SEW-Eurodrive ONP1L User manual

*27806308_0523*
Drive Technology \ Drive Automation \ System Integration \ Services
Assembly and Operating
Instructions
Industrial Gear Units
Motor Pump with Pressure Lubrication /ONP1L
Edition 05/2023 27806308/EN

SEW-EURODRIVE—Driving the world

Table of Contents
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L 3
Table of Contents
1 General information.................................................................................................................. 5
1.1 About this documentation ...............................................................................................5
1.2 Structure of the safety notes ...........................................................................................5
1.2.1 Meaning of signal words ................................................................................ 5
1.2.2 Structure of section-related safety notes........................................................ 5
1.2.3 Structure of embedded safety notes .............................................................. 6
1.3 Decimal separator in numerical values ...........................................................................7
1.4 Product names and trademarks......................................................................................7
1.5 Recycling und re-use ......................................................................................................7
1.6 Copyright notice ..............................................................................................................7
1.7 Rights to claim under limited warranty ............................................................................7
1.8 Other applicable documentation .....................................................................................7
2 Safety notes .............................................................................................................................. 8
2.1 Preliminary information ...................................................................................................8
2.2 Duties of the user............................................................................................................8
2.3 Target group ...................................................................................................................9
2.4 Designated use ...............................................................................................................9
2.5 Other applicable documentation ...................................................................................10
2.6 Safety symbols..............................................................................................................10
2.7 Storage and transport conditions ..................................................................................11
2.7.1 Internal conservation.................................................................................... 11
2.7.2 Exterior corrosion protection ........................................................................ 11
2.7.3 Packaging .................................................................................................... 11
2.7.4 Storage conditions ....................................................................................... 11
3 Motor pump /ONP1L............................................................................................................... 13
3.1 Functional description ...................................................................................................13
3.2 Structure .......................................................................................................................13
3.2.1 Gear unit in mounting position M1 – mounting surface: Oil supply system on
F6 ................................................................................................................. 14
3.2.2 Gear unit in mounting position M5 – mounting surface: Oil supply system on
F1 ................................................................................................................. 14
3.2.3 Scope of delivery.......................................................................................... 15
3.3 Function ........................................................................................................................16
3.3.1 Oil pump....................................................................................................... 16
3.3.2 Temperature switch /NTB (optional) ............................................................ 16
3.3.3 Pressure switch............................................................................................ 16
3.4 Nameplate.....................................................................................................................17
3.5 Type designation...........................................................................................................18
3.6 Hydraulics plan .............................................................................................................19
3.6.1 Standard....................................................................................................... 19
3.7 Technical data...............................................................................................................20
3.8 Dimension sheets .........................................................................................................21
3.8.1 Motor pump /ONP1L [mm] ........................................................................... 21
3.9 Interlocking specifications .............................................................................................24
27806308/EN – 05/2023

Table of Contents
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L
4
3.9.1 Gear unit enable........................................................................................... 24
3.9.2 STOP gear unit/warning............................................................................... 24
4 Installation/assembly ............................................................................................................. 25
4.1 Mechanical connection ................................................................................................25
4.2 Electrical connection .....................................................................................................25
4.3 Wiring diagram (schematic illustration) .........................................................................26
4.3.1 Control circuit with optional temperature switch /NTB.................................. 26
4.3.2 Main circuit ................................................................................................... 27
4.4 Pressure switch.............................................................................................................28
4.4.1 Dimensions .................................................................................................. 28
4.4.2 Electrical connection .................................................................................... 28
4.4.3 Technical data.............................................................................................. 28
4.5 Limit temperature for startup of the oil cooling system .................................................29
4.6 Notes on checking the oil level .....................................................................................29
4.6.1 Additionally required gear unit oil ................................................................. 29
5 Startup ..................................................................................................................................... 30
5.1 Notes.............................................................................................................................30
5.2 Venting the oil pump .....................................................................................................30
6 Inspection/maintenance......................................................................................................... 31
6.1 Inspection and maintenance intervals...........................................................................31
6.2 Notes.............................................................................................................................31
6.3 Checking hose pipes.....................................................................................................32
7 Permitted lubricants............................................................................................................... 33
7.1 Structure of the tables and abbreviations .....................................................................33
7.2 Explanation of the various lubricants ............................................................................34
7.3 Explanation of the oil supply systems and the oil viscosity...........................................34
7.4 Lubricant tables.............................................................................................................35
8 Malfunctions/remedy.............................................................................................................. 38
8.1 Notes.............................................................................................................................38
8.2 Possible failures/remedy...............................................................................................39
8.3 Service ..........................................................................................................................40
8.4 Waste disposal..............................................................................................................40
9 Supplier documentation......................................................................................................... 41
9.1 Transfer Gear Pumps - Operating and Maintenance Instructions ................................42
9.2 Flow switch - Operating instructions ...........................................................................105
9.3 Flow switch - data sheet .............................................................................................118
9.4 Pressure Switch - Operating Instructions....................................................................121
9.5 Pressure sensors - Installation instructions ................................................................123
9.6 Bimetal thermometer - data sheet...............................................................................130
9.7 Bourdon tube pressure gauge - data sheet ................................................................136
27806308/EN – 05/2023

