Machine W263B - صفحه اصلی W263B PAGE 1. Safety 1.1 Explanation of symbols used 6 1.2 General...

ThyssenKrupp Aufzugswerke

A company of ThyssenKrupp

Elevator

Operating Manual Machine W263B

OPERATING MANUAL

ThyssenKrupp Aufzugswerke GmbH 3

Imprint

All rights reserved Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH

P.O. box 23 03 70, D-70623 Stuttgart Printed in Germany, The copyright of this documentation rests with THYSSENKRUPP AUFZUGSWERKE GmbH. This documentation or extracts of it shall not be copied, distributed or used for the purpose of competition. Any reprint, 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 or higher standard of the machine W263B 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 machine W263B (which is referred to as W263B below) - and its intended possibilities of use. Important information concerning safety and hazards helps you to safely use the W263B. W263B is subject to technical alterations.

OPERATING MANUAL


Table of Contents: Machine W263B PAGE

1. Safety 1.1 Explanation of symbols used 6 1.2 General safety instructions 7

2. Transport and Storage 10 3. Product description

3.1 Description of machine W263B 12 3.2 Functional description 13 3.3 Technical data 15 3.4 Motor versions 18

3.4.1 Motor data for frequency-controlled THYSSEN motors (without energy regeneration) 19 3.4.2 Motor data for frequency-controlled THYSSEN motors (with energy regeneration) 22 3.4.3 Motor data for standard third-party motors (with energy regeneration) 23

3.5 Dimensions 25 3.6 Machine frame 28 3.7 Lubrication 33 3.8 Nameplate 34

4. Mounting and connection 4.1 Mounting of machine in machine room 35 4.2 Mounting of rope guard for traction sheave 36 4.3 Motor connection 37 4.4 Terminal plan for machine motor and magnetic clamps 38

4.4.1 Motor connection acc. to BV 6531 – 09 39 4.4.2 Motor connection acc. to BV 6531 – 14 40 4.4.3 Bridge connection for motor terminals 41

4.5 Pulse encoder connection 4.5.1 For motor mounting 42 4.5.2 Tacho-generator / pulse encoder mounted at worm shaft 44

4.6 Connection diagram 45

5. Putting into operation 5.1 Putting the machine into operation 46

6. Servicing 6.1 Servicing of machine W263B 47 6.2 Checking of flank clearance 48

OPERATING MANUAL


Table of Contents:

7. Maintenance 7.1 Replacement of brake shoes 49 7.2 Setting of brake deceleration 49 7.3 Setting of brake shoe stroke and armature disc plate 50 7.4 Replacing of traction sheave 51 7.5 Replacing of motor 52 7.6 Replacing of external bearing 53

8. Special versions (optional) 8.1 Overview 59 8.2 SA3 Brake monitoring circuit 61 8.2.1 Variant designed for Thyssen controls TCI; TCM 61

8.2.2 Variant designed for third-party and older controls (not applicable to TCI; TCM) 62

8.3 SA7 Tacho-generator and pulse encoder mounting 64

9. Annex 9.1 Tightening torque – Mechanical strength 66 9.2 Flexible coupling for B5 motors 67 9.3 Manufacturer's instruction for pulse encoder 69 9.4 Manufacturer's instructions for SA7 tacho-generator 73 9.5 Product information for pulse encoder from Wachendorff 77 9.6 Blocking clamp 78

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. Warnings must always be observed!

Warning This symbol draws attention to an impending danger. Disregard can cause injury to persons or extensive damage to property. Warnings 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 the proper 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 instructions

Information on the operating manual Knowledge of the basic safety requirements is a prerequisite for the safe use and fail-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 employees working for compliance 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 on safety measures The operating manual must always be available at the location of the

installation. The general and local regulations for the prevention of accidents and

environmental regulations must also 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 W263B is designed in accordance with the state of the art and the generally accepted safety regulations. W263B shall only be used for its intended purpose be used only if safe operation is ensured. W263B shall exclusively be used as drive for lifts. Any other use or any use exceeding the scope of above definitions is regarded as use outside of the intended purpose. THYSSENKRUPP AUFZUGSWERKE 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 fulfillment of the instructions applying to putting into service, installation

description and inspection and repair work.

Guarantee and liability The "General Conditions and Terms of Sale" 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 W263B outside the scope of its intended purpose inexpert mounting, putting into service, operating and maintaining of

W263B use of W263B with defective and/or non-operative safety and protective

devices disregard of the instructions in the operating manual that apply to

transportation, storage, mounting, putting into service, operation and maintenance of W263B

unauthorized constructional modifications of W263B unauthorized of drives (rating etc.) unsatisfactory supervision of parts that are subject to wear



inexpert repair work catastrophes caused by outside influences and Act of God.

Constructional modification of machine W263B W263B is adjusted at the factory and delivered ready for work. Attention : Fill in oil before you start putting the machine into service! In the case of any modifications THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable.

Use of W263B and possible hazards Traction sheave and handwinding wheel of the W263 do not have protecting covers. This means that the machine is to be operated in a closed machine room only. See to it that the safety distance to all revolving parts (marked yellow) is observed by persons working in the machine room / headroom. Inexpert handling can cause danger to life for the user or third parties resp. impairment of the component or material property. Failures which possibly impair the correct functioning are to be eliminated immediately.

OPERATING MANUAL 2. TRANSPORT AND STORAGE

Thyssen Aufzugswerke GmbH 10

2. Transport and storage

Packing: W236B is delivered wrapped in foil on a special pallet. Dependent on the order volume, it is pre-assembled on a securing machine frame or two u-profiles. Transport: Machine and frame must be perfectly horizontal and the safety precautions observed. Transport by fork lift: The forks must be of proper length to prevent the machine from tilting. See to it that the forks are attached to the frame or transport pallet and

not to the machine. Pay attention to projecting parts! There is the risk of injury to persons or

damage! Transport by crane: Do not stay below suspended loads! Fasten transport chain or rope using transport aids. Do not lift the motor housing! Remove transport aids after transport.

Note the pictographs fastened on the packing or other visible places.

Top Handle with care Keep dry

Do not expose to heat

Do not use handheld grippers

Fasten here

OPERATING MANUAL 2. TRANSPORT AND STORAGE


Dimensions and weight The weight is indicated on a sticker on the packing of the machine. 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 transport damage After receipt of goods make sure that there is no damage caused during transport.

Information

Immediately document the damage noticed (drawing, photograph, description of damage).

Immediately send the respective documents to THYSSENKRUPP AUFZUGSWERKE GmbH.

Unpacking Information

Dispose packing equipment in accordance with the environmental standards or make it available for further use.

Special transport aids and transport contrivances remain at the customer.

Intermediate storage

If the component is not installed directly after delivery, it should be stored in dry places and protected with humidity-proof covering.

Do not store the component in the open air. Parts without surface coating lack long-time preservation.

Environmental conditions

Information Surrounding at the final site of the machine (humidity, temperature) shall comply with the requirements for machine rooms set out in the Lift Directive.

OPERATING MANUAL 3. PRODUCT DESCRIPTION


3.1 Description of machine W263B

The machine consists of :

Pos. Designation Pos. Designation 1 Pulse encoder 10 Rope guard support 2 Motor 11 Bearing cover 3 Terminal box 12 External bearing 4 Brake release lever 13 Pedestal bearing 5 Brake spring 14 Rope guard 6 Inspection port cover 15 Brake shoes 7 Gear housing 16 Armature base plate at brake8 Traction sheave rim 17 Magnetic clamp 9 Traction sheave hub 18 Handwinding wheel

1

Fig. 1

2 3 4 5 6 7 8 9 10

11 12 13141516 1017 18



Variants: The following machine variants are available in accordance with the customer-specific requirements: gear speed reduction, gear mounted on right / left side (illustration of right-hand variant see fig. 1) Traction sheave variant, motor variant. Optionally available special versions see chapter 8.1.

