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Operating manual

Servicing and Maintenance

TW160 drive

TK Aufzugswerke

Version 08/2021

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

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

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

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

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



DANGER

Insecure threaded connection!

Death or severe physical injury due to parts coming loose.



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



Chapter 10.2

Designation

Item Designation

Traction sheave

Hole for pressure screw (3x)

Securing bolt (3x)

Mounting plate

Fig. 8.9-1

Summary of Contents for TW160

Page 1: ...OPERATING MANUAL TW160 Drive 08 2021 6234002860...

Page 2: ...nical nature for the purpose of improving our products or enhancing the safety standard includ ing without a separate announcement Choice of colours The choice of colours used in our documents for the...

Page 3: ...15 3 3 Version with emergency brake NBS 16 3 4 Version for traction sheave in the shaft SA9 17 3 5 Version for vapour proof partition wall SA4 18 3 6 Special versions SA2 SA3 SA3 1 SA11 SA12 SA15 19 3...

Page 4: ...rication 69 8 4 Checking the backlash 71 8 5 Replacing the brake shoes 73 8 6 Setting and checking the brake shoe stroke and armature base plate 74 8 7 Braking deceleration setting 77 8 8 Brake readju...

Page 5: ...ating manual Table of Contents TW160 drive TK Aufzugswerke Version 08 2021 10 6 Manufacturer specifications for Bernstein switch 105 10 7 Details regarding ABV ESV EU BD as well as shaft calculations...

Page 6: ......

Page 7: ...ction Second action Interim result optional Third action Final action step with end marker Result of action optional Course of action with independent steps Action step Action step Action step Informa...

Page 8: ...danger disregarded Measures to avert the danger 2 1 2 Indications of danger to persons DANGER Danger with a high degree of risk If ignored leads to death or serious injury Read and observe warning WA...

Page 9: ...rules at the location of use with regard to environmental protection and the regulations of work safety and accident prevention must be observed All safety and hazard notices on the installation must...

Page 10: ...out agreement or approval Deficient monitoring of parts that are subject to wear Repairs that are carried out improperly Cases of catastrophe due to third party interference or force majeure Use on no...

Page 11: ...ns that can impair safety must be rectified immediately When working on the drive it must be de energised before work is started and the system must be secured against inadvertent switching on A sign...

Page 12: ...5 International occupational health and safety regulations Table 2 5 1 International rules for occupational health and safety can also be found in various languages on our ELI web platform and can be...

Page 13: ...ed loads Falling tool Transport of heavy load Sharp pointed objects Danger of crushing in the foot area Cut or stab injury in the foot area Foot protection Sharp objects Mechanical parts Sharp pointed...

Page 14: ...2021 3 Product Description 3 1 Standards and legal requirements EN81 1 2010 06 and EN81 20 50 The TW160 machines comply with the European standard EN81 1 2010 06 and EN81 20 50 The drive is part of t...

Page 15: ...Operating manual Product Description TW160 drive TK Aufzugswerke 15 Version 08 2021 3 2 Description 3 2 1 Standard version...

Page 16: ...n 11 Traction sheave mount 12 Brake release lever mounted 13 Motor terminal box with connection 14 Mounting surface for machine base frame 15 Internal ventilator for motor cooling 16 Air vents for mot...

Page 17: ...tem Designation Item Designation 1 TW160 machine SA9 2 Traction sheave shaft SA4 9 version 3 External bearing bearing housing with self aligning bearing on adapter sleeve 4 Traction sheave SA4 9 versi...

Page 18: ...n 1 TW160 machine SA4 2 Traction sheave shaft SA4 9 version 3 External bearing bearing housing with self aligning bearing on adapter sleeve 4 Traction sheave SA4 9 version 5 Compensating support for s...

Page 19: ...versions SA2 SA3 SA3 1 SA11 SA12 SA15 Item Designation Item Designation 1 Brake monitoring SA3 3 1 and or brake test switches for SA15 2 Handwinding wheel on gear side SA2 3 Oil drain side SA11 5 Add...

Page 20: ...5 model series flanged on design with 2 bearings a flexible coupling SA14 is required between the motor and gear drive Brake The dual circuit outside shoe brake is spring actuated Two independently ac...

Page 21: ...part traction sheaves are fastened overhung on the drive shaft by using a cone 1 15 and a mounting plate including 3 screws M16 8 8 microencapsulated with locking washer Chapter 8 8 Actual value senso...

Page 22: ...rake NBS Ft 97 kN Traction sheave shaft SA 4 9 with external bearing Ft 77 kN 4 1 2 Mass moment of inertia The value for the mass moment of inertia includes the driving gear with brake disc and coupli...

