Benzlers BD 100 Installation & Maintenance Download Page 1

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IMC-1.00GB01/11

Series BD - Screw Jacks

Installation & Maintenance

Summary of Contents for BD 100

Page 1: ...IMC 1 00GB01 11 Series BD Screw Jacks Installation Maintenance ...

Page 2: ...r to prevent the machinery being started 7 Installation Maintenance and Storage a In the event that equipment is to be held in storage for a period exceeding 6 months prior to installation or commissioning we must be consulted regarding special preservation requirements Unless otherwise agreed equipment must be stored in a building protected from extremes of temperature and humidity to prevent det...

Page 3: ...itch LS 13 3 2 3 Locked against rotation two options 13 3 2 4 LR Locked Against Rotation Tube 14 3 2 5 LRK Locked Against Rotation Key 15 3 2 6 Safety Nut SHM 15 3 2 7 Antibacklash ABL 16 4 SAFETY INFORMATION 17 4 1 General machine safety 17 4 1 1 Emergency stop function 17 4 1 2 Safety layout emergency safety stops zones 17 4 1 3 Hazard text 17 4 2 Operators locations 18 4 2 1 Noise 18 4 2 2 Stab...

Page 4: ...ce operations 30 9 2 Control of safety functions 30 9 2 1 Control of markings 30 9 3 Adjustment 30 9 3 1 Prevent self loosening object 30 9 4 Maintenance and cleaning by users 31 9 4 1 Lubrication general 31 9 4 2 Lubrication temperature limitations 31 9 4 3 Screw jack body grease quantity 32 9 4 4 Lubrication periods 33 9 4 5 Worm wheel and Lifting nut 33 9 4 6 Measuring of thread wear in worm wh...

Page 5: ...At the slightest doubt you are requested to contact our Sales Department They will help you with computer calculations and suggestions for both standard and special applications WARNING SELECTION AND DESIGN As improvements in design are being made continual ly the contents of this catalogue are not to be regar ded as binding in detail and drawings and capacities are subject to alterations without ...

Page 6: ...ound 7 Worm wheel of centrifugally cast tin bronze 8 Bellows in PVC or steel Not shown Other materials are available upon request 1 1 3 System overview 1 1 4 Drawings layouts NOTE ABOUT DRAWINGS LAYOUT Drawings layouts for your specific application may where appropriate also be supplied from our website if appropriate also including technical documentation from subcontractors 1 2 3 4 5 6 7 ...

Page 7: ...0 Ratio L 9 1 7 1 6 75 1 7 1 7 1 7 1 7 5 1 12 1 Starting torque Nm 6 23 55 210 320 640 1280 2120 Ratio H 27 1 30 1 27 1 28 1 28 1 28 1 30 1 36 1 Starting torque Nm 4 8 10 1 32 5 117 164 323 624 1265 1 2 2 External Electrical Power Supply data Connecting information regarding electric system Connecting voltage and number of phases See Product Sign Frequency See Product Sign Power See Product Sign M...

Page 8: ...suf ficient quantity to interfere with the satisfactory operation of the equip ment complete protection against contact Water projected by a nozzle against enclosure from any direction shall have no harmful effects NOTE ABOUT IP CODE FOR THE JACK The IP code for the jack is different from the motor s IP code and only jacks in stainless execution not standard are allowed to operate in a moist envir...

Page 9: ...ivery SHM IEC motor flange Max running power at 20 degree of utaliza tion IEC size Gap at delivery SHM Free input shaft Reducer only Max running power at 20 de gree of utalization Gap at delivery SHM 4 Line 4 Lubrication Lub Total weight of the unit Kg 5 Line 5 Order number and sub number of the order position Manufacturing year Product examples Motor IEC motor flange Free input shaft 1 3 1 Produc...

Page 10: ...ions on page 6 1 3 2 Option extra sign according to ATEX directive Jacks ordered to comply with EU directive 94 9 EC ATEX 100a have an extra sign Figur 3 Extra sign according to ATEX directive NOTE ABOUT ATEX AB Benzlers must be consulted in advance to adapt the jack to comply with 94 9 EC ATEX 100a The jack will be marked with an extra sign according to ATEX directive For more information see our...

Page 11: ...with 94 9 EC ATEX 100a and marked with an ATEX sign are allowed to be used in an explosive environment The jack will be typically marked as shown Figur 4 ATEX marking The maximum surface temperatures for the jack are 200 C T3 and 135 C T4 CAUTION RISK OF MACHINE DAMAGE Standard configuration is not suitable for these temperatures The protection type in areas with combustible dust and in hazardous ...

