Operating Manual Machine TW63

Operating Manual Machine TW63 A company of ThyssenKrupp Elevator ThyssenKrupp Aufzugswerke ThyssenKrupp

Printer s imprint All rights reserved Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH P.O. box 23 03 70, D-70623 Stuttgart Printed in Germany, January 2005 The right of reprint or reproduction, even in the case of only partly exploitation, is subject to express, written permission of THYSSENKRUPP AUFZUGSWERKE GmbH. Any reproduction, copying or storing in data processing machines in any form or by any means without prior permission of THYSSENKRUPP AUFZUGSWERKE GmbH is regarded as infringement of the current Copyright Act and will be prosecuted. Technical modifications for reasons of improvement of TW 63 or for reasons of improving the safety standard of TW 63 are subject to decisions of THYSSENKRUPP AUFZUGSWERKE GmbH without prior notice. The responsibility for the content lies with the editor: THYSSENKRUPP AUFZUGSWERKE GmbH Preface We are pleased that you decided to purchase a quality product from THYSSENKRUPP AUFZUGSWERKE GmbH. This operating manual assists you in getting familiar with the drive for moving cars the TW 63 machine which is referred to as TW 63 below and with its intended possibilities of use. Important information concerning safety and hazards helps you to safely use the TW 63 as intended. TW 63 is subject to technical alterations. ThyssenKrupp Aufzugswerke GmbH 3 Issue 01.2005

Table of content : Machine TW63 PAGE 1. Safety 1.1 Explanation of symbols used 6 1.2 General safety information 7 2. Product description 2.1 Description of machine TW63 10 2.2 Functional description 11 2.3 Dimensions 14 2.4 Technical data 17 2.5 Name plate 18 2.6 Lubrication 19 2.7 Motor types 21 2.8 Connection von Windenmotoren 22 2.9 Terminal diagram for VVVF motors 23 and magnetic clamps 2.10 Connection of motors acc. to BV 6531-21 24 2.11 Connection of motors acc. to BV 6531-22 25 2.12 Connection of VFD motors 26 2.13 Motor data phase-shift controlled motors (A4) 27 2.14 Motor data VVVF motors (A4) 28 2.15 Motor data - phase-shift controlled motors (A4) 29 2.16 Motor data special motors (B5) 30 2.17 Machine frame 31 3. Transportation and storage 40 4. Mounting of machine in machine room 43 4.1 Mounting of rope guards for traction sheave 44 5. Putting into service 45 5.1 Emergency operation 46 6. Servicing 47 6.1 Checking of backlash 48 7. Maintenance 7.1 Replacing of brake shoes 49 7.2 Adjusting of braking deceleration 50 7.3 Adjusting of brake shoe stroke / armature base plate 51 7.4 Replacing - Montage of traction sheave 52 7.5 Replacing - Montage of motor 53 8. Special versions (optional) 8.1 Special versions 54 8.2 SA3 Brake monitoring TCM 55 8.3 SA3 Brake monitoring BRC 57 9. Annex 9.1 Tightening torque mechanical strength 59 9.2 Flexible coupling for B5 motors 61 9.3 Pulse generators 63 9.4 Manufacturer s information pulse generator page 1-4 65 9.5 Manufacturer s information product information 69 9.6 Blocking clamp 70 ThyssenKrupp Aufzugswerke GmbH 5 Issue 01.2005

1. SAFETY 1.1 Explanation of symbols used The following pictographs and designations are used in this operating manual: Danger This symbol draws attention to an extreme danger to life or risk of injury to persons. Disregard of warning means danger to life! Danger This symbol draws attention to an immediate impending danger to life or risk of injury to persons caused by electric current. Warning notices must always be observed! Warning This symbol draws attention to an impending danger. Disregard can cause injury to persons or extensive damage to property. Warning notices must always be observed! Note This symbol draws attention to important information and instructions for operation. Disregard can lead to damages, hazards or failures. Inspection This symbol draws attention to inspection sequence. These inspection notices must be observed in any case. Disregard can lead to injury to persons or damage to property. ThyssenKrupp Aufzugswerke GmbH 6 Issue 01.2005

1. SAFETY 1.2 General safety information Information about the operating manual Knowledge of the basic safety requirements is a prerequisite for the safe use and the failure-free operation of this component. This operating manual comprises the most important information how to safely use the component. The operating manual and, in particular, the safety information must be observed by all persons who perform any work on the component. In addition the rules and requirements concerning the regulations for prevention of accidents which apply to the installation location must be observed. Duties of the owner and / or the installer The owner and / or the installer ensure that only persons are authorized to work at the component, who are familiar with the requirements concerning safe working and prevention of accidents and who were trained how to use the component; have read the safety information and the warning notices in this operating manual. Note: Check the compliance of the employees method of working with the safety requirements in regular intervals. Duties of the employees Persons who are authorized to perform work at the component are obliged to observe the requirements concerning safe working and prevention of accidents; to read the safety information and the warning notices in this operating manual prior to start working. Training of the employees Only trained and instructed, technically competent persons shall perform work at the component. The competence of the employees must be clearly defined for all tasks concerning putting into service, operation, maintenance and repair work. Organizational measures The owner or the installer must provide the necessary personal protective gear. All existing safety devices must be checked regularly in accordance with the maintenance plan. ThyssenKrupp Aufzugswerke GmbH 7 Issue 01.2005

1. SAFETY Informal information about safety measures The operating manual must always be available at the location of the installation. In addition to the operating manual the general and local regulations for the prevention of accidents and environmental regulations must be made available and observed. Clearly and easily visible statutory safety instructions must be made available for the users. See to it that all information concerning safety and hazards is always visibly and legibly made available on the machine. Use as intended TW 63 was designed in accordance with the state of the art and the recognized safety regulations. TW 63 shall only be used for its intended purpose be used exclusively if safe operation is ensured. TW 63 drive shall exclusively be used as drive for lifts. Any other use or any use exceeding the scope of the above definitions is regarded as use outside of the intended purpose. THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable for any damages resulting from this and for any damages which are caused by any errors of procedure. Use within the scope of its intended purpose also comprises observance of all information of the operating manual fulfilment of the instructions applying to putting into service, installation description and inspection and repair work. Guarantee and liability The General sales and delivery terms of THYSSENKRUPP AUFZUGSWERKE GmbH apply generally. Any claims for guarantee and liability are excluded in the case of injury to persons or damage to property resulting from one or several of the causes below: use of TW 63 outside the scope of its intended purpose inexpert mounting, putting into service, operating and maintaining of TW 63 operating the TW 63 with defective and/or non-operative safety and protective devices disregard of instructions of operating manual that apply to transportation, storage, mounting, putting into service, operating and maintaining of TW 63 ThyssenKrupp Aufzugswerke GmbH 8 Issue 01.2005

1. SAFETY unauthorized constructional modifications of TW 63 unauthorized modification of drive (performance etc.) unsatisfactory supervision of parts which are subject to wear inexpert repair work catastrophes caused by outside influence and Act of God. Constructional modifications of machine TW 63 TW 63 is adjusted at the factory and is delivered ready for work. Attention : oil necessary for putting TW 63 into service has been filled in at the factory already! Please check oil-level glass prior to initial startup of TW 63. (See chapter 2.6 fig. 7 / 9). In the case of any modifications of the machine THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable. Use of TW 63 and possible hazards The traction sheave and the handwheel of TW 63 are designed without protective cover and shall only be used within a closed room. See to it that the necessary safety distance to all revolving parts (marked yellow) is observed by persons working in the machine room. Note: do not place any objects (such as tools etc.) on the handwheel of TW 63 V since there is the danger of injury caused by flinging parts. In the case of incorrect use there will be danger to life of the user or third parties resp. impairment of the component or material property. Failures which possibly impair the correct functioning shall be eliminated immediately. ThyssenKrupp Aufzugswerke GmbH 9 Issue 01.2005

