Lenze G-motion GPA Series User manual

BA 12.0030
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Operating Instructions
G-motion

GPA servo planetary geared motors
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2BA 12.0030 EN 2.0
Product key
()
Gearbox
type
Gearbox
size
Step
number
Input design Output design Drive size
Planetary gearbox Solid shaft
smooth
Square flange (through
holes)
A
C
MC
14
l
1
GP A
Expanded servomotor key
Square measure (example: 142 mm)
Length of coil module
Rated speed, value 100/min (example: 2000 min
-1
)
Resolver p=1
Without brake
PM brake 24 VDC
PM brake 24 VDC uprated
GN
Servomotor, synchronous,
externally ventilated
S
servo motor,
asynchronous, externally
ventilated
C024
Without foot mounting with centering
C
...
Tacho generator and phase angle sensor
Separately ventilated with fan
Separately ventilated with fan
PM-brake DC 205V
PM-brake DC 205V uprated
not for
UL design, UR approval
20
Square measure
Length of coil module
Sin-Cos-Absolute value encoder Singleturn, Hiperface, SCS70
Sin-Cos-Absolute value encoder Multiturn, Hiperface, SCM70
Sin-Cos-Absolute value encoder Singleturn, Hiperface, SRS50
Sin-Cos-Absolute value encoder Multiturn, Hiperface, SRM50
Sin-Cos-Absolute value encoder Singleturn, EnDat, ECN 1313
Sin-Cos-Absolute value encoder Multiturn, EnDat, EQI 1329
Incremental encoder TTL, 2048, ITD 21
Incremental encoder TTL, 2048, CDD 50
l
EIQ
T 2 0
C D D
Brake
Cooling
B0
P1
P2
P5
P6
F 1 0
S 00
Sin-Cos-Absolute value encoder Multiturn, EnDat, EQN 1325
E NQ
E C N
S R M
S SR
S C S
S C M
R OS
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3
BA 12.0030 EN 2.0
GPA mounting positions A, C, D
A C D
Nameplate (sample)

