Instruction Manual 07/2002 Edition Geared Motors Helical Gearbox D with 1FU8... SIEMOSYN-Motor...
SIEMENS AG Automation and Drives Group Motion Control Systems Business Division Postfach 3180 D-91050 Erlangen www.siemens.com The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved. Exclusion of liability We have checked the contents of this document to ensure that they coincide with the described hardware and software. However, differences cannot be completely excluded, so that we do not accept any guarantee for complete conformance. However, the information in this document is regularly checked and necessary corrections will be included in subsequent editions. We are grateful for any recommendations for improvement. Siemens AG 2002 All rights reserved We reserve the right to make technical changes -
Edition 07.02 List of contents List of contents 1 General safety information and instructions... 6 2 Product information... 7 2.1 Product description... 7 2.2 Scope of supply... 7 3 Technical data of the helical gearbox... 9 3.1 Rating plate, type and design key... 9 3.2 Technical data... 10 4 Installation, mounting... 11 4.1 Transport... 11 4.2 Storage... 11 4.3 Installing the helical geared motor... 12 4.4 Lubrication quantities... 14 4.4.1 For foot-mounted casings... 14 4.4.2 For flange-mounted casings... 15 4.4.3 Lubrication quantities when the gearbox is mounted at an inclined angle... 16 4.5 Overview, design / mounting position D1 D9... 17 4.6 Mounting the helical gearbox, attaching and removing drive elements19 5 Commissioning... 21 5.1 Prerequisites... 21 5.2 Checks during commissioning... 22 6 Service and maintenance... 23 6.1 Checking before starting work and during work... 23 6.2 Gearboxes/oil lubrication... 23 Helical Gearbox D Instruction Manual 3
List of contents Edition 07.02 6.2.1 Oil quality... 23 6.2.2 Oil level monitoring... 24 6.2.3 Oil change... 24 6.2.4 Flushing... 25 6.3 Mounting, disassembly, direct drive-in... 25 6.3.1 Gearbox sizes, D1 D5... 25 6.3.2 Gearbox sizes, D6 D9... 26 6.3.3 Tightening torques... 27 7 Options, Instruction Manuals... 28 Note For reasons of transparency, this Instruction Manual does not discuss all of the details or take into account every conceivable application situation which could occur. If you require further information, or if specific problems occur which are not handled in enough detail in this Instruction Manual, then please contact your local Siemens office. Furthermore, we would like to point out that the contents of this Instruction Manual neither change an earlier or existing agreement nor change the contractual liability. All of Siemens contractual liabilities are clearly specified in the particular purchase contract which also specifies the complete and exclusive warranty. The contractual warranty issues are neither expanded nor restricted by the information contained in this Instruction Manual. 4 Helical Gearbox D Instruction Manual
Edition 07.02 Definitions, warning information Definitions, warning information Qualified personnel For the purpose of this Instruction Manual and warning information on the product itself, a "Qualified person" is someone who is familiar with the installation, mounting, start-up and operation of the equipment and the hazards involved. He or she must have the following qualifications: Safety Guidelines Trained and authorized to energize, de-energize, clear, ground and tag circuits and equipment in accordance with established safety procedures. Trained in the proper care and use of protective equipment in accordance with established safety procedures. Trained in rendering first aid. Perfect and safe operation of the product means that it must be correctly and professionally transported, correctly stored, installed and mounted and carefully operated and maintained. The information and instructions in the various Instruction Manuals provided must be carefully observed. It is of extreme importance that the information in the various Instruction Manuals is carefully read and understood in order to avoid hazardous situations and damage. Special versions or other mechanical designs can mean that some of the technical details differ. We