Benzlers Radicon G Series, Installation & Maintenance

Page 1: ...IMC 1 00GB01 11 Series G Industrial Reducers Installation Maintenance ...

Page 2: ...r to prevent the machinery being started 7 Installation Maintenance and Storage a In the event that equipment is to be held in storage for a period exceeding 6 months prior to installation or commissioning we must be consulted regarding special preservation requirements Unless otherwise agreed equipment must be stored in a building protected from extremes of temperature and humidity to prevent det...

Page 3: ...2 General Safety 12 9 3 Units for use in potentially explosive atmosphere 12 10 Maintenance 10 1 Prior to any Maintenance Operations 13 10 2 Oil Plugs Ventilator 13 10 3 Lubrication 13 10 4 Bearings 14 10 5 Grease Lubrication 14 10 6 Cleaning 14 11 Fault Diagnosis 15 Appendix 1 Cooling Coils 16 2 Lubrication Information 17 19 3 Approved Bearing Greases 20 4 Shaft Alignment 21 22 Safety Warning Sym...

Page 4: ...ons of the machinery directive 2006 42 EC The equipment shall only be loaded within the framework of our recommendations and installed and operated in accordance with our installation and maintenance instructions The company hereby draws attention to the dangers of improper use of this equipment and particularly warns users against operating with inadequate guarding of rotating parts and the use o...

Page 5: ...its are to operate in extreme conditions or where they are to stand for long periods without running e g during plant construction consult our application engineers so that arrangements for adequate protection can be made 3 Reading the Nameplate 3 1 8QLW GHQWL FDWLRQ Lubrication Grade The lubrication grade is marked on the nameplate See Appendix 2 for type and quantity of lubricant When requesting...

Page 6: ...W WWHG FRUUHVSRQGV ZLWK WKH FODVVL FDWLRQ RI WKH SRWHQWLDOO H SORVLYH DWPRVSKHUH in which the unit is to be installed Examples RQH RFFDVLRQDO KD DUGRXV H SORVLYH DWPRVSKHUH RQH UDUH VKRUW WHUP KD DUGRXV H SORVLYH DWPRVSKHUH RQH RFFDVLRQDO KD DUGRXV H SORVLYH DWPRVSKHUH GXULQJ QRUPDO RSHUDWLRQ GXH WR SUHVHQFH of combustible dust RQH VKRUW WHUP KD DUGRXV H SORVLYH DWPRVSKHUH GXH WR SUHVHQFH RI FRPEX...

Page 7: ... not ben damaged 5 2 2 Check the gear unit motor nameplate matches the requirements of the machine the unit is to be installed into 5 2 3 Thoroughly clean the gearbox mounting surfaces that are to be used and the shafts of paint anti corrosion agents using a commercially available solvent Ensure solvent does not make contact with the oil seals 5 3 Fitting Of Components To Either The Unit Input Or ...

Page 8: ...l 2 Stage M30 x 63 mm deep M42 x 81 mm deep Parallel 3 4 Stage M20 x 43 mm deep Right Angle 3 Stage M24 x 52 mm deep Right Angle 4 Stage M20 x 43 mm deep 5 4 Lifting 2QO WKH OLIWLQJ SRLQWV LGHQWL HG EHORZ PXVW EH XVHG IRU OLIWLQJ RSHUDWLRQV GXULQJ LQVWDOODWLRQ Gearbox Only The gearbox can be lifted using any of the eight lifting points Gearbox on Bedplate The lifting points on the gear unit and mo...

Page 9: ... VSHFL HG LQ 7DEOH EHORZ 6HFXUH XQLW RU EDVHSODWH LI WWHG WR D ULJLG IRXQGDWLRQ XVLQJ KHDY GXW EROWV WR 62 JUDGH PLQLPXP ï 0D LPXP SHUPLVVLEOH ÀDWQHVV HUURU IRU PRXQWLQJ VXUIDFH LV PP 5 6 Shaft Mounted Units 5 6 1 The following procedure is recommended for all shaft and foot shaft mounted units OHDQ VKDIW H WHQVLRQV GULYHQ PDFKLQH VKDIW JHDU XQLW ERUH DQG YHQWLODWRU ZKHQ WWHG 5 6 1 2 Locate in pos...

Page 10: ...KDIW 7KH µVKULQN GLVF LV D IULFWLRQ GHYLFH ZLWKRXW keys which exerts an external clamping force on the hollow output shaft thus establishing a mechanical VKULQN W EHWZHHQ WKH JHDU XQLW KROORZ VKDIW DQG GULYHQ VKDIW µ6KULQN GLVF FDSDFLWLHV KDYH DPSOH PDUJLQV in dealing with transmitted torques and external loading imposed on gear units 5 6 2 1 Working Principle 7KH µVKULQN GLVF FRQVLVWV RI D ORFNLQ...

