REHFUSS Gearboxes - Operating Instructions
REHFUSS Gearboxes - Operating Instructions
REHFUSS Gearboxes - Operating Instructions
Operating Instructions
Types SR, FG, S, SS, SM, SSM
1 Important Notes 4
2 Safety Notes 5
2.1 Safety notes for standard use 5
2.2 Designated use 5
2.3 Transport 5
2.4 Gearboxes with extended storage 6
2.5 Installation 6
2.6 Start up 6
2.7 Inspection / Maintenance 6
3 Construction of gearbox 7
3.1 Basic construction helical gear 1-step SR120 SR160 7
3.2 Basic construction helical gear 2-step SR210 SR260 8
3.3 Basic construction helical gear 3-step SR320 SR360 9
3.4 Basic construction helical gear SR270 SR370 10
3.5 Basic construction shaft mounted gearboxes Type FG 11
3.6 Basic construction worm gearbox S030 S050 solid shaft 12
3.7 Basic construction worm gearbox S030 S050 hollow shaft 13
3.8 Basic construction helical worm gearbox SS130 SS150 solid shaft 14
3.9 Basic construction helical worm gearbox SS130 SS150 hollow shaft 15
3.10 Basic construction helical worm gearbox SS160 SS170 solid shaft 16
3.11 Basic construction helical worm gearbox SS160 SS170 hollow shaft 17
3.12 Basic construction worm gearbox SM011 SM031 solid shaft / hollow shaft 18
3.13 Basic construction worm gearbox SM041 solid shaft / hollow shaft 19
3.14 Basic construction worm gearbox SM051 SM061 solid shaft 20
3.15 Basic construction worm gearbox SM051 SM061 hollow shaft 21
3.16 Basic construction worm gearbox SSM121 SS131 22
3.17 Basic construction worm gearbox SSM151 SS161 23
3.18 Basic construction slip clutch 24
3.19 Basic construction IEC Adapter 25
3.20 Basic construction free input shaft 26
4 Mechanical Installation 27
4.1 Required tools 27
4.2 Before you start 27
4.3 Preparation 27
4.4 Installation of gearbox 28
4.5 Gears with solid shaft 29
4.6 Mounting torque arm 30
4.7 Mounting / dismantling of shaft gearboxes with hollow shaft 30
4.8 Mounting / dismantling of shaft gears with shrink discs and cowl 30
4.9 Mounting IEC Adapter 31
4.10 Mounting IEC Adapter with adapter flange 32
4.11 Mounting IEC Adapter SM041 33
4.12 Mounting on free input shaft 34
5 Installation 35
5.1 Control lubricant with Oil level screw 35
5.2 Control lubricant on gearboxes without Oil level screw 35
5.3 Starting of worm gearboxes 35
5.4 Starting of helical and shaft mounted gearboxes 35
5.5 Starting gears and geared motors 35
6 Inspection and Maintenance 36
6.1 Inspection and maintenance intervals 36
6.2 Change intervals of lubrications 36
6.3 Change intervals of rolling bearings 36
6.4 Inspection and maintenance gearboxes 37
6.5 Inspection and maintenance IEC Adapter 37
6.6 Inspection and maintenance free input shaft 37
7 Malfunctions 38
7.1 Malfunction of gearbox 38
7.2 Malfunction of IEC Adapter 39
7.3 Malfunction on free input shaft 39
8 Types / Mounting positions 40
8.1 General information about mounting positions 40
8.2 Mounting position SR 1-step 41
8.3 Mounting position SR 2-step 42
8.4 Mounting position FG 43
8.5 Mounting position S 44
8.6 Mounting position SS 45
8.7 Mounting position SM / SSM 46
9 Lubricants 47
Table: Capacity 48
Table: Lubrications 49
1 Important Notes
Always follow the safety and warning instructions contained in this publication!
Electrical hazard
Possible consequences: Severe or fatal injuries.
Hazard
Possible consequences: Severe or fatal injuries.
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the drive and the environment
A requirement of fault-free operation and fulfilment of any rights to claim under guarantee is that you adhere to the
information in the operating instructions. Consequently, read the operating instructions before you star operating the drive!
Keep the operating instructions in the vicinity of the unit since they contain important information about servicing the unit.
Waste disposal
(please dispose of the parts in accordance with the applicable regulations)
parts of housing, gears, shafts and rolling bearings of the gearboxes are to be disposed as iron. Cast parts as well when
there is no special collection.
