Related Manuals for Siemens FLENDER K1N
Summary of Contents for Siemens FLENDER K1N
- Page 1 Bevel gear unit K1N and K1A Sizes 1 to 9 Assembly and operating instructions BA 5230 en 04/2011 FLENDER gear units...
- Page 2 Technical data Bevel gear unit General notes Safety instructions K1N and K1A Sizes 1 to 9 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,...
- Page 3 Notes and symbols in these assembly and operating instructions Note: The term "Assembly and operating instructions" will in the following also be shortened to "instructions" or "manual". Legal notes Warning-note concept This manual comprises notes which must be observed for your personal safety and for preventing material damage. Notes for your personal safety are marked with a warning triangle or an "Ex"...
- Page 4 Intended use of Siemens products Observe also the following: 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.
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Page 5: Table Of Contents
Contents Technical data ........... . . General technical data . - Page 6 Fitting ............. General information on fitting .
- Page 7 Startup ............Procedure before startup .
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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: Measuringsurface Soundpressure Level
P stated on the rating plate, as measurement obtained on the Siemens test bench. If several figures are given, the highest speed and power values apply. The measuringsurface soundpressure level includes addon lubrication units, if applicable. With outgoing and incoming pipes, the interfaces are the flanges. -
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 disruption caused by disregard of these instructions. The "FLENDER bevelgear unit" dealt with in these instructions has been developed for driving machines in general engineering applications. -
Page 11: Safety Instructions
Safety instructions Entry to the gear unit and its addon components is not permitted! Caution! Risk of falling! Any changes on the part of the user are not permitted. This applies equally to safety features designed to prevent accidental contact. Obligations of the user •... -
Page 12: Environmental Protection
Screws which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type. • Spare parts must always be obtained from Siemens (see section 11, "Spare parts, customer service"). Environmental protection •... -
Page 13: Transport And Storage
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. If there is any visible damage, the gear unit must not be put into operation. -
Page 14: Storing The Gear Unit
Fig. 3: Attachment points For a detailed illustration of the gear unit and the position of the attachment points, please refer to the drawings in the orderspecific gearunit documentation. For drive units where addon parts such as drive motor or addon coupling are fitted on the gear unit, an additional attachment point may be required because of the shift in the centre of gravity. -
Page 15: 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 external coat depend on the ambient conditions stipulated in the order relating to method of transport and area of application. The gear unit is normally delivered completely ready, with a priming and a finish coat. -
Page 16: Interior Preservation With Preservative Agent
36 months (Prior to startup replace screw plug with air filter.) For storage periods longer than 36 months, Siemens should be consulted before. Resistant to tropical conditions and sea water; max. ambient temperature 50 °C 4.4.2 Exterior preservation... -
Page 17: Technical Description
Technical description Observe the instructions in section 3, "Safety instructions"! General description The gear unit described is a bevelgear unit developed for driving machines in general engineering applications. The gear unit is delivered as a singlestage bevelgear unit. It is designed for installation in the position specified in the order. -
Page 18: Housing
Housing The housing is made of cast iron; if necessary, it can also be made of nodular cast iron. The housing is made in one part. It is of torsionally rigid design and its shape imparts very favourable noise and temperature characterics. The gearunit housing comes with the following equipment: •... -
Page 19: Toothed Components
Fig. 4: Gearunit features Drive shaft Oillevel indicator Shaft bearing Housing Airguide cover Oil drain Bearing cover Breather Eye bolts Oil inlet Inspection and/or assembly holes A detailed view of the gear unit can be obtained from the drawings in the gearunit documentation. Toothed components The toothed components of the gear unit are casehardened. -
Page 20: Forced Lubrication
5.4.2 Force-feed lubrication In case of high input speeds or high peripheral speeds at the toothed systems, the splash lubrication can, depending on the order, be supplemented by or replaced with a forcedfeed lubrication. In case of forcedfeed lubrication the bearings and/or teeth situated higher than the oil level can be adequately supplied with oil by pipework. -
Page 21: Taconite Seal
5.6.2 Taconite seal Taconite seals have been specially developed for use in a dusty environment. The penetration of dust is prevented by a combination of three sealing elements (radial shaftsealing ring, lamellar seal and greasecharged re-chargeable labyrinth seal). Fig. 6: Taconite seal Radial shaftsealing ring Greasecharged labyrinth seal, rechargeable... -