Hans-Lenze-Strasse 1 
D-31855 Aerzen
http://www.Lenze.com
UL 
File no.
N
Made in 
Germany
3~MOT GPA00-1SGCN-09FN38 
330 V 1.2 kW n1eck 3750 min-1 M212 Nm !n2eck 938 min-1 "
2.5 A #1.6 HP $c=2.1 %M2GN 25 Nm &i=4 '
max. 5.9 A (250 Hz )Cooling type S00 ICLP 150  000A 
I.CL.F  IP 55  Fan data 
Ta 30 °C  C86:1314  Uin V Item 00452320
Brake !!
Brake V A Nm
Encoder
""
Feedback
RS 0
SN 15005432100065566 ## IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII $$
Manufacturer  Lubricant type
Assembly plant  Position of system modules / mounting position
UL file no.  Insulation class
CE designation  Enclosure
Motor type  Fan data
Gearbox type  Ambient operating temperature
Rated voltage  Code for motor parameterisation
Motor driving power  Induced voltage
Input speed ID number
!Rated output torque of geared motor !! Brake data
"Output speed "" Encoder data
#Rated current ## Serial number
$Motor driving power $$ Bar code
%Load capacity
&Rated output torque of gearbox
'Ratio
(Maximum current
)Rated frequency
ICooling type S00
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4BA 12.0030 EN 2.0
What is new?/ What has been changed in the Operating Instruction?
Material number Edition Important Contents
00 491 027 1.0 05/04 TD09 1st edition First printing
13 011 303 2.0 08/04 TD09 1st edition Completion of the product key
Completion of the chart transport weights
© 2004 Lenze Drive Systems GmbH , Hans-Lenze-Straße 1 , 31855 Aerzen
No part of this documentation may be reproduced or made accessible to third parties without written consent by Lenze Drive
Systems GmbH
.
All information given in this documentation has been selected carefully and complies with the hardware and software described.
Nevertheless, deviations cannot be ruled out. We do not take any responsibility or liability for damages which might possibly occur.
Necessary corrections will be included in subsequent editions.
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Contents i
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5
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1 Preface and general information 6............................................
1.1 About these Operating Instructions 6.....................................
1.2 Terminology used 6....................................................
1.3 Scope of supply 6......................................................
1.4 Lenze drive systems 7...................................................
1.5 Legal regulations 7.....................................................
2Safety 8...................................................................
2.1 Personnel responsible for safety 8........................................
2.2 General safety information 8............................................
2.3 Definition of notes used 9...............................................
3 Technical data 10............................................................
3.1 Product features 10.....................................................
3.2 Transport weights 11....................................................
3.3 General data/operating conditions 12......................................
3.3.1 Temperatures 12................................................
3.3.2 Ambient conditions 12...........................................
4 Mechanische Installation 13...................................................
4.1 Storage 13.............................................................
4.2 Mounting 13...........................................................
4.2.1 Preparation 13..................................................
4.2.2 General information about the assembly of drive systems 14...........
4.2.3 Assembly of transmission elements on solid shafts 14................
5 Electrical installation 15.......................................................
5.1 Motor connection 15............................................
6 Commissioning and operation 16...............................................
6.1 Before switching on 16..................................................
6.2 During operation 16.....................................................
7 Maintenance 17.............................................................
7.1 Maintenance intervals 17................................................
7.1.1 Replacing the lubricant 18........................................
7.1.2 Lubricant quantity 19............................................
8 Troubleshooting and fault elimination 20.......................................
9Disposal 21..................................................................
10 Appendix 22................................................................
10.1 Manufacturer’s Certification 22...........................................
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Preface and general information
About these Operating Instructions
1
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6BA 12.0030 EN 2.0
1 Preface and general information
1.1 About these Operating Instructions
ƒ These Operating Instructions are intended for safety-relevant operations on and
with the gearboxes G. They contain safety instructions which must be observed.
ƒ All personnel working on and with the gearboxes G must have the Operating
Instructions available and observe the information and notes relevant for them.
ƒ The Operating Instructions must always be complete and perfectly readable.
1.2 Terminology used
Term In the following text used for
Gearboxes Gearbox of product family G
Drive system Drive system with gearboxes G and other Lenze drive components
1.3 Scope of supply
ƒ The drive systems are combined individually according to a modular design. The
scope of supply can be obtained from the pertinent papers.
ƒ After 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.
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Preface and general information
Lenze drive systems
1
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1.4 Lenze drive systems
Labelling
Lenze drive systems are uniquely designated by the content of their nameplates.
Manufacturer
Lenze Drive Systems GmbH
Hans-Lenze-Straße 1
31855 Aerzen
Application as directed
ƒLenzedrivesystems
– 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
ƒ The information, data, and notes in the Operating Instructions met on the state of
theartatthetimeofprinting.Claimsreferringtodrivesystemswhichhavealready
been supplied cannot be derived from the information, illustrations, and
descriptions.
ƒ We 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
ƒ Conditions of warranty: see terms of sale and delivery of Lenze Drive Systems GmbH.
ƒ Warranty claims must be made to Lenze immediately after detecting the deficiency
or fault.
ƒ The warranty is void where liability claims cannot be made.
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Safety
Personnel responsible for safety
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8BA 12.0030 EN 2.0
2Safety
2.1 Personnel responsible for safety
Operator
ƒ An operator is any natural or legal person who uses the drive system or on behalf of
whom the drive system is used.
ƒ The 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 andwho are able to recognise potential
hazards.
(See IEC 364, definition of skilled personnel)
2.2 General safety information
ƒ This safety information is not claimed to be complete. In case of questions and
problems, please contact your Lenze representative.
ƒ At the time of delivery the drive system meets the state of the art and ensures
basically safe operation.
ƒ The 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.
ƒ The 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.
ƒ Makesurebyappropriatemeasuresthatincaseoffailureofthedrivesystemno
material damage is caused.
ƒ Operate the drive system only when it is in a proper state.
ƒ Retrofittings, modifications, or redesigns of the drive system are basically
prohibited. Lenze must be contacted in all cases.
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Safety
Definition of notes used
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2.3 Definition of notes used
The following signal words and symbols 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 trouble-free operation
X Tip!
Useful tip for simple handling
H
Reference to another documentation
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Technical data
Product features
3
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10 BA 12.0030 EN 2.0
3 Technical data
ƒ The most important technical data are indicated on the nameplate (for Design and
Contentsseepage3).
ƒ Additional technical data are listed in the product catalogues.
3.1 Product features
Design
Drive systems have a modular design.
They consist of:
ƒ Speed reduction gearboxes
–Planetarygearbox
ƒ Motors
– Servomotor
ƒ Frequency inverters
Mode of operation
ƒ Torque and speed conversion
ƒ The reaction torque must be supported by the flange mounting in a suitable way.
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Technical data
Transport weights
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3.2 Transport weights
Geared servo motor Drive size (square measure)
GPA 



