Explosion-protected industrial gear units, B 2050

Explosion-protected industrial gear units, B 2050
EN
B 2050
Explosion-protected industrial gear units
Operating and Assembly Instructions
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 4 /Anl eitung en/Getriebe/0. Prol og/0.1 Sic her hei ts- und Anwendungs hinweis e für Getri ebe @ 3\mod_1375086447713_388.doc x @ 84071 @ @ 1
General safety and operating instructions
5. Electrical Connection
1. General
Depending on its protection class, the device may have live, bare, When working on live three-phase motors, the applicable
moving or rotating parts or hot surfaces during operation,.
national accident prevention regulations must be complied with
Unauthorised removal of covers, improper use, incorrect installation or (e.g. BGV A3, formerly VBG 4).
operation causes a risk of serious personal injury or material damage.
The electrical installation must be implemented according to the
All transport, installation, commissioning and maintenance work must be applicable regulations (e.g. cable cross-section, fuses, earth
carried out by qualified specialist personnel (national accident lead connections).
prevention regulations must be observed).
Information regarding EMC-compliant installation – such as
Within the meaning of this basic safety information, qualified specialist shielding, earthing and installation of cables – can be found in
personnel are persons who are familiar with the installation, assembly, the three-phase motor documentation. Compliance with the
commissioning and operation of the product and who have the training limiting values specified in the EMC regulations is the
responsibility of the manufacturer of the system or machine.
and experience to recognise and avoid any hazards and risks.
6. Operation
2. Correct use
NORD products may only be used according to the information in the Appropriate safety measures must be taken for applications
where failure of the device may result in injury.
catalogue and the associated technical documentation.
Compliance with the operating and installation instructions is a Where necessary, systems in which NORD devices are installed
prerequisite for fault-free operation and for the fulfilment of any must be equipped with additional monitoring and protective
warranty claims. These operating and installation instructions must equipment according to the applicable safety requirements, e.g.
legislation concerning technical equipment, accident prevention
be read before working with the device!
regulations, etc.
These operating and installation instructions contain important
information about servicing. They must therefore be kept close to the All covers and guards must be kept closed during operation.
7. Maintenance and repairs
device.
All details regarding technical data and permissible conditions at the After the device has been disconnected from the power supply,
installation site must be complied with.
live equipment components and power connections should not
be touched immediately, because of possible charged
3. Transport, storage
capacitors.
Information regarding transport, storage and correct handling must be
Further information can be found in this documentation.
complied with.
4. Installation
The device must be protected against impermissible loads. In particular,
during transport and handling, components must not be deformed or
changed. Touching of electronic components and contacts must be
avoided.
These safety instructions must be kept in a safe place!
Pos : 5 /Allgemei n/Allgemei ngültige Modul e---------- Seitenumbruc h ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
2
B 2050 EN-0916
Documentation
Pos : 9 /Anl eitung en/Getriebe/0. Prol og/0.3 D okumentati on - Versi onslis te [B 2050] @ 5\mod_1408353710973_388.doc x @ 147852 @ @ 1
Documentation
Name:
B 2050
Part No.:
6053002
Series:
Gear units and geared motors
Type series:
Industrial gear units
Gear unit
types:
Version list
Title,
Order number
Comments
Date
B 2050,
February
2013
6053002 / 0613
-
B 2050,
September
2014
6053002 / 3814
General corrections
B 2050,
April 2015
6053002 / 1915
General corrections
B 2050,
March 2016
6053002 / 0916
Revision of ATEX documentation / extension of options
extension of series,
new declarations of conformity,
general corrections
Table 1: Version list B 2050
Pos : 10 /Allgemein/Allgemeing ültige M odul e/Urheberrechts vermer k @ 5\mod_1410955083459_388.doc x @ 150427 @ @ 1
Copyright notice
As an integral component of the device described here, this document must be provided to all
users in a suitable form.
Any editing or amendment or other utilisation of the document is prohibited.
Pos : 11 /Allgemein/Allgemeing ültige M odul e/H erausgeber @ 0\mod_1325779078002_388.doc x @ 5270 @ @ 1
Publisher
Getriebebau NORD GmbH & Co. KG
Getriebebau-Nord-Straße 1 • 22941 Bargteheide, Germany • http://www.nord.com/
Fon +49 (0) 45 32 / 289-0 • Fax +49 (0) 45 32 / 289-2253
=== Ende der Liste für T extmar ke Copyright ===
B 2050 EN-0916
3
Explosion-protected industrial gear units – Operating and Assembly Instructions
4
B 2050 EN-0916
Table of Contents
Pos : 13 /Allgemein/Steuermodul e/Inhalts verz eic hnis @ 0\mod_1317978518480_388.doc x @ 4078 @ @ 1
Table of Contents
=== Ende der Liste für T extmar ke Inhalts verz eichnis ===
1
Notes .......................................................................................................................................................... 10
1.1
General information.......................................................................................................................... 10
1.2
Safety and information symbols ....................................................................................................... 11
1.2.1
Explanation of designations used ....................................................................................... 11
1.3
Correct use ...................................................................................................................................... 11
1.4
Safety information ............................................................................................................................ 12
1.5
Other documents.............................................................................................................................. 14
1.6
Disposal ........................................................................................................................................... 14
2
Description of gear unit ............................................................................................................................ 15
2.1
Type designations and gear unit types............................................................................................. 15
3
Assembly instructions, storage, preparation, installation .................................................................... 17
3.1
Transporting the gear unit ................................................................................................................ 17
3.2
Storage ............................................................................................................................................ 20
3.3
Long-term storage ............................................................................................................................ 20
3.4
Inspecting the drive unit ................................................................................................................... 22
3.5
Checking the type plate data............................................................................................................ 22
3.6
Checking the configuration............................................................................................................... 24
3.7
Preparing for installation .................................................................................................................. 25
3.8
Installing the gear unit ...................................................................................................................... 26
3.9
Fitting hubs on the gear shafts ......................................................................................................... 29
3.10 Fitting push-on gear units................................................................................................................. 31
3.11 Torque support................................................................................................................................. 33
3.12 Fitting shrink discs............................................................................................................................ 34
3.13 Fitting the covers .............................................................................................................................. 36
3.14 Fitting a standard motor ................................................................................................................... 37
3.15 Mounting the external cooling system (cooling unit) ........................................................................ 40
3.16 Gear unit monitoring sensors ........................................................................................................... 41
3.17 Temperature sticker ......................................................................................................................... 41
4
Commissioning ......................................................................................................................................... 43
4.1
Check the oil level ............................................................................................................................ 43
4.2
Lubricant cooling with internal water cooler ..................................................................................... 45
4.3
Temperature measurement.............................................................................................................. 45
4.4
Checking the gear unit ..................................................................................................................... 47
4.5
Gear unit cooling with a fan.............................................................................................................. 47
4.6
Lubricant cooling with internal water cooling (cooling coil) ............................................................... 48
4.7
Lubricant cooling using an external cooling system (cooling unit).................................................... 48
4.8
Operation with pressure circulation lubrication ................................................................................. 50
4.9
Pressure safeguard .......................................................................................................................... 51
4.10 Temperature monitor (PT100).......................................................................................................... 51
4.11 Operation with a back stop or freewheeling (Option WX)................................................................. 52
4.12 Checklist .......................................................................................................................................... 55
4.13 Operation of the gear unit in explosive areas ................................................................................... 56
5
Service and maintenance ......................................................................................................................... 57
5.1
Service and Maintenance Intervals .................................................................................................. 57
5.2
Service and Maintenance Work ....................................................................................................... 58
6
Appendix .................................................................................................................................................... 65
6.1
Configurations and maintenance ..................................................................................................... 65
6.2
Lubricants ........................................................................................................................................ 68
6.3
Lubricant quantities .......................................................................................................................... 69
6.4
Torque values .................................................................................................................................. 72
6.5
Troubleshooting ............................................................................................................................... 73
B 2050 EN-0916
5
Explosion-protected industrial gear units – Operating and Assembly Instructions
6.6
6.7
6.8
6.9
6
Leaks and seals ............................................................................................................................... 74
Declaration of Conformity................................................................................................................. 75
6.7.1
Explosion protected industrial gear units, Category 2G and 2D ......................................... 75
6.7.2
Explosion protected industrial gear units, Category 3G and 3D ......................................... 76
Repair information ............................................................................................................................ 77
6.8.1
Repairs ............................................................................................................................... 77
6.8.2
Internet information............................................................................................................. 77
Abbreviations ................................................................................................................................... 77
B 2050 EN-0916
List of illustrations
Pos : 15 /Allgemein/Steuermodul e/Abbildungs verz eichnis @ 0\mod_1317978515699_388.doc x @ 3917 @ @ 1
List of illustrations
=== Ende der Liste für T extmar ke Abbildungs verzeic hnis ===
Figure 1: Gear unit lifting points ............................................................................................................................. 18
Figure 2: Transport of gear unit with motor............................................................................................................ 18
Figure 3: Transport of gear unit with motor swing base or base frame .................................................................. 19
Fig. 4:Type plate (example) ................................................................................................................................... 22
Figure 5: Activation of the pressure vent ............................................................................................................... 26
Figure 6: Example of a simple pulling device ........................................................................................................ 29
Figure 7: Permissible application of force to drive and driven shafts ..................................................................... 30
Figure 8: Applying lubricant to the shaft and the hub............................................................................................. 31
Fig. 9: Assembly .................................................................................................................................................... 32
Figure 10: Securing ............................................................................................................................................... 32
Figure 11: Dismantling ........................................................................................................................................... 32
Figure 12: Permissible installation deviations of the torque support ...................................................................... 33
Figure 13: Mounting the solid shaft with a shrink disc ........................................................................................... 34
Figure 14: Fitting the coupling to the motor shaft................................................................................................... 38
Figure 16: Industrial gear unit with CS1 and CS2 cooling systems ....................................................................... 40
Figure 17: Hydraulic diagram of the industrial gear unit with CS1 and CS2 cooling systems ................................ 41
Figure 18: Position of the temperature label for helical and helical bevel gear units ............................................. 42
Fig. 19: Checking the oil level with a dipstick ........................................................................................................ 44
Figure 20: ATEX labelling ...................................................................................................................................... 46
Fig. 21: Temperature sticker .................................................................................................................................. 46
Figure 22: Industrial gear unit with back stop ........................................................................................................ 52
Figure 23: Position of the oil screws in the gear unit ............................................................................................. 66
Figure 24: Installation orientations for helical gear units ........................................................................................ 67
Figure 25: Installation orientations for bevel helical gear units .............................................................................. 67
Figure 26: Declaration of Conformity for Category 2G / 2D ................................................................................... 75
Figure 27: Declaration of Conformity for Category 3G / 3D ................................................................................... 76
B 2050 EN-0916
7
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 17 /Allgemein/Steuermodul e/T abellenverzeic hnis @ 0\mod_1317978519199_388.doc x @ 4124 @ @ 1
List of tables
=== Ende der Liste für T extmar ke Tabellenverz eic hnis ===
Table 1: Version list B 2050 ..................................................................................................................................... 3
Table 2: Disposal of materials ............................................................................................................................... 14
Table 3: Helical gear units - Type designation and gear unit types ....................................................................... 15
Table 4: Bevel helical gear units - Type designation and gear unit types .............................................................. 16
Table 5: Motor weights .......................................................................................................................................... 37
Table 6: Lift-off speeds for back stops ................................................................................................................... 54
Table 7: Lubricant table ......................................................................................................................................... 68
Table 8: Lubricant quantities for helical gear units................................................................................................. 70
Table 9: Lubricant quantities for bevel helical gear units ....................................................................................... 71
Table 10: Torque values ........................................................................................................................................ 72
Table 11: Overview of malfunctions....................................................................................................................... 73
Table 12: Definition of leaks according to DIN 3761 .............................................................................................. 74
8
B 2050 EN-0916
List of tables
Pos : 19 /Anl eitungen/Getriebe/1. Hinweis e/1. Hi nweis e @ 3\mod_1368690405560_388.doc x @ 65212 @ 1 @ 1
B 2050 EN-0916
9
Explosion-protected industrial gear units – Operating and Assembly Instructions
1 Notes
Pos : 20 /Anl eitungen/Getriebe/1. Hinweis e/1.1 Allgemeine Hi nweise @ 3\mod_1368690552960_388.doc x @ 65516 @ 2 @ 1
1.1
General information
Read the Operating Manual carefully prior to performing any work on or putting the gear unit into
operation. Strict compliance with the instructions in this Operating Manual is essential. This Operating
Manual and all associated special documentation must be kept in the immediate vicinity of the gear
unit.
Getriebebau NORD accepts no liability for damage to persons, materials or assets as a result of the
non-observance of this Operating Manual, operating errors or incorrect use. General wearing parts,
e.g. radial seals are excluded from the warranty.
If additional components are attached to or installed on or in the gear unit (e.g. motor, cooling system,
pressure sensor etc.) or components (e.g. cooling system) are supplied with the order, the operating
instructions for these components must be observed.
If geared motors are used, compliance with the Motor Operating Manual is also necessary.
If you do not understand the contents of this Operating Manual or additional operating instructions,
please consult Getriebebau NORD!
Pos : 21 /Allgemein/Allgemeing ültige M odul e---------- Seitenumbruc h ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
10
B 2050 EN-0916
List of tables
Pos : 22 /Anl eitungen/Getriebe/1. Hinweis e/1.2 Sic herheits- und Hi nweiszeic hen [_Titel ] @ 3\mod_1370591783249_388.doc x @ 76351 @ 2 @ 1
1.2
Safety and information symbols
Pos : 24 /Anl eitungen/Getriebe/1. Hinweis e/1.2 Sic herheits- und Hi nweiszeic hen Erläuterungen [Text_2000_2050] @ 4\mod_1382005356030_388.doc x @ 102406 @ 3 @ 1
1.2.1
Explanation of designations used
DANGER!
Indicates an immediate danger, which may result in death or serious injury.
DANGER!
Indicates an immediate danger, which may result in death or serious injury.
Contains important information regarding explosion protection.
