Siemens KMS Assembly And Operating Instructions Manual Download Page 6

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BA 9137 en 12/2015

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6.1

General assembly information

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6.2

Set-up conditions

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6.2.1

Dimensions and weights

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6.2.2

Lifting device

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6.3

Preparatory measures for gear unit installation

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6.3.1

Maintaining preservation if the gear unit has been opened in the meantime

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6.3.2

Foundation

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6.4

Assembly of the gear unit

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6.5

Installing the pipework

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6.6

Pickling of adapted pipes

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6.7

Installing the couplings

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6.8

Installing the motor

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6.9

Assembly of loose add-on parts included in the delivery

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6.10

Welding work on the mill

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6.11

Final work

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6.12

Screw connection classes, tightening torques and initial stressing forces

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6.12.1

Screw connection classes

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6.12.2

Tightening torques and initial stressing forces

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Start-up

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7.1

Procedure before start-up

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7.1.1

Removal of preservative agent from exterior

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7.1.2

Removal of preservative agent from interior

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7.1.3

Draining preservative oils

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7.1.4

Flushing before initial start-up

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7.1.4.1 Oil quantity for flushing

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7.1.5

Fill in operating oil

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7.1.5.1 Oil level

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7.1.5.2 Procedure for filling

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7.1.6

Oil-supply system

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7.1.7

Checks before start-up

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7.2

Start-up

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7.2.1

Pre-lubrication phase

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7.2.2

Initial start-up

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7.2.3

Checking procedure

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7.3

Removal from service

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7.3.1

Renewal of the gear unit interior preservation on gear units having already been in operation

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7.3.1.1 Renewal of the interior preservation of the gear unit using the oil- supply system

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7.3.1.2 Renewal of the gear unit interior preservation with "Castrol Corrosion Inhibitor N 213"

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7.3.1.3 Renewal of the gear unit interior preservation through complete filling with preservative

or operating oil

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7.3.2

Exterior corrosion prevention

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Operation

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8.1

General

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8.2

Oil level

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8.3

Irregularities

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Faults, causes and remedy

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9.1

General information on faults and malfunctions

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9.2

Faults, causes and remedy

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Summary of Contents for KMS

Page 1: ...FLENDER gear units Vertical mill gear unit KMS Sizes 225 to 850 Assembly and operating instructions BA 9137 en 12 2015 ...

Page 2: ...ns 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: ...ith the documentation relating to the work concerned particularly the safety and warning notes contained in those documents Qualified personnel must be specially trained and have the experience necessary to recognise risks associated with these products and to avoid possible hazards Proper use of Siemens products Observe also the following WARNING Siemens products must be used only for the applica...

Page 4: ...imminent risk of explosion in the meaning of Directive 2014 34 EU This symbol additionally indicates an imminent risk of burns due to hot surfaces in the meaning of standard DIN EN ISO 13732 1 This symbol warns against risks from lifted and or suspended loads Earth connection point Air relief point yellow Oil filling point yellow Oil draining point white Oil level red Oil level red Oil level red C...

Page 5: ...reservation of the gear unit 20 4 4 2 2 Combined storage packaging 22 4 4 3 Renewal of the interior preservation of the gear unit for longer periods of storage of the gear unit that has not been taken into operation yet 26 4 4 3 1 Renewal of the gear unit interior preservation with Castrol Corrosion Inhibitor N 213 26 4 4 3 2 Renewal of the gear unit interior preservation through complete filling ...

Page 6: ...moval of preservative agent from interior 51 7 1 3 Draining preservative oils 53 7 1 4 Flushing before initial start up 54 7 1 4 1 Oil quantity for flushing 54 7 1 5 Fill in operating oil 54 7 1 5 1 Oil level 55 7 1 5 2 Procedure for filling 55 7 1 6 Oil supply system 57 7 1 7 Checks before start up 57 7 2 Start up 59 7 2 1 Pre lubrication phase 59 7 2 2 Initial start up 59 7 2 3 Checking procedur...

