TW45B

A company
of ThyssenKrupp
Elevator
ThyssenKrupp Aufzugswerke
Operating Manual
Machine TW45B
Ein Unternehmen
von ThyssenKrupp
Elevator
ThyssenKrupp Aufzugswerke
Anlageblatt zur Betriebsanleitung Maschine TW45B
Appendix to instruction manual machine TW45B
Annexe auxnderung
instructions
machine
TW45B
Betrifft:
an de
denservice
Bremsen
2x50Nm
Subject:
Objet:
11.10.2007
Modification of brakes 2x50Nm

Modification des freines 2x50Nm
Anschluss TCM / TCI Steuerungen

Connection TCM / TCI controls
Raccordement manuvres TCM / TCI
Bremsansteuerung bei nicht TCM / TCI

Brake control if not TCM / TCI
Commande de frein en cas de non TCM
/ TCI
Betrifft:
Subject:
Objet:
Neuer Bremslfthebel fr Bremse 2x50Nm

New brake release lever for brake 2x50Nm
Nouveau levier de desserrage de frein pour frein 2x50Nm
Vor Einsatz des Bremslfthebels Anlage ausschalten, Antrieb elektrisch stillsetzen

Before use of the brake release lever switch off installation, stop drive electrically
Avant lusage du levier de desserrage de frein dsactiver linstallation, arrter
lentranement lectriquement
Bremslfthebel spreizen
Spread brake release lever
carter levier de desserrage
de frein
Rndelschraube festziehen
Tighten knurled thumb
screw
Serrer vis molete
an der Maschine
(Bremsen) einbauen
install at the machine
(brakes)
monter la machine
(freines)
Beide Bremslfthebel sind

angebracht
Both brake release levers are
fixed
Tous les deux leviers de
desserrage de frein sont fixs
Beide Bremslfthebel gleichmig in Richtung Handrad ziehen

Pull both brake release levers equally to the handwinding wheel
Tirer rgulirement tous les deux leviers de desserrage de frein vers
le volant de dpannage
an den Bremsen fixieren

attach to the brakes
fixer aux freines
Bremslfthebel fixiert
Fixed brake release lever
Levier de desserrage de
frein fix
einzelne Bremse lften

release single brake
desserer frein
sparment
Bremshebel mssen nach Bentzung entfernt werden

Brake levers must be removed after utilization.
Enlever les leviers de frein aprs Iutilisation.
.
Anlageblatt zur Betriebsanleitung Maschine TW45B

Appendix to instruction manual machine TW45B
Annexe aux instructions de service machine TW45B
Betrifft: nderung Bremslfthebel und el. Anschluss der Bremsen.
Subject: Modification of brake release lever and electrical connection of brakes
Objet: Modification du levier de desserrage de frein et raccordement lectrique des freines
Folgende Kapitel sind durch das Anlageblatt betroffen:

The appendix refers to the following chapters:
Lannexe fait rfrence aux chapitres suivants:
2.2
4.2
5.1
5.2
7.3
7.4
OPERATING INSTRUCTIONS
Imprint
All rights reserved
Copyright by: THYSSENKRUPP AUFZUGSWERKE GmbH
Postfach 23 03 70, D-70623 Stuttgart
Printed in Germany
These operating instructions may even in extract form only be reprinted or otherwise
copied with the express written approval of THYSSENKRUPP AUFZUGSWERKE GmbH.
All copying, distribution or saving in any form on data storage media which is not
authorised by THYSSENKRUPP AUFZUGSWERKE GmbH constitutes a copyright
infringement and will result in prosecution. We expressly reserve the right to carry out
technical alterations which lead to an improvement of our products or increase the safety
standard also without special prior notice.
The issuer responsible for the content:

THYSSENKRUPP AUFZUGSWERKE GmbH
Preface
We are delighted that you have decided upon a quality product from the company
THYSSENKRUPP AUFZUGSWERKE GmbH.
These operating instructions will help you to get to know our products and to benefit from
their intended applications. Important safety and hazard instructions will help you to
operate our products safely and properly.
Subject to technical alterations.
ThyssenKrupp Aufzugswerke GmbH
OPERATING MANUAL
Table of contents :
Machine TW45B
PAGE
1. Safety
1.1 Explanation of symbols used
1.2 General safety information
10
11
2. Product description
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Description of machine TW45B

Functional description
Dimensions
Technical data
Machine frame
Name plate
Lubrication
14
15
18
24
28
34
35
3. Transport and storage
37
4. Mounting of machine in machine room
40
42
43
4.1 Mounting of rope guard

4.2 Connection
5. Putting into service

5.1 Putting machine into service
5.2 Emergency operation
5.2.1 Drive for machine-room-less installation without
emergency braking system NBS
5.2.2 Drive with emergency braking system NBS
5.2.3 Drive for machine in shaft with emergency braking system
5.2.4 (Optional) brake release levers for manual release
46
47
6. Servicing
6.1 Servicing of machine
6.2 Checking of drive brake
6.3 Checking of flank clearence
6.4 Checking of escaping grease / oil
50
51
54
55
7. Maintenance
7.1
7.2
7.3
7.4
Replacing of traction sheave - installation

Replacing of motor installation
Replacing of brake with machine room version (TWR)
Replacing of brake with shaft version (MRL)
57
58
59
61
8. Annex
8.1 Tightening torque mechanical strength
8.2 Blocking clamp
Manufacturers instruction brake / coupling
Single-disk brake Mayr (TWR)
Double-disk brake Warner (MRL)
Encoder
Manufacturers instruction sheets 1-3 - encoder
Manufacturers instruction product supplement - encoder
Manufacturers instruction - motors
63
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OPERATING MANUAL
1.1
TW45B
1. SAFETY
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 inspection sequence.
These inspection notices must be observed in any
case. Disregard can lead to injury to persons or
damage to property.
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OPERATING MANUAL
1.2
TW45B
1. SAFETY
General safety information
Notes on the operating manual

Persons who perform work on the component must know the basic safety
precautions to ensure safe use and failure-free operation of this component.
This operating manual comprises the most important instructions how to
safely use the component.
The operating manual and, in particular, the safety instructions 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 work on the component shall only
be performed by trained and qualified persons who
observe the accident prevention regulations;
have read the safety information and the warning notices in this operating
manual.
Note: Check whether these instructions are observed in regular intervals.
Duties of the employees

Persons who perform work on the component must
observe the accident prevention regulations and safety precautions;
read the safety information and the warning notices in this operating
manual prior before they start working.
Training of the employees

Work on this component shall not be performed by other than trained and
qualified persons.
These persons shall not perform any work other than the instructions given
for 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.
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OPERATING MANUAL
TW45B
1. SAFETY
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
TW45B is exclusively designed in accordance with the state of the art and
the recognized safety regulations. TW45B shall only
be used for its intended purpose
be used exclusively if safe operation is ensured.
TW45B 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 TW45B outside the scope of its intended purpose
inexpert mounting, putting into service, operating and maintaining of
TW45B
operating the TW45B with defective and/or non-operative safety and
protective devices
disregard of and instructions of the operating manual that apply to
transportation, storage, mounting, putting into service, operating and
maintaining of TW45B
unanauthorized constructional modifications of TW45B
unauthorized modification of drive (performance etc.)
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OPERATING MANUAL
TW45B
1. SAFETY
unsatisfactory supervision of parts which are subject to wear

inexpert repair work
catastrophes caused by outside influence and Act of God.
Modifications of machine TW45B
TW45B is delivered factory-adjusted, pre-assembled and ready for operation.
In the case of any modifications of the machine THYSSENKRUPP
AUFZUGSWERKE GmbH cannot be hold liable.
Attention : the machine is delivered with oil filled in ! Please check oil level
using gauge glass before you start operation.
Use of TW45B and possible hazards
Traction sheave and handwheel of TW45 B do not have any protective cover.
The drive shall only be operated in a closed machine 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: danger of injury caused by objects (such as tools etc.) placed on the
handwheel.
In case of inexpert use there will be the risk of damage to the user or third
parties or impairment of the component or material property. Failures which
may affect safe operation must be eliminated immediately.
Attention: works on the handwheel shall only be performed with the power
supply switched off and the drive protected against unintentional switching on
(e.g. by locking of key-operated switch or removing of power supply fuses).
A warning sign to that effect must be provided at the control cabinet when
performing works at the drive.
Emergency brake NBS: installation sequence is different with emergency
brake mounted on. The same applies to testing and setting. Observe notes in
enclosed operating manual.
Attention: the model for placement in the shaft (MRL) is delivered without
manual release. Handwheel operation is only possible using proper electrical
accessories which are not part of the supply schedule.
The manufacturer of the lift installation must provide proper measures:
a) to be able to operate the brake in cases of emergency (power failure).
b) to be able to lift the car when the safety gear is engaged. (For example
rope device at car or counterweight.)
c) to be able to check the two brake circuits separately.
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OPERATING MANUAL
2.1
TW45B
2. PRODUCT DESCRIPTION
Description of machine TW45B

