SEW-Eurodrive X Series User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Addendum to the Assembly and
Operating Instructions
Industrial Gear Units
Helical and Bevel-Helical Gear Units
X.. Series
Oil-Water Cooler for Splash Lubrication /OWC
Edition 01/2014 20230540 / EN

2Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC
Contents
Contents
1 Important information......................................................................................... 3
2 Oil-water cooler for splash lubrication /OWC................................................... 4
2.1 Structure/function........................................................................................ 4
2.1.1 Structure...................................................................................... 4
2.1.2 General information..................................................................... 8
2.1.3 Function....................................................................................... 8
2.1.4 Interlocking specifications............................................................ 8
2.1.5 Sizes, cooling capacity and selection.......................................... 9
2.2 Wiring diagram (schematic illustration)..................................................... 10
2.3 Installation/assembly................................................................................. 11
2.3.1 Mechanical connection ............................................................. 11
2.3.2 Electrical connection.................................................................. 11
2.3.3 Cooling media............................................................................ 12
2.3.4 Installation and connection information ..................................... 13
2.4 Notes on checking the oil level ................................................................. 13
2.5 Startup ...................................................................................................... 14
2.5.1 Notes ......................................................................................... 14
2.5.2 Venting the motor pump ............................................................ 14
2.6 Inspection/maintenance............................................................................ 15
2.6.1 Inspection and maintenance intervals ....................................... 15
2.6.2 Check hose pipes...................................................................... 15
2.7 Lubricant fill quantities .............................................................................. 16
2.8 Malfunctions.............................................................................................. 16
3 Supplier documentation................................................................................... 18
3.1 Dimension sheets and list of spare parts.................................................. 19
3.2 Circulation pump BFP - Description.......................................................... 25
3.3 Circulation pump BFP - Operation and installation................................... 33
3.4 Oil-water cooler BWT series – Description ............................................... 47
3.5 Oil-air cooler BWT series – Operation and installation ............................. 55

Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC 3
1
Important information
Oil-Water Cooler for Splash Lubrication /OWC
1 Important information
INFORMATION
This addendum describes amendments to the "Industrial Gear Units, Helical and
Bevel Gear Units" operating instructions. Please use the data specified in this
document.
This document does not replace the detailed operating instructions.

4Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC
2Structure/function
Oil-water cooler for splash lubrication /OWC
2 Oil-water cooler for splash 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.
SEW-EURODRIVE uses 2 different types of heat exchangers:
• For gear unit sizes X140 – X170, a plate heat exchanger is used for oil supply sys-
tems OWC 005/015/025.
INFORMATION
• Consult 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. The cooling
system with motor pump only cools the gear unit oil.
• Also refer to the operating instructions of the cooling system manufacturer.
18014402105552907
[1] Motor
[2] Pump
[3] Oil-water heat exchanger
[4] Suction pipe (not visible in this view)
[5] Pressure line
[6] Temperature switch with two switching points (TSK2)
[7] Water supply
[8] Water return
[6]
[5]
[2]
[1]
[3]
[4]
[7]
[8]

Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC 5
2
Structure/function
Oil-water cooler for splash lubrication /OWC
The following figure shows an example of the unit structure for gear unit sizes X140
– X170.
18014402099868555
[1] Motor
[2] Pump
[3] Oil-water heat exchanger
[4] Riser pipe
[5] Pressure line
[6] Temperature switch with two switching points (TSK2)
[7] Water supply
[8] Water return
[3]
[4]
[6]
Base plate
Water
in
Water
out
Oil
in
Oil
out
System oil supply system
[5]
[7]
[8]
[2]
M
[1]

6Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC
2Structure/function
Oil-water cooler for splash lubrication /OWC
• For gear unit sizes X180 – X320, a shell and tube heat exchanger is used for oil sup-
ply systems OWC 10/20/30/40/50/60/70.
18014402106563851
[1] Motor
[2] Pump
[3] Oil-water heat exchanger
[4] Riser pipe
[5] Pressure line
[6] Temperature switch with two switching points (TSK2)
[7] Water supply
[8] Water return
[3]
[6]
[5]
[2]
[1]
[7/8]
[4]

Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC 7
2
Structure/function
Oil-water cooler for splash lubrication /OWC
The following figure shows an example of the unit structure for gear unit sizes X180 –
X320.
9450567691
[1] Motor
[2] Pump
[3] Oil-water heat exchanger
[4] Riser pipe
[5] Pressure line
[6] Temperature switch with two switching points (TSK2)
[7] Water supply
[8] Water return
[3]
[4]
[6]
Base plate
Water
in
Water
out
Oil
in
Oil
out
Oil supply system
[5]
[7]
[8]
[2]
Venting
M
[1]

8Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC
2Structure/function
Oil-water cooler for splash lubrication /OWC
2.1.2 General information
The cooling system is delivered as a complete unit but without electrical connections.
The standard design of the basic cooling system comprises:
• Pump with directly mounted asynchronous motor
• Oil-water heat exchanger
• Temperature switch with 2 switching points for
– Controlled startup of the pump motor at an oil temperature of > 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 installation, but without piping to the gear unit
The customer has to perform the following electrical wiring:
• Between temperature switch and pump motor
•Pumpmotor
2.1.3 Function
Observe the following control information for the individual components.
Pump For gear unit sizes X180 – X320, a pressure control valve integrated the pump limits the
plant pressure if the pump is operated.
Oil-water cooling
system The gear unit is cooled by an oil-water cooling system.
•AtT>60°C→COOLER ON
TSK2 temperature
switch The plant's temperature is monitored via a temperature switch [6] connected to a display and monitoring unit.
•AtT>60°C→COOLER ON
• When T > 90 °C →GEAR UNIT STOP / WARNING
2.1.4 Interlocking specifications
Enabling the gear
unit The gear unit is enabled if the following condition is met:
• Oil temperature T < 90 °C
Gear unit stop /
warning Gear unit stop / warning if one of the following conditions is met:
• Oil temperature T > 90 °C
STOP
Do not change the default setting of the valve!

Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC 9
2
Structure/function
Oil-water cooler for splash lubrication /OWC
2.1.5 Sizes, cooling capacity and selection
The power data of the standardized cooling systems is summarized in the following ta-
ble.
The cooling capacity values given in the table apply to a cooling water temperature of
30 °C, an oil temperature of 70 °C, equivalent volume flow of oil and cooling water, and
50 Hz line frequency.
Size
Cooling system Cooling capacity Cooling system
[kW]
Flow volume
Cooling system
[l/min]
Connection power
Pump motor
[kW]
OWC 0051)
1) Cooling system with plate heat exchanger
4 8 0.75
OWC 010 5 9.6 0.75
OWC 0151) 816 1.1
OWC 020 8.5 21 1.1
OWC 0251) 12 16 1.5
OWC 030 14 28.3 1.5
OWC 040 22 53 2.2
OWC 050 30 77 3.0
OWC 060 45 91 4.0
OWC 070 70 144 5.5
INFORMATION
The values differ slightly for operation with a line frequency of 60 Hz. Please consult
SEW-EURODRIVE.

10 Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC
2Wiring diagram (schematic illustration)
Oil-water cooler for splash lubrication /OWC
2.2 Wiring diagram (schematic illustration)
18014401559504267
F2
F1
T1
Control circuit
temperature switch
Control circuit
main motor
L1
N
K1 K2
K3
T2
S0
S1
Main ciruit
pump motor
F4
M
3
Switch on when > 60°C
Main circuit
main motor
L1
F3
Control
Main motor
L2
L3
M
3
Signal from contactor K2
via temperature sensor
Type TSK-2-63/4 (NC contact)
Warning; switch off
PE
K3 K1
Main motor
M2
M1
K3 > 60°C opens at
oil
> 90°C
Temp. signal to
control circuit main
motor /
Warning: switch off
Main contactor „on“
for main motor
control
closes at
oil
ϑϑ
oil
Emergency off S0 Emergency off
Pump motor
ϑ

Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC 11
2
Installation/assembly
Oil-water cooler for splash lubrication /OWC
2.3 Installation/assembly
2.3.1 Mechanical connection
Connect the heat exchanger to the cooling circuit according to the identifying markings
observing local regulations.
In this respect, observe the following:
• Do not reduce the indicated cable cross-section.
• It is important that you choose the correct wall thickness and material when selecting
pipes, hoses and screw fittings.
2.3.2 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.
• The temperature switch should be integrated into the circuit in such a manner that:
– The motor 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).

