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1. SLED SE RENE Operating Instructions P002 P082 Series Planetary Gear Units 45 131 00 08 23 3 Gear Unit Design Mounting position sheets 344 PF KF 270 T 45 132 00 08 amp amp 480 eA 0 180 L D a O X Uc X 90 B me UU OC TOR REUTERS a a EI 24 Operating Instructions P002 P082 Series Planetary Gear Units Gear Unit Design 3 Mounting positions of the primary gear units 3 5 Mounting positions of the primary gear units TIP In addition to the mounting position the following information
2. 12 13 Storage location 13 Storage UME retail 13 Surface temperature 60 Symbols on the gear unit 9 Temperature sensor PT100 Dimensions 56 Electrical 56 Technical data 56 Tightening torque for gear unit mounting 39 Tightening torques for torque arms 41 Tolerances idet eei edens 32 32 TOrq e arm in xenon nn fees 30 41 Transportes ee mte 10 Transport conditions 12 Transport damage 10 Operating Instructions P002 P082 Series Planetary Gear Units EURODRIVE EURODRIVE SEW EURODRIVE Driving the world Drive Technology Drive Automation System Integration Services
3. 52 64 Input shaft assembly with backstop AD RS 55 Input shaft assembly with centering shoulder AD ZR 53 INSPECHON teer idee ped 62 Inspection intervals 63 Installation tenor 32 Installation nee 33 Installing the gear 35 Internal corrosion protection 12 61 L Long term protection internal corrosion protection12 Lubricant change 5 65 Lubricant fill quantities 80 Lubricant table for planetary gear units 78 Lubricants est ste seit exec 76 M Maintenance 62 Maintenance 63 Malf nctlons ied trs st ta 71 sn ec e chelates eed eid 32 Mounting input 5 37 Mounting notes 33 Mounting of couplings sseeeeeeeeeeeeeeresseeerrrsseeenss 39 Mounting position 19 Operating Instructions P002 P082 Series Planetary Gear Units 92 Mounting position sheets 20 GY 20 hei at id 24 PESREZZ aie ee ce
4. Fault Possible cause Remedy Unusual regular running noise Meshing grinding noise Bearing damage Check the oil replace the bearing Knocking noise Irregularity in the gearing Contact customer service Unusual irregular run ning noise Foreign objects in the oil Checking the oil Stop the drive contact customer service Oil is leaking 1 At the inspection cover At the motor flange At the motor oil seal At the gear unit flange At the output end oil seal Rubber seal on the inspection cover leaking Tighten the screws on the gear cover plate and observe the gear unit If oil still leaks Contact customer service Seal defective Contact customer service Gear unit not ventilated Vent gear unit Oil leaking from breather valve Too much oil Correct the oil level Drive operated in incorrect mounting position e Install the breather valve correctly e Correcting the oil level Frequent cold starts oil foams and or high oil level Use an oil expansion tank Output shaft does not turn although the motor is running or the input shaft is rotated Connection between shaft and hub in gear unit interrupted Send in the gear unit gearmotor for repair Operating temperature at backstop too high No blocking function Damaged defective backstop e Check backstop replace if necessary Contact customer service 1 Short
5. wh Industrial Gear Units POO2 PO82 Series Planetary Gear Units Edition 10 2008 Operating Instructions 16649613 EN SEW EURODRIVE Driving the world Contents Contents 1 Important Notes aa Ea aaa a amaaa ANa raa aaa aa aaa aiaiai 5 1 1 How to use the operating instructions 5 1 2 Structure of the safety notes 5 1 3 Rights to claim under warranty sssseee 6 1 4 Exclusion of liability ret a 6 Ton eie trm ans a eid eda d Fiere crea 6 2 Safety Notes etre centi tepore ceste tie ce ere ER OD oleo re Pio Ce cia 7 2 1 Preliminary remark ss 7 2 2 General information 7 2 9 Designated USC eel td 7 2 4 Applicable documents 8 2 52 Largetgroupsizs cioe seme DR eei bs Mete 8 2 60 Disposal cite e enn len D e tede ete 8 2 7 Safety symbols on the gear unit 9 2 68 Transport oue eie 10 2 9 Storage and transport conditions 12 3 Gear Unit Design ertet ertt reor teen EE tren 14 3 1 Combination of planetary gear unit with primary gear unit 14 3 2 Nameplate and unit designation 15 3 8 r Mounting Postos ae o eroe he ptr e s 19 3 4 Mounting position sheets sssssssen emen 20 3 5 Mounting posi
6. P002 P082 Series Planetary Gear Units Installation Assembly Gear units with solid shaft 5 6 Gear units with solid shaft 5 6 1 Mounting input and output components NOTICE Bearing hosing or shaft may be damaged due to improper assembly Potential damage to property Only use a mounting device for installing input and output elements Use the center bore and the thread on the shaft end for positioning Never force belt pulleys couplings pinions etc onto the shaft end by hitting them with a hammer This will damage the bearings housing and the shaft nthe case of belt pulleys make sure the belt is tensioned correctly in accordance with the manufacturer s instructions Assembly with The following figure shows a mounting device for installing couplings or hubs on gear mounting device unit or motor shaft ends Should you be able to tighten the screw without any problems you may not need the thrust bearing on the mounting device 211368587 1 Gear shaft end 2 Thrust bearing 3 Coupling hub Operating Instructions P002 P082 Series Planetary Gear Units 37 5 Installation Assembly Gear units with solid shaft Avoid excessive Avoid high overhung loads by Installing the gear or chain sprocket according to figure overhung loads A if possible 1 M YS H jdpe
7. 1 2 Observe the notes in section Preliminary work regarding inspection maintenance see page 62 Check the oil level according to the following figure 460483980 1 The oil level must be within this range 3 Proceed as follows if the oil level is too low e Open the oil fill plug Fill in new of the same type via the oil fill plug up to the mark Screw in the oil fill plug 7 5 Checking the oil consistency 1 A N Observe the notes in section Preliminary work regarding inspection maintenance see page 62 Determine the position of the oil drain plug and place a container underneath Unscrew the oil drain plug slowly and take an oil sample Re insert the oil drain plug Check the oil consistency For more detailed information on checking the oil for water content and viscosity contact your lubricant manufacturer f you can see that the oil is heavily contaminated change the oil even if this is outside of the specified oil change intervals Operating Instructions P002 P082 Series Planetary Gear Units 67 68 7 6 7 6 1 Inspection Maintenance Changing the oil Changing the oil Notes NOTICE Improper oil change may result in damages to the gear unit Potential damage to property Note the following When changing the oil always refill the gear unit with the grade of oil that was used before Mixing oils of different gr
8. i X1 2 85 1 1 A B X1 lt gt 1055550219 1 A unfavorable B correct TIP Mounting is easier if you first apply lubricant to the output element or heat it up briefly to 80 140 C 38 Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly Gear unit mounting for foot mounted units 5 6 2 Coupling mounting A CAUTION Input and output components such as belt pulleys couplings etc are in fast motion dur ing operation Risk of jamming and crushing Cover input and output components with a touch guard Adjust the following misalignments according to the coupling manufacturer s specifica tions when mounting couplings a Maximum and minimum clearance b Axial offset c Angular offset 211395595 Gear unit mounting for foot mounted units The following table shows the thread sizes and the tightening torques of the individual gear unit sizes Tightening torque screw nut Size Screw nut Number Strength class 8 8 P002 M20 012 M20 410 P022 M20 P032 M24 710 P042 M30 8 1450 P052 M36 P062 M36 SPUR P072 M42 4000 P082 M42 4000 TIP The bolts must not be lubricated during assembly Operating Instructions P002 P082 Series Planetary Gear Units 39 Installation Assembly Gear unit mou
9. Ambient temperature Manufacturer Type Gear unit anti friction 5 2 bearings 40 C 80 C Fuchs Renolit CX TOM 15 30 40 Castrol Obeen F82 WY See 20 40 C Aralube BAB EP2 SAI TIP The following grease quantities are required Forfast running bearings gear unit input end Fill the cavities between the rolling elements one third full with grease Forslow running bearings gear unit input side Fill the cavities between the rolling elements two thirds full with grease Operating Instructions P002 P082 Series Planetary Gear Units T9 9 Lubricants Lubricant fill quantities 9 3 Lubricant fill quantities The specified fill quantities are recommended values The precise values vary depend ing on the number of stages and gear ratios Check the oil level in a planetary gear unit at the oil sight glass or the dipstick and primary gear unit at the oil level screw TIP In case of a pivoted mounting position refer to the oil fill quantity specified on the name plate 9 3 1 Planetary gear units 7 Fill quantity in liters Size M1 M2 M3 M4 M5 M6 002 4 7 4 7 4 4 012 6 11 6 11 6 6 022 8 14 8 14 8 8 032 11 20 11 20 11 11 042 15 29 15 29 15 15 052 20 38 20 38 20 20 062 25 48 25 48 25 25 072 30 58 30 58 30 30 082 40 83 40 83 40 40 9 3 2 Helical RF p
10. P002 P082 Series Planetary Gear Units 10 87 10 Address List Norway Assembly Moss SEW EURODRIVE A S Tel 47 69 24 10 20 Sales Solgaard skog 71 Fax 47 69 24 10 40 Service N 1599 Moss http www sew eurodrive no sew sew eurodrive no Peru Assembly Lima SEW DEL PERU MOTORES REDUCTORES Tel 51 1 3495280 Sales S A C Fax 51 1 3493002 Service Los Calderos 120 124 http www sew eurodrive com pe Urbanizacion Industrial Vulcano ATE Lima sewperu sew eurodrive com pe Poland Assembly Lodz SEW EURODRIVE Polska 2 Tel 48 42 67710 90 Sales ul Techniczna 5 Fax 48 42 67710 99 Service PL 92 518 d http www sew eurodrive pl sew sew eurodrive pl 24 Hour Service Tel 48 602 739 739 48 602 SEW SEW sewis sew eurodrive pl Portugal Assembly Coimbra SEW EURODRIVE LDA Tel 351 231 20 9670 Sales Apartado 15 Fax 351 231 20 3685 Service P 3050 901 Mealhada http www sew eurodrive pt infosew sew eurodrive pt Romania Sales Bucuresti Sialco Trading SRL Tel 40 21 230 1328 Service str Madrid nr 4 Fax 40 21 230 7170 011785 Bucuresti sialco sialco ro Russia Assembly St Petersburg ZAO SEW EURODRIVE Tel 7 812 3332522 7 812 5357142 Sales P O Box 36 Fax 7 812 3332523 Service 195220 St Petersburg Russia http www sew eurodrive ru sew sew eurodrive ru Senegal Sales Dakar SENEMECA Tel 221 338 494 770 M canique G n rale Fax
11. During operation the backstop permits rotation in one specified direction of rotation only NOTICE Operating the motor in the direction that is blocked could destroy the backstop Potential damage to property Do not start up the motor in the blocking direction Be sure that the motor power supply is correctly attached so that the motor rotates in the required direction The backstop can be operated in blocking direction with half the output torque once for control purposes 1044634507 The direction of rotation is determined with a view to the output shaft LSS Clockwise CW Counterclockwise CCW The permitted direction of rotation is indicated on the housing Operating Instructions P002 P082 Series Planetary Gear Units 59 6 60 xd Startup Measuring the surface and oil temperature 6 5 6 5 1 Measuring the surface and oil temperature Measuring the surface temperature It is essential to measure the surface temperature under maximum load when starting up the gear unit The measurement can be made using commercially available thermometers The sur face temperature must be measured in a steady state condition It may not exceed 100 C Stop the drive immediately if the temperature is above this value Consult SEW EURODRIVE The measuring of the surface temperature depends on the mounting position of the planetary gear unit The area marked in gray show
12. Installation Assembly Temperature sensor PT100 5 13 Temperature sensor PT100 5 13 1 Dimensions ee el PG9 PG11 35 Y 1 359154443 5 13 2 Electrical connection 359158539 1 2 Resistor element connection 5 13 3 Technical data Variant with immersion sleeves and changeable gauge slide Sensor tolerance K 0 3 0 005 x T corresponds to DIN IEC 751 class B T Oil temperature C Plug connector DIN EN 175301 803 PG9 IP65 The tightening torque for the retaining screw in the back of the plug connector for electrical connection is 0 25 Nm 56 Operating Instructions P002 P082 Series Planetary Gear Units Startup go 6 6 1 Startup Important notes on startup Important notes on startup NOTICE Improper startup may result in damages to the gear unit Potential damage to property Note the following RF KF primary gear units are normally delivered with oil fill Refer to the order doc uments for discrepancies Check the thermal rating heating for the following operating conditions High ambient temperatures above 45 C Mounting position M2 M4 and or motor speed above 1800 rpm Contact SEW EURODRIVE The most important technical data is included on the nameplate Additional data rel evant for operation is available in drawings order confirmations or any order specifi