urgently recommend that if there is any uncertainty about any of the information, that the manufacturer is immediately contacted or any maintenance/repair work is carried-out by a SIEMENS Service Center. Exclusion of liability We have checked the contents of this document to ensure that they coincide with the described hardware and software. However, differences cannot be completely excluded, so that we do not accept any guarantee for complete conformance. However, the information in this document is regularly checked and necessary corrections will included in subsequent editions. We are grateful for any recommendations for improvement. We reserve the right to make technical modifications within the scope of further development of the helical geared motors described in this document. The data, diagrams, and descriptive information in this document are only intended for information purposes. Warning Electrical equipment contains components which are at dangerous voltage levels. If these instructions are not strictly adhered to, this can result in severe bodily injury and material damage. Only appropriately qualified personnel may work on this equipment or in its vicinity. This personnel must be completely knowledgeable about all of the warnings and service measures according to this Instruction Manual. The successful and safe operation of this equipment means that it must be correctly handled, installed, operated and maintained. Domestic safety guidelines and regulations must be strictly observed. Helical Gearbox D Instruction Manual 5
General safety information and instructions Edition 07.02 1 General safety information and instructions Helical geared motors comprise a gearbox flanged to a 1FU8 synchronous motor. The characteristics of the synchronous motor are described in Instruction Manual 610.41390.02. Correct use The gearboxes are permitted for all applications involving traversing, hoisting and rotary motion in industrial environments. It is extremely important to observe the application conditions when using these drives (e.g. degree of protection, ambient temperature, installation altitude...). Inadmissible activities, obvious incorrect use Under certain conditions, it is inadmissible to operate helical geared motors, because this can result in erroneous functions, equipment faults or even danger to human life, for example, Aggressive air, containing acids, as cooling medium Operation outside the normal air pressure. The motors have to be de-rated if they are operated outside the normal air pressure specifications. Operation with a high air humidity or in the presence of spray water. It is forbidden to use these geared motors in hazardous zones unless it has been expressly confirmed that this is permissible. Safety equipment may neither be disabled nor modified or used differently than the way specified. Warning Warning against hazardous voltages! The geared motors are connected to the line supply voltage or to AC drive inverters/converters. Severe bodily injury or even death can occur if live components are touched. The motors have permanent magnet rotors with a high magnetic flux density and a strong force of attraction to ferro-magnetic bodies. Voltage is present at the motor terminals when the rotor spins! Danger Personnel with heart pacemakers are in danger when they come close to a disassembled rotor. Caution Data, saved on electronic data mediums can be destroyed. Correct use means that all of the information and instructions in this Instruction Manual as well as the Instruction Manuals of the mounted components according to Section 7(e.g. spring-operated brake, mounted AC drive inverter...) which are mounted to form a drive unit, are carefully observed. ❶ 6 Helical Gearbox D Instruction Manual
