Tkaw-Manual-Ba Atr tw63 2018 09-En

Operating manual
TW63B drive
thyssenkrupp Aufzugswerke
Legal information
All rights reserved

© Copyright by thyssenkrupp Aufzugswerke GmbH
Note on industrial property rights ISO 16016
Printed in Germany
This document – including excerpts – may only be reprinted or otherwise copied with the
express approval in writing of thyssenkrupp Aufzugswerke GmbH.
Any duplication, dissemination or storage on data media unauthorised by thyssenkrupp
Aufzugswerke GmbH is an infringement of copyright and shall give rise to prosecution.
Subject to change without notice
We expressly reserve the right to make changes of a technical nature for the purpose of
improving our products or enhancing the safety standard - even without a separate
announcement.
Choice of colours
The choice of colours used in our documents for the components is solely for illustration
purposes in the documentation.
Contact your thyssenkrupp Aufzugswerke sales partner for details of colours for your specific
products.
Form of address
To improve readability, a gender-specific form of address has not been used. Gender-specific
pronouns therefore refer to both men and women.
Issued by
thyssenkrupp Aufzugswerke GmbH
Bernhäuser Strasse 45
73765 Neuhausen a. d. F.
Germany
Tel.: +49 7158/12-0
E-mail: Doku.elevator.plant.de@thyssenkrupp.com
Internet: www.thyssenkrupp-elevator-eli.de
Operating manual Table of Contents
TW63B drive
Table of Contents
1 About these instructions................................................... 5
1.1 Guide to layout ................................................................................ 5
2 Safety .................................................................................. 6
2.1 Warning notes ................................................................................. 6
2.2 Safety requirements ........................................................................ 7
2.3 Warranty and liability ....................................................................... 8
2.4 Dangers in handling the product ..................................................... 9
2.5 International occupational health and safety regulations ................10
2.6 Personal protective equipment .......................................................11
3 Product Description......................................................... 12
3.1 Standards and legal requirements..................................................12
3.2 Description .....................................................................................12
3.3 Functional description ....................................................................17
4 Technology ....................................................................... 20
4.1 Technical data ................................................................................20
4.2 Dimensions of machine ..................................................................21
4.3 Machine base frame .......................................................................25
4.4 Machine base frame dimension sheets ..........................................29
4.5 Encoder ..........................................................................................38
4.6 Brake ..............................................................................................39
5 Transportation and storage ............................................ 40

5.1 Packaging ......................................................................................40
5.2 Transport ........................................................................................41
5.3 Checking the delivery .....................................................................43
5.4 Packaging materials .......................................................................44
5.5 Ambient conditions .........................................................................44
5.6 Standstill maintenance ...................................................................44
6 Installation ........................................................................ 45
6.1 Setting up the machine base frame ................................................45
6.2 Installing and aligning the machine ................................................46
6.3 Mounting the rope guard ................................................................48
6.4 Connecting motors .........................................................................49
thyssenkrupp Aufzugswerke Version 05/2016

Operating manual Table of Contents
TW63B drive
7 Commissioning ................................................................ 53
7.1 Work steps .....................................................................................53
7.2 Emergency operation .....................................................................54
8 Servicing / Maintenance .................................................. 56

8.1 Maintenance period ........................................................................56
8.2 Maintenance measures ..................................................................56
8.3 Lubrication ......................................................................................57
8.4 Checking the backlash ...................................................................59
8.5 Replacing the brake shoes .............................................................61
8.6 Setting and checking the brake shoe stroke and armature base
plate ...............................................................................................63
8.7 Braking deceleration setting ...........................................................65
8.8 Brake readjustment in the event of brake lining wear .....................65
8.9 Replacing the traction sheave ........................................................66
8.10 Replacing the motor .......................................................................68
8.11 Replacing the encoder ...................................................................69
8.12 Check for escaping grease / oil ......................................................71
9 Special versions (optional) ............................................. 73

9.1 Overview of SA special versions ....................................................73
9.2 Brake monitoring circuit ..................................................................74
10 Appendix ........................................................................... 79
10.1 Blocking clamp ...............................................................................79
10.2 Tightening torques..........................................................................80
10.3 Front page Operating Manual Emergency Brake System NBS ......81
10.4 Front page Operating Manual Explosion-proof machines (ATEX) ..82
10.5 Manufacturer specifications Wachendorff, encoder WDG 100H ....83
10.6 Manufacturer specifications mayr, ROBA-stop-z ............................89
10.7 Manufacturer specifications Centaflex..........................................103
10.8 Manufacturer specifications Lapp cable gland SKINTOP MS-SC-
M ..................................................................................................105
thyssenkrupp Aufzugswerke Version 05/2016

Operating manual About these instructions
TW63B drive
1 About these instructions
1.1 Guide to layout

Sequence of actions involving several steps
1. First action.
2. Second action.
 Interim result (optional)
3. Third action.
4. Final action step with end marker.
 Result of action (optional)
Course of action with independent steps

 Action step.
 Action step.
 Action step.
Information
Information must always be read and observed.
Reference
 Chapter 2
List
 Superordinate item of a list
 Subordinate item of a list
 Subordinate item of a list
 Superordinate item of a list
thyssenkrupp Aufzugswerke 5 Version 09/2018

Operating manual Safety
TW63B drive
2 Safety
2.1 Warning notes

 Warning notes are intended for the protection of persons and property.
 Warning notes must be read and observed by every person who works on the
product.
 Warning notes precede activities that pose a hazard for people and the product.
2.1.1 Structure
SIGNAL WORD AND SIGNAL COLOUR
Type and source of danger!
Consequences if danger disregarded.
 Measures to avert the danger.
2.1.2 Identification of personal injury
DANGER
Danger with a high degree of risk!
If ignored, leads to death or serious injury.
 Read and observe warning.
WARNING
May lead to death or serious injury.
CAUTION
Danger with a low degree of risk!
May lead to minor or moderate injury.
2.1.3 Identification of damage to property
NOTE
Hazard with possible damage to property!
May lead to product function impairments or function loss.

TW63B drive
2.2 Safety requirements

This document contains important information for safe operation of the product.
 Keep this document and all other applicable documents at the location of use for
the entire working life of the product.
2.2.1 Area of applicability

This document applies only to the product described here.
Other applicable documents

 International occupational health and safety regulations
2.2.2 Basic requirements for safety

 All existing safety devices are to be tested regularly in accordance with the
maintenance schedule.
 This document, in particular the chapter entitled “Safety", together with the
warning notes and all other applicable documents must be observed by all
persons who work with the product.
 Supplementary to this document, the rules at the location of use with regard to
environmental protection, and the regulations of work safety and accident
prevention must be observed.
 All safety and hazard notices on the installation must be kept in legible condition.
 Safety information and instructions required by law must be displayed to users in
plain view.
 A requirement for safe handling and non-disruptive operation of this product is
knowledge of the fundamental safety regulations.
2.2.3 Obligations of the operating company and installation firm

 Only deploy trained and instructed qualified personnel.
 Provide personnel with the required personal protective equipment.
 Check personnel at regular intervals to ensure that they follow safety-conscious
work practices and comply with national provisions.
 Make all other applicable documents as well as this document available to
personnel.
2.2.4 Duties of personnel

 Clearly establish all areas of responsibility prior to any activity.
 Always wear the personal protective equipment made available to you.

TW63B drive
2.3 Warranty and liability

The 'General Terms of Sale and Delivery' of thyssenkrupp Aufzugswerke GmbH
apply.
The product is configured in the factory and delivered ready for operation.
Warranty and liability claims in the event of injury or damage to property will be
invalidated if attributable to at least one of the following causes:
 Improper use that is not in line with the intended purpose of the product.
 chapter 2.3.1
 Improper installation, commissioning, operation and maintenance of the product
 Operation of the product with defective or inoperative safety devices, guards or
protection devices
 Noncompliance with the information and instructions in the operating manual in
respect of transport, storage, installation, assembly, commissioning, operation
and maintenance
 Structural modification to the product without agreement or approval
 Modification to product features without agreement or approval
 Deficient monitoring of parts that are subject to wear
 Repairs that are carried out improperly
 Cases of catastrophe due to third-party interference or force majeure
 Use on non-approved auxiliary materials and operating fluids
2.3.1 Use in line with intended purpose

The product has been constructed using state-of-the-art technology and in line with
the recognised technical safety regulations. It may only be used in accordance with its
intended purpose and when the technical safety devices are in satisfactory condition.
Any other or additional form of use shall be regarded as non-compliant with the
intended use. thyssenkrupp Aufzugswerke GmbH shall not be liable for any damage
arising from such use and any damage arising due to operator errors.
To comply with the intended use of the product:
 Use the product only as a drive for elevators.
 Read and comply with the document, in particular the chapter entitled “Safety",
together with the warning notes and all other applicable documents.
 Follow the commissioning instructions, observe the installation description and
maintain the required inspection and maintenance work.

TW63B drive
2.4 Dangers in handling the product

 The traction sheave and handwinding wheel of the TW63B are designed without
safety covers. This means that the drive may only be operated in a closed room.
It must be ensured when persons are in the vicinity of the machine that there is
adequate safety clearance to all revolving parts (marked in yellow).
 With the vertical version, do not place any objects (e.g. tools etc.) on the
handwinding wheel, as there is a risk of injury as a result of parts being thrown.
 In the event of improper use, there is a risk of personal injury or to the life of the
user or third parties, or impairment on the subassembly or other assets can
arise. Malfunctions that can impair safety must be rectified immediately.
 When working on the drive, it must be de-energised before work is started, and
the system must be secured against inadvertent switching on.
 A sign indicating that maintenance work is under way on the drive must be
attached in the area of the main switch.
 Emergency brake, NBS: if an emergency brake NBS is fitted, the sequence and
procedure for emergency rescue change. This also applies to testing and setting
up procedures. Follow the instructions in the separately supplied operating
manual.
 The shaft version of the machine (MRL) usually has no manual release (possible
as an option). It can only be operated with suitable electrical additional measures
that are not included in the scope of supply.
 Suitable measures must be taken by the manufacturer of the elevator
installation:
 to be able to operate the brake in emergencies (power failure).
 to enable release of the car from the engaged position if the safety gear is
triggered. (For example, by means of a winching device for ropes on the elevator
car or counterweight.)
 to be able to carry out an individual check of the two brake circuits.
 It must be ensured that a fault generated by the encoder, the brake or the brake
activation is detected by the elevator control or frequency inverter. The control
system must immediately place the elevator in a safe state.
 The elevator system must be fitted with a safety device complying with EN81 or
that detects unintended elevator car movement with the door opened and
initiates suitable measures.

TW63B drive
2.5 International occupational health and safety regulations
Table 2.5-1
International rules for occupational health and safety can also be found in various
languages on our ELI web platform and can be downloaded at:
 http://www.thyssenkrupp-elevator-eli.de/nc/de/downloads.html

TW63B drive
2.6 Personal protective equipment

Danger Cause (examples) Risks Remedy Equipment
 Unprotected shaft Fall Safety harness
 Falling tool
 Suspended load Head
Head injury
 Transport of heavy load protection
 Sharp-pointed objects
 Falling tool
Danger of crushing
 Suspended load in the foot area
Foot protection
 Transport of heavy load Cut or stab injury in
the foot area
 Sharp-pointed objects
Cut or stab injury in

 Sharp objects the foot area
 Mechanical parts Danger of crushing
in the foot area Hand
 Sharp-pointed objects protection
Cut or stab injury in
 Caustic substances the hand area
Acid / alkali burns
 Severe noise pollution Noise damage Ear protection
 Flying parts
 Flying particles Eye injury
Loss of Eye protection
 Laser beams sight/blinding
 Optical beams
Enable source
 Electrical voltage Electric shock
of energy
Table 2.6-1

Operating manual Product Description
TW63B drive
3 Product Description
3.1 Standards and legal requirements

EN81-1:2010-06
The TW63B machines comply with the European standard EN81-1:2010-06 and
EN81-20/50.
The drive is part of the protection device according to DIN EN81-1:2010-06 / 9.11 and
EN81-20/5.6.7.
3.2 Description
3.2.1 Version with vertical motor position IMV1

TW63B Machine with motor version V3F (shown is the vertical IMV1 motor position -
and brake monitoring - SA3/3.1)

TW63B drive
Description of items for Fig. 3.2-1
Item Designation Item Designation

Traction sheave (standard
1 Driving gear (vertical version) 2 version)
Motor of type IMB5/V1 in
accordance with building code
BV6530-06/Bl.6 with integrated
3 4 Operational brake
special flange (standardised
motors) or BV6530-06/Bl.1 with
additional intermediate flange
Handwinding wheel (D270) with
5 Encoder (type WDG100) with V3F 6 V3F and/or flywheel rim with AC2
7 Rope guard (adjustable) 8 Oil drain (3/4")
Oil filling hole and ventilation
9 (R3/4")
10 Oil level monitoring (gauge glass)
Connection for motor and

11 Traction sheave mount 12 temperature monitoring
Intermediate terminal and
connection of the operational Mounting surface for machine
13 brake (only available for the
14 base frame
standardised motors)
Lever for manual brake release Brake monitoring - SA3/3.1
15 16
(not mounted) (optional)
Motor terminal box in extended
version for intermediate terminal
Air entry openings for motor with
17 connection of the operational 18 screen grid
brake (only available for the
standardised motors)
19 Machine name plate 20 Motor type plate
Fig. 3.2-1

TW63B drive
3.2.2 Version with horizontal IMB5 motor position

TW63B machine with motor version V3F (shown with horizontal IMB5 motor position)

Oil filling hole and ventilation
1 Driving gear (horizontal version) 2 (R3/4")
3 Oil level monitoring (gauge glass) 4 Oil drain (R3/4")
Mounting surface for machine Transport hanger (for
5 base frame
6 transportation only)
7 Machine name plate
Fig. 3.2-2

TW63B drive
3.2.3 Version with emergency brake, NBS

TW63B machine with NBS emergency brake system (shown in the horizontal IMB5
motor position, and left-hand traction sheave position)

1 Disc brake - emergency brake 2 Cover plate for brake
system
3 Socket wrench for manual release 4 Screws for manual release (screw
head marked in red)
5 Brake test switch with connection 6 Connection line for brake voltage
line (length approx. 1 m) (length approx. 1 m)
7 Protective cover for brake
Fig. 3.2-3

TW63B drive
3.2.4 Version for traction sheave position in the shaft (SA9)

1 TW63B machine, shown with 2 Traction sheave shaft (SA9
vertical motor position IMV1 version)
3 External bearing (bearing housing 4 Traction sheave (SA9 version)
with self-aligning bearing on
adapter sleeve; shown is the
vertical installation position for
upward rope pull direction)
5 Compensating support (for 6 Mounting surfaces for machine
statically defined machine base frame
mounting)
Fig. 3.2-4
3.2.5 Versions
 Vertical upright (IMV1) motor position with traction sheave position on left
 Horizontal motor position (IMB5) with traction sheave position on left/right
The following versions of the machine can be selected depending on customer
requirements:
 Gear reduction
 Traction sheave version
 Motor version
 Motor arrangement (vertical / horizontal)
 Version of encoder

