NORD B2050 User Manual
Intelligent Drivesystems, Worldwide Services
GB
B2050
Operating and Maintenance Instructions for Explosion Protected
Industrial Gear Units SK 72 07 - SK 155 07
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 ............................................................................................................................ 6
2. Description of gear units ............................................................................................... 7
2.1 Type designations and gear unit types ............................................................................. 7
3. Storage, transport, preparation, installation ................................................................ 8
3.1 Storing the gear unit.......................................................................................................... 8
3.2 Long-term storage ............................................................................................................. 8
3.3 Inspecting the drive unit .................................................................................................... 9
3.4 Checking the name plate data .......................................................................................... 9
3.5 Checking the configuration ............................................................................................. 11
3.6 Transporting the gear unit ............................................................................................... 11
3.7 Preparing for installation ................................................................................................. 14
3.8 Installing the gear unit ..................................................................................................... 15
3.9 Fitting hubs on the gear shafts ....................................................................................... 16
3.10 Fitting push-on gear units ............................................................................................... 17
3.11 Torque support ................................................................................................................ 19
3.12 Fitting shrink discs .......................................................................................................... 20
3.13 Fitting the covers ............................................................................................................. 21
3.14 Fitting a standard motor .................................................................................................. 22
3.15 Subsequent paintwork .................................................................................................... 23
3.16 Temperature sticker ........................................................................................................ 24
3.17 Mounting the external cooling system (cooling unit) ....................................................... 25
4. Commissioning ............................................................................................................. 27
4.1 Check the oil level ........................................................................................................... 27
4.2 Lubricant cooling using an external cooling system (cooling unit) ................................. 28
4.3 Operation with pressure circulation lubrication ............................................................... 29
4.4 Pressure safeguard......................................................................................................... 29
4.5 Operation with back stop ................................................................................................ 30
4.6 Temperature measurement ............................................................................................ 31
4.7 Checking the gear unit .................................................................................................... 32
4.8 Checklist ......................................................................................................................... 32
4.9 Operation of the gear unit in explosive areas ................................................................. 33
5. Service and maintenance ............................................................................................. 34
5.1 Service and Maintenance Intervals ................................................................................. 34
5.2 Service and Maintenance Work ...................................................................................... 34
6. Appendix ........................................................................................................................ 39
6.1 Versions and maintenance ............................................................................................. 39
6.2 Lubricant quantities ......................................................................................................... 41
6.3 Lubricants ....................................................................................................................... 43
6.4 Torque values ................................................................................................................. 44
6.5 Troubleshooting .............................................................................................................. 45
6.6 Declaration of Conformity ............................................................................................... 46
Table of Contents
www.nord.com B2050-GB-0613 -3-
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.
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.
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 regarding explosion protection
1.3 Correct use
These gear units generate a rotational movement and are intended for use in commercial
systems. They satisfy the explosion-proof requirements of Directive 94/9EG (ATEX100a) for the
product category indicated on the name plate.
Strict compliance with the technical data on the name 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.
Only components which comply with the applicable regulations of Directive 94/9/EU may be
fitted and operated.
-4- B2050-GB-0613 www.nord.com
1.4 Safety information
Danger!
All work including transportation, storage, installation, electrical connection,
commissioning, servicing and maintenance must be performed in a non-explosive
atmosphere.
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.
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.
Danger!
Serious physical and property damage may result from inappropriate installation, nondesignated use, incorrect operation, non-compliance with safety information,
unauthorised removal of housing components or safety covers and structural
modifications to the gear unit.
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, the operating instructions for options and drive units which are fitted or
provided.
www.nord.com B2050-GB-0613 -5-
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 (name plate code: CLP PG) Polyglycol-based lubricants
Cooling spiral, screw fittings Copper, yellow brass
1. Notes
Steel
Aluminium
-6- B2050-GB-0613 www.nord.com
V
2. Description of gear units
2. Description of gear units
2.1 Type designations and gear unit types
Helical gear unit
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 unit
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
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
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
NEMA Standard NEMA motor attachment
S Shrink disc
V Solid shaft
VL Reinforced bearings
VL2 Agitator design
VL3 Drywell agitator design
W Free drive shaft
W2 Two drive shaft journals
W3 Three drive shaft journals
Double gear units consist of two single gear units. Gear units SK11207 – SK15507 are to be
treated according to these instructions and attached gear units are to be treated according to the
operation and maintenance instructions B2000, each as two individual gear units. Type
designation of double gear units: e.g. SK13307/7282 (consisting of single gears SK13307 and
SK 7282).
www.nord.com B2050-GB-0613 -7-
3. Assembly instruction,
3. Storage, transport, preparation, installation
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,
No vibration or oscillation
3.2 Long-term storage
storage, transport, preparation, installation
o
C to +50 oC without large fluctuations
alkalis, salts, radioactivity etc.) in the immediate vicinity
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
Temperature in the range from –5
o
C to +40 oC without large fluctuations
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.
