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FLENDER H3LV
Assembly And Operating Instructions Manual
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Siemens FLENDER H3LV Assembly And Operating Instructions Manual

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Page 1
Gear unit
H3LV Sizes 6 to 18
Assembly and operating instructions BA 5080 en 06/2014
FLENDER gear units
Page 2
T
echnical data
T
T
1
Gear unit
General notes
H3LV Sizes 6 to 18
Assembly and operating instructions
Translation of the original assembly and operating instructions
Safety instructions
ransport and
storage
echnical
description
Fitting
Startup
Operation
2
3
4
5
6
7
8
Faults, causes and remedy
Maintenance and repair
Spare parts, customer service
Declarations
9
10
11
12
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Page 3
Legal notes
Warning note concept
This manual comprises notes which must be observed for your personal safety and for preventing material damage. Notes for your personal safety are marked with a warning triangle, those only for preventing material damage appear without a warning triangle. Depending on the level of hazard, the warning notes are shown in reverse order of seriousness, as follows.
DANGER
means, that death or serious injury will result, if the appropriate preventive action is not taken.
WARNING
means that death or serious injury may result, if the appropriate preventive action is not taken.
CAUTION
means that a slight injury may result, if the appropriate preventive action is not taken.
NOTICE
means that material damage may result, if the appropriate preventive action is not taken.
Where there is more than one hazard level, the warning note for whichever hazard is the most serious is always used. If in a warning note a warning triangle is used to warn of possible personal injury, a warning of material damage may be added to the same warning note.
Qualified personnel
The product or system to which this documentation relates may be handled only by persons qualified for the work concerned and in accordance with the documentation relating to the work concerned, particularly the safety and warning notes contained in those documents. Qualified personnel must be specially trained and have the experience necessary to recognise risks associated with these products and to avoid possible hazards.
Proper use of Siemens products
Observe also the following:
WARNING
Siemens products must be used only for the applications provided for in the catalogue and the relevant technical documentation. If products and components of other makes are used, they must be recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper transport, proper storage, erection, assembly, installation, startup, operation and maintenance. The permissible ambient conditions must be adhered to. Notes in the relevant documentations must be observed.
Trademarks
All designations to which the registered industrial property mark ® is appended are registered trademarks of Siemens AG. Other designations used in this document may be trademarks the use of which by third parties for their own purposes may infringe holders’ rights.
Exclusion of liability
We have checked the content of the document for compliance with the hard and software described. Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The information given in this document is regularly checked, and any necessary corrections are included in subsequent editions.
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Page 4
Foreword
The term "Assembly and operating instructions" will in the following also be shortened to "instructions" or "manual".
Symbols in these assembly and operating instructions
This symbol additionally indicates an imminent risk of explosion in the meaning of Directive 94/9/EC.
This symbol additionally indicates an imminent risk of burns due to hot surfaces in the meaning of standard "DIN EN ISO 137321".
This symbol warns against risks from lifted and/or suspended loads.
Earthconnection point Airrelief point yellow
Oilfilling point
Oil level
Oil level
Lubricating point red Apply grease
Lifting eye Eye bolt
Do not unscrew
Alignment surface, horizontal Alignment surface, vertical
These symbols indicate the oillevel checking procedure using the oil dipstick.
These symbols indicate that the oil dipstick must always be firmly screwed in.
yellow Oildraining point white
red Oil level red
red
Connection for vibrationmonitoring device
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Page 5

Contents

1. Technical data 8.....................................................
1.1 General technical data 8...............................................................
1.1.1 Ambient temperature 9................................................................
1.2 Measuringsurface soundpressure level 9...............................................
1.3 Weights 9...........................................................................
1.4 List of equipment 9....................................................................
2. General notes 10.....................................................
2.1 Introduction 10........................................................................
2.2 Copyright 10..........................................................................
3. Safety instructions 11.................................................
3.1 Obligations of the user 11...............................................................
3.2 Special dangers and personal protective equipment 12......................................
3.3 The five safety rules 13.................................................................
3.3.1 Five safety rules 13....................................................................
3.4 Environmental protection 14.............................................................
4. Transport and storage 15.............................................
4.1 Scope of supply 15....................................................................
4.2 Transport 15..........................................................................
4.3 Storing the gear unit 17.................................................................
4.4 Standard coating and preservation 18....................................................
4.4.1 Interior preservation with preservative agent 18............................................
4.4.1.1 Represerving the interior of the gear unit (main gear unit) in case of longer periods of storage 19..
4.4.2 Exterior preservation 22................................................................
4.4.2.1 Represervation of the metallic bright exterior surfaces of the gear unit 22......................
5. Technical description 23..............................................
5.1 General description 23.................................................................
5.2 Construction and method of operation 25..................................................
5.2.1 Spentgrain removal and spentgrain cutting 25............................................
5.2.2 Vertical adjustment of the spentgrain cutting machine 25....................................
5.2.3 Bevelgear motor (electric motor I) 25.....................................................
5.2.4 Height adjustment 25...................................................................
5.2.4.1 Bevelgear motor (electric motor II) 25....................................................
5.2.4.2 Hydraulic cylinder (optional) 26..........................................................
5.2.5 Helicalgear unit 26....................................................................
5.2.6 Strokemounting flange 26..............................................................
5.2.6.1 Strokemounting flange with bevelgear motor 26...........................................
5.2.6.2 Strokemounting flange with lifting cylinder 26..............................................
5.2.7 Gearunit cam-operated switch (optional) 26...............................................
5.2.8 Oilequalising tank 27..................................................................
5.2.9 Bellows 27............................................................................
5.2.10 Limit switch (optional) 27................................................................
5.2.11 Shaft coupling and limitswitch plate (optional) 27..........................................
5.2.12 Frequency inverter (optional) 27.........................................................
5.3 Housing 28...........................................................................
5.4 Toothed components 30................................................................
5.5 Lubrication 31.........................................................................
5.5.1 Splash lubrication 31...................................................................
5.6 Shaft bearings 31......................................................................
5.7 Shaft seal 31..........................................................................
5.7.1 Radial shaftsealing rings 31............................................................
5.8 Oillevel monitoring (optional) 31.........................................................
5.9 Indication of oil level 31.................................................................
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6. Fitting 32.............................................................
6.1 General information on fitting 32.........................................................
6.2 Unpacking 33.........................................................................
6.3 Fitting the gear unit 33..................................................................
6.3.1 Fitting the gearunit on a housing base 33.................................................
6.3.1.1 Foundation 33.........................................................................
6.3.1.2 Fitting the hydraulic cylinder 34..........................................................
6.3.2 Description of fitting work 35.............................................................
6.3.2.1 Alignment 37..........................................................................
6.3.2.2 Fitting on a foundation frame 38..........................................................
6.4 Shrink disk 39.........................................................................
6.4.1 Fitting the shrink disk 39................................................................
6.4.2 Demounting the shrink disk 42...........................................................
6.4.3 Cleaning and greasing the shrink disk 43..................................................
6.4.4 Refitting the shrink disk 44..............................................................
6.4.5 Inspection of the shrink disk 44..........................................................
6.5 Oillevel monitoring (optional) 44.........................................................
6.6 General notes on addon components 44.................................................
6.7 Fitting the limit switch (optional) 44.......................................................
6.7.1 Tangential alignment of the limit switch relative to the switch plate (optional) 45.................
6.7.2 Axial positioning of the limit switch relative to the switch plate (optional) 45.....................
6.8 Fitting the frequency inverter (optional) 45.................................................
6.9 Final work 45..........................................................................
6.10 Screwconnection classes, tightening torques and initialtensioning forces 46..................
6.10.1 Screwconnection classes 46............................................................
6.10.2 Tightening torques and initialtensioning forces 46..........................................
7. Startup 48...........................................................
7.1 Procedure before startup 48............................................................
7.1.1 Removal of preservative agent from exterior 48............................................
7.1.2 Removal of preservative agent from interior 48.............................................
7.1.3 Filling with lubricant 51.................................................................
7.1.3.1 Helicalgear unit (main gear unit) 51......................................................
7.1.3.2 Bevel-gear unit 52.....................................................................
7.2 Setting of the cam-operated switches (in the gearunit cam operated switch) 53.................
7.3 Setting the rotary angle transducer (in the gearunit cam operated switch) 53...................
7.4 Setting of the EMERGENCYOFF limit switches 53.........................................
7.5 Startup 54...........................................................................
7.5.1 Oil level 54............................................................................
7.5.2 Temperature measurement 54...........................................................
7.5.3 Oillevel monitoring (optional) 55.........................................................
7.5.4 Checking procedure 55.................................................................
7.6 Shutting down 55......................................................................
7.6.1 Interior preservation for longer disuse 56..................................................
7.6.1.1 Interior preservation with gearunit oil 56..................................................
7.6.1.2 Interior preservation (main gear unit) with "Castrol Alpha SP 220 S" preservative agent 57........
7.6.2 Exterior preservation 58................................................................
7.6.2.1 Exteriorpreservation procedure 58.......................................................
8. Operation 59.........................................................
8.1 General 59............................................................................
8.2 Oil level 59............................................................................
8.3 Irregularities 59........................................................................
9. Faults, causes and remedy 60.........................................
9.1 General information on faults and malfunctions 60..........................................
9.2 Possible faults 61......................................................................
9.2.1 Leakage and leaktightness 63...........................................................
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10. Maintenance and repair 64............................................
10.1 General notes on maintenance 64........................................................
10.1.1 General service lives of oils 65...........................................................
10.2 Description of maintenance and repair works 65............................................
10.2.1 Examine water content of oil, conduct oil analyses 65.......................................
10.2.2 Changing the oil (main gear unit) 66......................................................
10.2.3 Replace the wetair filter 67.............................................................
10.2.4 Clean the air filter 68...................................................................
10.2.5 Clean the gear unit 68..................................................................
10.2.6 Top up oil 68..........................................................................
10.2.7 Check tightness of fastening bolts 69.....................................................
10.3 Final work 69..........................................................................
10.4 General inspection of the gear unit 69.....................................................
10.5 Lubricants 69.........................................................................
11. Spare parts, customer service 70......................................
11.1 Stocking spare parts 70.................................................................
11.2 Addresses for ordering spare parts and customer service 70.................................
12. Declarations 71.......................................................
12.1 Declaration of incorporation 71..........................................................
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Page 8

1. Technical data

1.1 General technical data

The most important technical data are shown on the rating plate. These data and the contractual agreements between Siemens and the customer for the gear unit determine the limits of its correct use.
①
②
③
⑤
⑦
④ ⑥
⑧
⑨ ⑩
⑪
⑫ ⑬
Fig. 1: Rating plate on gear unit
① Company logo ② Manufacturing number ③ Total weight in kg ④ Special information ⑤ Type, size *) ⑥ Power rating P
in kW or torque T2 in Nm
2
#)
⑦ Speed n ⑧ Speed n ⑨ Oil data (oil type, oil viscosity, oil quantity) ⑩ Instructions number(s) ⑪ Special information ⑫ Manufacturer and place of manufacture ⑬ Country of origin
#)
Code production plant / order number, item, sequence number / year built
)
*
Example
1
2
H3 LV 6
Size 6 ... 18......................
Mounting position V = Vertical..........
Type of output shaft L = Lauter tun.........
Vertically adjustable output shaft
Number of stages 3..........
Gear-unit type H = Helical-gear unit.............
Data on weights and measuringsurface soundpressure levels of the various gearunit types are given in items 1.2 and 1.3.
For further technical data, refer to the drawings in the gearunit documentation and the orderspecific data sheet.
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Page 9

1.1.1 Ambient temperature

Note
Unless otherwise agreed by contract, the gear unit must not be exposed to harmful environmental factors such as chemically aggressive products. By adopting various suitable measures the gear unit may be used at ambient temperatures of between  40 °C and + 60 °C. However, Siemens must always have approved and confirmed this in the order specification.
1.2 Measuringsurface soundpressure level
The measuringsurface soundpressure level for the gear unit at a distance of 1 m can be found in table 1.
The measurement is carried out to standard "DIN EN ISO 9614" Part 2, using the soundintensity method.
The workplace of the operating personnel is defined as the area on the measuring surface at a distance of 1 metre in the vicinity of which persons may be present.
The soundpressure level applies to the warmedup gear unit at input speed n on the rating plate, as measurement obtained on the Siemens test bench. If several figures are given, the highest speed and power values apply.
The measuringsurface soundpressure level includes addon lubrication units, if applicable. With outgoing and incoming pipes, the flanges are the interfaces.
The soundpressure levels stated in the table were obtained by statistical evaluation by our Quality Control Dept. The gear unit can be statistically expected to comply with these noise levels.
Table 1: Measuringsurface soundpressure level
Type
H3LV

1.3 Weights

Table 2: Weights (approximate values)
Type
H3LV
and output power P2 stated
1
Measuring-surface sound-pressure level LpA in dB(A)
Gear-unit size
6 8 10 12 13 14 15 16 17 18
79 81 82 83 82 83 81 79 82 83
Approximate weight (kg)
Gear-unit size
6 8 10 12 13 14 15 16 17 18
760 1190 1720 2770 3520 4200 5150 6200 6600 7200
Note
All weights are indicated for units without oil filling and without addon parts. For the exact weights, refer to the drawings in the gearunit documentation.

