Seepex BN 5-12 Series Operation & Maintenance Manual
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Seepex BN 5-12 Series Operation & Maintenance Manual

Progressive cavity pump
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Progressive Cavity Pump Operation & Maintenance Manual
Supply of SEEPEX, Inc. pumps & accessories: consisting of engineering drawings,
descriptive literature, operating data and related information.
Orange County Sanitation District Sludge Dewatering & Odor Control-Plant #1
Specifications Section: 11309 Progressing Cavity Pumps
Denomination:
Active Dilute Polymer Pump
For the Supply of SEEPEX Pumps & Accessories
To:
W.M. Lyles Co. Contractors
42142 Roick Dr.
Temecula, CA 92590
Phone#: 661-301-7266
Attn: Grant Gourley,
ggourley@wmlylesco.com
Project:
PO#: T1113-20
seepex Job#: 2115517
Equipment No:
Pump Type:
BN 5-12
Represented By:
Cortech Engineering
22785 Savi Ranch Pkwy.
Yorba Linda, CA 92887
Phone#: 714-779-0911, Fax#: 714-693-1715
Attn: Marc Sanchez,
marc@cortechpumps.com
By:
SEEPEX , Inc.
511 Speedway Dr.
Enon, OH 45323
Phone#: 937-864-7150, Fax#: 937-864-7157
January 2015
Page 1
Commission#:
835294-296
15LPMP810, 820 & 830
 
