A company of ThyssenKrupp Elevator ThyssenKrupp Aufzugswerke Operating Manual Machine TW160
OPERATING INSTRUCTIONS Imprint All rights reserved Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH Postfach 23 03 70, D-70623 Stuttgart Printed in Germany These operating instructions may even in extract form only be reprinted or otherwise copied with the express written approval of THYSSENKRUPP AUFZUGSWERKE GmbH. All copying, distribution or saving in any form on data storage media which is not authorised by THYSSENKRUPP AUFZUGSWERKE GmbH constitutes a copyright infringement and will result in prosecution. We expressly reserve the right to carry out technical alterations which lead to an improvement of our products or increase the safety standard also without special prior notice. The issuer responsible for the content: THYSSENKRUPP AUFZUGSWERKE GmbH Preface We are delighted that you have decided upon a quality product from the company THYSSENKRUPP AUFZUGSWERKE GmbH. These operating instructions will help you to get to know our products and to benefit from their intended applications. Important safety and hazard instructions will help you to operate our products safely and properly. Subject to technical alterations.
Machine TW 160 Table of contents PAGE 1. Safety 1.1 Explanation of the symbols used 7 1.2 General safety instructions 8 2. Product description 2.1 Description 11 2.2 Functional description 12 3. Technology 3.1 Technical data 13 3.2 Machine base frame 15 3.2.1 Machine base frame without deflecting pulley 17 3.2.2 Machine base frame with deflecting pulley 19 3.2.3 Machine base frame, concrete support with deflecting pulley 22 3.2.4 Machine base frame, traction sheave in the shaft 25 3.3 Motor data 27 3.4 Type plate 27 3.5 Pulse generator 27 4. Transport and storage 28 5. Mounting the machine 5.1 Machine setup 30 5.2 Connecting the machine 31 5.3 Terminal connecting plan for gear drive motor and magnetic clamps 32 5.4 Terminal connecting information for motors complying with BV 6531-09 33 5.5 Terminal connecting information for motors complying with BV 6531-14 34 5.6 Bridge connection at motor terminals 35 5.7 Mounting the rope guard for the traction sheave 36 6. Commissioning 37 7. Maintenance / service 7.1 Maintenance 38 7.2 Lubrication 39 7.3 Checking the backlash 40 7.4 Replacing brake blocks 41 7.5 Setting braking deceleration 41 7.6 Setting brake block stroke and armature base plate 42 7.7 Traction sheave replacement 43 7.8 Motor replacement 44 7.9 Checking for escaping grease / oil 45
8. Special versions (optional) 8.1 Overview of special versions 47 8.2 Brake monitoring circuit SA3 48 8.2.1 Brake monitoring circuit (TCM) 48 8.2.2 Brake monitoring circuit (external) 49 8.3 Tachometer and pulse generator SA7 51 8.4 Mounting the tachometer and pulse generator SA7 52 9. Appendix 9.1 Tightening torques - tightness values 53 9.2 Blocking clamp 55 9.3 Manufacturer information, tacho-generators SA7 56 Manufacturer information, flexible coupling for B5 motors Manufacturer information, pulse generator
1. SAFETY 1.1 Explanation of the symbols used 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 bodily 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. Check Test steps are specified with this symbol. The test instructions marked in this way are to be followed without fail. They contribute to preventing personal injury or damage to property. 7
1. SAFETY 1.2 General safety instructions Notes regarding the operating manual A requirement for safe handling and non-disruptive operation 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 usage site are to be complied with. Obligations of the operator and/or of the installation firm The operator and / or installation firm 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. Obligation of the personnel Persons assigned to work on the assembly 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 device are to be checked regularly in accordance with the maintenance plan. 8
1. SAFETY 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 TW 160 has been constructed using state-of-the-art technology and in line with the recognised technical safety regulations. The TW 160 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 TW 160 is to drive elevators. Any other or additional form of use shall be regarded as non-compliant with the intended use. 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 the commissioning instructions, the installation description as well as the 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 TW 160 Installation, commissioning, operation and maintenance of the TW 160 that is not in line with accepted technical principles Operation of the TW 160 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 TW 160 Constructional changes to the TW 160 performed by the operator 9