1
General information
About this documentation
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L 5
1 General information
1.1 About this documentation
The documentation at hand is the original.
This documentation is an integral part of the product. The documentation is intended
for all employees who perform work on the product.
Make sure this documentation is accessible and legible. Ensure that persons respon-
sible for the systems and their operation as well as persons who work on the product
independently have read through the documentation carefully and understood it. If you
are unclear about any of the information in this documentation or if you require further
information, contact SEW‑EURODRIVE.
1.2 Structure of the safety notes
1.2.1 Meaning of signal words
The following table shows the graduation and meaning of the signal words in the
warnings:
Signal word Meaning Consequences if not observed
DANGER Imminent danger Death or severe injuries
WARNING Possible, dangerous situation Death or severe injuries
CAUTION Possible, dangerous situation Slight injuries
NOTICE Possible damage to property Damage to the product or its envi-
ronment
INFORMATION Useful information or tip: Simplifies
handling of the product.
1.2.2 Structure of section-related safety notes
Section-related safety notes do not apply to a specific action but to several actions
pertaining to one subject. The hazard symbols used either indicate a general hazard
or a specific hazard.
This is the formal structure of a safety note for a specific section:
SIGNAL WORD
Type and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the hazard.
27806308/EN – 05/2023

1General information
Structure of the safety notes
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L
6
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
Warning of hot surfaces
Warning of automatic restart
1.2.3 Structure of embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous step.
This is the formal structure of an embedded safety note:
 SIGNAL WORD! Type and source of danger. Possible consequence(s) if disre-
garded. Measure(s) to prevent danger.
27806308/EN – 05/2023

1
General information
Decimal separator in numerical values
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L 7
1.3 Decimal separator in numerical values
In this document, a period is used to indicate the decimal separator.
Example: 30.5kg
1.4 Product names and trademarks
The product names mentioned in this documentation are trademarks or registered
trademarks of the respective titleholders.
1.5 Recycling und re-use
SEW‑EURODRIVE makes sure to keep the use of new natural resources as low as
possible in the manufacture of its products. A key aspect of this is the recycling econo-
my with recycling and re-use of components and materials. Recycling and re-use are
only used at SEW‑EURODRIVE if the parts obtained from these processes corre-
spond to the quality of new parts.
1.6 Copyright notice
©2023SEW‑EURODRIVE. All rights reserved. Copyright law prohibits the unautho-
rized reproduction, modification, distribution and use of this document – in whole or in
part.
1.7 Rights to claim under limited warranty
Read the information in this documentation. This is essential for fault-free operation
and fulfillment of any rights to claim under limited warranty. Read the documentation
before you start working with the product.
1.8 Other applicable documentation
The following documentation should also be observed:
• Operating instructions X..e series helical and bevel-helical gear units
• Order documents, e.g. dimension sheet, order confirmation, etc.
• If required, the operating instructions of the options installed (e.g. DriveRadar®)
27806308/EN – 05/2023

2Safety notes
Preliminary information
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L
8
2 Safety notes
2.1 Preliminary information
The following general safety notes serve the purpose of preventing injury to persons
and damage to property. They primarily apply to the use of products described in this
documentation. If you use additional components, also observe the relevant warning
and safety notes.
2.2 Duties of the user
As the user, you must ensure that the basic safety notes are observed and complied
with. Make sure that persons responsible for the machinery and its operation as well
as persons who work on the device independently have read through the documenta-
tion carefully and understood it.
As the user, you must ensure that all of the work listed in the following is carried out
only by qualified specialists:
• Setup and installation
• Installation and connection
• Startup
• Maintenance and repairs
• Shutdown
• Disassembly
Ensure that the persons who work on the product pay attention to the following regula-
tions, conditions, documentation, and information:
• The national and regional regulations governing safety and the prevention of acci-
dents
• The warning and safety signs on the product
• All other associated project planning documents, installation and startup instruc-
tions, as well as wiring diagrams
• Do not assemble, install or operate damaged products
• All system-specific specifications and regulations
Ensure that systems in which the product is installed are equipped with additional
monitoring and protection devices. Observe the applicable safety regulations and leg-
islation governing technical work equipment and accident prevention regulations.
27806308/EN – 05/2023

