SEW-EURODRIVE Easy Guide Industrial Gear Units X.. Series Helical and Bevel-Helical Gear Units Edition 05/2018 24803731/ EN
2/16 Gear unit structure 1 Safety notes 2 Gear unit designs 3 Mounting positions 4 Mounting surfaces Risk of crushing Hot surfaces No open fires HSS X.F.. LSS M6 M1 M2 F1 F4 Rotating parts Falling parts HSS X.K.. LSS M4 M5 F2 F5 HSS X.T.. M3 F6 Grounding, required Leaking oil LSS HSS = Input shaft LSS = Output shaft F3 5 Nameplate 6 Safety symbols on the gear unit Type Type designation No. Serial number PK1 Operating power on the input shaft (HSS) MK2 Gear unit output torque n1 Input speed (HSS) n2 Output speed (LSS) i Exact gear unit ratio Fs Service factor PM Nominal motor power Ta Deviation from the standard temperature range IM Mounting position and mounting surface Greasing points Number of points that require regreasing Fan Fan Mass Gear unit weight Year Year of manufacture Oil type / Viscosity / Oil quantity 12345 Additional text, e.g. service number Oil dipstick Oil level glass Oil sight glass Temperature sensor Breather Greasing points Air outlet Water return/connection Water supply/connection Oil return/connection Oil supply/connection Hot surfaces Risk of burns due to hot gear oil The brake is not set at the factory
3/16 Lifting and moving/installing 1 Transport 2 Transport 3 Transport 4 Notes Lifting eyebolts Motor adapter Transport Swing base 5 Installing the gear unit Notes 6 Installing the gear unit Foot mounting 7 Installing the gear unit Mounting flange Observe the information specified on the dimension sheet * Size Screws * Tightening torque Nm Strength class 8.8 * X100 110 M20 464 X120 130 M24 798 X140 150 M30 1597 X160 170 M36 2778 X180 190 M36 2778 X200 230 M42 3995 X240 280 M48 6022 X290 320 M56 9650 Screws * Tightening torque Nm Strength class 10.9 M12 137 M16 338 M20 661 M24 1136 *Screws are not included in the delivery. *Screws are not included in the delivery.
4/16 First filling prior to startup 1 Before 2 Oil type/oil quantity 3 Checking the oil level 4 switching on Checking the oil level in pivoted mounting position (option) Before switching on the gear unit for the first time, you have to fill it with oil. The oil quantity on the nameplate is an approximate value. Check the exact oil level using the oil dipstick or checking the oil level glass. The required mounting position for the oil level check is specified on an additional information label. 5 Filling in oil 6 Gear unit with shaft end pump (option) 7 Gear unit with oil expansion tank (option) The shaft end pump [1] must be filled with oil prior to startup. a b c
5/16 Lubricant table 1 Lubricant table Required minimum oil temperature in C CLP Mineral oil CLP HC Synthetic oil CLP HC NSF H1 Food grade oil E Ester oil *) Only with service factor 1.3 Further information on www.sew-eurodrive.de/lubricants
6/16 Gear unit cooling 1 Gear unit with fan (option) 2 Gear unit with 3 water cooling cover (option) Gear unit with cooling water cartridge (option) Standard fan/ axial fan Advanced fan a b Max. 6 bar 4 Oil-air cooler for splash lubrication /OAC (option) 5 Oil-air cooler for pressure lubrication /OAP (option) 6 Installing the oil-air cooler Gear units with pressure lubrication must only be operated with connected pressure switch. Standard: h 2 < h 1 A: l max = 2.5 m B: l max = 1.5 m With h 2 h 1 [1] Gear unit oil supply [2] Pump with motor [3] Oil pump suction pipe [5] Heat exchanger [8] Temperature switch /TSK [11] Fan motor [2] Pump with motor [9] Pressure switch [10] Contamination indicator [11] Fan motor
7/16 Gear unit cooling 7 Minimum distance 8 Oil-water cooler for splash lubrication /OWC (option) 9 to the cooler Design and connection Observe the requirements on the cooling media (see operating instructions). Oil-water cooler for pressure lubrication /OWP (option) Design and connection Gear units with pressure lubrication must only be operated with connected pressure switch. [1] Gear unit oil supply [2] Pump with motor [5] Heat exchanger [6] Cooling water return [7] Cooling water inflow [8] Temperature switch /TSK [1] Gear unit oil supply [2] Pump with motor [5] Heat exchanger [6] Cooling water return [7] Cooling water inflow [8] Temperature switch /TSK [9] Pressure switch [10] Contamination indicator 10 Heat exchanger (OWC/OWP) 11 Control of the oil cooling system X140 X170 X180 X320 Trip points STOP drive Temperature switch /TSK With pressure lubrication Pressure switch /PS Cooling ON Cooling OFF Controller [1] Gear unit oil supply [4] Oil pump pressure pipe [5] Heat exchanger [6] Cooling water return [7] Cooling water inflow Switch on the pump at least 10 minutes before switching on the main drive.
