1AM, 1UP, 2AM, 4AM, 6AM, 8AM, 16AM, NL22

Transcription

1 Ihr flexibler Problemlöser in der Fluidtechnik Compressed-air helical geared motors 1AM, 1UP, 2AM, 4AM, 6AM, 8AM, 16AM, NL22 with helical gearboxes SK DRUMAG GmbH Fluidtechnik Glarnerstrasse Bad Säckingen Telefon: +49 (0)7761 / Fax: +49 (0)7761 / Web: info@specken-drumag.com Operating instructions Edition 08/

2 Contents 1. Important instructions 3 2. Safety instructions General safety instructions in normal and intrinsically safe EX operation Additional safety instructions for use in the intrinsically safe EX area Checklists 5 3. Design General technical data Design of compressed-air motor Nameplate, Model designation 7 4. Installation Before you start Preliminary work Installation instructions Installation in an area subject to the risk of explosion Pneumatic installation Settings Commissioning Commissioning Measuring the surface temperature (only when used in the intrinsically safe EX area) Maintenance and repair Maintenance Repair Decommissioning and storage Faults on the geared motor Declarations of conformity Helical gear box NORD 2 Operating instructions for helical gear air motors

3 Important instructions 1. Important instructions Safety instructions and warnings It is essential that you follow the safety instructions and warnings contained here! Impending danger. Possible consequences: Death or serious injury Dangerous situation. Possible consequences: Slight or minor injuries Damaging situation Possible consequences: Damage to the drive unit or the surrounding area Important instructions on the prevention of explosions Application tips and useful information Disposal Adherence to the operating instructions is an essential prerequisite for fault-free operation and for any guarantee claims to be met. For that reason you should first read the operating instructions, before working with the motor! The operating instructions contain important notes on service; it should therefore be stored close to the motor (please adhere to the current regulations): Sections of housing, toothed gearwheels and bearings are to be disposed of as steel scrap. This also applies to cast iron parts, provided that there is no separate collection. Operating instructions for helical gear air motors 3

4 Safety instructions 2. Safety instructions 2.1 General safety instructions in normal operation (not intrinsically safe EX operation) and when operated in the intrinsically safe EX area. Preliminary remark Handling compressed air Intended use Read these instructions carefully before using the geared motor for the first time. Please also take into account the supplementary safety instructions in the individual chapters of these operating instructions. The geared motors have moving parts and possibly hot surfaces during and after operation. All work connected with installation, making connections, commissioning, maintenance and servicing must be carried out by qualified technical staff. Improper use, installation or operation may lead to serious personal injury and damage to property. Wear safety glasses. Do not loiter in the immediate vicinity of the stream of compressed air. Do not operate the equipment with other gases or liquids. Do not operate the equipment with higher pressures than that recommended for your model. Damage may be incurred if the machine is operated at higher speeds than those recommended These geared motors are intended for the generation of rotary motion in industrial installations. They comply with the relevant standards and regulations, and satisfy the requirements of directive 94/9/EC (ATEX). Technical data and details of permissible conditions can be found in this documentation. It is essential that you adhere to all the details. 2.2 Additional safety instructions for use in the intrinsically safe EX area Combustible gas mixtures or dust concentrations in combination with hot and moving parts may cause serious or mortal injury. Installation, connections, commissioning and all maintenance and repair work on the geared motor must only be carried out by qualified technical staff, taking into account these instructions the warning and instruction plates on the geared motor. all other planning documents, commissioning instructions and circuit diagrams associated with the drive unit. the provisions and requirements specific to the plant the currently valid national/regional regulations (protection against explosion, safety, accident prevention) 4 Operating instructions for helical gear air motors

5 Safety instructions Intended use These geared motors are intended for the generation of rotary motion in industrial installations and must only be used as specified in the technical documentation, and in accordance with the details on the nameplate. They comply with the relevant standards and regulations, and satisfy the requirements of directive 94/9/EC (ATEX). They are not permitted to be used for braking. 2.3 Checklists Before commissioning This checklist contains all the actions that are to be undertaken before commissioning a geared motor in accordance with ATEX100a in the intrinsically safe EX area. Check before commissioning in the intrinsically safe EX area Do the following details on the nameplate of the geared motor match the permissible intrinsically safe EX area on site: Equipment group EX category EX zone Explosion group temperature class Maximum surface temperature Has it been ensured that there are no atmospheres, oils, acids, gases, vapours or radiation that may cause an explosion present when the geared motor is being fitted? Is the ambient temperature being maintained in accordance with the technical data? Has it been ensured that the geared motors are adequately ventilated and that there is no external influx of heat (e.g. via couplings)? The cooling air must not exceed a temperature of 40 C. Have all the drive elements to be fitted ATEX approval? Checked Information in chapter During commissioning This checklist contains all the actions that are to be undertaken during commissioning of a geared motor in accordance with ATEX100a in the intrinsically safe EX area. Check during commissioning in the intrinsically safe EX area After 4 hours in operation, measure the surface temperature. Find detailed information in chapter 4.3 of gearbox manual Checked Information in chapter in Instruction manual NORD gears Operating instructions for helical gear air motors 5

6 Design 3. Design 3.1 General technical data Preliminary remark Operating pressure Temperature range Data on power and air consumption, as well as connector dimensions can be found in our "Compressed-Air Motors" catalogue. Maximum operating pressure: 7 bar / Models 1UP and NL: 5.6 bar Ambient temperature in normal operation (non-ex area): +1 C to +50 C Compressed air temperature Ambient temperature in the intrinsically safe EX area): +1 C to +40 C The temperature of the compressed air fed in must not exceed the ambient temperature. 3.2 Design of compressed-air motor 1. Housing 2. Drive bearing cover 3. End bearing cover 4. Rotor 5. Vanes 6. Ball bearings 7. Shaft seal 8. End cap 9. Bolts 6 Operating instructions for helical gear air motors

7 Design 3.3 Nameplate, model designation Nameplate (example) Customer number Article number Typ 6AM-ARV-54- SK22F-160/42,82-ATEX G No /2012 Order number Model designation Production week and year II 2G c IIC T4-X Key: II Equipment group II 2 Equipment category 2 G For gas atmospheres c Safety of construction IIC Explosion group T4 Temperature class (135 C) -Range of ambient temperature (s. technical data) X -Temperature measurement during commissioning Model designation (example) 6AM-ARV-54 SK22F-160/42,82-ATEX G Gear ratio Gearbox size Motor model Operating instructions for helical gear air motors 7

8 Mechanical Installation 4. Installation 4.1 Before you start The geared motor must only be installed if the details on the nameplate of the geared motor match the permissible EX application area on site (equipment group, category, zone, temperature class, maximum surface temperature the geared motor is undamaged it has been ensured that there are no atmospheres, oils, acids, gases, vapours or radiation that may cause an explosion present during installation 4.2 Preliminary work Drive shafts and flange surfaces must be thoroughly cleaned of anticorrosives, contamination etc. (using commercially available solvents). Do not permit solvents to penetrate to the bearing seals - they will be damaged! 4.3 Installation instructions Installation the gear motor only in the mounting position specified on the nameplate of the gearbox. Angle variations admitted between ±5 respect to the horizontal axis. Please use only attachment elements of the required sizes Use only the existing attachment holes in order to fix the device in place The fixing to the machine must be secure and without vibrations; the structure must not be torsionally stressed. Handle all rotating parts with particular care Only driven elements with ATEX approval may be used. Under no circumstances should you force pulleys, couplings, pinions etc. onto the end of the shaft by hitting them with a hammer (damage to bearings, housing and shaft!) Unscrew the cap or disc facing the end of the shaft, so that the centred shaft end is exposed. The shaft can be supported under a press and in that way the pulley or coupling can be pulled onto the shaft. A puller device is required for disassembly When pulleys are used please ensure that the tension in the belt is correct (according to manufacturer's specification). Only belts with adequate electrical resistance < 10 9 must be used. If the motor shaft is directly connected to the component to be driven without a coupling, you must ensure that that radial offset (centrifugal errors) and any effect of axial forces (tension or pressure) are excluded. Under no circumstances should you exceed the permissible radial and axial forces on the shaft 8 Operating instructions for helical gear air motors

9 Mechanical Installation You will simplify assembly if you first lubricate or briefly warm the drive element (to C). Drive elements such as pulleys, couplings etc. must be covered by a guard. 4.4 Installation in an environment where there is a risk of explosion Ambient temperature Temperature class / Surface temperature Protection category Ambient conditions Power output and torque Braking operation When installing the geared motor in an environment where there is a risk of explosion, please ensure that you follow the safety instruction in chapter 2.2! The geared motors that are protected against explosion meet the design regulations of equipment group II, category 2G (EX atmosphere gas ). They are intended for use in zones 1/21 Geared motors in category II2G must only be used at temperatures between +1 C and +40 C. In the case of ambient temperatures that do not comply, you must contact SPECKEN-DRUMAG! Geared motors in category II2G (EX atmosphere gas) are approved for temperature class T4. This corresponds to a maximum surface temperature of 135 C. All geared motors comply with protection category IP54 in accordance with EN You must ensure that the geared motors are adequately ventilated and there is no external influx of heat (e.g. via couplings). Adherence to output torque and the permissible transverse and axial forces must be assured. The geared motors must not be used for braking in the EX area. Braking operation is an operating state in which the motor is driven by an externally applied torque in the opposite direction to the one prescribed for air input. Operating instructions for helical gear air motors 9

