Page 1
Vertical mill gear unit Sizes 225 to 850 Assembly and operating instructions BA 9137 en 12/2015 FLENDER gear units...
Page 2
Technical data Vertical mill gear unit General notes Safety instructions Sizes 225 to 850 Transport and storage Technical Assembly and operating instructions description Translation of the original assembly and operating instructions Fitting Startup Operation Faults, causes and remedy Maintenance and repair Spare parts, customer service Declarations...
Page 3
All designations to which the registered industrial property mark ® is appended are registered trademarks of Siemens AG. Other designations used in this document may be trademarks the use of which by third parties for their own purposes may infringe holders’ rights.
Page 4
Foreword The 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 to directive 94/9/EC, if the product is put on the market by 19.04.2016, and to the version designed in conformity to directive 2014/34/EU, if the product is put on the market on or after 20.04.2016.
Technical data General technical data The most important technical data are shown on the rating plate. These data and the contractual agreements between Siemens and the customer for the gear unit determine the limits of its correct use. ① ②...
- 40 °C to + 60 °C. However, the temperature range and the expanded temperature range must generally be approved by Siemens and be specified in the order text. In individual cases the permissible ambient temperature range specified on the rating plate always applies.
Siemens accepts no responsibility for damage or disruption caused by disregard of these instructions. The "FLENDER Bevel-helical gear unit" of the type "KMS" described in these instructions has been designed for driving a vertical mill. The gear unit is designed only for the application specified in the order-specific gear unit documentation.
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.
Page 12
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 are supplied with power (e. g. motors, generators, etc.), it must be ensured that no current can flow through the gear unit.
• Spare parts must be obtained from Siemens (see section 11. "Spare parts, customer service"). Special dangers and personal protective equipment Depending on operating conditions, the surface of the gear unit may develop extreme temperatures.
Note In addition to any generally prescribed personal protection equipment (protection shoes, protection clothing, helmet, etc.) handling the gear unit requires wearing suitable safety gloves and suitable safety glasses. Note The gear unit complies with the requirements in Directive 2014/34/EU. DANGER Explosion hazard Danger to life from ignition of a present explosive atmosphere is possible when carrying out assembly...
The content of the delivery is listed on the packing slip. The completeness of the scope of delivery must be 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 writing within 2 weeks.
Page 16
WARNING Risk of crushing Risk of being crushed by a transported component when the used lifting gear and load-bearing equipment is not suitable and the component comes loose. Attach the product for transport only on the marked attachment points. Lifting gear and load equipment must be used that has adequate load-bearing capacity.
Page 17
Fig. 3: Alternative attachment points Wooden block Note The detailed illustration of the gear unit, the position of the attachment points, and the positioning of the wooden blocks for the protection of the gear unit during transport can be found on the dimensioned and transport drawings in the order-specific gear unit documentation.
─ 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 protection of the external coating will be within the customer's responsibility.
Page 19
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 coat according to the standard procedures relevant for the specific application.
4.4.1 Exterior preservation of metallic bright exterior surfaces 4.4.1.1 Maximum durability period of the exterior preservation Table 2: Durability period for exterior corrosion prevention of shaft ends and other bright machined surfaces Durability Preservative agent Layer thickness Remarks of protection Long-term wax-based preservative agent: for indoor storage up...
Page 21
If damaged, the packing must be restored to its seaworthy condition. Note If different statements were made in agreement with the customer, as to the protective periods on precisely defined conditions, a description can be found in the order confirmation from Siemens. BA 9137 en 12/2015 21 / 89...
4.4.2.2 Combined storage / packaging If the type of packaging and/or storage is changed within the durability period as HD , which is applicable to the existing preservation and the present type of packaging and/or storage, a new HD has to be 2äq determined as the equivalent remaining durability period applicable as of the date of the change.
Page 23
Example: ─ A gear unit is stored exposed outdoors after sea transport, in climatic zone B, while it is kept in seaworthy packaging = 20 months (climatic zone: B, transport type: sea transport, transport packaging: seaworthy packaging, packaging for storage: seaworthy packaging, place of storage: exposed outdoors) ─...
Page 24
Table 4: Examples of combined storage (maximally one change in storage) and the resulting remaining durability of the interior preservation of the gear unit Original place of storage of the gear In which climatic zone is the construction site Setup in climatic zone A and at least 50 km located? distance from larger bodies of salt water How was the gear unit packaged for transport?
