Operating
Instructions
Initial Installation
2K800/2K801/2K802
18
EN 4161.758.103n – 2015-10
3.6
Electrical connection, gearchange
The gearbox is electrically connected using the
supplied 8-pole Harting connector (HAN 8 U). The
plug-in connection is located on the shift unit.
3.6.1
Shift unit
Technical data:
Power consumption
84 W
Supply voltage
24 V DC ± 10 %
Max. pickup current
5 A
Nominal current
3.5 A
Index of protection
IP64
The required cable lead diameter is 1.5 mm².
The 24 V DC connection voltage and 5 A power
consumption must be assured on the shift unit
connector.
Losses due to cable length and transition resistors
must be taken into account.
Scope of supply:
Sleeve housing, screw connection, socket insert
and 8 jacks, type Harting AWG16. The shift unit
can only be obtained as a complete part.
Gearbox shift mechanism:
Gearchanges are effected when the 24 V voltage
is applied to pin 2 and 3. The polarity of the
applied 24 VDC voltage dictates which gear is
engaged.
In 1st gear
=> Pin 2: + / Pin 3:
‒
In 2nd and 3rd gear
=> Pin 2:
‒
/ Pin 3: +
During the gearchange, the main spindle motor
should make the shaft osc5° or -5° at a rate
of 1 to 5 rotation direction changes per second.
Major pendulum motion may lead to damage at
the meshing gears. The gears usually already
mesh at the first rotation direction change, so that
the switchover time is approx. 300 to 400 ms.
In average, this means: n
Mot
= 5°/s = 5° 60/min =
300°/min = 300/360 rpm = 0.83 rpm.
Conversion
Pendulum speed
pendulum rotary motion
Speed
[rpm]
Angle
[°/min]
Time
[sec]
Angle
[°/sec]
0.25
90
3.33 5
0.50
180
1.67 5
1.00
360
0.83 5
2.00
720
0.42 5
3.00
1080
0.28 5
4.00
1440
0.21 5
5.00
1800
0.17 5
The machine optimum is to be determined on
the basis of shift tests in relation to the different
masses and thereto connected drag torques of
the spindle.
The limit switch signals of S1 – gear 1 (contact 4)
and S2 – gear 2 (contact 6) serve to shut off the
shift unit once the gearchange is complete.
CAUTION
After the limit switch signals have been reached,
the shift unit is allowed to be live for a maximum
of 0.5 second. The limit switch signals must be
monitored during the operating time.
The limit switches must only be energized with
the control current (0.1 – 0.5 A) and not with the
changeover current (5 A).
Rotation direction
changes
