hydrocyclone pump1

Operating and Assembly InstructionProgressive Cavity Pump

TypeBE 70-12

Commission-no.238543

Read instruct ions beforebeginning any work!

Always keep instruct ionshandy on the worksi te.

Original Instructions

Issue 28.04.2010

seepex France SARL 1,Rue Pelloutier F-77183 Croissy Beaubourg Tel+33.1.64114450 Fax+33.1.64114469 [email protected] www.seepex.com

24h Helpline: www.seepex.com

Index

1 Safety................................................................................................................................................... 11.1 General notes1.2 Safety and warning notes

1.2.1 Warning notes 1.2.2 Danger symbols1.2.3 Information symbols

1.3 Dangers that can be caused by the machine1.4 Qualification of the personnel1.5 Authorised people

1.5.1 Tasks and information for the owner/operators1.5.2 Safety notes for maintenance, inspection and assembly work

1.6 Personal protective equipment1.7 Safety and protective devices1.8 Foreseeable misuse1.9 Designated use1.10 Warranty

2 Description of the pump.....................................................................................................................52.1 General description2.2 Mode of action and pumping principle of the seepex pump2.3 Constructive design

3 Technical Data .................................................................................................................................... 63.1 Data sheet ................................................................................................................................73.2 Characteristic Curves...............................................................................................................93.3 Declaration of conformity / Declaration of incorporation.........................................................10

4 Transport........................................................................................................................................... 114.1 Safety4.2 Transport

4.2.1 Dimensions, weight and centre of gravity4.2.2 Symbol4.2.3 Lashing points (AP) for lifting devices4.2.4 Unpacking the machine

4.3 Temporary storage/corrosion protection4.4 Disposal

Index

5 Assembly / Installation.....................................................................................................................135.1 Mounting tools / lifting gear5.2 Space requirement

5.2.1 Dimension for stator replacement5.2.2 Space requirement for service work

5.3 Assembly of the complete mounted pump5.4 Power supply of the seepex pump5.5 Pipelines

5.5.1 Suction and pressure connection5.5.2 Pipeline dimensions5.5.3 Residue-free pipelines5.5.4 Tension-free assembly

5.6 Dimensional Drawing............................................................................................................. 15

6 Commissioning / De-Commissioning............................................................................................. 166.1 Commissioning report............................................................................................................ 166.2 Measures before commissioning............................................................................................17

6.2.1 Checking pipelines6.2.2 Protective devices on the pump6.2.3 Electrical / hydraulic connections6.2.4 Direction of rotation check6.2.5 Additional devices - optional

6.3 Initial commissioning/repeated commissioning6.3.1 Avoiding dry running of the pump6.3.2 Pressure in the suction and pressure connection

6.4 De-commissioning6.4.1 Switching off the pump6.4.2 Emptying the pump6.4.3 Dismantling the pump6.4.4 Preservation/storage of the pump

7 Maintenance...................................................................................................................................... 217.1 Preventative measures

7.1.1 Pump down-time7.2 Lubrication

7.2.1 Joint grease7.3 Inspection

8 Malfunctions, causes, rectification................................................................................................. 23

9 Pump Dismantling / Reassembly.................................................................................................... 259.1 Pump Dismantling / Reassembly........................................................................................... 25

Index

9.2 Rotating unit – individual parts .............................................................................................. 509.2.1 Dismantling9.2.2 Rotating unit (RTE) - prepare individual parts for reassembly9.2.3 Rotating unit (RTE) - individual parts - reassembly

9.3 Holding band - assembly........................................................................................................549.3.1 Prepare the holding band9.3.2 Check the holding band9.3.3 Assembling the holding band9.3.4 Correct tension for the holding band (HBD)9.3.5 Cant up the holding band 9.3.6 Shear the holding band9.3.7 Check the holding band after assembly

9.4 Single acting mechanical seal ................................................................................................569.4.1 Safety9.4.2 Application conditions and material version9.4.3 Design9.4.4 Commissioning 9.4.5 Monitoring during operation9.4.6 Dismantling of mechanical seal9.4.7 Reassembly of mechanical seal

9.6 Sectional drawing shaft sealing..............................................................................................59

10 Spare parts........................................................................................................................................ 6010.1 Order template for spare parts............................................................................................... 6110.2 Sectional drawing and parts list..............................................................................................63

11 Special tools......................................................................................................................................6711.1 Order template for special tools

12 Related documents...........................................................................................................................6812.1 Accessories............................................................................................................................6912.2 Technical Information............................................................................................................. 7012.3 Manufacturer's documents shaft seal.....................................................................................73

13 Appendix ........................................................................................................................................... 7413.1 Manufacturer's documents / suppliers

13.1.1 gearbox......................................................................................................................7513.1.2 Motor ....................................................................................................................... 167

Subsidiaries

1Ausgabeissue C / 11.10.2005 Dokument

document OM.SAF.01e Blattsheet 1 (4)

1Safety

1.1 General notes

Always keep the operating and maintenance instructions close by the machine. If problems cannot be solved with reference to the operating and maintenance instructions,

please contact the manufacturer.Observe the following points in addition to these operating and maintenance instructions:• Prohibition, warning and mandatory signs, warning notes on the machine• Relevant laws and ordinances• Statutory provisions on accident prevention• Corresponding harmonised standards and regulations

1.2 Safety and warning notes

Comply with safety and warning notes for safe and efficient use of the product.Signal words for specific dangers and (possible) consequences are explained below. Theseare supplemented by symbols (pictograms) if necessary.

1.2.1 Warning notes

NOTICE

Caution for machine!Possible danger.Material damage can occur.

CAUTION

Caution for people and machine!Possible danger.Minor injury or damage to property can occur.

WARNING

Warning for people!Possible danger.Death or serious injury can occur.

DANGER

Danger for people!Possible danger.Immediate risk of sever or fatal injury.

2

1Safety

Ausgabeissue C / 11.10.2005 Dokument


1.2.2 Danger symbols

1.2.3 Information symbols

Instruction to act/take measures• List item

Warning: Suspended load.

Warning: Tipping over.

Warning: Hand injuries.

Warning: Dangerous electri-

cal voltage.

Warning: Pull-in hazard.

Warning: Excess pressure.

Warning: Risk to the environ-

ment.

Warning: Hot surfaces.

NOTICE

Observe operating and maintenance

instructions.

Ensure environ-mental protection.

Disconnect power plug before opening.

Wear eye protection.

Wear gloves.

3

1Safety



1.3 Dangers that can be caused by the machine

seepex machines are built in accordance with the state of the art.Nevertheless, there is a residual risk, because the machine works with:• Mechanical movements that pose a danger• Electrical voltages and currentsWe have used design measures and applied safety technology to minimise the risk to thehealth of people posed by this danger.

1.4 Qualification of the personnel

This handbook is intended for:• Owner• Operators• Setters• Maintenance personnel

1.5 Authorised people

People authorised to undertake operation, set up and maintenance are instructed and trainedspecialists employed by the owner/manufacturer.

The owner is responsible for:• Personnel training• Compliance with safety regulations• Compliance with operating and maintenance instructionsThe operator must:• Have received instruction• Read and understood the relevant parts of the operating instructions before starting work• Know the safety devices and regulations

1.5.1 Tasks and information for the owner/operators Regularly check and maintain the machine, replacing all parts in good time which no longer

guarantee safe operation. It is essential to comply with the procedure described in the operating instructions for shut-

ting down the machine.• On completion of work, attach all safety and protective devices and make sure they are

functioning.

1.5.2 Safety notes for maintenance, inspection and assembly work Do not work on the machine or system unless it is stationary and depressurised. Switch off the master switch and pull out the power plug before starting work on live com-

ponents. Comply with the procedure for shutting down the machine as described in the Shut-down

chapter. Decontaminate (de-toxify) machines that are used for pumping media that can be harmful

to health. Refer to the Initial start-up chapter before repeated start-up of the machine.

Detailed technical knowledge is essential for performing any work on the machine.

4

1Safety



1.6 Personal protective equipment

Wear personal protective equipment and/or additional equipment for your own safety. Avoid/limit risks by the use of collective technical protective equipment or by organisational

measures at work.

1.7 Safety and protective devices

Prior to start-up, bolt seepex machines onto a concrete foundation so as to ensure stability. Starting and stopping devices must be clearly recognisable. Take appropriate measures to

avoid defects.• No protective device is necessary for checking and/or setting the shaft seal.• Hot surfaces are identified with a danger symbol on the machine.

1.8 Foreseeable misuse

Serious personal injury and damage to property can be caused by:• Incorrect use• Incorrect installation or operation of the machine• Impermissible removal of necessary protective equipment

1.9 Designated use

• Only use seepex machines if they are in perfect condition and in compliance with the oper-ating and maintenance instructions.

• Do not start up the machine unless the system in which the machine is installed is in accor-dance with the provisions of the applicable guidelines and statutory regulations.

• Equivalent sustained sound pressure level at workplaces of operating personnel C75 dB (A). Cavitation-free operation of the machine and screwed connection to concrete founda-tion are essential.

• seepex machines are components that are exclusively intended for pumping media in ac-cordance with the technical data (chapter 3.0). Written approval must be obtained from the manufacturer before other media are pumped.

• Refer to the information on the type plate and the operating instructions for technical data (chapter 3.0), and comply with them.

• The operating instructions are assigned to the seepex machine based on the commission number.

Similar illustration

1.10 Warranty

• Warranty in accordance with our terms and conditions of delivery and order confirmation.• It is a condition of the machine warranty that the machine must correspond to the listed op-

erating instructions in accordance with the type plate/data sheet.• All wearing parts are excluded from the warranty.• These operating instructions are subject to copyright. Reproduction is not permitted and will

be punished. Contravention will be pursued through the courts.

24h Helpline: www.seepex.com

sc

Kommissions-Nr.commission no.

Drehrichtungdirection of rotation

Typtype

seepex GmbHScharnhölzstraße 34446240 BottropTelefon +49.2041.996-0Fax +49.2041.996-400

5Ausgabeissue A / 10.06.2008

Dokumentdocument OM.DES.01e Blatt

sheet 1 (1)

2 Description of the pump

2.1 General description

seepex pumps are members of the group of rotating displacement pumps.• Characteristic features

– Special configuration/arrangement of the rotor and stator pumping elements.– Motion sequence

2.2 Mode of action and pumping principle of the seepex pump

• Seal lines are created by the geometrical configuration/contact between both pumping ele-ments.

