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FLENDER gear units

REDUREX

Gear Unit

Assembly and operating instructions
BA 5200 EN 08/2010

Содержание REDUREX

Страница 1: ...FLENDER gear units REDUREX Gear Unit Assembly and operating instructions BA 5200 EN 08 2010 ...

Страница 2: ... 12 12 12 12 10 Maintenance and repair 12 12 12 12 12 12 12 12 12 12 9 Faults causes and remedy 12 12 12 12 12 12 12 12 12 12 8 Operation 12 12 12 12 12 12 12 12 12 12 7 Start up 12 12 12 12 12 12 12 12 12 12 6 Fitting 12 12 12 12 12 12 12 12 12 12 5 Technical description 12 12 12 12 12 12 12 12 12 12 4 Transport and storage 12 12 12 12 12 12 12 12 12 12 3 Safety instructions 12 12 12 12 12 12 12 ...

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: ...vation with preservative agent 19 4 4 2 Exterior preservation 19 5 Technical description 20 5 1 General description 20 5 2 Housing 20 5 3 Toothed components 22 5 4 Lubrication 22 5 4 1 Splash lubrication 22 5 4 2 Forced lubrication 22 5 5 Shaft bearings 22 5 6 Shaft seals 22 5 6 1 Radial shaft sealing rings 22 5 6 2 Labyrinth seals 23 5 6 3 Taconite seals 23 5 7 Cooling 24 5 7 1 Fan 24 5 7 2 Cooli...

Страница 6: ...6 5 1 2 Axial fastening 37 6 6 Shrink disk 38 6 6 1 Fitting the shrink disk 38 6 6 2 Demounting the shrink disk 40 6 6 3 Cleaning and greasing the shrink disk 40 6 6 4 Re mounting the shrink disk 41 6 6 5 Inspection of the shrink disk 41 6 7 Couplings clutches 41 6 8 Gear unit with torque arm 43 6 9 Gear unit with gear unit swing 43 6 10 Gear units with cooling coil 43 6 11 Gear units with add on ...

Страница 7: ...or preservation procedure 52 8 Operation 53 8 1 General 53 8 2 Oil level 53 8 3 Irregularities 53 9 Faults causes and remedy 54 9 1 General information on faults and malfunctions 54 9 2 Possible faults 54 10 Maintenance and repair 57 10 1 General notes on maintenance 57 10 1 1 General oil service lives 58 10 2 Description of maintenance and repair work 58 10 2 1 Examine water content of oil conduc...

Страница 8: ...scosity oil quantity Special information Instructions number s Types sizes Special information Power rating P2 in kW or torque T2 in Nm Manufacturer and place of manufacture Speed n1 Country of origin Example 1 S E N Size 80 800 Type of output shaft N Solid shaft gear unit with base A Shaft mounting gear unit with base O Shaft mounting gear unit without base Number of stages E one helical gear sta...

Страница 9: ... unit type S Helical gear unit K Bevel helical gear unit 140 Example 4 S O N D Size refer to the drawings in the gear unit documentation Gear unit type Series type special gear unit on the basis of REDUREX gear units with slight modifications to the catalogue design refer to the drawings in the gear unit documentation 475 Data on weights and measuring surface sound pressure levels of the various g...

Страница 10: ... 175 245 330 460 SDA 150 205 285 390 540 SVN 205 290 400 550 SVO 175 245 330 460 SVA 205 290 400 550 SFO SSO KLN 310 430 600 KLA 310 430 600 KSN KEN 28 49 87 160 300 540 KEO 42 77 140 260 480 KEA 49 87 160 300 540 KZN 62 85 115 160 220 310 420 570 KZO 51 70 96 135 190 260 360 490 KZA 62 85 115 160 220 310 420 570 KDN 160 225 320 430 580 KDA 160 225 320 430 580 All weights are for units without oil...

Страница 11: ...0 1100 1450 2000 2700 3900 5200 7300 11000 14000 SFO 1150 1500 2000 2700 3800 5100 7100 SSO 1180 1550 2050 2750 3900 5200 7200 KLN 840 1180 1680 2300 3250 KLA 840 1180 1680 2300 3250 KSN KEN 780 1050 1450 2050 2800 3800 KEO 670 910 1250 1750 2400 3200 KEA 780 1050 1450 2050 2800 3800 KZN 800 1100 1450 2100 2850 4100 5500 7600 10500 14500 KZO 680 920 1200 1700 2350 3300 4400 6000 8100 11500 KZA 800...

