Lenze G Series User manual

.S>) Ä.S>)ä
Operating Instruction EN
G... GKK
Bevel gearbox with clutch


Please read these instructions before you start working!
Follow the enclosed safety instructions.
0Abb. 0Tab. 0

Contents i
3
Lenze • BA 12.0032 • 4.0
1 About this documentation 5......................................................
1.1 Document history 5.....................................................
1.2 Conventions used 6......................................................
1.3 Terminology used 6.....................................................
1.4 Notes used 7...........................................................
2 Safety instructions 8.............................................................
2.1 General safety instructions for drive components 8...........................
2.2 Application as directed 11................................................
2.3 Foreseeable misuse 11....................................................
2.4 Residual hazards 12......................................................
2.5 Disposal 13..............................................................
3 Product description 14.............................................................
3.1 Identification 14.........................................................
3.1.1 Product features 14..............................................
3.1.2 Mounting positions 15...........................................
3.1.3 Nameplate 16...................................................
3.1.4 Gearbox code 18.................................................
3.1.5 Encoder code 18.................................................
3.2 Transport weights 19.....................................................
4 Technical data 20.................................................................
4.1 Important notes 20.......................................................
4.2 Characteristics for light load application 20..................................
4.3 Characteristics for heavy load application 20.................................
4.4 General data and operating conditions 21..................................
5 Mechanical installation 22.........................................................
5.1 Storage 22..............................................................
5.1.1 Direction of rotation 23...........................................
5.2 Mounting 23............................................................
5.2.1 Preparation 23..................................................
5.2.2 General information about the assembly of drive systems 24...........
5.2.3 Assembly of transmission elements on solid shafts 24.................
5.2.4 Gearboxes with breathers 25......................................
5.2.5 Breather position, oil filling screw and drain plug 26..................
6 Electrical installation 27...........................................................
6.1 Motor connection 27.....................................................
6.2 Motor options 27........................................................
6.3 Frequency inverter connection 27..........................................
7 Commissioning and operation 28...................................................
7.1 Before switching on 28...................................................

Contentsi
4Lenze • BA 12.0032 • 4.0
7.2 During operation 28......................................................
7.3 Clutches at the GKK gearbox 28............................................
7.4 Operation of clutch at GKK gearbox 29......................................
7.4.1 Switching via clutch lever 29......................................
7.4.2 Manual switching 29.............................................
8 Maintenance 30..................................................................
8.1 Maintenance intervals 30..................................................
8.2 Maintenance operations 31................................................
8.2.1 Opening the condensation drain hole 31............................
8.2.2 Lubricate roller bearings 32.......................................
8.2.3 Table of lubricants 32............................................
8.2.4 Replacing the lubricant 34.........................................
8.2.5 Lubricant quantity 35.............................................
8.3 Repair 35...............................................................
9 Troubleshooting and fault elimination 36............................................

About this documentation
Document history
1
5
Lenze • BA 12.0032 • 4.0
1 About this documentation
Contents
• This documentation serves for safety-relevant operations on and with the
gearboxes. It contains safety instructions which must be observed.
• All personnel working on and with the gearboxes must have the documentation
available during the work and observe the information and notes relevant for
them.
• The documentation must always be complete and in a perfectly readable state.
Tip!
Information and tools concerning the Lenze products can be found in the
download area at
www.lenze.com
Validity
This documentation applies to bevel gearboxes:
Type Name
GKK Bevel geared motor with clutch
Target group
This documentation is directed at qualified skilled personnel according to IEC 60364.
Qualifiedskilledpersonnelarepersonswhohavetherequiredqualificationstocarryout
all activities involved in installing, mounting, commissioning, and operating the
product.
1.1 Document history
Material number Version Description
13014719 1.0 08/2004 TD09 First printing
13053411 2.0 05/2005 TD09 Revision of sections Mounting positions,
Transport weights, Breather position and
Lubricant tables
13430271 3.0 03/2013 TD09 Complete editorial revision
.S>) 4.0 11/2015 TD09 New layout revision
Operating condition: ”Mechanical” deleted
Supplement of encoder code