8/16 Installing shrink disk X100 X160 1 2 3 4 5 a a 0 mm NOCO FLUID b 2. b * * *Not included in the delivery *Not included in the delivery 6 A 7 8 = 6 1 5 2 4 3 Size A (mm) ±0.5 Size A (mm) ± 0.5 X100 37.5 X130 140 41 X110 38 X150 42 X120 39 X160 48 =
9/16 Installing shrink disk X170 X320 1 2 3 4 5 a a 0 mm NOCO FLUID b 2. b * * *Not included in the delivery *Not included in the delivery 6 A 7 8 = 6 1 5 2 Size A (mm) ±0.5 Size A (mm) ±0.5 4 3 X170 190 37 X270 280 49 X200 210 38 X290 300 49 = X220 230 39 X310 320 60 X240 260 48
10/16 Mounting the flange coupling Clean coupling and shaft Heat the coupling 1 3 Mount the coupling onto the shaft Clean the coupling flange Screw on the end ring 4 a a b Size Screws X100 110 M16 138 171 X120 140 M20 278 333 X150 170 M24 478 576 X180 220 M30 958 1146 X230 300 M36 1666 1992 X310 320 M42 2397 3186 b * Only with key 5 Align the shafts 6 Connect the coupling halves Tightening torque Nm Strength class 8.8 10.9 Tighten the screws 7 Size Screws Tightening torque Nm Strength class 8.8 10.9 X100 110 M16 230 285 X120 140 M20 464 555 X150 170 M24 798 960 X180 220 M30 1597 1910 X230 300 M36 2778 3320 X310 320 M42 3995 5310
11/16 Startup 1 Checks prior to startup 2 Starting up the shaft end pump (option) Checklist OK Checklist OK Checklist OK Gear unit has not been damaged during transport. All transport protection has been removed. All retaining screws and nuts are tightened to the specified torque. Correct oil level has been checked by means of oil dipstick or oil level glass. When using an oil heater /OH: Thermostat is connected and works properly. When using a temperature sensor PT100: Temperature sensor is connected and works properly. When using a pressure switch /PS: Pressure switch is connected and works properly. The pressure switch is connected and ready for operation. The limit temperature (minimum oil temperature) for gear unit start is observed. When using water cooling: Cooling water supply is connected and works properly. When using oil-air cooling system: Fan motor and pump motor are connected and work properly. When using fan motor and pump motor: Direction of rotation has been checked and is correct. When using an oil heater /OH: Oil heater is connected and works properly. When using a temperature switch /TSK /NTB: Temperature switch is connected and works properly. All gear units and electrical mount-on components are grounded. The shafts are aligned correctly. Rotating shafts and couplings are equipped with protection covers. When using gear units with long-term protection: The screw plug has been replaced by a breather. The shaft end pump has been filled with oil before startup. The shaft end pump provides sufficient oil pressure within 20 seconds. The minimum speed of the shaft end pump of 400 min -1 is observed. 3 Starting up 4 Starting up the motor pump (option) a gear unit with backstop (option) 5 Inspection intervals Checklist OK Checklist OK Time interval What to do? The pressure switch is connected and ready for operation. The motor pump has been running for 15 min prior to startup. The oil level has been checked and corrected after motor pump startup. The limit temperature (minimum oil temperature) for gear unit start is observed. The direction of rotation of the input shaft (HSS) matches the direction arrow on the input end. The direction of rotation of the output shaft (LSS) matches the direction