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BWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite1DriveSystemsSeries51BGServoBevel-GearUnitsBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite2ContentsCompanyAddress.
3General.
3Whoshouldstudytheseinstructions3Safetynotes.
3Othersignsandsymbols.
3Exclusionofliability.
4Modifications,conversions.
4ECMachineryDirective.
4Technicalchanges4Properuse.
4Improperuse5QualifiedPersonnel5Generalsafetyinstructions5Shortdescription.
6Itemnumber7Tighteningtorques.
9Checklist-start-up.
9Start-up/operation.
10Maintenance.
11Shaftsealingrings:11Maintenanceintervals12Changingthegearoil.
12Cleaning.
14Mountinginstruction15Preparingtheinstallation.
15Installationofbevel-gearunits:15Mountingtheoutputdriveshaft(Versionwithshrink-disc)16Mountingtheoutput-drivepinionshaftBG50(Versionwithkey)18Mountingtheoutput-drivepinionshaftBG63andBG80(Versionwithkey)19Mountingtheclutchonthemotorshaft20Mountingthemotor21Transportandhandling.
23Storage.
23Failurelist(Troubleshooting)24Disposal.
25CAUTION!
Theobservanceoftheseoperationandmaintenanceinstructionsispre-requisitefortheundisturbedoperationandtheacceptanceofliabilityforpossibledefects.
Thereforestudytheoperationandmaintenanceinstructionsbeforestartingtousethegearunit.
Makesurethattheoperationandmaintenanceinstructionsaremadeaccessibletotheassemblypersonnelinlegiblecondition.
Observeanynational/regionalregulationsconcerningsafetyandpreventionofac-cidents.
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DOCSeite3CompanyAddressATLANTAAntriebssystemeTelefon:+49(0)7142-7001-0E.
SeidenspinnerGmbH&Co.
KGTelefax:+49(0)7142-7001-99Adolf-Heim-Strae16/18E-Mail:info@atlantagmbh.
de74321Bietigheim-BissingenInternet:http://www.
atlantagmbh.
deGeneralWhoshouldstudytheseinstructionsTheseinstructionsareaddressedtoallpersonsinstalling,operatingormaintainingtheseries51BGservobevel-gearunits.
YoumustnotusetheSeries51BGservobevel-gearunitsbeforehavingreadandunderstoodtheseoperatingandmaintenanceinstructions.
Pleasegivethesafetyinstructionsalsotootherpersons.
SafetynotesThefollowingsignalsymbolsandwordsareusedintheinstructionstowarnyouand/orinformyouofsomething.
warnsyouabouthighinjuryhazardswarnsyouaboutpossibleinjuryhazardswarnsyouaboutminorinjuryhazardsand/ordamagehazardsEnvironmentallyhazardous-warnsyouaboutapollutionhazardfortheenvironmentTransportwarnsyouofinjuryhazardswhentransportingandhandlingbulkyobjectsOthersignsandsymbolsbyan"instructiontoact"youareaskedtodosomethingbyahint"youareinformedofapossiblesimplificationorimprovement#Maintenance:suggestsoptimaloperationWhenoperatedinareaswithexplosionhazardtheinstructionsidentifiedbythesym-bolaretobeobserved.
ThesewerepreparedonthebasisoftheignitiondangerratingKGA114.
Thissymbolreferstothenameplate.
Thestoragesymbolindicateshowthebevel-gearunitsshouldbestored.
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DOCSeite4ExclusionofliabilityThemanufacturerwillnotacceptliabilityfordamagesorinjuriesresultingfromimproperuseorhandlingoftheseries51BGservobevel-gearunits.
Impropermanipulationsandotheractsnotinaccordancewiththeseinstructionsimpairthequal-ityoftheproduct.
ThiswillleadtotheexclusionofwarrantyclaimsagainstATLANTAAntrieb-ssystemeE.
SeidenspinnerGmbH&Co.
KG.
Modifications,conversionsModificationsand/orconversionsofthegearunitarenotpermissibleunlessexpresslyapprovedbyATLANTAinwriting.
ECMachineryDirectiveAsdefinedbytheECMachineryDirective98/37ECthegearunitisnotconsideredanautono-mousmachinebutacomponenttobeinstalledinmachines.
WithinthepurviewoftheECdirectivetheunitmustnotbeoperatedunlessthemachineintowhichthisproductisinstalledfulfillstherequirementsofthedirective.
TechnicalchangesATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KGreservetherighttomaketechni-calchangestoimprovetheproduct.
ProperuseTheATLANTAseries51BGservobevel-gearunitmayonlybeusedforspeedandtorqueconversioninmachinesandmechanicalequipmentunderatmosphericpressureconditions.
Itmustnotbeusedoutdoors.
Thepermissibleinputspeedandoutputtorqueaswellasthepermissibleadditionalloadsmustnotbeexceeded.
ThelayoutinstructionsintheAtlantacataloguemustbeobserved.
Themaximumtorquespermittedarelistedinourcatalogueorourwebsite:http://www.
atlantagmbh.
deThegearboxmustnotbeusedincombinationwithcombustionengines–dangerofoverheating,inadmissibleshockloading!
Thegearunitisdesignedforinputdriveviabevel-gearshaftwithATLANTAE-servospecialclutchorATLANTAspecialclutchTheinputdriveviabevel-gear(hollowoutputshaft)maybechosenonlyafterconsultingATLANTA.
Theefficiencyratingindicatedisbaseduponinputdriveviathesplinedshaft.
Thegearunitisnotself-braking.
Thegearunitmustnotbeusedoutdoorsorunderwater.
Thesurfacetemperatureofthegearboxmustnotexceed80°Cduringoperation.
WhenusedinareaswithexplosionhazardthetemperatureofBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite5thehousingmustnotexceed65°C.
Ifnecessary,measurethesurfacetemperatureandwarnorswitchoffwhenitexceeds65°C.
Thegearunitisdesignedforintermittentoperation(S3acc.
toDINEN60034-1).
Continuousoperation(S1acc.
toDINEN60034-1)isnotpermissiblewithoutthemanufac-turer'swrittenapproval.
Continuousoperationisdefinedbythedutycycle.
Ifitexceeds30%orislongerthan20minutes,itisconsideredcontinuousoperation.
Whenusedinareaswithexplosionhazardtheinstructionsidentifiedbythesymbolaretobeobserved.
ImproperuseJWhenevertheabovementionedlimitsareexceeded(especiallyhighertorqueorspeed),thisshallbeconsideredimproperusewhichisforbidden.
Itisforbiddentooperatethegearunitif:itisnotcorrectlymounted(e.
g.
fasteningofthemotor),itisnotproperlyinstalled(e.
g.
fixingscrews),thegearunitisverydirty(e.
g.
dustdeposits)thereisnosufficientlubrication.
QualifiedPersonnelSomeresidualdangerforpersonsandobjectsmayemanatefromtheseries51BGservobevel-gearunit.
Thereforeonlyskilledandtrainedpersonnelbeingawareofpossiblerisksmaycarryoutmounting,installation,start-up,service,andmaintenancework.
Thepersonnelmusthavethenecessaryqualificationfortheworktobedoneandmustbefamiliarwithmounting,installation,startingupandoperatingtheproduct.
Inadditiontheymustcarefullyread,understandandobservetheoperatinginstructionand,inparticular,thesafetyinstructions.
Thefollowingworksshouldalsobecarriedoutonlybyqualifiedpersonnel:Transport,storage,erection/installation,connection,start-up,service,maintenanceGeneralsafetyinstructionsWedonotclaimthesesafetyinstructionstobecomplete.
IncaseofquestionsorproblemspleasecontactATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KG.
Thegearunitincorporatesthelatesttechnologicaldevelopmentatthetimeofdeliveryandcanbeprincipallyregardedassafetooperate.
Impropermanipulationsmayleadtoinjuriesanddamages.
Makesurethatthegearunitisonlyinstalled,serviced,ordisassembledbyspeciallytrainedskilledpersonnel.
Foreignmatterflungaboutmaycauseseriousinjurie.
Makesurethatnoforeignmatterortoolsarenearthegearunitbeforestartingoperation.
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DOCSeite6Contactwithhotsurfacesmaycauseburns.
Nevertouchgearunitswhentheyhavehighoperatingtemperatures,orusesuitableprotec-tiveequipment(e.
g.
gloves).
Rotatingpartsmaycauseinjuries.
