Siemens FLENDER K1A Assembly And Operating Instructions Manual Download Page 1

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FLENDER gear units

Bevel gear unit

K1N and K1A
Sizes 1 to 9

Assembly and operating instructions
BA 5230 en 04/2011

Summary of Contents for FLENDER K1A

Page 1: ...FLENDER gear units Bevel gear unit K1N and K1A Sizes 1 to 9 Assembly and operating instructions BA 5230 en 04 2011 ...

Page 2: ... Translation of the original assembly and operating instructions Technical data Spare parts customer service Maintenance and repair Faults causes and remedy Operation Start up Fitting Technical description Transport and storage Safety instructions General notes Declarations 1 12 11 10 9 8 7 6 5 4 3 2 ...

Page 3: ...ge to the product Disregarding these notes may result in material damage NOTE The notes indicated by this symbol must be treated as general operating information Disregarding these notes may result in undesirable results or conditions WARNING Hot surfaces The notes indicated by this symbol are made to prevent risk of burns due to hot surfaces and must always be observed Disregarding these notes ma...

Page 4: ...nstructions may be trademarks the use of which by third parties for their own purposes may infringe holders rights Exclusion of liability We have checked the content of the instructions for compliance with the hard and software described Nevertheless variances may occur and so we can offer no warranty for complete agreement The information given in these instructions is regularly checked and any n...

Page 5: ...servation 15 4 4 1 Interior preservation with preservative agent 16 4 4 2 Exterior preservation 16 5 Technical description 17 5 1 General description 17 5 2 Housing 18 5 3 Toothed components 19 5 4 Lubrication 19 5 4 1 Splash lubrication 19 5 4 2 Forced lubrication 20 5 5 Shaft bearings 20 5 6 Shaft seals 20 5 6 1 Radial shaft sealing rings 20 5 6 2 Taconite seal 21 5 7 Cooling 22 5 7 1 Fan 22 5 7...

Page 6: ...ar unit with hollow shaft and shrink disk 38 6 5 1 Fitting 38 6 6 Shrink disk 38 6 6 1 Fitting the shrink disk 39 6 6 2 Demounting the shrink disk 40 6 6 3 Cleaning and greasing the shrink disk 41 6 6 4 Re fitting the shrink disk 41 6 6 5 Inspection of the shrink disk 42 6 7 Couplings clutches 42 6 8 Gear unit with cooling coil 44 6 9 Gear unit with add on air oil cooler 44 6 10 Gear unit with add...

Page 7: ... 3 2 Exterior preservation 53 7 3 2 1 Exterior preservation procedure 53 8 Operation 54 8 1 General 54 8 2 Oil level 54 8 3 Irregularities 54 9 Faults causes and remedy 55 9 1 General information on faults and malfunctions 55 9 2 Possible faults 55 9 2 1 Leakage leaktightness 58 10 Maintenance and repair 59 10 1 General notes on maintenance 59 10 1 1 General service lives of oils 60 10 2 Descripti...

Page 8: ... oil quantity Total weight in kg Instructions number s Special information Special information Type size Manufacturer and place of manufacture Power rating P2 in kW or torque T2 in Nm Country of origin Speed n1 Example K 1 N 5 Size 1 9 Type of output shaft N Solid shaft A Hollow shaft Number of stages 1 Single stage Gear unit type K Bevel gear unit For specifications for the measuring surface soun...

Page 9: ...for bevel gear units K with fan Table 1 Measuring surface sound pressure level LpA in dB A for bevel gear units with fan c Type iN n1 1 min Gear unit size 1 1 2 1 5 2 3 4 5 6 7 8 9 K1 1 1500 70 72 74 77 79 82 85 87 90 92 94 1000 65 67 70 72 75 79 81 83 86 88 90 1 6 750 60 62 65 67 70 72 74 76 79 81 85 1 8 1500 67 69 71 74 77 81 83 86 88 91 93 1000 63 64 67 68 73 76 78 80 82 85 87 2 8 750 1 1 61 62...

Page 10: ...nce with the state of the art and is delivered in a condition for safe and reliable use The gear unit must be used and operated strictly in accordance with the conditions laid down in the contract governing performance and supply agreed by Siemens and the customer The gear unit described in these instructions reflects the state of technical development at the time these instructions went to print ...

