Edition. Planetary Gear Units P..RF.., P..KF.. Series 12/2002. Operating Instructions X / EN

Transcription

1 Planetary Gear Units P..RF.., P..KF.. Series Edition 12/2002 Operating Instructions X / EN

2 SEW-EURODRIVE

3 Contents M1 M6 1 Important Notes Safety Notes Extended storage Corrosion and exterior surface protection Gear Unit Design Design of a planetary gear unit Nameplate Structure Planetary gear unit nameplate RF../KF.. nameplate primary gear unit RF../KF.. nameplate primary gear unit as geared motor Mechanical Installation Required tools / resources Before you begin Preliminary work Installing the gear unit Gear units with solid shaft Flange mounting Foot mounting Installing torque arms for hollow shaft gear units Installation / removal of hollow shaft gear units and shrink disks Mounting the coupling of adapter AM Mounting the coupling of adapter AQ Mounting on input shaft assembly AD Inspection and Maintenance Inspection and maintenance periods Lubricant replacement Inspection and maintenance of the gear unit Malfunctions Mounting Positions General information about mounting positions Mounting positions of KF primary gear units Key to the mounting position sheets P.. RF.. DT/DV PH.. RF.. DT/DV PF.. RF.. DT/DV PHF.. RF.. DT/DV P.. KF.. DT/DV PH.. KF.. DT/DV PF.. KF.. DT/DV PHF.. KF.. DT/DV Oil expansion tank / oil riser pipe for the planetary gear unit Lubricants General information about lubricants Lubricant table Lubricant fill quantities Planetary geared motor with shared oil chamber Revision Index Address list Operating Instructions Planetary Gear Units P..RF.., P..KF.. 3

4 1 1 Important Notes Safety and warning instructions Always follow the safety and warning instructions contained in this publication! Electrical hazard Possible consequences: Severe or fatal injuries. Hazard Possible consequences: Severe or fatal injuries. Hazardous situation Possible consequences: Slight or minor injuries. Harmful situation Possible consequences: Damage to the drive and the environment. Tips and useful information. A requirement of fault-free operation and fulfillment of any rights to claim under guarantee is that you adhere to the information in the operating instructions. Consequently, read the operating instructions before you start operating the drive! The operating instructions contain important information about servicing; as a result, they should be kept in the vicinity of the unit. The planetary gear units are supplied without lubricants. RF../KF.. primary gear units have a lubricant fill in accordance with their mounting position. The oil chambers of both gear units are separate. Exceptions are specifically identified as such. Adjust the lubricant fill quantity and the position of the breather valve accordingly if you change the mounting position (see Sec. "Lubricants" and Sec. "Mounting positions"). Oil expansion tanks and/or an oil riser pipe are required if you change to a vertical mounting position. Please follow the instructions in Sec. "Mechanical installation" / "Installing the gear unit"! Waste disposal Please follow the current instructions: Housing parts, gears, shafts and anti-friction bearings of the gear units must be disposed of as steel scrap. The same applies to gray cast iron castings unless there are separate collection arrangements. Collect waste oil and dispose of it correctly. 4 Operating Instructions Planetary Gear Units P..RF.., P..KF..

5 2 2 Safety Notes Preliminary remarks The following safety notes are principally concerned with the use of gear units. For operation of geared motors, please also refer to the safety notes for motors in the corresponding operating instructions. Please also take account of the supplementary safety notes in the individual sections of these operating instructions. General information During and after operation, geared motors and gear units have live and moving parts and their surfaces may be hot. All work related to transportation, putting into storage, setting up/mounting, connection, startup, maintenance and repair should only be performed by trained personnel observing the corresponding detailed operating instructions and wiring diagrams, the warning and safety signs on the gear unit/geared motor, the specific regulations and requirements for the system and national/regional regulations governing safety and the prevention of accidents. Severe injuries and damage to property may result from incorrect use, incorrect installation or operation, unauthorized removal of the necessary protection cover. Designated use These geared motors/gear units are designed for operation in industrial systems. They correspond to the applicable standards and regulations. The technical data and the information about permitted conditions are to be found on the nameplate and in the documentation. It is essential to observe all specified information! Operating Instructions Planetary Gear Units P..RF.., P..KF.. 5

6 2 Transportation / putting into storage Inspect the delivery for any damage in transit as soon as you receive the delivery. Inform the transportation company immediately. It may be necessary to preclude startup. SEW-EURODRIVE planetary gear units and planetary geared motors are suspended from the transportation points marked in the drawings below. Do not use the transportation lugs or lifting eyebolts on motors or primary gear units (RF../KF..). Figure 1: Transportation 02065AXX Use suitable, sufficiently rated handling equipment if necessary. Remove any transportation fixtures prior to startup. Installation/ mounting Operation Follow the instructions in Sec. "Mechanical Installation!" Secure the shaft keys for test mode without drive elements. Do not render monitoring and protection equipment inoperative even for test mode. Switch off the geared motor if in doubt whenever changes occur in relation to normal operation (e.g. increased temperature, noise, vibration). Determine the cause; contact SEW-EURODRIVE if necessary. Inspection and maintenance Heating Follow the instructions in Sec. "Inspection and maintenance!" Contact SEW-EURODRIVE if an ambient temperature of 45 C is permanently exceeded with the planetary and primary gear unit in the horizontal mounting position. Contact SEW-EURODRIVE if an ambient temperature of 45 C and/or a motor speed of 1800 rpm are permanently exceeded with either the planetary gear unit or the primary geared motor in a vertical mounting position. 6 Operating Instructions Planetary Gear Units P..RF.., P..KF..