10 Mechanical Installation 4.5 Pneumatic Installation For lengths of less than two metres between the main supply pipe and the machine you should use connecting pipes of the nominal diameter of the connector to the machine, and for lengths over two metres, pipes that are one size larger than the nominal diameter. In the case of applications with one direction of rotation, a silencer should be fitted to the air outlet. This is part of the equipment supplied. In the case of a reversible machine that can be operated in both directions, a fourway valve can be used. In this case the valve is connected to both connectors on the machine, and the silencer is fitted to the air outlet or valve connector. Remove the plastic covers from the connectors. Keep the covers in a safe place in case you want to decommission the machine at a later date and put it into storage (see also "Decommissioning and Storage") Set the air input to "Off". Do not use a jubilee clip to seal the threaded pipe connection. The air feed to the motor must be filtered. We recommend a filter grade of 5 microns. The maintenance unit, the directional control valve and the volume controller must be selected according to the air consumption of the motor, and not according to the size of the connections to the motor. Calculate the pipe cross-sections so that the pressure loss between the maintenance unit and the motor is less than 0.5 bar. The compressed-air motors must be lubricated. Exception: Non-lubricated motors NL... Fill the oil reservoir of the lubricator to the prescribed oil level. As a lubricant you should use acid-free, easily atomisable proprietary oils with a viscosity of 200 mm 2 /s. Before you connect the compressed air connector to the machine you should first clean out the pipe by blowing air through it at low pressure, in order to remove any particles of dirt from the pipe. When doing so you must wear safety glasses and not get in the way of the jet of air. 4.6 Adjustments Filtration and lubrication Lubricator adjustment Speed control A filter, controller and lubricator (not supplied) of a suitable size are to be fitted to the compressed air pipe at a distance of 1-2 metres from the machine. Adjust the lubricator so that one drop of oil is delivered for every m 3 of air throughput. No adjustments are possible to the machine. (not for Non-lubricated motors NL ) If the speed is to be controlled, a valve must be included to control the flow of air (pressure regulator, ball valve etc.) 10 Operating instructions for helical gear air motors

11 Commissioning 5. Commissioning 5.1 Commissioning Before commissioning the geared motor you should ensure that all the components that carry air are correctly connected. Do not loiter in the immediate vicinity of the stream of compressed air. Set the air input to "ON". Adjust the pressure or the flow as necessary to achieve the required speed or the required torque. Adjust the lubricator as described in chapter 4.6. (Exception: Non-lubricated motors NL ) Check the oil level once a day and top up with oil if necessary. (Exception: Non-lubricated motors NL...) 5.2 Measuring the surface temperature (only when used in the EX area) Measuring surface temperature The details of maximum surface temperature on the nameplate are based on measurements taken under normal ambient and installation conditions. Even minimal changes to these conditions (such as confined installation conditions) may have a significant influence on temperature. When the geared motor is being commissioned it is essential to carry out a measurement of the surface temperature under maximum load. This measurement can be carried out using commercially available temperature measuring equipment. Find detail information in chapter 4.3 of gearbox instruction manual. If the surface temperature is higher than that, the geared motor must be stopped immediately. In this event you must contact SPECKEN DRUMAG. Operating instructions for helical gear air motors 11

12 Maintenance and Repair 6. Maintenance and Repair 6.1 Maintenance Lifetime lubrication Loss of power With adequate lubrication the compressed-air motor (exception: Non-lubricated motors NL...) operates practically maintenance-free. The gearbox is lubricated for life. The gearbox should be checked for noises and/or increased play in the bearings at regular intervals. Clean the filters in the maintenance unit regularly when in operation, and empty any condensation. Check the oil level in the lubricator at regular intervals and top up if necessary. If the motor is not running perfectly after being in operation for a longer period, this is usually attributable to resinous oil residues that are impeding the free movement of the blades in the rotor slots. In this case it is appropriate to rinse out the motor with paraffin. Release all pressure from the motor. Unscrew both pipes or the silencer from the motor and pour a few drops of paraffin into the inlet, then turn the shaft by hand for a few minutes in both directions. Repeat this process, then connect the air pipe, and at low pressure (approx. 0.5 bar) and low speed, start up the motor. Protect your face and eyes! Cleaning the silencer Dust coating Oil level Gear seals Dismantle the silencer and clean the felt filter. When air emerges that is free of paraffin mist, lubricate the motor with 3 or 4 drops of oil. Check also the maintenance unit. If the motor is still not delivering full power you should repeat the process, or it may be due for overhaul. It is necessary to verify that there isn t any dust coating thicker than 5mm on the gear motor. Remove dust periodically. Verify the correct oil quantity through the oil level plug, if present. Gears without oil level plug are lubricated for life. Refer to information in gearbox instruction manual 12 Operating instructions for helical gear air motors

13 Maintenance and Repair 6.2 Repair Vane wear Gearbox service With regular maintenance the wear to moving parts is minimal. Lubricated motors: It is only necessary to replace the vanes and ball bearings in the motor after between 5,000 and 8,000 hours in operation. This also depends on the speed at which the motor is run, the air pressure and lubrication. Non-lubricated motors: It is necessary to replace the vanes after between 2,500 and 5,000 hours in operation. This also depends on the speed at which the motor is run, the air pressure and quality of air (purity, humidity). If you intend to carry out the repair yourself, order a repair kit for the motor. It contains all the parts that can be replaced. We recommend that you should send in the motors for repair to our factory. We have all the necessary tools for disassembly, all the original spare parts and the experts to set the motor with all the correct clearances following the repair. Performance, efficiency and service life all depend crucially on the clearances. In normal circumstances do not remove the gear casing closing cover for any reason. In the case of planned maintenance, only by a qualified person, it is possible to disassemble the gearbox ensuring the casing has first reached normal ambient temperature and ensuring no foreign bodies are allowed into the inside of the box and when reassembled the unit is tested to ensure to original specification. Operating instructions for helical gear air motors 13

14 Maintenance and Repair 6.3 Decommissioning and Storage Switch the compressed air feed to "OFF". Release all pressure from the motor. Disconnect the motor from the compressed air pipe. Disconnect the geared motor from the machine to which it is fitted. Remove the silencer element. Blow clean, dry air at low pressure into the inlet of the machine. Pour a few drops of oil into the inlet and turn the shaft by hand to distribute the oil. Fit the plastic covers to the connectors. The machine can now be stored until it is next used. 6.4 Faults on the geared motor Fault Cause Remedial action Torque too low Speed too low Motor will not run Motor becomes hot Motor runs, becoming slower in operation Dirt or foreign bodies Corrosion inside the motor Faulty mating Check and clean Check and clean Refit the motor Air pressure too low Increase pressure Hose diameter to small Fit bigger hoses Restricted exhaust Check and repair Internal components seized Dismantle and repair Compressor too small / inadequate air supply Provide greater volume of air Air supply too far away from the motor Optimise installation 14 Operating instructions for helical gear air motors

15 Konformitätserklärung Konformitätserklärung Declaration of Conformity (im Sinne der Richtlinie 94/9/EG, Anhang VIII) (according to EC Directive 94/9/EC, Appendix VIII) Ihr flexibler Problemlöser in der Fluidtechnik DRUMAG GmbH erklärt in alleiniger Verantwortung, dass die Druckluft-Stirnradgetriebemotoren der Baureihen 1AM, 1UP, 2AM, 4AM, 6AM, NL22 mit Getrieben SK, der Kategorie 2G, auf die sich diese Erklärung bezieht, übereinstimmen mit der declares in sole responsibility that the Air gear motors types 1AM, 1UP, 2AM, 4AM, 6AM, NL22 with gears type SK in category 2G that are subject to this declaration are meeting the requirements set forth in Richtlinie 94/9/EG Directive 94/9/EC Angewandte Normen/ DIN EN : , DIN EN : , Applicable standards: DIN EN : Die Produkte sind mit folgender Kennzeichnung versehen: The products are marked with the following characteristics: II 2G c IIC T4-X DRUMAG GmbH hinterlegt die gemäß 94/9/EG Anhang VIII geforderten Unterlagen bei benannter Stelle: TÜV Product Service GmbH, EU-Kennnummer 0123 EG-Bescheinigung Nr. EX DRUMAG GmbH will archive the documents required according to 94/9/EC at the following location: TÜV Product Service GmbH, EC-Code 0123 EC-Certificate No. EX DRUMAG GmbH Bad Säckingen, den Ort und Datum der Ausstellung Place and date of issue Funktion: Geschäftsführung U. Ziegler Function: Managing director U. Ziegler Drumag GmbH Fluidtechnik Postfach 1142 D Bad Säckingen Glarnerstraße 2 D Bad Säckingen Telefon 07761/55050 Telefax 07761/ Internet: technik@specken-drumag.com

16 Intelligent Drivesystems, Worldwide Services GB B2000 Operating and Installation Instructions for Explosion Protected Gear Units and Geared Motors

