LiftEquip TW160 User manual

OPERATING MANUAL
TW160
Drive
08/2021
6234002860

Company and contact information
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© Copyright by TK 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 TK Aufzugswerke GmbH.
Any duplication, dissemination or storage on data media unauthorised by TK 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 –includ-ing 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!
You can find out about the colours for your products from your TK Aufzug-swerke GmbH sales
partner.
Form of address
In the interest of better legibility, we use exclusively the masculine grammat-ical form, for example
"fireman". At the same time, it always refers to human genders: male, female, diverse.
Issued by
TK Aufzugswerke GmbH
Bernhäuser Straße 45
73765 Neuhausen a. d. F.
Germany
Tel.: [phone]
E-Mail: [e-mail]
Internet: eli.tkelevator.com

Operating manual Table of Contents
TW160 drive
TK Aufzugswerke Version 08/2021
Table of Contents
1 About these instructions...................................................7
1.1 Guide to layout................................................................................ 7
2 Safety..................................................................................8
2.1 Warning notes................................................................................. 8
2.2 Safety requirements........................................................................ 9
2.3 Warranty and liability......................................................................10
2.4 Dangers in handling the product ....................................................11
2.5 International occupational health and safety regulations................12
2.6 Personal protective equipment.......................................................13
3 Product Description.........................................................14
3.1 Standards and legal requirements..............................................14
3.2 Description .....................................................................................15
3.3 Version with emergency brake - NBS.............................................16
3.4 Version for traction sheave in the shaft SA9 ..................................17
3.5 Version for vapour-proof partition wall SA4....................................18
3.6 Special versions SA2 / SA3 / SA3.1 / SA11 / SA12/SA15..............19
3.7 Version with safeguard measures complying with EN81-77...........20
3.8 Functional description ....................................................................20
4 Technology.......................................................................22
4.1 Technical data................................................................................22
4.2 Dimensions of machine..................................................................27
4.3 Type plate ......................................................................................31
4.4 Motor data......................................................................................31
4.5 Machine base frame.......................................................................31
4.6 Machine base frame dimension sheets..........................................41
4.7 Encoder..........................................................................................50
5 Transportation and storage............................................51
5.1 Packaging ......................................................................................51
5.2 Transport........................................................................................52
5.3 Checking the delivery.....................................................................54
5.4 Packaging materials.......................................................................54
5.5 Ambient conditions.........................................................................54
5.6 Standstill maintenance...................................................................55

Operating manual Table of Contents
TW160 drive
TK Aufzugswerke Version 08/2021
6 Installation........................................................................56
6.1 Setting up the machine base frame................................................56
6.2 Aligning the machine......................................................................56
6.3 Installation (frame with rope pulley)................................................57
6.4 Mounting the rope guard................................................................59
6.5 Mounting the rope guard complying with EN81-77.........................60
6.6 Mounting the shift protection complying with EN81-77...................61
6.7 Connecting motors.........................................................................62
7 Commissioning................................................................65
7.1 Work steps.....................................................................................65
7.2 Emergency operation.....................................................................66
8 Servicing and Maintenance.............................................68
8.1 Maintenance period........................................................................68
8.2 Maintenance measures..................................................................68
8.3 Lubrication......................................................................................69
8.4 Checking the backlash...................................................................71
8.5 Replacing the brake shoes.............................................................73
8.6 Setting and checking the brake shoe stroke and armature base
plate ...............................................................................................74
8.7 Braking deceleration setting...........................................................77
8.8 Brake readjustment in the event of brake lining wear.....................77
8.9 Replacing the traction sheave........................................................78
8.10 Replacing the motor.......................................................................80
8.11 Replacing the Encoder...................................................................83
8.12 Check for escaping grease / oil......................................................86
8.13 Check of the brake linkage.............................................................88
9 Special versions (optional).............................................89
9.1 Overview of special versions..........................................................89
9.2 Brake monitoring circuit..................................................................90
10 Appendix...........................................................................94
10.1 Blocking clamp...............................................................................94
10.2 Tightening torques..........................................................................95
10.3 Manufacturer specifications for Wachendorf ..................................96
10.4 Manufacturer specifications for Centaflex coupling......................102
10.5 Manufacturer information Radio Energie......................................104

