Power and Dynamics - Drive Lines · ZF-Duoplan 2K600 Standard for Belt Drives ZF-Duoplan 2K250...

Power and Dynamics

Two-Speed Gearbox for Machine Tools

ZF-Duoplan 2K600 Standardfor Be l t Dr ives


ZF-Duoplan 2K250 TSC (Through-Spindle-Cooling) Allows cutting liquids like emulsions, hydraulic oils and air-oil mixtures to be passed through the gearbox and spindle, directly to the tool

ZF-Duoplan 2K120 INLINEDirect Mount ing to Spind le

Application, Benefits , Design

Modular Design

Technical Data

Motor Connection

Motor Output Shaft

Adaptions

Bearing Lifetime

Torsional Backlash

Lubrication

Connections for

Recirculation Lubrication

Overview Installation Drawings

Ordering Information

3


page 4-5

page 6-7

page 8-9

page 10

page 11-12

page 13

page 14-15

page 16

page 17

page 18-20

page 21-34

page 35-41

Precision in movement

The ZF Friedrichshafen division SpecialDriveline Technology is able to offer you a wide range of machine drives, brakes andclutches for applications in engineering aswell as customer specific drive solutions.

Our development and production activitiesare focused on servo-assisted drives forautomation engineering, two-speed drivegearboxes for machine tools as well as customer-specific drives, such as for print-ing machines, robot applications and eleva-tor gearboxes.

Our innovative standard products rangefrom low backlash servogearboxes(ZF-Servoplan), and high precision robusttwo-speed gearboxes (ZF-Duoplan) to hyste-resis clutches and brakes for non-contactweb control (ZF-Tiratron).

ZF Douplan - Two-speed gearboxes

BenefitsMachine tools are designed to be universal so that they can process different materials. This requires both high cutting speeds for soft materials as well as high cutting forces for hard materials requirements which a two-speedgearbox can fulfill, since it can either retain high motor speeds (i = 1:1) or multiply the motor torque (e.g. ratio i = 4.00) and reduce the speeds, both by the same factor.

Flexible

The cutting power is therefore constant and remains available across a widespeed range. This flexibility can only be economically achieved by using a gearbox.

Direct Mounting to Spindle (INLINE + TSC)

This gearbox is mounted directly to the spindle. No more belt drives are used.The gearbox is dedicated for today’s high speed requirements in machine tools.

Torque-power curve

Speed ranges with constant power of up to 1:20 can be achieved for the spindle withthe gearbox, depending on the controllable range of the motor. This provides hightorque at low speeds on the one hand and high power at high speeds on the other,allowing the cutting power of modern tools to be fully utilized.

ApplicationThe ZF Duoplan two-speed gearbox is mainly used in machine tool main-spindle drives, test-benches and applications where high torque is needed. By way of example, the gearbox can be used in turning machines (horizontal B3/B5), machining centers (vertical V1/V3) thanks to its variable installation position (see page 10). The gearbox is also suitable for use in many systems in which torque increase and/or speed reduction is required.

4

1) Motor-gearbox in i2 = 1.00

or motor without gearbox

2) Motor-gearbox in i2 = 4.00

Nm

rpm

Torque

kW

rpm

Power

400% increased motor torque. Doubled constant power range.

Torque - Power Curve - e.g. ZF-Duoplan 2K250

ZF-Duoplan Standard

Wide bearing base for

high cantilever force

5

ZF-Duoplan INLINE

Short output housing

for direct mounting

to spindle

Machining Center

ZF-Duoplan - Design

Design

ZF developed the ZF-Duoplan gearbox as a single-stage planetary design with ashift mechanism, hereby meeting today’s high demands of low noise operation.

In contrast to conventional spur gearboxes in lay-shaft design, this planetarygearbox has the distinct advantage of allowing an extremely compact and space-saving design since the power is distributed among 4 or 5 planetary gears.

In addition, the four resp fire simultaneously meshing planetary gears with helical gearing also assure low-noise operation at high speeds.

Misalignments and concentricity issues are ideally concentrated by the floatingdesign of the sun gear. Thus such a planetary gearbox is much less sensitive totolerances.

The motor-gearbox unit is commonly fixed to the machine frameor bed by using the gearbox foot mount. (Available for 2K120, 2K250, 2K300, 2K450, 2K600 only).

Each gearbox also has available an output side pilot for flange mounts.

For each application there is an ideal choice of output bearings with awide bearing base.

A range of output housing variants cater to different spindle drive designs:e.g. ZF-Duoplan STANDARD with wide bearing base for belt drives with highcantilever forces, ZF-Duoplan INLINE with short output housing and angularcontact bearings for direct drive and ZF-Duoplan TSC (Through-Spindle-Cooling) to facilitate the transfer of cutting liquids like emulsions, hydraulic oils and air-oil mixtures with up to 140 bars of pressure at a flow rate of 35 l/min through thegearbox and spindle, directly to the tool.

ZF-DUOPLAN 2K250 INLINE

ZF-DUOPLAN 2K120 Standard

6

Main components of the gearbox:

Adapter parts:

1: Drive hub

2: Adapter plate

3: with radial shaft seal

4: and hub bearing

Housing:

5: Gearbox housing

Input:

6: Sun gear

7: Ring gear

8: Ring gear bearing

Output:

9: Output housing

10: Output bearings

11: Output bearings

12: Output shaft

13: Radial shaft seal

14: Planetary carrier

15: Axial bearing with cup springs

Gear shift mechanism:

16: Sliding sleeve

17: Gear shift fork

18: Brake disc

Shift unit:

19: Switch unit

20: Gear shift finger

2

13

12

6

19

1

3

20 17

18

16

10 11

4

5

14978

033245

15 10 11

12

9

033247

Adapter parts:

1: Keyless hub

6: Sun gear

22: Counter holder

23: Clampig rings

24: Pressure piece with bushing

ZF-DUOPLAN 2K250 TSC

Output:

12: Output shaft

TSC:

25: Pipe

26: Rotary union joint

1

26

22

23

2425

6

15

12

ZF-Duoplan TSC

Through-Spindle-Cooling:

Allows cutting liquids like

emulsions, hydraulic oils

and air-oil mixtures with

up to 140 bars of pressure

at a flow rate of 35 l/min

to be passed through the

gearbox and spindle,

directly to the tool.

7

033246

Technical Data

Operator i s f ree to def ine bear ing load and l i fet ime. See insta l la t ion drawings or page 14 - 15 for bear ing data .1) Mass moments o f iner t ia for other ra t ios on request .2) admiss ib le wi th o i l coo ler, other wise nmax for reduct ion rat io .3) max. speed on ly permi t ted wi th o i l connect ion at por t K+ T (see pages 18/19 for o i l rec i rcu lat ion

systems connect ions) .4) max. speed on ly permi t ted wi th in tegrated o i l channel vers ions* on request** DSL = Dr y Sump Lubr icat ion*** i=5,5 = reduced input torque

Gea rbox S i z e s :

i 2K1202K 121

2K250 2K300 2K450 2K600

N o m i n a l d a t a :

Motor frame size 100/112 132 160 160/180 180

Nominal power (kW) 19 39 47 47 63

Nominal speed (min-1) 1 500 1 500 1 500 1 000 1 000

Nominal input torque (continuous operation S1) (Nm) 120 250 300/250*** 450 600

Output torque (Nm) 1.00 120 250 300/- 450 600

(Nm) 3.16 379 - - - -

(Nm) 3.17 - 792 951/- - -

(Nm) 4.00 480 1 000 1 200/- 1 800 2 400

(Nm) 4.91 589 - - / - - -

(Nm) 5.00 - - - 2 250 3 000

(Nm) 5.50 - 1 375 - / 1 375 - -

M a x i m u m d a t a :

Maximum torque in Nm (intermitted loading

Input (Nm) 140 400 400 630 840

Output (Nm) 1.00 140 400 400 630 840

(Nm) 3.16 442 - - - -

(Nm) 3.17 - 1 268 1 268 - -

(Nm) 4.00 560 1 600 1 600 2520 3360

(Nm) 4.91 687 - - - -

(Nm) 5.00 - - - 3150 4200

(Nm) 5.50 - 2 200 2 200 - -

Maximum permitted input speed (min-1) - - - - -

in reduction ratio i ≠ 1 (min-1) ≠ 1 8 000 6 300 6 300 5000 5000

for direct drive i = 12) (min-1) 12) 12 000 3) 10 000 3)4) 10 000 3)4) 8000 5000

Maximum vibration value (mm/s) 2.0 1.4 1.4 ≤2.0 ≤2.5

reduced (mm/s) 1.2 1.0 1.0INLINE (mm/s) 1.0 1.0 1.0reduced (mm/s) 0.7 0.7 0.7at reference speed (min-1) 6 000 5 000 5 000 4 000 4 000

