6.2. TW63 - Operating Manual - English PDF

Operating Manual
Machine TW63
ThyssenKrupp
A company of
ThyssenKrupp
Elevator
ThyssenKrupp Aufzugswerke
OPERATING MANUAL
Printer’s imprint
All rights reserved

 Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH
P.O. box 23 03 70, D-70623 Stuttgart
Printed in Germany, January 2005

The right of reprint or reproduction, even in the case of only partly exploitation, is subject to
express, written permission of THYSSENKRUPP AUFZUGSWERKE GmbH.
Any reproduction, copying or storing in data processing machines in any form or by any
means without prior permission of THYSSENKRUPP AUFZUGSWERKE GmbH is
regarded as infringement of the current Copyright Act and will be prosecuted. Technical
modifications for reasons of improvement of TW 63 or for reasons of improving the safety
standard of TW 63 are subject to decisions of THYSSENKRUPP AUFZUGSWERKE
GmbH without prior notice.
The responsibility for the content lies with the editor:

THYSSENKRUPP AUFZUGSWERKE GmbH
Preface
We are pleased that you decided to purchase a quality product from

THYSSENKRUPP AUFZUGSWERKE GmbH.
This operating manual assists you in getting familiar with the drive for moving cars – the
TW 63 machine which is referred to as TW 63 below – and with its intended possibilities of
use. Important information concerning safety and hazards helps you to safely use the
TW 63 as intended. TW 63 is subject to technical alterations.
ThyssenKrupp Aufzugswerke GmbH 3 Issue 01.2005

OPERATING MANUAL
Table of content :
Machine TW63 PAGE
1. Safety
1.1 Explanation of symbols used 6
1.2 General safety information 7
2. Product description
2.1 Description of machine TW63 10
2.2 Functional description 11
2.3 Dimensions 14
2.4 Technical data 17
2.5 Name plate 18
2.6 Lubrication 19
2.7 Motor types 21
2.8 Connection von Windenmotoren 22
2.9 Terminal diagram for VVVF motors 23
and magnetic clamps
2.10 Connection of motors acc. to BV 6531 - 21 24
2.11 Connection of motors acc. to BV 6531 - 22 25
2.12 Connection of VFD motors 26
2.13 Motor data – phase-shift controlled motors (A4) 27
2.14 Motor data – VVVF motors (A4) 28
2.15 Motor data - phase-shift controlled motors (A4) 29
2.16 Motor data – special motors (B5) 30
2.17 Machine frame 31
3. Transportation and storage 40
4. Mounting of machine in machine room 43
4.1 Mounting of rope guards for traction sheave 44
5. Putting into service 45
5.1 Emergency operation 46
6. Servicing 47
6.1 Checking of backlash 48
7. Maintenance
7.1 Replacing of brake shoes 49
7.2 Adjusting of braking deceleration 50
7.3 Adjusting of brake shoe stroke / armature base plate 51
7.4 Replacing - Montage of traction sheave 52
7.5 Replacing - Montage of motor 53
8. Special versions (optional)
8.1 Special versions 54
8.2 SA3 Brake monitoring TCM 55
8.3 SA3 Brake monitoring BRC 57
9. Annex
9.1 Tightening torque – mechanical strength 59
9.2 Flexible coupling for B5 motors 61
9.3 Pulse generators 63
9.4 Manufacturer’s information pulse generator page 1 - 4 65
9.5 Manufacturer’s information – product information 69
9.6 Blocking clamp 70
OPERATING MANUAL 1. SAFETY
1.1 Explanation of symbols used
The following pictographs and designations are used in this operating manual:
Danger
This symbol draws attention to an extreme danger to
life or risk of injury to persons. Disregard of warning
means danger to life !
Danger
This symbol draws attention to an immediate
impending danger to life or risk of injury to persons
caused by electric current.
Warning notices must always be observed!
Warning
This symbol draws attention to an impending danger.
Disregard can cause injury to persons or extensive
damage to property.
Warning notices must always be observed!
Note
This symbol draws attention to important information
and instructions for operation. Disregard can lead to
damages, hazards or failures.
Inspection
This symbol draws attention to inspection sequence.
These inspection notices must be observed in any
case. Disregard can lead to injury to persons or
damage to property.

1.2 General safety information
Information about the operating manual

Knowledge of the basic safety requirements is a prerequisite for the safe use
and the failure-free operation of this component.
This operating manual comprises the most important information how to
safely use the component.
The operating manual and, in particular, the safety information must be
observed by all persons who perform any work on the component.
In addition the rules and requirements concerning the regulations for
prevention of accidents which apply to the installation location must be
observed.
Duties of the owner and / or the installer

The owner and / or the installer ensure that only persons are authorized to
work at the component, who
• are familiar with the requirements concerning safe working and prevention
of accidents and who were trained how to use the component;
• have read the safety information and the warning notices in this operating
manual.
Note: Check the compliance of the employees method of working with the
safety requirements in regular intervals.
Duties of the employees

Persons who are authorized to perform work at the component are obliged
• to observe the requirements concerning safe working and prevention of
accidents;
• to read the safety information and the warning notices in this operating
manual prior to start working.
Training of the employees

Only trained and instructed, technically competent persons shall perform
work at the component.
The competence of the employees must be clearly defined for all tasks
concerning putting into service, operation, maintenance and repair work.
Organizational measures
The owner or the installer must provide the necessary personal protective
gear. All existing safety devices must be checked regularly in accordance
with the maintenance plan.

Informal information about safety measures

• The operating manual must always be available at the location of the
installation.
• In addition to the operating manual the general and local regulations for
the prevention of accidents and environmental regulations must be made
available and observed.
• Clearly and easily visible statutory safety instructions must be made
available for the users.
• See to it that all information concerning safety and hazards is always
visibly and legibly made available on the machine.
Use as intended
TW 63 was designed in accordance with the state of the art and the
recognized safety regulations. TW 63 shall only
• be used for its intended purpose
• be used exclusively if safe operation is ensured.
TW 63 drive shall exclusively be used as drive for lifts.
Any other use or any use exceeding the scope of the above definitions is
regarded as use outside of the intended purpose. THYSSENKRUPP
AUFZUGSWERKE GmbH cannot be hold liable for any damages resulting
from this and for any damages which are caused by any errors of
procedure. Use within the scope of its intended purpose also comprises
• observance of all information of the operating manual
• fulfilment of the instructions applying to putting into service, installation
description and inspection and repair work.
Guarantee and liability

