Lenze L−force GST Operating Instructions Manual
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Lenze L−force GST Operating Instructions Manual

Geared motors
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BA 12.0023−EN
.A0=
L−force Geared Motors
LL
G
GST, GFL, GKS/GKL, GKR, GSS
Gearbox
Operating Instructions
l

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Summary of Contents for Lenze L−force GST

  • Page 1 BA 12.0023−EN L−force Geared Motors .A0= Operating Instructions GST, GFL, GKS/GKL, GKR, GSS Gearbox...
  • Page 2 Product key − Legend for product key Gearbox type Helical gearbox Shaft−mounted helical gearbox GKS/GKL Helical−bevel gearbox Bevel gearbox Helical−worm gearbox Gearbox size Number of stages Input design Servo motor, asynchronous, totally enclosed fan−cooled Disco variable speed drive Three−phase AC motor with Motec SDS three−phase AC motor Servo motor, asynchronous, internal cooling Compact unit...
  • Page 3 Document history Material number Version Description 00 390 375 11/1995 TD09 1st edition for pilot series 00 393 076 03/1997 TD09 Completely revised 00 393 076 04/2000 TD09 Addendum to Ch. 4.4.1 Preparatory work Updated illustrations for Ch. 4.4.10 Gearbox with breather 00 407 986 12/2000 TD09...
  • Page 4 Nameplate Geared motor Standard version Nameplate GNG−001.iso CSA/UL version Nameplate GNG−002.iso BA 12.0023−EN 6.0...
  • Page 5 Pos. Contents Production site Motor type / standard Gearbox type Motor type Technical data Ratio Rated torque Rated speed (rated frequency) Mounting position / position of the system modules Lubricant Brake data (if fitted) Type AC/DC brake voltage Braking torque, electrical power consumption Feedback /pulse encoder or resolver data (if fitted) Production data Order number...
  • Page 6 M and N version with motor K (compact unit) and D (Disco) − version sion Pos. Production site / country; www.Lenze.com Gearbox type Gearbox and motor type Year of manufacture/ week of manufacture Mounting position / position of the system modules...
  • Page 7 Mounting position (A−F) and position of system modules (1−6) Terminal box, Motec, connector: 2, 3, 4, 5 Without terminal box, Motec, connector: 0 Solid shaft: 6 Foot: 3, 4 Terminal box, Motec, connector: 2, 3, 4, 5 Hollow shaft: 0 Without foot: 0 Without terminal box, Motec, connector: 0 Hollow shaft with shrink disc: 1, 6...

  • Page 8: Table Of Contents

    ............Lenze drive systems .
  • Page 9 Contents Electrical installation ............Motor connection .

  • Page 10: Preface And General Information

    After receipt of the supply, check immediately whether it corresponds with the ƒ accompanying papers. Lenze does not grant any warranty for subsequent claims. Claim for – visible transport damages immediately to the forwarder.

  • Page 11: Lenze Drive Systems

    – improper working on and with the drive system, – operating faults, – disregarding the Operating Instructions. Warranty Conditions of warranty: see terms of sale and delivery of Lenze Drives GmbH. ƒ Warranty claims must be made to Lenze immediately after detecting the deficiency ƒ...

  • Page 12: Safety Instructions

    Be sure to take appropriate measures in the case of drive system failure so that no ƒ material damage occurs. Operate the drive system only when it is in a proper state. ƒ Retrofittings, modifications, or redesigns of the drive system are basically ƒ prohibited. Lenze must be contacted in all cases. BA 12.0023−EN 6.0...

  • Page 13: Notes Used

    Safety instructions Notes used Notes used The following pictographs and signal words are used in this documentation to indicate dangers and important information: Safety instructions Structure of safety instructions: Danger! (characterises the type and severity of danger) Note (describes the danger and gives information about how to prevent dangerous situations) Pictograph and signal word Meaning...

  • Page 14: Technical Data

    Technical data Product features Technical data The most important technical data are given on the nameplate (structure and ƒ contents ^ page 4 to 6). The product catalogues contain further technical data. ƒ Product features Design Drive systems have a modular design. They consist of: Reduction gearboxes ƒ...

  • Page 15: Transport Weights

    Technical data Transport weights Transport weights Geared motors Gearbox size Motor frame sizes 063−LL 071−LL 080−LL 090−LL 100−LL 112−LL GLL03 < 10 < 10 GLL04 < 30 < 30 < 40 < 50 GLL05 < 50 < 50 < 60 <...

