Operating Instructions GST-GFL-GKS-GKL-GKR
Contents
1. 3 stage GSS 3 stage 2 stage T x 2 stage 3 stage BA 12 0023 EN 7 0 Lenze 16 Product description 3 Product features 3 2 Product features Design Drive systems have a modular design They consist of Reduction gearboxes Helical gearboxes Shaft mounted helical gearboxes Helical worm gearboxes Helical bevel gearboxes Bevel gearbox Variable speed drives gt Motors Mode of operation Torque and speed conversion Product family Pre stage 1st stage 2nd stage 3rd stage Helical gearbox lt Helical Shaft mounted helical gearbox Helical Helical bevel gearbox Helical Helical Bevel Bevel gearbox Helical worm gearbox Helical Worm lt The torque reaction must be supported in a suitable manner BA 12 0023 EN 7 0 Lenze 17 3 Product description Product features Mounting position A F and position of system modules 1 6 GST Terminal box Motec connector 2 3 4 5 VVithout terminal box Motec connector 0 F GFL Solid shaft 6 Foot 3 4 Terminal box Motec connector 2 3 4 5 Hollow shaft 0 Without foot 0 Without terminal box Motec connector 0 Hollow shaft with shrink disc 1 6 1 5 lt gt al 3 3 ee EL Na as 2 6 B C D E F GKS GSS GKL Solid shaft 3 5 8 345 Flange 3 5 8 345 Terminal box Motec connector 2 3 4 5 Hollow shaft 0 Without flange 0 Without terminal box Motec2. 1 CLP HC VG 220 VG 320 CLP VG 460 CLPHC VG 320 CLPPG VG 460 do VG320 CLP VG 460 CLPHC VG 320 CLPPG VG 460 CLP VG 460 CLPHC VG 320 CLPPG VG 220 CLPPG VG 460 CLP VG 460 CLP HC VG 320 1 VG 460 1 VG 220 1 VG 220 1 CLPPG VG 460 CLP VG 460 CLPHC VG 320 Lenze Gearbox type GKL GST GFL GKS GKR GKK04 06 Omala 460 as of 2011 Omala S2 G 460 Omala HD 320 as of 2011 Omala S4 GX 320 Naturelle Gear Fluid EP 320 Kl beroil GEM 1 460N Kl bersynth GEM 4 320N Kl ber Summit HySyn FG 46 Kl bersynth GEM 4 46N Kl beroil 4 UH1 220N Kl bersynth GEM 2 320 Renolin CLP 460 Renolin Unisyn CLP 320 Plantogear 320 S AGIP BLASIA 460 AGIP BLASIA SX 320 Energol GR XP 460 Enersyn EP XF 320 Mobilgear 600 XP 460 Mobilgear SHC Gear 320 Mobil SHC Cibus 460 Mobil SHC Cibus 220 Carter EP 460 Carter SH 320 Gearbox type GSS GKK07 Tivela S 220 as of 2011 Omala S4 WE 220 Tivela S 460 as of 2011 Omala S4 WE 460 Naturelle Gear Fluid EP 3201 Kl bersynth GH 6 460 2 Kl bersynth GH 6 220 2 Kl bersynth GH 6 32 1 2 Kl bersynth GEM 2 320 1 Renolin PG 4601 2 Plantogear 3201 AGIP BLASIA S 460 1 2 Enersyn SG XP 220 1 2 Enersyn SG XP 460 1 2 Mobil Glygoyle 220 1 2 Mobil Glygoyle 460 1 2 BA12 0023 EN 7 0 Ambient temperature C 50 0 50 10 50 3 Am 20 40 LUBRITECH
3. 3 0 Amount of lubricant in litres Tab 13 with version VLIK at the output end 71 Lenze BA12 0023 EN 7 0 8 2 6 72 Maintenance Maintenance operations Amount of lubricant for combined mounting positions Amount of lubricant for combined mounting positions For the gearbox sizes 03 05 a combination of different mounting positions vvith amounts of lubricant to suit are permissible as per the follovving tables Advantage Easier logistics for users vvho use gearboxes in different mounting positions Disadvantage On some gearboxes more lubricant is necessary in the gearbox than is necessary technically As a result a higher internal pressure is produced Helical gearbox GSTO3 05 2 VO Versions VOR VOL Mounting position GST03 GST04 GSTO5 AEF 0 35 0 7 BC 0 20 0 50 0 85 D 0 55 1 0 Version VLIK AEF 0 35 0 55 BC 0 17 0 45 0 7 D 0 6 0 95 Shaft mounted helical gearbox GFLO4 05 2 VAO Versions VOR VOL Mounting position GFL04 GFLO5 ABE 0 7 1 4 CD 1 0 1 7 F 0 3 0 7 Version VLIK ABE 0 8 1 4 CD 1 1 1 7 F 0 35 0 7 Helical bevel gearbox GKS04 05 3 VOC Versions VOR VOL Mounting position GKS04 6 505 0 8 1 3 BCEF 1 4 2 0 D 1 0 1 6 Version VLIK A 0 8 1 4 BCEF 1 5 2 1 D 1 1 1 7 Lenze ps 8 3 8 4 BA 12 0023 EN Bevel gearbox GKR03 05 2 VOC Mounting position A BCDE Repair Versions VOR VOL GKR03 GKR04 0 4 0 35 0 7 0 4 Version VLIK 0 4 0 35 0 7 0 4
4. A Y 11 9 10 4 Iso CL F i 5 2 2 180 Y 1119 104 Iso CL F n2 282 7 r min 1 50Hz 206 180 20 6 IP54 n2 282 7 r min 1 50Hz A 20 6 18 0 20 6 154 A 002 CLP 460 r min 1470 1775 2580 TKO KTY A 002 CLP 460 r min 1470 1775 2580 TKO KTY BFK458 16N 230V AC 103V DC 56W 80Nm T 89 2 90 3 91 8 BFK458 16N 230V AC 103V DC 56W 80Nm N 89 2 90 3 91 8 Ta 40 C 1G2024 5V T BEG 261 460 cos o 0 77 0 77 0 82 1G2024 5V T BEG 261 460 cos p 0 77 0 77 0 82 ALR 81 12345678 C86 1537 1538 12345678 C86 1537 1538 15499496 12345678901234 n 50Hz 89 3 75 88 2 50 15499494 12345678901234 n 50H2 89 3 75 88 2 50 a xi III RR N N Doom Typenschild GNG 003 iso dms Typenschild GNG 003 iso dms Gearbox N and W version M and N version with motor K compact unit and D Disco version 1 lenze gt di QH 4 GHE O i 1 8 o 9 D 10 11 12 Typenschild GST 004 iso Typenschild GST 005 iso Typenschild GKS 006 iso Version N and W version M and N version with motor K compact unit and D Disco version Pos Production site country www Lenze com 2 Gearbox type Gearbox and motor type 3 Year of manufacture week of manufacture 4 Mounting position position of the system modules 5 Rated torque rated speed Rated torque Operating frequency Rated speed rated frequency Rated torque rated speed Application factor data
5. F kW T Y e V A A Y a A e r min r ul z l cos p pm c86 D 1 p a A Lenze mw Nameplate GNG 002 iso 19 20 Product description Product features Nameplate Pos Contents 1 Manufacturer production location 2 Motor type standard 3 Gearbox type 4 Motor type 5 Technical data Ratio Rated torque Rated speed Rated frequency Mounting position position of the system blocks Lubricant Brake data if fitted Type 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 AC DC brake voltage Braking torque electrical povver input Feedback pulse encoder or resolver data if fitted see product key 23 Manufacture data Order number Material number Serial number Bar code Rectifier designation Information on operating mode Additional motor Temperature class specifications Enclosure Motor protection Valid conformities CE identification CCC identification approvals and certificates cURus logo UL file number UL energy efficiency logo Rated data for Hz frequency various frequencies kW motor power r min motor speed V motor voltage A motorcurrent n Motor efficiency at a rated power of 10076 cosg motor power factor Application factor given if lt 1 0 load capacity Year week of manufacture UL file number Additional customer data Inverter duty motor Mo
6. Mounting positions F GSS07 3M O00 090 11 GSS07 3M O00 100 11 Pos 2 only with on both sides opposite KE Breathing oil filler plug Oil drain plug Oil control plug BA 12 0023 EN 7 0 Lenze 52 Mounting Mechanical installation Breather position oil filling screw and drain plug Bevel gearbox GKR N Ce vo GT GNG GKR 2 001 A F iso dms Breathing oil filler plug Mounting positions F 53 Lenze BA 12 0023 EN 7 0 5 Mechanical installation Mounting Breather position oil filling screw and drain plug Helical bevel gearbox GKL 07 09 3 C E iso dm A F Mounting positions Breathing oil filler plug on both sides Oil drain plug opposite e Oil control plug Pos 1or2 depending on version Sealing plug without function 54 Lenze BA 12 0023 EN 7 0 Mechanical installation 5 Mounting Gearbox with compensation container for mounting position C 5 4 12 Gearbox with compensation container for mounting position C GFL GKS d b 1 77 H L PI ER 7 a DIS Wis BA EN s iz 9 K12 0956 Fig 12 Position of the compensation container in mounting position C 1 Intermediate cover 9 Plug sc
7. Standard hubs clamping hubs and clamping ring hubs are maintenance free We recommend checking the star shaped spider and system components when inspecting the drive Assembly of standard hub clamping hub 1 7 0 Fit motor key 2 Fit enclosed key for drive sizes LIC LIE OF Push the coupling hub over the motor shaft mounting dimension m see Fig 3 and must be observed Secure coupling hub against axial movement using the fixing screvv or clamping screvv 1 Lay spider in the coupling clavv on the gearbox side Align clavvs of the motor side coupling hub vvith its counterpart Slowly push on motor and bolt on to the gearbox flange Lenze 33 5 Mechanical installation Mounting Coupling hubs 5 4 5 2 Assembiy of clamping ring hub Fig 4 Coupling 1 Clamping ring hub 2 Camping ring 3 Clamping screvvs DIN912 Notel The motor shaft must be designed with fit k6 1 Grease the contact surfaces of the motor shaft using a thin bodied oil e g Castrol 4 in 1 or Kl ber Quitsch Ex Stopl Do not use oil or grease with molybdenum disulphide or high pressure additives or grease pastesl 2 Push the coupling hub over the motor shaft mounting dimension m see Fig 3 and must be observed 3 Align the hub and tighten the clamping screvvs until they have contact 4 Tighten the clamping screws evenly and crossvvise with gradually rising torque until th
