Siemens KMS, Flender KMP Series, Flender KMPS Series, Flender KMPP Series Assembly And Operating Instructions Manual

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Page 1

Vertical mill gear unit

KMS Sizes 225 to 850

Assembly and operating instructions BA 9137 en 12/2015

FLENDER gear units

Page 2

echnical data

Vertical mill gear unit

General notes

KMS Sizes 225 to 850

Assembly and operating instructions

Translation of the original assembly and operating instructions

Safety instructions

ransport and

storage

echnical

description

Fitting

Startup

Operation

Faults, causes and remedy

Maintenance and repair

Spare parts, customer service

Declarations

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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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Foreword

The term "Assembly and operating instructions" will in the following also be shortened to "instructions" or "manual".

The term directive 94/9/EC, if the product is put on the market by 19.04.2016, and to the version designed in conformity to directive 2014/34/EU, if the product is put on the market on or after 20.04.2016.

"2014/34/EU" used in these instructions applies to the version designed in conformity to

Symbols in these assembly and operating instructions

This symbol additionally indicates an imminent risk of explosion in the meaning of Directive 2014/34/EU.

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

yellow Oildraining point white

red Oil level red

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.

red

Connection for vibrationmonitoring device

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1. Technical data 8.....................................................

1.1 General technical data 8...............................................................

1.2 Marking of the gear unit designed in accordance with Directive 2014/34/EU 9.................

1.2.1 Ambient temperature 9................................................................

1.3 Measuring-surface sound pressure level 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 13......................................

3.3 The five safety rules 14.................................................................

3.4 Environmental protection 14.............................................................

4. Transport and storage 15.............................................

4.1 Content and check of the scope of delivery 15.............................................

4.2 Transport 15..........................................................................

4.3 Storing the gear unit 18.................................................................

4.4 Standard coating and corrosion prevention 18.............................................

4.4.1 Exterior preservation of metallic bright exterior surfaces 20..................................

4.4.1.1 Maximum durability period of the exterior preservation 20....................................

4.4.1.2 Prolongation of the preservation of metallic bright exterior surfaces of the gear unit 20...........

4.4.2 Preservation of the interior of the gear unit 20..............................................

4.4.2.1 Maximum durability period of the interior preservation of the gear unit 20.......................

4.4.2.2 Combined storage/packaging 22.........................................................

4.4.3 Renewal of the interior preservation of the gear unit for longer periods of storage of the gear unit

4.4.3.1 Renewal of the gear unit interior preservation with "Castrol Corrosion Inhibitor N 213" 26.........

4.4.3.2 Renewal of the gear unit interior preservation through complete filling with preservative or

4.4.3.3 Renewal of the interior preservation of the gear unit using the oil- supply system 30.............

that has not been taken into operation yet 26...............................................

operating oil. 28.......................................................................

5. Technical description 32..............................................

5.1 General description 32.................................................................

5.2 Delivery condition of the gear unit 32.....................................................

5.3 Lubrication 33.........................................................................

5.3.1 Hydrodynamic lubrication of the axial tilting pad thrust bearings 33............................

5.3.2 Hydrodynamic lubrication of the axial tilting pad thrust bearings in gear units

5.3.3 Hydrodynamic lubrication of the axial tilting pad thrust bearings with radial piston pump 34.......

5.3.4 Labyrinth seals 34.....................................................................

5.4 Drive coupling 35......................................................................

5.5 Heating 35............................................................................

5.6 Heating element on ex-version 36........................................................

5.6.1 Oil level monitoring of the heating elements 36.............................................

5.7 Indication of oil level 36.................................................................

5.8 Oil temperature monitoring 37...........................................................

5.9 Oil level monitoring system 37...........................................................

with hydrostatic start-up assistance 33....................................................

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6. Fitting 38.............................................................

6.1 General assembly information 38........................................................

6.2 Set-up conditions 39...................................................................

6.2.1 Dimensions and weights 39.............................................................

6.2.2 Lifting device 39.......................................................................

6.3 Preparatory measures for gear unit installation 40..........................................

6.3.1 Maintaining preservation if the gear unit has been opened in the meantime 41..................

6.3.2 Foundation 42.........................................................................

6.4 Assembly of the gear unit 42............................................................

6.5 Installing the pipework 43...............................................................

6.6 Pickling of adapted pipes 43.............................................................

6.7 Installing the couplings 44...............................................................

6.8 Installing the motor 45..................................................................

6.9 Assembly of loose add-on parts included in the delivery 46..................................

6.10 Welding work on the mill 46.............................................................

6.11 Final work 47..........................................................................

6.12 Screw connection classes, tightening torques and initial stressing forces 47....................

6.12.1 Screw connection classes 47............................................................

6.12.2 Tightening torques and initial stressing forces 48...........................................

7. Start-up 50...........................................................

7.1 Procedure before start-up 50............................................................

7.1.1 Removal of preservative agent from exterior 50............................................

7.1.2 Removal of preservative agent from interior 51.............................................

7.1.3 Draining preservative oils 53............................................................

7.1.4 Flushing before initial start-up 54.........................................................

7.1.4.1 Oil quantity for flushing 54...............................................................

7.1.5 Fill in operating oil 54...................................................................

7.1.5.1 Oil level 55............................................................................

7.1.5.2 Procedure for filling 55..................................................................

7.1.6 Oil-supply system 57...................................................................

7.1.7 Checks before start-up 57...............................................................

7.2 Start-up 59...........................................................................

7.2.1 Pre-lubrication phase 59................................................................

7.2.2 Initial start-up 59.......................................................................

7.2.3 Checking procedure 60.................................................................

7.3 Removal from service 60...............................................................

7.3.1 Renewal of the gear unit interior preservation on gear units having already been in operation 61...

7.3.1.1 Renewal of the interior preservation of the gear unit using the oil- supply system 61.............

7.3.1.2 Renewal of the gear unit interior preservation with "Castrol Corrosion Inhibitor N 213" 63.........

7.3.1.3 Renewal of the gear unit interior preservation through complete filling with preservative

7.3.2 Exterior corrosion prevention 66.........................................................

or operating oil 65......................................................................

8. Operation 67.........................................................

8.1 General 67............................................................................

8.2 Oil level 68............................................................................

8.3 Irregularities 68........................................................................

9. Faults, causes and remedy 70.........................................

9.1 General information on faults and malfunctions 70..........................................

9.2 Faults, causes and remedy 71...........................................................

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10. Maintenance and repair 74............................................

10.1 General notes on maintenance 74........................................................

10.2 Clean the gear unit 75..................................................................

10.3 Clean the air filter 75...................................................................

10.3.1 Replacing the air filter cartridge 76.......................................................

10.4 Flushing 76...........................................................................

10.5 Oil filling 76...........................................................................

10.6 Inspection 77.........................................................................

10.7 Maintenance 78.......................................................................

10.7.1 Examine water content of oil, conduct oil analyses 79.......................................

10.7.2 Change oil 80.........................................................................

10.7.3 Check tightness of screw connections 82.................................................

10.8 Welding work on the mill 82.............................................................

10.9 Vibration measurements 83.............................................................

10.10 Repair 84.............................................................................

10.11 General inspection of the gear unit 85.....................................................

10.12 Lubricants 85.........................................................................

11. Spare parts, customer service 86......................................

11.1 Stocking spare parts 86.................................................................

11.2 Addresses for ordering spare parts and customer service 86.................................

12. Declarations 87.......................................................

12.1 Declaration of incorporation 87..........................................................

12.2 EU declaration of conformity 88..........................................................

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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

⑨

⑩

(see item 1.2)

⑪ ⑫

Fig. 1: ATEX Rating plate on gear unit

① Company logo ② Serial number

③ Total weight (without oil filling) in kg ④ Special information ⑤ Type, size ⑥ Power rating P

Production site code / Order no. item seq. no. / Year built

*)Example

in kW or torque T2 in Nm

④

⑥

⑧

⑦ Rotation speed n ⑧ Rotation speed n

in min

-1

⑨ Oil data (oil type, oil viscosity, oil quantity) ⑩ Instruction manual numbers ⑪ Manufacturer and place of manufacture ⑫ Country of origin

KMS

For details regarding weight and further technical data, refer to the drawings in the gear unit documentation and the order-specific data sheet.

225

Size 225 … 850......................

Model S = Spur wheel section.....................

Area of use M = Vertical mill................

Gear unit type K = Bevel gear unit..............

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1.2 Marking of the gear unit designed in accordance with Directive 2014/34/EU

Table 1: ATEX identification for above-ground applications

Equipment

group

II 3 Dust (D) - -

a min.

a max.

Equipment

1.2.1 Ambient temperature

The specifications of Directive2014/34/EU apply to the ambient temperature range of from

- 20 °C to + 40 °C. By adopting various suitable measures, the gear unit may be used in ambient temperatures from - 40 °C to + 60 °C. However, the temperature range and the expanded temperature range must generally be approved by Siemens and be specified in the order text. In individual cases the permissible ambient temperature range specified on the rating plate always applies.

1.3 Measuring-surface sound pressure level

Explosion

group

Temperature

class

Mark

II 3 D 120 °C bck Ta..

A measuring-surface sound pressure level during operation cannot be specified, as the gear unit is operated without load during the test run on the Siemens test bench.

1.4 List of equipment

Note

All important accessory components are specified in the order specific equipment list including your technical data.

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2. General notes

2.1 Introduction

These instructions are a part of the gear unit delivery and must always be kept on hand near the gear unit.

NOTICE

Property damage

Damage to the gear unit or occurrence of operating failures is possible. All persons carrying out work on the gear unit must have read and understood the instructions and must adhere to them. Siemens accepts no responsibility for damage or disruption caused by disregard of these instructions.

The "FLENDER Bevel-helical gear unit" of the type "KMS" described in these instructions has been designed for driving a vertical mill.

The gear unit is designed only for the application specified in the order-specific gear unit documentation. Deviating operating conditions require new contractual agreements.

The gear unit is manufactured in accordance with the state of the art and is delivered in a condition ready for safe and reliable use. The gear unit complies with the requirements in Directive 2014/34/EU.

The gear unit may only be used and operated in accordance with the conditions laid down in the service and supply contract concluded between Siemens and the customer.

The gear unit described in these instructions conforms to the state of technical development at the time when these instructions went to print.

In the interest of technical further development we reserve the right to make changes to the individual assembly groups and accessory parts as we deem appropriate in order to increase their capacity and safety while maintaining their essential characteristics.