  • Page 16: General Data And Operating Conditions

    3.3.3 Paint Lenze offers paints with different resistance characteristics for drive systems. Since the resistance may be reduced when the paint coat is damaged, defects in paint work (e.g. through transport or assembly) must be removed professionally to reach the required corrosion resistance.

  • Page 17: Mechanical Installation

    Transport equipment for gearbox As of size 05, Lenze GST, GKS and GSS gearboxes are as standard available with a transport thread for eye bolts according to DIN 580. The thread position can be seen from the below figures.
  • Page 18 Mechanical installation Transport equipment for gearbox Gearbox size Thread max. load carrying capacity of eye bolt to DIN 580 single−strand two−strand (45°) GT−GNG−005.iso/dms 1200 1200 Tab. 2 Load carrying capacity of eye bolt in kg Danger! Completely screw in eye bolts. They must be located evenly and all−over! If possible, the eye bolts should be loaded vertically in the direction of the screw axis! Diagonal or lateral tension reduces the load carrying capacity! Observe data in DIN 580!

  • Page 19: Storage

    The backstops are fitted with centrifugally operated sprags, i.e. at a certain rotation speed, the sprags lift off and the backstop then operates without any wear and maintenance free. The lifting speed of the Lenze backstop is reached at a motor speed n > 900 r/min.
  • Page 20 Before switching on the motor, it is absolutely necessary to make sure that the motor starts in the intended direction of rotation. The Lenze motors are designed such that the motor rotates CCW when viewed on the fan cover when a CW three−phase field L1 W U1, L2 WV1, L3 W W1 is applied.

  • Page 21: Mounting

    Condensation drain hole Note! Lenze delivers motors with condensation drain holes with sealed condensation drain holes. The holes are sealed with a plastic plug or a plug screw. This does not impair the enclosure and the motor is protected against ingress of foreign particles during transport and operation.

  • Page 22: General Information About The Assembly Of Drive Systems

    Mechanical installation Mounting General information about the assembly of drive systems 4.4.2 General information about the assembly of drive systems Stop! The lubricant fill quantity of the gearboxes is matched to the mounting position. The mounting position indicated on the nameplate must be observed to avoid damage to the gearbox.

  • Page 23: Attachment Of Motors To Gearboxes With Bearing Housing (Input Design N)

    Mechanical installation Mounting Attachment of motors to gearboxes with bearing housing 4.4.4 Attachment of motors to gearboxes with bearing housing (input design N) K12.0621 Fig. 3 Input side design N Spider / gear rim Locking screw Coupling hub Keyway Drive size Motor shaft Assembly Standard hub...

  • Page 24: Coupling Hubs

    Mechanical installation Mounting Coupling hubs 4.4.5 Coupling hubs General Note! Standard hubs, clamping hubs and clamping ring hubs are maintenance−free.We recommend checking the star−shaped spider and system components when inspecting the drive. 4.4.5.1 Assembly of standard hub / clamping hub 1.
  • Page 25 Mechanical installation Mounting Coupling hubs 4.4.5.2 Assembly of clamping ring hub Fig. 4 Coupling Clamping ring hub Clamping ring Clamping screws (DIN912) Note! The motor shaft must be designed with fit k6. 1. Grease the contact surfaces of the motor shaft using a thin−bodied oil, e. g. Castrol 4 in 1"...
  • Page 26 Mechanical installation Mounting Coupling hubs 4.4.5.3 Disassembly of clamping ring hub 1. Loosen the clamping screws evenly one after the other. Stop! Each screw must only be loosened by half a revolution per pass! Unscrew all clamping screws by 3 − 4 threads. 2.

  • Page 27: Attachment Of Gearboxes With Hollow Shafts And Keyway

    Mechanical installation Mounting Attachment of gearboxes with hollow shafts and keyway 4.4.6 Attachment of gearboxes with hollow shafts and keyway Mounting 1. Draw the gearbox with hollow shaft onto the machine shaft to be driven: – Apply the supplied assembly paste (Fig. 5) on the shaft and in the hollow shaft bore.
  • Page 28 Mechanical installation Mounting Attachment of gearboxes with hollow shafts and keyway 2. Secure the gearbox axially: – The hollow shaft has snap ring grooves for axial securing. Parts used to fix the shaft are not included in the scope of supply. K12.0611 Auxiliary tool (recommended dimensions) Æ...