The „General sales and delivery terms“ of THYSSENKRUPP
AUFZUGSWERKE GmbH apply generally.
Any claims for guarantee and liability are excluded in the case of injury to
persons or damage to property resulting from one or several of the causes
below:
• use of TW 63 outside the scope of its intended purpose
• inexpert mounting, putting into service, operating and maintaining of
TW 63
• operating the TW 63 with defective and/or non-operative safety and
protective devices
• disregard of instructions of operating manual that apply to
transportation, storage, mounting, putting into service, operating and
maintaining of TW 63

• unauthorized constructional modifications of TW 63

• unauthorized modification of drive (performance etc.)
• unsatisfactory supervision of parts which are subject to wear
• inexpert repair work
• catastrophes caused by outside influence and Act of God.
Constructional modifications of machine TW 63

TW 63 is adjusted at the factory and is delivered ready for work.
Attention : oil necessary for putting TW 63 into service has been filled in at
the factory already ! Please check oil-level glass prior to initial startup of
TW 63. (See chapter 2.6 fig. 7 / 9).
In the case of any modifications of the machine
THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable.
Use of TW 63 and possible hazards

The traction sheave and the handwheel of TW 63 are designed without
protective cover and shall only be used within a closed room. See to it that
the necessary safety distance to all revolving parts (marked yellow) is
observed by persons working in the machine room.
Note: do not place any objects (such as tools etc.) on the handwheel of TW
63 V since there is the danger of injury caused by flinging parts.
In the case of incorrect use there will be danger to life of the user or third
parties resp. impairment of the component or material property. Failures
which possibly impair the correct functioning shall be eliminated immediately.

OPERATING MANUAL 2. PRODUCT DESCRIPTION
2.1 Description of machine TW 63
The machine consists of:

1 Real value generator 9 Rope guard
2 Handwheel / flywheel 10 Machine frame (optional)
3 Separately driven fan (optional) 11 Name plate
4 Motor 12 Gear housing
5 Armature base plate 13 Rope guard carrier
6 Brake shoe 14 Brake monitoring switch
7 Traction sheave 15 Motor terminal box
8 Washer on traction sheave shaft 16 Brake magnet
1 2 3 4
6
15 7
14
8
13 9
12
11
10
Fig. 1 Design of TW63 V

(vertical motor mounting)
Versions:
The following machine versions are available: gear with speed reduction,
traction sheave version, motor version, generator version,

8 7 12 6 15
4
9
3
10
9 5 16
Fig. 2
Design of TW63 H (horizontal motor mounting)
2.2 Functional description
The machine TW63 is designed as drive for use in lifts.
The gear (machine) is a single-stage, anti-friction bearing worm gear. The

housing is a monobloc design with an end plate integrated on one side and
an integrated dual-circuit brake. The worm teeth are oil-submersed in
operation. A overhung traction sheave is used.
Drive version is subject to motor mounting: the power is transmitted from a

three-phase motor which is vertically mounted onto the gear or a three-phase
motor which is horizontally flanged to the gear drive on the wormshaft to the
worm-wheel, the traction-sheave shaft up to the traction sheave.
The following constructional sizes of drive motors are available:

A4 (standard version): one-piece worm and rotor shaft.
B5: worm shaft and rotor shaft are linked with a flexible coupling (SA14).
Drive types
Dependent on the respective arrangement of motor, pulse generator,
flywheel rim, etc. the drive can be used for
• pole-changing (AC2)
• phase-shift-controlled (ACVV) or
• frequency-controlled (VVVF)
installations.

Brake:
The dual-circuit brake shoe is spring-operated. Two independently acting
brake shoes press the brake lining to the brake disc at a preset spring force.
The braking force is rated in such a way that one shoe will be capable of
stopping the car loaded with full rated load.
Electrically operated magnetic clamps cause the brake to be released.
If operated manually, the accompanying brake release lever must be applied
to the cast-on recesses of the brake shoe ends. By pressing in direction of
the machine (see fig. 2 in arrow direction) the brake shoes will be expanded,
thus releasing the brake.
1 Brake shoe
2 Brake release lever
Fig. 3
Traction sheave:
Overhung one-piece version fastened on drive shaft by taper;
Groove form: seat and V-groove;
Hardened groove flanks as a standard (50 HRc).
Diameter - ∅ DT mm 450 510 590 675

Rim width mm 132 96
Max. grooves – z ∗ d 8 ∗∅ 8 8∗∅ 8 8∗∅ 8 6∗∅ 8
7 ∗ ∅ 10/11 7 ∗ ∅ 10/11 7 ∗ ∅ 10/11 5 ∗ ∅ 10/11
6 ∗ ∅ 12 6 ∗ ∅ 12 4 ∗ ∅ 12
Material Specially alloyed EN-GJL 250 (HB 190 to 230)

SA Special versions TW 63 (optional)
(Additional parts for special applications)
SA3 Brake test switches for checking the brake shoes

(open-closed) and wear of brake lining.
Note: check and re-set the setting of the brake test switches
after every brake setting.
For description of setting see SA3 brake monitoring
SA 9 with extended traction sheave shaft for separating drive and well.
The traction sheave shaft is supported by a bearing.
SA 12 with additional terminal box for terminal connection of brake

release magnets for motors without terminal box acc. to BV6531.
SA 14 with flexible coupling for motors of constructional type B5 acc. to

BV 6530-05 for compensating possible misalignment in the case of
motor shafts with double bearings.
For description see annex 9.2 coupling from Centaflex
SA 15 with magnetic clamps for brake in (Ex) sG4 version

SA3 and SA12 are not possible in combination with SA15.
Note: for detailed description of special versions see 8.1

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

TW 63 V, SA9 dimensions (with outside bearing and extended traction sheave shaft)
Machine frame dimension with

horizontal rope departure
372 ±1 3)
422 ±1 4)
260 3)
310 4)
1 1
Comment:
1) Centre self-aligning bearing
2) Centre bearing box
3) Vertical motor mounting
3 4) Horizontal motor mounting
4
1 Comp. support
2 Traction sheave
3 Outside bearing
Fig. 5 4 Tractions sheave shaft
Machine with outside bearing:

For machines with additional bearing for extended traction sheave shaft
(SA9) 2 compensating supports are mounted below the machine at the
factory (see above fig.). Therefore the traction sheave shaft has two statically
determined bearing points.

