Beckhoff AG2800 Operating Instructions Manual Download Page 1

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Operating instructions | EN

AG2800

Stainless steel planetary gear unit

1/4/2021 | Version 2.0

Summary of Contents for AG2800

Page 1: ...Operating instructions EN AG2800 Stainless steel planetary gear unit 1 4 2021 Version 2 0 ...

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Page 3: ...l data 20 Definitions 20 Data for operation and environment 22 HDV015 MF 23 HDV025 MF 25 HDV035 MF 27 Scope of supply 29 Packaging 29 Transport and storage 30 Conditions 30 Transport 30 Long term storage 32 Technical description 33 Installation position 33 Mechanical installation 34 General tightening torques 34 Motor on gear unit 36 Gear unit to machine 39 Commissioning 41 Before operation 42 Dur...

Page 4: ...T G Ether CAT G10 EtherCAT P Safety over EtherCAT TwinSAFE XFC XTS and XPlanar are registered and licensed trademarks of Beckhoff Automation GmbH The use of other brand names or designations by third parties may lead to an infringement of the rights of the owners of the corre sponding designations 1 1 2Patents The EtherCAT technology is protected by patent rights through the following registration...

Page 5: ... nullify the liability of Beckhoff Automation GmbH Co KG The following is excluded from the liability Failure to observe these operating instructions Improper use Use of untrained personnel Use of unauthorized spare parts 1 1 4Copyright Beckhoff Automation GmbH Co KG Germany The copying distribution and utilization of this document as well as the communication of its contents to others without exp...

Page 6: ...ived from the German original Product features Only the product properties specified in the current operating in structions are valid Further information given on the product pages of the Beckhoff homepage in emails or in other publications is not authoritative 1 3Scope of the documen tation Apart from these operating instructions the following documents are part of the overall documentation Docum...

Page 7: ...uirements including all appli cable laws regulations provisions and standards Instructed person Instructed persons have a clearly defined task area and have been informed about the work to be carried out Instructed persons are fa miliar with the necessary protective measures and protective devices the intended use and risks that can arise from use other than for the intended purpose Trained person...

Page 8: ...r technical train ing They have an understanding of control technology and automa tion They are familiar with relevant standards and directives Quali fied electricians can independently recognize avoid and eliminate sources of danger implement specifications from the accident prevention regula tions assess the work environment independently optimize and carry out their work ...

Page 9: ...ement The triangle indicates instructions that you should execute The bullet point indicates an enumeration The square parentheses indicate cross references to other text passages in the document The plus sign in square brackets indicates ordering options and accessories 1 6 1Pictograms In order to make it easier for you to find text passages pictograms and signal words are used in warning notices...

Page 10: ...code via which you can watch videos or animations Internet access is required in order to use it You can read the QR code for example with the camera of your Smartphone or Tablet PC If your camera doesn t support this func tion you can download a free QR code reader app for your Smart phone Use the Appstore for Apple operating systems or the Google Play Store for Android operating systems If you c...

Page 11: ...emises Hotline 49 0 5246 963 5000 Fax 49 0 5246 963 95000 E mail training beckhoff com Web www beckhoff de training 1 7 3Service The Beckhoff Service Center supports you with after sales services such as on site service repair service or spare parts service Hotline 49 0 5246 963 460 Fax 49 0 5246 963 479 E mail service beckhoff com Web www beckhoff de service 1 7 4Download area In the download are...

Page 12: ...ore regarded as incomplete machines They must be installed in a machine or plant by the machine manufacturer The documen tation created by the machine manufacturer must be read 2 1 1Before operation Keep the immediate environment clean Keep your workplace and the surrounding area clean Ensure safe working Shut down and secure the machine or plant Shut down the machine or plant Secure the machine o...

Page 13: ... off immediately if the temperature is too high Do not touch any moving or rotating components Do not touch any moving or rotating parts during operation Fasten all parts or components on the machine or plant 2 1 3After operation De energize and switch off components before working on them Check the functionality of all safety relevant devices Secure the working environment Secure the machine or p...

Page 14: ...umber Explanation 1 Screw plug 2 4 holes for output side 3 Feather key 4 4 holes for the motor attachment 5 Gear housing 6 Clamping hub with spacer sleeve 7 Adapter plate 8 Output shaft with center bore 9 Shaft seal at the output 10 O ring seal ...