Page 7: ...ne water content of oil conduct oil analyses 79 10 7 2 Change oil 80 10 7 3 Check tightness of screw connections 82 10 8 Welding work on the mill 82 10 9 Vibration measurements 83 10 10 Repair 84 10 11 General inspection of the gear unit 85 10 12 Lubricants 85 11 Spare parts customer service 86 11 1 Stocking spare parts 86 11 2 Addresses for ordering spare parts and customer service 86 12 Declarat...

Page 8: ...g in kg Special information Type size Power rating P2 in kW or torque T2 in Nm Rotation speed n1 in min 1 Rotation speed n2 in min 1 Oil data oil type oil viscosity oil quantity Instruction manual numbers Manufacturer and place of manufacture Country of origin Production site code Order no item seq no Year built Example K M S 225 Size 225 850 Model S Spur wheel section Area of use M Vertical mill ...

Page 9: ...marking for the applicable case of application 1 2 1 Ambient temperature The specifications of Directive2014 34 EU apply to the ambient temperature range of from 20 C to 40 C By adopting various suitable measures the gear unit may be used in ambient temperatures from 40 C to 60 C However the temperature range and the expanded temperature range must generally be approved by Siemens and be specified...

Page 10: ...condition ready for safe and reliable use The gear unit complies with the requirements in Directive 2014 34 EU The gear unit may only be used and operated in accordance with the conditions laid down in the service and supply contract concluded between Siemens and the customer The gear unit described in these instructions conforms to the state of technical development at the time when these instruc...

Page 11: ...the unit the relevant safety and environmental regulations must be observed at all times The gear unit may only be operated maintained and or repaired by persons qualified for the work concerned see Qualified personnel on page 3 of this manual The outside of the gear unit must not be cleaned with high pressure cleaning equipment All work must be carried out with great care and due regard for safet...

Page 12: ...perty damage Damage to the gear unit is possible Immediately stop the gear unit by turning off the drive unit when inexplicable changes are noticed during the operation such as a significantly increased operating temperature or changed sounds of the gear unit DANGER Danger to life from rotating and or moving parts Risk of being gripped or drawn in by rotating and or moving parts Rotating and or mo...

Page 13: ...e obtained from Siemens see section 11 Spare parts customer service 3 2 Special dangers and personal protective equipment Depending on operating conditions the surface of the gear unit may develop extreme temperatures WARNING Risk of burns Serious injury caused by burns on hot surfaces 55 C is possible Wear suitable protection gloves and protection clothing WARNING Risk of low temperatures Serious...

Page 14: ...e in the order cited above 1 Disconnect Also disconnect the auxiliary currents e g standstill heating 2 Secure against re connection 3 Verify that disconnected parts are have zero voltage 4 Earth and short circuit 5 Cover or shield adjacent live parts Upon completion of the work undo the taken measures in the reverse order 3 4 Environmental protection Existing packaging material must be disposed o...

Page 15: ...g is opened nonetheless section 4 4 must be observed WARNING Serious personal injury can be caused by a defective product If there is any visible damage the gear unit must not be taken into operation 4 2 Transport Note The product weight is indicated on the rating plate DANGER Danger to life Danger to life from load falling down due to deficient attachment Do not stay underneath suspended loads Wh...

Page 16: ...pplicable additional items are delivered packaged separately Depending on the size of the unit and transport route the gear unit will have different types of packaging Unless agreed otherwise by contract the packaging complies with the Packaging Guidelines of the HPE Federal Association of Wood Packaging Pallets Export Packaging The symbols marked on the packaging must be observed at all times The...

Page 17: ...e wrong attachment points Use only the lifting eyes provided to attach lifting gear to the unit Attach slings with shackles to the eyebolts Transporting of the gear unit by attaching it to the pipework is not permitted The pipework must not be damaged Do not use the front threads at the shaft ends to attach slinging and lifting gear for transport Slinging and lifting gear must be adequate for the ...

