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Siemens SIMOTICS 1LA, Compact Operating Instructions

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Siemens SIMOTICS 1LA Compact Operating Instructions Download Page 152

Getriebe − Nocken − Endschalter Reihe 51 / 51 DZ
Geared Cam Limit Switches Series 51 / 51 DZ

16

Datum / Date 10.2008

1.14 Kunststoff − Modul − Gehäuse IP66
Bauform B14

1.14 Plastic module housing IP66
Construction B14

Blindstopfen/Blanking plug

DD1_40165V

35

18

15

27

M20x1.5

36

25

96

M6x10 tief/deep

3

P9

 

6

L1

M20 x 1,5

M20 x 1,5

x1.8

+0.1

ø8

 

h9

ø40

  −0.1

128

59

153

 

Merkmale:
Gehäuse  aus GF − verstärktem  Polycarbonat  in Schutzart
IP66.
Modultechnik  ermöglicht bestmögliche Raumausnutzung
auch bei Sonderausführungen.
Gesamtlänge  durch den Einbau von 25 mm breiten Zwi−
schenstücken  nahezu beliebig verlängerbar.

Features:
Housing made of glass fibre reinforced polycarbonate with
the degree of protection IP66.
Modular  design enables optimal space utilisation also for spe−
cial types.
Overall length can be extended as required with 25mm wide
intermediate  pieces.

Getriebe −

größe

G

i

2 Kontakte/Contacts

A

4 Kontakte/Contacts

B

6 Kontakte/Contacts

C

8 Kontakte/Contacts

D

51

51 DZ

g

Gear size

L1 / mm

Anz. Zwst.

L1 / mm

Anz. Zwst.

L1 / mm

Anz. Zwst.

L1 / mm

Anz. Zwst.

4,1NM
6,5NM

11NM

67DZM

110DZM
180DZM

1

132

0

132

0

132

0

157

1

17,5BM

29BM
48BM

280DZM
470DZM
770DZM

2

132

0

132

0

157

1

182

2

75BM

125BM
205BM

1200DZM
2000DZM
3300DZM

3

132

0

132

0

157

1

182

2

323BM
540BM
880BM

5200DZM
8700DZM

14200DZM

4

132

0

157

1

182

2

182

2

1384BM
2288BM
3735BM

5

132

0

157

1

182

2

207

3

5900BM
9800BM

16000BM

6

157

1

157

1

182

2

207

3

Mehr als 8 Kontakte auf Anfrage möglich / More than 8 contacts on request
Abmessungen bei mehr als 8 Kontakten und bei Sonderausführungen, z. B. Poti, auf Anfrage
Dimensions with more than 8 contacts and with special executions , e.g. potentiometer, on request
Für jedes weitere Zwischenstück sind zu L1 25 mm zu addieren / For any further intermediate piece add 25 mm to L1

Summary of Contents for SIMOTICS 1LA

Page 1: ...nstallation maintenance 54 6 Trolley motor Siemens Installation maintenance See Hoist motor 7 Trolley gear Bonfigioli Installation maintenance See Hoist gear Slewing motor Siemens Installation maintenance See Hoist motor Slewing gear Bonfigioli Installation maintenance 46 8 Slewing brake Krøll K Brake Adjustment 2 9 Limit switches Stromag Serie 51 51 DZ Installation adjusting 31 ...

Page 2: ...677 01 4196220 01 1 55 03 1 17 00063202 SLEWING MANUFAC TYPE SERIAL NO kW RPM RATIO QTY P N MOTOR without encoder Siemens 1LA7113 4AA11 Z 11 5 2850 1 15 00050889 MOTOR with encoder Siemens 1LA7113 4AA11 Z 11 5 2850 1 15 00050890 BRAKE Krøll Cranes A S K Brake 180V 2 16 00045720 GEAR Bonfiglioli 309L4HZ SK 1500863X 1 465 2 17 00057190 SLEWING RING Rothe Erde 061 50 1390 203 49 1502 1 37 00037277 TR...

Page 3: ...Compact Operating Instructions SIMOTICS Low voltage motors GP SD DP 1LA 1LE 1LF 1LG 1LP 1PC 1PF 1PK 1PP 1PQ 2KG 02 2013 Ausgabe 5 610 00000 02 001 Siemens AG 2013 Answers for industry ...

Page 4: ...his electric machine has been designed and built in accordance with the specifications contained in Directive 2006 95 EC Low Voltage Directive and is intended for use in industrial plants Please observe the country specific regulations when using the electric machine outside the European Community Follow the local and industry specific safety and setup regulations The persons responsible for the p...

Page 5: ...al damage when carrying out any work always observe the safety instructions and the following five safety rules according to EN 50110 1 Working in a voltage free state Apply the five safety rules in the sequence stated before starting work Five safety rules 1 Disconnect the system Disconnect the auxiliary circuits for example anti condensation heating 2 Prevent reconnection 3 Make sure that the eq...

Page 6: ...parts Fatal or severe injuries and substantial material damage can occur if the required covers are removed or if the machines are not handled operated or maintained properly Only remove covers in compliance with the applicable regulations Operate the machines properly Perform regular maintenance on the machine Secure free standing shaft extensions WARNING Hot surfaces Electrical machines have hot...

Page 7: ...lied with in the plant or system itself when the motors are installed Note Machine directive Low voltage motors are components designed for installation in machines in accordance with the current Machinery Directive The system may not be commissioned until confirmation has been given that the final product is in conformance with this directive observe EN 60204 1 Forced ventilation optional Cooling...

Page 8: ...condensation drain holes e g using T plugs before commissioning the machine Note Storage If the machines are used or stored outdoors we recommend keeping them under a shelter or an additional cover Avoid exposing them to direct intense solar radiation rain snow ice or dust for extended periods If necessary please consult us or seek advice regarding technical issues Environmental requirements The m...

Page 9: ...hing straps EN12195 2 WARNING Suspended transport If several items of transport material are used for fastening two straps must be able to carry the whole load Use additional suitable means of support for transport and during installation Secure the support equipment to prevent it from slipping Storage time Turn the shafts 1x every year to avoid bearing brinelling Prolonged storage periods reduce ...

Page 10: ...enclosure NOTICE Before start up please check that the customer has set the correct direction of rotation of the machine e g by decoupling from the driven machine by taking appropriate measures there are no temperature sensitive parts cables etc which are in contact with the machine enclosure condensation drain holes are always located at the lowest point of the motor Note Please note the technica...

Page 11: ...e 5 3 Balancing CAUTION Safety precautions The general touch protection measures for drive output elements must be observed Output elements may only be attached or withdrawn using the correct equipment The feather keys are only secured against falling out during shipping If you commission a machine without an output element the feather keys must be secured to prevent them from being thrown out The...

Page 12: ... be precise in the case of direct coupling Fastening surfaces must be clean Look out for any damage to paint this must be rectified immediately and correctly Look out for traces of anti corrosion protection agents these must be removed using mineral turpentine Look out for installation related resonances with the rotating frequency and double line frequency these must be prevented Listen for unusu...

Page 13: ...plays any deviations from the rated values in terms of voltage frequency curve form or symmetry such deviations will increase the temperature and influence electromagnetic compatibility WARNING Line supply with non grounded neutral point Operating the machine on a line supply system with a non grounded neutral point is only permitted over short time intervals that occur rarely e g the time leading...

Page 14: ...re the feather keys without output elements Note The terminal box must be sealed so that dust and water cannot enter WARNING Dangerous voltage Loosening the safety torx screw can result in death serious injury or material damage Do not loosen the safety torx screw with respect to the center terminal as this ensures a conductive connection between the grounding conductor and frame NOTICE Serious da...

Page 15: ...rcuit hazard During disassembly and particularly when installing the cover plate make sure that the connection cables are not clamped between enclosure parts and the cover plate CAUTION It must be ensured that there are no foreign bodies dirt or moisture in the terminal base of the machine enclosure Use O rings or suitable flat gaskets to seal entries in cover plates DIN 42925 and other open entri...

Page 16: ...s and so on 6 1 5 Installation and routing NOTICE Damage to terminal board Observe the following measures to prevent damage to the terminal board Remove the screw type connections EN 50262 only when the terminal box is closed Tighten the screw type connections to rated torque value only when the terminal box is closed Tighten the screw type connections only finger tight when the terminal box is op...

Page 17: ...any other screw type connections such as adapters Table 6 1 Tightening torques for cable glands Clamping range in mm Metal 10 Nm Plastic 10 Nm Standard 30 C 100 C Ex 30 C 90 C Ex 60 C 105 C O ring Cord mm M 12 x 1 5 8 1 5 3 0 7 0 M 16 x 1 5 10 2 4 5 10 0 6 0 10 0 M 20 x 1 5 7 0 13 0 6 0 12 0 M 25 x 1 5 12 4 9 0 17 0 10 0 16 0 M 32 x 1 5 11 0 21 0 13 0 20 0 M 40 x 1 5 18 19 0 28 0 20 0 26 0 M 50 x ...