Max. axial force in reduction (N) 3.16 - - -

(N) 3.17 - 3 090 3 710 - -

(N) 4.00 - 3 964 4 756 5 439 7 253

(N) 4.91 - - - - -

(N) 5.00 - - - 7 139 9 519

(N) 5.50 - 5 288 5 288 - -

Mass moment of inertia1) (J in kgcm2) 1.00 110 270 270 tbd tbd

Output 4.00 144 570 570 tbd tbd

Input 9 36 36 tbd tbd

O p e r a t i n g d a t a :

Oil fill volume in dm3 Horizontal (B5) 1.0/1.4 1.5 2.8 5,1 5,4Approx. oil fill in dm³. Oil level in middle of oil sight glassis most accurate reading Vertical (V1/V3)

Oil grade for:

splash lubrication

recirculating lubrication

recirculating lubrication with heat exchanger

recirculating lubrication with DSL**

Oil change interval

Oil temperature

We i g h t :

Standard (approx. kg) 42/52 68 86 155 165

E l e c t r i c a l C o n n e c t i o n :

f o r s h i f t u n i t :

power consumption W 120 120 120 120 120

Supply voltage (at shift unit) V 24±10% 24±10% 24±10% 24±10% 24±10%

current supply at 24V A 5,0 5,0 5,0 5,0 5,0

ratio in counter clockwise (ccw) operationrunning and max. input torquesee permissible

HPL 68 as per ISO VG 68




5 000 hoursmax. 120° C permitted depending on application , installation position, lubrication and cooling

for V1 and V3 installation positions oil recirculating system is mandatory

(max. accelarating torque)

recirculation lubrication

S6 cycle duration 10 min, ED. max. 60 %)

8

Technical Data Gea rbox S i z e s :

i 2K8002K801/2K802

standard

2K8002K801/2K802

mit STW

2K2100standard

ohne Abtrieb

2K2100mit STW

N o m i n a l d a t a :

Motor frame size 180/200/225 180/200/225 225/280 225/280

Nominal power (kW) 84 84 120 120

Nominal speed (min-1) 1 000 1 000 500 500

Nominal input torque (continuous operation S1) (Nm) 800 800 2 100 2 100

Output torque (Nm) 1.00 800 989 2 100 2 932

(Nm) 3.16 - - - -

(Nm) 3.17 - - - -

(Nm) 3.19 2 552 3 154 - -

(Nm) 4.00 3 200 3 955 8 400 11 726

(Nm) 4.91 - - - -

(Nm) 5.50 - - - -

M a x i m u m d a t a :

Maximum torque in Nm (intermitted loading

Input (Nm) 900 900 * *

Output (Nm) 1.00 900 1 112 - -

(Nm) 3.16 - - - -

(Nm) 3.17 - - - -

(Nm) 3.19 2 871 3 549 - -

(Nm) 4.00 3 600 4 450 - -

(Nm) 4.91 - - - -

(Nm) 5.50 - - - -

Max. permitted input speed (min-1) 5 000 5 000 3 500 3 500

in reduction ratio i ≠ 1 (min-1) ≠ 1 - - - -

for direct drive i = 12) (min-1) 12) - - 3 000 -

Max. vibration value (mm/s) 3,0 3,0 5,0 *

reduced (mm/s)INLINE (mm/s)reduced (mm/s)at refence speed (min-1) 4 000 4 000 * *

Max. axial force in reduction (N) 3.16 - - - -

(N) 3.17 - - - -

(N) 3.19 - - - -

(N) 4.00 - - - -

(N) 4.91 - - - -

(N) 5.50 - - - -

Mass moments of inertial1) (J in kgcm2) 1.00 1 956 * * *

Output 4.00 1 766 * * *

Input 110 * * *

O p e r a t i n g d a t a :

Oil fill volume dm3 Horizontal (B5)

Approx. oil fill in dm³. Oil level in middle of oil sight glass is most accurate reading Vertical (V1/V3)

Oil grade for:

splash lubrication

recirculating lubricaton

recirculation lubrication with heat exchanger

recirculating lubrication with DSL**

Oil change interval

Oil temperature

We i g h t :

Standard (approx. kg) 175 325 180 400

E l e c t r i c a l c o n n e c t i o n :

f o r s h i f t u n i t :

Power consumption W 120 120 85 85

Supply voltage (at shift unit) V 24±10% 24±10% 24±10% 24±10%

Current supply at 24V A 5,0 5,0 5,0 5,0

ratio in counter clockwise (ccw) operationrunning and max. input torqueSee permisible axial force for motor shaft

HLP 68 as per ISO VG 68




5 000 hoursmax. 120° C permitted depending on application, installation position, lubrication and cooling

for V1 oder V3 installation positions oil recirculating system is mandatory



S6 cycle duration 10 min, ED.max. ED. max. 60%)

(max. accelerating torque)

9

Operator i s f ree to def ine bear ing load and l i fet ime. See insta l la t ion drawings or page 14 - 15 for bear ing data .1) Mass moments o f iner t ia for other ra t ios on request .2) admiss ib le wi th o i l coo ler, other wise nmax for reduct ion rat io .* on request

S2

e2

h

I

db

2K800 / 2K801 / 2K802 / 2K2100

Standard Motor Connection Dimensions

S2

a1e2

I

d b

Gea rbox s i z e s :

10

2K120 2K121 2K250 2K300 2K450 2K600 2K801 2K802 2K2100 2K2100

M o t o r f r a m e s i z e : 100 112 132 160 160/180 180 200 225 225 280

Standard motor-

motor connection dimension

h 100 112 132 160 160/180 180 200 225 225 280

d 38 48 42 55 55/60 65 65 75 75 90

l 80±0.1 110±0.1 110-0.2 110-0.2 110–0.2

140–0.2

140–0.2 140±0.2 140±0.2 140±0.2 170±0.2

b 180 230 250 300 300 300 350 450 450 550e2 215 265 300 350 350 400 400 500 500 600a1 - - - - 400 450 450 550 550 660s2 14 15 18 18 18 18 19 19 19 24

EN 50347: 2001

2K120 / 2K121 / 2K250 / 2K300 / 2K450 / 2K600

All measure in mm

Nabe

Motorwelle

See DIN ISO 8821

For half-key balancing the key type B is standard.

For a full-key balanced motorshaft both types can be used.

Application with smooth motorshaft without keyway on request.

Motor output shafts with standard fitted key

H o r i z o n t a l B 5S h i f t u n i t o n r i g h t s i d e( v i e w f r o m o u t p u t )G e a r b o x r o t a t e d a l o n gl o n g i t u d i n a l a x i s( f o r 2 K 1 2 0 / 2 K 2 5 0 /2 K 3 0 0 / 2 K 4 5 0 / 2 K 6 0 0 )

Installation positions

11

Gearbox sizes

ZF-Duoplan

Shaft diameter

[mm]

Fitted key

b x h [mm]

Fitted key length

[mm]

2K120/121 38 10x8 7032 10x8 7042 12x8 90

2K250 42 12x8 9048 14x9 9055 16x10 90

2K300 55 16x10 9048 14x9 9042 12x8 9060 18x11 125

2K450 60 18x11 12555 16x10 90

2K600 65 18x11 1252K800/801 60/65 18x11 1252K802/2K2100 75 20x12 125

80 22x14 150

Hub

Motor shaft

Half-key balancing Full-key balancing

Ve r t i k a l V 1 Ve r t i k a l V 3

H o r i z o n t a l B 5

11

Output / Motor interface

Output

There is a choice of two different output variants. The standard long bearing base output flange version is used for beltdrives, allowing high cantilever forces. For the 2K300 an extended output version is optional for even higher belt forces.Further options include short output housings as ZF-Duoplan INLINE for space saving direct drives. This version is supplied as a standard with angular contact bearings. ZF-Duoplan TSC (Through-Spindle-Cooling) allows cutting liquids like emulsions, hydraulic oils and air-oil mixtures with up to 140 bars of pressure at a flow rate of 35 l/min through the gearbox and spindle, directly to the tool.The STW (spur gearbox with fixed ratio as spindledrive) option is used for high output torque drives in conjunction with 2K800 and 2K2100.