2.2 Copyright

The copyright to these instructions is held by Siemens AG.

These instructions may be used neither in full nor in part for competitive purposes nor be made available to third parties without our approval.

Technical enquiries should be directed to our factory or to one of our customer service centres:

Siemens AG Am Industriepark 2 46562 Voerde

Tel.: +49 (0)2871 / 92‐0 Fax: +49 (0)2871 / 92‐1544

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3. Safety instructions

WARNING

Risk of falling

Serious injury from falling is possible. The gear unit and its add-on parts must not be accessed during operation. The gear unit may only be accessed for maintenance and repair works during standstill of the gear unit.

WARNING

Risk of injury from changes made on own initiative

Changes made on own initiative are prohibited. This also pertains to the protection equipment that is installed as contact protection.

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 to the user and third parties,

─ ensure the safety and reliability of the gear unit,

─ avoid loss of use and environmental damage caused by incorrect use.

• During transport, assembly, installation, demounting, operation and maintenance of the unit, the relevant safety and environmental regulations must be observed at all times.

• 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 due regard for safety.

DANGER

Danger to life from switched on system

For carrying out work on the gear unit, the gear unit and an added on or separate oil-supply system must generally be set in standstill. The drive unit must be secured against accidental start-up (e.g. by locking the key switch or removing the fuses from the power supply). Attach a notice on the start switch stating clearly that work is in progress on the gear unit. At the same time, the complete system must be free from load so that no danger is caused during the disassembly work.

• No welding work may be done at all on the drive. The drive systems must not be used as an earthing point for electric-welding operations. Toothed parts and bearings can be irreparably damaged by welding.

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NOTICE

Property damage

Damage to the gear unit is possible. For gear units, which are operated together with electrical machines that generate power or that are supplied with power (e. g. motors, generators, etc.), it must be ensured that no current can flow through the gear unit. The flow of current can lead to irreparable damages on rolling bearings and gear teeth. Flow of current can arise, e. g. through short circuits, flash arcs, conductive dust layers, etc. Suitable measures may be: – Use of isolators – Earth the gear unit professionally

DANGER

Electrostatic discharge

Danger to life from ignition of present explosive atmosphere by electrostatic discharge. A potential equalisation in accordance with the applying regulations and directives must be carried out. Threaded holes for an earth connection are provided on the gear units or on the output flange. This work must always be done by trained electricians.

NOTICE

Property damage

Damage to the gear unit is possible. Immediately stop the gear unit by turning off the drive unit when inexplicable changes are noticed during the operation, such as a significantly increased operating temperature or changed sounds of the gear unit.

DANGER

Danger to life from rotating and/or moving parts

Risk of being gripped or drawn in by rotating and/or moving parts. Rotating and/or movable drive parts must be provided 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 requirements, notes and descriptions contained in these instructions are incorporated in its own instructions.

DANGER

Explosion hazard

Danger to life from ignition of present explosive atmosphere by use of unsuitable add-on parts. All add-on parts must satisfy the requirements in Directive 2014/34/EU. Simple electrical means (such as monitoring devices, switches, Pt100 measuring resistance) without identification in accordance with Directive 2014/34/EU must be connected intrinsically safe by means of suitable isolation amplifiers.

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DANGER

Electrostatic discharge

Danger to life from ignition of present explosive atmosphere by electrostatic discharge. The coating must not carry an electrostatic charge. The operator must ensure that highly effective mechanisms which can set up a charge in the coating are safely avoided.

• Removed safeguards must be refitted 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 screws 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 develop extreme temperatures.

WARNING

Risk of burns

Serious injury caused by burns on hot surfaces (> 55 °C) is possible. Wear suitable protection gloves and protection clothing.

WARNING

Risk of low temperatures

Serious injury from cold damage (pain, numbness, frostbites) on cold surfaces (< 0 °C) is possible. Wear suitable protection gloves and protection clothing.

WARNING

Risk of scalding

Serious injury from discharging hot operating media is possible when these are changed. Wear suitable protection gloves, protection glasses and protection clothing.

WARNING

Risk of eye injury

Small foreign matter such as sand or dust can get into the cover plates of the rotating parts and might be thrown back by these. Wear suitable protective glasses.

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Note

In addition to any generally prescribed personal protection equipment (protection shoes, protection clothing, helmet, etc.) handling the gear unit requires wearing suitable safety gloves and suitable

safety glasses.

Note

The gear unit complies with the requirements in Directive 2014/34/EU.

DANGER

Explosion hazard

Danger to life from ignition of a present explosive atmosphere is possible when carrying out assembly or disassembly works on the gear unit. The gear unit must not be assembled or disassembled in an explosive environment.

3.3 The five safety rules

For your personal safety as well as avoidance of property damages, please always observe the safety notices and the following five safety rules pursuant to the standard "DIN EN 50110-1" (Operations in powered-down condition) when working on the electrical components of the system. Apply the five safety rules from the start of the work on the machine, in the order cited above.

1) Disconnect Also disconnect the auxiliary currents, e. g. standstill heating.

2) Secure against re-connection.

3) Verify that disconnected parts are have zero voltage.

4) Earth and short-circuit.

5) Cover or shield adjacent live parts.

Upon completion of the work, undo the taken measures in the reverse order.

3.4 Environmental protection

• Existing packaging material must be disposed of in accordance with the regulations or be given to recycling.

• When changing oil, the used oil must be collected in suitable containers. Remove any pools of oil immediately using an oil binding agent.

• Preservative agents should be stored separately from used oil.

• Used oil, preservative agents, oil binding agents and oil-soaked cleaning cloths must be disposed of in accordance with environmental regulations.

• Disposal of the gear unit after its service life:

─ Drain all operating oil, preservative agent and/or cooling agent from the gear unit and dispose of it

in accordance with the regulations.

─ Depending on the national regulations, gear unit components and/or add-on parts may have to be

disposed of separately or be given to recycling.

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4. Transport and storage

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

4.1 Content and check of the scope of delivery

The content of the delivery is listed on the packing slip. The completeness of the scope of delivery must be checked against the packing slip directly on receipt. The packaging must not be opened for the check. Damages on packaging and/or items missing from the package must be reported to Siemens in writing within 2 weeks.

NOTICE

Property damage

Damage to the gear unit from corrosion is possible. The packaging must not be opened in any case. Otherwise, the durability period of the gear unit preservation will reduce.

Note

If the packaging is opened nonetheless, section 4.4 must be observed.

WARNING

Serious personal injury can be caused by a defective product

If there is any visible damage, the gear unit must not be taken into operation.

4.2 Transport

Note

The product weight is indicated on the rating plate.

DANGER

Danger to life

Danger to life from load falling down due to deficient attachment. Do not stay underneath suspended loads. When attaching, lifting, lowering and shifting the load, pay attention to the following: – Observe the load limits – Proper fastening of the attachment equipment – Centre of gravity possibly being off centre – Even load distribution on load-bearing equipment with multiple load hook-ups – Low process speed – Oscillating the load and/or attaching the load to objects

or building parts is prohibited. – Load hooks may not be loaded at their tip – Set down products only on even, non-slipping and stable underground

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WARNING

Risk of crushing

Risk of being crushed by a transported component when the used lifting gear and load-bearing equipment is not suitable and the component comes loose. Attach the product for transport only on the marked attachment points. Lifting gear and load equipment must be used that has adequate load-bearing capacity. Observe the notes regarding load distribution on the packaging. When being lifted the product must be transported slowly and carefully in order to avoid personal injury and damage to the gear unit. For example, impact on free shaft ends might lead to damage on the gear unit. Gear units provided with pipework must be transported with particular care.

The gear unit is delivered in a fully assembled condition. If applicable, additional items are delivered packaged separately.

Depending on the size of the unit and transport route, the gear unit will have different types of packaging. Unless agreed otherwise by contract, the packaging complies with the Packaging Guidelines of the HPE (Federal Association of Wood Packaging, Pallets, Export Packaging).

The symbols marked on the packaging must be observed at all times. These 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 may only be transported by means of transport equipment suitable for this purpose. The gear unit should be transported without oil filling and be kept in/on the transport packaging. If the gear unit is in seaworthy packaging (wooden box), the attachment points marked on the packaging have to be used. If the gear unit is delivered without seaworthy packaging, the attachment points as shown in Figure 3 have to be used.

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Page 17

Fig. 3: Alternative attachment points

1 Wooden block

Note

The detailed illustration of the gear unit, the position of the attachment points, and the positioning of the wooden blocks for the protection of the gear unit during transport can be found on the dimensioned and transport drawings in the order-specific gear unit documentation.

NOTICE

Property damage

Damage to the gear unit is possible when using the wrong attachment points. Use only the lifting eyes provided to attach lifting gear to the unit. Attach slings with shackles to the eyebolts. Transporting of the gear 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. To prevent the housing, output flange and pipework from being damaged by the deflection of the transport rope, wooden blocks must be placed under the rope. The output flange of the gear unit must never be lifted.

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4.3 Storing the gear unit

The gear unit must be stored with a cover, placed on a vibration-free dry base in a sheltered place, in the position of the original packaging or in the position of use. Any storage methods deviating from this affect the durability period of the gear unit preservation (see item 4.4).

NOTICE

Property damage

Any damage to the coating may cause the failure of the exterior protective coating and consequently lead to corrosion. When temporarily storing the gear unit and any components supplied with it, the applied corrosion protection has to be preserved. Ensure that the coat is not damaged.

DANGER

Danger to life from the gear unit toppling or dropping

Risk of being crushed or struck by a gear unit toppling or dropping. Do not stack gear units on top of one another.

NOTICE

Property damage

Damage to the gear unit by deposit of foreign matter or moisture. If the gear unit is stored outdoors, it must be covered particularly carefully and it must be ensured that neither moisture nor foreign material can collect on the unit. Waterlogging must be avoided.

NOTICE

Property damage

Damage to the gear unit from external effects. Unless agreed otherwise by contract, the gear unit must not be exposed to harmful effects, such as chemically aggressive products. Special environmental conditions during transport (e.g. transport by ship) and storage (climate, termites) must be agreed on by contract.

4.4 Standard coating and corrosion prevention

The gear unit is to be provided with interior preservation on delivery (see "Technical data" in the gear unit documentation prepared specifically for the order), and the free shaft ends are to be provided with protective preservation (see Table 2 in item 4.4.1.1).