Page 18: ...tor connections sheet metal fan covers Thread M 4 M 5 M 6 min 4 7 5 12 5 Nm Max 5 9 5 15 5 6 3 General information on conductor connection Cross sections that can be connected depending on the size of the terminal possibly reduced due to size of cable entries WARNING Short circuit hazard Electric machines contain hazardous voltages If the appropriate precautions are not taken death or serious phys...

Page 19: ...is possible for supply voltages up to 500 V 10 in motorized operation Use a special insulation system or adopt special measures e g output filter for higher voltages NOTICE Machines must always be connected to frequency converters using shielded machine supply cables The most effective method of shielding is to conductively connect the cable to the metal terminal box of the machine with metal scre...

Page 20: ...order not to damage the cable insulation freely arrange the connecting cables Connect the machine corresponding to the specified direction of rotation Keep the inside of the terminal box clean and free from trimmed off ends of wire Ensure that all seals and sealing surfaces are undamaged and clean Correctly and professionally close unused openings in the terminal boxes The pressure relief device i...

Page 21: ...e you have measured the insulation resistance discharge the winding by connecting to the ground potential Checking the insulation resistance NOTICE The insulation resistance needs to be checked prior to start up and again after any extended periods of storage or periods during which the equipment is not in operation Before you begin measuring the insulation resistance please read the operating man...

Page 22: ...e insulation resistance Limit values of the stator winding insulation resistance The following table indicates the measuring circuit voltage and the limit values for the minimum insulation resistance and the critical insulation resistance of the stator winding Table 7 1 Insulation resistance of the stator unwinding at 25 C Rated voltage Urated 2 kV Measuring circuit voltage 500 V Minimum insulatio...

Page 23: ...tical value you must check the insulation resistance at suitably frequent intervals Measures before commissioning Once the system has been correctly installed you should check the following prior to commissioning The machine has been assembled and aligned correctly The machine has been connected so that it rotates in the direction specified The operating conditions match the data specified on the ...

Page 24: ...d to prevent them becoming loose The rotor can turn without coming into contact with the stator All touch protection measures for both moving and live parts have been implemented In cases where the shaft extension is not being used and is therefore exposed it has been covered and the feather key has been secured to prevent it from being thrown out If being used the external fan is ready for operat...

Page 25: ...tor is running Rotating or live parts are dangerous Death serious injury or material damage can result if the required covers are removed De energize the machine and bring it into a no voltage condition before removing any covers Ensure that any covers which are designed to prevent active or rotating parts from being touched which are necessary to ensure correct air guidance and thus effective coo...

Page 26: ...midity can condense within the machines If available remove the screw plugs to drain the water depending on the ambient and operating conditions Reinsert them afterwards If the machine is equipped with drainage plugs the water can drain away automatically WARNING Machines with textile fan covers The machine fan is not completely protected against contact The customer must put suitable measures in ...

Page 27: ...of service For details of measures that need to be implemented please refer to Section Preparing for use Page 39 Lubricating before recommissioning NOTICE The machine must be relubricated during commissioning if it has been out of service for more than 1 year in order to ensure that the grease is distributed throughout the bearings The shaft must rotate for the grease to be distributed Please obse...

Page 28: ... in place and that personal protective gear such as gloves goggles face masks or similar are worn If you are using chemical cleaning agents observe the instructions and any warnings provided in the relevant safety data sheet Chemical agents must be compatible with the machine s components especially if these contain plastics Note Operation characteristics can vary widely For this reason only gener...

Page 29: ...emperature rises sharply at first then drops to the normal value again when the excess grease is displaced out of the bearing 9 1 2 Cleaning Cleaning the greasing channels and used grease chambers The used grease collects outside each bearing in the used grease chamber of the outer bearing cap When replacing bearings remove the used grease Note You have to separate the active parts of the bearings...

Page 30: ...ety instructions specified in this manual are concerned are those who have the necessary authorization to commission ground and identify tag equipment systems and circuits in accordance with the relevant safety standards Instructions relevant to safety WARNING Before you begin working on the three phase machine in particular before you open the covers of active parts make sure that the three phase...

Page 31: ...lacement intervals 40 C Horizontal coupling operation 40 000 h 40 C With axial and radial forces 20 000 h Note Special operating conditions Examples of factors that can reduce operating hours are vertical machine installation high vibrational and impact loads frequent reversing higher ambient temperature higher speeds etc Note Do not reuse bearings that have been removed Remove any existing contam...

Page 32: ... directly under the web risk of breakage Do not damage the snap mechanisms If any damage is caused request new parts Canopy incremental encoder under the canopy Loosen the fixing screws on the external surface of the protective cover Under no circumstances should the spacing bolts or the mounting bracket be disassembled or forcibly separated from each other or the cover Forcibly removing or separa...

Page 33: ...ble service center on your behalf You can find your local contact partner here Technical queries or additional information If you have any technical queries or you require additional information please contact the Siemens Service Center Please have the following machine data ready Machine type Serial number You can find this data on the rating plate of the machine Service numbers Table A 1 Siemens...

Page 34: ...000 02 000 Operating_Instructions_Simotics GP SD DP XP 5 610 00000 02 001 Operating_Instructions_Compact_Simotics GP SD DP 5 610 00000 02 002 Operating_Instructions_Compact_Simotics XP 5 610 00002 09 000 Incremental encoder 1XP8012 1x 5 610 00002 09 001 Incremental encoder 1XP8012 2x 5 610 70000 02 015 External fan 5 610 70000 10 020 Spring loaded brake Siemens AG Industry Sector Postfach 48 48 90...

Page 35: ...INDUSTRY PROCESS AND AUTOMATION SOLUTIONS C A F S VF W A T E X INCLUDED Installation use and service manual ...

Page 36: ......

Page 37: ... 0 TESTING THE GEAR UNIT 17 7 0 USING THE EQUIPMENT 19 8 0 MAINTENANCE 20 8 1 ROUTINE MAINTENANCE 21 8 2 LUBRICANTS 23 8 3 OIL CHANGE 23 8 4 RECOMMENDED PERMITTED OILS 24 8 5 CHECKING EFFICIENCY 26 8 6 CLEANING 26 8 7 PAINT 26 9 0 REPLACING PARTS 27 9 1 TAKING APART OF THE IEC STANDARD FLANGED MOTOR 27 9 2 SCRAPPING THE GEAR UNIT 27 10 0 TROUBLESHOOTING 28 ANNEX 1 CHECKING OIL LEVEL ON ATEX SPECIF...

Page 38: ...must be requested directly from the Manufacturer quoting the code of this manual The manual reflects the state of the art at the time of commercialisation of the gear unit The Manufacturer reserves the right to modify supplement and improve the manual without the present pu blication being for that reason considered inadequate Particularly significant sections of the manual and important specifica...

Page 39: ...ture class or maximum surface temperature Maximum surface temperature CE Mark Environmental limits ambient temperature range between 20 C and 40 C Maximum surface temperature temperature class T4 for 2G and 130 C for 2D Some types of gear unit shown in the catalogue are exceptions to this rule and are marked temperature class T3 for 2G or 160 C for 2G and 2D Certifying agency with whom the technic...

Page 40: ...ts vents etc If any such compo nents are damaged they must be replaced and the reason for the damage identified 1 4 REQUESTING TECHNICAL ASSISTANCE For any technical service needs contact the Manufacturer s sales network quoting the information on the unit s nameplate the approximate hours of service and the type of defect 1 5 MANUFACTURER S LIABILITY The Manufacturer declines all liability for ca...

Page 41: ...rostatic charge irreversible temperature indicator supplied along with each unit for installations in zones 21 and 22 the User must schedule and implement a regular cleaning programme of all surfaces and recesses to avoid a build up of dust of more than 5 mm in depth to prevent dust build ups in difficult to access areas the units are equipped with a variety of se als in proximity to the couplings...

Page 42: ...nce of 1 m from the unit and 1 6 m above ground level without vibration was less than 85 dB A The vibrations produced by the gear unit do not constitute a health risk for personnel Excessive vibration may be the result of a fault and should be immediately reported and eliminated Modification of the gearbox configuration or mounting position is only permitted if previously aut horised by the BONFIG...

Page 43: ...nd others in compliance with the provisions of law on health and safety at work All maintenance inspection and repairs must only be done by an expert maintenance technician fully fami liar with the attendant hazards It is therefore essential to implement operating procedures which address potential hazards and their prevention for the entire machine The expert maintenance technician must al ways w...

Page 44: ...0 Storage in all other conditions requires specific packaging In order to facilitate handling heavy packages can be loaded on pallets The most frequent types of packaging are shown in the figures below Wooden crate for miscellaneous products shipped by sea Carton pallet packaging for single products and kits On receipt of the gear unit check that the delivery item corresponds to the purchase order...

Page 45: ...the package itself Har ness heavy packages with chains belts and steel ropes after checking that they are capable of sustaining the weight of the load which is generally specified When handling the load keep it level to avoid instability and or tipping 4 2 2 Moving the equipment All the following operations must be done with due care and caution and without sudden mo vements Identify the attachmen...