Page 15: ...Product overview Version 2 0 15 AG2800 3 1Name plate 3 1 Number Explanation 1 Series 2 Gear unit type 3 Ratio 4 Date of manufacture 5 Lubrication 6 Country of manufacture 7 Serial number ...

Page 16: ...ubrication S Standard M Gear unit variant M Motor mounted gear unit F Gear unit version F Standard 1 No of stages 1 single stage 2 two stage 3 Ratio See documentation 1 Type of output 0 smooth shaft 1 feather key DIN 6885 shape A 2 splined shaft DIN 5480 C Clamping hub identifying letter Not freely selectable Is selected on the basis of the motor to be mounted 1 Torsional backlash 1 Standard AM883...

Page 17: ...nt Hygienic design The stainless steel planetary gear units have been specially devel oped for hygienically demanding applications in food processing They are made of highly resistant stainless steel and are suitable for cleaning with aggressive cleaning agents or disinfectants Direct process integration The direct process integration of the stainless steel planetary gear units allows new construc...

Page 18: ...are defined via the type key and must be ordered separately The listed components cannot be retrofitted 3 4 1Feather key 3 4 1 A feather key transmits torque to an output element The gear units are available with feather key groove and inserted feather key according to DIN 6885 ...

Page 19: ...ective 2014 34 EN ATEX and are approved for use in potentially explo sive atmospheres The performance data are limited and can be found in the chapter Technical data of this translation of the origi nal instructions Read the entire drive system documentation This translation of the original instructions Original operating instructions for the motors Machine manufacturer s complete documentation fo...

Page 20: ...at is rele vant for dimensioning the gear unit Equivalent application torque T2_eq Nm The equivalent application torque describes the torque that is rele vant for the dimensioning of the gear unit Dimensioning factor fa The dimensioning factor describes the influence of the daily operat ing time and the operating factor on the application torque Operating mode factor KM The operating mode factor d...

Page 21: ... flange This distance acts as lever arm The lateral force generates a bending moment Maximum torque at the output T2a Nm Represents the maximum torque that can be transmitted by the gear unit This value may be lower depending on application specific boundary conditions EMERGENCY STOP torque T2Emerg Nm The EMERGENCY STOP torque is the maximum permissible torque at the gear unit output It may be rea...

Page 22: ...e life of the products Environmental requirements Climate category 2K3 according to EN 60721 Ambient temperature during operation 25 C to 40 C extended temperature range Ambient temperature for transport and storage 0 C to 40 C maximum fluctuation 20 K hour Permissible humidity in operation 15 to 95 relative humidity no condensation Permissible humidity during transport and storage 15 to 95 relati...

Page 23: ...cycles per hour 32 32 32 29 32 32 32 32 32 32 29 EMERGENCY STOP torque T2Em stop Nm Possible 1000 times during the ser vice life of the gear unit 75 Nominal input speed n1N min 1 3000 3700 Maximum input speed n1Max min 1 6000 Idle torque T012 Nm Based on the drive 0 15 Torsion and forces Maximum torsional backlash jt ar cmin Standard 10 Standard 15 Maximum torsional rigidity Ct21 ar cmin 2 3 2 3 2...

Page 24: ...al drawing All figures in millimeters Dimensions without tolerance 1 mm Clamping hub diameter depending on the motor size Center bore according to DIN 332 DR M5x12 Feather key 5h9x25 according to DIN 6885 A 4 3 1 11 stage 4 3 1 1 4 3 1 22 stage 4 3 1 2 ...

Page 25: ...00 cycles per hour 80 80 80 72 80 80 80 80 80 80 72 EMERGENCY STOP torque T2Em stop Nm Possible 1000 times during the ser vice life of the gear unit 190 Nominal input speed n1N min 1 2700 3400 Maximum input speed n1Max min 1 6000 Idle torque T012 Nm Based on the drive 0 3 Torsion and forces Maximum torsional backlash jt ar cmin Standard 10 Standard 15 Maximum torsional rigidity Ct21 ar cmin 7 5 7 ...

Page 26: ...al drawing All figures in millimeters Dimensions without tolerance 1 mm Clamping hub diameter depending on the motor size Center bore according to DIN 332 DR M6x12 Feather key 6h9x28 according to DIN 6885 A 4 4 1 11 stage 4 4 1 1 4 4 1 22 stage 4 4 1 2 ...