1
2
12
11
10
9
8
7
7
Fig. 1
Figure: TW45B, vertical motor position, machine in machine room
Machine TW45B (vertical motor position) consists of:

1
Handwinding wheel
Rope guard
Real value generator
Rope guard support
Motor
Gear
Transport eyebolt
10
Disk brake
Traction sheave
11
Brake release lever
Disk at traction sheave shaft
12
Motor connection
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OPERATING MANUAL
TW45B
Versions:
Two versions are available:
a) Vertical and horizontal motor position for machine in machine room
(TWR)
b) Horizontal motor position for machine in shaft (MRL)
Compared to version with machine in machine room (TWR) the model of the
machine for use in shaft (MRL) is equipped with two-surface disc brakes in
tandem arrangement with higher braking torque but without mounted-on
brake release levers and handwinding wheel.
The following versions are available:
Drive rating
Gear ratio
Traction sheave version
Traction sheave in left-hand and right-hand design with horizontal motor
position (seen from motor to gear)
Encoder version
An optionally mounted emergency braking system NBS prevents
overspeed in upwards direction. It has an additional disk brake acting on the
traction sheave shaft.
Note: It is not possible to retrofit an existing machine with an NBS
emergency braking system !
2.2
Functional description
Machine TW45B is designed for driving lift cars with rated load 450 kg and
speed 1,0 v 1,25 m/s.
The gear (shaft) consists of a single-stage worm gear in monoblock housing
with separated AS/BS bearing brackets.
A flexible coupling transmits the power from motor to gear. A dual-circuit disc
brake is installed between motor and gear.
An overhung traction sheave is used. Tooth system operating in synthetic oil.
Attention: the gear can be considered self-locking for ratio > 25.5. Observe
that this does not apply to lower ratio.
Different designs of drives are used dependent on the position of the flanged
three-phase motor. The drive transmits power to the worm shaft and from
there to the worm wheel, traction sheave shaft and traction sheave.
TW45B has flange-mounted motors (250 mm) in B5 / V1 design.
Integrated posistors protect the motor against thermal overload. The thermal
motor monitoring is connected in the motor terminal box.
Details see chapter 2.4.
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OPERATING MANUAL
TW45B
Drive type:
TW45B is available with frequency-controlled three-phase motor only. An
encoder for speed monitoring is available optionally. It is mounted on the
motor shaft.
Technical data and manufacturers instrutions for available encoder versions
see chapters 8.3 8.5
A mounted-on handwinding wheel is available with drives models with
machine in machine room (TWR).
Coupling:
Worm wheel and rotor shaft of motor are connected through a flexible,
maintenance-free coupling.
The coupling half connected to the gear has a sprocket, which transmits the
drive movement to the brake rotor of the disc brake.
Brake:
Note: the brakes of the TW45B machine are intended for static applications
as holding brakes. Any dynamic braking is restricted to emergency and test
braking. Normal use will not lead to any noticeable wear of lining.
These brakes can in no way replace the safety braking systems required for
downwards travelling cars.
Function:
Two different operational brake designs are used with TW45B.
a) A two-surface disc brake with radial armature base plate designed for version
with machine in machine room (TWR).
Two independently operating radial armature base plates press onto the
brake lining of the rotor. The disc moves on the hub, forces the friction lining
onto the gear housing and is thus stopped.
b) A two-surface disk brake with two brake rotors in tandem arrangement for
version with machine in shaft (MRL).
Two independently operating armature base plates with preset spring
resistance press onto the brake lining of the rotors. The two discs move on
the coupling hub, force the friction lining onto the bearing cover and armature
base plate and are thus stopped.
The torque of the two spring-operated brakes has been adjusted at the
factory and shall not be re-adjusted.
The braking force is adjusted in such a way that one brake shoe con stop the
car loaded with full loading capacity. The disc brakes are released through
electrically-operated magnetic clamps.
Manual release of brake is only possible with machine in machine room
(TWR). The brake release levers at transition motor-gear (fig. 1, pos. 11)
must be operated.
When the brake release levers are pressed, the armature base plate and the
rotor are separated. (fig. 25, pos. 5)
The rotor is connected to the motor and the worm shaft through a toothing
system; the brake is released. Tooth system for vertical motor position
Drawing and important manufacturers instructions related to installation and
details see chapter 8.2.1.
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OPERATING MANUAL
TW45B
Note: TW45B machine for placement in shaft (MRL) does not have mountedon brake release levers. Manual release of the brake is not possible!
Emergency braking system NBS:

The optional NBS emergency braking system protects the elevator car
travelling upwards from overspeed.
Description and details of the emergency braking system see operating
manual NBS.
Traction sheave:
The one-piece (rim and hub) traction sheave is fixed using a cone and a
mounting plate overhanging the shaft drive.
Further details see chapter 2.4 Technical data.
Pulse generator:
An overview of pulse encoders used incl. technical data see chapter 8.3 and
manufacturers instructions in chapters 8.4 8.5.
Environmental conditions:
Surrounding at the final site of the drive (humidity, temperature) shall comply
with the requirements for machine rooms (between +5 and +40 C
according to EN81.)
Relative humidity of air shall not exceed 70%.
Attention: the torque of the two-surface disc brake can intensively drop by
dewing in case of temperature around or under the freezing point.
There is the danger that friction linings seize up at the friction surfaces in
case of standstill for longer time.
The user of the assembly must provide proper counter measures.
17
Version 05/2009
TW45B
OPERATING MANUAL
2.3
Dimensions
TW45B vertical motor position (version for machine in machine room (TWR) with NBS)
Manual release
operational brake
Fig. 2
Oil drain
Motor connection
200
Pulse generator
Fig. 3
approx. 991
Manual release mounting
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TW45B
OPERATING MANUAL
TW45B horizontal motor position

(version for machine in machine room (TWR) with NBS)
B =115
NBS mounting
119
Fig. 4
392
Version for machine in machine room (TWR) incl. rope guard acc. to EN81
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Version 05/2009
OPERATING MANUAL
TW45B
TW45B (TWR) vertical motor position
Brake release lever

Oil level
gauge glass
Oil drain
Fig. 5
Fig. 6
Version for machine in machine room (TWR) incl. rope guard acc. to EN81
20
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OPERATING MANUAL
TW45B
Fig. 7
Fig. 8
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OPERATING MANUAL
TW45B
TW45B version for machine in shaft (MRL) without handwinding wheel and
mechanical brake release
742,8
DT / 2
kproj = 438
155
285
1) 200
27
200
100
1) Thread M16 x 25 deep
Fig. 9
Fig. 10
Version for machine in shaft (MRL) without rope guard
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Version 05/2009
TW45B
OPERATING MANUAL
1)
1)
1)
1)
TW45B version for machine in shaft (MRL) rear view
393
1)
1)
Fig. 11
1) Thread M16 x 25 deep
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Version 05/2009
TW45B
OPERATING MANUAL
2.4
Technical data
Gear unit:
TW45B
Gear type:
Manufacturer:

Machine room
Shaft
(TWR)
(MRL)
120
Application:
Axle distance:
[mm]
Gear ratio:
Oil filling:
Type of oil:
46:1; 32:1
[liter]
approx. 5,5
Synthetic gear oil (polyalkylenglycol)
Sort of oil:
Circumferential
backlash:
Weight (machine)
40:3
SM1 (TRIBOL 800 / ISO 460)

[]
0,03 0,07
[kg]
approx. 105
Designed for use in installations with rated load of 450 kg and

vrat 1,0 vn 1,25 m/s
Permissible radial load of traction sheave: max. 26 kN
Mass moment of inertia:
component
gear
motor
hand wheel
total
J1 [kgm]
0.0045
0.018
0.01
0.0325
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OPERATING MANUAL
TW45B
Operational brake:
Application:
Machine room (TWR)
Shaft (MRL)
Manufacturer:
Mayr / Mauerstetten
Warner & Turco
Type:
ROBASTOP RSZ 60
ERS VAR09 SZ 50/50
2 x 30
2 x 50
Braking torque :
[Nm]
Adjustment of torque
Type:
not possible
2 surface disc brake with
2 surface disc brake in
radial armature base plate tandem arrangement
Brake linings
asbestos-free
Brake disc :
[mm]
131
150
Operating voltage:
[VDC]
[VDC]
180 with overexcitation

90 with retentive voltage
90 per magnet with overex.