TW63 H: (horizontal motor mounting)
Brake release lever (loose, variable

operating position)
Transport aid (to be removed after
transport)
Oil drain
Oil level glass

Gravity center
Opening for oil filling
Fig. 6
Comment:
1) to 3) for motors of constructional size A4, see standard version for vertical
motor position.
4) With motors of constructional size B5 (SA14)
5) Illustrated as left-hand version, right-hand version mirror-inverted to A - A

2.4 Technical data
Designed for use in installations with rated load up to 630 kg and

vrated 1.6 m/s or rated load up to 1000 kg and vrated 1.0 m/s (suspension 1:1)
Axle distance: 155 mm
Permissible load of traction sheave shaft:

for standard version max. 43 kN
for SA 9 (extended wheel shaft) max. 41 kN
Brake magnet connection:

With machine TW63 the two magnets
Connection magnetic clamp: are connected in series.
Rated voltage: 50 V Power supply
Rated current: 1.1 A for high-speed exit.: 200 V
Protection class: IP65 for withstand voltage: 100 V
Magnetic clamp rating : 2* 2500 N

Max. braking torque : approx. 2* 90 Nm
Brake disc ∅: 200 mm
Motor connection:
For terminal connection diagram of motor and magnetic clamps see cover
inside of motor terminal block.
Note: for details about standard motors see chapter 2.6
Weight:
Standard version: motor of constructional size A4
Machine (without motor and traction sheave) 250 kg
Machine SA 9 (without motor and traction sheave) 290 kg
Machine (with motor and traction sheave) approx. 370 kg
Machine SA 9 (with motor and traction sheave) approx. 410 kg
Traction sheave acc. to order 450–675mm ∅ approx.50 -70 kg
Noise level
Airborne noise of standard machine version with motor of constructional size
A4 in normal operation (measured in machine room at a distance of 1 m):
With integrated fan: approx. 65 dB(A);
with separately driven fan: approx. 67 dB(A)
Oil filling:
Vertical mounting 11 litres synthetic gear oil SM1
Horizontal mounting 9 litres synthetic gear oil SM1
Supply by THYSSENKRUPP AUFZUGSWERKE GmbH

2.5 Name plate of machine TW 63
To be differentiated acc. to customer
1. THYSSENKRUPP AUFZUGSWERKE GmbH
2. Lift Equip

2.6 Lubrication of TW 63
Lubricator Oil change interval Motorlage Filling quantity

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

Horizontal motor position
Fig. 9
1 2 3
1 Opening for oil filling

2 Oil level glass
3 Oil drain

2.7 Motor types
The following motors are available for machine TW63:
Constructional size A4
1. Pole-changing motors (AC2) constructional size A4
Range of ratings: 5.0; 6.8 KW
Forced ventilation
Motor data see 2.13
2. Frequency-controlled motors (VVVF) constructional size A4

Range of ratings: 5.7; 11.0; 16.0 KW
Integrated ventilation
Motor data see 2.15
3. Phase-shift-controlled motors (ACVV) constructional size A4

Range of ratings: 6.8 KW
Forced ventilation
Motor data see 2.14
Constructional size B5
Gear and motor are connected by means of flexible coupling (SA14) in
accordance with BV 6530-06
4. Pole-changing motors (AC2)

Range of ratings: > 6.8 KW
Forced ventilation
5. Phase-shift controlled motors (ACVV) constructional size B5

Range of ratings: > 6.8 KW
Forced ventilation
Motor data see 2.16
6. Special motors
Data and version acc. to customer specification
Flywheel rim:
Pole-changing motors (AC2) are equipped with a flywheel rim in accordance
with order specification.
Hand wheel:
Controlled A4 motors (ACVV / VVVF) are equipped with a plastic handwheel
of 270 mm dia. and B5 motors are equipped with a hand wheel of
dia. 360 mm (Siemens motor dia 270 mm)

General motor data:

a) with vertical motor mounting:
Protection class: IP 21
Insulation class: F
Protective motor switch 6 posistors (3 with frequency-controlled motors)
b) with horizontal motor mounting:

Protection class: IP 20
Insulation class: F
Protective motor switch 6 posistors (3 with frequency-controlled motors)
Data of forced ventilation: (if available)

Mains voltage: 230 V
Mains frequency: 50 Hz
Power: 0.1 KVA
Currency: 0.44 A
Speed: 2000 1/min
Capacitor: 2 µF
2.8 Connection
How to connect the motor:
When you connect the motor observe the terminal diagram enclosed in the
motor terminal box and/or the circuit diagram of this operating manual as well
as the respective building codes.
Motors with pulse generators:

For connection and technical data concerning connection of the pulse
generator see chapters 9.3 – 9.5.

2.9 Terminal diagram for VVVF motors

and magnetic clamps
for frequency-controlled motors
Anschlußplan = terminal diagram = schema de branchement

Anschlußkasten Motor / terminal box motor / Boite a bornes de monteur
ACHTUNG! ATTENTION!
Klemmenleiste An den Klemmen der Kaltleiter keine
Terminal strip Spannung größer als 2.,V anlegen!
Do not apply more than 2.5V at the
Reglette de raccordement
terminals of the PTC thermistors!
DEE 132 / 140 Ne pas mettre tension plus que 2,5V
aux bornes des condukteurs a froid!
Anschlußkasten Bremse
Terminal box solenoids
boite a bornes de electro
frein
Kaltleiter
PTC-thermistors
conducteurs
a froid
N BM
Motor connection
Magnetic clamp
connection
Fig. 10

2.10 Connection of motors acc. to BV 6531 – 21
for three-phase pole-changing motors
Disconnector
Make contact in winding
Starting capacitor for fan

2.11 Connection of motors acc. to BV 6531 – 22
for phase-shift-controlled three-phase motors

with DC brake winding
Disconnector
Make contact in winding
Starting capacitor for

fan
Low-speed winding as
DC winding or
switched in series to
brake circuit

2.12 Connection of VFD motors
for special motors of constructional size B5

Schaltung nach Angabe Bremswicklung ϑ = Kaltleiter
am Leistungsschild. Brake winding PTC thermistors
Connection as stated on Bobinage au frein Conducteurs à froid
the rating plate. Schaltung abhängig Achtung! Attention!
Branchement suivant von der
An die Klemmen der Kaltleiter keine Spannung
indication sur la plaque Wicklungsausführung.
größer als 2,5V anlegen
indicatrice. Do not apply more than 2,5V at the terminals of the
thermistors.
Ne pas mettre tension plus que 2,5V aux bornes
Delta
des conducteurs à froid
Triangle
Forced ventilation
Ventilation forcèe
Fremdbelüftung
Drehzahlgeber
Speed control
Transmetteur de vitesse
Hohe Drehzahl Zum Regelgerät 3 * UK 16

High speed To the control Star connection
Grand vitesse device
Vers l`appareil de
règlage
Brake magnet wiring in separate

terminal box of shaft (SA12)

