PGR PH Series User manual

ATEX
ENMAINTENANCE AND OPERATION INSTRUCTIONS
PH / PB SERIES
Industral Type Gear Unts
GEAR UNIT WITH MOTORS / WITHOUT MOTORS
Certf cate No: KY3723/05/10-R15
1
Doc. No: PG.AG.KK.002_01
Publcaton DateRev. / : 06.2023 TSE K 558

The copyrghts of the usage Mantenance nstructon are belong to PGR company.
Usage gude could not be used partally or fully wthout our permsson to the purpose of competton and not
submtted to the use of thrd partes.
The rght of changng nformatons whch stated n the usage mantenance nstructon partally or fully wthout
gvng any notce before or rght of full changng and abolshment are kept reserved by us.

www.pgr.com.tr < 01
Important Warnngs
General Informaton
Correct Use
Safety Informaton
Qualfied Personnel
Specal Types of Hazards and Personal Protectve Equpment
Responsblty
Transportaton, Freghtage and Storage
Scope of Delvery
Freghtage
Connecton Ponts
Specal Condtons for Lubrcatng and Protectng the Reducer
Specal Condtons of Protecton of the Reducer
Transportaton
Transport of Gearboxes
Storage
Long Term Storage Suggestons
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.5
1.6
1.6.1
1.6.2
1.6.3
1.6.4
1.6.5
1.7
1.7.1
1.8
1.8.1
8 - 10
11
11
12
12
13 - 15
15
16 - 17
16
16 - 17
17
17
17
18 - 19
18 - 19
20
21
Output Shaft Versons
Housng
Reducer Equpment
Ol Supply to Reducer
Splashed Lubrcaton
Pressure Lubrcaton
Pump
Ol Flter
Bearng Arrangement of Shafts
Seals
Rotary Shaft Seals
Labyrnth Seal
Taconte Seals
Tacolab Seal
Backstop
Torque Lmter Backstop (Specal Verson)
Coolng
Fan
Cooler Col
Mounted Ol Supply System
Ol Supply System Mounted wth Ar-Ol Cooler
Ol Supply System Mounted wth Water-Ol Cooler
Pump
Ol Flter
External Ol Supply System
Couplngs
Shrnk Dsc
Heatng
Ol Level Indcator
3.1
3.2
3.2.1
3.3
3.3.1
3.3.2
3.3.2.1
3.3.2.2
3.4
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.6
3.7
3.8
3.8.1
3.8.2
3.8.3
3.8.3.1
3.8.3.2
3.8.3.3
3.8.3.4
3.8.4
3.9
3.10
3.11
3.12
27
27
28 - 29
29
29
30 - 31
31
31
31
31
31 - 32
32
32 - 34
34 - 35
35
36
37
37
38
39
39 - 40
40 - 41
41
41
42
42
42
42 - 44
44
Gear Unt Label
Compatblty Declaraton
Explanatons
Abbrevatons
2.1
2.2
2.3
2.4
22
22
23 - 25
26
PRODUCT DESCRIPTION
2. UNIT
GENERAL INFORMATION
1. UNIT
TECHNICAL INFORMATION AND ACCESSORIES
3. UNIT
CONTENTS