7 Extended storage Extended storage Type You can also order gear units prepared for "extended storage." In this case, a VCI (volatile corrosion inhibitor) is added to the lubricant in these gear units (except for planetary gear units and planetary geared motors with a shared oil chamber). Unless specified otherwise, the gear unit will be provided with exterior surface protection OS1. However, OS2 or OS3 are available instead of OS1. The planetary gear units are only filled with oil if you order "extended storage," otherwise they are supplied without an oil fill. Please contact SEW-EURODRIVE if you order the "extended storage" option. Surface protection OS1 OS2 OS3 Suitable for Low environmental pollution Medium environmental pollution High environmental pollution Oil fill for helical and helical-bevel primary gear units Note the following points concerning the oil fill: Mineral oil (CLP) and synthetic oil (CLP HC): At the factory, the gear units are filled with oil to the appropriate level depending on the specified mounting position (M1 M6). Synthetic oil (CLP PG): In some cases, gear units are supplied with an increased oil level. Before startup, adjust the oil level to match the required mounting position (M1 M4). The oil fill quantities for the gear units are specified in Sec. "Design and operating notes." The gear units must remain tightly sealed until taken into operation to prevent evaporation of the VCI corrosion protection agent. Always check the oil level before taking the gear unit into operation. Oil fill planetary gear unit (standard) Planetary gear units are completely filled in accordance with the information on the nameplate with an oil of the same corresponding type and viscosity. Before startup, correct the oil level in accordance with the quantity information on the nameplate of the planetary gear unit. Oil fill planetary geared motor with shared oil space (option) Planetary geared motors are completely filled in accordance with the information on the nameplate of the planetary gear unit with an oil of the corresponding type and viscosity. Before startup, correct the oil level in accordance with the quantity information on the nameplate of the planetary gear unit. Operating Instructions Planetary Gear Units P..RF.., P..KF.. 7

8 2 Extended storage Comply with the storage conditions specified in the following table for extended storage: Climate zone Packaging 1) Storage location Storage time Temperate (Europe, USA, Canada, China and Russia, excluding tropical zones) Tropical (Asia, Africa, Central and South America, Australia, New Zealand excluding temperate zones) Packed in containers, with desiccant and moisture indicator sealed in the plastic film. Open Packed in containers, with desiccant and moisture indicator sealed in the plastic film. Protected against insect damage and mildew by chemical treatment. Open With roof, protected against rain and snow, no shock loads. With roof, enclosed, at constant temperature and atmospheric humidity (5 C < ϑ < 60 C, < 50 % relative atmospheric humidity). No sudden temperature fluctuations and controlled ventilation with filter (free from dirt and dust). No aggressive vapors and no shock loads. With roof, protected against rain, no shock loads. With roof, enclosed, at constant temperature and atmospheric humidity (5 C < ϑ < 60 C, < 50 % relative atmospheric humidity). No sudden temperature fluctuations and controlled ventilation with filter (free from dirt and dust). No aggressive vapors and no shock loads. Protection against insect damage. Max. 3 years with regular checks on the packaging and moisture indicator (rel. atmospheric humidity < 50 %). 2 years or more given regular inspections. Check for cleanliness and mechanical damage as part of the inspection. Check to make sure that the corrosion protection is intact. Max. 3 years with regular checks on the packaging and moisture indicator (rel. atmospheric humidity < 50 %). 2 years or more given regular inspections. Check for cleanliness and mechanical damage as part of the inspection. Check to make sure that the corrosion protection is intact. 1) Packaging must be performed by an experienced company using the packaging materials which have been expressly qualified for the particular application. 8 Operating Instructions Planetary Gear Units P..RF.., P..KF..

9 Corrosion and exterior surface protection Corrosion and exterior surface protection Exterior surface protection OS Instead of the standard surface protection, motors and gear units are optionally available with exterior surface protection OS1, OS2 or OS3. Surface protection Standard OS1 OS2 OS3 Structure of coats 1 dip priming 1 two-compoment top coat 1 dip priming 1 two-component base coat 1 two-component topcoat 1 dip priming 2 two-component base coat 1 two-component topcoat 1 dip priming 2 two-component base coat 2 two-component topcoat 1) according to DIN EN ISO Coat thickness [µm] Suitable for c. 60 Normal ambient conditions Relative humidity below 90 % Surface temperature up to max. 120 C Corrosivity category C1 1) c Low environmental pollution Relative humidity max. 95 % Surface temperature up to max. 120 C Corrosivity category C2 1) c Medium environmental pollution Relative humidity up to 100 % Surface temperature up to max. 120 C Corrosivity category C3 1) c High environmental pollution Relative humidity up to 100 % Surface temperature up to max. 120 C Corrosivity category C4 1) Output shafts and machined metal surfaces are tectyl-coated in accordance with the storage conditions. Operating Instructions Planetary Gear Units P..RF.., P..KF.. 9

10 3 Design of a planetary gear unit 3 Gear Unit Design 3.1 Design of a planetary gear unit The following figure shows the design of the P..RF.., P..KF.. series planetary gear unit. The gear unit consists of a planetary gear unit and an RF../KF.. primary gear unit. RF.. KF.. P.. Figure 2: Gear unit design 51061AXX P.. = Planetary gear unit RF.. = Helical gear unit (flange mounted) KF.. = Helical-bevel gear unit (flange mounted) 10 Operating Instructions Planetary Gear Units P..RF.., P..KF..

11 Planetary gear unit nameplate 4 4 Nameplate Structure 4.1 Planetary gear unit nameplate Figure 3: Example of planetary gear unit 05845AEN Key to nameplate No. Production number of the planetary gear unit Type Unit designation Ratio Gear ratio Power Installed motor power [kw] HSS speed Input speed [min-1] Mounting Position Mounting position Weight Weight [kg] Year Year of construction Oil Typ Oil type Amount of oil Oil capacity [l] Sample unit designation: P H F 031 KF87 DV 112M4 Motor size + number of poles Motor series Primary gear unit size Primary gear unit series Planetary gear unit size Flange type of the planetary gear unit Hollow shaft for shrink disc Planetary gear unit Operating Instructions Planetary Gear Units P..RF.., P..KF.. 11

12 4 RF../KF.. nameplate: primary gear unit 4.2 RF../KF.. nameplate: primary gear unit Figure 4: Example of KF primary gear unit 05831ADE Key to nameplate Type Unit designation No. Production number of the primary gear unit Pe Input power of the gear unit [kw] Ma Output torque [Nm] n Input/output speed [rpm] IM Mounting position i Gear ratio Kg Weight [kg] Sample unit designation: KF 87 AM 112 Adapter size Adapter for mounting IEC/NEMA motors Primary gear unit size Primary gear unit series 12 Operating Instructions Planetary Gear Units P..RF.., P..KF..

