Operating Instructions - SEVA
Contents
1. Oil Quantities ANTRIEBSTECHNIK ENERGIEANLAGEN 43 Operating Instruction E Series Troubleshooting Guide 10 Troubleshooting Guide All the operations bellow must be done by authorized and skilled mechanician electrician Inform SEVA before making any change to the gearbox Only oil change is allowed to change without information Do not make any think if you are not sure what you are doing and contact SEVA Any change or operation done without the information of SEVA is in your own risk and responsibility and SEVA does not take any responsibility Problem Observation Remedy Gearbox Does Not Start Up You hear no noise and shaft is not turning You are not using any driver or frequency inverter Please Check the voltage supply and frequency of your electric connection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Still does not work go to ID 100 Gearbox Does Not Start Up You hear no noise and shaft is not turning You are using frequency inverter or driver Please observe the frequency incerter driver manual Chech the2. dart Bt ao _ 61 B3_ en PT B2 g D i i b1 1 L j 1 1 M H H B ee A L1 u Ex xxx 05 _B3 __ 61 BB B2_ jf _B2 lt R Ao le ke L 4 9 Hb yp e de l M M g g A eens cl B L3 Ex xxx 02 34 S E VAJ ENERGIEANLAGEN a 7 4 1 Use the torque arm connection according the following drawing 7 4 Torque Arm Connection Operating Instruction E Series Mounting 35 WY ES NRZ SINN ZA S 7 A E A X ANE y e z gt a 2 VA 4 a Operating Instruction E Series Mounting 7 4 2 Assemble the parts as shown bellow z 92 gt oO S F E Machine connection arm 5 2 Washer 36 Operating Instruction E Series Mounting 7 4 3 For the fixing bold position refer to the following dimensions ANTRIEBSTECHNIK ENERGIEANLAGEN ay 37 Operating Instruction a0 E Series Mounting A 7 5 Fitting outputshaft elements Use the following illustration to assemble output shaft units 1 2 1 Gear shaft end 2 Thrust bearing 3 Coupling
3. 220 V RST OOO Z M an Delayed Running Brake 24 V RSTN SGG LZ 55o Sudden Braking ANTRIEBSTECHNIK ENERGIEANLAGEN 220 V RSTN 55bio M 3 Sudden Brake 24 V RSTN M 29 Operating Instruction E Series Mounting 30 6 5 Check the mounting position The mounting position must be in accordance with the mounting position mentioned on the name plate If different please contact SEVA for possibilities of using in a different mounting position Refer to the mounting positions and oil quantities on this manual and adjust the oil level accordingly with the recommended oil types given on this manuel Do not mix synthetic oils with mineral oils which can cause serious damage on the gear unit 6 6 Use of breather plug Breather plugs are not needed for D series under normal ambient and working conditions Up to 30 C ambient temperature and up to 8 hours per day If heavy ambient conditions and long time working hours then breather plug are recommended by SEVA and delivered with the gearbox together Replace the breather plug with the most top plug according to your mounting position Some plug positions are not machined accordi
4. E Series Gear Units OIECE0200 1112 Operating Instructions Operating Instructions E Series Contents 2 T T a a ee a 02 1 How To Use This Manual sss sese 05 2 Type Designation a2 400 ee 06 2 1 Detailed unit designations sese 06 2 2 Nameplate unit design lion ce 07 3 Part List of Standard Type Gear Units ses ssssssssssssssssssseeeee ereenn ennenen 08 SUITES Teen an ea Rue 08 39 02 E01 TVpes nee ee ee ed 09 303 E02 Wpeze nn ae ee tee 10 S DI E 03 Wpes ame rennen ga Een 11 3 05 E 04 Pesch 12 3 06 E 09 acess cere aeneae nese eee pele aa se ea ee 13 OP Ee OB Ty ata ae ee ers iaa eS 14 3 08 ET 0 TYPES 2 2 ee eng 15 9 09 ET 01 TYPES ae ee 16 910 ET 02 TYPES ee ee ee ea E EERE 17 3 N OS TYPES eision a ende 18 i B08 TVpss zu 22 A oe de a cat 19 SAIREL 05 TYPES sen ee ee 20 3 14 ET 08 TYPES ne ea ee ee 21 A Salely an nenne 22 4 1 lntented to use anne ran toa een ann ner enge as 22 4 2 Impr er USS nen Anden 22 4 3 Safety InSi clons steel 23 4 3 1 General Safety Instruclions u een 23 4 3 1 1 Working on gear reducer essnssnennnnneenennnennenese seen 23 4 3 1 2 ODEISUDN rennen 23 4 3 1 3 Maintenance siehe 23 4 3 14 LGC een 23 4 3 1 5 Ambient Conditions ee 23 4 4 un Ses D 24 4 5 Case Al File dus E ee EE AE E AA E E EEEE 24 4 5 1 Suitable extinguishing agents protective equipment 24 4 5 2 Unsuitable extinguishing agenta eee eee 24 5 Thinks to Check Befo
5. Ensure that the load is slowly and carefully handled and placed 25 Operating Instruction E Series Control 26 5 2 Storage If the geared unit or geared motor will be stored up to 3 years refer to the following in structions With Packing Use corrosion protection oil for the output shaft and connection surfaces like flange sur face or foot assembling surface Seal the unit in a plastic wrap and pack it in container A moisture indicator should be placed around the container to observe the moisture Rela tive atmospheric humidity should not exceed 50 The container should be kept under roof which protects from snow and rain Under this condition the gear unit can be stored up to 3 year with regular check The ambient temperature should be between 5 to 60 C Without Packing Use protection oil for the output shaft and connection surfaces like flange surface or foot assembling surface If no packing is used and the gearbox is stored without packing the ambient temperature should be between 5 to 60 C The gearbox must be kept under enclosed roof with constant temperature and constant humidity not exceeding 50 The storage should be free of dust and dirt and ventilated with filter If the gearbox is stored without packing it is recommended not to store more than 2 years and regular check dur ing this time is recommended If stored in open protect against insect damage 6 Installing The Gear Unit 6 1 Before