Page 11: ...the gear unit must be carried out only when it is at a standstill The drive unit must be secured against being switched on accidentally e g by locking the key switch or removing the fuses from the power supply A notice should be attached to the start switch stating clearly that work is in progress No electrical welding work must be done at all on the drive system The drive systems must not be used...

Page 12: ... of the gear unit after its useful life Drain all the operating oil preservative agent and or cooling agent from the gear unit and dispose of in accordance with regulations Depending on national regulations gear unit components and or add on parts may have to be disposed of or sent for recycling separately 3 3 Special dangers and personal protective equipment Depending on operating conditions the ...

Page 13: ...s otherwise agreed the packaging complies with the HPE Packaging Guidelines The symbols marked on the packing must be observed at all times These have the following meanings Top Fragile Keep dry Keep cool Centre of gravity Use no hand hook Attach here Fig 2 Transport symbols Transport of the gear unit must be carried out so as to avoid personal damage and damage to the gear unit If for example the...

Page 14: ...ion free dry base and covered over When temporarily storing the gear unit and any single components supplied with it the preservative agent should be left on them It must not be damaged otherwise there is a risk of corrosion Do not stack gear units on top of one another If the gear unit is being stored out of doors it must be particularly carefully covered and care must be taken that neither moist...

Page 15: ...t alone is not suitable to provide a sufficient long term corrosion protection Ensure that the coat is not damaged Any damage may cause failure of the external protective coating and corrosion Unless otherwise contractually agreed the durability period of the interior gear unit preservation specified in table 3 or 4 will apply provided the related requirements are adhered to The durability period ...

Page 16: ...filter For storage periods longer than 36 months Siemens should be consulted before 1 Resistant to tropical conditions and sea water max ambient temperature 50 C 4 4 2 Exterior preservation Table 5 Durability period for exterior preservation of shaft ends and other bright machined surfaces Duration of protection Preservative agent Layer thickness Remarks In case of indoor storage up to 36 months 1...

Page 17: ...rrows with the direction of rotation show the correlation between the directions of rotation of the input and output shafts Table 6 Versions and correlation of direction of rotation Type Version A B C D E F K1N K1A When fitting the auxiliary drive as maintenance and or load drive the assignment of the direction of rotation to the design is defined in the dimensioned drawing The gear units are char...

Page 18: ...using comes with the following equipment Eye bolts adequately dimensioned for transport Inspection and or assembly holes for oil filling and or inspection Oil level indicator or oil dipstick for checking the oil level Oil drain plug or oil drain cock to drain the oil Air filter for venting Colour codes for ventilating oil inlet oil level and oil drainage Air relief point yellow Oil draining point ...

Page 19: ...ed components The toothed components of the gear unit are case hardened The bevel gear teeth are ground or lapped The high quality of the teeth leads to a significant noise reduction and ensures safe and reliable running The bevel gear wheel is joined to the shaft by interference fit and parallel key This type of joint transmits with adequate reliability the torque generated 5 4 Lubrication 5 4 1 ...

Page 20: ...unit see item 5 7 4 External oil supply system fitted separately see item 5 7 5 For an accurate illustration of the gear unit and oil supply system refer to the drawings in the gear unit documentation In case of gear units with oil supply system before starting the unit up all monitors must be connected so as to be ready for operation 5 5 Shaft bearings All shafts are fitted in rolling bearings 5 ...

Page 21: ...ar seal and grease charged re chargeable labyrinth seal 1 2 3 4 Fig 6 Taconite seal 1 Radial shaft sealing ring 3 Grease charged labyrinth seal re chargeable 2 Lamellar seal 4 Flat grease nipple AM10x1 to DIN 3404 Taconite seals are divided into the following types 1 2 3 1 4 Taconite F F and F H Taconite E Taconite F Taconite F K Fig 7 Taconite seal variants E F F F F H and F K 1 Output 3 Taconite...

