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GEARED MOTOR UNITSR, S, F, K SERIES
INSTALLATION & MAINTENANCE GUIDE
Declaration of Conformity
Products:
R, S, F & K Series - Gear Units.
Renold Gears hereby declares that products listed above have been designed in accordance with the following Directives and Standards.
•TheMachineryDirective2006/42/EC •ENISO12100-1,2TheSafetyofMachinery •Conformstoallotherharmonisedstandards,tests,andspecifications,(Inasmuchastheyapplytoourproducts)
Declaration of Incorporation
Weherebydeclarethattheabovemachineryisintendedtobeincorporatedintoothermachinery&mustnotbeputintoserviceuntilthemachineryitistobeincorporatedintohasbeendeclaredinconformitywiththeessentialHealth&SafetyrequirementsoftheMachineryDirectives2006/42/EC&CEmarked.Themachineryhasbeendesigned&manufacturedinaccordancewiththefollowingtransposedharmonisedEuropeanstandards:- BS EN ISO 12100:2010-Safetyofmachinery.Generalprinciplesfordesign-Riskassessmentandriskreduction BS EN ISO 13857:2008-Safetyofmachinery.Safetydistancestopreventhazardzonesbeingreachedbyupperandlowerlimbs EN349: 1993+A1:2008-SafetyofMachinery.Minimumgapstoavoidcrushingofpartsofthehumanbody. BS EN ISO 13850:2015-Safetyofmachinery.Emergencystopfunction.Principlesfordesign BS EN 60204-1:2006+A1:2009-Safetyofmachinery.Electricalequipmentofmachines-Generalrequirements Othergeneralrequirementsinclude:
PD 5304:2014-Guidanceonsafeuseofmachinery
ENGINEERINGMANAGERRadiconTransmissionUKLtd
Renold Gears Station Rd Milnrow Rochdale Lancashire OL163LSUnitedKingdom
Tel+441706751000Fax+441706751001
Web www.renold.com
INFORMATION
1
STOP
Electrical HazardCouldresultindeathorseriousinjury
Danger (Touch Hazard)Couldresultindeathorseriousinjury
ImportantnotesonExplosionProtection
DangerCouldresultinserious,slightorminorinjuries
Damaging SituationCouldresultindamagetogearunitordrivenmachinery
CleaningPeriodic cleaning necessary
INFORMATION
RISK OF ELECTRICAL
SHOCK
DANGER
Pinch Points Watch Your Hands
CAUTION
Section Description PageNo
- DeclarationofConformity/Incorporation
1 GeneralInformation 2
2 ExternalProtection 2
3 ReadingtheNameplate 2
4 TheMarking 2
5 Installation 35.1SafetyWarning 35.2PriortoInstallation 35.3FittingComponentstoInputorOutputShafts 35.4FittingtheMotor 45.5InstallingFootorFlangeMountedUnits 45.6InstallingShaftMountedUnits 55.7Lifting 55.8SpecialInstructionsforunitsinapotentiallyexplosiveatmosphere 5
6 Lubrication 66.1General 66.2Ventilator 66.3OilLevel 6
7 MotorConnections 7
8 StartingUp 7
9 Operation 79.1Noise 79.2GeneralSafety 79.3Gearunitsforuseinpotentiallyexplosiveatmosphere 7
10 Maintenance 810.1Priortoanymaintenanceoperations 810.2OilPlugs&Ventilator 810.3Lubrication 810.4Bearings 910.5GreaseLubrication 910.6Cleaning 910.7MotorReplacement 9
11 Fault Diagnosis 10
1 ShaftAlignment 11-122A S,F&KSeriesStandardHollowOutputBoreDetails 13-152B FSeriesKiboBush 16-172C KSeriesShrinkDisc 182D S,F&KSeriesTorqueBrackets 19-203 ThreePhaseInductionMotorInstallation 214 LubricationInformation 22-32
Appendix
Safety Warning Symbols
2
1. General Information
Thefollowinginstructionswillhelpyouachieveasatisfactoryinstallationofyourgearunit,ensuringthebestpossibleconditionsfor a long and trouble free operation.
Allunitsaretestedandcheckedpriortodespatch,agreatdealofcareistakeninpackingandshippingarrangementstoensurethattheunitarrivesatthecustomerintheapprovedcondition.
2. External Protection
AllRSF&KSeriesunitsareprovidedwithprotectionagainstnormalweatherconditions.Whereunitsaretooperateinextremeconditions,orwhere theyare tostand for longperiodswithout running,e.g.duringplantconstruction,consultourapplicationengineerssothatarrangementsforadequateprotectioncanbemade.
3. Reading the Nameplate
3.1 Unit Identification
Whenrequestingfurtherinformation,orservicesupportquotethe followinginformationfromthenameplate:
•OrderNumber •PartNumber
3.2 Group/Category/Temperature Class
OnlyunitsspecificallyselectedforuseinapotentiallyexplosiveatmospherewillbefactorymarkedwiththeExgroup,categoryandtemperatureclass.Thoseitemsmarked‘ATEX.Notapplicable’arenotsuitableforuseinapotentiallyexplosiveatmosphere.
4. The Marking
Gearunitswithmarkingarespecificallyselectedforuseasacomponentofanindustrialsystemoperatinginapotentiallyexplosiveatmosphere
Providedthegearunitiscorrectlyselected,ExmarkedandinstalledinaccordancewiththeseinstructionsitwillcomplywiththeEUdirective94/9EC(ATEX100a)
Unitsmaybeselectedbyourapplicationengineersforuseonlyinthefollowingpotentiallyexplosiveatmospheres:HazardGroupIICat2(zones1&21)orGroupIICat3(zones2&22)Motors,couplings,oranyotherequipmentfittedtothegearunitmustalsocomplywiththisdirective.
Ifthegearunitissuppliedasagearedmotorpackageitisimportanttocheckthenameplatesofboththegearunitandthemotor(oranyotherequipmentfitted)correspondswiththeclassificationofthepotentiallyexplosiveatmosphereinwhichtheunitistobe installed.
INFORMATION
3
5. Installation
INSTALLATION
Shaft Diamater Threaded Hole
13-16 M5x0.8p
17-21 M6x1.0p
22-24 M8x1.25p
25-30 M10x1.5p
31-38 M12x1.75p
39-50 M16x2.0p
51-85 M20x2.5p
86-130 M24x3.0p
5.2. Prior to Installation
5.2.1. Checkgearunithasnotbeendamaged.5.2.2. Checkthegearunit/motornameplatematchestherequirementsofthemachinethe unit is to be installed on.5.2.3. Thoroughlycleantheshaftandmountingsurfacesthataretobeusedofanti-corrosionagentsusinga commerciallyavailablesolvent.Ensuresolventdoesnotmakecontactwiththeoilseals.
5.3. Fitting of components to either the unit input or output shaft
5.3.1. Ensureshaftextensions,bores&keysetcarecleaned.5.3.2. TheinputoroutputshaftextensiondiametertoleranceistoISOtolerancek6(forshaftdiameter≤50mm)andm6 (forshaftdiameter>50mm)andthefittedcomponentsshouldbetoISOtoleranceM7(forborediameter≤50mm) andK7(forborediameter>50mm).5.3.3. Items(suchasgears,sprockets,couplingsetc)shouldnotbehammeredontotheseshaftssincethiswould damagetheshaftsupportbearings.5.3.4. Theitemshouldbepushedontotheshaftusingascrewjackdevicefittedintothethreadedholeprovidedinthe endoftheshaft.Seetable1below.5.3.5. Itemsbeingfittedmaybeheatedto80/100°Ctoaidassemblyfurther.
Table 1
WARNING! Thecustomershallberesponsiblefortheproperuseofarticlessuppliedbythecompany,particularly rotatingshaftsbetweenthedrivinganddrivenmembers,andtheprovisionofsafetyguarding.
Thecompanyshallnotberesponsibleforanyinjuryordamagesustainedasaresultoftheimproperuseof the articles supplied.
Attentionisherebydrawntothedangerofusingnakedlightsinproximitytoopeningsingearboxesandgear unitssuppliedbythecompany,andthecompanyshallnotbeliableforanyclaimforinjuryordamagearising fromanyactionincontraventionofthiswarning.
CAUTION
STOP
5.1 Safety Warning
4
5.4. Fitting the Motor Follow these instructions only if the product is supplied without motor
5.4.1. Ensuremotorbushing(ifsupplied)iscorrectlyassembledintothegearunitplug-inshaft.5.4.2. Fitthemotordrivekeyorthespecialcarbonfibredrivekey(ifsupplied) Note! The carbon fibre drive key may require shortening to suit certain motors.5.4.3. Spraytheplug-inborewithanti-frettingcompound(RocolDFSMorequivalent)5.4.4. Slidethemotorshaftfullyintotheplug-inbore(donothammer)5.4.5. Securemotorflangetothegearunitwiththefasteningsprovided5.4.6. TorquetightentheboltstovaluespecifiedinSection5.5-Table2,(Note!Bolttorquesfor aluminiumflangedmotorsshouldbe75%ofthevalueslistedinTable2)
5.5. Foot Mounted or Flange Mounted Units
5.5.1. Ensurethebasefoundation/flangemountingsurfaceisflat¹,vibrationabsorbingandtorsionallyrigid. (¹Maximumpermissibleflatnesserrorforthemountingsurfaceis0.12mm)5.5.2. Thegearunitmustbeinstalledinthespecifiedmountingposition.Themaximumdeviationfromthedesignated mountingpositionis±5°(unlessgearunitissuitablymodifiedandapprovedfornonstandardmountingpositions).5.5.3. Alignunit(seeAppendix1).
