12. ACCESSORY’S DOCUMENTATIONTwo-speed gearboxes for AC and DC main spindle drives 2K 10,2 K 12,2K 15,2 K 20 Operating Instructions February 1994 Technical change without notice Copyright by ZF Reproduction in whole or in part permitted only with our prior written permission. Printed in Germany ZF FRIEDRICHSHAFEN AG D-88038 Friedrichshafen Tel.: (0 75 41) 77-0 + Telex: 7 34 207 + Telefax: (0 75 41) 77-34 70CONTENTS L 1 12 13 La 1s 16 2a 22 23 24 25 Installation and commissioning... Axial and radial runout tolerances of the elect Installation of 2 K 10,2 K 12, 2 K 15 and 2 K 20 gearboxes on the electric motor motor mounting flange Lubrication Electrical connections Changing gear... Braked earboxes.. Maintenance fc Oil change intervals on gearboxes with splash lubrication... ett Checking, adjusting and replacing the selector unit on 2 K 10 and 2 K 12 gearboxes Checking, adjusting and replacing the selector unit on 2 K 15 and 2 K 20 gearboxes... Adjusting the shift travel, Braked gearboxes... Page 4 4 4/3/6/7 8/9 I 12/13 B 4 14 vee 13 16/17 18/19 20 20"INSTALLATION AND COMMISSIONING 1. Install in and commissioning 1.1 Axial and radial runout tolerances of the electric motor mounting flange | Gearbox Tolerance type |B ie tae 2K10 0.021 0.050 0.050 | + 0.100 2K12 0.025 0.050 0.050 | +0.100 2K15 | 0.025 | 0.063 | 0.063 | -0.200 | |. 2K20_ | 0.025 | 0.063 | 0.063 | - 0.200 B Cc Tolerances A, B, C10 DIN 42955R Please note tolerance "L" (shaft length) which is more stringent than DIN. TA uM Fig. 2 1.2 Installation of 2 K 10, 2K 12,2 K 15 and 2 K 20 gearboxes on the electric motor (see also Section 82.8 "Assembly Drawings") Key to drawing: 1- ZF gearbox 2+ Main spindle motor 3+ Sungear 4+ Planet gear 5+ Ring gear 6- Spider (planet carrier) 7- Selector unit 8- Sliding sleeve 9- Input hub 10 Gearbox output shaft 11 = Oniput housing 12 - Selector moror 13 - Beh pulley (not supplied byZF)41.2 (continued) Installation of 2K 10,2 K 12,2 K 1S and 2 K 20 gearboxes on the electric motor 12.1 ‘The gearbox hub is pushed onto the motor shaft. The base of the hub bore must be in contact with the end face of the motor shaft. NOTE, To simplify assembly, the hub may be heated to a max. temperature of 120°C The hub is secured with a threaded pin to DIN 916. Coat the threaded pin with a screw-locking compound before inserting it. 1.22 The O-ring on the motor mounting (see Figs. 4 and 5) is supplied loose with the gearbox. Grease it and insert it into the sealing ring groove in the housing. 123 Check the position of the gearbox selector unit before installing the electric motor onto the gearbox. Make shure the sliding sleeve is moved to the stop for shift position 1 (low speed). Refer to the assembly drawings (Figs. 4 and 5), 1.24 Pick up the electrie motor by the ring bolts. Carefully insert the motor shaft into the gearbox with the input hub in place, NOTE Insert the spline profile of the sun gear into the spline profile of the hub. This is made easier by turning the ‘motor shaft or the gearbox output to the left and right. 128 Screw the electric motor and the gearbox together using hex bolts to DIN 933. Use a sealing compound. 