6. SL 320 Biodegradable Oil Biologisch abbaubar l Mineral Grease 20 Mineral Fett 20 120 Working Temperature C 120 Betriebstemperatur C Aralub HL3 Energrease LS 3 Tribol BioTop 1418 320 Spheerol AP3 Kl bersynth GEM 2 320 Centoplex 2EP Mobilux EP3 Alvania RL3 Multis Complex EP2 Synthetic Grease 30 100 Working Temperature C Synthetisches Fett 30 100 Betriebstemperatur C ANTRIEBSTECHNIK ENERGIEANLAGEN Energrease SY 2202 Petamo GHY 133 N Mobiltemp SHC 100 Cassida RLS2 Multis Complex SHD 220 41 Operating Instruction E Series Lubrication 9 2 Changing the oil Refer to the nameplate to find out the correct oil filled inside the gearbox oO Do not mix synthetic oils with mineral oils which will cause serious damage to the gear unit The O oil change must be done by using the filling draining and level plugs according the mounting position illustrated in section 9 4 Extended intensive contact with oils can lead to skin irritations N Avoid extended contact with oil and clean oil off skin thorough Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 9 3 Mounting Positions ANTRIEBSTECHNIK 42 SEV Al ENERGIEANLAGEN Operating Instruction E Series Lubrication 9 4 Oil Quantities
7. you start Observe the gear unit for damages of storage or transportation If any damage please contact SEVA Be sure that you have all the equipment necessary for installing like Spanners torque wrench shims and distance rings fixing devices for input and output elements lubricant bolt adhesive etc This manual is not for 94 9 EC ATEX conforming gear units For 94 9 EC conforming gear units refer to the ATEX range manual ATEX conforming gear units have name plates indicating the zone and the temperature class and are different from standard type geared units Therefore Standard units can not be installed on Potentially explosive atmospheres Operating Instructions E Series Control 6 2 Check the shaft dimensions to fit Output Shaft Flange Centering Tolerance DIN748 Centering Sho Shoulder Up to 50mm k6 ulder Tolerance Over 50mm m6 Diameter g6 Hollow Hollow Shaft Output Shaft Tolerance Shaft Diameter H8 Diameter 6 3 Check the ambient temperature The ambient temperature must be between 5 C to 40 C for standard type gear units If different contact SEVA for special solutions 6 4 Check the voltage supply The standard geared motors are supplied with 230 400 V 50 60 Hz up to 3 kW including 3 kW and 400 690 V 50 60 Hz over 3 kW and is indicated on the motors name plate unless it is differently ordered In case of only gear unit is supplied from SE
8. 60 N Mobilgear XMP 460 Carter EP 460 Energol GR XP 320 Kl beroil GEM 1 320 N Mobilgear XMP 320 Carter EP 320 Energol GR XP 220 Kl beroi GEM 1 220 N Mobilgear XMP 220 Carter EP 220 Energol GR XP 150 Kl beroi GEM 1 150 N Mobilgear XMP 150 Carter EP 150 Energol GR XP 100 Energsyn SG XP 680 Kl beroi GEM 1 100 N Kl bersynth GH 6 680 Mobil Glygoyle 680 Tivela S 680 Carter EP 100 Energsyn SG XP 460 Aphasyn PG 460 Kl bersynth GH 6 460 Mobil Glygoyle 460 Tivela S 460 Energsyn SG XP 320 Aphasyn PG 320 Kl bersynth GH 6 320 Mobil Glygoyle 320 Tivela S 320 Energsyn SG XP 220 Aphasyn PG 220 Kl bersynth GH 6 220 Tivela S 220 Energsyn SG XP 150 Aphasyn PG 150 Kl bersynth GH 6 150 Tivela S 150 Kl bersynth GH 6 100 Kl bersynth GEM 4 680 N Mobilgear SHC XMP 680 Enersyn EP XF 460 Kl bersynt GEM 4 460 Mobilgear SHC XMP 460 Enersyn EP XF 320 Kl bersyn GEM 4 320 Mobilgear SHC XMP 320 Enersyn EP XF 220 Kl bersyn GEM 4 220 Mobilgear SHC XMP 220 Enersyn EP XF 150 Kl bersyn GEM 4 150 Mobilgear SHC XMP 150 Kl bersynth GEM 4 100 N Food Grade Oil Schmierung f r Lebensmitteldl Optileb GT 320 Kl beroi 4 UH1 320 N Mobil SHC Cibus 320 Cassida Fluid GL 320 Nevastane
9. VA please observe the name plate of the electric motor and the instructions of the supplier Check the basic electric connection diagrams below Use experienced electric technician STOP Using wrong connection or voltage can damage the electric motor or environment ANTRIEBSTECHNIK S E V Aji 27 ENERGIEANLAGEN Operating Instruction E Series Mounting The following wiring diagram is for standard 230 400 V 50 Hz AC electric motors For differ ent voltages please contact SEVA For gear units supplied without motor refer to the motor manufacturers user manual The electric connection must be done by experienced electric technician The gearbox the motor and the brake must be grounded to prevent potential differences of earth and gearbox motor Nominal Powers at 400V 50Hz 230V D 400V Y 400V D Pole Number Starting Principle Direct or Y D Basic motor connection wiring diagram L1 L2 L3 L1 L2 L3 230V 230V 400V 400V 230V 400V 11T 12 131 1 12 131 Ll L2 L3 28 ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Mounting Standard type brakes basic wiring diagram The electric connection must be done by experienced electric technician An The gearbox and the motor must be grounded to prevent potential differences of earth and gearbox motor Delayed Braking
10. ck for oil leakage x Check for oil level Check oil leakage from seal x Check Rubber buffer x Change if necessary x Change Check Bearings Noise if necessary x See Below for Change Mineral Oil details x See Below for Change Synthetic PAO Oil details Change Sealing Change Bearing Grease Change Bearings Check for noise Changes 45000 40000 35000 Y 30000 25000 20000 15000 10000 5000 Mineral Synthetic PAO Synthetic PG Oil change interval Hours 70 80 90 100 110 120 130 140 150 160 Oil bath temperature Celcius i For normal ambient conditions 70 C oil bath temperature should be taken as reference Synthetic oil are using in E 030 E 040 E 050 E 063 E 075 E 080 types and Mineral oil are using for E 100 and E 125 types 40 SEV AL ENERGIEANLAGEN Operating Instruction E Series Lubrication 9 Lubrication 9 1 Oil Types Lubricant Art des Schmiers DIN 51517 3 Ambient Temperature C Umgebungstemperatur C Beyond Petroleum Kl ber Lubrication Dip Lubrication Tauchschmier Forced Lubrication Druckschmier bp KLUBER LUBRICATION Mobil TOTAL Mineral Oil Mineral l Synthetic Oil Synthetisches l Energol GR XP 680 Kl beroil GEM 1 680 N Mobilgear XMP 680 Carter EP 680 Energol GR XP 460 Kl beroil GEM 1 4
