OPERATING INSTRUCTIONS Variable speed gearboxes
Contents
1. r em AO Fre 4 _ T eek hed boefa power A a planetroll GmbH amp Co KG Telephone 49 7393 9518 0 TUV Brunnenbergstra e 11 13 or 49 700 planetroll Ss 9 D89597 M underkingen Telefax 49 7393 9518 98 office planetroll de www planetroll de OPERATING INSTRUCTIONS Variable speed gearboxes Olaromaster Directive 94 9 EC ATEX 95 DOKU SekGF 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 1 of 14 CONTENTS MANUAL plaromaster General references 11 1 Safety references 11 2 Intended use 2 _ Safety references 3 Description of gearboxes Technical data 4 1 Outputdata of identificationplate 4 2 Housing o 4 3 Tractionfluid o O 44 Rotaryshaftseals 45 O ins ooo O 4 amp 6 Bearing S 48 Varnishing 5 Storage of the gearboxes Examination of the gearboxes Preparation for setting up Setting up of the gearboxes Control of traction fluid before setting up Control of traction fluid after setting up urface temperature of the gearboxes Control of the gearboxes 7 5 Check list for setting up Maintenance and servicing M aintenance details Intervals for inspection and maintenance Inspection and maintenance work 9 Quantity plan for traction fluid DOKU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 2 of 14 1 General references The available manual is a component of the variable speed gearboxes plaromaster2. mentioned gearboxes in the following Always keep the manual close to the gear The exact knowledge of the manual ensures a safe and troublefree operating of the gear by avoidance of operating errors and inappropriate use Therefore it is in the interest of the operator that the manual is read understood and observed in all points by the persons responsible for transport assembly and operation and or application For motors clutches brake motors reduction or transmission gears as well as other additional equipments which are mounted on the gearbox the further provided manuals must be observed There is no separate manual for the planetroll planetary gearboxes planetdrive mounted to the variable speed gearboxes ex work as these planetary gearboxes are tuned power related to the variable speed gearbox and maintenance free In connection with the variable speed gearbox plaromaster these planetary gearboxes fulfill all ATEX requirements In this respect the references of this manual are to be applied by analogy to the planetary gearbox The transmissions and or drives described here correspond to the technical conditions at that time of printing this manual In the interest of advancing we reserve ourselves the right for carrying out changes in this manual which are considered as useful while keeping the substantial characteristics for efficiency and safety of the gearboxes and or drives described here The copyr
3. cloth The cleaning should be accomplished in the cold gearbox condition DOKU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 13 of 14 9 Quantity plan for traction fluid The filling quantity of traction fluid depends on mounting position and is marked with the figures1 2 3 4 5 and 6 on 2 V3 V6 V19 L va V5 V18 Symbolerkl rung Symbol explanation y Einf llschraube filling screw vw Kontrollschraube control screw m Ablassschraube drain plug Traction fluid capacity plaromaster capacity ml traction fluid M RV 1 2 3 4 5 5 traction fluid filling for life 15 ml MRI fi 2 5 4 15 6 160 MR3 er BEE BE T a sort of traction fluid according to identification plate of each variable speed gearbox DO KU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 14 of 14
4. fluid leakage of the gear and from penetration of impurities Dependent on the temperature rings with a material having the ability to resist high temperatures are used with a thermal range of application from 20 C up to 200 C O rings Flanged on transmission covers are sealed with o ings with a material having the ability to resist high temperatures with a thermal range of application from 20 C up to 200 C Bearing All shafts are executed with an antifriction bearing They are continuously lubricated for life Cooling The gearbox surface is designed for the dissipation of the convection and radiation heat infrared heat Itis important that the gearbox surface remains clean Varnishing The gearbox housing is made up of aluminium sand casting alloy and in standard execution itis unvarnished The drive units can be varnished in different RAL colors according to customer s request In case of a subsequent lacquer finish of the gearbox rotary shaftseals in and output shaft may not get in contact with colors lacquers and solvents Operationally rubbed plastic surfaces can load themselves electrostatica lly W ith application in zone 21 and 22 types of dust the layer thickness may notbe thicker than 200 um 5 Storage of the gearboxes During storage following points are to be considered The gearboxes are to be secured against falling down Brigth connecting surfaces and shafts are to be oiled lightly Storage in dry