About this documentation
Conventions used
1
6Lenze • BA 12.0032 • 4.0
1.2 Conventions used
This documentation uses the following conventions to distinguish different types of
information:
Type of information Writing Example/notes
Spelling of numbers
Decimal Normal spelling Example: 1234
Decimal separator Point The decimal point is always used.
For example: 1234.56
Icons
Page reference Reference to another page with additional
information
For instance: 16=seepage16
Documentation reference Reference to another documentation with
additional information
Example: EDKxxx = see EDKxxx documentation
Wildcard Wildcard for options, selection data
1.3 Terminology used
Term Describes the following
Gearboxes Gearbox of product range G
Drive system Drive systems with gearboxes Gand other Lenze drive components

About this documentation
Notes used
1
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Lenze • BA 12.0032 • 4.0
1.4 Notes used
The following pictographs and signal words are used in this documentation to indicate
dangers and important information:
Safety instructions
Layout of the 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
Tip! Useful tip for easy handling
Reference to another document

Safety instructions
General safety instructions for drive components
2
8Lenze • BA 12.0032 • 4.0
2 Safety instructions
2.1 General safety instructions for drive components
(in compliance with Low-Voltage Directive 2006/95/EC)
Atthetimeofdispatch,thedrivecomponentsareinlinewiththelateststateoftheart
and can be regarded as operationally safe.
Scope
The following general safety instructions apply to all Lenze drive and automation
components.
The product-specific safety and application notes given in this documentation must be
observed!
General hazards
Danger!
Disregarding the following basic safety measures may lead to severe
personal injury and damage to material assets!
• Lenze drive and automation components ...
... must only be used for the intended purpose.
... must never be operated if damaged.
... must never be subjected to technical modifications.
... must never be operated unless completely assembled.
... must never be operated without the covers/guards.
... can - depending on their degree of protection - have live, movable or rotating parts
during or after operation. Surfaces can be hot.
• All specifications of the corresponding enclosed documentation must be
observed.
This is vital for safe and trouble-free operation and for achieving the specified
product features.
• Only qualified skilled personnel are permitted to work with or on Lenze drive and
automation components.
According to IEC 60364 or CENELEC HD 384, these are persons ...
... who are familiar with the installation, assembly, commissioning and operation of
the product,
... possess the appropriate qualifications for their work,
... and are acquainted with and can apply all the accident prevent regulations,
directives and laws applicable at the place of use.

Safety instructions
General safety instructions for drive components
2
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Lenze • BA 12.0032 • 4.0
Temperatures
The permissible temperature range is determined by the following:
• The lubricant specifications in connection with the expected oil temperatures in
operation (see chapter 8.1 and nameplate).
• 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!
Stop!
With mineral oil, the upper temperature limit for continuous operation is
80°C, with synthetic oil and shaft sealing rings made of FP (Viton) 100°C.
If these temperatures are exceeded, measures are necessary to reduce
the temperature, see chapter 9.
Danger!
Depending on the operating conditions, surfaces may be hot, provide
protection against accidental contact.
Ambient media
• Gearboxes are protected against dust and spray water.
• Motors according to their enclosure (see nameplate and/or Operating Instructions
for the motor).
• Ambient media - especially chemically aggressive - can destroy shaft seals and
coatings (plastic). Abrasive media endanger shaft seals.
• The installation site of the drive must be free of shocks and vibration.
• Dirt of dust deposits impede the heat dissipation (cooling).
Transport, storage
• Transport and storage in a dry, low-vibration environment without aggressive
atmosphere; preferably in the packaging provided by the manufacturer.
–Protect against dust and impacts.
–Observe climatic conditions according to the technical data.
• Use load carrying equipment for transport! (22)
Before transport
• check that all component parts are safely mounted;
• check that all component parts with a loose fastening are secured or removed;
• tighten all transport aids (eye bolts or support plates).
Use an appropriate means of transport and lifting equipment! (22)

