5 Lubrication, Cooling, and Heating

Transcription

1 Lubrication,, and Heating Overview of the and cooling types Lubrication,, and Heating.1 Overview of the and cooling types The following combinations of and cooling types are possible. Lubrication Splash Bath with shaft end pump /SEP with motor pump without cooling without cooling without cooling /ONP Fan Fan Fan Standard /FAN Standard /FAN Standard /FAN Advanced /FAN-ADV Built-in cooling Advanced /FAN-ADV Built-in cooling Advanced /FAN-ADV Built-in cooling Water cooling cover /CCV Water cooling cover /CCV Water cooling cover /CCV Water cooling cartridge /CCT Water cooling cartridge /CCT Water cooling cartridge /C Circulation cooling Circulation cooling Oil-water cooler /OWC Oil-water cooler /OWP Oil-air cooler /OAC Oil-air cooler /OAP Heater Heater Oil heater /OH Heater Oil heater /OH Heater Oil heater /OH 68308AEN Catalog Helical and Bevel-Helical Gear Units X.. Series 7

2 Lubrication,, and Heating Lubricant selection / lubricant table.2 Lubricant selection / lubricant table The oil viscosity and type (mineral/synthetic) to be used are determined by SEW- EURODRIVE specifically for each order. This information is noted in the order confirmation and on the gear unit's nameplate. Any deviation from these conditions requires consultation with SEW-EURODRIVE..2.1 General information on selecting the oil Unless a special arrangement is made, SEW-EURODRIVE delivers the drives without oil fill. This does not apply to auxiliary drives and primary gear units. This means the gear unit must be filled with the correct oil grade and quantity before startup. You find the corresponding information on the nameplate of the gear unit. The following tables provide an overview of mineral and synthetic oils. Mineral oil Standards Lubrication oils are divided into ISO VG viscosity classes according to ISO 3448 and DIN 119. ISO Class ISO Designation DIN Designation AGMA 900-D94 Designation 10 ISO-L-CKC 10 DIN 117-CLP 10 AGMA 4 EP 220 ISO-L-CKC 220 DIN 117-CLP 220 AGMA EP 320 ISO-L-CKC 320 DIN 117-CLP 320 AGMA 6 EP 460 ISO-L-CKC 460 DIN 117-CLP 460 AGMA 7 EP 680 ISO-L-CKC 680 DIN 117-CLP 680 AGMA 8 EP Synthetic oil Standards Lubrication oils are divided into ISO VG viscosity classes according to ISO 3448 and DIN 119. ISO Class ISO Designation DIN 119 Designation AGMA 900-D94 Designation 10 ISO-L-CKT 10 CLP HC 10 AGMA 4 EP 220 ISO-L-CKT 220 CLP HC 220 AGMA EP 320 ISO-L-CKT 320 CLP HC 320 AGMA 6 EP 460 ISO-L-CKT 460 CLP HC 460 AGMA 7 EP 680 ISO-L-CKT 680 CLP HC 680 AGMA 8 EP 76 Catalog Helical and Bevel-Helical Gear Units X.. Series

3 Lubrication,, and Heating Lubricant selection / lubricant table In addition to the required viscosity, the oil must fulfill the following criteria: CLP oils according to DIN Micro-pitting test according to FVA, FV no. 4/ I-IV, GFT class high, damage force level >10 If synthetic oil is used, SEW-EURODRIVE recommends polyalphaolefin-based oil (CLP HC). Observe the operating temperature of the gear unit when specifying the oil change intervals. If required, a cooling system must be used or the oil change interval must be shortened (see "Lubricant Change Intervals" in the "Helical and Bevel-Helical X.. Series Gear Units" operating instructions")..2.2 Permitted lubricants The standard for viscosity and oil grade is the type of oil that is specified by SEW- EURODRIVE in the order (see order confirmation and nameplate). Consult SEW-EURODRIVE if you use bio and food grade lubricants or polyglycol oils. Check the compatibility of the greases and oils used. Key to the lubricant table The lubricant table shows the permitted lubricants for SEW-EURODRIVE industrial gear units. This information is provided to preselect the lubricant. The proper and final lubricant selection is made by SEW-EURODRIVE to match the specific project. Consider the used abbreviations, meaning of shading and notes. CLP = Mineral oil CLP HC = Synthetic polyalphaolefin E = Ester oil (water hazard classification 1) = Mineral lubricant = Synthetic lubricant 3) = Lubricants may only be used if service factor F s = 1.3 4) = Take into account critical startup behavior at low ambient temperatures 6) = Ambient temperature = Lubricant for the food industry (food grade oil) = Biodegradable oil (lubricant for agriculture, forestry, and water management) Oil Oil Catalog Helical and Bevel-Helical Gear Units X.. Series 77

