Related Manuals for FLENDER B3 A Series
Summary of Contents for FLENDER B3 A Series
- Page 1 FLENDER GEAR UNITS Belt-conveyor gear unit Assembly and operating instructions A5051en Edition 06/2020 B3.A, B3SF 7...16...
- Page 2 10.12.2020 02:53 V24.01...
- Page 3 Introduction Safety instructions Description FLENDER GEAR UNITS Application planning Belt-conveyor gear unit A5051en Assembly Commissioning Assembly and operating instructions Operation Servicing Service & Support Disposal Spare parts B3.A, B3SF Declaration of incorporation 7...16 Technical data Original assembly and operating instructions...
- Page 4 Note the following: WARNING Flender products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Flender. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
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Page 5: Table Of Contents
Table of contents Introduction ............................11 General information......................11 Lubricants.......................... 12 Safety instructions ..........................15 Security notes ........................15 The five safety rules ......................15 General information......................16 General warnings and symbols................... 17 Special types of danger and personal protective equipment ..........18 Intended use........................ - Page 6 Table of contents 3.17 Bearing monitoring ......................41 3.17.1 Bearing monitoring using a Pt 100 resistance thermometer ..........41 3.17.2 Bearing monitoring by acceleration sensor ................. 42 3.18 Speed encoder........................43 3.19 Auxiliary drive........................44 3.19.1 Auxiliary drive, designed as maintenance drive..............45 3.19.2 Overrunning clutch ......................
- Page 7 Table of contents Connecting components ....................87 5.9.1 Gear units with mounted components ................87 5.9.2 Connecting the cooling coil....................88 5.9.3 Connecting the heating element ..................88 5.9.4 Connecting the oil-level monitoring system ................ 89 5.9.5 Connecting the Pt 100 resistance thermometer ..............89 5.9.6 Connecting a speed encoder ....................
- Page 8 Table of contents Service & Support ..........................115 Disposal ............................. 117 Spare parts............................119 Declaration of incorporation ......................121 Technical data............................ 123 General technical data ..................... 123 Ambient temperature....................... 124 Types..........................124 Weights ........................... 125 Enveloping surface sound pressure level................125 Index ..............................
- Page 9 Table of contents Figure 3-9 Gear unit fan .......................... 35 Figure 3-10 Heating on type B3.. gear units ....................38 Figure 3-11 Angled oil level indicator......................39 Figure 3-12 Ölniveauüberwachung an Getrieben der Bauart B3..............40 Figure 3-13 Oil temperature monitoring system on type B3.. gear units............40 Figure 3-14 Bearing monitoring using a Pt 100 resistance thermometer: ............
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Page 10: Table
Table of contents Figure 5-13 Dismantling using hydraulic pulling equipment for gear units with hollow shaft and spline ..80 Figure 5-14 Preparation for gear units with hollow shaft and shrink disk ............ 84 Figure 5-15 Possible displacements ......................86 Figure 5-16 Alignment process based on the example of a flexible coupling .......... -
Page 11: Introduction
Failure to observe these operating instructions can cause product or property damage or personal injury. Flender does not accept any liability for damage or operating failures which are due to non- adherence to these operating instructions. The gear unit described in these instructions reflects the state of technical development at the time these operating instructions went to print. -
Page 12: Lubricants
The quality of the oil used must meet the requirements of the operating instructions BA 7300, which is provided as a separate item, otherwise the warranty provided by Flender will be void. Flender urgently recommends using one of the oils listed in BA 7300, all of which have been appropriately tested and meet the requirements. - Page 13 Introduction 1.2 Lubricants Flender recommends regular inspection to ascertain whether the selected lubricating oil is still approved by Flender. If it is not, another brand of oil should be selected instead. Assembly and operating instructions A5051en Edition 06/2020...
- Page 14 Introduction 1.2 Lubricants Assembly and operating instructions A5051en Edition 06/2020...
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Page 15: Safety Instructions
In order to safeguard plants, systems, machines and networks against cyber threats it is necessary to implement (and continually maintain) a holistic industrial security concept that corresponds to the current state of the art. Flender products and solutions undergo continuous development in this respect. -
Page 16: General Information
Safety instructions 2.3 General information General information Introduction All work on the gear unit should be performed with care and only by qualified personnel. Symbols on the gear unit The following symbols apply to the gear unit; some of which are found as coloured markings on the gear unit: Table 2-1 Symbols and markings... -
Page 17: General Warnings And Symbols
Safety instructions 2.4 General warnings and symbols Points labelled on the gear unit Symbol Coloured markings Do not unscrew Alignment surface, horizontal Alignment surface, vertical These symbols indicate the oil level check‐ ing procedure using the oil dipstick. These symbols indicate that the oil dipstick must be firmly screwed in. -
Page 18: Special Types Of Danger And Personal Protective Equipment
Safety instructions 2.5 Special types of danger and personal protective equipment Special types of danger and personal protective equipment Requirements Fulfil the following requirements before commencing work on the gear unit: • Ensure that the oil pressure lines are depressurised. •... - Page 19 Safety instructions 2.5 Special types of danger and personal protective equipment Switch the gear unit to standstill immediately if inexplicable changes are noticed during operation. Such changes may include unusual gear unit noise or a significant increase in operating temperature. WARNING Risk of falling There is an increased risk of falling when standing or walking on the gear unit during operation.
