FLENDER gear units - Siemens · FLENDER gear units Vertical mill gear unit KMP, KMPS, KMPP Assembly...

FLENDER gear units

Vertical mill gear unit

KMP, KMPS, KMPP

Assembly and operating instructionsBA 9180 en 12/2015

2 / 84BA 9180 en 12/2015


KMP, KMPS, KMPP

Assembly and operating instructions

Translation of the original assembly and operating instructions

Technical data

Spare parts,customer service

Maintenanceand repair

Faults, causesand remedy

Operation

Startup

Fitting

Technicaldescription

Transport andstorage

Safety instructions

General notes

Declarations

1

12

11

10

9

8

7

6

5

4

3

2

3 / 84BA 9180 en 12/2015

Legal notes

Warning note conceptThis manual comprises notes which must be observed for your personal safety and for preventing materialdamage. Notes for your personal safety are marked with a warning triangle, those only for preventingmaterial damage appear without a warning triangle. Depending on the level of hazard, the warning notesare shown in reverse order of seriousness, as follows.

DANGER

means, that death or serious injury will result, if the appropriate preventive action is not taken.

WARNING

means that death or serious injury may result, if the appropriate preventive action is not taken.

CAUTION

means that a slight injury may result, if the appropriate preventive action is not taken.

NOTICE

means that material damage may result, if the appropriate preventive action is not taken.

Where there is more than one hazard level, the warning note for whichever hazard is the most serious isalways used. If in a warning note a warning triangle is used to warn of possible personal injury, a warningof material damage may be added to the same warning note.

Qualified personnelThe product or system to which this documentation relates may be handled only by persons qualified forthe work concerned and in accordance with the documentation relating to the work concerned, particularlythe safety and warning notes contained in those documents.Qualified personnel must be specially trained and have the experience necessary to recognise risksassociated with these products and to avoid possible hazards.

Proper use of Siemens productsObserve also the following:

WARNING

Siemens products must be used only for the applications provided for in the catalogue and the relevant

technical documentation. If products and components of other makes are used, they must be

recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper

transport, proper storage, erection, assembly, installation, startup, operation and maintenance. The

permissible ambient conditions must be adhered to. Notes in the relevant documentations must be

observed.

TrademarksAll designations to which the registered industrial property mark ® is appended are registered trademarksof Siemens AG. Other designations used in this document may be trademarks the use of which by thirdparties for their own purposes may infringe holders’ rights.

Exclusion of liabilityWe have checked the content of the document for compliance with the hard and software described.Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. Theinformation given in this document is regularly checked, and any necessary corrections are included insubsequent editions.

4 / 84BA 9180 en 12/2015

ForewordThe term "Assembly and operating instructions" will in the following also be shortened to "instructions"or "manual".

The term "2014/34/EU" used in these instructions applies to the version designed in conformity todirective 94/9/EC, if the product is put on the market by 19.04.2016, and to the version designed inconformity to directive 2014/34/EU, if the product is put on the market on or after 20.04.2016.

Symbols in these assembly and operating instructions

This symbol additionally indicates an 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 ofstandard "DIN EN ISO 137321".

This symbol warns against risks from lifted and/or suspended loads.

Earthconnection point Airrelief point yellow

Oilfilling point yellow Oildraining point white

Oil level red Oil level red

Oil level redConnection forvibrationmonitoring device

Lubricating point red Apply grease

Lifting eye Eye bolt

Do not unscrew

Alignment surface, horizontal Alignment surface, vertical

These symbols indicate the oillevel checking procedure using the oil dipstick.

These symbols indicate that the oil dipstick must always be firmly screwed in.

5 / 84BA 9180 en 12/2015

Contents

1. Technical data 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 General technical data 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Measuring-surface sound pressure level 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 List of equipment 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. General notes 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Introduction 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Copyright 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Safety instructions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Obligations of the user 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Special dangers and personal protective equipment 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 The five safety rules 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Environmental protection 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Transport and storage 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Content and check of the scope of delivery 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Transport 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Storing the gear unit 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Standard coating and corrosion prevention 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Exterior preservation of metallic bright exterior surfaces 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1.1 Maximum durability period of the exterior preservation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1.2 Prolongation of the preservation of metallic bright exterior surfaces of the gear unit 19. . . . . . . . . . .

4.4.2 Preservation of the interior of the gear unit 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2.1 Maximum durability period of the interior preservation of the gear unit 19. . . . . . . . . . . . . . . . . . . . . . .

4.4.2.2 Combined storage/packaging 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3.1 Renewal of the gear unit interior preservation with "Castrol Corrosion Inhibitor N 213" 25. . . . . . . . .

4.4.3.2 Renewal of the gear unit interior preservation through complete filling with preservative or operating oil 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3.3 Renewal of the interior preservation of the gear unit using the oil-supply system 29. . . . . . . . . . . . . .

5. Technical description 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 General description 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Delivery condition of the gear unit 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Lubrication 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Hydrodynamic lubrication of the axial tilting pad thrust bearings 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 Hydrodynamic lubrication of the axial tilting pad thrust bearings in gear units with hydrostatic start-up assistance 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.3 Hydrodynamic lubrication of the axial tilting pad thrust bearings with radial piston pump 32. . . . . . .

5.3.4 Labyrinth seals 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Drive coupling 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Heating 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Indication of oil level 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Oil temperature monitoring 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 / 84BA 9180 en 12/2015

6. Fitting 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 General assembly information 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Set-up conditions 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Dimensions and weights 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2 Lifting device 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Preparatory measures for gear unit installation 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Maintaining preservation if the gear unit has been opened in the meantime 39. . . . . . . . . . . . . . . . . .

6.3.2 Foundation 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Assembly of the gear unit 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Installing the pipework 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 Pickling of adapted pipes 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Installing the couplings 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Installing the motor 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 Assembly of loose add-on parts included in the delivery 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 Welding work on the mill 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 General notes on add-on components 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12 Final work 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13 Screw connection classes, tightening torques and initial stressing forces 44. . . . . . . . . . . . . . . . . . . .

6.13.1 Screw connection classes 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13.2 Tightening torques and initial stressing forces 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Start-up 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 Procedure before start-up 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Removal of preservative agent from exterior 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.2 Removal of preservative agent from interior 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.3 Draining preservative oils 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.4 Flushing before initial start-up 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.4.1 Oil quantity for flushing 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.5 Fill in operating oil 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.5.1 Oil level 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.5.2 Procedure for filling 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.6 Oil-supply system 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.7 Checks before start-up 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Start-up 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.1 Pre-lubrication phase 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.2 Initial start-up 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.3 Checking procedure 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Removal from service 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1 Renewal of the gear unit interior preservation on gear units having already been in operation 58. . .

7.3.1.1 Renewal of the interior preservation of the gear unit using the oil-supply system 58. . . . . . . . . . . . . .

7.3.1.2 Renewal of the gear unit interior preservation with "Castrol Corrosion Inhibitor N 213" 60. . . . . . . . .

7.3.1.3 Renewal of the gear unit interior preservation through complete filling with preservative or operating oil 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.2 Exterior corrosion prevention 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Operation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1 General 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Oil level 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Irregularities 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. Faults, causes and remedy 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 General information on faults and malfunctions 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Faults, causes and remedy 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 / 84BA 9180 en 12/2015

10. Maintenance and repair 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1 General notes on maintenance 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 Clean the gear unit 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 Clean the air filter 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3.1 Replacing the air filter cartridge 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.4 Flushing 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.5 Oil filling 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.6 Inspection 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7 Maintenance 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7.1 Examine water content of oil, conduct oil analyses 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7.2 Change oil 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7.3 Check tightness of screw connections 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8 Welding work on the mill 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.9 Vibration measurements 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.10 Repair 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.11 General inspection of the gear unit 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.12 Lubricants 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. Spare parts, customer service 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1 Stocking spare parts 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2 Addresses for ordering spare parts and customer service 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. Declarations 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.1 Declaration of incorporation 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1. Technical data

1.1 General technical data

The most important technical data are shown on the rating plate. These data and the contractualagreements between Siemens and the customer for the gear unit determine the limits of its correct use.

①

②

③ ④

⑤ ⑥

⑦ ⑧

⑨

⑩

⑪

⑫⑬

Fig. 1: Rating plate on gear unit

① Company logo

② Serial number #)

③ Total weight (without oil filling) in kg

④ Special information

⑤ Type, size *)

⑥ Power rating P2 in kW or torque T2 in Nm

⑦ Rotation speed n1 in min-1

⑧ Rotation speed n2 in min-1

⑨ Oil data (oil type, oil viscosity, oil quantity)

⑩ Instruction manual numbers

⑪ Special information

⑫ Manufacturer and place of manufacture

⑬ Country of origin

#) Production site code / Order no. item seq. no. / Year built

*) Example

K M P S 546

Size 546. . . . . . . . . . . . . . . . . . . . . .

Model P = planetary stage. . . . . . . . . . . . . . . . . . . . .S = helical gear stage

Model P = planetary stage. . . . . . . . . . . . . . . . . . . . .

Area of use M = vertical mill. . . . . . . . . . . . . . . .

Gear unit type K = bevel gear unit. . . . . . . . . . . . . .

For details regarding weight and further technical data, refer to the drawings in the gear unit documentationand the order-specific data sheet.

1.2 Measuring-surface sound pressure level

A measuring-surface sound pressure level during operation cannot be specified, as the gear unit isoperated without load during the test run on the Siemens test bench.

1.3 List of equipment

Note

All important accessory components are specified in the order specific equipment list including yourtechnical data.

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2. General notes

2.1 Introduction

These instructions are a part of the gear unit delivery and must always be kept on hand near the gear unit.

NOTICE

Property damage

Damage to the gear unit or occurrence of operating failures is possible.All persons carrying out work on the gear unit must have read and understood the instructions and mustadhere to them.Siemens accepts no responsibility for damage or disruption caused by disregard of these instructions.

The "FLENDER vertical mill gear unit" described in these Instructions is designed for driving verticalmills.

The gear unit is designed only for the application specified in the order-specific gear unit documentation.Deviating operating conditions require new contractual agreements.

The gear unit is manufactured in accordance with the state of the art and is delivered in a condition readyfor safe and reliable use.

The gear unit may only be used and operated in accordance with the conditions laid down in the serviceand supply contract concluded between Siemens and the customer.

The gear unit described in these instructions conforms to the state of technical development at the timewhen these instructions went to print.

In the interest of technical further development we reserve the right to make changes to the individualassembly groups and accessory parts as we deem appropriate in order to increase their capacity andsafety while maintaining their essential characteristics.

2.2 Copyright

The copyright to these instructions is held by Siemens AG.

These instructions may be used neither in full nor in part for competitive purposes nor be made availableto third parties without our approval.

Technical enquiries should be directed to our factory or to one of our customer service centres:

Siemens Ltd.309/2, 'A' Block 100, Chettipedu VillageThandalam Post602105 ChennaiIndien

Tel.: +91 (44) 37174000

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3. Safety instructions

WARNING

Risk of falling

Serious injury from falling is possible.The gear unit and its add-on parts must not be accessed during operation.The gear unit may only be accessed for maintenance and repair works during standstill of the gear unit.

WARNING

Risk of injury from changes made on own initiative

Changes made on own initiative are prohibited.This also pertains to the protection equipment that is installed as contact protection.

3.1 Obligations of the user

• The operator must ensure that everyone carrying out work on the gear unit has read and understoodthese instructions and is adhering to them in every point in order to:

─ avoid injury or damage to the user and third parties,

─ ensure the safety and reliability of the gear unit,

─ avoid loss of use and environmental damage caused by incorrect use.

• During transport, assembly, installation, demounting, operation and maintenance of the unit, therelevant 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 workconcerned (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 safety.

DANGER

Danger to life from switched on system

For carrying out work on the gear unit, the gear unit and an added on or separate oil-supply system mustgenerally be set in standstill.The drive unit must be secured against accidental start-up (e. g. by locking the key switch or removingthe fuses from the power supply).Attach a notice on the start switch stating clearly that work is in progress on the gear unit.At the same time, the complete system must be free from load so that no danger is caused during thedisassembly work.

• No welding work may be done at all on the drive.The drive systems must not be used as an earthing point for electrical welding works. Toothed partsand bearings can be irreparably damaged by welding.

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NOTICE

Property damage

Damage to the gear unit is possible.For gear units, which are operated together with electrical machines that generate power or that aresupplied with power (e. g. motors, generators, etc.), it must be ensured that no current can flow throughthe gear unit. The flow 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

• Potential equalisation must be provided in accordance with the applicable regulations and/orguidelines!If no threaded holes for earth connection are available on the gear unit, other appropriate measuresmust be taken. This work must always be done by trained electricians.

NOTICE

Property damage

Damage to the gear unit is possible.Immediately stop the gear unit by turning off the drive unit when inexplicable changes are noticedduring the operation, such as a significantly increased operating temperature or changed sounds ofthe 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 movable drive parts must be provided with suitable safeguards to prevent contact.

Note

When the gear unit is incorporated in plant or machinery, the manufacturer of such plant or machinerymust ensure that the requirements, notes and descriptions contained in these instructions areincorporated in its own instructions.

• Removed safeguards must be refitted prior to starting up.

• Notices attached to the gear unit, such as rating plate and direction arrow, must always be observed.They must be kept free from dirt and paint at all times. Missing plates must be replaced.

• Screws which have been damaged during assembly or disassembly work must be replaced with newscrews of the same strength class and type.

• Spare parts must be obtained from Siemens (see section 11. "Spare parts, customer service").

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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 injury from cold damage (pain, numbness, frostbites) on cold surfaces (< 0 °C) is possible.Wear suitable protection gloves and protection clothing.

WARNING

Risk of scalding

Serious injury from discharging hot operating media is possible when these are changed.Wear suitable protection gloves, protection glasses and protection clothing.

WARNING

Risk of eye injury

Small foreign matter such as sand or dust can get into the cover plates of the rotating parts and mightbe thrown back by these.Wear suitable protective glasses.

Note

In addition to any generally prescribed personal protection equipment (protection shoes, protectionclothing, helmet, etc.) handling the gear unit requires wearing suitable safety gloves and suitablesafety glasses.