Operating manual Table of Contents
TW160 drive
TK Aufzugswerke Version 08/2021
10.6 Manufacturer specifications for Bernstein switch .........................105
10.7 Details regarding ABV, ESV, EU-BD as well as shaft
calculations ..................................................................................111

Operating manual About these instructions
TW160 drive
TK Aufzugswerke 7 Version 08/2021
1 About these instructions
1.1 Guide to layout
Sequence of actions involving several steps
First action.
Second action.
Interim result (optional)
Third action.
Final action step with end marker.
Result of action (optional)
Course of action with independent steps
Action step.
Action step.
Action step.
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

Operating manual Safety
TW160 drive
TK Aufzugswerke 8 Version 08/2021
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 Indications of danger to persons
DANGER
Danger with a high degree of risk!
If ignored, leads to death or serious injury.
Read and observe warning.
WARNING
Danger with a medium degree of risk!
If ignored, may lead to death or serious injury.
Read and observe warning.
CAUTION
Danger with a low degree of risk!
If ignored, may lead to minor or moderate injury.
Read and observe warning.
2.1.3 Indication of possible damage to property
NOTE
Hazard with possible damage to property!
If ignored, may lead to product function impairments or function loss.
Read and observe warning.

Operating manual Safety
TW160 drive
TK Aufzugswerke 9 Version 08/2021
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.

Operating manual Safety
TW160 drive
TK Aufzugswerke 10 Version 08/2021
2.3 Warranty and liability
The 'General Terms of Sale and Delivery' of TK 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. TK 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.

Operating manual Safety
TW160 drive
TK Aufzugswerke 11 Version 08/2021
2.4 Dangers in handling the product
The traction sheave and handwinding wheel of the TW160 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.
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.

Operating manual Safety
TW160 drive
TK Aufzugswerke 12 Version 08/2021
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:
 https://eli.tkelevator.com/support/occupational-safety-health

Operating manual Safety
TW160 drive
TK Aufzugswerke 13 Version 08/2021
2.6 Personal protective equipment
Danger
Cause (examples)
Risks
Remedy
Equipment
Unprotected shaft
Fall
Safety harness
WARNING: Do not walk
underneath suspended loads!
Falling tool
Transport of heavy load
Sharp-pointed objects
Head injury
Head
protection
WARNING: Do not walk
underneath suspended loads!
Falling tool
Transport of heavy load
Sharp-pointed objects
Danger of crushing
in the foot area
Cut or stab injury in
the foot area
Foot protection
Sharp objects
Mechanical parts
Sharp-pointed objects
Caustic substances
Danger of crushing
in the hand area
Cut or stab injury in
the hand area
Acid / alkali burns
Hand
protection
Severe noise pollution
Noise damage
Ear protection
Flying parts
Flying particles
Laser beams
Optical beams
Eye injury
Loss of
sight/blinding
Eye protection
Electrical voltage
Electric shock
Enable source
of energy
Table 2.6-1

Operating manual Product Description
TW160 drive
TK Aufzugswerke 14 Version 08/2021
3 Product Description
3.1 Standards and legal requirements
EN81-1:2010-06 and EN81-20/50
The TW160 machines comply with the European standard EN81-1:2010-06 and
EN81-20/50
The drive is part of the protection device according to DIN EN81-1:2010-06 / 9.11 and
EN81-20/50/5.6.7.