13 RF../KF.. nameplate: primary gear unit as geared motor RF../KF.. nameplate: primary gear unit as geared motor Figure 5: Example of KF primary gear unit as geared motor 05832ADE Key to nameplate Type Unit designation No. Production number of the primary geared motor i Ratio 1/min Input/output speed [rpm] Nm Output torque [Nm] KW Input power of the gear unit [kw] S1 Operating mode cos j Power factor of the motor V Connection voltage in delta/star connection [V] A Rated motor current in delta/star connection [A] Hz Supply frequency [Hz] IM Mounting position Kg Weight of the primary geared motor [kg] IP Enclosure of the motor KI Insulating material classification of the motor Bremse V Brake connection voltage [V] Nm Braking torque [Nm] Rectifier Brake rectifier complete drive Sample unit designation: KF 87 DV 112M4 Motor size + number of poles Motor series Primary gear unit size Primary gear unit series Operating Instructions Planetary Gear Units P..RF.., P..KF.. 13

14 5 Required tools / resources 5 Mechanical Installation 5.1 Required tools / resources Set of spanners Torque wrench (for shrink disks) Mounting device Shims and distance rings if necessary Retaining devices for input and output elements, for foot and flange mounting Installation tolerances Shaft end Diameter tolerance > 50 mm -> ISO m6 Center bore in accordance with DIN 332, shape D.. d, d1 > mm -> M24 > mm -> M30 > 180 mm -> - Flanges Centering shoulder tolerance -> ISO m8 IEC standard flanges of AC motors and explosionproof AC motors are identified by having their dimensions printed in bold 5.2 Before you begin The drive may only be installed if the entries on the nameplate of the geared motor match the voltage supply system, the drive is undamaged (no damage caused by transportationation or storage) and it is certain that the following requirements have been fulfilled: with standard gear units: ambient according to the lubricant table in Sec. "Lubricants", no oil, acid, gas, vapors, radiation, etc. with special designs: drive configured in accordance with the ambient conditions 14 Operating Instructions Planetary Gear Units P..RF.., P..KF..

15 Preliminary work Preliminary work The output shafts and flange surfaces must be thoroughly cleaned of anti-corrosion agents and contamination (use a commercially available solvent). Do not let the solvent come into contact with the sealing lips of the oil seals danger of damage to the material! Extended storage of gear units Please note: The service life of the lubricant in the bearings is reduced if the unit is stored for 1 year. Gear units of the "extended storage" type have an oil fill suitable for the mounting position so the unit is ready to run (mineral oil CLP and synthetic oil CLPHC). Nevertheless, check the oil level before startup (see Sec. "Inspection and maintenance"). a higher oil level in some cases (synthetic oil CLP PG). Correct the oil level before startup (see Sec. "Inspection and maintenance"). Oil check Fill the planetary gear unit with the oil grade and oil volume specified on the nameplate: Volume according to the mounting position (see Sec. "Lubricants") Oil level check at the oil sight glass Check the oil fill of the RF.. or KF.. primary gear unit is in accordance with the mounting position, see Sec. "Inspection and Maintenance" and Sec. "Lubricants." Operating Instructions Planetary Gear Units P..RF.., P..KF.. 15

16 5 Installing the gear unit 5.4 Installing the gear unit The gear unit or geared motor is only allowed to be installed in the specified mounting position on a level 1, vibration damping and torsionally rigid support structure. Do not tighten the housing legs and mounting flanges against one another in the process! The oil checking and drain plugs and the breather valves must be freely accessible! Use plastic inserts (2 3 mm thick) if there is a risk of electrochemical corrosion between the gear unit and the driven machine (connection between different metals such as cast iron and high-grade steel)! Also fit the bolts with plastic washers! Ground the housing additionally use the grounding bolts on the motor. Installation in damp areas or outdoors Breather valve in planetary gear unit Gear units are supplied in corrosion-resistant versions for use in damp areas or outdoors. Any damage to the paint work (e.g. on the breather valve) must be repaired. The breather valve is fitted at the factory and activated for the standard mounting positions. Breather valve in RF../KF.. primary gear unit As a rule, the breather valve is already activated at the factory in the case of RF../ KF.. primary gear units. If this is not the case, remove the transportation fixture from the breather valve before starting up the gear unit! 1. Breather valve with transportation fixture 2. Remove transportation fixture 3. Breather valve activated 02053BXX 02054BXX 02055BXX 1. Maximum permitted flatness error for flange mounting (approximate value with reference to DIN ISO 1101): With flange mm max. error mm 16 Operating Instructions Planetary Gear Units P..RF.., P..KF..

17 Installing the gear unit 5 Painting the gear unit If all or some of the surface of the drive is to be painted over, make sure that you carefully mask over the breather valve and the oil seals. Remove the strips of tape after completing the paint job. Pivoted mounting positions Pivoted mounting positions are mounting positions which differ from the standard mounting positions (see Sec. "Mounting positions"). In such cases, the breather filter of the planetary gear unit may be supplied as a loose part. The corresponding screw plug must then be replaced by the breather filter prior to startup. The screw plug is indicated on the gearcase by means of a sticker. 0 ± 90 Figure 6: Example for a pivoted mounting position 51062AXX 0 ± 90 Figure 7: Example for a pivoted mounting position 51148AXX Operating Instructions Planetary Gear Units P..RF.., P..KF.. 17

18 5 Gear units with solid shaft 5.5 Gear units with solid shaft Installing input and output elements The following figure shows an example of a mounting device for installing couplings or hubs on gear units or motor shaft ends. The thrust bearing on the mounting device may not be necessary. Figure 8: Example for a mounting device [1] Gear shaft end [2] Thrust bearing [3] Coupling hub 05820AXX The following illustration shows the correct mounting arrangement B of a gear or chain sprocket for avoiding excessively high overhung loads. [1] [1] Figure 9: Mounting arrangement of a gear or sprocket [1] Hub A = Incorrect B = Correct 05821AXX 18 Operating Instructions Planetary Gear Units P..RF.., P..KF..