1.4 List of equipment

Note
All important accessory components are listed in the orderspecific list of equipment as well as the related technical data.
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Page 10

2. General notes

2.1 Introduction

These instructions are an integral part of the gear unit supplied and must be kept in its vicinity for reference at all times.
NOTICE
Material damage
Risk of damage to the gear unit or disruptions to operation. All persons carrying out work on the gear unit must have read and understood these instructions and must adhere to them. Siemens accepts no responsibility for damage or disruptions to operation caused by disregard of these instructions.
The "FLENDER gear unit" described in these Instructions has been designed for driving lautertun spentgrain cutting machines.
The gear unit is designed only for the application specified in section 1, "Technical data". Other operating conditions must be agreed by contract.
The gear unit has been manufactured in accordance with the state of the art and is delivered in a condition for safe and reliable use.
The gear unit must be used and operated strictly in accordance with the conditions laid down in the contract governing performance and supply agreed by Siemens and the customer.
The gear unit described in these instructions reflects the state of technical development at the time these instructions went to print.
In the interest of technical progress we reserve the right to make changes to the individual assemblies and accessories which we regard as necessary to preserve their essential characteristics and improve their efficiency and safety.

2.2 Copyright

The copyright to these instructions is held by Siemens AG.
These instructions must not be wholly or partly reproduced for competitive purposes, used in any unauthorised way or made available to third parties without our agreement.
Technical enquiries should be addressed to the following factory or to one of our customer services:
Siemens AG Am Industriepark 2 46562 Voerde
Tel.: +49 (0)2871 / 92‐0 Fax: +49 (0)2871 / 92‐1544
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Page 11

3. Safety instructions

WARNING
Risk of falling
Risk of serious injury through falling. The gear unit and its addon parts must not be entered.
WARNING
Risk of injury through unauthorised modifications
Any changes on the part of the user are not permitted. This applies equally to safety features designed to prevent accidental contact.

3.1 Obligations of the user

• The operator must ensure that everyone carrying out work on the gear unit has read and understood these instructions and is adhering to them in every point in order to:
─ avoid injury or damage,
─ ensure the safety and reliability of the gear unit,
─ avoid disruptions to operation and environmental damage through incorrect use.
• During transport, assembly, fitting, demounting, operation and maintenance of the unit, the relevant safety and environmental regulations must be complied with.
• The gear unit may only be operated, maintained and/or repaired by persons qualified for the work concerned (see "Qualified personnel" on page 3 of this manual).
• The outside of the gear unit must not be cleaned with highpressure cleaning equipment.
• All work must be carried out with great care and with due regard to safety.
DANGER
Danger to life through switchedon installation
To carry out work on the gear unit, the gear unit must always be stopped. The drive unit must be secured against being switched on accidentally (e.g. by locking the key switch or removing the fuses from the power supply). A notice should be attached to the ON switch stating clearly that work is in progress on the gear unit. At the same time the complete installation must be without load, so that no danger occurs during demounting operations.
• No welding work must be done at all on the drive system. The drive systems must not be used as an earthing point for electricwelding operations. Toothed parts and bearings may be irreparably damaged by welding.
• A potential equalisation in accordance with the applying regulations and directives must be carried out! If no threaded holes for earth connection are available on the gear unit, other appropriate measures must be taken. This work must always be done by specialist electricians.
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NOTICE
Material damage
Risk of damage to the gear unit. If any inexplicable changes are noticed during operation of the gear unit, such as an important increase in temperature or unusual noises, the drive unit must be stopped immediately.
DANGER
Danger to life through rotating and/or movable parts
Risk of being caught or drawn in by rotating and/or movable parts. Rotating and/or movable parts must be fitted with suitable safeguards to prevent contact.
Note
When the gear unit is incorporated in plant or machinery, the manufacturer of such plant or machinery must ensure that the prescriptions, notes and descriptions contained in these instructions are incorporated in his own instructions.
• Removed safety equipment must be refitted prior to starting up.
• Notices attached to the gear unit, such as rating plate and direction arrow, must always be observed. They must be kept free from dirt and paint at all times. Missing plates must be replaced.
• Screws which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type.
• Spare parts must be obtained from Siemens (see section 11, "Spare parts, customer service").

3.2 Special dangers and personal protective equipment

Depending on operating conditions, the surface of the gear unit may heat up or cool down to extreme temperatures.
WARNING
Risk of burns
Risk of serious injury through burns on hot surfaces (> 55 °C). Wear suitable protective gloves and protective clothing.
WARNING
Danger through low temperatures
Risk of serious injury through frost (pain, numbness, frostbite) on cold surfaces (< 0 °C). Wear suitable protective gloves and protective clothing.
WARNING
Risk of scalding
Risk of serious injury through escaping hot operating media, when they are being changed. Wear suitable protective gloves, protective glasses and protective clothing.
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Page 13
WARNING
Risk of eye injury
Small foreign matter such as sand or dust can get into the cover plates of the rotating parts and be thrown back by these. Wear suitable protective glasses.
Note
In addition to any generally prescribed personal safety equipment (such as safety shoes, safety clothing, helmet) handling the gear unit requires wearing suitable safety gloves and suitable safety glasses.
DANGER
Risk of explosion
Danger to life through ignition of any explosible atmosphere resulting from of the gear unit. The gear unit does not comply with the requirements in Directive 94/9/EC and must therefore, in the area of applicability of this directive, not be used in potentially explosive areas.
Should the gear unit be used outside the area of applicability of Directive 94/9/EC within potentially explosive areas, the nationally applying protective prescriptions with regard to explosion protection must always be observed.

3.3 The five safety rules

For your personal safety and to avoid material damage, comply always with the safetyrelevant instructions and the safety rules to standard EN 501101 "Working in tensionfree status" indicated below, when working on electrical components of the plant. Apply the five safety rules in the indicated order, before starting work on the machine.

3.3.1 Five safety rules

1) Disconnect completely Disconnect the auxiliary circuits, e.g. standby heating
2) Secure against reconnection
3) Verify that the installation is voltagefree ("dead")
4) Carry out earth and shortcircuiting
5) Provide protection against adjacent live parts
After completion of the work the taken measures should be undone in the reverse order.
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Page 14

3.4 Environmental protection

• Dispose of any packaging material in accordance with regulations or separate it for recycling.
• When changing oil, the used oil must be collected in suitable containers. Any pools of oil which may have collected should be removed at once with an oilbinding agent.
• Preservative agents should be stored separately from used oil.
• Used oil, preservative agents, oilbinding agents and oilsoaked cloths must be disposed of in accordance with environmental legislation.
• Disposal of the gear unit after its useful life:
─ All the operating oil, preservative agent and/or cooling agent must be drained from the gear unit and
disposed of in accordance with regulations.
─ Gearunit components and/or addon parts may have to be disposed of or separated for recycling
in accordance with national regulations.
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Page 15

4. Transport and storage

Observe the instructions in section 3, "Safety instructions"!

4.1 Scope of supply

The products supplied are listed in the dispatch papers. Check on receipt to ensure that all the products listed have actually been delivered. Parts damaged and/or missing parts must be reported to Siemens in writing immediately.
WARNING
Serious injury through defective product
If there is any visible damage, the gear unit must not be put into operation.

4.2 Transport

Note
The weight of the product is specified on the rating plate.
DANGER
Danger of life
Danger to life from loads falling through incorrect slinging Do not stay under suspended loads. When attaching, lifting, lowering and shifting loads, observe the following:
– Note the load limits. – Correct fastening of the slinging equipment. – Any centre of gravity which is off the load centre. – Even load distribution when using loadcarrying means with several load hooks. – Low displacement speed. – The load must not be swung and/or attached to objects or building parts. – Lifting hooks must not be loaded by the tip. – Always place the items on an even, slipfree and stable surface.
WARNING
Danger of squeezing
Risk of being squeezed by a transported component, when the used lifting gear and loadcarrying means are not suitable and the component gets loose. The unit may be attached only at the marked slinging points. Use only lifting and loadcarrying equipment of sufficient loadbearing capacity. When lifting items, observe the notes regarding load distribution on the packing. The product must be handled slowly and carefully, when lifted, to avoid personal injury and damage to the gear unit. If, for example, the free shaft ends are knocked, this may cause damage in the gear unit.
The gear unit is delivered in the fully assembled condition. Additional items may be delivered separately packaged, if applicable.
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Page 16
Different forms of packaging may be used, depending on the size of the unit and method of transport. Unless agreed otherwise, the packaging complies with the HPE Packaging Guidelines.
The symbols marked on the packing must be observed at all times. They have the following meanings:
Top Fragile Keep dry Keep cool Centre of
gravity
Use no hand
hook
Attach
here
Fig. 2: Transport symbols
Note
The gear unit must be transported only with appropriate transport equipment. During transport the gear unit (main gear unit) should be left without oil filling and on the transport packing. The bevelgear units are delivered ex works with oil filling. In case of addon bevelgear motors the instructions applying must be observed.
NOTICE
Material damage
Risk of damage to the gear unit when using incorrect attachment points. Use only the eyes provided to attach lifting equipment to the unit. Transport of the unit by attaching it to the pipework is not permitted. The pipework must not be damaged. Do not use the front threads at the shaft ends to attach slinging and lifting gear for transport. Slinging and lifting gear must be adequate for the weight of the gear unit.
1)
2)
Fig. 3: Attachment points
1) Lauter tun with hoist gear unit 2) Lauter tun with lifting cylinder
For a detailed illustration of the gear unit and the position of the attachment points, refer to the drawings in the orderspecific gearunit documentation.
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Page 17

4.3 Storing the gear unit

The gear unit must be stored in a sheltered place in the position of the original packaging or in the position of use, placed on a vibrationfree, dry base, and covered over.
NOTICE
Material damage
Any damage to the coating may cause failure of the exterior protective coating and thus corrosion. When temporarily storing the gear unit and any single components supplied with it, the preservative agent should be left on them. Ensure that the coat is not damaged.
DANGER
Danger to life through tilting or falling gear unit
Risk of being squeezed or killed by a tipping or falling gear unit. Do not stack gear units on top of one another
NOTICE
Material damage
Risk of damage to the gear unit through build up of a layer of foreign bodies or moisture. If the gear unit is being stored out of doors, it must be particularly carefully covered, and care must be taken that neither moisture nor foreign material can collect on the unit. Waterlogging must be avoided.
NOTICE
Material damage
Risk of damage to the gear unit through external sources. Unless otherwise agreed by contract, the gear unit must not be exposed to harmful environmental factors such as chemically aggressive products. Provision for special environmental conditions during transport (e.g. transport by ship) and storage (climate, termites, etc.) must be agreed by contract.
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Page 18

4.4 Standard coating and preservation

The gear unit is provided with an interior preservative agent; the free shaft ends are painted for protection.
The characteristics of the exterior coat depend on the ambient conditions stipulated in the order relating to method of transport and area of application.
NOTICE
Material damage
Risk of damage to the gear unit through corrosion. The gear unit is normally delivered completely ready, with a priming and a finish coat. Where gear units are delivered with a priming coat only, it is necessary to apply a finish coat in accordance with directives applying to the specific application. The priming coat alone is not suitable to provide a sufficient longterm corrosion protection.
NOTICE
Material damage
Any damage to the coating may cause failure of the exterior protective coating and thus corrosion. Ensure that the coat is not damaged.
Note
Unless otherwise contractually agreed, the durability periods of the interior gear unit preservation specified in table 3 will apply, provided the related measures are adhered to. The durability period for the exterior preservation and the related requirements can be found in table 4.
The guarantee period starts on the date of delivery or that of the notice that the item is ready for shipment.
In case of a storage period other than the durability periods indicated in tables 3 and in table 4, the interior and the exterior preservation must be checked and, as necessary, be renewed (see items 7.6.1 and 7.6.2).

