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1. F 27 D I M1 M3 M5 M6 F 27 OR vu Me F 27 M1 M3 M5 M6 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 42 044 03 00 115 Mounting Positions Helical bevel gearmotors K 8 6 Helical bevel gearmotors K 8 6 1 K37 K157 KA37B KA157B KH37B KH157B KV37B KV107B 34 025 03 00 D 270 T 2 d IE I 4p 0 R 180 L Y ai mm db 90 B M1 wa SC A e M2 0 eL SP x a 71 428 S ar D o K47 QS j e 3 x rel T es K47 2 EJ 0 RE d O I 116 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W ax o 22 o9 d oo E Oo o s gt o o o0 gt L m Ki o I K187 KH167B KH187B 8 6 2 K167 34 026 03 00 2 a eG by Wi Ze E
2. EURODRIVE EURODRIVE EURODRIVE SEW EURODRIVE Driving the world Drive Technology Drive Automation System Integration Services How we re driving the world With people who With comprehensive With uncompromising think fast and With a worldwide With drives and controls knowledge in virtually quality that reduces the develop the service network thatis that automatically every branch of cost and complexity of future with you always close at hand improve your productivity industry today daily operations SEW EURODRIVE L Y Driving the world With a global presence With innovative With online information that offers responsive technology that solves and software updates an
3. 131 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W SPIROPLAN W gearmotors o o o e n D c c z o 8 8 6 WA37 WH37 WT 37 20 014 01 07 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 132 Technical Data Extended storage 9 Technical Data 9 1 Extended storage NOTE For storage periods longer than 9 months SEW EURODRIVE recommends the Ex tended storage design Gear units in this design are designated with a corresponding label In this case a VCI corrosion inhibitor volatile corrosion inhibitor is added to the lubri cant in these gear units Please note that this VCI corrosion inhibitor is only effective in a temperature range of 25 C 50 C The flange contact surfaces and shaft ends are also treated with an anti corrosion agent Observe the storage conditions specified in the following table for extended storage 9 1 1 Storage conditions The gear units must remain tightly sealed until taken into operation to prevent the VCI corrosio
4. 42 042 03 00 F 27 Se M1 M3 M5 M6 F 27 OR M1 M6 F 27 M1 M3 M5 M6 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 113 Mounting Positions Parallel shaft helical gearmotors F 8 5 2 FF27 FF157 FAF27 FAF157 FHF27 FHF157 FAZ27 FAZ157 FHZ27 FHZ157 FVF27 FVF107 FVZ27 FVZ107 42 043 03 00 gr m T 90 B Z ei HA X ZZZZZ7Z F 27 D I M1 M3 M5 M6 F 27 D M1 M6 F 27 M1 M3 M5 M6 114 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mounting Positions Parallel shaft helical gearmotors F 8 5 3 FA27 FA157 FH27 FH157 FV27 FV107 FT37 FT157 270 T d E
5. X 180 M Er 1 270 EN i 270 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 121 Mounting Positions Helical worm gearmotors S 97 8 7 2 S47 05 026 03 00 3 j j JY 90 B t H Ex Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 122 Mounting Positions Helical worm gearmotors S 8 7 3 SF37 SAF37 SHF37 05 027 03 00 EE EET EP MERE Operating Instructions Exp
6. Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mounting Positions SPIROPLAN W gearmotors 8 8 3 WA10 WA30 20 003 02 02 M6 M3 Ec 129 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 20 012 01 07 SS Z WSS e 0 R 4 T CO zm 2 Or 2 E Oo FO 1 E Wy o 0 U 2 SS o pe o9 3 Oz Se ODOL En CH SC E A li st c e NA et o Urs A Ho zo ed 8 8 4 W37 WA37B WH37B ML X Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 130 0 c o 0 D D D c E 5 el 2 2 o E G D O z Z lt x d an O or an Wa 8 8 5 WF37 WAF37 WHF37 20 013 01 07
7. Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W General Information Rights to claim under limited warranty 1 3 Rights to claim under limited warranty Adhering to the operating instructions is a prerequisite for fault free operation and the fulfillment of any right to claim under warranty Read the operating instructions before you start working with the unit 1 4 Exclusion of liability You must comply with the information contained in these operating instructions to en sure safe operation of the explosion proof R 7 F 7 K 7 S 7 SPIROPLAN W series gear units and to achieve the specified product characteristics and performance require ments SEW EURODRIVE assumes no liability for injury to persons or damage to equip ment or property resulting from non observance of these operating instructions In such cases any liability for defects is excluded Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Safety Notes Preface 2 2 1 2 2 Safety Notes The following basic safety notes are intended to prevent injury to persons and damage to property The operator must ensure that the basic safety notes are read and ob served Make sure that persons responsible for the system and its operation as well as persons who work independently on the unit have read through the operating instruc tions carefully and un
8. 212119307 1 Motor mounting platform 2 Stud bolt only AD6 P AD7 P 3 Support only AD6 P AD7 P 4 Nut 5 Threaded column 1 Set the motor mounting platform to the required mounting position by evenly tighten ing the adjusting nuts Remove the lifting eyebolt from helical gear units in order to achieve the lowest adjustment position Touch up any damage to the paint work 2 Align the motor on the motor mounting platform shaft ends must be in alignment and secure it 3 Mount the input elements on the input shaft end and the motor shaft line them up with one another and correct the motor position again if necessary 4 Put on the traction elements V belt chain etc and apply a preload by evenly ad justing the motor mounting platform Do not stress the motor mounting platform and the columns against each other when doing this 5 Tighten all the nuts not used for adjustment in order to fix the threaded columns Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 65 5 Mechanical Installation AD input shaft assembly 5 14 2 Only AD6 P and AD7 P Unscrew the nuts on the stud bolts before adjustment to allow the stud bolts to move axially in the support without restriction Do not tighten the nuts until the final adjustment position has been reached Do not adjust the motor mounting platform using the support 5 14 3 AD ZR input cover with cent
9. 1 When changing the oil seal ensure that there is a sufficient grease reservoir between the dust lip and protective lip depending on the type of gear unit 2 If you use double oil seals fill one third of the gap with grease 7 7 8 Painting gear units CAUTION Breather valves and oil seals may be damaged during the painting or re painting pro cess Potential damage to property Thoroughly cover the breather valves and the sealing lip of the oil seals with strips prior to the painting process Remove the strips after the process Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 105 0 c o 0 D D D c E 5 el Designation of the mounting positions Mounting Positions 8 Designation of the mounting positions 8 1 M6 The following illustra M6 tion shows the position of the gear unit in mounting positions M1 SEW differentiates between the six mounting positions M1 Q Cy St A WSAVES F AN Q ANTES L Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 106 Mounting Positions 8 2 Key NOTE The SPIROPLAN gearmotors are not dependent on the mounting position except for W37 in M4 mounting position Howev
10. 45 5 Mechanical Installation Shaft mounted gear units with shrink disk 5 Install the input shaft Make sure that the locking collars of the shrink disk are installed in parallel to each other For gear unit housings with shaft shoulder Mount the shrink disk onto the stop on the shaft shoulder For gear unit housings without shaft shoulder Install the shrink disk with a 1 to 2 mm distance from the gear unit housing Tighten the locking screws by working round with the torque wrench several times from one screw to the next not in diametrically opposite sequence For tighten ing torques refer to the following table 211542283 6 After the installation make sure the remaining gap between the outer rings is gt 0 mm 7 Grease the the area around the shrink disk outside of the hollow shaft to prevent cor rosion Gear unit type Screw Nm max SH37 WH37 M5 5 KH37 77 FH37 77 SH47 77 M6 12 KH87 97 FH87 97 SH87 97 M8 30 KH107 FH107 M10 59 60 KH127 157 FH127 157 M12 100 KH167 M16 250 KH187 M20 470 1 Maximum tightening angle per rotation 46 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Shaft mounted gear units with shrink disk 5 8 2 Removal notes A CAUTION Ris
11. Drive Technology Drive Automation System Integration Services III x_n Explosion Proof Gear Units R 7 F 7 K 7 S 7 Series Spiroplan W Edition 05 2008 Operating Instructions 11630213 EN SEW EURODRIVE Driving the world Contents Contents 1 General Information 15 wi cccsicecsciesetiececvesteneetcesecteeedteccseeeeeeeuttcesevevsitecuetevetieeserenticers 5 1 4 How to use the operating instructions 5 1 2 Structure of the safety notes 5 1 3 Rights to claim under limited warranty eeeeeeeeeeeeeeeserrneesernssserrrrsseeersse 6 ta Exclusion OF liability eoe beoe eai 6 2 Safety Notes nete Ee ne re ie ene Pete 7 ST Preface diia nd eed E edt Ld ed E ee E edad d E eet 7 2 2 General information esseseeeeeeeeieere A nna 7 2 9 Targat QIOUP WEE 8 24 Designated se ENNEN NENNEN een deen 8 2 5 Other applicable documentation sssssseseeesttnrnerestertttrnrtnrnnnssnnsttennt rnnr 9 2 0 UN rali SDOED EE 9 2 7 Extended storage eei dab en OO HE edel en 10 2 8 Installation assembly sssssssseee enm emm enn 10 2 9 Startup operation sssssssssssssssseeeeeernerene nnne 10 2 10 Inspection maintenance seiorn a a aaa a a a i aai 10 E ai i E E EE 11 3 1 Before startup aii can ene ees ee eek eden a ANNE REENEN a 11 3 2 Buring Startup EE 12 4 Gear Unit Design iniret eire SEENEN EENS NE
12. Fill the oil according to the quantity specified on the nameplate Check the oil level at the oil level plug Re insert the oil level plug and the breather valve Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance Inspection maintenance for the gear unit 7 7 3 Helical parallel shaft helical SPIROPLAN gear units without oil level plug with cover plate Checking the oil For gear units without oil level bore the oil level is checked via the cover plate opening level via the cover Proceed as follows plate 1 Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 2 For the cover plate to be on top you have to set up the gear unit in the following mounting position R07 R57 in M1 mounting position F27 in M3 mounting position W10 W30 in M1 mounting position 3 Loosen the screws 1 of the cover plate 2 and remove the cover plate 2 and the corresponding seal 3 see following figure 18643211 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 93 Inspection Maintenance Inspection maintenance for the gear unit 4 Determine the vertical distance x between oil level and sealing surface of the gear unit housing see following figure 18646283 5 Compare the determined value x to the max dista
13. M10 x 1 1 5 The correct minimum fill level according to the table value x corresponds to the check marks on the oil dipstick see following figure EET 1 6 If the oil level is too low fill in new oil of the same type via the oil level bore until the oil level reaches the lower edge of the bore 7 Re insert the oil level plug Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 101 7 Inspection Maintenance Inspection maintenance for the gear unit Checking the oil Proceed as follows to check the oil of the gear unit via the oil level T D Kn l 1 Observe the notes in section Preliminary work regarding gear unit inspection main pug tenance see page 81 2 Remove a little oil at the oil level plug 3 Check the oil consistency Viscosity f you can see that the oil is heavily contaminated we recommend that you change the oil even if this is outside the service intervals specified in Inspection and maintenance intervals see page 82 4 Check the oil level Changing the oil via the oil level plug A WARNING Danger of burns due to hot gear unit and hot gear unit oil Fatal injuries Letthe gear unit cool down before you begin with your work However the gear unit must still be warm otherwise the high viscosity of excessively cold oil will make it harder to drain the oil correctly 1
14. open Under roof enclosed at constant temperature and atmospheric humidity 5 C 9 50 C lt 50 relative humidity No sudden temperature fluctuations Controlled ventilation with filter free from dust and dirt Pro tected against aggressive vapors and shocks Protected against insect damage 2 years or more with regular inspections Check for clean liness and mechanical dam age during inspection Check corrosion protection 1 Packaging must be carried out by an experienced company using the packaging materials that have been explicitly specified for the particular application 2 SEW EURODRIVE recommends to store the gear units according to the mounting position Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 133 134 Technical Data Lubricants 9 2 Lubricants Unless a special arrangement is made SEW EURODRIVE supplies the drives with a lubricant fill adapted for the specific gear unit and mounting position You have to specify the mounting position M1 M6 see section Mounting Positions when you order the drive You must adapt the lubricant fill to any subsequent changes made to the mounting position NOTE ON EXPLOSION PROTECTION It is essential to contact SEW EURODRIVE regarding a subsequent change of mount ing position ATEX approval will become void without prior consultation 9 2 1 Lubricant ta
15. 2 Install the stop ring and the bushing on the customer shaft Y i Rl o z 211941003 3 Apply and thoroughly spread NOCOS Fluid on the bushing 211938827 4 Push the gear unit onto the customer shaft 211936651 48 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation 5 Shaft mounted gear unit with TorqLOC 5 Preassemble the torque arm do not tighten the screws 211943179 6 Push the busing onto the gear unit up to the stop 211945355 7 Tighten all the retaining screws of the torque arm 211947531 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 49 5 Mechanical Installation Shaft mounted gear unit with TorqLOC 8 Secure the bushing with the split ring Tighten the split ring on the bushing using the appropriate torque as specified in the following table 212000907 Type nickel plated Stainless steel Standard KT FT ST Torque Nm 37 18 7 5 37 47 18 7 5 47 57 18 7 5 57 67 67 35 18 77 77 35 18 87 87 35 18 97 97 35 18 107 38 38 127 65 65 157 150 150 9 Make sure that all screws are loosened and slide the shrink disk onto the hollow shaft 212003083 50 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Inst
16. 3 Washer 4 Circlip 5 Spacer tube 6 Customer shaft 3 Insert the forcing disc 8 and the fixed nut 7 from the SEW EURODRIVE installa tion removal kit between the customer shaft 6 and the circlip 4 4 Re install the circlip 4 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Shaft mounted gear unit with keyway or splined hollow shaft 5 Screw the retaining screw 1 back in Now you can force the gear unit off the shaft by tightening the bolt 211529227 1 Retaining screw 4 Circlip 6 Customer shaft 7 Fixed nut 8 Forcing disk Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 41 5 Mechanical Installation Shaft mounted gear unit with keyway or splined hollow shaft 5 7 3 SEW installation and removal kit The SEW EURODRIVE assembly disassembly kit can be ordered by quoting the spec ified part number eiie n t C4 L4 211531403 1 Retaining screw 7 Fixed nut for disassembly 8 Forcing disk Type pP M c4 C5 ce U 5 rT95 p35 L4 Part number of mm mm mm mm mm mm mm mm the installation removal kit WA 10 16 M5 5 5 12 4 5 18 15 7 50 643 712 5 WA 20 18 M6 5 6 13 5 5 5 20 5 17 7 25 643 682 X WA 20 WA 30 SA 37 WA 37 20 M6
17. 7 K 7 S 7 series SPIROPLAN W Startup ago 6 Helical parallel shaft helical helical bevel gear units 6 4 Helical parallel shaft helical helical bevel gear units 6 4 1 Stand alone gear units For gear units with an adapter or input shaft assembly you must ensure that the data specified on the nameplate are not exceeded It is essential that the gear unit is not over loaded 6 4 2 Mains operated motors Check that the data specified on the nameplate of the gear unit and the motor corre sponds to the ambient conditions at the location where the drive is to be installed 6 4 38 Inverter operated gearmotors e Check that the gearmotor is also approved for operation with an inverter nameplate The parameter settings made for the inverter must prevent the gear unit from being overloaded Refer to the nameplate for performance data permitted for the respective gear unit Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 73 6 74 ago 6 5 Startup Gear units with backstop Gear units with backstop The purpose of a backstop is to prevent undesirable reverse rotation During operation the backstop permits rotation in only one specified direction of rotation CAUTION Operating the motor in the direction that is blocked could destroy the backstop Potential damage to property Do not start up the motor in the blocking direction I
18. 7 Ki G i a34 C Ue Lagen Me per Lost Ee H e L 1 Hs Si cL U i I I a i Geet 1 o I eo i 1 Ne i C F 3 of VAENY 1 amp eu He i A H2S I x lt T T x lt i ee I o i CH I I I I 117 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mounting Positions Helical bevel gearmotors K 8 6 3 KF37 KF157 KAF37 KAF157 KHF37 KHF157 KAZ37 KAZ157 KHZ37 KHZ157 KVF37 KVF107 KVZ37 KVZ107 34 027 03 00 270 T We d 0 R ll pia 118 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mounting Positions Helical bevel gearmotor
19. 7 series SPIROPLAN W Inspection Maintenance Adapter AR Slip torques AR Cup springs No of cams or slots Z Adapter N ISI Setting type mM e range 123 45 6 7 8 9 10 11 12 13 14 15 16171819 20 21 ber ness mm Fig Nm Slip torque Mp in Nm 1 1 0 2 0 1 0 1 4 1 6 1 8 2 0 AR71 0 6 2 2 1 4 0 2 1 2 4 26 3 2 3 4 3 8 4 3 3 4 1 6 0 4 1 5 0 5 8 6 0 A 1 1 0 2 0 1 0 1 4 1 6 2 8 2 0 0 6 2 2 1 4 0 21 2 4 2 6 3 2 3 4 3 8 4 0 AR80 3 3 4 1 6 0 4 1 5 0 5 8 6 0 4 0 9 2 6 1 16 6 0 8 0 9 0 10 11 12 13 14 15 16 AR85 4 2 2 0 4 0 2 0 2 4 3 0 3 6 3 8 4 0 0 6 AR90 3 3 4 1 6 0 4 1 5 0 5 8 6 0 AR95 4 09 2 61 16 6 0 8 0 9 0 10 11 12 13 14 15 16 2 1 1 3 17 24 16 20 24 AR100 6 0 7 2 5 0 13 5 0 6 0 8 0 9 0 10 11 12 13 AR105 2 14 35 14 16 17 18 20 22 23 24 26 27 28 30 31 3235 AR112 2 1 45 36 41 45 48 54 58 60 AR115 3 36 80 AR132S M 1 15 32 15 18 22 24 26 28 30 32 AR132ML 2 33 65 33 40 50 58 67 4 1 5 AR135 3 66 130 68 100 120 13 AR145 z 5 4 15 1 30 45 32 36 38 40 41 42 40 44 45 AR160 2 46 85 46 48 60 65 70 75 80 85 2 2 7 2 86 200 86 90 110 125 135 150 160 180 190 200 1 30 45 32 36
