Page 1
g500 B45 ... B450 | 45 Nm ... 450 Nm
Bevel gearbox / Bevel gearbox with three−phase AC
motor
Mounting Instructions
EN
.Nj{
Ä.Nj{ä
Page 2
Please read these instructions before you start working!
Follow the enclosed safety instructions.
0Abb. 0Tab. 0
Page 3
Contents i
1 About this documentation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Document history 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Conventions used 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Terminology used 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Notes used 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General safety instructions for drive components 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Product description 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Important notes 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Identification 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Nameplate 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Transport weights 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Mechanical installation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Important notes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Transport equipment for gearbox 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Preparation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 General information about the assembly of drive systems 13. . . . . . . . . . .
4.3.2 Gearboxes with breathers 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 Condensation drain hole of the motor 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Mounting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Mounting gearboxes with solid shafts 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Attachment of motors to gearboxes with bearing housing
(input design N) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 Coupling hubs 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4 Attachment of gearboxes with hollow shafts and keyway 17. . . . . . . . . . .
4.4.5 Mounting the shrink disc with a rotating cover 19. . . . . . . . . . . . . . . . . . . .
4.4.6 Mounting the fixed cover 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.7 Mounting the hoseproof hollow shaft cover 23. . . . . . . . . . . . . . . . . . . . . .
5 Electrical installation 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Commissioning and operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Important notes 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EN
6.2 Before switching on 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 During operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lenze ¯ MA 12.0014 ¯ 1.0
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Contentsi
7 Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Important notes 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Maintenance intervals 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Maintenance operations 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Motors 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Repair 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Disposal 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Troubleshooting and fault elimination 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EN
4
Lenze ¯ MA 12.0014 ¯ 1.0
Page 5
About this documentation
1 About this documentation
Contents
¯ This documentation serves for safety−relevant operations on and with the
gearboxes. It contains safety instructions which must be observed.
¯ All personnel working on and with the gearboxes must have the documentation
available during the work and observe the information and notes relevant for
them.
¯ The documentation must always be complete and in a perfectly readable state.
Target group
This documentation is directed at qualified skilled personnel according to IEC 60364.
Qualified skilled personnel are persons who have the required qualifications to carry out
all activities involved in installing, mounting, commissioning, and operating the
product.
1
Document history
Tip!
Information and auxiliary devices related to the Lenze products can be
found in the download area at
http://www.Lenze.com
1.1 Document history
Material number Version Description
.Nj{ 1.0 02/2014 TD09 First edition for the pilot series
1.2 Conventions used
This documentation uses the following conventions to distinguish different types of
information:
Type of information Identification Examples/notes
Spelling of numbers
Decimal separator Point In general, the decimal point is used.
Icons
Page reference
Documentation reference
Wildcard
For instance: 1234.56
Reference to another page with
additional information
For instance: 16 = see page 16
Reference to another documentation
with additional information
For example: EDKxxx = see
documentation EDKxxx
Wildcard for options, selection data
EN
Lenze ¯ MA 12.0014 ¯ 1.0
5
Page 6
1
1.3 Terminology used
Term In the following text used for
Gearboxes Gearboxes of the g500 product family
About this documentation
Terminology used
EN
Drive system Drive systems with g500 gearboxes and other Lenze drive
1.4 Notes used
The following pictographs and signal words are used in this documentation to indicate
dangers and important information:
Safety instructions
Structure of safety instructions:
components
Danger!
(characterises the type and severity of danger)
Note
(describes the danger and gives information about how to prevent
dangerous situations)
Pictograph and signal word Meaning
Danger of personal injury through dangerous electrical
Danger!
Danger!
Stop!
voltage.
Reference to an imminent danger that may result in death
or serious personal injury if the corresponding measures are
not taken.
Danger of personal injury through a general source of
danger.
Reference to an imminent danger that may result in death
or serious personal injury if the corresponding measures are
not taken.
Danger of property damage.
Reference to a possible danger that may result in property
damage if the corresponding measures are not taken.