Page 23: ...motor type used this coupling may be rigid for the B9 type or flexible for the IMB5 type Unit Nm mm mm N A m 1 Version for explosion protection TW160_30201_ENG II 2 D Ex mb IIIC T95 C Db 1 Type appro...

Page 24: ...Operating manual Technology TW160 drive TK Aufzugswerke 24 Version 08 2021...

Page 25: ...l in the machine room traction sheave position in the shaft The traction sheaves for the standard versions differ from the SA4 9 versions in the dimensional assignment of traction sheave middle to con...

Page 26: ...th a factory standard see notes on factory standards in the chapter Type IMB5 V1 motors custom order motors from the motor lists e g Siemens Koncar etc In the case of pole changing version machines AC...

Page 27: ...160 drive TK Aufzugswerke 27 Version 08 2021 4 2 Dimensions of machine 4 2 1 Standard version Item Designation Item Designation 1 Additionally for SA1 2 Pictured traction sheave position right left mi...

Page 28: ...Operating manual Technology TW160 drive TK Aufzugswerke 28 Version 08 2021 4 2 2 Version with emergency brake NBS Fig 4 2 2...

Page 29: ...manual Technology TW160 drive TK Aufzugswerke 29 Version 08 2021 4 2 3 Version for traction sheave in the shaft SA9 Item Designation Item Designation 1 Centre rolling bearing 2 Centre bearing housing...

Page 30: ...l Technology TW160 drive TK Aufzugswerke 30 Version 08 2021 4 2 4 Version for vapour proof partition wall SA4 Partial Ex Item Designation Item Designation 1 Centre rolling bearing 2 Centre bearing hou...

Page 31: ...plate The current type and the technical data are specified on the type plate of the product 4 4 Motor data The technical data can be found on the type plate 4 5 Machine base frame The machine base fr...

Page 32: ...e diameter Installations with 2 1 or 4 1 rope suspension Item Designation Item Designation 1 TW 160 machine 2 TW160 machine base frame 3 Insulation elements 4 Mounting parts for machine base frame Fig...

Page 33: ...unterweight rope distance ASL 795 1400 mm in conjunction with traction sheaves dia 640 720 and 800 mm The versions D450 7 8x10 D540 7 8x13 and D640 for rope pulleys see factory standard 60 720 12 00 0...

Page 34: ...se frame Technical data Weight of machine base frame m TW160_31007_ENG weight incl rope pulley 420 D450 D640 rope pulley version mm 550 D540 kg 470 Table 4 5 1 Project planning dimensions Project plan...

Page 35: ...The complete machine base frame comprises the following components Machine base frame made from welded rolled profiles Hole pattern for machine mounting as per order depending on DT and ASL Pedestal...

Page 36: ...erke 36 Version 08 2021 Technical data Weight of machine base frame m TW160_31008_ENG weight incl rope pulley 340 D450 D640 rope pulley version mm 470 D540 kg 390 Table 4 5 2 Project planning dimensio...

Page 37: ...ame for Partial Ex installations with vapour proof wall duct SA4 in a version without a rope pulley for use in Installations with 1 1 rope suspension and direct rope departure for an elevator car coun...

Page 38: ...position left or right It is possible for the customer to provide a vapour proof enclosure of the entire machine base frame by using side plates on the base frame and by using the profile section of t...

Page 39: ...action sheave 3 TW160 M SR machine base frame 4 Rope guard complying with EN81 77 for rope pulley dia D450 D540 D640 5 Shift protection complying with EN81 77 Fig 4 5 5 The safeguard measures are only...

Page 40: ...ion devices that prevent the machine from changing its position Item Designation Item Designation 1 Shift protection complying with EN81 77 2 TW160 M SR machine base frame Fig 4 5 7 In the case of dep...

Page 41: ...rke 41 Version 08 2021 4 6 Machine base frame dimension sheets 4 6 1 Version without rope pulley Item Designation Item Designation 1 Machine with traction sheave position left 2 Machine with traction...

Page 42: ...e 640 720 800 TW160_31002_ENG traction sheave version DT project planning dimension L mm 295 200 240 280 255 215 traction sheave position left right unit Table 4 6 1 Position and number of insulation...

Page 43: ...with supports Version with rope pulley position on left Item Designation Item Designation 1 With rope pulley D540 2 With rope pulley D640 3 With rope pulley D450 4 Machine with traction sheave positio...

Page 44: ...pe pulley position on right Item Designation Item Designation 1 With rope pulley D540 2 With rope pulley D640 3 With rope pulley D450 4 Machine with traction sheave position left 5 Machine with tracti...

