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seepex France SARL 1,Rue Pelloutier F-77183 Croissy Beaubourg Tel+33.1.64114450 Fax+33.1.64114469 info.fr@seepex.
com www.seepex.com
24h Helpline: www.seepex.com
Commission-no. 238543
Type BE 70-12
Read instructions before beginning any work!
Always keep instructions handy on the worksite.
Issue 28.04.2010
Safety................................................................................................................................................... 1 1.1 General notes 1.2 Safety and warning notes 1.2.1 Warning notes 1.2.2 Danger symbols 1.2.3 Information symbols 1.3 Dangers that can be caused by the machine 1.4 Qualification of the personnel 1.5 Authorised people 1.5.1 Tasks and information for the owner/operators 1.5.2 Safety notes for maintenance, inspection and assembly work 1.6 Personal protective equipment 1.7 Safety and protective devices 1.8 Foreseeable misuse 1.9 Designated use 1.10 Warranty Description of the pump..................................................................................................................... 5 2.1 General description 2.2 Mode of action and pumping principle of the seepex pump 2.3 Constructive design Technical Data .................................................................................................................................... 6 3.1 Data sheet ................................................................................................................................ 7 3.2 Characteristic Curves ............................................................................................................... 9 3.3 Declaration of conformity / Declaration of incorporation......................................................... 10 Transport........................................................................................................................................... 11 4.1 Safety 4.2 Transport 4.2.1 Dimensions, weight and centre of gravity 4.2.2 Symbol 4.2.3 Lashing points (AP) for lifting devices 4.2.4 Unpacking the machine 4.3 Temporary storage/corrosion protection 4.4 Disposal
Assembly / Installation ..................................................................................................................... 13 5.1 Mounting tools / lifting gear 5.2 Space requirement 5.2.1 Dimension for stator replacement 5.2.2 Space requirement for service work 5.3 Assembly of the complete mounted pump 5.4 Power supply of the seepex pump 5.5 Pipelines 5.5.1 Suction and pressure connection 5.5.2 Pipeline dimensions 5.5.3 Residue-free pipelines 5.5.4 Tension-free assembly 5.6 Dimensional Drawing............................................................................................................. 15 Commissioning / De-Commissioning............................................................................................. 16 6.1 Commissioning report............................................................................................................ 16 6.2 Measures before commissioning............................................................................................ 17 6.2.1 Checking pipelines 6.2.2 Protective devices on the pump 6.2.3 Electrical / hydraulic connections 6.2.4 Direction of rotation check 6.2.5 Additional devices - optional 6.3 Initial commissioning/repeated commissioning 6.3.1 Avoiding dry running of the pump 6.3.2 Pressure in the suction and pressure connection 6.4 De-commissioning 6.4.1 Switching off the pump 6.4.2 Emptying the pump 6.4.3 Dismantling the pump 6.4.4 Preservation/storage of the pump Maintenance...................................................................................................................................... 21 7.1 Preventative measures 7.1.1 Pump down-time 7.2 Lubrication 7.2.1 Joint grease 7.3 Inspection Malfunctions, causes, rectification................................................................................................. 23 Pump Dismantling / Reassembly.................................................................................................... 25 9.1 Pump Dismantling / Reassembly........................................................................................... 25
Rotating unit – individual parts .............................................................................................. 50 9.2.1 Dismantling 9.2.2 Rotating unit (RTE) - prepare individual parts for reassembly 9.2.3 Rotating unit (RTE) - individual parts - reassembly Holding band - assembly........................................................................................................ 54 9.3.1 Prepare the holding band 9.3.2 Check the holding band 9.3.3 Assembling the holding band 9.3.4 Correct tension for the holding band (HBD) 9.3.5 Cant up the holding band 9.3.6 Shear the holding band 9.3.7 Check the holding band after assembly Single acting mechanical seal ................................................................................................ 56 9.4.1 Safety 9.4.2 Application conditions and material version 9.4.3 Design 9.4.4 Commissioning 9.4.5 Monitoring during operation 9.4.6 Dismantling of mechanical seal 9.4.7 Reassembly of mechanical seal Sectional drawing shaft sealing.............................................................................................. 59
Spare parts........................................................................................................................................ 60 10.1 Order template for spare parts............................................................................................... 61 10.2 Sectional drawing and parts list.............................................................................................. 63 Special tools...................................................................................................................................... 67 11.1 Order template for special tools Related documents........................................................................................................................... 68 12.1 Accessories ............................................................................................................................ 69 12.2 Technical Information............................................................................................................. 70 12.3 Manufacturer's documents shaft seal..................................................................................... 73 Appendix ........................................................................................................................................... 74 13.1 Manufacturer's documents / suppliers 13.1.1 gearbox...................................................................................................................... 75 13.1.2 Motor ....................................................................................................................... 167 Subsidiaries
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: • • • • 1.2 Prohibition, warning and mandatory signs, warning notes on the machine Relevant laws and ordinances Statutory provisions on accident prevention Corresponding harmonised standards and regulations
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. These are 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.
C / 11.10.2005
OM.SAF.01e
1.2.2 Danger symbols
Warning: Suspended load.
Warning: Tipping over.
Warning: Hand injuries.
Warning: Dangerous electrical voltage.
Warning: Pull-in hazard.
Warning: Excess pressure.
Warning: Risk to the environment.
1.2.3 Information symbols NOTICE
Observe operating and maintenance instructions.
Ensure environDisconnect power Wear eye protection. mental protection. plug before opening.
Wear gloves.  Instruction to act/take measures • List item
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 currents
We have used design measures and applied safety technology to minimise the risk to the health of people posed by this danger. 1.4 Qualification of the personnel This handbook is intended for: • • • • 1.5 Owner Operators Setters Maintenance personnel
Authorised people People authorised to undertake operation, set up and maintenance are instructed and trained specialists employed by the owner/manufacturer.
Detailed technical knowledge is essential for performing any work on the machine.
The owner is responsible for: • • • • • • Personnel training Compliance with safety regulations Compliance with operating and maintenance instructions 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 shutting 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 components.  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.
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. • • 1.8 No protective device is necessary for checking and/or setting the shaft seal. Hot surfaces are identified with a danger symbol on the machine.
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
Designated use • • • Only use seepex machines if they are in perfect condition and in compliance with the operating and maintenance instructions. Do not start up the machine unless the system in which the machine is installed is in accordance 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 foundation are essential. seepex machines are components that are exclusively intended for pumping media in accordance 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.
Kommissions-Nr. commission no.
seepex GmbH Scharnhölzstraße 344 46240 Bottrop Telefon +49.2041.996-0 Fax +49.2041.996-400 Typ type
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 operating 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.
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
Mode of action and pumping principle of the seepex pump • • Seal lines are created by the geometrical configuration/contact between both pumping elements. 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
Constructive design No. ANT 200 307 400 SEA 500 600 RTE 601 700 Designation Drive Lantern Plug-in shaft Coupling rod Shaft seal Suction casing Rotor Rotating unit Stator Pressure branch
A / 10.06.2008
OM.DES.01e
3.1 3.2 3.3 Data sheet Characteristic Curves Declaration of conformity / declaration of incorporation
B / 04.01.2010
OM.TED.01e
order no. date P89424/2009 18.12.09 commission no. offer no. 238543 2101/1687-4 001 K91258-13
seepex GmbH Postfach.PO Box 10 15 64 46215 Bottrop Scharnhölzstraße 344 46240 Bottrop Germany Tel +49.2041.996-0 Fax +49.2041.996-400 info@seepex.com www.seepex.com
purchase order no. project
PA Ressources Cde dze-157-09
item/denomination
seepex progressive cavity pump type BE 70 -12 /B2-A7-A7-H5-GAM3.2-X
denomination rate of solids size of solids density composition remarks water no advice no advice 1 kg/dm3 no advice Eau + hydrocarbures nom. min 30,00 140 8,00 flooded suction bar 12,80 kW max m3/h rpm bar operating torque starting torque 900 Nm Nm viscosity pH-value temperature unknown no advice 5 - 40°C
U 495 WA0010
conveying capacity pump speed press in press. branch press in suct. branch differential pressure required drive power remarks
technical pump data
range size pressure stage component lantern pressure casing pressure connection suction branch suction connection joint joint seal coupling rod rotor stator mechanical seal casing mechanical seal plug-in shaft special designs BE 70 12 material EN-JL-1040 (gci 25) steel 1.0037 (st.37-2) steel 1.0037 (st.37-2) t=14000 without 1.4571 1.4571 FPM-H5 1.4571 special construction standard Duktil coated 250 Em design equal wall with Quench for mechanical seal, internal Burgmann MG1/G60-100 Q1Q1 VGG kind of install. direction of rot. pos. of branch vertical drive on top clockwise 1
design/option standard semi-submersible variant O DN 3" ANSI B16,5 150lbs
1.4571 drilled Ø60x100 quench acc. to ZU.021.01 , design 3 incl. tank approx. 140 cm3 submersible pump with intermediate housing see remarks
Rechtsform GmbH HRB 9350 Gelsenkirchen
Geschäftsführender Gesellschafter: Ulli Seeberger
Data Sheet 238543 Page 2
kind of operation site of installation remarks continuous operation - 8 h/day indoor
type make model mounting position flange dia output shaft gear SEW RF97 AM180 IMV1 350 mm 716/0700-002B4 ratio output speed motor speed frequency i=12,390 nom./ min- max 141/ rpm 1740/ rpm 60/ Hz
make nominal power nominal speed mounting position starting ex-protection provid. of motor special/accessories HEW Herforder Elektr 21,0 kW 1740 rpm IMV1 direct on line EEx deIICT4 HEW with 3 PTC thermistors model voltage rated frequency protection thermal class size flange/shaft dia fitting of motor DEx 180M/4K 3 x 460 VAC V 60 Hz IP55 F 180 350 / 48 mm seepex BOT
standard drawing no. special/accessories KRANBÜGEL 824-200/0700-C-004A1 material surface St52-3 varnished
execution colour remarks standard RAL 5013 (blue)
packing type marking
dimensional drawing no. sectional drawing no. shaft sealing sect.view 271-G34/0700-C-001D2 071-K238-543A1 271-0GB/0700-0-081B3 operating manual 1 copy french 1 copy English
QA-documentation
CE-sign Rotor / Stator test record
additional accessories / special designs / remarks
special design: The pump is dismountable in 5 sections as per drawing-no.: ...