1. SAFETY Changes to the drive ratios (power output etc.) performed by the operator Deficient monitoring of parts that are subject to wear Repairs that are carried out improperly Case of catastrophe due to third-party interference and force majeure. Constructional changes to the TW 160 performed by the operator The TW 160 is set at the plant and delivered ready for operation. NB : before commissioning, add the supplied oil! If changes are made to the machine, the entire warranty of ThyssenKrupp Aufzugswerke GmbH shall become null and void Dangers in handling the TW 160 The traction sheave and the handwinding wheel of the TW 160 are designed without a safety cover and may only be used in an enclosed machine room. It must be ensured when persons are in the machine room that there is adequate safety clearance to all revolving (marked in yellow) parts. 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 diminish safety are to be rectified immediately. General warnings for working on electrical components Do not work on live devices, components or cables! When an installation is switched off it is to be secured against unauthorised reactivation! Attention: Residual voltage can still be expected on bare wires and energised parts after they have been switched off! Electronic and other components remain energised even after the removal of fuses. Work may only be performed on the device after a waiting time of 5 minutes or as soon as the intermediate circuit voltage has reduced to a residual voltage of less than 60 V! This is to be tested by using a measuring instrument. 10
2. PRODUCT DESCRIPTION 2.1 Description The machine consists of: Item Part designation Item Part designation 1 Disc on worm wheel shaft 8 Motor 2 Traction sheave 9 Handwinding wheel 3 Gear drive (worm gear) 10 Actual-value sensor 4 Rope fixing beam 11 Terminal box SA12 5 Brake blocks 12 Transport rail 6 Brake release lever 13 Armature base plate on brake 7 Terminal box 3 4 5 6 7 8 9 2 1 10 11 Fig. 1 Versions: 13 12 The following versions of the machine can be selected depending on customer requirements: gear reduction, right-hand / left-hand design, (Fig. 1 shows the left-hand design) traction sheave version motor version 11
2. PRODUCT DESCRIPTION 2.2 Functional description The TW 160 machine consists of a worm gear (gear drive) with flangeconnected motor. Power transmission takes place on motors of the B9 model series (flangedon design with 1 bearing) via a rigid connection between the motor and worm shaft via worm wheel, traction sheave shaft to the traction sheave. In the case of motors of the B5 model series (flanged-on design with 2 bearings), a flexible coupling (SA14) is required between the motor and gear drive. Brake: The dual-circuit outside brake shoe is spring actuated. Two independently acting brake blocks press the brake lining with preset spring force onto the brake disc. The braking force is configured in such a way that one of the brake blocks is sufficient to bring an elevator car loaded with full weight to a standstill. The brake is released by electrically operated magnetic clamps. For manual operation, a brake release lever is fitted. 12
3. TECHNOLOGY 3.1 Technical data TW 160, standard version Drawn without motor Transport hanger (max. 545) M16/25 deep Assembly support Fig. 2 Motor dimensions are given as an example; exact dimensions can be found in the plans of installation. Permitted load on the traction sheave shaft: for standard version max. 97 kn (radial) for SA 4 / SA 9 max. 77 kn Brake magnet connection: connection values for each magnetic clamp are: In the case of the gear drive TW 160, the two magnets connected in series (2 magnets). Rated voltage: 50 V Power supply Rated current: 1.7 A for field forcing device: 200 V Type of protection: IP65 for retentive voltage: 100 V 13
3. TECHNOLOGY Weight: The weight data includes the gear, motor, traction sheave and outside bearing for SA 4 / 9 Motor size Motor in size 180 Motor in size 200 Motor in size 250 Standard version approx. 860 kg approx. 940 kg approx. 1150 kg Special version SA 4/9 approx. 930 kg approx. 1010 kg approx. 1220 kg TW 160 special version SA 4 / SA 9 Machine with long traction sheave shaft Machine fastening with compensating support Drawn without motor Mounting the pedestal supports Compensating support 125 200 780 248 500 SA11 150 Fig. 3 205 14
3. TECHNOLOGY 3.2 Machine base frame (optional) Standardised versions Version: 3.2.1. Without deflecting pulley, for direct rope departure elevator car counterweight, or 2:1 suspension. See tables for version 1, shown in Fig. 4. 3.2.2. With deflecting pulley, base frame on steel supports with deflecting pulley mounted on roller bearings depending on order ( 640/ 720/ 800 mm) in left-hand or right-hand design (determined by location of the deflecting pulley). See tables for version 2, shown in Fig. 5. 3.2.3. With deflecting pulley, base frame for concrete pedestal with deflecting pulley mounted on roller bearings depending on order ( 640/ 720/ 800 mm) in left-hand or right-hand design (determined by location of the deflecting pulley). See tables for version 3, shown in Fig. 7. 3.2.4. Without deflecting pulley, version for machine with SA 4 / 9 (with extended wheel shaft, for direct drive in the shaft). See tables for version 4, shown in Fig. 9. Base frame for machine in left-hand or right-hand design with compensating support. Can be used for a shaft wall thickness of 140 mm. Setting up To isolate the body, the machine base frame is placed on isolation elements. These differ according to the type of mounting: a) Rubber block 100 x 100 x 50 high without base For mounting the machine on the machine room floor without a cement floor or directly surface mounted on the cement floor. b) Rubber block same as a) however with an additional base 140 x 140 x 80 mm high For mounting on a cement floor, support cast in the cement floor. (floor covering thickness 60 mm) Note: for the layout of the isolation, the load per isolation element should be 7 kn 12 kn. 15
