Operating Instructions - Stoewer
Contents
1.2. VE H6 Symbols Drain plug WII h V Vent plug SIT St wer Antriebstechnik GmbH Y ilevel Ee Only upon request 41 Operating Instruction D Series Troubleshooting Guide 42 10 Troubleshooting Guide av All the operations bellow must be done by othirized and skilled mechanichan electrican Inform ST WER before making any change to the gearbox Only oil change is allowed to change without information Do not make anythink if you are not sure what you are doing and contact St wer Any change or operation done without the information of ST WER is in your own risk and responsibility and St wer Antriebstechnik does not take any responsibility Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up You hear no noise and shaft is not turning You are not using any driver or frequency inverter You hear no noise and shaft is not turning You are using frequency inverter or driver You hear some noise but both motor shaft and gearbox shaft is not turning You are not using any driver frequency inverter or braked motor You hear some noise but both motor shaft and gearbox shaft is not turning You are using driver or frequency inverter You hear some noise but both motor shaft and gearbox shaft is not turning You are using braked
3. 30 St wer Antriebstechnik GmbH er Operating Instruction aU D Series Installing I oa d p i n f me N gt L J eg E RE Jedi ja d H O O j E amr St wer Antriebstechnik GmbH S Operating Instruction ES D Series A Installing 7 9 2 Assemble the parts as shown bellow 32 St wer Antriebstechnik GmbH er Operating Instruction D Series Installing 7 9 3 For the fixing bold position refer to the following dimensions INN Y UR 12 Type b b1 d R h h1 h2 DR23 10 DR33 10 40 20 12 27 5 200 150 170 50 25 14 27 5 250 182 210 Hv St wer Antriebstechnik GmbH 33 Operating Instruction aU D Series Installing 7 10 Fittting outputshaft elements Use the following ilustration to assemble output shaft units 1 Gear shaft end 2 Thrust bearing 3 Coupling hub 7 11 Correct position of otputshaft elements The Output Shaft unit transmision elements must placed as close as possible to the gear unit so that the radial load is as closest as possible to the gear unit M me 1 Hub
4. 34 St wer Antriebstechnik GmbH rer Operating Instruction aU D Series Installing 7 12 Fittting Couplings 7 12 1 By fitting couplings be sure that there is some clearanve between the two elements 7 12 2 By fitting couplings be sure that there is no exantricity between the two shafts 7 12 3 By fitting couplings be sure that the two shafts are not angular miss aligned Hm St wer Antriebstechnik GmbH gt Operating Instruction D Series Maintanace and Inspection 8 Maintanance and Inspections Under normal ambient and working conditions the gear unit should be checked according the follow ing intervals For definition of normal working conditions refer to the product catalogue Selecting Gearbox section Item to check replace Check for oil leakage Check oil leakage from seal Change Sealing Every 3 000 working or every 6 months Every 4 000 working Every 10 000 working Every 25 000 working hours hours or every 3 years hours x See Below for details Change Bearing Grease Change Bearings Check for noise Changes 25000 Oil change interval 70 80 90 Oil bath temperature Celcius 100 110 120 130 140 150 160 Mineral Synthetic PAO Synthetic PG For normal ambient conditions 70 degrees celsius oil bath temp should be taken as referance For D series Mineral oil is
5. Gear Units D Series Edition 01 2005 OIDCE 0101 0105 Operating Instructions St wer Antriebstechnik GmbH Enneststr 3 51702 Bergneustadt Tel 02261 40970 Fax 02261 41393 Operating Instruction D Series Contents Contents How Io Use This Manual asustusala 5 Unit DGS d EE 6 2 Detailedunit designations EE 6 2 2 Nameplate unit desi Eng OD saadama au 7 Part List of Standard Type Gear Units esse 8 S 19 00 opera DER tSp MSto a 8 32 DO Tessin 9 D NECEM RHET 10 tT omi NL rc 11 LE 12 40 lende eer 12 4 2 Improper ler nee 12 A 3 Safety Ins TAN HORS een 13 4 31 General Safety MSHI ONS assassinated aaa 13 4 3 1 1 Working on the gear PoC CT ur 13 4 3 1 2 Opel seien 13 4 3 1 3 MIDI NER esse 13 4 3 1 4 Lubricant eee ener eee M 13 4 3 1 5 Ambient Continue 13 4 4 Tightening TORQUE S saatanat eee rn AN aaa 14 E e EE 14 4 5 1 Suitable extinguishing agents protective equipment 14 4 5 2 Unsuitable extinguishing agents aussi 14 Thinks to Check Before the Gear Unit or Geared Motor is Installed 15 SO Me POM AION musa 15 lt ocu TT E 16 Inst lling The Gear Unit oen bn EX tmd eum sn anti am pee Me I7 6l TE E 17 6 2 Check the shan dimensi ns EE 17 6 3 Check the Een 17 GA Cheekthevollase uppuma alaalia 17 63 Check Ee aasta 20 6 0 Wise tine Dresthergli ps nee 20 6 7 Checkihe ARTE 20 6 8 Check shaft ends and mounting lesta aaa 20 6 9 Cover dbresive ambiente 20 6 10 Check accessibility to