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Page 20: Intended Use
Safety instructions 2.6 Intended use Chemical substances Injuries can be sustained when using chemical substances. WARNING Risk of chemical burns due to chemical substances There is a risk of chemical burns when handling aggressive cleaning agents. Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents. Wear suitable protective equipment (gloves, safety goggles). - Page 21 Flender will accept no liability or warranty whatsoever for damage occurring as a result of the use of non-approved spare parts. The same applies to any accessories which were not supplied by Flender.
- Page 22 Safety instructions 2.6 Intended use • Pay attention to the notices attached to the gear unit such as the rating plate, direction arrow symbol etc. Notices must not be concealed by paint or dirt. Replace missing plates. • Bolts which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type.
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Page 23: Description
It can essentially be operated in both directions of rotation. Gear units equipped with an axial fan, a backstop or an overrunning clutch are the exceptions in this case. Flender must be consulted if, for these versions, the direction of rotation is to be reversed. If only one direction of rotation is specified in the dimension drawing, it can be assumed that the gear unit is equipped with an axial fan. -
Page 24: Output Shaft Versions
Description 3.2 Output shaft versions Designs Various shaft arrangements (versions and directions of rotation) are possible. These are depicted schematically as a solid shaft below. The direction of rotation arrows indicate the dependency of the direction of rotation of the input and output shafts. Table 3-1 Designs and associated directions of rotation Design... -
Page 25: Housing
Description 3.3 Housing Solid shaft Hollow shaft for shrink disk Hollow shaft with parallel keyway Hollow shaft with spline according to DIN 5480 Figure 3-1 Output shaft versions Further information Further information, a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawing in the complete documentation for the gear unit. -
Page 26: Oil Supply To The Gear Unit
Description 3.4 Oil supply to the gear unit The lubrication points are designated using the following sign: Figure 3-2 Sign: Lubrication point Gear unit equipment The diagram below shows the gear unit equipment on type B3.. gear units: ① ⑧ Air guide cover Baseboards (mounted components) ②... -
Page 27: Bearing Arrangement Of The Shafts
Description 3.6 Shaft seal Bearing arrangement of the shafts All shafts are mounted on rolling-contact bearings. Shaft seal Introduction Depending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt from entering the gear unit. 3.6.1 Rotary shaft sealing rings Rotary shaft sealing rings are the standard seal used. -
Page 28: Taconite Seal
Description 3.6 Shaft seal 3.6.2 Taconite seal The taconite seal is a combination of two sealing elements: • Rotary shaft sealing ring to prevent the escape of lubricating oil • Grease-filled dust seal (comprising a labyrinth and a lamellar seal) to allow operation of the gear unit in extremely dusty environments The taconite seal is ideal for use in dusty environments. -
Page 29: Tacolab Seal
Description 3.6 Shaft seal 3.6.3 Tacolab seal Application Only use Tacolab seals with pressure lubrication and with a reduced oil level. Features Tacolab seals are non-contact, low-maintenance seals that do not wear. It is not therefore necessary to interrupt operation in order to service or replace them. The Tacolab seal is a combination of two sealing elements: •... -
Page 30: Backstop
Description 3.7 Backstop For reliable operation, Tacolab seals require a stationary, horizontal installation position without any contact with dirty water ‐ or high dust levels. Overfilling the gear unit can result in leaks, the same applies to oil with a high foam content. NOTICE Gear unit leaks caused by poor sealing Gear unit leaks caused by poor sealing are possible. - Page 31 Description 3.7 Backstop Principle of operation The backstop is fitted with centrifugally-operated sprags. If the gear unit rotates in the specified direction, the inner ring rotates together with the sprag cage in the direction of rotation of the shaft, while the outer ring remains stationary. Above a certain speed (disengagement speed) the sprags disengage from the outer ring.
