Lenze DISCO User Manual
BA 11.5032−EN
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Operating Instructions
Gearbox
DISCO−Variable speed drive
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Product key
DISCO variable speed drive with rear−mounted gearbox − D −
Lengend for the product key
Gearbox type GST
GKS
GSS
Helical gearbox
Helical−bevel gearbox
Helical−worm gearbox
Gearbox size
Number of stages
Disco variable speed drive
Output design
A
R
Drive size Motor frame size
V
H
S
B
C
K
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motor design
DISCO size
Solid shaft
Hollow shaft
Hollow shaft with shrink disk
Foot mounting, with centring
Foot mountin, without centring
Without foot, with centring
Without flange
With flange (through holes)
With flange (threaded holes)
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BA 11.5032−EN 3.0
DISCO variable speed drive without rear−mounted gearbox 11. 7 0 0 0.
Lengend for the product key
Product group
Product family 1
DISCO size
Free output shaft 1
0
no data
with motor
with free drive shaft
without motor
Standard
BA 11.5032−EN 3.0
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Nameplate
DISCO variable speed drive without rear−mounted gearbox
Pos. Contents
1 Production location / Name of product
2 Gearbox type
3 Order number
4 Rated speed:drive | output
5 Year of manufacture/ week of manufacture
6 Rated torque
7 Material number
8 Power
GT−DISCO−002.iso
DISCO variable speed drive with rear−mounted gearbox
DISCO nameplate Nameplate of rear−mounted gearbox
GT−DISCO−001.iso GT−DISCO−006.iso
Pos. Contents
1 Production location / Name of product
2 Gearbox type
3 Order number
4 Rated speed:drive | output
5 Year of manufacture/ week of manufacture
6 Mounting position / position of the system modules
7 Rated torque
8 Lubricant
9 Material number / serial number
10 Ratio
11 Power
12 Bar code
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BA 11.5032−EN 3.0
Document history
Material number Version Description
410700 1.0 09/1999 TD09 Completely revised
483298 1.1 12/2003 TD09 Revised description of the mounting position and position of the system blocks
13251318 2.0 10/2007 TD09 New nameplate: Compact unit and DISCO version
Table of oil grades and new representation of the positions of ventilation, oil
filler plug and oil drain plug
.=<Q 3.0 12/2008 TD09 New edition due to reorganisation of the company
0Fig. 0Tab. 0
BA 11.5032−EN 3.0
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Mounting position (A−F) and position of system modules (1−6)
DISCO variable speed drive with helical gearbox
GST − 1D VDR (foot on variable speed drive)
Terminal box: 2, 3, 4, 5Spindle housing: 2, 3, 4, 5 Handwheel/adjusting device: 2, 3, 4, 5
A B
C D
E F
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BA 11.5032−EN 3.0
GST − D
Terminal box: 2, 3, 4, 5Spindle housing: 2, 3, 4, 5 Handwheel/adjusting device: 2, 3, 4, 5
A B
C D
E F
BA 11.5032−EN 3.0
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DISCO variable speed drive with helical−bevel gearbox and helical−worm gearbox
GKS − D / GSS − D
Solid shaft: 2, 3, 8 (3+5) Hollow shaft: 0 Hollow shaft with shrink disc: 3, 5
Flange: 2, 3, 8 (3+5) Without flange: 0
Terminal box: 2, 3, 4, 5 Spindle housing: 2, 3, 4, 5 Handwheel/adjusting device: 2, 3, 4, 5
A B
C D
E F
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BA 11.5032−EN 3.0
DISCO variable speed drive without rear−mounted gearbox
11.70
Terminal box: 2, 3, 4, 5Handwheel/adjusting device: 2, 3, 4, 5
A B
C D
E F
BA 11.5032−EN 3.0
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Contentsi
1 Preface and general information 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 About these Operating Instructions 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Terminology used 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Scope of supply 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Lenze drive systems 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1 Labelling 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Legal regulations 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Personnel responsible for safety 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 General safety information 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Definition of notes used 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Technical data 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Product features 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Transport weights 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Operating conditions 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Temperatures 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Ambient conditions 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Mechanical installation 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Storage 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Installation 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Electrical installation 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Connection of main motor 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Electrical adjusting device 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Operational check 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Commissioning and operation 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Before switching on 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 During operation 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Oil filling quantities for DISCO gearboxes 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Oil grades for DISCO variable speed drives 25 . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2 Breather position, oil filling screw and drain plug 26 . . . . . . . . . . . . . . . . . .
