guard carrier 2 Rope guard

NB: For machines with rope run-in direction of 0 - 90° above the horizontal (e.g.: machine arrangement up/down beside), an additional rope guard is required to prevent the entry of foreign bodies between the rope and groove. If the rope run-in zone is protected within the machine base frame, the function "protection against injury" is not required.

Fig. 5.1 max. 1 - 2 mm

1

2

1

2

Fig. 5.2

33 08-2012



5.3 Connecting the machine

On connecting the motor, the enclosed terminal connecting plan in the motor connection box is to be complied with. The connection values can be found on the type plate. Representation in star circuit < < < < and various versions. If necessary, reconnect in delta section VVVV according to wiring diagram. Versions:

1 W2

2 U2

3 V2

4 Earth connection

5 PTC thermistor temperature sensor

6 PTC thermistor temperature sensor

7 U1

8 V1

9 W1

Fig. 5.3

TKAW ( EME (CEG)

7 9 8

Siemens 1LA7130-33

5 6

4 7 9 8

Fig. 5.4

5 6

1 3 2 4 1 3 2 4

CSA execution Voltage switchover 230/460V Comply with terminal connecting plan in the cover

7 9 8

5 6 1 3 2

4

Fig. 5.5

34 08-2012



Connecting the PTC thermistor

A triggering device (motor protection device) is required for evaluation of the PTC thermistor temperature sensor installed in the motor. This is to be connected to the terminals in Fig. 5.3 - 5.5, items 5 and 6. Do not apply a voltage greater than 2.5 V at the terminals of the posistor. Adhere to the internal resistance of the measurement devices!

35 08-2012



5.3.1 Connecting the brake

The scope of delivery of the machine includes a connection line, see illustration for version.

Brake control

Emergency brake NBS (optional)

If the emergency brake system is fitted, a description with all the details regarding connection and operation of the emergency brake can be found in the separately enclosed operating manual for the emergency brake system, NBS.

TCM / TCI control systems if not TCM / TCI

Fig. 5.5

36 08-2012

OPERATING MANUAL TW45C COMMISSIONING


6. Commissioning

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

• Mounting of the machine, traction sheave and base frame checked

• Rope guard fitted and distance to traction sheave set

• Setup of the machine, base frame, pedestal and rope departure checked

• With a side or oblique rope departure, gear box casing secured against moving with steady plates and set screws

• Bolts tightened and secured with the prescribed torque (see chapter 8)

• Gear oil level checked

• Plastic screw plugs against release screw with cap at the filling opening at the gear housing and oil drain screw on housing front at the height of the traction sheave shaft mounted and sealed

• Power connections and earthing of motor, forced ventilation and brake magnets connected and secured

• Connection values (voltage, frequency) must match the manufacturer specifications

• Monitoring devices (pulse generator, thermal element) connected and function checked

• Parking brake and emergency brake, NBS, (if present) connected and brake function checked

• Direction arrow (Up / Down) attached above traction sheave and clearly visible on the motor near the handwinding wheel according to the direction of travel

• Safety, auxiliary and installation tools removed from the danger zone Note: if the traction sheave is delivered separately, it is to be mounted properly with the supplied microencapsulated screws. See chapter 7. 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. See 'Tightening torques', chapter 8.

For assembly and repair, use only original parts from ThyssenKrupp Aufzugswerke GmbH, as otherwise no warranty can be provided.

37 08-2012



6.1 Emergency operation

6.1.1 Drive with brake in machine room version (TWR) without emergency

brake, NBS

The TW45C machine room version is equipped for emergency operation with

a handwinding wheel and optionally 2 brake release levers. (One lever for

each brake circuit.)

Simultaneous operate of the two brake release levers in the direction of the

motor releases the disc brake.

For emergency rescue of trapped persons, the handwinding wheel might also

have to be moved to bring the elevator car into the nearest landing.