Edition 07.02 2 Product information 2 Product information 2.1 Product description DEMAG manufactures the helical gearbox D for SIEMENS. DEMAG mounts the 1FU8 permanent-magnet synchronous motors to the gearbox and the unit is then checked and tested. The helical gearboxes, used here, are essentially identical to the gearboxes as described in Catalog M15. However, instead of 1LA7 squirrel-cage induction motors, SIEMOSYN 1FU8 permanent-magnet synchronous motors are used. For helical gearboxes D with 1FU8, there is no clear assignment between the gearbox and a particular motor. This means that there is no MRPD (Machine Readable Product Designation) for these helical geared motors. The geared motor must be engineered on an application-for-application basis (selecting the helical gearbox D, 1FU8 motors etc.). Contact partner: - your local SIEMENS office The 1FU8 synchronous motor directly drives the gearbox. This means that the motor and gearbox are flanged together. The series of helical gearboxes includes 9 gearbox sizes which can be flanged to motors having different sizes. The gearbox sizes D1 to D4 have a casing manufactured out of high quality die cast metal or chill casting, which guarantees a high degree of stability with a high power density and low intrinsic weight. Gearboxes, Sizes D5 to D9 have a gray cast iron casing. Depending on the gearbox ratio, the gearboxes are either 2-stage or 3-stage gearboxes by flanging on an additional stage. The geared motor can be optionally equipped with an integrated AC drive inverter Micromaster/Combimaster 411 (6SE64). The gearbox, motor, mounted AC drive inverter components have their own rating plates; the Instruction Manuals for the mounted components are provided when the equipment is shipped. 2.2 Scope of supply As soon as you have received your geared motor, check that the equipment which has been supplied corresponds to the associated paperwork. The helical geared motors comprise a gearbox D and a 1FU8 synchronous motor. They can also be shipped with an integrated AC drive inverter, Micromaster/Combimaster 411 (6SE64). Siemens does not accept any warranty claims for defects which are subsequently notified. Helical Gearbox D Instruction Manual 7
2 Product information Edition 07.02 The following should be immediately notified: - The supplier, of any transport damage which has been identified - Your local SIEMENS office for any defects/incomplete shipment. The Instruction Manual(s) is (are) included with the scope of supply and must be kept where they are always accessible. ❶ 8 Helical Gearbox D Instruction Manual
Edition 07.02 3 Technical data of the helical gearbox 3 Technical data of the helical gearbox 3.1 Rating plate, type and design key Demag Cranes & Components GmbH 1) Type: DFV40 DD Öl = 1.3 l 2) Design: B5.0-30-0-23,3 3) Serial No.: 300 919 45 4) Order No.: 604 206 00 5) ASN: 00601 787 095 44 Made in Germany Fig. 3-1 Example of a rating plate for a helical gearbox 1) Type: DFV Gearbox designation 40 Size D Number of stages D Drive input "Direct drive-in" Oil Lubricating medium and quantity 2) Design: B5.0 Design and mounting position 30 Drive shaft code 0 Terminal box position 23.3 Ratio 3) Serial No.: Consecutive production number 4) Order No.: Internal DEMAG Order No. 5) Entry No.: Number of the production batch Helical Gearbox D Instruction Manual 9
3 Technical data of the helical gearbox Edition 07.02 Type designation Design code Ratio Terminal box position Design code Drive-out shaft code D F V 40 D D B5.0 30 0 23,3 Number of stages D 2-stage T 3-stage Sizes 10, 20, 30, 40, 50, 60, 70, 80, 90 Drive-in type: D Direct drive L Light coupling S Heavy coupling R Slip-type coupling Drive shaft version V Solid shaft with keyway Case design G Foot-mounting design (the gearbox is mounted through holes in its feet) F Flange version (mounted through holes in the flange) Gearbox type: D Helical gearbox Gearboxes 3.2 Technical data Table 3-2 Function conditions for standard versions Conditions Transport temperature Storage temperature Storage conditions Ambient operating temperature Ambient conditions Cooling medium Cooling-medium temperature Installation altitude Air flow Mounting Mounting clearance Max. input speed Lubricating medium -20... +40 C 0... +40 C Dry areas -10... +50 C Low amount of dust, no acids Fresh air Max. +40 C Max. 1000 m above sea level Free air flow over the gearbox Low vibration Cooling must be guaranteed 3600 RPM Refer to the rating plate 10 Helical Gearbox D Instruction Manual
