Operating Instructions ASSEMBLY UNITS VG
1 System overview Z - types U - types Gear flange Gear pedestal Helical Gearbox Agitator Gearbox Warm Gearbox Bevel Gearbox Helical Shaft Mount.
Contents 1 System overview Contents 2 3 General 4 1.1 1.2 1.3 2 3 Safety information 7 7 8 9 Technical data 10 10 10 11 11 11 12 13 Product characteristics 3.1.1 Mechanical construction 3.1.2 General description 3.1.3 Mode of operation Operating conditions Figures 3 and 4 Figures 5 and 6 Installation 4.4 6 Persons responsible for safety General safety information Conventions used for safety information 3.1 4.1 4.2 4.3 5 8 14 Incoming inspection and transportation Storage Assembly 4.3.
General 1 General 1.1 How to use these Operating Instructions The Operating Instructions are a part of the consignment of the BERGES attachments VG. They contain safety information that must be followed. Conse quently, always keep the Op. Inst. near to the VG. Caution! The only way to achieve safe, trouble - free operation, by avoiding operating errors and incorrect use of the VG , is to read and be throughly amiliar with the Op. Inst. It is thus important that the Op. Inst.
General 1.3 BERGES assembly units 1.3.1 Identification BERGES assembly units are uniquely identified by the information on the rating plate. When used in hazardous areas: II 2 G D c T4 135°C Manufacturer: BERGES ANTRIEBSTECHNIK GMBH & CO.KG POSTFACH 1140 INDUSTRIESTRAßE 13 D - 51709 MARIENHEIDE TELEFON ( 02264 ) 17- 0 TELEFAX ( 02264 ) 17 125 1.3.
General We reserve the right to make modifications to the drives in the interests of technical improvement and in order to enhance safety. The Op. Inst. may not be duplicated nor used for the purposes of competition in unauthorised manner or made available to third parties without our prior consent. Amendements or supplements to the Op. Inst. may be made solely by us; vio lation of this clause will result in all warranty claims being null and void. Copyright to these Op. Inst.
Safety information 2 Safety Information 2.1 Persons reponsible for safety User The user is any natural person or legal entity whd or which uses the VG or on whose behalf/on behalf of which the VG are used. The user resp. his Security Officer shall guarantee: - that all relevant regulations, instructions and laws are complied with. - that only qualified personnel work on and with the VG.
Safety information 2.2 General safety information This safety information does not claim to be complete. Please contact the reponsible BERGES company should you have any questions or problems. The VG comply with the state of the art on the date of delivery and are always delivered in a safe operating condition. The VG may be used and operated only within the framework of the conditions stipulated in the Performance and Supply Contract.
Safety information 2.3 Conventions used for safety information All safety information in these Operating Instructions has a uniform structure Signal word Information text - The pictogramm identifies the type of danger - The signal word identifies the severity of the danger - The information text describes the danger and provides information on how to avoid the danger Warning against personal injury Pictograms used Signal words Warns against directly imminent danger.
Technical Data 3 Technical Data The most important technical data is specified on the rating plate. This data and the contractual agreements for the drives stipulate the limits to use as intended. Please refer to the product catalogues fo further technical data. On complete gears ( RGAE with reduction gear and motor ), three rating plates are normally attached. One rating plate is attached to the motor, one is attached to the gear and one attached to the RGAE.
Technical Data 3.1.2 General description The RGAE are supplied as a variable-speed gear attachment unit, of base or flange design, or with reduction gear and are suitable for all conventional installation positions. The variable-speed gear casings consits of aluminium and have a symmetrical design. They are sturdy, vibration-damping and designed for continuous operation.
Technical Data Figure 3 BERGES Variable Speed Gear VG mounting position U Figure.
Gear flange Motor flange Technical Data Figure 5 BERGES ASSEMBLY UNITS RGAE Gear base Item 7.2 Gear flange Pos.7.1 Figure 6 BERGES ASSEMBLY UNITS RGAE ( with Base a.
Installation 4 Installation 4.1 Incoming inspection and transportation The consignment must be examined immediately on arrival for completeness and transport damage. We are able to replace damage equipment free of charge only if an advice of damage is drawn up in the presence of the haulage contractor. Caution ! Use only slinging equipment with a adequate load-carrying capacity to transport the drive. Ensure that the equipment is correctly secured. Avoid shocks and jolts.
Installation As early as the planning stage, ensure that the space provided is adequte for the drive soas to be able to perform installation, care and sirvicing work unhindered. The mounting areas on which the VG are to be fitted must be level, torsionally resistant and free of vibration. ( levelness ≤ 0,1 mm ) Align the VG on the mounting surface precisly in line with the machine shaft to be driven. Ensure that the units are mounted free of stresses and strain so as to avoid additional loading.
Installation 4.4.2 Connection of the electrical remote control motor Stop! The motor of the electrical remote control may be operated only with the main motor operating. 1. Connect the motor in accordance with the circuit diagram (Figure 7). 2. Check the direction of rotation in inching mode: - Briefly press button S1; the operating pin must move towards the bolt-on flange. - Briefly press button S2; the operating pin must move in the opposite direction.