• Seal lines provide total separation between the suction and pressure sides.Result:– Increased suction lift capability of the pump– High pressure build-up irrespective of the rotation speed

2.3 Constructive design

No. DesignationANT Drive200 Lantern307 Plug-in shaft400 Coupling rodSEA Shaft seal500 Suction casing600 RotorRTE Rotating unit601 Stator700 Pressure branch

6Ausgabeissue B / 04.01.2010

Dokumentdocument OM.TED.01e Blatt

sheet 1 (1)

3Technical data

3.1 Data sheet

3.2 Characteristic Curves

3.3 Declaration of conformity / declaration of incorporation

7

scData Sheet 238543 Page 1

seepex GmbHPostfach.PO Box 10 15 6446215 BottropScharnhölzstraße 34446240 BottropGermany

Tel +49.2041.996-0Fax [email protected]

seepexorder no. P89424/2009 commission no. 238543date 18.12.09 offer no. 2101/1687-4 001 K91258-13customer PA Ressourcespurchase order no. Cde dze-157-09 item/denomination project 1 off seepex progressive cavity pump

type BE 70 -12 /B2-A7-A7-H5-GAM3.2-X conveying product U 495 WA0010denomination waterrate of solids no advice viscosity unknownsize of solids no advice pH-value no advicedensity 1 kg/dm3 temperature 5 - 40°Ccomposition no adviceremarks Eau + hydrocarburesperformance data nom. min maxconveying capacity 30,00 m3/h pump speed 140 rpmpress in press. branch 8,00 bar press in suct. branch flooded suctiondifferential pressure bar operating torque Nmrequired drive power 12,80 kW starting torque 900 Nmremarks technical pump datarange BE kind of install. vertical drive on topsize 70 direction of rot. clockwisepressure stage 12 pos. of branch 1

component material design/optionlantern EN-JL-1040 (gci 25) standardpressure casing steel 1.0037 (st.37-2) semi-submersible variant Opressure connection DN 3" ANSI B16,5 150lbs suction branch steel 1.0037 (st.37-2) suction connection t=14000joint joint seal withoutcoupling rod 1.4571 special constructionrotor 1.4571 standard Duktil coated 250 µmstator FPM-H5 design equal wallmechanical seal casing 1.4571 with Quench for mechanical seal, internalmechanical seal Burgmann MG1/G60-100 Q1Q1 VGG plug-in shaft 1.4571 drilled Ø60x100special designs quench acc. to ZU.021.01 , design 3 incl. tank approx. 140 cm3 submersible pump with intermediate housing see remarks

Rechtsform GeschäftsführenderGmbH Gesellschafter:HRB 9350 Gelsenkirchen Ulli Seeberger

8

scData Sheet 238543 Page 2

seepex GmbHPostfach.PO Box 10 15 6446215 BottropScharnhölzstraße 34446240 BottropGermany

Tel +49.2041.996-0Fax [email protected]

general operating datakind of operation continuous operation - 8 h/daysite of installation indoorremarks drivetype gearmake SEW ratio i=12,390model RF97 AM180mounting position IMV1 nom./ min- maxflange dia 350 mm output speed 141/ - rpmoutput shaft 716/0700-002B4 motor speed 1740/ - rpm frequency 60/ - Hzelectric motormake HEW Herforder Elektr model DEx 180M/4Knominal power 21,0 kW voltage 3 x 460 VAC Vnominal speed 1740 rpm rated frequency 60 Hzmounting position IMV1 protection IP55starting direct on line thermal class F

size 180 flange/shaft dia 350 / 48 mmex-protection EEx deIICT4provid. of motor HEW fitting of motor seepex BOTspecial/accessories with 3 PTC thermistorsbaseplatestandard KRANBÜGEL material St52-3drawing no. 824-200/0700-C-004A1 surface varnishedspecial/accessories paintingexecution standardcolour RAL 5013 (blue)remarks packingpacking type marking documentationdimensional drawing no. 271-G34/0700-C-001D2 operating manual 1 copy frenchsectional drawing no. 071-K238-543A1 1 copy Englishshaft sealing sect.view 271-0GB/0700-0-081B3QA-documentation CE-sign Rotor / Stator test recordadditional accessories / special designs / remarks

special design:The pump is dismountable in 5 sections as per drawing-no.: ...

order desk Sabine Zanger sales engineer Johannes Beckmannphone 02041.996-0 issue 28.04.10 / 15:35

Rechtsform GeschäftsführenderGmbH Gesellschafter:HRB 9350 Gelsenkirchen Ulli Seeberger

10

BE 70-12

238543

28.04.2010

Rechtsform: Geschäftsführender GmbH Gesellschafter: HRB 9350 Gelsenkirchen Ulli Seeberger

seepex GmbH Scharnhölzstraße 344 46240 Bottrop Postfach 10 15 64 46215 Bottrop PO Box 10 15 64 46215 Bottrop Germany Tel +49.2041.996-0 Fax +49.2041.996-400 [email protected] www.seepex.com

EC declaration of conformityaccording to Machinery Directive 2006/42/EC, Annex II A

We hereby declare that the following product

Progressive cavity pump unit

meets the provisions of the directive indicated above, includingthe modifications holding at the time of declaration.

The product also meets all the provisions of the following directives:

The following harmonised standards were applied:

Bottrop,

Manufacturer: seepex GmbH

Address: Scharnhölzstrasse 344D-46240 Bottrop, Germany

Type:

Comm. no.:

2006/95/EC2004/104/EC

Electrical equipmentElectromagnetic compatibility

DIN EN ISO 12100-1DIN EN ISO 12100-2DIN EN ISO 13857DIN EN 809

Safety of machinery, Part 1Safety of machinery, Part 2Safety distances, upper and lower limbsPumps and pump units for liquids

Responsible for documentation: Thomas HümmerichTechnical documentationTel +49 2041 996 - 309Fax +49 2041 996 [email protected]

p.p. Klemens FockenbergTechnology Managerseepex GmbH

p.p. Roland HeckerQuality Control Managerseepex GmbH

11Ausgabeissue A / 29.08.07 Dokument

document OM.TRA.01e Blattsheet 1 (2)

4Transport

4.1 Safety

4.2 Transport

4.2.1 Dimensions, weight and centre of gravity Note the dimensional drawing (chapter 5.6).

4.2.2 Symbol• Meaning of symbol

4.2.3 Lashing points (AP) for lifting devices

4.2.4 Unpacking the machine Comply with the symbols and notices on the packaging. Remove the screwed connection between the machine and packaging. Remove the machine with a lifting machine/industrial truck.

CAUTION

Damage to property/injuries due to incorrect transport.Slight injury or damage to property can occur. Comply with the safety notes and transport notes on the packaging. Use suitable means of transport, lifting devices and tools. Use protective equipment.

Top Fragileitem

Against moisture protect

Centre of gravity Lashing points

WARNING

Warning of suspended load.Death or serious injury can occur. Use the lashing points (AP) for lifting devices. Note the centre of gravity (dimensional drawing chapter 5.6).

Lifting machine Industrial trucks

AP AP

12

4Transport

Ausgabeissue A / 29.08.07 Dokument

document OM.TRA.01e Blattsheet 2 (2)

4.3 Temporary storage/corrosion protection

• All seepex machines have corrosion protection applied as standard prior to transport.

4.4 Disposal

NOTICE

Damage to property if corrosion protection is missing.Property damage can occur due to corrosion. Temporary storage must be in a dry, enclosed, frost-free room in order to provide protec-

tion against ambient influences. Contact seepex regarding the necessary corrosion protection for temporary storage.

NOTICE

Environmental protection.Material damage can occur. Drain the pumping medium and dispose of it in accordance with the regulations. Dispose of the machine with regard to its composition and existing regulations.


Dokumentdocument OM.INS.06e Blatt

sheet 1 (2)

5Assembly / Installation

5.1 Mounting tools / lifting gear

5.2 Space requirement

The required space should be determined by considering the following factors: • Dimensions and weight.• Requisite transport and lifting equipment. • Pipe routing – dismantling (dimension for stator replacement).

5.2.1 Dimension for stator replacement (P)

5.2.2 Space requirement for service work

Note the following measure:

CAUTION

Pump falling over.Slight injury or damage to property can occur. Adhere to the lifting tool’s starting point. Pay attention to the dimensions, weight and centre of gravity of the pump. Use suitable mounting tools/lifting gear.

Refer to the dimensional drawing.

A Provide a working area of approx. 1 m/40 inch width alongside the pump.

B When changing the stator, provide suspension points above the stator and in front of the pressure branch.

C For dismantling/assembly the drive, provide suspension points above the drive unit.

D For dismantling/assembly of the suc-tion casing/hopper, provide suspen-sion points above the housing.

P Dimension for stator replacement.

P A

B B

B

D C

A

A

14

5Assembly / Installation

Ausgabeissue B / 23.06.2008

Dokumentdocument OM.INS.06e Blatt

sheet 2 (2)

5.3 Assembly of the complete mounted pump

Assemble according to technical data (chapter 3.). Note the dimensional drawing.

Tension-free mounting of the pump Balance unevenness with suitable supports..• Applies to mounting on foundations/load-bearing elements.• Total areas of all pump bearing areas are resting on the surface.

Correct position of the drives• All drives are set up ready for operation and mounted.• Correct displacements of the drive during transport/installation of the pump by adjusting/fix-

ing the drive.

5.4 Power supply of the seepex pump

5.5 Pipelines

5.5.1 Suction and pressure connection

• Refer to the dimensional drawing for position, nominal width and standard.• Note the direction of rotation/flow direction.

5.5.2 Pipeline dimensions

• Adhere to specifications regarding pressure in the pressure respectively suction connec-tion.

• Note technical data (chapter 3.).• Nominal width of suction pipe = nominal width of pump suction connection.

5.5.3 Residue-free pipelines

5.5.4 Tension-free assembly

Assemble pipelines and other components in a tension-free manner on the pump.

CAUTION

Safety protective devices.Slight injury or damage to property can occur. Connect safety protection devices and activate.

DANGER

Line voltage and line frequencyDeath or serious injury can occur. Note the type plate on the pump. Pay attention to manufacture’s directions (chapter 13.). Pay attention to safety regulations.

NOTICE

Damage to property through assembly residue.No claims under guarantee if violated. Keep all pipelines free from foreign objects. Remove weld spatter, screws, steel chips, etc.

16Ausgabeissue B / 17.03.2006 Dokument

document OM.COM.05e Blattsheet 1 (1)

6Commissioning / De-commissioning

Master Copy

6.1 Commissioning report

Send commissioning report online towww.seepex.com\

From:

Must be specified with every order!Commission: Model: Contact person: ...........................................

_________________________ _____________________Tel.: .............................................................Fax: ...........................................................E-mail: ........................................................

Customer Service:seepex GmbHPostfach 10 15 64 D-46215 Bottrop

Germany Phone:+49 2041.996-231Fax: +49 2041.996-431

Address of plant: .................................................................

Rest of Europe

Phone:+49 2041.996-224Fax: +49 2041.996-424

.................................................................

.................................................................service@seepex.com Outside

EuropePhone:+49 2041.996-120Fax: +49 2041.996-432

.................................................................

.................................................................

Delivery date:Date of installation: Assembly check carried out on:

Please enter operational data:Conveying liquid: Temperature:Fuse level/motor protection or power consumption

Frequency control no

yes If yes:

Supplied by seepex

Supplied by customer

Frequency:Speed:Power consumption:

________________________________ _______________________________________Place, date Signature / company stamp




6.2 Measures before commissioning

Note the technical data (chapter 3.).

6.2.1 Checking pipelines

6.2.2 Protective devices on the pump

6.2.3 Electrical/hydraulic connections

Check flange screwed connections (SCH).

Check threaded connections (G).

NOTICE

Ensure the liquid can flow through without obstruction.Malfunction and/or irreparable damage to the pump. Open all shut-off elements before switching on the pump.

SCH

G

DANGER

Missing protective device.Danger of pulling in and crushing. Equip the pump with a protective device. Protective devices provided for preventing con-

tact with surfaces or moving parts must be regarded as suitable if contact is not possible in a test involving a test finger, with regard to the penetration possibility, strength and shock resistance.

Comply with national protection regulations. In pumps with an open suction flange/feed hopper, attach touch protection. These safety

clearances protect those persons who are attempting to reach danger areas without addi-tional help and under the conditions defined for various situations of reaching up, reaching under or reaching through

In shaft seals, touch protection is only necessary if there are components on the rotatingshaft.

DANGER

Dangerous voltage.Death or serious injury can occur. Observe safety regulations. Disconnect the pump from all sources of energy. Prevent electrical connections from being switched on again.

18


Ausgabeissue B / 18.10.2005 Dokument


6.2.4 Direction of rotation check

6.2.5 Additional devices - optional Refer to additional devices (chapter 12.1).

6.3 Initial commissioning/repeated commissioning

Start up the pump.

6.3.1 Avoid dry running of the pump

6.3.2 Pressure in the suction and pressure connection

6.4 De-commissioning

Protect the pump and additional devices against the following:• Frost• Deposit of solids• Sedimentation from the liquid• Corrosion of parts that come into contact with the medium

flow direction

The pump direction of rotation determines the flow direction of the pumping medium.

Note the direction of rotation arrow on the type plate.

counter clockwise clockwise

NOTICE

Dry running of the pump.Malfunction and/or irreparable damage to the pump. Fill the suction casing with liquid in order to lubricate the pumping elements.

NOTICE

High temperature between rotor and stator.Stator material burned.Complete failure of the pump Make sure that the suction-side conveying capacity does not cavitate. If this cannot be guaranteed on the machine side, assemble a seepex dry running

protection (DRP)

CAUTION

High pressure.Malfunction and/or irreparable damage to the shaft seal or pump. Maintain pressure in the suction connection in accordance with the technical data

(chapter 3.). Assemble an oil-filled contact pressure gauge to monitor and deactivate the pump.