4 Lubrication,, and Heating Lubricant selection / lubricant table.2.3 Lubricant table C 3) 3) 4) 3)4) 3) 3) 3)4) Oil CLP CC VG 320 CLP CC VG 10 CLPCC VG Oil 6) ISO,NLGI Mobil DIN (ISO) Mobilgear 600XP Mobilgear 600XP Mobilgear 600XP CLP CC VG 460 Mobilgear 600XP CLP CC VG 680 Mobilgear 600XP CLP CC VG 1000 CLP HC VG 320 Mobil SHC Gear 320 Mobil SHC CLP HC VG 32 Mobil SHC CLP HC VG 68 Mobil SHC CLP HC CLP HC CLP HC CLP HC VG 10 VG 220 VG 460 VG 680 CLP HC VG 1000 Mobil SHC Gear 10 Mobil SHC 629 Mobil SHC Gear 220 Mobil SHC 630 Mobil SHC Gear 460 Mobil SHC 634 Mobil SHC Gear 680 Mobil SHC 636 Mobil SHC Gear 1000 Mobil SHC CLP HC NSF H1 VG 460 VG VG E VG 460 Sh e ll Shell Omala F 320 Shell Omala F 220 Shell Omala F 460 Shell Omala S4 GX 320 Shell Omala S4 GX68 Shell Omala S4 GX 10 Shell Omala S4 GX 220 Shell Omala S4 GX 460 Shell Omala S4 GX 680 Shell Naturelle Gear Fluid EP 460 bp BP Energol GR-XP-320 BP Energol GR-XP-10 BP Energol GR-XP-220 BP Energol GR-XP-460 BP Energol GR-XP-680 BP Enersyn EP-XF-320 BP Enersyn EP-XF-68 BP Enersyn EP-XF-10 BP Enersyn EP-XF-220 BP Enersyn EP-XF-460 BP Enersyn EP-XF-680 LUBRICATION Klüberoil GEM N Klüberoil GEM 1-10 N Klüberoil GEM N Klüberoil GEM N Klüberoil GEM N Klübersynth GEM N Klübersynth GEM 4-68 N Klübersynth GEM 4-10 N Klübersynth GEM N Klübersynth GEM N Klübersynth GEM N Klübersynth GEM N Klüberöl 4UH1-460 N Klüberöl 4UH1-220 N Klüberöl 4UH1-68 N Klüberbio CA2-460 ARAL FUCHS TEXACO Tribol Optimol Meropa 320 Alpha SP 320 Tribol 1100/320 Optigear BM 320 Renolin CLP 320 Plus Renolin High Gear 320 Meropa 10 Alpha SP 10 Tribol 1100/10 Optigear BM 10 Renolin CLP 10 Plus Renolin High Gear 10 Meropa 220 Alpha SP 220 Tribol 1100/220 Optigear BM 220 Renolin CLP 220 Plus Renolin High Gear 220 Meropa 460 Alpha SP 460 Tribol 1100/460 Optigear BM 460 Renolin CLP 460 Plus Renolin High Gear 460 Meropa 680 Alpha SP 680 Tribol 1100/680 Optigear BM 680 Renolin CLP 680 Plus Renolin High Gear 680 Tribol 1100/1000 Pinnacle EP 320 Alphasyn EP 320 Optigear Synthetic X 320 Renolin Unisyn CLP 320 Renolin High Gear Synth 320 Pinnacle EP 10 Pinnacle EP 220 Pinnacle EP 460 Pinnacle EP 680 Alphasyn EP 10 Alphasyn EP 220 Alphasyn EP 460 Optigear Synthetic X 68 Optigear Synthetic X 10 Optigear Synthetic X 220 Optigear Synthetic X 460 Optigear Synthetic X 680 Reolin Unisyn CLP 68 Reolin Unisyn CLP 10 Renolin Unisyn CLP 220 Renolin High Gear Synth 220 Renolin Unisyn CLP 460 Renolin High Gear Synth 460 Reolin Unisyn CLP 680 Optileb GT 460 Cassida Fluid GL 460 Optileb GT 220 Cassida Fluid GL 220 Optileb HY 68 Cassida Fluid GL 68 Plantogear 460 S Q8 Goya NT 320 Goya NT 10 Goya NT 220 Goya NT 460 Goya NT 680 El Greco 320 El Greco 10 El Greco 220 El Greco 460 El Greco 680 TO T A L O T A L Carter EP 320 Carter EP 220 Carter EP 460 Carter EP 680 Carter SH 320 Carter SH 10 Carter SH 220 Carter SH 460 Carter SH Catalog Helical and Bevel-Helical Gear Units X.. Series

5 Lubrication,, and Heating Lubricant selection / lubricant table.2.4 Oil quantity for horizontal gear units / M1 mounting position The specified oil quantity is a guide value. The precise value varies depending on the gear ratio and the number of stages. The mark on the oil sight glass, oil level glass and/or oil dipstick is the decisive indicator for the correct oil level. The following tables list the oil quantities for splash, bath and pressure. X.F.. Splash Splash lubri- Splash lubri- X2F.. X3F.. cation X4F.. cation X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X.K.. Splash Splash lubri- Splash lubri- X2K.. X3K.. cation X4K.. cation X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K Catalog Helical and Bevel-Helical Gear Units X.. Series 79

6 Lubrication,, and Heating Lubricant selection / lubricant table X2K.. Splash X3K.. Splash X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X4K.. Splash X.T.. X3T.. Splash Bath X4T.. Splash Bath X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T Catalog Helical and Bevel-Helical Gear Units X.. Series