11. d 013 Gearbox is noisy Regular nocking noise run without load If you still hear the noise one of the gears inside is defect Goto ID 100 Check the output shaft connection alements for runout Take out the 014 Gearbox is noisy Regular up and down noise output shaft element and run without load If you still hear the noise one of the gears has runout problem Goto ID 100 Gearbox is with braked motor Low randomly clicking noise may come from the brake disk which is 015 Gearbox is noisy and noise is comming from the normal If noise level is disturbing the brake may be defect or brake brake side randomly clearance is not adjusted Goto ID 100 l The frequency inverter parameters are not optimized for the frequ You are using frequency inver l x ency range or motor you are using Observe the frequency inverters 016 Gearbox is noisy ter and the noise level is chan f manual If still same problem change the ratio of gearbox Goto ID ging according your speed 100 If ambient Temp is over 40 Celsious or none stop work over 16 a l hours please change the top plug with a breather plug Observe this 017 Oil is Leaking Oil Leakage from Seal 2 manual for using breather plug If this is not your case the seal could be damaged Goto ID 100 If you are using breather plug be sure it is in the correct place This is the most top plug position according your mounting position The 018 Oil is Leaking Oil Leakage from Plug plug may be no
12. e designed to work under max 120 Celsius If higher than 120 Celsius and using ATEX conforming gear box immidiately stop the system and contact SEVA If not ATEX gearbox the gearbox is designed to work under max 80 Celsious If higher than 80 Celsius check the oil type and oil quantitiy level according your mounting position and check the nameplate mounting position If nameplate mounting position does not fit the actual position goto ID 100 Gearbox is Heating Up too Much Ambient Temp is over 40 Celsius Standart Gearboxes are designed to work under 40 Celsius ambient temperature If ambient temp is higher than 40 Celsius special soluti ons gearboxes are required Please contact SEVA Gearbox is noisy Noise is regular continious Check Your moving parts for noise Disassemble the gearbox and run without load If you still hear the noise motor bearings or gearbox bea rings are defect Change bearings Goto ID 100 Gearbox is noisy Noise is random Check Your moving parts for noise Disassemble the gearbox and run without load If you hear still the noise the oil may has some particles inside Change the oil and look for small particles If metal particles are found the gearbox may have some demage Goto ID 100 Operating Instruction E Series Troubleshooting Guide ID Problem Observation Remedy Check Your moving parts for noise Disassemble the gearbox an
13. e defect Goto ID 100 Check the motor Fan Hub and rips They must be free of dust If you 023 Motor is heating are using forced external fan check if it is working If you are using up Ambient is dusty frequency inverter in low speeds and you do not have forced exter nal fan you may need forced external fan Goto ID 100 Operating Instruction E Series Troubleshooting Guide Problem Observation Motor is running but Gearbox shaft does Scratching noise comes out Some part key gear may be defect inside gearbox Goto ID 10 not turn The radial load or poligon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or en a cork the plate you assemble the gearbox is rigit enough Check if you Gearbox Housing is You are using chain drive or l i are using the correct diameter of chain drive and you are not Defect pinion gear l B exceeding max allowed radial load Check the position of your output element and re calculate your radyal load and check if this fit to the maximum allowed radial load Goto ID 100 The radial load or poligon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigit enough Check if you You are using chain drive or Output Shaft is Defect are using the correct diameter of chain drive and you are not pinion gear i exceeding max allowed radial l
14. f gearbox to work inside the reccomended range Gearbox Does Not Start Mornings or Af ter Long Time Stop Ambient Temperature is below 5 Celsius The oil is not in accordance with your working conditions Change to lo wer viscosity oils Observe this manuel for using the correct oil Working in higher ambient temperatures is an other solution if possible If still same problem you need higher motor power Gearbox is Heating Up too Much You are using Worm Gear Box and ambient tenp is lower than 40 Celsius Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox and is normal All ATEX conforming gearboxes and standart worm gearboxes are designed to work under max 120 Celsius If higher than 120 Celsius and using ATEX conforming gear box immidiately stop the system and contact SEVA Go to ID 100 If not ATEX confirming check the oil type and oil quantitiy level according your mounting position and check the nameplate mounting position If na meplate mounting position does not fit the actual position goto ID 100 Gearbox is Heating Up too Much You are using Helical Gear Box Ambient temp is lower than 40 Celsius Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox and is normal All ATEX conforming gearboxes ar