Sabine Zanger 02041.996-0
sales engineer issue
Johannes Beckmann 28.04.10 / 15:35
according to Machinery Directive 2006/42/EC, Annex II A
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 info@seepex.com www.seepex.com
seepex GmbH Scharnhölzstrasse 344 D-46240 Bottrop, Germany
We hereby declare that the following product Progressive cavity pump unit
BE 70-12
Comm. no.:
meets the provisions of the directive indicated above, including the modifications holding at the time of declaration. The product also meets all the provisions of the following directives: 2006/95/EC 2004/104/EC Electrical equipment Electromagnetic compatibility
The following harmonised standards were applied: DIN EN ISO 12100-1 DIN EN ISO 12100-2 DIN EN ISO 13857 DIN EN 809 Safety of machinery, Part 1 Safety of machinery, Part 2 Safety distances, upper and lower limbs Pumps and pump units for liquids
Thomas Hümmerich Technical documentation Tel +49 2041 996 - 309 Fax +49 2041 996 417 thuemmerich@seepex.com
p.p. Klemens Fockenberg Technology Manager seepex GmbH
p.p. Roland Hecker Quality Control Manager seepex GmbH
Rechtsform: GmbH HRB 9350 Gelsenkirchen
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. 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
Against moisture Centre of gravity protect
4.2.3 Lashing points (AP) for lifting devices 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).
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.
A / 29.08.07
OM.TRA.01e
4.3 Temporary storage/corrosion protection • All seepex machines have corrosion protection applied as standard prior to transport. 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 protection against ambient influences.  Contact seepex regarding the necessary corrosion protection for temporary storage. 4.4 Disposal NOTICE Environmental protection. Material damage can occur.  Drain the pumping medium and dispose of it in accordance with the regulations.  Dispose of the machine with regard to its composition and existing regulations.
5 Assembly / Installation
5.1 Mounting tools / lifting gear
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. 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)  Refer to the dimensional drawing.
5.2.2 Space requirement for service work Note the following measure: A B Provide a working area of approx. 1 m/ 40 inch width alongside the pump. When changing the stator, provide suspension points above the stator and in front of the pressure branch. For dismantling/assembly the drive, provide suspension points above the drive unit. For dismantling/assembly of the suction casing/hopper, provide suspension points above the housing. Dimension for stator replacement.
B / 23.06.2008
OM.INS.06e
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/fixing the drive. CAUTION Safety protective devices. Slight injury or damage to property can occur.  Connect safety protection devices and activate.
Power supply of the seepex pump DANGER Line voltage and line frequency Death 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.
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 connection. Note technical data (chapter 3.). Nominal width of suction pipe = nominal width of pump suction connection.
5.5.3 Residue-free pipelines 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. 5.5.4 Tension-free assembly  Assemble pipelines and other components in a tension-free manner on the pump.
6 Commissioning / De-commissioning Master Copy
6.1 Commissioning report From:
Send commissioning report online to www.seepex.com\ Must be specified with every order! Commission: _________________________ Model: _____________________
Contact person: ........................................... Tel.: ............................................................. Fax: ........................................................... E-mail: ........................................................
Customer Service: seepex GmbH Postfach 10 15 64 D-46215 Bottrop service@seepex.com
Germany Rest of Europe Outside Europe
Phone:+49 2041.996-231 Address of plant: Fax: +49 2041.996-431 Fax: +49 2041.996-424 Fax: +49 2041.996-432 ................................................................. ................................................................. ................................................................. Phone:+49 2041.996-224 ................................................................. Phone:+49 2041.996-120 .................................................................
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
B / 17.03.2006
OM.COM.05e
6 Commissioning / De-commissioning
6.2 Measures before commissioning  Note the technical data (chapter 3.). 6.2.1 Checking pipelines  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. 6.2.2 Protective devices on the pump DANGER Missing protective device. Danger of pulling in and crushing.  Equip the pump with a protective device. Protective devices provided for preventing contact 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 additional 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 rotating shaft. 6.2.3 Electrical/hydraulic connections 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.
B / 18.10.2005
OM.COM.01e
6.2.4 Direction of rotation check 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 6.2.5 Additional devices - optional  Refer to additional devices (chapter 12.1). 6.3 Initial commissioning/repeated commissioning  Start up the pump. 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. 6.3.1 Avoid dry running of the pump 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) 6.3.2 Pressure in the suction and pressure connection CAUTION High pressure. Malfunction and/or irreparable damage to the shaft seal or pump.  Maintain pressure in the suction connection in accordance with the technical data (chapter 3.).  Assemble an oil-filled contact pressure gauge to monitor and deactivate the pump. 6.4 De-commissioning Protect the pump and additional devices against the following: • • • • Frost Deposit of solids Sedimentation from the liquid Corrosion of parts that come into contact with the medium clockwise
6.4.1 Switching off the pump 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. 6.4.2 Emptying the pump 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. 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 connections. 6.4.3 Removing the pump WARNING Risk of pump tipping or falling. Death or serious injury can occur.  Support the drive unit to guarantee stability. Pipeline dismantling  Remove flange bolts (SCH) and flange seals (DFL). with/without base plate  Remove bolts (SCH) from the pump feet.
SCH DFL
Pipeline dismantling  Remove threaded connections (G). with/without base plate  Remove bolts (SCH) from the pump feet.
6.4.4 Preservation/storage of the pump 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.
7.1 Preventive measures The maintenance personnel must have these operating instructions, follow them and also require corresponding qualifications. • No liability will be accepted in the event of violation.
DANGER Dangerous voltage. Death or serious injury can occur.  Observe safety regulations.  Disconnect the pump from all sources of energy.  Prevent electrical connections from being switched on again. 7.1.1 Pump down-time NOTICE Pump down-time. Production failure due to wear.  Acquisition of a set of wearing parts and a set of gaskets.
Denomination Pin joint Pin joint Drive
Lubricant seepex special grease (30321) seepex special grease (30321)
Lubricant change in operating hours 10000 h 10000 h
Fill volume 14 cm3 14 cm3
Refer to manufacturer's documentation (chapter 13.1) Conveying medium Conveying medium ---------
Rotor/stator Shaft seal
A / 28.06.2007
OM.WTG.03e
7.2.1 Joint grease NOTICE Other grease types. Malfunction and/or irreparable damage to the joints or the pump.  Exclusively use seepex special grease.
Inspection Component Joints Shaft seal Drive unit Interval Every week Every 3000 operating hours, at least every 6 months Action Visual check for leaks Comply with manufacturer's documentation
Every 10,000 operating hours Renew joint grease
8 Malfunctions, causes, rectification
Refer to technical data (chapter 3.) for application range of the pump. Malfunction Pump seized / pump does not pump Conveying capacity is not achieved Causes Rectification
Pressure head is not reached
Pump is loud when running
Pump pumping unevenly
Pump does not start up
Premature stator wear
Pump is not sucking
Motor gets too hot X
X Static friction between sta- Apply lubricant (liquid soap) tor/rotor too great. between stator and rotor. Incorrect direction of rotation. Check direction of rotation and swap over motor connections if necessary. Eliminate leaks. Check the suction head, if necessary increase pipe cross section on suction pipe and use a larger filter, open suction-side valve fully. Check/adapt (data sheet). Correct rotation speed (data sheet). Avoid air bubbles in the conveying product.
Shaft seal is leaky Suction pipe or shaft seal leaking. Suction head too great. Viscosity of conveying product too great. Pump rotation speed incorrect. Pressure head too great.
Check pressure head with pressure gauge, reduce pressure head by using larger pressure pipe crossed section or shortening the pressure pipe. Check there is adequate conveying product available on the suction side. Dry running protection DRP. If necessary, move pump in relation to drive, check wear on coupling gear, re-adjust coupling if necessary. Increase rotation speed for low-viscosity media/large suction volume.