-

SGCN 06 09 12 14 19
GPA 00 - 1 < 6 <10
GPA 01 - 1 <8 <12 <19
GPA 02 - 1 <15 <22 <37
GPA 03 - 1 <30 <45 <59
GPA 04 - 1 <75
GPA 05 - 1 <90
GPA 00 - 2 <7
GPA 01 - 2 <9 <13
GPA 02 - 2 <17 <24
GPA 03 - 2 <36 <51
GPA 04 - 2 <84
GPA 05 - 2 < 112
Geared servo motor Drive size (square measure)
GPA 



-

AGCN 10 13 14 17 19 21
GPA 00 - 1 < 10
GPA 01 - 1 <11 <17
GPA 02 - 1 <14 <20 <25 <35
GPA 03 - 1 <28 <33 <43 <68 <81
GPA 04 - 1 <84 <96
GPA 05 - 1 <99 < 111
GPA 00 - 2 <11
GPA 01 - 2 <12 <18
GPA 02 - 2 <23 <28 <37
GPA 03 - 2 <74
GPA 04 - 2 <92 < 105
GPA 05 - 2 < 120 < 132
Tab. 1 Transport weight in [kg]
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Technical data
General data/operating conditions
Temperatures
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12 BA 12.0030 EN 2.0
3.3 General data/operating conditions
3.3.1 Temperatures
The permissible temperature range is determined by the following:
ƒ The lubricant specifications in connection with the expected oil temperatures in
operation (see chapter 7.1 and nameplate).
ƒ The thermal class of the motor considering the motor temperature expected during
operation (see nameplate and/or Operating Instructions of the motor).
The operating temperature is determined by the power loss, the ambient temperature and
the cooling system!
3.3.2 Ambient conditions
ƒ Gearboxes are protected against dust and spray water.
ƒ Motors according to their enclosure (see nameplate and/or Operating Instructions of
the motor).
ƒ Ambient media - especially chemically aggressive - can destroy shaft seals and
coatings (plastic). Abrasive media endanger shaft seals.
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Mechanical installation
Storage
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4 Mechanische 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 exclusivelydetermined 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 gearbox immediately, ensure appropriate conditions of storage.
ƒUptooneyear:
– Without special measures in dry and dust-free rooms and protected from sunlight.
ƒOverayear:
– Requires consultation with the plant.
4.2 Mounting
4.2.1 Preparation
 Stop!
Thoroughly remove anticorrosion agents from output shafts and flange faces.
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Mechanical installation
Mounting
General information about the assembly of drive systems
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14 BA 12.0030 EN 2.0
4.2.2 General information about the assembly of drive systems
ƒ Take safety measures prior to any operation:
– Disconnect the machine from the mains, ensure standstill of the machine and
avoid any machine movement.
– Check the proper state of the drive system. Never install and set up damaged drive
systems.
– Check the combination of drive function and machine functions. Check the
direction of rotation.
ƒ The mounting surfaces must be even, without torsion, and free from vibration.
ƒ Align the drive system on the mounting surfaces exactly with the machine shaft to
be driven.
– Ensure that the assembly is without torsion, to avoid additional load.
– Compensate for minor misalignments by using suitable flexible couplings.
ƒ Support the reaction torque appropriately.
ƒ Fixings of accessories and attachments must be secured against loosening. We
recommend that screw connections are glued.
 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.
4.2.3 Assembly of transmission elements on solid shafts
ƒ Draw the transmission elements onto the output shaft only by using the centering
thread.
 Stop!
Shocks and blows to the shafts damage the roller bearings.
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Electrical installation 5
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5 Electrical installation
 Danger!
Electrical connections must only be made by skilled personnel!
5.1 Motor connection
To correctly connect the motor options, please observe:
ƒ the notes in the terminal box of the motor
ƒ the notes in the Operating Instructions of the motor
ƒ the technical data on the motor nameplate.
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Commissioning
Before switching on
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16 BA 12.0030 EN 2.0
6 Commissioning and operation
 Stop!
The drive may only be commissioned by skilled personnel!
6.1 Before switching on
Check:
ƒ Is the mechanical fixing o.k.?
ƒ Are the electrical connections o.k.?
ƒ Are all rotating parts and surfaces, which may become hot, protected against
contact?
6.2 During operation
ƒ During operation, check the drive periodically and take special care of:
– unusual noises or temperatures,
–leakages,
– loose fixing elements,
– the condition of the electrical cables.
ƒ If any interference should occur, proceed according to the troubleshooting list in
chapter 8. If the interference cannot be eliminated, please contact the Lenze Service.
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Maintenance
Maintenance intervals
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7 Maintenance
Gearboxes and geared motors from Lenze are filled with a drive-specific and
design-specific lubricant filling at delivery. The mounting position and design are decisive
at ordering for the required lubricant quantity.
 Note!
When changing the lubricant, Lenze recommends also changing the grease
packing of the bearings and replacing the radial shaft seal rings!
7.1 Maintenance intervals
ƒ The mechanical power transmission system is free of maintenance.
ƒ Shaft seals:
– The service life depends on the ambient conditions.
– Replace seals in case of leakage to avoid consequential damage.
ƒ Lubricating intervals:
– Gearboxes of type GPA are lubricated for life and hermetically sealed. In normal
operation, a lubricant change is not required.
– With extremely severe operation, we recommend changing the lubricant every
10,000 operating hours.
– The type of lubricant is indicated on the nameplate. Replace the lubricant only by
thesametype.
 Stop!
For drive systems: Also observe the maintenance intervals for the other drive
components!
Lubricants Changing intervals
Type Specification Ambient
temperature
Note
g
g
CLP PAO 150 Oil on synthetic basis
(polyglycol)
-20 °C...40 °C Do not mix with
mineral oils!
10,000 operating hours, no longer
than three years
(oil temperature 70...100 °C)
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Maintenance
Maintenance intervals
Replacing the lubricant
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18 BA 12.0030 EN 2.0
7.1.1 Replacing the lubricant
 Stop!
ƒ Gearbox should be warm.
ƒ Secure drive system and machine from inadvertent movement and mains
connection.
1. Drain lubricant by removing the oil drain/filler plug.
2. Fill recommended lubricant in the specified amount.
3. Insert oil drain/filler plug with new seal.
4. Dispose of waste oil according to applicable regulations.