7 Lubrication,, and Heating Lubricant selection / lubricant table.2. Oil quantity for horizontal gear units / M3 mounting position The specified oil quantity is a guide value. The precise value varies depending on the gear ratio and the number of stages. The mark on the oil sight glass, oil level glass and/or oil dipstick is the decisive indicator for the correct oil level. The following tables list the oil quantities for splash and bath. X.F.. Splash Splash lubrica- Splash lubrica- X2F.. X3F.. tion X4F.. tion X2F X3F X4F100 - X2F110 1 X3F110 1 X4F110 - X2F X3F X4F120 2 X2F X3F X4F130 2 X2F140 3 X3F X4F X2F10 37 X3F10 38 X4F10 40 X2F X3F X4F X2F X3F X4F X2F180 7 X3F X4F X2F190 7 X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F20 17 X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F310 0 X3F X4F X2F320 0 X3F X4F X.K.. Oil quantity [l] Oil quantity [l] Splash Splash lubri- Bath lubri- Splash lubri- X2K.. X3K.. cation cation X4K.. cation X2K X3K X4K100 - X2K X3K X4K110 - X2K X3K X4K X2K X3K X4K X2K140 2 X3K X4K X2K10 28 X3K X4K10 38 X2K X3K X4K X2K X3K X4K Catalog Helical and Bevel-Helical Gear Units X.. Series 81

8 Lubrication,, and Heating Lubricant selection / lubricant table X2K.. Oil quantity [l] Splash X3K.. Splash Bath X4K.. Oil quantity [l] Splash X2K X3K X4K180 7 X2K X3K X4K190 7 X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K20 17 X2K260 - X3K X4K X2K270 - X3K X4K X2K280 - X3K X4K X2K290 - X3K X4K X2K300 - X3K X4K X2K310 - X3K X4K X2K320 - X3K X4K X.T.. X3T.. Splash Bath X4T.. Splash Bath X3T X4T X3T X4T X3T X4T120-0 X3T X4T130-2 X3T X4T X3T10-84 X4T10-84 X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T Catalog Helical and Bevel-Helical Gear Units X.. Series

9 Lubrication,, and Heating Lubricant selection / lubricant table.2.6 Oil quantities for vertical gear units / M and M6 mounting positions The specified oil quantity is a guide value. The precise value varies depending on the gear ratio and the number of stages. The mark on the oil sight glass, oil level glass and/or oil dipstick is the decisive indicator for the correct oil level. The following tables list the oil quantities for bath and pressure as well as pressure with Drywell. Note that for gear unit combinations in M or M6 mounting position with pressure and oil heater, the oil quantity must be increased by 20%. Observe the information on the nameplate. X.F.. Bath Bath Bath lubrica- lubrica- X2F.. X3F.. tion X4F.. tion X2F X3F X4F with Drywell with Drywell X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F with Drywell X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F Catalog Helical and Bevel-Helical Gear Units X.. Series 83

10 Lubrication,, and Heating Lubricant selection / lubricant table X.K.. Bath Bath Bath lubrica- lubrica- X2K.. X3K.. tion X4K.. tion X2K X3K X4K with Drywell with Drywell X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K with Drywell X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K Catalog Helical and Bevel-Helical Gear Units X.. Series

11 Lubrication,, and Heating Lubricant selection / lubricant table X.T.. with Drywell with Drywell Bath Bath lubri- X3T.. X4T.. cation X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T Catalog Helical and Bevel-Helical Gear Units X.. Series 8

12 Lubrication,, and Heating Lubricant selection / lubricant table.2.7 Oil quantities for upright gear units / M2 mounting position The specified oil quantity is a guide value. The precise value varies depending on the gear ratio and the number of stages. The mark on the oil sight glass, oil level glass and/or oil dipstick is the decisive indicator for the correct oil level. The following tables list the oil quantities for bath. X.F.. X2F.. Bath X3F.. Bath X4F.. Bath X2F X3F X4F100 - X2F X3F X4F110 - X2F X3F X4F X2F130 3 X3F X4F X2F140 6 X3F140 4 X4F X2F10 9 X3F10 8 X4F10 0 X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F20 26 X4F X.K.. X2K.. Bath X3K.. Bath X4K.. Bath X2K X3K X4K100 - X2K X3K X4K110 - X2K120 2 X3K X4K X2K X3K X4K X2K X3K X4K140 4 X2K10 42 X3K10 0 X4K10 7 X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K200 1 X4K X2K X3K210 1 X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K20 20 X3K20 26 X4K Catalog Helical and Bevel-Helical Gear Units X.. Series

13 Lubrication,, and Heating Lubricant selection / lubricant table X.T.. X3T.. Bath X4T.. Bath X3T X4T100 - X3T X4T110 - X3T X4T X3T X4T X3T X4T140 6 X3T10 46 X4T10 60 X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T Catalog Helical and Bevel-Helical Gear Units X.. Series 87

14 Lubrication,, and Heating Lubricant selection / lubricant table.2.8 Oil quantities for upright gear units / M4 mounting position The specified oil quantity is a guide value. The precise value varies depending on the gear ratio and the number of stages. The mark on the oil sight glass, oil level glass and/or oil dipstick is the decisive indicator for the correct oil level. The following tables list the oil quantities for bath and pressure. X.F.. Bath Bath lubrica- Bath lubrica- X2F.. X3F.. tion X4F.. tion X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F X3F X4F X2F290-2 X3F290-2 X4F290-2 X2F300-2 X3F300-2 X4F300-2 X2F X3F X4F X2F X3F X4F X.K.. Bath Bath lubrica- Bath lubrica- X2K.. X3K.. tion X4K.. tion X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K Catalog Helical and Bevel-Helical Gear Units X.. Series