45 per magnet with retent.
Performance data:
[W]
[W]


Brake monitoring:
without
Air gap:
[mm]
0,4 0,05
0,25 0,05
Max. after wear
[mm]
1,7
je Spalt 0,6
Adjustment of air gap:
not possible
Electrical release
1 magnetic clamp
Manual release:
1 brake release lever per

brake circuit
Protection class:
Weight:
1 magnetic clamp per

brake circuit (series
connection)
without
IP54
[kg]
approx. 15
Weight:
Standard version of TW45B
Machine (with motor and traction sheave 360)
[kg]
200
[kg]
215
[kg]
225
Version with NBS (to be added)
[kg]
40
Sound level:
Airborne sound level in machine room at a distance of 1 m
under operation at normal rating: 65 dB(A)
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Version 05/2009
TW45B
OPERATING MANUAL
Motor data:
VVVF three-phase motor in B5 design
The following motor operational specifications apply to the use of TAW
frequency converters of type CPI10; CPI15/15E; CPI26E.
Machine room (TWR)
Application
Shaft (MRL)
Manufacturer:
Siemens AG
Type:
1LA7130-4AA19Z
Voltage / frequency:
[V/Hz]
340 / 42
S5 operational data
Speed range:
Rating:
Torque range for speed:
Rated current:
1LA7133-4AA19Z
180 c/h 50%ED

[1/min]
1000 1249
1250 1800
1250 1415
[kW]
4,2 5,2
5,2
[Nm]
[1/min]
40
1000 1249
40 28
1250 1800
52 46
1250 1415
[A]
Allowable starting
torque
[Nm]
Allowable starting
current:
[A]
12,5
70
16,5
70 63
Efficiency:
88
20
32
0,84
0,82
Design:
IMB5/V1
Protection class:
IP54
Ventilation:
Integrated ventilator
Handwinding wheel:
[mm]
kproj. ( see fig. 2 + 7)
[mm]
Weight:
without 1)
270 (plastic)
485
[kg]
50

(standard)
60
WDG100-38-1024/4096 TTL

(special)
1
) For use in the shaft (MRL)
WDG100-38-1024 HTL
WDG100-38-1024 sine/cosine
The electrical data applies to the following environmental conditions:

max. altitude
1000 m above sea level
max. temperature
+ 40 C at max. 50% air humidity
max. relative humidity
70 % at 20 C
If the conditions listed above are exceeded, derating as set out in VDE0530
applies.
The connecting cable at the real value generator is 10 m long. A connector
is provided at the cable end of the standard generator (1024 TTL).
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Version 05/2009
TW45B
OPERATING MANUAL
Motor connection:
Motor connection see chapter 4.2. The terminal diagram is imprinted or
enclosed at the inside of the terminal block .
Traction sheave:
The monobloc traction sheaves overhanging the shaft drive are fixed using a
cone.
Groove type: seat or V-grooves
Hardened groove flanks as standard ( 50 HRc)
Machine room
Application:
Diameter - DT
[mm]
Rim width:
Max. grooves
zd
[mm]
[mm]
Groove type/
undercut angle:
Weight:
440
Shaft
520
360
115
7 8
6 10
6 * 11
[]
77
5* 8
7 8
6 10
6 * 11
5 * 12
acc. to order
[kg]
45
Material:
55
30
specially alloyed EN-GJL 250

(HB 190 to 230)
Note: Emergency braking system NBS see separate operating

manual NBS.
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OPERATING MANUAL
2.5
TW45B
Machine frame TW45B
(optional)
The machine base frame consists of brackets of plate edge construction with
two welded face plates.
It is designed for use with machines with horizontal motor position.
A hole grid in the machine frame allows the machines with vertical motor
position to be moved in increments for customer-specific arrangement.
Standard models for machines in machine room and in shaft:
1.
With deflection pulley, for direct rope departure to be used in:

a) installations with 1:1 rope suspension for car counterweight rope
distance ASL 620 mm and car traction sheave rope distance
520 mm
b) installations with 2:1 rope suspension. See tables model 1,
shown in fig. 12.
The frame is installed using impact soundproof elements.
2.
With deflection pulley, frame with deflection pulley 360 or

450 mm and variable rope distance in left-hand or right-hand design
used for installations with 1:1 rope suspension and
ASL : 608 ASL 833 mm.
(depending on position of deflection pulley. See tables model 2,
shown in fig. 13
Note: frames 2 have supports to house the deflection pulleys. Arrangement

and dimensions shown in fig. 13 and table for model 2.
Installation
Machine frames are installed in the machine room using soundproof
elements. These elements differ depending on the installation:
a) Isolation elements 100 x 100 x 50 mm high without base. (60 309 01 14 0)
To be used for installation of machine directly on the machine room floor
without plaster floor or directly on the plaster floor.
b) Isolation elements as above, but with base 140 x 140 x 80 mm high.
(60 300 04 37 0)
To be used for installation of machine on plaster floor, base casted in plaster
floor. (covering thickness 60 mm)
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OPERATING MANUAL
TW45B
Frame mounting (frame without deflection pulley)

Screw the frame delivered disassembled together in the machine room.
See to it that the supports with additional (two) bore holes and the rope
pulley are mounted on the proper side. (The side where the deflection
pulley is to be arranged.)
Mount and secure deflection pulley and axle to pulley support.
Arrange and align frame on isolation elements in accordance with layout
drawing.
Tighten the fastening screws with the pre-set torque.
Mount machine on frame using hoist, the traction sheave must be at the
deflection pulley side.
Laterally move machine on frame until the required ASL measure (rope
distance car - counterweight at rope departure) is reached.
Screw machine and frame together. Observe not to distort the machine
housing. To ensure that the base is perfectly horizontal put enclosed
metal plates under, if required.
Align the rope grooves of the traction sheave so that they are in parallel
line to the rope grooves of the deflection pulley.
Tighten the fastening screws with the pre-set torque. See chapter 8.1.
Align the rope departure so that it is in vertical line with the rope pulley at
the car and/or the fastening at the car or counterweight.
Attention: in case of lateral or diagonal rope departure the gear box casing
is to be secured against shifting using plates bolted to the machine frame.
Explanation of abbreviations:
ASL = parallel distance of ropes at rope departure (fig. 13)
DT = diameter of traction sheave
SR = diameter of deflection pulley
= angle of wrap at traction sheave

With frame model 1, fig. 12
X1
= distance 1 between rope departure and outer edge of frame
X2
With frame model 2 fig. 13
X1
= distance 1 between axle center of rope pulley and bearing surface
of frame support at machine frame
X2
support
Y1
Y2
Z1
1) 2)
vertical axle distance between traction sheave and deflection

pulley
vertical distance between deflection pulley center and support
bearing
distance 1 between center of rope departure and outer edge frame
support at deflection pulley side
See remarks representation fig. 1 (fig. 12)
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OPERATING MANUAL
Data machine frame model 1

Shown in fig. 12
Traction
sheave
diameter
DT
Arrangement of machine
left
right
x1 min
x1 max
x2 min
x2 max
440
[mm]
52
342
52
342
520
[mm]
52
262
52
262
Weight: machine frame 1 without supports and deflection pulley

approx. 50 kg
Note: left or right means that the machine 1) in right-hand design
(traction sheave seen from motor towards machine) can be moved in
respective direction to outer mounting holes in the frame.
x1 or x2 is the distance between rope departure and outer edge of machine
frame dependent on the traction sheave .
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OPERATING MANUAL
Data machine frame model 2

Shown in fig. 13
Rope distance measurements (ASL) and angle of wrap
(Intermediate results for ASL measurements can be adjusted in increments
of 40 mm in accordance with the mounting holes in frame)
Traction sheave
diameter
DT
[mm]
Minimum rope distance car counterweight and