The properties of the exterior preservation when using a Siemens standard priming are resistant to:

─ weak acids and alkalis

─ solvents

─ weathering, also tropical

─ temperatures up to 120 °C / 248 °F (for short periods up to 140 °C / 284 °F)

If a different exterior coating is intended by the customer (contrary to the Siemens standard), the protection of the external coating will be within the customer's responsibility.

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NOTICE

Property damage

Damage to the gear unit from corrosion is possible. The gear unit is normally delivered completely ready with a priming and a finishing coat. Where gear units are delivered with a priming coat only, it is necessary to apply a finishing coat according to the standard procedures relevant for the specific application. The priming coat alone is not suitable to provide sufficient long-term corrosion protection.

Note

The coating complies with the requirements for the conductivity of the coating and the limitation of the layer thickness of the applied coating according to the standard "DIN EN 13463-1". Electrostatic charging is not expected if coatings have a thickness of <200µm. Where gear units are delivered with a priming coat only, it is necessary to apply a finishing coat according to the standard procedures relevant for the specific application. The priming coat alone is not suitable to provide sufficient long-term corrosion protection.

DANGER

Electrostatic discharge

Note

Examples of highly effective charge-generating mechanisms are: – the rapid passage of heavily dust-laden air near by – the sudden escape of particle-laden compressed gases – other heavy friction action (not manual cleaning or rubbing with cleaning cloths)

NOTICE

Property damage

Any damage to the coating may cause the failure of the exterior protective coating and consequently lead to corrosion. Ensure that the coat is not damaged.

Note

Corrosion prevention durations of the interior preservation depend on the kind of transport, type of packaging and the place of installation and/or storage (see Table 3 in item 4.4.2.1). The durability period of the exterior preservation and the related requirements can be found in Table 2 under item 4.4.1.1. The warranty starts upon notification of readiness for delivery (see "Technical data" in the gear unit documentation). The provided interior gear unit preservation is also shown in "Technical data".

When storing differently from the durability periods of preservation as specified in Tables 2 and 3 applicable for the gear unit, the interior preservation must be prolonged (see item 4.4.3) and if necessary, the exterior preservation must be renewed (see item 4.4.1).

Each prolongation of the interior preservation and any renewal of the exterior preservation must be logged.

Note

The record must be kept with these instructions.

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4.4.1 Exterior preservation of metallic bright exterior surfaces

4.4.1.1 Maximum durability period of the exterior preservation

Table 2: Durability period for exterior corrosion prevention of shaft ends and other bright machined

surfaces

Durability

of protection

for indoor storage up

to 36 months

for outdoor storage

up to 12 months

The gear unit must be stored with a cover on a vibration-free, dry base in a place sheltered from

Preservative agent

Tectyl 846 K19 approx. 50 µm

Layer thickness Remarks

Long-term wax-based preservative agent:

– resistant to sea water

– and tropical conditions

– soluble with CH

weathering, in the position of use.

If the gear unit is stored outdoors, it must be covered particularly carefully and it must be ensured that neither moisture nor foreign material can collect on the unit. Waterlogging must be avoided.

4.4.1.2 Prolongation of the preservation of metallic bright exterior surfaces of the gear unit

In case storage periods exceed the periods specified in Table 2 under item 4.4.1.1, the exterior of the gear unit must be re-preserved using the preservative agent shown in Table 2.

• Clean the surfaces.

• Apply preservative agent (see table 2).

Note

Before start-up, all preservation coats have to be removed from the gear unit according to section 7.1.1.

compounds

4.4.2 Preservation of the interior of the gear unit

4.4.2.1 Maximum durability period of the interior preservation of the gear unit

Table 3 shows the maximum durability of the interior gear unit preservation, depending on the kind of transport, type of packaging and the setup or storage site.

Definition of climatic zones:

North Pole 90°N

Arctic Circle 66.5°N

Northern Tropic 23.5°N

South Pole 90°S

Equator 0°

Southern Tropic 23.5°S

Antarctic Circle 66.5°S

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Table 3: Maximum durability period of the interior preservation of the gear unit

Setup and transport

Setup in climatic zone A and at least 50 km

distance from larger bodies of

None or simple

transport packaging

Without sea

transport

salt water

With sea

transport

Transport in

seaworthy

packaging

With or without

sea transport

Storage

Packaging for

storage

Storage place of

packaged unit

maximum durability of the interior gear unit preservation HD (Durability Period)

months

Setup in climatic zone B and/or less than

50 km distance from larger bodies of

None or simple

transport packaging

Without sea

transport

salt water

With sea transport

Transport in

seaworthy

packaging

With or

without sea

transport

/ HD

packaging

covered at

least with

loose tarpaulin

seaworthy

packaging

exposed outdoors

covered with

loose tarpaulin

under roof

in closed, dry

exposed outdoors

under roof

in closed, dry

exposed outdoors

covered with

loose tarpaulin

under roof

in closed, dry

room

5 3 5 3 3 3

7 3 8 4 3 5

15 3 20 11 3 14

7 3 8 4 3 5

19 3 24 13 3 17

15 3 20 15 3 20

19 3 24 19 3 24

1) under roof: no direct exposure to sunlight and no direct contact with water (rain or draining water)

2) Seaworthy packaging: use of wooden box lined with bitumen paper. The content is sealed in foil and protected against moisture by addition of drying agents for the prescribed storage period.

Note

On the goods receipt, the seaworthy packaging must be inspected for damages. If damaged, the packing must be restored to its seaworthy condition.

Note

If different statements were made in agreement with the customer, as to the protective periods on precisely defined conditions, a description can be found in the order confirmation from Siemens.

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4.4.2.2 Combined storage / packaging

If the type of packaging and/or storage is changed within the durability period as HD to the existing preservation and the present type of packaging and/or storage, a new determined as the equivalent remaining durability period applicable as of the date of the change. For this purpose, the following formula has to be used:

If several packaging and/or storage types are combined the following formula must be applied as from the second change in packaging and/or storage types ( to determine the

= Storage period for the existing preservation

= Maximum durability period of the existing preservation

2äq

according to table 3 in item 4.4.2.1

= Maximum durability period after the change in the type of storage and/or packaging

according to table 3 in item 4.4.2.1

= Maximum remaining durability period after the change in the type of storage and/or

packaging

equivalent remaining durability period applying to the preservation:

n*äq

+ (HD

2äq

+ (1 *

n*1äq

* LD

) HD

equivalent remaining durability period > HD

n*1

) (

, which is applicable

2äq

)

n*1

has to be

2 äq

)

= Calculated durability period with the previous storage conditions

äq

n-1

= Actual duration of storage with the previous storage conditions

n-1

= Maximum durability period with the present storage conditions

n-1

äq

specified in table 2 in item 4.4.2.1

= Maximum durability period with the previous storage conditions

specified in table 2 in item 4.4.2.1

= Remaining durability period after change in the packaging and/or storage types

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Example:

─ A gear unit is stored exposed outdoors after sea transport, in climatic zone B, while it is kept in seaworthy

packaging

= 20 months

(climatic zone: for storage: seaworthy packaging, place of storage: exposed outdoors)

B, transport type: sea transport, transport packaging: seaworthy packaging, packaging

─ After 5 months (LD

besides the mill.

= 4 months

(climatic zone: for storage: no packaging, place of storage: covered with loose tarpaulin)

Now, the remaining durability period HD

The remaining durability period of the interior gear-unit preservation after changing the storage type is 3 months.

After one additional month (LD remaining durability period HD

Given:

), the gear unit is unpacked, covered with a loose tarpaulin, and placed outdoors

B, transport type: sea transport, transport packaging: seaworthy packaging, packaging

has to be calculated as follows:

2äq

) HD

) 4

), the gear-unit is placed outdoors exposed without packaging. Now, the

3äq

+ (1 *

2äq

+ (1 *

2äq

is to be calculated as follows:

+ 3months

2äq

The remaining durability period of the interior gear-unit preservation is 1.5 months after combining the storage types described in the example.

= 3 months (previously calculated)

2äq

= 1 month (actual duration of storage with the previous storage conditions)

= 3 months (maximum durability period with the present storage conditions

n-äq

specified in table 2 in item 4.4.2.1

= 4 months (maximum durability period with the previous storage conditions

specified in table 2 in item 4.4.2.1

= HD

3äq

+ (HD

3äq

* LD2) (

2äq

+ (3 * 1) (

+ 1.5months

3 4

)

HD HD

)

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Table 4: Examples of combined storage (maximally one change in storage) and the resulting remaining

durability of the interior preservation of the gear unit

Original place of storage of the gear

In which climatic zone is the construction site

located?

How was the gear unit packaged for transport? None or simple

How was the gear unit transported? without sea transport with or without sea transport

In what packaging was the gear unit stored at the

construction site?

Where/how was the packed unit stored?

in closed room or under roof

Setup in climatic zone A and at least 50 km

distance from larger bodies of salt water

Transport packaging

no packaging seaworthy packaging

covered with

loose tarpaulin

in closed room or under roof

Transport in

seaworthy packaging

Change in place of storage

New

Packaging for

storage

Storage place of

the newly

packaged unit

Change of

original storage

method after

1 month 4 1/2 4 5 4 1/2

3 months 4 3 4 1/2 4

6 months 3 1 4 3 1/2

Durability period of interior preservation of the gear unit for the new

storage method in consideration of the previous storage period in months

exposed

outdoors

covered with

loose tarpaulin

without

packaging

covered with

loose tarpaulin

exposed

outdoors

exposed outdoors

12 months 1

not permissible,

18 months

1 month 6 1/2 6 7 1/2 7 1/2

3 months 5 1/2 4 7 7

6 months 4 1 6 5 1/2

12 months 1 1/2

18 months

max. durability

period

15 months

not permissible,

max. durability

period

15 months

not permissible,

max. durability

period 7 months

not permissible,

max. durability

period 7 months

not permissible,

max. durability

period 7 months

not permissible,

max. durability

period 7 months

2 1/2 2

1 1/2 1/2

4 3

2 1

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Page 25

Original place of storage of the gear

In which climatic zone is the construction site

located?

How was the gear unit packaged for transport? None or simple

How was the gear unit transported? without sea transport with or without sea transport

In what packaging was the gear unit stored at the

construction site?

