Summary of Contents for Regal Rexnord Bauer Gear Motor BG Series
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Assembly and Operating Instructions Regal Rexnord MCM-P-8407-BGM-EN-A4 bauergears.com Edition 03/25 Geared Motors Gears Series BG.. / BF.. / BK.. / BS.. / BM.. Motor Series D.. / E.. / S.. English Bauer Gear Motor GmbH Eberhard-Bauer-Str. 37 ▪ 73734 Esslingen ▪ Germany...
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Assembly/Operating Instructions . Geared Motors Digital documentation Scan the QR code to view and download more languages. BG Сканирайте QR кода, за да видите и да изтеглите още езици. CN 扫描二维码以查看和下载更多语言。 CZ Pro zobrazení a stažení dalších jazyků naskenujte QR kód. DE Scannen Sie den QR-Code, um weitere Sprachen anzusehen und herunterzuladen.
Assembly/Operating Instructions . Geared Motors Table of contents About this documentation ......................... 7 Product name .....................................7 Validity ......................................7 Applicable documents ................................7 Symbols and means of representation ..........................8 1.4.1 Warnings ......................................8 1.4.2 Symbols and means of representation ..........................8 Abbreviations .....................................9 Copyright .....................................9 Safety ................................10 Intended use ....................................
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Assembly/Operating Instructions . Geared Motors 6.2.3 Inspections and preparatory work before installation ..................... 23 Installation of hollow shaft, gearbox with hollow shaft with keyway or spline ..........23 Assembly of shaft-mounted gear with hollow shaft with shrink disc connection ........24 Installation of torque arm ..............................
Assembly/Operating Instructions . Geared Motors About this documentation About this documentation These Assembly and Operating Instructions (hereinafter referred to as “documentation”) are an integral part of the product. It is intended for persons carrying out work associated with the product and contains impor- tant information on safety and safe handling of the device.
About this documentation Assembly/Operating Instructions . Geared Motors Symbols and means of representation 1.4.1 Warnings Warnings are used in this document to warn of situations that could cause damage to property and person- al injury. Read and observe warning notices. Follow all steps marked with the warning symbol and warning word.
Assembly/Operating Instructions . Geared Motors About this documentation Abbreviations Abbreviation Definition Description Alternating current AC current Output code for absolute encoder with SSI interface Helical gear Shaft-mounted gear Bevel Monorail gear Worm gear Output format for absolute encoder with SSI interface Direct current DC current Decentralised Periphery...
Safety Assembly/Operating Instructions . Geared Motors Safety The safety instructions serve to prevent personal injury and material damage. They relate only to the drive unit concerned in this document. When using special options/components: Also refer to additional product-specific documents provided. The product is part of a drive system and may only be put into operation if it has been properly determined that the machine or system can be operated safely.
Assembly/Operating Instructions . Geared Motors Safety Residual risks Hazardous voltage Serious or fatal injuries may result. Before working on electrical components of the product, ensure that there is no voltage. Take appropriate measures to prevent unintentional or accidental restart, such as removing fuses, assign- ing personnel to monitor, placing warning signs, etc.
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Safety Assembly/Operating Instructions . Geared Motors Risk of injury when disconnecting transmission elements Serious or fatal injuries may result. Only loosen and disconnect transmission elements such as couplings, chain and belt drives, etc. if no force or torque is acting on the output shaft. With shaft-mounted gears, only remove the torque arms if no force or torque is being applied.
Assembly/Operating Instructions . Geared Motors Safety Pictograms on product Symbol Meaning The geared motor is suitable for use in potentially explosive atmospheres. This is not a lifting point. Hot surface, can cause burns. Operate permanent magnet synchronous motor only via inverter. PMSM USE WITH VARIABLE SPEED DRIVE...
Product description Assembly/Operating Instructions . Geared Motors Product description Product identification: geared motor Geared motors are used to drive slow-running machines, devices, and systems. Products are identified using the type codes described below. 3.1.1 Rating plate/type plate All essential data and information is stated on the rating plate in accordance with EN 60034. 73734 Esslingen 73734 Esslingen Made in Germany...
Assembly/Operating Instructions . Geared Motors Product description 3.1.2 Type code/type designation BK 50 Z - 1 1 U W A / D.. 09L A 4 - TF - S / ES 010 A 9 HN / C2 Gear type, size, and design Motor attachments Motor type, size, and integrated designs Additional options...
Assembly/Operating Instructions . Geared Motors Product description Inclined installation positions - Explanation of the abbreviations on the type plate Information on rating plate (example) Explanation H4/V1 30° [Installation position 1] / [Installation position 2] [Deviation value] Example for BG y Installation position 1: Output installation position y Installation position 2: Installation position in which the gear- box is rotated y Deviation value: Twist angle in degrees [°]...