-8- B2050-GB-0613 www.nord.com
Measures before commissioning
If the storage or standstill period exceeds 2 years or the temperature during short-term
If the gear unit is completely filled, the oil level must be reduced before commissioning.
storage, transport, preparation, installation
storage greatly deviates from the standard range, the lubricant in the gear unit must be
replaced before commissioning.
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.
3. Assembly instruction,
3.4 Checking the name plate data
The name 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 name plate is illegible or damaged.
Figure 3-1: Name Plate (example)
www.nord.com B2050-GB-0613 -9-
3. Assembly instruction,
Explanation of the name plate
Abbreviation Unit Name Refer to
Type - NORD gear unit type
No. - Serial number
i
- Overall gear unit ratio
ges
storage, transport, preparation, installation
n2
n1
IM - Configuration (installation orientation) Sec. 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 Sec. 3.9
FR1 kN Max. permissible transverse force on the gear unit drive shaft for option W Sec. 3.9
Tu °C Permissible ambient temperature for the gear unit
FA2 kN Max. permissible axial force on the gear unit driven shaft Sec. 3.9
FA1 kN Max. permissible axial force on the gear unit drive shaft for option W Sec. 3.9
MI h Interval between general overhauls of the gear unit in operating hours
xR2 mm Max. dimension for the point of application of the transverse force FR2 Sec. 3.9
Oil - Gear unit oil type (standard designation) Sec. 6.3
min-1
min-1
Rated speed of gear unit drive shaft*
Rated speed of the gear unit drive shaft or the drive motor*
or details of the non-dimensional maintenance class CM
Sec. 5.2
Sec. 5.2
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) or
special max. surface temperature see special documentation (TX)
6. Temperature measurement on commissioning (X)
is central on the drive shaft journal (See Figure 3-7).
R2
Sec. 4.6
-10- B2050-GB-0613 www.nord.com
3. Assembly instruction,
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.
Please note that for geared motors (gear units with attached electric motors) the electric motor
has its own name plate and separate ATEX designation. 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 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 name 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 name
plate complies with the installation orientation and that the installation orientation does
not change during operation.
storage, transport, preparation, installation
3.6 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 four ring bolts (1) (See Figure 3-2) 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.
www.nord.com B2050-GB-0613 -11-
3. Assembly instruction,
storage, transport, preparation, installation
Figure 3-2: Gear unit lifting points
For additional drive units and components, an additional lifting point may be necessary.
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.
Figure 3-3: Transport of gear unit with motor
-12- B2050-GB-0613 www.nord.com
3. Assembly instruction,
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.
storage, transport, preparation, installation
Figure 3-4: Transport of gear unit with motor swing base or base frame
www.nord.com B2050-GB-0613 -13-
storage, transport, preparation, installation
3.7 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.
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.
Attention!
Gear units and geared motors are filled with oil as standard when delivered from the
factory. For filling, the lubricant stated on the name plate must be used. Please refer to
section 6.2 for the amount of lubricant.
As an option, the gear unit can be filled with lubricant.
In all cases, the oil level must be checked as per Section 4.1 prior to commissioning.
3. Assembly instruction,
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.
Attention!
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.
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.
Figure 3-5: Activation of the pressure vent
-14- B2050-GB-0613 www.nord.com
storage, transport, preparation, installation
3.8 Installing the gear unit
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 strong
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 and/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.
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.
3. Assembly instruction,
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 operating instructions.
The tolerances of the shaft ends and the flange connections should be obtained from the
dimension sheet.
Welding of the gear unit is prohibited. The gear unit must not be used as the earth connection for
welding work, as this may cause damage to the bearings and gear wheels.
The gear 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 orientation (See Section 6.1). All gear unit
feet on each side or all flange screws must be used. Bolts must have a minimum quality of 8.8.
The bolts must be tightened to the correct torques (refer to Section 6.4 for torque values).
Tension-free bolting must be ensured, particularly for gear units with a foot and flange.
Oil checking and drain screws 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.
www.nord.com B2050-GB-0613 -15-
Loading...