Pulling-inrisk!
Keepsufficientdistancetorotatingmachineparts.
Neverinstalloroperatedefectiveproducts.
Incaseofdamagepleasecomplainimmediately.
ShortdescriptionTheATLANTABGservobevelgearunitwasdevelopedforusewiththree-phaseACandDCservomotors.
Itfeaturesalow-clearancegearing.
Thelight-metalcasingensuresoptimalheatdissipation.
Robustbearingsandanexcellentstiffnesspermitthetransmissionofhightorquesandadditionalforces.
Thegearunitissuppliedtest-run,tightness-checkedandthusreadyforoperation.
Thegearunitisavailablewithdifferentreductionratios.
Withinonegearboxsizeanddesignallcomponents,exceptforthesetofwheels,arethesame.
Thelast2digitsoftheitemnumberstandforthenominalreductionratio.
Theexactreductionratiocanbeseenfromtheta-blebelow.
Itemno.
ActualgearreductionApplicableto51xxx0519/4=4,75allsizes51xxx0727/4=6,75allsizes51xxx0939/4=9,75allsizesThisgearunitisavailablewith2outputvariations:hollowoutputshaftforkeyconnectionshollowoutputshaftforclampedconnectionsBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite7ItemnumberTheitemnumberiscomposedasfollows:ExampleBGservobevel-gearunitBG=80mm,i=4.
75versionwithkeyorshrink-discIdentificationThegearunitisidentifiedbyanameplatecontainingthegearboxtype,thegearratio,themax.
performanceforS3operation,themax.
speedforS3operation,theassemblydate,andtheserialnumberofthegearunit.
TypeGearratioMax.
performanceforS3operation[kW]Max.
speedforS3operation[min-1]Mass[kg]Serialnumber51050055715005BG-ServoKegelrad-getriebeBG-ServoBevelgearunitBG-ServoKegelrad-getriebeBG-ServoBevelgearunitPafeder-AusführungKeywaydesignSchrumpfscheiben-AusführungShrink-discdesignBaugreBG=80Construction-sizeBaugreBG=80Construction-sizeGehuse-IdentnummerOrdercodeofhousingGehuse-IdentnummerOrdercodeofhousingbersetzungi=4,75Ratiobersetzungi=4,75RatioBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite8Aseparateoilratingplatespecifiesthetypeofoil:Whenusedinareaswithexplosionhazardthegearunitmustbeadequatelyidentifiedbyameansofanameplate.
Onlythenitmaybeusedinsuchareas:BWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite9TighteningtorquesAllscrewconnectionsforwhichtighteningtorquesarespecifiedareprincipallytobetightenedandcheckedwithacalibratedtorquewrench.
Thetighteningtorquescanbetakenfromtablesinrelevantbooks.
Shouldscrewsbeemployedacc,toDIN912,youcanusethefollowingtable:Forthecountersunkholes:Whenapplyingtorquesacc.
toyourowncompanystandard,whichallowstheutilizationof90%oftheyieldpointofthescrew,asuitablewasher/bushingshouldbeused.
Hexag.
socket-headscrewsDIN912Strengthclass8.
8/aluminiumhousingM5M6M8M10M12M16TighteningtorqueinNm*)3,58,918.
84045117Tighteningtorqueinlbfin*)31781663543981035.
5Forthethreadedholes::(Effectivelengthofthreadmin.
1.
5xdnenn/bearingsurfacesteelwithmin.
pG>300N/mm2)Hexag.
socket-headscrewsDIN912Strengthclass8.
8M5M6M8M10M12M16TighteningtorqueinNm*)5,59,5234680195Tighteningtorqueinlbfin*)48842034077081725*)Useonlycalibratedtorquewrenches!
Ifthetighteningtorqueistoolow,therequiredtorquewillnotbetransmitted.
Ifthetighteningtorqueistoohigh,thescrewswillbeoverstrainedandbecomeunusable.
Checklist-start-upBeforestartingupWhathastobecheckedCheckedDelivery:ArethesuppliesinconformitywiththeconsignmentnoteAnytransportdamageshouldbereportedimmediatelytothecarrier.
Obviousdefects/incompletenessshouldbereportedimmediatelytoATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KG.
Applicationinareaswithexplosionhazard:Arethefollowingdataonthenameplateofthegearboxes/motorsinconformitywiththepermissibleEx"applicationareaonthesite–Explosiongroup–Category–Zone–Temperatureclass–Max.
surfacetemperatureAmbienttemperature:Istheambienttemperaturerangeacc.
tothedataonthelubricanttableobservedThemax.
ambienttemperatureof40°Cmustnotbeexceededthrough-outthewholeoperatingtime.
thetemperaturemustnotfallbelowthemin.
ambienttemperatureof-10°Cthroughoutthewholeoperatingtime.
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DOCSeite10Ventilation:IssufficientventilationofthegearboxensuredInputandoutputdriveelements:Areallinputandoutputdriveelementstobemountedsuitableforthespecificex"protectionuseNameplateinformation:ArethedataonthegearboxnameplatenotexceededDuringstart-upWhathastobecheckedCheckedEnvironment:Itmustbeensuredthattherearenoatmospheres,oils,acids,gases,vapours,orcombustibledustsaroundwhichmayexplode!
Temperaturemeasurement:Thetemperaturemustbemeasuredafter3hoursofoperationundermax.
operatingloadconditions!
Thetemperaturemeasurementsshallbetakenintheinputareainplaceswhichareprotectedfromthecoolingaircurrent.
Itisadvis-abletomeasureinvariousplacesinordertodeterminethemaxi-mum.
Theabsolutetemperatureof80°Conthesurfaceofthegearboxmustnotbeexceededsothatthethermalstressonshaftsealsandlubricantsiskeptlow;thishasapositiveinfluenceupontheservicelife.
Start-up/operationMakesurethatthefollowingpreconditionsfortheoperationarefulfilled:Thecontrolandprotectivesystemsmustnotbeshutoff.
Thisappliesalsofortrialrunsandstart-upoperation.
Thegearunitsmustnotbeoperatedunderthefollowingambientconditions:oExplosiveatmosphere,(exceptionCEII3GT4/II3DT130°C)ooils,oacids,ogases,(exceptionCEII3GT4/II3DT130°C)ovapours,oradiation.
Dependinguponthelubricantsusedtheambienttemperatureshouldbebetween10°Cand+40°C.
Iftheambienttemperatureslieoutsidethepermissiblerange,getintocontactwithATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KG.
Thegearunitsmustnotbeoperatedunlesssufficientventilationisensuredinordertoavoidanyheatcongestion.
Whenusedinareaswithexplosionhazard,theoperatormustensurethatthesurfacetemperatureofthegearboxdoesnotexceed65°C.
;ifnecessary,controlthesurfacetemperatureofthehousing.
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DOCSeite11Thesurfaceofthegearboxcanreachtemperaturesofmorethan65°C.
duringoperationandcancauseburns.
Theper-soninstallingthegearunitmusttakecarethatpersonscannotbeinjuredduetohotsurfaces.
Rotatingpartscancatchpiecesofclothing,hair,andmem-bersofthebodyandcaninjurepersons.
Thepersoninstallingthegearunitmusttakecarethatpersonscannotbeinjuredbyrotatingparts.
MaintenanceAccidentalstartingofthegearunitwhilemaintenanceworkisbeingcarriedoutcanleadtoseriousaccidents.
Makesurethatnobodycanstartthegearunit,whilemaintenanceworkisbeingperformed.
Evenshortoperationofthegearunitwhilemaintenanceworkisbeingcarriedoutcancauseaccidents,ifthesafetydevicesareshutoffandinoperative.
Makesurethatallsafetydevicesaremountedandoperative.
Shaftsealingrings:Shaftsealingringssealthegapbetweenthehousingandtherotatingshafts.
Theyarewearingpartswhichhavetobereplacedwhentheyreachthepermissiblelimitofwear.
Theservicelifeofshaftsealingringsisinfluencedbyamultitudeofparameters.
Theseareamongothers.
:peripheralspeedatthesealingliptemperatureinternalpressureinthegearboxviscosityoflubricantchemicalanalysisandadditivationoflubricantsmountingsituation(lubricantsupplytothesealinglip)particlesand/ormetallicfinesinthelubricantmaterialoftheshaftsealingringexternalpollutionThismultitudeofinfluencingparametersmakeitpracticallyimpossibletopredictthepreciseser-vicelifewithoutmakingexperimentssimulatingtherespectiveapplication.