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18 Contents 1 Notes General information Safety and information symbols Correct use Safety information Disposal Description of gear units Type designations and gear unit types Storage, preparation, installation Storing the gear unit Long-term storage Inspecting the drive unit Checking the rating plate data Checking the configuration Preparing for installation Installing the gear unit Fitting hubs on the gear shafts Fitting push-on gear units Fitting shrink discs Fitting the covers Fitting a standard motor Subsequent paintwork Temperature sticker Fitting the cooling coil to the cooling system Commissioning Check the oil level Activating the Automatic Lubricant Dispenser Temperature measurement Operation with lubricant cooling Checking the gear unit Checklist Operation of the gear unit in explosive areas Service and maintenance Service and Maintenance Intervals Service and Maintenance Work Appendix Versions and maintenance Lubricants Torque values Troubleshooting Declaration of Conformity Adresses B2000 GB -3-

19 1. Notes 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! Risk of fatalities and injury Attention! Machine may be damaged Note! Useful information 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. -4- B2000 GB

20 1. Notes 1.4 Safety information 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. 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. 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. 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. 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 Disposal Observe the current local regulations. In particular, lubricants must be collected and disposed of correctly. Gear unit components: Material: Toothed wheels, shafts, rolling bearings, parallel keys, locking rings, Gear unit housing, housing components, Light alloy gear unit housing, light alloy gear unit housing components, Worm gears, bushes,... Radial seals, sealing caps, rubber components, Coupling components Flat seals Gear oil Synthetic gear oil (Rating plate labelling: CLP PG) Cooling spiral, embedding material of the cooling spiral, screw fittings Steel Grey cast iron Aluminium Bronze Elastomers with steel Plastic with steel Asbestos-free sealing material Additive mineral oil Polyglycol-based lubricants Copper, epoxy, yellow brass B2000 GB -5-

21 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) 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 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 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 B2000 GB

22 2. Description of gear units 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 (2-stage) SK 372.1,. SK (2-stage) SK 373.1,. SK (3-stage) SK 772.1, SK 872.1, SK (2-stage) SK 773.1, SK 873.1, SK (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 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 B2000 GB -7-

23 2. Description of gear units Parallel shaft gear units Type designations: SK 0182NB, SK 0282NB, SK 1282,... SK 9282, SK 10282, SK (2-stage) SK 1382NB, SK 2382,.. SK 9382, SK 10382, SK 11382, SK (3-stage) 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 design 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 -8- B2000 GB

24 2. Description of gear units Bevel gear units Type designations: SK 92072, SK 92172, SK 92372, SK 92672, SK (2-stage) SK , SK , SK , SK , SK , SK , SK , SK , SK , SK , SK , SK (3-stage) SK , SK , SK , SK , SK , SK (4-stage) 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 design 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 Contrate worm gear unit Type designations: SK 02040, SK 02050, SK 12063, SK 12080, SK 32100, SK (2-stage) SK 13050, SK 13063, SK 13080, SK 33100, SK (3-stage) 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 B2000 GB -9-

25 2. Description of gear units MINIBLOC worm gear units Type designations: SK1 S32, SK1 S40, SK 1S50, SK 1S63, SK 1SU..., SK 1SM31, SK 1SM40, SK 1SM50, SK 1SM63 (1-stage) SK 2S32NB, SK 2S40NB, SK 2S50NB, SK 2S63NB, SK 2SU, SK 2SM40, SK 2SM50, SK 2SM63 (2-stage) 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 UNIVERSAL worm gear units Type designations: SK 1SI31, SK 1SI40, SK 1SI50, SK 1SI63, SK 1SI75, SK 1SIS31,, SK 1SIS75, SK 1SD31, SK 1SD40,SK 1SD50, SK 1SD63, SK 1SIS-D31,, SK 1SIS-D63 (1-stage) SK 2SD40, SK 2SD50, SK 2SD63, SK 1SI /31, SK 1SI /H10, SK 2SIS-D40,, SK 2SIS-D63 (2-stage) 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) -10- B2000 GB

26 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 o C to +50 o C 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 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 o C 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. B2000 GB -11-

27 3. Storage, preparation, installation 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 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. 3.4 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) -12- B2000 GB

28 3. Storage, preparation, installation Explanation of the Rating Plate Abbreviation Unit Designation See Typ - NORD gear unit type No. - Serial number i ges - Overall gear unit ratio n 2 min -1 Rated speed of gear unit drive shaft* n 1 min -1 Rated speed of the gear unit drive shaft or the drive motor* IM - Configuration (installation orientation) Section 6.1 M 2 Nm Max. permissible gear unit drive shaft torque P 1 kw Max. permissible drive power or motor power Bj - Year of manufacture F R2 kn Max. permissible transverse force on the gear unit driven shaft Section 3.8 F R1 kn Max. permissible transverse force on the gear unit drive shaft for option W Section 3.8 T u C Permissible ambient temperature range F A2 kn Max. permissible axial force on the gear unit driven shaft Section 3.8 F A1 kn Max. permissible axial force on the gear unit drive shaft for option W Section 3.8 MI h Interval between general overhauls of the gear unit in operating hours or details of the non-dimensional maintenance class CM Section 5.2 Section 5.2 x R2 mm Max. dimension for the point of application of the transverse force F R2 Section 3.8 Oil - Gear unit oil type (standard designation) Section 6.2 Last line - Labelling as per ATEX (DIN EN ): 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) Section Temperature class (T1-T3 or T4 for gas) or max. surface temperature e.g. 125 C for dust) 6. Temperature measurement on commissioning (X) 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 P 1 is not exceeded. If the fields F R1, F R2, F A1 und F A2 are empty, the forces are zero. If the field x R2 is empty, the point of application of force F R2 is central on the drive shaft journal (See Figure 3-4). 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 B2000 GB -13-

29 3. Storage, preparation, installation 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 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 Type SK1Sl worm gear units do not depend on the configuration. 3.6 Preparing for installation 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. 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. Oil expansion tanks (Option OA) must be fitted in accordance with the attached works standard WN For M10x1 screw fixings, the attached works standard WN 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 B2000 GB

30 3. Storage, preparation, installation Figure 3-2: Activation of the pressure vent 3.7 Installing the gear unit 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. 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 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: 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. B2000 GB -15-

31 3. Storage, preparation, installation 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 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 -16- B2000 GB

32 3. Storage, preparation, installation Drive and driven elements, such as belt drives, chain drives and couplings must be fitted with contact protection. 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 F R1 and F R and axial forces F A1 and F A as specified on the rating plate (See Section 3.4). Observe the correct tension, particularly on belts and chains. Additional loads due to unbalanced hubs are not permitted. 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 F R1 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 F R2 must not exceed the dimension x R2. If the transverse force F R2 for the driven shaft is stated on the rating plate, but no dimension x R2 is stated, the application of the force is assumed to be to the centre of the shaft journal. Free drive shaft (Option W) Driven shaft Figure 3-4: Permissible application of force to drive and driven shafts B2000 GB -17-

33 3. Storage, preparation, installation 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. Assembly and subsequent dismantling is aided by applying an anti-corrosive lubricant to the shaft before fitting. Figure 3-5: Applying lubricant to the shaft and the hub Note! The gear unit can be fitted to shafts with and without a shoulder using the fastening element (Option B). Tighten the bolt of the fastening element to the correct torque. (See Chapter 6.3 for torque values.) For gear units with option H66, the factory-fitted closing cap must be removed before fitting. For shaft mounted gear units with option H66 and fastening element (Option B) the pressed-in closing cap must be pushed out before fitting the gear unit. The pressed-in closing cap may be destroyed during dismantling. As standard a second closing cap is supplied as a loose spare part. After fitting the gear unit, fit the new / new condition closing cap as described in Section Figure 3-6: Removing the factory-fitted closing cap -18- B2000 GB

34 3. Storage, preparation, installation Figure 3-7: Gear unit mounted to shaft with a shoulder using the fastening element Figure 3-8: Gear unit mounted to shaft without a shoulder using the fastening element A gear unit can be dismantled from a shaft with shoulder using the following device, for example. Figure 3-9: Dismantling using dismantling device When mounting push-on gears with torque supports, the support must not be distorted. Tensionfree mounting is aided by the rubber buffer (Option G and/or VG). Figure 3-10: Mounting the rubber buffer (Option G and/or VG) on parallel shaft gear units B2000 GB -19-

35 3. Storage, preparation, installation Always support torque support on both sides! Figure 3-11: Attaching the torque support on bevel gear and worm gear units Tighten the bolts on the rubber buffer and the torque support to the correct torque (see Section 6.3 for torque values) and secure to prevent loosening (e.g. Loctite 242, Loxeal 54-03) Fitting shrink discs Shrink disc type, Mat. No. and torque details for tensioning screws Tensioning flanges Solid shaft of machine Tensioning screws DIN 931 (933) Shaft and hollow shaft bore GREASE FREE! Hollow shaft of gear unit The shrink discs are supplied by the manufacturer ready for fitting. They must not be dismantled prior to fitting. Double half-slotted inner ring Figure 3-12: Hollow shaft with shrink disc Attention! Do not tighten the tensioning screws if the shaft is not inserted! Assembly sequence: 1. Remove any transport securing devices. 2. Loosen but do not remove tightening bolt and tighten gently by hand until there is no play between the flanges and the inner ring B2000 GB

