Hansen P4 Installation Manual
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Hansen P4 Installation Manual

Standardized gear units
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Standardized gear units
Hansen Industrial Transmissions nv
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  • Page 1 Installation manual Standardized gear units Hansen Industrial Transmissions nv IM_405...
  • Page 2 This document could contain technical inaccuracies or typographical errors. Hansen Industrial Transmissions NV reserves the right to revise the content of this document from time to time without the obligation of Hansen Industrial Transmissions NV to notify any person of such revision or change.

  • Page 3: Table Of Contents

    Contents Contents Customer data sheet................7 Manual Disclaimer................... 9 About this document................10 Function of the document......................10 Language...........................10 Illustrations..........................10 Use of steps, lists and titles in this document................10 How to use this document......................10 Warnings, cautions and notes used in the document..............10 Related documents........................11 Storage of this document and the related documents...............
  • Page 4 Contents Storage....................26 General storage instructions...................... 26 Indoor storage for maximum 1 year................... 26 Extended storage outdoors for maximum 2 years (extended outdoor storage)......26 Extended storage indoors for maximum 5 years (extended indoor storage)......27 Installation....................28 Maximum time between installation and commissioning............28 Remove the packaging material....................
  • Page 5 Contents Commissioning..................44 Maximum time between commissioning and operation............. 44 Do a check on the gear unit....................... 44 Start instructions (backstop)...................... 44 Start instructions (heater)......................44 Start instructions (force-feed lubrication, pump with a motor)............44 Start instructions (force-feed lubrication, integrated pump)............45 Start instructions (drive group with a 2-speed motor)..............
  • Page 6 Contents 13.14.2 Additional gear oil specifications (heater)..............61 13.14.3 Mineral gear oil and related grease................62 13.14.4 Synthetic gear oil and related grease................ 63 13.15 Grease quantity at lubrication points for bearings..............64 13.15.1 Grease quantity type....................64 13.15.2 Grease quantity types Q1, Q2, Q3, Q6, Q7 and Q8..........65 13.15.3 Grease quantity type Q4....................

  • Page 7: Customer Data Sheet

    Customer data sheet Customer data sheet Customer References Name Project Application Hansen Industrial Transmissions References Manufacturing Number Order Gear Unit Type Technical Specifications AGMA Power Rating [kW] AGMA Torque Rating [kNm] Exact Ratio Input Speed(s) constant [RPM] Input Speed(s) variable [RPM]...
  • Page 8 Customer data sheet Lubrication Maximum ambient temperature [ºC] Maximum continuous tempera- ture of the gear oil in the oil bath, during operation [ºC] Maximum peak temperature of the gear oil in the oil bath, dur- ing operation, [ºC] Grease type Storage and protection The gearbox is adequately treated for storage and corrosion protection up to 1 year indoors...

  • Page 9: Manual Disclaimer

    Neither Hansen Industrial Transmissions nv nor any of its directors, officers, employees or agents shall be liable in contract, tort or in any other manner whatsoever to any person...

  • Page 10: About This Document

    About this document Function of the document The document is only applicable for the "Hansen P4" gear unit, from here on in the document referred to as the gear unit. The document is for approved installation engineers and gives the information that is necessary to install and remove the gear unit.

  • Page 11: Related Documents

    About this document Type Description Icon Note A note gives more data. Related documents Document name Document code Target audience General conditions of sale • All personnel Order acknowledgement • Approved installation engi- neers Certified drawing • Approved installation engi- neers Installation manual •...

  • Page 12: Storage Of This Document And The Related Documents

    • Make sure that the document and the related documents are available to all personnel. Abbreviations Abbreviation Description H.I.T. Hansen Industrial Transmissions NV Low-Speed Shaft High-Speed Shaft Customer support 3.10 Procedure If more information is necessary, speak to H.I.T. Give the manufacturing number and gear unit type to H.I.T. Refer to the type plate.

  • Page 13: Description

    Description Description Intended use The gear unit is a part of a machine. Only use the gear unit for the application, ambient conditions, operation conditions and other conditions of use shown in the order acknowledgement. Resonant vibrations may cause severe overloads on components which may be several times higher than the nominal load.

