NORD B1050 User Manual
Intelligent Drivesystems, Worldwide Services
GB
B1050
Operating and Maintenance Instructions for
Industrial Gear Units SK 7207 - SK 15507
DRIVESYSTEMS
1.
Notes .............................................................................................................................. 4
1.1 General information ........................................................................................................ 4
1.2 Safety and information symbols ..................................................................................... 4
1.3 Correct use ..................................................................................................................... 4
1.4 Safety information ........................................................................................................... 5
1.5 Other documents ............................................................................................................ 5
1.6 Disposal .......................................................................................................................... 5
2. Description of gear units .............................................................................................. 6
2.1 Type designations and gear unit types ........................................................................... 6
2.2 Name plate ..................................................................................................................... 7
3. Storage, transport, preparation, installation .............................................................. 8
3.1 Storing the gear unit ....................................................................................................... 8
3.2 Long-term storage .......................................................................................................... 8
3.3 Transporting the gear unit .............................................................................................. 9
3.4 Preparing for installation ............................................................................................... 12
3.5 Installing the gear unit .................................................................................................. 12
3.6 Fitting hubs on the gear shafts ..................................................................................... 13
3.7 Fitting push-on gear units ............................................................................................. 14
3.8 Torque support ............................................................................................................. 16
3.9 Fitting shrink discs ........................................................................................................ 16
3.10 Fitting the covers ........................................................................................................ 17
3.11 Fitting a standard motor .............................................................................................. 17
3.12 Fitting the cooling coil to the cooling system .............................................................. 19
3.13 Mounting the external cooling system (cooling unit) .................................................. 19
3.14 Retrospective paintwork ............................................................................................. 20
Contents
4. Commissioning ........................................................................................................... 21
4.1 Checking the oil level .................................................................................................... 21
4.2 Lubricant cooling with internal water cooler ................................................................. 21
4.3 Lubricant cooling with external oil/water cooler (cooling system) ................................ 21
4.4 Lubricant cooling with external oil/water cooler (cooling system) ................................ 22
4.5 Gear unit cooling with a fan .......................................................................................... 22
4.6 Checking the Taconite seals ........................................................................................ 23
4.7 Pressure safeguard ...................................................................................................... 23
4.8 Checklist ....................................................................................................................... 24
5. Service and maintenance ........................................................................................... 25
5.1 Service and maintenance intervals ............................................................................... 25
5.2 Service and maintenance work .................................................................................... 25
6. Appendix ...................................................................................................................... 29
6.1 Versions and maintenance ........................................................................................... 29
6.2 Lubricant quantities ....................................................................................................... 31
6.3 Lubricants ..................................................................................................................... 33
6.4 Bolt torque values ......................................................................................................... 35
6.5 Troubleshooting ............................................................................................................ 36
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1. Notes
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.
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 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 you do not understand the contents of this Operating Manual or additional operating
instructions, please consult Getriebebau NORD!
1.2 Safety and information symbols
Please always observe the following safety and information symbols!
Danger!
1. Notes
Risk of fatalities and injury
Attention!
Machine may be damaged
Note!
Useful information
1.3 Correct use
These gear units generate a rotational movement and are intended for use in commercial
systems. The gear unit must only be used according to the information in the technical
documentation from Getriebebau NORD.
Danger!
Use in explosion hazard areas is prohibited.
Strict compliance with the technical data on the rating plate is essential.
The documentation must be observed.
Appropriate safety measures must be taken for applications where failure of a gear unit or
geared motor may result in injury.
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1.4 Safety information
All work including transportation, storage, installation, electrical connection, commissioning,
servicing, maintenance and repair must be performed only by qualified specialist personnel.
It is recommended that repairs to NORD Products are carried out by the NORD Service
department.
Danger!
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.
Tighten the drive elements or secure the parallel key before switching on.
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!
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 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.
1. Notes
1.5 Other documents
Further information may be obtained from the following documents:
- Gear Unit Catalogue (G1050)
- Operating and maintenance instructions for the electric motor
- If applicable, operating instructions for attached or supplied options
1.6 Disposal
Observe the current local regulations. In particular, lubricants must be collected and dispose d of
correctly.
Gear unit components: Material:
Toothed wheels, shafts, rolling bearings,
parallel keys, locking rings, …
Gear unit housing, housing components, … Grey cast iron
Light alloy gear unit housing, light alloy gear unit
housing components, …
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 (rating plate code: CLP PG) Polyglycol-based lubricants
Cooling spiral, screw fittings Copper, epoxy, yellow brass
Steel
Aluminium
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V
2. Description of Gear Unit
2. Description of gear units
2.1 Type designations and gear unit types
Helical gear units
SK 7207, SK 8207, SK 9207, SK 10207
SK 11207, SK 12207, SK 13207, SK 15207
(2-stage)
SK 7307, SK 8307, SK 9307, SK 10307
SK 11307, SK 12307, SK 13307, SK 15307
(3-stage)
Bevel helical gear units
SK 7407, SK 8407, SK 9407, SK 10407
SK 11407, SK 12407, SK 13407, SK 15407
(3-stage)
SK 7507, SK 8507, SK 9507, SK 10507
SK 11507, SK 12507, SK 13507, SK 15507
(4-stage)
ersions / Options
- Foot mounting with solid shaft
A Hollow shaft version
B Fixing element
CC Integrated cooling coil
CS1 Cooling system oil / water
CS2 Cooling system oil / air
D Torque support
EA Hollow shaft with internal spline
ED Elastic torque support
EV Solid shaft with internal spline
EW Drive shaft with internal spline
F Block flange
FAN Fan
FK Collar flange
F1 Drive flange
H Covering cap as contact guard
IEC Standard IEC motor attachment
L Solid shaft both sides
LC Lubricant circulation
MC Motor bracket
MF.. Motor base frame
…B with brake
…K with elastic coupling
…T with hydrodynamic coupling
MS.. Motor swing base
…B with brake
…K with elastic coupling
…T with hydrodynamic coupling
MT Motor mount
NEMA Standard NEMA motor attachment
OA Oil expansion vessel
OH Oil heater
OT Oil level tank
R Back stop
S Shrink disc
V Solid shaft
VL Reinforced bearings
VL2 Agitator version
VL3 Drywell agitator version
W Free input shaft
W2 Two drive shaft journals
W3 Three drive shaft journals
WX Auxiliary drive unit
Double gear units consist of two single gear units. They are to be treated as per the instructions
in this Manual, i.e. as two individual gear units. Type designation of double gear units:
e.g. SK 13307/7282 (consisting of single gears SK 13307 and SK 7282)
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2.2 Name plate
Example of a gear unit name plate.
