g500 .Nj{ Ä.Nj{ä Bevel gearbox / Bevel gearbox with three−phase AC motor B45 ... B450 | 45 Nm ...
Please read these instructions before you start working! Follow the enclosed safety instructions. 0Abb. 0Tab.
Contents 1 i About this documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1 Document history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2 Conventions used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.3 Terminology used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i 7 8 Contents Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7.2 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7.3 Maintenance operations . . . . . . . . . . . . . . . . . . . . . . . .
About this documentation 1 Document history 1 About this documentation Contents ¯ This documentation serves for safety−relevant operations on and with the gearboxes. It contains safety instructions which must be observed. ¯ All personnel working on and with the gearboxes must have the documentation available during the work and observe the information and notes relevant for them. ¯ The documentation must always be complete and in a perfectly readable state.
1 About this documentation Terminology used 1.3 Terminology used Term Gearboxes In the following text used for Gearboxes of the g500 product family Drive system Drive systems with g500 gearboxes and other Lenze drive components 1.
Safety instructions 2 General safety instructions for drive components 2 Safety instructions 2.1 General safety instructions for drive components Danger! Disregarding the following basic safety measures may lead to severe personal injury and damage to material assets! ¯ Store in dry, low−vibration environment without aggressive atmosphere; if possible in the manufacturer’s packaging. – Protect against dust and impacts.
3 Product description Important notes 3 Product description 3.1 Important notes ¯ The most important technical data are indicated on the nameplate (structure and contents 9 to 11). ¯ The product catalogues contain further technical data. 3.2 Identification Mounting position (A−F) and position of system modules (1−6) EN Hollow shaft: Solid shaft: Hollow shaft with shrink disc: 8 0 3, 5, 8 (3+5) 3, 5 without flange: Flange: Terminal box/ Motec: 0 3, 5, 8 (3+5) 2, 3, 4, 5 Lenze ¯ MA 12.
Product description 3 Identification Nameplate 3.2.1 Nameplate Geared motor Note! In the geared motor version the nameplate is attached to the motor. g500−X−001.iso Example EN g500−X−001.iso Lenze ¯ MA 12.0014 ¯ 1.
3 Product description Identification Pos.
Product description 3 Transport weights Gearbox N version Example G500−X−002.iso Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 3.3 Contents Manufacturer / production location Gearbox and motor type Year / week of manufacture Mounting position / position of the system blocks Rated torque Rated speed/rated frequency Lubricant amount / type of lubricant Ratio Material number / serial number Bar code Order number Operating factor (indicated when <1.
4 Mechanical installation Important notes 4 Mechanical installation 4.1 Important notes ¯ Use load carrying equipment for transport! ¯ Before the transport – check that all components are safely mounted, – fasten all transport aids (eye bolts or support plates). Danger! Danger due to toppling or falling loads! ¯ The payload of the hoists and load handling devices must at least correspond to the weight of the load. ¯ The load must be secured in such a way that it cannot topple or fall down.
Mechanical installation 4 Preparation General information about the assembly of drive systems 4.3 Preparation Note! Thoroughly remove anticorrosion agents from output shafts and flange faces. 4.3.1 General information about the assembly of drive systems Stop! The lubricant fill quantity of the gearboxes is matched to the mounting position. The mounting position indicated on the nameplate must be observed to avoid damage to the gearbox. 4.3.
4 Mechanical installation Mounting Condensation drain hole of the motor 4.3.3 Condensation drain hole of the motor Note! Lenze delivers motors with condensation drain holes with sealed condensation drain holes. The holes are sealed with a plastic plug or a locking screw. This does not affect the type of protection and the motor is protected against the ingress of foreign substances during transport and operation. Further information, ( 34). 4.4 Mounting 4.4.
4 Mechanical installation Mounting Coupling hubs Drive size 1A 1B 2B 1C 2C 3C 4C 6C 7C 1D 2D 1E 2E 3E 4E Motor shaft Assembly dimension D max. l M [ mm ] [ mm ] [ mm ] 11 14 11 19 14 14 14 11 19 24 19 28 24 19 24 23 40 23 40 40 40 40 40 40 60 60 60 60 60 50 23 25 23 25 25 25 25 25 25 30 30 30 30 30 50 Standard hub Locking screw Thread Tightening torque [ Nm ] [ mm ] M4 M5 M4 1.5 2.0 1.5 M5 2.0 −−− −−− M5 2.0 Tab.
