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BA 5814 en 09/2014

7.3

Removal from service

•

Switch off the drive unit.

Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch!

•

Start the gear unit and allow it to run briefly (5 to 10 minutes) approx. every 3 weeks (during a shutdown
period no longer than 6 months).

•

Treat the gear unit with preservative agent, see items 7.3.1 and 7.3.2 (before a shutdown period
exceeding 6 months).

7.3.1

Interior preservation for longer disuse

7.3.1.1 Interiorpreservation procedure

•

Place a suitable container under the oildraining point of the gearunit housing.

•

Unscrew the oildrain plug and/or open the oildrain cock.

•

Drain the oil into a suitable container (see section 10, "Maintenance and Repair").

There is a danger of scalding from the hot oil emerging from the housing. Wear safety
gloves and safety glasses!
Any oil spillage must be removed immediately with an oilbinding agent.

Check the condition of the sealing ring (the sealing ring is vulcanised onto the oildrain plug);
if necessary, use a new oildrain plug.

•

Close the oildrain cock and/or screw in the oildrain plug.

•

Unscrew and remove the air filter from the housing top.

Carefully clean the air filter (see item 10.2.3) and keep it on a safe place (it will be
required when starting up again).

•

Fill the gear unit with "Castrol Alpha SP 220 S", until the gears are immersed.
Filling quantity according to the gearunit dimensions (length x width x height) x 0.1.

In all cases the special oil "Castrol Alpha SP 220 S" with additional
corrosionprevention features (addition "S") must be used.

Any oil spillage must be removed immediately with an oilbinding agent.

•

Start the gear unit and allow it to idle briefly.

•

Replace the air filter with the plug screw.

•

Screw in the screw plug.

The labyrinth seals on the shafts must be sealed airtight at the latest one hour after
filling in the preservative oil (using adhesive tape) (see figure 4).
Before restarting the gear unit the adhesive tape must be removed.

Replace the screw plug with the air filter.

If the gear unit is to be filled with a PGbased synthetic operating oil after preservation,
the preservative oil must be drained off before initial startup and the gear unit
thoroughly flushed out with operating oil (for this see also item 10.2.2). The flushing
oil must not be used for operation of the unit.

Gear unit with auxiliary drive:

For interior preservation works on the auxiliary drive the special operating instructions should
be observed.

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Содержание FLENDER GHDP

Страница 1: ...FLENDER gear units Glazing cylinder gear unit GHZP GHDP Sizes 360 to 2680 Assembly and operating instructions BA 5814 en 09 2014 ...

Страница 2: ...uctions 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 ...

Страница 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...

Страница 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...

Страница 5: ... seals 17 4 4 2 Interior preservation with preservative agent 17 4 4 2 1 Re preserving the interior of the gear unit in case of longer periods of storage 18 4 4 3 Exterior preservation 19 4 4 3 1 Re preservation of the metallic bright exterior surfaces of the gear unit 19 5 Technical description 20 5 1 General description 20 5 2 Housing 20 5 3 Toothed components 21 5 4 Lubrication 22 5 4 1 Force f...

Страница 6: ... 38 6 7 1 Gear unit with add on oil supply system 39 6 8 Gear unit with add on components 39 6 9 Bearing monitoring system 40 6 10 Gear unit with oil temperature monitoring system 40 6 11 Final work 40 6 12 Screw connection classes tightening torques and initial tensioning forces 41 6 12 1 Screw connection classes 41 6 12 2 Tightening torques and initial tensioning forces 41 7 Start up 43 7 1 Proc...

Страница 7: ...lives of oils 55 10 2 Description of maintenance and repair works 55 10 2 1 Test the water content of the oil 55 10 2 2 Change oil 55 10 2 3 Clean the air filter 56 10 2 4 Clean the gear unit 57 10 2 5 Check hose lines 57 10 2 6 Check tightness of screw connections 57 10 3 Final work 57 10 4 General inspection of the gear unit 57 10 5 Lubricants 58 11 Spare parts customer service 59 11 1 Stocking ...

