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BA 5060 EN 04/2011

10.

Maintenance and repair

51

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10.1

General notes on maintenance

51

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10.1.1

General oil­service lives

52

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10.2

Description of maintenance and repair works

52

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10.2.1

Examine water content of oil, conduct oil analyses

52

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10.2.2

Change oil

53

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10.2.3

Clean the oil filter

55

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10.2.4

Replace wet­air filter

55

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10.2.5

Clean fan and gear unit

56

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10.2.6

Type with oil­dam pipe: recharge with grease

57

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10.2.7

Refill Taconite seals with grease

57

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10.2.8

Check hose lines

57

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10.2.9

Top up oil

57

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10.2.10 Check tightness of fastening bolts

58

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10.3

Final work

58

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10.4

General inspection of the gear unit

58

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10.5

Lubricants

58

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11.

Spare parts, customer service

59

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11.1

Spare parts and customer­service addresses

59

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12.

Declarations

60

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12.1

Declaration of incorporation

60

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12.2

Declaration of conformity

61

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Содержание Flender H2NV Series

Страница 1: ...FLENDER gear units Cooling tower gear unit H2NV Sizes 105 to 112 Assembly and operating instructions BA 5060 EN 04 2011 ...

Страница 2: ...ons 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: ...14 4 2 Transport 14 4 3 Storing the gear unit 16 4 4 Standard preservation 16 4 4 1 Interior preservation with preservative agent 17 4 4 2 Exterior preservation 18 5 Technical description 19 5 1 General description 19 5 2 Housing 19 5 3 Toothed components 20 5 4 Combined splash and forced lubrication by means of an attached oil pump 21 5 4 1 Pump 22 5 4 1 1 Filter 22 5 5 Shaft bearings 22 5 6 Shaf...

Страница 6: ... before start up 38 7 1 1 Removal of preservative agent 38 7 1 2 Filling with lubricant 39 7 1 2 1 Oil quantities 40 7 1 2 2 Grease lubricated rolling bearing 40 7 2 Start up 41 7 2 1 Oil level 41 7 2 2 Connection of monitoring instruments 41 7 2 3 Gear unit with backstop 42 7 2 3 1 Checking the direction of rotation using a phase sequence indicator 42 7 2 3 2 Direction of rotation check by dismou...

Страница 7: ...ce wet air filter 55 10 2 5 Clean fan and gear unit 56 10 2 6 Type with oil dam pipe recharge with grease 57 10 2 7 Refill Taconite seals with grease 57 10 2 8 Check hose lines 57 10 2 9 Top up oil 57 10 2 10 Check tightness of fastening bolts 58 10 3 Final work 58 10 4 General inspection of the gear unit 58 10 5 Lubricants 58 11 Spare parts customer service 59 11 1 Spare parts and customer servic...

Страница 8: ... oil viscosity oil quantity Total weight in kg Instructions number s Special information Manufacturer and place of manufacture Type size Country of origin Power rating P2 in kW or torque T2 in Nm Speed n1 Example H 2 N V 110 Size 105 112 Fitting position V Vertical Type of output shaft N Solid shaft with reinforced bearing arrangement Number of stages 2 Gear unit type H Helical gear unit For speci...

Страница 9: ... 40 C By adopting various suitable measures the gear unit may be used at ambient temperatures of between 40 C and 60 C However this must always be approved by Siemens In individual cases the permissible ambient temperature range specified on the rating plate always applies 1 3 Measuring surface sound pressure level The measuring surface sound level of the gear unit at a distance of 1 metre can be ...

Страница 10: ...7 69 70 71 73 74 76 18 3000 84 85 88 90 92 1500 73 75 77 78 80 82 84 86 1000 67 68 71 72 73 75 77 78 28 750 64 65 67 68 69 71 73 74 1 3 2 Measuring surface sound pressure level for helical gear units without fan Table 3 Measuring surface sound pressure level LpA in dB A for helical gear units without fan Type iN n1 1 min Gear unit size 105 106 107 108 109 110 111 112 H2 6 3 1500 74 75 76 77 79 79 ...

Страница 11: ...art and is delivered in a condition for safe and reliable use It complies with the requirements in Directive 94 9 EC 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 thes...

Страница 12: ...d to safety All work on 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 In addition the gear unit must be secured to the fan at the output side in su...

Страница 13: ...oil which may have collected should be removed at once with an oil binding agent Preservative agents should be stored separately from used oil Used oil preservative agents oil binding agents and oil soaked cloths must be disposed of in accordance with environmental legislation Disposal of the gear unit after its useful life Drain all the operating oil preservative agent and or cooling agent from t...

