NORD B2000 User Manual

Intelligent Drivesystems, Worldwide Services
GB
B2000
Operating and Installation Instructions for Explosion Protected Gear Units and Geared Motors
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 Disposal ................................................................................................................. 5
2 Description of gear units ........................................................................................ 7
2.1 Type designations and gear unit types .................................................................. 7
3 Storage, preparation, installation ......................................................................... 12
3.1 Storing the gear unit ............................................................................................ 12
3.2 Long-term storage................................................................................................ 12
3.3 Inspecting the drive unit ....................................................................................... 13
3.4 Checking the rating plate data ............................................................................. 13
3.5 Checking the configuration .................................................................................. 15
3.6 Preparing for installation ...................................................................................... 15
3.7 Installing the gear unit .......................................................................................... 16
3.8 Fitting hubs on the gear shafts ............................................................................ 17
3.9 Fitting push-on gear units .................................................................................... 18
3.10Fitting shrink discs ............................................................................................... 21
3.11Fitting the covers .................................................................................................. 22
3.12Fitting a standard motor ....................................................................................... 23
3.13Subsequent paintwork ......................................................................................... 25
3.14Temperature sticker ............................................................................................. 25
3.15Fitting the cooling coil to the cooling system ....................................................... 25
4 Commissioning .................................................................................................... 27
4.1 Check the oil level ................................................................................................ 27
4.2 Activating the Automatic Lubricant Dispenser ..................................................... 28
4.3 Temperature measurement ................................................................................. 29
4.4 Operation with lubricant cooling ........................................................................... 30
4.5 Checking the gear unit ......................................................................................... 31
4.6 Checklist .............................................................................................................. 31
4.7 Operation of the gear unit in explosive areas ...................................................... 32
5 Service and maintenance .................................................................................... 33
5.1 Service and Maintenance Intervals ...................................................................... 33
5.2 Service and Maintenance Work ........................................................................... 33
6 Appendix .............................................................................................................. 41
6.1 Versions and maintenance .................................................................................. 41
6.2 Lubricants ............................................................................................................ 54
6.3 Torque values ...................................................................................................... 55
6.4 Troubleshooting ................................................................................................... 55
6.5 Declaration of Conformity .................................................................................... 56
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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. This Operating Manual and all associated special documentation must be kept in the immediate vicinity of the gear unit. If geared motors are used, compliance with the Motor Operating Manual is also necessary.
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
Danger!
Important information about explosion protection
1.3 Correct use
These gear units generate a rotational movement and are intended for use in commercial systems. They fulfil the explosion protection requirements of Directive 94/9EU (ATEX100a) for the category stated on the rating plate. No mixture from categories IID and IIG may be present during operation. The ATEX approval is void in case of a hybrid mixture.
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
Danger!
No explosive atmosphere may be present during any work e.g. transportation, storage, electrical connection, maintenance or repair.
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. The drive must be isolated and secured to prevent accidental start-up.
Tighten the drive elements or secure the parallel key before switching on.
Danger!
1. Notes
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.
1.5 Disposal
Observe the current local regulations. In particular, lubricants must be collected and disposed of correctly.
The ringbolts which are screwed to the gear unit must be used for transport. No additional load may be attached to the gear unit during transport. If geared motors have an additional eyebolt attached to the motor, this must also be used. Avoid pulling the eyebolts at an angle. Transportation aids and lifting gear must have an adequate load­bearing capacity.
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.