Страница 8: ...Type size Manufacturer and place of manufacture Power rating PRDC PNRL in kW Country of origin Speed n1 Example G H Z P 360 Size 360 2680 Field of application P Paper processing machines Number of stages Z 2 stage D 3 stage Version H Hollow shaft design Gear unit type G Glazing cylinder gear unit Data on weights and measuring surface sound pressure levels of the various gear types are given in ite...

Страница 9: ...9 61 BA 5814 en 09 2014 1 2 Versions 1 2 1 Gear unit types GHZP 360 680 GHDP 360 680 GHZP 2450 2680 GHDP 2450 2680 Fig 1 Gear type ...

Страница 10: ...units if applicable With outgoing and incoming pipes the flanges are taken as interfaces The sound pressure levels stated in the table were obtained by statistical calculation by our Quality Control Dept The gear unit can be statistically expected to comply with these sound pressure levels If repeat measurements on site do not produce conclusive results with regard to measuring technology the meas...

Страница 11: ...dition 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 In the interest of technical progress we reserve the ri...

Страница 12: ... 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 The add on or external oil supply system must also be stopped if installed No electrical welding work must be done at all on the drive syst...

Страница 13: ... 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 ...

Страница 14: ...t Unless 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 exam...

Страница 15: ...nts on gear units without auxiliary drive Fig 4 Attachment points on gear units with auxiliary drive unit For a detailed illustration of the gear unit and the position of the attachment points please refer to the drawings in the order specific gear unit documentation ...

Страница 16: ...re painted for protection The properties of the outer paint coat are as follows Resistant to acids weak alkalis solvents atmospheric action temperatures up to 120 C briefly up to 140 C and to tropical conditions The gear unit is normally delivered completely ready with a priming and a finish coat Where gear units are delivered with a priming coat only it is necessary to apply a finish coat in acco...

Страница 17: ...ould be filled with preservative agent and run without load Table 2 Durability period and measures for interior preservation when using mineral oil or PAO based synthetic oil Duration of protection Preservative agent Special measures Up to 6 months Castrol Alpha SP 220 S None Up to 24 months Close all holes on the gear unit Replace the air filter with the plug screw Prior to start up replace screw...

Страница 18: ... longer than 24 months see table 2 or 36 months see table 3 the interior preservation of the gear unit must be renewed The following procedure is recommended Place a suitable container under the oil draining point of the gear unit housing Unscrew the oil drain plug and or open the oil drain cock and drain the used preservation oil into a suitable container Dispose of the residue of the preservativ...

Страница 19: ...in the position of use in a sheltered place it must be placed on a vibration free dry wooden base and covered over 2 If the gear unit is being stored out of doors it must be particularly carefully covered and care must be taken that neither moisture nor foreign material can collect on the unit Waterlogging should be avoided The procedure for interior and exterior preservation treatment is describe...

Страница 20: ...ure characteristics of the gear unit are achieved by its high degree of efficiency and its large housing surface area The gear unit must be supplied with oil by an add on or external oil supply system 5 2 Housing The housing is in two sections and made of cast iron if required it may also be of steel The housing is rigid in design and due to its form has excellent noise and temperature characteris...

Страница 21: ... Oil level sight glass angular oil level indicator 7 Shaft seals 14 Inspection cover A detailed view of the gear unit can be obtained from the drawings in the gear unit documentation 5 3 Toothed components The externally toothed components of the gear unit are case hardened The helical gear teeth are ground The high quality of the teeth leads to a significant noise reduction and ensures safe and r...

Страница 22: ...tem observe the operating instructions of the components For technical data refer to the data sheet and or the list of equipment For the exact position and size and a view of the connections of the pressure and suction lines refer to the drawings in the gear unit documentation 5 5 Shaft bearings Drive shafts and helical gear are fitted in rolling bearings 5 6 Shaft seals Radial shaft sealing rings...

