FLENDER K.A Series Operating Instructions Manual Download

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FLENDER GEAR UNITS

REDUREX Gear unit
Operating Instructions 5200en
Edition 03/2019

Flender GmbH

Alfred-Flender-Straße 77
46395 Bocholt
GERMANY

Summary of Contents for K.A Series

Page 1: ...FLENDER GEAR UNITS REDUREX Gear unit Operating Instructions 5200en Edition 03 2019 S N S O S A K N K O K A S NS S LS S AS S OS S DS K NS K LS K AS K OS K DS K OV K OH K AU SOND 80 800...

Page 2: ...07 03 2019 13 01 V4 00...

Page 3: ...NS K LS K AS K OS K DS K OV K OH K AU SOND 80 800 Translation of the original instructions Edition 03 2019 Introduction 1 Safety instructions 2 Description 3 Application planning 4 Mounting 5 Commiss...

Page 4: ...sonnel are those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Flender products Note...

Page 5: ...Splash lubrication 24 3 4 2 Pressure lubrication 24 3 5 Bearing arrangement of the shafts 25 3 6 Shaft seal 25 3 6 1 Rotary shaft sealing rings 25 3 6 2 Labyrinth seals 25 3 6 3 Taconite seal 26 3 6 4...

Page 6: ...the gear unit swing base 62 5 3 2 3 Mounting the torque arm for the gear unit housing 62 5 4 Shaft mounted gear unit with hollow shaft and parallel keyway 63 5 4 1 Mounting 64 5 4 1 1 Mounting 64 5 4...

Page 7: ...rities in operation 89 7 3 Taking the unit out of service 90 8 Maintenance 91 8 1 General maintenance activities 91 8 2 Maintenance schedule 92 8 3 Maintenance and service work 93 8 3 1 Cleaning the f...

Page 8: ...5 2 Preload forces and tightening torques 79 Table 7 1 Operating data 89 Table 8 1 Maintenance and servicing activities 92 Table 8 2 Possible faults and their rectification 100 Table B 1 Weights 118 T...

Page 9: ...t points at type K S gear units 49 Figure 4 7 Oil filling locations and oil drain locations for type S N gear units 50 Figure 4 8 Oil filling locations and oil drain locations for type K N gear units...

Page 10: ...Table of contents REDUREX Gear unit 5200en 10 Operating Instructions 03 2019...

Page 11: ...bility for damage or operating failures which are due to non adherence to these operating instructions The gear unit described in these instructions reflects the state of technical development at the...

Page 12: ...requirements To avoid misunderstandings Flender points out that by making this recommendation Flender is not approving the product in the sense of expressing a warranty for the quality of the lubrican...

Page 13: ...tps www siemens com industrialsecurity Flender products and solutions undergo continuous development in order to make them even safer Flender strongly recommends that you regularly carry out any updat...

Page 14: ...e 2 1 Symbols and markings Points labelled on the gear unit Symbol Coloured markings Earth connection point Air relief point yellow Oil filling point yellow Oil draining point white Oil level indicato...

Page 15: ...following table contains general warnings and their associated symbols Table 2 2 General warnings ISO ANSI Warning Warning hazardous electrical voltage Warning explosive substances Warning entanglemen...

Page 16: ...re plant is de energised before starting electrical installation work Protective equipment Wear the following personal protective equipment when handling the gear unit Safety shoes Overalls Helmet Saf...

Page 17: ...u in Secure rotating and or moving parts against contact using safeguards Surface temperature The surface temperatures of the gear unit can become very extreme depending on the operating conditions WA...

Page 18: ...he oil used Wear suitable protective equipment gloves safety goggles Use an oil binding agent to immediately clean up spilt oil Danger of explosion An explosion may occur in a potentially explosive at...

Page 19: ...nvironmental protection regulations must be complied with at all times during transport assembly dismantling operation maintenance and servicing The outside of the gear unit must not be cleaned using...

Page 20: ...work Secure the drive unit against being operated accidentally as follows Turn off the key operated switch Remove the fuses in the power supply Attach a notice to the start switch clearly stating that...