2.13 Motor data - pole-changing motors (AC2)
Motor type: LNLA 132 LN-20Y LNLA 132 LP-20Y Moment of inertia
Synchronous speed: [1/min] 1500 1500 flywheel rim
Rated speed: (asyn.) [1/min] 1380 / 275 1380 / 275
∅ JS
Moment of inertia: (J1.) [kgm²] 0.043 0.043
mm kgm2
Moment of : (JM.) [kgm²] 0,047 0,057
330 0,342
Moment of : (JH.) [kgm²] 0,010 0,010
Moment of : (Js.) [kgm²] see right-hand table see right-hand table 360 0,515
370 0,590
S 5 operating data with 180 F/h, 40 % ED 380 0,657

400 0,815
Power: (PN.) [KW) 5,0 6,8
410 0,957
Rated torque: [Nm] 35 47
430 1,127
Starting torque: [Nm] 80 / 60 106 / 80
Rated current: [A] 12.8 / 9 16.2 / 11.9
Permissible starting current: [A] 48.0 / 12.0 60 / 16
Rated voltage – motor: [V] 400 400
Rated frequency: [Hz] 50 50
Generator marks:: -- --
Weight: (rotor / stator) [kg] 12.55 / 30 14.9 / 36
Length: (motor incl. flywheel rim) [mm] 446 446

2.14 Motor data – phase-shift-controlled motors (ACVV)
Motor type: LNLA 132 LS-20Y
Synchronous speed: (1/min) 1500
Rated speed: (asyn.) (1/min) 1370
Moment of inertia: (J1) (kgm²) 0.043
Moment of; (JM) (kgm²) 0,057
Moment of; (JH) (kgm²) 0,010
Moment of; (Jges.) (kgm²) 0,110
S 5 operating data with 180 F/h, 40 % ED
Power: (KW) 6.8

Rated torque: (Nm) 47
Starting torque: (Nm) 113
Rated current: (A) 16.3
Permissible starting current: (A) 57
Rated voltage – motor: (V) 400
Rated frequency: (Hz) 50
Generator marks: 2 x 64
Weight: (rotor / stator) (kg) 14.9 / 36
Length: (motor incl. handwheel) (mm) 459

2.15 Motor data – VVVF motors (frequency-controlled VVVF)
Motor type: DEE 132 K 005 DEE 132 M 003 DEE 140 S 009
Speed range: (1/min) 1300-1450 1451-1700 1250-1450 1451-1650 1250-1400 1401-1650
Moment of : (J1) (kgm²) 0,056 0,056 0,056
Moment of : (JM) (kgm²) 0,027 0,042 0,065
Moment of : (JH) (kgm²) 0,010 0,010 0,010
Moment of : (Jges.) (kgm²) 0,093 0,108 0,131
S 5 operating data with 240 F/h, 50 % ED
Power: (KW) 5,7 11.0 16.0

Torque range: (Nm) 43,5-34,0 34,0-32,0 84,0-72,5 72,4-63,7 122-109 109-92,6
Current: (A) 15.5 26.5 38.5
Permissible starting torque: (Nm) 80 65 170 150 240 220
Permissible starting current: (A) 25 48 67
Sinusoidal voltage – motor: (V) 340 340 330
Generator marks: VN <1.5 m/s / VN ≥1.5 m/s 1024 / 4096 1024 / 4096 1024 / 4096
Weight: (kg) 22 38 47
Length: (motor incl. handwheel) (mm) 459 459 459

2.16 Motor data – ThyssenKrupp/Siemens special motors
Constructional size B5 (with hand wheel Ø 360mm 270mm)

Ausführung ACVV VVVVF
Schutzart: IP21 IP54
Motor type: LNLA 160 LS-20C 1LA6- 166-4AA-11Z
Synchronous speed: (1/min) 1500
Rated speed: (asyn.) (1/min) 1350 1250 - 1500
Moment of : (J1.) (kgm²) 0,054 0,054
Moment of : (JM.) (kgm²) 0,135 0,055
Moment of : (JH.) (kgm²) 0,0292 0,010
Permissible mass moment of inertia: (Jges.) (kgm²) 0,218 0,119
S 5 operating data with 240 F/h, 50 % ED 180 F/h, 40 % ED 240 F/h, 50 % ED
Power: (KW) 10.0 13,0

Rated torque: (Nm) 70 100 - 83
Starting torque: (Nm) 170 170
Rated current: (A) 23 32
Permissible starting current: (A) 80 47
Rated voltage – motor: (V) 400 330
Rated frequency: (Hz) 50 max. 50
Generator marks: 2 x 64 4096
Weight: (kg) 157 114
Length: (motor incl. handwheel) (mm) 627 589

2.17 Machine frame TW63 (optional)
Standardized versions:
The machine frames for TW 63 described below are designed for mounting in
the machine room above the well.
1.Without deflection pulley: for direct rope departure car – counterweight or

2:1 suspension. See fig. 11
2.With deflection pulley: standard frame incl. deflection pulley ∅ 450 mm

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

Mounting of frame
Loosely screw frames which are delivered as pre-fabricated parts together in
the machine room. See to it that the brackets with additional drilled holes (2
holes) and pulley support are mounted on the correct side. Mount deflection
pulley and axle on the pulley support and secure.
Place frame on insulation elements as shown in plan of installation and align.
Place machine on frame by means of hoist; traction sheave shall be mounted
on the side of deflection pulley. Laterally shift machine on frame until the
necessary ASL measure is reached (parallel rope distance on rope
departure). Screw machine to frame. Parallelly align traction sheave and
deflection pulley. Level uneven base by placing enclosed bearing elements
under. See to it that you do not strain the housing. Tighten screws with
required torque. Note that rope departure is aligned towards rope pulley on
car or fastening on car and counterweight.
Attention: in the case of lateral or diagonal rope departure secure the gear
housing on the machine frame against dislocating by means of stoppers
fastened with set screws.
Explanation code designations:

ASL = Parallel rope distance on rope departure
DT = Diameter of traction sheave
SR = Diameter of deflection pulley
α = Angle of wrap on traction sheave
X1 = Distance 1 between rope departure and outer edge of frame
X2 = Distance 2 between rope departure and outer edge of frame
Y1 = Vertical axle distance between traction sheave and deflection
pulley
Y2 = Vertical distance between centre deflection pulley and support
base
Z1 = Distance 1 between rope departure centre and outer edge of
frame
1 – 6) see explanations in representation of version 1 (fig. 11).