Edition 07.02 4 Installation, mounting 4 Installation, mounting 4.1 Transport Warning Hoisting and transporting always represent potentially dangerous operations! Bodily injury and/or material damage can be caused if the units are incorrectly transported or if unsuitable or damaged equipment is used to transport or hoist them. Hoisting platforms, trucks/trolleys and load suspension equipment must be in full conformance with all of the relevant regulations. Significance of the symbols on the packaging: Top Fragile Protect against moisture Protect against heat Top heavy Hooks forbidden Suspend here Center of gravity The helical geared motor is supplied, assembled: - Only use suitable load suspension equipment for transport and mounting - If provided, use the hoisting lugs to transport the helical geared motors - When transporting machine sets, only use the hoisting lugs and rings provided! Machine sets may not be hoisted by simply attaching the suspension equipment to individual machines! Observe the load capacity of the hoisting equipment used. 4.2 Storage The gearboxes must be stored as follows: In dry rooms with low temperature fluctuations. In the position in which they will be used. Protected against dust and moisture. Helical Gearbox D Instruction Manual 11
4 Installation, mounting Edition 07.02 On a wooden surface. Vibration-free (no shocks/jolts). It is not permissible to stack gearboxes one on top of the other. Note If not otherwise contractually agreed, there is a 6 month warranty for gearboxes which are conserved as standard. The warranty starts on the day that the equipment is shipped. Caution! Otherwise the gearboxes could be damaged! For longer storage times, it may be necessary to take additional measures for the 1FU8 synchronous motor. It may be necessary to check the insulation resistance of the winding. 4.3 Installing the helical geared motor Caution! Never use compressed air to clean the drives The standard drive is suitable for use under normal industrial conditions. If the ambient temperature, atmosphere or air humidity deviates from these conditions, then only special versions of the helical gearbox may be used (refer to the rating plate). Ambient temperature: From 10 C to +40 C Installation altitude: Up to 1000 m above sea level The helical gearbox should be mounted as follows The circulating air to dissipate the heat must be able to flow over the equipment without any restrictions and the hot air may not be immediately drawn-in again. No chippings of the production material may be allowed to accumulate on the helical geared motor, fall between the out-drive elements or damage the sealing ring. The oil filling and oil drain holes as well as the rating plate must be accessible. Before the unit is mounted, it must be carefully checked as to whether the helical geared motor will be operated in the mounting position as stamped on the rating plate. The amount of lubricating medium depends on the mounting position. We recommend a canopy for types of construction with air entry from the top. For air entry from the bottom, a cover must be provided at the mounting location which prevents foreign bodies dropping into the fan. Gearbox sizes, D1 D5: These gearbox sizes are not vented. If, deviating from the series units, the gearbox vent (valve) is at the side, the oil filling plug at the highest point on the gearbox is replaced by the vent valve. (tightening torque, 5Nm) Refer to Section 4.5 for the actual arrangement. Refer to Section 6.3.3 for the tightening torque, motor/gearbox casing 12 Helical Gearbox D Instruction Manual
Edition 07.02 4 Installation, mounting Gearbox sizes, D6 - D9: A vent valve is supplied as standard. This is located at the highest position and must be replaced by the oil filling plug (tightening torque, 15Nm). Refer to Section 4.5 for the actual arrangement. Refer to Section 6.3.3 for the tightening torque, motor/gearbox casing. Special instructions for mounting the helical geared motor For motors which have condensation water drain plugs, the drain holes must be located at the lowest part of the motor, as otherwise water can enter the motor. If the position of the helical geared motor changes and the drain holes are no longer required, then the openings must be permanently sealed. Note The vent valve is separately packaged together with the Safety and Commissioning Information and provided with the equipment when shipped. Helical Gearbox D Instruction Manual 13