6. 120 Celsius If higher than 120 Celsius and using ATEX conforming gear box immidiately stop the system and contact If not ATEX gearbox the gearbox i designed to work under max 80 Celsious If higher than 80 Celsius check the oil type and oil quantitiy level according your mounting position and check the nameplate mounting position If nameplate mounting position does not fit the actual position goto ID 100 Standart Gearboxes are designed to work under 40 Celsius ambient temperature If ambient temp is higher than 40 Celsius special solutions gearboxes are required Please contact Check Your moving parts for noise Disassemble the gearbox and run without load If you still hear the noise motor bearings or gearbox bearings are defect Change bearings Goto ID 100 Check Your moving parts for noise Disassemble the gearbox and run without load If you hear still the noise the oil may has some particles inside Change the oil and look for small particles If metal particles are found the gearbox may have some demage Goto ID 100 43 Operating Instruction D Series Troubleshooting Guide 44 Gearbox is noisy Regular nocking noise Regular up and down noise Gearbox is with braked Guer ema motor and noise is comming from the brake side randomly You are using frequency NR inverter and the noise level Gearbox is noisy is changing according your speed Oil Leakage from Seal Gearbox is noisy Oil is Leak
7. filling breather and drain plugs 21 SIT St wer Antriebstechnik GmbH 03 Operating Instruction D Series Contents 7 Mechanical Installation vaata 21 7 1 Installing customer shaft with shoulder a n une an 22 7 2 Installing customer shaft without shoulder sess 23 7 3 Disassembling customer shaft with shoulder sess 24 7 4 Disassembling customer shaft without sboulder sss 25 7 3 ovat CUD DAL STINT UE 26 7 6 Recomended shaft dimensions and disassembling nut dimensions 27 7 7 Assembling customer shaft with shrink dek 28 7 8 Disassembling customer shaft with shrink dusk sss 30 7 9 Assembling gear unit with orgue am 31 7 10 Fittting outp tshaft dementiert 34 7 11 Correct position of otpulshafrelemenfte uiu i paar ti coded eain oque ec nae deas 34 2 12 ren E 35 8 Maintanance amp Inspection M rr nn na 36 9 Igino MT ssd ennen nss ini senses YX 37 XE heu oot 37 92 Ee o NERO TC samased ajatu 37 93 MOM GMAT EET 38 9 4 ee 40 10 Troubleshooting E uii edat tin pad ato dud ges aa ra ea Fed euo enun e Pea bna 42 EMERICUS SE SE F r 45 111 e go E 45 11 2 DISPOSAL GE e 45 NER S cus Bur E 45 PSEE 000 0 aE EEE E AEE EE 46 12 1 Manufacturer RT ioina enna gaala 47 122 EE 48 12 3 icon A TER 49 124 Service C
8. install the unit You have received the correct operation manual of the your product The gearbox and all its parts are transported without damage The gearbox is stored correctly according the instructions in this manual You have the latest product catalogue or you have acces to our web page 5 1 Transportation When the goods arrive first check for any damage If some damage observed immediately contact the transport company and inform about the damage Contact ST WER for the damage and do not start to install the unit until it is agreed that the damage has no affect of operation Use the supplied eyebolts or lifting holes for lifting up the gear unit The eyebolts are capable to carry the weight of gearboxes only Do not hang additional loads Use suitable hoistin equipment which is capable to hold the gear units weight Refer to the catalogue for various es weights See drawing bellow for hoisting point Do not stay beneath under the lifting hoisting equipment which may cause serious injuries by alling down objects accidental movements unexpected accidents Falling or hard placement can damage the gear unit Only use hoisting and securing equipment which is permitted for the size weigt of your gear unit Ensure that the load is slowly and carefully handled and placed TT St wer Antriebstechnik GmbH 15 Operating Instruction D Series Checking 16 5 2 Storage Ifthe geared unit or gearedmotor will be s
9. motor Please Check the voltage supply and frequency of your electric connection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Still does not work go to ID 100 Please observe the frequency incerter driver manual Chech the motor by supplying direct voltage to see if the problem is on your driver frequency inverter Still does not work go to ID 001 Please Check the voltage supply and frequency of your electric connection They must be in accordance with the nameplate ofthe motor Observe motor manufacturers start up manual Still same problem the load may be too high for the choosen motor Loosen the gearbox from the load torque If it works than the starting torque is insufficient and higher motor power is needed For monophaze motors check the starting up condansator and running condansator as well If notting helps go to ID 100 Please observe the frequency inverters or drivers manual To see if the problem is on your driver or frequency inverter take out the driver frequency inverter and make direct voltage supply to the motor according the motors nameplate Still does not work go to ID 100 Please Check the voltage supply and frequency of your electric connection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Be sure that the brake is working Observe the brake manufacturers manuel If brake is supplied from St wer o