Pump running partially/ completely dry.
Check coupling.
Rotation speed too low.
B / 11.09.2007
OM.REC.01e
Malfunction Pump seized / pump does not pump Conveying capacity is not achieved Causes Rectification
Shaft seal is leaky Rotation speed too high.
Reduce rotation speed for high-viscosity media, risk of cavitation. Check mounting of coupling rod bushing. Dismantle pump, remove foreign bodies, replace defective parts. Dismantle pump and renew defective parts. Renew joint parts, use seepex pin joint grease. Clean the suction pipe. Check temperature, use an undersize rotor. Loosen packing gland or tighten. Renew unusable packing rings. Reduce pump speed, install screen with permitted mesh width. Increase liquid proportion.
Joint play too large. Foreign objects in pump.
Stator/rotor worn. Joint parts worn. Suction pipe blocked. Temperature of pumping liquid too high. X Gland packing too firm/ worn. X Solid content and/or grain size too great.
X X Sedimentation/gumming of Rinse through and clean solids when pump station- the pump immediately. ary. X X Conveying product hardHeat the pump. ens when the temperature drops below a certain limit. X X Stator swollen and unable to withstand conveying product. X Bearings in pump drive housing or drive unit defective. Select a suitable stator material, use an undersize rotor. Renew bearings.
X Mechanical seal defective. Check sliprings and Orings for wear/resistance, renew if necessary.
9 Dismantling / Reassembly
9.1 Atex documents Range: BE Size: 70-12
9.1.1 Assembly/reassembly WARNING Tilting or falling pump. Death or serious injury can result. Secure pump parts. Use suitable hoisting devices. 9.1.1.1 Conveyor unit (FEH) - pre-assembly
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 direction. Dispense lubricant (GM) on the stator internal 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
A / 16.04.2010
OM.MAI.238543
9.1.1.2 Coupling rod (480)/Intermediate element (534) - pre-assembly
Tool (W105, W106/lifting device)
Screw threaded bushing (489) with coupling rod (482). Assemble tool (W105). Insert o-ring (538) into intermedialte element (534). Assemble tool (W106).
W105 489 483 482 W106
9.1.1.3 Conveyor unit (FEH), coupling rod (482)/intermediate element (534) - assembly Tool (W104/holding device) Fix tool (W104) onto mounting hole (ML). – Note the position of the tool (W104). Insert and secure the pre-assembly conveyor 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 lifting device (TR1) and (TR2) Screw flange coupling rod (482) / Rotor (601).
FEH W104 ML W104 TR 535 482 490 491 492 493 600
TR2 TR1 534
9.1.1.4 Intermediate elements (535, 534) - assembly
Tool (W103/holding device)
dismantle tool (W103). Screw intermediate elements (535, 534).
534 539 W103 535 540 541
9.1.1.5 Lowering the pump parts 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.
TR2 W106 534 W104
9.1.1.6 Secure rotating unit (RTE)
Tool (W102/holding device)
Tool (W107bearing ring)
Hoist rotating unit (RTE). Secure the rotating unit (RTE) with tool (W102, W107). Remove lifting device (TR1). Dismantle tool (W105).
RTE RTE W102 W107 TR1 W105
9.1.1.7 Coupling rod (481)/Intermediate element (536) - pre-assembly
Tool (W105, W106/lifting device) Screw threaded bushing (489) with coupling rod (481). Assemble tool (W105). Insert o-ring (538) into intermedialte element (536). Assemble tool (W106).
W105 489 483 481 W106
9.1.1.8 Coupling rod (481)/intermediate element (536) - assembly Tool (W104/holding device) Secure pre-assembly unit, coupling rod (481)/intermediate element (536) with lifting device (TR1) and (TR2) Screw threaded bushing (489) with coupling rod (481). Assemble intermediate elements (536, 534).
481 489 483 482 482 W102 W107 534 539
TR2 TR1 536
9.1.1.9 Lowering the pump parts 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 (536). Adjust tool (W104). – Note the position of the tool (W104). Lower pump parts to limit stop.
TR2 W106 536 W104
9.1.1.10 Secure rotating unit (RTE)
Tool (W102/holding tool; W107/bearingring)
Tool (W107/bearing ring)
RTE W102 W107 TR1 W105
9.1.1.11 Coupling rod (480)/Intermediate element (537) - pre-assembly
Screw threaded bushing (489) with coupling rod (480). Assemble tool (W105). Insert o-ring (538) into intermedialte element (537). Assemble tool (W106).
W105 489 483 480 W106
9.1.1.12 Coupling rod (480)/intermediate element (537) - assembly Tool (W104/holding device) Secure pre-assembly unit, coupling rod (480)/intermediate element (537) with lifting device (TR1) and (TR2) Screw threaded bushing (489) with coupling ros (480). Assemble intermediate elements (537, 536).
480 489 483 481 481 W102 W107 536 539
TR2 TR1 537
9.1.1.13 Lowering the pump parts 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 (537). Adjust tool (W104). – Note the position of the tool (W104). Lower pump parts to limit stop.
TR2 W106 537 W104
9.1.1.14 Secure rotating unit (RTE)
Tool (W102/holding tool)
9.1.1.15 Coupling rod (480)/Intermediate element (534) - pre-assembly
Screw threaded bushing (489) with coupling rod (480). Assemble tool (W105). Insert o-ring (538) into intermedialte element (534). Assemble tool (W106).
W105 489 483 480
9.1.1.16 Coupling rod (480)/intermediate element (534) - assembly Tool (W104/holding device) Secure pre-assembly unit, coupling rod (480)/intermediate element (534) with lifting device (TR1) and (TR2) Screw threaded bushing (489) with coupling rod (480). Assemble intermediate elements (534, 537).
480 489 483 480 480 W102 W107 537 539
9.1.1.17 Lowering the pump parts 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.
9.1.1.18 Secure rotating unit (RTE)
9.1.1.19 Coupling rod (480)/pressure casing (500) - pre-assembly
Tool (W105, W106/lifting device) Screw threaded bushing (489) with coupling rod (400). Assemble tool (W105). Assemble tool (W106) at pressure casing (500).
W105 489 483 400
W106 500
9.1.1.20 Coupling rod (481)/pressure casing (500) - assembly Secure pre-assembly unit, coupling rod (400)/pressure casing (500) with lifting device (TR1) and (TR2) Screw threaded bushing (489) with coupling rod (400). Assemble intermediate element (534) at pressure casing (500).
400 489 483 480
500 480 W102 W107 534 539
9.1.1.21 Coupling rod (400)/pressure casing (500) - pre-assembly
Screw threaded bushing (489) with coupling rod (400). Assemble tool (W105). Insert o-ring (536) into intermedialte element (534). Assemble tool (W106).
TR2 W106
9.1.1.22 Lowering the pump parts Tool (W104/holding tool) Hoist pump parts and adjust tool (W104). – Note position of the tool (W104) Lower pump parts to limit stop and assemble.
RTE RTE W102
TR1 W105
9.1.1.23 Drive unit - pre-assembly Lantern (200)/drive (ANT) - reassembly Clean the flange bearing surfaces (FLS), bolt circle (ZD) and output pivot of the drive (ANT).
Shaft Seal (SEA) - assembly Assemble shaft sealing – Note shaft sealing assembly (chapter 9._).
Fit-up aid (MH) - assembly Assemble fit-up aid (MH) at lantern (200).
9.1.1.24 Drive (ANT) - pre-assembly Secure drive (ANT) with lifting device (TR). Screw coupling rod (400) and plug- in shaft (307) with threaded bushing (489).
TR ANT 307 489 483 400
9.1.1.25 Drive (ANT) - assembly
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 TR ANT 200 500 509 507 506
9.1.2 Dismantling 9.1.2.1 Drive unit (ANT) - dismantling
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)
TR 200 509 507 506 500
ANT SEA MH RTE W102
Dismantle threaded bushing (489) from coupling rod (400) and plug-in shaft (309).
307 489 483 400
Fit-up aid (MH) - dismantling
MH 200 ANT
Dismantle fit-up aid (MH) from lantern (200).
plug-in shaft (307) dismantling Remove the flush connections on the casing of the shaft seal (SEA). Lift/slide splash ring (310), push out plugin shaft pin (309) horizontally. Remove plug-in shaft (307) with shaft sealing (SEA) from the drive shaft. Remove o-ring (501). Shaft Sealing (SEA) - dismantling Saft Sealing dismantling – Note Shaaft sealing dismantling (chapter 9.4). Lantern (200)/Drive (ANT) - dismantling
210 200 212 213 ANT 307 310 501 SEA
9.1.2.2 Release Pump
Tool (W105/lifting device)
Assemble tool (W105) on threaded bushing (489). Assemble tool (W102) at pressure casing (500). fix lifting device (TR1).
W105 489
TR1 W102 500
9.1.2.3 Pressure casing (500)/coupling rod (400) - dismantling
Tool (W106/lifting device)
Tool (W104/holding device) Fix tool (W106) at pressure casing (500). Dismantle anchor bolts at pressure casing (500). Hoist pump parts up to the flange of the intermediate element (534). Fix tool (W104) on mounting hole (ML). – Note the position of the tool (W104).