20. Mounting Positions Helical worm gearmotors S 8 7 6 SA47 SA97 SHAT SH97 ST47 ST97 28 021 03 00 Poe 126 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mounting Positions SPIROPLAN W gearmotors 8 8 SPIROPLAN W gearmotors 8 8 1 W10 W30 x 270 T 20 001 01 02 2 M4 d M2 JA Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 127 128 Mounting Positions SPIROPLAN W gearmotors 8 8 2 WF10 WF30 WAF10 WAF30 0 R 20 002 01 02 EE q 180 L A 90 B x
21. PROPRIETARY LIMITED Tel 27 31 700 3451 2 Monaceo Place Fax 27 31 700 3847 Pinetown dtait sew co za Durban P O Box 10433 Ashwood 3605 Spain Assembly Bilbao SEW EURODRIVE ESPANA S L Tel 34 94 43184 70 Sales Parque Tecnol gico Edificio 302 Fax 34 94 43184 71 Service E 48170 Zamudio Vizcaya http www sew eurodrive es sew spain sew eurodrive es Sweden Assembly J nk ping SEW EURODRIVE AB Tel 46 36 3442 00 Sales Gnejsv gen 6 8 Fax 46 36 3442 80 Service S 55303 J nk ping http www sew eurodrive se Box 3100 S 55003 J nk ping info sew eurodrive se Switzerland Assembly Basel Alfred Imhof A G Tel 41 61 417 1717 Sales Jurastrasse 10 Fax 41 61 417 1700 Service CH 4142 M nchenstein bei Basel http www imhof sew ch info imhof sew ch Thailand Assembly Chonburi SEW EURODRIVE Thailand Ltd Tel 66 38 454281 Sales 700 456 Moo 7 Donhuaroh Fax 66 38 454288 Service Muang sewthailand sew eurodrive com Chonburi 20000 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Address List Tunisia Sales Tunis T M S Technic Marketing Service Tel 216 71 4340 64 71 4320 29 5 Rue El Houdaibiah Fax 216 71 4329 76 1000 Tunis tms tms com tn Turkey Assembly Istanbul SEW EURODRIVE Tel 90 216 4419164 3838014 Sales Hareket Sistemleri San ve Tic Ltd Sti 3738015 Service Bagdat Cad Koruma Cikmazi No 3 Fax
22. formed and verified by a final measuring step Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 77 C ps Startup 6 Installation and adjustment of the WEX speed monitor 6 7 2 Installation and adjustment of other speed monitors If other speed monitors are used they must feature an intrinsically safe sensor input identification color blue for evaluation of sensors according to DIN 19234 NAMUR and be approved for use of this sensor in potentially explosive atmospheres NOTE The voltage encoder sensor generally features a blue connection lead and must con form to DIN 19234 NAMUR The corresponding inspection number may be attached to the voltage encoder or the connection lead 78 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Startup ego 6 Installation of the voltage encoder Installation of the voltage encoder The following figure illustrates the installation of the voltage encoder and the setting of the switching interval x NEN Lun d m ERER E Zz 1 ee M AE Ke RED ME 7 Ga d mE X Ka N 1 N TW 2 18712331 1 Adapter flange bearing cover 3 Lock nut 2 Screw head 5 Voltage encoder 1 Rotate the output shaft of the adapter until the slotted screw head can be seen through the tapped hole in the beari
23. oil drain plug and the breather valve depends on the mounting position Refer to the diagrams of the mounting positions See chapter Mounting Positions see page 106 gt ee Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 81 82 Inspection Maintenance Inspection maintenance intervals 7 1 4 Cleaning the gear unit NOTE ON EXPLOSION PROTECTION Do not use materials or procedures e g compressed air that cause processes caus ing electrical charge on the coating 7 2 Inspection maintenance intervals Time interval What do I do Every 3000 operating hours at least every 6 months Check running noise for possible bearing damage Visually check the seals for leakage Check oil and oil level in case you suspect any leakages For gear units with a torque arm Check the rubber buffer and change it if necessary Every 10 000 hours of operation Check oil and oil level Depending on the operating and ambient conditions see illustration below at least every 3 years Replace breather valve Depending on the operating and ambient conditions see illustration below at least every 5 years according to oil temperature Change synthetic oil Replace cover plate seal Replace anti friction bearing grease recommendation Replace oil seal do not install it in the same track Varying depending on externa
24. 2 Gearwheel 24 5 Pinion shaft 25 6 Gearwheel 26 7 Output shaft 30 8 Key 31 9 Oil seal 32 11 Deep groove ball bearing 33 12 Circlip 36 19 Key 37 Gear unit housing 44 Eyebolt 59 Deep groove ball bearing 61 Housing stage 1 68 Deep groove ball bearing 72 Key 80 Spacer tube 88 Circlip 89 Hex head screw 106 Deep groove ball bearing 133 O ring Screw plug Circlip Circlip Circlip Key Circlip Closing cap Stud Shim 26 36 137 150 183 506 518 519 520 521 522 523 605872395 Shim Hexagonal nut Oil seal Shim Shim Shim Shim Shim Shim Shim Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Gear Unit Design Nameplate unit designation 47 Nameplate unit designation 4 7 1 Nameplate e SEWE EVRODRIVE Bruchsal Germany C E Typ RF47 A ll2GD Nr 01 3229561201 0001 03 M M1 na min 113 nemax 1 min 1400 IP 65 o Ma Nm 186 Memax Nm 14 6 kg 37 o FRamaxN 2820 FRemax N i 12 54 MR Nm Mas Nm fo 1 05 Bedienungsanleitung muss beachtet werden Il 2GD c k_T4 120 C z Schmierstoff CLP HC 220 Synth OI 0 71 V FSA GmbH EU Code 0588 Made in Germany 117 882 2 10 210927627 fp Service factor FRamax N Maximum overhung load on the output side FRemax N Maximum overhung load on the input side with input shaft assembly AD i Gea
25. 37 Roller bearing 131 Closing cap 12 Circlip 39 Circlip 181 Closing cap 17 Spacer tube 41 Circlip 506 Shim Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 13 4 2 1 2 3 4 5 6 7 9 11 14 16 17 19 20 14 Gear Unit Design Basic design of parallel shaft helical gear units Basic design of parallel shaft helical gear units Pinion Gearwheel Pinion shaft Gearwheel Pinion shaft Gearwheel Hollow shaft Oil seal Roller bearing Hex head screw output flange Spacer tube Key Breather valve 515 b al m 506 ES Eu 22 25 30 31 32 37 39 41 42 43 45 59 81 88 en A i E D I il Gear unit housing Roller bearing Roller bearing Key Spacer tube Roller bearing Circlip Circlip Roller bearing Key Roller bearing Screw plug Nilos ring Circlip 91 92 93 94 100 101 102 131 160 161 165 181 183 Circlip Disc Lock washer Hex head screw Gear cover plate Hex head screw Seal Closing cap Closing plug Closing cap Closing plug Closing cap Oil seal 506 507 508 515 516 517 521 522 523 Shim Shim Shim Shim Shim Shim Shim Shim Shim 19298059 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Gear Unit Design Basic desi
26. 38 40 41 44 45 AR165 4 1 5 AR180 2 46 85 40 48 60 65 70 75 80 85 AR185 2 86 200 86 90 110 125 135 150 160 170 180 190 200 2 2 7 AR195 3 201 300 200 zen 79 1 For sequence of cup springs refer to the legend below Key Fig 1 Double alternating sequence 00 Fig 2 Alternating sequence Fig 3 Aligned sequence Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 87 Inspection Maintenance Inspection maintenance for the AD input cover 7 5 3 Replacing the encoder of the adapter A HAZARD Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Disconnect the gearmotor from the power supply before starting work and protect it against unintentional re start 1 Remove the fan guard from the driving motor 2 Remove the encoder connection 3 Unscrew the lock nut on the encoder and remove the old encoder 4 install new encoder See section Installing the voltage encoder see page 79 5 Connect the encoder to the speed slip monitor 6 Install the fan guard NOTE Use only OEM spare parts according to the delivered spare parts lists 7 6 Inspection maintenance for the AD input cover Time interval What do do Every 3000 operating hours at least every 6 months Check running noise for possible bearing damage e Visually check the adapter for leakage e after 25 0
27. 5 6 15 5 5 5 225 19 7 25 643 683 8 FA 27 SA 47 25 M10 5 10 20 7 5 28 24 7 35 643 684 6 FA 37 KA 37 SA 47 SA 57 30 M10 5 10 25 7 5 33 29 7 35 643 685 4 FA 47 KA 47 SA 57 35 M12 5 12 29 9 5 38 34 7 45 643 686 2 FA 57 KA 57 FA 67 KA 67 SA 67 40 M16 5 12 34 11 5 41 9 39 7 50 643 687 0 SA 67 45 M16 5 12 38 5 13 5 48 5 44 7 50 643 688 9 FA 77 KA 77 SA 77 50 M16 5 12 43 5 13 5 53 5 49 7 50 643 689 7 FA 87 KA 87 SA 77 SA 87 60 M20 5 16 56 17 5 64 59 7 60 643 690 0 FA 97 KA 97 SA 87 SA 97 70 M20 5 16 65 5 19 5 74 5 69 7 60 643 691 9 FA 107 KA 107 SA 97 90 M24 5 20 80 24 5 95 89 7 70 643 692 7 FA 127 KA 127 100 M24 5 20 89 27 5 106 99 7 70 643 693 5 FA 157 KA 157 120 M24 5 20 107 31 127 119 7 70 643 694 3 1 Retaining screw 42 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Shaft mounted gear unit with keyway or splined hollow shaft NOTE The SEW installation kit for attaching the customer shaft is a recommendation by SEW EURODRIVE You must always check whether this design can compensate the axial loads In particular applications e g mounting mixer shafts a different design may have to be used to secure the shaft axially In these cases customers can use their own devices However you must ensure that these designs do not cause potential Sources of c
28. 70 K compared to the ambient temperature If the value is gt 70 K stop the drive immediately and contact SEW EURODRIVE Measure the oil temperature Add 10 K to the measured value Determine lubricant change interval using 6 2 this value Observe for gear units with AM adapter or AD input shaft assembly with RS backstop 5 11 and 5 12 In rated operation the lift off speeds of the backstops must not drop below the minimum values Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Gear Unit Design Basic design of helical gear units 4 Gear Unit Design NOTE The following figures are block diagrams Their purpose is only to make it easier to as sign components to the spare parts lists Discrepancies may occur depending on the gear unit size and version 4 1 Basic design of helical gear units dr 506 VE 19194251 1 Pinion 19 Key 42 Roller bearing 507 Shim 2 Gearwheel 20 Breather valve 43 Key 508 Shim 3 Pinion shaft 22 Gear unit housing 45 Roller bearing 515 Shim 4 Gearwheel 24 Lifting eyebolt 47 Circlip 516 Shim 5 Pinion shaft 25 Roller bearing 59 Screw plug 517 Shim 6 Gearwheel 30 Roller bearing 88 Circlip 521 Shim 7 Output shaft 31 Key 100 Gear cover plate 522 Shim 8 Key 32 Spacer tube 101 Hex head screw 523 Shim 9 Oil seal 34 Roller bearing 102 Seal 11 Roller bearing
29. 74 5 28 38 M8 M5 10 6 AQA AQH 190 1 2 76 5 AQA AQH 190 3 38 45 100 M8 M6 10 10 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 61 Mechanical Installation Adapter with a torque limiting coupling AR 5 13 Adapter with a torque limiting coupling AR CH SS 3 1 Trigger cams 4 Friction lining 7 Friction hub 2 Encoder 5 Cup spring 8 Speed monitor 3 Driving disk 6 Slotted nut Drives with a torque limiting coupling consist of a standard gear unit and motor variable speed geared motor with an adapter installed between them The torque limiting cou pling is installed in this adapter In gearmotors with a multi stage gear unit the torque limiting coupling may be located between the first and second gear units Via the friction lining 4 of the driving disk 3 the input friction hub 7 with cup springs 5 and slotted nut 6 drives the output coupling plate with connecting pin The slip torque is individually set in the factory according to the specific drive selection The speed of the coupling plate at the output end is picked up by an encoder 2 and passed on to a monitoring unit 8 Soeed monitors and slip monitors are used as mon itoring units These can be mounted in conjunction with contactors fuse units etc ona
30. Area Shenyang 110141 Wuhan SEW EURODRIVE Wuhan Co Ltd Tel 86 27 84478398 10A 2 6th Road Fax 86 27 84478388 No 59 the 4th Quanli Road WEDA 430056 Wuhan Additional addresses for service in China provided on request Colombia Assembly Bogota SEW EURODRIVE COLOMBIA LTDA Tel 57 1 54750 50 Sales Calle 22 No 132 60 Fax 57 1 54750 44 Service Bodega 6 Manzana B http www sew eurodrive com co Santaf de Bogota sewcol sew eurodrive com co Croatia Sales Zagreb KOMPEKS d o o Tel 385 1 4613 158 Service PIT Erd gy 4 II Fax 385 1 4613 158 kompeks inet hr Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 12 147 12 148 Address List Czech Republic Sales Praha SEW EURODRIVE CZ S R O Tel 420 255 709 601 Business Centrum Praha Fax 420 220 121 237 Luzn 591 http www sew eurodrive cz CZ 16000 Praha 6 Vokovice sew sew eurodrive cz Denmark Assembly Kopenhagen SEW EURODRIVEA S Tel 45 43 9585 00 Sales Geminivej 28 30 Fax 45 43 9585 09 Service DK 2670 Greve http www sew eurodrive dk sew sew eurodrive dk Egypt Sales Cairo Copam Egypt Tel 20 2 22566 299 1 23143088 Service for Engineering amp Agencies Fax 20 2 22594 757 33 El Hegaz ST Heliopolis Cairo http www copam egypt com copam datum com eg Estonia Sales Tallin ALAS KUUL AS Tel 372 6593230 Reti tee 4
31. Director Sales and Marketing Directeur g n ral international commercial et marketing Bruchsal 05 11 2003 dann H Sondermann Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 143 11 Declarations of Conformity Gear units in category II3G and II3D with AR adapter 11 3 Gear units in category II3G and II3D with AR adapter EG Konformitatserklarung c S EC Declaration of Conformity N ENIS S001 D claration de conformit EC EURODRIVE im Sinne der Richtlinie 94 9 EG Anhang VIII Nr No N 106 05 according to EC Directive 94 9 EC Appendix VIII au sens de la directive CE 94 9 CE Annexe VIII SEW EURODRIVE GmbH amp Co KG Ernst Blickle StraRe 42 D 76646 Bruchsal erkl rt in alleiniger Verantwortung die Konformitat der folgenden Produkte declares under sole responsibility conformity of the following products d clare sous sa seule responsabilit que les produits R K F und S Getriebe mit der Anbaukomponente AR der Kategorien 3GD R K F and S gear with the input components AR in categorys 3GD R ducteurs R K F et S avec les composants d entr e AR de cat gories 3GD mit der Richtlinie 94 9 EG with the directive 94 9 EC respectent la directive 94 9 CE angewandte Normen EN 1127 1 1997 03 applied standards EN 13463 1 2001 11 Normes appliqu es EN 13463 5 2003 12 EN 13463 8 2003 09 EN 60529 2000 09 SEW EUROD
32. Fax 372 6593231 EE 75301 Peetri k la Rae vald Harjumaa veiko soots alas kuul ee Finland Assembly Lahti SEW EURODRIVE OY Tel 358 201 589 300 Sales Vesim entie 4 Fax 358 3 780 6211 Service FIN 15860 Hollola 2 sew sew fi http www sew eurodrive fi Production Karkkila SEW Industrial Gears OY Tel 358 201 589 300 Assembly Valurinkatu 6 Fax 358 201 589 310 Service FIN 03600 Karkkila sew sew fi http www sew eurodrive fi Gabon Sales Libreville Electro Services Tel 241 7340 11 B P 1889 Fax 241 7340 12 Libreville Great Britain Assembly Normanton SEW EURODRIVE Ltd Tel 44 1924 893 855 Sales Beckbridge Industrial Estate Fax 44 1924 893 702 Service P O Box No 1 http www sew eurodrive co uk GB Normanton West Yorkshire WF6 1QR info sew eurodrive co uk Greece Sales Athen Christ Boznos amp Son S A Tel 30 2 1042 251 34 Service 12 Mavromichali Street Fax 30 2 1042 251 59 P O Box 80136 GR 18545 Piraeus http www boznos gr info boznos gr Hong Kong Assembly Hong Kong SEW EURODRIVE LTD Tel 852 2 7960477 79604654 Sales Unit No 801 806 8th Floor Fax 852 2 7959129 Service Hong Leong Industrial Complex contact sew eurodrive hk No 4 Wang Kwong Road Kowloon Hong Kong Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Address List Hungary Sales Budapest SEW EURODRIVE Kft Tel 3
33. M6 x 16 11 Nm WA30 4 x M6 x 16 11 Nm WA37 4 x M8 x 20 25 Nm Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation 5 Shaft mounted gear unit with keyway or splined hollow shaft 5 7 Shaft mounted gear unit with keyway or splined hollow shaft NOTE Concerning the configuration of the customer shaft please also refer to the design notes in the Gearmotors catalog 5 7 1 Installation notes 1 Apply and thoroughly spread NOCO Fluid 211516171 2 Install the shaft and secure it axially mounting is facilitated by using a mounting device The three mounting types are described below 2A standard scope of delivery 2B installation and removal kit for customer shaft with contact shoulder 2C installation and removal kit for customer shaft without contact shoulder 2A Installation with standard scope of delivery 5 211518347 1 Short retaining screw standard delivery scope 2 Lock washer 3 Washer 4 Circlip 5 Customer shaft Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 37 Mechanical Installation Shaft mounted gear unit with keyway or splined hollow shaft 2B Installation with SEW EURODRIVE installation and removal kit see page 42 customer shaft with contact shoulder 5 211520523 1 Retaining screw 2 Lock washer 3 Was
34. bevel gear units sssssssssss 15 Helical worm gear units ssssess 16 Parallel shaft helical gear units 14 SPIROPLAN W10 W30 gear units 17 SPIROPLAN W37 gear units 18 H Helical gear units ssseee 13 Helical bevel gear units 15 Helical worm gear units seseess 16 I Inspection ien te et dee as 81 AD input Cover 88 AL AM AQ adapter nenn nrnreesreeerene 84 Changing the OU 89 Checking the ol 89 Checking the oil Ievel eeeeeeeeeeteeeeeeenees 89 Gear ul 89 Inspection intervals sssssssssesssees 82 Installation Mechanicali 2 pet ibi gione 21 Installation tolerances ccccceeeeeteeeeeetteeeeeeeenaees 21 L Lubricant change intervals sssssse 83 M Maintenance cose need cune reda eain 81 AL AM AQ adapter renren neneseeeerne 84 Changing the ol 89 Checking the ol 89 Checking the oil level 89 Gear nitesine er n dee sid ae dus 89 Input cover AD sssssee 88 Maintenance intervals 2 rreren 82 Malfunctions AD input shaft assembly ssss 139 AM AQ AL adatter 139 Gear Ult idc e reet de 138 Mechanical Installation sessssssse 21 Mounting positions DeSignation cccccssscceeeeeeecceeeeeeneeceseeeneneees 106 Helical gearmoto
35. for use in damp areas or outdoors Repair any damage to the paint work e g on the breather valve or the eyebolts When mounting the motors onto AM AQ AR AT adapters seal the flange areas with a suitable sealing compound e g Loctite 574 No breather plug is required for the following gear units RO in mounting positions M1 M2 M3 M5 and M6 R17 R27 and F27 in mounting positions M1 M3 M5 and M6 SPIROPLAN W10 W20 W30 gear units SPIROPLAN W37 gear units in mounting positions M1 M2 M3 M5 M6 SEW EURODRIVE supplies all other gear units with the breather valve installed and ac tivated according to the particular mounting position Exceptions 1 SEW supplies the following gear units with a screw plug on the vent hole provided 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 provided breather valve 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 NOTE ON EXPLOSION PROTECTION The assembly of gear head units with motors or adapters may be performed by au thorized personnel only Please consult SEW EURODRIVE Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 5 Mecha