www.pgr.com.tr
02 >
Ol Level Indcator System
Ol Temperature Indcator
Bearng Indcator
Bearng Control Usng Pt 100 Resstance Thermometer
Bearng Montorng wth Shock Impact Converter
Bearng Montorng wth Speed Sensor
Encoder
Auxlary Drve Reducer
Auxlary Drve Reducer Desgned as Mantenance Gear Reducer
Auxlary Drve Reducer Desgned as a Load Reducer
3.13
3.14
3.15
3.15.1
3.15.2
3.15.3
3.16
3.17
3.17.1
3.17.2
44
45
46
46
46
47
47
47 - 48
48 - 49
49 - 50
Assembly
Prerequstes of Assembly
General Assembly Instructons
Unpackng the Reducer
Installaton of Reducer
Foundaton
Descrpton of Assembly Work
Algnment
Reducer Mountng on Housng Foot
Installaton on Foundaton Housng
Installaton on Concrete Foundaton Usng Concrete Bolts or Foundaton Blocks
Mountng on Concrete Foundaton Usng Jont Bolts
Mountng the Reducer on the Connecton Platform
Mountng on Block Flange
Assembly of Reducer wth Block Flange
Torque Arm Assembly for Reducer Housng
Torque Arm Assembly
Hollow Shaft Coupled Reducer
Shaft Coupled Gearbox wth Hollow Shaft and Wedge Connecton
Preparaton
Assembly
Dsassembly
Hollow Shaft and Sldng Shaft Coupled Reducer Accordng to DIN 5480
Preparatons
Assembly
Dsassembly
Hollow Shaft and Concal Compresson Shaft Coupled Reducer
Assembly
Dsassembly
F Type Flange Shaft Reducer
Requrements
Installaton of Reducer
Couplngs
Connectng Components
Reducers wth Mounted Components
Makng Termnal Box Connectons for Pre-Wred Reducers
Connectng the Cooler Col
Connectng the Ar-Ol Cooler
Connectng the Water-Ol Cooler
Connectng the Heatng Element
Connectng the Pressure Indcator
Establshng a Separate Ol Supply System
Connectng the Ol Level Indcator System
4.1
4.1.1
4.1.2
4.2
4.3
4.3.1
4.3.2
4.3.2.1
4.3.3
4.3.3.1
4.3.3.2
4.3.3.3
4.3.3.4
4.3.4
4.3.4.1
4.3.5
4.3.5.1
4.4
4.4.1
4.4.1.1
4.4.1.2
4.4.1.3
4.4.2
4.4.2.1
4.4.2.2
4.4.2.3
4.4.3
4.4.3.1
4.4.3.2
4.5
4.5.1
4.5.2
4.6
4.7
4.7.1
4.7.2
4.7.3
4.7.4
4.7.5
4.7.6
4.7.7
4.7.8
4.7.9
51
51 - 52
53
54
54
54
55 - 56
56 - 57
57
57 - 58
58 - 59
60 - 61
61 - 62
63
64
64
64 - 65
65
65
65
66 - 67
67 - 69
70
70
70 - 72
72 - 74
74
74 - 76
76
76
76
77
77 - 78
78
78
78
79
79
79
80
80
80
80
ASSEMBLY
4. UNIT
TECHNICAL INFORMATION AND ACCESSORIES
3. UNIT
CONTENTS

www.pgr.com.tr < 03
Connectng the Pt 100 Resstance Thermometer
Connectng the Temperature Indcator
Connecting the Bearing Monitoring System
Connectng the Encoder
Connectng the Motor Pump
Electrcal Connectons
Clampng Procedure
Bolts
Bolt Connecton Classes
Preload Forces and Tghtenng Torques
Temperature Stcker
Vsual Inspecton of the Temperature Stcker
Fnal Thngs to be Completed
4.7.10
4.7.11
4.7.12
4.7.13
4.7.14
4.7.15
4.8
4.8.1
4.8.2
4.8.3
4.9
4.9.1
4.10
81
81
81
81
81
82
82
82
83
83 - 84
85
85
86
ASSEMBLY
4. UNIT
Commssonng
Pre-Commssonng Measures
Locked Reducer
Auxlary Drve Reducer
Ol Level Indcator System
Cooler Col Reducers
Heated Reducer
Reducer wth Ol Supply System
Ol Fllng n Lock or Auxlary Drve Reducers
Precautons Durng Commssonng
Torque Lmter Locked Reducers
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.2
5.2.1
87
87
87
88
88
88
89
89
89
90
90
6.1
6.1.1
6.2
Operatng
Operatng Data
Dsorders n Operaton
91
91
91
7.1
7.1.1
7.2
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
7.3.7
7.3.8
7.3.9
7.3.10
7.3.11
7.3.12
7.3.13
7.3.14
7.3.15
7.3.16
Servce
General Mantenance Informaton
Control and Perodc Mantenance
Mantenance and Servce Work
Checkng the Ol Temperature
Fllng the Lock wth Ol
Checkng the Outer Cage of the Torque-Lmtng Backstop
Fllng the Auxlary Drve Reducer's Mechancal Clutch wth Ol
Checkng Auxlary Drve Reducer
Cleanng the Fan and Reducer
Checkng the Cooler Col
Control of Shrnk Dsc
Cleanng the Straner Flter
Cleanng the Double Flter
Checkng Speed Indcator of Auxlary Drve Reducer
Measurng the Vbraton Levels of Bearngs
Measurng Temperature n Bearngs
Check all Fastenng Bolts are Tght
General Inspecton of Reducer
Fnal Thngs to be Completed
92
92
92 - 93
93
94
94
94 - 95
95
95
95
96
96
96
97
97
97
97
98
98
98
5. UNIT COMMISSIONING
6. UNIT OPERATING THE REDUCER
7. UNIT CONTROL AND MAINTENANCE
CONTENTS