Page 21: ...tions in this case Flender must be consulted if for these versions the direction of rotation is to be reversed Designs Various shaft arrangements designs and directions of rotation are possible Additi...

Page 22: ...r Oil filling point for refilling with oil Oil sight glass oil level indicator or dipstick for checking the oil level Oil drain screw or oil drain valve for changing the oil Venting screw air filter o...

Page 23: ...the gear unit equipment on type K N gear units Upper housing section Pressure screws 360 Inspection and or assembly cover Lower housing section Rating plate Shaft seals Alignment surfaces 360 Gear uni...

Page 24: ...fic individual applications a motor pump can be used instead of a flange pump Designs The following designs are possible Mounted oil supply system Separate oil supply system Note All of the monitoring...

Page 25: ...ft sealing ring might not be able to effectively seal the gear unit In very dusty atmospheres do not use rotary shaft sealing rings unless they have additional protection The diagram below shows a rot...

Page 26: ...o sealing elements Rotary shaft sealing ring to prevent the escape of lubricating oil Grease filled dust seal comprising a labyrinth and a lamellar seal to allow operation of the gear unit in extremel...

Page 27: ...non contact low maintenance seals that do not wear It is not therefore necessary to interrupt operation in order to service or replace them The Tacolab seal is a combination of two sealing elements La...

Page 28: ...il supply system When installing the gear unit make sure that unhindered convection across the housing surface is possible in order to protect the gear unit against overheating 3 7 1 Fan Principle of...

Page 29: ...pped with a cooling coil in the oil sump The cooling coil is connected to a cooling water supply The cooling water connection must be provided by the operator The cooling water can be fresh water sea...

Page 30: ...h air oil cooler Introduction Depending on the order specification an oil supply system with air oil cooler can be used This oil cooling system is mounted on the gear unit Principle of operation The a...

Page 31: ...nformation such as connection dimensions and a detailed illustrated description of the gear unit and the oil supply system with air oil cooler can be found in the dimension drawing in the complete gea...

Page 32: ...g the valves observe the flow direction of the pump Refer to the pump operating instructions in the complete gear unit documentation to ascertain whether the flow direction of the pump used depends on...

Page 33: ...ition for ensuring the correct function high operational reliability and long service life of the pump 3 7 3 4 Oil filter Introduction The oil filter protects downstream units measuring and control de...

Page 34: ...tion the inner ring rotates together with the sprag cage in the direction of rotation of the shaft while the outer ring remains stationary Above a certain speed disengagement speed the sprags disengag...

Page 35: ...ion NOTICE Damage to the backstop and gear unit due incorrect direction of rotation Damage to the backstop and gear unit due incorrect direction of rotation possible Do not operate the motor adversely...

Page 36: ...joint pressure between the hollow and stub shafts generated by the shrink disk Further information Further information about the shrink disk can be found in the shrink disk operating instructions Thes...

Page 37: ...perature in C 0 9 10 to 0 0 8 0 to 25 0 7 25 to 50 Heating element control Heating elements can be controlled by a temperature monitor The temperature monitor provides a signal to be amplified when th...

Page 38: ...n be equipped with an oil level monitoring system using a filling level limit switch The oil level monitoring system has been designed to check the oil level when the gear unit is at a standstill befo...

Page 39: ...nd the technical data can be found in the operating instructions for the oil temperature monitor and in the list of equipment in the complete documentation for the gear unit 3 15 Bearing monitoring 3...

Page 40: ...ce thermometer and in the list of equipment in the complete documentation for the gear unit 3 15 2 Bearing monitoring by acceleration sensor Depending on the order specification the gear unit can be s...

Page 41: ...gear unit to be operated at a lower output speed in the same direction of rotation Either Flender or the customer provides the auxiliary drive The auxiliary drive is connected to the main gear unit t...

Page 42: ...clutch When the auxiliary drive is used to drive the gear unit the overrunning clutch allows torque to be transferred in one direction of rotation while free wheeling operation applies when driven by...

Page 43: ...shaft of the main gear unit also slowly rotates It is not permissible that this rotary motion is prevented A brake located on the drive side in the main drive must be opened when driven by the auxili...