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Page 32: Torque Limiting Backstop (Special Version)
3.8 Torque limiting backstop (special version) The blocking direction of the backstop can be changed by turning over the cage. You must always contact Flender in advance if you wish to change the blocking direction. NOTICE Damage to the backstop and gear unit due incorrect direction of rotation Damage to the backstop and gear unit due incorrect direction of rotation possible. -
Page 33: Figure 3-8 Torque Limiting Backstop
You can change the blocking direction of the backstop by turning over the cage. You must always contact Flender in advance if you wish to change the blocking direction. NOTICE Damage to the backstop and gear unit due incorrect direction of rotation Damage to the backstop and gear unit due incorrect direction of rotation possible. -
Page 34: Cooling
It is not permissible that dimension "x “ specified on the backstop type plate is fallen below. min. Flender must be contacted once this dimension is reached. WARNING Risk of injury as a result of moving system parts There is a risk that after the motor is switched off the load cannot be securely kept in position, and that it can accelerate in the reverse direction. -
Page 35: Cooling Coil
Description 3.9 Cooling The diagram below shows a gear unit fan: ① ③ Motor bell housing Air guide cover ② Figure 3-9 Gear unit fan Further information Further information and a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawings in the complete documentation for the gear unit. -
Page 36: Couplings
Description 3.11 Shrink disk • If there is a risk of freezing temperatures, drain the cooling water out of the coil and blow the coil out with compressed air to remove any water residue. • Use a suitable cooling water flow regulator (e.g. a pressure reducing valve or an appropriate isolation valve) in order to prevent excessive water pressure at the cooling water inlet. -
Page 37: Heating
Description 3.12 Heating Further information Further information about the shrink disk can be found in the shrink disk operating instructions. These are included in the complete documentation for the gear unit. 3.12 Heating Introduction At low ambient temperatures it may be necessary to preheat the gear unit oil before switching on the drive or while it is in operation. -
Page 38: Oil Level Indicator
Description 3.13 Oil level indicator ① ② Heating element Temperature monitor Figure 3-10 Heating on type B3.. gear units Heating element control Heating elements can be controlled by a temperature monitor. The temperature monitor provides a signal to be amplified when the minimum and maximum temperatures are reached. Further information Further information about the position of the mounted components and a detailed illustration of the gear unit can be found in the dimension drawing in the complete documentation for the... -
Page 39: Angled Oil Level Indicator
Description 3.15 Oil level monitoring system 3.14 Angled oil level indicator The gear unit can be optionally equipped with an oil level indicator for visually checking the oil level when the unit is at a standstill. The oil level is checked according to minimum and maximum markings on the sight glass of the oil level indicator when the oil is cool. -
Page 40: Oil Temperature Monitoring
Description 3.16 Oil temperature monitoring The diagram below shows the oil level monitoring system for the gear unit: ① Oil level monitoring system Figure 3-12 Ölniveauüberwachung an Getrieben der Bauart B3.. Further information Further information, a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawing in the complete documentation for the gear unit. -
Page 41: Bearing Monitoring
Description 3.17 Bearing monitoring Further information Further information, a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawing in the complete documentation for the gear unit. Further information about oil temperature monitoring (such as control instructions) and the technical data can be found in the operating instructions for the oil temperature monitor and in the list of equipment in the complete documentation for the gear unit. -
Page 42: Bearing Monitoring By Acceleration Sensor
Description 3.17 Bearing monitoring 3.17.2 Bearing monitoring by acceleration sensor Depending on the order specification, the gear unit can be supplied with threaded holes in which acceleration sensors can be inserted. These threaded holes have an M6 or M8 thread depending on the variant. -
Page 43: Speed Encoder
Description 3.18 Speed encoder Figure 3-16 Fully assembled acceleration sensor (C), and the threaded connector (D) for variants 5A and Further information Further information and a detailed illustration of the gear unit with attached sensors can be found in the dimension drawing in the complete documentation for the gear unit. Further information about the sensors can be found in the operating instructions for the sensors. -
Page 44: Auxiliary Drive
Either Flender or the customer provides the auxiliary drive. The auxiliary drive is connected to the main gear unit through an overrunning clutch. The auxiliary drive is mounted onto a connection flange, which in turn is attached to the main gear unit. -
Page 45: Auxiliary Drive, Designed As Maintenance Drive
Description 3.19 Auxiliary drive The basic configuration of the gear unit with main and auxiliary drive is shown in the following diagram. ① ⑤ Main gear unit Main motor ② ⑥ Output shaft of the main gear unit Auxiliary motor ③... - Page 46 Description 3.19 Auxiliary drive Oil supply for the auxiliary gear unit The auxiliary gear unit has its own oil circuit, which is separate from that of the main gear unit. The auxiliary gear unit is already filled with oil when delivered. Speed monitoring To avoid overspeeds if the overrunning clutch was to malfunction, for safety reasons, customers should equip the drive combination with a speed monitoring system.