Application notes
Pictograph and signal word Meaning
Note!
Tip!
6
Important note to ensure troublefree operation
Useful tip for simple handling
Reference to another documentation
Lenze ¯ MA 12.0014 ¯ 1.0
Page 7
Safety instructions
General safety instructions for drive components
2 Safety instructions
2.1 General safety instructions for drive components
Danger!
Disregarding the following basic safety measures may lead to severe
personal injury and damage to material assets!
¯ Store in dry, low−vibration environment without aggressive atmosphere; if
possible in the manufacturer’s packaging.
– Protect against dust and impacts.
– Observe the climatic conditions according to the technical data, catalogue.
¯ Lenze drive and automation components ...
... must only be used as intended.
... must never be commissioned despite noticeable damage.
... must never be technically changed.
... must never be commissioned in an incompletely mounted state.
... must never be operated without the required covers.
... may have live, moving or rotary parts during and after operation − corresponding
to their type of protection. Surfaces may be hot.
... must not be operated with large vibrations.
... must not be operated in the frequency range of a plant or the drive system.
¯ All specifications of the corresponding enclosed documentation must be
observed.
This is vital for a safe and trouble−free operation and for achieving the specified
product features.
2
EN
¯ Only qualified skilled personnel are permitted to work with or on Lenze drive and
automation components.
According to IEC 60364 or CENELEC HD 384, these are persons ...
... who are familiar with the installation, assembly, commissioning and operation of
the product,
... possess the appropriate qualifications for their work,
... and are acquainted with and can apply all the accident prevent regulations,
directives and laws applicable at the place of use.
Lenze ¯ MA 12.0014 ¯ 1.0
7
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3
3 Product description
3.1 Important notes
¯ The most important technical data are indicated on the nameplate (structure and
¯ The product catalogues contain further technical data.
3.2 Identification
Mounting position (A−F) and position of system modules (1−6)
Product description
Important notes
contents 9 to 11).
EN
Hollow shaft: 0 without flange: 0
Solid shaft: 3, 5, 8 (3+5) Flange: 3, 5, 8 (3+5)
Hollow shaft with shrink disc: 3, 5 Terminal box/
Motec:
2, 3, 4, 5
8
Lenze ¯ MA 12.0014 ¯ 1.0
Page 9
3.2.1 Nameplate
Geared motor
Note!
In the geared motor version the nameplate is attached to the motor.
Product description
Identification
Nameplate
3
Example
g500−X−001.iso
EN
g500−X−001.iso
Lenze ¯ MA 12.0014 ¯ 1.0
9
Page 10
EN
3
Product description
Identification
Pos. Contents
1 Manufacturer / production location
2 Motor type / standard
3 Gearbox type
4 Motor type
5 Technical data
6 Mounting position / position of the system blocks
7 Lubricant amount and type of lubricant
8 Brake data (if fitted)
9 Feedback /pulse encoder or resolver data (if fitted)
10 Manufacture data
11 Bar code
12 Year / week of manufacture
13 Operating mode
14
Temperature class
Enclosure
Motor protection
15 Valid conformities,
approvals and certificates
16 Rated data for
various frequencies
18 Frequencies and corresponding motor data
19
Standard version: Voltage tolerance range "Range A"
UL version: UL file number
20 Additional customer data
21 UL category (e.g. inverter duty motor)
22 Efficiency and part load efficiency
23 Energy efficiency (logo)
27 Permissible ambient temperature range
29 Standstill current (ampere locked rotor ALR)
30 Weight (optional)
Ratio
Rated torque
Rated speed
Rated frequency
Brake
Braking torque
AC/DC brake voltage
Electrical power input
Order number
Material number
Serial number
CE identification
CCC identification
UL mark
UL energy efficiency mark
Hz = frequency
kW = motor power
V = motor voltage
A = motor current
r/min. = motor speed
h = Motor efficiency: at a rated power of
100%
cos j = motor power factor
C 86 = Motor code for controller
parameterisation (code 0086)
10
Lenze ¯ MA 12.0014 ¯ 1.0
Page 11
Gearbox
N version Example
Pos. Contents
1 Manufacturer / production location
2 Gearbox and motor type
3 Year / week of manufacture
4 Mounting position / position of the system blocks
5 Rated torque
Rated speed/rated frequency
6 Lubricant amount / type of lubricant
7 Ratio
8 Material number / serial number
9 Bar code
10 Order number
11 Operating factor (indicated when <1.0)
12 Additional customer data
13 Permissible ambient temperature range
Product description
Transport weights
G500−X−002.iso
3
EN
3.3 Transport weights
Motor frame size
063 071 080 090 100
Gearbox type/size
g500−B45 <15 <15
g500−B110 <15 <20 <25 <30
g500−B240 <20 <25 <30 <35 <35
g500−B450 <25 <25 <30 <40 <40
Tab. 1 Weights in kg
Lenze ¯ MA 12.0014 ¯ 1.0
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4
4 Mechanical installation
4.1 Important notes
¯ Use load carrying equipment for transport!