10. used unless it is differently ordered For oil type and quantities refer to the following tables 36 St wer Antriebstechnik GmbH mer Operating Instruction D Series Oil Types 9 Lubrication 9 1 Oil Types Usage Temparature ISO Viscosity Class e ISO VG 680 E M ISO VG 460 e M ISO VG 320 a Mineral Oil ER Boa Siet ISO VG 150 a ISO VG 100 a Enersyn ISO VG 680 SG XP680 Enersyn Glycolube ISO VG 460 SG XP460 460 Enersyn Glycolube ISO VG 320 SG XP320 320 Synthetic Oil Enersyn ISO VG 220 SG XP220 Enersyn ISO VG 150 SG XP 150 ISO VG 100 Enersyn SG XP 100 Aralup Energrease Beacon 9 2 Changing the oil LUBRICATION GEM 1 680 GEM 1 460 GEM 1 320 GEM 1 220 GEM 1 150 GEM 1 100 Syntheso D 680 EP Syntheso D 460 EP Syntheso D 320 EP Syntheso D 220 EP Syntheso D 150 EP Syntheso D 150 EP Centoplex 2 ISOFLEX Topas L152 Mobilgear 636 Mobilgear 634 Mobilgear 632 Mobilgear 630 Mobilgear 629 Mobilgear 627 Gylgoyle HE 680 Gylgoyle HE 460 Gylgoyle HE 320 Gylgole Alphasyon PG 460 Alphasyon PG 320 Alphasyon PG 220 Alphasyon PG 150 Mobilux Alvania Spheerol R3 APT3 Mobiltemp SHC 100 Cassida RLS 00 Refer to the nameplate to find out the correct oil filled inside the gearbox Do not mix sythetic oils with mineral oils which will cause serious damage to the ear unit The oil change must be done by using the fillin
11. 14 flange and output shaft 10 15 DT33 01 DT33 i 10 15 geared unit with input shaft and output shaft Brake 1 L 220 V With fan P 24V With fan S 220 V Without fan Z 24V Without fan 01 10 Nm 02 25 Nm 04 40 Nm 05 50 Nm 10 100 Nm 20 200 Nm 30 300 Nm 40 400 Nm St wer Antriebstechnik GmbH er Operating Instruction D Series Type Designation 2 2 Nameplate unit designation Nameplate unit designation is a short abbreviation from the detailed designation A sample name plate for D Series Type DR33 90L 4 Power L5 kW speed 16 Ratio 87 62 Serial Nr 04 25520 M Pos B3 Oil Qty 1 3 tt OIL FILLED MINERAL VG220 Abreviations Serial N Serial Number M Pos Mounting Position Type Designation DR33 90 4 Type Motor Size X 2 DR With Motor DT With input shaft DV With Motor and IEC Flange DN Without Motor and IEC Flange 04 25520 Year of manufacturing Order Number TEET St wer Antriebstechnik GmbH 07 Operating Instruction D Series Part Designation 3 Part List of Standard Type Gear Units 3 1 D 00 Types il Standard D 00 type basic part diagram Parts may differ for special applications Standard Part List 08 St wer Antriebstechnik GmbH er perating Instruction D Series Part Designation 3 2 D 01 Types Standard D 01 type ba
12. 50 GPS SS PP PP Amer St wer Antriebstechnik GmbH 13 Operating Instruction D Series Safety gt gt 14 4 4 Tightening Torques All screwed connections for which a tightenning torque is specified must on principle be tightened with a calibrated torque wrench and checked Use the follwing torques for the threaded bores over the gear unit housing For connecting elements refer to the machanical installation part BotSze Chss TORUS Toque Nm ll 4 5 Case of Fire The gear reducer itself is not combustible However it usually contains a synthetic or mineral gear oil Please observe the following ifthe gear reducer is situated in a burning environment 4 5 1 Suitable extinguishing agents Protective equipment Alwase keep suitable extinguishing protective equipment like carbon dioxide powder foam fog easly accessible arround the gear unit High temperature produce irritating steam Use a protective breathing apparatures 4 5 2 Unsuitable extinguishing agents Do not spray with water St wer Antriebstechnik GmbH er perating Instruction D Series Checking 5 Thinks to Check Before the Gear Unit or Geared Motor is Installed If gearedmotors are used please also refer to the manual of the motor manufacturer Before you install the gearbox you have to be sure that the gearbox is arrived with the all necessary equipment and without damage Thinks to take into consideration before you start to
13. ST WER For special application and modified gear units ask STOWER for validity This manual does not cover 94 9 EC compatible gearboxes For 94 9 EC contactus MEET St wer Antriebstechnik GmbH 05 Operating Instruction D Series Type Designation 06 2 Unit Designation 2 1 Detailed unit designation Detailed KR series gear units designation for ordering This Designation is different from the short nameplate designation 3 0kW 29rpm 48 86 DR33 00 100L 4b L02 Power kW Output Ratio i Type Specification Motor Size Speed rpm DR With Motor DT With input shaft DV With Motor and IEC Flange DN Without Motor 00 Standart hollow shaft mounting 01 With output shaft 02 With flange and output shaft 03 With flange and hollow shaft 04 With double output shaft 05 With double flansch and double output shaft 06 Double flange hollow output shaft X0 Special gearbox Standart hollow shaft mounting X1 Special gearbox with output shaft X2 Special gearbox with flange and output shaft X3 Special gearbox with flange and hollow shaft X4 Special gearbox with double output shaft X5 Special gearbox with flansch and double output shaft X6 Special Double flange hollow output shaft Example 0 75 24 58 09 DN33 01 B08 0 75 kW 1500 rpm geared motor with 80 type B14 flange and output shaft gearbox type DR33 10 15 DN33 01 B08 DN33 i 10 15 geared unit with 80 type B
14. ating Instruction D Series Troubleshooting Guide Motor is running but Gearbox shaft does not turn Scratchinh noise comes Some part key gear may be defect inside gearbox Goto out ID 10 The radial load or poligon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigit Gearbox Housing You are using chain drive enough Check if you are using the correct diameter of chain is Defect or pinion gear drive and you are not exceeding max allowed radial load Check the position of your output element and re calculate your radyal load and check if this fit to the maximum allowed radialload Goto ID 100 The radial load or poligon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigit Output Shaft is You are using chain drive enough Check if you are using the correct diameter of chain 026 Se Defect or pinion gear drive and you are not exceeding max allowed radial load Check the position of your output element and re calculate your radyal load and check if this fit to the maximum allowed radial load Goto ID 100 Please check the wiring diagram of the brake There are two Gearbox is You are using braked different kind of brake wiring diagram The standart gearbox stopping too late motor delivered from our factory is set to delayed braking For sudden braking ch