  • Page 29: Mounting The Shrink Disc With A Rotating Cover

    Mechanical installation Mounting Mounting the shrink disc with a rotating cover Dismounting 1. Undo axial gearbox locking in the hollow shaft. 2. Remove/extract the gearbox from the motor shaft using an appropriate auxiliary tool (Fig. 6). K12.0611 Fig. 6 Dismantling of gearboxes with hollow shaft using the auxiliary tool, not for GKR Auxiliary tool (recommended dimensions) Æ...
  • Page 30 Mechanical installation Mounting Mounting the shrink disc 4.4.7.1 Mounting the shrink disc Depending on the design, the shrink discs may be equipped with a rotating cover (protective cap, pos. 1). Note! This cover is fitted to the shrink disc on delivery. KL_GFL06_001−dms Fig.
  • Page 31 Mechanical installation Mounting Mounting the shrink disc GT−GNG−003.iso/dms Fig. 8 Explanation: "one after the other" Tip! Several (in general more than 5 ) passes are necessary until the full tightening torque is reached at all screws! The shrink disc is mounted correctly and fixed when the faces of the outer ring and the inner ring are aligned (Fig.
  • Page 32 Mechanical installation Mounting Mounting the shrink disc Dismounting Danger! Loose drive components or drive components falling down may cause injury to persons or damage to the machine. Secure the drive components before disassembly. 1. Remove protective cap (1). 2. Loosen clamping screws (2) evenly one after the other each by ¼ revolution in several passes.

  • Page 33: Mounting The Fixed Cover

    Mechanical installation Mounting Mounting the fixed cover 4.4.8 Mounting the fixed cover for size 09, 11 and 14 Note! This cover is supplied loose on delivery! 3x120° Fig. 10 Protection cover Cheese head screw Thread reducing sleeve 1. Screw the three reducing bushes (3) into the flange with a screwdriver so they are flush and staggered by 120°.

  • Page 34: Mounting The Hoseproof Hollow Shaft Cover

    Mechanical installation Mounting Mounting the hoseproof hollow shaft cover 4.4.9 Mounting the hoseproof hollow shaft cover for size 09, 11 and 14 3x120° Fig. 11 Protection cover Cheese head screw Thread reducing sleeve Seal 1. Screw the three reducing bushes (3) into the flange with a screwdriver so they are flush and staggered by 120°.

  • Page 35: Gearboxes With Breathers

    Mechanical installation Mounting Gearboxes with breathers 4.4.10 Gearboxes with breathers Stop! Do not place gearbox onto breather valve! When using gearbox sizes 03, 04 and 05 (except for GSS 05) it is not necessary to provide special breathing measures. Breather elements are mounted for gearbox sizes 06 to 14 and GSS 05. In special cases, they may be done without.

  • Page 36: Breather Position, Oil Filling Screw And Drain Plug

    Mechanical installation Mounting Breather position, oil filling screw and drain plug 4.4.11 Breather position, oil filling screw and drain plug Helical gearbox GST 05...09−1 GT−GNG−GST−1−001_A−F.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos.
  • Page 37 Mechanical installation Mounting Breather position, oil filling screw and drain plug Helical gearbox GST 05 ... 14−2, foot mounting GT−GNG−GST−2−001_A−F.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN...
  • Page 38 Mechanical installation Mounting Breather position, oil filling screw and drain plug Helical gearbox GST 05 ... 14−2, flange housing GT−GNG−GST−009.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN 6.0...
  • Page 39 Mechanical installation Mounting Breather position, oil filling screw and drain plug Helical gearbox GST 06...14−3 GT−GNG−GST−3−001_A−F.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN...
  • Page 40 Mechanical installation Mounting Breather position, oil filling screw and drain plug Shaft−mounted helical gearbox GFL 05 ... 14−2 GT−GNG−GFL−2−001.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN 6.0...
  • Page 41 Mechanical installation Mounting Breather position, oil filling screw and drain plug Shaft−mounted helical gearbox GFL 06 ... 14−3 GT−GNG−GFL−3−001.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN...
  • Page 42 Mechanical installation Mounting Breather position, oil filling screw and drain plug Helical bevel gearbox GKS 06 ... 14−3 GT−GNG−GKS−3−001_A−F.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN 6.0...
  • Page 43 Mechanical installation Mounting Breather position, oil filling screw and drain plug Helical bevel gearbox GKS 06 ... 14−4 GT−GNG−GKS−4−001_A−F.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN...
  • Page 44 Mechanical installation Mounting Breather position, oil filling screw and drain plug Helical−worm gearbox GSS 05...07−2 GT−GNG−GSS−2−001_A−F.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN 6.0...
  • Page 45 Mechanical installation Mounting Breather position, oil filling screw and drain plug Helical−worm gearbox GSS 06...07−3 GT−GNG−GSS−3−001_A−F.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN...
  • Page 46 Mechanical installation Mounting Breather position, oil filling screw and drain plug Bevel gearbox GKR 05...06−2 GT−GNG−GKR−2−001_A−F.iso/dms A...F Mounting positions Breathing / oil filler plug BA 12.0023−EN 6.0...
  • Page 47 Mechanical installation Mounting Breather position, oil filling screw and drain plug Helical−bevel gearbox GKL 07...09−3 GT−GNG−GKL−001.iso/dms A...F Mounting positions Breathing / oil filler plug on both sides Oil drain plug opposite Oil−control plug Pos. 1 or 2 depending on version Sealing plug without function BA 12.0023−EN...