¯ Before the transport
Mechanical installation
Important notes
– check that all components are safely mounted,
– fasten all transport aids (eye bolts or support plates).
Danger!
Danger due to toppling or falling loads!
¯ The payload of the hoists and load handling devices must at least
correspond to the weight of the load.
¯ The load must be secured in such a way that it cannot topple or fall
down.
¯ Do not stay under a pending load!
EN
4.2 Transport equipment for gearbox
Danger!
The motors attached to the gearbox are partially equipped with eyebolts.
These are exclusively determined for mounting/dismounting the motor
to the gearbox and must not be used for the complete geared motor!
g500−B45 ... B450
1.
2.
Fig. 1 Eye bolt position
Stop!
Observe load carrying capacity!
Staying under floating load is prohibited!
12
Lenze ¯ MA 12.0014 ¯ 1.0
Page 13
Mechanical installation
General information about the assembly of drive systems
4.3 Preparation
Note!
Thoroughly remove anticorrosion agents from output shafts and flange
faces.
4.3.1 General information about the assembly of drive systems
Stop!
The lubricant fill quantity of the gearboxes is matched to the mounting
position. The mounting position indicated on the nameplate must be
observed to avoid damage to the gearbox.
4.3.2 Gearboxes with breathers
4
Preparation
Stop!
Do not place gearbox onto breather valve!
No ventilation measures are required for the gearboxes g500−B45 ... g500−B240.
Gearboxes which are delivered with a ventilation unit are equipped with a label on the
gearbox.
Remove the transport locking device on the vent valve before the first commissioning.
GT−GNG−13285760.iso/dms
Note!
Loosely enclosed vent valves must be mounted in accordance with the
mounting position, ( 29).
EN
Lenze ¯ MA 12.0014 ¯ 1.0
13
Page 14
4
4.3.3 Condensation drain hole of the motor
Mechanical installation
Mounting
Condensation drain hole of the motor
Note!
Lenze delivers motors with condensation drain holes with sealed
condensation drain holes. The holes are sealed with a plastic plug or a
locking screw. This does not affect the type of protection and the motor is
protected against the ingress of foreign substances during transport and
operation. Further information, ( 34).
4.4 Mounting
4.4.1 Mounting gearboxes with solid shafts
¯ Draw the transmission elements onto the output shaft only by using the
centering thread.
EN
Stop!
Shocks and blows to the shafts damage the roller bearings.