Safety instructions
General safety instructions for drive components
2
10 Lenze • BA 12.0032 • 4.0
If you do not install the motor immediately, ensure proper storage conditions.
• Up to one year:
–Shafts and uncoated surfaces are delivered in a protected against rust status.
Aftertreatment is required where the corrosion protection has been damaged.
–Remove the plug for motors with condensation drain holes (special version).
• More than one year, up to two years:
–Apply a long-term corrosion preventive (e.g. Anticorit BW 366 from the Fuchs
company) to the shafts and uncoated surfaces before storing the motor away.
Corrosion protection
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.
Mechanical installation
• Provide for careful handling and avoid mechanical overload. During handling
neither bend components, nor change the insulation distances.
Electrical installation
• Carry out the electrical installation according to the relevant regulations (e. g.
cable cross-sections, fusing, connection to the PE conductor). Additional notes are
included in the documentation.
• The Instructions contain notes concerning wiring according to EMC regulations
(shielding, earthing, filters and cable routing). The compliance with limit values
required by the EMC legislation is the responsibility of the manufacturer of the
machine or system.
Warning: The inverters are automation components which can be used in industrial
environment according to EN 61000-6-4. These products may cause radio
interference in residential areas. If this happens, the operator may need to take
appropriate action.
• Only plug in or remove pluggable terminals in the deenergised state!
Commissioning
• If required, you have to equip the system with additional monitoring and
protective devices in accordance with the respective valid safety regulations (e. g.
law on technical equipment, regulations for the prevention of accidents).
• Before commissioning remove transport locking devices and keep them for later
transports.

Safety instructions
Application as directed
2
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Lenze • BA 12.0032 • 4.0
Geared motors for deep-freeze applications
• Geared motors for deep-freeze applications are specially optimised to operation
at very low temperatures. Observe that for operation outside the temperature
range specified (e.g. during commissioning) increased wear or even failures may
occur.
• We recommend loading the gearbox with a maximum of 50 % of the rated output
torque if it is outside the specified temperature range during commissioning.
2.2 Application as directed
All products which this documentation applies to are no household appliances but are
exclusively intended as components for re-utilisation for commercial use or
professional use in terms of IEC/EN 61000-3-2. They meet the requirements of the
Low-Voltage Directive 2006/95/EC and the requirements ofthe harmonised standards
of the IEC/EN 60034 series.
Only use the products under the operating conditions and power limits specified inthis
documentation.
Donotusethebrakesinstalledasfail-safebrakes.Itcannotberuledoutthatthebraking
torque is reduced by disruptive factors which cannot be influenced.
•Drives
–... must only be operated under the operating conditions and power limits
specified in this documentation.
–... comply with the protection requirements of the EU Low-Voltage Directive.
Any other use shall be deemed inappropriate!
2.3 Foreseeable misuse
• Do not operate the motors
–... in explosion-protected areas
–... in aggressive environments (acid, gas, vapour, dust, oil)
–... in water
–... in radiation environments
Note!
Increased surface and corrosion protection can be achieved by using
adapted coating systems.

Safety instructions
Residual hazards
2
12 Lenze • BA 12.0032 • 4.0
2.4 Residual hazards
Protection of persons
•Riskofburnst!
–Hot surfaces up to 140 °C during operation! Provide protection against contact.
• High-frequency voltages can be capacitively transferred to the motor housing
through the inverter supply.
–Earth motor housing carefully.
• Risk of injury due to rotating shaft!
–Before working on the motor ensure that the motor is at standstill.
• Danger of unintentional starting or electrical shocks!
–Connections must only be made when the equipment is deenergised and the
motor is at standstill.
–Installed brakes are no fail-safe brakes.
• Dangerous voltages at the power terminals, even if the plug is removed: residual
voltage >60 V!
Motor protection
• Installed thermal detectors do not offer full protection to the machine.
–If required, limit the maximum current, parameterise the inverter so that it will
be switched off after some seconds of operation with I > IN, especially if there is
the danger of blocking.
–Installed overload protection does not prevent an overload under any
conditions.
• Installed brakes are no fail-safe brakes.
–The torque can be reduced due to disruptive factors that cannot be influenced,
e.g. by ingressing oil due to a defect shaft sealing ring on the A side.
• Fuses are no motor protection.
–Use current-dependent motor protection switches at an average operating
frequency.
–Use installed thermal detectors at a high operating frequency.
• Excessive torques lead to a break of the motor shaft or demagnetisation.
–The maximum torques according to catalogue must not be exceeded.
• Lateral forces from the motor shaft may occur.
–Align shafts of motor and driving machine exactly to each other.
• If deviations from normal operation occur, e.g. increased temperature, noise,
vibration, determine the cause and, if necessary, contact the manufacturer. If in
doubt, switch off the motor.
• Design with plug:
–Never disconnect plug when energised! Otherwise, the plug can be destroyed.
–Switch off power supply and inhibit controller prior to disconnecting the plug.