Page 46: ...nsis or equivalent pro duct with similar properties and application range 6 Fill the unit with lubricating oil SAFETY PRECAUTIONS to be taken when returning the gear unit to service after storage The output shafts and external surfaces must be thoroughly cleaned of all rustproofing product contaminants and other impurities use a standard commercial solvent Do this outside any explosion hazard area...

Page 47: ...k environment is corrosive for the gear unit or any of its parts take the special precautions re quired for aggressive environments In this case contact the BONFIGLIOLI RIDUTTORI sales service 9 We recommend applying a protective paste to all couplings between the gear unit motor and other parts Klüberpaste 46 MR 401 or equivalent product with similar properties and application range to ensure opt...

Page 48: ...F 30 F 40 F 50 F 60 F 70 F 80 F 90 S 10 S 20 S 30 S 40 S 50 VF 27 VF 30 VF 44 VF 49 VF 130 VF 150 VF 185 VF 210 VF 250 W 63 W 75 W 86 W 110 A1 Life time lubrication Life time lubrication with ATEX specified unit only Cap vent thread Pitch Tightening torque Nm 1 8 28 5 1 4 19 7 3 8 19 7 1 2 14 14 3 4 14 14 1 11 25 Bolt size Tightening torque Nm 5 10 Bolt class 8 8 10 9 M4 3 3 8 M5 5 9 8 0 M6 10 3 1...

Page 49: ...cooling units etc comply with the Essential Health and Safety Requirements of the ATEX directives Handle them with extreme care to avoid altering their characteristics Remove the bolts sealing the threaded holes if provided for securing the gear unit Do not da mage the coupling surfaces When assembling gear units with a torque arm make sure that during operation the metal parts which move relative...

Page 50: ...mer To minimise the loads on the shaft bearings when mounting transmission elements with asymmetrical hubs the preferred layout is shown in diagram A below 5 1 2 Gear units with hollow output shaft To facilitate mounting hollow shaft gear units onto the machine s driven shaft proceed as indicated in the diagram below Also refer to Annex 3 of this Manual for dimension information on customer s shaf...

Page 51: ...5 Fully tighten down the shrink disk bolts gradually following a circular sequence using a torque wrench This operation usually must be repeated several times to reach the tightening torque Mt specified in the table below A 10 A 20 A 30 A 41 A 50 A 60 A 70 A 80 A 90 Mt Nm 14 5 14 5 14 5 14 5 35 35 35 69 69 F 10 F 20 F 30 F 40 F 50 F 60 F 70 F 80 F 90 Mt Nm 8 5 14 5 14 5 14 5 14 5 35 35 69 69 A2 Mt...

Page 52: ...EC electric motor proceed as follows Apply a layer of sealant Loctite 510 or equivalent product with similar properties and applica tion range to the motor gear unit mounting flanges spigot and frontal coupling surfaces as shown in diagram S1 S1 After mounting the motor apply a layer of sealant Loctite 5366 or equivalent product with simi lar properties and application range around the edges of th...

Page 53: ...leaks from the caps or gaskets The unit does not run noisily or with excessive vibration Before starting up the unit check and ensure that Assembly is not carried out in a potentially explosive atmosphere oil acid gas vapour or ra diation and that there is no dust deposits thicker than 5 mm on the gear unit During service the gear unit is sufficiently ventilated and that it is not subject to radia...

Page 54: ...easured at the coupling between the gear unit and motor and at the points which are most shielded from the motor s fan cooling S2 IMPORTANT The maximum surface temperature is reached after 3 hours operation at full load The temperature measured in these conditions must not differ DT from the ambient tempe rature by more than the following values Should the temperature differential exceed these val...

Page 55: ...rough an inverter Only in this way and subject to certification by the assembler shall the assembly in cluding the gear unit itself be compliant with the requirements of Directive 94 9 EC 7 0 USING THE EQUIPMENT Before putting the gear unit into service the User must ensure that the plant in which it is installed complies with all applicable directives especially those regarding health and safety ...

Page 56: ...se of non original spa re parts and non routine work which modifies the safety requirements without the express prior authorisation of the Manufacturer Refer to the specific spare parts catalogue when ordering spare parts for the gear unit Do not dump polluting liquids worn parts and maintenance waste into the environment Di spose of all such materials as stipulated by applicable legislation Obser...

Page 57: ...xternal seals Replace if aged worn Depending on the temperature reached by the lubricant it should be replaced at the intervals indica ted in table A4 below Oil temperature t C Hours t 65 25000 65 t 80 15000 80 t 95 12500 A4 For installations in zones 21 and 22 the User must schedule and implement a regular clea ning programme for all surfaces and recesses to avoid build up of dust more than 5 mm ...

Page 58: ...ynthetic oil and bearing grease if the gear unit is not life time lubricated Replace all externally accessible seal rings unless this has already been done as a result of problems occurring before the scheduled maintenance deadline Every 5000 h of operation at rated torque The minimum overhaul interval indicated here may increase considerably depending on actual conditions of service see table A5 ...

Page 59: ...drain better if it is warm 3 Wait for a few minutes until all the oil has drained out then screw the drain plug back on with a new ga sket 4 Fill the gear unit with the new oil in its actual mounting position to the centre of the level plug 5 Tighten down the filler plug after fitting a new gasket The gear unit may be supplied with or without lubricant as specified by the User The quan tity of oil...

Page 60: ...ear trains Shell Tivela GL 00 alternative for greased gear trains Klüberpaste 46 MR 401 to facilitate coupling of cylindrical parts ITP Fluorocarbon gel 880 for greasing contact seals Oils as alternatives to Shell Tivela Oil S 320 Shell Tivela Oil SC320 Aral Degol GS 320 IP Telium Oil VSF 320 o Agip Klüber Klübersynth GH 6 320 Total Carter SY 320 Mobil Glygoyle HE 320 ...

Page 61: ...elium VSF 320 Spartan EP 220 Spartan EP 320 Klübersynth GH 6 220 Klübersynth GH 6 320 Klübersynth UH1 6 460 F F F F F F F F Glygoyle HE 320 Glygoyle HE 460 Mobilgear SHC XMP 220 Mobilgear SHC XMP 320 Mobil SHC 630 Mobil SHC 632 DTE FM 460 Alphasyn PG 220 Alphasyn PG 320 Carter SY 220 Carter SY 320 Carter SY 460 Degol GS 220 Degol GS 320 Degol PAS 220 Synlube CLP 220 Synlube CLP 320 Renoling PG 220...

Page 62: ...te off the gear unit Do not use solvents or other products which are incompa tible with the construction material and do not direct high pressure jets of water at the gear unit 8 7 PAINT COATING In the factory the cast iron casing of the gear unit is magnetised and sprayed with polyester heat setting re sin which is then baked on Aluminium casings are not paint coated Table A6 shows in colour the ...

Page 63: ...e the flanges and coupling surfaces but proceed as indicated below S3 1 Drill and thread the motor shaft fan side 2 Screw an impact extractor tool into the tap 3 Undo the screws fixing the motor to the gear unit 4 Remove the motor by means of the inertial force of the extractor 9 2 SCRAPPING THE GEAR UNIT This must only be done by operators trained in the observance of applicable laws on health an...

Page 64: ...nning noise Gears damaged Contact authorised workshop Bearing axial backlash too high Contact authorised workshop Bearings defective or worn Contact authorised workshop Service load too high Correct service load to nominal values given in Sales Catalogue Impurities in oil Replace oil Abnormal noise at gear unit mounting Mounting bolts loose Tighten down to specified torque Mounting bolts worn Repl...

Page 65: ...nd of the shape shown in the figu re below If the level is more than 3 mm below the overflow level top up and check the reason for the drop in oil level Helical in line gear units C11 C21 and C31 all mounting positions and bevel helical gear units A10 A20 and A30 in mounting positions B6 and B7 only do not feature a level plug The oil level must therefore be checked not as described above but via ...

Page 66: ...must be less than the value given in table A7 B3 B6 B7 B8 V5 V6 B5 B51 B53 B52 V1 V3 B5 B51 B53 B52 V1 V3 C 11 2_ P63 P71 70 70 70 70 70 45 70 70 70 70 60 30 70 70 70 70 60 30 C 11 2_ P80 P112 75 75 75 75 75 45 75 75 75 75 70 30 75 75 75 75 70 30 C 21 2_ P63 P71 HS 70 70 70 70 70 40 70 70 70 70 70 45 70 70 70 70 70 45 C 21 2_ P80 P112 75 75 75 75 75 40 75 75 75 75 75 45 75 75 75 75 75 45 C 21 3_ P...

Page 67: ...gram S5 2 Insert a dipstick through the yellow service cap on top of the gear unit until it touches the floor of the casing Mark the level of the upper surface of the casing on the dipstick in this po sition 3 Extract the dipstick and measure the distance X shown in diagram S5 above 4 The value X must be less than the value given in table A8 B6 B7 A 10_ P63 P112 30 30 A 20_ P63 P112 HS 25 25 A 30_...