1.26 NOTE Before putting the electric motor and gearbox unit into ion, ensure that the gearbox output can be turned INSTALLATION AND COMMISSIONING 1.2.7 Belt drive output Centre the belt pulley on the external diameter of the output flange (tolerance K6). Bolt the belt pulley firmly on, observing possible tightening torques. The belt pul- ley should be balanced to quality 5 or 6 to ensure low vibra tion operation. CAUTION Do not exceed the specified maximum tension of the belt. Failure to do so can overload the bearings. CAUTION The gearboxes can be operated under the same protec- tion conditions as specified for the AC and DC motors. ‘When setting up the gearbox, make sure the ventilation inlet and outlet of the motor are not obstructedINSTALLATION AND COMMISSIONING 1.2.8 Assembly drawings for gearboxes 2K10/2K12and2K15/2K 20 Fig. 4 Assembly drawing for gearboxes ? K 10 and 2 K 12 Key to drawing 1 - Sun gear (Supplied by ZF) 2+ Hub (Supplied by ZF) (May be heated to max. 120°C for mounting) 3+ Sliding sleeve 4+ Oupui flange 6 5S Key DIN 6885 6- Threaded pin DIN 916 (Supplied by ZF) (Secure with Loctite) 7 Oil sight glass (on both sides) 8- O-ring (Supplied by ZF) (Check itis seated correctly!) CContnoed on Page 7INSTALLATION AND COMMISSIONING tssembly drawing for gearboxes 2K 15 and 2K 20 \ \ ao10ss / \ \ / 1 \ 5 7 6 9 - Shaft sealing ring A- Attachment for dise pulley etc. Do not paint. (in motor) B- Flange face and centring ring on gearbox. 10 - Hex bolt DIN 933 Do not paint. 11 - Shims inserted here if needed, C- Pole surface with brake fitted. Do not paint (clearance setting with cup springs fully depressed) if fied,T INSTALLATION AND COMMISSIONING 1.3 Lubrication 1.3.1 Splash lubrication (Fig. 6, Panels J and 4) CAUTION Splash lubrication is suitable for intermittant operation, This supposes frequent speed changes, different opera- ting speeds and idle times, such as occuring when chan- ging tools, For such applications, install the two-speed gearboxes in installation position IMB 35 and IMV 1 (see Fig. 6, Panels | and 4). Fill with gearbox oil up to the centre of the oil sight glass. Fill with oil to this level; do not immediately fill with the quantity in litres given on the information plate as this is only an approximate value Approximate values for oil fill: 2k10[2K12)2K15]2K20 Ibssl os 35 Gearbox type: il fill quantity (litre) | for install. pos. IM vil a4] 0s |} 09 | 15 Use an oil dipstick with a suitable calibration mark instead of the oil sight glass if the gearbox is installed at an angle (e.g. if required for specific belt tensioning equipment) heck the calibration mark by testing. Make sure the oil level in the gearbox is the same as for horizontal installation. 1.3.2 Recirculating lubrication CAUTION Use recirculating lubrication with a central oil supply in all gearbox installation positions if the gearbox is used for continuous operation, for operation over long peri- ods at the same speed setting as well as intermitant operation with only brief idle times. Lubricating oil supply Certain application require a very low operating tempe- rature, This can be achieved using a suitably designed lubricating oil supply unit (if necessary, with oil coo- ling). The various gearbox types have been prepared for such equipment. Fig. 6, Panel 2 Standard solution for IMB 35 operation: Replace oil drain plug (No. 1) with an oil inlet (1 to 1.5 Vmnin.). Replace the oil sight glass with an oil outlet (an oil drain tube is supplied with the gearbox), (M4251.5/No. 2). Fig. 6, Panel 3 Central jet lubrication for IMB 35 operation: ‘Compulsory for continuous operation, for operation over long periods at the same speed and for intermiztant operation with brief idle times. Oil inlet (1 to 1.5 Vmin), oil pressure approx. 