Page 11: ...9 M20 570 22 230 g6 240 g6 229 5 235 835 145 105 M30 60 6 280 81 230 30 2 80 460 132 M20 570 Unit Size Hollow Shaft End Plate ØD1 ØD2 ØD3 L L1 L2 L3 C C1 Ød5 Ød6 ØK1 M crs P Circlip 14 95 100 96 415 180 255 276 20 10 0 9 8 99 75 99 50 78 26 55 M12 D1300 1000 15 110 115 111 420 180 260 276 20 10 0 9 8 114 75 114 50 90 26 65 M12 D1300 1150 16 125 130 126 533 230 325 348 25 12 0 11 8 129 75 129 50 10...

Page 12: ...t protective cover Note When the hollow output shaft is to operate in a vertical position it is essential that the shaft of the driven machine is provided with a shoulder When the thrust load is not taken by the shoulder on the driven shaft a thrust plate as shown in Figure 1 must EH WWHG W LV UHFRPPHQGHG WKDW FXVWRPHUV VKDIWV DW WKH QRQ FODPSHG HQG RI WKH VOHHYH VKRXOG be coated with Molykote 321...

Page 13: ...SOLQJV RU DQ RWKHU HTXLSPHQW WWHG WR WKH JHDU XQLW KDV 7 DSSURYDO Check information listed on nameplates correspond to the environmental conditions of the site 5 7 8 Ensure gearbox is not subjected to any loading greater than those marked on the nameplate 5 7 9 For units operated with inverter drives check motor suitability for use with the inverter Ensure that the inverter parameters do not excee...

Page 14: ...le run the unit without load for a short time to circulate the lubricant thoroughly then stop the unit and re check the oil level after allowing the unit to stand for 10 minutes and if necessary top up to the FRUUHFW PDUN RQ WKH GLSVWLFN RU DQ RWKHU OHYHO LQGLFDWRU WWHG VLJKW JODVV HWF 51 1 R QRW RYHU OO DV H FHVV PD FDXVH RYHUKHDWLQJ DQG OHDNDJH KHFN DQG UH W DOO SOXJV WLJKWHQ WR FRUUHFW WRUTXH J...

Page 15: ...QFUHDVHG WHPSHUDWXUH QRLVH YLEUDWLRQV power consumption etc suggests a malfunction inform maintenance personnel immediately 8QLWV WWHG ZLWK EDFNVWRS HQVXUH PRWRU LV FRUUHFWO ZLUHG IRU IUHH GLUHFWLRQ RI URWDWLRQ 9 Operation 9 1 Noise 7KH UDQJH RI XQ FRROHG RU ZDWHU FRROHG 6HULHV SURGXFW VDWLV HV D QRLVH VRXQG SUHVVXUH OHYHO RI G RU OHVV ZKHQ PHDVXUHG DW PHWUH IURP WKH XQLW VXUIDFH DQ FRROHG XQLWV P...

Page 16: ...rs should be used to determine the frequency at which these are carried out a Oil temperature unit operating under load b Type of oil c Environment humidity dust etc d Operating conditions shock loading etc 10 3 2 2 At elevated temperatures the effective life of the oil is very much reduced This is most pronounced with oils containing fatty and EP additives To prevent damage to the unit through lu...

Page 17: ...s installed in potentially explosive atmosphere it is essential to ensure that the oil is FKDQJHG RQ RU EHIRUH WKH UHQHZDO SHULRG VSHFL HG LQ 7DEOH 0 10 4 Bearings 10 4 1 Bearings should be replaced every 5 years for marked units Alternatively they should be UHSODFHG LQ DFFRUGDQFH ZLWK WKH DJUHHG VSHFL FDWLRQ 10 5 Grease Lubrication 10 5 1 On certain units the output bearings are grease lubricated...

Page 18: ... XQLW ÀDQJH IURP RXWSXW HQG RLO VHDO a Defective gasket on gear unit cover b Defective gasket c Gear unit not ventilated a Retighten screws on gear unit cover and observe gear unit If still oil leaks contact our Application Engineers or your local 6DOHV 2I FH b Contact our Application Engineers or RXU ORFDO 6DOHV 2I FH c Vent the gear unit Oil leaking from the ventilator D HDU XQLW RYHU OOHG ZLWK ...