Itisimportanttoensurewhenaligningunitonabaseplatethatallmachinedmounting points are supported over their full area. Ifsteelpackingsareused,theseshouldbeplacedeithersideofasclosetothefoundationboltaspossible. Duringfinalboltingensuretheunitorbaseplateisnotdistortedasthiswouldcausestrainsinthegearcaseresulting inerrorsofalignmentofshaftsandgearing. Checkallmountingpointsarefullysupportedandadjustifnecessarybyusingsteelpackings. TorquetightentheboltstovaluespecifiedinTable2exceptaluminiumflangemotors,Bolttorquesforaluminium flangedmotorsshouldbe75%ofthevalueslistedbelow. Note:Secureunitorbaseplate(iffitted)toaridgidfoundationusingheavydutyboltstoISOgrade8.8minimum.
5.5.4. Recomendedfastenersforsecuringbasemountedunits(ISOGrade8.8).
BoltSize Torque
M6 10Nm
M8 25Nm
M10 50Nm
M12 85Nm
M16 200Nm
M20 350Nm
M24 610Nm
M30 1220Nm
M36 2150Nm
Table 2
R01 M8x25L K03 M10x25L S03 M8x20LR02 M8x30L K04 M10x30L S04 M10x30LR03 M8x30L K05 M12x35L S05 M10x30LR04 M12x40L K06 M12x40L S06 M12x40LR05 M12x40L K07 M16x50L S07 M16x50LR06 M12x40L K08 M20x60L S08 M20x65LR07 M16x45L K09 M24x70L S09 M24x75LR08 M16x60L K10 M30x80L S10 M24x80LR09 M20x70L K12 M36x100LR10 M24x80LR13 M30x90LR14 M36x100L
Table 3
STOP
STOP
CAUTION
INSTALLATION
Note:
5
5.7. Lifting
5.7.1.Useonlytheliftingpointsprovided.5.7.2.F&KSeriesunitshavealiftingholeinthegearhousingasindicatedwiththearrow.
5.7.3.LargerR&SSeriesunitsaresuppliedwithaliftingeye.
5.7.4Ifthemotorissuppliedwithaliftingeye,theliftingpointonthemotoraswellastheliftingpointon the gear unit should be used.
5.6. Installing Shaft mounted units
5.6.1. Thegearunitmustbeinstalledinthespecifiedmountingposition.5.6.2. Assemblyofgearunitontothemachineshaft: Therethreeassemblymethodsdependantonthegearunittype: •Standardstraightborewithkeyway.SeeAppendix2A. •UnitfittedwithKIBO®bushes.SeeAppendix2B. •Unitfittedwithshrinkdisc.SeeAppendix2C.5.6.3. Anchorgearunittoasecurepointonthestructurebymeansofatorquearm.(SeeAppendix2D).
5.8. Special Instructions for units to be used in a potentially explosive atmosphere
5.8.1. Iftheunithasbeendamagedintransitdonotuse.(Removealltransportfixturesandpackingspriortostartup)
5.8.2. Checknameplateofunitcorrespondswiththesitespotentiallyexplosiveatmosphereclassification.
5.8.3. Checkambienttemperaturefallswithinlubricantgraderecommendations.(SeeApprovedLubricantsinAppendix4)
5.8.4. Makesurenopotentiallyexplosiveatmosphereexistsduringinstallation.
5.8.5. Makesurethatgearunitissufficientlyventilatedwithnoexternalheatinput–coolingairtemperatureshouldnot exceed40°C
5.8.6. Ensuremountingpositioncorrespondstothatmarkedonthenameplate.(Note!ATEXapprovalisonlyvalidforthe mountingpositionspecifiedonthenameplate)
5.8.7. Checkmotors,couplingsoranyotherequipmenttobefittedtothegearunithasATEXapproval. Checkinformationlistedonthenameplatescorrespondtotheenvironmentalconditionsofthesite.
5.8.8. Ensuregearboxisnotsubjectedtoanyloadinggreaterthanthosemarkedonthenameplate.
5.8.9. For units operated with inverter drives,checkmotorsuitabilityforusewiththeinverter. Ensurethattheinverterparametersdonotexceedthoseofthemotor.
5.8.10. For belt driven units,checkallbeltsfittedareofsufficientelectricalleakageresistance.(<109Ω).
5.8.11. Ensurethegearunitandotherequipmentfittediselectricallygrounded(Earthed).
5.8.12. Checkandadjustsafetyguardsandcoverssothatthereisnoignitionsourcefromsparksthatmaybethrownby movingpartsmakingcontactwithguardsetc.
5.8.13. Ensuresafetyguardsandcoversetc...aredesigneddusttightordesignedtopreventabuildupofdustdeposits fromformingwhentheunitisusedinZone21orZone22classificationareas.
STOP
CAUTION
INSTALLATION
Series K
Series FF SeriesKSeries
6
6. Lubrication
6.1. General
6.1.1. RF&KSeriessize7andbelowwillbesuppliedfactoryfilledwithaquantityofEPmineraloil(Grade6E) appropriatetotheintendedmountingposition.Howeverif,asrequested,thegearunitissuppliedwithoutlubricantthen theoilquantityrequiredisobtainedfromAppendix4.6.1.2. RF&KSeriessize8andlargeraresuppliedwithoutlubricant(unlessfactoryfilledbyrequest). RecommendedlubricantsarelistedinourApprovedLubricantspagesinAppendix4.6.1.3. SSeriessize6andbelowaresuppliedfactoryfilledwithsyntheticlubricant(Grade6G).6.1.4. SSeriessize7andlargeraresuppliedwithoutlubricant(unlessfactoryfilledbyrequest). RecommendedlubricantsarelistedinourApprovedLubricantspagesinAppendix4.
Temperature LimitationsThestandardlubricantissuitableforoperationinambienttemperaturesof0°to35°C.ForuseoutsideofthesetemperaturesconsultTableL1(below)orconsultourapplicationengineers.
Table L1
6.2. Ventilator
6.2.1. Clean&securetheventilator(ifsupplied)inthecorrectlocationfortherequiredmountingposition.(SeeAppendix4)
6.3. Oil Level:Alwayscheckthatlevel,drainandventilatorpositionsarecorrectfortherequiredmountingpositionandensurethattheoillevelis correct by following the instructions below.
Units supplied without oil:
6.3.1. Fillgearunitwithcorrecttypeoflubricantuntiloilescapesfromlevelplug.SeeAppendix4
Factory filled units:
6.3.2. Iftheunitisfittedwithalevelplug,(SeeAppendix4)checkoillevelandtopupwithcorrectoiltypeas necessary.
WARNINGDonotoverfillasexcessmaycauseoverheatingandleakage.
6.3.3. Re-fitplugs&tightentocorrecttorquefigure–seenotesinmaintenancesection.Cleanawayanyoilspillagefrom thesurfaceofthegearunitanddrivenmachinery.
CAUTION
CAUTION
LUBRICATION
-5°Cto20°C(5E)-30°Cto20°C(5G&5H) 0°Cto35°C 20°Cto50°C
5EISOCLP(CC)VG220
6EISOCLP(CC)VG320
7EISOCLP(CC)VG460
5HISOCLP(HC)VG220
5HISOCLP(HC)VG220
6HISOCLP(HC)VG320
5GISOCLP(PG)VG220
6GISOCLP(PG)VG320
7GISOCLP(PG)VG460
F Series
K Series
R Series
S Series
7
7. Motor Connections
Tomains:
7.1. Connectionoftheelectricmotortothemainssupplyshouldbemadebyaqualifiedperson.Thecurrentratingof themotorwillbeidentifiedonthemotorplate,andcorrectsizingofthecablestoelectricalregulationsisessential.
Motor terminal connection:
7.2. Themotorshouldbewiredinaccordancewiththemanufacturersinstructions. (Generalcircuitdiagramsfor‘OwnBrand’motorsareshowninAppendix3)
7.3. Ifanalternativebrandmotorissupplied,itshouldalwaysbewiredinaccordancewiththemanufacturers instructions.
8. Starting Up
8.1. Prior to starting up
8.1.1. Ensuretheventilatorisfitted(ifsupplied)seelubricationsection6.2
8.1.2. Checkoillevel,topupifnecessary.
8.1.3. Ensureallsafetydevicesareinplace(i.e.guardsfitted).Checkandadjustguardsandcoverssothatthereisno ignitionsourcefromsparksthatmaybethrownbymovingpartsmakingcontactwithguardsetc.Ensurecouplingguards, coversetcaredusttightoraredesignedinsuchawaythatabuildupofdustdepositscannotformwhentheunitisused inZone21&Zone22classificationareas.