Data machine frame version 1

Illustration see fig.11
Weight machine frame: approx. 80 kg
Traction sheave Arrangement maschine Arangement machine

∅ DT left-hand version 4) 5) right-hand version 4) 5)
(mm) Measure x1 Measure x2 Measure x1 Measure x2
450 96,5 386,5 386,5 96,5
510 66,5 338,5 338,5 66,5
590 94,5 230,5 230,5 94,5
675 120 120
Traction sheave Arrangement maschine Arrangement maschine

∅ DT left-hand version 6) left-hand version 6)
(mm) Measure x1 Measure x2 Measure x1 Measure x2
450 136,5 328,5 340,5 124,5
510 106,5 298,5 310,5 66,5
590 66,5 258,5 202,5 122,5
675 92,0 148,0 160,0 80,0
Note: left-hand or right-hand version means that the machine 5) (right-hand

version – position of traction sheave with view from motor onto machine) is
displaced into mentioned direction up to last possible row of mounting holes.
Measures x1 or x2 indicate the distance between rope departure and outer
edge of frame dependent on traction sheave ∅.


Weight machine frame incl. deflection pulley ∅ 450 :approx. 170 kg
Traction sheave Rope distance Angle of wrap α (°)

∅ DT car – counterweight
(mm) ASL Motorlage Motorlage
(mm) vertikal horizontal
450 745 155 155
510 775 158 158
590 775 164 164
Comments see version 1 fig. 11
Weight machine frame incl. deflection pulley ∅ 360 approx.170 kg

incl. deflection pulley ∅ 450 approx.200 kg
incl. deflection pulley ∅ 540 approx.230 kg
Rope distance measures and angle of wrap
Traction sheave Minimum rope distance car – counterweight

∅ DT (mm) and maximum angle of wrap
ASLmin (mm) and αmax (°)
With deflection pulley ∅ SR (mm)
∅ 360 ∅ 450 ∅ 540
ASLmin αmax ASLmin αmax ASLmin αmax
450 622 166 566 169 566 168
510 652 168 664 166 664 164
590 760 166 704 170 704 168
675 802 169 815 168 883 160

Traction sheave Maximum rope distance car – counterweight

∅ DT (mm) and minimum angle of wrap
ASLmax (mm) and αmin (°)
With deflection pulley SR (mm)
∅ 360 ∅ 450 ∅ 540
ASLmax αmin ASLmax αmin ASLmax αmin
450 1098 137 1042 137 1042 133
510 1128 139 1072 139 1072 135
590 1100 146 1044 145 1044 142
675 1143 149 1087 147 1087 145
Intermediate values for ASL in modular dimension of 68 mm
Project planning dimensions
Deflection Measure Measure Measure Measure Measure

pulley x1 x2 y1 y1 z1
SR (mm) (mm) (mm) (mm) (mm) (mm)
360 130 61 700 190 245
450 231 116 655 235 255
540 276 116 575 315 255

Machine frame with 2 pulleys for drive arranged below - beside
Weight of machine frame incl. two rope pulleys ∅ 400 approx. 210 kg
Traction sheave - ∅ DT Angle of wrap α

(mm) (°)
450 187
510 191
590 197
675 203

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

Version 2 Machine frame TW63 with deflection pulley

Left-hand version is illustrated (mirror-inverted right-hand version)
Fig. 12

Version 3 Machine frame TW63 with deflection pulley

Right-hand version is illustrated (mirror-inverted left-hand version)
Fig. 13

Version 4 Machine frame TW63 with 2 deflection pulleys

and drive arranged below beside
Left-hand frame mounting Right-hand frame mounting
View A
Fig. 14
Comments see version 1 fig. 11.

OPERATING MANUAL 3. TRANSPORTATION
3. Transportation and storage
Packaging:
In the as-delivered condition the TW 63 is mounted on a special pallet.
Dependent on the order volume machine frame, supports and deflection
pulley are enclosed. In the case of delivery by sea the machine incl.
additional parts are wrapped in seaworthy packing.
Transportation:
Transportation shall be subject to observation of the safety requirements and
the gravity centre of the machine.
Attention: machine is filled with oil. It shall be transported and stored in

upright position only.
Transportation by means of fork lift:

• In the case of transportation by means of fork lift see to it that the fork is
attached to the pallet and not to the machine.
• Pay attention to projecting parts! There is the risk of injury to persons or
damage to property!
Transportation by means of crane:

• Do not stay below suspended loads!
• Fasten machine without frame on motor by means of a rope as shown in
the figure below. See to it that the ventilation grid cannot be damaged.
• Wrap rope around motor of machine without frame and secure to crane
as shown in figure below !
• Secure machine against sliding and turning over.
Transport aid
Fig 15
Rope fastening: wrap transport rope under terminal box and ventilation
opening around motor in the case of machine without machine frame.
See figure.

Note the pictographs fastened on the packing or on other visible places.
Top Handle with care Keep dry
Do not expose to Do not use hand- Fasten here

heat held grippers
Dimensions and weight

The weight is indicated on a sticker on the packing placed below the
transport rail.
For dimensions see delivery note.
For rough data see chapter 2.3 Technical data.
Examination by customer on receipt of goods

Examine the delivered parts for completeness, damage or anything strange.
Report and document transportation damages

After receipt of goods make sure that there is no damage caused during
transportation.
Information
• Immediately document the damages noticed (drawing, photograph,
description of the damage).
• Send the respective reports immediately to THYSSENKRUPP
AUFZUGSWERKE GmbH
Unpacking
Information
• Dispose packing equipment in accordance with the environmental
requirements or make it available for further use.
• Special transport aids and transport contrivances shall not be sent
back to THYSSENKRUPP AUFZUGSWERKE GmbH but remain at
the customer.

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

OPERATING MANUAL 4. MOUNTING OF MACHINE
4. Mounting of machine in machine room
Dependent on the order volume the TW63 machine is delivered including

machine frame and deflection pulley. Dependent on the customer
requirements the frame is mounted on supports, brackets, concrete socle or
is casted directly in plaster floor on the machine room floor.
To make installation and mounting of the frame supports easier, drawing and
parts list of the frame are enclosed.
Attention: mount the frame acc. to drawing and fasten by enclosed

elements. Observe indicated strength and respective torque. See data in
chapter 9.1
In order to better comply with the requirements concerning noise reduction /

structure-borne noise transmission insert the insulation elements delivered
between frame support and floor.
The number of rubber elements depends on the overall weight load. The
individual rubber elements should be loaded at between 7000 and 12 000 N /
rubber element.
(For position and arrangement of the rubber elements see layout drawing).
Note: on arranging the rubber elements observe that the overall gravity
centre shall lie within the rubber elements ( the same applies if the car is
suspended from the deflection pulley side).
If cast plaster floor is used as supporting surface for the machine frame see
to it that the thickness of the coating shall be ≤ 60 mm. Insert insulation
elements with wooden base (80 mm). The base part shall also be cast.
For mounting and machine frame data see chapter 2.16 – 2.17.
Aligning of machine
Place the machine in accordance with the layout drawing. Align the rope
departure of the traction sheave acc. to the drawing so that it is in vertical line
with the car fastening resp. with the rope pulley and the counterweight. If the
ropes are tensioned the machine shall be horizontally aligned and mounted
on its supporting surface on the rubber elements. Level uneven position by
placing metal or wooden plates underneath.
SA9 traction sheave in well, machine with extended traction sheave shaft
and pedestal bearing.
Attention: when placing a gear with outside bearing see to it that the
following points are observed by all means
• Mount and fasten the colums in accordance with the requirements
• Horizontally align the worm wheel shaft
• Exactly align the bearings of the machine and the outside bearings

