SEW-Eurodrive VARIBLOC VU01 User manual

VARIBLOC®Variable Speed Gear Unit
and Options
Edition
09/2000
Operating Instructions
0922 1913 / EN

SEW-EURODRIVE

"VARIBLOC
®
Variable Speed Gear Unit" – Operating Instructions
3
1 Important Notes................................................................................................. 4
2 Safety Notes ...................................................................................................... 5
3 VARIBLOC®Design .......................................................................................... 6
3.1 Type designation....................................................................................... 6
3.2 VARIBLOC®variable speed gear unit – unit design................................. 6
3.3 Overview of VARIBLOC®mounting options ............................................. 7
4 Installation ......................................................................................................... 8
4.1 Before you begin....................................................................................... 8
4.2 Preliminary work ....................................................................................... 8
4.3 Installation of VARIBLOC®....................................................................... 8
4.4 Required tools........................................................................................... 9
4.5 Mounting of output components................................................................ 9
5 Startup.............................................................................................................. 11
5.1 VARIBLOC®startup................................................................................ 11
6 Installation and Setup of Optional Equipment ............................................. 12
6.1 Installation and setup of EF/EFPA adjustment device............................ 12
6.2 Installation and setup of hydraulic adjustment unit HY........................... 16
6.3 Installation and setup of GW, IG, TW and TA......................................... 17
7 Inspection / Maintenance ............................................................................... 23
7.1 Inspection and maintenance intervals..................................................... 23
7.2 Before you begin..................................................................................... 23
7.3 Inspection / maintenance of VARIBLOC®............................................... 23
7.4 Replacing wide V-belt............................................................................. 24
7.5 Limiting the speed range for designs NV, H, HS .................................... 28
7.6 Lubricate EF/ EFPA adjusting spindle .................................................... 28
8 Operation and Service.................................................................................... 29
8.1 Malfunction of VARIBLOC®variable speed gear unit............................. 29
8.2 Malfunction of optional equipment.......................................................... 29
00
I

1
4
"VARIBLOC
®
Variable Speed Gear Unit" – Operating Instructions
Important Notes
1 Important Notes
Safety
and warning
instructions
Always follow warnings and safety instructions in this publication!
Close adherence to these instructions is required for fault-free operation and fulfillment
of any warranty claims. Read these instructions carefully before you start operating the
drive!
These operating instructions contain vital servicing information and should be stored
next to the drive unit.
Disposal (Please observe all applicable regulations):
• Housing components, gear wheels, shafts and rolling bearings of gear units should
be disposed of as steel scrap. This also applies to components made of cast iron if
no separate collection is available.
• The wide V-belt may be disposed of as residual waste.
Electrical hazard
Possible effects: Serious or fatal injury.
Immediate danger
Possible effects: Serious or fatal injury.
Dangerous situation
Possible effects: Minor injury.
Harmful situation
Possible effects: Damage to equipment or surroundings.
Application hints and useful information.
Revisions to edition 7/95 are indicated by a gray bar in the margin.

"VARIBLOC
®
Variable Speed Gear Unit" – Operating Instructions
5
2
Safety Notes
2 Safety Notes
Preliminary
remarks
The following safety notes refer to the use of variable speed gear units.
When using variable speed geared motors, please observe safety notes for gear units
and motors in the appropriate operating instructions.
Please refer to the additional safety notes in the individual sections of these
operating instructions.
General All tasks related to transport, storage, installation/assembly, connection, startup,
service and maintenance may be performed by qualified technical personnel only
with strict adherence to:
• detailed operating instruction(s) and block diagrams
• warning and safety labels on the gear unit/geared motor
• system-specific regulations and requirements
• national/regional safety and accident prevention regulations
Serious personal injuries and material damage may occur through
• incorret use
• improper installation or operation
• inadmissible removal of required protective covers or of the housing
Be aware that variable speed geared motors/gear units contain live and moving
components and that some surfaces may get hot during and after operation.
Intended usage These variable speed geared motors/variable speed gear units are intended for
industrial systems. They comply with existing standards and regulations. The technical
data and information on approved operating conditions can be found on the nameplate
and in the documentation.
All details must be strictly observed!
Transport /
Storage
Inspect the shipment for damages upon receipt. Inform the shipping company
immediately of any damages. In case of damages, startup may have to be
cancelled.
Securely tighten lifting eyebolts. The eyebolts are specifically designed for the weight of
the geared motor/gear unit; no additional loads may be applied.
If necessary, use appropriate and sufficiently dimensioned handling equipment.
Remove existing shipping braces prior to startup.

3
6
"VARIBLOC
®
Variable Speed Gear Unit" – Operating Instructions
Type designation
3 VARIBLOC
®
Design
3.1 Type designation
Example
03794AEN
3.2 VARIBLOC
®
variable speed gear unit – unit design
03711AXX
Figure 1: VARIBLOC
®
design
1 Adjustment device front adjustment
2 Adjustment discs
3 Wide V-belt
4 Bearing cover
5 Two-part housing, variable speed gear unit
6 Coupled reduction gear unit
7 Output flange
8 Drive motor
Manual brake release, lock-type
Brake
Angle selection element with handwheel
and position indication
U-shaped flow of energy
VU 21 HS BMG HF
VARIBLOC®Variable Speed Gear Unit size
VARIBLOC®Variable Speed Gear Unit series
8
1
2
3
4
5
7
6