Installation 4.4.3 Connection of the rev-counter The electrical rev-counter is an option and can be retrofitted at any time. The rev counter is supplied with a connection cable. This is connected user-specifically - if using an indicator provided by the customer - or in accordance with the regulations for the BERGES indicator.
Commissioning 5 Commissioning Stop! The drive may be commissioned only by trained specialists. Caution ! Fit the wide V - belt beforehand if commissioning after three months ( see also Point 4.2, Page 14 ). 5.1 Before commissioning Caution ! Secure the drive to prevent the power supply being switched on unintentionally.
Commissioning 5.3 Placing out of operation Place the drive out of operation by switching off the drive assembly. Caution ! Lock the drive to prevent the power supply being switched on. ( Attach a corresponding information sign to the switch-on point ). If you intend to place the drive out of operation for a long period , operate the drive briefly every 2 weeks. If you intend to place the drive out of operation for longer than three months, remove the wide V-belt. ( see also Point 4.2, Page 14 ). 5.
Servicing 6 Servicing and maintenance 6.1 Servicing intervals Stop! Please complay with the servicing intervals for all drive components. ( Variable-speed pulley, wide V-belt, gear box and motor ) Damages to the variable speed gear VG should be avoided. Check for damages regulary. Variable - speed pulleys and spring pulleys feature at lifetime grease lubrication system and thus require virtually no maintenance.
Servicing Fitting U and Z version ( see also Figures 3 and 4, Page 12 ) 1. First fit the new wide V-belt into the spring-loaded spring pulley F ( Item 2 ) and thread it up by hand and then fit it into the fully-open mechanically adjustable variable-Speed pulley R ( Item 1 ). Turn the drive by hand until the belt is taut. 2. Bolt the halves of the housing ( Items 3 und 4 ) back together ( 4, 6 or 8 bolted connections ) 3. Conduct a trial run.
Servicing Stop! Never adjust the speed at standstill! Adjusting the speed at standstill damages theRGAE. Always ensure that the wide V-belt does not contact the base of the hub ( clearly audible, whistling running noise ). cannot move beyond the edge of the variable-speed pulley and/or spring pulley. Procedure in the case of electrical remote control ( Figure 7 ) 1. Swich on the drive motor ( Pos.8 ). 2.
Servicing Figure 10 Spindle adjustment SS 4 Cover plate 5 Securing bolt 6 Nut 7 Setscrew 8 Handwheel 9 Scale insert Figure 11 Angle adjustment WS 4 Cover plate 5 Securing belt 6 Nut 7 Tetscrew 8 Handwheel 9 Scale insert Drawn 90° - offset 23
Servicing 6.2.3 Changing the variable-speed pulleys Installing the variable-speed and spring pulley ( Figure 12 ) The pulley bores are manufactures to DIN 7154, fit H7. The dimensions of the spli nes comply with DIN 6885, Sheet 1 (3) and the tolerance also complies with fit H7. The variable - speed pulleys must be fitted on the drive and output shafts with a sli ding fit (do not use force, e.g. by hammering).
Servicing Removing the variable-speed and spring pulleys ( Figure14 ) The variable-speed and spring pulleys can be removed by removing the cheese-head screw ( Item 6 ), the spring washer ( Item 8 ), the securing disc ( Item 5 ) and the circlip (Item 7) from the bore. Place a smooth disc (Item 9 ) in front of the shaft stub in order to protect the shaft thread, guide the attachment disc ( Item 5 ) the other way around into the bore and press the circlip ( Item 7 ) back into the recess of the bore.
Troubleshooting 7 Troubleshooting If faults or malfunctions occur when operating the BERGES attachments VG, please check the possible causes of the fault on the basis of the table below. If the fault cannot be remedied by any of the measures listed in the table or if the fault which has occurred is not attributable to one of the causes specified in the table please inform one of the BERGES service addresses.
Service 8 Stocking spare parts, after-sales servicing adresses 8.1 Stocking spare parts We advise you to stock the most important spare parts and parts subject to wear with a view to maintaining the VG constantly ready for operation. We provide warranty only for original spare parts s upplied by us. Caution! We must expressly point out that only the spare parts and accessories supplied by us have also been inspected and approved by us.
Manufacturer's declarations 9 Manufacturer's declaration Manufacturer's declaration As defined by the EC - Machinery Directive 98/37/EEC, Annex II B We hereby declare that the Variable Speed Gears VG VG 1/80 .......
Conformity declarations 10 CONFORMITY DECLARATION EG-Konformitätserklärung EG-Declaration of Conformity Berges Antriebstechnik GmbH & Co. KG erklärt, dass Verstellgetriebe der Typen VG1 - VG9 mit der Berges Antriebstechnik GmbH & Co. KG certifies herewith, that the variable speed gears type VG1 - VG9 comply with the Explosionsschutzrichtlinie 94/9/EG übereinstimmen.