arrow on the output end. The direction of rotation is specified as viewed onto the output shaft (LSS). Clockwise rotation (CW) Counterclockwise rotation (CCW) The permitted direction of rotation is indicated on the housing. Daily Check the housing temperature Check for gear unit noise Monthly Check the oil level Check the gear unit for signs of leakage After 500 operating hours First oil change after initial startup Every 6 months Check the screw fittings and piping for leakage Every 3000 operating hours Check the oil consistency Refill sealing grease Depending on the operating conditions At least every 12 months Approx. 5000 operating hours* Change mineral oil Approx. 10000 operating hours* Change synthetic oil *Depending on the operating conditions Check the breather. Check alignment of shafts Check retaining screws Check condition of oil-water or oil-air cooler Clean housing Touch up or renew surface/anti-corrosion coating
12/16 1 Possible failures/remedy 24 h service hotline: 0800 7394357 Failure Possible cause Remedy Unusual noise in the area where the gear unit is mounted Gear unit mounting has loosened Tighten retaining screws and nuts to the specified torque. Replace the damaged/defective retaining screws or nuts. Operating temperature too high Too much oil Check the oil level, correct if necessary. Temperature at bearing points too high Oil leaking at the cover plate, gear unit cover or bearing cover Oil too old The oil is heavily contaminated Ambient temperature too high Gear units with fan: Air intake opening/gear unit housing contaminated For gear units with built-in cooling: Cooling liquid flow rate too low; cooling liquid temperature too high; deposits in cooling system Malfunction of the oil-air or oil-water cooling system Malfunction in the water cooling (water cooling cover, water cooling cartridge) Not enough oil Oil too old Bearing damaged Seal broken at the cover plate, gear unit cover or bearing cover Check when the oil was last changed; change the oil, if necessary. Analyze the oil to determine the cause; take measures, if necessary; change the oil. Protect the gear unit from external heat sources (e.g. provide shade). Check air intake openings, clean them if necessary; clean the gear unit housing. Check the cooling liquid flow rate; check the entry temperature of the cooling liquid, clean the cooling system. Observe the separate operating instructions for the oil-water and oil-air cooling system. Check the cooling water throughput and the entry temperature of the cooling water, clean the cooling system. Check the oil level, correct if necessary. Check when the oil was last changed; change the oil, if necessary. Check the bearing and replace it if necessary. Contact SEW-EURODRIVE. Tighten the bolts on the respective cover. Observe the gear unit. Contact SEW-EURODRIVE if oil is still leaking. Oil leaking from oil seal Too much oil Check the oil level; correct if necessary Sealing lip of the oil seal turned up Oil seal damaged/worn Vent the gear unit; monitor the gear unit. Contact SEW-EURODRIVE if oil is still leaking. Check oil seals; replace if necessary. Oil leaking from gear unit breather Too much oil Check the oil level, correct if necessary. Drive not installed in proper mounting position Frequent cold starts (oil foams) and/or high oil level Install breather plug correctly and adjust the oil level. Install oil expansion tank.