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Page 47: Figure
Description 3.19 Auxiliary drive ① ⑤ Pulse encoder for speed monitoring Main gear unit ② ⑥ Auxiliary gear unit Backstop ③ ⑦ Overrunning clutch Output shaft of the main gear unit ④ Intermediate flange Figure 3-19 Gear unit design Assembly and operating instructions A5051en Edition 06/2020... -
Page 48: Overrunning Clutch
Description 3.19 Auxiliary drive Gear unit equipment with auxiliary drive The diagram below shows the gear unit equipment on type B3.. gear units: ① ⑧ Speed monitoring Baseboards (mounted components) ② ⑨ Electric motor Backstop ③ ⑩ Air guide cover Shaft seal ④... -
Page 49: Gear Units With Auxiliary Drive And Torque-Limiting Backstop
Description 3.19 Auxiliary drive Principle of operation The overrunning clutch as centrifugally-operated sprags. When the main gear unit rotates with the specified direction of rotation, the inner ring with the sprags rotates, while the outer ring remains stationary. Above a certain speed the sprags disengage, and the overrunning clutch operates without any wear. - Page 50 Description 3.19 Auxiliary drive Assembly and operating instructions A5051en Edition 06/2020...
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Page 51: Application Planning
Application planning Scope of delivery The scope of delivery is listed in the shipping documents. Immediately upon receiving the gearbox, check that everything has been delivered. Report any damaged and/or missing parts to Customer Services (Page 115) immediately. WARNING Serious injury through defective product Serious injury may occur. - Page 52 Application planning 4.2 Transport WARNING Risk of crushing There is a risk of being crushed by a component that becomes detached because the hoisting gear and load suspension device are not suitable for handling it. When lifting, please observe the load distribution information on the packaging. When the product is in a raised position, transport it slowly and carefully to avoid injury to persons or damage to the gear unit.
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Page 53: Attachment Points
Application planning 4.3 Attachment points • Loads must not be suspended from the tip of a load hook • Always place the products down on a level, non-slip and stable base DANGER Falling load There is a risk of fatal injury from falling loads if these have not been securely attached to the lifting equipment. -
Page 54: Figure
Application planning 4.3 Attachment points The shear pulling must not exceed 45° when the lifting equipment is attached to sling swivels. Note Damage to the gear unit during transport Using the wrong attachment points can cause damage when transporting large gear units. Always use sling swivels for gear units larger than size 23. -
Page 55: Attachment Points And Pulling Direction On Type B3.A Gear Units With Auxiliary Drive
Application planning 4.3 Attachment points The diagram below shows the position of the attachment points on type B3SF gear units: Figure 4-4 Attachment points and pulling direction on type B3SF gear units The diagram below shows the position of the attachment points on type B3.A gear units with auxiliary drive: Figure 4-5 Attachment points and pulling direction on type B3.A gear units with auxiliary drive... -
Page 56: Attachment Points And Pulling Direction On Type B3.A Gear Units With Motor
Application planning 4.3 Attachment points Figure 4-7 Attachment points and pulling direction on type B3.A gear units with motor The diagram below shows the position of the attachment points on type B3.A gear units with gear unit swing base: Figure 4-8 Attachment points and pulling direction on type B3.A gear units with gear unit swing base Drive units with additional components mounted on the gear unit (such as drive motor, coupling, etc.) may require an extra attachment point owing to the displacement in the centre... -
Page 57: Special Aspects Of Gear Unit Lubrication And Preservation
Application planning 4.4 Special aspects of gear unit lubrication and preservation Special aspects of gear unit lubrication and preservation 4.4.1 Oil filling and oil drain The diagram below shows the oil filling points and the oil draining points on type B3.A gear units: ①... -
Page 58: Figure
Application planning 4.4 Special aspects of gear unit lubrication and preservation ① ④ Oil filling point (backstop) Venting screw or air filter (screw plug) ② ⑤ Oil filling point (auxiliary gear unit) Oil dipstick ③ ⑥ Oil filling point (main gear unit) Oil drain screw Figure 4-11 Oil filling points and oil draining points on type B3.A gear units with auxiliary drive... -
Page 59: Preservation Of Gear Units With Tacolab Seals
Application planning 4.4 Special aspects of gear unit lubrication and preservation The diagram below shows the oil filling points and the oil draining points for a backstop: ① ④ Oil filling screw plug Residual oil drain screw ② ⑤ Gear unit Backstop cover ③... - Page 60 Application planning 4.4 Special aspects of gear unit lubrication and preservation Assembly and operating instructions A5051en Edition 06/2020...