36 3. Storage, preparation, installation 3. Slide the shrink disc onto the hollow shaft until the outer clamping flange is flush with the hollow shaft. The shrink disc is easier to slide on if the bore of the inner ring is lightly greased. 4. Prior to mounting, grease the solid shaft only in the area which will later come into contact with the bronze bush in the hollow shaft of the gear unit. Do not grease the bronze bush, in order to prevent grease penetrating the area around the shrink connection. 5. The hollow shaft of the gear unit must be completely de-greased and completely free of grease. 6. In the area of the shrink connection the solid shaft of the machine must be degreased and completely free of grease. 7. Insert the solid shaft of the machine into the hollow shaft so as to completely fill the area around the shrink connection. 8. Position the clamping flange by gently tightening the bolts. 9. Tighten the bolts successively in a clockwise direction by several turns not crosswise with approx. ¼ rotation per turn. Tighten the bolts with a torque wrench to the torque indicated on the shrink disc. 10. When the tensioning bolts have been tightened, there must be an even gap between the clamping flanges. If this is not the case, the gear unit must be dismantled and the shrink disc connection checked for correct fit. 11. The hollow shaft of the gear unit and the solid shaft of the machine should be marked with a line (felt-tip pen) in order to detect any slippage under load. Risk of injury from incorrect mounting and dismantling. Dismantling sequence: 1. Loosen the bolts successively in a clockwise direction by several turns with approx. ¼ rotation per turn. Do not remove the bolts from their thread. 2. Loosen the clamping flanges from the cone of the inner ring. 3. Remove the gear unit from the solid shaft of the machine. If a shrink disk has been in use for a long period or is dirty, it must be dismantled, cleaned and the conical surfaces coated with Molykote G Rapid Plus or a similar lubricant before it is refitted. The treads and head surfaces of the screws must be treated with grease without Molykote. In case of damage or corrosion, damaged components must be replaced Fitting the covers Shrink disks require protection against contact. Covers (Option H) serve as contact protection. These must always be used if contact protection is not provided by other methods. B2000 GB -21-

37 3. Storage, preparation, installation Covers must be inspected for transportation damage e.g. dents and warping before they are fitted. Damaged covers must not be used, as they may cause rubbing. All fixing screws must be used and coated prior to use with a securing lubricant e.g. Loctite 242, Loxeal and tightened to the correct torque. (See Section 6.3 for torque values) For covers with option H66, press in the new / new condition closing cap by tapping it lightly with a hammer. Figure 3-13: Fitting the covers, Option SH, Option H, and Option H Fitting a standard motor Only standard motors with an adequate ATEX Zone category according to the rating plate may be used. In addition, for ATEX category 2D gear units (see the ATEX labelling on the last line of the gear unit rating plate), the motor must have at least protection class IP6x. The maximum permitted motor weights indicated in the table below must not be exceeded: Maximum permitted motor weights IEC motor size NEMA Motor size 56C 143T 145T 182T 184T 210T 250T 280T 324T 326T 365T Max. motor weight [kg] Assembly procedure to attach a standard motor to the IEC adapter (Option IEC)/NEMA adapter 1. Clean motor shaft and flange surfaces of motor and adapter and check for damage. Mounting dimensions and tolerances of the motor must conform to DIN EN 50347/NEMA MG1 Part Push the coupling sleeve onto the motor shaft so that the motor parallel key engages into the groove in the sleeve on tightening. 3. Tighten the coupling sleeve on the motor shaft in accordance with the motor manufacturer s instructions until it touches the collar. With motor sizes 160, 180 and 225, any spacer bushes must be positioned between the coupling sleeve and the collar. With standard helical gear units, dimension B between the coupling sleeve and the collar must be observed (see Figure 3-14). Certain NEMA adapters require the adjustment of the coupling in accordance with the specifications indicated on the adhesive plate B2000 GB

38 3. Storage, preparation, installation 4. Secure the coupling half with the threaded pin. The threaded pin must be coated prior to use with a securing lubricant e.g. Loctite 242, Loxeal and tightened to the correct torque. (See Chapter 6.3 for torque values) 5. The flange surfaces of motor and adapter must be completely coated with surface sealant e.g. Loctite 574 or Loxeal prior to mounting the motor, so that the flange seals after mounting. (only necessary for category 2D gear units see ATEX labelling on the last line of the gear unit rating plate) Sealing of the flange surfaces is also recommended for installation outdoors or in damp environments. 6. Mount the motor to the adapter. Do not forget to fit the gear rim or the sleeve. (See Figure 3-14) 7. Tighten the adapter bolts to the correct torque. (See Chapter 6.3 for torque values) Figure 3-14: Fitting the coupling onto the motor shaft - various types of coupling I II III IV Gear coupling (BoWex ), one-part Gear coupling (BoWex ), two-part Gear coupling (BoWex ), two-part with spacer bush Claw coupling (ROTEX ), two-part V Claw coupling (ROTEX ), two-part, observe dimension B: VI Standard helical gear unit: SK0, SK01, SK20, SK25, SK30, SK33 (2-stage) SK010, SK200, SK250, SK300, SK330 (3-stage) IEC size 63 IEC size 71 Dimension B (Figure 3-12 V) B = 4.5mm B = 11.5 mm Claw coupling (ROTEX ), two-part with spacer bush 3.13 Subsequent paintwork With subsequent painting of the gear unit, the radial seals, rubber elements, vent valves, hoses and motor coupling components must not come into contact with paints, lacquers and solvents. B2000 GB -23-

39 3. Storage, preparation, installation 3.14 Temperature sticker With temperature class T4 gear units with a maximum surface temperature of less than 135 C the supplied self-adhesive temperature sticker (printed with value 121 C) must be affixed to the gear unit housing. (Part No.: ). The temperature class or the maximum surface temperature can be seen from the ATEX labelling in the last line of the rating plate. Examples: II 2G c IIC T4 X or II 3D 125 C X The temperature sticker must be affixed next to the oil level screw (See Section 6.1) towards the motor. For gear units with an oil level vessel, the temperature sticker must be affixed in the same position as for gear units without an oil level vessel. For gear units which are lubricated for life, without oil maintenance, the temperature sticker should be affixed next to the rating plate. Figure 3-15: Position of the temperature sticker 3.15 Fitting the cooling coil to the cooling system The cooling coil is recessed into the housing cover (See Item 2, Figure 3-16). Cutting ring screw threads (see Item 1, Figs. 3-16) are located at the casing cover for the connection of a pipe with an external diameter of 10 mm according to DIN Remove the drain plug from the screw neck prior to assembly to avoid any contamination of the cooling system. The screw necks should be connected with the coolant circuit, which must be provided by the operator. The flow direction of the coolant is irrelevant. Make sure not to twist the screw necks during or after assembly as the cooling coil may be damaged (see Item 3, Figure 3-16). You must ensure that no external forces act on the cooling coil Figure 3-16: Cooling cover -24- B2000 GB

40 4. Commissioning 4 Commissioning 4.1 Check the oil level Before commissioning, the oil level must be checked with the supplied dipstick. The installation must comply with the configuration on the rating plate. Section 6.1 describes the versions and the corresponding oil level screws. With double gear units, the oil level must be checked on both units. The pressure vent must be at the position marked in Section 6.1. The oil level does not need to be checked on gear units without oil level screw (see Section 6.1). Gear unit types that are not supplied full of oil must be filled before the oil level is checked. (See Section 5.2) Checking the oil level: 1. The oil level must only be checked when the gear unit is at a standstill and has cooled down. The gear unit must be secured to prevent accidental switch-on. 2. Gear units with oil level screw: Standard configuration V1 and V5 helical gear units have an angled pipe for checking the oil level. This must point vertically upwards as shown in Figure 4-1 C. Before checking the oil level, the pressure vent must be unscrewed. (See Figure 3-2, right) The oil level screw corresponding to the version must be screwed out. (See Section 6.1) The oil level in the gear unit should be checked with the supplied dipstick (Part No.: ) as shown in Figure 4-1 A, C. To do this, the part of the dipstick which is submerged in the oil must be held vertically. The maximum oil level is the lower edge of the oil level hole. The minimum oil level is approx. 4 mm below the lower edge of the oil level hole. The dipstick then just dips into the oil. If the oil level is not correct, it must be adjusted by draining off oil or topping up with the type of oil stated on the rating plate. If the screw lock coating in the thread of the oil drain screw or oil level screw is damaged, a new oil level screw must be used or the thread cleaned and coated with securing adhesive, e.g. Loctite 242, Loxeal prior to insertion. The sealing ring must be replaced if damaged. Fit the oil level screw together with the sealing ring and tighten to the correct torque. (See Section 6.3 for torque values) If the pressure vent has been unscrewed, reinsert it together with the sealing ring and tighten to the correct torque. (See Section 6.3 for torque values) 3. Gear units with an oil level vessel: The oil level must be checked in the oil level vessel with the aid of the dipstick plug (thread G1 1/4). The oil level must be between the upper and lower marking when the dipstick is fully screwed in (see Figure 4-1 B). These gearboxes may only be operated in the configuration stated in Section Gear units with oil inspection glass: The oil inspection glass provides the possibility of checking whether oil is circulated by the moving parts in the gear unit housing during operation. B2000 GB -25-