19 Gear units with solid shaft 5 Use a mounting device (see previous page) for installing input and output elements. Use the center bore and the thread on the shaft end for positioning purposes. Never drive belt pulleys, couplings, pinions, etc. onto the shaft end by hitting them with a hammer (damage to bearings, housing and the shaft!). In the case of belt pulleys, make sure the belt is tensioned correctly (in accordance with the manufacturer s instructions). Power transmission elements should be balanced after installation and must not give rise to any excessive radial or axial forces (see the "Planetary Geared Motors" catalog for permitted values). Note: Mounting is easier if you first apply lubricant to the output element or heat it up briefly (to C). Mounting couplings Couplings must be mounted and balanced according to the information provided by the coupling manufacturer: a) Maximum and minimum clearance b) Axial misalignment c) Angular misalignment a) b) c) Figure 10: Clearance and misalignment for clutch mounting 03356AXX Input and output elements such as belt pulleys, couplings, etc. must be equipped with a touch guard! Operating Instructions Planetary Gear Units P..RF.., P..KF.. 19

20 5 Flange mounting 5.6 Flange mounting Use only class 8.8 bolts in accordance with the table and tighten them to the specified tightening torque. Also apply Loctite 640 [1] to the bolt contact surface. Figure 11: Flange mounting 05824AXX Gear unit type P Bolts Thread Quantity Strength classes Tightening torque Dimensions in [mm] DIN [Nm] ± 20% S H L L1 A B C P /931 M f8 P /931 M f8 P /931 M f8 P /931 M f8 P /931 M f8 P /931 M f8 P /931 M f8 P /931 M f8 P /931 M f8 5.7 Foot mounting Only use class 8.8 bolts in accordance with the table and tighten them to the specified tightening torque. Gear unit type P DIN bolts Thread Quantity Strength class Tightening torque [Nm] ±20 % P /931 M P /931 M P /931 M P /931 M P /931 M P /931 M P /931 M P /931 M P /931 M Operating Instructions Planetary Gear Units P..RF.., P..KF..

21 Installing torque arms for hollow shaft gear units Installing torque arms for hollow shaft gear units Installing torque arms Do not place torque arms under strain during installation! Double-sided torque arm L A D5 L O D3 X S D2 D1 D4 J K M H ØD6 S F E T E N C C B V Figure 12: Double-sided torque arm 51055AXX Dimensions in [mm] Size A B C D1 D2 D3 D4 D5 D6 E F H Dimensions in [mm] Quantity Weight Size J K L M N O S T V X [kg] Operating Instructions Planetary Gear Units P..RF.., P..KF.. 21

22 5 Installing torque arms for hollow shaft gear units Single-sided torque arm Figure 13: Single-sided torque arm 51056AXX Dimensions in [mm] Quantity Weight Size A B C D1 D2 D5 O S T X [kg] Operating Instructions Planetary Gear Units P..RF.., P..KF..

23 [8] Installation / removal of hollow shaft gear units and shrink disks Installation / removal of hollow shaft gear units and shrink disks Installation notes [7] [2] [1] A A [6] [4] [3] [5] Figure 14: Hollow shaft gear unit with shrink disk 51184AXX [1] Locking collar [5] Inner ring [2] Locking screw [6] Free from grease [3] Customer shaft [7] Free from grease [4] Hub [8] Correct position of the shrink disk 1. Degrease the hub [4] and customer shaft [3]! 2. Check the correct position of the shrink disk [8]. The shrink disk is positioned correctly when it is in contact with the shaft shoulder. The outside surface of the hub [4] can be greased in the area of the shrink disk seat. Never tighten the locking screws [2] until the customer shaft [3] has been installed. 3. Install the customer shaft [3] or push the hub [4] onto the customer shaft. Perform the mounting sequence slowly to allow the compressed air to escape around the outside of the shaft. 4. Tighten all locking screws [2] (working at evenly spaced intervals) to the correct tightening torques. Tighten all locking screws until the front lateral surfaces of the locking collar and inner ring are in alignment. Gear unit type P Bolts Rated torque [Nm] Tightening torque [Nm] ±20 % P001 M P011 M P021 M P031 M P041 M P051 M P061 M P071 M P081 M Operating Instructions Planetary Gear Units P..RF.., P..KF.. 23

24 5 Installation / removal of hollow shaft gear units and shrink disks Disassembly note Danger of injury if disassembly is not performed correctly! 1. Unscrew the locking screws [2] evenly one after the other. 2. If the locking collar [1] does not come away from the inner ring [5] automatically, it is possible to unscrew a few locking screws [2] and screw them into the adjacent forcing threads. This makes the job of unfastening easy. 3. Remove the shaft or pull the hub [4] off the shaft. (It is first necessary to remove any rust which may have formed between the hub and the end of the shaft.) 4. Pull the shrink disk off the hub. Cleaning and lubrication There is no need to strip down and re-grease disassembled shrink disks before they are screwed back on. The shrink disk only needs to be cleaned and re-greased if it is contaminated. Use a solid lubricant with a friction factor of Lubricant Molykote 321 R (lube coat) Molykote spray (powder spray) Molykote G Rapid Aemasol MO 19R Molykombin UMFT 1 Unimoly P5 Sold as Spray Spray Spray or paste Spray or paste Spray Powder 24 Operating Instructions Planetary Gear Units P..RF.., P..KF..