Where/how was the packed unit stored?

in closed room or under roof

Setup in climatic zone B and/or less than 50 km

distance from larger bodies of salt water

Transport packaging

no packaging seaworthy packaging

covered with

loose tarpaulin

in closed room or under roof

Transport in

seaworthy packaging

Change in place of storage

New

Packaging for

storage

without

packaging

Storage place of

the newly

packaged unit

exposed outdoors

Change of

original storage

method after

1 month 2 1/2 2 3 3

3 months 2 1 2 1/2 2 1/2

6 months 1 1/2

12 months

Durability period of interior preservation of the gear unit for the new

storage method in consideration of the previous storage period in months

not permissible,

max. durability

period

11 months

not permissible,

max. durability

period 4 months

not permissible,

max. durability

period 4 months

2 2

1 1/2 1

exposed

outdoors

covered with

loose tarpaulin

covered with

loose tarpaulin

exposed outdoors

not permissible,

18 months

1 month 3 1/2 3 5 5

3 months 3 1 4 1/2 4

6 months 2

12 months

18 months

max. durability

period

11 months

not permissible,

max. durability

period

11 months

not permissible,

max. durability

period

11 months

not permissible,

max. durability

period 4 months

not permissible,

max. durability

period 4 months

not permissible,

max. durability

period

4 months

not permissible,

max. durability

period

4 months

1 1/2

4 3 1/2

2 1/2 2

1 1/2 1/2

1) under roof: no direct exposure to sunlight and no direct contact with water (rain or draining water)

2) Seaworthy packaging: use of wooden box lined with bitumen paper. The content is sealed in foil and protected against moisture by addition of drying agents for the prescribed storage period.

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Note

On the goods receipt, the seaworthy packaging must be inspected for damages. If damaged, the packing must be restored to its seaworthy condition.

Note

If different statements were made in agreement with the customer, as to the protective periods on precisely defined conditions, a description can be found in the order confirmation from Siemens.

4.4.3 Renewal of the interior preservation of the gear unit for longer periods of storage of the gear unit that has

not been taken into operation yet

If the gear unit is taken into operation at a point in time, when the maximum durability of the interior preservation of the gear unit exceeds the durability as specified in Table 3 under item 4.4.2.1 or if it has reached remaining durability period specified in item 4.4.2.2, the interior preservation of the gear unit must be renewed following the expiration of the durability period.

4.4.3.1 Renewal of the gear unit interior preservation with "Castrol Corrosion Inhibitor N 213"

For the renewal of the gear unit interior preservation, the VCI gas discharging fluid "Castrol Corrosion Inhibitor N 213" is recommended.

CAUTION

Risk of injury

Risk of injury to eyes or hands from chemically aggressive operating substances. Wear suitable protection glasses and protection gloves. Remove any spilled oil immediately using an oil binding agent.

Note

In this renewal of the gear unit interior preservation, it must be ensured that the ambient and gear unit temperature is above 5 °C during filling.

The following control measures must be taken:

• The pressure, suction and/or return lines are sealed with blind flanges.

• The oil drain cocks on the gear unit and on the tilting pad thrust bearing chamber are sealed with screw plugs.

• The labyrinth seal on the output flange is sealed with the round cord hollow profile (13) and masked airtight (see Figure 4 in item 4.4.3.2).

The following procedure is recommended:

• Remove screw plugs that have been screwed in for transport instead of the air filter.

• Fill gear unit with "Castrol Corrosion Inhibitor N 213" through the openings of the air filters. Filling quantity: 1 litre per cubic metre of the entire free interior volume of the gear unit (to be enquired from Siemens). The interior volume of the gear unit can be ascertained in approximation also by means of the length x width x height of the gear unit.

• The vent holes of the air filter for the gear unit have to be closed and sealed again with screw plugs (these must be replaced again at the start-up).

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NOTICE

Property damage

Corrosion is possible when the gear unit is opened for too long. Close the gear unit airtight again, at the latest one hour after opening.

Table 5 shows the maximum durability period for the preservation renewal with "Castrol Corrosion Inhibitor N 213" depending on the packaging and setup or storage site. The definition of climatic zones can be found in item 4.4.2.1.

Note

If the gear unit is transported after the preservation was renewed, the durability period according to Table 3 in item 4.4.2.1 has to be observed.

Table 5: Maximum durability period of the preservation renewal with

"Castrol Corrosion Inhibitor N 213"

Packaging for

Storage

packaging

covered at least

with

loose tarpaulin

seaworthy

packaging

Setup in climatic zone A and at

least 50 km distance from larger

Storage place of

packaged unit

exposed outdoors 5 3

covered with loose

tarpaulin

under roof

in closed,

dry room

exposed outdoors 8 5

under roof

in closed,

dry room

exposed outdoors

covered with loose

tarpaulin

under roof

in closed,

dry room

bodies of salt water

Maximum durability period of the preservation renewal with

"Castrol Corrosion Inhibitor N 213" (in months)

8 5

20 14

24 17

20 20

24 24

Setup in climatic zone B and/or

less than 50 km distance from

larger bodies of

salt water

1) under roof: no direct exposure to sunlight and no direct contact with water (rain or draining water)

2) Seaworthy packaging: use of wooden box lined with bitumen paper. The content is sealed in foil and protected against moisture by addition of drying agents for the prescribed storage period.

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NOTICE

Property damage

With larger filled-in quantities of the "Corrosion Inhibitor N 213" (above 5 % of the operating oil quantity), the mixture of operating oil and "Corrosion Inhibitor N 213" must not be used as operating oil. Before start-up, the remaining "Corrosion Inhibitor N 213" has to be drained and the gear unit must be flushed thoroughly with operating oil (in this regard, see item 10.4.)

NOTICE

Property damage

Damage to the gear unit is possible. The gear unit may not be turned.

Note

Before start-up of the gear unit, the measures according to section 7.1 and 7.2 have to be carried out.

4.4.3.2 Renewal of the gear unit interior preservation through complete filling with preservative or operating oil.

A further possibility for renewal of the gear unit interior preservation is to fill the gear unit with preservative or operating oil until the oil level indicator on the tilting pad thrust bearing chamber shows it is filled completely with oil. The durability of this kind of preservation depends on the used oil and has to be enquired with the oil manufacturer.

For the complete filling, a sealing cap (can be obtained from Siemens) must be mounted on the gear unit for sealing the input shaft.

The preservation will remain intact for as long as the gear unit remains sealed and the storage durability of the oil is not exceeded.

Note

Refer to the BA 7300 operating instructions supplied separately for the approved preservative oils. The viscosity of the operating oil is stated on the rating plate. For better filling it is recommended to choose an oil with low viscosity, which however is not suitable for later operation of the gear unit and will thus have to be fully drained. When filling, the filled-in oil should have a maximum viscosity of 7500 cSt (at VG 320 > 0°C). For complete filling, also the later operating oil can be used, which has to be drained to the operating oil level before start-up.

NOTICE

Property damage

Insufficient lubrication due to the incompatibility of the oils. If the gear unit is preserved with "TRIBOL 1390" (see "Technical data"), it must be flushed before the complete filling (see BA 7300). This flushing oil must not be used for operation.

NOTICE

Property damage

Corrosion damages on the gear unit possible from the loss of the preservative effect Filled gear units can become untight and the gear unit oil might leak. Tightness of the filled gear units must be monitored. Leaks must be removed. Siemens does not accept any liability for damages that are caused from leaking gear unit oil during storage.

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Page 29

The following control measures must be taken:

• The pressure, suction and/or return lines (6, 8, 9) are sealed with blind flanges.

• The oil drain cock of the tilting pad thrust bearing chamber (10) is sealed with a screw plug.

• The vent holes for the gear unit (4) are sealed with a screw plug.

• The labyrinth seal of the output flange is sealed with the round cord hollow profile (13) and masked airtight.

The following procedure is recommended:

• Seal input shaft with a sealing cap (3).

• Seal bottom oil drain of the sealing cap (2) with a screw plug.

• The oil to be filled in must be filtered beforehand with a filter mesh of 25 μm (0.0010 inch).

Fig. 4: Gear unit features for preservation measures

1 Breather of sealing cap 2 Oil drain sealing cap 3 Sealing cap 4 Air filter (gear unit) 5 Oil level indicator (gear unit) 6 Suction line (gear unit) 7 Oil drain (gear unit)

8 Pressure line (gear unit) 9 Pressure line (tilting pad thrust bearing

chamber)

10 Oil drain tilting pad thrust bearing

chamber

12 Indication of oil level (tilting pad thrust

bearing chamber)

13 Round cord hollow profile

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• Fill sealing cap on the input shaft through the ventilation of the sealing cap (1) The ventilation (1) is to be closed, only once the oil filling of the gear unit is completed, unless oil is escaping from this opening before then.

• For filling, remove the sealing cap that seals the oil drain cock of the gear unit (7). The gear unit must be filled with oil through the bottom oil drain cock of the gear unit (7).

Note

The gear unit will be filled completely only when the oil level indicator on the tilting pad thrust bearing chamber (12) is filled completely with oil.

• The lower oil drain cock on the gear unit (7) must be provided and sealed with a screw plug.

• If not already done beforehand, close ventilation of the sealing cap (1).

Note

Before the start-up of the gear unit, the measures according to section 7.1 and 7.2 have to be carried out.

4.4.3.3 Renewal of the interior preservation of the gear unit using the oil- supply system

The prerequisite for this is that the gear unit is still below the mill and connected to the oil-supply system. "Castrol Alpha SP 220 S" or "Tribol 1390" can be used as preservative agent. The oil level must never be below the MIN mark on the oil level indicator of the main gear unit, the tilting pad thrust bearing chamber and/or on the oil-supply system (if the model has a tank, also see the operating manual of the oil-supply system). For this purpose, the oil-supply system has to be switched on and the gear unit must be turned without load (at least 1 rotation on the output shaft). The oil must be drained, the gear unit and oil-supply system be closed, masked and sealed airtight. Air filters have to be replaced for sealing caps and be sealed. The gear unit has to be sealed airtight with a round cord hollow profile between the gear unit housing and the output flange. The labyrinth seals on the input shaft and on the output flange must be masked airtight within 1 hour.

Note

Clean the air filters thoroughly (see item 10.3) and keep it in a safe place (these will be required when starting up again).

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Table 6: Maximum durability period of the interior preservation of the gear unit through operating the

oil-supply system.