41 4. Commissioning Check the oil level as described under 2. The oil level must be checked by means of its position in the oil inspection glass. 5. Final check: Previously loosened screws must be correctly tightened. Figure 4-1: Check the oil level with a dipstick 4.2 Activating the Automatic Lubricant Dispenser A B C Some gear unit types with standard motor (Option IEC/NEMA) have an automatic lubricant dispenser for the rolling bearings. This dispenser must be activated prior to commissioning. The cartridge case cover has a red information sign for the activation of the lubricant dispenser. Activating the Automatic Lubricant Dispenser: 1. Loosen and remove cylinder bolts M8x16 (1) 2. Lift off cartridge case cover (2) 3. Insert activation screw (3) into the lubricant dispenser (5) until the lug (4) breaks off at the defined fracture point 4. The flange surfaces of the cartridge case cover (2) must be completely coated with surface sealant e.g. Loctite 574 or Loxeal prior to assembly, so that the cover seals after it has been fitted. (Only necessary for Category 2D gear units see ATEX labelling, last line of the rating plate) 5. Refit cartridge case cover (2) and fasten using cylinder bolt (1). (See Chapter 6.3 for torque values) 6. Mark activation date on the adhesive plate (6) indicating month/year Attention! Screw in the activation screw until the lug breaks off before commissioning the gear unit. Dispensing time: 12 Months Month Activation date Year B2000 GB

42 4. Commissioning Figure 4-2: Activating the automatic lubricant dispenser with standard motor mounting 4.3 Temperature measurement The details of the ATEX temperature class or the maximum surface temperature are based on normal installation conditions (See Section 3.6). Even small changes to the installation conditions can have a significant effect on the temperature of the gear unit. On commissioning, a surface temperature measurement of the gear unit must be made under maximum load. (This does not apply to gear units which are labelled as temperature class T1 T3 or a maximum surface temperature of 200 C in the last line of the rating plate.) For the measurement, a normal temperature measuring device is required, with a measurement range from 0 C to 130 C and a precision of at least ± 4 C and which enables the measurement of the surface temperature and the temperature of the air. Temperature measurement procedure: 1. Allow the gear unit to run at maximum speed under maximum load for approx. 4 hours. 2. After it has warmed up, measure the temperature of the surface of the gear unit housing T gm immediately next to the temperature label (See Section 3.14). 3. Measure the temperature of the air T um in the immediate vicinity of the gear unit. The gear unit must be shut down and Getriebebau NORD must be consulted if any of the following criteria do not apply: The measured air temperature T um is within the permissible range stated on the rating plate. The measured temperature of the surface of the gear unit housing T gm is below 121 C and the temperature sticker has not turned black. (See Figure 4-3) The measured temperature of the surface of the gear unit housing plus the difference between the highest permissible air temperature Tu stated on the rating plate and the measured air temperature must be at least 15 C lower than the maximum permissible surface temperature, i.e.: ATEX labelling: II 2G c T4 / II 3G T4: T gm + T u T um < 135 C 15 C ATEX labelling: II 2D c T max / II 3D T max : T gm + T u T um < T max 15 C T gm : measured temperature of the surface of the gear unit housing in C T um : measured air temperature in C T max : maximum surface temperature according to gear unit rating plate (ATEX labelling) in C T u : upper value of the permissible ambient temperature range according to the rating plate in C B2000 GB -27-

43 4. Commissioning Centre dot is white: OK Figure 4-3: Temperature sticker Centre is black: Temperature was too high 4.4 Operation with lubricant cooling The drive may only be commissioned after the cooling spiral has been connected to the cooling circuit, and the cooling circuit has been put into operation. The coolant must have a similar thermal capacity as water (specific thermal capacity at 20 C c=4.18 kj/kgk). Industrial water without any air bubbles or sediments is recommended as a coolant. The water hardness must be between 1 dh and 15 dh, and the ph value must be between ph 7.4 and ph 9.5. No aggressive liquids should be added to the coolant! The coolant pressure must not exceed 8 bar. The required quantity of coolant is 10 litres/minute, and the coolant inlet temperature should not exceed 40 C; we recommend 10 C. We also recommend fitting a pressure reducer at the coolant inlet to avoid any damage due to excessive pressure. If there is a danger of frost the operator should add a suitable anti-freeze solution to the cooling water. The temperature of the cooling water and the cooling water flow rate must be supervised and ensured by the operator. The ATEX approval is void if these instructions are not observed! -28- B2000 GB

44 4. Commissioning 4.5 Checking the gear unit During a test run under full load, the gear unit should be checked for: Unusual noises, such as grinding, knocking or rubbing noises Unusual vibrations, oscillations and movements Production of steam or smoke After the test run, the gear unit should be checked for: Leaks Slippage of the shrink disks. For this, the cover should be removed and a check carried out whether the marking described in Section 3.10 shows a relative movement of the hollow shaft of the gear unit and the machine shaft. Then the cover should be fitted as described in Section The drive must be shut down and Getriebebau Nord consulted if any irregularities are observed during the checks described above. 4.6 Checklist Checklist Object of the check Checked on: Information see Section Is any transportation damage or damage apparent? Section 3.3 Does the labelling on the rating plate conform to the specifications? Section 3.4 Does the configuration on the rating plate conform to the actual installation? Section 0 Is the pressure vent screwed in? Section 3.6 Do all drive and driven elements have ATEX approval? Are the external gear shaft forces within permitted limits (chain tension)? Section Section Are contact guards fitted to rotating components? Section 0 Does the motor also have a relevant ATEX approval? Section 3.12 Is the temperature sticker affixed? Section 3.14 Has the correct oil level for the configuration been checked? Section 4.1 Is the automatic lubricant dispenser activated? Section 4.2 Has the temperature measurement been carried out? Section 4.3 Has the centre of the temperature sticker turned black? Section 4.3 Is the cooling cover connected to the cooling circuit? Section 3.15/4.4 Has the gear unit been checked with a test run? Section 4.5 Has the shrink disk connection been checked for slippage? Section B2000 GB -29-

45 4. Commissioning 4.7 Operation of the gear unit in explosive areas When operating the gear unit, the instructions in this operating manual must be complied with. The prescribed inspection and servicing intervals must be complied with. It must be ensured that the power ratings stated on the rating plate are not exceeded. If, e.g. for variable speed drive units, there are several operating points, the maximum permissible drive power P 1 or the maximum permissible torque on the driven shaft M 2 or the maximum permissible speed must not be exceeded at any operating point. Overload of the gear unit must be ruled out. If the gear unit is equipped with a cooling coil, it may only be put into operation if the cooling coil has been connected to the cooling circuit and the cooling circuit is in operation. The temperature of the cooling fluid and the cooling fluid flow rate must be monitored and ensured by the operator. Gear units with an integrated back stop on the drive shaft may only be operated at more than the minimum speed of the gear unit drive shaft, n 1min = 900 min -1. During operation, no electrostatic charging mechanisms (e.g. friction on the housing surface) may act on the surface of the gear unit. During operation, if any of the irregularities described in Section 4.5 are detected, or the temperature sticker has turned black, the gear unit must be shut down and Getriebebau NORD must be consulted B2000 GB

46 5. Service and maintenance 5 Service and maintenance 5.1 Service and Maintenance Intervals Service and Maintenance Intervals Service and Maintenance Work Information see Section Weekly or every 100 operating hours Every 2500 operating hours, at least every six months Every 5000 operating hours, at least every year (Only for standard IEC/NEMA motor attachment) Every operating hours, at least every 2 years According to the interval specified in field MI of the rating plate at least every 10 years (Only for Category 2G and 2D) - Perform a visual inspection for leaks - Check the gear unit for unusual running noises and/or vibrations - Only for gear units with cooling cover: Visual inspection of temperature sticker - Check oil level - Visual inspection of rubber buffer - Visual inspection of hose - Visual inspection of temperature sticker - Remove dust (only for category 2D) - Check coupling (Only for category 2G and standard IEC/NEMA motor attachment) - Re-grease (applicable only to free drive shaft / Option W and for agitator bearings / Option VLII / VLIII) / Replace the automatic lubricant dispenser 5.2 / Changing the oil - Check the cooling coil for deposits General overhaul Service and Maintenance Work No explosive atmosphere must be present during servicing and repair work. Servicing and maintenance work must only be performed by qualified specialist personnel. When cleaning the gear unit, do not use procedures or materials which may cause electrostatic charging of the gear unit or adjacent non-conducting components. 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. B2000 GB -31-