15. hub K 7 6 Correct position of output shaft elements The Output Shaft unit transmission elements must placed as close as possible to the gear unit so that the radial load is as closest as possible to the gear unit i Fyi T 1 Hub ANTRIEBSTECHNIK 38 SE V Aj ENERGIEANLAGEN Operating Instruction RC E Series Mounting 6 7 7 Fitting Couplings 7 7 1 By fitting couplings be sure that there is some clearance between the two elements Tat 7 7 2 By fitting couplings be sure that there is no eccentric between the two shafts 7 7 3 By fitting couplings be sure that the two shafts are not angular miss aligned ENERGIEANLAGEN Operating Instruction a0 E Series L Maintenance and Inspections 9 8 Maintenance and Inspections Under normal ambient and working conditions the gear unit should be checked according the following intervals For definition of normal working conditions refer to the product catalogue Selecting Gearbox section Every 3 000 working hours or every 6 months Every 10 000 working hours or every 3 years Item to check Replace Every 4 000 working hours Every 25 000 working hours Che
16. ing 19 Input Flange 2 Output Flange 8 Worm Wheel 14 Seal 20 Bolt 3 Seal 9 Bearing 15 Oil Plug 21 Seal 10 Housing 16 Worm Gear 5 Side Cover 11 Closing Cap 17 Bearing 6 O Ring 12 Circlips 18 O Ring ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 8 ET 00 Types Standard ET 00 type basic part diagram Parts may differ for special applications Standard Part List 5 Bearing 11 Bearing 17 O Ring 6 Worm Wheel 12 Seal 18 Flange 7 Bearing 13 Oil Plug 19 Bolt 8 Housing 14 Worm Gear 20 Seal 9 Closing Cap 15 Key 10 Circlips 16 Bearing Operating Instructions E Series Part Designation 3 9 ET 01 Types Standard ET O1 type basic part diagram Parts may differ for special applications Standard Part List 1 Key 7 Bearing 13 Bearing 19 Bearing 2 Solid Output Shaft 8 Worm Wheel 14 Circlips 20 O Ring 3 Seal 9 Bearing 15 Seal 21 Input Flange 4 Bolt 10 Housing 16 Oil Plug 22 Bolt 5 Side Cover 11 Closing Cap 117 Worm Gear 23 Seal 6 O ring 12 Circlips 18 Key ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 10 ET 02 Types Standard ET 02 type basic part diagram Parts may differ for special applications Standard Part List 1 Key 7 Side Cover 13 Closi
17. l 20 Bolt 3 Seal 9 Bearing 15 Oil Plug 21 Seal 4 Bolt 10 Housing 16 Worm Gear 5 Side Cover 11 Closing Cap 17 Bearing 6 O Ring 12 Circlips 18 O Ring ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 5 E 04 Types Standard E 04 tyoe basic part diagram Parts may differ for soecial applications Standard Part List 7 Bearing 13 Bearing 19 Bearing 8 Worm Wheel 14 Circlips 20 O Ring 9 Bearing 15 Washer 21 Input Flange 10 Housing 16 Seal 22 Bolt 11 Closing Cap 17 Oil Plug 23 Seal 12 Circlips 18 Worm Gear ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 6 E 05 Types Standard E 05 type basic part diagram Parts may differ for special applications Standard Part List 1 Key 7 Bolt 13 Housing 19 Oil Plug 25 Seal 2 Solid Output Shaft 8 Side Cover 14 Closing Cap 20 Worm Gear 3 Circlips 9 O Ring 15 Circlips 21 Bearing 4 Bolt 10 Bearing 16 Bearing 22 O Ring 5 Flange 11 Worm Wheel 17 Circlips 23 Input Flange 6 O Ring 12 Bearing 18 Seal 24 Bolt ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 7 E 08 Types Standard E 08 type basic part diagram Parts may differ for special applications Standard Part List 1 Bolt 7 Bearing 13 Bear
18. motor by supplying direct voltage to see if the problem is on your driver frequency inverter Still does not work go to ID 001 Gearbox Does Not Start Up You hear some noise but both motor shaft and gearbox shaft is not turning You are not using any driver frequency in verter or braked motor Please Check the voltage supply and frequency of your electric connection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Still same problem the load may be too high for the choosen motor Loosen the gearbox from the load torque If it works than the starting torque is insufficient and higher mo tor power is needed For monophaze motors check the star ting up condansator and running condansator as well If notting helps go to ID 100 Gearbox Does Not Start Up You hear some noise but both motor shaft and gearbox shaft is not turning You are using driver or frequency inverter Please observe the frequency inverters or drivers manual To see if the problem is on your driver or frequency inverter take out the driver frequency inverter and make direct voltage sup ply to the motor according the motors nameplate Still does not work go to ID 100 44 Gearbox Does Not Start Up You hear some noise but both motor shaft and gearbox shaft is not turning You are using braked motor Please Check the voltage supply and frequency of your electric connection They mu
19. nd is applicable only for E series If any different type of gearbox is used please ask SEVA for the operating instructions of that type This instruction can be used only for standard type geared units of SEVA For special ap plication and modified gear units ask SEVA for validity This manual does not cover 94 9 EC compatible gearboxes For 94 9 EC contact SEVA Operating Instructions E Series Type Designations 2 Unit Designation 2 1 Detailed unit designation Detailed E series gear units designation for ordering This Designation is different from the short nameplate designation E V 063 01 90S 4 L05 Brake L 220V With Fan P 24V With Fan S 220 Without Fan Z 24 V Without Fan 01 10 Nm 10 100Nm 02 25 Nm 20 200 Nm 04 40 Nm 30 300 Nm 05 50 Nm 40 400 Nm Motor Size For EV types For EN Types 905 4 A06 63 B5 A10 100B5 A20 200 B5 a 63 B14 B10 100 B14 A22 225 B5 Pole Number A11 112 B5 A25 250 B5 Frame Lenght B11 112 B14 A28 280 B5 Motor size R Output Shaft Option 00 Hollow Shaft Output 01 Solid Output Shaft 02 Solid Output Shaft and with Flange 03 Flanged and Hollow Shaft Output 04 With Double Shaft Output 05 Double Flanged and Double Output Shaft 06 With Shaft Extension on the Motor Fan Cover Side 07 With Double Input Shaft 08 Double Flanged and Hollow Output Shaft Housing Size E 030 E 040 E 050 E063 E 075 E 080 E 100 E 125 Input Ty