DANGER

Explosion hazard

Danger to life from ignition of a present explosive atmosphere is possible in the operation of the gearunit.The gear unit does not comply with the requirements of Directive 2014/34/EU and therefore, in thearea of applicability of this directive, it must not be used in areas with explosion hazard.

Should the gear unit be used outside the area of applicability of Directive 2014/34/EU in areas withexplosion hazard, the nationally applying protective prescriptions with regard to explosion protectionmust always be observed.

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3.3 The five safety rules

For your personal safety as well as avoidance of property damages, please always observe the safetynotices and the following five safety rules pursuant to the standard "DIN EN 50110-1" (Operations inpowered-down condition) when working on the electrical components of the system. Apply the five safetyrules from the start of the work on the machine, 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 of in accordance with the regulations or be given torecycling.

• When changing oil, the used oil must be collected in suitable containers. Remove any pools of oilimmediately using an oil binding agent.

• Preservative agents should be stored separately from used oil.

• Used oil, preservative agents, oil binding agents and oil-soaked cleaning cloths must be disposed ofin accordance with environmental regulations.

• Disposal of the gear unit after its service life:

─ Drain all operating oil, preservative agent and/or cooling agent from the gear unit and dispose of itin accordance with the regulations.

─ Depending on the national regulations, gear unit components and/or add-on parts may have to bedisposed of separately or be given to recycling.

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4. Transport and storage

Observe the instructions in section 3. "Safety instructions"!

4.1 Content and check of the scope of delivery

The content of the delivery is listed on the packing slip. The completeness of the scope of delivery mustbe checked against the packing slip directly on receipt. The packaging must not be opened for the check.Damages on packaging and/or items missing from the package must be reported to Siemens in writingwithin 2 weeks.

NOTICE

Property damage

Damage to the gear unit from corrosion is possible.The packaging must not be opened in any case. Otherwise, the durability period of the gear unitpreservation will reduce.

Note

If the packaging 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.When attaching, lifting, lowering and shifting the load, pay attention to the following:– Observe the load limits.– Proper fastening of the attachment equipment.– Centre of gravity possibly being off centre.– Even load distribution on load-bearing equipment with multiple load hook-ups.– Low process speed.– Oscillating the load and/or attaching the load to objects

or building parts is prohibited.– Load hooks may not be loaded at their tip.– Set down products only on even, non-slipping and stable underground.

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WARNING

Risk of crushing

Risk of being crushed by a transported component when the used lifting gear and load-bearingequipment is not suitable and the component comes loose.Attach the product for transport only on the marked attachment points. Lifting gear and load equipmentmust be used that has adequate load-bearing capacity.Observe the notes on the packaging regarding the load distribution when applying loads.When being lifted the product must be transported slowly and carefully in order to avoid personal injuryand damage to the gear unit.For example, impact on free shaft ends might lead to damage on the gear unit.

The gear unit is delivered in a fully assembled condition. If applicable, additional items are deliveredpackaged 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. These have the following meanings:

Top Fragile Keep dry Keep cool Centre ofgravity

Use no handhook

Attachhere

Fig. 2: Transport symbols

Note

The gear unit may only be transported by means of transport equipment suitable for this purpose.The gear unit should be transported without oil filling and be kept in/on the transport packaging.If the gear unit is in seaworthy packaging (wooden box), the attachment points marked on thepackaging have to be used.If the gear unit is delivered without seaworthy packaging, the attachment points as shown in Figure 3or in Figure 4 have to be used.

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Fig. 3: Attachment points

Note

If no transport lobes are provided on the base of the gear unit, the transport lobes that are marked onthe fins have to be used. If no cable pulley is on the gear unit head, wooden blocks have to be used forprotection of the gear unit (see Figure 4).

1 1 1 1

Fig. 4: Alternative attachment points

1 Wooden block

17 / 84BA 9180 en 12/2015

Note

The detailed illustration of the gear unit, the position of the attachment points, and the positioning ofthe wooden blocks for the protection of the gear unit during transport can be found on the dimensionedand transport drawings in the order-specific gear unit documentation.

NOTICE

Property damage

Damage to the gear unit is possible when using the wrong attachment points. Use only the lifting eyesprovided to attach lifting gear to the unit.Transporting the gear unit by attaching it to the pipework is not permitted.The pipework must not be damaged.Do not use the threads in the front sides of the shaft ends to attach slinging and lifting gear for transport.Slinging and lifting gear must be adequate for the weight of the gear unit.

4.3 Storing the gear unit

The gear unit must be stored with a cover, placed on a vibration-free dry base in a sheltered place, in theposition of the original packaging or in the position of use. Any storage methods deviating from this affectthe durability period of the gear unit preservation (see item 4.4).

NOTICE

Property damage

Any damage to the coating may cause the failure of the exterior protective coating and consequentlylead to corrosion.When temporarily storing the gear unit and any components supplied with it, the applied corrosionprotection has to be preserved.Ensure that the coating is not damaged.

DANGER

Danger to life from the gear unit toppling or dropping

Risk of being crushed or struck by a gear unit toppling or dropping.Do not stack gear units on top of one another.

NOTICE

Property damage

Damage to the gear unit by deposit of foreign matter or moisture. If the gear unit is stored outdoors, itmust be covered particularly carefully and it must be ensured that neither moisture nor foreign materialcan 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 aschemically aggressive products.Special environmental conditions during transport (e.g. transport by ship) and storage (climate,termites) must be agreed on by contract.

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4.4 Standard coating and corrosion prevention

The gear unit is to be provided with interior preservation on delivery (see "Technical data" in the gear unitdocumentation prepared specifically for the order), and the free shaft ends are to be provided withprotective preservation (see Table 1 in item 4.4.1.1).

The properties of the exterior preservation when using the Siemens standard priming are resistant to:

─ weak acids and alkalis,

─ solvents,

─ weathering, also tropical weathering

─ temperatures up to 120 °C / 248 °F (for short periods up to 140 °C / 284 °F)

If a different exterior coating is intended by the customer (contrary to the Siemens standard), the protectionof the external coating will be within the customer's responsibility.

NOTICE

Property damage

Damage to the gear unit from corrosion is possible.The gear unit is normally delivered completely ready with a priming and a finishing coat.Where gear units are delivered with a priming coat only, it is necessary to apply a finishing coataccording to the standard procedures relevant for the specific application.The priming coat alone is not suitable to provide sufficient long-term corrosion protection.

Note

Corrosion prevention durations of the interior preservation depend on the kind of transport, type ofpackaging and the place of installation and/or storage (see Table 2 in item 4.4.2.1).The durability period of the exterior preservation and the related requirements can be found in Table 1under item 4.4.1.1.The warranty starts upon notification of readiness for delivery (see "Technical data" in the gear unitdocumentation). The provided interior gear unit preservation is also shown in "Technical data".

When storing differently from the durability periods of preservation as specified in Tables 1 and 2applicable for the gear unit, the interior preservation must be prolonged (see item 4.4.3) and if necessary,the exterior preservation must be renewed (see item 4.4.1).

Each prolongation of the interior preservation and any renewal of the exterior preservation must be logged.

Note

The record must be kept with these instructions.

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4.4.1 Exterior preservation of metallic bright exterior surfaces

4.4.1.1 Maximum durability period of the exterior preservation

Table 1: Durability period for exterior corrosion prevention of shaft ends and other bright machinedsurfaces

Durabilityof protection

Preservative agent Layer thickness Remarks

with indoor storage upto 36 months 1)

Tectyl 846 K19 approx. 50 μm

Long-term wax-basedpreservative agent:

– resistant to sea water

– resistant to tropicalconditions

– soluble with CHcompounds

for outdoor storageup to 12 months 2)

1) The gear unit must be stored with a cover on a vibration-free, dry base in a place sheltered fromweathering, in the position of use.

2) If the gear unit is stored outdoors, it must be covered particularly carefully and it must be ensured thatneither 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 1 under item 4.4.1.1, the exterior of the gearunit must be re-preserved using the preservative agent shown in Table 1.

• Clean the surfaces.

• Apply preservative agent (see table 1).

Note

Before start-up, all preservation coats have to be removed from the gear unit according to section 7.1.1.

4.4.2 Preservation of the interior of the gear unit

4.4.2.1 Maximum durability period of the interior preservation of the gear unit

Table 2 shows the maximum durability of the interior gear unit preservation, depending on the kind oftransport, type of packaging and the setup or storage site.

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°

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Table 2: Maximum durability period of the interior preservation of the gear unit

Setup and transport

Setup in climatic zone A and at least 50 kmdistance from larger bodies of

salt water

Setup in climatic zone B and/or less than50 km distance from larger bodies of

salt water

None or simpletransport packaging

Transport inseaworthy

packaging 2)

None or simpletransport packaging

Transport inseaworthy

packaging 2)

withoutsea

transport

withsea

transport

with or withoutsea transport

withoutsea

transport

withsea

transport

with or withoutsea transport

Storage

Packaging forstorage

Storage place ofthe packaged

unit

maximum durability of the interior gear unit preservation HD (Durability Period)1 / HD2 inmonths

Nopackaging

exposedoutdoors

5 3 5 3 3 3

covered withloose tarpaulin

7 3 8 4 3 5

under roof1)

15 3 20 11 3 14in closed, dry

room

covered atleast with

loose tarpaulin

exposedoutdoors

7 3 8 4 3 5

under roof1)

19 3 24 13 3 17in closed, dry

room

seaworthypackaging 2)

exposedoutdoors

15 3 20 15 3 20covered with

loose tarpaulin

under roof1)

19 3 24 19 3 24in 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 protected against moisture byaddition of drying agents for the prescribed storage period.

Note

On the goods receipt, the seaworthy packaging must be inspected for damages.If damaged, the packaging must be restored to its seaworthy condition.

Note

If different statements were made in agreement with the customer, as to the protective periods on preciselydefined conditions, a description can be found in the order confirmation from Siemens.

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4.4.2.2 Combined storage / packaging

If the type of packaging and/or storage is changed within the durability period as HD1, which is applicableto the existing preservation and the present type of packaging and/or storage, a new HD2äq has to bedetermined as the equivalent remaining durability period applicable as of the date of the change. For thispurpose, the following formula has to be used:

HD2äq � (1 �

LD1

HD1) � HD2

LD1 = Storage period for the existing preservation

HD1 = Maximum durability period of the existing preservationaccording to table 2 in item 4.4.2.1

HD2 = Maximum durability period after the change in the type of storage and/or packagingaccording to table 2 in item 4.4.2.1

HD2äq = Maximum remaining durability period after the change in the type of storage and/orpackaging

If several packaging and/or storage types are combined the following formula must be applied as fromthe second change in packaging and/or storage types (equivalent remaining durability period > HD2 äq)to determine the equivalent remaining durability period applying to the preservation:

HDn�äq � (HDn�1äq � LDn�1) � (HDn

HDn�1)

HDn-1äq = Calculated durability period with the previous storage conditions

LDn-1 = Actual duration of storage with the previous storage conditions

HDn = Maximum durability period with the present storage conditionsspecified in table 2 in item 4.4.2.1

HDn-1 = Maximum durability period with the previous storage conditionsspecified in table 2 in item 4.4.2.1

HDn-äq = Remaining durability period after change in the packaging and/or storage types

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Example:

─ A gear unit is stored exposed outdoors after sea transport, in climatic zone B, while it is kept in seaworthypackagingHD1 = 20 months(climatic zone: B, transport type: sea transport, transport packaging: seaworthy packaging, packagingfor storage: seaworthy packaging, place of storage: exposed outdoors)

─ After 5 months (LD1), the gear unit is unpacked, covered with a loose tarpaulin, and placed outdoorsbesides the mill.HD2 = 4 months(climatic zone: B, transport type: sea transport, transport packaging: seaworthy packaging, packagingfor storage: no packaging, place of storage: covered with loose tarpaulin)

Now, the remaining durability period HD2äq has to be calculated as follows:

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 is3 months.

After one additional month (LD2), the gear-unit is placed outdoors exposed without packaging. Now, theremaining durability period HD3äq is to be calculated as follows:

Given:

HD2äq = 3 months (previously calculated)

LD2 = 1 month (actual duration of storage with the previous storage conditions)

HD3 = 3 months (maximum durability period with the present storage conditionsspecified in table 2 in item 4.4.2.1

HD2 = 4 months (maximum durability period with the previous storage conditionsspecified in table 2 in item 4.4.2.1

HDn-äq = HD3äq

HD3äq � (HD2äq � LD2) � (HD3

HD2)

HD3äq � (3 � 1) � (34

)

HD3äq � 1.5�months

The remaining durability period of the interior gear-unit preservation is 1.5 months after combining thestorage types described in the example.

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Table 3: Examples of combined storage (maximally one change in storage) and the resulting remainingdurability of the interior preservation of the gear unit

Original storage place of the gear unit

In which climatic zone is the construction sitelocated?

Setup in climatic zone A and at least 50 kmdistance from larger bodies of salt water

How was the gear unit packaged for transport? None or simpletransport packaging

Transport inseaworthy packaging2)

How was the gear unit transported? without sea transport with or without sea transport

In what packaging was the gear unit stored at theconstruction site?

no packaging seaworthy packaging 2)

Where/how was the packed unit stored?in closed room

orunder roof 1)


in closed roomor

under roof 1)

exposedoutdoors orcovered with

loose tarpaulin

Change of storage

Newpackaging for

storage

Storage place ofthe

repackaged unit

Change oforiginalstorage

method after

Durability period of interior preservation of the gear unit for the newstorage method in consideration of the previous storage period in months

withoutpackaging

exposedoutdoors

1 month 4 1/2 4 5 4 1/2

3 months 4 3 4 1/2 4

6 months 3 1 4 3 1/2

12 months 1not permissible,max. durability

period 7 months2 1/2 2

18 months

not permissible,max. durability

period15 months


period 7 months1 1/2 1/2


exposedoutdoors

1 month 6 1/2 6 7 1/2 7 1/2

3 months 5 1/2 4 7 7

6 months 4 1 6 5 1/2

12 months 1 1/2not permissible,max. durability

period 7 months4 3

18 months


period15 months


period 7 months2 1

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Original storage place of the gear unit

In which climatic zone is the construction sitelocated?