Astheservicelifeoftheshaftsealingringsissubjecttotheabovementionedfluctuations,it.
.
isabsolutelynecessarytocheckthematregularintervals.
Onlyregularcheckscanpreventunnoticedlossoflubricantinthegearbox.
Whenevertheshaftsealingisreplacedyoushouldalsochecktherunningsurfaceofthelipsofthesealontheshaft.
Ifseizuremarksarevisible,theshaftmustberepairedorreplaced.
Alterna-tivelyitispossibletoinserttheshaftsealingringinaslightlyaxiallydisplacedpositionsothatthelipofthesealrunsinapracticallynewplaceBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite12MaintenanceintervalsProvidedthatthegearunitsareusedproperlyasdescribedinthecatalogue,theseries51BGservobevel-gearunitsaredesignedandbuiltfor12,000hofoperationexceptforwearingpartssuchasthebearingsandtheshaftsealingrings.
Thefollowingmaintenanceworksshouldbeperformedfortheseries51BGservobevel-gearunits.
IntervalWhatshouldbedoneEvery2000machinehours,butatleasteverysixmonthsChecktherunningnoisetodetectpossibledefectsinthebearingsInspectthemotorflangesforleakageInspectthesealsforleakage.
Shouldanyleakagebede-tected,pleasecontactus.
After5000…8000hours,butafter3yearsatthelatestReplacetheshaftsealingringsChangingthegearoilAsufficientamountoflubricantisabsolutelynecessaryforsafeoperation.
Thelubricantensuresthatdryrunningandconsequentlyexcessivelyhighsurfacetemperatures,wear(play),orme-chanicsparkingispreventedinthemetalliccontacts.
Themaindangerisanunnoticedlossoflubricant.
Thereforethegearunitsmustberegularlycheckedforlossoflubricant.
ATLANTAEservobevel-gearunitsarefilledwithsyntheticpolyglycoloil.
Underthefollowingpreconditionsthisisalifetimelubrication:ThelayoutofthegearunitisstrictlyinaccordancewiththeguidelinesgivenintheATLANTAcatalogue(www.
atlantagmbh.
de).
Thegearunitisexclusivelyoperatedwithinthepermissiblecharacteristicandlimitvalues(www.
atlantagmbh.
de).
Theoperatorchecksthegearunitregularly(every2weeks)forlossofoil.
Thesurfacetemperaturemustnotexceedmax.
80°Cduringoperation.
Inthecaseofoperationwithmostlylowinputspeeds(peripheralspeedofthebevelgearv40°CThemostsuitablepointforcontrollingthemax.
permissiblesurfacetemperatureofthehous-ingisintheareaoftheinput-sidebevel-gearshaftbearings.
Theverticalarrangementoftheshaft(inputoroutputverticallydownward)isonlypermissiblewithanoillevelmonitorstoppingthegearunitincaseofasuddenlossofoil.
Mountingtheoutputdriveshaft(Versionwithshrink-disc)Fortheoutputdriveshaftwerecommendtoleranceh6(DINISO286).
Thematerialmusthaveaminimumyieldpointof385N/mm2.
IfyouhaveboughttheoutputdriveshaftfromATLANTAandifitisnotsuppliedalreadymounted,werecommendtoproceedasfollows:Cleantheseatofthehollowshaftandoilitslightly(donotusegrease).
Wipeoffanyexcessoilwitharag.
Slidetheshrink-discontothehollowshaft.
Donottightenthescrewsbeforehand!
Cleantheshankoftheoutputdriveshaftandoilitslightly.
Wipeoffanyexcessoilwitharag.
abutmentscrewingsurfaceBevel-gearunitlateralforcesBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite17Pushtheoutputdriveshaftintotheborerightuptothestop.
Attachtheshrink-discbyevenlytighteningthescrewsoneaftertheother(notcrosswise).
Makesurethatthetwoclampingdiscsareplaneparallel.
Severalpassesarenecessaryuntilthescrewsaretightenedtothespecifiedtorqueacc.
tothetablebelow.
OrdercodeTighteningtorque*)808403612Nm808505012Nm808606212Nm*)Useonlycalibratedtorquewrenches!
Ifthetighteningtorqueistoolow,therequiredtorquewillnotbetransmitted.
Ifthetighten-ingtorqueistoohigh,thescrewswillbeoverstrainedandbecomeunusable.
Soilingmayimpedethetransmissionofthetorque.
Donotdisassembletheshrink-discclampingsetbeforemountingitIfthegearunitiscleanedinthesealingareawithacleansingagentapprovedbyATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KGthesurfacescleanedmustbeprotectedagainagainstcorro-sion.
Theforcesoftheshrink-disccandeformthehollowshaft.
Alwaysinstallthemachineshaftbeforetighteningtheclampingscrewsoftheshrink-disc.
Slantingtheshaftsmaycausedamage.
MakesurethatthehollowshaftandthemachineshaftarealigneWhenusedinareaswithexplosionhazardimproperinstallationmayleadtoinadmissiblyhightemperatures.
Checkthetighteningtorquesandaxialfixingafter10hoursunderoper-atingconditions.
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DOCSeite18Mountingtheoutput-drivepinionshaftBG50(Versionwithkey)Unlesstheoutputpinionshaftcomesalreadyfullyassembled,werecommendtoproceedasfol-lows:CleantheseatofthehollowshaftandrubwithMoS2-powderorgrease(reducesfrettingcorrosion).
Insertthelockingwasherintotherecessofthehollowshaft.
.
Insertthelockingwasherfromtheoppositesideuptothestopinsidethehollowshaft.
.
Connectthemountingplateandtheoutputshaftbymeansofthescrew.
Securethescrewusingsuitableadhesive(e.
g.
Loctite243).
*)Drylubricant:Improvestheslidingpropertiesofmachinepartsandreducesfrictionandwearwithinawidetemeperaturerange;minimumfrictionwithmaximumloadcapacit.
GearboxwithoutoutputshaftInsertpinionshaftMountretainingdisk/lockscrewandtightenTheretainingring,washerandscrewsuppliedwiththedriveshaftservefortheaxialfixationoftheinputdrivingshaft.
ForgearboxessizeBG50anadditionalwasher25109001isrequiredwhichreplacesthetwoitemsretainingring+lockingwashersuppliedtogetherwiththedrivingshaft.
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DOCSeite19Mountingtheoutput-drivepinionshaftBG63andBG80(Versionwithkey)Unlesstheoutputpinionshaftcomesalreadyfullyassembled,werecommendtoproceedasfol-lows:CleantheseatofthehollowshaftandrubwithMoS2-powderorgrease(reducesfrettingcorrosion).
Inserttheretainingringintotherecessofthehollowshaft.
Pushintheoutputshaftrightuptothestop.
Insertthelockingwasherfromtheoppositesideuptothestopinsidethehollowshaft.
Connectthemountingplateandtheoutputshaftbymeansofthescrew.
Securethescrewusingsuitableadhesive(e.
g.
Loctite243)*)Drylubricant:Improvestheslidingpropertiesofmachinepartsandreducesfrictionandwearwithinawidetemeperaturerange;minimumfrictionwithmaximumloadcapacit.
GearboxwithoutoutputshaftInsertSpringInsertpinionshaftMountretainingdisk/lockscrewandtightenHexagonsockethead-screwsDIN912strengthrating8.
8/lockingwasherM5M8M12M16TighteningtorqueinNm5.
52380195Tighteningtorqueinlbfin48.
5203.
57081726*)Useonlycalibratedtorquewrenches!
Ifthetighteningtorqueistoolow,therequiredtorquewillnotbetransmitted.
Ifthetighteningtorqueistoohigh,thescrewswillbeoverstrainedandbecomeunusableSlantingtheshaftsmaycausedamage.
Makesurethatthehollowshaftandthemachineshaftarealigned.
Mountthemachineshaftinthehollowshaftwithoutusingforce.
Nevertrytomountitbymeansofknockingitin.
Useonlysuitabletoolsanddevices.
Whenusedinareaswithexplosionhazard,improperinstallationmayleadtoinadmissiblyhightemperatures(seeignitiondangerratingacc.
toKGA114).
Checkthetighteningtorquesandtheaxialfixingafter10hworkunderoperatingconditions.