3.2 Functional description Machine W263B has a single-stage worm gear (machine) with flanged-on three-phase motor. A split-type gear housing (upper and lower part) is used. The wheel shaft is located in the middle of the gear housing. The motor flange is an integral part of the upper gear housing. A coupling is used for connecting the motor, worm shaft and worm wheel to traction sheave. The motor is generally positioned horizontally. The sleeve bearing wheel shaft and the sleeve and self-aligning bearing worm shaft located above are lubricated using mineral gear oil. The traction sheave shaft of this machine comes with additional, pre-assembled outside bearings (self-aligning bearings) and gear housing with compensating supports to minimize the forces acting on the base plate (fig. 1, pos. 16). Coupling: motors of constructional size B9 have a rigid coupling for connecting the motor, worm shaft, worm wheel, wheel shaft to traction sheave. Motors of constructional size IMB5 must have a flexible coupling (SA14) between brake disc and motor. Motor: The machine can be designed to accommodate various drive systems by appropriately configuring the components - motor variant, speed governor and handwinding wheel or flywheel rim: Pole-changing installations (AC2) – optional special variant Phase-shift controlled installations (ACCV) – optional special variant Frequency-controlled installations (VVVF) Overview of available motor variants and technical data see chapter 3.4. Brake: a two-circuit, spring-operated shoe brake is used. The brake lining is pressed onto the brake disc with pre-set force by two independently operating brake shoes. The brake force setting ensures that the fully loaded car can be stopped with one brake shoe operated only. The brake is released by electrically operated magnetic clamps. A brake release lever for manual operation is attached.



Traction sheave: A two-piece traction sheave is used. The traction sheave hub of the standard version is pressed onto the wheel shaft. The traction sheave rim is screw-connected to the traction sheave hub using hexagon screws. The rim can be removed from the hub through the threads in the traction sheave rim. For the variant of the traction sheave within the shaft SA9, the hub is attached to the shaft front using a cone and a mounting plate including 3 screws (micro-encapsulated with locking washer). The traction sheave has hardened groove flanks (min. 50 HRc). Overspeed governor: A rotary pulse encoder is attached to the motor shaft end as standard. (In front of the handwinding wheel). See fig. 1, pos. 1. Four different digital encoders are available dependent on the inverter and control type. See connection in chapter 4.5 and manufacturer's instructions in chapters 9.3 - 9.5. Tacho-generator and / or pulse encoder (optional SA7.1 – 7.4): For the variant of digital controls a tacho-generator or pulse encoder may be mounted at the worm shaft end, if required. Details on tacho-generator and pulse encoder connection see chapter 8.3 or manufacturer's instructions in chapters 9.4. - 9.5. Environmental conditions: The ambient temperature at the site of location must comply with the standard requirements for machine rooms (humidity, temperature) and thus be maintained between +5° and +40° (in accordance with EN 81). The relative humidity of air shall not exceed 70%.



3.3 Technical data Gear ratio of W263B: 40:1; 41:2; 50:2; 60:2 Circumferential backlash: 0.021 ° - 0.05 ° Permissible load on traction sheave shaft:

for standard versions max. 84 kN for SA4 max. 67 kN for SA 9 max. 76 kN for SA13 max. 126 kN for SA13 + SA4 max. 100 kN

Mass moment of inertia Jrot: 1.520 kgm² Gear with brake disc and coupling as well as traction sheave parts are implied. The mass moment of inertia for motor with handwinding wheel or flywheel rim as well as flywheel rim for AC2 variants are not included. Additional flywheel masses: Depending on the installation requirements flywheel masses are to be provided on the motor shaft of pole-changing motors (AC2). The additional flywheel mass consists of flywheel hub and screw-connected flywheel ring.

Designation Unit Mass moment of inertia Jrot [kgm²] Size ¬ mm 330 360 370 380 400 410 430 455 480 510

Flywheel ring 0.285 0.458 0.533 0.600 0.758 0.900 1.070 1.435 1.750 2.280Flywheel ring

hub 0.057

Total

kgm²

0.342 0.515 0.590 0.657 0.815 0.957 1.127 1.492 1.807 2.337

Machine for constructional size: Unit Jrot B9 0.4075

IMB5 Kgm²

0.4130



Brake data: The brake release magnets of the machine W263B are series-connected.

Braking magnet connection:

Connected load of magnetic clamp: .

Rated voltage: 50 V Current supply Rated current: 1,7 A Fast-response

excitation: 180 V

Protection class: IP65

Withstand voltage: 90 V

Rated load magnetic clamp: 2* 5000 N Max. braking torque : approx. 2* 320 Nm (adjustable) Brake disc diameter: 320 mm Air gap: 0.3 mm (re-adjustable) Release by hand: using mounted-on brake release lever Brake test switches (SA3) for brake control are optionally available. Protection class for explosion-proof variant (SA4): II2G EEx m II T5. The brake linings are asbestos-free.

Motor connection: Terminal connection diagram for motor and magnetic clamps see cover of motor connection box. Connection data see nameplate and chapter 3.4.

Weight: Machine (without motor and traction sheave) 610 kg Order-specific traction sheave ¬ 540–800mm 125 -230 kg Motor variant see nameplate or motor data in chapter 3.4.

kg

The additional flywheel masses are to be added to the individual weight of pole-changing motors (AC2). Weight of standard machine frames: approx. 250 kg Details see chapter 3.6. Illustration of frames.

Flywheel ring size ¬

mm 330 360 370 380 400 410 430 455 480 510

Weight kg 14 20 22 24 28 31 35 42 48 57



Noise level: The airborne noise level in the machine room at 1 m distance is between 68 and 78 dB(A) during normal rating depending on motor size and version.

Standard traction sheave data:

Ø DT N rope * rope Ø Width/mm Weight/kg 540 7 * 13 160 125 640 7 * 13 / 8 * 13 160 150 700 8 * 13 180 185 740 7 * 10 / 7 * 13 160 195 800 7 * 13 160 230

Oil filling : 20 liter mineral gear oil M1 Supply through THYSSENKRUPP AUFZUGSWERKE GmbH



3.4 Motor versions

The following motor versions are available:

1. THYSSEN motor, frequency-controlled (without energy regeneration) < 400 V, protection class IP 23 Ratings: 11,25; 16; 20; 18,5; 27,5 ;36; 39 KW Motor data see 3.4.1 2. THYSSEN motors, frequency-controlled (with energy regeneration)

> 400V, protection class IP 23 Ratings: 33,5; 37; 42 KW Motor data see 3.4.2 3. Standard third-party motors, frequency-controlled

Protection class IP 55 Ratings: 22; 33,5; 50; 65; 75 KW Motor data see 3.4.3 4. Special motor versions

Pole-changing, phase-controlled, frequency-controlled and custom-built motors in constructional size IMB5. The motor data differ in accordance with the installation-specific requirements. Please see motor plate or schematic diagrams in motor terminal box.