5. force Fr lies outside the center of output shaft then the permissible force values reduce x gt L 2 and or the permissible force values increase x lt L 2 Points of load attack on the gearbox output shaft Fa permissible axial force Fr permissible radial force Lo shaftlength x space Permissible Output shaftloading Fr MR MR3 MR5 MR7 MR9 MRII Standard reinforced 250 300 370 500 600 800 700 1000 900 1300 2100 3700 DOKU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 10 of 14 7 Starting up 7 1 Control of traction fluid before starting up Before starting up the level of traction fluid must be checked For this the gearbox motor AN is to be switched free from voltage secured against unintentional switching on M ounting position has to be considered see quantity plan for traction fluid Ex The maximum conditions are the bottom edge of the tapped hole for the control screw of traction fluid If no traction fluid is flowing out from the opened tapped hole then traction fluid must be refilled until level of traction fluid reaches the bottom edge of tapped hole of the control screw of traction fluid The conditions for traction fluid are to be controlled quarterly every third month Basis for this is the quantity plan for traction fluid Control of traction fluid after starting up O n the first day after starting up thereafter once a week it must be accom
6. rooms DO KU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 7 of 14 Temperature without large fluctuations in the range of 5 C up to 50 C Relative humidity smaller than 60 N o direct sun exposure or ultraviolet light N o aggressive corrosive materials in the environment N o vibrations and oscillations 6 Setting up of the gearboxes 6 1 Examination of the gearboxes The gearbox is to be examined and only is to be installed if no damages by storage or transportare visible Special attention applies for the rotary shaft seals 6 2 Preparation for setting up Itis to be considered that the components and driving motors mounted on the gearbox are designed according to ATEX conformity provided that the gearboxes and or drives are operated in an explosion proof area Ifa wrong direction of rotation can lead to a damage or to a risk then the correct direction of output shaft ist to be determined by a test run of the drive in non coupling condition and itis to be guaranteed for later operation N o aggressive corrosive materials may be present in the environment of the gearbox which would cause an attack to the material traction fluid lubricant or elastomers This applies also to later operation Setting up of the gearboxes W hen setting up the gearbox no explosive atmosphere may be present The foundation and or construction unit to which the gearbox is fastened should be oscillation poor tors
7. are hand can lead to uncontrolled frig htfull reaction or to a burn Attention no lifting operations The gear is not self locking N ot suitable for lifting operations All work is to accomplish carefully conscientiously and under the criterion of security During transportation assembly and dismantling operation as well as attendance and maintenance the relevant regulations of industrial safety and environmental protection must be followed The driving motor is to be set out of operation immediately if during the operation changes on gear are determined e g an increased operating temperature unusual gearbox noises gt Pe o DOKU SekG F 146 TEN O perating Instructions M R ATEX Rev 07 date 2007 11 1 page 5 of 14 gt D W ith installing the drive in devices or plants the manufacturer of the devices or plants is obligated to consider in his own manual the regulations references and descriptions of this manual W ith the change of traction fluid the used up traction fluid is to be collected in a suitable tank Run out traction fluid is to be eliminated immediately by means of an oil binding agent The used up traction fluid is to be disposed according to the relevant environmental regulations just like oil binding agents and the cleaning cloths 3 Description of gearboxes The variable speed gearbox plaromaster is an infinitely variable speed ball gearbox il Life span of in and output sha
8. ft bearings amounts to at least 20 000 operating hours O utputspeed can be adjusted to speed zero 4 Technical data 4 1 Output data of identification plate The identification plate of the gearbox contains the most important technical data These data and the contractual agreements for the drives specify the borders of the intended use Housing Achtung Betriebsanleitung unbedingt beachten Attention M anual must be strictly observed Ae UW N e ATEX execution of variable speed gear type description planetroll fabrication no mounting position see also quantitiy plan for traction fluid inputspeed rpm speed range rpm maximum torque in speed range torque at maximum outputspeed specification of traction fluid filling quantity 4 2 amp G earbox housing consists of aluminium sand casting Housing covers consist of aluminium continuous casting DOKU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 6 of 14 4 5 Traction fluid Attention Traction fluid is not a standard gear lubricating oil W ith horizontal mounting position the gearbox transmission parts are moistened with traction fluid by immersing W ith vertical mounting position the parts are moistened with traction fluid by immersing and fine dispersion The external shaft bearings are grease lubricated for life Rotary shaft seals Radial rotary shaft seals on shaft entrance and shaft outlet prevent from traction
