Operating manual - Meliormotion · 2019. 3. 19. · The operating manual must be kept within easy...

Revision 1.01 PSC Series/3P0203-EN Operating Manual I

Operating manual PSC series precision gearbox

Revision 1.01 PSC Series/3P0203-EN Operating Manual II

Melior Motion GmbH

Ohsener Str. 79-83

D-31789 Hameln

Tel: +49 5151 911 300 0

Fax: +49 5151 911 300 199

E-mail: [email protected]

www.meliormotion.com

© Copyright Melior Motion GmbH 2019

All technical data corresponds to the state of printing. As we are constantly

developing our products further, we reserve the right to make technical changes.

Unfortunately, errors cannot be completely ruled out. No legal claims can be

derived from the information, illustrations and descriptions in this manual. The

information and characteristics listed here shall only become a binding part of the

contract if they have been agreed with us in writing.

All drawings, texts and other representations contained in this document are the

protected property of Melior Motion GmbH. Any further use in print or electronic

media requires our express consent.

Revision Date

1.01 05/03/2019

Table of contents

Revision 1.01 PSC Series/3P0203-EN Operating Manual III

Table of contents

Table of contents .................................................................................. III

1 General information ............................................................................. 1

1.1 Using the operating manual ................................................................. 1

1.2 Safety and warning notices .................................................................. 1

1.2.1 Structure ................................................................................... 1

1.2.2 Signal words .............................................................................. 1

1.2.3 Safety symbols and information signs ........................................... 2

1.3 Personnel qualifications ....................................................................... 2

1.4 Warranty and liability .......................................................................... 2

2 Safety ................................................................................................... 3

2.1 Proper use ......................................................................................... 3

2.2 Foreseeable misuse ............................................................................ 3

2.3 Operating conditions ........................................................................... 3

2.4 Directives and standards ..................................................................... 4

2.4.1 Machinery directive ..................................................................... 4

2.4.2 Low-voltage directive .................................................................. 4

2.5 General safety notes ........................................................................... 4

3 Description of the gearbox ................................................................... 6

3.1 Type plate ......................................................................................... 7

3.2 Technical data .................................................................................... 8

3.3 Overview of variants ........................................................................... 8

3.4 Product key ....................................................................................... 8

4 Transport and storage .......................................................................... 9

4.1 Scope of delivery ................................................................................ 9

4.2 Transport .......................................................................................... 9

4.3 Storage prior to commissioning ............................................................ 9

4.3.1 Storage location ......................................................................... 9

4.3.2 Storage period of up to 12 months ............................................... 9

4.3.3 Storage period of up to 24 months ............................................. 10

4.4 Gearbox standstill of up to 24 months ................................................. 10

5 Installation ........................................................................................ 12

5.1 Preparations .................................................................................... 12

5.2 Gearbox assembly ............................................................................ 12

5.3 Installing the drive ........................................................................... 14

5.3.1 Coupling and lantern - Variant 0 ................................................. 15

5.3.2 Clamp connection - Variant 1 ..................................................... 16

5.3.3 Free input shaft - Variant 2 ........................................................ 17

5.3.4 Direct motor connection - Variant 4 ............................................ 18

5.3.5 Bevel gear input - Variant 6 ....................................................... 19

Table of contents

Revision 1.01 PSC Series/3P0203-EN Operating Manual IV

5.4 Oil levels ......................................................................................... 19

5.4.1 Installation positions B50, B51, B52, B53 .................................... 20

5.4.2 Installation position V1 - output bottom, drive top ........................ 21

5.4.3 Installation position V3 - output top, drive bottom ........................ 21

5.5 Output ............................................................................................ 22

5.5.1 Flange – Variant F (Standard) .................................................... 22

5.5.2 Shaft end - Variant W ............................................................... 23

5.5.3 Pinion - Variant R ..................................................................... 23

5.6 Miscellaneous ................................................................................... 23

6 Commissioning and operation ............................................................ 24

6.1 Initial commissioning ........................................................................ 24

6.2 Test run .......................................................................................... 24

6.3 Operation ........................................................................................ 25

6.4 Protective measures ......................................................................... 25

7 Maintenance and disposal .................................................................. 26

7.1 Maintenance work ............................................................................ 26

7.2 Oil changes ...................................................................................... 26

7.3 Lubricant ......................................................................................... 27

7.4 Disposal .......................................................................................... 27

8 Troubleshooting ................................................................................. 28

9 FAQs – Frequently asked questions .................................................... 29

10 Notes ................................................................................................ 31

1 General information

Revision 1.01 PSC Series/3P0203-EN Operating Manual 1


1.1 Using the operating manual

This operating manual contains important information on the proper and safe

installation, operation, maintenance and storage of Melior Motion PSC series

precision gearboxes.