8.1.4. Removeanysafetydevicesfittedtopreventmachinerotation.
8.1.5. Startingupshouldonlybeperformedorsupervisedbysuitablyqualifiedpersonnel.
Caution:Anydeviationfromnormaloperatingconditions,(increasedtemperature,noise,vibrations,powerconsumptionetc)suggestamalfunction,informmaintenancepersonnelimmediately.
8.1.6. Forunitsfittedwithbackstopdevice,ensuremotoriscorrectlywiredforfreedirectionofrotation.
9. Operation
9.1. Noise
Therangeofproductsatisfiesanoise(soundpressurelevel)of85dB(A)orlesswhenmeasuredat1metrefromtheunitsurface.MeasurementstakeninaccordancewithB.S.7676Pt1:1993(ISO8579-1:1993).
9.2. General Safety
Potentialhazardswhichcanbeencounteredduringinstallation,maintenanceandoperationofdrivesiscoveredingreaterdetailintheproductsafetypageatthefrontofthisbooklet.
Adviceisalsogivenonsensibleprecautionswhichneedtobetakentoavoidinjuryordamage.PLEASE READ!
9.3. Gear units for use in a potentially explosive atmosphere
After3hoursofoperationcheckthegearunitsurfacetemperature.Thistemperatureshouldnotexceed110°C.If temperatureexceedsthislimit,shutdownimmediatelyandcontactourapplicationengineers.
RISK OF ELECTRICAL
SHOCK
DANGER
Pinch Points Watch Your Hands
CAUTION
START UP
8
10. Maintenance
10.1. Prior to any maintenance operations
10.1.1. De-energisethedriveandsecureagainstun-intentionalswitchon.
10.1.2. Waituntiltheunithascooleddown–Dangerofskinburns&pressurebuildup.
10.2. Oil plugs/ventilator
10.2.1. Priortoremovingplugs,ensurethattheunithascooledsufficientlysothatoilwillnotburn.
10.2.2. Removeventilatorplugpriortoremovingleveland/ordrainplug.Warning do not stand over ventilator plug whilst removingaspressurebuildupbehindthevalvedventilatormaycauseittoejectwhenremoved.
10.2.3. Placeacontainerundertheoildrainplugtoberemoved.Note:itisrecommendedthattheoilshouldbeslightly warm,(40-50°C)whendrained.(Cooleroilwillbemoredifficulttodraincorrectly).
10.2.4. Topupsorrefillsshouldbedonethroughtheventilatorposition.
10.2.5. RemembertorefitallplugsandtorquetightentotableM1below.
10.2.6. Cleanawayanyoilspillage.
Table M1
Plug Torque
M10 12Nm
M12 20Nm
M14 26Nm
M16 34Nm
M22 65Nm
10.3. Lubrication
10.3.1. Periodicinspection.
Forunitsfittedwithlevelplugorotherlevelindicatingdevice.Checktheoillevelevery3000hoursor6months(whicheverissooner)andifnecessarytopupwiththerecommendedtypeoflubricant.
10.3.2. Oilchanges.
Smallersizeunits(withoutventilator)aresuppliedfactoryfilledandlubricatedforlifeexceptforthefollowing conditions:•Mineraloilfilledunitsoperatingatover70°Csurfacetemperatureshouldbedrainedandrefilledwiththecorrectquantityofoilafter3yearsoperation.•Allunitsthatarerequiredtoworkinpotentiallyexplosiveatmospheres(GroupIIcategory2zones1&21or category3zones2&22)shouldbedrainedandrefilledwithcorrectquantityoflubricantinaccordancewiththescheduleaslistedinTableM2-SeeAppendix4forcorrectoilquantity.
Alllargersizeunits(suppliedwithventilator)shouldbedrainedandrefilledwithcorrectquantityoflubricantinaccordancewiththeTablesM2-SeeAppendix4forcorrectoilquantity.
Warning.
DonotmixSyntheticandMinerallubricants.Donotoverfilltheunitasthiscancauseleakageandoverheating.
DANGER
Pinch Points Watch Your Hands
CAUTION
STOP
CAUTION
MAINTENANCE
9
UNITOPERATINGTEMPERATURE°C
RENEWALPERIOD
MINERALOIL SYNTHETICOIL
<75°C 17000HOURSOR3YEARS 26000HOURSOR3YEARS
80°C 12000HOURSOR3YEARS 26000HOURSOR3YEARS
85°C 8500HOURSOR3YEARS 21000HOURSOR3YEARS
90°C 6000HOURSOR2YEARS 15000HOURSOR3YEARS
95°C 4200HOURSOR17MONTHS 10500HOURSOR3YEARS
100°C 3000HOURSOR12MONTHS 7500HOURSOR21/2YEARS
105°C 2100HOURSOR8MONTHS 6200HOURSOR2YEARS
110°C 1500HOURSOR6MONTHS 2100HOURSOR18MONTHS
UNITOPERATINGTEMPERATURE°C
RENEWALPERIOD
MINERALOIL SYNTHETICOIL
<65°C 17000HOURSOR3YEARS 26000HOURSOR3YEARS
70°C 12000HOURSOR3YEARS 26000HOURSOR3YEARS
75°C 8500HOURSOR3YEARS 22000HOURSOR3YEARS
80°C 6000HOURSOR2YEARS 15000HOURSOR3YEARS
85°C 4200HOURSOR17MONTHS 10500HOURSOR3YEARS
90°C 3000HOURSOR12MONTHS 7500HOURSOR21/2YEARS
95°C 2100HOURSOR8MONTHS 6000HOURSOR2YEARS
100°C 1500HOURSOR6MONTHS 4500HOURSOR18MONTHS
NB: INITIAL FILL OF OIL SHOULD BE CHANGED IN A NEW GEAR UNIT AFTER 1000 HOURS OPERATION OR ONE YEAR WHICHEVER IS THE SOONEST
10.4. Bearings
10.4.1Formarkedunitsbearingsshouldbecheckedafter5yearsoperation,andreplaced(ifnecessary) 10.5. Grease Lubrication
10.5.1. Wherere-greasingpointsareprovidedadd2shotsmonthlyofNLGI2gradegrease.Seeappendix4fordetailsof approved grease.
10.6. Cleaning
10.6.1. Withthedrivestationary,periodicallycleananydirtordustfromthegearunitandtheelectricmotorcoolingfinsand fan guard to aid cooling.
10.6.2. Ensureanydustbuildupdoesnotexceed5mm(maximum)
10.7. Motor Replacement 10.7.1. Isolateandsecurethedrivenmachine,anddisconnectthemotorpowersupply
10.7.2. Removethemotorflangefastenings
10.7.3. Carefullyslidethemotorawayfromthegearunit(donothammer)
10.7.4. Cleanthegearunitplug-inboreandtheflangesurface
10.7.5. Checkthereplacementmotoristheofcorrectframesizeandpowerratingforthegearunit,andre-fitthemotoras describedinSection5.4
10.7.6. Re-connectmotorpowersupply–SeeSection7
Connection of the electric motor to the mains supply should be made by a qualified person.
Oil Change Period: F K & R Series
CAUTION
RISK OF ELECTRICAL
SHOCK
MAINTENANCE
Oil Change Period: S Series
10
11. Fault diagnosis
11.1. Gear unit problems:
Symptom PossibleCauses Remedy
Outputshaftdoesnotrotate,eventhoughthemotorisrunningor the input shaft is rotating.
Drive between shafts interupted in the gear unit Returnthegearunit/gearedmotorforrepair
Unusual,regularrunningnoise
a)Ameshingorgrindingsound:damageto bearingsb)Aknockingsound:irregularityinthegearing
a)Checkoil(SeeInspectionandMaintenance)b)ContactourApplicationEngineers
Unusual,irregularrunningnoise Foreignmatterpresentintheoil a)Checkoil(SeeInspectionandMaintenance)
b)Stoptheunit,ContactourApplicationEngineers
Oilleaking¹•fromthegearunitcover•fromthemotorflange•fromthegearunitflange•fromtheoutputendoilseal
a)Defectivegasketongearunitcoverb)Defectivegasketc)Gearunitnotventilated
a)Retightenscrewsongearunitcoverandobservegearunit.IfoilstillleakscontactourApplicationEngineersb)ContactourApplicationEngineersc)Ventthegearunit(seeAppendix4-Mountingpositions)
Oilleakingfromtheventilator
a)Gearunitoverfilledwithoilb)Gearunitinstalledinanincorrectmounting positionc)Frequentcoldstarts(oilfoaming)and/orhigh oil level.
a)Correcttheoillevel(seelubricationsection)b)Fittheventilatorinthecorrectposition(seeAppendix4-Mountingpositions)andcheckoillevel(seelubrication)c)Checktheoillevel(seelubrication)
1)itisnormalforsmallamountsofoil/greasetoleakoutoftheoilsealduringtherunninginperiod(24hoursrunningtime)
When contacting our sales office
Pleasehavethefollowinginformationavailable:
• Nameplatedata(complete)• Typeandextentoftheproblemencountered• Thetimeandthecircumstancestheproblemoccurred• Apossiblecause
Anyfurtherinformationorclarificationrequiredmaybeobtainedbycontactingoursalesoffice,pleaseseecontactdetailsatthebackofthisbooklet.
