SEEPEX_OM_371144_EN

Operating and Assembly Instruction
Progressive Cavity Pump
Commission-no. Type
371144 BT 2-6L
Read instructions before Always keep instructions

beginning any work! handy on the worksite.
Original Instructions
Issue 14.10.2019
Index
1 Safety ....................................................................................................................................................
Safety....................................................................................................................................................
....................................................................................................................................................11
1.1 Notes on these instructions
1.2 Safety-related Information
1.3 Designated use
1.4 Foreseeable misuse
1.5 Structure of warning notes
1.5.1 Warning levels
1.5.2 Warning symbols
1.6 Qualification of the personnel
1.7 Tasks, notes for the owners, operators and technicians
1.8 Personal protective equipment
1.9 Safety and protective devices
1.10 Safety clearance
2 Description of the machine ................................................................................................................. 11

machine.................................................................................................................
2.1 General description
2.2 Mode of action and pumping principle of the machine
2.3 Constructive design
3 Technical Data ....................................................................................................................................

Data.................................................................................................................................... 12
....................................................................................................................................12
3.1 Data sheet .............................................................................................................................. 14
3.2 Characteristic Curves ............................................................................................................. 16
3.3 Declarations........................................................................................................................... 20
4 Transport, Intermediate storage, Disposal ..........................................................................................

Disposal.......................................................................................... 22
..........................................................................................22
4.1 Safety
4.2 Transport
4.2.1 Dimensions, weight and centre of gravity
4.2.2 Symbol
4.2.3 Lashing points (AP) for lifting devices
4.2.4 Unpacking the machine
4.3 Temporary storage/corrosion protection
4.4 Disposal
Index
5 Assembly / Installation ........................................................................................................................ 25

Installation........................................................................................................................
5.1 Mounting tools / lifting gear
5.2 Space requirement
5.2.1 Dimension for stator replacement
5.3 Assembly of the complete mounted machine
5.4 Power supply of the machine
5.5 Pipelines
5.5.1 Suction and pressure connection
5.5.2 Pipeline dimensions
5.5.3 Residue-free pipelines
5.5.4 Tension-free assembly
5.6 Dimensional Drawing............................................................................................................. 27
6 Commissioning / De-Commissioning ..................................................................................................

De-Commissioning.................................................................................................. 27
..................................................................................................27
6.1 Commissioning report............................................................................................................ 27
6.2 Measures before commissioning............................................................................................ 28
6.2.1 Checking pipelines
6.2.2 Protective devices on the pump
6.2.3 Electrical / hydraulic connections
6.2.4 Direction of rotation check
6.2.5 Additional devices - optional
6.3 Initial commissioning/repeated commissioning
6.3.1 Avoiding dry running of the pump
6.3.2 Pressure in the suction and pressure connection
6.4 De-commissioning
6.4.1 Switching off the pump
6.4.2 Emptying the pump
6.4.3 Dismantling the pump
6.4.4 Preservation/storage of the pump
7 Maintenance ....................................................................................................................................... 33
Maintenance.......................................................................................................................................
7.1 Preventative measures
7.1.1 Machine down-time
7.2 Lubrication
7.2.1 Joint grease
7.3 Inspection
8 Malfunctions, causes, rectification ...................................................................................................... 35

rectification......................................................................................................
9 Dismantling / Reassembly .................................................................................................................. 37

Reassembly..................................................................................................................
9.1 Dismantling / Reassembly of the machine............................................................................. 37
9.1.1 Prepare the machine for dismantling
9.1.2 Dismantling
9.1.3 Reassembly
Index
9.2 Rotating unit – individual parts .............................................................................................. 43

9.2.1 Dismantling
9.2.2 Rotating unit (RTE) - prepare individual parts for reassembly
9.2.3 Rotating unit (RTE) - individual parts - reassembly
9.3 Holding band - assembly........................................................................................................ 48
9.3.1 Prepare the holding band
9.3.2 Check the holding band
9.3.3 Assembling the holding band
9.3.4 Correct tension for the holding band (HBD)
9.3.5 Cant up the holding band
9.3.6 Shear the holding band
9.3.7 Check the holding band after assembly
9.4 Mechanical seal ..................................................................................................................... 51
9.4.1 Safety
9.4.2 Application conditions and material version
9.4.3 Design
9.4.4 Commissioning
9.4.5 Monitoring during operation
9.4.6 Dismantling of mechanical seal
9.4.7 Reassembly of mechanical seal
9.6 Sectional drawing shaft sealing.............................................................................................. 55
10 Spare parts ......................................................................................................................................... 56

parts.........................................................................................................................................
10.1 Order template for spare parts............................................................................................... 58
10.2 Sectional drawing ................................................................................................................... 61
10.2.1 Parts list ..................................................................................................................... 61
11 Special tools ....................................................................................................................................... 63
12 Associated documents ........................................................................................................................

documents........................................................................................................................ 64
........................................................................................................................64
13 Appendix .............................................................................................................................................
Appendix............................................................................................................................................. 66
.............................................................................................................................................66
13.1 Manufacturer's documents / suppliers
13.1.1 Gearbox ..................................................................................................................... 68
13.1.2 Motor ....................................................................................................................... 145
Subsidiaries
1. Safety
1. Safety
1.1 Notes on these instructions
1.1.1 General notes

 Always keep the operating and maintenance instructions close by the
machine.
 If problems cannot be solved with reference to the operating and
maintenance instructions, please contact SEEPEX.
Observe the following points in addition to these operating and maintenance
instructions:
 Prohibition, warning and mandatory signs, warning notes on the machine
 Relevant laws and ordinances
 Statutory provisions on accident prevention
 Corresponding harmonised standards and regulations
1.1.2 Validity of these instructions

• These operating and assembly instructions are valid exclusively for ma-
chines with the commission no. specified on the cover sheet.
• The operating and assembly instructions are correlated with the SEEPEX
machine by means of the commission no. on the type plate (TYS).
Figure similar
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1. Safety
1.1.3 Symbols, notes and abbreviations
1.1.3.1 Information symbols
Symbol Application
 Instruction/measure
 supplementary instruction/measure
 List item
Information
 Cross-reference
1.1.3.2 Abbreviations
Abbreviations facilitate readability in drawings.
Abbreviations are explained below:
Abbrevia- Designation Abbrevia- Designation

tion tion
ANT Drive K Terminal
AP Lashing points KF Kinetic ring grease
ATG Drive casing KUL Crank
CBH Feed hopper screw fit- P Dimension for stator re-
ting placement
CFL Flanged connection RTE Rotating unit
CTH Threaded connection S Support
DFL Flange seal SCH Screw fitting
ELT Feed hopper SCL Holding band loop
ERD Earth connection SEA Shaft sealing
FCO Flange cover SH Protective cover
FLS Flange bearing surface SHL Cutting lever
GC Anti-seize graphite pe- SSU Flush connection
troleum
GF Joint grease TSE Dry-running protection
device
GM Lubricant TYS Type plate
GS Soft soap ZA Sealing -/ centering sur-
face
HBD Holding band ZD Centering surface
HS Label
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1. Safety
1.2 Safety-related Information

SEEPEX machines are built in accordance with the state of the art. Neverthe-
less, there is a residual risk, because the machine works with:
• Mechanical movements that pose a danger
• Electrical voltages and currents
1.3 Designated use

SEEPEX machines are individually configured. The machine is allocated to the
operating and assembly instructions based on the commission no. The commis-
sion no. is indicated on the type plate of the machine and on the cover sheet of
the operating and assembly instructions.
Observe the following points to ensure compliance with the intended use:
 Use the machine only for conveying media in accordance with the technical
data ( chapter 3)
 Use the machine only within the performance data as specified in the tech-
nical data ( chapter 3)
 Make alterations and modifications to the machine only after obtaining the
approval of SEEPEX
 Use the machine only in commercial and industrial areas
 Do not use the machine in explosive areas
1.4 Foreseeable misuse

Any use other than the intended use or any different use of the machine will be
considered as improper use and can cause serious physical injury and damage
to property.
In particular, the following is not admissable:

 Conveyance of conveying products other than those specified in the techni-
cal data ( chapter 3)
 Operating the machine outside of the performance data specified in the tech-
nical data ( chapter 3)
 Operating the machine without safety and protection devices
 Mechanical or electrical bypassing of machines or machine parts
 Use of parts other than the original parts
 Alterations, modification and manipulation
 Non-compliance with instructions and prescribed operating, maintenance
and servicing conditions
 Non-compliance with the rules and regulations in the country of use and the
statutory provisions and accident prevention regulations when handling the
machine
 Operating the machine in explosive areas
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1. Safety
1.5 Structure of warning notes

 For the protection of personnel and for the safe and efficient use of the ma-
chine, observe warning notes.
Preceding warning notes
Preceding warning notes are placed at the beginning of each chapter or sequence of actions, and relate to
the instructions following directly after.
DANGER
Type and source of danger.
Possible consequences.
 Measures to avert the danger.
Preceding warning notes with warning or mandatory signs

Specific dangers are identified with additional warning or mandatory signs.
Example:
DANGER
Type and source of danger.
Possible consequences.
Embedded warning notes

Embedded warning notes describe immediately relevant dangers, and are shown within a sequence of ac-
tions. They are placed immediately before the danger.
Examples:
 Type and source of danger. Possible consequences. Meas-

ures to avert the danger.
Type and source of danger. Possible consequences.

1.5.1 Warning levels

Warning notes are identified by coloured warning symbols and signal word fields.
The different warning levels are identified by additional signal words, and de-
scribe the extent of the danger.
Personal injury
DANGER
DANGER indicates a dangerous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a dangerous situation which, if not avoided, may result in death or serious injury.
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1. Safety
CAUTION
CAUTION indicates a dangerous situation which, if not avoided, may result in minor or
moderate injury.
Property damage
NOTICE
NOTICE is used when the situation is not associated with personal injury.
1.5.2 Warning symbols

In these operating and assembly instructions and on the machine, there are
warning symbols.
 Ensure that these warning symbols are complied with.
 Warning symbols on the machine must be fully present and easily legible at
all times.
Warning symbols Hazard

Suspended load warning
Electric voltage warning
Hot surface warning
Warning for automatic start
Warning against falling into/reaching into the

feed hopper
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1. Safety
1.6 Qualification of the personnel
Detailed technical knowledge is essential for performing any work on the

machine, in order to be able to independently recognise and avoid potential
dangers.
Activity Person proven knowledge

 Instruction of person- Owner  Knowledge of safety regulations
nel  Knowledge of these operating and assembly in-
 Definition of respon- structions
sibilities
 Definition of respon-
sibilities
 Monitoring of ade-
quate qualification of
personnel
 Operation Operator  Instruction for the machine
 Operational monitor-  Before starting any activity, the operating and as-
ing sembly instructions must be read and
 Easy maintenance understood
work and trouble-  Knowledge of safety devices and
shooting regulations
 Electrical installation Electrical technician  Technical training, knowledge and experience
 Commissioning with the machine in relation to electrical compo-
 Maintenance nents
 Repair  Knowledge of the relevant standards and regula-
tions
 Decommissioning
 Safe handling of tools
 Assembly and dis-
mantling  Knowledge of these operating and assembly in-
structions
 Commissioning Mechanical technician  Technical training, knowledge and experience
 Maintenance with the machine in relation to mechanical com-
 Repair ponents
 Decommissioning  Knowledge of the relevant standards and regula-
tions
 Assembly and dis-
mantling  Safe handling of tools
 Knowledge of these operating and assembly in-
structions
1.7 Tasks, notes for the owners, operators and technicians

 Do not work on the machine or plant unless it is at a standstill and de-
pressurised.
 Switch off the main switch and pull out the power plug before starting work
on live components.
 Observe the procedure for shutting down the machine (  chapter 6).
– Follow decommissioning procedure.
– Secure the machine against recommissioning.
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1. Safety
 On completion of all work, attach all safety and protective devices

and make sure they are functioning.
 Refer to chapter Commissioning before recommissioning the machine
(  chapter 6).
1.8 Personal protective equipment

 Wear personal protective equipment and/or additional equipment for your
own safety.
Sign Meaning Scope of application

Wear safety Work in the area of the
shoes machine
Wear eye protection Work on the machine

during which parts may
be ejected at speed and
parts may be pressurised
Wear protective Possible contact with ag-

gloves gressive media, hot sur-
faces or sharp edges
Wear ear protection Sustained sound

pressure level
> C 75 dB (A)
Wear safety helmet Work with suspended

loads and overhead work
Wear protective clothing Possible contact with

aggressive media
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1. Safety
1.9 Safety and protective devices

 Before commissioning, bolt SEEPEX machines to a suitable foundation to en-
sure stability.
 Start-stop equipment must be clearly recognisable. In order to avoid errors,
the operator must arrange corresponding measures.
Protective devices protect those persons who are attempting to reach danger
areas without additional help and under the conditions defined for various
situations of reaching up, reaching under or reaching through.
 Equip pump with a protective device

• In order to prevent contact with hot surfaces
• In order to prevent contact with moving parts
– Use finger probe to check protective device.
1.10 Safety clearances
Protective structure
 Use a physical barrier (e.g. guard, part of a machine) in order to limit
movement of the body.
Safety clearance
 Observe appropriate minimum clearance by means of the protective structure
in front of the danger area.
1.10.1 Values for safety clearances - requirements

Safety clearances defined as follows:
• Protective structures and openings in them retain their shape and position
• Measure safety clearances between limiting surfaces and the body or
affected body part
• Danger area can be reached with difficulty
• The reference level is the level on which people normally stand, e.g. floor
or working platform
• Do not use any objects such as chairs, ladders to change the reference level
• Do not use any objects such as rods or tools to extend the natural reach of
upper extremities
1.10.2 Safe reaching over protective structures

 If the danger area represents a severe risk, then the values in the table or
other technical safety measures must be used.
 If the known values for a, b or c fall between two values in the table, use
values that result in a higher level of safety.
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1. Safety
1
3
1 AST
b
a
3 3
b
b
a
a
c c c
a Height of the danger area

b Height of the protective structure
c Horizontal safety clearance from the danger area
1 Danger area (shortest distance)
2 Reference level
3 Protective structure
AST Extension hopper
Table 1
Height of the Height of the protective structure b 1)

danger area 1000 1200 1400 1600 1800 2000 2200 2400 2500 2700
a Horizontal distance to the danger area c
2)
2700 - - - - - - - - - -
2600 900 800 700 600 600 500 400 300 100 -
2400 1100 1000 900 800 700 600 400 300 100 -
2200 1300 1200 1000 900 800 600 400 300 - -
2000 1400 1300 1100 900 800 600 400 - - -
1800 1500 1400 1100 900 800 600 - - - -
1600 1500 1400 1100 900 800 500 - - - -
1400 1500 1400 1100 900 800 - - - - -
1200 1500 1400 1100 900 700 - - - - -
1000 1500 1400 1000 800 - - - - - -
800 1500 1300 900 600 - - - - - -
600 1400 1300 800 - - - - - - -
400 1400 1200 400 - - - - - - -
200 1200 900 - - - - - - - -
0 1100 500 - - - - - - - -
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1. Safety
1) Protective structures less than 1000 mm are not included, because

movement is not satisfactorily restricted.
2) Protective structures not present in danger area > 2600 mm.
(Source: DIN EN ISO 13857)
1.10.3 Safe reaching around/reaching through openings

Limitation of movement in the working area of rotating shafts.
Only at shoulder and sr =  850 mm

armpit A
sr
120 1)
Arm supported up to the sr =  550 mm

elbow A
1)
300 sr
120
Arm supported up to the sr =  230 mm

wrist A
120 1)
620
sr
Arm and hand supported sr =  130 mm

up to the finger root A
120 1)
sr
720
A Movement area of the arm

sr Radial safety clearance
1) Either the diameter of a circular opening, the side of a square opening, or
the width of a slot-shaped opening
(Source: DIN EN ISO 13857)
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2
Description of the pump
2.1 General description

seepex pumps are members of the group of rotating displacement pumps.
• Characteristic features
– Special configuration/arrangement of the rotor and stator pumping elements.
– Motion sequence
2.2 Mode of action and pumping principle of the seepex pump

• Sealing bands are produced through geometric design/contact of both conveying elements.
• Sealing bands ensure a perfect fit between the suction and pressure side.
Result:
– Increased pump suction.
– Higher pressure build-up independent of speed possible.
2.3 Constructive design
No. Designation
ANT Drive
200 Lantern
307 Plug-in shaft
400 Coupling rod
SEA Shaft seal
500 Suction casing
600 Rotor
RTE Rotating unit
601 Stator
700 Pressure branch
Ausgabe Dokument Blatt

issue B / 12.11.2012 document OM.DES.01e sheet 1 (1) 11
12
3
Technical data
3.1 Data sheet
3.2 Characteristic Curves
3.3 Declaration of conformity / declaration of incorporation

issue B / 04.01.2010 document OM.TED.01e sheet 1 (1) 13
14
Commission no.: 371144
Type: BT 2-6L
Application data
Conveyed product unknown
Product temperature 0°C - 50°C
Kind of operation continuous

Operating hours 8 h/day
Location indoor, dry atmosphere
Installation horizontal
Direction of rotation counter clockwise (left)
Performance data
Capacity Pressure Speed
1240.85 l/h 4 bar 198 norm
Starting torque 35 Nm
Req. operating power at pump shaft 0.34 kW
Inlet pressure flooded suction
NPSHr 2.16 m
Performance data remark Capacity, rotation and power depends on
d.s., filling level and pressure.
Tolerances according to SEEPEX standards.

Materials and executions
Pressure connection DN 40 PN 16 DIN EN 1092 (DIN2501)

Feed hopper - Design special design
[drawing-no. 064-500/0010-0-452_2]
Hopper type welded in- and outside according to instructions,
the striking point and the
welding spillings have been removed outside.
welding seams inside have only been teated completely on he
area of the transition
pieces of the pipes, on all other welding seams only striking
points and welding spillings
removed in- and outside glass blead blow.
Feed hopper - Hopper position position 1
Feed hopper - Flushing connection without
Feed hopper - Flushing connection position without
Joint - Design pin joint with joint sleeve, grease filled
Joint - Joint Grease joint grease SEEPEX 30321
Coupling rod - Design screw design
Shaft sealing mechanical seal
Code GA - single acting mechanical seal
Drive
Drive Type Gear motor
Type Gearmotor
Make Nord
Model SK01F-90LP/4
Norm
Speed 198
Frequency 50 Hz
Rated output 1.5 kW
15
16
17
18
19
20
Declaration of incorporation
for incomplete machines
according to Machinery directive 2006/42/EC, Annex II B
Location: Bottrop
Date: 14.10.2019
Manufacturer: SEEPEX GmbH

Address: Scharnhölzstraße 344, 46240 Bottrop, Germany
We hereby declare that the following product
Progressive cavity pump unit
Type: BT 2-6L
Commission no.: 371144
meets the provisions of the directive indicated above.
The product also meets all the provisions of the following directives:
2014/35/EU Electrical equipment

2014/30/EU Electromagnetic compatibility
Put the incomplete product into operation only after having installed it into the complete
machine. The complete machine meets the provisions of the 2006/42/EC directive.
The following harmonised standards are applied:
DIN EN ISO 12100 Safety of machines Issue 03/2011

DIN EN ISO 13857 Safety distances, upper and lower limbs Issue 06/2008
DIN EN 809 Pumps and pump units for liquids Issue 10/2012
The manufacturer is obliged to provide the technical documents for the incomplete
product in electronic form to national authorities upon request. The technical documents
for the product were created according to Annex VII Part B.
Responsible for documentation:
SEEPEX GmbH
Scharnhölzstraße 344 Phone +49.2041.996-0
46240 Bottrop info@seepex.com
i.V. Mario Koch

Manager Quality Assurance
SEEPEX GmbH
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4
Transport, Intermediate storage, Disposal
4.1 Safety
CAUTION
Damage to property/injuries due to incorrect transport

Slight injury or damage to property can occur
¾ Comply with the safety notes and transport notes on the packaging.
¾ Use suitable means of transport, lifting devices and tools.
¾ Use protective equipment.
4.2 Transport
4.2.1 Dimensions, weights and center of gravity

¾ Note the dimensional drawing (→ chapter 5.6).
4.2.2 Symbols
• Meaning of symbol
Top Fragile Against moisture Centre of gravity Lashing points

item protect
4.2.3 Sling points (AP) for lifting devices
WARNING
Warning of suspended load.

Death of serious injury can occur.
¾ Use the lashing points (AP) for lifting divices.
¾ Note the centre of gravity (→ dimensional drawing, chapter 5.6).
Lifting machine Industrial trucks
4.2.4 Unpacking the machine

¾ Comply with the symbols and notices on the packaging.
¾ Remove the screwed connection between the machine and packaging.
¾ Remove the machine with a lifting machine/industrial truck.
4.3 Temporary storage/Corrosion protection

• All seepex machines have corrosion protection applied as standard prior to transport.

issue
D / 27.08.2012 document
OM.TRA.01e sheet
1 (2)
23
4
Transport, Intermediate storage, Disposal
NOTICE
Damage to property if corrosion protection is missing
Property damage can occur due to corrosion.
¾ Temporary storage must be in a dry, enclosed, frost-free room in order to provide protec-
tion against ambient influences.
¾ Contact seepex regarding the necessary corrosion protection for temporary storage.
4.4 Disposal
NOTICE
Environmental protection
Material damage can occur.
¾ Drain the pumping medium and dispose of it in accordance with the regulations.
¾ Dispose of the machine with regard to its composition and existing regulations.

issue
D / 27.08.2012 document
OM.TRA.01e sheet
2 (2)
24
5
Assembly / Installation
5.1 Mounting tools / lifting gear
CAUTION
Pump falling over.

Slight injury or damage to property can occur.
¾ Adhere to the lifting tool’s starting point.
¾ Pay attention to the dimensions, weight and centre of gravity of the pump.
¾ Use suitable mounting tools/lifting gear.
5.2 Space requirement

The required space should be determined by considering the following factors:
• Dimensions and weight.
• Requisite transport and lifting equipment.
• Pipe routing – dismantling (dimension for stator replacement).
5.2.1 Dimension for stator replacement (P)

¾ Refer to the dimensional drawing.
5.3 Assembly of the complete mounted pump

¾ Assemble according to technical data (→ chapter 3.).
¾ Note dimensional drawing.
Tension-free mounting of the pump

¾ Balance unevenness with suitable supports.
• Applies to mounting on foundations/load-bearing elements.
• Total areas of all pump bearing areas are resting on the surface.
Correct position of the drives

• All drives are set up ready for operation and mounted.
• Correct displacements of the drive during transport/installation of the pump by adjusting/fix-
ing the drive.
CAUTION
Safety protection equipment.

Slight injury or damage to property may result.
¾ Connect safety protection equipment and activate.

issue C / 11.10.2012 document OM.INS.01e sheet 1 (2) 25
5
Assembly / Installation
5.4 Power supply of the seepex pump
DANGER
Supply voltage and power frequency.

Death or serious injury will result.
¾ Heed type plate on the pump.
¾ Pay attention to manufacturer’s directions (→ chapter 13.).
¾ Pay attention to safety regulations.
5.5 Pipelines
5.5.1 Suction and pressure connection

• Refer to the dimensional drawing for the position, nominal width and standard.
• Note direction of rotation/flow direction.
5.5.2 Pipeline dimensions

• Adhere to specifications regarding pressure in the pressure respectively suction connec-
tion.
• Note technical data (→ chapter 3.).
• Nominal width of suction pipe = nominal width of suction connection of pumps.
5.5.3 Residue-free pipelines
NOTICE
Damage to property through assembly residue.
No claims under guarantee if violated.
¾ Keep all pipe work free of foreign objects.
¾ Remove weld spatters, screws, steel chips etc.
5.5.4 Tension-free assembly

¾ Assemble pipelines and other components in a tension-free manner on the pump.

issue C / 11.10.2012 document OM.INS.01e sheet 2 (2) 26
28
6
Commissioning / De-commissioning
Master Copy
6.1 Commissioning report
Send commissioning report online to From:

www.seepex.com\
Must be specified with every order!
Commission: Model: Contact person: .............................................
Tel.: ................................................................
_________________________ _____________________ Fax: ...............................................................
E-mail: ...........................................................
Customer Service: Germany Phone:+49 2041.996-231 Address of plant:

seepex GmbH Fax: +49 2041.996-431 .......................................................................
Postfach 10 15 64 Rest of Phone:+49 2041.996-224 .......................................................................
D-46215 Bottrop Europe Fax: +49 2041.996-424 .......................................................................
service@seepex.com Outside Phone:+49 2041.996-120 .......................................................................
Europe Fax: +49 2041.996-432 .......................................................................
Delivery date:
Date of installation:
Assembly check carried out on:
Please enter operational data:

Conveying liquid:
Temperature:
Fuse level/motor protection or power
consumption
Frequency control no
yes If yes:
Supplied by seepex
Supplied by customer
Frequency:
Speed:
Power
consumption:
________________________________ _______________________________________
Place, date Signature / company stamp

issue
B / 17.03.2006 document
OM.COM.05e sheet
1 (1)
29
30
6
6.2 Measures before commissioning
 Note the technical data (chapter 3.).
6.2.1 Checking pipelines

 Check flange screwed connections (SCH).
 Check threaded connections (G).
NOTICE
Ensure the liquid can flow through without obstruction.
Malfunction and/or irreparable damage to the pump.
 Open all shut-off elements before switching on the pump.
6.2.2 Protective devices on the pump
DANGER
Missing protective device.

