5 Lubrication, Cooling and Heating · PDF file680 ISO-L-CKT 680 CLP HC 680 / CLP PG 680 AGMA 8...
Transcript of 5 Lubrication, Cooling and Heating · PDF file680 ISO-L-CKT 680 CLP HC 680 / CLP PG 680 AGMA 8...
Catalog – Helical and Bevel-Helical Gear Units Series X.. Horizontal 53
5Overview and termsLubrication, Cooling and Heating
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5 Lubrication, Cooling and Heating5.1 Overview and terms
The following combinations of lubrication and cooling types are possible.
X = Described in catalogO = Contact SEW-EURODRIVE.
5.1.1 Type of lubrication A basic concept for the type of lubrication has been specified for each SEW-EURODRIVE gear unit. Fundamentally, a combination of types is possible:
Splash lubricationThe oil level is low; gearing and bearing parts that are not immersed in the oil bath arelubricated by splashing oil. Standard lubrication type for horizontal mounting positions(M1 or M3).
Bath lubrication The gear unit is (almost) completely filled with oil; all gearing and bearing sockets areeither completely or partly submerged in the oil bath.• Standard lubrication type with oil compensator for:
– Swiveling mounting positions with horizontal gear units beyond a certaininclination angle (depending on type of gear unit, version and size)
– Vertical gear units (mounting position M5) (separate publication)– Upright mounting position (M4) (separate publication) with X.K gear units
• Standard lubrication type without oil compensator for:– Upright mounting position (M4) with X.F gear units (separate publication)
Pressure lubrication
The gear unit is equipped with a pump (shaft end pump or motor pump). The oil level islow and may even be reduced when compared to splash lubrication. The gearing andbearing parts that are not immersed in the oil bath are lubricated by oil throughlubrication piping.Pressure lubrication is used when• Splash lubrication is not possible (see the relevant mounting positions and variants
under "Bath lubrication")• Instead of bath lubrication, when that is not desired or is not thermally advantageous
(see the relevant mounting positions and variants)• A drywell is required (only with a vertical output shaft with LSS facing down, separate
publication)• High input speeds are present and the speed limit for other types of lubrication is
exceeded (dependant on the gear unit size, version, and number of stages)
Type of cooling
Type of lubrication Without Fan Integrated cooling Circulation cooling
Splash lubrication X X X X
Bath lubrication O O O O
Pressure lubrication O O O O
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5.1.2 Types of cooling:The following types of cooling are differentiated for the gear units:
Natural cooling The gear unit is cooled by natural convection.
Fan cooling A fan is installed on the gear unit input shaft; its airflow improves the transmission of heatfrom the gear unit surface to the environment (→ section 5.3.1)
Integrated cooler This refers to cooling systems installed directly in the gear unit housing or mounted veryclose to it, e.g. a water cooling cover (→ section 5.3.2) or a cooling cartridge (→ section5.3.3).
Circulation cooling
The gear unit oil is pumped out of the gear unit to an external heat exchanger by a pump(motor pump or shaft end pump). This normally involves oil supply systems with oil-water or oil-air heat exchangers.
5.1.3 Oil heaterAn oil heater pre-heats the gear unit oil using heating elements in the gear unit oil bath.Oil heating may be required to ensure lubrication at startup when the ambient tempera-ture is low (→ section 5.4).
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5.2 Selection of lubricants and accessories
5.2.1 General information on selecting oilUnless a special arrangement is made, SEW-EURODRIVE supplies drives without oilfill.
In addition to having the required viscosity, the oil must fulfill the following criteria:• CLP oils according to DIN 51517-3• Micro-pitting test according to FV VA F Proc. No. 54/ I-IV, GFT class high, damage
force level >10 must be fulfilled.
If synthetic oil is used, SEW-EURODRIVE recommends polyalphaolefin-based oil (CLPHC).
The oil viscosity and type (mineral/synthetic) that are to be used are determinedby SEW-EURODRIVE specifically for each order. This information is noted in theorder confirmation and on the gear unit's nameplate.You must contact SEW-EURODRIVE in case of a deviation from this specification.
That means that the gear unit must be filled with the correct oil grade and quantitybefore startup. The corresponding information can be found on the nameplate ofthe gear unit.
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Mineral oilStandards Lubrication oils are divided into ISO VG viscosity classes according to ISO 3448 and
DIN 51519.