12 Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC
2Installation/assembly
Oil-water cooler for splash lubrication /OWC
2.3.3 Cooling media
Permitted cooling media
• Water, water/glycol cooling liquids, HFC refrigerants
• Cooling water temperature and volume flow of oil and cooling water according to the
order documents.
Dirt The quantity of suspended solids (ball-shaped, particle size < 0.6 mm) should be less
than 10 mg/l. Threadlike contaminants increase the risk of pressure loss.
Corrosion Limit values: free chlorine < 0.5 ppm, chlorine ions < 200 ppm, sulfate < 100 ppm,
ammonia < 10 ppm, free CO < 10 ppm, pH 7-10.
The following ions do not have a corrosive effect under normal conditions: phosphate,
nitrate, nitrite, iron, manganese, sodium, potassium.
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 contents of the cooling
medium.
• Special procedures are required when sea water or brackish water is used. Consult
SEW-EURODRIVE.
INFORMATION
Observe the additional manufacturer's documentation.

Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC 13
2
Notes on checking the oil level
Oil-water cooler for splash lubrication /OWC
2.3.4 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 installation but without electrical connections and piping. 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-EURO-
DRIVE.
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 selecting
pipes, hoses and screw fittings. Preferably use composite material seals for screw
fittings.
SEW-EURODRIVE recommends the following cable cross sections for connecting the
cooling system to the gear unit and the cooling circuit:
2.4 Notes on checking the oil level
Using an oil supply system might influence the oil level (page 16). The fill quantities
specified on the nameplate are guide values and refer only to the gear unit. The mark
on the oil sight glass, oil level glass or oil dipstick is the decisive indicator for the correct
oil level.
Observe the chapter "Checking the oil level" in the operating instructions for the X.. Se-
ries Industrial Gear Units.
Size
Cooling sys-
tem
Pump suction
connection Suction pipe1) Cooler pressure connection Pressure pipe2) Cooling water
connection of
cooler
Inner Ø of the
cooling water
line
OWC 005 GE22-LR 3/4” DN20 / Ø22 GE18-LR 1/2" DN16 / Ø18 G3/4" Ø25
OWC 010 GE22-LR 1/2” DN20 / Ø22 GE18-LR 1/2" DN16 / Ø18 G1/2“ Ø13
OWC 015 GE28-LR 1" DN25 / Ø28 GE22-LR 3/4” DN20 / Ø22 G3/4" Ø25
OWC 020 GE35-LR 1 1/4" DN32 / Ø35 GE28-LR 1" DN25 / Ø28 G1/2“ Ø19
OWC 025 GE35-LR 1 1/4" DN32 / Ø35 GE28-LR 1" DN25 / Ø28 G3/4" Ø25
OWC 030 GE35-LR 1 1/4" DN32 / Ø35 GE28-LR 1" DN25 / Ø28 G1" Ø25
OWC 040 GE42-LR 1 1/2” DN40 / Ø42 GE35-LR 1 1/2" DN32 / Ø35 G3/4" Ø25
OWC 050 GE42-LR 1 1/2” DN40 / Ø42 GE35-LR 1 1/2" DN32 / Ø35 G1 1/4" Ø32
OWC 060 SAE 2" SFL DN50 / Ø2" GE42-LR 1 1/2” DN40 / Ø42 G1 1/2" Ø38
OWC 070 SAE 2 1/2“ SFL DN50 / Ø2" GE42-LR 1 1/2” DN40 / Ø42 G1" Ø38
1) max. length 1.5 m
2) max. length 2.5 m
INFORMATION
For dimensions of the oil-water cooler, refer to the catalog. Detailed technical data of
the various cooling systems is available from SEW-EURODRIVE on request.