Страница 14: ...ng complies with the HPE Packaging Guidelines The symbols marked on the packing must be observed at all times They 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 free shaft ends are knocked th...

Страница 15: ...lted Fig 4 Attachment points on gear unit with motor If the gear unit is to be transported with add on parts additional attachment points may be required For a detailed illustration of the gear unit and the position of the attachment points please refer to the drawings of the order specific gear unit documentation ...

Страница 16: ...ar unit is provided with an interior preservative agent the free shaft ends are painted for protection The characteristics of the external coat depend on the ambient conditions stipulated in the order relating to method of transport and area of application The gear unit is normally delivered completely ready with a priming and a finish coat The coating complies with the requirements for the conduc...

Страница 17: ...r preservation with preservative agent Table 4 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 in the gear unit Replace wet air filter with screw plug Prior to start up replace screw plug with wet air filter...

Страница 18: ... tropical conditions soluble with CH compounds In case of outdoor storage up to 12 months 2 1 The gear unit must be stored 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 co...

Страница 19: ...ised by a low noise level which is achieved by helical gears with a high contact ratio and a sound damping housing The good temperature characteristics of the gear unit are achieved by its high degree of efficiency large housing surface and performance related cooling system 5 2 Housing The housing is made of cast iron if necessary it may also be made of steel The housing is made in one part It is...

Страница 20: ...tion 13 Residual oil drain 7 Rating plate A detailed view of the gear unit can be obtained from the drawings in the gear unit documentation 5 3 Toothed components The toothed components of the gear unit are case hardened Helical gear teeth are ground The high quality of the teeth leads to a significant noise reduction and ensures safe and reliable running The gear wheels are joined to the shafts b...

Страница 21: ...g bearing arranged at the bottom is grease lubricated The oil supply system is part of the commission and comprises a flanged on or motor pump a coarse filter a pressure monitoring device pipework 1 3 2 Fig 6 Gear unit fitted with flanged on pump 1 Flanged on pump 2 Pressure monitor 3 Coarse filter incorporated in the gear unit A detailed view of the gear unit can be obtained from the drawings in ...

Страница 22: ...he 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 precondition of a proper functioning high reliability and long service life of the pump is in particular a clean and lubrifying delivery medium 5 4 1 1 Filter The filter protects downstream aggregates measuring and control devices...

Страница 23: ...n against dry running a re greasable Taconite seal may be used see item 5 6 4 Fig 8 Radial shaft sealing ring 5 6 2 Oil dam pipe By sealing the vertically downward pointing input shaft with a contact free and wear free shaft seal a so called oil dam pipe the shaft outlet is sealed absolutely tight to prevent oil escaping This system is used only for forced lubrication The lower anti friction beari...

Страница 24: ...nning 1 Set screw 3 Ring 2 Radial shaft sealing ring 4 Grease filling 5 6 4 Taconite seal Taconite seals have been specially developed for use in a dusty environment The penetration of dust is prevented by a combination of three sealing elements radial shaft sealing ring lamellar seal and grease charged labyrinth seal 1 2 3 4 Fig 11 Taconite seal 1 Radial shaft sealing ring 3 Grease charged labyri...

Страница 25: ...he motor must not be run adversely to the stop direction of the gear unit Observe the notice fixed to the gear unit The backstop must be replaced after 10 000 operating hours If the gear unit is operated at speeds below the speed at which the backstop disengages the backstops must be regularly renewed The frequency of change is stated on the dimensioned drawing prepared in accordance with the orde...

Страница 26: ...e cooling effect is considerably reduced if the fan or the housing surface are dirty see section 10 Maintenance and repair 5 9 Couplings clutches As a rule flexible couplings should be provided for the drive of the gear unit The fitted fan must not cause axial forces exceeding the maximum forces agreed in the contract For maintenance and operation of the couplings refer to the specific operating i...

Страница 27: ...ements can be controlled by a temperature monitor or a Pt 100 resistance thermometer which emits a signal when minimum and maximum temperatures are reached the signal requires amplification When switching the heating elements by means of a Pt 100 resistance thermometer the signal must be processed by an evaluating instrument to be provided by the customer The switch point to be set as well as the ...

Страница 28: ...eating elements For a detailed view refer to the drawings in the gear unit documentation Be sure to observe the operating instructions of the oil level monitoring system for operation and maintenance Refer to the separate order specific data sheet Technical data and the List of equipment for technical data and control information The gear unit is fitted with a level monitor which complies with the...

Страница 29: ...r unit can be obtained from the drawings in the gear unit documentation When operating and servicing the components observe the operating instructions relating to the components For technical data refer to the data sheet and or the list of equipment 5 13 Vibration monitoring of the bearings The gear unit has been prepared for bearing monitoring For fitting the measuring nipples for shock pulse tra...