2. PRODUCT DESCRIPTION 2.1 Description of machine TW 63 The machine consists of: 1 Real value generator 9 Rope guard 2 Handwheel / flywheel 10 Machine frame (optional) 3 Separately driven fan (optional) 11 Name plate 4 Motor 12 Gear housing 5 Armature base plate 13 Rope guard carrier 6 Brake shoe 14 Brake monitoring switch 7 Traction sheave 15 Motor terminal box 8 Washer on traction sheave shaft 16 Brake magnet 1 2 3 4 5 6 15 14 13 7 8 9 12 11 9 10 Fig. 1 Versions: Design of TW63 V (vertical motor mounting) The following machine versions are available: gear with speed reduction, traction sheave version, motor version, generator version, ThyssenKrupp Aufzugswerke GmbH 10 Issue 01.2005

2. PRODUCT DESCRIPTION 8 7 12 6 15 4 2 9 3 10 Fig. 2 9 5 16 Design of TW63 H (horizontal motor mounting) 2.2 Functional description The machine TW63 is designed as drive for use in lifts. The gear (machine) is a single-stage, anti-friction bearing worm gear. The housing is a monobloc design with an end plate integrated on one side and an integrated dual-circuit brake. The worm teeth are oil-submersed in operation. A overhung traction sheave is used. Drive version is subject to motor mounting: the power is transmitted from a three-phase motor which is vertically mounted onto the gear or a three-phase motor which is horizontally flanged to the gear drive on the wormshaft to the worm-wheel, the traction-sheave shaft up to the traction sheave. The following constructional sizes of drive motors are available: A4 (standard version): one-piece worm and rotor shaft. B5: worm shaft and rotor shaft are linked with a flexible coupling (SA14). Drive types Dependent on the respective arrangement of motor, pulse generator, flywheel rim, etc. the drive can be used for pole-changing (AC2) phase-shift-controlled (ACVV) or frequency-controlled (VVVF) installations. ThyssenKrupp Aufzugswerke GmbH 11 Issue 01.2005

2. PRODUCT DESCRIPTION Brake: The dual-circuit brake shoe is spring-operated. Two independently acting brake shoes press the brake lining to the brake disc at a preset spring force. The braking force is rated in such a way that one shoe will be capable of stopping the car loaded with full rated load. Electrically operated magnetic clamps cause the brake to be released. If operated manually, the accompanying brake release lever must be applied to the cast-on recesses of the brake shoe ends. By pressing in direction of the machine (see fig. 2 in arrow direction) the brake shoes will be expanded, thus releasing the brake. 1 1 Brake shoe 2 Brake release lever 2 Fig. 3 Traction sheave: Overhung one-piece version fastened on drive shaft by taper; Groove form: seat and V-groove; Hardened groove flanks as a standard (50 HRc). Diameter - DT mm 450 510 590 675 Rim width mm 132 96 Max. grooves z d 8 8 7 10/11 8 8 7 10/11 6 12 8 8 7 10/11 6 12 6 8 5 10/11 4 12 Material Specially alloyed EN-GJL 250 (HB 190 to 230) ThyssenKrupp Aufzugswerke GmbH 12 Issue 01.2005

2. PRODUCT DESCRIPTION SA Special versions TW 63 (optional) (Additional parts for special applications) SA3 Brake test switches for checking the brake shoes (open-closed) and wear of brake lining. Note: check and re-set the setting of the brake test switches after every brake setting. For description of setting see SA3 brake monitoring SA 9 SA 12 with extended traction sheave shaft for separating drive and well. The traction sheave shaft is supported by a bearing. with additional terminal box for terminal connection of brake release magnets for motors without terminal box acc. to BV6531. SA 14 with flexible coupling for motors of constructional type B5 acc. to BV 6530-05 for compensating possible misalignment in the case of motor shafts with double bearings. For description see annex 9.2 coupling from Centaflex SA 15 with magnetic clamps for brake in (Ex) sg4 version SA3 and SA12 are not possible in combination with SA15. Note: for detailed description of special versions see 8.1 ThyssenKrupp Aufzugswerke GmbH 13 Issue 01.2005

2. PRODUCT DESCRIPTION 2.3 Dimensions TW 63 V of constructional size A4 (vertical motor mounting) Transport aid Handwheel Flywheel 1) ( acc. to order) Terminal box for motor and brake release magnet Separately driven fan Name plate motor Oil level glass Oil drain Name plate shaft Rope guard Fig. 4 Gravity center Comment: 1) pole-changing (AC2) 2) phase-shift-controlled (ACVV) 3) frequency-controlled (VVVF) ThyssenKrupp Aufzugswerke GmbH 14 Issue 01.2005

2. PRODUCT DESCRIPTION TW 63 V, SA9 dimensions (with outside bearing and extended traction sheave shaft) 260 3) 310 4) 372 ±1 3) 422 ±1 4) Machine frame dimension with horizontal rope departure 1 1 2 3 Comment: 1) Centre self-aligning bearing 2) Centre bearing box 3) Vertical motor mounting 4) Horizontal motor mounting 4 Fig. 5 1 Comp. support 2 Traction sheave 3 Outside bearing 4 Tractions sheave shaft Machine with outside bearing: For machines with additional bearing for extended traction sheave shaft (SA9) 2 compensating supports are mounted below the machine at the factory (see above fig.). Therefore the traction sheave shaft has two statically determined bearing points. ThyssenKrupp Aufzugswerke GmbH 15 Issue 01.2005

2. PRODUCT DESCRIPTION TW63 H: (horizontal motor mounting) Transport aid (to be removed after transport) Brake release lever (loose, variable operating position) Oil drain Fig. 6 Gravity center Oil level glass Opening for oil filling Comment: 1) to 3) for motors of constructional size A4, see standard version for vertical motor position. 4) With motors of constructional size B5 (SA14) 5) Illustrated as left-hand version, right-hand version mirror-inverted to A - A ThyssenKrupp Aufzugswerke GmbH 16 Issue 01.2005

2. PRODUCT DESCRIPTION 2.4 Technical data Designed for use in installations with rated load up to 630 kg and v rated 1.6 m/s or rated load up to 1000 kg and v rated 1.0 m/s (suspension 1:1) Axle distance: 155 mm Permissible load of traction sheave shaft: for standard version max. 43 kn for SA 9 (extended wheel shaft) max. 41 kn Brake magnet connection: Connection magnetic clamp: With machine TW63 the two magnets are connected in series. Rated voltage: 50 V Power supply Rated current: 1.1 A for high-speed exit.: 200 V Protection class: IP65 for withstand voltage: 100 V Magnetic clamp rating : 2* 2500 N Max. braking torque : approx. 2* 90 Nm Brake disc : 200 mm Motor connection: For terminal connection diagram of motor and magnetic clamps see cover inside of motor terminal block. Note: for details about standard motors see chapter 2.6 Weight: Standard version: motor of constructional size A4 Machine (without motor and traction sheave) 250 kg Machine SA 9 (without motor and traction sheave) 290 kg Machine (with motor and traction sheave) approx. 370 kg Machine SA 9 (with motor and traction sheave) approx. 410 kg Traction sheave acc. to order 450 675mm approx.50-70 kg Noise level Airborne noise of standard machine version with motor of constructional size A4 in normal operation (measured in machine room at a distance of 1 m): With integrated fan: approx. 65 db(a); with separately driven fan: approx. 67 db(a) Oil filling: Vertical mounting 11 litres synthetic gear oil SM1 Horizontal mounting 9 litres synthetic gear oil SM1 Supply by THYSSENKRUPP AUFZUGSWERKE GmbH ThyssenKrupp Aufzugswerke GmbH 17 Issue 01.2005

2. PRODUCT DESCRIPTION 2.5 Name plate of machine TW 63 To be differentiated acc. to customer 1. THYSSENKRUPP AUFZUGSWERKE GmbH 2. Lift Equip ThyssenKrupp Aufzugswerke GmbH 18 Issue 01.2005

2. PRODUCT DESCRIPTION 2.6 Lubrication of TW 63 Lubricator Oil change interval Motorlage Filling quantity Synthetic gear oil SM1 First time after 4 years, Vertical = 11 litres then every 8 years Horizontal = 9 litres Oil changing See to it that the gear has heated up to working temperature prior to changing oil. Discharge gear oil by removing the cap on the oil drain pipe. Collect waste oil in the tank provided for this purpose. After discharging the gear close the oil drain by means of sealing tape and cap. Fill the recommended oil quantity into top opening of gear box (red cap, see fig. 8 or 9). Check the oil level by means of oil level glass (see fig.7 or 9 pos.2 below). Enter date of next oil change in name plate on cover of oil-level glass. See fig. 1 pos. 11. Never mix different types of oil. Avoid entry of oil into groundwater. Dispose of waste oil as well as cleaning cloths or rags dirtied with oil and fat in accordance with the local requirements. Only use lubricators recommended by THYSSENKRUPP AUFZUGSWERKE GmbH. Note: For any damages caused by lubricators which were not recommended THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable. Oil level glass Opening for oil filling Fig. 7 Oil drain Fig. 8 ThyssenKrupp Aufzugswerke GmbH 19 Issue 01.2005