3.4.1 Motor data for W263B THYSSEN motors (frequency-controlled)

(without energy regeneration) Page 1

Motor type DTE 132 DTE 140 DTE 140 Version M 003 S 009 L 010 Elevator speed: to 1.75 m/s to 2.0 m/s to 2.5 m/s

Speed range: [U/Min] 1250-14501451-1650 1250-1400 1401-1650 1250-14001401-1650 Moment of inertia: (motor + hand wheel)

[kgm²] 0.055 0.073 0.105

S 5 Operating data with 240 F/h. 50 % ED

Rating: [KW] 11.25 16.0 20 Speed range: [Nm] 86-74 74-65 122-109 109-93 153-137 137-116 Current: [A] 27 37 45 Permissible starting torque: [Nm] 150 125 240 210 300 265 Permissible starting current: [A] 43 65 78 Sinusoidal voltage - motor [V] 340 340 340

Encoder increments: custom-made See chapter 4.5 See chapter 4.5 See chapter 4.5 Weight: [kg] 95 115 135 Length (fully assembled including hand wheel)

[mm] 509 605 605




(without energy regeneration) Page 2

Motor type DTE 180 DTE 180 Version S 601 S 003 Elevator speed: to 2.0 m/s to 2.5 m/s Speed range: [U/Min] 800-150 1250-14001401-1650Moment of inertia: (motor+hand wheel)

[kgm²] 0.23 0.23


Rating: [KW] 18.5 27.5 Speed range: [Nm] 221-188 210-188 188-159 Current: [A] 42 60 Permissible starting torque: [Nm] 350 400 350 Permissible starting current: [A] 67 100 Sinusoidal voltage - motor [V] 340 325

Encoder increments: custom-made See chapter 4.5 See chapter 4.5 Weight: [kg] 190 190 Length (fully assembled including hand wheel)

[mm] 640 640




(with energy regeneration) Page 3

Motor type DTE 180 DTL 180 Version M 001 M 001 Elevator speed: to 2.5 m/s to 2.5 m/s Speed range: [U/Min] 800-150 1250-1400 1401-1650 Moment of inertia: (motor + hand wheel)

[kgm²] 0.33 0.33


Rating: [KW] 36 39 Speed range: [Nm] 236 257 Current: [A] 67 72 Permissible starting torque [Nm] 440 450 Permissible starting current: [A] 125 150 Sinusoidal voltage - motor [V] 380 380

Encoder increments: customer-specification See chapter 4.5 See chapter 4.5 Weight: [kg] 225 230 Length (fully assembled including hand wheel)

[mm] 759 759




(with energy regeneration) Page 1

Motor type DTE 180 DTL 180 DTL 180 Version M 004 M 005 M 100 Elevator speed: to 2.5 m/s to 2.5 m/s to 2.5 m/s Speed range: [U/Min] 1250-14501451-1650 1250-1400 1401-1650 1400-1650 Moment of inertia: (motor + hand wheel)

[kgm²] 0.055 0.073 0.105

S 5 Operating data 240 F/h. 50 % ED

Rating: [KW] 33.5 37 42 Speed range: [Nm] 256-229 229-194 283-252 252-214 286 - 243 Current: [A] 55 59 66 Permissible starting torque: [Nm] 525 460 630 535 630 Permissible starting current: [A] 100 115 135 Sinusoidal voltage - motor [V] 435 440 440

Encoder increments: custom-made See chapter 4.5 See chapter 4.5 See chapter 4.5 Weight: [kg] 225 225 225 Length (fully assembled including hand wheel)

[mm] 700 700 700



3.4.3 Motor data for standardized third-party motors W263B (frequency-controlled)

(without energy regeneration) Page 1 Motor type: 1LG4 186-4AA Structural shape: IMB5 Protection class: IP55 Speed range: [U/Min] 1250 - 1500 Moment of inertia: (motor + hand wheel)

[kgm²] 0.12 + 0.032

S 5 Operating data with 240 F/h. 50 % ED Rating: [KW] 20 Speed range: [Nm] 153 - 127 Current: [A] 45 Starting torque: [Nm]) 260 Starting current: [A] 65 Sinusoidal voltage - motor [V] 330

Encoder increments: custom-made See chapter 4.5 Weight: [kg] 155 Length (fully assembled including hand wheel)

[mm] Kproj. 727



3.4.3 Motor data for standardized third-party motors W263B (frequency-controlled)

(with energy regeneration) Page 2 Motor type: 1LG4 220-4AA 1LA6 253-4AA 1LA6 280-4AA 1LA6 283-4AA Structural shape: IMB5 IMB5 IMB5 IMB5 Protection class: IP55 IP55 IP55 IP55 Speed range: [U/Min] 1250 - 1500 1250 – 1500 1250 – 1500 1250 – 1500 Moment of inertia: (motor + hand wheel)

[kgm²] 0.37 + 0.035 0.79 + 0.032 1.4 + 0.032 1.6 + 0.032

S 5 Operating data with 240 F/h, 50 % ED Rating: [KW] 33.5 50 65 75 Speed range: [Nm] 256 - 213 382 - 318 497 - 414 573 - 477 Current: [A] 56 82 109 125 Starting torque: [Nm]) 440 760 1000 1150 Starting current: [A] 90 145 196 225 Sinusoidal voltage - motor [V] 430 430 430 430

Encoder increments: custom-made See chapter 4.5 See chapter 4.5 See chapter 4.5 See chapter 4.5 Weight: [kg] 265 450 610 660 Length (fully assembled including hand wheel)

[mm] Kproj. 831 Kproj. 924 Kproj. 999 Kproj. 999



3.5 Dimensions

Mac

hine

with

trac

tion

shea

ve

on th

e le

ft; d

raw

n w

ithou

t mot

or

Fig. 2

Show

n w

ith tr

actio

n sh

eave

on

the

le

ft; ri

ght-h

and

vers

ion

mirr

or-in

vert

ed

1232

955

407 15

DT

DT

B

540

160

64

0 1

60 /

180

/ 215

70

0 1

80 /

215

740

160

/ 21

5 80

0 1

60

22

18263 407 190 250

945

Stan

dard

ver

sion

foundation

22

60

105

115frame

max. 654

B =

160

/180→

B

= 2

15

→

Inst

alla

tion

supp

ort



W263B SA 4 (with partition wall and extended wheel shaft)

900

S

150

210

1315

bei B

= 1

60/1

80

bei B

= 2

15

Fig. 3

Sho

wn

with

trac

tion

shea

ve o

n th

e le

ft;

right

han

d ve

rsio

n m

irror

-inve

rted

S =

cen

ter o

f gra

vity

mac

hine

Dra

wn

with

out m

otor



W263B SA 9 (with external bearing and extended traction sheave shaft)

1

1 Traction sheave 2 External bearing 3 Installation support 4 Support

Fig. 4

1075

150

205 233

130

Drawn without motor

3 4

2

3



3.6 Machine frame W263B (optional)

Standard versions Version: 1. Without deflection pulley; for direct rope departure car – counterweight

or 2:1 suspension. Version see table 1, illustration see fig. 5. 2. With deflection pulley; a set of screw connections is available to fasten

the machine incl. rolling or sleeve bearings to the machine base frame with deflection pulley ¬ 540 mm. The machine base frame is available in left or right-hand design depending on the machine's traction sheave and deflection pulley position. Versions shown in fig. 6.

Mounting The machine base frames are mounted in the machine room using impact sound-proof isolation elements. The elements used depend on the respective type of installation: a) Rubber block 100 x 100 x 50 high without base.

To be used for mounting the machine on the 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 for mounting the machine on the plaster floor with the base casted in. (Coating thickness = 60 mm).

Note: the individual rubber elements should be loaded between 7000 and 12 000 N / rubber element.

Frame mounting The pulley supports of frames with deflection pulley are delivered separately. Arrange the machine frame and the isolation elements on concrete supports in accordance with the drawings. See to it that the pulley supports are mounted on the proper side. Attach deflection pulley axle to rope pulleys and secure with axle holder. Lift machine onto frame using a lifting device. a) Frame without deflection pulley: the traction sheave must be located within the frame profiles. Align machine to frame center. Fig.5 b) Frame with deflection pulley: the traction sheave must be on the deflection pulley side. Observe hole pattern when adjusting the machine to the respective ASL (parallel distance of ropes at the point of rope departure). Screw-connect machine and frame. The traction sheave and the deflection pulley must be in vertical line. Place enclosed plates under the base, if required. The machine housing must be arranged perfectly horizontal. Tighten screws with tightening torque. See chapter 9.1.