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
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Steel
Aluminium
Coupling components Plastic with steel Flat seals Asbestos-free sealing material Gear oil Additive mineral oil Synthetic gear oil (Rating plate labelling: CLP PG) Polyglycol-based lubricants
1. Notes
Cooling spiral, embedding material of the cooling spiral, screw fittings
Copper, epoxy, yellow brass
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2. Description of gear units
2 Description of gear units
2.1 Type designations and gear unit types
Helical gear units
Type designations:
SK 11E, SK 21E, ..... SK 51E (single-stage)
SK 02, SK 12, ........ SK 52, SK 62N (2-stage)
SK 03, SK 13, SK 23, SK 33N, SK 43, SK 53 (3-stage)
Helical gear units
Type designations: SK 62, SK 72, SK 82, SK 92, SK 102 (2-stage)
SK 63, SK 73, SK 83, SK 93, SK 103 (3-stage)
Versions / Options
- Foot-mounted version F Output flange B5 XZ Base and output flange B14 XF Base and output flange B5 VL Reinforced bearings AL Reinforced axial bearings IEC Standard IEC motor attachment NEMA Standard NEMA motor attachment W With free drive shaft VI Viton radial seals OA Oil expansion vessel SO1 Synthetic oil ISO VG 220
Versions / Options
- Foot-mounted version F Output flange B5 XZ Base and output flange B14 XF Base and output flange B5 VL Reinforced bearings IEC Standard IEC motor attachment NEMA Standard NEMA motor attachment W With free drive shaft VI Viton radial seals OA Oil expansion vessel SO1 Synthetic oil ISO VG 220
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NORDBLOC helical gear units
Type designations:
SK 320, SK 172, SK 272, ..... SK 972 (2-stage)
SK 273, SK 373, ..... SK 973 (3-stage)
SK 072.1, SK 172.1 (2-stage) SK 372.1, …. SK 672.1 (2-stage) SK 373.1, …. SK 673.1 (3-stage) SK 772.1, SK 872.1, SK 972.1 (2-stage) SK 773.1, SK 873.1, SK 973.1 (3-stage)
2. Description of gear units
Versions / Options
- Foot-mounted version F Output flange B5 XZ Base and output flange B14 XF Base and output flange B5 VL Reinforced radial bearings AL Reinforced axial bearings IEC Standard IEC motor attachment NEMA Standard NEMA motor attachment W With free drive shaft VI Viton radial seals OA Oil expansion vessel SO1 Synthetic oil ISO VG 220
Standard helical gear units
Type designations: SK 0, SK 01, SK 20, SK 25, SK 30, SK 33 (2-stage) SK 000, SK 010, SK 200, SK 250, SK 300, SK 330 (3-stage)
Versions / Options
- Foot-mounted version Z Output flange B14 XZ Base and output flange B14 XF Base and output flange B5 F Output flange B5 5 Reinforced output shaft V Reinforced drive AL Reinforced axial bearings IEC Standard IEC motor attachment NEMA Standard NEMA motor attachment W With free drive shaft VI Viton radial seals SO1 Synthetic oil ISO VG 220
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Parallel shaft gear units
Type designations:
SK 0182NB, SK 0282NB, SK 1282, ..... SK 9282, SK 10282, SK
11282 (2-stage) SK 1382NB, SK 2382, ….. SK 9382, SK 10382, SK 11382, SK 12382 (3-stage)
2. Description of gear units
Versions / Options
A Hollow shaft version V Solid shaft version Z Output flange B14 F Output flange B5 X Foot mounting S Shrink disc VS Reinforced shrink disc EA Hollow shaft with internal spline G Rubber buffer VG Reinforced rubber buffer B Fixing element H Covering cap as contact guard H66 Covering cap IP66 VL Reinforced bearings VLII Agitator design VLIII Drywell agitator de sign IEC Standard IEC motor attachment NEMA Standard NEMA motor attachment W With free drive shaft VI Viton radial seals OA Oil expansion vessel SO1 Synthetic oil ISO VG 220 CC Casing cover with cooling spiral OT Oil level tank
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Bevel gear units
Type designations: SK 92072, SK 92172, SK 92372, SK 92672, SK 92772 SK 92072.1, SK 92172.1, SK 92372.1, SK 92672.1, SK 92772.1, SK 93072.1, SK 93172.1, SK 93372.1, SK 93672.1, SK 93772.1 (2-stage) SK 9012.1, SK 9016.1, SK 9022.1, SK 9032.1, SK 9042.1, SK 9052.1, SK 9062.1, SK 9072.1, SK 9082.1, SK 9086.1, SK 9092.1, SK 9096.1 (3-stage) SK 9013.1, SK 9017.1, SK 9023.1, SK 9033.1, SK 9043.1, SK 9053.1 (4-stage)
Contrate worm gear unit
Type designations: SK 02040, SK 02050, SK 12063, SK 12080, SK 32100, SK 42125 (2-stage) SK 13050, SK 13063, SK 13080, SK 33100, SK 43125 (3-stage)
2. Description of gear units
Versions / Options
- Foot mounting with solid shaft A Hollow shaft version V Solid shaft version L Solid shaft both sides Z Output flange B14 F Output flange B5 X Foot mounting D Torque support K Torque console S Shrink disc VS Reinforced shrink disc EA Hollow shaft with internal spline R Back stop B Fixing element H Covering cap as contact guard H66 Covering cap IP66 VL Reinforced bearings VLII Agitator design VLIII Drywell agitator de sign IEC Standard IEC motor attachment NEMA Standard NEMA motor attachment W With free drive shaft VI Viton radial seals OA Oil expansion vessel SO1 Synthetic oil ISO VG 220 CC Casing cover with cooling spiral