8. chapter BJ If the interference cannot be eliminated please contact the Lenze Service Lenze ps 8 1 BA 12 0023 EN 7 0 Maintenance 8 Maintenance intervals Maintenance Lenze gearboxes and geared motors are filled with a drive and design specific lubricant filling upon delivery This original filling corresponds to the lubricant listed in the column of the respective gearbox type from Lenze The important factors for the lubricant filling on ordering are the mounting position and the design Note Gearboxes of size 03 and 04 are lubricated for life Because of the minimum thermal load it is not necessary to replace the lubricant Maintenance intervals The mechanical power transmission system is free of maintenance Gearboxes as of size 05 pre stages as of size 06 require regular lubricant replacement The type of lubricant is indicated on the nameplate Replace the lubricant only with the same type The lubricant maintenance interval depends on the oil temperature see Fig 14 Shaft seals and roller bearings The service life depends on the operating conditions Replace seals in case of leakage to avoid consequential damage Note When changing the lubricant Lenze recommends also changing the grease packing of the bearings and replacing the rotary shaft seals Stop For drive systems Also observe the maintenance intervals for the other drive components Lenze 59 8 Maintenance
9. 063 00 lt 10 lt 30 lt 50 lt 70 132 001 lt 150 lt 200 lt 275 lt 425 lt 700 Transport weights in kg values may differ from table value 071 00 lt 10 lt 30 lt 50 lt 70 lt 125 lt 200 160 011 lt 250 lt 325 lt 450 lt 750 Geared motors Motor frame sizes 080 001 lt 40 lt 60 lt 80 lt 125 lt 200 lt 350 Geared motors Motor frame sizes 180 00 lt 475 lt 600 lt 850 Lenze 090 011 lt 50 lt 60 lt 90 lt 150 lt 225 lt 375 lt 625 200 011 lt 550 lt 700 lt 950 100 017 lt 70 lt 100 lt 150 lt 225 lt 375 lt 650 225 001 lt 850 lt 1100 112111 lt 125 lt 175 250 400 650 Gearboxes 30 lt 50 70 lt 150 250 lt 400 lt 625 BA12 0023 EN 7 0 4 Technical data Technical data 4 General data and operating conditions 4 1 General data and operating conditions General data Conformity and approval Conformity CE 2006 95 EC Approvals KAN File No E210321 CCC Protection of persons and equipment Degree of protection IEC EN 60034 5 Thermal class F 155 C IEC EN 60034 1 Permissible voltage EMC Noise emission IEC EN 61800 3 Noise immunity Operating conditions Ambient conditions Climatic Transport IEC EN 60721 3 2 Storage IEC EN 60721 3 1 Operation IEC EN 60721 3 3 Site altitude Humidity Electrical Motor connection depen
10. 1D 0 8 0 8 1 1 1 2 1 7 1 7 2 1 1 7 2 4 M 132 A 2112 N 21G VVz1G 3 0 3 0 4 3 3 2 4 1 M 132 A2112 N gt 1G W gt 1G Tab 9 Amount of lubricant in litres gt Drive 90 132 A M N W Drive end version 1A 2K 7 0 Lenze 0 12 0 15 1 5 2 0 2 7 4 0 0 2 0 3 0 4 0 8 1 7 W 1C 0 15 0 3 0 6 M gt 132 A 112 N21G W21G M gt 132 A 112 N21G W21G Motor size Drive size 0 3 0 35 2 5 2 9 4 6 5 2 0 2 0 3 0 4 0 8 1 7 W 1C 0 4 0 7 1 4 M gt 132 A 112 N21G W21G M gt 132 A 112 N21G 67 Mounting position GST04 GSTO5 GST06 GST07 GST09 Mounting position GST04 GSTO5 GST06 GST07 GST09 68 Maintenance Maintenance operations Lubricant quantity Helical gearbox GSTOO 10 VALI VBO foot housing 0 1 0 2 0 6 M 90 A 80 N gt 1D 0 4 12 0 65 0 85 0 7 0 7 VV x 1E 0 7 2 3 13 15 15 15 13 M 132 2 7 M 132 2 2 M 132 A gt 112 A gt 112 A gt 112 16 16 16 W21G W21G W21G 12 41 2 8 2 7 2 5 2 5 2 5 M 132 48 M 132 3 7 M 132 A gt 112 A gt 112 A gt 112 16 16 16 W21G W21G W21G Helical gearbox GSTOO 10 VCO flange housing A B C D E F 0 1 0 3 0 2 0 5 0 2 0 55 Mz 90 A 280 N gt 1D 0 4 1 0 45 0 85 0 6 0 6 1 W gt 1E 0 8 1 6 0 85 1 6 1 3 1 3 15 M gt 132 2 0 M gt 132 2 3 M gt 132 A gt 112 A gt 112 A gt 112 Nz1G N gt 1G N gt 1G W21G W21G W21G 16 3 0 1 7 2 7 2 3 2 3 2 7 M gt 132 3 5 M gt 132 3 7 M gt 1
11. Low Voltage Directive 2006 95 EC At the time of dispatch the drive components are in line with the latest state of the art and can be regarded as operationally safe Scope The following safety instructions generally apply to Lenze drive components The product specific safety and application notes given in this documentation must be observed General hazards N Dangerl Disregarding the follovving basic safety measures may lead to severe personal injury and damage to material assets gt Lenze drive components must only be used as directed must never be commissioned in the event of visible damage must never be technically changed must never be commissioned before assembly has been completed must never be operated without required covers can include live and rotating parts depending on their type of protection during and after operation Surfaces can be hot gt Allspecifications of the corresponding enclosed documentation must be observed This is vital for a safe and trouble free operation and for achieving the specified product features gt Only qualified skilled personnel is permitted to work on and with Lenze drive components According to IEC 60364 CENELEC HD 384 these are persons who are familiar with the installation mounting commissioning and operation of the product have the qualifications required for their occupation know and are able to appl
12. Lubricant table 13124908 3 0 11 2005 TDO9 New geared motor nameplate included Revision of the lubricant table 13166718 4 0 08 2006 TDO9 Revision of the nameplate marking New nameplate CSA UL version Supplement with Ch Mounting the shrink disc with a rotating cover Revision of the Ch Position of the breathing oil filler plug and oil drain plug Addition of the drive sizes 3F 4E 6C and 7C 13290892 5 0 03 2009 TDO9 Complete revision 13321528 6 0 10 2009 TDO9 Conversion from G motion to L force Geared Motors Supplement Ch Condensation drain hole 13404748 7 0 11 2011 TDO9 Update of the lubricant table Changed lubricant quantities for GST Transport weights extended Table of the roller bearing greases extended 6 Lenze BA 12 0023 EN 7 0 1 2 1 3 BA 12 0023 EN 7 0 About this documentation D Conventions used Conventions used This documentation uses the follovving conventions to distinguish different types of information Type of information Identification Examples notes Spelling of numbers Decimal separator Point In general the decimal point is used For instance 1234 56 Icons Page reference Ea Reference to another page with additional information For instance CJ 16 see page 16 Document reference 9 Reference to another documentation providing additional information E g 6 Softvvare manual Terminology used Term In the follovving text used for Gearboxes Gearbox of product family COO Drive
13. Maintenance intervals Lubricants Type Specification Ambient temperature Note CLP 460 Oil on mineral basis with 0 C 40 C additives CLP PG 460 Oil on synthetic basis 20 C 40 C Do not mix with mineral polyglycol oil CLP HC 220 USDA H1 Food compatible oil on 20 C 40 C Approval acc to USDA H1 synthetic basis CLP HC 320 Oil on synthetic basis 25 C 50 C Can be mixed with CLP HC 220 synthetic hydrocarbon residual mineral oil CLP HC 46 Oil on synthetic basis 40 C 0 C Good cold flow behaviour synthetic hydrocarbon CLP PG 220 USDA H1 Food compatible oil on 20 C 40 C Approval acc to USDA H1 synthetic basis Tab 8 Overview of lubricant change Notel In case of ambient temperatures lt 20 C or gt 40 C please contact Lenze Observe increased starting torques at low temperatures 120 110 100 90 80 gt 70 16000 h 25000 h 1000 10000 100000 B gt GT GNG 002 iso dms Fig 14 gt o Oil sump temperature C Oil life changing intervals operating hours h Synthetic oil CLP HC CLP PG Mineral oil CLP D 60 Lenze BA 12 0023 EN 7 0 Maintenance Maintenance operations Opening the condensation drain hole OO 8 2 Maintenance operations 8 2 1 Opening the condensation drain hole Note Depending on the mounting position the condens
14. OHHH od 22 Id Nr 13211352 X Lenze Drive Systems GmbH Postfach 101352 D 31763 Hameln GT GNG GKR 011 iso GT GNG GKR 011_a iso Fig 5 Application of assembly paste against fretting corrosion included in the scope of supply Stop Take up forces only via the hollow shaft and not via gearbox housing 2 Secure the gearbox axially The hollow shaft has snap ring grooves for axial securing Parts used to fix the shaft are not included in the scope of supply BA 12 0023 EN 7 0 Lenze 35 36 Mechanical installation Mounting Attachment of gearboxes vvith hollovv shafts and keyvvay g 4 7 Auxiliary tool recommended dimensions d M6 M10 M12 M16 M16 M20 M20 M20 M24 Dimensions in mm Note With bevel gearbox GKR the hollow shafts are turned free in the middle of the hollow shaft i e the bore diameter is 0 1 mm higher here A sufficient length of the machine shaft must be observed GKR size 03 04 05 06 Tab 5 C oo N OW 11 13 14 16 24 12 0611 f r h l min I max 85 100 105 120 127 143 150 170 Dimensions in mm BA 12 0023 EN 7 0 Mechanical installation 5 Mounting Mounting the shrink disc with a rotating cover Dismounting 1 Undo axial gearbox locking in the hollow shaft 2 Remove extract the gearbox from the motor sh