3. TECHNOLOGY Mounting the base frame Loosely bolt together base frames supplied as single parts in the machine room. Make sure that the supports are mounted with additional drilled holes (2 holes) and pulley support on the correct side. 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. (Dimension "L" specifies the distance between the outer edge of the base frame and the securing holes for the machine.) Bolt the machine onto the base frame. Align the traction sheave and deflecting pulley as parallel. Balance out uneven surfaces by inserting the enclosed shims. The machine housing must not be tensioned. Tighten the screws with the prescribed torque. See chapter 9.1. Plumb the rope departure on the rope pulley at the elevator car and/or mounting on the car and counterweight. Explanation of abbreviated designations: ASL = parallel gap between the ropes on the rope departure DT = diameter of traction sheave SR = diameter of deflecting pulley L = distance from the outer edge of the base frame to the mounting hole for the machine on the machine base frame. Note: The specified direction for left-hand or right-hand design of the machine is defined by the arrangement of the traction sheave, viewed from the motor onto the machine (arrangement of the traction sheave on the right-hand side corresponds to right-hand design). 16
3. TECHNOLOGY 3.2.1 Machine base frame without deflecting pulley, version 1 Machine in left-hand design (right-hand design mirror-inverted) Machine isolation Fig. 4 Base Rahmen frame Number and location of isolation elements Isolation element number Static shaft load P (kn) / number of elements per point of support I II III IV V VI 90 2 2 2 2 1 1 75 2 2 1 1 1 1 60 2 2 1 1 1 1 30 1 1 - - 1 1 17
3. TECHNOLOGY Weight of the machine base frame: approx. 147 kg S = centre of gravity of the base frame DT Diameter of traction sheave 640 720 800 Version Dimension Machine L L 295 R 200 L 255 R 240 L 215 R 280 L = distance from the outer edge of the base frame to the mounting hole for the machine. 18
3. TECHNOLOGY 3.2.2 Machine base frame with deflecting pulley, version 2 Gear drive Right-hand design Base frame, right-hand design Accessory, pulley frame SR Base frame Fig. 5 19
3. TECHNOLOGY Arrangement variants: Gear drive L Gear drive R Base frame R Base frame L Gear drive L Base frame L Fig. 6 Number and location of isolation elements ASL 800 1000 1200 1400 Number of the I II III IV I II III IV I II III IV I II III IV support Static 90 2 4 1 2 3 4 2 2 4 3 2 2 4 2 2 1 shaft load P (kn) 75 2 4 1 2 3 3 1 2 3 3 2 1 4 2 2 1 60 2 3 1 2 2 3 1 1 3 2 1 1 3 2 2 1 30 1 2 1 1 2 2 1 1 2 1 1 1 2 1 1 1 Weight of the base frame with pulley frame and supports with rope pulley: (1) Diameter 540 mm, (2) Diameter 640 mm, (3) Diameter 450 mm, approx. (1), 470 kg, (2) 550 kg, or (3) 420 kg S = centre of gravity of the base frame with pulley frame with rope pulley: (1) Diameter 540 mm, (2) Diameter 640 mm, (3) Diameter 450 mm, 20
3. TECHNOLOGY DT Diameter of traction sheave 640 720 800 Version Dimension Machine L L 295 R 200 L 255 R 240 L 215 R 280 L = distance from the outer edge of the base frame to the mounting hole for the machine on the base frame. 21
3. TECHNOLOGY 3.2.3 Machine base frame, concrete supports with deflecting pulley, version 3 Gear drive Right-hand design Base frame, right-hand design max. max. Accessory, pulley frame SR Fig. 7 22
3. TECHNOLOGY Weight of the base frame with pulley frame with rope pulley: (1) Diameter 540 mm, (2) Diameter 640 mm, (3) Diameter 450 mm, approx. (1), 390 kg, (2) 470 kg, or (3) 340 kg Arrangement variants: S = centre of gravity of the base frame with pulley frame with rope pulley: (1) Diameter 540 mm, (2) Diameter 640 mm, (3) Diameter 450 mm, Gear drive L Base frame R Gear drive R Base frame L Gear drive L Base frame L Fig. 8 L = distance from the outer edge of the base frame to the mounting hole for the machine on the base frame. Number and location of isolation elements ASL 800 1000 Number of the I II III IV V VI VII VIII I II III IV V VI VII VIII support Static 90 1 1-2 1 2 1 1 1 1 1 1 1 2 1 1 shaft load P (kn) 75 1 1-1 1 2 1 1 1 1 1 1 1 1 1 1 60 1 1-1 - 1 1 1 1 1-1 1 1 1 1 30 1 1 - - - - 1 1 1 1 - - - - 1 1 23
3. TECHNOLOGY Number and location of isolation elements ASL 1200 1400 Number of the I II III IV V VI VII VIII I II III IV V VI VII VIII support Static 90 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 shaft load P (kn) 75 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 60 1 1 1-1 1 1 1 1 1-1 1 1 1 1 30 1 1 - - - - 1 1 1 1 - - - - 1 1 24
3. TECHNOLOGY 3.2.4 Machine for base frame, traction sheave in the shaft, version 4 Special version for SA4 / SA9 Partition w all Gear drive / base frame L 275 ± 0.1 Pretension the sealing ring (gastight) against the bearing housing via the plate Fig. 9 Gear drive / base frame R Illustration of left-hand design (right-hand design mirror-inverted) 25
3. TECHNOLOGY Side view for version 4 in Fig. 9 max. Fig. 10 Illustration of left-hand design (right-hand design mirror-inverted) Weight of the machine base frame approx. 350 kg Installation instruction: the sealing ring is to be pretensioned (gastight) between the bearing housing and cover plate against the bearing housing. See Fig. 9 26
3. TECHNOLOGY 3.3 Motor data The technical data can be found on the type plate. In the case of synchronous machines, the max. current must not exceed the value on the type plate. 3.4 Type plate The current type and the technical data are specified on the type plate of product. 1. THYSSENKRUPP AUFZUGSWERKE GmbH 2. Lift Equip 3.5 Pulse generator See special versions, chapter 8.0 27