Packaging for

Storage

packaging

covered at least

with

loose tarpaulin

seaworthy

packaging

Setup in climatic zone A and at

least 50 km distance from larger

Storage place of

packaged unit

exposed outdoors 5 3

covered with loose

tarpaulin

under roof

in closed,

dry room

exposed outdoors 8 5

under roof

in closed,

dry room

exposed outdoors

covered with loose

tarpaulin

under roof

in closed,

dry room

bodies of salt

water

Maximum durability period of the preservation renewal through

operation of the oil-supply system (in months)

8 5

20 14

24 17

20 20

24 24

Setup in climatic zone B and/or

less than 50 km distance from

larger bodies of salt water

1) under roof: no direct exposure to sunlight and no direct contact with water (rain or draining water)

2) Seaworthy packaging: use of wooden box lined with bitumen paper. The content is sealed in foil and protected against moisture by addition of drying agents for the prescribed storage period.

Note

Before restarting the gear unit, the measures according to section 7.1 and 7.2 have to be carried out.

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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 Bevel- helical gear unit" of the type "KMS" designed for driving a vertical mill.

The axial and radial forces resulting from the grinding process are led into the foundation through the gear unit housing.

A detailed illustration of the gear unit is contained the drawings in the gear unit documentation.

NOTICE

Property damage

Destruction of the gear unit or gear unit parts from wrong rotation direction is possible. The gear unit is approved for one direction of rotation only. Observe the direction-of-rotation arrows on the housing.

5.2 Delivery condition of the gear unit

The input shaft of the gear unit is equipped with a radial shaft sealing ring (1), which is installed hidden and ensures the necessary airtight sealing of the gear unit interior for the specified preservation period (see Figure 5). Removing the radial shaft sealing ring during the start-up is not required. Should the radial shaft sealing ring no longer fulfil its sealing function after start-up, this does not impede the reliability of the shaft sealing.

A round cord hollow profile (2) is used as sealing between the gear unit housing and the output flange. This seal additionally serves for the airtight sealing of the gear unit interior for the specified preservation period.

If the gear unit is opened (e.g. by removing the adhesive tape on the labyrinth seal of the input shaft and/or the output flange, by removing the round cord hollow profile (2) or by opening a lid or screw plug), the start-up must take place within one week or the gear unit must be re-preserved according to item 4.4.3.

1 Radial shaft sealing ring 2 Round cord hollow profile

Fig. 5: Arrangement of the round cord hollow profile and radial shaft sealing ring (schematic

illustration)

NOTICE

Property damage

Corrosion is possible when the gear unit is opened too early. Any opening of the gear unit (e.g. by removing the adhesive tape on the input shaft or on the output flange, removing the round cord hollow profile, or by opening a lid or a screw plug) reduces the guaranteed preservation period. If the gear unit is opened, it must be taken into operation within one week. If the start-up is delayed, special measures are necessary to maintain preservation (see item 4.4.3).

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5.3 Lubrication

The lubrication and cooling is provided by continuous oil circulation through a separate oil-supply system. To prevent vibration and to compensate for heat expansion, compensators are provided in the pipe system.

Note

When operating and servicing the components of the oil supply system, observe the operating instructions of the components. For technical data, refer to the data sheet and/or the list of equipment. For a detailed illustration of the gear unit and oil-supply system, refer to the drawings in the gear unit documentation.

The kind of lubrication can be found on the order-specific equipment list, the lubrication diagram and the "Technical Data Sheet" of the gear unit. Depending on the gear unit version, one of the following three lubrication systems is installed in the gear unit.

Toothed parts and rolling bearings are force-lubricated and cooled through the low-forced lubrication circuit.

5.3.1 Hydrodynamic lubrication of the axial tilting pad thrust bearings

In low ambient temperatures, the oil must be pre-warmed. If agreed by contract, immersion heaters will be installed in the gear unit housing or the oil tank, or a separate heating circuit will be provided (see equipment list and lubrication diagram).

The oil is drawn in by the oil pump, cleaned in the double-changeover filter, which is fitted with an optical and electrical contamination indicator, then cooled in the cooler and conducted to the lubricating points. The oil flow is divided by valves and orifice plates or control valves for the lubrication of the gears and tilting pad thrust bearing.

Volumetric flow, pressure and temperature are constantly monitored by monitoring equipment. To prevent vibration and to compensate for heat expansion, compensators are provided in the pipe system.

5.3.2 Hydrodynamic lubrication of the axial tilting pad thrust bearings in gear units with hydrostatic start-up assistance

In addition to the hydrodynamic lubrication, part of the oil is fed immediately downstream of the cooler to the high-pressure pump through a branch circuit.

The high-pressure pump is designed as a radial piston pump and supplies a constant oil quantity at each connection. The oil is conducted to four axial thrust bearing segments distributed around the circumference. Before the mill is started, the oil is pumped between the pads and the race. A bearing oil film will form immediately. After 2 minutes in operation at operating speed, the high-pressure pump must be turned off.

Pressure switches without pressure transmitter this operating phase and the non-return valves built into the pads prevent the oil from backing up during normal operation.

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5.3.3 Hydrodynamic lubrication of the axial tilting pad thrust bearings with radial piston pump

In addition to the hydrodynamic lubrication, part of the oil is fed immediately downstream of the cooler to the high-pressure pumps through a branch circuit.

The high-pressure pumps are designed as radial piston pumps and supply a constant oil quantity at each connection. The same oil quantity is supplied to each bearing pad independently of the counter pressure. The oil connections are distributed so that no two adjacent pads are supplied by one high-pressure pump. The drive can continue to be operated throughout the time required for replacing a broken-down high-pressure pump.

In order to ensure that the high-pressure pumps are operating and no oil line is defective, the oil flows are monitored for minimum and maximum pressure. The pressure is set through the pressure actually exerted by the grinding rollers.

If the minimum setting of a pressure- or flow-monitored component is fallen short of, the main drive will be switched off. If the maximum pressure is exceeded, a warning is given or the main drive is shut off. The non-return valves built into the pads prevent the oil from backing up during normal operation.

5.3.4 Labyrinth seals

The input shaft and output flange are sealed with labyrinth seals. Air filters are provided on the housing to regulate the pressure.

Labyrinth seals are non-contacting seals. Labyrinth seals prevent wear and tear on the shaft, are maintenance-free and ensure favourable temperature characteristics.

Fig. 6: Labyrinth seal (schematic illustration)

1 Labyrinth seal on output flange 2 Labyrinth seal on input shaft

NOTICE

Property damage

Deficient lubrication is possible from oil leakage on the gear unit. For reliable operation, labyrinth seals require stationary, horizontal positioning away from dirty water and high dust concentrations. Overfilling of the gear unit can cause leakage, as can oil with high foam content.

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Page 35

5.4 Drive coupling

A flexible coupling is to be provided for the gear unit drive. Observe the operating instructions of the coupling for assembly, operation and maintenance of the coupling.

NOTICE

Property damage

Damage to the gear unit or individual components is possible from inadequate alignment. When installing the drives, make absolutely certain that the individual components are accurately aligned to one other. Unacceptable large errors in the alignment of the shaft ends to be connected due to angular and/or axial misalignments result in premature wear and material damage.

Note

If couplings of other manufacturers are used, the Siemens standard operating instructions for equivalent couplings provide the minimum requirements for the alignment of the coupling. It cannot be assured by Siemens whether these minimum requirements are sufficient in any case. If stricter requirements in the operating instructions of the supplier or similar document are defined, these will apply.

5.5 Heating

At low temperatures, it may be necessary to heat the gear oil before switching on the drive unit or even during operation. In such cases, e. g. heating elements can be used. These heating elements convert electrical energy into heat which is conducted to the surrounding oil. The heating elements are located in protective tubes inside the housing, thus making it possible to replace them without draining the oil beforehand.

Heating elements must fully submerge into the oil bath.

The heating elements can be controlled by a resistance thermometer or a temperature monitor, which emits a signal that is amplified when minimum and maximum temperatures are reached.

A detailed illustration of the gear unit and the position of the add-on parts can found in the drawings of the gear unit documentation.

DANGER

Explosion and fire hazard

Fire hazard or ignition of an explosive atmosphere by exposed heating rods is possible. Never switch on the heating elements, unless complete immersion of the heating element in the oil bath is ensured. If heating elements are installed afterwards, the maximum heating capacity (see table7) on the outer surface of the heating element must not be exceeded.

Table 7: Specific heating capacity P

as a function of the ambient temperature

Ambient temperature

(W/cm²)

0.9

0.8

+ 10 to 0

0 to - 25

°C

0.7

-25 to - 50

Note

Observe the information contained in the relevant operating instructions for operation and maintenance. For technical data and control information, refer to the list of equipment.

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Page 36

5.6 Heating element on ex-version

If heating elements are designed explosion-proof, the gear unit is additionally equipped with oil-level monitoring by means of a level limit switch. This monitoring checks the oil level of the gear unit for the submersion of the heating rods (see item 5.6.1).

5.6.1 Oil level monitoring of the heating elements

The gear unit is equipped with oil level monitoring. This monitoring system checks the oil level in the gear unit (minimum oil level for immersion of the heating rods).

The "Oil level too low" signal must be wired so that the heating elements are switched off when the signal is given. This ensures that the heating elements are not operated if these are not completely immersed.

DANGER

Explosion and fire hazard

Fire hazard or ignition of an explosive atmosphere by exposed heating rods is possible. Never switch on the heating elements, unless complete immersion of the heating element in the oil bath is ensured. If heating elements are installed afterwards, the maximum heating capacity (see table 7) on the outer surface of the heating element must not be exceeded.

A detailed illustration of the gear unit and the position of the add-on parts can found in the drawings of the gear unit documentation.

Note

Be sure to observe the operating instructions of the oil level monitoring device for operation and maintenance. The technical data and control information can be found in the data sheet prepared specially for the order or in the equipment list.

5.7 Indication of oil level

The gear unit is equipped with an oil level indicator (oil-level indicator with MIN and MAX mark) for a visual check of the oil level at standstill. The oil level is checked when the oil has cooled down (on the oil level indicator).

A detailed illustration of the gear unit and the position of the add-on parts can found in the drawings of the gear unit documentation.

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5.8 Oil temperature monitoring

The gear unit can be fitted with a Pt 100 resistance thermometer for measuring the oil temperature in the oil sump. In order to measure the temperatures and/or temperature differences, the Pt 100 resistance thermometer, which complies with the requirements of Directive 2014/34/EU, must be connected to a suitable analysis instrument provided by the customer.