15. gearbox roller bearing Lovv temperature oils observe critical starting 40 80 C Kl ber Asonic GHY 72 performance at low temperatures Biodegradable oil lubricant for forestry 40 50 C Fuchs Plantogel 0120S agriculture and vvater economy The follovving lubricant quantities are required gt For fast running bearings motor and drive end of gearbox fill approx one third of the hollovv space betvveen rolling bodies vvith grease gt For slovv running bearings in gearbox and driven side of gearbox fill approx tvvo thirds of the hollovv space betvveen roller bearings vvith grease 62 Lenze BA 12 0023 EN 7 0 Maintenance Maintenance operations Table of lubricants OO 8 2 3 Table of lubricants Note Please note that the recommendation of a lubricant grease or its listing in a Lenze lubricant table does not mean that Lenze is liable for these lubricants or damages resulting from incompatibilities of materials used The lubricants listed in the lubricant table are permissible for Lenze drives Specialty lubricants must be used for example for long term storage or special operating conditions These corresponding lubricants are available at a surcharge Observe the following legend of the lubricant table for the selection of lubricants CLP CLP PG CLP PAO CLP E 1 2 3 4 BA 12 0023 EN 7 0 y UU UU U y y y Mineral oil Polyglycol oil Synthetic hydrocarbon or poly alpha olef
16. if lt 1 0 6 Lubricant 7 Ratio 8 Material number serial number 9 Bar code 10 Order number 11 Additional information 12 Additional customer data BA 12 0023 EN 7 0 Lenze 21 Product features Product key 3 2 2 Product key Geared motors Legend for product key A 22 Gearbox type Gearbox size Number of stages Input design Product description GST GFL GKS GKL GKR GSS Lenze DOO Helical gearbox Shaft mounted helical gearbox Helical bevel gearbox Bevel gearbox Helical worm gearbox Servo motor asynchronous totally enclosed fan cooled Disco variable speed drive Three phase AC motor with Motec SDS three phase AC motor Servo motor asynchronous internal cooling Compact unit Three phase AC motor Gearbox with bearing flange for IEC standard motors or NEMA DC permanent magnet motor 13 12x SGS DC motor smooth housing MGFOU MGFOK DC motor ribbed housing MGFRK Servo motor synchronous totally enclosed fan cooled DC shunt motor 13 5xx Three phase AC motor 13 71x 13 75x Gearbox with free drive shaft BA 12 0023 EN 7 0 BA 12 0023 EN Product description Legend for product key E Output design G V H S F A B C D G R K I H Drive size Motor Examples Mounting flange free input shaft Mech variable speed dri
17. system Drive system with gearboxes COO and other Lenze drive components Lenze 7 About this documentation Notes used Notes used The follovving pictographs and signal vvords are used in this documentation to indicate dangers and important information Safety instructions Structure of safety instructions N Dangerl characterises the type and severity of danger Note describes the danger and gives information about hovv to prevent dangerous situations Pictograph and signal vvord Meaning Danger of personal iniury through dangerous electrical voltage I Reference to an imminent danger that may result in death or Danger serious personal injury if the corresponding measures are not taken Danger of personal injury through a general source of danger I Reference to an imminent danger that may result in death or Danger serious personal injury if the corresponding measures are not taken Danger of property damage Stop Reference to a possible danger that may result in property damage if the corresponding measures are not taken Application notes Pictograph and signal word Meaning Note Important note to ensure troublefree operation el Tipl Useful tip for simple handling 45 Reference to another documentation Lenze ps 2 1 BA 12 0023 EN Safety instructions 2 General safety instructions for drive components Safety instructions General safety instructions for drive components in accordance with
18. year Shafts and uncoated surfaces are delivered in a protected against rust status Aftertreatment is required where the corrosion protection has been damaged Remove the plug for motors with condensation drain holes special version More than one year up to two years Apply a long term corrosion preventive e g Anticorit BW 366 from the Fuchs company to the shafts and uncoated surfaces before storing the motor away Stop Observe load carrying capacity Staying under floating load is prohibited Lenze ps BA 12 0023 EN 7 0 Safety instructions 2 General safety instructions for drive components Corrosion protection Lenze offers paints with different resistance characteristics for drive systems Since the resistance may be reduced when the paint coat is damaged defects in paint work e g through transport or assembly must be removed professionally to reach the required corrosion resistance Mechanical installation gt Provide for a careful handling and avoid mechanical overload During handling neither bend components nor change the insulation distances Electrical installation gt Carry out the electrical installation according to the relevant regulations e g cable cross sections fusing connection to the PE conductor Additional notes are included in the documentation gt The documentation contains notes for the EMC compliant installation shielding earthing arrangement of filters a
19. 0 8 0 35 0 4 Maintenance Repair OO GKRO5 0 8 1 5 1 0 0 8 1 5 1 6 1 0 gt t is recommended to have all repairs performed by Lenze Service Delivery of spare parts is available upon request Disposal Protect the environment Packing material can be recycled Dispose of your separated resources according to the waste disposal regulations or via a waste management company The following table provides recommendations for an environmentally friendly disposal of the machine and its components What Transport material Lubricants Components 7 0 Pallets Packaging material Oil grease Detergents and solvents Paint residues Housing Bearings gear wheel shafts Seals electronic scrap Cast iron aluminium copper Steel Hazardous waste Lenze Where Return to the manufacturer or forwarder Cardboard box to waste paper Plastics to plastics recycling or residual waste Reuse or dispose of wood wool Dispose according to current regulations Separate valuable substances and dispose 73 vL 9ZU9 0 4 N3 EZ00 ZT V8 8 5 Spare parts list geared motors 2BA IBA 6BA Lenze 5BA 22BA 23BA 0 16BA 7BA BBA 18 19BA Lenze i di 3B
20. 11 E 0 17 0 3 0 45 0 9 1 0 M gt 132 15 19 M gt 132 A gt 112 Nz1G W21G 2 8 3 4 M gt 132 A gt 112 Nz1G W 1G 6 9 5 Motor size Drive size 0 3 0 55 1 0 11 M 132 1 7 2 1 M 132 A gt 112 N gt 1G W 1G 3 1 3 7 M 132 A2112 N 1G W 1G 7 11 F 0 17 0 3 0 45 0 9 1 0 M 132 1 5 19 M 132 A2112 N 1G W 1G 2 8 3 4 M2132 A2112 N 1G W21G 6 9 5 69 Maintenance Maintenance operations Lubricant quantity Shaft mounted helical gearbox GFLOO 2 3 Mounting position GFLO4 GFLO5 GFLO6 GFLO7 GFLO9 GFL11 GFL14 Mounting position GKS helical bevel gearbox 11 3 4 GKS04 0 8 1 4 1 5 1 1 1 3 1 3 GKS05 1 4 2 2 1 1 7 1 9 1 9 GKS06 2 4 3 6 4 3 3 6 3 6 GKS07 4 5 6 7 7 7 5 6 6 5 6 5 GKS09 6 14 16 10 14 14 GKS11 11 5 27 29 21 25 25 GKS14 21 50 56 38 47 47 Helical worm gearbox GSSLT 1 2 3 GSS04 0 5 1 0 1 0 1 0 0 8 0 8 GSS05 1 2 1 7 1 7 1 7 1 4 1 4 GSS06 1 8 3 0 3 0 3 0 2 6 2 6 GSS07 3 6 5 6 5 9 5 6 4 8 4 8 Helical bevel gearbox GKLOD GKLO7 2 6 5 0 6 8 4 8 4 8 4 8 GKLO9 4 6 8 4 10 4 7 7 8 8 8 4 Tab 12 Amount of lubricant in litres m Drive 70 Lenze BA12 0023 EN 7 0 Maintenance Maintenance operations Lubricant quantity Bevel gearbox GKR Mounting position 0 35 0 4 0 7 0 8 0 35 0 5 0 35 0 4 0 8 GKR03 GKR04 GKRO5 GKRO6 1 5 1 6 1 3 3 0 3 2 2 3 1 5 Mounting position nt now O O O o D tz GG Ge ls ls ls UDO 1 0 1 8 1 5 1 4 2 6
21. 32 A gt 112 A gt 112 A gt 112 Nz1G N gt 1G N gt 1G W 1G W21G W21G Tab 10 Amount of lubricant in litres gt Drive 90 132 Motor size A M N VV Drive end version 1A 2K Drive size Lenze Mounting position GST03 GST04 GSTO5 GST06 GST07 GST09 GST11 GST14 Mounting position GST03 GST04 GSTO5 GST06 GST07 GST09 GST11 GST14 BA 12 0023 EN Tab 11 7 0 0 6 0 7 2 2 2 6 4 2 4 8 0 5 0 6 1 8 2 2 35 4 1 Maintenance OO Maintenance operations Lubricant quantity Helical gearbox GSTOO 20 30 VAL VBO foot mounting 0 35 0 5 M2132 M2132 112 16 W 1G M 132 112 16 16 8 5 15 0 17 0 35 0 45 M2132 M2132 A2112 N 1G W21G M2132 112 16 W 1G 7 5 13 Amount of lubricant in litres gt Helical gearbox M2132 M2132 A2112 N 1G W 1G M 132 A2112 N 1G W 1G 0 17 0 45 M2132 M 132 A2112 N 1G W21G M2132 A2112 N 1G W21G 8 5 16 Drive A M N VV Drive end version C 44 Lenze 17 1 8 3 7 6 1 7 3 M 132 M 132 A2112 N 1G W21G M2132 A2112 N 1G W21G 11 5 20 1 6 1 7 2 7 34 55 6 7 0 95 M2132 M 132 A2112 N 1G W21G M2132 A2112 N 1G W21G 10 5 18 90 132 JA 2K GSTOO 20 30 VCO flange housing 0 3 0 55 1 0 11 M gt 132 1 7 21 M gt 132 A gt 112 Nz1G W21G 3 1 3 7 M gt 132 A gt 112 Nz1G W 1G 7