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

opening the brake. Immediately let go of the handwinding wheel and control

the speed of the elevator car by releasing the brake release lever with

varying degrees of force. (interval brake)

NB: when using the handwinding wheel (e.g. "drawing out of the safety

gear"), the person carrying out the work must have a secure footing and

stance. If the electrical recall is operated simultaneously, there is a risk of

injury.

6.1.2 Drive with emergency brake, NBS

Mounting the emergency brake, NBS, fundamentally changes the

procedure and sequence for emergency operation.

Comply with the separate NBS operating manual!

The part number for the NBS operating manual is: 65 990 01 86 0

Chapters 1, 6 and 7 describe the changed procedure for handling the

emergency brake, NBS!

6.1.3 Drive with brake in without add-on brake release lever and without optionally available brake release lever)

The manufacturer of the elevator system is to implement suitable measures to enable emergency rescue in the event of a power failure.

The followings points are to be to be taken into account here:

• Metered opening of the electrically operated brake

• Setting the elevator car in motion with a balanced weight ratio elevator car / counterweight, whereby static friction of the guides and the automatic interlock of the worm gear are to be overcome

• Check of the speed of movement after opening the brakes to prevent triggering of the safety devices against overspeed

38 08-2012



6.1.4 With deployment of the optional brake release lever for to release drives manually.

Before deployment of the brake release lever, switch off the installation

NB: before beginning elevator operation, it must be ensured that both release levers have been removed. No elevator operation with brake release levers inserted!

Install on the machine (brakes)

Fix to the brakes Extend the brake release levers

Tighten the knurled thumb screw

Both brake release levers are fitted

Release the individual brake

Release the individual brake Pull both brake release levers evenly towards the handwinding wheel

39 08-2012

OPERATING MANUAL TW45C MAINTENANCE AND SERVICE


7. Maintenance and service

7.1 Maintenance

Maintenance period: maintenance of the machine should take place within the framework of central maintenance of the elevator, at least once a year. Note: commissioning and maintenance work may only be carried out by trained and instructed qualified personnel. All laws and regulations for elevator systems as well as accident prevention regulations must be known and complied with.

More details on the sequence, settings and data can be found in chapter: Check the oil level; top up if necessary. 7 Change the oil when the change date is reached 7 Clean the release screw on the gear housing; the ventilation

opening must be clear 3

Check the gear and bearings for leakage Check brake and release gap, maximum 0.6 mm per release

gap) 7

Check the brake function 7 Check the braking deceleration 7 Check worm gear toothing for wear Check the backlash between the worm shaft and worm wheel,

0.05 mm to 0.12 mm at 20° C (max. 1.5 mm)

Check groove profile on the traction sheave for damage and wear Check secure seating of bolts of the traction sheave mount 7.8 With the drive on the machine base frame, check the mount of

the machine, supports and rope pulley carriers 3

Check rope pulley grooves for damage and wear Check proper and adequate condition and safety of electrical

connections

Check that protective and safety devices are present and correctly set

Check the seals on the shaft in the area of the brake 7

40 08-2012



7.2 Lubrication

Lubricant Replacement interval Motor position Filling amount

Synthetic gear oil SM1 For the first time after

4 years then every 8 years

vertical approx. 5.0 litres horizontal approx. 4.0 litres

Oil change

Before the oil change, run the gear until it reaches operating temperature. (at least 35°C) Discharge the gear oil by removing the sealing screw on the oil drain pipe. Caution: hot oil represents a risk of scalding! Collect the old oil in a container specifically designed for the purpose. Close off the oil drain after discharging the gear with the sealing screw and

sealing tape. Fill the machine with the prescribed amount of oil through the upper opening on the gear box casing (remove release screw, see Fig. 7.1 to 7.3).

Check the level at the oil gauge glass. Enter the date for the next oil change in the type plate on the gear box

casing. Never mix various types of oil. Do not let any oil seep through to the groundwater. Dispose of old oil as well as cleaning cloths contaminated with oil and grease according to applicable regional regulations. Only use lubricants approved by THYSSENKRUPP AUFZUGSWERKE

GmbH. Note: THYSSENKRUPP AUFZUGSWERKE GmbH shall not be liable for losses caused by the use of non-approved lubricants.