36. gear unit nameplate correspond with the permitted conditions for 4 7 and 5 4 potentially explosive atmospheres on site Equipment group e Atex category e Atex zone Temperature class Maximum surface temperature Have arrangements been made to prevent explosive atmospheres oils acids gases vapors or radiation 5 2 during installation of the gear unit Is the ambient temperature maintained according to the lubricant table 9 2 Have arrangements been made for sufficient ventilation and that there will be no external heat generation 5 3 and 5 4 e g via clutches The cooling air must not exceed a temperature of 40 C Does the mounting position on the gear unit nameplate correspond to the indicated mounting position 5 3 and 8 1 Important The mounting position may be changed only after prior consultation with SEW EURODRIVE ATEX approval will become void without prior consultation Does the oil level for the mounting position on the gear unit nameplate correspond to the indicated oil fill 5 3 quantity Are all oil check and drain plugs as well as breather plugs and valves freely accessible 5 3 Do all input and output elements to be installed have ATEX certification 5 5 Have you checked that the data on the nameplate of the gear unit are not exceeded for standalone gear 6 2 units with adapter or input shaft assembly When mounting gear units with hollow shaft and shrink disk 5 8 e sthe cover mounted properly When mounting the coupling of A
37. image of A ZO Hl ees ze OTZA 3 1 211362059 Gear unit Screws Tightening torque KA37 4x M10 x 25 8 8 48 Nm KA47 4 x M10 x 30 8 8 48 Nm KA67 4 x M12 x 35 8 8 86 Nm KA77 4 x M16 x 40 8 8 210 Nm KA87 4x M16 x 45 8 8 210 Nm KA97 4 x M20 x 50 8 8 410 Nm KA107 4 x M24 x 60 8 8 710 Nm KA127 4 x M36 x 130 8 8 2500 Nm KA157 4 x M36 x 130 8 8 2500 Nm 5 6 3 Helical worm gear units The following figure shows the toque arm for helical worm gear units Bushing 1 with bearings on both ends ES 211491723 Gear unit Screws Tightening torque SA37 4x M6 x 16 8 8 11 Nm SA47 4x M8 x 20 8 8 25 Nm SA57 6 x M8 x 20 8 8 25 Nm SA67 8 x M12 x 25 8 8 86 Nm SA77 8x M12 x 35 8 8 86 Nm SA87 8 x M16 x 35 8 8 210 Nm SA97 8 x M16 x 35 8 8 210 Nm Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 35 36 Mechanical Installation Torque arms for shaft mounted gear units 5 6 4 SPIROPLAN W gear units The following figure shows the toque arm for SPIROPLAN W gear units e Bushing 1 with bearings on both ends Es 211489547 Gear unit Screws Tightening torque WA10 4x M6 x 16 11 Nm WA20 4 x
38. plug A WARNING Danger of burns due to hot gear unit and hot gear unit oil Fatal injuries Letthe gear unit cool down before you begin with your work However the gear unit must still be warm otherwise the high viscosity of excessively cold oil will make it harder to drain the oil correctly 1 Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 2 Set up the gear unit in M5 or M6 mounting position See chapter Mounting Posi tions see page 106 3 Place a container underneath the screw plug 4 Remove the screw plugs on the A and B side of the gear unit 5 Drain all the oil Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance Inspection maintenance for the gear unit 6 Re insert the lower screw plug 7 Fill in new oil of the same type via the upper screw plug bore otherwise consult the customer service You must not mix different synthetic lubricants Fill the oil according to the quantity specified on the nameplate Check the oil level 8 Re insert the upper screw plug 7 7 7 Replacing the oil seal CAUTION Oil seals with a temperature below 0 C may get damaged during installation Potential damage to property Store oil seals at ambient temperatures over 0 C Warm up the oil seals prior to installation if required
39. standard 35 mm rail to DIN EN 50022 in the switch cabinet or they can be attached using two holes 5 13 1 WEN speed monitor The speed monitor 8 is used with constant speed gearmotors and is connected to the encoder 2 in the adapter Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation 5 Adapter with a torque limiting coupling AR 5 13 2 Assembly Mounting the 1 Remove the fan guard from the driving motor encoder 2 Slowly turn the motor or adapter shaft extension until a trip cam head of the cheese head screw becomes visible in the threaded hole 3 Screw in the encoder until contact is made with the trip cam 4 Turn the encoder 1 back by two turns corresponds to a clearance of 2 mm 1 2mm Illi 5 Use a lock nut to secure the encoder on the outside of the adapter 6 Check Slowly turn the motor or adapter shaft extension Correct mounting trip cams do not touch the encoder 7 Install the fan guard NOTE ON EXPLOSION PROTECTION The speed monitor must be located outside the potentially explosive atmosphere Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 63 64 Mechanical Installation AD input shaft assembly Connecting moni toring devices NOTE ON EXPLOSION PROTECTION D
40. the oil 1 via the screw plug Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 Open the cover plate of the gear unit according to section Checking the oil via the screw plug see page 97 3 Take an oil sample via the screw plug bore 4 Check the oil consistency Viscosity f you can see that the oil is heavily contaminated we recommend that you change the oil even if this is outside the service intervals specified in Inspection and maintenance intervals see page 82 5 Check the oil level 6 Re insert and tighten the screw plug Changing the oil via the screw plug A WARNING Danger of burns due to hot gear unit and hot gear unit oil Fatal injuries Let the gear unit cool down before you begin with your work However the gear unit must still be warm otherwise the high viscosity of excessively cold oil will make it harder to drain the oil correctly Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 Open the cover plate of the gear unit according to section Checking the oil via the screw plug see page 97 3 Completely drain the oil via the screw plug bore 4 Fill in new oil of the same type via the control bore otherwise consult the customer service You must not mix different synthetic lubricants Fill the oil according to the quant
41. the same time as changing the oil Ambient temperature Manufacturer Type Gear unit roller bearings 40 C 80 C Fuchs Renolit CX TOM 15 30 C 40 C Aral Eural Grease EP 2 ss 20 C 40 C Aral Aralube BAB EP2 ZOS NOTE The following grease quantities are required Forfast running bearings gear unit input end Fill the cavities between the rolling elements one third full with grease Forslow running bearings gear unit input side Fill the cavities between the rolling elements two thirds full with grease Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 135 bel we a lt c X T LE Lubricants Lubricant table 017680300 09 9 LHN uju Asadeqniy 09v eg juAsndo 09r ava JoBeg jeay S 09v LH Mas 4 qn1y 09 ZV2 oiqJeqnii pJepuels 09v LD qeindo O97 1899 jeang jeav N 09 LHNY Iro49qnp4 2 93 U S H gjununs 1eqniy 097 19 Pinia episse eus v29 DHS IIqoiN Ov pjepueis Dr 929 DHS Woo OSL dg ajoeuuld N 0SI v W39 yjuAsieqniy 629 DHS IIqoiN 09v dg ajoeuuld N 09t t WAD uu sieqniy 2 93 u S H gjuung 1eqniy GH 097 elewo Iys ve9 DHS IIqoiN vc9 DHS IIqoiN 8 DIGDUEIG 929 DHS QO OSL dg ajoeuuld N 0S b t WAD HE al 6Z9DHS IIqoiN 022 d19 uAsiun uioues 022 v 9134 u g 1eoBdo 022 d3 ajoeuu
42. use impulse drivers or torque wrenches in order to prevent the cover plate from being damaged no impact drivers 6 8 5 PI 16 2 GK oo f9 cj 4 3 5 4 D E 18649739 Gear unit Illus Retaining Rated tightening torque Ty Minimum tightening torque Ty type tra thread Nm Nm tion R RF07 E M5 6 4 R RF17 27 D R RF47 57 A M6 11 7 F27 B W10 C M5 6 4 W20 C M6 11 7 W30 A Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 95 96 Inspection Maintenance Inspection maintenance for the gear unit Checking the oil via the cover plate Checking the oil via the cover plate Proceed as follows to check the oil of the gear unit 1 Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 Open the cover plate of the gear unit according to section Checking the oil via the cover plate see page 93 Take an oil sample via the cover plate opening 4 Check the oil consistency Viscosity f you can see that the oil is heavily contaminated we recommend that you change the oil even if this is outside the service intervals specified in Inspection and maintenance intervals see page 82 5 Check the oil level 6 Screw on the cover plate Observe the order and the tightening torques according to section
43. 00 30 000 hours of operation Renew the anti friction bearing grease Replace the oil seal Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance Inspection maintenance for the gear unit 7 7 Inspection maintenance for the gear unit 7 7 1 Checking the oil level and changing the oil The procedure when checking the oil level and changing the oil depends on the following factors Gearunit type Size Mounting position Observe the references to the respective sections as well as the following table Refer to chapter Mounting Positions see page 106 for notes on the mounting positions Code letter Section Checking the oil level and changing the oil Reference A Helical gear units see page 90 e Parallel shaft helical gear units e Helical bevel gear units Helical worm gear units With oil level plug B e Helical gear units see page 93 Parallel shaft helical gear units SPIROPLAN gear units without oil level plug with cover plate C S37 helical worm gear units see page 97 without oil level plug and cover plate D SPIROPLAN W37 see page 100 in mounting positions M1 M2 M3 M5 M6 with oil level plug E SPIROPLAN W37 see page 97 in M4 mounting position without oil level plug and cover plate
44. 2 With AR 132 195 Unscrew the clamping screw on the slotted round nut 7 Unscrew the slotted round nut somewhat until you can easily adjust the torque limit ing coupling by hand With AR 71 115 Mark the position of the slotted round nut 3 With AR 132 195 Mark the driving disk 4 Unscrew and remove the slotted round nut remove the cup springs 6 Note Note the sequence of the cup springs Inspect the friction lining 5 change them if they are worn Note Do not allow any lubricants to get onto the friction surface this will ir reparably damage the surface Inspect the cup springs 6 change them if they are burned out 10 Reinstall the cup springs 6 in the same sequence as before 11 Screw on the slotted round nut up to the mark 12 Measuring setting with a torque wrench Connect the torque wrench to the hole in the hub Measure the torque in both directions if necessary readjust using the slotted round nut Rough setting without torque wrench Use the hook spanner to set the torque limiting coupling Slip torque according to value Z see the following table calculated from the marking with AR 71 115 Number of cams of the lock washer with AR 132 195 Number of slots in the slotted round nut 13 Secure the slotted round nut with the lock washer clamping screw 14 Assemble the drive in reverse order 86 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S
45. 6 1 437 06 58 Service H 1037 Budapest Fax 36 1 437 06 50 Kunigunda u 18 office sew eurodrive hu India Assembly Vadodara SEW EURODRIVE India Private Limited Tel 91 265 2831086 Sales Plot No 4 GIDC Fax 91 265 2831087 Service POR Ramangamdi Vadodara 391 243 http www seweurodriveindia com Gujarat sales seweurodriveindia com subodh ladwa seweurodriveindia com Ireland Sales Dublin Alperton Engineering Ltd Tel 353 1 830 6277 Service 48 Moyle Road Fax 353 1 830 6458 Dublin Industrial Estate info alperton ie Glasnevin Dublin 11 http www alperton ie Israel Sales Tel Aviv Liraz Handasa Ltd Tel 972 3 5599511 Ahofer Str 34B 228 Fax 972 3 5599512 58858 Holon http www liraz handasa co il office liraz handasa co il Italy Assembly Milano SEW EURODRIVE di R Blickle amp Co s a s Tel 39 02 96 9801 Sales Via Bernini 14 Fax 39 02 96 799781 Service 1 20020 Solaro Milano http www sew eurodrive it sewit sew eurodrive it Ivory Coast Sales Abidjan SICA Tel 225 2579 44 Ste industrielle et commerciale pour l Afrique Fax 225 2584 36 165 Bid de Marseille B P 2323 Abidjan 08 Japan Assembly Iwata SEW EURODRIVE JAPAN CO LTD Tel 81 538 373811 Sales 250 1 Shimoman no Fax 81 538 373814 Service Iwata http www sew eurodrive co jp Shizuoka 438 0818 sewjapan sew eurodrive co jp Korea Assembly Ansan City SEW EURODRIVE KOREA CO LTD Tel 82 31 492 8051 Sales B 601 4 Banweol Industrial Estate Fax 82 31 492 8056 Service 104
46. 6 18 The wiring diagram below shows possible wiring of the speed monitor 24V oF rh C E ED ED ED G3 9 GE E 8 9 ED E B 18698891 1 Sensor 14 Startup bypass 3 Sensor 23 DC 24 V voltage supply 10 Relay 1 common wiring 24 DC 24 V voltage supply 11 Relay 1 normally open contact 19 Auxiliary output for customer application 12 Relay 1 normally closed contact 20 Auxiliary output for customer application 76 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Startup go 6 Installation and adjustment of the WEX speed monitor 2 KFU8 UFC Ex1 D 18702219 Front side of the speed monitor LED in CHK 1 yellow red For indicating input pulses flashes yellow input interference blinks red and LED PWR green LED OUT 1 yellow LED OUT 2 yellow LED OUT 3 yellow RS 232 Display unit malfunction continuously red for indicating the supply voltage For indicating that relay 1 is active For indicating that relay 2 is active For indicating that the transistor is active The RS 232 interface for connecting a PC for setting parameters and diagnos ing the UFC with PACTware for indicating measured values and faults in parameter assignment mode NOTE ON EXPLOSION PROTECTION The start bypass time may not exceed 3 seconds This setting must be carefully per
47. 7 M30 137 127 107 167 M36 147 167 157 127 157 187 The following table shows the thread sizes of the gear units with B14 flange and or hol low shaft depending on the gear unit type and size Gear unit type Screw RZ FAZ FHZ KAZ SA WA KHZ KVZ SAZ SHZ M6 07 17 27 37 10 20 30 M8 37 47 27 37147 37 47 47157 37 M10 57 67 M12 77 87 57 67 77 57 67 77 67 77 M16 87 97 87 97 87 97 M20 107 127 107 127 M24 157 157 The following table shows the thread sizes of the gear units with B5 flange depending on the gear unit type size and flange diameter Gear unit type Screw RF FF KF KAF SF WF WAF Flange R F RM FAF FHF KHF KVF SAF SHF mm 80 M6 10 110 M8 20 120 M6 07 17 27 37 10 20 30 37 140 M8 07 17 27 160 M8 07 17 27 37 47 27 37 37 37 47 30 37 200 M10 37 47 57 67 47 47 57 67 250 M12 57 67 77 87 57 67 57 67 77 300 M12 67 77 87 77 77 350 M16 77 87 97 107 87 87 87 450 M16 97 107 137 147 97 107 97 107 97 550 M16 107 137 147 167 127 127 660 M20 147 167 157 157 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Installing the gear unit 5 3 3 Installation in damp locations or in the open 5 3 4 Breather Drives are supplied in corrosion resistant versions with an according surface protection coating
48. 8 4 Shingil Dong http www sew korea co kr Ansan 425 120 master sew korea co kr Busan SEW EURODRIVE KOREA Co Ltd Tel 82 51 832 0204 No 1720 11 Songjeong dong Fax 82 51 832 0230 Gangseo ku master sew korea co kr Busan 618 270 Latvia Sales Riga SIA Alas Kuul Tel 371 7139253 Katlakalna 11C Fax 371 7139386 LV 1073 Riga http www alas kuul com info alas kuul com Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 12 149 12 Address List Lebanon Sales Beirut Gabriel Acar amp Fils sarl Tel 961 1 4947 86 B P 80484 961 1 4982 72 Bourj Hammoud Beirut 961 3 2745 39 Fax 961 1 4949 71 gacar beirut com Lithuania Sales Alytus UAB Irseva Tel 370 315 79204 Naujoji 19 Fax 370 315 56175 LT 62175 Alytus info irseva t http www sew eurodrive It Luxembourg Assembly Brissel CARON VECTOR S A Tel 32 10 231 311 Sales Avenue Eiffel 5 Fax 32 10 231 336 Service B 1300 Wavre http www sew eurodrive lu info caron vector be Malaysia Assembly Johore SEW EURODRIVE SDN BHD Tel 60 7 3549409 Sales No 95 Jalan Seroja 39 Taman Johor Jaya Fax 60 7 3541404 Service 81000 Johor Bahru Johor sales sew eurodrive com my West Malaysia Mexico Assembly Queretaro SEW EURODRIVE MEXIKO SA DE CV Tel 52 442 1030 300 Sales SEM 981118 M93 Fax 52 442 1030 301 Service Tequisquiapan No 102 h
49. 838 50 BY 220033 Minsk sales sew by Belgium Assembly Br ssel SEW Caron Vector S A Tel 32 10 231 311 Sales Avenue Eiffel 5 Fax 32 10 231 336 Service B 1300 Wavre http www sew eurodrive be info caron vector be Service Compe tence Center Industrial Gears SEW Caron Vector S A Rue de Parc Industriel 31 BE 6900 Marche en Famenne Tel 32 84 219 878 Fax 32 84 219 879 http www sew eurodrive be service wallonie sew eurodrive be Brazil Production Sao Paulo SEW EURODRIVE Brasil Ltda Tel 55 11 6489 9133 Sales Avenida Amancio Gaiolli 152 Rodovia Presi Fax 55 11 6480 3328 Service dente Dutra Km 208 http www sew eurodrive com br Guarulhos 07251 250 SP sew sew com br SAT SEW ATENDE 0800 7700496 Additional addresses for service in Brazil provided on request Bulgaria Sales Sofia BEVER DRIVE GmbH Tel 359 2 9151160 Bogdanovetz Str 1 Fax 359 2 9151166 BG 1606 Sofia bever fastbg net Cameroon Sales Douala Electro Services Tel 237 33 431137 Rue Drouot Akwa B P 2024 Douala Fax 237 33 431137 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Address List HR 10 000 Zagreb Canada Assembly Toronto SEW EURODRIVE CO OF CANADA LTD Tel 1 905 791 1553 Sales 210 Walker Drive Fax 1 905 791 2999 Service Bramalea Ontario L6T3W1 http w
50. 90 216 3055867 TR 34846 Maltepe ISTANBUL http Awww sew eurodrive com tr sew sew eurodrive com tr Ukraine Sales Dnepropetrovsk SEW EURODRIVE Tel 380 56 370 3211 Service Str Rabochaja 23 B Office 409 Fax 380 56 372 2078 49008 Dnepropetrovsk http www sew eurodrive ua sew sew eurodrive ua USA Production Southeast SEW EURODRIVE INC Tel 1 864 439 7537 Assembly Region 1295 Old Spartanburg Highway Fax Sales 1 864 439 7830 Sales P O Box 518 Fax Manufacturing 1 864 439 9948 Service Lyman S C 29365 Fax Assembly 1 864 439 0566 Cooporate Offices Fax Confidential HR 1 864 949 5557 http www seweurodrive com cslyman seweurodrive com Assembly Northeast SEW EURODRIVE INC Tel 1 856 467 2277 Sales Region Pureland Ind Complex Fax 1 856 845 3179 Service 2107 High Hill Road P O Box 481 csbridgeport seweurodrive com Bridgeport New Jersey 08014 Midwest Region SEW EURODRIVE INC Tel 1 937 335 0036 2001 West Main Street Fax 1 937 440 3799 Troy Ohio 45373 cstroy seweurodrive com Southwest SEW EURODRIVE INC Tel 1 214 330 4824 Region 3950 Platinum Way Fax 1 214 330 4724 Dallas Texas 75237 csdallas seweurodrive com Western Region SEW EURODRIVE INC Tel 1 510 487 3560 30599 San Antonio St Fax 1 510 487 6433 Hayward CA 94544 cshayward seweurodrive com Additional addresses for service in the USA provided on request Venezuela Assembly Valencia SEW EURODRIVE Venezuela S A Tel 58 241 832 9804 Sales Av Norte Sur No 3 Galpon 84 319 Fa