Page 25
Original place of storage of the gear In which climatic zone is the construction site Setup in climatic zone B and/or less than 50 km located? distance from larger bodies of salt water How was the gear unit packaged for transport? None or simple Transport in Transport packaging...
Filling quantity: 1 litre per cubic metre of the entire free interior volume of the gear unit (to be enquired from Siemens). The interior volume of the gear unit can be ascertained in approximation also by means of the length x width x height of the gear unit.
Page 27
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 shows maximum durability period preservation renewal 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.
The durability of this kind of preservation depends on the used oil and has to be enquired with the oil manufacturer. For the complete filling, a sealing cap (can be obtained from Siemens) must be mounted on the gear unit for sealing the input shaft.
Page 29
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. •...
• Fill sealing cap on the input shaft through the ventilation of the sealing cap (1) The ventilation (1) is to be closed, only once the oil filling of the gear unit is completed, unless oil is escaping from this opening before then.
Page 31
Table 6: Maximum durability period of the interior preservation of the gear unit through operating the oil-supply system. Setup in climatic zone A and at Setup in climatic zone B and/or least 50 km distance from larger less than 50 km distance from bodies of salt larger bodies of salt water water...
Observe the instructions in section 3. "Safety instructions"! General description The gear unit described is a "FLENDER Bevel- helical gear unit" of the type "KMS" designed for driving a vertical mill. The axial and radial forces resulting from the grinding process are led into the foundation through the gear unit housing.
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 pipe system. Note When operating and servicing the components of the oil supply system, observe the operating instructions of the components.
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 to the high-pressure pumps through a branch circuit. The high-pressure pumps are designed as radial piston pumps and supply a constant oil quantity at each connection.
It cannot be assured by Siemens whether these minimum requirements are sufficient in any case. If stricter requirements in the operating instructions of the supplier or similar document are defined, these will apply.
Heating element on ex-version If heating elements are designed explosion-proof, the gear unit is additionally equipped with oil-level monitoring by means of a level limit switch. This monitoring checks the oil level of the gear unit for the submersion of the heating rods (see item 5.6.1). 5.6.1 Oil level monitoring of the heating elements The gear unit is equipped with oil level monitoring.
Oil temperature monitoring The gear unit can be fitted with a Pt 100 resistance thermometer for measuring the oil temperature in the oil sump. In order to measure the temperatures and/or temperature differences, the Pt 100 resistance thermometer, which complies with the requirements of Directive 2014/34/EU, must be connected to a suitable analysis instrument provided by the customer.
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 qualified personnel. Siemens is not liable/does not extend a warranty for damages caused by incorrect implementation.
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, the installation plan is enclosed with the documentation.
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. •...
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 –...
6.3.2 Foundation The foundation should be laid out in such a way that no resonance vibrations are created and that no vibrations are transmitted from adjacent foundations. The foundation structure on which the unit is to be assembled must be rigid. The structure must be laid out according to the weight and torque in consideration of the forces acting on the gear unit.
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. 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.
Note For permissible alignment errors in couplings supplied by Siemens, refer to the instructions manuals for the couplings. When using couplings manufactured by other manufacturers, ask these manufacturers which alignment errors are permissible, stating the radial loads occurring.
It cannot be assured by Siemens whether these minimum requirements are sufficient in any case. If stricter requirements in the operating instructions of the supplier or similar document are defined, these will apply.
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 the mill. DANGER Risk of personal injury from electrical shock or through electrostatic discharge Risk of electrical shock during welding work or risk of personal injury from ignition of a present explosive atmosphere caused by electrostatic discharge.
6.11 Final work After installation of the gear unit, check all screw connections for the connection of the gear unit and □ the system for tight fit. Check of the alignment after tightening the fastening elements. The alignment must not have changed. □...
6.12.2 Tightening torques and initial stressing forces The tightening torques apply to friction coefficients of μ = 0.14. total The friction coefficient μ = 0.14 applies here to lightly oiled steel bolts, black-annealed or phosphatised total and dry, cut counter threads in steel or cast iron. Lubricants which alter the friction coefficient are not permitted and might overload the screw connection.
