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Summary of Contents for Benzlers BS Series
- Page 1 Series BS Installation & Maintenance...
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Page 3: Table Of Contents
CONTENTS PRODUCT SAFETY INFORMATION INFORMATION .................... 4 General information ................4 Safety warning Symbols ..............4 Weather Protection of Unit ..............5 Reading the Nameplate ..............5 Marking ..................6 INSTALLATION ................... 7 Safety Warning ................... 7 Prior to Installation ................7 Fitting of components to either the unit input or output shaft ..... -
Page 4: Information
INFORMATION 1.1 General information The following instructions will help you achieve a satisfactory installation of your Benzlers or Radicon gear unit, ensuring the best possible conditions for a long and trouble free operation. All units are tested and checked prior to despatch, a great deal of care is taken in packing and shipping arrangements to ensure that the unit arrives at the customer in the approved condition. -
Page 5: Weather Protection Of Unit
INFORMATION 1.3 Weather Protection of Unit All series BS units are provided with protection against normal weather conditions. Where units are to operate in extreme conditions, or where they are to stand for long periods without running, e.g. during plant construction, please consult your local sales office so that arrangements for adequate protection can be made. Gear units that are installed outdoors or have to work under adverse conditions, for example in hot, dusty or damp premises, must be fitted with appropriate protection. The circulation of air around the gear unit must not be obstructed, however. -
Page 6: Marking
INFORMATION Marking Gear units with -marking are especially selected for use as a component of an industrial system operating in a potentially explosive atmosphere. Provided they are correctly installed in accordance with these instructions (gear units only) they comply with the EU directive 94/9/EC (ATEX 100a). -
Page 7: Installation
Attention is hereby drawn to the danger of using naked lights in proximity to openings in gearboxes and gear units supplied by Benzlers or Radicon, and they shall not be liable for any claim for injury or damage arising from any action in contravention of this warning. -
Page 8: Lifting
INSTALLATION 2.4 Lifting The gear motor must never be lifted by the lifting eye on the motor alone. NOTE! The gear motor must never be lifted by the lifting eye on the motor alone. 2.5 Foot mounted or flange mounted units 1. Ensure the base foundation mounting surface is flat , vibration absorbing and torsionally rigid. - Page 9 INSTALLATION Tightening Torque according Screw to quality class 8.8 Size Holding Down Bolts/ Output Flange Bolts 2.8 Nm = 25 Lbf.in 5.5 Nm = 49 Lbf.in 10 Nm = 89 Lbf.in 25 Nm = 221 Lbf.in 50 Nm = 442 Lbf.in 85 Nm = 752 Lbf.in 200 Nm = 1770 Lbf.in Table 1...
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Page 10: Shaft Mounted Units
INSTALLATION Follow the mounting procedure below: 1. Fit the flange or flange adaptor without tightening the bolts. 2. Fit the locking ring for the extra bearing on the shaft. 3. Fix the bearing on the shaft with Loctite 641 or an equivalent before sliding it up against the locking ring. 4. -
Page 11: Lubrication
LUBRICATION 3 Lubrication 3.1 General BS40-BS71 gear units are supplied with synthetic oil MOBIL SHC 634. These lubricants are specially suited to worm gears. During normal operation, the lubricant will never require replacement. Ambient temperature range ±30°C. 3.2 Ventilator Clean and secure the ventilator in the correct location for the required mounting position (See Appendix 4). -
Page 12: Motor Connections
START UP 4 Motor connections To mains Connection of the electric motor to the mains supply should be made by a qualified person. The current rating of the motor will be identified on the motor plate, and correct sizing of the cables to electrical regulations is essential. High voltage! Caution when working with the mains. Motor terminal connection Circuit diagrams for the correct wiring of the motor terminal box are included as Appendix 3 of this document if the motor is supplied separately or if fitted with a motor from a different manufacturer, then this should have appropriate documentation provided with it. -
Page 13: Operation
START UP 6 Operation 6.1 Noise The range of product satisfies a noise (sound pressure level) of 85 dB(A) or less when measured at 1 meter from the unit surface. Measurements taken in accordance with ISO 8579-1:2002. 6.2 General Safety Potential hazards which can be encountered during installation, maintenance and operation of drives is covered in greater detail in the product safety page at the front of this booklet. (See chapter 1 Information). Advice is also given on sensible precautions which need to be taken to avoid injury or damage. -
Page 14: Maintenance 1
MAINTENANCE 7. Maintenance 7.1 Prior to any maintenance operations 1. De-energize the drive and secure against unintentional switch-on. 2. Wait until the unit has cooled down. Hot Surfaces! Danger of skin burns & pressure build-up. 7.2 Oil plugs / Ventilator 1. Prior to removing plugs, ensure that the unit has cooled sufficiently so that oil will not burn on units without ventilator. Danger! Do not stand over plug whilst removing, as pressure build-up may cause it to eject when removed. 2. - Page 15 MAINTENANCE 7.3.2 Oil changes Smaller BS worm gear units are supplied lubricated for life except for the following conditions: Units that are required to work in explosive atmosphere (94/9/EC ATEX 100a Group II Category 2 Zones 1 & 21 & Category 3 Zones 2 & 22) should be drained and refilled with correct quantity of lubricant in accordance with the renewal period of Table M2. See Appendix 4 for correct oil quantity. Following factors should be used to determine the frequency at which oil changes are carried out: a.
