SEW-Eurodrive Varimot 16-46 Series User manual

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
Explosion-Proof
VARIMOT
®
Variable Speed Gear Units
and Accessories
O perating I nstructions
Edition 11/2006
11529016 / EN

SEW-EURODRIVE – Driving the world

Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories 3
Contents
1 Important Information about the Operating Instructions .............................. 4
1.1 Explanation of symbols ............................................................................. 6
2 Safety Notes ...................................................................................................... 7
2.1 Safety notes for the use of VARIMOT®..................................................... 7
3 VARIMOT®in Explosion-Proof Version .......................................................... 8
3.1 Unit design ............................................................................................... 8
3.2 Unit designation ........................................................................................ 9
3.3 Nameplate............................................................................................... 10
3.4 Overview of mounting options................................................................. 11
4 Installation ....................................................................................................... 12
4.1 VARIMOT®in category 2G ..................................................................... 12
4.2 VARIMOT®in categories 3G and 3D...................................................... 13
4.3 Permitted overhung loads without primary gear unit............................... 13
4.4 Before you begin..................................................................................... 16
4.5 Preliminary work...................................................................................... 16
4.6 Installation............................................................................................... 17
4.7 Gear units with solid shafts ..................................................................... 19
5 Startup.............................................................................................................. 21
5.1 Installation and setup of optional equipment........................................... 21
6 Inspection and Maintenance .......................................................................... 32
6.1 Inspection and maintenance intervals..................................................... 32
6.2 Before you begin..................................................................................... 33
6.3 Checking torsional play........................................................................... 33
6.4 Checking the friction ring......................................................................... 34
6.5 Replacing the friction ring........................................................................ 35
6.6 Measuring the temperature of the anti-friction bearing ........................... 36
6.7 Completing the inspection/maintenance process ................................... 37
7 Operation and Service .................................................................................... 38
7.1 Customer service .................................................................................... 38
7.2 Malfunction of VARIMOT®speed gear units........................................... 38
7.3 WEXA/WEX speed monitor..................................................................... 39
8 Declaration of Conformity .............................................................................. 40
8.1 Variable speed gear units category 2G, VARIMOT®series 16-46 ......... 40
8.2 Variable speed gear units category 3G and 3D,
VARIMOT®series 16-46......................................................................... 41
9 Index................................................................................................................. 42

1Important Information about the Operating Instructions
4Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories
1 Important Information about the Operating Instructions
Introduction You must follow the information in the operating instructions to ensure trouble-free oper-
ation and for the fulfillment of any rights to claim under the limited warranty. Read the
operating instructions before you start working with the unit.
Make sure that the operating instructions are available to persons responsible for the
system and its operation, as well as to persons who work independently on the unit.
Also observe other technical documents, contracts for delivery or other agreements.
Intended use
VARIMOT®variable speed gear units are intended for commercial and industrial
systems and may only be used in accordance with the information provided in SEW-
EURODRIVE's technical documentation and the information given on the nameplate.
It corresponds to valid standards and regulations and meet the requirements of
EC Directive 94/9/EC and the EC Directive for Machinery 98/37/EC.
Gear unit loads other than those specified and areas of application other than industrial
and commercial systems can only be used after consultation with SEW-EURODRIVE.
Any application other than those mentioned is considered non-intended use.
A drive motor connected to the VARIMOT®may not be operated on the frequency
inverter.
Qualified personnel
VARIMOT®variable speed gear units represent a potential hazard for persons and
material. Consequently, assembly, installation, startup and service work may only be
performed by trained personnel who are aware of the potential hazards.
Personnel must possess the required qualifications for the relevant task and be familiar
with the:
• Assembly
• Installation
•Startup
•Operation
• Maintenance
• Servicing
of the product.
Personnel must carefully read the operating instructions, in particular the safety notes
section, and understand and comply with them.