20. near the gear reducer 4 3 1 2 Operation Touching hot surfaces can lead to burns Do not touch the gear reducer if their operation temperatures are too high or use suitable safety equipment like gloves Rotating machinery can lead to injuries There is danger of being trapped or pulled in Keep a sufficient distance and make safeguarding to rotating machinery See relevant norms EN349 A1 EN13857 4 3 1 3 Maintenance An unintentional start of the machine during maintenance work can lead to serious accidents Make sure no one can start the machine while you are working on it Even a brief running of the machine during maintenance work can lead to accidents if the safety devices are not operating Make sure that all safety devices are mounted and active 4 3 1 4 Lubricant Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thoroughly Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 4 3 1 5 Ambient Conditions Standard gearboxes are allowed to work in ambient temperatures between 5 to 40 C unless differently specified on the nameplate Using the gear unit out of this range can cause damage to the gear unit or_ environment Over 40 C ambient conditions the gear unit surface temp could be so high causing burns when touched If the gear unit will be used in outdoor applications the gear unit mu
21. ng 17 Input Flange 6 Worm Wheel 12 Seal 18 Bolt ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 2 E 01 Types Standard E 01 type basic part diagram Parts may differ for special applications Standard Part List 1 Key 7 Bearing 13 Bearing 19 O ring 2 Solid Output Shaft 8 Worm Wheel 14 Circlips 20 Input Flange 3 Seal 9 Bearing 15 Seal 21 Bolt 4 Bolt 10 Housing 16 Oil Plug 22 Seal 5 Side Cover 11 Closing Cap 17 Worm Gear 6 O ring 12 Circlips 18 Bearing ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 3 E 02 Types Standard E 02 type basic part diagram Parts may differ for special applications Standard Part List 1 Key 7 Side Cover 13 Closing Cap 19 Worm Gear 2 Solid Output Shaft 8 O Ring 14 Circlips 20 Bearing 3 Bolt 9 Bearing 15 Bearing 21 O Ring 4 Flange 10 Worm Wheel 16 Circlips 22 Motor Flange 5 Seal 11 Bearing 17 Seal 23 Bolt 6 Bolt 12 Housing 18 Oil Plug 24 Seal ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 4 E 03 Types Standard E 03 type basic part diagram Parts may differ for special applications Standard Part List 1 Bolt 7 Bearing 13 Bearing 19 Motor Flange 2 Flange 8 Worm Wheel 14 Sea
22. ng Cap 19 Worm Gear 25 Seal 2 Solid Output Shaft 8 O Ring 14 Circlips 20 Key 3 Bolt 9 Bearing 15 Bearing 21 Bearing 4 Flange 10 Worm Wheel 16 Circlips 22 O Ring 5 Seal 11 Bearing 17 Seal 23 Input Flange 6 Bolt 12 Housing 18 Oil Plug 24 Bolt ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 11 ET 03 Types Standard ET 03 type basic part diagram Parts may differ for special applications Standard Part List 7 Bearing 13 Bearing 19 O Ring 8 Worm Wheel 14 Seal 20 Motor Flange 9 Bearing 15 Oil Plug 21 Bolt 10 Housing 16 Worm Gear 22 Seal 11 Closing Cap 17 Key 12 Circlips 18 Bearing ENERGIEANLAGEN Operating Instruction E Series Part Designation 3 12 ET 04 Types e basic part diagram Parts may differ for special applications Standard ET 04 t Standard Part List 1 Key 7 Bearing 13 Bearing 19 Key 2 Solid Output Shaft 8 Worm Wheel 14 Circlips 20 Bearing 9 Bearing 15 Washer 21 O Ring 10 Housing 16 Seal 22 Input Flange 5 Side Cover 11 Closing Cap 17 Oil Plug 23 Bolt 6 O Ring ANTRIEBSTECHNIK ENERGIEANLAGEN 12 Circlips 18 Worm Gear 24 Seal Operating Instructions E Series Part Designation 3 13 ET 05 Types Standa
23. ng mounting position If no mounting position is mentioned by ordering the standard M1 position plugs are machined 6 7 Check the oil level On the mounting position tables the oil level plug is shown Please refer to those tables and be sure that the oil level is correct according the mounting position by screwing half way out the level plug and see if oil comes out from that plug If oil comes out tighten the plug again If no oil comes out take out the filling plug and add oil until oil comes out from the level plug and tighten both plugs after finish Be sure you are using the correct oil mentioned on the oil tables on this manual Do not mix synthetic oils with mineral which can cause serious damage on the gear unit 6 8 Check shaft ends and mounting faces Before you start to installing be sure that all the connection elements are free of oil and dust The output shaft may be protected by anti corrosion oil Please remove this using available solvents on your market By using this do not touch sealing lips or painting of the housing 6 9 Cover abrasive ambient If the gear unit will be placed on a abrasive ambient be sure that the output seals are covered so that no abrasive material chemicals or water touches the seals Any pressure coming from outside over the seals can cause that the out staying substances to enter the gearbox and cause serious damage to the gear unit If pressure or abrasive material can not be prevented from comi