51. Checking the oil level via the cover plate see page 93 A WARNING Danger of burns due to hot gear unit and hot gear unit oil Fatal injuries Let the gear unit cool down before you begin with your work However the gear unit must still be warm otherwise the high viscosity of excessively cold oil will make it harder to drain the oil correctly Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 Open the cover plate of the gear unit according to section Checking the oil via the cover plate see page 93 3 Completely drain the oil in to a vessel via the cover plate opening 4 Fillin new oil of the same type via the cover plate opening otherwise consult the cus tomer service You must not mix different synthetic lubricants Oil quantity according to the nameplate 5 Check the oil level 6 Screw on the cover plate Observe the order and the tightening torques according to section Checking the oil level via the cover plate see page 93 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance Inspection maintenance for the gear unit 7 7 4 37 helical worm gear units without oil level plug and cover plate Checking the oil The S37 gear unit is not equipped with an oil level plug or a cover plate This is why the level via the screw oil level is checked via
52. Code letter for section Checking the oil level and changing the oil Series Gear unit M1 M2 M3 M4 M5 M6 R07 R27 B R R47 R57 A B A R57 R167 A RX57 R107 A F27 B F F37 F157 A K K37 K187 A 37 C S S47 897 A W10 W30 B W W 37 D E D Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 89 7 Inspection Maintenance Inspection maintenance for the gear unit 7 7 2 Helical parallel shaft helical helical bevel and helical worm gear units with oil level plug Checking the oil level via the oil level plug CAUTION The multi stage gear units series R R in mounting positions M1 and M2 S JR in mounting position M3 have require a higher oil level for sufficient lubrication This is why the provided oil level plugs must not be used Contact SEW EURODRIVE Proceed as follows to check the oil level of the gear unit Observe the notes in section Preliminary work regarding gear unit inspection maintenance see page 81 Determine the position of the oil level plug and the breather valve using the mounting position sheets See chapter Mounting Positions see page 106 Place a container underneath the oil level plug Slowly remove the oil level plug Small amounts of oil may leak out e Check the oil level via the oil level bore 3 with the provided oil dipstick 1 Forthe measurement make sure that the auxili
53. Do not place torque arms under strain during installation Use bolts of quality 8 8 to fasten torque arms 5 6 1 Parallel shaft helical gear units The following figure shows the toque arm for parallel shaft helical gear units gt d 4 cul Di aS zzi Be t S el SC F Q 211366411 1 Screw 2 Washer 3 Nut Proceed as follows to mount the rubber buffers 1 Use screws 1 and washers according to the following table 2 Use two nuts to secure the screw connection 3 3 Tighten the screw until the initial stress A L of the buffers is reached according to the table rubber buffer Gear unit Diameter Internal Length Washer width A L taut diameter loose a mm b mm c mm d mm mm FA27 40 12 5 20 5 1 FA37 40 12 5 20 5 1 FA47 40 12 5 20 5 1 5 FA57 40 12 5 20 5 1 5 FA67 40 12 5 20 5 1 5 FA77 60 21 0 30 10 1 5 FA87 60 21 0 30 10 1 5 FA97 80 25 0 40 12 2 FA107 80 25 0 40 12 2 FA127 100 32 0 60 15 3 FA157 120 32 0 60 15 3 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Torque arms for shaft mounted gear units 5 6 2 Helical bevel gear units The following figure shows the toque arm for helical bevel gear units Bushing 1 with bearings on both ends nstall connection end B as a mirror
54. ES 13 4 1 Basic design of helical gear umnits eee ceeeeee eee eeeeeeeeeeteeeeeeeeeeteneaeees 13 4 2 Basic design of parallel shaft helical gear units sesessssss 14 4 3 Basic design of helical bevel gear umits eee ceeeeeeeeeteeeteeeeeteeeneeees 15 4 4 Basic design of helical worm gear untts ceeeeeeeeeeeeeteeeeeeettteeeeeeeees 16 4 5 Basic design of SPIROPLAN w10 W30 gear unten 17 4 6 Basic design of SPIROPLAN w37 gear units stesse cadat 18 4 7 Nameplate unit designation em 19 5 Mechanical Installation eeeeeeeeeeeneeneennnn nennen nnns 21 5 1 Required toolsiresources sssesseeeeeesrterrerrsresstrtttttrrnnnnnnenrrsrttttn trne nnn 21 5 2 Prerequisites for assembly REAREA E ener 22 5 3 Installing the gear unit menn 23 5 4 Gear units with solid ebhaft ee ceccee eee eeneeeeeeeeneeeeeeeeteeeeeeeeiaeeeeeeeaes 29 5 5 Gear units and gearmotors in category II2GD eee eeeeeteeeeeeeenaes 32 5 6 Torque arms for shaft mounted gear units eee ceeeeeeeeeeeeeeeeentteeeeeeeeaes 34 5 Shaft mounted gear unit with keyway or splined hollow shaft 37 5 8 Shaft mounted gear units with shrink dek 44 5 9 Shaft mounted gear unit with TorqLOC Bine pene eua us 48 5 10 Installing the protective Cover 54 5 11 Coupling of AM adapter eee 56 5 12 Coupling of AQ adapter ssssssssssssssssee eene 60 5 13 Adapter with a torque limiting coupling A
55. Fax 421 2 33595 200 SK 831 06 Bratislava sew sew eurodrive sk http www sew eurodrive sk Zilina SEW Eurodrive SK s r o Tel 421 41 700 2513 Industry Park PChZ ulica M R Stef nika 71 SK 010 01 Zilina Fax 421 41 700 2514 sew sew eurodrive sk Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 12 151 12 152 Address List Slovakia Bansk SEW Eurodrive SK s r o Tel 421 48 414 6564 Bystrica Rudlovsk cesta 85 Fax 421 48 414 6566 SK 974 11 Bansk Bystrica sew sew eurodrive sk KoSice SEW Eurodrive SK s r o Tel 421 55 671 2245 Slovenska ulica 26 Fax 421 55 671 2254 SK 040 01 KoSice sew sew eurodrive sk Slovenia Sales Celje Pakman Pogonska Tehnika doo Tel 386 3 490 83 20 Service UI XIV divizije 14 Fax 386 3 490 83 21 SLO 3000 Celje pakman siol net South Africa Assembly Johannesburg SEW EURODRIVE PROPRIETARY LIMITED Tel 27 11 248 7000 Sales Eurodrive House Fax 27 11 494 3104 Service Cnr Adcock Ingram and Aerodrome Roads http www sew co za Aeroton Ext 2 dross sew co za Johannesburg 2013 P O Box 90004 Bertsham 2013 Capetown SEW EURODRIVE PROPRIETARY LIMITED Tel 27 21 552 9820 Rainbow Park Fax 27 21 552 9830 Cnr Racecourse amp Omuramba Road Telex 576 062 Montague Gardens dswanepoel sew co za Cape Town P O Box 36556 Chempet 7442 Cape Town Durban SEW EURODRIVE
56. Fax 49 5137 8798 55 D 30823 Garbsen near Hannover sc nord sew eurodrive de East SEW EURODRIVE GmbH amp Co KG Tel 49 3764 7606 0 Dankritzer Weg 1 Fax 49 3764 7606 30 D 08393 Meerane near Zwickau sc ost sew eurodrive de South SEW EURODRIVE GmbH amp Co KG Tel 49 89 909552 10 DomagkstraRe 5 Fax 49 89 909552 50 D 85551 Kirchheim near Munchen sc sued sew eurodrive de West SEW EURODRIVE GmbH amp Co KG Tel 49 2173 8507 30 Siemensstrake 1 Fax 49 2173 8507 55 D 40764 Langenfeld near Dusseldorf sc west sew eurodrive de Electronics SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1780 Fax 49 7251 75 1769 sc elektronik sew eurodrive de Drive Service Hotline 24 Hour Service 49 180 5 SEWHELP 49 180 5 7394357 Additional addresses for service in Germany provided on request Zone industrielle 2 rue Denis Papin F 77390 Verneuil l Etang France Production Haguenau SEW USOCOME Tel 33 3 88 73 67 00 Sales 48 54 route de Soufflenheim Fax 33 3 88 73 66 00 Service B P 20185 http www usocome com F 67506 Haguenau Cedex sew usocome com Production Forbach SEW EUROCOME Tel 33 3 87 29 38 00 Zone Industrielle Technop le Forbach Sud B P 30269 F 57604 Forbach Cedex Assembly Bordeaux SEW USOCOME Tel 33 5 57 26 39 00 Sales Parc d activit s de Magellan Fax 33 5 57 26 39 09 Service 62 avenue de Magellan B P 182 F 33607 Pessac Cedex Lyon SEW USOCOME Tel 33 4 72 15 37 00 Parc d Affaires Roos
57. II Nr No N 111 05 according to EC Directive 94 9 EC Appendix VIII au sens de la directive CE 94 9 CE Annexe VIII SEW EURODRIVE GmbH amp Co KG Ernst Blickle StraRe 42 D 76646 Bruchsal erkl rt in alleiniger Verantwortung die Konformitat der folgenden Produkte declares under sole responsibility conformity of the following products d clare sous sa seule responsabilit que les produits R K F und S Getriebe mit den Anbaukomponenten AM AQA AL und AD der Kategorien 2GD R K F and S gear with the input components AM AQA AL and AD in categorys 2GD R ducteurs R K F et S avec les composants d entr e AM AQA AL et AD des cat gories 2GD mit der Richtlinie 94 9 EG with the directive 94 9 EC respectent la directive 94 9 CE angewandte Normen EN 1127 1 1997 10 applied standards EN 13463 1 2001 11 Normes appliqu es EN 13463 5 2003 12 EN 13463 8 2003 09 EN 60529 2000 09 SEW EURODRIVE hinterlegt die gem 94 9EG Anhang VIII geforderten Unterlagen bei benannter Stelle FSA GmbH EU Kennnummer 0558 SEW EURODRIVE will archive the documents required according to 94 9 EC Appendix VIII at the following location FSA GmbH EU Code 0558 SEW EURODRIVE tient disposition la documentation sp cifi e dans la directive 94 9 CEE Annexe VIII pour consultation l endroit d sign FSA GmbH code UE 0558 Ort Datum Gesch ftsf hrer Vertrieb und Marketing Place date Lieu et date Managing
58. M AQA adapters 5 11 and You must not use distance bushings as an assembly tool 5 12 When mounting a motor on the AD input shaft assembly 5 14 Has the belt between input shaft end and motor shaft sufficient electrical leakage resistance lt 10 0 Before mounting a protection cover Does a risk analysis performed by the manufacturer of the protection cover demonstrate that no sources of ignition can occur such as impact sparks from grinding For mains operated motors 6 2 Check that the data specified on the nameplate of the gear unit and the motor corresponds to the ambient conditions at the location where the drive is to be installed For inverter operated gearmotors Check that the gearmotor is approved for operation with an inverter 6 2 The parameter settings made for the inverter must prevent the gear unit from being overloaded gear unit nameplate Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 11 Checklists During startup 3 2 During startup This checklist includes all activities that will have to be executed during startup of a gear unit according to Directive 94 9 EC for operation in potentially explosive atmo spheres Check during startup in potentially explosive atmospheres checked Information in section Measure the surface temperature after three hours of operation Do not exceed a temperature difference of 6 2
59. Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 2 Set up the gear unit in M5 or M6 mounting position See chapter Mounting Posi tions see page 106 Place a container underneath the oil level plug Remove the oil level plugs on the A and B side of the gear unit Drain all the oil Re insert the lower oil level plug o oc o Fill in new oil of the same type via the upper oil level plug bore otherwise consult the customer service You must not mix different synthetic lubricants Fill the oil according to the quantity specified on the nameplate Check the oil level 8 Re insert the upper oil level plug 102 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance 7 Inspection maintenance for the gear unit 7 7 6 SPIROPLAN W37 in M4 mounting position without oil level plug and cover plate Checking the oil The W37 gear unit is not equipped with an oil level plug or a cover plate This is why the level via the screw oil level is checked via the control bore plug 1 Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 2 Set up the gear unit in M5 or M6 mounting position 3 Remove the screw plug 4 Insert the dipstick vertically via the control bore all the way to the bottom of the gear unit housing Mark the point
60. PLAN W Malfunctions Service M Ze AM AQ AL adapter lt 2 10 2 AM AQ AL adapter Malfunction Possible cause Remedy Unusual regular running noise Meshing grinding noise Bearing damage Contact SEW EURODRIVE customer service Oil leaking Seal defective Contact SEW EURODRIVE customer service Output shaft does not turn although the motor is run ning or the input shaft is rotated Connection between shaft and hub in gear unit interrupted Send the gear unit to SEW EURODRIVE for repair Change in running noise and or vibrations Annular gear wear short term torque transfer through metal contact Change the annular gear Bolts to secure hub axially are loose Tighten the screws Premature wear in annular gear Contact with aggressive fluids oils ozone influence too high ambient temperatures etc which can cause a change in the physical properties of the annular gear Impermissibly high ambient contact temperature for the annular gear maximum permitted temperature 20 C to 80 C Overload Contact SEW EURODRIVE customer service 10 3 AD input shaft assembly Malfunction Possible cause Remedy Unusual regular running noise Meshing grinding noise Bearing damage Contact SEW EURODRIVE customer service Oil leaking Seal defective Contact SEW EURODRIVE customer service Output shaft does not turn a
61. Potential damage to property In rated operation the lift off speeds must not drop below the minimum values During startup or braking the lift off speeds may drop below the minimum levels Type Maximum locking torque of backstop Minimum lift off speed Nm rpm AD2 RS 65 820 AD3 RS 425 620 AD4 RS 850 530 AD5 RS 1450 480 AD6 RS 1950 450 AD7 RS 1950 450 AD8 RS 1950 450 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 69 6 70 Startup ago Checking the oil level 6 Startup NOTE ON EXPLOSION PROTECTION Prior to startup check that the oil level is as specified for the mounting position The oil checking and drain screws and the breather valves must be freely accessible 6 1 Checking the oil level Before startup make sure that the oil level corresponds to the mounting position Ob serve section Checking the oil level and changing the oil 6 2 Measuring surface and oil temperature NOTE The nameplate data on maximum surface temperature is based on measurements at standard ambient conditions and installation altitudes Even slight changes of these conditions such as limited installation space can have a tremendous impact on the temperature 6 2 1 Measuring the surface temperature It is absolutely necessary to measure the surface temperature at maximum load during startup of the g
62. Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Coupling of AQ adapter 4 Type AQH Tighten the screws evenly in diametrically opposite sequence working round several times Make sure that all the screws are tightened with the tightening torque T4 according to the following table Type AQA Secure the coupling halves using the setscrew see table 5 Check the position of the coupling half clearance A see table Install motor onto the adapter making sure that the dogs of the two coupling halves engage in each other The force that must be applied when joining the two coupling halves is dissipated after final assembly so there is no risk of any axial load being applied to adjacent bearings NOTE Only for AQA not permitted for AQH To avoid contact corrosion we recommend applying NOCOS Fluid to the motor shaft before mounting the coupling half CAUTION Dampness might enter the adapter when mounting a motor to the adapter Potential damage to property Seal adapter with anaerobic fluid seal 5 12 2 Setting dimensions tightening torques Type Coupling size Clearance A Bolts DIN 912 Tightening torque TA mm Nm AQA AQH AQA AQH AQA AQH 80 1 2 3 44 5 AQA AQH 100 1 2 39 19 24 M5 M4 2 3 AQA AQH 100 3 4 53 AQA AQH 115 1 2 62 AQA AQH 115 3 62 24 28 M5 M5 2 6 AQA AQH 140 1 2 62 AQA AQH 140 3
63. R sesesssseesees 62 5 14 AD input shaft assembly ssssssssssseee eene 64 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Contents 10 11 12 cg eT 70 6 1 Checking the oil levok rerien sietan neki eana EE enne nennen tnn nnne 70 6 2 Measuring surface and oil temperature 00 ee eeeeeeeeeeee treet etnteeeeeeeaee 70 6 3 Helical worm and SPIROPLAN W gear UNIS eens ee reis 72 6 4 Helical parallel shaft helical helical bevel gear units 73 6 5 Gear units with backetop een 74 6 6 Speed monitoring eise seien i n ne d n E daa 75 6 7 Installation and adjustment of the WEX speed monitor 75 6 8 Installation of the voltage encoder 0 eee eeeeeeeeeneeeeeeeeneteeeeeetaeeeeeeeeaaes 79 Inspection Maintenance eeeeseesesseessesseseee enne ennt tnmen nnne nnne 81 7 1 Preliminary work regarding gear unit inspection maintenance 81 7 2 Inspection maintenance Irtervale nenene ne 82 7 3 Lubricant change intervals emen 83 7 4 Inspection maintenance for the AL AM AQ adatter 84 7 5 Adapter AR ii AERCH 84 7 6 Inspection maintenance for the AD input Cover 88 7 7 Inspection maintenance for the gear unt 89 Mounting Positions eese ennemi innen nnns 106 8 1 Designation of the mounting positions ee eeee
64. R17 R27 G i M1 M3 M5 M6 E R07 R17 R27 B R47 R57 M5 108 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mounting Positions Helical gearmotors R 8 3 2 RFO7 RF167 RZ07 RZ87 0 R 270 T RF RZ07 RF RZ17 27 RF RZO7 17 27 BE Gei RF RZ47 57 N 4p 04 041 03 00 M4 C3 0 E 3 me xis M5 M3 M6 e M1 M2 M3 M5 M6 M1 M3 M5 M6 BE ws Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 109 Mounting Positions Helical gearmotors R 04 042 03 00 RO7F M1 M2 M3 M5 M6 R17F R27F M1 M3 M5 M6 E RO7F R17F R27F V R47F R57F M5 110 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN
65. RIVE h lt folgende technische Dokumentationen zur Einsicht bereit SEW EURODRIVE has the following documentation available for review SEW EURODRIVE tient disposition la documentation technique suivante pour consultation VorschriftsmaRige Bedienungsanleitung Installation and operating Instructions in conformance with applicable regulations Notice d utilisation conforme aux prescriptions Technische Bauunterlagen Technical design documentation Dossier technique de construction Ort Datum Gesch ftsf hrer Vertrieb und Marketing Place date Lieu et date Managing Director Sales and Marketing Directeur g n ral international commercial et marketing Bruchsal 04 11 2003 dann H Sondermann 144 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Address List 12 Address List Ernst Blickle Straf e 42 D 76646 Bruchsal Germany Headquarters Bruchsal SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 0 Production Ernst Blickle Straf e 42 Fax 49 7251 75 1970 Sales D 76646 Bruchsal http www sew eurodrive de P O Box sew sew eurodrive de Postfach 3023 D 76642 Bruchsal Service Compe Central SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1710 tence Center Ernst Blickle StraRe 1 Fax 49 7251 75 1711 D 76676 Graben Neudorf sc mitte sew eurodrive de North SEW EURODRIVE GmbH amp Co KG Tel 49 5137 8798 30 Alte Ricklinger Stra e 40 42
