VARIBLOC - SEW-EURODRIVE of Canada
Contents
1. accordance with speed control range R Table 1 on page 14 03799AXX Figure 8 Adjusting the display Adjust geared motor to desired maximum speed Set display with potentiometer MAX to 100 Adjust geared motor to medium speed display 50 96 If display does not read 50 re adjust display with Center potentiometer repeat steps 13 through 16 If necessary limit the speed range in accordance with the limit speeds listed under points 13 and 15 Section Limiting the speed range for EF EFPA on page 14 VARIBLOC Variable Speed Gear Unit Operating Instructions 13 14 Installation and setup of EF EFPA adjustment device Limiting the speed range for EF EFPA Speet contel Setting values of potentiometer Center range R VUO1 VU11 VU21 VU31 VUA VU51 VU6 VZ01 VZ11 VZ21 VZ31 VZ41 1 8 34 96 22 96 38 1 6 32 96 35 96 27 96 28 35 38 1 4 36 96 Setting values of potentiometer Min 1 8 13 96 1 6 17 96 1 4 25 Table 1 Setting values of potentiometer Center and potentiometer Min in accordance with speed control range R The operating cams for the limit switches are factory set so that the complete speed range of the variable speed geared motor VARIBLOC can be used It can be limited as follows Figure 9 Caution Limit the adjustment range only via limit switches do not run motor2. EURODRIVE Edition VARIBLOC Variable Speed Gear Unit and Options 09 2000 m Uil minit V _ Operating Instructions 0922 1913 EN A L dh Y E ul i SEHE EURODRIVE 1 Important Notes eege e di 2 EINE DOCI ES 3 VARIBLOC Design esee ttt raras 3 1 Type designation nne 3 2 VARIBLOC variable speed gear unit unit design 3 3 Overview of VARIBLOC mounting options ee 4 Installation B 4 1 Before you begm nn nncnnnnnnnnnannanna nes 4 2 Preliminary Work anne een een 4 3 Installation of VARIBLOC eesseesssesssessseessneeseesscesneeeseceseeeseecseesneeses 4 4 Required tools cce ee 4 5 Mounting of output Components nennen mann 5 151 E110 E 5d WARIBLOCO slalfupaciss eese teen bitte tdt eee ie l gt 6 Installation and Setup of Optional Equipment eee 6 1 Installation and setup of EF EFPA adjustment device 6 2 Installation and setup of hydraulic adjustment unit HY 6 3 Installation and setup of GW IG TWandTAa 7 Inspection Maintenance eneeeeee enne nennen nennen nnn nnne 7 1 Inspection and maintenance intervals seen 4 2 Before e e sen na 7 8 Inspection maintenance of VARIBLOCS sssssssssssss 7 4 Replacing wi
3. Service http www SEW EURODRIVE de P O Box 3023 D 76642 Bruchsal sew sew eurodrive de Production Graben SEW EURODRIVE GmbH amp Co Phone 0 72 51 75 0 Ernst Blickle Stra e 1 Fax 0 72 51 75 29 70 D 76676 Graben Neudorf Telex 7 822 276 P O Box 1220 D 76671 Graben Neudorf Assembly Garbsen SEW EURODRIVE GmbH amp Co Phone 0 51 37 87 98 30 Service near Hanover Alte Ricklinger Stra e 40 42 Fax 0 51 37 87 98 55 D 30823 Garbsen P O Box 110453 D 30804 Garbsen Kirchheim near Munich SEW EURODRIVE GmbH amp Co DomagkstraBe 5 D 85551 Kirchheim Phone 0 89 90 95 52 10 Fax 0 89 90 95 52 50 Langenfeld near Dusseldorf SEW EURODRIVE GmbH amp Co SiemensstraBe 1 D 40764 Langenfeld Phone 0 21 73 85 07 30 Fax 0 21 73 85 07 55 Meerane near Zwickau SEW EURODRIVE GmbH amp Co Dankritzer Weg 1 D 08393 Meerane Phone 0 37 64 76 06 0 Fax 0 37 64 76 06 30 Additional addresses for service in Germany provided on request France Production Haguenau SEW USOCOME SAS Phone 03 88 73 67 00 Sales 48 54 route de Soufflenheim Fax 03 88 73 66 00 Service B P 185 http www USOCOME com F 67506 Haguenau Cedex sew usocome com Production Forbach SEW USOCOME SAS Zone industrielle Technopole Forbach Sud B P 30269 F 57604 Forbach Cedex Assembly Bordeaux SEW USOCOME SAS Phone 05 57 26 39 00 Service Parc d activit s de Magellan Fax 05 57 26 39 09 Technic
4. disc halves TVa Remove old wide V Belt 7 and install new wide V Belt Install driving adjustment disc half TV ball bearing 6 snap ring 5 adjustment sleeve 4 Remove wood wedge Bolt control box halves A and B together Install adjustment unit and bearing cover Attach ventilation plates Tighten wide V belt turn positioning spindle clockwise using adjustment unit 3 until resistance is noticeable Check torsional play at output shaft correct minor torsional play is noticeable Remove block from output side see point 2 Switch on geared motor Slowly pass through the speed range correct drive runs smoothly and evenly VARIBLOC Variable Speed Gear Unit Operating Instructions IA Replacing wide V belt SE a 03710AXX Figure 17 Replacing wide V belt for VU 01 51 and VZ 01 41 1 2 3 4 5 6 7 8 V V Ventilation plate Bearing cover Adjustment unit Adjustment sleeve Snap ring Ball bearing Wide V belt Wood wedge Driving adjustment disc Driven adjustment disc Q d VARIBLOC Variable Speed Gear Unit Operating Instructions Ek d e Replacing wide V belt Replacing wide V 1 Adjust and set geared motor to highest speed belt for VU 6 Figure 18 2 De energize the drive and secure it against unintentional re start Block output side 3 Fully open driving adjustment disc TV turn counterclockwise via adjustment unit