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  • Page 1 Progressive Cavity Pump Operation & Maintenance Manual Supply of SEEPEX, Inc. pumps & accessories: consisting of engineering drawings, descriptive literature, operating data and related information. For the Supply of SEEPEX Pumps & Accessories W.M. Lyles Co. Contractors 42142 Roick Dr.
  • Page 2 This documentation must be kept available for at If modifications to the machines are least 10 years. carried out in agreement with seepex, a new set of operating instructions will be provided, or the existing operating instructions will be supplemented by an additional sheet together with a new cover sheet.
  • Page 3 1.2.13 Operating Range Employment of the machine is not permissible for purposes other than those stated in the data sheet, see Point 9. seepex cannot accept liability for damage arising through failure to comply with this operating range. Supplementary Information 1.3.1...
  • Page 4 Safety Safety Personnel Qualifications and Training These operating instructions contain basic require- Personnel charged with operation, maintenance, ments to be observed during the installation, opera- inspection and assembly must be in possession tion and maintenance of the machine. Therefore, the of the appropriate qualifications for the tasks.
  • Page 5 Safety Safety Instructions for the Operating Unauthorized Modification and Manufacture of Company/Machine Operator Replacement Parts - Any potentially hazardous hot or cold machine Conversions or modifications of the machine are parts must be provided with protection against permissible only in consultation with the manu- accidental contact at the customer´s premises.
  • Page 6 Employ appropriate transport means, hoists and tools when transporting and storing the machine, always observing the safety instructions. Transport Depending on its weight, the seepex machine must be transported manually or with appropriate trans- port means. Comply with the transport instructions on the packing.
  • Page 7 Refer to the data sheet, Point 9, for the design of the seepex progressive cavity pump. Other design General Description, Design and Mode of Operation variants are possible, whereby seepex must first check whether a particular pump is suitable for the Like all progressive cavity pumps, seepex pumps intended purpose.
  • Page 8 Ensure also that the pipe work can be dismounted at The customer must check the dimensions and weight this location too. of the seepex progressive cavity pump to ascertain whether the available hoisting apparatus is sufficient for the assembly and fitting of the pump.
  • Page 9 The technical description is given under Point 9. For this reason we recommend the purchase of the complete drive, including frequency inverter, from seepex, so that the frequency inverter can be tuned on the seepex test field along with a trial run. Ausgabe Dokument Blatt B / 02.01.2006...
  • Page 10 Performance Check 6.2.1.2 Any optional extras must be subjected to a See manufacturer's documents, Point 10, for drive performance check in conformity with the bearings. specifications by seepex or other manufacturers, see manufacturer's documents. 6.2.2 Shaft Sealing 6.3.2 Setting See document OM.SEA.__,.
  • Page 11 If a continuous flow cannot be guaranteed for the Machines must be fitted with mechanical plant, it is essential to fit the seepex dry running protective devices complying with DIN EN protection device TSE, available as an optional 809.
  • Page 12 The pump must be preserved prior to storage. casing by opening/ removing the Appropriate preservation measures must be agreed screwed sealing plugs (705) and (502), with seepex. Always state the pump commission sealing rings (706) and (503). Casings number when making inquiries. without screwed plug must be evacuated by the connection branch (SAG and DRS).
  • Page 13 TAB 1 – DEVICE DATA SHEETS...
  • Page 14 W.M. Lyles seepex job no. 2115517 offer/item: 5383/0167 item 4 Amend. 1 project PO# T1113-20 3 of seepex progressive cavity pump type BN 5-12 / A6-A7-A7-H0-IE-X X=08E4, 20A7 conveying product U/495/CH denomination active dilute polymer rate of solids <0.5% viscosity ass.
  • Page 15 Data Sheet 835294-835296 Page 2 general operating data kind of operation continuous operation site of installation indoors dry atmosphere remarks drive type Gearbox make ratio i= 4.34 model RF47AM213RS nom./ min- max mounting position M1 (B5) output speed 403 / 225 – 417 flange dia 160 mm motor speed...
  • Page 16 Data Sheet 835294-835296 Page 3 pressure switch and gauge assembly (suction) quantity 1 per pump diaphragm seal manufacturer Onyx model top material 316 SS connection size 1” NPT bottom material 316 SS fill fluid silicone instrument oil diaphragm material Viton w/ Teflon coating special features flush port, ¼”...
  • Page 17 Data Sheet 835294-835296 Page 4 Seismic calculations provided under separate informational submittal. anchor bolts Hilti HAS-R 316 ¾”x9-5/8” anchor rod (2045010), quantity 6 (each pump). Seal flush parts to be supplied loose: (installed in the field by contractor) Qty. Qty. per pump Part no.
  • Page 18 TAB 2 – APPROVED SUBMITTAL...
  • Page 19 Motors | Automation | Energy | Transmission & Distribution | Coatings Severe Duty is Standard with WEG W22 motors. You do not need a special motor for severe duty. Severe Duty is standard with WEG W22 motors. USAW22SEVDUTY...
  • Page 20 www.weg.net You do not need a special motor for severe duty. Severe Duty is standard with WEG. Features that make a difference: All NEMA Premium ratings have a 1.25 service factor (up to 100 HP) resulting in cooler operation and extended life of the motor All Cast Iron Construction, including Terminal Box and Fan Cover (*) Solid feet for reduced vibration levels and impact absortion Optimized ventilation system for cooler operation and extended life...
  • Page 21 www.weg.net www.weg.net Severe Duty is standard with WEG. SEVERE DUTY/ GENERAL PURPOSE – NEMA PREMIUM EFFICIENCY   FEATURES – ELECTRICAL Features Standard Optional Special Poles 2 up to 8 – – 208–230/460V (up to 215T–9 terminals and from Voltage 575V and others –...
  • Page 22 www.weg.net WITH W22 MOTORS SEVERE DUTY IS STANDARD Epact Efficiency NEMA Premium Efficiency SEVERE DUTY - THREE PHASE Super Premium Efficiency TEFC – Foot Mount, CONTINUED NEMA Mult. Approx. Shipping Service “C” Dimension Catalog Number List Price FL Amps FL. Eff (%) Voltage (V) Notes Frame...
  • Page 23 www.weg.net 1-800-ASK-4WEG All data subject to change without notice...
  • Page 24 www.weg.net Catalog Notes: 1.0 Service Factor Product Might Not be Available in Stock Roller Bearing Z-Frame; Bigger Shaft Diameter and Bearings 105K Tempature Rise High Efficiency (EPACT) W22 Severe Duty All data subject to change without notice...
  • Page 25 www.weg.net WEG Electric Corp. offers the following products, and more! With a full range of IEC/NEMA Global Certifications and a full line of products, WEG can supply the right solution for your needs anywhere in the world. To learn more about WEG’s products and solutions or to locate a Distributor near you, please call 1-800-ASK-4WEG or visit www.weg.net/us.
  • Page 26 Your advantages: our pumps.
  • Page 27 Our company, headquartered in Bottrop, Germany, has a presence in over 50 countries. Today, over 400 of the more than 700 seepex employees worldwide are working in Bottrop on the development, manufacture and sale of progressive cavity pumps, macerators and controlling systems. In add ition...
  • Page 28 Molded-to-size – the stator design Different geometries allow the pumps to be optimally designed seepex stators are built for every size and pressure stage. With for the most diverse applications. The most economical solution their precise geometry and a multitude of elastomers, they...
  • Page 29 Your conveying solution. Joint connection consisting of just 5 components. Power transmission through wear resistant, hardened and replaceable joint parts: easily repaired. Pressure branch Dry running protection TSE, thermoelectronic prevents the stator from being damaged by dry running, optional available. Tie bolts/screws Universal joint sleeve protection Stator...
  • Page 30 Universal joint sleeve with holding bands Shaft seal with gland packing or a variety of mechanical seals Drive geared motors, variable speed drives or hydraulic motors of all major manufacturers, directly flanged to the pump without additional couplings or guards. Lantern Suction casing Plug-in shaft...
  • Page 31 • Transport of sealing • Breweries compounds and protective coatings Pharmaceutical/Cosmetic • Waste oil disposal Industry • Paint and enamel • Dryer feeding processing • Metering of additives • Filling of end products Further application areas are listed at www.seepex.com...
  • Page 32 An overview of the rotor/stator geometries. The diversity of customer requirements demand made-to-order solutions. Which is why we will supply the correct rotor/stator geometry – whatever the application. The right geometry is selected on the basis of the conveying capacity, the pressure and the substance being transported.
  • Page 33 The geometries in detail: 6L, conventional, Tricam. The essential difference between the individual geometries can best be represented by the following formulas. The theoretical conveying capacity of the 6L and the = 4e · d · 2s · n · 60 conventional geometry is calculated as follows: = A ·...
  • Page 34 Constant conveying capacities 6L geometry, single stage Due to a smaller rotor diameter, the seepex 6L geometry results in surface velocities, which are lower than the single helix conventional geometry by about 20 %, when operating at the same pump speed. This results in a significant extension to the service life of the rotor and stator.
  • Page 35 An overview of the pump designs. Ever higher demands on conveyance, spending cuts and a lack of space in the industrial sector have meant that progressive cavity pump designs have been continually enhanced. The connection from the drive to the pump is one element that has been further developed.
  • Page 36 In our block design pumps, the drive is flanged directly to the pump. This design is selected for the correct axial load, shaft dimensions and flange dimensions, so that seepex pumps of all sizes and pressure stages can be delivered in block design.
  • Page 37 The plug-in shaft connection. The plug-in connection between the shaft seal and the drive unit or drive casing makes maintenance work much easier. For example when • replacing rotor and joint parts • replacing the plug-in shaft in the sealing area •...
  • Page 38 An overview of the joint designs. As our pumps are used in virtually all areas of industries, they have to be equipped to meet requirements in different situa- tions. There are actually a total of four joint designs to choose from –...
  • Page 39 The pin joint in detail. Optimum NPSH value Fluid-tight design for long-term operation Our pumps are equipped with two joints, to enable the eccen- The joint is thus optimally protected against penetration by the tric motion of the rotor and to transfer the rotation by means usually abrasive product being pumped.
  • Page 40 The rotor and its principle of operation. Rotors from seepex, as the rotating core of our pumps, are seepex design Industry standard as individual as your pumping process. Along with the vari- ous basic geometries, it is the material qualities, the different...
  • Page 41 An even compres- sion between the two main pump elements is crucial. Unlike stators made from cylindrical cores, which have a strong pull-in area at only the middle, seepex stators are made from Adjusted Not adjusted...
  • Page 42 The stator – readjustable. The function of our retensioning device is to extend the Stator retensioning device with natural wearing of the stator. It allows you to significantly eight tie bolts for even retensioning increase the life of the stator. of the stator The principle is simple: The stator used with the retensioning device is fitted with axial slots, which guarantee even radial...
  • Page 43 Longer service life “Smart Conveying Technology” (SCT) is the result of the con- tinuous development of the established seepex stator tech- nologies. It offers a longer service life for the rotor and stator, due to the integrated retensioning device, simple exchange of pumping elements without dismantling the pump, and time and costs savings of up to 30 %.
  • Page 44 The dry running protection TSE. With its unique functional principle, this optional device, which has been developed and patented by seepex for all our progressive cavity pumps, offers completely reliable protection against dry running – the most common cause of downtime with a progressive cavity pump.
  • Page 45 And what can we get flowing for you? Your nearest contact: Or visit www.seepex.com...
  • Page 46 No.: Date: 04-APR-2014 Customer TECHNICAL PROPOSAL Three-phase induction motor - Squirrel cage rotor : W22 NEMA Premium - Ball Bearings Product line Catalog Number : 00718ET3E213TC-W22 List Price : $ Contact Us! Notes: Performed by: Checked:...
  • Page 47 No.: Date: 04-APR-2014 DATA SHEET Three-phase induction motor - Squirrel cage rotor Customer Product line : W22 NEMA Premium - Ball Bearings Frame : 213/5T Output : 7.5 HP Frequency : 60 Hz Poles Full load speed : 1765 Slip : 1.94 % Voltage : 208-230/460 V...
  • Page 48 No.: Date: 04-APR-2014 PERFORMANCE CURVES RELATED TO RATED OUTPUT Three-phase induction motor - Squirrel cage rotor 90 100 110 120 130 Percent of rated output (%) Customer : W22 NEMA Premium - Ball Bearings Product line Frame : 213/5T Locked rotor current (Il/In) : 7.1 Output : 7.5 HP...
  • Page 49 No.: Date: 04-APR-2014 CHARACTERISTIC CURVES RELATED TO SPEED Three-phase induction motor - Squirrel cage rotor 10.0 Speed related to rated speed (%) Customer : W22 NEMA Premium - Ball Bearings Product line Frame : 213/5T Locked rotor current (Il/In) : 7.1 Output : 7.5 HP Duty cycle...
  • Page 50 Notes: 8.500 1.772 9.764 10.669 8.583 Performed by: 5.500/7.000 2.165 8.858 3.500 5.921 Checked: 1.375 3.375 2.480 0.313 1.203 depth Customer: 0.313 5.250 0.669 2.985 10.841 W22 NEMA Premium - Ball Bearings 1.772 5.250 7.000 3.150 0.406 19.517 22.546 5.512 5.236 NPT 1"...
  • Page 51 LOW VOLTAGE HIGH VOLTAGE Notes: Performed by: Checked: Customer: W22 NEMA Premium - Ball Bearings Three-phase induction motor 04-APR-2014 Frame 213/5T - IP55...
  • Page 53 BN 5‐12 , commission #835294‐296 Characteristic Curve Size: 5-12 24 gpm Q: 104 PSI 12 gpm BHP: 104 PSI (2.9Hp) (1.5Hp) Starting Torque =59 lb.ft. Speed RPM Values based upon water 68 F:For notes on drive selection refer to PER...
  • Page 54 NPSH Calculation Dokument / document TI.122.01us Ausgabe / issue M / 15.04.10 Blatt / sheet 1 (2) type constant c type constant c 0005-24 3,1076 52-6L 0,0194 0015-24 1,7972 52-6LS 0,0177 003-12 1,4381 52-12 0,0127 003-24 1,4229 55-6LT 0,0432 006-12 0,9558 55-12T 0,0278...
  • Page 55 NPSH Calculation Dokument / document TI.122.01us Ausgabe / issue M / 15.04.10 Blatt / sheet 2 (2) 35,0 34,0 33,0 32,0 31,0 30,0 29,0 28,0 27,0 26,0 25,0 24,0 23,0 22,0 21,0 20,0 19,0 18,0 17,0 16,0 15,0 14,0 13,0 12,0 11,0 10,0...
  • Page 56 Customer Position / Item Reference Pump Type BN 5-12 / Norm. Min. Max. Nenn. Capacity 23.08 USGPM Differential pressure Pump speed Allowed speed min Allowed speed max 1000 1000 1000 Operating power * [Pb] 1.53 2.85 2.74 Operating torque [Mb] lb.ft NPSHr value 2.13...
  • Page 57 2013 / 10 / 08 Michael Kreitzer / SEW USA, Troy Customer: SEEPEX Project: RF47AM213 Gear unit recalculation For rated operation RF47AM213/215 = 4.34 = 2,98 amax = 417,41 1/min = 1.810 1/min Output side: A = 49 Nm = 11,98 Nm...
  • Page 58 Rotor Material   Thickening Polymer Feed Pumps (C/N: 835294‐835296)   Dewatering Polymer Feed Pumps (C/N: 835300‐835302)    o Material: ANSI 316ti  o Coating: none  o Hardness: 76‐95 HRB ...
  • Page 59 316Ti/1.4571 SERVICING THE OIL & GAS INDUSTRY FOR OVER 30 YEARS 316Ti/1.4571 precipitation occurring. The presence of Titanium gives some improvements to mechanical strength especially Type 316L Ti is an improved corrosion resistant chrome- at elevated temperatures. nickel steel alloy with high content of Molybdenum and some Titanium.
  • Page 60 Stator Material   Thickening Polymer Feed Pumps (C/N: 835294‐835296)   Dewatering Polymer Feed Pumps (C/N: 835300‐835302)    o Material: HO; Fluoroelastomer (FKM)  o Hardness: Shore “A” 70‐76 Durometer  o Bonding: Chemlok 5150 chemically bonded to a mild steel drawn‐on‐mandrill tube that  has been chemically cleaned, descaled and prepared according to requirements of the  adhesive manufacturer.  Elastomer is injection molded and molded‐to‐size with integral  gaskets on each end of the stator.    ...
  • Page 61 OK for #4-#6 not use on oils that are above 25° API fuel oils. Same as F0 (NBR) The seepex material is unique as it is filled with silica and Most food products where the most white elastomers are filled with...