Align rope departure and rope pulley and/or car and counterweight anchorage. Explanation of abbreviations: ASL = parallel rope distance at point of rope departure ¬DT = diameter of traction sheave ¬SR = diameter of deflection pulley Note: traction sheave mounted on left-hand side is referred to as left-hand version. Version with traction sheave mounted on right-hand side is referred to accordingly.



Machine frame without rope pulley Weight of frame approx. 90 kg Position of isolation elements see layout drawing. Number and position of isolation elements depend on

Number of isolation element

100 4 3 2 2

80 3 2 2 1

60 3 2 2 1

Static shaft load Ft [kN] / number of elements per support point

40 2 1 1 1

Fig. 5

III III IV

Machine/frame L

AY frame L

External bearing center

Machine center

Wall-mountedcabinet



Machine frame with rope pulley

Fig. 6

Frame R Machine L

Rubber element60 309 01 14 0

AY frame 60 330 10 10 2

AY pulley block

Machine center

External bearing center



Possible arrangement W263B

Planning dimensions machine frame

Bild 6

Fig. 7

Rope departure car - counterweight Traction sheave version DT

Unit ASLmin ASLmax

540 700 640 800 700 860 740 900 800

mm 960

1350

Frame L Machine L

Frame L Machine R

Frame R Machine R

Isolation elements

Static shaft load P (kN)

Number and position of isolation elements



3.7 Lubrication

Lubricant Oil change interval Quantity Mineral gear oil M1 For the first time after 3 years,

afterwards every 3 years 20 liter

Oil change Before you change oil run the gear until it is warmed to working

temperature (approx. 35°C) Attention: there is the risk of scalding! Discharge gear oil by the plug at the oil drain. Discharge waste oil in collecting pan provided. Close gear oil filler cap using a sealing tape and check for proper sealing. Remove cover and pour in recommended quantity of lubricator in the

special filling hole at the machine housing . Check oil level at oil gauge (see illustration below) Note date of next oil change in name plate at gear housing and

close filling hole. Never mix different types of oil. Oil must not be allowed to flow in the groundwater. Waste oil as well as oily, dirty and greasy cleaning rags must be disposed of in accordance with the local rules and regulations. Only use type of lubricants released and recommended by THYSSENKRUPP AUFZUGSWERKE GmbH . Note: THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable for any damages caused by non-released lubricants.

Oil level check Pull out gauge and check oil level. The oil level should lie in between the markings.

Oil level gauge

Max. Min.

Markings

Fig. 8 Oil level



3.8 Name plate

Two different name plates are available: 1. THYSSENKRUPP AUFZUGSWERKE GmbH

2. Lift Equip

1 Machine type : Gear ratio : 9

2 Max. shaft load : Weight without motor : 10

3 Serial No.: Year of construction: 11

4 Lubricant: Type of oil: 12

5 Oil quantity: Next oil change: 13

6 Brake magnet No.: Protection class brake magnet connection: 14

7 Tightening torque magnet: Tightening torque brake magnet : 15

8 Order No. Customer order No.: 16

17 Power supply brake magnet :

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

17

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

17

OPERATING MANUAL 4. MOUNTING OF MACHINE


4.1 Mounting of machine in machine room

The machine is delivered assembled on the machine frame. The frame is assembled on supports, brackets, concrete base or machine room floor in accordance with the customer-specific requirements. To comply with the requirements for noise reduction / structure-borne noise transmission, isolation elements shall be inserted between the frame supports and the enclosed isolation elements. The number of rubber elements depends on the overall weight load. The individual rubber elements should be loaded between 7000 and 12 000 N / rubber element. Position and arrangement of the rubber elements see layout drawing. Note: the rubber elements are to be arranged in such a way that the load is distributed equally. Also applies to cars suspended on the diverter pulley side. The wooden base of the isolation elements must be casted in plaster floor (covering thickness approx. 80mm). How to attach for diagonal or vertical rope departure (SA1) The forces acting in the direction of rope departure must be considered in these cases. How to align the machine The machine shall be assembled in accordance with the layout drawing. Align the rope departure of the traction sheave in accordance with the drawing so that it is in vertical line with the car anchorage and the car rope pulley. The machine shall be arranged horizontally aligned on the rubber elements. Use metal or wooden plates to ensure that the base is perfectly horizontal. SA9 Machine with extended worm wheel shaft and external bearing

Attention: when installing machines with external bearings

please verify that

the pedestal supports are properly attached and secured the worm wheel shaft is horizontally aligned the traction sheave shaft bearings of machine and external bearings are

properly aligned.



4.2 Mounting of rope guard for traction sheave Loosen the bearing setscrews and turn rope guard support angle towards traction sheave. Screw-connect rope guard and rope guard support using enclosed screws. Turn the rope guard supports in such a way that the distance between rope and rope guards is as small as possible on the traction sheave side where the ropes enter and leave. (1 -2 mm). In case of diagonal rope departure re-adapt position of rope guards to changed rope direction. Note: align rope guards; then tighten the fastening screws at the rope guard support in accordance with recommended tightening torque in the annex. Attention: If the ropes enter the traction sheave at any angle above the horizontal up to a maximum of 90° (e.g. machine arranged on bottom / top beside) an additional rope guard is required to avoid the penetration of objects between ropes and pulleys. If the ropes enter the traction sheave at a protected area within the machine frame, function "protection against bodily injury" is not necessary.

Fig. 9

max. 1 - 2 mm

1 Rope guard support 4 External bearing 2 Rope guard support 5 Bearing setscrews 3 Supporting angle 6 External bearing console

4

5

2

1

2

1

3

6

Vertical rope departure



4.3 Motor connection

How to connect the motor:

Observe terminal diagram at the cover of the motor connection box as well as the respective local requirements and regulations. Terminal diagrams for connection of standard motors and pulse encoders in accordance with the requirements / regulations please see the following chapters. Please also see special notes and manufacturer's instructions in chapters 9... Motor data see chapter 3.4. Attention: please observe that terminals 16 and 9 must be bridged in case of phase-controlled motors Isostop 12 / 16M (Isostop 25M). Disregard may cause deterioration of the circuit board (brake board). (See 4.4.1 – 4.4.3)



4.4. Terminal plan for machine motor and magnetic clamps:

Fig. 11 Motor connection

Magnetic clamp and thermistor terminals

Motor terminals Fig. 10



Attention: observe bridge connection!

4.4.1 Motor connection acc. to BV 6531 -09

for pole-changing three-phase motors

Fig. 12



Attention: observe bridge connection!

4.4.2 Motor connection acc. to BV 6531 - 14

for phase-controlled three-phase motors with DC brake winding

Fig. 13



4.4.3 Bridge connection for motor terminals

Applies to phase-controlled motors in combination with Isostop 12M, 16M and 25M controls

The machine is delivered with the motor terminals 16 - 9 bridged.

In case only one external supply line is provided, terminals 16 - 9 must remain bridged! In case terminals 16 and 9 have an own supply line each, the bridge is to be removed!

Attention: Disregard may cause deterioration of the circuit board (brake board)!

Fig.14



4.5 Pulse encoder connection

4.5.1 Encoder mounted at motor The encoder type depends on the control type

1. TTL for THYSSEN control CPI for v < 1.5 m/s with 2 x 1024 pulses, part number 9950 000 6021 for v = 1.5 m/s with 2 x 4096 pulses, part number 9950 000 6022

Use cable of 10 m length and SUB-D tab with screw locking.

Connector assignment Electrical data: Connection Pin Color Power supply 5 V DC Minus 7 white Power consump.: max. 60 mA Plus 9 brown Output: push-pull Channel A 2 green Load max.: 40 mA Channel B 3 yellow Signal level at 20 mA: H >2,5 VDC Zero pulse 5 gray L < 1,2 VDC Channel A inv. 1 red Pulse frequency max.: 200 kHz Channel B inv. 4 black Circuit protection: no Zero pulse inv. 6 violet Shield 8+conductively connected encoder and connector housing

View connector side

Please observe manufacturer's instructions in chapters 9.3 – 9.5.

