SEW-Eurodrive X Series User manual

*22860851_0317*
Drive Technology \ Drive Automation \ System Integration \ Services
Addendum to the Assembly and
Operating Instructions
Industrial Gear Units
X.. Series Helical and Bevel-Helical Gear Units
Oil-Water Cooler for Splash or Bath Lubrication /OWC
Edition 03/2017 22860851/EN

SEW-EURODRIVE—Driving the world

Table of contents
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 3
Table of contents
1 Important information .............................................................................................................. 4
2 Oil-water cooler for splash or bath lubrication /OWC........................................................... 5
2.1 Structure/function............................................................................................................5
2.2 Wiring diagram (schematic illustration) ...........................................................................9
2.3 Installation/assembly.....................................................................................................11
2.4 Notes on checking the oil level .....................................................................................14
2.5 Startup ..........................................................................................................................15
2.6 Inspection/maintenance ................................................................................................16
2.7 Malfunctions..................................................................................................................17
2.8 Permitted lubricants ......................................................................................................18
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1Important information
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
4
1 Important information
INFORMATION
This addendum describes amendments to the Oil-Water Cooler operating instruc-
tions. Observe the additional information specified in this document.
This document does not replace the detailed operating instructions.
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Oil-water cooler for splash or bath lubrication /OWC
Structure/function
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 5
2 Oil-water cooler for splash or bath lubrication /OWC
2.1 Structure/function
2.1.1 Structure
An oil-water cooling system can be used if the thermal rating of the naturally cooled
gear unit or cooling using a fan on the input shaft is not sufficient. The prerequisite for
using an oil-water cooling system is that appropriate cooling water is available on site.
INFORMATION
• Contact SEW‑EURODRIVE if you use chemically aggressive cooling media such
as brackish water or salt water.
• The following information applies to gear units with splash lubrication or bath lub-
rication.
• Also refer to the operating instructions of the cooling system manufacturer.
SEW‑EURODRIVE uses 2 types of oil-water coolers:
• A plate heat exchanger is used for the oil-water cooling system OWC 005/015/025.
• A shell and tube heat exchanger is used for the oil-water cooling system OWC
10/20/30/40/50/60/70.
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Structure/function
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
6
2.1.2 General information
The cooling system including the cooling circuit piping but without electrical wiring is
mounted directly to the gear unit at factory.
Optionally, the cooling system can be delivered on a mounting frame for separate
mounting but without electrical wiring and piping to the gear unit.
The standard delivery of the cooling system includes:
• Pump with directly mounted asynchronous motor
• Oil-water heat exchanger
• Temperature switch /TSK2 with 2 switching points for
– Controlled start of the pump motor at an oil temperature > 60°C
– Monitoring of the cooling group, i.e. warning or gear unit shutdown when the oil
temperature exceeds 90°C
The following cooling system types are available:
• Directly mounted on the gear unit, incl. cooling circuit piping, or
• On the mounting frame, for separate mounting, but without piping to the gear unit
Optional accessories
The cooling system can be equipped with the following components as an option:
• PT100 temperature sensor
• Oil filter with electrical/optical maintenance indicator
– Single filter
– Duplex filter
• Flow rate sensor
• Manometer
• Thermometer
• Thermostat valve
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Structure/function
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 7
2.1.3 Function
Observe the following control information for the individual components.
Oil-water cooler
The gear unit is cooled by an oil-water cooler.
• SEW‑EURODRIVE recommends using the cooling water at a temperature of 60°C
or higher. An optional thermostat valve can be used for controlling the cooling sys-
tem if the user is required to adjust the switching temperature.
Temperature switch /TSK2
The temperature of the plant is monitored via a temperature switch with defined
switching points.
• At T > 60°C →Pump of the oil-water cooler – ON
• At T < 50°C →Pump of the oil-water cooler – OFF
• At T > 90°C →STOP GEAR UNIT/WARNING
PT100 temperature sensor (optional)
Optionally, a PT100 temperature sensor instead of a temperature switch /TSK2 can be
used to control the cooling system. The evaluation of the temperature signal and the
controlling of the operator's switching devices is performed by the operator's control.