TW63B drive
3.3 Functional description

The TW63B machine (B = generation) is only operated with IMB5 motors.
Machine with worm gear, anti-friction bearings, lubrication with synthetic gear oil for
traction elevators
3.3.1 Gear
The gear (gear drive) consists of a single-stage worm gear mounted on roller
bearings. The housing is in monoblock design with a bearing bracket integrated on
one side or on both sides and integrated dual-circuit brake. The worm gear toothing
runs in oil. The traction sheave is overhung.
3.3.2 Drive
Depending on the version, the drive comes from a three-phase motor standing (IMV1)
vertically on the gear or flange-connected horizontally (IMB5) on the gear to the worm
shaft, via worm wheel, traction sheave shaft to the traction sheave.
3.3.3 Drive motors

The drive motors are designed as device category IMB5 / V1 to accommodate the
motor. PTC thermistors are installed in the motor to provide protection against thermal
overloads.
3.3.4 Connection
The connection of the thermal motor monitoring and operational brake is located in
the motor terminal box.
More details on the motor can be found in  chapter 6.3
3.3.5 Type of drive

As standard, the TW63B is delivered with a frequency-controlled three-phase motor.
An encoder for speed monitoring can be supplied as an option. This is fitted on the
motor shaft.
Technical data and manufacturer specifications of the offered encoder versions can
be found in  chapter 9.2.4.
In the case of drives for the machine room (TWR), a handwinding wheel is firmly
mounted
For deployment on non-controlled installations, a version with pole changing motor
(AC2 4/16-pin) with flywheel rim is available.
3.3.6 Coupling
Worm shaft and rotor shaft of the motor are connected by a flexible coupling. This
transfers the driving motion to the brake rotor of the disc brake.
3.3.7 Brake
The dual circuit shoe brake is spring actuated. Two independently acting brake shoes
press the brake lining onto the brake disc with spring force preset on the system.
The braking force is configured in such a way that one of the brake shoes is sufficient
to bring an elevator car loaded with full weight to a standstill.

TW63B drive
The brake is released by electrically operated magnetic clamps with armature base
plate.
Release by manual operation
1. Apply the supplied brake release lever to the cast-on recesses of the ends of the
brake blocks.
2. Press the lever in the direction of the machine in the direction of the arrow (see
Fig. 3.3-1).
 This presses the brake shoes apart, releasing the brake. 
1
Item Designation
1 Brake shoes
2 Brake release lever
Fig. 3.3-1
3.3.8 Emergency braking device NBS

The optional version of the emergency brake (NBS) meets the requirements for the
protection device that prevents overspeed in the upward-moving elevator car in
accordance with DIN EN81-1:1998 / 9.10 or DIN EN81-20/5.6.6 and unintended
elevator car movements in accordance with DIN EN81-1:2010-06 / 9.11 (EN81-1/A3)
or DIN EN81-20/5.6.7.
Details of the emergency brake (NBS) can be found in a separate operating manual
that is supplied if the brake is fitted.
3.3.9 Traction sheave

The one-part traction sheaves are fastened overhung on the traction sheavehaft by
using a cone (1:15) and a mounting plate including 3 screws (M16-8.8
microencapsulated with locking washer).
Different versions of traction sheave are used, depending on the location of the
machine.
 Standard version - Traction sheave position in the machine room
 Special version SA9 - Traction sheave position in the shaft

TW63B drive
name unit technical data

machine design standard / SA9
diameter - DT mm 450 510 590 520 675
rim width - B mm 132 110 96
9 x8 7 x8 6 x8
8 x9 7 x9 6 x9
2)
max. number of grooves - z x d 7 x 10/11 6 x 10 5 x 10/11
6 x 12 3) 5 x 11/12 4 x 12 3)
6 x 13 3) 5 x 13 3) 4 x 13 3)
groove type 1)
seat / vee groove
angle of the vee grooves ° depends on order 1)
weight kg 50 60 70 50 70
material special alloyed EN-GJL 250
1)
Version in accordance with product description groove profiles with hardened groove flanks (min. 50 HRc).
2)
With minimum groove clearance - RAmin in accordance with product description groove profiles
3)
with Tmin for hardened grooves in accordance with product description groove profiles TW63_30301_ENG
Table 3.3-1

Operating manual Technology
TW63B drive
4 Technology
4.1 Technical data

manufacturer ThyssenKrupp Elevator
gear type TW63B
axle distance mm 155
gear ratio 54:1 / 48:1 / 33:1 / 48:2 / 43:3
vertical motor position: approx. 11
oil filling l
horizontal motor position: approx. 9
synthetic gear oil
type of oil
(polyalkyleneglycol with additives)
designation SM1
circumfer. backlash ° 0.025 - 0.07
weight kg approx. 190
TW63_30101_ENG
Table 4.1-1
Load data traction sheave shaft

The load values Ftzul set out below represent the limiting value of the permissible
radial load on the traction sheave shaft calculated from the overall masses present at
the installation.
 Traction sheave shaft - standard version and emergency brake system Ft  43
kN
 Traction sheave shaft - SA 9 (with external bearing): Ft  41 kN
For the machine with the traction sheave shaft in the standard version, there are
restrictions in place for Ft for the horizontal and vertical upwards rope departure
directions:
 Machine with horizontal motor position: Ft  35 kN
 Machine with vertical motor position: Ft  43 kN,
i.e. no restriction
Weight
Standard version of motor in IMB5/V1 design.
Components Values
Gear drive (without traction sheave) approx. 180 kg
Gear drive SA 9 (without motor, without traction sheave) approx. 220 kg
Gear drive
approx. 230 - 250 kg
(without motor, with traction sheave depending on size)
Traction sheave according to order 450 - 675 mm approx. 50 - 70 kg
Motor see motor type plate

TW63B drive
4.2 Dimensions of machine
4.2.1 Version with vertical motor position IMV1
TW63_30906_GER

Mount of machine on machine
1 Machine centre of gravity 2
base frame
Operation lever for manual
3
brake release (plug-in)
Fig. 4.2-1

TW63B drive
4.2.2 Version with horizontal motor position IMB5
TW63_30907_GER

Mount of machine on machine
1 Machine centre of gravity 2
base frame
Operation lever for manual
3
brake release (plug-in)
Fig. 4.2-2

TW63B drive
4.2.3 Version with emergency brake, NBS (additional masses)
TW63_30908_GER
Fig. 4.2-3

TW63B drive
4.2.4 Version for traction sheave in the shaft - SA9 (additional masses)
TW63_30909_GER

260 with vertical motor position
Mount of machine and external
1 310 with horizontal motor 2
bearing on machine base frame
position
Fig. 4.2-4

TW63B drive
4.3 Machine base frame

The machine base frames with and without rope pulley described below are intended
for installation of the machine in the machine room above or below, beside the shaft.
4.3.1 AY machine base frame TW63 NO/2:1

Machine base frame version without rope pulley for use in:
 Installations with 1:1 rope suspension and direct rope departure for a rope
distance elevator car to counterweight ASL  775 mm and traction sheave dia.
675 mm (e.g. installations of type NO41/51)
 Installations with 2:1 or 4:1 rope suspension
 Weight of machine base frame: approx. 80 kg
TW63 machine base frame NO/2:1

(shown with TW63B machine in vertical motor position)

TW63 machine base frame
1 TW63B machine 2 NO/2:1
Insulation elements (shown is the Mounting parts for machine on
3 4
version with support) machine base frame
Fig. 4.3-1

TW63B drive
4.3.2 AY machine base frame TW63 NO/MSR

Machine base frame in version with rope pulley depending on the pulley hub position
in left-hand or right-hand configuration for use with:
 Installations with 1:1 rope suspension and rope distance elevator car to
counterweight ASL = 745  775 mm in conjunction with traction sheaves dia.
450, 510 and 590 mm (e.g. installations of type NO41/51)
 Weight of machine base frame (including rope pulley): approx. 170 kg
The rope pulley that is used is the version D450-7x10 with groove clearance = 18
mm (rope pulleys, see product description for mechanical elevator parts, type 6070-
6079_NBO2 - standard sheet 60 720 12 00 0). The rope pulley has maintenance-free
rolling bearings.
TW63 machine base frame NO/MSR (shown is the machine base frame with rope
pulley position on left and TW63B machine in horizontal motor position with NBS
emergency brake system)

1 TW63B machine 2 Upper frame part NO/MSR
3 Supports for rope pulley D450 4 Rope pulley D450 - 7x10
Mounting parts for machine on
5 Supports for insulation elements 6 machine base frame
Insulation elements (shown is the
7 version with support)
Fig. 4.3-2

TW63B drive
4.3.3 AY machine base frame TW63 BO/MSR

Machine base frame in version with rope pulley depending on the pulley hub position
in left-hand or right-hand configuration for use with:
 Installations with 1:1 rope suspension and rope distance elevator car to
counterweight
ASL = 566  1143 mm (e.g. installations of type BO/SO 41/51)
The rope pulleys used are the versions D360-7x8, D450-7x10 mm or D540-7x13
(rope pulleys, see product description for mechanical elevator parts, type 6070-
6079_NBO2 - standard sheet 60 720 12 00 0). The rope pulleys have maintenance-
free rolling bearings.
TW63 machine base frame BO/MSR (shown is the machine base frame with rope
pulley position on left and TW63B machine in horizontal motor position and traction
sheave position on left)

TW63B drive

1 TW63B machine 2 Upper frame part NO/MSR
Supports for rope pulley D360,
3 450 or 540
4 Rope pulley D360, 450 or 540
Mounting parts for machine on

5 Supports for insulation elements 6 machine base frame
Insulation elements (shown is the
7 version with support)
Fig. 4.3-3
Weight of machine base frame

rope pulley version[mm] m weight including rope pulley
D360 170
D450 kg 200
D540 230
TW63_31007_ENG
Table 4.3-1
4.3.4 Mounting parts for machine on machine base frame

A set of bolting elements (M20-8.8) is available for mounting the TW63B NO/2:1,
NO/MSR and BO/MSR machine on the machine base frame.

TW63B drive
4.4 Machine base frame dimension sheets
4.4.1 Version without rope pulley NO/2:1
TW63 machine base frame NO/2:1 with TW63B machine

Horizontal motor position/traction
1 Vertical motor position 2 sheave position - right
Additional insulation element for
3 4 load of traction sheave shaft
sheave position - left
P > 38 kN
Fig. 4.4-1

TW63B drive
Project planning dimensions:

Project planning dimensions x1 and x2 (see dimension sheet for machine base frame
NO/2:1)
Intermediate values for x1 and x2 in the modular dimension of 68 mm possible
traction sheave version configuration with machine on frame
1), 2) 1), 2)
DT [mm] left right left 3) right 3)
x1 x2 x1 x2 x1 x2 x1 x2
mm mm mm mm mm mm mm mm
450 96,5 368,5 368,5 96,5 136,5 328,5 340,5 124,5
510 66,5 338,5 338,5 66,5 106,5 298,5 310,5 94,5
520 61,5 333,5 333,5 61,5 101,5 293,5 305,5 89,5
590 94,5 230,5 230,5 94,5 66,5 258,5 202,5 122,5
675 120,0 92,0 148,0 160,0 80,0
Remarks TW63_31005_ENG
1) machine with upright motor

2) machine with horizontal motor / traction sheave on the right
3) machine with horizontal motor / traction sheave on the left
Table 4.4-1

TW63B drive
4.4.2 Version with rope pulley NO/MSR/rope pulley position on left
TW63 machine base frame - NO/MSR / left rope pulley position with TW63B machine

1 Vertical motor position 2 sheave position - right
3 sheave position - left
Fig. 4.4-2

TW63B drive

 Rope clearance dimensions elevator car to counterweight ASL and wrap angle 
traction sheave design ASL [mm]  [°]
DT [mm] 1) 2)
450 745 155 156
510 775 158 159
590 775 164 165

2) machine with horizontal motor
Table 4.4-2

TW63B drive
4.4.3 Version with rope pulley NO/MSR/rope pulley position on right
TW63 machine base frame - NO/MSR / right rope pulley position with TW63B
machine

Horizontal motor position/
1 Vertical motor position 2 traction sheave position - right
3 traction sheave position - left
Fig. 4.4-3

TW63B drive

 Rope clearance dimensions elevator car to counterweight ASL and wrap angle 
traction sheave design ASL [mm]  [°]
DT [mm] 1) 2)
450 745 155 156
510 775 158 159
590 775 164 165

2) machine with horizontal motor
Table 4.4-3

TW63B drive
4.4.4 Version with rope pulley BO/MSR/rope pulley position on left
TW63 machine base frame - BO/MSR / left rope pulley position with TW63B machine

Fig. 4.4-4

TW63B drive

Rope clearance dimensions elevator car to counterweight ASL and wrap angle 
 Clearance dimensions for ASL possible in the modular dimensions 68 mm
version rope pulley version[mm]
traction sheave D360 D450 D540
ASL  ASL  ASL  ASL  ASL  ASL 
DT [mm]
min max max min min max max min min max max min
450 622 166 1098 137 566 169 1042 137 566 168 1042 133
510 [mm] / 652 168 1128 139 664 166 1072 139 664 164 1072 135
520 - - - - - - - - 669 164 1077 135
590 [°] 760 166 1100 145 704 170 1044 146 704 168 1044 142
675 802 169 1143 147 815 168 1087 149 883 160 1087 145
TW63_31008_ENG
Table 4.4-4
rope pulley version dimension x1 dimension x2 dimension y1 dimension y2 dimension z1

SR [mm] [mm] [mm] [mm] [mm] [mm]
360 130 61 700 190 245
450 231 116 655 235 255
540 276 116 575 315 255
TW63_31009_ENG
Table 4.4-5

TW63B drive
4.4.5 Version with rope pulley BO/MSR/rope pulley position on right
TW63 machine base frame - BO/MSR / right rope pulley position with TW63B
machine

Fig. 4.4-5

TW63B drive

Rope clearance dimensions elevator car to counterweight ASL and wrap angle 
 Clearance dimensions for ASL possible in the modular dimensions 68 mm
version rope pulley version[mm]
traction sheave D360 D450 D540
ASL  ASL  ASL  ASL  ASL  ASL 
DT [mm]
min max max min min max max min min max max min
450 622 166 1098 137 566 169 1042 137 566 168 1042 133
510 [mm] / 652 168 1128 139 664 166 1072 139 664 164 1072 135
520 - - - - - - - - 669 164 1077 135
590 [°] 760 166 1100 145 704 170 1044 146 704 168 1044 142
675 802 169 1143 147 815 168 1087 149 883 160 1087 145
TW63_31008_ENG
Table 4.4-6
rope pulley version dimension x1 dimension x2 dimension y1 dimension y2 dimension z1