Operating manual Product Description
TW160 drive
TK Aufzugswerke 15 Version 08/2021
3.2 Description
3.2.1 Standard version

Operating manual Product Description
TW160 drive
TK Aufzugswerke 16 Version 08/2021
Item
Designation
Item
Designation
1
Driving gear
2
Traction sheave (standard
version)
3
Motor (version V3F, frequency
controller)
4
Operational brake
5
Actual-value sensor (type
WDG100)
6
Handwinding wheel
7
Rope guard (adjustable)
8
Oil drain (3/4")
9
Oil filling hole with cover
10
Oil level monitor (dipstick) and
ventilation
11
Traction sheave mount
12
Brake release lever (mounted)
13
Motor terminal box with
connection
14
Mounting surface for machine
base frame
15
Internal ventilator for motor
cooling
16
Air vents for motor
17
Inspection opening with cover for
gear teeth check
Fig. 3.2-1
3.3 Version with emergency brake - NBS
Item
Designation
Item
Designation
1
Disc brake, emergency brake
system
2
Cover plate for brake
3
Socket wrench for manual release
4
Screws for manual release (screw
head marked in red)
5
Brake test switch with connection
line
6
Connection line, brake voltage
7
Protective cover for brake
Fig. 3.3-1

Operating manual Product Description
TW160 drive
TK Aufzugswerke 17 Version 08/2021
3.4 Version for traction sheave in the shaft SA9
Item
Designation
Item
Designation
1
TW160 machine SA9
2
Traction sheave shaft, SA4/9
version
3
External bearing (bearing housing
with self-aligning bearing on
adapter sleeve)
4
Traction sheave, SA4/9 version
5
Compensating support (for
statically defined machine
mounting)
6
Mounting surfaces for machine
base frame
Fig. 3.4-1
TW160_23001_GER

Operating manual Product Description
TW160 drive
TK Aufzugswerke 18 Version 08/2021
3.5 Version for vapour-proof partition wall SA4
Item
Designation
Item
Designation
1
TW160 machine SA4
2
Traction sheave shaft, SA4/9
version
3
External bearing (bearing housing
with self-aligning bearing on
adapter sleeve)
4
Traction sheave, SA4/9 version
5
Compensating support (for
statically defined machine
mounting)
6
Mounting surfaces for machine
base frame
7
Partition wall with seal for TW160
machine base frame SA4
Fig. 3.5-1
TW160_24001_GER

Operating manual Product Description
TW160 drive
TK Aufzugswerke 19 Version 08/2021
3.6 Special versions SA2 / SA3 / SA3.1 / SA11 / SA12/SA15
Item
Designation
Item
Designation
1
Brake monitoring SA3 / 3.1 and/or
brake test switches for SA15
2
Handwinding wheel, on gear side
-SA2
3
Oil drain, side - SA11
5
Additional terminal box - SA12 for
intermediate terminal connection
of the magnetic clamps
Fig. 3.6-1

Operating manual Product Description
TW160 drive
TK Aufzugswerke 20 Version 08/2021
3.7 Version with safeguard measures complying with EN81-77
Installation in the machine room, with earthquake safeguard complying with EN81-77.
Item
Designation
Item
Designation
1
Traction sheave
(D640/D720/D800)
2
Earthquake safeguard complying
with EN81-77
Fig. 3.7-1
3.8 Functional description
The TW 160 machine consists of a worm gear (gear drive) with flange-connected
motor.
Power transmission takes place on motors of the IMB9 model series (flanged-on
design with 1 bearing) via a rigid connection between the motor and worm shaft via
worm wheel, traction sheave shaft to the traction sheave.
In the case of motors of the IMB5 model series (flanged-on design with 2 bearings), a
flexible coupling (SA14) is required between the motor and gear drive.
Brake
The dual-circuit outside shoe brake is spring actuated. Two independently acting
brake shoe press the brake lining with preset spring force onto the brake disc.
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.
The brake is released by electrically operated magnetic clamps with armature base
plate.
For manual operation, a brake release lever is fitted.
Gear housing
The TW160 has a monobloc housing with two fitted and screw-connected bearing
brackets. The motor flange is cast onto the housing.
The right-hand or left-hand version of the traction sheave is created with the
corresponding installation of the bearing brackets in the housing.
The gear housing is cast from EN-GJL 250.