25 Mounting the coupling of adapter AM Mounting the coupling of adapter AM IEC adapter AM / NEMA adapter AM Figure 15: Cleaning the adapter [1] Coupling half [2] Setscrew [3] Key [4] Spacer tube [5] Motor shaft * = NEMA adapter only 05822AXX 1. Clean the motor shaft [5] and flange surfaces of the motor and the adapter. 2. IEC adapter: Remove the key [3] from the motor shaft [5] and replace it with the supplied key. NEMA adapter: Remove the key [3] from the motor shaft [5], push the spacer tube [4] onto the motor shaft [5] and insert the supplied key. 3. Heat the coupling half [1] to approx C, push the coupling half onto the motor shaft [5]. for IEC adapters: up to the stop against the collar of the motor shaft [5]. for NEMA adapters: up to the stop against the spacer tube [4]. 4. Use the setscrew [2] to secure the key [3] and coupling half [1] on the motor shaft [5]. 5. Mount the motor on the adapter. When doing this, make sure the coupling claws of the adapter shaft engage in the plastic cam ring. Note: To avoid contact corrosion, we recommend applying NOCO Fluid to the motor shaft before mounting the coupling half. Operating Instructions Planetary Gear Units P..RF.., P..KF.. 25

26 5 Mounting the coupling of adapter AM IEC adapter AM250/AM280 Figure 16: IEC adapter [1] Coupling half [2] Motor shaft [3] Setscrew 05823AXX 1. Clean the motor shaft [2] and flange surfaces of the motor and the adapter. 2. Remove the key from the motor shaft [2] and insert the supplied key (only size AM280). 3. Heat the coupling half [1] to 80 C 100 C) and push it onto the motor shaft [2] (A = 139 mm). 4. Secure the coupling half with the setscrew [3] and check its position (clearance "A"). 5. Mount the motor on the adapter. When doing this, make sure the claws of both coupling halves [1] engage in the plastic cam ring. Note: To avoid contact corrosion, we recommend applying NOCO Fluid to the motor shaft before mounting the coupling half. 26 Operating Instructions Planetary Gear Units P..RF.., P..KF..

27 Mounting the coupling of adapter AM 5 Option backstop AM../RS Dimensions The backstop is completely integrated within the adapter. This means the dimensions are identical with the input shaft assembly without backstop. Locking torques Type Maximum locking torque of backstop [Nm] Lift-off speed [rpm] AM80/90, AM143/ AM100/112, AM 182/ AM 132, AM 213/ AM160/180, AM AM 200/225, AM Output direction of rotation Check the direction of rotation of the drive before starting up the machine in order to avoid damage. Please inform SEW customer service if the direction of rotation is incorrect. The permitted direction of rotation is indicated by an arrow on the gear unit. Input speed Note that the permitted input speed is limited. Please contact SEW-EURODRIVE if the input speeds are faster than specified on the nameplate. Operating Instructions Planetary Gear Units P..RF.., P..KF.. 27

28 5 Mounting the coupling of adapter AQ 5.11 Mounting the coupling of adapter AQ Figure 17: Mounting the coupling AQA = With keyway / AQH = Without keyway [1] Coupling half [2] Spacer tube [3] Motor shaft [4] Setscrew [5] Bolt 05819CXX 1. Clean the motor shaft [3] and flange surfaces of the motor and the adapter. 2. Type AQH: Push spacer tube [2] onto the motor shaft [3]. 3. Type AQH: Unscrew the bolts [5] of the coupling half [1] and loosen the conical connection. 4. Heat the coupling half [1] to 80 C 100 C) and push it onto the motor shaft [3]. for type AQH: up to the stop against the spacer tube [2]. for type AQA: up to clearance "A" (see table). 5. Type AQH: Tighten the bolts [5] on the coupling half [1] (work round several times tightening the bolts evenly one after the other) until all bolts reach the tightening torque TA specified in the table. Type AQA: Use the setscrew [4] to secure the coupling half [1]. 6. Check the position of the coupling half [1] (clearance "A", see table). Install the motor onto the adapter, making sure that the claws of the two coupling halves [1] engage in one another. The force which must be applied when joining the two coupling halves is dissipated after final assembly, so there is no risk of any axial load being applied to adjacent bearings. 28 Operating Instructions Planetary Gear Units P..RF.., P..KF..

29 Mounting the coupling of adapter AQ 5 Setting dimensions, tightening torques Type Coupling size Clearance "A" [mm] Bolts DIN 912 1) Tightening torque TA 1) [Nm] AQA / AQH 80 /1/2/ AQA / AQH 100 /1/ /24 AQA / AQH 100 /3/4 53 M4 3 AQA / AQH 115 /1/2 62 AQA / AQH 115 / /28 AQA / AQH 140 /1/2 62 M5 6 AQA / AQH 140 / /38 AQA / AQH 190 /1/ M5 6 AQA / AQH 190 /3 38/ M6 10 1) only type without keyway (AQH) Operating Instructions Planetary Gear Units P..RF.., P..KF.. 29

30 5 Mounting on input shaft assembly AD 5.12 Mounting on input shaft assembly AD Cover with motor mounting platform AD../P Please refer to Sec. "Installing input and output shafts" concerning the mounting of input elements. Figure 18: Cover with motor mounting platform [1] Motor mounting platform [2] Stud bolt (only AD6/P / AD7/P) [3] Support (only AD6/P / AD7/P) [4] Nut [5] Threaded column 05818AXX Mounting the motor and adjusting the motor mounting platform [1] 1. Set the motor mounting platform [1] to the required mounting position by evenly tightening the adjusting nuts. It may be necessary to remove the lifting eyebolt from helical gear units in order to achieve the lowest adjustment position. Touch up any damage to the paint work. 2. Align the motor on the motor mounting platform [1] (shaft ends must be in alignment) and secure it. 3. Mount the input elements on the input shaft end and the motor shaft. Line them up with one another. Correct the motor position again if necessary. 4. Put on traction elements (V-belt, chain, etc.) and apply a preload by evenly adjusting the motor mounting platform [1]. Do not cause tension between motor mounting platform and threaded columns [5] when doing this. 5. Tighten the threaded columns [5] using the nuts [4] which are not used for adjustment. AD6/P and AD7/P only: Unscrew the nuts on the stud bolts before adjustment to allow the stud bolts to move axially in the support without restriction. Do not tighten the nuts until the final adjustment position has been achieved. Do not adjust the motor mounting platform using the support. 30 Operating Instructions Planetary Gear Units P..RF.., P..KF..