Danger of pulling in and crushing.
 Equip the pump with a protective device. Protective devices provided for preventing con-
tact with surfaces or moving parts must be regarded as suitable if contact is not possible
in a test involving a test finger, with regard to the penetration possibility, strength and shock
resistance.
 Comply with national protection regulations.
 In pumps with an open suction flange/feed hopper, attach touch protection. These safety
clearances protect those persons who are attempting to reach danger areas without addi-
tional help and under the conditions defined for various situations of reaching up, reaching
under or reaching through
In shaft seals, touch protection is only necessary if there are components on the rotating
shaft.
6.2.3 Electrical/hydraulic connections
DANGER
Dangerous voltage.
Death or serious injury can occur.
 Note safety regulations.
 Disconnect motor from all sources of energy.
 Secure electrical connections against restarting.

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6.2.4 Direction of rotation check
flow direction
 The pump direction of rotation determines
the flow direction of the pumping medium.
 Note the direction of rotation arrow on the
type plate.
counter clockwise clockwise
6.2.5 Additional devices - optional

 Refer to additional devices (chapter 12.1).
6.3 Initial commissioning/repeated commissioning

 Start up the pump.
NOTICE
Dry running of the pump.
Malfunction and/or irreparable damage to the pump.
 Fill the suction casing with liquid in order to lubricate the pumping elements.
6.3.1 Avoid dry running of the pump
NOTICE
High temperature between rotor and stator.
Stator material burned.
Complete failure of the pump.
 Make sure that the suction-side conveying capacity does not cavitate.
 If this cannot be guaranteed on the machine side, assemble a seepex dry running
protection (TSE).
6.3.2 Pressure in the suction and pressure connection
CAUTION
High pressure.
Malfunction and/or irreparable damage to the shaft seal or pump.
 Maintain pressure in the suction connection in accordance with the technical data
(chapter 3.).
Recommendation:
 Assemble an oil-filled contact pressure gauge to monitor and deactivate the pump.

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6.4 De-commissioning
Protect the pump and additional devices against the following:
• Frost
• Deposit of solids
• Sedimentation from the liquid
• Corrosion of parts that come into contact with the medium
6.4.1 Switching off the pump
DANGER
Dangerous voltage.
6.4.2 Emptying the pump
CAUTION
Liquid draining out.

Minor injury or damage to property can occur.
 Wear suitable protective clothing.
 Refer to the technical data (chapter 3.) for the corresponding configuration of the pump
housing.
To drain the pump:

 If the pump housing has screwed plugs, remove the screwed plugs.
 Drain using a connection branch (suction casing, pressure branch) if the pump housing is
coated or the housing does not have screwed plugs.
 Drain the residual liquid from the pump housing.
 Drain the pipelines on the suction and pressure sides, or shut off behind the pump connec-
tions.

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6.4.3 Removing the pump
WARNING
Risk of pump tipping or falling.

 Support the drive unit to guarantee stability.
Pipeline dismantling
 Remove flange bolts (SCH) and flange

seals (DFL).
with/without base plate
 Remove bolts (SCH) from the pump feet.
Pipeline dismantling
 Remove threaded connections (G).

with/without base plate
 Remove bolts (SCH) from the pump feet.
6.4.4 Preservation/storage of the pump
NOTICE
Damage to property due to lack of corrosion protection.
Property damage can occur due to corrosion.
 Contact seepex to discuss suitable preservation measures.
– State the commission number of the pump.

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7
Maintenance
7.1 Preventive measures
The maintenance personnel must have these operating instructions, follow them and also
require corresponding qualifications.
DANGER
Dangerous voltage.
 Disconnect pump from all sources of energy.
7.1.1 Pump down-time
NOTICE
Pump down-time.
Production failure due to wear.
 Acquisition of a set of wearing parts and a set of gaskets.
7.2 Lubrication
No. Denomination Lubricant Lubricant change in Fill volume

operating hours
1 Pin joint seepex special grease 10000 h 14 cm3
(30321)
2 Pin joint seepex special grease 10000 h 14 cm3
(30321)
3 Drive Refer to manufacturer's documentation (chapter 13._)
Rotor/stator Conveying medium --- ---
Shaft seal Conveying medium --- ---

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Maintenance
7.2.1 Joint grease
NOTICE
Other grease types.
Malfunction and/or irreparable damage to the joints or the pump.
 Exclusively use seepex special grease.
7.3 Inspection
Component Interval Action

Joints Every 10,000 operating hours Renew joint grease
Stator Every week Visual check for leaks
Shaft seal Every week Visual check for leaks
Drive unit Every 3000 operating hours, Comply with manufacturer's
at least every 6 months documentation

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Malfunctions, causes, rectification
Refer to technical data (chapter 3.) for application range of the pump.
Malfunction Causes Rectification
Pump seized / pump does not pump

Conveying capacity is not achieved
Pressure head is not reached
Pump is loud when running

Pump pumping unevenly
Pump does not start up
Premature stator wear

Pump is not sucking
Motor gets too hot
Shaft seal is leaky

X X X Static friction between sta- Apply lubricant (liquid soap)
tor/rotor too great. between stator and rotor.
X Incorrect direction of rota- Check direction of rotation
tion. and swap over motor con-
nections if necessary.
X X X X X Suction pipe or shaft seal Eliminate leaks.
leaking.
X X X X Suction head too great. Check the suction head, if
necessary increase pipe
cross section on suction
pipe and use a larger filter,
open suction-side valve
fully.
X X X Viscosity of conveying Check/adapt (data sheet).
product too great.
X X X Pump rotation speed Correct rotation speed (data
incorrect. sheet).
X X Avoid air bubbles in the
conveying product.
X X X X X Pressure head too great. Check pressure head with
pressure gauge, reduce
pressure head by using
larger pressure pipe
crossed section or shorten-
ing the pressure pipe.
X X X X X Pump running partially/ Check there is adequate
completely dry. conveying product avail-
able on the suction side.
Dry running protection DRP.
X X Check coupling. If necessary, move pump in
relation to drive, check wear
on coupling gear, re-adjust
coupling if necessary.
X X Rotation speed too low. Increase rotation speed for
low-viscosity media/large
suction volume.

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Malfunctions, causes, rectification
Malfunction Causes Rectification
Pump seized / pump does not pump

Conveying capacity is not achieved
Pressure head is not reached
Pump is loud when running

Pump pumping unevenly
Pump does not start up
Premature stator wear

Pump is not sucking
Motor gets too hot
Shaft seal is leaky

X X X Rotation speed too high. Reduce rotation speed for
high-viscosity media, risk
of cavitation.
X Joint play too large. Check mounting of cou-
pling rod bushing.
X X X X X Foreign objects in pump. Dismantle pump, remove
foreign bodies, replace
defective parts.
X X X X Stator/rotor worn. Dismantle pump and
renew defective parts.
X X X X Joint parts worn. Renew joint parts, use
seepex pin joint grease.
X X X X Suction pipe blocked. Clean the suction pipe.
X X X X X Temperature of pumping Check temperature, use
liquid too high. an undersize rotor.
X X X X X Gland packing too firm/ Loosen packing gland or
worn. tighten. Renew unusable
packing rings.
X X X X Solid content and/or grain Reduce pump speed,
size too great. install screen with permit-
ted mesh width. Increase
liquid proportion.
X X X X Sedimentation/gumming of Rinse through and clean
solids when pump station- the pump immediately.
ary.
X X X X X Conveying product hard- Heat the pump.
ens when the temperature
drops below a certain limit.
X X X X Stator swollen and unable Select a suitable stator
to withstand conveying material, use an under-
product. size rotor.
X X Bearings in pump drive Renew bearings.
housing or drive unit
defective.
X Mechanical seal defective. Check sliprings and O-
rings for wear/resistance,
renew if necessary.

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9
Dismantling / Reassembly
9.1 Pump Dismantling/Reassembly
Range: BT
Size: 05-24 up to 300-6L
9.1.1 Preparing the pump for dismantling
DANGER
Dangerous voltage.
 Empty pipelines.
 Allow pipelines to cool down.
 Remove pipeline connections (suction
side/pressure side).
 Note decommissioning (chapter 6.4).
9.1.2 Dismantling
WARNING

 Fasten the lantern (200) to secure the
pump.
9.1.2.1 Pressure branch (700) - Dismantling
 Prop up stator (601) with a support (S).

 Remove screw fitting (604, 606).
 Remove pressure branch (700).
 Remove tie bolt (602).

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9.1.2.2 Stator (601) - Dismantling
 Raise/move splash ring (310).

 Remove the plug-in shaft pin (309).
 Insert tool (WS).
 Turn tool (WS) upwards.
Tool (W2/chain wrench)
 Add lubricant (GM) to the opening on

pressure branch side between the rotor
(600) and the stator (601).
 Turn the stator (601) in the “leftt” rotating
direction and remove.
– Use tool (W2).
 Prop up the rotor (600) with support (S).
9.1.2.3 Feed hopper (500) - Dismantling
 Put a protective cover (SH) on the rotor

(600).
 Prop up rotor (600) with a support (S).
 Remove screw fitting (507, 509).
 Remove feed hopper (500) and casing
gasket (501).
 Remove tool (WS).
9.1.2.4 Rotating unit (RTE) - Dismantling
Tool (W10/dismantling tool)
Tool (W9/mounting lever)
with flush connection
 Remove the flush connection (SSÜ) on the

shaft seal casing (SEA).

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 Assemble tool (W10/dismantling tool).
 Pull the rotating unit (RTE) with shaft seal

(SEA) off from the output shaft of the drive
(ANT).
– Use tool (W9/mounting lever).
 Dismantle tool (W10/dismantling tool).
 Pull off the splash ring (310).

 Pull off the shaft seal casing (SEA).
– Note dismantling shaft seal
(chapter 9.4).
without flush connection
 Assemble tool (W10/dismantling tool).
 Pull the rotating unit (RTE) with shaft seal

(SEA) off from the output shaft of the drive
(ANT).
– Use tool (W9/mounting lever).
 Dismantle tool (W10/dismantling tool).
 Pull off the splash ring (310).

 Pull off the shaft seal casing (SEA).
– Note dismantling shaft seal
(chapter 9.4).

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9.1.2.5 Rotor (600), auger feed screw (400), plug-in shaft (307) - dismantling
 Joint (G) dismantling note rotating unit -

individual parts (chapter 9.2).
9.1.2.6 Lantern (200)/drive (ANT) - Dismantling
CAUTION
Falling or tilting drive.

Slight injury can occur.
 Secure the drive (ANT).
 Remove the screw fitting (210, 212, 213).

 Remove the drive (ANT).
9.1.3 Reassembly
WARNING

 Fasten the lantern (200) to secure the
pump.
9.1.3.1 Lantern (200)/drive (ANT) - Reassembly
 Clean the flange bearing surfaces (FLS),

bolt circle (ZD) and the output shaft of the
drive unit (ANT).
 Mount the drive (ANT) to the lantern (200)
with screw fittings (210, 212, 213).
9.1.3.2 Rotor (600), auger feed screw (400), plug-in shaft (307) - Reassembly
 Joint (G) reassembly note rotating unit -

individual parts ( chapter 9.2).

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9
9.1.3.3 Rotating unit (RTE) - Reassembly
 Slide on shaft seal casing (SEA).

– Note reassembly shaft seal
( chapter 9.4).
 Moisten splash ring (310) and plug-in shaft
(307) with antiseize graphite petroleum.
 Slide splash ring (310) onto plug-in shaft
(307).
– Observe fitting position of splash ring
(see lettering).
 Apply antiseize graphite petroleum to the
output shaft of drive (ANT).
 Slide on rotating unit (RTE).
with flush connection
 Mount the flush connection (SSÜ).
9.1.3.4 Feed hopper (500) - Reassembly
 Put a protective cover (SH) on the rotor

(600).
 Prop up rotor (600) with a support(S).
 Push on the casing gasket (501).
 Mount and align the feed hopper (500)
with screw fitting (507, 509).
– Use spirit level (W).
 Remove the protective cover (SH).
9.1.3.5 Stator (601) - Reassembly
 Insert tool (WS).

 Turn tool (WS) down.

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Tool (W2/chain wrench)
 Moisten outer surface of the rotor (600)

with lubricant (GM).
 Moisten inner surface of the stator (601)
 Prop up stator (601) with support (S).
 Turn stator (601) in the “right” rotating
direction and slide onto rotor (600).
– Use tool (W2).
 Remove tool (WS).
 Slide in plug-in shaft pin (309).
 Pay attention to the position of the splash

ring (310).
 Insert the splash ring collar at a distance of
0.5 mm from the lantern (200).
9.1.3.6 Pressure branch (700) - Reassembly
 Prop up stator (601) with a support (S).

 Insert tie bolts (602) loosely into the
suction casing (500).
 Push pressure branch (700) on to the

stator (601).
 Insert tie bolts (602) loosely in the
pressure branch (700).
 Remove the support (S).
 Mount screw fitting (604, 606).

 Tighten tie bolts (602) equally.

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9.2 Rotating unit individual parts
9.2.1 Dismantling
9.2.1.1 Holding band (406, 407) - dismantling
CAUTION
Danger of injury.
Parts might be thrown out.
 Wear safety glasses.
 Detach holding band loop (SCL).

– Use suitable tool (WH).
 Push out parts of holding band loop (SCL).
 Remove holding band (406, 407).
 Pull back universal joint sleeve (405).
9.2.1.2 Retaining sleeve (401) - dismantling
 Knock back retaining sleeve (401).

– Use suitable tool (WM).
9.2.1.3 Detach joint
Tool (W5/drift)
 Eject coupling rod pins (402).

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 Bend (A) the coupling rod (400). Knock

guide bushing (403) out with tool (W5).
 Remove coupling rod (400).
9.2.2 Rotating unit (RTE) - prepare individual parts for reassembly
9.2.2.1 Rotor (600)
 Remove any damage.

 Clean rotor (600).
Tool (W4/assembly mandrel)
 Press in guide bushings (403)

(depth = 2/3).
– Use tool (W4).
9.2.2.2 Coupling rod (400)
 Clean the coupling rod (400).

 Examine bore head for wear.
– If wearing is detected on the bore
head, replace the coupling rod (400).

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9
9.2.2.3 Plug-in shaft (307)

 Clean rotor (600).
 Press in guide bushings (403)

(depth = 2/3).
– Use tool (W4).
9.2.3 Rotating unit (RTE) - individual parts - reassembly
NOTICE
Malfunction of the joints.
Malfunction and/or destruction of joints.
 Replace coupling rod pins (402) and guide bushings (403) jointly.
9.2.3.1 Coupling rod (400) - reassembly

 Slide the universal joint sleeve (405) and holding bands (406, 407) onto coupling rod (400).
 Fit the diameter and width of the holding band of the universal joint sleeve.
 Fill the joint head with seepex joint grease.
Rotor (600)
 Insert coupling rod pins (402).

 Slide on retaining sleeve (401).
 Connect rotor/coupling rod.
Tool (W5/drift)
 Slide in the coupling rod pins (402).

 Knock the guide bushings (403) in.
– Use tool (W5).

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Plug-in shaft (307)
 Insert coupling rod pins (402).

 Slide on retaining sleeve (401).
 Connect plug-in shaft/coupling rod.
Tool (W5/drift)
 Slide in the coupling rod pins (402).

 Knock the guide bushings (403) in.
– Use tool (W5).
9.2.3.2 Retaining sleeve (401) - reassembly
 Knock back retaining sleeve (401).

– Use tool (W4).
Rotor (600) unhardened material
 Secure retaining sleeve (401) in a dis-

placed manner (2x180°).
– Use suitable tool (WK).
Rotor (600) hardened material
 Secure retaining sleeve (401) in a dis-

placed manner (2x180°).
– Use suitable tool (WK).

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9.2.3.3 Universal joint sleeve (405) - reassembly
 Moisten the surface of coupling rod (400) /

inner surface of universal joint sleeve
(405) with joint grease (maintenance 
chapter 7.).
 Slide on universal joint sleeve (405).
 Remove air from the inside of the joint.

– Use suitable tool (WS).
 Assemble the holding band.

– Holding band assembly
(chapter 9).

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9
9.3 Holding band - assembly
9.3.1 Prepare the holding band
 Only use prefabricated double-band holding bands may.
9.3.2 Check the holding band

• Bent-over holding band (HBD) is in con-
tact with holding band loop (SCL) to avoid
damaging universal joint sleeve.
 Press on holding band (HBD) using tool

(WZ) if necessary.
9.3.3 Assemble the holding band
 Use tool (W3/mounting tool)
 Feed holding band into tool (W3).
 Hold ends of holding band with the eccen-

tric lever (EX).
 Turn the crank (KU) until the holding band

is strained and lies against the holding
band loop (SCL).
 Carefully pull the holding band together

until it is in contact with the circular groove
of universal joint sleeve.
9.3.4 Correct tension of holding band (HBD)

Correct
The holding band (HBD) has drawn in the out
shape of the universal joint sleeve and is
firmly seated.
Incorrect
The holding band (HBD) is too loose, can slip
off.
Incorrect
The holding band (HBD) is too tight, univer-
sal joint sleeve will be damaged/sheared off.

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9
9.3.5 Cant up the holding band
 Swivel mounting tool (W3) approx. 60° up-
wards.
 Loosen crank (KU) by a half turn.
 Swivel cutting lever (SH) forward until the

pressure piece is lying behind the holding
band loop (SCL).
9.3.6 Shear the holding band (material: 1.4301; 1.4401)

 Hit the cutting lever (SH) with the inside of
your hand.
– Cant up and shear the end of the
holding band behind the loop (SCL).
– Carefully straighten up the holding
band (HBD) if it rises up on the
sheared side.
NOTICE
Universal joint seal damage.
Pin joint grease can emerge.
 Avoid hammering or striking.
9.3.7 Check the holding band after assembly

 The holding band must lie in the groove of
the universal joint sleeve.
 Replace the holding band if the holding

band slips back through the loop.

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9. Dismantle/reassembly of shaft seal
9.4 Dismantle/reassembly of shaft seal
• Single acting mechanical seal (SEA)
Recommended auxiliary materials

Keep the auxiliary materials listed available (not included in the scope of deliv-
ery):
 Lubricant (GM)
– Diluted liquid soap
NOTICE
Damage due to unauthorised lubricant (GM).
Damage to components. Contamination of the conveying product.
 Note resistance to the materials used and to the conveying product.
 Use only suitable lubricant (GM) ones.
• Shaft seals are high-quality precision parts. Therefore, be

careful during installation.
• The sliding surfaces of the shaft seal must be clean, dry and free of dust.
9.4.1 Dismantle mechanical seal (330)

For the execution of shaft sealing, see the technical data ( chapter 3) and the
shaft sealing sectional drawing ( chapter 9.6).
 Clean plug-in shaft (307).
9.4.1.1 Design without set ring (372)

 Moisten plug-in shaft (307) with lubricant (GM) for easier dismantling of
mechanical seal casing (333) and mechanical seal (330).
 Remove mechanical seal casing (333) together

with counter ring (330G) from plug-in shaft (307).
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 Remove mechanical seal (330) from plug-in

shaft (307).
 Remove counter ring (330G) together with

O-ring from mechanical seal casing (333).
9.4.1.2 Design with set ring (372) for axial securing

 Moisten plug-in shaft (307) with lubricant (GM) for easier dismantling of
mechanical seal casing (333) and mechanical seal (330).
 Remove mechanical seal casing (333) together

with counter ring (330G) from plug-in shaft (307).
 Remove mechanical seal (330) from plug-in

shaft (307).
 Loosen set screw (378) on the set collar (372).

 Remove set collar (372) from plug-in shaft (307).
 Remove counter ring (330G) together with

O-ring from mechanical seal casing (333).
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9.4.2 Assemble mechanical seal (330)

 Clean plug-in shaft (307).
9.4.2.1 Design with set ring (372) for axial securing
 Clean mechanical seal casing (333).

 Moisten O-ring of the counter ring (330G) with
lubricant (GM).
 Insert counter ring (330G) together with O-ring
evenly into the mechanical seal casing (333).
 Remove set screw (378) from set ring (372).

 Lubricate set screw (378) with screw retention
and install into set ring (372).
– Use screw retention (Loctite 243).
 Push set ring (372) on to plug-in shaft (307) and
fix with set screw (378).
 Adjust the set ring (372) to prescribed size.
– Observe sectional drawing of shaft seal
( chapter 9.6).
 Fasten and secure set screw (378).
 Moisten plug-in shaft (307) and elastomer parts

of the mechanical seal (330) with lubricant (GM)
for easier assembly.
 Push the mechanical seal (330) onto plug-in
shaft (307).
– Observe sectional drawing of shaft seal
( chapter 9.6).
 Slide mechanical seal casing (333) together with

counter ring (330G) onto plug-in shaft (307).
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55
9.4.2.2 Design without set ring (372)
 Clean mechanical seal casing (333).

 Moisten O-ring of the counter ring (330G) with
lubricant (GM).
 Insert counter ring (330G) together with O-ring
evenly into the mechanical seal casing (333).
 For easier assembly, lubricate plug-in shaft (307)

and elastomer parts of the mechanical seal (330)
 Push the mechanical seal (330) onto plug-in
shaft (307).
 Slide mechanical seal casing (333) together with

counter ring (330G) onto plug-in shaft (307).
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57
58
10
Spare parts
10.1 Spare parts list
10.2 Sectional drawing and parts list

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10
Spare parts
Version for copying
10.1 Spare parts list
Spare parts can be ordered online or requested from Type: BT 05-24 to 300-6L
www.seepex.com\
Request Order Sender:
Must be included in every order or enquiry!