Maximum angle of wrap
ASLmin [mm] and max []
With deflection pulley SR [mm]
360
ASLmin
450
440
582
max
167
520
662
167
Traction sheave
diameter
DT
[mm]
ASLmin
566
max
168
616
170
Maximum rope distance car counterweight and

Minimum angle of wrap
ASLmax [mm] and min []
with deflection pulley SR [mm]
360
ASLmax
450
440
832
min
149
520
832
154
ASLmax
776
min
150
776
157
Project planning dimensions see fig. 13

Deflection
pulley
SR
[mm]
360
Measure
x1
[mm]
Measure
x2
[mm]
Measure
y1
[mm]
Measure
y2
[mm]
Measure
z1
[mm]
130
61
645
190
245
450
231
116
600
235
255
Weight:machine frame model 2 incl. deflection pulley 360 approx .140 kg

incl. deflection pulley 450 approx.170 kg
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OPERATING MANUAL
Model 1
TW45B
Machine frame TW45B without deflection pulley
Fig.12
Remarks:
1) Machine with horizontal motor position / traction sheave right
2) Machine with horizontal motor position / traction sheave left
3) Machine with vertical motor position / traction sheave right
4) Machine with vertical motor position / traction sheave left
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OPERATING MANUAL
Model 2
TW45B
Machine frame TW45B with deflection pulley
Shown with rope pulley position in right-hand design

(left-hand design mirror-inverted)
Fig. 13
Explanation of remarks see version 1 fig. 12
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2.6
TW45B
Name plate of TW45B

The current model and the technical data are stated on the nameplate of the
product.
1. Name plate of gear (ThyssenKrupp Aufzugswerke):
2. Name plate of gear (Lift Equip)
3. Name plate of motor
(laterally fastened at the motor)
4. Name plate of operational brake:

(With vertical motor position fastened at motor flange below brake covering)
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2.7
Lubrication
Lubricator
Synthetic gear oil SM1
TRIBOL 800 / ISO460
Oil change interval

Motor position
Quantity
First change after 4 years, Vertical
approx. 5.5 liter
thereafter at a period of 8 horizontal
approx. 5,5 liter
years
Oil change
Before you change oil run the gear until it is warmed to working
temperature (at least 35C).
Discharge gear oil by the plug at the oil drain.
Attention, there is the risk of scalding !
Discharge waste oil in collecting pan provided.
Close oil drain after discharging the gear oil filler cap and sealing tape.
Pour in recommended quantity of lubricator in the special filling hole at the
gear housing (remove vent screw, see figs. 14 to 16).
Check oil level at oil gauge.
Note date of next oil change in name plate at gear housing.
Never mix different sorts of oil.
Oil must not be allowed to flow in the groundwater.
Waste oil and oily, dirty and greasy cleaning cloths must be disposed of in
accordance with the local requirements.
Only use types of grease recommended by THYSSENKRUPP
AUFZUGSWERKE for refill.
Note: For any damages caused by lubricators not recommended
THYSSENKRUPP AUFZUGSWERKE GmbH cannot be hold liable.
Version with horizontal motor position
Version with vertical motor position
ventilation
oil charging hole
ventilation
oil charging hole
Fig. 14
Oil drain
Fig. 15
Oil level gauge
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Oil level gauge
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OPERATING MANUAL
TW45B
TW45 version with horizontal motor position

(Figure: version with machine in shaft (MRL) without brake release lever)
1
Fig. 16
2
Oil charging hole / ventilation
Oil drain
Note: the correct oil level is even with the center of the oil gauge.
The gear is properly lubricated when it leaves the factory. Please observe
during transport or any changes at the oil charging hole.
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OPERATING MANUAL
3.
TW45B
3. TRANSPORT AND STORAGE
Transport and storage

Packing:
TW45B without frame is delivered securely mounted to a Europallet.
The traction sheave is enclosed.
Machines with frames are delivered with frame disassembled.
Optionally the machine may be delivered completely assembled and aligned.
For transport by sea, machine and accessories are shipped in seaworthy
crates.
Transport:
The safety precautions are to be observed and the machine and frame
must be perfectly horizontal, both in cross and lengthwise direction.
Attention: machine is filled with oil. Make sure that it is always
transported and stored in vertical position.
Transport by forklifts:
Always lift the machine, not transport pallet ! Secure machine against
tilting.
Pay attention to projecting parts. Risk of injury to persons or damage to
property !
Transport by crane:
Do not stay below suspended loads!
Lift machine without frame using transport eyebolts and rope. Hook bolts
on the shaft are not suitable for handling the machine !
Secure transport rope at frame in case of machine assembled on
machine frame.
Protect the machine against tilting.
Rope fastening: fasten transport rope at
eyebolts in case of machine without machine
frame.
See fig. 17 or 18
Use transport eyebolts below motor with vertical
motor position.
Protect handwinding wheel against damage.
Ropes and chains shall not be adjacent to
handwinding wheel during transport.
Fig. 17
Vertical motor position
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Use transport eyebolts at motor and gear box housing with motor in horizontal
position.
Protect handwinding wheel against damage. Ropes or chaines shall not be

close to handwinding wheel during transport.
Fig. 18
Motoranordnung
horizontal
Horizontal
motor position
Note the pictographs fastened on the packing or on other visible places.
Top
Handle with care
Keep dry
Do not expose to
heat
Do not use handheld grippers
Fasten here
Dimensions and weight

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

Examine the delivered parts for completeness, damage or anything strange.
Report and document shipping damage
After receipt of goods make sure that there is no damage caused during
transport.
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TW45B
Information
Immediately document the damaged noticed (drawing, photograph,

description of damage).
Send the respective documents immediately 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 shall not be sent
back to THYSSENKRUPP AUFZUGSWERKE GmbH but remain at
the customer.
Intermediate storage
Even if the component is not mounted 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.
Note: do not damage surface coating and preservation !
Mechanical (scratches), chemical (acids, alkalines) or thermal (sparks,
welding beads, heat) damages may cause corrosion and thus failure of
surface protection.
Environmental conditions
Information
Surrounding at the final site of the machine (humidity, temperature) shall
comply with the requirements for machine rooms. (Between +5 and +40
C according to EN 81)
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OPERATING MANUAL
4.
TW45B
4. MOUNTING OF MACHINE
Mounting of machine in machine room

General installation instructions:
Installation shall only be performed by trained and competent persons.
Utmost care must be taken. ThyssenKrupp Aufzugswerke GmbH cannnot be
hold liable for any damage caused by inexpert installation.
Sufficient free area around the drive must be ensured for installation,
maintenance and cleaning works.
Sufficient lifting devices must be provided for installation works.
Attention: do not perform any welding works at the drive.
The drive is not suitable as connection to earth. Gear teething or bearing
parts may be impaired.
Attention: use all mountings available. Mounting are subjected to
respective design.
Ensure that air supply for cooling the drive is not affected.
It must be possible to check the oil level.
Place of installation / base:
Ensure that the place of installation is perfectly horizontal, with max.
tolerance of 0.5 mm.
The base must also be perfectly horizontal both in cross and lengthwise,
verify that it is stable enough for the forces acting on the base.
Installation (machine delivered without frame or disassembled):
Remove packing, arrange machine on base.
Remove surface coating at worm wheel shaft, connection and traction
sheave bores.
Attention: do not touch shaft sealing ring when performing any cleaning
works !
Ensure proper ventilation. Do not smoke.
Mount traction sheave to machine. (See chapter 7.1) Secure traction sheave
by tightening the screws using torque wrench. Note tightening torque
(75Nm). See chapter 8.1
Machines with machine frame and rope pulley are mounted in accordance
with customers specification on supports, brackets, base or directly casted in
plaster floor.
Installation and mounting of frame supports see enclosed drawing and parts
list.
Attention: Mount frame in accordance with drawing using enclosed
mounting elements. Observe strength and respective tightening torque. See
details in chapter 8.1
In order to comply with the requirements concerning noise reduction /
structure-borne noise transmission insert the isolation elements delivered
between frame support and floor.
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TW45B
The number of isolation elements depends on the overall weight load. The
individual isolation element should be loaded between 7000 and 12 000 N /
isolation element.
Arrange the isolation elements in accordance with layout drawing.
Note: arrange the isolation elements in such a way that the load is distributed
equally (the same applies to car suspended at rope pulley side).
When the machine is mounted on plaster floor, coating thickness shall be
60 mm. Use isolation elements with base (80 mm high). The base part
shall also be cast.
How to arrange the machine
Arrange 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 mounting or the car rope pulley and the counterweight. When the
ropes are tensioned, the machine must be arranged horizontally aligned at
the base plate. Use metal plates to ensure that the base is perfectly
horizontal.
After roping mount the rope guards (chapter 4.1).
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4.1
TW45B
Mounting of rope guard