Page 49
Nominal Strength Initial tensioning force for screw Tightening torque for screw diameter of class of the connection classes from table 8 connection classes from table 8 the thread bolt M min. 1190000 760000 475000 21500 18500 16500 M80x6 10.9 1690000 1100000 675000 30500...
Any setting of the drive in motion represents a start-up. Procedure before start-up The start-up must be carried out with great care by authorised, trained and qualified personnel. Siemens is not liable/does not extend a warranty for damages caused by incorrect implementation.
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 basic preservation applied (see Technical data) on the gear unit. Detailed descriptions of the procedure as well as regarding the particularities, which must be taken into account, can be found in the following items 7.1.3 to 7.1.5 and in the separately provided operating instructions BA 7300.
Page 52
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 gear unit must be flushed thoroughly with operating oil before start-up after draining the mixture of operating and preservative (in this regard, see item 10.4.) have already been...
7.1.3 Draining preservative oils For the position of the oil draining points is marked on the dimensioned drawing in the gear unit documentation. • Place suitable containers under the oil drain points. • Unscrew the oil drain plug and/or open the oil drain cock. •...
If the oil-supply system and the pipework are not included in the scope of delivery by Siemens, the operating oil quantity for the gear unit is shown on the rating plate (see section 1. "Technical data").
The quality of the oil used must meet the requirements of the separately supplied BA 7300 instructions manual, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in Table "T 7300" (for a link to the Internet, see back cover), as they have been tested and meet the requirements.
Page 56
Note If gear units have oil-supply systems, the oil circuit must be filled additionally. If systems have a motor pump 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 with oil before the start-up of the gear unit.
If the quality of the oil used does not meet the requirements of the separately supplied BA 7300 instructions manual, the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in the document "T 7300" (for a link to the internet, see back cover), because they have been tested and meet the requirements.
Page 58
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 it would be conducted through the gear unit before it could be filtered out at the filter of the oil-supply system.
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. BA 9137 en 12/2015 59 / 89...
7.2.3 Checking procedure The following visual checks must be conducted and recorded when starting up: Presence of the "Ex" marking. □ Oil level □ Leak tightness of the oil cooling or oil supply lines □ Opening condition of the shut-off valves □...
If it is taken out of service for > 7 days, the lubricating system has to be taken into operation once a week for 1 hour. At the same time, the gear unit has to be turned every 2 weeks (at least one rotation on the output flange).
Page 62
Table 12: Maximum durability period of the interior preservation of the gear unit through operating the oil-supply system. Setup in climatic zone A and at Setup in climatic zone B and / or least 50 km distance from larger less than 50 km distance from bodies of salt larger bodies of salt water water...
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 tightened on the gear unit for sealing the input shaft.
Page 64
Table 13: Durability period of prolonged interior preservation of the gear unit with "Castrol Corrosion Inhibitor N 213" Setup in climatic zone A and at Setup in climatic zone B and / or least 50 km distance from larger less than 50 km distance from bodies of salt larger bodies of salt water water...
The durability of this kind of preservation depends on the used oil and has to be enquired with the oil manufacturer. For the complete filling, a sealing cap (can be obtained from Siemens) must be mounted on the gear unit for sealing the input shaft.
Fig. 8: Gear unit features for preservation measures Breather of sealing cap Pressure line (tilting pad thrust bearing Oil drain sealing cap chamber) Sealing cap Oil drain tilting pad thrust bearing Air filter (gear unit) chamber Oil level indicator (gear unit) Indication of oil level (tilting pad thrust Suction line (gear unit) bearing chamber)
50 °C (122 °F) If the oil-supply temperature reaches critical values (see lubrication plan and equipment list), the gear unit must be shut down immediately and Siemens consulted. Oil pressure of the oil-supply system or □...
Table 14, "Faults, causes and remedy", contains a list of possible faults, their causes and suggested remedies. If the cause cannot be found, a specialist from one of the Siemens Customer Service Centres should be called in (see section 2. "General notes").
Page 69
DANGER Explosion hazard Ignition of an explosive atmosphere is possible from overheating of the gear unit with too low an oil level because of leakages. Existing oil drain cocks must be secured against accidental opening. If an oil-sight glass is used for monitoring the oil level, it must be protected against damage. Note If any safety device has triggered, it must only be possible to start the drive again after releasing the reclosing interlock.