Commission: Type: Contact: .........................................................
Tel.: ................................................................
_________________________ _______________________ Fax: ...............................................................
E-mail: ...........................................................
Customer service: Germany Tel +492041.996-231 Delivery address:

seepex GmbH Fax +492041.996-431 .......................................................................
Postfach 10 15 64 Rest of Europe Tel +492041.996-224 .......................................................................
D-46215 Bottrop Fax +492041.996-424 .......................................................................
service@seepex.com Outside Europe Tel +492041.996-120 .......................................................................
Fax +492041.996-432 .......................................................................
No. Quantity Component Material Comment
Minor set of wearing parts
301 1 Set of packing rings according to data sheet (chapter 3.1)

311 1 Flushing ring
330 1 Mechanical seal according to data sheet (chapter 3.1)
601 1 Stator
Major set of wearing parts

307 1 Plug-in shaft
311 1 Rinse ring
330 1 Mechanical seal according to data sheet (chapter 3.1)
400 1 Coupling rod with coupling
rod bushings
402 2 Coupling rod pin
403 4 Guide bushing
405 2 Universal joint sleeve
406 2 Holding band, large
407 2 Holding band, small
600 1 Rotor
601 1 Stator
__________________________________ _______________________________________

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Spare parts
Version for copying
No. Quantity Component Material Comment
Set of gaskets

310 1 Splash ring according to data sheet (chapter 3.1)
330 1 Mechanical seal
501 1 Casing gasket
503 3 Sealing ring
706 1 Sealing ring
Plug-in shaft & shaft seal
301 Set of packing rings according to data sheet (chapter 3.1)

307 Plug-in shaft
309 Plug-in shaft pin
310 Splash ring according to data sheet (chapter 3.1)
330 Mechanical seal according to data sheet (chapter 3.1)
Coupling rod & joint parts
400 Coupling rod with coupling

rod bushings
401 Retaining sleeve
402 Coupling rod pin
403 Guide bushing
405 Universal joint sleeve
406 Holding band, large
407 Holding band, small
401-407 Complete set of joint parts
Conveying elements
600 Rotor
601 Stator
Miscellaneous parts
501 Casing gasket

098 Pin joint grease 1 cartridge = 300 g (approx. 315 cm³)
Grease quantity according to maintenance
(chapter 7.0)
__________________________________ _______________________________________

issue
D / 19.08.2010 document
OM.WPS.04e sheet
2 (2)
62
64
Stückliste
Parts List
Liste des pièces
DE EN FR
Baureihe BT range BT série BT
Schnittzeichnung Nr. sectional drawing No. plan no.
065-002D1 065-002D1 065-002D1
Benennung denomination désignation
Stck. Pos. Stck. / Pos. Qty. / Item Qté. / Poste
1 200 Laterne lantern lanterne
1 202 Typenschild type plate plaque signalitique
4 210 6kt-Schraube hexagon bolt vis
211 6kt-Schraube hexagon bolt vis
4 212 Federring spring washer rondelle frein
4 213 6kt-Mutter hexagon nut écrou
2 240 Abdeckblech cover plate tôle de protection
4 242 Zylinderschraube socket screw vis à tête cylindrique
4 243 Federring spring washer rondelle frein
1 307 Steckwelle plug-in shaft arbre à broche
1 309 Steckwellenbolzen plug-in shaft pin cheville pour arbre à broche
1 310 Spritzring splash ring bague de projection
1 400 Transportschnecke auger feed screw vis transporteuse
2 401 Gelenkhülse retaining sleeve douille d'articulation
2 402 Kuppelstangenbolzen coupling rod pin axe d'articulation
4 403 Führungsbuchse guide bushing douille de guidage
2 404 Kuppelstangenbuchse coupling rod bushing chemise d'axe
2 405 Manschette universal joint sleeve manchette
2 406 Halteband holding band collier de serrage
2 407 Halteband holding band collier de serrage
1 500 Einlauftrichter feed hopper trémie d'entrée
1 501 Sauggehäusedichtung casing gasket étanchéité du carter d'aspiration
1 502 Verschlussschraube screwed plug bouchon de vidange
1 503 Dichtring sealing ring joint d'étanchéité
4 506 Stiftschraube stud bolt boulon fileté
4 507 Fächerscheibe fan type lock washer rondelle à dents chevauchantes
extérieures
1 °) 535 Stopfteil stuffing part pièce de compression
1 °) 536 O-Ring o-ring joint torique
6 °) 537 Stiftschraube stud bolt boulon fileté
6 °) 538 Federring spring washer rondelle frein
6 °) 539 6kt-Mutter hexagon nut écrou
1 600 Rotor rotor rotor
1 601 Stator stator stator
4 602 Spannschraube tie bolt tirant
10 606 Scheibe washer rondelle
1 607 Stützbock trestle pied
1 700 Druckstutzen pressure branch bride de refoulement
1 705 Verschlussschraube screwed plug bouchon de vidange
1 706 Dichtring sealing ring joint d'étanchéité
Document SL.065.002def Issue D/12.12.2018 1/2

65
Stückliste
Parts List
Liste des pièces
DE EN FR
Baureihe BT range BT série BT
Schnittzeichnung Nr. sectional drawing No. plan no.
065-002D1 065-002D1 065-002D1
Benennung denomination désignation
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 Montageanleitung see Operating and Assembly voir instructions de montage et
entnehmen Instruction de fonctionnement
Verschleißteile und Dichtungen: Wearing parts and sealings: pièces d'usure et étanchéités:
Werkzeuge: Tools: Outils:
Wellenabdichtung: shaft sealing: dispositif d' etanchéité:
siehe Schnittzeichnung see sectional drawing voir vue éclatée
Gleitringdichtung mechanical seal garniture mécanique
versetzt gezeichnet drawn displaced plan separé
°) Option option option
Document SL.065.002def Issue D/12.12.2018 2/2

66
11
Special tools
Version for copying
Spare parts can be ordered online or requested from Sender:

www.seepex.com\
Must be specified with every order!
Commission: Mark tool! Contact: .........................................................
Tel.: ................................................................
__________________________ X Fax: ...............................................................
E-mail: ...........................................................
Customer service: Germany Tel +492041.996-231 Delivery address:

seepex GmbH Fax +492041.996-431 .......................................................................
Postfach 10 15 64 Rest of Europe Tel +492041.996-224 .......................................................................
D-46215 Bottrop Fax +492041.996-424 .......................................................................
service@seepex.com Outside Europe Tel +492041.996-120 .......................................................................
Fax +492041.996-432 .......................................................................
For installation of: Packing gland Stator Coupling rod

bushings
Tool no. W1 W2 W14

Chain pipe wrench +
Denomination: Packing lever Pressing tool
replacment chain
Order no. PKZ KRZ PWZ
For installation of: Rotating unit

Holding band Joint Joint Plug-in shaft
Tool no. W3 W4 W5 W10
Denomination: Mounting tool Assembly mandrel Drift Dismantling tool

Order no. MHB MTD DHS AZV
For installation of: General
Tool no. W9
Denomination: Mounting lever
Order no. MHL

issue
A / 21.09.2006 document
OM.STO.02e sheet
1 (1)
67
68
12
Associated documents
12.1 Accessories
• not available
12.2 Technical information

• not available

issue A / 19.06.2008 document OM.ZUG.02e sheet 1 (1) 69
70
13
Appendix
13.1 Manufacturer's documents / suppliers
• available

issue
B / 19.06.2008 document
OM.MDS.01e sheet
1 (1)
71
72
B 1000 – en
Gear units
Operating and Assembly Instructions
73
Gear units – Operating and Assembly Instructions
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Read the operating and installation instructions
Read this operating and installation manual carefully prior to performing any work on or putting the
gear unit into operation. Always observe the instructions in this operating and assembly manual.
Keep this operating and installation manual in the vicinity of the gear unit so that it is available if
required.
Please also note the following documents:
• Gear unit catalogues (G1000, G1012, G1014, G1035, G1050, G2000),
• Operating and maintenance instructions for the electric motor,
• Operating instructions for equipment which is attached or provided.
Please contact Getriebebau NORD GmbH & Co. KG if you require further information.
Pos : 5 /Allgemei n/Allgemei ngültige Modul e/---------- Seitenumbr uch ---------- @ 1\mod_1329145698658_0.doc x @ 15891 @ @ 1
2 B 1000 en-5018
74
Documentation
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Documentation
Designation: B 1000
Material number: 6052802
Series: Gear units and geared motors
Type series:
Gear unit types: Helical gear units
NORDBLOC helical gear units
Standard helical gear units
Parallel shaft gear units
Bevel gear units
Helical worm gear units
MINIBLOC worm gear units
UNIVERSAL worm gear units
Version list
Title, Order Comments
Date number
B 1000, 6052802 / -
February 2013 0713
B 1000, 6052802 / • General corrections
September 2014 3814
B 1000, 6052802 / • New gear unit types SK 10382.1 + SK 11382.1
April 2015 1915
March 2016 0916 • New bevel gear units SK 920072.1 + SK 930072.1
September 2016 3816 • New helical gear units SK 071.1, SK 171.1, SK 371.1, SK 571.1,
SK 771.1;
B 1000 June 6052802 / • General corrections
2018 2518 • New parallel shaft gear units SK 0182.1, SK 0282.1, SK 1282.1,
SK 1382,1
• New worm gear unit SK 02040.1
B 1000 December 6052802 / • General corrections
2018 5018 • Revision of safety and warning information
• New parallel shaft gear units NORDBLOC SK 871.1, SK 971.1,
SK 1071.1
Table 1: Version list B 1000

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B 1000 en-5018 3
75
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Copyright notice
As an integral component of the device described here, this document must be provided to all
users in a suitable form.
Any editing or amendment or other utilisation of the document is prohibited.
Pos : 9 /Allgemei n/Allgemei ngültige Modul e/H erausgeber @ 0\mod_1325779078002_388.doc x @ 5270 @ @ 1
Publisher
Getriebebau NORD GmbH & Co. KG
Getriebebau-Nord-Straße 1 • 22941 Bargteheide, Germany • http://www.nord.com/
Fon +49 (0) 45 32 / 289-0 • Fax +49 (0) 45 32 / 289-2253
Member of the NORD DRIVESYSTEMS Group

=== Ende der Liste für T extmar ke Copyright ===
4 B 1000 en-5018
76
Publisher
B 1000 en-5018 5
77
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Table of Contents
=== Ende der Liste für T extmar ke Inhalts verz eichnis ===
1 Safety information ..................................................................................................................................... 10

1.1 Intended use .................................................................................................................................... 10
1.2 Do not make any modifications. ....................................................................................................... 10
1.3 Performing inspection and maintenance work ................................................................................. 10
1.4 Personnel qualification ..................................................................................................................... 10
1.5 Safety for particular activities ........................................................................................................... 11
1.5.1 Check for transport damage ............................................................................................... 11
1.5.2 Safety information for installation and maintenance ........................................................... 11
1.6 Hazards............................................................................................................................................ 11
1.6.1 Hazards when lifting ........................................................................................................... 11
1.6.2 Hazards due to rotating parts ............................................................................................. 11
1.6.3 Hazards due to high or low temperatures ........................................................................... 11
1.6.4 Hazards due to lubricants and other substances ................................................................ 12
1.6.5 Hazards due to noise.......................................................................................................... 12
1.6.6 Hazards due to pressurised coolants ................................................................................. 12
1.7 Explanation of markings ................................................................................................................... 13
2 Description of gear units .......................................................................................................................... 14
2.1 Type designations and gear unit types............................................................................................. 14
2.2 Type plate ........................................................................................................................................ 16
3 Assembly instructions, storage, preparation, installation .................................................................... 17
3.1 Transporting the gear unit ................................................................................................................ 17
3.2 Storage ............................................................................................................................................ 17
3.3 Long-term storage ............................................................................................................................ 17
3.4 Preparing for installation .................................................................................................................. 19
3.5 Installing the gear unit ...................................................................................................................... 21
3.6 Fitting hubs on the gear shafts ......................................................................................................... 22
3.7 Fitting push-on gear units................................................................................................................. 23
3.8 Fitting shrink discs............................................................................................................................ 26
3.9 Fitting the covers .............................................................................................................................. 27
3.10 Fitting the covers .............................................................................................................................. 27
3.11 Fitting a standard motor ................................................................................................................... 28
3.12 Fitting the cooling coil to the cooling system .................................................................................... 30
3.13 External oil-air cooler ....................................................................................................................... 31
3.13.1 Assembling the cooling system .......................................................................................... 31
3.13.2 Oil-air cooler electrical connection ...................................................................................... 31
3.14 Installation of an oil expansion tank, Option OA............................................................................... 31
3.15 Subsequent paintwork...................................................................................................................... 32
4 Commissioning ......................................................................................................................................... 33
4.1 Check the oil level ............................................................................................................................ 33
4.2 Activating the automatic lubricant dispenser .................................................................................... 33
4.3 Operation with lubricant cooling ....................................................................................................... 34
4.4 Running-in time for the worm gear unit ............................................................................................ 35
4.5 Checklist .......................................................................................................................................... 35
5 Service and maintenance ......................................................................................................................... 36
5.1 Service and Maintenance Intervals .................................................................................................. 36
5.2 Service and Maintenance Work ....................................................................................................... 37
6 Disposal ..................................................................................................................................................... 41
7 Appendix .................................................................................................................................................... 42
7.1 Versions and maintenance............................................................................................................... 42
7.2 Lubricants ........................................................................................................................................ 57
7.3 Lubricant quantities .......................................................................................................................... 60
7.4 Torque values .................................................................................................................................. 68
6 B 1000 en-5018
78
Table of Contents
7.5 Troubleshooting ............................................................................................................................... 69
7.6 Leakage and leak-tightness ............................................................................................................. 70
7.7 Repair information ............................................................................................................................ 71
7.7.1 Repairs ............................................................................................................................... 71
7.7.2 Internet information............................................................................................................. 71
7.8 Warranty .......................................................................................................................................... 71
7.9 Abbreviations ................................................................................................................................... 72
B 1000 en-5018 7
79
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List of illustrations
=== Ende der Liste für T extmar ke Abbildungs verzeic hnis ===
Figure 1: Type plate (example) with explanation of type plate fields ..................................................................... 16
Figure 2: Activating the vent plug .......................................................................................................................... 20
Figure 3: Activating the vent plug .......................................................................................................................... 20
Figure 4: Removing the vent plug and fitting the special pressure vent................................................................. 20
Figure 5: Example of a simple pulling device ........................................................................................................ 22
Figure 6: Correct assembly of drive elements ....................................................................................................... 22
Figure 7: Applying lubricant to the shaft and the hub............................................................................................. 23
Figure 8: Removing the factory-fitted closing cap .................................................................................................. 24
Figure 9: Gear unit mounted to shaft with a shoulder using the fastening element ............................................... 24
Figure 10: Gear unit mounted to shaft without a shoulder using the fastening element ........................................ 24
Figure 11: Dismantling using dismantling device ................................................................................................... 24
Figure 12: Mounting the rubber buffer (Option G or VG) on parallel shaft gear units ............................................ 25
Figure 13: Attaching the torque support on bevel gear and worm gear units ........................................................ 25
Figure 14: Hollow shaft with shrink disc ................................................................................................................. 26
Figure 15: Fitting the covers, Option SH, Option H, and Option H66..................................................................... 27
Figure 16: Removal and fitting of the cover cap .................................................................................................... 27
Figure 17: Fitting the coupling onto the motor shaft - various types of coupling .................................................... 29
Figure 18: Cooling cover ....................................................................................................................................... 30
Figure 19: Connecting the cooling system ............................................................................................................. 31
Figure 20: Installing the expansion tank ................................................................................................................ 32
Figure 21: Activating the automatic lubricant dispenser with standard motor mounting ........................................ 33
Figure 22: Adhesive label ...................................................................................................................................... 34
Figure 23: Checking the oil level with a dipstick .................................................................................................... 38
Figure 24: Replacing the automatic lubricant dispenser with standard motor mounting ........................................ 39
Figure 25: Oil level check with oil level tank .......................................................................................................... 43
8 B 1000 en-5018
80
List of tables
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List of tables
=== Ende der Liste für T extmar ke Tabellenverz eic hnis ===
Table 1: Version list B 1000 ..................................................................................................................................... 3

Table 2: Type designations and gear unit types .................................................................................................... 15
Table 3: Disposal of materials ............................................................................................................................... 41
Table 4: Roller bearing greases............................................................................................................................. 57
Table 5: Lubricant table ......................................................................................................................................... 59
Table 6: Lubricant quantities for helical gear units................................................................................................. 61
Table 7: Lubricant quantities for NORDBLOC ....................................................................................................... 62
Table 8: Lubricant quantities for NORDBLOC helical gear units ........................................................................... 63
Table 9: Lubricant quantities for standard helical gear units .................................................................................. 64
Table 10: Lubricant quantities for parallel shaft gear units .................................................................................... 65
Table 11: Lubricant quantities for bevel gear units ................................................................................................ 66
Table 12: Lubricant quantities for helical worm gear units ..................................................................................... 67
Table 13: Torque values ........................................................................................................................................ 68
Table 14: Overview of malfunctions....................................................................................................................... 69
Table 15: Definition of leaks according to DIN 3761 .............................................................................................. 70
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B 1000 en-5018 9
81
1 Safety information
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1.1 Intended use

These gear units are used to transmit and transform rotary movements. They are intended for use as
part of a drive system in commercially used plant and machinery. The gear units must not be operated
until it has been established that the plant or machinery can be safely operated with the gear unit. The
plant or machinery must comply with the local laws and regulations and all applicable health and
safety requirements must be fulfilled. In particular, the Machinery Directive 2006/42/EC for the
particular field of application must be observed.
The gear units may not be used in environments in which an explosive atmosphere can occur.
The gear units must only be used according to the information in the technical documentation from
Getriebebau NORD GmbH & Co. KG. Damage to the gear unit may result if the gear unit is not used
as intended and according to the information in the operating and assembly manual This may also
result in personal injury.
The foundation or the gear unit fastening must be appropriately designed for the weight and torque. All
of the fastenings provided must be used.
Some gear units are equipped with a cooling coil. These gear units may only be operated if the cooling
circuit is connected and in operation.
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1.2 Do not make any modifications.

Do not make any modifications to the gear unit. Do not remove any protective devices.
Pos : 21 /Anl eitungen/Getriebe/1. Hinweis e/Sic herheits hinweis e/Ins pektionen und Wartung durchführen @ 22\mod_1530529678502_388.doc x @ 2429333 @ 2 @ 1
1.3 Performing inspection and maintenance work

Due to lack of maintenance and damage, malfunctions may occur which can result in personal injury.
• Carry out all servicing and maintenance work at the specified intervals.
• Also note that servicing is necessary after long storage periods prior to commissioning.
• Do not operate damaged gear units. The gear unit must not have any leaks.
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1.4 Personnel qualification

All transport, storage, installation, commissioning and maintenance work must be carried out by
qualified specialist personnel.
Qualified specialist personnel are persons who have the training and experience to recognise and
avoid any possible risks.
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10 B 1000 en-5018
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1.5 Safety for particular activities

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1.5.1 Check for transport damage

Transport damage may cause malfunctions of the gear unit, which may cause personal injury. Oil
which escapes due to leaks may cause a slipping hazard.
• Check the packaging and the gear unit for transport damage.
• Do not operate damaged gear units.
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1.5.2 Safety information for installation and maintenance

Before starting work on the gear unit disconnect the drive from the power supply and secure it against
accidental switch-on. Allow the gear unit to cool down. Depressurise the cooling circuit lines.
Damaged or defective components, attachment adapters, flanges and covers may have sharp edges.
Wear work gloves and work clothing.
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1.6 Hazards
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1.6.1 Hazards when lifting

Persons may be injured by falling or swinging gear units. Therefore also observe the following
information:
• Cordon off a wide area around the hazard area. Pay attention to adequate space for avoiding
swinging loads.
• Never stand under suspended loads.
• Select lifting gear and transport equipment according to the weight of the gear unit. The weight of
the gear unit can be obtained from the type plate.
• Only lift the gear units by the eyebolts which are provided. The eyebolts must be fully screwed in.
Only pull on the eyebolts vertically, never cross-wise or at an angle. Only use the eyebolts to lift the
gear unit without other components. The eyebolts are not designed for lifting the gear unit with
attachments. Use the eyebolts on both the gear unit and the motor to lift a geared motor.
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1.6.2 Hazards due to rotating parts

Rotating parts cause a risk of entanglement. Therefore provide a contact guard. In addition to shafts,
this also applies to fans as well as drives and drive elements such as belt drives, chain drives, shrink
discs and couplings.
For test operation do not switch on the drive without an installed drive element or secure the parallel
key.
Take possible run-on of the machine into consideration for the design of protective guards.
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1.6.3 Hazards due to high or low temperatures

The gear unit may heat up to 90 °C during operation. Touching hot surfaces or contact with hot oil may
result in burns. At very low ambient temperatures freezing may occur on contact.
• Only touch the gear unit when wearing gloves after operation or at very low ambient temperatures.
• Before starting maintenance work, allow the gear unit to cool down sufficiently after operation.
• Provide a contact guard if there is a risk that persons may touch the gear unit when it is in
operation.
• Bursts of hot oil mist may be emitted from the pressure vent screw during operation. Provide a
suitable guard so that persons cannot be injured by this.
B 1000 en-5018 11
83
• Do not place any flammable materials on the gear unit.
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1.6.4 Hazards due to lubricants and other substances

Chemical substances which are used with the gear unit may be toxic. Eye injuries may result if these
substances enter the eyes. Lubricants and adhesives may cause skin irritation.
Oil mist may escape when vent screws are opened.
Due to lubricants and conservation materials, gear units may be slippery and slip out of the hands.
There is a slipping hazard from spilled lubricants.
• When working with chemical substances wear chemical-resistant gloves and work clothing. Wash
your hands after working.
• Wear protective goggles if there is a possibility of splashed chemicals, for example when filling oil
or during cleaning work.
• If chemicals enter the eyes, rinse with large amounts of cold water immediately. Consult a
physician in case of symptoms.
• Observe the safety data sheets for the chemicals. Keep the safety data sheets in the vicinity of the
gear unit.
• Collect spilled lubricants immediately with a binding agent.
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1.6.5 Hazards due to noise

Some gear units or attached components may cause hazardous noise levels during operation. Wear
hearing protection if work has to be carried out close to such gear units.
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1.6.6 Hazards due to pressurised coolants

The cooling system is under high pressure. Damage or opening a cooling line which is under pressure
may result in injury. Depressurise the cooling circuit before working on the gear unit.
12 B 1000 en-5018
84
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1.7 Explanation of markings
DANGER
Indicates an immediate danger, which may result in death or very serious injury if it is not avoided.
WARNING
Indicates a dangerous situation, which may result in death or serious injury if it is not avoided.
CAUTION
Indicates a dangerous situation, which may result in minor injuries if it is not avoided.
NOTICE
Indicates a situation, which may result in damage to the product or its environment if it is not avoided.
Information
Indicates hints for use and especially important information to ensure reliability of operation.
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B 1000 en-5018 13
85
2 Description of gear units

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2.1 Type designations and gear unit types
Gear unit types / Type designations

Helical gear units
SK 11E, SK 21E, SK 31E,SK 41E, SK 51E (1-stage)
SK 02, SK 12, SK 22, SK 32, SK 42, SK 52, SK 62N (2-stage)
SK 03, SK 13, SK 23, SK 33N, SK 43, SK 53 (3-stage)
SK 62, SK 72, SK 82, SK 92, SK 102 (2-stage)
SK 320, SK 172, SK 272, SK 372, SK 472, SK 572, SK 672, SK 772, SK 872, SK 972 (2-stage)
SK 273, SK 373, SK 473, SK 573, SK 673, SK 773, SK 873, SK 973 (3-stage)
SK 071.1, SK 371.1, SK 571.1, SK 771.1, SK 871.1, SK 971.1, SK 1071.1 (1-stage)
SK 072.1, SK 172.1, SK 372.1, SK 572.1, SK 672.1, SK 772.1, SK 872.1, SK 972.1 (2-stage)
SK 373.1, SK 573.1, SK 673.1, SK 773.1, SK 873.1, SK 973.1 (3-stage)
SK 0, SK 01, SK 20, SK 25, SK 30, SK 33 (2-stage)
SK 0182NB, SK 0182.1, SK 0282NB, SK 0282.1, SK 1282, SK 1282.1, SK 2282, SK 3282, SK 4282, SK 5282,
SK 0182.1, SK 0282.1, SK 1382NB, SK 1382.1, SK 2382, SK 3382, SK 4382, SK 5382, SK 6382, SK 7382,
SK 8382, SK 9382, SK 10382, SK 10382.1, SK 11382, SK 11382.1, SK 12382 (3-stage)
Bevel gear units
SK 92072, SK 92172, SK 92372, SK 92672, SK 92772;
SK 920072.1, SK 92072.1, SK 92172.1, SK 92372.1, SK 92672.1, SK 92772.1, SK 930072.1. SK 93072.1,
SK 93172.1, SK 93372.1, SK 93672.1, SK 93772.1 (2-stage)
SK 9012.1, SK 9016.1, SK 9022.1, SK 9032.1, SK 9042.1, SK 9052.1, SK 9062.1, SK 9072.1, SK 9082.1,
SK 9086.1, SK 9092.1, SK 9096.1 (3-stage)
SK 9013.1, SK 9017.1, SK 9023.1, SK 9033.1, SK 9043.1, SK 9053.1 (4-stage)
SK 02040, SK 02040.1, SK 02050, SK 12063, SK 12080, SK 32100, SK 42125 (2-stage)
MINIBLOC worm gear units
SK 1S32, SK 1S40, SK 1S50, SK 1S63, SK 1SU..., SK 1SM31, SK 1SM40, SK 1SM50, SK 1SM63 (1-stage)
SK 2S32NB, SK 2S40NB, SK 2S50NB, SK 2S63NB, SK 2SU…, SK 2SM40, SK 2SM50, SK 2SM63 (2-stage)
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2 Description of gear units
Gear unit types / Type designations
UNIVERSAL worm gear units
SK 1SI31, SK 1SI40, SK 1SI50, SK 1SI63, SK 1SI75,
SK 1SIS31, …, SK 1SIS75,
SK 1SID31, …, SK 1SID63,
SK 1SMI31, …, SK 1SMI75,
SK 1SMID31, …, SK 1SMID63,
SK 1SIS-D31, …, SK 1SIS-D63 (1-stage),
SK 2SMID40, SK 2SMID50, SK 2SMID63, SK 2SID40, …, SK 2SID63 (2-stage)
Versions / Options
- Foot mounting with solid shaft D Torque support IEC Standard IEC motor mounting
A Hollow shaft version K Torque bracket NEMA Standard NEMA motor
attachment
V Solid shaft version S Shrink disc W With free drive shaft
L Solid shaft both sides VS Reinforced shrink disc VI Viton radial seals
Z Output flange B14 EA Hollow shaft with internal spline OA Oil expansion tank
F Output flange B5 G Rubber buffer OT Oil level tank
X Foot mounting VG Reinforced rubber buffer SO1 Synthetic oil ISO VG 220
XZ Base and output flange B14 R Back stop CC Housing cover with cooling spiral
XF Base and output flange B5 B Fastening element
AL Reinforced axial output bearings H Covering cap as contact guard DR Pressure venting
5 Reinforced output shaft H66 Covering cap IP66 H10 Modular helical pre-stage
(Standard helical gear units)
V Reinforced drive VL Reinforced bearings /31 Worm pre-stage
(Standard helical gear units)
VL2 Agitator version /40 Worm pre-stage
VL3 Drywell agitator version
Table 2: Type designations and gear unit types
Double gear units consist of two single gear units. They are to be treated as per the instructions in this
manual, i.e. as two individual gear units.
Type designation for double gear units: e. g. SK 73 / 22 (consisting of single gear units SK 73 and
SK 22).
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2.2 Type plate

