Lenze DISCO GST Series User manual

BA 11.5032−EN
.=<Q
Ä.=<Qä
Operating Instructions
Gearbox
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DISCO−Variable speed drive

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2 BA 11.5032−EN 3.0
Product key
DISCO variable speed drive with rear−mounted gearbox   − D   −  








Lengend for the product key
Gearbox type GST
GKS
GSS
Helical gearbox
Helical−bevel gearbox
Helical−worm gearbox
Gearbox size
Number of stages
Disco variable speed drive
Output design V
H
S
Solid shaft
Hollow shaft
Hollow shaft with shrink disk
A
B
C
Foot mounting, with centring
Foot mountin, without centring
Without foot, with centring
R
K
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Without flange
With flange (through holes)
With flange (threaded holes)
Drive size Motor frame size
motor design
DISCO size

l3
BA 11.5032−EN 3.0
DISCO variable speed drive without rear−mounted gearbox 11. 7  0  00. 




Lengend for the product key
Product group
Product family 1
0
with motor
with free drive shaft
DISCO size
Free output shaft 1
no data
without motor
Standard

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4 BA 11.5032−EN 3.0
Nameplate
DISCO variable speed drive without rear−mounted gearbox
GT−DISCO−002.iso
Pos. Contents
1 Production location / Name of product
2Gearbox type
3Order number
4Rated speed:drive | output
5Year of manufacture/ week of manufacture
6Rated torque
7Material number
8 Power
DISCO variable speed drive with rear−mounted gearbox
DISCO nameplate Nameplate of rear−mounted gearbox
GT−DISCO−001.iso GT−DISCO−006.iso
Pos. Contents
1 Production location / Name of product
2Gearbox type
3Order number
4Rated speed:drive | output
5Year of manufacture/ week of manufacture
6Mounting position / position of the system modules
7Rated torque
8 Lubricant
9Material number / serial number
10 Ratio
11 Power
12 Bar code

l5
BA 11.5032−EN 3.0
Document history
Material number Version Description
410700 1.0 09/1999 TD09 Completely revised
483298 1.1 12/2003 TD09 Revised description of the mounting position and position of the system blocks
13251318 2.0 10/2007 TD09 New nameplate: Compact unit and DISCO version
Table of oil grades and new representation of the positions of ventilation, oil
filler plug and oil drain plug
.=<Q 3.0 12/2008 TD09 New edition due to reorganisation of the company
0Fig. 0Tab. 0

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6 BA 11.5032−EN 3.0
Mounting position (A−F) and position of system modules (1−6)
DISCO variable speed drive with helical gearbox
GST − 1D VDR (foot on variable speed drive)
Terminal box: 2, 3, 4, 5Spindle housing: 2, 3, 4, 5 Handwheel/adjusting device: 2, 3, 4, 5
A B
C D
E F

l7
BA 11.5032−EN 3.0
GST − D
Terminal box: 2, 3, 4, 5Spindle housing: 2, 3, 4, 5 Handwheel/adjusting device: 2, 3, 4, 5
A B
C D
E F

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8 BA 11.5032−EN 3.0
DISCO variable speed drive with helical−bevel gearbox and helical−worm gearbox
GKS − D / GSS − D
Solid shaft: 2, 3, 8 (3+5) Hollow shaft: 0 Hollow shaft with shrink disc: 3, 5
Flange: 2, 3, 8 (3+5) Without flange: 0
Terminal box: 2, 3, 4, 5 Spindle housing: 2, 3, 4, 5 Handwheel/adjusting device: 2, 3, 4, 5
A B
C D
E F

l9
BA 11.5032−EN 3.0
DISCO variable speed drive without rear−mounted gearbox
11.70
Terminal box: 2, 3, 4, 5Handwheel/adjusting device: 2, 3, 4, 5
A B
C D
E F