31 Mounting on input shaft assembly AD 5 Design with centering shoulder AD../ZR Mounting of applications on the input shaft assembly with centering shoulder Figure 19: Cover with centering shoulder l = t+a t = Screw-in depth (see table) a = Thickness of the application s = Retaining thread (see table) 02725CXX 1. Provide retaining bolts of a suitable length for the application. The length l of the new bolts is calculated as follows: Round down the calculated bolt length to the next smaller standard length. 2. Remove the retaining bolts from the centering shoulder. 3. Clean the contact surface and the centering shoulder. 4. Clean the threads of the new bolts and apply a bolt locking compound (e.g. Loctite 243) to the first few threads. 5. Position the application against the centering shoulder and tighten the retaining bolts to the specified tightening torque T A (see table). Type Screw-in depth t Retaining thread s Tightening torque T A [Nm] AD2/ZR 25.5 M8 25 AD3/ZR 31.5 M10 48 AD4/ZR 36 M12 86 AD5/ZR 44 M12 86 AD6/ZR 48.5 M AD7/ZR 49 M AD8/ZR 42 M12 86 Operating Instructions Planetary Gear Units P..RF.., P..KF.. 31

32 5 Mounting on input shaft assembly AD Option backstop AD../RS Dimensions The backstop is completely integrated within the cover. This means the dimensions are identical with the input shaft assembly without backstop. Locking torques Type Maximum locking torque of backstop [Nm] Lift-off speed [rpm] AD2/RS AD3/RS AD4/RS AD5/RS AD6/RS AD7/RS AD8/RS Output direction of rotation Check the direction of rotation of the drive before starting up the machine in order to avoid damage. Please inform SEW customer service if the direction of rotation is incorrect. The permitted direction of rotation is indicated by an arrow on the gear unit. Input speed Note that the permitted input speed is limited. Please contact SEW-EURODRIVE if the input speeds are faster than specified on the nameplate. 32 Operating Instructions Planetary Gear Units P..RF.., P..KF..

33 Inspection and maintenance periods 6 6 Inspection and Maintenance 6.1 Inspection and maintenance periods P gear unit tíme interval RF../KF.. primary gear unit time interval Frequency After 500 operating hours Every 3000 operating hours, at least every 6 months Depending on the operating hours (see illustration below), at the latest every 2 years Depending on the operating hours (see illustration below), at the latest every 3 years Frequency Every 3000 operating hours, at least every 6 months Depending on the operating conditions (see illustration below), at the latest every 3 years Depending on the operating conditions (see illustration below), at the latest every 5 years Varying (depending on external factors) What to do Change the oil in the planetary gear unit Check the oil Change mineral oil Change synthetic oil What to do Check the oil Change mineral oil Renew the anti-friction bearing grease Change synthetic oil Renew the anti-friction bearing grease Touch up or renew the surface/anticorrosion coating 6.2 Lubricant change schedule Change the oil more frequently when using special designs subject to more severe/aggressive environmental conditions 04640AXX Figure 20: Change intervals for planetary and primary gear units at standard environmental conditions. (1) Operating hours (2) Sustained oil bath temperature Average value per oil type at 70 C Operating Instructions Planetary Gear Units P..RF.., P..KF.. 33

34 6 Inspection and maintenance of the gear unit 6.3 Inspection and maintenance of the gear unit Do not mix different synthetic lubricants and do not mix synthetic and mineral lubricants! Mineral oil is the standard lubricant. The position of the oil level and oil drain plug and the breather valve depends on the mounting position. Refer to the diagrams of the mounting positions. Checking the oil level 1. De-energize the geared motor and secure it to prevent it from being switched back on inadvertently! Wait until the gear unit cools down Danger of burns! 2. Please refer to Sec. "Important Notes" and "Mechanical Installation" if the mounting position is changed! 3. For gear units with an oil level screw: Remove the oil level screw, check the fill level and correct it if necessary. Screw the oil level screw back in. Check the oil 1. De-energize the geared motor and secure it to prevent it from being switched back on inadvertently! Wait until the gear unit cools down Danger of burns! 2. Remove a little oil from the oil drain plug. 3. Check the oil consistency: Viscosity If you can see that the oil is heavily contaminated, we recommend that you change the oil even if this is outside the service intervals specified in "Inspection and maintenance periods." 4. For gear units with an oil level screw: Remove the oil level screw, check the fill level and correct it if necessary. Screw the oil level screw back in. 34 Operating Instructions Planetary Gear Units P..RF.., P..KF..