Explanation
1 Matrix – Barcode
2 NORD gear unit type
3 Operating mode
4 Year of manufacture
5 Serial number
Rated torque of gear unit
6
output shaft
7 Drive power
Weight according to ordered
8
version
9 Overall gear unit ratio
10 Installation orientation
Rated speed of gear unit
11
output shaft
Lubricant type,
12
viscosity and quantity
13 Customer’s part number
14 Operating factor
Figure 1: Type plate (example) with explanation of type plate fields

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3 Assembly instructions, storage, preparation, installation
Please note all safety information (please see chapter 1 "Safety information")and warning information
in the relevant sections.
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3.1 Transporting the gear unit
WARNING
Hazard due to falling loads
• The thread of the eyebolt must be fully screwed in.
• Do not pull on the eyebolt at an angle.
Only use the eyebolts attached to the gear unit for transport. If geared motors have an additional
eyebolt attached to the motor, this must also be used.
Transport the gear unit with care. Impacts to the free ends of the shafts may cause internal damage to
the gear unit.
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3.2 Storage
For short-term storage before commissioning, please observe the following:
• Store gear units in the fitting position ((please see chapter 7.1 "Versions and maintenance")) and
secure them against falling,
• Lightly oil bare metal housing surfaces and shafts
• Store in a dry place,
• Temperature in the range from – 5 °C to + 50 °C without large fluctuations,
• Relative humidity less than 60 %,
• No direct exposure to sunlight or UV light,
• No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis,
salts, radioactivity etc.) in the immediate vicinity,
• No vibration or oscillation
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3.3 Long-term storage

For storage or standstill periods in excess of 9 months, Getriebebau NORD recommends the long-
term storage option. With the use of the measures listed below, storage for up to 2 years is possible.
As the actual influences on the unit greatly depend on the local conditions, these times should only be
regarded as guide values.
Conditions of the gear unit and storage area for long-term storage prior to commissioning:
• Store in the fitting position (please see chapter 7.1 "Versions and maintenance")and secure them
against falling.
• Transportation damage to the external paint must be repaired. Check that a suitable rust inhibitor is
applied to the flange bearing surfaces. If necessary apply a suitable rust inhibitor to the surfaces.
• Gear units with the long-term storage option are completely filled with lubricant or have VCI
corrosion protection agent mixed with the gear oil (see adhesive label on the gear unit, or are not
filled with oil, but rather with small quantities of VCI concentrate.
• The sealing band in the vent plug must not be removed during storage. The gear unit must remain
sealed tight.
B 1000 en-5018 17
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• Store in a dry place.
• In tropical regions the drive unit must be protected against damage by insects.
• Temperature in the range from – 5 °C to + 40 °C without large fluctuations.
• Relative humidity less than 60 %.
• No direct exposure to sunlight or UV light.
• No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis,
salts, radioactivity etc.) in the immediate vicinity.
• No vibration or oscillation
Measures during storage or standstill periods
• If the relative humidity is < 50 % the gear unit can be stored for up to 3 years.
Measures before commissioning
• Inspect the gear unit before commissioning.
• If the storage or standstill period exceeds 2 years or the temperature during short-term storage has
greatly deviated from the standard range, the lubricant in the gear unit must be replaced before
commissioning.
• If the gear unit is completely filled, the oil level must be reduced before commissioning.
• For gear units without oil filling, the oil level for the version must be filled before commissioning.
The VCI concentrate may remain in the gear unit. Lubricant quantities and types must be filled
according to the details on the type plate.
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3.4 Preparing for installation

Please examine the delivery for transport and packaging damage immediately on receipt. The drive
unit must be examined and may only be installed if no damage is apparent. In particular the radial
seals and the sealing caps must be inspected for damage. Report any damage to the carrier
immediately. Gear units with transport damage must not be commissioned.
All bare metal surfaces and shafts of the gear unit are protected against corrosion with oil, grease or
corrosion protection agents before shipping.
Thoroughly remove all oil, grease or corrosion protection agents and any dirt from the shafts and
flange surfaces before assembly.
In applications where an incorrect rotational direction may result in damage or potential risk, the
correct rotational direction of the output shaft must be established by test running the drive when
uncoupled and guaranteeing such for subsequent operation.
Gears with integrated return stops are marked with arrows on the drive/driven sides. The arrows point
in the rotation direction of the gear unit. When connecting the motor and during motor control, it must
be ensured that the gear unit can only operate in the direction of rotation. (For further explanations see
catalogue G1000 and Works Standard 0-000 40)
Ensure that no aggressive or corrosive substances which attack metal, lubricants or elastomers are
present in the area surrounding the installation site or are subsequently expected during operation.
Gear units with nsd tupH surface treatment must be electrically decoupled by the use of non-
conductive intermediate layers. In case of doubt, please contact Getriebebau NORD and take the
recommended action.
Oil expansion tanks (Option OA) must be fitted in accordance with Works Standard 0-530 04. For gear
units with an M10x1 vent plug, Works Standard 0-521 35 must be also be observed during installation.
Oil level tanks (Option OT) must be fitted in accordance with Works Standard 0-521 30.
If venting of the gear unit is provided, the vent or the pressure vent must be activated before
commissioning. To activate, remove the transport securing device (sealing cord). Position of the vent
screw 7.1 "Versions and maintenance".
B 1000 en-5018 19
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Explanation
1 Standard vent plug

2 Transport securing device
Figure 2: Activating the vent plug
Explanation
1 Vent screw
2 Transport securing device
Figure 3: Activating the vent plug
Special pressure vents are supplied as loose parts. Before commissioning, the vent screws must be
replaced with the special pressure vents which are supplied as loose parts. This is done by
unscrewing the vent fitting and replacing it with the special pressure vent and seal (refer to Section 7.1
"Versions and maintenance"). Double gear units consist of two single units and are equipped with 2 oil
chambers and possibly 2 pressure vents.
Explanation
1 Standard vent plug 2 Transport securing device 3 Special vent screw
Figure 4: Removing the vent plug and fitting the special pressure vent
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3.5 Installing the gear unit
NOTICE!
Damage to the gear unit due to overheating
• For geared motors, check that the cooling air from the motor fan can circulate around the gear unit
without obstruction.
The eyebolts screwed into the gear units must be used during installation. No additional load may be
attached to the gear unit.
If geared motors have an additional eyebolt attached to the motor, this must also be used. Avoid
pulling the eyebolts at an angle. Observe the safety information (please see chapter 1 "Safety
information").
The base and/or flange to which the gear unit is fitted should be vibration-free, torsionally rigid and flat.
The smoothness of the mating surface on the base or flange must be according to tolerance class K
according to DIN ISO 2768-2. All contamination to the bolting surfaces of gear unit and base and/or
flange must be thoroughly removed.
The gear housing must always be earthed. With geared motors, earthing via the motor connection
must be ensured.
The gear unit must be precisely aligned with the drive shaft of the machine in order to prevent
additional forces from being imposed on the gear unit due to distortion.
Welding of the gear unit is prohibited. The gear unit must not be used as the earth connection for
welding work, as this may cause damage to the bearings and gear wheels.
The gear unit must be installed in the correct orientation (please see chapter 7.1 "Versions and
maintenance"). (UNIVERSAL SI and SM gear unit types do not depend on the configuration).
Changes to the installation position after delivery require adjustment of the quantity of oil, and often
other measures such as e.g. the installation of encapsulated roller bearings. Damage may result if
the stated installation position is not observed.
All gear unit feet and/or all flange bolts on each side must be used. Bolts must have a minimum quality
of 8.8. The bolts must be tightened to the correct torques (please see chapter 7.4 "Torque values").
Tension-free bolting must be ensured, particularly for gear units with a foot and flange.
The oil inspection screws, oil drain screws and the vent valves must be accessible.
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3.6 Fitting hubs on the gear shafts
NOTICE!
The gear unit may be damaged by axial forces.
• Do not allow any harmful axial forces to act on the gear unit. Do not strike the hub with a hammer.
Drive and driven elements, e.g. coupling and chain-wheel hubs must be mounted onto the drive and
driven shaft of the gear unit using suitable pullers that will not apply damaging axial forces to the gear
unit.
Information
Use the end thread of the shafts for pulling. Fitting can be aided by coating the hub with lubricant or
heating it up to approx. 100 °C beforehand.
Figure 5: Example of a simple pulling device
Drive and driven elements may only subject the drive unit to the maximum radial forces FR and
axial forces FA which are specified in the catalogue. Observe the correct tension, particularly on
belts and chains.
Additional loads due to unbalanced hubs are not permitted.
The transverse force must be applied to the gear unit as closely as possible.
Figure 6: Correct assembly of drive elements

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3.7 Fitting push-on gear units
WARNING
When the screw fastenings of the torque arm are removed, the gear unit will rotate around the
output shaft
• Secure the screw fastening against loosening, e.g. with Loctite 242 or a second nut.
NOTICE!
The gear unit may be damaged by axial forces.
The bearings, gear wheels, shafts and housing may be damaged by incorrect fitting.
• Use suitable pulling devices.
• Do not strike the gear unit with a hammer.
Assembly and subsequent dismantling is aided by applying an anti-corrosive lubricant to the shaft
before fitting (e.g. NORD Anti-Corrosion Part No. 089 00099). Excess grease or anti-corrosion agent
may escape after assembly and may drip off. Clean these points on the output shaft after a running-in
time of approx. 24 hours. This escape of grease is not due to a leak in the gear unit.
Figure 7: Applying lubricant to the shaft and the hub
Information
The gear unit can be fitted to shafts with and without a shoulder using the fastening element
(Option B). Tighten the bolt of the fastening element to the correct torque (please see chapter 7.4
"Torque values"). For gear units with option H66, the factory-fitted closing cap must be removed
before assembly.
For push-on gear units with option H66 and fastening element (Option B) the pressed-in closing cap
must be pushed out before fitting the gear unit. The pressed-in closing cap may be destroyed during
dismantling. As standard a second closing cap is supplied as a loose spare part. After fitting the gear
unit, fit the new closing cap as described in Section (please see chapter 3.9 "Fitting the covers").
B 1000 en-5018 23
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Figure 8: Removing the factory-fitted closing cap
Figure 9: Gear unit mounted to shaft with a shoulder using the fastening element
Figure 10: Gear unit mounted to shaft without a shoulder using the fastening element
A gear unit can be dismantled from a shaft with a shoulder using the following device, for example.
Figure 11: Dismantling using dismantling device
When assembling push-on gears with torque supports, the support must not be distorted. Tension-free
mounting is aided by the rubber buffer (Option G or VG).
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Figure 12: Mounting the rubber buffer (Option G or VG) on parallel shaft gear units
To fit the rubber buffer, tighten the screw fastening until there is no play between the contact surfaces
when there is no load.
Then turn the fastening nut half a turn in order to pre-tension the rubber buffer (only applies for screw
fastenings with adjusting threads). Greater pre-tension is not permissible.
Explanation
1 Always support torque support on
both sides
Figure 13: Attaching the torque support on bevel gear and worm gear units
Tighten the fastenings of the torque support with the correct tightening torques (please see chapter
7.4 "Torque values")and secure against loosening (e.g. Loctite 242, Loxeal 54-03).
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3.8 Fitting shrink discs
NOTICE!
Damage to the hollow shaft
• Do not tighten the clamping bolts if the solid shaft is not inserted.
Explanation
1 Shrink disc, type, part no. and torque details
for tensioning screws
2 Tensioning flanges
3 Solid shaft of machine
4 Shaft and hollow shaft bore FREE OF
GREASE
5 Hollow shaft of gear unit
6 Double half-slotted inner ring
7 Tensioning screws DIN 931 (933) -10.9
Figure 14: Hollow shaft with shrink disc
The shrink discs are supplied by the manufacturer ready for fitting. They must not be dismantled prior
to fitting.
The solid shaft of the machine runs free of grease in the hollow shaft of the gear unit.
Assembly sequence
1. Remove any transport securing devices.
2. Loosen but do not remove tightening bolt and tighten gently by hand until there is no play between
the flanges and the inner ring.
3. Slide the shrink disc onto the hollow shaft until the outer clamping flange is flush with the hollow
shaft. The shrink disc is easier to slide on if the bore of the inner ring is lightly greased.
4. Prior to mounting, grease the solid shaft only in the area which will later come into contact with the
bronze bush in the hollow shaft of the gear unit. Do not grease the bronze bush, in order to prevent
grease penetrating the area around the shrink connection.
5. The hollow shaft of the gear unit must be completely de-greased and completely free of grease.
6. In the area of the shrink connection the solid shaft of the machine must be degreased and
completely free of grease.
7. Insert the solid shaft of the machine into the hollow shaft so as to completely fill the area around
the shrink connection.
8. Position the clamping flange by gently tightening the bolts.
9. Tighten the tensioning bolts successively in a clockwise direction by several turns – not crosswise
– with approx. ¼ rotation per turn. Tighten the bolts with a torque wrench to the torque indicated on
the shrink disc.
10. When the tensioning bolts have been tightened, there must be an even gap between the clamping
flanges. If this is not the case, the gear unit must be dismantled and the shrink disc connection
checked for correct fit.
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Dismantling sequence:
1. Loosen the tensioning bolts successively in a clockwise direction by several turns with approx. ¼
rotation per turn. Do not remove the bolts from their thread.
2. Loosen the clamping flanges from the cone of the inner ring.
3. Remove the gear unit from the solid shaft of the machine.
If a shrink disk has been in use for a long period or is dirty, it must be dismantled, cleaned and the
conical surfaces coated with Molykote G Rapid Plus or a similar lubricant before it is refitted. The
threads and head surfaces of the screws must be treated with grease without Molykote. Any damaged
or corroded elements must be replaced.
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3.9 Fitting the covers

All fixing screws must be used and tightened to the correct torque (please see chapter 7.4 "Torque
values"). For covers with Option H66, press in the new / new condition closing cap by tapping it lightly
with a hammer.
Figure 15: Fitting the covers, Option SH, Option H, and Option H66
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3.10 Fitting the covers

Many versions of the universal worm gear unit are supplied with plastic cover caps as standard. These
cover caps protect the shaft sealing ring against the entry of dust and other possible contamination.
The cover caps can be removed by hand without the use of tools and pushed onto the A or B side.
The cover cap must be removed before installing the universal worm gear unit. After installation is
complete, the cover cap must be pushed into the threaded holes on the output flange on the
corresponding side. Care must be taken that the cover cap is removed and pushed on vertically, in
order not to damage the expansion elements of the cover cap.
Figure 16: Removal and fitting of the cover cap

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3.11 Fitting a standard motor

The maximum permitted motor weights indicated in the table below must not be exceeded when
attaching the motor to an IEC/NEMA adapter:
Maximum permitted motor weights

IEC motor size 63 71 80 90 100 112 132 160 180 200 225 250 280 315
NEMA motor size
/400TC
140TC
180TC
210TC
250TC
280TC
320TC
360TC
56C
Max. motor weight [kg] 25 30 40 50 60 80 100 200 250 350 500 700 1000 1500
Assembly procedure to attach a standard motor to the IEC adapter (Option IEC/NEMA adapter)
1. Clean the motor shaft and flange surfaces of the motor and the IEC /NEMA adapter and check for
damage. The mounting dimensions and tolerances of the motor must conform to
DIN EN 50347 / NEMA MG1 Part 4.
2. Push the coupling sleeve onto the motor shaft so that the motor parallel key engages into the
groove in the sleeve on tightening.
3. Tighten the coupling sleeve on the motor shaft in accordance with the motor manufacturer’s
instructions until it touches the collar. With motor sizes 90, 160, 180 and 225, any spacer bushes
must be positioned between the coupling sleeve and the collar. With standard helical gear units,
dimension B between the coupling sleeve and the collar must be observed (see Figure 17). Certain
NEMA adapters require adjustment of the coupling in accordance with the specifications indicated
on the adhesive plate.
4. If the coupling half contains a threaded pin, the coupling must be secured axially on the shaft. The
threaded pin must be coated prior to use with a securing lubricant e. g. Loctite 242, Loxeal 54-03
and tightened to the correct torque (please see chapter 7.4 "Torque values").
5. Sealing of the flange surfaces of the motor and the IEC/NEMA adapter is recommended if the
motor is installed outdoors or in a humid environment. Before the motor is installed, the flange
surfaces must be completely coated with surface sealant Loctite 574 or Loxeal 58-14 so that the
flange seals after mounting.
6. Mount the motor on the IEC/NEMA adapter. Do not forget to fit the gear rim or the splined sleeve
provided (see illustration below).
7. Tighten the bolts of the IEC/NEMA adapter with the correct torque (please see chapter 7.4 "Torque
values").
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Figure 17: Fitting the coupling onto the motor shaft - various types of coupling
I Curved tooth coupling

II Curved tooth coupling, two-part
III Curved tooth coupling, two-part with spacer bush
IV Claw coupling, two-part
V Claw coupling, two-part, observe dimension B:
Standard helical gear unit:
IEC size 63 IEC size 71
Dimension B (Fig. V) B = 4.5 mm B = 11.5 mm
VI Claw coupling two-part with spacer bush
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3.12 Fitting the cooling coil to the cooling system

The cooling coil is installed in the housing cover. Cutting ring screw threads according to DIN 2353 are
located at the casing cover for the connection of a pipe with an external diameter of 10 mm.
Remove the closing cap from the screw neck prior to assembly to avoid any contamination of
the cooling system. The screw necks should be connected with the coolant circuit, which must be
provided by the operator. The flow direction of the coolant is irrelevant.
Make sure not to twist the screw necks during or after assembly as the cooling coil may be
damaged. It must be ensured that no external forces act on the cooling coil.
Explanation
1 Cutting ring screw threads

2 Cooling coil
3 Housing cover
Figure 18: Cooling cover

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3.13 External oil-air cooler
NOTICE!
The gear unit is supplied without the oil filling.
• Fill the gear unit with oil before commissioning.
The oil-air cooler is delivered as an additional unit. The scope of delivery includes the oil-air cooler and
the necessary connection hoses. Installation of the hoses and commissioning are performed by the
plant operator.
3.13.1 Assembling the cooling system

Connect the cooling system as shown in the illustration.
1 Oil-air cooler
2 Gear unit
3 Optional temperature monitoring
S Intake connection / gear unit oil drain
Gear unit pressure connection above or
P
below the oil level
Figure 19: Connecting the cooling system
Fit the union nuts according to(please see chapter 7.4 "Torque values").
After assembling the oil lines, fill the gear unit housing with the gear oil type and quantity that is printed
on the type plate. Approximately 4.5 l of oil are additionally required for the hose lines. When filling,
always use the oil level screw as an indicator of the precise quantity of oil. The oil quantity on the type
plate is a guide value and may vary, depending on the gear ratio.
3.13.2 Oil-air cooler electrical connection

Please comply with all national safety regulations for the electrical connection. Please observe all
applicable documents, in particular the operating and installation instructions for the oil-air cooler.
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3.14 Installation of an oil expansion tank, Option OA

The expansion tank must be installed vertically with the hose connection facing downwards and the
vent plug upwards. If the tank is not fitted, observe the following steps for fitting:
B 1000 en-5018 31
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• After installing the gear unit (motor), remove the vent screw on the gear unit.
• For modules 0.7 l, 2.7 l and 5.4 l the reduction / extension is screwed in with the
existing sealing ring.
• Now fit the expansion tank (see below for suggested position).
Note: If the necessary screw insertion depth of 1.5d can no longer be achieved, use a
5 mm longer screw. If a longer screw cannot be fitted, use a stud and a nut with
appropriate dimensions.
If the fastening screw is screwed into a through hole, seal the thread with a medium
strength screw securing material such as LOXEAL 54-03 or Loctite 242.
• The tank should be fitted as high as possible. - Note the length of the hoses!! -
• After this, fit the vent hose with the enclosed hollow screws and seals.
Finally, screw the enclosed M12x1.5 vent screw and sealing ring into the tank.
Notice: For ATEX gear units, screw the enclosed M12x1.5 vent screw into the tank.
Figure 20: Installing the expansion tank
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3.15 Subsequent paintwork

For retrospective painting of the gear unit, the radial seals, rubber elements, pressure venting valves,
hoses, type plates, adhesive labels and motor coupling components must not come into contact with
paints, lacquers or solvents, as otherwise components may be damaged or made illegible.
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32 B 1000 en-5018
104
4 Commissioning
4 Commissioning
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4.1 Check the oil level

The oil level must be checked prior to commissioning (please see chapter 5.2 "Service and
Maintenance Work").
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4.2 Activating the automatic lubricant dispenser

Some gear unit types with standard motor (Option IEC/NEMA) have an automatic lubricant dispenser
for the roller bearings. This dispenser must be activated prior to commissioning. The cartridge case
cover of the adapter for attaching an IEC/NEMA standard motor has a red information sign for the
activation of the lubricant dispenser. A grease escape opening which is closed with a G1/4 cap screw
is located opposite to the lubricant dispenser. After activation of the lubricant dispenser, the cap screw
can be removed and replaced with the grease collection container (Part No. 28301210) which is
supplied separately with the delivery.
Activating the automatic lubricant dispenser:
1. Loosen and remove the cylindrical screws.
2. Remove the cartridge cover.
3. Screw the activation screw into the lubricant dispenser until the lug breaks off at the defined
fracture point
4. Re-fit the cartridge cover and fasten it with the cylindrical screw (please see chapter 7.4 "Torque
values").
5. Mark activation date on the adhesive label indicating the month/year
Explanation
1 Cylindrical screw M8 x 16
2 Cartridge cover
3 Activation screw
4 Lug
5 Lubricant sensor
6 Position of adhesive label
Figure 21: Activating the automatic lubricant dispenser with standard motor mounting
B 1000 en-5018 33
105
Adhesive label:
Notice!
Screw in the activation screw until the lug breaks off before
commissioning the gear unit.
Dispensing time: 12 Months
Month Activation date Year
1 2 3 4 5 6 7 8 9 10 11 12 06 07 08 09 10
11 12 13 14 15
Figure 22: Adhesive label

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4.3 Operation with lubricant cooling