  • Page 62 Immersion tests always recommended Special Materials (May be stocked as finished parts for some customers. Elastomer is special order from the seepex supplier. If the parts has never been made before, special tooling AND minimum order size or tooling charges may apply.
  • Page 67 MATERIAL SAFETY DATA SHEET 1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION Product name: CHEMLOK 5150 Product Use/Class: ADHESIVE TRANSPORTATION EMERGENCY: LORD CORPORATION CHEMTREC 24 HR EMERGENCY NO. 111 LORD DRIVE 800 424-9300 (Outside Continental U.S. 703 527-3887) CARY, NC 27511-7923 NON-TRANSPORTATION EMERGENCY: INFORMATION TELEPHONE: 814 763-2345 814 868-0924...
  • Page 68 Product: CHEMLOK 5150, Effective Date: 12/21/2009 solvent overexposure may result in permanent central nervous system damage. May affect the gastrointestinal system. Prolonged or repeated contact may result in dermatitis. ACGIH considers Ethyl alcohol to be an A3 carcinogen (confirmed animal carcinogen with unknown relevance in humans). PRIMARY ROUTE(S) OF ENTRY: Skin Contact, Skin Absorption, Inhalation, Ingestion, Eye Contact 4.
  • Page 69 Product: CHEMLOK 5150, Effective Date: 12/21/2009 8. EXPOSURE CONTROLS / PERSONAL PROTECTION ENGINEERING CONTROLS: Sufficient ventilation in pattern and volume should be provided in order to maintain air contaminant levels below recommended exposure limits. Caution: Solvent vapors are heavier than air and collect in lower levels of the work area.
  • Page 70 Product: CHEMLOK 5150, Effective Date: 12/21/2009 12. ECOLOGICAL INFORMATION ECOLOGICAL INFORMATION: No Information 13. DISPOSAL CONSIDERATIONS DISPOSAL METHOD: Disposal should be done in accordance with Federal (40CFR Part 261), state and local environmental control regulations. If waste is determined to be hazardous, use licensed hazardous waste transporter and disposal facility.
  • Page 71 Product: CHEMLOK 5150, Effective Date: 12/21/2009 VOLATILE ORGANIC COMPOUNDS Calculated: 6.29 lb/gal, 753 g/l LEGEND: N.A. - Not Applicable, N.E. - Not Established, N.D. - Not Determined DISCLAIMER The information contained herein is, to the best of our knowledge and belief, accurate. However, since the conditions of handling and use are beyond our control, we make no guarantee of results, and assume no liability for damages incurred by use of this material.
  • Page 80 4.53 Industrial ® MACROPOXY & FAST CURE EPOXY Marine Coatings B58-600 ERIES B58V600 ARDENER PRODUCT INFORMATION Revised 9/07 RODUCT ESCRIPTION ECOMMENDED MACROPOXY 646 FAST CURE EPOXY is a high solids, high • Marine applications build, fast drying, polyamide epoxy designed to protect steel •...
  • Page 81 4.53 Industrial ® MACROPOXY & FAST CURE EPOXY Marine Coatings B58-600 ERIES B58V600 ARDENER PRODUCT INFORMATION ECOMMENDED YSTEMS URFACE REPARATION Immersion and atmospheric: Surface must be clean, dry, and in sound condition. Remove all oil, dust, grease, dirt, loose rust, and other foreign material to ensure Steel: good adhesion.
  • Page 82 4.53A Industrial ® MACROPOXY & FAST CURE EPOXY Marine Coatings B58-600 ERIES B58V600 ARDENER APPLICATION BULLETIN Revised 9/07 URFACE REPARATION PPLICATION ONDITIONS Surface must be clean, dry, and in sound condition. Remove all oil, Temperature: 40°F minimum, 140°F maximum dust, grease, dirt, loose rust, and other foreign material to ensure (air, surface, and material) adequate adhesion.
  • Page 83 4.53A Industrial ® MACROPOXY & FAST CURE EPOXY Marine Coatings B58-600 ERIES B58V600 ARDENER APPLICATION BULLETIN PPLICATION ROCEDURES ERFORMANCE Surface preparation must be completed as indicated. Stripe coat all crevices, welds, and sharp angles to prevent early failure in these areas. Mix contents of each component thoroughly with power agita- tion.
  • Page 84 5.22 Industrial ACROLON™ 218 HS & ACRYLIC POLYURETHANE Marine B65-600 LOSS ERIES Coatings B65-650 LOSS ERIES B65V600 ARDENER PRODUCT INFORMATION Revised 2/07 RODUCT ESCRIPTION ECOMMENDED ACROLON 218 HS acrylic polyurethane is a VOC compliant, Specifically formulated for in-shop applications. For use over prepared metal and masonry surfaces in industrial envi- polyester modified, aliphatic, acrylic polyurethane formulated ronments such as: specifically for in-shop applications.
  • Page 85 5.22 Industrial ACROLON™ 218 HS & ACRYLIC POLYURETHANE Marine B65-600 LOSS ERIES Coatings B65-650 LOSS ERIES B65V600 ARDENER PRODUCT INFORMATION ECOMMENDED YSTEMS URFACE REPARATION Surface must be clean, dry, and in sound condition. Remove Steel: all oil, dust, grease, dirt, loose rust, and other foreign material 1 ct.
  • Page 86 5.22A Industrial ACROLON™ 218 HS & ACRYLIC POLYURETHANE Marine B65-600 LOSS ERIES Coatings B65-650 LOSS ERIES B65V600 ARDENER APPLICATION BULLETIN Revised 2/07 URFACE REPARATION PPLICATION ONDITIONS Surface must be clean, dry, and in sound condition. Remove Temperature: 40°F minimum, 120°F maximum all oil, dust, grease, dirt, loose rust, and other foreign material (air, surface, and material) to ensure adequate adhesion.
  • Page 87 5.22A Industrial ACROLON™ 218 HS & ACRYLIC POLYURETHANE Marine B65-600 LOSS ERIES Coatings B65-650 LOSS ERIES B65V600 ARDENER APPLICATION BULLETIN PPLICATION ROCEDURES ERFORMANCE Stripe coat all crevices, welds, and sharp angles to prevent Surface preparation must be completed as indicated. early failure in these areas.
  • Page 88 Constant Speed Reducers R/F/K/S 2002 Product Catalog Up to 98% Efficient • Superior Uptime • Long Life • Low Maintenance • Compact Design • Modular Components • Custom Assembled...
  • Page 89 Power Transmission Solutions SEW-Eurodrive’s extensive Modular Program offers over 1.2 million custom drive configurations. ® Our product range is one of the largest AC motors and brakemotors SNUGGLER : Compact in the industry. Power ratings from from 1/4 to 60 HP. parallel helical speed reducers.
  • Page 90 Service Factor 1.0 Input Speed 1750 rpm Constant Speed Gear Reducers R/F/K/S AM182 AM184 AM213 AM215 Output Input Output Input Output Output Input Output Output Input Output Output Input Output Output Speed Power Torque Stages Power Torque Power Torque Power Torque Power Torque...
  • Page 91 R Series Dimension Sheets Constant Speed Gear Reducers R/F/K/S AM182-365 RF47.. 9.25 2.36 .39 Ø .35 7.01 2.36 .39 Ø 2.36 Ø 2.36 3/8 - 16 x 0.87 1.69 AM182 8.50 0.39 7.250 0.20 8.98 15.06 0.12 0.59 5.81 0.65 1.125 2.72 1.24...
  • Page 92 Mounting Positions Helical gearmotors R 7.7.2 RF07 ... RF167, RZ07 ... RZ87 (page 103) Assembly and Operating Instructions – Gear Unit Types R..7, F..7, K..7, S..7, SPIROPLAN® W...
  • Page 93 Mounting Positions and Important Order Information Constant Speed Gear Reducers R/F/K/S 7. Mounting Positions and Important Order Information 7.1. General information about mounting positions Mounting position designation SEW differentiates between six mounting positions, M1 — M6, for gear reducers. The following figure shows the orientation of the gear reducer in each mounting position.
  • Page 94 Constant Speed Gear Reducers R/F/K/S Design and Operating Notes Lubricant table Mobil ® ISO, NLGI DIN (ISO) +100 ˚C Standard Mobilgear Shell Omala Klüberoil Aral Degol BP Energol Tribol Optigear Renolin R... CLP(CC) VG 220 Meropa 220 GEM 1-220 BG 220 GR-XP 220 1100/220 BM 220...
  • Page 95 Design and Operating Notes Constant Speed Gear Reducers R/F/K/S Lubricant fill quantities The specified fill quantities are guide values. The precise values vary depending on the stages and gear ratio. When filling, it is essential to check the oil level plug since this indicates the precise oil capacity. The following tables show guide values for lubricant fill quantities depending on the mounting position M1 –...
  • Page 96 Technical Note R-Series Gear Reducer R-Series Features The SEW-Eurodrive R-Series gear reducer contains a solid shaft and 1, 2 or 3 helical gear stages. Additional features are shown below. SAE Class 30 or equivalent (GG20) gray Exclusive interlocking 2-piece seal cast iron housing and flanges (except design consisting of a patented bi-helix ...
  • Page 97 Technical Note Additional Features: • Style: Helical-Parallel. Output shaft parallel and offset to input shaft. Available as “RX” (1 stage) or “R” (2 or 3 stages) • Input Types: Available with adapters to accommodate NEMA or IEC motor frames, solid input shafts, backstops, adjustable motor mounting platforms, and scoops.
  • Page 98 Technical Note Housing Material: Except for the R07, R17, and R27, which are made from high strength cast aluminum, all SEW reducer housings and flanges are manufactured from SAE 30 or equivalent (GG20) gray cast iron due to the following benefits: •...
  • Page 99 Technical Note Flange Mounting A B5 flange with through-holes is optional on all R-series reducers. It contains an O-ring and a tenon (pilot) as shown at right. The O-ring helps prevent oil leakage that could occur if the flange is mounted to a “flat” surface O-ring that exceeds the recommended flatness tolerance.
  • Page 100 VALVES & CONTROLS KUNKLE SAFETY AND RELIEF PRODUCTS MODELS 71S, 171, 171P AND 171S Non-code Liquid Relief Valve Model descriptions Features Model 71S: Cast iron body with SS seat and • Suitable for back pressure to disc. Pressure-tight hood. 50 psig. Model 171: Carbon Steel (CS) with SS seat •...
  • Page 101 KUNKLE SAFETY AND RELIEF PRODUCTS MODELS 71S, 171, 171P AND 171S Parts and Materials Models 71S, 171, 171S Part Name 171S Nozzle SS A479-316 SS A479-316 SS A479-316 Body Gasket Teflon Teflon Teflon ® ® ® Disc SS A743-CF8M SS A743-CF8M SS A743-CF8M Stem End SS A479-316...
  • Page 102 KUNKLE SAFETY AND RELIEF PRODUCTS MODELS 71S, 171, 171P AND 171S Capacities Non-code Liquid - 25% Accumulation (GPM) Set Pressure ——————–– Valve Inlet and Outlet Size ——————— (psig) " " 1" " " 2" Note: 1. Liquid Overpressure Factors To determine capacities at other than 25% overpressure/accumulation, multiply capacity shown by: 10% Acc.
  • Page 103 KUNKLE SAFETY AND RELIEF PRODUCTS MODELS 71S, 171, 171P AND 171S Dimensions Note: Models 71S, 171, 171P, 171S " size has " outlet. Inlet and Outlet ––––––––––––––––––––– Dimensions, in –––––––––––––––––––––– Weight Female, NPT (lb) (in) 71S, 171, 171S 171P, 171S Dimensions are for reference only.
  • Page 104 Inc. 511 Speedway Drive Enon, OH 45323 Phone (937) 864-7150 Fax (937) 864-7157 sales@seepex.net www.seepex.com Pressure Switch/Gauge Details Project: WM Lyles-Cortech-OCSD-PO#: T1113-20 Active Dilute Polymer Pumps BN 5-12 835294-296 Suction Side Seal: 1. Manufacturer: Onyx–K-1/2“ 2. Diaphragm Seal: 3. Liquid Fill? Yes –...
  • Page 105 Pressure Switch/Gauge Details Project: WM Lyles-Cortech-OCSD-PO#: T1113-20 Active Dilute Polymer Pumps BN 5-12 835294-296 Discharge Side Seal: 1. Manufacturer: Onyx–K-1/2“ 2. Diaphragm Seal: 3. Liquid Fill? Yes – Silicone instrument oil Pressure Switch Detail: 1. Manufacturer: Ashcroft 2. Model No.: B4-50-B-X06-300PSI 3.
  • Page 106 ONYX VALVE 835 Industrial Hwy, Cinnaminson, NJ 08077 phone: 856-829-2888 | Fax: 856-829-3080 | onyxvalve.com Model K The Onyx Model-K series diaphragm seal provides outstanding protection for pressure instruments against chemical attack and corrosion. The exclusive convoluted rolling diaphragm design features: •...
  • Page 107 B-Series Switches – Pressure, Differential Pressure, Temperature & Hydraulic Thermowells FEATURES Thermowells must be used on any appli- B-Series switches have proven reliable cation where the stem of the temperature in such harsh environments as: switch may be exposed to pressure, cor- •...
  • Page 108 B-Series Switches – Pressure, Differential Pressure, Temperature & Hydraulic Temperature Switches ship that exists between temperature and span setpoint repeatability with very high B-Series temperature switches feature pressure according to the vapor pressure overtemperature ratings. a SAMA Class II vapor pressure thermal laws.
  • Page 109 B-Series Switches – Pressure, Differential Pressure, Temperature & Hydraulic Pressure & Differential Pressure Switches B-Series pressure, differential pressure and of construction. maximum reliability. This design is available in vacuum switches use two different actuators 316 SS or Monel. Differential pressure models All standard models feature ±1 percent of depending on setpoint require-ments.
  • Page 110 B-Series Switches – Pressure, Differential Pressure, Temperature & Hydraulic B-SERIES PRESSURE AND DIFFERENTIAL PRESSURE SWITCH MODEL NUMBER: To specify the exact switch desired, select entries from appropriate tables as shown in example below. 600 PSI X P K 1 – ENCLOSURE 2 –...
  • Page 111 B-Series Switches – Pressure, Differential Pressure, Temperature & Hydraulic OPTIONAL FEATURES AND ACCESSORIES NOTES: B-SERIES SWITCH OPTIONS 1 Buna N and Viton diaphragm. Appicable Switch Series 2 Advise static or working pressure for differential pressure switches. 3 Buna N cannot be cleaned for oxygen service. Differential Temp- 4 N/A on 700 Series.
  • Page 112 B-Series Switches – Pressure, Differential Pressure, Temperature & Hydraulic Dimensions – 400 Series 2.27 Ø 0.28 X 3 HOLES Pressure switch – inches of water ranges Pressure switch – psi ranges (58) 0.22 4.03 (102) 1.25 Ø 0.28 X 3 HOLES (32) 4.03 (102)
  • Page 113 Type 1279 Duragauge Pressure Gauge Available With PLUS ™ Performance Option • Solid front case design, field PRODUCT SPECIFICATIONS Model Number: 1279 convertible to hermetically sealed Accuracy: ⁄ % full scale (Grade 2A, or liquid filled style ASME B40.100) • Pressure ranges from vacuum — Ranges: Vac., compound to 30,000 psi 30,000 psi...
  • Page 114 Type 1279 Duragauge Pressure Gauge Available With PLUS ™ Performance Option Compound Dimensions Figure Interval Minor Grads Range Mounting hardware in Hg in Hg supplied by Ashcroft 30˝ Hg/15 psi 30˝ Hg/30 psi 30˝ Hg/60 psi Hole in 30˝ Hg/100 psi panel 30˝...
  • Page 115 • Excellent weathering resistance; Seepex standard HIS Internally Threaded Inserts Resistance against elevated epoxy anchor system. temperatures • Suitable for oversized holes Seepex only supplies Rebar (supplied by contractor) ® ® • Seismic qualified per IBC /IRC anchor bolts for each ®...
  • Page 116 Adhesive Anchoring Systems HIT-RE 500 Epoxy Adhesive Anchoring System 4.2.7 Threaded Rods HAS Rods 5.8 HAS Super A193, B7 High Strength Rods HAS-R Rods 304 Stainless Steel HAS-R Rods 316 Stainless Steel Master Carton Item No. (Box) (MC) Description (in.) Box/MC Item No.
  • Page 117 TAB 3 – INSTALLATION, OPERATIONS, AND MAINTENANCE...
  • Page 118 Pin Joint OM.WPS.02. The pin joints are filled with special grease and lubricated for the expected duration of service. The seepex joint grease specified in the index of these operating instructions should be used exclusively for any required maintenance work. CAUTION...
  • Page 119 Maintenance • Lock drive shaft against rotation. While dismantling the stator (601) with tool Dismantling the seepex Progressive Cavity Pump (W2/see Point 9) prop up the rotor (600) with Tools are required for dismantling and re-assembly. support (S) to prevent it from falling.
  • Page 120 Service and Maintenance 7.3.5 Rotating Pump Parts - Dismantling Re-assembly Before commencing the re-assembly, 7.3.5.1 fasten the lantern (200) in such a way Rotor (600), Coupling Rod (400) that it cannot tip over or fall down Detach the rotor (600) and coupling rod (400) from during the re-assembly of the drive and the plug-in shaft (307) by dismantling the joint (G) in all pump components.
  • Page 121 Service and Maintenance 7.4.6 Prepare main components: Pressure Flange (700) - Assembly Prepare rotor (600), coupling rod (400) and CAUTION plug-in shaft (307) as described in document Tighten tie bolts (602 and 603) in equally. OM.PJT.02, Point 2. to 2.3 Joint (G) re-assembly as described in document OM.PJT.02, Point 3.
  • Page 122 (404), we recommend the employment of coupling rods (400) whose coupling rod bushes (404) have been pressed in by seepex. The coupling rod bush (404) is pushed out of the coupling rod (400) with tools (W4 and W14/see Retaining Sleeve (401) - Dismantling Point 9).
  • Page 123 (403) and coupling rod bushes (404) ployment of coupling rods (400) whose bushes (404) all at the same time. have been pressed in by seepex. • Joint head on rotor (600) and plug-in shaft (307) Press in new coupling rod bushes (404 using tool - Press guide bushes (403) in by only 2/3 of their (W4) and (W14/see Point 9).
  • Page 124 Pin Joint Assembly • Retaining sleeve (401) • Holding bands re-assembly Mount holding bands (406 and 407) using tool (W3/see Point 9) as described in document OM.HBD.01. • Securing of retaining sleeve For drive shafts, plug-in shafts and rotors made of unhardened materials such as St 70, AISI 304, AISI 316, Hastelloy C, secure 2 x 180°...