4.4.2 Attachment of motors to gearboxes with bearing housing (input design N)
Fig. 2 Input side design N
Spider / gear rim 1 Locking screw
Coupling hub 2 Keyway
g500−H_000.iso
14
Lenze ¯ MA 12.0014 ¯ 1.0
Page 15
Mechanical installation
Mounting
Coupling hubs
4
Drive size
1A 11 23 23 M4 1.5 M3 1.34 * M3 1.34
1B 14 40 25 M5 2.0 M6 10.5 B5 x 5 x 16 M4 2.9
2B 11 23 23 M4 1.5 M3 1.34 * M3 1.34
1C 19 40 25
2C 14 40 25
4C 14 40 25
6C 11 40 25 −−− −−− * −−− −−−
7C 19 40 25
1D 24 60 30
2D 19 60 30 B6 x 6 x 18
1E 28 60 30
2E 24 60 30
3E 19 60 30 B6 x 6 x 18
4E 24 50 50 *
Tab. 2 Attachment of motors to gearboxes with mounting flange
Motor shaft Assembly
D
max. l
[ mm ]
* Use original key for the motor
1)
Key for standard hub and clamping hub
[ mm ]
dimension
M
[ mm ]
Standard hub
Locking screw
Thread
[ mm ]
M5 2.0
M5 2.0
Tightening
torque
[ Nm ]
Clamping hub Key
Thread
[ mm ]
Tightening
torque
[ Nm ]
M6 10.5
M6 10.5
1)
Clamping ring hub
DIN
6885/1
[ mm ]
B6 x 6 x 16
B5 x 5 x 163C 14 40 25
B6 x 6 x 16 M4 2.9
B8 x 7 x 18
B8 x 7 x 18
Thread
[ mm ]
M4 2.9
M5 6
Tightening
torque
[ Nm ]
4.4.3 Coupling hubs
General
EN
Note!
Standard hubs, clamping hubs and clamping ring hubs are
maintenance−free.We recommend checking the star−shaped spider and
system components when inspecting the drive.
Mounting the standard hub / clamping hub
1. Fit motor key (2).
– Fit enclosed key for drive sizes C, E, F.
2. Push the coupling hub over the motor shaft, mounting dimension m (see Fig. 2
and Tab. 2) must be observed.
3. Secure coupling hub against axial movement using the fixing screw or clamping
screw (1).
4. Lay spider in the coupling claw on the gearbox side.
5. Align claws of the motor−side coupling hub with its counterpart.
6. Slowly push on motor, and bolt on to the gearbox flange.
Lenze ¯ MA 12.0014 ¯ 1.0
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4
Mounting the clamping ring hub
Fig. 3 Coupling
Mechanical installation
Mounting
Coupling hubs
2
1 Clamping ring hub
2 Clamping ring
3 Clamping screws (DIN912)
Note!
The motor shaft must be designed with fit k6.
1
3
EN
1. Grease the contact surfaces of the motor shaft using a thin−bodied oil, e. g.
Castrol 4 in 1" or Klüber Quitsch Ex"!
Stop!
2. Push the coupling hub over the motor shaft, mounting dimension m" (see Fig. 2
and Tab. 2) must be observed.
3. Align the hub and tighten the clamping screws until they have contact.
4. Tighten the clamping screws evenly and crosswise with gradually rising torque
until the indicated tightening torque (see Tab. 2) is reached at all clamping screws.
In the intermediate steps, this procedure should also be repeated until the
indicated tightening torque is reached at all clamping screws.
5. Lay spider in the coupling claw on the gearbox side.
6. Align claws of the motor−side coupling hub with its counterpart.
7. Slowly push on motor, and bolt on to the gearbox flange.
Do not use oil or grease with molybdenum−disulphide or high−pressure
additives, or grease pastes!
16
Lenze ¯ MA 12.0014 ¯ 1.0
Page 17
Mechanical installation
Attachment of gearboxes with hollow shafts and keyway
Dismounting the clamping ring hub
1. Loosen the clamping screws evenly one after the other.
Stop!
Each screw must only be loosened by half a revolution per pass! Unscrew
all clamping screws by 3 − 4 threads.
2. Remove the screws next to the forcing threads and screw them into the other
threads until they have contact.
3. Tighten the screws in the forcing threads crosswise and step−by−step so that the
clamping ring is loosened.
4. Clean and grease all contact surfaces including threads and head of the clamping
screws before reassembly.
4.4.4 Attachment of gearboxes with hollow shafts and keyway
4
Mounting
1. Draw the gearbox with hollow shaft onto the machine shaft to be driven:
– Apply the supplied assembly paste (Fig. 4) on the shaft and in the hollow shaft
bore.