Water cooling
The coolant must have a similar thermal capacity as water (specific thermal capacity at 20 °C
c=4.18 kJ/kgK). Industrial water without any air bubbles or sediments is recommended as a coolant.
The hardness of the water must be between 1 dH and 15 dH; the pH value must be between pH 7.4
and pH 9.5. No aggressive liquids may be added to the coolant!
The coolant pressure must not exceed 8 bar. The required quantity of coolant is 10 litres/minute,
and the coolant inlet temperature must not exceed 40 °C; we recommend 10 °C.
We also recommend fitting a pressure reducer or similar at the coolant inlet to avoid damage due to
excessive pressure.
If there is a danger of frost the operator should add a suitable anti-freeze solution to the cooling water.
The temperature of the cooling water and the cooling water flow rate must be supervised and
ensured by the operator.
Air/Oil cooler
The version and all important data for the air/oil cooler can be obtained from Catalogue G1000, or
contact the manufacturer of the cooling unit.
34 B 1000 en-5018
106
4 Commissioning
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4.4 Running-in time for the worm gear unit

In order to achieve maximum efficiency of the worm gear unit, the gear unit must be subjected to a
running-in period of approx. 25 h – 48 h under maximum load.
There may be a reduction in efficiency before the running-in period is complete.
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4.5 Checklist
Checklist
Subject of check Date Information

checked: see Section
Is the vent plug activated or the pressure vent screwed in? 3.4
Does the required configuration conform with the actual 7.1
installation?
Are the external gear shaft forces within permitted limits (chain 3.6
tension)?
Is the torque support correctly fitted? 3.7
Are contact guards fitted to rotating components? 3.9
Is the automatic lubricant dispenser activated? 4.2
Is the cooling cover connected to the cooling circuit? 3.12
3.13
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B 1000 en-5018 35
107
5 Service and maintenance

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5.1 Service and Maintenance Intervals
Service and Maintenance

Intervals Service and Maintenance Work Information
see Section
At least every six months • Visual inspection 5.2
• Check for running noises
• Check the oil level
• Visual inspection of hose
• Re-grease / remove excess grease
(only applicable for free drive shaft / Option W and for agitator
bearings / Option VL2 / VL3)
• Replace the automatic lubricator /
remove excess grease
(for operating times < 8 h/day: A replacement interval of
1 year is permissible for the lubricant dispenser) (Only for
IEC / NEMA standard motor mounting). Empty or replace the
lubricant collection container with every second replacement
of the lubricant dispenser.
For operating temperatures • Change the oil (the interval is doubled if filled with synthetic 5.2
up to 80 °C, products)
every 10000 operating • Cleaning or replacing the vent plug
hours, • Replace the shaft sealing rings
at least every 2 years
Every 20000 operating • Re-lubrication of the bearings in the gear unit 5.2
hours,
at least every 4 years
At least every 10 years • General overhaul 5.2
Information
The oil change intervals apply for normal operating conditions and operating temperatures up to
80 °C. The oil change intervals are reduced in the case of extreme conditions (operating temperatures
higher than 80 °C, high humidity, aggressive environment and frequent fluctuations in the operating
temperature).
36 B 1000 en-5018
108
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5.2 Service and Maintenance Work

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Visual inspection
The gear unit must be checked for leaks. In addition, the gear unit must be inspected for external
damage and cracks in the hoses, hose connections and rubber buffers. Have the gear unit repaired in
case of leaks, e.g. dripping gear oil or cooling water, damage or cracks. Please contact the NORD
service department.
Information
Shaft sealing rings are components with a limited life and are subject to wear and ageing. The service
life of shaft sealing rings depends on various ambient conditions. Temperature, light (especially UV
light), ozone and other gases and liquids affect the ageing process of shaft sealing rings. Some of
these influences may change the physical or chemical properties of the shaft sealing rings and result
in a significant reduction of their service life. Foreign substances (e.g. dust, sludge, sand, metallic
particles) and excess temperature (excessive speed or external heating) accelerate the wear of the
sealing lip. These sealing lips are made of an elastomer material and are lubricated with a special
grease at the factory. This reduces the wear due to their function and ensures a long service life. An
oil film in the region of the rubbing sealing lip is therefore normal and is not due to leakage (please
see chapter 7.6 "Leakage and leak-tightness").
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Check for running noises

If the gear unit produces unusual running noises and/or vibrations, this could indicate damage to the
gear unit. In this case the gear should be shut down and a general overhaul carried out.
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Check the oil level

Section 7.1 "Versions and maintenance"describes the mounting positions and the corresponding oil
level screws. With double gear units, the oil level must be checked on both units. The pressure vent
must be at the position marked in Section 7.1 "Versions and maintenance".
The oil level does not need to be checked on gear units without oil level screw (please see chapter 7.1
"Versions and maintenance").
Gear unit types that are not supplied full of oil must be filled before the oil level is checked.
Check the oil level with an oil temperature of between 20 °C to 40 °C.
1. The oil level may only be checked when the gear unit is at a standstill and has cooled down. The
gear unit must be secured to prevent accidental activation.
2. The oil level screw corresponding to the actual mounting position must be screwed out(please see
chapter 7.1 "Versions and maintenance").
Information
At the first oil level check a small amount of oil may escape, as the oil level may be above the lower
edge of the oil level hole.
3. Gear units with oil level screw: The correct oil level is at the bottom edge of the oil level hole. If
the oil level is too low, this must be corrected with the appropriate type of oil. Optionally, an oil level
glass is also possible instead of the oil level screw.
4. Gear units with oil tank: Der The oil level must be checked with the aid of the cap screw with
dipstick (G1¼ thread) in the oil tank. The oil level must be between the top and bottom marking
when the dipstick is fully screwed in (see Figure 23). Top up the oil level with the relevant type of oil
B 1000 en-5018 37
109
as necessary. These gearboxes may only be operated in the mounting position stated in
Section 7.1 "Versions and maintenance".
5. The oil level screw or the cap screw with dipstick and all other loosened screws must be correctly
re-tightened.
Figure 23: Checking the oil level with a dipstick

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Visual inspection of hose

Gear units with an oil tank (Option OT) and external cooling units have rubber hoses. After assembling
the oil lines, fill the gear unit housing with the gear oil type and quantity that is printed on the type
plate. Please contact the NORD service department.
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Re-greasing
Some gear unit designs (free drive shaft, Option W, agitator designs VL2 and VL3) are equipped with
a re-greasing device.
For agitator versions VL2 and VL3, the vent screw located opposite to the grease nipple must be
unscrewed before re-greasing. Grease should be injected until a quantity of 20 - 25 g escapes from
the vent hole. After this, the vent plug must be reinserted and tightened.
For Option W and some IEC adapters, the outer roller bearing must be re-greased with approx.
20 - 25 g of grease via the grease nipple provided. Remove any excess grease from the adapter.
Recommended grease: Petamo GHY 133N (please see chapter 7.2 "Lubricants")(Klüber Lubrication),
a food compatible grease is possible as an option.
38 B 1000 en-5018
110
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Replacing the automatic lubricant dispenser
Explanation
1 Cylindrical screws M8 x 16
2 Cartridge cover
3 Activation screw
4 Lug
5 Lubricant sensor
6 Position of adhesive label
Figure 24: Replacing the automatic lubricant dispenser with standard motor mounting
The cartridge cover must be unscrewed. The lubrication dispenser is screwed out and replaced with a
new component (Part No. 28301000 or for food-compatible grease Part No.: 28301010). Remove any
excess grease from the adapter. Then activate (please see chapter 4.2 "Activating the automatic
lubricant dispenser").
Empty or replace the grease collection container (Part No. 28301210) with every second replacement
of the lubricant container. To empty the container, unscrew it from the screw fitting. The container has
an internal piston, which can be pressed back with a rod with a maximum diameter of 10 mm. Collect
the grease which is pressed out and dispose of it correctly. Due to the shape of the container, a
residual quantity of grease remains in the container. After emptying and cleaning the container, it can
be screwed back into the drain hole in the IEC adapter. Replace the container with a new one if it is
damaged.
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Change the oil

The figures in Section 7.1 "Versions and maintenance"show the oil drain screw, the oil level screw and
the pressure vent screw for various designs.
Procedure:
1. Place a catchment vessel under the oil drain screw or the oil drain tap.
2. Completely remove the oil level screw or screwed sealing plug with dipstick if an oil level tank is
being used and unscrew oil drain screw.
3. Drain all the oil from the gear unit.
4. If the sealing ring of the oil drain screw or oil level screw is damaged in the thread, a new oil level
screw must be used or the thread must be cleaned and coated with securing lubricant, e.g.
Loctite 242, Loxeal 54-03 prior to insertion.
5. Screw the oil drain screw into the hole and tighten to the correct torque (please see chapter 7.4
"Torque values").
6. Using a suitable filling device, refill with oil of the same type through the oil level hole until oil
emerges from the oil level hole. (The oil can also be filled through the pressure vent screw or a
sealing plug located higher than the oil level). If an oil level tank is used, fill the oil through the
upper inlet (thread G1¼) until the oil level is set as described in Section 5.2 "Service and
Maintenance Work".
7. Wait at least 15 minutes, or at least 30 minutes if an oil level tank is used, and then check the oil
level. Proceed as described in Section 5.2 "Service and Maintenance Work".
B 1000 en-5018 39
111
Information
The oil does not need to be changed on gear units without oil level screw (please see chapter 7.1
"Versions and maintenance"). These gear units are lubricated for life.
Standard helical gear units have no oil level screw. Here, the oil is topped up through the pressure
vent bolt using the quantities listed in the table in Section "Helical gear units".
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Cleaning or replacing the vent plug

Unscrew the vent screw and thoroughly clean it (e.g. with compressed air) and fit the vent screw in the
same place, If necessary, use a new vent screw with a new sealing ring.
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Replace the shaft sealing ring

Once the shaft sealing ring has reached the end of its service life, the oil film in the region of the
sealing lip increases and a measurable leakage with dripping oil occurs. The shaft sealing ring must
then be replaced. The space between the sealing lip and the protective lip must be filled
approximately 50 % with grease on fitting (recommended grease: PETAMO GHY 133N). Take care
that after fitting, the new shaft sealing ring does not run in the old wear track.
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Re-lubricating bearings
For bearings which are not oil-lubricated and whose holes are completely above the oil level, replace
the roller bearing grease (recommended grease: PETAMO GHY 133N). Please contact the NORD
service department.
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General overhaul
For this, the gear unit must be completely dismantled. The following work must be carried out:
– clean all gear unit components,
– examine all gear unit components for damage,
– all damaged components must be replaced,
– all roller bearings must be replaced,
– replace back stops if fitted,
– replace all seals, radial seals and Nilos rings,
– replace plastic and elastomer components of the motor coupling.
The general overhaul must be carried out by qualified personnel in a specialist workshop with
appropriate equipment in observance of national regulations and laws. We recommend that the
general overhaul is carried out by the NORD Service department.
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40 B 1000 en-5018
112
6 Disposal
6 Disposal
Observe the current local regulations. In particular, lubricants must be collected and disposed of
correctly.
Gear unit components Material
Gear wheels, shafts, rolling bearings, parallel keys,locking rings, … Steel
Gear unit housing, housing components, … Grey cast iron
Light alloy gear unit housing, light alloy gear unit housing components, … Aluminium
Worm gears, bushes, ... Bronze
Radial seals, sealing caps, rubber components,… Elastomers with steel
Coupling components Plastic with steel
Flat seals Asbestos-free sealing material
Gear oil Additive mineral oil
Synthetic gear oil (adhesive label: CLP PG) Polyglycol-based lubricants
Cooling spiral, embedding material of the cooling spiral, screw fittings Copper, epoxy, yellow brass
Table 3: Disposal of materials

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B 1000 en-5018 41
113
7 Appendix
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7.1 Versions and maintenance

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Explanation of symbols for the following mounting position illustrations:
Venting
Oil level
Oil drain
Information
SK 320, SK 172, SK 272, SK 372 as well as SK 273 and SK 373, SK 01282 NB, SK 0282 NB,
SK 1382 NB and UNIVERSAL / MINIBLOC gear units are lubricated for life. These gear units do not
have an oil filler screw.
UNIVERSAL / MINIBLOC worm gear units

NORD UNIVERSAL / MINIBLOC worm gear units are suitable for all installation positions. They have
an oil filling which is independent of the mounting position.
As an option, types SI and SMI can be equipped with a vent screw. Gear units with vents must be
installed in the stated mounting position.
Types SI, SMI, S, SM and SU as 2-stage gear unit types and types SI, SMI as worm gear units for
direct motor mounting have an oil filling which depends on the mounting position and must be installed
in the stated position.
42 B 1000 en-5018
114
7 Appendix
Parallel shaft gear units with oil level tank

The following applies for parallel shaft gear units SK 9282, SK 9382, SK 10282, SK 10382,
SK 10382.1, SK 11282, SK 11382, SK 11382.1 and SK 12382 in installation position M4 with oil tank:
Figure 25: Oil level check with oil level tank

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B 1000 en-5018 43
115
44 B 1000 en-5018
116
7 Appendix
B 1000 en-5018 45
117
46 B 1000 en-5018
118
7 Appendix
B 1000 en-5018 47
119
48 B 1000 en-5018
120
7 Appendix
B 1000 en-5018 49
121
50 B 1000 en-5018
122
7 Appendix
B 1000 en-5018 51
123
52 B 1000 en-5018
124
7 Appendix
B 1000 en-5018 53
125
54 B 1000 en-5018
126
7 Appendix
B 1000 en-5018 55
127
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56 B 1000 en-5018
128
7 Appendix
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7.2 Lubricants
With the exception of type SK 11282, SK 11382, SK 12382 and SK 9096.1 gear units, all gear units
are filled with lubricant ready for operation in the required installation position when delivered. This
initial filling corresponds to a lubricant from the column for the ambient temperatures (normal version)
in the lubricant table.
Roller bearing greases
This table shows comparable roller bearing greases from various manufacturers. The manufacturer
can be changed for a given grease type. Getriebebau NORD must be contacted in case of change of
grease type or ambient temperature range, as otherwise no warranty for the functionality of our gear
units can be accepted.
Lubricant type Ambient

temperature
Mineral Renolit
oil-based grease Tribol GR 100-2 PD GP 2 Gadus S2
-30 … 60 C - Mobilux EP 2
Renolit V100 2
LZR 2 H
Renolit WTF
-50 … 40 C Optitemp LG 2 - - -
2
Synthetic grease Renolit PETAMO
Tribol GR 4747/220-
HLT 2 GHY 133 N Mobiltemp
-25 … 80 °C 2 HAT
Renolit Klüberplex SHC 32
LST 2 BEM 41-132
Biodegradable Plantogel Klüberbio Mobil SHC Grease
-25 … 40 °C - Naturelle Grease EP2
grease 2S M 72-82 102 EAL
Table 4: Roller bearing greases
B 1000 en-5018 57
129
Lubricant table
This table shows comparable lubricants from various manufacturers. The manufacturer can be
changed within a particular viscosity or lubricant type. Getriebebau NORD must be contacted in case
of change of viscosity or lubricant type, as otherwise no warranty for the functionality of our gearboxes
can be accepted.
Lubricant Details on DIN (ISO) /
type type plate Ambient
temperature
Alpha EP 680 Carter EP 680

Alpha SP 680 Renolin CLP 680 Carter XEP 680
ISO VG 680 Klüberoil Mobilgear Omala
CLP 680 Optigear BM 680 Renolin CLP 680
0...40 °C GEM 1-680 N 600 XP 680 S2 G 680
Optigear Synthetic Plus
1100/680
Renolin CLP 220
Alpha SP 220 Carter XEP 220
Mineral oil
ISO VG 220 Renolin CLP 220

Optigear BM 220 Klüberoil Mobilgear Omala
CLP 220 -10…40 °C Plus
Optigear Synthetic GEM 1-220 N 600 XP 220 S2 G 220
Renolin Gear 220
1100/220
VCI

Alpha SP 100 Renolin CLP 100
ISO VG 100 Klüberoil Mobilgear Omala
CLP 100 Optigear BM 100 Renolin CLP 100
-15…25 °C GEM 1-100 N 600 XP 100 S2 G 100
Optigear Synthetic Plus
1100/100
ISO VG 680 Alphasyn GS 680 Carter SY 680
CLP PG Renolin Klübersynth Mobil Omala
-20...40 °C Optigear Synthetic Carter SG 680
Synthetic oil
(Polyglycol)
680 PG 680 GH 6-680 Glygoyle 680 S4 WE 680

800/680
Alphasyn GS 220 -
ISO VG 220
CLP PG Alphasyn PG 220 Renolin Klübersynth Mobil Omala
-25…80 °C
220 Optigear Synthetic PG 220 GH 6-220 Glygoyle 220 S4 WE 220
800/220
Alphasyn EP 460 Carter SH 460
CLP HC ISO VG 460 Renolin Unisyn Klübersynth Mobil Omala
(hydrocarbon)
Synthetic oil
460 -30…80 °C Optigear Synthetic CLP 460 GEM 4-460 N SHC 634 S4 GX 460
PD 460
Alphasyn EP 220 Renolin Unisyn Carter SH 220
CLP HC ISO VG 220 CLP 220 Klübersynth Mobil Omala
220 -40…80 °C Optigear Synthetic Renolin Unisyn GEM 4-220 N SHC 630 S4 GX 220
PD 220 Gear VCI
ISO VG 680 -
CLP E 680 - Plantogear 680 S - - -
Bio-degradable
-5…40 °C
Performance Bio -
Naturelle
oil
GE 220 ESS
ISO VG 220 Klübersynth Gear
CLP E 220 Performance Bio Plantogear 220 S -
-5…40 °C GEM 2-220 Fluid
GE 220 ESU
EP 220
58 B 1000 en-5018
130
7 Appendix
Lubricant Details on DIN (ISO) /

type type plate Ambient
temperature
Optileb GT -
CLP PG ISO VG 680 Klübersynth Mobil
1800/680 Cassida Fluid WG
H1 680 -5…40 °C UH1 6-680 Glygoyle 680
680
Nevastane SY
Food grade oil
CLP PG ISO VG 220 Optileb GT Klübersynth Mobil 220

Cassida Fluid WG
H1 220 -25…40 °C 1800/200 UH1 6-220 Glygoyle 220
220
CLP HC ISO VG 680 Cassida Fluid GL Klüberoil -

Optileb GT 680 680 -
H1 680 -5…40 °C 4 UH1-680 N
Mobil Nevastane
CLP PG ISO VG 220 Cassida Fluid GL Klüberoil
Optileb GT 220 SHC Cibus XSH 220
H1 220 -25…40 °C 220 4 UH1-220 N
220
Mobil Multis EP 00
Gear unit fluid
Tribol GR 100-00 Renolit Duraplex MICROLUBE Alvania

Chassis
PD EP 00 GB 00 EP(LF)2
grease
Grease LBZ
-25 … 60 °C Tribol GR
3020/1000-00 PD Mobil Marson SY 00
Renolit Klübersynth
Spheerol EPL 00 Glygoyle -
LST 00 GE 46-1200
Grease 00
Table 5: Lubricant table

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7.3 Lubricant quantities
Information
After changing the lubricant, and in particular after the initial filling, the oil level may change during the
first few hours of operation, as the oil galleries and the hollow spaces only fill gradually during
operation.
The oil level is still within the permissible tolerance.
If at the express request of the customer, an oil inspection glass is installed at an additional charge,
we recommend that the customer corrects the oil level after an operating period of approx. 2 hours, so
that when the gear unit is at a standstill and has cooled down, the oil level is visible in the inspection
glass. Only then, is it possible to check the oil level by means of the inspection glass.
The filling quantities stated in the following tables are for guidance only. The precise quantities vary
depending on the exact gear ratio. When filling, always observe the oil level screw hole as an
indicator of the precise quantity of oil.
Gear unit types SK 11282, SK 11382, SK 11382.1, SK 12382 and SK 9096.1 are normally supplied
without oil.
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60 B 1000 en-5018
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7 Appendix
Helical gear units
Table 6: Lubricant quantities for helical gear units
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133
NORDBLOC
Table 7: Lubricant quantities for NORDBLOC
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7 Appendix
Table 8: Lubricant quantities for NORDBLOC helical gear units
B 1000 en-5018 63
135
Table 9: Lubricant quantities for standard helical gear units
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7 Appendix
Table 10: Lubricant quantities for parallel shaft gear units
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137
Bevel gear units
Table 11: Lubricant quantities for bevel gear units
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7 Appendix
Table 12: Lubricant quantities for helical worm gear units

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7.4 Torque values
Bolt torques [Nm]
Screw connections in the Screw

strength classes Cover Threaded pin connections
Dimensions
screws on coupling on protective
8.8 10.9 12.9
covers
M4 3.2 5 6 - - -
M5 6.4 9 11 - 2 -
M6 11 16 19 - - 6.4
M8 27 39 46 11 10 11
M10 53 78 91 11 17 27
M12 92 135 155 27 40 53
M16 230 335 390 35 - 92
M20 460 660 770 - - 230
M24 790 1150 1300 80 - 460
M30 1600 2250 2650 170 - -
M36 2780 3910 4710 - - 1600
M42 4470 6290 7540 - - -
M48 6140 8640 16610 - - -
M56 9840 13850 24130 - - -
G½ - - - 75 - -
G¾ - - - 110 - -
G1 - - - 190 - -
G1¼ - - - 240 - -
G1½ 300 -
Table 13: Torque values
Assembling the hose fittings

Oil the thread of the union nut, the cutting ring and the screw neck. Tighten the union nut with the
wrench until the point where the union nut can only be turned with considerably more force. Turn the
union nut of the screw fitting approx. 30° to 60° further but not more than 90°. For this the screw neck
must be held with a wrench. Remove excess oil from the screw fitting
68 B 1000 en-5018
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7 Appendix
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7.5 Troubleshooting
WARNING
Danger of slipping in case of leaks
• Clean the soiled floor before starting troubleshooting.
NOTICE!
Gear unit damage
• Shut down the gear unit immediately in case of malfunction.
Gear unit malfunctions

Fault Possible cause Remedy
Oil too low or
Unusual running noises,
bearing damage or Consult NORD Service
vibrations
gear wheel damage
Oil escaping from the gear unit
Defective seal Consult NORD Service
or motor
Incorrect oil level or
Oil change,
Oil escaping from pressure vent incorrect, contaminated oil or
use oil expansion tank (Option OA)
unfavourable operating conditions
Unfavourable installation conditions
Gear unit becomes too hot Consult NORD Service
or gear unit damage
Replace elastomer gear rim,
Defective motor coupling or
Shock when switching on, tighten motor and gear unit
loose gear unit mounting or
vibrations fastening bolts,
defective rubber element
replace rubber element
Fracture in gear unit or
Output shaft does not rotate
defective motor coupling or Consult NORD Service
although motor is running
shrink disc slippage
Table 14: Overview of malfunctions

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7.6 Leakage and leak-tightness

Gear units are filled with oil or grease to lubricate the moving parts. Seals prevent the escape of
lubricants. A complete seal is technically not possible, as a certain film of moisture, for example on the
radial shaft sealing rings is normal and advantageous for a long-term seal. In the region of vents,
moisture due to oil may be visible due to the escape of oil mist because of the function. In the case of
grease-lubricated labyrinth seals, e.g. Taconite sealing systems, used grease emerges from the
sealing gap due to the principle of operation. This apparent leak is not a fault.
According to the test conditions as per DIN 3761, the leak is determined by the medium which is to be
sealed, which in test bench tests exceeds the function-related moisture in a defined test period and
which results in dripping of the medium which is to be sealed. The measured quantity which is then
collected is designated as leakage.
Definition of leakage according to DIN 3761 and its appropriate use