OPERATING MANUAL 4. MOUNTING OF MACHINE
4.1 Mounting of rope guards for traction sheave
Screw the rope guards to the rope guard brackets by means of the enclosed
screws. Turn the rope guard brackets in such a way that the distance
between rope and rope guards is as small as possible on the side of the
traction sheave where the ropes enter and leave. (1 -2 mm)
In the case of diagonal rope departure adapt the position of the rope
guards to the changed rope departure direction.
Note: first align, then tighten the fastening screws of the rope guard brackets
on the machine with pre-set torque.
For tightening torques see table in annex of operating manual
.
1
1
2
2
max. 1 - 2 mm
Fig. 16 Fig. 17 (W191 illustrated)
1 Rope guard bracket

2 Rope guard
Attention:
If the ropes are entering the traction sheave at any angle above the
horizontal up to a maximum of 90° (example: machine arranged on
bottom/top beside) an additional provision is necessary to avoid the
introduction of objects between ropes and pulleys.
If the ropes enter the traction sheave at a protected area within the machine
frame, the function "protection against bodily injury " is not necessary.
Note: for SA9 (traction sheave in well) rope guard is not provided by
THYSSENKRUPP AUFZUGSWERKE GmbH.

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

fastening parts from ThyssenKrupp Aufzugswerke GmbH.

OPERATING MANUAL 5. PUTTING INTO SERVICE
5.1 Emergency operation
TW 63 is equipped with handwheel and accompanying brake release lever

for emergency operation.
The brake release lever shall be applied to the cast-on recesses of the brake
shoe ends (see fig. 3A). By pressing the levers the brake shoes will be
expanded, thus releasing the brake.
In the case of emergency rescuing of trapped passengers also turn the
handwheel, if necessary, in order to move the car to the nearest landing.
Depending on the load the car can start moving quickly as soon as the brake
is released. Immediately stop moving the handwheel and regulate the speed
of the car by pressing the brake release lever accordingly.
Attention: if the handwheel is used for servicing and maintenance works

(e.g. "safety gear operation") see to it that the person performing the work
stands on a safe working area. Note that there is the danger of injury if
electric recall is operated at the same time.
1 Brake shoe
2 Brake release lever
Fig. 3A
ThyssenKrupp Aufzugswerke 46 Issue 01.2005

OPERATING MANUAL 6. SERVICING
6. Servicing
Maintenance interval: maintenance of the machine should at least be

carried out once a year, preferably in the course of the general lift
maintenance.
Note: installation and maintenance works shall only be carried out by trained
and instructed, technically competent personnel.
They shall be familiar with all directives and requirements for lift installations
as well as with the requirements for the prevention of accidents and they
shall observe them accordingly.
For further information concerning proceeding, adjustment and data see chapter:
⇓
• Check oil level and fill in oil, if necessary 2.6

• Change oil (observe date of oil change) 2.6
• Check brake shoes for wear, residual brake lining shall be at least 7.3
3 mm
• Check brake adjustment, brake stroke shall be 0.3 mm + 0.1 mm 7.3
• Check armature base plate for pre-tension and movability 7.2

• Check brake deceleration 7.3
• Check worm teeth for wear

• Check backlash between worm shaft and worm wheel 6.1
(0.04 mm to 0.12 mm with 20° C.)
• Check groove profile on traction sheave for damage and wear

• Check screws of traction sheave fastening for correct tightening 9.1
• Check grooves on rope pulleys for damage and wear
• Check electrical supplies for correct working and safety
• Check provision and correct adjustment of protective and safety

equipment
Notes on lubrication (oil change, quantity, maintenance interval) see

chapter 2.6.

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

ME = measured result M
r = radius – worm wheel
all dimensions in mm

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

7.2 Adjusting of braking deceleration
Only adjust brake with one acting brake shoe each while moving the car
loaded with rated load downwards (full – down) or the empty car upwards
(empty – up) in accordance with the deceleration values stated in the
table below.
Adjust the brake shoe torque by pre-tensioning the brake springs for each
lift type individually and at both brake shoes evenly.
Machine with Machine with

flywheel masse handwinding wheel
≤ ≤ ≤ ≤ >
v m/s 0.63 1.25 0.63 1.25 1.25
- a full-down) m/s² 0.2 0.3 0.3 0.4 0.50
- a (empty-up) m/s² 0.4 0.5 0.5 0.6 0.75
Table: brake deceleration values
1 2 3 4 2 1
10
Fig. 20
12 11
1 Brake shoe bolt 7 Washer

2 Safety screw incl. washer 8 Counternuts
3 Oil vent 9 Anchor bolt
4 Inspection opening 10 Armature base plate
5 Brake shoe 11 Cover ring
6 Rubber disk 12 Magnetic clamp

7.3 Adjusting of brake shoe stroke / armature base plate
Before first startup and during regular inspection check the working stroke of
the brake shoes as well as the pre-tension and the movability of the armature
base plates.
How to proceed:
1. Check armature base plate for movability:
After a long time of use the rubber disk between armature base plate and
brake shoe (fig. 16 pos. 6) may sink and, consequently, the pre-tension of the
armature base plate may be too low.
To restore the pre-tension re-adjust the counternuts between brake shoe and
armature base plate. The pretension is correct if the armature base plate
slightly clings on the anchor bolt and can be turned.
2. Check stroke :
Align dial gauge to brake shoes and measure on the level of the brake disk
centre. Release brake shoes by operating the drive and check stroke of
brake shoe. Stroke travel shall be 0.3 mm + 0.1 mm.
Re-adjust: unscrew counternuts (fig. 20 pos. 8) and re-adjust armature base

plate by means of hexagon socket screw key in the case of deviations.
Secure adjustment.
Note: release brakes and see to it that both brake shoes work with the same
stroke.
3. Adjust pre-tension of springs:
Correct adjustment of pre-tension is only possible in the course of adjusting
the braking deceleration (see 7.2) Do not exceed the maximum pre-tension
value of 13,5 mm.
Note: if brake test switches are provided (SA3) check or re-adjust them after
e every brake adjustment.
See brake monitoring SA3 chapter 8.2