Page 45: ...DT 640 720 mm 795 ASLmin 875 Table 4 6 3 Position and number of insulation elements depending on the static shaft load and rope pulley and traction sheave positions I II III IV I II III IV I II III IV...

Page 46: ...ncrete foundation Version with rope pulley position on left Item Designation Item Designation 1 With rope pulley D540 2 With rope pulley D640 3 With rope pulley D450 4 Machine with traction sheave pos...

Page 47: ...pe pulley position on right Item Designation Item Designation 1 With rope pulley D540 2 With rope pulley D640 3 With rope pulley D450 4 Machine with traction sheave position left 5 Machine with tracti...

Page 48: ...ley and traction sheave positions I II III IV V VI VII VIII I II III IV V VI VII VIII 90 1 1 2 1 2 1 1 1 1 1 1 1 2 1 1 75 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 60 1 1 1 1 1 1 1 1 1 1 1 1 1 30 1 1 1 1 1 1 1 1...

Page 49: ...TK Aufzugswerke 49 Version 08 2021 4 6 4 Version with vapour proof partition wall SA4 Item Designation Item Designation 1 Machine with traction sheave position left 2 Machine with traction sheave posi...

Page 50: ...nding on the control system deployed The following encoders are available for the TW160 Encoder type Pulses Use 1024 4096 4096 LiftEquip for ships elevators 4096 LiftEquip for CT inverter E300 1024 tk...

Page 51: ...are placed under the gear housing and the gear housing is bolted onto the pallet For the special versions SA4 and SA9 the compensating supports are packaged separately and secured to the pallet Fig 5...

Page 52: ...vity of the product Do not lift the machine by the motor or pedestal bearings Always lift the machine by both transport hangers NB machine is filled with oil It may only be transported and stored upri...

Page 53: ...dimensioned lifting gear The specified means of transport are only configured for transportation of the machine the installed brake and traction sheave Do not use them to transport any other loads On...

Page 54: ...diately by means of a sketch photo or description of the damage 3 Report damage to the manufacturer 5 4 Packaging materials Specific transport equipment and shipping braces remain with the customer Di...

Page 55: ...ly 1 Release the operational brake manually by means of the brake release lever and if present the emergency break manually by releasing the emergency release screws 2 Turn the traction sheave disc by...

Page 56: ...dividual load should be between 7 KN and 12 KN per element When arranging the supports the overall centre of gravity must lie within the rubber elements The arrangement under the machine base frame sh...

Page 57: ...0 washers tightening torque 190 Nm 6 3 Installation frame with rope pulley Fig 6 3 1 8 6 0 b e i a t D p 5 4 0 b e i a t D p 4 5 0 6 4 0 9 6 0 5 4 0 b e i a t D p 5 4 0 b e i a t D p 6 4 0 5 8 7 b e i...

Page 58: ...eans of the supplied shims 8 Align the rope grooves of the traction sheave and deflecting pulley in parallel 9 Tighten the screws with the prescribed tightening torque Chapter 10 2 10 Plumb the rope d...

Page 59: ...uring bolts of the rope guard carrier on the gear drive after alignment with the prescribed tightening torque Chapter 10 2 Item Designation Item Designation 1 Rope guard carrier 2 Rope guard Fig 6 4 1...

Page 60: ...ns is greater than 90 mount a third rope guard in such a way that the angle between all rope guards is not more than 90 6 With inclined pulling adapt the location of the rope guard carrier by remounti...

Page 61: ...materials are included in the scope of supply The installation instructions of the manufacturers are to be strictly complied with 4 Align the shift protection in such a way that the rubber elements of...

Page 62: ...wiring diagram in this operating manual and corresponding building codes are to be complied with 6 7 1 Terminal connecting plan for motor and magnetic clamps Comply with the documents supplied with t...

Page 63: ...Operating manual Installation TW160 drive TK Aufzugswerke 63 Version 08 2021 Terminal connecting plan for Motorlift motors Fig 6 7 2...

Page 64: ...em Designation 1 Motor 2 Posistor 3 Encoder 4 Brake intermediate terminal connection Fig 6 7 3 Survey diagram for DTE 132 140 180 motors 6 7 3 Wiring diagram DTL Item Designation Item Designation 1 Mo...

Page 65: ...ting of the machine and base frame 6 With a side or oblique rope departure the gear housing is secured against moving with end stops and set screws 7 Make sure that the bolts are tightened with the pr...

Page 66: ...ease lever is additionally secured in the rest position with a retaining clip The brake lever is set in the operation position approx 5 10 above the horizontal as shown in the following illustration O...