The operator must ensure that this operating manual has been read and

understood by all persons charged with installation, operation or maintenance.

All persons working in the vicinity of the machine in which the precision gearbox

is installed must be familiarised with the safety instructions.

The operating manual must be kept within easy reach near the machine.

1.2 Safety and warning notices

Safety and warning notices point out possible dangers, prohibitions and important

information.

1.2.1 Structure

Safety

symbol

SIGNAL WORD

Type of danger and possible consequences

Hazard prevention measures

1.2.2 Signal words

The following signal words are used to draw attention to the dangers of personal

injury or damage to property as well as important information:

Imminent danger

Consequence: Severe injuries or even death

Possible danger

Consequence: Severe injuries or even death

Possible danger

Consequence: Minor injuries

Possible danger

Consequence: Damage to property or the environment

Important information for correct handling of the

precision gearbox

DANGER

WARNING

CAUTION

ATTENTION

NOTE



1.2.3 Safety symbols and information signs

The following safety symbols are used in this operating manual:

Warning of general danger

Warning of hand injuries

Warning of flammable substances

Warning of hot surface

Warning of suspended load

Warning of danger of drawing in

Warning of dangers for the environment

Notice of important information

1.3 Personnel qualifications

Only qualified personnel who have read and understood this operating manual may

work on the precision gearbox.

1.4 Warranty and liability

Observance of this operating manual is a basic requirement for safe and trouble-

free use of the precision gearbox.

Warranty and liability claims against Melior Motion GmbH for personal injury or

material damage shall be excluded in the event of improper storage, transport,

maintenance, repair, assembly and use, as well as non-compliance with the

operating manual.

2 Safety


2 Safety

2.1 Proper use

NOTE

The precision gearbox may only be used under the following

conditions. Exception: Melior Motion GmbH has expressly agreed

to a different use.

The gearbox serves as a component for converting speeds and torques in industrial

uses such as machines or systems and is designed exclusively for this purpose. It

may only be used within the performance limits as specified on the type plate and

in the operating manual.

2.2 Foreseeable misuse

Any use of the precision gearbox in which the maximum permissible technical data

(section 2.3, section 3.1, section 3.2) is exceeded is considered improper and

therefore inadmissible. Operation in potentially explosive atmospheres, in

aggressive environments (acids, gases, vapours, dusts, oils), under water and

under radiation is prohibited.

2.3 Operating conditions

Operating

ambient temperature: 0°C to +40°C

Set-up height: Up to 1000 m above sea level

Operating temperature: Permissible continuous temperature of max. 65°C

ATTENTION

Excessive operating temperatures can damage the engine and

gearbox.

Comply with the thermal class of the motor.

Surrounding media: Gearboxes are protected against dust and water jets

(static: IP67; dynamic: IP54)

Gearbox installation kits are not protected

For motors, comply with their operating manual

Abrasive or chemically aggressive media can damage the

gearbox or gear parts

2 Safety


2.4 Directives and standards

2.4.1 Machinery directive

According to the Machinery Directive 2006/42/EC, precision gearboxes are not

machines or incomplete machines, but components intended for installation in

plants and machines.

Precision gearboxes may only be put into operation after they have been installed

in a machine or system that complies with the Machinery Directive 2006/42/EC.

2.4.2 Low-voltage directive

Systems and machines in which precision gears are installed must comply with

Directive 2014/35/EU (old 2006/95/EC).

2.5 General safety notes

The gearbox is state of the art at the time of delivery and is generally considered

safe to operate.

Comply with legal regulations for accident prevention in addition to this operating

manual.

WARNING

Incorrect installation, operation, use and maintenance can result

in serious damage to property and serious injury or even death.