Setup in climatic zone B and/or less than 50 kmdistance from larger bodies of salt water

How was the gear unit packaged for transport? None or simpletransport packaging

Transport inseaworthy packaging2)

How was the gear unit transported? without sea transport with or without sea transport

In what packaging was the gear unit stored at theconstruction site?

no packaging seaworthy packaging 2)

Where/how was the packed unit stored?in closed room

orunder roof 1)


in closed roomor

under roof 1)

exposedoutdoors orcovered with

loose tarpaulin

Change of storage

Newpackaging for

storage

Storage place ofthe newly

packaged unit

Change oforiginalstorage

method after

durability period of interior preservation of the gear unit for the newstorage method in consideration of the previous storage period in months

withoutpackaging

exposedoutdoors

1 month 2 1/2 2 3 3

3 months 2 1 2 1/2 2 1/2

6 months 1 1/2not permissible,max. durability

period 4 months2 2

12 months


period11 months


period 4 months1 1/2 1

18 months


period11 months


period 4 months1 1/2


exposedoutdoors

1 month 3 1/2 3 5 5

3 months 3 1 4 1/2 4

6 months 2not permissible,max. durability

period 4 months4 3 1/2

12 months


period11 months


period 4 months

2 1/2 2

18 months


period11 months


period 4 months

1 1/2 1/2

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 protected against moisture byaddition of drying agents for the prescribed storage period.

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Note

On the goods receipt, the seaworthy packaging must be inspected for damages.If damaged, the packaging must be restored to its seaworthy condition.

Note

If different statements were made in agreement with the customer, as to the protective periods onprecisely defined conditions, a description can be found in the order confirmation from Siemens.

4.4.3 Renewal of the interior preservation of the gear unit for longer periods of storage of the gear unit that hasnot been taken into operation yet

If the gear unit is taken into operation at a point in time, when the maximum durability of the interiorpreservation of the gear unit exceeds the durability as specified in Table 2 under item 4.4.2.1 or if it hasreached remaining durability period specified in item 4.4.2.2, the interior preservation of the gear unit mustbe renewed following the expiration of the durability period.

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

For the renewal of the gear unit interior preservation, the VCI gas discharging fluid"Castrol Corrosion Inhibitor N 213" is recommended.

CAUTION

Risk 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 unittemperature is above 5 °C during filling.

The following control measures must be taken:

• the pressure, suction and/or return lines are sealed with blind flanges.

• The oil drain cocks on the gear unit and on the tilting pad thrust bearing chamber are sealed with screwplugs.

• The labyrinth seal on the output flange is sealed with the round cord hollow profile (13) and maskedairtight (see Figure 5 in item 4.4.3.2).

The following procedure is recommended:

• Remove screw plugs that have been screwed in for transport instead of the air filter.

• 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 enquiredfrom Siemens). The interior volume of the gear unit can be ascertained in approximation also by thelength x width x height of the gear unit.Tilting pad thrust bearing chamber and gear unit chamber each have to be filled with half of thepreservative volume.

• The vent holes of the air filter for the gear unit and the tilting pad thrust bearing chamber have to beclosed and sealed again with screw plugs (these must be replaced again at the start-up).

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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 opening.

Table 4 shows the maximum durability period for the preservation renewal with"Castrol Corrosion Inhibitor N 213" depending on the packaging and setup or storage site. The definitionof climatic zones can be found in item 4.4.2.1.

Note

If the gear unit is transported after the preservation was renewed, the durability period according toTable 2 in item 4.4.2.1 has to be observed.

Table 4: Maximum durability period of the preservation renewal with"Castrol Corrosion Inhibitor N 213"

Setup in climatic zone A and atleast 50 km distance from larger

bodies of salt water

Setup in climatic zone B and/orless than 50 km distance from

larger bodies of salt water

Packaging for storage

Storage place ofpackaged unit

Maximum durability period of the preservation renewal with"Castrol Corrosion Inhibitor N 213" (in months)

Nopackaging

exposed outdoors 5 3

covered with loose

tarpaulin8 5

under roof 1)

20 14in closed,dry room

covered at leastwith

loose tarpaulin


under roof 1)



exposed outdoors

20 20covered with loosetarpaulin

under roof 1)



2) Seaworthy packaging:use of wooden box lined with bitumen paper. The content is sealed in foil and protected against moistureby addition of drying agents for the prescribed storage period.

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NOTICE

Property damage

With larger filled-in quantities of the "Corrosion Inhibitor N 213" (above 5 % of the operating oilquantity), the mixture of operating oil and "Corrosion Inhibitor N 213" must not be used as operatingoil. Before start-up, the remaining "Corrosion Inhibitor N 213" has to be drained and the gear unit mustbe flushed thoroughly with operating oil (in this regard, see item 10.4.)

NOTICE

Property damage

Damage to the gear unit is possible.The gear unit may not be turned.

Note

Before start-up of the gear unit, the measures according to section 7.1 and 7.2 have to be carried out.

4.4.3.2 Renewal of the gear unit interior preservation through complete filling with preservative or operating oil

A further possibility for renewal of the gear unit interior preservation is to fill the gear unit with preservativeor operating oil until the oil level indicator on the tilting pad thrust bearing chamber shows it is filledcompletely with oil.The durability of this kind of preservation depends on the used oil and has to be enquired from the oilmanufacturer.

For the complete filling, a sealing cap (can be obtained from Siemens) must be mounted on the gear unitfor sealing the input shaft.

The preservation will remain intact for as long as the gear unit remains sealed and the storage durabilityof the oil is not exceeded.

Note

Refer to the BA 7300 operating instructions supplied separately for the approved preservative oils. Theviscosity of the operating oil is stated on the rating plate.For better filling it is recommended to choose an oil with low viscosity, which however is not suitablefor later operation of the gear unit and will thus have to be fully drained. When filling, the filled-in oilshould have a maximum viscosity of 7500 cSt (at VG 320 > 0 °C).For complete filling, also the later operating oil can be used, which has to be drained to the operatingoil level before start-up.

NOTICE

Property damage

Insufficient lubrication due to the incompatibility of the oils.If the gear unit is preserved with "TRIBOL 1390" (see "Technical data"), it must be flushed before thecomplete filling (see BA 7300).This flushing oil must not be used for operation.

NOTICE

Property damage

Corrosion damages on the gear unit are possible from the loss of the preservative effectFilled gear units can become untight and the gear unit oil might leak. Tightness of the filled gear unitsmust be monitored. Leaks must be removed. Siemens does not accept any liability for damages thatare caused from leaking gear unit oil during storage.

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The following control measures must be taken:

• The pressure, suction and/or return lines (6, 8, 9) are sealed with blind flanges.

• The oil drain cock of the tilting pad thrust bearing chamber (10) is sealed with a screw plug.

• The vent hole for the gear unit (4) is sealed with a screw plug.

• The labyrinth seal of the output flange is sealed with the round cord hollow profile (13) and maskedairtight.


• Seal input shaft with a sealing cap (3).

• Seal bottom oil drain of the sealing cap (2) with a screw plug.

• Remove the screw plug from the tilting pad thrust bearing chamber that has been screwed in insteadof the air filter (11).

• The oil to be filled in must be filtered beforehand with a filter mesh of 25 μm (0.0010 inch).

1 3

2 4 7 5

12 11

13

10

9

8

6

Fig. 5: Gear unit features for preservation measures

1 Ventilation sealing cap2 Oil drain sealing cap3 Sealing cap4 Air filter (gear unit)5 Oil level indicator (gear unit)6 Suction line (gear unit)7 Oil drain (gear unit)

8 Pressure line (gear unit)9 Pressure line (tilting pad thrust bearing

chamber)10 Oil drain tilting pad thrust bearing

chamber11 Air filter (tilting pad thrust bearing)12 Oil level indicator (tilting pad thrust

bearing chamber)13 Round cord hollow profile

• Fill sealing cap on the input shaft through the ventilation of the sealing cap (1). The ventilation (1) is tobe closed, only once the oil filling of the gear unit is completed, unless oil is escaping from this openingbefore then.

• For filling, remove the sealing cap that seals the oil drain cock of the gear unit (7). The gear unit mustbe filled with oil through the bottom oil drain cock of the gear unit (7).

Note

The gear unit will be filled completely only when the oil level indicator on the tilting pad thrust bearingchamber (12) shows it is filled completely with oil.

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• Close and seal the vent hole for the tilting pad thrust bearing chamber (11) with a screw plug again.

• The lower oil drain cock on the gear unit (7) must be provided and sealed with a screw plug.

• If not already done, close ventilation of the sealing cap (1).

Note

Before the start-up of the gear unit, the measures according to section 7.1 and 7.2 have to be carriedout.

4.4.3.3 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 underneath the mill and connected to the oil-supplysystem. "Castrol Alpha SP 220 S" or "Tribol 1390" can be used as preservative agent. The oil level mustnever be below the MIN mark on the oil level indicator of the main gear unit, the tilting pad thrust bearingchamber and/or on the oil-supply system (if the model has a tank, also see the operating manual of theoil-supply system). For this purpose, the oil-supply system has to be switched on and the gear unit mustbe turned without load (at least 1 rotation on the output shaft). The oil must be drained, the gear unit andoil-supply system be closed, masked and sealed airtight. Air filters have to be replaced for sealing capsand be sealed. The gear unit has to be sealed airtight with a round cord hollow profile between the gearunit housing and the output flange. The labyrinth seals on the input shaft and on the output flange must bemasked airtight within 1 hour.

Note

Clean the air filters thoroughly (see item 10.3) and keep them in a safe place (these will be requiredwhen starting up again).

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Table 5: Maximum durability period of the interior preservation of the gear unit through operating theoil-supply system.





Packaging for storage


Maximum durability period of the preservation renewal throughoperation of the oil-supply system (in months)

Nopackaging


covered with loose

tarpaulin8 5

under roof 1)



loose tarpaulin


under roof 1)



exposed outdoors


under roof 1)



2) Seaworthy packaging:use of wooden box lined with bitumen paper. The content is sealed in foil and protected against moistureby addition of drying agents for the prescribed storage period.

Note

Before restarting the gear unit, the measures according to section 7.1 and 7.2 have to be carried out.

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5. Technical description


5.1 General description

The gear unit described is a "FLENDER vertical mill gear unit" designed for driving vertical mills.

The vertical mill gear units of the types KMP / KMPS / KMPP are bevel-helical gear units or bevel-planetarygear units for driving a vertical mill.

The axial and radial forces resulting from the grinding process are led into the foundation through the gearunit housing.

A detailed illustration of the gear unit is contained the drawings in the gear unit documentation.

NOTICE

Property damage

Destruction of the gear unit or gear unit parts from wrong rotation direction is possible.The gear unit is approved for one direction of rotation only. Observe the direction-of-rotation arrows on the housing.

5.2 Delivery condition of the gear unit

The input shaft of the gear unit is equipped with a radial shaft sealing ring (1), which is installed hidden andensures the necessary airtight sealing of the gear unit interior for the specified preservation period(see Figure 6). Removing the radial shaft sealing ring during the start-up is not required. Should the radialshaft sealing ring no longer fulfil its sealing function after start-up, this does not impede the reliability of theshaft sealing.

A round cord hollow profile (2) is used as sealing between the gear unit housing and the output flange. Thisseal 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 labyrinth seal of the input shaft and/orthe output flange, or by opening a lid or screw plug), the start-up must take place within one week or thegear unit must be re-preserved according to item 4.4.3.

2

1

1 Radial shaft seal 2 Round cord hollow profile

Fig. 6: Arrangement of the round cord hollow profile and radial shaft sealing ring (schematicillustration)

NOTICE

Property damage

Corrosion is possible when the gear unit is opened too early.Any opening of the gear unit (e.g. by removing the adhesive tape on the input shaft or on the outputflange, removing the round cord hollow profile, or by opening a lid or a screw plug) reduces theguaranteed preservation period. If the gear unit is opened, it must be taken into operation within oneweek. If the start-up is delayed, special measures are necessary to maintain preservation (see item 4.4.3).

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5.3 Lubrication

The lubrication and cooling is provided by continuous oil circulation through a separate oil-supply system.To prevent vibration and to compensate for heat expansion, compensators are provided in the pipesystem.

Note

When operating and servicing the components of the oil supply system, observe the operatinginstructions of the components.For technical data, refer to the data sheet and/or the list of equipment.For a detailed illustration of the gear unit and oil-supply system, refer to the drawings in the gear unitdocumentation.

The kind of lubrication can be found on the order-specific equipment list, the lubrication diagram and the"Technical Data Sheet" of the gear unit.Depending on the gear unit version, one of the following three lubrication systems is installed in the gearunit.

Toothed parts and rolling bearings are force-lubricated and cooled through the low-forced lubricationcircuit.

5.3.1 Hydrodynamic lubrication of the axial tilting pad thrust bearings

In low ambient temperatures, the oil must be pre-warmed. If agreed by contract, immersion heaters will beinstalled in the gear unit housing or the oil tank, or a separate heating circuit will be provided (see equipmentlist and lubrication diagram).

The oil is drawn in by the oil pump, cleaned in the double-changeover filter, which is fitted with an opticaland 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 tiltingpad thrust bearing.

Volumetric flow, pressure and temperature are constantly monitored by monitoring equipment.

5.3.2 Hydrodynamic lubrication of the axial tilting pad thrust bearings in gear units with hydrostatic start-upassistance

In addition to the hydrodynamic lubrication, part of the oil is fed immediately downstream of the cooler tothe high-pressure pump through a branch circuit.

The high-pressure pump is designed as a radial piston pump and supplies a constant oil quantity at eachconnection. The oil is conducted to four axial thrust bearing segments distributed around thecircumference. Before the mill is started, the oil is pumped between the pads and the race. A bearing oilfilm will form immediately. After 2 minutes in operation at operating speed, the high-pressure pump mustbe turned off.

Pressure switches without pressure transmitter this operating phase and the non-return valves built intothe pads prevent the oil from backing up during normal operation.

5.3.3 Hydrodynamic lubrication of the axial tilting pad thrust bearings with radial piston pump

In addition to the hydrodynamic lubrication, part of the oil is fed immediately downstream of the cooler tothe high-pressure pumps through a branch circuit.