7.2 Maintenance intervals 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Maintenance operations 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Replacing the lubricant 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Spare parts list 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Repair 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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BA 11.5032−EN 3.0
Contents i
8 Troubleshooting and fault elimination 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Disposal 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Appendix 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Spare−parts list 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.1 DISCO variable speed drive size 02 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.2 DISCO variable speed drive size 03 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.3 DISCO variable speed drive size 04−07 34 . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.4 DISCO variable speed drive size 08−18 36 . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.5 Speed adjustment mechanism, size 02−07 38 . . . . . . . . . . . . . . . . . . . . . . . .
10.1.6 Speed adjustment mechanisms, size 08−18 40 . . . . . . . . . . . . . . . . . . . . . . .
BA 11.5032−EN 3.0
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Preface and general information
About these Operating Instructions
1 Preface and general information
1.1 About these Operating Instructions
ƒ These Operating Instructions provide information about safety−relevant work on
and with DISCO variable speed drives. They contain safety instructions which must
be observed.
ƒ All personnel working on and with DISCO variable speed drives must have these
Operating Instructions available and observe the information and notes relevant for
them.
ƒ The Operating Instructions must always be in a complete and perfectly readable
state.
1.2 Terminology used
Term In the following text used for
DISCO Disco variable speed drive
Drive system Drive systems with DISCO variable speed drives and other drive
1.3 Scope of supply
ƒ The drive systems are combined individually according to a modular design. The
scope of supply can be obtained from the pertinent papers.
ƒ After receipt of the supply, check immediately whether it corresponds with the
accompanying papers. Lenze does not grant any warranty for subsequent claims.
Claim for
– visible transport damages immediately to the forwarder.
– visible deficiencies / incompleteness immediately to the responsible Lenze
subsidiary / agency.
components
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BA 11.5032−EN 3.0
1.4 Lenze drive systems
1.4.1 Labelling
Lenze drive systems are uniquely designated by the content of their nameplates.
Manufacturer
Lenze Drives GmbH
Postfach 10 13 52
D−31763 Hameln
Application as directed
ƒ Lenze drive systems
– are intended for use in machinery and plant,
– must only be used for the purposes ordered and confirmed,
– must only be operated under the ambient conditions prescribed in these
Operating Instructions,
– must not be operated beyond their corresponding power limits.
Preface and general information
Lenze drive systems
Labelling
1
Any other use shall be deemed inappropriate!
1.5 Legal regulations
Liability
ƒ The information, data, and notes in the Operating Instructions were state of the art
at the time of printing. Claims referring to drive systems which have already been
supplied cannot be derived from the information, illustrations, and descriptions.
ƒ We do not accept any liability for damage and operating interference caused by:
– inappropriate use,
– unauthorised modifications to the drive system,
– improper working on and with the drive system,
– operating faults,
– disregarding the Operating Instructions.
Warranty
ƒ Conditions of warranty: see terms of sale and delivery of Lenze Drive Systems
GmbH.
BA 11.5032−EN 3.0
ƒ Warranty claims must be made to Lenze immediately after detecting the deficiency
or fault.
ƒ The warranty is void where liability claims cannot be made.
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Safety instructions
Personnel responsible for safety
2 Safety instructions
2.1 Personnel responsible for safety
Operator
ƒ An operator is any natural or legal person who uses the drive system or on behalf of
whom the drive system is used.
ƒ The operator or his safety officer must ensure
– that all relevant regulations, instructions and legislation are observed.
– that only qualified personnel work with and on the drive system.
– that the personnel have the Operating Instructions available for all corresponding
operations.
– that non−qualified personnel are prohibited from working with and on the drive
system.
Skilled personnel
Skilled personnel are persons who − because of their education, experience, instructions,
and knowledge about corresponding standards and regulations, rules for the prevention
of accidents, and operating conditions − are authorised by the person responsible for the
safety of the plant to perform the required actions and who are able to recognise potential
hazards.
(See IEC 364, definition of skilled personnel)
2.2 General safety information
ƒ This safety information does not claimed to be complete. In case of questions and
problems, please contact your Lenze representative.
ƒ At the time of delivery the drive system meets the state of the art and ensures safe
basic operation.
ƒ The drive system is a source of danger for persons, for the drive system itself, and for
other material assets of the operator, if
– unqualified personnel works with and on the drive system,
– the drive system is used inappropriately.
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ƒ The drive systems must be designed such that they perform their functions after
proper installation and with application as directed in fault−free operation and that
they do not cause hazards for persons. This also applies for their interaction with the
complete plant.
ƒ Be sure to take appropriate measures in the case of drive system failure so that no
material damage occurs.
ƒ Operate the drive system only when it is in a proper state.
ƒ Retrofittings, modifications, or redesigns of the drive system are basically
prohibited. Lenze must be contacted in all cases.
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BA 11.5032−EN 3.0
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