WARNING
Indicates a possibly dangerous situation, which may result in death or
serious injury.
CAUTION
Indicates a possibly dangerous situation, which may result in slight or
minor injuries.
NOTICE
Information
Indicates a possibly harmful situation, which may cause damage to the
product or the environment.
Indicates hints for use and useful information.
Pos : 26 /Anl eitungen/Getriebe/1. Hinweis e/1.3 Besti mmungsg emäß e Ver wendung [_Titel] @ 3\mod_1370592165719_388.doc x @ 76375 @ 2 @ 1
1.3
Correct use
Pos : 28 /Anl eitungen/Getriebe/1. Hinweis e/1.3 Besti mmungsg emäß e Ver wendung [Text_2000_2050] @ 3\mod_1368692711701_388.doc x @ 65817 @ @ 1
These gear units generate a rotational movement and are intended for use in commercial systems.
They satisfy the explosion-protection requirements of Directive 94/9EC (ATEX100a) for the product
category indicated on the type plate.
Commissioning (start of proper operation) is prohibited until it has been established that the machine
complies with the local laws and directives. The EMC Directive 2004/108/EC and the Machinery
Directive 2006/42/EC in their currently valid scope of application must be complied with in particular.
WARNING
Danger to persons
Appropriate safety measures must be taken for applications where failure of a gear unit or geared motor may
result in injury.
Safeguard a wide area around the hazard zone.
B 2050 EN-0916
11
Explosion-protected industrial gear units – Operating and Assembly Instructions
WARNING
Explosion hazard
Only components which comply with the applicable regulations of Directive 94/9/EU may be
fitted and operated.
Observe the Declaration of Conformity and all safety information for the components.
WARNING
Material damage and personal injury
If the gear unit is not used as designed, this may cause damage to the gear unit or the premature failure of
components. Personal injury as a result of this cannot be ruled out.
Strict compliance with the technical data on the type plate is essential. The documentation must be observed.
Pos : 29 /Anl eitungen/Getriebe/1. Hinweis e/1.4 Sic herheits hinweise [_Titel] @ 3\mod_1370592350264_388.doc x @ 76399 @ 2 @ 1
1.4
Safety information
Pos : 31 /Anl eitungen/Getriebe/1. Hinweis e/1.4 Sic herheits hinweise [T ext_2000_2050] @ 3\mod_1368692987197_388.doc x @ 65865 @ @ 1
Observe all safety information, including that provided in the individual sections of this Operating
Manual. All national and other regulations on safety and accident prevention must also be observed.
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
All work, e.g. transportation, storage, installation, electrical connection, commissioning,
servicing and maintenance must be performed in a non-explosive atmosphere.
DANGER!
Severe personal injury
Serious physical and property damage may result from inappropriate installation, non-designated use, incorrect
operation, non-compliance with safety information, unauthorised removal of housing components or safety covers
and structural modifications to the gear unit.
• All work, e.g. transportation, storage, installation, electrical connection, commissioning, servicing,
maintenance and repair must only be performed by qualified specialist personnel.
• Observe the Operating Manual.
• Observe the safety information.
• Observe the safety and accident prevention regulations.
• Tighten the driven elements or secure the parallel key before switching on.
• Do not make any structural modifications.
• Do not remove any safety devices.
• If necessary, wear hearing protection when working in the immediate vicinity of the gear unit.
• All rotating components must be provided with guards. In standard cases, covers are fitted by NORD . The
covers must always be used if contact protection is not provided by other methods.
12
B 2050 EN-0916
List of tables
DANGER!
Severe personal injury
The surfaces of gear units or geared motors may become hot during or shortly after operation.
• Installation and maintenance work must only be performed when gear unit is at a standstill and has cooled
down. The drive must be isolated and secured to prevent accidental start-up.
• Wear protective gloves.
• Shield hot surfaces with contact guards.
• Do not store inflammable objects or substances in the immediate vicinity of the gear unit.
WARNING
Serious personal injury and material damage
Serious injury and material damage due to improper transport are possible.
• No additional loads may be attached.
• Transportation aids and lifting gear must have an adequate load-bearing capacity.
• Pipes and hoses must be protected from damage.
CAUTION
Cutting hazard
Danger of cuts from exterior edges of attachment adapters, flanges and covers.
Contact freezing with metallic components in case of low temperatures.
In addition to personal protective equipment, wear suitable protective gloves and suitable goggles during
assembly, commissioning, inspection and maintenance, in order to prevent injuries.
It is recommended that repairs to NORD Products are carried out by the NORD Service department.
B 2050 EN-0916
13
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 32 /Anl eitungen/Getriebe/1. Hinweis e/1.5 Weiter e Unterl agen @ 3\mod_1368693112418_388.doc x @ 65889 @ 2 @ 1
1.5
Other documents
Further information may be obtained from the following documents:
•
•
•
Gear unit catalogues (G1000, G1012, G1014, G1035, G1050, G2000),
Operating and maintenance instructions for the electric motor,
if applicable, the Operating Manuals for attached or supplied options
Pos : 33 /Anl eitungen/Getriebe/1. Hinweis e/1.6 Ents orgung @ 3\mod_1368693227234_388.doc x @ 65913 @ 2 @ 1
1.6
Disposal
Observe the current local regulations. In particular, lubricants must be collected and disposed of
correctly.
Gear unit components
Material
Gear wheels, shafts, rolling bearings, parallel keys, locking rings, …
Steel
Gear unit housing, housing components, …
Grey cast iron
Light alloy gear unit housing, light alloy gear unit housing
components, …
Aluminium
Worm gears, bushes, ...
Bronze
Radial seals, sealing caps, rubber components,…
Elastomers with steel
Coupling components
Plastic with steel
Flat seals
Asbestos-free sealing material
Gear oil
Additive mineral oil
Synthetic gear oil (type plate code: CLP PG)
Polyglycol-based lubricants
Cooling spiral, embedding material of the cooling spiral, screw
fittings
Copper, epoxy, yellow brass
Table 2: Disposal of materials
Pos : 34 /Anl eitungen/Getriebe/2. Getriebebesc hrei bung/2. Getriebebesc hreibung @ 3\mod_1368691027023_388.doc x @ 65591 @ 1 @ 1
14
B 2050 EN-0916
List of tables
2 Description of gear unit
Pos : 38 /Anl eitungen/Getriebe/2. Getriebebesc hrei bung/2.1 T ypenbezeic hnungen und Getriebearten [2050] @ 3\mod_1374757067509_388.doc x @ 83981 @ 2 @ 1
2.1
Type designations and gear unit types
Gear unit types / Type designations
Helical gear units
SK 7207, SK 8207, SK 9207, SK 10207,
SK 11207, SK 12207, SK 13207, SK 14207,
SK 15207 (2-stage)
SK 7307, SK 8307, SK 9307, SK 10307,
SK 11307, SK 12307, SK 13307, SK 14307,
SK 15307 (3-stage)
Versions / Options
A
B
CC
CS1)
CS2)
D
ED
F
FAN
FK
F1
H
IEC
KL2
KL3
KL4
Foot mounting with solid shaft
Hollow shaft version
Fastening element
Cooling coil
Cooling system oil/water
Cooling system oil/air
Torque support
Elastic torque support
Block flange
Fans
Collar flange
Drive flange
Covering cap as contact guard
Standard IEC motor mounting
Agitator version
Drywell agitator version
True Drywell agitator version
KL6
L
LC2)
MF...
…K
…T
MS…
…K
…T
NEMA
OA
OT
PT100
R
S
True Drywell foot mounted
agitator version
Solid shaft both sides
Lubricant circulation
Motor base frame
with elastic coupling
with hydrodynamic coupling
Motor swing base
with elastic coupling
with hydrodynamic coupling
Standard NEMA motor
attachment
Oil expansion tank
Oil level tank
Temperature sensor
Back stop
Shrink disc
V
VL
VL2
VL3
VL4
VL6
W
W2
W3
WX
Solid shaft
Reinforced bearings
Agitator version
Drywell agitator version
True Drywell agitator version
True Drywell foot mounted
agitator version
Free input shaft
Two drive shaft journals
Three drive shaft journals
Auxiliary drive unit
_____
1)
2)
with PT100
with pressure switch
Table 3: Helical gear units - Type designation and gear unit types
B 2050 EN-0916
15
Explosion-protected industrial gear units – Operating and Assembly Instructions
Gear unit types / Type designations
Bevel helical gear unit
SK 7407, SK 8407, SK 9407, SK 10407, SK 11407,
SK 12407, SK 13407, SK 14407, SK 15407
(3-stage)
SK 7507, SK 8507, SK 9507, SK 10507, SK 11507,
SK 12507, SK 13507, SK 14507, SK 15507
(4-stage)
Versions / Options
A
B
CC
CS1)
CS2)
D
ED
F
FAN
FK
F1
H
IEC
KL2
KL3
KL4
Foot mounting with solid shaft
Hollow shaft version
Fastening element
Cooling coil
Cooling system oil/water
Cooling system oil/air
Torque support
Elastic torque support
Block flange
Fans
Collar flange
Drive flange
Covering cap as contact guard
Standard IEC motor mounting
Agitator version
Drywell agitator version
True Drywell agitator version
KL6
L
LC2)
MF...
…K
…T
MS…
…K
…T
NEMA
OA
OT
PT100
R
S
True Drywell foot mounted
agitator version
Solid shaft both sides
Lubricant circulation
Motor base frame
with elastic coupling
with hydrodynamic coupling
Motor swing base
with elastic coupling
with hydrodynamic coupling
Standard NEMA motor
attachment
Oil expansion tank
Oil level tank
Temperature sensor
Back stop
Shrink disc
V
VL
VL2
VL3
VL4
VL&
W
W2
W3
WX
Solid shaft
Reinforced bearings
Agitator version
Drywell agitator version
True Drywell agitator version
True Drywell foot mounted
agitator version
Free input shaft
Two drive shaft journals
Three drive shaft journals
Auxiliary drive unit
_____
1)
2)
with PT100
with pressure switch
Table 4: Bevel helical gear units - Type designation and gear unit types
Double gear units consist of two single gear units.
Gear units SK 7207 – SK 15507 are to be treated according to these instructions and attached gear
units are to be treated according to the operation and maintenance instructions B2000, each as two
individual gear units.
Type designation for double gear units: e.g. SK 13307 /7282 (consisting of single gear units SK 13307
and SK 7282).
Pos : 43 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3. Montageanleitung, Lager ung, Vorbereitung, Aufstellung @ 3\mod_1368691184786_388.doc x @ 65616 @ 1 @ 1
16
B 2050 EN-0916
List of tables
3 Assembly instructions, storage, preparation, installation
Please observe all general safety instructions (please see chapter 1.4 "Safety information"), the safety
information in the individual sections and the proper use (please see chapter 1.3 "Correct
use")bestimmungsgemäße Verwendung.
Pos : 46 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.6 Transport des Getriebes [2050] @ 3\mod_1368707852637_388.doc x @ 69504 @ 255 @ 1
3.1
Transporting the gear unit
WARNING
Hazard due to heavy loads
Severe injuries and material damage due to falling, swinging or tipping heavy loads are possible.
• To prevent injury, the danger area must be generously cordoned off.
• Standing under the gear unit during transport is extremely dangerous.
• Use adequately dimensioned and suitable means of transportation. Lifting tackle must be designed for the
weight of the gear unit. The weight of the gear unit can be obtained from the dispatch documents.
• If geared motors have an additional eyebolt attached to the motor, this must not be used.
• Only the four ring bolts provided may be used for transporting the gear unit.
CAUTION
Slipping hazard
Transport damage to the gear unit or gear unit components may result from the leakage of lubricants. There is a
slipping hazard due to leaked lubricants.
The drive unit must be inspected and may only be installed if no transportation damage or leaks are visible. In
particular the radial seals and the sealing caps must be inspected for damage.
NOTICE
Gear unit damage
Damage to the gear unit due to improper use is possible.
• Prevent damage to the gear unit. Impacts to the free ends of the shafts may cause internal damage to the
gear unit.
• The ends of the shafts must not be used for transportation, as this may seriously damage the gear unit.
B 2050 EN-0916
17
Explosion-protected industrial gear units – Operating and Assembly Instructions
For additional drive units and components, an additional lifting point may be necessary.
1
Transport eyebolts
Figure 1: Gear unit lifting points
Gear units with motor adapter
Gear units with a motor adapter may only be transported with lifting ropes and chains or lifting straps
at an angle of 90° to 70° to the horizontal.
The ring bolts on the motor must not be used for transportation.
Explanation
1
Lifting strap
2
Lifting rope
Figure 2: Transport of gear unit with motor
18
B 2050 EN-0916
List of tables
Gear units on motor swing base or base frame
Gear units on a motor swing base or base frame must only be transported with vertically tensioned
lifting ropes or chains. Only use the attachment points on the motor swing base or base frame.
1
Lifting
strap
1
Lifting strap
Figure 3: Transport of gear unit with motor swing base or base frame
B 2050 EN-0916
19
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 47 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.1 Lagerung @ 3\mod_1368704012647_388.doc x @ 69282 @ 2 @ 1
3.2
Storage
For short-term storage before commissioning, please observe the following:
Store in the installation position (please see chapter 6.1 "Configurations and maintenance") and
secure the gear unit against falling,
• Lightly oil bare metal housing surfaces and shafts
• Store in a dry place.
• Temperature in the range from – 5 °C to + 50 °C without large fluctuations,
• Relative humidity less than 60 %,
• No direct exposure to sunlight or UV light,
• No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis,
salts, radioactivity etc.) in the immediate vicinity,
• No vibration or oscillation
Pos : 48 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.2 Langz eitlag erung @ 3\mod_1368704158304_388.doc x @ 69306 @ 2555 @ 1
3.3
Long-term storage
CAUTION
Injury to persons
Incorrect, or excessively long storage may result in malfunctions of the gear unit.
Perform an inspection of the gear unit prior to commissioning if the permissible storage time has been exceeded.
Information
Long-term storage
For storage or standstill periods in excess of 9 months, Getriebebau NORD recommends the long-term storage
option.