The high-pressure pumps are designed as radial piston pumps and supply a constant oil quantity at eachconnection. The same oil quantity is supplied to each bearing pad independently of the counter pressure.The oil connections are distributed so that no two adjacent pads are supplied by one high-pressure pump.The drive can continue to be operated throughout the time required for replacing a broken-downhigh-pressure pump.

In order to ensure that the high-pressure pumps are operating and no oil line is defective, the oil flows aremonitored for minimum and maximum pressure. The pressure is set through the pressure actually exertedby the grinding rollers.

If the minimum setting of a pressure- or flow-monitored component is fallen short of, the main drive will beswitched off. If the maximum pressure is exceeded, a warning is given or the main drive is shut off. Thenon-return valves built into the pads prevent the oil from backing up during normal operation.

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5.3.4 Labyrinth seals

The input shaft and output flange are sealed with labyrinth seals. Air filters are provided on the housing toregulate the pressure.

Labyrinth seals are non-contacting seals. Labyrinth seals prevent wear and tear on the shaft, aremaintenance-free and ensure favourable temperature characteristics.

1

2

Fig. 7: Labyrinth seal (schematic illustration)

1 Labyrinth seal on output flange 2 Labyrinth seal on input shaft

NOTICE

Property damage

Deficient lubrication is possible from oil leakage on the gear unit.For reliable operation, labyrinth seals require stationary, horizontal positioning away from dirty waterand high dust concentrations.Overfilling of the gear unit can cause leakage, as can oil with high foam content.

5.4 Drive coupling

A flexible coupling is to be provided for the gear unit drive. Observe the operating instructions of thecoupling for assembly, operation and maintenance of the coupling.

NOTICE

Property damage

Damage to the gear unit or individual components is possible from inadequate alignment.When installing the drives, make absolutely certain that the individual components are accuratelyaligned to one other. Unacceptable large errors in the alignment of the shaft ends to be connected dueto angular and/or axial misalignments result in premature wear and material damage.

Note

If couplings of other manufacturers are used, the Siemens standard operating instructions forequivalent couplings provide the minimum requirements for the alignment of the coupling. It cannot beassured by Siemens whether these minimum requirements are sufficient in any case. If stricterrequirements in the operating instructions of the supplier or similar document are defined, these willapply.

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5.5 Heating

At low temperatures, it may be necessary to heat the gear oil before switching on the drive unit or evenduring operation. In such cases, e. g. heating elements can be used. These heating elements convertelectrical energy into heat which is conducted to the surrounding oil. The heating elements are located inprotective tubes inside the housing, thus making it possible to replace them without draining the oilbeforehand.

Heating elements must fully submerge into the oil bath.

The heating elements can be controlled by a resistance thermometer or a temperature monitor, whichemits a signal that is amplified when minimum and maximum temperatures are reached.

A detailed illustration of the gear unit and the position of the add-on parts can found in the drawings of thegear unit documentation.

WARNING

Fire hazard

Fire hazard by exposed heating rods is possible.Never switch on the heating elements, unless complete immersion of the heating element in the oil bathis ensured.If heating rods are retrofitted, the maximum heating capacity (see Table 6) on the outer surface of theheating rods must not be exceeded.

Table 6: Specific heating capacity PHoas a function of the ambient temperature

PHo(W/cm²)

Ambient temperature°C

0.9

0.8

0.7

+ 10 to 0

0 to - 25

-25 to - 50

Note

Observe the information contained in the relevant operating instructions for operation andmaintenance.For technical data and control information, refer to the list of equipment.

5.6 Indication of oil level

The gear unit is equipped with an oil level indicator (oil-level indicator with MIN and MAX mark) for a visualcheck of the oil level at standstill. The oil level is checked when the oil has cooled down (on the oil levelindicator).


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5.7 Oil temperature monitoring

The gear unit can be equipped with a resistance thermometer or temperature monitor for measuring theoil temperature in the oil sump.In order to measure the temperatures and/or temperature differences, the temperature monitor should beconnected to an evaluating device by the customer.

Note

In order to measure the temperatures and/or the temperature differences with a Pt 100 resistancethermometer without evaluating instrument, the Pt 100 resistance thermometer must be connected toan evaluation instrument provided by the customer.


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 theorder.

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6. Fitting


6.1 General assembly information

When transporting the gear unit, observe the notes in section 4. "Transport and storage".

Assembly work on the mill must be performed with great care by authorised, trained and qualifiedpersonnel. Siemens is not liable/does not extend a warranty for damages caused by incorrectimplementation.

Adequate lifting gear must be available before beginning the fitting work.

NOTICE

Property damage

Damage to the gear unit is possible.For gear units, which are operated together with electrical machines that generate power or that aresupplied with power (e. g. motors, generators, etc.), it must be ensured that no current can flow throughthe gear unit. The flow 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

NOTICE

Property damage

Because it must be prevented that the gear unit heats up during operation through external influencessuch as direct sunlight or other sources of heat, suitable measures must be taken to avert such heatingup.Suitable measures may be:– an additional cooling unit– a temperature monitoring device in the oil sump with a shut-off function.A heat concentration must be avoided.

NOTICE

Property damage

Damage to the gear unit from dropping objects, heaping over, welding work or inadequate fastening.The operator must ensure the following:– The gear unit must be protected against dropping objects and heaping over.– No welding work may be done at all on the drive.– The gear unit must not be used as an earthing point for electrical welding work.– 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 screws of the same strength class and type.

Note

When fitting in the vertical mill, the mill manufacturer's special instructions must be observed.

Note

Every time the drive is set in motion and any operation of the oil-supply system (with connected gearunit) represents a start-up.

37 / 84BA 9180 en 12/2015

6.2 Set-up conditions

As early as during the planning phase, sufficient space must be allowed around the gear unit for later careand maintenance work.

Note

It must be ensured that the oil can be drained and an adequate air supply is provided. It must bepossible to check the internal parts through the holes in the inspection hole covers.

Upstream and downstream machines have to be arranged accordingly.

If the pipes connecting the gear unit and oil-supply system are included in the Siemens delivery, theinstallation plan is enclosed with the documentation.

6.2.1 Dimensions and weights

Refer to the drawings in the gear unit documentation and the order-specific data sheet for details regardingweight and further technical data.

6.2.2 Lifting device

Adequate lifting gear must be available before beginning the fitting work.

The load-bearing capacity of the lifting gear used or to be installed must correspond at least to the weightof the product that is to be transported (for details see section 1. "Technical data").

Refer to section 4. "Transport and storage", for notes regarding transport.

6.3 Preparatory measures for gear unit installation

NOTICE

Property damage

Damage to the gear unit from corrosion is possible.The packaging must not be opened or damaged beforehand if the packaging is part of the preservation.

The products supplied are listed in the dispatch papers. Check for completeness immediately on receipt.Parts damaged and/or missing parts must be immediately reported in writing to Siemens.

• Before installation of the gear unit in the vertical mill, remove the packaging material and transportequipment, and dispose of it according to regulations.

• Perform a visual check for damages and soiling.

Note

Adhesive tapes on the labyrinths and the round cord hollow profile between the gear unit housing andthe output flange may only be removed directly before the start-up.

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.The instructions in section 4. "Transport and storage" must be observed.

NOTICE

Property damage

Corrosion 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 outputflange, removing the round cord hollow profile, or by opening a lid) reduces the guaranteedpreservation period. If the gear unit is opened, it must be taken into operation within one week. If thestart-up is delayed, special measures are necessary to maintain preservation (see item 6.3.1).

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NOTICE

Property damage

Damage to the sliding bearings is possible.The input shaft of the gear unit may be rotated maximally 1 time for positioning during installation, onlywhen the tilting pad thrust bearing chamber is filled with oil up to the specified level.

• Remove the corrosion protection from all of the preserved surfaces using a suitable cleaning agent.

NOTICE

Property damage

Damage from inadequate stability of the gear unit is possible.The gear unit must be set up on a level, secure, vibration-free and rigid foundation. The levelness ofthe gear unit set-up surface is especially important, as the contact pattern of the teeth and the carryingportion of the axial tilting pad thrust bearings depend on it and the service life of the gear unit is affectedby it.Clean the gear unit and foundation set-up surface.

DANGER

Danger to life



CAUTION

Risk of injury from chemical substances

Observe manufacturer’s instructions for handling lubricants and solvents.Wear suitable protective clothing.

WARNING

Serious personal injury

Risk of personal injury from inflammation caused by solvent steams during cleaning work.Observe also the following:– Keep away from sources of ignition.– Do not smoke.– Ensure adequate ventilation.

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

If a gear unit, which has been opened in the meantime for longer than 1 week, is left standing withouttransport packing in exposed meanwhile roofed surroundings and if it is not possible every 7 days to flushthe gear unit for one hour with the oil-supply system and turn it for 15 minutes, the preservation can bemaintained in part by applying the measures specified in item 4.4.3.

6.3.2 Foundation

The foundation should be laid out in such a way that no resonance vibrations are created and that novibrations are transmitted from adjacent foundations. The foundation structure on which the unit is to beassembled must be rigid. The structure must be laid out according to the weight and torque inconsideration of the forces acting on the gear unit.

NOTICE

Property damage

Damage from inadequate stability of the gear unit is possible.The gear unit must be set up on a level, secure, vibration-free and rigid foundation. The levelness ofthe gear unit standing surface is especially important, as the contact pattern of the teeth and thecarrying portion of the axial tilting pad thrust bearings depend on it and the service life of the gear unitis affected by it.All points on the gear unit base must lie between two imaginary parallel planes0.1 mm per 500 mm (0.0036 inch per 1.5 ft) apart. The permissible deviation of the gear unit base from the horizontal plane is0.2 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 beforeassembly 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 themill manufacturer.

6.4 Assembly of the gear unit

The gear unit must be installed under the vertical mill in accordance with the mill manufacturer'sinstructions.

NOTICE

Property damage

Damage to the sliding bearings is possible.The input shaft of the gear unit may be rotated maximally 1 time for positioning during installation, onlywhen the tilting pad thrust bearing chamber is filled with oil up to the specified level.

The floor screw connection has to be provided according to the requirements of the mill manufacturer.

Note

The separate operating instructions have to be observed if "superbolt nuts" are used.

All other screws that are used for inspection or maintenance have to be tightened as specified in item 6.13.

Once the gear unit is aligned, the pins must be fitted if these are specified in the dimensional drawing.Lateral stops can also be mounted in addition to prevent the gear unit from shifting.

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NOTICE

Property damage

Destruction of the gear unit or gear unit parts from wrong rotation direction is possible.The gear unit is approved for one direction of rotation only. The direction of rotation of the motor must correspond to the direction indicated by the arrow on thegear unit input shaft.

Note

The alignment of the gear unit must be documented.The record must be kept with these instructions.

6.5 Installing the pipework

Pipework has to be checked for damages and dirt before assembly and be cleaned thoroughly and flushedwith a fluid oil.

The pipework must be screwed on in accordance with the specifications on the drawings. Blank flangesand plugs must be removed beforehand. The screw connections seal metallically, while the associatedseals must be used for the 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 pipeworkinstallation.

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 must be carefully pickled and neutralised afterwelding (see item 6.6 "Pickling of adapted pipes").

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6.6 Pickling of adapted pipes

CAUTION


Chemical burns on face and hands from pickling solution.Wear protective glasses and gloves, ensure sufficient ventilation.Observe the manufacturer’s instructions for the handling of pickling solutions.

• The lower end of each pipe must be sealed with a plug.

• Pickling solution: 33 % hydrochloric acid (HCl) diluted with the same quantity of water (H2O).

Note

Air bubbles must not under any circumstances be allowed to form on the inside of the pipes.

• The pipes must be filled with the pickling solution (acting time: 1 hour).

• Drain pickling solution completely out of the pipes without residues and dispose of it according toregulations.

• Flush out pipes thoroughly with water (H2O).

• After emptying the pipes, they must be filled with a neutralising solution (sodium lye 3 % to 5 % NaOH)(neutralisation period 15 minutes). Flush out pipes once again with water (H2O).

• Flush out pipes thoroughly with flushing oil through a 25 μm (0.001 inch) filter.

NOTICE

Property damage

Damage from corrosion.If the adapted pipes are not installed straight away, they must be carefully preserved.If the preserved pipework is reinstalled, item 6.5 has to be observed.

6.7 Installing the couplings

A flexible coupling is used for the gear unit output.

Before beginning the assembly, thoroughly clean shaft ends and the coupling parts.

Fit couplings on the shaft ends using the thread centring hole. Secure the couplings against being shiftedaxially.

Note

Couplings must be balanced in accordance with the specifications in the pertinent instructions manual.When operating and servicing the couplings, observe the operating instructions relating to thecouplings.

Increased system service life and reliability and reduced running noise can be achieved through theleast 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 must not be damaged when pulling on in the coupling parts.

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NOTICE

Property damage

Damage to the gear unit or individual components is possible from inadequate alignment.When installing the drives, make absolutely certain that the individual components are accuratelyaligned to one other. Unacceptable large errors in the alignment of the shaft ends to be connected dueto angular and/or axial misalignments result in premature wear and material damage.

Note

For permissible alignment errors in couplings supplied by Siemens, refer to the instructions manualsfor the couplings.When using couplings of other manufacturers, ask these manufacturers which alignment errors arepermissible, stating the radial loads occurring.

Note

If couplings of other manufacturers are used, the Siemens standard operating instructions forequivalent couplings provide the minimum requirements for the alignment of the coupling. It cannot beassured by Siemens whether these minimum requirements are sufficient in any case. If stricterrequirements in the operating instructions of the supplier or similar document are defined, these willapply.

• Record alignment dimensions.

Note


6.8 Installing the motor

Align and the drive motor central axis of the input shaft of the gear unit when connected with the couplingand fix it in its position.

• Record the alignment of the motor.

Note


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 dangerto life and limb.Align the gear unit precisely.

Damage to the gear unit or its components or add-on parts is possible.The accuracy of the alignment of the shaft axes to each other is decisive for the lifespan of shafts,bearings and couplings. Therefore, the deviation should be zero in nearly all cases. For this purpose,e. g. also the special requirements for the couplings can be found in the related operating instructions.

