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Explosion-protected industrial gear units – Operating and Assembly Instructions

2 B 2050 en-3023

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Table 1: Version List B 20506
Table of Contents9
Safety Information14
Intended Use14
Safety Information for Explosion Protection14
Field of Use15
Attachments and Equipment15
Lubricants15
Operating Conditions15
Radial and Axial Forces16
Assembly, Installation and Commissioning16
Service and Maintenance16
Protection against Electrostatic Charging16
Applied Ignition Protection Classes According to DIN en ISO 80079-3717
Do Not Make any Modifications17
Performing Inspection and Maintenance Work17
Personnel Qualification17
Safety for Particular Activities17
Check for Transport Damage17
Safety Information for Installation and Maintenance18
Hazards18
Hazards When Lifting18
Hazards Due to Rotating Parts18
Danger on Entry18
Hazards Due to High or Low Temperatures19
Hazards Due to Lubricants and Other Substances19
Hazards Due to Noise19
Hazards Due to Pressurised Coolants19
Description of Gear Units20
Gear Unit Types and Type Designations20
Table 2: Gear Unit Overview MAXXDRIVE ® Standard - Parallel Gear Units20
Table 3: Gear Unit Overview MAXXDRIVE ® Standard - Right-Angle Gear Units20
Table 4: Gear Unit Overview MAXXDRIVE ® XT - Right-Angle Gear Units20
Table 5: Gear Unit Overview MAXXDRIVE ® XD - Parallel Gear Units21
Table 6: Gear Unit Overview MAXXDRIVE ® XJ - Right-Angle Gear Units21
Table 7: Gear Unit Overview MAXXDRIVE ® Special Version21
Figure 1: MAXXDRIVE ® XT 2-Stage Helical Bevel Gear Unit22
Table 8: Versions and Options24
Name Plate25
Figure 2: Name Plate25
Transport, Storage, Assembly27
Transporting the Gear Unit27
Transport of Standard Gear Units28
Figure 3: Transport of Standard Gear Unit28
Transport of Gear Units with Motor Adapter29
Figure 4: Transport of Gear Units with Motor Adapter29
Transport of Gear Units with Auxiliary Drives or First Stage Gear Units (Option: WG, WX)30
Figure 5: Transport of Gear Units with Auxiliary Drives or First Stage Gear Units30
Transport of Gear Units with V-Belt Drives31
Figure 6: Transport of Gear Units with V-Belt Drives31
Transport of Agitator Version Gear Units32
Figure 7: Transport of Agitator Version Gear Units32
Transport of Gear Unit with Motor Swing Base or Base Frame33
Figure 8: Transport of Gear Unit with Motor Swing Base or Base Frame33
Storage and Downtimes34
General Measures34
Storage and Downtimes in Excess of 3 Months34
Storage and Standstill Periods of more than 9 Months34
Checking the Version35
Preparing for Installation36
Check for Damages36
Remove Corrosion Protection Agents36
Check Rotational Direction36
Check Ambient Conditions36
Installing the Oil Reservoir Tank (Option OT)36
Seal Adapter for Vertical Gear Units (Option : SAFOMI)36
Installing the Gear Unit37
Installation of a Hub on Solid Shaft (Option: V, L)38
Figure 9: Example of a Simple Pulling Device38
Figure 10: Permissible Application of Force to Drive and Driven Shafts39
Assembly of Gear Units with Hollow Shaft (Option A, EA)40
Figure 11: Applying Lubricant to the Shaft and the Hub40
Fitting a Hollow Shaft with Fastening Element (Option B)41
Figure 12: Assembly and Disassembly of the Fixing Element (Schematic Diagram)41
Fitting a Hollow Shaft with Shrink Disc (Option: S)42
Figure 13: Fixing Element (Example)42
Figure 14: Machine Shaft Assembly for Special Hollow Shafts with Shrink Discs43