22. 40 04 0 40 0 40 0 40 25 50 3 25 50 3 25 50 3 TS 20 40 ECastrol 40 03 25 50 3 20 40 20 40 20 40 20 40 20 40 BA 12 0023 EN 7 0 DIN 51517 3 CLP ISO 12925 1 CKC CKD f l f l 19 1 CLP HC CLP PG CLP HC CLP CLP CLP CLP HC CLP HC CLP HC CLP E CLP HC CLP HC CLP CLP PG CLP PG CLP PG CLP PG VG 460 VG 220 VG 46 VG 460 VG 460 VG 460 VG 320 VG 320 VG 320 VG 320 VG 46 VG 320 VG 220 VG 220 VG 460 VG 220 VG 460 Lenze Maintenance Maintenance operations Table of lubricants Gearbox type Gearbox type GKL GST GFL GKS GSS GKR GKKOA 06 GKK07 Cassida Fluid GL 460 Cassida Fluid GL 220 Cassida HF 46 Alpha SP 460 Optigear BM 460 Tribol 1100 460 Alphasyn EP 320 Optigear Synthetic A 320 Tribol 1510 320 Tribol Bio Top 1418 320 Optileb HY 46 Optileb GT 220 Food Proof 1810 220 Tribol 800 220 1 2 Tribol 800 460 1 2 Alphasyn PG 220 1 2 Alphasyn PG 460 1 2 OO 65 8 Maintenance Maintenance operations Replacing the lubricant 8 2 4 Replacing the lubricant Stopl Gearbox should be warm gt Secure drive system and machine from inadvertent movement and mains connection Stopl With gearbox types GSTLT 1 3 GFLL T 1 3 GSSLT 1 3 and GKSLIL1 4 the pre stage is separately lubricated all gearbox components have to be completely drained Q Tip When changing the lubricant also change the grease packing
23. 5 07 ec Q9 GKs05 07 GT GNG GKS 3 001 A F iso dms A F Mounting positions Pos 1 Standard z on both sides Pos 2 only GKS05 3M O00 090CE TCI b opposite With GKS05 3M O00 100CE TCI amp Breathing oil filler plug GKS06 3M O00 112C00 e Oil drain plug GKS07 3M DOD eo o Oil control plug BA 12 0023 EN 7 0 Lenze 49 5 Mechanical installation Mounting Breather position oil filling screw and drain plug Helical bevel gearbox GKS 05 14 4 A B C GKS06 14 69 exsos 14 GT GNG GKS 4 001 A F iso dms A F Mounting positions Pos 1 Standard on both sides Pos 2 only GKS07 4M O00 090CL TL ii opposite With GKS07 4M O00 100C00 e Breathing oil filler plug GKS09 4M O00 112C00 Oil drain plug o Oil control plug 50 Lenze BA 12 0023 EN 7 0 Mechanical installation 5 Mounting Breather position oil filling screw and drain plug Helical vvorm gearbox GSS 05 07 2 GT GNG GSS 2 001 A F iso dms A F Mounting positions Pos 1 Standard on both sides Pos 2 only GSS05 2M O00 090 1 opposite With GSS05 2M OOO 100 amp Breathing oil filler plug GSS06 2M O00 112C00 e Oil drain plug GSS07 2M O00 160C00 e Oil control plug BA 12 0023 EN 7 0 Lenze 51 Mechanical installation Mounting Breather position oil filling screw and drain plug Helical worm gearbox GSS 05 07 3 5506 07 5506 07 GT GNG GSS 3 001 A F iso dms Standard Pos 1
24. 5 iso dms AR ee 4 We 2 Su Ge VOS E La e GSS 5 d GFL 2 WS Mechanical installation Specified directions of rotation GKS GKL YA GT GNG GST 008 iso dms Specified directions of rotation 5 3 29 GT GNG GSS 007 iso dms GT GNG GKS GKL 004 iso dms GT GNG GKR 006 iso dms Direction of rotation of drive Fig 2 BA 12 0023 EN 7 0 5 4 5 4 1 30 Mechanical installation Mounting Preparation Mounting Preparation Stopl Thoroughly remove anticorrosion agents from output shafts and flange faces Correcting the oil quantity If the oil quantity has been increased in the gearbox for long term storage see chapter 5 2 the oil must be completely drained and then filled in again for the corresponding mounting position The following steps must be observed 1 Place receptacle under oil drain plug Remove ventilation oil filler plug Completely drain lubricant Screvv in oil drain plug Fill in oil quantity for the corresponding mounting position 0 66 no po WH Screvv in ventilation oil filler plug Condensation drain hole Notel Lenze delivers motors vvith condensation drain holes vvith sealed condensation drain holes The holes are sealed vvith a plastic plug or a plug screvv This does not impair the enclosure and the motor is protected against ingress of foreign particles during transport and operation For further information
25. A 4BA 24BA 7 17BA 10BA 20BA 218A K12 0715 2 SIOJOW pajeas 151 sped leds e ueusjuiew 8 6 Spare parts list gearbox and gearbox vvith variable speed drive N3 COO CT va TIBA 12BA BBA OL TBA BBA 9ZU9 9BA 20BA ZIBA K12 0715 3 SL paads ai0EUEA yym XoqJeas pue xoquea8 951 sued a eds e ueusjuiew 8 7 Sender Maintenance Order form Order form Street PO box Postcode tovvn city Delivery address Invoice recipient Date Position 1BA 2BA 3BA 4BA 5BA 6BA 7BA 8BA 9BA 10BA 11BA 76 Please state if different to sender Name Basic gearbox GST OO Basic gearbox GFLOO Basic gearbox GKS DIO Basic gearbox GKR OO Basic gearbox GSS DIO Output flange Shrink disc Pre stage Quantity Intermediate cover Motor Fan Fan cover Spring applied brake Separate fan Mounting flange Recipient Lenze Postcode town city Fax no Customer no Order no Originator Telephone Fax Delivery date Signature Position Name Quantity 12BA Spider 13BA Coupling hub 14BA Free drive shaft 15BA Variable speed belt drive 16BA Backstop 17BA Tacho generator position encoder 18BA Handwh
26. EN Qe N so RO ON L force Geared Motors Operating Instructions GST GFL GKS GKL GKR GSS Gearbox Lenze 45 Please read these instructions before you start working Follow the enclosed safety instructions 2 Lenze BA 12 0023 EN 7 0 Contents i IS documentation 0 5 4 4 Attachment of motors to gearboxes with bearing housing 5 4 12 earbox with compensation container for mounting position C 55 BA 12 0023 EN 7 0 Lenze 3 1 Contents ectriCal Installation 4 Lenze BA 12 0023 EN 7 0 BA 12 0023 EN 7 0 About this documentation 1 About this documentation Contents These Operating Instructions are intended for safety relevant operations on and with the gearboxes GOO They contain safety instructions which must be observed gt All personnel working on and with the gearboxes GHH must have the Operating Instructions available and observe the information and notes relevant for them gt The Operating Instructions must always be complete and perfectly readable G Tip nformation and auxiliary devices related to the Lenze products can be found in the download area at http vvvvvv Lenze com Validity These instructions are valid for the following gearbox types Type Name GST Helical gearbox GFL Shaft mounted helical gearbox GKS GKL Helical bevel g
27. STO6 14 GT GNG GST 3 001 A F iso dms A F Mounting positions Oil control plug on both sides Pos 1 Standard a opposite Pos 2 only GST05 3M VOO 090C00 e Breathing oil filler plug With GST05 3M VOO 100C00 e Cil drain plug GST06 3M VOO 112C00 46 Lenze BA 12 0023 EN 7 0 Mechanical installation 5 Mounting Breather position oil filling screw and drain plug Shaft mounted helical gearbox GFL 05 14 2 A B C A F Mounting positions Pos 1 Standard on both sides Pos 2 only GFL05 2M O00 090CE TCI opposite YA GFL05 2M ETT 100600 e Breathing oil filler plug GFL06 2M DOO 112C00 e Cil drain plug GFL07 2M O00 160C00 e Oil control plug BA 12 0023 EN 7 0 Lenze 47 5 Mechanical installation Mounting Breather position oil filling screw and drain plug Shaft mounted helical gearbox GFL 06 14 3 A B C GFLO6 14 GrLo6 14 CELOS BA GFL06 14 GT GNG GFL 3 001 iso dms A F Mounting positions Pos 1 Standard on both sides Pos 2 only GFL07 3M O00 090cO0 opposite WI GFL07 3M ETT 100600 e Breathing oil filler plug GFL09 3M ELL 112C00 e Oil drain plug e Oil control plug 48 Lenze BA 12 0023 EN 7 0 Mechanical installation 5 Mounting Breather position oil filling screw and drain plug Helical bevel gearbox GKS 05 14 3 A B C 1 GKS09 14 8 g GKS05 07 GKS09 14 69 GKS09 14 ZAZ 1 GKS0
28. aft using an appropriate auxiliary tool Fig 6 K12 0611 Fig 6 Dismantling of gearboxes with hollow shaft using the auxiliary tool not for GKR Auxiliary tool recommended dimensions dH7 Cg Co 25 10 3 30 35 12 3 40 16 4 45 50 16 5 55 20 60 20 5 70 80 20 6 100 24 8 Tab 6 Dimensions in mm 5 4 7 Mounting the shrink disc with a rotating cover Stop BA 12 0023 EN 7 0 Do not dismantle nevv shrink disc Never tighten clamping screvvs before the machine shaft is pushed in Othervvise the hollovv shaft may be deformed plastically Protect the shrink disc against contact vvhile in operation by appropriate measures e g cover Degrease hollovv shaft bore and machine shaftl Lenze 37 5 4 7 1 38 Mechanical installation Mounting Mounting the shrink disc vvith a rotating cover Mounting the shrink disc Depending on the design the shrink discs may be equipped vvith a rotating cover protective cap pos 1 Notel This cover is fitted to the shrink disc on delivery KL GFLOG 001 dms Fig 7 1 Protection cover 2 Camping screws 1 Remove protective cap 1 if available 2 Check machine shaft Diameter in fit tolerance h6 Surface roughness R x 15 um 3 Thoroughly clean and degrease hollow shaft bore and machine shaft Note Now P Thoroughly degrease the bore over the entire hollovv shaft length to make sure that remainders