GT−GNG−GKR−011.iso GT−GNG−GKR−011_a.iso
Fig. 4 Application of assembly paste against fretting corrosion (included in the scope of supply)
Stop!
Take up forces only via the hollow shaft, and not via gearbox housing.
2. Secure the gearbox axially:
– The hollow shaft has snap ring grooves for axial securing. Parts used to fix the
shaft are not included in the scope of supply.
EN
Lenze ¯ MA 12.0014 ¯ 1.0
K12.0611
17
Page 18
4
Mechanical installation
Mounting
Attachment of gearboxes with hollow shafts and keyway
Auxiliary tool (recommended dimensions)
H7
Æ d
18
20
25
30
35 M12 7
40
45
50
55
60
70
80 M20 16
100 M24 24
Tab. 3 Dimensions in [mm]
d
2
M6 4
M10 5
M16 8
M16
M20
M20 13
Dismounting
1. Undo axial gearbox locking in the hollow shaft.
10
11
14
c
7
6
9
EN
2. Remove/extract the gearbox from the motor shaft using an appropriate auxiliary
tool (Fig. 5).
Fig. 5 Disassembly of gearboxes with hollow shaft, with auxiliary tool
Auxiliary tool (recommended dimensions)
H7
Æ d
25
30
35 12 3
40
45
Tab. 4 Dimensions in [mm]
Note!
With the bevel gearbox, the hollow shafts are turned free in the middle
of the hollow shaft, i.e. the bore diameter is 0.1 mm higher here! A
sufficient length of the machine shaft must be observed.
c
8
10 3
16 4
c
9
K12.0611
18
Lenze ¯ MA 12.0014 ¯ 1.0
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Mechanical installation
Mounting the shrink disc with a rotating cover
Gearbox type/size l1 min l max.
g500−B45 85 100
g500−B110 105 120
g500−B240 127 143
g500−B450 134 150
Tab. 5 Dimensions in mm
4.4.5 Mounting the shrink disc with a rotating cover
Stop!
Do not dismantle new shrink disc.
Never tighten clamping screws before the machine shaft is pushed in.
Otherwise the hollow shaft may be deformed plastically. Protect the
shrink disc against contact while in operation by appropriate measures
(e.g. cover).
Degrease hollow shaft bore and machine shaft!
4
Mounting
EN
Lenze ¯ MA 12.0014 ¯ 1.0
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4
4.4.5.1 Mounting the shrink disc
Depending on the design, the shrink discs may be equipped with a rotating cover
(protective cap, pos. 1).
Mechanical installation
Mounting
Mounting the shrink disc
Note!
This cover is fitted to the shrink disc on delivery.
2
1
5.
1.
EN
Fig. 6
1 Protection cover
2 Clamping screws
1. Remove protective cap (1), if available.
2. Check machine shaft
1
2
– Diameter in fit tolerance h6
– Surface roughness R
3. Thoroughly clean and degrease hollow shaft bore and machine shaft.
£ 15 mm
z
Note!
Thoroughly degrease the bore over the entire hollow shaft length to
make sure that remainders of the anticorrosion agent will not be carried
off into the area of the shrink disc when pushing on the machine shaft.
4. Slightly loosen clamping screws (2) one after the other, do not unscrew!
5. Push drive onto machine shaft.
6. Slightly tighten clamping screws manually.
7. Tighten clamping screws (2) one after the other (see Fig. 7) in several passes, with
rising torque, evenly until the indicated screw−tightening torque (see Tab. 6 ) is
reached at all screws.
KL_GFL06_001−dms
20
Lenze ¯ MA 12.0014 ¯ 1.0
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Mechanical installation
Mounting the shrink disc
GT−GNG−003.iso/dms
Fig. 7 Explanation: "one after the other"
Tip!
Several (in general more than 5 ) passes are necessary until the full
tightening torque is reached at all screws!