24. ng over the sealing contact SEVA for solutions Abrasive material chemicals water positive or negative pressure exceeding 0 2 bar can affect or damage the sealing lip or output shaft Inside entering substances from the seals can cause serious damage to the gear unit ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Mounting 6 10 Check accessibility to filling breather and drain plugs The filling breather and drain plugs must be freely accessible for further checking and service 7 Mechanical Installation The gear unit can only be installed using the supplied connection points like foot and flange assembling points To install the gear unit without the supplied connection points can cause serious injuries D loosening or braking the gear unit Even the gear unit is installed totally correctly accordin this manual be sure that no one will be harmed by accidentally brake downs or loosening The mounting plate must be rigid enough not allowing torsions flat enough to prevent strains by tightening the bolts and stable enough not allowing vibrations By using chain drives this becomes much more important because of the polygon effect on chain drives According to your connection elements the maximal permitted radial and axial load of the gear unit must be in accordance with your application Check the product catalogue for permitted radial loads and calculation If the output or input shaft is o
25. oad Check the position of your output element and re calculate your radyal load and check if this fit to the maximum allowed radial load Goto ID 100 Please check the wiring diagram of the brake There are two Gearbox is stopping different kind of brake wiring diagram The standart gearbox de You are using braked motor too late livered from our factory is set to delayed braking For sudden braking check the wiring diagram For fast opening of big brakes over 100Nm you may need You are using braked motor shock transformators which is supplied by SEVA Goto ID 100 Gearbox is starting too late Please contact SEVA Service point See on the back side of this manual Changing mechanical parts of gearbox can only be l l l done by SEVA or with information of SEVA Any change without Service Required No self solution found i informing SEVA will cancel the waranty manufacturer declerati on and SEVA will take no responsibility 11 Disposal If your product is no longer of use and you wish to dispose of it refer to the instructions here If you have any questions regarding ecological disposal methods please consult our service points given on the backside of this manuel 11 1 Disposal of Oil Lubricants oil and greases are hazardous substances which can contaminate soil and water Collect drained lubricant into suitable receptacles and dispose of it according to the valid national guid line
26. pe A13 132 B5 B08 80 B14 06 code is optional input shaft types for EN and EV types Can be shown as EN050 00 07 ET050 00 07 N IEC B5 B14 Flange without Motor V IEC B5 B14 Flange with Motor T Without Motor Gearbox Type E serie 07 Code is optional input shaft types for ET Types Can be shown as ANTRIEBSTECHNIK S E VAJ ENERGIEANLAGEN Operating Instructions E Series Type Designations 2 2 Nameplate unit designation Nameplate unit designation is a short abbreviation from the detailed designation A sample name plate for E Series ANTRIEBSTECHNIK SEV A CE ENERGIEANLAGEN Type EV080 00 90S 4 Serial N 10053604 Power 1 14 kW Ratio 60 8 Speed 23 rpm M Pos m1 Oil nara OH QW 64 It Abreviations Serial N Serial Number M Pos Mounting Position Type Designation EV080 00 90S 4 Type Output Shaft Motor Type ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Part Designation 3 Part List of Standard Type Gear Units 3 1 E 00 Types Standard E 00 t e basic part diagram Parts may differ for special a lications Standard Part List 1 Oil Seal 7 Bearing 13 Oil Plug 19 Seal 2 Bolt 8 Housing 14 Worm Gear 3 Side Cover 9 Closing Cap 15 Bearing 4 O ring 10 Circlips 16 O Ring 5 Bearing 11 Beari
27. rd ET 05 type basic part diagram Parts may differ for special applications Standard Part List 1 Key 7 Bolt 13 Housing 19 Oil Plug 25 Bolt 2 Solid Output Shaft 8 Side Cover 14 Closing Cap 20 Worm Gear 26 Seal 3 Circlips 9 O Ring 15 Circlips 21 Key 4 Bolt 10 Bearing 16 Bearing 22 Bearing 5 Output Flange 11 Worm Wheel 17 Circlips 23 O Ring 6 Seal 12 Bearing 18 Seal 24 Input Flange 20 Operating Instruction E Series Part Designation 3 14 ET 08 Types Standard ET 08 type basic part diagram Parts may differ for special applications Standard Part List 1 Bolt 7 Bearing 13 Bearing 19 O Ring 2 Output Flange 8 Worm Wheel 14 Seal 20 Input Flange 3 Seal 9 Bearing 15 Oil Plug 21 Bolt 4 Bolt 10 Housing 16 Worm Gear 22 Seal 5 Side Cover 11 Closing Cap 17 Key 6 O Ring 12 Circlips 18 Bearing ANTRIEBSTECHNIK SEV Al 21 ENERGIEANLAGEN Operating Instruction E Series Safety Hee H N N 4 Safety 4 1 Intended Use The gear reducer is designed for use in industrial machines Please refer to our catalogue or our web page for the maximum permitted torques and speeds The most important maxi mum permitted values are indicated on the nameplate of the product But the whole data can be found on our product catalogues Using the product out of the product catalogue nameplate s pe
28. re the Gear Unit or Geared Motor is Installed 25 51 Ian Teen eT 25 5 2 Storage ee ee 26 6 Installing The Gear Unit eee 26 6 1 Before you San 22 ee eines 26 6 2 Check the shaft dimensions oh 27 6 3 Check the ambient temperature sese eee ee eee 27 6 4 Check the voltage SuppIV sees 27 6 5 Check Ihe mounting DOSIuon 2er ae 30 6 6 Use the breather PlUG 2 2202 en 30 B 7 Check he lllevel ae ea 30 6 8 Check shaft ends and mounting faces sees eee 30 Operating Instructions E Series Contents 6 9 Cover abrasive ambient ogo ztecog asea ee 30 6 10 Check accessibility to filling breather and drain plugs 31 7 Mechanical installation ss ssssssssssssseeeeeeeee ereer eenn eenn ennenen ennn 31 7 1 Installing customer shaft with shoulder sees eee 32 7 2 Shaft tightening torques u en 31 7 3 Recommended shaft dimensions and disassembling nut dimensions 34 7 4 Assembling gear unit with torque arm eee eee eee eee eee 36 7 5 Fitting output shaft elemente 35 2 6 Fitting COUPINGS 32 2000 een ana sarii Enia 39 8 Maintenance amp Inspection uuu0uunuu00000000000H RnB nnnu nn nn nn nn nnmnnn nunnnnnunnnnnnnnennnen 40 9 Lubrieatian u as aeg nee ee ee ee ee 41 TOI el 42 9 2 Changing ine Ola aa ee 42 9 3 Mo nting ee rennen 42 9 4 elai 43 10 Troubleshooting Guide 444 444 ecesenceecceceecnseeeeenncesnscannennennaeceecce
