Related Manuals for Siemens FLENDER H3LV
Summary of Contents for Siemens FLENDER H3LV
- Page 1 Gear unit H3LV Sizes 6 to 18 Assembly and operating instructions BA 5080 en 06/2014 FLENDER gear units...
- Page 2 Technical data Gear unit General notes Safety instructions H3LV Sizes 6 to 18 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". Symbols in these assembly and operating instructions This symbol additionally indicates an imminent risk of explosion in the meaning of Directive 94/9/EC. This symbol additionally indicates an imminent risk of burns due to hot surfaces in the meaning of standard "DIN EN ISO 137321".
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Page 5: Table Of Contents
Contents Technical data ........... . . General technical data . - Page 6 Fitting ............. General information on fitting .
- Page 7 Maintenance and repair ..........10.1 General notes on maintenance .
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Page 8: Technical Data
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... -
Page 9: Ambient Temperature
By adopting various suitable measures the gear unit may be used at ambient temperatures of between 40 °C and + 60 °C. However, Siemens must always have approved and confirmed this in the order specification. -
Page 10: General Notes
All persons carrying out work on the gear unit must have read and understood these instructions and must adhere to them. Siemens accepts no responsibility for damage or disruptions to operation caused by disregard of these instructions. The "FLENDER gear unit" described in these Instructions has been designed for driving lautertun spentgrain cutting machines. -
Page 11: Safety Instructions
Safety instructions WARNING Risk of falling Risk of serious injury through falling. The gear unit and its addon parts must not be entered. WARNING Risk of injury through unauthorised modifications Any changes on the part of the user are not permitted. This applies equally to safety features designed to prevent accidental contact. -
Page 12: Special Dangers And Personal Protective Equipment
• 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 heat up or cool down to extreme temperatures. -
Page 13: The Five Safety Rules
WARNING Risk of eye injury Small foreign matter such as sand or dust can get into the cover plates of the rotating parts and be thrown back by these. Wear suitable protective glasses. Note In addition to any generally prescribed personal safety equipment (such as safety shoes, safety clothing, helmet) handling the gear unit requires wearing suitable safety gloves and suitable safety glasses. -
Page 14: Environmental Protection
Environmental protection • Dispose of any packaging material in accordance with regulations or separate it for recycling. • When changing oil, the used oil must be collected in suitable containers. Any pools of oil which may have collected should be removed at once with an oilbinding agent. •... -
Page 15: Transport And Storage
Scope of supply The products supplied are listed in the dispatch papers. Check on receipt to ensure that all the products listed have actually been delivered. Parts damaged and/or missing parts must be reported to Siemens in writing immediately. WARNING Serious injury through defective product If there is any visible damage, the gear unit must not be put into operation. - Page 16 Different forms of packaging may be used, depending on the size of the unit and method of transport. Unless agreed otherwise, the packaging complies with the HPE Packaging Guidelines. The symbols marked on the packing must be observed at all times. They have the following meanings: Fragile Keep dry Keep cool...
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Page 17: Storing The Gear Unit
Storing the gear unit The gear unit must be stored in a sheltered place in the position of the original packaging or in the position of use, placed on a vibrationfree, dry base, and covered over. NOTICE Material damage Any damage to the coating may cause failure of the exterior protective coating and thus corrosion. When temporarily storing the gear unit and any single components supplied with it, the preservative agent should be left on them. -
Page 18: Standard Coating And Preservation
Standard coating and preservation The gear unit is provided with an interior preservative agent; the free shaft ends are painted for protection. The characteristics of the exterior coat depend on the ambient conditions stipulated in the order relating to method of transport and area of application. NOTICE Material damage Risk of damage to the gear unit through corrosion. -
Page 19: Represerving The Interior Of The Gear Unit (Main Gear Unit) In Case Of Longer Periods Of Storage
4.4.1.1 Represerving the interior of the gear unit (main gear unit) in case of longer periods of storage CAUTION Risk of injury Risk of injury to eyes or hands through chemically aggressive operating media. Wear suitable protective glasses and protective gloves. Remove any oil spillage immediately with a binding agent. - Page 20 (II) (Ia) (Ib) (III) (III) (III) (II) (II) Fig. 4: Oil inlet and oil drain – gear unit with hoist gear unit Air filter or wet-ait filter Ventilation / oil filling (III) hoist Ventilation (I) main gear unit gear unit Oil filling (I) main gear unit Oil level (III) hoist gear unit Dipstick;...