15. bient temperature must be between 5 40 celsius and no abresieve media must attack the paint and seals If different working conditions this must be informed to St wer before ordering The gearbox maintenance oil change check must be done according this manual 4 2 Improper Use Every usage which exceeds the limits stated above the nameplate and catalogue of the product especially highert torques and speeds is not compliant with the regulations and thus prohibited The operation ofthe gear reducer is prohibited if It was not mounted installed according to regulations and this manual The gear reducer is very soiled Itis operated without lubricant It is operated out of the permited values provided on catalogues and or nameplate St wer Antriebstechnik GmbH mer perating Instruction D Series Safety 4 3 Safety Instructions 4 3 1 General Safety Instructions 4 3 1 1 Working on the gear reducer Inappropriately executed work can lead to injury or damage Make sure that the gear reducer is only installed maintained and dismantled by trained technicans Foreign bodies spinning through the air can cause grave injury Before putting the gear reducer into operation check that there are no foreign bodies or tools near the gear reducer 4 3 1 2 Operation Touching hot surfaces can leat to burns Do not touch the gear reducer if their operation temperatures are too high or use suitable safety equi
16. bserve this manuel for correct brake wiring diagram If still not work supply the brake with voltage according its nameplate directly For example 198V DC You will hear a clicking noise explaining that the brake is opening If you hear no noise the brake or rectifier is defect If you hear the clicking noise the brake is working You should this clicking noise by your normal electric connection as well By supplying direct supply to the brake you hear the clicking noise and at same time you supply the motor with direct voltage according to its name plate and still same problem the load may be too high for the choosen motor Goto ID 003 St wer Antriebstechnik GmbH er Operating Instruction D Series Troubleshooting Guide Remedy Gearbox Does Not Work in Low Speeds frequenci es You are using frequency inverter Gearbox Does Not Start Mornings or After Long Time Stop Gearbox is 008 Heating Up too Much Ambient Temperature is below 5 Celsius You are using Worm Gear Box and ambient tenp is lower than 40 Celsius Gearbox is Heating Up too Much You are using Helical Gear Box Ambient temp is lower than 40 Celsius Gearbox is Heating Up too Much Ambient Temp is over 40 Celsius Nois is regular continious Gearbox is noisy Gearbox is noisy Nois is random atm St wer Antriebstechnik GmbH For very low speeds the frequency inverters frequency is lowering down For very low frequencies the inver
17. e please contact St wer Antriebstechnik GmbH Be sure that you have all the equipment necessary for installing like Spanners torque wrench shims and distance rings fixing devices for input and output elements lubricant bolt adhesive etc This manual is not for 94 9 EC ATEX conforming gear units For 94 9 EC conforming gear units refer to the ATEX range manual ATEX conforming gear units have name plates indicating the zone and the temperature class and are different from standard type geared units Therefore Standard units can not be installed on Potentially explosive atmospheres 6 2 Check the shaft dimensions to fit Output Shaft Type Hollow Shaft Hollow Shaft Output Shaft Tolerance Deg alder Mee Shoulder yp Diameter Tolerance H8 Diameter DIN748 ms Tolerance Up to 50mm k6 Diameter 86 Over 50mm m6 D 22 23 D 32 33 D 42 43 IR RRE D 62 63 D 72 73 6 3 Check the ambient temperature The ambient temperature must be between 5 celsius to 40 celsius for standart type gear units If different contact St wer Antriebstechnik for special solutions 6 4 Check the voltage supply The standard gearedmotors are supplied with 230 400 V 50 60Hz up to 3kW including 3kW and 400 690 V 50 60 Hz over 3kW and is indicated on the motors name plate unless it is differently ordered In case of only gear unit is supplied from ST WER please observe the name plate of the electric m
18. eck the wiring diagram For fast opening of big brakes over 100Nm you may need shock transformators which is supplied by St wer Goto ID 100 Gearbox is starting You are using braked too late motor Please contact St wer Service point See on the back side of this manual Changing mechanical parts of gearbox can only be done by ST WER or with information 100 ervice Required No self solution foun St wer Any change without informing St wer will cancel the waranty manufactor decleration and will take no waranty manufacturer decleration and responsibility 11 Disposal If your product is no longer of use and you wish to dispose of it refer to the instructions here If you have any questions regarding ecological disposal methods please consult our service points given on the backside ofthis manuel 11 1 Disposal of Oil Lubricants oil and greases are hazardous substances which can contaminate soil and water Collect drained lubricant into suitable receptacles and dispose of it according to the valid national guidlines 11 2 Disposal of Sealings Remove the sealing rings from the gear reducer and clean them of oil and grease resudies Dispose ofthe sealings as composite material metal plastic 11 3 Disposal of Metal Divide up the remainder ofthe gear reducer into iron aluminium non ferrous havy metal if possible Dispose of it according to the valid national guidlines Syr St wer Antriebstechnik GmbH 45