Page 44: ...Description 3 16 Auxiliary drive REDUREX Gear unit 5200en 44 Operating Instructions 03 2019...

Page 45: ...onal items such as shrink disks couplings oil coolers pipework and valves may be delivered separately packaged as necessary When transporting the gear unit observe the following instructions to avoid...

Page 46: ...is evenly distributed between them Note the eccentric centre of gravity Make sure that the lifting equipment is securely attached Keep your speed down when moving the load Do not allow the load to swa...

Page 47: ...on The shear pulling must not exceed 45 when the lifting equipment is attached to sling swivels Note Damage to the gear unit during transport Using the wrong attachment points can cause damage when tr...

Page 48: ...nd K N 280 gear units S N 280 K N 280 Figure 4 3 Position of the attachment points at type S N 280 and K N 280 gear units The diagram below shows the position of the attachment points on type S N 280...

Page 49: ...gear unit such as drive motor coupling etc may require an extra attachment point owing to the displacement in the centre of gravity caused by the mounted components Further information Further informa...

Page 50: ...shows the oil filling points and the oil draining points on type K N gear units Inspection and or assembly cover Oil drain screw Housing ventilation and bleeding Oil filling point Oil dipstick Figure...

Page 51: ...space around the gear unit to enable subsequent upkeep and maintenance work Take suitable measures to ensure that unhindered convection across the housing surface is possible so that the gear unit do...

Page 52: ...ventilation Do not smoke 5 2 Unpacking the gear unit Introduction The scope of delivery is listed in the shipping documents WARNING Risk of serious injury due to defective product A defective gear uni...

Page 53: ...st be braced Requirements of the foundation The foundation must meet the following requirements Construct the foundation in such a way that it does not generate any resonance vibrations and that it is...

Page 54: ...the mounting work Measures to be taken prior to assembly CAUTION Risk of chemical burns due to chemical substances There is a risk of chemical burns when handling aggressive cleaning agents Please ob...

Page 55: ...a result of poor alignment When installing and mounting the drive ensure that the individual components are precisely aligned with one another Inadmissibly high alignment errors of the shaft ends to...

Page 56: ...the alignment of the shaft axes does not apply to ZAPEX couplings In this context please also refer to the relevant operating instructions for further information about for example the requirements o...

Page 57: ...ame is horizontal and level It is particularly important that the surface on which the gear unit is mounted is level because this determines the contact pattern of the teeth and the load on the bearin...

Page 58: ...uirements The lower side of the gear unit mounting feet must be clean Mounting a gear unit using stone bolts The following diagram shows a stone bolt Washer Foundation Hexagon nut Stone bolt Gear unit...

Page 59: ...foundation Set screw Height of the prepared foundation Figure 5 3 Foundation block Proceed as follows to mount the gear unit using foundation blocks 1 Attach the foundation blocks with washers and fas...

Page 60: ...the fastening bolts Ensure that the gear unit is not deformed or distorted when tightening the fastening bolts Mounting on a concrete foundation using anchor bolts Requirements The lower side of the g...

Page 61: ...ar that you screw into the thread on the end face 2 Attach the washer 3 Screw on the hexagon nut by hand a few turns 4 Align the gear unit with the supports Page 56 Observe the values on the alignment...

Page 62: ...s before tensioning the anchor bolts 5 3 2 2 Mounting the gear unit swing base NOTICE Damage to the gear unit due to incorrect attachment of the gear unit swing base The gear unit can be damaged by in...

Page 63: ...t 1 form A Furthermore it should have a hole centred in its end face as defined by DIN 332 form DS with thread The connection dimensions for the driven machine shaft can be found in the dimension draw...

Page 64: ...lean them again Apply an appropriate lubricant to the contact surfaces to protect them against fretting corrosion NOTICE Risk of damage to shaft sealing rings from cleaning agent Aggressive chemical c...

Page 65: ...le The gear unit is supported by the hollow shaft The diagram below shows the mounting process with screw spindle for gear units with a hollow shaft and parallel keyway Bolts Nut Hollow shaft Screw sp...

Page 66: ...llow shaft bearings for damage before reattaching the gear unit to the machine shaft Note Reducing the risk of corrosion When using jacking screws or screw spindles to avoid the risk of corrosion roun...