4.4.1 Interior preservation with preservative agent

Table 3: Durability period and measures for interior preservation when using mineral oil
Durability period Preservative agent Special measures
Up to 6 months
Castrol Alpha SP 220 S
Up to 24 months
For storage periods longer than 24 months, renew the preservative agent (see item 4.4.1.1).
Note
The procedure for interiorpreservation treatment is described in section 7 (see item 7.6.1).
None
– Close all holes on the gear unit.
– Replace the air filter or wet-air filter with
the screw plug. (Replace the screw plug with the air filter or wet-air filter before start-up.)
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Page 19
4.4.1.1 Represerving the interior of the gear unit (main gear unit) in case of longer periods of storage
CAUTION
Risk of injury
Risk of injury to eyes or hands through chemically aggressive operating media. Wear suitable protective glasses and protective gloves. Remove any oil spillage immediately with a binding agent.
For storage periods longer than 24 months (see table 3), renew the preservation in the interior of the gear unit. The following procedure is recommended:
• Unscrew the air filter or wetair filter (1) on the oilequalising tank (see fig. 4 or fig. 5).
• Place a suitable container under the oildrain points (4 and 5) of the gearunit housing.
• Open the oildrain cock (4) and unscrew the residualoil drain plug (5) and drain the used preservative oil into a suitable container.
• Dispose of the residue of the preservative oil in accordance with regulations.
• Shut the oildrain cock (4) and screw in the residualoil drain plug (5).
• Fill the gear unit with "Castrol Alpha SP 220 S". Determine the filling quantity according to the gearunit dimensions: length x width x height x 0.05.
NOTICE
Material damage
Corrosion possible through use of an unsuitable preservative agent. Use special oil "Castrol Alpha SP 220 S" with additional anticorrosive agent (additive "S").
• Screw in the air filter or wetair filter (1).
• Replace the air filter or wetair filter (1) with the screw plug.
NOTICE
Material damage
Corrosion possible through leaving the gear unit open too long. Close the gear unit airtightly at the latest one hour after opening. Before restarting the gear unit take the following measure:
– Replace the screw plug with the air filter or wetair filter.
The gear unit has thus been preserved for another period of 24 months.
NOTICE
Material damage
Risk of damage to the gear unit through inadequate lubrication through preservative agent and operating oil being mixed up. The use of synthetic oil is not permissible.
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8
16
(II)
(III)
9
(II)
7
(II)
6
(Ia)
(Ib)
(III)
(III)
(I)
(I)
13
12
4
5
14
10
11
15
1
2,3
Fig. 4: Oil inlet and oil drain – gear unit with hoist gear unit
1 Air filter or wet-ait filter
Ventilation (I) main gear unit 2 Oil filling (I) main gear unit 3 Dipstick; oil filling (I) main gear unit 4 Oil-drain cock (Ia); oil drain main gear unit 5 Oil-drain plug; residual oil (Ib) main gear unit 6 Ventilation; oil filling (II) primary gear unit 7 Oil level (II) primary gear unit 8 Oil-drain plug (II) primary gear unit
9 Ventilation / oil filling (III) hoist
gear unit 10 Oil level (III) hoist gear unit 11 Oil-drain plug (III) hoist gear unit 12 Bellows 13 Vent hole 14 Leak hole 15 Leak hole 16 Inspection and/or assembly cover
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16
(II)
8
(Ia)
(Ib)
13
12
4
5
14
(II)
7
(II)
6
(I)
(I)
1
2,3
Fig. 5: Oil inlet and oil drain – gear unit with lifting cylinder
1 Inspection and/or assembly cover
Ventilation (I) main gear unit 2 Oil filling (I) main gear unit 3 Dipstick (I); oil filling (I) main gear unit 4 Oil-drain cock (Ia); oil drain main gear unit 5 Oil-drain plug; residual oil (Ib) main gear unit
7 Oil level (II) primary gear unit
8 Oil-drain plug (II) primary gear unit 12 Bellows 13 Vent hole 14 Leak hole 16 Inspection and/or assembly cover
6 Ventilation; oil filling (II) primary gear unit
For a detailed illustration of the gear unit and the position of the addon parts, refer to the drawings in the gearunit documentation.
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4.4.2 Exterior preservation

Table 4: Durability period for exterior preservation of shaft ends and other bright machined surfaces
Durability period Preservative agent
In case of indoor storage up
to 36 months
In case of outdoor storage
up to 12 months
1)
The gear unit must be stored in the position of use in a sheltered place; it must be placed on
1)
Tectyl 846 K19 Approx. 50 Îźm
2)
Layer thickness Remarks
a vibrationfree, dry base, and covered over.
2)
If the gear unit is being stored out of doors, it must be particularly carefully covered, and care must be taken that neither moisture nor foreign material can collect on the unit. Waterlogging must be avoided.
Note
The procedure for exteriorpreservation treatment is described in section 7 (see item 7.6.2).
4.4.2.1 Represervation of the metallic bright exterior surfaces of the gear unit
In case of storage periods exceeding the periods specified in table 4 the exterior of the gear unit must be represerved using the preservative agent specified in table 4.
Long-term wax-based preservative agent:
– resistant to seawater
– resistant to tropical
conditions
– soluble with
CH compounds
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5. Technical description

Observe the instructions in section 3, "Safety instructions"!

5.1 General description

The gear unit described is a "FLENDER gear unit" designed for driving lautertun spentgrain cutting machines.
The gear unit can be operated in both directions of rotation.
The gear unit is characterised by a low noise level, which is achieved by helical gears with a high contact ratio and a sounddamping housing.
The good temperature characteristics of the gear unit are achieved by its high degree of efficiency, large housing surface and performancerelated cooling system.
The lauter tun drive is delivered as a complete drive unit assembled from various components.
The drive is designed for vertical mounting and must be operated only with the vertically adjustable shaft pointing upwards.
8
9
10
1
2
Fig. 6: Gearunit configuration with hoist gear unit
1 Bevel-gear motor (electric motor I) 2 Helical-gear unit 3 Bevel-gear motor (electric motor II) 4 Stroke-mounting flange 5 Gear-unit cam operated switch
7
6
4
3
5
6 Oil-equalising tank 7 Bellows 8 Limit switch 9 Shaft coupling
10 Limit-switch plate
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6
5
1
4
2
3
7
Fig. 7: Gearunit configuration with lifting cylinder
1 Bevel-gear motor (electric motor I) 2 Helical-gear unit 3 Stroke-mounting flange 4 Oil-equalising tank
5 Bellows 6 Shaft coupling 7 Lifting cylinder
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5.2 Construction and method of operation

The combination drive performs 3 functions:
I Spentgrain removal (high speed)
Clockwise rotation (looking at the end of the drive shaft)
II Spentgrain cutting (low speed)
Clockwise rotation (looking at the end of the drive shaft)
III Vertical adjustment of the output shaft
while stationary, without load or during operation (under load)
5.2.1 Spentgrain removal and spentgrain cutting
During cutting and removal of the spent grain the bevelgear motor (electric motor I) drives the spentgrain cutting machine via a multistage helicalgear unit. The required speed is set via a frequency inverter.
5.2.2 Vertical adjustment of the spentgrain cutting machine
The spentgrain cutting machine can be displaced a previously specified lifting distance vertically by means of a bevelgear motor (electric motor II) or a hydraulic cylinder. Displacement can be carried out at any time under load, without load or while stationary.
5.2.3 Bevelgear motor (electric motor I)
The electric motor complies with the relevant standards and regulations as well as any additional agreements. The connecting dimensions deviate from any standard. The motor shaft and the connecting flange are adapted to the bevelgear unit. The motor is of a type designed for operation with a frequency inverter, which can be additionally fitted with an incremental transmitter, PTCthermistor sensors and a separate fan.
Note
Be sure to observe the operating instructions for the bevelgear motor for operation and maintenance. For technical data, refer to the data sheet and/or the list of equipment. The detailed view (position of terminal box and arrangement) is shown on the dimensioned drawing.

5.2.4 Height adjustment

5.2.4.1 Bevelgear motor (electric motor II)
The electric motor complies with the relevant standards and regulations as well as any additional agreements. The connecting dimensions deviate from any standard. The motor shaft and the connecting flange are adapted to the bevelgear unit.
The rolling bearings of the motors are lubricated with grease.
The bevelgear unit is supplied with oil by splash lubrication.
Note
Be sure to observe the operating instructions for the bevelgear motor for operation and maintenance. For technical data, refer to the data sheet and/or the list of equipment. The detailed view (position of terminal box and arrangement) is shown on the dimensioned drawing.
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5.2.4.2 Hydraulic cylinder (optional)
The hydraulic cylinder is connected to the strokemounting flange and the adapter sleeve located inside it. In this way the insert shaft of the helicalgear unit can be vertically adjusted. When mounting, the mounting dimensions specified on the dimensioned drawing must be observed.
Note
Be sure to observe the operating instructions for the hydraulic cylinder for operation and maintenance. For technical data, refer to the data sheet and/or the list of equipment.
5.2.5 Helicalgear unit
The torque is transmitted to the vertically adjustable, upwardly protruding insert shaft via a multistage vertical helicalgear unit with shafts fitted on rolling bearings and a hollow output shaft provided with splines.
The oil is fed to the toothed parts, the rolling bearings and the splines on the hollow shaft and the insert shaft by splash lubrication. The gear unit thus requires very little maintenance.
5.2.6 Strokemounting flange
5.2.6.1 Strokemounting flange with bevelgear motor
The insert shaft is heightadjusted on the drive via the spindle drive inside the strokemounting flange. It is fitted on below the helicalgear unit in the area of the output shaft. The spindle is guided in the strokemounting flange by means of rolling bearing. This rolling bearing is adequately dimensioned to enable it to absorb the axial forces exerted.
The drive journal of the spindle projects downwards from the strokemounting flange. Two shaftsealing rings at the shaft outlet prevent oil from escaping.
The rolling bearing and the spindle drive are also lubricated by splash lubrication. The stroke-mounting flange together with the helicalgear unit form a common oil chamber.
5.2.6.2 Strokemounting flange with lifting cylinder
The strokemounting flange is attached below the helicalgear unit in the area of the output shaft (insert shaft). Using an attached hydraulic cylinder, the insert shaft can be vertically adjusted via an adapter sleeve with internal rolling bearing.
This rolling bearing is adequately dimensioned to enable it to absorb the axial forces exerted.
The rolling bearing is lubricated by splash lubrication. The stroke-mounting flange together with the helicalgear unit form a common oil chamber.
The junction of the strokemounting flange and the hydraulic cylinder is sealed with gaskets. If gaskets made from PTFE are used, they should be preheated to 60 to 80 °C in an oil or water bath before fitting. When the gasket has been placed in the groove on the intermediate cover, the piston rod of the hydraulic cylinder must be inserted (for calibration).
5.2.7 Gearunit cam-operated switch (optional)
The gearunit cam-operated switch is fitted with four freely adjustable cam operated switches for positioning the spentgrain cutting machine and a rotaryangle transducer to indicate the lifting distance.
The gearunit cam operated switch must be adjusted by the system constructor before startup.
Note
Be sure to observe the operating instructions for the gearunit cam operated switch for operation and maintenance. For technical data, refer to the data sheet and/or the list of equipment.
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5.2.8 Oilequalising tank
The oilequalising tank ensures the appropriate volumetric compensation, when the volume of oil increases with temperature.

5.2.9 Bellows

The bellows protects the teeth of the insert shaft and thus the interior of the helicalgear unit against contamination. The air outlet is through a bore in the face collar of the shaft coupling.

5.2.10 Limit switch (optional)

Above the helicalgear unit are two limit switches for switching the bevelgear motor (electric motor II) OFF in an EMERGENCY.
The unit is delivered loose and must be fitted by the system constructor before startup. It must be precisely positioned by the system constructor before startup and regularly inspected.
Note
Be sure to observe the operating instructions for the limit switch for operation and maintenance. For technical data, refer to the data sheet and/or the list of equipment.
5.2.11 Shaft coupling and limitswitch plate (optional)
The shaft coupling connects the output shaft of the lautertun drive to the shaft of the spentgrain cutting machine by a friction fit. The limitswitch plate actuates the EMERGENCYOFF limit switch. The limitswitch plate is placed between the contact faces of the shaft and the shaft coupling.
The shaft coupling and the limitswitch plate are delivered loose and must be fitted by the system constructor before startup.