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 of improper use of the gear unit, modifications carried out without the approval by Siemens or use of spare parts not originally supplied by Siemens.
Faults, causes and remedy Table 14: Faults, causes and remedy Faults Possible causes Remedy Changes in gear noise. Damage to gear teeth. Contact Customer Service. Check toothed components. If necessary exchange damaged components. Bearing backlash too high or too Contact Customer Service. low.
Page 72
Faults Possible causes Remedy Pressure monitor triggers Oil level too low. Check the oil level. alarm. Fill up oil if necessary. Oil pump defective. Check oil pump and replace if necessary. Operating temperature increased. see Faults "Operating temperature too high". Oil filter dirty.
Page 73
Faults Possible causes Remedy Oil foams. Water in oil. Examine oil. Change oil if necessary. Oil too old (defoaming agent used Examine oil. up). Change oil if necessary. Unsuitable oils mixed up. Examine oil. Change oil if necessary. Water in oil. Cooler leaky.
Maintenance and repair Observe the instructions in section 3. "Safety instructions" and in section 9. "Faults, causes and remedy"! Once the maintenance and repair work is completed, the information in section 7. "Start-up" should be noted. 10.1 General notes on maintenance Maintenance comprises all measures for preserving and restoring the target condition and for ascertaining and assessing the actual condition of the technical means of a system.
10.2 Clean the gear unit DANGER Explosion hazard Ignition of an explosive dust layer by overheating of the gear unit. 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 done in accordance with the local operating conditions.
The BA 7300 instructions manual relating to the gear unit lubrication and Table "T 7300" containing the current lubricant recommendations of Siemens can also be consulted on the internet (see back cover). BA 9137 en 12/2015...
10.6 Inspection The inspection comprises all measures for ascertaining and assessing the actual condition. The measures must be recorded. Note The record must be kept with these instructions. Table 15: Inspection measures Measures Periods Remarks General visual check for cracks, leaks every 4 weeks and damage.
10.7 Maintenance Maintenance comprises all measures for preserving the required condition. Table 16: Maintenance measures Measures Periods Remarks The proper function and see instructions of the The operator must ensure this. measurement accuracy of the manufacturer. ignition protection system for the temperature monitoring should be checked at regular intervals according to the instructions of the...
Detailed information about testing the oil for water content or conducting oil analyses can be obtained from your lubricant manufacturer or Siemens customer service. ─ A fresh sample of the used operating lubricating oil must be sent as reference to the testing institute along with the used oil sample for analysis.
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 thoroughly from sludge, metal particles and oil residue by flushing it with oil.
Page 81
The BA 7300 instructions manual relating to the gear unit lubrication and Table "T 7300" containing the current lubricant recommendations of Siemens can also be consulted on the internet (see back cover). Note For the oil filling of the gear unit, see the information in item 7.1.5.
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 the mill. DANGER Risk of personal injury from electrical shock or through electrostatic discharge Risk of electrical shock during welding work or risk of personal injury from ignition of a present explosive atmosphere caused by electrostatic discharge.
A detailed illustration of the gear unit is contained the drawings in the gear unit documentation. Vibration measurements and their evaluation should be conducted by Siemens personnel and/or in close collaboration with Siemens personnel. This way, experience gained from measurements conducted on comparable bevel-gear planetary gear units can be incorporated into the measurement and the evaluation of its results.
For this 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.
The total operating oil quantity for the gear unit, the oil-supply system, and the pipework can be found in the set-up plan. If the oil-supply system and the pipework are not included in the scope of delivery by Siemens, the operating oil quantity for the gear unit is shown on the rating plate (see section 1. "Technical data").
Any liability and warranty of Siemens is precluded for damages caused by the use of non-original spare parts. The same applies to any accessories not supplied by Siemens.
12.1 Declaration of incorporation Declaration of incorporation in accordance with Directive 2006/42/EC, Annex II 1 B The manufacturer, Siemens AG, 46395 Bocholt, Germany, declares with regard to the partly completed machinery Vertical mill gear unit Sizes 225 to 850 for driving vertical mills: –...
EC Directive 94/9/EC of 23.03.1994 and the legal requirements laid down for its implementation The manufacturer, Siemens AG, 46395 Bocholt, Germany, declares that the equipment described in these assembly and operating instructions: Vertical mill gear unit...