7.4 Replacing of traction sheave
Disassembly:
• Switch off power supply, secure car and counterweight,.

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

7.5 Replacing of motor
Note: with motors of constructional size A4 the rotor is shrink-fit to the

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

OPERATING MANUAL 8. SPECIAL VERSIONS
8.1 SA Special versions (optional)
(Additional parts for special applications)
Survey:
SA 3 with brake monitoring switches
SA 9 traction sheave in well (with extended traction sheave shaft)
SA 12 with additional terminal box for brake release magnets for motors
without terminal box
SA 14 with flexible coupling for motors of constructional size B5
SA 15 with brake release magnets in ex (sG4) version
SA3 Brake monitoring switches for monitoring the brake shoes

(open-closed) and the wear of brake lining.
Note: check and, if necessary, re-adjust existing brake monitoring switches
every time you adjust the brake.
See 8.2 SA3 adjustment description of brake monitoring switches
SA9 With extended traction sheave shaft if the traction sheave is arranged
directly in the well. The traction sheave shaft is supported by a bearing. The
machine is fastened on pedestal supports for compensating the shaft load
and the forces acting on the bearings.
SA12 Additional terminal box for intermediate terminals of brake release magnets
(for motors without terminal box acc. to BV 65 31)
SA14 For motors of constructional size B5 possible misalignments between brake

disk and motor coupling are compensated by means of a flexible coupling.
For description of coupling see annex 9.2 flexible coupling for motors of
constructional size B5
SA15 Brake release magnets in ex-(sG4) version

(not possible in combination with SA3 and SA12)

8.2 SA3 Brake monitoring TCM
Version for TCM controls
The brake monitoring is designed for monitoring the brake shoes.

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

Fig. 22 Brake test switches mounted on machine
1 2 3 4 5
Fig. 23 Adjustment of test switch on hexagon screw
1 Spring clamp
2 Brake shoe
3 Adjusting screw
4 Test switch (sensor)
5 Plunger

8.3 SA3 Brake monitoring BRC

Version for third-party and older controls ( not TCM ! )
The brake monitoring BRC is a retrofit electronic device designed for monitoring of brake
shoes. The signals sent from the sensors are evaluated and transmitted to the secondary
control electronics. The device automatically switches off if the set sensor value is
reached.
Light-emitting diodes on the sensors and the BRC brake monitoring switches are provided
for failure display. If a Teleservice device is connected the error will be indicated on
display.
Make contact Connection K1 interrupter contact
Travel contactor Teleservice in safety circuit
L1 N W Teles. K1
Brake monitoring BRC Failure display
Cable length acc. to order

(standard length approx. 5 m)
Sensor mounted on
cable 3*0.75 mm² with PVC
machine, adjusted to
sheath
respective integrally cast
surface of brake shoe
Fig. 24 Terminal connection diagram for brake monitoring BRC

applies to third-party and older controls (not TCM)
Connections :
L1 a.N for mains 230 V
W for make contact to W contactor
B1 sensor 1 with voltage supply 24V/0V
B2 sensor 2 with voltage supply 24V/0V
K1 make contact for evaluation (e.g.connection to safety circuit)
Teles. for connection to THYSSENKRUPP Teleservice device
(remote monitoring of lift)

Black B1 Black B2
Blue 0V
Brown Blue 0V Brown 24V
Fig. 25 Terminal connection diagram for sensors

OPERATING MANUAL 9. ANNEX
9.1 Tightening torques- strength
Attention: to be strictly observed when performing work on the machine or

replacing parts!
Strength DIN / Tight.-
ISO torque
Nm
Handwheel on hub
Cheese head screw M 8*12 8.8 4762 20
Lock washer S8
Hub on shaft
Cheese head screw M 12 * 35 microencapsul. 8.8 4762 75
Detent edged disk SK M12
Dowel pin 6 *18 8752 9
Pulse generator on motor casing

Cheese head screw M 6 *12 8.8 4762 9
Motor bearing cover on motor casing

Cheese head screw M 6 *12 8.8 4762 9
Motor casing on gear box casing

Cheese head screw M 12 * 35 8.8 4762 75
Brake disk on worm shaft (only with A4 motors)

Shaft nut M 55 * 2 8.8 600
Bearing cover on inside box casing

Disk on conic. end of worm wheel shaft

Cheese head screw M16 * 40 microencapsul. 8.8 4762 100
Bearing bracket on casing

Bearing cover on bearing bracket

Hexagon nut M10 * 30 8.8 4017 40
Disk on bearing – worm wheel shaft


th ISO torque
Nm
Locking screw on brake shoe bolts

Cheese head screw M6 * 12 8.8 4762 9
Brake release magnet on casing

Hexagon screw M16 * 120 8.8 4014 150
Machine on machine frame versions 1 - 3 / 4

Hexagon screw M20 * 90 8.8 4014 190 / 350
Washer 21 7349
Hexagon nut M20 8 4032
Lock nut M20 7967
Tightening torques for screwing the fastening parts

on the machine frame
Hexagon screw M 6 * 20 8.8 4017 9
Hexagon screw M10 * 16 8.8 4017 40
Hexagon screw M12 * 35 8.8 4017 75
Hexagon screw M16 * 25 8.8 4017 190
Hexagon screw M16 * 40 8.8 4017 190
Hexagon screw M16 * 80 8.8 4017 190
Note: install screws, washers, detent edged disks, nuts and lock nuts acc. to
the information of enclosed drawings and tighten with the torque specified.
Note: only use micro-encapsulated screws once, then replace.
Any warranty obligation on parts is subject to use of original mounting and

fastening parts from ThyssenKrupp Aufzugswerke GmbH.

9.2 Annex Flexible coupling for B5 motors sheet 1
Design for TW63

9.2 Annex Flexible coupling for B5 motors sheet 2
TW63

9.3 Pulse Generators
Versions: the following pulse generators are available for TW63

Type classification dependent on the control used
1.TTL for THYSSENKRUPP control CPI
for v < 1.5 m/s with 1024 pulses part No. 00 990 13 03 0
for v ≥ 1.5 m/s with 4096 pulses part No. 00 990 14 03 0
Use cable of 10 m length, SUB-D 9 tab and locking lever acc. to DIN
46342 for connection.
Connector assignment Electrical data:

Connection Pin Colour Supply voltage 5 V DC
Minus 7 white Power consumpt.: max. 60 mA
Plus 9 brown Output: push-pull
Channel A 2 green Max load.: 40 mA
Channel B 3 yellow Level with 20 mA: H >3,6 VDC
Zero pulse 5 grey L < 1.2 VDC
Channel A inv. 1 red Max. pulse frequency: 200 kHz
Channel B inv. 4 black Terminal protector: no
Zero pulse inv. 6 lilac
Shield 8+casing black
Please note manufacturer’s information in chapters 9.5 – 9.5
2.HTL for third-party controls or converters

with 2 x 64 pulses part No. 00 990 12 03 0
Use cable of 10 m length insulated with end sleeves for connection.
.
Connection Pin Colour Supply voltage 15V DC
Channel A 6 grey Power consumpt. +15V: ≥ 90 mA
Channel B 5 pink Power consumpt. -15V: ≥ 10 mA
Channel C 3 green Output: A Channel 64 I/U
Mass 4 yellow B Channel 64 I/U
Plus 15 V 1 brown C Channel 128 I/U
Minus 15 V 2 white
Shield open


with 1024 pulses part No. 00 990 16 03 0

Connection Colour Supply voltage 15V DC
Channel A green Power consumpt.: max.60 mA
Channel B yellow Channels: A, B, N, ABN inv.
Channel N grey Output: HTL- differential driver
Channel A inv. red Load: max. 40 mA
Channel B inv. black Level: with 20 mA
Channel N inv. lilac H > UB – 2,5 VDC
Mass yellow L > 2,5 VDC
Plus 15 V brown Pulse frequency: max. 200 kHz
Minus white Terminal protector: yes
Shield strand Early warn. output: NPN OC, 10 mA
Early warning output:pink Umax. = 30 VDC
Cable length: max. 100 m

with 1024 pulses part No. 00 990 19 03 0

Connection Colour Supply voltage: 5V DC
Channel +A green Power consumpt.: max. 100 mA
Channel +B grey without load
Channel +N black Channels /output: sine, cos., N
Channel - A yellow Output load : min 120 Ohm
Channel - B pink Termin. resistor between + and
Channel - N lilac - outputs.
Plus 5 V brown Level: 1 Vss +/- 25 %
Minus white Max. frequency (-3dB): 100 kHz
Shield strand Terminal protector: no
Early warning output: conductive in
operating state
Cable length: max. 150m with <260pF/m
General design:
acc. to DIN VDE 0160

9.4 Pulse Generator Manufacturer’s Instruction Sheet 1
Part No.: 00 990 12 03 0 with 2 x 64 pulses

9.4 Pulse Generator Manufacturer’s Instruction Sheet 2
Part No. 00 990 13 03 0 with 1024 pulses


9.4 Pulse Generator Manufacturer’s Information Sheet 3

9.4 Pulse Generator Manufacturer’s Information Sheet 4
Part No.: 00 990 19 03 0 with 1024 pulses

9.5 Pulse Generator Manufacturer’s Instruction

Product Information

9.6 Blocking clamp
Every machine is equipped with a blocking clamp suitable for the respective
traction sheave (rim width and design)
Use of blocking clamp:

Use the blocking clamp during assembly works on the car or on the
counterweight in order to avoid movements by slip of ropes on traction
sheave or during works for which the traction of the installation is not
sufficient (for example for safety gear operation).
Note: Tighten the blocking clamp by means of the screw connection in such
a way that slip of ropes on traction sheave is impossible.
4 5
3 6
2
7
1
Fig. 26
Mounting the blocking clamp to the traction sheave (illustration without ropes)
1 Traction sheave groove

2 Rope
3 Pressure plate
4 Washer
5 Hexagon nut
6 Spacer
7 Clamp clip
Attention: After terminating mounting works disassemble blocking clamp,

since otherwise there is the risk of damage to the installation.

ThyssenKrupp Aufzugswerke GmbH
A company of ThyssenKrupp Elevator
62 320 02 86 0 Issue 01/2005
Bernhäuser Strasse 45
73765 Neuhausen a. d. F.
Germany
Tel.: +49 7158/12-0
Fax: +49 7158/12-2585
E-Mail: info@tke-aufzuege-de.thyssenkrupp.com
www.thyssenkrupp-aufzuege.com

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Operating Manual

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Printed in Germany, January 2005

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We are pleased that you decided to purchase a quality product from

ThyssenKrupp Aufzugswerke GmbH 3 Issue 01.2005

1.1 Explanation of symbols used

ThyssenKrupp Aufzugswerke GmbH 6 Issue 01.2005

1.2 General safety information

Information about the operating manual

Duties of the owner and / or the installer

Duties of the employees

Training of the employees

ThyssenKrupp Aufzugswerke GmbH 7 Issue 01.2005

Informal information about safety measures

Guarantee and liability

ThyssenKrupp Aufzugswerke GmbH 8 Issue 01.2005

• unauthorized constructional modifications of TW 63

Constructional modifications of machine TW 63

Use of TW 63 and possible hazards

ThyssenKrupp Aufzugswerke GmbH 9 Issue 01.2005

2.1 Description of machine TW 63

The machine consists of:

Fig. 1 Design of TW63 V

ThyssenKrupp Aufzugswerke GmbH 10 Issue 01.2005

2.2 Functional description

The machine TW63 is designed as drive for use in lifts.

The gear (machine) is a single-stage, anti-friction bearing worm gear. The

Drive version is subject to motor mounting: the power is transmitted from a

The following constructional sizes of drive motors are available:

ThyssenKrupp Aufzugswerke GmbH 11 Issue 01.2005

Diameter - ∅ DT mm 450 510 590 675

ThyssenKrupp Aufzugswerke GmbH 12 Issue 01.2005

SA Special versions TW 63 (optional)

(Additional parts for special applications)

SA3 Brake test switches for checking the brake shoes

SA 12 with additional terminal box for terminal connection of brake

SA 14 with flexible coupling for motors of constructional type B5 acc. to

SA 15 with magnetic clamps for brake in (Ex) sG4 version

Note: for detailed description of special versions see 8.1

ThyssenKrupp Aufzugswerke GmbH 13 Issue 01.2005

TW 63 V of constructional size A4 (vertical motor mounting)

Separately driven fan

Name plate motor

Oil level glass

Name plate shaft

ThyssenKrupp Aufzugswerke GmbH 14 Issue 01.2005

Machine frame dimension with

Machine with outside bearing:

ThyssenKrupp Aufzugswerke GmbH 15 Issue 01.2005

TW63 H: (horizontal motor mounting)

Brake release lever (loose, variable

Oil level glass

ThyssenKrupp Aufzugswerke GmbH 16 Issue 01.2005

2.4 Technical data

Designed for use in installations with rated load up to 630 kg and

Axle distance: 155 mm

Permissible load of traction sheave shaft:

Brake magnet connection:

Magnetic clamp rating : 2* 2500 N

ThyssenKrupp Aufzugswerke GmbH 17 Issue 01.2005

2.5 Name plate of machine TW 63

To be differentiated acc. to customer