Page 67: ...C60 N or higher strength should have a hole centred in its end face as defined by DIN 332 form DS with thread Depending on the version hollow shafts can be equipped with DU bushings to guide the shaft...

Page 68: ...f damage to shaft sealing rings Aggressive chemical cleaning agents may cause damage to shaft sealing rings Do not allow the cleaning agent to come into contact with the shaft sealing rings Note The b...

Page 69: ...e hollow shaft may be mounted on a machine shaft shoulder only if the gear unit features one of the following Torque arm Supported by gear unit swing base Proceed as follows to mount the gear unit wit...

Page 70: ...gear unit is properly axially locked It is not necessary to install any further axial locking elements 5 5 2 Dismantling the shaft mounted gear unit Procedure 1 Dismantle the shrink disk 2 Lift the ge...

Page 71: ...peration of the system Due to thermal expansion Due to shaft deflection Due to machine frames that are too soft NOTICE Damage or destruction of the coupling through incorrect alignment Refer to the co...

Page 72: ...ler gauge Figure 5 11 Alignment process based on the example of a flexible coupling Note It is advisable to insert shims or metal sheets under the mounting feet in order to align the drive components...

Page 73: ...tation You can find the technical data of the mounted components in the contract list of equipment provided in the complete gear unit documentation 5 7 2 Connecting the cooling coil Procedure To conne...

Page 74: ...7 4 Connecting the water oil cooler NOTICE Damage to the water oil cooler When installing the piping it is not permissible that the connections of the water oil cooler are subject to force torque or...

Page 75: ...tion or install it as a separate system 3 Avoid distorting the piping when installing Further information Further information about the oil supply system can be found in the oil supply system operatin...

Page 76: ...the complete documentation for the gear unit 5 7 8 Connecting the oil level monitoring system Procedure To connect the oil level monitoring system to the gear unit proceed as follows 1 Ensure that th...

Page 77: ...1 Check that the Pt 100 resistance thermometer connection is not damaged 2 Install the electrical wiring between the Pt 100 resistance thermometer and the evaluation unit The customer is responsible f...

Page 78: ...lts Mounting Bolt connection class Scatter of the tor que emitted on the tool Tightening procedure Gear unit Motor Brake Torque arm C 5 to 10 Hydraulic tightening with mechanical screwdriver Torque co...

Page 79: ...00 16 900 10 600 65 4 56 4 50 4 12 9 30 900 19 800 12 400 76 5 66 0 58 9 M12 8 8 26 300 16 800 10 500 76 7 66 1 59 0 10 9 38 600 24 700 15 400 113 97 1 86 6 12 9 45 100 28 900 18 100 132 114 101 M16 8...

Page 80: ...800 M80x6 8 8 1 190 000 760 000 475 000 21 500 18 500 16 500 10 9 1 690 000 1 100 000 675 000 30 500 26 400 23 400 12 9 1 980 000 1 360 000 790 000 35 700 31 400 27 400 M90x6 8 8 1 510 000 968 000 605...

Page 81: ...rnative measures This work must always be done by specialist electricians Protect the cable entries against penetrating moisture Further information Further information about the gear unit and all ass...

Page 82: ...Mounting 5 9 Final work REDUREX Gear unit 5200en 82 Operating Instructions 03 2019...

Page 83: ...about oil and replacement of air filters can be found in the operating instructions BA 7300 in the complete documentation for the gear unit Further information about individual components can be foun...

Page 84: ...operating instructions for the auxiliary drive Fill the overrunning clutch with oil via the intermediate flange Use the same oil type and viscosity as for the gear unit itself If required release the...

Page 85: ...s of lubrication or insufficient cooling The gear unit can sustain damage as a result of inadequate or complete loss of cooling or lubrication Open wide the shutoff valves in the coolant inflow and ou...

Page 86: ...leak free For gear units with bearing monitoring by measuring the vibration Measure the vibration levels of the rolling contact bearings Page 96 to create initial and comparison values For gear units...