Page 22: Cooling
Table 7: Variant description Taconite seal Taconite Application Remarks type variant All input shafts "E" with or without fan Re-chargeable labyrinth Output shaft "F" Type S (Solid shaft) Output shaft Labyrinth re-chargeable on both sides, Type H (Hollow shaft with parallel keyway) incl. -
Page 23: Cooling Coil
5.7.2 Cooling coil The gear unit can be fitted with a cooling coil in the oil sump. Cooling water is supplied by way of a water connection. The operator must ensure this. Either fresh water, sea water or brackish water can be used for cooling purposes. -
Page 24: Addon Oilsupply System With Air Oilcooler
5.7.3 Addon oilsupply system with air oilcooler An orderspecific oilsupply system with air oilcooler can be used. This oilcooling system is permanently attached to the gear unit. Components: • one air oilcooler • one flangedon pump • one coarse filter •... -
Page 25: Addon Oilsupply System With Water Oilcooler
5.7.4 Addon oilsupply system with water oilcooler An orderspecific oilsupply system with water oilcooler can be used. This is permanently attached to the gear unit. Components: • pump • one water oilcooler • pipework • filter • monitoring equipment The flow direction of the pump used is independent of the direction of rotation, if nothing is specified in the documentation to the contrary. -
Page 26: Separate / External Oilsupply System
5.7.5 Separate / external oilsupply system It is possible to use an oilsupply system which is separately supplied by Siemens or an external system to ensure cooling of the oil. Be sure to observe the operating instructions of the oilsupply system for operation and maintenance. -
Page 27: Heating
5.10 Heating At low temperatures it may be necessary to heat the gear oil before switching on the drive unit or even during operation. In such cases the use of heating elements is possible. These heating elements convert electrical energy into heat which is conducted to the surrounding oil. The heating elements are located in protective tubes inside the housing, thus making it possible to replace them without draining off the oil. -
Page 28: Bearing Monitoring By Pt 100 Resistance Thermometer
5.13 Bearing monitoring by Pt 100 resistance thermometer The gear unit may be fitted with Pt 100 resistance thermometers for monitoring the bearings. In order to measure the temperatures or temperature differences, the Pt 100 resistance thermometer should be connected to a suitable instrument provided by the customer. The thermometer has a connection head (protection type IP 54) for the wiring. -
Page 29: 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 30: 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. The packaging must not be opened or damaged, if this is part of the preservation method! •... -
Page 31: Alignment
The elements must be pulled smartly onto the shaft as far as stated in the dimensioned drawing prepared in accordance with the order. Fit the coupling with the aid of suitable fitting equipment. The parts must not be driven on by abrupt force, as this may damage the gear unit. The shaftsealing rings and running surfaces of the shaft must not be damaged when pulling in the coupling parts. -
Page 32: Fitting On A Frame
6.3.2.2 Fitting on a frame • Clean the undersurface of the gearunit. • Using suitable lifting gear, place the gear unit on the frame. • Tighten the foundation bolts to the specified torque (see item 6.17); if necessary, use stops to prevent displacement. -
Page 33: Fitting On A Concrete Foundation By Means Of Anchor Bolts
• Using suitable lifting gear, place the gear unit on the concrete foundation. • Align gear unit horizontally by in and output shafts. ─ if using stone bolts, with shims. ─ if using foundation blocks, with the aid of the set screws (if available). •... -
Page 34: Assembly Of A Shaftmounted Gear Unit With Hollow Shaft And Parallel Keyway
• Record alignment dimensions. ─ The record must be kept with these instructions. 1 Anchor bolt 2 Support 3 Base plate 4 Washer 5 Hexagon nut 6 Base plate 7 Finegrout concrete 8 Raw foundation Fig. 13: Anchor bolt Prior to tensioning the anchor bolts, the finegrout concrete must have set for at least 28 days. -
Page 35: Preparatory Work
6.4.1 Preparatory work To facilitate demounting (see also item 6.4.3), we recommend providing a connection for pressure oil on the end of the driven-machine shaft. For this a hole must be drilled through to the hollow-shaft recess (see figure 14). This connection may also be used for supplying rustreleasing agent. Fig. -
Page 36: Fitting
6.4.2.1 Fitting • Fit the gear unit by means of nut and threaded spindle. The counterforce is provided by the hollow shaft. The hollow shaft must be exactly aligned with the machine shaft to avoid canting. Fig. 15: Hollow shaft with parallel keyway, fitting with threaded spindle Machine shaft End plate Hollow shaft... - Page 37 The end plate and/or the auxiliary plate for forcing off the gear unit are not included in our delivery. Each of the two end faces of the hollow shaft is provided with 2 threaded holes (for dimensions, see figure 18) for fastening the end plate to the hollow shaft. Fig.