Versions / Options
- Foot mounting with solid shaft A Hollow shaft version V Solid shaft version L Solid shaft both sides X Foot mounting Z Output flange B14 F Output flange B5 D Torque support S Shrink disc B Fixing element H Covering cap as contact guard H66 Covering cap IP66 VL Reinforced bearings IEC Standard IEC motor attachment NEMA Standard NEMA motor attachment W With free drive shaft VI Viton radial seals OA Oil expansion vessel
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MINIBLOC worm gear units
Type designations: SK 1S 32, SK 1S 40, SK 1S 50, SK 1S 63, SK 1SU... , SK 1SM 31, SK 1SM 40, SK 1SM 50, SK 1SM 63, (1-stage) SK 2S32NB, SK 2S40NB, SK 2S50NB, SK 2S63NB, SK 2SU…, SK 2SM40, SK 2SM50, SK 2SM63 (2-stage)
UNIVERSAL worm gear units
Type designations: SK 1SI31, SK 1SI40, SK 1SI50, SK 1SI63, SK 1SI75, SK 1SID31, SK 1SID40, SK 1SID50, SK 1SID63, SK 1SID75 SK 1SIS31,…, SK 1SIS75, SK 1SD31, SK 1SD40, SK 1SD50, SK 1 SD63, SK 1SIS-D31,…, SK 1SIS-D63 SK 1SMI31, SK 1SMI40, SK 1SMI50, SK 1SMI63, SK 1SMI75 SK 1SMID31,…, SK 1SMID63 (1-stage) SK 2SD40, SK 2SD50, SK 2SD63, SK 1SI…/31, SK 1SI…/H10, SK 2SID40,…, SK 2SID63 SK 2SIS-D40,…, SK 2SIS-D63 SK 2SMI40, SK 2SMI50, SK 2SMI63 SK 2SMID40, SK 2SMID50, SK 2SMID 63 (2-stage)
2. Description of gear units
Versions / Options
- Foot mounting with solid shaft A Hollow shaft version V Solid shaft version L Solid shaft both sides Z Output flange B14 F Output flange B5 D Torque support X Foot mounting B Fixing element IEC Standard IEC motor attachment NEMA Standard NEMA motor attachment W With free drive shaft VI Viton radial seals
Versions / Options
V Solid shaft or plug-in shaft A Hollow shaft version L Solid shaft both sides X Feet on three sides Z Output flange B14 F Output flange B5 D Torque support H Covering cap H10 Modular contrate pre-stage /31 Worm pre-stage /40 Worm pre-stage IEC Standard IEC motor attachment NEMA Standard NEMA motor attachment W With free drive shaft VI Viton radial seals
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 73/22 (consisting of single gears SK 73 and SK 22)
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3. Storage, preparation, installation
3 Storage, preparation, installation
3.1 Storing the gear unit
The following must be observed for storage:
Store in the fitting position (see Section 3.4 and 3.5) and secure gear units against falling Lightly grease bare metal housing surfaces and shafts Store in dry rooms Temperature must not fluctuate beyond the range of –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
o
C to +50 oC
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 3.4 and 3.5) 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 Temperature must not fluctuate beyond the range of –5
o
C to +40 oC
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.
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3. Storage, preparation,
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 (See Section 5.2).
If the gear unit is completely filled, the oil level must be reduced before commissioning (See
Section 3.5 and 6.1).
3.3 Inspecting the drive unit Danger!
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 shaft
sealing rings, 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.
installation
3.4 Checking the rating plate data
The rating 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 rating plate is illegible or damaged.
Figure 3-1: Rating plate (example)
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3. Storage, preparation,
g
1
1
A
A
Explanation of the Rating Plate Abbreviation Unit Designation See Typ - NORD gear unit type No. - Serial number i
- Overall gear unit ratio
es
n2 min n1 min IM - Configuration (installation orientation) Section 6.1 M2 Nm Max. permissible gear unit drive 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 driven shaft Section 3.8 FR1 kN Max. permissible transverse force on the gear unit drive shaft for option W Section 3.8
Tu °C Permissible ambient temperature for the gear unit
-
Rated speed of gear unit drive shaft*
-
Rated speed of the gear unit drive shaft or the drive motor*
installation
F
kN Max. permissible axial force on the gear unit driven shaft Section 3.8
2
F
kN Max. permissible axial force on the gear unit drive shaft for option W Section 3.8
1
MI h Interval between general overhauls of the gear unit in operating hours
or details of the non-dimensional maintenance class CM xR2 mm Max. dimension for the point of application of the transverse force FR2 Section 3.8 Oil - Gear unit oil type (standard designation) Section 6.2 Last line
S - 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 und FA2 are empty, the forces are zero. If the field xR2 is empty, the point of
application of force F
-
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)
6. Temperature measurement on commissioning (X)
is central on the drive shaft journal (See Figure 3-4).
