SEW-Eurodrive BS.F Series User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
Gear Unit Series
BS.F.., PS.F.. and PS.C..
Edition 08/2009 16806417 / EN

SEW-EURODRIVE—Driving the world

Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C.. 3
Content
Content
1 General Information ............................................................................................ 5
1.1 How to use the operating instructions......................................................... 5
1.2 Structure of the safety notes ....................................................................... 5
1.3 Rights to claim under limited warranty ........................................................ 6
1.4 Exclusion of liability..................................................................................... 6
1.5 Copyright..................................................................................................... 6
2 Safety Notes ........................................................................................................ 7
2.1 Preface........................................................................................................ 7
2.2 General information .................................................................................... 7
2.3 Target group ............................................................................................... 8
2.4 Designated use ........................................................................................... 8
2.5 Other applicable documentation ................................................................. 8
2.6 Transport..................................................................................................... 9
2.7 Installation/assembly................................................................................... 9
2.8 Startup/operation ........................................................................................ 9
2.9 Inspection/maintenance .............................................................................. 9
3 Gear Unit Design ............................................................................................... 10
3.1 Basic structure – Gear unit ....................................................................... 11
3.2 Basic structure – Adapter.......................................................................... 15
3.3 Variants and options – BS.F.. helical-bevel gear units ............................. 18
3.4 Variants and options – PS.F.. planetary gear units................................... 19
3.5 Variants – PS.C.. planetary gear units...................................................... 19
3.6 Unit designation and nameplate ............................................................... 20
4 Mechanical Installation..................................................................................... 23
4.1 Required tools/resources .......................................................................... 23
4.2 Prerequisites for installation...................................................................... 24
4.3 Installing the gear unit............................................................................... 24
4.4 Installation in a machine: BS.F.. helical-bevel gear unit ........................... 28
4.5 Installation in a machine: PS.F.. planetary gear unit................................. 30
4.6 Installation in a machine: PS.C.. planetary gear unit ................................ 30
4.7 Mounting output elements to solid shafts of BS.F.., PS.F.. and PS.C.. gear
units .......................................................................................................... 31
4.8 Mounting of couplings ............................................................................... 34
4.9 Installing a torque arm on BS.F.. shaft-mounted gear units...................... 35
4.10 Shaft-mounted gear units with keyway ..................................................... 36
4.11 Shaft-mounted gear unit with shrink disk .................................................. 38
4.12 Motor Mounting ......................................................................................... 42
4.13 Demounting the motor .............................................................................. 48

4Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C..
Content
5 Startup................................................................................................................ 49
5.1 Design-related special features ................................................................ 49
5.2 Measuring the surface temperature .......................................................... 50
6 Inspection and Maintenance ............................................................................ 51
6.1 Preliminary work regarding gear unit inspection/maintenance ................. 51
6.2 Inspection/maintenance intervals.............................................................. 52
6.3 Lubricant change intervals ........................................................................ 52
7 Mounting Positions........................................................................................... 54
7.1 General information about mounting positions ......................................... 54
7.2 BS.F.. helical-bevel servo gearmotors ...................................................... 56
7.3 PS.F.., PS.C.. planetary servo gearmotors............................................... 59
8 Technical Data................................................................................................... 61
8.1 Lubricants ................................................................................................. 61
9 Malfunctions ...................................................................................................... 65
9.1 Gear unit ................................................................................................... 65
9.2 Customer service ...................................................................................... 65
9.3 Disposal .................................................................................................... 66
10 Manufacturer’s Declaration.............................................................................. 67
Index................................................................................................................... 68

Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C.. 5
1
How to use the operating instructions
General Information
1 General Information
1.1 How to use the operating instructions
The operating instructions are an integral part of the product and contain important in-
formation for operation and service. The operating instructions are written for all employ-
ees who assemble, install, startup, and service the product.
The operating instructions must be legible and accessible at all times. Make sure that
staff responsible for the plant and its operation, as well as persons who work indepen-
dently on the unit, have read the operating instructions carefully and understood them.
If you are unclear about any of the information in this documentation, or if you require
further information, contact SEW-EURODRIVE.
1.2 Structure of the safety notes
The safety notes in these operating instructions are designed as follows:
Pictogram SIGNAL WORD
Type and source of danger.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the danger.
Pictogram Signal word Meaning Consequences if
disregarded
Example:
General danger
Specific danger,
e.g. electric shock
DANGER Imminent danger Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the drive system or its
environment
INFORMATION Useful information or tip.
Simplifies the handling of the
drive system.

6Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C..
1Rights to claim under limited warranty
General Information
1.3 Rights to claim under limited warranty
Adhering to the operating instructions is a prerequisite for fault-free operation and the
fulfillment of any right to claim under warranty. Read the operating instructions before
you start working with the unit.
1.4 Exclusion of liability
You must comply with the information contained in these operating instructions to en-
sure safe operation of the BS.F.. helical-bevel gear units and PS.F../PS.C.. planetary
gear units and to achieve the specified product characteristics and performance require-
ments. SEW-EURODRIVE assumes no liability for injury to persons or damage to equip-
ment or property resulting from non-observance of these operating instructions. In such
cases, any liability for defects is excluded.
1.5 Copyright
© 2009 - SEW-EURODRIVE. All rights reserved.
Copyright law prohibits the unauthorized duplication, modification, distribution, and use
of this document, in whole or in part.

Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C.. 7
2
Preface
Safety Notes
2 Safety Notes
The following basic safety notes must be read carefully to prevent injury to persons and
damage to property. The operator must ensure that the basic safety notes are read and
observed. Make sure that persons responsible for the plant and its operation, as well as
persons who work independently on the unit, have read through the operating instruc-
tions carefully and understood them. If you are unclear about any of the information in
this documentation, or if you require further information, please contact SEW-
EURODRIVE.
2.1 Preface
The following safety notes are primarily concerned with the use of gear units. If using
gearmotors, please also refer to the safety notes for motors in the corresponding oper-
ating instructions.
Also observe the supplementary safety notes in the individual sections of these operat-
ing instructions.
2.2 General information
Removing covers without authorization, improper use as well as incorrect installation or
operation may result in severe injuries to persons or damage to property.
Refer to the documentation for additional information.
DANGER
During operation, motors and gearmotors may have live, bare and movable or rotating
parts as well as hot surfaces, depending on their protection type.
Severe or fatal injuries.
• All work related to transportation, storage, setup/mounting, connection, startup,
maintenance and repair may only be carried out by qualified personnel, in strict
observation of:
– The relevant detailed operating instructions
– The warning and safety signs on the motor/gearmotor
– All other project planning documents, operating instructions and wiring
diagrams related to the drive
– The specific regulations and requirements for the system
– The national/regional regulations governing safety and the prevention of
accidents
• Never install damaged products
• Immediately report any damage to the shipping company

8Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C..
2Target group
Safety Notes
2.3 Target group
Any mechanical work may only be performed by adequately qualified personnel. Quali-
fied personnel in this context are persons who are familiar with the setup, mechanical
installation, trouble shooting and maintenance for this product. Further, they are quali-
fied as follows:
• Training in mechanical engineering, e.g. as a mechanic or mechatronics technician
(final examinations must have been passed).
• They are familiar with these operating instructions.
Any electronic work may only be performed by adequately qualified electricians. Quali-
fied electricians in this context are persons who are familiar with the electronic installa-
tion, startup, trouble shooting and maintenance for this product. Further, they are qual-
ified as follows:
• Training in electrical engineering, e.g. as an electrician or mechatronics technician
(final examinations must have been passed).
• They are familiar with these operating instructions.
All work in further areas of transportation, storage, operation and waste disposal may be
carried out only by persons who are trained appropriately.
2.4 Designated use
The gear units/gearmotors are intended for industrial systems and may only be used in
accordance with the information provided in the technical documentation of SEW-
EURODRIVE and the information given on the nameplate. They fulfill the applicable
standards and regulations. Using these products in potentially explosive atmospheres
is prohibited, unless specifically designated otherwise.
2.5 Other applicable documentation
The following publications and documents have to be observed as well:
• Operating Instructions "AC Motors, Asynchronous Servomotors" for gearmotors
• "Synchronous Servomotors" operating instructions
• Operating instructions of any attached options
• "Synchronous Servo Gearmotors" catalog
• "Asynchronous Servomotors" catalog
• "Gear Units" catalog and/or
• "Gearmotors" catalog
• "Servo Gear Units" catalog

Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C.. 9
2
Transport
Safety Notes
2.6 Transport
Inspect the shipment for any damage that may have occurred in transit as soon as you
receive the delivery. Inform the shipping company immediately. It may be necessary to
preclude startup.
Tighten installed eyebolts. They are designed to only carry the weight of the motor/gear-
motor; do not attach any additional loads.
The built-in lifting eyebolts meet DIN 580. Always observe the loads and regulations
listed in this standard. If the gearmotor is equipped with 2 suspension eye lugs or lifting
eyebolts, then both of the suspension eye lugs should be used for transportation. In this
case, the tension force vector of the slings must not exceed a 45° angle according to
DIN 580.
Use suitable, sufficiently rated handling equipment if necessary. Remove any transpor-
tation fixtures prior to startup.
2.7 Installation/assembly
Observe the notes in section "Mechanical Installation" (see page 23).
2.8 Startup/operation
Check the oil level before startup as described in chapter "Inspection/Maintenance".
Check that the direction of rotation is correct in decoupled status. Listen out for unusual
grinding noises as the shaft rotates.
Secure keys for test mode without output elements. Do not deactivate monitoring and
protection equipment even in test mode.
Switch off the gearmotor if in doubt whenever changes occur in relation to normal oper-
ation (e.g. increased temperature, noise, vibration). Determine the cause and contact
SEW-EURODRIVE, if required.
2.9 Inspection/maintenance
Observe the notes in chapter "Inspection/Maintenance" (see page 51).

10 Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C..
3Gear Unit Design
3 Gear Unit Design
INFORMATION
For information about the scope of delivery and project planning, refer to the "Synchro-
nous Servo Gearmotors" catalog and the operating instructions for the motor used to
drive the gear unit.
INFORMATION
The following illustrations are intended to explain the general structure. They help you
to assign components to the spare parts list. Discrepancies may occur depending on
the gear unit size and variant.

Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C.. 11
3
Basic structure – Gear unit
Gear Unit Design
3.1 Basic structure – Gear unit
3.1.1 BS.F.. helical-bevel gear unit
1840072331
[3]
[99]
[98]
[7b]
[183]
[335]
[168]
[43][48]
[42]
[538]
[537]
[536]
[131]
[9] [12]
[166] [518]
[519]
[520]
[11]
[17]
[251] [49]
[29]
[22]
[45]
[2] [113]
[116]
[1]
[84] [25]
[23] [88]
[103]
[153]
[160]
[85]
[521]
[522]
[523]
[250]
[6]
[7c]
[19]
[250]
[142]
[89]
[7a]
[1] Pinion [19] Key [85] Centering flange [160] Closing plug
[2] Wheel [22] Gear unit housing [88] Retaining ring [166] Supporting ring
[5] Bevel pinion shaft [23] Supporting ring [89] Closing cap [168] Protection cap
[6] Bevel gear [25] Taper roller bearings [98] shrink disk [183] Oil seal
[7a] Output shaft (BSF..) [29] Adhesive and sealing
compound
[99] Protection cover [250] Retaining ring
[7b] Output shaft (BSKF..) [42] Taper roller bearings [103] O-ring [251] Retaining ring
[7c] Key (BSKF..) [43] Key [113] Slotted nut [335] Torque arm
[9] Oil seal [45] Taper roller bearings [116] Thread locker [518] -
[523]
Shims
[11] Taper roller bearings [48] Supporting ring [131] Closing cap [536] -
[538]
Shims
[12] Retaining ring [49] O-ring [142] Machine screw
[17] Supporting ring [84] Nilos ring1) [153] Adhesive and sealing
compound
1) only for mounting position M5