Figure 15: Fitted Shrink Disc44
Installing a Flange Version Gear Unit (Option: F, FK, VL2/3/4/5, KL2/3/4)45
Agitator Version (Option: VL2, KL2)45
Figure 16: VL2 Option45
Agitator Version with Drywell (Option: VL3, KL3)46
Agitator Version with True Drywell (Option: VL4, KL4)46
Extruder Flange Version (Option: VL5)46
Figure 17: Option VL3/KL3 and VL4/KL446
Agitator Version with True Drywell and Foot Mounting (Option: VL6, KL6)47
True Drywell Version Gear Units (Option: VL4, KL4, VL6, KL6, DRY)47
Figure 18: Option VL6/KL647
Figure 19: Schematic Diagram (Option: DRY)47
Motor Base Frame (Option: MF)48
Motor Swing Base (Option: MS)49
Installing the Cover Cap, Air Baffle (Option: H, H66, FAN, MF50
Fitting a Standard Motor (Option IEC, NEMA, SAFOMI, F1)50
Figure 20: Centre of Gravity of Motor51
Table 9: IEC and NEMA Motor Weights51
Table 10: Transnorm Motor Weights51
Fitting a Motor with Standard Claw Coupling (Option IEC, NEMA)52
Figure 21: Fitting the Coupling to the Motor Shaft52
Fitting a Motor with Standard Claw Coupling (Option SAFOMI)53
Installing the Drive Coupling53
Dog Coupling53
Turbo Coupling53
Dog Coupling54
Installing the Output Coupling54
Figure 22: Fusible Plug with Separate Mechanical Switch54
Connecting a Cooling Coil (Option CC)55
Figure 23: Cooling Cover with Cooling Coil Fitted (Schematic Diagram)56
Installation of an External Cooling System (Option: CS1-X, CS2-X)57
Installing a Fan (Option: FAN-A, FAN-R)58
Figure 24: Industrial Gear Unit with CS1-X and CS2-X Cooling Systems58
Figure 25: Hydraulic Plan of Industrial Gear Units with CS1-X and CS2-X Cooling Systems58
Installation of the Lubricant Circulation (Option: LC, LCX)59
Gear Unit Monitoring Sensors (Option: MO)59
Attaching the Temperature Sticker59
Installing the Torque Arm (Option D, ED, MS)60
Figure 26: Temperature Sticker Position for Helical and Bevel Helical Gear Units60
Figure 27: Permissible Installation Tolerances of the Torque Arm (Option D and ED) (Schematic Diagram)61
Connecting the Oil Heater (Option: OH)62
Subsequent Painting62
Commissioning63
Checking the Oil Level63
Activating the Vent63
Table 11: Oil Spaces as Delivered63
Process Heat Due to Hollow Output Shaft64
Figure 28: Activation of the Pressure Vent64
Lubricant Circulation (Option: LC, LCX)65
Gear Unit Cooling with Fan (Option: FAN-A, FAN-R)66
Cooling Coil (Option: CC)67
External Cooling System (Option CS1-X, CS2-X)68
Oil / Water Cooler (Option: CS1-X)68
Oil Heater (Option: OH)69
Temperature Monitoring (Option: PT100)69
Backstop/Auxiliary Drive (Option: R, WX)70
Figure 29: Industrial Gear Unit with Back Stop (Schematic Diagram)70
Table 12: Back Stop Lift-Off Speeds SK 5..07 - SK 10..0771
Table 13: Back Stop Lift-Off Speeds SK 11..07 - SK 15..0772
Temperature Measurement73
Figure 30: ATEX Labelling73
Table 14: Back Stop Lift-Off Speeds SK 5..17 - SK 11..1773
Test Run74
Figure 31: Temperature Sticker74
Checklist75
Mandatory75
Table 15: Mandatory Checklist for Commissioning75
Optional76
Table 16: Optional Checklist for Commissioning76
Service and Maintenance77
Inspection and Maintenance Intervals77
Table 17: Inspection and Maintenance Intervals78
Service and Maintenance Work80
Visual Inspection for Leaks80
Check for Running Noises80
Check Fan and Spaces between the Ribs (Maxxdrie XT) (Option: FAN-A, FAN-R)81
Cleaning the Heat Exchanger (Option: CS2-X)81
Device Category 2D: Cleaning the Cover Cap (Option: H) and the Motor Adapter (Options: IEC, NEMA)81