1
Important Information about the Operating Instructions
Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories 5
Exclusion of liability
You must comply with the information contained in these operating instructions to
ensure safe operation of the VARIMOT® variable speed gear unit and to achieve the
specified product characteristics and performance requirements.
SEW-EURODRIVE GmbH & Co KG assumes no liability for injury to persons or damage
to equipment or property resulting from non-observance of these operating instructions.
In such cases, any liability for defects is excluded.
Product names and trademarks
The brands and product names contained within these operating instructions are trade-
marks or registered trademarks of the titleholders.
Waste disposal (Please follow the current instructions):
• Housing parts, gears, shafts and anti-friction bearings of the gear unit must be dis-
posed of as steel scrap. This also applies to gray-cast iron parts if there is no special
collection.
• Collect waste oil and dispose of it according to the regulations in force.

1Important Information about the Operating Instructions
Explanation of symbols
6Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories
1.1 Explanation of symbols
The operating instructions contain important information that deals with general and
operational safety. This information is emphasized in particular with the following
symbols.
Electrical hazard
Possible consequences: Severe or fatal injuries.
Hazard
Possible consequences: Severe or fatal injuries.
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the drive and the environment.
Tips and useful information.
Important information about explosion protection.

Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories 7
2
Safety notes for the use of VARIMOT®
Safety Notes
2 Safety Notes
2.1 Safety notes for the use of VARIMOT®
The following safety notes apply to variable speed gear units.
Assembly, connection, startup, maintenance and repair work on the VARIMOT®
variable speed gear units and the optional electrical components may only be
performed by qualified personnel while taking the following into account:
• These operating instructions
• Warning and instruction labels on the variable speed gear unit/variable speed gear-
motor
• All other project planning documents, operating instructions and wiring diagrams
belonging to the drive
• The specific regulations and requirements for the system
• National/regional regulations on explosion protection, safety, and prevention of acci-
dents that are currently in effect
Optional
equipment
Optional equipment complies with existing standards and regulations:
In addition to general installation guidelines, the following regulations in accordance with
ElexV 1 (or other national regulations) must be observed for electrically operated
options:
Technical data and information on approved conditions on site can be found on the
nameplate and in these operating instructions.
These details must be strictly observed.
When using variable speed gearmotors, also refer to the safety notes for gear units
and motors in the relevant operating instructions.
Take into consideration the supplementary safety notes in the individual sections
of these operating instructions.
Explosive gas mixtures or dust concentrations when combined with hot, live, and
moving parts of electrical machinery can cause serious injury or death.
• EN 50014
• EN 50018 for protection type "d"
• EN 50019 for protection type "e"
• EN 50020 intrinsically safe "i"
• EN 50281-1-1/EN 50281-1-2 "Electrical apparatus for use in the presence of
combustible dust"
• EN 60079-14 "Electrical apparatus for explosive gas atmospheres"
• EN 50281-1-2 "Electrical apparatus for use in the presence of combustible dust"
• DIN VDE 105-9 "Operating electrical equipment" or other national regulations
• DIN VDE 0100 "Erection of power installations with rated voltages below 1000 V" or
other national regulations
• System-specific regulations

3VARIMOT® in Explosion-Proof Version
Unit design
8Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories
3 VARIMOT®in Explosion-Proof Version
3.1 Unit design
52018AXX
Fig. 1: VARIMOT®in explosion-proof version
[1] Complete output shaft
[3] Plate
[4] Adjusting plate
[5] Housing cover
[6] Drive disk
[7] Needle bearing
[8] Housing with tapped hole
[9] Complete hollow shaft
[10] Friction ring
[1] [9]
[5] [4][6][10] [7]
[3]
[8]

3
VARIMOT® in Explosion-Proof Version
Unit designation
Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories 9
3.2 Unit designation
The following diagram shows the type code structure:
DV 26B WEX II2G eDT 90L 4 TF
Temperature sensor
Number of motor poles
Motor size
Motor series
Explosion-proof version according to ATEX 100a
Speed monitor
VARIMOT®variable speed gear unit size B
indicates wet version
VARIMOT®variable speed gear unit series flange
version