- Page 21 (II) (Ia) (Ib) (II) (II) Fig. 5: Oil inlet and oil drain – gear unit with lifting cylinder Inspection and/or assembly cover Oil level (II) primary gear unit Ventilation (I) main gear unit Oil-drain plug (II) primary gear unit Oil filling (I) main gear unit Bellows Dipstick (I);...
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Page 22: Exterior Preservation
4.4.2 Exterior preservation Table 4: Durability period for exterior preservation of shaft ends and other bright machined surfaces Durability period Preservative agent Layer thickness Remarks Long-term wax-based preservative agent: In case of indoor storage up to 36 months – resistant to seawater Tectyl 846 K19 Approx. -
Page 23: Technical Description
Technical description Observe the instructions in section 3, "Safety instructions"! General description The gear unit described is a "FLENDER gear unit" designed for driving lautertun spentgrain cutting machines. The gear unit can be operated in both directions of rotation. The gear unit is characterised by a low noise level, which is achieved by helical gears with a high contact ratio and a sounddamping housing. - Page 24 Fig. 7: Gearunit configuration with lifting cylinder Bevel-gear motor (electric motor I) Bellows Helical-gear unit Shaft coupling Stroke-mounting flange Lifting cylinder Oil-equalising tank BA 5080 en 06/2014 24 / 72...
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Page 25: Construction And Method Of Operation
Construction and method of operation The combination drive performs 3 functions: Spentgrain removal (high speed) Clockwise rotation (looking at the end of the drive shaft) Spentgrain cutting (low speed) Clockwise rotation (looking at the end of the drive shaft) Vertical adjustment of the output shaft while stationary, without load or during operation (under load) 5.2.1 Spentgrain removal and spentgrain cutting... -
Page 26: Hydraulic Cylinder (Optional)
5.2.4.2 Hydraulic cylinder (optional) The hydraulic cylinder is connected to the strokemounting flange and the adapter sleeve located inside it. In this way the insert shaft of the helicalgear unit can be vertically adjusted. When mounting, the mounting dimensions specified on the dimensioned drawing must be observed. Note Be sure to observe the operating instructions for the hydraulic cylinder for operation and maintenance. -
Page 27: Oilequalising Tank
5.2.8 Oilequalising tank The oilequalising tank ensures the appropriate volumetric compensation, when the volume of oil increases with temperature. 5.2.9 Bellows The bellows protects the teeth of the insert shaft and thus the interior of the helicalgear unit against contamination. The air outlet is through a bore in the face collar of the shaft coupling. 5.2.10 Limit switch (optional) Above the helicalgear unit are two limit switches for switching the bevelgear motor (electric motor II) OFF in an EMERGENCY. -
Page 28: Housing
Housing The housing is designed as a multipiece. It is of torsionally rigid design and due to its shape imparts very favourable noise and temperature characteristics. The gearunit housing comes with the following equipment: ─ Lifting eyes (adequately dimensioned for transport) ─... - Page 29 (Ia) (Ib) Fig. 8: Gearunit features on gear units with hoist gear unit Air filter or wet-ait filter; Cover Ventilation (I) main gear unit Rating plate Oil filling (I) main gear unit Gear-unit fastening Dipstick (I); oil filling (I) main gear unit Inspection and/or assembly cover Oil-drain cock (Ia);...
