Download
Share
Print this page
  1. Manuals
  2. Brands
  3. FLENDER Manuals
  4. Industrial Equipment
  5. H1SM
  6. Assembly and operating instructions manual

FLENDER H1SM Assembly And Operating Instructions Manual

Gear unit
Hide thumbs

Advertisement

Quick Links

Download this manual
FLENDER GEAR UNITS
Gear unit
Assembly and operating instructions 5026en
Edition 06/2020
H1SM
22

Advertisement

loading
Need help?

Need help?

Do you have a question about the H1SM and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for FLENDER H1SM

Summary of Contents for FLENDER H1SM

  • Page 1 FLENDER GEAR UNITS Gear unit Assembly and operating instructions 5026en Edition 06/2020 H1SM...
  • Page 2 09.12.2020 12:01 V24.01...
  • Page 3 Introduction Safety instructions Description FLENDER GEAR UNITS Application planning Gear unit 5026en Assembly Commissioning Assembly and operating instructions Operation Servicing Service & Support Disposal Spare parts H1SM Declaration of incorporation Technical data Original assembly and operating instructions Edition 06/2020...

  • Page 4: Legal Information

    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.

  • Page 5: Table Of Contents

    Table of contents Introduction ............................9 General information......................9 Lubricants.......................... 10 Safety instructions ..........................13 Security notes ........................13 The five safety rules ......................13 General information......................14 General warnings and symbols................... 15 Special types of danger and personal protective equipment ..........16 Intended use........................
  • Page 6 Table of contents Assembly.............................. 35 General assembly instructions.................... 35 Unpacking the gear unit..................... 36 Gear unit assembly ......................37 5.3.1 Foundation ........................37 5.3.1.1 Mounting on a concrete foundation ................... 38 5.3.2 Mounting .......................... 40 5.3.2.1 Mounting on a housing foot....................40 Couplings ..........................
  • Page 7 Figures Figure 3-1 Sign: Lubrication point......................22 Figure 3-2 Gear unit equipment on a gear unit of type H1SM ..............23 Figure 3-3 Labyrinth seal ......................... 25 Figure 3-4 Oil temperature monitoring system for gear units, type H1SM ..........27 Figure 3-5 Bearing monitoring using a Pt 100 resistance thermometer: ............
  • Page 8 Table of contents Assembly and operating instructions 5026en Edition 06/2020...

  • Page 9: 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 10: 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 11 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 5026en Edition 06/2020...
  • Page 12 Introduction 1.2 Lubricants Assembly and operating instructions 5026en Edition 06/2020...

  • Page 13: 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 14: 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 15: 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 16: 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 17: Surface Temperature

    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.

  • Page 18: Chemical Substances

    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 19 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 20 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.

  • Page 21: Description

    Description General description The FLENDER gear unit (referred to below simply as "gear unit") described in these operating ® instructions has been developed for hydroelectric turbines. The gear unit is available as a single-stage helical gear unit. This is designed for horizontal mounting.

  • Page 22: Further Information

    Description 3.2 Housing The gear unit housing has the following features: • Attachment points for transporting the gear unit (from gear unit size 23 and higher, use a sling swivel) • Inspection cover for inspection • Oil filling point for refilling with oil •...

  • Page 23: Oil Supply To The Gear Unit

    Description 3.3 Oil supply to the gear unit Gear unit equipment The diagram below shows the available gear unit equipment on a gear unit of type H1SM: ① ⑦ Rating plate Gear unit fastening ② ⑧ Lifting eye Pressureless oil return ③...

  • Page 24: Bearing Arrangement Of The Shafts

    Description 3.5 Shaft seal Failure of the oil supply system The gear unit is equipped with an additional oil tank. When the oil supply system fails, the oil tank supplies the input and output shaft bearings with oil for a brief period of time (approximately 10 minutes).

  • Page 25: Cooling

    Description 3.7 Couplings Figure 3-3 Labyrinth seal To work reliably, labyrinth seals must be installed in stationary, horizontal positions without dirty water or any substantial amount of dust. Overfilling the gear unit can result in leaks, the same applies to oil with a high foam content. Cooling Introduction The gear unit can be equipped with a separate oil supply system depending on requirements:...

  • Page 26: Oil Level Indicator

    Description 3.10 Oil temperature monitoring Use of rigid couplings or other input or output elements that generate additional radial or axial forces (e.g. gear wheels, belt pulleys, flywheels or hydraulic couplings) must be agreed contractually. Further information You can find additional information about the couplings in the coupling operating instructions provided in the complete gear unit documentation.