2. HTL for third-party controls or inverters with 2 x 64 pulses, part number 00 990 12 03 0

Connection of insulated cable of 10 m length with end sleeves. Connector assignment Electrical data:

Connection Pin Color Power supply 15V DC

Channel A 6 gray Power consump. +15V: = 90 mA Channel B 5 pink Power consump. -15V: = 10 mA Channel C 3 green Outputs: A channel 64 I/U Mass 4 yellow B channel 64 I/U Plus 15 V 1 brown C channel 128 I/U Minus 15 V 2 white Shield open

Please note manufacturer's instructions in chapters 9.3 – 9.5



3. HTL for third-party controls or inverters with 2 x 1024 pulses, part number 00 990 16 03 0

Connection of insulated cable of 10 m length with end sleeves. Connection assignment Electrical data: Connection Color Supply voltage 15V DC Channel A green Power consump.: max.60 mA

Channel B yellow Channels: A, B, N, ABN inv. Channel N gray Output: HTL differential driver Channel A inv. red Load: max. 40 mA Channel B inv. black Level: at 20 mA Channel N inv. violet H > UB – 2,5 VDC Mass yellow L > 2,5 VDC Plus 15 V brown Pulse frequency: max. 200 kHz Minus white Circuit protection: yes Shield strand Early warning output: NPN OC, 10 mA Early warning output: pink Umax. = 30 VDC Cable length: max. 10 m Contact manufacturer for longer cables.


4. Sine, cosine for third-party controls or inverters

with 2 x 1024 pulses, part number 00 990 19 03 0 Connection of insulated cable of 10 m length with end sleeves.

Connection assignment Electrical data: Connection Color Supply voltage: 5V DC

Channel +A green Power consump. max. 100 mA without Channel +B gray Load Channel +N black Channels / output: sine, cosine, N Channel - A yellow Output load: min 120 Ohm Channel - B pink Terminating resistor between + and Channel - N violet - outputs. Plus 5 V brown Level: 1 Vss +/- 25 % Minus white Max.oper.frequency. (-3dB): 100 kHz Shield strand Circuit protection: no

Early warning output: conductive under load Cable length: max. 150m at <260pF/m General rating: acc. to DIN VDE 0160




4.5.2 Tacho-generator / pulse encoder mounted at worm shaft (SA7)

(Optional) Drive with mounted-on tacho-generator and pulse encoder:

Contact assignment of flange-mounted encoder socket for pulse encoders HG 90 THY 1 024 and HG 90 THY 4 096

Note: further details, data, illustrations and installation instructions see chapter 8.3 Special versions. Connecting cable of 10 m length between tacho-generator / pulse encoder and inverter is optionally available. (12-pole circular plug for SUB-D 9 tab with screw locking) available (material number 6596 000 5961).

K1 __

K1

K2 ___

K2

K0 ___ K0

Encoder: pulses: HG 90 THY 1 024 HG 90 THY 4 096



4.6 Connection diagram W263B

for

SA3

and

expl

osio

n-pr

oof-

vers

ions

onl

y

Bra

ke te

st s

witc

h

Bra

ke m

agne

t W

indi

ng

Mot

or

Puls

e en

code

r Te

mpe

ratu

re

mon

itorin

g

Fig. 15

OPERATING MANUAL 5. PUTTING INTO OPERATION


5.1 Putting the machine into operation Before you start putting the machine into service, the following works are to be performed: Remove safety, accessory and installation tools from danger zone. Check assembly of machine, frame, base and rope departure. Oil drain and oil-level gauge mounted and filling hole closed with cap. Check gear oil level. External bearings properly pre-lubricated (only with SA 9). Check fastening of machine and external bearing for proper fastening. Tighten screws as recommended in table tightening torque in the annex. Check brake shoes, stroke and setting. Check setting and function of brake test switches for SA3 version. Brake test switch performed with one brake shoe active. Check manual brake release for proper functioning. Check distance between rope fixing beam and traction sheave / ropes. Check supply terminals, earthing of motor, ventilation and brake magnet

for correct connection and fusing. Check special mountings (tacho generator / pulse encoder mounted and

checked properly). Visibly glue direction arrow (up/down) for respective travel direction at

motor (adjacent to handwinding wheel) Warning: before you start putting the machine into service, fill oil in the upper oil pockets. Disregard may cause deterioration of the bearings! Remove the upper cover and fill approx. 0.2 liter gear oil M1 into the left and right oilpan above the sleeve bearings using a hopper. Before the machine is started, the filling hole must be closed through cap and sealing ring. Attention: machine W263B shall not be run in creeping operation for more than 40 seconds. This particularly applies to pole-changing, low-speed motors. There is the risk that the sleeve bearings of the worm wheel and worm shaft will seize.

OPERATING MANUAL 6. SERVICING


6.1 Servicing of machine W263B

Servicing interval: servicing of the machine should be carried out at least once a year, preferably in the course of the general lift servicing. Note: installation and servicing works shall only be carried out by trained and qualified personnel.

These persons must know and observe the respective regulations and requirements for lift installations as well as the accident prevention regulations.

For further information concerning proceeding, adjustment and data see chapter: ⇓

Check oil level and re-fill, if required Change oil (see chapter 2.5) 2.5 Check brake shoes for wear; lining must be at least 3 mm Check brake setting; brake stroke should be between

0.3 mm + 0.1 mm. 7.3

Check armature base plate setting (pre-tension) 7.3 Check braking deceleration 7.2

Check worm toothing for wear Check flank clearance between worm shaft and worm wheel

(max. 2.5 mm) 6.1

Check traction sheave groove profile for damage and wear Check screws for traction sheave fastening for correct tightening 9.1 Check grooves of rope pulleys for damage and wear Check motor bearings for wear (noise, backlash) Check SA9 oil filling (F1*) and groove nut at external bearing. Re-

fill or re-tighten, if required.

Check electrical connections for proper functioning and test for

safety

Check protective and safety equipment and test for proper functioning and adjustment

Lubricant Interval Quantity Mineral gear oil M1 * For the first time after 3

years, then every 3 years 20 liter

* Supplied by ThyssenKrupp Aufzugswerke GmbH

OPERATING MANUAL 6. SERVICING


6.2 Checking of flank clearance

The flank clearance of the worm drive between worm wheel and worm shaft is increased by wear. As soon as the wear limit of 2.5 mm is reached, safe operation of the machine is no longer ensured. Worm wheel and worm shaft must be replaced or the machine exchanged. Measuring method: Remove load from machine; (discard ropes from traction sheave). Start measuring with the brake engaged. Place wooden wedge between

housing and brake disc. Provide stop at traction sheave, e.g. screw clamp. Determine radius (M) and mark measuring point Radius ( r ) for W263B = 221 mm Install dial gauge and magnetic holder at machine housing; adjust to

measuring point (M). Rotate traction sheave back and forth by hand until dial gauge starts

working. Rotate traction sheave to and fro until a stop is felt. The tooth flanks

should be loaded with approx. 20 - 50 N. Read dial gauge amplitude (ME). Calculate flank clearance using below formula. Measure at three points at least!

M = radius

ME = result r = radius - worm wheel in mm

Flank clearance = ME * r M

Fig. 16

Messuhr Traction sheave

Dial gauge

Worm wheel

OPERATING MANUAL 7. MAINTENANCE


7.1 Replacing of brake shoes

Note: if the residual line thickness is less than 3 mm or if the brake linings are defective, the necessary deceleration cannot be reached; the brake linings are to be replaced. Before you start working secure counterweight and car against

uncontrolled movements; disconnect power supply. Remove one brake shoe; attach brake linkages and armature base

plates to new brake shoe. Install pre-assembled brake shoe and align to brake disc center.