www.pgr.com.tr
04 >
CONTENTS
Product Dsposal
Dsposal
Possble Errors
Possble Malfunctons and ther Remedes
Troubleshootng
8.1
8.1.1
8.2
8.2.1
8.2.1.1
TROUBLESHOOTING
8. UNIT
Spare Parts
Requred Informaton for Orderng Spare Parts
10.1
10.1.1
SPARE PART
10. UNIT
11.1
11.2
11.3
11.4
11.5
Ambent Temperature
Product Types
Weghts
Ol Quanttes
Measurng Surface Sound Pressure Level
11. UNIT TECHNICAL DESCRIPTIONS
Authorzed Servce
9.1
AUTHORIZED SERVICE
9. UNIT
Contact Informaton
13.1
CONTACT INFORMATION
13. UNIT
12. UNIT WARRANTY
12.1
12.2
99
99
100
100
100 - 104
106
106
107
108
109 - 110
110 - 112
113 - 116
105
119
117
118
Declaraton of Conformty
ATEX Document

www.pgr.com.tr < 05
17
18 - 19
18
18
19
19
19
22
27
28
28
28
29
29
30
31
32
32
32
33
34
35
36
37
38
39
39
40
41
43
44
45
46
46
47
48
49
55
56
57
58
59
60
60
62
63
64
Lst of llustratons
Fgure 1 : Cross and Sde Pull on Eyebolts
Fgure 24
: Aqueous Ol Coolng System Mounted on PB Type Reducer
Fgure 25
: Heatng System n PH / PB Type Reducers
Fgure 26
: Ol Level Montorng System n PH / PB Type Reducers
Fgure 27 : Ol Temperature Montorng System n PH / PB Type Reducers
Fgure 28 : Bearng Montorng Usng a Pt 100 Resstance Thermometer
Fgure 29
: Montorng Usng Shock Pulses Transducer
Fgure 30 : Encoder
Fgure 2 : Transport of Gearboxes
Fgure 2- a : Poston of Addtonal Lftng Ponts for Reducers of Type PH / PB
Fgure 2 - b: Postons of Addtonal Lftng Ponts for Geared Motor Reducers of Type PH
Fgure 2 - c: Postons of Addtonal Lftng Ponts for Geared Motor Reducers of Type PB
Fgure 2 - d: Poston of Addtonal Lftng Ponts for Reducers wth Torque Arm, Type PB
Fgure 2 - e: Poston of Addtonal Lftng Ponts for Auxlary Drve Reducers of Type PB / PH
Fgure 3 : Gearbox Nameplate and Explanaton
Fgure 4 : Output Shaft Versons
Fgure 5 : PH - H ≤ 12 Type Reducer Equpment
Fgure 6 : PH - H ≥ 13 Type Reducer Equpment
Fgure 7 : PB - H ≥ 13 Type Reducer Equpment
Fgure 8 : PB3 - H ≤ 12 Type Reducer Equpment
Fgure 9
: PB3 - H ≥ 12 Type Reducer Equpment
Fgure 10 : Ol Supply System n PH Type Reducers
Fgure 11 : Ol Supply System n PB Type Reducers
Fgure 12 : Rotary Shaft Seal
Fgure 13 : Labyrnth Seal
Fgure 14 : Taconte Seal
Fgure 15 : Taconte Seal Types
Fgure 16 : Tacolab Seal
Fgure 17 : Backstop
Fgure 18
: Torque Lmter Backstop
Fgure 19 : Fan
Fgure 20 : Cooler Col Connecton
Fgure 21 : Ar Ol Coolng System Mounted on PH Type Reducer
Fgure 22 : Ar Ol Coolng System Mounted on PB Type Reducer
Fgure 23
: Aqueous Ol Coolng System Mounted on PH Type Reducer
Fgure 31 : Basc Desgn of Man and Auxlary Reducers
Fgure 32 : Reducer Desgn (Connectng Auxlary Drve Reducer)
Fgure 33 : Gap Sze n Grease Labyrnth
Fgure 34
: Algnment Surfaces for Reducers up to Frame Sze 12
Fgure 35 : Algnment Surfaces for Reducers wth Frame Sze 13 and Above
Fgure 36 : Concrete Bolt
Fgure 37 : Base Block
Fgure 38 : Installng Anchor Bolt
Fgure 39 : Clampng Anchor Bolt
Fgure 40 : Torque Support for Reducer
Fgure 41
: Block Flange Reducer
Fgure 42 : Torque Arm for Reducer Housng
CONTENTS

www.pgr.com.tr
06 >
Fgure 55: Temperature Stcker
65
67
68
68
69
70
71
73
73
75
77
78
85
94
108
Lst of llustratons
Fgure 43: Hollow Shaft, Keyway Reducers
Fgure 44: Ball Screw Assembly Process
Fgure 45: Dsmantlng by usng a Puller
Fgure 46: Dsassembly Usng Hydraulc Pullng Equpment
Fgure 47: Keyway, Hollow Shaft
Fgure 48: Preparation for a Hollow Shaft Gear Unit with a Flat Hole on one Side and a Spline on the Other Side
Fgure 49: Pre-Assembled Bushng Sleeve Assembly
Fgure 50: Dsmantlng by usng a Puller
Fgure 51: Dsassembly Usng Hydraulc Pullng Equpment
Fgure 52: Preparaton for Hollow Shaft, Concal Compresson Reducers
Fgure 53: Couplng Assembly
Fgure 54: Algnment Process wth Flexble Couplng
Fgure 56: Torque Lmt Backstop
Fgure 57: Product Types
CONTENTS

