Beckhoff AG2250 Documentation
Documentation
AG2250
Version:
Date:
1.4
2017-07-26
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation........................................................................................................... 5
1.2 Documentation issue status............................................................................................................ 6
1.3 Intended use .................................................................................................................................. 6
2 Guidelines and Standards .......................................................................................................................7
3 Safety..........................................................................................................................................................8
3.1 Safety instructions .......................................................................................................................... 8
3.2 Special safety instructions .............................................................................................................. 9
4 Handling ...................................................................................................................................................11
4.1 Transport ...................................................................................................................................... 11
4.2 Packaging ..................................................................................................................................... 11
4.3 Storage ......................................................................................................................................... 11
4.4 Maintenance / Cleaning ................................................................................................................ 12
4.4.1 Maintenance schedule .....................................................................................................12
4.4.2 Maintenance tasks ...........................................................................................................12
4.4.3 Commissioning after maintenance...................................................................................13
4.4.4 Notes on the lubricant used .............................................................................................14
4.5 Disposal ........................................................................................................................................ 14
5 Product ID PLE ........................................................................................................................................15
5.1 Scope of delivery AG2250-PLE .................................................................................................... 15
5.2 Type plate AG2250-PLE............................................................................................................... 15
5.3 Type key AG2250-PLE ................................................................................................................. 15
6 Technical description PLE......................................................................................................................16
6.1 Gear unit configuration ................................................................................................................. 16
6.2 Overview of PLE gear components .............................................................................................. 16
6.3 General technical data.................................................................................................................. 16
6.4 Transport, assembly and disassembly ......................................................................................... 16
7 Mechanical installation, PLE ..................................................................................................................17
7.1 Important notes............................................................................................................................. 17
7.2 Mounting the motor on the gear unit............................................................................................. 18
7.3 Mounting the gear unit at the machine ......................................................................................... 19
8 Technical data, PLE.................................................................................................................................20
8.1 PLE40 .......................................................................................................................................... 20
8.1.1 Dimensional drawing, PLE40...........................................................................................21
8.2 PLE60 ........................................................................................................................................... 22
8.2.1 Dimensional drawing, PLE60...........................................................................................23
9 Product ID WPLE .....................................................................................................................................24
9.1 Scope of delivery AG2250-WPLE................................................................................................. 24
9.2 Type label AG2250-WPLE............................................................................................................ 24
9.3 Type key AG2250-WPLE.............................................................................................................. 24
10 Technical description WPLE ..................................................................................................................25
10.1 Gear unit configuration ................................................................................................................. 25
10.2 Overview of WPLE gear components........................................................................................... 25
AG2250 3Version: 1.4
Table of contents
10.3 General technical data.................................................................................................................. 25
10.4 Transport, assembly and disassembly ......................................................................................... 26
11 Mechanical installation, WPLE...............................................................................................................27
11.1 Important notes............................................................................................................................. 27
11.2 Mounting the motor on the gear unit............................................................................................. 28
11.3 Mounting the gear unit at the machine ......................................................................................... 29
12 Technical data, WPLE .............................................................................................................................30
12.1 WPLE40........................................................................................................................................ 30
12.1.1 Dimensional drawing, WPLE40 .......................................................................................31
12.2 WPLE60........................................................................................................................................ 32
12.2.1 Dimensional drawing, WPLE60 .......................................................................................33
13 Commissioning........................................................................................................................................34
13.1 Important notes............................................................................................................................. 34
13.2 Guide for commissioning the gear units ....................................................................................... 35
13.3 Troubleshooting ............................................................................................................................ 36
14 Decommissioning....................................................................................................................................37
15 Support and Service................................................................................................................................38
AG22504 Version: 1.4
Foreword
1 Foreword
1.1 Notes on the documentation
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning the components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are registered
trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents:
EP1590927, EP1789857, DE102004044764, DE102007017835
with corresponding applications or registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents:
EP0851348, US6167425 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
AG2250 5Version: 1.4
Foreword
1.2 Documentation issue status
Version Comment
1.4 Chapter update:
Disposal 3.5
1.3 Chapter update:
Mounting the gear on the gear unit 7.2; Technical data 8.2; Guide for commissioning the gear
unit 13.2
1.2 Chapter update:
1.0 Foreword; 3.0 Safety
1.1 Chapter update:
13.1
1.0 First edition
1.3 Intended use
The gear unit is used for transforming torques and speeds. It is suitable for all industrial applications that are
not covered by Article 2 of EC Directive 2002/95/EC (restriction of the use of certain hazardous substances
in electrical and electronic equipment).
The gear unit must not be operated in potentially explosive atmospheres. In food processing applications,
the gear unit may only be used beside or below the food area.
The gear unit is intended for mounting on motors that:
• match type B5 (if different, please contact our service department);
• have a radial and axial run-out tolerance of at least "N" according to DIN 42955;
• have a smooth shaft.
Damage from improper use
Any use exceeding the maximum permissible speeds, torques and temperature is consid-
Attention
ered improper and is therefore not permitted.
AG22506 Version: 1.4
Guidelines and Standards
2 Guidelines and Standards
In addition to the safety instructions mentioned in this manual, the general statutory and other rules and
regulations for the prevention of accidents (e.g. personal protective equipment) and for environmental
protection must be followed.
Personal injuries!
The gear units are not products under the terms of the EC Machinery Directive. Operation
CAUTION
of the gear units in machines or systems is only permitted once the machine or system
manufacturers has provided evidence of CE conformity of the complete machine or system.