13. Victoria 3043 http www sew eurodrive com au enquires sew eurodrive com au Sydney SEW EURODRIVE PTY LTD Tel 61 2 9725 9900 9 Sleigh Place Wetherill Park Fax 61 2 9725 9905 New South Wales 2164 enquires sew eurodrive com au Austria Assembly Wien SEW EURODRIVE Ges m b H Tel 43 1 617 55 00 0 Sales Richard Strauss Strasse 24 Fax 43 1 617 55 00 30 Service A 1230 Wien http sew eurodrive at sew sew eurodrive at Belarus Sales Minsk SEW EURODRIVE BY Tel 375 17 298 38 50 RybalkoStr 26 Fax 375 17 29838 50 BY 220033 Minsk sales sew by Belgium Assembly Br ssel SEW Caron Vector Tel 32 10 231 311 Sales Avenue Eiffel 5 Fax 32 10 231 336 Service B 1300 Wavre http www sew eurodrive be info caron vector be Service Compe tence Center Industrial Gears SEW Caron Vector Rue de Parc Industriel 31 BE 6900 Marche en Famenne Tel 32 84 219 878 Fax 32 84 219 879 http www sew eurodrive be service wallonie sew eurodrive be Antwerp SEW Caron Vector Tel 32 3 64 19 333 Glasstraat 19 Fax 32 3 64 19 336 BE 2170 Merksem http www sew eurodrive be service antwerpen sew eurodrive be Brazil Production Sao Paulo SEW EURODRIVE Brasil Ltda Tel 55 11 2489 9133 Sales Avenida Amancio Gaiolli 152 Rodovia Presi Fax 55 11 2480 3328 Service dente Dutra Km 208 http www sew eurodrive com br Guarulhos 07251 250 SP sew sew com br SAT SEW ATENDE 0800 7700496 Additional addresses for service in Br
14. correct if necessary Brake does not release see the motor operating instructions Fuse has blown Replace fuse Motor protection has triggered Check motor protection for correct setting correct error if necessary Motor protection does not switch error in control Check motor protection control correct error if necessary Motor only starts with diffi culty or does not start at all Motor designed for delta connection but used in start connection Correct connection Voltage or frequency deviate considerably from setpoint at least while being switched on Provide better power supply system check cross section of supply cable Motor does not start in star connection only in delta connection Star connection does not provide sufficient torque Switch on directly if delta inrush current is not too great else use a larger motor or a special design contact SEW EURODRIVE Contact fault on star delta switch Rectify fault Incorrect direction of rota tion Motor connected incorrectly Swap over two phases Motor hums and has high current consumption Brake does not release gt see the motor operating instructions Winding defective Rotor rubbing Send motor to specialist workshop for repair Fuses blow or motor pro tection trips immediately Short circuit in line Repair short circuit Short circuit in motor Send motor to specialist works
15. http www sew eurodrive It Luxembourg Assembly Br ssel CARON VECTOR S A Tel 32 10 231 311 Sales Avenue Eiffel 5 Fax 32 10 231 336 Service B 1300 Wavre http www sew eurodrive lu info caron vector be Malaysia Assembly Johore SEW EURODRIVE SDN BHD Tel 60 7 3549409 Sales No 95 Jalan Seroja 39 Taman Johor Jaya Fax 60 7 3541404 Service 81000 Johor Bahru Johor sales sew eurodrive com my West Malaysia Mexico Assembly Qu retaro SEW EURODRIVE MEXICO SA DE CV Tel 52 442 1030 300 Sales SEM 981118 M93 Fax 52 442 1030 301 Service Tequisquiapan No 102 http www sew eurodrive com mx Parque Industrial Qu retaro scmexico seweurodrive com mx C P 76220 Qu retaro M xico Morocco Sales Casablanca Afit Tel 212 22618372 5 rue Emir Abdelkader Fax 212 22618351 MA 20300 Casablanca ali alami premium net ma Netherlands Assembly Rotterdam VECTOR Aandrijftechniek B V Tel 31 10 4463 700 Sales Industrieweg 175 Fax 31 10 4155 552 Service NL 3044 AS Rotterdam http www vector nu Postbus 10085 info vector nu NL 3004 AB Rotterdam New Zealand Assembly Auckland SEW EURODRIVE NEW ZEALAND LTD Tel 64 9 2745627 Sales P O Box 58 428 Fax 64 9 2740165 Service 82 Greenmount drive http www sew eurodrive co nz East Tamaki Auckland sales sew eurodrive co nz Christchurch SEW EURODRIVE NEW ZEALAND LTD Tel 64 3 384 6251 10 Settlers Crescent Ferrymead Christchurch Fax 64 3 384 6455 sales sew eurodrive co nz Operating Instructions
16. in no way represents a guarantee as to the quality of the lubricant delivered by each respective supplier Each lubricant manufacturer is responsible for the quality of its product Ensure that the planetary gear units and primary gear units are filled with the correct oil grade and volume before startup You can obtain the corresponding information from the gear unit nameplate and the lubricant table on the following page The lubricant fill quantity and viscosity with planetary geared motors with shared oil chamber depends only on the information on the nameplate of the planetary gear unit Planetary gear units and the primary gear units are delivered without oil fill Do not mix different synthetic lubricants and do not mix synthetic with mineral lubricants Operating Instructions P002 P082 Series Planetary Gear Units Lubricants Permitted lubricants 9 2 Permitted lubricants 9 2 1 General information The lubricant table on the following page shows the permitted lubricants for gear units Refer to the following legend for the lubricant table 9 2 2 Legend for the lubricant table Abbreviations meaning of shading and notes CLP Mineral oil CLP HC Synthetic polyalphaolefin Synthetic lubricant synthetic based anti friction bearing grease Mineral lubricant mineral based anti friction bearing grease Qu 1 Ambient temperature q 40 0 50 2 Pay attention to critical starting behavior at low t
17. 1 it 23 59 O kg 234 Schmierstoff CLP HC 220 Synt O1 1 51 Made in Germany 181 861 9 14 J 210927627 fb Service factor FRamax Maximum overhung load on the output side max N Maximum overhung load on the input side with input shaft assembly AD i Gear unit reduction ratio IM Mounting position IP Enclosure max 1 min maximum input speed na 1 min 7 output speed maximum input torque M Nm Output torque Mg Nm 7 Overload torque when using an AR adapter Mrs Nm Locking torque of the backstop Unit designation TIP For a detailed overview of unit designations and additional information refer to the fol lowing publications Gear Units catalog or Gearmotors catalog Example Helical gear units RF 47 For direct motor mounting Gear unit size Helical gear unit series flange mounted Operating Instructions P002 P082 Series Planetary Gear Units 3 Gear Unit Design Nameplate and unit designation 3 2 3 Primary gear unit with motor Sample nameplate S EVN 3 Bruchsal Germany 3 KF97 DRS160M4 Nr 01 3998708401 0001 01 3 IEC60034 1 min 1460 26 kW 11 S1 i 56 55 Nm 4070 V 400 690A Y cos 0 81 eff 90 7 V 380 420 A 660 725Y 22 5 13 0 130 B IM M1 IP 54 Hz 50 0 TP CLP 220 Miner I 7 0 kg 251 000 14197
18. 221 338 494 771 Km 8 Route de Rufisque senemeca sentoo sn B P 3251 Dakar Serbia Sales Beograd DIPAR Tel 381 11 347 3244 381 11 288 Ustanicka 128a 0393 PC Ko um IV floor Fax 381 11 347 1337 SCG 11000 Beograd office dipar co yu Singapore Assembly Singapore SEW EURODRIVE PTE LTD Tel 65 68621701 Sales No 9 Tuas Drive 2 Fax 65 68612827 Service Jurong Industrial Estate http www sew eurodrive com sg Singapore 638644 sewsingapore sew eurodrive com 88 Operating Instructions P002 P082 Series Planetary Gear Units Address List Slovakia Sales Bratislava SEW Eurodrive SK s r o Tel 421 2 33595 202 Rybni na 40 Fax 421 2 33595 200 SK 831 06 Bratislava sew sew eurodrive sk http www sew eurodrive sk Zilina SEW Eurodrive SK s r o Tel 421 41 700 2513 Industry Park PChZ Fax 421 41 700 2514 ulica M R Stefanika 71 sew sew eurodrive sk SK 010 01 Zilina Bansk Bystrica SEW Eurodrive SK s r o Tel 421 48 414 6564 Rudlovsk cesta 85 Fax 421 48 414 6566 SK 974 11 Bansk Bystrica sew sew eurodrive sk KoSice SEW Eurodrive SK s r o Tel 421 55 671 2245 Slovenska ulica 26 Fax 421 55 671 2254 SK 040 01 KoSice sew sew eurodrive sk Slovenia Sales Celje Pakman Pogonska Tehnika d o o Tel 386 3 490 83 20 Service UI XIV divizije 14 Fax 386 3 490 83 21 SLO 3000 Celje pakman siol net South Africa Assembly Johannesburg SEW EURODRIVE PROP
19. 6 months Check torsional play e Visually check the elastic annular gear Check running noise for possible bearing damage Visually check the adapter for leakage After 25 000 30 000 hours of operation Renew the anti friction bearing grease Replace oil seal do not install it in the same track Change the elastic annular gear 7 2 4 AD input shaft assembly Time interval Required maintenance inspection steps Every 3000 operating hours at least every 6 months Check running noise for possible bearing damage Visually check the adapter for leakage After 25 000 30 000 hours of operation Renew the anti friction bearing grease Replace the oil seal 64 Operating Instructions P002 P082 Series Planetary Gear Units Inspection Maintenance Lubricant change intervals 7 3 Lubricant change intervals Change the oil more frequently when using special designs subject to more severe ag gressive ambient conditions TIP Mineral CLP lubricants and synthetic polyalphaolefin based PAO lubricants are used for lubrication The synthetic lubricant CLP HC according to DIN 51502 shown in the following illustration corresponds to the PAO oils 30000 h 25000 20000 m 15000 10000 A 70 80 90 100 110 120 1 Operating hours 2 Sustained oil bath temperature Average value per oil type at
20. 70 C TIP In order to optimize the lubrication change intervals SEW EURODRIVE recommends that the gear unit oil be analyzed regularly see section 7 5 Operating Instructions P002 P082 Series Planetary Gear Units 65 7 Inspection Maintenance Checking the oil level 7 4 Checking the oil level NOTICE Improper checking of the oil level may result in damages to the gear unit Potential damage to property Check the oil level only when the gear unit has come to a standstill and a waiting period of 5 min has elapsed This ensures that the oil accumulates in the gear unit interior 7 4 4 Gear units with oil dipstick 1 Observe the notes in section Preliminary work regarding inspection maintenance see page 62 Unscrew the dipstick and remove it Clean the oil dipstick and re insert it by turning it hand tight into the gear unit up to the stop 4 Remove the oil dipstick and check the oil level i 1 460483852 1 The oil level must be within this range 5 Proceed as follows if the oil level is too low Open the oil fill plug Fill in new oil of the same type via the oil fill plug up to the mark Screw the oil fill plug 6 Re insert the oil dipstick 66 Operating Instructions P002 P082 Series Planetary Gear Units Inspection Maintenance 7 Checking the oil consistency 7 4 2 Gear unit with oil sight glass
21. Change the braking torque gt see motor operating instructions Bythe type and number of brake springs Brake BMG 05 by installing the same brake coil body design as in brake BMG 1 Brake BMG 2 by installing the same brake coil body design as in brake BMG 4 BM G only Working air gap so large that set ting nuts come into contact Setting the working air gap BR03 BM G only Manual brake release device not set correctly Set the setting nuts correctly Brake is applied with time lag Brake is switched on AC voltage side Switch on DC and AC voltage sides e g BSR refer to wiring diagram Noises in vicinity of brake Gearing wear caused by jolting startup Check project planning see motor operating instructions Operating Instructions P002 P082 Series Planetary Gear Units 75 9 Lubricants Lubricant selection 9 Lubricants 9 1 Lubricant selection NOTICE Selecting improper lubricants may result in damages to the gear unit Potential damage to property Note the following 76 The oil viscosity and type mineral synthetic that are to be used are determined by SEW EURODRIVE specifically for each order This information is noted in the order confirmation and on the gear unit s nameplate You must contact SEW EURODRIVE in case of a deviation from this specification This lubricant recommendation in chapter Lubricant table
22. Coupling of AM adapter Permitted loads NOTICE Potential damage to property Impermissibly high loads may occur when mounting a motor The load data specified in the following table are not to be exceeded 1178689291 Adapter type Fa N IEC NEMA x mm IEC adapter NEMA adapter AM63 71 AM56 77 530 410 80 90 143 145 113 420 380 100 112 182 184 144 2000 1760 1322 213 21522 m 1600 1250 AM132 AM213 215 4700 3690 160 180 254 286 251 4600 4340 AM200 225 AM324 AM365 297 5600 5250 AM250 280 390 11200 1 The maximum permitted weight of the attached motor must be reduced linearly as the cen ter of gravity distance x increases If this distance is reduced the maximum permitted weight Fqmax Cannot be increased 2 Diameter of the adapter output flange 160 mm Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly Coupling of AM adapter AM RS adapter Check the direction of rotation of the drive prior to assembly or startup Please inform AM with backstop the SEW EURODRIVE service in the case of incorrect direction of rotation The backstop is maintenance free in operation and does not require any further main tenance work Backstops have a minimum lift off speed depending on the size see fol lowing table CAUTION Potential damag
23. Haguenau SEW USOCOME Tel 33 3 88 73 67 00 Sales 48 54 route de Soufflenheim Fax 33 3 88 73 66 00 Service B P 20185 http www usocome com F 67506 Haguenau Cedex sew usocome com Production Forbach SEW EUROCOME Tel 33 3 87 29 38 00 Zone Industrielle Forbach Sud B P 30269 F 57604 Forbach Cedex Assembly Bordeaux SEW USOCOME Tel 33 5 57 26 39 00 Sales Parc d activit s de Magellan Fax 33 5 57 26 39 09 62 avenue Magellan 182 F 33607 Pessac Cedex Lyon SEW USOCOME Tel 33 4 72 15 37 00 Parc d Affaires Roosevelt Fax 33 4 72 15 37 15 Rue Jacques Tati F 69120 Vaulx en Velin Paris SEW USOCOME Tel 33 1 64 42 40 80 Fax 33 1 64 42 40 88 Additional addresses for service in France provided on request 82 Operating Instructions P002 P082 Series Planetary Gear Units Address List Algeria Sales Alger R ducom Tel 213 21 8222 84 16 rue des Fr res Zaghnoun Fax 213 21 8222 84 Bellevue El Harrach reducom_sew yahoo fr 16200 Alger Argentina Assembly Buenos Aires SEW EURODRIVE ARGENTINA S A Tel 54 3327 4572 84 Sales Centro Industrial Garin Lote 35 Fax 54 3327 4572 21 Service Ruta Panamericana Km 37 5 sewar sew eurodrive com ar 1619 Garin http www sew eurodrive com ar Australia Assembly Melbourne SEW EURODRIVE PTY LTD Tel 61 3 9933 1000 Sales 27 Beverage Drive Fax 61 3 9933 1003 Service Tullamarine
