Mounting and Operating Instructions Bevel Gearboxes KEK

Transcription

1 Mountng and Operatng Instructons Bevel Gearboxes KEK Responsble MÄDLER branches accordng to German Post Code Areas: For Swtzerland: PCA 1, 2 and 3 PCA 0, 4 und 5 PCA, 7, 8 und 9 MÄDLER Norm-Antreb AG Subsdary Subsdary Headquarter Postbox 74 MÄDLER GmbH MÄDLER GmbH MÄDLER GmbH Güterstr. Brooksteg 1 Bubltzer Str. 21 Tränkestr. -8 CH-8245 Feuerthalen D Stapelfeld D Düsseldorf D Stuttgart Tel Tel Tel Tel Fax Fax Fax Fax nfo@maedler.ch hamburg@maedler.de duesseldorf@maedler.de stuttgart@maedler.de Date Current on the nternet at

2 Table of contents 1 General nformaton Safety and nformaton symbols General hazard warnngs Intended use 3 Selecton and dmensonng 4 Storage 4 Mountng Mountng nstructons Mountng the gearbox Shaft dsplacement Operatng and mantenance 5 Wear and replacement Spare parts management Dsposal Important nformaton for Ex-zones Addtonal nformaton 12 Data sheet 7 2

3 1 General nformaton Carefully read through ths nstallaton manual before nstallng the bevel gearbox. Pay partcular attenton to the safety nstructons The nstallaton manual s an mportant document. Store t carefully and n the vcnty of the couplng. The copyrght for ths nstallaton manual shall reman wth MÄDLER GmbH Stuttgart, Germany. The language of the orgn manual s German. 1.1 Safety and nformaton symbols Danger Rsk of njury to personnel Cauton Damage could occur to the machne Note Note regardng mportant nformaton Cauton Notes / nstructons on use n Ex zones 1.2 General hazard warnngs Rotatng parts must always be protected by the user from unntentonal contact accordng to the requrements of the law. Movng parts can catch har, clothng, jewellery, tools or body parts. Ths could njure or kll persons. The housng or shaft endngs of the bevel gearbox must not be bored or modfed. A breakng housng or shaft could damage machnes and njure persons. Durng nstallaton and removal of the MÄDLER bevel gearbox, make sure that the entre drve tran s secured to prevent accdental actvaton, and that the system s depressursed. Falure to handle rotatng parts n the proper manner can cause serous njury. For ths reason, the followng safety nstructons should be read and followed wthout excepton. All work on the bevel gearbox should be performed from the perspectve of "Safety frst". Swtch off the drve unt before carryng out work on the shaft couplng. Secure the drve unt to prevent unntentonal actvaton, e.g. by attachng nformaton sgns to the swtchon ponts or removng the fuse at the power supply. Do not reach nto the workng area of the machne whle t s stll n operaton. Protect the rotatng parts to prevent accdental touchng. Attach the relevant protectve devces and covers. 2 Intended use The bevel gearbox KEK doesn t have the ablty to compensate angular, radal and axal dsplacement caused by manufacturng and assembly tolerances. If such dsplacements appear, you have to use an approprate shaft couplng. You may only nstall and mantan the gearbox f you have carefully read and understood the nstallaton manual are authorsed and traned to do so. The gearbox may only be used n accordance wth the techncal specfcatons. Unauthorsed structural changes to the gearbox are prohbted. We wll not accept any lablty for damage occurrng as a result of ths. In the nterest further development, we reserve the rght to make techncal changes. The gearboxes descrbed here correspond wth the latest techncal standards at the tme of publcaton of ths nstallaton manual. 3

4 3 Selecton and Dmensonng 3.2 Dmensonng The dmensonng s the responsblty of the user. The gearbox may only be used n accordance wth the techncal specfcatons, see the data sheet on the last page of ths manual. At drves rotatng wth hgh speed, you must pay attenton to resonant vrbratons. Necessarly, you have to consder the followng factors: Operatng Factors Type of Shock Load Type of Drve Unt Electrc Motors 4 - Cylnder 1-3 Cylnder Steam Turbnes Combuston Combuston Shaftngs Engnes Engnes Weak shock load Low startng torque, unform operaton small lght generators, small centrfugal pumps, small blowers, lght machne tools, lght transmssons Medum shock load Medum startng torque, slght torque fluctuatons larger conveyng machnery, large blowers, centrfugal pumps and generators, large machne tools and wood workng machnes, rapd presses, flower mlls and food grnders, shears, punches, grndng machnes, washng machnes, transmssons Strong shock load Hgh startng torque, strong shocks, alternatng sense of rotaton. centrfuges, gang saws, paper calender, roller tables, wet presses, ball and rod mlls, heavy rollng mlls for metal, rubber rollng mll, recprocatng machnes wthout flywheel, cement mlls, stone breakers 4 Storage The housng from anodzed alumnum s very corroson resstant. The shafts from normal steel are not protected aganst corroson. If the storage wll be longer than months, t s recommended to conserve the shafts wth ol. Provded that storage condtons are favourable, the propertes of the gearbox wll reman unaltered for up to 5 years. Damp storage areas are unsutable. Make sure that no condensaton s produced. A favourable relatve humdty level would be below 5 %. 5 Assembly.1 Assembly nstructons We recommend checkng the dmensonal accuracy of the bore and keyway of the correspondng part. The maxmum shaft loads (axal force and radal force), speed and torque must not be exceeded, see data sheet on the last page. If shaft dsplacement or shock loads appear, you have to use a flexble couplng. The couplng must be fxed onto the shaft. The hub may not move n axal drecton. Note the nstructons for the couplng. It s vtal that you pay attenton to hazards from gnton sources n areas where there s a rsk of exploson 4