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 side of the traction sheave
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 rope guard
support; verify that tightening torque is correct.
Tightening torque see table 8.1 in annex.
1
2
max. 1 - 2 mm
Fig. 19
Fig. 20
1
2
Rope guard support

Rope guard support
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.
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OPERATING MANUAL
4.2
Connection
Motor connection:
Observe terminal diagram at the cover of the motor connection box or
terminal diagram in operating manual as well as the respective local
requirements.
Motor connection data see chapter 2.4 Technical data.
Observe instructions of manufacturer in annex, chapter 8.6.
1
3
4
2
5
6
Fig. 21
9
W2
U2
Earth connection
V2
Posistor-temperature sensor
Posistor-temperature sensor
W1
V1
U1
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TW45B
30 V!
30 V!
30 V!
Pulse encoder connection:

Connection and encoder data for encoder connection see chapters
8.3 8.5.
Posistor- temperature sensor (motor thermal element) connection:

To evaluate the posistor temperature sensor integrated in the motor a control
unit (motor protection device) is required. This unit is to be connected to
terminals in fig. 21, pos. 5 and 6.
Holding brake for machine in machine room version (TWR),

make Mayr:
The connecting line (approx. 1 m long) of the holding brake leaves the gear
box at the gear flange side opposite the brake release levers. The magnet
coils of the disc brake are to be connected to the black connecting line.
The brake operates on a direct current supply.
Polarity of the connecting coils (brown/blue) does not affect the way the
brake operates.
The coil voltage is indicated on the name plate.
Attention: there is the risk of wear when operating the brake at lower than
intended connection voltage.
Further details see chapters 2.4 and 8.2.1
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TW45B
Holding brake for machine in shaft (MRL) make Warner:

A 6 m long 4-core connecting line with socket
at the line end is enclosed.
This connector is to be connected to the
connector at the connecting line.
The two magnet coils are to be connected to
the terminal block at the opposite line end.
The line cores are identified each.
Cores 1 and 2 for magnetic coil C
Cores 3 and 4 for magnetic coil D
See fig. 26, pos. 19
Connector PHOENIX
Coil C
Coil D
The brake operates on a direct current

supply.
Polarity does not affect the way the brake
operates.
Correct coil voltage acc. to name plate.
Attention: verify that connecting voltage is
correct. When operating the brake at lower
than intended voltage the brake may fail to
open completely. This may cause wear.
Further details see chapters 2.4 and 8.2.2
6000
Note: there are two outputs for the brake coil

connection to be able to operate each
braking circuit individually. This is required for
inspection by notified bodies (each brake
circuit is tested separately or releasing the
brakes step by step in cases of emergency
such as rescue of passengers.
Fig. 22
Attention: the drive is designed for
installation in shaft and does not have any
brake release levers. Please observe that the
owner of the lift installation must ensure that
the brake may be released step by step in case
of power failure.
Emergency braking system NBS (optional) :

Description and details of emergency braking system see enclosed operating
manual of NBS (if required).
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5.1
TW45B
5. PUTTING INTO SERVICE
Putting into service

Before you start putting the machine into service the following works are to
be performed:
Check fastening of machine, traction sheave and frame

Check whether rope guard is mounted and distance to traction sheave
adjusted
Check installation of machine, frame, base and rope departure
Secure gear housing against moving in case of lateral or diagonal rope
departure
Tighten screws and secure with pre-set tightening torque (see table
tightening torque 8.1)
Check gear oil level
Plastic plug in oil filling hole at gear housing removed and ventilation
screw inserted and closed. Plastic plug at front side of housing removed
and oil drain screw inserted and closed at height of traction sheave shaft
(figures 14 to 16).
Check supply terminals, earthing of motor, ventilation and brake magnets
for correct connection and fusing
Check connection (voltage, frequency) for compliance with
manufacturers instructions
Check monitoring devices (pulse generator, thermal element) for
connection and correct functioning
Check holding brake and emergency brake NBS (if available) for correct
connection and functioning
Check manual release of brake(s) for correct functioning (does not apply
to machine in shaft)
Check brake ventilation (for emergency evacuation, see chapter 1.2)
mounted by the customer for correct functioning in case of machine in
shaft (MRL)
Visibly glue direction arrows (up/down) for respective travel direction at
motor (adjacent to handwinding wheel)
Remove safety, accessory and installation tools from danger zone
Note: mount disassembled traction sheave using enclosed microencapsulated screws.

See chapter 7.1
In case the machine is disassembled for reasons of weight, transport or
space, re-assemble in original assembly condition and tighten fastening
elements with respective tightening torque. See table tightening torque 8.1
Only use ThyssenKrupp Aufzugswerke mounting parts and components for
installation and repairs. In case of disregard ThyssenKrupp Aufzugswerke
GmbH cannot be hold liable.
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5.2
TW45B
Emergency operation
5.2.1
Drive with machine in machine room (TWR) without emergency

braking system NBS:
TW45B with machine in machine room is equipped with a handwinding wheel
and two brake release levers (one lever for each brake circuit).
When operating both brake release levers at the same time, the disc brake
opens.
To rescue passengers trapped in the car, it may be necessary to move the
car to the nearest landing by handwheel mechanism.
When the car is opened, the car may start suddenly dependent on the load.
Immediately stop turning the handwinding wheel and move the car by
carefully releasing the brake release levers (galloping brake).
Attention: persons operating the handwinding wheel (e. g. "lifting the car
from the moment of safety gear operation"), must work on a secure platform.
There is the risk of injury to persons when operating emergency operation
control at the same time.
5.2.2
Drive with emergency braking system NBS:

Note that emergency operation proceeding changes with emergency
braking system NBS mounted on.
Observe instructions in operating manual NBS!
Material No. of operating manual NBS: 65 990 01 86 0
Proceeding with emergency braking system see chapters 1.3 and 2.2!
5.2.3
Drive with machine in shaft and emergency braking system (machineroom-less variant without brake release levers attached and (optionally
available) brake release levers
Corresponding counter measures are to be made by manufacturer of the
elevator installation to be able to rescue passengers in the case of power
failure.
Please note the following points:
Carefully open the electrically operated brake
Start car with weight of car / counterweight balanced and note that static
friction of guides and automatic interlock of worm gear are to be
overcome
Check moving speed with the brakes open to avoid the risk of safety
devices against overspeed being activated.
Further details on proceeding not possible as brake operation is subjected to
respective design and version of elevator installation.
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5.2.4
TW45B
Optionally available brake release levers for manual release operation for
drives equipped with tandem disc brakes from Warner (machine-room-less
variant).
Use of the lever mechanism necessitates the need of directly accessible
drives. (e.g. machine in shaft pit)
1. Release of single brake: (e. g. manual brake test with one brake circuit
active)
Attach the narrow end pieces of the two brake release levers between
armature base plate and magnet coil carrier of brake. See fig. 23.
Tighten both levers in direction of motor.
Fig. 23
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TW45B
2. Release of both brakes: (e. g. in case of emergency rescue)

Attach the two narrow end pieces of the release levers between armature
disc plate and magnet coil carriers at the brake. See fig. 24
Tighten both levers in direction of motor.
When operating both brake release levers at the same time, the two disc
brakes open.
Details on emergency rescue of trapped persons see proceeding in
chapter 5.2.1.
Fig. 24
Attention: remove brake release levers before the machine is switched on.
Never start operation with the brake release levers attached!
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OPERATING MANUAL
6.1
TW45B
6. SERVICING
Servicing of machine
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:
2.7
Check oil level and re-fill, if required
2.7
Change oil at the end of oil change interval
2.7
Clean ventilation screw and opening at gear housing
Check gear and bearings for leakage
Check brake and air gap (max. 1.7 mm with Mayr brake)
(max. 0.6 mm per air gap with Warner brake)
Check holding brake and manual release for correct functioning
Check brake deceleration
Check worm toothing for wear
Check circumferential flank clearance between worm shaft and
worm wheel; 0.05 mm to 0,12 mm at 20 C (max. 1.5 mm)
Check traction sheave groove profile for damage and wear
Check screws of traction sheave fastening for correct tightening
Check machine, supports and rope pulley supports for correct

fastening with machine mounted on machine
6.2
6.2
6.2
6.3
7.1
8.1
2.5
Check grooves of rope pulleys for damage and wear