19. g draining and level plugs according the mounting position illustrated in section 9 4 Hot oil can cause scalding AS Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thoroghly N When changing oil protect yourself against contacting hot oil Fer St wer Antriebstechnik GmbH 37 Betriebs und Wartungsanleitung D Serie Oil Quantities 9 3 Oil Quantities It Double Triple reduction Helical Hollow Shaft Types Ee 1 5 195 a a Four a Reduction Helical Hollow Shaft Types Five Six Stage Reduction Helical Hollow Shaft Types 38 St wer Antriebstechnik GmbH 22227 Operating Instruction D Series Oil Quantities 9 4 Mounting Positions M MEE Ic B5 B51 B6 B6 II B8 ej Symbols E Drain plug Vv Vent plug v Oil level bs Only upon request St wer Antriebstechnik GmbH er 40 Operating Instruction D Series Mounting Positions V1 V3 xx as tle H5
20. g Brake 380 V RST LZ Li Brake Coil Na Delayed Running Brake 4 24 V RSTN Brake Coil LZ III WWW YY s mer St wer Antriebstechnik GmbH Sudden Brake 380 V Brake Coil Ae 3 i Sudden Brake 24 V RSTN Brake Coil J 4 O00 oO 2 Leer db 4 3 c sie lt gt sie 3 E Jj 19 Operating Instruction D Series Installing 20 6 5 Check the mounting position The mounting position must be in accordance with the mounting position mentioned on the name plate If different please contact ST WER for possibilities of using in a different mounting position Refer to the mounting positions and oil quantities on this manual and adjust the oil level accordingly with the recommended oil types given on this manual Do not mix synthetic oils with mineral oils which can cause serious damage on the gear unit 6 6 Use of breather plug Breather plugs are not needed for D series under normal ambient and working conditions Up to 30 degree Celsius ambient temperature and up to 8 hours per day If heavy ambient conditions and long time working hours then breather plug are recommended by ST WER and delivered with the gearbox together Replace the breather plug with the most top plug according to your mounting position Some plug positions are not machined according mounting position If no mounting position is mentioned by ordering the standard B3 p
21. he gear unit using 8 8 or higher quality bolts Cover all the turning parts from human entering or touching Turning arts can cause severe or fatal injuries For different kind of basic installations refer to the following illustrations EET St wer Antriebstechnik GmbH 21 Operating Instruction aU D Series Installing 7 1 Installing customer shaft with shoulder 7 1 1 Use anti seize assembling paste available on your market Use a brush to apply the paste 7 1 2 Fasten the bold as shown below 1 Short retaining bolt Standart scope of delivery 2 Lock washer 3 Washer 4 Circlip 5 Hollow Shaft 6 Customer Shaft 6 22 St wer Antriebstechnik GmbH er Operating Instruction av D Series Installing 7 2 Installing customer shaft without shoulder 7 2 1 Use anti seize mounting paste available on your market Use a brush to apply the paste 7 2 2 Fasten the bold as shown below ps WHY ZA 1 Short retaining bolt Standart scope of delivery 2 Lock washer 3 Washer 4 Circlip 5 Hollow Shaft 6 Customer Shaft mw St wer Antriebstechnik GmbH u Operating Instruction D Series av Installing 7 3 Disassembling customer shaft with shoulder 7 3 1 Disassemble the bolt and take out the parts as shown 1 Short retaining bolt Standart scope of deliver
22. ing Oil Leakage from Plug Oil is Leaking Oil Leakage from Housing Oil is Leaking Oil Leakage from Cover Gearbox is moving regularly on its mounting point You are using Torque Arm Gearbox is moving randomly on its mounting point Motor is heating Motor is running over its up nominal current dd is heating Ambient is dusty You are using Torque Arm Remedy Check Your moving parts for noise Disassemble the gearbox and run without load If you still hear the noise one of the gears inside is defect Goto ID 100 Check the output shaft connection alements for runout Take out the output shaft element and run without load If you still hear the noise one of the gears has runout problem Goto ID 100 Low randomly clicking noise may come from the brake disk which is normal If noise level is disturbing the brake may be defect or brake clearance is not adjusted Goto ID 100 The frequency inverter parameters are not optimized for the frequency range or motor you are using Observe the frequency inverters manual If still same problem change the ratio of gearbox Goto ID 100 If ambient Temp is over 40 Celsious or none stop work over 16 hours please change the top plug with a breather plug Observe this manual for using breather plug If this is not your case the seal could be damaged Goto ID 100 If you are using breather plug be sure it is in the correct place This is the most top plug position according your mounting p