66. W Mounting Positions Helical gearmotors RX 8 4 Helical gearmotors RX 8 4 1 RX57 RX107 QE 0 R T 480 L N E Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 04 043 02 00 111 112 Mounting Positions Helical gearmotors RX 04 044 02 00 0 R 1 180 L Jp OA Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mounting Positions Parallel shaft helical gearmotors F 8 5 Parallel shaft helical gearmotors F 8 5 1 F27 F157 FA27B F157B FH27B FH157B FV27B FV107B 2 H S
67. age 21 29 Startup operation Check the oil level before startup as described in chapter Inspection Maintenance see page 81 Check that the direction of rotation is correct in decoupled status Listen out for unusual grinding noises as the shaft rotates Secure keys for test mode without output elements Do not deactivate monitoring and protection equipment even in test mode Switch off the gearmotor if in doubt whenever changes occur in relation to normal oper ation e g increased temperature noise vibration Determine the cause and contact SEW EURODRIVE if required 2 10 Inspection maintenance Observe the notes in chapter Inspection Maintenance see page 81 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Checklists Before startup 3 Checklists Before startup This checklist includes all activities that will have to be executed prior to startup of a gear unit according to Directive 94 9 EC for operation in potentially explosive atmo spheres Check prior to startup in potentially explosive atmospheres checked Intormation in section Inspect the shipment immediately upon receipt for any damage that may have occurred during transporta 2 6 tion Inform the shipping company immediately Startup may have to be precluded Remove transportation safety fixtures prior to startup Does the following information on the
68. allation 5 Shaft mounted gear unit with TorqLOC 10 Slide the counter bushing onto the customer shaft and into the hollow shaft 212005259 11 until the shrink disk is properly seated 12 Tap lightly on the flange of the counter bushing to ensure that the socket is fitted se curely in the hollow shaft 212007435 13 Make sure that the customer shaft is seated in the counter bushing 212009611 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 51 Mechanical Installation Shaft mounted gear unit with TorqLOC 14 Manually tighten the bolts of the shrink disk and ensure that the end rings of the shrink disk are parallel 212011787 15 Tighten the locking screws with a torque wrench by working round several times from one bolt to the next not in diametrically opposite sequence according to the follow ing table 212013963 Type nickel plated Stainless steel Standard KT FT ST Torque Nm 37 4 1 6 8 37 47 10 6 8 47 57 12 6 8 57 67 67 12 15 77 77 30 30 87 87 30 50 97 97 30 50 107 59 50 127 100 120 157 100 120 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Shaft mounted gear uni
69. ar Units R 7 F 7 K 7 S 7 series SPIROPLAN W 71 ag Startup Helical worm and SPIROPLAN W gear units 6 3 Helical worm and SPIROPLAN W gear units NOTES Note The direction of rotation of the output shaft in series S 7 helical worm gear units has been changed from CW to CCW this is different from the S 2 series Change in direction of rotation Swap two motor feeder cables 6 3 1 Run in period SPIROPLAN and helical worm gear units require a running in period of at least 48 h before reaching their maximum efficiency A separate run in period applies for each di rection of rotation if the gear unit is operated in both directions of rotation The table shows the average power reduction during the run in period Helical worm gear unit Worm i range n reduction 1 start approx 50 280 approx 12 2 start approx 20 75 approx 6 3 start approx 20 90 approx 3 4 start S 5 start approx 6 25 approx 3 96 6 start approx 7 25 approx 2 96 Spiroplan gear units W10 W20 W30 W37 i range n reduction i range n reduction approx 35 75 approx 15 approx 20 35 approx 10 approx 10 20 approx 8 approx 30 70 approx 8 approx 8 approx 5 approx 10 30 approx 596 approx 6 approx 3 96 approx 3 10 approx 396 Operating Instructions Explosion Proof Gear Units R 7 F
70. ary clip 2 of the oil dipstick 1 al ways points up vertically see following figure 18634635 Max fill level max Lower edge of the oil level bore 3 Minimum fill level min Maximum fill level max less the value x depending on diameter of oil level bore 3 see following table 90 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance Inspection maintenance for the gear unit Oil level bore M10 x 1 1 5 M12 x 1 5 M22 x 1 5 M33 x2 M42 x2 c1 Ry wl rd The correct minimum fill level according to the table value x corresponds to the check marks on the oil dipstick see following figure ER d 18637707 Proceed as follows if the oil level is too low Remove the breather valve Fill in oil of the same type via the vent hole Re insert the breather valve Re insert the oil level plug Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Minimum fill level x mm Check mark on oil dipstick Inspection Maintenance Inspection maintenance for the gear unit Checking the oil via the oil drain plug Changing the oil via the oil drain plug and the breather valve Proceed as follows to check the oil of the gear unit 1 Observe the notes in section Preliminary work regar
71. as specified for the mounting position see section Lubricants see page 134 or data on nameplate The gear units are filled with the required oil vol ume 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 Adjustthe lubricant fill volumes and the position of the breather valve accordingly in the event of a change of mounting position Consult the SEW customer service if you intend to change the mounting position of K gear units to or between M5 and M6 Consult the SEW customer service if you intend to change the mounting position of S gear units sizes S47 S97 to M2 and M3 NOTE ON EXPLOSION PROTECTION The mounting position may be changed only after prior consultation with SEW EURODRIVE ATEX approval will become void without prior consultation In case there is a risk of electrochemical corrosion between the gear unit and the driven machine use plastic inserts that are 2 to 3 mm thick The material used must have an electrical leakage resistance 10 Q Electrochemical corrosion can occur between var ious metals for example cast iron and high grade steel Also fit the bolts with plastic washers NOTE ON EXPLOSION PROTECTION Always ground the gear unit housing additionally Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Me
72. ate data complete Type and extent of the problem Time the problem occurred and any accompanying circumstances e Assumed cause 10 6 Disposal Dispose gear units in accordance with the regulations in force regarding respective ma terials Steel scrap Housing parts Gears Shafts Roller bearing 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 according to the regulations in force Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 141 11 Declarations of Conformity Gearmotors in categories II2G and II2D 11 Declarations of Conformity 11 1 Gearmotors in categories II2G and II2D EG Konformit tserkl rung WI CERT EC Declaration of Conformity D claration de conformit CE im Sinne der Richtlinie 94 9 EG Anhang VIII Nr No N 130 04 according to EC Directive 94 9 EC Appendix VIII au sens de la directive CE 94 9 CE Annexe VIII DIN EN ISO 9001 EURODRIVE SEW EURODRIVE GmbH amp Co KG Ernst Blickle StraRe 42 D 76646 Bruchsal erkl rt in alleiniger Verantwortung die Konformitat der folgenden Produkte declares under sole responsibility conformity of the following products d clare sous sa seule responsabilit que les produits R K F S und W Getriebemotoren der Kategorien 2GD R K F S and W gea
73. be able to tighten the screw without any problems you may not need the thrust bearing on the mounting device 211368587 1 Gear shaft end 2 Thrust bearing 3 Coupling hub 30 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation 5 Gear units with solid shaft Avoid excessive Avoid high overhung loads by Installing the gear or chain sprocket according to figure overhung loads B if possible 211364235 1 Hub A unfavorable B correct NOTE Mounting is easier if you first apply lubricant to the output element or heat it up briefly to 80 100 C 5 4 3 Assembling the couplings A CAUTION Input and output elements such as belt pulleys couplings etc are in fast motion during operation Risk of jamming and crushing Cover input and output elements with a touch guard Adjust the following misalignments according to the coupling manufacturer s specifica tions when mounting couplings a Maximum and minimum clearance b Axial offset c Angular offset a b c lt S E 211395595 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 31 5 Mechanical Installation Gear units and gearmotors in category II2GD 5 5 Gear units and gearmotors in category II2GD NOTES ON EXPLOSION PROTECTION Explosion pro
74. ble Key to the lubricant table The lubricant table on the following page shows the permitted lubricants for SEW EURODRIVE explosion proof gear units Observe the following legend with re gards to the lubricant table Abbreviations used meaning of shading and notes CLP Mineral oil CLPPG Polyglycol W gear units conforms to USDA H1 CLP HC synthetic hydrocarbons E Ester oil water hazard class 1 German regulation HCE Synthetic hydrocarbons ester oil USDA H1 certification HLP Hydraulic oil 7 synthetic lubricant 7 synthetic based roller bearing grease Mineral lubricant mineral based rolling bearing grease 1 Helical worm gear units with PG oil Please coordinate with SEW 2 Special lubricant for Spiroplan gear units only 3 Recommendation Select SEW fg 1 2 4 Pay attention to critical starting behavior at low temperatures 5 Low viscosity grease 6 Ambient temperature i Lubricant for the food industry food grade oil Q E Biodegradable oil lubricant for agriculture forestry and fisheries 727 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Technical Data Lubricants Anti friction bear The anti friction bearings in gear units and motors are given a factory fill with the ing greases greases listed below SEW EURODRIVE recommends regreasing anti friction bearings with a grease fill at
75. chanical Installation Installing the gear unit 5 3 4 Tightening torques for retaining screws Mount the gearmotors with the following tightening torques Tightening torque screw nut Screw nut Strength class 8 8 Nm M6 11 M8 25 M10 48 M12 86 M16 210 M20 410 M24 710 M30 1450 M36 2500 M42 4600 M48 6950 M56 11100 Mount the helical gearmotors in flange mounted design with the following increased tightening torques EE Tightening torque screw nut Flange Gear unit Strength class 10 9 Nm 120 RF37 M6 14 140 RF47 M8 35 160 RF57 M8 35 60ZR RZ37 M8 35 70ZR RZ47 M8 35 80ZR RZ57 M10 69 95ZR RZ67 M10 69 110ZR RZ77 M12 120 130ZR RZ87 M12 120 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Installing the gear unit Mechanical Installation 5 3 2 Mounting the gear units The following table shows the thread sizes of the gear units in foot mounted design de Foot mounted gear unit Gear unit with B14 flange and or hol low shaft Gear unit with B5 flange 26 pending on the gear unit type and size Gear unit type Screw R R F RX F K KH B S W FH B FA B KV B KA B M6 07 10 20 M8 17 27 37 27 37 37 30 37 M10 57 47 37 47 47 57 M12 47 57 67 67 57 67 57 67 67 M16 77 87 77 87 77 87 77 77 M20 97 97 107 97 87 87 M24 107 107 97 9
76. d reliable solutions tomorrow s problems via the Internet available Anywhere today around the clock EURODRIVE SEW EURODRIVE GmbH amp Co KG P O Box 3023 D 76642 Bruchsal Germany Phone 49 7251 75 0 Fax 49 7251 75 1970 sew sew eurodrive com www sew eurodrive com
77. d the resulting friction causes the temperature to increase Potential damage to property In rated operation the lift off speeds must not drop below the minimum values During startup or braking the lift off speeds may drop below the minimum levels Maximum locking torque of backstop Minimum lift off speed Type Nm rpm AM80 90 RS AM143 145 RS 95 529 AM100 112 RS AM182 184 RS 423 H AM132 RS AM213 215 RS 830 Ka AM160 180 RS AM254 286 RS Men 489 AM200 225 RS AM324 365 RS 1339 EE AM250 280 RS 4950 450 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 59 5 Mechanical Installation Coupling of AQ adapter 5 12 Coupling of AQ adapter NOTE ON EXPLOSION PROTECTION You must not use distance bushings as an assembly tool 5 12 1 AQA80 190 adapter AQH80 190 adapter AQA 479 ZZ ZZ PZZA SSSS 212114955 1 Motor shaft 2 Grub screw 3 screws AQA With keyway AQH Without keyway 1 Clean the motor shaft and the flange surfaces of the motor and the adapter 2 Type AQH Loosen the screws of the coupling half 479 and loosen the conical con nection 3 Heat up the coupling half 80 C 100 C and slide it onto the motor shaft AQA AQH design up to clearance A see table 60 Operating Instructions Explosion
78. derstood them If you are unclear about any of the information in this documentation please contact SEW EURODRIVE 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 corresponding oper ating instructions Also observe the supplementary safety notes in the individual sections of these operat ing instructions General information A HAZARD During operation the motors and gearmotors can have live bare and movable or ro tating parts as well as hot surfaces depending on their enclosure Explosive gas mixtures or dust concentrations in combination with hot energized and moving parts of electrical machinery can cause serious injury or death Severe or fatal injuries All work related to transportation storage setup mounting connection startup maintenance and repair may only be carried out by qualified personnel in strict observation of The relevant detailed operating instructions The warning and safety signs on the motor gearmotor All other project planning documents operating instructions and wiring diagrams belonging to the drive The specific regulations and requirements for the system The national regional regulations governing safety and the prevention of accidents Never install damaged products mmediately report any damage to the shipping company Removing covers w
79. ding gear unit inspection main tenance see page 81 Determine the position of the oil drain plug using the mounting position sheets See chapter Mounting Positions see page 106 Remove a little oil from the oil drain plug 4 Check the oil consistency Viscosity f you can see that the oil is heavily contaminated we recommend that you change the oil even if this is outside the service intervals specified in Inspection and maintenance intervals see page 82 Check the oil level A WARNING Danger of burns due to hot gear unit and hot gear unit oil Fatal injuries D Let the gear unit cool down before you begin with your work However the gear unit must still be warm otherwise the high viscosity of excessively cold oil will make it harder to drain the oil correctly 92 zl Oo 0c A W Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 Determine the position of the oil drain plug the oil level plug and the breather valve using the mounting position sheets See chapter Mounting Positions see page 106 Place a container underneath the oil drain plug Remove the oil level plug the breather valve and the oil drain plug Drain all the oil Re insert the oil drain plug Fill in new oil of the same type via the vent hole otherwise consult the customer ser vice Do not mix synthetic lubricants
80. e gearmotor match the voltage supply system The drive has not been damaged during transportation or storage Ensure that the following requirements have been met For standard gear units Ambient temperature according to the technical documentation nameplate and lubricant table in section Lubricants see page 134 No harmful oils acids gases vapors radiation etc in the vicinity For special versions The drive is designed in accordance with the ambient conditions Refer to the in formation on the nameplate For helical worm SPIROPLAN W gear units No large external mass moments of inertia which could exert a retrodriving load on the gear unit for n retrodriving 2 1 n lt 0 5 self locking You must clean the output shafts and flange surfaces thoroughly to ensure they are free of anti corrosion agents contamination or similar Use a standard solvent Do not expose the sealing lips of the oil seals to the solvent damage to the material When the drive is installed in abrasive ambient conditions protect the output end oil seals against wear Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Installing the gear unit 5 3 Installing the gear unit The gear unit or gearmotor is only allowed to be installed in the specified mounting po sition Refer to the information on the nameplate The SPIROPLAN gearmoto
81. e the key and coupling half using the setscrew 481 and tightening torque TA according to the table on the motor shaft 56 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Coupling of AM adapter 5 Check the dimension A 6 Seal the contact surfaces between the adapter and motor using a suitable sealing compound 7 Mount the motor on the adapter Ensure that the coupling claw of the adapter shaft is engaged in the plastic cam ring IEC AM 63 71 80 90 100 112 132 160 180 200 225 250 280 A 24 5 31 5 41 5 54 76 78 5 93 5 139 TA 1 5 1 5 4 8 4 8 10 17 17 17 Thread M4 M4 M M6 M8 M10 M10 M10 NEMA AM 56 143 145 182 184 213 215 254 256 284 286 324 326 364 365 A 46 43 55 63 5 78 5 85 5 107 107 TA 1 5 1 5 4 8 4 8 10 17 17 17 Thread M4 M4 M M6 M8 M10 M10 M10 NOTE To avoid contact corrosion we recommend applying NOCO Fluid to the motor shaft before mounting the coupling half CAUTION Dampness might enter the adapter when mounting a motor to the adapter Potential damage to property Seal adapter with anaerobic fluid seal Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 57 Mechanical Installation Coupling of AM adapter Permitted loads CAUTION Impermissibly high loads may occur when mo