2. PRODUCT DESCRIPTION Horizontal motor position Fig. 9 1 2 3 1 Opening for oil filling 2 Oil level glass 3 Oil drain ThyssenKrupp Aufzugswerke GmbH 20 Issue 01.2005

2. PRODUCT DESCRIPTION 2.7 Motor types The following motors are available for machine TW63: Constructional size A4 1. Pole-changing motors (AC2) constructional size A4 Range of ratings: 5.0; 6.8 KW Forced ventilation Motor data see 2.13 2. Frequency-controlled motors (VVVF) constructional size A4 Range of ratings: 5.7; 11.0; 16.0 KW Integrated ventilation Motor data see 2.15 3. Phase-shift-controlled motors (ACVV) constructional size A4 Range of ratings: 6.8 KW Forced ventilation Motor data see 2.14 Constructional size B5 Gear and motor are connected by means of flexible coupling (SA14) in accordance with BV 6530-06 4. Pole-changing motors (AC2) Range of ratings: > 6.8 KW Forced ventilation 5. Phase-shift controlled motors (ACVV) constructional size B5 Range of ratings: > 6.8 KW Forced ventilation Motor data see 2.16 6. Special motors Data and version acc. to customer specification Flywheel rim: Pole-changing motors (AC2) are equipped with a flywheel rim in accordance with order specification. Hand wheel: Controlled A4 motors (ACVV / VVVF) are equipped with a plastic handwheel of 270 mm dia. and B5 motors are equipped with a hand wheel of dia. 360 mm (Siemens motor dia 270 mm) ThyssenKrupp Aufzugswerke GmbH 21 Issue 01.2005

2. PRODUCT DESCRIPTION General motor data: a) with vertical motor mounting: Protection class: IP 21 Insulation class: F Protective motor switch 6 posistors (3 with frequency-controlled motors) b) with horizontal motor mounting: Protection class: IP 20 Insulation class: F Protective motor switch 6 posistors (3 with frequency-controlled motors) Data of forced ventilation: (if available) Mains voltage: 230 V Mains frequency: 50 Hz Power: 0.1 KVA Currency: 0.44 A Speed: 2000 1/min Capacitor: 2 µf 2.8 Connection How to connect the motor: When you connect the motor observe the terminal diagram enclosed in the motor terminal box and/or the circuit diagram of this operating manual as well as the respective building codes. Motors with pulse generators: For connection and technical data concerning connection of the pulse generator see chapters 9.3 9.5. ThyssenKrupp Aufzugswerke GmbH 22 Issue 01.2005

2. PRODUCT DESCRIPTION 2.9 Terminal diagram for VVVF motors and magnetic clamps for frequency-controlled motors Anschlußplan = terminal diagram = schema de branchement Anschlußkasten Motor / terminal box motor / Boite a bornes de monteur Klemmenleiste Terminal strip Reglette de raccordement DEE 132 / 140 ACHTUNG! ATTENTION! An den Klemmen der Kaltleiter keine Spannung größer als 2.,V anlegen! Do not apply more than 2.5V at the terminals of the PTC thermistors! Ne pas mettre tension plus que 2,5V aux bornes des condukteurs a froid! Anschlußkasten Bremse Terminal box solenoids boite a bornes de electro frein Kaltleiter PTC-thermistors conducteurs a froid N BM Motor connection Magnetic clamp connection Fig. 10 ThyssenKrupp Aufzugswerke GmbH 23 Issue 01.2005

2. PRODUCT DESCRIPTION 2.10 Connection of motors acc. to BV 6531 21 for three-phase pole-changing motors Disconnector Make contact in winding Starting capacitor for fan ThyssenKrupp Aufzugswerke GmbH 24 Issue 01.2005

2. PRODUCT DESCRIPTION 2.11 Connection of motors acc. to BV 6531 22 for phase-shift-controlled three-phase motors with DC brake winding Disconnector Make contact in winding Starting capacitor for fan Low-speed winding as DC winding or switched in series to brake circuit ThyssenKrupp Aufzugswerke GmbH 25 Issue 01.2005

2. PRODUCT DESCRIPTION 2.12 Connection of VFD motors Schaltung nach Angabe am Leistungsschild. Connection as stated on the rating plate. Branchement suivant indication sur la plaque indicatrice. Delta Triangle for special motors of constructional size B5 Bremswicklung Brake winding Bobinage au frein Schaltung abhängig von der Wicklungsausführung. ϑ = Kaltleiter PTC thermistors Conducteurs à froid Achtung! Attention! An die Klemmen der Kaltleiter keine Spannung größer als 2,5V anlegen Do not apply more than 2,5V at the terminals of the thermistors. Ne pas mettre tension plus que 2,5V aux bornes des conducteurs à froid Fremdbelüftung Forced ventilation Ventilation forcèe Drehzahlgeber Speed control Transmetteur de vitesse Hohe Drehzahl High speed Grand vitesse Zum Regelgerät To the control device Vers l`appareil de règlage 3 * UK 16 Star connection Brake magnet wiring in separate terminal box of shaft (SA12) ThyssenKrupp Aufzugswerke GmbH 26 Issue 01.2005

2. PRODUCT DESCRIPTION 2.13 Motor data - pole-changing motors (AC2) Constructional size A4 Motor type: LNLA 132 LN-20Y LNLA 132 LP-20Y Synchronous speed: [1/min] 1500 1500 Rated speed: (asyn.) [1/min] 1380 / 275 1380 / 275 Moment of inertia: (J 1.) [kgm²] 0.043 0.043 Moment of : (J M.) [kgm²] 0,047 0,057 Moment of : (J H.) [kgm²] 0,010 0,010 Moment of : (J s. ) [kgm²] see right-hand table see right-hand table S 5 operating data with 180 F/h, 40 % ED Power: (P N. ) [KW) 5,0 6,8 Rated torque: [Nm] 35 47 Starting torque: [Nm] 80 / 60 106 / 80 Rated current: [A] 12.8 / 9 16.2 / 11.9 Permissible starting current: [A] 48.0 / 12.0 60 / 16 Rated voltage motor: [V] 400 400 Rated frequency: [Hz] 50 50 Generator marks:: -- -- Weight: (rotor / stator) [kg] 12.55 / 30 14.9 / 36 Length: (motor incl. flywheel rim) [mm] 446 446 Moment of inertia flywheel rim J S mm kgm 2 330 0,342 360 0,515 370 0,590 380 0,657 400 0,815 410 0,957 430 1,127 ThyssenKrupp Aufzugswerke GmbH 27 Issue 01.2005

2. PRODUCT DESCRIPTION 2.14 Motor data phase-shift-controlled motors (ACVV) Constructional size A4 Motor type: LNLA 132 LS-20Y Synchronous speed: (1/min) 1500 Rated speed: (asyn.) (1/min) 1370 Moment of inertia: (J 1 ) (kgm²) 0.043 Moment of; (J M ) (kgm²) 0,057 Moment of; (J H ) (kgm²) 0,010 Moment of; (J ges.) (kgm²) 0,110 S 5 operating data with 180 F/h, 40 % ED Power: (KW) 6.8 Rated torque: (Nm) 47 Starting torque: (Nm) 113 Rated current: (A) 16.3 Permissible starting current: (A) 57 Rated voltage motor: (V) 400 Rated frequency: (Hz) 50 Generator marks: 2 x 64 Weight: (rotor / stator) (kg) 14.9 / 36 Length: (motor incl. handwheel) (mm) 459 ThyssenKrupp Aufzugswerke GmbH 28 Issue 01.2005