Product description Assembly/Operating Instructions . Geared Motors Functional description 3.4.1 Three-phase motor Induction motor Bauer geared motors and Bauer motors for three-phase connection are supplied with specially designed asynchronous technology. This design enables maximum operational reliability with high torque and low inrush current. Permanent magnet synchronous motor PMSM motor rotors are equipped with embedded permanent magnets.
Assembly/Operating Instructions . Geared Motors Included with delivery 3.4.3 Gearbox ventilation The gearboxes are dimensioned in such a way that no gearbox ventilation is required in many installation positions. Install a pressure relief valve as necessary. 3.4.4 Encoder system Incremental rotary encoders Incremental rotary encoders (impulse generators/encoders) determine the position of motor shafts.
Transport and storage Assembly/Operating Instructions . Geared Motors Transport and storage Goods Receiving Incomplete or damaged products complicate or hinder operation. Do not install or put damaged products into operation. Immediately check delivery for completeness upon receipt. Verify that the technical design of the product corresponds to the order. Check rating plate.
Assembly/Operating Instructions . Geared Motors Installation 5.3.2 Long-term storage Storage space requirements Storage space is dry, dust-free, ventilated, and free of vibrations (permissible vibrations v <0.2 mm/s). Storage temperature range: -20°C to +40°C with minor fluctuations. Air in the room should be free from aggressive, corrosive, or radioactive elements. Do not expose product to direct sunlight or any other source of UV radiation.
Installation Assembly/Operating Instructions . Geared Motors 6.1.2 Cooling air supply Cooling air supply to the motor is unobstructed (at least 10 cm away from the air inlet in the fan cover). 6.1.3 Installation outdoors or in damp rooms Geared motors starting from motor size 63 (D06...) are suitable as standard for protection rating IP65 and for use outdoors or in damp rooms.
Assembly/Operating Instructions . Geared Motors Installation 6.2.3 Inspections and preparatory work before installation Work can only be carried out if the following requirements are met: Product is not damaged or leaking. The information on the product rating plate matches the requirements with regard to power, speed, voltage, frequency, installation position, and ambient temperature in particular.
Installation Assembly/Operating Instructions . Geared Motors Assembly of shaft-mounted gear with hollow shaft with shrink disc connection CAUTION Damage to hollow shaft Risk of material damage due to improper handling Tighten screws on shrink disc connection only with the solid shaft installed. 1.
Assembly/Operating Instructions . Geared Motors Installation Installation of torque arm WARNING Improper installation of torque arm Observe specified pre-stresses (see tables). The dimension “L”, see following graphics and tables, determines both the pre-stress force of the torque arm and the tightening torque of the fixing screw “G”. Play leads to knocking and gearbox overload.
Installation Assembly/Operating Instructions . Geared Motors 6.5.2 Rubber buffer for torque arm with bevel gearboxes With supplied torque arm for gearbox code BK..-0: Rubber buffers are included with delivery. Attachments are not included with delivery. ØD Not included with delivery Rubber buffer nicht im Lieferumfang enthalten not included in delivery...
Assembly/Operating Instructions . Geared Motors Installation 6.5.3 Rubber buffer for torque arm with worm gearboxes With supplied torque arm for gearbox code BS..-0: Rubber buffers are included with delivery. Attachments are not included with delivery. ØD Not included with delivery Rubber buffer –...
Installation Assembly/Operating Instructions . Geared Motors 6.5.4 Torque arm for gearboxes BK04, BK08, and BK17 For gearbox code BKH..-0: The torque arm is delivered as a set, consisting of a mounting kit and the torque arm as an accessory with the drive. The torque arm is not suitable for switching operation.
Assembly/Operating Instructions . Geared Motors Installation Use the following tightening torques: Size Tightening torque [Nm] Tab. 9: Tightening torques for torque arm installation Installation of protective cover HAZARD Dangerous rotating parts Serious or fatal injuries may result. If no protection is provided on site, install a protective cover for the SSV in accordance with accident prevention regulations (UVV) (available as an option).
Installation Assembly/Operating Instructions . Geared Motors Gear side FRONT (V) Gear side REAR (H) ØB Fig. 5: SSV cover for bevel gearbox BK10 ... BK90 Gear side FRONT (V) Gear side REAR (H) ØB Fig. 6: SSV cover for worm gearbox BS10 ... BS40 Install covers as contact guard for drives with shrink disc connection.
Assembly/Operating Instructions . Geared Motors Installation 6.6.2 Protective covers for hollow shafts with keyway or splines Drives with hollow shafts can be protected against contact and the ingress of occasional splashed water or dirt by installing sealing caps (VK) or sealing covers (VD). Before mounting the sealing cover, degrease sealing surfaces and seal with a suitable liquid seal.