The shrink disc is mounted correctly and fixed when the faces of the outer ring and the
inner ring are aligned (Fig. 8). Minimum misalignments are permissible.
4
Mounting
GT−GNG−001.iso
Fig. 8 Hollow shaft with shrink disk
3 Outer ring
4 Inner ring
Hollow shaft bore [mm] 20 25 30 35 40 50 60 65 80 100
Torque [ Nm ] 12 30 30 30 30 30 59 70 59 100
Tab. 6 Tightening torque for the clamping screws
free of grease
Note!
If a different tightening torque is indicated on the shrink disc, this
tightening torque has priority over the value indicated in the table.
8. Push protective cap (1, Fig. 6) onto the shrink disc.
EN
Tip!
For finding out the cause of non−reached torques of the shrink disc
connection, please go through the troubleshooting list in chapter 8.
Lenze ¯ MA 12.0014 ¯ 1.0
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Page 22
4
Dismounting
Mechanical installation
Mounting
Mounting the shrink disc
Danger!
Loose drive components or drive components falling down may cause
injury to persons or damage to the machine. Secure the drive
components before disassembly.
1. Remove protective cap (1).
2. Loosen clamping screws (2) evenly one after the other each by ¼ revolution in
several passes. Do not unscrew clamping screws completely to prevent accidents!
3. Press off outer ring (see Fig. 8), if necessary. For this, loosen the outer ring using
the forcing threads and some clamping screws (number corresponding to the
forcing threads in the inner ring). For loosening the outer ring, screw in the screws
evenly to prevent canting. Press off the outer ring until loosened completely.
4. Remove the drive from the machine shaft.
EN
Stop!
Dismantle the shrink disc only for cleaning purposes. Afterwards, grease
bevel surfaces and screws using a solid lubricant with a friction factor of
m = 0.04.
¯ Suitable lubricants on molybdenum−disulphide lubricant (MoS2) basis are, e.g.:
– Molykote G Rapid (company Dow Corning)
– Molykote BR2 Plus (company Dow Corning)
– Molykombin UMFT1 (company Klüber Lubrication)
Usually, disassembly problems only occur if:
¯ the connection is spinning due to overload or a too low friction factor and fretting
corrosion has occurred,
¯ the shrink disc has been tightened too much leading to a plastic deformation of
components,
¯ the components are corroded.
22
Lenze ¯ MA 12.0014 ¯ 1.0
Page 23
4.4.6 Mounting the fixed cover
Note!
This cover is supplied loose on delivery!
Mechanical installation
Mounting
Mounting the fixed cover
X
X
4
Clip the protection cover on the bore holes.
4.4.7 Mounting the hoseproof hollow shaft cover
3x120°
4
1
3
2
Fig. 9
1 Protection cover
2 Cheese head screw
3 Thread reducing sleeve
4 Seal
1. Screw the three reducing bushes (3) into the flange with a screwdriver so they are
flush and staggered by 120°.
EN
2. Fit seal (4) between flange and protective cap (1).
3. Fasten the protective cap (1) over the reducing bushes (3) on the flange using
three cheese head screws (2).
Lenze ¯ MA 12.0014 ¯ 1.0
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Page 24
Electrical installation5
5 Electrical installation
Danger!
Electrical connections must only be carried out by skilled personnel!
Read the motor documentation for a correct electrical connection of the
motor!
EN
24
Lenze ¯ MA 12.0014 ¯ 1.0
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Commissioning and operation
6 Commissioning and operation
6.1 Important notes
Stop!
The drive may only be commissioned by skilled personnel!
¯ Take safety measures prior to any operation:
– Disconnect the machine from the mains, ensure standstill of the drive system
and avoid any machine movement.
6.2 Before switching on
Please check:
¯ Drive function - machine function assignment
¯ The direction of rotation of the drive shaft
6
Important notes
g500−B 2−stage g500−B 3−stage
¯ Does the drive appear undamaged?
¯ Is the mechanical fixing o.k.?
¯ Is the electrical connection correct?
¯ Are all rotating parts and surfaces that may become hot protected against
contact?