23. number for ordering the disassembling nut LJ UZ mm 277 D Part No GN10 _ Tip Type Typ Part no example GN10 DR33 lt 60 gt Dismounting Mounting i D y TEET St wer Antriebstechnik GmbH Pulling Out eM KITT 27 Operating Instruction AU D Series Installing N 7 7 Assembling customer shaft with shrink disk 7 7 1 Loosen the bolts ofthe shrink disk 7 7 2 Use a solvent available in your market to clean all the dirt an oil from the shaft and shrink disk hollow The surfaces must be free from oil or any dirt The solvent must be removed from the sur faces ass well 28 St wer Antriebstechnik GmbH er Operating Instruction aU D Series Installing 7 7 3 Insert the shaft and tighten the bolts as shown Be sure that there is a clearance between the shrink disk shoulder and the hollow shaft shoulder ofthe gearbox 2 3 oh MANN P mw 1 Customer Shaft 2 Bronze Ring 5 Hollow Shaft 4 Shrink Disc snar St wer Antriebstechnik GmbH E Operating Instruction aU D Series Installing N 7 8 Disassembling customer shaft with shrink disk 7 8 1 Loosen the bolds ofthe shrink disk and take out the shaft
24. ontact PODES oou avait doa nd pint Vai aseo Ce Ts M EDO 50 04 St wer Antriebstechnik GmbH mer Operating Instruction D Series General Information 1 How To Use This Manual Take attention to the following safety and warning signs for proper understanding and quick reference O gt e Electric Hazard Can cause severe or fatal injuries Mechanical Hazard Can cause severe or fatal injuries Likely to be Hazardous Can cause minor or fatal injuries Damage Risk Can damage the drive or environment Important Information EC Machinery Directive Within terms ofthe EC machinery directive 98 37 EC the gear reducer is not considered an autono mous machine but as a component to install in machines Operation is prohibited within the area of validity ofthe EC directive until it has been determined that the machine in which this product is installed corresponds to the regulations within this directive The operating instructions contain important information to ensure Trouble free operation Fulfilment of any rights to claim under guarantee The operating instruction must be kept close to the gearbox and must be available in case it is needed This operating instruction is written for D series gear units and is applicable only for D series If any different type of gearbox is used please ask St wer for the operating instructions of that type This instruction can be used only for standard type geared units of
25. osition The plug may be not tight enough There are some particles under the plug rubber surface Clean and tifgten the plug If still same problem goto ID 100 Observe exactly where the oil is comming out It could be seal or plug point where it comes out and leakes over the housing If this is your case goto ID 018 019 If you are sure oil comes out from housing than housing has some micro split crack Goto ID 100 The sealing liquit under cover is split defect Disassemle the cover and put new sealing liquit Assemle the cover and tighten the bolts If still same problem goto ID 100 The movement of gear box is because of the runout of the shaft which you assemle the gearbox This has no bad affect or harm to the gearbox and is normal unless you are using torque arm The movement of gear box is because of the runout and clearance ofthe shaft which you assemle the gearbox Check the clearance of the assemling shaft and the clearances on your machine This has no bad affect or harm to the gearbox unless you are using torque arm The motor power is not enough or some overload to the motor is possible The motor may be defect Goto ID 100 Check the motor Fan Hub and rips They must be free of dust If you are using forced external fan check if it is working If you are using frequency inverter in low speeds and you do not have forced external fan you may need forced external fan Goto ID 100 St wer Antriebstechnik GmbH Her Oper
26. osition plugs are machined 6 7 Check the oil level On the mounting position tables the oil level plug is shown Please refer to those tables and be sure that the oil level is correct according the mounting position by screwing half way out the level plug and see if oil comes out from that plug If oil comes out tighten the plug again If no oil comes out take out the filling plug and add oil until oil comes out from the level plug and tighten both plugs after finish Be sure you are using the correct oil mentioned on the oil tables on this manual Do not mix synthetic oils with mineral which can cause serious damage on the gear unit 6 8 Check shaft ends and mounting faces Before you start to installing be sure that all the connection elements are free of oil and dust The output shaft may be protected by anti corrosion oil Please remove this using available solvents on your market By using this do not touch sealing lips or painting ofthe housing 6 9 Cover abrasive ambient Ifthe gear unit will be placed on a abrasive ambient be sure that the output seals are covered so that no abrasive material chemicals or water touches the seals Any pressure coming from outside over the seals can cause that the out staying substances to enter the gearbox and cause serious damage to the gear unit If pressure or abrasive material can not be prevented from coming over the sealing contact ST WER for solutions Abrasive material chemicals water