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Page 38: Shaftmounted Gear Unit With Hollow Shaft And Shrink Disk
Fig. 18: Hollow shaft with parallel keyway For exact dimensions, refer to the drawings in the gearunit documentation. When using forcingoff screws or threaded spindles, the head of the thread pressing against the driven machine should be rounded and well greased to reduce the risk of seizing at this point. -
Page 39: Fitting The Shrink Disk
6.6.1 Fitting the shrink disk • Before beginning installation, the hollow shaft and the stub shaft must be carefully cleaned. Observe manufacturer’s instructions for handling lubricants and solvents. Do not allow cleaning agent or solvent to affect surfaces with paint coating. The bore of the hollow shaft and the stub shaft must be absolutely clean and free of grease and oil in the area of the shrinkdisk seat. -
Page 40: Demounting The Shrink Disk
M 16 M 33 2650 The shrink disk has been identitymarked on the outer ring (4). In case of contacting Siemens this identification must be referred to. For safety reasons, a protective cover should be fitted to prevent contact! This cover must be applied after completion of all works on the shrink disk. -
Page 41: Cleaning And Greasing The Shrink Disk
6.6.3 Cleaning and greasing the shrink disk Only dirty shrink disks must be disassembled and cleaned. • Check all parts for any damage. Damaged parts must be replaced with new ones! The use of damaged parts is not permitted! Only the complete shrink disks supplied by the manufacturer may be used. Combining components from different shrink disks is not permitted. -
Page 42: Inspection Of The Shrink Disk
For permissible alignment errors in case of couplings supplied by Siemens, please refer to the operating instruction manuals for the couplings. If you use couplings manufactured by other manufacturers, ask these manufacturers which alignment errors are permissible, stating the radial loads occurring. - Page 43 The coupling parts may get out of alignment: • due to imprecise alignment during assembly or installation • during operation of the system due to: ─ heat expansion ─ shaft flexure ─ too weak machine frames, etc. ΔKa Axial misalignment Angular misalignment Radial misalignment (ΔKa)
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Page 44: Gear Unit With Cooling Coil
Gear unit with cooling coil • Before connecting the cooling coil the screw plugs must be removed from the connecting bushes. • Flush the cooling coil (in order to remove any contamination). • Connect the coolingwater in and outflow pipes (for exact position of the connections, see dimensioned drawing). -
Page 45: Final Work
6.16 Final work • After installation of the gear unit check all screw connections for tight fit. • Check the alignment after tightening the fastening elements (the alignment must not have been changed). • Check that all the devices which have been demounted for transport reasons have been refitted. For this refer to the details in the data sheet, the list of equipment and the associated drawings. -
Page 46: Tightening Torques And Initialtensioning Forces
6.17.2 Tightening torques and initialtensioning 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, blackannealed or total phosphatised and dry, cut mating threads in steel or cast iron. Lubricants which alter the friction coefficient must not be used and may overload the screw connection. - 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 11 from table 11 M min 1190000 760000 475000 21500 18500 16500 M80x6 10.9 1690000 1100000 675000 30500 26400 23400 12.9 1980000 1360000...
