Page 1
Operating manual
Explosion-protected right angle servo gear units KL/KS/PHK/PHKX/PHQK/PK/PKX
101/2019
WE KEEP THINGS MOVING
ID 443005_en.01
en
www.stober.com
These operating instructions contain information about the
transport, assembly, commissioning and service of gear units
from STOBER. Observe the applicable documents of
attached motors and additional drive components.
1 Operation in accordance with its
intended use
Explosion-protected gear units from STOBER meet the
requirements of the ATEX Directive 2014/34/EU and comply
with the following standards:
• EN 1127-1:2011-07
• EN ISO 80079-36:2016-04
• EN ISO 80079-37:2016-04
The gear units are intended for installation in commercial
machines and systems. Intended use includes:
• Use of the gear unit exclusively for the application that it
was designed for.
• No modifications to the gear unit by the customer.
• Use of the gear unit only in the zone subject to explosion
hazard that corresponds to the identification on the ATEX
nameplate.
• Use of the gear unit in the surrounding temperature range
Ta that is specified on the ATEX nameplate.
• The maximum thickness of the dust deposit on the gear
unit may not be more than 5 mm according to EN 502812-1.
• No overload of the gear unit with regard to the maximum
permitted speeds and torques that are specified in the
order confirmation.
• Compliance with the inspection and maintenance
intervals.
• Observe these operation instructions.
WARNING!
Unintended use of the gear unit can lead to explosions
that can cause serious injuries or even death.
Only use the gear unit as intended!
2 Safety information
WARNING!
Failure to comply with these operating instructions can
cause ignition sources when using the gear unit in areas
subject to explosion hazard and lead to explosions that
can cause serious injuries or even death.
Comply with the instructions in these operating
instructions!
Also follow the applicable national, local and system-specific
requirements.
CAUTION!
Burns!
The surface temperature of the gear unit can significantly
exceed 65° C in operation!
Allow the gear unit to cool down sufficiently before
touching it or wear protective gloves.
2.1 Ignition hazard and protective
measures
The following is an overview of ignition hazards that can arise
when operating the gear unit and protective measures that
are described in these operating instructions.
Ignition hazard: hot surfaces
Possible causes: increased friction due to improper
assembly, wear, overload or leaks.
Protective measures:
• Compliance with the maximum permitted torques and
speeds
• Limitation of the motor current
• Control before commissioning
• Measurement of the maximum surface temperature
during commissioning
• Regular inspection and maintenance
Ignition hazard: mechanically generated sparks
Possible causes: improper assembly of leaks
• Control before commissioning
• Regular inspection and maintenance
Ignition hazard: electrostatic discharge
Possible causes: friction processes, potential differences
between components
• Exclusive use of components with ATEX approval
• Earth the gear unit housing
2.2 Personnel requirements
All work on the electrical equipment of the drive units must be
performed by qualified electricians. Installation, maintenance
and repairs of mechanical parts must be performed by fitters,
industrial mechanics or persons with comparable
qualifications.
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Operating manual
Explosion-protected right angle servo gear units KL/KS/PHK/PHKX/PHQK/PK/PKX
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ID 443005_en.01
WE KEEP THINGS MOVING
01/2019
en
www.stober.com
3 Description of the gear unit
The technical data of the gear unit/geared motor can be found
in the order confirmation. This refers to the lubricant used that
is specified on the nameplate of the gear unit. Other technical
data as well as dimensional drawings can be found in the
appropriate catalog from STOBER.
3.1 ATEX identification
The gear unit is identified on the ATEX nameplate as follows.
1) According to IEC 60079-10-X
4 Transportation and storage
When transporting the gear units/geared motors make certain
not to damage the shafts and bearings with impacts.
Use the ring screws on the gear unit housing for vertical
transport of the gear units. Sling the gear units without ring
screw with a suitable support cable directly on the gear unit
housing.
Note that ring screws are only intended for vertical transport
of the gear units without additional attachments. In addition
sling the motor mounted on the gear unit and make sure that
there is no diagonal pull.
If the ring screws are removed after assembly, permanently
seal the threaded holes according to the protection class of
the gear unit.
The gear units/geared motors may only be stored in
enclosed, dry rooms. Storage in open air areas with a roof is
only permitted for brief periods. Protect the gear units/geared
motors from all damaging environmental effects and
mechanical damage.
Avoid extreme temperature fluctuations with high relative
humidity when the gear units/geared motors are being stored
temporarily to prevent formation of water from condensation.
Long-term storage
If long-term storage is planned, protect the bare parts of the
gear unit against corrosion. Completely fill the gear unit with
lubricant that is specified on the nameplate. Reduce the
lubricant to the correct filling quantity according to the
nameplate before commissioning the drive.