Page 27: ...aximum 1000 cycles per hour 200 200 200 180 200 200 200 200 200 200 180 EMERGENCY STOP torque T2Em stop Nm Possible 1000 times during the ser vice life of the gear unit 480 Nominal input speed n1N min 1 2000 2600 Maximum input speed n1Max min 1 4800 Idle torque T012 Nm Based on the drive 0 5 Torsion and forces Maximum torsional backlash jt ar cmin Standard 10 Standard 15 Maximum torsional rigidity...

Page 28: ...al drawing All figures in millimeters Dimensions without tolerance 1 mm Clamping hub diameter depending on the motor size Center bore according to DIN 332 DR M10x22 Feather key 8h9x40 according to DIN 6885 A 4 5 1 11 stage 4 5 1 1 4 5 1 22 stage 4 5 1 2 ...

Page 29: ...des the following items Gear units from the AG2800 series with packaging Short information Bolts for fastening the gear unit to the motor or the machine are not included in the scope of delivery No motor is included in the standard delivery of a planetary gear unit from the AG2800 series 5 1Packaging Instructions for handling are printed on the packaging Symbol Explanation This is the correct posi...

Page 30: ...age only in a horizontal position Use of the vendor s original packaging 6 2Transport WARNING Do not move under suspended loads Use suitable means of transport and secure the gear unit against falling down If the gear unit falls down it can cause a fatal accident Use means of transport with a sufficient lifting capacity Use means of transport or hoists with a sufficient lifting capacity to transpo...

Page 31: ...t Without aids by hand in compliance with the legal requirements for the lifting of loads Using suitable transport slings on the gear unit with averaged center of gravity with sufficiently dimensioned hoists using suitable transport slings on the gear unit and on the motor with averaged center of gravity with sufficiently dimensioned hoists ...

Page 32: ...bare surfaces with corrosion protection Store the gear units in a horizontal position Failure to comply with the specified storage conditions and storage times may result in changes in the processed materials and sur faces on and in the gear unit Prevent the formation of condensation Ensure a constant ambient temperature in the range from 25 C to 70 C at the storage location Avoid high humidity Fa...

Page 33: ...left on the flange for a longer period can penetrate the motor through capillary action In mounting position IM V1 liquid can escape If you do not observe the maintenance intervals the motor may overheat depending on the mounting position Ingress and leakage of liquids may damage the motor The standard installation position of the gear unit is the motor at tachment M Alternatively it can be used i...

Page 34: ... and bolts are mathematical values based on the following requirements Calculation according to VDI 2230 February 2003 edition Friction coefficient for threads and contact surfaces µ 0 10 Elastic limit utilization 90 Torque tools type II classes A and D according to ISO 6789 The setting values are rounded to conventional scalings or adjust ment possibilities Bolt size Quality of the bolts 8 8 10 9...

Page 35: ...y valid for bolts according to ISO 4762 ISO 4014 ISO 4017 Only valid for nuts according to ISO 4032 ISO 4033 Torque tools type II classes A and D according to ISO 6789 The setting values are rounded to conventional scalings or adjust ment possibilities Bolt size Quality of the bolts Ax 50 Ax 70 Ax 80 Tightening torque in Nm M3 0 376 0 806 1 07 M4 0 868 1 86 2 48 M5 1 72 3 68 4 91 M6 2 95 6 4 8 4 M...

Page 36: ...ance according to EN 50347 Smooth shaft Motor attachment if possible in a vertical position 8 2 1Clamping hub The following table provides a description of the clamping hub Infographic Position Name C Clamping hub H Set screw J Spacer sleeve K Grooved motor shaft L Smooth motor shaft M Marking hole 8 2 1 1Tightening torques Information on the bolt sizes and tightening torques can be found in the t...

Page 37: ...ts Centering and motor shaft Internal diameter of the clamping hub Spacer sleeve inside and outside In case of motor with feather key Remove feather key and insert half wedge Remove the screw plug 1 from the mounting hole 2 Turn the clamping hub 1 until the set screw can be seen above the mounting hole 2 Loosen the set screw of the clamping hub by one turn ...

Page 38: ...cer sleeve Make sure that there is an O ring seal between the motor and the gear unit The seal is included in the scope of delivery of the AM88xx Insert the motor shaft 1 into the clamping hub 2 inside the gear unit Make sure that no gap is created between the motor and the adapter plate This example shows a motor size with four fixing points in the flange Coat bolts with washers 1 2 3 and 4 with ...