27. otor and the instructions of the supplier Check the basic electric connection diagrams below Use experienced electric technician Using wrong connection or voltage can damage the electric motor or environment s mer St wer Antriebstechnik GmbH 17 Operating Instruction D Series Installing A 18 The following wiring diagram is for standart 230 400 V 50Hz AC electric motors For different voltages please contact ST WER For gear units suplied without motor refer to the motor manufacturers user manuel The electric connection must be done by experienced electric technician The gearbox the motor and the brake must be grounded to prewent potential differences of earth and gearbox motor Nominal Powers at 400V 50Hz s omm 033m s oom xm Basic motor connection wiring diagram LI L2 L3 L1 L2 L3 220V 220V 380V 380V 220V 380V ny 12 I 13 I II I3 Y U2 c VI Ye E N Upn U yo N M N ui gt V2 gt W2 Wl Ul u C ans N IN N i AR LIN N 3 7 1 2 mi N 6 men o D 4 Pa ya n 2 B L1 2 L3 ke St wer Antriebstechnik GmbH er Operating Instruction D Series Installing Standard type brakes basic wiring diagram AN The elctric connection must be done by experienced electric technician The gearbox and the motor must be grounded to prewent potential differences of earth and gearbox motor Delayed Runnin
28. pment like gloves Rotating machinery can lead to injuries There is danger of being trapped or pulled in Keep a sufficient distance and make safeguarding to rotating machinery See relevant norms EN349 EN294 4 3 1 3 Maintenance An unintentional start of the machine during maintanance work can lead to serious accidents Make sure no one can start the machine while you are working on it Even a brief running of the machine during maintenance work can lead to accidents if the safety devices are not operating Make sure that all safety devices are mounted and active 4 3 1 4 Lubricant Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thoroghly Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 4 3 1 5 Ambient Conditions Standart gearboxes are allowed to work in ambient temperatures between 5 to 40 celsius unless differently specified on the nameplate Using the gear unit out of this range can cause damege to the gear unit or environment Over 40 celsius ambient conditions the gear unit surface temp could be so high causing burns when touched If the gear unit will be used in outdoor applications the gear unit must be prevented from rain snow and dust Entering substances inside the gear unit from seals can damage the gear unit Observe the safety instructions for outdoor use EN292 1 EN292 2 EN 10
29. positive or negative pressure exceeding 0 2 bar can affect or damage the sealing lip or output shaft Inside entering substances from the seals can cause serious damage to the gear unit St wer Antriebstechnik GmbH 4er Operating Instruction D Series Installing N 6 10 Check accessibility to filling breather and drain plugs The filling breather and drain plugs must be freely accessible for further checking and service 7 Mechanical Installation The gear unit can only be installed using the supplied connection points like foot and flange assem bling points To install the gear unit without the supplied connection points can cause serious injuries by loosening or braking the gear unit Even the gear unit is installed totally correctly according this manuel be sure that no one will be harmed by accidentially brake downs or loosenings The mounting plate must be rigid enough not allowing torsions flat enough to prevent strains by tightening the bolts and stable enough not allowing vibrations By using chain drives this becomes much more important because of the polygon effect on chain drives According to your connection elements the maximal permitted radial and axial load of the gear unit must be in accordance with your application Check the product catalogue for permitted radial loads and calculation If the output or input shaft is overloaded by radial or axial loads it can cause serious damage to the gear unit Secure t
30. product catalogue and the nameplate ofthe gearbox They comply with the applicable standards and regulations and meet the requirements ofthe directive 98 3T EC The gearbox must be started up maintained and operated according this manual The gear box most be incorporated with 98 37 EC confirming parts machines A motor connected to the gear unit is only allowed to be operated in the frequency entries so that the data provided on nameplate catalogue of the gear unit is not exceeded and is accord ance with the nameplate catalogue The speed range will be provided on the name plate if ST WER is informed that the gear unit will be used with fr equency inverter If not informed the nameplate will have a single fixed speed and only this speed is allowed The electric motor and frequency inverter must be in accordance with 98 3 7 EC If the gear units input is used with variable speed gear unit this must be informed to St wer before ordering and on the nameplate the allowed maximum and minimum speeds speed range will be provided If not mentioned by ordering the gear units speed will be a fixed single input speed and only this speed is allowed If the gear unit will be driven by belt coupling chain drive etc the gear unit is only allowed to be used according the nameplate catalogue entries Diffrent speed higher motor power higher radial axial loads etc than nameplate catalogue is not allowed The am