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Page 30: Toothed Components
10,13 (Ia) (Ib) Fig. 9: Gearunit features on gear units with lifting cylinder Air filter or wet-ait filter; Cover Ventilation (I) main gear unit Rating plate Oil filling (I) main gear unit Gear-unit fastening Dipstick (I); oil filling (I) main gear unit Inspection and/or assembly cover Oil-drain cock (Ia);... -
Page 31: Lubrication
Lubrication 5.5.1 Splash lubrication Unless otherwise agreed in the order, the teeth and bearings are adequately splashlubricated with oil. The gear unit thus requires very little maintenance. Shaft bearings All shafts are fitted in rolling bearings. Shaft seal Radial shaftsealing rings, labyrinth seals, Taconite seals or special seals at the shaft outlets prevent oil from escaping from, or dirt from entering into the gear unit. -
Page 32: Fitting
Fitting Observe the instructions in section 3, "Safety instructions"! General information on fitting When transporting the gear unit, observe the notes in section 4, "Transport and storage". Fitting work must be done with great care by authorised, trained and qualified personnel. The manufacturer cannot be held liable for damage caused by incorrect assembly and installation. -
Page 33: Unpacking
The products supplied are listed in the dispatch papers. Check immediately on receipt to ensure that all the products listed have actually been delivered. Parts damaged and/or missing parts must be reported to Siemens in writing immediately. • Remove packaging material and transporting equipment and dispose of in accordance with regulations. -
Page 34: Fitting The Hydraulic Cylinder
6.3.1.2 Fitting the hydraulic cylinder If the hydraulic cylinder is not part of the delivery by Siemens, the cylinder must be fitted in mounting position prior to setting upright and prior to fitting the drive unit. To do so the transport lock must be removed. -
Page 35: Description Of Fitting Work
• Undo the bolts (3) and demount the locking plate (4). The bolts are used again for fastening the hydraulic cylinder. • Demount the Intermediate cover (5). Place sealing ring (6) into the groove of the Intermediate cover (5). • •... - Page 36 Unless specified otherwise, the components may be heated inductively, with a burner, or in a furnace. WARNING Risk of burns Risk of serious injury through burns on hot surfaces (> 55 °C). Wear suitable protective gloves and protective clothing. NOTICE Material damage Risk of damage to the shaftsealing rings through heating to over 100 °C.
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Page 37: Alignment
6.3.2.1 Alignment Orderspecific machined surfaces (alignment surfaces) are provided on the gearunit top side for preliminary alignment in horizontal direction. Alignment surface: For the exact position of the alignment surfaces, refer to the drawings in the gearunit documentation. These alignment surfaces are for aligning the gear unit horizontally, in order to ensure correct running of the gear unit. -
Page 38: Fitting On A Foundation Frame
The final fine alignment with the units on the in and output side must be carried out accurately by the shaft axes, using: ─ Rulers ─ Spirit level ─ Clock gauge ─ Feeler gauge, etc. Only then should the gear unit be fastened, and then the alignment should be checked once again. •... -
Page 39: Shrink Disk
Fitting and startup must be carried out by properly trained specialist personnel. Prior to startup these instructions must be read, understood and adhered to. Siemens accept no liability for personal injury or damage due to nonobservance of the instruction manual. - Page 40 Fig. 13: Fitting the shrink disk Greased Absolutely grease- Installation height and oil-free Stub shaft Outer ring Hollow shaft Tensioning bolt Inner ring Note The outer surface of the hollow shaft must be lightly greased in the area of the shrinkdisk seat. For a detailed view, refer to the dimensioned drawing in the gearunit documentation.
- Page 41 M 16 M 33 2400 Note The shrink disk has been identitymarked on the outer ring (4). In case of contacting Siemens this identification must be referred to. DANGER Danger to life through rotating and/or movable parts Risk of being caught or drawn in by rotating and/or movable parts.
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Page 42: Demounting The Shrink Disk
6.4.2 Demounting the shrink disk • Remove the protective cover. • Remove any rust deposits from the shaft and the interior of the hollow shaft. WARNING Serious injury Risk of injury through flying fragments of the tensioning bolts. Do not unscrew the tensioning bolts one after the other, in order to avoid them to break off due to overload or due to uncontrolled loosening of the shrink disk. -
Page 43: Cleaning And Greasing The Shrink Disk
6.4.3 Cleaning and greasing the shrink disk Note Only dirty shrink disks must be disassembled and cleaned. • Check all parts for any damage. WARNING Serious injury Risk of injury through single parts being slung out (e.g. tensioning bolts). Damaged parts must be replaced with new ones. The use of damaged parts is not permitted. -
Page 44: Refitting The Shrink Disk
Table 6: Recommended lubricants for shrink disks after their cleaning Lubricant Form Manufacturer Molykote G Rapid Spray or paste DOW Corning Aemasol MO 19 P Spray or paste A. C. Matthes Unimoly P 5 Powder Klüber Lubrication gleitmo 100 Spray or paste Fuchs Lubritec Other lubricants may be used;... -
Page 45: Tangential Alignment Of The Limit Switch Relative To The Switch Plate (Optional)
6.7.1 Tangential alignment of the limit switch relative to the switch plate (optional) • Screw the EMERGENCYOFF limitswitch unit delivered loose by Siemens oil and splashwatertight into the gearunit housing over the tube. • Align the rail with the limit switches at a tangent to the switch plate via the tube clips so that the rollerpressure pin of the limit switch can turn in the direction of run and not be subjected to additional... -
Page 46: Screwconnection Classes, Tightening Torques And Initialtensioning Forces
6.10 Screwconnection classes, tightening torques and initialtensioning forces 6.10.1 Screwconnection classes The specified screw connections are to be fastened applying the tightening torques specified observing the table below. NOTICE Material damage Risk of damage to the bolts and/or mating threads through incorrect tightening. Foundation bolts, hub bolts and bearingcover bolts must always be tightened in accordance with screwconnection class "C". - Page 47 Nominal Strength Initial-tensioning force Tightening torque thread class for screw-connection classes for screw-connection classes diameter of the bolt from table 7 from table 7 M min. 49300 31600 19800 10.9 72500 46400 29000 12.9 85000 54400 34000 77000 49200 30800 10.9 110000 70400...