  • Page 27: Bearing Monitoring

    ① Pt 100 resistance thermometer Figure 3-4 Oil temperature monitoring system for gear units, type H1SM 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 28: Figure 3-5 Bearing Monitoring Using A Pt 100 Resistance Thermometer

    Description 3.11 Bearing monitoring You must connect the Pt 100 resistance thermometer to an evaluation unit provided by the customer to be able to measure temperatures or temperature differences. The resistance thermometer has a connection head for the wiring. A two-wire circuit is provided in the factory. However, customers can also configure a three or four-wire circuit.

  • Page 29: Bearing Monitoring By Shock-Pulse Transducer

    Description 3.12 Hydraulic motor Further information about bearing monitoring using a Pt 100 resistance thermometer (such as control instructions) and the technical data can be found in the operating instructions for the Pt 100 resistance thermometer and in the list of equipment in the complete documentation for the gear unit.

  • Page 30: Holding Brake

    Description 3.13 Holding brake 3.13 Holding brake Depending on the order specification, the high-speed shaft can be equipped with a holding brake mounted on the gear unit. The following diagram shows a gear unit with holding brake: ① ② Holding brake Output shaft10 Figure 3-7 Gear unit with holding brake...

  • Page 31: 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 69) immediately. WARNING Serious injury through defective product Serious injury may occur.
  • Page 32 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.

  • Page 33: Lifting Eyes

    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 34: Figure 4-2 Position Of The Attachment Points For Gear Units, Type H1Sm

    Application planning 4.3 Attachment points Position of attachment points The following diagram shows the position of the attachment points for gear units, type H1SM: Figure 4-2 Position of the attachment points for gear units, type H1SM: Further information Further information, a detailed illustration of the gear unit and the position of the attachment points can be found in the dimension drawings in the complete documentation for the gear unit.

  • Page 35: 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 36: 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 37: 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 38: Mounting On A Concrete Foundation

    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 39 Assembly 5.3 Gear unit assembly NOTICE Poor stability Damage to the gear unit is possible if it is not mounted on a stable foundation. The foundation frame must be horizontal and level. It is particularly important that the surface on which the gear unit is mounted is level because this determines the contact pattern of the teeth and the load on the bearings, and so has an influence on the service life of the gear unit.

  • Page 40: Mounting

    Assembly 5.3 Gear unit assembly 5.3.2 Mounting 5.3.2.1 Mounting on a housing foot Description of assembly work Measures to be taken prior to assembly CAUTION 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.
  • Page 41 Assembly 5.3 Gear unit assembly NOTICE Damage as a result of blows or impact Damage in the gear unit as a result of blows or impact as possible. Pull on the coupling using the appropriate pulling equipment. Avoid damaging the shaft sealing rings and the shaft running surfaces when fitting coupling parts.

  • Page 42: Figure 5-1 Alignment Surface

    Assembly 5.3 Gear unit assembly Alignment Depending on the order specification, the top of the housing has machined surfaces (alignment surfaces) to assist with provisional alignment of the gear unit in the horizontal direction. 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 43: Figure 5-2 Alignment Thread For Gear Units, Type H1Sm

    Assembly 5.3 Gear unit assembly The following diagram shows the alignment thread for gear units, type H1SM: ① Alignment thread Figure 5-2 Alignment thread for gear units, type H1SM: Further information Further information and the precise position of the alignment thread are provided in the dimension drawing in the overall gear unit documentation.

  • Page 44: Couplings

    Assembly 5.4 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 45: Figure 5-4 Alignment Process Based On The Example Of A Flexible Coupling

    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 46: Installing The Piping

    Assembly 5.5 Installing the piping Installing the piping 5.5.1 Procedure Proceed as follows to install the piping: 1. Carefully clean the piping and purge the piping using low viscosity oil. 2. Remove the dummy flange and plugs. 3. Screw on the pipes according to the dimension drawings. The screw connections seal metal on metal, while the associated seals/gaskets must be used for the flanges.

  • Page 47: Connecting Components

    Assembly 5.6 Connecting components • After you have emptied the pipes, you must fill them with a neutralisation solution (3 % to 5 % NaOH). The neutralisation solution should act for 15 minutes. • Then flush out the pipes again using water. •...

  • Page 48: Connecting The Pressure Monitor

    Assembly 5.6 Connecting components 5.6.3 Connecting the pressure monitor For gear units with mounted oil supply system or separate oil supply system, you must connect the pressure monitor so that it functions correctly. Further information You can find additional information on pressure monitoring in the pressure monitor operating instructions, provided in the complete gear unit documentation.

