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France SARL
1,Rue Pelloutier
F-77183 Croissy
Beaubourg
Tel+33.1.64114450
Fax+33.1.64114469
info.fr@seepex.com
www.seepex.com
Commission-no. Type
238543 BE 70-12
Original Instructions
Issue 28.04.2010
Index
1 Safety................................................................................................................................................... 1
1.1 General notes
1.2 Safety and warning notes
1.2.1 Warning notes
1.2.2 Danger symbols
1.2.3 Information symbols
1.3 Dangers that can be caused by the machine
1.4 Qualification of the personnel
1.5 Authorised people
1.5.1 Tasks and information for the owner/operators
1.5.2 Safety notes for maintenance, inspection and assembly work
1.6 Personal protective equipment
1.7 Safety and protective devices
1.8 Foreseeable misuse
1.9 Designated use
1.10 Warranty
4 Transport........................................................................................................................................... 11
4.1 Safety
4.2 Transport
4.2.1 Dimensions, weight and centre of gravity
4.2.2 Symbol
4.2.3 Lashing points (AP) for lifting devices
4.2.4 Unpacking the machine
4.3 Temporary storage/corrosion protection
4.4 Disposal
Index
6 Commissioning / De-Commissioning............................................................................................. 16
6.1 Commissioning report............................................................................................................ 16
6.2 Measures before commissioning............................................................................................ 17
6.2.1 Checking pipelines
6.2.2 Protective devices on the pump
6.2.3 Electrical / hydraulic connections
6.2.4 Direction of rotation check
6.2.5 Additional devices - optional
6.3 Initial commissioning/repeated commissioning
6.3.1 Avoiding dry running of the pump
6.3.2 Pressure in the suction and pressure connection
6.4 De-commissioning
6.4.1 Switching off the pump
6.4.2 Emptying the pump
6.4.3 Dismantling the pump
6.4.4 Preservation/storage of the pump
7 Maintenance...................................................................................................................................... 21
7.1 Preventative measures
7.1.1 Pump down-time
7.2 Lubrication
7.2.1 Joint grease
7.3 Inspection
10 Spare parts........................................................................................................................................ 60
10.1 Order template for spare parts............................................................................................... 61
10.2 Sectional drawing and parts list.............................................................................................. 63
11 Special tools...................................................................................................................................... 67
11.1 Order template for special tools
12 Related documents........................................................................................................................... 68
12.1 Accessories ............................................................................................................................ 69
12.2 Technical Information............................................................................................................. 70
12.3 Manufacturer's documents shaft seal..................................................................................... 73
13 Appendix ........................................................................................................................................... 74
13.1 Manufacturer's documents / suppliers
13.1.1 gearbox...................................................................................................................... 75
13.1.2 Motor ....................................................................................................................... 167
Subsidiaries
1
Safety
1.1 General notes
Always keep the operating and maintenance instructions close by the machine.
If problems cannot be solved with reference to the operating and maintenance instructions,
please contact the manufacturer.
Observe the following points in addition to these operating and maintenance instructions:
• Prohibition, warning and mandatory signs, warning notes on the machine
• Relevant laws and ordinances
• Statutory provisions on accident prevention
• Corresponding harmonised standards and regulations
NOTICE
Caution for machine!
Possible danger.
Material damage can occur.
CAUTION
WARNING
DANGER
NOTICE
Wear gloves.
Instruction to act/take measures
• List item
Detailed technical knowledge is essential for performing any work on the machine.
sc Scharnhölzstraße 344
46240 Bottrop
Telefon +49.2041.996-0
Fax +49.2041.996-400
direction of
rotation
Kommissions-Nr. Typ
commission no. type
Similar illustration
1.10 Warranty
• Warranty in accordance with our terms and conditions of delivery and order confirmation.
• It is a condition of the machine warranty that the machine must correspond to the listed op-
erating instructions in accordance with the type plate/data sheet.
• All wearing parts are excluded from the warranty.
• These operating instructions are subject to copyright. Reproduction is not permitted and will
be punished. Contravention will be pursued through the courts.
No. Designation
ANT Drive
200 Lantern
307 Plug-in shaft
400 Coupling rod
SEA Shaft seal
500 Suction casing
600 Rotor
RTE Rotating unit
601 Stator
700 Pressure branch
Tel +49.2041.996-0
seepex Fax +49.2041.996-400
order no. P89424/2009 commission no. 238543 info@seepex.com
date 18.12.09 offer no. 2101/1687-4 001 www.seepex.com
K91258-13
customer PA Ressources
purchase order no. Cde dze-157-09 item/denomination
project
Rechtsform Geschäftsführender
GmbH Gesellschafter:
HRB 9350 Gelsenkirchen Ulli Seeberger
7
sc
Data Sheet 238543 Page 2
seepex GmbH
Postfach.PO Box 10 15 64
46215 Bottrop
Scharnhölzstraße 344
46240 Bottrop
Germany
Tel +49.2041.996-0
Fax +49.2041.996-400
info@seepex.com
www.seepex.com
general operating data
kind of operation continuous operation - 8 h/day
site of installation indoor
remarks
drive
type gear
make SEW ratio i=12,390
model RF97 AM180
mounting position IMV1 nom./ min- max
flange dia 350 mm output speed 141/ - rpm
output shaft 716/0700-002B4 motor speed 1740/ - rpm
frequency 60/ - Hz
electric motor
make HEW Herforder Elektr model DEx 180M/4K
nominal power 21,0 kW voltage 3 x 460 VAC V
nominal speed 1740 rpm rated frequency 60 Hz
mounting position IMV1 protection IP55
starting direct on line thermal class F
size 180
flange/shaft dia 350 / 48 mm
ex-protection EEx deIICT4
provid. of motor HEW fitting of motor seepex BOT
special/accessories with 3 PTC thermistors
baseplate
standard KRANBÜGEL material St52-3
drawing no. 824-200/0700-C-004A1 surface varnished
special/accessories
painting
execution standard
colour RAL 5013 (blue)
remarks
packing
packing type
marking
documentation
dimensional drawing no. 271-G34/0700-C-001D2 operating manual 1 copy french
sectional drawing no. 071-K238-543A1 1 copy English
shaft sealing sect.view 271-0GB/0700-0-081B3
QA-documentation
CE-sign
Rotor / Stator test record
special design:
The pump is dismountable in 5 sections as per drawing-no.: ...