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DOCSeite20655XXXX654XXXXMountingtheclutchonthemotorshaftATLANTAEservospecialclutch655XXXXorATLANTAspecialclutch654XXXXTheclutchissuppliedpre-assembled.
VBeforemountingtheclutchonthemotorshaftcleanallcontactsur-facesandcoatthemwithathinoilfilm(nogrease).
AnyexcessoilshouldbewipedoffwitharagRubtheDIN5480profileoftheclutchwithMoS2powderorgrease(reducesfrettingcorrosion)Ifthemotorshafthasakey,itshouldberemoved.
Slidetheclutchontothemotorshaftasfarasspecifiedinthecata-logueasX1"(655XXXX)and/orrightuptothestop(654XXXX/shoulderorretainingring).
Inthecaseofclutch655XXXXintermediatesleevesmaybeusedinordertoreachthemotor-shaftdiameter.
Insuchacasetheslotintheintermediatesleevemustbealignedwiththeslotintheclutchbody.
Slightlytightentheclampingscrews.
Tightenscrewsuniformlybyturningthemalternately(crosswisewith654XXXX).
.
Checkclutchfortruerunningatthereferencediameter(fr<0.
04mm).
Severalpassesarenecessaryuntilthescrewsaretightenedtothetighteningtorquespeci-fiedinthetablebelow.
Makesurethatthewidthofthegapbetweenclutchandpressuresurfaceremainsuniform.
Checkatreferencediameterfortruerunning.
OrdercodeofclutchTighteningtorque*)OrdercodeofclutchTighteningtorque*)6551xxx7Nm62lbfin6543xxx7Nm62lbfin6553xxx7Nm62lbfin6544xxx10Nm88,5lbfin6554xxx10Nm88,5lbfin6546xxx10Nm88,5lbfin6555xxx25Nm221lbfin6547xxx25Nm221lbfin*)Useonlycalibratedtorquewrenches!
Ifthetighteningtorqueistoolow,therequiredtorquewillnotbetransmitted.
Ifthetighten-ingtorqueistoohigh,thescrewswillbeoverstrainedandbecomeunusable.
Whenusedinareaswithexplosionhazard,improperinstallationmayleadtoinadmissiblyhightemperatures(seeignitiondangerratingacc.
toKGA114).
Checkthetighteningtorquesandtheaxialfixingafter10hrsworkunderoperatingconditions.
Whenusedinareaswithexplosionhazard,usecorrosion-protectedscrews.
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DOCSeite21MountingthemotorCleanflangesurfaceandcenteringshoulderonmotorandgearbox.
Slidethemotorwithcouplingmountedontotheteethoftheinputdriveshaftandintothegearcenteringpiecesothattheplanesurfacestouch.
Ifnecessary,rotatethemotoraroundthemotoraxleuntiltheclutchandtheinputshaftteethmesh.
.
Themotormustslideoneasily.
Theremustnotbeanygapbetweenthemotorandthegearboxflange.
Mountingmotorshavinglongershaftsthanpermissiblefortherespectivegearunitleadstotensionswhichdamagethemotorandthegearunit.
Checktheinterferingedgesbymeasuringoutorbycheckingthedimensionaccordingtoourcataloguedataandthemotormanufacturer'sdata.
Screwmotorandgearboxtogether.
Hexagonnutsorscrewsaretobetightenedtothespeci-fiedtorqueandsecured.
Thecorrecttighteningtorquecanbeseenfromtherespectiveta-bles.
Inthiscontextitisparticularlyimportanttopayspecialattentiontothestrengthclassofthescrewandthematerialofthesupportingsurfaces.
Themotorcanbemountedoptimallycenteredbypositioningthegearboxinsuchawaythatthebevel-gearshaftisstandingupvertically.
Usescrewswithaneffectivelengthofatleast1.
6xthreaddiameter.
Whenusedinareaswithexplosionhazard,usecorrosion-protectedscrewsMounttheclutchonthemotorshaftandfastenasdescribedCleanmotorandclutchsurfacesBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite22Screwmotortogearbox,Usepropertighteningtorqueforscrews*)Drylubricant:Improvestheslidingpropertiesofmachinepartsandreducesfrictionandwearwithinawidetemeperaturerange;minimumfrictionwithmaximumloadcapacity.
CleanscrewingsurfacesofmotorandgearboxandrubwithMoS2*)powderorgreaseBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite23TransportandhandlingTherearenospecialholesorthreadsprovidedfortransportingandhandlingthegearunit.
Thereare,however,numerousfixingthreadsavailableinthegearhousingpermittingtoscrewineye-boltssothatitispossibletohandlethegearboxsafely.
Observeallsafetyregulationsinconnectionwithtransportandhandlingusingliftinggear.
Makesurethattheloadishandledandsetdownslowlyandcarefully.
GearboxsizeWeightwithoutattachmentsBG50≈3,2kgBG63≈6kgBG80≈8kgStorageIfthegearunitisnotinstalledimmediatelyafteritsdelivery,thefollowingmeasuresaretobetaken:Storethegearunitwithhorizontalhollowoutputshaftandhorizontalinputdriveshaft(wormshaft)ontopinsuchawaythat-exceptforthesupportingsurface-itcannotcomeintocontactwithanyotherobjectsProtectthegearunitsfromdetrimentalenvironmentalinfluences(highairhumidity,saltyair,aggressivegases;UVlight,electricwelding;dust;dirt,shocks;temperaturefluctuations;[0°Cto+30°C],etc.
).
Connectingparts,e.
g.
clutchoroutputshaft,aretobestoredseparately.
Protectthesteelpartsagainstcorrosion.
Aslogisticsprincipleforstore-keepingwerecommendthefirstin–firstout"principle.
Occasionallyturningtheinputshaftofthegearunitwillfacilitatethestart-upThemax.
storagetimeundersuchconditionsis2years.
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DOCSeite24Failurelist(Troubleshooting)Youshouldtakeremedialmeasuresatonce,ifyougetawareofoilloss,increasedoperatingnoises,orincreasedoperatingtemperatures.
Anydisturbancesoccurringduringthewarrantyperiodrequiringtherepairofthegearunit,mayonlyberemediedbyATLANTA.
Werecommendtoaskforourassistancealsoaftertheexpirationofthewarrantyperiod.
Alwaysshutdownthegearboxduringtheeliminationofdisturbances.
Securethedrivingunitagainstinadvertantstarting.
Postanoticeattheswitchingposition.
ProblemPossiblecauseRemedyLayouttoweak;Speed/torquetoohighCheckthetechnicaldataMotorheatsupthegearunitChecktheattachmentcircuit,replacethemotor,orprovideaninsulationbetweenmotorandgearunitAmbienttemperaturetoohighEnsureadequatecoolingIncreasedoper-atingtempera-tureDutycycletoolongVerifythelayoutDefectivebearingDefectivetoothsystemPleasecontactusThefixingofthegearunithasloosened.
Tightenscrews/nutswiththespecifiedtight-eningtorque.
Replacedefectivescrews/nuts.
Increasedopera-tingnoiseAdjustmentofcontroller.
Checktheservo-motorparametersLeakageGetintocontactwithus.
LossofoilApparentleakageAtemporaryleakageduetomuchgreasebetweensealinglipandprotectivelip.
Thesurplusgreasecanpenetrateoutsideasanapparentleakage.
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DOCSeite25DisposalPleaseobservethenationalregulations!
Ifrequired,disposeoftheindividualcomponentsseparatelydependingontheirnatureandanyexistingspecificnationalregulations,e.
gas:Steelscrapogearwheelsoshafts(hollowshafts)oantifrictionbearingsocastironpartsoclutchesAluminiumscrapohousingelementsoadaptorelementsBronzescrapobevelgear(separatedfromhollowshaft)CollectwasteoilanddisposeofasdirectedATLANTAdoesnotacceptliabilityforanydamagetothetransmissionoranyconsequentialdamage,iftheseinstructionsarenotobserved.
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DOCSeite1DriveSystemsSeries51BGServoBevel-GearUnitsBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite2ContentsCompanyAddress.
3General.
3Whoshouldstudytheseinstructions3Safetynotes.
3Othersignsandsymbols.
3Exclusionofliability.
4Modifications,conversions.
4ECMachineryDirective.
4Technicalchanges4Properuse.
4Improperuse5QualifiedPersonnel5Generalsafetyinstructions5Shortdescription.
6Itemnumber7Tighteningtorques.
9Checklist-start-up.
9Start-up/operation.
10Maintenance.