Pay attention to qualified specialist personnel.

Comply with all additional safety instructions in this operating

manual.

Comply with all safety instructions in supplementary sheets and

documents from suppliers.

Comply with warning and safety notices on the gearbox.

WARNING

Retrofitting, conversions and modifications to the gearbox can lead

to changes in the technical data of the gearbox and thus to serious

injuries or even death.

Only operate the gearbox in perfect condition.

Do not make any modifications or changes to the gearbox.

2 Safety


WARNING

Body parts and clothing can be drawn in by rotating parts on the

gearbox. This can lead to severe injuries or even death.

Only work on the gearbox when it is at a standstill.

Maintain a sufficient distance from rotating gear parts during

operation.

CAUTION

The gearbox heats up during operation. Touching hot surfaces can

cause severe burns.

Wait until the gearbox has cooled down after an extended period

of standstill before working on it.

Wear suitable protective gloves.

CAUTION

There is a risk of crushing hands and feet when handling the

gearbox.

Use only suitable lifting equipment.

Never stay under suspended loads.

Wear suitable protective gloves and safety boots.

ATTENTION

Lubricants, oils and parts of the gearbox can pollute the

environment.

Dispose of lubricants and all components of the gearbox in

accordance with environmental regulations.

3 Description of the gearbox



The PSC precision gearbox is a planetary gearbox with integrated helical gear

stage. High drive ratios allow high drive speeds. The self-regulating, ground

gearing system leads to high accuracy over the entire service life.

The precision gearbox is available in various versions with regard to size, design,

gear ratio, input, mounting position and output (section 3.3, section 3.4).

NOTE

The illustrations used in this operating manual are to be

understood as examples of the different variants and designs of

the gearbox. Some variations may occur.

M1, n1 M2, n2



3.1 Type plate

The type plate is attached to the precision gearbox in accordance with the following

illustrations and should also be legible after installation in order to identify the

gearbox.

Designation Unit Description

Type - Product key of the gearbox type (section 3.4)

No. - Serial number/sequential no./year of construction

E - Product number

kg kg Weight

M NOT-AUS Nm Emergency stop torque

Macc Nm Acceleration torque

n2 max rpm Maximum output speed

Iex - exact ratio

Oil - Specification of oil type, viscosity

Litres l Oil quantity



3.2 Technical data

Torsional backlash at output: ≤0.1 arcmin

Lost motion at output: ≤0.6 arcmin

Angular transmission accuracy: ≤50 arcsec

Efficiency at full load: ≥90%

Running noise:

4 Transport and storage



4.1 Scope of delivery

Immediately after receipt of the delivery, check the shipping documents for

completeness and inform the carrier and Melior Motion GmbH immediately of any

damage or missing parts.

NOTE

Melior Motion GmbH shall not assume any warranty for defects

claimed at a later date.

4.2 Transport

WARNING

Suspended loads may fall and cause serious injury or even death.

Do not stay under suspended loads.

Use suitable and sufficiently dimensioned means of transport.

Fasten the transport lugs. They are only designed for the weight

of the gearbox.

ATTENTION

Improper transport can damage the gearbox.

Avoid impacts during transport.

Set down the gearbox slowly and carefully.

4.3 Storage prior to commissioning

4.3.1 Storage location

Prior to commissioning, gearboxes must be stored in the ordered installation

position in a dry, dust-free and low-vibration environment at 0°C to +40°C and a

maximum of 50% relative humidity.

4.3.2 Storage period of up to 12 months

Gearboxes can be stored without special measures in accordance with section

4.3.1. The gearbox must be hermetically sealed. Ventilation elements must not be

used.



4.3.3 Storage period of up to 24 months

Please comply with the instructions in section 4.3.1. Storage must be in VCI

corrosion protection bags and in an atmosphere free of aggressive gases, vapours,

dusts and salts.

The following measures must be carried out by the customer.

• Drain the oil in the gearbox and completely fill it with rust-protection oil.

Attach a clearly visible label with the inscription “No operating lubricant” to

the gearbox.

• Hermetically seal all gear openings (oil drain plug, venting valve).

• Unprotected metal surfaces such as shaft ends and flanges must additionally

be provided with long-term corrosion protection.

• Turn the output flange by two revolutions every three months.