SR [mm] [mm] [mm] [mm] [mm] [mm]
360 130 61 700 190 245
450 231 116 655 235 255
540 276 116 575 315 255
TW63_31009_ENG
Table 4.4-7
4.5 Encoder
The installation and connection are described in  Chapter9.2.4 external operating
manual in the Appendix
Encoders are distinguished by type depending on the control system deployed.
The following encoders are available for the TW63B.
Encoder type Pulses Use
1024
TKAW inverters and third-party inverters
TTL 4096
1024 TK Brazil 1)
HTL 1024 Third-party control systems and/or inverters
Sine-cosine 1024 Third-party control systems and/or inverters
1) Version with adapted connector for TK Brazil
MOTOREN_34300_ENG
Table 4.5-1

TW63B drive
4.6 Brake
4.6.1 Service brake

Redundant electromagnetic dual-circuit outside shoe brake on the motor / worm shaft
integrated in the gear or motor flange. The electric ventilation of the brake circuit takes
place via magnetic clamps. The magnetic clamp are available in standard and in
explosion-proof versions.
A flexible coupling must be integrated on the brake disc to connect the motor and
worm shafts.
manufacturer ThyssenKrupp Aufzugswerke
type TW63B
braking torque Nm max. 2 x 90
braking torque adjustment possible
double-circuit outside shoe brake
design
with brake disk of EN-GJL 250
brake lining made without asbestos
brake disc diameter mm 200
air gap mm 0,3
air gap adjustment possible
1 magnetic clamp per brake circuit
electrical ventilation
(2 magnetic clamps in series connection)
nominal force - magnetic clamps N 2500
180 - overexitation
operating voltage VDC
90 - retentive voltage
rated current A 1.5
monotoring devices brake test switch
manual ventilation brake release lever (not installed)
type of protection - magnetic clamps IP65

II 2 G EEx m II T5
length of connection cable m 1.3 1.5
type approval sign without (not required)
TW63_30201_ENG
On the electromagnetically operated 2-circuit outside brake shoe, the two brake
magnets are connected in series. The table values apply as total connection values
for series connection.
4.6.2 Emergency brake

More detailed information as well as technical information for setting up and operation
of machines with NBS emergency brake can be found in a separate
operating manual. These are delivered with drives with emergency brake
system equipment.
The part number for the German instructions is: 65 990 01 86 0
The part number for the English instructions is: 65 990 02 86 0
The part number for the French instructions is: 9710 000 9229

Operating manual Transportation and storage
TW63B drive
5 Transportation and storage
5.1 Packaging
Fig. 5.1-1
The gear box casing is bolted directly onto the special pallet.
Further packaging depends on the order and is country-specific (air/sea/land freight).
Pay attention to the picture symbols on the packaging or other visible areas.
Top Fragile goods Protect Protect Hand Attach here

against against hooks
water heat prohibited
Fig. 5.1-2

TW63B drive
Dimensions and weight

3. Consult the label on the packaging below the transport hanger for the weight
data.
4. Refer to the delivery note for the dimensions.
5. Consult the technical data for the approximate details. Chapter 4.1
5.2 Transport
Transportation must be effected in compliance with the safety regulations and
observing the centre of gravity of the machine.
NB: machine is filled with oil. It may only be transported and stored upright.
NOTE
Inappropriate transport of the machine!
Damage to the machine.
 Comply with the safety regulations and pay attention to the centre
of gravity of the machine and frame.
 Do not lift the machine at the motor or pedestal bearings.
 For transport, always pick up the transport pallet, not the machine
itself, with the forklift.
5.2.1 Fork-lift truck transport

CAUTION
Pay attention to protruding parts!
Danger of injury and damage.
 When transporting the machine, maintain a safe distance.
5.2.2 Crane transport

WARNING
Falling transported goods!
Death or crushing of limbs.
 Do not walk underneath suspended loads.
 Secure the machine without base frame with rope on the

transport hanger. In the case of a machine that is mounted on the
machine base frame, attach a transport rope to the base frame.
 Secure the machine against slipping and falling over.

TW63B drive
NOTE
Damage during transport!
May lead to product function impairments or function loss.
 Transport type only for machines without machine base frame
 Use only high-strength eyebolts (grade 8).
 Protect the fan hood against damage.
 In the case of the AC2 6.8 kW motor, use the welded-on transport
eyebolts.
Machine with horizontal motor position (without machine base frame)
Fig. 5.2-1
Fig. 5.2-2
Description of items for Fig. 5.2-1 and Fig. 5.2-2

1 Transport hanger

TW63B drive
Machine with vertical motor position (without machine base frame)

Permitted transport eyebolts M10
(2x)
1 Lifting gear 2 grade 8, high-strength
(not included in the scope of
supply)
Fig. 5.2-3
 Lift the machine with suitable lifting gear slowly without jerking.
5.3 Checking the delivery

1. Check the completeness of the delivery.
2. Compare the order and delivery documents.
3. Check the packaging for damage and any other conspicuous anomalies.
In the case of damage

4. Document any damage you have determined immediately in a sketch or photo
and provide a written description in a damage report.
5. Forward the damage report immediately to thyssenkrupp Aufzugswerke GmbH.

TW63B drive
5.4 Packaging materials
Specific transport equipment and shipping braces remain with the customer.
 Dispose of packaging materials in an environmentally compatible manner.
5.5 Ambient conditions
5.5.1 Intermediate storage
Bare parts have no long-term preservation.
 The product may be exposed to a maximum relative air humidity of 60% (at 20
°C).
 Store the product carefully in a protected location.
 Protect it against the formation of condensation and moisture.
 Protect against dirt in the machine.
5.5.2 During operation

 The environment at the final location must correspond to normal indoor climate
conditions for elevator machines and pulley rooms (in accordance with EN81,
between + 5 °C and + 40 °C).
5.6 Standstill maintenance

If the drive is not installed for a longer period, the following measures are to be carried
out annually:
1. Release the operational brake manually by means of the brake release lever and
(if present) the emergency break manually by releasing the emergency release
screws.
2. Turn the traction sheave disc by means of the handwheel at the motor by 3
revolutions in both directions.
3. Depending on the storage conditions, replace the corrosion protection of the
bare parts (for example with Rivolta KSP 317 corrosion protection wax).

Operating manual Installation
TW63B drive
6 Installation
6.1 Setting up the machine base frame

The base frame is set up depending on the customer on supports, beams, a concrete
pedestal or directly cast in the machine room floor.
For reducing noise and sound transmission, we offer insulation elements, which can
be inserted between the frame supports and the ground. These differ according to the
type of mounting:
 Rubber block 100 x 100 x 50 without packing.
 For mounting the drive on the machine room floor without a cement floor
or directly surface-mounted on the cement floor.
 Rubber block 100 x 100 x 50 with additional packing 140 x 140 x 80 mm
 For installation on cement floor, packing cast into cement floor
(thickness ≤ 60 mm). The packing component must be cast in when
installing the cement floor.
The number and arrangement of rubber elements is based on the total load and
distance between the rope departures (ASL) dimension.
When arranging the supports, the overall centre of gravity must lie within the rubber
elements.
The arrangement under the machine base frame should be such that the stress
and/or buffering of the insulation elements (maximum difference 3 - 5 mm) is as even
as possible.
1. Loosely bolt together the delivered base frame in the machine room.
2. Mount the supports with additional drilled holes and pulley support on the side of
the deflecting pulley.

TW63B drive
Left-hand design Right-hand design
3. Mount and secure the deflecting pulley with axle on the pulley supports.
4. Set up the frame on the insulation elements according to the general arrangement
drawing.
6.2 Installing and aligning the machine

NOTICE
Wear on rope pulley, traction sheave and rope!
Imprecise alignment of the rope pulley and traction sheave can lead to
excessive wear of the components.
 Align the drive on the frame by displacing it along the parallel
distance (ASL) to the outgoing rope.
 The rope departure from the traction sheave and diverter pulley is
to be aligned plumb according to plan of installation on the elevator
car rope pulley or the counterweight pulley.
1. Use lifting gear to place the machine on the base frame; the traction sheave
must be on the deflecting pulley side.
2. Move the machine sideways on the base frame in accordance to the punched
grid until the required ASL dimension (parallel gap between the ropes at the rope
departure) is reached

TW63B drive
3. Balance out uneven surfaces by inserting the enclosed shims.

(Balancing by means of the supplied shims)
4. Bolt the machine onto the frame, whereby the machine housing must not be
tensioned.
5. Align the rope grooves of the traction sheave and deflecting pulley in parallel.
6. Tighten the screws with the prescribed tightening torque.  Chapter 10.2
7. Plumb the rope departure on the rope pulley at the elevator car and/or mounting
on the car and counterweight.
With a horizontal rope departure, the gear box casing on the machine base frame is
to be secured against shifting by means of car steady plates.
SA9 traction sheave in the shaft, machine with extended traction sheave shaft
and pedestal bearing.
Important: On setting up a gear drive with pedestal bearing, it must be ensured
without fail that
 the compensating supports are mounted and secured according to instructions
 the traction sheave shaft is aligned horizontally
 the bearings of the machine and the outside bearing are exactly aligned

TW63B drive
6.3 Mounting the rope guard

1. Use the enclosed screws to bolt the rope guard onto the rope guard carrier.
2. Pivot the rope guard carrier to set the guard in such a way that the gap between
the rope and guard on the rope run-in and run-out side of the traction sheave is
as small as possible. (1 -2 mm)
3. With inclined pulling, adapt the location of the rope guard carrier by remounting
the changed rope pull direction.
Tighten the securing bolts of the rope guard carrier on the gear drive after alignment
with the prescribed tightening torque.  Chapter 10.2
2 1
max. 1-2 mm

1 Rope guard carrier 2 Rope guard
Fig. 6.3-1
CAUTION
Danger with a low degree of risk!
May lead to minor or moderate injury.
 For machines with rope run-in direction from 0 - 90°above

horizontal (e.g. machine arrangement down/up beside),
an additional rope guard is required to prevent foreign
bodies penetrating between the rope and grooves.
If the rope run-in zone is protected within the machine base frame, the function
"protection against injury" is not required.
For SA9 traction sheave in the shaft, no rope guard is fitted at the plant.

TW63B drive
6.4 Connecting motors
NOTE
Danger with potential damage to property!
Can result in functional impairment or loss of function of the product.
 On connecting the motor, the enclosed terminal connecting plan in

the motor connection box is to be complied with.
The connection values can be found on the type plate.
 For EMC compliant installation of motor, break and encoder use

appropriate shield supports.
6.4.1 Terminal connecting plan for motor, PTC thermistor and magnetic
clamps

1 Connection of magnetic clamps 2 Motor connection
3 Connection of PTC thermistor 4 Connection of positive earth
Fig. 6.4-1

TW63B drive
6.4.2 Connecting the motor line
2 3
1 4

1 Cable with shielding braid 2 Lock nut
3 Lamellar insert 4 Cap nut
Abb. 6.4-2
1. Strip the insulation from the connection line.

2. Route cable through the cable gland.
3. Connect the positive earth to the green-yellow series terminal and/or the intended
screwed connection.
4. Connect the three motor wires to the terminals U, V and W, as specified in the
terminal connecting plan.
5. Pull the shielding braid evenly over the lamellar insert.
 The braid must not protrude beyond the lamellar insert into the thread.
6. Pull the cable through the cap nut.
7. Push the cap nut over the shielding.
8. Tighten the cap nut with the recommended torque in accordance with
manufacturer documentation  chapter 10.8
6.4.3 Connecting the PTC thermistor

A triggering device (motor protection device) is required for evaluation of the PTC
thermistor temperature sensor installed in the motor. This is to be connected to the
terminals acc. to Fig. 6.4-3 and Fig. 6.4-4.
Do not apply a voltage greater than 2.5 V at the terminals of the posistor. Adhere to
the internal resistance of the measurement devices!
1. Strip the insulation from the connection line.

2. Connect the protective earth conductor to the green-yellow terminal block.
3. Connect the two wires as specified in the terminal connecting plan.
4. Tighten the cap nut with the recommended torque in accordance with
manufacturer documentation  chapter 10.8.

TW63B drive
6.4.4 Connecting the brake

The brake (2 magnetic clamps) is to be connected via the motor connection box (see
Fig. 6.4 1).
6.4.5 Terminal connecting plan V3F

1 Motor 2 Posistor
Brake (intermediate terminal
3 Encoder 4 connection)
Fig. 6.4-3 Survey diagram for CEG MT132S and
MOTORLIFT CMRF160L1 motors for TW63B

TW63B drive
6.4.6 Terminal connecting plan AC2
1 2 3 5 4
TW63_39002_GER

1 Motor (high speed) 2 Motor (slow speed)
Intermediate terminal connection,
3 Posistor 4 brake
Forced ventilation with
5 temperature switch (70°C)
Fig. 6.4-4 Survey diagram TW63B pole changing (AC2) in design

Operating manual Commissioning
TW63B drive
7 Commissioning
7.1 Work steps
For assembly, use only original construction and mounting parts from thyssenkrupp
Aufzugswerke GmbH, as otherwise no warranty can be provided.
Before commissioning the machine, the following points must be checked and carried
out:
OK Work step 
1. Remove safety, auxiliary and installation tools from the


danger zone.
2. Check setup and alignment of machine, base frame, rope


departure and base.
3. Check the oil drain pipe is seated securely and leak-tight.


(Machine is filled with oil at the plant)
 4. Check the gear oil level.
 5. Check the secure mounting of the machine and base frame.
6. With a side or oblique rope departure, the gear housing is


secured against moving with end stops and set screws.
7. Make sure that the bolts are tightened with the prescribed
  Chapter 10.2
torque and secured.
 8. Check the brake shoe stroke and setting  Chapter 8.5.2
9. With SA3, SA3.1 and SA15, check the setting and function of
  Chapter 9.1
the brake test switches.
 10. Conduct a brake test with one brake shoe in each case.  Chapter 8.6
 11. Check the function of the handbrake release.  Chapter 10.2
 12. Fit the rope guard and set the distance to the traction sheave.  Chapter 6.3
13. Check whether the power connections and earthing of the

 motor, forced ventilation and brake magnet are connected
and secured.
14. Stick the direction arrow (Up / Down) clearly visible on the
 motor near the handwinding wheel according to the direction
of travel.
Table 7.1-1

TW63B drive
If the traction sheave and rope pulley are delivered separately, they are to be
mounted properly.
If the machine was dismantled due to weight, transport or space, removed parts are
to be reassembled to their original state and the mounting parts tightened with the
corresponding tightening torque.  Chapter 10.2.
7.2 Emergency operation

The TW63B is equipped for emergency operation with a handwinding wheel and a
brake release lever that is delivered separately.
Emergency rescue of trapped persons

1. The brake release lever is to be applied to the cast-on recesses of the ends of
the brake shoes.  Fig. 7.2-1
2. Pressing the levers together presses the brake shoes apart, opening the brake.
3. The brake opens.
4. The handwinding wheel might also have to be moved to bring the elevator car
into the nearest landing.
5. Depending on the load, the elevator car can begin to move quickly after opening
the brake.
6. Immediately let go of the handwinding wheel and control the speed of the
elevator car by pressing the brake release lever with varying degrees of force. 
CAUTION
Abrasion injuries
If the handwinding wheel is used for installation and maintenance
purposes (e.g. pulling out of the safety gear), the person performing the
operation must ensure they have a firm and safe stance.
There is also a risk of injury when simultaneously operating electrical
recall.
 Pay special attention.