W106 500 W104 ML 534 W104 TR2 500
9.1.2.4 Raising pump parts Tool (W104/lifting device)
Fix tools (W102, W107) at intermediate element (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).
500 481 W102 W107 534 TR2 TR1 500
400 539 489 483 540 541 W104
9.1.2.5 Pressure casing (500)/coupling rod (400) - dismantling
Tool (W105, W106/lifting device) Dismantle tool (W105) on threaded bushing (489). Dismantle threaded bushing (489). Dismantle tool (W106) on pressure casing (500).
9.1.2.6 Secure pump
Assemble tool (W105) at threaded bushing (489). Fix lifting device (TR1) on tool (W105). Remove tools (W102, W107).
W105 489 W102 W107
9.1.2.7 Raising pump parts
Tool (W104/holding device) Assemble tool (W106) at intermediate element (534). Fix lifting device (TR2) on tool (W106). Hoist pump parts up to the flange of the intermediate element (534). Adjust tool (W104). – Note the position of the tool (W104).
W106 W104 534 W104
9.1.2.8 Intermediate element (534)/coupling rod (481) - dismantling
Tool (W104/holding device) 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).
480 W102 W107 537 539 534 TR2 TR1 534 480 489 483 480
540 541 W104
9.1.2.9 Intermediate element (534), coupling rod (481) - individual parts
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).
9.1.2.10 Secure pump
9.1.2.11 Raising pump parts
Tool (W104/holding device) Assemble tool (W106) at intermediate element (537). Fix lifting device (TR2) on tool (W106). Hoist pump parts up to the flange of the intermediate element (537). Adjust tool (W104). – Note the position of the tool (W104).
W106 W104 537 W104
9.1.2.12 Intermediate element (537)/coupling rod (480) - dismantling
Tool (W104/holding device) Fix tools (W102, W107). Adjust tool (W104). – Note the position of the tool (W104). Remove screwing coupling rod (480)/ threaded bushing (489). Remove intermediate element (537), coupling rod (480). Remove lifting device (TR1, TR2).
480 W102 W107 536 539 537 TR2 TR1 537
480 489 483 481
9.1.2.13 Intermediate element (537), coupling rod (400) - individual parts
Dismantle tool (W105) from threaded bushing (489). Dismantle threaded bushing (489). Dismantle tool (W106) from intermediate element (537).
538 W106
9.1.2.14 Secure pump
9.1.2.15 Raising pump parts
Tool (W104/holding device) Assemble tool (W106) at intermediate element (536). Fix lifting device (TR2) on tool (W106). Hoist pump parts up to the flange of the intermediate element (534). Adjust tool (W104). – Note the position of the tool (W104).
W106 W104 536 W104
9.1.2.16 Intermediate element (536)/coupling rod (480) - dismantling
Tool (W104/holding device) Fix tools (W102, W107). Adjust tool (W104). – Note the position of the tool (W104). Remove screwing coupling rod (481)/ threaded bushing (489). Remove intermediate element (536), coupling rod (481). Remove lifting device (TR1, TR2).
482 W102 W107 534 539 536 TR2 TR1 536 481 489 483 482
9.1.2.17 Intermediate element (536), coupling rod (400) - individual parts
Dismantle tool (W105) from threaded bushing (489). Dismantle threaded bushing (489). Dismantle tool (W106) from intermediate element (536).
9.1.2.18 Secure pump
9.1.2.19 Raising pump parts
Tool (W104/holding device) Assemble tool (W106) at intermediate element (534). Fix lifting device (TR) on tool (W106). Hoist pump parts up to the flange of the intermediate element (534). Adjust tool (W104). – Note the position of the tool (W104).
9.1.2.20 Intermediate element (534)/coupling rod (482) - dismantling Tool (W104/holding device)
Tool (W103/holding device) 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)/coupling rod (482). Remove lifting device (TR1, TR2).
535 W103 482 539 600 540 541 W104 490 491 492 493 534 TR2 TR1 534
9.1.2.21 intermediate element (534), coupling rod (482) - individual parts
9.1.2.22 Conveyor unit (FEH) - dismantling Tool (W104/holding device) 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).
FEH W104 ML W104 TR 535
9.1.2.23 Suction branch (700) - dismantling
Tool (W103/holding device) Dismantle tool (W103).
Dismantle suction branch (700) from stator (601).
9.1.2.24 Stator (601) - dismantling 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 direction. Dispense lubricant (GM) on the stator internal surface in order to reduce friction between the rotor and stator.
9.2 Rotating unit individual parts
9.2.1 Dismantling 9.2.1.1 Holding band (406, 407) - dismantling 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).
9.2.1.2 Retaining sleeve (401) - dismantling  Knock back retaining sleeve (401). – Use suitable tool (WM).
9.2.1.3 Detach joint
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).
W5 404
C / 06.07.2007
OM.PJT.02e
9.2.2 Rotating unit (RTE) - prepare individual parts for reassembly 9.2.2.1 Rotor (600)  Remove any damage.  Clean the rotor (600).
Tool (W4/assembly mandrel)  Press in the guide bushing (403) (depth = 2/3). – Use tool (W4).
W4 600 403 403
9.2.2.2 Coupling rod (400)  Clean the coupling rod (400).  Examine bore head for wear. – If wearing is detected on the bore head, replace the coupling rod (400). 9.2.2.3 Plug-in shaft (307)  Remove any damage.  Clean the plug-in shaft (307).
9.2.3 Rotating unit (RTE) - individual parts - reassembly NOTICE Malfunction of the joints. Malfunction and/or destruction of joints.  Replace the coupling rod pins (402) and guide bushings (403) jointly.
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)  Insert coupling rod pins (402).  Slide on retaining sleeve (401).  Connect the rotor/coupling rod.
600 402 401 405 400 406 407
Tool (W5/drift)  Slide in the coupling rod pins (402).  Knock the guide bushings (403) in.
W5 403
Plug-in shaft (307)  Insert coupling rod pins (402).  Slide on retaining sleeve (401).  Connect the plug-in shaft/coupling rod.
407 406 400 405 401 402 307
9.2.3.5 Retaining sleeve (401) - reassembly
Tool (W4/assembly mandrel)  Knock back retaining sleeve (401). – Use tool (W4).
Rotor (600) unhardened material  Secure retaining sleeve (401) in a displaced manner (2x180°). – Use suitable tool (WK).
401 WK
Rotor (600) hardened material  Secure retaining sleeve (401) in a displaced manner (2x180°). – Use suitable tool (WK).
9.2.3.6 Universal joint sleeve (405) - reassembly  Moisten the surface of the coupling rod (400)/ inner surface of the universal joint sleeve (405) with joint grease (maintenance, 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._).
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 • 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
HBD ø
9.3.3 Assemble the holding band Use tool (W3/mounting tool) Feed holding band into tool (W3). Hold ends of holding band with the eccentric 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. 9.3.4 Correct tension of the holding band (HBD) Correct The holding band (HBD) has drawn in the out shape of the universal joint sleeve and is firmly seated.
W3 KU SCL EX
Incorrect The holding band (HBD) is too loose, can slip off.
C / 17.03.2006
OM.HBD.01e
Incorrect The holding band (HBD) is too tight, universal joint sleeve will be damaged/sheared off.
9.3.5 Cant up the holding band Swivel mounting tool (W3) approx. 60° upwards. Loosen crank (KU) by a half turn.
ca .6 0°
Swivel cutting lever (SH) forward until the pressure piece is lying behind the holding band loop (SCL).
9.3.6 Shear the holding band (material: 1.4301; 1.4571) 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. 9.3.7 Check the holding band after assembly 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
9.4 Single acting mechanical seal
9.4.1 Safety 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. 9.4.2 Operating conditions and material combination • Adjust to the relevant application – Refer to technical data (chapter 3).
9.4.3 Design • Single acting mechanical seal
9.4.4 Commissioning NOTICE Dry running of the mechanical seal. Damage to property may result.  The mechanical seal must be laid in liquid medium before being commissioned. 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. NOTICE Shaft seal is not leakage free. Damage to property through leakage.  Components which come into contact with leakage must be corrosion-resistant or otherwise suitably protected. 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).
B / 29.06.2009
OM.SEA.02e
9.4.5 Monitoring during operation 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).
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  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 mechanical 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).
330G 333
307 333 330G
Without axial locking device  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).
330G 333 330
9.4.7 Reassembly of mechanical seal 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.  Assembly aids such as oil/grease are not permitted. With axial locking device  Clean the mechanical seal casing (333).  Moisten the seal with lubricant (thinned liquid soap).  Attach the counter ring and seal using even pressure into the mechanical seal casing (333).  Clean the plug-in shaft (307), remove edges/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 lubricant (thinned liquid soap).  Slide mechanical seal (330) onto the plugin shaft (307) until the installation edge has been reached. Without axial locking device  Clean the mechanical seal casing (333).  Moisten the seal with lubricant (thinned liquid soap).  Attach the counter ring and seal using even pressure into the mechanical seal casing (333).  Clean the plug-in shaft (307), remove edges/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 lubricant (thinned liquid soap).  Slide mechanical seal (330) onto the plugin shaft (307) until the installation edge has been reached.