Страница 30: ...ing a sunshade roof or fitting an additional cooling unit or fitting the oil sump with a temperature monitoring device with a cut out function The ambient temperature range indicated on the rating plate must be adhered to 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 ...

Страница 31: ...wise specified the components may be heated inductively with a burner or in a furnace Take precautions to avoid burns from hot parts Wear suitable protective gloves Protect shaft sealing rings from damage and heating to over 100 C use heat protective screens to protect against radiant heat The elements must be pulled smartly onto the shaft as far as stated in the dimensioned drawing prepared in ac...

Страница 32: ... others the special requirements for the couplings refer to the specific operating instructions Non observance can cause shaft rupture resulting in serious injury or danger of life 6 3 2 Steel frame The steel frame must be horizontal and plain The gear unit must not be excessively stressed when tensioning the fastening bolts The steel frame should be designed in such a way that no resonance vibrat...

Страница 33: ...sibly large errors in the alignment of the shaft ends to be connected due to angular and or axial misalignments result in premature wear and or material damage Insufficiently 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 For permissible alignment errors in case of couplings supplied b...

Страница 34: ...al loads occurring For alignment of the drive components vertical direction it is recommended to use packing or foil plates underneath the mounting feet The use of claws with set screws on the foundation for lateral adjustment of the drive components is also advantageous 6 5 Gear unit with wiring in the terminal box All pre wired appliances see order specific list of equipment must be wired in acc...

Страница 35: ... electrical means such as monitoring devices switches Pt 100 resistance thermometers without identification in accordance with Directive 94 9 EC are to be connected intrinsically safely by suitable isolation amplifiers 6 8 Final work After installation of the gear unit check all screw connections for tight fit Check the alignment after tightening the fastening elements the alignment must not have ...

Страница 36: ...forces The 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 s...

Страница 37: ...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 38: ...w the oil drain plug or open 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 to do so Dispose of remaining preservative 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 ...

Страница 39: ...r filling with oil Fill the gear unit with fresh oil using a filter maximum mesh 25 μm The quality of the oil used must meet the requirements 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 document supplied separately because they have been teste...

Страница 40: ...ex works with the necessary grease charge for the lower output shaft bearing 1 Lower output shaft bearing 2 Lubricating point 1 2 Fig 20 Lubricating point for lower output shaft bearing A detailed view of the gear unit can be obtained from the drawings in the gear unit documentation For longer periods of storage 6 months in a situation which is different from the mounting position a corresponding ...

Страница 41: ...dipstick 1 Should both be available use of the oil dipstick has priority When the oil is cool the oil level should be at the upper mark on the oil dipstick screwed in When the oil is warm it may slightly exceed this mark It must in no case be allowed to fall below the mark If necessary top up to the correct level The grease lubricated output bearing is protected by an oil dam pipe from oil see ite...

Страница 42: ...quency of change is stated on the dimensioned drawing prepared in accordance with the order and on a plate on the gear unit This plate is attached to the gear unit housing close to the backstop 7 2 3 1 Checking the direction of rotation using a phase sequence indicator Before connecting the motor determine the direction of rotation of the three phase current supply using a phase sequence indicator...

Страница 43: ... 5 13 vibration measurements must be taken in order to obtain initial values and or standard values for the diagnosis These measurements must be recorded and filed 7 2 6 Heating Never switch the heating on unless complete immersion of the heating elements in the oil bath is ensured Fire hazard The correct setting of the switch points must be checked 7 2 7 Checking procedure The following visual ch...

Страница 44: ...rculation cooling and or non contacting shaft seals should be filled with preservative agent and run without load 7 3 1 1 Interior preservation procedure Stop the gear unit Drain the oil into a suitable container see section 10 Maintenance and repair Unscrew the oil dipstick or screw plug Pour in the preservative agent through the hole up to the upper mark on the oil dipstick or to the middle of t...

Страница 45: ...reservation procedure 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 6 in item 4 4 2 ...

Страница 46: ...with present measuring sequence 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 8 2 Oil level To check the oil level stop operation of the gear unit Depending on the features the following oil levels apply Middle of the oil sight glass Upper mark on the oil dipstick When the oil is hot the oi...

Страница 47: ...rt switch In addition the gear unit must be secured to the fan at the output side in such a manner that the fan cannot drive the gear unit 9 2 Possible faults Table 11 Faults causes and remedy Faults Causes Remedy Changes in gear noise Damage to gear teeth Excessive bearing play Bearing defective Overrunning noise caused by the frequency converter operation Contact Customer Service Check all tooth...