2. PRODUCT DESCRIPTION 2.15 Motor data VVVF motors (frequency-controlled VVVF) Constructional size A4 Motor type: DEE 132 K 005 DEE 132 M 003 DEE 140 S 009 Speed range: (1/min) 1300-1450 1451-1700 1250-1450 1451-1650 1250-1400 1401-1650 Moment of : (J 1 ) (kgm²) 0,056 0,056 0,056 Moment of : (J M ) (kgm²) 0,027 0,042 0,065 Moment of : (J H ) (kgm²) 0,010 0,010 0,010 Moment of : (J ges.) (kgm²) 0,093 0,108 0,131 S 5 operating data with 240 F/h, 50 % ED Power: (KW) 5,7 11.0 16.0 Torque range: (Nm) 43,5-34,0 34,0-32,0 84,0-72,5 72,4-63,7 122-109 109-92,6 Current: (A) 15.5 26.5 38.5 Permissible starting torque: (Nm) 80 65 170 150 240 220 Permissible starting current: (A) 25 48 67 Sinusoidal voltage motor: (V) 340 340 330 Generator marks: V N <1.5 m/s / V N 1.5 m/s 1024 / 4096 1024 / 4096 1024 / 4096 Weight: (kg) 22 38 47 Length: (motor incl. handwheel) (mm) 459 459 459 ThyssenKrupp Aufzugswerke GmbH 29 Issue 01.2005

2. PRODUCT DESCRIPTION 2.16 Motor data ThyssenKrupp/Siemens special motors Constructional size B5 (with hand wheel Ø 360mm 270mm) Ausführung ACVV VVVVF Schutzart: IP21 IP54 Motor type: LNLA 160 LS-20C 1LA6-166-4AA-11Z Synchronous speed: (1/min) 1500 Rated speed: (asyn.) (1/min) 1350 1250-1500 Moment of : (J 1.) (kgm²) 0,054 0,054 Moment of : (J M.) (kgm²) 0,135 0,055 Moment of : (J H.) (kgm²) 0,0292 0,010 Permissible mass moment of inertia: (J ges.) (kgm²) 0,218 0,119 S 5 operating data with 240 F/h, 50 % ED 180 F/h, 40 % ED 240 F/h, 50 % ED Power: (KW) 10.0 13,0 Rated torque: (Nm) 70 100-83 Starting torque: (Nm) 170 170 Rated current: (A) 23 32 Permissible starting current: (A) 80 47 Rated voltage motor: (V) 400 330 Rated frequency: (Hz) 50 max. 50 Generator marks: 2 x 64 4096 Weight: (kg) 157 114 Length: (motor incl. handwheel) (mm) 627 589 ThyssenKrupp Aufzugswerke GmbH 30 Issue 01.2005

2. PRODUCT DESCRIPTION 2.17 Machine frame TW63 (optional) Standardized versions: The machine frames for TW 63 described below are designed for mounting in the machine room above the well. 1.Without deflection pulley: for direct rope departure car counterweight or 2:1 suspension. See fig. 11 2.With deflection pulley: standard frame incl. deflection pulley 450 mm for defined rope distance as left-hand or right-hand version (to be determined by position of deflection pulley). See fig. 12 3.With deflection pulley: frame with order-specific deflection pulley ( 360/ 450/ 540 mm) as left-hand or right-hand version (to be determined by position of deflection pulley). See fig. 13 4. With 2 pulleys: standardized version for machine room below beside the well. See table version 4, representation in fig. 14. Machine frame with bolted sheating, trapezoidal supports and rope coverings incl. two diverter pulleys. Left-hand and right-hand frame versions dependent on pulley supports. Designed for use with well wall thickness of 180 320 mm by means of adjustable support. Non-changeable rope and pulley distance measures. Rope pulley data:. Ø 400 mm for ropes of 4 x Ø 10 Range of use: Installations with 1:1 suspension Q` 450 kg for F` 900 kg and v rated 1.6 m/s Installations with 2:1 suspension Q` 1050 kg with F` 1500 kg and v rated 1.0 m/s Note: frames 2. and 3. are designed for housing deflection pulleys with supports. For arrangement and dimensions see fig. 12/13 and tables of versions 2/3. Mounting Place machine frame on insulation elements for prevention of structure-borne noise. Different types of insulation elements are available which differ dependent on the way of mounting: a) Rubber block 100 x 100 x 50 high without base Shall be used for mounting the machine on a machine room without plaster floor or directly on the plaster floor. b) Rubber block like a) but with additional base 140 x 140 x 80 mm high. Shall be used for mounting the machine frame on plaster floor, base casted directly in plaster floor. (coating 60 mm) ThyssenKrupp Aufzugswerke GmbH 31 Issue 01.2005

2. PRODUCT DESCRIPTION Mounting of frame Loosely screw frames which are delivered as pre-fabricated parts together in the machine room. See to it that the brackets with additional drilled holes (2 holes) and pulley support are mounted on the correct side. Mount deflection pulley and axle on the pulley support and secure. Place frame on insulation elements as shown in plan of installation and align. Place machine on frame by means of hoist; traction sheave shall be mounted on the side of deflection pulley. Laterally shift machine on frame until the necessary ASL measure is reached (parallel rope distance on rope departure). Screw machine to frame. Parallelly align traction sheave and deflection pulley. Level uneven base by placing enclosed bearing elements under. See to it that you do not strain the housing. Tighten screws with required torque. Note that rope departure is aligned towards rope pulley on car or fastening on car and counterweight. Attention: in the case of lateral or diagonal rope departure secure the gear housing on the machine frame against dislocating by means of stoppers fastened with set screws. Explanation code designations: ASL = Parallel rope distance on rope departure DT = Diameter of traction sheave SR = Diameter of deflection pulley α = Angle of wrap on traction sheave X 1 = Distance 1 between rope departure and outer edge of frame X 2 = Distance 2 between rope departure and outer edge of frame Y 1 = Vertical axle distance between traction sheave and deflection pulley Y 2 = Vertical distance between centre deflection pulley and support base Z 1 = Distance 1 between rope departure centre and outer edge of frame 1 6) see explanations in representation of version 1 (fig. 11). ThyssenKrupp Aufzugswerke GmbH 32 Issue 01.2005

2. PRODUCT DESCRIPTION Data machine frame version 1 Illustration see fig.11 Weight machine frame: approx. 80 kg Traction sheave Arrangement maschine left-hand version 4) 5) Arangement machine right-hand version 4) 5) DT (mm) Measure x 1 Measure x 2 Measure x 1 Measure x 2 450 96,5 386,5 386,5 96,5 510 66,5 338,5 338,5 66,5 590 94,5 230,5 230,5 94,5 675 120 120 Traction sheave Arrangement maschine left-hand version 6) Arrangement maschine left-hand version 6) DT (mm) Measure x 1 Measure x 2 Measure x 1 Measure x 2 450 136,5 328,5 340,5 124,5 510 106,5 298,5 310,5 66,5 590 66,5 258,5 202,5 122,5 675 92,0 148,0 160,0 80,0 Note: left-hand or right-hand version means that the machine 5) (right-hand version position of traction sheave with view from motor onto machine) is displaced into mentioned direction up to last possible row of mounting holes. Measures x 1 or x 2 indicate the distance between rope departure and outer edge of frame dependent on traction sheave. ThyssenKrupp Aufzugswerke GmbH 33 Issue 01.2005

2. PRODUCT DESCRIPTION Data machine frame version 2 Weight machine frame incl. deflection pulley 450 :approx. 170 kg Traction sheave DT (mm) Rope distance car counterweight ASL (mm) Motorlage vertikal Angle of wrap α ( ) Motorlage horizontal 450 745 155 155 510 775 158 158 590 775 164 164 Comments see version 1 fig. 11 Data machine frame version 3 Weight machine frame incl. deflection pulley 360 approx.170 kg incl. deflection pulley 450 approx.200 kg incl. deflection pulley 540 approx.230 kg Rope distance measures and angle of wrap Traction sheave DT (mm) Minimum rope distance car counterweight and maximum angle of wrap ASL min (mm) and α max ( ) With deflection pulley SR (mm) 360 450 540 ASL min α max ASL min α max ASL min α max 450 622 166 566 169 566 168 510 652 168 664 166 664 164 590 760 166 704 170 704 168 675 802 169 815 168 883 160 ThyssenKrupp Aufzugswerke GmbH 34 Issue 01.2005