4. TRANSPORT AND STORAGE 4. Transport and storage Packaging: The TW 160 is shipped on a special pallet, whereby the machine is shrinkwrapped in foil. Depending on the scope of the order, it is fully mounted on a machine base frame or bolted onto two U-profiles. The profiles are to be removed before setting up at the place of destination. Transport: Transport must be effected in compliance with the safety regulations and observing the centre of gravity of the machine. Fork-lift truck transport: In the case of transport with a fork lift, the forks used must be long enough to prevent the transported goods from tipping over. Always pick up the transport pallet with the forks, not the machine itself. Pay attention to protruding parts! Danger of injury and damage! Crane transport: Do not walk underneath suspended loads! Use transport hangers to mount the transportation chain or rope. Do not lift by the housing! After transport, remove the transport hangers. Pay attention to the icons on the packaging or elsewhere. Top Fragile goods Protect against water Protect against heat Hand hooks prohibited Attach here 28
4. TRANSPORT AND STORAGE Dimensions and weight The weight data is specified on the packaging on a label below the transport hangers. Please refer to the delivery note for the dimensions. Rough specifications, see chapter 2.3 '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. Information 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 Information Dispose of packaging materials in an environmentally compatible manner or reuse them. Specific transport aids 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 Information The environment at the final location (moisture, temperature) must correspond to normal indoor climate conditions for machine rooms in line with regulations. 29
5. MOUNTING THE MACHINE 5.1 Machine setup Depending on the scope of the order, the gear drive is delivered mounted on the machine base frame. The base frame is set up depending on the customer on supports, beams, a concrete pedestal or directly cast in the machine room floor. In order to better comply with regulations for noise abatement and/or sound transmission, isolation elements are to be inserted between the frame supports and the ground. The number of rubber elements is based on the total weight load. The required individual load should be between 7000 and 12 000 N / per element. The location and arrangement of the rubber elements can be found in the plan of installation. Note: On arrangement of the supports, it is to be taken into account that the overall centre of gravity lies within the rubber elements (also in the case of elevator car suspension on the deflecting pulley side). If the supporting surface of the machine base frame is cast as a cement floor, the floor thickness should be 60 mm. Isolation elements with supports (80 mm high) are to be inserted. Part of the base is also to be cast in the floor. Mounting with inclined pulling or rope departure upwards (SA1) For the machine and base frame mount, the forces that arise in the pulling direction are also to be taken into account. Aligning the machine The machine is to be set up according to the plan of installation. 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 horizontally on its support. Irregularities are to be balanced out by inserting shims under the floor support. SA4, SA9 gear drive with extended worm wheel shaft and outside bearing NB: On setting up a gear drive with outside bearing, it must be ensured without fail that the pedestal supports are mounted and secured according to instructions the worm wheel shaft is aligned horizontally the gear shaft bearings of the machine and the outside bearing are exactly aligned 30
5. MOUNTING THE MACHINE 5.2 Connecting the machine Connecting motor: Connect the motor in line with building regulations; wiring diagram on the inside of the cover of the motor terminal box or comply with enclosed terminal connecting information. NB: In the case of operating-angle-controlled motors, comply with the special instructions for the bridge connection of pinch 16 and 9, as the printed circuit board (brake board) will be destroyed of incorrectly connected (see 2.12). Motors with pulse generator: (optional) For connection of the pulse generator with frequency converter drive, there is a plan with terminal and pin assignment of the pulse generator flange tube in the motor terminal box. Contact assignment of the pulse generator flange tube for pulse generator HG 90 THY 1 024 and HG 90 THY 4 096 Type: Pulse number: HG 90 THY 1 024 HG 90 THY 4 096 K1 K1 K2 K2 K0 K0 31
5. MOUNTING THE MACHINE 5.3 Terminal connecting plan for gear drive motor and magnetic clamps Connection terminals Connection terminals Motor terminal box Fig. 12 32
5. MOUNTING THE MACHINE 5.4 Terminal connecting information for motors complying with BV 6531-09 Anschlußhinweise für Motore nach BV 6531. 09. pole changing for three-phase motors Isolating disk NB: follow the instructions regarding bridge connection! 33
5. MOUNTING THE MACHINE 5.5 Terminal connecting information for motors complying with BV 6531-14 for operating-anglecontrolled three-phase motor with direct current brake winding Anschlußhinweise für Motore nach BV 6531-14. Electrical circuit depending on winding design Isolating disk NB: follow the instructions regarding bridge connection! 34
5. MOUNTING THE MACHINE 5.6 Bridge connection at motor terminals Concerns operating-angle-controlled motors with the control systems Isostop 12 M, 16M and 25M On shipment of the machine, motor terminals 16-9 are bridged. If there is only one external supply line for terminals 16-9, the bridge must remain! If terminals 16 and 9 are each connected with a separate external supply line, the bridge must be removed! NB: if this instruction is ignored, the printed circuit board (brake activation board) will be destroyed! 35