Page 12: ...tmosphere where a cloud of combus tible dust in the air is likely to occur in normal operation occasionally 3 Normal level of safety Safe in normal operation Where explosive atmospheres are likely to occur infrequently and be of short duration Zone 2 An atmosphere where a mixture of air and flammable substances in the form of gas vapor or mist is not likely to occur in nor mal operation but if it ...

Page 13: ...be updated when the machine owner makes completions or other modifications of this equipment In case of owner exchange the manual shall be enclosed to the new owner or user of the equipment In case of rebuilding or reconstruction a new risk analysis should be established All changes shall be approved by the machine owner 2 3 TARGET GROUP FOR THIS INFORMATION The manual shall be used for informatio...

Page 14: ...izes as standard This type is the most frequently used screw jack competively priced NOTE ABOUT STOP NUT BD is available with a stop nut If you chose not to use the stop nut another security feature must be included in the system The jack is used to push pull lift lower and position loads of anything from a couple of kilograms up to one hundred of tons with good precision and consistency ...

Page 15: ... can be attached to the control device itself or immediately alongside it NOTE ABOUT CONTROL DEVICES Control devices are not included at standard delivery WARNING CRUSHING RISK This protection prevents the possibility of pinched fingers or chruched hands which can lead to permanent injury WARNING RISK OF ENTANGLEMENT This shaft protection prevents for example loose clo thing or similar to entangle...

Page 16: ...e on the product sign that is mounted on the jack 3 2 1 Stop nut SM Stop nuts can be fitted to all screw jacks both above and below the main body These must be included when there is an inherent risk of over travel resulting in the spindle becoming disengaged from the worm thread Figur 6 6 Stop nut 7 Protection tube 8 Tube sleeve ...

Page 17: ...so available on request Figur 7 1 Stop nut 2 Carrier 3 Limit switch 3 2 3 Locked against rotation two options are available LR Locked Against Rotation Tube LRK Locked Against Rotation Key NOTE IMPORTANT INFORMATION ABOUT THESE OPTIONS For applications where a load is to be raised lowered and permanent fixing i e top plate clevis is not prac tical the spindle must be prevented from rotating Combina...

Page 18: ...2 Locking nut 3 Locking assembly size dependent variant 1 4 Tube 5 Pin size dependent variant 2 3 2 5 LRK Locked Against Rotation Key Jack internals are modified to incorporate a rectangular key which engages in a precision keyway cut into the spindle length Primarily used in precision applications requiring minimal radial movement Figur 9 1 Jack cover 2 Lifting screw 3 Key ...

Page 19: ...ted Monitoring of the safety gap s between the spacer 2 and the safety nut 1 gives an indication of the intermediate wear NOTE THE SAFETY GAP MUST BE CHECKED REGULARY When the safety gap reaches zero the thread in worm wheel has reached its wear limit and requires chang ing In applications where the safety nut is inacces sible electro mechanical switches are available to indicate maximum wear more...

Page 20: ...g contact on both face and flank of driving thread Backlash 0 0l 0 05 mm During operation excessive backlash can be removed by adjustment of the top cover The nuts are separated by a pre determined gap to eliminate the adjustment of the backlash eliminator when drive thread width has been reduced by 25 NOTE IMPORTANT INFORMATION ABOUT THIS OPTION Combinations with other options are restricted Figu...

Page 21: ...circuits 4 1 2 Safety layout emergency safety stops zones AB Benzlers is not normally responsible for the installation The integrator must draw a security layout of the whole system 4 1 3 Hazard text Danger Warning Caution and Note texts have the following meanings in the manual DANGER Neglecting this information will result in instant danger to life WARNING Neglecting this information may cause d...

Page 22: ...afety and Health 2003 10 EG During normal operation the sound level of the jack does not exceed 70 dB A NOTE CHECK MOTOR NOISE Do not forget to check the sound level of the connec ted motor according to EN 60204 32 CAUTION RISK OF HEARING LOSS Noise protection must be built if the sound level of the connected motor exceeds 70 dB 4 2 2 Stability For lifting instructions see Lifting on page 23 DANGE...

Page 23: ...n be situated in the danger zones during operation DANGER RISK OF BURNS Be aware of hot surfaces during operation DANGER RISK OF ENTANGLEMENT Be aware of moving parts Additional protective bel lows are available upon request if the residual risks can not be reduced when integrated in the security layout DANGER CUTTING RISK Be aware of sharp edges Additional protective bel lows are available upon r...