14 Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC
2Startup
Oil-water cooler for splash lubrication /OWC
2.5 Startup
2.5.1 Notes
• Before taking the gear unit into operation for the first time, run the oil-water cooling
system at least 15 minutes to ensure that all oil chambers are filled with oil. After 15
minutes, shut down the oil-water cooler and check the oil level. If necessary, adjust
the oil level.
• If there is a risk of frost and the oil-water cooler is not operated for an extended time,
drain the cooling water.
• The operator/ordering party must provide for the necessary water connections.
2.5.2 Venting the motor 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 oil supply system on the pressure side during start, if possible at the highest
point.
NOTICE
Improper startup of gear units with oil-water cooling systems can damage the gear unit
or the oil-water cooling system.
Possible damage to property.
• Note the following:
WARNING
Danger due to leaking and squirting gear unit oil.
Serious injury.
• You must wear safety goggles.
• Be very careful when you vent the motor pump.

Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC 15
2
Inspection/maintenance
Oil-water cooler for splash lubrication /OWC
2.6 Inspection/maintenance
2.6.1 Inspection and maintenance intervals
Adhere to the following inspection and maintenance intervals.
2.6.2 Check hose pipes
• 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 replaced
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 operational
safety.
Time interval What to do?
• Depending on the operating con-
ditions, at least every 12 months • Check the condition of the oil-water cooler /OWP. If neces- sary, replace the filter element.
• Varying (depending on external
factors) • Check all hose pipes for any leaks
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.
Possible damage to property.
• Note the following:

16 Addendum to the Assembly and Operating Instructions – Oil-Water Cooler for Splash Lubrication
/OWC
2Lubricant fill quantities
Oil-water cooler for splash lubrication /OWC
2.7 Lubricant fill quantities
The following table shows the lubricant fill quantity which has to be filled into the gear
unit additionally for the oil supply system (OSS).
2.8 Malfunctions
Size Fill
quantity
OSS
max. fill quantity
Suction pipe (1.5 m) max. fill quantity Pressure pipe (2.5 m) max. Total oil
quantity
[l] [DN]1)/[mm]2)
1) Size of hose pipes
2) Outer diameter of pipes
[l] [DN]1)/[mm]2) [l] [l]
OWC 005 1.5 DN20 / Ø 22 0.5 DN16 / Ø 18 0.5 2.5
OWC 010 1.5 DN20 / Ø 22 0.5 DN16 / Ø 18 0.5 2.5
OWC 015 2.7 DN25 / Ø 28 0.8 DN20 / Ø 22 0.8 4.5
OWC 020 2.7 DN32 / Ø 35 1.2 DN25 / Ø 28 1.3 5.5
OWC 025 3.0 DN32 / Ø 35 1.2 DN25 / Ø 28 1.3 5.5
OWC 030 3.0 DN32 / Ø 35 1.2 DN25 / Ø 28 1.3 5.5
OWC 040 3.0 DN40 / Ø 42 1.8 DN32 / Ø 35 2.0 7.0
OWC 050 3.0 DN40 / Ø 42 1.8 DN32 / Ø 35 2.0 7.0
OWC 060 4.0 DN50 / Ø 2'' 3.0 DN40 / Ø 42 2.9 10.0
OWC 070 4.0 DN50 / Ø 2'' 3.0 DN40 / Ø 42 2.9 10.0
Malfunctions Possible cause Remedy
No oil pump suction
• Air in the pipes
• Motor not running
• Wrong direction of rotation of the
motor
• Not enough oil in the gear unit
• Wrong oil grade
• Fill suction pipe and oil pump with oil
• Vent pressure pipe on startup
• Check electrical connections
• Check electrical connections
• Check oil level in gear unit
• Check oil grade (in particular when temperatures are low)
Delivery rate of oil pump not
sufficient
• Wrong motor speed
• Oil circulation clogged
• Negative pressure at pump suction
side too high
• Wrong oil grade
• Check pump motor speed
• Open valves and plugs
• Increase cross section of suction line
• Decrease suction lift
• Check oil grade (in particular when temperatures are low)
Pump excessively loud • Negative pressure at pump suction
side too high
• Increase cross section of suction line
• Decrease suction lift
• Avoid distortion of the suction line
• Avoid reductions in the suction pipes
The pump delivers foam • Leaky suction line
• Not enough oil in the gear unit • Check screw fittings for leaks • Check oil level in gear unit
Cooling capacity is not
reached • Cooling water supply closed • Cooler dirty • Check supply line • Clean the cooler