4 Installation, mounting Edition 07.02 4.4 Lubrication quantities 4.4.1 For foot-mounted casings Table 4-1 Lubrication quantity in liters depending on the size and mounting position of the footmounted casings D1 Size D2 D3 D4 D5 D6 D7 D8 D9 D22 D23 D32 D33 D42 D43 D52 D53 D62 D63 D72 D73 D82 D83 D92 D93 Mounting position Ratio I, from... to 2.94 66.5 3.40 61.6 66.4 253 3.18 58.6 60.5 240 2.88 63.3 69.2 259 2.78 61.4 71.9 251 6.44 48.4 57.5 197 6.89 51.3 56.7 201 7.03 49.5 55.5 193 7.49 51.2 55.1 220 0.4 0.8 1.3 0.9 1.6 1.4 2.3 2.7 4 5 6 7 9.5 12 14 24 28 A B 0.4 0.6 0.7 0.9 1.1 1.3 1.5 2.5 3.3 4.5 5 6.5 8 8.5 9.5 16 18 1. 0.4 0.6 1.3 0.8 1.8 1.3 2.3 2.5 3.3 4.5 5 6.5 8 8.5 9.5 16 18 1. 0.4 0.7 1 0.9 1.4 1.4 2.2 2.2 3.2 3.5 4.7 4.5 5 12 14 20 23 0.6 1.1 1.8 1.8 2.5 2.4 3.8 3.8 6 7.5 10 10 15.5 16.5 23.5 35 41 1. 0.6 1 1.8 1.4 2.1 2.1 3.2 3.5 5.2 7.5 9 10 13.5 17.5 21 35 41 1. 14 Helical Gearbox D Instruction Manual
Edition 07.02 4 Installation, mounting 4.4.2 For flange-mounted casings Table 4-2 Lubrication quantity in liters depending on the size and mounting position for flange mounted casings D1 Size D2 D3 D4 D5 D6 D7 D8 D9 D22 D23 D32 D33 D42 D43 D52 D53 D62 D63 D72 D73 D82 D83 D92 D93 Mounting position Ratio I, from... to 2.94 66.5 3.40 61.6 66.4 253 3.18 58.6 60.5 240 2.88 63.3 69.2 259 2.78 61.4 71.9 251 6.44 48.4 57.5 197 6.89 51.3 56.7 201 7.03 49.5 55.5 193 7.49 51.2 55.1 220 A 0.3 0.6 1.2 0.8 1.5 1.3 2.2 2.2 3.5 4 5 5.5 8.5 12 14 20 24 B 0.4 0.6 0.7 0.9 1.1 1.2 1.4 2.1 3.2 4 4.5 6.5 7.5 8 9 14 16 1. 0.3 0.6 1 0.8 1.2 1.3 2.1 2.2 3.2 3.5 4.7 4.5 5 12 14 20 23 1. 0.3 0.6 1.1 0.8 1.8 1.1 2.1 2.1 3.2 4 4.5 6.5 7.5 8 9 14 16 0.5 1 1.6 1.3 2 1.9 3.2 3.3 5.2 6.5 8.8 9 14 14 22 26 35 1. 0.5 1 1.7 1.4 2 1.9 3 3 4.8 6.5 8.1 9 12.5 16.5 20.5 31 35 1. Helical Gearbox D Instruction Manual 15
4 Installation, mounting Edition 07.02 4.4.3 Lubrication quantities when the gearbox is mounted at an inclined angle When the gearbox is mounted at an inclined angle, the lubrication quantities correspond to the mounting positions as shown in Fig. 4-1. A D B C Fig. 4-1 Lubrication quantities when the gearbox is mounted at an inclined angle 16 Helical Gearbox D Instruction Manual
Edition 07.02 4 Installation, mounting 4.5 Overview, design / mounting position D1 D9 The gearboxes must be operated in the design or mounting position shown on the rating plate. This guarantees that the optimum amount of lubricant is used. Significance of the symbols: Oil filling hole Oil drain hole Table 4-3 B 3 B 5.0 Design and mounting position, gearbox sizes D1 D5 B 6 B 5.1 A B B 8 B 5.2 B 7 B 5.3 C D V 5 V 1 In this mounting position, it is not possible to completely drain the gearbox without disassembling it V 6 V 3 Before commissioning, vent through the oil filling plug E F Helical Gearbox D Instruction Manual 17
4 Installation, mounting Edition 07.02 The gearboxes must be operated in the design or mounting position shown on the rating plate. This guarantees that the optimum amount of lubricant is used. Significance of the symbols: Vent Oil filling hole Oil drain hole Table 4-4 B 3 B 5.0 Design and mounting position, gearbox sizes D6 D9 B 6 B 5.1 Oil drain plug is located on the A opposite side B B 8 B 5.2 B 7 B 5.3 C Oil drain plug is located on the opposite side D V 5 V 1 In this mounting position, it is not possible to completely drain the gearbox without disassembling it V 6 V 3 Before commissioning, vent through the oil filling plug. E F 18 Helical Gearbox D Instruction Manual