Contentsi
l10 BA 11.5032−EN 3.0
1 Preface and general information 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 About these Operating Instructions 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Terminology used 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Scope of supply 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Lenze drive systems 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1 Labelling 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Legal regulations 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Personnel responsible for safety 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 General safety information 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Definition of notes used 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Technical data 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Product features 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Transport weights 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Operating conditions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Temperatures 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Ambient conditions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Mechanical installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Storage 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Electrical installation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Connection of main motor 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Electrical adjusting device 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Operational check 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Commissioning and operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Before switching on 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 During operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Oil filling quantities for DISCO gearboxes 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Oil grades for DISCO variable speed drives 25. . . . . . . . . . . . . . . . . . . . . . . .
7.1.2 Breather position, oil filling screw and drain plug 26. . . . . . . . . . . . . . . . . .
7.2 Maintenance intervals 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Maintenance operations 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Replacing the lubricant 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Spare parts list 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Repair 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents i
l11
BA 11.5032−EN 3.0
8 Troubleshooting and fault elimination 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Disposal 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Appendix 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Spare−parts list 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.1 DISCO variable speed drive size 02 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.2 DISCO variable speed drive size 03 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.3 DISCO variable speed drive size 04−07 34. . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.4 DISCO variable speed drive size 08−18 36. . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1.5 Speed adjustment mechanism, size 02−07 38. . . . . . . . . . . . . . . . . . . . . . . .
10.1.6 Speed adjustment mechanisms, size 08−18 40. . . . . . . . . . . . . . . . . . . . . . .

Preface and general information
About these Operating Instructions
1
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12 BA 11.5032−EN 3.0
1 Preface and general information
1.1 About these Operating Instructions
ƒThese Operating Instructions provide information about safety−relevant work on
and with DISCO variable speed drives. They contain safety instructions which must
be observed.
ƒAll personnel working on and with DISCO variable speed drives must have these
Operating Instructions available and observe the information and notes relevant for
them.
ƒThe Operating Instructions must always be in a complete and perfectly readable
state.
1.2 Terminology used
Term In the following text used for
DISCO Disco variable speed drive
Drive system Drive systems with DISCO variable speed drives and other drive
components
1.3 Scope of supply
ƒThe drive systems are combined individually according to a modular design. The
scope of supply can be obtained from the pertinent papers.
ƒAfter receipt of the supply, check immediately whether it corresponds with the
accompanying papers. Lenze does not grant any warranty for subsequent claims.
Claim for
– visible transport damages immediately to the forwarder.
– visible deficiencies / incompleteness immediately to the responsible Lenze
subsidiary / agency.

Preface and general information
Lenze drive systems
Labelling
1
l13
BA 11.5032−EN 3.0
1.4 Lenze drive systems
1.4.1 Labelling
Lenze drive systems are uniquely designated by the content of their nameplates.
Manufacturer
Lenze Drives GmbH
Postfach 10 13 52
D−31763 Hameln
Application as directed
ƒLenze drive systems
– are intended for use in machinery and plant,
– must only be used for the purposes ordered and confirmed,
– must only be operated under the ambient conditions prescribed in these
Operating Instructions,
– must not be operated beyond their corresponding power limits.
Any other use shall be deemed inappropriate!
1.5 Legal regulations
Liability
ƒThe information, data, and notes in the Operating Instructions were state of the art
at the time of printing. Claims referring to drive systems which have already been
supplied cannot be derived from the information, illustrations, and descriptions.
ƒWe do not accept any liability for damage and operating interference caused by:
– inappropriate use,
– unauthorised modifications to the drive system,
– improper working on and with the drive system,
– operating faults,
– disregarding the Operating Instructions.
Warranty
ƒConditions of warranty: see terms of sale and delivery of Lenze Drive Systems
GmbH.
ƒWarranty claims must be made to Lenze immediately after detecting the deficiency
or fault.
ƒThe warranty is void where liability claims cannot be made.