Check electrical connections for correct functioning and test for
safety
4.2
Check protective and safety equipment and test for correct

functioning and adjustment
Notes on lubrication (oil change, quantity, oil change interval)
see chapter 2.7
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6.2
TW45B
6. SERVICING
Checking of drive brake

Inspection interval: once a year in the course of the general lift servicing
1.) Functional test of holding brake
electrical test:
power supply off

power supply on
brake closed
brake released
mechanical test (only possible in case of machine in machine room (TWR):

press both release levers
press each release lever
separately
brake released
brake closed
When the brake opens, the armature disc moves away from the friction
disc, and the air gap is closed. See fig. 24 / 26
2.) Inspection of wearing condition:
Wear at the friction linings of the rotor is caused by improper setting or
defects. When wearing limit is reached, replace friction linings or disc brake.
Inspection of wearing condition by checking the air gap:
The maximum permissible air gap is:
1.7 mm
for Mayr brake (TWR version)
2 x 0.6 mm
for Warner brake (MRL version)
Description of the inspection sequence see 7.2

3.) Inspection of deceleration
a) Test of one single brake circuit. To check the brake circuits for
correct operation each brake circuit must be inspected separately.
The brake shall be checked with one brake circuit effective only.
Note: holding brake of lifts equipped with an emergency braking system
NBS can only be checked with the emergency braking system NBS out of
service !
Description see operating manual Emergency braking system NBS.
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6. SERVICING
Before testing:
Inspection signs must be made available at the landing doors during
inspection work at the lift.
Close the doors acc. to the rules.
Make sure that the car is empty.
The car must be at least two landings below respective terminal landing
(seen from run direction).
Car empty
run direction up;
Car loaded with rated load
run direction down.
The single brake circuits are tested by energizing the single brake coils
with 90 V / 45 V excitation / withstand voltage.
When a single circuit is tested, the brake of the 2. brake circuit must be
released during the braking process. Therefore, the magnet coil of the
2. brake circuit is energized with withstand voltage.
Attention: should the lift move after release of one brake circuit or not
decelerate sensibly during the braking process, the energized coil must be
switched off immediately.
The dual circuit braking function is not guaranteed. Check brake !
Test sequence: inspection of the brake deceleration to be made for each
brake circuit individually
Connect deceleration measuring device
Activate normal run (brake to be tested is released)
Activate emergency stop as soon as rated speed is reached
(brake to be tested closes)
Determine deceleration for 1. brake circuit using a measuring device
Compare result of the measurement and reference value
Remove continuous voltage supply at continuously open 2. brake circuit
and connect to 1. brake circuit.
Connect test terminal at deceleration measuring device to 2. brake circuit.
Repeat test at 2. brake circuit.
Deceleration values:
Minimum deceleration for one brake circuit
0.4 m/s
Minimum deceleration for both brake circuits
1.0 m/s
Attention: when the single brake test is terminated, the continuous control
voltage at the 2. brake is to be removed, and the original condition
established (operation of both brakes).
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6. SERVICING
Simple inspection of brake deceleration without measuring device:

(this inspection method only applies to travel heights 7m and control point
observable from operation point)
Inspection sequence:
The measures described in before testing are to be observed.
Provide terminal for continuous power supply at brake circuit of the 2.
brake coil.
The car loaded with max. permissible rated load must be at least two
landings above bottom-most.
The ropes shall be marked level at control point height.
The control point shall be easily visible from the brake operation position.
(Marking at bracket height, for example)
Move the car upwards to nearest landing.
Energize 2. brake with continuous control voltage during inspection
process.
Note: brake shall not be de-energized when the main switch is switched off,
as otherwise both brakes will become effective.
Move car downwards at normal speed. Observe control point and ropes
from brake operation position.
Switch off main switch as soon as rope marking reaches the control point.
Measure distance between rope marking and control point. This distance
is equivalent to the stopping distance of the tested brake circuit.
Compare determined stopping distance and reference value.
Stopping distance
The max. stopping distance for single brake circuit shall not exceed:
In case of installations with VN 1,0 m/s 1,25 m, with VN 1,25 m/s 2,0 m
(These values apply for simple inspection only)
Disconnect continuous voltage supply and connect to tested brake coil.
Repeat described sequence with 2. brake circuit.
Attention: when the brake test is terminated, the original condition is to be
established (operation of both brake coils at the same time).
b) Inspection of both brake circuits
When single circuits are inspected, test of both brake circuits follows by
activating emergency stop.
The deceleration value must considerably exceed the value measured during
single inspection!
Remove inspection signs when inspection and service works are terminated.
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6.3
6. SERVICING
Checking of flank clearance

The flank clearance of the worm gear (between worm wheel and worm shaft)
increases due to wear.
As soon as the wear limit (flank clearance) 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 ) = 95 mm for TW 45B)
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. Do not move the worm
wheel since this may cause falsified measurement results (bearing
clearance).
Read dial gauge deflection (ME).
Calculate flank clearance acc. to the equation below.
Perform measurement at three different points at least!
Dial gauge
Traction sheave
Worm wheel
Fig. 23
M = measuring radius
ME = measured result
r
= radius worm wheel
all dimensions in mm
Flank clearance =
54
ME * r
M
Version 05/2009
OPERATING MANUAL
6.4
TW45B
6. MAINTENANCE/ SERVICE
Checking for escaping grease / oil

Examine the areas around the brake disc and armature base plate for traces
of oil.
Contamination level
No escaping oil determined
Procedure
Check regularly within the
framework of maintenance
If a large amount of
escaping oil is determined
or oil is escaping from the
brake disc / brake linings
Clean the drive and, if

necessary, the brake and
carry out short-term repairs
Before continuing operation
until modification, run a brake
test. If the braking effect is
inadequate, shut down the
installation.
55
Every 3 months
(6 months if
elevator used
infrequently, <
50 000 runs per
year)
Repair after 4
weeks at the
latest
Version 05/2009
OPERATING MANUAL

Diagram of the horizontal version

TW45B
6. MAINTENANCE/ SERVICE
Bearing cover
Shaft sealing
ring
Fett
Armature base
plates
Brake discs
Fig. 6.4.1
56
Version 05/2009
TW45B
OPERATING MANUAL
7.1
7. MAINTENANCE
Replacing of traction sheave - installation

Disassembly:
Switch off power supply, secure car and counterweight.
Remove rope guard plates.
Remove load from traction sheave; discard ropes.
Secure traction sheave with lifting device.
Loosen screws on mounting disc of traction sheave; put screws in outer
hole circle of disk and loosely screw in traction sheave hub.
Place a washer approx. 5 10mm thick between shaft end and disk.
Tlighten screws uniformly and remove traction sheave from motor shaft.
Assembly:
Clean shaft end and traction sheave holes; never make any dimensional
changes in featherkey, groove, shaft or drilled holes.
Check whether the contact surfaces are free from visible damage.
Never grease or oil shaft and holes.
Carefully fit and screw new traction sheave to conical end of motor wheel
shaft.
Bring position of featherkey and groove in line.
Push traction sheave on motor shaft.
Screw-connect disk at inner hole circle using enclosed screws
(micro-encapsulated) and detent edged washers. Tighten screws uniformly
in several operations.
Attention danger: the traction sheave may work loose if assembled
improperly.
Observe screw strength 8.8 and tightening torque = 75 Nm !
1
Fastening screws
Forcing screw / hole
Traction sheave
Mounting disk
Rope guard plate
Fig. 24
5
5
2
Remove securing devices at traction sheave with lifting device
Replace ropes
Mount and align rope guard plates
Remove securing devices at car and counterweight
57
Version 05/2009
OPERATING MANUAL
7.2
TW45B
7. MAINTENANCE
Replacing of motor installation

a) version for machine in machine room (TWR) with Mayr brake
Disassembly :
Switch off power supply, secure car and counterweight.