R2
Section 5.2 Section 5.2
Section 4.3
Danger!
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.
It should be noted that with geared motors, the electric motor has its own rating plate with a separate ATEX labelling. The motor labelling must also comply with data for the planning of the plant or the machine. The lowest explosion protection of the gear unit and the motor
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3. Storage, preparation,
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.
3.5 Checking the configuration Danger!
The gear unit may only be operated in the stated configuration. The permissible configuration is stated on the rating 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, 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 rating plate complies with the installation orientation and that the installation orientation does not change during operation. The UNIVERSAL worm gear units type SK1SI... do not depend on the version, as with
these types of gear unit, the abbreviation UN is entered in the IM field of the type plate.
3.6 Preparing for installation
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.
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.
installation
Danger!
Care must be taken that drive elements attached to the gear unit, such as clutches, pulleys etc. and drive motors are also ATEX-compliant.
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.
Danger!
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. Switching of the motor into the blocked direction of rotation, i.e. the wrong direction of rotation may cause damage to the gear unit.
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.
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3. Storage, preparation,
Oil expansion tanks (Option OA) must be fitted in accordance with works standard WN 0-530 04. For M10x1 screw fixings, the attached works standard WN 0-521 35 must also be observed.
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. Position of the vent plug: see Section 6.1.
Figure 3-2: Activation of the pressure vent
3.7 Installing the gear unit
installation
Danger!
The eyebolts screwed into the gear units must be used during installation. During installation, no additional weights may be attached to the gear unit. If geared motors have an additional eyebolt attached to the motor, this must also be used. Avoid pulling the eyebolts at an angle.
Danger!
No explosive atmosphere must be present when installing the gear unit.
The base and/or flange to which the gear unit is fitted should be vibration-free, torsionally rigid and flat (flatness error <0.2 mm). All contamination to the bolting surfaces of gear unit and base and/or flange must be thoroughly removed.
The gear unit 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 configuration (See Section 3.5 and 6.1). All gear unit feet and/or all flange bolts on each side must be used. Bolts must have a minimum quality of 10.9. The bolts must be tightened to the correct torques (refer to Section 6.3 for torque values). Tension-free bolting must be ensured, particularly for gear units with a foot and flange.
The oil inspection screws, oil drain screws and the vent valves must be accessible.
To ensure that the gearbox does not get too warm and to avoid injury to persons, observe the following during installation:
Danger!
The surfaces of gear units or geared motors may become hot during or shortly after operation. Attention: danger of burns! Protection against accidental contact may need to be installed.
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3. Storage, preparation, installation
Danger!
The cooling air supplied to the gear unit/geared motor must be within the permissible
temperature range stated on the rating plate.
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 rating plate.
Enable the 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 pile up dust in the area of the gear unit
3.8 Fitting hubs on the gear shafts Danger!
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.
Note!
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
o
C beforehand.
Figure 3-3: Example of a simple pulling device
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3. Storage, preparation, installation
Danger!
Drive and driven elements, such as belt drives, chain drives and couplings must be fitted with contact protection.
Danger!
Care must be taken that drive and driven elements attached to the gear unit must also be ATEX-compliant.
Drive and driven elements may only subject the drive units to the maximum radial forces
and FR and axial forces FA1 and FA as specified on the rating plate (See Section 3.4).
F
R1
Observe the correct tension, particularly on belts and chains. Additional loads due to unbalanced hubs are not permitted.
Danger!
The radial 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 driven shafts, the application of the transverse force FR2 must not exceed the dimension xR2 . If the transverse force F rating plate, but no dimension xR2 is stated, the application of the force is assumed to be to the centre of the shaft journal.
for the driven shaft is stated on the
R2
Free drive shaft (Option W) Driven shaft Figure 3-4: Permissible application of force to drive and driven shafts
3.9 Fitting push-on gear units Attention!
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.
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