Rechtsform Geschäftsführender
GmbH Gesellschafter:
HRB 9350 Gelsenkirchen Ulli Seeberger
8
9
seepex GmbH
Scharnhölzstraße 344
46240 Bottrop
Postfach 10 15 64
46215 Bottrop
PO Box 10 15 64
EC declaration of conformity 46215 Bottrop
according to Machinery Directive 2006/42/EC, Annex II A Germany
Tel +49.2041.996-0
Fax +49.2041.996-400
info@seepex.com
www.seepex.com
Type: BE 70-12
The product also meets all the provisions of the following directives:
Bottrop, 28.04.2010
Rechtsform: Geschäftsführender
GmbH Gesellschafter:
HRB 9350 Gelsenkirchen Ulli Seeberger 10
4
Transport
4.1 Safety
CAUTION
4.2 Transport
4.2.2 Symbol
• Meaning of symbol
WARNING
AP AP
NOTICE
Damage to property if corrosion protection is missing.
Property damage can occur due to corrosion.
Temporary storage must be in a dry, enclosed, frost-free room in order to provide protec-
tion against ambient influences.
Contact seepex regarding the necessary corrosion protection for temporary storage.
4.4 Disposal
NOTICE
Environmental protection.
Material damage can occur.
Drain the pumping medium and dispose of it in accordance with the regulations.
Dispose of the machine with regard to its composition and existing regulations.
CAUTION
P A
B When changing the stator, provide
suspension points above the stator
A
CAUTION
DANGER
5.5 Pipelines
• Refer to the dimensional drawing for position, nominal width and standard.
• Note the direction of rotation/flow direction.
NOTICE
Damage to property through assembly residue.
No claims under guarantee if violated.
Keep all pipelines free from foreign objects.
Remove weld spatter, screws, steel chips, etc.
Delivery date:
Date of installation:
Assembly check carried out on:
Frequency control no
yes If yes:
Supplied by seepex
Supplied by customer
Frequency:
Speed:
Power
consumption:
________________________________ _______________________________________
Place, date Signature / company stamp
NOTICE
Ensure the liquid can flow through without obstruction.
Malfunction and/or irreparable damage to the pump.
Open all shut-off elements before switching on the pump.
DANGER
DANGER
Dangerous voltage.
Death or serious injury can occur.
Observe safety regulations.
Disconnect the pump from all sources of energy.
Prevent electrical connections from being switched on again.
NOTICE
Dry running of the pump.
Malfunction and/or irreparable damage to the pump.
Fill the suction casing with liquid in order to lubricate the pumping elements.
NOTICE
High temperature between rotor and stator.
Stator material burned.
Complete failure of the pump
Make sure that the suction-side conveying capacity does not cavitate.
If this cannot be guaranteed on the machine side, assemble a seepex dry running
protection (DRP)
CAUTION
High pressure.
Malfunction and/or irreparable damage to the shaft seal or pump.
Maintain pressure in the suction connection in accordance with the technical data
(chapter 3.).
Assemble an oil-filled contact pressure gauge to monitor and deactivate the pump.
6.4 De-commissioning
Protect the pump and additional devices against the following:
• Frost
• Deposit of solids
• Sedimentation from the liquid
• Corrosion of parts that come into contact with the medium
DANGER
Dangerous voltage.
Death or serious injury can occur.
Observe safety regulations.
Disconnect the pump from all sources of energy.
Prevent electrical connections from being switched on again.
CAUTION
WARNING
Pipeline dismantling
SCH
SCH
NOTICE
Damage to property due to lack of corrosion protection.
Property damage can occur due to corrosion.
Contact seepex to discuss suitable preservation measures.
– State the commission number of the pump.
The maintenance personnel must have these operating instructions, follow them and also
require corresponding qualifications.
• No liability will be accepted in the event of violation.
DANGER
Dangerous voltage.
Death or serious injury can occur.
Observe safety regulations.
Disconnect the pump from all sources of energy.
Prevent electrical connections from being switched on again.
NOTICE
Pump down-time.
Production failure due to wear.
Acquisition of a set of wearing parts and a set of gaskets.
7.2 Lubrication
1 2 3
NOTICE
Other grease types.
Malfunction and/or irreparable damage to the joints or the pump.
Exclusively use seepex special grease.
7.3 Inspection
9.1.1 Assembly/reassembly
WARNING
Tool (W103/Haltewerkzeug)
FEH W103
9.1.1.3 Conveyor unit (FEH), coupling rod (482)/intermediate element (534) - assembly
W104
534
539
W103 535
540
541
534
W104
540
534 541
536
W104
542
540
536
541
537
W104
540
537
541
TR2
W106
534
W104
400
489 539
480
483 W102
480 W107
540
534
541
W106
307 310
307
489
483
400
9.1.2 Dismantling
ANT
307
Dismantle threaded bushing (489) from
489
coupling rod (400) and plug-in shaft (309).
