Operating Instructions Industrial Transmission
Contents
1. 5 General Information 1 4 Explanation of symbols Important notes such as notes on safety are highlighted by the corresponding symbols These notes must be strictly followed in order to avoid accidents and damage to the transmission A WARNING In these operating instructions this symbol highlights all notes on safety that need to be observed to avoid the risk of injury or death Comply with these notes on industrial safety and exercise extreme care in such situations A WARNING Danger caused by electric current This symbol identifies dangerous situations with electric current Non compliance with these notes on safety causes the risk of injury or even death Necessary work must only be performed by a well instructed electrician Li ATTENTION In these operating instructions the Attention symbol highlights all notes on safety that must strictly be followed because their negligence may result in damage to and or malfunctions of the transmission EXPLOSION PROTECTION In these operating instructions this symbol emphasizes contents and instructions for the use of the transmission in explosion endangered environments as specified in the ATEX guideline The non observance of these contents and instructions can lead to the loss of the explosion protection ES note This symbol emphasizes hints and particularly useful information in these operating instructions For an effective operation of the transmission all notes2. Clean the working area and remove any substances such as fluids work materials and similar that may have leaked out Make sure that all safety features of the machine are functioning correctly GB10 12 41 n LEETE 42 Operating Instructions Industrial Transmission Trouble shooting 8 Trouble shooting Faults on electric installations must only be rectified by qualified professionals The same applies for faults in the areas of mechanics pneumatics and hydraulics In case of faults that cannot be rectified by following the described measures you should consult ASS AG EXPLOSION PROTECTION For work on ATEX approved transmissions the following points must be observed e Installation assembly and maintenance work must only be performed in a non explosive atmosphere e Ask for a written permission before starting work e Use only tools which have been approved for use in explosion protected plants e Failure to meet these notes results in the loss of the explosion protection 8 1 What to do in case of faults In case of faults that impose a direct threat for persons objects and the operating safety of transmission and plant the transmission must be shut down immediately with EMERGENCY STOP function In case of faults that do not impose such a threat both transmission and plant can be shut down via the plant control The user must in any case be immediately informed about the fault The user must order the appropriate
3. expert personnel to perform trouble shooting and to rectify the fault The notes in chapter 7 must be observed before during and after fault rectification work GB10 12 Operating Instructions Industrial Transmission Trouble shooting 8 2 Fault rectification Faut Jposiblecause remy Speed load too high Adjust the plant accordingly Dust deposits Clean the transmission Transmission noise Gearing damaged Consult ASS AG Service Department Bearing noises Bearings damaged Consult ASS AG Service Department Vibrations on Bearings damaged Consult ASS AG Service transmission Department Gearing damaged Consult ASS AG Service Department Transmission fastening Fasten the transmission loose Oil leak on transmission Radial seal defective Replace the radial seal Oil fitting leaking Retighten the fitting Gasket leaking Replace the gasket Alarm pressure switch Oil pressure too low Check the oil level Check the oil filter Check the function of the oil pump Alarm contamination Oil filter dirty Clean the filter and replace it indicator if necessary If a double switch over filter is installed switch the filter over and clean or replace the dirty filter element GB10 12 Spare parts Operating Instructions Industrial Transmission Nana 9 Spare parts If you require the service of our After Sales Service Department or spare parts during the lifetime of your transmission we ask you kindly to provide the following informatio
4. in the transmission are fitted with roller bearings designed acc to DIN ISO 281 All roller bearings are oil lubricated Depending on transmission design and installation position the transmission may also be equipped with grease lubricated roller bearings Torque transmitting components such as key and groove connections acc to DIN6885 and splined connections acc to DIN5480 have been designed acc to the applicable standards The transmission has been designed or selected according to the technical specifications demanded by the operating condition The transmission will warm up during operation The required cooling can be achieved by natural convection an additional fan or by an oil cooling system ASS AG tas taken this into account already when selecting your drive and the transmission is therefore equipped accordingly The correct transmission oil level is adjusted and monitored by means of oil lug dipstick or inspection glass The oil drain plug see dimension drawing is used to change the oil All shafts protruding from the transmission are sealed by radial seals Depending on application and design grease filled labyrinth seals or mechanical seals see dimension drawing may be used 3 3 Connecting structure Depending on the transmission design the transmission will apply considerable forces and torques with probably changing directions to the machine shaft and also to the connecting structure Weight forces and reactive moments
5. must be introduced into the customer provided structure in a suitable form ASS AG is not responsible for the design and construction of connecting structures and foundations 18 GB10 12 Operating Instructions Industrial Transmission Transport Packaging and Storage 4 Transport Packaging and Storage 4 1 Notes on safety A WARNING Danger of injury Transport as well as loading and unloading activities always impose the risk of injury by falling down parts The following notes on safety must therefore always be observed Always move the transmission with greatest care and caution The transmission must only be lifted by the lifting points provided for this purpose see dimension drawing Use only lifting tackle of sufficient load bearing capacity Ropes belts or other lifting tackle must be fitted with safety hooks Observe the centre of gravity when using ropes belts or similar for transport Do not lift by the shafts protruding from the transmission Do not use any ropes showing signs of cracks chafe marks Ropes and belts must be free of knots Ropes and belts should not run across sharp edges Do not lift loads over persons 4 2 Transport inspection We recommend checking the complete delivery for completeness and possible transport damage immediately after arrival M ATTENTION The liability of the insurer may become null and void if the following instructions f