  • Page 125 Holding Band Re-assembly • Correct holding band tension (HBD) Holding Band (HBD) - Assembly Tools required for the re-assembly, see document OM.SPT.01. • Prepare holding band Only prefabricated double-band holding bands Correct Incorrect Incorrect should be used. The diameter ( ) and in particular Holding band Holding band Holding band...
  • Page 126 Holding Band Re-assembly • Shearing off holding band (HBD) made of material AISI 304 and AISI 316 A blow with the palm of the hand against the cutting lever (SH) causes the end of the holding band behind the loop (SCL) to be folded back and sheared off.
  • Page 127 Breakdown, Reasons, Remedies Breakdown seepex progressive cavity pumps will operate trouble-free if they are used in accordance with our data sheet (see item 9) and our operating and maintenance instructions: Reasons / Remedies Adhesion between rotor and stator excessive (as delivered). Lubricate (soft soap, genuine soap) between stator and rotor.
  • Page 128 Stückliste Parts List Liste des pièces Baureihe BN Range BN Série BN Schnittzeichnung Nr. sectional drawing no. plan no. 062-004_1 062-004_1 062-004_1 Benennung denomination désignation Stck. Pos. Stck. / Pos. Qty. / Item Qté. / Poste 200 Laterne lantern lanterne 202 Halbrundkerbnägel round head grooved pins rivet...
  • Page 129 Stck. Pos. Stck. / Pos. Qty. / Item Qté. / Poste 098 seepex Gelenkfett seepex joint grease seepex graisse d' articulations Typ und Füllmenge: type and filling quantity: sommaire pour type et quantité: Betriebs- und see Operating and Maintenance voir Instructions de service et...
  • Page 130 When ordering parts from seepex, call ahead and get a quote. The Commission No. is needed. Phone: (937) 864-7150 Fax: (937) 864-7157 Predicted Life/ Recommended Spare Parts Part Designation 2 years 5 years Gasket Corresponding Part Number Number to Sectional Pump Drawing...
  • Page 131 Operating Instruction for Double-Acting Dokument / document Mechanical Seals / Back-to-Back Arrangement ZU.016.02e Ausgabe / issue A / 18.06.98 Blatt / sheet 1 (2) General Double-acting mechanical seals or mechanical seals in back-to-back arrangement are used when conveying liquids that have typically the following characteristics: −...
  • Page 132 Operating Instruction for Double-Acting Dokument / document Mechanical Seals / Back-to-Back Arrangement ZU.016.02e Ausgabe / issue A / 18.06.98 Blatt / sheet 2 (2) Flushing systems to API 610, Plan 53 and Plan 54 A flushing system has the following functions: a) To maintain pressure in flushing area b) Leakage compensation c) Circulation of flushing liquid...
  • Page 133 Page 37...
  • Page 134 Sizes: 05-24, 1-6 to 300-6L To avoid the expenses incurred by lengthy stop periods of the pump, seepex recommend the acquisition of a set of wearing parts and a set of gaskets. The table below shows the contents of these sets.
  • Page 135 Werkzeuge Tools Allgemeine normierte Werkzeuge / Standardized tools Werkzeug Nr. tool No. zur Montage von: Packung Stator Gelenk Lager allgemein Mutter für Teflon- Stator manschette tool for mounting packing stator joint bearing general nut for teflon Stator universal joint sleeve Benennung: Packungszieher Ketten-Rohrzange Durchschlag...
  • Page 136 Werkzeuge Tools Empfohlene seepex Werkzeuge Aufgrund der Ausführung für bestimmte Montagen empfohlen, durch allgemeine normierte Werkzeuge bedingt ersetzbar. Recommended seepex tools Due to the design recommended for certain repairs, these tools partially replace the standardized tools. Werkzeug Nr. tool zur Montage von: Gelenk...
  • Page 137 Werkzeuge Tools Spezial- Empfohlene seepex Werkzeuge werkzeuge Aufgrund der Ausführung für bestimmte Montagen empfohlen, durch allgemeine normierte Werkzeuge bedingt ersetzbar. Recommended seepex tools Special tools Due to the design recommended for certain repairs, these tools partially replace the standardized tools.
  • Page 138 240-18L 400-12TR 300-18TU 300-24TV 300-27TH 400-18TU Empfohlene seepex Werkzeuge Spezialwerkzeuge Aufgrund der Ausführung für bestimmte Montagen empfohlen, durch allgemeine normierte Werkzeuge bedingt ersetzbar. Recommended seepex tools Special tools Due to the design recommended for certain repairs, these tools partially replace the standardized tools Werkzeug Nr.
  • Page 139 (18%) per year (equivalent to a authorization in writing for such returns has been seepex, Inc. be liable for any loss or damage nominal monthly interest rate of 1½%) will be obtained beforehand. A copy of this authorization of whatever kind of nature out of defects in applied on overdue accounts.
  • Page 140 Yorba Linda, Ashbrook Simon-Hartley Operations, LP 11600 East Hardy Rd. CA 92887 Houston, TX 77093 714-779-0911 Phone#: 800-362-9041 Fax#: 281-449-3317 seepex, Inc. Sales Manager Steve Gordon 3109 Brant St. Katy, TX 77493 Phone#: 281-881-1346 Email: sgordan@seepex.com seepex, Inc. Service Department Jack Kibby 511 Speedway Dr.
  • Page 141 SEEPEX, Inc. 511 Speedway Dr. Enon, OH 45323 Phone (937) 864-7150 Maintenance Schedule Fax (937) 864-7157 www.seepex.com Item Action Frequency Remarks -Adjust packing gland Check leakage rate and tighten / loosen to allow 1-6 Packing Weekly nuts ½ turn per minute...
  • Page 142 Pump After 3,000 Shell Alvania EP2 Repack with grease (if equiped) Bearings operating hours (or equal) Rotor replacement Pump SEEPEX, Inc. 30321 or 10,000 Universal Repack with grease grease operating hours Joints (no equal) (whichever is first) *check pump datasheet for use of special gear oil used for certain applications...
  • Page 143 If a piping pressure test is required, check pump accessories for compatibility. Remove if necessary. All parts are covered against defects in material and workmanship per SEEPEX, Inc.‘s warranty. See O&M for specific details. The below date signifies data of installation.
  • Page 144 Check TSE and sensor, verify set temperature. VFD Controlled - check pump in Auto Mode and Manual Mode. Note: This is to be signed by a qualified SEEPEX, Inc.employee or representative. The below date signifies the date that the start-up was completed.
  • Page 145 Store pump in a cool dry atmosphere. Energize motor heaters if installed. Note: This is to be signed by a qualified SEEPEX, Inc.employee or representative. The below date signifies the date that the shut-down was completed. ________________________________/___________________ ___________________________ SEEPEX, Inc.
  • Page 146 Long-term storage/preservation of seepex Dokument / document progressive cavity pumps TI.114.01e Ausgabe / issue I / 04.06.2013 Blatt / sheet 1 (3) Scope • Size: 0005-24 ... 500-6L • Range: BN, NS, N, MD Storage period: > 3 months  24 months •...
  • Page 147 Long-term storage/preservation of seepex progressive cavity pumps Dokument / document TI.114.01e Ausgabe / issue I / 04.06.2013 Blatt / sheet 2 (3) Particular environmental influences must be specified by the customer and checked and approved by seepex before storage. Recommissioning ...
  • Page 148 3 (3) Notes and comments When storing the pump for over 24 months, because of potential corrosion and natural aging of elastomers, greases and oils, we recommend having seepex Customer Service assess the pump before recommissioning it. Documents seepex internal manufacturing instructions for long-term storage/preservation: HA.LKO.01...
  • Page 149 Manufacturer’s documents 10.0 Manufacturer’s documents from sub-supplier Ausgabe Dokument Blatt B / 17.01.2006 1 (1) OM.MDS.01e issue document sheet Page 43...
  • Page 150 Drive Technology \ Drive Automation \ System Integration \ Services Assembly and Operating Instructions Gear Units ® R..7, F..7, K..7, K..9, S..7, SPIROPLAN Edition 10/2013 20200544 / EN Page 52...
  • Page 151 General Information How to use this documentation General Information Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN¬Æ W How to use this documentation The documentation is an integral part of the product and contains important information on operation and service. The documentation is written for all employees who assemble, install, start up, and service this product.
  • Page 152 General Information Rights to claim under warranty Rights to claim under warranty A requirement of fault-free operation and fulfillment of any rights to claim under limited warranty is that you adhere to the information in the documentation. Therefore read the documentation before you start working with the unit.
  • Page 153 Safety Notes Preliminary information Safety Notes The following basic safety notes must be read carefully to prevent injury to persons and damage to property. The operator must ensure that the basic safety notes are read and adhered to. Make sure that persons responsible for the system and its operation, as well as persons who work independently on the unit, have read through the operating instructions carefully and understood them.
  • Page 154 Safety Notes Target group Target group Any mechanical work may only be performed by adequately qualified personnel. Quali- fied personnel in the context of this documentation are persons familiar with the design, mechanical installation, troubleshooting and servicing of the product who possess the following qualifications: •...
  • Page 155 Safety Notes Transport/storage Transport/storage Inspect the shipment for any damage that may have occurred in transit as soon as you receive the delivery. Inform the shipping company immediately in the event of damage. It may be necessary to preclude startup. Tighten the eyebolts securely.
  • Page 156 Gear Unit Structure Basic structure of helical gear units Gear Unit Structure INFORMATION The following figures are block diagrams. Their purpose is only to make it easier to as- sign components to the spare parts lists. Discrepancies may occur depending on the gear unit size and version.
  • Page 157 Gear Unit Structure Nameplate/type designation Nameplate/type designation 3.8.1 Nameplate The following figure shows an example of a nameplate for a helical-bevel gear unit with input cover: 76646 Bruchsal K87 AD4 70,46 1400/20 r/min 2700 Mamax Nm Memax Made in Germany CLP HC 220 Synth.
  • Page 158 Mechanical Installation Required tools/resources Mechanical Installation Required tools/resources • Set of wrenches • If necessary, torque wrench for: – Shrink disks – Motor adapter AQH Or EWH – Input shaft assembly with centering shoulder • Mounting device • Compensation elements (shims, spacing rings) •...
  • Page 159 Mechanical Installation Installation requirements Installation requirements CAUTION Risk of injury due to protruding gear unit parts. Minor injuries. • Keep a sufficient safety distance to the gear unit/gearmotor. NOTICE Damage to the gear unit/gearmotor due to improper installation. Possible damage to property •...
  • Page 160 Mechanical Installation Installing the gear unit Installing the gear unit NOTICE Danger due to static overdetermination if gear units with foot (e.g. KA19/29B, KA127/157B or FA127/157B) are mounted both via the torque arm and via the foot plate. Risk of injuries and damage to property. •...
  • Page 161 Mechanical Installation Installing the gear unit Secure gearmotors using quality 8.8 screws. Secure the following gearmotors using quality 10.9 screws: • RF37, R37F with flange Ø = 120 mm • RF37, RF47, R47F with flange Ø = 140 mm • RF57, R57F with flange Ø...
  • Page 162 Mechanical Installation Installing the gear unit 4.3.1 Tightening torques for retaining screws Mount the gearmotors with the following tightening torques: Tightening torque screw / nut Strength class 8.8 Bolt/nut [Nm] 1450 2500 4600 6950 11100 Mount the specified gearmotors in flange-mounted design with the following increased tightening torques: Tightening torque screw / nut Bolt/nut...
  • Page 163 Mechanical Installation Installing the gear unit 4.3.2 Gear unit mounting INFORMATION ® For gear units in foot/flange-mounted design in connection with VARIBLOC variable- speed gear units, use quality 10.9 bolts and suitable washers for connecting the cus- tomer flange. To improve the friction contact between flange and mounting surface, SEW- EURODRIVE recommends anaerobic gaskets or an anaerobic glue.
  • Page 164 Mechanical Installation Installing the gear unit The following table shows the thread sizes of the gear units with B5 flange depending Gear units with B5 on the gear unit type, size and flange diameter: flange Gear unit type Flange Ø Screw RF / FF /...
  • Page 165 Mechanical Installation Installing the gear unit 4.3.3 Installation in damp locations or outdoors Drives are supplied in corrosion-resistant versions with a surface protection coating for use in damp areas or outdoors. Repair any damage to the paint work (e.g. on the breather valve or the eyebolts).
  • Page 166 Mechanical Installation Installing the gear unit Check whether the breather valve is activated. If the breather valve has not been acti- Activating the vated, you must remove the transportation protection device from the breather valve be- breather valve fore starting up the gear unit. 1.
  • Page 167 Mechanical Installation Gear units with solid shaft 4.3.5 Painting the gear unit NOTICE Breather valves and oil seals may be damaged during painting or re-painting. Possible damage to property. • Thoroughly cover the breather valves and the sealing lip of the oil seals with strips prior to painting.
  • Page 168 Mechanical Installation Gear units with solid shaft Avoid high overhung loads by installing the gear or chain sprocket according to figure B Avoiding excessive if possible. overhung loads 211364235 [1] Hub [A] Unfavorable [B] Correct INFORMATION Mounting is easier if you first apply lubricant to the output element or heat it up briefly (to 80 - 100 °C).
  • Page 169 Mechanical Installation Torque arms for shaft-mounted gear units Torque arms for shaft-mounted gear units NOTICE Improper mounting may result in damage to the gear unit. Possible damage to property. • Do not place torque arms under strain when mounting. • Use screws of quality 8.8 to fasten torque arms.
  • Page 170 Mechanical Installation Torque arms for shaft-mounted gear units 4.5.2 Helical-bevel gear units K..19 – 29 The following figure shows the torque arm for helical-bevel gear units KA19 – 29. • Apply bearings to both sides of the bushing [1]. • Mount connection side B so that it mirrors A.
  • Page 171 Mechanical Installation Installing the protective cover 4.8.4 Cleaning and lubrication There is no need to dismantle removed shrink disks before re-installing them. Clean and lubricate the shrink disk if it is dirty. Lubricate the tapered surfaces with one of the following solid lubricants: Lubricant (Mo S2) Sold as Molykote 321 (lube coat)
  • Page 172 Mechanical Installation Installing the protective cover 4.9.2 Installing the fixed cover 1. To fasten the cover, remove the plastic plug on the gear unit housing (see figure 1) 2. Use the delivered screws to mount the cover to the gear unit housing (see figure 2). 4.9.3 Installation without cover In certain individual cases (e.g.
  • Page 173 Mechanical Installation Coupling of AM adapters 4.10 Coupling of AM adapters 4.10.1 IEC adapter AM63 - 280 / NEMA adapter AM56 - 365 9007199466840971 Motor shaft [479] Coupling half [481] Setscrew [484] Key [491] Spacer tube 1. Clean the motor shaft and flange surfaces of the motor and the adapter. 2.
  • Page 174 Mechanical Installation Coupling of AM adapters 5. Check the dimension A. 6. Seal the contact surfaces between the adapter and motor using a suitable sealing compound. 7. Mount the motor on the adapter. Ensure that the coupling claws of the adapter shaft are engaged in the plastic cam ring.
  • Page 175 Mechanical Installation Coupling of AM adapters 4.10.2 Permitted loads CAUTION Impermissibly high loads may occur when mounting a motor. Potential damage to property • The load data specified in the following table are not to be exceeded. 18513419 Gear unit series R..7, F..7, K..7, K..9, and S..7: Adapter type NEMA [mm]...
  • Page 176 Mechanical Installation Coupling of AM adapters 4.10.3 AM adapter with AM../RS backstop Check the direction of rotation of the drive prior to assembly or startup. Inform the SEW- EURODRIVE service in the case of incorrect direction of rotation. The backstop is maintenance-free in operation, and does not require any further main- tenance work.
  • Page 177 Mechanical Installation AD input shaft assembly 4.13 AD input shaft assembly Observe section "Assembling the input and output components" (page 27) when install- ing input components. 4.13.1 AD../P – cover with motor mounting platform Mounting the motor and adjusting the motor mounting platform. 212119307 [1] Motor mounting platform [2] Stud bolt (only AD6/P / AD7/P)
  • Page 178 Mechanical Installation AD input shaft assembly 4.13.2 Only AD6/P and AD7/P Unscrew the nuts on the stud bolts before adjustment to allow the stud bolts to move axially in the support without restriction. Do not tighten the nuts until the final adjustment position has been reached.