483
400
MH 200 ANT
ML
534
W104
W104
400
W106
W104
534
W104
W104
W106
W104
537
W104
W104
537
480
542
W106
W104
536
W104
W104
481 536
W106
W104
534
W104
FEH
W104
ML
W104
W103
9.2.1 Dismantling
CAUTION
Risk of injury.
Possibility of parts spinning out.
Wear protective goggles.
Tool (W5/drift)
403 402
NOTICE
Malfunction of the joints.
Malfunction and/or destruction of joints.
Replace the coupling rod pins (402) and guide bushings (403) jointly.
Rotor (600)
Tool (W5/drift)
Tool (W5/drift)
Correct
Incorrect
0°
band loop (SCL).
.6
ca
SCL
NOTICE
Universal joint sleeve damage.
Pin joint grease can emerge.
9.4.1 Safety
WARNING
9.4.3 Design
• Single acting mechanical seal
307
SEA
333
9.4.4 Commissioning
NOTICE
Dry running of the mechanical seal.
Damage to property may result.
The mechanical seal must be laid in liquid medium before being commissioned.
NOTICE
Shaft seal is not leakage free.
Damage to property through leakage.
Components which come into contact with leakage must be corrosion-resistant or other-
wise suitably protected.
NOTICE
Shaft wear.
Damage to property may result.
Conduct a daily visual inspection. 307
Install a new shaft seal (SEA).
Possibly replace the plug-in shaft (307).
SEA
333
Spare parts can be ordered online or requested from Type: BE 1-6 to 202-6L
www.seepex.com\
Request Order Sender:
__________________________________ _______________________________________
Place, date Signature / company stamp
Set of gaskets
Pumping elements
600 Rotor
601 Stator
Miscellaneous parts
__________________________________ _______________________________________
Place, date Signature / company stamp
Ausgabe Dokument Blatt
issue
C / 02.02.2010 document
OM.WPS.19e sheet
2 (2)
62
63
Stückliste
Parts List
Liste des pièces
DE EN FR
Baureihe BE range BE série BE
Schnittzeichnung Nr. sectional drawing No. plan no.
071-K238-543_2 071-K238-543_2 071-K238-543_2
Benennung denomination désignation
Stck. Pos. Stck. / Pos. Qty. / Item Qté. / Poste
1 200 Laterne lantern lanterne
2 202 Halbrundkerbnägel round head grooved pins rivet
1 203 Typenschild type plate palque signalitique
4 210 6kt-Schraube hexagon bolt vis
4 212 Fächerscheibe fan type lock washer rondelle à dents chevauchantes
extérieures
4 213 6kt-Mutter hexagon nut écrou
1 307 Steckwelle plug-in shaft arbre à broche
1 309 Steckwellenbolzen plug-in shaft pin cheville pour arbre à broche
1 310 Spritzring splash ring bague de projection
1 330 Gleitringdichtung mechanical seal garniture mécanique
1 400 Kuppelstange coupling rod barre d' accouplement
2 480 Kuppelstange coupling rod barre d' accouplement
1 481 Kuppelstange coupling rod barre d' accouplement
1 482 Kuppelstange coupling rod barre d' accouplement
20 483 Zylinderschraube socket screw vis à tête cylindrique
5 489 Gewindebuchse threaded bushing filetage
6 490 6kt-Schraube hexagon bolt vis
6 491 Scheibe washer rondelle
6 492 Federring spring washer rondelle frein
6 493 6kt-Mutter hexagon nut écrou
1 500 Druckgehäuse pressure casing carter de refoulement
1 501 O-Ring o-ring joint torique
1 502 Verschlussschraube screwed plug bouchon de vidange
1 503 Dichtring sealing ring joint d’étanchéité
4 506 Stiftschraube stud bolt boloun fileté
4 507 Federring spring washer rondelle frein
4 509 6kt-Mutter hexagon nut écrou
2 534 Zwischenelement intermediate element carter intermédiaire
1 535 Zwischenelement intermediate element carter intermédiaire
1 536 Zwischenelement intermediate element carter intermédiaire
1 537 Zwischenelement intermediate element carter intermédiaire
5 538 O-Ring o-ring joint torique
30 539 6kt-Schraube hexagon bolt vis
30 540 Federring spring washer rondelle frein
30 541 6kt-Mutter hexagon nut écrou
1 542 Kunststoffring synthetic material ring anneau de plastique
1 600 Rotor rotor rotor
1 601 Stator stator stator
6 602 Spannschraube tie bolt tirant
12 604 6kt-Mutter hexagon nut écrou
12 606 Scheibe washer rondelle
1 700 Saugstutzen suction branch bride d’aspiration
6 702 Abstandsbolzen distance pin cheville de distance
1 3000 Quench quench quench
siehe Zusatzeinrichtung see optional extras voir accessoire
Blatt ZU.021.01 sheet ZU.021.01 feuille ZU.021.01
DE EN FR
Baureihe BE range BE série BE
Schnittzeichnung Nr. sectional drawing No. plan no.
071-K238-543_2 071-K238-543_2 071-K238-543_2
Benennung denomination désignation
Stck. Pos. Stck. / Pos. Qty. / Item Qté. / Poste
Verschleißteile und Dichtungen: Wear parts and sealings: pièces d'usure et étanchéités:
Betriebs- und see Operating and voir Instructions de service et
Wartungsanleitung entnehmen Maintenance Instruction d'entretien
Werkzeuge: Tools: Outils:
Betriebs- und see Operating and voir Instructions de service et
Wartungsanleitung entnehmen Maintenance Instruction d'entretien
siehe Schnittzeichnung see sectional drawing voir vue éclatée
Gleitringdichtung mechanical seal garniture mécanique
versetzt gezeichnet drawn displaced plan separé
.......................................................................