There are two output variants to choose from. Output flanges are standard. Output shafts or STW (spur gearbox with fixed ratio directly onto spindle) are available as an option.

Motor connection

The hubs are generally fitted with a keyway for power transmission. It should be noted that the hub must be balanced in the same way as the motor.

There are two types of balancing: Half-key and full-key. In the case of full-key balancing, the motor shaft is balancedwith a fitted key, the hub without. The length of the fitted key is unimportant in this instance. In the case of half-keybalance, however, the keyway is filled out with a balance compensator. The shape, length, and position of the keywaymust be adapted. For this reason, it is necessary to provide ZF with details of the motor – including the relevant dimen-sions and balancing type – when ordering.

For straight motor shaft a keyless hub with clamping ring is mandatory. To this end and in accordance with DIN 332-2,the motor shaft must feature a centering bore with a thread.If the motor connection dimensions do not permit directmounting to the ZF-Duoplan, an adapter plate or adapter ring is required. These adapter parts can be included in thesupply on request, depending to motor manufacturer.

Note

For motor-gearbox units that are fixed in the machine with the gearbox output housing/flange only, no preload supporton motor B-side is permitted.

+ = Standard0 = Option

Version for Through-Spindle-Cooling to facilitate the transfer of cutting liquids like emulsions, hydraulic oils and air-oil mixtures without dissolving or abrasive additives, with up to 140 bars of pressure at a flow rate of 35 l/minthrough the gearbox and spindle, directly to the tool.

Gea rbox s i z e s :

12

ZF Duoplan 2K120 2K121 2K250 2K300 2K450 2K600 2K800 2K801 2K802 2K2100

Gearbox OutputØ 100 + +Ø 118 + 0Ø 130 0 +Ø 140 +Ø 150 +Ø 38 0 0Ø 42 0 0Ø 55 0 0Ø 60 0Ø 65 0 0 0Ø 90 0Ø 180 + + +Ø w i t h S T W 0 0 0 +Ø w i t h o u t O u t p u t 0 0 0 0Ø 38 I N L I N E 0 0Ø 42 I N L I N E 0 0Ø 70 T S C * 0 0 0 0

*

13

Open Design(with/without adapter ring)

Closed Design(with hub bearing and shaft seal)

Closed Design(with shaft seal)

Possible Connections

Open design

The open version gearbox is without adapter plate. Sealing with motor shaft seal.

Closed design (with hub bearing and shaft seal)

There is a version with ball bearing available for certain motors. The hub in this version is also fixed by the bearing to prevent axial hub movement, rsp.present axial forces from the helical gearing onto themotor shaft (see technical data page 8). Assembly ontospindle motor is made easier due to a fixed hub positionas supplied bythe factory.

Closed Version (with shaft seal)

This version incorporates an adapter plate with shaftseal, which means that the gearbox forms a compact,closed unit.

Adapter Ring

The adapter ring allows adaptation to different dimen-

sions. A shaft seal is required on the motor shaft.

Input flange: (2K250 / 2K450 / 2K600 / 2K800 / 2K2100)

Besides the classic motor - gearbox - adaptation (motorshaft, key way, hub) we offer - on request - a gearboxwith input flange to mount a pulley, clutch or similar(as shown on page 33).

Output bearings

The output bearings vary depending on the type and levelof load on the output shaft. Cylindrical roller bearings areused to cope with high radial forces, e.g. in belt pulleydrives. In contrast, angular-contact ball bearings are suitable for coaxial drives, low radial backlash or axial forces. The flexible design of the output housings andshafts allows a range of selections.

Gearbox interface:

2K120 / 2K121

nab/out = 375 min-1

nab/out = 1 500 min-1





2K300-LA

Bearing B Bearing ANU 2211NUP 211

0

5000

10000

15000

20000

25000

30000

0 10 20 30 40 50 60 70 80 90 100 110 120 130

2K300

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70Bearing B Bearing A

0

5000

10000

15000

20000

25000

30000

NU 2211NUP 211

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70Bearing B Bearing A

NU 2210NUP 209

0

5000

10000

15000

20000

250002K250

Position [mm]

Tran

sver

se f

orce

[N

]

2K250 / 2K 300 / 2K 300 long

nab/out = 375 min-1






Versions and Lifetime Calculation based on XY-method

Pemitted Cantilever Forces

For standard bearing

service life = 36 000 hours

Note:

Take into account the motor

manufacturer’s permitted

cantilever forces.

14

00 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75

2000

4000

6000

8000

10000

12000

14000

16000

Bearing B

2K120

Bearing ANU 22086208

2K600 / 2K800 / 2K800 long

2K450

nab/out = 200 min-1

nab/out = 500 min-1





Permitted Cantilever Forces

For standard bearing

service life = 36 000 hours

Note:

Take into account the motor

manufacturer’s permitted

cantilever forces

2K600


0

10000

40000

20000

30000

50000

0 20 30 40 50 60 70 80 90 100 110 12010


2K800

0

20000

80000

40000

60000

100000

0 20 30 40 50 60 70 80 90 100 110 12010

Bearing B Bearing A

2K800-LA

0

20000

80000

40000

60000

100000

0 20 30 40 50 60 70 80 90 100 110 120 130 140 15010

NU 22218NUP 2217

2K450


0

5000

10000

15000

20000

15000

30000

35000

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Postion [mm]

Tran

sver

se f

orce

[N

]Versions and Lifetime Calculation based on XY-method

nab/out = 250 min-1






15

16

Application and Examples

Workpiece Processing with Constant Cutting Force

Class 3*: Normal torsional backlash < 30 arcminOnly for turning machine drives involving workpiece processing with constant cutting force.

a) For turning machine drives when cutting is uninterrupted while the workpiece is being processed or in the case of predominant facing involving cutting speed adjustment.

b) Boring millsc) Milling machines and machining centres

Extreme Milling Work

Class 2: Reduced torsional backlash < 20 arcminFor milling machines and machining centres used to execute extreme millingwork, e.g. tool side milling cutters with very coarse index/division (interruptedcutting), workpieces made from tough material, milling of ribbed workpieces.

Highly-dynamic Machine Tools

Class 1: Especially reduced torsional backlash < 15 arcminAs class 2; except in lightweight highly-dynamic machine tools incorporatingcomponents with high internal elasticity; designed to prevent resonance vibration.

Torsional backlash

Three backlash classes in

reduction mode are available:

Class 3*:

Normal torsional

backlash < 30 arcmin

Class 2:

Reduced torsional


Class 1:

Especially reduced torsional


*Torsional backlash in

2K800 / 801 / 802 / 2100

Class 3: Normal torsional


17

Lubrication

Splash type lubrication

The standard gearbox version B5 has splash type lubrication. Splash type lubricationis suitable for intermittent operation. In this instance, frequent gear changes, varyingspeeds and idle time (e.g. due to retooling) are a prerequisite.

Recirculating lubrication

The 2K120/2K121/2K250/2K300/2K450/2K600 gearboxes (vertical V1 and V3 installation positions) require recirculating lubrication. In this instance, the type of recirculating lubrication depends on the operating temperature levels required.The 2K800/2K801/2K802 and 2K2100 gearboxes must always be operated with recirculating lubrication (refer also to installation drawings).

Forced recirculating lubrication

Some applications require a very low operating temperature level. Forced recirculating lubrication is recommended in such instances. Figures on page18/19 show the possible oil inlet and outlet positions on the gearbox. Please refer tothe relevant installation drawings for detailed dimensions.

Standard recirculating lubrication in V1/B5 with oil tank installation

The oil inlet is attached in place of the oil drain plug. The oil flow rate is approx. 1.5 l/min. (only for 2K120/2K121/2K250/2K300); approx. 2,0 l/min. (only for 2K450/2K600); approx. 2,5 l/min. (only for 2K800). In the case of V3 vertical installation position, the lubrication oil can be supplied in either radial direction or centrally.