Страница 48: ...oil change oil if necessary Test the oil change oil if necessary Test the oil change oil if necessary Oil foams in sump Water in oil Gear unit exposed to cold air from machine room ventilator Water condensing Protect gear unit with suitable heat insulation Close air outlet or alter its direction by structural measures Wet air filter changes colour from top to bottom Water in oil Contact Customer S...

Страница 49: ... monitor triggers alarm Pressure falls below the minimum pressure specified in the order related documentation Check oil level at room temperature and if necessary top up oil Check and if necessary clean oil filter Contact Customer Service Check that oil pump is functioning correctly Repair or replace oil pump Wet air filter completely discoloured Wet air filter worn out Replace wet air filter ...

Страница 50: ...xtending 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 sh...

Страница 51: ...is also applies if the maintenance work is included in the operator s internal maintenance schedules Table 13 Maintenance and repair work Measures Periods Remarks Check the oil temperature Daily Check for unusual gear unit noise Daily Check the oil level Monthly Middle of the oil sight glass and or Upper mark on the oil dipstick Comparison of vibration values for bearing monitoring with initial va...

Страница 52: ... quality They are calculated on the basis of an average oil temperature of 80 C for mineral oils biologically degradable oils and physiologically safe synthetic esters oils 2 years or 10 000 operating hours does not apply to natural esters such as rape seed oils for poly α olefins and polyglycols 4 years or 20 000 operating hours The actual service lives may differ The general rule is that an incr...

Страница 53: ... or with other synthetic oils When changing to any different oil type the gear unit must be flushed thoroughly using the new oil type When changing the oil the housing and the oil supply system must be flushed with oil to remove sludge metal particles and oil residue Use the same type of oil as is used for normal operation High viscosity oils must be heated beforehand using suitable means Ensure t...

Страница 54: ...e housing Unscrew the oil drain plug or open the oil drain cock and drain the oil into the collecting container There is a danger of scalding from the hot oil emerging from the housing Wear protective gloves Any oil spillage must be removed immediately with an oil binding agent Check the condition of the sealing ring the sealing ring is vulcanised onto the oil drain plug If necessary use a new oil...

Страница 55: ...spillage must be removed immediately with an oil binding agent Demount the oil filter and clean Damaged filters and sealing rings must be replaced by one ones Screw in the oil filter with sealing ring and drain plug Fill with oil see item 7 1 2 10 2 4 Replace wet air filter The wet air filter has a container filled with silica gel The air humidity absorbed by the silica gel changes the colour of t...

Страница 56: ...he cover plates Using a stiff brush remove any dirt adhering to the fan wheel cover plates and safety grid Remove any corrosion Refit the cover plates Screw the safety grid to the motor bell housing using the fastening bolts It must be ensured that the cover plates are correctly fastened The fan must not come into contact with the cover plates To prevent the build up of dust on the gear unit clean...

Страница 57: ...ill Taconite seals with grease Inject approx 30 g lithium based bearing grease into each of the lubrication points of the Taconite seal The lubrication points are fitted with flat grease nipples type AM10x1 to DIN 3404 Remove and dispose of any old grease escaping in accordance with regulations 10 2 8 Check hose lines Even when adequately stored and subjected to permissible loads hoses and hose li...

Страница 58: ...the oils listed in table T 7300 for a link see the BA 7300 document 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 the t...

Страница 59: ...eby 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 technical dev...

Страница 60: ...ut in Directive 2006 42 EC Annex I are applied and are satisfied 1 1 1 1 2 1 1 3 1 1 5 1 2 6 1 3 1 1 3 4 1 3 6 1 3 8 1 1 4 1 1 4 2 1 1 5 1 1 5 2 1 5 4 1 5 11 1 5 13 1 6 1 1 6 2 1 7 1 1 7 2 1 7 4 1 7 4 3 The partly completed machinery is in conformity with the provisions of the Directive s 94 9 EC The manufacturer undertakes in response to a reasoned request by the national authorities to transmit ...

Страница 61: ...assembly and operating instructions Cooling tower gear unit H2NV Sizes 105 to 112 is equipment in the meaning of Article 1 and Article 8 Paragraph 1 c of Directive 94 9 EC and complies with the requirements of Directive 94 9 EC and the following standards DIN EN 1127 1 02 2008 DIN EN 13463 1 07 2009 DIN EN 13463 5 03 2004 DIN EN 13463 6 07 2005 DIN EN 13463 8 01 2004 DIN EN 60079 0 05 2007 Penig 2...

Страница 62: ...Siemens AG Industry Sector Mechanical Drives Alfred Flender Straße 77 46395 Bocholt GERMANY www siemens com drivetechnology Subject to modifications Siemens AG 2011 ...

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