5.2.12 Frequency inverter (optional)

The bevelgear motors can be set by means of frequency inverters. This enables the rotation speed of the drive shaft to be adjusted to requirement during cutting and removal of the spent grain.
Note
Be sure to observe the operating instructions for the frequency inverter for operation and maintenance. For technical data, refer to the data sheet and/or the list of equipment.
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5.3 Housing

The housing is designed as a multipiece. It is of torsionally rigid design and due to its shape imparts very favourable noise and temperature characteristics.
The gearunit housing comes with the following equipment:
─ Lifting eyes (adequately dimensioned for transport)
─ Inspection cover (for oil filling and/or inspection)
─ Dipstick with MIN and MAX marks (for checking the oil level)
─ Oildrain plug and/or oildrain cock (to drain the oil)
─ Air filter or wetair filter (for aeration and ventilation)
Colour codes for bleeding, oil inlet, oil level and oil drainage:
Air-relief point
yellow Oil-drain point white
Oil-filling point yellow Lubricating point red
Oil level: Dipstick
red
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14
7
(I)
2,3
6
9
10
15
11
16
13
(Ia)
4
(Ib)
5
8
12
Fig. 8: Gearunit features on gear units with hoist gear unit
1 Air filter or wet-ait filter;
Ventilation (I) main gear unit 2 Oil filling (I) main gear unit 3 Dipstick (I); oil filling (I) main gear unit 4 Oil-drain cock (Ia); oil drain main gear unit 5 Oil-drain plug; residual oil (Ib) main gear unit 6 Housing 7 Shaft seal
(I)
1
(I)
2,3
8 Cover
9 Rating plate 10 Gear-unit fastening 11 Inspection and/or assembly cover 12 Alignment surface 13 Alignment thread 14 Lifting eye 15 Cover 16 Cover
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7
2,3
(I)
14
9
6
10,13
(Ia)
2,3
4
(Ib)
5
(I)
1
(I)
15
11
16
12
8
Fig. 9: Gearunit features on gear units with lifting cylinder
1 Air filter or wet-ait filter;
Ventilation (I) main gear unit 2 Oil filling (I) main gear unit 3 Dipstick (I); oil filling (I) main gear unit 4 Oil-drain cock (Ia); oil drain main gear unit 5 Oil-drain plug; residual oil (Ib) main gear unit 6 Housing 7 Shaft seal
For a detailed illustration of the gear unit and the position of the addon parts, refer to the drawings in the gearunit documentation.

5.4 Toothed components

The externally toothed components of the gear unit are casehardened. The helicalgear teeth are ground. The high quality of the teeth leads to a significant noise reduction of the gear unit and ensures safe and reliable running.
The gears are connected with the shafts by interference fits and parallel keys or by shrink fits. These types of joints transmit the torques generated with adequate reliability.
8 Cover
9 Rating plate 10 Gear-unit fastening 11 Inspection and/or assembly cover 12 Alignment surface 13 Alignment thread 14 Lifting eye 15 Cover 16 Cover
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5.5 Lubrication

5.5.1 Splash lubrication

Unless otherwise agreed in the order, the teeth and bearings are adequately splashlubricated with oil. The gear unit thus requires very little maintenance.

5.6 Shaft bearings

All shafts are fitted in rolling bearings.

5.7 Shaft seal

Radial shaftsealing rings, labyrinth seals, Taconite seals or special seals at the shaft outlets prevent oil from escaping from, or dirt from entering into the gear unit.
5.7.1 Radial shaftsealing rings
Radial shaftsealing rings are the standard type of seal. Radial shaftsealing rings seal with contact and are fitted with an additional dust lip to protect the actual sealing lip from exterior contamination.
NOTICE
Material damage
Destruction of the radial shaftsealing ring possible through high dust concentration. Do not use radial shaftsealing ring in an environment with high dust concentration.
Fig. 10: Radial shaftsealing ring
5.8 Oillevel monitoring (optional)
The gear unit can be fitted with an oillevel monitor by means of a fillinglevel limit switch. The oillevel monitoring device has been designed for checking the oil level when the gear unit is at a standstill, prior to operating start.
If an oillevel monitoring device is in use, it is very important that the unit is in the horizontal position.
For a detailed illustration of the gear unit and the position of the addon parts, refer to the drawings in the gearunit documentation.
Note
For the operation and maintenance the operating manuals specified in the orderspecific annex must be observed. For technical data and control information, refer to the orderspecific list of equipment.

5.9 Indication of oil level

The gear unit is fitted with an oillevel indication (dipstick with MIN and MAX marks) for visual oillevel checking at standstill. Checking of the oil level can be carried out by the dipstick when the oil has cooled down.
For a detailed illustration of the gear unit and the position of the addon parts, refer to the drawings in the gearunit documentation.
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6. Fitting

Observe the instructions in section 3, "Safety instructions"!

6.1 General information on fitting

When transporting the gear unit, observe the notes in section 4, "Transport and storage".
Fitting work must be done with great care by authorised, trained and qualified personnel. The manufacturer cannot be held liable for damage caused by incorrect assembly and installation.
As early as during the planning phase sufficient free space must be allowed around the gear unit for later care and maintenance work.
Note
Free convection through the surface of the housing must be ensured by suitable measures.
Adequate lifting equipment must be available before beginning the fitting work.
NOTICE
Material damage
During operation the unit must not be allowed to heat up through exposure to heat from external sources such as sunlight, and suitable measures must be taken to prevent this. Heat concentration must be avoided.
This can be done as follows: – fitting an additional cooling unit
NOTICE
Material damage
Risk of damage to the gear unit caused by falling objects, heaping over, welding work or insufficient fastening. The operator must ensure the following:
– The gear unit must be secured against falling objects and heaping over. – No welding work must be done at all on the drive system. – The gear unit must not be used as an earthing point for electricwelding operations. – All the fastening points provided by the design of the unit must be used. – Screws which have been damaged during assembly or disassembly work must be replaced with new
screws of the same strength class and type.
Note
To ensure proper lubrication during operation, the mounting position specified on the drawings must always be observed.
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6.2 Unpacking

NOTICE
Material damage
Risk of damage to the gear unit through corrosion. The packaging must not be opened or damaged beforehand, if this is part of the preservation method.
The products supplied are listed in the dispatch papers. Check immediately on receipt to ensure that all the products listed have actually been delivered. Parts damaged and/or missing parts must be reported to Siemens in writing immediately.
• Remove packaging material and transporting equipment and dispose of in accordance with regulations.
• Perform a visual check for any damage and contamination.
WARNING
Serious injury through defective product
If there is any visible damage, the gear unit must not be put into operation. The instructions in section 4, "Transport and storage", must be observed.

6.3 Fitting the gear unit

6.3.1 Fitting the gearunit on a housing base
6.3.1.1 Foundation
NOTICE
Material damage
Risk of damage through insufficiently safe positioning of the gear unit. The foundation must be horizontal and level. The gear unit must not be excessively stressed when tensioning the fastening bolts.
The foundation should be designed in such a way that no resonance vibrations are created and that no vibrations are transmitted from adjacent foundations. The structure on which the unit is to be fitted must be rigid. It must be designed according to the weight and torque, taking into account the forces acting on the gear unit.
Careful alignment with the units on the in and output sides must be ensured. Any elastic deformation through operating forces must be taken into consideration.
NOTICE
Material damage
Risk of damage through insufficiently safe positioning of the gear unit. Fastening bolts and nuts must be tightened to the prescribed tightening torque. For the correct tightening torque, refer to item 6.10. Bolts of at least strength class 8.8 must be used.
If external forces are acting upon the gear unit, it is advisable to prevent the unit from displacement by means of lateral stops.
Note
For dimensions, space requirement and arrangement of supply connections, refer to the drawings in the gearunit documentation.
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6.3.1.2 Fitting the hydraulic cylinder
If the hydraulic cylinder is not part of the delivery by Siemens, the cylinder must be fitted in mounting position prior to setting upright and prior to fitting the drive unit. To do so the transport lock must be removed.
WARNING
Serious injury
Risk of injury through slippage of the insert shaft. The insert shaft is no longer secured and may slip away if incorrectly stored.
• Remove hexagon nut (1) from the threaded rod (2).
8
5
3
2
1
Fig. 11: Fitting the hydraulic cylinder
9
11
5
12
4
7
10
3
6
1 Hexagon nut 2 Threaded rod 3 Bolt 4 Sealing plate 5 Intermediate cover 6 Sealing ring
7 Hydraulic cylinder 8 Insert shaft
9 Threaded flange 10 Set screw 11 Stroke-mounting flange 12 Bolt
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• Undo the bolts (3) and demount the locking plate (4). The bolts are used again for fastening the hydraulic cylinder.
• Demount the
• Place sealing ring (6) into the groove of the
• Place the specified torque.
• Unscrew the threaded rod (2) from the centering of the insert shaft (8).
• Vent the hydraulic cylinder (7) and screw in the end of the piston rod, with the piston run out, into the threaded flange (9).
Note
The fitting dimension is specified on the dimensioned drawing in the gearunit documentation.
• Screw in and secure the set screw (10).
• Place the strokemounting flange (11). Tighten the bolts (12) to the specified torque.

6.3.2 Description of fitting work

Intermediate cover (5).
Intermediate cover (5) on the flange of the hydraulic cylinder (7). Tighten the bolts (3) to the
intermediate cover (5) and hydraulic cylinder (7) with slight rotary motions on the
WARNING
Serious injury
Risk of injury through ignition of solventagent vapours during cleaning work. Observe the following:
– Ensure adequate ventilation. – Do not smoke.
Intermediate cover (5).
• Remove the anticorrosive agent from the shafts using a suitable cleaning agent.
CAUTION
Risk of injury through chemical substances
Observe manufacturer’s instructions for handling lubricants and solvents. Wear suitable protective clothing.
NOTICE
Material damage
Risk of damage to the shaftsealing rings through chemically aggressive cleaning agents. The cleaning agent must in no way be allowed to come into contact with the shaftsealing rings.
• Fit and secure drive elements (e.g. coupling parts) on shafts. If these are to be fitted in heated condition, refer to the dimensioned drawings in the coupling documentation for the correct joining temperatures.
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Unless specified otherwise, the components may be heated inductively, with a burner, or in a furnace.
WARNING
Risk of burns
Risk of serious injury through burns on hot surfaces (> 55 °C). Wear suitable protective gloves and protective clothing.
NOTICE
Material damage
Risk of damage to the shaftsealing rings through heating to over 100 °C. Use heat shields to protect against radiant heat.
The elements must be pulled smartly onto the shaft as far as stated on the dimensioned drawing prepared in accordance with the order.
NOTICE
Material damage
Damage to the gear unit possible through knocking or impacts. Fit the coupling using suitable fitting equipment. The shaftsealing rings and running surfaces of the shaft must not be damaged when pulling on the coupling parts.
NOTICE
Material damage
Risk of damage to the gear unit or single components through incorrect alignment. When fitting the drives, make absolutely certain that the individual components are accurately aligned in relation to each other. Inadmissibly large errors in the alignment of the shaft ends to be connected through angular and/or axial misalignments result in premature wear and material damage. Insufficiently rigid base frames or substructures can also during operation cause a radial and/or axial misalignment, which cannot be measured when the unit is at a standstill.
Note
Gear units with a weight that requires the use of lifting gear must be attached at the points shown in section 4, "Transport and storage". If the gear unit is to be transported with addon parts, additional attachment points may be required. The position of these attachment points is shown on the orderspecific dimensioned drawing.
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6.3.2.1 Alignment
Orderspecific machined surfaces (alignment surfaces) are provided on the gearunit top side for preliminary alignment in horizontal direction.
Alignment surface:
For the exact position of the alignment surfaces, refer to the drawings in the gearunit documentation.
These alignment surfaces are for aligning the gear unit horizontally, in order to ensure correct running of the gear unit.
Note
The values punched into the alignment surfaces must be observed.
2
1
1
Fig. 12: Alignment surfaces on gear units type H3LV
2
1
1
The final fine alignment with the units on the in and output side must be carried out accurately by the shaft axes, using:
1 Alignment surfaces 2 Alignment thread
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The final fine alignment with the units on the in and output side must be carried out accurately by the shaft axes, using:
─ Rulers
─ Spirit level
─ Clock gauge
─ Feeler gauge, etc.
Only then should the gear unit be fastened, and then the alignment should be checked once again.
• Record alignment dimensions.
Note
The record must be kept with these instructions.
DANGER
Danger to life through flying fragments
Nonobservance of the alignment accuracy can cause shaft rupture, resulting in serious injury and danger to life. Align the gear unit precisely (adhere to the specified values).
Risk of damage to the gear unit or its components or addon parts. The accuracy of shaftaxis alignment is an important factor in determining the life span of shafts, bearings and couplings. If possible, the deviation should be zero (exception: ZAPEX couplings). For the special requirements for the couplings, refer to the pertinent operating instructions as well.
6.3.2.2 Fitting on a foundation frame
• Clean the undersurface of the gearunit bases.
• Using suitable lifting gear, place the gear unit on the foundation frame.
• Tighten the foundation bolts to the specified torque (see item 6.10); if necessary, use stops to prevent displacement.
NOTICE
Material damage
Damage to the gear unit possible through uneven tightening of the fastening bolts. Tighten the fastening bolts evenly; the gear unit must not be excessively stressed when tensioning the fastening bolts.
• Align the gear unit exactly with the input and output units (see item 6.3.2.1).
• Record alignment dimensions.
Note
The record must be kept with these instructions.
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6.4 Shrink disk