The tank of the pump unit must be ventilated. Oil back pressure in the return pipeto the gearbox must be avoided (Ø min. 20 mm). The tank capacity should be at leastten times the recirculating oil quantity. A 60 μm filter and a pressure limitation valveshould also be used as a safeguard.

Recirculating lubrication with heat exchanger

A heat exchanger is installed in the recirculating lubrication system to assureadditional temperature reduction. For best cooling results without any influence onlubrication, various connection parts for different installation positions and operatingmodes are provided.

In order to achieve an optimal temperature development of the gearbox and to enablethe max. speeds, an integrated oil channel version is offered (oil port connection seepages 18/19, ordering code see pages 35 - 39).In addition, it is possible to operate the 2K250/300 without oil level (dry sump lubri-cation).

Note

For continuous operation in direct drive one gear change per hour is mandatory witha short turn in reduction ratio. If this is impossible please request special solution.

Installation position: Oil inlet* Max. pressure Oil outlet*

V1 (closed version) M (0.5 dm³/min) 0.5 bar D/E

K/R and/or L/S (1.0 dm³/min) 0.5 bar

V1 (open version) K/R and/or L/S (1.5 dm³/min) 0.5 bar D/E

B5 G (1.5 dm³/min) 1.5 bar D/E

F (1.5 dm³/min) 1.5 bar

B5 turned, right* I or F (1.5 dm³/min) 1.5 bar H

V3 P (1.5 dm³/min) 1.5 bar H

or K/R and/or L/S (1.5 dm³/min) 0.5 bar

Connections for recirculating lubrication

*View toward gearbox output:D/G = Mainly counter clockwise rotationE/F = Mainly clockwise rotation

Note:For applications using max. speeds of 12 000 rpm, it is mandatory to use port K and/or L with 1.5 dm3/min.In addition an oil recirculating system using an oil chiller with > 0.3 kW capacity and oil volume >15 litres is necessary.

18

MK

G

E

I

L

DF

P

H

R S

033244

2K120 / 2K121

*View toward gearbox output:D/G = Mainly anti-clockwise rotationE/F = Mainly clockwise rotation

In V1/V3 recirculation lubrication necessary for 2K250/300.

Note:For applications using max. speeds of 10 000 rpm port K or R is mandatory.In addition an oil recirculating system using an oil chiller > 0.3 kW and oil volume >15 litres is necessary.

The integrate oil channe version is available for 2K250/300/450/600 (see note page 36/37).This permits a gearbox operation without oil level, however a safety check of oil supply needs to be includedin the oil system.

Connections for recirculating lubrication

19

Installation position: Oil inlet* Max.

pressure

Oil outlet* Oil inlet* Max.

pressure

Oil Outlet*

V1, V3 M (0.5 dm³/min) 0.5 bar D/E M (0.5 dm³/min) 0.5 bar D/E

(closed version) K or R (1.0 dm³/min) 0.5 bar T (1.5 dm³/min) 0.5 bar

L additional possible 1.5 bar L additional possible 1.5 bar

V1, V3 K or R (1.5 dm³/min) 0.5 bar D/E T (2.0 dm³/min) 0.5 bar D/E

(open version) L additional possible 1.5 bar 1.5 bar

B5 G (1.5 dm³/min) 1.5 bar D/E G (2.0 dm³/min) 1.5 bar D/E

F (1.5 dm³/min) 1.5 bar or F (2.0 dm³/min) 1.5 bar

B5 turned right* I or F 1.5 bar H I or F 1,5 bar H

V3 P (1.5 dm³/min)

K or R (1.5 dm³/min)

L additional possible

1.5 bar

0.5 bar

1.5 bar

H T (2.0 dm³/min) 1.5 bar H

2K250 / 2K300 2K450 / 2K600

I

L

DF

K M

E

G

T

P

N

H

R

033243

Installation Drawings

21

2K120

2K121

2K120/121 INLINE TSC

2K250

2K300

2K250/300 INLINE TSC

2K450

2K600

2K800

2K801

2K802

Options 2K800/801/802

2K2100

page 22

page 23

page 24

page 25

page 26

page 27

page 28

page 29

page 30

page 31

page 32

page 33

page 34

Installation Drawing:2K120

22

4270

OEL

STA

ND

SSCH

AUG

LAS

OIL

LEV

EL S

IGH

T G

LASS

(LIN

KS U

ND

REC

HTS

)(L

EFT

AN

D R

IGH

T)

7208

BE

C=36

KN

2K12

0

4.1

131

83

39.5

15

17.5

273

207.

5

116 11

7

103835

55

65.5

ø32

17

3

ø14

18

5.1

2512

4.5

13.5

10

35

163

80

10

45°

8x45

°

215

M8

80

87.5

-0.5

87.5

- 0.5

4

209

197

M 12x1.5

Ø MA*

Ø M

A*

MO

TORA

NSC

HLU

SSM

ASS

MO

TOR

DIM

ENSI

ON

180H7

ø100k6

ø188

ø190g6

ø100

30ø14

ø14

98.5

108

250

12

208

92

6363

17 M42

x1.5

MAX

MIN

6208

C=31

KN

BEI G

ESCH

LOSS

ENER

VARI

AN

TEFO

R CL

OSE

D V

ERSI

ON

NU

220

8C=

75 K

NST

AN

DA

RDO

PTIO

N72

08 B

EC=

36 K

N

STA

ND

ARD

2K12

0 IN

LIN

E

M 10x1

92

315

- 25

FQ*)

18

28

80 8370

28

10N

9

ø38k6

M12

ø100

5

WU

CHTU

NG

MIT

PA

SSFE

DER

BALA

NCE

WIT

H K

EYPA

SSFE

DER

/KEY

A10

x 8

x 7

0

OEL

SORT

E:

HLP

68

NAC

H IS

O V

G 6

8 BE

I TAU

CHSC

HM

IERU

NG

H

LP 4

6 N

ACH

ISO

VG

46

BEI U

MLA

UFS

CHM

IERU

NG

H

LP 3

2 N

ACH

ISO

VG

32

BEI U

MLA

UFS

CHM

IERU

NG

MIT

WA

ERM

ETAU

SCH

ERO

IL G

RAD

E: H

LP 6

8 AC

C. T

O IS

O V

G 6

8 W

ITH

SPL

ASH

LU

BRIC

ATIO

N

HLP

46

ACC.

TO

ISO

VG

46

WIT

H R

ECIR

CULA

TIN

G L

UBR

ICAT

ION

HLP

32

ACC.

TO

ISO

VG

32

WIT

H R

ECIR

CULA

TIN

G L

UBR

ICAT

ION

AN

D H

EAT

EXCH

AN

GER

STA

ND

ARD

O

PTIO

NU

EBER

SETZ

UN

G:

i 1 = 4

.00

i 1 =

3.1

6

i 2 = 1

.0

i 2 =

1.0

TRA

NSM

ISSI

ON

RAT

IO:

i 1 = 1

.0

i

1 = 3

.16

i 2 =

1.0

i2 =

1.0

GEW

ICH

T: c

a. 4

2 kg

W

EIG

HT:

c

a. 4

2 kg

M 12x1.5

M22x1.5

5

M16x1.5

OPT

ION

ABT

RIEB

SWEL

LEO

PTIO

N O

UT

PUT

SHA

FT

BEI V

ERTI

KALE

INBA

U V

1IN

VER

TICA

L IN

STA

LLAT

ION

V1

BEI V

ERTI

KALE

INBA

U V

3IN

VER

TICA

L IN

STA

LLAT

ION

V3

*) B

EI D

ER L

AGER

AUSL

EGU

NG

A

NG

ENO

MM

ENE

WIR

KUN

GSL

INIE

D

ER R

ESU

LTIE

REN

DEN

RIE

MEN

KRA

FT

ASS

UM

ED L

INE

OF

RESU

LTIN

G

PU

LLEY

FO

RCE

FOR

B

EARI

NG

CA

LCU

LATI

ON

116

83

130

ø38k6 4

STA

ND

AR

DS

CH

ALT

UN

GS

EIN

HEI

T O

HN

E N

EUTR

ALS

TELL

UN

GS

HIF

T U

NIT

WIT

HO

UT

NEU

TRA

L PO

SIT

ION

OPT

ION

SC

HA

LTU

NG

SEI

NH

EIT

MIT

NEU

TRA

LSTE

LLU

NG

SH

IFT

UN

IT W

ITH

NEU

TRA

L PO

SIT

ION

45°

8x45

° M8

ø80

103

265 87.5

82.5

87.5

82.5

240

300

R 20

48

4.1

151

293

15

17.5

4275

15 -

25

116

10ø32

ø100k6

ø100

ø190g6

ø188

17

ø230 H7

ø14 25

3

117

39.5

124.