  • Page 179 Mechanical Installation AD input shaft assembly ® 4. Clean the threads of the new bolts and apply a bolt locking compound (e.g. Loctite 243) to the first few threads. 5. Attach the application to the centering shoulder and tighten the retaining screws with the specified tightening torque T (see table).
  • Page 180 Mechanical Installation AD input shaft assembly Permitted loads NOTICE Impermissibly high loads may occur when mounting a motor. Potential damage to property • The load data specified in the following table are not to be exceeded. The following figure shows the permitted force application points for the permitted max- imum weights: 212123659 Motor's center of gravity...
  • Page 181 Mechanical Installation AD input shaft assembly 4.13.4 AD../RS – cover with backstop Check the direction of rotation of the drive prior to assembly or startup. Inform the SEW- EURODRIVE service in the case of incorrect direction of rotation. The backstop is maintenance-free in operation, and does not require any further main- tenance work.
  • Page 182 Mechanical Installation Accessory equipment 4.14 Accessory equipment 4.14.1 AR.. and AT.. centrifugal and friction couplings Drives with a friction coupling consist of a standard gear unit and motor/variable speed AR.. friction gearmotor with an adapter installed between them. This adapter accommodates the fric- coupling tion coupling.
  • Page 183 Mechanical Installation Accessory equipment Hydraulic centrifugal couplings are fluid couplings based on the Föttinger principle. They AT.. hydraulic consist of 2 hinged hemispheres with blades separated by a tight gap. centrifugal coupling The applied torque is transmitted by the inertial force of the streaming fluid. This fluid circulates within a closed circuit, between the pump wheel (primary side) [12] on the driv- ing shaft (motor shaft) and the turbine wheel (secondary side) [9] on the driven shaft (gear unit input shaft).
  • Page 184 Mechanical Installation Accessory equipment 4.14.2 Diagnostic units DUV and DUO The DUV30A diagnostic unit evaluates vibration signals using frequency analysis meth- DUV diagnostic ods. A micromechanical acceleration sensor is used in the unit. Data can be recorded, unit processed and evaluated locally without any expert knowledge. The DUV30A diagnostic unit is suitable for early recognition of rolling element bearing damage or unbalance.
  • Page 185 Mechanical Installation Accessory equipment 4.14.3 Gear unit heater for gear unit series R..7, F..7, and K..7 Oil heating can be required in order to allow for a smooth startup in the event of a cold start at low ambient temperatures. An oil heater is available with external or integrated thermostat depending on the gear unit design.
  • Page 186 Mechanical Installation Accessory equipment 4.14.4 Flange coupling Flange couplings [1] are rigid couplings for connecting 2 shafts [2]. They are suitable for operation in both directions of rotation, but cannot compensate any shaft misalignments. Torque between shaft and coupling is transmitted via a cylindrical interference fit. The two coupling halves are mounted together at their flanges.
  • Page 187 Mechanical Installation Accessory equipment 4.14.5 Regreasing the labyrinth seal The following figure shows an example of a regreasable radial labyrinth seal (taconite). Output shaft • Single oil seal with radial labyrinth seal • Used in very dusty environments with abrasive particles 9007204406135947 INFORMATION Make sure that the gear unit shaft is rotating during the regreasing process.
  • Page 188 Mechanical Installation Accessory equipment INFORMATION Immediately remove the old grease that leaked out. Observe the following inspection and maintenance intervals for the regreasing of laby- Inspection and rinth seals: maintenance intervals Time interval What to do? Every 3000 operating hours, at least every Fill regreasable sealing systems with grease.
  • Page 189 Mechanical Installation Accessory equipment 4.14.7 Oil expansion tank The oil expansion tank is to compensate for oil volume variations in the system caused by temperature fluctuations. When the gear unit temperature increases, the expansion tank absorbs some of the increasing oil volume and feeds it back to the gear unit as the temperature goes down.
  • Page 190 Mechanical Installation Accessory equipment The following figure shows an example of a standard parallel-shaft helical gear unit next to an oil-air cooler. 8981051403 [1] Motor for pump and fan [4] Suction pipe connections [2] Oil-air heat exchanger [5] Pressure pipe connections [3] Temperature switch with two switching points [6] Option: Oil expansion tank connection INFORMATION...
  • Page 191 Startup Startup CAUTION Improper startup may result in damage to the gear unit. Possible damage to property. • Note the following: • Before startup, check that the oil level is correct. Refer to the unit's nameplate for lu- bricant fill quantities. •...
  • Page 192 Startup Checking the oil level Checking the oil level Before startup, make sure that the oil level corresponds to the mounting position. Ob- serve section "Checking the oil level and changing the oil" (page 89). If the gear unit is equipped with an oil sight glass, you can also determine the oil level at the oil sight glass.
  • Page 193 Startup Helical/parallel-shaft helical/helical-bevel gear units Helical/parallel-shaft helical/helical-bevel gear units No special startup instructions are required for helical, parallel-shaft helical and helical- bevel gear units providing the gear units have been installed in accordance with chapter "Mechanical Installation" (page 18). Gear units with backstop The purpose of a backstop is to prevent undesirable reverse rotation.
  • Page 194 Startup Components made of elastomers with fluorocarbon rubber Components made of elastomers with fluorocarbon rubber Under normal operating conditions and at temperatures up to 200 °C, fluorocarbon rub- ber is very stable and safe. However, when heated to more than 300 °C, e.g. by fire or the flame of a cutting torch, it forms harmful gases and vapors as well as harmful resi- due.
  • Page 195 Inspection/Maintenance Preliminary work regarding gear unit inspection/maintenance Inspection/Maintenance The following gear units are lubricated for life: • Helical gear units R07, R17, R27 • Parallel-shaft helical gear units F27 ® • SPIROPLAN gear units Depending on external factors, the surface/corrosion protection might have to be repaired or renewed.
  • Page 196 Inspection/Maintenance Inspection/maintenance intervals • Strict adherence to the inspection and maintenance intervals is absolutely necessary to ensure safe working conditions. • Before releasing shaft connections, make sure that there are no active torsional moments present (tensions within the system). • Prevent foreign bodies from entering the gear unit during maintenance and inspec- tion work.
  • Page 197 Inspection/Maintenance Lubricant change intervals Lubricant change intervals The following figure shows the change intervals for standard gear units under normal environmental conditions. Change the oil more frequently when using special versions subject to more severe/aggressive environmental conditions! 30000 25000 20000 15000 10000 5000...
  • Page 198 Inspection/Maintenance Inspection/maintenance for the AL / AM / AQ. / EWH adapter Inspection/maintenance for the AL / AM / AQ. / EWH adapter The following table lists the obligatory intervals and the corresponding measures: Time interval What to do? • Every 3 000 hours of operation, at least every •...
  • Page 199 Inspection/Maintenance Inspection/maintenance for the gear unit Inspection/maintenance for the gear unit 6.6.1 Checking the oil level and changing the oil The procedure when checking the oil level and changing the oil depends on the following factors: • Gear unit type •...
  • Page 200 Inspection/Maintenance Inspection/maintenance for the gear unit 6.6.2 A: Helical, parallel-shaft helical, helical-bevel and helical-worm gear units with oil level plug Proceed as follows to check the oil level of the gear unit: Checking the oil level via oil level 1. Observe the notes in chapter "Preliminary work regarding gear unit inspection/main- plug tenance"...
  • Page 201 Inspection/Maintenance Inspection/maintenance for the gear unit Proceed as follows to check the oil of the gear unit: Checking the oil via oil drain plug 1. Observe the notes in chapter "Preliminary work regarding gear unit inspection/main- tenance" (page 85). 2. Determine the position of the oil drain plug using the mounting position sheets. See chapter "Mounting Positions"...
  • Page 202 Inspection/Maintenance Inspection/maintenance for the gear unit ® 6.6.3 B: Helical, parallel-shaft helical, SPIROPLAN gear units without oil level plug with cover plate For gear units without oil level bore, the oil level is checked via the cover plate opening. Checking the oil Proceed as follows: level via cover plate...
  • Page 203 Inspection/Maintenance Inspection/maintenance for the gear unit 5. Compare the determined value "x" to the max. distance (depending on the mounting position) between the oil level and the sealing surface of the gear unit housing as specified in the following table. Adjust the fill level if required. Gear unit type Max.
  • Page 204 Inspection/Maintenance Inspection/maintenance for the gear unit 6. Close the gear unit after the oil level check: • Re-attach the gasket of the cover plate. Make sure that the sealing surfaces are clean and dry. • Screw on the cover plate. Tighten the cover screws with the rated tightening torque according to the following table from the inside to the outside in the order illustrated in the figure.
  • Page 205 Inspection/Maintenance Inspection/maintenance for the gear unit Proceed as follows to check the oil of the gear unit: Checking the oil via cover plate 1. Observe the notes in chapter "Preliminary work regarding gear unit inspection/main- tenance" (page 85). 2. Open the cover plate of the gear unit according to section "Checking the oil via the cover plate"...
  • Page 206 Inspection/Maintenance Inspection/maintenance for the gear unit 6.6.4 C: Helical-worm gear units S..37 and helical-bevel gear units K..19/K..29 without oil level plug and cover plate The gear units S..37, K..19, and K..29 are not equipped with an oil level plug or a cover Checking the oil plate.
  • Page 207 Inspection/Maintenance Inspection/maintenance for the gear unit 5. Determine the size of the section "x" of the dipstick covered with lubricant using a cal- iper (see following figure). 18661771 6. Compare the determined value "x" to the min. value depending on the mounting po- sition specified in the following table.
  • Page 208 Inspection/Maintenance Inspection/maintenance for the gear unit 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main- Checking the oil tenance" (page 85). via screw plug 2. Open the cover plate of the gear unit according to section "Checking the oil level via screw plug".
  • Page 209 Mounting Positions Designation of the mounting positions Mounting Positions Designation of the mounting positions SEW differentiates between six mounting positions, M1 – M6. The following figure shows the spatial orientation of the gearmotor in mounting positions M1 – M6. Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W Page 111...
  • Page 210 Mounting Positions Churning losses Churning losses Churning losses may occur in some mounting positions. Contact SEW-EURODRIVE * → Page XX in case of the following combinations: Input speed Mounting position Gear unit type Gear unit size [rpm] 97 – 107 >...
  • Page 211 Mounting Positions Helical gearmotors R 7.7.2 RF07 – RF167, RZ07 – RZ87 * → (page 105) Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W Page 113...
  • Page 212 Technical Data Extended storage Technical Data Extended storage INFORMATION For storage periods longer than 9 months, SEW-EURODRIVE recommends the "Extended storage" variant. Gear units in this design are designated with a corre- sponding label. The lubricant of those gear units is then mixed with a VCI anti-corrosion agent (volatile corrosion inhibitors).
  • Page 213 Technical Data Lubricants Lubricants Unless a special arrangement is made, SEW-EURODRIVE supplies the drives with a lubricant fill adapted for the specific gear unit and mounting position. The mounting po- sition (M1 – M6, see chapter "Mounting positions") must be specified with the order. You must adapt the lubricant fill in case of any subsequent changes made to the mounting position, see chapter "Lubricant fill quantities"...
  • Page 214 Technical Data Lubricants 8.2.2 Lubricant table The lubricant table on the following page shows the permitted lubricants for SEW- EURODRIVE gear units. Observe the following key to the lubricant table. Abbreviations used, meaning of shading and notes: Key to the lubricant table CLP PG = Polyglycol (W gear units, conforms to USDA-H1)
  • Page 215 Technical Data Lubricants Lubricant table 01 751 09 04 36028799863966091 Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W Page 117...
  • Page 216 Technical Data Lubricants 8.2.3 Lubricant fill quantities The specified fill quantities are recommended values. The exact values vary depend- ing on the number of gear stages and reduction ratio. Check the oil level plug for the exact oil quantity when you fill in the oil. The following tables show guide values for lubricant fill quantities in relation to the mounting position M1 –...
  • Page 217 Malfunctions Gear units Malfunctions WARNING Risk of crushing if the drive starts up unintentionally. Severe or fatal injuries. • De-energize the motor before you start working on the unit. • Secure the motor against unintended power-up. CAUTION Risk of burns due to hot gear unit and hot gear unit oil. Serious injuries •...
  • Page 218 Malfunctions Adapters AM / AQ. / AL / EWH Malfunction Possible cause Remedy Oil leaking from breather Too much oil Correct the oil fill quantity →see "Inspection/mainte- valve nance for the gear unit" (page 89), Function-related oil mist There is no fault. Drive installed in incorrect mounting position •...
  • Page 219 Malfunctions AD input shaft assembly AD input shaft assembly Malfunction Possible cause Remedy Unusual, regular running Meshing/grinding noise: Bearing damage Contact SEW-EURODRIVE customer service noise Oil leaking Gasket defective. Contact SEW-EURODRIVE customer service Output shaft does not turn Connection between shaft and hub in gear Send the gear unit to SEW-EURODRIVE for repair.
  • Page 220 SEW-EURODRIVE—Driving the world SEW-EURODRIVE Driving the world SEW-EURODRIVE GmbH & Co KG P.O. Box 3023 76642 BRUCHSAL GERMANY Phone +49 7251 75-0 Fax +49 7251 75-1970 sew@sew-eurodrive.com www.sew-eurodrive.com Page 122...
  • Page 221 Parts List 01 266 09 97 Helical gear unit Page 1 / 3 RF47 11.06.2012 Mount-on gear units have motors, variable speed gear units or special input shaft assemblies mounted on the drive end. For parts see appropriate parts list. When ordering spare parts always quote nameplate data with serial number and designation with part number! Copyright reserved! All rights reserved according to DIN ISO 16016.
  • Page 222 Parts List 01 266 09 97 Helical gear unit Page 2 / 3 RF47 11.06.2012 Description Additional specifications SEW standard label Part No. Qty. STEEL Pinion STEEL Gear STEEL Pinion shaft STEEL Gear STEEL Pinion shaft STEEL Gear STEEL Output shaft Ø...
  • Page 223 Parts List 01 266 09 97 Helical gear unit Page 3 / 3 RF47 11.06.2012 Description Additional specifications SEW standard label Part No. Qty. STEEL Circlip DIN471 25x1,2-FS 00102741 CAST ALUMINUM Gearcase cover 10682244 STEEL Hex head screw ISO4017 M6x12-8.8-A2F 00110221 RUBBER Gasket...
  • Page 224 Parts List 23 270 06 00 Adapter Page 1 / 2 AM213/215 28.01.2014 Backstop for mounting NEMA motors version with dog clutch When ordering spare parts always quote nameplate data with serial number and designation with part number! Copyright reserved! All rights reserved according to DIN ISO 16016. SEW-EURODRIVE GmbH &...
  • Page 225 Parts List 23 270 06 00 Adapter Page 2 / 2 AM213/215 28.01.2014 Backstop for mounting NEMA motors version with dog clutch Description Additional specifications SEW standard label Part No. Qty. STEEL Retaining ring pinion shaft end Ø22 DIN471 22x1,2-FS 00102725 STEEL pinion shaft end Ø22...
  • Page 226 www.weg.net Português English Español Deutsch Română Български Manual of Electric Motors Page 128...
  • Page 227 www.weg.net INSTALLATION, OPERATION AND MAINTENANCE MANUAL OF ELECTRIC MOTORS This manual provides information about WEG induction motors fitted with squirrel cage, permanent magnet or hybrid rotors, low, medium and high voltage, in frame sizes IEC 56 to 630 and NEMA 42 to 9606/10. The motor lines indicated below have additional information that can be checked in their respective manuals: Smoke Extraction Motors;...