Страница 23: ...operating instructions of this oil supply system should 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 8 Couplings clutches As a rule cardan shafts or all steel couplings should be provided for the gear unit drive If rigid couplings or other in and or output elements which create additional r...

Страница 24: ...ar unit to be operated at a lower output speed in the same direction of rotation The auxiliary drive is connected with the main gear unit by an overrunning clutch For the basic drive train configuration refer to figure 10 Basic design of the gear unit with main and auxiliary drives 7 6 5 2 4 3 1 Fig 10 Design of the gear unit with main and auxiliary drives 1 Main motor 4 Main gear unit 7 Output sh...

Страница 25: ...it The Special operating instructions should be observed for operation of the auxiliary gear unit Type KF MOTOX bevel gear motor To avoid overspeeds in case of malfunctions of the overrunning clutch the drive combination must be equipped with a speed monitoring device by the customer for safety reasons The speed monitoring device consists of a pulse generator fitted in the intermediate flange figu...

Страница 26: ... oil circuit of the gear unit Maintenance and oil change take place simultaneously with maintenance and oil change of the main drive The overrunning clutch is provided with centrifugally operated grippers If the main gear unit is rotating in the specified direction of rotation the inner ring will rotate together with the grippers while the outer ring remains stationary From a certain speed of rota...

Страница 27: ...d as an earthing point for welding operations Toothed parts and bearings may be irreparably damaged by welding All the fastening points provided by the design of the unit must be used Screws which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type Take precautions to avoid burns from hot parts Wear suitable protective gloves To ...

Страница 28: ...k the parts with a suitable tool and clean them again Coat with a suitable lubricant to prevent frictional corrosion of the contact surfaces 6 2 1 1 Fitting Observe details at item 4 2 Transport Fit the gear unit by means of nut and threaded spindle The counterforce is provided by the hollow shaft The hollow shaft must be exactly aligned with the machine shaft to avoid canting 6 7 5 4 2 3 1 Fig 12...

Страница 29: ... Depending on the facilities available on site the gear unit may be forced off the shaft using forcing off bolts in an end plate see figure 14 a central threaded spindle or preferably a hydraulic lifting unit 2 1 3 4 5 6 Fig 14 Demounting 1 Machine shaft 4 Hydraulic lifting unit 2 Hollow shaft 5 Threaded spindle 3 Parallel key 6 Auxiliary plate for forcing out Instead of the nut and threaded spind...

Страница 30: ...n 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 grease Observe manufacturer s instructions for handling lubricants and solvents 6 3 1 1 Fitting Fit the gear unit by means of nut and threaded s...

Страница 31: ...the shrink disk Before beginning fitting work the hollow shaft and the stub shaft must be carefully cleaned Observe manufacturer s instructions for handling lubricants and solvents Do not allow cleaning agent or solvent to affect surfaces with paint coating The bore of the hollow shaft and the stub shaft must be absolutely clean and free of grease and oil in the area of the shrink disk seat This i...

Страница 32: ...ly To avoid overloading the individual bolts the maximum tightening torque see table 5 must not be exceeded If when tightening the clamping bolts at maximum tightening torque the inner and outer ring are not aligned Siemens must be consulted Table 5 Maximum tightening torques for tensioning bolts Tensioning bolt thread Maximum tightening torque per bolt Tensioning bolt thread Maximum tightening to...

Страница 33: ...llow shaft Pull the shrink disk off the hollow shaft For transporting and lifting the shrink disk it may be required to use a suitable lifting device 6 3 2 3 Cleaning and greasing the shrink disk Only dirty shrink disks must be disassembled and cleaned Check all parts for any damage Damaged parts must be replaced with new ones The use of damaged parts is not permitted Only the complete shrink disk...

Страница 34: ...ufacturer s instructions for handling lubricants Fitting and start up must be carried out by properly trained specialist personnel 6 3 2 4 Re fitting the shrink disk For re fitting the shrink disk the procedure described in item 6 3 2 1 must be adhered to 6 3 2 5 Inspection of the shrink disk In all cases the inspection of the shrink disk should be carried out simultaneously with the inspection of...