Page 68: ... 2 1 1 9 2 6 3 2 C 41 4 2 8 2 6 2 8 2 6 3 5 3 9 2 8 2 6 2 8 2 6 3 5 3 9 C 51 2 3 1 3 0 3 1 3 0 4 3 5 0 3 1 3 0 3 1 3 0 4 3 5 0 C 51 3 3 0 2 8 3 1 3 0 4 1 4 9 3 0 2 8 3 1 3 0 4 1 4 9 C 51 4 4 3 4 1 4 4 4 2 5 4 6 1 4 3 4 1 4 4 4 2 5 4 6 1 C 61 2 4 2 4 0 4 2 4 1 6 0 6 7 4 2 4 0 4 2 4 1 6 0 6 7 C 61 3 4 2 4 0 4 2 4 1 6 0 6 7 4 2 4 0 4 2 4 1 6 0 6 7 C 61 4 6 1 5 9 6 1 6 0 7 9 8 6 6 1 5 9 6 1 6 0 7 9 8 ...

Page 69: ... 16 19 14 A 70 3 10 14 10 15 20 14 A 70 4 13 14 10 15 23 14 A 80 3 15 22 15 26 35 22 A 80 4 20 22 15 26 39 22 A 90 3 31 35 37 44 66 39 A 90 4 41 35 37 44 73 39 A10 oil l A11 B3 B6 B7 B8 VA VB A 10 2 0 80 1 2 1 2 1 1 A 20 2 1 2 1 7 1 8 1 5 A 20 3 1 5 1 7 2 4 1 6 A 30 2 1 8 2 3 2 6 2 1 A 30 3 2 3 2 4 3 5 2 3 A 41 2 4 0 4 1 4 1 4 7 5 2 4 4 A 41 3 4 0 4 0 4 0 4 7 6 1 3 9 A 50 2 4 9 8 1 4 7 8 4 11 9 2 ...

Page 70: ...5 11 oil l Life time lubricated gear units Lubricant is not factory filled H1 H2 H3 H4 H5 H6 F 10 2 0 95 0 95 0 95 0 95 0 95 0 95 F 20 2 1 4 1 4 1 4 1 4 1 4 1 4 F 20 3 1 8 1 8 1 8 1 8 1 8 1 8 F 30 2 2 6 2 1 1 5 2 1 2 9 2 1 F 30 3 2 6 2 1 1 5 2 1 2 9 2 1 F 30 4 2 9 2 4 1 7 2 4 3 2 2 4 F 40 2 5 0 3 9 4 0 3 1 5 1 4 0 F 40 3 5 0 3 9 4 0 3 1 5 1 4 0 F 40 4 5 3 4 3 4 3 3 3 5 5 4 4 F 50 2 9 2 6 7 7 6 4 7...

Page 71: ...5 3 6 4 3 3 0 VFR 150 V HS P IEC 1 0 0 80 0 80 0 40 0 60 1 0 VF 150 A F FC FR P HS 4 5 3 5 3 5 3 0 3 9 3 9 VF 150 A F FC FR P P IEC 4 3 3 5 3 5 3 0 3 9 3 9 VFR 150 A F FC FR P HS P IEC 0 60 0 80 0 80 1 0 0 40 1 0 VF 185 N HS P IEC 5 0 5 5 5 5 7 8 6 6 6 8 VFR 185 N HS P IEC 1 0 0 80 0 80 0 60 0 40 1 0 VF 185 V HS P IEC 6 8 5 5 5 5 6 4 7 8 5 4 VFR 185 V HS P IEC 1 0 0 80 0 80 0 40 0 60 1 0 VF 185 A ...

Page 72: ...2 M3 1 5 1 7 1 7 1 9 1 7 1 6 7 i 15 1 5 1 7 1 7 1 9 1 7 1 6 20 i 100 2 7 1 7 1 7 1 9 1 7 1 6 A15 oil l Single stage helical gear units series S P F B3 B6 B7 B8 V5 V6 B5 B51 B52 B53 V1 V3 S 10 1 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 S 20 1 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 S 30 1 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 S 40 1 1 6 1...

Page 73: ... 2 33 8 h9 0 5 1 5 8x7x25 A A 30 47 40 h7 39 158 23 112 30 2 2 43 12 h9 0 5 1 5 12x8x30 A 42 35 h7 34 158 23 112 30 2 2 38 10 h9 0 5 1 5 10x8x30 A A 41 52 45 h7 44 184 28 128 45 2 5 2 5 49 5 14 h9 1 2 14x9x45 A 47 40 h7 39 184 28 128 50 2 5 2 5 43 12 h9 1 2 12x8x50 A A 50 63 55 h7 54 226 37 5 151 55 2 5 2 5 59 16 h9 1 2 16x10x55 A 57 50 h7 49 226 37 5 151 65 2 5 2 5 53 5 14 h9 1 2 14x9x65 A A 60 7...

Page 74: ... 70 2 5 2 5 74 5 20 h9 1 2 0 20x12x70 A 68 60 h7 59 180 38 104 70 2 5 2 5 64 18 h9 1 2 0 18x11x70 A F 70 89 80 h7 79 229 58 113 75 3 3 85 22 h9 2 5 2 5 22x14x75 A 78 70 h7 69 229 58 113 75 3 3 74 5 20 h9 2 5 2 5 20x12x75 A F 80 99 90 h7 89 272 78 116 100 3 3 95 25 h9 2 5 2 5 25x14x100 A 89 80 h7 79 272 78 116 100 3 3 85 22 h9 2 5 2 5 22x14x100 A F 90 111 100 h7 99 333 87 5 158 110 3 3 106 28 h9 2 ...

Page 75: ...2 5 53 5 14 h9 2 5 2 14x9x70 A VF 185 68 60 f7 59 188 63 62 80 2 5 2 5 64 18 h9 2 5 2 18x11x80 A VF 210 99 90 f7 89 258 83 92 80 3 3 95 25 h9 2 5 2 5 25x14x80 A VF 250 121 110 h7 109 318 83 152 80 3 3 116 28 h9 2 5 2 5 28x16x80 A A21 A22 A1 A2 A3 B B1 B2 C D E F G R S UNI 6604 W 63 30 25 24 118 38 42 35 2 2 28 8 h9 1 1 5 8x7x35 A W 75 35 28 27 125 38 49 40 2 2 31 8 h9 1 1 5 8x7x40 A 35 30 29 125 3...

Page 76: ...oximate weight 15 Kg 15 Kg Instruction Recommended method for po sitioning Recommended method for handling and positioning Warning The load may be unstable The load may sway or oscillate Solution Slide the lifting ring to align it with the load s centre of gravity as shown in the diagrams below Lock the ropes under the ring with a cable clamp or similar device so as to prevent them sliding and lif...

Page 77: ...fitted to gear units C50 C100 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Series C A B A B B C41 C51 C41 C51 C41 C51 C41 C51 C41 C51 C41 C51 C41 C51 2 3 1 C41 C51 2 3 1 2 3 A 1 P F U UF M05 M1 M2 M3 M4 M5 C 05 M C 11 M A M M C 21 M A M M C 31 M A M M C 35 A A A C 41 A B A B A B C 51 A B A B A B C 61 A B A A B A B C 70 A B A A B A B C 80 A B A A B A B C 90 A B A A B A B C 100 A B A ...

Page 78: ...AX Maximum permissible tilt during handling 15 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Lift manually weight 15 kg M Lift as per diagram A A Lift as per diagram B B M05 M1 M2 M3 M4 M5 A 10 M A M M A 20 A B M P63 P90 M A B P100 P112 A 30 A A A A 41 A B A B A B A 50 A B A B A B A 60 B A B A B A 70 B B B A 80 B B B A 90 B B B Reccomended solution A for positioning solution B for po...

Page 79: ...elets 2 Rope and hooks 1 Ring harness Lift manually weight 15 kg M Lift as per diagram A A Lift as per diagram B B M05 M1 M2 M3 M4 M5 F 10 M A B M M F 20 A B M P63 P90 M A B P100 P112 F 30 A A A F 40 A B A B A B F 50 A B A B A B F 60 A B A B A B F 70 A B A B A B F 80 A B A B A B F 90 A B A B A B Reccomended solution A for positioning solution B for positioning and handling ...

Page 80: ... permissible tilt during handling 15 1 5 1 5 MAX 1 Ring harness Lift manually weight 15 kg M Lift as per diagram A A M05 M1 M2 M3 M4 S 10 1 M A M M S 20 1 M A M M S 30 1 M A M M S 40 1 A A A S 50 1 A A A Reccomended solution A for positioning ...

Page 81: ...5 1 5 MAX Lift manually weight 15 kg M Lift as per diagram A A Lift as per diagram B B 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Eyebolt Snap hook use with rope Screw clamp use with harness W 63 WR 63 M M M W 75 WR 75 A B M M W 86 WR 86 A B M M W 110 WR 110 A B B A B Reccomended solution A for positioning solution B for positioning and handling ...