Secure motor with lifting device.
Disconnect electrical terminals and connecting lines to motor.
(Motor, encoder and brake connections)
Remove mounting nuts at housing flange; carefully remove motor from
coupling; put motor down.
Loosen set screw (fig. 25, pos.5); remove coupling half (fig. 25 pos. 2
hub 2) from motor shaft end using pull-off device.
Assembly:
Make sure that replacement motor is available; compare motor data.

Warm up coupling half to temperature of approx. 200C and push
shaft end on replacement motor. Secure with set screw.
See to it that the coupling half claws project the shaft end. The claw
bottom must be at the level of the shaft end.
Secure replacement motor with lifting device.
Lift motor with lifting device and bring motor, coupling and housing
flange in line.
Turn motor shaft and bring slightly greasy coupling halves in line.
(Tooth in line with gap). The flexible gear ring (fig. 25 pos. 3) must be
between the two coupling halves.)
Connect motor and gear coupling.
Turn motor and bring mounting holes and threaded bolts at gear flange
in line.
Push on motor, until the motor face is adjacent to gear flange or flange
ring.
Screw motor to gear flange with nuts and tighten uniformly in several
operations. Observe tightening torque. (See table with tightening
torques 8.1 in annex)
Inter-connect lines and terminal box at motor; connect electrical
connections acc. to terminal plan in chapter 4.2.
Inter-connect brake connection, encoder connection and control.
Check braking system for correct functioning before startup.
Note: see installation and connection instructions of brake manufacturer in

chapter 8.2.
b) Version for machine in shaft (MRL) with Warner brake
To replace the motor repeat above steps and see fig. 27.
Remove set screw (fig. 27, pos.2) before you remove the coupling half.
58
Version 05/2009
OPERATING MANUAL
TW45B
7. MAINTENANCE
7.3 Replacing of brake with machine room version

(TWR)
Measure
Fig. 25
Air gap
Hub 1
11
Cheese-head screw (4x)
Hub 2
12
Pressure spring (4x)
Gear ring
13
Pressure spring (4x)
Set screw
14
Release lever 1
Set screw
15
Release lever 2
O ring
16
Coil carrier with magnet coil
17
Two-piece armat.base plate
18
Damping elements (6x)
Rotor
19
Connect. cable appr. 1m long
10
Socket (4x)
20
Screw
Replacing of dual-circuit disk brake (Mayr)

To replace brake proceed as follows:
Remove motor as described in chapter 7.2
Disconnect connecting cable (19)
Remove screws (16), remove release levers (14) and (15)
Remove gear ring (3)
Remove screws (11), pull off brake
59
Version 05/2009
TW45B
OPERATING MANUAL
7. MAINTENANCE
Loosen set screw (4), remove hub with rotor (9) from worm shaft
Put hub 1 of new brake with mounted rotor onto worm shaft end
(note mounting direction)
Attention: mechanical impacts onto the worm shaft will damage the rolling
bearings.
To assemble brake, repeat steps in reverse order
Mount motor with mounted hub at drive, connect connections
See to it that:
Tightening torque of screws fig. 25 pos. 11 : 22 Nm
Tightening torque of screws fig. 25 pos. 16 : 6 Nm
Secure screws (16) with Loctite 213
Check air gap
Check brake release (the rotor must be able to be turned in an energized
condition of the brake free of brake torque using the handwinding wheel,
fig. 26 pos. 2)
Note: the emergency braking device NBS must be released during testing.
Screw release screws at NBS in. See operating manual NBS.
Air gap check: put a feeler gauge between armature disc (3) and magnet
coil carrier (4) and check air gap (7). Repeat several times at the
circumference.
The brake magnets must be de-energized. (Brake de-energized).
The air gap of new linings should be 0.35-0.45 mm.
See 6.2 Checking of drive brake
1
Gear housing
Rotor with brake linings
Armature disk
Magnet coil carrier
Brake release lever
Motor flange
Air gap
Fig. 26
60
Version 05/2009
TW45B
OPERATING MANUAL
7. MAINTENANCE
7.4 Replacing of brake with shaft version (MRL)

Brake (from Warner) without brake release levers and 2 rotors
Air gap at coil carriers
9 10
11 12
13 14
15
16
6
5
4
3
2
1
Fig. 27
22
21 20
19
18
17
Motor shaft
12
Rotor 2
Set screw
13
Bearing cover
Coupling half
14
Armature disk D
15
Shaft sealing ring
Magnet coil carrier D
16
Gear housing
17
O ring (3x)
Motor flange
18
Worm shaft
Flange ring
19
Brake connection
Rotor 1
20
Retaining washer
10 Magnet coil carrier C
21
Coupling hub
11 Armature disc C
22
Flexible gear ring
61
Version 05/2009
OPERATING MANUAL
TW45B
7. MAINTENANCE
Do not perform any work at the brake without observing the instructions of
the manufacturer in chapter 8.2.2.
Note: when the air gap reaches the maximum value (0.6 mm/gap) or the
brake is defective, it must be completely replaced.
Disassembly:
Switch off power supply and secure drive against unintentional switching
on; secure car and counterweight
Disconnect brake and motor connections; remove motor
Remove flexible coupling
Remove retaining washer at worm shaft front (pos. 20)
Secure brake package using enclosed lockings screws. The respective
mounting holes are in the hole circle of the fastening screws.
Attention: before you loosen the fastening screws, secure brake unit with
enclosed two screws M6 x 80 K8 with red screw head.
Highly pre-tensioned pressure springs are installed between armature base
plate and coil carrier. These parts may burst in case the brake unit is not
secured.
Unscrew cheese-head screws pos. 6.

Remove secured brake unit incl. coupling hub from worm shaft (pos. 18)
using pull-off device screw-connected to front coupling hub by two M5
screws.
Assembly:
Pull new brake unit up onto worm shaft. Align borings with the brake
energized (electrically released).
Bring fastening screws and thread in bearing cover in line and loosely
screw.
Screw-connect coupling hub and worm shaft using retaining washer
pos. 20, cheese-head screw M12 x 25 8.8 and retaining ring. (75 Nm)
Lock fastening screws pos. 6 with Loctite 243 and tighten with required
tightening torque. (9 Nm)
Remove locking screws for brake assembly.
Put flexible gear ring in coupling hub.
Mount motor to gear housing; bring motor coupling and brake in line by
turning the motor shaft.
Tighten motor fastening screws, connect brake and motor.
Check air gap between magnet coil carrier and armature base plates. Repeat
several times at the circumference.
Attention: check brake for correct functiong before it is released for lift
operation.
62
Version 05/2009
OPERATING MANUAL
8.1
TW45B
8. ANNEX
Tightening torque Strength

Attention: verify that screw strength and tightening torque in below table are
observed when work is performed on the machine or parts exchanged.
Secure non-microencapsulated screws against unintentional working loose
by placing washers under and seal with Loctite 243 or the like.
Observe tightening torque and tighten screws using torque wrenches !
The values given apply to the following applications described below. For
motor and connection see instructions of the manufacturer in chapter 8.6.
Below table applies to the remaining fastenings without specification.
DIN/ Tightening
Stren- ISO torque
gth
[Nm]
Disk on worm wheel shaft
Cheese-head screw M16 * 40 micro-encapsulated
Detent edged washer SK M16
Motor at gear flange
Locking screw M12 * 25
Lock washer S12
Counternut M12
8.8
4762
8.8
938
75
75
Brake housing at gear flange

Cheese-head screw M8 * 75 (fig. 24, pos.11)
8.8
4762
22
Release lever at brake housing

Cheese-head screw M5 * 12 (fig. 24, pos.16)
8.8
4762
8.8
4762
1481
75
Handwinding wheel at motor shaft

Lock washer S12
Cheese-head screw M12 * 35
Clamping sleeve 4 * 10
Bearing bracket at housing
Cheese-head screw M10 * 30 micro-encapsulated
Pulse encoder at ventilation grid
Clips nut M4
Cheese-head screw M4 * 8
Lock washer S4
63
40
8.8
8.8
84
Version 05/2009
TW45B
OPERATING MANUAL
8. ANNEX
Cheese-head screws ISO 4762 (DIN 912)

Hexagon bolts ISO 4014 / 4017 (DIN 931 / 933)
Dimension
Tightening torque MA (Nm)
Strength
8.8
10.9
12.9
M4
M5
M6
M8
M10
M12
M16
M20
M24
2,6
5,3
9
23
45
75
190
370
640
12
30
60
110
270
520
900
15
35
75
130
320
620
1100
Note: use micro-encapsulated screws once only.