Location of leak
Radial shaft
Term Explanation In IEC adapter Housing joint Venting
seal
No moisture No reason for No reason for No reason for No reason for
Sealed
apparent complaint complaint complaint complaint
Moisture film locally
No reason for No reason for No reason for No reason for
Damp restricted (not an
complaint complaint complaint complaint
area)
Moisture film beyond
No reason for No reason for Repair if No reason for
Wet the extent of the
complaint complaint necessary complaint
component
Measurable Recognisable Repair Repair Repair Repair
leakage stream, dripping recommended recommended recommended recommended
Temporary
malfunction of the
Temporary No reason for No reason for Repair if No reason for
sealing system or oil
leakage complaint complaint necessary complaint
leak due to
transport *)
Apparent leakage,
e.g. due to soiling,
Apparent No reason for No reason for No reason for No reason for
sealing systems
leakage complaint complaint complaint complaint
which can be re-
lubricated
Table 15: Definition of leaks according to DIN 3761
*) Previous experience has shown that moist or wet radial shaft sealing rings stop leaking later.
Therefore, under no circumstances can replacement be recommended at this stage. The reason for
momentary moisture may be e.g. small particles under the sealing lip.
70 B 1000 en-5018
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7 Appendix
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7.7 Repair information

For enquiries to our technical and mechanical service departments, please have the precise gear unit
type (type plate) and if necessary the order number (type plate) to hand.
7.7.1 Repairs
The device must be sent to the following address if it needs repairing:

Service Department
Getriebebau-Nord-Straße 1
22941 Bargteheide
No guarantee can be given for any attachments, such as encoders or external fans, if a gear unit or
geared motor is sent for repair.
Please remove all non-original parts from the gear unit or geared motor.
Information
If possible, the reason for returning the component/device should be stated. If necessary, at least one
contact for queries should be stated.
This is important in order to keep repair times as short and efficient as possible.
7.7.2 Internet information

In addition, the country-specific operating and installation instructions in the available languages can
be found on our Internet site: www.nord.com
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7.8 Warranty
NORD GmbH & Co. KG accepts no liability for damage to persons, materials or assets as a result of
failure to observe this operating manual, operating errors or incorrect use. General wearing parts, e.g.
radial seals are excluded from the warranty.
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7.9 Abbreviations
2D Dust explosion protected gear units zone 21 FA Axial force
2G Explosion protected gear units with ignition IE1 Motors with standard efficiency
protection class "c"
3D Dust explosion protected gear units zone 22 IE2 Motors with high efficiency
ATEX ATmospheres EXplosibles IEC International Electrotechnical Commission
B5 Flange fastening with through holes NEMA National Electrical Manufacturers Association
B14 Flange fastening with threaded holes IP55 International Protection
CW Clockwise, right-hand direction of rotation ISO International Standardisation Organisation
CCW Counter-clockwise, left-hand direction of pH pH value
rotation
°dH Water hardness in German hardness PPE Personal Protective Equipment
degrees: 1°dH = 0.1783 mmol/l
DIN German standards institute RL Directive
EC European Community VCI Volatile Corrosion Inhibitor
EN European standard WN Getriebebau NORD factory standard
FR Radial transverse force
=== Ende der Liste für T extmar ke Inhalt ===
72 B 1000 en-5018
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Key word index
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Key word index

=== Ende der Liste für T extmar ke Stichwortverzeic hnis ===
A Check the oil level ..................................... 37
Activating the vent .........................................19 Lubricant sensor ........................................ 39
Address..........................................................71 Radial shaft seal ........................................ 40
Assembly .......................................................19 Re-greasing VL2, VL3 and IEC ................. 38

Standard vent plug .................................... 40
C
Visual inspection ....................................... 37
Change the oil ...............................................39
Marking ......................................................... 13
Check the hose ..............................................38
Motor weights for IEC adapters .................... 28
Check the oil level .........................................37
N
Coolant ..........................................................34
Cooling cover .................................................30 nsd tupH ........................................................ 19
Correct use ....................................................10 O

Covers ...........................................................27 Option H66 .................................................... 23
D Overhaul ....................................................... 40
Disposal of materials .....................................41 P
F Painting the gear unit .................................... 32
Faults .............................................................69 Pulling devices .............................................. 22

Push-on gear unit.......................................... 23
G
R
Gear unit types ..............................................14
General overhaul ...........................................40 Radial shaft seal ........................................... 40
Re-grease the bearings ................................ 40
H
Re-greasing .................................................. 38
Hose fitting .....................................................68
Repairs .......................................................... 71
I
Roller bearing greases .................................. 57
Installation......................................................19
Running noises ............................................. 37
Installing the gear unit ...................................21
Running-in time ............................................. 35
Internet...........................................................71
S
L
Safety information ............................. 10, 17, 21
Leakage .........................................................70
Service .......................................................... 71
Long-term storage .........................................17
Service intervals ............................................ 36
Lubricant sensor ......................................33, 39
Shrink disc .................................................... 26
Lubricants ......................................................58
Standard motor ............................................. 28
M Standard vent plug ........................................ 40
Maintenance ..................................................71 Storage ......................................................... 17
Maintenance intervals ....................................36 Surface treatment
Maintenance work nsd tupH .................................................... 19
Changing the oil .........................................39 T
Check for running noises ...........................37
Tightening torques ........................................ 68
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Transport .......................................................17 Visual inspection of hose .............................. 38
Type plate ......................................................16 W
V Warning information ...................................... 13
Visual inspection ............................................37
74 B 1000 en-5018
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Key word index
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147
148
Part-No. 6052802 / 5018
B 1091 – en
Motors
Operating and Assembly Instructions
149
Motors – Operating and Assembly Instructions
Safety and operating instructions for electric motors

(according to: Low Voltage Directive2006/95/EEC (as of 20/04/2016: 2014/35/EU
1 General The devices must be protected against impermissible loads.

During operation, devices may, depending on their protection class, Especially during transport and handling, components must not
have live, bare, moving or rotating parts or hot surfaces. be deformed and/or insulation distances must not be changed.
Unauthorised removal of covers, improper use, incorrect installation or Electrical components must not be mechanically damaged or
operation causes a risk of serious personal injury or material damage. destroyed (this may cause a health hazard!).
Further information can be found in this documentation. 5. Electrical Connection
All transportation, installation commissioning and maintenance work When working on live devices, the applicable national accident
must be carried out by qualified personnel (compliant with IEC 364 or. prevention regulations must be complied with (e.g. BGV A3,
CENELEC HD 384 or DIN VDE 0100 and IEC 664 or DIN VDE 0110 formerly VBG 4).
and national accident prevention regulations). The electrical installation must be implemented according to the
For the purposes of these basic safety instructions, qualified personnel applicable regulations (e.g. cable cross-section, fuses, earth
are persons who are familiar with the assembly, installation, lead connections). Further instructions can be found in the
commissioning and operation of this product and who have the relevant documentation.
qualifications for their work. Information regarding EMC-compliant installation – such as
2. Proper use in Europe shielding, earthing, location of filters and installation of cables –
The devices are components intended for installation in electrical can be found in the documentation for the devices. These
systems or machines. instructions must be complied with even with CE marked
devices. Compliance with the limiting values specified in the
When installed in machines, the devices must not be commissioned (i.e.
EMC legal regulations is the responsibility of the manufacturer
commencement of the proper use) until it has been ensured that the
of the system or machine.
machine meets the provisions of the EC Directive 2006/42/EEC
(Machinery Directive); EN 60204 must also be complied with. 6. Operation
Commissioning (i.e. implementation of proper use) is only permitted if Where necessary, systems in which the devices are installed
the EMC directive (2004/108/EEC) is complied with (as of must be equipped with additional monitoring and protective
equipment according to the applicable safety requirements, e.g.
20/04/2016: 2014/30/EU)).
legislation concerning technical equipment, accident prevention
Devices with a CE label meet the requirements of the Low Voltage
regulations, etc.
Directive 2006/95/EEC (as of 20/04/2016: 2014/35/EU). The stated
The parameterisation and configuration of the devices must be
harmonized standards for the devices are used in the declaration of
conformity. selected so that no hazards can occur.
All covers must be kept closed during operation.
Technical data and information for connection conditions can be found
on the rating plate and in the documentation, and must be complied 7. Maintenance and repairs
with. The following applies in particular for operation with frequency
The devices may only be used for safety functions which are described inverters:
and explicitly approved. After the devices are disconnected from the power supply, live
3. Transport, storage equipment components and power connections should not be
touched immediately, because of possible charged capacitors.
Information regarding transport, storage and correct handling must be
Observe the applicable information signs located on the device.
complied with.
Further information can be found in this documentation.
4. Installation
The installation and cooling of the equipment must be implemented
according to the regulations in the corresponding documentation.
These safety instructions must be kept in a safe place!
2 B 1091 en-2319
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Documentation
Documentation
Title: B 1091
Order – No.: 6051302
Series: Asynchronous motors / Synchronous motors
• 1 and 3-phase asynchronous motors
SK 63*1)/*2) *3) up to SK 315*1)/*2) *3)
1) Power code: S, SA, SX, M, MA, MB, MX, L, LA, LB, LX, R, X, Y, A, W
- optionally supplemented with: H, P
2) Pole number labelling: 2, 4, 6, 8, …
3) further options
• 3-phase synchronous motors

SK 63*1)*2)/*3) *4) up to SK 132*1)*2)/*3) *4)
1) Winding version: T, F, …
2) Power number: 1 to 9
3) Pole number labelling: 4, 6, 8, …
4) further options
• Three-phase asynchronous motors

SK 63*1)/*2) 2D *3) up to SK 200*1)/*2) 2D *3)
1)
Power code: S, SA, SX, M, MA, MB, MX, L, LA, LB, LX, R, X, Y, A, W
2)
Pole number labelling: 2, 4, 6
3) Options
with ATEX labelling II 2D Ex tb IIIC T . . . °C Db
SK 63*1)/*2) 3D *3) up to SK 200*1)/*2) 3D *3)

1)
2)
3) Options
with ATEX labelling II 3D Ex tc IIIB T . . . °C Dc
SK 63*1)/*2) 2G *3) up to SK 200*1)/*2) 2G *3)

1)
2)
3) further options
with ATEX labelling II 2G Ex eb IIC T3 Gb
SK 63*1)/*2) 3G *3) up to SK 200*1)/*2) 3G *3)

1)
2)
3) further options
with ATEX labelling II 3G Ex ec IIC T3 Gc
B 1091 en-2319 3
151
Version list
Title, date Order number Comments
B 1091, 6051302 / 0215 -
January
2015
B 1091, 6051302 / 1016 • General corrections
March 2016 • Structural adjustments to document
December
2016
B 1091, 6051302 / 2417 • Technical supplements
June
2017
B 1091, 6051302 / 3517 • Technical supplements
August 2017
June 2018 • Update of EU/EC Declaration of Conformity 2D/3D
August 2018 • Section for operation with frequency inverter removed
• Section for special operating conditions, permissible surrounding
area supplemented
• Ignition protection type labelling and type plates updated
• Update of EU/EC Declaration of Conformity 2G/3G
Copyright notice
As an integral component of the device described here, this document must be provided to all
users in a suitable form.
Any editing or amendment or other utilisation of the document is prohibited.
Publisher
Getriebebau-Nord-Straße 1 • 22941 Bargteheide, Germany • http://www.nord.com/
Fon +49 (0) 45 32 / 289-0 • Fax +49 (0) 45 32 / 289-2253
Member of the NORD DRIVESYSTEMS Group
4 B 1091 en-2319
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Publisher
B 1091 en-2319 5
153
Table of Contents
1 General ......................................................................................................................................................... 8
1.1 Safety and installation notes .............................................................................................................. 9
1.1.1 Explanation of labels used .................................................................................................... 9
1.1.2 List of safety and installation notes ..................................................................................... 10
1.2 Field of use ...................................................................................................................................... 11
1.3 Correct handling of electric motors................................................................................................... 12
1.3.1 Transport, storage .............................................................................................................. 12
1.3.2 Installation .......................................................................................................................... 13
1.3.3 Balancing, drive elements .................................................................................................. 13
1.3.4 Alignment ........................................................................................................................... 14
1.3.5 Output shafts ...................................................................................................................... 14
1.3.6 Electrical connection........................................................................................................... 15
1.3.7 Operation with frequency inverter ....................................................................................... 16
1.3.8 Checking the insulation resistance ..................................................................................... 17
1.3.9 Commissioning ................................................................................................................... 17
1.3.10 Disposal .............................................................................................................................. 18
2 Maintenance and servicing ...................................................................................................................... 19
2.1 Safety measures .............................................................................................................................. 19
2.2 Bearing replacement intervals .......................................................................................................... 20
2.3 Maintenance intervals ...................................................................................................................... 21
2.4 General overhaul.............................................................................................................................. 21
3 ATEX Explosion hazard areas .................................................................................................................. 22
3.1 Motors with increased ignition protection, type Ex eb ...................................................................... 22
3.1.1 Cable gland ........................................................................................................................ 23
3.1.2 Cable connections .............................................................................................................. 23
3.1.3 Terminal box cover seals .................................................................................................... 24
3.1.4 Motor position – special features for IM V3, IM V6 ............................................................. 24
3.1.5 Further operating conditions ............................................................................................... 25
3.1.6 Protective devices .............................................................................................................. 25
3.1.8 Repairs ............................................................................................................................... 27
3.1.9 Painting .............................................................................................................................. 27
3.1.10 Type plate for NORD Ex eb motors according to EN 60079 ............................................... 28
3.1.11 Applied standards ............................................................................................................... 28
3.2 Motors with ignition protection class Non Sparking Ex ec ................................................................ 29
3.2.1 Cable gland ........................................................................................................................ 30
3.2.2 Cable connections .............................................................................................................. 30
3.2.6 Protective devices .............................................................................................................. 32
3.2.7 Repairs ............................................................................................................................... 33
3.2.8 Painting .............................................................................................................................. 33
3.2.9 Type plate for NORD Ex ec motors according to EN 60079 ............................................... 34
3.2.10 Applied standards ............................................................................................................... 34
3.3 Motors for use in Zone 21 and Zone 22 according to EN 60079-0 and IEC 60079 .......................... 35
3.3.1 Commissioning information / Field of application................................................................ 36
3.3.3 Electrical Connection .......................................................................................................... 37
3.3.4 Cable and wiring glands ..................................................................................................... 37
3.3.5 Permissible ambient temperature range ............................................................................. 39
3.3.6 Painting .............................................................................................................................. 39
3.3.7 IEC-B14 motors .................................................................................................................. 39
3.3.10 Structure and method of use .............................................................................................. 40
3.3.11 Minimum cross section of bonding conductors ................................................................... 40
3.3.12 Maintenance ....................................................................................................................... 41
3.4 Options for motors for use in Zone 21 and Zone 22 ......................................................................... 42
6 B 1091 en-2319
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Table of Contents
3.4.2 External fan ........................................................................................................................ 43
3.4.3 Second temperature sensor 2TF ........................................................................................ 44
3.4.4 Back stop ............................................................................................................................ 44
3.4.5 Brake .................................................................................................................................. 44
3.4.6 Overview of brake installation for NORD ATEX motors ...................................................... 45
3.4.7 NORD Ex motor type plate (Ex tb, EX tc) according to EN 60079 for operation with a
frequency inverter ............................................................................................................... 46
3.5 Explosion protected motors according to TP TC012/2011 for the Eurasian Economic Union .......... 47
3.5.1 Type plates / Labelling........................................................................................................ 47
3.5.2 Standards ........................................................................................................................... 48
3.5.3 Service life .......................................................................................................................... 48
3.5.4 Special operating conditions (X-labelling)........................................................................... 48
4 Synchronous motors – special information ........................................................................................... 49
4.1 Type designation .............................................................................................................................. 49
4.2 Connection ....................................................................................................................................... 49
4.3 Encoders .......................................................................................................................................... 50
4.4 Commissioning ................................................................................................................................ 50
4.5 Maintenance and servicing .............................................................................................................. 50
5 Replacement parts .................................................................................................................................... 51
6 Declarations of Conformity ...................................................................................................................... 52
B 1091 en-2319 7
155
1 General
These operating instructions must be read before NORD motors are transported, installed,
commissioned, serviced or repaired. All persons who are involved in these tasks must observe these
operating instructions. In order to prevent injury or damage, all of the safety information in these
operating instructions must be strictly observed.
The information and instructions in the instructions, safety and commissioning information which is
supplied, as well as all other instructions must be observed.
This is essential to prevent injury and damage.
The applicable national, local and plant-specific regulations and requirements and regulations must be
observed.
Technical details may vary for special designs and constructions. In case of doubt, we urgently
recommend that the manufacturer is contacted, giving details of the type designation and the
motor number.
Qualified personnel are persons who due to their training, experience and instruction, and their
knowledge of the relevant standards, accident prevention regulations and operating conditions are
authorised to carry out the necessary activities.
This also includes knowledge of first aid measures and the local emergency services.
It is assumed that the work for transport, assembly, installation, commissioning, maintenance and
repair will be performed by qualified staff.
In particular, the following must be observed:
• Technical data and information regarding permissible use, installation, connection, ambient and
operating conditions, which are contained in the catalogue, the order documents and other
documentation for the product.
• Local and plant-specific regulations and requirements
• Correct use of tools, lifting and transportation equipment
• Use of personal protective equipment
For reasons of clarity, the operating instructions do not contain detailed information about possible
versions and therefore do not consider all possible cases of installation, operation or servicing.
Because of this, these operating instruction essentially only contain the information which is necessary
for proper use by qualified personnel.
In order to prevent faults it is necessary that the prescribed service and inspection work is carried out
by appropriately qualified personnel.
• For the operation on an inverter, the planning guideline B1091-1 forms a part of these operating
instructions.
• The supplementary operating instructions must be observed if an external fan is present.
• For braking motors, the supplementary brake operating instructions must be observed..
If the operating instructions or the planning guide are lost for any reason, these documents must be
obtained from NORD.
8 B 1091 en-2319
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1 General
1.1 Safety and installation notes

The devices are operating materials intended for use in industrial high voltage systems, and are
operated at voltages that could lead to severe injuries or death if they are touched.
The device and its accessories must only be used for the purpose which is intended by the
manufacturer. Unauthorised modifications and the use of spare parts and additional equipment which
has not been purchased from or recommended by the manufacturer of the device may cause fire,
electric shock and injury.
All of the associated covers and protective devices must be used.
Installation and other work may only be carried out by qualified electricians with strict adherence to the
operating instructions. Therefore keep these Operating Instructions at hand, together with all
supplementary instructions for any options which are used, and give them to each user.
Local regulations for the installation of electrical equipment and accident prevention must be complied
with.
1.1.1 Explanation of labels used
DANGER Indicates an immediate danger, which may result in death or serious injury.
Indicates a possibly dangerous situation, which may result in death or

WARNING serious injury.
Indicates a possibly dangerous situation, which may result in slight or

CAUTION minor injuries.
Indicates a possibly harmful situation, which may cause damage to the

NOTICE product or the environment.
Note Indicates hints for use and useful information.
B 1091 en-2319 9
157
1.1.2 List of safety and installation notes
DANGER! Electric shock

The motor is operated with a dangerous voltage. Touching certain conducting components (connection terminals
and supply cables) will cause electric shock with possibly fatal consequences.
Even when the motor is at a standstill (e.g. due to the electronic block of a connected frequency inverter or a
jammed drive unit) the connection terminals and supply cables may carry a dangerous voltage. A motor standstill
is not identical to electrical isolation from the mains.
Even if the drive unit has been disconnected from the mains, a connected motor may rotate and possibly
generate a dangerous voltage.
Installation and work must only be carried out when the motor is at a standstill and is disconnected (all phases
disconnected from the mains).
Follow the 5 Safety Rules (1. Switch off the power, 2. Secure against switching on, 3. Check for no voltage, 4.
Earthing and short circuiting, 5. Cover or fence off neighbouring live components).
WARNING Hazard due to heavy loads

The large weight of the motor must be taken into account during any transportation or installation work.
Incorrect handling may cause the motor to fall or swing without control and therefore cause severe, and possibly
fatal injuries due to impact, crushing and other physical injuries. In addition, severe damage to the motor and its
surroundings are possible.
Therefore:
– Do not stand under suspended loads
– Only use the attachment points provided
– Check that lifting equipment and lashings have and adequate load capacity and are undamaged
– Avoid hectic movements
– Use personal protective equipment
WARNING Injury due to movement

Under certain conditions (e.g. switching on the power supply, releasing a holding brake) the motor may start to
move. The machinery which it drives (press / chain hoist / roller / fan etc.) may then make an unexpected
movement. This may cause various injuries, including to third parties.
Before switching on, secure the danger area by warning and removing all persons from the danger area.
WARNING Hazard due to loose parts

Care must be taken that there are no loose parts on the motor. Otherwise, these may cause injury during
transportation and installation work, or when the motor in in operation.
Loose carrying or lifting eyes may cause the motor to fall during transportation.
Parallel keys on the motor shaft may be thrown out when the motor shaft rotates.
Fasten or remove loose parts and carrying or lifting eyes; secure or remove free parallel shaft keys on the motor
shaft(s).
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CAUTION Danger of burns

The surface of the motor may heat up to temperatures in excess of 70°C.
Touching the motor may cause local burns to the affected parts of the body (hands, fingers, etc.).
To prevent such injuries, allow sufficient time for cooling down before starting work - the surface temperature
should be checked with suitable measuring equipment. In addition, keep sufficient distance from adjacent
components during installation, or install protection against contact.
1.2 Field of use

Use of the motors:
The motors may only be used for their intended purpose (to drive machinery).
The motors are constructed with at least protection class IP55 (for the protection class: see rating
plate). They may be installed in dusty or damp environments.
In principle the conditions of use and the ambient conditions determine the necessary protection class
and any other additional measures. For outdoor installation and vertical versions, e.g. V1 or V5 with
the shaft pointing downwards, Getriebebau NORD recommends the use of the double fan cover option
[RDD].
Motors must be protected against intensive sunlight, e.g. by the use of a protective cover. The
insulation is tropicalised.
Installation altitude: ≤ 1000 m
Ambient temperature: -20°C...+40°C
For standard motors an extended ambient temperature range from -20°C...+60°C is permissible.. In
this case, the rated power must be reduced to 82% of the value stated in the catalogue. If the
maximum ambient temperature is between +40°C and +60°C, the power output should be inversely
linearly interpolated between 100% and 82%.
The motor connection cables and the cable glands must be suitable for temperatures ≥ 90°C.
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1.3 Correct handling of electric motors

All work must only be carried out with the power to the system switched off.
1.3.1 Transport, storage
WARNING Danger of falling

Incorrect handling during transport may cause the motor to fall or swing without control and therefore cause
severe, and possibly fatal injuries due to impact, crushing and other physical injuries. In addition, severe damage
to the motor and its surroundings are possible.
Therefore:
– Use all available carrying eyes on the motor during transport
– Do not attach any additional loads The lifting eyes are only designed for the weight of the motor
– Only use the intended carrying eyes or bolts for transporting attached machinery (e.g. gear unit
attachments)
– Sets of machinery must not be lifted by suspension from the individual machines.
To prevent damage to the motor, the motor must always be used with suitable lifting equipment. The
roller bearings should be replaced if the time from delivery to commissioning of the motor exceeds 4
years in good conditions (storage in dry, dust and vibration-free areas). This time is greatly reduced in
case of unfavourable conditions. If necessary, unprotected machined surfaces (flange surfaces, shaft
ends) must be treated with corrosion inhibitors. If necessary, the insulating resistance of the windings
must be checked ( 1.3.8 "Checking the insulation resistance").
Changes in comparison with normal operation (higher current consumption, higher temperatures or
vibrations, unusual noises or smells, triggering of monitoring devices, etc.) are indications that the
function is impaired. To prevent injury and damage, the responsible maintenance personnel must be
informed of these changes.
In case of doubt, switch off the motor as soon as the state of the plant permits.
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1.3.2 Installation
• After installation, screwed-on lifting lugs must be tightened or removed.
• Smooth running: Precise alignment of the clutch and a well-balanced drive element (clutch, pulleys,
fan, etc.) are prerequisites for smooth vibration-free running.
• Complete balancing of the motor and the drive elements may be necessary.
• The top section of the terminal box and the position of the terminal box can be rotated by 4 x 90
degrees.
• Even if not required, on IEC B14 motors all four fixing screws, must be screwed into the flanged
bearing plate! The fixing screw threads must be inserted with a sealant, e.g. Loctite 242.
WARNING Electric shock