Page 19: ... D VXLWDEOH VWUDLJKW FRXSOLQJ DWHU VXSSO RROLQJ FRLOV DUH VXLWDEOH IRU IUHVK EUDFNLVK RU VHD ZDWHU ZLWK ÀRZ LQ HLWKHU GLUHFWLRQ Connections are therefore interchangeable For best performance the water supply should be at 10 C 12 C temperature and at a ÀRZ UDWH RI OLWUHV PLQXWH Size of Unit A B C 14 310 120 163 15 270 120 163 16 370 150 220 17 315 150 220 18 315 200 285 19 385 200 285 21 410 200 35...

Page 20: ...nd for 10 minutes and if necessary top up to the FRUUHFW PDUN RQ WKH GLSVWLFN RU DQ RWKHU OHYHO LQGLFDWRU WWHG VLJKW JODVV HWF In addition where bearings are grease packed the greases approved are given in Appendix 3 Table 1 Lubricant Quantity Litres 2LO TXDQWLWLHV DUH DSSUR LPDWH OO WR WKH OHYHO PDUNHG RQ WKH GLSVWLFN RU DQ RWKHU OHYHO LQGLFDWRU WWHG VLJKW JODVV HWF R QRW RYHU OO DV H FHVV PD FDX...

Page 21: ...evron International Oil Company Limited HDU RPS 3 86 YHU HDU RPS 3 DVWHUQ YHU Ultra Gear Eko Elda Abee Eko Gearlub Engen Petroleum Limited Gengear Esso Exxon Spartan EP h Fuchs Lubricants Powergear 3 HDU 0 Renogear V 3 3 3 Renogear WE Renolin CLPF Super e Klüber Lubrication Klüberoil GEM1 Kuwait Petroleum International Q8 Goya Lubrication Engineers Inc Almasol Vari Purpose Gear Mobil Oil Company L...

Page 22: ...HUNH PE Optigear Synthetic A Petro Canada Super Gear Fluid e Shell Oils 2PDOD c Texaco Limited Pinnacle EP Pinnacle WM c Total DUWHU 3 7 7ULERO PE Tribol 1510 Table 3 Approved Lubricants Type H 3RO DOSKDROH Q EDVHG V QWKHWLF OXEULFDQWV ZLWK QWL HDU RU 3 DGGLWLYHV These have a medium to high load carrying capacity NOTES F 7KHVH OXEULFDQWV KDYH EHHQ WHVWHG IRU PLFUR SLWWLQJ 7 SH WHVW UHVXOWV DUH DYD...

Page 23: ...ational Limited Energrease LS EP 30 130 Caltex Multifak EP 0 120 Castrol International 0 UHDVH 40 150 Spheerol AP 30 110 Spheerol EPL 10 120 Fuchs Lubricants Renolit EP 25 100 Klüber Lubrication Klüberlub BE 41 542 20 140 Mobil Oil Company Limited 0RELOJUHDVH 3 15 150 0RELOLWK 6 20 180 Omega Manufacturing Division Omega 85 40 230 2SWLPRO gOZHUNH PE Longtime PD 45 140 Shell Oils Albida RL 20 150 Al...

Page 24: ...ne can be found by proportion Similarly the difference between the reading 2 and 4 gives the amount of sideways adjustment necessary to correct any errors of alignment in the horizontal plane Generally however the coupling faces will not be absolutely true whilst any errors so found could be allowed for in checking angularity by the stationary method an easier presents itself This consists in maki...

Page 25: ...opriate installation and maintenance manual for coupling type and VL H WWHG ii Output Shaft SPECIAL NOTE CONCERNING RIGID COUPLINGS In lining up elements involving rigid couplings it is important that no attempt is made to correct errors of DOLJQPHQW RU HFFHQWULFLW JUHDWHU WKDQ WKRVH DERYH E WLJKWHQLQJ RI WKH FRXSOLQJ EROWV 7KLV DSSOLHV ZKHQ the system is cold or at operating temperature The resul...

Page 26: ...23 SERIES G NOTES ...

Page 27: ... Helsingfors Finland Tel 358 9 340 1716 Fax 358 10 296 2072 INDIA Elecon Engineering Company Ltd Anand Sojitra Road Vallabh Vidyanagar 388120 Gujarat India Tel 91 2692 236513 Fax 91 2692 227484 SWEDEN NORWAY AB Benzlers Box 922 Landskronavägen 1 251 09 Helsingborg Sweden Tel 46 42 18 68 00 Fax 46 42 21 88 03 THAILAND Radicon Transmission Thailand Ltd 700 43 Moo 6 Amata Nakorn Industrial Estate Tum...

Page 28: ... 34 03 00 Finland 358 9 340 1716 Germany 49 800 350 4000 Sweden 46 42 186800 The Netherlands 31 77 324 59 00 www benzlers com Radicon Thailand 66 3845 9044 United Kingdom 44 0 1484 465 800 USA 1 847 593 9910 www radicon com ...