13/16 2 Possible failures/remedy 24 h service hotline: 0800 7394357 Failure Possible cause Remedy Oil leaking - from screw plug - from the oil drain valve Gasket not tight Fittings loosened Retighten screw. Retighten the fitting and screw. Heavy V-belt wear Inadequately aligned belt pulleys Check V-belt pulley alignment and pretension of the belts. Harmful ambient conditions (e.g. abrasive particles, chemical substances) V-belt overloaded Protect V-belt drive from environmental influences; sufficient ventilation must be ensured. Replace V-belt if necessary; contact SEW-EURODRIVE. No oil pump suction Air in the suction line of the oil pump Fill oil into the suction line and the oil pump, vent the pump at the pressure side. Oil pump defective Contact SEW-EURODRIVE. Pressure switch not switching Air in the suction line of the oil pump Fill oil into the suction line and the oil pump and vent the pump at the pressure side. Malfunction in the oil-water or oil-air cooling system Gear unit does not reach cold start temperature Operating temperature at backstop too high, no blocking function Pressure switch connected incorrectly Pressure switch defective Oil pump defective Malfunction of the oil-water or oil-air cooling system Thermostat set incorrectly Oil heating defective or connected incorrectly Heat dissipation too great due to unfavorable climatic conditions Damaged/defective backstop Check the connection. Replace pressure switch. Contact SEW-EURODRIVE. Observe the separate operating instructions for the oil-water or oil-air cooling system. Check the setting of the thermostat. Check the oil heater for proper connection and function; replace if necessary. Protect the gear unit from cooling off during the warm-up phase. Check the backstop, replace it if necessary. Contact SEW-EURODRIVE.
14/16 Notes
15/16 Safety notes 1. Important Notes 1.1. Safety notes The following basic safety notes must be read carefully to prevent injury to persons and damage to property. The operator must ensure that the basic safety notes are read and adhered to. Ensure that persons responsible for the machinery and its operation as well as persons who work on the unit independently have read through the documentation carefully and understood it. If you are unclear about any of the information in this documentation, or if you require further information, please contact SEW-EURODRIVE. 1.2 General information Never install or start up damaged products. Report any damage to the shipping company immediately. During operation, the gear units can have movable or rotating parts as well as hot surfaces. All work related to transportation, storage, installation, assembly, connection, startup, maintenance and repair may only be carried out by qualified personnel, in strict observance of the comprehensive operating instructions. Removing covers without authorization, improper use, or incorrect installation and operation may result in severe injuries to persons or damage to machinery. 1.3 Target group Any mechanical work may only be performed by adequately qualified personnel. Qualified personnel in this context are persons who are familiar with the setup, mechanical installation, troubleshooting and maintenance for this product. Further, they have training in mechanical engineering, e.g. as a mechanic or mechatronics technician (final examinations must have been passed). Any electronic work may only be performed by adequately electrically skilled persons. Electrically qualified personnel in this context are persons who are familiar with electrical installation, startup, troubleshooting and maintenance for this product. Further, they have training in electrical engineering, e.g. as an electrician or mechatronics technician (final examinations must have been passed). All work in further areas of transportation, storage, operation and waste disposal must only be carried out by persons who are trained appropriately. All qualified personnel must have read and understood the comprehensive operating instructions and wear appropriate protective clothing. 1.4 Designated use The industrial gear units are gear units run by motors for industrial and commercial systems. The units may only be run at the speeds and powers shown in the technical data or on the nameplate. Implementing gear unit loads other than the permitted values or operating the gear units in areas of application other than industrial and commercial systems is only permitted after consultation with SEW-EURODRIVE. Using these products in potentially explosive atmospheres is prohibited, unless specifically designated otherwise. In compliance with the EC Machinery Directive 2006/42/EC, the X.. series industrial gear units are components for installation in machinery and systems. In the scope of the EC directive, you must not take the machinery into operation in the designated fashion until you have established that the end product complies with Machinery Directive 2006/42/EC. 1.5 Other applicable documentation The following publications and documents have to be observed as well: Operating Instructions: Helical and Bevel-Helical Gear Units X.. Series Catalog: Helical and Bevel-Helical Gear Units X.. Series Order documents, e.g. dimension sheet, order confirmation, etc. If required, the "AC Motors" operating instructions If required, the operating instructions of the installed options 1.6 Safety symbols on the gear unit The safety symbols on the gear unit must be observed. Refer to the comprehensive operating instructions regarding the meaning of the symbols. 1.7 Transportation/storage Observe the notes in the comprehensive operating instructions regarding transportation, storage, and proper handling. Comply with the requirements for climatic conditions stated in chapter "Storage and transportation conditions". 1.8 Installation/Assembly The units must be installed and assembled according to the regulations and specifications in the corresponding documentation. 1.8 Startup The units must be started up according to the regulations and specifications in the corresponding documentation.