Page 67: ...uries If the handwinding wheel is used for installation and maintenance purposes e g pulling out of the safety gear the person performing the operation must ensure they have a firm and safe stance The...

Page 68: ...ngs Chap 8 3 1 4 Check the brake shoes for wear the remaining lining thickness must be at least 3 mm Chap 8 5 5 Check the brake setting the shoe stroke should be 0 3 0 1 mm Chap 8 6 6 Check the brakin...

Page 69: ...filling took place at the plant Synthetic gear oil SM1 can be obtained from TK Aufzugswerke GmbH Lubricant Replacement interval Motor position filling amount Synthetic gear oil SM1 For the first time...

Page 70: ...e upper opening on the gear housing fill opening cap see Fig 3 2 1 5 Check the level with the oil dipstick see Fig 8 3 1 Only rest the oil dipstick do not screw in 6 Enter the date for the next oil ch...

Page 71: ...lash of 1 5 mm is reached the gear drive must be replaced Measurement possibility 1 Take load off the ropes move the counterweight onto the buffers and lift the elevator car with lifting gear The trac...

Page 72: ...Servicing and Maintenance TW160 drive TK Aufzugswerke 72 Version 08 2021 Fig 8 4 1 M measured radius ME measurement result r radius worm wheel All dimensions in mm Backlash ME r M Dial gauge Traction...

Page 73: ...s on the bolt on which the compression springs for the pre tension are located 4 Undo the two M8 bolts that hold the brake shoe pin in place 5 Push the cover ring over the magnetic clamp and armature...

Page 74: ...pin and locking screws 6 Pre tension the compression springs by approx 20 5 mm and secure the setting with the lock nuts 7 Set the brake shoe stroke by adjusting the armature base plate screw on the...

Page 75: ...s 0 3 mm 0 1 mm on the middle of the brake disc 4 Brake disc 5 Brake release lever Pressure piece with pressure rod 6 Rubber disc 7 Washer 8 Hexagon nut 9 Lock nut 10 Armature screw 11 Cover ring Fig...

Page 76: ...stroke 1 Align a dial gauge on the brake shoe at the height of the centre of the brake disc 2 Switch the drive to operate the brake shoes while checking the stroke of the brake shoes The path should...

Page 77: ...ked or adjusted after brake adjusting See chapter 9 2 8 8 Brake readjustment in the event of brake lining wear With wear on the brake linings the stroke of the brake shoes increases compared with the...

Page 78: ...screws diagonally and evenly remove the traction sheave from the shaft WARNING Falling traction sheave The traction sheave can suddenly come loose Secure the traction sheave with chains or ropes For...

Page 79: ...d screws microencapsulated and detent edged washers on the inner circle of holes of the sheave Tighten the screws evenly and alternately DANGER Insecure threaded connection Death or severe physical in...

Page 80: ...the rigid coupling In the case of the flexible coupling the elastomer part of the coupling remains screw connected to the brake disc 7 In the case of the rigid coupling the spacer washers remain betw...

Page 81: ...ach and secure the replacement motor to the lifting gear 3 Raise the motor using the lifting gear and align the motor coupling to the brake disc 4 Push the motor into the gear flange and tighten the n...

Page 82: ...e 82 Version 08 2021 Structural shape IMB9 with rigid coupling Fig 8 10 2 Check the dimension 95 0 5 at the spacer washers Fit the nuts to mount the clutch hub onto the brake disc Chapter 10 2 Both st...

Page 83: ...the handwinding wheel Item Designation Item Designation 1 Handwinding wheel 2 Locking washer 3 Flat countersunk nib bolt 4 Stud 5 Actual value sensor 6 Motor 7 Encoder connection cable 8 Cable ties 9...

Page 84: ...heel hub with axial adapter sleeve Motorlift motors 1 Remove the screw in the middle of the handwinding wheel 2 Pull the handwinding wheel and hub off together Encoder 1 Use an Allen key 2 mm to loose...

Page 85: ...lat countersunk nib bolt to secure it in the motor shaft borehole Handwinding wheel hub pinned on the shaft end with adapter sleeve 1 Push the hub onto the shaft end 2 Align to the borehole 3 Support...

Page 86: ...g oil grease is determined Clean and check regularly within the framework of maintenance Every 3 months 6 months in case of reduced frequency 50 000 runs per year If a large amount of escaping oil gre...

Page 87: ...Operating manual Servicing and Maintenance TW160 drive TK Aufzugswerke 87 Version 08 2021 Item Designation Item Designation 1 Brake drum 2 Bearing cover 3 Shaft sealing ring 4 Fig 8 12 1 2 1 1 3...