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Page 48: Startup
Startup Observe the instructions in section 3, "Safety instructions"! The gear unit must not be started up, if the required instructions are not available. Procedure before startup 7.1.1 Removal of preservative agent The location of the oildraining points is marked by an appropriate symbol on the dimensioned drawing in the gearunit documentation. -
Page 49: Filling With Lubricant
The quality of the oil used must meet the requirements of the separately supplied BA 7300 instructions manual, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in table "T 7300" (for a link, see the BA 7300 instructions manual supplied separately), because they have been tested and meet the requirements. -
Page 50: Gear Unit With Cooling Coil Or Addon Oilsupply System
If the oil temperature is < 10 °C the oil should be heated up applying suitable measures, or Siemens should be consulted. Be sure to observe the operating instructions of the oilsupply system for operation and maintenance. -
Page 51: Gear Unit With Backstop
The maximally permissible oilsump temperature is 90 °C (for mineral oil) or 100 °C (for synthetic oil). At higher temperatures the gear unit must be shut down immediately and Siemens Customer Service should be consulted. 7.2.8 Bearing monitoring (vibration measurement) If the necessary measures have been takenfor vibration measurement as bearing monitoring (see item 5.13), vibration measurements must be taken in order to obtain... -
Page 52: Checking Procedure
7.2.10 Checking procedure The following visual checks must be conducted and recorded when starting up: Oil level □ Leaktightness of the oilcooling or oilsupply lines □ Opening condition of the shutoff valves □ Effectiveness of the shaft seals □ Freedom of the rotating parts from contact □... -
Page 53: Interiorpreservation Procedure
7.3.1.3 Interiorpreservation procedure • Stop the gear unit. • Drain the oil into a suitable container (see section 10, "Maintenance and Repair"). • Unscrew the air filter including the reducing screw. • Pour in the preservative agent through the hole in the reducing screw up to the upper mark on the oillevel indicator. -
Page 54: Operation
Operation Observe the instructions in section 3, "Safety instructions", in section 9, "Faults, causes and remedy", and in section 10, "Maintenance and repair"! General To achieve a satisfactory and troublefree operation of the equipment, be certain to observe the operating values specified in section 1, "Technical Data", as well as the information given in the operating instructions of the oilsupply system (only with correspondingly equipped gear unit). -
Page 55: Faults, Causes And Remedy
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 Siemens’... - Page 56 Faults Causes Remedy Increased operating temperature. Oil level in housing too high. Check the oil level at room temperature and, if necessary, adjust oil level. Oil too old. Check date of last oil change and, if necessary, change oil. See section 10. Oil badly contaminated.
- Page 57 Faults Causes Remedy Oil foams in oil sump. Water in oil. Check state of oil by the testtube method for water contamination. Have oil analysed by a chemical laboratory. Defective oilsupply system or Check the oilsupply system or cooling coil. cooling coil, replace any defective parts.
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Page 58: Leakage / Leaktightness
In 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 listed in the following overview. -
Page 59: 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 done with care and by duly trained and qualified personnel only. The following applies to all work in item 10.2: Switch the gear unit and addon components off. -
Page 60: General Service Lives Of Oils
Measures Periods Remarks Check cooling coil for deposits Every 2 years See item 10.2.6. Check the hose lines Yearly See item 10.2.9. Change the hose lines 6 years from the manufacturing See item 10.2.9. date impressed Check tightness of fastening bolts After approx. -
Page 61: Clean The Air Filter
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. -
Page 62: Clean Fan And Gear Unit
• Before using these cleaning agents, ensure that they will not damage the cooling coil materials (consult Siemens). Observe the manufacturer’s instructions at all times when using different cleaning agents by several manufacturers. Avoid burns when working with corrosive cleaning agents. Always observe the manufacturers’... -
Page 63: Check Air Oilcooler
10.2.7 Check air oilcooler • The instructions in items 5.7.3 and 10.1 must be observed! • Remove dirt from the cooler block. • Check the condition of screw connections and, if necessary, replace. 10.2.8 Check water oilcooler • The instructions in items 5.7.4 and 10.1 must be observed! •... -
Page 64: Final Work
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 65: Spare Parts, Customer Service
When ordering spare parts, always state the following: Order number, item Type, size Part number Quantity 11.2 Spare parts and customerservice addresses When ordering spare parts or requesting a service specialist, please contact Siemens first (see section 2, "General notes"). BA 5230 en 04/2011 65 / 67... -
Page 66: 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 Bevel gear unit K1N and K1A Sizes 1 to 9 for driving machines in general engineering applications: ‐... - Page 67 Weitere Informationen "FLENDER gear units" im Internet www.siemens.de/getriebe "FLENDER couplings" im Internet www.siemens.de/kupplungen Service & Support: http://support.automation.siemens.com/WW/view/de/10803928/133300 Schmierstoffe: http://support.automation.siemens.com/WW/view/de/42961591/133000 Siemens AG Subject to modifications Industry Sector Mechanical Drives © Siemens AG 2011 Alfred-Flender-Straße 77 46395 Bocholt GERMANY www.siemens.com/drive-technologies...