Page 22: ...instructions for this oil supply system must also be observed When installing the gear unit free convection must be ensured on the housing surface in order to definitely avoid overheating the gear unit 5 7 1 Fan As a rule the fan is fitted on the high speed shaft of the gear unit and is protected from accidental contact by an air guide cover The fan sucks air through the grid of the air guide cove...

Page 23: ...n flow through the gear unit in either direction The pressure of the cooling water must not exceed 8 bar If the gear unit is being withdrawn from service for a longer period and if there is a danger of freezing the cooling water must be drained off Remove any remaining water with compressed air The ends of the cooling coil must never be twisted because this could destroy the cooling coil The reduc...

Page 24: ...the direction of rotation if nothing is specified in the documentation to the contrary When connecting the fittings the actual flow direction must however be observed A detailed view of the gear unit can be obtained from the drawings in the gear unit documentation When installing the gear unit with an add on air oil cooler it must be ensured that the air circulation is not obstructed The required ...

Page 25: ...nger period and if there is a danger of freezing the cooling water must be drained off Remove any remaining water with compressed air Be especially careful when blowing with compressed air Wear protective glasses 5 7 4 1 Pump The pumps used are suitable for the delivery of lubricants The flow medium must not contain abrasive components and must not chemically affect the materials of the pump A pre...

Page 26: ... unit The direction of rotation is marked by a corresponding arrow on the input and output side of the gear unit The backstop is fitted oiltight on an adapter flange on the gear unit and integrated in its oil circulation system The backstop is fitted with centrifugally operated sprags If the gear unit rotates in the prescribed direction the inner ring rotates with the sprag cage in the direction o...

Page 27: ...with the pertinent operating instructions For technical data refer to the list of equipment 5 11 Indication of oil level The gear unit is fitted with an oil level indicator oil level indicator or oil dipstick for visual oil level checking at standstill Checking of the oil level can be carried out by looking at the MIN and MAX marks of the oil level indicator or oil dipstick when the oil has cooled...

Page 28: ...n type IP 54 for the wiring A two wire circuit is provided by the manufacturer However the customer may also fit a three or four wire circuit For control information refer to the list of equipment Observe the operating instructions relating to the device in all instances For a detailed illustration of the gear unit and the position of the add on parts please refer to the drawings in the gear unit ...

Page 29: ...l sump with a temperature monitoring device with a shut off function If a sunshade roof is fitted heat must be prevented from building up If a temperature monitoring device is fitted a warning signal must be emitted when the maximum permitted oil sump temperature is reached If the maximum permitted oil sump temperature is exceeded the drive must be shut off Such shutting off may cause the operator...

Page 30: ...on the gear unit Careful alignment with the machine on the in and output side must be ensured Any elastic deformation through operating forces must be taken into consideration Fastening bolts or nuts must be tightened to the prescribed torque For the correct torque refer to item 6 17 Bolts of the minimum strength class 8 8 must be used If external forces are acting upon the gear unit it is advisab...

Page 31: ... standstill Gear units whose weight requires the use of lifting gear must be attached at the points shown in section 4 Transport and storage If the gear unit is to be transported with add on parts additional attachment points may be required The position of these attachment points is shown in the order related dimensioned drawing 6 3 2 1 Alignment The final fine alignment with the assemblies on th...

Page 32: ...g is only permitted when using a base plate Clean the undersurface of the gear unit base If using stone bolts Hook stone bolts with washers and hexagon nuts into the foundation fastening points on the base plate see figure 10 The hexagon nuts must only be tightened when the concrete has set 4 5 3 2 1 1 Hexagon nut 2 Washer 3 Base plate 4 Stone bolt 5 Foundation Fig 10 Stone bolt If using foundatio...

Page 33: ...mitted when using a base plate Clean the undersurface of the gear unit base Place support on the base plate in the fine grout Insert anchor bolts Place pressure plates in position and screw nuts on Place wood under the anchor bolts so that they are about 10 mm from the upper edge of the support see figure 12 1 Anchor bolt 2 Support 3 Base plate 4 Pressure plate 5 Hexagon nut 6 Wood 7 Fine grout co...