TW63B drive

1 Brake shoes 2 Brake release lever
Fig. 7.2-1

Operating manual Servicing / Maintenance
TW63B drive
8 Servicing / Maintenance
8.1 Maintenance period

Maintenance of the machine should take place within the framework of central
maintenance of the elevator, at least once a year.
8.2 Maintenance measures

OK Work step 
 1. Check the oil level and top up if necessary. Chapter8.3.3
 2. Change the oil when the change date is reached. Chapter 8.3
Chapter 8.5
3. Check the brake shoes for wear; the remaining lining

thickness must be at least 3 mm.
Chapter 8.7
4. Check the brake setting; the shoe stroke should be 0.3 + 0.1

mm.
 Chapter 8.6
5. Check the braking deceleration.
Chapter8.7
6. Check the armature base plate setting and its ease of

movement.
 7. Check worm gear toothing for wear.

Chapter8.4
8. Check the backlash between the worm shaft and worm

wheel.
9. Check the groove profile on the traction sheave for damage


and wear.
Chapter 10.2
10. Check that the bolts of the traction sheave mount are

securely seated.
 11. Check rope pulley grooves for damage and wear.
12. Check proper and adequate condition and safety of electrical


connections.
13. Check that protective and safety devices are present and

correctly set.
Table 8.2-1

TW63B drive
8.3 Lubrication
NOTE
Gear and bearing damage
Damage to the gear and outside bearing due to unsuitable lubricant
 Use only the specified lubricants.
8.3.1 External warehouses

On delivery, the initial filling took place at the plant.
Material number Denomination grease quantity

AY multipurpose grease F1 Annually:
60 300 27 900
400 g cartridge 80 g re-lubrication
Table 8.3-1
8.3.2 Gearbox
On delivery, the initial filling took place at the plant.
Lubricant Replacement interval Motor position = filling

amount
For the first time after 4
vertical = 11 litres
Synthetic gear oil SM1 years
horizontal = 9 litres
then every 8 years
Table 8.3-2
Never mix different types of oil.

Do not let any oil seep through to the groundwater.
Dispose of old oil as well as cloths contaminated with oil and grease according to
prevailing regional regulations.
Only use lubricants approved by THYSSENKRUPP AUFZUGSWERKE GmbH
Oil change
1. Before the oil change, run the gear until it reaches operating temperature (at
least 35°C).
2. Discharge the gear oil by removing the cap on the oil drain pipe and collect the
old oil in a container specifically designed for the purpose.

TW63B drive
WARNING
Risk of scalding!
Caution: hot oil represents a risk of scalding!
 Be particularly careful.
3. Close the oil drain after discharging the gear with sealing tape and the cap.
4. Fill the machine with the prescribed oil quantity through the upper opening on the
gear housing (red cap, see Fig. 8.3-1
5. Check the level at the oil gauge glass (see Fig. 8.3-1)
6. Enter the date for the next oil change in the type plate on the gear box casing.
tical motor position
Horizontal motor position

1 Oil filling hole 2 Oil gauge glass
3 Oil drain
Fig. 8.3-1

TW63B drive
8.3.3 Checking the oil level

The oil level must be +/- 5 mm from the middles of the gauge glass.
When topping up, the machine should remain at a standstill for a certain period (at
least 5 minutes).
The drive is filled with oil at the plant.
Oil level at middle of gauge glass +/- 5 mm
Fig. 8.3-2
8.4 Checking the backlash

DANGER
Leads to death or serious physical injury.
Wear enlarges the backlash on the worm drive between the worm wheel
and worm shaft.
If the wear limit value (backlash) of 1.5 mm is reached, the gear drive
can no longer be deployed for safety reasons. Replace the gear drive.
Measurement possibility:
1. Take the load off the gear drive; (remove ropes from the traction sheave).
2. Run the measuring operation with the brake closed.
3. Fit a measuring attachment to the traction sheave; e.g. screw clamp.
4. Specify the measured radius (M).
5. Mark the measuring point. The radius (r) for the TW63B = 130 mm.
6. Attach a dial gauge with magnet stator at the gear drive housing and align to the
measuring point (M).
7. Turn the traction sheave by hand until the dial gauge pointer moves.
8. Move the traction sheave back and forth until resistance is felt in both directions.
9. The tooth flanks of the worm wheel should be applied a load of approx. 20 - 50 N.
The worm shaft must not move, as otherwise the measurement result is falsified
(bearing clearance).
10. Reader of the movement of the dial gauge.

TW63B drive
11. Use the formula below to calculate the backlash.

12. This measurement is to be carried out in at least three different positions on the
worm gear toothing!
Traction
she
ave
Worm wheel
Fig. 8.4-1
M = measured radius
ME = measurement result
r = radius - worm wheel All dimensions in mm
Backlash = ME * r
M

TW63B drive
8.5 Replacing the brake shoes

With a remaining lining thickness of less than or equal to 3 mm or if the linings are
damaged (e.g. glazing), the brake linings must be replaced.
8.5.1 Disassembly
1. Switch off the installation power supply.
2. Secure the car and counterweight before starting work.
3. Loosen the nuts on the tension springs and remove.
4. Remove the bolt and locking screw and brake shoe pins.
5. Undo the cover ring from the armature base plate.
6. Undo the lock nuts on the armature screw and turn the armature screw together
with the armature base plate slightly back to enlarge the gap between the
magnetic clamp and armature base plate.
7. Remove the brake shoe pin by means of the locking screw and the thread on the
face of the pin.
8. Remove the compression springs, including spring plates and bolt
9. Remove one brake shoe.

TW63B drive
8.5.2 Installation
1. Mount the armature base plate on a new brake shoe. In doing so, lightly grease
the rubbing surface between the armature base plate and armature screw.
2. Check the ease of movement of the armature base plate; adjust if necessary. It
should be possible to move the armature base plate with low resistance on the
screw. If required, lightly grease the sliding surface between the armature base
plate and armature screw.
3. Secure the setting of the armature base plate pre-tension by tightening the lock
nuts.
4. Install the pre-assembled brake shoes; do not tighten the nuts on the tension
springs. Make sure the thread on the brake shoe pins is on the outside on
installation, as the pin can otherwise no longer be pulled out. Mount the locking
screw with washer for the pin.
5. Use the hexagon head nut to pre-tension the compression springs to a maximum
of 13.5 mm. (approx. 10.8 revolutions) Secure the settings with the lock nut.
6. Set the brake shoe stroke by adjusting the armature base plate screw on the
brake shoe. The brake shoe stroke should be 0.3 mm + 0.1 mm, measured to
the middle of the brake disc.
7. Push the cover ring over the gap between the magnetic clamp and armature
base plate.
8. Replace and set the second brake shoe in the same way.
9. After replacement of the brake shoes, run the elevator with electrical recall and
observe whether both brake shoes open uniformly.
10. Check the travel and deceleration and readjust if necessary.

TW63B drive
1 2 3 4
9
Stroke 0.3 + 0.1
mm

1 Tightening screw 2 Worm shaft
3 Brake disc 4 Magnetic clamp
5 Cover ring 6 Armature base plate
7 Armature base plate screw 8 Brake shoes
9 Dial gauge
Fig. 8.5-1
8.6 Setting and checking the brake shoe stroke and armature
base plate
Before first commissioning and during monitoring, the working stroke of the brake
shoes, the pretension of the brake springs and movement of the armature base plates
are to be checked.
Sequence:
Check ease of movement of the armature base plate

1. After a longer period of use, it can occur that the rubber disc settles between the
armature base plate and brake shoe (Fig. 8.6-1, item 10). This means that the
pretension of the armature base plate becomes insufficient.
 To restore the pretension, the lock nuts between the brake shoe and armature
base plate must be adjusted.
2. Correct pretension is achieved when the armature base plate can be turned on
the armature screw despite light suction.
Check the stroke.

3. Align a dial gauge on the brake shoe at the height of the centre of the brake disc.

TW63B drive
4. Switch the drive to operate the brake shoes while checking the stroke of the
brake shoes. The path should be 0.3 mm + 0.1 mm.
Adjust the stroke

5. In the event of deviations, loosen the lock nuts (Fig. 8.6-1, Item 7)
6. Adjust the anchor bolt with an Allen key. On opening the brakes, make sure that
both brake shoes work with the same stroke.
7. Then secure the setting. 
Set the initial tension of the springs

A correct setting of the initial tension is only possible within the framework of a
deceleration measurement. In doing so, do not exceed the maximum initial
tension distance of 13.5 mm.
1 2 3
5
12
11
6
10 9 8 7

1 Oil ventilation 2 Control opening
3 Locking screw with disc 4 Brake shoe pin
5 Brake shoes 6 Armature screw
7 Lock nuts 8 Cover ring
9 Magnetic clamp 10 Rubber disc
11 Washer 12 Armature base plate
Fig. 8.6-1

TW63B drive
If brake test switches SA3 are present, these must be checked or adjusted after the
brake adjustment. See  chapter 9
8.7 Braking deceleration setting

The brake adjustment is to be carried out only with one effective brake shoe with the
elevator car loaded with the rated load on a descending run (full down) or with an
empty elevator car on an ascending run (empty up) according to the deceleration
values in the table below.
The braking torque must be set on uniformly on both brake shoes by pre-tensioning
the brake spring depending on the installation.
Machine with Machine with handwinding

Braking deceleration
flywheel mass wheel
v in m/s  0.63  1.25  0.63  1.25  1.25
a in m/s2 (full down)  0.2  0.3  0.3  0.4  0.50
a in m/s2 (empty up)  0.4  0.5  0.5  0.6  0.75
Table 8.7-1
8.8 Brake readjustment in the event of brake lining wear

With wear on the brake linings, the stroke of the brake shoes increases compared
with the reference state (0.3 mm + 0.1 mm). As of a limit value of 0.6 mm, the
following settings on the brake are to be checked and, if required, corrected:
1. Armature base plate pre-tension: check and, if required, adjustment of the pre-
tension
2. Stroke of the brake shoes: setting to reference value 0.34 mm + 0.1 mm to
middle of brake disc
3. Pre-tension of the compression springs: setting of the reference value to a
maximum of 13.5 mm, as well as check of the deceleration  Chapter
Fehler! Verweisquelle konnte nicht gefunden werden.
4. Setting for brake test switches

TW63B drive
8.9 Replacing the traction sheave
8.9.1 Disassembly
3. Take the load off the traction sheave and disengage the ropes.
4. Use a rope or chain to secure the traction sheave on the lifting gear.
5. Undo the three screws on the mounting plate for the traction sheave and loosely
screw them in the outer circle of holes of the traction sheave into the traction
sheave hub (see Fig. 8.8.1, Item 2).
6. Place a spacer (approx. 5 – 10 mm thick, smaller than inner diameter of hub
hole) between the shaft end and the sheave.
7. By tightening the screws diagonally and evenly, remove the traction sheave from
the shaft.
WARNING
Falling traction sheave!
The traction sheave can suddenly come loose.
 Secure the traction sheave with chains or ropes.
8.9.2 Installation
DANGER
Traction sheave not resting properly on cone (is loose)!
Traction sheave tumbles and can come loose. Elevator car can crash.
 Do not change the dimension of the feather key, groove, cone of

shaft or traction sheave bore hole under any circumstances.
 Avoid damage and contamination of the traction sheave.
 Ensure correct installation.
In the case of traction sheave replacement, the new bolts that are supplied must be
used.
Ensure bolts are secure and tightening torque is correct!

TW63B drive
1. Place the new traction sheave on the conical shaft end of the worm wheel shaft.
2. Align the locations of the feather key and groove in relation to one another.
3. Push the traction sheave onto the worm wheel shaft.
4. Screw on a disc with the supplied screws (microencapsulated) and detent edged
washers on the inner circle of holes of the sheave. Tighten the screws evenly
and alternately.
DANGER
Insecure threaded connection!
Death or severe physical injury due to parts coming loose.
 When mounting the traction sheave, care must be taken to ensure

that the prescribed bolt / screw strength 8.8 and tightening torques
of 150 Nm are complied with  chapter 10.2.