11Shaftsealingrings:11Maintenanceintervals12Changingthegearoil.
12Cleaning.
14Mountinginstruction15Preparingtheinstallation.
15Installationofbevel-gearunits:15Mountingtheoutputdriveshaft(Versionwithshrink-disc)16Mountingtheoutput-drivepinionshaftBG50(Versionwithkey)18Mountingtheoutput-drivepinionshaftBG63andBG80(Versionwithkey)19Mountingtheclutchonthemotorshaft20Mountingthemotor21Transportandhandling.
23Storage.
23Failurelist(Troubleshooting)24Disposal.
25CAUTION!
Theobservanceoftheseoperationandmaintenanceinstructionsispre-requisitefortheundisturbedoperationandtheacceptanceofliabilityforpossibledefects.
Thereforestudytheoperationandmaintenanceinstructionsbeforestartingtousethegearunit.
Makesurethattheoperationandmaintenanceinstructionsaremadeaccessibletotheassemblypersonnelinlegiblecondition.
Observeanynational/regionalregulationsconcerningsafetyandpreventionofac-cidents.
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DOCSeite3CompanyAddressATLANTAAntriebssystemeTelefon:+49(0)7142-7001-0E.
SeidenspinnerGmbH&Co.
KGTelefax:+49(0)7142-7001-99Adolf-Heim-Strae16/18E-Mail:info@atlantagmbh.
de74321Bietigheim-BissingenInternet:http://www.
atlantagmbh.
deGeneralWhoshouldstudytheseinstructionsTheseinstructionsareaddressedtoallpersonsinstalling,operatingormaintainingtheseries51BGservobevel-gearunits.
YoumustnotusetheSeries51BGservobevel-gearunitsbeforehavingreadandunderstoodtheseoperatingandmaintenanceinstructions.
Pleasegivethesafetyinstructionsalsotootherpersons.
SafetynotesThefollowingsignalsymbolsandwordsareusedintheinstructionstowarnyouand/orinformyouofsomething.
warnsyouabouthighinjuryhazardswarnsyouaboutpossibleinjuryhazardswarnsyouaboutminorinjuryhazardsand/ordamagehazardsEnvironmentallyhazardous-warnsyouaboutapollutionhazardfortheenvironmentTransportwarnsyouofinjuryhazardswhentransportingandhandlingbulkyobjectsOthersignsandsymbolsbyan"instructiontoact"youareaskedtodosomethingbyahint"youareinformedofapossiblesimplificationorimprovement#Maintenance:suggestsoptimaloperationWhenoperatedinareaswithexplosionhazardtheinstructionsidentifiedbythesym-bolaretobeobserved.
ThesewerepreparedonthebasisoftheignitiondangerratingKGA114.
Thissymbolreferstothenameplate.
Thestoragesymbolindicateshowthebevel-gearunitsshouldbestored.
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DOCSeite4ExclusionofliabilityThemanufacturerwillnotacceptliabilityfordamagesorinjuriesresultingfromimproperuseorhandlingoftheseries51BGservobevel-gearunits.
Impropermanipulationsandotheractsnotinaccordancewiththeseinstructionsimpairthequal-ityoftheproduct.
ThiswillleadtotheexclusionofwarrantyclaimsagainstATLANTAAntrieb-ssystemeE.
SeidenspinnerGmbH&Co.
KG.
Modifications,conversionsModificationsand/orconversionsofthegearunitarenotpermissibleunlessexpresslyapprovedbyATLANTAinwriting.
ECMachineryDirectiveAsdefinedbytheECMachineryDirective98/37ECthegearunitisnotconsideredanautono-mousmachinebutacomponenttobeinstalledinmachines.
WithinthepurviewoftheECdirectivetheunitmustnotbeoperatedunlessthemachineintowhichthisproductisinstalledfulfillstherequirementsofthedirective.
TechnicalchangesATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KGreservetherighttomaketechni-calchangestoimprovetheproduct.
ProperuseTheATLANTAseries51BGservobevel-gearunitmayonlybeusedforspeedandtorqueconversioninmachinesandmechanicalequipmentunderatmosphericpressureconditions.
Itmustnotbeusedoutdoors.
Thepermissibleinputspeedandoutputtorqueaswellasthepermissibleadditionalloadsmustnotbeexceeded.
ThelayoutinstructionsintheAtlantacataloguemustbeobserved.
Themaximumtorquespermittedarelistedinourcatalogueorourwebsite:http://www.
atlantagmbh.
deThegearboxmustnotbeusedincombinationwithcombustionengines–dangerofoverheating,inadmissibleshockloading!
Thegearunitisdesignedforinputdriveviabevel-gearshaftwithATLANTAE-servospecialclutchorATLANTAspecialclutchTheinputdriveviabevel-gear(hollowoutputshaft)maybechosenonlyafterconsultingATLANTA.
Theefficiencyratingindicatedisbaseduponinputdriveviathesplinedshaft.
Thegearunitisnotself-braking.
Thegearunitmustnotbeusedoutdoorsorunderwater.
Thesurfacetemperatureofthegearboxmustnotexceed80°Cduringoperation.
WhenusedinareaswithexplosionhazardthetemperatureofBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite5thehousingmustnotexceed65°C.
Ifnecessary,measurethesurfacetemperatureandwarnorswitchoffwhenitexceeds65°C.
Thegearunitisdesignedforintermittentoperation(S3acc.
toDINEN60034-1).
Continuousoperation(S1acc.
toDINEN60034-1)isnotpermissiblewithoutthemanufac-turer'swrittenapproval.
Continuousoperationisdefinedbythedutycycle.
Ifitexceeds30%orislongerthan20minutes,itisconsideredcontinuousoperation.
Whenusedinareaswithexplosionhazardtheinstructionsidentifiedbythesymbolaretobeobserved.
ImproperuseJWhenevertheabovementionedlimitsareexceeded(especiallyhighertorqueorspeed),thisshallbeconsideredimproperusewhichisforbidden.
Itisforbiddentooperatethegearunitif:itisnotcorrectlymounted(e.
g.
fasteningofthemotor),itisnotproperlyinstalled(e.
g.
fixingscrews),thegearunitisverydirty(e.
g.
dustdeposits)thereisnosufficientlubrication.
QualifiedPersonnelSomeresidualdangerforpersonsandobjectsmayemanatefromtheseries51BGservobevel-gearunit.
Thereforeonlyskilledandtrainedpersonnelbeingawareofpossiblerisksmaycarryoutmounting,installation,start-up,service,andmaintenancework.
Thepersonnelmusthavethenecessaryqualificationfortheworktobedoneandmustbefamiliarwithmounting,installation,startingupandoperatingtheproduct.
Inadditiontheymustcarefullyread,understandandobservetheoperatinginstructionand,inparticular,thesafetyinstructions.
Thefollowingworksshouldalsobecarriedoutonlybyqualifiedpersonnel:Transport,storage,erection/installation,connection,start-up,service,maintenanceGeneralsafetyinstructionsWedonotclaimthesesafetyinstructionstobecomplete.
IncaseofquestionsorproblemspleasecontactATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KG.
Thegearunitincorporatesthelatesttechnologicaldevelopmentatthetimeofdeliveryandcanbeprincipallyregardedassafetooperate.
Impropermanipulationsmayleadtoinjuriesanddamages.
Makesurethatthegearunitisonlyinstalled,serviced,ordisassembledbyspeciallytrainedskilledpersonnel.
Foreignmatterflungaboutmaycauseseriousinjurie.
Makesurethatnoforeignmatterortoolsarenearthegearunitbeforestartingoperation.
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DOCSeite6Contactwithhotsurfacesmaycauseburns.
Nevertouchgearunitswhentheyhavehighoperatingtemperatures,orusesuitableprotec-tiveequipment(e.
g.
gloves).
Rotatingpartsmaycauseinjuries.
Pulling-inrisk!
Keepsufficientdistancetorotatingmachineparts.
Neverinstalloroperatedefectiveproducts.
Incaseofdamagepleasecomplainimmediately.
ShortdescriptionTheATLANTABGservobevelgearunitwasdevelopedforusewiththree-phaseACandDCservomotors.
Itfeaturesalow-clearancegearing.
Thelight-metalcasingensuresoptimalheatdissipation.
Robustbearingsandanexcellentstiffnesspermitthetransmissionofhightorquesandadditionalforces.
Thegearunitissuppliedtest-run,tightness-checkedandthusreadyforoperation.