Note

In order to measure the temperatures and/or the temperature differences with a Pt 100 resistance thermometer without evaluating instrument, the Pt 100 resistance thermometer must be connected to an evaluation instrument provided by the customer.

A detailed illustration of the gear unit and the position of the add-on parts can found in the drawings of the gear unit documentation.

Note

For operation and maintenance, the operating manuals in the order specific annex must be observed. For technical data and control information, refer to the list of equipment prepared specifically for the order.

5.9 Oil level monitoring system

The gear unit may be fitted with a filling level limit switch for oil level monitoring. The oil level monitoring device is designed for checking the oil level when the gear unit is at a standstill prior to start-up.

When using oil level monitoring, the oil level in the gear unit must be horizontal, regardless of the mounting position.

A detailed illustration of the gear unit and the position of the add-on parts can found in the drawings of the gear unit documentation.

Note

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6. Fitting

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

DANGER

Explosion hazard

Danger to life from ignition of a present explosive atmosphere is possible when carrying out assembly works on the gear unit. During the assembly of the gear unit, it must be ensured that no explosive atmosphere is present.

6.1 General assembly information

When transporting the gear unit, observe the notes in section 4. "Transport and storage".

Assembly work on the mill must be performed with great care by authorised, trained and qualified personnel. Siemens is not liable/does not extend a warranty for damages caused by incorrect implementation.

Adequate lifting gear must be available before beginning the fitting work.

NOTICE

Property damage

DANGER

Explosion hazard

Danger to life is possible from overheating of the gear unit due to external influences and thereby ignition of explosive atmosphere. Because it must be prevented that the gear unit heats up during operation through external influences such as direct sunlight or other sources of heat, suitable measures must be taken to avert such heating up. Suitable measures may be: – a sunshade roof – an additional cooling unit – a temperature monitoring device in the oil sump with a shut-off function. A heat concentration must be avoided. The ambient temperature range indicated on the rating plate must be adhered to.

Note

Any heat concentration must be prevented when using a sunshade roof. When using a temperature monitoring device, a warning signal must be emitted when the maximum permitted oil sump temperature is reached. If the maximum permitted oil sump temperature is exceeded, the drive must be shut off. Such a shut-off may entail a standstill of operations.

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DANGER

Electrostatic discharge

NOTICE

Property damage

Damage to the gear unit from dropping objects, heaping over, welding work or inadequate fastening. The operator must ensure the following: – The gear unit must be protected against dropping objects and heaping over. – No welding work may be done at all on the drive. – The gear unit must not be used as an earthing point for electrical welding work. – 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

When fitting in the vertical mill, the mill manufacturer's special instructions must be observed.

Note

Every time the drive is set in motion and any operation of the oil-supply system (with connected gear unit) represents a start-up.

6.2 Set-up conditions

As early as during the planning phase, sufficient space must be allowed around the gear unit for later care and maintenance work.

Note

It must be ensured that the oil can be drained and an adequate air supply is provided. It must be possible to check the internal parts through the holes in the inspection hole covers.

Upstream and downstream machines have to be arranged accordingly.

If the pipes connecting the gear unit and oil-supply system are included in the Siemens delivery, the installation plan is enclosed with the documentation.

6.2.1 Dimensions and weights

Refer to the drawings in the gear unit documentation and the order-specific data sheet for details regarding weight and further technical data.

6.2.2 Lifting device

Adequate lifting gear must be available before beginning the fitting work.

The load-bearing capacity of the lifting gear used or to be installed must correspond at least to the weight of the product that is to be transported (for details see section 1. "Technical data").

For information about transport please refer to section 4. "Transport and storage."

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6.3 Preparatory measures for gear unit installation

NOTICE

Property damage

Damage to the gear unit from corrosion is possible. The packaging must not be opened or damaged beforehand if the packaging is part of the preservation.

The products supplied are listed in the dispatch papers. Check for completeness immediately on receipt. Parts damaged and/or missing parts must be immediately reported in writing to Siemens.

• Before installation of the gear unit in the vertical mill, remove the packaging material and transport

equipment, and dispose of it according to regulations.

• Perform a visual check for damages and soiling.

Note

Adhesive tapes on the labyrinths and the round cord hollow profile between the gear unit housing and the output flange may only be removed directly before the start-up.

WARNING

Serious personal injury can be caused by a defective product

If there is any visible damage, the gear unit must not be taken into operation. The instructions in section 4. "Transport and storage", must be observed.

NOTICE

Property damage

Corrosion is possible when the gear unit is opened for too long. Any opening of the gear unit (e.g. by removing the adhesive tape on the input shaft or on the output flange, removing the round cord hollow profile, or by opening a lid) reduces the guaranteed preservation period. If the gear unit is opened, it must be taken into operation within one week. If the start-up is delayed, special measures are necessary to maintain preservation (see item 6.3.1).

NOTICE

Property damage

Damage to the sliding bearings is possible. The input shaft of the gear unit may be rotated maximally 1 time for positioning during installation, only when the tilting pad thrust bearing chamber is filled with oil up to the specified level.

• Remove the corrosion protection from all of the preserved surfaces using a suitable cleaning agent.

NOTICE

Property damage

Damage from inadequate stability of the gear unit is possible. The gear unit must be set up on a level, secure, vibration-free and rigid foundation. The levelness of the gear unit standing surface is especially important, as the contact pattern of the teeth and the carrying portion of the axial tilting pad thrust bearings depend on it and the service life of the gear unit is affected by it. Clean the gear unit and foundation set-up surface.

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DANGER

Danger to life

or building parts is prohibited. – Load hooks may not be loaded at their tip – Set down products only on even, non-slipping and stable underground

CAUTION

Risk of injury from chemical substances

Observe manufacturer's instructions for handling lubricants and solvents. Wear suitable protective clothing.

DANGER

Explosion hazard

Danger to life from ignition of solvent steams or other explosive atmosphere during cleaning work. The gear unit must not be cleaned in an explosive atmosphere. Observe also the following: – Keep away from sources of ignition. – Do not smoke. – Ensure adequate ventilation.

6.3.1 Maintaining preservation if the gear unit has been opened in the meantime

If a gear unit, which has been opened in the meantime for longer than 1 week, is left standing without transport packing in exposed meanwhile roofed surroundings and if it is not possible every 7 days to flush the gear unit for one hour with the oil-supply system and turn it for 15 minutes, the preservation can be maintained in part by applying the measures specified in item 4.4.3.

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6.3.2 Foundation

The foundation should be laid out in such a way that no resonance vibrations are created and that no vibrations are transmitted from adjacent foundations. The foundation structure on which the unit is to be assembled must be rigid. The structure must be laid out according to the weight and torque in consideration of the forces acting on the gear unit.

NOTICE

Property damage

0.1 mm per 500 mm (0.0036 inch per 1.5 ft) apart. The permissible deviation of the gear unit base from the horizontal plane is

0.2 mm per 1 m (0.0072 inch per 3 ft)

Note

The levelness of the mounted base plate (gear unit set-up surface) has to be documented before assembly of the gear unit. The record must be kept with these instructions. The foundation structure and the screw connection of the gear unit are within the responsibility of the mill manufacturer.

6.4 Assembly of the gear unit

The gear unit must be installed under the vertical mill in accordance with the mill manufacturer's instructions.

NOTICE

Property damage

The floor screw connection has to be provided according to the requirements of the mill manufacturer.

Note

The separate operating instructions have to be observed if "superbolt nuts" are used.

All other screws that are used for inspection or maintenance have to be tightened as specified in item 6.12.

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Once the gear unit is aligned, the pins must be fitted if these are specified in the dimensional drawing. Lateral stops can also be mounted in addition to prevent the gear unit from shifting.

NOTICE

Property damage

Destruction of the gear unit or gear unit parts from wrong rotation direction is possible. The gear unit is approved for one direction of rotation only. The direction of rotation of the motor must correspond to the direction indicated by the arrow on the gear unit input shaft.

Note

The alignment of the gear unit must be documented. The record must be kept with these instructions.

6.5 Installing the pipework

Pipework has to be checked for damages and dirt before assembly and be cleaned thoroughly and flushed with a fluid oil.

The pipework must be screwed on in accordance with the specifications on the drawings. Blank flanges and plugs must be removed beforehand. The screw connections seal metallically, while the associated seals must be used for the flanges.

NOTICE

Property damage

Damage to the gear unit from inadequate lubrication because of leakage from deformed pipework. No forces, moments or vibrations must work on the pipework flange connections during the pipework installation.

The pipework must be supported with struts according to the drawings of the gear unit documentation.

If the pipework is adapted at the construction site, the pipes must be carefully pickled and neutralised after welding (see item 6.6 "Pickling of adapted pipes").

6.6 Pickling of adapted pipes

CAUTION

Risk of injury from chemical substances

Chemical burns on face and hands from pickling solution. Wear protective glasses and gloves, ensure sufficient ventilation. Observe the manufacturer's instructions for the handling of pickling solutions.

• The lower end of each pipe must be sealed with a plug.

• Pickling solution: 33 % hydrochloric acid (HCl) diluted with the same quantity of water (H

Note

O).

Air bubbles must not under any circumstances be allowed to form on the inside of the pipes.

• The pipes must be filled with the pickling solution (acting time: 1 hour).

• Drain pickling solution completely out of the pipes without residues and dispose of it according to regulations.

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• Flush out pipes thoroughly with water (H2O).

• After emptying the pipes, they must be filled with a neutralising solution (sodium lye 3 % to 5 % NaOH) (neutralisation period 15 minutes). Flush out pipes once again with water (H

• Flush out pipes thoroughly with flushing oil through a 25 µm (0.001 inch) filter.

NOTICE

Property damage

Damage from corrosion. If the adapted pipes are not installed straight away, they must be carefully preserved. If the preserved pipework is reinstalled, item 6.5 has to be observed.

6.7 Installing the couplings

A flexible coupling is used for the gear unit output.

Before beginning the assembly, thoroughly clean shaft ends and the coupling parts.

Fit couplings on the shaft ends using the thread centring hole. Secure the couplings against being shifted axially.

Note

Couplings must be balanced in accordance with the specifications in the pertinent instructions manual. When operating and servicing the couplings, observe the operating instructions relating to the couplings.

O).