With the long-term storage option and the use of the measures listed below, storage for up to 2 years is possible.
As the actual influences on the unit greatly depend on the local conditions, these times should only be regarded
as guide values.
20
B 2050 EN-0916
List of tables
Conditions of the gear unit and storage area for long-term storage prior to commissioning:
•
•
•
•
•
•
•
•
•
•
•
Store in the installation position (please see chapter 6.1 "Configurations and maintenance") and
secure the gear unit against falling.
Transportation damage to the external paint must be repaired. Check that a suitable rust inhibitor is
applied to the flange bearing surfaces. If necessary apply a suitable rust inhibitor to the surfaces.
Gear units with the long-term storage option are completely filled with lubricant or have VCI
corrosion protection agent mixed with the gear oil (see adhesive label on the gear unit, or are not
filled with oil, but rather with small quantities of VCI concentrate.
The sealing band in the vent plug must not be removed during storage. The gear unit must remain
sealed tight.
Store in a dry place.
In tropical regions, the gear unit must be protected against damage by insects
Temperature in the range from – 5 °C to + 40 °C without large fluctuations,
Relative humidity less than 60 %,
No direct exposure to sunlight or UV light,
No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis,
salts, radioactivity etc.) in the immediate vicinity,
No vibration or oscillation
Measures during storage or standstill periods
•
If the relative humidity is <50 % the gear unit can be stored for up to 3 years.
Measures before commissioning
•
•
•
If the storage or standstill period exceeds 2 years or the temperature during short-term storage has
greatly deviated from the standard range, the lubricant in the gear unit must be replaced before
commissioning.
If the gear unit is completely filled, the oil level must be reduced before commissioning.
For gear units without oil filling, the oil level for the version must be filled before commissioning.
The VCI concentrate may remain in the gear unit. Lubricant quantities and types must be filled
according to the details on the type plate.
Pos : 49 /Allgemein/Allgemeing ültige M odul e---------- Seitenumbruc h ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
B 2050 EN-0916
21
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 50 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.3 Prüfung des Getriebes [2000_2050] @ 3\mod_1368704276505_388.doc x @ 69330 @ 2 @ 1
3.4
Inspecting the drive unit
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
All work, e.g. transportation, storage, installation, electrical connection, commissioning,
servicing and maintenance must be performed in a non-explosive atmosphere.
The drive unit must be inspected and may only be installed if:
•
•
•
•
No damage, e.g. due to storage or transport is apparent. In particular the radial seals, the
sealing caps and the covers must be inspected for damage.
No leakage or no oil loss is visible.
No corrosion or other indications of incorrect or damp storage is apparent.
The packaging material has been completely removed.
Pos : 52 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.4 Prüfung der T ypenschil ddaten [2050] @ 3\mod_1370609556435_388.doc x @ 76519 @ 2 @ 1
3.5
Checking the type plate data
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
It must be checked and ensured that the gear unit type, all technical data and the ATEX
labelling conform to the planning of the plant or the machine.
The type plate must be firmly attached to the gear unit and must not be subjected to permanent
soiling. Please contact the NORD service department if the type plate is illegible or damaged.
Fig. 4:Type plate (example)
22
B 2050 EN-0916
List of tables
Explanation of the type plate
Abbreviations
Unit
Designation
See Section
Type
-
NORD gear unit type
No.
-
Serial number
iges
-
Overall gear unit ratio
n2
rpm
Rated speed of gear unit output shaft*
n1
rpm
Rated speed of the gear unit drive shaft or the drive motor*
IM
-
Configuration (installation orientation)
M2
Nm
Max. permissible gear unit output shaft torque
P1
kW
Max. permissible drive power or motor power
Bj
-
Year of manufacture:
FR2
kN
Max. permissible transverse force on the gear unit output shaft
3.9
FR1
kN
Max. permissible transverse force on the gear unit drive shaft for
option W
3.9
Tu
°C
Permissible ambient temperature for the gear unit
FA2
kN
Max. permissible axial force on the gear unit output shaft
3.9
FA1
kN
Max. permissible axial force on the gear unit drive shaft for option W
3.9
MI
h
Interval for general overhaul of the gear unit in operating hours
or according to the specification of the dimensionless maintenance
class CM
5.2
xR2
mm
Max. dimension for the point of application of the transverse force FR2
3.9
Oil
-
Gear unit oil type (standard designation)
6.2
Last line
-
Labelling as per ATEX (DIN EN 13463-1):
1. Group
(always II, not for mines)
2. Category
(2G, 3G for gas or 2D, 3D for dust)
3. Ignition protection type if fitted (c)
4. Explosion group if applicable (IIC, IIB)
5. Temperature class (T1-T3 or T4 for gas) or max. surface
temperature (e.g. 125°C for dust) or special max. surface
temperature see special documentation (TX)
6. Temperature measurement on commissioning (X)
4.3
S
-
6.1
Number of the special documentation, consisting of serial no. / year
* The maximum permissible speeds are 10% above the rated speed, if the maximum permissible drive power
P1 is not exceeded.
If the fields FR1, FR2, FA1 and FA2 are empty, the forces are zero. If the field xR2 is empty, the point of
application of force FR2 is central on the driven shaft journal (please see chapter 3.9 "Fitting hubs on the gear
shafts").
B 2050 EN-0916
23
Explosion-protected industrial gear units – Operating and Assembly Instructions
Please note that for geared motors (gear units with attached electric motors) the electric motor has its
own type plate and separate ATEX designation. The motor labelling must also comply with data for the
planning of the plant or the machine.
The lowest explosion protection level on the gear unit and the motor labelling applies for the
geared motor unit.
If the electric motor is driven with a frequency inverter, the motor requires ATEX approval for inverter
operation. If the motor is operated with an inverter, significant differences between the nominal speeds
on the type plates of the motor and the gearbox are normal and permissible. For operation of the
motor with the mains supply, differences of the nominal speeds on the motor and the gear unit of up to
± 60 rpm are permissible.
Pos : 54 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.5 Prüfung der Baufor m [2050] @ 3\mod_1368705245035_388.doc x @ 69432 @ 2 @ 1
3.6
Checking the configuration
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• The gear unit may only be operated in the stated configuration.
• The permissible configuration is stated on the type plate (IM…). If an X is present in the
field IM, the special documentation, whose number is in field S, must be observed.
Section 6.1 "Configurations and maintenance", or the special documentation, shows the
configuration of the individual types of gear units.
• It must be checked and ensured that the configuration as stated on the type plate complies
with the installation orientation and that the installation orientation does not change during
operation.
Pos : 57 /Allgemein/Allgemeing ültige M odul e/---------- Seitenumbruc h ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
24
B 2050 EN-0916
List of tables
Pos : 59 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.7 Vorbereitungen z um Aufstell en [2050] @ 3\mod_1369211440098_388.doc x @ 70173 @ 2 @ 1
3.7
Preparing for installation
CAUTION
Injury to persons
Transport damage may cause malfunctions of the gear unit, which may cause material damage or personal
injury.
Please inspect the delivery for transport and packaging damage immediately on receipt. Report any damage to
the carrier immediately. Gear units with transport damage must not be commissioned.
The drive unit must be inspected and may only be installed if no damage is apparent. In particular the radial seals
and the sealing caps must be inspected for damage.
Pay attention to leaked lubricants, they may cause slips.
All bare metal surfaces and shafts of the gear unit are protected against corrosion with oil, grease or
corrosion protection agents before shipping.
Thoroughly remove all oil, grease or corrosion protection agents and any dirt from the shafts and
flange surfaces before assembly.
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
Care must be taken that drive elements attached to the gear unit, such as clutches, pulleys
etc. and drive motors are also ATEX-compliant.
Information
Oil filling
Gear units and geared motors are filled with oil as standard when delivered from the factory. For filling, the
lubricant stated on the type plate must be used. Please refer to section 6.2 "Lubricants" for the amount of
lubricant.
As an option, the gear unit can be filled with lubricant. In all cases, the oil level must be checked as per
Section 4.1 "Check the oil level" prior to commissioning.
In applications where an incorrect rotational direction may result in damage or potential risk, the
correct rotational direction of the output shaft is to be established by test running the drive when
uncoupled and guaranteeing such for subsequent operation.
Gears with integrated return stops are marked with arrows on the drive/driven sides. The arrows point
in the rotation direction of the gear unit. When connecting the motor and during motor control, it must
be ensured, e.g. by testing the rotating field, that the gear unit can only operate in the direction of
rotation (for further explanations see Catalogue G1000 and WN 0-000 40).
B 2050 EN-0916
25
Explosion-protected industrial gear units – Operating and Assembly Instructions
NOTICE
Gear unit damage
With gear units with an integrated back stop, switching the drive motor to the blocked direction of rotation, i.e.
incorrect direction of rotation, may result in damage to the gear unit.
Take care that the direction of rotation of the gear unit is correct when connecting the motor and the motor control
unit.
NOTICE
Gear unit damage
Damage to the gear unit due to aggressive or corrosive environments.
Ensure that no aggressive or corrosive substances are present in the area surrounding the installation site or are
subsequently expected during operation, which attack metal, lubricants or elastomers. In case of doubt, please
contact Getriebebau NORD and take the recommended action.
The pressure vent must be activated prior to commissioning. To activate, remove the transport
securing devices.
Double gear units consist of two single units and are equipped with 2 oil chambers and 2 pressure
vents.
Explanation
1
Vent screw
2
Transport securing
device
Figure 5: Activation of the pressure vent
Pos : 63 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.8 Aufstellen des Getriebes [2050] @ 3\mod_1369212645695_388.doc x @ 70269 @ 2 @ 1
3.8
Installing the gear unit
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• No explosive atmosphere must be present when installing the gear unit.
• The cooling air supplied to the gear unit/geared motor must be within the permissible
temperature range stated on the type plate.
• Protect the gear unit from direct sunlight (e.g. with a sunshade)
• If a sunshade is not possible, in case of direct sunlight falling onto the gear unit, the
cooling air supplied to the gear unit/geared motor must be at least 10°C below the highest
permissible temperature of the ambient temperature range Tu, which is stated on the type
plate.
26
B 2050 EN-0916
List of tables
WARNING
Hazard due to heavy loads
Danger of injury and damage to the device may be caused by incorrect attachment.
• The eyebolts screwed into the gear unit must be used during installation.
• Do not attach additional loads to the gear unit.
• Use the additional eyebolts attached to the geared motor if fitted.
• Avoid pulling the eyebolts at an angle.
WARNING
Danger of burns
The surfaces of gear units or geared motors may become hot during or shortly after operation.
Hot surfaces which can be touched directly must be protected with a contact guard.
NOTICE
Damage to the gear unit due to overheating
The gear unit may be damaged by overheating.
During installation::
• Ensure a free flow of air to all sides of the gear unit.
• Ensure adequate space around the gear unit.
• With geared motors, the cooling air of the motor fan must be able to flow unobstructed onto the gear unit.
• Do not enclose or encase the gear unit/geared motor.
• Do not subject the gear unit to highly energetic radiation.
• Do not direct warm exhaust air from other units onto the gear unit/geared motor.
• The base or flange to which the gear unit is attached must not input any heat into the gear unit during
operation.
• Do not allow dust to accumulate in the area of the gear unit
B 2050 EN-0916
27
Explosion-protected industrial gear units – Operating and Assembly Instructions
The base and/or flange to which the gear unit is fitted should be vibration-free, torsionally strong and
flat. The smoothness of the mating surface on the base or flange must be according to
tolerance class K according to DIN ISO 2768-2. All contamination to the bolting surfaces of gear
unit and base and/or flange must be thoroughly removed.
The base must be designed according to the weight and torque, taking into account the forces acting
on the gear unit. Bases which are insufficiently rigid may lead to radial and axial displacement during
operation, which is not measurable when the unit is stopped.
When attaching the gear unit to a concrete base using masonry bolts or base blocks, appropriate
recesses must be provided in the base. Tensioning bars must be cast into the concrete base in their
aligned state.
The gear unit must be precisely aligned with the drive shaft of the machine in order to prevent
additional forces from being imposed on the gear unit due to distortion.
Information
Orientation
The service life of shafts, bearings and couplings depends on the precision of alignment of the shaft. Therefore,
zero deviation should always be aimed for in alignment. For this, e.g. the requirements for the coupling should be
obtained from the special Operating Manuals.
The tolerances of the shaft ends and the flange connections should be obtained from the dimension
sheet.
Welding of the gear unit is prohibited. The gear unit must not be used as the earth connection for
welding work, as this may cause damage to the bearings and gear wheels.
The gear housing must always be earthed. With geared motors, earthing via the motor connection
must be ensured.
The gear unit must be installed in the correct orientation (please see chapter 6.1 "Configurations
and maintenance"). All gear unit feet and/or all flange bolts on each side must be used. Bolts must
have a minimum quality of 8.8. The bolts must be tightened to the correct torques (please see
chapter 6.4 "Torque values"). Tension-free bolting must be ensured, particularly for gear units with a
foot and flange.
Oil checking and oil drain screws must be accessible.
28
B 2050 EN-0916
List of tables
Pos : 66 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.9 M ontage von N aben auf Getriebewell en [2050] @ 3\mod_1369214058373_388.doc x @ 70341 @ 2 @ 1
3.9
Fitting hubs on the gear shafts
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
Care must be taken that drive and driven elements attached to the gear unit must also be
ATEX-compliant.
DANGER!
Risk of injury
There is a danger of injury due to drive and driven elements.
• Drive and driven elements, such as belt drives, chain drives and couplings must be fitted with contact
protection.
NOTICE
Gear unit damage
The gear unit may be damaged by axial forces.
• Do not subject the gear unit to harmful axial forces when fitting the hubs. In particular, do not hit the hubs with
a hammer.
Drive and driven elements, e.g. coupling and chain-wheel hubs must be mounted onto the drive and
driven shaft of the gear unit using suitable pullers that will not apply damaging axial forces onto the
gear unit. In particular, do not hit the hubs with a hammer.
Information
Assembly
Use the end thread of the shafts for pulling. Fitting can be aided by coating the hub with lubricant or heating it up
to approx. 100°C beforehand.