19




6.4.1 Switching off the pump

6.4.2 Emptying the pump

To drain the pump: If the pump housing has screwed plugs, remove the screwed plugs. Drain using a connection branch (suction casing, pressure branch) if the pump housing is

coated or the housing does not have screwed plugs. Drain the residual liquid from the pump housing. Drain the pipelines on the suction and pressure sides, or shut off behind the pump connec-

tions.

6.4.3 Removing the pump

Pipeline dismantling

DANGER


CAUTION

Liquid draining out.Minor injury or damage to property can occur. Wear suitable protective clothing. Refer to the technical data (chapter 3.) for the corresponding configuration of the pump

housing.

WARNING

Risk of pump tipping or falling.Death or serious injury can occur. Support the drive unit to guarantee stability.

Remove flange bolts (SCH) and flange seals (DFL).

with/without base plate Remove bolts (SCH) from the pump feet.

DFL

SCH

SCH

20




Pipeline dismantling

6.4.4 Preservation/storage of the pump

Remove threaded connections (G).with/without base plate Remove bolts (SCH) from the pump feet.

G

SCH

NOTICE

Damage to property due to lack of corrosion protection.Property damage can occur due to corrosion. Contact seepex to discuss suitable preservation measures.

– State the commission number of the pump.


document OM.WTG.03e Blattsheet 1 (2)

7Maintenance

7.1 Preventive measures

7.1.1 Pump down-time

7.2 Lubrication

The maintenance personnel must have these operating instructions, follow them and also require corresponding qualifications.• No liability will be accepted in the event of violation.

DANGER


NOTICE

Pump down-time.Production failure due to wear. Acquisition of a set of wearing parts and a set of gaskets.

No. Denomination Lubricant Lubricant change in operating hours

Fill volume

1 Pin joint seepex special grease (30321)

10000 h 14 cm3

2 Pin joint seepex special grease (30321)

10000 h 14 cm3

3 Drive Refer to manufacturer's documentation (chapter 13.1)

Rotor/stator Conveying medium --- ---Shaft seal Conveying medium --- ---

1 2 3

22

7Maintenance


document OM.WTG.03e Blattsheet 2 (2)

7.2.1 Joint grease

7.3 Inspection

NOTICE

Other grease types.Malfunction and/or irreparable damage to the joints or the pump. Exclusively use seepex special grease.

Component Interval Action

Joints Every 10,000 operating hours Renew joint greaseShaft seal Every week Visual check for leaksDrive unit Every 3000 operating hours,

at least every 6 monthsComply with manufacturer's documentation


document OM.REC.01e Blattsheet 1 (2)

8Malfunctions, causes, rectification

Refer to technical data (chapter 3.) for application range of the pump.

Malfunction Causes Rectification

Pum

p is

not

suc

king

Pum

p pu

mpi

ng u

neve

nly

Con

veyi

ng c

apac

ity is

not

ach

ieve

dP

ress

ure

head

is n

ot re

ache

dP

ump

does

not

sta

rt up

Pum

p se

ized

/ pu

mp

does

not

pum

pP

ump

is lo

ud w

hen

runn

ing

Mot

or g

ets

too

hot

Pre

mat

ure

stat

or w

ear

Sha

ft se

al is

leak

y

X X X Static friction between sta-tor/rotor too great.

Apply lubricant (liquid soap) between stator and rotor.

X Incorrect direction of rota-tion.

Check direction of rotation and swap over motor con-nections if necessary.

X X X X X Suction pipe or shaft seal leaking.

Eliminate leaks.

X X X X Suction head too great. Check the suction head, if necessary increase pipe cross section on suction pipe and use a larger filter, open suction-side valve fully.

X X X Viscosity of conveying product too great.

Check/adapt (data sheet).

X X X Pump rotation speed incorrect.

Correct rotation speed (data sheet).

X X Avoid air bubbles in the conveying product.

X X X X X Pressure head too great. Check pressure head with pressure gauge, reduce pressure head by using larger pressure pipe crossed section or shorten-ing the pressure pipe.

X X X X X Pump running partially/completely dry.

Check there is adequate conveying product avail-able on the suction side. Dry running protection DRP.

X X Check coupling. If necessary, move pump in relation to drive, check wear on coupling gear, re-adjust coupling if necessary.

X X Rotation speed too low. Increase rotation speed for low-viscosity media/large suction volume.

24

8Malfunctions, causes, rectification


document OM.REC.01e Blattsheet 2 (2)

Malfunction Causes Rectification

Pum

p is

not

suc

king

Pum

p pu

mpi

ng u

neve

nly

Con

veyi

ng c

apac

ity is

not

ach

ieve

dP

ress

ure

head

is n

ot re

ache

dP

ump

does

not

sta

rt up

Pum

p se

ized

/ pu

mp

does

not

pum

pP

ump

is lo

ud w

hen

runn

ing

Mot

or g

ets

too

hot

Pre

mat

ure

stat

or w

ear

Sha

ft se

al is

leak

y

X X X Rotation speed too high. Reduce rotation speed for high-viscosity media, risk of cavitation.

X Joint play too large. Check mounting of cou-pling rod bushing.

X X X X X Foreign objects in pump. Dismantle pump, remove foreign bodies, replace defective parts.

X X X X Stator/rotor worn. Dismantle pump and renew defective parts.

X X X X Joint parts worn. Renew joint parts, use seepex pin joint grease.

X X X X Suction pipe blocked. Clean the suction pipe.X X X X X Temperature of pumping

liquid too high.Check temperature, use an undersize rotor.

X X X X X Gland packing too firm/worn.

Loosen packing gland or tighten. Renew unusable packing rings.

X X X X Solid content and/or grain size too great.

Reduce pump speed, install screen with permit-ted mesh width. Increase liquid proportion.

X X X X Sedimentation/gumming of solids when pump station-ary.

Rinse through and clean the pump immediately.

X X X X X Conveying product hard-ens when the temperature drops below a certain limit.

Heat the pump.

X X X X Stator swollen and unable to withstand conveying product.

Select a suitable stator material, use an under-size rotor.

X X Bearings in pump drive housing or drive unit defective.

Renew bearings.

X Mechanical seal defective. Check sliprings and O-rings for wear/resistance, renew if necessary.


document OM.MAI.238543 Blattsheet 1 (25)

9Dismantling / Reassembly

9.1 Atex documents

Range: BESize: 70-12

9.1.1 Assembly/reassembly

9.1.1.1 Conveyor unit (FEH) - pre-assembly

WARNING

Tilting or falling pump.Death or serious injury can result. Secure pump parts. Use suitable hoisting devices.

Tool (W2/chain pipe wrench)

Tool (W103/Haltewerkzeug)

Add lubricant (liquid soap) to the opening on suction branch side between the rotor (600) and the stator (601).

Turn the stator in the “right” rotating direc-tion.

Dispense lubricant (GM) on the stator in-ternal surface in order to reduce friction between the rotor and stator.

Fix rotor (600) against twist. Turn stator (601) on the right and push it

over the rotor (600).– Use tool (W2).

Push suction branch (700) with distance bolt (702) over stator (601).

Fix tool (W103) on rotor (601).– Note clearance

GM

W2 601 600

602604 606

700 601702 535 538

W103FEH

26




9.1.1.2 Coupling rod (480)/Intermediate element (534) - pre-assembly

9.1.1.3 Conveyor unit (FEH), coupling rod (482)/intermediate element (534) - assembly

Tool (W105, W106/lifting device)

Screw threaded bushing (489) with cou-pling rod (482).

Assemble tool (W105). Insert o-ring (538) into intermedialte ele-

ment (534). Assemble tool (W106). 482

489483

W105

W106538

534

Tool (W104/holding device)

Fix tool (W104) onto mounting hole (ML).– Note the position of the tool (W104).

Insert and secure the pre-assembly con-veyor unit into the mounting hol with tool (W104).– Note the position of the tool (W104).

Secure pre-assembly unit, coupling rod (482)/intermediate element (534) with lift-ing device (TR1) and (TR2)

Screw flange coupling rod (482) / Rotor (601).

ML

FEH

W104

W104

490

492493

491

TR1TR2

482

600

TR

535

534

27




9.1.1.4 Intermediate elements (535, 534) - assembly

9.1.1.5 Lowering the pump parts


dismantle tool (W103). Screw intermediate elements (535, 534).

W103

539

540541

534

535

Tool (W104/holding tool)

Hoist pump parts and adjust tool (W104).– Note position of the tool (W104)

Lower the pump parts up to the flange (100 mm) of the intermediate element (534).

Adjust tool (W104). – Note the position of the tool (W104).

Lower pump parts to limit stop.

W104

W106TR2

534

28




9.1.1.6 Secure rotating unit (RTE)



Tool (W107bearing ring)

Hoist rotating unit (RTE). Secure the rotating unit (RTE) with tool

(W102, W107). Remove lifting device (TR1). Dismantle tool (W105).

W107W102

W105TR1

RTERTE




ment (536). Assemble tool (W106).

481

489483

W105

W106538

536

29




9.1.1.8 Coupling rod (481)/intermediate element (536) - assembly





Assemble intermediate elements (536, 534).

489483

481

TR1TR2

482

536

534

W107W102

482

539

540541






W104

W106TR2

536

30






Tool (W102/holding tool; W107/bearingring)

Tool (W107/bearing ring)



W107W102

W105TR1

RTERTE




ment (537). Assemble tool (W106). 480

489483

W105

W106538

542

537

31








Screw threaded bushing (489) with cou-pling ros (480).


489483

480

TR1TR2

481

537

536

W107W102

481

539

540541






W104

W106TR2

537

32










W107W102

W105TR1

RTERTE

tool (W105, W106/lifting device)




480

489483

W105

W106538

534

33










489483

480

TR1TR2

480

534

537

W107W102

480

539

540541






W104

W106TR2

534

34





9.1.1.19 Coupling rod (480)/pressure casing (500) - pre-assembly

9.1.1.20 Coupling rod (481)/pressure casing (500) - assembly

Tool (W102/holding tool; W107/bearingring)



W107W102

W105TR1

RTERTE



Assemble tool (W105). Assemble tool (W106) at pressure casing

(500).

400

489483

W105W106

500

Secure pre-assembly unit, coupling rod (400)/pressure casing (500) with lifting de-vice (TR1) and (TR2)


Assemble intermediate element (534) at pressure casing (500).

489483

400

TR1TR2

480

539

540541

480

500

534

W107W102

35




9.1.1.21 Coupling rod (400)/pressure casing (500) - pre-assembly






W106

TR2



Lower pump parts to limit stop and assem-ble. RTE

W102W105TR1

RTE

36




9.1.1.23 Drive unit - pre-assemblyLantern (200)/drive (ANT) - reassembly

Shaft Seal (SEA) - assembly

Fit-up aid (MH) - assembly

9.1.1.24 Drive (ANT) - pre-assembly

Clean the flange bearing surfaces (FLS), bolt circle (ZD) and output pivot of the drive (ANT).

Assemble shaft sealing– Note shaft sealing assembly (chapter

9._).

Assemble fit-up aid (MH) at lantern (200).

210 213212ZD

FLS200 ANT

501 340

307

309

310

SEA

MH 200

Secure drive (ANT) with lifting device (TR). Screw coupling rod (400) and plug- in

shaft (307) with threaded bushing (489).

307

TR

ANT

489483400

37




9.1.1.25 Drive (ANT) - assembly

9.1.2 Dismantling

9.1.2.1 Drive unit (ANT) - dismantling


Remove tool (W102). Dismantle fit up aid (MH) Lower drive unit (ANT) Screw lantern (200) with pressure casing

(500). Remove lifting device (TR).

ANT

MH

W102

ANT509507

506

TR

200

500


Fix lifting device (TR). Remove screwing pressure casing (500)/

lantern (200). Lift drive (ANT) and rotating unit (RTE)

– Secure shaft sealing (SEA) with fit-up aid (MH).

Assemble tool (W102) at rotating unit (RTE)

Dismantle threaded bushing (489) from coupling rod (400) and plug-in shaft (309).