1 Traction sheave 2 Hole for pressure screw (2x)
3 Securing bolt (3x) 4 Mounting plate
Fig. 8.9-1

TW63B drive
8.10 Replacing the motor
Order a motor with clutch hub. Note: the motors of the CEG and Motorlift
makes already contain the clutch hub.
8.10.1 Disassembly
3. Attach and secure the motor to the lifting gear.
4. Unplug the electrical connections.
5. Disconnect the lines from the motor (motor and magnetic clamp connection).
6. Remove the nuts on the flange between the motor and gear.
7. Comply with the installation instructions for the flexible coupling  chapter 9.2.4
8. Carefully pull off the motor from the studs and place on the floor.
9. Remove the 4 radial screws on the flexible coupling and dismantle the coupling
element.
10. If the replacement motor was delivered without a handwinding wheel and
encoder or flywheel rim, remove these and use them for the new motor.
Installation instructions for encoder and handwinding wheel in  Kap.Fehler! V

erweisquelle konnte nicht gefunden werden..
8.10.2 Installation
1. Compare the motor data of both motors.
2. Mount the coupling element by means of the 4 radial screws between the
coupling element and clutch hub in line with  Chap. 9.2.4
3. Raise the motor using the lifting gear and align the motor coupling to the brake
disc.
4. Push the motor into the gear flange and tighten the nuts.
5. Tighten the nuts evenly with the prescribed torque. (see  chapter10.2 ) 
Installation instructions for flexible coupling SA14 in  chapter 9.2.4.
6. Plug in the electrical connections, see  chapter 6.3

TW63B drive
8.11 Replacing the encoder
8.11.1 Removal
1. Before starting work, switch off the power to the installation and secure against
reactivation.
2. Unplug the encoder connection cable at the frequency inverter.
3. Remove the central screw in the middle of the handwinding wheel hub.
4. Pull the handwinding wheel and hub off together.
5. Use an Allen key (2 mm) to loosen the two studs on the collar of the encoder
inner ring (do not remove).
6. Undo and remove the screw on the bracket of the encoder mounting
7. Remove the cable ties holding back the cables.
8. Pull the encoder off the end of the motor shaft.
9. Check that the technical data of the new encoder match
8.11.2 Installation
1. Fit the encoder mount of the removed encoder onto the new encoder.
2. Fit the clip nut of the removed motor onto the new motor, ensuring an identical
position of the 8x8 hole in the fan hood.
3. Push the new encoder onto the clean shaft end of the motor until it makes
contact with the shaft collar and/or spring plate on the motor.
4. The mounting collar of the encoder must point towards the shaft end.
5. Screw on the encoder mount on the motor.
6. Secure the encoder inner ring by tightening the stud on the motor shaft.
7. Align the hub to axial pin in the shaft and mount the hub with handwinding
wheel by means of the central screw and disc; tighten with 75 Nm.
8. Secure the cable by means of cable ties

TW63B drive
5 8
2
6
1
Pos. Designation Pos. Designation

1 Fan hood of motor 2 Encoder
Central screw for handwinding
3 Handwinding wheel with hub 4
wheel mount
5 Encoder mount (spring plate) 6 Screw for encoder mount
Studs for mounting encoder on
7 Clip nut 8
shaft

TW63B drive
8.12 Check for escaping grease / oil

 Examine the area around the bearing cover, brake drum and brake linings for
traces of oil.
Degree of soiling Procedure

No escaping oil / grease Check regularly within the Every 3 months
determined framework of maintenance (6 months in case of
reduced frequency,
< 50,000 runs per year)
If a small amount of escaping Clean and check regularly within Every 3 months
oil / grease is determined the framework of maintenance (6 months in case of
reduced frequency,
< 50,000 runs per year)
If a large amount of escaping Clean the drive and, if necessary, Repair after 4 weeks at
oil / grease is determined or the brake and carry out short-term the latest
brake disc/brake linings repairs.
already fouled with oil / grease Before continuing operation until
present modification, run a brake test. If
the braking effect is inadequate,
shut down the installation.
If necessary, check on a daily
basis whether oil / bold is still
escaping. If this is the case: shut
down the installation.
Table 8.12-1
NOTE
Use of incorrect cleaning agent!
Damage to the break
 For cleaning work on the brake, only use the cleaning agent isopropanol
(isopropyl alcohol).
 Only carry out cleaning work on the brake surfaces.

TW63B drive
Horizontal guide Vertical guide
5 Item Designation
1 Brake drum
4 Roller bearing sealing
2
disc
Hub unit with integrated
3
bearing cover
4 Grease filling
5 Gear oil
Fig. 8.12-1

Operating manual Special versions (optional)
TW63B drive
9 Special versions (optional)
9.1 Overview of SA special versions

Overview:
SA 3* with brake monitoring (light barrier sensor)
SA 3.1*with brake monitoring (microswitch)
SA 9 Traction sheave position in the shaft (extended drive shaft with pedestal bearing
and machine on compensating supports for statically defined mounting of the drive
shaft
SA11* Side oil drain
SA12 Additional terminal box
SA15 Gear, magnetic clamps and brake test switches* in full Ex version; motor and
encoder in full Ex version
The special versions marked with * are delivered separately due to the risk of damage.
Explanation:
SA3 Brake test switch (light barrier sensor) to check the brake shoe position
(opened-closed) and the brake lining wear.
SA3.1 Brake test switch (microswitch) to check the brake shoe position (opened-
closed) and the brake lining wear
SA11 On version with horizontal motor arrangement for improve accessibility for oil
change
SA 9 Traction sheave position in the shaft (extended drive shaft) with arrangement of
the traction sheave directly in the shaft. The drive shaft is supported here by a bearing.
SA12 Additional terminal box to connect the brake magnets if there is no possibility in
the motor terminal box.
SA15 Gear, magnetic clamps and brake test switch in full Ex version; motor and
encoder in full Ex version
More detailed information as well as technical information for setting up and operation
of full or partial Ex drives can be found in a separate operating manual. These are
delivered with drives with Ex equipment.
The part number for the German instructions is: 60 000 20 86 0
The part number for the English instructions is: 60 000 21 86

TW63B drive
9.2 Brake monitoring circuit

 The brake monitoring circuit checks the brake shoes.
 It prevents motor movements when the brake is partially or fully closed and
enables detection of any brake lining wear at an early stage.
 Switches (sensors SA3 or microswitches SA3.1) are used to check whether the
brake shoes are closed, open, or worn.
 The travel signal - derived from the W/W1 contactor - is used for the evaluation.
 It is indicated by means of light emitting diodes
 on the sensors (SA3).
 on the brake monitoring in the control cabinet and/or by deactivation of the
drive.
If a Teleservice device is connected, the fault is shown on the display.
9.2.1 Installation
1. If not included in the scope of supply, make 2 lines (3 x 0.75 mm² for SA3 and 2
x 0.75 mm² for SA3.1 with PVC sheaths) for direct connection of the switches to
the control system and connect the switches.
2. Mount the hexagon screws (microencapsulated) with lock nut to be adjusted on
the brake shoes (pre-assembled at the plant). The switch tappet on the sensor
must be opposite the setting screw, but should not make contact with it. 
9.2.2 Setting SA3

Before starting to set the sensor; the stroke of the brake shoes must be adjusted!
Description, see  chapter Fehler! Verweisquelle konnte nicht gefunden werden.
1. Switch on the emergency operation switch and elevator control system.
2. Adjust the setting screw for the switch.
3. The LED lights up.
4. Turn back the screw slowly.
5. The LED goes out.
6. Move the adjusting screw by ¼ turns (corresponds to approx. 0.3 mm) in the
direction of the switch and secure with a lock nut.
7. LED lights up continuously.
8. Open and close the brakes by switching the motor
9. In doing so, check that the sensors switch between open and closed brake.
9.2.3 Setting SA3.1

The break contact with contacts 11 and 12 is used to monitor the position of the brake
shoes. With the brake open, the switch is closed.
The make contact closes contacts 23 / 24 only when the wear limit of the brake linings
has been reached and the brake is closed. The contacts must be switched in such a

TW63B drive
way that when one contact of both switches closes the drive is prevented from starting
up.
With a correctly set brake test switch, all switch contacts must be interrupted with a
closed brake.
Before starting to set the sensor; the stroke of the brake shoes must be adjusted!
Description, see  chapter Fehler! Verweisquelle konnte nicht gefunden werden.
1. Connect the continuity test device to contacts 11 and 12 of the break contact.
The adjusting screw must not touch the control tappet.
2. In home position of the drive (brake magnet without current) unscrew the
adjusting screw for the brake test from the brake shoe in direction control tappet
until opening of the contact is indicated by a signal interruption at the continuity
test device.
3. Continue unscrewing the adjusting screw a further approx. 1/4 revolution.
4. Secure this setting by tightening the lock nut.
5. Repeat the setting procedure at the second brake test switch.
Checking setting:
Open and close the brakes by switching the motor. Observe whether the switch at the
contacts corresponds to the procedure described above.
Push the feeler gauge between adjusting screw and control tappet. Select the
thickness of the feeler so that contact 23/24 is closed.
When one of the contacts is closed, it must no longer be possible to start up the drive.

TW63B drive
Terminal connecting diagram - brake test switch

SA3 - version

1 Button 1 2 Button 2
3 A (black) 4 - (blue)
5 + (brown) 6
Fig. 9.2-1
SA3.1 - version

1 Button 1 2 Button 2
Fig. 9.2-2

TW63B drive
1 2 3 4 5

Screw for compression spring
1 2 Brake shoes
on brake
3 Adjusting screw 4 Switch tappet
5 Brake test switch
Fig. 9.2-3

TW63B drive
9.2.4 Switch mounting SA15
The switch mounting for SA15 is described in the operating manual 'Explosion
protection for machines (ATEX)'.

Operating manual Appendix
TW63B drive
10 Appendix
10.1 Blocking clamp

NOTE
Leaving the blocking clamp fitted after completion of the installation
work!
Can damage the installation.
 Remove the blocking clamp after completion of the installation
work.
A blocking clamp that matches the traction sheave (rim width and design) is part of
each machine
Deployment of the blocking clamp:
 During installation work on the elevator car or counterweight to prevent
movement due to slipping ropes.
 In the case of work where the rope traction of the system is insufficient, e.g.
removing from the safety gear, use the blocking clamp.
The blocking clamp is to be tensioned via the screwed connection until it is excluded
that ropes will slip.
4
5
3
2
7
1

1 Traction sheave 2 Ropes
3 Pressure piece 4 Washer
5 Hexagon nut 6 Spacer sleeve
7 Clamp clip
Fig. 10.1-1

Operating manual Appendix
TW63B drive
10.2 Tightening torques

DANGER
Insecure threaded connection!
Death or severe physical injury due to parts coming loose.
 When working on the machine or in the case of parts replacement,

comply with the prescribed bolt tightness and tightening torques.
 Only use suitable tools (torque wrench).
 Non-microencapsulated bolts / screws are to be secured against

unwanted loosening during installation using detent edged washers or
Loctite 243 and a similar means of securing bolts / screws.
 Microencapsulated screws are to be replaced after they have been

used once.
The tightening torques given here apply for screwed connections without specifications at the
corresponding location.
If in the drawing or elsewhere in the document other tightening torques are predefined for the
particular bolt size, these have to be observed!
The values listed below apply to screwed connections with regular threads (not fine
threads):
 Allen screws DIN 912 ISO 4762
 Hexagon head bolts DIN 931/933 ISO 4014/4017
Tightness 8.8 10.9 12.9

Screw / bolt size Tightening torque (Nm)
M4 2.6 - -
M5 5.3 - -
M6 9.0 12 15
M8 20 30 35
M10 40 60 75
M12 75 105 130
M14 120 170 205
M16 190 265 320
M20 370 520 620
M24 640 900 1080
M30 1300 1800 2150
Tab. 10.2-1
For assembly, use only original construction and mounting parts from thyssenkrupp
Aufzugswerke GmbH, as otherwise no warranty can be provided.

ABV, ESV and the shaft calculations can be found in the following
operating manual:
Document number
DE 65 999 01 86 0
EN 65 999 02 86 0
FR 9710 000 9229
Operating Manual
Emergency Brake System NBS
for: TW45C, TW63; TW130; TW160
ThyssenKrupp Aufzugswerke
TW63 W191
TW130
W263
W332
TW160
Operating
Manual
Explosion-proof
Machines
ATEX
Supplement
to
Operating
Manuals:
TW63;
W191;
TW130;
TW160;
W263B;
W332B
ThyssenKruppAufzugswerke
Encoder
Overview:
The following encoders are available for the TW45C
1. 1024 - (standard version) / 4096 - TTL (optional)

for v < 1.5 m/s 1024 impulses
for v < 1.5 m/s 4096 impulses
Connection takes place with line SUB-D 9 ribbon connector and knurled screw
UNC4-40
2. 1024 HTL (optional)-

1024 impulses
Connection takes place with line stripped of insulation and wire end sleeves
attached.
3. 1024 – sine / cosine HTL (optional)

1024 impulses
Connection takes place with line stripped of insulation and wire end sleeves
attached.
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.
Wachendorff Automation GmbH & Co. KG
Industriestrasse 7
D-65366 Geisenheim
Tel.: +49 (0) 67 22 / 99 65 - 25
Fax: +49 (0) 67 22 / 99 65 - 70
Hollow shaft Encoder WDG 100H www.wachendorff.de
Specifications
Mechanical Data
Housing
- Servo flange: Aluminium
- Housing: Aluminium,
- Depth: 42 mm
- Attachment: about Hollow-shaft with
2 set screw M4
Hollow shaft
- Material: Stainless steel
- Diameter: : 38 mm
- Loading on shaft- max. 200 N radial
end: max. 100 N axial
- Starting torque: approx.1.5 Ncm at
ambient temperatur
Attachment: 2 x Hub M4, DIN 913
Bearings
- Type: 2 precision ball
Order-No.: WDG 100H-38-1024-AB-R05-K3-J66-100 bearings
10
- Service life: 3 x 10 revs. at 100%
Suggested shaft adjustment: of full rated shaft load
about hollow shaft diameter 38mm: 38m6 (k6, j6) 11
4 x 10 revs. at 40%
Max. concentricity deviation of motor shaft: 0,05 mm 12
3 x 10 revs. at 20%
Speed: max. 3.500 r.p.m.
Thyssen-No.: 9950 001 1304
Weight: ca. 720 g
Connection: radial with 10 m
Electrical data: shielded cable with
5V Power supply: 4,75 ... 5,5 VDC connector
1kW 100W 1kW
26ET31 Current consumption: max. 70 mA (7-pol. Phönix terminal)

A,B 26LS32 Channels: A, B and
Evaluation
Electrical Data
WDG
AB inv.
Output: push-pull General Layout: DIN VDE 0160
Signal Load: max. 40 mA Supply / Output: ® Output circuit
A,B Signal level: bei 20 mA Cable lenght: max. 100 m
H > 2,5 VDC
Ground L < 1,2 VDC Optics
Shield Pulse frequency: max. 200 kHz
Circuit protection: no Light source: IR - LED
Service life: typ. 100.000 hrs.
Scanning: differential
Output circuit: 5 VDC: R05
Accuracy
in % einer Periodendauer des Signals A
100
Quadratue phasing: 90° + 7,5%

Pulse on/off ratio: 50% + 7%
Environmental Data
10000
11 Measured mounted and housing grounded .