Page 88: ...ng effect impaired Make sure that the brake linkages are free and unable to chafe Item Designation 1 Break the cast edge at the brake shoe debur or radius 2 Examine the brake release pressure rod for...

Page 89: ...and the brake lining wear Note After adjusting the brake the setting of the brake test switches must be checked and readjusted if necessary Description of setting see 8 2 2 SA3 brake monitoring circu...

Page 90: ...circuit checks the brake shoes It prevents motor movements when the brake is partially or fully closed and enables detection of any brake lining wear at an early stage Switches sensors SA3 or microswi...

Page 91: ...on the emergency operation switch and elevator control system 2 Adjust the setting screw for the switch 3 The LED lights up 4 Turn back the screw slowly 5 The LED goes out 6 Move the adjusting screw...

Page 92: ...rewing the adjusting screw a further approx 1 4 revolution 4 Secure this setting by tightening the lock nut 5 Repeat the setting procedure at the second brake test switch Checking setting Open and clo...

Page 93: ...ion Item Designation Item Designation 1 Button 1 2 Button 2 Fig 9 2 3 9 2 4 switch mounting SA15 Full EX Fig 9 2 4 The switch mounting for SA15 is described in the operating manual Explosion protectio...

Page 94: ...m width and design is part of each machine Deployment of the blocking clamp During installation work on the elevator car or counterweight to prevent movement due to slipping ropes In the case of work...

Page 95: ...e been used once The tightening torques given here apply for screwed connections without specifications at the corresponding location If in the drawing or elsewhere in the document other tightening to...

Page 96: ...kugellager 10 Lebensdauer 3 x 10 U bei 100 Lagerlast 11 4 x 10 U bei 40 12 3 x 10 U bei 20 Drehzahl max 3 500 U min Gewicht ca 720 g Anschluss radialer Kabelabgang mit 10m Kabel und konfektioniertem m...

Page 97: ...GY RD BK VT Litze Flex Toron Cord n Cavetto 3 Kabel cable C ble Cable cavo K3 1 2 3 4 5 6 7 8 9 Steckergeh use Schirm mit Gebergeh use leitend verbunden Connector housing shield electrically connecte...

Page 98: ...rting torque approx 1 5 Ncm at ambient temperatur Attachment 2 x Hub M4 DIN 913 Bearings Type 2 precision ball bearings 10 Service life 3 x 10 revs at 100 of full rated shaft load 11 4 x 10 revs at 40...

Page 99: ...Anschluss radialer Kabelabgang mit 10m Kabel mit Aderendh lsen Elektrische Daten Allgemeine Auslegung gem DIN VDE 0160 Versorgung Ausg nge Ausgangsschaltung Kabell nge max 100 m Optik Lichtquelle IR...

Page 100: ...d verbunden Nicht S7 K1 K2 K3 Connector housing shield electrically connected to encoder housing not S7 K1 K2 K3 B tier de connexion Ecran avec bo tier d ementteur li s de mani re conductrice No S7 K1...

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Page 104: ...Tachogenerator RE 0444 zu SA 1 Anschlusshinweis...

Page 105: ...Operating diagram Description BI2 U1Z W Article number 6085103100 Tolerance Operating Point 0 25 mm Operating force 10 On Off Electrical Data Rated insulation voltage Ui 400 V AC Conv thermal current...

Page 106: ...unting Connection 4 screw connections M3 5 Conductor cross sections Solid 0 5 1 5 mm Litz wire with ferrules 0 5 1 5 mm Cable entrance 2 x M16 x 1 5 Weight 0 08 kg Installation position operator defin...

Page 107: ......

Page 108: ...chriebenen Beschaffenheit ausgeschlossen ist nderungen bleiben vorbehalten Ausgabedatum 29 03 2011 Blatt 1 von 2 Dokument 6659381003_de Stand 1 0152 11 Baureihe OR81 Typbezeichnung OR81GL DHTN 0005 AL...

Page 109: ...4 5 St raussendung CISPR 11 Mechanische Daten Geh use PA6 rot Deckel PA66 schwarz St el Bet tigung POM natur Manschette CR schwarz Befestigung 2 x M4 2 x M5 2 x M3 Frontbefestigung Betriebstemperatur...

Page 110: ...Guide 22 1982 Informations on manufacturer s declaration of conformity with standards or other technical specifications La version allemande est la langue d origine de la declaration de conformite Le...

Page 111: ...OPERATING MANUAL EMERGENCY BRAKE SYSTEMS NBS TW45 TW63 TW130 TW160...

Page 112: ...TK Aufzugswerke GmbH Bernh user Stra e 45 73765 Neuhausen a d F Deutschland E Mail doku elevator plant de tkelevator com...

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