Worm wheels are partly made from non-ferrous materials and are to be disposed of in accordance to applicable
regulations.
Collect used oil and dispose of in accordance to applicable regulations.
2 Safety Notes
General
During and after operating geared motors, gearboxes and motors have live and rotating parts as well as possibly hot
surfaces. All works to transport, stocking, connection, start up, repair and maintenance may only be performed by qualified
personnel under strict consideration of
inexpert application
false installation or use
not allowed removal of necessary protection covers or housing
These gearboxes / geared motors are intended for industrial systems, they correspond to applicable standards and
regulations and meet the requirements of directive 94/9EC (Atex 100a).
Technical data and information to applicable regulations are listed on the nameplate and in the documentation. All
instructions must be strictly observed!
2.3 Transport
Please check all shipments immediately upon receipt for possible damaged in transport. Announce these
without delay to the forwarding agent. Start up has to be postponed if necessary. Fix screwed transport rings.
They are only designed for the weight of the gearbox / geared motor, no additional load must be added. Build in
ring screws correspond to DIN 580. Loads and instructions contained therein have to be observed strictly. When
two transport rings or ring screws are fixed, transport has to be executed on both transport rings. Direction of
draw angle may not exceed 45 according to DIN 580. If necessary use sufficient means of transport. If there
are transport securities please remove before start-up.
Gearboxes with extended storage contain a typical, ready for use oil filling with oil. Please check oil level before start up.
Packaging has to be done by experienced personnel with for the usage qualified packing material.
2.5 Installation
2.6 Start up
Check correct direction when not coupled (listen for unusual grinding noises when turning). For test running without driving
elements protect feather .Do not turn off control and protection functions even for tests. When there are changes to regular
use as there are rise of temperature, noise, vibrations) geared motor has to be stopped. search reason , if necessary
contact REHFUSS.
3 Construction of gearbox
version R
version R
version R
version R
version WG,WF,WL,WD
version HG,HF,HL,HD
version WG,WF,WL,WD
version HG,HF,HL,HD
version WG,WF,WL,WD
version HG,HF,HL,HD
version WG,WGU,WF,WFU
version HG,HGU,HF,HFU
version WG,WGU,WF,WFU
version HG,HGU,HF,HFU
version WG,WGU,WF,WFU
version HG,HGU,HF,HFU
worm gearbox S, SS
size 56 71
size 80 180
4 Mechanical Installation
mounting press
lubricant
screw protection (for cover on input side with centring ring). z. B. Loctite
all screws which had to be disengaged have to be secured again with screw protection (liquid or
mechanical)
Tolerances at installation
Information on nameplate of drive corresponds to the approved on site explosion application range
(equipment group, category, zone, temperature class or maximum surface temperature)
There are no potentially explosive atmospheres, oils, acids, gases, vapours, radiation etc. during installation.
For worm gearboxes: there is no extern mass moment of inertia which might drive back gearbox on
load
[at ' (back driving) = 2 - 1/ < 0,5 retained by friction].
4.3 Preparation
Output shafts and flanges must be completely free of anti-corrosion agents, contamination or other impurities ( use a
commercially available solvent) Do not let solvent get in contact with the sealing lips of the oil seals danger of damage of
the material.
Before starting check specified lubricate quantity! (Chapter Lubricant information on nameplate)
We deliver gears with necessary lubricant quantity. Slight deviation is possible and allowed within tolerance.
Check oillevel before starting (-> chapter Inspection / Maintenance).
Use plastic inserts when there is danger of electrochemical corrosion between gear and machine (connection of mixed
materials as cast/steel). Use plastic inserts 2-3 mm thick. Use plastic washers for screws! Plastic used must have bleeder
9
resistor of < 10 . Ground gear housings on principle. For geared motors use additionally grounding screws on motor.
Ensure adequate supply of cooling air and that heated air from other units is not drawn in. The cooling air may not exceed
a temperature of 40C. No metal parts must be mounted isolated.
Ventilation of gearboxes
No ventilation necessary for below gearboxes:
SM/SSM gearboxes
All remaining gears are supplied by Rehfuss with adequate and activated breather valves.
Exception:
Gearboxes for extended storage and when mounted on sloping level are supplied with protection cap on breather bore.