Synthetic oilStandards Lubrication oils are divided into ISO VG viscosity classes according to ISO 3448 and
DIN 51519.
The same minimum requirements apply as for mineral oil.
ISO-Class
ISO 6743-6Description
DIN 51517-3Description
AGMA 9005-D94Description
150 ISO-L-CKC 150 DIN 51517-CLP 150 AGMA 4 EP
220 ISO-L-CKC 220 DIN 51517-CLP 220 AGMA 5 EP
320 ISO-L-CKC 320 DIN 51517-CLP 320 AGMA 6 EP
460 ISO-L-CKC 460 DIN 51517-CLP 460 AGMA 7 EP
680 ISO-L-CKC 680 DIN 51517-CLP 680 AGMA 8EP
Observe the operating temperature of the gear unit; oil change intervals may needto be shortened.If required, a cooling system must be used or the oil change interval must beshortened (see "Lubricant Change Intervals" in the operating instructions).
ISO-Class
ISO 6743-6Description
DIN 51519Description
AGMA 9005-D94Description
150 ISO-L-CKT 150 CLP HC 150 / CLP PG 150 AGMA 4 EP
220 ISO-L-CKT 220 CLP HC 220 / CLP PG 220 AGMA 5 EP
320 ISO-L-CKT 320 CLP HC 320 / CLP PG 320 AGMA 6 EP
460 ISO-L-CKT 460 CLP HC 460 / CLP PG 460 AGMA 7 EP
680 ISO-L-CKT 680 CLP HC 680 / CLP PG 680 AGMA 8 EP
Observe the operating temperature of the gear unit; oil change intervals may needto be shortened.If required, a cooling system must be used or the oil change interval must beshortened (see "Lubricant Change Intervals" in the operating instructions).
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5.2.2 Approved lubricantsNotes on the lubricant table
The lubricant table on the following page shows the approved lubricants for SEW-EURODRIVE gear units. Please refer to the following key for the lubricant table.
Key to the lubricant table
Abbreviations used, meaning of shading, and notes:
The standard for viscosity and oil type is the type of oil that is specified by SEW-EURODRIVE in the order (see order confirmation and nameplate).
Consult SEW-EURODRIVE if you use bio- and food grade lubricants or polyglycoloils.
CLP = Mineral oilCLP HC = Synthetic polyalphaolefin
= Synthetic lubricant = Mineral lubricant
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Lubricant table
OilOilOil
VG 150
Mobilgear
SHC XMP150
Mobilgear
XMP220VG 220
BP Energol
GR-XF 320
DIN (ISO)
ISO VG
class
CLP
CLP HC
CLP HC
CLP HC
CLP HC
CLP
Degol BG
150 Plus
Mobil®
Degol BG
220 Plus
Degol BG
320 Plus
Degol BG
460 Plus
Degol BG
680 Plus
BP Energol
GR-XF 150 Meropa 150
BP Energol
GR-XF 220
BP Energol
GR-XF 460
BP Energol
GR-XF 680
Optigear BM 150
Meropa 220
Meropa 320
Meropa 460
Shell
Omala F220
Shell
Omala F 320
Shell
Omala F460
Mobilgear
XMP320
Mobilgear
XMP460
Mobilgear
XMP680
KLÜBER
GEM 1-150N
KLÜBER
GEM 1-220N
KLÜBER
GEM 1-320N
KLÜBER
GEM 1-460N
KLÜBER
GEM 1-680N
Renolin
CLP150Plus
Renolin
CLP 220 Plus
Renolin
CLP 320 Plus
Renolin
CLP 460 Plus
Renolin
CLP 680 Plus
Goya NT 150
Goya NT 220
Goya NT 320
Goya NT 460
Goya NT 680
Alphamax 150
Alpha SP 150
VG 150
Degol
PAS 150
BP Enersyn
EP-XF 150 ELGreco 150
ELGreco 220
ELGreco 320
ELGreco 460
Klüber
GEM4-150N
Renolin
Unisyn CLP 150Carter
SH 150
Carter
EP 220
Degol
PAS 220
BP Enersyn
EP-XF 220
Optigear
Synthetic X 150
Tribol 1710/150
Tribol 1510/150
Optigear
Synthetic X 220
Optigear
Synthetic A 220
Tribol 1710/220
Tribol 1510/220
Optigear
Synthetic X 460
Optigear
Synthetic A 320
Tribol 1710/ 460
Tribol 1510/ 460
Optigear
Synthetic X 320
Tribol 1710/ 320
Tribol 1510/ 320
Tribol 1100/150
Optigear BM 220
Alphamax 220
Alpha SP 220
Tribol 1100/220
Optigear BM 320
Alphamax 320
Alpha SP 320
Tribol 1100/320