24. Service 12 Mavromichali Street Fax 30 2 1042 251 59 P O Box 80136 GR 18545 Piraeus http www boznos gr info boznos gr Operating Instructions P002 P082 Series Planetary Gear Units 10 85 1 0 Address List Hong Kong Assembly Hong Kong SEW EURODRIVE LTD Tel 852 36902200 Sales Unit No 801 806 8th Floor Fax 852 36902211 Service Hong Leong Industrial Complex contact sew eurodrive hk No 4 Wang Kwong Road Kowloon Hong Kong Hungary Sales Budapest SEW EURODRIVE Kft Tel 36 1 437 06 58 Service H 1037 Budapest Fax 36 1 437 06 50 Kunigunda u 18 office sew eurodrive hu India Assembly Vadodara SEW EURODRIVE India Private Limited Tel 91 265 2831086 Sales Plot No 4 GIDC Fax 91 265 2831087 Service POR Ramangamdi Vadodara 391 243 http www seweurodriveindia com Gujarat sales seweurodriveindia com subodh ladwa seweurodriveindia com Ireland Sales Dublin Alperton Engineering Ltd Tel 353 1 830 6277 Service 48 Moyle Road Fax 353 1 830 6458 Dublin Industrial Estate info alperton ie Glasnevin Dublin 11 http www alperton ie Israel Sales Tel Aviv Liraz Handasa Ltd Tel 972 3 5599511 Ahofer Str 34B 228 Fax 972 3 5599512 58858 Holon http www liraz handasa co il office Oliraz handasa co il Italy Assembly Milano SEW EURODRIVE Blickle 4 Co s a s Tel 39 02 96 9801 Sales Via Bernini 14 Fax 39 02 96 79
25. and Additional Features 4 Input components 4 Structure of Options and Additional Features 41 Input components The following figure shows an overview of the components on the the input side DR S AD ZR AD AD RS J AR WS AT RS gt AT BM G Operating Instructions P002 P082 Series Planetary Gear Units 29 4 Structure of Options and Additional Features Torque arm 42 Torque arm A torque arm is available to support the reaction torque of solid and hollow shaft gear units in the shaft mounted version The torque arm can bear tensile stress as well as thrust loads 4 2 1 Single sided torque arm The torque arm is enclosed in the delivery or can be mounted according to customer re quirements The retaining screws are included in the scope of delivery The following figure shows a sample combination of a planetary gearmotor with a torque arm on one side 1138611211 43 PT100temperature sensor The temperature sensor PT100 can be used to measure the temperature of the oil in the gear unit The temperature sensor is located in the gear unit s oil sump The exact position de pends on the gear unit variant 30 Operating Instructions P002 P082 Series Planetary Gear Units Structure of Options and Additional Features Oil expansion tank oil riser pipe 4 44 Oil expansion ta
26. gear units 3 5 2 RF primary helical gear unit For the primary helical gear units RF positions 0 90 180 or 270 are fixed To reduce the churning losses in the primary gear unit to a minimum SEW EURODRIVE recommends to choose from the standard mounting positions displayed below TIP Contact SEW EURODRIVE in case of deviating mounting positions 1043719691 Key M1 2 4 5 6 Mounting position of planetary gear unit 0 90 180 270 cur AE position of primary helical gear Operating Instructions P002 P082 Series Planetary Gear Units 27 Gear Unit Design Pivot mounting position 3 6 Pivot mounting position Pivot mounting positions are mounting positions which differ from the standard mounting positions The designation of the pivot mounting positions is set up as follows M1 M4 208 Dp 3 1 Starting mounting position 2 Target mounting position 3 Pivoting angle The following figure shows 4 examples 5 20 M1 M6 20 40 14 er M5 M1 30 1 2 30 TIP Pivot mounting positions may involve restrictions for accessories and technical data and possibly longer delivery times Contact SEW EURODRIVE 28 Operating Instructions P002 P082 Series Planetary Gear Units Structure of Options
27. may have oc curred during transportation Inform the shipping company immediately in the event of damage It may be necessary to preclude startup The weight of the gear unit is indicated on the nameplate or the dimension sheet Ob serve the loads and specifications given on the nameplate Use suitable sufficiently rated handling equipment if necessary The gearunit must be transported in a manner that prevents damage to the gear unit For example impacts against exposed shaft ends can damage the gear unit Planetary gear units and planetary gearmotors are suspended from the transport points marked in the drawings below Transport straps indicated with broken lines in the following figures help balancing and supporting the planetary gear unit Remove securing devices used for transportation prior to startup Operating Instructions P002 P082 Series Planetary Gear Units Safety Notes 2 Transport 2 8 2 Foot mounted planetary gear unit The following figure shows an example of how to transport a foot mounted planetary gear unit 2 8 3 Flange mounted planetary gear unit The following figure shows an example of how to transport a flange mounted planetary gear unit Operating Instructions P002 P082 Series Planetary Gear Units 11 2 Safety Notes Storage and transport conditions 2 9 Storage and transport conditions 2 9 1 Internal corrosion protection Standard After the test run t
28. packaging The gear unit is attached to a pallet wrapped in film and equipped with appropriate cor rosion protection material in the film packaging Application Land transport and for long term storage Seaworthy packaging The gear unit is packaged in a seaworthy wooden box and is delivered on a pallet that is appropriate for sea transport The gear unit is wrapped in a film and equipped with appropriate corrosion protection material in the film packaging Application Sea transport and for long term storage 12 Operating Instructions P002 P082 Series Planetary Gear Units Safety Notes Storage and transport conditions 2 9 4 Storage conditions NOTICE Improper storage may result in damages to the gear unit Potential damage to property The gear unit must be stored in a shock free manner in order to prevent damage to the anti friction bearing races The gear units are delivered without an oil fill different protection systems are required depending on storage period and storage conditions Climate zone Packaging corrosion protection Storage location Storage duration Temperate Europe USA Canada China and Russia excluding tropical zones Long term packaging Long term corrosion protec tion With roof protected against rain and snow no shock loads Up to three years with regular checks of the packaging and moisture indicator Relative humidity
29. reduced if the unit is stored for 2 1 year only applies to bearings with grease lubrication Replace the enclosed breather with the corresponding screw plug 5 4 2 Oil filling process Fill the gear unit with the oil grade and oil volume specified on the nameplate The amount depends on the mounting position and the lubrication type Checkoil level using the oil level glass or the oil dipstick 34 Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly Installing the gear unit 5 5 Installing the gear unit 5 5 1 Breather valve with RF KF primary gear unit Check whether the breather valve is activated If the breather valve has not been acti vated you must remove the transport fixture from the breather valve before starting up the gear unit 1 Breather valve with transport fixture 211319051 2 Remove the transport fixture 2 211316875 3 Activated breather valve ES 211314699 Operating Instructions P002 P082 Series Planetary Gear Units 35 Installation Assembly Installing the gear unit 5 5 2 Foundation To ensure quick and successful mounting the type of foundation should be correctly se lected and the mounting carefully planned in advance Foundation drawings with all nec essary construction and dimension details should be available To avoid harmful vibrations and oscillations adequate rigidity must be ensured when mounti
30. term oil grease leakage at the oil seal is possible in the run in phase 48 hours running time 8 5 Malfunctions of AM AL adapters Fault Possible cause Remedy Unusual regular running noise Meshing grinding noise Bearing damage Contact SEW EURODRIVE customer service Cil is leaking Seal defective Contact SEW EURODRIVE customer service Output shaft does not turn although the motor is running or the input shaft is rotated Connection between shaft and hub in gear unit interrupted Send in gear unit to SEW EURODRIVE for repair Change in running noise and or vibrations Annular gear wear short term torque transfer through metal contact Change the annular gear Bolts to secure hub axially are loose Tighten the screws Premature wear in annu lar gear Contact with aggressive fluids oils ozone influence too high ambient temperatures etc which can cause a change in the physical properties of the annular gear Impermissibly high ambient contact temperature for the annular gear maximum permitted temperature 20 to 80 Overload Contact SEW EURODRIVE customer service Operating Instructions P002 P082 Series Planetary Gear Units T3 Malfunctions Malfunctions of the motor 8 6 Malfunctions of the motor Fault Possible cause Remedy Motor does not start up Supply cable interrupted Check connections
31. 0 Center bores to DIN 332 D gt 85 130mm gt M24 gt 130 180 M30 1 Dimensions not according to DIN 332 the thread depth including the counterbore is at least twice that of the rated thread diameter Keys according to DIN 6885 domed type Centering shoulder tolerance ISO f7 Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly Notes on installation mounting 5 3 Notes on installation mounting NOTICE Improper installation mounting may result in damages to the gear unit Potential damage to property Note the following Strictly observe the safety notes in the individual chapters The planetary gear units are delivered without oil fill RF KF primary gear units have a lubricant fill in accordance with their mounting po sition The oil chambers of both gear units are separate Exceptions are specifically identi fied as such The most important technical data is included on the nameplate Additional data rel evant for operation is available in drawings order confirmations or any order specific documentation The mounting position may only be changed after consultation with SEW EURO DRIVE The warranty will become void without prior consultation Oil expansion tanks and or an oil riser pipe are required if you change to a vertical mounting position Adjust the lubricant fill quantities and the position of the breather va
32. 22 DA 022 X 1eoBndo 099 uju s 1899 959 JHS 089 WM 089 739 089 qow arowan UE ereuo 089 9 uljouay 089 OLSL 1031 089 X 2neuju S 089 0201513 1eoBndo 09v 10121 1031 WUAs 1289 759 DHS 09v 1015 UBIHUIOUSX WM 09Y 4X da NO9r VIW3O 097 09v da UR 02915 13 d19 uAsiun u s19uz BIEWO IUS oorawx 5 JeeBliqon OZE 10121 109111 oze 10181 103 Oze uyufs 200 229 DHS W IHUNOU H 026 ax da ozesva Mirco REIS CESSARE 419 9I euuld u sjeua dg Iys OZE X 1eoBndo JeoBliqon 0S L 00LL snid 051 412 OSL dX009 OSL IX Y9 SnIdOSL NOSL L W39 JeeBliqon osi 9 0 LN ost am 061 edoJ9W 98 10690 43907H n 051 ds OZZ 00LL ozz 1899 022 dX009 ozz AX H9 snid 022 2 0224 eewo ozz 0zz LN ozz ufsiun 022 edoisn da 9g106eq 1945 dWX 022 dS eudiv 089 0011 1031 089 1
33. 225 until stop at motor shaft shoulder IEC adapter AM250 280 to dimension A NEMA adapter with spacer tube 491 to dimension A 4 Secure the key and coupling half using the setscrew 481 and tightening torque according to the table on the motor shaft 48 Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly Coupling of AM adapter 5 Check the dimension A 6 Seal the contact surfaces between the adapter and motor using a suitable sealing compound 7 Mount the motor on the adapter Ensure that the coupling claw of the adapter shaft is engaged in the plastic cam ring IEC AM 63 71 80 90 100 112 132 160 180 200 225 250 280 24 5 31 5 41 5 54 76 78 5 93 5 139 1 5 1 5 4 8 4 8 10 17 17 17 Thread M4 M4 M6 M6 M8 M10 M10 M10 NEMA AM 56 143 145 182 184 213 215 254 256 284 286 324 326 364 365 A 46 43 55 63 5 78 5 85 5 107 107 Ta 1 5 1 5 4 8 4 8 10 17 17 17 Thread M4 M4 M6 M6 M8 M10 M10 M10 TIP To avoid contact corrosion we recommend applying NOCOS Fluid to the motor shaft before mounting the coupling half NOTICE Dampness might enter the adapter when mounting a motor to the adapter Potential damage to property Seal adapter with anaerobic fluid seal Operating Instructions P002 P082 Series Planetary Gear Units 49 50 Installation Assembly
34. 22611 Sales Tianjin 300457 info sew eurodrive cn Service http www sew eurodrive cn Assembly Suzhou SEW EURODRIVE Suzhou Co Ltd Tel 86 512 62581781 Sales 333 Suhong Middle Road Fax 86 512 62581783 Service Suzhou Industrial Park suzhou sew eurodrive cn Jiangsu Province 215021 Guangzhou SEW EURODRIVE Guangzhou Co Ltd Tel 86 20 82267890 No 9 JunDa Road Fax 86 20 82267891 East Section of GETDD guangzhou sew eurodrive cn Guangzhou 510530 Shenyang SEW EURODRIVE Shenyang Co Ltd Tel 86 24 25382538 10A 2 6th Road Fax 86 24 25382580 Shenyang Economic Technological Develop shenyang sew eurodrive cn ment Area Shenyang 110141 Wuhan SEW EURODRIVE Wuhan Ltd Tel 86 27 84478398 10A 2 6th Road Fax 86 27 84478388 No 59 the 4th Quanli Road WEDA 430056 Wuhan Additional addresses for service in China provided on request Colombia Assembly Bogota SEW EURODRIVE COLOMBIA LTDA Tel 57 1 54750 50 Sales Calle 22 No 132 60 Fax 57 1 54750 44 Service Bodega 6 Manzana B http www sew eurodrive com co Santaf de Bogota carlos gomez sew eurodrive com co Operating Instructions P002 P082 Series Planetary Gear Units Address List Croatia Sales Zagreb KOMPEKS 4 0 385 1 4613 158 Service PIT 4 Fax 385 1 4613 158 HR 10 000 Zagreb kompeks inet hr Czech Republic Sales Praha SEW EURO