Figure 6: Example of a simple pulling device
B 2050 EN-0916
29
Explosion-protected industrial gear units – Operating and Assembly Instructions
Drive and driven elements must only introduce the maximum radial transverse forces FR1 and
FR2 as stated on the type plate and the axial forces FA1 and FA2 into the gear unit (please see
chapter 3.5 "Checking the type plate data"). Observe the correct tension, particularly on belts and
chains.
Additional loads due to unbalanced hubs are not permitted.
The transverse force must be applied as closely as possible to the gear unit.
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• The transverse force must be applied to the gear unit as closely as possible.
• For drive shafts with free shaft ends – Option W – the maximum permissible transverse
force FR1 applies for the application of the transverse force to the centre of the free shaft
journal.
• For output shafts, the application of the transverse force FR2 must not exceed the
dimension XR2.
• If the transverse force FR2 for the output shaft is stated on the type plate, but no
dimension XR2 is stated, the application of the force is assumed to be to the centre of the
shaft journal.
Figure 7: Permissible application of force to drive and driven shafts
Pos : 67 /Allgemein/Allgemeing ültige M odul e---------- Seitenumbruc h ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
30
B 2050 EN-0916
List of tables
Pos : 71 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.10 M ontag e von Aufs tec kg etrieben [2050] @ 3\mod_1370942889953_388.doc x @ 77181 @ 2 @ 1
3.10 Fitting push-on gear units
NOTICE
Gear unit damage
The bearings, gear wheels, shafts and housing may be damaged by incorrect fitting.
• Observe the assembly instructions.
• The push-on gear unit must be fitted onto the shaft using a suitable puller, which will not exert damaging axial
forces on the gear unit. In particular, do not hit the gear unit with a hammer.
Assembly and subsequent dismantling is aided by applying an anti-corrosive lubricant to the shaft
before fitting (e.g. Nord Anti-Corrosion Part No. 089 00099). Excess grease or anti-corrosion agent
may escape after assembly and may drip off. Clean these points on the driven shaft after a running-in
time of approx. 24 hours. This escape of grease is not due to a leak in the gear unit.
Figure 8: Applying lubricant to the shaft and the hub
Information
Fastening element
The gear unit can be fitted to shafts with and without a shoulder using the fastening element (Option B). Tighten
the bolt of the fastening element to the correct torque (please see chapter 6.4 "Torque values").
B 2050 EN-0916
31
Explosion-protected industrial gear units – Operating and Assembly Instructions
Fig. 9: Assembly
Explanation
1
Fastening element
2
Circlip
3
Assembly – threaded rod
4
Assembly – threaded nut
5
Securing screw
6
Protective cover
7
Disassembly of threaded rod
8
Disassembly element
9
Disassembly – threaded nut
Figure 10: Securing
Figure 11: Dismantling
When assembling push-on gears with torque supports, the support must not be distorted. Distortionfree assembly is made easier if an elastic element (Option DG) is used.
32
B 2050 EN-0916
List of tables
Pos : 73 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.11 Dr ehmoments tütz e [2050] @ 3\mod_1370943749357_388.doc x @ 77205 @ 2 @ 1
3.11 Torque support
Explanation
1
Fork head with bolt
2
Threaded bolt
3
Maintenance-free joint head
4
Fork plate with bolt
Figure 12: Permissible installation deviations of the torque support
The length of the torque support can be adjusted within a certain range.
Assembly should be carried out from the side of the machine, in order to reduce the bending moment
on the machine shaft. Tension and pressure and installation upwards or downwards are permissible.
Distortion of the torque support during assembly or operation must be avoided, as otherwise the
service life of the output shaft bearings may be reduced. Torque supports are not suitable for the
transmission of radial forces, therefore they may only be used in combination with motor adapters or
couplings which cannot transmit radial forces.
For helical gear units with motor adapters, the torque support is located opposite to the motor adapter.
The gear unit is aligned horizontally by means of the threaded bolt and the nuts of the torque support
and secured with lock-nuts.
Tighten the fastenings of the torque support with the correct tightening torques (please see
chapter 6.4 "Torque values") and secure against loosening (e.g. Loctite 242, Loxeal 54-03).
B 2050 EN-0916
33
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 77 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.12 M ontag e von Sc hrumpfs cheiben [2050] @ 3\mod_1369219543040_388.doc x @ 70539 @ 255 @ 1
3.12 Fitting shrink discs
:
CAUTION
Risk of injury
Risk of injury from incorrect mounting and dismantling of the shrink disc.
Observe the instructions.
NOTICE
Gear unit damage
If the tensioning bolts are tightened without the solid shaft inserted, the hollow shaft may be permanently
deformed.
Do not tighten bolts if the solid shaft is not inserted!
1
No grease here
Figure 13: Mounting the solid shaft with a shrink disc
34
B 2050 EN-0916
List of tables
Assembly sequence
1. Remove any transport securing devices.
2. Loosen but do not remove tightening bolt and tighten gently by hand until there is no play between
the flanges and the inner ring.
3. Push the shrink disc up to the collar onto the hollow shaft (see illustration).
The shrink disc is easier to slide on if the bore of the inner ring is lightly greased.
4. Prior to mounting, grease the solid shaft only in the area which will later come into contact with the
bronze bush in the hollow shaft of the gear unit. Do not grease the bronze bush, in order to prevent
grease penetrating the area around the shrink connection.
5. The hollow shaft of the gear unit must be completely de-greased and completely free of grease.
6. In the area of the shrink connection the solid shaft of the machine must be degreased and
completely free of grease.
7. Insert the solid shaft of the machine into the hollow shaft so as to completely fill the area around
the shrink connection.
8. Tighten the tensioning bolts successively in a clockwise direction by several turns – not crosswise
– with approx. ¼ rotation per turn.
9. After tightening the tensioning bolts the face of the inner ring on the screw side must be flush with
the face of the outer ring. The distortion of the shrink disc must be checked visually.
10. The hollow shaft of the gear unit and the solid shaft of the machine should be marked with a line
(felt-tip pen) in order to detect any slippage under load.
Dismantling sequence:
1. Loosen the tensioning bolts successively in a clockwise direction by several turns with approx. ¼
rotation per turn. Do not remove the bolts from their thread.
2. If the external ring does not detach from the inner ring after approx. one turn of all screws, the
external ring can be released with the aid of the push-off thread. For this, the required number of
tensioning bolts are uniformly screwed into the push-off thread until the external ring separates
from the internal ring.
3. Remove the gear unit from the solid shaft of the machine.
If a shrink disk has been in use for a long period or is dirty, it must be dismantled, cleaned and the
conical surfaces coated with Molykote G Rapid Plus or a similar lubricant before it is refitted. The
threads and head surfaces of the screws must be treated with grease without Molykote. Any damaged
or corroded elements must be replaced.
B 2050 EN-0916
35
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 83 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.13 M ontag e von Abdec khauben [2050] @ 3\mod_1369220981292_388.doc x @ 70655 @ 2 @ 1
3.13 Fitting the covers
DANGER!
Explosion hazard
Explosion hazard due to damaged and rubbing covers. Failure to comply may cause severe,
or even fatal injuries.
• Damaged covers must not be used, as they may cause rubbing.
• Covers must be inspected for transportation damage e.g. dents and warping before they
are fitted.
WARNING
Risk of injury
There is a danger of injury due to shrink discs and freely rotating shaft journals.
• Use a cover (Option H) as a guard.
• If this does not achieve sufficient protection against contact according to the required protection type, the
machinery and plant constructor must ensure this by means of special attached components.
All fixing screws must be used and coated prior to use with a securing lubricant e.g. Loctite 242,
Loxeal 54-03 and tightened to the correct torque (please see chapter 6.4 "Torque values").
36
B 2050 EN-0916
List of tables
Pos : 88 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.14 M ontag e eines N ormmotors [2050] @ 3\mod_1369223613725_388.doc x @ 70781 @ 25 @ 1
3.14 Fitting a standard motor
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• Only standard motors with an adequate ATEX Zone category according to the type plate
may be used.
• In addition, for ATEX category 2D gear units (see the ATEX labelling on the last line of the
gear unit type plate), the motor must have at least protection class IP6x.
• Only couplings which are approved and labelled for use in explosion hazard areas may be
used. The ATEX labelling must conform to the details of the system and/or machine
design.
The maximum permitted motor weights indicated in the table below must not be exceeded when
attaching the motor to an IEC/NEMA adapter:
Maximum permitted motor weights
63
IEC motor size
NEMA motor size
71
80
90
100
112
132
56C
143T
145T
182T
184T
210T
Max. motor weight
[kg]
25
30
40
50
60
80
100
IEC motor size
160
180
200
225
250
280
315
NEMA motor size
250T
280T
324T
326T
365T
Max. motor weight
[kg]
200
250
350
500
700
1000
1500
Transnorm
315
355
400
450
Max. motor weight
[kg]
1500
2200
3200
4400
Table 5: Motor weights
B 2050 EN-0916
37
Explosion-protected industrial gear units – Operating and Assembly Instructions
WARNING
Risk of injury
Severe injuries may be caused by rapidly rotating parts when installing and servicing couplings.
• Secure the drive unit against accidental switch-on.
• The operating and assembly instructions for the coupling must be observed.
Gear units with IEC/NEMA adapters must be operated with self-ventilated motors which comply with
IC411 (TEFC) or IC416 (TEBC) externally ventilated motors compliant with EN60034-6, which
generate a continuous airflow towards the gear unit. Please contact NORD if the use of IC410 (TENV)
motors without fans is intended.
Assembly procedure to attach a standard motor to the IEC adapter (Option IEC/NEMA adapter)
1. Clean motor shaft and flange surfaces of motor and adapter and check for damage. The mounting
dimensions and tolerances of the motor must conform to DIN EN 50347/NEMA MG1 Part 4.
2. Push the coupling sleeve onto the motor shaft so that the motor parallel key engages into the
groove in the sleeve on tightening.
3. Pull the coupling sleeve onto the motor shaft according to the instructions of the motor
manufacturer. The shaft end of the motor must be adjusted so that it is parallel with the face of the
coupling (see Figure 14).
4. Secure the coupling half with the threaded pin. The threaded pin must be coated prior to use with a
securing lubricant e.g. Loctite 242, Loxeal 54-03 and tightened to the correct torque (please see
chapter 6.4 "Torque values").
5. Sealing of the flange surfaces of the motor and the adapter is recommended if the motor is
installed outdoors or in a humid environment. Before the motor is installed, the flange surfaces
must be completely coated with surface sealant Loctite 574 or Loxeal 58-14 so that the flange
seals after mounting.
6. Mount the motor to the adapter. Do not forget to fit the gear rim or the sleeve.
7. Tighten the adapter bolts to the correct torque (please see chapter 6.4 "Torque values").
Figure 14: Fitting the coupling to the motor shaft
Information
Coupling
The operating instructions for the coupling must be observed.
Pos : 91 /Allgemein/Allgemeing ültige M odul e---------- Seitenumbruc h ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
38
B 2050 EN-0916
List of tables
Pos : 94 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.15 Ans chl uss der inter nen Wass er kühlung (Kühlschl ange) [2050] @ 10\mod_1457001445395_388.doc x @ 311610 @ @ 1
WARNING
Risk of injury
Possibility of injury due to pressure discharge.
The pressure must be released from the cooling circuit before carrying out any work on the gear unit.
For the inlet and outlet of cooling fluid, connections with G1/2 pipe thread are located in the gear unit
or the casing cover for fitting pipes or hoses.
Remove the drain plug from the screw neck prior to assembly to avoid any contamination of
the cooling system. The screw necks should be connected with the coolant circuit, which must be
provided by the operator. The flow direction of the coolant is irrelevant.
NOTICE
Damage to the device
Make sure not to twist the screw necks during or after assembly as the cooling coil may be damaged.
It must be ensured that no external forces act on the cooling coil.
1
Cooling coil
Figure 15: Cooling cover with cooling coil fitted
B 2050 EN-0916
39
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 96 /Anl eitungen/Getriebe/3. Montage, Lager ung, Vorberei tung, Aufstellung/3.16 M ontag e der externen Kühlanlag e (Kühlaggregat) [2050] @ 3\mod_1369225047815_388.doc x @ 70877 @ 2 @ 1
3.15 Mounting the external cooling system (cooling unit)
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• For operation in explosion hazard atmospheres, only approved and labelled cooling
systems may be used.
• The ATEX labelling must conform to the details of the system and/or machine design.
NOTICE
•
•
External cooling system
The separate manufacturer’s documentation must be observed for assembly.
With circulation lubrication (LC) use the connection diagram included by NORD.
Connect the cooling system as shown in the illustration. Other connection plans can be agreed upon
during consultation with NORD.
Explanation
1
Gear unit intake connection
2
Pump / cooling system intake
connection
3
Cooling system pressure connection
4
Gear unit pressure connection
5
Temperature monitoring
6
Cooling water connection
Figure 16: Industrial gear unit with CS1 and CS2 cooling systems
40
B 2050 EN-0916
List of tables
Figure 17: Hydraulic diagram of the industrial gear unit with CS1 and CS2 cooling systems
Pos : 100 /Anleitungen/Getri ebe/3. M ontage, Lagerung, Vorbereitung, Aufs tell ung/3.18 Sensori k zur Getriebeüber wachung [B2050] @ 10\mod_1457003461988_388.doc x @ 311644 @ 2 @ 1
3.16 Gear unit monitoring sensors
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• For operation in explosion hazard atmospheres, only approved sensors (PT100, pressure
monitors, speed monitors, oil level monitors, vibration sensors, etc.) which have been
approved and labelled for this purpose may be used.
• The ATEX labelling must conform to the details of the system and/or machine design.
NOTICE
•
•
Sensors
The separate manufacturer’s documentation must be observed for assembly.
The position of the sensors must be obtained from the enclosed NORD connection diagram.
Pos : 101 /Anleitungen/Getri ebe/3. M ontage, Lagerung, Vorbereitung, Aufs tell ung/3.17 Temperaturaufkl eber [2050] @ 3\mod_1369225615185_388.doc x @ 70925 @ 2 @ 1
3.17 Temperature sticker
DANGER!