5. gt 50 mm Center hole in accordance with DIN 332 shape DR Centering shoulder tolerances in accordance with DIN 42948 SOj6 with b4 lt 230 mm ISO h6 with b 230 mm 45 Mounting of output components Figure 3 shows an example of a mounting device for mounting clutches or hubs onto shaft ends of variable speed gear units or motors The thrust bearing on the mounting device may become redundant Gear unit shaft end Thrust bearing Coupling hub Figure 3 Example of a fitting tool VARIBLOC Variable Speed Gear Unit Operating Instructions 03371AEN 4 Mounting of output components Figure 4 shows the correct mounting arrangement 2 of a gear or sprocket wheel in order to avoid excessive overhung loads incorrect correct 03369AEN Figure 4 Correct mounting arrangement of a gear or sprocket wheel Only use a mounting device see Figure 3 for installing input and output elements Use the center bore and the thread on the shaft end for positioning purposes Never drive belt pulleys clutches pinions etc onto the shaft end by hitting them with a hammer damage to bearings housing and the shaft Please observe correct tension of the belt for belt pulleys in accordance with manufacturer s specifications Mounted transmission elements should be balanced and may not cause any unacceptable radial or axial forces see Figure 4 see Geared Motors catalog for ap
6. VECTOR Aandrijftechniek B V Phone 010 4 46 37 00 Sales Industrieweg 175 Fax 010 4 15 55 52 Service NL 3044 AS Rotterdam Postbus 10085 NL 3004AB Rotterdam New Zealand Assembly Auckland SEW EURODRIVE NEW ZEALAND LTD Phone 09 2 74 56 272 74 00 77 Sales P O Box 58 428 Fax 09 274 0165 Service 82 Greenmount drive sales sew eurodrive co nz East Tamaki Auckland Christchurch SEW EURODRIVE NEW ZEALAND LTD Phone 09 3 84 62 51 10 Settlers Crescent Ferrymead Fax 09 3 84 64 55 Christchurch sales sew eurodrive co nz Norway Assembly Moss SEW EURODRIVE A S Phone 69 2410 20 Sales Solgaard skog 71 Fax 69 2410 40 Service N 1539 Moss Peru Assembly Lima SEW DEL PERU MOTORES REDUCTORES Phone 511 349 52 80 Sales S A C Fax 511 349 30 02 Service Los Calderos 120 124 Urbanizacion Industrial Vulcano ATE Lima Poland Sales Lodz SEW EURODRIVE Polska Sp z o o Phone 042 6 16 22 00 ul Pojezierska 63 Fax 042 6 16 22 10 91 338 Lodz sew sew eurodrive pl 08 2000 e SEW Worldwide L Portugal Assembly Coimbra SEW EURODRIVE LDA Phone 0231 20 96 70 Sales Apartado 15 Fax 0231 20 36 85 Service P 3050 901 Mealhada infosew sew eurodrive pt Romania Sales Bucharest Sialco Trading SRL Phone 01 2 30 13 28 Service str Madrid nr 4 Fax 01 2 30 71 70 71222 Bucuresti sialco mediasat ro Russia Sales St Petersburg ZAO SEW EURO
7. back voltage pulse encoder 2 by two turns clearance 2 mm 4 Secure voltage pulse encoder 2 with lock nut 5 If no display is present correct input sensitivity increase or decrease clearance between voltage pulse encoder and bolt head 02415AXX Figure 13 IG voltage pulse encoder VARIBLOC Variable Speed Gear Unit Operating Instructions Installation and setup of GW IG TW and TA 6 Connection The contact free digital remote speed display DA is connected to the AC encoder GW adjustment of DA _ or the IG voltage pulse encoder Figure 14 and Figure 15 1 Connect the device Figure 14 2 Ensure perfect ground connection at terminal 1 3 Adjust measuring interval Figure 15 and Section DA calculation examples on page 22 calculation using a formula data in accordance with Table 3 on page 21 4 Adjust input sensitivity Figure 15 turn input sensitivity potentiometer clockwise until pulse indicator light starts to glow Voltage pulse encoder IG AC encoder GW 1 2 3 4 5 6 7 8 9 10 poen 230 V 115V jumper 8 9 jumper 7 9 and 8 10 03693AEN Figure 14 Connecting the DA digital remote speed display Time basis s Pulse multiplier 1 0 1 0 010 001 x10 xi Pulse control Decimal p
8. setup of GW IG TW and TA AC encoder GW IG voltage pulse encoder Installing the AC encoder GW Figure 12 Installing right angle tachometer TW shaft tachometer TA Connecting analog remote speed display FA FD 1 Use the AC encoder GW for VU 01 51 VZ 01 41 2 Use the IG voltage pulse encoder for VU 6 and for VU VZ 01 41 with brake BMG 1 Install the AC encoder 6 in the adapter tachogenerator 3 tongue must fit in shaft slot 4 2 Secure AC encoder 6 with threaded pin 2 02413AXX Figure 12 Installing AC encoder GW right angle tachometer TW shaft tachometer TA The tachometers TW 1 and TA 5 can be installed instead of the AC encoder Figure 12 The analog remote speed displays FA with scale from 0 96 to100 96 or FD with customized scale are connected to the AC encoder GW 1 Connect the device to an AC encoder in accordance with the terminal designation 2 Operate drive at maximum speed 3 Adjust the device to 100 indicator deflection with the potentiometer on the back of the unit VARIBLOC Variable Speed Gear Unit Operating Instructions 17 18 Mounting the voltage pulse encoder IG Figure 13 Installation and setup of GW IG TW and TA 1 Move bolt head 1 in front of bore for voltage pulse encoder 2 2 Install voltage pulse encoder 2 into the appropriate thread of the geared motor housing until it touches the bolt head 1 3 Turn
9. to mechanical stop potential material damage 1 Adjust VARIBLOC to desired minimum speed 2 a Lower operating cam 2 loosen with screwdriver turn counterclockwise until switching point is reached x EI 03724AXX Figure 9 Position and detail view of setting cam VARIBLOC Variable Speed Gear Unit Operating Instructions Installation and setup of EF EFPA adjustment device 6 for design with potentiometer 5 also Figure 10 A ae b Loosen lower screw of coupling 4 c Turn potentiometer 5 on coupling counterclockwise until stop is reached clockwise by approx 15 until terminals 6 and 7 measure approx 120 to 180 Q d Tighten lower screw of coupling 4 3 Tighten lower operating cam 2 4 Adjust VARIBLOC to desired maximum speed 5 Upper operating cam 3 lt gt loosen with screwdriver E turn clockwise until switching point is SS reached E tighten al 6 Install housing cover 1 enclose wiring diagram 03720AXX Figure 10 Position and detail view of setting cams VARIBLOC Variable Speed Gear Unit Operating Instructions 15 Installation and setup of hydraulic adjustment unit HY 6 2 Installation and setup of hydraulic adjustment unit HY Installing the positioning cylinder Limiting the speed range 16 SESS rA SE iss ua Bes A 03752AXX Figure 11 Hyaraulic adjustment unit The