ESD (DIN EN 61000-4-2): 8 kV
Burst (DIN EN 61000-4-4): 2 kV
2 x set screw Protection rating (EN 60529): IP54
63
M 4 x 4 DIN 913 Vibration 50m/s² (10-2000 Hz)

(DIN EN 60068-2-6):
3 Shock 1000m/s² (6 ms)
,05
+0 0,03
+
(DIN EN 60068-2-27):
Operating temperature: -20°C to +80°C
Storage temperature: -30°C to +80°C
40
15
°
Cable connection, 10 m shielded cable

37 100
42 Pin arrangemant:
Function Pin Colour
Dimensional drawing WDG 100H, Dimensional specifications in mm.
Negative 6 white
Positiv 7 brown
A 5 green
A
A inv. 4 grey
R05 A B 3 yellow
B B inv. 2 pink
Shield 6 braiding
B
View from shaft end, rotating clockwise.
19.05.14/Specifications without engagement, subject to errors and

Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)
Design according to
Drawing number: E073 01 046 000 1 10
Article number: 8227821
Please read these Operational Instructions carefully and follow them accordingly!
Ignoring these Instructions may lead to malfunctions or to brake failure, resulting in damage to other parts.
These Installation and Operational Instructions (I + O) are part of the brake delivery.
Please keep them handy and near to the brake at all times.
Contents: Safety and Guideline Signs

Page 1: - Contents DANGER
- Safety and Guideline Signs
- Guidelines on EU Directives Immediate and impending danger, which can
lead to severe physical injuries or to death.
Page 2: - Safety Regulations
Page 5: - Brake Illustrations CAUTION
Page 6: - Parts List Danger of injury to personnel and
damage to machines.
Page 7: - Technical Data
- Switching Times
Page 8: - Application
- Design
- Function
- Scope of Delivery / State of Delivery Please Observe!
- Installation Conditions Guidelines on important points.
Page 9: - Installation
- Noise Damping
Page 10: - Electrical Connection and Wiring
Page 11: - Permitted Shaft Misalignments
- Shaft Alignment
Page 12: - Braking Torque According to German notation, decimal points
- Brake Inspection in this document are represented with a
- Dual Circuit Brake Functional Inspection comma (e.g. 0,5 instead of 0.5).
Page 13: - Release Monitoring
Page 14: - Maintenance
- Disposal
- Malfunctions / Breakdowns
Guidelines on the Declaration of Conformity

A conformity evaluation has been carried out for the product (electromagnetic safety brake) in terms of the EC low voltage
directive 2006/95/EC. The Declaration of Conformity is laid out in writing in a separate document and can be requested if
required.
Guidelines on the EMC Directive (2004/108/EC)
The product cannot be operated independently according to the EMC directive.
Due to their passive state, brakes are also non-critical equipment according to the EMC.
Only after integration of the product into an overall system can this be evaluated in terms of the EMC.
For electronic equipment, the evaluation has been verified for the individual product in laboratory conditions, but not in the
overall system.
Guidelines on the Machinery Directive (2006/42/EC)
The product is a component for installation into machines according to the machinery directive 2006/42/EC.
The brakes can fulfil the specifications for safety-related applications in coordination with other elements.
The type and scope of the required measures result from the machine risk analysis. The brake then becomes a machine
component and the machine manufacturer assesses the conformity of the safety device to the directive.
It is forbidden to start use of the product until you have ensured that the machine accords with the regulations stated in the
directive.
Guidelines on the ATEX Directive
Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion.
For application of this product in areas where there is a high danger of explosion, it must be classified and marked
according to directive 94/9/EC.
14/10/2013 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Page 1 of 14 www.mayr.com, E-Mail: info@mayr.com
Size 125 (E073 01 046 000 4 EN)
Safety Regulations
These Safety Regulations are user hints only and may not be complete!
General Guidelines Guidelines for Electromagnetic Compatibility

DANGER
(EMC)
Danger of death! In accordance with the EMC directives 2004/108/EC, the
Do not touch voltage-carrying cables and individual components produce no emissions. However,
components. functional components e.g. mains-side energisation of the
brakes with rectifiers, phase demodulators, ROBA ®-switch
devices or similar controls can produce disturbance which lies
Brakes may generate further risks, among other things: above the allowed limit values. For this reason it is important to
read the Installation and Operational Instructions very carefully
and to keep to the EMC directives.
Application Conditions
Hand- Danger of Contact with Magnetic The catalogue values are guideline values which
injuries seizure hot fields have been determined in test facilities. It may be
surfaces necessary to carry out your own tests for the
intended application. When dimensioning the
Severe injury to people and damage to objects may result if: brakes, please remember that installation
 the electromagnetic brake is used incorrectly. situations, braking torque fluctuations, permitted friction work,
run-in behaviour and wear as well as general ambient
 the electromagnetic brake is modified. conditions can all affect the given values. These factors should
 the relevant standards for safety and / or installation therefore be carefully assessed, and alignments made
conditions are ignored. accordingly.
During the required risk assessment when designing the
machine or system, the dangers involved must be evaluated and  Mounting dimensions and connection dimensions must be
removed by taking appropriate protective measures. adjusted according to the size of the brake at the place of
installation.
To prevent injury or damage, only professionals and
specialists are allowed to work on the devices. They must be  Use of the brake in extreme environmental conditions or
familiar with the dimensioning, transport, installation, inspection outdoors, directly exposed to the weather, is not permitted.
of the brake equipment, initial operation, maintenance and  The brakes are designed for a relative duty cycle of 50 %.
disposal according to the relevant standards and regulations. A duty cycle > 50 % leads to higher temperatures, which
cause premature ageing of the noise damping and
Before product installation and initial operation, therefore lead to an increase in switching noises. The max.
please read the Installation and Operational permitted switching frequency is 180 1/h.
Instructions carefully and observe the Safety These values are valid for intermittent periodic duty S3
Regulations. Incorrect operation can cause injury 50 %. The permitted surface temperature on the brake
or damage. flange must not exceed 70 °C at a max. ambient
At the time these Installation and Operational Instructions go to temperature of 40 °C. The overexcitation time should be at
print, the electromagnetic brakes accord with the known least double the separation time t2.
technical specifications and are operationally safe at the time of
delivery.  The braking torque is dependent on the present run-in
condition of the brake.
 The brakes are only designed for dry running. The torque is
 Technical data and specifications (Type tags and lost if the friction surfaces come into contact with oil,
Documentation) must be followed. grease, water or similar substances or foreign bodies.
 The correct connection voltage must be connected  The surfaces of the outer components have been
according to the Type tag and wiring guidelines. phosphated manufacturer-side to form a basic corrosion
 Check electrical components for signs of damage before protection.
putting them into operation. Never bring them into contact
CAUTION The rotors may rust up and seize up in
with water or other fluids.
corrosive ambient conditions and/or after longer
 Please observe the EN 60204-1 requirements for electrical downtimes.
connection when using in machines. The user is responsible for taking appropriate
countermeasures.
Only carry out installation, maintenance and
repairs in a de-energised, disengaged state and
secure the system against inadvertent switch-
on.

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Safety Regulations
Ambient temperature: 0 °C up to +45 °C Brake Storage

CAUTION At temperatures of around or under freezing  Store the brakes in a horizontal position, in dry rooms and
point, both condensation and the special dust and vibration-free.
characteristics of the linings (lower friction  Relative air humidity < 50 %.
values at lower temperatures) can strongly  Temperature without major fluctuations within a range
reduce the braking torque. from –20 ° up to +60 °C.
The user is responsible for taking respective countermeasures,  Do not store in direct sunlight or UV light.
e.g. selecting brakes with higher nominal braking torques.
 Do not store aggressive, corrosive substances (solvents /
Frequent and extensive temperature fluctuations at high
acids / lyes / salts etc.) near to the brakes.
humidity promote the formation of corrosion, which can lead to
seized linings. The brake function must be inspected both once For longer storage of more than 2 years, special measures are
attachment has taken place as well as after longer system required (please contact the manufacturer).
downtimes, in order to prevent the drive starting up against
possibly seized linings. The customer is responsible for Handling
providing a protective cover against contamination caused by Before installation, the brake must be inspected and found to
construction sites. be in proper condition.
Temperatures of over 70 °C on the brake mounting flange can The brake function must be inspected both once attachment
have a negative effect on the switching times, the braking has taken place as well as after longer system downtimes, in
torque levels and the noise damping behaviour. order to prevent the drive starting up against possibly seized
linings.
Intended Use
User-implemented Protective Measures:
This safety brake is intended for use in electrically operated
 Please cover moving parts to protect against injury
elevators and goods elevators according to
through seizure.
EN 81-1:1998+A3:2009.
The safety brake corresponds to DIN EN 81, Part 1 [Sections  Place a cover on the magnetic part to protect against injury
9.10.2, 9.11.3, 12.4.2.1 (2nd paragraph), 12.4.2.2, and 12.4.2.5] through high temperatures.
in its general design and its mode of operation.  Protection circuit: When using DC-side switching, the coil
must be protected by a suitable protection circuit according
Earthing Connection to VDE 0580, which is integrated in mayr®-rectifiers. To
The brake is designed for Protection Class I. This protection protect the switching contact from consumption when using
covers not only the basic insulation, but also the connection of all DC-side switching, additional protective measures are
conductive parts to the protective conductor (PE) on the fixed necessary (e.g. series connection of switching contacts).
installation. If the basic insulation fails, no contact voltage will The switching contacts used should have a minimum
remain. Please carry out a standardised inspection of the contact opening of 3 mm and should be suitable for
protective conductor connections to all contactable metal parts! inductive load switching. Please make sure on selection that
the rated voltage and the rated operating current are
sufficient. Depending on the application, the switching
Class of Insulation F (+155 °C) contact can also be protected by other protection circuits
The insulation components on the magnetic coils are (e.g. mayr ®-spark quenching unit, half-wave and bridge
manufactured at least to class of insulation F (+155 °C). rectifiers), although this may of course then alter the
switching times.
Protection  Take precautions against freeze-up of the friction
(mechanical) IP10: Protection against large body surfaces and surfaces in high humidity and at low temperatures.
large foreign bodies > 50 mm in diameter. No protection against
water.
(electrical) IP54: Dust-proof and protected against contact as
well as against water spray from any direction.

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Safety Regulations
Standards, Directives and Regulations Used Liability

The information, guidelines and technical data in these
DIN VDE 0580 Electromagnetic devices and documents were up to date at the time of printing. Demands on
components, general specifications previously delivered brakes are not valid.
Liability for damage and operational malfunctions will not be
2006/95/EC Low voltage directive taken if:
CSA C22.2 No. 14-2010 Industrial Control Equipment - the Installation and Operational Instructions are ignored or
UL 508 (Edition 17) Industrial Control Equipment neglected.
95/16/EC Elevator Directive - the brakes are used inappropriately.
EN 81-1 Safety regulations for the construction - the brakes are modified.
and installation of elevators - Part 1: - the brakes are worked on unprofessionally.
Electrically operated passenger and - the brakes are handled or operated incorrectly.
goods elevators
BGV C1 (previously VGB 70) Safety regulations Guarantee
for theatre stage technical systems
 The guarantee conditions correspond with
EN ISO 12100 Safety of machinery - General the Chr. Mayr GmbH + Co. KG sales and delivery
principles for design - Risk assessment conditions.
and risk reduction  Mistakes or deficiencies are to be reported to mayr ® at
DIN EN 61000-6-4 Interference emission once!
EN 12016 Interference immunity (for elevators,
escalators and moving walkways) CE Identification
EN 60204-1 Electrical equipment of machines according to the
Low Voltage Directive 2006/95/EC and the Elevator
Directive 95/16/EC
Conformity Markings
in terms of the Canadian and American
approval
Identification
mayr ® components are clearly marked and described on the Type tag:
Product name Serial number Article number Approval number (if available)
®
C US
CE marking Size/Type Voltage Power Braking torque DataMatrix code

only for voltages > 72V
(CE identification with ID number of the respective inspection authority, only for prototype-inspected brakes)

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
18.3 11 23 18.5 18.4 21/22 20 18.1 18.3
18.2 18.7 18.9/18.10 18.6 9 19 18.6 18.7 18.8/18.11 18.2

Fig. 1 Fig. 2 Fig. 3
11.4 11.3
Installation dimension
115 +1 mm 14 11.2
24 4
20 11.1
7 3
21/22 2
2.1 1.1 5 11.5
Fig. 5
1.1 12
1 12.1
Insertion position for Insertion position for
brake circuit 2 inspection brake circuit 1 inspection
1.2 13 Item 10
5 15
2 6
8 b b 14
Air gap "a"
Fig. 4
Fig. 6 Fig. 7

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Parts List (Only use mayr original parts)

Item Name Pcs.
1 Hub 1
1.1 O-ring D60 x 3 2
1.2 Set screw M6 x 10 1
2 Brake body 1
2.1 Magnetic coil 1
3 Cap screw M8 x 85 3
4 Washer D16 / 8,4 x 1,6 3
5 Rotor 1 1
6 Rotor 2 1
7 Distance bolt 3
8 Thrust spring D15,5 / 2,8 x 39,5 4
9 Cable 2 x AWG18 1
10 Reference gauge 2
11 Release monitoring (page 12) 1
11.1 Microswitch 1
11.2 Hexagon head screw M5 x 20 1
11.3 Hexagon nut M5 1
11.4 Spring washer A5 1
11.5 Cap screw M4 x 8 2
12 Hub 1
12.1 Set screw M6 x 10 1
13 Elastomeric element 1
14 Armature disk 1
15 Brake plate 1
16 1) Headless screw M8 x 30 2
17 1) Plastic tube D10 / 8 x 14 2
18 Hand release 1
18.1 Switch bracket A 1
18.2 Switch bracket B 2
18.4 Hand release rod 1
18.5 Hexagon nut M16 1
18.6 Headless screw M8 x 30 2
18.7 Flat headed screw M8 x 10 2
18.8 Thrust spring holder 1
18.10 Washer A6,4 1
18.11 Thrust spring D15,5 / 2,5 x 28 1
19 Noise damping 4
20 Earthing strand 1
21 Cap screw M4 x 8 2
22 Contact washer M4 2
2)
23 Hexagon nut M8 1
24 Type tag 1
We reserve the right to make dimensional and constructional alterations!
1)
Items 16 and 17 are included loose in delivery and are not shown in the Figure.
2)
Plastic nut, serves only as transportation lock

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Table 1: Technical Data

Nominal braking torque (+60 %) 100 (2 x 50) Nm
Nominal voltage 90 V
Overexcitation voltage 180 V
Overexcitation time span 1s
Coil power (nominal power at 20°C) 76 W
Coil power on overexcitation 303 W
Inductivity 8,8 H
Rotor thickness, new condition 10,5 mm
Nominal air gap “a” total (braked) 0,5 +0,25 mm
Limit air gap “a” for rotor replacement 1,0 mm
Inspection air gap “b” released, per single circuit min. 0,15 mm
Tightening torque Item 1.2 3 Nm
Tightening torque Item 3 24 Nm
Tightening torque Item 16 8,5 Nm
Tightening torque Item 18.6 8,5 Nm
Tightening torque Item 18.7 8,5 Nm
Max. speed 2250 rpm
Max. permitted friction work for both rotors at a speed of 1800 rpm 5000 J
Weight 11,4 kg
Table 2: Switching Times

Attraction t2 50 ms
Drop-out t11 AC 180 ms
Drop-out t1 AC 340 ms
Drop-out t1 DC 5) 55 ms
Drop-out t0 (DC): 25 ms
Drop-out t 50 (DC) 6): 35 ms
6)
Drop-out t 90 (DC) : 40 ms
5)
Referring to the effective braking torque on disconnection from holding voltage (nominal voltage)
6)
Referring to the nominal braking torque on disconnection from double the holding voltage (overexcitation)
The stated switching times can only be achieved using the respective correct electrical wiring. This also refers to the
protection circuit for brake control and the response delay times of all control components. If the brake is operated using
overexcitation, the respective switch-on and switch-off times for overexcitation must be taken into account.
The use of varistors for spark quenching increases the DC-side switching times.

