Manual
Drive
TW45C
ThyssenKruppAufzugswerke
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Issued by
ThyssenKrupp Aufzugswerke GmbH
Bernhäuser Strasse 45
73765 Neuhausen a. d. F.
Germany
E-mail: Eli.elevator.plant.de@thyssenkrupp.com
Internet: www.thyssenkrupp-elevator-eli.de
OPERATING MANUAL TW45C
List of contents
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.
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.
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.
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.
2. Product description
2.1 Description
1
2
11
10 5
4 6
8
7
7
Fig. 2.1
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.
Hub-Unit
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.
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.
Encoder
An overview of the encoders deployed with technical details can be found in
chapter 8.
Ambient conditions
3. Technology
Table 3.1
3.1.2 Weight
TW45C in standard version
Machine room
Machine location m (kg) Headroom
Shaft pit
1)
Assembly, winch TW45C 120 x x x x
2)
Assembly, winch TW45C 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 D440 45 x x
Traction sheave D360 25 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 3.2
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).
Table 3.3
Fig. 3.1
1 Driving gear (vertical motor position / 2 Traction sheave (D360 / D440 / D520 /
mounting surface - foot) 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. 3.2
1 Driving gear (horizontal motor position / 2 Traction sheave (D360 / D440 / D520 /
mounting surface - foot) D590)
3 Motor 4
5 Actual-value sensor 6 Handwinding wheel (D270)
7 Rope guard (adjustable) 8 Oil drain (R3/4")
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 eyebolt 14 Mounting surface machine base frame
(foot mounting)
15 Operational brake (2x50 Nm) 16 Manual release for operational brake
(plug-in)
TW45B_24001_GER
Fig. 3.4
Fig. 3.5
1 Driving gear (horizontal motor position / 2 Traction sheave (D360 / 440 / 520 /
mounting surface - flange) 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")
9 Oil filling hole and ventilation (R3/4") 10 Oil level monitoring (gauge glass)
11 Traction sheave mount 12 Mounting surfaces of machine base
frame (flange fixing)
13 Handwinding wheel D270 (optional)
Fig. 3.6
Fig. 3.7
Fig. 3.8
3.3.4 Version for machine location in the shaft pit (flange fixing)
Fig. 3.9
3.3.5 Version for machine location in the shaft pit (foot mounting)
Fig. 3.10
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.
3.5 Encoder
The following hollow shaft encoders are available
3.6 Brake
Technical data
Packaging
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.
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.
Lifting - vertical
Fig. 4.4
In the case of the horizontal version, the transport eyebolt cast on the gear is
to be used.
Fig. 4.5
This way up Fragile goods Protect Protect Hand hooks Attach here
against against heat prohibited
water
The machine base frames are set up over impact soundproof elements
(rubber block 100 x 100 x 50 mm high) in the machine room.
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
2
max. 1 - 2 mm
Fig. 5.1 Fig. 5.2
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.
Versions:
Siemens 1LA7130-33 TKAW ( EME (CEG)
1 2 3 4 1 2 3 4
5 6
5 6
7 8 9 7 8 9 4
Fig. 5.3 Fig. 5.4
CSA execution
Voltage switchover 230/460V
Comply with terminal connecting plan in the cover
5 6 1 2 3
1 W2
2 U2
3 V2
4 Earth connection
4 5 PTC thermistor
temperature sensor
6 PTC thermistor
temperature sensor
7 U1
8 V1
7 8 9 Fig. 5.5 9 W1
Brake control
Fig. 5.5
6. Commissioning
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.
6.1.3 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
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
Extend the brake release Install on the machine Fix to the brakes
levers (brakes)
Tighten the knurled thumb Both brake release levers Release the individual
screw are fitted brake
7.1 Maintenance
More details on the sequence, settings and data can be found in chapter:
7.2 Lubrication
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
Ventilation Ventilation
fill opening fill opening
Fig. 7.3
Oil drain
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).
Fig. 7.3.1
Test interval: once a year within the framework of the central maintenance
of the elevator
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).
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.
7 8 9 10 11 12 13 14 15 16
6
5
4
3
2
Fig. 7.4
22 21 20 19 18 17
When working on the brake, the instructions and specifications of the brake
manufacturer in chapter 8 must be complied with.
ThyssenKrupp Aufzugswerke GmbH 45 08-2012
OPERATING MANUAL TW45C MAINTENANCE AND SERVICE
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.
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!
Dial gauge
Dial
Traction sheave
Worm wheel
Fig. 7.5
M = radius
ME = measurement result Backlash = ME * r
r = radius of worm wheel M
All dimensions in mm
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!
1 2 3 4
1 Securing bolt
2 Hole for pressure screw
3 Traction sheave
4 Mounting plate
5 Rope guard plate
Fig. 7.6
5 2 5
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
ThyssenKrupp Aufzugswerke GmbH 48 08-2012
OPERATING MANUAL TW45C MAINTENANCE AND SERVICE
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.
ÖL
Oil
Fett
Grease
Brake discs
Fig. 7.8
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]
For assembly, use only original construction and mounting parts from
ThyssenKrupp Aufzugswerke GmbH, as otherwise no warranty can be
provided.
A blocking clamp that matches the traction sheave (rim width and design) is
part of each machine
Note: the blocking clamp is to be tensioned via the screwed connection until
it is excluded that ropes will slip.
4
5
3
6
2 7
Fig. 8.1
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.
9. Changes
Changes
Version
Chapter
08/2012 new gear ratio (now 41:2) 3
Overview:
Fig.1
Fig.2
Fig.3
Check the tools for current functioning before you start installation work !
Document number
DE 65 999 01 86 0
EN 65 999 02 86 0
FR 9710 000 9229
Operating Manual
Emergency Brake System NBS
for: TW45C, TW63; TW130; TW160
ThyssenKrupp Aufzugswerke
ThyssenKrupp Aufzugswerke GmbH
Nr. 62 310 03 86 0
Bernhäuser Strasse 45
Version 08/2012
73765 Neuhausen a. d. F.
Germany
E-mail: Eli.elevator.plant.de@thyssenkrupp.com
Internet: www.thyssenkrupp-elevator-eli.de