Page 82: ...ift as per diagram B B Snap hook use with rope Screw clamp use with harness Eyebolt already fitted to gear units VF130 VF250 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness VF 30 M VF 44 VFR 44 VF 49 VFR 49 VF 130 VFR 130 A B A B A B VF 150 VFR 150 VF 185 VFR 185 VF 210 VFR 210 VF 250 VFR 250 Reccomended solution A for positioning solution B for positioning and handling ...

Page 83: ...n fit the stop bushing B1 and tighten down the two grub screws 7 while hol ding it snug against the pinion 1 see figure on the right 6 Lubricate the seal ring lips with a film of grease 7 For type VFR 49 units which are lubricated for life and hence do not have a service plug fill with the quantity of lubricant specified in the corresponding chapter of the catalogue dealing with lubrication of VFR...

Page 84: ...ur ned freely by hand 2 A centre punch is used to make two corresponding reference marks at the same angular position on the ring nut and the protruding section of the output shaft This reference position is the starting point from which all further turns of the ring nut are counted and thus the torque calibration is measured 3 The ring nut is now screwed in by the fractions of a turn which corres...

Page 85: ...49 ...

Page 86: ...DEX OF REVISIONS R We reserve the right to implement modifications without notice This catalogue cannot be reproduced even partially without prior consent R3 Corrected oil quantities for gear units VF 150 35 ...

Page 87: ...rshire B98 9PB Tel 44 1527 65022 Fax 44 1527 61995 www bonfiglioli co uk marwaha bonfiglioli com GREECE BONFIGLIOLI HELLAS S A O T 48A T O 230 C P 570 22 Industrial Area Thessaloniki Tel 30 2310 796456 Fax 30 2310 795903 www bonfiglioli gr sales bonfiglioli gr HOLLAND ELSTO AANDRIJFTECHNIEK Loosterweg 7 2215 TL Voorhout Tel 31 252 219 123 Fax 31 252 231 660 www elsto nl imfo elsto nl HUNGARY AGISY...

Page 88: ...COD 1261 R3 INDUSTRY PROCESS AND AUTOMATION SOLUTIONS w w w b o n f i g l i o l i c o m ...

Page 89: ... i Bonfiglioli Trasmital 300 series Installation use and service manual ATEX INCLUDED ...

Page 90: ...5 1 4 lnstalling accessories on solid input and output shafts 5 2 INSTALLING THE ELECTRIC MOTOR 5 3 INSTALLING THE HYDRAULIC MOTOR 5 4 CONNECTING THE HYDRAULIC BRAKE 5 5 LUBRICATION 6 0 TESTING THE GEAR UNIT 7 0 USING THE EQUIPMENT 8 0 MAINTENANCE 8 1 ROUTINE MAINTENANCE 8 2 Oll CHANGES 8 3 CHECKING OPERATIONAL EFFICIENCY 8 4 CLEANING 9 0 REPLACING PARTS 9 1 REMOVING THE MOTOR 9 2 DECOMMISSIONING ...

Page 91: ...his manual This manual reflects the state of the art at the time of commercialisation of the gear unit The Manufacturer reserves the right to modify supplement and improve the manual without the present pu blication being for that reason considered inadequate Particularly significant sections of the manual and important specifications are highlighted by symbols whose meanings are explained below S...

Page 92: ...IO 1 I ø SERIAL N I ø I DRWG N I G IDATEi ø I COD N I fD I IMADE IN ITALY I Ø Manufacturer Ø Produet identification 9 Bonfiglioli Trasmital produet code Ø Reduction ratio Ø Serial number G Installation drawing code G Date of manufacture G Client produet code Supplementary nameplate on ATEX specified gear units CE r i Bonfiglioli Trosmitol IC EC Cert No IEX 9 0 4 0 7 5 338 70 01I 0 Gearbox complian...

Page 93: ...he Manufacturer declines all liability in the event of use of the gear unit in contravention of local safety at work legislation incorrect installation disregard or incorrect application of the instructions provided in this manual incorrect or defective electrical hydraulic power supply gearmotors modifications or tampering work done on the unit by unqualified or unsuitable persons The safety of t...

Page 94: ... electrostatic charge or if present duly shielded for installations in zones 21 and 22 the User must schedule and implement a regular cleaning programme for all surfaces and recesses to avoid dust build ups of more than 5 mm in depth 2 2 CONFORMITY All gear units or gearmotors when supplied with electric motor are designed in compliance with the provi sions of applicable Essential Health and Safet...

Page 95: ...ersonal health and safety and economic damages The applications permitted by the Manufacturer are the industrial applications for which the gear units have been designed Keep the gear unit at its maximum efficiency by foliowing the routine maintenance schedule Good mainte nance ensures the unit s maximum performance extended service life and continued compliance with sa fety regulations When worki...

Page 96: ...onditions requires speci fic packaging The most frequent types of packaging are shown in the figures below Paekaging on pallet with heat shrink film for ground shipping Paekaging in wooden erate for shipping by sea or air A On reeeipt of the gear unit make sure the delivery eorresponds to the purehase order and that it is not damaged or faulty in any way Report any noneonformity to your BONFIGLIOL...

Page 97: ... the produet to be lifted is given in the Sales Catalogue The following pages illustrate in detail the different attachment methods for the various produet series sizes and configurations described in this Manual The most suitable solution for lifting and handling the produet in safety is indicated for each Symbols Type of lifting Manual With mechanical equipment Symbol M A B Approximate weight 15...

Page 98: ...1 _ 6 _L ffi I D I Q I 3_ 1_ 7_ L_ _ _ 3_ 2_ 1 _ L ffi I D I G l l CD Ring hamess Rope and hooks Open hamess with eyelets Bonfiglioli Trosmitol Screw clamp use with hamess ffei Snap hook W use with rope 6 Eyebolt already fitted W on gear units 317 321 J Maximum permissible tilt during handling 15 1 æ t t 9 ...

Page 99: ...1_R __ Cl I 0 1 Q I D Ring hamess Rope and hooks Open hamess with eyelets 10 ft Screw clamp use with harness 91 Snap hook W use with rope ii j Eyebolt already fitted W ongearunits317 321 I Maximum permissible Lil tilt during handling 15 Bonfiglioli Trosmltol ...

Page 100: ... 3_ 17 R_ _ _ 3_ 2_ 1 _ R _ _ __J Cl I 111 1 CD Ring hamess Rope and hooks Open hamess with eyelets Bonfiglioli Trosmltol ft Screw ciamp use with hamess fiiii Snap hook W use with rope Eyebolt already fitted JV on gear units 317 321 11 ...

Page 101: ... 1 ___ ffi I D I CD Ring hamess Rope and hooks Open hamess with eyelets 12 r l RI Screw clamp use with hamess iiii Snap hook W use with rope 5j Eyebolt already fitted W on gear units 317 321 Maximum permissible tilt during handling 15 It _ Bonfiglioli Trasmitol ...

Page 102: ...th eyelets Bonfiglioli Trosmitol 300 L 321 L Q I y 300 R 321 R Q I 3V 00 3V 21 Q I ft Screw clamp use with hamess fÆ Snap hook W usewith rope Eyebolt already fitted JV on gear units 317 321 Q I y Q I Q I Maximum pennissible tilt during Lil handling 15 E _ I 13 ...

Page 103: ... the instructions on the packaging itself lf the gear unit is to be stored for more than 6 months the following additional precautions must be taken 5 Cover all machined external surfaces with a rustproofing produet such as Shell Ensis or other produet with similar properties and application range 6 Fill the unit with lubricating oil and make sure the vent plug is positioned uppermost Before putti...

Page 104: ...r unit s external moving parts 8 lf the work environment is corrosive for the gear unit or any of its parts follow the special precautions re quired for aggressive environments In this case contact the BONFIGLIOLI TRASMITAL sales service 9 We recommend applying a protective paste to all gear unit motor mating surfaces and other parts Kluberpaste 46 MR 401 or other produet with similar properties a...

Page 105: ...overhung loads or loads are less than 60 of the permissible load For heavier loads the mounting must use both spigots on the gear unit lf the gear unit is instead required to transmit high torque or is subject to heavy shock loads and inversions in the direction of rotation the counterflange must be drilled to accept the spigots At the time of installation move the spigots mounted on the gear unit...

Page 106: ...mum transmitted torques greater than or equal to 70 of the torque indicated as M2max and with fre quent inversions of the direction of rotation use at least class 10 9 bolts 5 1 2 Foot mounting Foot mounted motor execution Gear units of this type must be mounted on a suitably rigid base machined flat with a planarity error margin of no more than 0 2 mm I 100 mm See diagram below 300 321 Foot mount...

Page 107: ... a circular direction repeating the operation seve ral times until all bolts are tightened to the torque specified in chart 2 in accordance with the type of disk gear unit N B Do not tighten down diametrically opposed bolts in sequence 300 321 Rt516 µm l I I J R 600 N mm2 Do not use molybdenum bisulphide or any other grease which could reduce the friction of the mating surfaces and affect the perf...

