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Operating manual

Commissioning

TW160 drive

TK Aufzugswerke

Version 08/2021

CAUTION

Abrasion injuries

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.

There is also a risk of injury when simultaneously operating electrical
recall.



Pay special attention.

Содержание TW160

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 103: ......

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

Страница 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...

Страница 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...

Страница 107: ......

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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