Страница 12: ...45 2905 4140 5460 7610 10610 SVAS 235 335 465 635 885 1235 1640 2325 3090 4360 5855 8205 11305 SVOS 217 310 430 590 825 1155 1530 2145 2905 4140 5460 7610 10610 SVDS 217 310 430 590 825 1155 1530 2145 2905 4140 5460 7610 10610 KENS 408 742 944 1265 1760 2470 3360 4545 KELS 382 692 875 1175 1630 2395 3125 4235 KEAS 408 742 944 1265 1760 2470 3360 4545 KEOS 382 692 875 1175 1630 2395 3125 4235 KEDS ...

Страница 13: ...unit has been manufactured in accordance with the state of the art and is delivered in a condition for safe and reliable use The gear unit must be used and operated strictly in accordance with the conditions laid down in the contract governing performance and supply agreed by Siemens and the customer The gear unit described in these instructions reflects the state of technical development at the t...

Страница 14: ...out with great care and with due regard to safety All work on the gear unit must be carried out only when it is not in operation The drive unit must be secured against being switched on accidentally e g by locking the key switch or removing the fuses from the power supply A notice should be attached to the start switch stating clearly that work is in progress No electrical welding work must be don...

Страница 15: ... 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 surface of the ge...

Страница 16: ...rms of packaging may be used depending on the size of the unit and method of transport 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 ...

Страница 17: ...Type SZNS Type KZNS Fig 4 Attachment points A detailed view of the gear unit can be obtained from the drawings in the gear unit documentation On gear units with an add on drive motor the centre of gravity may shift In this case the slinging and lifting equipment should be attached to the motor as well ...

Страница 18: ...nds 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 Where gear units are delivered with a priming coat only it is necessary to apply a finish coat in accordance with directives appl...

Страница 19: ...p replace screw plug with air filter For storage periods longer than 36 months Siemens should be consulted before 1 Resistant to tropical conditions and sea water max ambient temperature 50 C 4 4 2 Exterior preservation Table 6 Durability period for exterior preservation of shaft ends and other bright machined surfaces Duration of protection Preservative agent Layer thickness Remarks in case of in...

Страница 20: ... contact ratio and special sound damping housings The good temperature characteristics of the gear unit are achieved by its high degree of efficiency large housing surface and performance related cooling system If required standard range gear units can be fitted with a motor bell housing motor swing base torque reaction arm oil cooler and backstop 5 2 Housing The housing is made of cast iron in tw...

Страница 21: ...g eyes 2 Housing top 11 Transport lugs 3 Cover 12 Transport lugs 360 4 Cover 13 Pressure bolts 360 5 Cover 14 Alignment surfaces 360 6 Inspection and or assembly cover 15 Housing ventilation 7 Shaft seals 16 Oil drain plug 8 Shaft seals 17 Rating plate 9 Oil dipstick 18 Gear unit fastening 19 Oil inlet A detailed view of the gear unit can be obtained from the drawings in the gear unit documentatio...

Страница 22: ...ange over filter the operating instructions specified in the annex must be observed The following configurations of forced lubrication are possible Add on oil supply system fixed to the gear unit see item 5 7 3 External oil supply system fitted separately see item 5 7 4 In the case of gear units with oil supply system before starting the unit up all monitors must be connected so as to be ready for...

Страница 23: ...dust Overfilling of the gear unit can cause leakage as can oil with high foam content 5 6 3 Taconite seals Taconite seals were specially developed for use in a dusty environment The penetration of dust is prevented by a re greasable labyrinth seal 1 2 3 4 Fig 8 Taconite seal 1 Radial shaft sealing ring 3 Grease charged labyrinth seal re chargeable 2 Lamellar seal 4 Flat grease nipple AM10x1 to DIN...