Страница 35: ...ng against the driven machine should be rounded and well greased to reduce the risk of seizing at this point 6 4 Fitting the torque arm for the gear unit housing 6 5 Support bracket Fig 18 Support bracket For the position of the torque arm refer to the dimensioned drawing in the gear unit documentation The support bracket must be vertical and level in the area of the torque reaction arm It must be...

Страница 36: ... into contact with the shaft sealing rings Ensure adequate ventilation Do not smoke Danger of explosion Fit and secure input drive elements e g coupling parts on shafts If they are to be heated before fitting refer to the dimensioned drawings in the coupling documentation for the correct joining temperatures Unless specified otherwise the components may be heated inductively with a burner or in a ...

Страница 37: ...ciently rigid base frames or sub structures can also during operation cause a radial and or axial misalignment which cannot be measured when the unit is at a standstill Gear units with a weight that 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 requ...

Страница 38: ...tructures can also during operation cause a radial and or axial misalignment which cannot be measured when the unit is at a standstill For permissible alignment errors in case of couplings supplied by Siemens please refer to the operating instructions manuals for the couplings If you use couplings manufactured by other manufacturers ask these manufacturers which alignment errors are permissible st...

Страница 39: ...ystem before starting the unit up all monitors must be connected so as to be ready for operation In case of gear units with add on oil supply system before starting the unit up the oil flow limiter and the pressure monitor must always be connected so as to be ready for operation Remove the sockets and or flanges from the suction and delivery lines prior to connecting the system Fit the system to t...

Страница 40: ... secured against accidental opening The gear unit must be protected against falling objects Protective devices for rotating parts must be checked for correct seating Contact with rotating parts is not permitted A potential equalisation in accordance with the applying regulations and directives must be carried out If no threaded holes for earth connection are available on the gear unit other approp...

Страница 41: ...tightening torques apply to friction coefficients of μtotal 0 14 The friction coefficient μtotal 0 14 applies here to lightly oiled steel bolts black annealed or phosphatised and dry cut mating threads in steel or cast iron Lubricants which alter the friction coefficient must not be used and may overload the screw connection Table 8 Initial tensioning forces and tightening torques for screw connec...

Страница 42: ...6810 6080 M56 8 8 568000 363000 227000 7430 6400 5710 10 9 806000 516000 323000 10500 9090 8120 12 9 944000 604000 378000 12300 10600 9500 M64 8 8 744000 476000 298000 11000 9480 8460 10 9 1060000 676000 423000 15600 13500 12000 12 9 1240000 792000 495000 18300 15800 14100 M72x6 8 8 944000 604000 378000 15500 13400 11900 10 9 1340000 856000 535000 22000 18900 16900 12 9 1570000 1000000 628000 2580...

Страница 43: ...ug with the air filter see also notice on the gear unit Remove adhesive tape from the labyrinth seals The location of the oil draining points is marked by an appropriate symbol on the dimensioned drawing in the gear unit documentation Oil draining point Place suitable containers under the oil draining points Unscrew the oil drain plug and or open the oil drain cock Remove remaining preservative ag...

Страница 44: ...ents of the separately supplied BA 7300 instructions manual otherwise the guarantee given by Siemens will lapse We urgently recommend using one of the oils 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 Information on the type quantity and viscosity of the oil is given on the rating plate on the gear...

Страница 45: ...d operating direction of rotation When rotating in the operating direction of rotation the blocking action of the overrunning clutch carrier operation becomes effective Coupling and thus rotation of the output shaft of the main gear unit in operating direction of rotation takes place To avoid damaging the backstop or the gear unit the motor must not be run adversely to the stop direction of the ge...

Страница 46: ...an 1 5 bar 7 2 4 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 maximum permissible oil sump temperature is 90 C applies to mineral oil or 100 C applies to synthetic oil At higher temperatures the gear unit must be shut down immediately and the Sie...