10. 3 until it stops 4 a for front adjustment design remove plate cover 1 snap ring 2 and support disc 3 turn adjustment unit 4 clockwise to maximum setting loosen screws on cover 5 remove cover and detach adjustment unit b for all other designs remove complete adjustment unit 4 5 Loosen housing screws remove control box half A Secure driven spring loaded adjustment disc GV with wood wedge 10 Caution Disc halves should not be allowed to snap together through spring load 7 At driving adjustment disc TV remove support disc 3 and snap ring 2 remove ball bearing 8 and adjustment disc half TV 8 Remove old wide V Belt 7 and install new wide V Belt Install at driving adjustment disc adjustment disc half TVa ball bearing 6 snap ring 5 and support disc 3 10 Remove wood wedge 8 11 Bolt control box halves A and B together 12 Install adjustment unit 4 in reverse order of points 4a 4b 13 Tighten wide V belt 7 turn positioning spindle clockwise using adjustment unit 4 until resistance is noticeable 14 Remove block from output side see point 2 15 Switch on geared motor 16 Slowly pass through the speed range correct drive runs smoothly and evenly 26 VARIBLOC Variable Speed Gear Unit Operating Instructions Nr P d Replacing wide V belt NS 7 ANA 03761 AXX Figure 18 Replacin
11. DRIVE Phone 812 3 26 09 41 5 35 04 30 P O Box 193 Fax 812 5 35 22 87 193015 St Petersburg sewrus post spbnit ru Singapore Assembly Singapore SEW EURODRIVE PTE LTD Phone 8 62 17 01 705 Sales No 9 Tuas Drive 2 Fax 8 61 28 27 Service Jurong Industrial Estate Telex 38 659 Singapore 638644 Jurong Point Post Office P O Box 813 Singapore 91 64 28 South Africa Assembly Johannesburg SEW EURODRIVE PROPRIETARY LIMITED Phone 11 49 44 380 Sales Eurodrive House Fax 11 49 42 300 Service Cnr Adcock Ingram and Aerodrome Roads Aeroton Ext 2 Johannesburg 2013 P O Box 27032 2011 Benrose Johannesburg Capetown SEW EURODRIVE PROPRIETARY LIMITED Phone 021 5 11 09 87 Rainbow Park Fax 021 5 11 44 58 Cnr Racecourse amp Omuramba Road Telex 576 062 Montague Gardens 7441 Cape Town P O Box 53 573 Racecourse Park 7441 Cape Town Durban SEW EURODRIVE PROPRIETARY LIMITED Phone 031 700 34 51 39 Circuit Road Telex 622 407 Westmead Pinetown P O Box 10433 Ashwood 3605 Spain Assembly Bilbao SEW EURODRIVE ESPANA S L Phone 9 44 31 84 70 Sales Parque Tecnologico Edificio 302 Fax 9 44 31 84 71 Service E 48170 Zamudio Vizcaya sew spain sew eurodrive es Sweden Assembly J nk ping SEW EURODRIVE AB Phone 036 34 42 00 Sales Gnejsvagen 6 8 Fax 036 34 42 80 Service S 55303 J nk ping www sew eurodrive se Box 3100 S 55003 J nk ping Switzerland Assembly Basel Alfred Imhof A G Phone 061 4 17 17 17 Sales Jurastr
12. Operating Instructions Overview of VARIBLOC mounting options 3 3 Overview of VARIBLOC mounting options A KL TO LLL as C Figure 2 Overview of VARIBLOC mounting options 1 2 3 4 5 6 7 8 Brake BM G with IG voltage pulse encoder Bearing cover Right angle tachometer TW AC tachogenerator GW Axial tachometer TA Voltage pulse encoder IG Adjustment device with handwheel and position indication HS Hydraulic variable speed unit HY Electromechanical remote speed adjustment EF Adjustment device with handwheel H with free shaft end NV Front adjustment with sprocket wheel Front adjustment with handwheel standard design zb Zb N00 VARIBLOC Variable Speed Gear Unit Operating Instructions H 03712AXX Before you begin 4 Installation Never adjust variable speed gear unit at standstill Damages to the adjustment device and the wide V belt may result 4 1 Before you begin The drive may only be installed if the entries on the nameplate of the drive match the supply voltage the drive is not damaged no damage resulting from transport or storage the following requirements have been properly fulfilled ambient temperature between 0 C and 40 C nooils acids gases vapors radia
13. Redutores Ltda Fax 011 64 80 43 43 Service Caixa Postal 201 0711 970 sew brasil originet com br Rodovia Presidente Dutra km 213 CEP 07210 000 Guarulhos SP Bulgaria Sales Sofia BEVER DRIVE GMBH Phone 92 9 53 25 65 Bogdanovetz Str 1 Fax 92 9 54 93 45 BG 1606 Sofia bever mbox infoPhone bg Canada Assembly Toronto SEW EURODRIVE CO OF CANADA LTD Phone 905 7 91 15 53 Sales 210 Walker Drive Fax 905 7 91 29 99 Service Bramalea Ontario L6T3W1 Vancouver SEW EURODRIVE CO OF CANADA LTD Phone 604 9 46 55 35 7188 Honeyman Street Fax 604 946 2513 Delta B C V4G 1 E2 Montreal SEW EURODRIVE CO OF CANADA LTD Phone 514 3 67 11 24 2555 Rue Leger Street Fax 514 3 67 36 77 LaSalle Quebec H8N 2V9 Chile Assembly Santiago de Chile SEW EURODRIVE CHILE Phone 02 6 23 82 03 6 23 81 63 Sales Motores Reductores LTDA Fax 02 6 23 81 79 Service Panamericana Norte No 9261 Casilla 23 Correo Quilicura RCH Santiago de Chile China Production Tianjin SEW EURODRIVE Tianjin Co Ltd Phone 022 25 32 26 12 Assembly No 46 7th Avenue TEDA Fax 022 25 32 26 11 Sales Tianjin 300457 Service 08 2000 SEW Worldwide i Colombia Assembly Bogot SEW EURODRIVE COLOMBIA LTDA Phone 0571 5 47 50 50 Sales Calle 22 No 132 60 Fax 0571 5 47 50 44 Service Bodega 6 Manzana B Santaf de Bogota Croatia Sales Zagreb KOMPEKS d