15 Lubrication,, and Heating Lubricant selection / lubricant table X2K.. Bath X3K.. Bath X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K X4K X2K X3K290-2 X4K290-2 X2K X3K300-2 X4K300-2 X2K X3K X4K X2K X3K X4K X4K.. Bath X.T.. X4T.. Bath Bath X3T.. X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T X3T X4T Catalog Helical and Bevel-Helical Gear Units X.. Series 89

16 Lubrication,, and Heating Lubricant selection / lubricant table.2.9 Sealing grease / bearing grease in Drywell sealing systems The table shows the grease types recommended by SEW-EURODRIVE for operating temperatures from -20 C to 100 C. Manufacturer Grease Group Fuchs Renolit CX TOM 1 OEM 1) BP Energrease LS-EP 2 Castrol Longtime PD 2 Castrol Spheerol EP 2 Klüber Centoplex EP2 Klüber Petamo GHY 133 N Group 1 Kuwait Q8 Rembrandt EP2 Mobile Mobilux EP 2 Shell Gadus S2 V220 2 Texaco Mulifak EP2 Total Multis EP 2 Castrol Obeen FS 2 1) Group 2 Oil Oil Fuchs Plantogel 2 S 1) Group 3 1) Grease used by the factory should be preferred! The greases may only be replaced within the same group. It is not permitted to mix different groups. If a customer wants to use a grease that is not listed in the table, the customer has to make sure that it is suitable for the intended application. 90 Catalog Helical and Bevel-Helical Gear Units X.. Series

17 Lubrication,, and Heating Accessories.3 Accessories The following section describes the accessories for the several types of. The position of accessories might vary depending on the gear unit type and size. For dimensions of oil dipstick, oil drain valve and oil level glass, see page General accessories The following figure shows the general accessories. [2] [3] [4] 6668AXX [2] Oil dipstick (optional) Gear unit breather [3] [4] Oil level glass Oil drain Visual oil level check The following types are available as standard for gear units in M1 mounting position with splash : Oil dipstick (see page 23) for gear unit sizes 100 to 170 Oil level glass (see page 26) for gear unit sizes 180 to 320 For other mounting positions and types of, the gear unit is equipped with an oil dipstick as standard. Gear unit venting The purpose of a gear unit breather is to prevent that non-permitted pressure occurs from heating during operation. The gear units are equipped with a high-quality breather filter with a filter mesh of 2 µm as standard. Oil drain The gear unit is equipped with an oil drain plug as standard. An oil drain valve can be provided as option (see page 2). This valve allows for a drain pipe to be easily attached when changing the gear unit oil. Catalog Helical and Bevel-Helical Gear Units X.. Series 91

18 Lubrication,, and Heating Accessories.3.2 Additional bath accessories Oil expansion tank /ET The purpose of the oil expansion tank is to compensate for oil volume variations in the system caused by temperature fluctuations. If the gear unit temperature increases, the expansion tank absorbs some of the increasing oils volume and feeds it back to the gear unit as the temperature goes down, thus the gear unit is always completely filled with oil. Based on the oil level specified by SEW-EURODRIVE, the oil expansion tank is designed to compensate the oil volume change within the permitted operating temperature range. A temperature decrease below the permitted range causes the expansion tank to be completely emptied and air being sucked into the gear unit. This might result in insufficient and a malfunction of the gear unit. An increase above the permitted range causes an overfilling of the expansion tank and oil might leak from the gear unit. During operation, any oil level below or above the level specified by SEW- EURODRIVE is permitted as long as there is oil in the expansion tank and the expansion tank does not overflow. The following figure shows the accessories for mounting positions M1, M4 and M. [2] Mounting position M4 [4] [2] [4] Mounting position M1 Mounting position M [2] [4] [3] [3] [3] 69236AEN [2] Gear unit breather Oil dipstick [3] [4] Oil drain Oil expansion tank For dimension sheets of oil expansion tanks, refer to page 426 ff. 92 Catalog Helical and Bevel-Helical Gear Units X.. Series

19 Lubrication,, and Heating Accessories.3.3 Additional accessories for pressure Shaft end pump /SEP The figure shows the accessories for M mounting position. [] [4] [3] [2] 69214AXX [2] [3] Shaft end pump switch Oil drain [4] [] Gear unit breather Oil dipstick A shaft end pump (direction-independent) supplies all bearing points and gearing outside the oil sump with oil via a tube system. The pump is mounted externally to the gear unit and is driven by the input shaft or intermediate shaft of the gear unit. A high reliability of the pump function is ensured in this way. Different pump sizes are available. The adequate flow rate for the specific application depends on the following factors: Oil quantity required to supply the points Pump position (connected to input shaft or intermediate shaft) Gear unit reduction ratio Speed range of the gear unit Proper functioning of the shaft end pump is monitored via the connected pressure switch. For detailed information, refer to page 138. Consult SEW-EURODRIVE for selecting the suitable flow rate. For dimensions, see page 430 ff. A minimum input speed is required for the shaft end pump to operate properly. If you use variable input speeds (e.g. inverter-controlled drives) or if you intend to change the input speed of a gear unit equipped with a shaft end pump, it is essential that you contact SEW-EURODRIVE. Catalog Helical and Bevel-Helical Gear Units X.. Series 93