2. PRODUCT DESCRIPTION Traction sheave DT (mm) Maximum rope distance car counterweight and minimum angle of wrap ASL max (mm) and α min ( ) With deflection pulley SR (mm) 360 450 540 ASL max α min ASL max α min ASL max α min 450 1098 137 1042 137 1042 133 510 1128 139 1072 139 1072 135 590 1100 146 1044 145 1044 142 675 1143 149 1087 147 1087 145 Intermediate values for ASL in modular dimension of 68 mm Project planning dimensions Deflection pulley SR (mm) Measure x 1 (mm) Measure x 2 (mm) Measure y 1 (mm) Measure y 1 (mm) Measure z 1 (mm) 360 130 61 700 190 245 450 231 116 655 235 255 540 276 116 575 315 255 Data machine frame version 4 Machine frame with 2 pulleys for drive arranged below - beside Weight of machine frame incl. two rope pulleys 400 approx. 210 kg Traction sheave - DT (mm) Angle of wrap α ( ) 450 187 510 191 590 197 675 203 ThyssenKrupp Aufzugswerke GmbH 35 Issue 01.2005

2. PRODUCT DESCRIPTION Version 1 Machine frame TW63 without deflection pulley Machine arranged on left-hand right-hand side Rubber block Base Fig. 11 Comments: 1) Version with motor of constructional size A4 2) Version with motor of constructional size B5 3) Additional insulation elements with load of traction sheave shaft P > 38 kn 4) Vertical motor position 5) Horizontal motor position right-hand machine mounting 6) Horizontal motor position left-hand machine mounting ThyssenKrupp Aufzugswerke GmbH 36 Issue 01.2005

2. PRODUCT DESCRIPTION Version 2 Machine frame TW63 with deflection pulley Left-hand version is illustrated (mirror-inverted right-hand version) Fig. 12 Comments see version 1 fig. 11 ThyssenKrupp Aufzugswerke GmbH 37 Issue 01.2005

2. PRODUCT DESCRIPTION Version 3 Machine frame TW63 with deflection pulley Right-hand version is illustrated (mirror-inverted left-hand version) Fig. 13 Comments see version 1 fig. 11 ThyssenKrupp Aufzugswerke GmbH 38 Issue 01.2005

2. PRODUCT DESCRIPTION Version 4 Machine frame TW63 with 2 deflection pulleys and drive arranged below beside Left-hand frame mounting Right-hand frame mounting Fig. 14 View A Comments see version 1 fig. 11. ThyssenKrupp Aufzugswerke GmbH 39 Issue 01.2005

3. TRANSPORTATION 3. Transportation and storage Packaging: In the as-delivered condition the TW 63 is mounted on a special pallet. Dependent on the order volume machine frame, supports and deflection pulley are enclosed. In the case of delivery by sea the machine incl. additional parts are wrapped in seaworthy packing. Transportation: Transportation shall be subject to observation of the safety requirements and the gravity centre of the machine. Attention: machine is filled with oil. It shall be transported and stored in upright position only. Transportation by means of fork lift: In the case of transportation by means of fork lift see to it that the fork is attached to the pallet and not to the machine. Pay attention to projecting parts! There is the risk of injury to persons or damage to property! Transportation by means of crane: Do not stay below suspended loads! Fasten machine without frame on motor by means of a rope as shown in the figure below. See to it that the ventilation grid cannot be damaged. Wrap rope around motor of machine without frame and secure to crane as shown in figure below! Secure machine against sliding and turning over. Transport aid Fig 15 Rope fastening: wrap transport rope under terminal box and ventilation opening around motor in the case of machine without machine frame. See figure. ThyssenKrupp Aufzugswerke GmbH 40 Issue 01.2005

3. TRANSPORTATION Note the pictographs fastened on the packing or on other visible places. Top Handle with care Keep dry Do not expose to heat Do not use handheld grippers Fasten here Dimensions and weight The weight is indicated on a sticker on the packing placed below the transport rail. For dimensions see delivery note. For rough data see chapter 2.3 Technical data. Examination by customer on receipt of goods Examine the delivered parts for completeness, damage or anything strange. Report and document transportation damages After receipt of goods make sure that there is no damage caused during transportation. Information Immediately document the damages noticed (drawing, photograph, description of the damage). Send the respective reports immediately to THYSSENKRUPP AUFZUGSWERKE GmbH Unpacking Information Dispose packing equipment in accordance with the environmental requirements or make it available for further use. Special transport aids and transport contrivances shall not be sent back to THYSSENKRUPP AUFZUGSWERKE GmbH but remain at the customer. ThyssenKrupp Aufzugswerke GmbH 41 Issue 01.2005

3. TRANSPORTATION Intermediate storage If the component is not mounted directly after delivery carefully store it at a sheltered place and see to it that it is provided with a humidity-proof covering. Do not store the component in the open air. Parts without surface coating lack long-time preservation. Environmental conditions Information Surroundings at the final site of the machine (humidity, temperature) shall comply with the requirements for machine and pulley rooms acc. to the standards in force. (Between +5 and + 40 C acc. to EN 81). ThyssenKrupp Aufzugswerke GmbH 42 Issue 01.2005

4. MOUNTING OF MACHINE 4. Mounting of machine in machine room Dependent on the order volume the TW63 machine is delivered including machine frame and deflection pulley. Dependent on the customer requirements the frame is mounted on supports, brackets, concrete socle or is casted directly in plaster floor on the machine room floor. To make installation and mounting of the frame supports easier, drawing and parts list of the frame are enclosed. Attention: mount the frame acc. to drawing and fasten by enclosed elements. Observe indicated strength and respective torque. See data in chapter 9.1 In order to better comply with the requirements concerning noise reduction / structure-borne noise transmission insert the insulation elements delivered between frame support and floor. The number of rubber elements depends on the overall weight load. The individual rubber elements should be loaded at between 7000 and 12 000 N / rubber element. (For position and arrangement of the rubber elements see layout drawing). Note: on arranging the rubber elements observe that the overall gravity centre shall lie within the rubber elements ( the same applies if the car is suspended from the deflection pulley side). If cast plaster floor is used as supporting surface for the machine frame see to it that the thickness of the coating shall be 60 mm. Insert insulation elements with wooden base (80 mm). The base part shall also be cast. For mounting and machine frame data see chapter 2.16 2.17. Aligning of machine Place the machine in accordance with the layout drawing. Align the rope departure of the traction sheave acc. to the drawing so that it is in vertical line with the car fastening resp. with the rope pulley and the counterweight. If the ropes are tensioned the machine shall be horizontally aligned and mounted on its supporting surface on the rubber elements. Level uneven position by placing metal or wooden plates underneath. SA9 traction sheave in well, machine with extended traction sheave shaft and pedestal bearing. Attention: when placing a gear with outside bearing see to it that the following points are observed by all means Mount and fasten the colums in accordance with the requirements Horizontally align the worm wheel shaft Exactly align the bearings of the machine and the outside bearings ThyssenKrupp Aufzugswerke GmbH 43 Issue 01.2005

4. MOUNTING OF MACHINE 4.1 Mounting of rope guards for traction sheave Screw the rope guards to the rope guard brackets by means of the enclosed screws. Turn the rope guard brackets in such a way that the distance between rope and rope guards is as small as possible on the side of the traction sheave where the ropes enter and leave. (1-2 mm) In the case of diagonal rope departure adapt the position of the rope guards to the changed rope departure direction. Note: first align, then tighten the fastening screws of the rope guard brackets on the machine with pre-set torque. For tightening torques see table in annex of operating manual. 1 1 2 2 max. 1-2 mm Fig. 16 Fig. 17 (W191 illustrated) 1 Rope guard bracket 2 Rope guard Attention: If the ropes are entering the traction sheave at any angle above the horizontal up to a maximum of 90 (example: machine arranged on bottom/top beside) an additional provision is necessary to avoid the introduction of objects between ropes and pulleys. If the ropes enter the traction sheave at a protected area within the machine frame, the function "protection against bodily injury " is not necessary. Note: for SA9 (traction sheave in well) rope guard is not provided by THYSSENKRUPP AUFZUGSWERKE GmbH. ThyssenKrupp Aufzugswerke GmbH 44 Issue 01.2005