307 333 330G 330 330G 333
10.1 Spara parts list 10.2 Sectional Drawing and Part List
OM.SZG.02e
10.1 Order template for spare parts Spare parts can be ordered online or requested from www.seepex.com\ Request Order Sender:
Type: BE 1-6 to 202-6L
Must be included in every order or enquiry!
Commission: Type: Contact: .................................................... Tel.: .......................................................... _________________________ _______________________ Fax: ......................................................... E-mail: ...................................................... Customer service: seepex GmbH Postfach 10 15 64 D-46215 Bottrop service@seepex.com
Europe outside Germany Intercontinental outside Germany Germany
Tel +492041.996-231 Tel +492041.996-224 Tel +492041.996-120
Delivery address: ...................................................................... ......................................................................
Fax +492041.996-431 ...................................................................... Fax +492041.996-424 ...................................................................... Fax +492041.996-432 ...................................................................... Material Comment
Minor set of wearing parts 301 330 392 601 1 1 1 1 Set of packing rings Mechanical Seal Lip seal Stator according to data sheet (chapter 3.1) according to data sheet (chapter 3.1)
Major set of wearing parts 301 307 330 392 400 402 403 405 406 407 411 412 600 601 1 1 1 1 1 2 4 2 2 2 1 1 1 1 Set of packing rings Plug-in shaft Mechanical seal Lip seal Coupling rod with coupling rod bushings Coupling rod pin Guide bushing Universal joint sleeve Holding band, large Holding band, small Holding band Holding band Rotor Stator according to data sheet (chapter 3.1) according to data sheet (chapter 3.1)
__________________________________ Place, date
C / 02.02.2010
OM.WPS.19e
10.1 Order template for spare parts No. Quantity Component Material Comment
Set of gaskets 301 310 330 501 503 536 1 1 1 1 3 2 Set of packing rings Splash ring Mechanical seal Casing gasket Sealing ring O-ring according to data sheet (chapter 3.1) according to data sheet (chapter 3.1)
Plug-in shaft & shaft seal 301 307 309 310 392 330 Set of packing rings Plug-in shaft Plug-in shaft pin Splash ring Lip seal Mechanical seal according to data sheet (chapter 3.1) according to data sheet (chapter 3.1) according to data sheet (chapter 3.1)
Coupling rod & joint parts 400 401 402 403 405 406 407 411 412 401-412 Pumping elements 600 601 Miscellaneous parts 501 098 Casing gasket Pin joint grease 1 cartridge = 300 g (approx. 315 cm³) Grease quantity according to maintenance (chapter 7.) Rotor Stator Coupling rod with coupling rod bushings Retaining sleeve Coupling rod pin Guide bushing Universal joint sleeve Holding band, large Holding band, small Holding band Holding band Complete set of joint parts
Stückliste Parts List Liste des pièces
Stck. 1 2 1 4 4 4 1 1 1 1 1 2 1 1 20 5 6 6 6 6 1 1 1 1 4 4 4 2 1 1 1 5 30 30 30 1 1 1 6 12 12 1 6 1
Pos. 200 202 203 210 212 213 307 309 310 330 400 480 481 482 483 489 490 491 492 493 500 501 502 503 506 507 509 534 535 536 537 538 539 540 541 542 600 601 602 604 606 700 702 3000
DE Baureihe BE Schnittzeichnung Nr. 071-K238-543_2 Benennung Stck. / Pos. Laterne Halbrundkerbnägel Typenschild 6kt-Schraube Fächerscheibe 6kt-Mutter Steckwelle Steckwellenbolzen Spritzring Gleitringdichtung Kuppelstange Kuppelstange Kuppelstange Kuppelstange Zylinderschraube Gewindebuchse 6kt-Schraube Scheibe Federring 6kt-Mutter Druckgehäuse O-Ring Verschlussschraube Dichtring Stiftschraube Federring 6kt-Mutter Zwischenelement Zwischenelement Zwischenelement Zwischenelement O-Ring 6kt-Schraube Federring 6kt-Mutter Kunststoffring Rotor Stator Spannschraube 6kt-Mutter Scheibe Saugstutzen Abstandsbolzen Quench siehe Zusatzeinrichtung Blatt ZU.021.01
EN range BE sectional drawing No. 071-K238-543_2 denomination Qty. / Item lantern round head grooved pins type plate hexagon bolt fan type lock washer hexagon nut plug-in shaft plug-in shaft pin splash ring mechanical seal coupling rod coupling rod coupling rod coupling rod socket screw threaded bushing hexagon bolt washer spring washer hexagon nut pressure casing o-ring screwed plug sealing ring stud bolt spring washer hexagon nut intermediate element intermediate element intermediate element intermediate element o-ring hexagon bolt spring washer hexagon nut synthetic material ring rotor stator tie bolt hexagon nut washer suction branch distance pin quench see optional extras sheet ZU.021.01
FR série BE plan no. 071-K238-543_2 désignation Qté. / Poste lanterne rivet palque signalitique vis rondelle à dents chevauchantes extérieures écrou arbre à broche cheville pour arbre à broche bague de projection garniture mécanique barre d' accouplement barre d' accouplement barre d' accouplement barre d' accouplement vis à tête cylindrique filetage vis rondelle rondelle frein écrou carter de refoulement joint torique bouchon de vidange joint d’étanchéité boloun fileté rondelle frein écrou carter intermédiaire carter intermédiaire carter intermédiaire carter intermédiaire joint torique vis rondelle frein écrou anneau de plastique rotor stator tirant écrou rondelle bride d’aspiration cheville de distance quench voir accessoire feuille ZU.021.01
A / 24.03.10
SL.071.K238543def
DE Baureihe BE Schnittzeichnung Nr. 071-K238-543_2 Benennung Pos. Stck. / Pos. Verschleißteile und Dichtungen: Betriebs- und Wartungsanleitung entnehmen Werkzeuge: Betriebs- und Wartungsanleitung entnehmen siehe Schnittzeichnung Gleitringdichtung versetzt gezeichnet
EN range BE sectional drawing No. 071-K238-543_2 denomination Qty. / Item Wear parts and sealings: see Operating and Maintenance Instruction Tools: see Operating and Maintenance Instruction see sectional drawing mechanical seal drawn displaced
FR série BE plan no. 071-K238-543_2 désignation Qté. / Poste pièces d'usure et étanchéités: voir Instructions de service et d'entretien Outils: voir Instructions de service et d'entretien voir vue éclatée garniture mécanique plan separé
11 Special tools Version for copying
Spare parts can be ordered online or requested from www.seepex.com\ Sender:
Must be specified with every order!
Commission: __________________________ Mark tool! X Contact: ......................................................... Tel.: ................................................................ Fax: ............................................................... E-mail: ........................................................... Customer service: seepex GmbH Postfach 10 15 64 D-46215 Bottrop service@seepex.com Rest of Europe Outside Europe Germany Tel +492041.996-231 Tel +492041.996-224 Delivery address: .......................................................................
Fax +492041.996-431 ....................................................................... Fax +492041.996-424 ....................................................................... Tel +492041.996-120 ....................................................................... Fax +492041.996-432 ....................................................................... .......................................................................
For installation of: Tool no. Denomination: Order no.
Packing gland W1 Packing puller PKZ W2
Universal joint sleeve W15 Mounting plate MTP
Chain wrench plus spare chain KRZ
For installation of: Holding band Tool no. Denomination: Order no. W3 Mounting tool MHB W4 Drift MTD Joint
Rotating unit Plug-in shaft W10 Dismantling Tool AZV
A / 22.09.2006
OM.STO.01e
12.1 Additional components 12.2 Technical information 12.3 Manufacturer's documents shaft seal
B / 12.01.2010
OM.ZUG.01e
Gleitringdichtung mit Quench mechanical seal with quench
Dokument / document ZU.021.01de Ausgabe / issue H / 10.11.04 Blatt / sheet 1 (1)
Eine GLRD wird gequencht bei Medien die zu Kristallisati on an den Gleitflächen neigen, bzw. adhäsiv sind. Desweiteren ist Quenchung bei Vakuum Betrieb zur Vermeidung von Trockenlauf erforderlich. Die Quenchflüssigkeit muss mit dem Fördermedium verträglich und auf die Werkstoffe der GLRD abgestimmt sein. Achtung: Quenchflüssigkeit drucklos fahren, max 0,1 - 0,15 bar. Bei größerem Druck Ausrücksicherung für Wellendichtring erforderlich, siehe HA.RDO.02.
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.
A mechanical seal is quenched, when the medium (product) tends to crystallization at the seal faces, or when it is adhesive. Moreover, quenching is necessary during vacuum -operation to avoid dry-running. The quench liquid must be compatible with the pumped product and with the selected material of the mechanical seal. Attention: Quench liquid is used pressureless, max 0,1 - 0,15 bar. Regarding higher pressure, a disengaging device is required for the shaft sealing ring, see HA.RDO.02.
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).