20 Lubrication,, and Heating Accessories Position of the shaft end pump X.F.. For helical gear units, the shaft end pump is located opposite the input shaft AXX X2K / X4K / X4T For X2K/X4K/X4T bevel-helical gear units, the shaft end pump is located opposite the output shaft AXX X3K / X3T For X3K/X3T gear units, the shaft end pump is located on the output shaft side AXX 94 Catalog Helical and Bevel-Helical Gear Units X.. Series

21 Lubrication,, and Heating Accessories Motor pump /ONP Structure With pressure, a motor pump supplies all bearing points and gearing above the oil sump with oil via a tube system inside the gear unit. The motor pump is used, for example, when the required speed of the shaft end pump ( 400 rpm) is not reached. It is also used in inverter operation where a shaft end pump cannot be used or can only be used under certain circumstances. The motor pump is mounted externally to the gear unit and depends on the speed of the gear unit. The figure shows an example of a motor pump. [6] [7] [] [2] M [2] [6] [8] [4] [9] [] [3] [3] [4] 6822AXX Motor [6] switch [2] Pump [7] Contamination indicator [3] Suction pipe [8] Temperature switch, optional (NTB) [4] line [9] Check valve [] Oil filter The motor pump is delivered as a complete unit but without electrical connections. In its basic variant, the scope of the motor pump includes the following components: Pump with directly connected asynchronous motor (pump always running) Oil filter with filter element and electrical/optical contamination indicator switch that monitors the pump pressure. Warning or switch-off signal when the oil pressure reaches < 0. bar Option: Temperature switch with trip point for monitoring the cooling group, i.e. warning or gear unit shutdown when the oil temperature exceeds 90 C The following motor pump types are available: Directly mounted on the gear unit, incl. piping, or On the mounting frame, for separate installation, but without piping to the gear unit The customer has to carry out the following electrical wiring: switch to the customer's evaluation unit Electrical contamination indicator of the oil filter Pump motor Option: Between temperature switch and pump motor Catalog Helical and Bevel-Helical Gear Units X.. Series 9

22 Lubrication,, and Heating Accessories Gear unit size and selection The specified delivery rates of the motor pump apply to a line frequency of 0 Hz. Gear unit size Motor pump Flow volume Motor pump [l/min] Connection power Pump motor [kw] ONP ONP ONP ONP ONP ONP ONP ONP Motor pumps ONP are designed for gear unit sizes 140 to 320. The values differ slightly for operation with a line frequency of 60 Hz. Please consult SEW-EURODRIVE. Installation and connection information for separate installation The motor pump is mounted directly on the gear unit as standard. The motor pump can be delivered as a complete unit on a mounting frame but without electrical connections and piping. Provide for a low-vibration installation location max. 1 meter from the gear unit. The cooling system must be installed at the same level as the gear unit or lower. If this is not possible, contact SEW-EURODRIVE. Adhere to the following basic conditions when connecting the motor pump to the gear system: 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. Preferably, use composite material seals. SEW-EURODRIVE recommends the following cable cross sections for connecting the motor pump: Gear unit size Motor pump 1) max. length 1. m 2) max. length 2. m Pump suction connection Suction pipe connection 1) max. pipe 2) ONP 00 GE22-LR 3/4" DN20 / Ø22 GE18-LR 1/2" DN16 / Ø18 ONP 010 GE22-LR 1/2" DN20 / Ø22 GE18-LR 1" DN16 / Ø18 ONP 01 GE28-LR 1" DN2 / Ø28 GE22-LR 3/4" DN20 / Ø22 ONP 020 GE22-LR 1/2" DN20 / Ø22 GE18-LR 1" DN16 / Ø18 ONP 030 GE3-LR 1 1/4" DN32 / Ø3 GE28-LR 1" DN2 / Ø28 ONP 040 GE3-LR 1 1/4" DN32 / Ø3 GE28-LR 1" DN2 / Ø28 ONP 00 GE3-LR 1 1/4" DN32 / Ø3 GE3-LR 1 1/2" DN32 / Ø3 ONP 060 GE42-LR 1 1/2" DN40 / Ø42 GE3-LR 1 1/2" DN32 / Ø3 For dimension sheets of motor pumps, refer to page 431 ff. Detailed technical data is available from SEW-EURODRIVE on request. 96 Catalog Helical and Bevel-Helical Gear Units X.. Series