Page 34: ...or initial tensioning forces see item 6 17 Using a suitable tool screw hexagon nuts on as far as the stop To ensure correct handling and setting of the initial tensioning tool the manufacturer s operating instructions must be adhered to The tensioning pressures and or the initial tensioning forces should be recorded see also item 7 2 10 6 4 Assembly of a shaft mounted gear unit with hollow shaft a...

Page 35: ...preparation 1 Machine shaft 3 Parallel key 2 Hollow shaft 4 Pressure oil connection 6 4 2 Fitting Remove the corrosion protection from the hollow shaft and machine shaft with a suitable cleaning agent The cleaner must not be allowed to come into contact with the shaft sealing rings Ensure adequate ventilation Do not smoke Danger of explosion Check the hollow and machine shafts to ensure that seats...

Page 36: ...unit swing base With a different arrangement the bearings may be excessively stressed 6 4 2 2 Axial fastening Depending on type secure the hollow shaft axially on the machine shaft e g with locking ring end plate set screw 6 4 3 Demounting Remove the axial securing device from the hollow shaft If frictional corrosion has occurred on the seating surfaces rust releasing agent may be used in order to...

Page 37: ...haft with parallel keyway demounting with hydraulic lifting unit Lukas 1 Machine shaft 5 Threaded spindle 2 Hollow shaft 6 Pressure oil connection 3 Parallel key 7 Auxiliary plate for forcing out 4 Hydraulic lifting unit Lukas 5 4 6 3 1 2 Fig 17 Hollow shaft with parallel keyway demounting with end plate 1 Machine shaft 4 End plate for forcing out 2 Hollow shaft 5 Screws 3 Parallel key 6 Forcing o...

Page 38: ...eck the hollow and machine shafts to ensure that seats and edges are not damaged If necessary rework the parts with a suitable tool and clean them again The bore of the hollow shaft and the machine shaft must be absolutely free of grease in the area of the shrink disk seat This is essential for safe and reliable torque transmission Do not use contaminated solvents or dirty cloths for removing grea...

Page 39: ... ring The outer surface of the hollow shaft must be lightly greased in the area of the shrink disk seat For a detailed view refer to the dimensioned drawing in the gear unit documentation Place the shrink disk on the hollow shaft and fasten if required For the exact installation height W of the shrink disk refer to the dimensioned drawing For transporting and lifting the shrink disk it may be requ...

Page 40: ... is not permitted 6 6 2 Demounting the shrink disk Remove the protective cover Remove any rust deposits from the shaft and the hollow shaft Under no circumstances must the bolts be unscrewed individually one after the other Undo all tensioning bolts one after the other by approx 1 4 turn The stored energy of the outer ring is slowly loosened during disassembly via the bolts to be loosened For this...

Page 41: ...t surface and on the thread with lubricant Use a solid lubricant paste with a high MoS2 based molybdenum disulphide content which will not slide during fitting work and which shows the following characteristics friction coefficient μ 0 04 resistant to pressure up to a maximum pressure of 300 N mm2 ageing resistant Table 10 Recommended lubricants for shrink disks after their cleaning 1 Lubricant Fo...

Page 42: ...pertinent instructions manual For maintenance and operation of the couplings refer to the specific operating instructions for the couplings When installing the drives make absolutely certain that the individual components are accurately aligned in relation to each other Inadmissibly large errors in the alignment of the shaft ends to be connected due to angular and or axial misalignments result in ...

Page 43: ... 2 Fig 21 Example of alignment on a flexible coupling 1 Ruler 2 Feeler gauge 3 Measuring points The maximum permissible misalignment values are specified in the operating instructions for the coupling they must under no circumstances be exceeded during operation Angular and radial misalignments may occur at the same time The sum of both misalignments must not exceed the maximum permissible value o...

Page 44: ...lso item 5 7 4 6 11 Gear unit with separate oil supply system Remove the sockets and or flanges from the suction and delivery lines prior to connecting the system Fit the system to the gear unit or install it separately in accordance with the drawings supplied in the gear unit documentation The pipework must not be overstressed during the fitting procedure For the exact position and size of the co...

Page 45: ...t be taken This work must always be done by specialist electricians Cable entries should be protected against moisture 6 17 Screw connection classes tightening torques and initial tensioning forces 6 17 1 Screw connection classes The specified screw connections are to be fastened applying the tightening torques specified in the table below Table 11 Screw connection classes Fastening of Screw conne...