PROBLEM SOLVING
11
Shaft Alignment.Errorsofalignmentfallintocategoriesofangularity(seeFigure1)andeccentricity(seeFigure2),oracombinationofboth.
Errorsofangularityshouldbecheckedfor,andcorrected,beforeerrorsofeccentricity.
AlignmentinaccordancewiththefollowingprocedurewillensurevibrationlevelsmeetingthosesetoutinISO10816Part1.
Errors of Angularity.Ifthefacesareperfectlytrue,theangularitycanbecheckedbykeepingbothshaftsstationaryandtakingmeasurementswithablockgaugeandfeelersatthefourpoints1,2,3and4asshowninFigure3.Thedifferencebetweenthereadings1and3willgivetheerrorofalignmentintheverticalplane,overthelengthoftheshaftequaltothediameterofthecouplingflanges,andfromthisthedifference in the relative heights of the feet of themotororotherconnectedmachinecanbefoundbyproportion.Similarly,thedifferencebetweenthereading2and4givestheamountofsidewaysadjustmentnecessarytocorrectanyerrorsofalignmentinthehorizontalplane.
Generally,however,thecouplingfaceswillnot be absolutely true and whilst any errors sofoundcouldbeallowedforincheckingangularitybythestationarymethodaneasiermethodpresentsitself.Thisconsistsinmarkingthepoints1onboth“A”and“B”androtatingbothhalfcouplings,keepingthemarkedpointstogether.Bytakingmeasurementseachquarter-revolutiontheerrorsintheverticalandhorizontalplanesareagain found.
NOTE: Checkthealignmentafterrunningthe unit until it has attained its normalworkingtemperature.Anydiscrepanciescanthenberectified.
Thepermittedangularityerrorisasfollows:
NOTE: Disthediameter(mm)atwhichthegapismeasured.
TypeofCoupling AllowableGap(G)(mm)
RigidCoupling G=0.0005D
Allothertypes PleaseseeappropriateInstallationandMaintenanceManualforcouplingtypefitted
APPENDIX 1
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
12
Errors of EccentricityTheprocedureformeasuringeccentricityispreciselyanalogoustothatusedforangularity.Inthiscase,however,themeasurementsaretakeninaradialdirectionandthemostconvenientandaccuratemeansofdoingthisutilisesadialindicatorsuitablyclampedtoonehalfcoupling,andbearingonthehuborflangeoftheother,asshowninfigures4and5onpage11.
Caremust,however,betakentoensurethesupportforthedialindicatorissufficientlyrigidtopreventtheweightoftheindicatorfromcausingdeflectionand,inconsequenceinaccuratereadings.Extracareshouldbetakenwheretaperrollerbearingsarefittedtoensurethatalignmentischeckedwithshaftsinmid-pointpositionandafinalcheckmadewiththeunitatoperatingtemperature.
SPECIAL NOTE CONCERNING RIGID COUPLINGSInliningupelementsinvolvingrigidcouplingsitisimportantthatnoattemptismadetocorrecterrorsofalignmentoreccentricitygreaterthanthoseabovebytighteningofthecouplingbolts(Thisapplieswhenthesystemiscoldoratoperatingtemperature).Theresultismiss-alignmentandthesettingupofunduestressesintheshaft,couplingandbearings.Thiswillberevealedbythespringingapartofthecouplingfacesiftheboltsareslackenedoff.Acheckontheangularityofapre-assembledjob,afterboltingdown,canbeobtainedinthecaseofrigidcouplingsbyslackeningoffthecouplingbolts,whenanymis-alignmentwillcausethecouplingfacestospringapart.Thischeckmaynot,however,revealanystrainsduetoeccentricityowingtotheconstantrestraintimposedbythespigot.
COUPLINGSWeproducestandardflexiblecouplingstocoverthecompleterangeofgearunits,pleasecontactApplicationEngineeringfordetails.
TypeofCoupling UnitSize AllowableEccentricity(mm)
Rigid SIZE08&UNDER 0.025
SIZE09&OVER 0.035
Allothertypes Pleaseseeappropriateinstallationandmaintenancemanualforcouplingtypefitted
APPENDIX 1
13
T
u
I5
d d
l
I1I2
I3 I4
d
R
da
u1
m
Pr ot ec tive Cov er
Sp ac er -onl y us ed whe n sh aft has no sh ou lder
ProtectiveCoverSpacer-onlyusedwhenshafthas no shoulder
UNIT Bore d da l l1 l2 l3 l4 l5 m R T u u1
S03 Std 19.993/19.980 19.6 82 30 10 613
61.0 3 22 M6x1.016deep 0.8R 16.5
16.46.000/5.970
0.160.25R
S04Reduced 29.993/
29.980 24.6 99 38 13 79.379.0 3 23 M10x1.5
22deep0.8R 21.0
20.88.000/7.964
0.160.25R
Std 29.993/29.980 29.6 99 45 15 79.3
79.0 3 26 M10x1.522deep 0.8R 26.0
25.88.000/7.964
0.160.25R
S05Reduced 29.993/
29.980 29.6 104 45 15 79.379.0 3 23 M10x1.5
22deep 0.8R 26.025.8
8.000/7.964
0.160.25R
Std 34.991/34.975 34.6 104 53 18 77.3
77.0 3 23 M12x1.7522deep 0.8R 30.0
29.810.000/9.964
0.160.25R
S06Reduced 39.991/
39.975 39.6 125 60 20 100.5100.0 3 31 M16x2
36deep 0.8R 35.034.8
12.000/11.957
0.40.25R
Std 44.991/44.975 44.6 125 68 23 101.5
101.0 3 31 M16x236deep 0.8R 39.5
39.314.000/9.957
0.40.25R
S07Reduced 49.991/
49.975 49.6 153 75 25 130.5130.0 3 35 M16x2
38deep 1.2R 44.544.3
14.000/13.957
0.40.25R
Std 59.990/59.971 59.6 153 90 30 148.5
148.0 3 38 M20x2.542deep 1.2R 53.0
52.818.000/17.957
0.40.25R
S08Reduced 59.990/
59.971 59.6 183 91 31 148.5148.0 3 37 M20x2.5
42deep 1.2R 53.052.8
18.000/17.957
0.40.25R
Std 69.990/69.971 69.6 183 105 35 177.5
177.0 3 37 M20x2.542deep 1.2R 62.5
62.320.000/19.948
0.60.4R
S09Reduced 69.990/
69.971 69.6 227 105 35 177.5177.0 3 58 M20x2.5
42deep 1.2R 62.562.3
20.000/19.948
0.60.4R
Std 89.998/89.966 76.6 227 135 45 221.5
221.0 3 58 M24x3.050deep 1.2R 81.0
80.825.000/24.948
0.60.4R
S10Reduced 79.990/
79.971 79.6 260 120 40 225.5225.0 3 53 M20x2.5
42deep 1.2R 71.070.8
22.000/21.946
0.60.4R
Std 99.988/99.966 99.6 327 150 45 238.5
238.0 10 46 M24x3.050deep 0.8R 90.0
89.828.000/27.948
0.60.4R
F02 - 24.9931/24.980 24.6 82 40 13 70.3
70.0 3 23 M10x1.522deep 0.8R 21.0
20.88.000/7.964
0.160.25R
F03&K03 - 29.993/29.980 29.6 82 45 15 70.3
70.0 3 23 M10x1.522deep 0.8R 26.0
25.88.000/7.964
0.160.25R
F04&K04 - 34.991/34.975 34.6 109 60 20 90.5
90.0 3 23 M12x1.7528deep 0.8R 30.0
29.810.000/9.964
0.160.25R
F05&K05 - 39.991/39.975 39.6 112 60 20 92.5
92.0 3 30 M16x236deep 0.8R 35.0
34.812.000/11.957
0.40.25R
F06&K06 - 39.991/39.975 39.6 126 75 25 100.5
100.0 3 30 M16x236deep 0.8R 35.0
34.812.000/11.957
0.40.25R
F07&K07 - 44.991/44.975 49.6 153 75 25 101.5
101.0 3 30 M16x236deep 0.8R 44.5
44.314.000/13.957
0.40.25R
F08&K08 - 59.990/59.971 59.6 173 90 30 148.5
148.0 3 37 M20x2.542deep 0.8R 53.0
52.818.000/17.957
0.40.25R
F09&K09 - 69.990/69.971 69.6 232 105 35 161.5
161.0 3 38 M20x2.542deep 0.8R 62.5
62.320.000/19.948
0.60.4R
F10&K10 - 79.990/79.971 79.6 275 120 40 188.5
188.0 5 37 M20x2.542deep 0.8R 71.0
70.822.000/21.946
0.60.4R
F11 - 89.988/89.996 89.9 265 60 55 206.5
206.0 42 - M24x3.050deep 0.8R 81.0/
80.825.000/24.948
0.60.4R
F12 - 99.988/99.996 99.6 329 59 60 228.5
228.0 50 - M24x3.050deep 0.8R 90.0
89.828.000/27.948
0.64R
K12 - 99.988/99.966 99.6 327 150 45 238.5
238.0 10 46 M24x3.050deep 0.8R 90.0
89.828.000/27.948
0.60.4R
Shaft Mounted Units - Standard Bore/Shaft Assembly
Customers Shaft Details
APPENDIX 2A
Seenextpageforshaftassemblyinstructions.