Universal joint
For installation of: Packing gland Stator
sleeve
Dismantling
Denomination: Mounting tool Drift
Tool
Order no. MHB MTD AZV
Ausgabe / issue
H / 10.11.04
Blatt / sheet
1 (1)
Information:
Eine GLRD wird gequencht bei Medien die zu Kristallisati on an den Gleitflächen neigen,
bzw. adhäsiv sind. Desweiteren ist Quenchung bei Vakuum Betrieb zur Vermeidung von
Trockenlauf erforderlich. Die Quenchflüssigkeit muss mit dem Fördermedium verträglich
und auf die Werkstoffe der GLRD abgestimmt sein.
Achtung: Quenchflüssigkeit drucklos fahren, max 0,1 - 0,15 bar.
Bei größerem Druck Ausrücksicherung für E
Wellendichtring erforderlich, siehe HA.RDO.02.
Information:
A mechanical seal is quenched, when the medium (product) tends to crystallization at the seal
faces, or when it is adhesive. Moreover, quenching is necessary during vacuum -operation to avoid
dry-running. The quench liquid must be compatible with the pumped product and with the selected
material of the mechanical seal.
Attention: Quench liquid is used pressureless, max 0,1 - 0,15 bar.
Regarding higher pressure, a disengaging device is required for the shaft sealing ring, see
HA.RDO.02.
2a
A
3a
Ausgabe / issue
E / 19.11.08
Blatt / sheet
1 (3)
1 Scope
2 Description
Moisten exposed surfaces of the drive shaft with corrosion inhibitor/spray wax.
2.1.4 Gear
70
Long term preservation of Dokument / document
seepex Progressive cavity pumps TI.114.01e
Ausgabe / issue
E / 19.11.08
Blatt / sheet
2 (3)
2.1.5 Motor
By the turn of the fan shaft (see point 2.1.2) a protection of the bearing in the motor is
obtained at the same time.
2.1.6 Recommissioning
NOTICE
In case of the correct storage and under consideration of the preservation measures, a
storage of the pump is possible for max. 2 years.
NOTICE
In case of a longer storage period, the dimensions and shore hardness can change.
The function of the pump can be impaired.
Bevor recommissioning Elastomere parts (stator, joint seal, gaskets, ...) have to be
checked for crack formation and change of the surface.
Moisten exposed surfaces of the drive shaft with corrosion inhibitor/spray wax.
71
Long term preservation of Dokument / document
seepex Progressive cavity pumps TI.114.01e
Ausgabe / issue
E / 19.11.08
Blatt / sheet
3 (3)
2.2.4 Gear
2.2.5 Motor
2.2.6 Recommissioning
NOTICE
4 Alteration service
This document is subject to the alteration service of the engineering department (TE) and ist
relevant valid issue is released by the quality assurance (QA). All alteration requests are
handled and checked by engineering.
72
Dokument
document BA.BUR.01e
BURGMANN Mechanical Seals Blatt
sheet 1 (1)
Instructions for installation and
Datum
operation date 08.07.98
Safety recommendations
Please read these instructions carefully.
Contact BURGMANN if any points are unclear.
Burgmann mechanical seals are precision-made, tested machine elements, special knowledge is
required to operate them correctly.
Pay due attention to the rules and regulations governing occupational safety, accident prevention,
working with hazardous materials and normal usage.
Before carrying out any work on a mechanical seal, make sure that the system has been shut down,
is no loger pressurized and has cooled off. Conversions and changes to the seal are prohibited (seal
failure, loss of warranty rights). Use original BURGMANN spare parts only. For your own safety, any
repairs should be carried out by BURGMANN.
General procedures
• clean the seal compartment and examine for signs of damage. Check the installation and
connection dimensions. Check the accuracy of the axial and radial run-out tolerance between the
shaft and the casing.
• The shaft surface in the areas of dynamically loaded sealing elements (e.g. O-ring) should display
a roughness depth of Rmax = 5 µm. Sealing surfaces for statically loaded O-rings are to be
manufactured with a value of Rz = 10 µm or better.
• Any edges, shoulders and transitions which come into contact with the sealing elements (e.g.
O-rings) during installation should be sufficiently chamfered or rounded off (e.g. 2 mm x 30° or in
accordance with DIN 24960)
• Assemble under extra-clean conditions and with great care. Use no force! This could result in
permanent deformations and broken ceramic parts.
• The sequence of steps for installing and dismantling a mechanical seal depends on the design of
the machine in question.
To reduce friction during assembly, wet all sliding surfaces for the O-rings with water or alcohol or
lubricate with silicone grease.
• Note special instructions for storing and handling elastomer parts.
• Keep elastomer parts made of EP rubber away from lubricants based on mineral oil.
• When installing double PTFE-wrapped sealing rings, make sure that the joint of the outer sheath
points away from the direction of assembly (A). Sharp bending of the PTFE foil will destroy the
O-ring.
• Take plenty of time and use little force when assembling O-rings made of solid PTFE in order to
avoid damage to other seal elements.
• Never apply lubricant to seal faces. Assemble in a completety dry, dust-free and clean condition.
Special procedures
Series M2, M3
Mechanical seals with conical springs are dependent on the direction of rotation. A clockwise rotating
shaft requires a right-handed spring and vice versa (looking from the drive side). To ease fitting, push
the conical spring onto the shaft whilst twisting the spring in the direction of its hand of coiling.
Series MG
Elastomer bellows seals are to be pushed onto the shaft using low-surface-tension water (addition of
a detergent) and a screwing movement. Use no oil or grease! Apply pressure only on the corner rings.
When you are finished with the assembly, check that the corner rings, the spring and the seal face fit
correctly.
Series M7, HJ
Independent of the direction of rotation. Secure drive screws by applying Loctite 241
Series MFL
Never compress a metal bellows seal to its solid height.