5

20 35

MAX

MIN

6208

C=31

KN

F Q*) N

U 2

208

C=75

KN

STA

ND

ARD

OPT

ION

7208

BE

C=36

KN

7208

BE

C=36

KN

2K12

1

OEL

STA

ND

SSCH

AUG

LAS

OIL

LEV

EL S

IGH

T G

LASS

(LIN

KS U

ND

REC

HTS

)(L

EFT

AN

D R

IGH

T)

243120

20

ø14

*) B

EI D

ER L

AGER

AUSL

EGU

NG

AN

GEN

OM

MEN

E W

IRKU

NG

SLIN

IED

ER R

ESU

LTIE

REN

DEN

RIE

MEN

KRA

FTA

SSU

MED

LIN

E O

F RE

SULT

ING

PULL

EY F

ORC

E FO

RBE

ARI

NG

CA

LCU

LATI

ON

OEL

SORT

E:

HLP

68

NAC

H IS

O V

G 6

8 BE

I TAU

CHSC

HM

IERU

NG

H

LP 4

6 N

ACH

ISO

VG

46

BEI U

MLA

UFS

CHM

IERU

NG

H

LP 4

6 N

ACH

ISO

VG

46

BEI U

MLA

UFS

CHM

IERU

NG

H

LP 3

2 N

ACH

ISO

VG

32

BEI U

MLA

UFS

CHM

IERU

NG

MIT

WA

ERM

ETAU

SCH

ER

HLP

68

ACC.

TO

ISO

VG

68

WIT

H S

PLA

SH L

UBR

ICAT

ION

OIL

GRA

DE:

H

LP 4

6 AC

C. T

O IS

O V

G 4

6 W

ITH

REC

IRCU

LATI

NG

LU

BRIC

ATIO

N

HLP

32

ACC.

TO

ISO

VG

32

WIT

H R

ECIR

CULA

TIN

G L

UBR

ICAT

ION

AN

D H

EAT

EXCH

AN

GER

UEB

ERSE

TZU

NG

:

STA

ND

ARD

OPT

ION

i 1 = 4

.00

i 1 =

3.1

6

i 2 =

1.0

i 1 = 3

.16

i 2 = 1

.0

i 2 =

1.0

TRA

NSM

ISSI

ON

RAT

IO:

i1 =

4.0

0

i 1 = 3

.16

i 2 = 1

.0

i 2 =

1.0

GEW

ICH

T:

ca.

52

kgW

EIG

HT:

ca.

52

kg

M 12x1.5

M 12x1.5

4

M22x1.5

M16x1.5

55

17

M42

x1.5

70

STA

ND

ARD

BEI V

ERTI

KALE

INBA

U V

1IN

VER

TICA

L IN

STA

LLAT

ION

V1

BEI V

ERTI

KALE

INBA

U V

3IN

VER

TICA

L IN

STA

LLAT

ION

V3

80 8370

28

10N

9

ø38k6

M12

5

WU

CHTU

NG

MIT

PA

SSFE

DER

BALA

NCE

WIT

H K

EYPA

SSFE

DER

/KEY

A10

x 8

x 7

0

OPT

ION

ABT

RIEB

SWEL

LEO

PTIO

N O

UT

PUT

SHA

FT

13.5

116

130

83

3

70

207.

5

163

80

10

2K12

1 IN

LIN

E

ø38k6 4

STA

ND

AR

DS

CH

ALT

UN

GS

EIN

HEI

T O

HN

E N

EUTR

ALS

TELL

UN

GS

HIF

T U

NIT

WIT

HO

UT

NEU

TRA

L PO

SIT

ION

OPT

ION

SC

HA

LTU

NG

SEI

NH

EIT

MIT

NEU

TRA

LSTE

LLU

NG

SH

IFT

UN

IT W

ITH

NEU

TRA

L PO

SIT

ION


23

116

130

83

3

STA

ND

AR

DS

CH

ALT

UN

GS

EIN

HEI

T O

HN

E N

EUTR

ALS

TELL

UN

GS

HIF

T U

NIT

WIT

HO

UT

NEU

TRA

L PO

SIT

ION

OPT

ION

SC

HA

LTU

NG

SEI

NH

EIT

MIT

NEU

TRA

LSTE

LLU

NG

SH

IFT

UN

IT W

ITH

NEU

TRA

L PO

SIT

ION

Installation Drawing:2K120/121 INLINE + TSC

Dim

ensi

ons

of b

asic

gea

rbox

see

inst

alla

tion

draw

ing

p. 2

2/23

24

150

106

5.1

10

25 -

35

4658

±0.2

75

M22x1.5

270

135

ø350ø300

118.

5

118.

5

100

M12

12x3

0°

30°

15°

R58.3

15°

20

129.

5

171.

5

221

133

83.5

25

5.1

135

268

258.5

ø18

ø18

ø MA*

ø116R 68.5

30

ø127.3ø249

ø250 g6

ø118 k6

128.5

10835

136

12

8711

711

787

30

35

72.1

M10

x1

46.9

73.6

45.4

142.

5

20°

M22x1.5

9.5

ø14

2020

24

55

149

12h9

42k6

M1056070

6.5

23.5

72

MAX

MIN

NU

P 20

9EC=

6050

0NN

U 2

210

ECP

C=78

100N

(FQ

*)

STA

ND

ARD

OPT

ION

7209

BE

C=37

700N

7210

BE

C=39

000N

5

2

5

135

2020

10

4

WU

CHTU

NG

MIT

PA

SSFE

DER

BALA

NCI

NG

WIT

H K

EYPA

SSFE

DER

/KEY

A12

x 8

x 6

0

OPT

ION

ABT

RIEB

SWEL

LEO

PTIO

N O

UTP

UT

SHA

FT

ø116

ø250H7

OEL

STA

ND

SSCH

AUG

LAS

OIL

LEV

EL S

IGH

T G

LASS

(LIN

KS U

ND

REC

HTS

)(L

EFT

AN

D R

IGH

T)

2K25

0

Ø M

A*

BEI G

ESCH

LOSS

ENER

VARI

AN

TEFO

R CL

OSE

D V

ERSI

ON

STA

ND

ARD

2K25

0 IN

LIN

E

*) B

EI D

ER L

AGER

AUSL

EGU

NG

AN

GEN

OM

MEN

E W

IRKU

NG

SLIN

IED

ER R

ESU

LTIE

REN

DEN

RIE

MEN

KRA

FTA

SSU

MED

LIN

E O

F RE

SULT

ING

PULL

EY F

ORC

E FO

RBE

ARI

NG

CA

LCU

LATI

ON

MO

TORA

NSC

HLU

SSM

ASS

MO

TOR

DIM

ENSI

ON

OEL

SORT

E:

HLP

68

NAC

H IS

O V

G 6

8 BE

I TAU

CHSC

HM

IERU

NG

HLP

46

NAC

H IS

O V

G 4

6 BE

I UM

LAU

FSCH

MIE

RUN

G

H

LP 3

2 N

ACH

ISO

VG

32

BEI U

MLA

UFS

CHM

IERU

NG

MIT

WA

ERM

ETAU

SCH

ERO

IL G

RAD

E:

HLP

68

ACC.

TO

ISO

VG

68

WIT

H S

PLA

SH L

UBR

ICAT

ION

HLP

46

ACC.

TO

ISO

VG

46

WIT

H R

ECIR

CULA

TIN

G L

UBR

ICAT

ION

HLP

32

ACC.

TO

ISO

VG

32

WIT

H R

ECIR

CULA

TIN

G L

UBR

ICAT

ION

AN

D H

EAT

EXCH

AN

GER

STA

ND

ARD

OPT

ION

UEB

ERSE

TZU

NG

:

i 1 = 4

.00

i 1 =

3.1

7 BZ

W. 5

.50

i 2 = 1

.0

i 2 =

1.0

TRA

NSM

ISSI

ON

RAT

IO:

i 1 =

4.0

0

i 1 = 3

.17

OR.