35. 7 440 3799 Troy Ohio 45373 cstroy seweurodrive com Southwest SEW EURODRIVE INC Tel 1 214 330 4824 Region 3950 Platinum Way Fax 1 214 330 4724 Dallas Texas 75237 csdallas seweurodrive com Western Region SEW EURODRIVE INC Tel 1 510 487 3560 30599 San Antonio St Fax 1 510 487 6433 Hayward CA 94544 cshayward seweurodrive com Additional addresses for service in the USA provided on request Venezuela Assembly Valencia SEW EURODRIVE Venezuela S A Tel 58 241 832 9804 Sales Av Norte Sur No 3 Galpon 84 319 Fax 58 241 838 6275 Service Zona Industrial Municipal Norte http www sew eurodrive com ve Valencia Estado Carabobo ventas sew eurodrive com ve sewfinanzas cantv net Operating Instructions P002 P082 Series Planetary Gear Units Index A NE iem e e Ta e a a EE a 29 AD input shaft assembly 52 Adapter 64 Adapter with backstop AM RS 51 Additional features 29 Aligning the shaft 36 AM adapter ici it 29 Ambient conditions 34 AR adapter ceda 29 AT adapter earnest andes 29 Backstop anche PE hte de 59 Belt 37 Breather valve 33 35 Centering shoulder 0 32 Changing the oil 68 Checking a
36. 899 089 dX009 6 089 3X N9 089 1 IN39 0895 089 Wa 089 1 PAOD snidoggd19 089 edos w 1 want m 089 dS eudiv 089 0894719 uijousy seaBliqow 1299 09v 00LL loq uouoy dX009 4 9 0 NO9b L WHO 0974 eewo Wa 097 1 eoo 097 edo 1 di Moos JeoBligon 5 09vd12 025 1899 1oquL 4651H 028 dX009 es JX MO NOZ L 0224 025 2409 snidozed19 028 edoioW 98 10690 1945 uyjousy M OZE dWX JeoBliqon Oze OZEd19 i ssep OSI 101359 HON Jonosi 5 1200251787 Operating Instructions P002 P082 Series Planetary Gear Units 78 Lubricants Permitted lubricants 9 2 5 Sealing grease The anti friction bearings in RF KF primary gear units and motors are given a factory fill with the greases listed below SEW EURODRIVE recommends regreasing anti friction bearings with a grease fill at the same time as changing the oil Observe the separate operating instructions for RF KF primary gear units and motors
37. 91115 Type Unit designation No Serial number of primary gearmotor i Transmission ratio rpm min Input output speed Nm Nm Output torque kW Input power of the gear unit 1 Operating mode cos Power factor of the motor M Supply voltage for delta star connection A A Rated motor current in delta star connection Hz Hz Line frequency IM Mounting position kg kg Weight of the primary gearmotor IP Degree of protection of the motor Brake V IV Brake connection voltage Nm Nm Braking torque TA Oil grade and viscosity class oil volume Sample unit designation KF 97 DRS 160M4 Motor size number of poles Motor series Primary gear unit size Primary gear unit series 18 Operating Instructions P002 P082 Series Planetary Gear Units Gear Unit Design Mounting position Mounting position 3 3 The mounting position defines the spatial orientation of the gear unit housing and is des ignated M1 M6 The mounting positions apply to planetary gear units with solid shafts and hollows shafts 1028148619 19 Operating Instructions P002 P082 Series Planetary Gear Units 20 3 4 Gear Unit Design Mounting position sheets Mounting position sheets The following table shows the symbols used in the mounting position sheets and what they mean Symbol Description Breather valve Oil level plug Oil drain plu
38. 9781 Service 1 20020 Solaro Milano http www sew eurodrive it sewit sew eurodrive it Ivory Coast Sales Abidjan SICA Tel 225 2579 44 Ste industrielle et commerciale pour l Afrique Fax 225 2584 36 165 Bld de Marseille B P 2323 Abidjan 08 Japan Assembly Iwata SEW EURODRIVE JAPAN CO LTD Tel 81 538 373811 Sales 250 1 Shimoman no Fax 81 538 373814 Service Iwata http www sew eurodrive co jp Shizuoka 438 0818 sewjapan sew eurodrive co jp Korea Assembly Ansan City SEW EURODRIVE KOREA CO LTD Tel 82 31 492 8051 Sales B 601 4 Banweol Industrial Estate Fax 82 31 492 8056 Service 1048 4 Shingil Dong http www sew korea co kr Ansan 425 120 master sew korea co kr Busan SEW EURODRIVE KOREA Co Ltd Tel 82 51 832 0204 No 1720 11 Songjeong dong Fax 82 51 832 0230 Gangseo ku master sew korea co kr Busan 618 270 86 Operating Instructions P002 P082 Series Planetary Gear Units Address List Latvia Sales Riga SIA Alas Kuul Tel 371 7139253 Katlakalna 11C Fax 371 7139386 LV 1073 Riga http www alas kuul com info alas kuul com Lebanon Sales Beirut Gabriel Acar amp Fils sarl Tel 961 1 4947 86 B P 80484 961 1 4982 72 Hammoud Beirut 961 3 2745 39 Fax 961 1 4949 71 ssacar g inco com Ib Lithuania Sales Alytus UAB Irseva Tel 370 315 79204 Naujoji 19 Fax 370 315 56175 LT 62175 Alytus info irseva lt
39. A 22 23 PARE 21 Mounting positions of the primary gear units 25 MO iiiter pa PUR iia diria 19 N 15 NEMA adapter AM56 365 48 OM CHANGE 68 Oil expansion tank 31 Oil riserplp t iie Gert t nie lade eer 31 Oil Seals iut maar t ee 34 Oil temperature ne 60 OPTIONS P 29 Packaging ERES 12 Painting the gear unit 36 PictOgralms om 9 PIDIOD a 37 Pivoted mounting position 28 Preliminary work 34 Protection devices 33 PTT100 ehe 30 PT100 temperature sensor 30 R Refilling grease 70 Removing the shrink disk 46 Run in period 58 S Sealing grease 79 etes 34 SAT AXIS cen tuo 36 Shrink diSK c io ig 43 Shutting down gear units 61 Solid shaft ina 37 Standard packaging 12 Standard protection internal corrosion protection 12 Otartup xaiu det eer bita td etes 57 Stickers on the gear unit 9 Storage conditions
40. B 270 90 A 180 270 0 B 90 A 180 270 KF67 1 1 2 4 1 1 3 7 2 7 2 7 2 7 2 7 1 1 3 7 1 1 2 4 KF77 2 1 4 1 2 1 5 9 4 5 4 5 4 5 4 5 2 1 5 9 2 1 4 1 KF87 3 7 8 2 3 7 11 9 8 4 8 4 8 4 8 4 3 7 11 9 3 7 8 2 KF97 7 0 14 7 7 0 21 5 16 5 16 5 16 5 16 5 7 0 21 5 7 0 14 7 KF107 10 0 21 8 10 0 35 1 25 2 25 2 25 2 25 2 10 0 35 1 10 0 21 8 KF127 21 0 41 5 21 0 55 0 41 0 41 0 41 0 41 0 21 0 55 0 21 0 41 5 KF157 31 0 66 31 0 92 0 62 0 62 0 62 0 62 0 31 0 92 0 31 0 66 0 Fill quantity in liters M4 M5 M6 Size 0 A 90 A 180 270 A 90 180 270 A 0 B 90 A 180 A 270 KF67 2 7 2 7 2 7 2 7 2 4 1 1 3 7 1 1 3 7 1 1 2 4 1 1 KF77 4 5 4 5 4 5 4 5 4 1 2 1 5 9 2 1 5 9 2 1 4 1 2 1 87 8 4 8 4 8 4 8 4 8 2 3 7 11 9 3 7 11 9 3 7 8 2 3 7 97 15 7 15 7 15 7 15 7 14 7 7 0 21 5 7 0 21 5 7 0 14 7 7 0 107 25 2 25 2 25 2 25 2 21 8 10 0 35 1 10 0 35 1 10 0 21 8 10 0 127 41 0 41 0 41 0 41 0 41 5 21 0 55 0 21 0 55 0 21 0 41 5 21 0 157 62 0 62 0 62 0 62 0 66 0 31 0 92 0 31 0 92 0 31 0 66 0 31 0 M1 2 M3 4 5 6 Mounting position of planetary gear unit 0 90 180 270 Mounting position of primary bevel gear unit A B Position of the mounting flange at the primary bevel gear unit Operating Instructions P002 P082 Series Planetary Gear Units 81 10 Address List 10 Address List Ernst Blickle Stra
41. DRIVE CZ S R O Tel 420 255 709 601 Business Centrum Praha Fax 420 220 121 237 Luzna 591 http www sew eurodrive cz CZ 16000 Praha 6 Vokovice sew sew eurodrive cz Denmark Assembly Kopenhagen SEW EURODRIVEA S Tel 45 43 9585 00 Sales Geminivej 28 30 Fax 45 43 9585 09 Service DK 2670 Greve http www sew eurodrive dk sew sew eurodrive dk Egypt Sales Cairo Copam Egypt Tel 20 2 22566 299 1 23143088 Service for Engineering amp Agencies Fax 20 2 22594 757 33 El Hegaz ST Heliopolis Cairo http www copam egypt com copam datum com eg Estonia Sales Tallin ALAS KUUL AS Tel 372 6593230 Reti tee 4 Fax 372 6593231 EE 75301 Peetri k la Rae Harjumaa veiko soots alas kuul ee Finland Assembly Lahti SEW EURODRIVE OY Tel 358 201 589 300 Sales Vesim entie 4 Fax 358 3 780 6211 Service FIN 15860 Hollola 2 sew sew fi http www sew eurodrive fi Production Karkkila SEW Industrial Gears Oy Tel 358 201 589 300 Assembly Valurinkatu 6 Fax 358 201 589 310 Service FIN 03600 Karkkila sew sew fi http www sew eurodrive fi Gabon Sales Libreville Electro Services Tel 241 7340 11 B P 1889 Fax 241 7340 12 Libreville Great Britain Assembly Normanton SEW EURODRIVE Ltd Tel 44 1924 893 855 Sales Beckbridge Industrial Estate Fax 44 1924 893 702 Service Box No 1 http www sew eurodrive co uk GB Normanton West Yorkshire WF6 1QR info sew eurodrive co uk Greece Sales Athen Christ Boznos amp Son S A Tel 30 2 1042 251 34
42. Gear Units Contents 10 SR 57 6 1 Important notes ON startup 57 6 27 RUn N period cio et 58 6 3 Startup of gear units with long term protection 58 6 4 Gear units with amp 59 6 5 Measuring the surface and oil temperature 60 6 6 Shutting down gear units 61 Inspection Maintenance iii 62 7 1 Preliminary work regarding inspection maintenance 62 7 2 Inspection and maintenance intervals 63 7 3 Lubricant change 65 7 4 Checking the oil level 66 7 5 Checking the oil consistency 67 7 6 Changing the oil iecit d eet i ier ete ere ret ee epa doen 68 7 7 Checking and cleaning the breather plug 70 7 9 RefilliNG QreaSes a eti ern dte 70 Malf nctions iu 71 8 1 Notes on malfunctions 71 8 2 Customer Service andes whan dus 71 8 3 Malfunctions of P
43. How driving the world With people who With comprehensive With uncompromising think fast and With a worldwide With drives and controls knowledge in virtually quality that reduces the develop the service network thatis that automatically every branch of cost and complexity of future with you always close at hand improve your productivity industry today daily operations SEW EURODRIVE 14 Driving the world With a global presence With innovative With online information that offers responsive technology that solves software updates and reliable solutions tomorrow s problems via the Internet available Anywhere today around the clock EURODRIVE SEW EURODRIVE GmbH amp Co KG Box 3023 D 76642 Bruchsal Germany Phone 49 7251 75 0 Fax 49 7251 75 1970 sew sew eurodrive com www sew eurodrive com
44. RIETARY LIMITED Tel 27 11 248 7000 Sales Eurodrive House Fax 27 11 494 3104 Service Cnr Adcock Ingram and Aerodrome Roads http www sew co za Aeroton Ext 2 info sew co za Johannesburg 2013 P O Box 90004 Bertsham 2013 Cape Town SEW EURODRIVE PROPRIETARY LIMITED Tel 27 21 552 9820 Rainbow Park Fax 27 21 552 9830 Cnr Racecourse amp Omuramba Road Telex 576 062 Montague Gardens cfoster sew co za Cape Town P O Box 36556 Chempet 7442 Cape Town Durban SEW EURODRIVE PROPRIETARY LIMITED Tel 27 31 700 3451 2 Monaceo Place Fax 27 31 700 3847 Pinetown hengela sew co za Durban P O Box 10433 Ashwood 3605 Spain Assembly Bilbao SEW EURODRIVE ESPANA S L Tel 34 94 43184 70 Sales Parque Tecnol gico Edificio 302 Fax 34 94 43184 71 Service E 48170 Zamudio Vizcaya http www sew eurodrive es sew spain sew eurodrive es Sweden Assembly J nk ping SEW EURODRIVE AB Tel 46 36 3442 00 Sales Gnejsv gen 6 8 Fax 46 36 3442 80 Service 5 55303 J nk ping http www sew eurodrive se Box 3100 S 55003 J nk ping info sew eurodrive se Operating Instructions P002 P082 Series Planetary Gear Units 10 89 10 90 Address List Switzerland Assembly Basel Alfred Imhof A G Tel 41 61 417 1717 Sales Jurastrasse 10 Fax 41 61 417 1700 Service CH 4142 M nchenstein bei Basel http www imhof sew ch info imhof sew ch Thailand As
45. Structure of the safety notes The safety notes in these operating instructions are structured as follows Symbol SIGNAL WORD Nature and source of hazard Possible consequence s if disregarded Measure s to prevent the hazard gt Symbol Signal word Description Consequences if disregarded Example 1 DANGER Imminent danger Severe or fatal injuries _ WARNING Possible hazardous situation Severe or fatal injuries General danger CAUTION Possible hazardous situation Minor injuries Specific danger e g electric shock NOTICE Potential damage to property Damage to the drive system or its environ ment TIP Useful information or tip Simplifies handling of the drive system Operating Instructions P002 P082 Series Planetary Gear Units Important Notes Rights to claim under warranty 1 3 Rights to claim under warranty Adhering to the operating instructions is a prerequisite for fault free operation and the fulfillment of any right to claim under warranty Therefore read the operating instructions before you start working with the unit 14 Exclusion of liability You must comply with the information contained in these operating instructions to en sure safe operation of the P002 P082 series planetary gear units and to achieve the specified product characteristics and performance requirements SEW EURODRIVE does not assume liability for injury t
46. ace torque arms under strain during installation 5 9 1 Single sided torque arm standard The reactive force due to the gear unit torque is absorbed via the torque arm with lever arm A The illustration shows an example for absorption in a welded construction with design dimensions Two supporting plates are welded with the suggested dimensions on the machine design Once the gear unit has been mounted a connecting cover plate is welded onto the two supporting plates The force of the gear unit torque acts on the support divided by the length of the lever arm A The reaction force also acts on the gear unit and machine shafts Dimensions The following figure shows a sample torque arm 1143100811 Dimensions in mm Quantity Weight DE A B C D1 D2 5 X Kg P002 650 60 50 334 370 25 22 880 16 25 P012 700 70 60 374 410 30 22 955 20 35 P022 750 90 70 414 460 35 22 1035 24 48 P032 800 110 90 464 510 35 26 1125 20 58 P042 900 150 120 484 560 40 33 1270 20 93 P052 1000 160 130 534 590 40 33 1390 24 102 P062 1200 180 150 614 690 50 39 1655 24 183 P072 1500 230 200 694 770 60 39 2020 24 317 P082 1600 230 200 754 840 70 45 2160 24 420 Operating Instructions P002 P082 Series Planetary Gear Units 41 Installation Assembly Torque arms for hollow shaft gear units Tightening t