Assembly/Operating Instructions . Geared Motors Installation Installation of oil expansion tank The oil expansion tank and the components required for installation are supplied as a three-piece accessory set delivered with the drive. Drive correctly positioned for installation according to rating plate Install oil expansion tank on gearbox in system on site.
Installation Assembly/Operating Instructions . Geared Motors 6.7.1 Attach oil expansion tank to gearbox housing The gearbox is delivered with pre-installed threaded bolt, spring washer, and hex nut. Hex nut Spring washer Stud bolt Fig. 11: Accessory set, Part 2: Mounting set with nut and spring washer Place oil expansion tank (1, Fig.
Assembly/Operating Instructions . Geared Motors Installation 6.7.3 Attach connection hose to gearbox housing Screw plug (M16x1.5) Gasket Banjo bolt Banjo screw Gasket Reducer Fig. 13: Accessory set, Part 3: Hollow screw and two gaskets To ensure that the expansion tank functions correctly, connect the free end of the connection hose to the gearbox using the banjo bolt as follows: 1.
Installation Assembly/Operating Instructions . Geared Motors 6.8.2 Prerequisites Only install the product if the mains voltage and frequency match the motor data or, with inverter duty, the output voltage of the inverter matches the connection voltage of the motor, see chapter 3.1.1, p. 14 and drive rating plate.
Assembly/Operating Instructions . Geared Motors Installation Single-wire Fine-wire Crimped 8. Pull out screwdriver. Cable is clamped automatically. à 9. Once the connection is complete, screw on the terminal box cover. Make sure that no cable strands are crushed. Ensure that the seal is seated correctly. 10.
Installation Assembly/Operating Instructions . Geared Motors 6.8.6 Electrical connection with plug-in connection on terminal box, CleanConnect® plug, or cable version (CleanDrive) Optionally available Product with following connection variants: Connection variant Description Connection diagram Remarks Plug-in connection Plug installed on terminal Included with delivery - on terminal box box for electrical...
Assembly/Operating Instructions . Geared Motors Installation 6.8.10 Stator standstill heating CAUTION Incorrect connection voltage for auxiliary heating via heater bands Motor damage and material damage due to drive failure can result. Note the connection voltage, see rating plate. Only switch on the heater bands when at a standstill. Apply the heating voltage (AC voltage) according to the wiring diagram of the parking heater.
Installation Assembly/Operating Instructions . Geared Motors 6.8.11 Electrical connection for brakes When making electrical connection for brakes: Follow factory regulations or rules from professional asso- ciations for connecting brakes, e.g. phase failure protection or other safety circuits. There are 2 options for supplying power to the DC solenoid: y Externally from an existing DC control network or through a rectifier in the control cabinet.
Assembly/Operating Instructions . Geared Motors Commissioning Commissioning CAUTION Hearing hazard due to high noise emissions Wear hearing protection. Observe the values on the rating plate. Follow instructions in chapters 2, p. 10, 6.2, p. 22 and 6.8, p. 35 . Observe motor speeds, e.g.
Normal operation Assembly/Operating Instructions . Geared Motors Commissioning after long-term storage 7.3.1 Gearbox measures Detailed information and instructions on lubricant recommendations can be found in chapter 11.4.2, p. 52. For lubricant quantities, see rating plate or customer service manual. Before commissioning, reduce the lubricant level of the gearbox back to the value specified on the rating plate or in these Operating Instructions.
Assembly/Operating Instructions . Geared Motors Malfunctions and troubleshooting Malfunctions and troubleshooting Motor malfunctions Malfunction Possible cause Remedy Motor not starting No voltage connected to motor Correct connections, eliminate interruptions as necessary. Fuse switched off/burnt Switch on or replace fuse. Brake not releasing. Configure drive and connections correctly.
Malfunctions and troubleshooting Assembly/Operating Instructions . Geared Motors Malfunction Possible cause Remedy Motor becomes too hot. Drive is overloaded. Take a power measurement. If necessary, consult If necessary, select different drive with Bauer Gear Motor and reconfigure. GmbH Connection voltage at motor Voltage drop too large.
Assembly/Operating Instructions . Geared Motors Malfunctions and troubleshooting Brake malfunctions Malfunction Possible cause Remedy Brake does not release No voltage present. Check and correct control. If possible due to connection used, place missing connection between rectifier and terminal board. Rectifier defective, replace. Incorrect voltage applied.
Repair Assembly/Operating Instructions . Geared Motors Repair Any work on the products must be performed by qualified specialist personnel. Follow the troubleshooting instructions in chapter 9, p. 43 . Repairs must be made in compliance with chapters 2, p. 10, 6.2, p. 22, 6.8, p. 35, 7, p. 41, 8, p. 42, and 15, p.
Assembly/Operating Instructions . Geared Motors Maintenance Assembly Component Maintenance interval Activities Brakes E003B and Holding brake: See chapter 11.3.1, p. 49 E004B Every 2 years Service brake: Every 3,000 operating hours, every six months at the latest, or according to specifications from system manufacturer or operator Single-disc Holding brake:...