AG2250 7Version: 1.4
Safety
3 Safety
3.1 Safety instructions
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the
application. Modifications to hardware or software configurations other than those described in the
documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Description of symbols
In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!
Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the
DANGER
life and health of persons.
Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and
WARNING
health of persons.
Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to
CAUTION
persons.
Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the en-
Attention
vironment or equipment.
Note
Tip or pointer
This symbol indicates information that contributes to better understanding.
UL pointer
This symbol indicates important information about the UL-compliant.
AG22508 Version: 1.4
Safety
3.2 Special safety instructions
The safety instructions are designed to avert danger and must be followed during installation,
commissioning, production, troubleshooting, maintenance and trial or test assemblies.
The gear units of the AG2250 series are not designed for stand-alone operation and are always installed in a
machine or system. After installation the additional documentation and safety instructions provided by the
machine manufacturer must be read and followed.
Personal injuries
• Carefully read this manual before using the gear unit thoroughly, paying particular at-
CAUTION
WARNING
tention to the safety instructions. In the event of any uncertainties please notify your
sales office immediately and refrain from working on the gear unit.
• Only trained, qualified personnel with good knowledge of drive technology may work on
this gear unit.
• If a gear unit is installed in a machine it must not be commissioned until proof of compliance of the machine with the latest version of the EC Machinery Directive has been
provided. This includes all relevant harmonized standards and regulations required for
implementation of this Directive in national legislation.
Serious risk of injury through hot surfaces!
• The surface temperature may exceed 50 °C, resulting in a risk of burns.
• Avoid touching the housing during or shortly after operation.
• Allow the gear unit to cool down for at least 15 minutes after switching off.
• Use a thermometer to check whether the surface has cooled down sufficiently.
WARNING
WARNING
WARNING
Attention
WARNING
Objects flung out by rotating components can cause serious injuries.
• Remove any items and tools in the vicinity of the gear unit before starting up the unit.
• Remove/secure the feather key (if present), if the gear unit is operated without attachments on the output/drive side.
Rotating components on the gear unit can pull in parts of the body and
cause serious injury or death.
• When the gear unit is running, keep sufficient distance to rotating machine parts.
• During assembly and maintenance work, secure the machine against restarting and unintentional movements (such as uncontrolled lowering of lifting axes).
A damaged gear unit can lead to accidents with risk of injury.
• Do not operate a gear unit that has been overloaded due to incorrect operation or a machine crash.
• Replace affected gear units, even if no external damage is visible.
Loose or overloaded screw connections can damage the gear unit.
• Install and check all screw connections for which tightening torques are specified, using
a calibrated torque wrench.
Lubricants are flammable.
• Do not use a water jet for extinguishing flames.
• Suitable extinguishing media are powder, foam, water spray or carbon dioxide.
• Follow the safety instructions of the lubricant manufacturer.
AG2250 9Version: 1.4
Safety
CAUTION
Attention
Solvents and lubricants can cause skin irritations.
• Avoid direct skin contact.
Solvents and lubricants can pollute soil and water.
• Cleaning solvents and lubricants must be used and disposed of properly.
AG225010 Version: 1.4
4 Handling
4.1 Transport
• No special mode of transport is prescribed for the gear unit.
• Only by qualified personnel
• Only in the manufacturer's original packaging
• Avoid hard shocks.
• If the packaging is damaged check the gear unit and any accessories for visible damage. Inform the
transport company and, if necessary, the manufacturer.
Suspended loads may fall and cause serious injury or death.
• Never stand under suspended loads.
WARNING
Attention
• Secure the gear unit with suitable fastenings (e.g. straps) prior to transport.
Hard impacts, e.g. due to falling or dropping, may damage the gear unit.
• Use only lifting gear and load handling devices with sufficient load-bearing capacity.
• Do not exceed the permitted lifting weight.
• Set the gear unit down slowly.
Handling
4.2 Packaging
• Recyclable cardboard with inserts
• Dispose of the packaging materials at designated disposal sites.
Observe the relevant national disposal regulations
4.3 Storage
• The gear units must not be stored outdoors. The storage space must be adequately ventilated and dry.
• The gear units may only be stored in the original recyclable manufacturer's packaging.
• The gear units may only be stored in a horizontal position.
• Storage temperature: -30 °C to +60 °C in the original packaging
• Storage time: 2 years max.
Possible damage to the gear unit seals
If the gear units are stored at temperature ranges above 60°C or subjected to direct sun-
Note
light or ultraviolet light, the gear unit seals may become damaged. Storage temperatures of
up to 85°C are permitted for a maximum of 2 weeks. However, please note that even
short-term storage at such temperatures will result in premature ageing of the seals. Therefore, please check the seals before commissioning the gear unit.
AG2250 11Version: 1.4
Handling
4.4 Maintenance / Cleaning
4.4.1 Maintenance schedule
Maintenance tasks During commis-
sioning
Visual inspection x x x x
Check the tightening torques x x
Lubrication x x x
For the first
time, after 500
operating hours
or 3 months
Every 3 months Annually
4.4.2 Maintenance tasks
4.4.2.1 Visual inspection
• Check the entire gear unit for external damage.
• Check the entire gear unit for leaks.
◦ Further general information on the gear units can be found
◦ In the installation position, check that no foreign media (e.g. oil) accumulate on the drive and
output shaft.
4.4.2.2 Check the tightening torques
• Check the tightening torque of the fastening screws on the gear housing.
◦ The specified tightening torques can be found in Section 7 "Mechanical installation".
• Check the tightening torque of the set screws on the motor mounting.
◦ The specified tightening torques can be found in Section 7 "Mechanical installation".
AG225012 Version: 1.4
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