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Page 16: Bearings
MAINTENANCE Warning! Do not mix Synthetic with Mineral lubricants. Do not overfill the unit as this can cause leakage and overheating. 7.4 Bearings Bearings should be replaced every 5 years for marked units. 7.5 Oil Seals Oil seals have dimensions: Unit Input Shaft Resp. Output Shaft BS 40 20 x 47 x 7 47 x 6.5*) 30 x 47 x 7 BS 50... -
Page 17: Fault Diagnosis
PROBLEM SOLVING 8 Fault diagnosis 8.1 Gear unit problems Symptom Possible Causes Remedy Output shaft does not Drive between shafts Return the gear unit / geared rotate, even though the interrupted in the gear unit. motor motor is running or the for repair. -
Page 18: Appendix 1 Shaft Alignment
APPENDIX 1 Shaft Alignment Errors of alignment fall into categories of angularity (See Figure 1) and eccentricity (see Figure 2), or a combination of both. Errors of angularity should be checked for, and corrected, before errors of eccentricity. Alignment in accordance with the following procedure will ensure vibration levels meeting those set out in ISO 10816 Part 1 Errors of Angularity If the faces are perfectly true, the angularity can be checked by... - Page 19 APPENDIX 1 The permitted angularity error is as follows: Type of Coupling Allowable Gap (G) (mm) Rigid Coupling G = 0.0005 D All other types Please see appropriate Installation and Maintenance Manual for coupling type fitted. Table 5 Note! D is the diameter (mm) at which the gap is measured. Errors of Eccentricity The procedure for measuring eccentricity is precisely analogous to that used for angularity.
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Page 20: Appendix 2 Alternative Shaft Fixing Methods
APPENDIX 2 Alternative Shaft Fixing Methods... -
Page 21: Appendix 2A Torque Arm Details Bs
APPENDIX 2A Torque Arm Details BS The torque arm should be fitted on that side of the gear unit which is adjacent to the driven machine Caution! The angle between the torque arm and the high speed shaft must not exceed 20°. The torque arm must be positioned so that it is loaded in tension i.e. in the direction of torque reaction, which is opposite to the direction of shaft rotation, as shown above. For reversing applications two torque arms must be fitted in opposite mounting positions. Gear units must be locked axially when mounted in position, and supported by the low speed sleeve for a minimum of 90% of the bore length. -
Page 22: Appendix 3 Three Phase Induction Motor Installation
Note! It is important that the mains supply details are checked against the motor nameplate data and that they are connected as indicated on the nameplate. The correct sizing of the cables to electrical regulations is essential. • To change the direction of rotation of the electric motor, one of the three main line terminals should be changed with the other. • Connect the earth conductors to the marked earth terminals. Note! This instruction only applies to Benzlers and Radicon plated motors. Motors fitted by the customer or requested by the customer of Benzlers or Radicon from a different manufacturer will have separate documentation provided with it. -
Page 23: Appendix 4 Approved Lubrication
APPENDIX 4 Approved Lubrication Lubricant and Quantity The oil grade is stamped on the name plate. BS40, BS50, BS63 and BS71 are filled with a certain oil quantity and have no oil level plug. See Table 7 and Table 8: Unit Quantity (liter) BS40 0.20 BS50 0.25 BS63 0.40 BS71 0.75 Table 7: Lubricant quantity (liters) Single units BS40 – BS71. Applicable for all mounting positions. - Page 24 APPENDIX 4 Ventilator Position for BS40 – BS71...
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Page 25: Appendix 5 Declaration Of Conformity
APPENDIX 5...
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