12 Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C..
3Basic structure – Gear unit
Gear Unit Design
3.1.2 PSF.. / PSKF.. planetary gear units
1881393163
[8]
[6]
[1]
[41]
[18]
[17]
[55]
[39]
[22]
[106]
[112]
[123]
[113]
[105]
[122]
[114]
[7]
[12]
[13]
[30]
[24]
[118]
[46]
[100]
[107] [116]
[56]
[110]
[121] [109]
[25]
[58]
[146]
[1] Planet carrier for output, complete [30] Nilos ring1) [109] Grooved ball bearing
[6] Key2) [39] Safety disk [110] Retaining ring
[7] Shaft nut [41] Countersunk pin [112] Needle roller
[8] Oil seal [46] Adhesive and sealing compound [113] Planet gear
[12] Taper roller bearings [55] Thrust plate [114] Sun gear
[13] Taper roller bearings [56] O-ring [116] O-ring
[17] Planet gear [58] Eyebolt [118] Housing preliminary stage
[18] Needle roller [100] Stud [121] Snap ring
[22] Sun gear [105] Thrust plate [122] Safety disk
[24] Housing [106] Planet carrier, complete [123] Countersunk pin
[25] Screw plug [107] Hex nut [146] Adhesive and sealing compound
1) Only for mounting position M2
2) For PSKF only

Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C.. 13
3
Basic structure – Gear unit
Gear Unit Design
3.1.3 PSBF.. planetary gear units
1881492491
[106]
[112]
[123]
[113]
[105]
[122]
[114]
[118]
[100]
[116][146]
[56]
[8]
[12]
[13]
[57]
[24]
[110] [121] [109]
[46]
[25] [1]
[17]
[18]
[16]
[22]
[58]
[107]
[1] Planet carrier for output [25] Screw plug [110] Retaining ring
[8] Oil seal [46] Adhesive and sealing compound [112] Needle roller
[12] Angular contact ball bearing1) [56] O-ring [113] Planet gear
[12] Taper roller bearings2) [57] Shaft nut [114] Sun gear
[13] Angular contact ball bearing1) [58] Eyebolt [116] O-ring
[13] Taper roller bearings2) [100] Stud [118] Housing preliminary stage
[16] Planetary gear axle [105] Thrust plate [121] Snap ring
[17] Planet gear [106] Planet carrier, complete [122] Safety disk
[18] Needle roller [107] Hex nut [123] Countersunk pin
[22] Sun gear [109] Grooved ball bearing [146] Adhesive and sealing compound
[24] Housing
1) Only for PSBF222
2) For PSBF322 – 822 only

14 Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C..
3Basic structure – Gear unit
Gear Unit Design
3.1.4 PS.C.. planetary gear unit
1885879563
]
[1] Planet carrier for output [18] Needle roller [106] Preliminary stage planet car-
rier
[5] Hardened cylindrical pin [21] Retaining ring [111] Planetary gear axle
[6] Key1)
1) For PSKC and PSKCZ
[22] Sun gear [112] Needle roller
[8] Oil seal [24] Drive flange [113] Planet gear
[11] O-ring [46] Adhesive and sealing com-
pound
[114] Sun gear
[12] Grooved ball bearing [55] Thrust plate [116] O-ring
[13] Grooved ball bearing [56] O-ring [118] Annulus
[16] Planetary gear axle [59] Annulus [146] Adhesive and sealing com-
pound
[17] Planet gear [105] Thrust plate [246] Adhesive and sealing com-
pound

Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C.. 15
3
Basic structure – Adapter
Gear Unit Design
3.2 Basic structure – Adapter
3.2.1 EBH.. adapter for BS.F.. helical-bevel gear units
1840077707
[201] Retaining ring/snap ring [217] Grooved ball bearing [402] Retaining ring
[202] Key [220] Screw plug1) / Breather valve2)
1) For mounting positions M1 – M3, M5, M6 only
2) only for mounting position M4
[404] Retaining ring
[203] Oil seal with optimized spring force [223] Grooved ball bearing [442] Adapter flange
[204] Stud [229] Clamping ring [470] Machine screw
[205] Toothed washer [230] Coupling sleeve [471] Toothed washer
[207] Flange [232] Press-fit bolt [483] Coupling
[212] Adapter shaft [399] Closing plug [502] -
[504]
Shims
[216] Adhesive and sealing compound
[230]
[470]
[471]
[442]
[229]
[232]
[483]
[404]
[203]
[204]
[220]
[223]
[202]
[402]
[212]
[217]
[504]
[503]
[502]
[205]
[206]
[207]
[201]
[399]
[216]