47. ades and or manufacturers is not permitted Espe cially synthetic oils may not be mixed with mineral oils or other synthetic oils Flush the gear unit with the new oil grade thoroughly when switching from mineral oil or when switching from synthetic oil of one basis to synthetic oil of a different basis Refer to the lubrication table in section 9 2 to determine which oils from the various lubricant manufacturers can be used Information such as the oil grade oil viscosity and required oil quantity is listed on the nameplate of the gear unit The oil quantity specified on the nameplate is an ap proximate quantity The mark on the oil sight glass or stick is the decisive indicator of the correct oil level Only change the oil when the gear unit is warm When changing the oil flush the gear unit interior thoroughly with oil to remove oil sludge oil residue and abrasion products Use the same grade of oil that is used to operate the gear unit Fill with fresh oil only after all residues have been removed For the position of the oil level plug oil drain plug and the breather valve refer to the order documents Dispose of the used oil in accordance with applicable regulations Operating Instructions P002 P082 Series Planetary Gear Units Inspection Maintenance Changing the oil 7 6 2 Procedure A WARNING Danger of burns due to hot gear unit and hot gear unit oil Fatal injuries Let the gear unit cool
48. ar unit e g by falling objects or coverings Protect the gear unit from direct cold air currents Condensation may cause water to accumulate in the oil For the standard mounting positions the breather valve on planetary gear units is mounted at the factory and activated if the gear unit is supplied without an oil fill Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly Preliminary work Check the correct mounting and the function of the breather valve e Gear units are supplied with a coating suitable for use in damp areas or in the open air Repair any damage to the paint work e g on the breather valve 5 4 Preliminary work Check that the following conditions have been met The entries on the nameplate of the gearmotor match the voltage supply system The drive has not been damaged during transportation or storage Ambient temperature according to the technical documentation nameplate and lu bricant table in section Lubricants see page 78 No harmful oils acids gases vapors radiation etc in the vicinity You must clean the output shafts and flange surfaces thoroughly to ensure they are free of anti corrosion agents contamination or similar Use a commercially available solvent Do not expose the sealing lips of the oil seals to the solvent damage to the material 5 4 1 Extended storage Note The service life of the lubricant in the bearings is
49. ay result in damages to the gear unit Potential damage to property Prevent foreign objects from entering into the gear unit 1 Remove any deposits located near the breather plugs 2 Replace clogged breather plugs with new ones 7 8 Refilling grease Regreasable sealing systems may be refilled with lithium soap grease see section 9 4 Use moderate pressure to force grease into each lubrication point until new grease leaks out of the sealing gap Used grease including contaminants and sand is thus pressed out of the sealing gap TIP Remove the old grease that leaked out Operating Instructions P002 P082 Series Planetary Gear Units Malfunctions Notes on malfunctions 8 Malfunctions 8 1 Notes on malfunctions Observe the following notes before you start to determine the reason for the malfunction DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries De energize the motor before you start working on the unit Secure the motor against unintended power up Danger of burns due to hot gear unit and hot gear unit oil Fatal injuries Letthe gear unit cool down before you start working on it NOTICE Improper handling of the gear unit and the motor may lead to damages Potential damage to property Anyrepair work on SEW drives may be performed by qualified personnel only Only qualified personnel is pe
50. azil provided on request Bulgaria Sales Sofia BEVER DRIVE GmbH Tel 359 2 9151160 Bogdanovetz Str 1 BG 1606 Sofia Fax 359 2 9151166 bever fastbg net Operating Instructions P002 P082 Series Planetary Gear Units 10 83 10 84 Address List Cameroon Sales Douala Electro Services Tel 237 33 431137 Rue Drouot Akwa Fax 237 33 431137 2024 Douala Canada Assembly Toronto SEW EURODRIVE CO OF CANADA LTD Tel 1 905 791 1553 Sales 210 Walker Drive Fax 1 905 791 2999 Service Bramalea Ontario L6T3W1 http www sew eurodrive ca marketing sew eurodrive ca Vancouver SEW EURODRIVE CO OF CANADA LTD Tel 1 604 946 5535 7188 Honeyman Street Fax 1 604 946 2513 Delta B C V4G 1 E2 marketing sew eurodrive ca Montreal SEW EURODRIVE CO OF CANADA LTD Tel 1 514 367 1124 2555 Rue Leger Fax 1 514 367 3677 LaSalle Quebec H8N 2V9 marketing sew eurodrive ca Additional addresses for service in Canada provided on request Chile Assembly Santiago de SEW EURODRIVE CHILE LTDA Tel 56 2 75770 00 Sales Chile Las Encinas 1295 Fax 56 2 75770 01 Service Parque Industrial Valle Grande http www sew eurodrive cl LAMPA ventas sew eurodrive cl RCH Santiago de Chile P O Box Casilla 23 Correo Quilicura Santiago Chile China Production Tianjin SEW EURODRIVE Tianjin Co Ltd Tel 86 22 25322612 Assembly No 46 7th Avenue TEDA Fax 86 22 253
51. c documentation Before startup check that the oil level is correct Refer to the unit s nameplate for the lubricant volumes After having installed the gear unit ensure that all retaining screws are tight Make sure that the orientation has not changed after tightening the mounting ele ments It is absolutely necessary to avoid open flames or sparking when working with the gear unit Ensure that rotating shafts as well as couplings are equipped with suitable protective 5 If there are oil drain valves ensure that they cannot be opened unintentionally If an oil sight glass is used ensure that it is protected against damage Protect the gear unit from falling objects For gear units with long term protection Replace the screw plug at the location indi cated on the gear unit with a breather plug position see order documents Make sure that the monitoring devices are functioning before you start up the unit Strictly observe the safety notes in the individual chapters Operating Instructions P002 P082 Series Planetary Gear Units 6 57 6 58 Startup Run in period 6 2 Run in period SEW EURODRIVE recommends running in the gear unit as first startup phase Increase load and revolutions in 2 to 3 steps up to maximum level The running in phase takes about 10 hours Check the following points during the running in phase Verify the power values specifie
52. d on the nameplate at startup because their level and frequency may be a decisive factor for the service life of the gear unit Does the gear unit run smoothly Are there vibrations or unusual running noise Are there signs of oil leakages on the gear unit Check to be sure that the additional devices such as oil pump cooler etc a functioning properly TIP For detailed information and troubleshooting refer to the Malfunctions chapter 6 3 Startup of gear units with long term protection Adhere to the following points for gear units with long term protection 6 3 1 Anti corrosion agent You must clean the output shafts and flange surfaces thoroughly to ensure they are free of anti corrosion agents contamination or similar Use a commercially available solvent Do not expose the sealing lips of the oil seals to the solvent damage to the material 6 3 2 Oil level Since the planetary gear units with long term protection are delivered complete with oil the correct oil volume and oil level should be checked before startup gt Correct the oil level to the appropriate fill level 6 3 3 Breather plug Replace the screw plug by the enclosed breather filter Operating Instructions P002 P082 Series Planetary Gear Units Startup go 6 Gear units with backstop 6 4 Gear units with backstop The backstop is integrated in the AD RS input shaft assembly The purpose of it is to prevent undesirable reverse rotation
53. down before you start working on it However the gear unit must still be warm otherwise the high viscosity of excessively cold oil will make it harder to drain the oil correctly Observe the notes in section Preliminary work regarding inspection maintenance see page 62 2 Place a container underneath the oil drain plug 3 Remove the oil drain plug 4 Remove the oil fill plug or the breather valve If a gear unit has no oil fill plug depending on the mounting position the breather valve is used as oil filling hole 5 Drain all the oil 6 Re insert the oil drain plug 7 Fill in new oil of the same grade via the oil filling hole Use a funnel to fill the oil filter mesh max 25 um Pourin the oil quantity in accordance with the specification on the nameplate The oil volume specified on the nameplate is an approximate value Check whether the oil level is correct using the oil sight glass oil dipstick When using an external oil air or oil water cooling system observe the separate operating instructions 8 Screw in the oil fill plug or the breather valve TIP Any dripping oil must be removed immediately with an oil binding agent Operating Instructions P002 P082 Series Planetary Gear Units 69 70 Inspection Maintenance Checking and cleaning the breather plug 7 7 Checking and cleaning the breather plug NOTICE Improper cleaning m
54. e to property In rated operation the lift off speeds must not drop below the minimum values During startup or braking the lift off speeds may drop below the minimum levels If the actual speed level is below the minimum lift off speed level the backstops are sub ject to wear and the resulting friction causes the temperature to increase Maximum locking torque of backstop Minimum lift off speed Type Nm rpm AM80 90 RS AM143 145 RS Li a AM100 112 RS AM182 184 RS 200 672 AM132 RS AM213 215 RS d ee AM160 180 RS AM254 286 RS 630 220 AM200 225 RS AM324 365 RS 1430 an Operating Instructions P002 P082 Series Planetary Gear Units 51 52 Installation Assembly AD input shaft assembly 5 12 AD input shaft assembly Observe chapter Mounting input and output components see page when installing input components 5 121 Cover with motor mounting platform AD P Mounting the motor and adjusting the motor mounting platform 1 Motor mounting platform 2 Stud bolt only AD6 P AD7 P IN 74 DURS MN a nA PS 1 a ji p 212119307 4 Nut 5 Threaded column 3 Support only AD6 P AD7 P 1 Set the motor mounting platform to the required mounting position by evenly tighten ing the adjusting nuts Remove the lifting eyebolt from helical gear units in order to achieve the lowest adj
55. emperatures Lubricant for the food industry food grade oil wig Biod dable oil lubricant fi icult forest d fisheri EAD iodegradable oil lubricant for agriculture forestry and fisheries 22 9 2 3 Notes on the lubricant table NOTICE Selecting improper lubricants may result in damages to the gear unit Potential damage to property The temperature ranges are to be considered guide values The decisive factor is the viscosity information on the nameplate Contact SEW EURODRIVE if you operate the unit under extreme conditions such as cold heat or if the operating conditions differ from those based on the project planning Operating Instructions P002 P082 Series Planetary Gear Units 47 049 02 05 Lubricants Permitted lubricants 9 2 4 Lubricant table 09 S 097 2 44 pinj4 uyyuAsueqniy 945 097 19 097 4S 099 9 LHN 09 19 PINIA qaindo 5 ujuAsieqnI 525 reus 09v 9 d19 OSL 10121 10qUL el onem ufsiun OSL WM ost 3X d3 0SLSVA NOSL b SHS uAsJau n PEERS uljousy 1eoBndo 022 10121 022 419 OZZWM ozz 4x da NOZZ v W39 ozz 022 uAseydiy ozz 09819713 u sJeu3 ewo eus 0
56. ents Risk of injuries Remove the shrink disk correctly Never completely unscrew the retaining screws because the shrink disk might jump off and cause an accident Observe the following removal note 1 Loosen the locking screws 4 working around in 1 4 turns for each screws 1056915211 If the inner and outer ring do not loosen from each other unscrew as many locking screws 4 as there are forcing threads and screw these equally into the forcing threads until the tapered bushing is pushed out of the tapered ring CAUTION The outer ring of the shrink disk can jump off when it is removed incorrectly Risk of injuries Under no circumstances should more locking screws 4 be unscrewed than there are forcing threads present 46 Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly 5 Hollow shaft and shrink disk 2 Remove the machine shaft 2 or pull the hub 1 off the customer shaft first remove any corrosion which may have formed between the hub and the shaft end 2 1056918411 3 Remove the shrink disk 3 from the hub 1 5 10 3 Cleaning and lubrication NOTICE Improper cleaning and lubrication may result in damages to the shrink disk Potential damage to property You must perform the following steps carefully in order to ensure that the shrink disk functions perfectly Use only products that are comparable
57. f e 42 D 76646 Bruchsal Germany Headquarters Bruchsal SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 0 Production Ernst Blickle StraRe 42 Fax 49 7251 75 1970 Sales D 76646 Bruchsal http www sew eurodrive de P O Box sew sew eurodrive de Postfach 3023 D 76642 Bruchsal Service Compe Central SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1710 tence Center Ernst Blickle StraRe 1 Fax 49 7251 75 1711 D 76676 Graben Neudorf sc mitte sew eurodrive de North SEW EURODRIVE GmbH amp Co KG Tel 49 5137 8798 30 Alte Ricklinger Stra e 40 42 Fax 49 5137 8798 55 D 30823 Garbsen near Hannover sc nord sew eurodrive de East SEW EURODRIVE GmbH amp Co KG Tel 49 3764 7606 0 Dankritzer Weg 1 Fax 49 3764 7606 30 D 08393 Meerane near Zwickau sc ost sew eurodrive de South SEW EURODRIVE GmbH amp Co KG Tel 49 89 909552 10 DomagkstraRe 5 Fax 49 89 909552 50 D 85551 Kirchheim near Munchen sc sued sew eurodrive de West SEW EURODRIVE GmbH amp Co KG Tel 49 2173 8507 30 SiemensstraRe 1 Fax 49 2173 8507 55 D 40764 Langenfeld near Dusseldorf sc west sew eurodrive de Electronics SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1780 Fax 49 7251 75 1769 sc elektronik sew eurodrive de Drive Service Hotline 24 Hour Service 49 180 5 SEWHELP 49 180 5 7394357 Additional addresses for service in Germany provided on request Zone industrielle 2 rue Denis Papin F 77390 Verneuil l Etang France Production