  • Page 49: Tightening Procedure

    Assembly 5.7 Tightening procedure Further information You can find additional information about the electrical connections in the terminal diagrams and equipment lists provided in the complete gear unit documentation. Tightening procedure 5.7.1 Introduction Bolts The bolts must have the following properties: •...

  • Page 50: Bolt Connection Classes

    Assembly 5.7 Tightening procedure 5.7.2 Bolt connection classes In order to affix fastening bolts, note the information in the following table: Table 5-1 Information on tightening fastening bolts Mounting Bolt connection Scatter of the tor‐ Tightening procedure class que emitted on the tool Gear unit ±...

  • Page 51: Table

    Assembly 5.7 Tightening procedure The following table lists the preload forces and tightening torques for bolt connections, strength classes 8.8; 10.9; 12.9: Table 5-2 Preload forces and tightening torques Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec‐ thread di‐...

  • Page 52: Final Work

    Assembly 5.8 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 50).
  • Page 53 Assembly 5.8 Final work You can find additional technical specifications in the separate data sheet in the complete gear unit documentation. Assembly and operating instructions 5026en Edition 06/2020...
  • Page 54 Assembly 5.8 Final work Assembly and operating instructions 5026en Edition 06/2020...

  • Page 55: 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 56: Measures During Commissioning

    Commissioning 6.2 Measures during commissioning Measures during commissioning Please observe the following measures to commission the gear unit and document these: • For gear units with oil supply system: Check that the oil supply system is working properly. • Check the oil level. •...

  • Page 57: 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 Operating temperature...

  • Page 58: 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 63) 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 59: 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 60: 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 61: 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 62: Checking The Oil Temperature

    4. Compare the measured value with the maximum permissible oil temperature (Page 57). 5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded. Contact Flender Customer Services. 8.3.3 Check that all of the fastening bolts are tight...

  • Page 63: General Inspection Of The Gear Unit

    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 64: 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 65 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 66 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 67 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 •...
  • Page 68 Servicing 8.4 Possible faults Assembly and operating instructions 5026en Edition 06/2020...

  • Page 69: 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 5026en Edition 06/2020...
  • Page 70 Service & Support Assembly and operating instructions 5026en Edition 06/2020...

  • Page 71: 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 72 Disposal Assembly and operating instructions 5026en Edition 06/2020...

  • Page 73: 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 74 Spare parts Assembly and operating instructions 5026en Edition 06/2020...

  • Page 75: Declaration Of Incorporation

    Declaration of incorporation Assembly and operating instructions 5026en Edition 06/2020...
  • Page 76 Declaration of incorporation Assembly and operating instructions 5026en Edition 06/2020...

  • Page 77: 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 78: Ambient Temperature

    By applying various suitable measures, the gear unit can be used in the ambient temperature range extending from 0 °C up to 40 °C. However, this must always be authorised by Flender and specified in the order text. Weights The precise weights are specified in the dimension drawings in the complete documentation or on the rating plate.
  • Page 79 Technical data B.4 Enveloping surface sound pressure level Adherence to limit values can, under specified Flender test conditions, be assumed with statistical certainty. Assembly and operating instructions 5026en Edition 06/2020...
  • Page 80 Technical data B.4 Enveloping surface sound pressure level Assembly and operating instructions 5026en Edition 06/2020...

  • Page 81: Index

    Index Tightening procedure, 50 Tightening torque, 50 Fault, 63 Fault rectification, 64 Alignment Final work, 52 Alignment surface, 42 Prealignment, 42 Attachment points, 35 Gear unit design, 21 Gear unit equipment, 23 Gear unit housing, 22 Bearing monitoring Gear unit markings, 14 Resistance thermometer, 27 General inspection of the gear unit, 63 Shock-pulse transducer, 29...
  • Page 82 Index Oil level indicator, 26 Oil supply system Commissioning, 55 Cooling, 25 Venting screw Oil temperature Cleaning, 61 Checking, 62 Oil temperature monitoring Connecting the resistance thermometer, 48 Design, 27 Resistance thermometer, 26 Warning symbols, 15 Operating data, 57 Oil, 57 Ordering spare parts, 69, 73 Protective equipment, 16 Rating plate, 77...
  • Page 84 FLENDER GEAR UNITS Gear unit Assembly and operating instructions 5026en Edition 06/2020 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt GERMANY...