Страница 24: ... fan or the gear housing are dirty see section 10 Maintenance and repair 5 7 2 Cooling coil The gear unit can be fitted with a cooling coil in the oil sump Cooling water is supplied by way of a water connection The operator must provide this connection Either fresh water sea water or brackish water can be used for cooling purposes When water is flowing through the cooling coil a certain amount of ...

Страница 25: ...h compressed air Be especially careful when blowing with compressed air Wear protective glasses 5 7 3 1 Pump The pumps used are suitable for the delivery of lubricants The flow medium must not contain abrasive components and must not chemically affect the materials of the pump A precondition of a proper functioning high reliability and long service life of the pump is in particular a clean and lub...

Страница 26: ...ng the backstop or the gear unit the motor must not be run adversely to the stop direction of the gear unit Observe the notice fixed to the gear unit Before connecting the motor determine the direction of rotation of the three phase current supply using a phase sequence indicator and connect the motor in accordance with the pre determined direction of rotation 5 10 Heating element At low temperatu...

Страница 27: ...level can be carried out by looking at the MIN and MAX marks of the oil dipstick when the oil has cooled down A view of the gear unit can be obtained from the drawings in the gear unit documentation If an oil dipstick is fitted the oil level must be at the middle of the oil sight glass 5 13 Oil level monitoring system The gear unit can be fitted with an oil level monitor by means of a filling leve...

Страница 28: ...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 If a sunshade roof is fitted heat must be prevented from building up If a temperature monitoring device is fitted a warning signal must be emitted when the maximum permitted oil sump temperature is reached If the maximum permitted oil sump temperature is ex...

Страница 29: ...alignment with the units on the in and output sides must be ensured Any elastic deformation through operating forces must be taken into consideration Fastening bolts or nuts must be tightened to the prescribed torque For the correct torque refer to item 6 20 Bolts of the minimum strength class 8 8 must be used If external forces are acting upon the gear unit it is advisable to prevent the unit fro...

Страница 30: ...p side for preliminary alignment in horizontal direction Alignment surface The alignment surfaces are for aligning the gear unit horizontally in order to ensure correct running of the gear unit The values punched into the alignment surfaces must always be observed The final fine alignment with the assemblies on the in and output side must be carried out accurately by the shaft axes using rulers sp...

Страница 31: ...foundation blocks Clean the undersurface of the gear unit base Placing stone bolts Hook stone bolts with washers and hexagon nuts into the foundation fastening points on the gear unit housing see fig 10 The hexagon nuts must only be tightened when the concrete has set 4 5 3 2 1 1 Hexagon nut 2 Washer 3 Gear unit base 4 Stone bolt 5 Foundation Fig 10 Stone bolt Placing the foundation blocks Hook th...

Страница 32: ...s 6 3 2 4 Mounting on a concrete foundation by means of anchor bolts Clean the undersurface of the gear unit base Place support on the base plate in the fine grout Insert anchor bolts Place pressure plates in position and screw nuts on Place wood under the anchor bolts so that they are about 10 mm from the upper edge of the support see fig 12 4 6 5 2 3 1 7 8 1 Anchor bolt 2 Support 3 Base plate 4 ...

Страница 33: ...t 28 days Keep anchor bolts in their position by tightening the nut with your fingers Place the protective sleeve Place hydraulic tensioning device in position Initially tension the bolts alternately for initial tensioning forces see item 6 20 Using a suitable tool screw hexagon nuts on as far as the stop To ensure correct handling and adjustment of the pretensioning tool the manufacturer s operat...

Страница 34: ...y 1 Machine shaft 4 End plate 2 Hollow shaft 5 Screws 3 Parallel key 6 4 1 Fitting Remove the preservative agent from the hollow shaft and the machine shaft with a suitable cleaning agent such as benzine Do not allow the cleaning agent e g benzine to contact the shaft sealing rings Ensure adequate ventilation Do not smoke Danger of explosion Check the hollow and machine shafts to ensure that seats...

Страница 35: ...ng Torque arm Support with gear unit swing base With a different arrangement the bearings may be excessively stressed 6 4 1 2 Axial fastening Depending on type secure the hollow shaft axially on the machine shaft e g with locking ring end plate set screw 6 4 2 Demounting Remove the axial securing device from the hollow shaft If frictional corrosion has occurred on the seating surfaces rust releasi...