Page 87: ...tch fire if exposed heating elements are switched on Never switch on the heating elements until you have checked that they are completely immersed in the oil bath Further information Further informati...

Page 88: ...Commissioning 6 2 Measures to be taken during commissioning REDUREX Gear unit 5200en 88 Operating Instructions 03 2019...

Page 89: ...il pressure of the oil supply system 0 5 bar Further information You can find additional technical data of the gear unit in the separate data sheet and in the equipment list in the complete gear unit...

Page 90: ...will remain out of service Switch off the drive assembly For gear units with a cooling coil or a water oil cooler Drain the water out of the cooling coil or the water oil cooler if there is a risk of...

Page 91: ...e average time limits here These refer to the following conditions of use Daily operating time 24 h Duty cycle ED 100 Gear unit input speed 1500 rpm Permissible average oil temperature Page 89 WARNING...

Page 92: ...f the fastening bolts are tight Every 3 months Check the speed monitoring of the auxiliary drive Check the auxiliary drive Clean the oil filter Clean the air filter Every 3 000 operating hours Measure...

Page 93: ...for the gear unit 8 3 Maintenance and service work Introduction You can find maintenance and servicing measures relating to gear unit lubrication and preservation which are not provided in this chapt...

Page 94: ...crew with cleaning solvent or a similar cleaning agent 4 Dry the venting screw and blow it out using compressed air 8 3 3 Checking the oil temperature Damage to the gear unit due to excessively high o...

Page 95: ...op Procedure Proceed as follows to replace the backstop 1 Replace the backstop 2 Fill the new backstop with oil Page 95 8 3 5 Filling the backstop with oil Oil type and filling filter When filling the...

Page 96: ...cumentation 8 3 7 Measuring the temperature at the rolling contact bearings Procedure Proceed as follows to measure the temperature at the rolling contact bearings 1 Measure the temperature at the rol...

Page 97: ...edure Proceed as follows to fill the overrunning clutch with oil 1 Open the oil filling screw of the overrunning clutch 2 Fill the amount of oil that is specified on the overrunning clutch rating plat...

Page 98: ...ain lines to the cooling coil 8 3 11 Inspecting the shrink disk Introduction The shrink disk inspection is limited to a visual assessment of its condition Aspects of the inspection Observe the followi...

Page 99: ...intended as a troubleshooting guide If any faults occur while the unit is still under warranty do not allow anyone except Flender Customer Services to attempt a repair Even after the warranty period...

Page 100: ...fastening has worked loose Tighten bolts and nuts to the specified tightening torque Replace damaged bolts and nuts Outer surface of gear unit soiled with oil Inadequate sealing of the housing cover...

Page 101: ...s Defective rotary shaft sealing rings Check the rotary shaft sealing rings Replace if necessary Oil is foaming in the gear unit Preservation agent not completely drained off Change the oil Oil supply...

Page 102: ...iled Clean the air guide cover and gear unit housing Coolant temperature too high Check the temperature Correct the temperature if necessary Defective oil pump Check the oil pump function If required...

Page 103: ...ents if necessary Read the operating instructions for the oil supply system Engine room fan is blowing cold air onto gear unit Water condenses Install suitable thermal insulation to protect gear unit...

Page 104: ...Maintenance 8 4 Possible faults REDUREX Gear unit 5200en 104 Operating Instructions 03 2019...

Page 105: ...ory or one of our customer service addresses Flender GmbH Am Industriepark 2 46562 Voerde Deutschland Germany Tel 49 0 2871 92 0 Fax 49 0 2871 92 1544 Further information Further information about ser...

Page 106: ...Service Support REDUREX Gear unit 5200en 106 Operating Instructions 03 2019...

Page 107: ...rotection Observe the following environmental protection measures for disposal Dispose of or recycle packaging material according to applicable national regulations When changing the oil collect the u...

Page 108: ...Disposal REDUREX Gear unit 5200en 108 Operating Instructions 03 2019...

Page 109: ...ics of the gear unit and thus impair its active or passive safety Flender will accept no liability or warranty whatsoever for damage occurring as a result of the use of non approved spare parts The sa...

Page 110: ...Spare parts REDUREX Gear unit 5200en 110 Operating Instructions 03 2019...