Brake linkages shall be aligned. Adjust brake shoe stroke. The brake shoe stroke read in brake disc

center shall be 0.3 mm. Pre-tension springs by approx. 25 mm. For second brake shoe proceed accordingly. When the brake shoes are replaced, move the car in emergency

recall operation and check whether the two brake shoes will be disengaged evenly.

Check stroke distance and re-adjust, if required.

7.2 Setting of brake deceleration

The brake is to be set 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.

The braking torque is to be set for each lift type individually and at both brake shoes evenly.

Machine with

flywheel mass Machine with

handwinding wheel = = = = >

v m/s 0,63 1,25 0,63 1,25 1,25 -a (full -down) m/s² 0,2 0,3 0,3 0,4 0,50

-a (empty-up) m/s² 0,4 0,5 0,5 0,6 0,75 Table braking deceleration values

Note: check and re-adjust the brake test switches SA3 every time you

adjust the brake. See brake test switch mounting SA3.



7.3 Setting of brake shoe stroke and armature base plate

The brake shoes, the pre-tension and the armature base plate are to be checked before the machine is put into service. The brake shoe is delivered with the stroke adjusted to 0.3 mm + 0.1 mm (measured at the height of the brake disc center). When the brakes release, the brake shoes must work with the same stroke. The working stroke is adjusted by loosening and then tightening the counternut at the armature base plate. The rubber plate between armature base plate and brake shoe may be flat and the pre-tension too low after some time of use. Restore pretension by placing spacers between armature base plate and brake shoes. To check the pretension, turn the anchor bolt and observe whether the armature base plate easily slides.

1 Magnetic clamp 2 Cover ring 3 Armature base plate 4 Rubber disc 5 Anchor bolt 6 Counternut 7 Brake release lever 8 Brake disc 9 Working stroke shoes 0.3mm

Note: check and re-adjust the brake test switches (SA3) every time you adjust the brake. See SA3 Brake test circuit chapter 8.2

7

9 = 0.3 mm

1 3

5

8

6

2 4

Fig.17 Brake setting



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 hoist. Remove rope guard; remove fastening screws at external

bearing console Unscrew screws at traction sheave hub and screw in pressure-test

thread at traction sheave. Remove traction sheave from shaft by tightening the screws

uniformly and evenly. Attention: support worm wheel shaft before you remove the external bearing (self-aligning bearing!); remove external bearing; put traction sheave down using lifting device.

Assembly: Clean hub locating surface and traction sheave holes;

never grease or oil locating surfaces. Carefully put traction sheave on hub fit using lifting device. Loosely screw fastening screws and bring holes in line. Fit traction sheave to hub by tightening the screws in several

operations. Screw in hexagon screws, detent edged washers and nuts;

tighten and bring to required torque in several operations using a torque wrench.

Screw in new lock nut. Attention: the traction sheave may work loose if assembled

improperly. Observe screw strength and tightening torque!

See table 9.1. in annex.



7.5 Replacing of motor

Disassembly :

Provide new motor; check technical data.

Switch off power supply; secure car and counterweight. Securely fasten motor on lifting device. Disconnect electrical terminals and connecting lines to motor. (Motor and magnetic clamp connections) Remove nuts at brake and coupling disc. For motors of constructional shape B5 (SA14) see 9.2 Flexible coupling for B5 motors. Remove nuts at motor flange. Loosen set screws, carefully remove motor; put motor down.

Assembly : Secure motor at lifting device and secure. Lift motor using lifting device; bring motor coupling and brake disc in line. The mounting holes and the screws must be aligned. Push motor and coupling onto screws at shaft and brake disc. Tighten nuts uniformly in several operations (tightening torque see 9.1. in annex).

Note: For motors of constructional shape B5 (SA14) see 9.2 Flexible coupling for B5 motors.



7.6 Replacing of external bearing Illustration: External bearing arranged at wheel shaft end (without rope guard mounting)

Note: the different versions (standard, SA4/SA9/SA13) have different bearing dimensions and thus also different setting and test values for the min. admissible radial clearance for the installed bearing. For values see end of chapter.

Fig. 18

1 Self-aligning bearing 9 Grease chamber 2 Hub nut 10 Sealing ring (felt) 3 Adapter sleeve 11 Inner bearing ring 4 Bearing cover 12 Outer bearing ring 5 Traction sheave shaft 13 Housing bottom 6 Locking plate 14 Console 7 Spacer rings 15 Hexagon screw 8 Housing top

15

2

1

8

7

9

6

5

4

3

10

12

13

11

14

Bearing clearance



Disassembly Put base below wheel shaft or support using lifting device (pedestal

support with two-point bearing) Remove traction sheave at shaft end (only for SA9) Remove outer bearing console (not with SA9) Remove bearing housing top Remove grease and disassemble the two spacer rings Turn bent tooth of toothed lock washer in hub of hub nut Remove hub nut using sickle spanner A135-145 or A 205 - 220 (SA9) Loosen adapter sleeve by manual impacts (see to it that bearing housing

is not be damaged!) Push housing half and bearing towards shaft end and remove

Fig.: external bearing without bearing half top and traction sheave Bearing with support in shaft center before traction sheave (SA9)

1 Bearing housing bottom 2 Spacer rings 3 Sliding pedestal bearing 4 Toothed lock washer 5 Adapter sleeve 6 Traction sheave shaft

1 2 3 4 5 6

Fig. 19



Assembly: Note: only slightly grease the clean bearing hole and the fitting surface of shaft and adapter sleeve. There is the risk that the bearing spacer ring and adapter sleeve start to slightly move during operation.

Push rope guard fastening onto shaft. (Observe mounting direction!) Align flange side of adapter sleeve towards machine and push onto wheel

shaft end. Push bearing and hub nut onto adapter sleeve. Slightly tighten hub nut

using hook wrench (A 120 -130 or A 180 – 195 with SA9) and pretension bearing.

Check distance between bearing and traction sheave hub or shaft end (SA9). Attach the bearing 233 mm from shaft end. See fig. 21.

Re-adjust distance, if required. Slightly move adapter sleeve on shaft by manual impacts.

Remove groove nut; insert locking plate and screw on groove nut. Tighten groove nut using hook wrench until the required radial clearance

at both roller body rows is reached. See description „radial clearance test“ in this chapter.

Secure setting by turning down a tooth of the toothed lock washer into the groove of the groove nut.

Insert felt sealing into outer ring grooves at housing bottom of pedestal bearing.

Lift housing bottom and join to roller bearings from below. Push console under housing bottom; align mounting holes and loosely

screw-connect housing bottom and console. Join spacer rings into housing bottom before the self-aligning bearing. Insert felt sealing; oil and align to outer ring grooves in housing top. Grease self-aligning bearing using grease F1. Place housing top of bearing onto bottom part and screw-connect. Remove traction sheave support; check whether the traction sheave is

perfectly horizontal and place plates under support or outside bearing, if required. With SA9 proceed as follows: mount the traction sheave onto shaft end and secure by screw-connecting the curved washer using new micro-encapsulated screws; then check traction sheave.

Tighten screw-connection between console and bearing housing; mount traction sheave rope guard and adjust, if required.

Note: in case of diagonal rope departure (SA1), align console and bearing housing; the bearing housing must rest on the console flange at the rope departure side.