  • Page 14: Signs In The Documentation And On The Gear Unit

    Description Variable input speed n1-n1' (variable output speed n2-n2') Type of gear oil Viscosity of the gear oil Minimum temperature for the oil bath for startup Maximum ambient temperature for which the viscosity of the gear oil is applicable Quantity of gear oil Grease quantity type Number of lubrication points Grease type...
  • Page 15 Description Sign Description Magnetic Drain valve with hose coupling Oil fill plug Breather plug Anti-humidity Condensation drain Lubrication point for grease Lubrication point for grease at bearing Lubrication point for grease at labyrinth seal Direction of rotation: clockwise Direction of rotation: counterclockwise IM_405_002_EN...
  • Page 16 Description Sign Description Breather plug to prevent ingress of moisture Level indicator Gauge glass Overflow Inspection opening Pump lubrication Filter Filter with mechanical contamination indicator Filter with electrical contamination indicator Temperature indicator Temperature transmitter Level switch Flow switch IM_405_002_EN...

  • Page 17: Description Of The Lubrication Of The Gear Unit

    Description Sign Description Pressure switch Pressure transmitter Pressure indicator Pressure relief valve Built-in backstop Heater Protection cap for bolt or nut Hole for vibration sensor Ground connection ATEX Description of the lubrication of the gear unit Function of lubrication 4.4.1 Lubrication is necessary for these functions: •...

  • Page 18: Splash Lubrication

    Description These parameters have an effect on the type of lubrication system for the gear unit: • Gear speed • Mounting position of the gear unit • Operation conditions The certified drawing shows the lubrication system that is used for your gear unit. Splash lubrication 4.4.2 Splash lubrication is the standard for gear units with horizontal LSS of these types:...

  • Page 19: Direction Of Rotation Of The Shafts

    Description Direction of rotation of the shafts As a standard, the shafts of the gear unit can turn in two directions. If the shafts of the gear unit can only turn in one direction, a sign on the gear unit and the certified drawing shows this.

  • Page 20: Safety

    Safety Safety Restrictions Warning: Use of the gear unit in ways other than described in the related documents may result in injury, death, or property and equipment damage. Use the gear unit only as described in the related documents. H.I.T. cannot be held responsible for injuries or damages resulting from non-standard, unintended use of the gear unit.

  • Page 21: Safety Instructions For Installation

    Safety Safety instructions for installation • Make sure that the personnel that lift the gear unit are approved and obey state-of-the- art safety procedures and state-of-the-art lifting equipment. • Obey the European Directives 2006/42/EG and the local safety regulations and install guards and other safety equipment.

  • Page 22: Warranty

    Safety Warranty The warranty clause of the general conditions of sale applies to gear units installed and maintained as per instructions contained in this document, including the related documents, and in any additional instruction leaflets supplied with the gear unit insofar as the gear unit operates within the service and rating conditions put forward in the order acknowledgment and on the certified drawing.

  • Page 23: Transport

    Transport Transport Off-site transport Caution: Prevent vibration of the gear unit. Vibration can cause damage to the gears and the bearings. Procedure If you move the gear unit with a train, prevent damage to gears and bearings. Use an anti-brinelling device. On-site transport Lift the gear unit 6.2.1...
  • Page 24 Transport Prepare to lift the gear unit Warning: • Make sure that the personnel that lift the gear unit are approved and obey state-of-the-art safety procedures and use state-of-the-art lifting equipment. • Do not connect the lifting equipment to other parts of the gear unit than the lifting points.
  • Page 25 Transport Procedure For gear units with horizontal LSS with integrated lifting eyes: make sure that the maximum angle (X) of the lifting cables (A) is 45° in the plane of the long side of the gear unit. For all other gear units, make sure that all lifting cables (B) are vertical and parallel to each other.

  • Page 26: Storage

    Storage Storage General storage instructions The storage period starts when the gear unit leaves H.I.T. Procedure Prevent vibration of the gear unit. Make sure that: Ambient • The ambient conditions for storage are correct. Refer to section conditions for storage on page 53.