5. PUTTING INTO SERVICE 5. Putting into service Prior to putting the machine into service first check whether the following works were carried out: Safety, accessory and installation tools are removed from danger zone Check mounting of machine, frame, base and rope departure Oil drain is assembled and closed with cap Check gear oil level Fastening of machine and frame is checked In the case of lateral or diagonal rope departure secure gear housing against displacing by means of stops and set screws. Screws are tightened and secured with pre-set torque (see table with tightening torques in 9.1) Brake shoe stroke and adjustment are checked With SA3 adjustment and function of brake test switches are checked Brake test with one brake shoe each is carried out Functioning of manual brake release is checked Rope guards are mounted and distance to traction sheave is adjusted Supply terminals and earthing of motor, forced ventilation and brake release magnet are connected and secured Direction arrow (up/down) for the respective travel direction is clearly visibly glued on the motor near the handwinding wheel Note: in case that traction sheave and rope pulley are delivered as separate parts install see to it that they will be correctly installed. If the machine is delivered disassembled for reasons of weight, transportation or space, re-assemble the dismantled parts to the original condition and observe the respective torque when screwing the fastening parts (see table tightening torque 9.1) Any warranty obligation on parts is subject to use of original mounting and fastening parts from ThyssenKrupp Aufzugswerke GmbH. ThyssenKrupp Aufzugswerke GmbH 45 Issue 01.2005

5. PUTTING INTO SERVICE 5.1 Emergency operation TW 63 is equipped with handwheel and accompanying brake release lever for emergency operation. The brake release lever shall be applied to the cast-on recesses of the brake shoe ends (see fig. 3A). By pressing the levers the brake shoes will be expanded, thus releasing the brake. In the case of emergency rescuing of trapped passengers also turn the handwheel, if necessary, in order to move the car to the nearest landing. Depending on the load the car can start moving quickly as soon as the brake is released. Immediately stop moving the handwheel and regulate the speed of the car by pressing the brake release lever accordingly. Attention: if the handwheel is used for servicing and maintenance works (e.g. "safety gear operation") see to it that the person performing the work stands on a safe working area. Note that there is the danger of injury if electric recall is operated at the same time. 1 1 Brake shoe 2 Brake release lever 2 Fig. 3A ThyssenKrupp Aufzugswerke 46 Issue 01.2005

6. SERVICING 6. Servicing Maintenance interval: maintenance of the machine should at least be carried out once a year, preferably in the course of the general lift maintenance. Note: installation and maintenance works shall only be carried out by trained and instructed, technically competent personnel. They shall be familiar with all directives and requirements for lift installations as well as with the requirements for the prevention of accidents and they shall observe them accordingly. For further information concerning proceeding, adjustment and data see chapter: Check oil level and fill in oil, if necessary 2.6 Change oil (observe date of oil change) 2.6 Check brake shoes for wear, residual brake lining shall be at least 7.3 3 mm Check brake adjustment, brake stroke shall be 0.3 mm + 0.1 mm 7.3 Check armature base plate for pre-tension and movability 7.2 Check brake deceleration 7.3 Check worm teeth for wear Check backlash between worm shaft and worm wheel (0.04 mm to 0.12 mm with 20 C.) 6.1 Check groove profile on traction sheave for damage and wear Check screws of traction sheave fastening for correct tightening 9.1 Check grooves on rope pulleys for damage and wear Check electrical supplies for correct working and safety Check provision and correct adjustment of protective and safety equipment Notes on lubrication (oil change, quantity, maintenance interval) see chapter 2.6. ThyssenKrupp Aufzugswerke GmbH 47 Issue 01.2005

6. SERVICING 6.1 Checking of flank clearence The backlash of the worm gear (between worm wheel and worm shaft) increases due to wear. As soon as the wear limit (backlash) of 1.5 mm is reached safe operation of the machine is no longer ensured. Replace the machine. Possibilities of measuring: Remove load from machine (by unroping the traction sheave) Perform measurement with the brake engaged Apply stop to traction sheave, e.g. screw clamp Determine measuring radius (M) and mark measuring point (radius ( r ) = 130 mm for TW 63) Attach dial gauge and magnet holder to machine casing and adjust to measuring point (M). Manually move the traction sheave until the hand of the dial gauge starts moving. Move traction sheave to and fro until a stop is felt.the tooth flank of the worm wheel is to be loaded with approx. 20-50 N. Read dial gauge deflection (ME). Calculate backlash acc. to the equation below. Perform measurement at three different points at least! Traction sheave Dial gauge Worm wheel Fig. 18 M = measuring radius ME = measured result r = radius worm wheel all dimensions in mm Backlash = ME * r M ThyssenKrupp Aufzugswerke GmbH 48 Issue 01.2005

7. MAINTENANCE 7.1 Replacing of brake shoes Note: if the residual lining thickness is 3mm or less, or if the linings are damaged (e. g. glazing etc.) the brake linings shall be replaced. Before you start working secure counterweight and car and switch off power supply. Unscrew and remove nuts on tension spring. Remove pin lock bolt and brake shoe pin. Remove one brake shoe, then mount armature base plate on new brake shoe. Slightly grease sliding surface between armature base plate and armature screw. Check movability of armature base plate, re-adjust, if necessary. It should be possible that the armature base plate can be moved on the bolt at low resistance. Secure adjustment by tightening the lock nut. Mount the pre-assembled brake shoe, do not tighten nuts on tension spring. Attention: see to it that the thread of the brake shoe bolt projects, since otherwise it cannot be removed any more. Pre-tension brake tension springs to max. 13.5 mm. (approx. 11 turns of counternuts) Adjust brake shoe stroke by changing the armature base plate bolt on brake shoe. Measure brake shoe stroke 0.3 mm + 0.1 mm to centre of brake disk. Replace and adjust second brake shoe in the same way. After replacement of the brake shoes is finished, run car under emergency electrical operation and check whether both shoes of the brake are disengaged uniformly. Check stroke travel and deceleration and re-adjust, if necessary. 9 1 2 3 4 5 6 7 8 1 Worm shaft 2 Brake disk 3 Magnetic clamp 4 Cover ring 5 Armature base plate 6 Armature base plate screws 7 Brake shoe 8 Dial gauge 9 Tension screws Stroke 0.3 + 0.1 Fig: 19 Brake shoe adjustment, illustrated without motor and traction sheave ThyssenKrupp Aufzugswerke GmbH 49 Issue 01.2005

7. MAINTENANCE 7.2 Adjusting of braking deceleration Only adjust brake with one acting brake shoe each while moving the car loaded with rated load downwards (full down) or the empty car upwards (empty up) in accordance with the deceleration values stated in the table below. Adjust the brake shoe torque by pre-tensioning the brake springs for each lift type individually and at both brake shoes evenly. Machine with flywheel masse Machine with handwinding wheel > v m/s 0.63 1.25 0.63 1.25 1.25 - a full-down) m/s² 0.2 0.3 0.3 0.4 0.50 - a (empty-up) m/s² 0.4 0.5 0.5 0.6 0.75 Table: brake deceleration values 1 2 3 4 2 1 5 6 7 8 9 8 Fig. 20 12 11 10 1 Brake shoe bolt 7 Washer 2 Safety screw incl. washer 8 Counternuts 3 Oil vent 9 Anchor bolt 4 Inspection opening 10 Armature base plate 5 Brake shoe 11 Cover ring 6 Rubber disk 12 Magnetic clamp ThyssenKrupp Aufzugswerke GmbH 50 Issue 01.2005

7. MAINTENANCE 7.3 Adjusting of brake shoe stroke / armature base plate Before first startup and during regular inspection check the working stroke of the brake shoes as well as the pre-tension and the movability of the armature base plates. How to proceed: 1. Check armature base plate for movability: After a long time of use the rubber disk between armature base plate and brake shoe (fig. 16 pos. 6) may sink and, consequently, the pre-tension of the armature base plate may be too low. To restore the pre-tension re-adjust the counternuts between brake shoe and armature base plate. The pretension is correct if the armature base plate slightly clings on the anchor bolt and can be turned. 2. Check stroke : Align dial gauge to brake shoes and measure on the level of the brake disk centre. Release brake shoes by operating the drive and check stroke of brake shoe. Stroke travel shall be 0.3 mm + 0.1 mm. Re-adjust: unscrew counternuts (fig. 20 pos. 8) and re-adjust armature base plate by means of hexagon socket screw key in the case of deviations. Secure adjustment. Note: release brakes and see to it that both brake shoes work with the same stroke. 3. Adjust pre-tension of springs: Correct adjustment of pre-tension is only possible in the course of adjusting the braking deceleration (see 7.2) Do not exceed the maximum pre-tension value of 13,5 mm. e Note: if brake test switches are provided (SA3) check or re-adjust them after every brake adjustment. See brake monitoring SA3 chapter 8.2 ThyssenKrupp Aufzugswerke GmbH 51 Issue 01.2005