1 bar, fit- ted centrally (No. 1) or radially (No. 2) on the output. Oil outlet (M 2241.5 / No. 3) optionally right or left or at (M 2641.5 / No. 4) Fig. 6, Panel 5 Standard solution for IMV 1 operation: Replace oil drain plug (No. 1) with an oil inlet (I to 1.5 Uimin.), Replace the oil sight glass with an oil outlet (an oil drain tube is supplied with the gearbox) (M 4251.5 (No. 2).Fig. 6, Panel 6 Central jet lubrication for IMV 1 operation: The gearbox output is supplied without a shaft sealing ring as an option (No. 3). In conjunction with the open oil drain on the bearing housing (No. 2), this provides sufficient oil flow. il inlet volume: 1 to 1,5 | min, oil pressure approx. 1.5, bar. Fig. 6, Panel 7 Recirculating lubrication is compulsory for installation position IMV 3 Depending on the gearbox version and operating mode, lubricating oil is fed to the gearbox centrally (No. 1) or radially (No. 2) Oil inlet volume: 1 to 1.5 Vmin, oil pressure approx. 1.5, bar. NOTE Please refer to the installation drawing for each specific gearbox for the exact dimensions of the position and size of oil connections. INSTALLATION AND COMMISSIONING CAUTION Please note that * the gearbox area be vented by the standard air serew, + the tank for the pump unit must be vented, + the internal diameter of the oil return line from the gearbox to the tank is large enough (approx. 20 mm) to prevent back-pressure in the gearbox. 133 Oil quality Use CLP oils to DIN 51 517 or HLP oils to DIN SI 524 which offer good resistance to aging and contain additi- ves giving increased corrosion and wear protection in the viscosity class ISO-VG 68 If temperature monitoring and limiting equipment is fit. ted, CLP or HLP oils with lower viscosities can also be used.INSTALLATION AND COMMISSIONING Fig. 6: Installation positions and lubricating oil supply IMB 35 Panel 2K10 2K13_ | Panel2 2K10 2KIS | Panel3 2K IS | 2K12 2K20 2K12 2K20 2K20 | 2 TI JE=}- feo == ==} Splash lubrication 2 ae | Standard recirculating lubrication . | Splash bricaion 1s Labricaing olf ier Central brcation "4 2 Ot drain rhrugh 142515 off | Tor 2~ rian infer drain be 3° drain right and ef | Screw oil drain ube in instead ofthe} 4 Base ol drain | et sig gas RY and LH sides DVT Panel 4 2K10° 2KI15 | Panels 2K10 2K 15-| Panel 6 2K 15 2K12° 2K20 2K12 2K20 2K20 | fl oz | TT ial i i | QLOl? oitreves I F : c , : iO Ho 1 sean i 1 pi 3 ‘Standard recirculating lubrication I Lubricating oil inlet 2- Oil drain through M42 x 1.5 oil drain tube - screw oil drain tube in instead of oll sight glass T 1 Central lubrication Special version 1 Lubricating oil inlet 2and 3 - choice of oil drain points Panel 7 | Central lubrication 10 IMV3 2KIS 2K20 J or 2- lubricating oil inlet 3+ Oil drain |INSTALLATION AND COMMISSIONING 1.4 Electrical connections for 2K10, 2K12, 2K15 and 2K20 gearboxes The gearbox is connected up electrically using the 7-pin Harting plug (HAN 8 U) which is supplied with it. On braked gearboxes the brake receives its power through contacts { and 7. The servo motor and brake are powered by a 24 V DC supply and have a power consumption of 47 W each. Plug contact Number and in | Out Voltage Current No. designation put | put 2and3 I servo motor o | - De2v pelea 4106 2 limit switches ° * Jun aa hii Tmax = 5A Coton) —_fasvaednyop cone] © | ~ | PCY ae 13 Changing gear 1.5.1 Function During the gearchange process, the main spindle motor After that, a new shift must be initiated. A 10 sec. time ‘must change its direction of rotation approximately 5 limit applies for the next four shift attempts. Check the times per second. However, the gear engagement splines system if the gear is not shifted within that time. in the gearbox usually mesh with each other at the first change of direction, so gearchanges tend to take about == CAUTION 300 - 400 milliseconds. Do not change gear without oscillatory movement at The