14. VE INC Phone 214 3 30 48 24 3950 Platinum Way Fax 214 3 30 47 24 Dallas Texas 75237 Additional addresses for service in the USA provided on request Venezuela Assembly Valencia SEW EURODRIVE Venezuela S A Phone 041 32 95 83 32 98 04 32 Sales Av Norte Sur No 3 Galpon 84 319 94 51 Service Zona Industrial Municipal Norte Fax 041 32 62 75 Valencia sewventas cantr net sewfinanzas cantr net 08 2000 Notes EURODRIVE 09 2000
15. Variable Speed Gear Unit Operating Instructions Installation and setup of EF EFPA adjustment device 6 Connecting adjusting display unit for EFPA 10 11 12 13 15 16 17 18 19 Adjust display with potentiometer MIN in Set geared motor to desired maximum speed Remove housing cover 1 fromthe switch 1 element of the variable speed motor Set potentiometer 5 of variable speed motor and secure Figure 7 loosen lower screw of coupling 4 turn the potentiometer 5 at the coupling clockwise by approx 15 until terminals 6 and 7 measure approx 120 to 180 Q tighten lower screw of coupling 4 A mt 8 Connect the display unit with supply voltage Do not connect terminals 5 6 and 7 Set display with potentiometer Min to 0 96 Figure 9 Jumper display unit terminals 5 and 6 Turn potentiometer Center clockwise until it stops Set display with potentiometer Max to 100 Remove jumper between terminals 5 and 6 Connect terminals 5 and 7 of the display unit with terminals 5 and 6 of the variable speed motor 03762AXX Figure 7 Adjusting potentiometer of variable speed motor Adjust display with potentiometer Center in accordance with operating range R Table 1 on page 14 Connect display unit to the variable speed eo motor in accordance with enclosed wiring diagram Adjust geared motor to desired minimum 7 SL 220v MITTEN speed MIN MAX
16. al Office 62 avenue de Magellan B P 182 F 33607 Pessac Cedex Lyon SEW USOCOME SAS Phone 04 72 15 37 00 Parc d Affaires Roosevelt Fax 04 72 15 37 15 Rue Jacques Tati F 69120 Vaulx en Velin Paris SEW USOCOME SAS Phone 01 64 42 40 80 Zone industrielle 2 rue Denis Papin F 77390 Verneuil l Etang Fax 01 64 42 40 88 Additional addresses for service in France provided on request 08 2000 i SEW Worldwide Argentina Assembly Buenos Aires SEW EURODRIVE ARGENTINA S A Phone 3327 45 72 84 Sales Centro Industrial Garin Lote 35 Fax 3327 45 72 21 Service Ruta Panamericana Km 37 5 sewar sew eurodrive com ar 1619 Garin Australia Assembly Melbourne SEW EURODRIVE PTY LTD Phone 03 99 33 10 00 Sales 27 Beverage Drive Fax 03 99 33 10 03 Service Tullamarine Victoria 3043 Sydney SEW EURODRIVE PTY LTD Phone 02 97 25 99 00 9 Sleigh Place Wetherill Park Fax 02 97 25 99 05 New South Wales 2164 Austria Assembly Vienna SEW EURODRIVE Ges m b H Phone 01 6 17 55 00 0 Sales Richard Strauss Strasse 24 Fax 01 6 17 55 00 30 Service A 1230 Wien sew sew eurodrive at Belgium Assembly Bruxelles CARON VECTOR S A Phone 010 23 13 11 Sales Avenue Eiffel 5 Fax 010 2313 36 Service B 1300 Wavre http www caron vector be info caron vector be Brazil Production Sao Paulo SEW DO BRASIL Phone 011 64 60 64 33 Sales Motores
17. asse 10 Fax 061 4 17 17 00 Service CH 4142 M nchenstein near Basel http www imhof sew ch info imhof sew ch Thailand Assembly Chon Buri SEW EURODRIVE Thailand Ltd Phone 0066 38 21 45 29 30 Sales Bangpakong Industrial Park 2 Fax 0066 38 21 45 31 Service 700 456 M007 Tambol Bonhuaroh Muang District Chon Buri 20000 08 2000 O 1 SEW Worldwide Turkey Assembly Istanbul SEW EURODRIVE Phone 0216 4 41 91 63 4 41 91 64 Sales Hareket Sistemleri San ve Tic Ltd Sti 3 83 80 14 3 83 80 15 Service Bagdat Cad Koruma Cikmazi No 3 Fax 0216 3 05 58 67 TR 81540 Maltepe ISTANBUL seweurodrive superonline com tr Uruguay Please contact our office in Argentina USA Production Greenville SEW EURODRIVE INC Phone 864 4 39 75 37 Assembly 1295 Old Spartanburg Highway Fax Sales 864 439 78 30 Sales P O Box 518 Fax Manuf 864 4 39 99 48 Service Lyman S C 29365 Fax Ass 864 4 39 05 66 Telex 805 550 Assembly San Francisco SEW EURODRIVE INC Phone 510 4 87 35 60 Sales 30599 San Antonio Road Fax 510 4 87 63 81 Service P O Box 3910 Hayward California 94544 Philadelphia PA SEW EURODRIVE INC Phone 856 4 67 22 77 Pureland Ind Complex Fax 856 8 45 31 79 200 High Hill Road P O Box 481 Bridgeport New Jersey 08014 Dayton SEW EURODRIVE INC Phone 9 37 3 35 00 36 2001 West Main Street Fax 9 37 4 40 37 99 Troy Ohio 45373 Dallas SEW EURODRI
18. de V belt bank 7 5 Limiting the speed range for designs NV H H nn 7 6 Lubricate EF EFPA adjusting spindle cc eeeeeeeeeenneeeeeeeennaeeeeeeenaas NET 8 Operation and Service unnsnnsnnsnnsnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnannnnannnnnnnnnnnnnnnnnnnann SS LE BANDES 8 1 Malfunction of VARIBLOC variable speed gear unt 8 2 Malfunction of optional equipment nn VARIBLOC Variable Speed Gear Unit Operating Instructions Important Notes 1 Important Notes Safety Always follow warnings and safety instructions in this publication and warning instructions Electrical hazard Possible effects Serious or fatal injury Immediate danger Possible effects Serious or fatal injury Dangerous situation Possible effects Minor injury Harmful situation Possible effects Damage to equipment or surroundings Application hints and useful information E O e D Close adherence to these instructions is required for fault free operation and fulfillment of any warranty claims Read these instructions carefully before you start operating the ive LNH drive These operating instructions contain vital servicing information and should be stored next to the drive unit Disposal Please observe all applicable regulations Housing components gear wheels shafts and rolling bearings of gear units should be disposed of as steel scrap This also applies to components made of cast iron if no separate collectio