  • Page 228: Table Of Contents

    www.weg.net TABLE OF CONTENTS 1. TERMINOLOGy 2. INITIAL RECOMMENDATIONS 2.1. WARNING SyMBOL .......................... 62 2.2. RECEIVING INSPECTION ........................ 62 2.3. NAMEPLATES ........................... 63 3. SAFETy INSTRUCTIONS 4. HANDLING AND TRANSPORT 4.1. LIFTING .............................. 67 4.1.1. Horizontal motors with one eyebolt ..................67 4.1.2.
  • Page 229 www.weg.net 6.6. ALIGNMENT ............................84 6.7. CONNECTION OF OIL LUBRICATED OR OIL MIST LUBRICATED MOTORS ......85 6.8. CONNECTION OF THE COOLING WATER SySTEM ..............85 6.9. ELECTRICAL CONNECTION ......................85 6.10. CONNECTION OF THE THERMAL PROTECTION DEVICES ............88 6.11.
  • Page 230 www.weg.net 1. TERMINOLOGy the procedure by which the mass distribution of a rotor is checked and, if necessary, adjusted to Balancing: ensure that the residual unbalance or the vibration of the journals and/or forces on the bearings at a frequency corresponding to service speed are within specified limits in International Standards.

  • Page 231: Initial Recommendations

    www.weg.net 2. INITIAL RECOMMENDATIONS Electric motors have energized circuits, exposed rotating parts and hot surfaces that may cause serious injury to people during normal operation. Therefore, it is recommended that transportation, storage, installation, operation and maintenance services are always performed by qualified personnel. Also the applicable procedures and relevant standards of the country where the machine will be installed must be considered.

  • Page 232: Nameplates

    www.weg.net 2.3. NAMEPLATES The nameplate contains information that describes the construction characteristics and the performance of the motor. Figure 2.1 and Figure 2.2 show nameplate layout examples. Manual of Electric Motors Page 134...
  • Page 233 www.weg.net Figure 2.1 - IEC motor nameplate Manual of Electric Motors Page 135...
  • Page 234 www.weg.net Figure 2.2 - NEMA motor nameplate Manual of Electric Motors Page 136...

  • Page 235: Safety Instructions

    www.weg.net 3. SAFETy INSTRUCTIONS The motor must be disconnected from the power supply and be completely stopped before conducting any installation or maintenance procedures. Additional measures should be taken to avoid accidental motor starting. Professionals working with electrical installations, either in the assembly, operation or maintenance, should use proper tools and be instructed on the application of standards and safety requirements, including the use of Personal Protective Equipment (PPE) that must be carefully observed in order to reduce risk of personal injury during these services.

  • Page 236: Handling And Transport

    www.weg.net 4. HANDLING AND TRANSPORT Individually packaged motors should never be lifted by the shaft or by the packaging. They must be lifted only by means of the eyebolts, when supplied. Use always suitable lifting devices to lift the motor. Eyebolts on the frame are designed for lifting the machine weight only as indicated on the motor nameplate.

  • Page 237: Horizontal Motor With Two Eyebolts

    www.weg.net 4.1.2. Horizontal motor with two eyebolts When motors are fitted with two or more eyebolts, all supplied eyebolts must be used simultaneously for the lifting procedure. There are two possible eyebolt arrangements (vertical and inclined), as shown below: For motors with vertical lifting eyebolts, as shown in Figure 4.4, the maximum allowed lifting angle should not exceed 45°...