5.5

0

i 2 =

1.0

i 2 = 1

.0 G

EWIC

HT:

ca.

68

kgW

EIG

HT:

ca

. 68

kg

M 10x1

M 12x1.5

M12x1.5

M16x1.5

M42

x1.5

BEI V

ERTI

KALE

INBA

U V

1IN

VER

TICA

L IN

STA

LLAT

ION

V1

BEI V

ERTI

KALE

INBA

U V

3IN

VER

TICA

L IN

STA

LLAT

ION

V3

70 60

12

5

181

ø42k6

116

130

83

3

STA

ND

AR

DS

CH

ALT

UN

GSE

INH

EIT

OH

NE

NEU

TRA

LSTE

LLU

NG

SHIF

T U

NIT

WIT

HO

UT

NEU

TRA

L PO

SITI

ON

OPT

ION

SC

HA

LTU

NG

SEIN

HEI

T M

IT N

EUTR

ALS

TELL

UN

GSH

IFT

UN

IT W

ITH

NEU

TRA

L PO

SITI

ON


25

Dim

ensi

ons

of b

asic

gea

rbox

see

inst

alla

tion

draw

ing

p. 2

5/26

150

106

5.1

10

25 -

35

4658

75

20

142.

514

0.5

171.

5

261

137.

5

83.5

25

5.1

315

ø18

ø18

Ø MA*

ø249

ø250g6

ø140

ø130 k6

156.5

164

324

17

135+135

30

R73

ø300H7 35

69.8

M10

x1

48.2

7246

ø14

23

20

149

MAX M

IN

NU

P 21

1EC=

8420

0NN

U 2

211E

C=99

000N

(FQ

*)

STA

ND

ARD

OPT

ION

7211

BE

C=48

800N

7211

BE

C=48

800N

55 -

65(F

Q*)

2023

10

M 22x1.5

ø152

163

326

290

±0.2

55

15°

102.

510

2.5

30

55

55

ø350

118.

511

8.5

100 M

12

12x3

0°30

°

R70.3

20°

OEL

STA

ND

SSCH

AUG

LAS

OIL

LEV

EL S

IGH

T G

LASS

(LIN

KS U

ND

REC

HTS

)(L

EFT

AN

D R

IGH

T)5

M16x1.5

M42

x1.5

M22x1.5

400

9.5

15°

3

2K30

0

Ø M

A*

BEI G

ESCH

LOSS

ENER

VARI

AN

TEFO

R CL

OSE

D V

ERSI

ON

STA

ND

ARD

OPT

ION

LA

NG

ER A

BTRI

EBO

PTIO

NN

ALL

Y,

LON

G O

UTP

UT

VERS

ION

MO

TORA

NSC

HLU

SSM

ASS

MO

TOR

DIM

ENSI

ON

OEL

SORT

E:

HLP

68

NAC

H IS

O V

G 6

8 BE

I TAU

CHSC

HM

IERU

NG

H

LP 4

6 N

ACH

ISO

VG

46

BEI U

MLA

UFS

CHM

IERU

NG

H

LP 3

2 N

ACH

ISO

VG

32

BEI U

MLA

UFS

CHM

IERU

NG

MIT

WA

ERM

ETAU

SCH

ER

OIL

GRA

DE:

HLP

68

ACC.

TO

ISO

VG

68

WIT

H S

PLA

SH L

UBR

ICAT

ION

HLP

46

ACC.

TO

ISO

VG

46

WIT

H R

ECIR

CULA

TIN

G L

UBR

ICAT

ION

H

LP 3

2 AC

C. T

O IS

O V

G 3

2 W

ITH

REC

IRCU

LATI

NG

LU

BRIC

AT IO

N A

ND

HEA

T EX

CHA

NG

ER

S

TAN

DA

RD

OPT

ION

U

EBER

SETZ

UN

G:

i

1 = 4

.00

i 1 = 3

.17

BZW

. 5.5

0

i

2 = 1

.0

i 2 = 1

.0

TRA

NSM

ISSI

ON

RAT

IO: i

1 = 4

.00

i 1 = 3

.17

OR.

5.5

0

i

2 = 1

.0

i 2 = 1

.0

GEW

ICH

T:

ca. 8

6 kg

WEI

GH

T:

ca.

86

kg

4

M 10x1

M 12x1.5

M 12x1.5

16 P

9

55m

6

M12

ø140

109011

0

24.5

112

6

WU

CHTU

NG

MIT

PA

SSFE

DER

BALA

NCI

NG

WIT

H K

EYPA

SSFE

DER

/KEY

A12

x 8

x 6

0

OPT

ION

ABT

RIEB

SWEL

LEO

PTIO

N O

UTP

UT

SHA

FT

*) B

EI D

ER L

AGER

AUSL

EGU

NG

AN

GEN

OM

MEN

E W

IRKU

NG

SLIN

IED

ER R

ESU

LTIE

REN

DEN

RIE

MEN

KRA

FTA

SSU

MED

LIN

E O

F RE

SULT

ING

PULL

EY F

ORC

E FO

RBE

ARI

NG

CA

LCU

LATI

ON

BEI V

ERTI

KALE

INBA

U V

1IN

VER

TICA

L IN

STA

LLAT

ION

V1

BEI V

ERTI

KALE

INBA

U V

3IN

VER

TICA

L IN

STA

LLAT

ION

V3

ø130k6

ø140

20 23

236

47.5

135

NU

P 21

1EC=

8420

0NN

UP

2211

EC=

9900

0N

2K30

0 IN

LIN

E A

BTRI

EB W

IE B

EI 2

K250

INLI

NE

2K30

0 IN

LIN

E OU

TPU

T A

S IN

2K2

50 IN

LIN

E

130

83

116

130

83

STA

ND

AR

DS

CH

ALT

UN

GS

EIN

HEI

T O

HN

E N

EUTR

ALS

TELL

UN

GS

HIF

T U

NIT

WIT

HO

UT

NEU

TRA

L PO

SIT

ION

OPT

ION

SC

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26

55

116

83

130

3

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ION

Installation Drawing:2K250/300 INLINE, 2K250/300 TSC

27

28

CC

16x2

230

'(=36

0°)

M12

M12x1.520

28

33

3430

35

60 G7

18 P

9

64.4+0.2

M22x1.5

25 32

11

14.7

M12x1.5

16 225.7

3.7

40

M22x1.5

M22x1.5

M42

x1.5

102.

510

2.5

M42x1.5

M22

x1.5

55

350

175

M16x1.5

100

14

100

5015

5

28.5

28.5

200

2230

'

173.1

129.

5

28

90.1

MotoranschlussMotor connection

300H7

155

35

165

86.5

30.5

5

375215

83.5

160

160

1616

9

M42x1.5

370

18

30 b

is/to

40

65 G

7

69.4+0.2

18 P

9

80 G

7

85.4+0.2

22 P

9

55 G7

59.3+0.2

16 P

9

45

320g6

319.5

10

197

193

140 k6

142

197.

5

230

230

80.5

65.5

Harti

ng-S

teck

erHA

N 8U

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rtica

l insta

llatio

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ertik

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nbau

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2K45

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Inter

net:h

ttp://

indus

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s.zf.c

om

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of r

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ulley

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he b

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ft an

d rig

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Tube

for o

il ret

urn

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be fo

r oil f

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ual

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m A

ende

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x sie

he:

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he cu

rrent

mod

ificat

ion in

dex s

ee:

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hten

Pay a

ttent

ion

to

nur z

ur In

foni

cht i

m L

iefe

rum

fang

ent

halte

non

ly fo

r inf

orm

atio

nno

t inc

lude

d in

del

ivery

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orw

elle

: Fol

gend

e Na

ben

sind

liefe

rbar

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otor s

haft:

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wing

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s are

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able

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i Hor

izont

alei

nbau

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rizon

tal in

stalla

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B5Be

i Hor

izont

alei

nbau

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rizon

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stalla

tion

B5

SW14

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X

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alei

nbau

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rtica

l insta

llatio

n V3

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ertik

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nbau

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In ve

rtica

l insta

llatio

n V1

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ng p

lugHA

N 8U

(Slee

ve h

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rew

union

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cket

inse

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t bus

hings

are s

uppli

ed lo

ose)

NUP2

11 E

CP

NU22

11 E

/TN

Stan

dard

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ands

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ugla

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l leve

l sigh

t glas

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ks u

nd re

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Left

and

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Ansc

hlus

s MCo

nnec

tion

M

Ansc

hlus

s PCo

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tion

P

Ansc

hlus

s TCo

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tion

T

Y

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hlus

s ECo

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E

Ansc

hlus

s HCo

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H

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s DCo

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tion

D

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schl

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n G

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L PO

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CH

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I UM

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ARD

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ERSE

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i 1

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i 2 =

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i 2

= 1

.0

TRA

NSM

ISSI

ON

RAT

IO:

i 1 =

4.0

0

i 1 =

5.0

i 2 =

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= 1

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GEW

ICH

T:

ca.