Oil Level81
Oil Level Screw82
Figure 32: Checking the Oil Level with a Dipstick82
Oil Inspection Glass/Oil Level Glass (Option: OSG), Oil Level Indicator (Option: OST)83
Oil Dipstick (Option: PS)83
Oil Level Tanks (Option: OT)83
Figure 33: Checking the Oil Level with an Oil Dip-Stick83
Checking the Leak Indicator (Option: VL3, KL3 with Drywell)84
Auxiliary Drive (Option WX), First-Stage Gear Unit (Option WG), Fluid Coupling84
Seal Adapter for Vertical Gear Units (Option SAFOMI)85
Visual Inspection of the Rubber Elements of the Elastic Torque Arm (Option: ED)85
Figure 34: Illustration Air Space85
Visual Inspection of Cables86
Piping (Option: LC, LCX, OT)86
Hose Lines (Option: LC, LCX, CS1-X, CS2-X, OT)86
Oil Filter (Option: CS1-X, CS2-X, LC/LCX)86
Remove Dust86
Oil Change86
Checking the Cooling Coil for Deposits (Option: CC)87
Cleaning or Replacing the Vent88
Vent Filter (Option: FV)88
Cellulose Filter (Option: EF)88
Drying Agent Filter / Wet Air Filter (Option: DB)88
Figure 35: Vent Filter (Option FV)88
Figure 36: Cellulose Filter (Option EF)88
Figure 37: Drying Agent Filter, Example Version89
Figure 38: Installing the Drying Agent Filter89
Pressure Venting (Option: DR)90
Replacing the Shaft Sealing Ring90
Figure 39: MSS7 Seal90
Re-Lubrication of Bearings in the Gear Unit91
Re-Lubricating the Bearing in the Output Flange (Option: VL2/3/4/6, KL2/3/4/6)91
Check the Gear Unit Monitoring (Only for 2G / 2D)92
Resistance Thermometer92
Pressure Switch92
Table 18: Grease Quantities for Re-Greasing the Lower Output Shaft Bearing92
Inspection Cover93
Figure 40: Examples of Inspection Covers93
General Overhaul94
Disposal96
Table 19: Materials96
Appendix97
Versions and Mounting Position97
Parallel Gear Units97
Helical Bevel Gear Unit97
Figure 41: Helical Gear Unit Installation Positions with Standard Mounting Surface97
Figure 42: Bevel Gear Unit Installation Positions with Standard Mounting Surface97
Standard Positions of the Oil Drain, Vent and Oil Level98
Table 20: Position of Housing Options on Oil Screw Holes (Standard Installation Positions)99
Figure 43: Numbering of Oil Screw Holes on SK 5207 - SK 10507105
Figure 44: Numbering of Oil Screw Holes on SK 11207 - SK 15507111
Figure 45: Numbering of Oil Screw Holes on SK 5217 - SK 11217115
Lubricants116
Roller Bearing Greases116
Table 21: Roller Bearing Greases116
Gear Oils117
Table 22: Gear Oils117
Minimum Starting Temperatures118
Table 23: Minimum Starting Temperatures for Mineral Oils (Guideline Values for the Ambient Temperature)118
Table 24: Minimum Starting Temperatures for Synthetic Oils (Guideline Values for the Ambient Temperature)118
Lubricant Quantities119
Screw Tightening Torques119
Table 25: Screw Tightening Torques119
Tolerances for Bolting Surfaces120
Troubleshooting120
Table 26: Overview of Malfunctions121
Leakage and Leak-Tightness122
Noise Emissions122
Table 27: Definition of Leakage According to DIN 3761122
Declaration of Conformity123
Explosion Protected Gear Units and Geared Motors, Category 2G and 2D123
Figure 46: Declaration of Conformity for Category 2G / 2D, Labelling According to DIN en ISO 80079-36123
Explosion Protected Gear Units and Geared Motors, Category 3G and 3D124
Figure 47: Declaration of Conformity for Category 3G / 3D, Labelling According to DIN en ISO 80079-36124
Repair Information125
Repairs125
Internet Information125
Warranty125
Abbreviations125

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