Version with vertical motor position Version with horizontal motor position

Fig. 7.2 Oil drain

Ventilation fill opening

Ventilation fill opening

Oil gauge glass Oil gauge glassFig. 7.1

41 08-2012



Version with horizontal motor position (Fig.: shaft version (MRL) without brake release lever)

Checking the oil level The oil level must be +/- 5 mm from the middles of the gauge glass. When topping up, the machine should remain at a standstill for a certain period ( out of service for approx. 5 minutes). The drive is filled with oil at the plant.

Oil level at middle of gauge glass +/- 5 mm

Fig. 7.3.1

Fig. 7.3

Oil filling hole / ventilation

Oil drain

42 08-2012



7.3 Testing the brake

Test interval: once a year within the framework of the central maintenance of the elevator

Test the braking deceleration at each brake circuit. Note: Before beginning the test, the following preparations are required:

Signs indicating that maintenance work is under way must be attached to the elevator at all landing doors.

All doors are to be locked properly. Ensure that there is no one in the elevator car. The elevator car must be located at least two floors below the top landing. For the individual test of the brake circuits, the brake magnet coils must be

connected separately to the excitation / retentive voltage (90 V / 45 V). To be able to test one brake circuit separately, the brake of the brake circuit that is not being tested must remain open during the entire test operation. This is done by applying the retentive voltage to the magnet coil of the brake circuit that is not involved.

NB: If the elevator begins to move after releasing a brake circuit or does not noticeably decelerate during the brake operation, the live coil is to be switched off immediately. The dual brake function is not ensured. Check the brake! Activate the measuring device. Test sequence: test the braking deceleration on each brake circuit Initiate a normal run (brake to be tested is opened) After the rated speed has been reached, trigger an emergency stop (brake

to be tested closes) Determine the deceleration value for the 1st brake circuit with the

measuring device. Compare the measurement result with the standard value Disconnect the permanent power supply of the continuously opened 2nd

brake circuit and connect to the 1st brake circuit. Connect the measuring device to the 2nd brake circuit. Repeat the test operation on the 2nd brake circuit. Deceleration values:

The minimum deceleration value for one brake circuit is approx. 0.4 m/s² The minimum deceleration value for both brake circuits is approx. 1.0 m/s² NB: After completion of the individual brake test, disconnect the permanent operation voltage at the connection of the brake circuit not being tested and re-establish the original elec. circuit (operation of both brakes simultaneously).

43 08-2012



Testing of both brake circuits

Following an individual test, run a brake test with both brake circuits by triggering emergency braking. The deceleration value here must be significantly greater than the values determined in the individual tests!

Check for wear: Use a feeler gauge to check the air gap between the spool and armature base plate with the brake closed (coils without current). Repeat the operation at various positions of the circumference.

Table for brake air gap See chap. 8

Nominal air gap Brake closed (without current), lining in new condition Limit air gap Brake closed (without current), Lining worn Test air gap Brake opened (under voltage), minimum distance between friction lining and contact surface

Once the limit air gap is reached, the complete brake must be replaced. Repairs can only be carried out at the plant.

44 08-2012



7.4 Replacing the brake

Brake 2 x 50 Nm (Warner) When working on the brake, the instructions and specifications of the brake manufacturer in chapter 8 must be complied with.