155

kg

WEI

GH

T:

ca

. 155

kg

112

186+1


CC

16x2

2~30

'(=36

0°)

M12

Ø120

M12x1.520

Ø28

Ø33

3430

Ø35

Ø60

G7

18 P

9

64.4+0.2

M22x1.5

25 32

Ø11

Ø14.7

M12x1.5

16 22

Ø5.7

Ø3.7

40

M22x1.5

M22x1.5

M42

x1.5

102.

510

2.5

M42x1.5

M22

x1.5

55

350

175

Ø150 k6

Ø155

Ø230

Ø319.5

Ø320g6

232

236.

5

100

186+1

Ø14

100

5015

5

28.5

28.5

200

269.

5

10

241

22~3

0'

120

28

Ø300H7

155

35

165

375215

160

160

1616

9

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Ø370

Ø18

64.5

45 b

is/to

55

Ø65 G

7

69.4+0.2

18 P

9

Ø80 G

7

85.4+0.2

22 P

9

Ø55 G7

59.3+0.2

16 P

9

45

Ø MotoranschlussØ Motor connection


M16x1.5

59

84

116

93

89

130

178

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ng B

uchs

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n 8D

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ng b

ush

Han

8D

Y

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ertik

alei

nbau

V3

In ve

rtica

l insta

llatio

n V3

SW24

WAF

2K45

0/2K

600

Inter

net:h

ttp://

indus

trial-

drive

s.zf.c

om

F Q *

Bei

der

Lag

erau

slegu

ng o

ptim

ale

Wirk

ungs

linie

d

er re

sulti

eren

den

Riem

enkr

aefte

Optim

um lin

e of

actio

n of

resu

lting

pulle

y

fo

rces

at th

e be

aring

calcu

lation

F Q *

Links

und

rech

tsLe

ft an

d rig

ht

Stut

zen

fuer

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ruec

klauf

Tube

for o

il ret

urn

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zen

fuer

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zufu

hTu

be fo

r oil f

eedin

g

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ebsa

nlei

tung

Oper

ating

man

ual

Nach

akt

uelle

m A

ende

rung

sinde

x sie

he:

For t

he cu

rrent

mod

ificat

ion in

dex s

ee:

Nur z

ur In

form

atio

nNi

cht i

m L

iefe

rum

fang

ent

halte

nOn

ly fo

r inf

orm

ation

Not i

nclud

ed in

deli

very

Mot

orw

elle

: Fol

gend

e Na

ben

sind

liefe

rbar

Mot

orsh

aft:

Follo

wing

hub

s are

avail

able

Entlu

efte

rBr

eath

erBe

i Hor

izont

alei

nbau

B5

In ho

rizon

tal in

stalla

tion

B5Be

i Hor

izont

alei

nbau

B5

In ho

rizon

tal in

stalla

tion

B5

SW14

WAF

X

Bei V

ertik

alei

nbau

V3

In ve

rtica

l insta

llatio

n V3

Bei V

ertik

alei

nbau

V1

In ve

rtica

l insta

llatio

n V1

Harti

ng b

ush

Han

8D

NUP2

13E/

JNU

2213

E/TN

Stan

dard

Oelst

ands

scha

ugla

sOi

l leve

l sigh

t glas

s

Links

und

rech

tsLe

ft an

d rig

ht


Ansc

hlus

s MCo

nnec

tion

M

Ansc

hlus

s PCo

nnec

tion

P

Ansc

hlus

s TCo

nnec

tion

T

Y

Ansc

hlus

s ECo

nnec

tion

E

Ansc

hlus

s HCo

nnec

tion

H

Ansc

hlus

s DCo

nnec

tion

D

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hlus

s FCo

nnec

tion

FAn

schl

uss G

Conn

ectio

n G

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hlus

s ICo

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fuel

lung

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l fill

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befu

ellu

ngIni

tial fi

ll

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blas

s bei

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baul

age

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0

i 1 =

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ON

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IO:

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ICH

T:

ca.

165

kg

WEI

GH

T:

ca

. 165

kg

29


80

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490

Ø400

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821 Ø30

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314

324

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Specialversions

ZF-Duoplan Standard, INLINE, TSCOrdering numbers for gearbox types 2K120/2K121

2 L G

Two-speed gearbox

Motor balancing: without keyway* central thread mandatory 1Full-key 4Half-key* 5

Gearbox interface (see page 13):Open without hub 0Open with hub 2Closed with hub and hub bearing and RWDR1) * 3Closed with hub and RWDR1) * 4Open with hub and adapter ring * 5

Gearbox type:for motor frame size/ratio100/i1 = 4.00 12100/i1 = 3.16 13100/i1 = 4.91 09112/i1 = 4.00 11112/i1 = 3.16 14112/i1 = 4.91 08

Output bearings:Cylindrical roller / ball bearings 3Angular-contact ball bearings 4

Gearbox output:a1 = 38 mm Ba1 = 100 mm Ca1 = 38 mm smooth, without Keyway La1 = 38 mm (2K120/2K121) INLINE Pa1 = 38 mm smooth, without Keyway (2K120/2K121) INLINE Ga1 = 70x 70 mm (2K120/2K121) INLINE, TSC Ua1 = 70x 70 mm, DIN5480 INLINE, TSC W

Installation position:V1/ V3 / B5 / B5 (rotated around longitudinal axis to the right side) CV3 Central lube oil supply in output shaft/Radial lube oil supply in bearing housing B

Motor shaft diameter “d”without hub 028 mm 132 mm 238 mm 342 mm 448 mm 9

Torsional backlash on gearbox output:Normal backlash max. 30 arcmin 1Reduced backlash max. 20 arcmin 3Minimal reduced backlash max. 15 arcmin 4

Reduced vibration (1.2 mm/s ZF-Duoplan) (0.7 mm/s INLINE) S

Rotary union for output shaft T

35

Note:Standard = Bold typeOpt ion = Normal type

1) RWDR= Radia l shaf t sea l* motor-spec i f ic , on request

1 2 3 4 5 6 7 – 8 9 10 11 12 – 13 14 15

Specialversions

ZF-Duoplan Standard, INLINE, TSCOrdering numbers for gearbox types 2K250/2K300

2 L G

Two-speed gearbox

Motor balancing: without keyway*, central thread mandatory, motor shaft Ø max. 55 mm 1Full-key 4Half-key* 5

Gearbox interface (see page 13):Open without hub 0Open with hub 2Closed with hub and hub bearing and RWDR1) * 3Closed with hub and RWDR1) * 4Open with hub and adapter ring * 5Input flange D = 118 (only 2K250 standard) 9

Gearbox type:for motor frame size/ratio132/i1 = 4.00 15132/i1 = 3.17 16132/i1 = 5.50 (not for TSC) 17160/i1 = 4.00 20160/i1 = 3.17 21160/i1 = 5.50 (not for TSC) 22

Output bearings:Cylindrical roller / ball bearings 3Angular-contact ball bearings 4Spindle ball bearings 6

Gearbox output:a1 = 118 mm (2K250) Fa1 = 130 mm (2K300) Ja1 = 42 mm (2K250) Ka1 = 42 mm smooth without keyway La1 = 55 mm smooth without keyway Na1 = 55 mm smooth without keyway, INLINE Ha1 = 55 mm (2K300) Ma1 = 42 mm INLINE Pa1 = 130 mm wide bearing base Ra1 = 70x70 mm INLINE, TSC Ua1 = 70x70 mm, DIN 5480 INLINE, TSC Wa1 = 42 mm smooth without keyway INLINE G