35 Inspection and maintenance of the gear unit 6 Changing the oil Only change the oil when the gear unit is at operating temperature. 1. De-energize the geared motor and secure it to prevent it from being switched back on inadvertently! Wait until the gear unit cools down Danger of burns! Note: However, the gear unit must still be warm otherwise the high viscosity of excessively cold oil will make it harder to drain the oil correctly. 2. Place a container underneath the oil drain plug. 3. Remove the oil level screw, breather plug/breather valve and oil drain plug. 4. Drain the oil completely. 5. Screw in the oil drain plug. 6. Pour in new oil (see nameplate) through the vent hole. If changing the oil type, please first contact SEW customer service: Pour in the quantity of oil in accordance with the mounting position (see Sec. "Lubricant fill quantities") or as stated on the nameplate. Check at the oil level screw 7. Screw the oil level screw back in 8. Screw in the breather plug/breather valve Checking the breather plug As part of regular maintenance, check the breather elements (valves, breather plugs, etc.) for proper function. Remove any dirt and install a new breather plug if necessary. Operating Instructions Planetary Gear Units P..RF.., P..KF.. 35

36 7 Gear unit malfunctions 7 Malfunctions 7.1 Gear unit malfunctions Problem Possible causes Solution Unusual, regular running noise 1. Meshing/grinding noise: Bearing damage 2. Knocking noise: Irregularity in the gearing 1. Check the oil 2. Contact customer service Unusual, irregular running noise Foreign bodies in the oil 1. Check the oil 2. Stop the drive, contact customer service Oil leaking 1) from the motor flange from the motor oil seal from the gear unit flange from the output end oil seal Oil leaking from the breather valve Input shaft does not turn although the motor is running or the input shaft is rotated 1. Seal defective 2. Gear unit not vented 1. Too much oil 2. Breather valve installed incorrectly 3. Frequent cold starts (oil foams) and/or high oil level Shaft/hub gear unit in gear unit interrupted 1) It is normal for oil to emerge from the oil seal during the running-in phase (24 hour running time). Call customer service for 1. Vent the gear unit for Correct the oil level 2. Install the breather valve correctly Contact customer service or send in the gear unit/geared motor for repair Please have the following information available when contacting customer service: Nameplate data (complete) Nature and extent of the fault Time and peripheral circumstances of the fault Presumed cause 36 Operating Instructions Planetary Gear Units P..RF.., P..KF..

37 General information about mounting positions M1 M6 M6 8 8 Mounting Positions 8.1 General information about mounting positions Mounting position designations SEW-EURODRIVE distinguishes between mounting positions M1, M2 and M4 for planetary geared motors. The following diagram shows the spatial orientation of the gear unit. The mounting positions apply to planetary gear units with solid shafts and hollow shafts. M1 M1 M4 M2 M4 M2 P..RF M1 M4 M1 M2 M4 M2 P..KF Figure 21: Mounting positions 51001AXX Comparison of old/new The following table shows how the former SEW mounting position designations were transferred into the new system: Old B3 B5 V5 V1 V6 V3 New M1 M1 M4 M4 M2 M2 Operating Instructions Planetary Gear Units P..RF.., P..KF.. 37

38 8 M1 M6 M6 Mounting positions of KF primary gear units 8.2 Mounting positions of KF primary gear units The following mounting positions are available for the helical-bevel primary stage: Normal, X, Y, Z Z Y normal X Figure 22: Mounting positions of helical-bevel primary stages 51063AXX 8.3 Key to the mounting position sheets Symbols used The following table shows which symbols are used in the mounting position sheets and what they mean: Symbol Meaning Breather valve Oil level plug Oil drain plug Breather Dipstick Oil sight glass 38 Operating Instructions Planetary Gear Units P..RF.., P..KF..

39 P.. RF.. DT/DV M1 M6 M P.. RF.. DT/DV Operating Instructions Planetary Gear Units P..RF.., P..KF.. 39

40 8 M1 M6 M6 PH.. RF.. DT/DV 8.5 PH.. RF.. DT/DV 40 Operating Instructions Planetary Gear Units P..RF.., P..KF..

41 PF.. RF.. DT/DV M1 M6 M PF.. RF.. DT/DV Operating Instructions Planetary Gear Units P..RF.., P..KF.. 41

42 8 M1 M6 M6 PHF.. RF.. DT/DV 8.7 PHF.. RF.. DT/DV 42 Operating Instructions Planetary Gear Units P..RF.., P..KF..

43 P.. KF.. DT/DV M1 M6 M P.. KF.. DT/DV Operating Instructions Planetary Gear Units P..RF.., P..KF.. 43

44 8 M1 M6 M6 PH.. KF.. DT/DV 8.9 PH.. KF.. DT/DV 44 Operating Instructions Planetary Gear Units P..RF.., P..KF..

45 PF.. KF.. DT/DV M1 M6 M PF.. KF.. DT/DV Operating Instructions Planetary Gear Units P..RF.., P..KF.. 45

46 8 M1 M6 M6 PHF.. KF.. DT/DV 8.11 PHF.. KF.. DT/DV 46 Operating Instructions Planetary Gear Units P..RF.., P..KF..

47 Oil expansion tank / oil riser pipe for the planetary gear unit M1 M6 M Oil expansion tank / oil riser pipe for the planetary gear unit If there is little space available for installing the oil expansion tank or the oil riser pipes in mounting positions M2 and M4, the customer should request a separate scale drawing from SEW-EURODRIVE. Oil expansion tank in mounting position M2 Ø Ø28 Oil riser pipe in mounting position M4 Figure 23: Oil expansion tank 51010AXX Figure 24: Oil riser pipe 51011AXX Operating Instructions Planetary Gear Units P..RF.., P..KF.. 47