58. g Breather Oil dipstick Oil sight glass Operating Instructions P002 P082 Series Planetary Gear Units Gear Unit Design Mounting position sheets 3 4 1 P RF 270 T AAA IG 0 R li E 18049 IN MURDERED Operating Instructions P002 P082 Series Planetary Gear Units A 45 129 00 08 3 21 3 Gear Unit Design Mounting position sheets 3 4 2 PF RF 45 130 00 08 22 Operating Instructions P002 P082 Series Planetary Gear Units Gear Unit Design Mounting position sheets 34 3 P KF 270 T
59. h Too much oil Oil too old The oil is heavily contaminated Ambient temperature is too high Check the oil level correct if necessary see section 7 4 Check when the oil was changed last time change the oil if necessary see section 7 6 Protect from external heat sources e g provide shade Change the oil see section 7 6 Bearing point temperatures too high Not enough oil Oil too old Bearing damaged Check the oil level correct if necessary see section 7 4 Check when the oil was changed last time change the oil if necessary see section 7 6 Check bearing and replace if necessary contact customer service Oil is leaking Gasket on the gear unit is not tight Sealing lip of the oil seal turned up Oil seal damaged worn Too much oil Drive installed in incorrect mounting position Frequent cold starts oil foams and or high oil level Vent the gear unit observe the gear unit If oil still leaks Contact customer service Check shaft end ring replace if necessary Contact customer service Check oil level see chapter 7 4 Install the breather plug correctly 1 During the run in phase 24 hour run time it is normal for small amounts of oil grease to leak from the oil seal see also DIN 3761 Operating Instructions P002 P082 Series Planetary Gear Units Malfunctions of RF KF primary gear units Malfunctions 8 4 Malfunctions of RF KF primary gear units
60. he test oil fill is drained out of the gear unit The remaining oil film pro protection tects the gear unit against corrosion for a limited period of time Long term After the test run the test oil fill is drained out of the gear unit and the interior space is protection filled will a vapor phase inhibitor The breather filter is replaced by a screw plug and en closed with the gear unit 2 9 2 Exterior corrosion protection Bare uncoated parts are coated with an anti rust agent Remove it only using an appropriate solvent which is not harmful to the oil seal Sealing surfaces on radial oil seals are protected by an appropriate anti corrosion agent Small spare parts and loose pieces such as bolts nuts etc are packed in corrosion protection plastic bags VCI corrosion protection bags Threaded holes are covered by plastic plugs fthe gearunit is stored longer than six months you must check the protective coat ing of unpainted areas as well as the paint coating regularly Areas where the protec tive coating or paint has been damaged have to be repainted as needed The output shaft must be rotated at least one full rotation so that the position of the roller elements in the bearings of the input and output shafts changes This proce dure must be repeated every six months until startup 2 9 3 Packaging Standard package The gear unit is delivered on a pallet without cover Application Land transport Long term
61. hop for repair Lines connected incorrectly Correct connection Ground fault on motor Send motor to specialist workshop for repair Severe speed loss under load Overload Measure power use larger motor or reduce load if neces sary Voltage drops Increase cross section of incoming cable Motor heats up exces sively measure tempera ture Overload Measure power use larger motor or reduce load if neces sary Insufficient cooling Correct cooling air supply or clear cooling air passages retrofit forced cooling fan if necessary Ambient temperature is too high Comply with permitted temperature range Motor in delta connection instead of star connection as provided for Correct connection Loose contact in supply cable one phase missing Rectify loose contact Fuse has blown Look for and rectify cause see above replace fuse Mains voltage deviates from the rated motor voltage by more than 5 A higher voltage has a particularly unfavorable effect in motors with a low speed winding since in these the no load current is already close to the rated current even when the voltage is normal Adjust motor to supply voltage Rated operation type 51 to 510 DIN 57530 exceeded e g through excessive starting frequency Adjust the rated operating mode of the motor to the required operating conditions consult a professional to determine the correct drive if neces
62. is specified for the plan etary gear motors 3 5 4 KF primary bevel gear unit For the primary bevel gear units KF positions 0 90 180 or 270 are fixed The position of the mounting flange on the A or B side is also defined 1043984907 To reduce the churning losses in the primary gear unit to a minimum SEW EURODRIVE recommends to choose from the standard mounting positions displayed below TIP Contact SEW EURODRIVE in case of deviating mounting conditions Operating Instructions P002 P082 Series Planetary Gear Units 25 Gear Unit Design Mounting positions of the primary gear units A N EX YO lt a lt A NN N sr Aq D lt lt amp e gt Ry 2 lt lt E S E P 3 Ts N T A v 2 2 3 m lt n B E gt S 2 1043699211 Mounting position of planetary gear unit Mounting position of primary bevel gear unit Position of the mounting flange at the primary bevel gear unit M1 2 5 M6 0 90 180 270 Operating Instructions P002 P082 Series Planetary Gear Units 26 Gear Unit Design Mounting positions of the primary
63. l corrosion protection is required Internal corrosion protection Fill the gear unit up to the breather plug with the oil grade specified on the nameplate Set the gear unit in no load running operation for a short period of time at regular intervals TIP If this method of corrosion protection is not possible the interior of the gear unit should be sealed and protected with a suitable corrosion protection agent Consult with the re spective supplier regarding the compatibility with the oil that is used and the length of corrosion protection for your particular gear unit version Exterior corrosion protection Clean the surfaces Grease the shaft near the sealing lip to separate the sealing lip of the oil seal and the corrosion protectant Apply a wax based protective coating to shaft ends and unpainted surfaces as external corrosion protection TIP Refer to the Startup section before re starting the gear unit Operating Instructions P002 P082 Series Planetary Gear Units 61 Inspection Maintenance Preliminary work regarding inspection maintenance a 7 Inspection Maintenance 7 1 Preliminary work regarding inspection maintenance Observe the following notes before you start with the inspection maintenance work A DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries De energize the motor before y
64. lt 50 Standard packaging Standard corrosion protec tion Roofed enclosed at constant temperature and atmospheric humidity 5 C lt 8 lt 60 C relative humidity lt 50 No sudden temperature fluctuations Controlled ventilation with filter free from dust and dirt No aggressive vapors and no shock loads One year or more with regular inspections During inspection check for cleanliness and mechanical damages Check corrosion protection Tropical Asia Africa Central and South America Australia New Zealand excluding temperate zones Long term packaging Long term corrosion protec tion Protected against insect damage and mold through chemical treatment Under roof protected from rain and shocks Up to three years with regular checks of the packaging and moisture indicator Relative humidity lt 50 Standard packaging Standard corrosion protec tion Roofed enclosed at constant temperature and atmospheric humidity 5 lt 9 lt 60 C relative humidity lt 50 No sudden temperature fluctuations Controlled ventilation with filter free from dust and dirt No aggressive vapors and no shock loads Protection against insect damage One year or more with regular inspections During inspection check for cleanliness and mechanical damages Check corrosion protection Operating Instructions P002 P082 Series Planetary Gear Uni
65. lve accordingly Install mount the gear unit only in the specified mounting position on a level vibra tion damping and torsionally rigid support structure Do not twist housing legs and mounting flanges against each other Work on the gear unit only when the machine is not in use Secure the drive unit against unintentional power up Place an information sign near the ON switch to warn that the gear unit is being worked on The plugs for checking and draining oil and the breather valves must be freely acces sible Use plastic inserts 2 to 3 mm thick if there is a risk of electrochemical corrosion be tween the gear unit and the driven machine connection between different metals such as cast iron and high grade steel Also fit the bolts with plastic washers Ground the housing additionally and use grounding screws on the motor Only authorized personnel may assemble gear head units with motors and adapters Contact SEW EURODRIVE Do not weld anywhere on the drive Do not use the drive as a ground point for welding work Welding may destroy gearing parts and bearings Protect rotating drive parts such as couplings gears or belt drives using suitable de vices that protect from contact Units installed outdoors must be protected from the sun Suitable protective devices are required such as covers or roofs When using these avoid heat accumulation The operator must ensure that foreign objects do not impair the function of the ge
66. minimum speed max Operating point at maximum speed i Exact gear unit reduction ratio Fs Service factor 1 Actual overhung load acting on the input shaft Fro N Actual overhung load acting on the output shaft Fay N Actual axial load acting on the input shaft Faz N Actual axial load acting on the output shaft Mass kg Weight of the gear unit Number of greasing Number of relubrication points points Fans Number of installed fans TA Oil grade and viscosity class oil volume Year Year of construction IM Mounting position and mounting surface Operating Instructions P002 P082 Series Planetary Gear Units 3 Gear Unit Design Nameplate and unit designation Sample unit designation H 032 RF 97 DRS 160M4 Size number of poles Motor Series Size Primary gear unit Series Size Flange mounted design Planetary gear units Hollow shaft for shrink disk Gear unit type 16 Operating Instructions P002 P082 Series Planetary Gear Units Gear Unit Design Nameplate and unit designation 3 2 2 Primary gear unit Sample nameplate ROD 3 Bruchsal Germany Typ RF47 A 01 11124560001 00001 07 Pe kW 0 55 90 57 O IM
67. nd cleaning the breather plug 70 Checking the oil 67 Checking the oil 66 Churning losses Siera a EE 25 Closing down gear 61 Combination of planetary and primary gear units 14 TERMI NS 6 COFTOSION i ite n qute ota ete 33 PERIERE 39 Coupling of AM adapter 48 Customer service 71 D Diameter tolerance 32 Disposal ice ane it 8 E Exclusion of liability 6 Exterior corrosion protection 12 External corrosion protection 61 F ees 71 Flange mounted units 40 Foot mounted units 39 idee aceti 36 G Gear unit design 14 Gear unit mounting 39 Gear units with solid 37 H Hollow shaft rete eet 43 Hollow shaft gear units with torque arm 41 IEC adapter AM63 280 48 Input components 29 Input shaft assembly
68. ng the gear unit on a steel construction The foundation must be dimensioned ac cording to weight and torque of the gear unit by taking into account the forces acting on the gear unit Tighten retaining screws or nuts to the specified torque Use the screws and tightening torques specified in section 5 3 NOTICE An improper foundation may result in damages to the gear unit Potential damage to property The foundation must be level and flat the gear unit may not be deformed when the retaining screws are tightened 5 5 3 Aligning the shaft axis Shafts may break if shaft axes are not aligned exactly Severe or fatal injuries The separate operating instructions should be consulted regarding the requirements of the couplings The service life of the shafts bearings and couplings essentially depends on the preci sion of the alignment of the shaft axes with each other Always try to achieve zero deviation When doing so you should also consult the special operating instructions regarding the requirements of the clutches for example 5 5 4 Painting the gear unit NOTICE Breather valves and oil seals may be damaged during the painting or re painting pro cess Potential damage to property Thoroughly cover the breather valves and the sealing lip of the oil seals with strips prior to the painting process Remove the strips after the process Operating Instructions
69. ngth class 8 8 The maximum permitted weight of the attached motor F ymax must be reduced linearly as the center of gravity distance x increases When this distance is reduced Fgmax cannot be increased 2 Diameter of the adapter output flange 160 mm Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly AD input shaft assembly 5 12 4 AD RS input shaft assembly with backstop Check the direction of rotation of the drive prior to assembly or startup Inform the SEW EURODRIVE service in the case of incorrect direction of rotation The backstop is maintenance free in operation and does not require any further main tenance work Backstops have a minimum lift off speed depending on the size see fol lowing table NOTICE If the actual speed level is below the minimum lift off speed level the backstops are subject to wear and the resulting friction causes the temperature to increase Potential damage to property In rated operation the lift off speeds must not drop below the minimum values During startup or braking the lift off speeds may drop below the minimum levels Type Maximum locking torque backstop Minimum lift off speed Nm 1 min AD2 RS 45 800 AD3 RS 200 670 AD4 RS 470 660 AD5 RS 630 550 AD6 RS 1430 600 AD7 RS 1430 600 AD8 RS 1430 600 Operating Instructions P002 P082 Series Planetary Gear Units
