Installation and Operating Manual for
Contents
1. Replace or repair safety equipment Replace the tightening roller Use the correct belt pulley combination Retighten until creep is gone Realign pulleys Replace pulleys Replace by correct belt size Use the correct belt pulley combination Replace pulleys Use the correct belt pulley combination Replace pulleys Clean pulleys Use larger pulley diameter Retightening Use larger diameter for outer tightening roller Do not stretch belt too tight do not bend or inflect Avoid heat and direct sunlight STRONG OR SUUNUAL BELT WEAR V BELTS TWIST OR JUMP OFF THE DRIVE BELT EXTENSIOND BEYOND RETIGHTENING VALUE NOISE CAUSED BY BELTS FAULT Burned out and hard edges and substructure Extreme hardening of belt shell Flocky sticky or swollen belt surface Individual or composite belts Composite belts will not extend uniformly Individual belts or all belts expand in the same way Whistling or chirping Whipping noise Grinding noise POSSIBLE CAUSE Belt creep Worn out pulleys Insufficiently rated drive Wavy movement Hot surrounding of belt Pollution through oil or chemicals at belts or in the pulleys Shock load or vibration Foreign substances in pulley grooves Non aligned pulleys Worn out pulley grooves Traction body damaged Wrong position of flat tightening roller Wrong belt set Inappropriate drive design Non aligned drive Dirty pulley2. Ea Impression depth of free running part of belt Example of application Profile SPB small pulley e g motor pulley 180 mm length of free running part of belt 460 mm Test force from the Table 75 N impression depth 3 7 x 460 100 17 mm Installation and Operating Manual Taper Bush The Taper Bush system consists of conical clamping bushes with various bores in standardized sizes and the V belt or flat belt pulleys with appropriately executed conical bore The advantages of the taper bush system are easy assembly and dismantling and the capacity of the belt pulleys to adapt to different bore diameters by exchanging the corresponding taper bush Assembly Clean all polished bush surface from grease oil and dirt prior to assembly Such surfaces are in particular the bore the outside cone of the bush and all semi bores and semi thread bores Also degrease the conical bore of the belt pulley Introduce the taper bush now into the hub of the pulley until the specific semi bores in the hub and in the bush coincide Make sure that every thread semi thread in the bush corresponds to a smooth semi bore in the hub and vice versa The fastening screws for the bush included in the supply are slightly lubricated with oil at its thread point and bottom part of its head and manually screwed into the provided holes Further keep in mind that the fastening bores are those which are provided with a semi thread
3. 20 200 100 M 12 96 28 14 M 24 250 125 M 16 70 36 18 M 30 280 140 M 16 79 40 20 M 36 340 180 M 20 100 90 20 M 42 425 225 M 20 120 60 28 M 48 475 250 M 24 129 64 30 Fitting Example Foundation Block Shape A without cams Shape A with cams Elevation of final foundation Pint won Elevation of prepared foundation Mt Hy DIS Ao f Y 4 FIT qa A Z A sx 5 LIITA Or N Yy ASS 3 YH W GANN III W YY SS KR GY Sealing RWS Yj IN f G yy My MANS a Af LA SS I Yip J WN NNS GRENN YNNA compound ANV AAN UY SSS YY Aid NN Y LL rsss YE Installation and Operating Manual Motor Slide Rails 1 Quality Slide rail made of material EN GJL 200 according to DIN 1561 Fastening screws for the machine as well as straining screws are included in the supply Stone bolts with hexagonal nut for anchoring are to be ordered separately 2 Safety Precautions screws coming loose are very dangerous Always make sure that you keep to the prescribed starting torques for the screws and to check them regularly Never carry out adjusting work with the machine running Make sure to lock the main switch of the machine against unintentional restarting 3 Mounting the Slide Rail When fastening the slide rails to foundations check prior to tightening the stone bolts the firm 2 3 1 seat of the foundation screws after the specified setting period j When faste
4. grooves New alignment of drive Retighten FAULT Broken or damaged pulley Pollution U gt LLI el A L E Strong fast wear of grooves U H lt x LL Bent or broken shaft E U a T Safety equipment damaged LL O Over tightened drive belt Diameter of pulley too small Bad condition of bearings LLI am Pulleys are seated on shaft too O close to the front U z Belt creep POSSIBLE CAUSE Wrong assembly of pulleys Foreign substances in drive Excessive circumferential speeds Wrong assembly of belts Excessive tension of belts Sand dirt or other pollution Extreme overstrain of belts Over dimensioned drive Accidental damage Error of machine design Damage by error or inappropriate design of safety equipment Worn out grooves belt makes contact but no power is transmitted unless it is Over tightened Wrong tension Diameters of pulleys prescribed by motor manufacturer were not observed Over dimensioned bearings Insufficient maintenance of bearings Error or obstacle Tension of drive is too small REMEDY Do not tighten bush bolts beyond recommended torques Use appropriate safety equipment for drive Keep circumferential speed of pulleys below recommended maximum limits Do not use levers to mount belts on Pulleys Retighten check drive design Clean and protect the drive to the optimum extent Retighten Ch
5. in their hubs Now push the belt pulley unit with the pre assembled taper bush to its correct position of the shaft When using a key scat insert key first into keyway of shaft prior to assembling the bush Only use keys supporting on their edges Now tighten the fastening screws of the bush uniformly and step by step with the help of a torque wrench until reaching the recommended starting torque according to Table No 3 in order to prevent any cocking between bush and pulley Make sure that at first the bush is clamped on the shaft and that the hub slides into its end position only afterwards With light blows of a hammer on a sleeve or a wooden block you can drive down the clamping bush into the cone to slightly increase the clamping effect After that the screws can be tightened until the recommended starting torque is obtained Never exceed the starting torques mentioned in the assignment table With perpendicular shaft arrangement and particularly rough operation shock load take further safety precautions against any movement of the taper clamping bush on the shaft Empty bores are filled with grease to avoid penetration of dirt or foreign substances After a short warm up period of the drive under load it is recommended to check the fastening screws of the taper clamping bush Dismantling For dismantling loosen all the fastening screws of the taper bush degrease the bores filled with lubricant Degrease the pull off bor
6. ANTRIEBSELEMENTE Installation and Operating Manual for e V Belt Drives e Slide Rails e Foundation Blocks www luetgert antriebe de Installation and Operating Manual V Belt Drives All V belts used should be manufactured in conformance with standards Thoroughly remove any residues of oil and grease and other contamination No traces of rust are admissible on the V belt pulleys especially in the area of the wedged grooves All V belts used should be of one original set of identical length Avoid mixtures of V belts of different manufacturers The V belts should have been stored free from damages and to the state of the art according to manufacturer s specifications You can clean dirty V belts with a mix of glycerine and spirit in the ratio of 1 10 It is important to install the V belt pulleys parallel to the axis and aligning each other Make sure that pulley concentricity and run out tolerance will not exceed the predefined limit values according to DIN 2211 or 2217 also refer to Table 1 For installation approach the belt pulleys to each other until the V belts can be mounted without using force It is prohibited to use any aids such as tire levers or similar since this might lead to damage of the V belts If you have mounted the V belts conforming to the grooves tighten the drive according to manufacturer s specifications For this purpose tighten the belt pulley which can be moved parallel
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8. Grinding noise Unusually loud drive Fluttering belts Excessive vibration in drive system Cover band coming off Worn out or damaged cover band of belt Composite belt comes off the drive One or several ribs are miss tracking outside the pulley POSSIBLE CAUSE Bearings are damaged Wrong belt Worn out pulleys Dirt on grooves Tension of belt is too low Wrong belt sets Non alignment of pulleys Wrong belt Unsuitable design of machinery or Equipment Pulleys jumped out Loose drive components Worn out pulleys Wrong groove space Safety equipment is obstructed Malfunction or damage of outer tightening roller Dirty pulleys Non alignment Tension is too low REMEDY Replace align and grease Use correct belt size Replace pulleys Clean pulleys improve protection Remove rust colour or dirt from grooves Retighten Assemble new belt set Alignment of pulleys Use proper belt profile section for each pulley Check structure and clips for correct tightness Replace pulley Check all machine parts safety equipment motor supports motor padding bushes clips and housing for stability appropriate construction thickness correct maintenance and assembly Replace pulleys Measure pulley grooves and replace with standard pulleys Check safety equipment Repair or replace outer tightening roller Clean grooves use individual belts to avoid dirt collecting in the
9. eck drive design mount smaller belts or fewer belts if required Recalculation of safety equipment Check machine design Repair rate referring to long life Replace pulleys tighten the drive properly Retighten Recalculation of drive Check bearing calculation Align and lubricate bearings Position the pulleys as close as possible to bearings eliminate obstacles Retighten Too many drive belts or too wide ones can strongly affect the motor or driving shafts This may occur if load requirements for a drive are reduced but the belts are not recalculated accordingly This can also occur by calculation of too high quantities for belts The forces arising due to belt tension will be too high for those shafts Instructions for Foundation Block Installation Regarding their functional dimensions the foundation blocks are conforming to DIN 799 They are manufactured of the material EN GJL 200 in accordance with DIN EN 1561 For installation use foundation blocks without any paint Prepare openings in the provided cement floor in specified sizes referring to DIN 799 where the foundation blocks can be sealed To prevent concrete or mortar from penetrating into the threads seal them or fill them with grease For pouring the openings use concrete of the same solidity and granulation classes as for the surrounding concrete surfaces D1 L1 D3 D5 M 10 125 06 M8 39 M 12 150 12 M 12 40 22 10 M 16 180 85 M 12 90 20 12 M
10. es up to 2 items according to the bush size each and slightly lubricate them with oil Yu can recognize the pull off from the fact that the relevant semi threads are located on the bush side The screws are screwed into the pull off bores and steadily tightened until the taper bush comes free from the hub and is freely moveable on the shaft The parts can now be removed from the shaft Table No 3 Bush No screw tighten ing torque max Nm 5050 5040 6050 7060 Tightening and slip torques for taper bushes The indicated slip torques for the corresponding tightening torques were determined on the test bench for the respective bore and theoretical values for friction type connection without key If impact loading occurs then the slip torque should be divided by 2 In principle it is recommended that the bushshaft connection is always made with a key The recommended tightening torques should not be exceeded and are sufficient to secure the connection between the shaft and the bore against axial slip during normal operation For impact loaded vibrating or suspended operation an additional mechanical retaining device should be fitted to prevent slippage or creeping on the shaft Trouble Shooting Table PREMATURE BELT FAILURE STRONG OR UNUSUAL BELT WEAR FAULT Broken belt s Belt s do es not resist load creep no visible cause Failure lateral assembly Belt spalling and subst
11. ning the slide rails on frames plates and such use rails with machined base surface in pe order to avoid breakage due to _ distortion All contact surfaces 1 Slide rail should be even and properly 2 Tightening screw aligned 3 Fastening screw and nut The connecting screws may not turn themselves there must be enough space for the wrench 3 1 Arrangement of slide rails Keep to the motor foot distance X Arrangement of slide rails acc to Fig 1 Make sure that the slide rails are placed in parallel Maximum parallel deviation should not exceed X 1mm The height relating to each other can be checked with a spirit level 3 2 Slide Rail Design EEN a E 94 7 fat Fig 2 Lightweight version A up to 650 mm and DIN 42923 version up to 500 mm Fig 3 Lightweight version B up to 700 1500 mm and DIN 42923 version from 630 1000 mm Fig 4 Lightweight version C from 1600 2200 mm and DIN 42923 Version 1250 mm Fig 5 Heavy version WEN 40003 4 Fastening the Motor Place the motor on the slide rail and tighten the fastening nut until at first the motor still remains moveable Accurately align the motor by means of the straining screws With flat belt drives or chain drives adjust the required initial tension keep to supplier s instruction Then definitely tighten the fastening nuts Notes LUTGERT DRIVES V Belts Vt at Belts E al al Pi i l eys 33 AS
12. ructure detaching Wear on the upper belt shell Wear on the upper belt edge Wear on flanges Wear on lower belt edge Wear on lower belt shell Crack formation in substructure POSSIBLE CAUSE Insufficiently rated drive Belt is rolled or levered on pulley Foreign body dropped into drive Extreme shock load Insufficiently rated drive Traction body damaged Worn out pulley grooves Movement axle distance Non aligning pulleys Traction body damaged Pulley too small Traction body damaged Friction on safeguarding equipment Malfunction of tightening roller Incorrect belt pulley seat belt too small for groove Belt creep Non alignment Worn out pulleys Wrong belt Incorrect belt pulley seat Worn out pulleys Belt substructure on pulley groove belt too small for groove Worn out grooves Dirty pulleys Pulley diameter too small Belt creep Outer tightening roller too small Incorrect storage REMEDY New calculation required On assembly use retightening option Install suitable safety device or drive protection New calculation to adapt to shock load New calculation required Keep to correct assembly method Check groove wear replace if required Check drive for axle distance movement during operation Check and correct alignment Keep to correct assembly method Check drive design use larger pulleys Increase diameter of outer tightening roller accordingly
13. s Broken traction body or damaged Substructure Wrong belt set Not sufficient clearance for retightening High overloaded or not sufficiently rated drive Broken traction bodies Belt creep Dirt Loose belt Flat belt set Non alignment Safety equipment is in grinding contact REMEDY Retighten until creep is gone Replace the pulleys New calculation of drive Check if there are any changes in the axle distance Improve drive ventilation Do not use belt stretching agents remove oil grease or chemicals Check drive design use Power Band Shield grooves and drive New alignment of the pulleys Replace pulleys Use correct assembly and storage Procedures Carefully insert flat tightening roller into loose part of belt as close as possible to the driving pulley Replace with new belt set Do not mix old and new belts Check stability axle distance and means of reducing vibration Realign and retighten drive Clean pulleys Replace all belts assemble properly Assembly the correct belt set Check the amount of retightening Recalculation of the drive Replacement of belts crrect assembly Retightening required Clean belt and pulleys Retightening required Insert correct belt set New alignment of pulleys so that all pulleys are equally loaded Repair replacement or new design of safety equipment NOISES CAUSED BY UNUSUAL VIBRATION BELTS FAULTS WITH COMPOSITE V BELTS FAULT
14. to the axis for tightening by slowly turning the drive until the V belt has reached the required initial tension Always check the belt inital tension perpendicularly to the drawing part of the belt load part by means of appropriate strain viewers Refer to Table 2 for the required amounts for inital tension by using the impression depth mentioned on the continuation page of this Manual After a first service period of approx 0 5 to 2 hours check the belt initial tension again and retighten if required After further approx 20 operating hours under load it is recommended to check and retighten again in order to compensate for the V belt stretching during the start up period V belt drives using high capacity V belts of standardized profile series are mainly maintenance free during operation for their entire service lives It is advisable to regularly inspect the belts and belt pulleys for any trace of damage and wear and tear Table No 1 Effektive Y from 50 106 170 280 450 710 1120 1800 to 100 160 250 400 630 1000 1600 4000 Admissible pulley concentricity 0 2 0 3 0 4 0 5 0 6 0 8 1 0 1 2 and run out tolerance Table No 2 Profil Y small Pully Test force Impression depth mm N per 100mm Length of freerunning part of belt SPZ 63 180 25 2 3 SPA 90 140 50 3 2 160 250 50 2 7 SPB 140 200 75 37 224 400 75 2 7 SPC 224 315 125 3 2 355 630 125 2 7 L L Length of free running part of belt F Test force
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