Thegearunitisavailablewithdifferentreductionratios.
Withinonegearboxsizeanddesignallcomponents,exceptforthesetofwheels,arethesame.
Thelast2digitsoftheitemnumberstandforthenominalreductionratio.
Theexactreductionratiocanbeseenfromtheta-blebelow.
Itemno.
ActualgearreductionApplicableto51xxx0519/4=4,75allsizes51xxx0727/4=6,75allsizes51xxx0939/4=9,75allsizesThisgearunitisavailablewith2outputvariations:hollowoutputshaftforkeyconnectionshollowoutputshaftforclampedconnectionsBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite7ItemnumberTheitemnumberiscomposedasfollows:ExampleBGservobevel-gearunitBG=80mm,i=4.
75versionwithkeyorshrink-discIdentificationThegearunitisidentifiedbyanameplatecontainingthegearboxtype,thegearratio,themax.
performanceforS3operation,themax.
speedforS3operation,theassemblydate,andtheserialnumberofthegearunit.
TypeGearratioMax.
performanceforS3operation[kW]Max.
speedforS3operation[min-1]Mass[kg]Serialnumber51050055715005BG-ServoKegelrad-getriebeBG-ServoBevelgearunitBG-ServoKegelrad-getriebeBG-ServoBevelgearunitPafeder-AusführungKeywaydesignSchrumpfscheiben-AusführungShrink-discdesignBaugreBG=80Construction-sizeBaugreBG=80Construction-sizeGehuse-IdentnummerOrdercodeofhousingGehuse-IdentnummerOrdercodeofhousingbersetzungi=4,75Ratiobersetzungi=4,75RatioBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite8Aseparateoilratingplatespecifiesthetypeofoil:Whenusedinareaswithexplosionhazardthegearunitmustbeadequatelyidentifiedbyameansofanameplate.
Onlythenitmaybeusedinsuchareas:BWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite9TighteningtorquesAllscrewconnectionsforwhichtighteningtorquesarespecifiedareprincipallytobetightenedandcheckedwithacalibratedtorquewrench.
Thetighteningtorquescanbetakenfromtablesinrelevantbooks.
Shouldscrewsbeemployedacc,toDIN912,youcanusethefollowingtable:Forthecountersunkholes:Whenapplyingtorquesacc.
toyourowncompanystandard,whichallowstheutilizationof90%oftheyieldpointofthescrew,asuitablewasher/bushingshouldbeused.
Hexag.
socket-headscrewsDIN912Strengthclass8.
8/aluminiumhousingM5M6M8M10M12M16TighteningtorqueinNm*)3,58,918.
84045117Tighteningtorqueinlbfin*)31781663543981035.
5Forthethreadedholes::(Effectivelengthofthreadmin.
1.
5xdnenn/bearingsurfacesteelwithmin.
pG>300N/mm2)Hexag.
socket-headscrewsDIN912Strengthclass8.
8M5M6M8M10M12M16TighteningtorqueinNm*)5,59,5234680195Tighteningtorqueinlbfin*)48842034077081725*)Useonlycalibratedtorquewrenches!
Ifthetighteningtorqueistoolow,therequiredtorquewillnotbetransmitted.
Ifthetighteningtorqueistoohigh,thescrewswillbeoverstrainedandbecomeunusable.
Checklist-start-upBeforestartingupWhathastobecheckedCheckedDelivery:ArethesuppliesinconformitywiththeconsignmentnoteAnytransportdamageshouldbereportedimmediatelytothecarrier.
Obviousdefects/incompletenessshouldbereportedimmediatelytoATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KG.
Applicationinareaswithexplosionhazard:Arethefollowingdataonthenameplateofthegearboxes/motorsinconformitywiththepermissibleEx"applicationareaonthesite–Explosiongroup–Category–Zone–Temperatureclass–Max.
surfacetemperatureAmbienttemperature:Istheambienttemperaturerangeacc.
tothedataonthelubricanttableobservedThemax.
ambienttemperatureof40°Cmustnotbeexceededthrough-outthewholeoperatingtime.
thetemperaturemustnotfallbelowthemin.
ambienttemperatureof-10°Cthroughoutthewholeoperatingtime.
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DOCSeite10Ventilation:IssufficientventilationofthegearboxensuredInputandoutputdriveelements:Areallinputandoutputdriveelementstobemountedsuitableforthespecificex"protectionuseNameplateinformation:ArethedataonthegearboxnameplatenotexceededDuringstart-upWhathastobecheckedCheckedEnvironment:Itmustbeensuredthattherearenoatmospheres,oils,acids,gases,vapours,orcombustibledustsaroundwhichmayexplode!
Temperaturemeasurement:Thetemperaturemustbemeasuredafter3hoursofoperationundermax.
operatingloadconditions!
Thetemperaturemeasurementsshallbetakenintheinputareainplaceswhichareprotectedfromthecoolingaircurrent.
Itisadvis-abletomeasureinvariousplacesinordertodeterminethemaxi-mum.
Theabsolutetemperatureof80°Conthesurfaceofthegearboxmustnotbeexceededsothatthethermalstressonshaftsealsandlubricantsiskeptlow;thishasapositiveinfluenceupontheservicelife.
Start-up/operationMakesurethatthefollowingpreconditionsfortheoperationarefulfilled:Thecontrolandprotectivesystemsmustnotbeshutoff.
Thisappliesalsofortrialrunsandstart-upoperation.
Thegearunitsmustnotbeoperatedunderthefollowingambientconditions:oExplosiveatmosphere,(exceptionCEII3GT4/II3DT130°C)ooils,oacids,ogases,(exceptionCEII3GT4/II3DT130°C)ovapours,oradiation.
Dependinguponthelubricantsusedtheambienttemperatureshouldbebetween10°Cand+40°C.
Iftheambienttemperatureslieoutsidethepermissiblerange,getintocontactwithATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KG.
Thegearunitsmustnotbeoperatedunlesssufficientventilationisensuredinordertoavoidanyheatcongestion.
Whenusedinareaswithexplosionhazard,theoperatormustensurethatthesurfacetemperatureofthegearboxdoesnotexceed65°C.
;ifnecessary,controlthesurfacetemperatureofthehousing.
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DOCSeite11Thesurfaceofthegearboxcanreachtemperaturesofmorethan65°C.
duringoperationandcancauseburns.
Theper-soninstallingthegearunitmusttakecarethatpersonscannotbeinjuredduetohotsurfaces.
Rotatingpartscancatchpiecesofclothing,hair,andmem-bersofthebodyandcaninjurepersons.
Thepersoninstallingthegearunitmusttakecarethatpersonscannotbeinjuredbyrotatingparts.
MaintenanceAccidentalstartingofthegearunitwhilemaintenanceworkisbeingcarriedoutcanleadtoseriousaccidents.
Makesurethatnobodycanstartthegearunit,whilemaintenanceworkisbeingperformed.
Evenshortoperationofthegearunitwhilemaintenanceworkisbeingcarriedoutcancauseaccidents,ifthesafetydevicesareshutoffandinoperative.
Makesurethatallsafetydevicesaremountedandoperative.
Shaftsealingrings:Shaftsealingringssealthegapbetweenthehousingandtherotatingshafts.
Theyarewearingpartswhichhavetobereplacedwhentheyreachthepermissiblelimitofwear.
Theservicelifeofshaftsealingringsisinfluencedbyamultitudeofparameters.
Theseareamongothers.
:peripheralspeedatthesealingliptemperatureinternalpressureinthegearboxviscosityoflubricantchemicalanalysisandadditivationoflubricantsmountingsituation(lubricantsupplytothesealinglip)particlesand/ormetallicfinesinthelubricantmaterialoftheshaftsealingringexternalpollutionThismultitudeofinfluencingparametersmakeitpracticallyimpossibletopredictthepreciseser-vicelifewithoutmakingexperimentssimulatingtherespectiveapplication.
Astheservicelifeoftheshaftsealingringsissubjecttotheabovementionedfluctuations,it.
.
isabsolutelynecessarytocheckthematregularintervals.
Onlyregularcheckscanpreventunnoticedlossoflubricantinthegearbox.
Whenevertheshaftsealingisreplacedyoushouldalsochecktherunningsurfaceofthelipsofthesealontheshaft.
Ifseizuremarksarevisible,theshaftmustberepairedorreplaced.