23 Lubrication,, and Heating.4 If the permitted thermal rating of the gear unit is exceeded, additional cooling measures must be taken. The following cooling methods are available as standard: Water cooling cover (for gear unit sizes 100 to 130 and 180 to 210) Water cooling cartridge (for gear unit sizes 140 to 320) Circulation cooling with oil-water cooler with a motor pump Circulation cooling oil-air cooler with motor pump Fan in combination with water cooling cover (for gear unit sizes 100 to 130 and 180 to 210) Fan in combination with water cooling cartridge (for gear unit sizes 140 to 320) Fan on HSS (only for 2- and 3-stage X gear units).4.1 Fan /FAN Fans with optimized noise and flow engineering geometry are used. A fan may be retrofitted to raise the thermal rating or when the ambient conditions change after gear unit startup. The direction of rotation of the gear unit does not influence the operation of the fan. For information on dimensions, position and air intake clearance, refer to page 433 ff. X.F.. Fan (standard) /FAN SEW-EURODRIVE offers the following inverter types: AXX Air intake clearance Catalog Helical and Bevel-Helical Gear Units X.. Series 97

24 Lubrication,, and Heating X.K.. Fan (standard) /FAN AXX On request, the fan guard is available flush with the gear unit housing on one side. Please contact SEW-EURODRIVE if required. Observe the restricted thermal rating involved. X3K.. Advanced (option) /FAN- ADV When the type X3K.. Advanced is used, the connection element (e.g. hydraulic centrifugal coupling) can be mounted flush to the fan guard. The air intake clearance is integrated into the fan guard AXX Air intake clearance The X3K.. Advanced fan cannot be used together with a torque arm because the fan guard is mounted to the attachment point of the torque arm. 98 Catalog Helical and Bevel-Helical Gear Units X.. Series

25 Lubrication,, and Heating.4.2 Built-in cooling, water cooling cover /CCV The water cooling cover is located on the gear unit's assembly opening and is provided with cooling water through a water connection that is provided by the operator. It is available for gear unit sizes 100 to 130 and 180 to 210. For connection dimensions, refer to page 439. The amount of heat that can be dissipated depends on the intake temperature and the flow rate of the cooling medium that flows through the unit. For the permitted thermal rating, refer to the selection tables from page 13. Contact SEW-EURODRIVE if chemically aggressive cooling media, such as brackish or salt water, are used. Structure The figure shows an example of a gear unit with water cooling cover. [2] [3] 60982AXX [2] Water cooling cover Supply [3] Return The water cooling cover is made of a corrosion-resistant aluminum alloy. Two bores with pipe threads are available to connect to the cooling circuit. Gear unit sizes 100 to 130: G3/8" Gear unit sizes 180 to 210: G1/2" The piping is not included in the scope of delivery. Gear units with water cooling cover are delivered completely assembled. A water cooling cover can be retrofitted. Contact SEW-EURODRIVE. Notes on connection and operation To achieve the thermal rating listed in the selection tables (page 13 ff.), you need a cooling water volume flow (water entry temperature 1 C) according to the following table, depending on the gear unit size. The cooling capacity of the water cooling cover changes when the cooling water quantity or temperature changes or when specific cooling media are used. Consult SEW- EURODRIVE. Gear unit size water volume flow [l/min] Gear unit size water volume flow [l/min] 100 / / / / Catalog Helical and Bevel-Helical Gear Units X.. Series 99

26 Lubrication,, and Heating medium Note that the service life, the efficiency, and the maintenance intervals of the heat exchanger depend to a great degree on the quality and ingredients of the cooling medium. Special measures have to be taken when using sea water or brackish water. Consult SEW-EURODRIVE. Permitted cooling media The permitted cooling media is pure water. water additives, such as antifreeze or corrosion inhibitor, might negatively influence the cooling performance and compatibility of materials. Consult SEW-EURODRIVE. water temperature and flow rate of oil and cooling water according to the order documents. Dirt The quantity of suspended solids (ball-shaped, particle size < 0.2 mm) should be less than 10 mg/l. Threadlike contaminants increase the risk of pressure loss. Corrosion Limit values: free chlorine < 0. ppm, chlorine ions < 200 ppm, sulfate < 100 ppm, ammonia < 10 ppm, free CO < 10 ppm, ph 7-9. The following ions do not have a corrosive effect under normal conditions: phosphate, nitrate, nitrite, iron, manganese, sodium, potassium. 100 Catalog Helical and Bevel-Helical Gear Units X.. Series

27 Lubrication,, and Heating.4.3 Built-in cooling, water cooling cartridge /CCT The water cooling cartridge is mounted in the gear unit's oil sump and is supplied with cooling water through a water connection that is provided by the operator. It is available for sizes 140 to 320. For connection dimensions, refer to page 440. The amount of heat that can be dissipated depends on the intake temperature and the flow rate of the cooling medium that flows through the unit. For the permitted thermal rating, refer to the selection tables from page 13. Structure The figure shows an example of a gear unit with water cooling cartridge. [3] [4] [3] [4] [2] 60978AXX [2] pipes Connection piece [3] [4] Supply Return The water-cooling cartridge consists of 3 main parts: pipes (CuNi alloy) Tube plate (brass) Adapter piece (brass; gray cast iron; steel) Two bores with pipe threads are available to connect to the cooling circuit: Pipe thread G1/4" for gear unit sizes 140 to 170 Pipe thread G1/2" for gear unit sizes 180 to 320 as of week 37/2012. The piping is not included in the scope of delivery. Gear units with water-cooling cartridge are delivered completely assembled. Water cooling cartridges can be retrofitted under certain conditions. Contact SEW- EURODRIVE. For gear unit sizes 140, 160, 180, 200, 220, 240, 260, 290, 310, the water cooling cartridge option comprises two cartridges as standard; for sizes 10, 170, 190, 210, 230, 20, 270, 280, 300, 320, it comprises one cartridge. The possible use as well as the maximum number of water cooling cartridges depends among others from the gear unit size, mounting position, end gear position, and type of. Not all combinations of accessory options might be possible depending on the mounting position and mounting surface. Consult SEW-EURODRIVE. Catalog Helical and Bevel-Helical Gear Units X.. Series 101