47 5. Service and maintenance Visual inspection for leaks: The gear unit must be checked for leaks. Attention should be paid to escaping gear oil and traces of oil on the exterior or underneath the gear unit. In particular, the radial seals, cover caps, screw plugs, hoses and housing joints should be checked. If leaks are suspected, the gear unit should be cleaned and checked again for leaks after approx. 24 hours. If a leak is confirmed (dripped oil), the gear unit must be repaired immediately. Please contact the NORD service department. If the gear unit is equipped with a cooling coil in the housing cover, the connections and the cooling coil must be checked for leaks. If there are any leaks, these must be repaired immediately. Please contact the NORD service department. Check for running noises If the gear unit produces unusual running noises and/or vibrations, this could indicate damage to the gear unit In this case the gear should be shut down and a general overhaul carried out. Checking the oil level: See Section 4.1 Visual inspection of the rubber buffer Gear units with rubber buffers (Option G or VG) and gear units with torque supports are equipped with rubber elements. If these show damage such as tears to the rubber surface, the elements must be replaced. Please contact the NORD service department. Visual inspection of hose Gear units with an oil level vessel (Option OT) have rubber hoses. If damage to the external surface of the hoses as far as where they are inserted occurs, e.g. due to abrasions, cuts or tears, they must be replaced. Please contact the NORD service department. Visual inspection of the temperature sticker (Only necessary for temperature class T4 or max. surface temperature < 135 C) The temperature sticker must be checked that it has not turned black (See Figure 4-3). If the temperature sticker has turned black, the gear unit has become too hot. The cause of overheating must be established. Please contact the NORD service department immediately. The drive unit must not resume operation before the cause of overheating has been remedied and renewed overheating can be ruled out. Before recommissioning, a new temperature sticker must be affixed to the gear unit (See Section 3.14) B2000 GB

48 5. Service and maintenance Remove dust (Only necessary for Category 2D) Dust deposits on the gear unit housing must be removed if they are more than 5 mm thick. With gear units fitted with a covering cap (Option H) the covering cap must be removed. Dust deposits in the covering cap, on the driven shaft and on the shrink disk must be removed. Then the covering cap must be fitted (See Section 3.11). Note: Some covering caps can be completely sealed with liquid sealing agent. In such cases, there is no need for regular cleaning of the covering cap if it is completely sealed with a liquid sealing agent such as Loctite 574 or Loxeal Checking the coupling (Only necessary for Category 2G and IEC/NEMA standard motor attachments) The motor must be removed. Plastic or elastomer coupling components must be examined for traces of wear. If the limiting values listed below for the particular coupling versions and sizes are exceeded, the plastic or elastomer coupling components must be replaced. Caution: only use replacement parts with the same colour! With claw couplings (ROTEX ) the tooth thickness of the elastomer gear rim must be measured as per Figure 5-1. B min is the minimum permissible tooth thickness. Limiting wear values for coupling gear rims Type R14 R24 R38 R42 R48 R65 R90 B Bmin Figure 5-1: Measurement of gear rim wear with ROTEX claw couplings For gear couplings, the limiting wear value is X = 0.8 mm, as per Figure 5-2. Sleeve Sleeve Hub Hub New Wear limit X = 0.8mm Figure 5-2: Measurement of gear sleeve wear for gear BoWex couplings Note! If the examination only shows slight wear (25% of the limiting value), it is permissible to extend the interval for examination of the coupling to twice the normal period, i.e operating hours and at least every year. B2000 GB -33-

49 5. Service and maintenance Regreasing Some gear unit designs (free drive shaft, Option W, agitator designs VLII and VLIII) are equipped with a regreasing device. For agitator versions VLII and VLIII, the vent screw located opposite to the grease nipple must be unscrewed before regreasing. Grease should be injected until a quantity of 20-25g escapes from the vent hole. After this, the vent plug must be reinserted and tightened. For Option W and some IEC adapters, the outer roller bearing must be regreased with approx g of grease via the grease nipple provided Recommended grease: Petamo GHY 133N (see Section 6.4: Klüber Lubrication). Replacing the automatic lubricant dispenser Screw-off the cartridge case cover (2), (see Figure 4-2). The lubrication dispenser (5) is screwed out and replaced with a new component (Part No ). Then activate (see Chapter 4.2)! Changing the oil The figures in Section 6.1 show the oil drain screw, the oil level screw and the pressure vent screw for various designs. Sequence: 1. Place the drip tray below the oil drain screw 2. Completely remove oil level screw, screwed sealing plug with dipstick if an oil level tank is being used and oil drain screw. Warning: Hot oil! 3. Drain all the oil from the gear unit. 4. If the screw lock coating of the oil drain screw or oil level screw is damaged in the thread, a new oil level screw must be used or the thread cleaned and coated with securing lubricant, e.g. Loctite 242, Loxeal prior to inserting. The seal ring must be replaced if damaged. 5. Support the seal ring, insert the oil drain screw into the hole and tighten to the correct torque! (See Chapter 6.3 for torque values) 6. Using a suitable filling device, refill with new oil of the same type (see rating plate, Sections 3.4and 6.2) through the oil level hole until oil emerges from the oil level hole. (The oil can also be filled through the pressure vent screw or a sealing plug located higher than the oil level). If an oil level vessel is used, fill the oil through the upper inlet (thread G1¼) until the oil level is set as described in Section Wait at least 15 minutes, or at least 30 minutes if an oil level tank is used, and then check the oil level. Proceed as described in Section 4.1. Note! The oil does not need to be changed on gear units without oil level screw (see Section 6.1). These gear units are lubricated for life B2000 GB

50 5. Service and maintenance Note! Standard ATEX category 3G and 3D helical gear units (See rating plate, Section 3.4) do not have an oil level screw. Here, the oil is topped up through the threaded pressure vent bolt using the quantities listed in the table in the following table. [L] [L] M1, M3, M5, M6 M2, M4 M1, M3, M5, M6 M2, M4 SK0 0,13 0,22 SK0 F 0,13 0,22 SK01 0,22 0,38 SK01 F 0,22 0,38 SK20 0,55 1,00 SK20 F 0,35 0,60 SK25 0,50 1,00 SK25 F 0,50 1,00 SK30 0,70 1,40 SK30 F 0,70 1,40 SK33 0,80 1,60 SK33 F 0,80 1,60 SK000 0,24 0,41 SK000 F 0,24 0,41 SK010 0,38 0,60 SK010 F 0,38 0,60 SK200 0,80 1,30 SK200 F 0,60 1,04 SK250 1,40 1,50 SK250 F 1,40 1,50 SK300 1,40 1,50 SK300 F 1,40 1,50 SK330 1,50 1,58 SK330 F 1,50 1,58 Check the cooling coil for deposits The inner surface of the cooling coil must be checked for deposits, as in case of severe deposits (fouling) the dissipation of heat is no longer guaranteed. In this case, the cooling coil must be cleaned. If a chemical cleaner is used, it must be ensured that the cleaning agent does not attack the material of the cooling coil (Cu pipe and yellow brass fittings) General overhaul With Category 2G and 2D gear units, a general overhaul is necessary after a specified longer period of operation. The specification of the operating period in terms of operating hours, after which a general overhaul must be carried out, can be seen from the rating plate data in field MI. Alternatively, the maintenance class CM can be used to determine the operating period after which a general overhaul must be carried out. The data in field MI of the rating plate is then e.g.: MI CM=5. The time for the general overhaul with the stated maintenance class CM is calculated as follows: N A = C M f L k A N A : Number of years since commissioning. With calculated values of N A which exceed 10 years, a general overhaul is due 10 years after commissioning. C M : Maintenance class according to field MI of the rating plate B2000 GB -35-

51 5. Service and maintenance f L : Running time factor f L = 10 f L = 6 f L = 3 f L = 1.5 f L = 1 Maximum running time 2 hours per day Running time 2 to 4 hours per day Running time 4 to 8 hours per day Running time 8 to 16 hours per day Running time 16 to 24 hours per day k A : Utilisation factor If the utilisation factor is unknown, K A =1. If the actual power required by the application is known, longer maintenance intervals may result. The utilisation factor may be calculated as follows: k A 3 P 1 = Ptat P 1 : Max. permissible drive power or motor power in kw according to the rating plate P tat : Actual drive power or motor power in kw which is required by the application at the rated speed. This is determined e.g. by measurements. With variable loads with differing actual drive powers with rated speeds P tat1, P tat2, P tat3, with known percentage times q 1, q 2, q 3,, the following equivalent average drive power applies: P q tat = Ptat1 + Ptat2 + Ptat q 100 q The general overhaul must be carried out by qualified personnel in a specialist workshop with appropriate equipment in observance of national regulations and laws. We urgently recommend that the general overhaul is carried out by NORD Service. If a general overhaul is due, the gear unit must be completely dismantled. The following work must be carried out: Clean all gear unit components Examine all gear unit components for damage All damaged components must be replaced All roller bearings must be replaced Replace back stops if fitted Replace all seals, radial seals and Nilos rings Replace plastic and elastomer components of the motor coupling -36- B2000 GB

52 6. Appendix 6 Appendix 6.1 Versions and maintenance For versions which are not listed, please refer to the special documentation drawing. (See rating plate Section 3.4). Explanation of symbols for the following version illustrations: Vent Oil level Oil drain Standard helical gear units Standard ATEX category 3G and 3D helical gear units do not have oil filling screws. (See rating plate, Section 3.4) Parallel shaft gear units The following illustration applies for the version M4/H5 of gear unit types SK9282, SK9382, SK10282, SK10382, SK11282, SK11382 and SK12382 with oil level vessel. Figure 6-1: Parallel shaft gear units with oil level vessel Oil level screws are not fitted to gear unit types SK 0182 NB, SK 0282 NB and SK 1382 NB in the ATEX Categories 3G und 3D. (See rating plate, Section 3.4). In Category 2G and 2D, types SK 0182 NB, SK 0282 NB and SK 1382 NB only have one oil level screw. These gear unit types have checkable life-long lubrication NORDBLOC helical gear units Gear unit types SK 320, SK 172, SK 272, SK 372 and SK 273 and SK373 are not fitted with oil level screws for ATEX Categories 3G and 3D. (See rating plate, Section 3.4). In Category 2G and 2D, types SK 320, SK 172, SK 272, SK 372 and SK 273 and SK 373 only have one oil level screw. These gear unit types have checkable life-long lubrication. B2000 GB -37-