29. arbox sizes 03 04 and 05 except for GSS 05 it is not necessary to provide special breathing measures Breather elements are mounted for gearbox sizes 06 to 14 and GSS 05 In special cases they may be done without When using gearbox sizes 09 to 14 in mounting position C we recommend the use of an oil compensation container chapter 5 4 12 Gearboxes supplied with a breather element bear a corresponding label on the gearbox Remove shipping bracket on breather valve ACHTUNG CAUTIONIII Id Nr 13285760 Vor Inbetriebnahme die Transportsicherung des Entl ftungsventils entfernen Before commissioning remove the shipping brace of the ventilating valve GT GNG 13285760 iso dms For mounting positions differing from the standard mounting positions A F the breather function must be checked Mount breather elements supplied loose differing from the standard as described in chapter 5 4 11 Gearboxes which can be mounted in different positions see chapter 8 2 6 are supplied without breather element Ensure ventilation before initial commissioning Stop gt Rotate gearbox to the mounting position shown on the nameplate see nameplate page 1921 and chapter 5 4 11 gt With gearbox types GSTLT 1 3 GFLL T 1 3 GSSLT 1 3 and GKSLIL 4 the pre stage is separately ventilated Exception size 06 BA 12 0023 EN 7 0 Lenze 43 5 Mechanical installation Mounting Breather position oil filling screw and dra
30. ation drain holes are always at the bottom of the motor For condensate drainage the motor must be deenergised the plugs screws must be removed Stop To restore the enclosure re insert the plugs screws after condensate drainage If the condensation drain holes are not sealed again the IP enclosure of the motor will be reduced For horinzontal motor shafts to IP23 and for vertical motor shafts to IP20 The required maintenance intervals strongly depend on the corresponding ambient and operating conditions Initially the condensation drain holes should be opened more frequently at least once a week to obtain experimental values for the condensate quantity arising Fig 15 BA12 0023 EN 7 0 4 Motor vvith condensation drain holes Al Condensation drain holes Lenze 61 8 Maintenance Maintenance operations Lubricate roller bearings 8 2 2 Lubricate roller bearings The roller bearings on motors and gearboxes from Lenze are filled with the greases listed below Ambient temperature Manufacturer Type Gearbox roller bearing 30 50 C Fuchs Renolit H 443 GST GFL GKS GKR GKL 30 80 C Kl ber Petamo 133N 40 60 C Kl ber Microlube GHY 72 Gearbox roller bearing 30 80 C Kl ber Petamo GHY 133N GSS 15 60 C Kl ber Kl berplex BE 11 462 Motor roller bearing 30 C 70 C Lubcon Thermoplex 2TML 40 C 80 C Kl ber Asonic GHY 72 Special grease for
31. connection please go through the troubleshooting list in chapter BA 12 0023 EN 7 0 Lenze 39 40 Mechanical installation Mounting Mounting the shrink disc vvith a rotating cover Dismounting N Dangerl 4 Loose drive components or drive components falling down may cause injury to persons or damage to the machine Secure the drive components before disassembly Remove protective cap 1 Loosen clamping screws 2 evenly one after the other each by revolution in several passes Do not unscrew clamping screws completely to prevent accidents Press off outer ring see Fig 9 if necessary For this loosen the outer ring using the forcing threads and some clamping screws number corresponding to the forcing threads in the inner ring For loosening the outer ring screw in the screws evenly to prevent canting Press off the outer ring until loosened completely Remove the drive from the machine shaft Stop Dismantle the shrink disc only for cleaning purposes Afterwards grease bevel surfaces and screws using a solid lubricant with a friction factor of u 0 04 Suitable lubricants on molybdenum disulphide lubricant MoS2 basis are e g Molykote G Rapid company Dow Corning Molykote BR2 Plus company Dow Corning Molykombin UMFT1 company Kl ber Lubrication Usually disassembly problems only occur if gt the connection is spinning due to overload or a too low friction factor and fretting cor
32. connector 0 Hollow shaft with shrink disc 3 5 GKR Solid shaft 3 5 8 345 Flange 3 5 8 345 Terminal box Motec connector 2 3 4 5 Hollow shaft 0 Without flange 0 Without terminal box Motec connector 0 Hollow shaft with shrink disc 3 5 18 Lenze BA12 0023 EN 7 0 3 2 1 BA 12 0023 EN Nameplate Geared motor Standard version D Product description Product features Nameplate S CSA UL version 7 0 qua Hans Lenze Stra e 1 31855 Aerzen NZE ss Made in Hz Vt i y ml D kW V Y Range A G3 E L A Y CS 3 H A 14 ID r min Z Mn A s cos p A C 86 e N 10 11 12 30 20 28 Nameplate GNG 001 iso AA ui 7 ji Hans Lenze StraBe 1 SE MIN Germany 1 Made in de Hz PA d
33. dent on the controller Length of motor cable Length of cable for speed feedback Mechanical IEC EN60721 3 3 Low Voltage Directive See nameplate Degrees of protection only apply to horizontal installation All unused plug in connections must be sealed with protective caps or dummy connectors Exceedance of the temperature limit weakens or destroys the insulation According to limiting curve A of the pulse voltage from IEC TS 60034 25 image 14 Depending on the controller see documentation for the controller 2K3 20 70 C 1K3 20 60 C lt 3 months 1K3 20 40 C gt 3 months Without brake 15 C 40 C With brake 10 C 40 C gt 40 C With power reduction see catalogue Without power reduction lt 1000 m amsl without power reduction gt 1000 m amsl lt 4000m ams with power reduction see catalogue Average relative humidity 85 without condensation See inverter instructions 3M6 BA 12 0023 EN 7 0 Lenze 25 5 Mechanical installation Transport equipment for gearbox 5 Mechanical installation N Dangerl Only transport the drive vvith transport equipment or hoists vvhich are suitable for this load see transport vveights chapter LEERER MERKER Ensure a safe fixing Avoid shocksl The motors attached to the gearbox are partially equipped vvith eyebolts These are exclusively determined for motor gearbox mounting and dismounting and must not be used for th
34. e complete geared motorl 5 1 Transport equipment for gearbox As of size 05 Lenze GST GKS and GSS gearboxes are as standard available with a transport thread for eye bolts according to DIN 580 The thread position can be seen from the belovv figures The eye bolts are not contained in the delivery package GSTXX 1 GSTXX 2 3 GSSXX 2 3 and GKSXX 3 4 Notel As standard threads are delivered vvith plug screvvs The plug can be easily removed e g by using a screvvdriver blade For the thread size and load carrying capacity of the eye bolt please see 26 Lenze BA 12 0023 EN 7 0 Mechanical installation 5 Transport equipment for gearbox Gearbox size Thread max load carrying capacity of eye bolt to DIN 580 single strand two strand 45 Q er YA 7 X N GT GNG 005 iso dms 05 M8 140 100 06 M8 140 100 07 M12 340 240 09 M16 700 500 11 M20 1200 860 14 M20 1200 860 Tab 2 Load carrying capacity of eye bolt in kg AN Danger BA12 0023 EN 7 0 Completely screw in transport aids such as eye bolts or bearing plates they must be flat and applied over their entire surface If possible the transport aids such as eye bolts or bearing plates must be stressed vertically in the direction of the screw axis Angular tension or tension to the sides reduces the payload Observe the information provided in the DIN 580 Use additional appropriate lifting aids if required to achieve a direction of loading which is as vertical a
35. e indicated tightening torque see is reached at all clamping screws In the intermediate steps this procedure should also be repeated until the indicated tightening torque is reached at all clamping screws 5 Lay spider in the coupling claw on the gearbox side 6 Align clavvs of the motor side coupling hub vvith its counterpart Slowly push on motor and bolt on to the gearbox flange 34 Lenze BA 12 0023 EN 7 0 Mechanical installation 5 Mounting Attachment of gearboxes with hollow shafts and keyway 5 4 5 3 Disassembiy of clamping ring hub 1 Loosen the camping screws evenly one after the other Stopl Each screw must only be loosened by half a revolution per pass Unscrevv all clamping screvvs by 3 4 threads 2 Remove the screvvs next to the forcing threads and screvv them into the other threads until they have contact 3 Tighten the screvvs in the forcing threads crossvvise and step by step so that the clamping ring is loosened 4 Clean and grease all contact surfaces including threads and head of the clamping screws before reassembly 5 4 6 Attachment of gearboxes with hollow shafts and keyway Mounting 1 Draw the gearbox with hollow shaft onto the machine shaft to be driven Apply the supplied assembly paste Fig 5 on the shaft and in the hollow shaft bore Kl berpaste UH1 96 402 Paste 5 59 Paste gegen Passungsrost Abtriebseitige Getriebeausf hrung H