The maximum depth for screwing into the type plate is 2 x d. There is a danger that the motor windings may be
damaged if longer screws are used. This creates a danger of potential transfer to the housing and danger of
electric shock if touched.
• The motor must be inspected for damage before installation and commissioning. A damaged motor
must not be commissioned.
• Rotating shaft ends and unused shaft ends must be protected against contact. Unused parallel
shaft keys must be secured against being thrown out.
• The motor must be suitable for the installation location. (requirements prescribed by standards,
ambient conditions, installation altitude)
• Motor surfaces may become very hot during operation. Suitable protective measures must be
taken if there is a danger of contact or a hazard to the vicinity of the installation.
1.3.3 Balancing, drive elements

The fitting and removal of drive elements (clutch, pulley, gear wheel,…) must be performed with
suitable equipment. As standard the rotors are balanced with half key balancing. The appropriate
form of balancing must be observed if drive elements are installed on the motor shaft. Drive
elements must be balanced according to ISO 1940.
The generally required measures for protection against touching the drive elements must be observed.
If a motor is started without a drive element, the parallel key must be secured against being thrown
out. This also applies for any second shaft end. Alternatively, the parallel shaft key must be removed.
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1.3.4 Alignment
In particular with direct coupling, the motor shafts and the driven machine must be axially and radially
aligned to each other. Incorrect alignment may result in damage to the bearings, excessive vibration
and breakage of the shaft.
1.3.5 Output shafts

The maximum permissible axial (FA) and radial forces (FR) for the A side end of the motor shaft can be
obtained from the table below. Getriebebau NORD should be consulted if the radial force (FR) is
applied at a distance which is greater than the length E/2.
Type FR [N] FA [N]
63 530 480
71 530 480
80 860 760
90 910 810
100 1300 1100
112 1950 1640
132 2790 2360
160 3500 3000
180 .X 3500 3000
180 5500 4000
200 .X 5500 4000
225 8000 5000
No axial (FA) and radial forces (FR) are permissible for the B side shaft end.
NOTICE! Attachments must not cause rubbing (danger of excessive temperatures and sparking) or
impair the necessary flow of cooling air.
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1.3.6 Electrical connection

The connection cables must be passed through the cable glands in the terminal box. The terminal box
must be sealed against dust and water. The mains voltage and frequency must conform to the data on
the rating plate. ±5 % voltage or ±2 % frequency deviations are permissible without reduction of the
power. The connection and configuration of the jumpers must be made according to the circuit
diagram in the terminal box.
Please refer to the following table for the labelling of the auxiliary terminals
Auxiliary terminal designation

Additional equipment Labelling of auxiliary terminals Comments
New: EN 60034-8
Thermistor TP1 – TP2 Switch-off
1TP1 – 1TP2 Warning Winding 1
2TP1 – 2TP2 Switch-off Winding 1
3TP1 – 3TP2 Warning Winding 2
4TP1 – 4TP2 Switch-off Winding 2
Option: TF 5TP1 – 5TP2 Brake
1TB1 – 1TB2 Warning Winding 1
Bi-metal temperature sensor
2TB1 – 2TB2 Switch-off Winding 1
Normally closed
3TB1 – 3TB2 Warning Winding 2
Option: TW
4TB1 – 4TB2 Switch-off Winding 2
Bi-metal temperature sensor, 1TM1 – 1TM2 Warning Winding 1
normally open 2TM1 – 2TM2 Switch-off Winding 1
3TM1 – 3TM2 Warning Winding 2
4TM1 – 4TM2 Switch-off Winding 2
PT100 1R1 – 1R2 Winding 1 (Phase U)
2R1 – 2R2 Winding 1 (Phase V)
3R1 – 3R2 Winding 1 (Phase W)
KTY (+) 4R1 – 4R2 (-) Winding 1
Silicon temperature sensor (+) 5R1 – 5R2 (-) Winding 2
Standstill heating 1HE1 – 1HE2 Motor heater
Option: SH 2HE1 – 2HE2 Brake heater
Capacitor 1CA1 – 1CA2 with operating capacitor 1
Motor version: 2CA1 – 2CA2 with operating capacitor 2
EAR/EHB/EST 3CA1 – 3CA2 with starting capacitor 1
4CA1 – 4CA2 with starting capacitor 2
Direct current brake BD1 – BD2
Option: BRE...
Option: DBR… Brake1: BD1-BD2
Break2: BD3-BD4
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1.3.7 Operation with frequency inverter

Type SK 63 ./. – SK 225 ./. three phase asynchronous motors are qualified for operation with link
circuit inverters according to DIN EN 60034-18-41 (2014).
Please also observe the operating instructions for the frequency inverter which is used.
The insulation system used by NORD consists of suitable varnished copper wire, phase insulation,
homogeneous impregnation and groove lining as insulation against earth, and in the standard version
is designed for the increased requirements for link circuit inverters.
The maximum permissible FI input voltage is 500 V +10%. Link circuit voltages in excess of 750 V DC
are not permissible. When the motor is warm due to operation, the peak voltages due to the system,
the inverter, the cable or the motor must not exceed the following values.
Permissible impulse voltages depending on voltage rise-time

Impulse voltage [V]
Voltage rise time [µs]
If the values are outside of the permissible range, du/dt or sine wave filters may be used (not the
additional voltage drop).
The cable lengths shown in the diagram are for guidance only and may deviate according to the
specific conditions.
For additional information for operation with a frequency inverter, especially with regard to information
about the maximum speed, thermal design and possible torques, please refer to the current NORD
motor catalogue M7000.
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1.3.8 Checking the insulation resistance

Prior to initial commissioning of the motor after a long period of storage or standstill (approx. 6
months) the insulation resistance of the windings must be checked. During and immediately after the
measurements, the terminals have voltages which can be dangerous, and must not be touched.
Insulation resistance
The insulation resistance of new, cleaned, repaired windings against the housing and against each
other is > 200 MΩ.
Measurement
The insulation of the windings against the housing for operation voltages up to 400 V must be
measured with 500 V DC. For operating voltages up to 725 V the measurement must be made with
1000 V DC. The temperature of the windings should be 25°C ± 15°C.
Testing
If the minimum insulation resistance of the winding against earth is less than 50 MΩ, this may be due
to moisture. The windings must then be dried.
The insulation resistance may reduce after long periods of operation. As long as the measured value
does not fall below the calculated value for the critical insulation resistance of < 50 MΩ, operation of
the motor may continue. If the value is less than this, the cause must be established and if necessary
the windings or parts of the windings must be repaired, cleaned or dried.
1.3.9 Commissioning
Information Electromagnetic compatibility

NORD motors comply with the EU-Directive 2014/30/EU. Assembly or installation work must not cause
impermissible interference. Immunity from interference must still exist.
Production of interference: In cases of large differences of torque (e.g. when driving a piston
compressor) a non-sine wave motor current is induced, whose harmonics can cause an impermissible
effect on the mains and therefore impermissible production of interference.
With supply by frequency inverters, various strengths of interference are produced according to the
design of the frequency inverter (type, interference suppression, manufacturer). The EMC information
of the inverter manufacturer must be observed. If a shielded motor supply cable is recommended, the
shielding is most effective if a large area is electrically connected to the metal terminal box of the
motor (with metal EMC cable gland). With motors with integrated sensors (e.g. thermistors)
interference voltages due to the inverter may be produced in the sensor cables.
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Interference immunity: For motors with integrated sensors (e.g. thermistors) the operator must
ensure adequate immunity to interference by the selection of a suitable sensor cable (possibly with
screening, with connection as for the motor supply cable) and evaluation device. The information and
instructions in the operating instructions for the inverter and all other instructions must be observed
before commissioning. After installation of the motor, it must be checked for correct functioning. In the
case of brake motors, the correct function of the brake must also be checked.
1.3.10 Disposal
NOTICE Environmental damage

Incorrect disposal of the product may cause damage to the environment.
• Ensure correct disposal
• Comply with current local regulations
Content: aluminium, iron, electronic components, copper

Please observe the additional documentation for the attachments
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2 Maintenance and servicing

WARNING Injury due to movement

Under certain conditions (e.g. switching on the power supply, releasing a holding brake) the motor may start to
move. The machinery which it drives (press / chain hoist / roller / fan etc.) may then make an unexpected
movement. This may cause various injuries, including to third parties.
Before switching on, secure the danger area by warning and removing all persons from the danger area.
2.1 Safety measures

Before starting any work on the motor or the device, but especially before opening the covers of active
components, the motor must be isolated according to regulations. In addition to the main power
circuits, any additional or auxiliary circuits must be taken into account.
The usual "5 Safety Rules" e.g. according to DIN VDE 0105 are:
• Disconnect
• Secure to prevent reactivation
• Check for no voltage on all poles
• Earth and short circuit
• Cover or cordon off adjacent live components
These measures may only be removed when the maintenance work is complete.
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Motors must be properly inspected at regular intervals; current national standards and regulations
must be complied with. In particular, special attention must be paid to any mechanical damage, free
path of the cooling air, abnormal noises and correct electrical connection.
Only original parts may be used as spare parts with the exception of standardised, commercially
available and equivalent parts.
Swapping parts between motors of the same type is not permissible.
Information Condensation outlets

If the motors are designed with closed condensation outlets, these must be opened occasionally in order to allow
any accumulated condensation to drain off. Condensation outlets must always be located at the lowest point of
the motor. During installation of the motor care must be taken that the condensation outlets point downwards and
are closed. Open condensation outlets cause a reduction of the protection class.
2.2 Bearing replacement intervals

Under normal operating conditions, with horizontal installation of the motor, depending on the coolant
temperature and the motor speed, the bearing replacement interval [h] for IEC motors is:
25°C 40°C 60°C
up to 1,800 rpm approx. 40,000 h approx. 20,000 h approx. 8,000 h
up to 3,600 rpm approx. 20,000 h approx. 10,000 h approx. 4,000 h
Under special operating conditions, e.g. vertical motor installation, large stresses due to vibration and
shock, or operation with frequent reversing, the operating hours stated above are significantly
reduced.
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2.3 Maintenance intervals

The motor must be checked weekly, or every 100 operating hours for unusual running noise and/or
vibrations.
Please check the roller bearings at an interval of at least 10,000 h and replace them as required. In
addition, the electric connections, cables and wires as well as the fan are firmly fastened and free from
damage. Furthermore, the function of the insulation system must be checked.
Replace the shaft sealing rings every 10,000 hours.
The surface of the motor must not have any dirt deposits which could impair cooling.
A general overhaul of the motor must be carried out every 5 years.
2.4 General overhaul

For this the motor must be dismantled. The following work must be carried out:
• All components of the motor must be cleaned
• All components of the motor must be examined for damage
• All damaged components must be replaced
• All roller bearings must be replaced
• All seals and shaft sealing rings must be replaced
The general overhaul must be carried out by qualified personnel in a specialist workshop with
appropriate equipment. We urgently recommend that the general overhaul is carried out by NORD
Service.
If the drive unit is subjected to special operating conditions, the intervals stated above may be
considerably reduced.
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3 ATEX Explosion hazard areas
3.1 Motors with increased ignition protection, type Ex eb
DANGER! Explosion hazard

All work must only be carried out with the machine at a standstill and the power to the
system switched off.
Higher temperatures than the maximum permitted surface temperature of the housing may be
present inside the motor. The motor must therefore never be opened in an explosive
atmosphere!
Failure to comply with this may result in the ignition of an explosive atmosphere.
WARNING Explosion hazard

Excessively heavy dust deposits must be avoided, as these impair the cooling of the device!
Impairment or obstruction of the flow of cooling air, for example due to partial or large area
coverage of the fan cover or the entry of foreign bodies fall into the fan must be avoided in
order to ensure adequate cooling.
Only cable glands and reducers which are approved for use in explosion hazard areas may be
used.
All cable glands which are not used must be closed with blind screw plugs which are approved
for potentially explosive areas.
Only the original seals may be used.
Failure to comply increases the risk of ignition of an explosive atmosphere.
The following supplementary or special information applies for these motors.

The motors are suitable for use in Zone 1 and correspond to Device Group II, Category 2G and may
be used at an ambient temperature from -20 °C to +40 °C.
Type suffix: 2G e. g.: 80 L/4 2G TF

Labelling: II 2G Ex eb IIC T3 Gb
0102
If the motor is attached to a gear unit, the EX labelling of the gear unit must also be observed!
Explosive gas mixtures or dust concentrations may cause severe or fatal injuries in combination with
hot, electrically live and moving components of electrical machines.
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The increased danger in explosion hazard areas requires especially strict observance of the general
safety and commissioning information. The person responsible must be qualified according to the
national and local regulations.
Explosion protected electrical machines with ignition protection class Ex eb correspond to the
standard series EN 60034 (VDE 0530), as well as EN 60079-0:2014 and EN 60079-7:2015. The
degree of the explosion hazard determines the zone categorisation. DIN EN 60079, Part 10 A
provides information with regard to this. The operator is responsible for the categorisation of the
zones. The use of motors which are not certified for explosion hazard areas in explosion hazard areas
is prohibited.
3.1.1 Cable gland

The cable glands must be approved for explosion hazard areas. Unused openings must be closed
with approved blind plugs. When connecting the installation cables, the connections to the motor
terminals and to the earth lead must use U shaped bent cables placed under the relevant terminals so
that the clamping bars and the terminal bolts are equally loaded and are not deformed in any way.
Alternatively, the connections may be made with a cable lug. If increased thermal requirements are
made for the cables, these must be obtained from the information plate on the rotor.
For Sizes 63 to 132 an insulated cable lug must be used, if this is used to connect the earth lead in the
terminal box.
The nuts of the terminal board bolts must be tightened according to the following table.
Tightening torques for terminal board connections
Thread diameter M4 M5 M6 M8
Tightening torque (Nm) 1.2 2.0 3.0 6.0
Use of aluminium connecting wires is not permitted.
3.1.2 Cable connections

All motors with ignition protection class Ex eb are delivered with a certified cable gland.
If the supplied cable glands are used, cables with a circular cross-section must be used. The clamping
nuts of the cable gland must be tightened to the torque specified in the following table.
Clamping nut tightening torques
Cable gland M20x1.5 M25x1.5 M32x1.5 M40x1.5
Use of reduction adapters according to Directive 94/9 EEC or 2014/34/EU and/or cable glands with
ignition protection class Ex eb is permissible. For this, a minimum certified temperature of 80°C is
necessary.
When connecting, care must be taken that the permissible air gaps of at least 10 mm and the
permissible leakage tracks of at least12 mm between the electrically live components and components
with the same potential as the housing, or between live components are maintained.
Check that the terminal nuts and the screw for the earth lead are tight before closing the terminal box.
The terminal box seals and the seals of the cable glands must be correctly seated and must not be
damaged.
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3.1.3 Terminal box cover seals

The terminal box cover gasket is captively mounted on the terminal box cover. Please only use an
original seal when replacing the seal.
If the terminal box is opened during installation, maintenance, repair, troubleshooting or overhaul, the
terminal box cover must be re-fitted after the work is complete. There must be no dirt on the surface of
the seal or the sealing surface of the terminal box frame.
The screws for the terminal box cover must be tightened with a torque according to the list below.
Tightening torques for terminal box cover screws
Tightening torque (Nm) 0.8 - 1.2 1.2 - 1.8 1.5 - 2.5 3.0 – 5.0
3.1.4 Motor position – special features for IM V3, IM V6

If the end of the shaft faces upwards, e.g. version IMV3, IMV6, a cover must be provided by the
operator / installer, which prevents foreign bodies from falling into the fan cover of the motor (see
DIN EN 60079-0). This must not obstruct the fan from cooling the motor. If the end of the shaft faces
downwards (AS), e.g. versions IMV1, IMV5, the motors are normally provided with a protective cover
on the fan cover. A hand wheel on the second end of the shaft is not permitted.
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3.1.5 Further operating conditions

The motors are designed for continuous operation and normal, non recurring starting, in which no
significant starting heat occurs.
Range A in EN 60034-1 (VDE 0530 Part 1) - Voltage ± 5%, Frequency ± 2%, curve form, mains
symmetry - must be complied with so that the development of heat remains within the permissible
limits. Any major deviations from the rated values can cause an impermissible increase in the
development of heat in the motor.
The motor temperature class stated on the type plate must at least conform to the temperature class
of any combustible gas that may occur.
3.1.6 Protective devices

Each machine must be protected against excess heating by means of a current-dependent delayed
protection switch whose function is tested by a designated facility, with phase failure protection
according to VDE 0660 or an equivalent device. Protective devices must be adjusted to the rated
current. For windings with a delta circuit, the triggers are connected in series with the windings and
adjusted to 0.58x the rated current. If this circuit is not possible, additional protective measures are
necessary (e.g. thermal protection of the machine).
In case of a jammed rotor, the protective device must switch of within the specified tE-time for the
relevant temperature class.
Electrical machines with heavy starting (start-up time > 1.7 x tE-time) must be protected by means of
starting monitoring according to the details in the EEC type test certificate.
Thermal protection of the machine by means of direct temperature monitoring of the windings with a
thermistor temperature sensor is permissible, if this is certified and stated on the rating plate.
Do not apply voltages greater than 30 V to the thermistor temperature sensor.
If the only protection is a PTC thermistor temperature sensor, a performance-tested, PTC tripping
device certified by a designated body must be used. The PTC triggering device must be equipped with
the following protection class label:
II (2) G
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Information for motor protection

Type plate example: Type plate example:
No sole means of protection via temperature sensor Sole protection via temperature sensor
Notice! Danger! If the time tA is not stated on the A thermistor is permissible as the sole
type plate, the thermistor is not permissible as the sole
means of protection
It is essential that the motor is protected with a
motor protection relay which has been approved
by a testing facility. The motor protection relay must
be approved for the ignition protection class which is
stated on the motor.

Operation with a frequency inverter must be explicitly certified. The separate manufacturer's
information must be observed. The EMC Directive must be complied with.
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3.1.8 Repairs
Repairs must be carried out by Getriebebau NORD or by an officially recognised expert. The work
must be indicated with an additional repair plate. With the exception of standard, commercially
available and equivalent components, only original spare parts (see spare parts list) may be used. The
particularly applies for seals and connecting components.
For motors with closed condensation outlets, the threads of the closing screws must be coated with
Loctite 242 or Loxeal 82-21 after the condensation has been drained. The closing screws must be re-
inserted immediately. The electrical connections must be checked at regular intervals.
Check that the connection terminals, and the electrical bonding terminal are firmly fastened. Check
that the cable gland and the terminal box gasket are in good condition
All work on electrical machinery must be performed when the machine is at a standstill and with all
poles disconnected from the mains.
The motor must be removed for any measurement of the insulation resistance. The measurement
must not be performed in the explosion hazard area. As soon as measurement has been completed,
discharge the connecting terminals again immediately by shorting them in order to prevent any spark
discharges occurring in the explosive area.

Insulation measurements may cause sparks and therefore ignition of an explosive
atmosphere.
• Only perform insulation measurements outside of an explosive atmosphere.
• Discharge the connection terminals by short circuiting them after the measurement and
before returning to an explosive atmosphere.
3.1.9 Painting
Motors are provided with suitable painting ex-works. Subsequent painting may only be carried out
after consultation with Getriebebau NORD or a workshop which is approved for the repair of explosion
protected motors. Compliance with the valid standards and regulations is mandatory.
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3.1.10 Type plate for NORD Ex eb motors according to EN 60079

1 Data Matrix Code
2 Identification number of designated body
3 Number of phases
4 Type designation
5 Order number / motor number
7 Thermal class of the insulation system
8 IP protection class
9 Operating mode
10 Standard specifications
11 Nominal frequency
12 Nominal voltage
13 Permissible voltage range
14 EC prototype test certificate number
15 Power factor
16 Speed
17 Explosion protection marking
18 Starting current / nominal current
19 tE times
20 Note: TMS with specification of tA time only with
PTC triggering device in accordance with
II (2)G PTC DIN 44082
21 Notice! Pay attention to operating instructions

B1091
22 Rated power (mechanical power delivered to shaft)
23 Nominal current
24 Individual serial number
25 Efficiency
Before commissioning, the type plate must be compared with the requirements of the aforementioned
declaration, which result from the local regulations and operating conditions.
Explanation of standard specification in rating plate
EN 60034 (H), (A)/ EN 60079

Used range of standards for explosion protection
(Please pay attention to conformity declaration.)
Voltage range A in accordance with EN 60034-1
Half key balancing in accordance with EN 60034-14
Product standard
3.1.11 Applied standards

EN Standard Edition IEC Standard Edition
EN 60034-7 2001-12 IEC 60034-7 2001-02
EN 60034-6 1996-08 IEC 60034-6 1991-10
EN 60079-0 2014-06 IEC 60079-0 2011, modified; cor.:2012; cor.:2013
EN 60079-7 2015 IEC 60079-7 2015
EN 60529 2014-09 IEC 60529 1989 +A1:1999 + A2:2013
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3.2 Motors with ignition protection class Non Sparking Ex ec

atmosphere!

used.

The motors are suitable for use in Zone 2 and correspond to Device Group II, Category 3G and may
be used at an ambient temperature from -20 °C to +40 °C.
Type suffix: 3G e. g.: 80 L/4 3G TF

Labelling: II 3G Ex ec IIC T3 Gc With indication of the temperature
class
Explosive gas mixtures or dust concentrations may cause severe or fatal injuries in combination with
hot, electrically live and moving components of electrical machines.
The increased danger in explosion hazard areas requires especially strict observance of the general
safety and commissioning information. The persons responsible must be qualified according to the
national and local regulations.
Explosion protected electrical machines with ignition protection class Ex n correspond to the standard
series EN 60034 (VDE 0530), as well as EN 60079-0:2014 and EN 60079-7:2015. The degree of the
explosion hazard determines the zone categorisation. DIN EN 60079, Part 10 A provides information
with regard to this. The operator is responsible for the categorisation of the zones. The use of motors
which are not certified for explosion hazard areas in explosion hazard areas is prohibited.
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3.2.1 Cable gland

The cable glands must be approved for explosion hazard areas. Unused openings must be closed
with approved blind plugs. When connecting the installation cables, the connections to the motor
terminals and to the earth lead must use U shaped bent cables placed under the relevant terminals so
that the clamping bars and the terminal bolts are equally loaded and are not deformed in any way.
Alternatively, the connections may be made with a cable lug. If increased thermal requirements are
made for the cables, these must be obtained from the information plate on the rotor.
For Sizes 63 to 132 an insulated cable lug must be used, if this is used to connect the earth lead in the
terminal box.
The nuts of the terminal board bolts must be tightened according to the following table.
Use of aluminium connecting wires is not permitted.
3.2.2 Cable connections

If the supplied cable glands are used, cables with a circular cross-section must be used. The clamping
nuts of the cable gland must be tightened to the torque specified in the following table.
Cable gland M20x1.5 M25x1.5 M32x1.5 M40x1.5
Use of reduction adapters according to Directive 94/9 EEC or 2014/34/EU and/or cable glands with
ignition protection class Ex ec is permissible. For this, a minimum certified temperature of 80°C is
necessary.
When connecting, care must be taken that the permissible air gaps of at least 10 mm and the
permissible leakage tracks of at least12 mm between the electrically live components and components
with the same potential as the housing, or between live components are maintained.
Check that the terminal nuts and the screw for the earth lead are tight before closing the terminal box.
The terminal box seals and the seals of the cable glands must be correctly seated and must not be
damaged.
30 B 1091 en-2319
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B 1091 en-2319 31
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The motors are designed for continuous operation and normal, non recurring starting, in which no
significant starting heat occurs.
Range A in EN 60034-1 (VDE 0530 Part 1) - Voltage ± 5%, Frequency ± 2%, curve form, mains
symmetry - must be complied with so that the development of heat remains within the permissible
limits. Any major deviations from the rated values can cause an impermissible increase in the
development of heat in the motor.
The motor temperature class stated on the type plate must at least conform to the temperature class
of any combustible gas that may occur.
3.2.6 Protective devices

Protective devices must be adjusted to the rated current. For windings with a delta circuit, the triggers
are connected in series with the windings and adjusted to 0.58x the rated current.
Alternatively, the motors can be protected with thermistor temperature sensors. Protection with
thermistor temperature sensors is mandatory for inverter operation.
Do not apply voltages greater than 30 V to the thermistor temperature sensor.
We recommend the use of a functionally tested, certified PTC trigger device for protection with a
thermistor temperature sensor.
The following standards must be observed for the installation of electrical systems in
explosion hazard areas in Germany: DIN EN 60079-14 (VDE 0165-1), the Technical Rules for
Operating Safety (TRBS), the Operating Safety Regulations (BetrSichV), the Hazardous
Substances Regulation (GefStoffV) as well as the Explosion Protection Regulations (Ex-RL).
Other regulations must be observed if applicable. The applicable national regulation must be
observed outside of Germany.
32 B 1091 en-2319
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3.2.7 Repairs
Repairs must be carried out by Getriebebau NORD or by an officially recognised expert. The work
must be indicated with an additional repair plate. With the exception of standard, commercially
available and equivalent components, only original spare parts (see spare parts list) may be used. The
particularly applies for seals and connecting components.
For motors with closed condensation outlets, the threads of the closing screws must be coated with
Loctite 242 or Loxeal 82-21 after the condensation has been drained. The closing screws must be re-
inserted immediately. The electrical connections must be checked at regular intervals.
Check that the connection terminals, and the electrical bonding terminal are firmly fastened. Check
that the cable gland and the terminal box gasket are in good condition
All work on electrical machinery must be performed when the machine is at a standstill and with all
poles disconnected from the mains.
The motor must be removed for any measurement of the insulation resistance. The measurement
must not be performed in the explosion hazard area. As soon as measurement has been completed,
discharge the connecting terminals again immediately by shorting them in order to prevent any spark
discharges occurring in the explosive area.