MH

W102

509507506

TR200

500

ANT

RTE

SEA

307

ANT

489483

400

38




Fit-up aid (MH) - dismantling

plug-in shaft (307) dismantling

Shaft Sealing (SEA) - dismantling

Lantern (200)/Drive (ANT) - dismantling

9.1.2.2 Release Pump

Dismantle fit-up aid (MH) from lantern (200).

Remove the flush connections on the cas-ing of the shaft seal (SEA).

Lift/slide splash ring (310), push out plug-in shaft pin (309) horizontally.

Remove plug-in shaft (307) with shaft sealing (SEA) from the drive shaft.

Remove o-ring (501).

Saft Sealing dismantling– Note Shaaft sealing dismantling

(chapter 9.4).

MH 200 ANT

501

307

309

310

SEA

210 213212

200 ANT

Tool (W105/lifting device)


Assemble tool (W105) on threaded bush-ing (489).

Assemble tool (W102) at pressure casing (500).

fix lifting device (TR1).

489

W105

W102

TR1

500

39




9.1.2.3 Pressure casing (500)/coupling rod (400) - dismantling



Fix tool (W106) at pressure casing (500). Dismantle anchor bolts at pressure casing

(500). Hoist pump parts up to the flange of the in-

termediate element (534). Fix tool (W104) on mounting hole (ML).

– Note the position of the tool (W104).

W104

500

W106

ML

W104

500

TR2

534

40




9.1.2.4 Raising pump parts

9.1.2.5 Pressure casing (500)/coupling rod (400) - dismantling




Fix tools (W102, W107) at intermediate el-ement (534).

Adjust tool (W104).– Note the position of the tool (W104).

Remove screwing pressure casing (500)/intermediate element (534).

Remove screwing coupling rod (400)/threaded bushing (489).

Remove pressure casing (500), coupling rod (400).

Remove lifting device (TR1, TR2).

489483

400

TR1TR2

539

540541

481

500

534

W107W102

W104

500


Dismantle tool (W105) on threaded bush-ing (489).

Dismantle threaded bushing (489). Dismantle tool (W106) on pressure casing

(500).

400

489483

W105 W106

500

41




9.1.2.6 Secure pump





Assemble tool (W105) at threaded bush-ing (489).

Fix lifting device (TR1) on tool (W105). Remove tools (W102, W107). W107

W102

TR1

489

W105



Assemble tool (W106) at intermediate ele-ment (534).

Fix lifting device (TR2) on tool (W106). Hoist pump parts up to the flange of the in-

termediate element (534). Adjust tool (W104).


W104

W106

534W104

TR2

42




9.1.2.8 Intermediate element (534)/coupling rod (481) - dismantling

9.1.2.9 Intermediate element (534), coupling rod (481) - individual parts




Fix tools (W102, W107). Adjust tool (W104).

– Note the position of the tool (W104). Remove screwing coupling rod (480)/

threaded bushing (489). Remove pressure casing (500)/coupling

rod (480). Remove lifting device (TR1, TR2).

489483

480

TR1TR2

480

534

537

W107W102

480

539

540541

W104

534

Tool (W105, W106/holding device)

Dismantle tool (W105) from threaded bushing (489).

Dismantle threaded bushing (489). Dismantle tool (W106) from intermediate

element (534). Remove o-ring (538).

W106538

534480

489483

W105

43




9.1.2.10 Secure pump







W102

TR1

489

W105







W104

W106

537W104

TR2

44











threaded bushing (489). Remove intermediate element (537), cou-

pling rod (480). Remove lifting device (TR1, TR2).

489483

480

TR1TR2

480

537

536

W107W102

481

539

540541

W104

537




element (537).

542

537480

489483

W105 W106538

45











W102

TR1

489

W105







W104

W106

536W104

TR2

46











threaded bushing (489). Remove intermediate element (536), cou-


489483

481

TR1TR2

482

536

534

W107W102

482

539

540541

W104

536




element (536).

W106538

536481

489483

W105

47











W102

TR1

489

W105




Fix lifting device (TR) on tool (W106). Hoist pump parts up to the flange of the in-



W104

W106

534W104

TR2

48





9.1.2.21 intermediate element (534), coupling rod (482) - individual parts



Assemble tool (W103). Adjust tool (W104).

– Note the position of the tool (W104). Remove intermediate elements (535,

534). Hoist intermediate element (535). Remove flange screwing coupling rod

(482)/Rotor (600). Remove intermediate element (534)/cou-


TR1TR2

534

535

W103

539

540541

W104

490

492493

491600

482

534




element (534). Remove o-ring (538). 534

480

489483

W105 W106538

49




9.1.2.22 Conveyor unit (FEH) - dismantling

9.1.2.23 Suction branch (700) - dismantling

9.1.2.24 Stator (601) - dismantling


Hoist conveyor unit (FEH). Adjust tool (W104).

– Note the position of the tool (W104). Remove conveyor unit (FEH) out of the

mounting hole (ML). Remove lifting device (TR).

ML

FEH

W104

W104

TR

535


Dismantle tool (W103).

Dismantle suction branch (700) from stator (601).

W103

602604 606

700 601702 535 538

Add lubricant (liquid soap) to the opening on suction branch side between the rotor (600) and the stator (601).

Turn the stator in the “right” rotating direc-tion.

Dispense lubricant (GM) on the stator in-ternal surface in order to reduce friction between the rotor and stator.

GM

W2 601 600


document OM.PJT.02e Blattsheet 1 (4)


9.2 Rotating unit individual parts

9.2.1 Dismantling

9.2.1.1 Holding band (406, 407) - dismantling

9.2.1.2 Retaining sleeve (401) - dismantling

9.2.1.3 Detach joint

CAUTION

Risk of injury.Possibility of parts spinning out. Wear protective goggles.

Detach holding band loop (SCL).– Use suitable tool (WM).

Push out parts of holding band loop (SCL). Remove holding band (406, 407). Pull back universal joint sleeve (405).

SCL

Knock back retaining sleeve (401).– Use suitable tool (WM).

WM401

Tool (W5/drift)

Eject coupling rod pins (402). Bend (A) the coupling rod (400). Knock

guide bushing (403) out with tool (W5). Remove coupling rod (400).

W5403 404 400

402403

A

51




9.2.2 Rotating unit (RTE) - prepare individual parts for reassembly

9.2.2.1 Rotor (600)

9.2.2.2 Coupling rod (400)

9.2.2.3 Plug-in shaft (307)

9.2.3 Rotating unit (RTE) - individual parts - reassembly

Remove any damage. Clean the rotor (600).

Tool (W4/assembly mandrel)

Press in the guide bushing (403) (depth = 2/3).– Use tool (W4).

600 403

W4

403

Clean the coupling rod (400). Examine bore head for wear.

– If wearing is detected on the bore head, replace the coupling rod (400).

Remove any damage. Clean the plug-in shaft (307).


Press in the guide bushing (403) (depth = 2/3).– Use tool (W4).

600 403

W4

403

NOTICE

Malfunction of the joints.Malfunction and/or destruction of joints. Replace the coupling rod pins (402) and guide bushings (403) jointly.

52




9.2.3.4 Coupling rod (400) – reassembly Slide the universal joint sleeve (405) and holding bands (406, 407) onto coupling rod (400). Fit the diameter and width of the holding band of the universal joint sleeve. Fill the joint head with seepex joint grease.

Rotor (600)

Plug-in shaft (307)

Insert coupling rod pins (402). Slide on retaining sleeve (401). Connect the rotor/coupling rod.

Tool (W5/drift)

Slide in the coupling rod pins (402). Knock the guide bushings (403) in.

Insert coupling rod pins (402). Slide on retaining sleeve (401). Connect the plug-in shaft/coupling rod.

Tool (W5/drift)

Slide in the coupling rod pins (402). Knock the guide bushings (403) in.

402 401 400405 406 407600

402 402W5403

400 307402401405407 406

402 402W5403

53




9.2.3.5 Retaining sleeve (401) - reassembly

Rotor (600) unhardened material

Rotor (600) hardened material

9.2.3.6 Universal joint sleeve (405) - reassembly


Knock back retaining sleeve (401).– Use tool (W4).

Secure retaining sleeve (401) in a dis-placed manner (2x180°).– Use suitable tool (WK).

Secure retaining sleeve (401) in a dis-placed manner (2x180°).– Use suitable tool (WK).

401W4

401 WK

401 WK

Moisten the surface of the coupling rod (400)/ inner surface of the universal joint sleeve (405) with joint grease (mainte-nance, chapter 7.0).

Slide on the universal joint sleeve (405).

Vent the interior of the joint.– Use suitable tool (WS).

Assemble holding band.– Holding band assembly

(chapter 9._).

400 405

405 WS

407 405 406

54Ausgabeissue C / 17.03.2006

Dokumentdocument OM.HBD.01e Blatt

sheet 1 (2)


9.3 Holding band - assembly

9.3.1 Prepare the holding band

Only use prefabricated double-band holding bands may.

9.3.2 Check the holding band

9.3.3 Assemble the holding band

9.3.4 Correct tension of the holding band (HBD)

Correct

Incorrect

• Bent-over holding band (HBD) is in contact with holding band loop (SCL) to avoid damaging universal joint sleeve.

Press on holding band (HBD) using tool (WZ) if necessary.

SCL WZ

HBDø

b

Use tool (W3/mounting tool)

Feed holding band into tool (W3).

Hold ends of holding band with the eccen-tric lever (EX).

Turn the crank (KU) until the holding band is strained and lies against the holding band loop (SCL).

Carefully pull the holing band together until it is in contact with the circular groove of universal joint sleeve.

W3

SCL

EX

KU

The holding band (HBD) has drawn in the out shape of the universal joint sleeve and is firmly seated.

The holding band (HBD) is too loose, can slip off.

HBD

HBD

55


Ausgabeissue C / 17.03.2006

Dokumentdocument OM.HBD.01e Blatt

sheet 2 (2)

Incorrect

9.3.5 Cant up the holding band

9.3.6 Shear the holding band (material: 1.4301; 1.4571)

9.3.7 Check the holding band after assembly

The holding band (HBD) is too tight, univer-sal joint sleeve will be damaged/sheared off. HBD

Swivel mounting tool (W3) approx. 60° up-wards.

Loosen crank (KU) by a half turn.

Swivel cutting lever (SH) forward until the pressure piece is lying behind the holding band loop (SCL).

KU SH

ca. 6

0°

SCL

Hit the cutting lever (SH) with the inside of your hand.– Cant up and shear the end of the

holding band behind the loop (SCL).– Carefully straighten up the holding

band if it rises up on the sheared side.

NOTICE

Universal joint sleeve damage.Pin joint grease can emerge.

Avoid hammering or knocking.

SCL HBD

The holding band must lie in the groove of the universal joint sleeve.

Replace the holding band if the holding band slips back through the loop.

SCL HBD


document OM.SEA.02e Blattsheet 1 (3)


9.4 Single acting mechanical seal

9.4.1 Safety

9.4.2 Operating conditions and material combination• Adjust to the relevant application

– Refer to technical data (chapter 3).

9.4.3 Design

9.4.4 Commissioning

Circulation, flushing and/or flushing pipe• Additional flushing or circulation pipes are not required where shaft sealing lies in medium. • Flushing pipes may be possible under special circumstances and after speaking to seepex.

Adjust shaft seal It is absolutely vital to adjust at the application site in a manner appropriate for the operating

conditions. Refer to the sectional drawing of the shaft seal for setting measurements. Set the setting measurements of the shaft seal to the plug-in shaft (307).

WARNING

Shaft seal is leaky.Leakage may escape into the atmosphere. Take safety measures to protect persons and the environment. Wear suitable protective clothing. Dispose of leakage appropriately. Note applicable regulations when handling hazardous substances.

• Single acting mechanical seal

307

333SEA

NOTICE

Dry running of the mechanical seal.Damage to property may result. The mechanical seal must be laid in liquid medium before being commissioned.

NOTICE

Shaft seal is not leakage free.Damage to property through leakage. Components which come into contact with leakage must be corrosion-resistant or other-

wise suitably protected.