Page 46: ...49300 31600 19800 186 160 143 10 9 72500 46400 29000 273 235 210 12 9 85000 54400 34000 320 276 246 M20 8 8 77000 49200 30800 364 313 280 10 9 110000 70400 44000 520 450 400 12 9 129000 82400 51500 609 525 468 M24 8 8 109000 69600 43500 614 530 470 10 9 155000 99200 62000 875 755 675 12 9 181000 116000 72500 1020 880 790 M30 8 8 170000 109000 68000 1210 1040 930 10 9 243000 155000 97000 1720 1480 ...

Page 47: ... 18500 16500 10 9 1690000 1100000 675000 30500 26400 23400 12 9 1980000 1360000 790000 35700 31400 27400 M90x6 8 8 1510000 968000 605000 30600 26300 23500 10 9 2150000 1380000 860000 43500 37500 33400 12 9 2520000 1600000 1010000 51000 43800 39200 M100x6 8 8 1880000 1200000 750000 42100 36200 32300 10 9 2670000 1710000 1070000 60000 51600 46100 12 9 3130000 2000000 1250000 70000 60400 53900 Damage...

Page 48: ... the oil drain cock Remove remaining preservative agent and or running in oil from the gear unit using a suitable container Unscrew any existing residual oil drain plugs Dispose of remaining preservative agent and or running in oil in accordance with regulations Any oil spillage must be removed immediately with an oil binding agent The oil must not come into contact with the skin e g the operator ...

Page 49: ...on pump observing the description in section 8 Check the oil level in the gear unit housing The oil level must be between the marks on the oil level indicator Any oil spillage must be removed immediately with an oil binding agent Close oil filling hole with screw plugs 7 2 Start up Before start up replace the yellow plastic screw plug with the air filter see also notice on gear unit After the firs...

Page 50: ...rnal oil supply system 7 2 5 1 Pre lubrication phase Prior to start up the gear unit should be prelubricated for approx 3 minutes by means of the oil supply system During this time rolling bearings and gear teeth will be adequately supplied with oil for start up The pre lubrication phase must not take longer than 3 minutes since there will be heavy foaming of the oil at low temperatures If the oil...

Page 51: ...oil filler plug screw of the backstop Always use oil of the same type and viscosity as for the gear unit 7 2 7 Temperature measurement During the first start up and after maintenance work the oil sump temperature must be measured during correct use maximum machine performance after appropriate running in The maximally permissible oil sump temperature is 90 C for mineral oil or 100 C for synthetic ...

Page 52: ...nd outflow pipes To prevent freezing drain the water from the cooling coil or the water oil cooler Start the gear unit and allow it to run briefly 5 to 10 minutes approx every 3 weeks during a shut down period no longer than 6 months Treat the gear unit with preservative agent see items 7 3 1 and 7 3 2 before a shut down period exceeding 6 months 7 3 1 Interior preservation for longer disuse Depen...

Page 53: ...eservative agent into a suitable container Dispose of the preservative agent in accordance with the regulations There is a risk of scalding from the hot preservative agent draining from the gear unit Wear protective gloves Screw in the oil drain plug or reclose the oil drain cock Replace the air filter with the screw plug Before re starting the gear unit replace the screw plug with the air filter ...

Page 54: ...ise Possible oil leakage at the housing and shaft seals 8 2 Oil level To check the oil level stop operation of the gear unit When the oil is hot the oil level may slightly exceed the upper mark of the oil dipstick or the middle of the oil level indicator It must not be allowed to fall below the lower mark If necessary top up to the correct level The oil level in the oil supply system must be check...

Page 55: ... be taken out of service Secure the drive unit to prevent it from being started up unintentionally Attach a warning notice to the start switch 9 2 Possible faults Table 13 Faults causes and remedy Faults Causes Remedy Loud noises in the area of the gear unit fastening Gear unit fastening has worked loose Tighten bolts nuts to specified torque Replace damaged bolts nuts Changes in gear unit noise D...