7. MAINTENANCE 7.4 Replacing of traction sheave Disassembly: Assembly: Switch off power supply, secure car and counterweight,. Remove load from traction sheave by discarding ropes. Secure traction sheave with rope or chain to hoist. Unscrew screws on fastening disk of traction sheave and loosely screw them in outer hole circle of disk into traction sheave hub (see fig. 21 pos. 2 below) Place spacer (5 10 mm thick and somewhat smaller than diameter of drilled hub holes) between shaft end and disk. Remove traction sheave from shaft by alternately and uniformly tightening the screws Clean shaft end and drilled hole of traction sheave; never make any dimensional changes in featherkey, groove, shaft or drilled holes. Check contact surfaces for damage. Do not grease or oil shaft and drilled hole. Fit new traction sheave to conical shaft end of worm wheel shaft. Bring position of featherkey and groove in line. Slide traction sheave on worm wheel shaft. Screw disk with new (micro-encapsulated) screws and detent edged rings in inner hole circle of disk. Tighten screws alternately and uniformly. Attention danger: if the traction sheave is assembled incorrectly it can work loose. See to it that screws are tightened and check tightening torque 100 Nm! See table 9.1 in annex. 1 2 3 4 1 Traction sheave 2 Hole for forcing screw 3 Fastening disk 4 Fastening screw 2 Fig. 21 ThyssenKrupp Aufzugswerke GmbH 52 Issue 01.2005

7. MAINTENANCE 7.5 Replacing of motor Note: with motors of constructional size A4 the rotor is shrink-fit to the motor shaft. Therefore the rotor can only be replaced together with the worm shaft. This is why the motor shall be replaced at the factory. The following description of motor change only applies to motors of constructional size B5 (SA14) Disassembly : Assembly : Switch off power supply, secure car and counterweight. Fasten motor to hoist and secure. Disconnect electrical terminals and lines from motor (motor and magnetic clamp terminals). Remove nuts on motor, brake and coupling disk. For assembly of flexible coupling see annex 9.2. Carefully remove motor from studs and place it on the floor. Compare motor data of the two motors. Fasten spare motor to hoist and secure. Lift motor by means of hoist and bring motor coupling and brake disk into line. See to it that the mounting holes and the screws are aligned to each other. Mount motor and coupling unit to shaft and then screw coupling to brake disk. Screw on nuts and tighten uniformly in accordance with the required torque (see table of tightening torque in annex). Note: for assembly of flexible coupling SA14 see chapter 9.2. ThyssenKrupp Aufzugswerke GmbH 53 Issue 01.2005

8. SPECIAL VERSIONS 8.1 SA Special versions (optional) (Additional parts for special applications) Survey: SA 3 SA 9 SA 12 SA 14 SA 15 with brake monitoring switches traction sheave in well (with extended traction sheave shaft) with additional terminal box for brake release magnets for motors without terminal box with flexible coupling for motors of constructional size B5 with brake release magnets in ex (sg4) version SA3 Brake monitoring switches for monitoring the brake shoes (open-closed) and the wear of brake lining. Note: check and, if necessary, re-adjust existing brake monitoring switches every time you adjust the brake. See 8.2 SA3 adjustment description of brake monitoring switches SA9 With extended traction sheave shaft if the traction sheave is arranged directly in the well. The traction sheave shaft is supported by a bearing. The machine is fastened on pedestal supports for compensating the shaft load and the forces acting on the bearings. SA12 Additional terminal box for intermediate terminals of brake release magnets (for motors without terminal box acc. to BV 65 31) SA14 For motors of constructional size B5 possible misalignments between brake disk and motor coupling are compensated by means of a flexible coupling. For description of coupling see annex 9.2 flexible coupling for motors of constructional size B5 SA15 Brake release magnets in ex-(sg4) version (not possible in combination with SA3 and SA12) ThyssenKrupp Aufzugswerke GmbH 54 Issue 01.2005

8. SPECIAL VERSIONS 8.2 SA3 Brake monitoring TCM Version for TCM controls The brake monitoring is designed for monitoring the brake shoes. It prevents motor motions if the brake is partly or fully closed. It helps to detect possible brake lining wear at an early stage. Switches (sensors) are used to monitor whether the brake shoes are closed, open or worn-out. For better evaluation the run signal - deviated from W/W1 contactor - is used. Failure is displayed via light-emitting diodes on the sensors and the brake monitoring switches in the control cabinet. If a Teleservice device is connected the error will be indicated on the display. Mounting: 1. Manufacture 2 cables (0.3*0.75mm² with PVC sheath) if they are not part of the supply schedule for direct connection of sensors to control and connect sensors. 2. The (micro-encapsulated) hexagon screws to be adjusted as well as the counternuts have been pre-assembled on the brake shoes at the factory. The plunger on the switch shall be opposite but not in contact to the adjusting screw. Adjusting : Adjust brake shoe stroke prior to setting the sensors! For description see chapter 7.3 3. Switch on electrical emergency operation and lift control. 4. Turn adjusting screw towards switch until LED flickers. 5. Slowly turn screw back until LED will just go out. 6. Then turn screw back by one fourth of rotation (equivalent to approx. 0.3mm) towards the switch and lock it. LED flickers constantly. 7. Supply motor with power, then release and close brakes and check at the same time that switching of the sensors changes between engaged and disengaged brake. ThyssenKrupp Aufzugswerke GmbH 55 Issue 01.2005

8. SPECIAL VERSIONS Fig. 22 Brake test switches mounted on machine 1 2 3 4 5 Fig. 23 Adjustment of test switch on hexagon screw 1 Spring clamp 2 Brake shoe 3 Adjusting screw 4 Test switch (sensor) 5 Plunger ThyssenKrupp Aufzugswerke GmbH 56 Issue 01.2005

8. SPECIAL VERSIONS 8.3 SA3 Brake monitoring BRC Version for third-party and older controls ( not TCM! ) The brake monitoring BRC is a retrofit electronic device designed for monitoring of brake shoes. The signals sent from the sensors are evaluated and transmitted to the secondary control electronics. The device automatically switches off if the set sensor value is reached. Light-emitting diodes on the sensors and the BRC brake monitoring switches are provided for failure display. If a Teleservice device is connected the error will be indicated on display. Make contact Travel contactor Connection Teleservice K1 interrupter contact in safety circuit L1 N W Brake monitoring BRC Teles. K1 Failure display Cable length acc. to order (standard length approx. 5 m) cable 3*0.75 mm² with PVC sheath Sensor mounted on machine, adjusted to respective integrally cast surface of brake shoe Fig. 24 Terminal connection diagram for brake monitoring BRC applies to third-party and older controls (not TCM) Connections : L1 a.n for mains 230 V W for make contact to W contactor B1 sensor 1 with voltage supply 24V/0V B2 sensor 2 with voltage supply 24V/0V K1 make contact for evaluation (e.g.connection to safety circuit) Teles. for connection to THYSSENKRUPP Teleservice device (remote monitoring of lift) ThyssenKrupp Aufzugswerke GmbH 57 Issue 01.2005

8. SPECIAL VERSIONS Brown Black B1 Blue 0V Blue 0V Brown 24V Black B2 Fig. 25 Terminal connection diagram for sensors ThyssenKrupp Aufzugswerke GmbH 58 Issue 01.2005