Safety instructions
Personnel responsible for safety
2
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14 BA 11.5032−EN 3.0
2 Safety instructions
2.1 Personnel responsible for safety
Operator
ƒAn operator is any natural or legal person who uses the drive system or on behalf of
whom the drive system is used.
ƒThe operator or his safety officer must ensure
– that all relevant regulations, instructions and legislation are observed.
– that only qualified personnel work with and on the drive system.
– that the personnel have the Operating Instructions available for all corresponding
operations.
– that non−qualified personnel are prohibited from working with and on the drive
system.
Skilled personnel
Skilled personnel are persons who − because of their education, experience, instructions,
and knowledge about corresponding standards and regulations, rules for the prevention
of accidents, and operating conditions − are authorised by the person responsible for the
safety of the plant to perform the required actions and who are able to recognise potential
hazards.
(See IEC 364, definition of skilled personnel)
2.2 General safety information
ƒThis safety information does not claimed to be complete. In case of questions and
problems, please contact your Lenze representative.
ƒAt the time of delivery the drive system meets the state of the art and ensures safe
basic operation.
ƒThe drive system is a source of danger for persons, for the drive system itself, and for
other material assets of the operator, if
– unqualified personnel works with and on the drive system,
– the drive system is used inappropriately.
ƒThe drive systems must be designed such that they perform their functions after
proper installation and with application as directed in fault−free operation and that
they do not cause hazards for persons. This also applies for their interaction with the
complete plant.
ƒBe sure to take appropriate measures in the case of drive system failure so that no
material damage occurs.
ƒOperate the drive system only when it is in a proper state.
ƒRetrofittings, modifications, or redesigns of the drive system are basically
prohibited. Lenze must be contacted in all cases.

Safety instructions
Definition of notes used
2
l15
BA 11.5032−EN 3.0
2.3 Definition of 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
{Danger!
Danger of personal injury through dangerous electrical voltage.
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not
taken.
}Danger!
Danger of personal injury through a general source of danger.
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not
taken.
(Stop!
Danger of property damage.
Reference to a possible danger that may result in property damage
if the corresponding measures are not taken.
Application notes
Pictograph and signal word Meaning
)Note! Important note to ensure troublefree operation
ITip! Useful tip for simple handling
,Reference to another documentation

Technical data
Product features
3
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16 BA 11.5032−EN 3.0
3 Technical data
ƒThe most important technical data are provided on the nameplate (layout and
contents ^ page 4).
ƒThe product catalogues contain further technical data.
3.1 Product features
GT−DISCO−005.iso
Fig. 1 Layout of the DISCO variable speed drive
1 Pinion shaft 8 Clutch thrust collar
2 Left inner sun 9 Clutch collar
3 Right inner sun 10 Ball retainer ring
4 Disk spring 11 Pinion cage
5 Planet 13 Spindle
6 Slide block 14 Guide part
7 Thrust collar 15 Ball headed pin
The DISCO variable speed drive is a planetary gearbox, where all the functional parts run
in an oil bath. The planets, located in the pinion cage, rotate around the driving inner
sun. The speed and the force flow are transmitted from the drive shaft to the inner sun.
The flat, double−coned planets are driven by the inner sun, simultaneously rolling along
the outer rings which are fixed in the housing. So the planets don’t only rotate about
their own axes but also about the inner sun. They thus move the pinion cage with them,
which has a fixed connection with the output shaft.
The speed setting is altered by means of an adjustment spindle through rotating one of the
three outer rings on the housing. This moves the planets to a different radius of rotation,
depending on the size of the air gap between the outer rings. In this way, steplessly
adjustable output speeds are achieved. Supplementary gearboxes, in the form of single or

Technical data
Product features
3
l17
BA 11.5032−EN 3.0
multi−stage helical, conical or worm gearboxes, can be used to adjust output speed to the
requirements of the application.
(Stop!
The DISCO must only be changed to a fasterspeed while it is running!
Otherwise, the DISCO could be damaged!
Changing to a slowerspeed is allowed while the DISCO is standing still.