The shrink disk makes a pressfit connection between a hollow shaft and a stub or drivenmachine shaft, in the following also called "stub shaft". The interference fit can transfer torques, bending moments and forces. The joining pressure between the hollow and stub shafts generated by the shrink disk is essential for the torque and/or force transmission.
The shrink disk is delivered ready for fitting.
WARNING
Serious injury
Risk of injury through flying fragments of the shrink disk. The shrink disk must not be disassembled before fitting for the first time. Fitting and startup must be carried out by properly trained specialist personnel. Prior to startup these instructions must be read, understood and adhered to. Siemens accept no liability for personal injury or damage due to nonobservance of the instruction manual.

6.4.1 Fitting the shrink disk

• Before beginning fitting work, the hollow shaft and the stub shaft must be carefully cleaned.
CAUTION
Risk of injury through chemical substances
Observe manufacturer’s instructions for handling lubricants and solvents. Wear suitable protective clothing.
Note
Do not allow cleaning agent or solvent to affect surfaces with paint coating.
Note
The bore of the hollow shaft and the machine shaft must be absolutely free of grease in the area of the shrinkdisk seat. This is essential for safe and reliable torque transmission. Contaminated solvents and dirty cloths as well as cleaning agents containing oil (such as paraffin or turpentine) are not suitable for removing grease.
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W
A
4
5
3
1
B
2
Fig. 13: Fitting the shrink disk
A Greased B Absolutely grease-
W Installation height
and oil-free
1 Stub shaft 2 Hollow shaft
4 Outer ring 5 Tensioning bolt
3 Inner ring
Note
The outer surface of the hollow shaft must be lightly greased in the area of the shrinkdisk seat.
For a detailed view, refer to the dimensioned drawing in the gearunit documentation.
• Place the shrink disk on the hollow shaft and fasten, if required. For the exact installation height "W" of the shrink disk, refer to the dimensioned drawing.
WARNING
Serious injury
Risk of injury through falling shrink disk or single parts thereof. Make absolutely sure that the shrink disk cannot slip off the hollow shaft. For transporting and lifting the shrink disk it may be required to use a suitable lifting device.
NOTICE
Material damage
Risk of damage to the hollow shaft. Do not tighten the tensioning bolts (5) until the stub shaft has been installed too.
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• Tighten the tensioning bolts (5) gradually one after the other, working round several times by quarter turns.
• Tighten all the tensioning bolts (5) until the end faces of the inner ring (3) and outer ring (4) are flush and the maximum tightening torque of the tensioning bolts has been achieved. The correct flush situation is to be checked using a ruler. The maximum tolerance is ± 0.2 mm.
Note
The correct clamping condition can thus be checked visually.
NOTICE
Material damage
Risk of damage to or destruction of the tensioning bolts through incorrect tightening or through combination of components that do not match. To avoid overloading the individual bolts, the maximum tightening torque (see table 5) must not be exceeded. Tightening the tensioning bolts using an impact screwdriver is not permitted. If, when tightening the clamping bolts to maximum tightening torque, the inner and outer ring are not flush, Siemens must be consulted.
Table 5: Maximum tightening torques for tensioning bolts
Maximum tightening
Tensioning-bolt
thread
torque per bolt
Strength class 12.9
Tensioning-bolt
thread
Nm
M 8 35 M 20 570
M 10 70 M 24 900
M 12 120 M 27 1310
M 14 193 M 30 1800
M 16 295 M 33 2400
Maximum tightening
torque per bolt
Strength class 12.9
Nm
Note
The shrink disk has been identitymarked on the outer ring (4). In case of contacting Siemens this identification must be referred to.
DANGER
Danger to life through rotating and/or movable parts
Risk of being caught or drawn in by rotating and/or movable parts. Rotating and/or movable parts must be fitted with suitable safeguards to prevent contact.
NOTICE
Material damage
Risk of damage to the shrink disk through the combination of components that do not match. Only the complete shrink disks supplied by the manufacturer may be used. Combining components from different shrink disks is not permitted.
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6.4.2 Demounting the shrink disk

• Remove the protective cover.
• Remove any rust deposits from the shaft and the interior of the hollow shaft.
WARNING
Serious injury
Risk of injury through flying fragments of the tensioning bolts. Do not unscrew the tensioning bolts one after the other, in order to avoid them to break off due to overload or due to uncontrolled loosening of the shrink disk.
• Undo all the tensioning bolts one after the other by approx. 1/4 turn.
The stored energy of the outer ring is slowly loosened during disassembly via the bolts to be loosened. For this to be carried out correctly, the procedure described here must be carefully adhered to.
• All the tensioning bolts should now be further undone by loosening one after the other by approx. 1 turn.
The outer ring should now release of its own accord from the inner ring. If this is not the case, the outer ring can be detensioned with the forcing threads. To this purpose screw some of the adjacent fastening bolts into the forcing threads. The now releasing outer ring is braced against the remaining bolts. This operation must be carried out until the outer ring completely releases of its own accord.
• The shrink disk is to be secured against axial shifting.
• Draw the stub shaft out of the hollow shaft.
• Pull the shrink disk off the hollow shaft.
WARNING
Serious injury
Risk of injury through falling shrink disk or single parts thereof. Make absolutely sure that the shrink disk cannot slip off the hollow shaft. For transporting and lifting the shrink disk it may be required to use a suitable lifting device.
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6.4.3 Cleaning and greasing the shrink disk

Note
Only dirty shrink disks must be disassembled and cleaned.
• Check all parts for any damage.
WARNING
Serious injury
Risk of injury through single parts being slung out (e.g. tensioning bolts). Damaged parts must be replaced with new ones. The use of damaged parts is not permitted. Only the complete shrink disks supplied by the manufacturer may be used. Combining components from different shrink disks is not permitted.
• Thoroughly clean all parts.
CAUTION
Risk of injury through chemical substances
Observe manufacturer’s instructions for handling lubricants and solvents. Wear suitable protective clothing.
Note
The conical surfaces of the inner and outer rings (positions 3 and 4, see figure 13) must be free of grease and oil.
Contaminated solvents and dirty cloths as well as cleaning agents containing oil (such as paraffin or turpentine) are not suitable for removing grease.
• A thin layer of lubricant must be applied evenly to the conical surfaces of the inner and outer rings (positions 3 and 4, see figure 13).
• Provide the tensioning bolts (position 5, see figure 13) on the contact surface and on the thread with lubricant.
Use a solid lubricant paste with a high MoS slide during fitting work and which shows the following characteristics:
based molybdenum disulphide content which will not
2
─ Friction coefficient "μ" = 0.04
─ Resistant to pressure up to a maximum pressure of 300 N/mm
2
─ Ageingresistant
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Table 6: Recommended lubricants for shrink disks after their cleaning
Lubricant Form Manufacturer
Molykote G Rapid Spray or paste DOW Corning
Aemasol MO 19 P Spray or paste A. C. Matthes
Unimoly P 5 Powder KlĂźber Lubrication
gleitmo 100 Spray or paste Fuchs Lubritec
1)
Other lubricants may be used; however they must have the same characteristics.
• Join the inner ring (3) and the outer ring (4).
• Place the tensioning bolts and screw in some threads by your fingers.
6.4.4 Refitting the shrink disk
Note
For remounting the shrink disk the procedure described in item 6.4.1 must be adhered to.

6.4.5 Inspection of the shrink disk

Note
In all cases the examination of the shrink disk should be carried out simultaneously with the examination of the gear unit, however at least every 12 months.
1)
Inspection of the shrink disk is limited to a visual assessment of its condition. The following must be observed when carrying out this work:
─ Loose bolts
─ Damage caused by force
─ Flush position of the inner ring (3) in relation to the outer ring (4)
6.5 Oillevel monitoring (optional)
• Wire the oillevel limit switch electrically.
Note
Be sure to observe the corresponding operating instructions for operation and maintenance. For technical data, refer to the data sheet and/or the list of equipment.
6.6 General notes on addon components
Note
For operating and servicing the components described in section 6, the corresponding operating instructions and the specifications in section 5 must be observed. For technical data, refer to the data sheet and/or the list of equipment.

6.7 Fitting the limit switch (optional)

• Remove the protective plugs.
• Screw limit switches into the bores provided.
Note
For the position of the devices, refer to the dimensioned drawing.
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6.7.1 Tangential alignment of the limit switch relative to the switch plate (optional)

• Screw the EMERGENCYOFF limitswitch unit delivered loose by Siemens oil and splashwatertight into the gearunit housing over the tube.
• Align the rail with the limit switches at a tangent to the switch plate via the tube clips so that the rollerpressure pin of the limit switch can turn in the direction of run and not be subjected to additional transverse forces from contact with the switch plate.

6.7.2 Axial positioning of the limit switch relative to the switch plate (optional)

The EMERGENCYOFF switch points for the height adjustment can be found on the dimensioned drawing. The forcibly breaking safety switch with rollerpressure pins used in this design has a switching movement of 2 mm. The switching movement must be taken into account when positioning the switch.

6.8 Fitting the frequency inverter (optional)

Note
Observe separate operating instructions.