Push the seal onto the shaft by applying force only to the bellows carrier, which is sealed with an
O-ring. Evenly and gradually tighten any compression screws in sequence, maintaining an even gap
between the compression ring and the drive collar.
Seals with a pumping screw
(e.g. M7F, M74F-D) are dependent on the direction of rotation. Note drawing specifications!
Operation
A Properly operated mechanical seal requires no maintenance but is subject to a certain wear.
Single seals in tight compartments may require a suitably piped circulation of pumped medium across
them to dissipate heat. Evacuate the air from the compartment carefully before putting into operation.
Make sure the seal is completely immersed in liquid (or there will be a risk of dry running!)
Declaration
for the purposes of the EC Machine Guideline, Annex IIB.
Mechanical seals are intended for installation in, or assembly with, other machines and are unable to
function independently. Operation of a mechanical seal is only permitted when the machine in
question meets the requirements of the EC Machine Guideline (89/392/EEC). Applied harmonized
standards: EN292 Part 1 + Part 2.
Form 1081/11.97.02
73
13
Appendix
13.1 Manufacturer's documents / suppliers
• available
SPIROPLAN® W
Edition 05/2004
11226811 / EN Operating Instructions
75
SEW-EURODRIVE – Driving the world
76
Contents
1 Important Notes................................................................................................. 4
2 Safety Notes ...................................................................................................... 6
3 Gear Unit Structure ........................................................................................... 9
3.1 Basic structure of helical gear units .......................................................... 9
3.2 Basicstructure of parallel shaft helical gear units.................................... 10
3.3 Basic structure of helical-bevel gear units .............................................. 11
3.4 Basic structure of helical-worm gear units .............................................. 12
3.5 Basic structure of SPIROPLAN® gear units ............................................ 13
3.6 Nameplate, unit designation ................................................................... 14
4 Mechanical Installation................................................................................... 15
4.1 Required tools / aids ............................................................................... 15
4.2 Prerequisites for assembly...................................................................... 15
4.3 Installing the gear unit............................................................................. 16
4.4 Gear unit with solid shaft......................................................................... 19
4.5 Torque arms for mounted gear units....................................................... 21
4.6 Mounted gear unit with keyway or splined hollow shaft .......................... 23
4.7 Mounted gear units with shrink disc........................................................ 27
4.8 Mounted gear units with TorqLOC® ........................................................ 30
4.9 AM adapter coupling ............................................................................... 36
4.10 AQ adapter coupling ............................................................................... 38
4.11 AD input shaft assembly ......................................................................... 40
5 Startup.............................................................................................................. 44
5.1 Startup of helical-worm and SPIROPLAN® W gear units........................ 44
5.2 Startup of helical, parallel shaft helical and helical-bevel gear units....... 44
6 Inspection and Maintenance .......................................................................... 45
6.1 Inspection and maintenance intervals..................................................... 45
6.2 Lubricant change intervals ...................................................................... 45
6.3 Inspection and maintenance of the gear unit .......................................... 46
6.4 Inspection / maintenance of AM / AQA adapters .................................... 47
6.5 Inspection / maintenance of AD adapters ............................................... 47
7 Malfunctions .................................................................................................... 48
7.1 Gear unit malfunctions ............................................................................ 48
7.2 AM / AQA / AL adapter malfunctions ...................................................... 48
7.3 AD input shaft assembly malfunctions .................................................... 49
8 Mounting Positions......................................................................................... 50
8.1 General information on mounting positions ............................................ 50
8.2 Key to the mounting position sheets ....................................................... 51
8.3 Mounting positions for R helical gearmotors........................................... 52
8.4 Mounting positions of RX helical gearmotors.......................................... 55
8.5 Mounting positions for parallel shaft helical gearmotors ......................... 57
8.6 Mounting positions for helical-bevel gearmotors..................................... 60
8.7 Mounting positions for helical-worm gearmotors .................................... 65
8.8 Mounting positions for SPIROPLAN® W gearmotors.............................. 71
9 Lubricants........................................................................................................ 74
9.1 Lubricant table ........................................................................................ 74
9.2 Lubricant fill quantities ............................................................................ 77
10 Appendix.......................................................................................................... 82
10.1 Index of changes..................................................................................... 82
11 Index................................................................................................................. 83
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 773
Important Notes
1
1 Important Notes
Operating instructions
Safety and Always follow the safety and warning instructions in this publication!
warning
instructions
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.
• Adjust the lubricant fill volume and position of the breather valve accordingly in the
event of a change of mounting position (see Sec. "Lubricants" and "Mounting
Positions").
• Follow the instructions in Sec. "Mechanical installation" / "Installing the gear unit"!
4 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 78
Important Notes
1
Waste disposal Please follow the latest instructions: Dispose of the following materials in accordance
with the regulations in force:
• Steel scrap:
– Housing parts
– Gears
– Shafts
– Anti-friction bearing
– Gray-cast iron (if there is no special collection)
• Parts of the worm gears are made of non-ferrous metals. Dispose of the worm gears
as appropriate.
• Collect waste oil and dispose of it correctly.
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 5
79
Safety Notes
2
2 Safety Notes
Preface The following safety notes are primarily concerned with the use of gear units. If using
gearmotors, please also refer to the safety notes for motors in the relevant operating
instructions.
Please also consider the supplementary safety notes in the individual sections of
these operating instructions.