  • Page 27: Extended Storage Indoors For Maximum 5 Years (Extended Indoor Storage)

    Storage Extended storage indoors for maximum 5 years (extended indoor storage) The storage period starts when the gear unit leaves H.I.T.. For this date, refer to the dispatch document. Procedure Make sure that the gear unit is installed, started and in operation before the end of the maximum storage time.

  • Page 28: Installation

    Installation Installation Maximum time between installation and commissioning Procedure Make sure that the time between installation and commissioning is not more than 1 month. If this is not possible, speak to H.I.T. Remove the packaging material Procedure Move the package to a dry area that has a good airflow. Do a check for these items: •...

  • Page 29: Prepare

    Installation Prepare Procedure Remove the grease and contamination from the shaft extensions and from the coupling. Make sure that the specifications of the coupling agree with the specifications on the certified drawing. Apply the sealing paste Procedure Apply a sealing paste to the contact surfaces A, B, C and D.

  • Page 30: Remove Unwanted Sealing Paste And Apply Paint

    Installation Remove unwanted sealing paste and apply paint Procedure Remove the sealing paste from all surfaces that are not contact surfaces. Do a check for openings between the parts. If you see openings, apply sealing paste and do steps 1 and 2 again. Apply a protection on the oil seals of the gear unit to prevent them from contamination.

  • Page 31: Align The Gear Unit

    Installation Align the gear unit Align the gear unit in the horizontal plane 8.8.1 Procedure Put the gear unit in the correct position, as shown in the certified drawing. Transport For instructions on how to lift the gear unit, refer to section on page 23.

  • Page 32: Align The Hss

    Installation Align the HSS 8.8.4 Procedure Make sure that the misalignment is not more than specified. Refer to section Misalignment of the HSS (couplings) on page 53. If you use a flexible gear coupling, speak to H.I.T. and give all external causes that have an effect on the gear unit.
  • Page 33 Installation Lubricate the contact surface Procedure Clean and remove grease from the contact surfaces (A) and (B). Apply lubricant, only to contact surface (A). For the lubricant specification, refer to section Lubrication on page 58. Do not apply lubricant to the surfaces (B).

  • Page 34: Install The Shaft With Keyway Connection

    Installation Note: The instructions from this point in the procedure only apply to 2-part Shrink disk specifications (2-part shrink disk of the types shown in section shrink disk) on page 58. Procedure Install the shrink disk (A) to the position marked with a locating groove (B).
  • Page 35 Installation Lubricate the contact surface Procedure Clean and remove grease from the contact surfaces (A) and (B). Apply lubricant, only to contact surfaces (A) and (B). For the lubricant specification, refer to Lubrication section on page 58. Wait until the lubricant is dry. Install the installation key on the machine shaft Procedure Install the O-ring (A) on the...
  • Page 36 Installation Procedure Align the gear unit (A) with the machine shaft (B). Make sure that the keyways of the machine shaft and the hollow shaft align. Move the gear unit until the installation key (C) and the installation disk (D) touch each other.

  • Page 37: Install The Torque Arm

    Installation Install the locking disk Procedure Install the locking disk (A) and the bolts (B). Install the safety cover. Install the safety cover Procedure Install the safety cover. Install the torque arm 8.10.3 Install the torque arm Procedure Attach the gear unit to a torque reaction point. Use a torque arm. Refer to the certified drawing for the location of the torque arm on the gear unit.

  • Page 38: Install A Ground Connection

    Installation Procedure Turn the nut (A) to decrease the distance (X) with a distance (Y). (X) is the distance between the torque reation point (B) and the gear unit (C). • This step prestresses the disk springs. • For the specification of (Y), refer to section Prestress specifications for the torque arm...

  • Page 39: Instructions For Force-Feed Lubrication (Integrated Pump)

    Installation Note: For more information on and instructions for these parts of the gear unit, refer to the certified drawing and the service manual of the lubrication and cooling system: • Lubrication system • Instrumentation • Settings Instructions for force-feed lubrication (integrated pump) 8.12.2 Note: During startup, it is necessary to delay the alarm signal.