Page 18: ...arly carefully and it must be ensured that neither moisture nor foreign material can collect on the unit Waterlogging must be avoided NOTICE Property damage Damage to the gear unit from external effects Unless agreed otherwise by contract the gear unit must not be exposed to harmful effects such as chemically aggressive products Special environmental conditions during transport e g transport by sh...

Page 19: ...s which can set up a charge in the coating are safely avoided Note Examples of highly effective charge generating mechanisms are the rapid passage of heavily dust laden air near by the sudden escape of particle laden compressed gases other heavy friction action not manual cleaning or rubbing with cleaning cloths NOTICE Property damage Any damage to the coating may cause the failure of the exterior...

Page 20: ...either moisture nor foreign material can collect on the unit Waterlogging must be avoided 4 4 1 2 Prolongation of the preservation of metallic bright exterior surfaces of the gear unit In case storage periods exceed the periods specified in Table 2 under item 4 4 1 1 the exterior of the gear unit must be re preserved using the preservative agent shown in Table 2 Clean the surfaces Apply preservati...

Page 21: ... 3 3 3 covered with loose tarpaulin 7 3 8 4 3 5 under roof 1 15 3 20 11 3 14 in closed dry room covered at least with loose tarpaulin exposed outdoors 7 3 8 4 3 5 under roof 1 19 3 24 13 3 17 in closed dry room seaworthy packaging 2 exposed outdoors 15 3 20 15 3 20 covered with loose tarpaulin under roof 1 19 3 24 19 3 24 in closed dry room 1 under roof no direct exposure to sunlight and no direct...

Page 22: ... to table 3 in item 4 4 2 1 HD2äq Maximum remaining durability period after the change in the type of storage and or packaging If several packaging and or storage types are combined the following formula must be applied as from the second change in packaging and or storage types equivalent remaining durability period HD2 äq to determine the equivalent remaining durability period applying to the pr...

Page 23: ...lows HD2äq 1 LD1 HD1 HD2 HD2äq 1 5 20 4 HD2äq 3 months The remaining durability period of the interior gear unit preservation after changing the storage type is 3 months After one additional month LD2 the gear unit is placed outdoors exposed without packaging Now the remaining durability period HD3äq is to be calculated as follows Given HD2äq 3 months previously calculated LD2 1 month actual durat...

Page 24: ...ose tarpaulin in closed room or under roof 1 exposed outdoors or covered with loose tarpaulin Change in place of storage New Packaging for storage Storage place of the newly packaged unit Change of original storage method after Durability period of interior preservation of the gear unit for the new storage method in consideration of the previous storage period in months without packaging exposed o...

Page 25: ... method in consideration of the previous storage period in months without packaging exposed outdoors 1 month 2 1 2 2 3 3 3 months 2 1 2 1 2 2 1 2 6 months 1 1 2 not permissible max durability period 4 months 2 2 12 months not permissible max durability period 11 months not permissible max durability period 4 months 1 1 2 1 18 months not permissible max durability period 11 months not permissible m...

Page 26: ...k of injury Risk of injury to eyes or hands from chemically aggressive operating substances Wear suitable protection glasses and protection gloves Remove any spilled oil immediately using an oil binding agent Note In this renewal of the gear unit interior preservation it must be ensured that the ambient and gear unit temperature is above 5 C during filling The following control measures must be ta...

Page 27: ...st 50 km distance from larger bodies of salt water Setup in climatic zone B and or less than 50 km distance from larger bodies of salt water Packaging for Storage Storage place of packaged unit Maximum durability period of the preservation renewal with Castrol Corrosion Inhibitor N 213 in months No packaging exposed outdoors 5 3 covered with loose tarpaulin 8 5 under roof 1 20 14 in closed dry roo...

Page 28: ...ed on the gear unit for sealing the input shaft The preservation will remain intact for as long as the gear unit remains sealed and the storage durability of the oil is not exceeded Note Refer to the BA 7300 operating instructions supplied separately for the approved preservative oils The viscosity of the operating oil is stated on the rating plate For better filling it is recommended to choose an...