3VARIMOT® in Explosion-Proof Version
Nameplate
10 Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories
3.3 Nameplate
Example
60417AXX
Fig. 2: Nameplate
Typ Type code
Nr. Sales order number
naMinimum and maximum output speed
MaOutput torque at minimum and maximum output speed
IM Mounting position
R Control range
neInput speed
PeInput power
kg Weight
i Gear ratio
Typ
Nr.
nar/min
MaNm
IM
R
ner/min
P
e
kg
1:
kW
i=
Bedienungsanleitung muss beachtet werden
Zum Einbau in Komplettantrieb
Lagerfett synth. KHC2R Made in Germany 150 881 4.10
DF36/A/IGEX/II2G
01.1151703702.0001.06
159/798
84/38
M4
5
1440
3.6
104.242
RX77 D36/IGEX/II2G eDV112M4/C
II2G / T3
Bruchsal / Germany
168

3
VARIMOT® in Explosion-Proof Version
Overview of mounting options
Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories 11
3.4 Overview of mounting options
52019AXX
Fig. 3: Overview of mounting options
[1] Adjustment device with free shaft end NV
[2] Adjustment device with handwheel and position indication HS
[3] Adjustment device with handwheel (standard version)
[4] Indicator scale
[5] Voltage encoder IGEX
[2] [3]
[1]
[4]
[5]

4Installation
VARIMOT® in category 2G
12 Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories
4 Installation
4.1 VARIMOT®in category 2G
General
information
• SEW explosion-proof variable speed gear units of the VARIMOT®D/DF 16-46 series
and VARIMOT®D/DF 16-46B series meet the design requirements of equipment
group II, category 2G (explosive gas atmosphere). These units are intended for use
in zones 1 and 2.
• A standard feature of the SEW-EURODRIVE explosion-proof variable speed gear
units of the VARIMOT®series is a tapped hole for installing a voltage encoder.
Designation "X" • If the designation "X" appears after the certification number on the declaration of
conformity or the EC prototype test certificate, this indicates the certificate contains
special conditions for safe application of the variable gear unit.
Temperature class • VARIMOT®variable speed gear units, category 2G (explosive gas atmosphere) are
approved for temperature class T3. The temperature class of the variable speed gear
unit is indicated on the nameplate.
Ambient
temperature
• VARIMOT® variable speed gear units may only be used at an ambient temperature
of–20°C(–4°F)to+40°C(+104°F).
Output power and
output torque
• It is essential that nominal values of output power and/or output torque are main-
tained.
Speed monitoring • VARIMOT®variable speed gear units in category 2G may only be operated with a
speed monitoring device. The speed monitor must be correctly installed and adjusted
(see Sec. "Startup", Speed monitoring).
Strictly observe the safety notes on page 7 when installing the variable speed
gear unit.
Verify the speed monitoring function before startup.