  • Page 40: Add Gear Oil (Gear Unit With Motor Base)

    Installation Procedure For the correct type and viscosity of gear oil, refer to the type plate. Lubricants With the type and viscosity, select the gear oil from the tables in section on page 61. If the gear unit contains gear oil for storage, drain it. Add gear oil (gear unit with motor base) 8.13.2 Only do the procedure the first time you install the gear unit.

  • Page 41: Add Gear Oil (All Gear Units)

    Installation Add gear oil (all gear units) 8.13.5 Only do the procedure if it is necessary to add gear oil. Caution: Before you use a different type of gear oil that is in the gear unit, speak to the supplier of the gear oil. Not all gear oils are compatible with each other.

  • Page 42: Install The Oil-To-Air Cooler

    Installation Note: • The grease nipples agree with the standard DIN 71412 or optional DIN 3404. Technical data • For the grease quantity, refer to chapter on page 52. Procedure Add grease to the grease nipples. Refer to the signs on the gear unit. Use a grease gun.

  • Page 43: Install The Cooling Coils

    Installation Install the cooling coils 8.16.3 Procedure Connect the cooling coil to the cooling water supply. Make sure that the quality and water pressure of the cooling water agrees with the specifications. Cooling water Refer to section specifications on page 70. While you connect the cooling coil (A), hold the connection (B) with an open spanner (C), to prevent...

  • Page 44: Commissioning

    Commissioning Commissioning Maximum time between commissioning and operation Procedure Make sure that the time between commissioning and operation is not more than 2 weeks. If this is not possible, speak to H.I.T. Do a check on the gear unit Procedure Measure the gear oil level Do a check on the gear oil level.

  • Page 45: Start Instructions (Force-Feed Lubrication, Integrated Pump)

    Commissioning Start instructions (force-feed lubrication, integrated pump) Procedure Delay the alarm signal, to stop the motor that operates the gear unit when the oil flow is low, with 5 s. If not, unwanted alarms occur during startup. For more instructions, refer to the service manual of the lubrication and cooling system.

  • Page 46: Instructions For Operation

    Instructions for operation Instructions for operation General instructions for operation 10.1 Caution: If the instructions are not obeyed during operation, this causes damage to the gear unit. Procedure Give all the instructions in this chapter to the owner of the gear unit. These instructions are a part of the instructions of a larger system in which the gear unit is one part.

  • Page 47: Operate The Gear Unit For 5 Minutes Each 2 Weeks

    Instructions for operation Operate the gear unit for 5 minutes each 2 weeks Procedure Operate the gear unit for minimum 5 minutes each 2 weeks. In this condition, the gear oil prevents corrosion of the internal parts of the gear unit. Protect the gear unit with a volatile corrosion inhibitor Procedure Add a volatile corrosion inhibitor to the gear oil.

  • Page 48: Removal Of The Gear Unit

    Removal of the gear unit Removal of the gear unit General instructions for removal of the gear unit 11.1 Warning: • Obey the instructions on how to move the gear unit when it is on-site. On-site transport Refer to section on page 23.

  • Page 49: Disconnect The Keyway Connection

    Removal of the gear unit Remove the shrink disk Procedure Remove the safety cover. Loosen the bolts (A) 1/4 of a turn. Start with one bolt and continue counterclockwise until the last bolt. Do the step 1 again until all bolts are loose.
  • Page 50 Removal of the gear unit Remove the locking disk Procedure Remove the safety cover. Remove the bolts (B). Remove the locking disk (A). Remove the gear unit Procedure Install these parts: • Installation disk (A) • Bolts (B) (for the type of bolts, refer to the certified drawing) •...

  • Page 51: Care For The Environment

    Care for the environment Care for the environment Make sure to dispose the gearbox and its components in accordance with local regulations at the end of their service life. The best disposal is to avoid the creation of waste by recycling. •...

  • Page 52: Technical Data

    Technical data Technical data Dimensions and mass 13.1 Refer to the certified drawing. Materials of the gear unit 13.2 • Gear oil • Grease • FKM (a type of fluoroelastomer) • Copper • Aluminium • Polycarbonate (solid) • Polypropylene (with embedded glass fibre or with carbon) •...