6.9 Final work

□ After installation of the gear unit check all screw connections for tight fit.
□ Check the alignment after tightening the fastening elements. The alignment must not have been
changed.
□ Check that all the devices which have been demounted for transport reasons have been refitted.
For this refer to the details on the data sheet, in the list of equipment and on the associated drawings.
□ Any oildrain cocks must be secured against accidental opening.
□ The gear unit must be protected against falling objects.
□ Protective devices for rotating parts must be checked for correct seating. Contact with rotating parts
is not permitted.
□ A potential equalisation in accordance with the applying regulations and directives must be carried out!
If no threaded holes for earth connection are available on the gear unit, other appropriate measures must be taken. This work must always be done by specialist electricians.
□ Cable entries must be protected against moisture.
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6.10 Screwconnection classes, tightening torques and initialtensioning forces
6.10.1 Screwconnection classes
The specified screw connections are to be fastened applying the tightening torques specified observing the table below.
NOTICE
Material damage
Risk of damage to the bolts and/or mating threads through incorrect tightening. Foundation bolts, hub bolts and bearingcover bolts must always be tightened in accordance with screwconnection class "C".
Table 7: Screwconnection classes
Fastening of
Gear unit
Motor*
Protective hood E
Screw-connection
class
C
D
– Hydraulic tightening with mechanical screwdriver
– Hydraulic tightening with mechanical screwdriver
– Tightening with precision mechanical screwdriver
– Torque-controlled tightening with mechanical screwdriver
– Tightening with pulse screwdriver or impact wrench
– Tightening by hand, using a spanner without torque
*)The tightening torques applying to these addon parts can be found in the instructions supplied by the
manufacturers of the parts.
6.10.2 Tightening torques and initialtensioning forces
The tightening torques apply to friction coefficients of Îź The friction coefficient Îź
= 0.14 applies here to lightly oiled steel bolts, blackannealed or phosphatised
total
and dry, cut mating threads in steel or cast iron. Lubricants which alter the friction coefficient must not be used and may overload the screw connection.
Tightening procedure
with dynamic torque measuring
without adjustment checking device
measuring device
= 0.14.
total
Table 8: Initialtensioning forces and tightening torques for screw connections of strength classes
= 0.14
total
Tightening torque
for screw-connection classes
from table 7
M
A
Nm
Nominal
thread
diameter
d
mm
M10
M12
8.8; 10.9; 12.9 with a common friction coefficient of Îź
Strength
class
of the bolt
8.8 18000 11500 7200 44.6 38.4 34.3
10.9 26400 16900 10600 65.4 56.4 50.4
12.9 30900 19800 12400 76.5 66.0 58.9
8.8 26300 16800 10500 76.7 66.1 59.0
10.9 38600 24700 15400 113 97.1 86.6
12.9 45100 28900 18100 132 114 101
Initial-tensioning force
for screw-connection classes
from table 7
C D E C D E
F
M min.
N
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Nominal
thread
diameter
d
mm
M16
M20
M24
M30
M36
M42
M48
M56
M64
M72x6
M80x6
M90x6
M100x6
Strength
class
of the bolt
8.8 49300 31600 19800 186 160 143
10.9 72500 46400 29000 273 235 210
12.9 85000 54400 34000 320 276 246
8.8 77000 49200 30800 364 313 280
10.9 110000 70400 44000 520 450 400
12.9 129000 82400 51500 609 525 468
8.8 109000 69600 43500 614 530 470
10.9 155000 99200 62000 875 755 675
12.9 181000 116000 72500 1020 880 790
8.8 170000 109000 68000 1210 1040 930
10.9 243000 155000 97000 1720 1480 1330
12.9 284000 182000 114000 2010 1740 1550
8.8 246000 157000 98300 2080 1790 1600
10.9 350000 224000 140000 2960 2550 2280
12.9 409000 262000 164000 3460 2980 2670
8.8 331000 212000 132000 3260 2810 2510
10.9 471000 301000 188000 4640 4000 3750
12.9 551000 352000 220000 5430 4680 4180
8.8 421000 269000 168000 4750 4090 3650
10.9 599000 383000 240000 6760 5820 5200
12.9 700000 448000 280000 7900 6810 6080
8.8 568000 363000 227000 7430 6400 5710
10.9 806000 516000 323000 10500 9090 8120
12.9 944000 604000 378000 12300 10600 9500
8.8 744000 476000 298000 11000 9480 8460
10.9 1060000 676000 423000 15600 13500 12000
12.9 1240000 792000 495000 18300 15800 14100
8.8 944000 604000 378000 15500 13400 11900
10.9 1340000 856000 535000 22000 18900 16900
12.9 1570000 1000000 628000 25800 22200 19800
8.8 1190000 760000 475000 21500 18500 16500
10.9 1690000 1100000 675000 30500 26400 23400
12.9 1980000 1360000 790000 35700 31400 27400
8.8 1510000 968000 605000 30600 26300 23500
10.9 2150000 1380000 860000 43500 37500 33400
12.9 2520000 1600000 1010000 51000 43800 39200
8.8 1880000 1200000 750000 42100 36200 32300
10.9 2670000 1710000 1070000 60000 51600 46100
12.9 3130000 2000000 1250000 70000 60400 53900
Initial-tensioning force
for screw-connection classes
from table 7
F
M min.
N
Tightening torque
for screw-connection classes
from table 7
M
A
Nm
EDCEDC
Note
Damaged bolts must be replaced with new bolts of the same type and strength class.
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7. Startup
Observe the instructions in section 3, "Safety instructions"!
7.1 Procedure before startup

7.1.1 Removal of preservative agent from exterior

• The preserved shaft ends in the area of the couplings to be fitted must be depreserved, using suitable agents (special solvent etc.). The depreservation also applies to bright surfaces of the gear unit, onto which components are to be fitted.
CAUTION
Risk of injury through chemical substances
The solvent must not come into contact with the skin (e.g. the operator’s hands). The safety notes on the data sheets for the solvent used must be observed. Remove any solvent spillage immediately with a binding agent. Observe manufacturer’s instructions for handling lubricants and solvents. Wear suitable protective clothing.

7.1.2 Removal of preservative agent from interior

NOTICE
Material damage
Risk of damage to the gear unit through missing or insufficient ventilation. Replace the screw plug with the air filter or wetair filter before startup.
The position of the oildrain points is marked by a symbol on the dimensioned drawing in the gearunit documentation.
Oildrain point:
• Place suitable containers under the oildrain points (4 and 5).
• Open the oildrain cock (4) and unscrew the residualoil drain plug (5).
• Remove remaining preservative agent and/or runningin oil from the housing using a suitable container; to do so, unscrew all existing residualoil drain plugs.
• Dispose of remaining preservative agent and/or runningin oil in accordance with regulations.
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operator’s hands). The safety notes on the data sheets for the oil used must be observed. Remove any oil spillage immediately with a binding agent. Observe manufacturer’s instructions for handling lubricants and binding agents. Wear suitable protective clothing.
• Shut the oildrain cock (4) and screw in the residualoil drain plug (5) again.
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8
16
(II)
(III)
9
(II)
7
(II)
6
(Ia)
(Ib)
(III)
(III)
(I)
(I)
13
12
4
5
14
10
11
15
1
2,3
Fig. 14: Oil inlet and oil drain – gear unit with hoist gear unit
1 Ventilation (I) main gear unit 2 Oil filling (I) main gear unit 3 Dipstick; oil filling (I) main gear unit 4 Oil-drain cock (Ia); oil drain main gear unit 5 Oil-drain plug; residual oil (Ib) main gear unit 6 Ventilation; oil filling (II) primary gear unit 7 Oil level (II) primary gear unit 8 Oil-drain plug (II) primary gear unit
9 Ventilation / oil filling (III) hoist
gear unit 10 Oil level (III) hoist gear unit 11 Oil-drain plug (III) hoist gear unit 12 Bellows 13 Vent hole 14 Leak hole 15 Leak hole 16 Inspection and/or assembly cover
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16
(II)
8
(Ia)
(Ib)
13
12
4
5
14
(II)
7
(II)
6
(I)
(I)
1
2,3
Fig. 15: Oil inlet and oil drain – gear unit with lifting cylinder
1 Ventilation (I) 2 Oil filling (I) main gear unit 3 Dipstick (I); oil filling (I) main gear unit 4 Oil-drain cock (Ia); oil drain main gear unit
12 Bellows 13 Vent hole 14 Leak hole 16 Inspection and/or assembly cover
5 Oil-drain plug; residual oil (Ib) main gear unit 6 Ventilation; oil filling (II) primary gear unit 7 Oil level (II) primary gear unit 8 Oil-drain plug (II) primary gear unit
For a detailed illustration of the gear unit and the position of the addon parts, refer to the drawings in the gearunit documentation.
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7.1.3 Filling with lubricant

7.1.3.1 Helicalgear unit (main gear unit)
The gaps between the shaftsealing rings, if fitted, have already been filled with grease.
• Unscrew the dipstick (2) on the oilequalising tank.
Note
For data such as oil type, oil viscosity and oil quantity required, refer to section 1, "Technical data").
• Top up the gear unit with fresh oil, using a filter (mesh approx. 10 μm), to begin with with 60 to 70 % of the oil quantity indicated on the rating plate.
Note
The quality of the oil used must meet the requirements of the separately supplied BA 7300 operating instructions, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in table "T 7300" (for a link to the Internet, see the back cover), as they have been tested and meet the requirements. Information on the type, quantity and viscosity of the oil is given on the rating plate on the gear unit. The oil quantity shown on the rating plate is to be understood as an approximate quantity. The actual oil quantity to be put in is the MAX mark on the dipstick, when the insert shaft has been run out.
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operator’s hands). The safety notes on the data sheets for the oil used must be observed. Remove any oil spillage immediately with a binding agent. Observe the manufacturer’s instructions for handling lubricants. Wear suitable protective clothing.
• Screw in the dipstick (2) again.
NOTICE
Material damage
Risk of damage to the wetair filter. Prior to using the wetair filter, 2 of the 8 sealed bores at the underside of the wetair filter must be opened.
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• Move the spentgrain cutting machine to the upper position by means of the bevelgear motor (electric motor II) or the lifting cylinder.
NOTICE
Material damage
Risk of damage to the gear unit through incorrect direction of rotation. Check the direction of rotation of the electric motor II before switching on. Start the motor briefly. If the direction of rotation is incorrect, switch off immediately and interchanged the connections.
Note
Vertical adjustment must be done only when the helicalgear unit is filled with 60 to 70 % of the oil indicated on the rating plate. Startup via the electric motor I is not yet permitted. Since there is no adjustment of the limit switches the spindle drive must not be run out beyond the upper mark on the mechanical height indicator. Adjust any residual height necessary manually via the fan wheel of the electric motor II or via the lifting cylinder.
• Unscrew the dipstick (3) on the oilequalising tank.
• Fill in a further approx. 30 to 40 % of the oil quantity specified on the rating plate, using a filter (mesh approx. 10 μm) via the oilfilling hole, until the oil comes up to the lower mark on the dipstick. Do not put in any further oil. The viscosity of the oil in cold condition will cause the oil level to continue rising slowly. If necessary, put in further oil up to the MAX mark on the dipstick, only after the oil level has steadied.
• Check the oil level using the dipstick (3).
Note
The oil must come up to the MAX mark on the dipstick, when the insert shaft has been run out.
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operator’s hands). The safety notes on the data sheets for the oil used must be observed. Remove any oil spillage immediately with a binding agent. Wear suitable protective clothing.
• Screw in the dipstick (3) again.
7.1.3.2 Bevel-gear unit
• The bevelgear units have already been filled with oil as indicated in section 1, "Technical data".
Note
Observe separate operating instructions.
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7.2 Setting of the cam-operated switches (in the gearunit cam operated switch)
• Move the spentgrain cutting machine to the middle position by means of bevelgear motor (electric motor II).
• Determine the afterrun in both directions (afterrun is the number of revolutions between switching off and motor standstill)
• Run the machine onto the switching points of the cam-operated switches.
• Turn the drive back by the amount of afterrun determined.
NOTICE
Material damage
Risk of damage to the gear unit or lauter tun through setting of incorrect switch points. Check the setting of the switch points The switch points must be run onto from the same direction to set them, just as they will be in electrical operation afterwards.
• Set the switching cams to the individual switch points until a ratcheting noise can be clearly heard.
Note
Observe separate operating instructions.
7.3 Setting the rotary angle transducer (in the gearunit cam operated switch)
• Move the spentgrain cutting machine to the lower position by means of bevelgear motor (electric motor II).
• Using a screwdriver, set the 4 mA signal on the rear shaft bush of the rotary angle transducer.
• 100 % adjustment is not required. The transmitters are set for the respective drive angle to ≤ 20 mA at the factory in accordance with order specifications.
Note
Observe separate operating instructions.
7.4 Setting of the EMERGENCYOFF limit switches
• Set the EMERGENCYOFF limit switches so that the electric motor II or the lifting cylinder is switched off immediately when the upper and lower switch contacts of the gearunit cam operated switch are run over.
NOTICE
Material damage
Risk of damage to the gear unit or lauter tun through incorrect setting. Check the setting of the switch points Adjustment must be done with the greatest care to avoid damaging the lauter tun or the gear unit.
Note
Observe separate operating instructions.
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7.5 Startup
NOTICE
Material damage
Risk of damage to the gear unit through missing or insufficient ventilation. Replace the screw plug with the air filter or wetair filter before startup.
NOTICE
Material damage
Risk of damage to the wetair filter. Prior to using the wetair filter, 2 of the 8 sealed bores at the underside of the wetair filter must be opened.
• Check the oil level of the gear unit (see item 7.5.1).

7.5.1 Oil level

The following oil level is correct:
─ MAX mark on the dipstick with the insert shaft run out.
Note
When cooled down the oil must come up as far as between the MAX mark on the dipstick. Hot oil may slightly exceed the MAX mark on the dipstick.
NOTICE
Material damage
Insufficient lubrication possible through too low oil level. Check the oil level. Under no circumstances must it fall below the MIN mark on the dipstick. If necessary, top up oil to the correct level.