Page 29: ...Seal input shaft with a sealing cap 3 Seal bottom oil drain of the sealing cap 2 with a screw plug The oil to be filled in must be filtered beforehand with a filter mesh of 25 μm 0 0010 inch 13 1 3 12 10 7 2 5 8 9 6 4 4 Fig 4 Gear unit features for preservation measures 1 Breather of sealing cap 2 Oil drain sealing cap 3 Sealing cap 4 Air filter gear unit 5 Oil level indicator gear unit 6 Suction ...

Page 30: ...ing the oil supply system The prerequisite for this is that the gear unit is still below the mill and connected to the oil supply system Castrol Alpha SP 220 S or Tribol 1390 can be used as preservative agent The oil level must never be below the MIN mark on the oil level indicator of the main gear unit the tilting pad thrust bearing chamber and or on the oil supply system if the model has a tank ...

Page 31: ...exposed outdoors 5 3 covered with loose tarpaulin 8 5 under roof 1 20 14 in closed dry room covered at least with loose tarpaulin exposed outdoors 8 5 under roof 1 24 17 in closed dry room seaworthy packaging 2 exposed outdoors 20 20 covered with loose tarpaulin under roof 1 24 24 in closed dry room 1 under roof no direct exposure to sunlight and no direct contact with water rain or draining water...

Page 32: ...ger fulfil its sealing function after start up this does not impede the reliability of the shaft sealing A round cord hollow profile 2 is used as sealing between the gear unit housing and the output flange This seal additionally serves for the airtight sealing of the gear unit interior for the specified preservation period If the gear unit is opened e g by removing the adhesive tape on the labyrin...

Page 33: ...and lubrication diagram The oil is drawn in by the oil pump cleaned in the double changeover filter which is fitted with an optical and electrical contamination indicator then cooled in the cooler and conducted to the lubricating points The oil flow is divided by valves and orifice plates or control valves for the lubrication of the gears and tilting pad thrust bearing Volumetric flow pressure and...

Page 34: ...pressure actually exerted by the grinding rollers If the minimum setting of a pressure or flow monitored component is fallen short of the main drive will be switched off If the maximum pressure is exceeded a warning is given or the main drive is shut off The non return valves built into the pads prevent the oil from backing up during normal operation 5 3 4 Labyrinth seals The input shaft and outpu...

Page 35: ...ating elements can be used These heating elements convert electrical energy into heat which is conducted to the surrounding oil The heating elements are located in protective tubes inside the housing thus making it possible to replace them without draining the oil beforehand Heating elements must fully submerge into the oil bath The heating elements can be controlled by a resistance thermometer or...

Page 36: ...s possible Never switch on the heating elements unless complete immersion of the heating element in the oil bath is ensured If heating elements are installed afterwards the maximum heating capacity see table 7 on the outer surface of the heating element must not be exceeded A detailed illustration of the gear unit and the position of the add on parts can found in the drawings of the gear unit docu...

Page 37: ...wings of the gear unit documentation Note For operation and maintenance the operating manuals in the order specific annex must be observed For technical data and control information refer to the list of equipment prepared specifically for the order 5 9 Oil level monitoring system The gear unit may be fitted with a filling level limit switch for oil level monitoring The oil level monitoring device ...

Page 38: ...of current can lead to irreparable damages on rolling bearings and gear teeth Flow of current can arise e g through short circuits flash arcs conductive dust layers etc Suitable measures may be Use of isolators Earth the gear unit professionally DANGER Explosion hazard Danger to life is possible from overheating of the gear unit due to external influences and thereby ignition of explosive atmosphe...

Page 39: ...ons must be observed Note Every time the drive is set in motion and any operation of the oil supply system with connected gear unit represents a start up 6 2 Set up conditions As early as during the planning phase sufficient space must be allowed around the gear unit for later care and maintenance work Note It must be ensured that the oil can be drained and an adequate air supply is provided It mu...

Page 40: ...sion is possible when the gear unit is opened for too long Any opening of the gear unit e g by removing the adhesive tape on the input shaft or on the output flange removing the round cord hollow profile or by opening a lid reduces the guaranteed preservation period If the gear unit is opened it must be taken into operation within one week If the start up is delayed special measures are necessary ...