5. MOUNTING THE MACHINE 5.7 Mounting the rope guard for the traction sheave 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 torque. Tightening torque, see table in the Appendix of the operating manual. 1 1 2 2 max. 1-2 mm Fig. 14 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. 36
6. COMMISSIONING 6. Commissioning the machine Before commissioning the machine, the following points should be checked and carried out: Safety, auxiliary and installation tools removed from the danger zone Check the setup of the machine, base frame, pedestal and rope departure Oil drain pipe mounted and closed off with cap Gear oil added, oil level checked Outside bearing filled with grease; groove nut on the self-aligning bearing tightened (only for SA 4/ 9) Mounting of machine (and outside bearing for SA 4/ 9) checked Bolts tightened and secured with the prescribed torque (see table 'Tightening torques', 9) Brake block stroke and setting checked With SA3, setting and function of the brake test switch checked Brake test carried out with one brake block in each case Function of handbrake release checked Rope guard fitted and distance to traction sheave set Power connections and earthing of motor, forced ventilation and brake magnet connected and secured Special add-on components (tachometer / pulse generator add-on mounted and 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 37
7. MAINTENANCE/ 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 regulation 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 Carry out oil change 7 Check brake blocks for wear, remaining lining thickness must 7 be at least 3 mm Check the brake setting; the block stroke should be 0.3 + 0.1 mm 7 Check the braking deceleration 7 Check armature base plate setting (pretension) 7 Check worm gear toothing for wear Check the backlash between the worm shaft and worm wheel (max. 2.5 mm) 7 Check groove profile on the traction sheave for damage and wear Check secure seating of bolts of the traction sheave mount 9 Check pulley grooves for damage and wear Check motor bearings for wear (noise, play) (SA4/SA9) Check grease filling and seating of the groove nuts on the outside bearing. If required, add grease (F1); tighten groove nut. Replace grease filling every 2 years 7 Check proper and adequate condition and safety of electrical connections Check that protective and safety devices are present and correctly set 38
7. MAINTENANCE/ SERVICE 7.2 Lubrication Lubricant Replacement interval Filling amount Synthetic gear oil SM1 For the first time after 3 years 17 litres then every 6 years Oil change Before the oil change, run the gear until it reaches operating temperature. Discharge the gear oil by removing the cap on the oil drain pipe. Collect the old oil in a container specifically designed for the purpose. Close the oil drain after discharging the gear with sealing tape and the cap. Fill the machine with the prescribed amount of oil through the upper opening on the gear box. Check the level at the oil dip stick (see Fig. below). Enter the date for the next oil change in the type plate on the oil inspection hole cover, see chapter 3. 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 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. Oil level monitoring Only place the oil dip stick (red cap) in position to check the oil level; do not screw in. Rope guard carrier Rope guard (Version in accordance with EN 81-98) Oil dip stick Fig. 11 Oil drain pipe with cap 39
7. MAINTENANCE/ SERVICE 7.3 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 2.5 mm is reached, the gear drive can no longer be deployed for safety reasons. The gear set (worm wheel and worm shaft) is to be replaced or the gear drive is to be replaced. 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 TW 160 = 186 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 should have a load of approx. 20-50 N. 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! Dial Traction sheave Worm wheel Fig. 16 M = radius ME = measurement result r = radius - worm wheel All dimensions in mm Backlash = ME x r M 40
7. MAINTENANCE/ SERVICE 7.4 Replacing brake blocks Note: With a remaining lining thickness of less than or equal to 3 mm, or if the linings are glazed, the brake linings must be replaced. Before starting work, secure the counterweight and elevator car; switch off the power to the installation. Remove one brake block; mount the brake linkage and armature base plates on new brake blocks. Fit the pre-assembled brake block and align to the middle of the brake disc. Ensure that the brake linkage is aligned. Set the brake block stroke. The brake block stroke should be 0.3 mm + 0.1 mm, measured to the middle of the brake disc. Pretension the springs by approx. 20.5 mm. Modify, replace and set the second brake block in the same manner. After replacement, operate with electrical recall and observe whether both brake blocks open evenly. Check the stroke paths and, if required, adjust. 7.5 Setting braking deceleration The brake adjustment is to be carried out only with one effective brake block with the elevator car loaded with the rated load on a descending run (full down) or with an empty elevator car on an ascending run (empty up) according to the deceleration values in the table below. The braking torque must be set on uniformly on both brake blocks by pretensioning the brake spring depending on the installation. Machine with flywheel mass 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 Note: If brake test switch SA3 is present, this must be checked or adjusted after brake adjusting. See SA3 fitting the brake monitoring switch, chapter 8 41