4
Installation
VARIMOT® in categories 3G and 3D
Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories 13
4.2 VARIMOT®in categories 3G and 3D
General
information
• SEW-EURODRIVE explosion-proof variable speed gear units of the VARIMOT®
D/DF 16-46 and VARIMOT®D/DF 16-46B series meet the design requirements of
equipment group II, categories 3G (explosive gas atmosphere) and 3D (explosive
dust atmospheres). These units are intended for use in zones 2 and 22.
• A standard feature of the SEW-EURODRIVE explosion-proof variable speed gear
units of the VARIMOT®series is a tapped hole for installing a voltage encoder.
Temperature class • VARIMOT®variable speed gear units of category 3G (explosive gas atmosphere)
are approved for temperature class T3. The temperature class of the variable speed
gear unit is indicated on the nameplate.
Surface
temperature
• The maximum surface temperature of VARIMOT®variable speed gear units, cate-
gory 3D (explosive dust atmosphere) may not exceed 200 °C (392 °F). The system
operator must guarantee that a possible accumulation of dust will not exceed a
maximum thickness of 5 mm, in accordance with EN 50281-1-2.
Ambient
temperature
• VARIMOT® variable speed gear units may only be used at an ambient temperature
of–20°C(–4°F)to+40°C(+104°F).
Output power and
output torque
• It is essential that nominal values of output power and/or output torque are
maintained.
4.3 Permitted overhung loads without primary gear unit
Definition of force
application of
overhung loads
The development of the overhung load depicted in the diagrams refers to a point of
application at mid-point of the shaft extension as indicated in Figure 1. If force is applied
to areas other than the center of the shaft end, consult SEW-EURODRIVE for permitted
lateral forces.
FR[N] = permitted overhung load point of application at mid-point of shaft extension.
If an overload condition of the VARIMOT®as category 3G or 3D unit cannot be
ruled out during normal operation, a VARIMOT®unit with a functioning speed
monitor must be used (see Sec. "Startup", Speed monitoring).
50248AXX
Fig. 4: Definition of force application of overhung loads
F
R
d
l
l/2

4Installation
Permitted overhung loads without primary gear unit
14 Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories
51908AXX
51909AXX
VARIMOT®D16
n [1/min]
FR[N]
0
500
1000
1500
2000
2500
300 600 900 1200 1500 1800
DT71D4
DT80K4
DT80N4
F
R
[N] VARIMOT®D26
n [1/min]
0
500
1000
1500
2000
2500
3000
3500
4000
300 600 900 1200 1500 1800
DV100M4
DT90L4
DT90S4

4
Installation
Permitted overhung loads without primary gear unit
Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories 15
51911AXX
51912AXX
FR[N] VARIMOT®D36
n [1/min]
0
1000
2000
3000
4000
5000
6000
300 600 900 1200 1500 1800
DV100L4
DV112M4
DV132S4
F
R
[N] VARIMOT®D46
n
[
1/min
]
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
400 600 800 1000 1200 1400 1600 1800
DV132M4
DV132ML4
DV160M4

4Installation
Before you begin
16 Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories
4.4 Before you begin
The drive
may only be
installed if
• The information on the nameplate of the drive matches the approved on-site explo-
sion application range (equipment group, category, zone, temperature class or max-
imum surface temperature).
• The information on the nameplate of the drive matches the voltage supply system.
• The drive is undamaged (no damage caused by transportation or storage).
• It is certain that the following requirements have been met:
• Enclosure has been verified.
4.5 Preliminary work
Variable speed
gear units
The output shafts and flange surfaces must be thoroughly cleaned of anti-corrosion
agents, contamination or such (use a commercially available solvent).
Anti-friction
bearing grease
• Ambient temperature between –20 °C (–4 °F) and +40 °C (+104 F°)
• No oils, acids, gas, vapors, radiation, potentially explosive atmospheres, etc.
Risk of material damage
Do not let the solvent come into contact with the sealing lips of the oil seals or on
the wide V-belt.
Please note:
• The service life of the lubricant in the bearings is reduced if the unit is stored for
Ã1 year.
Ambient temperature Base Original filling Brand
Gear unit anti-friction
bearing
–20 °C (–4 °F) to +40 °C
(+104 °F)
Synthetic Mobiltemp SHC 100 Mobil