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Page 61: Assembly
Assembly General assembly instructions The assembly work must be performed very carefully by authorised, trained and suitably instructed personnel. Liability will be disclaimed for damage caused by the incorrect performance of this work. Requirements Improper use can damage the gear unit. Be sure to take the following precautions: •... -
Page 62: Unpacking The Gear Unit
Assembly 5.2 Unpacking the gear unit If you use a temperature monitoring device, it must be capable of issuing an alarm when the maximum permissible oil sump temperature is reached. It must also be capable of tripping the drive when the maximum permissible oil sump temperature is exceeded. The operator's process might be interrupted when the drive is shut down. -
Page 63: Gear Unit Assembly
Assembly 5.3 Gear unit assembly Requirement Check that everything has been delivered immediately upon receipt. NOTICE Damage to the gear unit due to corrosion Exposing the gear unit to moisture can result in damage from corrosion. Do not damage or open the packaging prematurely if the packaging is designed to preserve the unit. -
Page 64: Description Of Assembly Work
Assembly 5.3 Gear unit assembly • Align the foundation carefully with the equipment installed on the input and output sides of the gear unit. • Take into account any elastic deformation that may be caused by operating forces. • Install lateral stops to prevent displacement if external forces are acting on the gear unit. NOTICE Lack of stable foundation for the gear unit Damage to the gear unit is possible if it is not mounted on a stable foundation. - Page 65 Assembly 5.3 Gear unit assembly • If these input elements must be fitted hot, the joining temperatures required are listed in the dimension drawings in the coupling operating instructions. • Unless otherwise specified, heat the coupling parts by an induction heater, with a torch or in an oven.
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Page 66: Figure
Assembly 5.3 Gear unit assembly Alignment Alignment The gear unit housing has machined surfaces (alignment surfaces) to help you align the unit horizontally in the longitudinal axis. The machine shaft determines the horizontal mounting position in the transverse axis. DANGER Risk of fatal injury from flying fragments Failure to align the unit with the required degree of accuracy can cause the shaft to rupture. -
Page 67: Mounting On A Gear Unit Swing Base
Assembly 5.3 Gear unit assembly The diagram below shows the alignment surfaces on type B3.. gear units: ① Alignment surfaces Figure 5-2 Alignment surfaces on type B3.. gear units 5.3.1.2 Mounting on a gear unit swing base Assembling gear units with baseboards Use of incorrect attachment points Use of incorrect attachment points may result in damage to the gear unit. - Page 68 Damage to the gear unit due to incorrectly mounting the motor and gear unit swing base is possible. The motor and swing base may only be mounted after prior consultation with Flender. The torque arm must be attached on the machine side without resulting in any distortion or deformation.
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Page 69: Mounting The Torque Arm For The Gear Unit Housing
Damage to the gear unit due to incorrect mounting of the motor and torque arm is possible The motor and torque arm may only be mounted after prior consultation with Flender. Mount the torque arm to the machine side without causing any distortion or deformation. -
Page 70: Preparations
Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway 5.4.1 Preparations Preparatory measures To facilitate dismantling (Page 72), insert a pressure oil connector into the shaft end of the driven machine until it is flush with the bore of the hollow shaft. This connector can also be used to feed in rust remover. -
Page 71: Mounting
Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway • If necessary, rework the components with an appropriate tool and then clean them again. • Apply an appropriate lubricant to the contact surfaces to protect them against fretting corrosion. -
Page 72: Axial Locking
Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway The diagram below shows the mounting process with screw spindle for gear units with a hollow shaft and parallel keyway: ① ⑤ Machine shaft ② ⑥ End plate Hollow shaft ③... - Page 73 Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway Note Reducing the risk of corrosion When using jacking screws or screw spindles, to avoid the risk of corrosion, round off and grease the end of the thread (head) that presses against the driven machine. Procedure In order to dismantle a shaft-mounted gear unit from the machine shaft, proceed as follows: 1.
- Page 74 Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway The following diagram shows the dismantling procedure using hydraulic pulling equipment for gear units with hollow shaft and parallel keyway: ① ⑤ Screw spindle Machine shaft ② ⑥ Hydraulic pulling equipment Hollow shaft ③...