57




9.4.5 Monitoring during operation

9.4.6 Dismantling of the mechanical seal Refer to data sheet (chapter 3.1) and sectional drawing of the shaft seal (chapter 9._) for design.

With axial locking device

Without axial locking device

NOTICE

Shaft wear.Damage to property may result. Conduct a daily visual inspection. Install a new shaft seal (SEA). Possibly replace the plug-in shaft (307).

307

333SEA

Clean plug-in shaft (307), remove edges/burrs.

Moisten plug-in shaft (307) with lubricant (thinned liquid soap).

Pull mechanical seal casing (333) from the plug-in shaft (307).

Loosen the axial locking device of the me-chanical seal (330/372); pull mechanical seal (330) from the plug-in shaft (307).

Push counter ring of the mechanical seal (330G) with seal out of the mechanical seal casing (333).

Clean plug-in shaft (307), remove edges/burrs.

Moisten plug-in shaft (307) with lubricant (thinned liquid soap).

Pull mechanical seal casing (333) from the plug-in shaft (307).

Pull the mechanical seal (330) from the plug-in shaft (307).

Push counter ring of the mechanical seal (330G) with seal out of the mechanical seal casing (333).

333 330G307

372 330

333330G

330

333330G

58




9.4.7 Reassembly of mechanical seal

Assembly aids such as oil/grease are not permitted.

With axial locking device

Without axial locking device

Shaft sealings are high-quality precision parts. Their installation is therefore to be undertaken with care.Careful handling and the utmost of cleanliness are prerequisites.

Clean the mechanical seal casing (333). Moisten the seal with lubricant (thinned liq-

uid soap). Attach the counter ring and seal using

even pressure into the mechanical seal casing (333).

Clean the plug-in shaft (307), remove edg-es/burrs.

Adjust the set collar (372) in accordance with sectional drawing of shaft seal(chapter 9._).

Stick the set screw in and determine.– Use "medium-strength" adhesive.

Moisten plug-in shaft (307) and elastomer parts of the mechanical seal (330) with lu-bricant (thinned liquid soap).

Slide mechanical seal (330) onto the plug-in shaft (307) until the installation edge has been reached.

Clean the mechanical seal casing (333). Moisten the seal with lubricant (thinned liq-

uid soap). Attach the counter ring and seal using

even pressure into the mechanical seal casing (333).

Clean the plug-in shaft (307), remove edg-es/burrs.

Adjust mechanical seal (330).– Note sectional drawing of shaft seal

(chapter 9._). Moisten plug-in shaft (307) and elastomer

parts of the mechanical seal (330) with lu-bricant (thinned liquid soap).

Slide mechanical seal (330) onto the plug-in shaft (307) until the installation edge has been reached.

333330G

372 330

333330G

330G

330

333307


Dokumentdocument OM.SZG.02e Blatt

sheet 1 (1)

10 Spare Parts

10.1 Spara parts list

10.2 Sectional Drawing and Part List


document OM.WPS.19e Blattsheet 1 (2)

10Spare parts

10.1 Order template for spare parts

Spare parts can be ordered online or requested fromwww.seepex.com\

Type: BE 1-6 to 202-6L

Request Order Sender:

Must be included in every order or enquiry!Commission: Type: Contact: ....................................................

Tel.: .........................................................._________________________ _______________________ Fax: .........................................................

E-mail: ......................................................

Customer service:seepex GmbHPostfach 10 15 64D-46215 [email protected]

Germany Tel +492041.996-231Fax +492041.996-431

Delivery address:..............................................................................................................................................................................................................................................................................................................................................................

Europe outsideGermany

Tel +492041.996-224Fax +492041.996-424

IntercontinentaloutsideGermany

Tel +492041.996-120Fax +492041.996-432

No. Quantity Component Material Comment

Minor set of wearing parts

301 1 Set of packing rings according to data sheet (chapter 3.1)330 1 Mechanical Seal according to data sheet (chapter 3.1)392 1 Lip seal601 1 Stator

Major set of wearing parts

301 1 Set of packing rings according to data sheet (chapter 3.1)307 1 Plug-in shaft330 1 Mechanical seal according to data sheet (chapter 3.1)392 1 Lip seal400 1 Coupling rod with coupling

rod bushings402 2 Coupling rod pin403 4 Guide bushing405 2 Universal joint sleeve406 2 Holding band, large407 2 Holding band, small411 1 Holding band412 1 Holding band600 1 Rotor601 1 Stator

__________________________________ _______________________________________Place, date Signature / company stamp

62

10Spare parts


document OM.WPS.19e Blattsheet 2 (2)

10.1 Order template for spare parts

No. Quantity Component Material Comment

Set of gaskets

301 1 Set of packing rings according to data sheet (chapter 3.1)310 1 Splash ring according to data sheet (chapter 3.1)330 1 Mechanical seal501 1 Casing gasket503 3 Sealing ring536 2 O-ring

Plug-in shaft & shaft seal

301 Set of packing rings according to data sheet (chapter 3.1)307 Plug-in shaft309 Plug-in shaft pin310 Splash ring according to data sheet (chapter 3.1)392 Lip seal330 Mechanical seal according to data sheet (chapter 3.1)

Coupling rod & joint parts

400 Coupling rod with coupling rod bushings

401 Retaining sleeve402 Coupling rod pin403 Guide bushing405 Universal joint sleeve406 Holding band, large407 Holding band, small411 Holding band412 Holding band401-412 Complete set of joint parts

Pumping elements

600 Rotor601 Stator

Miscellaneous parts

501 Casing gasket098 Pin joint grease 1 cartridge = 300 g (approx. 315 cm³)

Grease quantity according to maintenance (chapter 7.)

__________________________________ _______________________________________Place, date Signature / company stamp

64

StücklisteParts List

Liste des pièces

Ausgabe issue A / 24.03.10 Dokument

document SL.071.K238543def Blatt sheet 1 (2)

DE EN FRBaureihe BE range BE série BESchnittzeichnung Nr. sectional drawing No. plan no.071-K238-543_2 071-K238-543_2 071-K238-543_2Benennung denomination désignation

Stck. Pos. Stck. / Pos. Qty. / Item Qté. / Poste1 200 Laterne lantern lanterne 2 202 Halbrundkerbnägel round head grooved pins rivet 1 203 Typenschild type plate palque signalitique 4 210 6kt-Schraube hexagon bolt vis 4 212 Fächerscheibe fan type lock washer rondelle à dents chevauchantes

extérieures 4 213 6kt-Mutter hexagon nut écrou 1 307 Steckwelle plug-in shaft arbre à broche 1 309 Steckwellenbolzen plug-in shaft pin cheville pour arbre à broche 1 310 Spritzring splash ring bague de projection 1 330 Gleitringdichtung mechanical seal garniture mécanique 1 400 Kuppelstange coupling rod barre d' accouplement 2 480 Kuppelstange coupling rod barre d' accouplement 1 481 Kuppelstange coupling rod barre d' accouplement 1 482 Kuppelstange coupling rod barre d' accouplement

20 483 Zylinderschraube socket screw vis à tête cylindrique 5 489 Gewindebuchse threaded bushing filetage 6 490 6kt-Schraube hexagon bolt vis 6 491 Scheibe washer rondelle 6 492 Federring spring washer rondelle frein 6 493 6kt-Mutter hexagon nut écrou 1 500 Druckgehäuse pressure casing carter de refoulement 1 501 O-Ring o-ring joint torique 1 502 Verschlussschraube screwed plug bouchon de vidange 1 503 Dichtring sealing ring joint d’étanchéité 4 506 Stiftschraube stud bolt boloun fileté 4 507 Federring spring washer rondelle frein 4 509 6kt-Mutter hexagon nut écrou 2 534 Zwischenelement intermediate element carter intermédiaire 1 535 Zwischenelement intermediate element carter intermédiaire 1 536 Zwischenelement intermediate element carter intermédiaire 1 537 Zwischenelement intermediate element carter intermédiaire 5 538 O-Ring o-ring joint torique

30 539 6kt-Schraube hexagon bolt vis 30 540 Federring spring washer rondelle frein 30 541 6kt-Mutter hexagon nut écrou 1 542 Kunststoffring synthetic material ring anneau de plastique 1 600 Rotor rotor rotor 1 601 Stator stator stator 6 602 Spannschraube tie bolt tirant

12 604 6kt-Mutter hexagon nut écrou 12 606 Scheibe washer rondelle 1 700 Saugstutzen suction branch bride d’aspiration 6 702 Abstandsbolzen distance pin cheville de distance 1 3000 Quench quench quench

siehe Zusatzeinrichtung see optional extras voir accessoire Blatt ZU.021.01 sheet ZU.021.01 feuille ZU.021.01

65

StücklisteParts List

Liste des pièces

Ausgabe issue A / 24.03.10 Dokument

document SL.071.K238543def Blatt sheet 2 (2)

DE EN FRBaureihe BE range BE série BESchnittzeichnung Nr. sectional drawing No. plan no.071-K238-543_2 071-K238-543_2 071-K238-543_2Benennung denomination désignation

Stck. Pos. Stck. / Pos. Qty. / Item Qté. / PosteVerschleißteile und Dichtungen: Wear parts and sealings: pièces d'usure et étanchéités: Betriebs- und Wartungsanleitung entnehmen

see Operating and Maintenance Instruction

voir Instructions de service et d'entretien

Werkzeuge: Tools: Outils: Betriebs- und Wartungsanleitung entnehmen

see Operating and Maintenance Instruction

voir Instructions de service et d'entretien

siehe Schnittzeichnung Gleitringdichtung

see sectional drawing mechanical seal

voir vue éclatée garniture mécanique

versetzt gezeichnet drawn displaced plan separé


document OM.STO.01e Blattsheet 1 (1)

11Special tools

Version for copying

Spare parts can be ordered online or requested fromwww.seepex.com\

Must be specified with every order!

Sender:

Commission: Mark tool! Contact: .........................................................Tel.: ................................................................

__________________________ X Fax: ...............................................................E-mail: ...........................................................

Customer service:seepex GmbHPostfach 10 15 64D-46215 [email protected]

Germany Tel +492041.996-231Fax +492041.996-431

Delivery address:.......................................................................

Rest of Europe

Tel +492041.996-224Fax +492041.996-424

.......................................................................

.......................................................................

.......................................................................

.......................................................................

.......................................................................

Outside Europe

Tel +492041.996-120Fax +492041.996-432

For installation of: Packing gland Stator Universal joint sleeve

Tool no. W1 W2 W15

Denomination: Packing puller Chain wrench plus spare chain Mounting plate

Order no. PKZ KRZ MTP

For installation of: Rotating unitHolding band Joint Plug-in shaft

Tool no. W3 W4 W10

Denomination: Mounting tool DriftDismantling

ToolOrder no. MHB MTD AZV


document OM.ZUG.01e Blattsheet 1 (1)

12Related documents

12.1 Additional components

12.2 Technical information

12.3 Manufacturer's documents shaft seal

69

Gleitringdichtung mit Quench mechanical seal with quench

Dokument / document ZU.021.01de Ausgabe / issue H / 10.11.04 Blatt / sheet

1 (1)

Information: Eine GLRD wird gequencht bei Medien die zu Kristallisati on an den Gleitflächen neigen, bzw. adhäsiv sind. Desweiteren ist Quenchung bei Vakuum Betrieb zur Vermeidung von Trockenlauf erforderlich. Die Quenchflüssigkeit muss mit dem Fördermedium verträglich und auf die Werkstoffe der GLRD abgestimmt sein. Inbetriebnahme und Wartung: a) prüfen ob Quenchflüssigkeit / (Lieferzustand) mit Medium verträglich ist. Bei Nicht - verträglichkeit ist eine geeignete Quenchflüssigkeit nach vollständiger Entleerung einzufüllen. b) Quenchflüssigkeitsmenge prüfen / nachfüllen und Quenchkammer durch öffnen der Verschlussschraube (E) entlüften. Information: A mechanical seal is quenched, when the medium (product) tends to crystallization at the seal faces, or when it is adhesive. Moreover, quenching is necessary during vacuum-operation to avoid dry-running. The quench liquid must be compatible with the pumped product and with the selected material of the mechanical seal. Commissioning and Maintenance: a) Check, if the quench liquid / (supplied with the pump) is compatible with the pumped product. If not, a suitable quench liquid has to be filled in after complete drain. b) Quench liquid has to be checked / refilled. Quench chamber has to be deaerated by opening the sealing screw (E).