Page 39: ...els and toothed belt pulleys without force on the output shaft and avoid mounting by driving or hammering on The gear unit can be damaged if stress occurs during mounting Seal any gap over a wide area when attaching to the output side Make sure that the surfaces of the attached parts have a low roughness Use only screw head seals and o rings for sealing 8 3 1 1Permissible axial forces The followin...

Page 40: ...r Fasten the gear unit to the machine with the suitable screws via the threaded holes 2 Make sure that the surface of the machine has a low roughness Attach the gear unit such that the screw plug faces downward and the name plate is readable Tightening torques In the following you will find supplementary information regarding the attachment of the gear unit to a machine Quality of the bolts stainl...

Page 41: ...the application of the components Example Limitation of rated motor current and peak motor current Calculation based on the rated motor current Standstill torque M0 of the motor 1 Nm Nominal torque T2N of the gear unit 8 Nm Output torque of the gear unit with a transmission ratio i of 10 1 Nm x 10 10 Nm Result The rated motor current must be limited to 80 Calculation based on the peak motor curren...

Page 42: ...es 9 2During operation Checklist that helps to check important points during operation Check function and adjustment of attachments Observe information for environment and operation Check protective measures against moving and live parts Pay attention to unusual noise developments Always check gear unit surfaces and cables for dirt leaks mois ture or dust Check temperature development Check for lu...

Page 43: ...d the gear unit as well as leakage problems Contamination dust or chips can have a negative effect on the func tion of the components In the worst case contamination can lead to failure Therefore clean and service the components at regular in tervals 10 1Cleaning agents Clean the components carefully with a damp cloth or a brush Use grease dissolving and non aggressive cleaning agents such as isop...

Page 44: ...s Fastening screw Gear unit housing During commission ing Thereafter Every three months Check tightening torques 10 2 1Lubrication Notes on lubrication Beckhoff gear units from the AG2800 series are lubricated for life The lubricant used does not have to be renewed If you wish to change the lubricant contact Beckhoff Service All gear units are lubricated for life with a food safe synthetic lubri c...

Page 45: ...motor Check the motor wiring Ensure sufficient cooling Replace the motor Ambient temperature too high Ensure sufficient cooling Increased operating noises Distorted motor mounting Contact Beckhoff Service Damage to the bearings Damage to the toothing Toothed belt tension too high Check and correct toothed belt ten sion Lubricant loss Lubricant quantity too high Wipe off lubricant refill and monito...

Page 46: ... Risk of injury from leaking oil Prevent oil from leaking Soak up any leaked oil with approved binding agents Mark the danger spot Leaking oil can cause slips and falls resulting in serious or fatal injury Impermissible removal of gear unit components Only Beckhoff Automation GmbH Co KG is permitted to disman tle the gear unit Contact Beckhoff Service for further information Removal of the gear un...

Page 47: ...and rechargeable batteries Batteries and rechargeable batteries may also be marked with the crossed out trash can symbol You must separate these compo nents from the waste and are legally obliged to return used batteries and rechargeable batteries within the EU Observe the relevant pro visions outside the area of validity of the EU Directive 2006 66 EC 12 2 1Returning to the vendor In accordance w...

Page 48: ... your request to info beckhoff com 13 2RoHS All homogeneous materials used in the gear unit fall below the pre scribed limit values of Directive 2011 65 EU Annex II The following table contains an overview of the proportional quantities of harmful substances Material Percentage share Lead 0 1 Mercury 0 1 Cadmium 0 01 Hexavalent chromium 0 1 Polybrominated biphenyls PBB 0 1 Polybrominated diphenyl ...

Page 49: ... elements Mounting 39 P Pictograms 9 Power derating 20 R RoHS Proportional quantities of harmful substances 48 S Safety 12 De energized and voltage free condition 13 General safety instructions 12 Hot surfaces 13 Intended use 19 Keep the environment clean 12 Moving or rotating components 13 Overheating 13 Secure feather key 12 Shut down and secure the machine or plant 12 Solvents and lubricants 13...

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Page 51: ...Beckhoff Automation GmbH Co KG Hülshorstweg 20 33415 Verl Germany Phone 49 5246 9630 info beckhoff com www beckhoff com More Information www beckhoff com ag2800 ...

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