¯ For gearboxes with breathing:
– Has the transport locking device been removed?
EN
Lenze ¯ MA 12.0014 ¯ 1.0
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Page 26
6
6.3 During operation
During operation, check the drive periodically and take special care of:
¯ changes compared to normal operation, like
¯ In case of faults:
If the fault cannot be remedied, please contact the Lenze customer service.
Commissioning and operation
During operation
– unusual noise, stronger vibrations or increased temperatures,
– leakages,
– loose fixing elements,
– the condition of the electrical cables.
– shut down the drive,
– check the troubleshooting table.
EN
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Lenze ¯ MA 12.0014 ¯ 1.0
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7 Maintenance
7.1 Important notes
Note!
¯ Gearboxes below 200 Nm are lubricated for life.
¯ The mechanical power transmission system is maintenance−free.
¯ Take safety measures prior to any operation:
– Disconnect the machine from the mains, ensure standstill of the drive system
and avoid any machine movement.
7.2 Maintenance intervals
¯ In case of gearboxes > 200 Nm, the lubricant must regularly be replaced.
– The type of lubricant is indicated on the nameplate. Replace the lubricant only
with the same type of lubricant.
– The lubricant maintenance interval depends on the lubricant temperature, see
Fig. 10.
Maintenance
Important notes
7
EN
Stop!
With drive systems: observe the maintenance intervals for the other drive
components!
100
90
3
16000 h
10000
2
25000 h
Synthetic oil CLP HC/CLP PG
Mineral oil CLP
100000
GT−GNG−002.iso/dms
80
0
70
1000
1
Fig. 10 Lubricant diagram
Oil sump temperature [°C]
Oil life/changing intervals [operating
hours h]
Shaft sealing rings and roller bearings are wearing parts. Their service life depends on
the operating conditions. If leakages occur, the shaft sealing rings must be replaced to
avoid consequential damage.
Lenze ¯ MA 12.0014 ¯ 1.0
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Page 28
7
7.3 Maintenance operations
Gearboxes and geared motors are ready to use on delivery and filled by Lenze with the
lubricant type and lubricant quantity indicated on the nameplate. The first filling
corresponds to the mounting position and design indicated on the nameplate.
Maintenance
Maintenance operations
Note!
Gearboxes of size B45 and B110 are lubricated for life. Because of the
minimum thermal load it is not necessary to replace the lubricant. No
ventilation required.
g500−B45 g500−B110
EN
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Lenze ¯ MA 12.0014 ¯ 1.0
Page 29
Breather position, oil filling screw and drain plug
Gearbox g500−B240
A B
+
+
Maintenance
Maintenance operations
+
+
7
C D
+
+
E F
+
+
EN
+
Filler Drain
Breather element Check
The shown oil bores are optional for gearbox size g500−B240!
Lenze ¯ MA 12.0014 ¯ 1.0
+
29
Page 30
7
Gearbox g500−B450
A B
C D
Maintenance
Maintenance operations
+
+
EN
+
+
E F
+
+
+
+
30
Filler Drain
Breather element Check
Lenze ¯ MA 12.0014 ¯ 1.0
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Maintenance
Maintenance operations
Oil−level inspection
Check the oil level by means of the displayed dipsticks. Manufacture them according to
the mounting position.
Model: Dipsticks for g500−B240
A, 3-stufig
B
A, 2-stufig
7
D
EN
C
E
F
Lenze ¯ MA 12.0014 ¯ 1.0
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7
Model: Dipsticks for g500−B450
Maintenance
Maintenance operations
A
B
C
EN
D
F
E
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Lenze ¯ MA 12.0014 ¯ 1.0
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Maintenance
Maintenance operations
Changing lubricant
Stop!
¯ Gearbox should be warm.
¯ Secure drive system and machine from inadvertent movement and
mains connection.
The type of lubricant indicated on the nameplate by the following manufacturers is
approved.