  • Page 238: Vertical Motors

    www.weg.net 4.1.3. Vertical motors For vertical mounted motors, as shown in Figure 4.7, the use of a spreader bar is required for maintaining the lifting element (chain or rope) in vertical position and thus preventing damage to the motor surface. Figure 4.7 - Lifting of vertical mounted motors Always use the eyebolts mounted on the top side of the motor, diametrically opposite, considering the mounting position.

  • Page 239: Procedures To Place Hgf Motors In The Vertical Position

    www.weg.net 3. Install a second pair of eyebolts, as shown in Figure 4.10; Figure 4.10 - Installation of the second pair of eyebolts 4. Reduce the load on the first pair of eyebolts to start the motor rotation, as shown in Figure 4.11. This procedure must be carried out slowly and carefully.

  • Page 240: Procedures To Place W22 Vertical Mount Motors In Horizontal Position

    www.weg.net 2. Lower the hoist fixed to motor drive end while lifting the hoist fixed to motor non-drive end until the motor reaches its equilibrium, see Figure 4.13; Figure 4.13 - Placing HGF motor in vertical position 3. Remove the hoist hooks from the drive end eyebolts and rotate the motor 180° to fix the removed hooks into the two eyebolts at the motor non-drive end, see Figure 4.14;...
  • Page 241 www.weg.net 1. Ensure that all eyebolts are tightened properly, as shown in Figure 4.1; 2. Install the first pair of eyebolts and lift the motor as shown in Figure 4.16; Figure 4.16 - Install the first pair of eyebolts 3. Install the second pair of eyebolts, as shown in Figure 4.17; Figure 4.17 - Install the second pair of eyebolts 4.

  • Page 242: Storage

    www.weg.net 5. STORAGE If the motor is not installed immediately, it must be stored in a dry and clean environment, with relative humidity not exceeding 60%, with an ambient temperature between 5 ºC and 40 ºC, without sudden temperature changes, free of dust, vibrations, gases or corrosive agents. The motor must be stored in horizontal position, unless specifically designed for vertical operation, without placing objects on it.

  • Page 243: Bearings

    www.weg.net 3) The feet of the crates above should always be supported by suitable wood battens (Figure 5.3) and never stand on the steel tape or without support (Figure 5.4); Figure 5.3 - Correct stacking Figure 5.4 - Incorrect stacking 4) When stacking smaller crates onto longer crates, always ensure that suitable wooden supports are provided to withstand the weight (see Figure 5.5).

  • Page 244: Oil Mist Lubricated Bearings

    www.weg.net 5.3.3 Oil Mist lubricated bearings The motor must be stored in horizontal position. Lubricate the bearings with ISO VG 68 mineral oil in the amount indicated in the Table 5.2 (this is also valid for bearings with equivalent dimensions). After filling with oil, rotate the shaft by hand, at least five revolutions) During the storage period, remove the shaft locking device (if any) and rotate the shaft by hand every week, at least five revolutions, stopping it at a different position from the original one.
  • Page 245 www.weg.net The insulation resistance must be measured with a megohmmeter. The machine must be in cold state and disconnected from the power supply. To prevent the risk of an electrical shock, ground the terminals before and after each measurement. Ground the capacitor (if any) to ensure that it is fully discharged before the measurement is taken. It is recommended to insulate and test each phase separately.
  • Page 246 www.weg.net The motor insulation condition must be evaluated by comparing the measured value with the values indicated in Table 5.5 (corrected to 40 °C): Table 5.5 - Evaluation of the insulation system Limit value for rated voltage Limit value for rated voltage Situation up to 1.1 kV (MΩ) above 1.1 kV (MΩ)

  • Page 247: Installation

    www.weg.net 6. INSTALLATION The insulation resistance must be measured in a safe environment. Check some aspects before proceeding with the installation: 1. Insulation resistance: must be within the acceptable limits. See item 5.4. 2. Bearings: a. Rolling bearings: oxidized bearings must be replaced. If no oxidation is detected, lubricate the bearings as described in Item 8.2.

  • Page 248: Foundations

    www.weg.net 8.Additional recommendations: a. Check the direction of motor rotation, starting the motor at no-load before coupling it to the load; b. Vertical mounted motors with shaft end down must be fitted with drip cover to protect them from liquids or solids that may drop onto the motors;...
  • Page 249 www.weg.net The motors may be mounted on: Concrete bases: are most used for large-size motors (see Figure 6.2); Metallic bases: are generally used for small-size motors (see Figure 6.3). Figure 6.2 - Motor installed on concrete base Figure 6.3 - Motor installed on metallic base The metallic and concrete bases may be fitted with sliding system.

  • Page 250: Motor Mounting

    www.weg.net 6.2. MOTOR MOUNTING Footless motors supplied with transportation devices, according to Figure 6.5, must have their devices removed before starting the motor installation. Figure 6.5 - Detail of the transportation devices for footless motors 6.2.1. Foot mounted motors The drawings of the mounting hole dimensions for NEMA or IEC motors can be checked in the respective technical catalogue.

  • Page 251: Pad Mounted Motors

    www.weg.net For flange mounting the thread engagement length of the mounting bolt should be at least 1.5 times the bolt diameter. In severe applications, longer thread engagement length may be required. In severe applications or if large motors are flange mounted, a foot or pad mounting may be required in addition to the flange mounting (Figure 6.7).

  • Page 252: Direct Coupling

    www.weg.net Remove or fix the shaft key firmly when the motor is operated without coupling in order to prevent accidents. 6.4.1. Direct coupling Direct coupling is characterized when the Motor shaft is directly coupled to the shaft of the driven machine without transmission elements.

  • Page 253: Leveling

    www.weg.net For coupling evaluation consider the maximum axial bearing clearance as shown in Table 6.1. The axial clearance of the driven machine and coupling influence the maximum bearing clearance. Table 6.1 - Clearance used for sleeve bearings Bearing size Total axial clearance (mm) 3 + 3 = 6 4 + 4 = 8 5 + 5 =10...

  • Page 254: Connection Of Oil Lubricated Or Oil Mist Lubricated Motors

    www.weg.net If alignment is made by a laser instrument, please consider the instructions and recommendations provided by the laser instrument manufacturer. The alignment should be checked at ambient temperature with machine at operating temperature. The coupling alignment must be checked periodically. Pulley and belt couplings must be so aligned that the driver pulley center lies in the same plane of the driven pulley center and the motor shaft and the shaft of the driven machine are perfectly parallel.
  • Page 255 www.weg.net Table 6.2 - Typical connection diagram for three-phase motors. Type of Configuration Quantity of leads Connection diagram connection Δ - Y YY - Y ΔΔ - Δ Single speed 11 12 12 10 12 10 12 10 11 12 11 12 12 10 12 10...
  • Page 256 www.weg.net If motors are supplied without terminal blocks, insulate the cable terminals with suitable insulation material that meets the power supply voltage and the insulation class indicated on the motor nameplate. Ensure correct tightening torque for the power cable and grounding connections as specified in Table 8.7 The clearance distance (see Figure 6.13) between non-insulated live parts with each other and between grounded parts must be as indicated in Table 6.3.

  • Page 257: Connection Of The Thermal Protection Devices

    www.weg.net After the motor connection has been completed, ensure that no tool or foreign body has been left inside the terminal box. Unused cable inlet holes in the terminal box must be properly closed to ensure the degree of protection indicated on the motor nameplate.

  • Page 258: Resistance Temperature Detectors (Pt-100)

    www.weg.net The alarm temperature limits and thermal protection shutdowns can be defined according to the application; however these temperature limits can not exceed the values in Table 6.4. Table 6.4 - Maximum activation temperature of the thermal protections Maximum temperature of the protection setting (°C) Component Insulation class Alarm...
  • Page 259 www.weg.net Table 6.5 - Equivalence between the Pt-100 resistance and the temperature ºC Ω ºC Ω ºC Ω ºC Ω ºC Ω 88.617 106.627 124.390 141.908 159.180 89.011 107.016 124.774 142.286 159.553 89.405 107.404 125.157 142.664 159.926 89.799 107.793 125.540 143.042 160.298 90.193...

  • Page 260: Connection Of The Space Heaters

    www.weg.net Temperatura (ºC) Figure 6.16 - Ohmic resistance of the Pt-100 x temperature 6.12. CONNECTION OF THE SPACE HEATERS Before switching ON the space heaters, check if the space heaters connection have been made according to the connection diagram shown on the space heater nameplate. For motors supplied with dual voltage space heaters (110-127/220-240 V), see Figure 6.17.

  • Page 261: Starting Methods

    www.weg.net 6.13. STARTING METHODS Whenever possible, the motor starting must be Direct On Line (DOL) at rated voltage. This is the most simple and feasible starting method. However, it must only be applied when the starting current does not affect the power supply.

  • Page 262: Motors Driven By Frequency Inverter

    www.weg.net 6.14. MOTORS DRIVEN By FREQUENCy INVERTER The operation with frequency inverter must be stated in the Purchase Order since this drive type may require some changes of the motor design. Wmagnet Motors must only be driven by WEG frequency inverter. The frequency inverter used to drive motors up to 690 V must be fitted with Pulse With Modulation (PWM) with vector control.

  • Page 263: Bearing Insulation

    www.weg.net 6.14.2. Bearing insulation Only the motors in IEC frame size 400 (NEMA 680) and larger are supplied, as standard, with insulated bearing. If motor must be driven by frequency inverter, insulate the bearing according to Table 6.9. Table 6.9 - Recommendation on the bearing insulation for inverter driven motors Frame size Recommendation IEC 315 and 355...

  • Page 264: Commissioning

    www.weg.net 7. COMMISSIONING 7.1. INITIAL START-UP After finishing the installation procedures and before starting the motor for the first time or after a long period without operation, the following items must be checked: If the nameplate data (voltage, current, connection diagram, degree of protection, cooling system, service factor, etc.) meet the application requirements;...
  • Page 265 www.weg.net Please consider the minimum distances shown in the Table 7.1 as reference value; Table 7.1 - Minimum distance between the fan cover and wall Frame size Distance between the fan cover and the wall (L) NEMA inches 0.96 1.02 1.18 143/5 1.30...

  • Page 266: Operating Conditions

    www.weg.net 7.2. OPERATING CONDITIONS Unless otherwise stated in the Purchase Order, electric motors are designed and built to be operated at altitudes up to 1000 meters above sea level and in a temperature range from -20 °C to +40 °C. Any deviation from the normal condition of motor operation must be stated on the motor nameplate.

  • Page 267: Limits Of Vibration

    www.weg.net NEMA MG 1 Part 12. The motor has been designed to be operated in one of the following variations: ±10% of the rated voltage, with rated frequency; ±5% of the rated frequency, with rated voltage; A combined variation in voltage and frequency of ±10%, provided the frequency variation does not exceed ±5%.

  • Page 268: Maintenance

    www.weg.net 8. MAINTENANCE The purpose of the maintenance is to extend the useful life of the equipment. The non-compliance with one of these previous items can cause unexpected machine failures. If motors with cylindrical roller or angular contact bearings are to be transported during the maintenance procedures, the shaft locking device must always be fitted.

  • Page 269: Grease Lubricated Rolling Bearings

    www.weg.net 8.2.1. Grease lubricated rolling bearings Excess grease causes bearing overheating, resulting in bearing failure. The lubrication intervals specified in Table 8.1, Table 8.2, Table 8.3 and Table 8.4 consider an absolute temperature on the bearing of 70 °C (up to frame size IEC 200 / NEMA 324/6) and 85 °C (for frame size IEC 225 / NEMA 364/5 and above), the motor running at rated speed, a motor mounted in horizontal position and greased with Mobil Polyrex EM grease.
  • Page 270 www.weg.net Table 8.2 - Lubrication intervals for cylindrical roller bearings LUBRICATION INTERVALS (hours) Amount W21 TEFC W22 TEFC Frame Bearing Poles (Totally Enclosed Fan (Totally Enclosed Fan designation grease (Open Drip Proof) Cooled) Cooled) NEMA 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz...