• At T > 60°C →Pump of the oil-water cooler – ON
• At T < 50°C →Pump of the oil-water cooler – OFF
• At T > 90°C →STOP GEAR UNIT/WARNING
Filter (optional)
The filter is monitored visually by a pressure deviation indicator, and electrically by a
pressure deviation monitoring device.
When mp > 2.2 bar →WARNING (clean filter)
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Structure/function
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
8
2.1.4 Interlocking specifications
Enabling of the gear unit
The gear unit is enabled if the following condition is met:
• Oil temperature T < 90°C
STOP gear unit/warning
STOP gear unit/warning if the following condition is met:
• Oil temperature T > 90°C
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Wiring diagram (schematic illustration)
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 9
2.2 Wiring diagram (schematic illustration)
The wiring diagrams show a possible setup of the control for the cooling system when
a TSK2 temperature switch and, optionally, a PT100 temperature sensor are used.
Use the wiring diagrams according to the structure of the cooling system.
2.2.1 Control circuit with control via temperature switch /TSK2
F2
F1
L1
N
K1 K2K3
S1
S2 K3
Temp. signal to
main motor
control:
Warning/switch off
Main contactor "On"
for main motor
control
S0 Emergency off
T1 T2
closes at
> 60°C
opens at
OIL
> 90°C
OIL
ϑϑ
ϑ
18014415990623371
2.2.2 Control circuit with control via PT100 temperature sensor
K1 ON at
K1 K2
> 60 °C
OIL
> 90 °C
Temp. signal to
main motor
control:
Warning/switch off
OIL
ϑ
K1 OFF at < 50 °C
OIL
ϑϑ
operator‘s
control
At
PT100
F1
L1
N
K3
S1
S2 K3
Main contactor "On"
for main motor
control
Emergency off
S0
18014415990626059
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Wiring diagram (schematic illustration)
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
10
2.2.3 Main circuit
F4
Switch on at
> 60°C
L1
F3
Main motor
control
L2
L3
M
3
Signal of contactor K2
via temperature switch TSK2
or temperature sensor PT100
Warning/switch off
PE
K3 K1
Main motor
M1
OIL
Pump motor
ϑ
M
M2
3
19121239947
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Oil-water cooler for splash or bath lubrication /OWC
Installation/assembly
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 11
2.3 Installation/assembly
INFORMATION
First adhere to the operating instructions of the oil supply system manufacturer.
2.3.1 Installation and connection information
The cooling system is mounted directly on the gear unit as standard.
Optionally, the cooling system can be delivered as a complete unit on a mounting
frame for separate mounting but without electrical wiring and piping. Ensure that the
installation site is subject to minimal vibrations and is a maximum distance of 1m from
the gear unit. Install the cooling system at the same level as the gear unit or lower. If
this is not possible, contact SEW‑EURODRIVE.
INFORMATION
For the dimensions of the cooling system and detailed technical data, refer to the op-
erating instructions of the cooling system manufacturer.
2.3.2 Mechanical connection
Connect the cooling system to the gear unit and the water supply according to the
designations observing the country-specific regulations.
Adhere to the following basic conditions when connecting the cooling system to the
gear unit:
• Do not reduce the specified cable cross sections.
• It is important that you choose the correct wall thickness and material when select-
ing pipes, hoses and screw fittings. Preferably use screw fittings with non-metallic
gaskets.
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Installation/assembly
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
12
2.3.3 Electrical connection
Observe country-specific regulations during the electrical connection.
Connect the motor and the temperature switch.
• Make sure that the pump rotates in the correct direction.
• Observe the motor data sheet.
• If a temperature switch/TSK2 is used, it must be integrated in the circuit in a way
that
– The pump of the oil-water cooler is switched on at the first switching point (at
60°C oil temperature).
– Either a warning signal is activated or the main drive is switched off at the
second switching point (at 90°C oil temperature).
• If a temperature sensor/PT100 is used, it must be integrated in the circuit in a way
that
– The pump of the oil-water cooler is switched on at an oil temperature of 60°C.
– The pump of the oil-water cooler is switched off if the oil temperature falls be-
low 50°C.