ATTENTION

Operating the gearbox with storage oil can cause damage to the

gearbox.

Drain the storage oil before commissioning the gearbox and

dispose of it in accordance with environmental regulations. For

refilling, comply with the instructions in section 5.4.

4.4 Gearbox standstill of up to 24 months

If the gearbox remains idle for a long time after installation and commissioning,

the protective oil film escapes from untreated surfaces. This can lead to corrosion

on parts inside the gearbox. To avoid corrosion and to re-wet the surfaces, the

gearbox should be turned by two revolutions at intervals of three months.

If regular rotation of the gearbox is not possible, an oil-soluble concentrate with

anti-corrosive additives (liquid or gaseous) in a concentration of approx. 2% can

be added to the oil. The exact information on the duration of effect, concentration

and compatibility can be found in the manufacturer's data of the supplier. In

addition, all gear openings must be hermetically sealed. However, the risk of rust

formation in the gearbox is slightly higher with this method compared to the

regular wetting of all surfaces with a protective oil film.

ATTENTION

Operating the gearbox with anti-corrosive additives in the oil can

cause damage to the gearbox.

Before restarting the gearbox, drain the old oil and dispose of it in

accordance with environmental regulations. Flush the gearbox with

flushing oil. For refilling, comply with the instructions in section 5.4.



NOTE

No vibrations or shocks may be transmitted from the foundations

to the gearbox during the standstill time.

NOTE

For gearbox standstills or storage which differ from the operating

manual, please contact Melior Motion GmbH.

5 Installation


5 Installation

WARNING

Failure to comply with the general safety instructions can lead to

serious damage to property and serious injury or even death.

Familiarise yourself with the general safety instructions in section

2.5 before carrying out any work on the gearbox.

NOTE

Please comply with the exact specifications of the product key

(section 3.4) during the following installation steps!

5.1 Preparations

NOTE

If the gearbox has been stored previously or has been at a

standstill for a longer period of time, comply with the instructions

in section 4.3 and section 4.4.

5.2 Gearbox assembly

NOTE

Comply with the safety instructions for transport in section 4.2.

ATTENTION

Inadequate alignment of the gearbox can lead to housing tension

and damage the gearbox and the peripherals.

Align the gearbox carefully.

ATTENTION

Using screws with insufficient strength can damage the gearbox.

All fastening screws must be sufficiently dimensioned.

5 Installation


PSC XXX–X– B –XXX–X–X–X–X PSC XXX–X– E –XXX–X–X–X–X

Screw housing E to the mounting using the bores in accordance with

the tables

Fasten the customer mounting via threaded bores with the output flange

in accordance with the tables

Screw flange cover B to the mounting using the bores in accordance

with the tables

Gearbox Screw size 1 Tightening torque 1 TA [Nm]

PSC056-X-E 16x M6 12.9 15.9

PSC080-X-E 20x M6 12.9 15.9

PSC112-X-E 16x M8 12.9 39

PSC160-X-E 20x M8 12.9 39

PSC224-X-E 20x M8 12.9 39

PSC300-X-E 20x M10 12.9 75

PSC400-X-E 24x M10 12.9 75


PSC056-V 12x M8 12.9 39

PSC056-H 10x M10 12.9 75

PSC080-V 16x M8 12.9 39

PSC080-H 10x M10 12.9 75

PSC112-V 16x M10 12.9 75

PSC112-H 15x M12 12.9 133

PSC160-V 20x M10 12.9 75

PSC160-H 15x M12 12.9 133

PSC224-V 20x M10 12.9 75

PSC224-H 15x M10 12.9 75

PSC300-V 20x M12 12.9 133

PSC300-H 20x M12 12.9 133

PSC400-V 24x M12 12.9 133

PSC400-H 15x M16 12.9 333

1

2

3

5 Installation



PSC056-X-B 12x M8 10.9 32

PSC080-X-B 12x M8 10.9 32

PSC112-X-B 12x M10 10.9 63

PSC160-X-B 12x M10 10.9 63

PSC224-X-B 12x M12 10.9 111

PSC300-X-B 12x M12 10.9 111

PSC400-X-B 12x M12 10.9 111

NOTE

Tightening torques for screws of strength classes 10.9 and 12.9 at

µtot = 0.125 (DIN EN ISO 4762 [old DIN 912], DIN EN 10058 [old

DIN 1017], DIN EN 10059 [DIN 1014], DIN EN ISO 4014 [old DIN

931], DIN EN ISO 4017 [old DIN 933])

The specified strength classes and tightening torques are only recommendations

from Melior Motion. The user is responsible for the safe connection between the

gearboxes and the peripherals.

5.3 Installing the drive

ATTENTION

Incorrect installation of the drive can damage the motor and the

gearbox.

Carry out the drive installation conscientiously.

NOTE

If there is a risk of electrochemical corrosion between the gearbox

and the system, intermediate inserts made of plastic must be used.

NOTE

If possible, the motor should be installed vertically on the gearbox

with the shaft end facing downwards.

5 Installation


5.3.1 Coupling and lantern - Variant 0

The cooling air intake of the motor must not be obstructed.

Clean motor shaft and coupling bores. The surfaces must be free of dust and oil.

PSC XXX–X–B–XXX– 0 –X–X–X

Slide the coupling onto the motor

shaft. The coupling must be at a

distance of “X” from the motor flange.

The value “X” is specified in the

dimension drawing that has been

released.

Clamp the coupling onto the motor by

tightening screw “S1” (tightening

torque TA in accordance with Table

S1/S2).

Remove screw plug “V”.

Position the motor and coupling so that

the second clamping screw “S2” can

be reached through the locking bore of

the lantern. The motor rests against

the lantern and is centred by it.

Tighten screw “S2” in accordance with

Table S1/S2.

Turn the motor to the desired position

and fasten it to the lantern using four

screws (not included in the scope of

delivery) through the bores provided

for this purpose. Comply with the

tightening torques for the screws.

S1/S2

Coupling AF [mm] TA [Nm]

TOOLFLEX S 20 4 6

TOOLFLEX S 30 5 10

TOOLFLEX S 38 6 25

TOOLFLEX S 42 6 25

TOOLFLEX S 45 8 49

TOOLFLEX S 55 10 86

5 Installation


5.3.2 Clamp connection - Variant 1

Clean the motor shaft and the drive shaft bore. The surfaces must be free of dust

and oil.


Remove screw plug “V”.

Turn the input shaft “W” so that the

screw “S” points to the closing bore.

Carefully insert the motor shaft end

into bore “D” of the input shaft until

the motor rests on flange surface “F”.

Tighten screw “S” in accordance with

the tightening torque TA in Table S.

S

AF [mm] TA [Nm]

5 15.9

6 39

8 75

10 133

5 Installation


5.3.3 Free input shaft - Variant 2

ATTENTION

Shocks can damage the gearbox when the attachments are placed

on the input shaft.

Carry out the drive installation conscientiously.

Clean the drive shaft and bore of the adapter part. The surfaces must be free of

dust and oil.


Align the keyway of the adapting part

with the key on the drive shaft. Slide

the attachment over the length “L5” as

far as it will go.

Gearbox L3

[mm]

b h9

[mm]

L5

[mm]

d1 k6

[mm]

PSC056 22 6 27 19

PSC080 22 6 27 19

PSC112 30 8 35 24

PSC160 30 8 35 24

PSC224 30 8 35 24

PSC300 40 8 45 30

PSC400 40 8 45 30

5 Installation


5.3.4 Direct motor connection - Variant 4

Design Variant B Design Variant E

PSC XXX–X–B–XXX– 4 –X–X–X PSC XXX–X–E–XXX– 4 –X–X–X

Please contact Melior Motion GmbH for

further information.

Install the pinion with axis distance A

and pinion distance B in accordance

with the following table, taking into

account the size and the shaft design.

Solid shaft V Hollow shaft H

Gearbox A

[mm]

Tolerance A

[mm]

B ±0.2

[mm]

PSC056-V-E 75 +0,022 /+0,037 42.25

PSC056-H-E 85 +0,022 /+0,037 42.25

PSC080-V-E 85 +0,022 /+0,037 49.5

PSC080-H-E 95 +0,022 /+0,037 49.5

PSC112-V-E 95 +0,027 /+0,042 55.75

PSC112-H-E 105 +0,027 /+0,042 55.75

PSC160-V-E 105 +0,027 /+0,042 58

PSC160-H-E 115 +0,027 /+0,042 58

PSC224-V-E 115 +0,027 /+0,042 62.75

PSC224-H-E 125 +0,027 /+0,042 62.75

PSC300-V-E 125 +0,030 /+0,045 70.25

PSC300-H-E 140 +0,030 /+0,045 70.25

PSC400-V-E 140 +0,030 /+0,045 73.5

PSC400-H-E 155 +0,030 /+0,045 73.5

5 Installation


5.3.5 Bevel gear input - Variant 6

PSC XXX–X–X–XXX– 6 –X–X–X

The installation is analogous to the

installation of the coupling and lantern

in section 5.3.1.



5.4 Oil levels

NOTE

Please comply with the marking of your product key! Oil levels

depend on the installation position! It is essential to comply with

and maintain the correct installation position!

ATTENTION

Faulty oil levels can lead to mechanical damage and overheating

of the gearbox.

Comply with the oil levels described in the operating manual.

NOTE

The customer is responsible for adequate lubrication of attached

components and pinions.

NOTE

All gearbox blocks are filled with the correct quantity of oil at the

factory on delivery.

5 Installation


5.4.1 Installation positions B50, B51, B52, B53


Horizontal input bottom, left, right

PSC XXX–X–B–XXX–X– –X–X

Horizontal input bottom/left/top/right

PSC XXX–X–E–XXX–X– –X–X

Fill the gearbox in the orientation

shown up to the lower edge of “O1”

and then rotate it into the correct

installation position.

Horizontal input top

PSC XXX–X–B–XXX–X– B52 –X–X

Depending on the size of the gearbox,

the oil level must reach up to the

height “L1” in accordance with the

table.

Gearbox L1 [mm]

PSC056-X-E 45

PSC080-X-E 52

PSC112-X-E 61

PSC160-X-E 65

PSC224-X-E 70

PSC300-X-E 82

PSC400-X-E 90


shown up to the lower edge of “O2”

and then rotate it into the correct

installation position.

B50

B51

B53

B50

B51

B52

B53

5 Installation


5.4.2 Installation position V1 - output bottom, input top


PSC XXX–X–B–XXX–X– V1 –X–X PSC XXX–X–E–XXX–X– V1 –X–X


shown up to the lower edge of “O3”.


the oil level must reach up to the height

“L2” in accordance with the table.

Gearbox L2 [mm]

PSC056-X-E 33

PSC080-X-E 40

PSC112-X-E 45

PSC160-X-E 46

PSC224-X-E 49

PSC300-X-E 55

PSC400-X-E 58

5.4.3 Installation position V3 - output top, input bottom


PSC XXX–X–B–XXX–X– V3 –X–X PSC XXX–X–E–XXX–X– V3 –X–X


the oil level must reach up to the

height “L4” in accordance with the

table (see Design Variant E).


the oil level must reach up to the height

“L4” in accordance with the table.

Gearbox L4 [mm]

PSC056 21

PSC080 24

PSC112 27

PSC160 29

PSC224 31

PSC300 36

PSC400 39

5 Installation


5.5 Output

5.5.1 Flange – Variant F (Standard)

PSC XXX–X–X–XXX–X–X– F –X

The centring must be complied with. Adapted parts must lie flat on the output

flange. Installation is carried out with the connection dimensions in accordance

with section 5.2.

Solid shaft V Hollow shaft H

Gearbox Centring diameter D H7 [mm] Centring length T [mm] D1 [mm]

PSC056-V 70 5.25

48.5

PSC056-H 83 --

PSC080-V 80 4.5

54.5

PSC080-H 98 --

PSC112-V 90 5.25

60.5

PSC112-H 114 --

PSC160-V 100 4.75

67.5

PSC160-H 120 --

PSC224-V 110 6

80

PSC224-H 130 --

PSC300-V 125 8

91.5

PSC300-H 150 --

PSC400-V 140 7.5

101

PSC400-H 170 --

5 Installation


5.5.2 Shaft end - Variant W

PSC XXX–X–X–XXX–X–X– W –X



5.5.3 Pinion - Variant R

PSC XXX–X–X–XXX–X–X– R –X



5.6 Miscellaneous

Order parameters 0 and 1 under “Miscellaneous” in the product key are not defined

for the customer. They are intended for internal use by Melior Motion GmbH.

6 Commissioning and operation



WARNING





WARNING

A drive system that has not been stopped can cause serious

injuries or even death when working on the gearbox.

Shut down the drive system before working on the gearbox.

6.1 Initial commissioning

Gearboxes without oil filling must be filled with a suitable lubricant in accordance

with the description in section 5.4.

Check all fastenings, output elements, protective elements and the electrical

connection.

Check the accessibility of all screw plugs and control screws.

6.2 Test run

NOTE

The gearbox may only be put into operation if it is ensured that all

previous instructions and specifications have been observed and

the degree of protection has been checked.

WARNING

An unsecured keyway can cause serious injury or even death

during the test run without an output element.

Secure the keyway.

Check the correct direction of rotation of the gearbox in the uncoupled state and

pay attention to unusual noises.

When using a brake motor, the correct functioning of the brake must be checked.



6.3 Operation

ATTENTION

Excessive temperatures, unusual noises or vibrations can cause

damage to the gearbox.

Check the gearbox at regular intervals.

Stop the gearbox and determine the cause of the fault. Rectify this

after consulting Melior Motion GmbH.

If excessive temperatures, unusual noises or vibrations are detected, the gearbox

must be stopped, the cause of the fault determined and, if necessary, rectified

after consulting Melior Motion GmbH.

6.4 Protective measures

NOTE

The lubricant ages faster and the sealing elements can be damaged

if the permissible continuous temperature of 65°C is exceeded.

7 Maintenance and disposal



7.1 Maintenance work

WARNING





WARNING

A drive system that has not been stopped can cause serious

injuries or even death when working on the gearbox.

Shut down the drive system before working on the gearbox.

The gearbox is maintenance-free and lubricated for life.

Regularly renewing the lubricant increases the service life. Please follow the

instructions below and contact Melior Motion GmbH.

7.2 Oil changes

The gearbox must be at operating temperature.

WARNING

The use of flammable cleaning agents can cause serious injury or

even death when working on a hot gearbox.

Comply with the manufacturer's safety instructions.

Do not use flammable cleaning agents on hot gearboxes.

CAUTION

The gearbox heats up during operation. Touching hot oil and

surfaces can cause severe burns.

Wear suitable protective clothing.

Stop the gearbox and remove the top screw plug. Open the oil drain plug and

carefully drain the warm oil into a suitable container. Dispose of used oil in

accordance with environmental protection regulations. Remove old lubricant



residues with suitable cleaning agents and screw the oil drain plug back in. Fill the

gearbox with oil as specified in section 5.4 and tighten the screw plug.

7.3 Lubricant

NOTE

Melior Motion GmbH only recommends lubricants. The company

shall not be liable for damage caused by lubricants incompatible

with the materials used.

The following lubricants are permitted for PSC series precision gearboxes in the

ambient temperature range from 0°C to 40°C. Lubricants must not be mixed.

• Castrol - Optigear EP320 PD or

• Vigooil - SB 150

Special lubricants for e.g. long-term storage or special operating conditions are

available from Melior Motion GmbH at an extra charge.

7.4 Disposal

Housing parts, gears, shafts, covers and flanges must be disposed of as scrap

metal in accordance with the relevant environmental regulations.

Used oil must be disposed of in accordance with the applicable environmental

regulations.

ATTENTION

Lubricants, oils and parts of the gearbox can pollute the

environment.

Dispose of lubricants and all components of the gearbox in

accordance with environmental regulations.

8 Troubleshooting


8 Troubleshooting

NOTE

If unexpected malfunctions occur in the gearbox which you cannot

rectify yourself, please contact Melior Motion GmbH. Have

information on the type plate, type and extent of the fault,

intended use of the gearbox and the time and circumstances of the

fault ready.

Error Possible causes Resolution

Drive not running Power supply interrupted Check connection

Incorrect electrical connection Check conformity of motor type plate

and power supply

Load too high Reduce load, check drive-machine

assignment

Output shaft does not

rotate while motor is

running

Connecting elements are

missing or defective

Check adapting parts

Force flow interrupted by

breakage in the gearbox

Notify Melior Motion customer service

Coupling uncoupled Couple the coupling

Unusual running noises

or vibrations

Overloading Reduce the load

Damage to the gearbox or

motor

Notify Melior Motion

Input pinion poorly aligned Check alignment of the input pinion

and correct if necessary

Excessive temperature Overloading Reduce the load

Excessive temperature

Loosened fastening

elements

Overloading

Insufficient heat dissipation

Check drive-machine assignment

Improve cooling air supply

Insufficient heat dissipation

Lack of lubricant

Clean gearbox/motor

Fill up lubricant as prescribed

Vibrations Avoid vibrations

Oil leakage Ventilation not installed Install ventilation (screw, filter, etc.)

Ventilation dirty Clean ventilation

Oil expansion tank not

installed

Install oil expansion tank

Loose venting screw plug Tighten venting screw plug

Incorrect oil level for the

design used

Check design and oil lubricant

components

Shaft seals defective Replace shaft seals

Damage in transit (e.g.

hairline cracks)

Inspect drive for damage in transit

9 FAQs – Frequently asked questions



Can the input pinion be adapted directly to the motor shaft?

Yes, but the motor used must be able to absorb the considerable radial and axial forces that originate from the gears.

Does the housing or the output flange rotate?

The housing and output flange move relative to each other. Depending on the

design, both bodies can be used as output.

Which dimensions in the dimensioned drawing may/can be used for centring or alignment?

For centring, the recess located within the bolt circle is provided (see section

5.5.1). On the dimensioned drawings it is always tolerated by “H7”.

Can the motor adapter be modified retrospectively to connect another

servomotor?

Yes, in many cases this is possible. Please contact Melior Motion regarding this.

With which rotation do the hollow shaft and the protection tube rotate?

The hollow shaft rotates in the same direction as the output flange, but 9 to 15

times faster. The hollow shaft protection tube is attached to the output flange and rotates just as quickly as the flange.

Can the hollow shaft be centred?

No, the hollow shaft rotates relative to both the output flange and the housing.

Can the gearboxes also be operated at a height above 1000 m?

Yes, but venting must first ensure that the excess pressure in the gearbox is not

too high. In addition, the heat dissipation is worse due to the lower air pressure, additional cooling may have to be provided.

Do the gearboxes have to be vented?

Not normally. Gearboxes that are operated in the V3 installation position and

become warmer than 60°C are an exception.

Can the installation position of a gearbox be changed retrospectively?

Yes, but the oil level must be adjusted to the new installation position.



Is there oil in the adapter housing?

The adapter housing contains oil that is required to lubricate the input shaft

bearings.

Does an oil change have to be carried out and if so, when?

The gearboxes are lubricated for life, an oil change is not necessary. However, if a particularly long service life is desired or the gearbox is operated at persistently

high temperatures, we recommend that an oil change is carried out regularly.

Can any mineral oil with a viscosity of 320 be used?

Any gear oil with a viscosity of 320 can be used in the temperature range from 0 to 65°C. However, it should be noted that not every lubricant is compatible with every shaft seal and leakage can occur. For this reason, we recommended using

an oil approved by Melior Motion.

Can food grade oil be used?

Yes, but the viscosity must match the operating temperature and compatibility with the seals must be ensured. Therefore, we recommend using only oil approved

by Melior Motion.

Can the gearboxes also be used at low temperatures (-40°C to 0°C

ambient temperature)?

Yes, this is possible if the gearbox is equipped with shaft seals made of NBR and

the appropriate oil is used. Please contact Melior Motion in this regard.

The service life of the gearbox is indicated as 20,000 hours. When this

time is up, is the gearbox worn out?

No, the service life of 20,000 hours was calculated for continuous use with continuous torque and external loads. If these values are not reached, which is

likely to be true in most instances, the gearboxes will last longer.

Which wearing parts (spare parts) can be replaced by the customer and is there a spare parts kit?

Spare parts kits are not currently planned. Please have wearing parts replaced

directly by Melior Motion.

Can the gearbox be repaired?

That depends entirely on the damage involved. Please contact Melior Motion with a detailed error description.

10 Notes


10 Notes

Operating manual - Meliormotion · 2019. 3. 19. · The operating manual must be kept within easy...

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