Increased system service life and reliability and reduced running noise can be achieved through the least possible radial and angular misalignment.

NOTICE

Property damage

Damage in the gear unit from blows or impact is possible. Fit the coupling with the aid of suitable fitting equipment. The running surfaces of the shaft must not be damaged when pulling on in the coupling parts.

NOTICE

Property damage

Note

For permissible alignment errors in couplings supplied by Siemens, refer to the instructions manuals for the couplings. When using couplings manufactured by other manufacturers, ask these manufacturers which alignment errors are permissible, stating the radial loads occurring.

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Note

• Record alignment dimensions.

Note

The record must be kept with these instructions.

6.8 Installing the motor

Align and the drive motor central axis of the input shaft of the gear unit when connected with the coupling and fix it in its position.

• Record the alignment of the motor.

Note

The record must be kept with these instructions.

Note

Observe the special operating instructions of the motor manufacturer for the assembly of the motor.

DANGER

Danger to life from airborne fracture pieces

Disregard for the precision of alignment can cause shaft rupture, resulting in serious injury and danger to life and limb. Align the gear unit precisely.

Damage to the gear unit or its components or add-on parts is possible. The accuracy of shaft-axis alignment is an important factor in determining the lifespan of shafts, bearings and couplings. Therefore, the deviation should be zero in nearly all cases. For this purpose, e.g. also the special requirements for the couplings can be found in the related operating instructions.

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6.9 Assembly of loose add-on parts included in the delivery

Seal in loose parts with thread connection.

NOTICE

Property damage

Damage to the gear unit possible from incompatibility of operating oil and sealing agent. No sealing agent must get into the gear unit.

• The plugs and/or sealing flanges must be removed, and the fittings supplied separately must be installed on the system according to the drawings in the gear unit documentation.

Note

Electrical lines and the motors and/or monitoring equipment must be connected in accordance with terminal diagrams, lists of equipment and general regulations. Electrical equipment for regulation and control must be wired in accordance with the equipment suppliers' instructions and Directive 2014/34/EU.

WARNING

Risk of personal injury from electrical shock

Risk of personal injury from electrical shock when connecting electrical components. Ensure zero voltage before connecting the devices.

6.10 Welding work on the mill

Note

Siemens will accept no liability for damage caused to the gear unit by welding work carried out on the mill.

DANGER

Risk of personal injury from electrical shock or through electrostatic discharge

Risk of electrical shock during welding work or risk of personal injury from ignition of a present explosive atmosphere caused by electrostatic discharge. Before welding work may be conducted on the mill, a potential equalisation must be provided according to the regulations and/or guidelines applicable for this purpose! The gear unit must not be used as an earthing point for welding operations. Optionally, an earth wire may be present on the tilting pad thrust bearing chamber, which must be connected with the output flange. For this purpose, use the threaded holes provided on the side of the output flange. When the welding work has finished, the earth cable must be removed from the output flange. Threaded holes for an earth connection are provided on the gear units or on the output flange. This work must always be done by trained electricians.

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6.11 Final work

□ After installation of the gear unit, check all screw connections for the connection of the gear unit and

the system for tight fit.

□ Check of the alignment after tightening the fastening elements. The alignment must not have changed.

□ Check that all devices that were uninstalled for transport reasons are reinstalled.

For this refer to the details in the data sheet, the list of equipment and the associated drawings.

DANGER

Explosion hazard

Ignition of an explosive atmosphere is possible from overheating of the gear unit with too low an oil level because of leakages. Existing oil drain cocks must be secured against accidental opening. If an oil-sight glass is used for monitoring the oil level, it must be protected against damage.

□ The gear unit must be protected against dropping objects.

□ Protective devices for rotating parts must be checked for correct seating. Contact with rotating parts

is not permitted.

DANGER

Electrostatic discharge

□ Cable entries must be protected against moisture.

6.12 Screw connection classes, tightening torques and initial stressing forces

6.12.1 Screw connection classes

The specified screw connections are to be fastened applying the tightening torques specified observing the table below.

Table 8: Screw connection classes

Fastening of

Inspection-hole cover

Protective hood

Screw connection

class

Tightening procedure

– Torque-controlled tightening with mechanical screwdriver

– Tightening with pulse screwdriver or impact wrench without

adjustment checking device

– Tightening by hand, using a spanner without

torque measurement

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6.12.2 Tightening torques and initial stressing forces

The tightening torques apply to friction coefficients of µ The friction coefficient µ

= 0.14 applies here to lightly oiled steel bolts, black-annealed or phosphatised

total

= 0.14.

and dry, cut counter threads in steel or cast iron. Lubricants which alter the friction coefficient are not permitted and might overload the screw connection.

Table 9: Initial stressing forces and tightening torques for screw connections of strength classes 8.8;

total

= 0.14

Tightening torque for screw

connection classes from table 8

Nominal

diameter of

the thread

M10

M12

M16

M20

M24

M30

M36

M42

M48

M56

M64

M72x6

10.9; 12.9 with a common friction coefficient of μ

Strength

class of the

Initial tensioning force for screw connection classes from table 8

bolt

C D E C D E

M min.

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

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

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Page 49

Nominal

diameter of

the thread

M80x6

M90x6

M100x6

Strength

class of the

Initial tensioning force for screw connection classes from table 8

bolt

M min.

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

Tightening torque for screw

connection classes from table 8

Note

Damaged bolts must be replaced with new bolts of the same type and strength class.

EDCEDC

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Page 50

7. Start-up

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

• Before and during the start-up, fill out the existing checklists (e. g. "Checklist for oil filling and oil change" and "Documentation sheet for oil change" in the separately enclosed operating instructions BA 7300) and file these with the documentation.

NOTICE

Property damage

Damage to the gear unit is possible. The gear unit must not be taken into operation if the required manual is not on hand. During start-up the initial run of the gear unit is load free, that is, without grinding material and roller pressure. There must not be an explosive environment. Any air barrier seal provided must be adjusted.

Note

Any setting of the drive in motion represents a start-up.

7.1 Procedure before start-up

The start-up must be carried out with great care by authorised, trained and qualified personnel. Siemens is not liable/does not extend a warranty for damages caused by incorrect implementation.

For this reason the operating instructions must be adhered to, particularly if maintenance work is carried out on the mill during which this is rotated and the gear unit along with it.

Before the initial start-up of the drive unit, the exterior and interior preservation might have to be removed if necessary (see items 4.4.1 to 4.4.4), the lubricant filled in, and various control measures carried out.

7.1.1 Removal of preservative agent from exterior

NOTICE

Property damage

Metallic bright surfaces without protection are susceptible to corrosion. For avoidance of corrosion, the exterior preservation may be removed only directly before the assembly.

• The corrosion prevention must be removed from the shaft ends in the area of the couplings that are to be mounted with suitable means (special solvent). The depreservation also applies to bright surfaces of the gear unit, onto which components are to be fitted.

CAUTION

Risk of injury from 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. Immediately remove any spilled oil immediately using an oil binding agent. Observe manufacturer's instructions for handling lubricants and solvents. Wear suitable protective clothing.

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7.1.2 Removal of preservative agent from interior

Note

The required measures prior to start-up are described in the following, as dependent on the basic preservation applied (see Technical data) on the gear unit. Detailed descriptions of the procedure as well as regarding the particularities, which must be taken into account, can be found in the following items 7.1.3 to 7.1.5 and in the separately provided operating instructions BA 7300.

Table 10: Measures before the start-up of gear units, which have not been taken into operation

before,

are as follows depending on the gear unit basic preservation / prolongation of

preservation.

Kind of basic

preservation

Castrol Alpha SP 220 S – None – Fill with operating oil.

Castrol Alpha SP 220 S

Castrol Alpha SP 220 S – Castrol Alpha SP 220 – Fill with operating oil.

Castrol Alpha SP 220 S – Castrol Tribol 1390

Castrol Tribol 1390 – None

Castrol Tribol 1390

Kind of preservation

prolongation

– Castrol Corrosion Inhibitor N 213

<= 5 % operating oil quantity

– Castrol Corrosion Inhibitor N 213

> 5 % operating oil quantity

– Completely filled with operating

oil (mineral oil or oil on PAO-basis)

– Completely filled with the

approved mineral oil (see specification in BA 7300)

– Castrol Corrosion Inhibitor N 213

<= 5% operating oil

Measures before

Start-up

– Fill with operating oil.

– Drain preservative oil, flush with

operating oil and fill with new operating oil.

– Drain preservative oil until operating oil

level is reached.

– Drain preservative oil and fill with new

operating oil.

– Flush with operating oil and fill with new

operating oil.

– Flush with operating oil and fill with new

operating oil.

– Flush with operating oil and fill with new

operating oil.

Castrol Tribol 1390

Castrol Tribol 1390 – Castrol Alpha SP 220

Castrol Tribol 1390 – Castrol Tribol 1390

– Castrol Corrosion Inhibitor N 213

> 5 % operating oil

– Completely filled with operating

oil (mineral oil or oil on PAO-basis)

– Completely filled with the

approved mineral oil (see specification in BA 7300)

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– Drain preservative oil, flush with

operating oil and fill with new operating oil.

– Drain preservative oil, flush with

operating oil and fill with new operating oil.

– Drain preservative oil, flush with

operating oil and fill with new operating oil.

– Flush with operating oil and fill with new

operating oil.

– Flush with operating oil and fill with new

operating oil.

Page 52

NOTICE

Property damage

With larger filled-in quantities of the Corrosion Inhibitor N 213 (above 5 % of the operating oil quantity), the mixture of operating oil and Corrosion Inhibitor N 213 must not be used as operating oil. The gear unit must be flushed thoroughly with operating oil before start-up after draining the mixture of operating and preservative (in this regard, see item 10.4.)

Table 11: Restart of preserved gear units, which have already been in operation

Kind of operating oil Kind of preservation Procedure before start-up

Mineral oil

Oil on PAO-basis

Mineral oil

Oil on PAO-basis

Mineral oil

Oil on PAO-basis

Mineral oil

Oil on PAO-basis

Mineral oil

Oil on PAO-basis

– Castrol Corrosion Inhibitor N 213

<= 5% operating oil

– Castrol Corrosion Inhibitor N 213

> 5% operating oil

– Completely filled with the

approved oil (see specification in BA 7300)

– Castrol Alpha SP 220 – Fill with operating oil.

– Tribol 1390

– Fill with operating oil.