Maintenance Assembly/Operating Instructions . Geared Motors Assembly Component Maintenance interval Activities Gearbox Entire gearbox After 3,000 operating hours, every See chapter 11.4.1, p. 52 6 months at the latest Only for worm Occasionally, depending on load Replace worm gear. gearboxes and operating mode, normally only after running for some time Lubricants...
Assembly/Operating Instructions . Geared Motors Maintenance 11.3 Inspection and maintenance of brakes HAZARD Hazard due to non-functional brake Brakes are components important for safety. Any work must be performed by qualified and personnel trained on the product. Do not expose any friction surfaces and brake discs to oil or grease. Even small quantities reduce the braking torque significantly.
Maintenance Assembly/Operating Instructions . Geared Motors 11.3.2 Maintenance of single-disc holding brakes ES010A ... ES250A, EH027A ... EH400A Holding brakes are only used to secure a position that has been approached. In the event of an emergency, a slowdown function can be used. This slowdown function causes abrasion, which makes it necessary to check the air gap and perform additional maintenance work as necessary.
Assembly/Operating Instructions . Geared Motors Maintenance 11.3.3 Maintenance of single-disc service brakes ESX010A … ESX250A, EHX027A … EHX400A For pos. numbers, see chapter 11.3.2, p. 50 Check air gap 1. Remove the fan cover (for brakes under the fan cover). 2.
Maintenance Assembly/Operating Instructions . Geared Motors 11.3.5 Maintenance of double-disc service brakes ZSX300A ... ZSX500A For pos. numbers, see chapter 11.3.4, p. 51 Check air gap 1. Remove the fan cover and fan blade. 2. Loosen fixing screws (14), take off plate (15), and remove cover (13). 3.
Assembly/Operating Instructions . Geared Motors Maintenance 11.4.3 Approved lubricant types for three-phase geared motors Lubricant Lubricant type manufacturer Mineral oil Synthetic oil USDA H1 oil ISO VG 220 ISO VG 68 ISO VG 220 ISO VG 460 ISO VG 220 Standard oil for gear- Low-temperature oil for gearbox- Standard oil for gear-...
Decommissioning Assembly/Operating Instructions . Geared Motors 11.5 Cleaning and maintenance CAUTION Material damage due to improper cleaning of paint coating Corrosion protection is impaired. The drive or its surroundings may be damaged. Only use non-abrasive cleaning tools. CAUTION Material damage due to penetration of liquid into device. Water exposure only permitted in accordance with protection rating IP (rating plate).
Assembly/Operating Instructions . Geared Motors Spare parts and accessories Spare parts and accessories Our worldwide service team is always ready to provide advice and support for supplying spare parts. You can find the nearest service partner online at www.bauergears.com/sales-and-service/global-service/ under “Sales Locator”.
Assembly/Operating Instructions . Geared Motors Technical data 16.5 Motor attachments and accessories 16.5.1 External fan For special applications, motors and brake motors starting at size D08 can be supplied with a mounted external fan. A connection with multivolt design – operating capacitor for single-phase operation is installed as standard. Operating Frame size Fan diameter Voltage range...
Technical data Assembly/Operating Instructions . Geared Motors 16.5.2 Brakes The spring-loaded brakes with DC release solenoid of series E003B, E004B, ES(X)010A ... ES(X)300A, ZS(X)500A, EH(X)027A ... EH(X)400A are not approved for use in potentially explosive atmospheres. Abbreviations Abbreviation Description Rated braking torque Braking torque tolerance: -10/+30% 1), Braking torque tolerance: -20/+30% when run in.
Assembly/Operating Instructions . Geared Motors Technical data 16.5.3 Encoder system Bauer standard encoders have a robust protective cover to prevent mechanical damage starting at motor size D05 (0.18 kW). Parameter Value Robust bearings Protection rating IP66 EMC tested Protected against polarity reversal Supply voltage 8-30 VDC A-, B-, and N-track and inverted signals or...
Technical data Assembly/Operating Instructions . Geared Motors Absolute rotary encoders Parameter with PROFIBUS-DP interface with SSI interface Supply voltage 11 … 27 V DC Current consumption without load <350 mA Total resolution ≤33 bit ≤25 bit Number of steps/revolutions, stand- ≤8,192/≤32,768 ≤8,192 ard/extended...
Assembly/Operating Instructions . Geared Motors Technical data 16.5.4 Backstop (RR, RL) With frequency inverter duty, note that correct operation of the backstop is only guaranteed at rotor speeds above 740/min. 16.6 Brake maintenance The following abbreviations are used in the following: Abbreviation Description Rated braking torque Braking torque tolerance: -10/+30%...
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