82. ear unit A commercially available thermometer is sufficient for this mea surement Measure the surface temperature at the transition space between gear unit and motor where the position of the terminal box prevents venting by the motor fan The maximum surface temperature will be reached after approximately three hours and must not exceed a difference value of 70 K when compared with the ambient temper ature NOTE ON EXPLOSION PROTECTION Stop the drive immediately if the difference exceeds the given value Consult SEW EURODRIVE For gear units with AM AQ AR adapter or AD input shaft assembly the surface tem perature is measured at the joint between input gear unit flange and customer motor flange see following picture Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Startup go 6 Measuring surface and oil temperature CH 18669579 6 2 2 Measuring the oil temperature It is necessary to measure the oil temperature to determine the lubricant change inter vals set forth in the section Inspection and Maintenance see page 81 To do so mea sure the temperature at the bottom of the gear unit In gear units with oil drain plug you will have to measure the temperature at the oil drain plug Add 10 K to the measured value Use this temperature value to determine the lubricant change interval Operating Instructions Explosion Proof Ge
83. ear unit housing 89 Closing cap 519 Shim 5 Worm 25 Roller bearing 100 Gear cover plate 520 Shim 6 Worm gear 30 Roller bearing 101 Hex head screw 521 Shim 7 Output shaft 37 Roller bearing 102 Seal 522 Shim 9 Oil seal 39 Circlip 131 Closing cap 523 Shim 11 Roller bearing 43 Key 137 Supporting ring 12 Circlip 59 Screw plug 506 Shim 19 Key 61 Circlip 507 Shim Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Gear Unit Design 4 Basic design of SPIROPLAN W10 W30 gear units 45 Basic design of SPIROPLAN W10 W30 gear units 37 100 101 7 65 66 71 143 72 AN S 518 WY 519 9 19307275 1 Pinion 19 Key 88 Circlip 251 Circlip 6 Gearwheel 22 Gear unit housing 89 Closing cap 518 Shim 7 Output shaft 25 Roller bearing 100 Gear cover plate 519 Shim 8 Key 65 Oil seal 101 Hex head screw 520 Shim 9 Oil seal 66 Roller bearing 102 Seal 521 Shim 11 Roller bearing 71 Supporting ring 132 Circlip 522 Shim 12 Circlip 72 Circlip 183 Oil seal 523 Shim 17 Spacer tube 143 Supporting ring 250 Circlip Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 17 18 Gear Unit Design Basic design of SPIROPLAN W37 gear units 4 6 Basic design of SPIROPLAN W37 gear units 1 Pinion 22
84. ed Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Required tools resources 5 Mechanical Installation 5 1 Required tools resources 5 1 1 Installation tol Set of wrenches Torque wrench for Shrink disks AQH motor adapter Input shaft assembly with centering shoulder Mounting device Compensation elements shims spacing rings Fasteners for input and output elements Lubricant e g NOCO Fluid Bolt locking compound for input shaft assembly with centering shoulder e g Loctite 243 Standard parts are not included in the delivery erances Shaft end Flanges Diameter tolerance in accordance with DIN 748 Centering shoulder tolerance to DIN 42948 ISO k6 for solid shafts with lt 50 mm e SOj6for b1 x 230 mm ISO m6 for solid shafts with Z 50 mm ISO h6 with b1 gt 230 mm ISO H7 for hollow shafts Center bore in accordance with DIN 332 shape DR Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 21 Mechanical Installation Prerequisites for assembly 5 2 Prerequisites for assembly CAUTION Improper assembly may result in damages to the gear unit gearmotor Potential damage to property Doclosely observe the notes in this chapter Ensure that the following conditions have been met The entries on the nameplate of th
85. eeeeeneeeeeeeeeneeeeeeeeaes 106 Dil EE 107 8 3 Helical gearmotors H 108 8 4 Helical gearmotors HX 111 8 5 Parallel shaft helical gearmotors E 113 8 6 Helical bevel gearmotors kb 116 8 7 Helical worm gearmotors S A 121 8 8 SPIROPLAN W gearmotors essen 127 Technical Dafa ET 133 9 1 Extended Storage ccccccccesscccceeeeetecceeeeeseecceeeeseeecceeeseaeaceeesteneaeeeeenneaaes 133 9 2 Die le Il 134 Malfunctions Service 2 cecceeceee eee eeeeeeeeeeeeeeneeseeeeeeeeeesenseseseaaneaeeeseeeeeeeens 138 INDIEN 138 10 2 AM AQ AL adapter iinei ei eeni diera idar aaaea aia 139 10 3 AD input shaft assembly sese 139 10 4 Adapter with a torque limiting coupling AR sess 140 10 5 Customer service eserini ia esie edited nennen 141 10 6 Disposal ru ee e n ee cod ee tud aim 141 Declarations of Conformity eeeeeeeeeeeeeeeeeeenen eren nnne nnn nens 142 11 1 Gearmotors in categories II2G and ID 142 11 2 Gear units in category II2G and II2D with AM AQA AL AD adapter 143 11 3 Gear units in category II3G and II3D with AR adapter 144 Address REN 145 DI aee TP 154 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W General Information How to use the operating instructions 1 General Information 1 1 Howto use the operating instructions The operating inst
86. ent of the speed monitor in accordance with the operating instructions of the speed monitor manufacturer The setting must cause the drive to be switched off when the actual speed falls below 95 of the rated speed of the motor used Refer to the nameplate of the drive motor for the rated speed The sensor integrated in the adapter generates 1 pulse per revolution of the adapter shaft If the switching speed of the adapter is too low i e the coupling slips the motor must be disconnected from the supply voltage immediately The cause of the problem must be eliminated and the operation of the adapter must be stopped for at least 15 minutes before re startup If incorrect operation by the operating personnel cannot be ruled out this interval should be triggered by an automatic restart lockout All installation and setting notes given below refer to the speed monitor or voltage en coder in WEX version If other speed monitors are used they must be installed and started up according to the manufacturer s documentation The speed monitor must be located outside the potentially explosive atmosphere Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 75 Installation and adjustment of the WEX speed monitor 6 go Startup 6 7 1 Installation and adjustment of the WEXA WEX speed monitor Relay 2 can be used for creating a warning signal or for machine control terminal as signment 1
87. er mounting positions M1 to M6 are also shown for SPIROPLAN gearmotors to assist you in working with this documentation Caution Apart from W37 the SPIROPLAN gearmotors cannot be equipped with breather valves oil level plugs or drain plugs 8 2 1 Symbols used The following table shows the symbols used in the mounting position sheets and what they mean Symbol Meaning Breather valve Oil level plug Oil drain plug 8 2 2 Churning losses Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Churning losses may occur in some mounting positions Contact SEW EURODRIVE in case of the following combinations Mounting position Gear unit type Gear unit size Input speed rpm 97 107 gt 2500 M2 M4 R gt 107 gt 1500 F 97 107 2500 gt 107 1500 M2 M3 M4 M5 M6 i 77 107 gt 2500 gt 107 gt 1500 S 77 97 gt 2500 107 Mounting Positions Helical gearmotors R 8 3 Helical gearmotors R 8 3 4 R07 R167 04 040 03 00 270 T 0 R R07 G i M1 M2 M3 M5 M6
88. ering shoulder Mounting applications on the input shaft assembly with centering shoulder 1 Retaining bolts of a suitable length must be used to secure the application The length of the new bolts is calculated as follows 212121483 I tra t Screw in depth see table a Thickness of the application s Retaining thread see table Round down the calculated screw length to the next smaller standard length 2 Remove the retaining screws from the centering shoulder 3 Clean the contact surface and the centering shoulder 66 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation AD input shaft assembly 4 Clean the threads of the new bolts and apply a bolt locking compound e g Loctite 243 to the first few threads 5 Attach the application to the centering shoulder and tighten the retaining screws with the specified tightening torque T4 see table Type S SE TA for PEE a E class t mm b 8 8 Nm AD2 ZR 25 5 M8 25 AD3 ZR 31 5 M10 48 AD4 ZR 36 M12 86 AD5 ZR 44 M12 86 AD6 ZR 48 5 M16 210 AD7 ZR 49 M20 410 AD8 ZR 42 M12 86 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 67 Mechanical Installation AD input shaft assembly Permitted loads CAUTION Imper
89. evelt Fax 33 4 72 15 37 15 Rue Jacques Tati F 69120 Vaulx en Velin Paris SEW USOCOME Tel 33 1 64 42 40 80 Fax 33 1 64 42 40 88 Additional addresses for service in France provided on request Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 12 145 12 146 Address List Algeria Sales Alger R ducom Tel 213 21 8222 84 16 rue des Fr res Zaghnoun Fax 213 21 8222 84 Bellevue El Harrach reducom_sew yahoo fr 16200 Alger Argentina Assembly Buenos Aires SEW EURODRIVE ARGENTINA S A Tel 54 3327 4572 84 Sales Centro Industrial Garin Lote 35 Fax 54 3327 4572 21 Service Ruta Panamericana Km 37 5 sewar sew eurodrive com ar 1619 Garin http www sew eurodrive com ar Australia Assembly Melbourne SEW EURODRIVE PTY LTD Tel 61 3 9933 1000 Sales 27 Beverage Drive Fax 61 3 9933 1003 Service Tullamarine Victoria 3043 http www sew eurodrive com au enquires sew eurodrive com au Sydney SEW EURODRIVE PTY LTD Tel 61 2 9725 9900 9 Sleigh Place Wetherill Park Fax 61 2 9725 9905 New South Wales 2164 enquires sew eurodrive com au Austria Assembly Wien SEW EURODRIVE Ges m b H Tel 43 1 617 55 00 0 Sales Richard Strauss Strasse 24 Fax 43 1 617 55 00 30 Service A 1230 Wien http sew eurodrive at sew sew eurodrive at Belarus Sales Minsk SEW EURODRIVE BY Tel 375 17 298 38 50 RybalkoStr 26 Fax 375 17 29
90. f Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance 7 Preliminary work regarding gear unit inspection maintenance 7 Inspection Maintenance The following gear units are lubricated for life and are thus maintenance free Helical gear units RO7 R17 R27 F27 Parallel Shaft Helical Gear Units SPIROPLAN gear units Depending on external factors the surface corrosion protection might have to be re paired or renewed The following inspection and maintenance intervals apply for all the other gear units 7 1 Preliminary work regarding gear unit inspection maintenance Observe the following notes before you start with the inspection maintenance work A HAZARD Risk of crushing if the drive starts up unintentionally Severe or fatal injuries Disconnect the gearmotor from the power supply before starting work and protect it against unintentional re start A WARNING Danger of burns due to hot gear unit and hot gear unit oil Fatal injuries Let motor cool down before beginning work Only remove the oil level and oil drain plug very carefully CAUTION Filling in the wrong oil may result in significantly different lubricant characteristics Potential damage to property Do not mix different synthetic lubricants and do not mix synthetic with mineral lubri cants Mineral oil is used as standard lubricant NOTE The position of the oil level plug
91. gn of helical bevel gear units 4 3 1 2 3 4 5 6 7 8 9 11 12 17 19 20 22 Basic design of helical bevel gear units 101 Pinion Gearwheel Pinion shaft Gearwheel Pinion shaft Gearwheel Output shaft Key Oil seal Roller bearing Circlip Spacer tube Key Breather valve Gear unit housing 523 25 Roller bearing 30 Roller bearing 31 Key 37 Roller bearing 39 Circlip 42 Roller bearing 43 Key 45 Roller bearing 59 Screw plug 83 Nilos ring 84 Nilos ring 88 Circlip 89 Closing cap 100 Gear cover plate 101 Hex head screw 30 542 5 5 89 d i s 43 44 102 Seal 113 Slotted nut 114 Multi tang washer 116 Thread locker 119 Spacer tube 131 Closing cap 132 Circlip 133 Supporting ring 135 Nilos ring 161 Closing cap 506 Shim 507 Shim 508 Shim 521 Shim 521 Shim 522 523 533 534 535 536 537 538 542 543 544 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Shim Shim Shim Shim Shim Shim Shim Shim Shim Shim Shim 19301131 Gear Unit Design Basic design of helical worm gear units 44 Basic design of helical worm gear units Gg dr bai pa 2 61 59 9r i 11 na 519 9 518 19304203 1 Pinion 20 Breather valve 88 Circlip 518 Shim 2 Gearwheel 22 G
92. her 4 Circlip 5 Customer shaft with contact shoulder 2C Installation with SEW EURODRIVE installation and removal kit see page 42 customer shaft without contact shoulder 211522699 1 Retaining screw 2 Lock washer 3 Washer 4 Circlip 5 Spacer tube 6 Customer shaft without contact shoulder Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Shaft mounted gear unit with keyway or splined hollow shaft 3 Tighten the retaining screw to the appropriate torque see table 211524875 Screw Tightening torque Nm M5 5 M6 8 M10 12 20 M16 40 M20 80 M24 200 NOTE In addition to avoid contact corrosion we recommend that you recess the customer shaft between the two contact surfaces Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 39 40 Mechanical Installation Shaft mounted gear unit with keyway or splined hollow shaft 5 7 2 Removal notes This description is only applicable when the gear unit was assembled using the installa tion and removal kit see page 42 from SEW EURODRIVE Observe section Installa tion notes see page 37 2B or 2C 1 Loosen the retaining screw 1 2 Remove parts 2 to 4 and if applicable the distance piece 5 211527051 1 Retaining screw 2 Lock washer
93. ithout authorization improper use as well as incorrect installation or operation may result in severe injuries to persons or damage to property Refer to the documentation for additional information Observe section Applicable doc umentation see page 9 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Safety Notes Target group 23 Target group Any mechanical work may only be performed by adequately qualified personnel Quali fied personnel in this context are persons who are familiar with the setup mechanical installation trouble shooting and maintenance for this product Further they are quali fied as follows They are educated in the mechanics field e g mechanical or mechatronic engineers having successfully passed a final exam They are familiar with these operating instructions Any electronic work may only be performed by adequately qualified electricians Quali fied electricians in this context are persons who are familiar with the electronic installa tion startup trouble shooting and maintenance for this product Further they are qual ified as follows They are educated in the electronics field e g electronic or mechatronic engineers having successfully passed a final exam They are familiar with these operating instructions All work in further areas of transportation storage operation and waste disposal may only be carried out by pers
94. ity specified on the nameplate 5 Check the oil level 6 Re insert and tighten the screw plug Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 99 7 Inspection Maintenance Inspection maintenance for the gear unit 7 7 5 SPIROPLAN W37 in mounting positions M1 M2 M3 M5 M6 with oil level plug Checking the oil Proceed as follows to check the oil level of the gear unit levelvia the oil n ani m 1 Observe the notes in section Preliminary work regarding gear unit inspection main level plug tenance see page 81 2 Setup the gear unit in M1 mounting position 3 Slowly remove the oil level plug see following figure Small amounts of oil may leak out 787235211 4 Check the oil level via the oil level bore 3 with the provided oil dipstick 1 5 For the measurement make sure that the auxiliary clip 2 of the oil dipstick 1 al ways points up vertically see following figure 18634635 Max fill level max Lower edge of the oil level bore 3 100 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance Inspection maintenance for the gear unit Minimum fill level min Maximum fill level max less the value x depending on diameter of oil level bore 3 see following table Oil level bore Minimum fill level x mm Check mark on oil dipstick
95. k of jamming and crushing due to improper removal of heavy components Risk of injury Observe the following removal notes Removing the shrink disk properly 1 Loosen the locking screws one after the other by a quarter rotation to avoid tilting the outer rings 2 Unscrew the locking bolts evenly one after the other Do not remove the locking screws completely 3 Remove the shaft or pull the hub off the shaft remove any rust that may have formed between the hub and the end of the shaft beforehand 4 Remove the shrink disk from the hub 5 8 3 Cleaning and lubrication There is no need to dismantle removed shrink disks before they are reinstalled Clean and lubricate the shrink disk if it is dirty Lubricate the tapered surfaces with one of the following solid lubricants Molykote G Rapid Aemasol MO 19P Aemasol DIO s tral 57 N lube coat Lubricant Mo S2 Sold as Molykote 321 lube coat Spray Molykote spray powder spray Spray Spray or paste Spray or paste Spray Grease the locking screws with a multipurpose grease such as Molykote BR 2 or similar Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 47 5 Mechanical Installation Shaft mounted gear unit with TorqLOC 5 9 Shaft mounted gear unit with TorqLOC 1 Clean the customer shaft and the inside of the hollow shaft Ensure that all traces of grease or oil are removed
96. l cases e g through shaft you cannot install the cover In such cases the cover is not necessary if the system or unit manufacturer provides corre sponding components to guarantee for the compliance with the required degree of pro tection to EN DIN 13463 1 If this results in additional maintenance you have to describe this in the operating in structions for the system component Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 55 5 Mechanical Installation Coupling of AM adapter 5 11 Coupling of AM adapter NOTE ON EXPLOSION PROTECTION You must not use distance bushings as an assembly tool 5 11 1 IEC adapter AM63 280 NEMA adapter AM56 365 479 NTR JL 484 ol eel 1 A A IEC lt AM182 IEC 2AM182 NEMA AM63 280 212099979 1 Motor shaft 479 Coupling half 481 Setscrew 484 Key 491 Spacer tube 1 Clean the motor shaft and the flange surfaces of the motor and the adapter 2 Remove the key from the motor shaft and replace it with the supplied key 484 not AM63 and AM250 3 Heat the coupling half 479 to approx 80 100 C and push the coupling half onto the motor shaft Position as follows IEC adapter AM63 225 Until stop at motor shaft shoulder IEC adapter AM250 280 to dimension A NEMA adapter with spacer tube 491 to dimension A 4 Secur