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 60200 gefüllt und beidseitig mit Verschlussschrauben verschlossen.
Liquid tank provided and mounted by the customer: 1) 1) Quench chamber is filled with seepex 50300 (Glycerin) , for food design with seepex 60200 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
Mit nachfüllbarem Vorlagebehälter 1) Die Quenchkammer ist mit Kühl-/Schmiermittel seepex 50300 (Glycerin) 1) bzw. bei Lebensmittelausführung mit seepex 60200 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
With refillable supply tank. 1) 1) Quench chamber is filled with seepex 50300 (Glycerin) , for food design with seepex 60200 , 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
Baugröße / size 0005-24 - 1-6L 1-12 - 500-6LA ca. 80 cm
Mit nachfüllbarem Vorlagebehälter. 1) Die Quenchkammer ist mit Kühl-/Schmiermittel seepex 50300 (Glycerin) 1) bzw. bei Lebensmittelausführung mit seepex 60200 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
With refillable supply tank. 1) Quench chamber is filled with seepex 50300 (Glycerin) , for food design with 1) seepex 60200 , 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 4L/3L
Baugröße / size 1-12 - 500-6LA 0,5L alternativ 4L / 3L
Lage der Einlassstellung für alle Ausführungen: Location of inlet position for all designs:
Sonder / spezial
1) Quenchflüssigkeit bei Standardausführung, andere Quenchflüssigkeit nach Bedarf. Quench liquids regarding standard design, other quench liquids upon request.
Long term preservation of seepex Progressive cavity pumps
Dokument / document TI.114.01e Ausgabe / issue E / 19.11.08 Blatt / sheet 1 (3)
Scope Size Period of Storing > 3 months > 9 months 130-12 ... 500-6L > 3 months > 9 months 9 months 9 months Preservation acc. to. Measures for preservation 1 Measures for preservation 2 Measures for preservation 1 Measures for preservation 2
025-12 ... 130-6L
Description Measures for preservation 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)
Dokument / document TI.114.01e Ausgabe / issue E / 19.11.08 Blatt / sheet 2 (3)
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.
Recommissioning NOTICE Before starting work read the operating instruction. • Pay attention to a correct re-assembly of parts dismantled before.
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.
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 constant tempered at 10-15°C (max. 25°C) protected against light / stored in darkness (e.g. in a closed case or packed accordingly)
Dokument / document TI.114.01e Ausgabe / issue E / 19.11.08 Blatt / sheet 3 (3)
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): • • • 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. 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)
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.
Advices and annotations Guarantee-/Warranty claims cannot be derived from this document.
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.
BA.BUR.01e 1 (1) 08.07.98
Blatt sheet Datum date
Please read these instructions carefully. Contact BURGMANN if any points are unclear. Burgmann mechanical seals are precision-made, tested machine elements, special knowledge is required to operate them correctly. Pay due attention to the rules and regulations governing occupational safety, accident prevention, working with hazardous materials and normal usage. Before carrying out any work on a mechanical seal, make sure that the system has been shut down, is no loger pressurized and has cooled off. Conversions and changes to the seal are prohibited (seal failure, loss of warranty rights). Use original BURGMANN spare parts only. For your own safety, any repairs should be carried out by BURGMANN.
• • clean the seal compartment and examine for signs of damage. Check the installation and connection dimensions. Check the accuracy of the axial and radial run-out tolerance between the shaft and the casing. The shaft surface in the areas of dynamically loaded sealing elements (e.g. O-ring) should display a roughness depth of Rmax = 5 µm. Sealing surfaces for statically loaded O-rings are to be manufactured with a value of Rz = 10 µm or better. Any edges, shoulders and transitions which come into contact with the sealing elements (e.g. O-rings) during installation should be sufficiently chamfered or rounded off (e.g. 2 mm x 30° or in accordance with DIN 24960) Assemble under extra-clean conditions and with great care. Use no force! This could result in permanent deformations and broken ceramic parts. The sequence of steps for installing and dismantling a mechanical seal depends on the design of the machine in question. To reduce friction during assembly, wet all sliding surfaces for the O-rings with water or alcohol or lubricate with silicone grease. Note special instructions for storing and handling elastomer parts. Keep elastomer parts made of EP rubber away from lubricants based on mineral oil. When installing double PTFE-wrapped sealing rings, make sure that the joint of the outer sheath points away from the direction of assembly (A). Sharp bending of the PTFE foil will destroy the O-ring. Take plenty of time and use little force when assembling O-rings made of solid PTFE in order to avoid damage to other seal elements. Never apply lubricant to seal faces. Assemble in a completety dry, dust-free and clean condition.
Series M2, M3 Mechanical seals with conical springs are dependent on the direction of rotation. A clockwise rotating shaft requires a right-handed spring and vice versa (looking from the drive side). To ease fitting, push the conical spring onto the shaft whilst twisting the spring in the direction of its hand of coiling. Series MG Elastomer bellows seals are to be pushed onto the shaft using low-surface-tension water (addition of a detergent) and a screwing movement. Use no oil or grease! Apply pressure only on the corner rings. When you are finished with the assembly, check that the corner rings, the spring and the seal face fit correctly. Series M7, HJ Independent of the direction of rotation. Secure drive screws by applying Loctite 241 Series MFL Never compress a metal bellows seal to its solid height. Push the seal onto the shaft by applying force only to the bellows carrier, which is sealed with an O-ring. Evenly and gradually tighten any compression screws in sequence, maintaining an even gap between the compression ring and the drive collar. Seals with a pumping screw (e.g. M7F, M74F-D) are dependent on the direction of rotation. Note drawing specifications!
A Properly operated mechanical seal requires no maintenance but is subject to a certain wear. Single seals in tight compartments may require a suitably piped circulation of pumped medium across them to dissipate heat. Evacuate the air from the compartment carefully before putting into operation. Make sure the seal is completely immersed in liquid (or there will be a risk of dry running!)
for the purposes of the EC Machine Guideline, Annex IIB. Mechanical seals are intended for installation in, or assembly with, other machines and are unable to function independently. Operation of a mechanical seal is only permitted when the machine in question meets the requirements of the EC Machine Guideline (89/392/EEC). Applied harmonized standards: EN292 Part 1 + Part 2.
Form 1081/11.97.02
13.1 Manufacturer's documents / suppliers • available
B / 19.06.2008
OM.MDS.01e
Gear Units, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W
11226811 / EN
Important Notes................................................................................................. 4 Safety Notes ...................................................................................................... 6 Gear Unit Structure ........................................................................................... 9 3.1 Basic structure of helical gear units .......................................................... 9 3.2 Basicstructure of parallel shaft helical gear units.................................... 10 3.3 Basic structure of helical-bevel gear units .............................................. 11 3.4 Basic structure of helical-worm gear units .............................................. 12 3.5 Basic structure of SPIROPLAN® gear units ............................................ 13 3.6 Nameplate, unit designation ................................................................... 14 Mechanical Installation................................................................................... 15 4.1 Required tools / aids ............................................................................... 15 4.2 Prerequisites for assembly...................................................................... 15 4.3 Installing the gear unit............................................................................. 16 4.4 Gear unit with solid shaft......................................................................... 19 4.5 Torque arms for mounted gear units....................................................... 21 4.6 Mounted gear unit with keyway or splined hollow shaft .......................... 23 4.7 Mounted gear units with shrink disc........................................................ 27 4.8 Mounted gear units with TorqLOC® ........................................................ 30 4.9 AM adapter coupling ............................................................................... 36 4.10 AQ adapter coupling ............................................................................... 38 4.11 AD input shaft assembly ......................................................................... 40 Startup.............................................................................................................. 44 5.1 Startup of helical-worm and SPIROPLAN® W gear units........................ 44 5.2 Startup of helical, parallel shaft helical and helical-bevel gear units....... 44 Inspection and Maintenance .......................................................................... 45 6.1 Inspection and maintenance intervals..................................................... 45 6.2 Lubricant change intervals ...................................................................... 45 6.3 Inspection and maintenance of the gear unit .......................................... 46 6.4 Inspection / maintenance of AM / AQA adapters .................................... 47 6.5 Inspection / maintenance of AD adapters ............................................... 47 Malfunctions .................................................................................................... 48 7.1 Gear unit malfunctions ............................................................................ 48 7.2 AM / AQA / AL adapter malfunctions ...................................................... 48 7.3 AD input shaft assembly malfunctions .................................................... 49 Mounting Positions......................................................................................... 50 8.1 General information on mounting positions ............................................ 50 8.2 Key to the mounting position sheets ....................................................... 51 8.3 Mounting positions for R helical gearmotors........................................... 52 8.4 Mounting positions of RX helical gearmotors.......................................... 55 8.5 Mounting positions for parallel shaft helical gearmotors ......................... 57 8.6 Mounting positions for helical-bevel gearmotors..................................... 60 8.7 Mounting positions for helical-worm gearmotors .................................... 65 8.8 Mounting positions for SPIROPLAN® W gearmotors.............................. 71 Lubricants........................................................................................................ 74 9.1 Lubricant table ........................................................................................ 74 9.2 Lubricant fill quantities ............................................................................ 77 Appendix.......................................................................................................... 82 10.1 Index of changes..................................................................................... 82 Index................................................................................................................. 83
Operating Instructions – Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN® W
Always follow the safety and warning instructions in this publication!