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Page 75: Table
Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway Threaded holes at the face sides of gear unit hollow shafts Refer to the following table for the dimensions of the threaded holes at the face sides of gear unit hollow shafts: Table 5-1 Dimensions for the threaded holes at the face sides of gear unit hollow shafts... -
Page 76: 5.5 Shaft-Mounted Gear Unit With Hollow Shaft And Spline According To Din 5480
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 Introduction The shaft end of the driven machine must have a spline according to DIN 5480. Furthermore, it should have a hole centred in its end face as defined by DIN 332, form DS (with thread). -
Page 77: Assembly
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 5.5.2 Assembly Measures to be taken prior to assembly CAUTION Risk of injury due to chemical substances Observe the manufacturer’s guidelines on how to handle lubricants and solvents. Wear suitable protective clothing. -
Page 78: Axial Locking
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 NOTICE Damage to the rolling-contact bearings The rolling-contact bearings can become damaged if the gear unit skews during mounting. The hollow shaft may be mounted on a machine shaft shoulder only if the gear unit features one of the following: •... -
Page 79: Dismantling
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 5.5.3 Dismantling Measures prior to dismantling NOTICE Damage to the gear unit The gear unit can become damaged if it skews during dismantling. Do not allow the gear unit to skew as you remove it from the machine shaft. When removing the gear unit using hydraulic pulling equipment, excessive force can be placed on the housing, bearings and other gear unit components. -
Page 80: Dismantling Using Hydraulic Pulling Equipment For Gear Units With Hollow Shaft And Spline
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 The following diagram shows the dismantling procedure using an end plate for gear units with a hollow shaft and spline: ① ④ Jacking screws Machine shaft ②... -
Page 81: Shaft-Mounted Gear Unit With Hollow Shaft And Shrink Disk
Assembly 5.6 Shaft-mounted gear unit with hollow shaft and shrink disk Refer to the following table for the maximum forcing pressures: Table 5-3 Maximum forcing pressures Gear unit size Maximum forcing Gear unit size Maximum forcing pressures in N pressures in N 22 600 97 200 33 000... -
Page 82: Assembly
Assembly 5.6 Shaft-mounted gear unit with hollow shaft and shrink disk 5.6.1 Assembly Measures to be taken prior to assembly CAUTION Risk of injury due to chemical substances Observe the manufacturer’s guidelines on how to handle lubricants and solvents. Wear suitable protective clothing. Improper use can damage the gear unit. -
Page 83: Pulling On With Integrated Du Bushing
Assembly 5.6 Shaft-mounted gear unit with hollow shaft and shrink disk 5.6.1.1 Pulling on with integrated DU bushing Procedure NOTICE Damage to the gear unit The gear unit can become damaged if it skews during assembly. The hollow shaft must be flush with the machine shaft during assembly of the gear unit on the machine shaft. -
Page 84: Axial Locking
Assembly 5.6 Shaft-mounted gear unit with hollow shaft and shrink disk The following diagram shows the preparation for gear units with hollow shaft and shrink disk: ① ⑤ Screw spindle End plate ② ⑥ Jacking screw Machine shaft ③ ⑦ Hollow shaft ④... -
Page 85: Shaft-Mounted Gear Unit With Flange Coupling
Assembly 5.7 Shaft-mounted gear unit with flange coupling NOTICE Use of incorrect attachment points Use of incorrect attachment points may result in damage to the gear unit. • Only attach the gear unit at the lifting eyes provided for this purpose. •... -
Page 86: Couplings
Assembly 5.8 Couplings Couplings Introduction The coupling parts might become misaligned as a result of: • Failure to accurately align the parts during assembly • During operation of the system: – Due to thermal expansion – Due to shaft deflection –... -
Page 87: Connecting Components
Further information You can find additional information about the permissible alignment errors for Flender couplings in the complete documentation for the gear unit. If couplings from other manufacturers are to be used, then, specifying the radial loads that occur, ask the manufacturer which alignment errors are permissible. -
Page 88: Connecting The Cooling Coil
Assembly 5.9 Connecting components Further information You can find additional information on operation and maintenance in the associated operating instructions, provided in the complete gear unit documentation. You can find the technical data of the mounted components in the contract-list of equipment provided in the complete gear unit documentation. -
Page 89: Connecting The Oil-Level Monitoring System
Assembly 5.9 Connecting components 5.9.4 Connecting the oil-level monitoring system Procedure To connect the oil-level monitoring system to the gear unit, proceed as follows: 1. Ensure that the filling level limit switch connection is not damaged. 2. Electrically connect the filling level limit switch. 3. -
Page 90: Electrical Connections
Assembly 5.10 Tightening procedure Further information You can find additional information on the speed encoder in the speed encoder operating instructions, provided in the complete gear unit documentation. 5.9.7 Electrical connections Procedure DANGER Electric shock Live parts can cause electric shock. Ensure that the entire plant is de-energised before starting electrical installation work. -
Page 91: Bolt Connection Classes
Assembly 5.10 Tightening procedure Note Replacing bolts Replace any bolts that are no longer fit for use by bolts of the same type and strength class. Mating threads The mating threads must have the following properties: • Made of steel or cast iron •... -
Page 92: Tightening Torques And Preload Forces
Assembly 5.10 Tightening procedure Further information You can find additional information about tightening torques when mounting motor and brake in the operating instructions from the particular manufacturer. 5.10.3 Tightening torques and preload forces The specified bolted connections must be tightened to the torques stated in the table below: The tightening torques apply to friction values of μ... -
Page 93: Final Work
Assembly 5.11 Final work Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec‐ thread di‐ strength classes from the table in tion classes from the table in chap‐ ameter class chapter Bolt connection classes ter Bolt connection classes (Page 91). - Page 94 Assembly 5.11 Final work • Perform potential equalisation in accordance with the applicable regulations and guidelines. If no threaded holes are available on the gear unit for an earth connection, please take suitable alternative measures. This work must always be done by specialist electricians. •...