29. rmitted ranges will cancel the warranty manufacturer declaration and SEVA will not take any responsibility The gear units are intended for industrial machines and may only be used in accordance with the information provided in this manual the product catalogue and the nameplate of the gearbox They comply with the applicable standards and regulations and meet the requirements of the directive 2006 42 EC The gearbox must be started up maintained and operated according this manual The gearbox most be incorporated with 2006 42 EC confirming parts machines A motor connected to the gear unit is only allowed to be operated in the frequency entries so that the data provided on nameplate catalogue of the gear unit is not exceeded and is ac cordance with the nameplate catalogue The speed range will be provided on the name plate if SEVA is informed that the gear unit will be used with frequency inverter If not informed the nameplate will have a single fixed speed and only this speed is allowed The electric motor and frequency inverter must be in accordance with 2006 42 EC If the gear units input is used with variable speed gear unit this must be informed to SEVA before ordering and on the nameplate the allowed maximum and minimum speeds speed range will be provided If not mentioned by ordering the gear units speed will be a fixed single input speed and only this speed is allowed lf the gear unit will be driven by belt coupling chain drive e
30. s 11 2 Disposal of Sealings Remove the sealing rings from the gear reducer and clean them of oil and grease resudies Dispose of the sealings as composite material metal plastic 11 3 Disposal of Metal Divide up the remainder of the gear reducer into iron aluminium non ferrous heavy metal if possible Dispose of it according to the valid national guidelines 47
31. sesnsnseeceeeeess 44 a n NS ENS cece E ea A E a a 47 111 Disposal of Al ne an a aea 47 11 2 Disposal of sealing Hr een een 47 11 2 Disposalofmeal aaa a een 47 12 Appendix a en Del 48 122 Warranty COnditiOnS ee ee te 49 123 VAINLY seen een ed 49 12 4 Service Contact Poins aeu au 51 Operating Instructions E Series General Informations 1 How To Use This Manual Take attention to the following safety and warning signs for proper understanding and quick reference H O gt gt Electric Hazard Can cause severe or fatal injuries Mechanical Hazard Can cause severe or fatal injuries Likely to be Hazardous Can cause minor or fatal injuries Damage Risk Can damage gearbox or environment Important Information EC Machinery Directive Within terms of the EC machinery directive 2006 42 EC the gearboxes are considered as not autonomous machine but as a component to install in machines Operation is prohibited within the area of validity of the EC directive until it has been de termined that the machine in which this product is installed corresponds to the regulations within this directive The operating instructions contain important information to ensure Trouble free operation Fulfilment of any rights to claim under guarantee The operating instruction must be kept close to the gearbox and must be available in case it is needed This operating instruction is written for E series gear units a
32. st be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Be sure that the brake is working Observe the brake manufactur ers manuel If brake is supplied from SEVA observe this ma nuel for correct brake wiring diagram If still not work supply the brake with voltage according its nameplate directly For exam ple 198V DC You will hear a clicking noise explaining that the brake is opening If you hear no noise the brake or rectifier is defect If you hear the clicking noise the brake is working You should this clicking noise by your normal electric connection as well By supplying direct supply to the brake you hear the click ing noise and at same time you supply the motor with direct voltage according to its name plate and still same problem the load may be too high for the choosen motor Goto ID 003 Operating Instruction E Series Troubleshooting Guide Problem Observation Remedy Gearbox Does Not Work in Low Speeds frequencies You are using frequency inverter For very low speeds the frequency inverters frequency is lowering down For very low frequencies the inverter parameter and motor parameter must be optimized Also for low speeds the efficiency of the gearbox may varry too much Specially for worm gearboxes The recomended frequ ency range is 20 70 Hz for worm gearboxes and 10 70 Hz for Helical Gear Boxes Use Higher motor power and Frequency inverter or change ratio o
33. st be prevented from rain snow and dust Entering substances inside the gear unit from seals can damage the ear unit Observe the safety instructions for outdoor use EN12100 2010 A A A A A A A A A 99 23 Operating Instruction E Series Safety A A 24 4 4 Tightening Torques All screwed connections for which a tightening torque is specified must on principle be tightened with a calibrated torque wrench and checked Use the following torques for the threaded bores over the gear unit housing For connecting elements refer to the mechanical installation part Tightining M16 190 M20 370 u24 S 4 5 Case of Fire The gear reducer itself is not combustible However it usually contains a synthetic or mineral gear oil Please observe the following ifthe gear reducer is situated in a burning environment 4 5 1 Suitable extinguishing agents Protective equipment Always keep suitable extinguishing protective equipment like carbon dioxide powder foam fog easily accessible around the gear unit High temperature produce irritating steam Use a protective breathing apparatuses 4 5 2 Unsuitable extinguishing agents Do not spray with water ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions E Series Safety as A D ANTRIEBSTECHNIK ENERGIEANLAGEN 5 Thinks to Check Before the Gear Unit or Geared Motor is Installed If geared motors are used please also refer to the manual of