6. 10 12 Operating Instructions Industrial Transmission Installation n LEE Lift the transmission by using appropriate lifting gear at the specified lifting points and position it in the fastening position of the connecting structure observe the additional notes in the dimension drawing The exact alignment is made via the shaft axes by using appropriate measuring equipment Use screws of strength class and length and washers specified in the dimension drawing Tighten the screws the specified tightening torque can be taken from the dimension drawing While tightening the screws do not constraint the transmission check the alignment again and correct it if necessary 5 3 5 Oil lubrication system option For the oil lubrication system observe the attached additional documentation Perform the following steps to install the oil lubrication system 1 2 3 4 If the oil lubrication system is not mounted to the transmission it must be installed on a suitable foundation The oil lines must be installed as specified in the dimension drawing and should not be mounted under tension The electric wiring for the oil pump can be taken from the attached additional documentation for the corresponding components w ATTENTION A wrong sense of rotation of the oil pump can lead to transmission damage Observe the attached additional documentation and the dimension drawing With water cooling the limits for water pre
7. 5 1 Storage over more than 6 months If the transmission is stored for longer than 6 months additional measures are required Remove the breather filter and fill the transmission completely up to the breather filter with the oil specified on the type plate Then close it air tight with a plug Before taking the transmission into service the oil level must be corrected as specified in the dimension drawing The condition of the lubrication oil must also be checked and the lubrication may need to be changed Check packaging and external conservation regularly every 3 months for damage renew or repair as necessary Transmission shafts and internal parts must be moved at regular intervals We recommend rotating the drive shaft every 3 months as often as is required to rotate the output shaft by more than 360 4 5 2 Storage over more than 12 months If the transmission is to be stored for longer than 12 months the radial seals must be checked for leak tightness and brittleness and if necessary replaced before the transmission is taken into operation In addition the external conservation must be adapted to the extended storage conditions consultation with ASS AG required See measures under 4 5 1 22 GB10 12 Operating Instructions Industrial Transmission Installation 5 Installation A WARNING Danger of injury Installation and assembly work must only be performed by specially qualified personnel and in com
8. N 51517 3 ISO 6743 6 and 9 AGMA 9005 D94 for improvement of corrosion prevention and resistance to aging and which reduce wear in mixed friction The oils have to fulfil the following tests e Scuffing resistance in the FZG test according to DIN ISO 14635 1 A 8 3 90 fail stage gt 12 e Low speed wear resistance according to DGMK 377 stage 1 4 wear category low stage 5 no wear increase to stage 4 pinion wear lt 25 mg e FE8 ball bearing test according to DIN 51819 3 D7 5 80 80 ball wear lt 10 mg cage wear lt 100 mg e Grey staining resistance according to FVA 54 I IV fail stage 10 GFT high e Flender foam test foam increase lt 15 1 minute after test e Seal compatibility approval by Freudenberg e Compatibility to 2 component poly epoxy paint e Compatibility to ASS AG corrosion protection oil If no additional information is provided in the technical specifications dimension drawing then ASS AG recommends using the lubricant from the accompanying table These lubricants contain special additive packages for the lubrication of roller bearings gears and other machine elements GB10 12 37 Operating Instructions Industrial Transmission Maintenance Based on ASS AG experience the recommended lubricants are fulfilling the above mentioned requirements Due to the batch and quality fluctuations ASS AG cannot grant a guarantee for the safe and reliable operation of these lubricants It is the sole responsibi
9. Operating Instructions Industrial Transmission Gear type P3K 091 N036 241 VHN Order No IP6203 ASSAG Switzerland Hauptstrasse 50 Antriebstechnik CH 3186 Dudingen Nu S i 3 7 Telefon 41 26 492 99 10 Technique d entrainement eo he ee ona Website www assag ch Operating Instructions Industrial Transmission Nana ASS AG Switzerland fully complies with the quality and environmental standards of ISO 9001 and ISO 14001 It is the environmental goal of ASS AG to develop products with a minized environmental impact in production use and waste disposal Please do not hesitate to contact us if you have any questions concerning environmental aspects in connection with the commissioning of our products 2 GB10 12 RC ne de D LAA LS LA A A 2 LAS 2 deceeccdceusienesotetuuidssesaed a a O dates cedlauevead a a Taaa 7 Tt Via Ua CUO SP PRE nee ee RP 7 1 2 Information ON operating instructions ccccssccsccccsccesccescceccesccescccsccusccuccsccusccesccesecescceccesccesccusccuscees 7 DEN and WAU ANNE os cess en ea tance a ne ee 8 1 4 Explanation of SV DOS cc ite ecin ec op Sees etek ca cence eee 9 MP SAVE S cnie ts cesns esunceusaecavestesueanepoubesccanecevesnceseec 10 CO UN ee de eee econ et ne ee ace done ste ne en eee ee ne eects 10 LP NAS SDS a ae ee ea rer 10 D D de 11 2 1 Responsibility of the USEM cccsccssccssccesccesccesccecccscccsccnsccusccusccesccecccececsccsccesccusccesccesccuccesccsc
10. ansmission carries a type plate with important technical data Oil type 1 0 ASS AG Schweiz Hauptstrasse 50 CH 3186 Dudingen Fig 1 Type plate example 1 Company logo 7 Operation factor 2 Serial number 8 Weight 3 Type designation 9 Year of construction 4 Ratio 10 Oil type 5 Drive torque or output power 11 Oil quantity 6 Drive speed 12 Manufacturer GB10 12 Operating Instructions Industrial Transmission Technical Description QE 5 3 1 2 ATEX Identification EXPLOSION PROTECTION Transmissions complying with EC directive 94 9 EC ATEX are marked with an ATEX decal e C E 11 3G T3 D170 C Tamax 50 C Fig 2 ATEX decal example Explanation CE symbol Ex Symbol for explosion endangered atmosphere Il Equipment group acc to EC directive 94 9 EC 3 Category acc to EC directive 94 9 EC G T3 Zone distribution for gas acc to ATEX temperature class D170 C Zone distribution for dust acc to ATEX max surface temperature Tamax max permissible ambient temperature GB10 12 17 Operating Instructions Industrial Transmission Nana Technical Description 3 2 Transmission All geared parts meet the requirements of IS06336 DIN3990 DIN3992 and have been designed with sufficient safety factors for high durability For maximum safety and wear resistance ASS AG solely uses case hardened nitrated annealed and austempered gear materials All necessary bearing points
11. ble covers and service hatches must stay closed Be aware that rotating parts may continue rotating for a certain time after the transmission has been shut down For this reason Do not remove and covers and service hatches during operation Do not start operation without the intended covers in place Make sure that all machine parts have come to a halt before starting work on the transmission A WARNING Danger of injury Depending on rotary speed power and environmental conditions the expected sound pressure level L acc to DIN 45635 T1 and T23 may be gt 80 db A Ear defenders may be necessary EXPLOSION PROTECTION During assembly and disassembly work the environment must be free of explosive gas mixtures and dust concentrations Failure to meet this requirement may result in the loss of the explosion protection EXPLOSION PROTECTION If the transmission is to be used in an explosion endangered environment all attachments must meet the conditions of directive 94 9 EG Failure to meet this requirement may result in the loss of the explosion protection 2 5 Emergency Stop switch The transmission is used in a plant and has no own control The user is obliged to ensure that Emergency Stop switches are installed in compliance with the applicable accident prevention regulations The user must inform the operating personnel about the locations and the function of these Emergency Stop switches 2 6 Operating personn