Insulation measurements may cause sparks and therefore ignition of an explosive
atmosphere.
• Only perform insulation measurements outside of an explosive atmosphere.
• Discharge the connection terminals by short circuiting them after the measurement and
before returning to an explosive atmosphere.
3.2.8 Painting
B 1091 en-2319 33
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3.2.9 Type plate for NORD Ex ec motors according to EN 60079

1 Data Matrix Code
3 Number of phases
4 Type designation
9 Operating mode
11 Nominal frequency
12 Nominal voltage
13 Permissible voltage range
15 Power factor
16 Speed
18 Starting current / nominal current
21 Notice! Pay attention to operating

instructions B1091
22 Rated power (mechanical power delivered to
shaft)
23 Nominal current
25 Efficiency
Explanation of standard specification in rating plate
EN 60034 (H), (A)/ EN 60079

Used range of standards for explosion protection
(Please pay attention to conformity declaration.)
Voltage range A in accordance with EN 60034-1
Half key balancing in accordance with EN 60034-14
Product standard
3.2.10 Applied standards

EN Standard Edition IEC Standard Edition
EN 60034-7 2001-12 IEC 60034-7 2001-02
EN 60034-6 1996-08 IEC 60034-6 1991-10
EN 60079-0 2014-06 IEC 60079-0 2011, modified; cor.:2012; cor.:2013
EN 60079-7 2015 IEC 60079-7 2015
EN 60529 2014-09 IEC 60529 1989 +A1:1999 + A2:2013
34 B 1091 en-2319
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3.3 Motors for use in Zone 21 and Zone 22 according to EN 60079-0 and IEC
60079

atmosphere!

used.

Motors which comply with EN 60079 and IEC 60079 are suitable according to their labelling for use in
Zone 21 or Zone 22 - non-conductive dust.
Type supplement:
according to Zone 21 2D e. g.: 80 L/4 2D TF
EN 60079
Zone 22 3D e. g.: 80 L/4 3D TF
according to Zone 21 EPL Db e. g.: 80 L/4 IDB TF
IEC 60079
Zone 22 EPL Dc e. g.: 80 L/4 IDC TF
Labelling:
according to II 2D Ex tb IIIC T125°C Db for category 2 (Zone 21)1)
IEC 60079 and
0102
2014/34 EU
(94/9 EC old)
II 3D Ex tc IIIB T125°C Dc for category 3 (Zone 22 –
non-conducting dust)1)
according to EX tb IIIC T125°C Db for category 2 1)

IEC 60079
Ex tc IIIB T125°C Dc for category 3 (Zone 22 –
non-conducting dust)1)
1) The details of the surface temperature may deviate from 125 °C and may be obtained from the type plate.
B 1091 en-2319 35
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DANGER Explosion hazard

The increased danger in areas with inflammable dust demands the strict observation of the
general safety and commissioning information. Explosive concentrations of dust may cause
explosions if ignited by hot or sparking objects. Such explosions may cause serious or fatal
injuries to persons or severe material damage.
The persons responsible must be qualified according to the national and local regulations.
3.3.1 Commissioning information / Field of application

If the motors are required for use with frequency inverters, this must be stated in the order. The
supplementary operating instructions B1091-1 must be observed. The motors must be protected
against overheating with suitable monitoring equipment! The thickness of dust deposits must not
exceed 5 mm! The motors are designed for the voltage and frequency range B of EN 60034 Part 1.
Exception: Size 132MA/4 2D, 132MA/4 3D, 132LH/4 2D, 132LH/4 3D motors comply with the voltage
and frequency range A.
Motors for use in Zone 21 and Zone 22, with labelling TF may be thermally monitored via the built-in
PTC in combination with a suitable triggering device as the sole protection.
Electrical equipment for use in areas with inflammable dust comply with the standards DIN EN
60079-0, IEC 60079-0, EN 60079-31, IEC 60079-31, as well as DIN EN 60034 and IEC 60034.
The valid version of the standard can be obtained from the EC Declaration of Conformity or the IECEx
CoC. The degree of the explosion hazard determines the zone categorisation. The operator /
employer is responsible for the assignment of zones (in Europe: RL 1999/92/EC).
If the certification is supplemented with an "X" the special conditions in the EC prototype certification,
the IECEX CoC and/or the relevant documentation must be observed. The use of standard motors
which are not certified for explosion hazard areas in explosion hazard areas is prohibited.
36 B 1091 en-2319
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3.3.3 Electrical Connection

The electrical connections of the terminal board are protected against twisting. The voltage supply to
the terminal board must be made by means of suitable ring terminals. The ring terminals are installed
between the two brass washers below the lock washer. The nuts must be tightened with a torque
according to the table below. The contact pressure is permanently maintained by means of the
specified torque and the lock washer. In addition, twisting of the ring terminals of the voltage supply is
prevented. The connection elements are corrosion-proof.
Tightening torque (Nm) 0,8 - 1,2 1,8 - 2,5 2,7 - 4,0 5,5 - 8,0
Exploded diagram of electrical connection
Cable lug provided by Brass nut

customer Lock washer
Brass washer
Brass nut
Ring terminal
Brass thread with collar
Mechanical protection against twisting
3.3.4 Cable and wiring glands

For Zone 21, the cable glands must be approved for Ex areas (minimum protection class IP 66) and
must be secured against accidental loosening. Unused apertures must be sealed with authorised
plugs (minimum protection class IP 66).
For Zone 22, the cable glands which are implemented according to EN 60079-0 and IEC 60079-0
must as a minimum correspond to the protection type specified on the type plate. Unused openings
must be closed with plugs, which as a minimum correspond to the protection class of the motor and
B 1091 en-2319 37
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the requirements of EN 60079-0 and IEC 60079-0. The cable glands and blank plugs must be suitable
for a temperature of at least 80 °C.
The motor must not be opened under hazardous atmospheres to connect the electrical cables or for
any other work. The voltage must always be switched off and secured against being switched on
again before opening the motor!
The motors are equipped with cable glands according to the following overview.
Assignment of Cable Glands to Motor Size
Cable glands for standard motors Cable glands for brake motors
Type Numbe Thread Number Thread Number Thread Number Thread Number Thread Number Thread
r
63 2 M20x1.5 4 M20x1.5 2 M12x1.5
71 2 M20x1.5 4 M20x1.5 2 M12x1.5
80 2 M25x1.5 4 M25x1.5 2 M12x1.5
90 2 M25x1.5 4 M25x1.5 2 M12x1.5
100 2 M32x1.5 4 M32x1.5 2 M12x1.5
112 2 M32x1.5 4 M32x1.5 2 M12x1.5
132 2 M32x1.5 4 M32x1.5 2 M12x1.5 2 M16x1.5
160/ 2 M40x1.5 2 M12x1.5 2 M16x1.5 2 M40x1.5 2 M12x1.5 2 M16x1.5
180/..X
180/ 2 M40x1.5 2 M12x1.5 2 M16x1.5 2 M40x1.5 2 M12x1.5 2 M16x1.5
200/..X
225 2 M50x1.5 2 M12x1.5 2 M16x1.5 2 M50x1.5 2 M12x1.5 2 M16x1.5
250 WP 2 M63x1.5 2 M12x1.5 2 M16x1.5 2 M63x1.5 2 M12x1.5 2 M16x1.5
If the motor is supplied with a certified cable

gland, the clamping nuts of the cable gland
must be tightened to the torque specified in
the following table.
Cable gland
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Cable gland M20x1.5 M25x1.5 M32x1.5 M40x1.5 M50x1.5 M63x1.5
Tightening torque (Nm) 5.0 5.0 10.0 13.5 20.0 20.0
3.3.5 Permissible ambient temperature range

For all motors, the permissible ambient temperature range is -20 °C...+40 °C. For motors for operation
in Zones 21 and 22, an extended ambient temperature range from -20 °C...+60 °C is permissible. In
this case, the rated power must be reduced to 72% of the value stated in the catalogue.
If the maximum ambient temperature is between +40 °C and +60 °C, the power output should be
inversely linearly interpolated between 100% and 72%. In this case thermal protection of the motor by
means of a thermistor sensor is essential. The motor connection cables and the cable glands must be
suitable for temperatures of at least 80 °C.
The extended ambient temperature range does not apply for optional conversions such as a brake
and/or external fan. Contact the manufacturer in case of doubt with regard to permissibility!
3.3.6 Painting
3.3.7 IEC-B14 motors

Please comply with the information in Section 1.3.2. Otherwise, explosion protection is not ensured.

B 1091 en-2319 39
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Unless otherwise specified for operating modes and tolerances in the test certificate, the power rating
plate or in IECEx CoC, electrical machinery is designed for continuous operation and normal
infrequent start-ups where insignificant start-up heating occurs. The motors may only be used for the
type of operation stated on the name plate.
The installation instructions must be strictly observed.
3.3.10 Structure and method of use

The motors are self-cooling. Shaft sealing rings are fitted both on the output side (DS) and on the
ventilation side (VS). Motors for Zone 21 and Zone 22 have metal fans. Motors with brakes for Zone
22 (Category 3D, non-conducting dust) have a special plastic fan. The motors have protection class
IP55, optionally protection class IP 66 (Zone 22 . non-conducting dust, EPL Dc) or IP 66 (Zone 21,
EPL, Db). Under normal operating conditions, the surface temperature does not exceed the surface
temperature stated on the name plate.
3.3.11 Minimum cross section of bonding conductors

Cross section of the phase conductor Minimum cross section of the associated
of the installation S [mm2] protective conductor SP [mm2]
S ≤ 16 S
16 < S ≤ 35 16
S > 35 0.5 S
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3.3.12 Maintenance
The voltage must always be switched off and secured against being switched on again before
opening the motor!
Notice! Higher temperatures than the maximum permitted surface temperature of the housing
may be present inside the motor. The motor must therefore never be opened in hazardous dust
atmospheres! The motors must be checked and tested regularly for functional safety! The
applicable national standards and regulations must be complied with!
Impermissibly thick dust deposits > 5 mm must not be allowed to build up! If functional safety cannot
be ensured, the motor may not be operated! When the ball bearings are replaced, the rotary shaft
seals must also be replaced. FKM rotary shaft seals as specified by Getriebebau NORD must be
used. Ensure that they are fitted correctly! The rotary shaft seals must be lubricated on the external
rings and on the seal lips. If an explosion protected gear is flanged dust-tight to the motor, an NBR
rotary shaft seal can be used on the drive side of the motor if the gear oil temperature does not
exceed 85°C. Only original parts may be used as spare parts with the exception of standardised,
commercially available and equivalent parts. This particularly applies to seals and connection
components. Parts for terminal boxes or spare parts for external grounding must be ordered as per the
spare parts list in the operating instructions.
The functionality of seals, rotary shaft seals and cable glands must be regularly checked!
Maintaining dust protection for the motors is of paramount importance for explosion
protection. Maintenance must be carried out by qualified personnel in a specialist workshop with
appropriate equipment. We urgently recommend that the general overhaul is carried out by NORD
Service.
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3.4 Options for motors for use in Zone 21 and Zone 22

atmosphere!

used.

The design of the insulation of NORD ATEX motors with ignition protection class tb and tc is suitable
for operation with a frequency inverter. Due to the variable speed range, temperature monitoring by
means of thermistors or temperature sensors is necessary. For safe planning and use, the planning
guide for the operating and installation instructions B1091-1 must be observed. The planning guide
provides information regarding the necessary conditions for inverter operation and the approved
speed ranges. Option Z (additional high inertia cast iron fan) is not permitted for inverter operation.
If the frequency inverter is not approved for operation within the explosive atmosphere, the frequency
inverter must be installed outside of the explosive atmosphere.
42 B 1091 en-2319
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3.4.2 External fan

Motors with the additional labelling F (e.g. 80S/4 3D F) are equipped with an external fan and must be
monitored with the integrated temperature sensor.

The motor must only be operated together with the external fan. Failure of the external fan
may cause the motor to overheat and therefore cause damage and/or injury up to and
including ignition of the explosive atmosphere.
The operating instructions for the external fan must be observed.
The power supply to the external fan is provided separately via the terminal box of the external fan.
The supply voltage of the external fan must comply with the voltage which is stated on the type plate.
The external fan must be protected against overheating with suitable monitoring equipment! The IP
protection class of the external fan may differ from that of the motor. The lower protection class
applies for the drive unit. The cable glands must as a minimum correspond to the protection class
which is specified on the type plate. Unused openings must be closed with plugs, which as a minimum
correspond to the protection class of the motor.
External fans and motors for use in explosion hazard areas have Ex labelling according to RL 94/9
EEC or 2014/34/EU. The labelling must be present on both the external fan and the motor. If there is a
difference between the labelling on the external fan and the motor, the lower labelled explosion
protection applies for the entire drive unit. The details of surface temperatures apply for the entire
drive unit; the stated max, temperature applies for the individual components. Any gear unit which is
present must also be taken into account. Please contact Getriebebau NORD in case of doubt. If any
component of the entire drive unit is not provided with Ex labelling, the entire drive unit may not be
used in an explosion hazard area.
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3.4.3 Second temperature sensor 2TF

Category 3D motors (Zone 22, non-conducting dust) can be supplied with a second temperature
sensor (2TF). This option can be used to implement a warning signal (overheating in the winding). It
should be noted that the temperature sensor with the lower trigger temperature should be used for the
warning; the temperature sensor with the higher trigger temperature must be used to evaluate the
switch-off signal.
3.4.4 Back stop

Motors with the additional code RLS (e.g. 80S/4 3D RLS) are equipped with a back stop. For motors
with a back stop, the direction of rotation is indicated by an arrow on the fan cover. The head of the
arrow points in the direction of the drive shaft. When connecting the motor and during motor control, it
must be ensured that the motor can only operate in the rotation direction, e.g. by means of a rotary
field test. Switching of the motor into the blocked direction of rotation, i.e. the wrong direction of
rotation may cause damage.
Back stops operate without wear above a speed of approx. 800 rpm. To prevent excessive heating
and premature wear of the back stop, back stops must not be operated below a speed of 800 rpm.
This must be observed for motors with a frequency of 50 Hz and pole numbers ≥ 8 as well as for
motors with a frequency inverter.
3.4.5 Brake
Motors with the additional labelling BRE (e.g. 80S/4 3D BRE 10) are equipped with a brake and must
be monitored with the integrated temperature sensor. Triggering of the temperature sensor of one of
the components (motor or brake) must result in the safe shut-down of the entire drive unit. The motor
and brake thermistors must be connected in series.
If the motor is operated with a frequency inverter, an external fan must be used for stator frequencies
less than 25 Hz. Operation with stator frequencies of 25 Hz is not permissible without an external fan.
The brake may be used as a holding brake with up to 4 activations per hour.
An optional manual release (with a lockable manual release lever) may only be used if no explosive
atmosphere is present.
NOTICE! The operating instructions for the brake must also be observed.
The DC supply for the brake is via a rectifier in the motor terminal box or via a direct DC supply. The
brake voltage which is stated on the type plate must be complied with.
The power supply cables must not be laid in the same cable as the temperature sensor lines. The
function of the brake must be checked before commissioning. No rubbing noises may occur, as
impermissibly high heating could occur.
44 B 1091 en-2319
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3.4.6 Overview of brake installation for NORD ATEX motors

Permissible brake sizes for Category 3D motors
Size LKZ Braking torque [Nm]

63 S, L 5
71 S, L 5
80 S, SH 5 10
80 L, LH 5 10
90 S, SH 10 20
90 L, LH 10 20
100 L, LH 20 40
100 LA, AH 20 40
112 M, SH, MH 20 40
132 S, SH 60
132 M, MH 60
132 MA 60
160 MH 100 150 250
160 LH 100 150 250
180 MH 250
180 LH 250
200 XH 250
225 SP, MP 400
250 WP 400
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3.4.7 NORD Ex motor type plate (Ex tb, EX tc) according to EN 60079 for operation
with a frequency inverter
1 Data Matrix Code
Code number of the designated facility (only for
2
Ex tb)
3 Number of phases
4 Type designation
9 Operating mode
11 Stator frequency
12 Stator voltage
14 EC prototype test certificate number
15 Power factor
16 Speed
Notice! Pay attention to operating instructions
21
Type plate example Ex tb B1091
Rated power (mechanical power delivered to
22
shaft)
23 Rated current at operating point
25 Efficiency
26 Weight
27 Brake information (option only for Ex tc)
28 Note: Supply by frequency inverter
29 Maximum permissible stator frequency
30 Minimum pulse frequency of frequency inverter
31 Frequency inverter modulation method
32 Data field for operation with frequency inverters
33 Data field for mains operation
34 Rated torque on the motor shaft
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3.5 Explosion protected motors according to TP TC012/2011 for the Eurasian

Economic Union
In addition to the information which is stated in the operating and maintenance instruction B1091, the
following information must be noted for EAC EX motors. If the motor is supplied with further
components or devices, the associated operating and maintenance instructions must also be
observed.
3.5.1 Type plates / Labelling

Motors with the labelling listed below have EAC Ex approval according to TP TC 012/2011 for the
Eurasian Economic Union.
These motors have two type plates. One type plate complies with ATEX Directive 2014/34 EU and the
relevant standards from the standard series EN 60079; the second type plate contains the additional
specifications according to Directive TP TC 012/2011.
The motors may only be operated in areas in which the ignition protection type stated on the motor
type plate is permissible. In addition, compliance with the temperature class and the maximum surface
temperature as stated on the type plate is mandatory.
B 1091 en-2319 47
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3.5.2 Standards
ГОСТ Standard IEC Standard
ГОСТ 31610.0-2014 IEC 60079-0:2011
ГОСТ Р МЭК 60079-31-2013 IEC 60079-31:2013
ГОСТ Р МЭК 60079-7-2012 IEC 60079-7:2006
ГОСТ 31610.15-2014 IEC 60079-15:2010
3.5.3 Service life

In addition to the service intervals which are stated in the operating and maintenance instructions, it
should be noted that the use of motors which are more than 30 years old is not permitted.
The year of manufacture of the motor is stated on the type plate.
WARNING Danger to persons

The motors must be disconnected from the mains before opening the terminal box.

Opening the terminal box in an explosive atmosphere is prohibited.
3.5.4 Special operating conditions (X-labelling)

Permissible ambient temperature range
For all motors with ignition protection type tb or tc, the permissible ambient temperature range is -
20°C...+40°C. For motors for operation in Zones 21 and 22, an extended ambient temperature range
from -20°C...+60°C is permissible. In this case, the rated power must be reduced to 72 % of the value
stated in the catalogue.
If the maximum ambient temperature is between +40 °C and +60 °C, the power output should be
inversely linearly interpolated between 100 % and 72 %. In this case thermal protection of the motor
by means of a thermistor sensor is essential. The motor connection cables and the cable glands must
be suitable for temperatures of at least 80 °C.
The extended ambient temperature range does not apply for optional attachments such as a brake
and/or external fan. Contact the manufacturer in case of doubt with regard to permissibility!
48 B 1091 en-2319
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4 Synchronous motors – special information
4 Synchronous motors – special information

4.1 Type designation

80 D 1 /4
Number of poles
Package length: The 1..9 code depends on the axis height and the length of
the active component
Winding type: T=2100 rpm in Y circuit, 3000 rpm in ∆ circuit
Axis height: 80, 90, 100
4.2 Connection
Notice! Hazardous voltages occur at the motor terminals when the motor shaft is rotating!
The motors must only be operated with suitable inverters For energy-efficient operation, the inverter
must detect the position of the rotor. Various methods both with and without encoders are available for
this. See also TI80_0010
Motors are normally supplied with a star circuit. Some operating points can only be used in a delta
circuit. For this, the bridges must be changed according to the circuit diagram in the terminal box
cover.
B 1091 en-2319 49
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4.3 Encoders
Incremental encoder with zero track
The incremental encoder is located under the fan cover and is attached to this. After installation, the
zero point offset is measured in the final test. The offset is provided with an adhesive label in the
terminal box.
Absolute encoders
The synchronisation of the encoder is adjusted by NORD prior to delivery of the geared motor and
does not require determination of the offset.
If the encoder is not synchronised, or has come out of adjustment due to an impact or removal of the
motor, the zero track of the encoder must be synchronised to the rotor position.
4.4 Commissioning
The choice of inverter must be checked with regard to the motor allocation. In addition to the
information in Section 1 "General" the operating manual for the frequency inverter must be observed.
Further information can be obtained from TI80_0010.
4.5 Maintenance and servicing

CAUTION! The motors contain magnetic components Dismantling without specialist knowledge and
suitable aids may result in injuries. This type of work must only be carried out by trained personnel.
50 B 1091 en-2319
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5 Replacement parts
5 Replacement parts
Please note our spare parts catalogue PL 1090 under www.nord.com.

We will be pleased to send you the spare parts catalogue on request.
B 1091 en-2319 51
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6 Declarations of Conformity
52 B 1091 en-2319
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54 B 1091 en-2319
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204
6051302 / 2319
205
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Operating and Assembly Instruction

Progressive Cavity Pump

Read instructions before Always keep instructions

2 Description of the machine ................................................................................................................. 11

3 Technical Data ....................................................................................................................................

4 Transport, Intermediate storage, Disposal ..........................................................................................

5 Assembly / Installation ........................................................................................................................ 25

6 Commissioning / De-Commissioning ..................................................................................................

8 Malfunctions, causes, rectification ...................................................................................................... 35

9 Dismantling / Reassembly .................................................................................................................. 37

9.2 Rotating unit – individual parts .............................................................................................. 43

10 Spare parts ......................................................................................................................................... 56

11 Special tools ....................................................................................................................................... 63

12 Associated documents ........................................................................................................................

1.1 Notes on these instructions

1.1.1 General notes

1.1.2 Validity of these instructions

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1.1.3 Symbols, notes and abbreviations

1.1.3.1 Information symbols

Abbrevia- Designation Abbrevia- Designation

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1.2 Safety-related Information

1.3 Designated use

1.4 Foreseeable misuse

In particular, the following is not admissable:

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1.5 Structure of warning notes

Preceding warning notes with warning or mandatory signs

Embedded warning notes

 Type and source of danger. Possible consequences. Meas-

Type and source of danger. Possible consequences.

1.5.1 Warning levels

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1.5.2 Warning symbols

Warning symbols Hazard

Electric voltage warning

Hot surface warning

Warning for automatic start

Warning against falling into/reaching into the

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1.6 Qualification of the personnel

Detailed technical knowledge is essential for performing any work on the

Activity Person proven knowledge

1.7 Tasks, notes for the owners, operators and technicians

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 On completion of all work, attach all safety and protective devices

1.8 Personal protective equipment

Sign Meaning Scope of application

Wear eye protection Work on the machine

Wear protective Possible contact with ag-

Wear ear protection Sustained sound

Wear safety helmet Work with suspended

Wear protective clothing Possible contact with

A / 18.09.2018 - OM.SAF.02EN - 7/10

1.9 Safety and protective devices

 Equip pump with a protective device

1.10 Safety clearances

1.10.1 Values for safety clearances - requirements

1.10.2 Safe reaching over protective structures