Страница 36: ... on the order hollow shafts can be fitted with red bronze bushes to guide the shafts Shrink disks are not included in the Siemens delivery Supply is possible on request 6 5 1 Fitting Remove the corrosion protection from the hollow shaft and machine shaft with a suitable cleansing agent The cleaner must not be allowed to come into contact with the shaft sealing rings Ensure adequate ventilation Do ...

Страница 37: ...h 1 Machine shaft 4 Nut 7 End plate 2 Hollow shaft 5 Threaded spindle 3 Red bronze bush 6 Nut Instead of the nut and threaded spindle shown in the diagram other types of equipment such as a hydraulic lifting unit type Lukas may be used The shaft must be pulled smartly into the hollow shaft as far as the end plate The hollow shaft may be tightened against a machine shaft collar only if the gear uni...

Страница 38: ... damage due to non observance 6 6 1 Fitting the shrink disk Before beginning installation the hollow shaft and the stub shaft must be carefully cleaned Observe manufacturer s instructions for handling lubricants and solvents Do not allow cleansing agent or solvent to affect surfaces with paint coating The bore of the hollow shaft and the stub shaft must be absolutely clean free of grease and oil i...

Страница 39: ...d visually To avoid overloading the individual bolts the maximum tightening torque see table 8 must not be exceeded If when tightening the clamping bolts at max tightening torque the inner and outer ring are not aligned Siemens must be consulted Table 8 Maximum torques for tensioning bolts Tensioning bolt thread max tightening torque per bolt Tensioning bolt thread max tightening torque per bolt S...

Страница 40: ...he hollow 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 6 3 Cleaning and greasing the shrink disk Only dirty shrink disks must be disassembled and cleaned Inspection of all parts for any damage Damaged parts must be replaced with new ones The use of damaged parts is not permissible Only the complet...

Страница 41: ... relation to outer ring 4 6 7 Couplings clutches As a rule flexible couplings or safety slip clutches are provided for the drive of the gear unit If rigid couplings or other in and or output elements which create additional radial and or axial forces e g gear wheels belt pulleys disk flywheels hydraulic couplings are to be used this must be agreed by contract Couplings must be balanced in accordan...

Страница 42: ...n be increased by using a dial gauge or a laser alignment system 3 3 3 3 1 2 Fig 20 Example of alignment on a flexible coupling 1 Ruler 2 Feeler gauge 3 Measuring points The maximum permissible misalignment values are specified in the operating instructions for the coupling they must under no circumstances be exceeded during operation Angular and radial misalignments may occur at the same time The...

Страница 43: ...the connections see dimensioned drawing Observe also item 5 7 2 6 11 Gear units with add on air oil cooler Connect pressure monitor electrically Connect contamination indicator of the double changeover filter if fitted electrically Connect the fan motor electrically 6 12 Gear units with add on water oil cooler Before connecting the water oil cooler remove the sockets from the cooling water connect...

Страница 44: ...peed transmitter electrically Observe the operating instructions for the speed transmitter 6 18 General notes on add on components For operating and servicing the components described in section 6 the pertinent instruction manuals and the specifications in section 5 must be observed 6 19 Final work After installation of the gear unit check all screw connections for tight fit Check the alignment af...

Страница 45: ...lass C 6 20 2 Tightening torques and initial tensioning 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 ...

Страница 46: ...3000 240000 6760 5820 5200 12 9 700000 448000 280000 7900 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...

Страница 47: ...servative 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 agent and or running in oil in accordance with regulations Remove any oil spillage immediately with an oil binding agent The oil must not come into contact with the skin e g the operator s hands The safety notes on the data she...

Страница 48: ...s are decisive for the amount of oil to be filled in In the case of gear units fitted with forced lubrication or an oil cooling system the oil circuit must also be charged with oil To do this briefly start up the gear unit with add on pump observing the description in section 8 Check the oil level in the gear unit housing The oil must come up to the middle of the oil sight glass The oil level must...

Страница 49: ...Check that connecting lines are correctly fastened and tight 7 2 3 Gear unit with cooling coil or external oil supply system Fully open the stop valves in the coolant in and outflow pipes After starting up the external oil supply system for the first time the oil level must be once more checked in accordance with item 7 2 1 7 2 3 1 Pre lubrication phase of the oil supply system Prior to start up t...

