ZF Duoplan 2K800 Operating Instructions Manual
Also see for Duoplan 2K801: Operating instructions
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Contents
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Operating InstructionsInitial Installation 2K800/2K801/2K80218 EN 4161.758.103n – 2015-103.6 Electrical connection, gearchangeThe gearbox is electrically connected using thesupplied 8-pole Harting connector (HAN 8 U). Theplug-in connection is located on the shift unit.3.6.1 Shift unitTechnical data:Power consumption 84 WSupply voltage 24 V DC ± 10 %Max. pickup current 5 ANominal current 3.5 AIndex of protection IP64The required cable lead diameter is 1.5 mm².The 24 V DC connection voltage and 5 A powerconsumption must be assured on the shift unitconnector.Losses due to cable length and transition resistorsmust be taken into account.Scope of supply:Sleeve housing, screw connection, socket insertand 8 jacks, type Harting AWG16. The shift unitcan only be obtained as a complete part.Gearbox shift mechanism:Gearchanges are effected when the 24 V voltageis applied to pin 2 and 3. The polarity of theapplied 24 VDC voltage dictates which gear isengaged.In 1st gear => Pin 2: + / Pin 3: ‒In 2nd and 3rd gear => Pin 2: ‒ / Pin 3: +During the gearchange, the main spindle motorshould make the shaft oscillate +5° or -5° at a rateof 1 to 5 rotation direction changes per second.Major pendulum motion may lead to damage atthe meshing gears. The gears usually alreadymesh at the first rotation direction change, so thatthe switchover time is approx. 300 to 400 ms.In average, this means: nMot = 5°/s = 5° 60/min =300°/min = 300/360 rpm = 0.83 rpm.ConversionPendulum speed pendulum rotary motionSpeed[rpm]Angle[°/min]Time[sec]Angle[°/sec]0.25 90 3.33 50.50 180 1.67 51.00 360 0.83 52.00 720 0.42 53.00 1080 0.28 54.00 1440 0.21 55.00 1800 0.17 5The machine optimum is to be determined onthe basis of shift tests in relation to the differentmasses and thereto connected drag torques ofthe spindle.The limit switch signals of S1 – gear 1 (contact 4)and S2 – gear 2 (contact 6) serve to shut off theshift unit once the gearchange is complete.CAUTIONAfter the limit switch signals have been reached,the shift unit is allowed to be live for a maximumof 0.5 second. The limit switch signals must bemonitored during the operating time.The limit switches must only be energized withthe control current (0.1 – 0.5 A) and not with thechangeover current (5 A).Rotation directionchanges |
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