  • Page 48: Gearbox With Compensation Container For Mounting Position C

    Mechanical installation Mounting Gearbox with compensation container for mounting position C 4.4.12 Gearbox with compensation container for mounting position C K12.0956 Fig. 12 Position of the compensation container in mounting position C Intermediate cover Plug screw 4.4.12.1 Component parts list K12.0956 Fig.
  • Page 49 Mechanical installation Mounting Gearbox with compensation container for mounting position C Mounting 1. Mount gearbox in mounting position C (motor on top). 2. Remove the plug (9) from the intermediate cover (1). 3. Mount housing (4) using seal (3) and fixing screw (2) to intermediate cover (1) (instead of the plug (9)).

  • Page 50: Electrical Installation

    Electrical installation Motor connection Electrical installation Danger! Electrical connections must only be carried out by skilled personnel! Motor connection To correctly connect the motor, please observe: the notes in the terminal box of the motor ƒ the notes in the Operating Instructions of the motor ƒ...

  • Page 51: Commissioning And Operation

    – the condition of the electrical cables. If any interference should occur, you have to stop the drive and go through the steps ƒ for troubleshooting and fault elimination (chapter 8). If the interference cannot be eliminated, please contact the Lenze Service. BA 12.0023−EN...

  • Page 52: Maintenance

    Lenze gearboxes and geared motors are filled with a drive and design−specific lubricant filling upon delivery. This original filling corresponds to the lubricant listed in the column of the respective gearbox type from Lenze. The important factors for the lubricant filling on ordering are the mounting position and the design.
  • Page 53 Approval acc. to USDA−H1 synthetic basis Tab. 8 Overview of lubricant change Note! In case of ambient temperatures <−20°C or >+40°C, please contact Lenze! Observe increased starting torques at low temperatures! GT−GNG−002.iso/dms Fig. 14 Oil sump temperature [°C] Synthetic oil CLP HC/CLP PG...

  • Page 54: Maintenance Operations

    Maintenance Maintenance operations Opening the condensation drain hole Maintenance operations 7.2.1 Opening the condensation drain hole Note! Depending on the mounting position, the condensation drain holes are ƒ always at the bottom of the motor! For condensate drainage ƒ – the motor must be deenergised; –...

  • Page 55: Roller Bearing Grease

    Maintenance Maintenance operations Roller bearing grease 7.2.2 Roller bearing grease The closed roller bearings on motors and gearboxes from Lenze are greased at the factory. The following greases can be used for regreasing: Ambient temperature Manufacturer Type Gearbox roller bearing GST, GFL, GKS, GKR, GKL −30...+80°C...

  • Page 56: Table Of Lubricants

    Note! Please note that the recommendation of a lubricant/grease or its listing in a Lenze lubricant table does not mean that Lenze is liable for these lubricants or damages resulting from incompatibilities of materials used. The lubricants listed in the lubricant table are permissible for Lenze drives. Specialty lubricants must be used, for example, for long−term storage or special operating...
  • Page 57 Maintenance Maintenance operations Table of lubricants Ambient temperature [°C] DIN 51517−3: CLP Gearbox type Gearbox type GKL, GST, GFL, GKS, ISO 12925−1: CKC/CKD GKR, GKK04 ... 06 −50 GKK07 VG 460 Omala 460 −25 CLP HC VG 320 Omala HD 320 ä...
  • Page 58 Maintenance Maintenance operations Table of lubricants Ambient temperature [°C] DIN 51517−3: CLP Gearbox type Gearbox type GKL, GST, GFL, GKS, ISO 12925−1: CKC/CKD GKR, GKK04 ... 06 −50 GKK07 Turmogearoil VG 460 460 OM −25 CLP HC VG 320 Turmofluid GV 320 −20 CLP PG VG 460...