2
Safety notes
Target group
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L 9
2.3 Target group
Specialist for me-
chanical work
Any mechanical work may be performed only by adequately qualified specialists. Spe-
cialists in the context of this documentation are persons who are familiar with the
design, mechanical installation, troubleshooting, and maintenance of the product, and
who possess the following qualifications:
• Qualifications in the field of mechanics in accordance with the national regulations
• Familiarity with this documentation
Specialist for elec-
trotechnical work
Any electrotechnical work may be performed only by electrically skilled persons with a
suitable education. Electrically skilled persons in the context of this documentation are
persons who are familiar with electrical installation, startup, troubleshooting, and main-
tenance of the product, and who possess the following qualifications:
• Qualifications in the field of electrical engineering in accordance with the national
regulations
• Familiarity with this documentation
Additional qualifi-
cations
In addition to that, these persons must be familiar with the valid safety regulations and
laws, as well as with the requirements of the standards, directives, and laws specified
in this documentation.
The persons must have the express authorization of the company to operate, pro-
gram, parameterize, label, and ground devices, systems, and circuits in accordance
with the standards of safety technology.
Instructed persons All work in the areas of transport, storage, installation, operation and waste disposal
may only be carried out by persons who are trained and instructed appropriately.
These instructions must enable the persons to carry out the required activities and
work steps safely and in accordance with regulations.
2.4 Designated use
The motor pump supplies all bearing points and gearing above the oil sump with oil via
a tube system inside the gear unit. Adhere to the permitted technical data on the
nameplate.
Using these products in potentially explosive atmospheres is prohibited, unless spe-
cifically designated otherwise.
In compliance with the EC Machinery Directive 2006/42/EC, the oil cooling system is a
partly completed machine for installation in machinery and systems. In the scope of
the EU Directive, you must not put the machinery into operation in the designated
fashion until you have established that the end product complies with Machinery Di-
rective 2006/42/EC.
27806308/EN – 05/2023

2Safety notes
Other applicable documentation
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L
10
2.5 Other applicable documentation
The following documentation should also be observed:
• Operating instructions X..e series helical and bevel-helical gear units
• Order documents, e.g. dimension sheet, order confirmation, etc.
• If required, the operating instructions of the options installed (e.g. DriveRadar®)
2.6 Safety symbols
CAUTION
Safety/caution signs and safety symbols can become dirty or illegible over time.
Risk of injury due to illegible symbols.
• Always make sure that safety, warning, and operating notes are legible.
• Replace damaged safety/caution signs and safety symbols.
The safety symbols on the oil cooling system must be observed. They have the follow-
ing meaning:
Safety symbol Meaning
Oil
in
Indicates the oil supply and serves to locate the connection op-
tion.
Oil
out
Indicates the oil return and serves to locate the connection op-
tion.
27806308/EN – 05/2023

2
Safety notes
Storage and transport conditions
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L 11
2.7 Storage and transport conditions
Oil cooling systems can be provided with the following protection and packaging
types, depending on the storage and transport conditions.
2.7.1 Internal conservation
Standard corrosion protection
After the test run, the test oil filling is drained out of the oil cooling system. The remain-
ing oil film protects the oil cooling system against corrosion for a limited period of time.
Long-term corrosion protection
After the test run, the test oil filling is drained out of the oil cooling system and the in-
terior space is filled with a vapor phase inhibitor.
Corrosion protection with VCI anti-corrosion agent is not permitted for oil cooling sys-
tems that are operated with food grade lubricants. Contact SEW‑EURODRIVE in such
cases.
2.7.2 Exterior corrosion protection
The following measures are taken for exterior corrosion protection:
• Small spare parts and loose pieces, such as bolts, nuts, etc., are packed in corro-
sion protection plastic bags (VCI corrosion protection bags).
• Threaded holes and blind holes are covered with plastic plugs.
• If the oil cooling system is stored for longer than six months, regularly check the
protective coating of unpainted areas as well as the paint coating. Areas with pro-
tective coating and/or paint that has been damaged may have to be repainted.
2.7.3 Packaging
Standard packaging
The system is packaged on a pallet without any covering.
Application: Land transport
Long-term packaging
Packaging in a wooden box that is also appropriate for sea transport.
Application: Sea transport and/or for extended storage
2.7.4 Storage conditions
NOTICE
Improper storage can cause damage.
Possible damage to property.
• During the storage period until startup, the system must be stored free of shocks
to prevent damage to the pump, pipes or other mounting options.
27806308/EN – 05/2023