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6.9 Assembly of loose add-on parts included in the delivery

Seal in loose parts with thread connection.

NOTICE

Property damage

Damage to the gear unit possible from incompatibility of operating oil and sealing agent.No sealing agent must get into the gear unit.

• The plugs and/or sealing flanges must be removed, and the fittings supplied separately must beinstalled in the system according to the drawings in the gear unit documentation.

Note

Electrical lines and the motors and/or monitoring equipment must be connected in accordance withterminal diagrams, lists of equipment and general regulations.

WARNING

Risk of personal injury from electrical shock

Risk of personal injury from electrical shock when connecting electrical components.Ensure zero 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 themill.

WARNING

Risk of personal injury from electrical shock

Risk of electrical shock during welding work.Before welding work may be conducted on the mill, potential equalisation must be provided accordingto the applicable regulations and/or guidelines.The gear unit must not be used as an earthing point for welding operations. Optionally, there may bean earth wire provided on the tilting pad thrust bearing chamber, which must be connected with theoutput flange. For this purpose, use the threaded holes on the side of the output flange. When thewelding work has finished, the earth cable must be removed from the output flange. If no threaded holesfor earth connection are available on the gear unit, other appropriate measures must be taken. Thiswork must always be done by specialist electricians.

6.11 General notes on add-on components

Note

For operating and servicing the components described in section 5., the relevant instruction manualsand the specifications in section 6. must be observed.For technical data and control information, refer to the data sheet and/or the equipment list that hasbeen compiled specifically for the order.

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6.12 Final work

□ After installation of the gear unit, check all screw connections for the connection of the gear unit andthe system for tight fit.

□ Check of the alignment after tightening the fastening elements. The alignment must not have changed.

□ Check that all devices that were uninstalled for transport reasons are reinstalled.For this refer to the details in the data sheet, the list of equipment and the associated drawings.

NOTICE

Property damage

Damage to the gear unit can be caused by overheating at too low an oil level due to leakages.Existing oil drain cocks must be secured against accidental opening.

□ The gear unit must be protected against dropping objects.

□ Protective devices for rotating parts must be checked for correct seating. Contact with rotating partsis not permitted.

□ Potential equalisation must be provided in accordance with the applicable regulations and/orguidelines!If no threaded holes for earth connection are available on the gear unit, other appropriate measuresmust be taken. This work must always be done by trained electricians.

□ Cable entries must be protected against moisture.

6.13 Screw connection classes, tightening torques and initial stressing forces

6.13.1 Screw connection classes

The specified screw connections are to be fastened applying the tightening torques specified observingthe table below.

Table 7: Screw connection classes

Fastening ofScrew connection

class Tightening procedure

D – Hydraulic tightening with mechanical screwdriver

Inspection-hole coverProtective hood

E

– Tightening with pulse screwdriver or impact wrench withoutadjustment checking device

– Tightening by hand, using a spanner without torque measurement

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6.13.2 Tightening torques and initial stressing 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 phosphatisedand dry, cut counter threads in steel or cast iron. Lubricants which alter the friction coefficient are notpermitted and might overload the screw connection.

Table 8: Initial stressing forces and tightening torques for screw connections of strength classes 8.8;10.9; 12.9 with a common friction coefficient of μtotal = 0.14

Nominaldiameter ofthe thread

Strengthclass of the

bolt

Initial stressing force for screwconnection classes from Table 7

Tightening torque for screwconnection classes from Table 7

C D E C D E

dmm

FM min.N

MANm

M10

8.8 18000 11500 7200 44.6 38.4 34.3

10.9 26400 16900 10600 65.4 56.4 50.4

12.9 30900 19800 12400 76.5 66.0 58.9

M12

8.8 26300 16800 10500 76.7 66.1 59.0

10.9 38600 24700 15400 113 97.1 86.6

12.9 45100 28900 18100 132 114 101

M16

8.8 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 1480 1330

12.9 284000 182000 114000 2010 1740 1550

M36

8.8 246000 157000 98300 2080 1790 1600

10.9 350000 224000 140000 2960 2550 2280

12.9 409000 262000 164000 3460 2980 2670

M42

8.8 331000 212000 132000 3260 2810 2510

10.9 471000 301000 188000 4640 4000 3750

12.9 551000 352000 220000 5430 4680 4180

M48

8.8 421000 269000 168000 4750 4090 3650

10.9 599000 383000 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 535000 22000 18900 16900

12.9 1570000 1000000 628000 25800 22200 19800

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Nominaldiameter ofthe thread

Tightening torque for screwconnection classes from Table 7

Initial stressing force for screwconnection classes from Table 7

Strengthclass of the

bolt

EDCEDC

dmm

MANm

FM min.N

M80x6

8.8 1190000 760000 475000 21500 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

Damaged bolts must be replaced with new bolts of the same type and strength class.

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7. Start-up


• Before and during the start-up, fill out the existing checklists (e. g. "Checklist for oil filling and oil change"and "Documentation sheet for oil change" in the separately enclosed operating instructions BA 7300)and file these with the documentation.

NOTICE

Property damage

Damage to the gear unit is possible.The gear unit must not be taken into operation if the required manual is not on hand.During start-up the initial run of the gear unit is load free, that is, without grinding material and rollerpressure.

Note

Any setting of the drive in motion represents a start-up.

7.1 Procedure before start-up

The start-up must be carried out with great care by authorised, trained and qualified personnel. Siemensis not liable/does not extend a warranty for damages caused by incorrect implementation.

For this reason the operating instructions must be adhered to, particularly if maintenance work is carriedout 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 removedif 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

Property damage

Metallic bright surfaces without protection are susceptible to corrosion.For avoidance of corrosion, the exterior preservation may be removed only directly before theassembly.

• The corrosion prevention must be removed from the shaft ends in the area of the couplings that are tobe mounted with suitable means (special solvent).The corrosion prevention must also be removed from the bright surfaces of the gear unit, onto whichcomponents are to be mounted.

CAUTION


The solvent must not come into contact with the skin (e. g. the operator’s hands).The safety notes on the data sheets for the solvent used must be observed.Immediately remove any spilled oil immediately using an oil binding agent.Observe manufacturer’s instructions for handling lubricants and solvents.Wear suitable protective clothing.

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7.1.2 Removal of preservative agent from interior

Note

The required measures prior to start-up are described in the following, as dependent on the basicpreservation applied (see Technical data) on the gear unit.Detailed descriptions of the procedure as well as regarding the particularities, which must be taken intoaccount, can be found in the following items 7.1.3 to 7.1.5 and in the separately provided operatinginstructions BA 7300.

Table 9: Measures before the start-up of gear units, which have not been taken into operationbefore, are as follows depending on the gear unit basic preservation/prolongation ofpreservation.

Kind of basicpreservation

Kind of preservationprolongation

Measures beforestart-up

Castrol Alpha SP 220 S – none – fill with operating oil.

Castrol Alpha SP 220 S– Castrol Corrosion Inhibitor N 213

<= 5 % operating oil quantity– fill with operating oil.

Castrol Alpha SP 220 S– Castrol Corrosion Inhibitor N 213

> 5 % operating oil quantity

– drain preservative oil, flush withoperating oil and fill with new operatingoil.

Castrol Alpha SP 220 S– completely filled with operating

oil (mineral oil or oil onPAO-basis)

– drain preservative oil until operating oillevel is reached.

Castrol Alpha SP 220 S– completely filled with the

approved mineral oil (seespecification in BA 7300)

– drain preservative oil and fill with newoperating 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 new

operating oil.

Castrol Tribol 1390 – none– flush with operating oil and fill with new

operating oil.

Castrol Tribol 1390– Castrol Corrosion Inhibitor N 213

<= 5 % operating oil– flush with operating oil and fill with new

operating oil.

Castrol Tribol 1390– Castrol Corrosion Inhibitor N 213

> 5 % operating oil


Castrol Tribol 1390– completely filled with operating

oil (mineral oil or oil onPAO-basis)


Castrol Tribol 1390– completely filled with the

approved mineral oil (seespecification in BA 7300)


Castrol Tribol 1390 – Castrol Alpha SP 220– flush with operating oil and fill with new

operating oil.

Castrol Tribol 1390 – Castrol Tribol 1390– flush with operating oil and fill with new

operating oil.

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NOTICE

Property damage

With larger filled-in quantities of the Corrosion Inhibitor N 213 (above 5 % of the operating oil quantity),the mixture of operating oil and Corrosion Inhibitor N 213 must not be used as operating oil. The gearunit must be flushed thoroughly with operating oil before start-up, after draining the mixture of operatingand preservative (in this regard, see item 10.4.)

Table 10: Restart of preserved gear units, which have already been in operation

Kind of operating oil Kind of preservation Procedure before start-up

Mineral oil

Oil on PAO-basis

– Castrol Corrosion Inhibitor N 213<= 5 % operating oil – fill with operating oil.

Mineral oil

Oil on PAO-basis

– Castrol Corrosion Inhibitor N 213> 5 % operating oil


Mineral oil

Oil on PAO-basis

– completely filled with theapproved oil (see specification inBA 7300)

– for operating oil: drain oil until operatingoil level is reached.

– other than operating oil: drain oil and fillwith new operating oil.

Mineral oil

Oil on PAO-basis– Castrol Alpha SP 220 – fill with operating oil.

Mineral oil

Oil on PAO-basis– Tribol 1390

– flush with operating oil and fill with newoperating oil.

NOTICE

Property damage

With larger filled-in quantities of the Corrosion Inhibitor N 213 (above 5 % of the operating oil quantity),the mixture of operating oil and Corrosion Inhibitor N 213 must not be used as operating oil. The gearunit must be flushed thoroughly with operating oil before start-up after draining the mixture of operatingand preservative (in this regard, see item 10.4.)

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7.1.3 Draining preservative oils

For the position of the oil draining points is marked on the dimensioned drawing in the gear unitdocumentation.

• Place suitable containers under the oil drain points.

• Unscrew the oil drain plug and/or open the oil drain cock.

• Remove preservative oil from the housing using a suitable container; to do so, unscrew any existingresidual oil drain plugs.

• Dispose of the residue of the preservative oil in accordance with regulations.

CAUTION


The oil must not come into contact with the skin (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 that have been.

2 4 6

5 1 3

Fig. 8: Oil filling and oil draining - gear unit (schematic diagram)

1 Oil drain of the gear unit2 Oil drain of tilting pad thrust bearing

chamber3 Oil level of gear unit

4 Oil level of tilting pad thrust bearing5 Air filter of gear unit6 Air filter of tilting pad thrust bearing


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7.1.4 Flushing before initial start-up

In general, it must be differentiated between flushing prior to the initial start-up and flushing before or afterrepairs and maintenance work (see item 10.4 "Flushing").

Flushing before initial start-up serves to minimise residues from previous lubricating oils or preservativeagents.

Flushing should be carried out with the selected service lubricating oil. Lower viscosities (e.g. VG 46 orVG 100) of oil of the same grade and brand as that one used as operating lubricating oil may also be usedas flushing oil.

• Put in flushing oil. For flushing, the gear unit and/or the tank of the oil-supply system must be filled withsufficient oil, so that the oil pump of the oil-supply system can be operated for flushing (see item 7.1.4.1"Oil quantity for flushing").

• Flushing times:For flushing, operate the oil pump of the low-pressure lubricating circuit for at least 6 hours.If a high-pressure lubrication circuit is present, it must be switched on after 2 minutes.

NOTICE

Property damage

Damage to the gear unit and 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 8 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 oilbefore re-use. The flushing oil must be filtered beforehand or during filling using a nominal filter meshof 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 flushing, the gear unit and/or the tank of the oil-supply system must be filled with sufficient oil, so thatthe oil pump of the oil-supply system can be operated for flushing, without air being aspired. The flushingoil quantity may be up to 100 % of the total oil filling required for operations, depending on the gear unitmodel. On the delivery of the gear unit, the connecting pipework, and the oil-supply system by Siemens,the total oil filling quantity can be found in the technical data of the order-specific gear unit documentation.

7.1.5 Fill in operating oil

Data, such as oil type and oil viscosity can be found in the order-specific "Technical data". The totaloperating oil quantity for the gear unit, the oil-supply system, and the pipework can be found in the set-upplan. If the oil-supply system and the pipework are not included in the scope of delivery by Siemens, theoperating oil quantity for the gear unit is shown on the rating plate (see section 1. "Technical data").

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7.1.5.1 Oil level

Fill in as much oil so that the required oil level of the gear unit is reached (MIN and MAX mark on the oil levelindicator of the main gear unit), the tilting pad thrust bearing chamber, (see Figure 8 in item 7.1.3) and/oron the oil-supply system (if the model has a tank), while the gear unit is stopped and the oil pump of theoil-supply system (low-pressure lubrication circuit) is in operation (also see the operating instructions forthe oil-supply system).

NOTICE

Property damage

Deficient lubrication by oil level too low is possible.Notice the oil level.The oil level must never be below the MIN mark on the oil level indicator of the main gear unit, the tiltingpad thrust bearing chamber and/or the oil-supply system (if the model has a tank, also see operatinginstructions for the oil-supply system).Fill up oil if necessary.

CAUTION


The oil must not come into contact with the skin (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.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 thepreservative oil are contained in the separately provided operating instructions BA 7300.

Please also notice the following information and processes in addition:

• Fill out the existing checklists and logs (e. g. "Checklist for oil filling and oil change" and "Documentationsheet for oil change" in the separately enclosed operating instructions BA 7300) and file these with thedocumentation.

NOTICE

Property damage

Damage can be caused to the gear unit if low-quality operating oils or not approved oils are used.The quality of the oil used must meet the requirements of the separately supplied BA 7300 instructionsmanual, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one ofthe oils listed in Table "T 7300" (for a link to the Internet, see back cover), as they have been tested andmeet the requirements.Data, such as oil type, oil viscosity can be found in the "Technical data" prepared specifically for theorder.

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Note

If gear units have oil-supply systems, the oil circuit must be filled additionally. If systems have a motorpump for the oil circuit, the pump must be turned on briefly.

Note

Oil pumps and parts with drill holes for oil filling that are marked with a special sign have to be filled withoil before the start-up of the gear unit.

