SEW-Eurodrive Varimot 16-46 Series, D 16, D 26, D 36, DF16D Operating Instructions Manual
...
Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
Explosion-Proof
VARIMOT
and Accessories
Edition 11/2006
11529016 / EN
®
Variable Speed Gear Units
O
perating
I
nstructions
SEW-EURODRIVE – Driving the world
Contents
1 Important Information about the Operating Instructions .............................. 4
1.1 Explanation of symbols ............................................................................. 6
2 Safety Notes ...................................................................................................... 7
2.1 Safety notes for the use of VARIMOT
®
3 VARIMOT
in Explosion-Proof Version .......................................................... 8
3.1 Unit design ............................................................................................... 8
3.2 Unit designation ........................................................................................ 9
3.3 Nameplate............................................................................................... 10
3.4 Overview of mounting options................................................................. 11
4 Installation ....................................................................................................... 12
4.1 VARIMOT
4.2 VARIMOT
®
in category 2G ..................................................................... 12
®
in categories 3G and 3D...................................................... 13
4.3 Permitted overhung loads without primary gear unit............................... 13
4.4 Before you begin..................................................................................... 16
4.5 Preliminary work...................................................................................... 16
4.6 Installation............................................................................................... 17
4.7 Gear units with solid shafts ..................................................................... 19
®
..................................................... 7
5 Startup.............................................................................................................. 21
5.1 Installation and setup of optional equipment........................................... 21
6 Inspection and Maintenance .......................................................................... 32
6.1 Inspection and maintenance intervals..................................................... 32
6.2 Before you begin..................................................................................... 33
6.3 Checking torsional play........................................................................... 33
6.4 Checking the friction ring......................................................................... 34
6.5 Replacing the friction ring........................................................................ 35
6.6 Measuring the temperature of the anti-friction bearing ........................... 36
6.7 Completing the inspection/maintenance process ................................... 37
7 Operation and Service .................................................................................... 38
7.1 Customer service .................................................................................... 38
7.2 Malfunction of VARIMOT
®
speed gear units........................................... 38
7.3 WEXA/WEX speed monitor..................................................................... 39
8 Declaration of Conformity .............................................................................. 40
8.1 Variable speed gear units category 2G, VARIMOT
8.2 Variable speed gear units category 3G and 3D,
VARIMOT
®
series 16-46......................................................................... 41
®
series 16-46 ......... 40
9 Index................................................................................................................. 42
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
3
1
Important Information about the Operating Instructions
1 Important Information about the Operating Instructions
Introduction You must follow the information in the operating instructions to ensure trouble-free oper-
ation and for the fulfillment of any rights to claim under the limited warranty. Read the
operating instructions before you start working with the unit.
Make sure that the operating instructions are available to persons responsible for the
system and its operation, as well as to persons who work independently on the unit.
Also observe other technical documents, contracts for delivery or other agreements.
Intended use
Qualified personnel
VARIMOT
systems and may only be used in accordance with the information provided in SEWEURODRIVE's technical documentation and the information given on the nameplate.
It corresponds to valid standards and regulations and meet the requirements of
EC Directive 94/9/EC and the EC Directive for Machinery 98/37/EC.
Gear unit loads other than those specified and areas of application other than industrial
and commercial systems can only be used after consultation with SEW-EURODRIVE.
Any application other than those mentioned is considered non-intended use.
A drive motor connected to the VARIMOT
inverter.
VARIMOT
material. Consequently, assembly, installation, startup and service work may only be
performed by trained personnel who are aware of the potential hazards.
Personnel must possess the required qualifications for the relevant task and be familiar
with the:
• Assembly
• Installation
•Startup
•Operation
• Maintenance
• Servicing
of the product.
Personnel must carefully read the operating instructions, in particular the safety notes
section, and understand and comply with them.
®
variable speed gear units are intended for commercial and industrial
®
may not be operated on the frequency
®
variable speed gear units represent a potential hazard for persons and
4
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
Important Information about the Operating Instructions
Exclusion of liability
You must comply with the information contained in these operating instructions to
ensure safe operation of the VARIMOT
specified product characteristics and performance requirements.
SEW-EURODRIVE GmbH & Co KG assumes no liability for injury to persons or damage
to equipment or property resulting from non-observance of these operating instructions.
In such cases, any liability for defects is excluded.
Product names and trademarks
The brands and product names contained within these operating instructions are trademarks or registered trademarks of the titleholders.
Waste disposal (Please follow the current instructions):
• Housing parts, gears, shafts and anti-friction bearings of the gear unit must be disposed of as steel scrap. This also applies to gray-cast iron parts if there is no special
collection.
• Collect waste oil and dispose of it according to the regulations in force.
®
1
variable speed gear unit and to achieve the
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
5
1
Important Information about the Operating Instructions
Explanation of symbols
1.1 Explanation of symbols
The operating instructions contain important information that deals with general and
operational safety. This information is emphasized in particular with the following
symbols.
Electrical hazard
Possible consequences: Severe or fatal injuries.
Hazard
Possible consequences: Severe or fatal injuries.
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the drive and the environment.