19. e intended for industrial systems They comply with existing standards and regulations The technical data and information on approved operating conditions can be found on the nameplate and in the documentation All details must be strictly observed Inspect the shipment for damages upon receipt Inform the shipping company immediately of any damages In case of damages startup may have to be cancelled Securely tighten lifting eyebolts The eyebolts are specifically designed for the weight of the geared motor gear unit no additional loads may be applied If necessary use appropriate and sufficiently dimensioned handling equipment Remove existing shipping braces prior to startup VARIBLOC Variable Speed Gear Unit Operating Instructions Type designation 3 VARIBLOC Design 3 1 Type designation Example VU 21 HS BMG HF L Manual brake release lock type Brake Angle selection element with handwheel and position indication VARIBLOC Variable Speed Gear Unit size L VARIBLOC variable Speed Gear Unit series U shaped flow of energy 03794AEN 3 2 VARIBLOC variable speed gear unit unit design be 03711AXX Figure 1 VARIBLOC design Adjustment device front adjustment Adjustment discs Wide V belt Bearing cover Two part housing variable speed gear unit Coupled reduction gear unit Output flange Drive motor oNOOIPOD VARIBLOC Variable Speed Gear Unit
20. g wide V belt for VU 6 Plate cover Snap ring Support disc Adjustment unit Cover Ball bearing Wide V belt Wood wedge Driving adjustment disc Driven adjustment disc se DO d OO P WD GO d lt VARIBLOC Variable Speed Gear Unit Operating Instructions 27 BS f 7 z Limiting the speed range for designs NV H HS 7 5 Limiting the speed range for designs NV H HS The limit speeds nmin and Nmax are factory set After wear of the belt or after installing a new wide V belt it may be necessary to define the speed range again 1 Remove cover plate 1 at adjustment unit 2 Setthe desired maximum speed loosen hammer screw 2 approach speed lock hammer screw in this position 3 Setthe desired minimum speed loosen hammer screw 3 approach speed lock hammer screw in this position 03702AXX Figure 19 Limiting the speed range for designs NV H HS 7 6 Lubricate EF EFPA adjusting spindle 1 Detach adjustment head 1 from control box 2 loosen screws 3 2 Lubricate adjusting spindle 4 with well adhering lubricant e g Never Seeze normal 3 Assemble in reverse order 03703AXX Figure 20 Lubricating EF EFPA adjusting spindle 28 VARIBLOC Variable Speed Gear Unit Operating Instructions Malfunction of VARIBLOC variable speed gear unit S 8 Operation and Service 8 1 Please provide the following informat
21. hydraulic adjustment unit is a closed system The required adjustment force is generated through the piston of the adjustment cylinder This cylinder receives the response force spring force of the driven adjustment disc The system is filled without enclosed air The travel of the actuator cylinder corresponds to that of the positioning cylinder since both piston diameters are identical The actuator cylinder is factory installed high pressure hose and positioning cylinder have to still be connected bending radius of high pressure hose 2 40 mm The positioning cylinder may be mounted to a device wall in any position Figure 11 1 Remove pin 2 and handwheel 1 2 Remove hex nuts 3 and 4 3 Attach positioning cylinder 6 to device wall 5 using four M5 machine screws according to DIN 912 4 Reinstall hex nuts handwheel and pin The limit speeds are factory set so the complete speed range of the VARIMOT geared motor can be used It can be limited as follows Figure 11 1 Limiting high speed setthe desired maximum speed turn hex nut 4 clockwise and secure with hex nut 3 2 Limiting low speed set the desired minimum speed remove cover plate 9 and loosen hammer screw 7 move hammer screw 7 up to the stop of the adjusting bolt 8 tighten hammer screw 7 VARIBLOC Variable Speed Gear Unit Operating Instructions Installation and setup of GW IG TW and TA 6 3 Installation and
22. inst penetration of foreign bodies or fluids cowl C 1 Maximum permitted flatness error for flange mounting approximate value with reference to DIN ISO 1101 with gt flange 120 600 mm max error 0 2 0 5 mm VARIBLOC Variable Speed Gear Unit Operating Instructions Required tools Installation in damp areas or in the open Painting the gear unit Ensure adequate supply of cooling air and that heated air from other units is not drawn in VARIBLOC gear units are supplied in corrosion resistant versions design B for use in damp areas or in the open Any damage to the paintwork e g atthe breather valve must be repaired Coat the threads of screwed cable glands and sealing plugs with sealant and tighten well apply another coat of sealant Properly seal the cable entry Thoroughly clean the sealing surfaces of the terminal box and terminal box cover before re assembly Replace porous seals If the drive will be painted or partially repainted ensure that the breather valve and oil seals are carefully covered with tape Remove tape strips after the paint work is finished 44 Required tools Installation tolerances Wrench set Mounting device Shims and distance rings if necessary Mounting materials for output components Multimeter Shaft end Flanges Diametric tolerances in accordance with DIN 748 ISO k6 for solid shafts with d d4 lt 50 mm ISO k7 for solid shafts with d d4