Optigear BM 460
Alphamax 460
Tribol 1100/460
Optigear BM 680
Alpha SP 680
Tribol 1100 / 680
Pinnacle
WM 150
Pinnacle
WM 220Shell Omala
Oil HD 220
Mobilgear
SHC XMP220Klüber
GEM4-220N
Renolin
Unisyn CLP 220Carter
SH 220
Degol
PAS 320BP Enersyn
EP-XF 320
Pinnacle
EP 320Shell Omala
Oil HD 320
Mobilgear
SHC XMP320
Mobil
SHC 632
Klüber
GEM4-320NRenolin
Unisyn CLP 320
Carter
EP 320
Carter
EP 460
Carter
EP 680
Carter
SH 320
VG 220
Degol
PAS 460
BP Enersyn
EP -XF 460Pinnacle
WM 460
Shell Omala
Oil HD 460
Mobilgear
SHC XMP460
Mobil
SHC 634
Klüber
GEM4-460N
Renolin
Unisyn CLP 460Carter
SH 460
Meropa 680
TO T A LO T A L
Q8
VG 460
CLP
CLP
VG 320CLP
VG 680
VG 460
VG 320
47 0490 105
X.K..X.F..
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5.2.3 Sealing greaseThe following overview shows the greases recommended by SEW-EURODRIVE.
Supplier Oil
Aral Aralub HLP2
BP Energrease LS-EPS
Castrol Spheerol EPL2
Chevron Dura-Lith EP2
Elf Epexa EP2
Esso Beacon EP2
Exxon Beacon EP2
Gulf Gulf crown Grease 2
Klber Centoplex EP2
Kuwait Q8 Rembrandt EP2
Mobil Mobilux EP2
Molub Alloy BRB-572
Optimol Olista Longtime 2
Shell Alvania EP2
Texaco Multifak EP2
Total Multis EP2
Tribol Tribol 3030-2
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5.2.4 Accessories
Visual oil level check on horizontal gear units with splash lubrication
Depending on the mounting position, SEW-EURODRIVE offers the following methodsof checking the oil level.
Gear unit venting When a gear unit is vented, non-permitted pressures, which arise from heating duringoperation, are avoided. The gear units are normally equipped with a high-qualitybreather with a filter mesh of 2 µm.
Oil drain The gear unit is normally equipped with an oil drain plug. An oil drain valve may beprovided as an option. This allows for a drain line to be easily attached when changingthe gear unit oil.
61540AXX
[1][2][3][4]
Position of the oil dipstick (optional)BreatherOil level glassOil drain
[2]
[1]
[3]
[4]
Mounting position Oil level check
M1 Oil level glass or oil dipstick (optional)
M3 Oil dipstick
M1 / M3 Two oil dipsticks
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5.3 CoolingIf the permitted thermal rating of the gear unit is exceeded, additional cooling measuresmust be applied.The following cooling methods are possible as standard:• Fan on the input shaft (only on X2.. and X3 gear units)• Water cooling cover (only on X2F.. gear units)• Water cooling cartridge• A fan in combination with a water cooling cover (only X2F.. ≤ 210) and cartridge• Circulation cooling with oil-water cooler with a motor pump
5.3.1 FanFans with optimized noise and flow engineering geometry are used. To raise the thermalrating or when the ambient conditions change after gear unit startup, a fan may be retro-fitted. The direction of rotation of the gear unit does not influence the operation of thefan.
Make sure that the air intake is not blocked or covered.
Information about the fan regarding dimensions, position and clear air intake isfound in the dimension diagrams (→ sections 10 and 11).
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SEW offers the following fan variants:X.F.. Fan (standard)
X.K.. Fan (standard)
X.K.. Advanced (option)
When the X3K Advanced version is used, the connection element (e.g. hydraulic cen-trifugal coupling) can be mounted flush on the fan guard.The air intake that must be kept clear is integrated into the fan guard.