www.pgr.com.tr < 07
Tablo 1 : Safety Alerts and Informaton Sgns
Tablo 2 : Symbols and Marks
Tablo 3 : General Warnngs
Tablo 4 : Product Descrpton (PH)
Tablo 5 : Product Descrpton (PB)
Tablo 6 : Product Descrpton (PB-PKD)
Tablo 7 : Abbrevatons
Tablo 8 : Taconte Seal Models
Tablo 9 : Water Flow Rates n the Col
Tablo 10 : Specfic Heat Output Table
Tablo 11 : Motor Selecton for Reducer Base
Tablo 12 : Motor Selecton for Foundaton Support
Tablo 13 : Gude Dmensons on Shaft Surface of Hollow Shaft Reducer
Tablo 14 : Maxmum Forcng Pressures
Tablo 15 : Tghtenng Torques of Flange Connectons
Tablo 16 : Informaton on Tghtenng the Connectng Bolts
Tablo 17 : Preload Forces and Tghtenng Torques
Tablo 18 : Operatng Data
Tablo 19 : Servce and Mantenance Operatons
Tablo 20 : Dsposal Table
Tablo 21 : Troubleshootng
Tablo 22 : Authorzed Servce
Tablo 23 : Weghts
Tablo 23 - 1a: Weghts
Tablo 23 - 1b: Weghts
Tablo 23 - 2a: For Auxlary Drven Reducers (Falure Mantenance Work)
Tablo 23 - 2b: For Auxlary Drven Reducers (Falure Mantenance Work)
Tablo 23 - 3a: For Auxlary Drven Reducers (Workng Under Load)
Tablo 23 - 3b: For Auxlary Drven Reducers (Workng Under Load)
Tablo 24 : Ol Quanttes
Tablo 24 - 1a
:Output Seal Ol Quanttes
Tablo 24 - 1b: Output Seal Ol Quanttes
Tablo 24 - 1c: Output Seal Ol Quanttes
Tablo 24 - 2 : Labyrnth Seal Ol Quanttes
Tablo 24 - 3a: Ol Quanttes for Intermedate Flange
Tablo 24 - 3b: Ol Quanttes for Intermedate Flange
Tablo 24 - 4a: Immerson Lubrcaton
Tablo 24 - 4b: Immerson Lubrcaton
Tablo 24 - 5a: Pressure Lubrcaton
Tablo 24 - 5b: Pressure Lubrcaton
Tablo 25 : Measurement Surface Sound Pressure Level
Tablo 25 - 1 : Measurng Surface Sound Pressure Level for Fan Cooled Concal Helcal Reducer LpA, dB [A]
Tablo 25 - 2 : Measurng Surface Sound Pressure Level LpA, dB [A] for Fanless Concal Helcal Reducer
Tablo 25 - 3 : Sound pressure level for fan cooled Helical Gearbox LpA, dB [A]
Tablo 25 - 4 : Sound pressure level for Fanless Helical Gearbox LpA, dB [A]
8
9
10
23
24
25
26
33 - 34
38
43
62
65
69
69
77
83
83 - 84
91
92 - 93
99
100 - 104
105
109 - 110
109
109
109
110
110
110
110 - 112
110
111
111
111
111
111
112
112
112
112
113 - 116
113
114
115
116
Lst of tables
CONTENTS

www.pgr.com.tr
08 >
1.1 Important Warnngs
Take nto consderaton the lsted safety warnngs and nformaton sgns below!
Table 1: Safety Alerts and Informaton Sgns
EXPLOSION !
Indcates an mmedate danger, whch may result n death or serous njury.
Contans mportant nformaton regardng exploson protecton.
NOTE !
Advce and useful nformaton for the user
Ths ndcates that property damage may occur f proper precautons
are not taken.
DANGER !
Harmful stuaton and possble outcome
Damage occurs n the reducers and the envronment.
If proper precautions are not taken, serious damage on the gearbox may
occur, death or serious personal injury will result.
DANGER OF ELECTRICITY !
Electrcal shock hazard and possble outcome
Death and serous njures
DANGER !
Danger and possble outcome
Death and serous njures
ATTENTION !
Dangerous stuaton and possble outcome
Mld or major/mnor njures
Ths ndcates that mnor personal njury may occur f proper
precautons are not taken.
WARNING !
General usage nformaton
If proper precautions are not taken that indicates serious personal
injury may occur.
GENERAL INFORMATION1. UNIT