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Application Installation Conditions

 ROBA-stop®-Z brake for use as a holding brake with  The eccentricity of the shaft end in relation to the mounting
occasional EMERGENCY STOP braking actions (max. 10 pitch circle must not exceed 0,2 mm.
per day).  The positional tolerance of the threads for the cap screws
 The max. permitted speed and friction work (see Technical (3) must not exceed 0,2 mm.
Data) must be observed.  The axial run-out deviation of the screw-on surface to the
shaft must not exceed the permitted axial run-out tolerance
of 0,05 mm acc. DIN 42955 R.
Design The reference diameter is the pitch circle diameter for
securement of the brakes.
The ROBA-stop®-Z brake is a spring applied, electromagnetically Larger deviations can lead to a drop in torque, to
releasing dual circuit safety brake, which applies a defined continuous grinding on the rotors and to overheating.
braking effect after the voltage is switched off or after a voltage
failure.  The shaft tolerance must be selected so that the hub
This brake is combined with a positive-locking, flexible coupling toothing (1) is not widened. Widening of the toothing leads
(ROBA®-ES coupling) for connecting two shafts whilst to the rotors (5 and 6) jamming on the hub (1) and
compensating for shaft misalignments. therefore to brake malfunctions. Recommended shaft
The ROBA®-ES coupling compensates for axial, radial and tolerance: k6.
angular shaft misalignments. The max. permitted joining temperature of 200 °C must not
be exceeded.
 The rotors (5 and 6) and the brake surfaces must be oil
Function and grease-free.
The ROBA-stop®-Z brake is a spring applied, electromagnetic  A suitable counter friction surface (steel or cast iron) must
safety brake. be used. Sharp-edged interruptions on the friction surfaces
must be avoided.
Spring applied function (brake): Recommended surface quality in the area of the friction
In de-energised condition, thrust springs (8) press against the surface Ra = 1,6 µm.
armature disk (14). Rotor 2 (Item 6) is held between the In particular customer-side mounting surfaces made
armature disk (14) and the brake plate (15), rotor 1 (Item 5) is of grey cast iron are to be rubbed down additionally
held between the brake body (2) and the machine wall via with fine sandpaper (grain  200 – 400), or ideally with
frictional locking. The braking torque is introduced into the drive a sander.
line via the toothing of the rotors (5 and 6) and the hub (1).  The toothings of the hub (1) and the rotors (5 and 6) must
not be oiled or greased.
Electromagnetic function (release):
 Please abstain from using cleaning agents containing
Due to the magnetic force of the coil in the brake body (2), the
solvents, as they could affect the friction material.
armature disk (14) is attracted against the spring pressure (8) to
the brake body (2). The brake is released and the brake rotors (5  During longer downtimes, we recommend the use of
and 6) with the hub (1) can rotate freely. suitable corrosion protection measures for the mounting
surface (e.g. zinc-phosphate coating) until initial operation.
Safety brake function:
The ROBA-stop®-Z brakes reliably and safely in the event of a
power switch-off, a power failure or an EMERGENCY STOP.
Scope of Delivery / State of Delivery

The ROBA-stop®-Z brake is pre-assembled.
The release monitoring (11) device is installed and set
manufacturer-side.
The brakes are set manufacturer-side to the braking torque
stipulated on order.
Please check the scope of delivery according to the Parts List as
well as the state of delivery immediately after receiving the
goods.
mayr ® will grant no guarantee for belated complaints.
Please report transport damage immediately to the deliverer.
Please report incomplete delivery and obvious defects
immediately to the manufacturer.

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Installation
All the screws (except the cap screw Item 21) 20. Mount plastic hoses (17) onto both headless screws (16) in
and the set screws mounted by the customer order to dampen vibration noises.
must be tightened using the tightening torque 21. Insert the elastomeric element (13) in the claws of the hub
stated in Table 1. (1).
We recommend that you secure the screws 22. Mount the hub (12) onto the motor shaft, bring it into the
using Loctite 243. correct axial position (installation dimension 115 +1 mm,
1. Remove all 3 hexagon nuts (Item 23 / transportation lock) see Fig. 4) and secure it using the set screw (12.1).
and remove the brake plate (15) from the brake body (2). 23. Establish the positive locking between the hub (12) and
2. Mount the hub (1) onto the shaft with inserted keys and the elastomeric element (13).
secure it axially. Due to the pre-tension on the flexible elastomeric element
Axial securement takes place using the set screw (1.2), (13), an axial installation force is required when joining
which presses onto the customer-side key. both hubs (1 and 12) (Fig. 5). The force required can be
reduced by lightly greasing the elastomeric element (13).
3. Lightly grease the first O-ring (1.1) and insert it into the hub
(1) groove nearest to the machine wall.
4. Push the rotor 1 (Item 5) over the inserted O-ring (1.1) Use PU-compatible lubricants (e. g. Vaseline or
onto the hub (1) by hand using light pressure (the rotor HP 222)!
collar should be facing away from the machine wall).
Check that the toothing moves easily.
5. Lightly grease the second O-ring (1.1) and insert it into the After joining both hubs, no axial pressure must
other (not occupied) hub (1) groove. be placed on the elastomeric element (13).
6. Push brake body (2) over the hub (1) and insert it in the Keep to the installation dimension 115 +1 mm,
gear housing. see Fig. 4.
7. Push the rotor 2 (6) over the O-ring (1.1) onto the hub (1)
by hand using light pressure (the rotor collar should be 24. Check air gap "a" (Fig. 4).
facing the machine wall). The nominal air gap acc. Table 1 must be given.
Check that the toothing moves easily. 25. Check the air gap single circuits "b" (Fig. 4) on rotors
8. Insert the cap screws (3) including the washers (4) in the 1 and 2.
distance bolts (7) through the brake plate (15). The respective minimal air gap acc. Table 1 must be given.
9. Secure the brake evenly all around using the cap screws
(3) with a torque wrench.
10. Attach the earthing strand (20) onto the brake body (2) Noise Damping (Item 19 / Fig. 2)
using the cap screw (21) and the contact washer (22).
To do this, the contact washer (22) must be inserted The noise damping was set and adjusted
between cable lug and brake body (2). manufacturer-side. However, this component is
subject to ageing dependent on the application
11. Attach the earthing strand (20) onto the brake plate (15) or operating conditions (torque adjustment,
using the cap screw (21) and the contact washer (22). To switching frequency, ambient conditions,
do this, the contact washer (22) must be inserted between system vibrations etc.).
cable lug and brake plate (15). Replacing the damping element is only
12. Screw the headless screws (18.6) on both sides into the permitted at the mayr ® site of manufacture.
armature disk (14).
13. Attach both switch brackets B (18.2) in the correct position
onto the brake body (2) using the flat headed screws
(18.7).
14. Secure the thrust spring holder (18.8) onto the brake body
(2) using the cap screw (18.9) and the washer (18.10), so
that the pin of the thrust spring holder (18.8) points in the
direction of the knob of switch bracket B (18.2).
15. Tilt switch bracket B (18.2) and join the thrust spring
(18.11) between the thrust spring holder (18.8) and switch
bracket B (18.2).
16. Screw switch bracket A (18.1) onto switch bracket B (18.2)
on both sides using the cap screws (18.3).
17. Screw the hexagon nut (18.5) up to contact on the thread
end onto the hand release rod (18.4).
18. Screw the hand release rod (18.4) into switch bracket A
(18.1) and counter the hexagon nut (18.5) with an open-
end wrench.
19. Screw both headless screws (Item 16 / not shown) as
contact for the hand release into the gear housing.

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Electrical Connection and Wiring Magnetic Field Removal

In safety applications, the rules for risk minimisation and error AC-side Switching
avoidance (e.g. redundance, diversity, resistance, monitoring The power circuit is
etc.) must be observed during electrical activation. ROBA -switch
R R
interrupted before the
The power is connected using a 2-core cable (9). 20/017.000.2
rectifier. The magnetic field
U– = 0,45×U~ Imax = 1,8A–
200 - 500V~ t: 0,05-2sec
slowly reduces. This delays
R: 0Ω-10MΩ
200 - 300V~ the rise in braking torque.
– +
The brake must only be operated with IN S DC OUT
overexcitation (see Technical Data). 1 2 3 4 5 6 7 8 When switching times are not

important, please switch AC-
1 2 3 4 5 6 7 8 side, as no protective
DC current is necessary for operation of the brake. The coil measures are necessary for
voltage is indicated on the Type tag as well as on the brake body the coil and the switching
S1
and is designed according to the DIN IEC 60038 (± 10 % Coil contacts.
tolerance). The brake must only be operated with overexcitation
(e.g. using a ROBA®-switch or -multiswitch fast acting rectifier or
F1
phase demodulator). The connection possibilities can vary
dependent on the brake equipment. Please follow the exact
connections according to the Wiring Diagram. The manufacturer N L F1: External fuse
and the user must observe the applicable regulations and

standards (e.g. DIN EN 60204-1 and DIN VDE 0580). Their AC-side switching means low-noise switching; however, the
observance must be guaranteed and double-checked! brake engagement time is longer (approx. 6-10 times longer than
with DC-side switching), use for non-critical braking times.
Earthing Connection
DC-side Switching
The brake is designed for Protection Class I. This protection
covers therefore not only the basic insulation, but also the The power circuit is
connection of all conductive parts to the protective conductor ROBA -switch
R R interrupted between the
(PE) on the fixed installation. If the basic insulation fails, no 20/017.000.2 rectifier and the coil as well as
U– = 0,45×U~ Imax = 1,8A–
contact voltage will remain. Please carry out a standardised 200 - 500V~
mains-side. The magnetic
t: 0,05-2sec
inspection of the protective conductor connections to all 200 - 300V~ R: 0Ω-10MΩ field reduces extremely
contactable metal parts! IN S DC
–
OUT
+ quickly. This causes a quick
1 2 3 4 5 6 7 8 rise in braking torque.
Device Fuses
When switching DC-side, high
To protect against damage from short circuits, please add 1 2 3 4 5 6 7 8
voltage peaks are produced

suitable device fuses to the mains cable. in the coil, which lead to wear
S1 on the contacts from sparks
Switching Behaviour Coil
and to destruction of the
The operational behaviour of a brake is to a large extent insulation.
dependent on the switching mode used. Furthermore, the F1
switching times are influenced by the temperature and the air
gap between the armature disk and the coil carrier (dependent N L F1: External fuse
on the wear condition of the linings).
DC-side switching means short brake engagement times (e.g.
Magnetic Field Build-up for EMERGENCY STOP operation); however, louder switching
noises.
When the voltage is switched on, a magnetic field is built up in
the brake coil, which attracts the armature disk to the coil carrier
Protection Circuit
and releases the brake.
When using DC-side switching, the coil must be protected by a
suitable protection circuit according to VDE 0580, which is
integrated in mayr®-rectifiers. To protect the switching contact
from consumption when using DC-side switching, additional
protective measures are necessary (e.g. series connection of
switching contacts). The switching contacts used should have a
minimum contact opening of 3 mm and should be suitable for
inductive load switching. Please make sure on selection that the
rated voltage and the rated operating current are sufficient.
Depending on the application, the switching contact can also be
protected by other protection circuits (e.g. mayr ®-spark
quenching unit, half-wave and bridge rectifiers), although this
may of course then alter the switching times.

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Permitted Shaft Misalignments Shaft Alignment

ROBA®-ES coupling compensates for radial, axial and angular Exact alignment of the coupling improves the running
shaft misalignments (Fig. 3) without losing its backlash-free smoothness of the coupling substantially, reduces the load on
function. However, the permitted shaft misalignments indicated the shaft bearings and increases the coupling service lifetime.
in Table 3 must not simultaneously reach their maximum value. We recommend alignment of the coupling using a dial gauge or
If more than one kind of misalignment takes place special laser on drives operating at very high speeds.
simultaneously, they influence each other. This means that the
permitted misalignment values are dependent on one another,
see Fig. 4.
The sum total of the actual misalignments in percent of the 100
maximum value must not exceed 100 %.
Δ Kr [%] Radial misalignment

The permitted misalignment values given in Table 3 refer to
coupling operation at nominal torque, an ambient temperature of 80
+30 °C. Δ Kw [%]
If the coupling is operated in other or more extreme operating Angular misalignment
conditions, please contact the manufacturers.
60
0%
Table 3
25
Max. permitted shaft misalignments 40
%
ΔKa ± 1,5 mm 30%
50
%
ΔKr 0,11 mm 20
75
30
%
%
ΔKw 0,9 °
20 40% 60 80 100
Δ Ka [%] Axial displacement
Fig. 9
ΔK w
ΔK r
L ΔK a
Axial Radial Angular

displacement misalignment misalignment
Fig. 8

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Braking Torque Dual Circuit Brake Functional Inspection

The (nominal) braking torque is the torque effective in the shaft The ROBA-stop®–Z brake is equipped with a double safety
train on slipping brakes, with a sliding speed of 1 m/s referring to (redundant) braking system. If one brake circuit fails, min. 50 %
the mean friction radius. of the braking torque remain. The single brake circuit inspection
The brake is loaded statically when used as a service brake and is carried out using the reference gauges (10) included in
loaded dynamically in EMERGENCY STOP operation. delivery.
Respectively, there are different speed values for the friction
material, which in practice also leads to different friction values DANGER Should the load begin to move after tilting the
and therefore braking torques. feeler gauges (10) or should it fail to react to
The braking torque is dependent on the respective run-in the braking procedure, the reference gauges
condition of the friction surfaces. must be pivoted back and removed
We recommend allowing the friction surfaces to run in when immediately.
installed and under permitted loads. The dual circuit braking function is not
Friction materials develop their optimum effect only under speed guaranteed.
at the appropriate contact pressure, as continuous regeneration Shut down the system, lower and secure the
of the friction surface then takes place (torque consistency). load, remove and inspect the brake.
Furthermore, friction materials (synthetic resin bonded rubber Please observe the accident prevention
mixtures) are subject to ageing, which is also influenced, among regulations.
other things, by higher temperatures and other ambient
influences. We recommend regular inspection of the braking Remove the reference gauges (ideally attached to the motor or
torque (1 x per year) including the respective dynamic braking the gearbox).
actions as a refresher.
Inspection brake circuit 1 (mounting-side, see Fig. 1):
1. Push both reference gauges, 180° offset to each other, with
Brake Inspection (before brake initial operation) the flattened section between the brake body (2) and the
 Air Gaps Inspection (Fig. 4) machine wall.
Measure the air gap "a" (brake de-energised) several times Set up the reference gauges at 90° (tilt) and hold in this
on the circumference. position (no spring force on rotor 1 (Item 5)).
The nominal air gap acc. Table 1 must be given. 2. Trigger an EMERGENCY STOP (with maximum load and at
Measure the min. individual air gap "b" (brake energised) of maximum speed) and inspect the stopping distance.
brake circuit 1 (inside) and brake circuit 2 (outside) several 3. Turn the flat sections of the reference gauges once more
times on the circumference. and remove them from the brake.
The respective minimal air gap acc. Table 1 must be given.
 Braking torque inspection: Inspection brake circuit 2 (brake plate-side, see Fig. 1):
Please compare the requested braking torque with the
torque stated on the Type tag (24). 1. Push both reference gauges, 180° offset to each other, with
the flattened section between the armature disk (14) and
 Release function inspection the brake plate (15). Set up the reference gauges at 90°
by energising the brake. (tilt)
 Hand Release functional Inspection and hold in this position (no spring force on rotor 2 (Item
By moving the hand release (18) manually, the friction 6)).
linings are relieved. The brake is free but for a residual 2. Trigger an EMERGENCY STOP (with maximum load and at
torque of max. 8 %. maximum speed) and inspect the stopping distance.
The braking torque is not achieved until after the run-in 3. Turn the flat sections of the reference gauges once more
procedure has been carried out. The braking torque is the torque and remove them from the brake.
effective in the shaft train on slipping brakes, with a sliding speed
of 1 m/s referring to the mean friction radius
(acc. DIN VDE 0580/07.2000). Attach the reference gauges to the motor or gearbox again.
When actuating the hand release (18), a

switching signal of the release monitoring
device (11) cannot be guaranteed.