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Page 95: Commissioning
Commissioning Measures prior to commissioning Take the following measures before commissioning the gear unit: • Read and observe the operating instructions. • Replace the screw plug with the air filter or the wet-air filter. Read operating instructions BA 7300 for further information. •... -
Page 96: Gear Unit With Auxiliary Drive
Commissioning 6.1 Measures prior to commissioning NOTICE The backstop and the gear unit can be damaged If you operate the gear unit adversely to the blocking direction of the backstop, the backstop and the gear unit can be damaged. Do not operate the gear unit adversely to the blocking direction of the backstop. Observe the information on the plate attached to the gear unit. -
Page 97: Measures During Commissioning
Commissioning 6.2 Measures during commissioning Further information Further information about the cooling coil can be found in the separate data sheet and the list of equipment in the complete documentation for the gear unit. Further information about connection dimensions and cooling water parameters can be found in the gear unit dimensional drawing in the complete documentation for the gear unit. - Page 98 Commissioning 6.2 Measures during commissioning WARNING The oil sump can catch fire The oil sump can catch fire if exposed heating elements are switched on. Never switch on the heating elements until you have checked that they are completely immersed in the oil bath. Further information Further information about heating elements can be found in the heating element operating instructions in the complete documentation for the gear unit.
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Page 99: Operation
Operation Operating data Introduction To ensure correct, trouble-free operation of the system, observe the operating data of the gear unit. The valid operating data can be found in the annex Technical data. The following operating data apply to the oil: Table 7-1 Operating data Maximum operating tempera‐... -
Page 100: Taking The Unit Out Of Service
1. Switch off the drive assembly if it exhibits irregular behaviour during operation. 2. Refer to the Fault information (Page 110) to find the cause of the fault. 3. If you still cannot determine the fault cause, contact Flender Customer Services. Taking the unit out of service... -
Page 101: Servicing
Servicing General maintenance information The operator must ensure compliance with the stipulated time limits. This also applies if the maintenance activities are included in the operator’s internal maintenance schedules. The gear unit could be damaged if the stipulated time limits for maintenance and servicing are not observed. -
Page 102: Maintenance Schedule
Servicing 8.2 Maintenance schedule Maintenance schedule Maintenance and servicing activities The following table provides an overview of all maintenance and servicing activities which you are required to perform continuously or at regular intervals. Table 8-1 Maintenance and servicing activities Intervals and time limits Measures As required Replace the wet-air filter... -
Page 103: Maintenance And Servicing Work
Servicing 8.3 Maintenance and servicing work Intervals and time limits Measures Every 2 years Carry out a general inspection of the gear unit Check the cooling coil Check that all of the fastening bolts are tight Clean the fan and gear unit Every 20 000 operating hours, at least every Change the oil if using semi-synthetic oil of API Group III, 4 years... -
Page 104: Checking The Oil Temperature
3. Measure the temperature of the oil in the oil sump. 4. Compare the measured value with the maximum permissible oil temperature (Page 99). 5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded. Contact Flender Customer Services. 8.3.3 Replacing the backstop... -
Page 105: Filling The Backstop With Oil
Servicing 8.3 Maintenance and servicing work 8.3.4 Filling the backstop with oil Oil type and filling filter When filling the backstop with oil, observe the following points: • Use the same oil type and oil viscosity as for the gear unit itself. •... -
Page 106: Checking The Friction Linings Of The Torque-Limiting Backstop
Servicing 8.3 Maintenance and servicing work 8.3.6 Checking the friction linings of the torque-limiting backstop Introduction The friction linings of the torque-limiting backstop can wear, especially for frequent slippage. Note Loss of warranty The warranty becomes null and void if you remove or damage the locking wire at the guide screws of the springs. -
Page 107: Checking The Auxiliary Drive
Servicing 8.3 Maintenance and servicing work Further information Additional information about the torque-limiting backstop can be found in the torque-limiting backstop operating instructions provided in the complete gear unit documentation. 8.3.7 Checking the auxiliary drive Further information You can find information on checking the auxiliary drive in the auxiliary drive operating instructions, provided in the complete gear unit documentation. -
Page 108: Cleaning The Fan And Gear Unit
Servicing 8.3 Maintenance and servicing work Further information You can find additional information on measuring the vibration levels at rolling-contact bearings in the operating instructions of the measurement sensor provided in the complete gear unit documentation. 8.3.10 Cleaning the fan and gear unit Introduction The gear unit can sustain damage due to inadequate cooling if you operate it with a damaged or soiled fan. -
Page 109: Inspecting The Shrink Disk
Before you use a cleaning agent, check whether it is suitable for use on the cooling coil materials. You must consult Flender Customer Services. Carefully read the instructions for use supplied by the manufacturer before using different kinds of cleaning agent. -
Page 110: Check That All Of The Fastening Bolts Are Tight
Possible faults The faults listed below are only intended as a troubleshooting guide. If any faults occur while the unit is still under warranty, do not allow anyone except Flender Customer Services to attempt a repair. Even after the warranty period has expired, you should still arrange for faults to be rectified by Flender Customer Services. -
Page 111: Possible Faults And Their Rectification
Servicing 8.4 Possible faults Possible faults and their rectification The following table provides you with an overview of possible faults and indicates how they can be rectified. Table 8-2 Possible faults and their rectification Possible faults Causes Possible remedies Pressure monitor trig‐ Oil pressure <... - Page 112 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Auxiliary drive motor Overload at the output • Reduce the load at the output does not start Defective auxiliary drive motor • Repair or replace motor Motor brake not released • Correct the electrical connection of the motor brake •...