Installation position:B5 DV1 / V3 / B5 (turned around longitudinal axis to the right side) CV3 Central lube oil supply in output shaft/Radial lube oil supply in bearing housing B

Motor shaft diameter “d”2K250 2K300without hub 042 mm 55 mm 148 mm 48 mm 255 mm 42 mm 360 mm 60 mm 4

Torsional backlash on gearbox output:Normal backlash max. 30 arcmin 1Reduced backlash max. 20 arcmin 3Minimal reduced backlash max. 15 arcmin 4

Reduced vibration (1.0 mm/s ZF-Duoplan) (0.7 mm/s INLINE) S

Integrated oil channel version for max. speeds and dry sumplubrication (for B5 please order V1 version)

M

Rotary union for output shaft T


1) RWDR = Radia l shaf t sea l* motor-spec i f ic , on request

Sonderaus-führungen

Note:Standard = Bold type 1) RWDR = Radia l shaf t sea lOpt ion = Normal type * motor spec i f ic , on request

1 2 3 4 5 6 7 – 8 9 10 11 12 13

ZF-Duoplan StandardOrdering numbers for gearbox types 2K450/2K600

2 L G – –

Specialversions

Two-speed gearbox

Motor balancing:Full key 4Half key* 5

Gearbox interface:Open without hub 0Open with hub 2Closed with hub and hub bearing and RWDR1)* 3

Gearbox type:for motor frame size/ratio160/i1 = 4.00 spigot Ø 300 mm 30160/i1 = 5.00 spigot Ø 300 mm 31180/i1 = 4.00 spigot Ø 300 mm 40180/i1 = 5.00 spigot Ø 300 mm 41200/i1 = 4.00 spigot Ø 350 mm 42200/i1 = 5.00 spigot Ø 350 mm 43

Output bearingswithout output 0cylindrical roller ball bearings 3Angular-contact ball bearings 4

Gearbox Output:without Na1 = 140 mm (2K450) Fa1 = 150 mm (2K600) Ja1 = 60 mm (2K450) Ka1 = 60 mm - smooth without keyway (2K450) La1 = 60 mm - Inline (2K450) Pa1 = 60 mm - smooth without keyway, INLINE (2K450) G

Installation Position:B5 / V1 / V3 C

Motor shaft diameter “d”

without hub 060x140 (2K450) 165x140 (2K600) 270x140 375x140 480x170 555x110 6

Torsional backlash on gearbox output:Normal backlash max. 30 arcmin 1Reduces backlash max. 20 arcmin 3

Neutral shift position N

37

1 2 3 4 5 6 7 – 8 9 10 11 12 – 13

Specialversions

ZF-Duoplan StandardOrdering numbers for gearbox types 2K800/2K801/2K802

2 L G

Two-speed gearbox

Motor balancing: Full-key 4Half-key* 5

Gearbox interface (see page 12):Open without hub 0Open with hub 2Closed with hub and RWDR1) * 4Open with hub and adapter ring * 5Input flange (Ø= 180 k6) 9

Gearbox type:for motor frame size/ratio180/i1 = 4.00 spigot Ø diameter 300 50180/i1 = 3.19 spigot Ø 300 51200/i1 = 4.00 spigot Ø 350 60200/i1 = 3.19 spigot Ø 350 61225/i1 = 4.00 spigot Ø 450 70160/i1 = 3.19 spigot Ø 450 71

Holding brake:without holding brake 1with holding brake 2

Gearbox output:without Na1 = 65 mm Ha1 = 65 mm smooth without keyway La1 = 180 mm Ja1 =.180 mm wide bearing base R

Installation position:V1/ B5 CV3 B

Motor shaft diameter “d”without hub 060 mm 165 mm 275 mm 380 mm 470 mm 5

Torsional backlash on gearbox output:Normal backlash max. 40 arcmin 1


38



1 2 3 4 5 6 7 – 8 9 10 11 12 – 13

Specialversions

ZF-Duoplan StandardOrdering numbers for gearbox types 2K2100

2 L GNote:Standard = Bold typeOpt ion = Normal type


Two-speed gearbox

Motor balancing: Full-key 4Half-key* 5

Gearbox interface (see page 12):Open without hub 0Open with hub 2Closed with hub and RWDR1) * 4Open with hub and adapter ring * 5Input flange (Ø = 190 k6) 9

Gearbox type:for motor frame size/ratiospigot Ø 450; FF500 80spigot Ø 400; Special motor 82spigot Ø 350; FF400 84spigot Ø 550; FF600 86spigot Ø 680; FF740 88

Holding brake:without holding brake 1

Gearbox output:without NSTW Sa1 = spigot Ø 90 x 140; keyway; 2x25x14x125 Ha1 = spigot Ø 90 x 140; smooth G

Installation position:V1/ B5 CV3 Central lube oil supply in output shaft B

Torsional backlash on gearbox output “d”without hub 075 mm x 140 180 mm x 170 290 mm x 170 395 mm x 170 4

Torsional backlash on gearbox output:Normal backlash max. 40 arcmin 1


39

1. Motor

motor brand:

type:

size:

nominal power (kW):

max. torque (Nm):

motor operating speed n1 to n2 (rpm) at constant power:

max. speed (rpm):

motor shaft diameter d (mm):

motor shaft length l (mm):

pilot diameter b1 (mm):

pilot width f1 (mm):

pcd e1 (mm):

hole diameter s1 (mm):

fitting key lxbxh (mm):

Motor shaft with keyway Motor shaft without keyway

Motor shaft with shaft seal Motor shaft without shaft seal

Full-key balanced motor shaft Half-key balanced motor shaft

2. ZF-Duoplan type:

2K120 2K300 2K800 2K2100

2K121 2K450 2K801

2K250 2K600 2K802

f1

l

db1

s1

e1

40

For quickest response please provide the following data to us by:

Fax: ++49/(0)7541/77-2379 or

E-Mail: [email protected]

Request for Quotation

Standard Option

Gearbox interface open with adapter plate, hub bearing and shaft seal

with adapter plate and shaft seal

with adapter ring

with input flange (2K250/300/800/2100)

Ratio i1 4.00 (Standard)

3.1 (2K120/121/250/300/800) 5.0 (2K450/600) 5.5 (2K250/300) 4.91 (2K120/121)

Installation position B5 V1 B5 rotated longit.axis to right V3

Holding brake without with (only available for 2K800/801)

Output bearings Cylindrical roller bearings Angular-contact ball bearings

Self aligning- and cylinder ball bearings (2K800/801/802)

Lubrication system Splash type lubrication Recirculating lubrication with oil tank

Integrated oil channel system Recirculating lubrication with heat exchanger

Dry sump lubrication

Gearbox output Gearbox with output flange Gearbox with output shaft

100 mm (2K120/2K121) 38 mm (2K120/121) INLINE

118 mm (2K250) 42 mm (2K250)

130 mm (2K300) 42 mm (2K250/300) INLINE

140 mm (2K450) 55 mm (2K300)

150 mm (2K600) 60 mm (2K450)

180 mm (2K800/801/802) 70 mm DIN 5480 (2K120 TSC/121 TSC/250 TSC/300 TSC)

STW (2K800/801/802/2100) 90 mm (2K2100)

gearboxes for direct mounting without output

Rotary union for output shaft Rotary union for spindle

Torsional backlash at gearbox output

< 30 arcmin < 20 arcmin < 15 arcmin

< 40 arcmin (2K800/801/802/2100)

Quantity per year:

Order-No.:

Application:

Subject to technical change without notice. For installation investigation purposes,

please request installation drawings; only the data contained therein is binding.

Please check out our homepage: www.zf.com/industrial-drives 41

(2K800/801/802/2100)

Driveline and Chassis Technology Prin

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ZF Friedrichshafen AGSpecial Driveline Technology88038 Friedrichshafen GermanyPhone +49 7541/77-3694Fax +49 7541/77-2379E-Mail: [email protected]/industrial-drives

Power and Dynamics - Drive Lines · ZF-Duoplan 2K600 Standard for Belt Drives ZF-Duoplan 2K250...

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Transcript of Power and Dynamics - Drive Lines · ZF-Duoplan 2K600 Standard for Belt Drives ZF-Duoplan 2K250...