Ausführung 1 Beistellung und Anbau des Flüssigkeitsbehälters durch den Kunden: Die Quenchkammer ist bei Auslieferung mit Kühl-/Schmiermittel seepex 50300 (Glycerin) 1) bzw. bei Lebensmittelausführung mit seepex 602001) gefüllt und beidseitig mit Verschlussschrauben verschlossen. Design 1 Liquid tank provided and mounted by the customer: Quench chamber is filled with seepex 50300 (Glycerin) 1), for food design with seepex 60200 1) and locked-up with sealing screws on both sides.

Ausführung 2 nicht mehr im Lieferprogrammm / design 2 is no more contained in our product program Ausführung 3 Mit nachfüllbarem Vorlagebehälter Die Quenchkammer ist mit Kühl-/Schmiermittel seepex 50300 (Glycerin) 1) bzw. bei Lebensmittelausführung mit seepex 602001) gefüllt, der Behälter ist leer und muss vor Inbetriebnahme aufgefüllt werden. Vorlagebehälter: 3 = Messing vernickelt, Plexiglas, NBR 3A = Ausführung ATEX: Messing vernickelt, Glas, NBR 3.1A = Ausführung ATEX: Messing vernickelt, Glas, NBR, mit Schutzrohr Design 3 With refillable supply tank. Quench chamber is filled with seepex 50300 (Glycerin) 1), for food design with seepex 60200 1) , container is empty and has to be filled before commissioning. Supply tank: 3 = brass nickel plating, plexiglass, NBR 3A = design ATEX: brass nickel plating, glass, NBR 3.1A = design ATEX: brass nickel plating, glass, NBR, with protection tube

Ausführung 4 Mit nachfüllbarem Vorlagebehälter. Die Quenchkammer ist mit Kühl-/Schmiermittel seepex 50300 (Glycerin) 1) bzw. bei Lebensmittelausführung mit seepex 602001) gefüllt, der Behälter ist leer und muss vor Inbetriebnahme aufgefüllt werden. Vorlagebehälter: 4.1 = Messing vernickelt, Plexiglas, NBR 4.2 = Polyethylen 4.1A = Ausführung ATEX: Messing vernickelt, Glas, NBR 4.2A = Ausführung ATEX: Edelstahl Design 4 With refillable supply tank. Quench chamber is filled with seepex 50300 (Glycerin) 1), for food design with seepex 60200 1), container is empty and has to be filled before commissioning. supply tank: 4.1 = brass nickel plating, plexiglass, NBR 4.2 = Polyethylen 4.1A = design ATEX: brass nickel plating, glass, NBR 4.2A = design ATEX: stainless steel

Ausführung Füllmenge Design Quantity

4.1 / 4.1A 0,5 L 4.2 / 4.2A 4 L / 3 L

Lage der Einlassstellung für alle Ausführungen: Location of inlet position for all designs: A Standard / standard

Sonder / spezial

1) Quenchflüssigkeit bei Standardausführung, andere Quenchflüssigkeit nach Bedarf. Quench liquids regarding standard design, other quench liquids upon request.

2a 3a

Achtung: Quenchflüssigkeit drucklos fahren, max 0,1 - 0,15 bar. Bei größerem Druck Ausrücksicherung für

Wellendichtring erforderlich, siehe HA.RDO.02.

Attention: Quench liquid is used pressureless, max 0,1 - 0,15 bar. Regarding higher pressure, a disengaging device is required for the shaft sealing ring, see

HA.RDO.02.

E

Baugröße / size 1-12 - 500-6LA

0,5L alternativ 4L / 3L

A

Baugröße / size 0005-24 - 1-6L 1-12 - 500-6LA

ca. 80 cm3 ca. 140 cm3

70

Long term preservation of seepex Progressive cavity pumps

Dokument / document TI.114.01e

Ausgabe / issue E / 19.11.08

Blatt / sheet 1 (3)

1 Scope

Size Period of Storing Preservation acc. to.

> 3 months ≤ 9 months Measures for preservation 1 025-12 ... 130-6L

> 9 months Measures for preservation 2

> 3 months ≤ 9 months Measures for preservation 1 130-12 ... 500-6L

> 9 months Measures for preservation 2

2 Description

2.1 Measures for preservation 1

2.1.1 Storing of the pump

• in dry and closed rooms

• free from vibration Particular adjacent influences have to be advised by the customer and have to be checked and released by seepex before storage.

2.1.2 Protection of the drive shaft (only for ranges N, NS)

Moisten exposed surfaces of the drive shaft with corrosion inhibitor/spray wax.

2.1.3 Protection of the stator

change the position of the once per month:

• Remove fan cover on the electric motor.

• Rotate the fan shaft 1/4 turn. Fan shaft and fan must not be damaged! If necessary remove the fan and protect the shaft against damage during this procedure.

2.1.4 Gear

Note instruction of the manufacturer.

• Follow advice on the gear.

• Reduce quantity of lubricant to the quantity stipulated for the operation before commissioning!

• Reinstall vent screw during commissioning.

Belt Variable Speed Drive:

Store the belt separate (relevant standard ISO 2230):

• dry

• constant tempered at 10-15°C (max. 25°C)

• protected against light / stored in darkness (e.g. in a closed case or packed accordingly)

71




Blatt / sheet 2 (3)

2.1.5 Motor

By the turn of the fan shaft (see point 2.1.2) a protection of the bearing in the motor is obtained at the same time.

2.1.6 Recommissioning

NOTICE

Before starting work read the operating instruction. • Pay attention to a correct re-assembly of parts dismantled before.

2.2 Measures for preservation 2

In case of the correct storage and under consideration of the preservation measures, a storage of the pump is possible for max. 2 years.

NOTICE

In case of a longer storage period, the dimensions and shore hardness can change. The function of the pump can be impaired. Bevor recommissioning Elastomere parts (stator, joint seal, gaskets, ...) have to be

checked for crack formation and change of the surface.

2.2.1 Storing of the pump/pump parts

• in dry and closed rooms

• free from vibration

Particular adjacent influences have to be advised by the customer and have to be checked and released by seepex before storage.

2.2.2 Protection of the drive shaft (only for ranges N, NS)

Moisten exposed surfaces of the drive shaft with corrosion inhibitor/spray wax.

2.2.3 Storing of the stator

Store the stator separate (relevant standard ISO 2230):

• dry



72




Blatt / sheet 3 (3)

2.2.4 Gear

Note instruction of the manufacturer.

• Follow advice on the gear.

• Reduce quantity of lubricant to the quantity stipulated for the operation before commissioning!

• Reinstall vent screw during commissioning.

Belt Variable Speed Drive:

Store the belt separate (relevant standard ISO 2230):

• dry



2.2.5 Motor

Turn the fan shaft once a month to protect the bearing:

• Remove fan cover on the electric motor.

• Rotate the fan shaft 1/4 turn.

Fan shaft and fan must not be damaged! If necessary remove the fan and protect the shaft against damage during this procedure.

2.2.6 Recommissioning

NOTICE

Before starting work read the operating instruction. • Pay attention to a correct re-assembly of parts dismantled before.

3 Advices and annotations

Guarantee-/Warranty claims cannot be derived from this document.

4 Alteration service

This document is subject to the alteration service of the engineering department (TE) and ist relevant valid issue is released by the quality assurance (QA). All alteration requests are handled and checked by engineering.

73

BURGMANN Mechanical SealsInstructions for installation and

operation

Dokumentdocument

Blattsheet

Datumdate

BA.BUR.01e

1 (1)

08.07.98

Safety recommendationsPlease read these instructions carefully.Contact BURGMANN if any points are unclear.Burgmann mechanical seals are precision-made, tested machine elements, special knowledge isrequired to operate them correctly.Pay due attention to the rules and regulations governing occupational safety, accident prevention,working with hazardous materials and normal usage.Before carrying out any work on a mechanical seal, make sure that the system has been shut down,is no loger pressurized and has cooled off. Conversions and changes to the seal are prohibited (sealfailure, loss of warranty rights). Use original BURGMANN spare parts only. For your own safety, anyrepairs should be carried out by BURGMANN.

General procedures• clean the seal compartment and examine for signs of damage. Check the installation and

connection dimensions. Check the accuracy of the axial and radial run-out tolerance between theshaft and the casing.

• The shaft surface in the areas of dynamically loaded sealing elements (e.g. O-ring) should displaya roughness depth of Rmax = 5 µm. Sealing surfaces for statically loaded O-rings are to bemanufactured with a value of Rz = 10 µm or better.

• Any edges, shoulders and transitions which come into contact with the sealing elements (e.g.O-rings) during installation should be sufficiently chamfered or rounded off (e.g. 2 mm x 30° or inaccordance with DIN 24960)

• Assemble under extra-clean conditions and with great care. Use no force! This could result inpermanent deformations and broken ceramic parts.

• The sequence of steps for installing and dismantling a mechanical seal depends on the design ofthe machine in question.To reduce friction during assembly, wet all sliding surfaces for the O-rings with water or alcohol orlubricate with silicone grease.

• Note special instructions for storing and handling elastomer parts.• Keep elastomer parts made of EP rubber away from lubricants based on mineral oil.• When installing double PTFE-wrapped sealing rings, make sure that the joint of the outer sheath

points away from the direction of assembly (A). Sharp bending of the PTFE foil will destroy theO-ring.

• Take plenty of time and use little force when assembling O-rings made of solid PTFE in order toavoid damage to other seal elements.

• Never apply lubricant to seal faces. Assemble in a completety dry, dust-free and clean condition.

Special procedures

Series M2, M3Mechanical seals with conical springs are dependent on the direction of rotation. A clockwise rotatingshaft requires a right-handed spring and vice versa (looking from the drive side). To ease fitting, pushthe conical spring onto the shaft whilst twisting the spring in the direction of its hand of coiling.Series MGElastomer bellows seals are to be pushed onto the shaft using low-surface-tension water (addition ofa detergent) and a screwing movement. Use no oil or grease! Apply pressure only on the corner rings.When you are finished with the assembly, check that the corner rings, the spring and the seal face fitcorrectly.Series M7, HJIndependent of the direction of rotation. Secure drive screws by applying Loctite 241Series MFLNever compress a metal bellows seal to its solid height.Push the seal onto the shaft by applying force only to the bellows carrier, which is sealed with anO-ring. Evenly and gradually tighten any compression screws in sequence, maintaining an even gapbetween the compression ring and the drive collar.Seals with a pumping screw(e.g. M7F, M74F-D) are dependent on the direction of rotation. Note drawing specifications!

OperationA Properly operated mechanical seal requires no maintenance but is subject to a certain wear.Single seals in tight compartments may require a suitably piped circulation of pumped medium acrossthem to dissipate heat. Evacuate the air from the compartment carefully before putting into operation.Make sure the seal is completely immersed in liquid (or there will be a risk of dry running!)

Declarationfor the purposes of the EC Machine Guideline, Annex IIB.Mechanical seals are intended for installation in, or assembly with, other machines and are unable tofunction independently. Operation of a mechanical seal is only permitted when the machine inquestion meets the requirements of the EC Machine Guideline (89/392/EEC). Applied harmonizedstandards: EN292 Part 1 + Part 2.