53 6. Appendix NORDBLOC helical gear units SK072.1 and SK172.1 Oil level check in the M4 installation orientation for SK072.1 and SK172.1: The oil level check for the M4 installation orientation must be carried out as follows in the installation orientation M2: 1. Bring the gear unit into the M2 installation orientation and remove the oil level screw for the M2 orientation. Figure 6-2: Bring the gear unit into the M2 installation orientation 2. Determine the measurement X between the upper edge of the gear unit housing and the oil level. If necessary, adapt the dipstick (see below). Upper edge of housing X Oil level Figure 6-3: Measuring the oil level 3. Compare the determined measurement X with the corresponding measurement in the following table. If necessary, adjust the oil level with the type of oil shown on the rating plate. Gear unit type Thread size Measurement X [mm] SK M8x1 22 ± 1mm SK M8x1 20 ± 1mm 4. Screw in and tighten the oil level screw in the installation orientation M2 as per Section Bring the gear unit back into the installation orientation M B2000 GB

54 6. Appendix UNIVERSAL worm gear units SK 1SI31 SK 1SI75 SK 1SIS31 SK 1SIS75 Figure 6-4: Orientation for oil level check. For the oil level check, the gear unit or the geared motor must be brought into the orientation shown above. To do this, it may be necessary to remove the gear unit or the geared motor. NB: An adequate resting time of the warm gear unit in the position shown in Figure 6-4 must be observed, in order to allow the oil to settle evenly. The oil level can then be checked as described in Section 4.1. In Category 2G and 2D the gear units only have one oil level screw. These gear unit types have a checkable life-long lubrication. In ATEX Category 3G and 3D, the gear units are not fitted with an oil level screw (See rating plate, Section 3.4). SK 1SD31 SK 1SD63 SK 2SD40 SK 2SD63 SK 1SIS-D31 SK 1SIS-D63 SK 2SIS-D40 SK 2SIS-D63 M1 H1 M6 H6 M2 H4 M4 H3 M5 H5 M3 H2 These gear units may only be used in ATEX Categories 3G and 3D. B2000 GB -39-

55 M1 B3+B5 M1 B3+B5 M6 B7+B5III M2 V6+V3 M6 B7+B5III M2 V6+V3 SK 11E SK 21E SK 31E SK 41E SK 51E SK 02 SK 12 SK 22 SK 32 SK 42 SK 52 SK 62N M4 V5+V1 M5 B6+B5II M4 V5+V1 M5 B6+B5II M3 B8+B5I M3 B8+B5I M1 B3+B5 * M1 B3+B5 M6 B7+B5III M2 V6+V3 M6 B7+B5III M2 V6+V3 SK 03 SK 13 SK 23 SK 33N SK 43 SK 53 SK 62 SK 72 SK 82 SK 92 SK 102 SK 63* SK 73* SK 83* SK 93* SK 103* * M4 V5+V1 M5 B6+B5II M4 V5+V1 M5 B6+B5II M3 B8+B5I M3 B8+B5I -40- B2000

56 * M1 B3+B5 M1 M6 B7+B5III M2 V3+V6 M6 M2 SK 472 SK 572 SK 672 SK 772 SK 872 SK 972 SK 473 SK 573 SK 673 SK 773 SK 873* SK 973* SK SK SK SK SK SK M4 V1+V5 M5 B6+B5II M4 M5 M3 B8+B5I M3 M1 M1 * M6 SK 372.1F SK 572.1F SK 672.1F SK 373.1F SK 573.1F SK 673.1F M2 * M6 SK SK SK SK 773.1* SK 873.1* SK 973.1* M2 * M4 M5 M4 * M5 M3 M3 B

57 M1 * * M6 SK 772.1F SK 872.1F SK 972.1F SK 773.1F* SK 873.1F* SK 973.1F* M2 * M4 * M5 M3 M1 M1 M6 M6 M2 M2 SK SK SK F SK F M4 M5 M4 M5 M3 M4 38 M3-42- B2000

58 M1 B3+B5 M2 V6+V3 M6 B7+B5III SK 0 SK 01 SK 20 SK 25 SK 30 SK 33 M4 V1+V5 M5 B6+B5II M3 B8+B5I M1 B3+B5 M2 V6+V3 M6 B7+B5III SK 000 SK 010 SK 200 SK 250 SK 300 SK 330 M4 V1+V5 M5 B6+B5II M3 B8+B5I II3G / II3D 35, 37 B

59 M1 H1 M1 H1 M6 H3 M2 H6 M6 H3 M2 H6 SK 1282 SK 2282 SK 3282 SK 4282 SK 5282 SK 2382 SK 3382 SK 4382 SK 5382 M4 H5 M5 H4 M4 H5 M5 H4 M6 H3 M3 H2 M1 H1 M2 H6 M6 H3 M3 H2 M1 H1 * M2 H6 M4 H5 SK 6282* SK 7282* SK 8282* SK 9282* SK 10282* SK 11282* SK 6382 SK 7382 SK 8382 SK 9382 SK SK SK * M5 H4 * M4 H5 SK 0182NB SK 0282NB SK 1382NB ** ** M5 H4 * M3 H2 37 M3 H2-44- B2000

60 M1 B3 M1 B3 M4 B3I M6 V6 SK SK SK SK M2 B6 M4 B3I M6 V6 SK M2 B6 M5 V5 M5 V5 M3 B8 M3 B8 M6 V6 M1 B3 M2 B6 M6 V6 M1 B3 M2 B6 M4 B3I SK SK SK SK SK SK SK SK SK SK SK SK M4 B3I SK SK SK SK SK SK M5 V5 M5 V5 M3 B8 M3 B8 B

61 M1 H1+B5I M1 H1+B5I M6 H6+V3 M2 H4+B5 M6 H6+V3 M2 H4+B5 SK SK SK SK SK M4 H3+B5II M5 H5+V1 M4 H3+B5II M5 H5+V1 M3 H2+B5III M3 H2+B5III M1 H1+B5I M6 H6+V3 M2 H4+B5 M6 H6+V3 M1 H1+B5I M2 H4+B5 SK SK SK SK SK SK SK SK SK SK SK SK SK SK SK SK SK SK M4 H3+B5II M5 H5+V1 M4 H3+B5II M5 H5+V1 M3 H2+B5III M3 H2+B5III -46- B2000

62 M1 B3 M1 B3 M6 V6 M4 B3I SK SK SK SK SK M2 B6 M6 V6 M4 B3I SK SK SK SK SK M2 B6 M5 V5 M5 V5 M3 B8 M3 B8 M1 H1+B5I M1 H1+B5I M6 H6+V3 SK SK SK SK SK M2 H4+B5 M6 H6+V3 SK SK SK SK SK M2 H4+B5 M4 H3+B5II M5 H5+V1 M4 H3+B5II M5 H5+V1 M3 H2+B5III M3 H2+B5III B

63 M1 B3 M6 V6 M2 B6 SK M4 B3I M5 V5 M3 B8 M1 H1+B5I M6 H6+V3 SK M2 H4+B5 M4 H3+B5II M5 H5+V1 M3 H2+B5III -48- B2000

64 M1 B3 M6 V5II M4 B6II SK 1S32- SK 1S63 SK 2S32NB SK 2S63NB SK 1SU32 SK 1SU63 SK 2SU32NB- SK 2SU63NB SK 1SM31 SK 1SM63 SK 2SM40 SK 2SM63 M2 B6 M5 V5 M3 B8 M1 H1+B5I M6 H6+V1I M4 H3+B5II SK 1S32- SK 1S63 SK 2S32NB SK 2S63NB SK 1SU32 SK 1SU63 SK 2SU32NB- SK 2SU63NB SK 1SM31 SK 1SM63 SK 2SM40 SK 2SM63 M2 H4+B5 M5 H5+V1 M3 H2+B5III 39 B

65 6. Appendix 6.2 Lubricants When changing oil or filling for the first time, the type of lubricant stated on the rating plate must be used. The following table shows the proprietary brands or product names according to the gear oil types stated on the rating plate (see Section 3.4). This means that a product corresponding to the type of oil shown on the rating plate must be used. Lubricant type Mineral oil Synthetic oil Biodegradable oil Foodstuffscompatible oil H1 as per FDA Type of oil stated on rating plate CLP 220 CLP 100 CLP PG 680 CLP PG 220 E 680 E 220 CLP PG H1 680 CLP PG H1 220 Alpha EP 220 Alpha SP Alphasyn GS Carelub GES Shell Omala S2 G Mobilgear 630 Mobilgear XMP 220 Shell Omala S2 G 100 Mobilgear: XMP 110 Shell Omala S4 WE 680 Glygoyle HE 680 Shell Omala S4 WE 220 Glygoyle HE Shell Naturelle Gear Oil EP Mobil DTE-FM Mobil DTE-FM 220 Gear unit oil type and name of product Spartan EP 220 Renolin CLP 220 Renolin CLP 220 Plus Klüberoil GEM Spartan EP 100 Renolin CLP 100 Renolin CLP 100 Plus Klüberoil GEM Renolin PG 680 Klübersynth GH Glycolube 220 Renolin PG 220 Klübersynth GH Plantogear 680 S Plantogear 220 S Klübersynth GEM Geralyn SF 680 Klübersynth UH Geralyn SF 220 Klübersynth UH B2000 GB