12. ce is the early response to possible failures in order to maintain a reliable and safe operating condition of the transmission This forward looking preventive maintenance includes the regular monitoring and inspection of the transmission during operation as well as the performance of scheduled maintenance work All tasks performed must be documented according to the following data e Date of assembly e Initial filling quality and quantity of oil e Start and end of running in as well as the detected peculiarities e Date of commissioning as well as the related performance measurements e Date of first oil change and operating hours e Dates of all other oil changes and oil analyses e Inspection reports including documentation of operating data e Documentation of maintenance work 7 1 Safety EXPLOSION PROTECTION For work on ATEX approved transmissions the following points must be observed e Installation assembly and maintenance work must only be performed in a non explosive atmosphere Ask for a written permission before starting work e Use only tools which have been approved for use in explosion protected plants e Failure to meet these notes results in the loss of the explosion protection GB10 12 Operating Instructions Industrial Transmission Maintenance A WARNING Work on the transmission must only be performed with transmission and plant shut down With all work related to operation installation and maintenance th
13. cuscesceees 11 PA 9 1121 0e Lee MU EEE E E E A E E E E E 12 2 3 Personal protective outfit ssesessecessecsssecsssecsssececsecessecesseoessecscsecscsececsecsssecesseceesecessecsesecsesecesseseseeoe 13 2 4 Dangers that may arise from the transmission ssessssessssesseseosececsscecsececsesecsececsesecsesecssseoseseosesecseseeeee 13 2 5 Emergency Stop switch sessesessecsececessecsssecessecsssecessecessececsecessecsssecseseceesecsssecessececsecessecsssecsesecessesseseoe 14 2 6 Operating PerSOnNE lsrin annn EEEO 14 Tec DESID ee E E ET E 16 JA SIAC IRIE IUN renina E E E E E E 16 Bee Be VIDS 0 ES A 16 71 2 ATEX TO CNCIICARION ee ea anse este 2 come de Does near caen eee ee see 17 Ja TANS MISSO N Eee PE RE Re 18 5 COMM CELINE SEC dE oarra E E E 18 4 Transport Packaging and Storage 2 2 0 ntm topiane decor tien insistent sta cet annee telnet 19 EA AU DEC On Sal CU esse testes A sees conaccueens saapeveeccatasceccauseanesuescocduosecene aueveeseues 19 4 2 Transport TING D COR ae a tente en den a ete ee ni res 19 PRS PA UN acest E E E se aneueescceesapeceeseeeetees 20 4 4 Unpacking and cleaning esessesessesessessosesseseseosessosessosessoseseosesessosessessosessosesessosesseseseesessosessosessesessosesse 20 ASSAG Switzerland Hauptstrasse 50 Antriebstechnik CH 3186 D dingen i 3 7 Telefon 41 26 492 99 10 Technique d entrainement eo he ee ona Website www assag ch Operating Instructions Industrial T
14. e shut down procedures described in these operating instructions and the necessary precautions must be strictly applied For any interruptions in operation the correct function of all necessary protective features must be assured After completing work on the transmission please check that all safety installations are correctly in place and fulfil their function Safety features must never be bypassed or taken out of function A WARNING Work on the transmission is only to be performed by qualified and specially trained personnel Always wear the following personal protective outfit when working near the transmission Tight fitting clothes no wide arms no rings etc Protective goggles to protect the eyes against flying parts and squirting out fluids Safety boots as protection against heavy falling down parts and slipping on a slippery floor QE 5 A WARNING Danger caused by electric current Work on electric equipment must only be carried out by qualified professionals and in compliance with the applicable safety regulations Switch off the electric power supply and secure it reliably against being switched on again before starting work A WARNING Danger of burning Due to the high temperatures on the transmission there is a danger of burning Do not touch the transmission during operation Make sure that the transmission has cooled down to room temperature before starting maintenance and r
15. el The necessary work must only be performed by trained or instructed personnel with appropriate knowledge and experience Each person entrusted with the installation GB10 12 Operating Instructions Industrial Transmission Safety n LEE commissioning operation and repair of the transmission must have read and understood the complete operating instructions before performing the corresponding work This applies also if the corresponding person has already worked with this or a similar type of transmission or has been trained by the manufacturer It is recommended that the user receives a written confirmation from his personnel that the content of these operating instructions has been read Knowing the content of these operating instructions is a prerequisite to protect the personnel against dangers to avoid errors and thus to operate the transmission in a safe and reliable manner The responsibilities for operation and maintenance must be clearly assigned to avoid any unclear assignment of competences under the aspect of safety The user must also make sure that no unauthorized persons perform any work on the transmission The operator is obliged to inform the user immediately about any occurring changes on the transmission which could affect the safety GB10 12 16 Operating Instructions Industrial Transmission NSS Technical Description 3 Technical Description 3 1 Identification 3 1 1 Type plate The tr
16. epair work ty ATTENTION GB10 12 33 y Operating Instructions Industrial Transmission n LEETE Maintenance Inappropriate cleaning work may cause damage to radial seals and contamination of the lubricant Never use high pressure cleaning equipment for external cleaning of the transmission 7 2 Monitoring the operating status During operation the following inspections must be performed on the transmission in regular intervals and any irregularities must be recorded EXPLOSION PROTECTION Instructions marked with this symbol must be strictly observed for transmissions with the intended use acc to ATEX Transmissions used in extremely dusty environments require regular temperature monitoring because dust deposits on the transmission will restrict the discharge of heat and cause an excessive build up of heat over the course of time Clean the drives regularly from dirt Failure to meet these notes results in the loss of the explosion protection 34 GB10 12 Operating Instructions Industrial Transmission Maintenance Interval Inspections Comments max housing temperature must be lt 90 C weekly Change in transmission noise o TS see SST weekly Operating parameters specification __ Oil filter contamination indicator option every 3 months Function of oil system pressure flow ms option every 3 MONS Funcion of oil cooler fopton _ every 6 months Safety e