Explosion hazard
Explosion hazard due to lack of labelling. Failure to comply may cause severe, or even fatal
injuries.
With temperature class T4 gear units with a maximum surface temperature of less than
135°C, the supplied self-adhesive temperature sticker (printed with value 121°C) must be
affixed to the gear unit housing. (Part No.: 8510400.)
The temperature class or the maximum surface temperature can be seen from the ATEX labelling in
the last line of the type plate.
Examples: II 2G c IIC T4 X or II 3D 125°C X
B 2050 EN-0916
41
Explosion-protected industrial gear units – Operating and Assembly Instructions
The temperature label must be attached in the area of the drive mount for gear units with an
IEC/NEMA adapter, the temperature label must be attached as for a helical gear unit.
Figure 18: Position of the temperature label for helical and helical bevel gear units
Pos : 107 /Anleitungen/Getri ebe/4. Inbetriebnahme/4. Inbetri ebnahme @ 3\mod_1368691822868_388.doc x @ 65671 @ 1 @ 1
42
B 2050 EN-0916
List of tables
4 Commissioning
Pos : 111 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.1 Ölstand pr üfen [2050] @ 3\mod_1369226943024_388.doc x @ 71045 @ 25 @ 1
4.1
Check the oil level
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
Before commissioning, the oil level must be checked with the supplied dipstick.
WARNING
Danger of burns
Danger of burns due to hot oil.
• Allow the gear unit to cool down before carrying out maintenance or repair work.
• Wear protective gloves.
The installation must comply with the configuration on the type plate. Section 6.1 "Configurations and
maintenance" describes the versions and the corresponding oil level screws. For double gear units
and gear units with an auxiliary drive unit (Option WX) the oil level must be checked on both gear
units. In the case of auxiliary drive units, the attached cylinder of the freewheeling coupling must also
be checked. The pressure vent must be at the position marked in Section 6.1 "Configurations and
maintenance".
Gear unit types that are not supplied full of oil must be filled before the oil level is checked (please see
chapter 5.2 "Service and Maintenance Work").
Oil filling and oil level checks may be necessary for attached couplings. The manufacturer
documentation must be complied with.
Check the oil level with an oil temperature of between 20°C to 40°C.
Checking the oil level:
1. The oil level may only be checked when the gear unit is at a standstill and has cooled down. The
gear unit must be secured to prevent accidental switch-on.
2. Gear units with oil level screw:
•
•
•
•
The oil level screw corresponding to the version must be screwed out (please see chapter 6.1
"Configurations and maintenance").
Check the oil level in the gear unit with the dipstick supplied (Part No.: 283 0050), as shown in Fig.
19. To do this, the part of the dipstick which is submerged in the oil must be held vertically.
The maximum oil level is the lower edge of the oil level hole.
The minimum oil level is approx. 4 mm below the lower edge of the oil level hole. The dipstick then
just dips into the oil.
B 2050 EN-0916
43
Explosion-protected industrial gear units – Operating and Assembly Instructions
•
If the oil level is not correct, it must be adjusted by draining off oil or topping up with the type of oil
stated on the type plate.
• If the integrated seal of the oil level screw is damaged, a new oil level screw must be used or the
thread cleaned and coated with securing adhesive, e.g. Loctite 242, Loxeal 54-03 prior to insertion.
Fit the oil level screw together with the sealing ring and tighten to the correct torque (please see
chapter 6.4 "Torque values").
• If the pressure vent has been unscrewed, reinsert it together with the sealing ring and tighten to the
correct torque (please see chapter 6.4 "Torque values").
3. Gear units with an oil level tank:
•
The oil level must be checked in the oil level tank with the aid of the dipstick plug (thread G1
1/4). The oil level must be between the upper and lower marking when the dipstick is fully
screwed in. These gearboxes may only be operated in the configuration stated in
Section 6.1 "Configurations and maintenance".
4. Gear units with oil inspection glass:
•
•
•
The oil level can be seen directly in the window
The correct oil level is: the middle of the oil inspection glass.
If the oil level is not correct, it must be adjusted by draining off oil or topping up with the type of oil
stated on the type plate.
5. Final check:
•
All previously removed screws must be screwed back in correctly.
Fig. 19: Checking the oil level with a dipstick
Pos : 112 /Allgemein/Allgemeingültig e Module---------- Seitenumbr uch ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
44
B 2050 EN-0916
List of tables
Pos : 115 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.2 Sc hmier mittel kühl ung interner Wass er kühler [B2050] @ 10\mod_1457004537929_388.doc x @ 311678 @ 28 @ 1
4.2
Lubricant cooling with internal water cooler
NOTICE
Gear unit damage
The gear unit may be damaged by overheating.
The drive may only be commissioned after the cooling spiral has been connected to the cooling circuit, and the
cooling circuit has been put into operation.
The coolant must have a similar thermal capacity as water (specific thermal capacity at 20°C
c=4.18 kJ/kgK). Industrial water without any air bubbles or sediments is recommended as a coolant.
The hardness of the water must be between 1 dH and 15 dH; the pH value must be between pH 7.4
and pH 9.5. No aggressive liquids may be added to the coolant!
The coolant pressure must not exceed 8 bar. The required quantity of coolant is 10 litres/minute,
and the coolant inlet temperature must not exceed 40°C; we recommend 10°C.
We also recommend fitting a pressure reducer or similar at the coolant inlet to avoid damage due to
excessive pressure.
If there is a danger of frost the operator should add a suitable anti-freeze solution to the cooling water.
The temperature of the cooling water and the cooling water flow rate must be supervised and
ensured by the operator.
Pos : 117 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.3 Temper atur mes sung [2050] @ 3\mod_1369297841211_388.doc x @ 71143 @ 2 @ 1
4.3
Temperature measurement
The details of the ATEX temperature class or the maximum surface temperature are based on normal
installation conditions (please see chapter 3.7 "Preparing for installation"). Even small changes to the
installation conditions can have a significant effect on the temperature of the gear unit.
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
On commissioning, a surface temperature measurement of the gear unit must be made under
maximum load.
(This does not apply to gear units which are labelled as temperature class T1 – T3 or a
maximum surface temperature of 200°C in the last line of the type plate.)
For the temperature measurement, a normal temperature measuring device is required, with a
measurement range from 0°C to 130°C and a precision of at least ± 4°C and which enables the
measurement of the surface temperature and the temperature of the air.
Temperature measurement procedure:
1. Allow the gear unit to run at maximum speed under maximum load for approx. 4 hours.
2. Following warm-up, the temperature of the gear unit housing surface Tgm is to be measured close
to the temperature-resistant adhesive label (please see chapter 3.17 "Temperature sticker").
B 2050 EN-0916
45
Explosion-protected industrial gear units – Operating and Assembly Instructions
3. Measure the temperature of the air Tum in the immediate vicinity of the gear unit.
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
The gear unit must be shut down and Getriebebau NORD must be consulted if any of the
following criteria do not apply:
•
•
•
The measured air temperature Tum is within the permissible range stated on the type plate.
The measured temperature of the surface of the gear unit housing Tgm is below 121°C and the
temperature indication label has not turned black (see Fig. 21).
The measured temperature of the surface of the gear unit housing plus the difference between the
highest permissible air temperature Tu stated on the type plate and the measured air temperature
must be at least 15°C lower than the maximum permissible surface temperature, i.e.:
ATEX labelling:
II 2G c T4 / II 3G T4 :
Tgm + Tu – Tum < 135°C – 15°C
ATEX labelling:
II 2D c Tmax / II 3D Tmax:
Tgm + Tu – Tum < Tmax – 15°C
Tgm:
Tum:
Tmax:
Tu:
Measured temperature of the surface of the gear unit housing in °C
Measured air temperature in °C
Maximum surface temperature according to gear unit type plate (ATEX labelling) in °C
Upper value of the permissible ambient temperature range according to the type plate in °C
Figure 20: ATEX labelling
Centre dot is white: OK
Centre dot is black: Temperature was too high.
Fig. 21: Temperature sticker
46
B 2050 EN-0916
List of tables
Pos : 121 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.5 Kontrolle des Getriebes [2050] @ 3\mod_1370611125759_388.doc x @ 76543 @ 255 @ 1
4.4
Checking the gear unit
During a test run under full load, the gear unit should be checked for:
•
•
•
Unusual noises, such as grinding, knocking or rubbing noises
Unusual vibrations, oscillations or other movements
Production of steam or smoke
After the test run, the gear unit should be checked for:
•
•
Leaks
Slippage of the shrink disks. To do this, remove the covering cap and confirm whether the marking
specified in Section 3.12 "Fitting shrink discs" indicates a relative movement of gear unit hollow
shaft and machine shaft. Then remount the covering cap as described in Chapter 3.13 "Fitting the
covers".
Information
Lubrication of the shaft sealing rings
Shaft sealing rings are rubbing seals and have sealing lips made from an elastomer material. These sealing lips
are lubricated with a special grease at the factory. This reduces the wear due to their function and ensures a long
service life. An oil film in the region of the rubbing sealing lip is therefore normal and is not due to leakage.
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
The drive must be shut down and Getriebebau NORD consulted if any irregularities are
observed during the checks described above.
Pos : 122 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.5 Getriebekühlung über Lüfter [B2050] @ 10\mod_1457004962720_388.doc x @ 311712 @ 2 @ 1
4.5
Gear unit cooling with a fan
DANGER!
Severe personal injury
Danger of injury due to rotating fan blades.
• Use a cover as a guard.
• If this does not achieve sufficient protection against contact according to the required protection type, the
machinery and plant constructor must ensure this by means of special attached components.
• Wear suitable goggles to prevent eye injuries due to thrown-up particles of dirt.
B 2050 EN-0916
47
Explosion-protected industrial gear units – Operating and Assembly Instructions
NOTICE
Overheating
The gear unit may be damaged by overheating.
An adequate air intake must be ensured. The air inlet grille and the fan blades must be kept clean.
NOTICE
Contact protection
Contact with the fan guard may cause damage to the fan.
Check the contact guard for damage (e.g. due to incorrect transportation or installation). Repair any damage prior
to commissioning.
Pos : 123 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.6 Sc hmier mittel kühl ung internen Wasser kühlung (Kühls chl ang e) [B2050] @ 10\mod_1457005018099_388.doc x @ 311746 @ 2 @ 1
4.6
Lubricant cooling with internal water cooling (cooling coil)
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
The temperature of the cooling water and the cooling water flow rate must be supervised and
ensured by the operator.
The ATEX approval is void if these instructions are not observed!
NOTICE
Gear unit damage
The gear unit may be damaged by overheating.
The drive may only be commissioned after the cooling spiral has been connected to the cooling circuit, and the
cooling circuit has been put into operation.
The coolant must have a similar thermal capacity as water (specific thermal capacity at 20°C
c=4.18 kJ/kgK). Industrial water without any air bubbles or sediments is recommended as a coolant.
The hardness of the water must be between 1 dH and 15 dH; the pH value must be between pH 7.4
and pH 9.5. No aggressive liquids may be added to the coolant!
The coolant pressure must not exceed 8 bar. The required quantity of coolant is 10 litres/minute,
and the coolant inlet temperature must not exceed 40°C; we recommend 10°C.
We also recommend fitting a pressure reducer or similar at the coolant inlet to avoid damage due to
excessive pressure.
If there is a danger of frost the operator should add a suitable anti-freeze solution to the cooling water.
Pos : 128 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.9 Sc hmier mittel kühl ung exter ner Öl / Luftkühl er (Kühl aggregat) [2050] @ 3\mod_1369301243235_388.doc x @ 71335 @ 2 @ 1
4.7
Lubricant cooling using an external cooling system (cooling unit)
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
When commissioning the cooling system, the operating instructions of the oil / air cooler or oil
/ water cooler must be observed.
48
B 2050 EN-0916
List of tables
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• The drive unit may only be commissioned after the cooling system has been connected
and commissioned.
• For operation in explosion hazard atmospheres, only approved and labelled cooling
systems may be used. The ATEX labelling must conform to the details of the system or
machine design.
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• The temperature of the cooling water and the cooling water flow rate must be supervised
and ensured by the operator.
• The resistance thermometer (PT100) must be connected to the customer's
evaluation device, which gives a warning signal above 80°C (only for Category 2
devices according to DIN EN 13463-6 / Ignition protection level IPL1)
• The ATEX approval is void if these instructions are not observed!
NOTICE
Gear unit damage
The gear unit may be damaged by overheating.
With oil/air coolers an adequate air intake must be ensured. The air inlet grille and the fan blades must be kept
clean.
Information
Frost damage
If there is a danger of frost the operator should add a suitable anti-freeze solution to the cooling water.
For Category 3 devices, temperature regulation can optionally be provided by using a temperature
switch or a resistance thermometer, which is installed in the oil sump of the gear unit. For Category 2
devices the gear unit must be equipped with a resistance thermometer (PT100) which is
connected to a customer's evaluation device.
B 2050 EN-0916
49
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 129 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.10 Betrieb mit U ml aufsc hmier ung [2050] @ 3\mod_1369301399762_388.doc x @ 71439 @ 2 @ 1
4.8
Operation with pressure circulation lubrication
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• The drive unit may only be commissioned after the pump for the pressure circulation
lubrication has been connected and commissioned.
• Observe the operating instructions for the pump.
• For operation in explosion hazard atmospheres, only approved and labelled circulation
pumps may be used. The ATEX labelling must conform to the details of the system and/or
machine design.
• During operation, the function of the lubricant circulation must be monitored and ensured.
• The gear unit must be shut down immediately in case of failure of the lubrication
circulation.
Information
Lubricant circulation
If pressure circulation lubrication is used, the operational viscosity of the gear oil on start-up must not exceed
1800 cSt. For ISO-VG220 this corresponds to a maximum temperature of 10°C for mineral oil, and a temperature
of at least 0°C for synthetic oil.