28 Lubrication,, and Heating Notes on connection and operation To achieve the thermal rating specified in the selection tables (from page 13), different cooling water volume flows are necessary depending on gear unit size, mounting position, and type of. The following table lists the approximate values for the volume flow required for the M mounting position (water inflow temperature 1 C). Contact SEW-EURODRIVE when using another cooling water flow rate, another cooling water temperature, special cooling media (the cooling capacity of the water-cooling cartridge changes), aggressive cooling media, such as brackish water or salt water. Gear unit water flow rate [l/min] / per cooling cartridge size 2-stage 3-stage 4-stage 140 / / / / / / / / / Max. cooling water flow rate [l/min] The cooling circuit must be connected in parallel for gear units with two water cooling cartridges. The table lists the cooling water volume flow for one cooling water cartridge. Twice the cooling water volume flow is required when using 2 cooling cartridges AXX 102 Catalog Helical and Bevel-Helical Gear Units X.. Series

29 Lubrication,, and Heating Requirements on the water quality Water hardness Special measures have to be taken when using sea water or brackish water. Consult SEW-EURODRIVE. The following requirements on the water quality are recommendations. In exceptional cases, certain concentrations of substances of content might cause unforeseen reactions. The quality of the water as well as its substances are important factors for assessing the cooling water available for water cooling cartridges. The water quality is determined by the water hardness and the ph value of the water. Water hardness is defined by the amount of hardeners (carbonates and bicarbonates) in the water. Hardeners accumulate on the surface of the water cooling cartridge in particular at high temperatures and in this way impair the performance. Take these deposits into account when selecting the water cooling cartridge for extremely hard water. The following table shows the classification of German degrees of hardness to water quality dh: Degree of hardness 1) Water quality 0 - dh Very soft water - 10 dh Soft water dh Medium hard water dh Hard water > 30 dh Very hard water 1) 10 mg/l of hardener corresponds to 1 dh ph value The water cooling cartridge partially consists of a copper and nickel alloy, to which the following applies: Corrosion problems when ph value < 6 With alkaline water: Corrosion problems when water hardness < 6 dh. Smaller values can cause corrosion due to free carbonic acid. The following table describes the classification of the water quality based on the ph value: ph value Water quality 4. Very acidic Acidic Slightly acidic 7.0 Neutral Slightly alkaline Alkaline 8.2 Very alkaline Catalog Helical and Bevel-Helical Gear Units X.. Series 103

30 Lubrication,, and Heating water assessment based on water substances The following table provides an overview of the resistance of copper pipes against substances in non-potable water. Assessment criterion ph value Chloride Sulfate Nitrate Free (aggressive) carbonic acid Oxygen Ammonium Iron (dissolved) Manganese (dissolved) Approximate concentration [mg/l] Assessment CuNi < to 9 + > 9 0 to > (< 2000 mg/l) up to to > (< 2000 mg/l) up to > up to to 0 0 > 0 - up to 2 + > 2 + up to to 20 + > 20 - up to 10 0 > 10 - up to 1 0 > 1 - Free chlorine up to constantly < 0. mg/l > intermittently < 3.0 mg/l Sulfide 0 Ammonia + (< 1 mg/l) Key 0 = usually good resistivity + = corrosion problems can occur in particular if several factors are assessed with 0 - = we advise against use 104 Catalog Helical and Bevel-Helical Gear Units X.. Series

31 Lubrication,, and Heating water types / characteristics Industrial water Usually untreated water (no drinking water) Often very contaminated A water analysis is necessary for assessment Copper, brass and steel are very resistant against industrial water Stream water and river water We recommend using copper brass pipes Cast iron parts must be protected against corrosion by suitable coating Usually untreated water (no drinking water) Often very contaminated A water analysis is necessary for assessment Catalog Helical and Bevel-Helical Gear Units X.. Series 10

32 Lubrication,, and Heating.4.4 Circulation cooling oil-water cooler for splash 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 cooler is that appropriate cooling water is available on site. Contact SEW-EURODRIVE if chemically aggressive cooling media, such as brackish or salt water, are used. The following information applies to gear units with splash. The cooling system with motor pump only cools the gear unit oil. When installing a filter in the OWC cooling system, make sure there is sufficient height for removing the filter element and the filter hood. Structure SEW-EURODRIVE uses two different types of heat exchangers: For gear unit sizes 140 to 170, a plate heat exchanger is used for oil supply systems OWC 00/01/02. [] [2] [6] [3] [8] [7] [4] 68912AXX Motor [2] Pump [3] Oil-water heat exchanger [4] Suction pipe (not visible in this view) [] line [6] Temperature switch with two switching points (TSK2) [7] Water supply [8] Water return 106 Catalog Helical and Bevel-Helical Gear Units X.. Series