60683AXX
[1] Keep the air intake clear
[1]
[1]
60684AXX
[1] Keep the air intake clear
[1]
[1]
60685AXX
[1] Keep the air intake clear
[1]
[1]
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5.3.2 Water cooling coverThe water cooling cover is located on the gear unit's assembly opening and is providedwith cooling water through a water connection that is provided by the operator. It isavailable for gear unit sizes X.180 to X. 210. The amount of heat that can be carried away depends on the inlet temperature and thevolume flow of the cooling medium flowing through it. It is offset in the thermal limit tables(→ sections 10.2 and 11.2).
Structure The water cooling cover [1] is made of a corrosion-resistant aluminum alloy.Two bores (G1/2") with pipe threads are available to connect to the cooling circuit. Thepiping is not included in the scope of delivery.Gear units in the water cooling cover version are delivered completely assembled.Gear units without water cooling covers may be retro-fitted; consult SEW-EURODRIVE.
Contact SEW-EURODRIVE if chemically aggressive cooling media, such as brackish orsalt water, are used.
The connection sizes are found in the data sheets in sections 10.3 and 11.3.
60982AXX
[1][2][3]
Water cooling coverInflowReturn
[1][1][2] [3]
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5.3.3 Water cooling cartridgeThe water cooling cartridge is mounted in the gear unit's oil sump and is provided withcooling water through a water connection that this provided by the operator. It isavailable for gear unit sizes X.180 to X. 250. The amount of heat that can be carried away depends on the inlet temperature and thevolume flow of the cooling medium flowing through it. It is offset in the thermal rating ta-bles (→ sections 10.2 and 11.2).
Structure The water cooling cartridge consists of two basic parts:• Cooling pipes (CuNi alloy)• Connection piece (brass)
Two bores (G1/2") with pipe threads are available to connect to the cooling circuit. Thepiping is not included in the scope of delivery.Gear units in the water cooling cartridge version are delivered completely assembled.Gear units without water cooling cartridges may possibly be retrofitted; consult SEW-EURODRIVE.
Contact SEW-EURODRIVE if chemically aggressive cooling media, such as brackish orsalt water, are used.
The connection sizes are found in the data sheets in sections 10.3 and 11.3.
60978AXX
[1][2][3][4]
Cooling pipes Connection pieceInflowReturn
[2][1][3] [4][4] [3]
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5.3.4 Oil/water cooler with motor pumpAn oil-water cooling system by be used if the thermal rating of the naturally cooled gearunit or cooling using a fan on the input shaft is not sufficient. The prerequisite for usingan oil-water cooling system is that appropriate cooling water is available on site.
Structure The cooling system consists of the following:• Pump with directly mounted asynchronous motor• Oil/water heat exchanger• Temperature switch with two switching points for
• Controlled startup of the motor pump with an oil temperature of 40 °C.• Monitoring of the cooling group, i.e. warning or gear unit shutdown when the oil
temperature reaches 90 °C.
The cooling system is delivered as a complete unit, but without electrical connections.The following versions are possible:• Directly mounted on the gear unit, including cooling circuit piping, or• On the mounting frame, for separate installation, but without piping
Contact SEW-EURODRIVE if chemically aggressive cooling media, such as brackish orsalt water, are used.
The following versions apply for gear units with splash lubrication. The cooling systemwith a motor pump only cools the gear unit oil.
61639AXX
[1] Pump with motor [5] Oil return
[2] Oil-water heat exchanger [6] Cooling water inflow
[3] Temperature switch with two switching points [7] Cooling water return
[4] Oil suction
M
[1]
[2]
[3]
[1]
[2][3] [7]
[6]
[4]
[5]
[4] [5]
[6]
[7]
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Further instrumentation available on request, such as:• Flow monitoring• Thermostatic valve in the oil and/or water circuit• Filter in the oil circuit
Sizes, cooling capacity and selection
The power data of the cooling systems that can be used is summarized in the followingtable.
The cooling capacities given apply for cooling water temperature of 20 °C with oil tem-perature of 60 °C and equivalent volume flows of oil and cooling water.