31. sic part diagram Parts may differ for special applications Standard Part List 15 Oil Seal 24 Circlip 33 Closing Cap 9 Solid Output Shaft 18 Bearing 27 Bearing mer St wer Antriebstechnik GmbH 09 Operating Instruction D Series Part Designation 3 3 D 02 Types 19 il Standard D 02 tvpe basic part diagram Parts may differ for special applications Standard Part List somas ceseco eme O O 10 St wer Antriebstechnik GmbH er perating Instruction D Series Part Designation 3 4 D 03 Types amp Standard D 03 type basic part diagram Parts may differ for special applications Standard Part List momo eme wew mow S97 St wer Antriebstechnik GmbH 11 Operating Instruction D Series Safety 12 E E e E El 4 Safety 4 1 Intended Use The gear reducer is designed for use in industrial machines Please refer to our catalogue or our web page for the maximum permitted torques and speeds The most important maximum permited values are indicated on the nameplate of the product But the whool data can be found on our product catalogues Using the product out of the product catalogue nameplate s permited ranges will cancel the waranty manufacturer decleration and ST WER will nottake any responsibility The gear units are intended for industrial machines and may only be used in accordance with the information provided in this manual the
32. ter parameter and motor parameter must be optimized Also for low speeds the efficiency ofthe gearbox may varry too much Specially for worm gearboxes The recomended frequency range is 20 70 Hz for worm gearboxes and 10 70 Hz for Helical Gear Boxes Use Higher motor power and Frequency inverter or change ratio of gearbox to work inside the reccomended range The oil is not in accordance with your working conditions Change to lower viscosity oils Observe this manuel for using the correct oil Working in higher ambient temperatures is an other solution if possible If still same problem you need higher motor power Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox and is normal All ATEX conforming gearboxes and standart worm gearboxes are designed to work under max 120 Celsius If higher than 120 Celsius and using ATEX conforming gear box immidiately stop the system and contact Stbwer Go to ID 100 If not ATEX confirming chec the oil type and oil quantitiy level according your mounting position and check the nameplate mounting position If nameplate mounting position does not fit the actual position goto ID 100 Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox and is normal All ATEX conforming gearboxes are designed to work under max
33. tored up to 3 years refer to the following instructions With Packing Use corrosion protection oil for the output shaft and connection surfaces like flange surface or foot assem bling surface Seal the unit ina plastic wrap and pack it in container A moisture indicator should be placed around the container to observe the moisture Relative atmospheric humidity should not exceed 5096 The container should be kept under roof which protects from snow and rain Under this condition the gear unit can be stored up to 3 year with regular check The ambient temperature should be between 5 to 60 Celsius degrees Without Packing Use protection oil for the output shaft and connection surfaces like flange surface or foot assembling surface If no packing is used and the gearbox is stored without packing the ambient temperature should be between 5 to 60 Celsius degrees The gearbox must be kept under enclosed roof with constant tem perature and constant humidity not exceeding 50 The storage should be free of dust and dirt and venti lated with filter Ifthe gearbox is stored without packing it is recommended not to store more than 2 years and regular check during this time is recommended If stored in open protect against insect damage St wer Antriebstechnik GmbH er perating Instruction D Series Installing 6 Installing The Gear Unit 6 1 Before you start Observe the gear unit for damages of storage or transportation If any damag
34. y 2 Lock washer 3 Washer 4 Circlip 5 Hollow Shaft 6 Customer Shaft 7 6 7 3 2 Use the disassemble set from St wer and fasten the bold as shown bellow to take out the output shaft For disassemble sets look the following pages 2 54 5 8 ch D 7 i X jum 7 gt Ma Retaining bolt 2 Circlip Fixed nut 4 Forcing Washer 5 Hollow Shaft 6 Customer Shaft 6 24 St wer Antriebstechnik GmbH Per Operating Instruction D Series Installing 7 4 Disassembling customer shaft without shoulder 7 4 1 Disassembly the bolt and take out the parts as Shown 2 3 4 5 65 qe Short retaining bolt 5 Standart scope of delivery Lock washer Washer Circlip Spacer Hollow Shaft Customer Shaft 7 4 2 Use the disassembly set from St wer and fasten the bold as shown bellow to take out the output shaft For disassembly sets look the following pages SIT St wer Antriebstechnik GmbH lt m L Retaining bolt Circlip Fixed nut Forcing Washer Hollow Shaft Customer Shaft 25 Operating Instruction aU D Series Installing 7 5 Shaft tightening torques Use the following table for shaft tightening torques D 32 33 M12 D 52 53 M16 D 72 73 26 St wer Antriebstechnik GmbH 4er Operating Instruction D Series Installing 7 6 Recomended shaft dimensions and disassembling nut dimensions Use the following part
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