Page 108: ...upplied in the shipment 5 1 4 lnstalling accessories on solid input and output shafts Do not use hammers or other tools that might damage the gear unit s shafts or bearings when mounting external parts lnstead proceed as illustrated in the diagram below Bolt 1 and spacer 2 are not included in the consignment To minimise the loads on the shaft bearings when mounting transmission mechanisms with asy...

Page 109: ...2 M12 M20 M20 HC M16 M16 M20 M20 PC M12 M16 M20 M20 VK M20 M20 20 9 9 e s M20 M20 M20 M20 M20 M20 M24 M20 M20 M20 M24 M20 M24 M24 M24 M24 M24 M24 M24 M24 M24 0 ro N Q M24 M24 M30 M24 M24 M24 M24 M30 M30 Bonfiglioli Trasmitol ...

Page 110: ... or another pro duet with similar properties and application range 8 8 Provided all the above checks have been performed and passed and all other instruc tions in this manual have been strictly observed an electric motor with ATEX rating equal to or greater than that of the gear unit may be installed thus forming a gearmotor which itself complies with the provisions of Directive 94 9 EC lf instead...

Page 111: ...it taking care to fit it correctly in its seat without damaging it 8 8 b Version with gasket already mounted to the coupling In this case no special intervention is required to ensure an oil tight seal since this is already provided by the motor coupling Merely smear the motorshaft with grease In both cases clean the spigot and the coupling where the motor is to be fitted fit the motor and tighten...

Page 112: ... Technical data 4 5 6 A B D F H K L B c E G K B c E G K L c Braking torque Mbs daNm 5 10 16 26 33 40 44 40 50 63 80 100 85 110 150 210 260 320 Minimum release bar 10 20 30 pressure 20 25 30 33 20 27 20 25 32 14 19 25 19 24 28 Max pressure bar 320 Weight kg 10 18 35 NOTE The static torque Mbs is the maximum torque the brake can exert Under dynamic loads the braking torque is reduced The actual Mbs ...

Page 113: ...ine For the electrical and hydraulic connection refer instead to the two sample diagrams below These are gene ric only since each specific installation has its own special requirements which must be evaluated on a per case basis by the Manufacturer Drive with electric motor L3 L2 L1 W1 V1 U1 U2 W2 L1 L1 U1 L3 L2 L1 U2 L2 24 Bonfiglioli Trasmitol ...

Page 114: ...ivery port must always be equipped with a pressure relief valve calibrated to a pressure no greater than the motor s pmax Refer to the hydraulic circuit diagrams below Closed loop circuit Open loop circuit RV RV RV pressure relief valves calibrated to pRV pmax Closed centre control valve I T I o B Open centre control valve lf this is not possible because the circuit must also actuate ether equipme...

Page 115: ...is connected up pressure at the shaft seal is always equal to the pressure in the drain line 2 lf the drain port is closed off pressure at the shaft seal never exceeds pressure in the return line The maximum values for pressure in the drain line case 1 or return line case 2 are given in the foliowing figure for continuous and intermittent operating conditions bar 250 225 200 175 150 125 100 75 50 ...

Page 116: ...t Control valve open center type Motor execution d Hydraulic oil B02P Control valve closed center type Motor execution P010 Use hydraulic mineral oil with viscosity ISO VG 46 46 Cst at t 40 C Motor execution It is recommended the oil temperature should be between 30 C and 70 C e Oil filtering P010 For reliable motor operation and long life it is important that the hydraulic circuit has a filterfor...

Page 117: ...ition the drain hole so that it is positioned uppermost for charging with fluid Make sure the hoses are routed in such a way as to prevent the motor casing from emptying and hence pre vent air pockets from forming which may affect pump suction during operation A B Supply lines T Drainage 28 T A T B 1 LJ Bonfiglioli Trasmitol ...

Page 118: ... EXP 150 220 HYPOGEAREP HYPOGEAREP CASTROL ALPHASP 150 ALPHASP 220 ALPHASYN EP 150 220 HYPOY HYPOY CEPSA ENGRANAJES HP 150 ENGRANAJES HP 220 ENGRANAJES HPX TRANSMISIONES EP TRANSMISIONES EP 150 220 CHEVRON N L GEAR COMPOUNDS N L GEAR COMPOUND TEGRA SYNTHETIC RPM UNIVERSAL GEAR RPM UNIVERSAL GEAR EP 150 EP 220 GEAR EP 150 220 LUBRICANTS LUBRICANTS GEAROILGX GEAROILGX ESSO SPARTAN EP 150 SPARTAN EP ...

Page 119: ...nd is free of dust build ups greater than 5 mm in depth during operation the gear unit is sufficiently ventilated and is not subject to radiation from exter nal heat sources during operation the cooling air does not exceed 40 C the oil level check and filler plugs and the vent plugs are all easily accessible all accessories mounted to the gear unit are ATEX certified gear units with hollow shafts ...

Page 120: ...n of the gear unit The Manufacturer declines all liability for injury to persons and damage to components due to the use of non original spare parts and non routine work that modifies the safety requirements without the Manufactu rer s express prior authorisation Refer to the specific spare parts catalogue when ordering spare parts for the gear unit Do not dump polluting liquids worn parts and mai...

Page 121: ... required Lubricant Replace Replace with new lubricant Gear unit seals and lnspect carefully for wear age Replace if aged worn gaskets ing of external seals For installations in zones 21 and 22 the User must schedule and implement a regular clea ning programme for all surfaces and recesses to avoid dust build ups of more than 5 mm in depth Every 1000 hrs of operation or after 6 months Measure the ...

Page 122: ...the new lubricant A lf a leak is found identify the cause of the fault and repair it before topping up the lubricant and operating the unit Lubricants solvents and detergents are toxic harmful to health I they may causa irritation in direct contact with the skin they may cause intoxication if inhaled they may be fatal if swallowed Handle them with care using suitable individual safety equipment Do...

Page 123: ...d as illustrated below DRILL AND THREAD IMPACT EXTRACTOR q E j fr 1 Drilland thread the motorshaft fan side 2 Screw an impact extractor tool into the bore 3 Undo the bolts fixing the motor to the gear unit 4 Detach the motor by means of the inertial force of the extractor 9 2 DECOMMISSIONING THE GEAR UNIT The unit must only be taken out of service by operators trained in the observance of applicab...

Page 124: ...ed workshop Bearing axial backlash too high Contact authorised workshop Abnormal running noise Bearings defective or worn Contact authorised workshop Excessive load applied Correct load to rated values given in Sales Catalogue Contaminant in oil Replace oil Abnormal noise at gear unit Mounting bolts loose Tighten bolts to specified torque mounting Mounting bolts worn Replace bolts Oil level too hi...

Page 125: ...ck that the oil level is between the MIN and MAX marks then screw the plug back in lf the level is more than 3 mm below the spill level top up and check the reason for the drop in oil level MIN N B MAKE SURE THE ROD IS POSITIONED FLAT AGAINST THE EDGE OF THE THREADED HOLE Gear units conforming to Directive 94 9 EC and designed for a vertical mounting position are normally equipped with an oil expa...

Page 126: ...2 2 L2 17 25 21 L2 1 9 2 9 2 7 314 L3 19 27 23 304 L3 2 2 3 2 3 0 L4 20 28 24 L4 2 5 3 5 3 3 L2 19 27 23 L1 1 6 2 6 2 4 315 L3 21 29 25 L2 2 1 3 1 2 9 L4 22 30 26 305 L3 2 4 3 4 3 2 L2 22 30 26 L4 2 7 3 7 3 5 316 L3 24 32 28 L1 2 5 3 5 3 2 L4 25 33 29 L2 3 3 4 3 4 0 L2 26 41 36 306 L3 3 6 4 6 4 3 317 L3 29 44 39 L4 3 9 4 9 4 6 L4 30 45 40 L1 3 5 5 0 4 5 L3 40 55 50 L2 4 5 6 0 5 5 318 L4 43 58 53 3...

Page 127: ...21 19 R4 2 8 3 4 3 2 R4 17 22 20 R2 2 3 2 9 2 7 R2 16 21 19 304 R3 2 8 3 4 3 2 313 R3 19 24 22 R4 3 1 3 7 3 5 R4 20 25 23 R2 2 5 3 1 2 9 R3 25 33 29 314 305 R3 3 0 3 6 3 4 R4 28 36 32 R4 3 3 3 9 3 7 R3 27 35 31 315 R2 4 0 5 0 4 8 R4 30 38 34 306 R3 4 8 5 8 5 6 R3 30 38 34 316 R4 5 1 6 1 5 9 R4 33 41 37 R2 6 0 8 0 7 0 R3 38 52 48 317 307 R3 7 0 9 0 8 0 R4 42 56 52 R4 7 5 9 5 8 5 318 R4 48 63 58 N B...