Tips and useful information.
Important information about explosion protection.
6
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
2 Safety Notes
Safety Notes
Safety notes for the use of VARIMOT®
2
2.1 Safety notes for the use of VARIMOT
The following safety notes apply to variable speed gear units.
When using variable speed gearmotors, also refer to the safety notes for gear units
and motors in the relevant operating instructions.
Take into consideration the supplementary safety notes in the individual sections
of these operating instructions.
Explosive gas mixtures or dust concentrations when combined with hot, live, and
moving parts of electrical machinery can cause serious injury or death.
Assembly, connection, startup, maintenance and repair work on the VARIMOT
variable speed gear units and the optional electrical components may only be
performed by qualified personnel while taking the following into account:
• These operating instructions
• Warning and instruction labels on the variable speed gear unit/variable speed gearmotor
• All other project planning documents, operating instructions and wiring diagrams
belonging to the drive
• The specific regulations and requirements for the system
• National/regional regulations on explosion protection, safety, and prevention of accidents that are currently in effect
®
®
Optional
equipment
Optional equipment complies with existing standards and regulations:
• EN 50014
• EN 50018 for protection type "d"
• EN 50019 for protection type "e"
• EN 50020 intrinsically safe "i"
• EN 50281-1-1/EN 50281-1-2 "Electrical apparatus for use in the presence of
combustible dust"
In addition to general installation guidelines, the following regulations in accordance with
ElexV 1 (or other national regulations) must be observed for electrically operated
options:
• EN 60079-14 "Electrical apparatus for explosive gas atmospheres"
• EN 50281-1-2 "Electrical apparatus for use in the presence of combustible dust"
• DIN VDE 105-9 "Operating electrical equipment" or other national regulations
• DIN VDE 0100 "Erection of power installations with rated voltages below 1000 V" or
other national regulations
• System-specific regulations
Technical data and information on approved conditions on site can be found on the
nameplate and in these operating instructions.
These details must be strictly observed.
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
7
3
[1]
[9]
[5]
[4][6] [10]
[7]
[3]
[8]
VARIMOT® in Explosion-Proof Version
Unit design
3 VARIMOT® in Explosion-Proof Version
3.1 Unit design
Fig. 1: VARIMOT® in explosion-proof version
52018AXX
[1] Complete output shaft
[3] Plate
[4] Adjusting plate
[5] Housing cover
[6] Drive disk
[7] Needle bearing
[8] Housing with tapped hole
[9] Complete hollow shaft
[10] Friction ring
8
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
3.2 Unit designation
The following diagram shows the type code structure:
DV 26B WEX II2G eDT 90L 4 TF
VARIMOT® in Explosion-Proof Version
Unit designation
Temperature sensor
Number of motor poles
Motor size
Motor series
Explosion-proof version according to ATEX 100a
Speed monitor
3
VAR IMOT
indicates wet version
VAR IMOT
version
®
variable speed gear unit size B
®
variable speed gear unit series flange
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
9
3
3.3 Nameplate
Example
VARIMOT® in Explosion-Proof Version
Nameplate
Bruchsal / Germany
DF36/A/IGEX/II2G
Typ
01.1151703702.0001.06
Nr.
159/798
r/min
n
a
M
Nm
84/38
a
IM
M4
Bedienungsanleitung muss beachtet werden
Zum Einbau in Komplettantrieb
RX77 D36/IGEX/II2G eDV112M4/C
II2G / T3
Lagerfett synth. KHC2R
Fig. 2: Nameplate
R
n
P
kg
i
Made in Germany 150 881 4.10
1:
5
r/min
e
1440
3.6
kW
e
104.242
=
168
60417AXX
Typ Type code
Nr. Sales order number
Minimum and maximum output speed
n
a
Output torque at minimum and maximum output speed
M
a
IM Mounting position
R Control range
Input speed
n
e
Input power
P
e
kg Weight
i Gear ratio
10
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
VARIMOT® in Explosion-Proof Version
3.4 Overview of mounting options
Overview of mounting options
3
[2]
[5]
Fig. 3: Overview of mounting options
[3]
[1]
[4]
52019AXX
[1] Adjustment device with free shaft end NV
[2] Adjustment device with handwheel and position indication HS
[3] Adjustment device with handwheel (standard version)
[4] Indicator scale
[5] Voltage encoder IGEX
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
11
4
Installation
VARIMOT® in category 2G
4 Installation
Strictly observe the safety notes on page 7 when installing the variable speed
gear unit.
4.1 VARIMOT® in category 2G
General
information
Designation "X" • If the designation "X" appears after the certification number on the declaration of
Temperature class • VARIMOT
Ambient
temperature
Output power and
output torque
Speed monitoring • VARIMOT
• SEW explosion-proof variable speed gear units of the VARIMOT® D/DF 16-46 series
and VARIMOT
group II, category 2G (explosive gas atmosphere). These units are intended for use
in zones 1 and 2.
• A standard feature of the SEW-EURODRIVE explosion-proof variable speed gear
units of the VARIMOT
conformity or the EC prototype test certificate, this indicates the certificate contains
special conditions for safe application of the variable gear unit.
approved for temperature class T3. The temperature class of the variable speed gear
unit is indicated on the nameplate.