9. ight of this manual remains with planetroll GmbH amp Co KG M underkingen Also the manual may not be multiplied without our agreement neither completely nor partly Itmay also not be used unauthorized for purposes of competition and it may not be made available against third persons O nly planetroll has the sole right to change this manual or to add specifications in it otherwise any warranty claim will expire Attention We acceptno responsibility for damages and operational disturbances caused by non observance of the manual DOKU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 3 of 14 1 1 Safety references Please take special care of the following safety and reference signs BP C6 1 2 Intended use danger danger to life and danger of injury for humans danger important references for protection against explosion danger threatening danger by current attention possible damages on the plant special caution is required reference useful information The variable speed gearboxes plaromaster are intended for the employment in il commercial plants They fulfill the explosion proof requirements according to Directive 94 9 EG ATEX 95 for the category indicated on the identification plate The technical data indicated on identification plate must be observed strictly O utside the power limits specified there the gears and or drives may not be operated Deviating operat
10. ing conditions require new contractual agreements DO KU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 4 of 14 2 Safety references Ex W ith all work such as installation assembly electrical connection starting up maintenance servicing and repair no explosive atmosphere may be present Explosive gas mixtures or dust concentration in connection with hot live and moved parts of electrical machines Can cause serious or fatal injuries W orking on the gearbox may be accomplished only by qualified personnel The operator has to ensure that the persons engaged with assembly operating care and maintenance as well as servicing have read the manual understood it and that they observe itin all points in order to avert danger for life and health of the user and of third persons guarantee the safety reliability of operation of the gear as well as of the necessary components exclude loss of use and environmental pollutions by wrong handling All work on the gear may be implemented only at rest The drive must be switched free from voltage and secured against unintentional switching on A sign is to be attached at the switching on place showing that somebody is working on the drive gt The references on the drive e g identifcation plates must be observed Keep them free from dirt and color M issing plates must be replaced gt Possibly the transmission housing heats up Accidental contact with b
11. ionally rigid and even The driven end is to be aligned carefully Contamination on the fixing surfaces is to be cleaned Accessible rotary parts are to be covered In order to avoid overheating of drive following points are to be considered during setting up 1 An unrestricted airdraught atall sides of gearbox is to be realized 2 A sufficient free space is to be planned around the gearbox 3 Cooling air of the motor fan of gear motor must flow against the gearbox unrestrictedly N o capsulating or lining of the gearbox Do not expose drive to heating up by direct sun exposure Do notlead warm exhaust air of other aggregates to the gearbox The foundation and or construction to which the gearbox Is fastened must notlead any heat inside the gearbox 8 No dust pouring in the area of the gearbox p IMD UI De DOKU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 8 of 14 6 4 Assembly The installing of in and output elements e g clutch hubs onto the output shaft of gearbox IN has to be realized by means of a suitable winding up mechanism in order to avoid an attack of harmful forces to the gearbox Hubs never must be impacted with the hammer There is a thread centering bore hole atthe in and output shaft which is suitable for winding up the hubs The assembly of the hube is facilitated if itis coated before with lubricant or if the hube is warmed up to 100 C In and output elements e g be