7.5.2 Temperature measurement

During the first startup and after maintenance work, the oilsump temperature must be measured during proper use (maximum drivenmachine performance) after warming up.
NOTICE
Material damage
Risk of damage to the gear unit through insufficient lubrication resulting from too high oil temperature. The maximum permissible oilsump temperature is 90 °C. At higher temperatures the gear unit must be shut down immediately and Siemens customer service consulted.
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7.5.3 Oillevel monitoring (optional)
The gear unit can be fitted with an oillevel monitor by means of a fillinglevel limit switch. The oillevel monitoring device has been designed for checking the oil level when the gear unit is at a standstill, prior to operating start.
Note
Wiring should be in such a way that, when the signal "Oil level too low" is given, the drive motor cannot start and that a warning signal is emitted. During operation, any signal should be bridged.

7.5.4 Checking procedure

The following visual checks must be conducted and recorded when starting up:
□
□ Oil level
□ Leaktightness of the oilcooling or oilsupply lines
□ Opening condition of the shutoff valves
□ Effectiveness of the shaft seals
□ Freedom of the rotating parts from contact
The tension pressures or pretensioning forces shown in item 6.3.2.2 must also be recorded in this document.
Note
The record must be kept with these instructions.

7.6 Shutting down

• Switch off the drive unit.
DANGER
Danger to life through switchedon installation
To carry out work on the gear unit, the gear unit must always be stopped. The drive unit must be secured against being switched on accidentally (e.g. by locking the key switch or removing the fuses from the power supply). A notice should be attached to the ON switch stating clearly that work is in progress on the gear unit.
• Start the gear unit and allow it to run briefly (5 to 10 minutes) approx. every 3 weeks (during a shutdown period no longer than 6 months).
• Treat the gear unit with preservative, see items 7.6.1 and 7.6.2 (before a removal from service for a period exceeding 6 months).
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7.6.1 Interior preservation for longer disuse

Depending on the type of lubrication and/or shaft sealing, the following types of interior preservation can be applied.
7.6.1.1 Interior preservation with gearunit oil
Gear units with splashlubrication systems and contacting shaft seals can be topped up with the type of oil already filled in to a level just below the air filter or wetair filter.
The durability period of this type of preservation depends on the age of the shaftsealing rings and the oil.
Note
After a preservation period exceeding 36 months the radial shaftsealing rings must be replaced before startup.
NOTICE
Material damage
Risk of damage through insufficient lubrication through undetected leakage. The leaktightness of the gear unit must be checked regularly every 4 weeks.
• Unscrew the air filter with reducing screw or the wetair filter (1) (see fig. 14 or fig. 15 in item 7.1.2).
• Top up gearunit oil through the hole up to just beneath the air filter or wetair filter.
Note
For gearunit oils refer to table "T 7300" (for a link to the Internet, see the back cover).
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operator’s hands). The safety notes on the data sheets for the oil used must be observed. Remove any oil spillage immediately with a binding agent. Wear suitable protective clothing.
• Replace the air filter with reducing screw or the wetair filter (1) with the screw plug.
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7.6.1.2 Interior preservation (main gear unit) with "Castrol Alpha SP 220 S" preservative agent
• Place a suitable container under the oildrain point of the gearunit housing.
• Open the oildrain cock (4). For this, refer to fig. 14 or fig. 15 in item 7.1.2.
• Drain the oil into a suitable container (see section 10, "Maintenance and Repair").
WARNING
Risk of scalding
Serious injury through escaping operating media possible whilst they are replaced. Wear suitable protective gloves, protective glasses and protective clothing.
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operator’s hands). The safety notes on the data sheets for the oil used must be observed. Remove any oil spillage immediately with a binding agent. Wear suitable protective clothing.
Note
Check the condition of the sealing ring; the sealing ring is vulcanised onto the oildrain plug. If necessary, use a new oildrain plug.
• Shut the oildrain cock (4) again.
• Unscrew the air filter or wetair filter (1) on the oilequalising tank.
• Replace the air filter or wetair filter (1) with the screw plug.
Note
Carefully clean the air filter (see item 10.2.4) and keep it on a safe place (it will be required again when starting up again) or use a new wetair filter at startup.
• Unscrew the dipstick (3) on the oilequalising tank.
• Fill the gear unit with "Castrol Alpha SP 220 S". Determine the filling quantity according to the gearunit dimensions: length x width x height x 0.1.
NOTICE
Material damage
Corrosion possible through use of an unsuitable preservative agent. Use special oil "Castrol Alpha SP 220 S" with additional anticorrosive agent (additive "S").
• Screw in the dipstick (3) again.
NOTICE
Material damage
Corrosion possible through leaving the gear unit open too long. Close the gear unit airtightly at the latest one hour after opening. Before restarting the gear unit take the following measure:
– Replace the screw plug with the air filter or wetair filter.
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7.6.2 Exterior preservation

7.6.2.1 Exteriorpreservation procedure
• Clean the surfaces.
NOTICE
Material damage
Risk of damage to the shaftsealing ring through contact with chemically aggressive preservative agent. For separation between the sealing lip of the radial shaftsealing ring and the preservative agent, the shaft should be brushed with grease in the area around the sealing lip.
• Apply preservative agent.
Note
For preservative agent, see table 4 in item 4.4.2.
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8. Operation

Observe the instructions in section 3, "Safety instructions", in section 9, "Faults, causes and remedy", and in section 10, "Maintenance and repair"!

8.1 General

To achieve a satisfying and troublefree operation of the equipment, be certain to observe the working values specified in section 1, "Technical data".
During operation the gear unit must be monitored for the following:
□ Operating temperature The gear unit is designed for an operating temperature
□ Changes in gear noise
□ Oil leakage at the housing and
shaft seals

8.2 Oil level

in continuous operation of:
90 °C (applies to mineral oil)
The maximum permitted temperature is:
100 °C (applies to mineral oil)
Note
For checking the oil level, the gear unit must be stopped. Depending on the type of the gearunit housing the following oil levels are correct when the oil has cooled down:
– MAX mark on the dipstick with the insert shaft run out
When cooled down the oil must come up as far as between the MAX mark on the dipstick. Hot oil may slightly exceed the MAX mark on the dipstick.
NOTICE
Material damage
Insufficient lubrication possible through too low oil level. Check the oil level. Under no circumstances must it fall below the visible MIN mark on the dipstick. If necessary, top up oil to the correct level.

8.3 Irregularities

NOTICE
Material damage
Risk of damage to the gear unit through fault conditions. Switch off the drive unit immediately on occurrence of the following situations.
□ If irregularities are found during operation.
Note
Determine the cause of the fault, using table 9, "Faults, causes and remedy" (see item 9.2). Table 9, "Faults, causes and remedy", contains a list of possible faults, their causes and suggested remedies. If the cause cannot be found, a specialist from one of the Siemens customerservice centres should be called in (see section 2, "General notes").
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9. Faults, causes and remedy

Observe the instructions in section 3, "Safety instructions", and in section 10, "Maintenance and repair"!

9.1 General information on faults and malfunctions

Faults and malfunctions occurring during the guarantee period and requiring repair work on the gear unit must be carried out only by Siemens customer service. In case of faults and malfunctions occurring after the guarantee period and whose cause cannot be precisely identified, we advise our customers to contact our customer service.
NOTICE
Material damage
Risk of damage to the gear unit through improper use. Siemens will not be bound by the terms of the guarantee or otherwise be responsible for further operation in cases of improper use of the gear unit, modifications carried out without the approval by Siemens or use of spare parts not originally supplied by Siemens.
DANGER
Danger to life through switchedon installation
To carry out maintenance and/or repair work, the gear unit must always be stopped. Secure the drive unit to prevent unintentional switchon. A notice should be attached to the ON switch stating clearly that work is in progress on the gear unit.
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9.2 Possible faults

Table 9: Faults, causes and remedy
Faults
Changes in gearunit noise. Damage to gear teeth.
Excessive bearing play.
Bearing is defective.
Loud noises in the area of the gearunit fastening.
Increased temperature at the bearing points.
Exterior of gear unit is oiled up. Inadequate sealing of housing
Gearunit fastening has worked loose.
Oil level in gearunit housing too low or too high.
Oil too old.
Bearing is defective.
covers and/or joints.
Causes Remedy
Contact Customer Service. Check toothed components. If necessary, replace damaged components.
Contact Customer Service. Adjust bearing play.
Contact Customer Service. Replace defective bearings.
Tighten bolts and nuts to the specified tightening torque. Replace damaged bolts and nuts.
Check oil level at room temperature. Top up oil, if necessary.
Check date of last oil change. Change oil, if necessary. See section 10.
Contact Customer Service. Check and, if necessary, replace bearings.
Seal housing covers and/or joints.
Oil leakage from the gear unit. Inadequate sealing of housing
covers and/or joints.
Radial shaftsealing rings defective.
Oil foaming in the gear unit. Preservative agent not completely
drained.
Gear unit too cold in operation.
Water in oil.
Oil too old (defoaming agent used up).
Unsuitable oils are mixed up.
Check and, if necessary, replace seals. Seal housing covers and/or joints.
Check and, if necessary, replace radial shaftsealing rings.
Change oil.
Shut down gear unit and have oil degassed. Restart without cooling water.
Check state of oil by the testtube method for water contamination. Have oil analysed by a chemical laboratory. Change oil, if necessary.
Examine the oil; change the oil, if necessary.
Examine the oil; change the oil, if necessary.
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Faults RemedyCauses
Water in oil. Gear unit exposed to cold air from
Increased operating temperature.
Temperature too high at the bearing points of the helicalgear unit with strokemounting flange
Bevelgear motors (Electric motors I and II)
Gearunit cam operated switch
EMERGENCYOFF limit switch Observe separate operating
Frequency inverter (optional) Observe separate operating
machineroom fan: Water condensing.
Climatic conditions.
Oil level in housing too high.
Oil too old.
Oil badly contaminated.
Oil level in housing too low.
Oil too old.
Bearing defective.
Protect gear unit with suitable heat insulation. Close air outlet or alter its direction by structural measures.
Contact Customer Service. If necessary, use wetair filter.
Check the oil level. Adjust oil level, if necessary.
Check date of last oil change. If necessary, change the oil; see section 10.
Change the oil; see section 10.
Check the oil level. Top up oil, if necessary.
Check date of last oil change. If necessary, change the oil; see section 10.
Contact Customer Service. Check and, if necessary, replace bearings.
Observe separate operating instructions.
Observe separate operating instructions.
instructions.
instructions.
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9.2.1 Leakage and leaktightness

In standard "DIN 3761" information is given on the subject of leakage on gear units. Based on this and building on the extensive experience gained at Siemens
*)
and other FVA 1) member companies, brief
descriptions, required measures and notes on this subject are included in the following overview.
2)
Table 10: Notes on the leaktightness of radial shaftsealing rings (RWDR
)
Condition Description Measures Notes
Leaktight, dry No moisture to be seen on
radial shaft-sealing ring.
Leaktight, damp Film of moisture formed
functionally in the area of the sealing edge but not extending beyond the bottom side of the radial shaft-sealing ring.
Leaktight, wet Moisture film extending
beyond the bottom side of the radial shaft-sealing ring but not dripping.
Measurable leak Small trickle to be seen on
the bottom side of the radial shaft-sealing ring, dripping.
None
Only when contaminated, wipe with clean cloth underneath sealing lip.
The sealing lip must not be contaminated.
Observe.
Wipe with clean cloth underneath sealing lip.
The sealing lip must not be contaminated.
Observe.
Change radial shaft-sealing ring, if necessary; identify possible cause of radial shaft-sealing ring failure and rectify.
The radial shaft-sealing ring often dries by itself in further operation.
No reason for complaint.
The radial shaft-sealing ring often dries by itself in further operation.
No reason for complaint.
May be a reason for complaint; one drop of oil a day is acceptable.
Short-term leak Short-term failure of the
sealing system.
Apparent leak Temporary leak. Wipe with clean cloth
Wipe with clean cloth underneath sealing lip.
The sealing lip must not be contaminated.
Observe.
underneath sealing lip.
The sealing lip must not be contaminated.
E.g. through small particles on the seal edge, which are removed again in further operation.
No reason for complaint.
Due mostly to excessive grease filling between seal and dust lip or oil secretions from the grease filling of labyrinth seals.
No reason for complaint.
*)Siemens AG, Mechanical Drives "MD" Business Unit
1)
FVA = Forschungsvereinigung Antriebstechnik e. V.
2)
RWDR = radial shaftsealing ring
Note
Oil mist escaping from a airrelief valve or a labyrinth seal is functional and therefore not a reason for complaint.
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10. Maintenance and repair

Observe the instructions in section 3, "Safety instructions", and in section 9, "Faults, causes and remedy"!