Electrical hazard Possible consequences: Severe or fatal injuries.
Hazard Possible consequences: Severe or fatal injuries.
Hazardous situation Possible consequences: Slight or minor injuries.
Harmful situation Possible consequences: Damage to the drive and the environment.
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 gear unit! The operating instructions contain important information about servicing. Therefore, keep the operating instructions close to the gear unit. • Adjust the lubricant fill volume and position of the breather valve accordingly in the event of a change of mounting position (see Sec. "Lubricants" and "Mounting Positions"). Follow the instructions in Sec. "Mechanical installation" / "Installing the gear unit"!
Please follow the latest instructions: Dispose of the following materials in accordance with the regulations in force: • Steel scrap: – – – – – • • Housing parts Gears Shafts Anti-friction bearing Gray-cast iron (if there is no special collection)
Parts of the worm gears are made of non-ferrous metals. Dispose of the worm gears as appropriate. Collect waste oil and dispose of it correctly.
The following safety notes are primarily concerned with the use of gear units. If using gearmotors, please also refer to the safety notes for motors in the relevant operating instructions. Please also consider the supplementary safety notes in the individual sections of these operating instructions.
During and after operation, gearmotors, gear units and motors have: • • • • • • • • • • • • • • • • • Live parts Moving parts Hot surfaces (may be the case) Transportation Putting into storage Installation / assembly Connection Startup Maintenance Servicing 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 Improper use Incorrect installation or operation Unauthorized removal of necessary protection covers or the housing
Only qualified personnel may carry out the following work:
The following information and documents must be observed during these processes:
Serious injuries and property damage may result from:
Gearmotors / gear units from SEW are intended for industrial systems. They correspond to the applicable standards and regulations. Technical data and information about the permitted conditions can be found on the nameplate and in the documentation. It is essential that you follow all the instructions!
Inspect the shipment for any damage that may have occurred in transit as soon as you receive the delivery. Inform the shipping company immediately. It may be that you are not permitted to startup the drive due to the damage. Tighten installed eyebolts. The eyebolts are only designed for the weight of the gearmotor / gear unit. Do not attach any additional loads. The installed lifting eyebolts comply with DIN 580. The loads and regulations specified in this standard must always be observed. If two eyebolts are available, use both of them for transport. In this case, the tension force vector of the slings must not exceed a 45° angle in accordance with DIN 580. Use suitable, sufficiently rated handling equipment if necessary. Remove any transportation fixtures prior to startup.
Extended storage 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 CLP and 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 the oil level before startup (see Sec. "Inspection / Maintenance" / "Inspection and maintenance of the gear unit").
Comply with the storage conditions specified in the following table for extended storage:
Climate zone Packaging1) Packed in containers, with desiccant and moisture indicator sealed in the plastic wrap. Storage location Storage time Up to three years with regular checks on the packaging and moisture indicator (relative atmospheric humidity < 50 %). Two years or more given regular inspections. Check for cleanliness and mechanical damage as part of the inspection. Check corrosion protection. Up to three years with regular checks on the packaging and moisture indicator (relative atmospheric humidity < 50 %).
Temperate (Europe, USA, Canada, China and Russia, excluding tropical zones)
With roof, protected against rain and snow, no shock loads.
With roof, enclosed at constant temperature and atmospheric humidity (5 °C < ϑ < 60 °C, < 50 % relative atmospheric humidity). No sudden temperature fluctuations and controlled ventilation with filter (free from dirt and dust). No aggressive vapors and no shock loads.
Tropical (Asia, Africa, Central and South America, Australia, New Zealand excluding temperate zones)
Packed in containers, with desiccant and moisture indicator sealed in the plastic wrap. Protected against insect damage and mildew by chemical treatment.
With roof, protected against rain, no shock loads.
With roof, enclosed at constant temperature and atmospheric humidity (5 °C < ϑ < 60 °C, < 50 % relative atmospheric humidity). No sudden temperature fluctuations and controlled ventilation with filter (free from dirt and dust). No aggressive vapors and no shock loads. Protection against insect damage.
Two years or more given regular inspections. Check for cleanliness and mechanical damage as part of the inspection. Check corrosion protection.
1) Packaging must be performed by an experienced company using the packaging materials that have been expressly specified for the particular application.
Installation / assembly Startup / operation
Observe the instructions in the sections "Installation" and "Assembly/Removal"! Check that the direction of rotation is correct in decoupled status. Listen out for unusual grinding noises as the shaft rotates. Secure the shaft keys for test mode without drive components. Do not render monitoring and protection equipment inoperative even for test mode. Switch off the gearmotor if in doubt whenever changes occur in relation to normal operation (e.g. increased temperature, noise, vibration). Determine the cause; contact SEW-EURODRIVE if necessary.
Follow the instructions in the section "Inspection and Maintenance"!
Gear Unit Structure Basic structure of helical gear units
Gear Unit Structure
The following figures are block diagrams. Their purpose is only to make it easier to assign components to the spare parts lists. Discrepancies may occur depending on the gear unit size and version!
Basic structure of helical gear units
Figure 1: Basic structure of helical gear units
1 2 3 4 5 6 7 8 9 Pinion Gear Pinion shaft Gear Pinion shaft Gear Output shaft Key Oil seal 19 Key 20 Breather valve 22 Gearcase 24 Lifting eyebolt 25 Anti-friction bearing 30 Anti-friction bearing 31 Key 32 Spacer 34 Anti-friction bearing 37 Anti-friction bearing 39 Circlip 41 Circlip 42 43 45 47 59 88 100 101 102 131 181 506 Anti-friction bearing Key Anti-friction bearing Circlip Screw plug Circlip Gearcase cover Hex head bolt Gasket Closing cap Closing cap Shim ring 507 508 515 516 517 521 522 523 Shim ring Shim ring Shim ring Shim ring Shim ring Shim ring Shim ring Shim ring
11 Anti-friction bearing 12 Circlip 17 Spacer
Gear Unit Structure Basicstructure of parallel shaft helical gear units
Basicstructure of parallel shaft helical gear units
2 515 516 42 517 43 3 4 32 31 506 507 39 508 37 5 183 165 160 102 100 101 59 17 81 9 11 30 45 22 20 59 1 161 59
19 521 88 25 522 523
Figure 2: Basic structure of parallel shaft helical gear units
1 2 3 4 5 6 7 9 Pinion Gear Pinion shaft Gear Pinion shaft Gear Hollow shaft Oil seal 22 25 30 31 32 37 39 41 42 43 45 59 81 88 Gearcase Anti-friction bearing Anti-friction bearing Key Spacer Anti-friction bearing Circlip Circlip Anti-friction bearing Key Anti-friction bearing Screw plug O-ring Circlip 91 92 93 94 Circlip Washer Lock washer Hex head bolt 506 Shim ring 507 Shim ring 508 Shim ring 515 Shim ring 516 Shim ring 517 Shim ring 521 Shim ring 522 Shim ring 523 Shim ring
100 Gearcase cover 101 Hex head bolt 102 Gasket 131 Closing cap 160 Closing plug 161 Closing cap 165 Closing plug 181 Closing cap 183 Oil seal
11 Anti-friction bearing 14 Hex head bolt 16 Output flange 17 Spacer 19 Key 20 Breather valve
Gear Unit Structure Basic structure of helical-bevel gear units
Basic structure of helical-bevel gear units
102 536 3 43 537 538 20 533 534 535 22 45 2 114 113 42 119 (116) 523 89 59 522 88 521 19 8 6 7 84 25 1 59 59 59 59
161 132 133 542 30 543 544 135 5 4
37 506 507 137 508
Figure 3: Basic structure of helical-bevel gear units
1 2 3 4 5 6 7 8 9 Pinion Gear Pinion shaft Gear Pinion shaft Gear Output shaft Key Oil seal 25 Anti-friction bearing 30 Anti-friction bearing 31 Key 37 Anti-friction bearing 39 Circlip 42 Anti-friction bearing 43 Key 45 Anti-friction bearing 59 Screw plug 83 Nilos ring 84 Nilos ring 88 Circlip 89 Closing cap 100 Gearcase cover 101 Hex head bolt 102 Adhesive and sealing compound 113 Slotted round nut 114 Multi-tang washer 116 Thread lock 119 Spacer 131 Closing cap 132 Circlip 133 Spacer 135 Nilos ring 161 Closing cap 506 Shim ring 507 Shim ring 508 Shim ring 521 Shim ring 521 Shim ring 522 Shim ring 523 Shim ring 533 Shim ring 534 Shim ring 535 Shim ring 536 Shim ring 537 Shim ring 538 Shim ring 542 Shim ring 543 Shim ring 544 Shim ring
11 Anti-friction bearing 12 Circlip 17 Spacer 19 Key 20 Breather valve 22 Gearcase
Gear Unit Structure Basic structure of helical-worm gear units