This is done by way of:

─ an oil-filling hole on the oil pump of the lubricating system or

─ an oil-filling hole on the pressure line or

─ an oil-filling hole marked with an instruction plate

These oil-filling holes must be tightly closed to prevent the pump from drawing in air and/or oil fromescaping.

A detailed illustration of the gear unit is contained the drawings in the gear unit documentation.

The gear unit can be filled with oil in different ways, depending on the equipping of the oil-supply system.

• The oil to be put in must be filtered beforehand with a nominal filter mesh of 25 μm (0.0010 inch).

─ If the oil-supply system is equipped with three-way cocks, the gear unit can be filled either through thethree-way cocks of the oil-supply system or through the oil drain cock of the tilting pad thrust bearingchamber of the gear unit.

─ If the oil-supply system is not equipped with three-way cocks, the gear unit is filled through the oil draincock of the tilting pad thrust bearing chamber.

─ If the oil-supply system is equipped with a tank, the gear unit can be also filled with oil through the oiltank of the oil-supply system. For this, it is necessary in the meantime to start the low-pressure pumpof the oil-supply system in order to also fill the tilting pad thrust bearing chamber of the gear unit withoil.

Note

Wherever possible, warm oil (approx. 30 °C to 50 °C) should be used for filling so that the viscosity isnot too high.

Note

The filling must be carried out while the gear unit and the oil-supply system are shut off.The oil is filled in manually through the oil drain cock of the tilting pad thrust bearing chamber or thesecondary circuit of the oil-supply system. Fill in oil until the required oil level of the gear unit is reached(MIN and MAX mark on the oil level indicator of the main gear unit, the tilting pad thrust bearingchamber, see figure Figure 8 in item 7.1.3) and/or the level marked on the oil-supply system (formodels with tank) (also see the operating instructions for the oil-supply system).If the required oil level is not reached, the oil-supply system cannot be turned on. Keep filling in oil untilthe required oil level of the gear unit is reached (MIN and MAX mark on the oil level indicator of the maingear unit, the tilting pad thrust bearing chamber, see Figure 8 in item 7.1.3) and/or the level marked onthe oil-supply system (for models with tank) when the gear unit is stopped and the oil pump of theoil-supply system (for models with tank) is in operation (also see the operating instructions for theoil-supply system).For the oil-supply system, the oil level is often higher when the oil-supply system is switched off thanwhen it is turned on, since oil can return from the pipes or hoses. Therefore, the correct oil level mustfrequently be reached iteratively in this case.

54 / 84BA 9180 en 12/2015

Note

If the quality of the oil used does not meet the requirements of the separately supplied BA 7300instructions manual, the guarantee given by Siemens will lapse. We urgently recommend using oneof the oils listed in the document "T 7300" (for a link to the internet, see back cover), because they havebeen tested and meet the requirements.Data, such as oil type, oil viscosity and approximately required oil quantity can be found on the ratingplate.

• Check the oil level in the gear unit housing.

CAUTION


The oil must not come into contact with the skin (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.Wear suitable protective clothing.

7.1.6 Oil-supply system

The main gear unit is supplied with lubricating and cooling oil by the oil-supply system (see operatinginstructions 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 partsand remove all material residues, tools and installation aids.

Check the entire drive for the following:

□ Has the foundation been correctly constructed?

□ Are all the foundation bolts tightened to specification?

□ Has the gear unit been correctly fastened in place?

□ Has the grinding bowl been correctly installed?

□ Are the direction of rotation of the motor and that of the gear unit identical (see direction of rotationarrow)?

□ Has the adhesive tape on the labyrinth seals been removed?

□ Has the round cord hollow profile been removed from the gear unit housing and the input flange?

□ Are all air filters installed?

NOTICE

Property damage

Damage to the gear unit due to absent or inadequate ventilation is possible.Prior to start-up, the screw plug must be replaced with air filter.Remove adhesive tape from the labyrinth seals.Remove the round cord hollow profile between the gear unit housing and the input flange.

55 / 84BA 9180 en 12/2015

□ Is all pipework cleaned and installed in accordance with the assembly instructions?

NOTICE

Property damage

Damage to the gear unit is possible.Particular care must be taken to ensure that the oil conducting pipework is clean, since any dirt in itwould be conducted through the gear unit before it could be filtered out at the filter of the oil-supplysystem.

□ Are the coupling and the motor correctly aligned?

□ Have the pipework and the hoses been correctly fitted?

□ Have the pipe and hose connections been checked for leaks? Particular attention must be given to theflange connections on the suction line. If air gets into it, the oil tends to foam.

□ Is the oil in the oil reservoir (tank of oil-supply system and/or gear unit) low-foaming on the surfaceduring operation? If there is foam, check all the suction line connections. If necessary, also contact theoil manufacturer.

□ Is the tank of the oil-supply system and/or the gear unit and the tilting pad thrust bearing chamber beenfilled with oil? The oil level must be checked while the oil-supply system is running and the gear unit isin 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 electric interlock between the gear unit, oil supply and mill drive motor been checked?

Document the following of the checks:

□ Function of the interlock according to interlock specifications.

□ Adjustment and function of flow monitor or flow transmitter, pressure switch or pressure transmitter,and temperature sensor.

□ Cooling-water supply opened, on oil-supply systems with water oil-cooler.

□ Sufficient air supply on the vents if the oil-supply system has an air cooler.

□ Has the alignment of the gear unit and adjacent components been checked, logged and documented?

□ Evenness of the foundation.

For further checks, see the operating instructions for the coupling, motor, oil-supply system and verticalmill.

Note

The report must be kept with these instructions.

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7.2 Start-up

7.2.1 Pre-lubrication phase

Prior to each start-up, always pre-lubricate the gear unit for approx. 30 minutes by means of the oil-supplysystem.

During this time rolling bearings, axial tilting pad thrust bearings and teeth for the initial start are suppliedwith lubricating oil.

For gear units with high-forced lubrication it has to be noticed that the low-forced lubrication system isstarted first and then the high-forced lubrication system 2 minutes later. This time is necessary to ensurethe pressure balance in the oil circuit.

Note

Start existing high-pressure pumps no later than 5 minutes before the auxiliary or main motor is started.

7.2.2 Initial start-up

• Observe all necessary instructions.

• Start the gear unit.

If possible, the gear unit should run for several hours on part load (50 % to 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 witha suitable instrument (e. g. stethoscope).

b) Foam formation

Is the oil in the oil reservoir (tank of oil-supply system and/or gear unit) low-foaming on the surface?Surface foam of up to approx. 10 mm is acceptable. If there is foam, check all the suction lineconnections. If necessary, also contact the oil manufacturer. With rising oil temperature, the formationof foam reduces.

c) Vibration measurement

(for this see section 10. "Maintenance and repair", item 10.9)

d) Oil leakages

Monitor all screw connections in the oil lines for oil leaks and reseal them if necessary!

Note

The date of initial start-up must be notified to Siemens within 4 weeks after start-up.

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7.2.3 Checking procedure

The following visual checks must be conducted and recorded when starting up:

□ Oil level

□ Leak tightness of the oil cooling or oil supply lines

□ Opening condition of the shut-off valves

□ Effectiveness of the shaft seals

□ Freedom of the rotating parts from contact

Note

The report must be kept with these instructions.

7.3 Removal from service

• Switch off the drive unit.

DANGER

Danger to life from switched on system

For carrying out work on the gear unit, the gear unit and the oil supply system must generally be shutdown.The drive unit must be secured against accidental start-up (e. g. by locking the key switch or removingthe fuses from the power supply).Attach a notice on the start switch stating clearly that work is in progress on the gear unit.

• Our recommendation is that during short interruptions the complete oil-supply system be keptoperating. If the unit is taken out of service for longer periods, we recommend keeping the oil-supplysystem 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-pressurepumps, when oil-supply systems with a high-pressure lubricating circuit are shut off.

• During a longer stoppage the shut-off valves in the coolant inlet and outlet lines must be closed. If awater-oil cooler is used, the water must be drained off to prevent damage from freezing atpossible sub-zero temperatures.

• If gear units are operated in a saline environment or in the vicinity of bodies of saline water, the oil-supplysystem must be run through its cycle to prevent damage from corrosion. In addition, the gear unit hasto be turned every two weeks powered by the auxiliary drive or main motor (at least one rotation on theoutput flange).If this is not possible, item 7.3.1 must be observed.

Note

After taking the gear unit out of service, it will be protected on the interior against corrosion with theoperating oil for 7 days.

If it is taken out of service for > 7 days, the lubricating system has to be taken into operation once a weekfor 1 hour. At the same time, the gear unit has to be turned every 2 weeks (at least one rotation on the outputflange).

Note


If it is not possible to start up the lubricating system once a week and to turn the gear unit every 2 weeksat the same time, or if the gear unit is taken out of service for longer than 7 days, the gear unit must bepreserved according to items 7.3.1 and 7.3.2.

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

Depending on the specific application, the following measures for renewing the interior preservation of thegear unit can be taken in case it is taken out of service for a longer period (> 7 days).

The durability period of this preservation kind depends on the measure for renewing the interiorpreservation of the gear unit, the packaging type, and the setup and/or storage place (see Table 11 orTable 12 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."Castrol Alpha SP 220 S" or "Tribol1390" can be used as preservative agent. The oil level must never bebelow the MIN mark on the oil level indicator of the main gear unit, the tilting pad thrust bearing chamberand/or the oil-supply system (if the model has a tank). See also operating instructions of the oil-supplysystem. For this purpose, turn on the oil-supply system and turn the gear unit without load (at least1 rotation on the output). Drain the oil, close, mask and seal the gear unit and oil-supply system airtight.Replace air filters for sealing caps and be seal them. Seal the gear unit airtight with a round cord hollowprofile between the gear unit housing and the output flange. Mask the labyrinth seals on the input shaft andon the output flange airtight within 1 hour.

Note

Clean the air filters thoroughly (see item 10.3) and keep it in a safe place (these will be required whenstarting up again).

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Table 11: Maximum durability period of the interior preservation of the gear unit through operating theoil-supply system.





Packaging for Storage


Maximum durability period of the preservation renewal throughoperation of the oil-supply system (in months)

nopackaging


covered with loose

tarpaulin8 5

under roof 1)



loose tarpaulin


under roof 1)



exposed outdoors


under roof 1)



2) Seaworthy packaging:use of wooden box lined with bitumen paper. The content is sealed in foil and it must be protected againstmoisture by addition of drying agents for the prescribed storage period.

Note


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

For prolonging the interior preservation, the VCI-gas discharging fluid "Castrol Corrosion Inhibitor N 213" is recommended.

For sealing the input shaft, a sealing cap (can be obtained from Siemens) must be mounted and tightenedon the gear unit for sealing the input shaft.

Note

Oil already filled in does not have to be drained.

CAUTION

Risk 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 unittemperature is above 5 °C during filling.


• Seal input shaft with a sealing cap.

• Seal bottom and top oil drain of the sealing cap with a screw plug.

• Seal the pressure, suction and/or return lines with blind flanges.

• Fit screw plugs on the oil drain cocks on the gear unit and the tilting pad thrust bearing chamber andseal them.

• Seal input flange with round cord hollow profile (2) (see Figure 6 in item 5.2) on the labyrinth. Mask thelabyrinth 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 enquiredfrom Siemens). The interior volume of the gear unit can be ascertained in approximation also by meansof the length x width x height of the gear unit.Fill the tilting pad thrust bearing chamber and gear unit chamber respectively up to half of thepreservative volume.

• Replace the air filters of the gear unit and the tilting pad thrust bearing chamber for screw plugs (replacethem again at start-up).

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 opening.When opening the gear unit multiple times, "Castrol Corrosion Inhibitor N 213" has to be refilled.

The following table shows the durability period of the gear unit interior preservation with"Castrol Corrosion Inhibitor N 213" depending on the packaging and setup or storage site.The definition of climatic zones can be found in item 4.4.2.1.

Note

If the gear unit is transported after the preservation was renewed, the durability period according toTable 2 in item 4.4.2.1 has to be observed.

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Table 12: Durability period of prolonged interior preservation of the gear unit with "Castrol Corrosion Inhibitor N 213"





Packaging for Storage


Maximum durability period of the preservation renewal with "CastrolCorrosion Inhibitor N 213" (in months)

Nopackaging


covered with loose

tarpaulin8 5

under roof 1)



loose tarpaulin


under roof 1)



exposed outdoors


under roof 1)



2) Seaworthy packaging:use of wooden box lined with bitumen paper. The content is sealed in foil and it must be protected againstmoisture by addition of drying agents for the prescribed storage period.

NOTICE

Property damage

With larger filled-in quantities of the "Corrosion Inhibitor N 213" (above 5 % of the operating oilquantity), the mixture of operating oil and "Corrosion Inhibitor N 213" must not be used as operatingoil. The gear unit must be flushed thoroughly with operating oil before start-up after draining the mixtureof operating and preservative (in this regard, see item 10.4.)

NOTICE

Property damage

Damage to the gear unit is possible.The gear unit may not be turned.

Note


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

A further possibility for prolonging the gear unit interior preservation is to fill the gear unit with preservativeor operating oil until the oil level indicator on the tilting pad thrust bearing chamber shows it is filledcompletely with oil.The durability of this kind of preservation depends on the used oil and has to be enquired with the oilmanufacturer.

For the complete filling, a sealing cap (can be obtained from Siemens) must be mounted on the gear unitfor sealing the input shaft.

The preservation will remain intact for as long as the gear unit remains sealed and the storage durabilityof the oil is not exceeded.

Note

Oil already filled in must be drained as described in Section 10. "Maintenance and repair".

Note

Refer to the BA 7300 operating instructions supplied separately for the approved preservative oils. Theviscosity of the operating oil is stated on the rating plate.For better filling, it is recommended to choose an oil with low viscosity, which however is not suitablefor later operation of the gear unit. This oil must be drained completely.It is recommended to use the later operating oil for the complete filling and to drain the oil before start-upuntil the operating oil level is reached.

NOTICE

Property damage

Corrosion damages on the gear unit possible from the loss of the preservative effectFilled gear units can become untight and the gear unit oil might escape. Monitor the tightness of thefilled gear units. Repair leaks. Siemens does not accept any liability for damages that are caused fromleaking gear unit oil during storage.