All gear units equipped with lubricant circulation must be provided with a pressure switch to monitor
the pump function. The connection of the pressure switch and the evaluation of the signal must be
carried out by the operator. The pressure switch must be connected so that operation is only possible
if the oil pump has built up pressure. During commissioning, a lower pressure is permissible for a short
time.
Pos : 132 /Allgemein/Allgemeingültig e Module---------- Seitenumbr uch ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
50
B 2050 EN-0916
List of tables
Pos : 133 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.13 Dr uc kwächter [1050_2050] @ 3\mod_1369302330260_388.doc x @ 71531 @ 2 @ 1
4.9
Pressure safeguard
The pressure switch is an electric switch, which monitors the lubrication pressure of gear units with
circulation lubrication or targeted lubrication. If the pre-set pressure is undershot, the applied electric
signal is interrupted by the pressure switch. Evaluate the signal accordingly.
NOTICE
Gear unit damage
Insufficient lubrication pressure may cause damage to the gear unit
• Connect the pressure switch so as to be fully functional before starting operation for the first time.
• The pressure switch can only be used in combination with a monitoring system.
Information
Commissioning
Evaluate the pressure switch after initially operating the pump, as pressure must be built up.
Pos : 134 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.10 T emper atur über wachung (PT 100) [B2050] @ 10\mod_1457006218807_388.doc x @ 311780 @ 2 @ 1
4.10 Temperature monitor (PT100)
The pressure switch is an electric switch, which monitors the lubrication pressure of gear units
with circulation lubrication or targeted lubrication. If the pre-set pressure is undershot, the
applied electric signal is interrupted by the pressure switch. Evaluate the signal accordingly.
NOTICE
Gear unit damage
Insufficient lubrication pressure may cause damage to the gear unit
• Connect the pressure switch so as to be fully functional before starting operation for the first time.
• The pressure switch can only be used in combination with a monitoring system.
Information
Commissioning
Evaluate the pressure switch after initially operating the pump, as pressure must first be built up.
Pos : 135 /Allgemein/Allgemeingültig e Module---------- Seitenumbr uch ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
B 2050 EN-0916
51
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 136 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.14 Betrieb mit R üc kl aufs perre [2050] @ 3\mod_1369302458881_388.doc x @ 71555 @ 2 @ 1
4.11 Operation with a back stop or freewheeling (Option WX)
Optional backstops, which allow rotation in only one direction and block the other direction of rotation
are available for attachment to the gear unit. With auxiliary drives (Option WX) the back stop is used
for freewheeling, in order to allow the gear unit to run at low speeds, e.g. for maintenance work. The
backstop / freewheeling coupling lubricated with the gear oil. The backstops or the freewheeling
coupling lift off due to centrifugal force above a certain lifting-off speed n1 (see Table 6) and are then
free of wear. For the freewheeling coupling the auxiliary drive must be at a standstill. Monitoring of the
freewheeling coupling can be carried out with an optionally available speed sensor.
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• In continuous operation, back stops may only be operated at above the lift-off speed.
• In continuous operation, freewheeling couplings may only be operated at above the lift-off
speed.
• The auxiliary drive must be secured or monitored to prevent it from idling.
Figure 22: Industrial gear unit with back stop
52
B 2050 EN-0916
List of tables
Gear units
Stages
Nominal gear ratio
iN
Lift-off speed n1
[rpm]
SK 7207
2
7.1 - 25
400
SK 7307
3
28 - 315
430
18 - 100
1636
SK 7407
SK 7507
3
112 - 400
1759
SK 8207
4
8 - 28
400
31.5 - 355
430
SK 8307
SK 8407
2
20 - 112
1636
SK 8507
3
125 - 450
1759
SK 9207
3
7.1 - 25
320
SK 9307
4
28 - 355
400
SK 9407
2
18 - 100
1309
SK 9507
3
112 - 400
1636
8 - 28
320
SK 10207
SK 10307
3
31.5 - 400
400
SK 10407
4
20 - 112
1309
125 - 450
1636
5.6 - 20
320
31.5 - 112
400
22.4 - 28
320
12.6 - 71
1136
112 - 400
1420
80 - 100
1136
SK 10507
SK 11207
2
SK 11307
3
SK 11407
3
SK 11507
4
SK 12207
2
5.6 - 20
250
SK 12307
3
22.4 - 112
320
SK 12407
3
12.6 - 71
888
SK 12507
4
80 - 400
1136
SK 13207
2
5.6 - 20
250
SK 13307
3
22.4 - 112
320
SK 13407
3
12.6 - 71
888
SK 13507
4
80 - 400
1136
B 2050 EN-0916
53
Explosion-protected industrial gear units – Operating and Assembly Instructions
SK 14207
2
7.1 – 25
240
SK 14307
3
28 – 140
250
SK 14407
3
20 – 90
865
SK 14507
4
100 - 400
890
SK 15207
2
5.6 - 20
220
SK 15307
3
22.4 - 112
250
SK 15407
3
12.6 - 71
781
SK 15507
4
80 - 400
888
Table 6: Lift-off speeds for back stops
Pos : 137 /Allgemein/Allgemeingültig e Module---------- Seitenumbr uch ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
54
B 2050 EN-0916
4 Commissioning
Pos : 141 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.15 C hec kliste [2050] @ 3\mod_1369303829167_388.doc x @ 71651 @ 2 @ 1
4.12 Checklist
Checklist
Subject of test
Date
checked:
Information
see Section
Is any transportation damage or damage apparent?
3.4
Does the labelling on the type plate conform to the
specifications?
6.1, 3.5
Does the required configuration conform with the actual
installation?
3.6
Is the direction of rotation specified and checked
(e.g. for the options R, WX, FAN, LC)?
3.7
Is the pressure vent plug activated?
3.7
Do all drive and driven elements have ATEX approval?
3.7
Is the gear unit earthed?
3.8
Is the gear unit correctly aligned?
3.8
Is the gear unit installed without tension?
3.8
Are the external gear shaft forces within permitted limits
(chain tension)?
3.9
Is the torque support correctly fitted?
3.11
Are contact guards fitted to rotating components?
3.13
Does the motor also have a relevant ATEX approval?
3.14
Is the temperature sticker affixed?
3.17
Has the correct oil level for the configuration been checked?
4.1
Is the cooling water or the cooling coil connected to the
cooling unit and open?
4.6, 4.7
Is the cooling system connected?
4.7
Has the pressure switch been functionally connected?
4.9
Has the temperature monitor been functionally connected?
4.10
Has the temperature measurement been carried out?
4.3
Has the centre of the temperature sticker turned black?
4.3
Has the gear unit been checked with a test run?
4.4
Has the shrink disk connection been checked for slippage?
4.4
B 2050 EN-0916
55
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 143 /Anleitungen/Getri ebe/4. Inbetriebnahme/4.16 Betrei ben des Getri ebes i m Ex- Ber eich [2050] @ 3\mod_1370949971373_388.doc x @ 77331 @ 2 @ 1
4.13 Operation of the gear unit in explosive areas
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• When operating the gear unit, the instructions in this operating manual must be complied
with.
• The prescribed inspection and servicing intervals must be complied with.
• It must be ensured that the power ratings stated on the type plate are not exceeded. If,
e.g. for variable speed drive units, there are several operating points, the maximum
permissible drive power P1 or the maximum permissible torque on the driven shaft M2 or
the maximum permissible speed must not be exceeded at any operating point. Overload of
the gear unit must be ruled out.
• If the gear unit is equipped with a cooling coil, it may only be put into operation if the
cooling coil has been connected to the cooling circuit and the cooling circuit is in operation.
The temperature of the cooling fluid and the cooling fluid flow rate must be monitored and
ensured by the operator.
• If the gear unit is equipped with a cooling system, the gear unit may only be commissioned
after the cooling system has been connected and commissioned. The temperature of the
air or cooling fluid and the cooling fluid flow rate must be monitored and ensured by the
operator.
• Gear units with a back stop may only be operated above the lift-off speed (Table 6) of the
gear unit drive shaft.
• The painting of the gear unit is designed for Category II2G Group IIB (Zone 1 Group IIB).
For use in Category 2G Group IIC (Zone 1 Group IIC) the gear unit must not be used or
installed in areas in which processes which cause electrostatic charging are to be
expected. This also includes occasional manual rubbing of the gear unit housing; cleaning
may only be carried out with a cloth which is moistened with water.
•
During operation, if any of the irregularities described in Section 4.4 "Checking the gear
unit" are detected, or the temperature sticker has turned black, the gear unit must be shut
down and Getriebebau NORD must be consulted.
Pos : 144 /Anleitungen/Getri ebe/5. Inspekti on und War tung/5. Ins pektion und Wartung @ 3\mod_1368691909479_388.doc x @ 65696 @ 1 @ 1
56
B 2050 EN-0916
5 Service and maintenance
5 Service and maintenance
WARNING
Danger of burns
The surfaces of gear units or geared motors may become hot during or shortly after operation.
• Installation and maintenance work must only be performed when gear unit is at a standstill and has cooled
down. The drive must be isolated and secured to prevent accidental start-up.
• Wear protective gloves.
• Shield hot surfaces with contact guards.
Pos : 148 /Anleitungen/Getri ebe/5. Inspekti on und War tung/5.1 Inspektions- und Wartungsinter valle [2050] @ 3\mod_1369304669762_388.doc x @ 71771 @ 2 @ 1
5.1
Service and Maintenance Intervals
Service and Maintenance
Intervals
According to
manufacturer's details
Service and Maintenance Work
Information
see Section
•
PT100: Check the function and measurement accuracy;
recalibrate as necessary
Pressure switch: Check the function and measurement
accuracy; recalibrate as necessary
Check the oil / air cooler
Service the oil / air cooler
Contact details
of manufacturer
5.2
•
•
•
Weekly
or every 100 operating
hours
•
•
Check the gear unit for unusual running noises and/or
vibrations
Visual inspection for leaks
At least once per month
•
Check the cover and the attachment adapter for dirt
5.2
Every 2500 operating
hours,
at least every six months
•
•
•
•
•
5.2
•
•
Visual inspection of the rubber buffer
Visual inspection of hoses and pipes
Visual inspection of shaft sealing ring
Visual inspection of the temperature sticker
Remove dust
(only for category 2D)
Check the oil level
Re-grease
(for agitator bearings Option VLII / VLIII)
Checking the oil filter
Clean or replace the vent plug or the vent filter
•
Check the oil / air cooler for dirt
5.2
•
•
At least every year
B 2050 EN-0916
57
Explosion-protected industrial gear units – Operating and Assembly Instructions
Service and Maintenance
Intervals
Service and Maintenance Work
Information
see Section
For operating temperatures
up to 80°C,
every 10000 operating
hours,
at least every 2 years
Higher temperatures
reduce the oil change
intervals
•
Change oil (if filled with synthetic oil, this period is
doubled)
Reduction of lubricant replacement interval under extreme
operating conditions (high humidity, aggressive
environment and high temperature fluctuations)
Replace the oil filter
Replace shaft sealing rings if worn
Check the internal water cooling (cooling coil)
5.2
Every 20000 operating
hours,
at least every 4 years
•
•
•
5.2
•
Re-lubrication of the bearings in the gear unit
Replace the hoses
Check the function of the resistance thermometer (only
2GD)
Check the function of the pressure switch (only 2GD)
•
General overhaul
5.2
According to the interval
specified in field MI of the
type plate
at least every 10 years
(Only for Category 2G and
2D)
•
•
•
Information
Oil change intervals
The oil change intervals apply for normal operating conditions and operating temperatures up to 80°C. The oil
change intervals are reduced in the case of extreme conditions (operating temperatures higher than 80°C, high
humidity, aggressive environment and frequent fluctuations in the operating temperature).
Pos : 152 /Anleitungen/Getri ebe/5. Inspekti on und War tung/5.2 Inspektions- und Wartungsar bei ten [2050] @ 3\mod_1370004806267_388.doc x @ 75585 @ 25555555555555555555555 @ 1
5.2
Service and Maintenance Work
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• No explosive atmosphere must be present during servicing and repair work. Servicing and
maintenance work must only be performed by qualified specialist personnel.
• When cleaning the surface of the gear unit, do not use and procedures or materials, which
could cause electrostatic charging of the surface of the gear unit.
WARNING
Severe personal injury
Severe injury and material damage may be caused by incorrect servicing and maintenance work.
Servicing and maintenance work must only be performed by qualified specialist personnel. Wear the necessary
protective clothing for servicing and maintenance work (e.g. industrial footwear, protective gloves, goggles, etc.)
58
B 2050 EN-0916
5 Service and maintenance
WARNING
Severe personal injury
Risk of injury due to rapidly rotating and hot machine components.
Installation and maintenance work must only be performed when gear units are at a standstill and have cooled
down. The drive must be isolated and secured to prevent accidental start-up.
WARNING
Severe personal injury
Particles or liquids thrown up during servicing and maintenance can cause injuries.
• Observe the safety information when cleaning with compressed air or a pressure washer.
WARNING
Danger of burns
Danger of burns due to hot oil.
•
•
Allow the gear unit to cool down before carrying out maintenance or repair work.
Wear protective gloves.
NOTICE
Leaks
Take care that no dirt or water enters the shaft sealing rings or the vents when cleaning
Dirt or water in the shaft sealing rings may cause oil leaks.
Visual inspection for leaks
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• The gear unit must be checked for leaks. Attention should be paid to escaping gear oil and
traces of oil on the exterior or underneath the gear unit. In particular, the radial seals,
cover caps, screw plugs, hoses and housing joints should be checked.
If leaks are suspected, the gear unit should be cleaned, the oil level checked (please see chapter 4.1
"Check the oil level") and checked again for leaks after approx. 24 hours. If a leak is confirmed
(dripped oil), the gear unit must be repaired immediately. Please contact the NORD service
department.
Check for running noises
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• If the gear unit produces unusual running noises and/or vibrations, this could indicate
damage to the gear unit. In this case the gear should be shut down and a general overhaul
carried out.