97. l factors Touch up or renew the surfaces anticorrosion coating Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance Lubricant change intervals 7 3 Lubricant change intervals The following figure shows the change intervals for standard gear units under normal environmental conditions Change the oil more frequently when using special versions subject to more severe aggressive environmental conditions 30000 1 Operating hours 3 CLP PG 2 Sustained oil bath temperature 4 CLP HC c e Average value per oil type at70 C B CLP HLP E SE Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 83 7 Inspection Maintenance Inspection maintenance for the AL AM AQ adapter 7 4 Inspection maintenance for the AL AM AQ adapter Time interval What do I do Check running noise for possible bearing damage e Visually check the adapter for leakage Every 3000 operating hours at least every 6 months After 10000 operating hours Check torsional play e Visually check the elastic annular gear e after 25 000 30 000 hours of operation Renew the anti friction bearing grease Replace oil seal do not install it in the same track Change the elastic annular gear 7 5 Adapter AR Time interval What do I do Every 3000 operating hours at lea
98. ld ET oqu loqui 022 SVd JoBeg jeay N OZZ v W39 uu saeqnix GH 022 elewo Iys 0 95HS QO ol OIN 191N os DOL3 ost 0 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 136 Technical Data Lubricants 9 2 2 Lubricant fill quantities Refer to the gear unit nameplate for prescribed lubricant fill quantities in explosion proof gear units Check the oil level after the filling process See section Inspection mainte nance for the gear unit see page 89 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 137 10 138 10 AE en Malfunctions Service SC Gear unit Malfunctions Service CAUTION Potential damage to property Improper handling of the gear unit and the motor may lead to damages Any repair work on SEW drives may be performed by qualified personnel only Only qualified personnel is permitted to separate drive and motor Consult SEW EURODRIVE customer service 10 1 Gear unit Malfunction Possible cause Remedy Unusual regular running noise Meshing grinding noise Bearing damage Check the oil gt see Inspection maintenance for the gear unit see page 89 change bearings Knocking noise Irregularity in the gearing Contact customer service Unusual irregular running noise Foreign bodies in
99. losion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 123 Mounting Positions Helical worm gearmotors S 8 7 4 SF47 SF97 SAF47 SAF97 SHF47 SHF97 SAZAT SAZ97 SHZAT SHZ97 05 028 03 00 270 T oe A E 180 L p amp 124 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mounting Positions Helical worm gearmotors S 8 7 5 SA37 SH37 ST37 28 020 04 00 D 270 T 0 R 180 L 90 B Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 125
100. lthough the input shaft is rotated Connection between shaft and hub in gear unit or cover interrupted Send the gear unit to SEW EURODRIVE for repair Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 10 139 10 MY a Malfunctions Service Sc Adapter with a torque limiting coupling AR 10 4 Adapter with a torque limiting coupling AR Malfunction Possible causes Solution Unusual regular running Meshing grinding noise Bearing damage Contact SEW EURODRIVE customer service noise Oil leaking Seal defective Contact SEW EURODRIVE customer service Encoder on adapter is defective Measure input pulses if necessary Evaluation unit display Friction lining worn Change encoder of the adapter see section empty Inspection Maintenance Changing the pulse encoder of the adapter Friction lining worn Inspect friction lining cup springs see section Inspec Slip torque is not reached Cup springs burned out or installed tion Maintenance Inspecting replacing friction lining incorrectly after maintenance adjusting the slip torque 140 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W lt 10 M Malfunctions Service gt Customer service lt 10 5 Customer service Please have the following information available if you require customer service assis tance e Namepl
101. missibly high loads may occur when mounting a motor Potential damage to property The load data specified in the following table are not to be exceeded Fy Y 212123659 x KA Typs mm N AD2 ZR 193 330 AD3 ZR 274 1400 AD4 ZR 1120 AD4 ZR a 3300 AD5S ZR 487 3200 AD6 ZR 567 3900 AD7 ZR 663 10000 AD8 ZR 516 4300 1 Maximum load values for connection screws of strength class 8 8 The maximum permitted weight of the attached motor F gmax must be reduced linearly as the center of gravity distance x increases When this distance is reduced Fgmax cannot be increased 2 Diameter of the adapter output flange 160 mm Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation AD input shaft assembly 5 14 4 AD RS cover with backstop Check the direction of rotation of the drive prior to assembly or startup Please inform the SEW EURODRIVE service in the case of incorrect direction of rotation The backstop is maintenance free in operation and does not require any further main tenance work Backstops have a minimum lift off speed depending on the size see fol lowing table CAUTION If the actual speed level is below the minimum lift off speed level the backstops are subject to wear and the resulting friction causes the temperature to increase
102. n IEC 60695 11 10 category FV 0 Power transmission elements should be balanced after fitting and must not give rise to any impermissible radial or axial forces see the Gearmotors or Explosion Proof Drives catalog for permitted values NOTE Mounting is easier if you first apply lubricant to the output element or heat it up briefly to 80 100 C Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 29 5 Mechanical Installation Gear units with solid shaft 5 4 2 Assembling the input and output components CAUTION Bearing hosing or shaft may be damaged due to improper assembly Potential damage to property Only assemble the input and output components with a mounting device Use the center bore and the thread on the shaft end for positioning Never force belt pulleys couplings pinions etc onto the shaft end by hitting them with a hammer nthe case of belt pulleys make sure the belt is tensioned correctly in accordance 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 Gearmotors or Explosion Proof Drives catalog for permitted values Assembly with The following figure shows a mounting device for installing couplings or hubs on gear mounting device unit or motor shaft ends Should you
103. n order to achieve the desired direction of rotation observe the correct power supply for the motor The backstop can be operated in blocking direction with half the output torque once for control purposes CCW 659173899 The direction of rotation is determined with a view to the output shaft LSS Clockwise CW Counterclockwise CCW The permitted direction of rotation is indicated on the housing Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Startup go 6 Speed monitoring 6 6 Speed monitoring 6 6 1 WEX option standard design The standard version of the explosion proof AR adapter features an M12x1 thread for mounting a voltage encoder in the motor flange of the adapter Speed monitor and volt age encoder are included in the scope of delivery 6 6 2 Manufacturer s data Speed monitor in WEX design Manufacturer Pepperl Fuchs Mannheim Type KFU8 UFC Ex1 D Auxiliary power DC 20 90 V AC 48 253 V ATEX certification number TUV 99 ATEX 1471 Voltage encoder in WEXA WEX IGEX design Manufacturer Pepperl Fuchs Mannheim Type NCB12 12GM35 NO in accordance with DIN 19234 NAMUR Housing M12x1 ATEX certification number TUV 99 ATEX 1471 6 7 Installation and adjustment of the WEX speed monitor 1 Read the operating instructions of the speed monitor manufacturer before you begin with the installation 2 Perform the basic adjustm
104. n protection agent from evaporating Gear units will be supplied with an oil fill according to the mounting position M1 M6 and are ready for operation Check the oil level before you start operating the gear unit for the first time Climate zone Packaging Storage location Storage duration temperate Packed in containers with desiccant and moisture indicator sealed in the plas With roof protected against rain and snow no shock loads Up to 3 years with regular checks of the packaging and moisture indicator rel humid Europe USA tic wrap ity lt 50 Canada China Under roof enclosed at constant temperature and f and Russia atmospheric humidity 5 C lt 9 lt 60 C lt 50 2 Years or more with regular excluding tropi relative humidity Heri SE ee cal zones rer No sudden temperature fluctuations Controlled Geer dere Check ventilation with filter free from dust and dirt Pro tected against aggressive vapors and shocks corrosion protection Tropical Asia Africa Central and South Amer ica Australia New Zealand excluding temper ate zones Packed in containers with desiccant and moisture indicator sealed in the plas tic wrap Protected against insect damage and mildew by chemical treatment Under roof protected against rain and shocks Up to 3 years with regular checks of the packaging and moisture indicator rel humid ity lt 50
105. nce between oil level and sealing surface of the gear unit housing specified in the following table Adjust the fill level if required Gear unit type Max distance x mm between oil level and sealing surface of the gear unit housing for mounting position M1 M2 M3 M4 M5 M6 2 stages 521 27 t1 27 t1 27 t1 27 t1 27 t1 Gi 3 stages 49 1 21 1 211 211 211 211 2 stages 63 1 18 1 46 1 18 1 46 1 46 1 a 3 stages 58 1 1142 40 2 WER 40 2 40 2 2 stages 7441 22 1 45 1 22 1 45 1 45 1 Ge 3 stages 76 1 19 1 42 1 19 1 42 1 42 1 ve 2 stages 39 1 3 stages 32 1 Hes 2 stages 32 1 3 stages 28 1 2 stages 78 1 31 1 7241 56 1 78 1 78 1 i 3 stages 7141 24t1 70 1 45 1 7141 7141 irrespective of the mounting position W10 12 1 W20 191 W30 311 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance Inspection maintenance for the gear unit 6 Close the gear unit after the oil level check e Re attach the seal of the cover plate Make sure that the sealing surfaces are clean and dry Screw on the cover plate Tighten the cover screws with the rated tightening torque according to the following table from the inside to the outside in the order illustrated in the figure Repeat the tightening procedure until the screws are properly tightened Only
106. ng cover 2 Voltage encoder carefully screw it into the thread in the adapter flange 1 of the variable speed gear unit until the voltage encoder 5 rests on the screw head 2 Turn the encoder back by 2 turns and secure with the lock nut 3 The switching interval is now set to 2 mm During operation the voltage encoder sup plies 1 pulse per revolution at this switching interval Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 79 6 80 Installation of the voltage encoder go Startup 6 8 1 Changing switching interval x If no circuit state change occurs at the voltage encoder LED display with rotating shaft of the adapter shaft operating with switching interval x 1 mm the switching interval can be changed as follows 1 With constantly lit LED 4 of the voltage encoder turn the voltage encoder a half turn counterclockwise at a time and check its function 2 It the LED is not lit 4 turn the voltage encoder clockwise by 90 degrees but no more than one time CAUTION A collision with the slotted screw heads may destroy the voltage encoder Potential damage to property Do not turn in the voltage encoder by more than half a turn 3 If a circuit change still does not occur check the voltage supply of the voltage en coder using the evaluation electronics with WEXA WEX design Operating Instructions Explosion Proo
107. nical Installation Installing the gear unit Activating the Check whether the breather valve is activated If the breather valve has not been acti breather valve vated you must remove the transport fixture from the breather valve before starting up the gear unit 1 Breather valve with transport fixture zm 211319051 2 Removing the transport fixture 211316875 3 Activated breather valve C 211314699 28 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Gear units with solid shaft 5 3 5 Painting the gear unit CAUTION Breather valves and oil seals may be damaged during the painting or re painting pro cess Potential damage to property Thoroughly cover the breather valves and the sealing lip of the oil seals with strips prior to the painting process Remove the strips after the process 5 4 5 4 1 Gear units with solid shaft Notes on installation NOTE ON EXPLOSION PROTECTION Use only input and output elements with ATEX approval if these are subject to Direc tive 94 9 EC Only use a mounting device for installing input and output elements Use the center bore and the thread on the shaft end for positioning NOTE ON EXPLOSION PROTECTION Use belts with sufficient electrical bleeder resistance lt 109 W only These have to meet the requirements set forth i
108. o not route the supply cables in multicore cables to avoid interference from arasitic voltages Maximum line lengths 500 m with core cross section 1 5 mm Use shielded cables if there is a risk of interference from power current or control cables and if the lines are longer than 10 m You must observe the respectively applicable standards Especially in poten tially explosive atmospheres 1 For design with WEX speed monitor Connect the incremental encoder of the adapter to the speed monitor using a 2 core cable ncremental encoder generates one pulse per revolution 2 Connect the speed monitor according to the wiring diagram supplied with the brake 5 14 AD input shaft assembly Observe section Assembling the input and output components see page 30 when in stalling input components NOTE ON EXPLOSION PROTECTION Use belts with sufficient electrical bleeder resistor 109 Q Before a protection cover can be installed a risk analysis must demonstrate that no sources of ignition e g impact sparks from grinding can occur The manufacturer of the protection cover must perform the risk analysis Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation AD input shaft assembly 5 14 1 AD P cover with motor mounting platform Mounting the motor and adjusting the motor mounting platform
109. of gear units and gearmotors in R F K W and S series comply with the design requirements for unit group II categories 2G potentially explosive gas atmosphere and 2D potentially explosive dust atmosphere These units are intended for use in zones 1 and 21 The explosion proof R F K and S series gear units with AR adapter adapter with torque limiting coupling comply with equipment group ll category 3G potentially explosive gas atmosphere and 3D potentially explosive dust atmosphere These units are intended for use in zones 2 and 22 Do not operate gear units and gearmotors in W10 series in a potentially explosive atmosphere 5 5 1 Ambient temperature All gearmotors in category II2D are only allowed to be used at ambient temperatures from 20 C to 40 C NOTE ON EXPLOSION PROTECTION Any ambient temperatures deviating from this range have to be listed on the name plate 5 5 2 Temperature class Mains operated gear units gearmotors in category II2G potentially explosive gas atmo sphere are approved for temperature classes T3 to T6 depending on their speed re duction ratio and mounting position The temperature class of the gear unit is indicated on the nameplate The situation for single gear units and inverter operated gearmotors only 4 and 6 pole is defined depending on the application subject to consultation with SEW EURODRIVE 5 5 3 Surface temperature The maximum
110. of the dipstick where it exits the gear unit Pull out the dipstick vertically see following figure 784447371 5 Determine the section x between the wetted part and the marking using a caliper see following figure 785020811 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 103 104 Inspection Maintenance Inspection maintenance for the gear unit 6 Compare the determined value x to the min value depending on the mounting po sition specified in the following table Correct the fill level if required Oil level wetted section x mm of the dipstick Mounting position during the check Gear unit type M5 M6 Lying on the A side Lying on the B side W37 in M4 mounting 37 1 29 1 position 7 Re insert and tighten the screw plug Checking the oil Proceed as follows to check the oil of the gear unit via the screw plug 1 Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 2 Remove a little oil at the oil screw plug 3 Check the oil consistency Viscosity f you can see that the oil is heavily contaminated we recommend that you change the oil even if this is outside the service intervals specified in Inspection and maintenance intervals see page 82 4 Check the oil level Changing the oil via the screw
111. ombustion according to DIN EN 13463 for example impact sparks Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 43 5 Mechanical Installation Shaft mounted gear units with shrink disk 5 8 Shaft mounted gear units with shrink disk 5 8 4 Installation notes CAUTION Tightening the screws without installed shaft may result in the hollow shaft being de formed Potential damage to property Only tighten the locking screws with the shaft installed 1 Loosen the locking screws by a few turns do not unscrew them completely 211533579 2 Carefully degrease the hollow shaft hole and the input shaft 0 o o D o o o 9 o H o 211535755 44 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Shaft mounted gear units with shrink disk 3 Hollow shaft input shaft after degreasing 211537931 4 Apply NOCOS Fluid to the input shaft in the area of the bushing It is essential to make sure that the clamping area of the shrink disk is free from grease Never apply NOCO Fluid directly to the socket 11 since the paste may get into the clamping area of the shrink disk when the input shaft is put on 211540107 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W
112. onous Servomotors for gearmotors and asynchronous servo gearmotors Operating Instructions Explosion Proof Synchronous Servomotors for synchronous CFM and CMP servo gearmotors Operating instructions of installed options if applicable Gear Units catalog or Explosion Proof Gear Units catalog 2 6 Transport Inspect the shipment immediately upon receipt for any damage that may have occurred during transportation Inform the shipping company immediately It may be necessary to preclude startup Tighten installed eyebolts They are only intended for the weight of the motor gearmotor do not attach any additional loads The built in lifting eyebolts comply with DIN 580 Always observe the loads and regula tions listed in this standard If the gearmotor is equipped with two suspension eye lugs or lifting eyebolts then both of the suspension eye lugs should be used for transporta tion In this case the tension force vector of the slings must not exceed a 45 angle ac cording to DIN 580 Use suitable sufficiently rated handling equipment if necessary Remove any transpor tation fixtures prior to startup Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 10 Safety Notes Extended storage 2 7 Extended storage Observe the notes in section Extended storage see page 133 28 Installation assembly Observe the notes in section Mechanical Installation see p