2Safety notes
Storage and transport conditions
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L
12
INFORMATION
The external oil supply and oil cooling system is delivered without any oil filling as
standard; different protection systems are required depending on the storage period
and storage conditions as shown in the following table.
Conservation +
packaging
Storage location Storage duration
Standard preservation
+
standard packaging
Under roof and enclosed at constant temperature
and humidity (5°C<ϑ <60°C, <50% relative hu-
midity).
No sudden temperature fluctuations and controlled
ventilation with filter (free of dirt and dust). No ag-
gressive vapors or shocks.
Maximum 6months with in-
tact surface protection.
Long-term preservation
+
standard packaging
Under roof and enclosed at constant temperature
and humidity (5°C<ϑ <60°C, <50% relative hu-
midity).
No sudden temperature fluctuations and controlled
ventilation of the storage room with filter (free of
dirt and dust). No aggressive vapors or shocks.
Maximum 3years with regu-
lar inspection and checking
for intactness.
Long-term preservation
+
long-term packaging
Under roof, protection against rain, vibration-free. Maximum 3years with regu-
lar inspection and checking
for intactness.
INFORMATION
When storing in tropical areas, ensure adequate protection against insect damage.
Contact SEW-EURODRIVE in case of deviating requirements.
27806308/EN – 05/2023

3
Motor pump /ONP1L
Functional description
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L 13
3 Motor pump /ONP1L
3.1 Functional description
ONP1L pressure lubrication draws the oil from the oil sump using a motor pump to
supply all bearing points and gearing above the oil sump with oil via a pipe system in-
side the gear unit.
The oil pump is switched on shortly before gear unit start and ensures a sufficient oil
flow during operation regardless of the speed of the gear unit.
The motor pump contains a bypass at the oil pump, which ensures the function of
pressure lubrication even with high viscosities via an integrated pressure limiting
valve.
3.2 Structure
The following figures show the gear unit in mounting positions M1 and M5 with the
standard mounting surfaces for the motor pump.
Mounting surfaces deviating from the standard require a new design. This may affect
the minimum oil viscosity. A comprehensive individual check is required. Contact
SEW‑EURODRIVE.
The motor pump is a complete unit directly mounted on the gear unit as standard. The
motor pump is delivered with the piping to the gear unit already installed. The elec-
trical wiring must be performed by the user prior to startup.
27806308/EN – 05/2023

3Motor pump /ONP1L
Structure
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L
14
3.2.1 Gear unit in mounting position M1 – mounting surface: Oil supply system on F6
[1]
[2]
[3]
[4]
[6] [5]
18014417388433163
[1]Pump motor [4] Gauge mounting block
[2]Oil pump [5] Pressure switch
[3]Suction pipe [6] Pressure pipe
3.2.2 Gear unit in mounting position M5 – mounting surface: Oil supply system on F1
[1] [2] [3] [4]
[5]
[6]
9007218133694859
[1]Pump motor [4] Gauge mounting block
[2]Oil pump [5] Pressure switch
[3]Suction pipe [6] Pressure pipe
27806308/EN – 05/2023

3
Motor pump /ONP1L
Structure
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L 15
3.2.3 Scope of delivery
The delivery includes the following:
• Oil pump with directly mounted asynchronous motor (oil pump always running)
• Pressure switch that monitors the pump pressure. Warning or switch-off signal
when the oil pressure reaches <0.5bar.
• Gauge mounting block (pressure switch installed as standard). As standard, the
motor pump always comes equipped with a gauge mounting block with pressure
switch and integrated check valve.
Optional accessories
The motor pump can be equipped with the following components as an option:
• Temperature switch/NTB with trip point for monitoring the oil sump temperature,
i.e. warning or gear unit shutdown at an oil temperature of >90°C.
• For installation on the gauge mounting block, the following is available:
– Flow switch
– Manometer
– Thermometer
– Pressure sensor
27806308/EN – 05/2023