7. MAINTENANCE/ SERVICE 7.6 Setting the brake block stroke and armature base plate (diagram W263) 8 7 9 = 0.3 mm 6 Before first commissioning and of both during monitoring, the working stroke of the brake blocks, the pretension and movement of the armature base plates are to be checked. On opening the brakes, make sure that both brake blocks work with the same stroke. The working stroke of the brake block should be 0.3 mm + 0.1 mm, measured at the height of the middle of the brake block. In the event of deviations, it can be corrected by adjusting the armature screw, item 5. To set the working stroke, the lock nut of the armature screw must be loosened and the prescribed stroke of the brake block set by turning the screw. After a longer period of use, it can occur that the rubber disc settles between the armature base plate and brake block, and this means that the pretension of the armature base plate to insufficient. To restore the pretension, the lock nuts between the brake block and armature base plate must be adjusted. In doing so, lightly grease the rubbing surface between the head of the screw and the armature base plate. Correct pretension is achieved when the armature base plate can be turned on the armature screw despite light suction. 1 2 3 4 Fig. 16 - brake adjusting 5 1 Magnetic clamp 2 Cover ring 3 Armature base plate 4 Rubber disc 5 Armature screw 6 Lock nut 7 Brake release lever 8 Brake disc 9 Working stroke of blocks 0.3 mm Note: If brake test switch SA3 is present, this must be checked or adjusted after brake adjusting. See SA3 brake monitoring circuit, chapter 8 42
7. MAINTENANCE/ SERVICE 7.7 Traction sheave replacement Disassembly: De-energise the system, secure car and counterweight. Ease load on traction sheave; lay down ropes. 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. NB: with SA9, the worm wheel shaft must be supported (self-aligning bearing!) before removing the outside bearing. 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. 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 new 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. Ensure screws are secure and tightening torque is correct! See table 9 in the Appendix. 43
7. MAINTENANCE/ SERVICE 7.8 Motor replacement Disassembly: Place the new motor in position; check the technical data. 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 and magnetic clamp connections). Remove the nuts from the brake and coupling disc. In the case of motors with design B5 SA14, follow the installation instructions for the flexible coupling in the Appendix. Remove the screws from the motor. Carefully pull the motor from the studs and place on the ground. Installation: Attach and secure the replacement motor to the lifting gear. Raise the motor using the lifting gear and align the motor coupling and brake disc. The locations of the securing holes must match those of the screws. Push the motor and coupling onto the screws on the gear drive and brake disc. Screw on the nuts and tighten evenly with the prescribed torque (see table with tightening torques in the Appendix). Note: In the case of motors with design B5, follow the assembly instructions for the flexible coupling SA14. 44
7. MAINTENANCE/ SERVICE 7.9 Checking for escaping grease / oil Examine the area around the bearing cover, brake drum and brake linings for traces of oil. A small amount of escaping oil means individual drops of oil or traces of oil in the area of the bearing seal. Contamination level No escaping oil determined If a small amount of escaping oil is determined If a large amount of escaping oil is determined or oil is escaping from the brake disc / brake linings Procedure Check regularly within the framework of maintenance Clean and check regularly within the framework of maintenance Clean the drive and brake, if necessary, and carry out short-term repair. Before continuing operation, run a brake test until replacement. If the braking effect is inadequate, shut down the installation Every 3 months (6 months if elevator used infrequently, < 50 000 runs per year) Every 3 months (6 months if elevator used infrequently, < 50 000 runs per year) Repair after 4 weeks at the latest 45
7. MAINTENANCE/ SERVICE Shaft sealing ring Öl Brake drum Bearing cover Fig. 7.9.1 46
8. SPECIAL VERSIONS 8.1 Overview of SA special version, optional (extras for certain applications) Overview: SA 1 reinforced mounting parts for horizontal or inclined pulling SA 2 extended worm shaft for handwinding wheel on gear drive SA 3* with brake monitoring SA 4 with wall bearing and extended worm wheel shaft SA 7.1* with tacho-generator (1 collector) SA 7.2* with tacho-generator (2 collectors) SA 7.3* with tacho-generator / pulse generator SA 7.4* with pulse generator SA 9 extended worm wheel shaft for traction sheave in the shaft SA11 with side oil drain SA12 for drive with frequency converter SA14 with flexible coupling for motors in design B5 SA15 with brake magnets in version (Ex) sg4 The special versions marked with * are delivered separately due to the risk of damage. SA3 SA 4 Brake test switch to check the brake block (opened-closed) and the brake lining wear. Note: After adjusting the brake, the setting of the brake test switch must be checked