1 Motor shaft 12 Rotor 2 2 Set screw 13 Bearing cover 3 Coupling half 14 Slotted pan head tapping

screw (4x) 4 Anchor disc D 15 Shaft sealing ring 5 Magnet coil bracket D 16 Gear housing 6 Slotted pan head tapping

screw (3x) 17 O-ring (3x)

7 Motor flange 18 Worm shaft 8 Flange ring 19 Brake connection 9 Rotor 1 20 Retaining washer 10 Magnet coil bracket C 21 Coupling hub 11 Anchor disc C 22 Elastic gear ring

Release gap at coil brackets

1

7

5

6

8

4

3

2

9 10 11 12 13 14 15

1718

Fig. 7.4

1920

16

22 21

45 08-2012



Note: when the wear limit (0.6 mm / gap) is reached or there is a defect in the brake, the complete brake is to be replaced in all cases. Disassembly: Switch the drive without current and secure against inadvertent

activations; the car and counterweight are to be secured by locking Disconnect the brake and motor connections, take off the motor Remove the elastic gear ring (Fig. 7.4, item 22) Remove the screw with retaining washer on the front of the worm shaft

(item 20) Secure the brake package by screwing in the supplied locking screws.

The mounting holes for this are located on the circle of holes of the securing bolts, item 6.

NB: before undoing the brake attachment screws (item 6), the brake unit must be secured by means of the 2 supplied M6 x 80 K8 screws marked with red screw heads. Pressure springs with high initial tensioning force are installed in the armature base plates between the coil bracket and armature base plate. If the brake unit is removed without being secured, there is a danger that on removing the screws the individual parts will suddenly come loose and be pressed apart.

Undo the slotted pan head tapping screws, item 6. Attach the pull-off device with 2 M5 screws to the front of the coupling hub

and pull the secured brake unit, including coupling hub, off the worm shaft (item 18).

Installation: Hoist the new brake unit onto the worm shaft with lifting gear. Align the mounting holes to the screws on the thread in the bearing cover

and screw in loosely. To align the holes and move the anchor discs, the brake must be connected and electrically released.

Use slotted pan head tapping screw M12 x 25 8.8 and locking ring S12 to screw the coupling hub with retaining washer, item 20, onto the worm shaft. (75 Nm)

Secure the securing bolts, item 6, with Loctite 243 (locking paint) and tighten with the prescribed tightening torque. (9 Nm)

Remove the locking screws that hold the brake together. Insert the elastic gear ring (item 22) in the coupling hub. Mount the motor on the gear housing, whereby the motor coupling is to be

aligned to the coupling hub of the brake by turning the motor shaft. Tighten the motor attachment screws; connect the brake and motor.

Check the release gap between the magnet coil brackets and the armature base plates at a number of positions on the perimeter.

NB: before giving approval for elevator operation, check the brake.

46 08-2012



7.5 Checking the backlash

Wear enlarges the backlash on the worm drive between the worm wheel and worm shaft. If the wear limit value (backlash) of 1.5 mm is reached, the gear drive can no longer be deployed for safety reasons. Replace the gear drive.

Measurement possibility:

Take the load off the gear drive; (remove ropes from the traction sheave) Run the measuring operation with the brake closed Fit a measuring attachment to the traction sheave; e.g. screw clamp Specify the measured radius (M) and mark the measuring point The radius ( r ) for the TW45C = 95 mm Attach a dial gauge with magnet stator at the gear drive housing and

align to the measuring point (M). Turn the traction sheave by hand until the dial gauge pointer moves. Move the traction sheave back and forth until resistance is felt in both

directions. The tooth flanks of the worm wheel are to have a load of approx. 20 - 50 N. The worm shaft must not move, as otherwise the measurement result is falsified. (bearing clearance)

Read off the dial gauge (ME). Use the formula below to calculate the backlash. This measurement is to be carried out in at least three different positions

on the worm gear toothing! M = radius ME = measurement result r = radius of worm wheel All dimensions in mm

Backlash = ME * r M

Fig. 7.5

Dial

Traction sheave

Worm wheel

Dial gauge

47 08-2012



7.6 Replacing the traction sheave

Disassembly:

Switch off the power to the installation; secure the car and counterweight in position.

Remove the rope guard plate. Ease load on traction sheave; lay down ropes. Secure the traction sheave to the lifting gear with a rope. Undo the 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.