5 .4 Assemblng the couplng Gears wth protrudng shaft ends should be set up on sold foundatons or should be mounted as a flange drve drectly on the machne to be drven. The shaft ends have to be algned very carefully for quet runnng and safety durng operaton. To compensate small assembly errors, we recommend the use of elastc couplngs. The couplngs should be warmed and then mounted or attached wth the ad of a D-centre and a bolt. Do not hammer them on Ths wll prevent damage to the tooth profles, roller bearngs and lockng rngs. Slp-on gears can be drectly attached to the shaft of the machne to be drven. They are axally attached wth an end plate and bolt. For flange gears t s mportant that the attachment surface s exactly rght angled to the machne shaft's axs. Otherwse the bearngs wll suffer too much stress and mght be damaged. The reacton torque correspondng to the output torque can be compensated for wth a torson bar. Please note: Normally, torson bars are not used for ths shape of gearboxes. They are not avalable from stock and have to be made as a customzed part. The bar should be mounted on the gears' machne sde n order to prevent addtonal bendng stresses. Do not mount the gears drectly on a foundaton plate when the machne shaft s bedded near the gears..4 Dsplacement types and values In order to guarantee a long servce lfe for the couplng and to avod hazards durng usage n Ex-zones, the shaft ends must be precsely algned. The more precsely the gearbox s algned, the longer ts lfetme wll be. If shaft dsplacement or shock loads appear, you have to use a flexble couplng. Operatng and Mantenance.1 Lubrcaton These permanently lubrcated drves are factory flled wth the correct type and quantty of lubrcant, requrng no further attenton to the lubrcaton. Refllng s only necessary, f a sgnfcant quantty s lost by leakage. In ths case, please ask your responsble MÄDLER branch for the correct ISO Grade No. and quantty and shaft seals..2 Startng operaton In condton lke delvered, the drves are ready to use. There s no ventlaton cap, flter or fller cap to be consdered..3 Mantenance All KEK gearboxes requre a mnmum of mantenance. Only regular checks for leakage are requred for these gearboxes wth permanent lubrcaton. 5

6 7 Wear and replacement The ball bearngs, bevel gears and shaft seals are wear parts. The wear depends on varous operatng condtons lke runnng tme, number of starts, shaft dsplacements, number and heght of shocks and so on. The shaft seals and ball bearngs are DIN parts and are avalable at MÄDLER or common ndustral supplers. Worn bevel gears are ndcated by large backlash or loud runnng nose. Then, the complete gearbox should be replaced. 8 Spare parts management Gearboxes wth worn bevel gears must be completely replaced. To avod unplanned downtmes at mportant usages, t s recommended to hold a replacement gearbox n stock. 9 Dsposal Accordng to federal law, t may be requred to dsmount the gearbox for seperate dsposal. Wear safety glasses and remove the shaft retanng rngs. Then the shafts can be pulled out together wth the seals, bearngs and bevel gears. 10 Important nformaton for Ex-zones Gearboxes used wth other add-on parts could produce heat, sparks and statc charges. For use n Ex-zones, there are strctly regulatons. Please contact us for the nfomaton for EX zone applcatons. 11 Addtonal nformaton The customer bears sole responsblty for all subsequent machnng on the gearbox and correspondng parts, whch are not performed by MÄDLER. All clams for warranty are excluded.

7 12 Data sheet bevel gearboxes KEK Angular drves wth hgh torques at very low dmensons. Sutable n a wde varety of applcatons 7 Szes. Rato 1:1. Housng: Alumnum, slver anodzed. Sealed aganst lubrcant leaks, protected aganst dust. Can be mounted n any poston. Gearng: Bevel gears from steel, surface hardened. Bearng: Ball bearngs wth rubber seal RS. Lubrcaton: Mantenance free grease lubrcaton. Angular backlash: 3 +/-1. Operatng tme: 20% at 5 mn. Lfe tme: 1,000 hours at max. performance at speed 500 mn -1 and operatng tme 20%. Permss. operatng temperature: -20 to +0 C. Orderng Detals: e.g.: Product No Bevel Gearbox KEK Sze 1 U S 1 (2x) d Z Rotatonal Sense (Rot. drecton nterchangeable) L 2 L 1 B 1 B 2 E S 2 (4x) L 4 F H H C 1 T P (8x) L 3 L 3 C 2 L 1 L 2 E O (2x) H H B 2 C 1 B 1 Performance Data Product No. Sze Shafts Rato Permttable Torque at Speed Permttable Power at Speed Shaft Load Weght Ø d j 100 mn mn mn mn mn mn -1 F R * F A ** mm Nm Nm Nm W W W N N g : 1 0,35 0,1 0,05 3,7 5,2 5, : 1 0,75 0,3 0,15 7,9 15,7 15, : 1 2,5 1 0,50 2,2 52,4 52, : 1 4 1,5 0,75 41,9 78,5 78, : , : , : , * Radal load F R max. (on mddle of the Output Shaft) for F A = 0. ** Axal load F A max. for F R = 0. Dmensones Sze B 1 B 2 C 1 C 2 d j E F H L 1 L 2 L 3 L 4 O P S 1 S 2 T U Z mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm , ,5 8,5,5 11 3,1 M3 x 10 M3 x 8 M3 x 8 0, , , ,5 10 3,1 M3 x 10 M3 x 8 M3 x 8 0, , ,1 M4 x 10 M4 x 8 M4 x , , ,1 M4 x 10 M5 x 8 M4 x , , ,1 M4 x 10 M5 x 8 M4 x , , ,1 M4 x 10 M5 x 8 M4 x , , , ,5 13, ,1 M4 x 10 M5 x 8 M4 x ,5 4 7