Safety instructions
Disposal
2
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Lenze • BA 12.0032 • 4.0
Fire protection
• Fire hazard
–Prevent contact with flammable substances.
2.5 Disposal
Sort individual parts according to their properties. Dispose of them as specified by the
current national regulations.

Product description
Identification
3
14 Lenze • BA 12.0032 • 4.0
3 Product descri ption
Stop!
The MOC geared motors GKK are classified as light load or heavy load;
see the characteristics in the following tables .
• The most important technical data is given on the nameplate.
• The product catalogues contain further technical data.
3.1 Identification
3.1.1 mêçÇìÅí ÑÉ~íìêÉë
Design
Drive systems have a modular design.
They consist of:
• Speed reduction gearbox
–Bevel gearbox in different ratios with integrated clutch
• Electric motor
–Three-phase AC motor
Mode of operation
• Torque and speed conversion
Product family 1st stage 2nd stage
Bevel gearbox Helical Bevel
Note!
The reaction torque must be supported by foot mounting, flange
mounting, or torque plate.
•Clutch
Jaw coupling between 1st and 2nd gearbox stage that is activated from the outside by
means of an operating lever.

Product description
Identification
Mounting positions
3
15
Lenze • BA 12.0032 • 4.0
3.1.2 Mounting positions
GKK mounting positions
A B
C D

Product description
Nameplate
3
16 Lenze • BA 12.0032 • 4.0
3.1.3 Nameplate
Three-phase AC motor for direct gearbox attachment
L
C86
cos j
Hz
kW
r/min
V
A
1
16.1
16.2
16.3
10.1
8.1
15
8.2 8.3
11
16.4
16.5
16.6
16.4
16.5
h%
10.2
9
2
3
4
67.1 7.2
5.1
5.3
5.2
5.4
18
25
27
14.3
14.2
14.1
13
23
16.7
22 22
26
19
15
29
17
21
20.2
20.1
Three-phase AC motor with standard output flange
L
h%
cos j
Hz
kW
r/min
V
A
9
2
1
4
16.1
16.2
16.3
10.1
9
22
8.1
24
18
14.2
15
21
8.2 8.3
23 26
14.1
11
10.2 10.3
16.4
16.5
16.6
16.7
29
27
14.3
16.4
16.5
13
20.1

Product description
Nameplate
3
17
Lenze • BA 12.0032 • 4.0
Pos. Contents
1Manufacturer / production location
2Type of motor / standard
3Gearbox type
4Motor type
5Technical data
5.1 Ratio
5.2 Rated torque
5.3 Rated speed
5.4 Rated frequency
5.10 Number of poles
6Mounting position / position of the system blocks
7Lubricant details
7.1 Lubricant amount
7.2 Lubricant type
8Brake data
8.1 Type
8.2 AC/DC brake voltage
8.3 Braking torque, electrical power input
9Forfeedback/pulseencoderorresolverdata,18
10 Production data
10.1 Order number
10.2 Material number
10.3 Serial number
11 Bar code
12 Motor number
13 Information with regard to the operating mode
14 Additional motor specifications
14.1 Temperature class
14.2 Enclosure
14.3 Motor protection
15 Applicable conformities, approvals and certificates
16 Rated data for various frequencies
16.1 Hz = frequency
16.2 kW = motor power
16.3 rpm = motor speed
16.4 V = motor voltage
16.5 A = motor current
16.6 cos = motor power factor
16.7 = motor efficiency: at a rated power of 100%
16.8 = motor efficiency: at a rated power of 75%
16.9 = motor efficiency: at a rated power of 50%
17 Application factor (specified if <1.0) / load capacity
18 Year of manufacture / week of manufacture
19 UL file number
20 Customer data
20.1 Additional customer data
20.2 Customer order number
21 UL category (e.g. inverter duty motor)
22 C86 = motor code for controller parameterisation (code 0086)
23 Efficiency class
24 Partial load efficiencies for 50Hz operation at a rated power of 50% and 75%
26 CC number Department of Energy (optional)
27 Permissible ambient temperature (e.g. Ta 40°C)
29 Standstill current (ampere locked rotor ALR)
31 Plug design (number of poles)