10.1 General notes on maintenance

All maintenance and repair work must be carried out carefully and by qualified personnel only (see section "Qualified Personnel" on page 3 of this manual).
The following applies to all work in item 10.2:
DANGER
Danger to life through switchedon installation
To carry out maintenance and/or repair work, the gear unit must always be stopped. Secure the drive unit to prevent unintentional switchon. A notice should be attached to the ON switch stating clearly that work is in progress on the gear unit.
The periods indicated in table 11 largely depend on the conditions under which the gear unit is operated. Only average periods can therefore be stated here. These refer to the following values:
daily operating time of 24 h
duty factor "ED" of 100 %
input-drive speed of 1500 1/min
operating temperature of 90 °C (applies to mineral oil)
NOTICE
Material damage
Risk of damage to the gear unit through nonobservance of the periods specified for maintenance and repair work. The operator must ensure that the intervals stated in table 11 are adhered to. This also applies if the maintenance work is included in the operator’s internal maintenance schedules.
Table 11: Maintenance and repair work
Measures Periods Remarks
Check the oil temperature Daily
Check for unusual gear-unit noise Daily
Check the oil level Monthly – Upper mark on the dipstick
with the insert shaft run out
Check the gear unit for leaks Monthly
Examine the water content of the oil After approx. 400 operating hours,
at least once a year
Perform the first oil change Approx. 400 operating hours
after start-up
See item 10.2.1.
See item 10.2.2.
Perform subsequent oil changes Every 24 months
or 10 000 operating hours
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See item 10.2.2.
Page 65
Measures RemarksPeriods
Replace the wet-air filter As required See item 10.2.3.
Clean the air filter Every 3 months See item 10.2.4.
Clean the gear unit Depending on requirements,
at least every 2 years
Check tightness of fastening bolts After the first oil change,
then every 2 years
Check shrink disk. Every 12 months See item 6.4.5.
Inspection of the gear unit Every 2 years See item 10.4.
Check electric motor I, electric motor II, bevel-gear unit and lifting cylinder
See separate instruction manual See separate instruction

10.1.1 General service lives of oils

According to the oil manufacturers, the following are the expected periods during which the oils can be used without undergoing any significant change in quality. They are calculated on the basis of an average oil temperature of 80 °C:
─ mineral oils, biodegradable oils and physiologically safe oils: 2 years or 10 000 operating hours.
Does not apply to natural esters such as rape seed oils.
Note
The actual service lives may differ. The general rule is that an increase in temperature of 10 K will halve the service life and a temperature decrease of 10 K will approximately double the service life.

10.2 Description of maintenance and repair works

See item 10.2.5.
See item 6.10.
manual

10.2.1 Examine water content of oil, conduct oil analyses

Detailed information about examining the oil for water content or conducting oil analyses is obtainable from your lubricant manufacturer or the Siemens customer service.
─ For reference purposes, a sample of the fresh operating lubricating oil in use must be sent with the
usedoil sample to the analysing institute for analysis.
─ A special sample container should be filled with the specified quantity of oil.
If there is no such sample container available, at least one litre of oil must be put in a clean, transportworthy, sealable vessel.
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10.2.2 Changing the oil (main gear unit)

As an alternative to the oilchange intervals specified in table 11 (see item 10.1), it is possible to have an oil sample tested at regular intervals, every 4 weeks, by the technical service of the relevant oil company and to have it cleared for further use.
If further usability has been confirmed, no oil change will be necessary.
Note
Please observe the separately annexed operating instructions BA 7300 and the notes in item 7.1.
• Drain the oil while the gear unit is still warm, i.e. immediately after stopping the machinery.
NOTICE
Material damage
Risk of damage to the gear unit through incorrect lubrication resulting from mixed oils. When changing the oil, always refill the gear unit with the same type of oil. Never mix different types of oil and/or oils made by different manufacturers. The use of synthetic oil is not permissible.
• Place a suitable container under the oildrain points of the gearunit housing.
• Open the oildrain cock (4) and drain off the oil into the container. See also fig. 14 or fig. 15 in item 7.1.2.
CAUTION
Risk of scalding
Risk of injury through escaping hot oil. Wear suitable protective gloves, protective glasses and protective clothing. Remove any oil spillage immediately with an oilbinding agent.
Note
Check the condition of the sealing ring; the sealing ring is vulcanised onto the oildrain plug. If necessary, use a new oildrain plug.
• Shut the oildrain cock (4).
• Unscrew the dipstick (3) on the oilequalising tank.
• Fill fresh oil into the gear unit (see item 7.1.3).
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To top up oil:
• Unscrew the dipstick (3) on the oilequalising tank.
• Top up the gear unit with fresh oil using a filling filter (mesh approx. 10 μm), until the oil reaches the lower mark on the dipstick. Do not put in any further oil. The viscosity of the oil in cold condition will cause the oil level to continue rising slowly. If necessary, put in further oil up to the MAX mark on the dipstick, with the insert shaft run out, only after the oil level has steadied.
Note
Always top up with the same type of oil as already used in the unit (see also item 10.2.2). For data such as oil type, oil viscosity and oil quantity required, refer to section 1 "Technical data").
• Check the oil level using the dipstick (3).
Note
The oil must come up to the MAX mark on the dipstick, when the insert shaft has been run out.
CAUTION
Risk of scalding
Risk of injury through escaping hot oil. Wear suitable protective gloves, protective glasses and protective clothing. Remove any oil spillage immediately with an oilbinding agent.
10.2.3 Replace the wetair filter
The wetair filter has a container filled with "silica gel". The air humidity absorbed by the "silica gel" changes the colour of the gel from "blue" to "pink" (visible through the transparent container). Replacement of the complete wetair filter is only necessary when the "silica gel" has gone completely pink.
• Unscrew the wetair filter and replace it with a new one.
NOTICE
Material damage
Risk of damage to the wetair filter. Prior to using the wetair filter, 2 of the 8 sealed bores at the underside of the wetair filter must be opened.
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10.2.4 Clean the air filter

Note
A period of 3 months has been specified for cleaning the air filter. If a layer of dust has built up, the air filter must already be cleaned, whether or not the period of 3 months has expired.
Note
If the air filter is protected with a filter cap, the filter cap must be removed for cleaning the air filter. After the air filter has been cleaned, the filter cap must be fitted again.
• Unscrew the air filter including the reducing screw.
• Clean the air filter using a suitable cleaning agent.
• Dry the air filter and/or blow out with compressed air.
WARNING
Risk of eye injury through compressed air
Remains of water and/or dirt particles may be harmful to the eyes. Wear suitable protective glasses.
NOTICE
Material damage
Risk of damage to the gear unit through entry of foreign bodies. Foreign bodies must be prevented from entering the gear unit.

10.2.5 Clean the gear unit

NOTICE
Material damage
Risk of damage to the gear unit through overheating. Layers of dust may affect the withdrawal of heat by way of the housing surface and cause overheating. To prevent the buildup of dust on the gear unit, cleaning must be done in accordance with the local operating conditions.
• Remove any dirt adhering to the gear unit, using a hard brush.
• Remove any corrosion.
NOTICE
Material damage
Risk of damage to the gear unit through entry of moisture. The gear unit must not be cleaned with highpressure cleaning equipment.

10.2.6 Top up oil

• The instructions in item 7.1 must be observed!
• Always top up with the same type of oil as already used (see also item 10.2.2).
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10.2.7 Check tightness of fastening bolts

• The instructions in item 10.1 must be observed!
• Check tightness of all the fastening bolts.
Note
Damaged bolts must be replaced with new bolts of the same type and strength class.

10.3 Final work

Note
For operating and servicing all components, the pertinent operating instructions and the specifications relating to the components in sections 5, "Technical description", and 7, "Startup", must be observed. For technical data, refer to the data sheet and/or the list of equipment.
The instructions in item 6.9 must be observed.
Damaged bolts must be replaced with new bolts of the same type and strength class.

10.4 General inspection of the gear unit

The general inspection of the gear unit should be carried out by the Siemens Customer Service, as our engineers have the experience and training necessary to identify any components requiring replacement.

10.5 Lubricants

Note
The use of synthetic oil is not permissible.
The quality of the oil used must meet the requirements of the separately supplied BA 7300 operating instructions, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in table "T 7300" (for a link to the Internet, see the back cover), as they have been tested and meet the requirements.
Note
To avoid misunderstandings, we should like to point out that this recommendation is in no way intended as a guarantee of the quality of the lubricant supplied. Each lubricant manufacturer is responsible for the quality of his own product.
Information on the type, viscosity and required quantity of the oil is given on the rating plate on the gear unit and/or in the supplied documentation.
The oil quantity shown on the rating plate is to be understood as an approximate quantity. The actual oil quantity to be put in is the MAX mark on the dipstick, when the insert shaft has been run out.
The BA 7300 manual relating to the gearunit lubrication and table "T 7300" containing the current lubricant recommendations of Siemens can also be consulted on the internet (see back cover).
The oils listed there are subjected to continuous tests. Under certain circumstances the oils recommended there may therefore later be removed from the range or replaced with further developed oils.
We recommend checking before any oil change whether the chosen lubricant is still approved by Siemens.
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11. Spare parts, customer service

11.1 Stocking spare parts

By stocking the most important spare and wearing parts on site you can ensure that the gear unit is ready for use at any time.
To order spare parts, refer to the spareparts list.
For further information refer to the spareparts drawing stated in the spareparts list.
NOTICE
Material damage
Risk of damage to the gear unit through improper use. Siemens guarantees only the genuine spare parts supplied by Siemens. Nongenuine spare parts have not been tested nor approved by Siemens. Nongenuine spare parts may alter technical characteristics of the gear unit, thereby posing an active or passive risk to safety. Siemens will assume no liability or guarantee for damage caused by spare parts not supplied by Siemens. The same applies to any accessories not supplied by Siemens.
Please note that certain components often have special production and supply specifications and that Siemens supplies you with spare parts which comply fully with the current state of technical development as well as current legislation.
When ordering spare parts, always state the following:
Order number, position Type, size Part number Quantity

11.2 Addresses for ordering spare parts and customer service

When ordering spare parts or requesting a service specialist, please contact Siemens first.
Siemens AG Am Industriepark 2 46562 Voerde
Tel.: +49 (0)2871 / 92‐0 Fax: +49 (0)2871 / 92‐1544
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12. Declarations

12.1 Declaration of incorporation

Declaration of incorporation
in accordance with Directive 2006/42/EC, Annex II 1 B
The manufacturer, Siemens AG, 46395 Bocholt, Germany, declares with regard to the partly completed machinery
Gear unit
H3LV
Sizes 6 to 18
for driving lauter-tun spent-grain cutting machines:
– The special technical documents described in Annex VII B have been prepared.
– The following basic health and safety requirements set out in Directive 2006/42/EC, Annex I,
are applied and are satisfied:
1.1, 1.1.2, 1.1.3, 1.1.5, 1.2.4.4, 1.2.6, 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.6, 1.3.7, 1.3.8.1, 1.4.1, 1.4.2.1, 1.5.1,
1.5.2, 1.5.4, 1.5.5, 1.5.6, 1.5.7, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.5.13, 1.5.15, 1.6.1, 1.6.2, 1.7.1, 1.7.1.1, 1.7.2,
1.7.4, 1.7.4.1, 1.7.4.2, 1.7.4.3
– The partly completed machinery must not be put into service until it has been established that the
machinery into which the partly completed machinery is to be incorporated has been declared to be in conformity with the provisions of Directive 2006/42/EC, as appropriate.
– The manufacturer undertakes, in response to a reasoned request by the national authorities,
to transmit in electronic form relevant information about the partly completed machinery.
– The person authorised to compile the relevant technical documentation is:
Mark Zundel (I DT MD AP EMEA VOE OE)
Voerde, 2014‐06‐30
Voerde, 2014‐06‐30
Mark Zundel
(I DT MD AP EMEA VOE OE)
Dr. Bernhard Hoffmann
(I DT MD AP)
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Page 72
Further Information:
"FLENDER gear units" on the Internet
www.siemens.com/gearunits
"FLENDER couplings" on the Internet
www.siemens.com/couplings
Service & Support:
http://support.automation.siemens.com/WW/view/en/10803928/133300
Lubricants:
http://support.automation.siemens.com/WW/view/en/42961591/133000
Siemens AG Industry Sector Mechanical Drives Alfred-Flender-Straße 77 46395 Bocholt GERMANY
Subject to modifications
Š Siemens AG 2014
www.siemens.com/drivetechnologies
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