17. euesuesces 8 42 L STOFAB Re sde ete annee 19 Lia DEN ne cd se tte 6 SOS ee teceeseeeeeesacece cee aenes 7 LuDricant Soak cee ntatctui ei cities 35 T M Technical Description 14 MaINTenANCe sers eassnanse 30 Tight fitting clothes 11 Maintenance plann cccsccsccsccssccscceccesccscceccess 34 Torque SUD DOME visicsceeseceissvssecaressvectvereeavicasessersncs 24 Manufacturer seseseeseosecsesesescsecsecsecseecsecsesesessee 5 Transport INSPECTION sessesecesecssscsesececseseseceoe 17 MICRO NAN dd anena aaa 32 Trouble shooting 40 ASSAG Switzerland Hauptstrasse 50 Antriebstechnik CH 3186 Dudingen i 3 7 Telefon 41 26 492 99 10 Technique d entrainement eo ee ee ane Website www assag ch Operating Instructions Industrial Transmission U Waste disposal UO SON RER Re 9 W Waranty sicssrasiiiec a 6 GB10 12 47 Antriebstechnik Technique d entrainement ASSAG Switzerland Hauptstrasse 50 CH 3186 D dingen Telefon 41 26 492 99 10 Fax 41 26 492 99 11 Website www assag ch
18. fety regulations resulting from the risk analysis of the work places on the transmission are gathered in operating instructions acc to Equipment Utilisation Regulation Arbeitsmittelbenutzungsverordnung 6 Non compliance with these safety regulations will lead to the loss of any compensation claims EXPLOSION PROTECTION In case of transmissions intended for installation into plants for operation in explosion endangered environments acc to the ATEX regulation the user must ensure compliance with the ATEX regulation for the overall plant Failure to meet this requirement results in the loss of the explosion protection 2 2 Intended use The operational reliability of the transmission can only be assured if the transmission is used for the purpose it has been intended for according to the information in these operating instructions and the technical documentation The transmission is solely intended for installation in a machine and must only be used and operated subject to the conditions contractually agreed upon between manufacturer and user Intended use also includes compliance with the conditions for installation operation and cleaning Any use beyond these boundaries is considered as unintended Any damage resulting from this is the sole responsibility of the user The transmission is used in a plant and has no own control During operation no operating personnel is required The user must make appropriate provisions for
19. he oil level by means of oil lug dipstick or inspection glass Install plugs or breather as specified in the dimension drawing Synthetic oils may only be used if this is specified in the dimension drawing and on the type plate see chapter 7 4 ty ATTENTION Changing between mineral and synthetic oils can cause damage to plastic materials paints and rubber materials Consult ASS AG before changing The mixing of oils from different manufacturers types and different viscosities is prohibited 6 2 Initial commissioning The following points must be checked before initial commissioning 30 Make sure that all guards and safety installations are in place correctly mounted and functioning Check transmission and all components for tight fit and check the screw fittings Make sure that the sense of rotation corresponds with the dimension drawing The ambient temperature must be within the agreed range if not you should consult ASS AG If an oil system has been planned for operation it should be running for 15 minutes before the transmission is switched on Make sure that the oil system works correctly and without leaks GB10 12 Operating Instructions Industrial Transmission Commissioning 5 QE 6 3 Running in The transmission can now be operated within the plant by observing all safety regulations Start the transmission without load if possible raise the rotary speed in two to three steps to nom
20. he transmission Catch the lubricant with a suitable vessel Dispose of fuels and lubricants conserving and cleansing agents according to the valid environmental regulations Keep the oil quantity remaining in the transmission as low as possible When draining off old oil do not apply pressure to the transmission as otherwise the plugs may be pressed out of their bores With heavily contaminated lubricants the transmission must be flushed out again with fresh oil Screw the oil drain plug back in and seal it properly If the transmission is equipped with an oil system the oil in oil lines filter and cooler must also be changed Clean the filter and replace it if necessary Use only the oil type specified on the type plate Adjust the oil level according to the oil level indicator see dimension drawing and close the filler opening again If the transmission is fitted with an oil system this should be run during filling to fill all lines with oil 7 6 Measures after maintenance work After performing maintenance work and before switching the transmission back on the following points must be observed in compliance with all safety regulations Check all previously loosened screw connections for tight fit Check that all previously removed guards covers container covers have been properly reassembled Make sure that all tools materials and other equipment used has been removed from the working area
21. hinery directive 2009 42 EG This technical documentation is part of the transmission delivery and must be available at the point of use of the machine at any time Special technical information for the respective transmission type can be found in other documents of the technical documentation technical specification dimension drawing assembly drawing bill of materials GB10 12 Operating Instructions Industrial Transmission General Information 5 QE gt vore Descriptions and graphic representations in these instructions may differ from the actual design of the transmission These operating instructions must be thoroughly read before installation and commissioning 1 3 Liability and warranty All information and notes on operation maintenance and cleaning of the transmission is provided under due consideration of our previous experience and to the best of our knowledge The manufacturer will not assume liability for damage or malfunctions resulting from the non observance of these operating instructions In the course of the ongoing development of this transmission we reserve the right for technical changes without prior notification Translations are also done to the bet of our knowledge We will not assume any liability for translation errors The German version of these operating instructions delivered with the transmission is decisive 8 GB10 12 Operating Instructions Industrial Transmission QE
22. ice for the assurance of compensation claims against third parties and for measures to reduce the damage Report the insurance claim immediately to the insurer and supply the insured with the complete damage documents as soon as possible but at the latest in due time before the expiration of possible exclusion and or limitation periods for compensation claims against third parties EXPLOSION PROTECTION In case of transport damage the transmission must not be taken into service Consult ASS AG 4 3 Packaging The transmissions can be delivered in different types of packaging The main packaging materials are wood cardboard and plastic materials foils foam rubbers bust also steel straps for coils The packaging material also includes materials which are added to the packed goods for protection against moisture e g bags of silicagel If no special arrangements concerning the return of the packaging material had been made the packaging material will remain with the customer m ATTENTION Waste disposal in compliance with the applicable waste disposal regulations must be assured If necessary entrust a specialized waste disposal company with the correct disposal of the packaging material 4 4 Unpacking and cleaning The following points must be observed for unpacking and cleaning Remove the packaging material without damaging the transmission and the attachment parts Lift the transmission out of the packaging mate