Страница 47: ...move the air filter from the housing top Carefully clean the air filter see item 10 2 3 and keep it on a safe place it will be required when starting up again Fill the gear unit with Castrol Alpha SP 220 S until the gears are immersed Filling quantity according to the gear unit dimensions length x width x height x 0 1 In all cases the special oil Castrol Alpha SP 220 S with additional corrosion pr...

Страница 48: ...re Clean the surfaces For separation between the sealing lip of the shaft sealing ring and the preservative agent the shaft should be brushed with grease in way of the sealing lip Apply preservative agent For preservative agent see table 4 in item 4 4 3 Seal the labyrinths at the shafts ends ...

Страница 49: ... 1 5 bar Change in gear noise Possible oil leakage at the housing and shaft seals Correct oil level see also section 7 Start up 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 sight glass of angular oil level indicator It must not be allowed to fall below the lower mark If necessary top up to the c...

Страница 50: ...ntentionally Attach a warning notice to the start switch 9 2 Possible faults Table 9 Faults causes and remedy Faults Causes Remedy Changes in gear unit noise Damage to gear teeth Excessive bearing play Bearing defective Contact Customer Service Check all toothed components and replace any damaged parts Contact Customer Service Adjust bearing backlash Contact Customer Service Replace defective bear...

Страница 51: ...oams in oil sump Oil supply system defective Gear unit exposed to cold air from machine room ventilator Water condensing Climatic conditions Check state of oil by the test tube method for water contamination Have oil analysed by a chemical laboratory Check the oil supply system replace any defective parts Consult operating instructions for oil supply system Protect gear unit with suitable heat ins...

Страница 52: ...or will start but the output shaft of the main gear unit will not rotate Wrong direction of rotation of the auxiliary motor Incorrect installation and or defect of cage with grippers of overrunning clutch Overrunning clutch defective Change polarity of motor Contact Customer Service Install cage of overrunning clutch turned by 180 and or replace Contact Customer Service Install a new overrunning c...

Страница 53: ... 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 ...

Страница 54: ... the periods indicated below must be adjusted accordingly Table 11 Maintenance and repair work Measures Periods Remarks Check the oil temperature Daily Check for unusual gear unit noise Daily Check the oil level Monthly Check the gear unit for leaks Monthly Test the water content of the oil After approx 400 operating hours once per year at least See item 10 2 1 Perform the first oil change Approx ...

Страница 55: ...ce 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 sample must be taken downstream of the filter of the oil supply system while the gear unit is running A suitable connection point is normally located upstream of the gear unit input e g oil drain cock in the pressure line A special sample container ...

Страница 56: ...e gear unit housing Unscrew the air filter on the top of the housing Unscrew the oil drain plug and or the open the 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 safety gloves and safety glasses Any oil spillage ...

Страница 57: ...lines must be inspected for safe working condition by an expert before the plant is first put into operation and thereafter at least once a year If during inspections faults are found these must be rectified immediately or suitable countermeasures taken 10 2 6 Check tightness of screw connections The instructions in item 10 1 must be observed Close the stop valves in the coolant in and outflow pip...

Страница 58: ...cosity and required quantity of the oil is given on the rating plate on the gear unit and or in the supplied documentation The oil quantity shown on the rating plate is to be understood as an approximate quantity The marks on the oil dipstick or oil sight glass are decisive for the amount of oil to be filled in The BA 7300 instructions manual relating to the gear unit lubrication and table T 7300 ...

Страница 59: ...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 ...

Страница 60: ... 1 1 4 2 1 1 5 1 1 5 2 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 1 5 9 1 5 10 1 5 11 1 5 13 1 5 15 1 6 1 1 6 2 1 7 1 1 7 1 1 1 7 1 2 1 7 2 1 7 4 1 7 4 1 1 7 4 2 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...

Страница 61: ...ject to modifications Siemens AG 2014 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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