External bearing for standard and SA13 variants Illustration external bearing

Fig. 20

1 Console 6 Traction sheave rim 2 Housing top 7 Rope guard support 3 Protective cover 8 Traction sheave hub 4 Housing top 9 Wheel shaft 5 Housing top 10 Rope guard support

X1 X2

4

7

8

9

10

3

1

2

6

5

b

Variant b X1 X2 Standard/SA13 SA4/SA4+SA13 160/180 152 75

Standard/SA13 SA4/SA4+SA13 215 152 92,5



Supporting bearing for variant SA9

150

205

233

Fig. 21

1 Self-aligning bearing 5 Wheel shaft SA 9 2 Disc 6 Gear housing 3 Traction sheave 7 Motor flange 4 Supporting bearing

2

5 6

1

3 4

7



Radial clearance control at outer self-aligning bearing Control the radial clearance at both roller body rows using a feeler gauge with feelers of unequal thickness. Control the radial clearance before, during and after the bearing is mounted. The clearance between outer bearing ring and unloaded roller is to be controlled (fig.. 22) Turn the bearing several times before you start controlling; the rollers will be distributed evenly at the bearing circumference. Side offset between outer and inner bearing can only be excluded, if the control values of the two roller rows are the same. Determine permissible bearing clearance on the basis of the bearing hole and the radial clearance group. The radial clearance group marked on the respective outer bearing ring depends on the operating conditions. Group C0 is to be applied for the external bearing. In case any other group is used, THYSSENKRUPP Aufzugswerke cannot be hold liable! Check clearance values before the bearing is mounted: Check values for permissible min. clearance of mounted-in bearings Radial clearance control using feeler gauge

¬ to 100 mm standard, SA4 and 13

¬ to 125 mm with SA9

Radial clearance group

min. max. min. max. C0 [mm] 0,08 0,11 0,12 0,16

Radial clearance group

¬ to 100 mm standard and SA4

¬ to 125 mm to SA9

C0 [mm] 0,035 0,055

Fig. 22

OPERATING MANUAL 8. SPECIAL VERSIONS


8.1 Special versions SA (optional)

(Accessories for particular applications)

Overview: SA 1 with bearing bushes mounted 90° rotated for horizontal rope departure

SA 2 extended worm wheel for extra handwinding / flywheel rim on gear side

SA 3* with brake monitoring SA 4 wall bearing with vapor-proof partition wall and extended worm

wheel shaft for explosion / partly explosion-proof variants SA 7.1* with motor-tachogenerator (1 collector) SA 7.2* with motor-tachogenerator (2 collectors) SA 7.3*with motor-tachogenerator / pulse encoder SA 7.4* with pulse encoder a) analog; d) digital

SA 9 with traction sheave in shaft - extended worm wheel shaft with pedestal bearing support

SA 11 with oil drain on side SA 12 with extra terminal box for intermediate clamping of brake magnets

(for motors without terminal box) SA 14 with flexible coupling for motors of constructional shape B5 SA 15 with (Ex) sG4 - proof brake magnets

The special versions marked * will be delivered separately for reasons of possible transport damage.

SA3 Brake test switches for monitoring the brake shoe condition (released - closed) and the brake lining wear.

Note: after testing each brake shoe separately, the brake test switches must be controlled and re-adjusted, if required.

Details see 8.2 SA3 Brake monitoring circuit SA4 Wall bearings with vapor-proof partition wall and extended worm wheel

shaft as partly explosion-proof version. A pedestal bearing under the shaft end supports the wheel shaft (like standard version). For mounting and operation of this variant see enclosed supplementary operating manual (material No. 60 000 20 86 0).

SA7.1-SA7.4 The pulse encoder and the tachogenerator are mounted at the worm shaft end opposite the motor. The pulse encoder and the tachogenerator are delivered as component parts for reasons of transport damage.

SA9 Extended worm wheel shaft. Partly explosion-proof version through

partition between drive and shaft by vapor-proof bearing bracket. The worm wheel shaft is on a bearing support. The traction sheave is pressed onto the conical end and secured by micro-encapsulated screws.



SA11 Oil drain with extension for access to machine in case of space problems. SA12 Additional terminal box for intermediate clamping of the brake magnets

(for motors without terminal box). SA14 Flexible coupling between brake disc and motor coupling for compensating

possible misalignment. Description of coupling see annex 9.2 Flexible coupling for motor of constructional shape B5.



8.2 SA3 Brake monitoring circuit

8.2.1 Variant designed for THYSSEN controls TCI ; TCM

The brake monitoring circuit is designed for monitoring the brake shoes. It prevents motor operation with the brake partly or fully closed. Brake lining wear is detected at an early stage. Switches (sensors) control the brake shoes for closed, open or wear condition. For better evaluation the run signal is used. As soon as the destination is reached, the monitoring circuit disconnects the drive. Failure etc. is displayed via light-emitting diodes on the sensors, on the control cabinet or disconnection of the drive. If a Teleservice device is connected, the error will be shown on the display.

Prerequisites for retrofitting: The setting screws must be fastened at the brake shoes surfaces, if available. If such surfaces are not available, the brake shoes must be replaced or a brake shoe mounting provided for that purpose.

Assembly:

1. Provide 2 lines (0.3*0.75mm² with PVC sheath) for direct connection between sensors and control, if they not enclosed. Connect the sensors.

2. Machines of W line ( W149; W191; W263; W332 ) Attach sensors at pressure rod for brake spring using angles. See fig. 25

3. Screw counternuts on enclosed hexagon screws and turn in brake shoe threads. The plunger-operated switch shall not contact the opposite setting screw.

Setting : Adjust brake shoe stroke before you start setting the sensors! Description see chapter 7.3

4. Switch on electrical emergency switch and elevator control. 5. Reset adjusting screw until LED flickers.

6. Slowly turn back screw until LED goes out. 7. Reset adjusting screw by quarter turn (approx. 0.3mm) and secure. LED flickers continuously.

8. Connect motor; release and close brakes. Check whether the LEDs alternate between brake applied and disengaged.



8.2.2 Variant SA3 BRC Variant designed for third-party and older controls (not applicable to TCI, TCM ! ) The brake monitoring circuit BRC is a retrofit unit for the brake shoe control. It evaluates and transmits the sensor signals to the secondary control electronics. The drive will be disconnected automatically when the set value is reached. The sensors and the BRC brake monitoring in the control cabinet have LEDs. If a Teleservice is available, errors will be shown on the display.

Fig. 23 Connection for brake monitoring BRC Applies to third-party and older controls (not TCI; not TCM) Connections :

L1 a.N for power connection 230 V W for make contact from W contactor B1 sensor 1 with voltage supply 24V/0V B2 sensor 2 with voltage supply 24V/0V K1 break contact for evaluation (e.g. connection to safety circuit)

Teles. for connection to ThyssenKrupp Teleservice device (remote elevator monitoring)

Cable length as necessary (approx. 5 m as standard) Cable 3*0.75 mm² With PVC sheat

Sensors attached to machine and adjusted to respective surface

Brake monitoring BRC K1 Teles. fault display

Make contact Run contactor

Teleservice K1 interrupting contact connection in safety circuit



Fig. 24 Connection sensors Switch mounting at W machines SA3

Fig. 25

1 Motor 6 Spring-operated tensioning screw

2 Test switch (sensor) 7 Brake shoes 3 Plunger rod 8 Brake disc 4 Brake release lever 9 Machine 5 Pressure spring 10 Adjusting screw

1 2 4 5

7

8

6

10 9

3

brown blue 0V brown 24 V

black black B2

blue 0V



8.3 SA7 tachogenerator and pulse encoder mounting

(Shown W 263 B)

Fig. 26 1 Bearing cover 5 Coupling 2 Disc 6 Flange 3 Bolt 7 Tachogenerator 4 Shaft sealing ring 8 Pulse encoder

Technical data: SA 7.1 00 990 04 03 0 tachogenerator RE.0444 1 x 60 V / 1000 U/min analog DC Imax 0,18 A Nmax 5000 U/min IP 44 SA 7.2 65 340 10 01 0 tachogenerator RE.0444 2 x 60 V / 1000 U/min Imax 2 x 0,09 A Nmax 5000 U/min IP 44 SA 7.3 66 300 01 67 0 tachogenerator with pulse encoder 1 x 60 V / 1000 U/min 2 x 120 Imp/U Imax 0,06 A Nmax 9000 U/min IP 55 voltage supply: 11 – 26 V DC SA 7.4 a 00 990 10 03 0 pulse encoder analog 2 x 1000 pulses Imax 0,15 A Nmax 9000 U/min IP 65 voltage supply: 10 – 30 V DC

d 69 700 01 02 6 pulse encoder digital 2 x 60pulses sampling frequency = 150 kHz; push-pull: 10 – 30 V DC

channel A and B 90° el. offset Nmax 12000 U/min I P 65 (delayed)

Note: values stated are dependent on the respective manufacturer. Exact data please see name plate.