66 6. Appendix 6.3 Torque values Bolt Torques [Nm] Size Screw connections in the strength classes Sealing Threaded pin screws on coupling M M M M M M M M M M M M Angled pipe, as in Figure G1¼ Troubleshooting Gear unit malfunctions Fault Possible cause Remedy Unusual running noises, vibrations Oil escaping from gear unit or motor Oil escaping from pressure vent Gear unit becomes too hot Shock when switched on, vibrations Drive shaft does not rotate although motor is running Oil too low or bearing damage or toothed wheel damage Defective seal Incorrect oil level or incorrect, contaminated oil or unfavourable operating conditions Unfavourable installation conditions or gear unit damage Defective motor coupling or loose gear unit mounting or defective rubber element Fracture in gear unit or defective motor coupling or shrink disc slippage Consult NORD Service Consult NORD Service Oil change Use oil expansion tank (Option OA) Consult NORD Service Replace elastomer gear rim, tighten motor and gear unit fastening bolts, replace rubber element Consult NORD Service Warning: shut down the gear unit immediately if any faults occur! B2000 GB -51-

67 6. Appendix 6.5 Declaration of Conformity -52- B2000 GB

68 6. Appendix B2000 GB -53-

69 6.6 Getriebebau NORD national Niederlassung Nord Getriebebau NORD GmbH & Co. KG Tel.: +49(0) 4532 / Hamburg / Schleswig-Holstein / Postfach Bargteheide Fax: +49(0) 4532 / Niedersachsen Rudolf-Diesel-Straße Bargteheide info@nord-de.com Vertriebsbüro Bremen Getriebebau NORD GmbH & Co. KG Tel.: +49(0) 4249 / westliches Niedersachsen / Vertriebsbüro Bremen Fax: +49(0) 4249 / Bremen Wohlers Feld 16 nl-bremen@nord-de.com Bassum Niederlassung West Getriebebau NORD GmbH & Co. KG Tel.: +49(0) 211 / Köln / Koblenz / Niederlassung West Fax: +49(0) 211 / südl. Nordrhein-Westfalen / Großenbaumer Weg 10 nl-duesseldorf@nord-de.com Ruhrgebiet / Düsseldorf Düsseldorf Vertriebsbüro Butzbach Getriebebau NORD GmbH & Co. KG Tel.: +49(0) 6033 / Hessen / Frankfurt / Vertriebsbüro Butzbach Fax: +49(0) 6033 / Wiesbaden / Darmstadt Marie-Curie-Straße 2 nl-frankfurt@nord-de.com Butzbach Niederlassung Ost Getriebebau NORD GmbH & Co. KG Tel.: +49(0) 371 / Sachsen / südl. Sachsen-Anhalt / Niederlassung Ost Fax: +49(0) 371 / Thüringen Leipziger Straße 58 nl-chemnitz@nord-de.com Chemnitz / Sachsen Vertriebsbüro Berlin Getriebebau NORD GmbH & Co. KG Tel.: +49(0) 30 / Berlin / Brandenburg Vertriebsbüro Berlin Fax: +49(0) 30 / Mecklenb.-Vorpommern / Roedernstr. 8 nl-berlin@nord-de.com nördl. Sachsen-Anhalt Berlin Niederlassung Süd Getriebebau NORD GmbH & Co. KG Tel.: +49(0) 7158 / Stuttgart / Baden-Würtemberg / Niederlassung Süd Fax: +49(0) 7158 / Saarland / südl. Rheinland-Pfalz Katharinenstr nl-stuttgart@nord-de.com Filderstadt Sielmingen Vertriebsbüro Nürnberg Getriebebau NORD GmbH & Co. KG Tel.: +49(0) 911 / Nürnberg / Nord-Bayern Vertriebsbüro Nürnberg Fax: +49(0) 911 / Schillerstraße 3 nl-nuernberg@nord-de.com Stein -54- B2000

70 Getriebebau NORD International: AT Getriebebau NORD GmbH Deggendorfstraße 8, A-4030 Linz Tel.: Fax: AUS NORD Drivesystems 18 Stoney Way 3030 Derrimut Vic, Australia Tel: +61 (0) BE NORD Aandrijvingen Belgie N.V. Boutersem Dreef 24, B-2240 Zandhoven Tel.: Fax: BR Nord Motoredutores do Brasil Ltda. Rua Dr. Moacyr Antonio de Morais 700 CEP: São Paulo Tel.: Fax: CA Nord Gear Limited 41 West Drive, CDN - Brampton, Ontario L6T 4A1 Tel.: Fax: info@nord-ca.com CN NORD Drivesystems No. 510 Chang Yang Street, Suzhou Industrial Park, P.R. China, Jiangsu Province Tel.: Fax: jblock@nord-cn.com HR NORD-Pogoni d.o.o. Obrtnicka 9, HR Krizevci Tel.: Fax: info@nord-hr.com CZ NORD-Poháněcí technika, s. r. o. Bečovská 1398/11, CZ Praha 10 - Uhříněves Tel.: Fax: info@nord-cz.com DK NORD-Gear Danmark A/S Kliplev Erhvervspark 28 Kliplev, DK Aabenraa Tel.: Fax: info@nord-dk.com FI NORD Gear Oy Aunankorvenkatu 7, FIN Tampere Tel.: Fax: info@nord-fi.com FR NORD Réducteurs sarl Av. G. Clémenceau, F Villepinte Cedex Tel.: Fax: info@nord-fr.com HU NORD Hajtastechnika Kft. Törökkö u. 5-7, H-1037 Budapest Tel.: Fax: info@nord-hu.com IN Nord Drivesystem Pvt. LTD 282/2, 283/2, Village Mann, Tal. Mulshi, IN Pune Tel.: +91-(0) Fax: +91-(0) info@nord-in.com ID PT. NORD Indonesia Jln. Raya Serpong KM7 Kompleks Rumah Multi Guna Blok D-No. 1 Pakulonan, Serpong Tangerang - West Java Tel.: Fax: info@nord-id.com IT NORD-Motoriduttori s.r.l. Via Newton 22, IT San Giovanni In Persiceto (BO) Tel.: Fax: info@nord-it.com MX NORD Gear corporation Av. Lázaro Cárdenas 1007 Pte San Pedro Garza Caría, N.L. MX Mexico, C.P. Tel.: Fax: HGonzales@nord-mx.com NL NORD Aandrijvingen Nederland B.V. Voltstraat 12, NL-2181 HA Hillegom Tel.: Fax: info@nord-nl.com NO NORD Gear Norge AS Hestehagen 5, PB 1043, N 1442 Drøbak Tel.: Fax: info@nord-no.com PL NORD Napêdy sp. z o.o. Ul. Grottgera 30, PL Wieliczka Tel.: Fax: biuro@nord.pl RU OOO NORD Privody Ul.A. Nevsky 9, RU St. Petersburg Tel.: Fax: info@nord-ru.com SG NORD GEAR Pte. Ltd. 33 Kian Teck Drive, Jurong - Singapore Tel.: Fax: info@nord-sg.com SK NORD Pohony, s.r.o. Stromová 13, SK Bratislava Tel.: Fax: info@nord-sk.com ES NORD Motorreductores S.A. Aptdo. de Correos 166, ES Sabadell Tel.: Fax: info@nord-es.com SE NORD Drivsystem AB Ryttargatan 277 / Box 2097, SE Upplands Väsby Tel.: Fax: info@nord-se.com CH Getriebebau NORD AG Bächigenstr.18, CH-9212 Arnegg Tel.: Fax: info@nord-ch.com TR NORD-Drivesystems Güç Aktarma Sýstemlerý San. Ve. Ltd. Ptý Ticaret Ltd. Sti., TR Tuzla - Istanbul Tel.: Fax: info@nord-tr.com UKR Getriebebau NORD GmbH Vasilkovskaja 1, Office 100/3, Ukr Kyiv Tel.: Fax: vtsoka@nord-ukr.com UK Nord Gear Limited (UK) 11 Barton Lane, Abingdon Science Park, GB-Abingdon, Oxfordshire OX14 3NB Tel.: Fax: info@nord-uk.com US NORD Gear Corporation 800 Nord Drive, P.O. 367, USA-Waunakee, WI Tel.: , Fax: info@nord-us.com VN NORD Gear Pte. Ltd Unit 401, 4F, An Dinh Building, 18 Nam Quoc Cang Street Pham Ngu Lao Ward District 1, Ho Chi Minh City, Vietnam Tel: Fax: info@vn.nord.com B

71 Intelligent Drivesystems, Worldwide Services Getriebebau NORD GmbH & Co. KG Rudolf-Diesel-Str. 1 D Bargteheide Fon +49 (0) 4532 / Fax +49 (0) 4532 / info@nord.com DRIVESYSTEMS Part. No /4210