- Page 113 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Oil cooling system fault - • Carefully observe the information in the oil cooling system instructions Elevated temperature Oil level in the gear unit housing too • Check the oil level during operation high •...
- Page 114 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Elevated vibration am‐ Defective rolling-contact bearings • Contact Customer Services plitude at bearing • Inspect the rolling-contact bearings and replace if neces‐ points sary Gear wheels defective • Contact Customer Services •...
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Page 115: Service & Support
Am Industriepark 2 46562 Voerde Germany Tel.: +49 (0)2871 / 92‐0 Fax: +49 (0)2871 / 92‐1544 Further information Further information about service and support can be found on the Internet. Service & Support (https://www.flender.com/service) Assembly and operating instructions A5051en Edition 06/2020... - Page 116 Service & Support Assembly and operating instructions A5051en Edition 06/2020...
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Page 117: Disposal
Disposal Disposal of the gear unit When disposing of the gear unit after its useful life, please observe the following measures: • Remove operating oil, preservative agents and coolant from the gear unit and dispose of it according to regulations. •... - Page 118 Disposal Assembly and operating instructions A5051en Edition 06/2020...
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Page 119: Spare Parts
Note Damage to the gear unit due to use of unsuitable spare parts Only use original spare parts from Flender. Flender shall not accept any warranty claims for spare parts that are not supplied by Flender. Other spare parts are not tested and approved by Flender. Non-approved spare parts may possibly change the design characteristics of the gear unit and thus impair its active or passive safety. - Page 120 Spare parts Assembly and operating instructions A5051en Edition 06/2020...
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Page 121: Declaration Of Incorporation
Declaration of incorporation Assembly and operating instructions A5051en Edition 06/2020... - Page 122 Declaration of incorporation Assembly and operating instructions A5051en Edition 06/2020...
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Page 123: Technical Data
Rating plate The limits of the intended use of the gear unit are defined on the basis of these data and the contractual agreements concerning the gear unit concluded between Flender and the customer. Further information Further information about these technical data can be found in the separate data sheet and the dimension drawings in the complete documentation for the gear unit. -
Page 124: Ambient Temperature
By applying various suitable measures, the gear unit can be used in the ambient temperature range extending from -40 °C up to 60 °C. However, this must always be authorised by Flender and specified in the order text. Types The gear units are designed as flange-mounted units (by shrink-fitting of a coupling flange) or as shaft-mounted units for mounting on the machine shaft. -
Page 125: Weights
The sound pressure level applies to a gear unit in the warm condition at an input speed n output power P according to the rating plate, for measurements carried out on a Flender test bench. If several values are given, then the highest speed and power values apply. -
Page 126: Table
Technical data B.5 Enveloping surface sound pressure level Refer to the following table for the enveloping surface sound pressure level L in dB(A) for gear units with fan. Table B-1 Enveloping surface sound pressure level Type in rpm Gear unit size B3SA 12.5 1800... -
Page 127: Index
Index Dip lubrication, 26 Directions of rotation, 24 Disclaimer, 11 Disposal, 117 Alignment Documentation landscape, 12 Alignment surface, 66 Prealignment, 66 Attachment points, 61 Auxiliary drive Checking, 107 Environmental protection, 117 Checking the speed monitoring, 107 Equipment features, 25 Commissioning, 96 Eye bolts, 54 Filling the overrunning clutch with oil, 105 Backstop... - Page 128 Index Interval, 102 Rating plate, 123 Irregularities in operation, 99 Example of type and size, 124 Reactivating, 22 Rolling-contact bearings Measuring the vibration levels, 107 Rotary shaft sealing ring, 27 Lateral pulling, 54 Lubricant, 12 Lubrication point, 26 Safety rules, 15 Scope of delivery, 51 Servicing activities, 102 Maintenance activities, 102...
- Page 129 Index Venting screw Cleaning, 103 Warning symbols, 17 Assembly and operating instructions A5051en Edition 06/2020...
- Page 130 Index Assembly and operating instructions A5051en Edition 06/2020...
- Page 132 FLENDER GEAR UNITS Belt-conveyor gear unit Assembly and operating instructions A5051en Edition 06/2020 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt GERMANY...
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