23. ion if you require assistance from customer service Nameplate information State type and extent of the fault Time and circumstances of the fault Presumed cause Malfunction of VARIBLOC variable speed gear unit Malfunction Possible cause Solution e 7 Replace wide V belt Section Inspect wide V Wide V belt is worn beit on page 23 Clean contaminated part Drive slips wie V belt or a ea ad Wide V belt use dry cloth or paper disc is contaminated Adjustment disc use solvent or similar product Load is too high Check measured power and reduce to catalog values Drive warms up excessively Load is too high see above Drive is too loud Wide V belt is damaged Note Damage can occur after brief stalling of the drive with intermittent loading of the drive 1 Correct cause 2 Replace wide V belt Section 7 4 8 2 Malfunction of optional equipment Electromechan ical remote speed adjuster EF EFPA Malfunction Possible cause Solution Speed cannot be adjusted Unit is not wired properly Wire unit correctly in accordance with circuit diagram Speed range cannot be reached Limit switches of variable speed motor switch off too early Adjust cams correctly for limit switch actuation Section Limiting the speed range for EF EFPA on page 14 No display Display unit is not properly connected Voltage supply is
24. ll Damages to the adjustment device and the wide V belt may result Secure key for trial run without output components Do not deactivate monitoring and protection devices not even for the trial run 6 1 Installation and setup of EF EFPA adjustment device Electrome chanical remote speedadjustment EF EFPA Connecting the variable speed motor EF EFPA The electromechanical remote speed adjustment option consists of a variable speed motor featuring a display unit in the EFPA design This display unit may be installed in a control cabinet The display does not indicate speed changes due to load fluctuations Note The electromechanical remote speed adjsutment option EF EFPA is designed for max 40 ED and a switching rate of lt 20 times per hour Adjustments on EF EFPA are done in the energized state 1 Remove housing cover 1 from the switch element of the variable speed motor 2 Electrically connect the device according to the enclosed wiring diagram in accordance with the information on the nameplate 3 a if desired limit the speed range for variable soeed motor EF Section Limiting the speed range for EF EFPA on page 14 otherwise replace housing cover b for EFPA variable speed motor connect the display unit according to the enclosed wiring diagram Section Connecting adjusting display unit for EFPA on page 13 A O 02425AXX Figure 6 Connecting variable speed motor EF EFPA VARIBLOC
25. mended measuring interval 0 5 to 2 s Pulse multiplier adjustment in the range from 1 to 99 after removing the face plate Decimal point setting via DIP switch after removing the face plate Calculation of measuring interval asuringinterval Su A 4 digit display at maximum speed without decimal indication n speed Table 3 on page 21 k pulse multiplier gt 1 Z pulses revolution Table 3 on page 21 f calculation factor at 50 Hz 1 at 60 Hz 1 2 i VARIBLOC reference speed rpm min Weiter a ert R 16 6 A 18 8 4 pole 6 pole 8 pole 4 pole 6 pole 8 pole VU VZ 01 3100 2045 1550 VU VZ 11 3250 2160 1615 3905 2530 1870 VU VZ 21 3100 2050 1530 4004 2631 1916 VU VZ 31 3100 2050 1540 4090 2688 2002 VU VZ 41 3053 2035 1505 VU VZ 51 3106 2056 1526 R 1 4 1 3 4 1 3 1 VU 6 D 200 2528 1668 1247 VU 6 D 225 8 2087 Table 3 DA reference data VARIBLOC Variable Speed Gear Unit Operating Instructions 22 Installation and setup of GW IG TW and TA DA calculation examples Example 1 Example 2 Drive R107R77VU21DADV100L4 R107R77VU21DADV100L4 Output speed Ng 1 0 6 3 Output speed na 1 0 6 3 Data Pulse rate z 4 Pulse rate z 4 max speed of variable speed gear n 3100 min max speed of variable speed gear n 3100 min Table 3 on page 21 Table 3 on page 21 De
26. missing or interrupted Connect display unit correctly in accordance with circuit diagram Incorrect display Display is not properly adjusted Adjust display on back of unit Section Connecting adjusting display unit for EFPA on page 13 VARIBLOC Variable Speed Gear Unit Operating Instructions 29 30 gt a Malfunction of optional equipment Contact free remote speed display FL and DA voltage pulse encoder IG Hydraulic variable speed unit HY Malfunction Possible cause Solution No display or no signal Input sensitivity clearance of pulse encoder screw head too high or too low Correct input sensitivity Increase or decrease clearance between IG voltage pulse encoder and screw head Section Mounting the voltage pulse encoder IG Figure 13 on page 18 e Unit is not properly connected Voltage supply is missing or interrupted Connect unit correctly in accordance with circuit diagram Malfunction Possible cause Solution Small loss of oil Not enough oil Add oil screw on positioning cylinder VARIBLOC Variable Speed Gear Unit Operating Instructions SEW Worldwide i SEW Worldwide Germany Headquarters Bruchsal SEW EURODRIVE GmbH amp Co Phone 0 72 51 75 0 Production Ernst Blickle Stra e 42 Fax 0 72 51 75 19 70 Sales D 76646 Bruchsal Telex 7 822 391