5 Mounting
Inspect the delivery for any transport damage immediately
after you receive it. Notify the transport company of any
damage immediately. Do not operate damaged gear units/
geared motors.
Remove the packaging of the gear unit/geared motor and
dispose of it according to the applicable legal requirements on
site.
Check the following before installing the gear unit:
• Do the specifications on the ATEX nameplate of the gear
unit (gear group, category, EPL, temperature class and
maximum surface temperature) correspond with the
zone subject to explosion hazard where the gear unit is
to be used?
• Is the gear unit installed in a zone that is not subject to
explosion hazard?
• Do all drive and output elements to be mounted have
appropriate explosion protection?
NOTICE
The lip seals of the shaft seal rings can be damaged by
the use of solvents.
When removing the corrosion protection, make sure that
the lip seals of the shaft seal rings do not come into
contact with solvents.
Completely remove all corrosion protection on the shaft ends
prior to installation.
5.1 Installation positions
The version of the gear unit and the lubricant amount filled at
the factory is matched to the installation position of the gear
unit. The gear unit may therefore only be installed at the
installation position specified in the order confirmation. A sign
on the gear units shows which gear unit side must point
downwards.
II 2 G Ex h IIC T3 Gb
Identification according to
ATEX Directive
Identification according to
EN ISO 80079-36
Code Designation Explanation
Ex-symbol According to ATEX
Directive
II Device group
2
3
Device category
G
D
Type of explosive
atmosphere
Gas
Dust
Ex Ex-symbol According to EN ISO
80079-36
h Code letter for non-
electrical devices
IIC
IIIC
Explosion group Gases (such as hydrogen)
Combustible suspended
particles non-conductive
and conductive dusts
T3
T4
T200°
T120°
Temperature class For gases (max. 200°C)
For gases (max. 135°C)
For dusts (max. 200°C)
For dusts (max. 120°C)
Gb
Gc
Db
Dc
Equipment Protection
Level (EPL)
For zone 1
1
For zone 2
1
For zone 21
1
For zone 22
1
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Operating manual
Explosion-protected right angle servo gear units KL/KS/PHK/PHKX/PHQK/PK/PKX
301/2019
WE KEEP THINGS MOVING
ID 443005_en.01
en
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5.2 Installation of gear unit
Mount the gear unit on an even, vibration-reducing and
torsion resistant substructure. Use screws of strength class
10.9 to fasten the gear unit KL, KS, PK, PKX . Use screws of
strength class 12.9 for all other gear units.
Fit the gear unit on the pilot (H7 fit).
Observe the following for assembly:
• Only for KL gear units with foot fastening: the housing
feet and attachment area may not be braced against
each other.
• The permitted shear and axial forces may not be
exceeded.
• Existing vent valves must be freely accessible.
• Earthing the gear unit housing via metal components of
the system must be ensured.
Gear units/geared motor with solid shaft; installation of
power transmission elements:
The output shaft is equipped with a centering thread
according to DIN 332, Sheet 2, which is provided both for
fitting and for axial mounting of transmission elements (gear,
chain wheel, pulley, coupling hub) by means of a central
screw. Shaft ends with a diameter up to 55 have tolerance
ISO k6, those larger than 55 have tolerance ISO m6. The
fitting keys correspond to DIN 6885, Sheet 1.
NOTICE
Damage to the bearing race.
Avoid all impacts to the output shafts.
Gear units/geared motor with hollow shaft and fitting key
connection:
a) Shaft-mounted gear units are mounted on the drive shaft of
the machine to be driven. The reactive torque must be
supported either by flange-mounting of the gear unit or a
torque bracket. If flange-mounted, the flange connection point
on the machine must not exceed a right-angle deviation to the
shaft axis of 0,03/100 mm (danger of distortion of bearings,
excessive bending strain on the machine shaft).For gear units
with a hollow shaft, always make sure that the machine shaft
is aligned with the hollow shaft of the gear unit (max. deviation
≤ 0.03 mm).b) The hollow shaft bore is designed according to
tolerance ISO H7 and the keyway according to DIN 6885
Sheet 1. The machine shaft must be ISO k6! The machine
shaft must have a centering thread according to DIN 332,
Sheet 2. The integrated fitting/push-off disk is provided for
axial mounting of the gear unit by means of a central screw.
Fitting the gear unit onto the machine shaft:
- Coat machine shaft with mounting grease
- Coat hollow shaft spiral groove and keyway with mounting
grease
- Fit gear unit by means of central screw. Do not use
hammer!
NOTICE
Rust on of the gear unit.
Never mount the gear unit without lubrication, since it will
rust on and cannot be removed for repairs.