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Page 48: Startup
Startup Observe the instructions in section 3, "Safety instructions"! Procedure before startup 7.1.1 Removal of preservative agent from exterior • The preserved shaft ends in the area of the couplings to be fitted must be depreserved, using suitable agents (special solvent etc.). The depreservation also applies to bright surfaces of the gear unit, onto which components are to be fitted. - Page 49 (II) (Ia) (Ib) (III) (III) (III) (II) (II) Fig. 14: Oil inlet and oil drain – gear unit with hoist gear unit Ventilation (I) main gear unit Ventilation / oil filling (III) hoist Oil filling (I) main gear unit gear unit Dipstick;...
- Page 50 (II) (Ia) (Ib) (II) (II) Fig. 15: Oil inlet and oil drain – gear unit with lifting cylinder Ventilation (I) Bellows Oil filling (I) main gear unit Vent hole Dipstick (I); oil filling (I) main gear unit Leak hole Oil-drain cock (Ia); oil drain main gear unit Inspection and/or assembly cover Oil-drain plug;...
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Page 51: Filling With Lubricant
The quality of the oil used must meet the requirements of the separately supplied BA 7300 operating instructions, 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 the back cover), as they have been tested and meet the requirements. -
Page 52: Bevel-Gear Unit
• Move the spentgrain cutting machine to the upper position by means of the bevelgear motor (electric motor II) or the lifting cylinder. NOTICE Material damage Risk of damage to the gear unit through incorrect direction of rotation. Check the direction of rotation of the electric motor II before switching on. Start the motor briefly. -
Page 53: Setting Of The Cam-Operated Switches (In The Gearunit Cam Operated Switch)
Setting of the cam-operated switches (in the gearunit cam operated switch) • Move the spentgrain cutting machine to the middle position by means of bevelgear motor (electric motor II). • Determine the afterrun in both directions (afterrun is the number of revolutions between switching off and motor standstill) •... -
Page 54: Startup
Risk of damage to the gear unit through insufficient lubrication resulting from too high oil temperature. The maximum permissible oilsump temperature is 90 °C. At higher temperatures the gear unit must be shut down immediately and Siemens customer service consulted. -
Page 55: Oillevel Monitoring (Optional)
7.5.3 Oillevel monitoring (optional) The gear unit can be fitted with an oillevel monitor by means of a fillinglevel limit switch. The oillevel monitoring device has been designed for checking the oil level when the gear unit is at a standstill, prior to operating start. -
Page 56: Interior Preservation For Longer Disuse
7.6.1 Interior preservation for longer disuse Depending on the type of lubrication and/or shaft sealing, the following types of interior preservation can be applied. 7.6.1.1 Interior preservation with gearunit oil Gear units with splashlubrication systems and contacting shaft seals can be topped up with the type of oil already filled in to a level just below the air filter or wetair filter. -
Page 57: Interior Preservation (Main Gear Unit) With "Castrol Alpha Sp 220 S" Preservative Agent
7.6.1.2 Interior preservation (main gear unit) with "Castrol Alpha SP 220 S" preservative agent • Place a suitable container under the oildrain point of the gearunit housing. • Open the oildrain cock (4). For this, refer to fig. 14 or fig. 15 in item 7.1.2. •... -
Page 58: Exterior Preservation
7.6.2 Exterior preservation 7.6.2.1 Exteriorpreservation procedure • Clean the surfaces. NOTICE Material damage Risk of damage to the shaftsealing ring through contact with chemically aggressive preservative agent. For separation between the sealing lip of the radial shaftsealing ring and the preservative agent, the shaft should be brushed with grease in the area around the sealing lip. -
Page 59: Operation
Table 9, "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 customerservice centres should be called in (see section 2, "General notes"). -
Page 60: Faults, Causes And Remedy