4 Mechanical installation Mounting Coupling hubs Mounting the clamping ring hub 1 3 2 Fig. 3 Coupling 1 2 3 Clamping ring hub Clamping ring Clamping screws (DIN912) Note! The motor shaft must be designed with fit k6. EN 1. Grease the contact surfaces of the motor shaft using a thin−bodied oil, e. g. Castrol 4 in 1" or Klüber Quitsch Ex"! Stop! Do not use oil or grease with molybdenum−disulphide or high−pressure additives, or grease pastes! 2.
Mechanical installation 4 Mounting Attachment of gearboxes with hollow shafts and keyway Dismounting the clamping ring hub 1. Loosen the clamping screws evenly one after the other. Stop! Each screw must only be loosened by half a revolution per pass! Unscrew all clamping screws by 3 − 4 threads. 2. Remove the screws next to the forcing threads and screw them into the other threads until they have contact. 3.
4 Mechanical installation Mounting Attachment of gearboxes with hollow shafts and keyway Æ dH7 Auxiliary tool (recommended dimensions) d2 c7 M6 4 M10 5 6 7 8 9 10 11 13 14 16 24 18 20 25 30 35 40 45 50 55 60 70 80 100 Tab. 3 M12 M16 M16 M20 M20 M20 M24 Dimensions in [mm] Dismounting 1. Undo axial gearbox locking in the hollow shaft. 2. Remove/extract the gearbox from the motor shaft using an appropriate auxiliary tool (Fig. 5). EN K12.0611 Fig.
Mechanical installation 4 Mounting Mounting the shrink disc with a rotating cover Gearbox type/size g500−B45 g500−B110 g500−B240 g500−B450 l1 min 85 105 127 134 Tab. 5 Dimensions in mm 4.4.5 Mounting the shrink disc with a rotating cover l max. 100 120 143 150 Stop! Do not dismantle new shrink disc. Never tighten clamping screws before the machine shaft is pushed in. Otherwise the hollow shaft may be deformed plastically.
4 Mechanical installation Mounting Mounting the shrink disc 4.4.5.1 Mounting the shrink disc Depending on the design, the shrink discs may be equipped with a rotating cover (protective cap, pos. 1). Note! This cover is fitted to the shrink disc on delivery. 2 1 5. 1. 1 EN 2 KL_GFL06_001−dms Fig. 6 1 2 Protection cover Clamping screws 1. Remove protective cap (1), if available. 2. Check machine shaft – Diameter in fit tolerance h6 – Surface roughness Rz £ 15 mm 3.
Mechanical installation 4 Mounting Mounting the shrink disc GT−GNG−003.iso/dms Fig. 7 Explanation: "one after the other" Tip! Several (in general more than 5 ) passes are necessary until the full tightening torque is reached at all screws! The shrink disc is mounted correctly and fixed when the faces of the outer ring and the inner ring are aligned (Fig. 8). Minimum misalignments are permissible. EN GT−GNG−001.iso Fig.
4 Mechanical installation Mounting Mounting the shrink disc Dismounting Danger! Loose drive components or drive components falling down may cause injury to persons or damage to the machine. Secure the drive components before disassembly. 1. Remove protective cap (1). 2. Loosen clamping screws (2) evenly one after the other each by ¼ revolution in several passes. Do not unscrew clamping screws completely to prevent accidents! 3. Press off outer ring (see Fig. 8), if necessary.
Mechanical installation 4 Mounting Mounting the fixed cover 4.4.6 Mounting the fixed cover Note! This cover is supplied loose on delivery! X X Clip the protection cover on the bore holes. EN 4.4.7 Mounting the hoseproof hollow shaft cover 3x120° 4 1 3 2 Fig. 9 1 2 3 4 Protection cover Cheese head screw Thread reducing sleeve Seal 1. Screw the three reducing bushes (3) into the flange with a screwdriver so they are flush and staggered by 120°. 2.
5 Electrical installation 5 Electrical installation Danger! Electrical connections must only be carried out by skilled personnel! Read the motor documentation for a correct electrical connection of the motor! EN 24 Lenze ¯ MA 12.0014 ¯ 1.