4
Installation
Installation
Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories 17
4.6 Installation
• The variable speed gearmotor may only be mounted or installed on a level1), vibra-
tion-damping and torsionally rigid support structure. Do not tighten housing legs and
mounting flanges against each other.
• Carefully align the variable speed gear drives to avoid overloading the output shafts
(observe permitted overhung loads and axial forces).
• Do not hit or hammer the shaft end.
• Ensure an unobstructed cooling air supply and that air heated by other apparatus
cannot be drawn in and reused. The cooling air may not exceed a temperature of
40 °C (104 °F).
Installation in
damp locations
or outdoors
• VARIMOT®gear units are supplied in corrosion-resistant versions (version B) for use
in damp areas or outdoors. Any damage to the coating (e.g. on the breather valve)
must be repaired.
Cable entry,
cable gland
• All cable entries are provided with ATEX certified plugs.
• To establish the correct cable entry, the plugs are replaced by ATEX certified
cable glands with strain relief.
• Select the cable gland according to the outer diameter of the cable used.
• All non-required cable entries must be sealed with an ATEX certified plug after
installation is completed.
• Coat the threads of cable glands and filler plugs with sealing compound and tighten
them well – then coat them again. Properly seal the cable entry.
• Properly clean the sealing surfaces of the terminal box and terminal box cover before
reassembly. Replace brittle gaskets.
Painting the
gear unit
If all or some of the surfaces of the drive are to be painted, make sure that you carefully
mask over the breather valve and the oil seals. Remove the strips of tape after com-
pleting the painting work.
1 Maximum permitted flatness error for flange mounting (approximate values with reference to DIN ISO 1101):
with Æflange 120 ... 600 mm max. error 0.2 ... 0.5 mm
•VARIMOT®version HS (handwheel with position indication) must be mounted
so that the adjusting spindle is horizontal; otherwise the position indication
will not function properly.
•The breather valves must be easily accessible. The plastic plug of the conden-
sation drain hole at the lowest position must be removed before operation
(danger of corrosion).

4Installation
Installation
18 Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories
Required tools/
resources
• Set of wrenches
• Mounting device
• Compensation elements (shims, spacing rings), if necessary
• Mounting materials for output components
Installation
tolerances Shaft end Flanges
Diameter tolerance in accordance with DIN 748
• ISO k6 for solid shafts with d, d1Â50 mm
• ISO k7 for solid shafts with d, d1> 50 mm
• Center bore in accordance with DIN 332, shape DR.
Centering shoulder tolerance in accordance with
DIN 42948
• ISO j6 at b1Â230 mm
• ISO h6 with b1> 230 mm

4
Installation
Gear units with solid shafts
Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories 19
4.7 Gear units with solid shafts
Mounting of input
and output
components
The following figure shows an example of a mounting device for installing couplings or
hubs on variable speed gear unit or motor shaft ends. You can remove the thrust bearing
on the mouthing device, if necessary.
Only use ATEX approved input and output components.
Input and output elements such as belt pulleys, couplings, etc. must have protec-
tion against contact.
•Never drive belt pulleys, couplings, pinions, etc. onto the shaft end by hitting
them with a hammer (this will cause damage to bearings, housing and the
shaft).
•With belt pulleys, ensure the belt is correctly tensioned according to manu-
facturer's specifications.
Assembly is easier if you first apply lubricant to the output element or heat it up briefly
(to 80 – 100 °C [176 – 212 °F]).
52020AXX
Fig. 5: Example of a mounting device
[1] Gear shaft end [3] Coupling hub
[2] Thrust bearing
[1] [2]
[3]

4Installation
Gear units with solid shafts
20 Operating Instructions – Explosion-Proof VARIMOT®Variable Speed Gear Units and Accessories
The following illustration shows the correct mounting arrangement (B)of a gear wheel
or chain sprocket for avoiding impermissibly high overhung loads.
• Do not install input and output elements without a mounting device. Use the center
bore with the thread on the shaft end for positioning.
• Power transmission elements should be balanced after fitting and must not give rise
to any excessive radial or axial forces (see the "Geared Motors" catalog for permitted
values).
Mounting
couplings
Couplings must be mounted and balanced according to the information provided
by the coupling manufacturer:
a) Maximum and minimum clearance
b) Axial offset
c) Angular offset
52021AXX
Fig. 6: Correct mounting arrangement of a gear or sprocket wheel
A Incorrect [1] Hub
BCorrect
[1]
[1]
03356AXX
Fig. 7: Clearance and misalignment for coupling mounting
a) b) c)