  • Page 53: Position Of The Gear Unit

    Technical data Position of the gear unit 13.6 Parameter Specification Inclination Maximum 5 mm per 1 m (5/32 inch per 3 feet or 5 mrad or 17 arc minutes) Accuracy of the vertical position from the fourth 0.1 (0.004) connection point [mm] ([inch]) Ambient conditions for storage 13.7 Parameter...

  • Page 54: Bolt Specifications (Gear Units With Solid Shafts)

    Technical data Type of coupling Speed of the HSS [1/min ] Maximum permitted misalign- ment [mm] ([mils]) 0.25 (2.5) Radial misalignment for the spacer shaft and membrane 0.20 (2.0) (disk) coupling, spacer length 1000 0.18 (1.8) 100 mm (1 inch) 1200 0.15 (1.5) 1500...

  • Page 55: Bolt Specifications (Multi-Stage, Horizontal Lss)

    Technical data Bolt specifications (multi-stage, horizontal LSS) 13.10.2 Table for bolts according to DIN 267 bolt quality grade 8.8 Gear unit type Gear unit size Bolt dimension [ISO] Torque [Nm] QH... 1350 1350 2350 2350 2350 2350 3800 3800 5700 5700 5700 9150...
  • Page 56 Technical data Table for bolts according to SAE bolt quality grade 5 Gear unit type Gear unit size Bolt dimension [UNC] Torque [lbf.in] QH... 5/8" 1550 3/4" 2950 7/8" 4850 1" 6000 1 1/4" 12000 1 1/4" 12000 1 1/2" 21000 1 1/2"...

  • Page 57: Bolt Specifications (Multi-Stage, Vertical Lss)

    Technical data Bolt specifications (multi-stage, vertical LSS) 13.10.3 Table for bolts according to DIN 267 bolt quality grade 8.8 Gear unit type Gear unit size Bolt dimension [ISO] Torque [Nm] QV... 1350 1350 2350 G, 2-stage 2350 G, 3-stage and 4-stage M42 3800 3800 3800...

  • Page 58: Torque Values For Oil Drain Screw

    Technical data Table for bolts according to SAE bolt quality grade 5 Gear unit type Gear unit size Bolt dimension [UNC] Torque [lbf.in] 5/8" 1550 3/4" 2950 1" 6000 1 1/8" 10300 1 1/4" 12000 1 1/2" 21000 G, 2-stage 1 1/2"...

  • Page 59: Torque Specifications

    Technical data Torque specifications 13.12.2 Gear unit size H.I.T.part number of the shrink Torque of the bolts (A), for the disk 2-part shrink disk [Nm] 901-SDA2D110001 901-SDA2D125001 901-SDA2D140001 901-SDA2D165001 901-SDA2D185001 901-SDA2D220001 901-SDA2D240001 901-SDA2D260001 901-SDA2D280001 901-SDA2D320001 901-SDA2D340001 901-SDA2D360001 901-SDA2D390001 1480 901-SDA2D420001 1480 901-SDA2D440001 1480...

  • Page 60: Prestress Specifications For The Torque Arm (Hollow Shaft)

    Technical data Prestress specifications for the torque arm (hollow shaft) 13.13 Note: (Y) is the difference between distance without load and the distance when the disk springs are prestressed. Gear unit type [mm] [inch] QH.A2 0.028 QH.B2 0.0.28 QH.C2 0.035 QH.D2 0.035 QH.E2...

  • Page 61: Lubricants

    Technical data Gear unit type [mm] [inch] QH.K3 0.055 QH.K4 0.055 QH.L3 0.055 QH.L4 0.055 QH.M3 0.055 QH.M4 0.055 Lubricants 13.14 General specifications for lubricants 13.14.1 Parameter Specification Initial gear oil cleanliness -/15/12 (or better) according to ISO 4406 Gear oil: maximum allowable water content 0,05 (Karl Fischer) [%] NLGI-Grade of grease...