12. lt drives must be provided with a contact protection The lateral force insertion should be as close as possible to the gearbox Mounting of driving motor Only IEC standard motors may be used for the drive of gearbox which prove a category sufficient for ATEX zone in accordance with the motor shield W ith gears of ATEX category 2D atleast the motor must show the protective system IP6 X Electrical connections must correspond to technical standards and must be implemented by qualified persons regulation for specialists see DIN VDE 0105 or IEC 364 M otor connection if motor is factory mounted then you will find electrical connection diagram together with safety regulations inside the terminal box The references and safety regulations indicated there must be obeyed strictly Further data are indicated on identification plates of motor and possibly other components ob Attention Before starting up of drive itis to be guaranteed that 1 the drive does not drive on block 2 brakes are possibly ventilated 3 all protection and safety devices are duly installed also during trial operation 4 the direction of rotation of the drive is correct DOKU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 9 of 14 6 6 Permissible output shaft loading The point of load attack corresponds to the center of the output shaft The values for Fr consider 30 of axial force If the force insertion of radial
13. plished a visual inspection for possible leakage places If leakage places are found then the drive is to be put out of service and planetroll has to be contacted immediately Op for control AN 1 The gearbox motor is to be switched free from voltage and secured against unintentional switching on 2 Check of oil level is to be accomplished only at standstill and cooled gearbox 3 The control screw for traction fluid appropriate to the design is to be unscrewed 4 Incase of damages of this screw or seal these parts have to be exchanged Surface temperature of gearboxes In continuous operation the gearbox is appropriate for surface temperature of 95 C For short time planetroll gearboxes can be loaded beyond a multiple of rated torque In dependence on the taken power on speed and on mounting position shortterm surface temperatures of 115 C are permissible The permissible ambient temperature for the gears amount to 10 C up to 40 C BP The gearbox may be installed only in the ordered mounting position In case of change in mounting position the quantity of traction fluid will change A change of mounting position may take place only after consultation with planetroll Changing the mounting position without any previous consultation with planetroll will lead to an expiring of the ATEX permission as well as to an expiring of any warranty claims DOKU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 da
14. te 2007 11 1 page 11 of 14 During operation the gearbox isto be checked on superelevated surface temperatures and for changed noises If irregularities are found then the gearbox and or drive is to be put out of service and planetroll has to be contacted immediately The surface temperature of gearbox has to be checked from time to time Please note that slightly changed ambient and setting up conditions e g restricted mounting conditions contrary to the instructions given by you planetroll ATEX check list can affect temperature conditions substantially 7 4 Control of the gearboxes During test run the gearbox Is to be examined under maximum load for the following unusual noises e g milled knocked or grinded noises unusual vibrations oscillations and movements formation of fog and or smoke After its test run the gearbox is to be examined for leakage places If any conspicuousness during the described check tests is determined then the gearbox is to be put out of service and planetroll has to be informed 7 5 Check list for setting up Before setting up within the ex area itis to be checked the following 1 The examination of the delivered goods immediately on their receipt on possible transportation damages The haulage firm has to be informed immediately of such damages 2 The correctness of the following maximum permissible data indicated on identification plate of gearbox compared with the actual ex area condi
15. tions of a group of equipment ex category ex zone temperature class maximum surface temperature oF The guarantee that there are no explosive atmospheres present during installation The free accessibility of all control screws for traction fluid and drain plugs 5 The correctness of the motor data indicated on identification plate regarding the actual ambient conditions at place of work gt DOKU SekG F 146 TEN O perating Instructions MR ATEX Rev 07 date 2007 11 1 page 12 of 14 8 Maintenance and servicing 8 1 Maintenance details 8 2 Intervals for inspection and maintenance From the date of setting up the variable speed gearbox itmustbe accomplished a rN change of traction fluid after every 5000 hours of operation planetrolle variable speed gearboxes must be filled exclusively with synthetic traction fluids indicated on identification plate of variable speed gearbox Attention The traction fluids specified above must not be mixed with mineral oil lubricating oil or other synthetic oils Even the mixture of smallest quantities of lubricating oil with traction fluid causes a loss in power irreversible damages on the gearbox transmission parts and thus the failure of the gearbox 8 3 Inspection and maintenance work amp Dust pollution on gearbox housing is to be removed regularly The dust pollution may notamountto any more than 5 mm N ever blow off dust danger by dust air atmosphere but wipe it off by means of a wet
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