General During and after operation, gearmotors, gear units and motors have:
information • Live parts
• Moving parts
• Hot surfaces (may be the case)
Only qualified personnel may carry out the following work:
• Transportation
• Putting into storage
• Installation / assembly
• Connection
• Startup
• Maintenance
• Servicing
The following information and documents must be observed during these processes:
• Relevant operating instructions and wiring diagrams
• Warning and safety signs on the gear unit / gearmotor
• System-specific regulations and requirements
• National / regional regulations governing safety and the prevention of accidents
Serious injuries and property damage may result from:
• Improper use
• Incorrect installation or operation
• Unauthorized removal of necessary protection covers or the housing
Designated use Gearmotors / gear units from SEW are intended for industrial systems. They correspond
to the applicable standards and regulations.
Technical data and information about the permitted conditions can be found on the
nameplate and in the documentation.
It is essential that you follow all the instructions!
6 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 80
Safety Notes
2
Transportation Inspect the shipment for any damage that may have occurred in transit as soon
as you receive the delivery. Inform the shipping company immediately. It may be
that you are not permitted to startup the drive due to the damage.
Tighten installed eyebolts. The eyebolts are only designed for the weight of the
gearmotor / gear unit. Do not attach any additional loads.
The installed lifting eyebolts comply with DIN 580. The loads and regulations specified
in this standard must always be observed. If two eyebolts are available, use both of them
for transport. In this case, the tension force vector of the slings must not exceed a 45°
angle in accordance with DIN 580.
Use suitable, sufficiently rated handling equipment if necessary. Remove any
transportation fixtures prior to startup.
Comply with the storage conditions specified in the following table for extended storage:
Climate zone Packaging1) Storage location Storage time
Up to three years with regular
Packed in containers, with
checks on the packaging and
desiccant and moisture With roof, protected against rain and snow, no
moisture indicator (relative
Temperate indicator sealed in the plas- shock loads.
atmospheric humidity
(Europe, USA, tic wrap.
< 50 %).
Canada, China
and Russia, With roof, enclosed at constant temperature and Two years or more given reg-
excluding tropi- atmospheric humidity (5 °C < ϑ < 60 °C, < 50 % ular inspections. Check for
cal zones) relative atmospheric humidity). cleanliness and mechanical
Open
No sudden temperature fluctuations and con- damage as part of the inspec-
trolled ventilation with filter (free from dirt and tion. Check corrosion
dust). No aggressive vapors and no shock loads. protection.
Packed in containers, with
desiccant and moisture Up to three years with regular
indicator sealed in the plas- checks on the packaging and
tic wrap. With roof, protected against rain, no shock loads. moisture indicator (relative
Tropical (Asia, Protected against insect atmospheric humidity
Africa, Central damage and mildew by < 50 %).
and South Amer- chemical treatment.
ica, Australia,
New Zealand With roof, enclosed at constant temperature and
Two years or more given reg-
excluding temper- atmospheric humidity (5 °C < ϑ < 60 °C, < 50 %
ular inspections. Check for
ate zones) relative atmospheric humidity).
cleanliness and mechanical
Open No sudden temperature fluctuations and con-
damage as part of the inspec-
trolled ventilation with filter (free from dirt and
tion. Check corrosion
dust). No aggressive vapors and no shock loads.
protection.
Protection against insect damage.
1) Packaging must be performed by an experienced company using the packaging materials that have been expressly specified for the
particular application.
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 7
81
Safety Notes
2
8 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 82
Gear Unit Structure
Basic structure of helical gear units
3
The following figures are block diagrams. Their purpose is only to make it easier to
assign components to the spare parts lists. Discrepancies may occur depending on the
gear unit size and version!
03438AXX
Figure 1: Basic structure of helical gear units
Key
1 Pinion 19 Key 42 Anti-friction bearing 507 Shim ring
2 Gear 20 Breather valve 43 Key 508 Shim ring
3 Pinion shaft 22 Gearcase 45 Anti-friction bearing 515 Shim ring
4 Gear 24 Lifting eyebolt 47 Circlip 516 Shim ring
5 Pinion shaft 25 Anti-friction bearing 59 Screw plug 517 Shim ring
6 Gear 30 Anti-friction bearing 88 Circlip 521 Shim ring
7 Output shaft 31 Key 100 Gearcase cover 522 Shim ring
8 Key 32 Spacer 101 Hex head bolt 523 Shim ring
9 Oil seal 34 Anti-friction bearing 102 Gasket
11 Anti-friction bearing 37 Anti-friction bearing 131 Closing cap
12 Circlip 39 Circlip 181 Closing cap
17 Spacer 41 Circlip 506 Shim ring
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 9
83
Gear Unit Structure
3 Basicstructure of parallel shaft helical gear units
2 45 20
59
43 22
515 1
516 42 3
517
181 41
161
4 30
32
59
31
5
506 37
507 39 183
508
131 165
160
19
102
94 521 88
93 25 522 100
92 523
91
101
7
59
17
9 11 6
81
14
16
05676AXX
Figure 2: Basic structure of parallel shaft helical gear units
Key
1 Pinion 22 Gearcase 91 Circlip 506 Shim ring
2 Gear 25 Anti-friction bearing 92 Washer 507 Shim ring