Edition 07.02 4 Installation, mounting 4.6 Mounting the helical gearbox, attaching and removing drive elements The mounting or flange surface must be such that no forces are introduced into the gearbox casing caused by tension. In order that the helical gearbox is correctly mounted to the mechanical assembly, the following conditions for the screw connections must be carefully maintained: Table 4-5 Tightening torques for foot-mounting Gearbox size Bolt 1) DIN EN ISO 4762 DIN EN ISO 4014 Washer DIN125 Tightening torque [Nm] Bolt 1) Security bolt Tightening torque [Nm] D1 (4x) M8, strength 8.8 A 8.4 25 (4x) M8 45 D2 (4x) M8, strength 8.8 A 8.4 25 (4x) M8 45 D3 (4x) M10, strength 8.8 A 10.5 51 (4x) M10 75 D4 (4x) M10, strength 8.8 A 10.5 51 (4x) M10 75 D5 (4x) M12, strength 8.8 A 13 87 (4x) M12 115 D6 (4x) M16, strength 8.8 A 17 215 (4x) M16 300 D7 (4x) M20, strength 8.8 A 21 430 (4x) M20 720 D8 (4x) M24, strength 8.8 A 25 670 - - D9 (4x) M30, strength 8.8 A 31 1500 - - 1) optionally Table 4-6 Tightening torques for flange-mounting Gearbox size Bolt 1) DIN EN ISO 4762 DIN EN ISO 4014 Washer DIN125 Tightening torque [Nm] Bolt 1) Security bolt Tightening torque [Nm] D1 (4x) M8, strength 8.8 A 8.4 23 (4x) M8 45 D2 (4x) M8, strength 8.8 A 8.4 23 (4x) M8 45 D3 (4x) M10, strength 8.8 A 10.5 46 (4x) M10 75 D4 (4x) M10, strength 8.8 A 10.5 46 (4x) M10 75 D5 (4x) M12, strength 8.8 A 13 79 (4x) M12 115 D6 (4x) M12, strength 8.8 A 13 79 (4x) M12 115 D7 (4x) M16, strength 8.8 A 17 195 (4x) M16 300 D8 (4x) M16, strength 8.8 A 17 195 (4x) M16 300 D9 (4x) M16, strength 8.8 A 17 195 (4x) M16 300 1) optionally Flange: Centering edge tolerance according to DIN 42948 - ISO j6 for b1 230 mm - ISO h6 for b1 > 230 mm Before attaching drive-out elements such as couplings, chain wheels, gear wheels or belt pulleys, the anti-corrosion protection must be carefully removed from the out-drive shaft. Ensure that the cleaning agent does not damage the sealing ring! Helical Gearbox D Instruction Manual 19
4 Installation, mounting Edition 07.02 The drive-out elements may only be attached and withdrawn using suitable equipment, if necessary, using the centering bore according to DIN 332 at the face shaft end. We recommend that the hub of the drive-out element is heated-up to approx. 100 C. The drive-out elements must be retained to the position on the shaft specified for the particular application. Under no circumstances may the specified axial and radial forces be exceeded. If you require more detailed information, please contact your local Siemens office. ❶ 20 Helical Gearbox D Instruction Manual
Edition 07.02 5 Commissioning 5 Commissioning 5.1 Prerequisites The transport company must be immediately notified if any damage is identified when the equipment is received; it may be necessary to stop any commissioning work. Only commission the geared motors, if: You have read all of the relevant Instruction Manuals (gearbox, motor...) and the operating company has given you detailed instructions. The Instruction Manuals must be available at the installation location. You are qualified and have been suitably trained. You are not under the influence of drugs, alcohol or medication which could have a negative impact on your reaction or the way you work The general accident prevention, operating and installation regulations have been taken into account (e.g. DIN-VDE 0100/0113). Before commissioning, ensure the following Heat can be easily dissipated (e.g. the cooling slots are free) It is absolutely guaranteed that the drive unit doesn't represent potential danger (e.g. there is no danger as a result of rotating parts or components under voltage). The gearbox is correctly mounted and the drive elements secured. There are no other sources of potential danger. All electrical connections of the motor have been correctly implemented and the plug connectors are tight and cannot become loose. All motor protective devices are active. The drive can rotate freely. If the drive is to be tested without drive-out element, the key, if available, is secured so that it cannot fly out. Helical Gearbox D Instruction Manual 21
5 Commissioning Edition 07.02 5.2 Checks during commissioning Please ensure, that: The helical geared motor runs perfectly (e.g. no speed fluctuations, no significant noise). There are no oil leaks. There is no significant vibration. ❶ 22 Helical Gearbox D Instruction Manual