Page 128: ...4 5 4 5 6 5 5 3N 11 L4 10 2 4 2 8 10 2 6 10 2 6 10 1 7 15 1 9 13 1 9 3N 13 L4 13 13 13 13 18 16 3N09 L3 5 5 5 0 5 6 5 6 3N 10 L3 6 3 6 3 6 3 6 3 7 8 7 3 3N14L4 19 4 3 4 5 19 3 9 19 3 9 19 3 0 27 3 5 23 3 5 3N 15 L4 21 21 21 21 29 25 3N 16 L4 24 24 24 24 32 28 3N 11 L3 9 9 9 9 14 12 3N 13 L3 12 12 12 12 17 15 7 8 9 6 6 7 6 7 5 0 5 5 5 5 3N 14 L3 17 17 17 17 25 21 3N 17 L4 29 29 29 29 44 39 3N 15 L3...

Page 129: ... 3 A 03 L2 1 3 3 2 2 3 3 2 2 0 3 2 1 3 3 2 1 3 3 2 i 1 3 3 2 3 A 04 L2 1 4 3 8 2 4 3 9 2 2 3 9 1 4 4 5 1 4 5 0 1 4 4 2 3 A05 L2 1 6 4 0 2 6 4 1 2 4 4 1 1 6 4 7 1 6 5 2 1 6 4 4 3 A 06 L2 2 5 4 9 3 5 8 1 3 2 4 7 2 5 8 4 2 5 11 2 5 9 2 3 A 07 L2 3 5 6 8 5 0 8 1 4 5 12 3 5 15 3 5 18 3 5 15 Life lubrication NOTE In combined gear units lubrication of the planetary stage is separate from that of the worm...

Page 130: ... Bonfiglioli Trasmitol 41 ...

Page 131: ...DEX OF REVISIONS R R2 We reserve the right to implement modifications without notice This catalogue cannot be reproduced even partially without prior consent 42 COD 7 998 3 3 01 7 R2 Bonfiglioli Trasmitol ...

Page 132: ......

Page 133: ...power control and green solutions Bonfiglioli has been designing and developing innovative and reliable power transmission and control solutions for industry mobile machinery and renewable energy applications since 1956 ...

Page 134: ...e torque according to the crane data sheet should always be fitted The maximum brake torque is obtained by turning the adjusting nut 12 up against the ring 5 If required the brake torque can be reduced by loosening the adjusting nut 12 thus releasing the compression of the spring 11 When used as a slewing brake the adjusting nut 12 must be loosened when the crane is out of service to allow the jib...

Page 135: ...SPRING APPLIED BRAKE WITH ELECTROMAGNETIC RELEASE 38 mm Page 2 of 2 180 Volts 16 39599 ...

Page 136: ...Sehr einfach einstellbar Gehäuse Kunststoff oder Aluminumguss Planetary gears plastics Precise Very simple adjustment Housing Plastics or aluminium cast Getriebe Nocken Endschalter Serie 51 51 DZ Geared Cam Limit switches safety in motion ...

Page 137: ...ellung 2 6 Ausführung für erhöhte Anforderungen nach BGV C1 VBG 70 Bühnentechnik 3 Allgemeines 3 1 Getriebedaten 3 2 Elektromagnet Federdruck Zahnkupplung EZX 0 1 3 3 Catalogue No D 142 This catalogue for geared cam limit switches series 51 and geared cam limit switches with differential tooth gear series 51 DZ cancels and replaces all former editions We reserve the right to modify the dimensions ...

Page 138: ...tkontakte gemeinsam ist durch eine einzige Verstellschnecke schwarz möglich ohne daß die Schaltpunkte der einzelnen Schaltkontakte zuein ander verändert werden S Große Nockenscheiben Durchmesser Das bedeutet eine gute Einstellbarkeit und eine hohe Schaltpunktwiederholgenauigkeit 1 Standard switches 1 1 General 51 series geared cam limit switches are universal mechanical switching devices that have...

Page 139: ...alen Planeten Getriebe der Reihe 51 zu verwenden s Tabelle 1 Die Abmessungen der Getriebegröße 1 der DZ Getriebe ent sprechen der Getriebegröße 1 der Planeten Getriebe Damit gelten alle Maßzeichnungen dieses Kataloges für beide Aus führungen 1 2 Construction of the geared limit switch The geared limit switch 51 consists of a gearbox and switch combination which are located within a housing The tor...

Page 140: ...rgendwelcher Teile ist nach der Ein stellung nicht erforderlich As for the normal planetary steps the input shaft can be ex tended to the rear side so that incremental encoders pulse generators or multiturn absolute value encoders can be mounted behind the gear switch see pages 20 and 23 Restrictions The simple block adjustment which is without any competi tion of the normal series 51 however cann...

Page 141: ...contacts to each other are not modified Caution To maintain identical system dimensions with series 51 DZ the block adjustment step is mounted The built in adjusting worm however does not act as block adjustment Nutzbare Umdrehung Usable revolutions Getriebedaten s Gear data see Tab 1 2 DZ Differenzzahn Getriebe Differential tooth gear N nur bei Getriebe Gr 1 ohne Blockverstellung for gearbox size...

Page 142: ...eiben 15_ Usable revs theor at cam discs 15_ Ge triebe i Gear ratio i Vorsatz stufe Input output stage Anzahl i ges Planeten stufen No of planetary stages i 1 Umdr der Antriebswelle Grad an der Nocken scheibe 1 rev of the drive shaft corresp to an ang motion of cam disc _ Rückschalt Umdr an der Antriebswelle für Schnapp schalter Reset rev at driving shaft for snap ac tion max Antriebs drehzahl max...

Page 143: ... 1200 1234 5 1284 9 2x 4 285 1x69 98 0 28 2 1 4 1 1800 199 0 3 2000 2040 7 2123 97 1 653 2x 4 285 1x69 98 0 17 3 5 10 3 1800 330 0 3300 3330 9 3466 66 2 698 2x 4 285 1x69 98 0 1 5 5 11 3 1800 539 0 5200 5290 2 5505 87 3x 4 285 1x69 98 0 06 9 1 17 8 1800 856 0 4 8700 8744 7 9101 2 1 653 3x 4 285 1x69 98 0 04 15 1 29 5 1800 1415 0 14200 14272 9 14854 8 2 698 3x 4 285 1x69 98 0 02 24 7 48 2 1800 1 1 ...

Page 144: ...r Schnapp schaltung Snap action Schrauban schluß Screw termi nal 99P1 Wechsler Change over cont Silber Silver Schnapp schaltung Snap action Flachstecker 6 3 Flat plug 6 3 0 5 60 99G1 3 Wechsler Change over cont Gold Schnapp schaltung Snap action Schrauban schluß Screw termi nal Nicht für Neukon struktion 92 2 Wechsler Change over cont Silber Silver Schnapp schaltung Snap action Schrauban schluß Sc...

Page 145: ... DZM 899 BM DZM 296 BM DZM 496 BM DZM 696 BM DZM 896 3 A 3 B 3 C 3 D 323 0 540 0 880 0 5200 8700 14200 BM DZM 299 BM DZM 499 BM DZM 699 BM DZM 899 BM DZM 296 BM DZM 496 BM DZM 696 BM DZM 896 4 A 4 B 4 C 4 D 1384 0 2288 0 3735 0 BM 299 BM 499 BM 699 BM 899 BM 296 BM 496 BM 696 BM 896 5 A 5 B 5 C 5 D 5900 0 9800 0 16000 0 BM 299 BM 499 BM 699 BM 899 BM 296 BM 496 BM 696 BM 896 6 A 6 B 6 C 6 D 1 Den ...

Page 146: ...h folgendermaßen The usable number of revolutions of the drive shaft of a geared switch enabled by a cam disc can be calculated as follows 0 15 60 270 315 360 1 2 3 4 DD _140184 Kontakt Contact Nockenwinkel Cam angle _ Beispielzeichnung Example drawing Switching point angle Rollenhebel des Schaltkontaktes Roller lever of switching contact Schaltpunkt Radius Switching point radius Usable angle of c...

Page 147: ...stemperatur ambient temperature Fmax 9 N Umgebungstemperatur Ambient Temperature DD1_40170V Elast Antriebsflansch F Flexible drive flange F Elast Antriebsflansch F M Flexible drive flange F M ø42 0 2 ø8 0 05 5 20 3x120 3x120 ø30 0 1 10 11 5 15 H7 h9 ø8 M6 ø42 0 2 10 14 22 ø3 ø54 max zulässige Betriebsdrehzahl max adm service speed n 1000 min 1 Verdrehwinkel bei twisting angle at 5Nm 5 0 5_ 1 11 El...

Page 148: ...erteil Bauform B3 An das Gehäusevorderteil wird zusätzlich ein Aluminium winkelfuß angeschraubt Bauform B5 An das Gehäusevorderteil wird zusätzlich ein Aluminium flansch angeschraubt 1 12 Housing variants 1 12 1 Component housing protection IP20 IP00 This housing variant is used where a housing is already avail able in which the geared switch can be integrated It is also used in the following desc...