• VARIMOT
of –20°C (–4°F) to +40°C (+104°F).
• It is essential that nominal values of output power and/or output torque are maintained.
speed monitoring device. The speed monitor must be correctly installed and adjusted
(see Sec. "Startup", Speed monitoring).
Verify the speed monitoring function before startup.
®
D/DF 16-46B series meet the design requirements of equipment
®
series is a tapped hole for installing a voltage encoder.
®
variable speed gear units, category 2G (explosive gas atmosphere) are
®
variable speed gear units may only be used at an ambient temperature
®
variable speed gear units in category 2G may only be operated with a
12
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
VARIMOT® in categories 3G and 3D
F
R
d
l
l/2
4.2 VARIMOT® in categories 3G and 3D
General
information
Temperature class • VARIMOT
Surface
temperature
Ambient
temperature
Output power and
output torque
• SEW-EURODRIVE explosion-proof variable speed gear units of the VARIMOT
D/DF 16-46 and VARIMOT® D/DF 16-46B series meet the design requirements of
equipment group II, categories 3G (explosive gas atmosphere) and 3D (explosive
dust atmospheres). These units are intended for use in zones 2 and 22.
• A standard feature of the SEW-EURODRIVE explosion-proof variable speed gear
units of the VARIMOT
®
variable speed gear units of category 3G (explosive gas atmosphere)
®
series is a tapped hole for installing a voltage encoder.
are approved for temperature class T3. The temperature class of the variable speed
gear unit is indicated on the nameplate.
• The maximum surface temperature of VARIMOT
gory 3D (explosive dust atmosphere) may not exceed 200 °C (392 °F). The system
operator must guarantee that a possible accumulation of dust will not exceed a
maximum thickness of 5 mm, in accordance with EN 50281-1-2.
• VARIMOT
®
variable speed gear units may only be used at an ambient temperature
of –20°C (–4°F) to +40°C (+104°F).
• It is essential that nominal values of output power and/or output torque are
maintained.
Installation
®
variable speed gear units, cate-
4
®
If an overload condition of the VARIMOT® as category 3G or 3D unit cannot be
ruled out during normal operation, a VARIMOT
monitor must be used (see Sec. "Startup", Speed monitoring).
4.3 Permitted overhung loads without primary gear unit
Definition of force
application of
overhung loads
The development of the overhung load depicted in the diagrams refers to a point of
application at mid-point of the shaft extension as indicated in Figure 1. If force is applied
to areas other than the center of the shaft end, consult SEW-EURODRIVE for permitted
lateral forces.
®
unit with a functioning speed
Fig. 4: Definition of force application of overhung loads
F
[N] = permitted overhung load point of application at mid-point of shaft extension.
R
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
50248AXX
13
4
VARIMOT® D16
n [1/min]
FR [N]
0
500
1000
1500
2000
2500
300 600 900 1200 1500 1800
DT71D4
DT80K4
DT80N4
Installation
Permitted overhung loads without primary gear unit
FR [N]
4000
3500
3000
2500
2000
1500
1000
500
0
300 600 900 1200 1500 1800
VARIMOT® D26
51908AXX
DV100M4
DT90L4
DT90S4
n [1/min]
51909AXX
14
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
Installation
FR [N]
VARIMOT® D36
n [1/min]
0
1000
2000
3000
4000
5000
6000
300 600 900 1200
1500
1800
DV100L4
DV112M4
DV132S4
[
]
Permitted overhung loads without primary gear unit
4
FR [N]
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
400 600 800 1000 1200 1400 1600 1800
VARIMOT® D46
DV132M4
DV132ML4
DV160M4
51911AXX
1/min
n
51912AXX
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
15
4
4.4 Before you begin
Installation
Before you begin
The drive
may only be
installed if
• The information on the nameplate of the drive matches the approved on-site explosion application range (equipment group, category, zone, temperature class or maximum surface temperature).
• The information on the nameplate of the drive matches the voltage supply system.
• The drive is undamaged (no damage caused by transportation or storage).
• It is certain that the following requirements have been met:
• Ambient temperature between –20 °C (–4 °F) and +40 °C (+104 F°)
• No oils, acids, gas, vapors, radiation, potentially explosive atmospheres, etc.
• Enclosure has been verified.
4.5 Preliminary work
Variable speed
gear units
Risk of material damage
Do not let the solvent come into contact with the sealing lips of the oil seals or on
the wide V-belt.
The output shafts and flange surfaces must be thoroughly cleaned of anti-corrosion
agents, contamination or such (use a commercially available solvent).
Anti-friction
bearing grease
Please note:
• The service life of the lubricant in the bearings is reduced if the unit is stored for
à 1 year.
Ambient temperature Base Original filling Brand
Gear unit anti-friction
bearing
–20 °C (–4 °F) to +40 °C
(+104 °F)
Synthetic Mobiltemp SHC 100 Mobil
16
Operating Instructions – Explosion-Proof VARIMOT® Variable Speed Gear Units and Accessories
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