• Seal input shaft with a sealing cap (3).

• Seal bottom oil drain of the sealing cap with a screw plug (2).

• Seal the oil drain cock of the tilting pad thrust bearing chamber (10) with a screw plug.

• Seal the pressure, suction and/or return lines (6, 8, 9) with blind flanges.

• Seal and mask labyrinth seal on the output flange airtight with a round cord hollow profile (13).

• Replace the air filter of the gear unit (4) with a screw plug (at start-up, the screw plug must be replaced for the air filter again).

• The oil to be put in must be filtered beforehand with a filter mesh of 25 μm (0.0010 inch).

• Fill sealing cap on the input shaft through the ventilation of the sealing cap (1).Close the ventilation (1) only once the oil filling of the gear unit is completed, unless oil is escaping fromthis opening before then.

• The gear unit must be filled with oil through the bottom oil drain cock of the gear unit (7).

• The gear unit will be filled completely only when the oil level indicator on the tilting pad thrust bearingchamber (12) is filled completely with oil.

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13

1012 11

72

1 3

4 5

9

8

6

Fig. 9: Gear unit features for preservation measures

1 Ventilation sealing cap2 Oil drain sealing cap3 Sealing cap4 Air filter (gear unit)5 Oil level indicator (gear unit)6 Suction line (gear unit)7 Oil drain (gear unit)

8 Pressure line (gear unit)9 Pressure line (tilting pad thrust bearing

chamber)10 Oil drain (tilting pad thrust bearing

chamber)11 Air filter (tilting pad thrust bearing

chamber)12 Oil level indicator (tilting pad thrust

bearing chamber)13 Round cord hollow profile

• Replace the air filter of the tilting pad thrust bearing chamber (11) with a screw plug (at start-up, the screw plug must be replaced for the air filter again).

• 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


7.3.2 Exterior corrosion prevention

• Clean the surfaces.

• Apply preservative agent.

Note

Preservative agent, see Table 1 in item 4.4.1.1.

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8. Operation

Observe the instructions in section 3. "Safety instructions", in section 9. "Faults, causes and remedy" andin section 10. "Maintenance and repair"!

8.1 General

To achieve a satisfactory operation of the equipment without failures, be certain to observe the operatingvalues specified in section 1. "Technical Data", as well as the information given in the operatinginstructions of the oil-supply system.

During operation, the gear unit must be monitored for the following:

□ Oil temperature The gear unit is designed for an oil distributiontemperaturein continuous operation of:50 °C (122 °F)If the oil-supply temperature reaches critical values(see lubrication plan and equipment list), the gear unitmust be shut down immediately and Siemensconsulted.

□ Oil pressure of the oil-supply system orgear unit lubricating system

□ Changes in gear noise

□ Possible oil leakage at the housing andshaft seals

□ Bearing vibrations withpresent measuring device

□ Storage temperatures with existingtemperature monitoring

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8.2 Oil level

Note

To check the oil level, the gear unit must be stopped and the oil level has to be checked while theoil-supply systems is running (low-pressure lubrication circuit).The following oil level applies as correct:

– middle between the MIN and MAX mark on the oil level indicator (on the bottom gear unit part)

The cooled down oil should be visible between the MIN and MAX mark on the oil level indicator. Hotoil may slightly exceed the MAX mark on the oil level indicator.If the upper mark on the oil level indicator is exceeded, increased foaming of the oil can arise, as thebevel wheel that is running quickly agitates the oil. If the upper mark on the oil level indicator isexceeded, also leaks can also develop on the input shaft. Adjust oil level if necessary.

NOTICE

Property damage

Deficient lubrication is possible from 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-supplysystem applies (not the oil level marks on the gear unit).The oil level in the tank must be above the warning mark. If this mark is not reached, refill oil.

8.3 Irregularities

NOTICE

Property damage

Damage to the gear unit from error states is possible.Turn off the drive unit immediately in the cases stated below.

□ If irregularities are found during the operation.

□ If a monitoring device triggers an alarm (only with correspondingly equipped gear unit).

Note

Determine the cause of the fault, by means of the information regarding faults provided in Table 13 (seeitem 9.2).Table 13, "Faults, causes and remedy", contains a list of possible faults, their causes and suggestedremedies.If the cause cannot be found, a specialist from one of the Siemens Customer Service Centres shouldbe called in (see section 2. "General notes").

Note

Continuous changes in the operating behaviour of the gear unit must be recorded with the aid of trendrecords.

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9. Faults, causes and remedy

Observe the instructions in section 3. "Safety instructions" and in section 10. "Maintenance and repair"!

9.1 General information on faults and malfunctions

Failures occurring during the guarantee period, which require repair of the gear unit, may only be carriedout by Siemens Customer Service.If failures occur after the guarantee period, the cause of which cannot be precisely identified, we adviseour customers to contact our Customer Service.

NOTICE

Property damage

Damage to the gear unit from improper use is possible.Siemens will not be bound by the terms of the guarantee or otherwise be responsible in cases ofimproper use of the gear unit, modifications carried out without the approval by Siemens or use of spareparts not originally supplied by Siemens.

DANGER


Risk of being gripped or drawn in by rotating and/or moving parts.Shut off the gear unit and the oil-supply system to perform maintenance and/or repair work or prior toremoving the safeguards. Secure the drive unit against accidental start-up. Attach a notice on the startswitch stating clearly that work is in progress on the gear unit.

WARNING

Risk of personal injury from energised parts

Removing covers, improper use of the machine, false operation or inadequate maintenance can leadto death, serious personal injury or property damage.

– Always observe the "five safety rules" when working on the machine.(see Section 3. "Safety instructions").

– Remove covers only in accordance with the instructions of this operating manual.– Operate the machine properly.– Conduct regular and professional maintenance on the machine.

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9.2 Faults, causes and remedy

Table 13: Faults, causes and remedy

Faults Possible causes Remedy

Changes in gear unit noise. Damage to gear teeth.

Bearing backlash too high or toolow.

Bearing defective.

Contact Customer Service.Check toothed components.If necessary exchange damagedcomponents.

Contact Customer Service.Adjust bearing backlash.

Contact Customer Service.Replace defective bearings.

Increased temperature at thebearing points.

Oil level in the gear unit housingtoo high or too low.

Oil too old.

Mechanical oil pump defective.

Bearing defective.

Electrical equipment defective.

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 workingcorrectly.Repair or replace oil pump.

Contact Customer Service.Check and, if necessary, replacebearings.

Check electrical devices and replacethem if necessary.

Oil leakage from gear unit. Inadequate sealing of housingcovers and/or joints.

Oil level in housing too high.

Check and, if necessary, replaceseals.Seal joints.

Check the oil level. Adjust oil level ifnecessary.

Volume flow measuring devicetriggers alarm.

Oil too cold.

Oil filter dirty.

Pipes leaky.

Device defective.

Heat oil.

Clean oil filter.Consult operating instructions foroil-supply system.

Check and, if necessary replace pipes.

Check device and replace itif necessary.

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Faults RemedyPossible causes

Pressure monitor triggersalarm.

Oil level too low.

Oil pump defective.

Operating temperature increased.

Oil filter dirty.

Pipes leaky.

Device defective.

Check the oil level.Fill up oil if necessary.

Check oil pump and replace ifnecessary.

See Faults "Operating temperature toohigh".

Clean the oil filter.Consult operating instructions foroil-supply system.

Check and, if necessary replace pipes.

Check device and replace itif necessary.

Increased operatingtemperature.

Oil level in the gear unit housingtoo high.

Oil too old.

Oil badly contaminated.

Oil pump defective.

Oil filter dirty.

Cooler defective (dirty).

Cooling-water feed and/orcooling-air feed defective.


Check the oil level. Adjust oil level ifnecessary.

Contact Customer Service.Check date of last oil change.

Contact Customer Service.Change oil.

Check oil pump,and change if necessary. Consultoperating instructions for oil-supplysystem.

Clean the oil filter.Consult operating instructions foroil-supply system.

Check the cooler and replace itif necessary. Observe operatinginstructions for cooler.

Check cooling-water feed and/orcooling-air feed. Observe operatinginstructions for cooler.


Excessive temperature ontemperature sensor in tiltingpad thrust bearing.

Oil filter dirty.

Oil quantity to tilting pad thrustbearing too small.

Monitoring devices defective.

May also be connected with alteredgrinding parameters, e. g. raising ofthe temperature of the gas in thevertical mill.


Check oil filter for dirt.Consult operating instructions foroil-supply system.

Check setting of the control valves.

Check all monitoring devices.Observe operating instructions of themonitoring devices.

Analyse and check milling parameters.


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Faults RemedyPossible causes

The oil foams. Water in oil.

Oil too old (defoaming agent usedup).

Unsuitable oils mixed up.

Examine oil.Change oil if necessary.



Water in oil. Cooler leaky.

Water condensing.

Replace cooler.

Change oil.

Reduce water content by heating theoil.

Fault in oil-supply system. Observe operating instructionsfor 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 7300 instructionsmanual.

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10. Maintenance and repair

Observe the instructions in section 3. "Safety instructions" and in section 9. "Faults, causes and remedy"!

10.1 General notes on maintenance

Maintenance comprises all measures for preserving and restoring the target condition and for ascertainingand assessing the actual condition of the technical means of a system.

In this context maintenance is a comprehensive generic concept which can be subdivided into three areas:

─ Inspection

─ Maintenance (including lubrication)

─ Repair

All maintenance and repair work must be carried out carefully and by qualified personnel only (see section"Qualified Personnel" on page 3 of these instructions).

WARNING

Serious personal injury can be caused by switched-on machine

Shut down the gear unit and the oil-supply system to perform maintenance and/or repair work or priorto removing the safeguards. Secure the drive unit against accidental start-up. Attach a notice on thestart 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 list of equipment prepared specifically for theorder.

WARNING

Risk of personal injury from energised parts

Removing covers, improper use of the machine, false operation or inadequate maintenance might leadto death, serious personal injury or property damage.

– Always observe the "five safety rules" when working on the machine.(see section 3. "Safety instructions").

– Remove covers only in accordance with the instructions of this operating manual.– Operate the machine properly.– Conduct regular and professional maintenance on the machine.

NOTICE

Property damage

Damage to the gear unit possible from non-compliance with the specified periods for maintenance andrepair works is possible.The operator must observe the deadlines specified and adopt these in its own maintenance plans ifrequired.

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10.2 Clean the gear unit

NOTICE

Property damage

Damage to the gear unit from overheating is possible.Dust deposits can affect the heat discharge through the housing surface and lead to overheating.To prevent the build-up of dust on the gear unit, cleaning must be adjusted to the local operatingconditions.

• Remove any dirt adhering to the gear unit, using a hard brush.

• Remove any corrosion.

NOTICE

Property damage

Damage to the gear unit due to penetration of moisture is possible.The gear unit must not be cleaned with high-pressure cleaning equipment.

10.3 Clean the air filter

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 hasexpired.

Note

If the air filter is protected with a filter cap, it must be disassembled before cleaning the air filter. Aftercleaning the air filter, the filter cap must be reassembled.

• Unscrew the air filter including the reducing screw.

• Clean the air filter using a suitable cleaning agent.

• Dry the air filter and/or blow with compressed air.

WARNING

Risk of injury to the eyes from pressurised air

Residual water and/or dirt particles can injure the eyes.Wear suitable protective glasses.

NOTICE

Property damage

Damage to the gear unit due to penetration of foreign bodies is possible.The penetration of foreign bodies into the gear unit must be prevented.

10.3.1 Replacing the air filter cartridge

Note

Annually or when the air filter is heavily soiled.

• Remove the air filter cover and replace the filter element (cleaning of the paper filter is not possible).

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10.4 Flushing

It must generally be distinguished between "flushing" during the initial start-up and "flushing before or afterrepair work.

Flushing before or after repair work serves for removal of soiling (e.g. bon deposits, oil foam, abradedmaterial) and must be conducted depending on the scope of the repair.

Flushing should be carried out with the selected service lubricating oil. In general, lower viscosities(e.g. VG 46 or VG 100) should be used for the flushing oil that is of the same brand as the oil type chosenas the operating oil.

• For flushing-oil quantity see item 7.1.4.1.

• Flushing times:For flushing, operate the oil pump of the low-pressure lubricating circuit for at least 6 hours.

NOTICE

Property damage

Damage to the gear unit and 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 8 in item 7.1.3) on the gear unit and the oil-supply system. It may be re-used only asflushing oil. Clean the flushing oil before re-use. The flushing oil must be filtered beforehand or duringfilling using a nominal filter mesh of 25 μm (0.0010 inch).The flushing oil can be reused for a maximum of 6 flushing operations.

Note

If the oil tends to increasing foaming during flushing, we recommend having the oil analysed by the oilsupplier as to its suitability for use.

10.5 Oil filling

NOTICE

Property damage

Damage to the gear unit and oil-supply system is possible.Fill the gear unit with oil after flushing and before the start-up of the gear unit.

Information on the type, viscosity and required quantity of the oil is given on the rating plate on the gear unitand/or in the documentation included in the delivery.The BA 7300 instructions manual relating to the gear unit lubrication and Table "T 7300" containing thecurrent lubricant recommendations of Siemens can also be consulted on the internet (see back cover).

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10.6 Inspection

The inspection comprises all measures for ascertaining and assessing the actual condition.

The measures must be recorded.

Note


Table 14: Inspection measures

Measures Periods Remarks

General visual check for cracks, leaksand damage.

every 4 weeks

Visual check of the tooth-flank conditionfor damage.

annually

Check oil filters of the oil-supply systemfor contamination.

every 4 weeksor if there is heavysoiling

Optical display, see also operatinginstructions oil-supply system.

Check of the instruments installed onsite (temperatures, oil pressures).

every 4 weeks

Inspection of the oil conducting lines forleaks.

weekly

Oil level check at the oil level indicatorson the gear unit and, if necessary, onthe oil-supply system (version withtank).

weekly See also operating instructions oil-supplysystem.

Check for- unusual noises,- temperature,- safety equipment.

weekly

Check of add-on parts such ascouplings, possibly auxiliary drive.

every 6 months See operating instructions for theindividual components.