14
Standard Bore/Shaft Assembly Instructions
1.Spraythehollowshaftboreandmatingdiameterofoutputshaftwithananti-fretcompound.
2.Fittheshafttohollowborelocationkeyinpositionintheoutputshaft.
3.Fitthecirclipintotheoutputsleeve.(UnitsF11andF12cannotbesecuredinthisway,itisrecommendedtousethealternativefixingmethodtypeBasshownbelow)
4.Fittheoutputshaftintotheoutputsleeve.Remembertofitaspacertube(notsupplied)iftheoutputshafthasnoshoulder.(seedimensiontablefordetails)
5.Secureinplacewiththewasherandbolt,Torquetightenthebolttothevaluesstatedinthetablebelow.
6.Fittheprotectivecoverovertheopenendoftheoutputsleeve.
Alternativeshaftfixingmethodsshownbelowmaybeconsidered
A B
C D
E
B
APPENDIX 2A
A-RetainedwithaCirclip B–RetainedwithaPlateandBolt
C–RetainedwithaLocknut D–RetainedwithaCollarandGrubscrew
E–RetainedwithaPlateandBolt
Bolt Torque
M10 15
M12 20
M16 45
M20 85
M24 200
CAUTION
15
Standard Bore/Shaft Disassembly.
UNIT Bore c4 c6 c7 D (H7) d2 d3 d4 l2 m m1 t u
S03 Std 5 10 12 20 7 19.9 11.2 120 3 M10x1.5 22 6
S04Reduced 5 15 17 25 13 24.9 16.2 23 3 M16x2 28 8
Std 5 15 17 30 13 29.9 20.8 160 3 M16x2 33 8
S05Reduced 5 15 17 30 13 29.9 20.8 260 3 M16x2 33 8
Std 5 15 17 35 13 34.9 25.2 160 3 M16x2 38 10
S06Reduced 5 20 23 40 20 39.9 30.9 220 3 M24x3 43 12
Std 5 20 23 45 20 44.9 34.1 220 3 M24x3 49 14
S07Reduced 5 20 23 50 20 49.9 39 220 3 M24x3 54 14
Std 8 24 27 60 26 59.9 47.4 250 5 M30x3.5 64 18
S08Reduced 8 24 27 60 26 59.9 47.4 250 5 M30x3.5 64 18
Std 8 24 27 70 26 69.9 58.4 310 5 M30x3.5 74.5 20
S09Reduced 8 24 27 70 26 69.9 58.4 310 5 M30x3.5 74.5 20
Std 8 24 27 90 26 89.9 75.3 360 5 M30x3.5 95 25
S10Reduced 8 24 27 80 26 79.9 65.5 360 5 M30x3.5 85 22
Std 8 30 34 100 32 99.9 84.1 420 5 M36x4 106 28
F02 - 5 15 17 25 10 24.9 16 120 3 M12x17.5 28 8
F03&K03 - 5 15 17 30 13 29.9 20.8 130 3 M16x2 33 8
F04&K04 - 5 15 17 35 13 34.9 25.2 160 3 M16x2 38 10
F05&K05 - 5 20 23 40 20 39.9 29.9 190 3 M24x3 43 12
F06&K06 - 5 20 23 40 20 39.9 29.9 190 3 M24x3 43 12
F07&K07 - 5 20 23 50 20 49.9 39 220 3 M24x3 53.5 14
F08&K08 - 8 24 27 60 26 59.9 47.4 250 5 M30x3.5 64 18
F09&K09 - 8 24 27 70 26 69.9 56.4 310 5 M30x3.5 74.5 20
F10&K10 - 8 24 27 80 26 79.9 65.5 360 5 M30x3.5 95 25
K12 - 8 30 34 100 32 99.9 84.1 420 5 M36x4 116 28
Disassembly Procedure
1.Removelocatingbolt,retainingplateandcirclip
2.Placeplateonshaftendtoprotecttheshaftscrewthread
3.Assembledisassemblytoolingasshownindiagramabove
4.Turnscrewtoapplypressuretoshaftend.
APPENDIX 2A
*Partssuppliedbycustomer
c5 c4
d3
I2m
1 x 45
m1
d2
t
u
d4
c6
c7
m1
*
*
*
d3
d3
D
16
F Series - With Kibo Bushes.
TheFSeriesKiboBushoptionrequiresagearunitwithaKibotypetaperedoutputbore,togetherwithaKibobushingkitcom-prisingof:bushes(2),lockingnuts(2),endplate,fasteningbolt,shaftkeyandprotectivecover.
Assembly
1.Assembletheinnerbushingandlocknutontothemachineshaft.Theinnerbushingmustbemountedagainstashoulderorretainingcirclip,theshoulderdiametershouldnotexceedinsidediameterofnut.
2.Fullybackofftheinnerlocknut.
3.Fitthekeyintotheshaftkeyway.
3.Assemblethegearunitontotheinnerbushingandshaft.
4.Assembletheouterbushingintothegearunitbore,fitlocknutandfingertightenuntilitmakescontactwiththegear unit shaft 5.Mounttheendplateandfixingbolt,tightenthebolttothecorrecttorque,theinnerbushingisnowlocked 6.Loosenoffthefixingbolt,sotheouterbushingisloose,backofftheouterlocknut.
7.Re-tightenthefixingbolttothecorrecttorque,theouterbushingisnowlocked.
8.Fingertightenboththelocknutsagainstthegearunitshaft,themountingisnowcomplete.
9. Fit the protective cover.
Disassembly
A.Removetheprotectivecover,fixingboltandendplate
B.Tightentheouterlocknutwithanadequatetooltowithdrawthebushingfromthegearunitshaft.
C.Removethegearunitfromtheshaft.
Seetableonnextpagefordimensions
NOTE:Ifreduceristobeusedinacorrosiveenvironment,machineshaftbushingsandnutsshouldbeoiledorgreased.DoNOTuseMolybdenumDisulfidebasedoilorgrease.
d
L
L1 L2
D4
d
d -0
.3
d
u
t
5x45
K (DIN 332)
Ak
Lk Lk
D
L4 L3
d5
dk
e
M1
k1
C
M
R
g4
w7
APPENDIX 2B
CAUTION
17
Uni
t Siz
e
Cus
tom
ers
Shaf
tEn
d Pl
ate
Cov
er
d (h8)
d4K
LL1
L2L3
L4r (
max
)t
ufk
m1
Ak
Lkd5
Cd4
Tigh
teni
ng
Torq
ue N
mg4
w7
min
max
Din
(332
)(N
9)M
ek1
F04
3540
42
M12x28
175
4036
6060
1.2
3010
65157
180
4045
10
M12
228
56
8134
3035
M10x22
268
M10
207
4025
3021
8
F05
4045
51
M16x36
198
5042
7765
1.2
3512
75179
207
5055
12
M16
2810
124
8543
3540
M12x28
3010
M12
228
70
3035
M10x22
268
M10
207
40
F06
4045
51
M16x36
225
5045
7778
1.2
3512
75205
233
5055
12
M16
2810
124
8543
3540
M12x28
3010
M12
228
70
3035
M10x22
268
M10
207
40
F07
5055
61
M16x36
258
5852
7993
1.2
44.5
14
80234
265
5865
14M16
2810
154
122
4345
5039.5
14
4045
3512
F08
6066
71
M20x42
293
6152
108
97.5
1.6
5318
98270
303
6175
16M20
3513
240
147
4755
6149
16
5056
M16x36
44.5
14M16
2810
169
F09
7076
81
M20x42
340
7050
131
751.6
62.5
20
110
330
369
67.5
8520
M20
3513
290
192
9065
7158
18
6066
5318
F10
8089
96
M20x42
390
7060
163
104
1.6
7122
130
370
414
53100
24M20
3513
274
242
9075
8467.5
20
7079
62.5
20
F11
9099
101
M24x50
368
7073
181
110
2
8125
140
390
57105
26M24
4215
308
8594
7622
8089
7122
F12
100
109
116
M24x50
428
8083
200
111
2.5
9028
155
450
83130
7M24
4215
451
95104
8625
9099
8125
APPENDIX 2BF
Serie
s - K
ibo
Bus
hes
Dimensions(mm)
18
K Series - With Shrink Disc
TheShrinkDiscoptionrequiresagearunitwithaShrinkDisctypeoutputbore,togetherwithaShrinkDisc(A)lockingdevice.