Page 149: ...haft dia 6 Option 2 Wellenende 2nd shaft end Nutzb Umdrehung Usable rev Anzahl Kontakte No of contacts Größe Size Maß Dim L1 Maß Dim L2 51 51 DZ 2 1A 62 5 32 5 4 1 NM 67 DZM 4 1B 83 5 53 5 6 5 NM 110 DZM 6 1C 104 5 74 5 11 NM 180 DZM 8 1D 125 5 95 5 2 2A 73 0 43 0 17 5 BM 280 DZM 4 2B 94 0 64 0 29 BM 470 DZM 6 2C 115 0 85 0 48 BM 770 DZM 8 2D 136 0 106 0 2 3A 81 5 51 5 75 BM 1200 DZM 4 3B 102 5 72...

Page 150: ...0 Geberanbau Al Deckel Cover 168 00125 Option Al Deckel Cover 168 00130 Option Poti Antrieb für Welle Potentiometer drive for shaft dia 6 Option Anzeigescheibe für Blockverstellung Indicating plate for block adjustment MH MN 1 13 Schalter im Aluminium Gehäuse IP65 Bauform B3 B3 5 Merkmale Getriebeschalter eingebaut im Aluminium Gehäuse für den Einsatz in rauher Umgebung 1 13 Switches in aluminium ...

Page 151: ...29 BMN BMH 48 BMN BMH 280 DZMN DZMH 470 DZMN DZMH 770 DZMN DZMH 2A 2B 2C 2D 2A 2B 2C 75 BMN BMH 125 BMN BMH 205 BMN BMH 1200 DZMN DZMH 2000 DZMN DZMH 3300 DZMN DZMH 3A 3B 3C 3D 3A 3B 3C 323 BMN BMH 540 BMN BMH 880 BMN BMH 5200 DZMN DZMH 8700 DZMN DZMH 14200 DZMN DZMH 4A 4B 4C 4A 4B 4C 1384 BMN BMH 2288 BMN BMH 3735 BMN BMH 5A 5B 5C 5A 5B 5900 BMN BMH 9800 BMN BMH 16000 BMN BMH 6A 6B 6A Beispiele f...

Page 152: ...th can be extended as required with 25mm wide intermediate pieces Getriebe größe G i 2 Kontakte Contacts A 4 Kontakte Contacts B 6 Kontakte Contacts C 8 Kontakte Contacts D 51 51 DZ g Gear size L1 mm Anz Zwst L1 mm Anz Zwst L1 mm Anz Zwst L1 mm Anz Zwst 4 1NM 6 5NM 11NM 67DZM 110DZM 180DZM 1 132 0 132 0 132 0 157 1 17 5BM 29BM 48BM 280DZM 470DZM 770DZM 2 132 0 132 0 157 1 182 2 75BM 125BM 205BM 12...

Page 153: ...an be extended as required with 25mm wide intermediate pieces Getriebe größe G i 2 Kontakte Contacts A 4 Kontakte Contacts B 6 Kontakte Contacts C 8 Kontakte Contacts D 51 51 DZ g Gear size L1 mm Anz Zwst L1 mm Anz Zwst L1 mm Anz Zwst L1 mm Anz Zwst 4 1NM 6 5NM 11NM 67DZM 110DZM 180DZM 1 138 0 138 0 138 0 163 1 17 5BM 29BM 48BM 280DZM 470DZM 770DZM 2 138 0 138 0 163 1 188 2 75BM 125BM 205BM 1200DZ...

Page 154: ...ed as required with 25mm wide intermediate pieces Getriebe größe G i 2 Kontakte Contacts A 4 Kontakte Contacts B 6 Kontakte Contacts C 8 Kontakte Contacts D 51 51 DZ g Gear size L1 mm Anz Zwst L1 mm Anz Zwst L1 mm Anz Zwst L1 mm Anz Zwst 4 1NM 6 5NM 11NM 67DZM 110DZM 180DZM 1 132 0 132 0 132 0 157 1 17 5BM 29BM 48BM 280DZM 470DZM 770DZM 2 132 0 132 0 157 1 182 2 75BM 125BM 205BM 1200DZM 2000DZM 33...

Page 155: ...mögliche Raumausnutzung auch bei Sonderausführungen Gesamtlänge durch den Einbau von 25 mm breiten Zwi schenstücken nahezu beliebig verlängerbar Features Housing made of glass fibre reinforced polycarbonate with the degree of protection IP66 Modular design enables optimal space utilisation also for spe cial types Overall length can be extended as required with 25mm wide intermediate pieces Getrieb...

Page 156: ...ion feedback Also tachogenerators can be directly driven by the drive shaft In relation to the weight of the encoder to be fitted various mounting executions are possible Hollow shaft encoders are directly slipped on the shaft and the housing is held by a torque support Encoders with power take off shaft up to a weight of approx 250 g and for vibration free and shock free applications are mounted ...

Page 157: ...rotation multi turn potentiometers are normally used Additionally installed potentiometers may increase the overall length of the geared switch For the exact overall length please consult us stating the po tentiometer dimensions Beispiel für Potianbau Example of potentiometer mounting Potentiometer DD1_40288V SW 15 16 Gummieinsatz ø 23 Aufnahmebohrung für Potiwelle Klemm Mutter PG 7 ø 6 19 DD1_402...

Page 158: ... use with our geared limit swit ches effectively prevent condensation and excessively low temperatures in the switches They are available in two ver sions and differ only by the permissible supply voltage The anti condensation heater which can be installed in any switch version will not increase the overall length of the swit ches and can also be retrofitted Anschlußklemme Connection terminal Beis...

Page 159: ... approx 110 mA and is short circuit proof To prevent excessive heating of the solenoid coils to be connected with a continuous signal the output amplifier disconnects each pulse after about 20 ms monoflop function With this pulse transmitter rotation of the limit switch is indica ted and the speed can be identified It is not possible to di stinguish between clockwise and counter clockwise rotation...

Page 160: ...driven block adjustment only for series 51 The possibility to adjust all contacts with a single adjusting worm offers the option of automating this adjustment by means of a small geared motor One of the switching contacts provided is used for disconnection of the adjusting motor Af ter adjustment of the drive system and subsequent reference operation all contacts can be reset to a predetermined po...

Page 161: ... oder an der B Seite außen am Gehäuse angebaut ist Da ein zusätzliches Schild für die Baumuster Teilprüfung am Schalter angebracht und auch zusätzliche Prüfzertifikate aus gestellt werden müssen benötigen wir unbedingt in Ihrer Bestellung den Vermerk mit Baumuster Teilprüfung nach BGV C1 3 Geared Cam Limit Switches Series 51 Variant for increased requirements according to BGV C1 VBG 70 stage techn...

Page 162: ... 59 97 5 8 07 9 34 78 3 1384 1280 0 1444 62 155 0 12 81 14 84 124 4 5 2288 2100 0 2387 96 256 0 21 18 24 52 205 6 3735 3400 0 3897 58 417 0 34 57 40 03 335 6 5900 5500 0 6190 204 663 7 55 07 63 57 520 1 6 9800 9000 0 10232 407 1097 0 91 04 105 08 856 6 6 16000 14500 0 16701 17 1790 7 148 59 171 51 1403 1 Tabelle Table 4 a Reihe Series 51 DZ Getriebe größe Gear size Nenn Umdrehung 15_ Nock enscheib...

Page 163: ...er hindert 9 Zusätzliche Zentrierung für das Aufbringen eines Schalt ringes zur Schaltzustandsüberwachung der Kupplung mittels berührungsfreien Schalters auch in geprüfter Sicherheit 3 3 EZX 0 1 Electromagnetic spring applied toothed clutch The EZX 0 1 positive locking electromagnetic spring ap plied toothed clutch has been developed specially for use with stage hoisting gear and can be combined w...

Page 164: ...bau von Encodern mit ø36 oder ø50 Flansch direkt am Gehäuse Elektr Federdruck Zahnkupplung EZX0 1 Elektr Spulenanschluß im Schaltergehäuse Spule Coil 24V 24 Watt Getr Schalter 51 mit El Zahnkupplung und Encoder für die Bühnentechnik DD1_40293H Geared switch 51 with el toothed clutch and encoder for stage technology Electromagnetic spring applied toothed clutch EZX0 1 Option assembly of encoder Ass...

Page 165: ...9 153 120 145 Elektr Federdruck Zahnkupplung EZX0 1 Elektr Spulenanschluß im Schaltergehäuse Electric coil connection in the switch housing 275 205 ø 32 ø 37 ø 40 4xM3 18 160 25 96 Spule Coil 24V 24 Watt 70 5 2 128 M20x1 5 36 Getr Schalter 51 mit El Zahnkupplung für die Bühnentechnik DD1_40347H Geared switch 51 with el toothed clutch for stage technology Electromagnetic spring applied toothed clut...

Page 166: ...Sociedade Electrotécnica S A Rua do Vale de Pereiro 8 1250 Lisboa Tel 351 21 9737111 Fax 351 21 9737003 geral sotecnica pt Russland Russ Föderation und ehem GUS Staaten Stromag Vertretung OOO BOLLFILTER Russland Datschnij Pr 2 1 Liter A Buero 23N St Petersburg 198207 Russland Tel Fax 7 812 3646180 Tel 7 901 3008961 info stromag ru Kompetenzzentrum Kompressoranwendungen Dr Spektor Boris A 127018 Mo...

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