Alterna-tivelyitispossibletoinserttheshaftsealingringinaslightlyaxiallydisplacedpositionsothatthelipofthesealrunsinapracticallynewplaceBWK115OperationandMaintenanceIn-structions4100-001-12.
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DOCSeite12MaintenanceintervalsProvidedthatthegearunitsareusedproperlyasdescribedinthecatalogue,theseries51BGservobevel-gearunitsaredesignedandbuiltfor12,000hofoperationexceptforwearingpartssuchasthebearingsandtheshaftsealingrings.
Thefollowingmaintenanceworksshouldbeperformedfortheseries51BGservobevel-gearunits.
IntervalWhatshouldbedoneEvery2000machinehours,butatleasteverysixmonthsChecktherunningnoisetodetectpossibledefectsinthebearingsInspectthemotorflangesforleakageInspectthesealsforleakage.
Shouldanyleakagebede-tected,pleasecontactus.
After5000…8000hours,butafter3yearsatthelatestReplacetheshaftsealingringsChangingthegearoilAsufficientamountoflubricantisabsolutelynecessaryforsafeoperation.
Thelubricantensuresthatdryrunningandconsequentlyexcessivelyhighsurfacetemperatures,wear(play),orme-chanicsparkingispreventedinthemetalliccontacts.
Themaindangerisanunnoticedlossoflubricant.
Thereforethegearunitsmustberegularlycheckedforlossoflubricant.
ATLANTAEservobevel-gearunitsarefilledwithsyntheticpolyglycoloil.
Underthefollowingpreconditionsthisisalifetimelubrication:ThelayoutofthegearunitisstrictlyinaccordancewiththeguidelinesgivenintheATLANTAcatalogue(www.
atlantagmbh.
de).
Thegearunitisexclusivelyoperatedwithinthepermissiblecharacteristicandlimitvalues(www.
atlantagmbh.
de).
Theoperatorchecksthegearunitregularly(every2weeks)forlossofoil.
Thesurfacetemperaturemustnotexceedmax.
80°Cduringoperation.
Inthecaseofoperationwithmostlylowinputspeeds(peripheralspeedofthebevelgearv40°CThemostsuitablepointforcontrollingthemax.
permissiblesurfacetemperatureofthehous-ingisintheareaoftheinput-sidebevel-gearshaftbearings.
Theverticalarrangementoftheshaft(inputoroutputverticallydownward)isonlypermissiblewithanoillevelmonitorstoppingthegearunitincaseofasuddenlossofoil.
Mountingtheoutputdriveshaft(Versionwithshrink-disc)Fortheoutputdriveshaftwerecommendtoleranceh6(DINISO286).
Thematerialmusthaveaminimumyieldpointof385N/mm2.
IfyouhaveboughttheoutputdriveshaftfromATLANTAandifitisnotsuppliedalreadymounted,werecommendtoproceedasfollows:Cleantheseatofthehollowshaftandoilitslightly(donotusegrease).
Wipeoffanyexcessoilwitharag.
Slidetheshrink-discontothehollowshaft.
Donottightenthescrewsbeforehand!
Cleantheshankoftheoutputdriveshaftandoilitslightly.
Wipeoffanyexcessoilwitharag.
abutmentscrewingsurfaceBevel-gearunitlateralforcesBWK115OperationandMaintenanceIn-structions4100-001-12.
93AbteilungTBSeite1725nd.
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DOCSeite17Pushtheoutputdriveshaftintotheborerightuptothestop.
Attachtheshrink-discbyevenlytighteningthescrewsoneaftertheother(notcrosswise).
Makesurethatthetwoclampingdiscsareplaneparallel.
Severalpassesarenecessaryuntilthescrewsaretightenedtothespecifiedtorqueacc.
tothetablebelow.
OrdercodeTighteningtorque*)808403612Nm808505012Nm808606212Nm*)Useonlycalibratedtorquewrenches!
Ifthetighteningtorqueistoolow,therequiredtorquewillnotbetransmitted.
Ifthetighten-ingtorqueistoohigh,thescrewswillbeoverstrainedandbecomeunusable.
Soilingmayimpedethetransmissionofthetorque.
Donotdisassembletheshrink-discclampingsetbeforemountingitIfthegearunitiscleanedinthesealingareawithacleansingagentapprovedbyATLANTAAntriebssystemeE.
SeidenspinnerGmbH&Co.
KGthesurfacescleanedmustbeprotectedagainagainstcorro-sion.
Theforcesoftheshrink-disccandeformthehollowshaft.
Alwaysinstallthemachineshaftbeforetighteningtheclampingscrewsoftheshrink-disc.
Slantingtheshaftsmaycausedamage.
MakesurethatthehollowshaftandthemachineshaftarealigneWhenusedinareaswithexplosionhazardimproperinstallationmayleadtoinadmissiblyhightemperatures.
Checkthetighteningtorquesandaxialfixingafter10hoursunderoper-atingconditions.
BWK115OperationandMaintenanceIn-structions4100-001-12.
93AbteilungTBSeite1825nd.
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DOCSeite18Mountingtheoutput-drivepinionshaftBG50(Versionwithkey)Unlesstheoutputpinionshaftcomesalreadyfullyassembled,werecommendtoproceedasfol-lows:CleantheseatofthehollowshaftandrubwithMoS2-powderorgrease(reducesfrettingcorrosion).
Insertthelockingwasherintotherecessofthehollowshaft.
.
Insertthelockingwasherfromtheoppositesideuptothestopinsidethehollowshaft.
.
Connectthemountingplateandtheoutputshaftbymeansofthescrew.
Securethescrewusingsuitableadhesive(e.
g.
Loctite243).
*)Drylubricant:Improvestheslidingpropertiesofmachinepartsandreducesfrictionandwearwithinawidetemeperaturerange;minimumfrictionwithmaximumloadcapacit.
GearboxwithoutoutputshaftInsertpinionshaftMountretainingdisk/lockscrewandtightenTheretainingring,washerandscrewsuppliedwiththedriveshaftservefortheaxialfixationoftheinputdrivingshaft.
ForgearboxessizeBG50anadditionalwasher25109001isrequiredwhichreplacesthetwoitemsretainingring+lockingwashersuppliedtogetherwiththedrivingshaft.
BWK115OperationandMaintenanceIn-structions4100-001-12.
93AbteilungTBSeite1925nd.
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DOCSeite19Mountingtheoutput-drivepinionshaftBG63andBG80(Versionwithkey)Unlesstheoutputpinionshaftcomesalreadyfullyassembled,werecommendtoproceedasfol-lows:CleantheseatofthehollowshaftandrubwithMoS2-powderorgrease(reducesfrettingcorrosion).
Inserttheretainingringintotherecessofthehollowshaft.
Pushintheoutputshaftrightuptothestop.
Insertthelockingwasherfromtheoppositesideuptothestopinsidethehollowshaft.
Connectthemountingplateandtheoutputshaftbymeansofthescrew.
Securethescrewusingsuitableadhesive(e.
g.
Loctite243)*)Drylubricant:Improvestheslidingpropertiesofmachinepartsandreducesfrictionandwearwithinawidetemeperaturerange;minimumfrictionwithmaximumloadcapacit.
GearboxwithoutoutputshaftInsertSpringInsertpinionshaftMountretainingdisk/lockscrewandtightenHexagonsockethead-screwsDIN912strengthrating8.
8/lockingwasherM5M8M12M16TighteningtorqueinNm5.
52380195Tighteningtorqueinlbfin48.
5203.
57081726*)Useonlycalibratedtorquewrenches!
Ifthetighteningtorqueistoolow,therequiredtorquewillnotbetransmitted.
Ifthetighteningtorqueistoohigh,thescrewswillbeoverstrainedandbecomeunusableSlantingtheshaftsmaycausedamage.
Makesurethatthehollowshaftandthemachineshaftarealigned.
Mountthemachineshaftinthehollowshaftwithoutusingforce.
Nevertrytomountitbymeansofknockingitin.
Useonlysuitabletoolsanddevices.
Whenusedinareaswithexplosionhazard,improperinstallationmayleadtoinadmissiblyhightemperatures(seeignitiondangerratingacc.
toKGA114).
Checkthetighteningtorquesandtheaxialfixingafter10hworkunderoperatingconditions.
BWK115OperationandMaintenanceIn-structions4100-001-12.
93AbteilungTBSeite2025nd.