3 Pinion shaft 30 Anti-friction bearing 93 Lock washer 508 Shim ring
4 Gear 31 Key 94 Hex head bolt 515 Shim ring
5 Pinion shaft 32 Spacer 100 Gearcase cover 516 Shim ring
6 Gear 37 Anti-friction bearing 101 Hex head bolt 517 Shim ring
7 Hollow shaft 39 Circlip 102 Gasket 521 Shim ring
9 Oil seal 41 Circlip 131 Closing cap 522 Shim ring
11 Anti-friction bearing 42 Anti-friction bearing 160 Closing plug 523 Shim ring
14 Hex head bolt 43 Key 161 Closing cap
16 Output flange 45 Anti-friction bearing 165 Closing plug
17 Spacer 59 Screw plug 181 Closing cap
19 Key 81 O-ring 183 Oil seal
20 Breather valve 88 Circlip
10 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 84
Gear Unit Structure
Basic structure of helical-bevel gear units
3
100 102
20
536
3 43 537 533 59
534 22
538
535
45 2
114
101 113
42 119 59
(116)
523 89 59
522 88
521
25
1
84
19
7 59
8
6 59
17
83
11
12
9 161
132
133
31 542
30 543
135 544
4
5
131 37
506
507
137 508
39
05675AXX
Figure 3: Basic structure of helical-bevel gear units
Key
1 Pinion 25 Anti-friction bearing 102 Adhesive and sealing 522 Shim ring
compound
2 Gear 30 Anti-friction bearing 113 Slotted round nut 523 Shim ring
3 Pinion shaft 31 Key 114 Multi-tang washer 533 Shim ring
4 Gear 37 Anti-friction bearing 116 Thread lock 534 Shim ring
5 Pinion shaft 39 Circlip 119 Spacer 535 Shim ring
6 Gear 42 Anti-friction bearing 131 Closing cap 536 Shim ring
7 Output shaft 43 Key 132 Circlip 537 Shim ring
8 Key 45 Anti-friction bearing 133 Spacer 538 Shim ring
9 Oil seal 59 Screw plug 135 Nilos ring 542 Shim ring
11 Anti-friction bearing 83 Nilos ring 161 Closing cap 543 Shim ring
12 Circlip 84 Nilos ring 506 Shim ring 544 Shim ring
17 Spacer 88 Circlip 507 Shim ring
19 Key 89 Closing cap 508 Shim ring
20 Breather valve 100 Gearcase cover 521 Shim ring
22 Gearcase 101 Hex head bolt 521 Shim ring
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 11
85
Gear Unit Structure
3 Basic structure of helical-worm gear units
59
101 20
100
131
39 506
137
507
37 102
22
5
43 30 2 61 59
19
89
88 59
523
25 522
521
6
11
520
12 519
518
9
50884AXX
Figure 4: Basic structure of helical-worm gear units
Key
1 Pinion 20 Breather valve 88 Circlip 518 Shim ring
2 Gear 22 Gearcase 89 Closing cap 519 Shim ring
5 Worm 25 Anti-friction bearing 100 Gearcase cover 520 Shim ring
6 Worm gear wheel 30 Anti-friction bearing 101 Hex head bolt 521 Shim ring
7 Output shaft 37 Anti-friction bearing 102 Rubber seal 522 Shim ring
9 Oil seal 39 Circlip 131 Closing cap 523 Shim ring
11 Anti-friction bearing 43 Key 137 Spacer
12 Circlip 59 Screw plug 506 Shim ring
19 Key 61 Circlip 507 Shim ring
12 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 86
Gear Unit Structure
Basic structure of SPIROPLAN® gear units
3
102 65 66 143
71 68
72
1
22
89
88
521
522
523
25
19 250
251
17
8
7
11
518
519
520
12
9
05674AXX
Figure 5: Basic structure of SPIROPLAN® gear units
Key
1 Pinion 19 Key 88 Circlip 251 Circlip
6 Gear 22 Gearcase 89 Closing cap 518 Shim ring
7 Output shaft 25 Anti-friction bearing 100 Gearcase cover 519 Shim ring
8 Key 65 Oil seal 101 Hex head bolt 520 Shim ring
9 Oil seal 66 Anti-friction bearing 102 Gasket 521 Shim ring
11 Anti-friction bearing 71 Spacer 132 Circlip 522 Shim ring
12 Circlip 72 Circlip 183 Oil seal 523 Shim ring
17 Spacer 143 Spacer 250 Circlip
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 13
87
Gear Unit Structure
3 Nameplate, unit designation
06687ADE
Figure 6: Sample nameplate
fb = Service factor
FRa max [N] = Maximum overhung load on the output side
FRe max [N] = Maximum overhung load on the input side (with input shaft assembly AD)
i = Gear unit reduction ratio
IM = Mounting position
IP.. = Enclosure
ne max [1/min] = Maximum input speed
na [1/min] = Output speed
Me max [Nm] = Maximum input torque
Ma [Nm] = Output torque
MR [Nm] = Overload torque when using an AR adapter
MRS [Nm] = Locking torque of the backstop
Unit designation
Example: Helical gear unit, category II2GD
RF 47 / A / II2GD
14 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 88
Mechanical Installation
Required tools / aids
4
4 Mechanical Installation
4.1 Required tools / aids
• Set of spanners
• Torque wrench for:
– Shrink discs
– AQH motor adapter
– Input shaft assembly with centering shoulder
• Mounting device
• Shims and distance rings if necessary
• Fixing devices for input and output elements
• Lubricant (e.g. NOCO® Fluid)
• Bolt adhesive (for input shaft assembly with centering shoulder), e.g. Loctite® 243
• Standard parts are not part of the delivery
Installation
tolerances
Shaft end Flanges
Diameter tolerance in accordance with DIN 748 Centering shoulder tolerance in accordance with
• ISO k6 for solid shafts with ∅ ≤ 50 mm DIN 42948
• ISO m6 for solid shafts with ∅ > 50 mm • ISO j6 with b1 ≤ 230 mm
• ISO H7 for hollow shafts • ISO h6 with b1> 230 mm
• Center bore in accordance with DIN 332, shape
DR
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 15
89
Mechanical Installation
4 Installing the gear unit
• You must clean the output shafts and flange surfaces thoroughly to ensure they are
free of anti-corrosion agents, contamination or similar. Use a commercially available
solvent. Do not let the solvent come into contact with the sealing lips of the oil seals
– danger of damage to the material!
• When the drive is installed in abrasive ambient conditions, protect the output end oil
seals against wear.
The oil checking and drain screws and the breather valves must be freely
accessible!