Form 1081/11.97.02


document OM.MDS.01e Blattsheet 1 (1)

13Appendix

13.1 Manufacturer's documents / suppliers

• available

75

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services

Gear Units, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W

Operating Instructions

A6.B01

Edition 05/200411226811 / EN

76

SEW-EURODRIVE – Driving the world

77

Contents

Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 3

1 Important Notes................................................................................................. 4

2 Safety Notes ...................................................................................................... 6

3 Gear Unit Structure ........................................................................................... 93.1 Basic structure of helical gear units .......................................................... 93.2 Basicstructure of parallel shaft helical gear units.................................... 103.3 Basic structure of helical-bevel gear units .............................................. 113.4 Basic structure of helical-worm gear units .............................................. 123.5 Basic structure of SPIROPLAN® gear units ............................................ 133.6 Nameplate, unit designation ................................................................... 14

4 Mechanical Installation................................................................................... 154.1 Required tools / aids ............................................................................... 154.2 Prerequisites for assembly...................................................................... 154.3 Installing the gear unit............................................................................. 164.4 Gear unit with solid shaft......................................................................... 194.5 Torque arms for mounted gear units....................................................... 214.6 Mounted gear unit with keyway or splined hollow shaft .......................... 234.7 Mounted gear units with shrink disc........................................................ 274.8 Mounted gear units with TorqLOC® ........................................................ 304.9 AM adapter coupling ............................................................................... 364.10 AQ adapter coupling ............................................................................... 384.11 AD input shaft assembly ......................................................................... 40

5 Startup.............................................................................................................. 445.1 Startup of helical-worm and SPIROPLAN® W gear units........................ 445.2 Startup of helical, parallel shaft helical and helical-bevel gear units....... 44

6 Inspection and Maintenance .......................................................................... 456.1 Inspection and maintenance intervals..................................................... 456.2 Lubricant change intervals ...................................................................... 456.3 Inspection and maintenance of the gear unit .......................................... 466.4 Inspection / maintenance of AM / AQA adapters .................................... 476.5 Inspection / maintenance of AD adapters ............................................... 47

7 Malfunctions .................................................................................................... 487.1 Gear unit malfunctions ............................................................................ 487.2 AM / AQA / AL adapter malfunctions ...................................................... 487.3 AD input shaft assembly malfunctions .................................................... 49

8 Mounting Positions......................................................................................... 508.1 General information on mounting positions ............................................ 508.2 Key to the mounting position sheets ....................................................... 518.3 Mounting positions for R helical gearmotors........................................... 528.4 Mounting positions of RX helical gearmotors.......................................... 558.5 Mounting positions for parallel shaft helical gearmotors ......................... 578.6 Mounting positions for helical-bevel gearmotors..................................... 608.7 Mounting positions for helical-worm gearmotors .................................... 658.8 Mounting positions for SPIROPLAN® W gearmotors.............................. 71

9 Lubricants........................................................................................................ 749.1 Lubricant table ........................................................................................ 749.2 Lubricant fill quantities ............................................................................ 77

10 Appendix.......................................................................................................... 8210.1 Index of changes..................................................................................... 82

11 Index................................................................................................................. 83

784 Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W

1 Important Notes

Operating instructions1 Important NotesSafety and warning instructions

Always follow the safety and warning instructions in this publication!

You must adhere to the operating instructions to ensure:

• Trouble-free operation

• Fulfillment of any rights to claim under guarantee

Consequently, read the operating instructions before you start working with the gearunit!

The operating instructions contain important information about servicing. Therefore,keep the operating instructions close to the gear unit.

Electrical hazardPossible consequences: Severe or fatal injuries.

Hazard Possible consequences: Severe or fatal injuries.

Hazardous situationPossible consequences: Slight or minor injuries.

Harmful situationPossible consequences: Damage to the drive and the environment.

Tips and useful information.

• Adjust the lubricant fill volume and position of the breather valve accordingly in theevent of a change of mounting position (see Sec. "Lubricants" and "MountingPositions").

• Follow the instructions in Sec. "Mechanical installation" / "Installing the gear unit"!

79Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W 5

1Important Notes

Waste disposal Please follow the latest instructions: Dispose of the following materials in accordancewith the regulations in force:

• Steel scrap:

– Housing parts– Gears– Shafts– Anti-friction bearing– Gray-cast iron (if there is no special collection)

• Parts of the worm gears are made of non-ferrous metals. Dispose of the worm gearsas appropriate.

• Collect waste oil and dispose of it correctly.


2 Safety Notes

2 Safety NotesPreface The following safety notes are primarily concerned with the use of gear units. If using

gearmotors, please also refer to the safety notes for motors in the relevant operatinginstructions.

Please also consider the supplementary safety notes in the individual sections ofthese operating instructions.

General information

During and after operation, gearmotors, gear units and motors have:

• Live parts

• Moving parts

• Hot surfaces (may be the case)

Only qualified personnel may carry out the following work:

• Transportation

• Putting into storage

• Installation / assembly

• Connection

• Startup

• Maintenance

• Servicing

The following information and documents must be observed during these processes:

• Relevant operating instructions and wiring diagrams

• Warning and safety signs on the gear unit / gearmotor

• System-specific regulations and requirements

• National / regional regulations governing safety and the prevention of accidents

Serious injuries and property damage may result from:

• Improper use

• Incorrect installation or operation

• Unauthorized removal of necessary protection covers or the housing

Designated use Gearmotors / gear units from SEW are intended for industrial systems. They correspondto the applicable standards and regulations.

Technical data and information about the permitted conditions can be found on thenameplate and in the documentation.

It is essential that you follow all the instructions!


2Safety Notes

Transportation Inspect the shipment for any damage that may have occurred in transit as soonas you receive the delivery. Inform the shipping company immediately. It may bethat you are not permitted to startup the drive due to the damage.

Tighten installed eyebolts. The eyebolts are only designed for the weight of thegearmotor / gear unit. Do not attach any additional loads.

The installed lifting eyebolts comply with DIN 580. The loads and regulations specifiedin this standard must always be observed. If two eyebolts are available, use both of themfor transport. In this case, the tension force vector of the slings must not exceed a 45°angle in accordance with DIN 580.

Use suitable, sufficiently rated handling equipment if necessary. Remove anytransportation fixtures prior to startup.

Extended stor-age of gear units

Gear units of the "extended storage" type have:

• An oil fill suitable for the mounting position so the unit is ready to run (mineral oil CLPand synthetic oil CLP HC). You should still check the oil level before startup (see Sec."Inspection / Maintenance" / "Inspection and maintenance of the gear unit").

• A higher oil level in some cases (synthetic oil CLP PG / food grade oil). Correct theoil level before startup (see Sec. "Inspection / Maintenance" / "Inspection andmaintenance of the gear unit").

Comply with the storage conditions specified in the following table for extended storage:

Climate zone Packaging1) Storage location Storage time

Temperate (Europe, USA, Canada, China and Russia, excluding tropi-cal zones)

Packed in containers, with desiccant and moisture

indicator sealed in the plas-tic wrap.

With roof, protected against rain and snow, no shock loads.

Up to three years with regular checks on the packaging and

moisture indicator (relative atmospheric humidity

< 50 %).

Open

With roof, enclosed at constant temperature and atmospheric humidity (5 °C < ϑ < 60 °C, < 50 %

relative atmospheric humidity).No sudden temperature fluctuations and con-trolled ventilation with filter (free from dirt and

dust). No aggressive vapors and no shock loads.

Two years or more given reg-ular inspections. Check for cleanliness and mechanical

damage as part of the inspec-tion. Check 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.

With roof, protected against rain, no shock loads.

Up to three years with regular checks on the packaging and

moisture indicator (relative atmospheric humidity

< 50 %).

Open

With roof, enclosed at constant temperature and atmospheric humidity (5 °C < ϑ < 60 °C, < 50 %

relative atmospheric humidity).No sudden temperature fluctuations and con-trolled ventilation with filter (free from dirt and

dust). No aggressive vapors and no shock loads. Protection against insect damage.

Two years or more given reg-ular inspections. Check for cleanliness and mechanical

damage as part of the inspec-tion. Check corrosion

protection.

1) Packaging must be performed by an experienced company using the packaging materials that have been expressly specified for theparticular application.


2 Safety Notes

Installation / assembly

Observe the instructions in the sections "Installation" and "Assembly/Removal"!

Startup / operation

Check that the direction of rotation is correct in decoupled status. Listen out for unusualgrinding noises as the shaft rotates.

Secure the shaft keys for test mode without drive components. Do not render monitoringand protection equipment inoperative even for test mode.

Switch off the gearmotor if in doubt whenever changes occur in relation to normaloperation (e.g. increased temperature, noise, vibration). Determine the cause; contactSEW-EURODRIVE if necessary.

Inspection / maintenance

Follow the instructions in the section "Inspection and Maintenance"!


3Basic structure of helical gear unitsGear Unit Structure

3 Gear Unit Structure

3.1 Basic structure of helical gear units

Key

The following figures are block diagrams. Their purpose is only to make it easier toassign components to the spare parts lists. Discrepancies may occur depending on thegear unit size and version!