70. nk oil riser pipe If there is little space available for installing the oil expansion tank M2 mounting posi tion or the oil riser pipes M4 mounting positions you can request an order specific di mension drawing from SEW EURODRIVE 44 1 Oil expansion tank for mounting position M2 e 1055542539 4 4 2 Oil riser pipe for mounting position M4 1124404619 Operating Instructions P002 P082 Series Planetary Gear Units 31 32 Installation Assembly Required tools resources 5 Installation Assembly 5 1 Required tools resources 5 2 Tolerances Not included in the scope of delivery Set of wrenches Torque wrench Mounting device Compensation elements shims spacing rings Fasteners for input and output elements Lubricant e g fluid from SEW EURODRIVE gt except for hollow shaft gear units For hollow shaft gear units gt aids for assembly disassembly onto the machine shaft Securing components for the gear unit base 5 2 1 P planetary gear units Shaft ends Mounting flange Diameter tolerance in accordance with DIN 748 Y gt 50mm 150 Center bores 120 210 mm M20 240 290 mm M24 Centering shoulder tolerance ISO f8 5 2 2 RF JKF primary gear unit Shaft ends Mounting flange Diameter tolerance in accordance with DIN 748 Y lt 50 ISOKk6 gt 50 15
71. nting for flange mounted units 5 8 Gear unit mounting for flange mounted units When mounting the gear unit to the torque arm and or machine frame secure the screws 1 additionally by using Loctite 640 The following figure shows an example of how flange mounted gear units are installed J 0 03 Y gt AAS lt m Tightening Dimensions in mm Size Thread Quan torque mm enel DIN screws tity classes Nn 20 05 H L L1 OB OC P002 M20 16 579 22 39 5 73 5 34 410 370 33018 012 M20 20 579 22 41 5 73 5 32 450 410 37018 022 M20 24 579 22 48 84 36 500 460 41018 P032 M24 20 1000 26 50 84 34 560 510 46018 DIN EN ISO 4017 P042 M30 20 2011 33 64 114 50 620 560 480f8 10 9 DIN EN ISO 4762 P052 M30 24 2011 33 64 114 50 650 590 530f8 P062 M36 24 3492 39 74 134 60 760 690 61018 P072 M36 24 3492 39 84 144 60 840 770 69018 082 M42 24 3492 45 84 154 70 920 840 750f8 40 Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly Torque arms for hollow shaft gear units 5 9 Torque arms for hollow shaft gear units NOTICE Improper assembling may result in damages to the gear unit Potential damage to property Do not pl
72. o persons or damage to equipment or property re sulting from non observance of these operating instructions In such cases any liability for defects is excluded 1 5 Copyright 9 2008 SEW EURODRIVE All rights reserved Copyright law prohibits the duplication modification distribution and use of any part of this document for ulterior purposes Operating Instructions P002 P082 Series Planetary Gear Units Safety Notes Preliminary remark 2 Safety Notes 2 1 Preliminary remark The following safety notes are primarily concerned with the use of gear units If using gearmotors also refer to the safety notes for motors in the corresponding operating in structions Also observe the supplementary safety notes in the individual sections of these operat ing instructions 2 2 General information DANGER During operation the gear units can have movable or rotating parts as well as hot sur faces Severe or fatal injuries All work related to transportation putting into storage setup mounting connection startup maintenance and repair may only be carried out by qualified personnel observing The relevant detailed operating instructions Warning and safety signs on the gear unit All other project planning documents operating instructions and wiring diagrams related to the drive The specific regulations and requirements for the system The national regional regulations governing
73. orques Tightening torque Size Thread Quantity Strength classes DIN screws Nm 20 P002 M20 16 579 P012 M20 20 579 P022 M20 24 579 P032 M24 20 1000 042 M30 20 2011 10 9 DIN EN ISO 4762 P052 M30 24 2011 P062 M36 24 3492 072 M36 24 3492 P082 M42 24 3492 Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly 5 Hollow shaft and shrink disk 5 10 Hollow shaft and shrink disk 5 10 1 Mounting 1 Before installing the shrink disk clean and degrease the hub 1 and the machine shaft 2 This is a very important factor for the reliability of torque transmission 1052851467 2 Ensure that the dimensions of the machine shafts 2 correspond to SEW specifica tions 3 Slide the loose shrink disk 3 onto the hub 1 4 Check the correct position of the shrink disk 3 The shrink disk is positioned cor rectly when it is in contact with the shaft shoulder 8 NOTICE Tightening the screws 4 without installed shaft may result in the hollow shaft being de formed Potential damage to property Tighten the locking screws 4 when the machine shaft 2 is installed 8 1053533067 Operating Instructions P002 P082 Series Planetary Gear Units 43 Installation Assembly Hollow shaft and shrink disk 5 Install the machine shaft 2 or slide the gear uni
74. ou start working on the unit Secure the motor against unintended power up WARNING Danger of burns due to hot gear unit and hot gear unit oil Fatal injuries Letthe gear unit cool down before you start working on it Only remove the oil level and oil drain plug very carefully NOTICE Filling in the wrong oil may result in significantly different lubricant characteristics Potential damage to property not mix different synthetic lubricants and do not mix synthetic with mineral lubri cants Improper maintenance may result in damages to the gear unit Potential damage to property Note the following Strict adherence to the inspection and maintenance intervals is absolutely necessary to ensure safe working conditions Observe the tightening torques Whenusing primary gearmotors also observe the maintenance notes for motors and primary gear units in the accompanying operating instructions Forthe position of the oil level plug oil drain plug and the breather valve refer to the mounting position sheets see chapter Mounting positions Useonly original spare parts according to the delivered spare and wearing parts lists Before releasing shaft connections be sure that there are no active torsional mo ments present tensions within the system Operating Instructions P002 P082 Series Planetary Gear Uni
75. planetary gear 72 8 4 Malfunctions of RF KF primary gear units 73 8 5 Malfunctions of AM AL adapters 73 8 6 Malfunctions of the motor nnne 74 8 7 Malfunctions of DR DV 75 t des 76 9 1 Lubricant selection 76 9 2 Permitted lubricants nnne 77 9 3 Lubricant fill quantities 80 Address Lio iii da 82 A MR D aS d s 91 Operating Instructions P002 P082 Series Planetary Gear Units Important Notes How to use the operating instructions 1 Important Notes 11 use the operating instructions The operating instructions are an integral part of the product and contain important in formation for operation and service The operating instructions are written for all employ ees who assemble install startup and service this product The operating instructions must be accessible and legible Make sure that persons re sponsible for the system and its operation as well as persons who work independently on the unit have read through the operating instructions carefully and understood them Consult SEW EURODRIVE if you have any questions or if you require further informa tion 1 2
76. rimary gear units The lubricant fill quantity depends on the mounting position of the planetary gear unit and the mounting position of the RF primary gearmotor For notes on the mounting positions of RF primary gear units refer to section 3 4 2 Delivery of the RF primary gear unit with oil fill Fill quantity in liters M1 M2 M3 M4 M5 M6 Size 0 0 180 0 270 90 RF77 1 2 3 10 3 30 3 60 2 40 3 00 RF87 2 4 6 4 7 1 7 2 6 3 6 4 RF97 5 1 11 9 11 2 14 0 11 2 11 8 RF107 6 3 15 9 17 0 19 2 13 1 15 9 RF137 9 5 27 0 29 0 32 5 25 0 25 0 RF147 16 4 47 0 48 0 52 0 42 0 42 0 RF167 26 0 82 0 78 0 88 0 65 0 71 0 Key M1 M2 M3 M4 M5 M6 Mounting position of planetary gear unit 0 90 180 270 Mounting position of primary helical gear unit 80 Operating Instructions P002 P082 Series Planetary Gear Units Lubricants Lubricant fill quantities 9 3 3 Primary bevel KF gear units The lubricant fill quantity depends on the mounting position of the planetary gear unit and the mounting position of the KF primary gearmotor For notes on the mounting positions of KF primary gear units refer to section 3 4 1 Delivery of the KF primary gear unit with oil fill Fill quantity in liters M1 M2 M3 Size 0 A 90 A 180
77. rmitted to separate drive and motor Consult SEW EURODRIVE customer service 8 2 Customer service Please have the following information available if you require customer service assistance Complete nameplate data Type and extent of the problem Time the problem occurred and any accompanying circumstances Assumed cause A digital photograph if possible Operating Instructions P002 P082 Series Planetary Gear Units 71 72 Malfunctions Malfunctions of P planetary gear units 8 3 Malfunctions of P planetary gear units Fault Possible cause Remedy Unusual regular running noise Meshing grinding noise Bearing damage Knocking noise Irregularity in the gearing Deformation of the housing upon tightening Noise generation caused by insufficient rigidity of the gear unit foundation Check oil consistency see chapter 7 5 replace bearings Contact customer service Check the gear unit mounting for possible deformation and correct if needed Reinforce the gear unit foundation Unusual irregular running noise Foreign objects in the oil Check the oil consistency see section 7 5 Stop the drive contact customer service Unusual noise in the area of the gear unit mounting Gear unit mounting has loosened Tighten retaining screws and nuts to the specified torque Replace the damaged defective retaining screws or nuts Operating temperature too hig
78. s Operating instructions of any attached options Target group Disposal All mechanical work must be carried out by trained staff only Qualified personnel in this context are persons who are familiar with the setup mechanical installation trouble shooting and maintenance for this product Further they are qualified as follows Training in mechanical engineering e g as a mechanic or mechatronics technician final examinations must have been passed They are familiar with these operating instructions All electrical engineering work may be carried out by only a qualified electrician Quali fied electricians in this context are persons who are familiar with the electronic installa tion startup trouble shooting and maintenance for this product Further they are qual ified as follows Training in electrical engineering e g as an electrician or mechatronics technician final examinations must have been passed They are familiar with these operating instructions All work in further areas of transportation storage operation and waste disposal may be carried out only by persons who are trained appropriately Housing parts gears shafts and roller bearings of the gear units must be disposed of as steel scrap This also applies to gray cast iron parts if there is no separate collection Collect waste oil and dispose of it according to the regulations in force Operating Instructions P002 P082 Serie
79. s Planetary Gear Units Safety Notes Safety symbols on the gear unit 2 7 Safety symbols on the gear unit The symbols on the gear unit must be observed They have the following meaning Symbol Meaning Oil fill plug Oil drain Oil level glass Oil dipstick Inspection opening Breather plug Flat grease nipple Taper grease nipple Air outlet screw Water inflow Water return Direction of rotation DELIVERED WITHOUT OIL Delivery state Hot surface GEAR UNIT IS VPI ANTI RUST TREATED COVER AND PLUG OF GEAR UNIT MUST NOT TO BE OPEND AND GEAR UNIT MUST NOT ROTATED BEFORE START UP BEFORE START UP THE PROTECTIVE PLUG MUST BE REMOVED AND REPLACED BY ENCLOSED AIR VALVE Extended storage Operating Instructions P002 P082 Series Planetary Gear Units 10 2 8 2 8 1 Safety Notes Transport Transport Notes on transport fs DANGER Suspended loads can fall Severe or fatal injuries The gear unit must be transported in a manner that prevents injuries to persons Secure the danger zone Stay away from beneath the gear unit during transport NOTICE Improper transport may result in damages to the gear unit Potential damage to property Note the following Immediately upon receipt inspect the shipment for any damage that
80. s where the surface temperature of the gear unit must be measured Mounting posi Measuring point of the surface temperature tion M1 1407712779 M3 M5 M6 1407716363 M2 1407720075 M4 1407761675 Operating Instructions P002 P082 Series Planetary Gear Units Startup go 6 Shutting down gear units 6 5 2 Measuring the oil temperature Oil temperatures must be measured to determine the oil change intervals See chapter Lubricant change intervals see page for a description Measure the temperature at the bottom of the gear unit If the gear unit has an oil drain plug measure the tempera ture on this plug Add 10 K to the measured value This value is the basis for the oil change intervals 6 6 Shutting down gear units DANGER Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Disconnect the gearmotor from the power supply before starting work and protect it against unintentional re start If the gear unit will not operated for an extended period of time you must activate it reg ularly at intervals of approx 2 3 weeks If the gear unit will not operated for a period longer than 9 months additiona