3Motor pump /ONP1L
Function
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L
16
3.3 Function
Observe the following control information for the individual components.
3.3.1 Oil pump
The pump motor has to be switched on 20s prior to gear unit startup and is always
running during operation of the gear unit.
The motor pump has several bypasses to limit the system pressure and maintain the
function even at high viscosities; for more information, refer to chapter "Hydraulics
plan"(→219).
3.3.2 Temperature switch /NTB (optional)
The temperature of the system is monitored using a temperature switch/NTB connect-
ed to the controller of the operator.
• At T > 90°C →STOP GEAR UNIT/WARNING
3.3.3 Pressure switch
The pressure switch ensures the function of the pressure lubrication. The latter must
be connected and monitored by the customer to prevent serious gear unit damage.
The oil pump is switched on 20 s before the gear unit starts. Within 10 s after the
pump starts, an oil pressure of 0.5bar should be applied to the pressure switch, which
indicates a sufficient oil volume flow for the pressure lubrication.
Start of the oil pump Oil pressure must be
above 0.5bar
Gear unit start
if oil pressure is OK
Oil pressure must
remain above
0.5bar
Oil pressure may
be below 0.5bar
without error output
10s startup override 10s Operation
40153292683
→ If the oil pressure p< 0.5bar →GEAR UNIT STOP/WARNING
27806308/EN – 05/2023

3
Motor pump /ONP1L
Nameplate
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L 17
3.4 Nameplate
The following example shows the structure of the nameplate.
76646 Bruchsal/Germany
CLP HC 220 - synthetic oil
Made in Bruchsal / Germany
+10...+40 °C
Type ONP1 16-020/M
No.
01.78159301.0001-0002.20
Q-oil
Mass
Ta [°C]
50/60 Hz
[l/min] 21.3
- [KW]
[Kg] 50
m asl. [m] 1000
Year 2023
- [KW]
nom. cooling capacity cal. cooling capacity
[1]
[2]
[3]
[4]
[5]
[7]
[8]
[9]
[10]
[6]
9007232233682955
[1] Type designation
[2] Serial number
[3] Oil grade and viscosity class
[4] Volume flow 50/60 Hz
[5] Cooling capacity:
Nominal cooling capacity at an ambient temperature of 40°C and an oil temper-
ature of 70°C.
[6] Cooling capacity:
Calculated cooling capacity with deviating temperatures.
[7] Ambient temperature range
[8] Installation altitude
[9] Mass
[10] Year of manufacture
27806308/EN – 05/2023

3Motor pump /ONP1L
Type designation
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L
18
3.5 Type designation
The following example shows the structure of the type designation.
ONP1L 12 - 0 0 0 /M
O Oil supply system
N Coolant
• N = No coolant
P Type
• P = Pressure lubrication
1 Generation
L L = Light
12 Pump size
• 06 – 25
0 Mounting positions
• 0 = M1
• 1 = M5
0 Frequency
• 0 = 50 Hz
• 1 = 60 Hz
• 2 = 50 Hz/60 Hz
0 Options
• 0 = No filter
• 9 = Special design
M Mounting type
• M = Mounted on the gear unit
• S = For separate installation
27806308/EN – 05/2023

3
Motor pump /ONP1L
Hydraulics plan
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L 19
3.6 Hydraulics plan
3.6.1 Standard
The following figure shows an example of the structure of the motor pump.
M
[1]
[2]
[3]
[4]
[5]
36028815836882827
[1]Motor [4] Check valve
[2]Oil pump [5] Gear unit
[3] Pressure switch
The following figure shows at a glance the possible options that can be installed.
[1] [2] [3]
[4]
19057234827
[1]Pressure sensor [3] Manometer
[2] Thermometer [4] Flow switch
27806308/EN – 05/2023

3Motor pump /ONP1L
Technical data
Assembly and Operating Instructions – Motor Pump with Pressure Lubrication /ONP1L
20
3.7 Technical data
The performance data of the standardized motor pump is summarized in the following
table.
Size
ONP1L
Oil pump
size
Motor data Connection power
motor oil pump in kW Global motor
in Hz
Pump capacity
at 15001/min
Type IEC stan-
dard
Number of
poles
6KF 6 RF DRN 80MK 4 0.55 50/60 8.4
8KF 8 RF DRN 80MK 4 0.55 50/60 10.5
10 KF 10 RF DRN 80M 4 0.75 50/60 13.7
12 KF 12 RF DRN 90S 4 1.1 50/60 17.1
16 KF 16 RF DRN 90S 4 1.1 50/60 21.8
20 KF 20 RF DRN 90L 4 1.5 50/60 27.1
25 KF 25 RF DRN 100ML 4 2.2 50/60 34.0
27806308/EN – 05/2023