"VARIBLOC
®
Variable Speed Gear Unit" – Operating Instructions
7
3
Overview of VARIBLOC®mounting options
3.3 Overview of VARIBLOC
®
mounting options
03712AXX
Figure 2: Overview of VARIBLOC
®
mounting options
1 Brake BM(G) (with IG voltage pulse encoder)
2 Bearing cover
3 Right-angle tachometer TW
4 AC tachogenerator GW
5 Axial tachometer TA
6 Voltage pulse encoder IG
7 Adjustment device with handwheel and position indication HS
8 Hydraulic variable speed unit HY
9 Electromechanical remote speed adjustment EF
10 Adjustment device with handwheel H / with free shaft end NV
11 Front adjustment with sprocket wheel
12 Front adjustment with handwheel (standard design)
12
11
10
9
8
7
1
2
3
4
5
6

4
8
"VARIBLOC
®
Variable Speed Gear Unit" – Operating Instructions
Before you begin
4 Installation
Never adjust variable speed gear unit at standstill! (Damages to the adjustment
device and the wide V-belt may result)
4.1 Before you begin
The drive may
only be installed
if
• the entries on the nameplate of the drive match the supply voltage
• the drive is not damaged (no damage resulting from transport or storage)
• the following requirements have been properly fulfilled:
– ambient temperature between 0 °C and +40 °C,
– no oils, acids, gases, vapors, radiation, etc.
• the degree of protection provided by the enclosure has been checked
4.2 Preliminary work
Variable speed
gear units
Output shafts and flange surfaces must be completely free of anti-corrosion agents,
contamination or other impurities (use a commercially available solvent). Do not let the
solvent come into contact with the sealing lips of the oil seals or the wide V-belt –
damage to the material may result!
Please note:
• The service life of the lubricant in the bearings is reduced if the unit is stored for
more than one (1) year.
• The enclosed wide V-belt must be installed.
4.3 Installation of VARIBLOC
®
• The variable speed geared motor may be mounted or installed only in the specified
position on a level1), vibration-free and torsionally rigid support structure. Do not
tighten housing legs and mounting flanges against each other.
Please note:
•VARIBLOC
®design HS (handwheel with position indication) must be mounted so
that the adjusting spindle is horizontal; otherwise the position indication will not
function properly.
• The breather valves must be easily accessible! The plastic plug of the
condensate drain hole at the lowest position must be removed prior to
operation (danger of corrosion!)
• Carefully align the motor and driven machine to avoid overloading the motor shaft
(observe approved overhung loads and axial forces!).
• Do not hammer or hit the shaft end.
• Protect vertically mounted motors with an appropriate cover against
penetration of foreign bodies or fluids! (cowl C)
1) Maximum permitted flatness error for flange mounting (approximate value with reference
to DIN ISO 1101): with →flange 120 – 600 mm max. error 0.2 – 0.5 mm

" VARIBLOC
®
Variable Speed Gear Unit" – Operating Instructions
9
4
Required tools
• Ensure adequate supply of cooling air and that heated air from other units is not
drawn in.
Installation in
damp areas or in
the open
•VARIBLOC
®gear units are supplied in corrosion-resistant versions (design B) for
use in damp areas or in the open. Any damage to the paintwork (e.g. at the breather
valve) must be repaired.
• Coat the threads of screwed cable glands and sealing plugs with sealant, and
tighten well – apply another coat of sealant.
• Properly seal the cable entry.
• Thoroughly clean the sealing surfaces of the terminal box and terminal box cover
before re-assembly. Replace porous seals!
Painting the gear
unit
If the drive will be painted or partially repainted, ensure that the breather valve and oil
seals are carefully covered with tape. Remove tape strips after the paint work is finished.
4.4 Required tools
• Wrench set
• Mounting device
• Shims and distance rings, if necessary
• Mounting materials for output components
• Multimeter
Installation
tolerances
4.5 Mounting of output components
Figure 3 shows an example of a mounting device for mounting clutches or hubs onto
shaft ends of variable speed gear units or motors. The thrust bearing on the mounting
device may become redundant.
03371AEN
Figure 3: Example of a fitting tool
Shaft end Flanges
Diametric tolerances in accordance with DIN 748
• ISO k6 for solid shafts with d, d1≤ 50 mm
• ISO k7 for solid shafts with d, d1> 50 mm
• Center hole in accordance with DIN 332, shape
DR..
Centering shoulder tolerances in accordance with
DIN 42948
• ISO j6 with b1 ≤ 230 mm
• ISO h6 with b1> 230 mm
Coupling hub
Gear unit shaft end Thrust bearing

4
10
"VARIBLOC
®
Variable Speed Gear Unit" – Operating Instructions
Mounting of output components
Figure 4 shows the correct mounting arrangement bof a gear or sprocket wheel in
order to avoid excessive overhung loads.
03369AEN
Figure 4: Correct mounting arrangement of a gear or sprocket wheel
• Only use a mounting device (see Figure 3) for installing input and output elements.
Use the center bore and the thread on the shaft end for positioning purposes.
• Never drive belt pulleys, clutches, pinions, etc. onto the shaft end by hitting
them with a hammer (damage to bearings, housing and the shaft!).
• Please observe correct tension of the belt for belt pulleys (in accordance with
manufacturer’s specifications).
• Mounted transmission elements should be balanced and may not cause any
unacceptable radial or axial forces (see Figure 4 / see "Geared Motors" catalog for
approved values).
Note:
Assembly is easier if you first apply lubricant to the output element or heat it up briefly
(80–100 °C).
Assembly of
clutches
While mounting clutches, the following items must be balanced in accordance
with clutch manufacturer specifications:
a) Maximum and minimum clearance
b) Axial offset
c) Angular offset
03356AXX
Figure 5
X1X1
bFX1
FX1
a
X1X1
bFX1
FX1
aHub Hub
incorrect correct
a) b) c)
Input and output elements such as belt pulleys, clutches, etc. must be equipped with a
touchguard device!