Place a spacer of approx. 5 – 10 mm thickness between the shaft end and the traction sheave.

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

Installation:

Clean shaft end and traction sheave bore. Under no circumstances, are the dimensions of the feather key, groove, shaft or drilled hole to be

changed. There must be no visible damage on the contact surfaces. Do not apply grease or oil to the shaft and bore. Place the new traction sheave on the conical shaft end of the worm wheel

shaft. Align the locations of the feather key and groove in relation to one another. Push the traction sheave onto the worm wheel shaft. Screw on a disc with supplied screws (microencapsulated) and detent

edged washers on the inner circle of holes of the disc. Tighten the screws evenly and alternately.

Danger: if mounted incorrectly, the traction sheave can come loose. Comply with the bolt tightness of 8.8 and tightening torque = 90 Nm!

Release the mount of the traction sheave from the lifting gear Hang up the ropes on the traction sheave Mount and align the rope guard plates (see chapter 5) Remove the securing devices from the car and counterweight

1

1 Securing bolt 2 Hole for pressure screw 3 Traction sheave 4 Mounting plate 5 Rope guard plate

2 3 4

525

Fig. 7.6

48 08-2012



7.7 Motor replacement Disassemb ly

Disconnect the power from the installation and secure the car and counterweight.

Attach and secure the motor to the lifting gear. Unplug the electrical connections and lines from the motor (motor,

pulse generator and brake connections). Undo the nuts of the motor mounting at the housing flange; carefully

pull off the motor from the coupling connection and place on the floor.

Before removing the coupling half, remove the set screw in Fig. 7.4, item 2.

Installation

Prepare to fit the replacement motor; compare the motor data. Heat the coupling half to approx. 200°C and push onto the shaft end of

the replacement motor. Secure the connection with the set screw. During installation, make sure that the clamps of the coupling half protrude beyond the shaft end. The base of the clamps should be flush with the shaft end.

Attach and secure the replacement motor to the lifting gear. Raise the motor using the lifting gear and align to the coupling and

housing flange of the gear. By turning the motor shaft, align the lightly greased coupling halves to

one another, (tooth to gap). The elastic gear ring must be located between the clamps of the two coupling halves.

Push the motor and gear coupling together. Turn the motor to align the position of the mounting holes to the

threaded bolts on the gear flange. Push on the motor until the face of the motor contacts the gear flange

or flange ring. Turn the nuts to screw the motor onto the gear flange and tighten

alternately and evenly with the prescribed torque. (see table with tightening torques 8.1 in the Appendix)

Connect the connection lines to the terminal box on the motor; connect the electrical connections according to the terminal connecting plan in chapter 5.

Establish the connections of the brake and pulse generator to the control system.

Before commissioning, check the function of the braking device.

Note: comply with the assembly and terminal connecting information of the brake manufacturer in chapter 8.

49 08-2012



7.8 Checking for escaping grease / oil

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

Pollution degree Procedure No escaping oil determined Check regularly within the

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

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

Clean the drive and brake, if necessary, and carry out short-term repair. Before continuing operation, run a brake test (see 7.3 "Testing the brakes") until replacement. If the braking effect is inadequate, shut down the installation

Repair after 4 weeks at the latest

Diagram of the horizontal version

Fig. 7.8

ÖL

Fett

Brake discs

Armature base plates

Bearing cover Shaft sealing ring

Oil

Grease

50 08-2012

OPERATING MANUAL TW45C APPENDIX


8. Appendix

8.1 Tightening torques – tightness values

Caution: When working on the machine or replacing parts, care must be taken to ensure that the prescribed bolt strength and tightening torques are complied with. 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. To comply with the prescribed torques, all bolt and screw connections are to be tightened using a torque wrench!