27. n is available The wide V belt may be disposed of as residual waste Revisions to edition 7 95 are indicated by a gray bar in the margin VARIBLOC Variable Speed Gear Unit Operating Instructions Safety Notes 2 Safety Notes Preliminary remarks General Intended usage Transport Storage The following safety notes refer to the use of variable speed gear units When using variable speed geared motors please observe safety notes for gear units and motors in the appropriate operating instructions Please refer to the additional safety notes in the individual sections of these operating instructions All tasks related to transport storage installation assembly connection startup service and maintenance may be performed by qualified technical personnel only with strict adherence to detailed operating instruction s and block diagrams warning and safety labels on the gear unit geared motor System specific regulations and requirements national regional safety and accident prevention regulations Serious personal injuries and material damage may occur through e incorret use improper installation or operation inadmissible removal of required protective covers or of the housing Be aware that variable speed geared motors gear units contain live and moving components and that some surfaces may get hot during and after operation These variable speed geared motors variable speed gear units ar
28. o o Phone 385 14 61 31 58 Service PIT Erd dy 4 II Fax 385 14 61 31 58 HR 10 000 Zagreb Czech Republic Sales Prague SEW EURODRIVE S R O Phone 02 20 12 12 34 20 12 12 36 Business Centrum Praha Fax 02 20 12 12 37 Luna 591 sew sew eurodrive cz 16000 Praha 6 Denmark Assembly Copenhagen SEW EURODRIVEA S Phone 4395 8500 Sales Geminivej 28 30 P O Box 100 Fax 4395 8509 Service DK 2670 Greve Estonia Sales Tallin ALAS KUUL AS Phone 6 59 32 30 Paldiski mnt 125 Fax 6 59 32 31 EE 0006 Tallin Finland Assembly Lahti SEW EURODRIVE OY Phone 3 589 300 Sales Vesim entie 4 Fax 3 780 6211 Service FIN 15860 Hollola 2 Greece Sales Athens Christ Boznos amp Son S A Phone 14 22 51 34 6 14 22 51 48 9 Service 12 Mavromichali Street Fax 1 4 22 51 59 P O Box 80136 GR 18545 Piraeus Boznos otenet gr Great Britain Assembly Normanton SEW EURODRIVE Ltd Phone 19 24 89 38 55 Sales Beckbridge Industrial Estate Fax 19 24 89 37 02 Service P O Box No 1 GB Normanton West Yorkshire WF6 1QR Hungary Sales Budapest SEW EURODRIVE Ges m b H Phone 01 2 02 74 84 Service Holl si Simon Hut 14 Fax 01 2 01 48 98 H 1126 Budapest Hong Kong Assembly Hong Kong SEW EURODRIVE LTD Phone 2 7 96 04 77 79 60 46 54 Sales Unit No 801 806 8th Floor Fax 2 7 95 91 29 Service Hong Leong Industrial Complex sew sewhk com No 4 Wang Kwong Road Kowloon Hong Kong India Assembly Baroda SEW EURODRIVE India Private Limited Phone 0 265 83 10 86 Sales Pl
29. oint setting Input sensitivity 03708AEN Figure 15 Adjusting the DA digital remote speed display Technical data Digital display unit Supply voltage 230 V 50 60 Hz Power consumption approx 4 2 VA Encoder connection with two core cable shielded VARIBLOC Variable Speed Gear Unit Operating Instructions 19 20 Installation and setup of GW IG TW and TA Connection The contact free analog remote speed display FL is connected to the voltage pulse adjustment of EL encoder IG at the VARIBLOC Figure 16 1 Connect the device 2 Operate drive at maximum speed 3 Adjust the unit via setting screws Coarse or Fine at the back of the display unit to a reading of 100 4 Ensure perfect ground connection at terminal M Voltage pulse encoder IG 230V M GBS S o D GROB 03709AEN Figure 16 Connecting and adjusting contact free FL remote speed display Technical data Analog display unit scale from 0 to 100 Supply voltage 230 V 40 60 Hz Encoder connection with two core shielded cable VARIBLOC Variable Speed Gear Unit Operating Instructions Installation and setup of GW IG TW and TA Adjustment data e Accuracy of indication 1 of last digit of digital remote Measuring interval quartz adjustment in increments of 0 001 s in the range of speed display DA 0 010s to 9 999s after removing the face plate recom
30. ot NO 4 Gidc Fax 0 265 83 10 87 Service Por Ramangamdi Baroda 391 243 sewindia wilnetonline net Gujarat lreland Sales Dublin Alperton Engineering Ltd Phone 01 8 30 62 77 Service 48 Moyle Road Fax 01 8 30 64 58 Dublin Industrial Estate Glasnevin Dublin 11 08 2000 1 SEW Worldwide Italy Assembly Milan SEW EURODRIVE di R Blickle amp Co s a s Phone 02 96 98 01 Sales Via Bernini 14 Fax 02 96 79 97 81 Service 1 20020 Solaro Milano Japan Assembly Toyoda cho SEW EURODRIVE JAPAN CO LTD Phone 0 53 83 7 3811 13 Sales 250 1 Shimoman no Fax 0 53 83 7 3814 Service Toyoda cho Iwata gun Shizuoka prefecture P O Box 438 0818 Korea Assembly Ansan City SEW EURODRIVE CO LTD Phone 031 4 92 80 51 Sales R 601 4 Banweol Industrial Estate Fax 031 4 92 80 56 Service Unit 1048 4 Shingil Dong Ansan 425 120 Luxembourg Assembly Bruxelles CARON VECTOR S A Phone 010 23 13 11 Sales Avenue Eiffel 5 Fax 010 2313 36 Service B 1300 Wavre http www caron vector be info caron vector be Macedonia Sales Skopje SGS Skopje Macedonia Phone 0991 38 43 90 Teodosij Sinactaski Fax 0991 38 43 90 6691000 Skopje Macedonia Malaysia Assembly Johore SEW EURODRIVE San Bhd Phone 07 3 54 57 07 3 54 94 09 Sales 95 Jalan Seroja 39 Fax 07 35414 04 Service 81100 Johore Bahru Johore Netherlands Assembly Rotterdam