– Either a warning signal is issued or the main drive is switched off when the oil
temperature reaches 90°C.
When using options:
• Connect the electrical maintenance indicator of the oil filter to the customer-
provided control.
• Connect the flow rate sensor to the customer-provided control.
2.3.4 Limit temperature for start-up of the oil supply system
To ensure a correct function of the oil supply system the gear unit oil must have at
least the minimum oil viscosity. The viscosity depends on the used oil, and on the oil
temperature in the oil pipes/hoses and in the oil pump. Observe chapter "Permitted
lubricants"(→218).
When the oil supply system is used at low ambient temperatures, it may be required to
adjust the oil supply system. Contact SEW‑EURODRIVE, if required.
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Installation/assembly
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 13
2.3.5 Cooling media
INFORMATION
• Note that the service life, the efficiency, and the maintenance intervals of the heat
exchanger depend to a great degree on the quality and ingredients of the cooling
medium.
• Special measures have to be taken when using sea water or brackish water. Con-
tact SEW‑EURODRIVE.
• Observe the information in the supplied manufacturer’s documentation regarding
water quality.
Permitted cooling media
• Water, water/glycol cooling liquids
• Cooling water temperature and flow rate of oil and cooling water according to the
order documents.
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Notes on checking the oil level
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
14
2.4 Notes on checking the oil level
Using an oil supply system might influence the oil level. The fill quantities specified on
the nameplate are guide values and refer only to the gear unit. The mark on the oil
dipstick, oil level glass or oil sight glass is the decisive indicator of the correct oil
quantity.
Observe the chapter "Checking the oil level" in the operating instructions for the gear
unit.
2.4.1 Additional gear unit oil
The following table shows the lubricant fill quantity which has to be filled into the gear
unit additionally for the oil supply system.
The information is based on the standard cross section of the pipes for a suction pipe
length of 1.5m and a pressure pipe length of 2.5m.
Size Additional oil quantity in the gear unit in l
OWC 005 2.5
OWC 010 2.5
OWC 015 4.5
OWC 020 5.5
OWC 025 5.5
OWC 030 5.5
OWC 040 7.0
OWC 050 7.0
OWC 060 10.0
OWC 070 10.0
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Startup
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 15
2.5 Startup
2.5.1 Notes
NOTICE
Improper startup may result in damages to the gear unit or oil supply system.
Possible damage to property.
• Observe the following information.
• Before startup, check the functionality of the monitoring devices. (Depending on
the types of pressure switch, flow monitor, temperature switch/temperature sensor,
maintenance indicator etc.)
• Before taking the gear unit into operation for the first time and after each oil
change, run the oil pump at least 10 minutes to ensure that all oil chambers are
filled with oil. Switch off the oil pump and control the oil level after a short period of
time. Correct the oil level if necessary.
• An oil heater is mandatory when operating the oil supply system at low ambient
temperatures. For further information, refer to chapter "Limit temperature for start-
up of the oil supply system"(→212).
• If there is a risk of frost and the oil-water cooler is not operated for an extended
time, drain the cooling water.
• The user party must provide for the necessary water connections.
2.5.2 Venting the pump
WARNING
Danger due to leaking and squirting gear unit oil.
Serious injury.
• You must wear safety goggles.
• Be very careful when you vent the pump.
If the pump does not supply oil immediately when the oil supply system starts, do the
following:
• Fill the pump with oil.
• Vent the pump on the pressure side during start, if possible at the highest point.
2.5.3 Setting the thermostat valve (optional)
The thermostat valve is not preset upon delivery. The system must be set depending
on the local conditions by the user during startup or during operation.
Set the thermostat valve so that the oil temperature at maximum operating power is
within the range specified in the order.
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Inspection/maintenance
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
16
2.6 Inspection/maintenance
INFORMATION
First adhere to the operating instructions of the oil supply system manufacturer.
2.6.1 Inspection and maintenance intervals
Adhere to the following inspection and maintenance intervals.
Time interval What is to be done?
•Depending on the operat-
ing conditions, at least
every 12months
• Check condition of oil-water cooler, replace fil-
ter element if necessary
•Varying (depending on ex-
ternal factors)
• Check all hose pipes for tightness.