TheShrinkDiscisafrictiondevice(withoutkeys)whichexertsanexternalclampingforceonthehollowgearboxshaftresultinginamechanicalshrinkfitofthegearunitanddrivenshaft.
SIZE D D6 d7 m4 m5 m6 m7 o o1 Torque Ta (Nm)
K03 30 30 50 31 20 36 25 60 86 29
K04 35 35 55 32 20 37 25 75 102 29
K05 40 40 60 36 20 41 25 83 112 29
K06 40 40 70 38 20 43 25 90 118 29
K07 50 50 80 36 30 41 35 105 136 35
K08 65 65 90 41 40 46 45 120 161 58
K09 75 75 100 55 40 60 55 150 195 58
K10 95 95 120 65 60 70 65 175 230 100
K12 105 105 140 85 60 90 75 205 280 160
Assembly
1.Cleananddegreasethelocatingdiametersofthegearunithollowshaftbore,thedrivenshaftandtheshrinkdisklocatingsurfaces
2.EnsuretheAnti-fretyellowmetalbush(C)iscorrectlyinsertedinthenondrivingendofthegearunithollowshaft
3.Drawthegearunitontothedrivenshaft.
4.Checkandre-applyifnecessarymolykote321R(orsimilar)tothetaperedsurfacesoftheShrinkDiscinnerringandlockingcollar. 5.FittheShrinkDiskinnerringandcollarintopositionontheshaft,fitandtightenallthelockingscrewsgraduallyinsuccession,donottighteninadiametricallyoppositesequence.Thistighteningsequencewillrequireseveralpassesuntilallthescrewsaretightenedtothetorquespecifiedinthetableabove. 6.Fittheprotectivecover.
Disassembly similartothereverseoftheassemblyprocedure.
A.RemoveanyrustanddirtfromtheassemblyB.Loosenoffthelockingscrewsinsuccessionbutdonotcompletelyremove.C.Removetheshrinkdiskandwithdrawthegearunitfromthedrivenshaft.
NOTE:IftheShrinkDiskistobere-useditshouldbedismantledandcleanedthoroughlyandMolykote321R(orsimilar)applied to the tapered surfaces of the inner ring and collar
D
D+0
.5
D6
o o1
d7
m5 m4
m7 m6
o + o1
D [h
6]
D6
[h6]
D-0
.3
ABC
APPENDIX 2C
CAUTION
Dimensions(mm)
19
1.Itisrecommendedthatthetorquebracketispositionedonthesideofthegearunitadjacenttothedrivenmachine.
2.Thetorquebracketrequiresaclevistypeanchoringasshownabove(notsupplied)
3.Theclevispositionshouldbecarefullyadjustedatassemblysothatitdoesnotexertanyexternalradialoraxialpressureonthetorquebracket
Torque Bracket Dimensions mm
Unit A B C D E F (min)
S03 110 47 36 10.4 23 41
S04 130 52 36 10.4 23 41
S05 160 52 36 10.4 23 41
S06 200 72 44 16.4 43 49
S07 250 78 60 16.4 43 65
S08 310 86 60 16.4 45 65
S09 380 98 80 25 50 85
S10 430 137 80 25 50 85
1.Torquearmcomponentsconsistofapairofrubberbuffers(1)thecustomermustsupplyothercomponents.2.Thegearunitshouldbeanchoredtoaplate(2)usingabolt(3),washers(4),nutandlocknut(5)asshownabove.3.Tightenbolt(3)tocompressrubberbushes(1)toachievedimension‘L’(listedintablebelow)securewithlocknut.
Unit L Bolt (3) a9 Unit L Bolt
(3) a9 Unit L Bolt (3) a9 Unit L Bolt
(3) a9
F02
52 M12
140 F0552 M12
198 F08 84 M20 346 F11 116 M24 485
F03 158 F06 218 F09 110M24
395 F12 146 M30 550
F04 170 F07 80 M20 278 F10 112 485 - - - -
A
BC
D
E
F
S Series Torque Bracket
1
2
3
44
5
L
a9
F Series Torque Buffers
APPENDIX 2D
CAUTION
CAUTION
Dimensions(mm)
20
K Series Torque Bracket
Unit A B C D E F (min) GK03 140 20 36 10.4 23.5 41 23K04 160 20 36 10.4 30 41 23K05 192 18 60 16.4 40 65 38K06 200 25 60 16.4 45 65 38K07 250 25 60 16.4 52.5 65 38K08 300 30 80 25 60 85 45K09 350 40 100 25 70 105 45K10 450 45 100 25 74 105 45K12 550 10 126 38 60 131 63
AEC
D
F
B
G
1.Itisrecommendedthatthetorquebracketispositionedonthesideofthegearunitadjacenttothedrivenmachine.
2.Thetorquebracketrequiresaclevistypeanchoringasshownabove(notsupplied)
3.Theclevispositionshouldbecarefullyadjustedatassemblysothatitdoesnotexertanyexternalradialoraxialpressureonthetorquebracket
Torque Bracket Dimensions mm
APPENDIX 2D
CAUTION
21
Three Phase Induction Motor Installation.
Connection to Mains Power Supply.
•Connectionoftheelectricmotortothemainssupplyshouldbedonebyaqualifiedperson.
•Connectmotorterminalsinaccordancewiththediagraminsidetheterminalboxcover.(Alsoidentifiedinthediagrambelow-thisinstructiononlyappliestoourownbrandplatedmotors)
•Motorsfittedbythecustomerorrequestedbythecustomerfromadifferentmanufacturerwillhaveseparatedocumentationprovidedwithit.
Note:Itisimportantthatthemainssupplydetailsarecheckedagainstthemotornameplatedataandthattheyareconnectedasindicatedonthenameplate.Thecorrectsizingofthecablestoelectricalregulationsisessential.
•Tochangethedirectionofrotationoftheelectricmotor,oneofthethreemainlineterminalsshouldbechangedwiththe other.
•Connecttheearthconductorstothemarkedearthterminals.
0.12Kw-2.2Kw220/240v,50Hz
230/280V,60Hz
≥3Kw380/420V,50Hz
440/480V,60Hz
APPENDIX 3
RISK OF ELECTRICAL
SHOCK
0.12Kw-2.2Kw380/420v,50Hz
440/480V,60Hz
≥3Kw 380/420V,50Hz
22
Approved Lubrication.TypeEMineraloilcontainingindustrialEPadditives.Thesehaveahighloadcarryingcapacity.
SUPPLIER LUBRICANTRANGE
GRADENUMBERS
5E 6E 7E
AMBIENTTEMPERATURERANGE°C
-5to20 0to35 20to50
BatoyleFreedom Remus 220(-2) 320(-2) 460(-2)BoxerServices/MillersOils Indus 220(-10) 320(-10) 460(-10)
BPOilInternationalLimitedEnergolGR-XF 220(-16) 320(-13) 460(-1)EnergolGR-XP 220(-15) 320(-10) 460(-7)
CaltexMeropa 220(-4) 320(-4) 460(-4)
RPMBorateEPLubricant 220(-7) 320(-4) 460(-7)
CarlBechemGmbHBerugearGSBM 220(-20) 320(-13) 460(-10)
Staroil G 220(-13) 320(-13) 460(-10)
CastrolInternationalAlphaMax 220(-19) 320(-13) 460(-10)AlphaSP 220(-16) 320(-16) 460(-1)
ChevronInternationalOilCompanyLimited
GearCompEP(USAver) 220(-16) 320(-13) 460(-10)GearCompEP(Easternver) 220(-13) 320(-13) 460(-13)
UltraGear 220(-10) 320(-7) 460(-7)Eko-EldaAbee EkoGearlub 220(-13) 320(-10) 460(-1)
EngenPetroleumLimited Gengear 220(-15) 320(-12) 460(-3)Esso/Exxon SpartanEP 220(-12) 320(-12) 460(-4)
FuchsLubricants
Powergear P/Gear(-16) M460(-4)RenogearV 220EP(-13) 320EP(-4) 460EP(-4)RenogearWE 220(-7) 320(-4) 400(-4)
RenolinCLPFSuper 6(-13) 8(-10) 10(-10)KlüberLubrication KlüberoilGEM1 220(-5) 320(-5) 460(-5)
KuwaitPetroleumInternational Q8Goya 220(-16) 320(-13) 460(-10)LubricationEngineersInc. AlmasolVari-PurposeGear 607(-18) 605(-13) 608(-10)
MobilOilCompanyLimitedMobilgear600series 630(-13) 632(-13) 634(-1)
MobilgearXMP 220(-19) 320(-13) 460(-7)OmegaManufacturingDivision Omega690 85w/140(-15)
OptimalÖlwerkeGmbHOptigearBM 220(-11) 320(-10) 460(-7)Optigear 220(-18) 320(-9) 460(-7)
Pertamina(Indonesia) Masri 220(-4) 320(-4) 460(-7)Petro-Canada UltimaEP 220(-22) 320(-16) 460(-10)
Rocol SapphireHi-Torque 220(-13) 320(-13) 460(-13)
SasolOil(Pty)LimitedCobalt 220(-4) 320(-1) 460(-4)Hemat 220(-10) 320(-7) 460(-4)
SaudiArabianLubr.OilCo. GearLubeEP EP220(-1) EP320(0) EP460(0)
ShellOilsOmala 220(-4) 320(-4) 460(-4)OmalaF 220(-13) 320(-10) 460(-4)
TexacoLimitedMeropa 220(-16) 320(-16) 460(-10)
MeropaWM 220(-19) 320(-16) 460(-11)
TotalCarterEP 220(-21) 320(-15) 460(-12)CarterXEP 220(-24) 320(-18) 460(-13)
TribolGmbHMolub-AlloyGearOil 90(-18) 690(-16) 140(-13)
Tribol1100 220(-20) 320(-18) 460(-16)
DANGER: Numbersinbracketsindicatetheminimumpourpointtemperatureofthespecifiedoilin°C
THEUNITMUSTNOTBERUNBELOWTHISTEMPERATURE.