23. inal speed and hold it at this level If no unusual behaviour is detected in this phase the load can be increased up to nominal torque nominal speed During this running in phase watch the function and the operating status of the transmission under the following aspects Uniformity of rotation vibrations running noises maximum surface temperature leaks and lubrication Shut the transmission down if a fault is suspected perform trouble shooting and repair the fault after consulting ASS AG EXPLOSION PROTECTION For running in transmissions with ATEX approval the following points must additionally be observed e When used in explosion endangered environments the maximum permissible surface temperature must be monitored e With safety installations make sure that components rotating towards each other do not touch and have a sufficient distance e Failure to meet these notes results in the loss of the explosion protection e With brake equipment installed it must be assured that the brake will not rub when released and that a sufficient brake pads have a sufficient thickness see dimension drawing ty ATTENTION The maximum performance data and environmental parameters specified in the dimension drawing must be complied with and should not be exceeded GB10 12 31 QE 32 Ua Operating Instructions Industrial Transmission Maintenance 7 Maintenance The most important purpose of monitoring and maintenan
24. lation n LEE Current flow through the transmission may cause damage Electric attachments such as motors frequency inverters etc must be separately grounded to avoid a possible current flow For the welding work the transmission must never be used as a ground point because this could damage roller bearings and tooth flanks 5 3 1 Attachment of quill drive with shrink disc Shrink discs with single taper are used to assemble the transmission However if a different shrink disc design is to be used the technical documentation will have additional instructions included In as delivered condition the shrink disc is pushed over the quill shaft by the manufacturer without clamping and secured with a disc against falling off during transport r ATTENTION Tightening the screws without the machine shaft inserted can damage the shrink disc Perform the following steps to install the transmission 1 Before assembling the transmission remove the axial locking dics from the quill shaft 2 Clean the quill shaft so that the mating surfaces are free of grease see chapter 4 4 3 Lift the transmission by the specified lifting points with a suitable hoist 4 Align the quill shaft of the transmission to the machine shaft and slide the transmission completely on Tighten the screws of the shrink disc one after the other in several cycles 6 Apply the tightening torque specified in the dimension drawing pi Perform the following ste
25. les take the specified tightening torque from the dimension drawing ATTENTION Transmissions with torque support must under any circumstances be free of constraint 5 3 3 Mounting of flange type transmission Perform the following steps to install the flange type transmission 1 pi Before assembling the flange type transmission into the machine frame the corrosion protection must be cleaned from all fastening areas flange areas see chapter 4 4 and the areas must be free of grease Attach suitable lifting gear to the lifting points specified in the dimension drawing lift the transmission and place it in fastening position on the connecting structure that has also been cleaned observe the additional notes in the dimension drawing The exact alignment is made via the shaft axes by using appropriate measuring equipment Use screws of strength class and length specified in the dimension drawing Tighten the screws crosswise with the specified torque see dimension drawing While tightening the screws do not constraint the transmission check the alignment again and correct it if necessary 5 3 4 Installation of foot type transmission The following points must be observed before installing the transmission 1 Before assembling the flange type transmission into the machine frame the corrosion protection must be cleaned from all fastening areas flange areas see chapter 4 4 and the areas must be free of grease GB
26. lity of the lubricant manufacturer Mineral oils Manufact Viscosity classes from to BP Aral ISO VG 150 ISO VG 680 ISO VG 150 ISO VG 680 BP Castrol ISO VG 150 ISO VG 680 BP Optimol ISO VG 150 ISO VG 680 BP Tribol ISO VG 150 ISO VG 680 Fuchs ISO VG 150 ISO VG 680 Fuchs ISO VG 150 ISO VG 680 Fuchs Lubritech ISO VG 150 ISO VG 680 Shell ISO VG 220 ISO VG 460 Ki ber ISO VG 150 ISO VG 680 Poly a Olefine PAO Manufact Viscosity classes from to Degol PAS ISO VG 150 ISO VG 460 Enersyn EP XF ISO VG 150 ISO VG 460 BP Aral BP Aral BP Castrol Alphasyn EP ISO VG 150 ISO VG 680 i PT BP Optimol ISO VG 220 ISO VG 460 BP Optimol ISO VG 220 ISO VG 460 BP Tribol ISO VG 220 ISO VG 460 Exxonmobil ISO VG 150 ISO VG 460 Exxonmobil ISO VG 150 ISO VG 680 Ki ber ISO VG 150 ISO VG 680 Poly glycoles PG Manufact Viscosity classes from to BP Aral ISO VG 150 ISO VG 680 800 BP Tribol 800 ISO VG 150 ISO VG 680 Kluber Klubersynth GH6 ISO VG 150 ISO VG 680 Lubrication grease 38 GB10 12 Operating Instructions Industrial Transmission Maintenance Manufact Consistency classes Aral Lagerfett HL3 NLGI 3 FAG Lagerfette Arcanol NLGI 2 NLGI 3 Mobilux EP2 NLGI 2 GB10 12 39 Maintenance Operating Instructions Industrial Transmission Nana 7 5 Maintenance work 7 5 1 Taking an oil sample A WARNING Danger of burning Hot tran
27. n together with your order e Serial number see type plate e Transmission type see type plate e Position number or article number see assembly drawing or bill of material e exact description of problem Please use only genuine spare parts from ASS AG 44 GB10 12 A O After Sales SEFVICR 2 2 ses 43 ORAN eee een ener 38 C OR ede eedes hus ceeteeceaveen eaves 27 Clean IND acc 19 Oil lubrication system option s sessese 0 25 Commissioning tasse es 27 Operating Instructions rennes 5 D Operating personne ssccsccsscssccsscescescceccess 13 Dan OG aio eo de 11 p E PACK RUNS nencen 18 Ear defenders issues 11 Personal protective outfit 11 Emergency Stop SWItCHN csccsscsscceccesccsccecees 12 Place of installation ccssecssscccseeccescceeees 21 F Protective ZOREIES ccsccsccsccesccscccscceccesccscceees 11 Fault rectification eeeosessesessecsecsescsecsescseesee 41 Q Flange type transmission 24 S LU ELLES E eea E EEEE 23 Foot type transmission 25 5 G RONDE Re nes a te dents 29 General Information ss 5 A SAR A A A 30 Initial commissioning 28 Sa YOON Sav escent ceseeteeeseseececesuesace 11 Installations 21 22 ST A4 LA L O CLEO ES En A SERRE 23 intended UG Sn A ed ds anses 10 Spare parts ss sescnsss scores ascers
28. oints must be observed e Installation assembly and maintenance work must only be performed in a non explosive atmosphere e Ask for a written permission before starting work e Use only tools which have been approved for use in explosion protected plants e Failure to meet these notes results in the loss of the explosion protection e During assembly and disassembly work the environment must be free of explosive gas mixtures and dust concentrations Failure to meet this requirement may result in the loss of the explosion protection e If the transmission is to be used in an explosion endangered environment all attachments must meet the conditions of directive 94 9 EG Failure to meet this requirement may result in the loss of the explosion protection 6 1 Oil filling The following points must be observed before filling the transmission Grease lubrication points on the transmission have been filled with grease in the factory The transmission is delivered without oil filling if not agreed differently Quantity and quality of oil lubricant type and viscosity class can be taken from the dimension drawing type plate Recommended lubricant see chapter 7 4 GB10 12 29 Commissioning Operating Instructions Industrial Transmission Nana pS ATTENTION Impurities in the lubricant can lead to transmission damage Fill in fresh oil through a 25 um filter For the oil filler bore refer to the dimension drawing Check t