Limit temperature for gear unit start
Limit temperature for gear unit start
The minimum permitted ambient temperature / oil temperature for gear unit starting de-
pends on the viscosity of the oil used and the lubrication type of the gear unit.
Mineral oil
Lowest permissible starting temperature for the gear unit
Synthetic oil
Lowest permissible starting temperature for the gear unit
NOTICE
Starting up the gear unit below the permitted minimum oil temperature may damage
the unit.
Possible damage to property.
• Adhere to the specified starting temperatures for gear units.
INFORMATION
The following tables show the limit temperatures (minimum ambient temperatures) for
gear unit startup without oil heater. Gear units and oil supply systems with heating el-
ements can be heated to the required starting temperature if ambient temperatures
are too low.
Lubrication type Design Lubricants
ISO VG320 ISO VG220 ISO VG150
Splash lubrication
Oil bath lubrication Initial temperature for gear unit start (minimum permitted oil bath temperature) -12 °C -15 °C -20 °C
Pressure lubrication
with
Shaft end pump
Initial temperature for gear unit start
(minimum permitted oil bath temperature) +5 °C 0 °C -5 °C
Pressure lubrication
with
motor pump
Initial temperature for gear unit start
(minimum permitted oil bath temperature) +15 °C +10 °C +5 °C
Lubrication type Design Lubricants
ISO VG320 ISO VG220 ISO VG150
Splash lubrication
Oil bath lubrication Initial temperature for gear unit start (minimum permitted oil bath temperature) -25 °C -25 °C -25 °C
Pressure lubrication
with
Shaft end pump
Initial temperature for gear unit start
(minimum permitted oil bath temperature) -5 °C -8 °C -15 °C
Pressure lubrication
with
motor pump
Initial temperature for gear unit start
(minimum permitted oil bath temperature) +8 °C +3 °C -3 °C
INFORMATION
The specified temperatures refer to the average values of the permitted lubricants
based on the lubricant table. In borderline cases, the permitted temperature of the lu-
bricant that is actually being used must be verified. When planning the motor, observe
the increased starting torque at low temperatures. It may be necessary to contact
SEW-EURODRIVE.

Drive Technology \ Drive Automation \ System Integration \ Services
3.0 Documentation of Suppliers

Öl aus / oil out G 1/2
Öl ein / oil in G 3/4
Wasser in / water in G 3/4
Wasser aus / water out G 3/4
Plattenwärmetauscher / Oil water cooler BWT B10x030
Förderpumpeneinheit / Circulation pump BFP 8-4-0,75 kW
SEW-Nr. 13318055 Spannung / voltage 230/400V 50Hz ± 5% 276/480V 60Hz ± 5%
8 l/min
M
water

Bezeichnung/designation Artikelnr./article no.
Ersatzteilliste / Ölversorgungsanlage OWC 005-0/M Spare parts list / Oil supply OWC 005-0/M 27SEWOWC0050M
Motorspannung / motor voltage 230/400V 50Hz ± 5% 276/480V 60Hz ± 5%
4x
4x
2x
2x
1
2
3
4
7
5
6
Pos. Art.-Nr. / part no Bezeichnung / designation 1 9009303 O-Ring 2 9009202 Simmerring / rotary shaft seal 3 37ET011 Wellenadapter / shaft adapter 4 9009301 O-Ring 5 37MT075804 Motor / motor 6 3410030 Plattenwärmetauscher / oil water cooler 7 37PU08075 Pumpenkopf komplett / pumphead complete