B 2050 EN-0916
59
Explosion-protected industrial gear units – Operating and Assembly Instructions
Check the cover and the attachment adapter for dirt
(Only necessary for Category 2D)
For gear units fitted with a cover (Option H), remove the cover in case of severe soiling. Dust deposits
in the covering cap, on the driven shaft and on the shrink disk must be removed. Then the covering
cap must be fitted (please see chapter 3.13 "Fitting the covers").
If the interior of the IEC/NEMA adapter is severely soiled, the motor must be removed and the dust
deposits removed from the interior and the coupling.
Then fit the motor as described in Section 3.14 "Fitting a standard motor".
Visual inspection of the rubber buffer
Gear units with an elastic torque support (Option DG) have rubber elements. If these show damage
such as tears to the rubber surface, the elements must be replaced. Please contact the NORD service
department.
Visual inspection of hoses and pipes
Gear units with an oil reservoir (Option OT) and external cooling units have pipes and hoses. If
damage to the external surface of the hoses as far as where they are inserted occurs, e.g. due to
abrasions, cuts or tears, they must be replaced. Check the connections for leaks. Please contact the
NORD service department.
Visual inspection of shaft sealing ring
Information
Shaft sealing rings
Shaft sealing rings are rubbing seals and have sealing lips made from an elastomer material. These sealing lips
are lubricated with a special grease at the factory. This reduces the wear due to their function and ensures a long
service life. An oil film in the region of the rubbing sealing lip is therefore normal and is not due to leakage.(please
see chapter 6.6 "Leaks and seals")
Visual inspection of the temperature sticker
(Only necessary for temperature class T4 or max. surface temperature < 135°C)
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
•
60
Check whether the temperature sticker has turned black (please see chapter 3.17
"Temperature sticker"). If the temperature sticker has turned black, the gear unit has
become too hot. In this case operation of the gear unit must be discontinued immediately.
B 2050 EN-0916
5 Service and maintenance
The cause of overheating must be established. Please contact the NORD service department
immediately. The drive unit must not resume operation before the cause of overheating has been
remedied and renewed overheating can be ruled out.
Before once more putting into operation, a new temperature-resistant adhesive label must be attached
to the gearbox (please see chapter 3.17 "Temperature sticker").
Remove dust
(Only necessary for Category 2D)
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• Dust deposits on the gear unit housing must be removed if they are more than 5 mm thick.
Check the oil level
(please see chapter 4.1 "Check the oil level").
Re-greasing
Some gear unit versions (agitator versions VL2 – VL6 and KL2 – KL6) are equipped with a relubrication point.
For these agitator versions, the vent screw located opposite to the grease nipple must be unscrewed
before re-greasing. Grease should be injected until a quantity of 20 - 25 g escapes from the vent hole.
After this, the vent plug must be reinserted and tightened.
Remove and dispose of escaping grease. Recommended grease: Petamo GHY 133N (Klüber
Lubrication).
Checking the oil filter
The oil filters are equipped with a visual or electro-mechanical contamination indicator. If
contamination is indicated, the oil filter must be replaced according to the operating instructions for the
particular cooling system or circulation pump.
Cleaning or replacing the vent plug or the vent filter
Unscrew the pressure vent/vent filter, thoroughly clean it (e.g. with compressed air) carry out a
function test and fit it in the same place. If necessary, use a new vent screw or vent filter.
B 2050 EN-0916
61
Explosion-protected industrial gear units – Operating and Assembly Instructions
Check the oil / air cooler
The oil/air cooler must be checked for dirt and leaks. All fan inlets and outlets must be cleaned. For
further information, please refer to the operating instructions for the cooling unit.
Change the oil
The figures in Section (please see chapter 6.1 "Configurations and maintenance") show the oil drain
screw, the oil level screw and the pressure vent screw for various designs.
Procedure:
1. Place a catchment vessel under the oil drain screw or the oil drain cock.
2. Completely unscrew the oil level screw and the oil drain screw, or open the oil drain cock.
WARNING
Danger of burns
Danger of burns due to hot oil.
• Allow the gear unit to cool down before carrying out maintenance or repair work.
• Wear protective gloves.
3. Drain all the oil from the gear unit.
4. If the sealing ring of the oil drain screw or oil level screw is damaged, a new oil level screw must be
used or the thread cleaned and coated with securing lubricant, e.g. Loctite 242, Loxeal 54-03 prior
to inserting.
5. Screw the oil drain screw into the hole and tighten to the correct torque or close the oil drain cock
(please see chapter 6.4 "Torque values").
6. Using a suitable filling device, refill with oil of the same type through the oil level hole until oil
emerges from the oil level hole. (The oil can also be filled through the pressure vent screw or a
sealing plug located higher than the oil level).
7. Check the oil level at least 15 min after filling and proceed as described in Section 4.1 "Check the
oil level".
62
B 2050 EN-0916
5 Service and maintenance
Replace the oil filter
The oil filter must be changed according to the operating instructions from the supplier.
Replace the shaft sealing ring
Once the shaft sealing ring has reached the end of its service life, the oil film in the region of the
sealing lip increases and a measurable leakage with dripping oil occurs. The shaft sealing ring must
then be replaced.
The space between the sealing lip and the protective lip must be filled approximately 50% with grease
on fitting (recommended grease: PETAMO GHY 133N).
Take care that after fitting, the new shaft sealing ring does not run in the old wear track.
Check the internal water cooling (cooling coil)
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• Overheating of the gear unit due to reduced cooling power because of deposits.
• The internal water cooling (cooling coil) must be cleaned or replaced if deposits are found.
The coolant supply must be turned off and the pipes disconnected from the cooling coil. If deposits are
apparent on the inner wall of the cooling coil, the deposits and the coolant must be analysed.
Please contact the NORD service department.
Re-lubricating bearings
For bearings which are not oil-lubricated and whose holes are completely above the oil level, replace
the roller bearing grease (recommended grease: PETAMO GHY 133N). Please contact the NORD
service department.
Replace the hoses
Due to natural ageing and external influences (e.g. UV radiation) hoses only have a limited service life
and must therefore be replaced as a precaution.
Please contact the NORD service department.
Check the function of the resistance thermometer (only 2GD)
A check of the effectiveness of the temperature monitoring is necessary for the function test. The
limiting value which is set must be reduced to a value which is achieved in normal operation and the
triggering behaviour observed. The function test must be documented. After this, the old limit value
must be set again.
Check the function of the pressure switch (only 2GD)
A check of the effectiveness of the pressure monitoring is necessary for the function test. The limiting
value which is set must be increased to a value which is achieved in normal operation and the
triggering behaviour observed. The documentation must be observed. Then set the old limit value
again.
General overhaul
B 2050 EN-0916
63
Explosion-protected industrial gear units – Operating and Assembly Instructions
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
• The general overhaul must be carried out by qualified personnel in a specialist workshop
with appropriate equipment in observance of national regulations and laws. We urgently
recommend that the general overhaul is carried out by NORD Service.
If a general overhaul is due, the gear unit must be completely dismantled. The following work must be
carried out:
–
–
–
–
–
–
–
Clean all gear unit components
Examine all gear unit components for damage
All damaged components must be replaced
All roller bearings must be replaced
Replace back stops if fitted
Replace all seals, radial seals and Nilos rings
Replace plastic and elastomer components of the motor coupling
Pos : 153 /Anleitungen/Getri ebe/6. Anhang/6. Anhang @ 3\mod_1368691985561_388.doc x @ 65721 @ 1 @ 1
64
B 2050 EN-0916
6 Appendix
6 Appendix
Pos : 154 /Anleitungen/Getri ebe/6. Anhang/6.1 Baufor men und Wartung [_Titel] @ 3\mod_1370592561316_388.doc x @ 76423 @ 2 @ 1
6.1
Configurations and maintenance
Pos : 159 /Anleitungen/Getri ebe/6. Anhang/6.1 Baufor men und Wartung_T eil1 [Text_2050] @ 3\mod_1369314328239_388.doc x @ 71923 @ 55 @ 1
Explanation of symbols for the following version illustrations:
E
Venting
1)
Special oil level
S
Oil level
2)
According to cover assembly
A
Oil drain
3)
DANGER!
Installation position M1 to M6
Page 67
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
The configuration and the position of the oil drain, vent and oil level should be primarily
obtained from the dimension sheet. If this does not contain any details, the following details
can be used.
B 2050 EN-0916
65
Explosion-protected industrial gear units – Operating and Assembly Instructions
Figure 23: Position of the oil screws in the gear unit
Installation position3)
Explanation
No.
Thread
M1
M2
M3
M4
M5
M6
1)
E
S
1)
A/E
A/E
1)
1)
A/E
A/E
1)
S
1
Both sides
G1 “
A
S
2
Both sides
G1 “
E
S
A
S
3
Both sides
G1 “
E
S
E
S
S
4
Both sides
G1 “
E
---
E
S
S
Up or down
G1 “
6
according to
installation
A/E
A
S
1)
2)
2)
A/E
1)
1)
S
1)
S
1)
1)
– the cover can be
rotated
66
7
G1 “
S
E
S
A
S
S
8
G1 “
S
A
S
E
A
E
9
G1 “
S
A
S
E
E
A
10
G1 “
A
E
E
A
S
1)
1)
1)
1)
1)
1)
S
B 2050 EN-0916
6 Appendix
Installation orientations for helical gear units
Figure 24: Installation orientations for helical gear units
Installation orientations for bevel helical gear units
Figure 25: Installation orientations for bevel helical gear units
B 2050 EN-0916
67
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 165 /Anleitungen/Getri ebe/6. Anhang/6.2 Sc hmierstoffe [2050] @ 3\mod_1369659244164_388.doc x @ 74685 @ 2 @ 1
6.2
Lubricants
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
When changing oil or filling for the first time, the type of lubricant stated on the type plate must
be used.
The following table shows the proprietary brands or product names according to the gear oil types
stated on the type plate (please see chapter 3.5 "Checking the type plate data"). This means that a
product corresponding to the type of oil shown on the type plate must be used.
Lubricant type
Type of oil
stated on
type plate
Mineral oil
CLP 220
Synthetic oil
(Polyglycol)
CLP PG 220
Synthetic oil
(hydrocarbons)
CLP HC 220
Bio-degradable oil
Food grade oil H1 as
per FDA 178.3570
Renolin
Alpha EP 220
CLP 220
Renolin
Alpha SP 220
CLP 220 Plus
Optigear
Renolin GEAR
BM 220
220 VCI
Tribol 1100 / 220
Tribol 800 / 220
Alphasyn
GS 220
Alphasyn
PG 220
Renolin
PG 220
Alphasyn EP 220 Renolin Unisyn
CLP 220
Tribol 1510/220
Renolin Unisyn
Optigear
Gear VCI
Synthetic X 220
CLP E 220
Tribol Bio Top
1418 / 220
CLP PG H1
220
Tribol FoodProof
1800 / 220
CLP PG H1
220
Optileb GT 220
Plantogea
220 S
Cassida Fluid
GL 220
Klüberoil
GEM 1-220 N
Mobilgear
600 XP 220
Klübersynth
GH-6-220
Mobile
Glygoyle 220
Klübersynth
GEM 4-220 N
Mobile
SHC 630
Klübersynth
GEM 2-220
Shell Omala
S2 G 220
Shell Omala
S4 WE 220
Omala
S4 GX 220
Naturelle Gear
Fluid EP 220
Klübersynth
UH1 6-220
Mobile
Glygoyle 220
Klüberoil
4 UH1-220 N
Mobile
SHC Cibus 220
Cassida WG
220
Table 7: Lubricant table
68
B 2050 EN-0916
6 Appendix
Pos : 168 /Anleitungen/Getri ebe/6. Anhang/6.3 Sc hmierstoffmengen [2050] @ 3\mod_1369660672911_388.doc x @ 74733 @ 255 @ 1
6.3
Lubricant quantities
DANGER!
Explosion hazard
Explosion hazard. Failure to comply may cause severe, or even fatal injuries.
When filling, always use the oil level screw as an indicator of the precise quantity of oil. After
filling, the oil level must be checked as described in Section 4.1 "Check the oil level".
Information
Lubricants
After changing the lubricant, and in particular after the initial filling, the oil level may change during the first few
hours of operation, as the oil galleries and the hollow spaces only fill gradually during operation.
The stated filling quantities are for guidance only. The precise quantities vary depending on the exact gear ratio.
If at the express request of the customer, an oil inspection glass is installed at an additional charge, we
recommend that the customer corrects the oil level after an operating period of approx. 2 hours, so that when the
gear unit is at a standstill and has cooled down, the oil level is visible in the inspection glass. Only then, is it
possible to check the oil level by means of the inspection glass.