Commissioning and operation 6 Important notes 6 Commissioning and operation 6.1 Important notes Stop! The drive may only be commissioned by skilled personnel! ¯ Take safety measures prior to any operation: – Disconnect the machine from the mains, ensure standstill of the drive system and avoid any machine movement. 6.
6 Commissioning and operation During operation 6.3 During operation During operation, check the drive periodically and take special care of: ¯ changes compared to normal operation, like – unusual noise, stronger vibrations or increased temperatures, – leakages, – loose fixing elements, – the condition of the electrical cables. ¯ In case of faults: – shut down the drive, – check the troubleshooting table. If the fault cannot be remedied, please contact the Lenze customer service.
Maintenance 7 Important notes 7 Maintenance 7.1 Important notes Note! ¯ Gearboxes below 200 Nm are lubricated for life. ¯ The mechanical power transmission system is maintenance−free. ¯ Take safety measures prior to any operation: – Disconnect the machine from the mains, ensure standstill of the drive system and avoid any machine movement. 7.2 Maintenance intervals ¯ In case of gearboxes > 200 Nm, the lubricant must regularly be replaced. – The type of lubricant is indicated on the nameplate.
7 Maintenance Maintenance operations 7.3 Maintenance operations Gearboxes and geared motors are ready to use on delivery and filled by Lenze with the lubricant type and lubricant quantity indicated on the nameplate. The first filling corresponds to the mounting position and design indicated on the nameplate. Note! Gearboxes of size B45 and B110 are lubricated for life. Because of the minimum thermal load it is not necessary to replace the lubricant. No ventilation required.
Maintenance 7 Maintenance operations Breather position, oil filling screw and drain plug Gearbox g500−B240 A B + + + + C D + + EN + + E F + + Filler Drain Breather element Check The shown oil bores are optional for gearbox size g500−B240! Lenze ¯ MA 12.0014 ¯ 1.
7 Maintenance Maintenance operations Gearbox g500−B450 A B + + C D + + EN + + E F + + 30 Filler Drain Breather element Check Lenze ¯ MA 12.0014 ¯ 1.
Maintenance 7 Maintenance operations Oil−level inspection Check the oil level by means of the displayed dipsticks. Manufacture them according to the mounting position. Model: Dipsticks for g500−B240 A, 3-stufig B A, 2-stufig EN C D E F Lenze ¯ MA 12.0014 ¯ 1.
7 Maintenance Maintenance operations Model: Dipsticks for g500−B450 A B C D EN F E 32 Lenze ¯ MA 12.0014 ¯ 1.
Maintenance 7 Maintenance operations Changing lubricant Stop! ¯ Gearbox should be warm. ¯ Secure drive system and machine from inadvertent movement and mains connection. The type of lubricant indicated on the nameplate by the following manufacturers is approved. Shell Klüber Fuchs 1. Place receptacle under oil drain plug. 2. Remove breating / oil filler plug. 3. Completely drain lubricant by removing the oil drain plug. EN 4. Reinsert drain plug (if necessary, replace seal). 5.
7 Maintenance Repair Motors 7.3.1 Motors Drain condensation Depending on the mounting position, the condensation drain holes are always at the bottom of the motor! ¯ For condensate drainage – the motor must be deenergised; – the plugs (screws) must be removed. Stop! To restore the enclosure, re−insert the plugs (screws) after condensate drainage. If the condensation drain holes are not sealed again, the IP enclosure of the motor will be reduced.
Troubleshooting and fault elimination 8 8 Troubleshooting and fault elimination If any malfunctions should occur during operation of the drive system, please check the possible causes using the following table. If the fault cannot be eliminated by one of the listed measures, please contact the Lenze Service.
© 02/2014 | MA 12.0014 | .Nj{ | 1.0 | TD09 Lenze Drives GmbH Postfach 10 13 52 D−31763 Hameln Germany +49 5154 82−0 +49 5154 82−2800 Lenze@Lenze.com www.Lenze.com Lenze Service GmbH Breslauer Straße 3 D−32699 Extertal Germany 0080002446877 (24 h helpline) +49 5154 82−1396 Service@Lenze.