Product description3
18 Lenze • BA 12.0032 • 4.0
3.1.4 Gearbox code
Example GKK 04 - 1 M VCR 071N32; 080-12 1C
Meaning Type Gearbox code
Gearbox type Bevel geared motor with clutch GKK
Gearbox size 04 / 05 / 06 / 07 XX
Number of stages 1-stage
-
1
2-stage 2
3-stage 3
Drive design Three-phase AC motor M
Output design Solid shaft (with keyway) V
Without foot, with centering C
Without flange R
With flange (through holes) K
With flange (threaded holes) L
Drive size
Example Motor 071N32; 080-12
Mounting flange/free drive shaft 1C
3.1.5 Encoder code
Example SFC 1024 -8V - K 2
Meaning Type Encoder code
Product line Resolver RS
Resolver for safety function RV
Incremental encoder IG
Incremental encoder with commutation signal IK
Singleturn absolute value encoder SFC
Multitum absolute value encoder AM
Number 2-pole resolver for servo motors 0
2-pole resolver for three-phase AC motors 1
Number of pole pairs for resolvers 2, 3, 4,...
Number of steps / increments per revolution 32, 128,
512,
1024,
2048, ...
Voltage Medium supply voltage
-
5V, 8V,
15V,
24V, ...
Interface or
signal level
Standard
-
TTL T
HTL (for incremental encoders) H
Hiperface (for absolute value encoders) H
EnDat E
sin/cos 1 Vss S
For safety function
TTL U
HTL (for incremental encoders) K
Hiperface (for absolute value encoders) K
EnDat F
sin/cos 1 Vss V
Safety integration level (SIL) 1
2
3
4

Product description
Transport weights
Encoder code
3
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Lenze • BA 12.0032 • 4.0
Note!
If feedback systems for safety functions are used, the manufacturer’s
documentation must be observed!
3.2 Transport weights
Note!
Weight depends on the drive version.
Gearbox size Motor size
063 071 080 090 100 112
GKK 04 15 17 22 --- ---
GKK 05 21 23 28 34 --- ---
GKK 06 51 53 58 64 71 ---
GKK 07 --- --- 88 94 101 115
Tab. 1 Transport weights in [kg]; values may differ from table value

Technical data
Important notes
4
20 Lenze • BA 12.0032 • 4.0
4 Technical data
4.1 Important notes
• The most important technical data are indicated on the nameplate (structure and
contents 16).
• The product catalogues contain further technical data.
The output torque and radial forces are rated data and dependent upon:
• Speed
• Mounting position
• Ambient temperature
•Ratio
• Motor power
• Application of force of radial load
Depending on the application, the permissible load can be reduced.
4.2 Characteristics for light load application
Gearbox
type
Max. torque Max. radial force Driven
shafts
Ratios Speed variants
[Nm] [N] dxl[mm] [i]
GKK
04-2M... 70 5600 20 x 35
7.72
15.16
19.52
40.84
FU
GKK
05-2M... 160 8000 25 x 35
12.38
19.74
24.56
38.57
FU
4.3 Characteristics for heavy load application
Gearbox
type
Max. torque Max. radial force Driven
shafts
Ratios Speed variants
[Nm] [N] dxl[mm] [i]
GKK
05-2M... 200 10000 25 x 35
12.38
19.74
24.56
38.57
FU
GKK
06-2M... 500 20000 35 x 70
17.50
27.90
34.71
54.51
FU
GKK
07-2M... 900
25000 45 x 90 15.43
27.00
43.07
86.79
FU
GKK
07-2M... 36000 55 x 110 FU