B 2050 EN-0916
69
Explosion-protected industrial gear units – Operating and Assembly Instructions
Helical gear units
[L]
M1
SK 7207
SK 7307
2)
2)
M2
M3
M4
M5
M6
max
36
45
36
48
46
46
62
36
45
36
48
46
46
62
SK 8207
44
55
44
59
57
57
76
SK 8307
44
55
44
59
57
57
76
SK 9207
57
71
57
76
74
74
98
SK 9307
57
71
57
76
74
74
98
SK 10207
72
89
72
96
92
92
123
SK 10307
72
89
72
96
92
92
123
SK 11207
105
130 ( 50 )
105
140 ( 40 )
135 ( 45 )
135 ( 45 )
180
SK 11307
105
130 ( 50 )
105
140 ( 40 )
135 ( 45 )
135 ( 45 )
180
SK 12207
116
185 ( 83 )
116
203 ( 65 )
199 ( 69 )
199 ( 69 )
268
SK 12307
116
185 ( 83 )
116
203 ( 65 )
199 ( 69 )
199 ( 69 )
268
SK 13207
154
256 ( 107 )
154
290 ( 73 )
268 ( 95 )
268 ( 95 )
363
SK 13307
154
256 ( 107 )
154
290 ( 73 )
268 ( 95 )
268 ( 95 )
363
SK 14207
225
374 ( 156 )
225
424 ( 107 )
392 ( 139 )
392 ( 139 )
531
SK 14307
225
374 ( 156 )
225
424 ( 107 )
392 ( 139 )
392 ( 139 )
531
SK 15207
358
415 ( 160 )
335
450 ( 125 )
405 ( 170 )
412 ( 163 )
575
SK 15307
358
415 ( 160 )
335
450 ( 125 )
405 ( 170 )
412 ( 163 )
575
3)
Table 8: Lubricant quantities for helical gear units
Bevel helical gear units
1)
M5
2)
M6
2)
[L]
M1
M2
M3
M4
max
SK 7407
36
47
38
50
49
50
64
SK 7507
36
47
38
50
49
50
64
SK 8407
47
58
47
62
60
62
79
SK 8507
47
58
47
62
60
62
79
SK 9407
61
75
61
80
78
80
102
SK 9507
61
75
61
80
78
80
102
SK 10407
77
94
77
101
97
101
128
SK 10507
77
94
77
101
97
101
128
SK 11407
112
137 ( 57 )
112
147 ( 47 )
142 ( 52 )
147 ( 47 )
187
SK 11507
112
137 ( 57 )
112
147 ( 47 )
142 ( 52 )
147 ( 47 )
187
SK 12407
126
195 ( 93 )
126
213 ( 75 )
209 ( 79 )
209 ( 79 )
278
SK 12507
126
195 ( 93 )
126
213 ( 75 )
209 ( 79 )
209 ( 79 )
278
70
3)
B 2050 EN-0916
6 Appendix
M4
1)
M5
2)
M6
2)
[L]
M1
M2
M3
max
SK 13407
168
270 ( 121 )
168
304 ( 87 )
282 ( 109 )
282 ( 109 )
377
SK 13507
168
270 ( 121 )
168
304 ( 87 )
282 ( 109 )
282 ( 109 )
377
SK 14407
246
395 ( 177 )
246
444 ( 127 )
412 ( 159 )
412 ( 159 )
551
SK 14507
246
395 ( 177 )
246
444 ( 127 )
412 ( 159 )
412 ( 159 )
551
SK 15407
382
439 ( 184 )
359
474 ( 149 )
429 ( 194 )
436 ( 187 )
599
SK 15507
382
439 ( 184 )
359
474 ( 149 )
429 ( 194 )
436 ( 187 )
599
3)
Table 9: Lubricant quantities for bevel helical gear units
Explanation of the oil fill quantity tables
The details stated in the table are in litres.
1)
Circulation lubrication necessary for bevel gear stages
2)
Oil filling quantity for circulation lubrication
3)
Poor efficiency, observe heat balance
B 2050 EN-0916
71
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 169 /Anleitungen/Getri ebe/6. Anhang/6.4 Sc hrauben-Anziehdrehmomente [1000-2050] @ 3\mod_1369657878674_388.doc x @ 74443 @ 25 @ 1
6.4
Torque values
Bolt Torques [Nm]
Dimensions
Screw connections in the strength
classes
Cover
screws
Screw
Threaded pin on connections on
coupling
protective
covers
8.8
10.9
12.9
M4
3.2
5
6
-
-
M5
6.4
9
11
-
2
-
M6
11
16
19
-
-
6.4
M8
27
39
46
11
10
11
M10
53
78
91
11
17
27
M12
92
135
155
27
40
53
M16
230
335
390
35
-
92
M20
460
660
770
-
-
230
M24
790
1150
1300
80
-
460
M30
1600
2250
2650
170
-
-
M36
2780
3910
4710
-
-
1600
M42
4470
6290
7540
-
-
-
M48
6140
8640
16610
-
-
-
M56
9840
13850
24130
-
-
-
G½
-
-
-
75
-
-
G¾
-
-
-
110
-
-
G1
-
-
-
190
-
-
G1¼
-
-
-
240
-
-
G1½
300
-
-
Table 10: Torque values
Assembling the hose fittings
Oil the thread of the union nut, the cutting ring and the screw neck. Tighten the union nut with the
wrench until the point where the union nut can only be turned with considerably more force. Turn the
union nut of the screw fitting approx. 30° to 60° further but not more than 90°. For this the screw neck
must be held with a wrench. Remove excess oil from the screw fitting
72
B 2050 EN-0916
6 Appendix
Pos : 172 /Anleitungen/Getri ebe/6. Anhang/6.5 Betriebsstörungen [2050] @ 3\mod_1369658447846_388.doc x @ 74589 @ 2 @ 1
6.5
Troubleshooting
WARNING
Injury to persons
There is a slipping hazard in case of leaks.
Clean the soiled floor and machine components before starting troubleshooting.
WARNING
Injury to persons
Risk of injury due to rapidly rotating and hot machine components.
Troubleshooting must only be performed when gear units are at a standstill and have cooled down. The drive
must be isolated and secured to prevent accidental start-up.
NOTICE
Gear unit damage
Damage to the gear unit is possible in case of faults.
Shut down the drive unit immediately in case of any faults in the gear unit.
Gear unit malfunctions
Fault
Possible cause
Remedy
Unusual running noises,
vibrations
Oil too low or
bearing damage or
gear wheel damage
Consult NORD Service
Oil escaping from the gear unit or
motor
Defective seal
Consult NORD Service
Oil escaping from pressure vent
Incorrect oil level or
incorrect, contaminated oil or
unfavourable operating conditions
Oil change,
use oil expansion tank (Option OA)
Gear unit becomes too hot
Unfavourable installation conditions
or gear unit damage
Consult NORD Service
Shock when switching
on,
vibrations
Defective motor coupling or
loose gear unit mounting or
defective rubber element
Replace elastomer gear rim,
tighten motor and gear unit
fastening bolts,
replace rubber element
Output shaft does not rotate
although motor is running
Fracture in gear unit or
defective motor coupling or
shrink disc slippage
Consult NORD Service
See the separate operating
instructions for the oil / air cooling
system
Fault or failure of the oil / air cooling
system
Pressure at the pressure safeguard
is too low
Pump is not delivering any oil or
leakage in the piping
Check the pump and the pipes
Table 11: Overview of malfunctions
B 2050 EN-0916
73
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 173 /Anleitungen/Getri ebe/6. Anhang/6.7 Lec kage und Dic htheit [1000-2050] @ 4\mod_1393493307129_388.doc x @ 120701 @ 2 @ 1
6.6
Leaks and seals
Gear units are filled with oil or grease to lubricate the moving parts. Seals prevent the escape of
lubricants. A complete seal is not technically possible, as a certain film of moisture, for example on the
radial shaft sealing rings is normal and advantageous for a long-term seal. In the region of vents,
moisture due to oil may be visible due to the escape of oil mist because of the function. In the case of
grease-lubricated labyrinth seals, e.g. Taconite sealing systems, used grease emerges from the
sealing gap due to the principle of operation. This apparent leak is not a fault.
According to the test conditions as per DIN 3761, the leak is determined by the medium which is to be
sealed, which in test bench tests exceeds the function-related moisture in a defined test period and
which results in dripping of the medium which is to be sealed. The measured quantity which is then
collected is designated as leakage.
Definition of leakage according to DIN 3761 and its appropriate use
Location of leak
Term
Explanation
Shaft sealing
ring
in IEC adapter
Housing joint
Venting
Sealed
No moisture
apparent
No reason for
complaint
No reason for
complaint
No reason for
complaint
No reason for
complaint
Damp
Moisture film locally
restricted (not an
area)
No reason for
complaint
No reason for
complaint
No reason for
complaint
No reason for
complaint
Wet
Moisture film beyond
the extent of the
component
No reason for
complaint
No reason for
complaint
Repair if
necessary
No reason for
complaint
Measurable
leakage
Recognisable
stream, dripping
Repair
recommended
Repair
recommended
Repair
recommended
Repair
recommended
Temporary
leakage
Temporary
malfunction of the
sealing system or oil
leak due to transport
*)
No reason for
complaint
No reason for
complaint
Repair if
necessary
No reason for
complaint
Apparent
leakage
Apparent leakage,
e.g. due to soiling,
sealing systems
which can be relubricated
No reason for
complaint
No reason for
complaint
No reason for
complaint
No reason for
complaint
Table 12: Definition of leaks according to DIN 3761
*) Previous experience has shown that moist or wet radial shaft sealing rings stop leaking later.
Therefore, under no circumstances can replacement be recommended at this stage. The reason for
momentary moisture may be e.g. small particles under the sealing lip.
74
B 2050 EN-0916
6 Appendix
Pos : 174 /Anleitungen/Getri ebe/6. Anhang/6.6 Konfor mitäts er klär ung @ 3\mod_1369658622319_388.doc x @ 74613 @ 2 @ 1
6.7
Declaration of Conformity
Pos : 177 /Anleitungen/Getri ebe/6. Anhang/6.6.3 Explosi onsgesc hützte Industriegetriebe, Kategori e 2G und 2D [B2050] @ 3\mod_1374648283046_388.doc x @ 83836 @ 3 @ 1
6.7.1
Explosion protected industrial gear units, Category 2G and 2D
Figure 26: Declaration of Conformity for Category 2G / 2D
B 2050 EN-0916
75
Explosion-protected industrial gear units – Operating and Assembly Instructions
Pos : 178 /Anleitungen/Getri ebe/6. Anhang/6.6.4 Explosi onsgesc hützte Industriegetriebe, Kategori e 3G und 3D [B2050] @ 3\mod_1374648286844_388.doc x @ 83861 @ 3 @ 1
6.7.2
Explosion protected industrial gear units, Category 3G and 3D
Figure 27: Declaration of Conformity for Category 3G / 3D
76
B 2050 EN-0916
6 Appendix
Pos : 179 /Anleitungen/Getri ebe/0. Prol og/9.2 Reparaturhi nweise [B 1000 - B 2050] @ 3\mod_1375092521205_388.doc x @ 84194 @ 233 @ 1
6.8
Repair information
For enquiries to our technical and mechanical service departments, please have the precise gear unit
type (type plate) and if necessary the order number (type plate) to hand.
6.8.1
Repairs
The device must be sent to the following address if it needs repairing:
Getriebebau NORD GmbH & Co. KG
Service Department
Getriebebau-Nord-Straße 1
22941 Bargteheide
No guarantee can be given for any attachments, such as encoders or external fans, if a gear unit or
geared motor is sent for repair.
Please remove all non-original parts from the gear unit or geared motor.
Information
Reason for return
If possible, the reason for returning the component or device should be stated. If necessary, at least one contact
should be stated in case of queries.
This is important in order to keep repair times as short and efficient as possible.
6.8.2
Internet information
In addition, the country-specific operating and installation instructions in the available languages can
be found on our Internet site: www.nord.com
Pos : 180 /Anleitungen/Getri ebe/0. Prol og/9.3 Abkürzungen [B 1000-2050] @ 3\mod_1375097948117_388.doc x @ 84300 @ 2 @ 1
6.9
2D
2G
3D
ATEX
B5
B14
CW
CCW
°dH
DIN
EC
EN
FR
Abbreviations
Dust explosion protected gear units zone 21
Explosion protected gear units with ignition
protection class "c"
Dust explosion protected gear units zone 22
ATmospheres EXplosibles
Flange fastening with through holes
Flange fastening with threaded holes
Clockwise, right-hand direction of rotation
Counter-clockwise, left-hand direction of
rotation
Water hardness in German hardness
degrees: 1°dH = 0.1783 mmol/l
German standards institute
European Community
European standard
Radial transverse force
FA
IE1
Axial force
Motors with standard efficiency
IE2
IEC
NEMA
IP55
ISO
pH
Motors with high efficiency
International Electrotechnical Commission
National Electrical Manufacturers Association
International Protection
International Standardisation Organisation
pH value
PPE
Personal Protective Equipment
RL
VCI
WN
Directive
Volatile Corrosion Inhibitor
Getriebebau NORD factory standard
Pos : 183 /Allgemein/Steuer module/Stichwortverzeic hnis @ 0\mod_1317978518730_388.doc x @ 4101 @ @ 1
Key word index
=== Ende der Liste für T extmar ke Inhalt ===
B 2050 EN-0916
77
Explosion-protected industrial gear units – Operating and Assembly Instructions
A
Lubricants ..................................................... 68
Activating the vent .........................................26
M
Address..........................................................77
Maintenance ................................................. 77
Assembly .......................................................25
Check oil level ........................................... 61
B
Cover cap .................................................. 60
Back stop .......................................................52
Hose .......................................................... 60
lift-off speed ...............................................54
Leaks ......................................................... 59
Oil / air cooler ............................................ 62
C
Oil change ................................................. 62
Check the oil level .........................................43
oil filter ................................................. 61, 63
Coolant ..........................................................48
Rubber buffers........................................... 60
Correct use ....................................................11
Running noises .......................................... 59
Covers ...........................................................36
D
Danger labels ................................................11
Data on the type plate ...................................22
Disposal of materials .....................................14
E
Temperature sticker .................................. 60
Maintenance intervals ................................... 57
Motor weights for IEC adapters .................... 37
O
Oil fill quantity
Bevel helical gear units ............................. 70
External cooling system...........................40, 41
F
Helical gear units ....................................... 70
P
Fans ............................................................... 47
Faults ............................................................. 73
Position of torque support ............................. 33
Pressure safeguard....................................... 51
G
Pulling devices .............................................. 29
Gear unit types ..............................................15
Push-on gear unit.......................................... 31
Bevel helical gear units ..............................16
Double gear units .......................................16
Helical gear units .......................................15
General overhaul ...........................................63
General safety information ............................12
H
Hose fitting .....................................................72
R
Repairs .......................................................... 77
S
Safety information ........................................... 2
Service .......................................................... 77
Shrink disc .................................................... 34
Standard motor ............................................. 37
I
Storage ......................................................... 20
Inspection intervals ........................................57
T
Installing the gear unit ...................................26
Internet...........................................................77
Introduction of forces .....................................30
L
Temperature sticker ...................................... 41
Test run ......................................................... 47
Tightening torques ........................................ 72
Transport ....................................................... 17
Leakage .........................................................74
motor adapter ............................................ 18
Long-term storage .........................................20
motor swing base ...................................... 19
Lubricant circulation .......................................50
78
B 2050 EN-0916
Key word index
V
W
Version testing ...............................................24
Water cooler .................................................. 45
B 2050 EN-0916
79
6053002 / 0916
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising