Gear limit switch Type series 51

Gear limit switchType series 51

Document No.: 151-00004 G

Date: 10/2015

EKM-0247

Translation of the Original assembly/operating instructionsEN-GB

GKN Stromag AG

Hansastraße 120D-59425 UnnaTel.: +49 (0) 2303 102-0Fax: +49 (0) 2303 [email protected]

Service address:Hansastraße 120D-59425 UnnaTel.: +49 (0) 2303 [email protected]

Contents

1 Introduction................................................................................................................................11.1 About this documentation........................................................................................................................... 11.1.1 Target group............................................................................................................................................ 11.1.2 Use/storage............................................................................................................................................. 11.2 Using the documentation correctly............................................................................................................. 21.2.1 Text formats.............................................................................................................................................21.2.2 Definition of terms....................................................................................................................................21.3 Warranty and liability.................................................................................................................................. 31.3.1 Guarantee................................................................................................................................................31.3.2 Copyright................................................................................................................................................. 3

2 For your safety...........................................................................................................................32.1 Safety concept of the documentation......................................................................................................... 32.2 Required personnel qualifications...............................................................................................................42.3 Intended use...............................................................................................................................................42.3.1 Application limits......................................................................................................................................42.3.2 Approvals.................................................................................................................................................42.4 Foreseeable misuse................................................................................................................................... 42.5 Non-intended use....................................................................................................................................... 42.6 EC Declaration of Conformity..................................................................................................................... 52.6.1 Standards applied....................................................................................................................................52.7 Possible residual risks................................................................................................................................ 52.7.1 Mechanical dangers.................................................................................................................................52.7.2 Thermal dangers......................................................................................................................................52.7.3 Electrical danger......................................................................................................................................52.8 Safety symbols/pictograms in the documentation...................................................................................... 52.8.1 Warning symbols..................................................................................................................................... 52.8.2 Hazard classifications..............................................................................................................................62.8.3 Mandatory symbols..................................................................................................................................62.8.4 Note......................................................................................................................................................... 62.8.5 Environmental protection/recycling..........................................................................................................62.9 GTES safety devices.................................................................................................................................. 72.10 Safety symbols/pictograms on the GTES...................................................................................................72.11 Wear personal protective equipment..........................................................................................................72.12 Basic responsibilities of the operator and personnel.................................................................................. 72.13 Safe handling of rotating components........................................................................................................ 72.14 Safe handling with hot surfaces..................................................................................................................72.15 Safe handling with electrical hazards......................................................................................................... 82.15.1 Responsibility of the operator.................................................................................................................. 82.15.2 Applying the five safety rules...................................................................................................................82.15.3 IP protection classes................................................................................................................................82.15.4 Electromagnetic compatibility.................................................................................................................. 82.16 Environmental protection............................................................................................................................8

3 Transport and storage.............................................................................................................. 93.1 Transport.................................................................................................................................................... 93.1.1 Unpacking................................................................................................................................................93.2 Scope of delivery........................................................................................................................................ 93.2.1 Pre-mounting condition............................................................................................................................93.3 Storage..................................................................................................................................................... 10

4 Technical specifications......................................................................................................... 104.1 Product data............................................................................................................................................. 104.1.1 Dimensions............................................................................................................................................104.1.2 Gear data, type series 51...................................................................................................................... 114.1.3 Gear data, type series 51 DZ.................................................................................................................124.1.4 General information, GTES type series 51............................................................................................13

II Original assembly/operating instructions Gear limit switch Type series 51 • No. 151-00004 G • 10/2015

4.1.5 Specific electrical values and position of the contact.............................................................................134.1.6 Contact positions................................................................................................................................... 144.1.7 Permissible radial force......................................................................................................................... 154.1.8 Type code..............................................................................................................................................164.1.9 Unit........................................................................................................................................................ 174.2 Dimensional drawing................................................................................................................................ 174.3 Marking on the product.............................................................................................................................17

5 Construction and function......................................................................................................185.1 Component designations..........................................................................................................................185.2 Design, task and function of the assembly groups................................................................................... 185.2.1 Electrical connection versions............................................................................................................... 185.2.2 Mounting position...................................................................................................................................185.2.3 Drive...................................................................................................................................................... 195.3 Optional equipment available................................................................................................................... 195.3.1 Drive flange............................................................................................................................................195.3.2 Block adjustment................................................................................................................................... 205.3.3 Special cam discs..................................................................................................................................215.3.4 Design with position feedback system...................................................................................................225.3.5 Design with heating resistor...................................................................................................................24

6 Assembly..................................................................................................................................256.1 Special safety guidelines.......................................................................................................................... 256.2 Conditions for assembly and fixing...........................................................................................................256.2.1 Special tools.......................................................................................................................................... 256.2.2 Assembly precision................................................................................................................................256.2.3 Tightening torques.................................................................................................................................256.3 Assembly mechanics................................................................................................................................266.3.1 Assembly design IP20 (without housing)...............................................................................................266.3.2 Housing assembly, IP65........................................................................................................................276.3.3 Housing assembly, IP66........................................................................................................................276.3.4 Assembly of the flange design, B5........................................................................................................ 286.3.5 Assembly of the mounting bracket, B3.................................................................................................. 286.4 Electrical assembly...................................................................................................................................286.4.1 Insert the connection cable into the GTES............................................................................................ 296.4.2 Connect the screw connections.............................................................................................................296.4.3 Connect the flat plug..............................................................................................................................306.4.4 Connect the earth conductor for IP66 housings.................................................................................... 306.4.5 Connect the earth conductor for IP65 housings.................................................................................... 306.5 Wiring diagram..........................................................................................................................................316.5.1 Electrics................................................................................................................................................. 316.6 Switching point adjustment.......................................................................................................................316.6.1 Mode of function.................................................................................................................................... 316.6.2 Adjusting the switching points................................................................................................................326.7 Complete the housing...............................................................................................................................336.7.1 Mount the MH housing, IP65................................................................................................................. 336.7.2 CxZ, MxZ housing, mount 0 - 1 intermediate piece...............................................................................336.7.3 Mount the CxZ, MxZ housing from 2 intermediate pieces..................................................................... 346.8 Correct disposal/recycling of operating and auxiliary materials................................................................34

7 Operation..................................................................................................................................347.1 Special safety guidelines.......................................................................................................................... 347.2 Initial commissioning.................................................................................................................................347.3 Use........................................................................................................................................................... 347.3.1 Operating conditions..............................................................................................................................347.4 Recommissioning..................................................................................................................................... 347.5 Decommissioning..................................................................................................................................... 347.5.1 Temporary decommissioning.................................................................................................................347.5.2 Final decommissioning.......................................................................................................................... 34

IIIOriginal assembly/operating instructions Gear limit switch Type series 51 • No. 151-00004 G • 10/2015

8 Maintenance and inspections................................................................................................ 358.1 Special safety guidelines.......................................................................................................................... 358.2 Measures for environmental protection.................................................................................................... 358.3 General points.......................................................................................................................................... 358.4 Maintenance and inspection intervals.......................................................................................................358.4.1 Cleaning.................................................................................................................................................35

9 Troubleshooting...................................................................................................................... 359.1 Operational issues and their solutions......................................................................................................35

10 Disassembly.............................................................................................................................3610.1 Special safety guidelines.......................................................................................................................... 3610.2 Removing the GTES.................................................................................................................................3610.3 Final decommissioning............................................................................................................................. 36

11 Ordering spare parts............................................................................................................... 3611.1 Data for ordering spare parts....................................................................................................................3611.2 Service address........................................................................................................................................36

12 EC Declaration of Conformity................................................................................................ 37

IV Original assembly/operating instructions Gear limit switch Type series 51 • No. 151-00004 G • 10/2015

1 Introduction

1.1 About this documentation

GKN Stromag AG strongly emphasises that the technical details such as dimensions, weights in kg, tolerances,tightening torques and units required for assembly, such as securing means and lubricants, must be obtainedfrom the dimensional drawing.

Should this information be necessary during assembly, a corresponding point in these mounting/operating in-structions will be referenced on the dimensional drawing.

A dimensional drawing is supplied as a separate document and can be requested additionally from our after-sales services, see section 11.2. For this, the information on ordering spare parts is required, see section 11.1.

For the purpose of simplification, the following designations are used in the mounting/operating instructions.

• Mounting/operating instructions will be referred to as Documentation in the following.

• The gear limit switch, type series 51, will be referred to as GTES in the following.

This documentation makes it easier for the operator to familiarise himself with the GTES and to use it for itsintended application.

This documentation covers various GTES designs. The figures used are partly by way of example only. Thespecific design of the supplied GTES is shown in the dimensional drawing, see section 4.2.

The documentation contains important instructions on how to operate the GTES safely, properly and economi-cally. Observing the documentation helps to avoid dangers, to reduce repair costs and down times and to in-crease the reliability as well as the operating life of the GTES. Read the documentation carefully and thoroughly.

1.1.1 Target group

The documentation is limited to use by qualified as well as trained personnel.

The documentation must be read and applied by every person that is assigned with performing at least one ofthe following tasks:

• transport

• assembly,

• use,

• maintenance and inspections,

• troubleshooting,

• disassembly

• disposal of operating and auxiliary materials

1.1.2 Use/storage

This documentation must always be kept to hand at the operation location of the GTES. The documentationmust then be integrated into the overall documentation of the machine and into the safety concept.

When selling the GTES, the documentation must also be passed on.

1Original assembly/operating instructions Gear limit switch Type series 51 • No. 151-00004 G • 10/2015

1.2 Using the documentation correctly

1.2.1 Text formats

The following symbols/figures are used for special text positions in the documentation:

Symbol Explanation● Indicates bulleted lists

— Indicates subordinate bulleted lists

► Indicates handling instructions and information in the safety guidelines

1. 2. 3. et seq. Indicates work steps

Fig. 1, 2, 3, et seq. Numbering of figures

A, B, C, et seq. Indicates areas in the figures

a, b, c, et seq. Indicates dimensions

Indicates position numbers in the figures

(1)/(2)/(3) Indicates position numbers in the text

1.2.2 Definition of terms

Operator

The operator is the businessperson/company that operates the GTES for its intended use or has it operated byqualified as well as trained personnel.

Trained personnel

Trained personnel are those that can prove they have been instructed by GKN Stromag AG or in accordancewith the technical documentation of GKN Stromag AG. They are able to carry out the work assigned to themand avoid known dangers.

User

The user is the person that has been trained by the operator and assigned with the use of the GTES.

Qualified personnel

Qualified personnel are those that are able to carry out the work assigned to them and identify and avoid anypossible dangers as a result of their professional training, knowledge and experience, as well as knowledge ofthe applicable standards and guidelines.

Qualified personnel are employees of the operator or those that have been authorised to carry out the work.

Qualified electrician

A qualified electrician is someone who is trained and has knowledge and experience of electrical equipment. Assuch, qualified electricians must have knowledge of the applicable standards and guidelines, be able to assessthe work assigned to them and identify and avoid potential hazards.

2 Original assembly/operating instructions Gear limit switch Type series 51 • No. 151-00004 G • 10/2015

1.3 Warranty and liability

The "General delivery and business terms and conditions" of GKN Stromag AG apply.

GKN Stromag AG shall not recognise any warranty or liability claims for personal and material damage if theyresult from one or more of the following causes:

• non-intended use of the GTES (see also "Intended use"), see section 2.3

• non-observance of the information, instructions and interdictions in this documentation

• unauthorised constructional modifications to the GTES

• insufficient monitoring of parts which are subject to wear and tear

• maintenance work performed improperly or too late

• catastrophic events caused by external influences or force majeure

1.3.1 Guarantee

The "General trade and delivery terms and conditions of delivery" of GKN Stromag AG always apply.

1.3.2 Copyright

This documentation is a certified document as per the terms of the law against unfair competition.

The copyright is held by:

GKN Stromag AGHansastraße 120D-59425 UnnaGermany

This documentation is intended for the operator of the GTES and his personnel. It contains text and drawingswhich, without the express permission of the manufacturer, must not be

• reproduced,

• distributed or

• made available to others in any other way, either in full or in part.

Non-compliance will result in damages being sought.

2 For your safety

2.1 Safety concept of the documentation

In accordance with the risk assessment carried out, the safety concept in this documentation is structured in thefollowing way:

• The general safety guidelines for the operator and the user are listed in this section.

• Section-related safety guidelines are listed at the start of the respective section.

• Safety guidelines related to handling must be followed before each safety-related work step.


2.2 Required personnel qualifications

The following table shows the qualifications specified for the different tasks.

Task PersonnelTransport Trained personnel

Assembly Qualified personnel

Initial commissioning Qualified personnel

Operation Qualified personnel

Preventive maintenance Qualified personnel

Troubleshooting Qualified personnel

Decommissioning Qualified personnel

Disassembly, disposal Trained personnel

• Only employ qualified or trained personnel.

• Do not authorise people whose ability to react is impaired, for example by the influence of drugs, alcohol,medication or similar. Observe the specific national age guidelines.

• Observe all other nationally-applicable guidelines of the respective country of use.

2.3 Intended use

The GTES is exclusively intended for use in industrial areas and must only be used to open electrical circuitsthrough the positive locking entrainment of a driven shaft. Geared cam limit switches of type series 51 (GTES)are universal, mechanical switchgear that show a maximum number of shaft revolutions to the angle of rotationof the installed cam disc. Mechanical contacts are actuated by these cam discs.

The GTES may only be operated with the correctly-installed and functioning IP protection classes.

2.3.1 Application limits

The application limits are defined in the technical specifications, see section 4.1. The GTES must not be used inpotentially explosive areas.

2.3.2 Approvals

Overview of the respective national and international approvals of the GTES, see section 4.1.8.

2.4 Foreseeable misuse

Engaging the contacts using elements other than the cam discs (e.g. screw drivers, wires, etc.) can cause dam-age.

2.5 Non-intended use

Any use other than the intended use of the GTES may lead to dangerous situations.

• Only use the GTES for its intended use in accordance with the details in this documentation, especially inobserving the application limits given in the technical specifications.

• Reconstruction, retrofitting or modification of the construction or individual equipment parts, with the aim ofchanging the application range or the usability of the GTES, should be avoided.

• Do not use the GTES as a climbing aid.

Claims for any damage resulting from non-intended use are exempted. The operator bears sole responsibilityfor damage caused by non-intended use.


2.6 EC Declaration of Conformity

The GTES is supplied with an EC Declaration of Conformity, see section 12. The EC Declaration of Conformitycertifies that the GTES complies with the essential health and safety requirements of the Machinery Directive interms of its design, including with the amendments applicable at the time of the declaration.

2.6.1 Standards applied

An overview of the applied harmonised standards can be found in the EC Declaration of Conformity supplied.

2.7 Possible residual risks

Residual risks are particular dangers that cannot be eliminated when using the GTES, despite its safety-orienta-ted construction.

Residual risks are not obviously recognisable and could be the source of a possible injury or health risk.

Special reference is made to possible residual risks in the following:

2.7.1 Mechanical dangers

Danger due to rotating parts during:

• operation without separating protective equipment or safety shut-down

2.7.2 Thermal dangers

Danger resulting from contact with hot surfaces/components when:

• optional heating is installed

• work is carried out on the GTES without personal protective equipment

2.7.3 Electrical danger

Danger due to contact with live components:

• when defect

• with an open housing cover

• caused by improper work on live components

2.8 Safety symbols/pictograms in the documentation

The following safety symbols/pictograms and indications of particularly important details are used in the docu-mentation.

2.8.1 Warning symbols

Required safety guidelines are indicated in the documentation through pictograms and in addition begin withsignal words that emphasise the extent of damage to be expected.

The safety guidelines are structured as follows:

SIGNAL WORD

Type and source of the hazard

Possible consequences of non-observance, as well as explanations of the source of the hazard.

► Measures/handling instructions to be followed in order to avoid hazards or any damage.


2.8.2 Hazard classifications

The safety symbol in conjunction with the signal word means:

DANGER

Indicates an immediate high risk danger, which can lead to death or serious physical injury if not avoi-ded.

CAUTION

Indicates a possible medium risk danger, which can lead to death or serious physical injury if not avoi-ded.

ATTENTION

Indicates a possible low risk danger, which can lead to slight or medium physical injury or materialdamage if not avoided.

2.8.3 Mandatory symbols

Basic protection

As basic protection when working, always wear the listed personal protective equipment.

Mandatory symbols ExplanationWear protective clothing

Wear hand protection

Wear foot protection

Wear head protection

2.8.4 Note

NOTE

Indicates special user tips and other particularly useful or important information for efficient work aswell as economical use.

2.8.5 Environmental protection/recycling

ENVIRONMENTAL HAZARD

Indicates environmental hazards as well as measures for environmental protection.

RECYCLING

Indicates measures for recycling or disposal of components as well as auxiliary and operating materi-als.


2.9 GTES safety devices

The GTES does not have any safety devices of its own.

Except for: certain GTESs with special housings, which are equipped with a protective cover in the gear wheelarea.

Rotating components of the GTES that can cause hazards after assembly due to pulling in, must be secured bythe machine operator.

2.10 Safety symbols/pictograms on the GTES

The GTES is equipped with the following safety symbols/pictograms.

Prohibition signs ExplanationObserve the instructions in the documentation.Do not step on or use as a climbing aid!

2.11 Wear personal protective equipment

Personal protective equipment must be worn for all work to be carried out, see section 2.8.3. The wearing ofpersonal protective equipment must be monitored by the operator. It may be the case that the operator has tomeet additional measures.

2.12 Basic responsibilities of the operator and personnel

The following fundamental responsibilities of the operator and personnel must always be observed when han-dling the GTES.

• After assembling the GTES, a risk analysis of the workplace must be carried out by the operator on the com-plete machine. In addition to the documentation, operating instructions must be created.

• In addition to the documentation, observe and instruct adherence to general legal and other binding regula-tions on accident prevention and protection of the environment. Such obligations can also, for e.g., affect thehandling of hazardous substances or the provision/wearing of personal protective equipment.

• Supplement the documentation with your own instructions, including supervisory and reporting obligations forspecific operational matters, e.g., with regards to the organisation of work, work sequences and appointedpersonnel.

• Never make changes, additions or conversions to the GTES without the manufacturer's approval. If changesare made to the GTES that affect safety, they must be reported to GKN Stromag AG immediately.

• Only use genuine spare parts.

2.13 Safe handling of rotating components

The following safety guidelines must always be observed when handling rotating components.

• Before commencing work, shut down the machine and secure it from switching back on.

• Never operate the machine without separating protective equipment.

• After inspection and maintenance work, remount the separating protective equipment.

2.14 Safe handling with hot surfaces

The following safety guidelines must always be observed when dealing with hot surfaces:

• Before commencing any work, first allow the hot surfaces to cool down.


2.15 Safe handling with electrical hazards

2.15.1 Responsibility of the operator

The operator is responsible for ensuring that the machine is operated in a technically perfect condition:

• The operator must ensure that electrical units are only mounted, modified and maintained by a qualified elec-trician or under the direction of a qualified electrician, in line with electrotechnical regulations. The operatormust further ensure that the electrical equipment and units comply with electrotechnical regulations.

• Live parts must be protected against accidental contact.

• If a defect is detected in an electrical unit, i.e. if it does not comply or no longer complies with electrotechni-cal regulations, the operator must ensure that the defect is repaired immediately, and that the electrical unitis not used in a defective condition if it presents an immediate danger.

• Work on electrical units is only to be performed by qualified electricians in accordance with electrotechnicalregulations. Observe all other nationally-applicable guidelines of the respective country of use.

2.15.2 Applying the five safety rules

The five safety rules must be always observed and applied when working on electrical units.

• disconnect

• secure against reconnection

• de-energise

• earth and short-circuit

• cover or shield any adjacent live parts

If it is not possible to de-energise the unit due to compelling reasons, e.g. when connecting the GTES, the oper-ator must ensure that:

• the type of instruments or tools used in this work eliminate danger due to electric shock or arcing

• such tasks are only assigned to personnel qualified to work on live parts

• further technical, organisational and personal safety measures are determined and performed if required,which ensure adequate protection from danger due to electrical shock or arcing

2.15.3 IP protection classes

After all work that requires the protective casing to be removed or disabled, re-establish the protection class andperform an operational check before reconnection.

2.15.4 Electromagnetic compatibility

The GTES has been constructed and marketed in compliance with relevant legal harmonisation regulations. It isthe operator's responsibility to ensure that EMC regulations for the machine are observed.

For any further questions or additional support required, please contact GKN Stromag AG after-sales services.

2.16 Environmental protection

The following instructions must always be observed in order to protect the environment.

• After the final decommissioning/disposal of the GTES, ensure that the individual components, as well as anypossible auxiliary and operating materials, are disposed of in an environmentally-friendly way.

• Recycle all metal and plastic components.


3 Transport and storage

3.1 Transport

NOTE

Be particularly careful when transporting the GTES in order to avoid damage caused by externalforces or careless loading and unloading. Depending on the type and duration of the transportation,corresponding transportation locks have been provided. Remove the transport lock only when begin-ning assembly, see section 6.3.

The information marked on the packing pieces must be observed.

During transportation, avoid:

► water condensation resulting from severe temperature fluctuations

► impacts

3.1.1 Unpacking

The transportation route is decisive in terms of the type of packing. The information marked on the packingpieces must be observed.

RECYCLING

Dispose of the packaging material according to the local guidelines properly and in an environmental-ly-friendly way.

3.2 Scope of delivery

On receipt, check the delivery for completeness using the packing list. Possible damage during transportationand/or missing parts must be reported immediately, see section 11.2 for the address.

3.2.1 Pre-mounting condition

The GTES is supplied assembled and ready for operation, and is prepared for direct assembly in the machine.

NOTICE

Damage to the machine due to the incorrect adjustment of the GTES

When the GTES has not been adjusted, traverse movements of the machine can lead to damage.

► Before commissioning the machine, always adjust the GTES first in accordance with the specifica-tions in the mounting/operating instructions.

NOTE

At the customer's request, GTESs can also be supplied in a defined basic position, e.g. for windfarms. These GTESs are equipped with a transport lock.


3.3 Storage

ATTENTION

Damage to the GTES due to incorrect storage

Incorrect storage can lead to damage to the components of the GTES. Only store the GTES underthe following conditions:

► Do not store outdoors.

► Store in a dry and dust-free place.

► Do not expose to aggressive media.

► Avoid mechanical vibrations.

► Storage temperature: same as the ambient temperature during operation, avoid rapid temperaturefluctuations.

► Maximum relative humidity, 60 %.

► GTESs of protection class IP00 and IP20 should be stored in their transport packaging, if possible.

For storage periods longer than 12 months, the general condition of all parts and the packing must be checkedregularly. Our after-sales services will provide you with information on this, see section 11.2 for the address.

NOTE

Details for storage on the packing pieces going beyond the requirements specified here, must be ob-served.

4 Technical specifications

4.1 Product data

4.1.1 Dimensions

For assembly of the housing cover, a longitudinal clearance space of 1,4 times the dimension of the housingcover must be left.

For the cable entry point, the minimum bending radius of the customer connecting cable must be observed.


4.1.2 Gear data, type series 51G

ear s

ize

Nom

inal

revo

lutio

ns a

t 15°

- ca

m d

isc

1 dr

ive

shaf

t rev

. = c

am d

isc

angl

e of

rota

-tio

n in

deg

rees

Mec

hani

cal h

yste

resi

s °

Max

. inp

ut s

peed

[rpm

]

Min

. inp

ut s

peed

[rpm

] (on

ly w

hen

used

as

a ch

ange

over

)

1 4,1 84 0,01 − 0,02 1000 0,67

6,5 50,8 0,01 − 0,02 1200 1,1

11 31,14 0,02 − 0,04 1500 1,8

2 17,5 19,6 0,03 − 0,06 1800 2,9

29,0 11,86 0,05 − 0,1 1800 4,7

48 7,27 0,08 − 0,16 1800 7,7

3 75 4,57 0,13 − 0,3 1800 12,2

125 2,77 0,21 − 0,42 1800 20,2

205 1,69 0,35 − 0,68 1800 33

4 323 1,06 0,6 − 1,17 1800 52

540 0,65 0,92 − 1,8 1800 87

880 0,4 1,5 − 2,9 1800 141

5 1384 0,25 2,4 − 4,7 1800 224

2288 0,15 3,9 − 7,7 1800 371

3735 0,09 6,5 − 12,7 1800 606

6 5900 0,06 10,3 − 20,1 1800 -

9800 0,04 17,0 − 33,3 1800 -

16000 0,02 27,8 − 54,2 1800 -

One revolution of the adjustment worm corresponds to 2,464° on the cam disc.


4.1.3 Gear data, type series 51 DZG

ear s

ize

Nom

inal

revo

lutio

ns a

t 15°

- ca

m d

isc

1 dr

ive

shaf

t rev

. = c

am d

isc

angl

e of

rota

tion

in d

egre

es

Mec

hani

cal h

yste

resi

s °

Max

. inp

ut s

peed

[rpm

]

Min

. inp

ut s

peed

[rpm

] (on

ly w

hen

used

as

a ch

ange

over

)

1 67 5,14 0,11 − 0,22 1800 10,9

110 3,11 0,19 − 0,4 1800 18,0

180 1,90 0,31 − 0,6 1800 29,4

2 280 1,20 0,5 − 1,0 1800 46,7

470 0,73 0,84 − 1,7 1800 77,1

770 0,44 1,35 − 2,6 1800 125,0

3 1200 0,28 2,1 − 4,1 1800 199,0

2000 0,17 3,5 − 10,3 1800 330,0

3300 0,1 5,5 − 11,3 1800 539,0

4 5200 0,06 9,1 − 17,8 1800 856,0

8700 0,04 15,1 − 29,5 1800 1415,0

14200 0,02 24,7 − 48,2 1800 -

One revolution of the adjustment worm corresponds to 3,168° on the cam disc.


4.1.4 General information, GTES type series 51

The gear parts of the GTES can be damaged by ozone concentrations above normal threshold values (Regula-tion 2008/50/EC); in particular in the direct vicinity of circuit breakers (ozone formation through electric arcs), theGTES may only be used if it is protected accordingly (min. IP54).

Information Value CommentOperating life of the contact 10.000.000 Mechanical circuits

Operating time 100 % Suitable for continuous operation

Max. speed 1.000 to 1.800 rpm Dependent on the frame size

Min. speed 0,67 to 606 rpm Dependent on the frame size

Radial force drive 9 to 82 N depending on the speed and the ambient temperature, see section 4.1.7

Axial force 0 N depending on the speed and the ambient temperature, see section 4.1.7

Ambient temperature -40 to +80 °C For cUL approval, the max. ambient temperature is 50° C.

Protection class IP00 Without housing (without protection against accidental contactwith voltages <25 V AC or 60 V DC with plug connections)

IP20 Without housing (contact on the circuit board or with protectionagainst accidental contact)

IP65 Aluminium housing (design B3/B14)

IP66 Plastic housing (design B3/B14/B5)

Max. permissible relativehumidity

0 to 60 %

4.1.5 Specific electrical values and position of the contact

EKM-0009_02

A)9999B99C

99L99P

99G1

2

4

1

2B)99A99T

C)

E)

D)

F)

12

4 1

2

1

4

1 24

4 2

Fig. 1

A Changeover circuit D Flat plug

B Circuit breaker/switch E Soldering pins

C-F Position of the contact connectors F Stranded wire output (1 = black, 4 = blue, 2 =grey)

C Screw connection


Contact Material Switchingsystem

Connection Function Electrical dataD

esig

natio

n

Circ

uit a

s a

chan

geov

er

Circ

uit a

s an

NC

con

tact

Silv

er

Gol

d (S

PS

app

licat

ion)

Qui

ck b

reak

sw

itch

Sw

itch

Sch

raub

ansc

hlus

s; 0

,5 -

1,5

mm

² / A

WG

16

... 2

2

Flat

plu

g 6,

3 m

m

Sol

derin

g pi

n

Stra

nded

wire

out

put

Forc

ed o

peni

ng a

ccor

ding

to E

N 6

0947

-5-1

App

endi

x K

Sho

rt-ci

rcui

t pro

tect

ion

Sw

itchi

ng p

ower

/ C

onne

ctin

g ca

ble

acco

rdin

g to

EN

609

47-5

-1

I th c

ontin

uous

ther

mal

cur

rent

Ui r

ated

insu

latio

n vo

ltage

99 ● ● ● ● ● 10AgG

AC–15:1,5 A, 230 V

DC-13:0,5 A, 60 V

10 A 250 V

99P ● ● ● ● ● 10AgG

99G ● ● ● ● ● 2AgR

99L ● ● ● ● ● 10AgG

99T ● ● ● ● ● 10AgG

99A ● ● ● ● ● 2AgR

99B ● ● ● ● ● 2AgR

99C ● ● ● ● ● 10AgG

4.1.6 Contact positions

The contacts are installed in each of the respective protective housings (exception: design IP00 / IP20).


4.1.7 Permissible radial force

Fmax

Fmax

FA FB

T

10

10

20

0 20 30 40 60 70 8050

30

40

50

60

70

80

90

100

[N]

[°C]

I = 13,5 mm

EKM-0248

Fig. 2

T = ambient temperature

Fmax = permissible radial force

FA = A-side radial force

FB = B-side radial force

Example of application: for speed n1 = 1800 rpm

Ambient temperature 40 °C: Fmax = 16 N

Ambient temperature 80 ℃: Fmax = 9 N

l = 13.5 mm (for standard shafts on GTES according to protection class IP20)

The following conditions must be observed:

• For drives with a chain drive system, timing belt system etc., the permissible radial force Fmax must not beexceeded.

• For protection class housings (except for CxZ and MC/MK housings), a grooved ball bearing is additionallymounted on the slide bearing. When using this housing, the permissible Fmax value can be doubled.

• For protective housings IP66 and IP65, the curve value can be doubled when another ball bearing is fitted.

• Impact-like axial forces are not permitted on the drive shaft.


4.1.8 Type code

EKM-0249

xxx xxx

xxxx

51_75_BMH_499_G

xx / xx

xxxxx xxxxxxxxxxx

Fig. 3Example: 51_75_BMH_499_G

51 Switch type: GTES type series 5175 Usable

revolutionsGear type N: 4.1, 6.5, 11

Gear type B: 17.5, 29, 48, 75, 125, 205, 323, 540, 880, 1384, 2288, 3735, 5900, 9800, 16000

Gear type DZ: 67, 110, 180, 280, 470, 770, 1200, 2000, 3300, 5200, 8700, 14200

B Gear type N: Without block adjustment

B: Block adjustment

DZ: Differential tooth gear

MH Housing type MH: IP65, GTES mounted in an aluminium housing

MC: IP55, GTES mounted in a plastic housing with a short housing cover

MK: IP55, GTES mounted in a plastic housing with a long housing cover

M: IP00/IP20, without a protective housing

MxZ: IP66, GTES mounted in a glass fibre reinforced polycarbonate housing x: Number ofintermediate pieces (0...9)

CxZ: IP65, GTES mounted in a glass fibre reinforced polycarbonate housing (compact) x:Number of intermediate pieces (0...9)

4 Number of fitted contacts: 1 − 16

99 Type of contact 99: Contact (changeover) with screw connections, contact material: Silver (standard)

99G: Contact (changeover) with screw connections, contact material: Gold

99L: Switch (changeover) with soldering pins (for PCB), contact material: Silver

99P: Contact (changeover) with flat plug connections, contact material: Silver

99T: Contact (switch) with screw connections, contact material: Silver

99A: Contact (switch) with screw connections, contact material: Gold

99B: Contact (changeover) with soldering pins, contact material: Gold

99C: Contact (changeover) with stranded wire output, contact material: Silver

G: G: With encoder/sensor

P: With potentiometer


All switches with CE marking, other approvals are possible, see marking on the type plate or in the attacheddocument:

CSA Canada EAC Eurasian Customs Union (Russia, Belarus,Kazakhstan, Kyrgyzstan, Tajikistan)

cUL USA DGUVV17

Certified for operation according to DGUV V17(previously BGV C1 / VBG70)

CCC China TAT Approval on request

4.1.9 Unit

To fix the GTES, do not use any screw locking agent, see the operating instructions of the complete machine.

NOTICE

Damage to the GTES due to contact with liquid screw locking agents.

Plastic components may be softened and damaged by contact with liquid screw locking agents.

► Prevent plastic components from coming into contact with liquid screw locking agents.

4.2 Dimensional drawing

NOTE

GKN Stromag AG strongly emphasises that the technical details, such as dimensions, weights, toler-ances, tightening torques and other technical specifications and units required for assembly, such assecuring devices and lubricants, must be obtained from the dimensional drawing.

Should this information be necessary during assembly, a reference will be made in the dimensionaldrawing at the respective point in this documentation.

A dimensional drawing is supplied as a separate document and can be requested additionally fromour after-sales services. For this, the same product data is required as when ordering spare parts.

4.3 Marking on the product

The following data can be found on the housing of the GTES:

Manufacturer's address, order number, designation, month/year of construction, marking, voltage Ui, current Ith.

NOTE

Switches and housings have identical type plates. The data, for e.g. for a spare part order, must beread from the respective assembly group.


5 Construction and function

5.1 Component designations

1 2 3

4

6

5 EKM-0002_02

72

4

Fig. 4

1 Gear part 5 Flange

2 Switch component 6 Drive shaft, design with parallel key

3 Housing, IP65 shown as an example 7 Cam disc in the gear part

4 Adjustment worm

5.2 Design, task and function of the assembly groups

The GTES consists of a gear component (1) and a switch component (2), which are accommodated in a hous-ing (3). The torque is transmitted in a positive locking way to the cam disc (7) by the continuous drive shaft (6).The gear parts are made of high quality plastic and are maintenance-free.

GTESs are manufactured as standard in protection class IP00 as built-in switches. The GTES can be mountedin an aluminium housing of protection class IP65 or in a glass fibre reinforced polycarbonate housing in protec-tion class IP66 and IP65. For the protection class of the available designs, see the type code section 4.1.8.

The planetary gears are made of thermoplastic material. The switching stages are constructed with the sameparts as the gear stages, through the applied modular technique. In addition, there is a cam disc (7) and anadjustment worm (4).

The gear and switching stages are mounted in a glass fibre reinforced plastic housing, see section 4.1.2 and section 4.1.3. The contacts are actuated by the switching stage cam discs.

5.2.1 Electrical connection versions

Various connection versions can be supplied:

• Screw connections for cross sectional area 0.5 − 1.5 mm2/ AWG 22 − 16

• Flat plug 6,3 x 0,8 mm2

IP00 without finger protection

IP20 with finger protection

5.2.2 Mounting position

The GTES can be mounted in any position with or without a housing.


5.2.3 Drive

The following mounting conditions must be observed:

• If possible, the drive should be engaged via a flexible connection, a flexible diaphragm coupling for example.

• The ideal drive is carried out over a torsionally-stiff flexible coupling with low axial and radial restoring forces.This compensates for any misalignments and offsets, e.g. drive flange type F / F+M, see section 5.3.1.

• Observe the permissible shear force values, see section 4.1.7.

5.3 Optional equipment available

5.3.1 Drive flange

BA

EKM-0250

6,2

M6

5

20 Ø54Ø42 ± 0,2

Ø54

Ø42 ± 0,210

14...22*

SW

10 3 3 Nm (+/- 0,5 Nm)

10

Ø8

-0,0

5

1,5

Fig. 5

A Elastic flange type F B Elastic flange type F+M* Adjustment range

Use of flange A/B

Flange Operating speed Torsion angle (with a torque of 5 Nm) Comment

F nmax = 1000 rpm 5 ± 0.5° not for MC/MK

F+M nmax = 1000 rpm 5 ± 0.5° not for MC/MK

Implement the counter flange according to the dimensional drawing.


5.3.2 Block adjustment

EKM-0031_02EKM-0031_02

1

2

Fig. 6

1 Block adjustment 2 Gear

The construction type of the gear with planetary stages allows a block adjustment to be additionally fitted forsingle contact adjustment from gear size 2. The final gear stage is therefore equipped with a black adjustmentworm.

All cam discs are adjusted together using this adjustment worm block adjustment (1). As such the relative ad-justment of the single contacts to each other remains unchanged.

When rotating the black adjustment worm by one revolution (360°), the cam discs rotate to the right by 0,575°(view from the B-side of the GTES).

NOTE

Using a DZ gearbox reduces the rotation of the cam discs to 0.04° per revolution of the block adjust-ment worm. Therefore, the effectiveness of the block adjustment is virtually non-existent in connectionwith DZ gearboxes. However, the block adjustment is still installed with DZ gearboxes (as of gearboxsize 2) due to the kit logic.


Indicator disc/dial (optional) for the block adjustment display

0.575

360

EKM-0005_02

34512

DD-140183 / Fig. 7

1 Cam disc 4 Dial, 5° separation

2 Adjustment worm of the final cam disc 5 Indicator

3 Indicator disc (optional)

By means of one of the indicator discs (3) attached to the back (B-side) of the GTES, the block adjustment set-ting can be read from the dial (4) on the back panel. The indicator disc rotates in parallel to the cam discs. Afteradjusting the final cam disc, the indicator (5) should be placed at zero. The indicator disc is clamped and can berotated by hand.

5.3.3 Special cam discs

A) B)

Ð3600 2702251801359045 315

EKM-0245

5

6

87

1

4

2

1

3

2

Fig. 8

A Cam angle diagram B Application examples

1 Effective cam angle α (=castor angle) 1 Effective cam angle 15°

2 Effective cam angle β 5 Effective cam angle 60°

3 Switching point radius 6 Effective cam angle 90°

4 Reset point radius 7 Effective cam angle 45°


The cam discs are named after the effective cam angle. For cam discs of series 51, this corresponds to theswitching point angle on the switching point radius of the cam disc.

Any cam angles (15° − 345°) can be supplied as a special design upon request.

The usable revolutions enabled by a cam disc on a GTES drive shaft, result in the following:

U =β * i

=(360° – α) * i

= 1 –α * i

360° 360° 360°

U = usable revolutionsα = Effective cam angleβ = Usable cam angle (β = 360° – α)i = gear ratio

5.3.4 Design with position feedback system

EKM-0041

Fig. 9

EKM-0042

Fig. 10


EKM-0043

Fig. 11The position feedback system is possible in the following designs:

Design Version Description

A Secondshaft end

Design with incremental encoder X impulses per revolution of the drive shaft.The drive shaft is guided through the GTES to the drive by the incremental encoder.

Design with multi-turn rotary encoder Output signals can be continued via a terminal group orplug.The drive shaft is guided through the GTES to the drive by the multi-turn rotary encoder.

B NDesign with single turn rotary encoder. Output signals can be continued via a terminal group orplug.The single turn rotary encoder is actuated via potentiometer coupling N.

C

Design with potentiometer. Output signals can be continued via a terminal group.The drive is engaged via a clamp coupling for a shaft diameter of 6mm.

N The potentiometer is actuated via the potentiometer coupling N (max. 345°).

S Max. angle of rotation ~ 1470° (345° x 4.285) for driving 5-gear potentiometers.

NOTE

For designs with potentiometers, the GTES is supplied premounted. The potentiometer must be se-curely mounted during assembly.

NOTE

For designs with Wertex absolute encoders, the response behaviour of the angle sensor can be ad-justed. The adjustment guidelines are enclosed as an extra appendix to this product and can also berequested from the customer service department, see section 11.2.

NOTE

In the case of designs with a cUL listing, the mounted encoder must be operated with a “class 2” pow-er supply according to UL in order to maintain the listing.

NOTE

For the “N” variant, an additional adjustment level is optionally available. This can be used to adjustthe single-turn encoder or the potentiometer without simultaneously changing the switching point ofthe last contact.


5.3.5 Design with heating resistor

EKM-0008

UB

PTC

1 2

A) B)

C)

21

DD1 40285V / Fig. 12

A PTC heating B View of PTC heating

1 PTC heating group C Circuit diagram

2 Connecting terminal

To avoid water condensation, a heating resistor can be mounted in the switch room. This heating is designed sothat a heat output of approx. 2.5 Watts or 4 Watts is available, depending on the voltage.

The electrical connection is (UB) 12 − 36 V AC/DC (max. 1,5 A AC/DC) or 110 − 250 V AC/DC (max. 4 A AC/DC).

The PTC heating is self-regulating and temperature-limiting, and thus leads to an automatic adjustment to theambient temperature. The connection is via a 2-pole terminal block.

ATTENTION

Risk of accidents due to hot surfaces

The surface of the heating can exceed 60 °C.

► Always allow components to cool down first.

Specific technical values

Design: UB 12 − 36 V AC/DC 110 − 250 V AC/DCHeat output (in lined out condition) approx. 2,5 Watts approx. 4 Watts

PTC cooling resistor (at 25 °C) R2520 Ω ± 35 % R251500 Ω ± 35 %

PTC reference temperature 50 °C 50 °C

Protection class (VDE 0100, 0160) II II

Connecting cable 2 x 0,25 mm2, silicone cable 2 x 0,25 mm2, silicone cable

Radiator Anodised aluminium Anodised aluminium

Weight approx. 40 g approx. 40 g


6 Assembly

6.1 Special safety guidelines

CAUTION

Risk of accidents caused by live components

For all work on components or individual parts, the machine must be switched off and securedagainst non-intended reconnection.

► Check that the machine is de-energised before beginning the work.

CAUTION

Risk of accidents caused by rotating components

Risk of entanglement in the area between the GTES and the machine due to rotating components.

► The operator must install a covering above the connecting flange.

NOTICE

Damage to the machine due to the incorrect adjustment of the GTES

When the GTES has not been adjusted, traverse movements of the machine can lead to damage.

► Before commissioning the machine, always adjust the GTES first in accordance with the specifica-tions in the mounting/operating instructions.

The installation regulations applicable on-site and the mounting instructions of the machine manufacturer mustbe observed.

6.2 Conditions for assembly and fixing

Required assembly space:

• 1,4 times the length of the housing

Assembly sequence:

• Mechanical assembly, see section 6.3.

• Electrical connection, see section 6.4.

• Switching point adjustment, see section 6.6.

• Completion of the housing, see section 6.7.

6.2.1 Special tools

A special tool is not necessary for standard designs.

6.2.2 Assembly precision

Avoid misalignments and offsets between the drive shaft of the GTES and the machine.

6.2.3 Tightening torques

Unless otherwise specified, the screws should be tightened according to the tightening torques provided in theDIN.

Machine and adjacent construction fixing elements must be tightened according to the manufacturer's instruc-tions.


6.3 Assembly mechanics

Before assembly of the GTES, the machine must be suitably positioned so that the installation space is easilyaccessible.

NOTE

GTESs with a preset switching position are provided with a transport lock.

The lock may only be removed directly before assembly. For assembly, the machine must be locatedin the corresponding predefined position.

NOTE

When driving screws into the machine-side threads, the following can be obtained from the operatinginstructions of the machine:

► Screw tightening torques,

► screw locking agent to be used, if necessary.

NOTE

The installation space must be and remain dust-free and dry.

6.3.1 Assembly design IP20 (without housing)

Mount the GTESon the machine

1. The connection between the drive shaft of the GTESand the machine must be positively locked.

2. Depending on the installation conditions: Mount theGTES on the housing or input side using screws.

Item

no.

Num

ber o

f scr

ews

Posi

tion

Scre

ws

Tigh

teni

ng to

rque

(1) 4 Housingside

see operat-ing instruc-tions of themachine

Unless oth-erwisespecified inthe operat-ing instruc-tions of themachine:1,5 Nm

(2) 3 Input side M56 mm deep

2,5 Nm

3. For adjusting switching points, see section 6.6.2.

EKM-0036

1 1

2

2

Fig. 13


6.3.2 Housing assembly, IP65


1. The connection between the drive shaft (1) of theGTES and the machine must be positively locked.

2. Depending on the installation conditions: Mount theGTES on the housing or input side using screws.

Item

no.

Num

ber o

f scr

ews

Posi

tion

Scre

ws

Tigh

teni

ng to

rque

(3) 4 Housingside

see operat-ing instruc-tions of themachine

See operat-ing instruc-tions of themachine.


5 Nm


4. Mount the housing cover, see section 6.7.

4

EKM-0013_02

Fig. 14

6.3.3 Housing assembly, IP66



2. Mount the GTES (1) with screws.

Item

no.

Num

ber o

f scr

ews

Posi

tion

Scre

ws

Tigh

teni

ng to

rque


2,5 Nm



2EKM-0032_02

Fig. 15


6.3.4 Assembly of the flange design, B5



2. Mount the flange (1) with screws.Ite

m n

o.

Num

ber o

f scr

ews

Posi

tion

Scre

ws

Tigh

teni

ng to

rque

(2) min.3

Input side M6, offsetby 120°(evenly dis-tributed onthe circum-ference)

See operat-ing instruc-tions of themachine



EKM-0014EKM-0014

Fig. 16

6.3.5 Assembly of the mounting bracket, B3



2. Mount the mounting bracket (2) with screws.

Item

no.

Num

ber o

f scr

ews

Posi

tion

Scre

ws

Tigh

teni

ng to

rque

(1) 4 Determinedby the de-

sign





EKM-00332

1 1

Fig. 17

6.4 Electrical assembly

After electrical assembly or maintenance, the safety measures applied must be tested (e.g. ground resistance).The connection of the stranded wire and soldering pin must be carried out by an electrician according to theElectrical Code of Practice.The safety guidelines attached to the GTES must be observed.


6.4.1 Insert the connection cable into the GTES

Insertion of theconnection cable

1. Insert the machine-side connection cable via the ca-ble entry point (1) in the switch housing.

NOTE

The cable screw connections used corre-spond to protection class >IP66. Whenmounting the cable, it is especially importantto ensure that the union nut (2) is carefullytightened (2 - 3 Nm) after the cable is inser-ted.As necking can cause the plastic sheath toremain deformed at the clamping point in thecable gland with some cables, retighten theunion nut (2) as necessary after 2 weeks.The cable entry point for the GTES should becarried out in such a way that no water canbe conducted by the cable to the cable gland.

EKM-0015

Fig. 18

6.4.2 Connect the screw connections

NOTE

For screw connections, only copper conductors may be used for the wiring.

Connection tothe screw con-nections

The screw connections are designed for cross sectionalareas of 0.5 … 1.5 mm² / AWG 22 … 16.Contacts with screw connections are generally suppliedwith protection against accidental contact. For thesecontacts, it must be ensured that before commission-ing, all screw connection screws are firmly tightened,whether or not they are used with a cable.

1. Strip the ends (1) of the connecting cables by 6 mm.

2. Insert cable underneath the clamp bolt and tightenscrew connection (2) with screw driver [1Nm].

EKM-0017

2

1

Fig. 19


6.4.3 Connect the flat plug

Connection withflat plug

CAUTION

Risk of accidents caused by live compo-nents

For contacts with a flat plug connection and voltagesover 25 V/AC or 60 V/DC, fully insulated flat plugs mustbe used by the customer as a protection against acci-dental contact.

► If only the NC function is required for the change-over contacts, the NO connection that is not re-quired must also be provided with a flat plug sleeveas a protection against accidental contact.

1. Prepare the ends of the connecting cables with a flatplug, 6 mm (1).

2. Fit the cable and check that it is securely seated onthe tongue (2).

EKM-0018

1

2

Fig. 20

6.4.4 Connect the earth conductor for IP66 housings

Earth conductorconnection

An earth conductor of up to 1,5 mm2 (min. wire cross-section of the connecting cable) can be connected andlooped via a bridge connection (1) on the rear contactcarrier.

NOTE

This design is only required for the CSA andcUL market.

1. Strip the ends of the earth conductors by approx. 6mm.

2. Plug the cable in and tighten the screws (2) [1 Nm].

EKM-0011

2

1

Fig. 21

6.4.5 Connect the earth conductor for IP65 housings

Earth conductorconnection

The earth conductor is laid on the housing.

1. Strip the ends of the earth conductors by approx. 6mm. Provided with a ring terminal end (2), if neces-sary.

2. Fit the cable and tighten the screw (1) [2.5 Nm].

EKM-0019

Fig. 22


6.5 Wiring diagram

6.5.1 Electrics

The contacts can be freely assigned. However, it is recommended that emergency stop functions are laid on thefirst contact.

6.6 Switching point adjustment

Adjustment procedure:

• Remove the cover.

• Carry out the adjustment.

• Remount the cover immediately.

After the switching point adjustment, immediately seal the GTES with the housing cover so that no dust or watercan enter and affect the safety off switch.

6.6.1 Mode of function

EKM-0021

Fig. 23

1 Cam disc A Effective cam angle

2 Adjustment worm B Usable cam disc angle

Each contact has a cam disc assigned to it that is continuously adjustable. The cam discs (1) can be adjustedwith the adjustment worm (2) independently of one other. This adjustment can be carried out without first loos-ening the parts. The adjustment worm is located in the self-locking device. The adjustment of the adjustmentworm can be carried out with 10 mm screwdrivers or 4 mm Allen keys.

Gear ratio, see section 4.1.2 and section 4.1.3.

• By rotating the adjustment worm to the right, the rotation of the cam disc is equally to the right (view from theB-side of the GTES).

The cam discs are designed so that a maximum nominal travel and overtravel are available. Cam discs withother nominal travels can be ordered as special cam discs and mounted in the factory.

No damage is caused to the GTES when the overtravel is exceeded. However, the contact may open or closeagain.


6.6.2 Adjusting the switching points

Adjustment ofthe switchingpoint - prepara-tions

CAUTION


There are live components in the area of the electrical connections.

► Ensure that the live connections in the GTES are covered with a protectionagainst accidental contact and that no contact with the connections is possible.

To prepare the switching point adjustment, carry out the following steps:

1. Carefully move the machine manually into the designated switch-off position of the GTES.

2. Switch the machine off and secure it against unintentional commissioning.

3. Loosen the housing cover screws, and, if applicable, remove the GTES housing cover.

CAUTION


When in open condition, the inner area of the GTES must be protected from dustand water.

► Protection classes IP00 and IP20 must be used dust-free.

CAUTION

Risk of accidents due to rotating parts

To adjust the switching point, the machine must be switched on, proceed as descri-bed below:

► Leave the movement area of the machine.

► Start the switching point at a safe distance from the machine.

► Switch the machine off and secure it from switching back on.

► Carry out the adjustment of the switching point that was started.

Adjustment ofthe switchingpoint - adjust-ment

To adjust the switching point, proceed as follows:

1. Adjust the switching point with the adjustment worm(1)-(n+1) of the switching cam.

Adjustment worm 0: Block adjustment(if applicable)

Adjustment worm 1: Contact 1





Adjustment worm n: Contact n

Adjustment worm n+1: Potentiometer adjust-ment(if applicable)

2. Adjust each switching cam.

EKM-0023_02

n+1n

01

23

Fig. 24


3. All adjustments must be looked at in an inspectionround and checked for functionality.

4. Mount the housing cover of the GTES, see sec-tion 6.7.

6.7 Complete the housing

When fitting the housing cover, ensure that the screws are fully and equally tightened in order to avoid a poorcontact pressure of the seal.

NOTE

The screws in the cover are secured against becoming lost.

Nuts on the housing from 2 intermediate pieces are not secured against becoming lost.

Screws and nuts must be fully screwed in.

6.7.1 Mount the MH housing, IP65

Housing coverassembly

1. Check the housing cover (2) seal (3) for cracks ordamage.

NOTE

Replace damaged seals.

2. Fit the housing cover with the seal.

3. Fasten the housing cover with 4 screws (1), see section 6.2.3.

EKM-0024

Fig. 25

6.7.2 CxZ, MxZ housing, mount 0 - 1 intermediate piece

Housing coverassembly, 0 - 1intermediatepiece

1. Check the housing cover (3) seal(s) (1) and the in-termediate pieces (2), if applicable, for cracks ordamage.

NOTE


2. Fit the intermediate pieces, if applicable, and thehousing cover.

3. Fix the housing cover with 4 screws (4), see sec-tion 6.2.3.

EKM-0035

12

13

4

4

Fig. 26


6.7.3 Mount the CxZ, MxZ housing from 2 intermediate pieces

Housing coverassembly, from 2intermediatepieces

According to the switching point number, the housingcover (3) will be extended with spacers (2).

1. Check the seal(s) (1) of the cover and the intermedi-ate pieces for cracks or damage.

NOTE


2. Fit the intermediate pieces and housing cover.

3. Fix the housing cover with 4 nuts (4), see sec-tion 6.2.3.

EKM-0034

12

12

13

4

4

Fig. 27

6.8 Correct disposal/recycling of operating and auxiliary materials.

Materials that can be recycled must be included in the waste disposal cycle.

Local regulations in the country of operation determine the disposal of components.

7 Operation

7.1 Special safety guidelines.

See operating instructions of the machine.

7.2 Initial commissioning

The adjustment of the GTES is only permitted when the machine is at a standstill.

7.3 Use

Use of the GTES is not necessary, see the operating instructions of the machine.

7.3.1 Operating conditions

See section 4.1.

7.4 Recommissioning

No specific measures are necessary for recommissioning.

7.5 Decommissioning

7.5.1 Temporary decommissioning

No specific measures are necessary for temporary decommissioning.

7.5.2 Final decommissioning

No specific measures are necessary for final decommissioning.

Dispose of materials according to local regulations.


8 Maintenance and inspections


CAUTION

Risk of accidents due to non-observance of the safety guidelines

There is a risk of accidents if the general safety guidelines are not observed.

► All safety guidelines must be observed, see Chapter 2.

8.2 Measures for environmental protection

RECYCLING

Dispose of components as well as auxiliary and operating materials according to the local guidelinesin a correct and environmentally-friendly way.

8.3 General points

The GTES switching points are checked as part of a performance check of the machine.

8.4 Maintenance and inspection intervals

In principle, no maintenance work or inspections are necessary for the GTES.

8.4.1 Cleaning

Dust deposits on the housing of the GTES are irrelevant in terms of the function. The dust can be removed dur-ing maintenance of the machine with a dry cloth.

NOTICE

Damage to the GTES caused by cleaning agents/solvents

Contact with cleaning agents or solvents may lead to damage.

► Any contact with cleaning agents or solvents must be avoided.

NOTICE

Damage to the GTES due to contamination

Dust deposits on the GTES must not be removed with compressed air.

By cleaning with compressed air, dust can enter the contact and the gear, and affect the switchingcapacity.

► Never hold a compressed air jet in an open housing.

► Only use dry cloths for cleaning.

NOTE

The housing cover seals must be replaced as necessary after repeated opening of the housing cover.

9 Troubleshooting

9.1 Operational issues and their solutions

No typical operating issues are known, should you have any queries regarding adjustment or commissioning,please contact our after-sales services, see section 11.2.


10 Disassembly


CAUTION

Risk of accidents due to non-observance of the safety guidelines

There is a risk of accidents if the general safety guidelines are not observed.

► All safety guidelines must be observed, see Chapter 2.

10.2 Removing the GTES

Disassembly of the GTES is carried out in the opposite way to assembly.

• Switch the machine off and secure it from switching back on.

• Remove housing cover, if applicable.

• Remove connection cable.

• Remove the GTES.

10.3 Final decommissioning

GTESs that have been finally decommissioned can be recycled.

11 Ordering spare parts

We only accept warranty claims for genuine spare parts. We express clearly that the assembly and/or use ofparts other than the genuine spare parts supplied by ourselves, can negatively change the given constructionalcharacteristics of the GTES and safety can thereby be directly and/or indirectly affected. For damage caused bythe use of spare parts and accessories that are not approved by GKN Stromag, as well as the incorrect replace-ment of spare parts, GKN Stromag AG is precluded from any warranty claims. Please bear in mind that specialmanufacturing and delivery specifications often apply to our own as well as to foreign parts and that we alwaysoffer spare parts according to the latest technical specifications and current legal regulations.

11.1 Data for ordering spare parts

NOTE

Switches and housings have identical type plates. The data, for e.g. for a spare part order, must beread from the respective assembly group.

The following data is required for ordering spare parts:

• Order number:See section 4.3.

• Type series and design:See section 4.3.

• Designation:Spare part designations can be obtained from the product overview, see section 5.1. Please contact our af-ter-sales services for more detailed information, see section 11.2.

• Quantity

11.2 Service address

The address for after-sales services and the spare parts sales department is:

GKN Stromag AG


Hansastraße 120D-59425 UnnaTel.: +49 (0) 2303 [email protected]

NOTE

Should you need the assistance of a service engineer, please contact our Technical after-sales ser-vices at the above address.

12 EC Declaration of Conformity

151-90593- BA / Fig. 28


EC Declaration of conformity (simplified)

according to Machinery Directive 2006/42/EC, Annex II 1.A (Translation of the original language)

Manufacturer: GKN Stromag AG

021 .rtsasnaH

annU 52495

Responsible for the documentation: Head of the construction TB-EKM

Product designation: Geared cam limit switch

15 seires epyT

The product complies with all relevant provisions of the above-mentioned directive.

The Low Voltage Directive 2006/95/EC was complied with in terms of its protective goals.

Applied harmonised standards:

EN ISO 12100

EN 60529:1991 + A1

EN 60947-5-1 incl. Annex K

EN ISO 13849-1

EN ISO 13849-2

GKN Stromag AG

Hansastraße 120D-59425 UnnaTel.: +49 (0) 2303 102-0Fax: +49 (0) 2303 [email protected]

Service address:Hansastraße 120D-59425 UnnaTel.: +49 (0) 2303 [email protected]

Gear limit switch Type series 51

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