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DOCSeite20655XXXX654XXXXMountingtheclutchonthemotorshaftATLANTAEservospecialclutch655XXXXorATLANTAspecialclutch654XXXXTheclutchissuppliedpre-assembled.
VBeforemountingtheclutchonthemotorshaftcleanallcontactsur-facesandcoatthemwithathinoilfilm(nogrease).
AnyexcessoilshouldbewipedoffwitharagRubtheDIN5480profileoftheclutchwithMoS2powderorgrease(reducesfrettingcorrosion)Ifthemotorshafthasakey,itshouldberemoved.
Slidetheclutchontothemotorshaftasfarasspecifiedinthecata-logueasX1"(655XXXX)and/orrightuptothestop(654XXXX/shoulderorretainingring).
Inthecaseofclutch655XXXXintermediatesleevesmaybeusedinordertoreachthemotor-shaftdiameter.
Insuchacasetheslotintheintermediatesleevemustbealignedwiththeslotintheclutchbody.
Slightlytightentheclampingscrews.
Tightenscrewsuniformlybyturningthemalternately(crosswisewith654XXXX).
.
Checkclutchfortruerunningatthereferencediameter(fr<0.
04mm).
Severalpassesarenecessaryuntilthescrewsaretightenedtothetighteningtorquespeci-fiedinthetablebelow.
Makesurethatthewidthofthegapbetweenclutchandpressuresurfaceremainsuniform.
Checkatreferencediameterfortruerunning.
OrdercodeofclutchTighteningtorque*)OrdercodeofclutchTighteningtorque*)6551xxx7Nm62lbfin6543xxx7Nm62lbfin6553xxx7Nm62lbfin6544xxx10Nm88,5lbfin6554xxx10Nm88,5lbfin6546xxx10Nm88,5lbfin6555xxx25Nm221lbfin6547xxx25Nm221lbfin*)Useonlycalibratedtorquewrenches!
Ifthetighteningtorqueistoolow,therequiredtorquewillnotbetransmitted.
Ifthetighten-ingtorqueistoohigh,thescrewswillbeoverstrainedandbecomeunusable.
Whenusedinareaswithexplosionhazard,improperinstallationmayleadtoinadmissiblyhightemperatures(seeignitiondangerratingacc.
toKGA114).
Checkthetighteningtorquesandtheaxialfixingafter10hrsworkunderoperatingconditions.
Whenusedinareaswithexplosionhazard,usecorrosion-protectedscrews.
BWK115OperationandMaintenanceIn-structions4100-001-12.
93AbteilungTBSeite2125nd.
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DOCSeite21MountingthemotorCleanflangesurfaceandcenteringshoulderonmotorandgearbox.
Slidethemotorwithcouplingmountedontotheteethoftheinputdriveshaftandintothegearcenteringpiecesothattheplanesurfacestouch.
Ifnecessary,rotatethemotoraroundthemotoraxleuntiltheclutchandtheinputshaftteethmesh.
.
Themotormustslideoneasily.
Theremustnotbeanygapbetweenthemotorandthegearboxflange.
Mountingmotorshavinglongershaftsthanpermissiblefortherespectivegearunitleadstotensionswhichdamagethemotorandthegearunit.
Checktheinterferingedgesbymeasuringoutorbycheckingthedimensionaccordingtoourcataloguedataandthemotormanufacturer'sdata.
Screwmotorandgearboxtogether.
Hexagonnutsorscrewsaretobetightenedtothespeci-fiedtorqueandsecured.
Thecorrecttighteningtorquecanbeseenfromtherespectiveta-bles.
Inthiscontextitisparticularlyimportanttopayspecialattentiontothestrengthclassofthescrewandthematerialofthesupportingsurfaces.
Themotorcanbemountedoptimallycenteredbypositioningthegearboxinsuchawaythatthebevel-gearshaftisstandingupvertically.
Usescrewswithaneffectivelengthofatleast1.
6xthreaddiameter.
Whenusedinareaswithexplosionhazard,usecorrosion-protectedscrewsMounttheclutchonthemotorshaftandfastenasdescribedCleanmotorandclutchsurfacesBWK115OperationandMaintenanceIn-structions4100-001-12.
93AbteilungTBSeite2225nd.
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DOCSeite22Screwmotortogearbox,Usepropertighteningtorqueforscrews*)Drylubricant:Improvestheslidingpropertiesofmachinepartsandreducesfrictionandwearwithinawidetemeperaturerange;minimumfrictionwithmaximumloadcapacity.
CleanscrewingsurfacesofmotorandgearboxandrubwithMoS2*)powderorgreaseBWK115OperationandMaintenanceIn-structions4100-001-12.
93AbteilungTBSeite2325nd.
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DOCSeite23TransportandhandlingTherearenospecialholesorthreadsprovidedfortransportingandhandlingthegearunit.
Thereare,however,numerousfixingthreadsavailableinthegearhousingpermittingtoscrewineye-boltssothatitispossibletohandlethegearboxsafely.
Observeallsafetyregulationsinconnectionwithtransportandhandlingusingliftinggear.
Makesurethattheloadishandledandsetdownslowlyandcarefully.
GearboxsizeWeightwithoutattachmentsBG50≈3,2kgBG63≈6kgBG80≈8kgStorageIfthegearunitisnotinstalledimmediatelyafteritsdelivery,thefollowingmeasuresaretobetaken:Storethegearunitwithhorizontalhollowoutputshaftandhorizontalinputdriveshaft(wormshaft)ontopinsuchawaythat-exceptforthesupportingsurface-itcannotcomeintocontactwithanyotherobjectsProtectthegearunitsfromdetrimentalenvironmentalinfluences(highairhumidity,saltyair,aggressivegases;UVlight,electricwelding;dust;dirt,shocks;temperaturefluctuations;[0°Cto+30°C],etc.
).
Connectingparts,e.
g.
clutchoroutputshaft,aretobestoredseparately.
Protectthesteelpartsagainstcorrosion.
Aslogisticsprincipleforstore-keepingwerecommendthefirstin–firstout"principle.
Occasionallyturningtheinputshaftofthegearunitwillfacilitatethestart-upThemax.
storagetimeundersuchconditionsis2years.
BWK115OperationandMaintenanceIn-structions4100-001-12.
93AbteilungTBSeite2425nd.
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DOCSeite24Failurelist(Troubleshooting)Youshouldtakeremedialmeasuresatonce,ifyougetawareofoilloss,increasedoperatingnoises,orincreasedoperatingtemperatures.
Anydisturbancesoccurringduringthewarrantyperiodrequiringtherepairofthegearunit,mayonlyberemediedbyATLANTA.
Werecommendtoaskforourassistancealsoaftertheexpirationofthewarrantyperiod.
Alwaysshutdownthegearboxduringtheeliminationofdisturbances.
Securethedrivingunitagainstinadvertantstarting.
Postanoticeattheswitchingposition.
ProblemPossiblecauseRemedyLayouttoweak;Speed/torquetoohighCheckthetechnicaldataMotorheatsupthegearunitChecktheattachmentcircuit,replacethemotor,orprovideaninsulationbetweenmotorandgearunitAmbienttemperaturetoohighEnsureadequatecoolingIncreasedoper-atingtempera-tureDutycycletoolongVerifythelayoutDefectivebearingDefectivetoothsystemPleasecontactusThefixingofthegearunithasloosened.
Tightenscrews/nutswiththespecifiedtight-eningtorque.
Replacedefectivescrews/nuts.
Increasedopera-tingnoiseAdjustmentofcontroller.
Checktheservo-motorparametersLeakageGetintocontactwithus.
LossofoilApparentleakageAtemporaryleakageduetomuchgreasebetweensealinglipandprotectivelip.
Thesurplusgreasecanpenetrateoutsideasanapparentleakage.
BWK115OperationandMaintenanceIn-structions4100-001-12.
93AbteilungTBSeite2525nd.
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DOCSeite25DisposalPleaseobservethenationalregulations!
Ifrequired,disposeoftheindividualcomponentsseparatelydependingontheirnatureandanyexistingspecificnationalregulations,e.
gas:Steelscrapogearwheelsoshafts(hollowshafts)oantifrictionbearingsocastironpartsoclutchesAluminiumscrapohousingelementsoadaptorelementsBronzescrapobevelgear(separatedfromhollowshaft)CollectwasteoilanddisposeofasdirectedATLANTAdoesnotacceptliabilityforanydamagetothetransmissionoranyconsequentialdamage,iftheseinstructionsarenotobserved.
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