29. or cases of damage are not observed Even if there is only the suspicion of damage the delivery should only be accepted with reservations e g shipping documents with information about the expected damage If goods are delivered in containers make sure that container and locks or seals are inspected by officials of the shipping company or the forwarding agent If containers are damaged or locks and seals have been broken are missing or deviate from the freight documents you should only accept the delivery with reservations and a description of the expected damage and keep damaged or incorrect locks and seals in a safe place Ensure compensation claims against third parties Shipping company other forwarders haulage companies warehouse companies customs and harbour authorities e ask for mutual inspection of the damage e ask for written confirmation of the damage GB10 12 19 A Operating Instructions Industrial Transmission T Ir Transport Packaging and Storage QE e make liable in writing with detailed description of the damage meaning in case of externally visible damage before accepting the goods in case of damage that is not visible from outside directly after the detection Determine and comply with complaints deadlines Ensure reduction for the already existing and avoidance of further damage Immediately consult the instance specified in the insurance documents to inspect the damage and to receive adv
30. or correct functioning In the end the user or the personnel authorized by him to work on the transmission within the scope of their duty is responsible for the trouble free operation of the transmission Any information concerning industrial safety is based on the currently valid regulations of the European Community In other countries the corresponding laws or country specific regulations must be observed and complied with For both the European Community and also for the other countries the user must determine the up to date status of all applicable standards Besides the notes on industrial safety in these operating instructions the generally valid safety and accident prevention regulations and the applicable environmental protection regulations must also be observed and complied with The user must clearly specify the responsibilities for operation and maintenance and ensure strict compliance with these responsibilities thus to rule out any unclear distribution of competencies under the aspect of safety All information in these operating instructions must be strictly followed In particular the user must make sure that a risk analysis acc to the Employment Protection Act 5 is carried out to identify any further dangers which may result from the specific work conditions at the point of use of the transmission GB10 12 11 Safety Operating Instructions Industrial Transmission Nana all other instructions and sa
31. pliance with the safety regulations EXPLOSION PROTECTION For work on ATEX approved transmissions the following points must be observed e Installation assembly and maintenance work must only be performed in a non explosive atmosphere e Ask for a written permission before starting work e Use only tools which have been approved for use in explosion protected plants e Failure to meet these notes results in the loss of the explosion protection See chapter 2 5 1 Requirements on the place of installation Before installing the transmission one must check whether the installation location meets the following requirements The foundation or connecting structure must be provided with suitable locating bolts see transmission measuring sheet Foundations or connecting structures must have sufficient rigidity and should not distort the component to be fastened when tightening the screws Ensure sufficient dimensioning size flatness and correct positioning of the mounting surface Vibrations or shocks from adjacent machines or plants must not be transferred to the transmission The foundation fastening structure must not be a source of resonance vibrations There must be sufficient space for installation maintenance and cleaning work GB10 12 23 Operating Instructions Industrial Transmission Installation n LPE A WARNING Incorrect mounting or insufficient load bearing capacity of the connecting s
32. ps to remove the transmission 1 Attach the lifting tackle to the specified lifting points on the transmission 2 Loosen the screws of the shrink disc in several cycles but do not unscrew completely 3 If necessary turn adjacent screws into the forcing threads to separate the inner from the outer ring 4 Once the pressure of the shrink disc has been relieved pull the transmission off the machine shaft do not skew 5 3 2 Installation of torque support The design of the torque support may vary with the transmission design Corresponding information can be taken from the dimension drawing The torque support may be mounted to the transmission or delivered separately M ATTENTION Ensure sufficient stability because the centre of gravity of the complete unit will change considerably after assembly GB10 12 25 QE 26 5 Operating Instructions Industrial Transmission Installation Perform the following steps to assemble the torque support 1 2 Before assembling the torque support the corrosion protection must be cleaned from all fastening areas flange areas see chapter 4 4 and the areas must be free of grease Use appropriate lifting gear and tools to position the torque support above the centring on the transmission and push it on observe additional notes in the dimension drawing Use screws of strength class and length specified in the dimension drawing Tighten the screws successively in several cyc
33. quipment correctly assembled at least every 6 Renove cdemaidn max dust deposit months 5 mm every 6 months Check radial seals PY every 6 months Adjustment of brakes every 6 months Check fastening screws for tight fit every 6 months Check the status of the lubricant use Oil analysis Due to the heating up of the fuel and the turbulences during operation the oil level is not correctly indicated during operation and should only be checked and corrected in the course of maintenance work and on a cold and resting transmission ty ATTENTION With housing temperatures above 90 C there is a risk of overheating Consult ASS AG immediately GB10 12 HGB 7 3 Maintenance plan Maintenance work must be periodically performed as specified in the following table see chapter 7 1 With every standstill Check the oil level EEE With oil change Oil change with optional oil filter Operating Instructions Industrial Transmission Maintenance After 500 operating Oil change irrespective of oil type hours At the latest after 3 months Every 3 months Every 6 months Clean the breather filter in case of Ss excessive dirt more frequently Check the usability of the lubricant by means of an oil analysis concerning additive degradation aging contamination water content etc Every 6 months Lubricate the grease point with optional grease nipples 1x annually Inspection by ASS AG Mineral oils at