Risk of damage to the gear unit through improper use. Siemens will not be bound by the terms of the guarantee or otherwise be responsible for further operation 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. -
Page 61: Possible Faults
Possible faults Table 9: Faults, causes and remedy Faults Causes Remedy Changes in gearunit noise. Damage to gear teeth. Contact Customer Service. Check toothed components. If necessary, replace damaged components. Excessive bearing play. Contact Customer Service. Adjust bearing play. Bearing is defective. Contact Customer Service. - Page 62 Faults Causes Remedy Water in oil. Gear unit exposed to cold air from Protect gear unit with suitable heat machineroom fan: Water insulation. Close air outlet or alter its condensing. direction by structural measures. Climatic conditions. Contact Customer Service. If necessary, use wetair filter. Increased operating Oil level in housing too high.
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Page 63: Leakage And Leaktightness
9.2.1 Leakage and leaktightness In standard "DIN 3761" information is given on the subject of leakage on gear units. Based on this and building on the extensive experience gained at Siemens and other FVA member companies, brief descriptions, required measures and notes on this subject are included in the following overview. -
Page 64: Maintenance And Repair
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 All maintenance and repair work must be carried out carefully and by qualified personnel only (see section "Qualified Personnel"... -
Page 65: General Service Lives Of Oils
Detailed information about examining the oil for water content or conducting oil analyses is obtainable from your lubricant manufacturer or the Siemens customer service. ─ For reference purposes, a sample of the fresh operating lubricating oil in use must be sent with the usedoil sample to the analysing institute for analysis. -
Page 66: Changing The Oil (Main Gear Unit)
10.2.2 Changing the oil (main gear unit) As an alternative to the oilchange intervals specified in table 11 (see item 10.1), it is possible to have an oil sample tested at regular intervals, every 4 weeks, by the technical service of the relevant oil company and to have it cleared for further use. -
Page 67: Replace The Wetair Filter
To top up oil: • Unscrew the dipstick (3) on the oilequalising tank. • Top up the gear unit with fresh oil using a filling filter (mesh approx. 10 μm), until the oil reaches the lower mark on the dipstick. Do not put in any further oil. The viscosity of the oil in cold condition will cause the oil level to continue rising slowly. -
Page 68: Clean The Air Filter
10.2.4 Clean the air filter Note A period of 3 months has been specified for cleaning the air filter. If a layer of dust has built up, the air filter must already be cleaned, whether or not the period of 3 months has expired. -
Page 69: Check Tightness Of Fastening Bolts
Damaged bolts must be replaced with new bolts of the same type and strength class. 10.4 General inspection of the gear unit The general inspection of the gear unit should be carried out by the Siemens Customer Service, as our engineers have the experience and training necessary to identify any components requiring replacement. 10.5... -
Page 70: Spare Parts, Customer Service
Siemens will assume no liability or guarantee for damage caused by spare parts not supplied by Siemens. The same applies to any accessories not supplied by Siemens. -
Page 71: Declarations
Declarations 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 Gear unit H3LV Sizes 6 to 18 for driving lauter-tun spent-grain cutting machines: –... - Page 72 Further Information: "FLENDER gear units" on the Internet www.siemens.com/gearunits "FLENDER couplings" on the Internet www.siemens.com/couplings Service & Support: http://support.automation.siemens.com/WW/view/en/10803928/133300 Lubricants: http://support.automation.siemens.com/WW/view/en/42961591/133000 Siemens AG Subject to modifications Industry Sector Mechanical Drives © Siemens AG 2014 Alfred-Flender-Straße 77 46395 Bocholt GERMANY www.siemens.com/drivetechnologies...