  • Page 59: Replacing The Lubricant

    11. Screw in breathing / oil filler plug. 12. Dispose of waste oil according to the applicable regulations. 7.2.5 Lubricant quantity Stop! At drive speeds below 200 r/min. the amount of lubricant may need to be increased. Consultation with Lenze is required. BA 12.0023−EN...
  • Page 60 Maintenance Maintenance operations Lubricant quantity Pre−stage GSTLL−3; GKSLL−4; GSSLL−3 Mounting position GT−GNG−GST/GFL−010.iso/dms GST05 0.12 0.15 0.15 Ww1C 0.35 Ww1C 0.35 Nw1B Ww1C GST06 0.15 0.35 Ww1C GST07 0.55 0.65 Mw90 A w80 N w1D GST09 GST11 Mw132 Mw132 Mw132 A w112 Aw112 Aw112 N w1G...
  • Page 61 Maintenance Maintenance operations Lubricant quantity Helical gearbox GSTLL−1L VAL / VBL (foot housing) Mounting position GST04 0.37 0.25 0.25 0.35 Ww1C GST05 0.35 0.35 0.35 Mw90 A w80 Nw1D GST06 0.65 0.85 Ww1E GST07 Mw132 Mw132 Mw132 Aw112 Aw112 Aw112 Nw1G Nw1G Nw1G...
  • Page 62 Maintenance Maintenance operations Lubricant quantity Helical gearbox GSTLL−2L; −3L VAL / VBL (foot mounting) Mounting position GST03 GST04 0.35 0.45 0.55 GST05 0.85 0.75 0.55 0.55 GST06 1.25 1.35 GST07 Mw132 Mw132 Mw132 Mw132 Mw132 Aw112 Aw112 Aw112 Aw112 Aw112 Nw1G Nw1G Nw1G...
  • Page 63 Maintenance Maintenance operations Lubricant quantity Shaft−mounted helical gearbox GFLJJ−2; −3 Mounting position GFL04 0.65 1.05 0.75 0.35 GFL05 GFL06 GFL07 GFL09 11.3 GFL11 GFL14 Right−angle gearbox Mounting position Helical−bevel gearbox GKSJJ−3; −4 GKS04 GKS05 GKS06 GKS07 GKS09 GKS11 11.5 GKS14 Helical−worm gearbox GSSJJ−2;...
  • Page 64 Maintenance Maintenance operations Lubricant quantity Bevel gearbox GKR Mounting position GKR03 0.35 0.35 0.35 / 0.4 * GKR04 0.7 / 0.8 * GKR05 1.5 / 1.6 * GKR06 3.0 / 3.2 * Mounting position GKR03 0.35 0.35 0.35 GKR04 GKR05 GKR06 Tab.

  • Page 65: Amount Of Lubricant For Combined Mounting Positions

    Maintenance Maintenance operations Amount of lubricant for combined mounting positions 7.2.6 Amount of lubricant for combined mounting positions For the gearbox sizes 03 ...05 a combination of different mounting positions with amounts of lubricant to suit are permissible as per the following tables. Advantage: Easier logistics for users who use gearboxes in different mounting positions.

  • Page 66: Repair

    Bevel gearbox GKR03 ... 05−2; VLL Versions VLR; VLL Mounting position GKR03 GKR04 GKR05 B C D E 0.35 Version VLK 0.35 B D E 0.35 Repair Lenze recommends that repairs are carried out by the Lenze Service. BA 12.0023−EN 6.0...

  • Page 67: Spare Parts List, Geared Motors

    Spare parts list, geared motors K12.0715−2...

  • Page 68: Spare Parts List, Gearbox And Gearbox With Variable Speed Drive

    Spare parts list, gearbox and gearbox with variable speed drive K12.0715−3...

  • Page 69: Order Form

    Maintenance Order form Order form Recipient: Lenze Postcode / town, city: Fax no.: Sender Customer no. Street / PO box Order no. Postcode / town, city Originator Delivery address Telephone Invoice recipient * Delivery date Date Signature Please state if different to sender...

  • Page 70: Troubleshooting And Fault Elimination

    If any malfunctions should occur during operation of the drive system, please check the possible causes using the following table. If the fault cannot be eliminated by one of the listed measures, please contact the Lenze Service. Fault Possible cause...

  • Page 71: Disposal

    Disposal Disposal Protect the environment! Valuable materials can be recycled. What? Where? Transport Pallets Return to the manufacturer or material forwarder Packaging material Cardboard box to waste paper Plastics to plastics recycling or residual waste Reuse or dispose of wood wool Lubricants Oil, grease Dispose according to current...
  • Page 72 © 10/2009 Lenze Drives GmbH Service Lenze Service GmbH Postfach 10 13 52 Breslauer Straße 3 D−31763 Hameln D−32699 Extertal Germany Germany +49 (0)51 54 / 82−0 00 80 00 / 24 4 68 77 (24 h helpline) Ê Ê...

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