36. e roller bearings BA 12 0023 EN 7 0 Lenze 31 5 Mechanical installation Mounting Attachment of motors to gearboxes vvith bearing housing 5 4 4 Attachment of motors to gearboxes vvith bearing housing input design N B14 B5 K12 0621 Fig 3 Input side design N Al Spider gear rim 1 Locking screw Bl Coupling hub 2 Keyway Drive size Motor shaft Assembly Standard hub Clamping hub Key 1 Clamping ring hub dimension Locking screvv D max M Thread Thread Tightening DIN Thread Tightening torque 6885 1 torque mm mm mm mm mm Nm mm mm Nm 1A 11 23 23 1B 14 30 30 M4 M3 134 gt M3 1 34 2B 11 23 23 1C 19 40 25 B6x6x16 2C 14 40 25 M5 M4 2 9 3C 14 40 25 B5x5x16 Me 10 5 AC 14 40 25 6C 11 40 25 7C 19 40 25 B6x6x16 M4 2 9 1D 24 50 50 M4 2 9 2D 19 40 50 50 M4 2 9 1E 28 30 60 30 B8x7x18 2E 24 30 60 30 M5 3E 19 30 60 30 B6x6 x18 Me 10 5 4E 24 50 50 1F 28 30 60 30 B8x7x18 M5 6 2F 24 30 60 30 3F 24 50 50 1G 38 80 80 2G 28 60 60 M6 M 25 3G 38 80 80 1H 42 110 110 2h 48 110 110 3H 38 80 80 M8 M10 69 M8 35 1K 55 110 110 2K 60 140 140 Tab 3 Attachment of motors to gearboxes with mounting flange Use original key for the motor 1 Key for standard hub and clamping hub 32 Lenze BA 12 0023 EN 7 0 5 4 5 5 4 5 1 BA 12 0023 EN Mechanical installation 5 Mounting Coupling hubs Coupling hubs General Note
37. earbox GKR Bevel gearbox GSS Helical worm gearbox Target group This documentation is directed at qualified skilled personnel according to IEC 60364 Qualified skilled personnel are persons who have the required qualifications to carry out all activities involved in installing mounting commissioning and operating the product Lenze 5 m About this documentation Document history 1 1 Document history Materialnumber Version Description 00 390 375 1 0 11 1995 TDO9 1st edition for pilot series 00 393 076 10 03 1997 TDO9 Completely revised 00 393 076 1 0 04 2000 TDO9 Addendum to Ch B 4 1 Preparatory work Updated illustrations for Ch 5 4 10 Gearbox with breather 00 407 986 10 12 2000 TDO9 Completely revised Revised product key and position of system blocks Supplement with gearbox 03 Ch 5 4 12 Gearbox with compensation container in mounting position C Ch Spare parts list compensation container Changes of lubricant quantities 00 425 604 10 08 2001 TDO9 Ch B 4 8 Assembly of shrink disk cover new Ch B 4 9 Assembly of hoseproof hollow shaft cover new Supplement with GKR 05 00 425 604 2 0 11 2001 TDO9 Changes of lubricant quantities 00 460 708 10 12 2002 TDO9 Changes of nameplates Supplement with GKR 06 Change of company s name 00 460 708 2 0 02 2003 TDO9 Supplement Warning in Ch E 00 476 711 2 1 10 2003 TDO9 Changes Product key and position of system blocks Supplement with Ch B 2 2 Roller bearing grease and Ch B 2 3
38. eel 19BA Shrink disc cover 20BA Hollow shaft cover 21BA Seal 22BA Seal 23BA Seal 24BA Seal 25BA Planetary variable speed drive Lenze BA 12 0023 EN 7 0 BA 12 0023 EN Troubleshooting and fault elimination 9 Troubleshooting and fault elimination If any malfunctions should occur during operation of the drive system please check the possible causes using the following table If the fault cannot be eliminated by one of the listed measures please contact the Lenze Service Fault Drive does not turn Possible cause Voltage supply interrupted Incorrect electrical connection Excessive load Motor running gearbox at standstill Fixing elements are missing or defective Gearbox is defective Clutch disengaged Unusual running noises Overload Damage in the gearbox or motor Excessive temperature Overload Insufficient heat dissipation Insufficient lubricant Loose fixing elements Vibrations Shrink disc connection is e spinning Correct screw tightening torque has not been reached Insufficient number of passes not all screws are tightened correctly e Machine shaft and hollow shaft bore not sufficiently degreased e Wrong component part dimensions Fits roughnesses e Yield point of machine shaft material is too low Re gt 300 N mm required e Friction factors are too low Coefficients of friction p gt 0 15 required The shrink disc itself has been degreased so that the screws and the bev
39. els are dry Due to incorrect friction factors the shrink disc cannot be tightened correctly ig Lenze Remedy Check connection Check if nameplate matches voltage supply Reduce load Check drive machine assignment Check attachment Contact Lenze Service Engage the clutch Reduce load Check drive machine assignment Contact Lenze Service Reduce load Check drive machine assignment Improve cooling air supply Clean gearbox motor Refill lubricant as specified Avoid vibrations Specifications for assembly dimensions and material not observed 77 78 Lenze BA 12 0023 EN 7 0 BA 12 0023 EN 7 0 Lenze 79 E eu O 11 2011 Lenze Drives GmbH Postfach 10 13 52 D 31763 Hameln Germany 449 0 51 54 82 0 449 0 51 54 82 28 00 Lenze Lenze de www Lenze com Service i B 10 CE Lenze Service GmbH Breslauer Stra e 3 D 32699 Extertal Germany 00 80 00 24 4 68 77 24h helpline 49 0 51 54 82 13 96 Service Lenze de BA 12 0023 EN a 13404748 a a 7 0 a TDO9 8 7 6 b 4 3 2 1
40. if a danger of blocking exists The integrated overload protection function does not prevent overloading under all circumstances Built in brakes are not fail safe brakes Torque reduction is possible through disruptive factors which cannot be influenced e g through oil ingress due to a defective shaft sealing ring at the A end Fuses do not protect the motor Use current dependent motor protection switches for average operating frequency Use built in thermal detectors at high operating frequency Excessive torques lead to a break of the motor shaft or demagnetisation Do not exceed the maximum torques according to the catalogue Lateral forces from the motor shaft are possible Perfectly align shafts of motor and driving machine to each other If deviations from normal operation occur e g increased temperature noise vibration determine the cause and if necessary contact the manufacturer If in doubt switch off the motor Fire protection gt BA 12 0023 EN 7 0 Fire hazard Avoid contact vvith inflammable substances Lenze 13 IN 2 4 1 2 4 2 14 Safety instructions Residual hazards Temperatures Temperatures The permissible temperature range is determined by the following gt The lubricant specifications in connection with the expected oil temperatures in operation see chapter 8 J and nameplate gt The thermal class of the motor considering the motor temperatu
41. in oil Diester oil water pollution class 1 No test results are currently available about the performance of listed lubricants for worm gearbox lubrication If these oils are used the permissible torque must be reduced to 8076 of the catalogue values Polyglycol oils cannot be mixed with other oil types For ambient temperatures higher than 40 C please contact the manufacturer for exact ambient conditions Observe critical starting behaviour for low temperatures For temperatures lower than 25 C special measures for the motor storage and NBR shaft seals are necessary Ambient temperature range Food grade lubricant Biodegradable lubricant lubricant for forestry agriculture and water supply and distribution Low temperature oils observe critical starting performance at low temperatures Lenze 63 Maintenance Maintenance operations Table of lubricants Ambient temperature C 50 0 50 0 40 25 50 3 20 40 20 40 20 50 3 0 40 25 50 3 20 40 20 40 30 03 KLOBE LUBRICATION 40 03 20 40 20 50 3 0 40 25 50 3 20 40 20 40 0 40 25 50 3 20 40 0 40 Ce 25 450 3 20 40 20 40 0 40 25 50 3 pe Mobil 10 50 10 40 20 40 20 40 9 0 40 e 25 50 3 64 DIN 51517 3 CLP ISO 12925 1 CKC CKD CLP VG 460 CLPHC VG 320 CLPPG VG 220 CLPPG VG 460 OPE VG320 CLP VG 460 CLPHC VG 320 CLPPG VG 460 CLPPG VG 220 sk CLPPG VG32 sk C PHC VG46
42. in plug 5 4 11 Breather position oil filling screw and drain plug Helical gearbox GST 05 09 1 A B C E 20 GT GNG GST 1 001_A F iso dms A F Mounting positions Oil drain plug on both sides e Oil control plug opposite Pos 1 Standard e Breathing oil filler plug Pos 2 only GSTO5 1A 080C22 with 44 Lenze BA 12 0023 EN 7 0 Mechanical installation 5 Mounting Breather position oil filling screw and drain plug Helical gearbox GST 05 14 2 foot mounting A B GSTO5 07 14 GSTO6 e GST05 07 14 20 GST06 E F GSTO6 VCR GSTO5 14 VBR GST05 07 14 VCR GSTO5 06 GSTO7 14 GT GNG GST 2 001 A F iso dms A F Mounting positions Pos 1 Standard on both sides Pos 2 only GSTO5 2M VOO 090C00 opposite With GSTO5 2M VOO 100C00 e Breathing oil filler plug GST06 2M VOO 112C00 e Oil drain plug GST07 2M VOO 160CL D Oil control plug BA 12 0023 EN 7 0 Lenze 45 5 Mechanical installation Mounting Breather position oil filling screw and drain plug Helical gearbox GST 06 14 3 A B GSTO6 14 GSTO5 14 GST05 07 14 e e csros 6 csro6 14 C D GST06 14 VCR GST06 14 GSTO7 14 GSTO5 06 Ge e e 0 GSTO06 14 9 e 1 GST07 14 GSTO6 VCR GST05 06 Ge e N 2 GST05 07 14 VCR D GSTO5 14 VBR GSTO5 1 e GSTO6 14 GST06 14 ZS 2g e GSTO5 GST06 14 G