2.6.2 Checking hose pipes
NOTICE
Hoses and hose pipes are subject to natural aging even if they are properly stored
and used. This is why the period of use is limited.
• The period of use of hose pipes should not exceed 6 years from the date of manu-
facture printed on them.
• The operator of the plant is responsible for making sure that hose pipes are re-
placed at adequate intervals even if they do not show any signs of safety-related
defects.
• Have hose pipes checked by a specialist at least once a year to ensure opera-
tional safety.
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Malfunctions
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 17
2.7 Malfunctions
Fault Possible cause Measure
No oil pump suction • Air in the pipes • Fill the suction line and oil pump with oil
• Vent pressure pipe on startup
• Not enough oil in the gear unit • Check oil level in gear unit
• Wrong oil grade in the gear unit • Check oil grade (in particular when
temperatures are low)
• Motor not running • Check electrical connections
• Wrong direction of rotation of the
motor
• Change the direction of rotation
Delivery rate of oil
pump not sufficient
• Oil circulation clogged • Open valves and plugs
• Wrong oil grade • Check oil grade (in particular when
temperatures are low)
• Wrong motor speed • Check pump motor speed
• Negative pressure at pump suc-
tion side too high
• Increase cross section of suction line
• Decrease suction lift
Oil pump very loud • Negative pressure at pump suc-
tion side too high
• Increase cross section of suction line
• Decrease suction lift
• Avoid distortion of the suction line
• Avoid reductions in the suction pipes
Oil pump delivers froth • Not enough oil in the gear unit • Check oil level in gear unit
• Suction line leaking • Check screw fittings for leaks
Cooling capacity is not
reached
• Cooling water supply closed • Check cooling water supply
• Cooler dirty • Clean the cooler
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2Oil-water cooler for splash or bath lubrication /OWC
Permitted lubricants
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
18
2.8 Permitted lubricants
This chapter describes the permitted lubricants and the permitted temperatures for in-
dustrial gear units from SEW‑EURODRIVE.
INFORMATION
• The standard for viscosity and oil grade is the type of oil that is specified by
SEW‑EURODRIVE in the order (see order confirmation and nameplate).
• Contact SEW‑EURODRIVE if you use bio and food grade lubricants or polyglycol
oils.
• Check the compatibility of the greases and oils used.
• The tables contain the lubricants approved by SEW‑EURODRIVE.
• Oils of the same viscosity class from different manufacturers do not have the
same characteristics. In particular, the minimum permitted oil bath temperatures
are manufacturer-specific. These temperatures are specified in the lubricant
tables.
• The minimum permitted oil bath temperatures depend on the lubrication type
used. These temperatures are specified in the lubricant tables. The values corres-
pond to the maximum viscosity of the individual lubricants.
• The values specified in the lubricant tables apply as of the time of printing of this
document. The data of the lubricants are subject to dynamic change on the part of
the lubricant manufacturers. For the latest information about the lubricants, visit:
www.sew-eurodrive.de/lubricants
2.8.1 Explanation of the structure of the tables and abbreviations
Icons Designation
CLP = Mineral oil
CLP HC = Synthetic polyalphaolefin (PAO)
E = Oil based on esters
= Mineral lubricant
= Synthetic lubricant
= Lubricant for the food industry (NSF H1-compliant)
Oil
Oil
= Biodegradable oil (lubricant for agriculture, forestry, and water man-
agement)
1) = Lubricants may only be used if service factor Fs ≥ 1.3
RWDR = Radial oil seal
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Oil-water cooler for splash or bath lubrication /OWC
Permitted lubricants
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 19
2.8.2 Explanation of the various lubricants
SEW070040013
-20
-5
+5
xyz
+65
[5]
[1]
[2]
[3]
[4]
[6]
[7]
18014416413363467
[1] Lowest cold start temperature in°C for splash lubrication*
[2] Lowest cold start temperature in°C for drives with pumps up to a max. oil vis-
cosity of 5000 cSt*
[3] Lowest cold start temperature in°C for drives with pumps up to a max. oil vis-
cosity of 2000 cSt*
[4] Trade name
[5] Manufacturer
[6] Highest oil bath temperature in°C. MUST NOT BE EXCEEDED.