Страница 50: ... the notice has been poured in through the oil filler plug screw of the backstop Always use oil of the same type and viscosity as for the gear unit 7 2 5 Gear unit with temperature measurement During 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 difference in temperature from the m...

Страница 51: ...unit and allow it to run briefly 5 to 10 minutes approx every 3 weeks during a shut down period no longer than 6 months Treat the gear unit with preservative see items 7 3 1 and 7 3 2 before a shut down period exceeding 6 months 7 3 1 Interior preservation during longer disuse Depending on the type of lubrication and or shaft sealing the following types of interior preservation can be applied 7 3 ...

Страница 52: ...eservative agent into a suitable container Dispose of preservative agent in accordance with regulations There is a risk of scalding from the hot preservative agent draining from the gear unit Wear protective gloves Screw the oil drain plug in and or close the oil drain cock Replace breather screw with the screw plug Before re starting the gear unit replace the screw plug with the breather screw Ob...

Страница 53: ...il level stop operation of the gear unit Depending on the type the following oil levels apply when the motor has cooled down Middle of the oil sight glass Top mark on the oil dipstick If the oil is hot the oil level marks may be slightly exceeded It must in no case be allowed to fall below the mark If necessary top up to the correct level The oil level in the oil supply system must be checked For ...

Страница 54: ...onally Attach a warning notice to the start switch 9 2 Possible faults Table 12 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 bearings ...

Страница 55: ... supply system or cooling coil 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 laboratory Check the oil supply system or cooling coil replace any defective parts Consult operating instructions for oil supply system Protect gear unit with suitable heat insulation C...

Страница 56: ...essure 0 5 bar Check oil level at room temperature and if necessary top up oil Check and if necessary replace the oil pump Check and if necessary clean oil filter See section 10 Temperature at backstop too high Locking function fails Damage to backstop Contact Customer Service Check backstop and if necessary replace ...

Страница 57: ...d in table 13 are adhered to This also applies if the maintenance work is included in the operator s internal maintenance schedules Table 13 Maintenance and repair work Maßnahmen Fristen Bemerkungen Check oil temperature Daily Check for unusual gear unit noise Daily Check oil level Monthly Middle of the oil sight glass Top mark on the oil dipstick Check gear unit for leaks Monthly Test the water c...

Страница 58: ... oils etc 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 increase in temperature of 10 K will halve the service life and a temperature decrease of 10 K will approximately double the service life 10 2 Description of maintenance and repair work 10 2 1 Examine water content of oil conducting oil analyses More inform...

Страница 59: ...and using suitable means Ensure that all residues have been removed before filling with fresh oil Place a suitable container under the oil draining point of the gear unit housing Unscrew the breather screw on the top of the housing Unscrew oil drain plug or open oil drain cock and drain the oil into the collecting container Drain the oil from the oil supply system see operating instructions to the...

Страница 60: ... 6 Refill 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 10 2 7 Check cooling coil Shut off the cooling water supply Disconnect the water in and outflow pipes from the cooling coil Check...

Страница 61: ...he hose lines must not exceed 6 years from the manufacturing date stamped on them The period of use can be determined using available test and empirical values taking into account the conditions of use The operator of the system must ensure that hose lines are replaced at suitable intervals of time even if no defects which may affect their safe operation are identifiable on them Hose lines must be...

Страница 62: ...y 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 type quantity and viscosity of the oil is given on the rating plate on the gear unit and or in the s...

Страница 63: ...ics of the gear 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 curre...

Страница 64: ...3 8 1 1 4 1 1 4 2 1 1 5 1 1 5 11 1 5 13 1 5 15 1 5 16 1 6 1 1 6 3 1 7 1 1 7 1 1 1 7 2 1 7 3 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 in conformity with the provisions of Directive 2006 42 EC as appropriate The manufacturer undertakes in respo...

Страница 65: ...Siemens AG Industry Sector Mechanical Drives Alfred Flender Straße 77 46395 Bocholt GERMANY www siemens com drivetechnologie Subject to modifications Siemens AG 2010 ...

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