43. ke torque reduction gt Drives must only be operated under the operating conditions and power limits specified in this documentation comply with the protection requirements of the EC Low Voltage Directive Any other use shall be deemed inappropriate Improper use gt Do not operate the motors in explosion protected areas n aggressive environments acid gas vapour dust oil in water in radiation environments Note Increased surface and corrosion protection can be achieved by using adapted coating systems Lenze DE Safety instructions 2 Residual hazards 2 4 Residual hazards Protection of persons b The motor surfaces can become very hot Danger of burns when touching Provide protection against accidental contact if necessary High frequency voltages can be capacitively transferred to the motor housing through the inverter supply Carefully earth the motor housing Danger of unintentional starting or electrical shocks Connections must only be made vvhen the equipment is deenergised and the motor is at standstill Built in brakes are not fail safe brakes Motor protection gt Integrated temperature sensors do not provide full protection for the machine Limit the maximum current if necessary Select parameter settings for the controller which ensure a switch off if operated at gt I after a couple of seconds particularly
44. nd installation of the cables The manufacturer of the system or machine is responsible for the compliance with the limit values required in connection with EMC legislation gt Only plug in or remove pluggable terminals in the deenergised state Commissioning gt If required you have to equip the system with additional monitoring and protective devices in accordance with the respective valid safety regulations e g law on technical equipment regulations for the prevention of accidents gt Before commissioning remove transport locking devices and keep them for later transports Lenze 11 IN 2 2 2 3 12 Safety instructions Application as directed Application as directed Low voltage machines are no household appliances they are designed as components for industrial or professional use in terms of IEC EN 61000 3 2 only They comply with the harmonised standards of the series IEC EN 60034 Low voltage machines are components for installation into machines as defined in the Machinery Directive 2006 42 EC Commissioning is prohibited until the conformity ofthe end product with this directive has been established follow i a IEC EN 60204 1 t is only permissible to use lovv voltage machines with IP23 protection or less outdoors if special protective measures are taken The integrated brakes must not be used as safety brakes It cannot be ruled out that interference factors which cannot be influenced cause a bra
45. of the anticorrosion agent vvill not be carried off into the area of the shrink disc when pushing on the machine shaft Slightly loosen clamping screws 2 one after the other do not unscrew Push drive onto machine shaft Slightly tighten clamping screws manually Tighten clamping screws 2 one after the other see in several passes with rising torque evenly until the indicated screw tightening torque see Tab 71 is reached at all screws Lenze L Mechanical installation 5 Mounting Mounting the shrink disc with a rotating cover GT GNG 003 iso dms DS G Tip Several in general more than 5 passes are necessary until the full tightening torque is reached at all screws The shrink disc is mounted correctly and fixed when the faces of the outer ring and the inner ring are aligned Fig 9 Minimum misalignments are permissible A GT GNG 001 iso Fig 9 Hollow shaft with shrink disk 3 Outer ring A free of grease 4 Inner ring Hollow shaft bore mm 20 25 30 35 40 50 60 65 80 100 Torque Nm 12 30 30 30 30 30 59 70 59 100 Tab 7 Tightening torque for the clamping screvvs Notel If a different tightening torque is indicated on the shrink disc this tightening torque has priority over the value indicated in the table 8 Push protective cap 1 Fig 7 onto the shrink disc x G Tip For finding out the cause of non reached torques of the shrink disc
46. of the bearings and replace the rotary shaft seals Place receptacle under oil drain plug Remove breating oil filler plug Completely drain lubricant by removing the oil drain plug Reinsert drain plug if necessary replace seal Fill up lubricant through filler quantity see chapter 8 2 5 Screw in breathing oil filler plug S SL Ur d Dispose of waste oil according to the applicable regulations 8 2 5 Lubricant quantity Stop At drive speeds below 200 rpm the amount of lubricant may need to be increased Consultation with Lenze is required 66 Lenze BA 12 0023 EN 7 0 Mounting position GSTO5 GST06 GST07 GST09 GST11 GST14 GFLO5 GFLO6 GFLO7 GFLO9 GFL11 GFL14 BA 12 0023 EN A Pre stage GSTLI 1 3 GKSET 1 4 GSSOO 3 C D Maintenance Maintenance operations Lubricant quantity OO TG evum GT GNG GST GFL 010 iso dms 0 12 0 3 0 15 0 3 0 15 Wz1C 0 35 W gt 1C 0 35 N gt 1B 0 4 VV 1C 0 15 0 4 0 35 0 3 0 4 W gt 1C 0 3 0 7 0 5 0 55 0 65 M gt 90 A 280 N gt 1D 0 6 1 4 1 1 1 2 1 5 2 5 2 1 1 7 2 0 M gt 132 2 9 M gt 132 2 4 M gt 132 A gt 112 A gt 112 A 112 N gt 1G N gt 1G N 21G W gt 1G W 1G W 1G 2 7 4 6 4 3 3 2 4 0 M 132 5 2 M 132 4 1 M 132 A2112 A2112 A2112 N gt 1G N gt 1G N gt 1G W 1G W gt 1G Shaft mounted helical gearbox GFL pre stage 00 30 0 2 0 2 0 15 0 3 035 N gt 1B 0 4 W gt 1C 0 3 0 3 0 35 0 3 0 4 W gt 1C 0 4 0 4 0 5 0 55 0 65 M gt 90 A 280 N gt
47. please see chapter 8 2 1 Lenze ps Mechanical installation 5 Mounting General information about the assembly of drive systems 5 4 2 General information about the assembly of drive systems Stopl The lubricant fill quantity of the gearboxes is matched to the mounting position The mounting position indicated on the nameplate must be observed to avoid damage to the gearbox Take safety measures prior to any operation Disconnect the machine from the mains ensure standstill of the drive system and avoid any machine movement Check the proper state of the drive system Never install and set up damaged drive systems Check the combination of drive function and machine functions Check the direction of rotation see 5 3 gt The mounting surfaces must be even without torsion and free from vibration gt Align the drive system on the mounting surfaces exactly with the machine shaft to be driven Ensure that the assembly is without torsion to avoid additional load Compensate for minor misalignments by using suitable flexible couplings Support the reaction torque appropriately Fixings of accessories and attachments must be secured against loosening We recommend that screw connections are glued 5 4 3 Assembly of transmission elements on solid shafts gt Draw the transmission elements onto the output shaft only by using the centering thread Stop Shocks and blows to the shafts damage th
48. re expected during operation see nameplate and or Operating Instructions of the motor The operating temperature is determined by the povver loss the ambient temperature and the cooling systeml Stopl VVith mineral oil the upper temperature limit for continuous operation is 80 C vvith synthetic oil and shaft sealing rings made of FP Viton 100 C If these temperatures are exceeded measures are necessary to reduce the temperature see chapter Pl N Dangerl Depending on the operating conditions surfaces may be hot provide protection against accidental contact Ambient conditions Gearboxes are protected against dust and spray water Motors according to their enclosure see nameplate and or Operating Instructions for the motor gt Ambient media especially chemically aggressive can destroy shaft seals and coatings plastic Abrasive media endanger shaft seals gt The installation site of the drive must be free of shocks and vibration Dirt of dust deposits impede the heat dissipation cooling Lenze anta Product description 3 Identification 3 Product description gt The most important technical data are given on the nameplate structure and contents LQ page 19 to 21 gt The product catalogues contain further technical data 3 1 Identification 1 stage 2 stage 3 stage 2 stage 3 stage BA 12 0023 EN 7 0 Lenze 15 Product description Identification BI GKS 4 stage