34. ransmission Nana DS SIDA ne ne eee tenue statue does ue ea etre esta ide Ro ee tone 21 4 5 1 Storage over more than 6 MONKHG ccccccsccsccecccsccsccecccsccscceccesccncceccescceccescescceccescessceccescessceccescs 22 4 5 2 Storage over more than 12 MONTHS cssccsccecccsccsccecccsccncceccesccnccescesccncceccesscnccescscceccescsscecceses 22 4 GB10 12 Operating Instructions Industrial Transmission SE LE LA 10 a PRE E RER RC 23 5 1 Requirements on the place of installation sccsccsccssccsccecccsccsccecccsccscceccesccncceccesccnccuscesccssceccesceecs 23 5 2 Measures before installation esosesosesosssosssessssosesosesosesosssossscssssosesosesosesosssossssosssosesosesosssosssosssessse 24 S Stala ON e a sn timonesodecenpsecdorace eacenavesaneennennennamonss 24 5 3 1 Attachment of quill drive with shrink disc ssesessessssecssssecsssecssseosssecsssecsssecsssecessecssseosssecssseosssesee 25 5 3 2 Installation of torque SUpport esessessessesececsecsesecseseososesecsecseseosececeosececseosecessoseceosececsessececeeseceeseoe 25 5 3 3 Mounting of flange type tranSMiSsiOn ccssccsccsccssccsccecccsccnccesccscceccescscceccesccscceccesccsscuccescosccucees 26 5 3 4 Installation of foot type traNSMISSION ccscccsccscccsccsccecccsccnccesccsccnccescncceccesccncceccesccssceccescoscccees 26 5 3 5 OIL l prication system OPTION seriiinngsseissn eaS NESS ENEN 27 Be CONC udne WOLK
35. renren ee RE Se 28 6 CON SS ONIN 2 AEE A E E E N E T E EA E D O E noue 29 CLOINNE co EA OA T O OO 29 6 2 UIE tell COMMISSIONINE 2 ane yedecccutedesececedeteceecoucsevedespwususeaseevedoecsesedusuecansvececoutuereensesaserceenecusete 30 O LUE LA LA LL ALLER RER PR A 31 MOIS AMOR a A E A ea a on a tre de S 32 r ME E RE RP RE E EEO EE RE PEER 32 7 2 Monitoring the operating status 2 15 ue cacesne bac nne da tecaece cabine ne cebussce cess eadesencencatesaseeneotee 34 TS Malntenance DA een aa ane ne eo dan de ce to ea e ee 36 7 4 Lubricant r commendatioi SSSR sente sde na codes fase desc e nece 37 7225 M intenance NOIR nee een aan n een een ne ace 40 7 5 1 Taking an oil sample ee ences 40 7 5 2 Performing an oil change sessesssssssessosececsececsecsesecsesecsesecseceoseceoseceoseceosececseseoseceosececseceeseseesessesese 40 7 6 Measures after maintenance workK sssssosssssssosesoosesosesosesosssossseosesosesosesosssosssossscosscosesosesosssosssosssessse 41 S TOUS OR E E E E E do 42 8 1 What to do in case COS nee sn eee ee a 42 8 2 Fault rectificatiOi ode ce re cscce ce teecensseeccca ed enecccaceenccereussanectsenctetestor snc usvetassensaswiestebeevactetcuesevehes vay 43 DS DAS o es ar crn assent a a en D tutes aad ee E E ENE E 44 GB10 12 Operating Instructions Industrial Transmission General Information 1 General Information 1 1 Manufacturer ASS AG Antriebstechnik Stefan Schoen AG CH 3186 Dudingen Haup
36. rial by the lifting points specified in the drawing 20 GB10 12 Operating Instructions Industrial Transmission Transport Packaging and Storage QE 5 Metallic bright surfaces such as shaft ends hollow shaft bores and flanges or foot areas are coated with corrosion protection agent The following points must be observed before removing the corrosion protection The corrosion protection must only be removed with a solvent and not by scratching or sanding Take care not to damage radial seals with solvent 4 5 Storage The corrosion protection applied before shipment is of such nature that the transmission can be installed in to the plant and taken into service immediately after arrival The transmission is delivered with an ex factory corrosion protection The internal conservation protects the transmission for max 6 months All exposed areas are either spray painted or coated with a corrosion protection The transmission must only be stored under roof and in a closed room T 0 C to 30 C dry air The floor of the storage room must be free of dust and dry The formation of condensation water on transmission and packaging material must be avoided Avoid mechanical shocks and damage Outdoors storage of the transmission is only permitted after consulting ASS AG accordingly GB10 12 Transport Packaging and Storage Operating Instructions Industrial Transmission Nana 4
37. should be observed GB10 12 y Operating Instructions Industrial Transmission n LE ETE General Information 1 5 Spare parts Use only genuine spare parts from ASS AG w ATTENTION Incorrect or faulty spare parts from other manufacturers may cause damage to the transmission However should spare parts other than the genuine spare parts from the manufacturer or spare parts not purchased from the manufacturer be used all obligations granted by the manufacturer or his dealers such as warranties servie contracts etc will become null and void without prior notification 1 6 Copyright These operating instructions must be treated confidentially It is only to be used by the authorized group of persons Passing these instructions on to third parties requires the written consent of the manufacturer All documents are protected by copyright law The distribution and reproduction of documents even in excerpts their use and the disclosure of their content is not permitted if not explicitly specified differently Violations are liable to prosecution and oblige to compensation We reserve the right to impose industrial property rights 1 7 Waste disposal Dispose of fuels and lubricants conserving and cleansing agents according to the valid environmental regulations Catch running out fluids and dispose of environmentally or if possible treat and recycle 10 GB10 12 Operating Instructions Industrial Transmis
38. shutting down the transmission when a dangerous situation arises or a fault occurs 12 GB10 12 Operating Instructions Industrial Transmission Safety 2 3 Personal protective outfit The following outfit should be worn when working on the transmission Tight fitting clothes low tear resistance no wide arms no rings etc Protective goggles to protect the eyes against flying parts and squirting out fluids Safety boots as protection against heavy falling down parts and slipping on a slippery floor Ear defenders as protection against hearing damage at sound pressure levels higher than 80 dB A 2 4 Dangers that may arise from the transmission This transmission is of state of the art design and meets all established rules and regulations on industrial safety However there will still be a remaining risk During operation the surface of the transmission reaches very high temperatures A WARNING Danger of burning Danger of burning caused by high surface temperatures of the transmission Do not touch the transmission during operation Make sure that the transmission has cooled down to room temperature before starting maintenance and repair work GB10 12 13 14 Safety Operating Instructions Industrial Transmission Najan The transmission works with rotating shafts A WARNING Danger of injury Rotating parts can cause severe injury During operation rotating parts must not be accessi
39. sion Safety QE 5 2 Safety The chapter on safety provides you with an overview of the safety aspects that need to be observed when operating the transmission In addition to the general notes on safety listed in this chapter further subject related safety instructions will be given in the individual chapters of this manual wherever this is necessary These are highlighted by symbols The transmission has been designed and built in compliance with the currently valid technical rules and regulations and is safe to operate However dangers may still arise from the transmission if it is operated by untrained personnel in an unprofessional way or is used for purposes it is not intended for In order to avoid dangers for persons and to assure the optimal power of the unit any changes and modifications made to the transmission require the explicit approval of the manufacturer Always keep safety and instruction decals such as sense of rotation arrows and operation signs on the machine in legible condition Damaged or illegible decals must be immediately replaced 2 1 Responsibility of the user These operating instructions must be available to all personnel entrusted with installation operation and cleaning at any time The user is obliged to ensure that the transmission is only operated in a proper and safe condition In particular all safety installations and interlocks must be well accessible and checked regularly f