Before starting user has to change supplied breather valve against sealing plug in the highest position.
For geared motors for extended storage and for mounting in sloping level supplied breather valve finds in Terminal Box of
motor.
Gearboxes in closed design are supplied without breather valve.
Breather valves are activated ex works normally.
The following figure shows the correct mounting arrangement B of a gear or sprocket to avoid excessive overhangs loaded.
1) shaft-hub
A = unfavourable
B = correct
Only use a mounting device for installing input and output-elements. Use the centre bore and the thread on
the shaft end for positioning purposes.
Never mount belt pulleys, clutches, pinions etc. onto the shaft end by hitting them with a hammer ( damage
to bearings, housing and the shaft!).
Observe correct tension of the belt for belt pulleys (in accordance with manufacturers specifications).
Power transmission elements should be balanced after installation and must not rise to excessive radial or
axial forces (see the Gearmotors catalogue for approved values).
Assembly is easier if you first apply lubricant to the output element or heat it up briefly (to 80-100C).
Mounting of couplings
The following items have to be balanced according to the coupling manufacturers specifications when mounting couplings:
a) Maximum and minimum clearance
b) Axial offset
c) angular offset
Input and output elements such as belt pulleys, clutches etc. must be equipped with a touch guard!
Only mount / dismantle drives with appropriate device. Hitting on drives or shafts might damage bearings,
housings or shafts).
Assembly
1. loosen clamping screws slightly (do not remove entirely!).
2. carefully lubricate hollow shaft boring and Input shaft.
3. join degreased hollow shaft/Input shaft.
Assemble input shaft, note parallel position of outer rings of shrink discs. For housing with shaft collar fix shrink disc wi th
bearing of 1 to 2 mm to housing of gearbox. Tighten clamping screws in a row (not crossing) with torque wrench till crews
do not move any more. Pick-up of crews are noted on shrink discs.
After assembly t
here must be a remaining clearance s > 1 mm.
Outer flanges of hollow shaft in reach of shrink disc should be greased for corrosion protection.
1. Slide the coupling (1) up the motor shaft (2) until the hub rests against the shaft collar (a) and flange facing (a)
lie on a single plane and that the highly chamfered side (b) faces the motor flange (3). This guarantees the
correct distance between the coupling and the coupling shaft (4).
3. Implace the motor on IEC-Adapter (6). In doing so, insure that the socket pins (7) have been correctly inserted
into the bore holes (c) of the coupling ring.
Note: We recommend to use anti-corrosion agents on motor shaft before mounting coupling hub.
1. Slide the coupling (1) up the motor shaft (2) up to distance X between hub and shaft collar. It is essential that
shaft collar (a) and flange (a) lie in line and the highly chamfered side (b) faces to motor flange (3). This
guarantees the correct distance between the coupling and the coupling shaft (4).
3. Implace the motor with adapter flange (8) on IEC-Adapter (6).. Ensure that socket pins (7) have been correctly
inserted into the bore holes (c) of the coupling ring.
Note: We recommend to use anti-corrosion agents on motor shaft before mounting coupling hub.
Gearbox (B) is supplied complete with Motor adaptor (C) and fixing screws (K) for Motor (E).
1. Loosen 3 locking screws (A) on gearbox side (do not take out!) Note marking X. Remove Motor adaptor (C)
from gearbox by turning (Bayonet). Then take off coupling (D) from drive pins.
2. Slide on coupling with face (Z) of the Coupling hub (H) onto the motor shaft towards motor flange side (E)
untill coupling hub (H) mounts to shaft collar (F). It is essential that shaft collar and flange face of motor are
in line. Tighten radial locking screw (G) of coupling hub.
3. Put on motor adaptor (C) on motor flange and align according to required terminal box position. Orientate
according to marking X on adaptor. Screw adaptor on motor flange.
4. Put motor with adaptor on gearbox and position by turning (bayonet). Markings on adaptor and gearbox have
to be in line. Then tighten the 3 locking screws (A).
Allowed loads
56 72 350
63/71 75 530
Maximum allowed weight of attached motor Fqmax has to be reduced linearly when distance of centre of
gravity x is increased. When distance of centre of gravity x is reduced no increase of maximum allowed
weight Fqmax is allowed.