Page 41: ...chemical substances Observe manufacturer s instructions for handling lubricants and solvents Wear suitable protective clothing DANGER Explosion hazard Danger to life from ignition of solvent steams or other explosive atmosphere during cleaning work The gear unit must not be cleaned in an explosive atmosphere Observe also the following Keep away from sources of ignition Do not smoke Ensure adequate...

Page 42: ...1 5 ft apart The permissible deviation of the gear unit base from the horizontal plane is 0 2 mm per 1 m 0 0072 inch per 3 ft Note The levelness of the mounted base plate gear unit set up surface has to be documented before assembly of the gear unit The record must be kept with these instructions The foundation structure and the screw connection of the gear unit are within the responsibility of th...

Page 43: ...flanges NOTICE Property damage Damage to the gear unit from inadequate lubrication because of leakage from deformed pipework No forces moments or vibrations must work on the pipework flange connections during the pipework installation The pipework must be supported with struts according to the drawings of the gear unit documentation If the pipework is adapted at the construction site the pipes mus...

Page 44: ...cing the couplings observe the operating instructions relating to the couplings Increased system service life and reliability and reduced running noise can be achieved through the least possible radial and angular misalignment NOTICE Property damage Damage in the gear unit from blows or impact is possible Fit the coupling with the aid of suitable fitting equipment The running surfaces of the shaft...

Page 45: ...nected with the coupling and fix it in its position Record the alignment of the motor Note The record must be kept with these instructions Note Observe the special operating instructions of the motor manufacturer for the assembly of the motor DANGER Danger to life from airborne fracture pieces Disregard for the precision of alignment can cause shaft rupture resulting in serious injury and danger t...

Page 46: ...ro voltage before connecting the devices 6 10 Welding work on the mill Note Siemens will accept no liability for damage caused to the gear unit by welding work carried out on the mill DANGER Risk of personal injury from electrical shock or through electrostatic discharge Risk of electrical shock during welding work or risk of personal injury from ignition of a present explosive atmosphere caused b...

Page 47: ...st be checked for correct seating Contact with rotating parts is not permitted DANGER Electrostatic discharge Danger to life from ignition of present explosive atmosphere by electrostatic discharge A potential equalisation in accordance with the applying regulations and directives must be carried out Threaded holes for an earth connection are provided on the gear units or on the output flange This...

Page 48: ... 8 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 14...

Page 49: ... 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 Note D...

Page 50: ...ered to particularly if maintenance work is carried out on the mill during which this is rotated and the gear unit along with it Before the initial start up of the drive unit the exterior and interior preservation might have to be removed if necessary see items 4 4 1 to 4 4 4 the lubricant filled in and various control measures carried out 7 1 1 Removal of preservative agent from exterior NOTICE P...

Page 51: ...l mineral oil or oil on PAO basis Drain preservative oil until operating oil level is reached Castrol Alpha SP 220 S Completely filled with the approved mineral oil see specification in BA 7300 Drain preservative oil and fill with new operating oil Castrol Alpha SP 220 S Castrol Alpha SP 220 Fill with operating oil Castrol Alpha SP 220 S Castrol Tribol 1390 Flush with operating oil and fill with n...

Page 52: ...sion Inhibitor N 213 5 operating oil Drain preservative oil flush with operating oil and fill with new operating oil Mineral oil Oil on PAO basis Completely filled with the approved oil see specification in BA 7300 For operating oil drain oil until operating oil level is reached Other than operating oil drain oil and fill with new operating oil Mineral oil Oil on PAO basis Castrol Alpha SP 220 Fil...

Page 53: ...kin e g the operator s hands The safety notes on the data sheets for the oil used must be observed here Remove any spilled oil immediately using an oil binding agent Observe the manufacturer s instructions for handling lubricants and binding agents Wear suitable protective clothing Screw the oil drain plug back in and or close oil drain cock again Screw back in any screws of the residual oil drain...

