SEW-Eurodrive X Series User manual

*22761055_1216*
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-Air Cooler for Pressure Lubrication /OAP
Edition 12/2016 22761055/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-air cooler for pressure lubrication/OAP ........................................................................... 5
2.1 Structure/function............................................................................................................5
2.2 Wiring diagram (schematic illustration) ...........................................................................8
2.3 Installation/assembly.....................................................................................................10
2.4 Notes on checking the oil level .....................................................................................13
2.5 Startup ..........................................................................................................................14
2.6 Inspection/maintenance ................................................................................................15
2.7 Malfunctions..................................................................................................................16
2.8 Permitted lubricants ......................................................................................................17
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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-air cooler operating instructions.
Observe the additional information specified in this document.
This document does not replace the detailed operating instructions.
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2
Oil-air cooler for pressure lubrication/OAP
Structure/function
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 5
2 Oil-air cooler for pressure lubrication/OAP
2.1 Structure/function
2.1.1 Structure
An oil-air cooler can be used if the thermal rating of a naturally cooled gear unit, or the
cooling via a fan on the input shaft is not sufficient.
INFORMATION
• The following information applies for gear units with pressure lubrication.
• Also refer to the operating instructions of the cooling system manufacturer.
2.1.2 General
The cooling system is delivered as a complete unit on a mounting frame for separate
installation but without electrical wiring and piping. As an option, the cooling system
can be mounted to the gear unit as a complete unit. In this case, the cooling system is
delivered with piping but without wiring.
The standard delivery of the basic cooling system includes:
• Pump with directly connected asynchronous motor (pump always running)
• Fan with directly mounted asynchronous motor
• Oil-air heat exchanger
• Oil filter with filter element and electrical/optical maintenance indicator
• Pressure switch that monitors the pump pressure. Warning or switch-off signal
when the oil pressure is < 0.5bar
• Temperature switch /TSK2 with 2 switching points for
– Controlled start of the fan motor at an oil temperature of > 60°C
– Monitoring of the oil-air cooler, i.e. warning or gear unit shutdown at an oil tem-
perature > 90°C
2.1.3 Optional accessories
The cooling system can be equipped with the following components as an option:
• Oil filter as duplex filter
The oil filter is available as single filter or duplex filter. For pressure lubrication sys-
tems, a single filter is included as standard.
• Flow rate sensor
• Manometer
• Thermometer
• PT100 temperature sensor
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2Oil-air cooler for pressure lubrication/OAP
Structure/function
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
6
2.1.4 Function
Observe the following control information for the individual components.
Oil pump/Oil-air heat exchanger
The fan motor of the oil-air heat exchanger is switched on and off depending on the
temperature.
The pump motor has to be switched on 20s prior to gear unit startup and is running
during operation of the gear unit.
INFORMATION
Do not change the default setting of the valve at the oil pump.
Fan
The driving motor of the fan is switched on and off depending on the temperature.
Temperature switch /TSK2
The temperature of the plant is monitored via a temperature switch with defined
switching points.
• At T > 60°C →Motor of the oil-air cooler – ON
• At T < 50°C →Motor of the oil-air 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 →Motor of the oil-air cooler – ON
• At T < 50°C →Motor of the oil-air cooler – OFF
• At T > 90°C →GEAR UNIT STOP/WARNING
Filter
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)
Pressure switch
The pressure switch requires a 10s delay.
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Oil-air cooler for pressure lubrication/OAP
Structure/function
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 7
2.1.5 Interlocking specifications
Enabling of the gear unit
Gear unit enable if the following conditions are met:
• Oil pressure p >0.5bar (startup delay of 10s)
• Oil temperature T<90°C
STOP gear unit/warning
Gear unit STOP/warning if one of the following conditions is met:
• Oil temperature T > 90°C
• Oil pressure p < 0.5bar
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2Oil-air cooler for pressure lubrication/OAP
Wiring diagram (schematic illustration)
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
8
2.2 Wiring diagram (schematic illustration)
The wiring diagrams show a possible setup of the control for the cooling system when
a temperature switch /TSK2 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
F6
F4
T1
K3 K4K5
N
T2
K6
S2 K6 Closes at
> 60°C
Opens at
oil > 90°C
Temp. signal
control:
Warning/switch-off
to main motor
F5
L1
K1
p> 0.5 bar
K2
p< 0.5 bar
oil
K6
ϑϑ
Emergency off
K1T
K1T
S0
S1
Emergency off
Pϑ
Main contactor "ON" Time relay
for main motor control
10 s
18888349195
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2
Oil-air cooler for pressure lubrication/OAP
Wiring diagram (schematic illustration)
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units 9
2.2.2 Control circuit with control via PT100 temperature sensor
K3 ON at
K3 K4
> 60 °C
oil > 90 °C
temp. signal
to main motor
Warning/switch-off
control:
oil
ϑ
K3 OFF at < 50 °C
oil
ϑϑ
Operator
control
At
PT100
F4
K5 K6
S2 K6
F5
L1
N
K1 K2
K6
K1T
K1T
10 s
S0
S1
Emergency off
p> 0.5 bar
p< 0.5 bar
P
Main contactor "ON" Time relay
for main motor
control
18888346763
2.2.3 Main circuit
Switch-on
at
oil > 60°C
Signal of contactor K4
via temperature switch /TSK2
or temperature sensor PT100
K3
Fan motor
L1
L2
L3
M
3
PE
Pump motor
M1
Signal via contactor K1, K2
by pressure switch (changer)
Warning/switch-off
K5
Main motor
Main motor
control
F1 F3
ϑ
K6
F2
M
3
M2 M
3
M3
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2Oil-air cooler for pressure lubrication/OAP
Installation/assembly
Addendum to the Assembly and Operating Instructions – X.. Series Helical and Bevel-Helical Gear Units
10
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 and the gear unit have to be set up separately as standard. As an
option, the cooling system can be mounted to the gear unit as a complete unit. In this
case, the cooling system is delivered with piping but without wiring.
Provide for a low-vibration installation location max. 1 meter 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.
Install the cooling system in such a way that input and output air can flow unobstruc-
tedly. Provide for sufficient ventilation and protection against dirt.
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 according to the identifying markings and
observing local regulations.
In this respect, observe the following basic conditions:
• Do not reduce the specified cable cross section.
• 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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