113. ons who have been adequately trained 24 Designated use The gear units gearmotors are intended for industrial systems and may only be used in accordance with the information provided in the technical documentation of SEW EURODRIVE and the information given on the nameplate They meet the require ments set forth in Directive 94 9 EC and comply with the applicable standards and reg ulations NOTES ON EXPLOSION PROTECTION A drive motor connected to the gear unit is only allowed to be operated under the con ditions described in section Starting up gear units gearmotors in potentially explosive atmospheres Operate any gear unit connected to the motor on the frequency inverter only if the data on the gear unit nameplate is met If a gear unit is operated in combination with a variable speed gear unit the operating instructions of the variable speed gear unit must be handled separately A motor mounted to a gear unit by means of an adapter or belt may only be operated if the data on the gear unit nameplate is met There may be no aggressive substances in the vicinity that could damage the paint and seals Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Safety Notes Other applicable documentation 25 Other applicable documentation The following publications and documents have to be observed as well Operating Instructions Explosion Proof AC Motors Asynchr
114. ources e Standard tools Hook spanner Hydraulic press Puller extractor threaded spindle with diameter like gear unit input shaft Torque wrench 7 5 2 Inspecting changing the friction lining adjusting the slip torque It is only possible to check and adjust the slip torque accurately by using a torque wrench with an appropriate connection piece See table for the setting values n 2 3 4 S 6 7 8 H i E m H 1 Safety screw 5 Friction lining 2 Cylinder head screw 6 Cup spring 3 Proximity switch 7 Slotted nut 4 Friction disk 8 Friction hub The following figure shows the rough torque adjustment AR71 115 AR132 195 4 1 Marking 4 Markings driving disk 2 Lock washer cam 5 Slotted nut 3 Slotted nut Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 85 7 Inspection Maintenance Adapter AR Severe or fatal injuries A HAZARD Risk of crushing if the drive starts up unintentionally Disconnect the gearmotor from the power supply before starting work and protect it against unintentional re start A OO N gt 9 Disconnect the motor variable speed geared motor from the adapter Unscrew the safety screw 1 pull the friction hub 8 off the shaft extension Clamp the friction hub 8 in a vise With AR 71 115 Unscrew the lock washer
115. r unit reduction ratio IM Mounting position IP Enclosure Ne max rpm maximum input speed Na rpm output speed Memax Nm maximum input torque Ma Nm Output torque Mr Nm Overload torque when using an AR adapter Mrs Nm Locking torque of the backstop Information on the special indication NOTE ON EXPLOSION PROTECTION In some cases SEW gear units gearmotors must only be operated in compliance with special measures For these cases there is a special indication on the nameplate I X These special measures may be necessary due to various reasons e g intermittent operation only reduced output torque etc The customer has been informed about the required special measures on the initial distribution of the gear unit gearmotor The customer is obliged to ensure the compliance with these special measures Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 19 Gear Unit Design Nameplate unit designation 4 7 2 Unit designation NOTE For a detailed overview of unit designations and additional information refer to the fol lowing publications Gear Units catalog Gearmotors catalog Explosion proof drives catalog Example Helical gear unit category IIl2GD RF 47 IA I2GD Lo Explosion proof design to directive 94 9 EC For direct motor mounting Gear unit size Helical gear unit series flange mount
116. red motors in categorys 2GD Motor ducteurs R K F S etW des cat gories 2GD mit der Richtlinie 94 9 EG with the directive 94 9 EC respectent la directive 94 9 CE angewandte Normen EN 1127 1 1997 10 applied standards EN 13463 1 2001 11 Normes appliqu es EN 13463 5 2003 12 EN 13463 8 2003 09 EN 60529 2000 09 SEW EURODRIVE hinterlegt die gem 94 9EG Anhang VIII geforderten Unterlagen bei benannter Stelle FSA GmbH EU Kennnummer 0558 SEW EURODRIVE will archive the documents required according to 94 9 EC Appendix VIII at the following location FSA GmbH EU Code 0558 SEW EURODRIVE tient a disposition la documentation sp cifi e dans la directive 94 9 CEE Annexe VIII pour consultation l endroit d sign FSA GmbH code UE 0558 Ort Datum Gesch ftsf hrer Vertrieb und Marketing Place date Lieu et date Managing Director Sales and Marketing Directeur g n ral international commercial et marketing Bruchsal 03 09 2004 V dua H Sondermann 142 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Declarations of Conformity o 11 Gear units in category II2G and II2D with AM AQA AL AD adapter 11 2 Gear units in category II2G and II2D with AM AQA AL AD adapter EG Konformitatserklarung EC Declaration of Conformity D claration de conformit CE TW gt S DIN EN ISO 9001 EURODRIVE im Sinne der Richtlinie 94 9 EG Anhang VI
117. rs H 108 Helical gearmotors HX 111 Helical bevel gearmotors K 116 Helical worm gearmotors S 121 ew D EE 107 Parallel shaft helical gearmotors F 113 SPIROPLAN W gearmotors 127 Symbols ricette pid dut 107 Mounting the gear units ssseeseeeeeees 26 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Index O Other applicable documentation oseseoenenaaaaenn P Painting the gear unt Parallel shaft helical gear units Rights to claim under limited warranty Run in period S SONCE zone andan eifdem id f d eeh 1 Shaft mounted gear unit Tor UE Shaft mounted gear units splined hollow shaft enrere SPIROPLAN W10 W30 gear units SPIROPLAN W37 gear units T Tightening torques ccccccesecccceeeeececeeeeeeecceeeeeeees Torque arm for shaft mounted gear units SPIROPLAN W gear umnits Torque arms for shaft mounted gear units Helical bevel gear unit eeen Helical worm gear unt Torque arms for shaft mounted gear units Parallel shaft helical gear units Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 155
118. rs are not dependent on the mounting position except for W37 in M4 mounting position The support structure must have the following characteristics Level Vibration damping Torsionally rigid The Maximum permitted flatness error for foot and flange mounting guide values with reference to DIN ISO 1101 e Gear unit size x 67 max 0 4 mm e Gear unit size 77 107 max 0 5 mm e Gear unit size 137 147 max 0 7 mm e Gear unit size 157 187 max 0 8 mm Do not tighten the housing legs and mounting flanges against one another and ensure that you comply with the permitted overhung and axial loads Secure gearmotors using quality 8 8 screws Secure the following gearmotors using quality 10 9 screws RF37 R37F with flange 120 mm e RF47 R47F with flange 140 mm e RF57 R57F with flange 160 mm and RZ37 RZ47 RZ57 RZ67 RZ77 RZ87 NOTES ON EXPLOSION PROTECTION The plugs for checking and draining oil and the breather valves must be freely accessible Processes that cause strong electrical charge due to fast moving particles on the coating must be excluded Prior to startup check that the oil level is as specified for the mounting position see section Lubricants see page 134 or data on nameplate Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Installing the gear unit Check that the oil level is
119. ructions are an integral part of the product and contain important in formation on operation and service The operating instructions are written for all employ ees who assemble install startup and service this product The operating instructions must be accessible and legible Make sure that persons re sponsible for the system and its operation as well as persons who work independently on the unit have read through the operating instructions carefully and understood them Consult SEW EURODRIVE if you have any questions or if you require further informa tion 1 2 Structure of the safety notes The safety notes in these operating instructions are structured as follows Symbol gt A SIGNAL WORD Nature and source of hazard Possible consequence s if disregarded Measure s to avoid the hazard Symbol Signal word Meaning Consequences if disre garded Example HAZARD Imminent hazard Severe or fatal injuries IN WARNING Possible hazardous situation Severe or fatal injuries General hazard A eh 1 CAUTION Possible hazardous situation Minor injuries Specific hazard e g electric shock CAUTION Possible damage to property Damage to the drive system or its environ ment NOTE ON EXPLO Important note on explosion pro Suspension of explosion protection and x SION PROTECTION tection resulting dangers NOTE Useful information or tip Simplifies handling of the drive system
120. s K 8 6 4 KA37 KA157 KH37 KH157 KV37 KV107 KT37 KT157 1 I I 1 I I 1 1 1 I I I 1 I I I I I I 1 1 I 1 1 1 1 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 39 025 04 00 119 Mounting Positions Helical bevel gearmotors K 8 6 5 KH167 KH187 39 026 04 00 270 T X mm TN B i 0 R 93 i 180 0 4p a ME Li ks 90 B 120 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mounting Positions Helical worm gearmotors S 8 7 Helical worm gearmotors S 8 7 1 S37 05 025 03 00 270 T Ec 0 R a 90 B X
121. st every 6 months Check running noise for possible bearing damage Visually check the adapter for leakage e after 25 000 30 000 hours of operation Renew the anti friction bearing grease Replace oil seal do not install it in the same track Unit unit part Time interval What do I do Chapter The periods of wear are affected Inspect and if neces n Adapter with by many factors and may be sary replace the friction podia a Ua torque limiting short lining and cup springs diis with AR torque limiting coupling At least every 3000 operating adjust the slip torque if coupling hours necessary Replace the friction lining if it lost more than 50 of its original thickness see following table New brake disk Type Friction lining thickness mm ART1 AR80 AR85 AR90 AR95 2 AR100 AR105 AR112 3 AR132 AR135 AR145 AR160 AR165 4 AR180 AR185 AR195 Setting tool dimensions Type d u Leer mm mm mm mm AR71 14 30 5 16 3 AR80 AR85 19 40 6 21 8 AR90 AR95 24 50 8 27 3 AR100 AR105 AR112 28 60 8 31 3 AR132 AR135 AR145 38 80 10 41 3 AR160 AR165 42 12 45 3 AR180 AR185 AR195 48 is 14 51 8 84 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance 7 Adapter AR 7 5 4 Required tools res
122. surface temperature of category II2D units is 120 C or 140 C depending on the speed gear ratio and mounting position Lower surface temperature limits are only permitted after consultation with SEW EURODRIVE and must be indicated on the nameplate The system operator must guarantee that a possible accumulation of dust will not exceed a maximum thickness of 5 mm in accordance with EN 50281 1 2 32 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Gear units and gearmotors in category II2GD 5 5 4 5 5 5 5 5 6 5 5 7 Degree of protection The degree of protection for all gear unit versions is IP65 according to EN 60529 Ambient conditions Provide sufficient ventilation for the gear units and prevent external heat generation e g via couplings Output power and output torque Observe the output torque and the permitted overhung load requirements Special designs Special designs e g modified output shaft may only be operated in potentially explo sive atmospheres after prior approval by SEW EURODRIVE Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 33 5 6 Mechanical Installation Torque arms for shaft mounted gear units Torque arms for shaft mounted gear units CAUTION Improper assembling may result in damages to the gear unit Potential damage to property
123. t with TorqLOC 16 After the installation make sure the remaining gap between the outer rings is gt 0 mm 17 The remaining gap between counter bushing and hollow shaft end as well as stop ring bushing and split ring must be 0 mm 0mm pet ot 212016139 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 53 5 Mechanical Installation Installing the protective cover 5 10 Installing the protective cover 54 E9 NOTE ON EXPLOSION PROTECTION Prior to installation make sure that there is a flawless glued connection between sealing and cover the bores of the seal and the cover correspond A CAUTION During operation output components are in fast motion Risk of jamming and crushing Disconnect the motor from the power supply before starting work and safeguard against accidental startup Cover input and output elements with a touch guard 5 10 1 Installing the fixed cover s SZ 1 To fasten the cover remove the plastic plug on the gear unit housing see figure 1 2 Use the delivered screws to mount the cover to the gear unit housing see figure 2 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Installing the protective cover 5 10 2 Installation without cover In certain individua
124. the control bore plug 1 Observe the notes in section Preliminary work regarding gear unit inspection main tenance see page 81 2 Set up the gear unit in M5 or M6 mounting position i e control bore always on top 3 Remove the screw plug 1 see following figure 18655371 4 Insert the dipstick vertically via the control bore all the way to the bottom of the gear unit housing Pull out the dipstick vertically see following figure 90 O SS tU ep GI S d o WINS 18658699 Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 97 Inspection Maintenance Inspection maintenance for the gear unit 5 Determine the size of the section x of the dipstick covered with lubricant using a cal iper see following figure 18661771 6 Compare the determined value x to the min value depending on the mounting po sition specified in the following table Correct the fill level if required Oil level wetted section x mm of the dipstick Gear unit Mounting position type M1 M2 M3 M4 M5 M6 37 10 1 24 1 34 1 37 1 24 t 1 24 1 7 Re insert and tighten the screw plug Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Inspection Maintenance 7 Inspection maintenance for the gear unit Checking
125. the oil Check the oil gt see Inspection maintenance for the gear unit see page 89 Stop the drive contact customer service Oil leaking From gear unit cover at the motor flange at the motor oil seal at the gear unit flange From the output end oil seal Rubber seal on the gear cover plate leaking Tighten the screws on the gear cover plate and observe the gear unit If oil still leaks Contact customer service Seal defective Contact customer service Gear unit not ventilated Vent the gear unit see Mounting Positions see page 106 Oil leaking from breather valve Too much oil Correct the oil fill quantity gt see Inspection mainte nance for the gear unit see page 89 Drive operated in incorrect mounting position e Properly adjust the breather valve gt see Mounting Positions see page 106 Correct the oil level gt see Inspection maintenance for the gear unit see page 89 Frequent cold starts oil foams and or high oil level Use an oil expansion tank Output shaft does not turn although the motor is run ning or the input shaft is rotated Connection between shaft and hub in gear unit interrupted Send in the gear unit gearmotor for repair 1 Short term oil grease leakage at the oil seal is possible in the run in phase 48 hours running time Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIRO
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127. unting a motor Potential damage to property The load data specified in the following table are not to be exceeded 18513419 Adapter type Fall N IEC NEMA x mm IEC adapter NEMA adapter AM63 71 AM56 77 530 410 AM80 90 AM143 145 113 420 380 AM100 112 AM182 184 144 2000 1760 AM1322 AM213 21522 RE 1600 1250 AM132 AM213 215 4700 3690 AM160 180 AM254 286 251 4600 4340 AM200 225 AM324 AM365 297 5600 5250 AM250 280 390 11200 1 The maximum permitted weight of the attached motor Fgmax must be reduced linearly as the cen ter of gravity distance x increases If this distance is reduced the maximum permitted weight Fgmax Cannot be increased 2 Diameter of the adapter output flange 160 mm Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W Mechanical Installation Coupling of AM adapter AM adapter with AM RS backstop Check the direction of rotation of the drive prior to assembly or startup Please inform the SEW EURODRIVE service in the case of incorrect direction of rotation The backstop is maintenance free in operation and does not require any further main tenance work Backstops have a minimum lift off speed depending on the size see fol lowing table CAUTION If the actual speed level is below the minimum lift off speed level the backstops are subject to wear an
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130. x 58 241 838 6275 Service Zona Industrial Municipal Norte http www sew eurodrive com ve Valencia Estado Carabobo ventas sew eurodrive com ve sewfinanzas cantv net Operating Instructions Explosion Proof Gear Units R 7 F 7 K 7 S 7 series SPIROPLAN W 12 153 Index Index A AD input shaft assembly n 64 Anti friction bearing greases ssss 135 C Changing the mounting position 24 Changing the ol 89 Checking the oil arrena aE 89 Checking the oil eye 89 Via oil level olug anesini erth 100 Via the cover plate ceceeeeeeeeeeeeceeeeeeeeteees 93 Via the screw pDlug rre 97 103 Churning losses eee 107 Coupling of AM adapter cceeeeeeeeeeeeeeeteees 56 Coupling of AQ adapter esses 60 Customer Service 1 0 2 eeeeeeeeeeeeeeeeeeteeeeeeeeteeeeaeeees 141 D Design Helical gear units seseeeeees 13 Helical bevel gear units 15 Helical worm gear units sesssess 16 Parallel shaft helical gear units 14 SPIROPLAN W10 W30 gear units 17 SPIROPLAN W37 gear units 18 Disposal emer tots 141 E Extended storage ssssssssssss 10 133 F Flatness errors oe osora ean E 23 G Gear unit design 13 Helical gear units sseeees 13 helical

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