  • Page 62: Mineral Gear Oil And Related Grease

    Technical data Mineral gear oil and related grease 13.14.3 Table 1: Mineral gear oil Supplier ISO VG150 ISO VG220 ISO VG320 ISO VG460 ADDINOL Eco Gear 150 M Eco Gear 220 M Eco Gear 320 M Eco Gear 460 M BP-CASTROL Alpha SP 150 Alpha SP 220...

  • Page 63: Synthetic Gear Oil And Related Grease

    Technical data Synthetic gear oil and related grease 13.14.4 The synthetic oil must be of the poly-alpha-olefin type (SHF-type, Synthetic Hydrocarbon Fluid). Table 3: Gear oil Supplier ISO VG150 ISO VG220 ISO VG320 ISO VG460 ADDINOL Eco Gear 150 S Eco Gear 220 S Eco Gear 320 S Eco Gear 460 S...

  • Page 64: Grease Quantity At Lubrication Points For Bearings

    Technical data Supplier ISO VG150 ISO VG220 ISO VG320 ISO VG460 SHELL Omala S4 GX 150 Omala S4 GX 220 Omala S4 GX 320 Omala S4 GX 460 SHELL Omala S4 GXV Omala S4 GXV Omala S4 GXV Omala S4 GXV SINOPEC SINOPEC AP-S SINOPEC AP-S...

  • Page 65: Grease Quantity Types Q1, Q2, Q3, Q6, Q7 And Q8

    Technical data Grease quantity types Q1, Q2, Q3, Q6, Q7 and Q8 13.15.2 Lubrication point Gear unit Grease quantity type size Q1 [g] Q2 [g] Q3 [g] Q6 [g] Q7 [g] Q8 [g] IM_405_002_EN...

  • Page 66: Grease Quantity Type Q4

    Technical data Grease quantity type Q4 13.15.3 Lubrication point Lubrication point Gear unit size Lubrication point A [g] B [g] Grease quantity type Q5 13.15.4 Lubrication point Lubrication point Gear unit size Lubrication point A [g] B [g] IM_405_002_EN...

  • Page 67: Grease Quantity Type Q9

    Technical data Gear unit size Lubrication point A [g] B [g] Grease quantity type Q9 13.15.5 B - C - D - E 30°- 45° Lubrication point at the lower side Lubrication point at the upper side Lubrication point at the upper side Lubrication point at the upper side Lubrication point at the upper side Gear unit size...

  • Page 68: Grease Quantity For Lubrication Points At Labyrinth Seals (Lss)

    Technical data Grease quantity for lubrication points at labyrinth seals (LSS) 13.16 Grease quantity type 13.16.1 The grease quantities only apply to the lubrication points that are indicated on the gear unit with the sign for lubrication point for grease at labyrinth seals. Grease quantity (single-stage) 13.16.2 Gear unit type...

  • Page 69: Grease Quantity For Lubrication Points At Labyrinth Seals (Hss)

    Technical data Gear unit type Grease quanitty [g] Gear unit size LSS type Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Solid Solid Solid Grease quantity for lubrication points at labyrinth seals (HSS) 13.17 Grease quantity type 13.17.1...

  • Page 70: Grease Quantity (Multi-Stage)

    Technical data Grease quantity (multi-stage) 13.17.3 Gear unit type Grease quantity [g] A to H J to T Cooling water specifications 13.18 Parameter Specification [MPa] [bar] [psi] Maximum water pres- sure on the cooling coils Quality Fresh water or salt water IM_405_002_EN...
  • Page 71 Technical data IM_405_002_EN...
  • Page 72 Headquarters Manufacturing EUROPE Hansen Industrial Transmissions NV Leonardo Da Vincilaan 1 B-2650 Edegem | Antwerp | Belgium Phone: +32 3 45012-11 | Fax: +32 3 45012-20 info@hansenindustrialgearboxes.com Sumitomo (SHI) Cyclo Drive Germany GmbH CycloStraße 92 | 85229 Markt Indersdorf | Germany Phone: +49 8136 66-0 | Fax: +49 8136 5771 marktind@sce-cyclo.com...

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