Basic structure of helical-worm gear units
101 59 20 100
37 5 43 30 2 61
11 520 12 519 518
Figure 4: Basic structure of helical-worm gear units
1 2 5 6 7 9 11 12 19 Pinion Gear Worm Worm gear wheel Output shaft Oil seal Anti-friction bearing Circlip Key 20 22 25 30 37 39 43 59 61 Breather valve Gearcase Anti-friction bearing Anti-friction bearing Anti-friction bearing Circlip Key Screw plug Circlip 88 89 Circlip Closing cap 518 519 520 521 522 523 Shim ring Shim ring Shim ring Shim ring Shim ring Shim ring
100 Gearcase cover 101 Hex head bolt 102 Rubber seal 131 Closing cap 137 Spacer 506 Shim ring 507 Shim ring
Gear Unit Structure Basic structure of SPIROPLAN® gear units
Basic structure of SPIROPLAN® gear units
66 143 68 72
89 88 521 522 523
25 6 19 250 251 17 7
11 518 519 520
Figure 5: Basic structure of SPIROPLAN® gear units
1 6 7 8 9 11 12 17 Pinion Gear Output shaft Key Oil seal Anti-friction bearing Circlip Spacer 19 Key 22 Gearcase 25 Anti-friction bearing 65 Oil seal 66 Anti-friction bearing 71 Spacer 72 Circlip 143 Spacer 88 89 100 101 102 132 183 250 Circlip Closing cap Gearcase cover Hex head bolt Gasket Circlip Oil seal Circlip 251 518 519 520 521 522 523 Circlip Shim ring Shim ring Shim ring Shim ring Shim ring Shim ring
Gear Unit Structure Nameplate, unit designation
Nameplate, unit designation
Figure 6: Sample nameplate
fb FRa max FRe max i IM IP.. ne max na Me max Ma MR MRS = Service factor = Maximum overhung load on the output side = Maximum overhung load on the input side (with input shaft assembly AD) = Gear unit reduction ratio = Mounting position = Enclosure [1/min] = Maximum input speed [1/min] = Output speed [Nm] = Maximum input torque [Nm] = Output torque [Nm] = Overload torque when using an AR adapter [Nm] = Locking torque of the backstop [N] [N]
Unit designation Example: Helical gear unit, category II2GD
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)
Mechanical Installation Required tools / aids
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
Shaft end 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
Flanges Centering shoulder tolerance in accordance with DIN 42948 • ISO j6 with b1 ≤ 230 mm • ISO h6 with b1> 230 mm
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" (see standard). 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 load on the gear unit. [At η’ (retrodriving) = 2 – 1/η < 0.5 self-locking]
Mechanical Installation Installing the gear unit
You must clean the output shafts and flange surfaces thoroughly to ensure they are free of anti-corrosion agents, contamination or similar. Use a commercially available solvent. Do not let the solvent come into contact with the sealing lips of the oil seals – danger of damage to the material! When the drive is installed in abrasive ambient conditions, protect the output end oil seals against wear.
The gear unit or gearmotor is only allowed to be installed in the specified mounting position. 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 with reference to DIN ISO 1101): • • • • Gear unit size ≤ 67: max. 0.4 mm Gear unit size 77 ... 107: max. 0.5 mm Gear unit size 137 ... 147: max. 0.7 mm Gear unit size 157 ... 187: max. 0.8 mm
Do not tighten the housing legs and mounting flanges against one another and ensure that you comply with the permitted overhung and axial loads! Secure the gearmotors with bolts of quality 8.8. Secure the following gearmotors with bolts of quality 10.9: • • • RF37, R37F with flange ∅ 120 mm RF47, R47F with flange ∅ 140 mm RF57, R57F with flange ∅ 160 mm
The oil checking and drain screws and the breather valves must be freely accessible! At the same time, also check that the oil fill is as specified for the mounting position (see Sec. "Lubricants" / "Lubricant fill quantities" or refer to the information on the nameplate). The gear units are filled with the required oil volume at the factory. There may be slight deviations at the oil level plug as a result of the mounting position, which are permitted within the manufacturing tolerances.
Adjust the lubricant fill volumes and the position of the breather valve accordingly in the event of a change of mounting position. Please contact our SEW customer service if you change the mounting position of K gear units to M5 or M6 or between M5 and M6. Please contact our SEW customer service if you change the mounting position of size S47 S97 S gear units to mounting position M2. Use plastic inserts (2 ... 3 mm thick) if there is a risk of electrochemical corrosion between the gear unit and the driven machine. The material used must have an electrical bleeder resistor < 109 Ω. Electrochemical corrosion can occur between various metals, for example, cast iron and high-grade steel. Also install the bolts with plastic washers! Ground the housing additionally – use the grounding bolts on the motor.
Installation in damp locations or in the open
Drives are supplied in corrosion-resistant versions for use in damp areas or in the open air. 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 a suitable sealing compound, e.g. Loctite® 574.
Gear unit venting
No breather plug is required for the following gear units: • • • R07 in mounting positions M1, M2, M3, M5 and M6 R17, R27 and F27 in mounting positions M1, M3, M5 and M6 SPIROPLAN® W gear units
SEW-EURODRIVE supplies all other gear units with the breather valve installed and activated according to the particular mounting position. Exceptions: 1. SEW supplies the following gear units with a screw plug on the vent hole provided: • • • Gear units for extended storage Pivoted mounting positions, if possible Gear units for mounting on a slant
The breather valve is located in the motor terminal box. Before startup, you must replace the highest screw plug with the breather valve supplied. 2. SEW supplies a breather valve in a plastic bag for gear head units requiring venting on the input end. 3. Enclosed gear units are supplied without a breather valve.
Activating the breather valve
As a rule, the breather valve is already activated at the factory. If the breather valve has not been activated, you must remove the transport fixture from the breather valve before starting up the gear unit!
2. Remove the transport fixture 3. Breather valve activated
Painting the gear unit
If you paint or respray the drive, ensure that you cover the breather valve and oil seals carefully. Remove the strips of tape after completing the painting work.
Mechanical Installation Gear unit with solid shaft
Gear unit with solid shaft
The following figure shows a mounting device for installing couplings or hubs on gear unit or motor shaft ends. It may be possible to dispense with the thrust bearing on the mounting device.
Installing input and output elements
1) Gear shaft end 2) Thrust bearing 3) Coupling hub
Avoid impermissibly high overhung loads: Install the gear or chain sprocket according to figure B.
1 = Hub A = Unfavorable B = Correct
Only use a mounting device for installing input and output elements. Use the center bore and the thread on the shaft end for positioning. Never drive belt pulleys, couplings, pinions, etc. onto the shaft end by hitting them with a hammer This will damage the bearings, housing and the shaft! In the case of belt pulleys, make sure the belt is tensioned correctly in accordance with the manufacturer's instructions. Power transmission elements should be balanced after fitting and must not give rise to any impermissible radial or axial forces (see the "Gearmotor" or "Explosion-Proof Drives" catalogs for permitted values).
Note: Assembly is easier if you first apply lubricant to the output element or heat it up briefly (to 80 ... 100 °C).
Couplings must be mounted and balanced according to the information provided by the coupling manufacturer: a) Maximum and minimum clearance b) Axial misalignment c) Angular misalignment
Figure 7: Clearance and misalignment for coupling installation
Input and output elements such as belt pulleys, couplings, etc. must be protected against contact!
Mechanical Installation Torque arms for mounted gear units
Torque arms for mounted gear units
Do not place torque arms under strain during installation!
Figure 8: Torque arm for parallel shaft helical gear units
Bush with bearings on both ends → (1). Install connection end B as a mirror image of A.
Figure 9: Torque arm for helical-bevel gear units
Gear unit KA37 KA47 KA67 KA77 KA87 KA97 KA107 KA127 KA157 Bolts 4 × M10 × 25 – 8.8 4 × M10 × 30 – 8.8 4 × M12 × 35 – 8.8 4 × M16 × 40 – 8.8 4 × M16 × 45 – 8.8 4 × M20 × 50 – 8.8 4 × M24 × 60 – 8.8 4 × M36 × 130 – 8.8 4 × M36 × 130 – 8.8 Tightening torque 48 Nm 48 Nm 86 Nm 210 Nm 210 Nm 410 Nm 710 Nm 2500 Nm 2500 Nm
Bush with bearings on both ends → (1).
Figure 10: Torque arm for helical-worm gear units
Gear unit SA37 SA47 SA57 SA67 SA77 SA87 SA97 Bolts M6 × 16 – 8.8 M8 × 20 – 8.8 M8 × 20 – 8.8 M12 × 25 – 8.8 M12 × 35 – 8.8 M16 × 35 – 8.8 M16 × 35 – 8.8 Tightening torque 11 Nm 25 Nm 25 Nm 86 Nm 86 Nm 210 Nm 210 Nm
SPIROPLAN® W gear units
Bush with bearings on both ends → (1)
Figure 11: Torque arm for SPIROPLAN® W gear units
Gear unit WA10 WA20 WA30 Bolts M6 × 16 M6 × 16 M6 × 16
Tightening torque 11 Nm 11 Nm 11 Nm
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