Page 54: ... off through the oil drain cocks see Figure 7 in item7 1 3 on the gear unit and the oil supply system It may be re used only as flushing oil Clean the flushing oil before re use The flushing oil must be filtered beforehand or during filling using a nominal filter mesh of 25 μm 0 0010 inch The flushing oil can be reused for a maximum of six flushing operations 7 1 4 1 Oil quantity for flushing For ...

Page 55: ...ny spilled oil immediately using an oil binding agent Observe the manufacturer s instructions for handling lubricants Wear suitable protective clothing 7 1 5 2 Procedure for filling Note The descriptions of the procedure as well as the particularities to be considered regarding the topic Filling in new gear unit oil and additional topics relating to the handling of the gear unit and or the preserv...

Page 56: ...stem For this it is necessary in the meantime to start the low pressure pump of the oil supply system in order to also fill the tilting pad thrust bearing chamber of the gear unit with oil Note Wherever possible warm oil approx 30 C to 50 C should be used for filling so that the viscosity is not too high Note The filling must be carried out while the gear unit and the oil supply system are shut of...

Page 57: ...ubricating and cooling oil by the oil supply system see operating instructions for the Oil supply system 7 1 7 Checks before start up When the installation has been completed and before the start up of the gear unit inspect all drive parts and remove all material residues tools and installation aids Check the entire drive for the following Has the foundation been correctly constructed Are all the ...

Page 58: ...d the tilting pad thrust bearing chamber been filled with oil The oil level must be checked while the oil supply system is running and the gear unit is in standstill Is the oil level between the MIN and MAX marks on the oil level indicators Has all the monitoring equipment been connected up in accordance with the terminal diagram Has the oil supply been checked for correct operation Has the electr...

Page 59: ... 70 If part load is not possible the gear unit can also be run without load and with the rolls and or rollers lifted Unless faults are indicated the load can be increased to full load under continuous observation During this time the following points have to be observed a Noise If possible it must be listened for unusual noises during this time on the gear unit at various points with a suitable in...

Page 60: ...r longer periods we recommend keeping the oil supply system running for approx 60 minutes to prevent heat from building up If there is a sudden stoppage e g caused by a power failure however no damage will result It should be noted that the high pressure pumps must be shut down first and then the low pressure pumps when oil supply systems with a high pressure lubricating circuit are shut off Durin...

Page 61: ... 12 or Table 13 in item 7 3 1 1 Definition of climatic zones A A B North Pole 90 N South Pole 90 S Arctic Circle 66 5 N Antarctic Circle 66 5 S Northern Tropic 23 5 N Southern Tropic 23 5 S Equator 0 7 3 1 1 Renewal of the interior preservation of the gear unit using the oil supply system The prerequisite for this is that the gear unit is still below the mill and connected to the oil supply system...

Page 62: ...ed outdoors 5 3 covered with loose tarpaulin 8 5 under roof 1 20 14 in closed dry room covered at least with loose tarpaulin exposed outdoors 8 5 under roof 1 24 17 in closed dry room seaworthy packaging 2 exposed outdoors 20 20 covered with loose tarpaulin under roof 1 24 24 in closed dry room 1 under roof no direct exposure to sunlight and no direct contact with water rain or draining water 2 Se...

Page 63: ...unit and the tilting pad thrust bearing chamber and seal them Seal input flange with round cord hollow profile 2 see Figure 5 in item 5 2 on the labyrinth Mask the labyrinth seal airtight Fill gear unit with Castrol Corrosion Inhibitor N 213 through the openings of the air filters Filling quantity 1 litre per cubic metre of the entire free interior volume of the gear unit to be enquired from Sieme...

Page 64: ...h loose tarpaulin under roof 1 24 24 in closed dry room 1 under roof no direct exposure to sunlight and no direct contact with water rain or draining water 2 Seaworthy packaging use of wooden box lined with bitumen paper The content is sealed in foil and it must be protected against moisture by addition of drying agents for the prescribed storage period NOTICE Property damage With larger filled in...