49. rew 5 4 12 1 Component parts list 8 5 6 7 ZE eg N A d N N 3 2 1 K12 0956 Fig 13 Component parts list compensation container 1 Intermediate cover 5 Cover 2 Fixing screw 6 Breather element 3 Sealing rings 7 Hexagon nut 4 Housing 8 Seal BA 12 0023 EN 7 0 Lenze 55 56 Mechanical installation Mounting Gearbox vvith compensation container for mounting position C Mounting 1 Mount gearbox in mounting position C motor on top 2 Remove the plug 9 from the intermediate cover 1 3 Mount housing 4 using seal 3 and fixing screvv 2 to intermediate cover 1 instead of the plug 9 4 Use hexagon nut 7 to bolt the breather element 6 to the cover 5 Mount cover 5 and seal 8 to the housing 4 Stopl For transport the compensation reservoir must be removed and the plug must seal the gearbox pos 9 Lenze anta 6 1 6 2 BA 12 0023 EN 7 0 Electrical installation 6 Motor connection Electrical installation A Danger Electrical connections must only be carried out by skilled personnel Motor connection To correctly connect the motor please observe gt the notes in the terminal box of the motor gt the notes in the Operating Instructions of the motor gt the technical data on the motor nameplate Motor options To correctly connect the motor options e g brakes or feedback systems please observe gt the notes in the corresponding terminal box gt the notes in
50. rosion has occurred the shrink disc has been tightened too much leading to a plastic deformation of components the components are corroded Lenze pos Mechanical installation Mounting Mounting the fixed cover 5 4 8 Mounting the fixed cover for size 09 11 and 14 Note This cover is supplied loose on delivery Fig 10 1 Protection cover 2 Cheese head screw 3 Thread reducing sleeve 1 Screw the three reducing bushes 3 into the flange with a screwdriver so they are flush and staggered by 120 Fasten the protective cap 1 over the reducing bushes 3 on the flange using three cheese head screws 2 BA 12 0023 EN 7 0 Lenze 41 5 4 9 42 Mechanical installation Mounting Mounting the hoseproof hollovv shaft cover Mounting the hoseproof hollovv shaft cover for size 09 11 and 14 3x120 Fig 11 1 2 3 4 Protection cover Cheese head screw Thread reducing sleeve Seal 1 Screwthe three reducing bushes 3 into the flange with a screwdriver so they are flush and staggered by 120 2 Fit seal 4 between flange and protective cap 1 3 Fasten the protective cap 1 over the reducing bushes 3 on the flange using three cheese head screws 2 Lenze Mechanical installation 5 Mounting Gearboxes with breathers 5 4 10 Gearboxes with breathers Stop Do not place gearbox onto breather valve When using ge
51. s possible highest payload Secure lifting aids against shifting Stop Observe load carrying capacity Staying under floating load is prohibited Lenze 27 5 2 28 Mechanical installation Storage Storage If you do not install the gearbox immediately ensure appropriate conditions of storage gt Generally Store gearbox in dry clean dust free and sunlight protected indoor rooms The storage location must be free of vibration and shocks Verr lt 0 2 mm s to avoid roller bearing downtime damage Temperature changes with condensate formation must be avoided Do not activate breather element to prevent air exchange with ambient air Up to one year Store the gearbox with breather such that the breather screw is located at the top Shafts and bright surfaces are delivered with protection against corrosion Spots with defective corrosion protection must be re treated On motors with condensation drain holes option the plug screw must be removed see chapter 8 4 1 Over one year up to two years Before storage shafts and bright surfaces must be provided with a long term anticorrosive agent e g Anticorit BW 366 from the company Fuchs Set up gearbox in mounting position A Fill gearbox with oil grade filled in see nameplate up to the top breather oil bore Then mount plug screw or breather element do not activate again Lenze anta GT GNG GFL 00
52. the corresponding operating instructions gt the technical data on the corresponding motor nameplate Lenze 57 7 1 7 2 58 Commissioning and operation Before svvitching on Commissioning and operation Stopl The drive may only be commissioned by skilled personnell Before svvitching on Please check Does the drive appear undamaged Is the mechanical fixing ok Has the electrical connection been carried out properly Are all rotating parts and surfaces that may become hot protected against contact vY vV Vv If the oil level of the drive has been increased due to storage purposes LL128 it must be reduced again to the height permissible for the intended mounting position For gearboxes with breathing Has the transport locking device been removed For gearboxes with backstop Will the motor start to rotate in the correct direction CA 129 During operation Notel The helical vvorm gearboxes reach their full performance only after a short running in period of 24 48 hours at rated torque During operation check the drive periodically and take special care of Deviations from normal operation such as abnormal noises stronger vibrations or increased temperatures leakages loose fixing elements the condition of the electrical cables gt If any interference should occur you have to stop the drive and go through the steps for troubleshooting and fault elimination
53. tor code for controller parameterisation code 0086 Efficiency class Maximum ambient temperature Grade A voltage tolerance range according to range A according to IEC EN 60034 1 CC number of the Department of Energy optional Ta x 40 C Partial load efficiencies for 50Hz operation at a rated povver of 5096 and 7576 ALR VVeight Lenze BA 12 0023 EN 7 0 Product description 3 Product features Examples Three phase AC motor vvith square flange for direct gearbox attachment Standard version CSA UL version Hans Lenze Stra e 1 Hans Lenze StraBe 1 Lenze 31855 Aerzen 31855 Aerzen CE cAlus Mo Energy CSS Verified Germany Germany Made in Germany de Hz 50 60 87 IE Made in Germany de Hz 50 60 87 1E2 3 Mot EN60034 kw 5 50 5 50 9 70 s 3 Mot EN60034 inverter duty Motor kW 5 50 5 50 9 70 s GST07 2MVAL 132C12 1127 v Y 400 460 Range A GST07 2MVAL 132C12 1127 V Y 400 460 E210321 MHEMABI132 12C1 A 230 265 400 1096 1096 1132 12 1 A 230 265 400 CC127B i 5 2 M2 180Nm
54. ve Feedback system Resolver encoder Legend A Type RS Resolver IG Incremental encoder IK Incremental encoder with commutation signal AS Singleturn absolute value encoder AM Multiturn absolute value encoder B Number 0 2 pole resolver for servo motors 1 2 pole resolver for three phase AC motors 2 3 4 Number of pole pairs for resolvers 32 512 Number of steps increments per revolution 1024 2048 Voltage 5V 9V Medium supply voltage 15V 24 V D Interface or signal level Standard T TTL U H HTL for incremental encoders K H Hiperface for absolute value encoders K E EnDat F S sin cos 1 Vss V 7 0 Lenze Product features Product key Solid shaft smooth without keyway Solid shaft with keyway Hollow shaft Hollow shaft with shrink disk Foot mounting with centering Foot mounting without centering Without foot with centering Without foot without centering Without flange With flange through holes With flange threaded holes 071C32 1C 071 1202C with safety function TTL HTL for incremental encoders Hiperface for absolute value encoders EnDat sin cos 1 Vss 23 3 3 Gearbox size GcLT103 GLL104 GLT105 GLL106 GL Uu GUog 0 1 11 GLT114 Gearbox size GLL104 GLT 05 621106 GLT107 GLT109 GUILL GLL114 24 Product description Transport vveights Transport vveights Tab 1
55. y all national regulations for the preventions of accidents directives and laws applicable on site ig Lenze 9 IN 10 Safety instructions General safety instructions for drive components Transport storage gt Transport and storage in a dry low vibration environment without aggressive atmosphere preferably in the packaging provided by the manufacturer Protect against dust and shocks Comply with climatic conditions according to the technical data Before transport Check that all transport locking devices are mounted Tighten all transport aids Note Do not apply extra loads to the product as the transport aids such as eye bolts or bearing plates are designed for the weight of the motor only refer to the catalogue for the weight N Dangerl Completely screvv in transport aids such as eye bolts or bearing plates they must be flat and applied over their entire surfacel If possible the transport aids such as eye bolts or bearing plates must be stressed vertically in the direction of the screvv axisl Angular tension or tension to the sides reduces the payload Observe the information provided in the DIN 5801 Use additional appropriate lifting aids if required to achieve a direction of loading which is as vertical as possible highest payload Secure lifting aids against shifting If you do not install the motor immediately ensure proper storage conditions gt Up to one
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