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10.7 Maintenance

Maintenance comprises all measures for preserving the required condition.

Table 15: Maintenance measures

Measures Periods Remarks

First oil change after start-up after approx. 1000 operating hoursor depending on the results of theoil analysis carried out

See item 10.7.2

Oil analyses first one after 1000 operatinghours, all subsequent onesannually

See item 10.7.1

Subsequent oil changes depending on the oil analysisresults; (without oil analysis: at thelatest after 18 months and/or10000 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 it.em 10.3.

Replacing the air filter cartridge annually or when the air filter isheavily soiled

See item 10.3.1.

Checking tightness of the foundationbolts

every 12 weeks See item 10.7.3

General inspection of the gear unit every 2 years See item 10.11

Maintenance work on the oil-supplysystem

See also operating instructionsoil-supply system.

See also operating instructionsoil-supply system.

Check couplings every 6 months See operating instructionsindividual components.

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10.7.1 Examine water content of oil, conduct oil analyses

Detailed information about testing the oil for water content or conducting oil analyses can be obtained fromyour lubricant manufacturer or Siemens customer service.

─ A fresh sample of the used operating lubricating oil must be sent as reference to the testing institutealong with the used oil sample for analysis.

─ The oil sample must be taken downstream from the filter of the oil-supply system while the gear unit isrunning. A suitable connection point is normally located upstream of the gear unit input (e. g. oil draincock in the pressure line). A suitable connection possibility is provided on the oil-supply system fortaking an oil sample from the filter.

─ A special sample container should be filled with the specified quantity of oil.If there is no such sample container available, at least one litre of oil must be put in a clean, sealablevessel that is safe for transport.

• The viscosity of the oil sample may not deviate by more than 10 % from the that of the oil specified inthe "Technical data".

• The oil purity should not be below -/19/16 according to the standard "ISO 4406".

• Limit values for oil contamination.

Table 16: Material-related contamination limit values of the oil

MaterialLimit content

[ mg/kg ] Possible source

Iron (Fe) 40 Gear rim with internal teeth, teeth, bearing cage.

Chrome (Cr) + 4 Rolling bearing, teeth.

Aluminium (Al) + 4 Oil-pump bearing.

Copper (Cu) + 4 Cage of bearing.

Lead (Pb) + 6 Plain thrust bearings, pump bearings.

Tin (Sn) + 2 Plain thrust bearings, pump bearings.

Nickel (Ni) + 2 Teeth.

Zinc (Zn) + 10Zinc-based primer (is sometimes used as additive). In this caseplease contact Siemens.

Silicon (Si) + 5Concrete dust or other environmental factors, some oils maycontain silicium.

Water (H2O) 300 ppm Condensation water; water-oil cooler defective (mineral oil).

The values shown with "+" refer to the reference sample of the fresh oil.

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10.7.2 Change oil

Note

Observe the separately attached operating instructions BA 7300 and the information in item 7.1.

• Drain the oil while the gear unit is still warm, i.e. immediately after stopping it.

WARNING

Serious personal injury can be caused by switched-on machine

Shut down the gear unit and the oil-supply system to perform maintenance and/or repair work or priorto removing the safeguards. Secure the drive unit against accidental start-up. Attach a notice on thestart switch stating clearly that work is in progress on the gear unit.

NOTICE

Property damage

Damage to the gear unit possible from inadequate lubrication because of mixed oils.When changing the oil, always refill the gear unit with the same type of oil.Never mix different types of oil and/or oils made by different manufacturers.When changing to any different oil type, the gear unit must be flushed thoroughly using the new oil type.Flushing is not necessary, if the new service oil is fully compatible with the old service oil in all respects.Compatibility must be 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 thoroughlyfrom sludge, metal particles and oil residue by flushing it with oil. Use the same type of oil as is usedfor normal operation. High-viscosity oils must be heated beforehand using suitable means. Ensure thatall residues have been removed before filling with fresh oil.

Note

In this regard, see Figure 10.

• Place suitable containers under the oil drain cocks of the gear unit housing and of the tilting pad thrustbearing chamber.

• Unscrew the screw plugs of the oil drain cocks and allow the oil to drain into the container.

CAUTION

Risk of scalding

Risk of injury from escaping hot oil.Wear suitable protection gloves, protection glasses and protection clothing.Remove any spilled oil immediately using an oil binding agent.Observe environmental protection regulations.

• If the oil-supply system is equipped with three-way cocks, the gear unit can be emptied through thethree-way cocks of the oil-supply system. The remaining residual oil must then be drained off throughthe oil drain cocks on the gear unit (1, 2).

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2 4 6

5 1 3

Fig. 10: Oil level, oil drain, and ventilating

1 Oil drain of the gear unit2 Oil drain of tilting pad thrust bearing3 Oil level of gear unit

4 Oil level of tilting pad thrust bearing5 Air filter of gear unit6 Air filter of tilting pad thrust bearing

• Screw the screw plugs of the oil drain cocks (1, 2) back in.

Note

Check the condition of the sealing ring; the sealing ring is vulcanised onto the oil drain plug. Ifnecessary, use a new oil drain plug.

Information on the type, viscosity and required quantity of the oil is given on the rating plate on the gear unitand/or in the documentation included in the delivery.The BA 7300 instructions manual relating to the gear unit lubrication and Table "T 7300" containing thecurrent 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 15 (see item 10.7), it is possible to have an oilsample tested at regular intervals every 4 weeks by the technical service of the relevant oil company andto have it released for further use.

If further usability has been confirmed, no oil change will be necessary.

Note

Observe the separately attached operating instructions BA 7300 and the information in item 7.1.

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10.7.3 Check tightness of screw connections

All screw connections that are used for inspection or maintenance have to be checked for firm seat (seeitem 6.13 "Screw connection classes, tightening torques and initial stressing forces").

Tighten plate screws with the required initial stressing force or torque.The initial stressing force or torque can be found on the dimensions sheet.

Note

The separate operating instructions have to be observed if "superbolt nuts" are used.

Note

Damaged bolts must be replaced with new bolts of the same type and strength class.

10.8 Welding work on the mill

Note

Siemens will accept no liability for damage caused to the gear unit by welding work carried out on themill.

WARNING

Risk of personal injury from electrical shock.

Risk of electrical shock during welding work.Before welding work may be conducted on the mill, a potential equalisation must be providedaccording to the regulations and/or guidelines applicable for this purpose.The gear unit must not be used as an earthing point for welding operations. Optionally, an earth wiremay be present on the tilting pad thrust bearing chamber, which must be connected with the outputflange. For this purpose, use the threaded holes provided on the side of the output flange. When thewelding work has finished, the earth cable must be removed from the output flange. If no threaded holesfor earth connection are available on the gear unit, other appropriate measures must be taken. Thiswork must always be done by specialist electricians.

79 / 84BA 9180 en 12/2015

10.9 Vibration measurements

DANGER


Risk of being gripped or drawn in by rotating and/or moving parts.If a mobile vibration measurement is taken on a gear unit while it is in operation, it is imperative to ensurethat the measurement is not taken directly near rotating parts in order to avoid accidental contact withthe rotating parts.

A3V 4V 5H 7H 6HA 8H 3V 4V 6H

3HA 4H 3H 4H 5H

"A"

Fig. 11: Measuring points

V Vertical measuring point H Horizontal measuring point

(Measuring points 1 and 2 are located at the bearing points on the motor.)

The measuring points shown in Figure 11 are the standard measuring points in a mobile measurement.All gear units of this type in the field can be measured on these measuring points. This enables directcomparison with other gear units of the same type and same size. A detailed illustration of the gear unit iscontained the drawings in the gear unit documentation.

Vibration measurements and their evaluation should be conducted by Siemens personnel and/or in closecollaboration with Siemens personnel. This way, experience gained from measurements conducted oncomparable bevel-gear planetary gear units can be incorporated into the measurement and the evaluationof its results.

80 / 84BA 9180 en 12/2015

When measuring vibration, the following should be observed in general:

a) Measure only at the measuring points indicated in Figure 11 above.

b) Do not measure on resonance cavities (e. g. fins, inspection covers, pipes, etc.).

c) The motor output should also be recorded at the time of measurement, as output fluctuations may resultin different measurements.

After start-up and continuous operation of the entire system, an initial measurement should be carried outto obtain the vibration profile of the gear unit. Subsequent measurements at monthly intervals will thenenable a trend analysis to be carried out.

Note

For assessing the gear unit according to the standard "DIN ISO 10816" the classification III applies tothis machine. It must be noted concerning this assessment, however, that the axial forces arising fromthe grinding process are conducted to the foundation through the gear unit housing so that it cannotbe ruled out that vibrations are due to the grinding process and are not generated by the gear unit. Forthis reason the standard "DIN ISO 10816" has only limited application for this type of gear unit.

Further information about vibration diagnosis is obtainable from:

http://www.automation.siemens.com/mcms/mechanical-drives/en/gear units/service

10.10 Repair

Note

Maintenance comprises all measures for reinstating the required 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 atany point on the unit, the welding current is not conducted through rolling bearings or other movableconnections and measuring equipment. The welding current return wire must therefore be connecteddirectly to the part to be welded.

WARNING

Risk of personal injury from electrical shock.

Risk of personal injury from electrical shock when connecting electrical components.Ensure zero voltage before connecting the devices.

DANGER

Danger to life



www.automation.siemens.com/mcms/mechanical-drives/en/gear-units/service

81 / 84BA 9180 en 12/2015

10.11 General inspection of the gear unit

The general inspection of the gear unit should be carried out by Siemens Customer Service, as ourengineers have the experience and training necessary to identify any components requiring replacement.

10.12 Lubricants

The quality of the oil used must meet the requirements of the separately supplied BA 7300 instructionsmanual, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of theoils listed in Table "T 7300" (for a link to the Internet, see back cover), as they have been tested and meetthe requirements.

Note

To avoid misunderstandings, we should like to point out that this recommendation is not intended asa guarantee for the quality of the lubricant delivered by your supplier. Every lubricant manufacturermust provide its own guarantee for the quality of its product.

Information on the type, viscosity and required quantity of the oil is given on the rating plate on the gear unitand/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 inthe set-up plan. If the oil-supply system and the pipework are not included in the scope of delivery by Siemens, theoperating oil quantity for the gear unit is shown on the rating plate (see section 1. "Technical data").

The quantity value specified in the setup plan and on the rating plate is understood as an approximatequantity. The marks on the oil level indicator of the main gear unit, the tilting-pad thrust bearing and/or theoil-supply system (for models with tank) are decisive for the oil quantity to be filled in.

The BA 7300 instructions manual relating to the gear unit lubrication and Table "T 7300" containing thecurrent lubricant recommendations of Siemens can also be consulted on the internet (see back cover).

The oils listed there are subject to continuous testing. Under certain circumstances, the oils recommendedthere may be removed from the range at a later time or be replaced by further developed oils.

We recommend checking before any oil change whether the chosen lubricant is still approved by Siemens.

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11. Spare parts, customer service

11.1 Stocking spare parts

By stocking the most important spare and consumable parts on site you can ensure that the gear unit isready for use at any time.

To order spare parts, refer to the spare-parts list.

For further information refer to the spare parts drawing stated in the spare parts list.

NOTICE

Property damage

Damage to the gear unit from improper use.Siemens extends a warranty only for original spare parts supplied by Siemens.Non-original spare parts have not been tested or approved by Siemens. Non-original spare parts mayalter the required technical characteristics of the gear unit, thereby causing an active or passive safetyhazard.Any liability and warranty of Siemens is precluded for damages caused by the use of non-original spareparts. The same applies to any accessories not supplied by Siemens.

Please note that certain components often have special production and supply specifications and thatSiemens supplies you with spare parts which comply fully with the current state of technical developmentas well as current legislation.

When ordering spare parts, always state the following:

order no., item type, size part no. quantity

11.2 Addresses for ordering spare parts and customer service

First contact Siemens when ordering spare parts or requesting a service specialist.

Siemens Ltd.309/2, 'A' Block 100, Chettipedu VillageThandalam Post602105 ChennaiIndien

Tel.: +91 (44) 37174000

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12. Declarations

12.1 Declaration of incorporation

Declaration of incorporation

in accordance with Directive 2006/42/EC, Annex II 1 B

The manufacturer, Siemens Ltd, 309/2, 'A' Block 100, Chettipedu Village,Thandalam Post, 602105 Chennai,Indien, declares with regard to the partly completed machinery


KMP, KMPS, KMPP

for driving vertical mills:

– The special technical documents described in Annex VII B have been prepared.

– The following basic health and safety requirements set out in Directive 2006/42/EC, Annex I, are appliedand are satisfied:

1.1, 1.1.2, 1.1.3, 1.1.5; 1.2.4.4, 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, 1.7.1.1, 1.7.2, 1.7.4 ‐ 1.7.4.3

– The partly completed machinery must not be put into service until it has been established that themachinery into which the partly completed machinery is to be incorporated has been declared to be inconformity with the provisions of Directive2006/42/EC, as appropriate.

– The manufacturer undertakes, in response to a reasoned request by the national authorities, to transmit inelectronic form relevant information about the partly completed machinery.

– The person authorised to compile the relevant technical documentation is:

Mark Zundel / Head of PD MD AP VOEAdresse: Am Industriepark 2, 46562 Voerde, Germany

Chennai, 2015‐12‐15Mr. Thirumala Rao Malla / Head of RC-IN PD MD-MF

Chennai, 2015‐12‐15Mr. Prasad Menon / Head of RC-IN PD MD BA

Translation of the original declaration of incorporation

Siemens AGProcess Industries and DrivesMechanical DrivesAlfred-Flender-Straße 7746395 BocholtGERMANY

www.siemens.com/drivetechnologies

Subject to modifications

© Siemens AG 2015

Further Information:

"FLENDER gear units" on the Internetwww.siemens.com/gearunits

"FLENDER couplings" on the Internetwww.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

www.siemens.com/drive-technologies

http://www.siemens.com/gearunits

http://www.siemens.com/couplings

http://support.automation.siemens.com/WW/view/en/10803928/133300

http://support.automation.siemens.com/WW/view/en/42961591/133000

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