Technical data
Transport weights
3
l
18 BA 11.5032−EN 3.0
3.2 Transport weights
DISCO with GST helical gearbox
Gearbox size Drive size
071−102 071−303 080−304 090−305 100−32 06 112−22 07 132−12 18 132−22 08
GST 04 < 18
GST 05 < 25 < 32 < 43
GST 06 < 36 < 40 < 51 < 67
GST 07 < 56 < 64 < 75 < 83 < 120 < 130
GST 09 < 99 < 110 < 127 < 150 < 161 < 223 < 230
GST 11 < 168 < 185 < 221 < 232 < 272 < 279
GST 14 < 296 < 333 < 343 < 406 < 413
DISCO with GKS helical−bevel gearbox
Gearbox size Drive size
071−102 071−303 080−304 090−305 100−32 06 112−22 07 132−12 18 132−22 08
GKS 04 < 28
GKS 05 < 41 < 49 < 59
GKS 06 < 64 < 69 < 79 < 96
GKS 07 < 104 < 113 < 123 < 131 < 168 < 178
GKS 09 < 191 < 202 < 218 < 242 < 252 < 315 < 322
GKS 11 < 329 < 346 < 382 < 392 < 433 < 440
GKS 14 < 574 < 607 < 621 < 684 < 709
DISCO with GSS helical−worm gearbox
Gearbox size Drive size
071−102 071−303 080−304 090−305 100−32 06 112−22 07
GSS 04 < 28
GSS 05 < 41 < 48 < 59
GSS 06 < 62 < 56 < 77 < 94
GSS 07 < 101 < 109 < 120 < 128 < 165 < 175
DISCO type 11.700 / 11.710
DISCO
size
Type 11.700 with motor size Type
11.700
071−1071−3080−1080−3090−1090−3100−1100−3112−22 132−12 132−22
02 < 10 < 5
03 < 19 < 13
04 < 27 < 28 < 21
05 < 42 < 45 < 35
06 < 74 < 78 < 58
07 < 89 < 58
09 < 151 < 88
11 < 158 < 85
Weight in [kg] with oil filling, for mounting position A, all values are aproximate

Technical data
Operating conditions
Temperatures
3
l19
BA 11.5032−EN 3.0
3.3 Operating conditions
3.3.1 Temperatures
ƒDISCO: permissible ambient temperature −15 bis +40°C
ƒRear−mounted gearbox (see Operating Instructions for the gearbox)
ƒMotor (see temperature class for the motor)
The operating temperature is determined by the power loss, the ambient temperature and
the cooling system!
3.3.2 Ambient conditions
ƒDISCO variable speed drives are dust and hose−proof.
ƒMotors corresponding to their degree of protection (s. nameplate and/or operating
instructions of the motor).
ƒAmbient media − especially chemically aggressive − can damage shaft sealing rings
and lacquers (plastics in general). Abrasive media may damage the shaft sealing
rings.

Mechanical installation
Storage
4
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20 BA 11.5032−EN 3.0
4 Mechanical installation
}Danger!
Only transport the drive with transport equipment or hoists which are suitable
for this load (see transport weights, chapter 3.2). Ensure a safe fixing. Avoid
shocks!
The motors attached to the gearbox are partially equipped with eyebolts.
These are exclusively determined for motor/gearbox mounting and
dismounting and must not be used for the complete geared motor!
4.1 Storage
If you do not install the DISCO at once, please ensure proper storage conditions.
ƒUp to one year:
– Without special measures in dry, dust−free enclosed rooms without direct sunlight.
– Store DISCO with ventilation in a manner that the breather screw is at the top.
– Shafts and bright surfaces are delivered with protection against corrosion.
ƒOver one year:
– Please consult the factory.
4.2 Installation
Mount the drive systems on an even surface, free from distortion. If they are mounted on
a baseplate, then the baseplate must also be mounted without distortion. If this is not
done, then stresses appear in the gearbox housing and have a bad effect on the parallel
alignment of the shafts and thus on the bearing and tooth alignment.
The output shaft of the drive system must be well aligned with the machine shaft that is
to be driven. Small inaccuracies can be compensated by using a flexible coupling.
Couplings, gear wheels, sprockets etc. must only be fixed by screwing to the shaft ends of
the drive system. Driving them on can damage the ball bearings.