5 Installation
Check appropriate oil level before starting. Oil control and drain screws as well as breather breather screws
and -valves must be easily accessible.
warmup time
Worm gearboxes need a warmup time of at least 24 hours, to reach maximum performance. Is gearbox operated in both
turning directions, a warmup time for each of the directions is necessary. Average reduction of performance during warmup
time is approximately 5%.
Mainsloaded motors
Make sure that information stated on nameplates of gearbox and motor correspond to ambient conditions in site.
Rehfuss recommends when replacing lubricant on rolling bearings with grease filling replace grease as well.
Below quantities are needed:
For fast running bearings (Motor and gearbox input side) fill hollow spaces between rolling elements up to
1/3
For slowly running bearings (in gearbox and gearbox output side): Fill 2/3 of hollow spaces with grease
Replace lubricant
Replace lubricant only on gearboxes that are worm from operation.
1. Switch gearbox dead, Protect against unintended start! Wait till gearbox has cooled down danger of
burning!
Note: Gearbox has to be warm however as total draining is more difficult when oil is too cold.
2. For gearboxes with drain screw/Oillevel screw:
3. Put vessel under drain screw.
4. remove oillevel screw, breather screw /-valve and drain screw
5. drain oil totally
6. insert oillevel screw again.
7. Replace lubrication of same kind into breather bore (otherwise contact service) quantity according to
variation (see chapter lubricant capacity) or to instruction on nameplate. Check on oillevel screw.
8. insert oillevel screw.
9. insert breather screw/valve.
every 3000 operating hours, at least every 6 months Check running noise
View for leaking
after 25000 - 30000 operating hours Replace rolling bearing grease if required
Replace shaft seals
7 Malfunctions
Service
Please provide the following information if you require assistance from our customer service:
Nameplate information (complete), Nature and extent of the problem, time and circumstances of problem, presumed cause
unusual, continuous running noise Noise reeling/grinding: damage on Check lubricant and quantity (see
bearing inspection and maintenance),
contact REHFUSS
replace bearing.
noise knocking: irregular toothing Contact REHFUSS
Unusual, differential running noise Alien element in lubricant Check lubricant and quantity (see
inspection and maintenance),
stop engine.
Contact REHFUSS
Oil leaking Bearing defective Contact REHFUSS
On motor shaft seals
On gear flange
On output shaft seal
Oil leaking on breather valve Too much oil contact REHFUSS
Drive used in incorrect mounting
position
Frequent cold started (oil frothing) and
/ or high oil level
Breather valve dirty
Output shaft not turning although Connection shaft-hub in gear Return to REHFUSS for repair.
motor is running or input shaft is interrupted
turned
Leaking oil/grease on shaft seal (low quantities) during warm up time (24 operating hours) are considered normal
(see DIN 3761).
Output shaft not turning, although Connection shaft-hub in gear is Return to REHFUSS for repair.
motor running or input shaft is turned interrupted
Changing noise and/or vibrations Coupling worn, short term Replace coupling
occurring transmission of torque by contact with Tighten screw and protect
metal
Screw for fastening hub axial loose.
Premature wearing of coupling Contact with aggressive oils, influence contact REHFUSS
of Ozone, ambient temperature to high
etc. which cause a physical change of
coupling or too high temperatures,
overload
Output shaft not turning, although Connection shaft-hub in gear is Return to REHFUSS for repair
input shaft is turned interrupted
8 Mounting positions
B3 B6 B7
B8 V1 V3
B
3 4 1 2
2 2
3 4 C A
1 1
3 4 2 1
Normally and unless otherwise specified the Terminal box is in position A and the cable entry is in pos. 1. If other terminal
box or cable entry positions are required they are to be specified when ordering.
Please note: no breather valves nor oillevel screws nor drain screws can be fixed on SM / SSM gears and
geared motors.
9 Lubricants
General
If not agreed specially REHFUSS supplies explosion proof drives with lubricant according to specification of gear and
mounting position. For this it is essential to advise mounting position when ordering the drive. When design is amended
later please contact REHFUSS necessarily.
Lubricant / Quantity
Please see the following table capacity for requested lubricant quantities. It is essential to watch oillevel screw for
indicator of exact quantity. For allowed lubrications please see table lubrications.
For fast running bearings (Motor and gearbox input side) fill hollow spaces between rolling elements up to
1/3
For slowly running bearings (in gearbox and gearbox output side): Fill 2/3 of hollow spaces with grease
Table: Capacity
Table: Lubrications