[7] Approvals
*In case of low temperatures, the oil must be heated to the specified minimum temper-
ature, for example by using an oil heater. The maximally permitted oil viscosity per
pump type is specified in the following chapter.
2.8.3 Explanation of the oil supply systems and the oil viscosity
In standard design, the motor pump of the cooling system is dimensioned for an oil
viscosity of 2000cSt.
Optionally, a motor pump with an increased suction capacity can be used. This motor
pump is dimensioned for an oil viscosity of 5000 cSt. Contact SEW‑EURODRIVE, if
required.
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2Oil-water cooler for splash or bath lubrication /OWC
Permitted lubricants
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
20
2.8.4 Lubricant tables
The lubricant table is valid when this document is printed. Please refer to www.sew-
eurodrive.de/lubricants for the latest version of the table.
Klüberoil
GEM 1-150 N
Klüberoil
GEM 1-220 N
Klüberoil
GEM 1-320 N
Klüberoil
GEM 1-460 N
Klüberoil
GEM 1-680 N
S0 S0 S0 S0 S0 S0 S0 S0
S0 S0 S0 S0 SEW070030013
S0 S0
S0 S0
S0 S0
S0 S0 S0
S0 S0
S0
S0 S0 S0
S0 S0
S0 S0 S0 S0 S0 S0 S0 S0
Optigear
BM 150
Alpha
SP 150
VG 150 1)
VG 320
DIN (ISO)
API
ISO,SAE
NLGI
CLP
VG 220
VG 460
VG 1000
VG 680
0
+15 +25
0
+15 +25
0
+15 +25
0
+15 +25
0
+15 +25
+90 +90
Alpha
SP 220
Optigear
BM 220
Alpha
SP 320
Optigear
BM 320
Alpha
SP 680
S0
+5
+20 +30
+90
Optigear
BM 1000
Optigear
BM 680
-5
+10 +20
+90
-10
+5
+15
+85
-15
0
+10
+75
-20
-5
+5
+65
-20
-5
+5
+65
-20
-5
+5
+65
-20
-5
+5
+65
-20
-5
+5
+65
-20
-5
+5
+65
-20
-5
+5
+65
-15
0
+10
+75
-15
0
+10
+75
-15
0
+10
+75
-15
0
+10
+75
-15
0
+10
+75
-15
0
+10
+75
-15
0
+10
+75
-15
0
+10
+75
-10
+5
+15
+80
-10
+5
+15
+80
-10
+5
+15
+80
-10
+5
+15
+80
-10
+5
+15
+80
-10
+5
+15
+80
-10
+5
+15
+80
Optigear
BM 460
-5
+10 +20
+90
-5
+10 +20
+90
-5
+10 +20
+90
-5
+10 +20
+90
-5
+10 +20
+90
-5
+10 +20
+90
-5
+10 +20
+90
-5
+10 +20
+90
Alpha
SP 460
+90 +90
Renolin
CLP 150 Plus
Renolin
CLP 220 Plus
Renolin
CLP 320 Plus
Renolin
HighGear 150
Renolin
HighGear 220
Renolin
HighGear 320
Renolin
HighGear 460
Renolin
CLP 460 Plus
Renolin
HighGear 680
Mobilgear 600
XP 680
SEW070030013
Mobilgear 600
XP 460
Renolin
CLP 680 Plus
+90
0
+15 +25
+90
0
+15 +25
+90
0
+15 +25
+90
SEW070030013 SEW070030013 SEW070030013
Mobilgear 600
XP 150
Mobilgear 600
XP 220
Mobilgear 600
XP 320
Shell Omala
Oil F 220
-10
+5
+15
+80
Shell Omala
Oil F 320
Shell Omala
Oil F 460
Meropa 150 Meropa 220 Meropa 320 Meropa 460
Meropa 680
Carter EP 220
Carter EP 320
Carter EP 460 Carter EP 680
Mobil
TO TA L
S
h
ll
e
FUCHS
TEXACO
LUBRICATION
17909427211
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