Shell Klüber Fuchs
1. Place receptacle under oil drain plug.
7
2. Remove breating / oil filler plug.
3. Completely drain lubricant by removing the oil drain plug.
4. Reinsert drain plug (if necessary, replace seal).
5. Fill in lubricant through filler hole (quantities see nameplate).
6. Screw in breathing / oil filler plug.
7. Dispose of waste oil according to the applicable regulations.
EN
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7
Maintenance
Repair
Motors
7.3.1 Motors
Drain condensation
Depending on the mounting position, the condensation drain holes are always at the
bottom of the motor!
¯ For condensate drainage
– the motor must be deenergised;
– the plugs (screws) must be removed.
Stop!
To restore the enclosure, re−insert the plugs (screws) after condensate
drainage. If the condensation drain holes are not sealed again, the IP
enclosure of the motor will be reduced. For horinzontal motor shafts to
IP23 and for vertical motor shafts to IP20.
EN
Fig. 11 Motor with condensation drain holes
Condensation drain holes
7.4 Repair
¯ We recommend that all repairs are carried out by the Lenze customer service.
7.5 Disposal
Protect the environment! Packing material can be recycled. Dispose of your separated
resources according to the waste disposal regulations or via a waste management
company.
The following table provides recommendations for an environmentally friendly
disposal of the machine and its components.
What? Where?
Transport
material
Lubricants Oil, grease
Components Housing:
Pallets Return to the manufacturer or
Packaging material Cardboard box to waste paper
Detergents and solvents
Paint residues
Cast iron, aluminium,
Bearings, gear wheel shafts:
Seals, electronic scrap
copper
Steel
Hazardous waste
forwarder
Plastics to plastics recycling or
residual waste
Reuse or dispose of wood wool
Dispose according to current
regulations
Separate valuable substances
and dispose
34
Lenze ¯ MA 12.0014 ¯ 1.0
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Troubleshooting and fault elimination 8
8 Troubleshooting and fault elimination
If any malfunctions should occur during operation of the drive system, please check the
possible causes using the following table. If the fault cannot be eliminated by one of the
listed measures, please contact the Lenze Service.
Fault Possible cause Remedy
Drive does not turn
Motor runs, gearbox does
not
Unusual running noises
Excessive temperature
Loose fixing elements Vibrations Avoid vibrations
Shrink disc connection is
spinning
Voltage supply interrupted Check connection
Faulty electrical connection Check that supply voltage
Excessive load Reduce load
Coupling components are missing or
defective
Gearbox is defective Inform Lenze Service
Clutch disengaged Engage the clutch
Overload Reduce load
Damage to the gearbox or motor Inform Lenze Service
Overload Reduce load
Inadequate heat dissipation Improve cooling air flow
Lack of lubricant Top up lubricant according to
¯ Correct screw tightening torque has not
been reached
– Insufficient number of passes, not all
screws are tightened correctly.
¯ Machine shaft and hollow shaft bore
not sufficiently degreased
¯ Wrong component part dimensions
– Fits, roughnesses
¯ Yield point of machine shaft material is
too low
– Re > 300 N/mm2 required
¯ Friction factors are too low
– Coefficients of friction m ³ 0.15
required
¯ The shrink disc itself has been
degreased so that the screws and the
bevels are dry. Due to incorrect friction
factors, the shrink disc cannot be
tightened correctly.
matches nameplate data
Check drive−machine
assignment
Check mounting
Check drive−machine
assignment
Check drive−machine
assignment
Clean gearbox / motor
regulations
Specifications for assembly,
dimensions and material not
observed
EN
Lenze ¯ MA 12.0014 ¯ 1.0
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Page 36
© 02/2014 | MA 12.0014 | .Nj{ | 1.0 | TD09
Lenze Drives GmbH
Postfach 10 13 52
D−31763 Hameln
Germany
+49515482−0
+49515482−2800
Lenze@Lenze.com
www.Lenze.com
Lenze Service GmbH
Breslauer Straße 3
D−32699 Extertal
Germany
0080002446877 (24 h helpline)
+49515482−1396
Service@Lenze.com
10987654321
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