Page 65: ... drain the oil before start up until the operating oil level is reached NOTICE Property damage Corrosion damages on the gear unit possible from the loss of the preservative effect Filled gear units can become untight and the gear unit oil might escape Monitor the tightness of the filled gear units Repair leaks Siemens does not accept any liability for damages that are caused from leaking gear unit...

Page 66: ...lting pad thrust bearing chamber 13 Round cord hollow profile The lower oil drain cock on the gear unit 7 must be provided and sealed with a screw plug If not already done beforehand close ventilation of the sealing cap 1 NOTICE Property damage Corrosion is possible when the gear unit is opened for too long Close the gear unit airtight again at the latest one hour after complete filling Note Befor...

Page 67: ...ing must not carry an electrostatic charge The operator must ensure that highly effective mechanisms which can set up a charge in the coating are safely avoided During operation the gear unit must be monitored for the following Oil temperature The gear unit is designed for an oil distribution temperature in continuous operation of 50 C 122 F If the oil supply temperature reaches critical values se...

Page 68: ...th too low an oil level Notice the oil level The oil level must never be below the MIN mark on the oil level indicator Fill up oil if necessary Note Check the oil level in the oil supply system If the oil supply system is equipped with an additional tank OWTM the oil level check on the oil supply system applies not the oil level marks on the gear unit The oil level in the tank must be above the wa...

Page 69: ... be secured against accidental opening If an oil sight glass is used for monitoring the oil level it must be protected against damage Note If any safety device has triggered it must only be possible to start the drive again after releasing the reclosing interlock The operator must ensure this Note Continuous changes in the operating behaviour of the gear unit must be recorded with the aid of trend...

Page 70: ...oval by Siemens or use of spare parts not originally supplied by Siemens DANGER Danger to life from rotating and or moving parts Risk of being gripped or drawn in by rotating and or moving parts Shut down the gear unit and the oil supply system to perform maintenance and or repair work or prior to removing the safeguards Secure the drive unit against accidental start up Attach a notice on the star...

Page 71: ...ve Check oil level at room temperature Refill oil if necessary Contact Customer Service Check date of last oil change Contact Customer Service Check that oil pump is working correctly Repair or replace oil pump Contact Customer Service Check and if necessary replace bearings Check electrical devices and replace them if necessary Oil leakage from gear unit Inadequate sealing of housing covers and o...

Page 72: ...stomer Service Change oil Check oil pump and if necessary replace Consult operating instructions for oil supply system Clean the oil filter Consult operating instructions for oil supply system Check the cooler and replace it and if necessary replace Observe operating instructions for cooler Check cooling water feed and or cooling air feed Observe operating instructions for cooler Check electrical ...

Page 73: ...il Change oil if necessary Water in oil Cooler leaky Water condensing Replace cooler Change oil Reduce water content by heating the oil Fault in oil supply system Operating instructions for the oil supply system NOTICE Property damage Damage can be caused to the gear unit if low quality operating oils are used The quality of the oil used must meet the requirements of the separately enclosed BA 730...

Page 74: ...Secure the drive unit against accidental start up Attach a notice on the start switch stating clearly that work is in progress on the gear unit Observe the relevant accident prevention regulations applicable at the location of the setup site Note For operation and maintenance the operating manuals in the order specific annex must be observed For technical data and control information refer to the ...

Page 75: ...er Note A period of 3 months applies to the cleaning of the air filter If a layer of dust has built up the air filter must already be cleaned even before the 3 month period has expired Note If the air filter is protected with a filter cap it must be disassembled before cleaning the air filter After cleaning the air filter the filter cap must be reassembled Unscrew the air filter including the redu...

Page 76: ... the oil supply system is possible from soiling of the oil After flushing the oil must be carefully drained off through the oil drain cocks see Figure 7 in item 7 1 3 on the gear unit and the oil supply system It may be re used only as flushing oil Clean the flushing oil before re use The flushing oil must be filtered beforehand or during filling using a nominal filter mesh of 25 μm 0 0010 inch Th...