34. t tight enough There are some particles under the plug rubber surface Clean and tifgten the plug If still same problem goto ID 100 Observe exactly where the oil is comming out It could be seal or me l plug point where it comes out and leakes over the housing If this is 019 Oil is Leaking Oil Leakage from Housing your case goto ID 018 019 If you are sure oil comes out from hou sing than housing has some micro split crack Goto ID 100 The sealing liquit under cover is split defect Disassemle the cover 020 Oil is Leaking Oil Leakage from Cover and put new sealing liquit Assemle the cover and tighten the bolts If still same problem goto ID 100 Gearbox is The movement of gear box is because of the runout of the shaft 021 moving regularly it i You are using Torque Arm which you assemle the gearbox This has no bad affect or harm to on its mountin int S the gearbox and is normal unless you are using torque arm poin The movement of gear box is because of the runout and clearance Gearbox is of the shaft which you assemle the gearbox Check the clearance of 022 moving randomly l i ii You are using Torque Arm the assemling shaft and the clearances on your machine This has on its mountin a s no bad affect or harm to the gearbox unless you are using torque oin 9 arm 023 Motor is heating Motor is running over its The motor power is not enough or some overload to the motor is up nominal current possible The motor may b
35. tc the gear unit is only allowed to be used according the nameplate catalogue entries _Different speed higher motor power higher radial axial_loads etc than nameplate catalogue is not allowed The ambient temperature must be between 5 40 C and no abrasive media must attack the paint and seals If different working conditions this must be informed to SEVA before ordering The gearbox maintenance oil change check must be done according this manual 4 2 Improper Use Every usage which exceeds the limits stated above the nameplate and catalogue of the product especially higher torques and speeds is not compliant with the regulations and thus prohibited The operation of the gear reducer is prohibited if It was not mounted installed according to regulations and this manual The gear reducer is very soiled It is operated without lubricant Itis operated out of the permitted values provided on catalogues and or nameplate ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instruction E Series Safety 4 3 Safety Instructions 4 3 1 General Safety Instructions 4 3 1 1 Working on the gear reducer Inappropriately executed work can lead to injury or damage Make sure that the gear reducer is only installed maintained and dismantled by trained technicians Foreign bodies spinning through the air can cause grave injury Before putting the gear reducer into operation check that there are no foreign bodies or tools
36. the motor manufacturer Before you install the gearbox you have to be sure that the gearbox is arrived with the all necessary equipment and without damage Points to take into consideration before you start to install the unit You have received the correct operation manual of the your product The gearbox and all its parts are transported without damage The gearbox is stored correctly according the instructions in this manual You have the latest product catalogue or you have access to our web page 5 1 Transportation When the goods arrive first check for any damage If some damage observed immediately contact the transport company and inform about the damage Contact SEVA for the damage and do not start to install the unit until it is agreed that the damage has no affect of operation Use the supplied eyebolts or lifting holes for lifting up the gear unit The eyebolts are capable to carry the weight of gearboxes only Do not hang additional loads Use suitable hoisting equipment which is capable to hold the gear units weight Refer to the catalogue for various types weights See drawing bellow for hoisting point Do not stay beneath under the lifting hoisting equipment which may cause serious injuries by fallin down objects accidental movements unexpected accidents Falling or hard placement can damage the gear unit Only use hoisting and securing equipment which is permitted for the size weight of your gear unit
37. verloaded by radial or axial loads it can cause serious damage to the gear unit Secure the gear unit using 8 8 or higher quality bolts Cover all the turning parts from human entering or touching Turning parts can cause severe or fatal injuries For different kind of basic installations refer to the following illustrations 31 a Operating Instruction E Series Mounting 7 1 Installing customer shaft with shoulder 7 1 1 Use anti seize assembling paste available on your market Use a brush to ap ply the paste 7 1 2 Fasten the bold as shown below 1 Retaining Bolt 2 Lock Washer 3 Washer 4 Circlips 5 Hollow Shaft 6 Customer Shaft 32 a Z i o F D E c lt F Bolt Type 7 2 Shaft tightening torques Use the following table for shaft tightening torques Operating Instruction E Series Mounting 33 HS gt sl S Sf Alu FR E 9 z Operating Instruction ac E Series F Mounting A 7 3 Advised Shaft Dimensions and Accessiories Advised shaft dimensions are indicated below and SEVA provides this dimensions as stan
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