Page 24: ...ar protective shoes during service and maintenance 4 4 SAFETY INSTRUCTION The following safety instruction is limited to cover only all work with or all work in the vicinity of this machine Beside the safety demands described in this manual it is important also to be informed of the local safety instructions of the factory See to it that no unauthorized personnel or other visitors are inside or ne...

Page 25: ...be consulted regarding special preservation requirements Unless otherwise agreed equipment must be stored in a buil ding protected from extremes of temperature and hu midity to prevent deterioration The rotating components gears and shafts must be turned a few revolutions once a month to prevent leaking from sealings 5 2 1 Repackaging to prevent damage in transport Tightly secure the jack in a pro...

Page 26: ...e Ensure removal of such devices after work is complete 1 Check that the screw jack unit has not been damaged 2 Check that the screw jack motor nameplate matches the requirements of the machine the unit is to be installed into 3 Thoroughly clean the screw jack and mounting surfaces that are to be used and check that the shafts of paint anti corrosion agents uses a commercially available solvent En...

Page 27: ...e See figure below Figur 12 Lifting CAUTION RISK OF MACHINE DAMAGE Do not use straps on the lifting screw or tube as this can cause bending or machine damage WARNING CRUSHING RISK Where provided on larger units only the lifting points or eyebolts must be used for lifting operations see maintenance manual or general arrangement drawing for lifting point positions Failure to use the lifting points p...

Page 28: ...ings or turns on the supporting beam of the jack CAUTION RISK OF MACHINE DAMAGE If radial loads occur in the machine that are bigger than maximum allowed value in catalogue additional guides are necessary CAUTION RISK OF MACHINE DAMAGE The screw jack should have a longer length of stroke than is actually required of the application Should it be necessary to use the total length of stroke this must...

Page 29: ...e of sufficient electrical leakage resistance 109 W Electrical equipment Ensure screw jack unit and other equipment is electrically grounded Earthed Guards and covers Check and adjust guards and covers so that there is no ig nition source from sparks that may be thrown by moving parts making contact with guards etc Ensure coupling guards covers etc are dust tight or are designed in such a way that...

Page 30: ...supplier NOTE BRAKING MECHANISMS Make sure that braking mechanisms operates automatically after the control device has returned to the OFF position or when the drive power is interrupted Also make sure that braking mechanisms are designed in away that the operator cannot alter their constructionally defined effect without the aid of tools WARNING RISK OF ELECTRICAL HAZARDS Observe hazard warnings ...

Page 31: ...us situations 7 1 PREPARATIONS BEFORE START 7 1 1 Start up of safety systems Ensure that all safety devices are in place i e guards fitted Check and adjust guards and covers so that there is no ignition source from sparks that may be thrown by moving parts making contact with guards etc Ensure coupling guards covers etc are dust tight or are desig ned in such a way that abuild up of dust deposits ...

Page 32: ...ature must not exceed 110 C If this temperature is exceeded shut down immediately and contact AB Benzlers 7 2 4 Spillage of grease Use an absorbate to soak up the grease Contaminated waste should be collected in a plastic bag and placed in containers for contaminated waste oil 8 EMERGENCY MISHAP AND SUSPENSION 8 1 CHANGE OF DIRECTION OF MOTION RELIEF OF STORED ENERGY AB Benzlers recommend that the...

Page 33: ...ion The rotating components gears and shafts must be turned a few revolutions once a month to prevent bearings brinelling If the the storage period exceeds five years the grease must be changed 8 5 TAKING PRODUCT OUT OF OPERATION The jack shall be unloaded and the lifting screw shall be in zero postion during decommissioning To lift the jack see Lifting on page 23 8 5 1 Advice on disposal disposal...

Page 34: ...void accidental contact WARNING RISK OF BURNS After extended running the lubricant in gear units and lubrication systems may reach temperatures sufficient to cause burns Allow equipment to cool before servicing or performing adjustments 9 2 CONTROL OF SAFETY FUNCTIONS 9 2 1 Control of markings Check the state of the markings and that no danger signs are missing The markings shall remain as the ini...

Page 35: ...ental to the skin The manufacturer s instructions must be followed when handling lubricants WARNING RISK OF PERSONAL INJURY AND MACHINE DAMAGE The lubrication status of the equipment must be checked before commissioning Read and carry out all instructions on the lubricant plate and in the instal lation and maintenance literature Heed all warning tags Failure to do so could result in mechanical da ...