Edition 07.02 6 Service and maintenance 6 Service and maintenance Only carry-out service and installation work if: You are trained and knowledgeable in this particular area. The motors are disconnected from the power source and are not rotating. There is no danger (e.g. danger of crushing, slipping etc.). The motors are locked-out so that they cannot be powered-up again (circuitbreaker/main switch in the off position and locked-out). All cables, motor terminals are in a no-voltage condition (use a voltmeter to determine this). Always work with insulated tools. Always use the original manufacturer's spare parts. 6.1 Checking before starting work and during work When defects or damage occur, it is not permissible that the helical geared motor is commissioned and it must be immediately shut down! It may only be commissioned after the fault has been removed. Checking the helical geared motor Type of check: Measure: External damage Inform the person responsible Oil leak Inform the person responsible Unusual noise when operational Inform the person responsible Accumulated dirt Remove the accumulated dirt 6.2 Gearboxes/oil lubrication The gearboxes are filled with lubricant in the plant. The quantity of oil depends on the type of construction and the mounting position of the helical geared motor. This is stamped on the rating plate. Standard lubricants are used if no data has been specified. 6.2.1 Oil quality As standard, a mineral oil according to DIN 51 502, CLP 220 is used, Helical Gearbox D Instruction Manual 23
6 Service and maintenance Edition 07.02 e.g.: BP ENERGOL GR-XP 220 ESSO Spartan EP 220 SHELL Omala Oel 220 Mobilgear 630 Aral Degol BG 220 Synthetic oils can also be used for special ambient conditions or where there are increased requirements placed on the gearboxes. 6.2.2 Oil level monitoring The oil level can only be visibly checked if the gearbox was ordered with an oil sight glass. Under normal operating conditions, the lubricant should be changed after 10 000 operating hours however, at the latest every 4 years. The oil must be changed earlier than this under exceptional operating conditions, e.g. increased ambient temperatures or extreme temperature fluctuations. Checking the oil status The oil should only be checked when the gearbox is in a warm operational state immediately after the motor has been powered-down so that the oil has been optimally distributed in the gearbox. Danger Danger - hot gearbox oil can cause burns! Drain the oil at the oil drain plug (plug in accordance with DIN 908). Check the oil properties (color, consistency, metal particles). If the oil is dirty, change it. Dispose of the old oil in an environmentally friendly way. 6.2.3 Oil change The oil should only be changed when the gearbox is in a warm operational state. This allows all of the oil to be drained (the warm oil has a lower viscosity). Danger Danger - hot gearbox oil can cause burns! Place a container under the oil drain plug Remove the oil drain plug and also one oil filling plug. Completely drain the oil. If the oil is extremely dirty, flush out again (refer to Flushing)! Insert the oil drain plug and tighten to a torque corresponding to the following table. Fill new oil through the oil filling hole (the oil quantity is stamped on the rating plate). 24 Helical Gearbox D Instruction Manual
Edition 07.02 6 Service and maintenance Tighten the oil filling plug or the vent valve to a torque corresponding to the following Table 6-1. Table 6-1 Tightening torque oil filling, oil drain plug, vent valve Plug Tightening torque [Nm] M10 x 1 5 M16 x 1.5 15 6.2.4 Flushing If the oil is extremely dirty then we recommend that after the oil has been changed, the gearbox is flushed before new oil is filled. Take twice the quantity of flushing fluid than that specified for the quantity of oil. The flushing oil should have a viscosity of between 46-68 mm²/s at 40 C. The flushing oil can be drained after several minutes with the gearbox operating under no-load conditions. By flushing several times, with the gearbox running under noload conditions, and if possible with alternating directions of rotation, the remainder of the old lubricant can also be completely removed and drained. Note Dispose of old oil in an environmentally-compatible fashion! 6.3 Mounting, disassembly, direct drive-in 6.3.1 Gearbox sizes, D1 D5 2-stage 3-stage 1 2 3 8 1 3 2 3 8 4 5 4 5 7 6 Fig. 6-1 Gearbox sizes D1 D5 Disassembly: 1. Drain the oil (refer to Section 6.2). 2. Release the mounting bolts/nuts (5) Helical Gearbox D Instruction Manual 25