Disassembly: Press the gear unit off by means of the pushoff disk and matching push-off screw. Support machine shaft
to keep it centered! If the shaft is stuck, we recommend
applying rust penetrating oil to the shaft ends in the key seat
for an extended period.
Gear units/geared motor with hollow shaft and shrink
disk:
The information under a) applies here as well and must be
observed! The description of the shrink disk connection and
the installation and safety instructions can be found in the
TECHNICAL INFORMATION SHEET “Installation
instructions for hollow shaft with shrink disk”.
5.3 Ventilation
The gear units are closed on all sides and are not vented.
6 Commissioning
6.1 Prior to commissioning
Check the following before commissioning:
• Is it ensured that the gear unit is adequately vented and
no external heat input (e.g. Via a coupling) is present?
The cooling air may not exceed a temperature of 40° C.
• For gear units with hollow shaft and shrink disk: were the
clamping bolts tightened to the specified torque? Is the
cover of the shrink disk properly mounted?
• Does the attached motor cover the full flange surface of
the motor adapter for gear units with motor adapters so
that IP65 protection class is provided?
• For gear units with motor adapter ME: is the clamp
coupling tightened to the specified torque? Is the plug
properly mounted?
• If ring screws were dismantled, are the holes sealed with
appropriate plugs?
• Is it ensured that no gear unit overload relating to the
permitted torque can occur due to the mounted motor?
(The permitted torque can be found in the order
confirmation.)
• When operating the attached motor at a drive controller:
is the drive controller parameterized so that a gear unit
overload is prevented?
WARNING!
Risk of injury due to moving parts!
Before switching on the drive, check the following:
Are no persons in danger due to start-up?
Is all protection and safety equipment properly installed,
in test operation too?
Is the drive not blocked?
Are the brakes released?
Is the direction of rotation of the drive correct?
Are components attached to the output such as feather
keys or coupling elements adequately secured against
centrifugal forces?
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Operating manual
Explosion-protected right angle servo gear units KL/KS/PHK/PHKX/PHQK/PK/PKX
4
ID 443005_en.01
WE KEEP THINGS MOVING
01/2019
en
www.stober.com
6.2 During commissioning
As the operating conditions for gear units are very different, it
must be ensured for safe operation under maximum
operating conditions that the surface temperature of the gear
unit does not exceed the maximum permitted value. For this
purpose, take the following measurement with a standard
commercial temperature measurement device.
Determine the surface temperature at the gear unit/motor
transition where the terminal box position prevents ventilation
by the motor fan.
For gear units with a motor adapter or free drive shaft,
determine the surface temperature at the joining seam
between the gear unit flange on the input side and the
attachments.
The maximum surface temperature is reached after approx. 3
hours under full load and may not exceed the maximum value
of 90° C for the highest surrounding temperature. Stop the
drive immediately if the maximum value is exceeded and
contact STOBER Service.
7 Service
7.1 Inspection and maintenance
To ensure safe operation with regard to explosion protection,
carry out the following inspections and maintenance work at
the specified intervals:
Daily or according to dust accumulation
• Remove dust deposits from the gear unit surface
(STOBER recommends removing dust deposits with a
thickness of 1 mm or more)
Every 500 operating hours, every 3 months at the latest
• Visually check the shaft seal rings for leaks
• Check operating noise for possible bearing damage
Every 5000 operating hours, every 5 years at the latest
• Replace lubricant
• Replace shaft seal rings
Every 10000 operating hours
• Replace rolling bearing
Comply with the lubricant specification and amount that is
stated on the nameplate of the gear unit when changing the
lubricant. Do not mix lubricants with different specifications.
7.2 In the event of disruptions
Changes compared to normal operation indicate that the
function of the drive has been impaired. This includes:
• Higher power consumption, temperatures or vibrations
• Unusual noises or odors
• Leaks on the gear unit
• Monitoring devices responding
In this case, stop the drive as quickly as possible and contact
STOBER Service.
7.3 Contact
STOBER Service will be happy to help you:
• If you have queries about the product
• In the event of a fault
• Carrying out maintenance work
• If you need spare parts.
Have the serial number and the type designation of the gear
unit ready when you contact us. This can be found on the
nameplate of the gear unit.
For spare part orders, you will also need the item number of
the spare part in the relevant spare parts list.
Contact data Parent company Germany:
STÖBER ANTRIEBSTECHNIK GmbH & Co. KG
Kieselbronner Str. 12
75177 Pforzheim
Service Hotline +49 7231 582-3000
[email protected]
Contact data Subsidiary USA:
STOBER Drives Inc.
1781 Downing Drive
Maysville KY 41056
Service Hotline +1 606 563-6035
[email protected]
7.4 Disposal
This product contains recyclable materials. Observe local
applicable regulations for disposal.
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