33 Lubrication,, and Heating For gear unit sizes 180 to 320, a shell and tube heat exchanger is used for OWC 10/20/30/40/0/60/70 oil supply systems. [7/8] [4] [2] [6] [] [3] 68913AXX Motor (provided by the customer) [] Suction pipe [2] Pump [6] Temperature switch with two switching points (TSK2) [3] Oil-water heat exchanger [7] Water supply [4] line [8] Water return The cooling system is delivered as a complete unit but without electrical connections. The standard delivery of the cooling system includes: Pump with directly mounted asynchronous motor Oil-water heat exchanger Temperature switch with 2 switching points for Controlled startup of the pump motor with an oil temperature of > 40 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, including 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 Pump motor Catalog Helical and Bevel-Helical Gear Units X.. Series 107

34 Lubrication,, and Heating Further instrumentation available on request, such as: Flow monitoring Thermostatic valve in the oil and/or water circuit Filter in the oil circuit Manometer Thermometer Sizes, cooling capacity, and selection The cooling capacities 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 0 Hz line frequency. Size system capacity system [kw] Flow volume system [l/min] 1) The cooling system is mounted on the gear unit Connection power Pump motor [kw] Weight [kg] 1) OWC 00 2) OWC OWC 01 2) OWC OWC 02 2) OWC OWC OWC OWC OWC ) system with plate heat exchanger The cooling systems OWC are designed for gear unit sizes 140 to 320. The values differ slightly for operation with a line frequency of 60 Hz. Please consult SEW-EURODRIVE. For information about selecting a suitable cooling system, refer to chapter "Selecting the cooling system" on page 66. In addition, the selection of an appropriate cooling system depends on the following factors: Actual power loss to be cooled Present cooling water temperature and volume flow Ambient temperature Ratio of oil quantity in the gear unit and oil volume flow of cooling system > 2 Consult SEW-EURODRIVE when selecting the appropriate cooling system based on the ambient conditions present for your system. 108 Catalog Helical and Bevel-Helical Gear Units X.. Series

35 Lubrication,, and Heating Installation and connection information for separate installation 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 but without electrical connections and piping. Install it in 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. Adhere to the following basic conditions when connecting the cooling system: 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. Preferably, use composite material seals. SEW-EURODRIVE recommends the following cable cross sections for connecting the cooling system to the gear unit and the cooling circuit. Size system Pump suction connection Suction pipe 1) connection pipe 2) water connection of cooler Inner Ø of the cooling water line OWC 00 GE22-LR 3/4" DN20 / Ø22 GE18-LR 1/2" DN16 / Ø18 G3/4" Ø2 OWC 010 GE22-LR 1/2" DN20 / Ø22 GE18-LR 1/2" DN16 / Ø18 G1/2" Ø13 OWC 01 GE28-LR 1" DN2 / Ø28 GE22-LR 3/4" DN20 / Ø22 G3/4" Ø2 OWC 020 GE3-LR 1 1/4" DN32 / Ø3 GE28-LR 1" DN2 / Ø28 G1/2" Ø19 OWC 02 GE3-LR 1 1/4" DN32 / Ø3 GE28-LR 1 1/4" DN2 / Ø28 G3/4" Ø2 OWC 030 GE3-LR 1 1/4" DN32 / Ø3 GE28-LR 1" DN2 / Ø28 G1" Ø2 OWC 040 GE42-LR 1 1/2" DN40 / Ø42 GE3-LR 1 1/2" DN32 / Ø3 G3/4" Ø2 OWC 00 GE42-LR 1 1/2" DN40 / Ø42 GE3-LR 1 1/2" DN32 / Ø3 G1 1/4" Ø32 OWC 060 SAE 2" SFL DN0 / Ø2" GE42-LR 1 1/2" DN40 / Ø42 G1 1/2" Ø38 OWC 070 SAE 2 1/2" SFL DN0 / Ø2" GE42-LR 1 1/2" DN40 / Ø42 G1" Ø38 1) max. length 1. m 2) max. length 2. m For dimension sheets of oil-water coolers with motor pump, refer to page 444 ff. More detailed technical data of the several cooling systems are available from SEW-EURODRIVE on request. Dimensions for OWC 00/01/02 cooling systems for separate installation are available from SEW-EURODRIVE on request. Catalog Helical and Bevel-Helical Gear Units X.. Series 109

36 Lubrication,, and Heating.4. Circulation cooling oil-water cooler for pressure /OWP 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. Consult SEW-EURODRIVE if you use chemically aggressive cooling media, such as brackish water or salt water. The cooling system with motor pump cools the gear unit oil and the pressure of the gear unit. When installing a filter in the OWP cooling system, make sure there is sufficient height for removing the filter element and the filter hood. Structure SEW-EURODRIVE uses two different types of heat exchangers: For gear unit sizes 140 to 170, a plate heat exchanger is used for oil supply systems OWP 00/01/02. [12] [3] [8] [2] [6] [9] [10] [11] [7] [] [4] 68914AXX Motor [7] Oil-water heat exchanger [2] line [8] switch [3] Contamination indicator [9] Temperature switch, optional (NTB) [4] Oil filter [10] water supply [] Suction pipe (not visible in this view) [11] water return [6] Pump [12] Check valve 110 Catalog Helical and Bevel-Helical Gear Units X.. Series