9. ANNEX 9.1 Tightening torques- strength Attention: to be strictly observed when performing work on the machine or replacing parts! Strength DIN / Tight.- ISO torque Nm Handwheel on hub Cheese head screw M 8*12 8.8 4762 20 Lock washer S8 Hub on shaft Cheese head screw M 12 * 35 microencapsul. 8.8 4762 75 Detent edged disk SK M12 Dowel pin 6 *18 8752 9 Pulse generator on motor casing Cheese head screw M 6 *12 8.8 4762 9 Motor bearing cover on motor casing Cheese head screw M 6 *12 8.8 4762 9 Motor casing on gear box casing Cheese head screw M 12 * 35 8.8 4762 75 Brake disk on worm shaft (only with A4 motors) Shaft nut M 55 * 2 8.8 600 Bearing cover on inside box casing Cheese head screw M 12 * 35 microencapsul. 8.8 4762 75 Disk on conic. end of worm wheel shaft Cheese head screw M16 * 40 microencapsul. 8.8 4762 100 Detent edged disk SK M16 Bearing bracket on casing Cheese head screw M 10 * 30 microencapsul. 8.8 4762 40 Bearing cover on bearing bracket Hexagon nut M10 * 30 8.8 4017 40 Detent edged disk SK M10 Disk on bearing worm wheel shaft Cheese head screw M 10 * 30 microencapsul. 8.8 4762 40 ThyssenKrupp Aufzugswerke GmbH 59 Issue 01.2005

9. ANNEX th ISO torque Nm Locking screw on brake shoe bolts Cheese head screw M6 * 12 8.8 4762 9 Detent edged disk SK M6 Brake release magnet on casing Hexagon screw M16 * 120 8.8 4014 150 Machine on machine frame versions 1-3 / 4 Hexagon screw M20 * 90 Washer 21 Hexagon nut M20 Lock nut M20 8.8 8 4014 7349 4032 7967 190 / 350 Tightening torques for screwing the fastening parts on the machine frame Hexagon screw M 6 * 20 8.8 4017 9 Hexagon screw M10 * 16 8.8 4017 40 Hexagon screw M12 * 35 8.8 4017 75 Hexagon screw M16 * 25 8.8 4017 190 Hexagon screw M16 * 40 8.8 4017 190 Hexagon screw M16 * 80 8.8 4017 190 Detent edged disk SK M10 Detent edged disk SK M12 Detent edged disk SK M16 Note: install screws, washers, detent edged disks, nuts and lock nuts acc. to the information of enclosed drawings and tighten with the torque specified. Note: only use micro-encapsulated screws once, then replace. Any warranty obligation on parts is subject to use of original mounting and fastening parts from ThyssenKrupp Aufzugswerke GmbH. ThyssenKrupp Aufzugswerke GmbH 60 Issue 01.2005

9. ANNEX 9.2 Annex Flexible coupling for B5 motors sheet 1 Design for TW63. ThyssenKrupp Aufzugswerke GmbH 61 Issue 01.2005

9. ANNEX 9.2 Annex Flexible coupling for B5 motors sheet 2 TW63 ThyssenKrupp Aufzugswerke GmbH 62 Issue 01.2005

9. ANNEX 9.3 Pulse Generators Versions: the following pulse generators are available for TW63 Type classification dependent on the control used 1.TTL for THYSSENKRUPP control CPI for v < 1.5 m/s with 1024 pulses part No. 00 990 13 03 0 for v 1.5 m/s with 4096 pulses part No. 00 990 14 03 0 Use cable of 10 m length, SUB-D 9 tab and locking lever acc. to DIN 46342 for connection. Connector assignment Electrical data: Connection Pin Colour Supply voltage 5 V DC Minus 7 white Power consumpt.: max. 60 ma Plus 9 brown Output: push-pull Channel A 2 green Max load.: 40 ma Channel B 3 yellow Level with 20 ma: H >3,6 VDC Zero pulse 5 grey L < 1.2 VDC Channel A inv. 1 red Max. pulse frequency: 200 khz Channel B inv. 4 black Terminal protector: no Zero pulse inv. 6 lilac Shield 8+casing black Please note manufacturer s information in chapters 9.5 9.5 2.HTL for third-party controls or converters with 2 x 64 pulses part No. 00 990 12 03 0 Use cable of 10 m length insulated with end sleeves for connection.. Connector assignment Electrical data: Connection Pin Colour Supply voltage 15V DC Channel A 6 grey Power consumpt. +15V: 90 ma Channel B 5 pink Power consumpt. -15V: 10 ma Channel C 3 green Output: A Channel 64 I/U Mass 4 yellow B Channel 64 I/U Plus 15 V 1 brown C Channel 128 I/U Minus 15 V 2 white Shield open Please note manufacturer s information in chapters 9.4 9.5 ThyssenKrupp Aufzugswerke GmbH 63 Issue 01.2005

9. ANNEX 3.HTL for third-party controls or converters with 1024 pulses part No. 00 990 16 03 0 Use cable of 10 m length insulated with end sleeves for connection. Connector assignment Electrical data: Connection Colour Supply voltage 15V DC Channel A green Power consumpt.: max.60 ma Channel B yellow Channels: A, B, N, ABN inv. Channel N grey Output: HTL- differential driver Channel A inv. red Load: max. 40 ma Channel B inv. black Level: with 20 ma Channel N inv. lilac H > U B 2,5 VDC Mass yellow L > 2,5 VDC Plus 15 V brown Pulse frequency: max. 200 khz Minus white Terminal protector: yes Shield strand Early warn. output: NPN OC, 10 ma Early warning output:pink U max. = 30 VDC Cable length: max. 100 m Please note manufacturer s information in chapters 9.4 9.5 4.HTL for third-party controls or converters with 1024 pulses part No. 00 990 19 03 0 Use cable of 10 m length insulated with end sleeves for connection. Connector assignment Electrical data: Connection Colour Supply voltage: 5V DC Channel +A green Power consumpt.: max. 100 ma Channel +B grey without load Channel +N black Channels /output: sine, cos., N Channel - A yellow Output load : min 120 Ohm Channel - B pink Termin. resistor between + and Channel - N lilac - outputs. Plus 5 V brown Level: 1 Vss +/- 25 % Minus white Max. frequency (-3dB): 100 khz Shield strand Terminal protector: no Early warning output: conductive in operating state Cable length: max. 150m with <260pF/m General design: acc. to DIN VDE 0160 Please note manufacturer s information in chapters 9.4 9.5 ThyssenKrupp Aufzugswerke GmbH 64 Issue 01.2005

9. ANNEX 9.4 Pulse Generator Manufacturer s Instruction Sheet 1 Part No.: 00 990 12 03 0 with 2 x 64 pulses ThyssenKrupp Aufzugswerke GmbH 65 Issue 01.2005

9. ANNEX 9.4 Pulse Generator Manufacturer s Instruction Sheet 2 Part No. 00 990 13 03 0 with 1024 pulses Part No. 00 990 14 03 0 with 1024 pulses ThyssenKrupp Aufzugswerke GmbH 66 Issue 01.2005

9. ANNEX 9.4 Pulse Generator Manufacturer s Information Sheet 3 Part No. 00 990 16 03 0 with 1024 pulses ThyssenKrupp Aufzugswerke GmbH 67 Issue 01.2005

9. ANNEX 9.4 Pulse Generator Manufacturer s Information Sheet 4 Part No.: 00 990 19 03 0 with 1024 pulses ThyssenKrupp Aufzugswerke GmbH 68 Issue 01.2005

9. ANNEX 9.5 Pulse Generator Manufacturer s Instruction Product Information ThyssenKrupp Aufzugswerke GmbH 69 Issue 01.2005

9. ANNEX 9.6 Blocking clamp Every machine is equipped with a blocking clamp suitable for the respective traction sheave (rim width and design) Use of blocking clamp: Use the blocking clamp during assembly works on the car or on the counterweight in order to avoid movements by slip of ropes on traction sheave or during works for which the traction of the installation is not sufficient (for example for safety gear operation). Note: Tighten the blocking clamp by means of the screw connection in such a way that slip of ropes on traction sheave is impossible. 4 5 3 6 2 1 7 Fig. 26 Mounting the blocking clamp to the traction sheave (illustration without ropes) 1 Traction sheave groove 2 Rope 3 Pressure plate 4 Washer 5 Hexagon nut 6 Spacer 7 Clamp clip Attention: After terminating mounting works disassemble blocking clamp, since otherwise there is the risk of damage to the installation. ThyssenKrupp Aufzugswerke GmbH 70 Issue 01.2005