APPENDIX 4
23
Approved Lubrication – S Series
TypeGPolyglycolbasedsyntheticlubricantswithAnti-WearorEPadditives.
SUPPLIER LUBRICANTTYPE 5G 6G 7G 8G 9G
BoxerServices/MillersOils BoxergearW 220(-31) 320(-31) 460(-28)
BPOilInternationalLimited EnersynSG-XP 220(-31) 460(-34) 680(-28)
Caltex SynlubeCLP 220(-34) 320(-31) 460(-28) 680(-31)
CarlBechemGmbH BerusynthEP 220(-25) 320(-25) 460(-25) 680(-28) 1000(-28)
CastrolInternational AlphasynPG 220(-34) 320(-31) 460(-28)
Esso/Exxon Glycolube 220(-25) 320(-25) 460(-23)
FuchsLubricants Renolin PG 220(-34) 320(-34) 460(-34) 680(-28) 1000(-28)
KlüberLubricationKlübersynthGH6 220(-25) 320(-25) 460(-20) 680(-20) 1000(-28)
KlübersynthUH16 220(-30) 320(-25) 460(-25)
KuwaitPetroleumInternational Q8Gade 220(-22) 320(-22) 460(-22)
LaportePerformanceChemicalsLimited
BeroxIndustrialLubricantSW 220(-25) 320(-25) 460(-23) 680(-20) 1000(-28)
BeroxSLRange 220(-40) 320(-37) 460(-23)
BeroxOilSolubleIndustrialLubex 220(-23)
MobilOilCompanyLimited Glygoyle HE220(-22) HE320(-37) HE460(-35)
OptimalÖlwerkeGmbH OptiflexA+ 220(-28) 320(-28) 460(-28) 680(-28) 1000(-25)
ShellOilsTivela SB(-25) SC(-25) SD(-23)
TivelaS 220(-34) 320(-34) 460(-34)
TexacoLimited SynlubeCLP 220(-34) 320(-31) 460(-10) 680(-31)
Total CarterSY 220(-25) 320(-28) 460(-22)
TribolGmbH Tribol800 220(-27) 320(-25) 460(-25) 680(-25) 1000(-23)
+NOTSUITABLEFORAPPLICATIONSREQUIRINGINDUSTRIALEPADDITIVESx THISPARTICULARLUBRICANTISCOMPATIBLEWITHTYPESE,ANDH
DANGER:Numbersinbracketsindicatetheminimumpourpointtemperatureofthespecifiedoilin°C
THEUNITMUSTNOTBERUNBELOWTHISTEMPERATURE
APPENDIX 4
24
Approved Lubrication.TypeHPolyalphaolefinbasedsyntheticlubricantswithAnti-WearorEPadditives.
SUPPLIER LUBRICANTTYPE 5H 6H
BatoyleFreedomGroup Titan 220(-31) 320(-28)
BoxerServices/MillersOils Silkgear 220(-35) 320(-35)
BPOilInternationalLimited EnersynEPX - 320(-28)
Caltex PinnacleEP 220(-43) 320(-43)
CarlBechemGmbH BerusynthGP 220(-38) 320(-35)
CastrolInternationalAlphasynEP 220(-37) 320(-31)
AlphasynT 220(-31) 320(-28)
ChevronInternationalOilCo Tegra 220(-46) 320(-33)
Esso/Exxon SpartanSyntheticEP 220(-46) 320(-43)
FuchsLubricantsRenogear SG 220(-32) 320(-30)
RenolinUnisynCLP 220(-37) 320(-34)
KlüberLubrication KlübersynthGEM4 220(-30) 320(-25)
KuwaitPetroleumInternational Q8ElGreco 220(-22) 320(-19)
LubricationEngineersInc. SynolecGearLubricant 220(-40) -
MobilOilCompanyLimitedMobilgearSHC 220(-40) 320(-37)
MobilgearXMP 220(-40) 320(-33)
OptimalÖlwerkeGmbH OptigearSyntheticA 220(-31) 320(-31)
Petro-Canada Super Gear Fluid 220(-43) 320(-37)
ShellOils OmalaHD 220(-43) 320(-40)
TexacoLimitedPinnacleEP 220(-43) 320(-43)
PinnacleWM 220(-43) 320(-40)
Total CarterSH 220(-48) 320(-42)
TribolGmbH Tribol1510 220(-36) 320(-33)
DANGER:Numbersinbracketsindicatetheminimumpourpointtemperatureofthespecifiedoilin°C
THEUNITMUSTNOTBERUNBELOWTHISTEMPERATURE
Approved GreaseNLGIgrade2greasesuitableforoperationinambienttemperaturesof-20°Cto50°C-ForuseoutsideofthisrangecontactourApplicationEngineers
SUPPLIER GREASETYPE
BPOilInternationalLimited EnergreaseLS-EP
Caltex MulifakEP
CastrolInternational
LMXGrease
SpheerolAP
SpheerolEPL
FuchsLubricants RenolitEP
KlüberLubrication KlüberlubBE41-542
MobilOilCompanyLimitedMobilgreaseXHP
MobilithSHC
Omega Omega85
Optimol LongtimePD
ShellOils
AlbidaRL
AlvaniaEPB
NeritaHV
TexacoLimited MultifakEP
APPENDIX 4
25
S Series Lubrication
1.S03toS06aresuppliedfactoryfilledwithaquantityofpolyglycolsyntheticoil(Grade6G)appropriatetothemounting position–Ifthegearunitisdrainedforanyreasonitmustbere-filledwiththecorrectgradeandquantityoflubricant as shown in the table below.
2.S07toS10aresuppliedwithoutlubricantandmustbefilledviatheventilatorpositionwithpolyglycolsyntheticoil (Grade6G)untiltheoilescapesthroughthelevelplughole–seetablebelowforapproximatelubricantquantity,
3.S07toS10Oillevelsforsomeunitsaredependentonmountingpositionandspeedofoperation.Level1(L-1)foroutputspeedsbelow100rpmLevel2(L-2)foroutputspeeds100rpmandabove
4.Maintenance:
•OillevelsforS07toS10canbecheckedandmaintainedbyfillingviatheventilatorpositionuntiloilescapesthroughthe levelplughole,•S03toS06theseunitsmustbefullydrainedandre-filledwiththecorrectquantityoflubricant
Lubricant Quantities (Litres)
Posn Level S0321 S0421 S0521 S0621 S0721 S0821 S0921 S1021
1L-1 0.3 0.4 0.7 1.5 4.5 7.1 17 28L-2 - - - - 3.0 5.9 11 17
2 - 0.5 0.7 1.0 2.3 3.5 6.2 12 213 - 0.5 0.7 1.0 2.3 3.5 6.2 12 21
4L-1 0.7 1.0 1.4 3.1 5.1 9.5 17 26L-2 - - - - 3.0 4.8 8.3 14
5 - 0.6 0.9 1.4 3.0 5.6 9.6 18 31
6L-1 0.7 1.0 1.4 3.2 7.4 12 25 42L-2 - - - - 5.1 9.5 17 28
Posn Level S0331 S0431 S0531 S0631 S0731
1L-1 0.4 0.5 0.9 2.1 4.8L-2 - - - - 3.8
2 - 0.8 0.9 1.4 2.5 3.73 - 0.8 0.9 1.4 2.5 3.7
4L-1 1.2 1.5 2.1 4.0 5.9L-2 - - - - 3.6
5 - 1.0 1.3 2.0 4.6 6.6
6L-1 1.2 1.5 1.9 4.0 9.2L-2 - - - - 6.9
5.S07toS10Fittheventilatorpluginthepositionappropriatetothemountingposition.S03toS06donotrequirea ventilator
6.QuadrupleReductionUnitsconsistofaRSeriesprimaryunitflangemountedontotheSSeriesunit,seeRSerieslubricationdatafordetailsappropriatetotheprimaryunit,bothunitsshouldcheckedforoiltypeandquantity.