40. smission oil can cause severe burns Wear protective outfit when taking oil samples The oil sample must be taken at operating temperature and generally at the lowest point of the oil sump or if available from the oil drain tap The removed oil quantity must be replenished 7 5 2 Performing an oil change See notes in chapter 6 1 The durability of the lubricant decisively depends on the operating conditions temperature load speed and contamination and the oil type used in the transmission The oil change intervals can therefore not be precisely specified The manufacturer recommends to have the usability of the lubricant analysed at regular intervals Your lubricant supplier will supply you with more detailed information Es ATTENTION Changing between mineral and synthetic oils can cause damage to plastic materials paints and rubber materials Consult ASS AG before changing The mixing of oils from different manufacturers types and different viscosities is prohibited A WARNING Danger of burning Hot transmission oil can cause severe burns Wear your protective outfit to change the oil 40 GB10 12 Operating Instructions Industrial Transmission Maintenance QE 5 The following points must be observed when changing oil Perform the oil change at operating temperature just after shutting the transmission down Unscrew the oil drain plug identified in the dimension drawing from the lowest point of t
41. ssure water quality and flow rate specified in the attached additional documentation and in the dimension drawing must be complied with 4 ATTENTION Installation position and height of the cooler and or the oil lubrication system can have a considerable effect on the function and must under no circumstances be changed without permission Observe the attached additional documentation and the dimension drawing EXPLOSION PROTECTION If the transmission is to be used in an explosion endangered environment all components of the oil lubrication system must meet the conditions of directive 94 9 EG GB10 12 27 Installation Operating Instructions Industrial Transmission Nana Failure to meet these notes results in the loss of the explosion protection 5 4 Concluding work After completion of installation work the following points must be observed The user must protect rotating parts against touching EXPLOSION PROTECTION Transmissions with ATEX approval must be fitted with equipotential bonding before commissioning Failure to meet this requirement results in the loss of the explosion protection 28 GB10 12 Operating Instructions Industrial Transmission Commissioning 6 Commissioning A WARNING Danger of injury Commissioning must only be performed by specially qualified personnel and in compliance with the safety regulations EXPLOSION PROTECTION For work on ATEX approved transmissions the following p
42. the latest after 6000 operating hours or 1 year synthetic oils at the latest after 20000 operating hours or 3 years Every 2 years Oil change when using mineral Observe specification oils as required after oil analysis recommendation of lubricant manufacturer Oil change when using synthetic Observe specification oils as required after oil analysis recommendation of lubricant manufacturer Inspection of roller bearings and Recommended gears Every 2 years Inspection of radial seals 36 GB10 12 Operating Instructions Industrial Transmission QE 5 Maintenance 7 4 Lubricant recommendation A WARNING Danger of poisoning Lubricants are harmful to health Skin contact with oils and lubrication grease can cause skin damage skin irritation inflammation allergies Therefore Observe the instructions and safety data sheets of the oil manufacturer Avoid long term excessive and repetitive skin contact Use suitable skin protection and skin care agents or wear oil proof gloves when handling lubricants Rinse splashes of oil out of the eyes with lots of water Wash lubricants off the skin with water and soap A WARNING Danger of injury Lubricants on the floor are a potential danger source because of the risk of slipping Saw dust or oil absorbing agents should be spread to bind and remove the lubricants ASS AG gear units require CLP quality gear oils according to DI
43. tructure can lead to severe bodily injury or material damage Install the transmission only if the connecting structure has a sufficient load bearing capacity and suitable receiving bores 5 2 Measures before installation EXPLOSION PROTECTION Before installation make sure that the transmission is complete and free of deformations and other damage which would indicate that it had dropped down Failure to meet these notes results in the loss of the explosion protection A WARNING The installation of a damaged or incomplete transmission can lead to severe bodily injury or material damage Install only a completely sound transmission In case of damage the transmission must not be taken into service Consult ASS AG 5 3 Installation The following points must be observed before installing the transmission Before installation check whether the correct transmission has been supplied with respect to the technical specifications The installation of the transmission the installation position and alignment must comply with the dimension drawing Subsequent changing of the installation position is not permitted A WARNING Danger caused by electric current Current flowing through the transmission can cause severe injury in case of bodily contact Attachment parts should therefore be separately grounded and never via the transmission r ATTENTION 24 GB10 12 Operating Instructions Industrial Transmission Instal
44. tstrasse 50 Phone 41 0 26 492 99 11 Fax 41 0 26 492 99 10 www assag ch Authorized person for documentation Marcel Wehr 1 2 Information on operating instructions The operating instructions in German language are the original operating instructions All other languages are translations from the original operating instructions These operating instructions are an important source of information and a reference guide for the personnel with respect to operation and maintenance of the transmission They shall enable safe and proper operation of the transmission This requires appropriate knowledge of all safety aspects to be observed during installation and operation as well as maintenance of the transmission Reading these operating instructions should therefore start with the chapter Safety The chapters thereafter are further focal points of information for the personnel For the avoidance of operating errors these operating instructions must always be kept near the transmission and should be available for the personnel at any time The accident prevention instructions and the general safety regulations must be strictly observed when operating the transmission The complete technical documentation consists of e operating instructions e technical specification dimension drawing e assembly drawing e bill of materials a operating instructions for accessories if available e declaration of incorporation acc Annex IIB EC mac
Download Pdf Manuals
Related Search