81. safety and the prevention of acci dents Never install damaged products mmediately report any damage to the shipping company Removing covers without authorization improper use as well as incorrect installation or operation may result in severe injuries to persons or damage to property Refer to the documentation for additional information 23 Designated use The designated use refers to the procedure specified in the operating instructions P002 P082 series planetary gear units are gear units driven by motors for industrial and commercial systems Gear unit utilizations other than those specified and areas of application other than industrial and commercial systems can only be used after consul tation with SEW EURODRIVE For the purpose of EC Machinery Directive 2006 42 EC the planetary gear units are com ponents for installation in machinery and systems In the scope of the EG directive you must not take the machinery into operation in the designated fashion until you have es tablished that the end product complies with the Machinery Directive 2006 42 EC Operating Instructions P002 P082 Series Planetary Gear Units 2 4 2 5 2 6 Safety Notes Applicable documents Applicable documents The following publications and documents have to be observed as well When using gearmotors also observe the safety notes for motors and primary gear units in the accompanying operating instruction
82. sary Excessively loud Ball bearing compressed dirty or damaged Re align motor inspect ball bearing re grease if neces replace Vibration of rotating parts Rectify cause possible imbalance Foreign bodies in cooling air passages Clean cooling air passages Operating Instructions P002 P082 Series Planetary Gear Units Malfunctions of DR DV brakes Malfunctions 8 7 Malfunctions of DR DV brakes Fault Possible cause Remedy Brake does not release Incorrect voltage on brake control unit Apply correct voltage Brake control unit failed Install a new brake control system check internal resis tance and insulation of brake coil check switchgear Max permitted working air gap exceeded because brake lining worn down Measure and set working air gap Voltage drop on supply cable gt 10 Correct connection voltage check cable cross section Inadequate cooling brake overheats Replace type BG brake rectifier with type BGE Brake coil has interturn fault or short circuit to exposed conductive part Replace complete brake and brake control system spe cialist workshop check switchgear Rectifier defective Replace the rectifier and brake coil Motor does not brake Working air gap not correct Measure and set working air gap Brake lining worn down Replace entire brake disk Incorrect braking torque
83. sembly Chonburi SEW EURODRIVE Thailand Ltd Tel 66 38 454281 Sales 700 456 Moo 7 Donhuaroh Fax 66 38 454288 Service Muang sewthailand sew eurodrive com Chonburi 20000 Tunisia Sales Tunis T M S Technic Marketing Service Tel 216 71 4340 64 71 4320 29 Zone Industrielle Mghira 2 Fax 216 71 4329 76 Lot No 39 tms tms com tn 2082 Fouchana Turkey Assembly Istanbul SEW EURODRIVE Tel 90 216 4419164 3838014 Sales Hareket Sistemleri San ve Tic Ltd Sti 3738015 Service Bagdat Cad Koruma Cikmazi No 3 Fax 90 216 3055867 TR 34846 Maltepe ISTANBUL http www sew eurodrive com tr sew sew eurodrive com tr Ukraine Sales Dnepropetrovsk SEW EURODRIVE Tel 380 56 370 3211 Service Str Rabochaja 23 B Office 409 Fax 380 56 372 2078 49008 Dnepropetrovsk http www sew eurodrive ua sew sew eurodrive ua USA Production Southeast SEW EURODRIVE INC Tel 1 864 439 7537 Assembly Region 1295 Old Spartanburg Highway Fax Sales 1 864 439 7830 Sales P O Box 518 Fax Manufacturing 1 864 439 9948 Service Lyman S C 29365 Fax Assembly 1 864 439 0566 Cooporate Offices Fax Confidential HR 1 864 949 5557 http www seweurodrive com cslyman seweurodrive com Assembly Northeast SEW EURODRIVE INC Tel 1 856 467 2277 Sales Region Pureland Ind Complex Fax 1 856 845 3179 Service 2107 High Hill Road P O Box 481 csbridgeport seweurodrive com Bridgeport New Jersey 08014 Midwest Region SEW EURODRIVE INC Tel 1 937 335 0036 2001 West Main Street Fax 1 93
84. t 5 to a stop on the machine shaft 2 Perform the mounting sequence slowly to allow the compressed air to escape around the outside of the shaft 2 1053536267 6 Tighten the locking screws 4 manually first Tighten all locking screws by working round equally not in diametrically opposite sequence in 1 4 turn increments 1053539467 44 Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly 5 Hollow shaft and shrink disk 7 Observe the tightening torque in the table below Tighten the locking screws 4 by continuing to work round in 1 4 turns until you reach the tightening torque Addition ally you can visually check to see that the front lateral surfaces are aligned to the inner 9 and outer rings 10 1053543307 Verify the type details on your shrink disk and choose the tightening torque Shrink disk type Size Screws Rated torque Nm Tightening torque Nm 20 3191 P002 M16 41000 250 012 M16 75500 290 P022 M16 95500 290 P032 M20 134000 570 P042 M20 194000 570 Te P052 M20 255000 570 P062 M24 405000 980 P072 M24 525000 980 P082 M24 720000 980 Operating Instructions P002 P082 Series Planetary Gear Units 45 5 Installation Assembly Hollow shaft and shrink disk 5 10 2 Removal CAUTION Risk of jamming and crushing due to improper removal of heavy compon
85. the application s Retaining thread see table Round down the calculated screw length to the next smaller standard length 2 Remove the retaining screws from the centering shoulder 3 Clean the contact surface and the centering shoulder 4 Clean the threads of the new bolts and apply a bolt locking compound e g Loctite 243 to the first few threads 5 Attach the application to the centering shoulder and tighten the retaining screws with the specified tightening torque T4 see table Screw in depth Retaining thread Tightening for connection screws of strength class t mm 5 8 8 Nm AD2 ZR 25 5 M8 25 AD3 ZR 31 5 M10 48 AD4 ZR 36 M12 86 AD5 ZR 44 M12 86 AD6 ZR 48 5 M16 210 AD7 ZR 49 M20 410 AD8 ZR 42 M12 86 Operating Instructions P002 P082 Series Planetary Gear Units 53 Installation Assembly AD input shaft assembly Permitted loads CAUTION Impermissibly high loads may occur when mounting a motor Potential damage to property The load data specified in the following table are not to be exceeded 1178977035 1 1 x q y mm IN AD2 ZR 193 330 AD3 ZR 274 1400 ADAIZR 1120 AD4 ZR 3300 AD5 ZR 487 3200 AD6 ZR 567 3900 AD7 ZR 663 10000 AD8 ZR 516 4300 1 Maximum load values for connection screws of stre
86. tions see chapter 7 3 every 3 years at the latest Changing the mineral oil Depending on the operating conditions see chapter 7 3 every 5 years at the latest Change synthetic oil Varying depending on external factors Touch up or renew the surfaces anticorrosion coating Operating Instructions P002 P082 Series Planetary Gear Units 63 7 Inspection Maintenance Inspection and maintenance intervals 7 2 2 RF KF primary gear unit Time interval Required maintenance inspection steps e Every 3000 operating hours at least every 6 months Check oil and oil level Check running noise for possible bearing damage Visually check the seals for leakage Depending on the operating conditions every Change mineral oil years at the latest e According to oil temperature Replace anti friction bearing grease recommendation Replace oil seal do not install it in the same track Depending on the operating conditions every 5 Change synthetic oil years at the latest According to oil temperature Replace anti friction bearing grease recommendation Replace oil seal do not install it in the same track Varying depending on external factors Touch up or renew the surfaces anticorrosion coating 7 2 3 adapter Time interval Required maintenance inspection steps Every 3000 operating hours at least every
87. tions of the primary gear 25 3 6 Pivot mounting position 28 4 Structure of Options and Additional Features 29 4 1 INPUE COMPONEN otie a 29 4 2 WONQUC Mita 30 4 3 PT100 temperature sensor 30 44 Oil expansion tank oil riser pipe 31 5 ercer 32 5 1 Required tools resources 32 5 2 enter tute td 32 5 3 Notes on installation mounting naar 33 54 Preliminary Work 2n tet pn Paetus 34 5 5 Installing the gear unit 35 5 6 Gear units with solid shaft 37 5 7 Gear unit mounting for foot mounted units 39 5 8 Gear unit mounting for flange mounted 40 5 9 Torque arms for hollow shaft gear 41 5 10 Hollow shaft and shrink disk 43 5 11 Coupling of AM adapter 48 512 AD Input shat etii e REL P e Le ec 52 5 13 Temperature sensor PT100 56 Operating Instructions P002 P082 Series Planetary
88. to the lubricant that is given Ifthe tapered surfaces of the shrink disk are damaged the shrink disk can no longer be used and must be replaced Do not disassemble and regrease the removed shrink disk before installing it again Only clean the shrink disk if it is contaminated Next regrease only the inner sliding surfaces of the shrink disk Usea solid lubricant with a friction factor of 0 04 Lubricant Sold as Molykote 321 R lube coat Spray Molykote spray powder spray Spray Molykote G Rapid Spray or paste Aemasol MO 19R Spray or paste Molykombin UMFT 1 Spray Unimoly P5 Powder Operating Instructions P002 P082 Series Planetary Gear Units 47 Installation Assembly Coupling of AM adapter 5 11 Coupling of AM adapter 5 11 1 IEC adapter AM63 280 NEMA adapter 56 365 479 1 484 IEC lt AM182 IEC gt 182 NEMA AMGS3 280 212099979 1 Motor shaft 479 Coupling half 481 Setscrew 484 Key 491 Spacer tube 1 Clean the motor shaft and the flange surfaces of the motor and the adapter 2 Remove the key from the motor shaft and replace it with the supplied key 484 not AM63 and 250 3 Heat the coupling half 479 to approx 80 100 C and push the coupling half onto the motor shaft Position as follows IEC adapter AM63
89. ts 13 3 Gear Unit Design Combination of planetary gear unit with primary gear unit 3 Gear Unit Design 3 1 Combination of planetary gear unit with primary gear unit The planetary gear units are a combination of 1 P planetary gear units Output stage 2 Primary gear unit RF or KF 3 Mount on components Motor coupling adapter and backstop The following figure shows a sample combination of a planetary gear unit a primary gear unit and a motor 1044069259 P Planetary gear units RF Helical gear unit flange mounted KF Bevel gear unit flange mounted 14 Operating Instructions P002 P082 Series Planetary Gear Units Gear Unit Design Nameplate and unit designation 3 2 Nameplate and unit designation 3 2 4 Planetary gear units Sample nameplate S SWE alu XO D Ed W Bruchsal German Type 1 norm mi n max PK1 kW 13 FS MK2 Nm FRI n1 t min FR2 n2 Operation instruction have to be observed FA2 Made in Germany Mass kg 840 Qty of greasing points __0 Fans Cd A CLPHC VG220 synth Oil 29 tr Year o HA JO 1124395915 Type Unit designation No 1 Serial number Px4 kW Operating power on the input shaft HSS 2 Nm Gear unit output torque n4 1 min Input speed HSS n2 1 min Output speed LSS norm Standard operating point min Operating point at
90. ts Inspection Maintenance Inspection and maintenance intervals 7 2 Inspection and maintenance intervals Prevent foreign bodies from entering into the gear unit during the following work Do not clean the gear unit with a high pressure cleaning system If one is used water may enter into the gear unit and the seals may be damaged Perform safety and function tests following all maintenance and repair work Strictly observe the safety notes in the individual chapters 7 2 1 P planetary gear units Time interval Required maintenance inspection steps Daily Check the housing temperature e With mineral oil max 90 C With synthetic oil max 100 C Check gear unit noise e Monthly Check gear unit for signs of leakage Checking the oil level section 7 4 After 500 hours of operation First oil change after initial startup section 7 6 Every 3000 operating hours at least every 6 months Checking the oil consistency section 7 5 Fill regreasable sealing systems with grease section 7 8 Depending on the operating conditions at least every 12 months Check whether retaining screws are tightly secured Check the condition of the oil water cooling system Clean oil filter replace filter element if necessary Checking the breather plug replacing it if required section 7 7 Checking the alignment of the input and output shaft chapter 5 6 Depending on the operating condi
91. ustment position Touch up any damage to the paint work and secure it Align the motor on the motor mounting platform shaft ends must be in alignment Mount the input elements on the input shaft end and the motor shaft line them up with one another and correct the motor position again if necessary Put on the traction elements V belt chain etc and apply a preload by evenly ad justing the motor mounting platform Do not stress the motor mounting platform and the columns against each other when doing this Tighten all the nuts not used for adjustment in order to fix the threaded columns Operating Instructions P002 P082 Series Planetary Gear Units Installation Assembly 5 AD input shaft assembly 5 12 2 Only AD6 P and AD7 P Unscrew the nuts on the stud bolts before adjustment to allow the stud bolts to move axially in the support without restriction Do not tighten the nuts until the final adjustment position has been reached Do not adjust the motor mounting platform using the support 5 12 3 AD ZR input shaft assembly with centering shoulder Mounting applications on the input shaft assembly with centering shoulder 1 Retaining bolts of a suitable length must be used to secure the application The length of the new bolts is calculated as follows 212121483 I t Screw in depth see table a Thickness of

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