16 Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C..
3Basic structure – Adapter
Gear Unit Design
3.2.2 EPH.. adapter for PS.F.. and PS.C.. planetary gear units
1881495179
[204]
[203]
[207]
[206]
[247]
[402]
[223]
[247]
[404]
[212]
[399]
[231]
[442]
[216]
[471]
[470]
[229] [230]
[203] Oil seal [223] Grooved ball bearing [402] Retaining ring
[204] Stud [229] Clamping ring [404] Retaining ring
[206] Hex nut [230] Coupling sleeve [442] Adapter flange
[207] Flange [231] Closing cap [470] Machine screw
[212] Adapter shaft [247] Shim washer [471] Toothed washer
[216] Adhesive and sealing compound [399] Closing plug

Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C.. 17
3
Basic structure – Adapter
Gear Unit Design
3.2.3 ECH.. adapter for PS.C.. planetary gear units
1885885323
[203] Oil seal [207] Adapter flange [230] Motor shaft sleeve
[204] Stud [212] Adapter shaft [399] Closing plug
[206] Hex nut [229] Setscrew [471] Washer

18 Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C..
3Variants and options – BS.F.. helical-bevel gear units
Gear Unit Design
3.3 Variants and options – BS.F.. helical-bevel gear units
BS.F.. helical-bevel gear unit with B5 output flange
Type Meaning
BSF.. Solid shaft without key
BSKF.. Solid shaft with key
BSBF.. Solid shaft with flange block shaft
BSHF.. Hollow shaft with shrink disk opposite the output end
BSAF.. Hollow shaft with keyway
BSF..B helical-bevel gear units with foot and front threaded holes for mounting
Type Meaning
BSF..B Solid shaft without key, with foot/front-end mounting
BSKF..B Solid shaft with key and foot/front-end mounting
BSBF..B Solid shaft with flange block shaft and foot/front-end mounting
BSHF..B Hollow shaft with shrink disk and foot/front-end mounting opposite the output end
BSAF..B Hollow shaft with keyway and foot/front-end mounting
Options for BS.F.. helical-bevel gear units
Type Meaning
../R Reduced backlash
../T Torque arm
../I Hollow shaft and shrink disk at the output end

Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C.. 19
3
Variants and options – PS.F.. planetary gear units
Gear Unit Design
3.4 Variants and options – PS.F.. planetary gear units
3.5 Variants – PS.C.. planetary gear units
PS.F.. helical-bevel gear unit with B5 output flange
Type Meaning
PSF.. Solid shaft without key
PSKF.. Solid shaft with key
PSBF.. Solid shaft with flange block shaft
Options for PS.F.. planetary gear units
Type Meaning
../R Reduced backlash
../M Minimized backlash
PS.C.. planetary gear unit with B5/B14 output flange
Type Meaning
PSC.. B5 output flange, solid shaft without key
PSKC.. B5 output flange, solid shaft with key
PSCZ.. B14 output flange, solid shaft without key
PSKCZ.. B14 output flange, solid shaft with key

20 Operating Instructions – Gear Unit Series BS.F.., PS.F.. and PS.C..
3Unit designation and nameplate
Gear Unit Design
3.6 Unit designation and nameplate
3.6.1 Example: Unit designation of PS.F.. planetary gear units with EPH.. adapter
A planetary gear unit with adapter, for example, has the following unit designation:
INFORMATION
The nameplate of the servo gearmotor is fixed to the servomotor.
PSF 521 /R EPH 07 /21 /13
Coupling hole classification
Code number for the flange geometry (centering, hole circle)
Code for performance class
Adapter for planetary servo gear units
Option for all PS.F.. gear units:
.../ R: Reduced circumferential backlash
.../ M: Minimized circumferential backlash
Gear unit size: e.g. 521
Gear unit
type:
PSF..
PSKF..
PSBF..