necessary oscillatory movement - through an angle low speeds. Satisfactory gearshifts cannot be guaran- of approx. + 8° to 10° or one division of the tacho gene- teed under these conditions. Fator commutator plate - is achieved by the input of a desired speed value signal of 30 - 30 mV at the conver- ter. The mechanical gearchange is performed by a selec- On request, gearboxes can be supplied with a neutral tor unit powered by a 24V direct current motor on the position between Ist and 2nd gear. Please request detai- gearbox. The gearbox shift element (a splined sliding _ led information about these units if required. sleeve moving in an axial direction) makes a positive connection. The shift positions are monitored by limit switches in the selector unit. A time relay must be provided to ‘monitor the time lag, and if the shift is not carried out within 2 secs. after its initiation (no signal is received from limit switches $1 or $2), the shift is cancelled.[INSTALLATION AND COMMISSIONING Gearchange control process Plug contact no. 2 3 | 4/50 5/6 (S2) when changing ratio from ig t0 iy a Initial position (f) | a 4 b Servo motor running peta an it a c Selector mechanism L 0 moved to stop *) when changing ratio from i, to iy 4. Initial position (e) | 7 7 » Servo motor running ov saan : | 7 | f Selector mechanism | 0 ie moved to stop (a) *) + After the switch movement, alinit switch (S1 oF $2) transmits a signal to the control unit to switch off the servo motor 1 Contact closed - Comract open n |INSTALLATION AND COMMISSIONING Shift logic Reduce speed of main spindle | motor from operating speed t0 zero, | Governor release signal must be present on converter. Immediately input desired speed of oscillatory movement into converter and speed regulator. fe | ‘Servo motor for gearehange ON. | 1 A> ange is Ait ised ia 2 sess. (Return stanal | |waneregy ss "| | oa Yellow eee ee Lea Fig. 12 Hirschmann-plug Ds4il If brake is fitted, | 2averarw free choice of polarity, 2.3.3 Setting the limit switches + Setting the limit switch for Ist gear Use a screwdriver to rotate the worm shaft to the right Until the selector fork is in contact with the Ist gear stop (perceptible resistance). The limit switch $1 must be heard to trip in this position. IF this is not the case, loo- sen the threaded pins (No. 840) and push the shift seg- ment (No, 830) round 1.5 to 2 mm past the shift point of the limit switch using a screwdriver (over-travel to guarantee switch function), + Setting the limit switch for 2nd gear (i= 1.00) Use a screwdriver to rotate the worm shaft to the left until the selector fork is in contact with the 2nd gear stop (perceptible resistance). ‘The limit switch $2 must be heard to trip in this position. If this is not the case, adjust the shift segment as described for Ist gear. Secure the threaded pins (No. 840) using a safety coa- ting,MAINTENANCE, 2.4 Adjusting the shift travel Fig. 15 Shift travel adjustment (A = shift travel) After setting the shift travel of the selector fork, also check the selector unit serting (limit switch signals), [eee era \ pee eee 2.5 Braked gearboxes Fig}16 ep pp z faaay (al putaeckazoce | | /| | NI I On braked gearboxes, check the clearance between the armature disc and counter- friction surface at monthly intervals. | The clearance must never exceed 1.3 mm. 0.410 1.3 mm clearance we 20Woo00YS maa] Peery ea) cee eee eel te Toor SGF meee] nem | | sonwaos | aon wOSANOD Inge “VSNVIEV - —06221— ie joan ONTUI ITA[—vooortes | is SOOOTILOY | ees = a= SONWYOS OO SOABANDD 13E rc a esey — ee tr 7 o-v60 ocsca— ~ ovit| <8¢1——— Md joeoee JONSNa