The selection tables (→ sections 10.2 and 11.2) contain our recommendations forselecting an appropriate cooling system based on gear unit version, size and gear unitreduction ratio.In addition, the selection of an appropriate cooling system is also dependent on thefollowing factors:• The actual power loss to be cooled• The cooling water temperature and flow volume available• The maximum ratio oil volume in the gear unit / flow volume of the cooling system > 2
When selecting the appropriate cooling system based on the ambient conditions presentfor your system, consult SEW-EURODRIVE.
SizeCooling system
Cooling capacityCooling system
[kW]
Flow volumeCooling system
[l/min]
Connection powerPump motor
[kW]
A 3.5 7.5 0.75
B 4.7 10 0.75
C 8.5 20 1.5
D 13 30 1.5
E 19 45 2.2
F 26 60 3
G 31 75 4
H 50 100 5.5
I 62 150 7.5
We will send you dimensions and detailed technical data of the various cooling systemsupon request.
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5.4 Oil heaterAn oil heater is required to ensure lubrication at startup.
5.4.1 DesignThe oil heater consists of two main parts:1. Resistor in the oil bath ("oil heater") with terminal box2. Temperature sensor with thermostat
60792AXX
[1] Oil heater
[2] Temperature sensor with thermostat
[2]
[1]
In order to prevent damage, it is essential that the heating elements are fullyimmersed in the oil bath.
The position of the thermostat and the temperature sensor varies with design andmounting position of the gear unit.
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5.4.2 Connection powerThe table below shows the power of the heaters that may be installed.
Pinst Pinst
Gear units 1H 2H
Size Version [kW] [K/h] [kW] [K/h]
180X2F.., X3K.., X3F.., X4K.. 1 x 1.6 4.2 2 x 1.6 14
X4F.. 1 x 1.1 2.9 2 x 1.1 9
190X2F.., X3K.., X3F.., X4K.. 1 x 1.6 4.1 - -
X4F.. 1 x 1.1 2.8 - -
200X2F.., X3K.., X3F.., X4K.. 1 x 1.9 4.0 2 x 1.9 13
X4F.. 1 x 1.3 2.7 2 x 1.3 9
210X2F.., X3K.., X3F.., X4K.. 1 x 1.9 3.9 - -
X4F.. 1 x 1.3 2.6 - -
220 X2F.., X3F.., X4F.., X3K.., X4K.. 1 x 2.25 3.7 2 x 2.25 12
230 X2F.., X3F.., X4F.., X3K.., X4K.. 1 x 2.25 3.7 - -
240 X2F.., X3F.., X4F.., X3K.., X4K.. 1 x 2.25 3.1 2 x 2.25 9
250 X2F.., X3F.., X4F.., X3K.., X4K.. 1 x 2.6 3.6 - -
1H = 1 heater
2H = 2 heaters
[K/h] = Heating power [Kelvins/hour]
Pinst = Power of the installed heater
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5.4.3 Limit temperatures for gear unit startup with splash lubricationThe minimum permissible ambient temperature for gear unit startup depends on thepour point of the oil that is used.
The table below shows the limit temperatures for gear unit startup (with and withoutheater).
Mineral oil
Synthetic oil
5.4.4 Operating notes• The oil heater's thermostat is set at the respective limit temperature at the factory.• The oil heater turns off when the set temperature is exceeded by 8 to 10 K.• The thermostat and oil heater are installed on the gear unit and ready for operation,
but they must be connected to the external power supply before startup.• Contact SEW-EURODRIVE if a differing oil viscosity class is used or if ambient
temperatures fall below the identified limit temperature.• Depending on the switching point, the resistor element may be controlled directly or
through a contactor. When connected in parallel, the switching power of the thermo-stat must be considered.
Gear units Version ISO VG320 ISO VG220 ISO VG150
XF180 - XF250
Without heater 10 °C 15 °C 20 °C
With heater(1 heater) 28 °C 33 °C 40 °C
With heater(2 heaters) 40 °C 40 °C 40 °C
Gear units Version ISO VG320 ISO VG220 ISO VG150
XF180 - XF250Without heater 35 °C 40 °C 40 °C
With heater(1 heater or 2 heaters) 40 °C 40 °C 40 °C
The temperatures specified refer to the average values of the permitted lubricants basedon the lubricant table (→ section 5.2.2). In borderline cases, the permitted temperatureof the lubricant that is actually being used must be verified. When planning the motor, observe the increased starting torque at low temperatures. Itmay be necessary to contact SEW-EURODRIVE.