03438AXXFigure 1: Basic structure of helical gear units

1 Pinion 19 Key 42 Anti-friction bearing 507 Shim ring

2 Gear 20 Breather valve 43 Key 508 Shim ring

3 Pinion shaft 22 Gearcase 45 Anti-friction bearing 515 Shim ring

4 Gear 24 Lifting eyebolt 47 Circlip 516 Shim ring

5 Pinion shaft 25 Anti-friction bearing 59 Screw plug 517 Shim ring

6 Gear 30 Anti-friction bearing 88 Circlip 521 Shim ring

7 Output shaft 31 Key 100 Gearcase cover 522 Shim ring

8 Key 32 Spacer 101 Hex head bolt 523 Shim ring

9 Oil seal 34 Anti-friction bearing 102 Gasket

11 Anti-friction bearing 37 Anti-friction bearing 131 Closing cap

12 Circlip 39 Circlip 181 Closing cap

17 Spacer 41 Circlip 506 Shim ring


3 Basicstructure of parallel shaft helical gear unitsGear Unit Structure

3.2 Basicstructure of parallel shaft helical gear units

Key

05676AXXFigure 2: Basic structure of parallel shaft helical gear units

18141

517

508

516

507

515

506

42 3

43

2 45

30

59

101

100

102

160

165

161

59

5920

221

521522523

25

88

183

32

4

31

537

39

131

14

16

819 11

176

7

9192

9394

19

1 Pinion 22 Gearcase 91 Circlip 506 Shim ring

2 Gear 25 Anti-friction bearing 92 Washer 507 Shim ring

3 Pinion shaft 30 Anti-friction bearing 93 Lock washer 508 Shim ring

4 Gear 31 Key 94 Hex head bolt 515 Shim ring

5 Pinion shaft 32 Spacer 100 Gearcase cover 516 Shim ring

6 Gear 37 Anti-friction bearing 101 Hex head bolt 517 Shim ring

7 Hollow shaft 39 Circlip 102 Gasket 521 Shim ring

9 Oil seal 41 Circlip 131 Closing cap 522 Shim ring

11 Anti-friction bearing 42 Anti-friction bearing 160 Closing plug 523 Shim ring

14 Hex head bolt 43 Key 161 Closing cap

16 Output flange 45 Anti-friction bearing 165 Closing plug

17 Spacer 59 Screw plug 181 Closing cap

19 Key 81 O-ring 183 Oil seal

20 Breather valve 88 Circlip


3Basic structure of helical-bevel gear unitsGear Unit Structure

3.3 Basic structure of helical-bevel gear units

Key

05675AXXFigure 3: Basic structure of helical-bevel gear units

100 102

3

101

43

538535

537534

536533

42 119

45 2

20

2259

59

59

59

1

114

113

(116)89 59

88521522523

2584

19

87

6

1783

1112

9

37

5

4

30

135

542543544

133132

161

31

506507508137

39

131

1 Pinion 25 Anti-friction bearing 102 Adhesive and sealing compound

522 Shim ring

2 Gear 30 Anti-friction bearing 113 Slotted round nut 523 Shim ring

3 Pinion shaft 31 Key 114 Multi-tang washer 533 Shim ring

4 Gear 37 Anti-friction bearing 116 Thread lock 534 Shim ring

5 Pinion shaft 39 Circlip 119 Spacer 535 Shim ring

6 Gear 42 Anti-friction bearing 131 Closing cap 536 Shim ring

7 Output shaft 43 Key 132 Circlip 537 Shim ring

8 Key 45 Anti-friction bearing 133 Spacer 538 Shim ring

9 Oil seal 59 Screw plug 135 Nilos ring 542 Shim ring

11 Anti-friction bearing 83 Nilos ring 161 Closing cap 543 Shim ring

12 Circlip 84 Nilos ring 506 Shim ring 544 Shim ring

17 Spacer 88 Circlip 507 Shim ring

19 Key 89 Closing cap 508 Shim ring

20 Breather valve 100 Gearcase cover 521 Shim ring

22 Gearcase 101 Hex head bolt 521 Shim ring


3 Basic structure of helical-worm gear unitsGear Unit Structure

3.4 Basic structure of helical-worm gear units

Key

50884AXXFigure 4: Basic structure of helical-worm gear units

13139

137507506

37

543 30

9

12

520519518

11

6

7

25

88

89

59523522521

19

2 59

102

10159

20

22

1

100

61

1 Pinion 20 Breather valve 88 Circlip 518 Shim ring

2 Gear 22 Gearcase 89 Closing cap 519 Shim ring

5 Worm 25 Anti-friction bearing 100 Gearcase cover 520 Shim ring

6 Worm gear wheel 30 Anti-friction bearing 101 Hex head bolt 521 Shim ring

7 Output shaft 37 Anti-friction bearing 102 Rubber seal 522 Shim ring

9 Oil seal 39 Circlip 131 Closing cap 523 Shim ring

11 Anti-friction bearing 43 Key 137 Spacer

12 Circlip 59 Screw plug 506 Shim ring

19 Key 61 Circlip 507 Shim ring


3Basic structure of SPIROPLAN® gear unitsGear Unit Structure

3.5 Basic structure of SPIROPLAN® gear units

Key

05674AXXFigure 5: Basic structure of SPIROPLAN® gear units

1

6872

1436671

65

100

102

22

89

521522523

88

25

6

250

251

17

7

11

8

19

518519520

12

9

101

1 Pinion 19 Key 88 Circlip 251 Circlip

6 Gear 22 Gearcase 89 Closing cap 518 Shim ring

7 Output shaft 25 Anti-friction bearing 100 Gearcase cover 519 Shim ring

8 Key 65 Oil seal 101 Hex head bolt 520 Shim ring

9 Oil seal 66 Anti-friction bearing 102 Gasket 521 Shim ring

11 Anti-friction bearing 71 Spacer 132 Circlip 522 Shim ring

12 Circlip 72 Circlip 183 Oil seal 523 Shim ring

17 Spacer 143 Spacer 250 Circlip


3 Nameplate, unit designationGear Unit Structure

3.6 Nameplate, unit designation

Sample nameplate

Unit designation

Example: Helical gear unit, category II2GD

Example: Serial number

06687ADEFigure 6: Sample nameplate

fb = Service factorFRa max [N] = Maximum overhung load on the output sideFRe max [N] = Maximum overhung load on the input side (with input shaft assembly AD)i = Gear unit reduction ratioIM = Mounting positionIP.. = Enclosurene max [1/min] = Maximum input speedna [1/min] = Output speedMe max [Nm] = Maximum input torqueMa [Nm] = Output torqueMR [Nm] = Overload torque when using an AR adapterMRS [Nm] = Locking torque of the backstop

RF 47 / A / II2GD

Explosion-proof design to directive 94/9/EC

For direct motor mounting

Gear unit size

Helical gear unit series (flange mounted)

3229561201. 0001. 03

Year number end digits of the year of manufacture (2-digit)

Part number (4-digit)

Order number (10 digits)


4Required tools / aidsMechanical Installation

4 Mechanical Installation4.1 Required tools / aids

• Set of spanners

• Torque wrench for:

– Shrink discs– AQH motor adapter– Input shaft assembly with centering shoulder

• Mounting device

• Shims and distance rings if necessary

• Fixing devices for input and output elements

• Lubricant (e.g. NOCO® Fluid)

• Bolt adhesive (for input shaft assembly with centering shoulder), e.g. Loctite® 243

• Standard parts are not part of the delivery

Installation tolerances

4.2 Prerequisites for assembly

Check that the following conditions have been met:

• The data on the nameplate of the gearmotor matches 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 lubricant table in Sec. "Lubricants" (seestandard). The drive must not be assembled in the following ambient conditions:– Potentially explosive atmosphere– Oil– Acids– Gas– Vapors– Radiation

– For special versions:The drive configured in accordance with the ambient conditions.

– For helical-worm / SPIROPLAN® W gear units:No large external mass moments of inertia which could exert a retrodriving loadon the gear unit.[At η’ (retrodriving) = 2 – 1/η < 0.5 self-locking]

Shaft end Flanges

Diameter tolerance in accordance with DIN 748• ISO k6 for solid shafts with ∅ ≤ 50 mm• ISO m6 for solid shafts with ∅ > 50 mm• ISO H7 for hollow shafts• Center bore in accordance with DIN 332, shape

DR

Centering shoulder tolerance in accordance with DIN 42948• ISO j6 with b1 ≤ 230 mm• ISO h6 with b1> 230 mm


4 Installing the gear unitMechanical Installation

• You must clean the output shafts and flange surfaces thoroughly to ensure they arefree of anti-corrosion agents, contamination or similar. Use a commercially availablesolvent. Do not let the solvent come into contact with the sealing lips of the oil seals– danger of damage to the material!

• When the drive is installed in abrasive ambient conditions, protect the output end oilseals against wear.

4.3 Installing the gear unit

The gear unit or gearmotor is only allowed to be installed in the specified mountingposition. SPIROPLAN® gear units are not dependent on the mounting position.

The support structure must have the following characteristics:

• Level

• Vibration damping

• Torsionally rigid

Maximum permitted flatness error for foot and flange mounting (approximate values withreference to DIN ISO 1101):

• Gear unit size ≤ 67: max. 0.4 mm

• Gear unit size 77 ... 107: max. 0.5 mm



Do not tighten the housing legs and mounting flanges against one another and ensurethat you comply with the permitted overhung and axial loads!

Secure the gearmotors with bolts of quality 8.8.

Secure the following gearmotors with bolts of quality 10.9:

• RF37, R37F with flange ∅ 120 mm



At the same time, also check that the oil fill is as specified for the mounting position (seeSec. "Lubricants" / "Lubricant fill quantities" or refer to the information on the nameplate).The gear units are filled with the required oil volume at the factory. There may be slightdeviations at the oil level plug as a result of the mounting position, which are permittedwithin the manufacturing tolerances.

The oil checking and drain screws and the breather valves must be freelyaccessible!


4Installing the gear unitMechanical Installation

Adjust the lubricant fill volumes and the position of the breather valve accordinglyin the event of a change of mounting position.

Please contact our SEW customer service if you change the mounting position of K gearunits to M5 or M6 or between M5 and M6.

Please contact our SEW customer service if you change the mounting position of sizeS47 S97 S gear units to mounting position M2.

Use plastic inserts (2 ... 3 mm thick) if there is a risk of electrochemical corrosionbetween the gear unit and the driven machine. The material used must have an electri-cal bleeder resistor < 109 Ω. Electrochemical corrosion can occur between variousmetals, for example, cast iron and high-grade steel. Also install the bolts with plasticwashers! Ground the housing additionally – use the grounding bolts on the motor.

Installation in damp locations or in the open

Drives are supplied in corrosion-resistant versions for use in damp areas or in the openair. Repair any damage to the paint work (e.g. on the breather valve).

When mounting the motors onto AM, AQ, AR, AT adapters, seal the flange areas with asuitable sealing compound, e.g. Loctite® 574.


4 Installing the gear unitMechanical Installation

Gear unit venting No breather plug is required for the following gear units:

• R07 in mounting positions M1, M2, M3, M5 and M6

• R17, R27 and F27 in mounting positions M1, M3, M5 and M6

• SPIROPLAN® W gear units

SEW-EURODRIVE supplies all other gear units with the breather valve installed andactivated according to the particular mounting position.

Exceptions:

1. SEW supplies the following gear units with a screw plug on the vent hole provided:

• Gear units for extended storage• Pivoted mounting positions, if possible• Gear units for mounting on a slant

The breather valve is located in the motor terminal box. Before startup, you must re-place the highest screw plug with the breather valve supplied.

2. SEW supplies a breather valve in a plastic bag for gear head units requiring ventingon the input end.

3. Enclosed gear units are supplied without a breather valve.

Activating the breather valve

As a rule, the breather valve is already activated at the factory. If the breather valve hasnot been activated, you must remove the transport fixture from the breather valve beforestarting up the gear unit!

Painting the gear unit

If you paint or respray the drive, ensure that you cover the breather valve and oil sealscarefully. Remove the strips of tape after completing the painting work.

1. Breather valve with transport fixture

2. Remove the transport fixture 3. Breather valve activated

02053BXX 02054BXX 02055BXX


4Gear unit with solid shaftMechanical Installation

4.4 Gear unit with solid shaft

Installing input and output elements

The following figure shows a mounting device for installing couplings or hubs on gearunit or motor shaft ends. It may be possible to dispense with the thrust bearing on themounting device.

Avoid impermissibly high overhung loads: Install the gear or chain sprocket accordingto figure B.

• Only use a mounting device for installing input and output elements. Use the centerbore and the thread on the shaft end for positioning.

• Power transmission elements should be balanced after fitting and must not give riseto any impermissible radial or axial forces (see the "Gearmotor" or "Explosion-ProofDrives" catalogs for permitted values).

03371BXX

1) Gear shaft end2) Thrust bearing3) Coupling hub

03369BXX

1 = Hub

A = UnfavorableB = Correct

• Never drive belt pulleys, couplings, pinions, etc. onto the shaft end by hittingthem with a hammer This will damage the bearings, housing and the shaft!

• In the case of belt pulleys, make sure the belt is tensioned correctly in accor-dance with the manufacturer's instructions.

Note:

Assembly is easier if you first apply lubricant to the output element or heat it up briefly(to 80 ... 100 °C).


4 Gear unit with solid shaftMechanical Installation

Installing couplings

Couplings must be mounted and balanced according to the information provided by thecoupling manufacturer:

a) Maximum and minimum clearance

b) Axial misalignment

c) Angular misalignment

03356AXXFigure 7: Clearance and misalignment for coupling installation

a) b) c)

Input and output elements such as belt pulleys, couplings, etc. must be protectedagainst contact!


4Torque arms for mounted gear unitsMechanical Installation

4.5 Torque arms for mounted gear units

Do not place torque arms under strain during installation!

Parallel shaft helical gear units

Helical-bevel gear units

• Bush with bearings on both ends → (1).

• Install connection end B as a mirror image of A.

01029BXXFigure 8: Torque arm for parallel shaft helical

gear units

01030CXXFigure 9: Torque arm for helical-bevel gear units

Gear unit Bolts Tightening torque

KA37 4 × M10 × 25 – 8.8 48 Nm

KA47 4 × M10 × 30 – 8.8 48 Nm

KA67 4 × M12 × 35 – 8.8 86 Nm

KA77 4 × M16 × 40 – 8.8 210 Nm

KA87 4 × M16 × 45 – 8.8 210 Nm

KA97 4 × M20 × 50 – 8.8 410 Nm

KA107 4 × M24 × 60 – 8.8 710 Nm

KA127 4 × M36 × 130 – 8.8 2500 Nm

KA157 4 × M36 × 130 – 8.8 2500 Nm


4 Torque arms for mounted gear unitsMechanical Installation

Helical-worm gear units

• Bush with bearings on both ends → (1).

SPIROPLAN® W gear units

• Bush with bearings on both ends → (1)

01031CXXFigure 10: Torque arm for helical-worm gear units


SA37 M6 × 16 – 8.8 11 Nm

SA47 M8 × 20 – 8.8 25 Nm

SA57 M8 × 20 – 8.8 25 Nm

SA67 M12 × 25 – 8.8 86 Nm

SA77 M12 × 35 – 8.8 86 Nm

SA87 M16 × 35 – 8.8 210 Nm

SA97 M16 × 35 – 8.8 210 Nm

02050CXXFigure 11: Torque arm for SPIROPLAN® W gear units


WA10 M6 × 16 11 Nm

WA20 M6 × 16 11 Nm

WA30 M6 × 16 11 Nm

45°

(1)

hydrocyclone pump1

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