and readjusted if necessary. Setting description, see chapter 8 'Brake monitoring circuit SA3' With an extended worm wheel shaft for separation of the drive and shaft by means of a sealing bearing bracket, partial Ex protection is achieved. The worm wheel shaft is supported here by a bearing. SA7.1-SA7.4 The tacho-generator / pulse generator is opposite the motor on the end of the work gear shaft. The tacho-generator / pulse generator fastening are delivered as loose parts due to the risk of damage. SA 9 SA11 SA12 SA14 With extended worm wheel shaft with arrangement of the traction sheave directly in the shaft. The worm wheel shaft is supported here by a bearing. Oil drain pipe with angled pipe leading away from the machine to the side. Additional terminal box to connect the brake magnets if there is no possibility in the motor terminal box. With the motor shaft double-supported by bearings (model series B5), any alignment irregularities are balanced out with the help of a flexible coupling. Description, see Appendix 9 Flexible coupling for motors of model series B5 47
8. SPECIAL VERSIONS 8.2 Brake monitoring circuit SA3 8.2.1 Version for THYSSEN TCM control systems The brake monitoring circuit checks the brake blocks. It prevents motor movements when the brake is partially or fully closed. It enables detection of any brake lining wear at an early stage. Switches (sensors) are used to check whether the brake blocks are closed, open, or worn. The travel signal is used for the evaluation. If the monitoring circuit triggers, it switches the drive off once the destination has been reached. The indicator is in the form of light emitting diode at the sensors. If a Teleservice device is connected, the fault is shown on the display. Requirements for retrofitting: Brake blocks with cast-on surfaces for mounting the setting screws. If these are not present, they must be replaced or a mechanical mounting must be created for mounting the screws. Installation: 1. If not included in the scope of delivery, make two cables (0.3*0.75 mm² with PVC jacket) for direct connection of the sensors to the control system and connect them. 2. With the TW 160 gear drive, attach each of the sensors with a bracket to the drilled holes for the transport hanger. See Fig. 3 3. Screw lock nuts onto the enclosed hexagon screws and screw into the thread on the brake blocks. The switch tappet must be opposite the setting screw, but should not make contact with it. Setting: Before making the sensor setting, the brake block stroke setting must be made! For description, see chapter 7 4. Switch on the emergency operation switch and elevator control system. 5. Adjust the setting screw for the switch until the LED lights up. 6. Slowly turn the screw back until the LED goes out. 7. Adjust the setting screw by ¼ revolution (corresponds to around 0.3 mm) towards the switch and tighten the nut. LED lights up continuously. 8. Activate the motor to open and close the brakes, checking as you do so that there is a switch change at the sensors between opened and closed brake. 48
8. SPECIAL VERSIONS 8.2.2 Version for third-party products and older control systems (not TCI, not TCM) The brake monitoring circuit BRC is a set of retrofit electronics for checking the brake blocks. It evaluates the signals of the sensors and forwards them to the downstream control electronics. When the value set at the sensor is reached, the device switches off the drive. Indication is in the form of light emitting diodes at the sensors and at the BRC brake monitoring in the control cabinet. If a Teleservice device is connected, the fault is shown on the display. Make contact, travel contactor Connection for Teleservice K1 interrupter contact in the safety circuit Brake monitoring BRC Teles. fault indicator Cable length as required (standard approx. 5 m ) Cable 3* 0.75 mm 2 with PVC sheath Sensor 1 Sensor 2 Sensors fitted on gear drive, set to each brake block contact surface. Fig. 17 Connection plan for brake monitoring BRC valid for third-party products and older control systems (not TCI, TCM) Connections: L1 and N for mains connection 230 V W for make contact from W contactor B1 Sensor 1 with power supply 24V/0V B2 Sensor 2 with power supply 24V/0V K1 Make contact for evaluation (e.g. integration in the safety circuit) Teleservice for connection to a THYSSENKRUPP Teleservice device (remote monitoring of the elevator) 49
8. SPECIAL VERSIONS Sensor 1 Sensor 2 brown 24 V black B1 blue 0 V blue 0 V black B2 brown 24 V Fig. 18 Connection plan for sensors Switch mounting SA3 on machine TW 160 7 4 8 1 2 3 4 5 6 Fig. 19 1 2 3 9 2 1 Spring tension screw 6 Pressure rod 2 Brake blocks 7 Motor 3 Setting screw 8 Pressure springs 4 Test switch (sensor) 9 gear 5 Brake release lever 50
8. SPECIAL VERSIONS 8.3 Tachometer and pulse generator SA7 (diagram W 263 B) 1 2 3 4 5 6 7 8 Fig. 20 Screw M6x16 1 Bearing cover 5 Coupling 2 Disc (not for TW 160) 6 Flange 3 Bolt 7 Tacho-generator 4 Shaft sealing ring 8 Pulse encoder Technical data: SA 7.1 00 990 04 03 0 Tacho-generator RE.0444 1 x 60 V / 1000 rpm analog DC I max 0.18 A N max 5000 rpm IP 44 SA 7.2 65 340 10 01 0 tacho-generator RE.0444 2 x 60 V / 1000 rpm I max 2 x 0.09 A N max 5000 rpm IP 44 SA 7.3 66 300 01 67 0 tachometer with pulse generator 1 x 60 V / 1000 rpm 2 x 120 imp/rev I max 0.06 A N max 9000 rpm IP 55 Power supply: 11 26 V DC SA 7.4 00 990 10 03 0 pulse generator 2 x 1000 impulses I max 0.15 A N max 9000 rpm IP 65 Power supply: 10 30 V DC Note: The values stated here can vary depending on the manufacturer; consult the type plate for exact details. 51