Page 56: ...just Check function of oil pump and if necessary repair or replace oil pump Clean air guide cover and gear unit housing Oil leakage from the gear unit Inadequate sealing of housing covers and or joints Radial shaft sealing rings defective Check and if necessary replace sealings Seal joints Check radial shaft sealing rings and if necessary replace Oil foaming in the gear unit Preservation agent not...

Page 57: ...s Consult operating instructions for oil supply system Protect gear unit with suitable heat insulation Close air outlet or alter its direction by structural measures Contact Customer Service if necessary place wet air filter Pressure monitor triggers alarm If gear unit with oil pump Oil pressure 0 5 bar Check oil level at room temperature and if necessary top up oil Check and if necessary replace ...

Page 58: ...extending beyond the bottom side of the radial shaft sealing ring but not dripping Wipe away with a clean cloth observe The radial shaft sealing ring often dries by itself in further operation No reason for complaint Measurable leak Small trickle to be seen on the bottom side of the radial shaft sealing ring dripping If necessary change radial shaft sealing ring identify possible cause of radial s...

Page 59: ... must ensure that the intervals stated in table 15 are adhered to This also applies if the maintenance work is included in the operator s internal maintenance schedules Table 15 Maintenance and repair work Measures Periods Remarks Check the oil temperature Daily Check for unusual gear unit noise Daily Check the oil level Monthly Comparison of vibration values for bearing monitoring with initial va...

Page 60: ...ance and repair works 10 2 1 Examine water content of oil conduct oil analyses More information about examining the oil for water content or conducting oil analyses is obtainable from your lubricant manufacturer or our customer service For reference purposes a fresh sample of the operating lubricating oil used must be sent with the used oil sample to the analysing institute for analysis The oil sa...

Page 61: ...r unit housing Unscrew the air filter including reducing screw at the housing top Unscrew the oil drain plug or open oil drain cock and drain the oil into the collecting container Drain the oil from the oil supply system see operating instructions to the oil supply system There is a danger of scalding from the hot oil emerging from the housing Wear protective gloves Any oil spillage must be remove...

Page 62: ...nd outflow pipes from the cooling coil Check the inside walls of the cooling coil for deposits If the cooling coil is dirty heat is no longer withdrawn effectively from the gear unit Any dirt adhering to the inside of the coil should be removed by chemical cleaning or the cooling coil should be replaced with a new one If thick deposits have formed on the inside of the cooling coil the cooling wate...

Page 63: ...rmined using available test and empirical values taking into account the conditions of use The operator of the system must ensure that hose lines are replaced at suitable intervals of time even if no defects which may affect their safe operation are identifiable on them Hose lines must be inspected for safe working condition by an expert before the plant is first put into operation and thereafter ...

Page 64: ...ils listed in table T 7300 for a link see the BA 7300 instructions manual supplied separately because they have been tested and meet the requirements To avoid misunderstandings we should like to point out that this recommendation is in no way intended as a guarantee of the quality of the lubricant supplied Each lubricant manufacturer is responsible for the quality of his own product Information on...

Page 65: ...ear unit thereby posing an active or passive risk to safety Siemens will assume no liability or guarantee for damage caused by spare parts not supplied by Siemens The same applies to any accessories not supplied by Siemens Please note that certain components often have special production and supply specifications and that we supply you with spare parts which comply fully with the current state of ...

Page 66: ...1 3 4 1 3 6 1 3 8 1 1 4 1 1 4 2 1 1 5 1 1 5 11 1 5 13 1 5 15 1 5 16 1 6 1 1 6 3 1 7 1 1 7 4 3 The partly completed machinery must not be put into service until it has been established that the machinery into which the partly completed machinery is to be incorporated has been declared to be in conformity with the provisions of Directive 2006 42 EC as appropriate The manufacturer undertakes in respo...

Page 67: ...Subject to modifications Siemens AG 2011 Weitere Informationen FLENDER gear units im Internet www siemens de getriebe FLENDER couplings im Internet www siemens de kupplungen Service Support http support automation siemens com WW view de 10803928 133300 Schmierstoffe http support automation siemens com WW view de 42961591 133000 ...

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Siemens FLENDER K1A, Assembly And Operating Instructions Manual

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