Only use mounting parts and components from ThyssenKrupp
Aufzugswerke GmbH. In case of disregard ThyssenKrupp
Aufzugswerke GmbH cannot be hold liable.
64
Version 05/2009
TW45B
OPERATING MANUAL
8.2
8. ANNEX
Blocking clamp
Each machine is equipped with a blocking clamp corresponding to the
respective traction sheave (rim width and design)
Use of blocking clamp:
Use the rope clamp to secure the ropes and prevent rope slip or secure
the car / counterweight (release from safety gear operation).
Note: install the two-piece rope clamp on the ropes. Clamp and tighten
clamp screwing accordingly.
Fig. 28
Rope clamp mounting at traction sheave
1
2
3
4
5
6
7
Traction sheave
Ropes
Pressure piece
Washer
Hexagon nut
Spacer
Clamp clip
Attention: remove blocking clamp when installation works are terminated.

Disregard will damage the installation.
65
Version 05/2009
6000
Overview: the following encoders are available for TW45B

1. 1024 - (standard version) / 4096 - TTL (optional)
for v < 1.5 m/s with 1024 pulses material number 9950 000 6021
for v 1.5 m/s with 4096 pulses material number 9950 000 6022
Use cable of 10 m length, SUB-D 9 tab and locking lever acc. to
DIN 46342 for connection
Connector assignment
Connection
Pin Colour
Electrical data:
Power supply: 5 V DC
Minus
Plus
Channel A
Channel B
7
9
2
3
Power consumpt.:
Output:
Load:
Signal level
Zero pulse
Channel A inv.
Channel B inv.
Zero pulse inv.
Shield
5
grey
1
red
4
black
6
violet
8+housing black
white
brown
green
yellow
Pulse frequency:
Circuit protection:
max. 60 mA
push-pull
max. 40 mA
at 20 mA:
H > 3.6 VDC
L < 1.2 VDC
max. 200 kHz
no
Please note instructions of the manufacturer in chapters 8.4 8.5

2. 1024 HTL (optional)with 1024 pulses material number 00 990 16 03 0
Connection by insulated cable of 10 m length with end sleeves.
Connection
Colour
Channel A
Channel B
Channel N
Channel A inv.
Channel B inv.
Channel N inv.
Mass
Plus 15 V
Minus
Shield
Control output:
green
yellow
grey
red
black
violet
yellow
brown
white
cord
rose
Electrical data:
Power supply:
10 - 30 V DC
Power consump.: max. 60 mA

Channels:
A, B, N, ABN inv.
Output:
HTL- differential driver
Load:
max. 40 mA
Signal level:
at 20 mA
H > UB 2,5 VDC
L > 2,5 VDC
Pulse frequency: max. 200 kHz
Circuit protection:: yes
Control output:
NPN OC, 10 mA
Umax. = 30 VDC
Cable length:
max. 10 m
Longer cables available. Please contact manufacturer.
3. 1024 Sine / Cosine - HTL (optional)with 1024 pulses material number 00 990 19 03 0
Connection by insulated cable of 10 m length with end sleeves.
Connection
Colour
Electrical data:
Power supply:
Channel +A
Channel +B
Channel +N
Channel - A
Channel - B
Channel - N
Plus 5 V
Minus
Shield
Power consump.:
max. 100 mA
without load
Channels / output:
sine, cosine, N
Output load:
min 120 Ohm
Terminal resistor between + and
- outputs.
Signal level:
1 Vss +/- 25 %
Max. frequency (-3dB): 100 kHz
Circuit protection:
no
Control output: conductive when defective
Cable length: max. 150m at <260pF/m
Design acc. to DIN VDE 0160
green
grey
black
yellow
rose
violet
brown
white
cord
4.75 5.5 V DC
Part No. 9950 000 6021 mit 1024 Imp.

Part No. 9950 000 6021 mit 4096 Imp.
Part No. 00 990 16 03 0 with 1024 pulses
Part No. 00 990 19 03 0 mit 1024 Imp.
Tightening torque specified by the manufacturer (Siemens)

Applies to specified works to be performed at motor and motor connections.
Fig.1
Tightening torque for screwing of electrical connections junction plate
connections (except for terminal strips)
Thread
M4
M5
M6
M8
M10
M12
M16
min.
[Nm]
0,8
1,8
2,7
5,5
14
27
max.
[Nm]
1,2
2,5
13
20
40
Fig.2
Tightening torque for metal (I) and plastic (II) screwings
M12x1,5 M16x1,5 M20x1,5
M25x1,5
Thread
M32x1,5
M40x1,5
M50x1,5
M63x1,5
I min.
[Nm]
10
I max.
[Nm]
7,5
12
14
II min.
[Nm]
II max.
[Nm]
3,5
Fig.3
Tightening torque for screws at electrical terminal blocks, bearing brackets
and protective conductor screwings
Thread
M4
M5
M6
M8
M10
M12
M16
M20
min.
[Nm]
3,5
16
28
46
110
225
max.
[Nm]
24
42
70
165
340
Check the tools for current functioning before you start installation work !
Nr. 62 310 03 86 0
Ein Unternehmen von ThyssenKrupp Elevator

Bernhuser Strasse 45
73765 Neuhausen a. d. F.
Deutschland
Tel.: +49 7158/12-0
Fax: +49 7158/12-2585
E-Mail: info.aufzuege.de@thyssenkrupp.com
www.thyssenkrupp-aufzuege.de
Issue 05/2009

TW45B

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TW45B

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A company

Modification of brakes 2x50Nm

Anschluss TCM / TCI Steuerungen

Bremsansteuerung bei nicht TCM / TCI

Neuer Bremslfthebel fr Bremse 2x50Nm

Vor Einsatz des Bremslfthebels Anlage ausschalten, Antrieb elektrisch stillsetzen

Beide Bremslfthebel sind

Beide Bremslfthebel gleichmig in Richtung Handrad ziehen

an den Bremsen fixieren

einzelne Bremse lften

Bremshebel mssen nach Bentzung entfernt werden

Anlageblatt zur Betriebsanleitung Maschine TW45B

Folgende Kapitel sind durch das Anlageblatt betroffen:

The issuer responsible for the content:

ThyssenKrupp Aufzugswerke GmbH

Description of machine TW45B

3. Transport and storage

4. Mounting of machine in machine room

4.1 Mounting of rope guard

5. Putting into service

Replacing of traction sheave - installation

Explanation of symbols used

ThyssenKrupp Aufzugswerke GmbH

General safety information

Notes on the operating manual

Duties of the employees

Training of the employees

ThyssenKrupp Aufzugswerke GmbH

Informal information about safety measures

The operating manual must always be available at the location of the

Guarantee and liability

unsatisfactory supervision of parts which are subject to wear

ThyssenKrupp Aufzugswerke GmbH

Description of machine TW45B

Machine TW45B (vertical motor position) consists of:

Real value generator

Rope guard support

Brake release lever

Disk at traction sheave shaft

ThyssenKrupp Aufzugswerke GmbH

ThyssenKrupp Aufzugswerke GmbH

ThyssenKrupp Aufzugswerke GmbH

Emergency braking system NBS:

ThyssenKrupp Aufzugswerke GmbH

TW45B horizontal motor position

ThyssenKrupp Aufzugswerke GmbH

TW45B (TWR) vertical motor position

Brake release lever

ThyssenKrupp Aufzugswerke GmbH

ThyssenKrupp Aufzugswerke GmbH

1) Thread M16 x 25 deep

Version for machine in shaft (MRL) without rope guard

ThyssenKrupp Aufzugswerke GmbH

TW45B version for machine in shaft (MRL) rear view

1) Thread M16 x 25 deep

ThyssenKrupp Aufzugswerke GmbH

ThyssenKrupp Aufzugswerke GmbH

SM1 (TRIBOL 800 / ISO 460)

Designed for use in installations with rated load of 450 kg and

ThyssenKrupp Aufzugswerke GmbH

Machine room (TWR)

Warner & Turco

ERS VAR09 SZ 50/50

180 with overexcitation