Page 111: ...H VSHFLDO WHFKQLFDO GRFXPHQWV DV GHVFULEHG LQ QQH 9 3DUW KDYH EHHQ SUHSDUHG 7KH SDUWO FRPSOHWHG PDFKLQHU PXVW QRW EH SXW LQWR VHUYLFH XQWLO LW KDV EHHQ HVWDEOLVKHG WKDW WKH PDFKLQHU LQWR ZKLFK WKH SDU...

Page 112: ...Quality documents A 1 Declaration of incorporation REDUREX Gear unit 5200en 112 Operating Instructions 03 2019...

Page 113: ...n Speed n1 Optional DMC Data Matrix Code Figure B 1 Rating plate The limits of the intended use of the gear unit are defined on the basis of these data and the contractual agreements concerning the ge...

Page 114: ...the enveloping surface sound pressure levels in chapters Weights Page 118 and Enveloping surface sound pressure level Page 121 Further information about these technical data can be found in the separa...

Page 115: ...VWDJHV WR 9HUWLFDO LQSXW VKDIW 6ROLG VKDIW JHDU XQLW ZLWK EHOO KRXVLQJ 6KDIW PRXQWHG JHDU XQLW ZLWK IRRW 6KDIW PRXQWHG JHDU XQLW ZLWKRXW IRRW 6KDIW PRXQWHG JHDU XQLW ZLWK WRUTXH DUP 2QH KHOLFDO JHDU...

Page 116: ...oping surface sound pressure level Page 121 Further information about these technical data can be found in the separate data sheet and the dimension drawings in the complete documentation for the gear...

Page 117: ...SZN SZO SZA SDN SDO SDA SVN SVO SVA SFO SSO KEN KEO KEA KZN KZO KZA KDN KDA Technical data B 3 Types REDUREX Gear unit 5200en Operating Instructions 03 2019 117...

Page 118: ...o the following tables for the weights approximate values in kg of the gear units Table B 1 Weights Type Gear unit size 80 100 112 125 140 160 180 200 225 250 SEN 14 26 52 105 210 400 SZN 53 72 100 13...

Page 119: ...0 1750 2450 3400 4600 6400 8800 12500 SZO 600 830 1100 1550 2150 3000 4000 5600 7700 SZA 680 950 1250 1750 2450 3400 4600 6400 8800 12500 SDN 750 1050 1400 1950 2650 3800 5100 7200 10800 14000 SDO 640...

Page 120: ...5 465 635 885 1235 1640 2325 3090 4360 5855 8205 11305 SDLS 200 217 310 430 590 825 1155 1530 2145 2905 4140 5460 7610 10610 SDAS 215 235 335 465 635 885 1235 1640 2325 3090 4360 5855 8205 11305 SDOS...

Page 121: ...0 3035 4400 5905 8005 10905 B 5 Enveloping surface sound pressure level The gear unit complies with a sound power level which places it in a gear unit type class defined in VDI 2159 which is applied t...

Page 122: ...Technical data B 5 Enveloping surface sound pressure level REDUREX Gear unit 5200en 122 Operating Instructions 03 2019...

Page 123: ...vices 105 D Danger of explosion 18 Directions of rotation 21 Disclaimer 11 Disposal 107 Documentation landscape 11 E Environmental protection 107 Equipment features 22 Eye bolts 47 F Fan Air guide cov...

Page 124: ...9 Output shaft versions 21 P Pressure lubrication 24 Protective equipment 16 Pump 33 R Rating plate 113 Example of type and size 114 115 116 Reactivating 20 Rolling contact bearings Measure temperatur...

Page 125: ...V Venting screw Cleaning 94 W Warning symbols 15 Water oil cooler 32 Index REDUREX Gear unit 5200en Operating Instructions 03 2019 125...

Page 126: ...Index REDUREX Gear unit 5200en 126 Operating Instructions 03 2019...

Page 127: ......

Page 128: ...FLENDER GEAR UNITS REDUREX Gear unit Operating Instructions 5200en Edition 03 2019 Flender GmbH Alfred Flender Stra e 77 46395 Bocholt GERMANY...

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