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Release Monitoring
The ROBA-stop®–Z brakes are supplied with manufacturer-side Customer-side Inspection of the Release Monitoring
set release monitoring. after Mounting the Brake
The microswitch (11.1) emits a signal for every brake condition The customer-side contact is an NO contact.
change: "brake opened or brake closed" Brake energised  Signal "ON"
Brake de-energised  signal " OFF "
The customer is responsible for a signal evaluation of both
conditions.
Microswitches cannot be guaranteed fail-safe.
From the point at which the brake is energised, a time span of Therefore, please ensure appropriate access
three times the separation time must pass before the for replacement or adjustment.
microswitch signal on the release monitoring is evaluated. The switching contacts are designed so that
they can be used for both small switching
11.4 11.3 powers and medium ones. However, after
switching a medium switching power, small
switching powers are no longer reliably
14 11.2 possible.
In order to switch inductive, capacitive and non-
20 11.1 linear loads, please use the appropriate
protection circuit to protect against electric arcs
and unpermitted loads!
21/22 2
5 11.5
Fig. 10
Function
When the magnetic coil (2.1) is energised in the brake body (2),
the armature disk (14) is attracted to the brake body (2), the
microswitch (11.1) emits a signal, the brake is released.
When actuating the hand release (18), a

switching signal of the release monitoring
device (11) cannot be guaranteed.
Microswitch Wiring Diagram:

NC Contact
grey connection
Connection when
2 brake closed
COM Contact 1
black connection 4
NO Contact
blue connection
Connection when
brake released
Microswitch Specification
Characteristic values for 250 V~ / 3 A
measurement:
Minimum switching power: 12 V, 10 mA DC-12
Recommended switching 24 V, 10...50 mA
power: DC-12
for maximum lifetime DC-13 with freewheeling
and reliability diode!
Usage category acc. IEC 60947-5-1:
DC-12 (resistance load), DC-13 (inductive load)

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Size 125 (E073 01 046 000 4 EN)
Maintenance Disposal
ROBA-stop®-Z brakes are mainly maintenance-free. The friction Our electromagnetic brake components must be disposed of
lining pairing is robust and wear-resistant. This ensures a separately as they consist of different materials. Please also
particularly long service lifetime. observe the relevant authority regulations. Code numbers may
However, the friction lining is subject to operational wear on vary according to the disassembling process (metal, plastic and
frequent EMERGENCY STOP braking actions. Normally, such cables).
occurrences are recorded and saved by the elevator control, or
they require the intervention of qualified personnel. When Electronic components
carrying out this maintenance work (especially when taking DIN (Rectifier / ROBA®-switch / Microswitch):
EN 13015 Appendix A into account), the causes of the Products which have not been disassembled can be disposed of
malfunction must be determined, assessed and removed by under Code No. 160214 (mixed materials) or components under
specialist personnel. Causal events such as the air gap can be Code No. 160216, or can be disposed of by a certified disposal
checked and respective measures can be taken. firm.
Brake bodies made of steel pads with coil /cable
The following checks must be carried out following the regular and all other steel components:
inspection intervals: Steel scrap (Code No. 160117)
 Braking torque or retardation inspection
(individual brake circuits). All aluminium components:
Non-ferrous metals (Code No. 160118)
 Air gap "a" inspection, braked, acc. Table 1.
 Inspection of toothing backlash from the hub (1) to the rotor Brake rotor (steel or aluminium pads with friction linings):
(5/6). Max. permitted toothing backlash 0,3°. Brake linings (Code No. 160112)
The inspection intervals must be determined customer-side Seals, O-rings, V-seals, elastomers, terminal boxes (PVC):
dependent on the applications, or at the latest during TÜV Plastic (Code No. 160119)
(German Technical Inspectorate) inspections.
In order to inspect the wear condition of the
rotors (5 and 6), please measure the air gap
"a", see Fig. 4.
If the brake limit air gap (1,0 mm) has been
reached, meaning that the friction linings are
worn down, the braking torque is lost and the
rotors (5 and 6) must be replaced.
Brake de-installation is carried out by following
the instructions in the section Installation (page
9) backwards.
Before Replacing the Rotors (5 and 6)

 Clean the brake and remove abraded particles using
compressed air.
Do not inhale brake dust (wear a dust mask).
 Measure the rotor thickness "new condition" (nominal
dimension 8 -0,05 mm).
Replacing the Rotors (5 and 6)

Replace the rotors (5 and 6) by following the Brake Installation
instructions backwards.
DANGER
The drive brake must be load-free on hoist
drives. Otherwise there is a danger of load
crashes!
Malfunctions / Breakdowns:
Malfunction Possible Causes Solutions
 Incorrect voltage on rectifier  Apply correct voltage
 Rectifier failure  Replace rectifier
Brake does not release
 Air gap too large (worn rotors)  Replace rotors
 Coil interrupted  Replace brake
Brake engagement delayed  Switch DC-side

 Brake is switched AC-side
on EMERGENCY STOP

Tel.: +49 8341 804-0, Fax: +49 8341 804-421
Design for TW63
.
U.I.LAPP GmbH
Schulze-Delitzsch-Straße 25 GEBRAUCHSANWEISUNG SKINTOP® MS-M, MSR-M, MS-M-XL, MSR-M-XL
D-70565 Stuttgart
Tel.0711/7838-1010
INSTRUCTION SHEET MS-SC-M, MS-SC-M-XL
Fax.0711/7838-2640
Internet:www.lappkabel.de
Klemm- und Dichtbereich

Clamping and Sealing range Approbationen
Bezeichnung
Approvals
Product
EN 50262 UL 514 B
Größe/Size Kat.der Anzugsdreh- Klemm- Diameter ∅

M Zug- momente bereich inch mm
entlastung Nm Ø mm
MS-M, MS-M-XL 3,5 - 7 .12 - .27 3,5 - 7
12x1,5 MSR-M, MSR-M-XL A 8 3,5 - 5 .04 - .20 1-5
MS-SC-M, MS-SC-M-XL 3,5 – 7 .12 - .27 3,5 - 7
MS-M, MS-M-XL 4,5 - 10 .17 - .35 4,5 - 10
16x1,5 MSR-M, MSR-M-XL A 10 3,5 - 7 .08 - .27 2-7
MS-SC-M, MS-SC-M-XL 4,5 – 9 .17 - .35 4,5 – 9
This drawing has to be changed by CAD only
MS-M, MS-M-XL 7 – 13 .27 - .51 7 – 13

Copyrights according to DIN ISO 16016
20x1,5 MSR-M, MSR-M-XL A 12 5 - 10 .20 - .04 5 - 10

MS-SC-M, MS-SC-M-XL 7 – 12,5 .27 - .49 7 – 12,5
MS-M, MS-M-XL 9 – 17 .35 - .65 9 – 17
25x1,5 MSR-M, MSR-M-XL A 12 6 - 13 .23 - .51 6 - 13
MS-SC-M, MS-SC-M-XL 9 – 16,5 .35 - .65 9 – 16,5
MS-M, MS-M-XL 11 - 21 .43 - .83 11 - 21
32x1,5 MSR-M, MSR-M-XL A 18 7 - 15 .27 - .59 7 - 15
MS-SC-M, MS-SC-M-XL 11 - 21 .43 - .83 11 - 21
MS-M, MS-M-XL 19 - 28 .75 – 1.1 19 - 28
40x1,5 MSR-M, MSR-M-XL A 18 15 - 23 .59 - .9 15 - 23
MS-SC-M, MS-SC-M-XL 19 - 28 .75 – 1.1 19 - 28
MS-M, MS-M-XL 27 - 35 1.06 – 1.38 27 - 35
50x1,5 MSR-M, MSR-M-XL A 20 22 - 29 .87 – 1.14 22 - 29
MS-SC-M, MS-SC-M-XL 27 - 35 1.06 – 1.38 27 - 35
MS-M 34 - 45 1.34 – 1.77 34 - 45
63x1,5 A 20
MSR-M 28 - 39 1.1 – 1.53 28 - 39
Bemerkungen/ Remarks Schutzart: IP 68; 5bar/30min.nach EN 60 529

Diese Zeichnung darf nur mittels CAD geändert werden.
IP 69K nach DIN 40 050

1. SKINTOP ins Gehäuse schrauben oder mit Gegenmutter festziehen
Screw SKINTOP into housing or tighten with locknut
2. Leitung durchziehen
Urheberschutz nach DIN ISO 16016
Put cable through

3. Hutmutter mit empfohlenem Drehmoment festziehen
Tighten nut with recomanded tightening torque
SKINTOP®
Ohne Gegenmutter: Usage without Locknut:

NUR IN GEWINDEBOHRUNGEN ONLY IN THREADED
VERWENDEN! HUB!
1 inch = 25,4mm
Temperaturbereich: –25 bis +100°C
Temperature range: -25 up to +100°C
UL File No. E 79903, Control Number 54 B 2

Hinweis / Note:
Sollte der Inhalt dieser Verpackung auf neue Verpackungen verteilt werden, so muss jeder neuen Verpackung eine Kopie dieser Betriebsanleitung beigelegt werden.
If the content of this bag will be split on two or more units, a copy of this instruction sheet must be placed in every packing units.
Art.Nr. 91100008 BS 04/2889-5
Druckfarbe: schwarz, Papierfarbe: hellgelb "CARNEVAL" 80g/qm (igepa Art.Nr.323-31)

Größe angepasst auf DIN A5, Falzung Kreuzbruch, Druck aussen
Toleranzen / tolerances: Werkstoff / material: Oberfläche / surface Gewicht / weight: Volumen / volume: Farbe / color:
DIN Papier
Bearb. Datum/date Name/name Geprüft Datum / date Name / name Maßangaben in
edited 27.05.04 M. Schmid checked 23.04.08 D.Müller dimension units mm
Projektion / projection : Maßstab / scale: Benennung / name:
1:1 SKINTOP MS-M Beipackzettel
SKINTOP MS-M operating instuction
Zeichnungs-Nr. / drawing no.: Blatt Dok. Art
05 500000001032 Mast1 26.03.2009 sheet: doc. type
Ind. Änderungs-Nr. Datum /date LAPP GROUP

U.I. Lapp GmbH BS04_2889 1/1 LBZ
DIN A 4
vs change number Bearb./edited Gepr./check. Ersatz für / substitute for: BS04_2889-3
thyssenkrupp Aufzugswerke GmbH
Bernhäuser Strasse 45
No. 62 320 02 86 0
73765 Neuhausen a. d. F.
Version 05/2016
Germany
E-mail: Doku.elevator.plant.de@thyssenkrupp.com
Internet: www.thyssenkrupp-elevator-eli.com

Tkaw-Manual-Ba Atr tw63 2018 09-En

Uploaded by

Copyright:

Available Formats

Tkaw-Manual-Ba Atr tw63 2018 09-En

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Tkaw-Manual-Ba Atr tw63 2018 09-En

Uploaded by

Copyright:

Available Formats

Operating manual

All rights reserved

5 Transportation and storage ............................................ 40

thyssenkrupp Aufzugswerke Version 05/2016

8 Servicing / Maintenance .................................................. 56

9 Special versions (optional) ............................................. 73

thyssenkrupp Aufzugswerke Version 05/2016

1 About these instructions

1.1 Guide to layout

Course of action with independent steps

Information must always be read and observed.

thyssenkrupp Aufzugswerke 5 Version 09/2018

2.1 Warning notes

2.1.2 Identification of personal injury

2.1.3 Identification of damage to property

thyssenkrupp Aufzugswerke 6 Version 09/2018

2.2 Safety requirements

2.2.1 Area of applicability

Other applicable documents

2.2.2 Basic requirements for safety

2.2.3 Obligations of the operating company and installation firm

2.2.4 Duties of personnel

thyssenkrupp Aufzugswerke 7 Version 09/2018

2.3 Warranty and liability

2.3.1 Use in line with intended purpose

thyssenkrupp Aufzugswerke 8 Version 09/2018

2.4 Dangers in handling the product

thyssenkrupp Aufzugswerke 9 Version 09/2018

2.5 International occupational health and safety regulations

thyssenkrupp Aufzugswerke 10 Version 09/2018

2.6 Personal protective equipment

 Unprotected shaft Fall Safety harness

Cut or stab injury in

 Severe noise pollution Noise damage Ear protection

thyssenkrupp Aufzugswerke 11 Version 09/2018

3.1 Standards and legal requirements

3.2.1 Version with vertical motor position IMV1

thyssenkrupp Aufzugswerke 12 Version 09/2018

Description of items for Fig. 3.2-1

Item Designation Item Designation

Connection for motor and

thyssenkrupp Aufzugswerke 13 Version 09/2018

3.2.2 Version with horizontal IMB5 motor position

Item Designation Item Designation

thyssenkrupp Aufzugswerke 14 Version 09/2018

3.2.3 Version with emergency brake, NBS

Item Designation Item Designation

thyssenkrupp Aufzugswerke 15 Version 09/2018

3.2.4 Version for traction sheave position in the shaft (SA9)

Item Designation Item Designation

thyssenkrupp Aufzugswerke 16 Version 09/2018

3.3 Functional description

3.3.3 Drive motors

3.3.5 Type of drive

thyssenkrupp Aufzugswerke 17 Version 09/2018

3.3.8 Emergency braking device NBS

3.3.9 Traction sheave

thyssenkrupp Aufzugswerke 18 Version 09/2018

name unit technical data