31. proved values Note Assembly is easier if you first apply lubricant to the output element or heat it up briefly 80 100 C Assembly of While mounting clutches the following items must be balanced in accordance clutches with clutch manufacturer specifications a Maximum and minimum clearance b Axial offset c Angular offset c 03356AXX Figure 5 Input and output elements such as belt pulleys clutches etc must be equipped with a touchguard device 10 VARIBLOC Variable Speed Gear Unit Operating Instructions VARIBLOC startup 5 Startup Never adjust variable speed gear unit at standstill Damages to the adjustment device and the wide V belt may result 5 1 VARIBLOC startup Check the correct direction of rotation in the disengaged state paying special attention to unusual sliding noises during racing phase Secure the key for the trial run without output components Do not deactivate monitoring and protection devices not even for the trial run If in doubt modifications to normal operation e g increased temperature noises vibrations may require that the variable speed geared motor be switched off Determine the cause and confer with SEW if necessary VARIBLOC Variable Speed Gear Unit Operating Instructions 11 12 Installation and setup of EF EFPA adjustment device 6 Installation and Setup of Optional Equipment Never adjust variable speed gear unit at standsti
32. re of the following questions with Yes the wide V belt must be replaced 7 4 Type of check Tests to be performed for VU 01 51 VZ 01 41 VU6 Functional test Is a loud noise noticeable Do speed fluctuations occur Visual inspection Remove ventilation plates Is alot of abrasive dust noticeable at the ventilation Is a lot of abrasive dust noticeable at the ventilation plates or in the housing openings Are the sides of the belt frayed sthe wide V belt between the fins cracking or already torn VARIBLOC Variable Speed Gear Unit Operating Instructions 23 7 24 Cs Ek Replacing wide V belt 7 4 Replacing wide V belt Caution Use only original parts in accordance with the valid spare parts list Replacing wide V 1 belt for VU 01 51 and VZ 01 41 Figure 17 10 11 12 13 14 15 16 17 18 Adjust and set geared motor to highest speed 2 De energize the drive and secure it against unintentional re start Block output side 3 Remove both lateral ventilation plates 1 4 Remove bearing cover 2 and adjustment unit 3 5 Loosen housing screws separate control box halves A and B 6 Secure driven spring opposed adjustment disc GV with wood wedge 8 Caution Disc halves should not be allowed to snap together through spring load Remove adjustment sleeve 4 for front adjustment snap ring 5 driving adjustment
33. sired indication Output speed A 1000 6 300 min Strip speed A 0 114 0 72 m min 60 A 60 6300 60 0720 EE LL 30 485 NN 3 484 RER 3100 1 4 1 otal s Recomm measuring 0 5 2s max 9 999 s interval Calculation with new K 25 60 6300 ird 60 0720 pulse multiplier Measuringinterval 3100 25 41 1 219 Measuringinterval ERC RER 0 871s Measuring interval 1 2 1 9 Measuring interval 0 8 7 1 Device setup Pulse multiplier 2 5 Pulse multiplier 0 4 Decimal point setting 1 Decimal point setting 1 VARIBLOC Variable Speed Gear Unit Operating Instructions Inspection and maintenance intervals gt SS 7 Inspection Maintenance 7 1 Inspection and maintenance intervals Unit unit part Interval What to do gt Further details on page VARIBLOC Weekly Pass through speed range Every 3000 hours of operation Inspect wide V belt Inspect wide V belt on page 23 VARIBLOG At least every six months Every 20 000 adjustments Check adjusting spindle see Lubricate EF EFPA adjusting EF EFP EFPA At least every six months replace if necessary spindle on page 28 otherwise lubricate 7 2 Before you begin Required tools Wrench set Hammer e Mandrel or drift punch Pliers for snap ring Lubricant Never Seeze normal 73 Inspection maintenance of VARIBLOC Inspect wide V belt If you answer one or mo
34. tion etc the degree of protection provided by the enclosure has been checked 42 Preliminary work Variable speed Output shafts and flange surfaces must be completely free of anti corrosion agents gear units contamination or other impurities use a commercially available solvent Do not let the solvent come into contact with the sealing lips of the oil seals or the wide V belt damage to the material may result Please note The service life of the lubricant in the bearings is reduced if the unit is stored for more than one 1 year The enclosed wide V belt must be installed 4 3 Installation of VARIBLOC The variable speed geared motor may be mounted or installed only in the specified position on a level vibration free and torsionally rigid support structure Do not tighten housing legs and mounting flanges against each other Please note VARIBLOC design HS handwheel with position indication must be mounted so that the adjusting spindle is horizontal otherwise the position indication will not function properly The breather valves must be easily accessible The plastic plug of the condensate drain hole at the lowest position must be removed prior to operation danger of corrosion Carefully align the motor and driven machine to avoid overloading the motor shaft observe approved overhung loads and axial forces Do not hammer or hit the shaft end Protect vertically mounted motors with an appropriate cover aga
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