For the remaining mounts, where no special details are provided, the following table applies. DIN/ Tightening Tight- ISO torque ness [Nm]

Disc on the traction sheave shaft Slotted pan head tapping screw M16 * 40 microencapsulated

8.8 4762 90

Detent edged washer SK M16

Motor to housing flange Stud M12 * 25 8.8 938 Locking washer S12 Lock nut M12 75

Handwinding wheel to motor shaft Locking washer 12 Slotted pan head tapping screw M12 * 35 8.8 4762 75 Adapter sleeve 4 * 10 1481

Bearing bracket on housing Slotted pan head tapping screw M10 * 30 microencapsulated

8.8 40

51 08-2012



Slotted pan head tapping screws ISO 4762 (DIN 912) Hexagon screws ISO 4014 / 4017 (DIN 931 / 933)

Dimensions Tightening torque MA (Nm) Tightness 8.8 10.9 12.9

M4 2.6 M5 5.3 M6 9 12 15 M8 23 30 35 M10 45 60 75 M12 75 110 130 M16 190 270 320 M20 370 520 620 M24 640 900 1100

Note: microencapsulated screws are to be replaced after they have been used once.

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

52 08-2012



8.2 Blocking clamp

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

Deployment of the blocking clamp: Use the blocking clamp to prevent movements due to slipping ropes during installation work on the elevator car or counterweight or during work where the rope traction of the installation is insufficient (e.g. pulling out of the safety gear). Note: the blocking clamp is to be tensioned via the screwed connection until it is excluded that ropes will slip.

Mounting the blocking clamp on the traction sheave

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

NB: after completion of the installation work, remove the blocking clamp, as otherwise the installation will be damaged.

5

6

7 2

3

4

1

Fig. 8.1

53 08-2012

OPERATING MANUAL� TW45C� CHANGES

ThyssenKrupp Aufzugswerke GmbH � ��

9. Changes

Version

Changes

Chapter

08/2012 new gear ratio (now 41:2) 3

54 08-2012

Encoder Overview: The following encoders are available for the TW45C 1. 1024 - (standard version) / 4096 - TTL (optional)

for v < 1.5 m/s 1024 impulses

for v < 1.5 m/s 4096 impulses

Connection takes place with line SUB-D 9 ribbon connector and knurled screw UNC4-40 2. 1024 HTL (optional)- 1024 impulses Connection takes place with line stripped of insulation and wire end sleeves attached. 3. 1024 – sine / cosine HTL (optional) 1024 impulses Connection takes place with line stripped of insulation and wire end sleeves attached.

Part No. 9950 000 6021 mit 1024 Imp. Part No. 9950 000 6021 mit 4096 Imp.

Part No. 00 990 16 03 0 with 1024 pulses

Part No. 00 990 19 03 0 mit 1024 Imp.



Tightening torque specified by the manufacturer (Siemens) Applies to specified works to be performed at motor and motor connections. Fig.1 Tightening torque for screwing of electrical connections – junction plate connections (except for terminal strips)

Thread ∅ M4 M5 M6 M8 M10 M12 M16

min. [Nm] 0,8 1,8 2,7 5,5 9 14 27

max. [Nm] 1,2 2,5 4 8 13 20 40

Fig.2 Tightening torque for metal (I) and plastic (II) screwings

Thread ∅ M12x1,5 M16x1,5 M20x1,5

M25x1,5

M32x1,5 M40x1,5

M50x1,5 M63x1,5

I min. [Nm] 4 5 6 8 10

I max. [Nm] 6 7,5 9 12 14

II min. [Nm] 2 3 4 5 6

II max. [Nm] 3,5 4 5 7 8

Fig.3 Tightening torque for screws at electrical terminal blocks, bearing brackets and protective conductor screwings

Thread ∅ M4 M5 M6 M8 M10 M12 M16 M20

min. [Nm] 2 3,5 6 16 28 46 110 225

max. [Nm] 3 5 9 24 42 70 165 340

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

ABV, ESV 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


Bernhäuser Strasse 45

73765 Neuhausen a. d. F.

Germany

E-mail: [email protected]

Internet: www.thyssenkrupp-elevator-eli.de

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Nr.

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Documents

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