8. SPECIAL VERSIONS 8.4 Mounting the tachometer and pulse generator SA7 Bearing cover replacement (only with later modification) NB: take the load the gear drive before starting work! (apply counterweight) Unscrew the rear bearing cover on the end of the work gear shaft of the gear drive. Screw the threaded bolt into the centre thread of the worm shaft and secure with Loctite. Grease the shaft sealing ring with multipurpose grease F1; press into the bearing cover. Pay attention to the installation position! Grease the ground collar at the end of the work gear shaft with multipurpose grease F1; push on the rear bearing cover (SA7) and bolt in place. Tighten the screws evenly with the prescribed torque. See table Screw the tachometer coupling onto the threaded bolt; secure the thread with Loctite. Use 3 screws to screw the flanged-on tachometer onto the rear bearing cover. Place the tachometer on the coupling; bolt onto the coupling and flange. Installing the tachometer / pulse generator (delivered as loose parts due to risk of damage) Remove the transport guard from the bearing cover (not required in the case of modification). Push the drive shaft of the tachometer / pulse generator into the coupling hole; secure with bolt. Firmly bolt the tachometer / pulse generator onto the flange. Connect as specified by the manufacturer, see 'Terminal plan' in the Appendix. Note: Comply with the safety, installation and connection instructions in the operating instructions and terminal plan supplied by the manufacturer! see Appendix in chapter 9. 52
9. APPENDIX 9.1 Tightening torques - tightness values for mounting parts NB: must be complied with when working on the machine or replacing parts! DIN/ Tightening Item no. Tight- ISO torque ness Nm Disc on worm wheel shaft 500 638 0 Slotted pan head tapping screw M16 * 60 microencapsulated 506 923 0 Detent edged washer SK M16 10.9 4762 250 Motor on gear drive 503 105 0 Stud M16FO * 40 5.6 939 90 506 835 0 Hexagon nut M16 8 7042 90 Motor shaft on coupling brake disc 503 365 0 Stud M16FO* 40 microencapsulated 8.8 190 506 835 0 Hexagon nut M16 8 7042 190 Brake disc on worm shaft 500 555 0 Locking screw M8 * 30 100 VZ 25 Locking screw on brake block pin 500 555 0 Locking screw M8 * 30 100 VZ 25 Bearing bracket on housing Hexagon screw M16 * 60 (for rope guard) 8.8 4017 190 500 339 0 Hexagon screw M16 * 40 8.8 4017 190 506 832 0 Locking washer S 16 Brake magnet on housing 500 217 0 Hexagon screw M16 * 130 8.8 4014 190 Rear bearing cover on housing 500 553 0 Locking screw M16 * 55 100 VZ 190 The table below applies to screwed connections that do not appear in this list. 53
9. APPENDIX The following tightening torque values apply for: Allen screws DIN 912 ISO 4762 Hexagon screws DIN 931 / 933 ISO 4014 / 4017 The threaded connections are to be tightened with a torque wrench! Dimensions Tightening torque M A [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 54
9. APPENDIX 9.2 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 the slip will slip. 3 4 2 5 1 6 Fig. 20 Mounting the blocking clamp on the traction sheave (illustration without ropes) 1 Traction sheave groove 2 Pressure piece 3 Washer 4 Hexagon nut 5 Spacer sleeve 6 Clamp clip NB: after completion of the installation work, remove the blocking clamp, as otherwise the installation will be damaged. 55
9. APPENDIX 9.3 Manufacturer information, tachometer / pulse generator SA 7 General: Installation Check the alignment of the tachodynamo and motor. Use a well-machined and balanced coupling. Maintenance: Every 2000 hours of operation. Brushes Check whether the brushes glide without obstruction in their housing. Blow the dust from the brush carriers (do not use compressed air, as it might contain oil particles). Replace the brushes at a length of 5 to 6 mm. The new brushes are preshaped to the contours of the collector. However, exact surface contact is only reached after 10 hours of operation. If a check means the brushes must be removed, select their position for later installation at the original location. Collector The layer that has formed under the brush path must not be removed. In the event of contamination, clean using a cloth lightly dampened with alcohol. It is strictly prohibited to use abrasives. Lubrication The dynamo is equipped with sealed bearings that have been given permanent lubrication at the plant. No other lubrication is required. Important note We urgently advise you not to remove the rotor from the stator. Every removal leads to a change in the dynamo calibration. 56
9. APPENDIX Tachodynamo RE.0444 N2B SA 7.2 2 windings Voltage: 60 V / 1000 rpm Notes on connection: Direction of rotation viewed towards A side: right left Connection 1 yellow wire - + green wire + - Connection 2 white wire - + blue wire + - Connection depending on the installation, see Installation terminal plan Tachodynamo with pulse generator SA 7.3 Type TDP 0.2 LT- 4 + OG 9D 120, design B10 Electrical data for tachodynamo: Tachometer voltage at 1000 rpm 60 V DC Max. tachometer speed 9000 rpm Intensity of current max. 67 ma Protection type IP 55 Electrical data for dual pulse generator: Impulses / revolution 2 x 120, el. offset by 90 Connection voltage +11 V to +26 V DC Output load current per system max. 60 ma Connect the tachodynamo with pulse generator using cable item no.: 65 000 34 87 0 to the rear-wall PCB in the control cabinet. See wiring diagram of the installation. 57
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