  • Page 271: Motor Without Grease Fitting

    www.weg.net Table 8.4 - Lubrication intervals for cylindrical roller bearings - HGF line Frame Lubrication intervals (hours) Bearing Amount of Poles designation grease (g) NEMA 50 Hz 60 Hz 4300 2900 315L/A/B and 5006/7/8 and NU320 315C/D/E 5009/10/11 6 - 8 4500 4500 3500...

  • Page 272: Oil Lubricated Bearings

    www.weg.net 8.2.2. Oil lubricated bearings To change the oil of oil lubricated motor proceed as follows: Switch-off the motor; Remove threaded oil drain plug; Open the valve and drain the oil; Close the drain vale again; Reinstall the threaded oil drain plug; Fill-up with the type and amount of oil as specified on the nameplate;...

  • Page 273: Motor Assembly And Disassembly

    www.weg.net Table 8.6 - Oil properties for sleeve bearings Frame Bearing Lubricant Poles Interval (h) Lubricant designation (liters) specification NEMA 315L/A/B and 5006/7/8T and 315C/D/E 5009/10/11T ISO VG32 355L/A/B and 5807/8/9T and mineral oil with Renolin 355C/D/E 5810/11/12T 9-80 8000 antifoam and DTA 10 antioxidant...

  • Page 274: Terminal Box

    www.weg.net 8.3.1. Terminal box Proceed as follows to remove the terminal box cover and to disconnect/connect the power supply cables and the cables of the accessory devices: Ensure that during the screw removal the terminal box cover does not damage the components installed inside the terminal box;...

  • Page 275: Spare Parts

    www.weg.net 8.5. SPARE PARTS When ordering spare parts, always provide complete motor designation, indicating the motor type, the code number and the serial number, which are stated on the motor nameplate. Spare parts must always be purchased from WEG authorized Service Centers. The use of non-original spare parts can cause motor failure, performance drop and void the product warranty.

  • Page 276: Environmental Information

    www.weg.net 9. ENVIRONMENTAL INFORMATION 9.1. PACkAGING WEG electric motors are supplied in cardboard, plastic or wooden packaging. These materials can be recycled and must be disposed according to the applicable laws and regulations in each country. All wood used in the packaging of WEG motors come from the company reforestation program and is not submitted to any chemical conservation treatment.

  • Page 277: Troubleshooting Chart X Solutions

    www.weg.net 10. TROUBLESHOOTING CHART X SOLUTIONS This troubleshooting chart provides a basic list of problems that may occur during motor operation, possible causes and recommended corrective actions. In case of doubts, please contact WEG Service Center. Problem Possible cause Corrective action Check the control panel and the motor Power cables are interrupted power supply cables...
  • Page 278 www.weg.net 11. WARRANTy TERM WEG Equipamentos Elétricos S/A, Motors Unit (“WEG”), offers warranty against defects in workmanship and materials for its products for a period of 18 months from the invoice date issued by the factory or distributor/ dealer, limited to 24 months from the date of manufacture. Motors of the HGF Line are covered for a period of 12 months from the invoice date issued by the factory or distributor / dealer, limited to 18 months from the date of manufacture.
  • Page 279 www.weg.net 12. EC DECLARATION OF CONFORMITy WEG Equipamentos Elétricos S/A Av. Prefeito Waldemar Grubba, 3000 89256-900 - Jaraguá do Sul – SC – Brazil, and its authorised representative established in the European Community, WEGeuro – Industria Electrica SA Contact person: Luís Filipe Oliveira Silva Castro Araújo Rua Eng Frederico Ulrich, Apartado 6074 4476-908 –...
  • Page 280 Pressure Relief Valves Installation and Operating Instructions KUNKLE Pre-Installation Handling Verification of Model and Service Media/ This pressure relief valve is designed to protect equipment from overpressure. The valve should be Capacity/Temperature/Pressure Limits handled with care, not subjected to heavy shock loads, and protected to prevent contamination (Reference attached Model Description/ from getting inside.
  • Page 281 DESCRIPTION DATE APP'D ONYX VALVE TITLE : 1" NPT DIAPHRAGM SEAL W/ ASHCROFT GAUGE & SWITCH SCALE : NONE DRAWN 10-14-13 DATE SEEPEX INC. 16.25 29469 ORDER/ER : CHK'D. DATE PO# 2837735 (MAX.) CUSTOMER : SEEPEX INC. APP'D. DATE ONYX SN# 29469 CODE DWG NO.
  • Page 282 ONYX VALVE CO – Model-K DIAPHRAGM SEAL Installation & Maintenance 10-July-2013 Safety: 1. Observe pressure and temperature limits. Do not use any diaphragm seal in a system that operates at pressure or temperatures in excess of maximum rated conditions. Anticipate abnormal conditions that may occur that could create higher than normal pressure or temperature.
  • Page 283 2. Suggestion: Use an isolation valve between the process pipe and the diaphragm seal so that you can remove the diaphragm seal for maintenance / service without having to shut down the process and depressurize the entire process piping system. ONYX VALVE The model-K is available in two variations: With the optional Clamp...
  • Page 284 What’s the difference? With the clamp ring: This assembly can be taken apart in the field (After isolating the system from process pressure). The clamp ring holds the rubber diaphragm in place, keeping the silicone fill fluid from leaking out and maintaining the integrity of the vacuum fill.
  • Page 285 4. Attach the gauge or other pressure element to a stinger fitting as shown in figure 2. 5. Attach the gauge and stinger fitting assembly to the fill tool adapter as shown in figure-2 6. Turn on the vacuum pump. 7.
  • Page 286 To Fill a Model-K Diaphragm Seal: Vacuum Instrument Pump 1. Assemble the vacuum filling kit as shown in figure 5. The vacuum pump can be either air powered or electric. If using an air-powered Isolator vacuum pump, make sure that your source of Ring compressed air can maintain 90-psi (6 bar) pressure continuously.
  • Page 287 Figure 7 6. Close the oil feed valve. Note that the picture shows an Isolator ring being fillled. The Model- 7. Turn on the vacuum pump. K diaphragm seal is filled in identical fashion. 8. Open the vacuum Valve. 9. Allow the pump to evacuate the isolator ring for 2 minutes.
  • Page 288 nstallation and Maintenance Instructions for ASHCROFT ® Pressure Gauges, Gauge Parts and Ring Designs, Engineering Data SELECTION PROPER USE Pressure Ranges – Select a gauge with a full scale pressure Apply pressure slowly. do not open gauge cock or valve too range of approximately twice the normal operating pressure.
  • Page 289 nstallation and Maintenance Instructions for ASHCROFT ® Pressure Gauges, Gauge Parts and Ring Designs, Engineering Data The drawing below shows a typical solid front, lower connec- When ordering parts – specify as much of the following data tion Duragauge with all of the parts designated by their stan- as possible: Size (Dial Diameter);...
  • Page 290 nstallation and Maintenance Instructions for B400 & B700 ASHCROFT ® Snap Action Switches for Pressure Control B400 Ø 0.28 Ø 0.28 (3 Holes) (3 Holes) A (X06) 3/4 NPT 3/4 NPT X06 Variation 1/2 NPT Male & 1/4 NPT 1/4 NPT Female Female Bracket When Ø...
  • Page 291 nstallation and Maintenance Instructions for B400 & B700 ASHCROFT ® Snap Action Switches for Pressure Control TERMINAL BLOCK INSTALLATION SWITCH A These controls are precision instruments and should never be left with internal components exposed. During installation insure TERMINAL BLOCK that covers are in place and conduit openings are closed except SWITCH B when actually working on the control.
  • Page 292 INSTALLATION, OPERATION MAINTENANCE MANUAL RUBBER EXPANSION JOINTS as supplied by: May 16, 2013 Proco Exansion Joint O&M Manual 6-15-2011 Page 194...
  • Page 293 INDEX STORAGE .................... 1 PREPARATION FOR INSTALLATION ..........1 INSTALLATION PROCEDURES ............2 OPERATION AND MAINTENANCE PROCEDURES ......3 TROUBLE SHOOTING ................ 4 Proco Exansion Joint O&M Manual 6-15-2011 Page 195...
  • Page 294 STORAGE Ideal storage is in a warehouse with a relatively dry, cool location. Store flanged units face down on a pallet or wooden platform. If storage is outside, keep expansion joint protected in waterproof protected crate until ready for installation. Keep expansion joint protected from external elements such as di- rect UV sunlight and/or animals from nesting.
  • Page 295 INSTALLATION PROCEDURES ATING LANGE NSPECTION Check that mating flanges are clean and free of all foreign matter before installing rubber expansion joint. A flat face mating flange is preferred. If raised face flanges are to be used, the flange lip is to be no more than 1/16" tall. XPANSION OINT OLTING...
  • Page 296 IGHTENING EQUIREMENTS Once the expansion joint and control rod plates are in place, tighten all bolts gradu- ally and equally by alternating around the flange. Bolts are not considered tight and "locked-on" until the edges of the expansion joint flanges bulge slightly. (Never tighten bolts on a rubber expansion joint to the point where there is contact between the retaining ring and pipe flange.
  • Page 297 REAKING UBBER XPANSION OINT In the event a rubber expansion joint is to be removed from the system and put back in service at a later date, the seal between the mating flange and joint will need to be broken. Drive small wooden wedges along the perimeter (on 18"...
  • Page 298 Proper Use & Installation Of Valve and Fitting Union Connections TECH-2-No.109 Union connections provide a removable joint that allows assembly and disassembly for temporary connections or installation of piping, valves and other equipment that may need to be removed from a system for servicing or replacement.
  • Page 299 Essential Installation Instructions Preparation Checks • Check that pipe ends are properly prepared for solvent cement or threaded installation of End Connectors. • Check that system has adequate free movement for fi nal assembly of Union Connection without misalignment or need to “draw together” any gaps. •...
  • Page 300 I&M No. V 5847 R2 - T84 Installation & Maintenance Instructions SERIES 2-WAY INTERNAL PILOT-OPERATED SOLENOID VALVES 8210 DIAPHRAGM TYPE — 3/8 AND 1/2 NPT NORMALLY CLOSED OPERATION Temperature Limitations NOTICE: See separate solenoid installation and maintenance • Max Valve Ambient Temperature: See Solenoid I&M or instructions for information on: Wiring, Solenoid Temperature, Catalog...
  • Page 301 Lubricate body gasket and solenoid base gasket with DOW Preventive Maintenance • CORNING® 200 fl uid lubricant or an equivalent high-grade Keep the medium fl owing through the valve as free from dirt and silicone fl uid. Lubricate manual operator stem gasket with DOW foreign material as possible.
  • Page 302 Indicates Parts Supplied BONNET SCREW (4) In ASCO Rebuild Kits Torque bonnet (See Note 1) screws (4) in a crisscross manner to 110±10 in-lbs. (See Note 1) Manual Operator Construction Suffi x “MO” Torque solenoid base sub-assemly to 175±25 in-lbs. Partial View of Mounting Bracket (Optional)
  • Page 303 BVO Series KOBOLD Instruments Inc. Flowmeter and Switch 1801 Parkway View Drive Installation Instructions Pittsburgh, PA 15205 1-412-788-2830 Fax: 1-412-788-4890 www.koboldusa.com BVO Model Number Information Range Fittings Pressure Loss Model Number GPM Water @ Max Flow Brass 304 SS PSIG 0.1-1.0 1/4”...
  • Page 304 Electrical Connections Normally Open SPST Contact SPDT Contact Adjusting the Switch Setpoint Adjusting to Switch on Increasing Flow Adjust the setpoint as follows: Loosen the hold-down screws on the reed contact housing. Slide the contact upwards along its rail until it reaches the stop. Open the medium feed line and set flow to desired volume.
  • Page 305 Number IN-3A Page 1 FOR TRERICE PRESSURE GAUGES Trerice Pressure Gauges are offered in a variety of styles, sizes, and bourdon tube materials. Gauges should be selected carefully to meet the demands of the situation and, in particular, the range should be selected so that the working pressure is approximately 50% of the total range. Principles of Operation Trerice Pressure Gauges utilize the bourdon type tube construction.
  • Page 306 TAB 4 – AS-BUILTS AND SUPPLEMENTAL INFORMATION...
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