6 Service and maintenance Edition 07.02 3. Withdraw the motor (8). Leave the centering pin (3) in the remaining halves. 4. Remove the seal (2) and clean the sealing surfaces. 5. For 3-stage gearboxes, withdraw the preliminary stage (6), remove the seal (7) and clean the sealing surfaces. Mounting: 6. 2-stage gearbox: Locate the seal (2) on the gearbox sealing surface. 7. 3-stage gearbox: Locate the seal (7) on the gearbox sealing surface and mount the preliminary stage (6). Locate the seal (2). 8. Mount the motor (8) to the gearbox (1) / preliminary stage (6). Tighten the retaining bolts/nuts (5) with washers (4). Tightening torque, refer to Section 6.3.3 9. Fill with oil (refer to Sections 4.4 and 6.2). 10. Commission the geared motor and check for any leaks. 6.3.2 Gearbox sizes, D6 D9 2-stage 3-stage 1 2 3 8 1 7 3 6 2 3 8 4 5 9 10 4 5 Fig. 6-2 Gearbox sizes D6 D9 Disassembly: 1. Drain the oil (refer to Section 6.2). 2. Release the mounting bolts/nuts; 2-stage (5), 3-stage (10) 3. Withdraw the motor (8). Leave the centering pin (3) in the remaining halves. 4. Remove the seal (2) and clean the sealing surfaces. For 3-stage gearboxes: 5. Release the retaining bolts / nuts (5) 6. Withdraw the preliminary stage (6), remove the seal (7) and clean the sealing surfaces. Mounting: 26 Helical Gearbox D Instruction Manual
Edition 07.02 6 Service and maintenance 7. 2-stage gearbox: Locate the seal (2) on the gearbox sealing surface, mount the motor (8) to the gearbox (1). Tighten the retaining bolt (5) with washer (4). 8. 3-stage gearbox: Locate the seal (7) on the gearbox sealing surface, mount preliminary stage (6), tighten the retaining bolts (5) with washers (4). Locate the seal (2) and mount the motor (8) onto the preliminary stage (6). Tighten the retaining bolt (10) with washer (9). Tightening torque, refer to Section 6.3.3. 9. Fill with oil (refer to Sections 4.4 and 6.2). 10. Commission the geared motor and check for leaks. 6.3.3 Tightening torques Table 6-2 Tightening torques for direct in-drives Gearbox size Motor size Motor gearbox casing bolts Tightening torque for the bolts [Nm] D1 63 to 80 10.5 D2 D3 D4 D5 D6 D7 D8 D9 D22 63 to 90 10.5 D23 63 to 71 10.5 D32 71 to 100 10.5 D33 71 to 80 10.5 D42 80 to 112 10.5 D43 80 10.5 D52 80 to 132 25 D53 80 25 D62 100 to 132 51 160 75 D63 80 to 112 10.5 112 to 132 51 D72 160 to 180 75 D73 80 to 132 25 D82 132 to 225 115 D83 100 to 132 51 160 75 D92 160 to 225 300 D93 112 to 132 51 160 to 180 75 ❶ Helical Gearbox D Instruction Manual 27
7 Options, Instruction Manuals Edition 07.02 7 Options, Instruction Manuals The helical geared motors with flanged SIEMOSYN 1FU8 synchronous motors can be supplied in the following combinations: a) Helical geared motor (gearbox with 1FU8 motor) b) Helical geared motor with integrated AC drive inverter Micromaster/Combimaster 411 c) Combination a) or b) with 2LM8 spring-operated brake Instruction Manuals: Product Component Document Identification No. Siemens SIMOSYN motor 1FU8 1FU8 Instruction Manual 610.41390.02 a, b Provision of the Instruction Manual for the above drive combination Helical gearbox D Demag Instruction Manual 610.41391.41 a, b Micromaster/Combi master 411 6SE64 Instruction Manual 6SE6400-5CA00-0AP0 b Spring-operated brake 2LM8 Instruction Manual 610.43427.21 c The Instruction Manuals for the components supplied in the particular combination are provided with the unit. The operating company must strictly observe the information and instructions in the various Instruction Manuals. The drive units are shipped, mounted and tested. The Micromaster/Combimaster 411 AC drive inverters are pre-programmed corresponding to the motor rating plate and if necessary, fine tuning must be done on-site. ❶ 28 Helical Gearbox D Instruction Manual
Siemens AG Automatisierungs- und Antriebstechnik Motion Control Systems Postfach 3180, D 91050 Erlangen Siemens AG 2002 Subject to change without prior notice Bundesrepublik Deutschland Order No.: 610.41391.41 www.ad.siemens.de Printed in the Federal Republic of Germany