At the same time, also check that the oil fill is as specified for the mounting position (see
Sec. "Lubricants" / "Lubricant fill quantities" or refer to the information on the nameplate).
The gear units are filled with the required oil volume at the factory. There may be slight
deviations at the oil level plug as a result of the mounting position, which are permitted
within the manufacturing tolerances.
16 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 90
Mechanical Installation
Installing the gear unit
4
Adjust the lubricant fill volumes and the position of the breather valve accordingly
in the event of a change of mounting position.
Please contact our SEW customer service if you change the mounting position of K gear
units to M5 or M6 or between M5 and M6.
Please contact our SEW customer service if you change the mounting position of size
S47 S97 S gear units to mounting position M2.
Use plastic inserts (2 ... 3 mm thick) if there is a risk of electrochemical corrosion
between the gear unit and the driven machine. The material used must have an electri-
cal bleeder resistor < 109 Ω. Electrochemical corrosion can occur between various
metals, for example, cast iron and high-grade steel. Also install the bolts with plastic
washers! Ground the housing additionally – use the grounding bolts on the motor.
Installation in Drives are supplied in corrosion-resistant versions for use in damp areas or in the open
damp locations or air. Repair any damage to the paint work (e.g. on the breather valve).
in the open When mounting the motors onto AM, AQ, AR, AT adapters, seal the flange areas with a
suitable sealing compound, e.g. Loctite® 574.
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 17
91
Mechanical Installation
4 Installing the gear unit
Gear unit venting No breather plug is required for the following gear units:
• R07 in mounting positions M1, M2, M3, M5 and M6
• R17, R27 and F27 in mounting positions M1, M3, M5 and M6
• SPIROPLAN® W gear units
SEW-EURODRIVE supplies all other gear units with the breather valve installed and
activated according to the particular mounting position.
Exceptions:
1. SEW supplies the following gear units with a screw plug on the vent hole provided:
• Gear units for extended storage
• Pivoted mounting positions, if possible
• Gear units for mounting on a slant
The breather valve is located in the motor terminal box. Before startup, you must re-
place the highest screw plug with the breather valve supplied.
2. SEW supplies a breather valve in a plastic bag for gear head units requiring venting
on the input end.
3. Enclosed gear units are supplied without a breather valve.
Activating the As a rule, the breather valve is already activated at the factory. If the breather valve has
breather valve not been activated, you must remove the transport fixture from the breather valve before
starting up the gear unit!
1. Breather valve with 2. Remove the transport fixture 3. Breather valve activated
transport fixture
Painting the gear If you paint or respray the drive, ensure that you cover the breather valve and oil seals
unit carefully. Remove the strips of tape after completing the painting work.
18 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 92
Mechanical Installation
Gear unit with solid shaft
4
03371BXX
Avoid impermissibly high overhung loads: Install the gear or chain sprocket according
to figure B.
1 = Hub
A = Unfavorable
B = Correct
03369BXX
• Only use a mounting device for installing input and output elements. Use the center
bore and the thread on the shaft end for positioning.
• Never drive belt pulleys, couplings, pinions, etc. onto the shaft end by hitting
them with a hammer This will damage the bearings, housing and the shaft!
• In the case of belt pulleys, make sure the belt is tensioned correctly in accor-
dance with the manufacturer's instructions.
• Power transmission elements should be balanced after fitting and must not give rise
to any impermissible radial or axial forces (see the "Gearmotor" or "Explosion-Proof
Drives" catalogs for permitted values).
Note:
Assembly is easier if you first apply lubricant to the output element or heat it up briefly
(to 80 ... 100 °C).
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 19
93
Mechanical Installation
4 Gear unit with solid shaft
Installing Couplings must be mounted and balanced according to the information provided by the
couplings coupling manufacturer:
a) Maximum and minimum clearance
b) Axial misalignment
c) Angular misalignment
a) b) c)
03356AXX
Figure 7: Clearance and misalignment for coupling installation
Input and output elements such as belt pulleys, couplings, etc. must be protected
against contact!
20 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 94
Mechanical Installation
Torque arms for mounted gear units
4
01029BXX
Figure 8: Torque arm for parallel shaft helical
gear units
01030CXX
Figure 9: Torque arm for helical-bevel gear units
Gear unit Bolts Tightening torque
KA37 4 × M10 × 25 – 8.8 48 Nm
KA47 4 × M10 × 30 – 8.8 48 Nm
KA67 4 × M12 × 35 – 8.8 86 Nm
KA77 4 × M16 × 40 – 8.8 210 Nm
KA87 4 × M16 × 45 – 8.8 210 Nm
KA97 4 × M20 × 50 – 8.8 410 Nm
KA107 4 × M24 × 60 – 8.8 710 Nm
KA127 4 × M36 × 130 – 8.8 2500 Nm
KA157 4 × M36 × 130 – 8.8 2500 Nm
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 21
95
Mechanical Installation
4 Torque arms for mounted gear units
01031CXX
Figure 10: Torque arm for helical-worm gear units
Gear unit Bolts Tightening torque
SA37 M6 × 16 – 8.8 11 Nm
SA47 M8 × 20 – 8.8 25 Nm
SA57 M8 × 20 – 8.8 25 Nm
SA67 M12 × 25 – 8.8 86 Nm
SA77 M12 × 35 – 8.8 86 Nm
SA87 M16 × 35 – 8.8 210 Nm
SA97 M16 × 35 – 8.8 210 Nm
(1)
02050CXX
Figure 11: Torque arm for SPIROPLAN® W gear units
Gear unit Bolts Tightening torque
WA10 M6 × 16 11 Nm
WA20 M6 × 16 11 Nm
WA30 M6 × 16 11 Nm
22 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 96