Fig. 1 Position of oil filler/drain plug
Oil filler/drain plug
Recommended lubricant
Manufacturer Mobil Optimol
Type Mobil SHC 629 Optigear Synthetic A 150
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Maintenance
Maintenance intervals
Lubricant quantity
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7.1.2 Lubricant quantity
Gearbox Mounting position
A C D
GPA 00 - 1 22 25 35
GPA 01 - 1 35 55 75
GPA 02 - 1 80 130 160
GPA 03 - 1 130 210 300
GPA 04 - 1 220 350 500
GPA 05 - 1 300 600 700
GPA 00 - 2 35 42 50
GPA 01 - 2 45 80 90
GPA 02 - 2 100 175 190
GPA 03 - 2 160 310 410
GPA 04 - 2 270 700 720
GPA 05 - 2 420 1200 1350
Tab. 2 Lubricant quantity in [ml]
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Troubleshooting and fault elimination8
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20 BA 12.0030 EN 2.0
8 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 Remedy
Drive is at standstill Voltage supply interrupted Check connection
Wrong electrical connection Check if nameplate matches voltage supply
Excessive load Reduce load
Check drive - machine combination
Motor running, gearbox at
standstill
Fixing elements are missing or
defective
Check attachment
Gearbox is defective Contact Lenze Service
Unusual noise Overload Reduce load
Check drive - machine combination
Damage in the gearbox or
motor
Contact Lenze Service
Excessive temperature Overload Reduce load
Check drive - machine combination
Insufficient heat dissipation Improve cooling air supply
Clean gearbox / motor
Insufficient lubricant Refill lubricant as specified
Loose fixing elements Vibrations Avoid vibrations
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