Page 36: ...D BDL 86 BD BDL 100 BD BDL 125W BD BDL 200 BDK 27 BDK 40 BDK 58 BDK 66 0 3 kg 0 5 kg 0 9 kg 1 2 kg 1 4 kg 2 5 kg 5 2 kg 15 kg 0 4 kg 0 7 kg 1 7 kg 2 0 kg To refill the jack see picture below Figur 14 Refill grease 1 Add grease with a grease gun through the grease nipple 2 The jack is refilled when grease leaks through the seals 1 2 ...

Page 37: ...erature unit operating under load Type of grease Environment humidity dust ambient temperature etc Operating conditions shock loading etc At elevated temperatures the effective life of the grease is very much reduced This is most pronounced with greases containing fatty and EP additives Renew grease every 400 hours of duty or after 24 months opera tion at the latest For units installed in potentia...

Page 38: ...CE WORKSHOPS Note that the spindle 1 at the Benzler measurement is loaded with appr 500 to 1000 N in the direction that the SHM shall secure and that 2 the SHM is displaced as much as possible from the SHM distance with mode rate force or enough force to get separation NOTE THE WEAR MUST BE CHECKED REGULARLY For monitoring of change of worm wheel wear in thread the same procedure must be applied t...

Page 39: ...ld be replaced every 5 years for EX marked units to avoid sparks and loose fragments which could lead to hazardous situations Alternatively they should be replaced in accordance with the agreed specification 9 4 10 Cleaning With the drive stationary periodically clean any dirt or dust from the screw jack unit and the electric motor cooling fins and fan guard to aid cooling and to avoid hazardous s...

Page 40: ...ck No Item 1 Housing 2 Cover 3 Bushing 4 Worm screw 5 Worm wheel 6 Bearing 7 Support ring 8 Bearing 9 Ring 10 Ring 11 Seal 12 Screw 13 Grease nipple 14 Lifting screw 15 Protection tube 16 Protection cap 17 Top plate 18 Pin 19 Clevis end 20 Strip rubber 21 Bellow 22 Bellow fixing 23 Hose clamp 24 Screw 25 Tube sleeve 26 Key 27 Shim Figur 16 Exploded view 18 3 26 23 ...

Page 41: ...ce b Stop the unit contact AB Benzlers Grease leaking 1 from worm gear unit cover from motor flange from gear unit flange from output end oil seal a Defective gasket on gear unit cover b Defective gasket a Retighten screws on gear unit cover and observe gear unit If still grease leaks contact AB Benzlers b Contact AB Benzlers 1 It is normal for small amounts of oil grease to leak out of the oil se...

Page 42: ... 4 as shown in the figure below 1 2 3 4 NOTE ABOUT WORKING TEMPERATURE Check the alignment after running the unit until it has attained its normal working temperature Any discrepancies can then be rectified Figur 18 Four points The difference between the reading 1 and 3 will give the error of alignment in the vertical plane over the length of shaft equal to the diameter of the coupling flanges and...

Page 43: ...the gap is measured Errors of Eccentricity Figur 19 Eccentricity Clamp a dial indicator suitably to one half coupling and bearing on the hub or flange of the other as shown in the figure below and measure the eccentricity Figur 20 Dial indicator NOTE ABOUT SUPPORT FOR DIAL INDICATOR Ensure that the support for the dial indicator is sufficiently rigid to prevent the weight of the indicator from cau...

Page 44: ...ecific maintenance demands for each component NOTE FUTHER INFORMATION Further information see manuals from our sub suppliers 11 2 ADDRESSES OF SERVICE AGENTS For addresses and service agents contact AB Benzlers or go to www benzlers com 11 3 REPACKAGING In case of claims on spare parts etc pack together and mark with the order or project number 11 4 LIST OF SPARE PARTS AND CONSUMABLES 11 4 1 Drawi...

Page 45: ... Helsingfors Finland Tel 358 9 340 1716 Fax 358 10 296 2072 INDIA Elecon Engineering Company Ltd Anand Sojitra Road Vallabh Vidyanagar 388120 Gujarat India Tel 91 2692 236513 Fax 91 2692 227484 SWEDEN NORWAY AB Benzlers Box 922 Landskronavägen 1 251 09 Helsingborg Sweden Tel 46 42 18 68 00 Fax 46 42 21 88 03 THAILAND Radicon Transmission Thailand Ltd 700 43 Moo 6 Amata Nakorn Industrial Estate Tum...

Page 46: ... 34 03 00 Finland 358 9 340 1716 Germany 49 800 350 4000 Sweden 46 42 186800 The Netherlands 31 77 324 59 00 www benzlers com Radicon Thailand 66 3845 9044 United Kingdom 44 0 1484 465 800 USA 1 847 593 9910 www radicon com ...

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