Page 77: ...r contamination every 4 weeks or if there is heavy soiling Optical display see also operating instructions oil supply system Check of the instruments installed on site temperatures oil pressures every 4 weeks Inspection of the oil conducting lines for leaks weekly Oil level check at the oil level indicators on the gear unit and if necessary on the oil supply system version with tank weekly See als...

Page 78: ...ts without oil analysis at the latest after 18 months and or 10000 operating hours See item 10 7 2 Clean the gear unit as required at least every 2 years See item 10 2 Clean the air filter every 3 months See item 10 3 Replacing the air filter cartridge annually or when the air filter is heavily soiled See item 10 3 1 Checking tightness of the foundation bolts every 12 weeks See item 10 7 3 General...

Page 79: ...tainer available at least one litre of oil must be put in a clean and lockable vessel which is suitable for transport The viscosity of the oil sample may not deviate by more than 10 from the that of the oil specified in the Technical data The oil purity should not be below 19 16 according to the standard ISO 4406 Limit values for oil contamination Table 17 Material related contamination limit valu...

Page 80: ... confirmed by the oil supplier If there is a change to another oil grade or make Siemens recommends flushing out the gear unit with the new grade of service oil Note When changing the oil the housing and the oil supply system if present must be cleaned thoroughly from sludge metal particles and oil residue by flushing it with oil Use the same type of oil as is used for normal operation High viscos...

Page 81: ...and or in the documentation included in the delivery The BA 7300 instructions manual relating to the gear unit lubrication and Table T 7300 containing the current lubricant recommendations of Siemens can also be consulted on the internet see back cover Note For the oil filling of the gear unit see the information in item 7 1 5 In alternative to the oil change intervals indicated in Table 16 see it...

Page 82: ...ER Risk of personal injury from electrical shock or through electrostatic discharge Risk of electrical shock during welding work or risk of personal injury from ignition of a present explosive atmosphere caused by electrostatic discharge Before welding work may be conducted on the mill a potential equalisation must be provided according to the regulations and or guidelines applicable for this purp...

Page 83: ...this type in the field can be measured on these measuring points This enables direct comparison with other gear units of the same type and same size A detailed illustration of the gear unit is contained the drawings in the gear unit documentation Vibration measurements and their evaluation should be conducted by Siemens personnel and or in close collaboration with Siemens personnel This way experi...

Page 84: ...d condition NOTICE Property damage Damage to the gear unit is possible When carrying out repair work especial care must be taken that when doing electric welding work at any point on the unit the welding current is not conducted through rolling bearings or other movable connections and measuring equipment The welding current return wire must therefore be connected directly to the part to be welded...

Page 85: ... unit and or in the documentation included in the delivery The total operating oil quantity for the gear unit the oil supply system and the pipework can be found in the set up plan If the oil supply system and the pipework are not included in the scope of delivery by Siemens the operating oil quantity for the gear unit is shown on the rating plate see section 1 Technical data The quantity value sp...

Page 86: ... characteristics of the gear unit thereby causing an active or passive safety hazard Any liability and warranty of Siemens is precluded for damages caused by the use of non original spare parts The same applies to any accessories not supplied by Siemens Please note that certain components often have special production and supply specifications and that Siemens supplies you with spare parts which c...

Page 87: ... 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 partly completed machinery is in conformity with the provisions of the Directive 2014 34 EU OJ L 96 29 03 2014 p 309 356 effe...

Page 88: ... EU and complies with the requirements of Directive 2014 34 EU and the following standards EN 1127 1 2011 EN 13463 1 2009 EN 13463 5 2011 EN 13463 6 2005 EN 13463 8 2003 EN 60079 0 2012 A11 2013 This declaration of conformity is issued under the sole responsibility of the manufacturer The object of the declaration described above is in conformity with the relevant Union harmonisation legislation D...

Page 89: ...ies Subject to modifications Siemens AG 2015 Further Information FLENDER gear units on the Internet www siemens com gearunits FLENDER couplings on the Internet www siemens com couplings Service Support http support automation siemens com WW view en 10803928 133300 Lubricants http support automation siemens com WW view en 42961591 133000 ...

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