APPENDIX 4
26
S Series Mounting Positions and Lubrication fill levels
DRAIN POSITION
LEVEL POSITION
VENTILATOR POSITION
APPENDIX 4
S03-S04-S05-S06
S03-S04-S05-S06
S03-S04 S05-S06
S07-S08 S09-S10
S0731 S07-S08 S09-S10
S03-S04 S05-S06
S03-S04-S05-S06
S03-S04-S05-S06
S07-S08-S09-S010
S07-S08-S09-S010
S07-S08-S09-S010
S07-S08-S09-S010
27
F Series Lubrication
1.F02toF07aresuppliedfactoryfilledwithaquantityofEPmineraloil(Grade6E)appropriatetothemountingposition.Ifthegearunitisdrainedforanyreasonitmustbere-filledwiththecorrectgradeandquantityoflubricantasshownin the table below.
2.F08toF10aresuppliedwithoutlubricantandmustbefilledviatheventilatorpositionwithEPmineraloil(Grade6E)untiloilescapesthroughthelevelplughole–seetablebelowforapproximatequantityoflubricant.
3.Maintenance:
•OillevelsforF05toF12canbecheckedandmaintainedbyfillingviatheventilatorpositionuntiloilescapesthroughthelevelplughole,•F02,F03andF04Theseunitsmustbefullydrainedandre-filledwiththecorrectquantityoflubricant.
Lubricant Quantities (Litres)Posn F0222 F0322 F0422 F0522 F0622 F0722 F0822 F0921 F1021 F1121 F12211 0.8 1.3 1.3 2.1 3.5 6.3 10.7 19 34 28 472 0.4 0.8 0.8 1.4 2.3 3.5 7.1 13 22 17 273 0.4 1.1 1.1 1.4 2.3 3.4 8.8 17 28 22 364 0.5 0.8 0.8 1.8 3.0 5.0 4.7 15 27 24 405 1.1 1.2 1.2 2.8 4.5 8.0 9.7 24 43 34 566 1.3 2.0 2.0 3.2 5.2 9.0 17.2 25 43 30 50
APPENDIX 4
Posn F0232 F0332 F0432 F0532 F0632 F0732 F0832 F0931 F1031 F1131 F12311 0.8 1.2 1.2 2.1 3.5 6.3 10.4 19 34 27 452 0.4 0.8 0.8 1.4 2.3 3.5 7.3 15 24 16 253 0.4 1.1 1.1 1.4 2.3 3.4 9.2 17 28 21 344 0.5 0.8 0.8 1.8 3.0 5.0 5.3 16 27 23 385 1.1 1.2 1.2 2.8 4.5 8.0 9.7 24 43 33 536 1.3 2.0 2.0 3.2 5.2 9.0 17.4 25 43 29 48
1.F09toF12unitsonly,fittheventilatorpluginthepositionappropriatetothemountingposition.F02toF08unitsdonot requireaventilator
2.QuadrupleReductionUnitsconsistofaRSeriesprimaryunitflangemountedontotheFSeriesunit,seeRSerieslubricationdatafordetailsappropriatetotheprimaryunit,bothunitsshouldcheckedforoiltypeandquantity.
28
F Series - Mounting Positions and Lubrication Fill Levels
DRAIN POSITION
LEVEL POSITION
VENTILATOR POSITION
APPENDIX 4
F02-F10
F02-F10
F02-F10
F02-F10
F02-F10
F02-F10F11-F12 F11-F12
F11-F12
F11-F12
F11-F12
F11-F12
29
K Series Lubrication
1.K03toK07aresuppliedfactoryfilledwithaquantityofEPmineraloil(Grade6E)appropriatetothemountingpositionIfthegearunitisdrainedforanyreasonitmustbere-filledwiththecorrectgradeandquantityoflubricantasshownin the table below.
2.K08toK12aresuppliedwithoutlubricantandmustbefilledviatheventilatorpositionwithEPmineraloil(Grade6E)untiloilescapesthroughthelevelplughole–seetablebelowforapproximatelubricantquantity,
3.Maintenance:
•OillevelsforK06toK12canbecheckedandmaintainedbyfillingviatheventilatorpositionuntiloilescapesthroughthelevelplughole,•K03,K04andK05Theseunitsmustbefullydrainedandre-filledwiththecorrectquantityoflubricant.
Lubricant Quantities (Litres)Posn K0332 K0432 K0532 K0632 K0732 K0832 K0931 K1031 K1231
1 0.5 0.7 1.1 1.5 2.7 4.4 9.3 15 23
2 0.7 0.9 1.5 1.8 3.6 3.7 8.3 15 27
3 0.8 1.1 1.7 2.8 4.0 7.6 18 28 33
4 1.0 1.3 1.9 2.7 4.5 7.5 17 30 39
5 1.2 1.7 2.5 3.6 5.7 9.6 21 34 50
6 0.9 1.2 2.0 2.6 4.5 7.6 16 25 35
4.K06toK12unitsonly,fittheventilatorpluginthepositionappropriatetothemountingposition.K03toK05unitsdonot requireaventilator.
5.QuintupleReductionUnitsconsistofaRSeriesprimaryunitflangemountedontotheKSeriesunit,seeSSerieslubricationdatafordetailsappropriatetotheprimaryunit,bothunitsshouldcheckedforoiltypeandquantity.
APPENDIX 4
30
K Series - Mounting Positions and Lubrication Fill Levels
DRAIN POSITION
LEVEL POSITION
VENTILATOR POSITION
APPENDIX 4
31
R Series Lubrication
1.R01toR07aresuppliedfactoryfilledwithaquantityofEPmineraloil(Grade6E)appropriatetothemountingpositionIfthegearunitisdrainedforanyreasonitmustbere-filledwiththecorrectgradeandquantityoflubricantasshownin the table below.
2.R08toR14aresuppliedwithoutlubricantandmustbefilledviatheventilatorpositionwithEPmineraloil(Grade6E)untiloilescapesthroughthelevelplughole–seetablebelowforapproximatelubricantquantity,
3.Maintenance:
a.OillevelsforR04toR14canbecheckedandmaintainedbyfillingviatheventilatorpositionuntiloilescapesthroughthelevelplughole,b.TheseunitsR01,R02andR03mustbefullydrainedandre-filledwiththecorrectquantityoflubricant.
Lubricant Quantities (Litres)Posn R0122 R0222 R0322 R0422 R0522 R0622 R0722 R0822 R0921 R1021 R1321 R1421
1 0.5 0.8 0.8 1.5 1.5 2.0 2.6 4.2 10.5 14 17 24
2 0.8 1.2 1.2 1.8 1.8 2.0 2.9 6.3 12.0 22 31 49
3 0.6 0.7 0.7 1.6 1.6 1.9 2.7 5.4 12.0 22 31 49
4 0.8 1.2 1.2 1.8 1.8 1.7 3.0 7.3 12.0 19 28 41
5 0.7 1.1 1.1 2.0 2.0 2.2 3.2 6.8 16.8 32 47 72
6 1.0 1.4 1.4 2.6 2.6 2.8 4.7 9.3 16.4 26 38 65
6.R04toR14unitsonly,fittheventilatorpluginthepositionappropriatetothemountingposition.R01toR03unitsdonot requireaventilator.
7.QuintupleReductionUnitsconsistofasmallerRSeriesprimaryunitflangemountedontothemainRSeriesgearunit,bothunitsshouldbecheckedforoiltypeandquantity.
APPENDIX 4
Posn R0132 R0232 R0332 R0432 R0532 R0632 R0732 R0832 R0931 R1031 R1331 R1431
1 0.6 0.8 0.8 1.6 1.6 2.1 2.7 4.4 11.5 14 18 25
2 0.9 1.3 1.3 1.9 1.9 2.1 3.0 6.5 12.0 24 33 50
3 0.7 0.7 0.7 1.7 1.7 2.0 2.8 5.6 12.0 24 33 50
4 0.9 1.2 1.2 1.9 1.9 1.8 3.1 7.5 12.0 21 30 43
5 0.7 1.1 1.1 2.1 2.1 2.3 3.3 6.8 16.8 32 47 72
6 1.1 1.6 1.6 2.7 2.7 2.9 4.8 9.7 16.5 28 40 67
32
R Series - Mounting Positions and Lubrication Fill Levels
VENTILATOR POSITION
APPENDIX 4
NOTES
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