48 9 General information about lubricants 9 Lubricants 9.1 General information about lubricants The planetary gear units are supplied without lubricants. RF../KF.. primary gear units are supplied from the factory with a lubricant fill in accordance with their mounting position. The oil chambers of both gear units are separate. The manufacturer defines the oil grades in accordance with the order (in particular the lubricant for the planetary gear unit). Only use the oil type with the corresponding viscosity as specified on the nameplate. Do not mix mineral and synthetic oils. General information Key to the lubricant table The decisive factor in determining the lubricant fill quantity is the mounting position (M1 M4, Sec. "Mounting positions") specified when ordering the drive. You must adapt the lubricant fill to any subsequent changes made to the mounting position ( Lubricant fill quantities). Abbreviations used, meaning of shading and notes: CLP (CC) = Mineral oil CLP PG = Polyglycol CLP HC = Synthetic hydrocarbons E = Ester oil (water pollution danger category WGK 1) HCE = Synthetic hydrocarbons + ester oil (USDA H1 certification) HLP = Hydraulic oil = Synthetic lubricant (= synthetic-based anti-friction bearing grease) = Mineral lubricant (= mineral-based anti-friction bearing grease) 1) Note critical starting behavior at low temperatures! 2) Ambient temperature Lubricant for the foodstuffs industry (food industry oil) Oil Oil Biodegradable oil (lubricant for use in agriculture, forestry and water resources) Anti-friction bearing greases for RF../KF.. primary gear units The anti-friction bearings in SEW gear units and motors are given a factory-fill with the greases listed below. SEW recommends regreasing anti-friction bearings with a grease fill at the same time as changing the oil. Anti-friction bearing in gear unit Ambient temperature Manufacturer Type -20 C +60 C Mobil Mobilux EP 2-40 C +80 C Mobil Mobiltemp SHC C +80 C Esso Unirex EQ3 Anti-friction bearing in -20 C +60 C Shell Alvania RL3 motor +80 C +100 C Klüber Barrierta L55/2-45 C -25 C Shell Aero Shell Grease 16 Special greases for anti-friction bearings in gear units: -20 C +40 C Aral Aral Eural Grease EP 2 Oil Oil -20 C +40 C Aral Aral Aralub BAB EP 2 The following grease quantities are required: For fast-running bearings (motor and gear unit input end): Fill the cavities between the rolling elements one third full with grease. For slow-running bearings (in gear units and gear unit output end): Fill the cavities between the rolling elements two thirds full with grease. 48 Operating Instructions Planetary Gear Units P..RF.., P..KF..

49 Lubricant table Lubricant table VG 220 VG 220 VG 220 VG 150 VG 150 VG 100 VG VG 32 VG 32 VG 22 VG 15 VG 460 VG 460 BP Energol GR-XP 220 BP Enersyn SG-XP 220 BP Energol GR-XP 100 BP Energol HLP-HM 10 Oil R... K... R...,K... 1) 1) 1) 1) 1) C 2) DIN (ISO) -10 Standard +40 CLP(CC) CLP PG CLP HC CLP (CC) HLP (HM) CLP HC HLP (HM) HCE E ISO VG 680 VG 460 VG 320 VG 220 VG 150 VG 220 VG 150 VG 100 Mobil Mobilgear 630 Mobil Glygolyle 30 Mobil SHC 630 Mobil SHC 629 Mobilgear 627 Mobil D.T.E. 13M Mobil SHC 624 Mobil D.T.E. 11M Shell Omala 220 Shell Tivela WB Shell Omala 220 HD Shell Omala 100 Shell Tellus T 32 Shell Tellus T 15 Shell Cassida Fluid GL 460 Klüberoil GEM Klübersynth GH Klübersynth EG Klübersynth EG Klüberoil GEM Klüberoil GEM 1-68 Klüber-Summit HySyn FG-32 Isoflex MT 30 ROT Klüberoil 4UH1-460 Klüberbio CA2-460 Aral Degol BG 220 Aral Degol GS 220 Aral Degol PAS 220 Aral Degol BG 100 Aral Degol BG 46 Aral Eural Gear 460 Aral Degol BAB 460 SPARTAN EP 680 SPARTAN EP 460 SPARTAN EP 320 SPARTAN EP 220 SPARTAN EP 150 Tribol 1100/220 Tribol 800/220 Tribol 1510/220 Tribol 1100/100 Tribol 1100/68 Meropa 220 Synlube CLP 220 Pinnacle EP 220 Pinnacle EP 150 Meropa 150 Rando EP Ashless 46 Cetus PAO 46 Rando HDZ 15 Optigear BM 220 Optiflex A 220 Optigear Synthetic A 220 Optigear BM 100 Optigear 32 Optileb GT 460 Optisynt BS 460 Renolin CLP 220 Renolin Unisyn CLP 220 Renolin CLP 150 Renolin B 46 HVI Wintershall Ersolan 680 GF Oil Oil P... DIN (ISO) CLP(CC) CLP(CC) CLP(CC) CLP(CC) CLP(CC) CLP PG CLP PG CLP PG ISO Mobil Mobilgear 636 Mobilgear 634 Mobilgear 632 Mobilgear 630 Mobilgear 629 Klüberoil GEM Klüberoil GEM Klüberoil GEM Klüberoil GEM Klüberoil GEM Syntheso D 220 EP Syntheso D 150 EP Syntheso D 100 EP Aral Degol BG 680 Aral Degol BG 460 Aral Degol BG 320 Aral Degol BG 220 Aral Degol BG 150 Tribol 1100/680 Tribol 1100/460 Tribol 1100/320 Tribol 1100/220 Tribol 1100/150 Tribol 800/220 Tribol 800/150 Tribol 800/100 Falcon CLP 680 Falcon CLP 460 Falcon CLP 320 Falcon CLP 220 Falcon CLP 150 Wintershall Ersolan 460 GF Wintershall Ersolan 320 GF Wintershall Ersolan 220 GF Wintershall Ersolan 150 GF Operating Instructions Planetary Gear Units P..RF.., P..KF.. 49

50 9 Lubricant fill quantities 9.3 Lubricant fill quantities The specified fill quantities are guide values. The precise values vary depending on the stages and gear ratios. Check the oil level in a planetary gear unit at the oil sight glass or the dipstick and in a primary gear unit at the oil level screw. The planetary gear units are supplied without lubricant. RF.. and KF.. gear units are supplied from the factory with a lubricant fill appropriate for their mounting position. The oil chambers of both gear units are separate. Refer to the oil fill volume stated on the nameplate in case of a pivoted mounting position. The following tables show recommended values for lubricant fill quantities depending on the mounting position M. Planetary (P) gear units Delivery without oil fill Gear unit type Fill quantity in liters M1 M2 / M4 P P P P P P P P P Helical (RF) gear units Delivery with oil fill Gear unit type Fill quantity in liters M1 M2 M4 RF RF RF RF RF RF RF Operating Instructions Planetary Gear Units P..RF.., P..KF..