2. Description of Gear Unit
Explanation of the name plate
1 Matrix – Barcode
2 NORD gear unit type
3 Operating mode
4 Year of manufacture
5 Serial number
6 Rated torque of gear unit output shaft
7 Drive power
8 Weight according to ordered version
9 Overall gear unit ratio
10 Installation orientation
11 Rated speed of gear unit output shaft
12 Lubricant type, viscosity and quantity
13 Customer’s part number
14 Operating factor
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3. Storage, Transport,
3. Storage, transport, preparation, installation
Please observe all of the general safety information in Section 1.4, 1.3 and in the individual
sections.
3.1 Storing the gear unit
For short-term storage before commissioning, please observe the following:
Store in the fitting position (see Section 6.1) and secure gear units against falling
Lightly grease bare metal housing surfaces and shafts
Store in dry rooms
Temperature in the range from –5
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
3.2 Long-term storage
Preparation, Installation
o
C to +50 oC without large fluctuations
Note!
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.
Conditions of the gear unit and storage area for long-term storage prior to
commissioning:
Store in the fitting position (see Section 6.1) and secure gear units 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 agents added to the gear oil. (See label on gear unit)
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 drive unit must be protected against damage by insects
o
Temperature in the range from –5
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
C to +40 oC without large fluctuations
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 greatly deviates 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.
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3.Storage, Transport,
Preparation, Installation
3.3 Transporting the gear unit
Danger!
To prevent injury, the danger area must be generously cordoned off. Standing under the
gear unit during transport is extremely dangerous.
Attention!
Avoid damage to the gear unit. Impacts to the free ends of the shafts may cause internal
damage to the gear unit.
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.
The gear unit should remain on the transport packaging during transportation. It must be
transported without oil. Only the f our ring bolts (1) provided may be used for transporting the
gear unit. For additional drive units and components, an additional lifting point may be
necessary. The ends of the shafts must not be used for transportation, as this may seriously
damage the gear unit. The ring bolts screwed into the gear unit must be used for transportation.
If geared motors have an additional eyebolt attached to the motor, this must not be used. When
lifting with the ring bolts, there must be no oblique force.
Figure 3-1: Gear unit lifting points
For additional drive units and components, an additional lifting point may be necessary.
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Gear units with motor adapter
Gear units with a motor adapter may only be transported with lifting ropes (2) and chains or
lifting straps (1) at an angle of 90° to 70° to the horizontal. The ring bolts on the motor must not
be used for transportation.
3. Storage, Transport,
Preparation, Installation
Figure 3-2: Transport of gear unit with motor
Drive units with V-belt drive
Gear units with V-belt drive must only be transported with lifting straps (1) and lifting ropes (2) at
an angle of 90° (vertical). The ring bolts on the motor must not be used for transportation.
Figure 3-3: Transport of gear unit with V-belt drive
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3.Storage, Transport,
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 (1) or chains.
Preparation, Installation
Figure 3-4: Transport of gear unit with motor swing base or base frame
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3.4 Preparing for installation
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.
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.
In applications where an incorrect rotational direction may result in damage or potential risk, the
correct rotational direction of the drive 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 driven/driving sides. The
arrows point in the rotation direction of the gear unit. It must be ensured, when connecting the
motor and during motor control, that the gear unit can only operate in the rotation direction, e.g.
by means of a rotary field test.
Attention!
With gear units with an integrated back stop, switching the drive motor to the blocked rotation
direction, i.e. incorrect rotation direction, can lead to gear damage.
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.
Oil expansion tanks (Option OA) must be fitted in accordance with the attached works standard
WN 0-530 04.
Oil expansion tanks (Option OA) must be fitted in accordance with the attached works standard
WN 0-521 30.
3. Storage, Transport,
Preparation, Installation
3.5 Installing the gear unit
The base or flange to which the gear unit is fitted should be vibration-free, torsionally rigid and
flat. The smoothness of the mating surface on the base or flange must be according to tolerance
class K of DIN ISO 2768-2. All contamination to the bolting surfaces of gear unit and base 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.
Note!
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 o perating instructions.
The tolerances of the shaft ends and the flange connections should be obtained from the
dimension sheet.
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