1 2 3 4 5 6 7 8

5 mm ± 1

Screw M6x16 (micro-encapsulated)



SA7 tachogenerator and pulse encoder mounting

Bearing cover to be replaced for reconstruction only Attention; before you start retrofitting works, remove load from machine ! (Secure car and counterweight)

Unscrew rear bearing cover (pos.1) at machine and unscrew disc (pos. 2) at worm wheel end.

Push bolt (pos. 3/4) into new disc; push disc and bolt (pos.3/4) to worm wheel center and screw. Check radial run-out of bolt (max. 0.05 mm) using dial gauge. If the max. value is exceeded, re-align disc.

Tighten screws in accordance with the permissible tightening torque. ⇒ See 9. Annex - Table tightening torque. Loosely screw new bearing cover (pos.1) to machine. Align bearing cover to bolt center (pos. 3) using centering sleeve;

tighten screws with admissible tightening torque. Grease shaft sealing ring (pos.4) with multi-purpose grease F1,

carefully push over bolt and press into bearing cover. Observe mounting position!

⇒ See illustration, fig. 4

Tachogenerator / pulse encoder installation (delivered disassembled as component parts for reasons of transport damage) Remove transport aids at bearing cover (not applicable

for re-construction jobs). Control bolt for true running (max. 0.05 mm) and align, if necessary. Push coupling (pos.5) onto bolt; screw-connect.

Observe measure 5mm ± 1. Screw flange (pos.6) to bearing cover using micro-encapsulated

screws. Attention: never use the screw several times!. Push drive shaft of tachogenerator / pulse encoder in coupling holes

and secure. Screw-connect tachogenerator / pulse encoder and flange.

Connection see manufacturer's instructions in annex 9.4. Note: observe safety, installation and connection instructions in operating manual and manufacturer's connection diagram! ⇒ See annex 9.3

Fastening screws for :

Bearing cover (pos.1) Disc (pos.2) 150 Nm 60 Nm

Table tightening torque Note: the centering sleeve to align the bearing cover alignment

is service equipment of ThyssenKrupp; obtainable on order at Lift Equip GmbH.

OPERATING MANUAL 9. ANNEX


9.1 Tightening torque - mechanical strength for mounting parts of machine W 263B

Attention: to be observed when performing any work on the machine or replacing any parts!

DIN/ Tight. Strength- ISO torque Nm Disc at worm wheel shaft Hexagon screw M16 * 50 micro-encapsulated 8.8 4762 180 Detent edged washer SK M16 Motor at machine Set screw M16FO * 40 5.6 939 90 Hexagon nut M16 8 7042 90 Motor shaft at coupling brake disc Hexagon adapter screw M16 * 60 8.8 609 150 Hexagon nut M16 8 7042 150 Brake disc at worm wheel Locking screw M10 * 30 8.8 912 40 Retaining ring A10 127 Retaining screw at brake shoe bolt Set screw M16 * 16 4017 Hexagon screw M8 * 16 8.8 4014 Bearing bracket at housing Cheese head screw M10 * 30 8.8 190 Cheese head screw M10 * 60 (rope guard) 8.8 190 Retaining ring A10 127 Brake magnet at housing Hexagon screw M16 * 150 8.8 4014 150 Hexagon nut M16 10511 150 Rear bearing cover at housing Retaining screw M16 * 55 8.8 4014 100



9.2 Annex Flexible coupling for B5 motors Page 1



9.2 Annex Flexible coupling for B5 motors Page 2



9.3 Manufacturer's instructions pulse encoder

Pulse encoder Material No.: 9950 000 6021 / 6022



Pulse encoder Material No.: 00 990 12 03 0









9.4 Manufacturer's instructions for SA 7 tacho-generators / pulse encoders General: Assembly

Check tacho-generator and motor for alignment. Use balanced coupling only. Service: Every 2000 operating hours. Brushes Check the brushes for freely rotating in the housing. The brush supports must be free of dust (do not use compressed-air cleaner

since the brushes may be oily. Replace when the brushes are 5 to 6 mm long. The new brushes will be adapted to the collector form. The exact surface contact will be reached after 10 operating hours. If the brushes must be disassembled, mark position to be able to re-install

them accordingly. Collector Do not remove the patina below the brush path. Slightly drench rag in alcohol and clean, if required. Never use abrasives. Lubrication The dynamo has sealed bearings with life-time lubrication.

Further lubrication not required. Important note We urgently advise not to remove the rotor from the stator. The dynamo must always be re-calibrated after disassembly.



SA 7.1 Tachogenerator RE.0444 Part No.: 00 990 04 03 0

Connection



SA 7.2 Tacho-generator RE.0444 N2B Part No.: 65 340 10 01 0

2 windings voltage: 60 V / 1000 U/Min Connection: Direction of rotation (seen from drive side: clock-wise anti-clockwise Connection 1 yellow wire - + Green wire + - Connection 2white wire - +

blue wire + - Installation-specific connection see respective connection diagram. SA 7.3 Tacho-generator with pulse encoder Part No.: 66 300 01 67 0 Type TDP 0,2 LT- 4 + OG 9D 120 constructional shape B10 Electrical data tacho-generator: Tacho-generator voltage at 1000 U/Min 60 V DC Max. tacho-generator speed 9000 U/MIN Max. strength of current 67 mA Protection class IP 55 Electrical data double pulse encoder: Pulses / rotation 2 x 120 electrically offset (delayed) by 90° Supply voltage +11 V to +26 V DC Output load current per system max. 60 mA

Connect tacho-generator and pulse encoder using cable (part No. 65 000 34 87 0) to rear wall board in control cabinet. See circuit diagram of installation.



SA 7.4 Pulse encoder Part No.: 00 990 10 03 0



9.5 Product information from Wachendorff


ThyssenKrupp Aufzugwerke GmbH 78

9.6 Blocking clamp The machine is equipped with a blocking clamp adapted to the respective traction sheave (rim width and design).

Use of blocking clamp: Before you start performing any works on the car or counterweight (e.g. release from safety gear operation), secure the ropes against rope slip using the rope clamp. The same applies to works where the elevator traction is insufficient. Note: attach the two-piece rope clamp to the ropes. Clamp and tighten clamp screwing accordingly.

Rope clamp attached to traction sheave

1 Traction sheave 2 Gear 3 Clamp bolt 4 Blocking clamp 5 Hexagon nut 6 Washer

Attention: remove blocking clamp when installation works are finished. Disregard will damage the installation.

Fig. 27

1 2 3 4

6

5

3

ThyssenKrupp Aufzugswerke GmbH Ein Unternehmen von ThyssenKrupp Elevator Bernhäuser Strasse 45 73765 Neuhausen a. d. F. Deutschland Tel.: +49 7158/12-0 Fax: +49 7158/12-2585 E-Mail: [email protected] www.thyssenkrupp-aufzuege.de Is

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06/

2006

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Date post:	26-Mar-2018
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Machine W263B - صفحه اصلی W263B PAGE 1. Safety 1.1 Explanation of symbols used 6 1.2 General...

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