– Drain preservative oil, flush with

operating oil and fill with new operating oil.

– For operating oil: drain oil until operating

oil level is reached.

– Other than operating oil: drain oil and fill

with new operating oil.

– Flush with operating oil and fill with new

operating oil.

NOTICE

Property damage

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7.1.3 Draining preservative oils

For the position of the oil draining points is marked on the dimensioned drawing in the gear unit documentation.

• Place suitable containers under the oil drain points.

• Unscrew the oil drain plug and/or open the oil drain cock.

• Remove preservative oil from the housing using a suitable container; to do so, unscrew any existing residual oil drain plugs.

• Dispose of the residue of the preservative oil in accordance with regulations.

CAUTION

Risk of injury from 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 here. Remove any spilled oil immediately using an oil binding agent. Observe the manufacturer's instructions for handling lubricants and binding agents. Wear suitable protective clothing.

• Screw the oil drain plug back in and/or close oil drain cock again.

• Screw back in any screws of the residual oil drain that have been.

Fig. 7: Oil filling and oil draining point - gear unit

1 Oil drain of the gear unit 2 Oil drain of tilting pad thrust bearing

4 Oil level tilting pad thrust bearing 5 Air filter gear unit

chamber

3 Oil level gear unit

A detailed illustration of the gear unit and the position of the add-on parts can found in the drawings of the gear unit documentation.

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7.1.4 Flushing before initial start-up

In general, it must be differentiated between flushing prior to the initial start-up and flushing before or after repairs and maintenance work (see item 10.4 "Flushing").

Flushing before initial start-up serves to minimise residues from previous lubricating oils or preservative agents.

Flushing should be carried out with the selected service lubricating oil. Lower viscosities (e.g. VG 46 or VG 100) of oil of the same grade and brand as that one used as operating lubricating oil may also be used as flushing oil.

• Put in flushing oil. For flushing, the gear unit and/or the tank of the oil-supply system must be filled with sufficient oil, so that the oil pump of the oil-supply system can be operated for flushing (see item 7.1.4.1 "Oil quantity for flushing").

• Flushing times: For flushing, operate the oil pump of the low-pressure lubricating circuit for at least 6 hours. If a high-pressure lubrication circuit is present, it must be switched on after 2 minutes.

NOTICE

Property damage

Damage to the gear unit and the oil-supply system is possible from soiling of the oil. After flushing, the oil must be carefully drained off through the oil drain cocks (see Figure 7 in item 7.1.3) on the gear unit and the oil-supply system. It may be re-used only as flushing oil. Clean the flushing oil before re-use. The flushing oil must be filtered beforehand or during filling using a nominal filter mesh of 25 μm (0.0010 inch). The flushing oil can be reused for a maximum of six flushing operations.

7.1.4.1 Oil quantity for flushing

For flushing, the gear unit and/or the tank of the oil-supply system must be filled with sufficient oil, so that the oil pump of the oil-supply system can be operated for flushing, without air being aspired. The flushing oil quantity may be up to 100 % of the total oil filling required for operations, depending on the gear unit model. On the delivery of the gear unit, the connecting pipework, and the oil-supply system by Siemens, the total oil filling quantity can be found in the technical data of the order-specific gear unit documentation.

7.1.5 Fill in operating oil

Data, such as oil type and oil viscosity can be found in the order-specific "Technical data". The total operating oil quantity for the gear unit, the oil-supply system, and the pipework can be found in the set-up plan. If the oil-supply system and the pipework are not included in the scope of delivery by Siemens, the operating oil quantity for the gear unit is shown on the rating plate (see section 1. "Technical data").

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7.1.5.1 Oil level

Fill in as much oil so that the required oil level of the gear unit is reached (MIN and MAX mark on the oil level indicator of the main gear unit, the tilting pad thrust bearing chamber, (see Figure 7 in item 7.1.3) and/or on the oil-supply system (if the model has a tank)), while the gear unit is stopped and the oil pump of the oil-supply system (low-pressure lubrication circuit) is in operation (also see the operating instructions for the oil-supply system).

Explosion hazard

Ignition of an explosive atmosphere is possible from overheating of the gear unit with too low an oil level. Notice the oil level. The oil level must never be below the MIN mark on the oil level indicator of the main gear unit, the tilting pad thrust bearing chamber and/or the oil-supply system (if the model has a tank, also see operating instructions for the oil-supply system). Fill up oil if necessary.

Risk of injury from chemical substances

DANGER

CAUTION

7.1.5.2 Procedure for filling

Note

The descriptions of the procedure as well as the particularities to be considered regarding the topic "Filling in new gear unit oil" and additional topics relating to the handling of the gear unit and/or the preservative oil are contained in the separately provided operating instructions BA 7300.

Please also notice the following information and processes in addition:

• Fill out the existing checklists and logs (e. g. "Checklist for oil filling and oil change" and "Documentation sheet for oil change" in the separately enclosed operating instructions BA 7300) and file these with the documentation.

NOTICE

Property damage

Damage can be caused to the gear unit if low-quality operating oils or not approved oils are used. The quality of the oil used must meet the requirements of the separately supplied BA 7300 instructions manual, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in Table "T 7300" (for a link to the Internet, see back cover), as they have been tested and meet the requirements. Data, such as oil type, oil viscosity can be found in the "Technical data" prepared specifically for the order.

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Note

If gear units have oil-supply systems, the oil circuit must be filled additionally. If systems have a motor pump for the oil circuit, the pump must be turned on briefly.

Note

Oil pumps and parts with drill holes for oil filling that are marked with a special sign have to be filled with oil before the start-up of the gear unit.

This is done by way of:

─ an oil-filling hole on the oil pump of the lubricating system or

─ an oil-filling hole on the pressure line or

─ an oil-filling hole marked with an instruction plate

These oil-filling holes must be tightly closed to prevent the pump from drawing in air and/or oil from escaping.

A detailed illustration of the gear unit is contained the drawings in the gear unit documentation.

The gear unit can be filled with oil in different ways, depending on the equipping of the oil-supply system.

• The oil to be put in must be filtered beforehand with a nominal filter mesh of 25 μm (0.0010 inch).

─ If the oil-supply system is equipped with three-way cocks, the gear unit can be filled either through the

three-way cocks of the oil-supply system or through the oil drain cock of the tilting pad thrust bearing chamber of the gear unit.

─ If the oil-supply system is not equipped with three-way cocks, the gear unit is filled through the oil drain

cock of the tilting pad thrust bearing chamber.

─ If the oil-supply system is equipped with a tank, the gear unit can be also filled with oil through the oil

tank of the oil-supply system. For this, it is necessary in the meantime to start the low-pressure pump of the oil-supply system in order to also fill the tilting pad thrust bearing chamber of the gear unit with oil.

Note

Wherever possible, warm oil (approx. 30 °C to 50 °C) should be used for filling so that the viscosity is not too high.

Note

The filling must be carried out while the gear unit and the oil-supply system are shut off. The oil is filled in manually through the oil drain cock of the tilting pad thrust bearing chamber or the secondary circuit of the oil-supply system. Fill in oil until the required oil level of the gear unit is reached (MIN and MAX mark on the oil level indicator of the main gear unit, the tilting pad thrust bearing chamber, see figure Figure 7 in item 7.1.3) and/or the level marked on the oil-supply system (for models with tank) (also see the operating instructions for the oil-supply system). If the required oil level is not reached, the oil-supply system cannot be turned on. Keep filling in oil until the required oil level of the gear unit is reached (MIN and MAX mark on the oil level indicator of the main gear unit, the tilting pad thrust bearing chamber, see Figure 7 in item 7.1.3) and/or the level marked on the oil-supply system (for models with tank) when the gear unit is stopped and the oil pump of the oil-supply system (for models with tank) is in operation (also see the operating instructions for the oil-supply system). For the oil-supply system, the oil level is often higher when the oil-supply system is switched off than when it is turned on, since oil can return from the pipes or hoses. Therefore, the correct oil level must frequently be reached iteratively in this case.

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Note

If the quality of the oil used does not meet the requirements of the separately supplied BA 7300 instructions manual, the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in the document "T 7300" (for a link to the internet, see back cover), because they have been tested and meet the requirements. Data, such as oil type, oil viscosity and approximately required oil quantity can be found on the rating plate.

• Check the oil level in the gear unit housing.

CAUTION

Risk of injury from chemical substances

7.1.6 Oil-supply system

The main gear unit is supplied with lubricating and cooling oil by the oil-supply system (see operating instructions for the "Oil-supply system").

7.1.7 Checks before start-up

When the installation has been completed and before the start-up of the gear unit, inspect all drive parts and remove all material residues, tools and installation aids.

Check the entire drive for the following:

□ Has the foundation been correctly constructed?

□ Are all the foundation bolts tightened to specification?

□ Has the gear unit been correctly fastened in place?

□ Has the grinding bowl been correctly installed?

□ Are the direction of rotation of the motor and that of the gear unit identical (see direction of rotation

arrow)?

□ Has the adhesive tape on the labyrinth seals been removed?

□ Has the round cord hollow profile been removed from the gear unit housing and the input flange?

□ Are all air filters installed?

NOTICE

Property damage

Damage to the gear unit due to absent or inadequate ventilation is possible. Prior to start-up, the screw plug must be replaced with air filter. Remove adhesive tape from the labyrinth seals. Remove the round cord hollow profile between the gear unit housing and the input flange.

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□ Is all pipework cleaned and installed in accordance with the assembly instructions?

NOTICE

Property damage

Damage to the gear unit is possible. Particular care must be taken to ensure that the oil conducting pipework is clean, since any dirt in it would be conducted through the gear unit before it could be filtered out at the filter of the oil-supply system.

□ Are the coupling and the motor correctly aligned?

□ Have the pipework and the hoses been correctly fitted?

□ Have the pipe and hose connections been checked for leaks? Particular attention must be given to the

flange connections on the suction line. If air gets into it, the oil tends to foam.

□ Is the oil in the oil reservoir (tank of oil-supply system and/or gear unit) low-foaming on the surface

during operation? If there is foam, check all the suction line connections. If necessary, also contact the oil manufacturer.

□ Is the tank of the oil-supply system and/or the gear unit and the tilting pad thrust bearing chamber been

filled with oil? The oil level must be checked while the oil-supply system is running and the gear unit is in standstill.

□ Is the oil level between the MIN and MAX marks on the oil level indicators?

□ Has all the monitoring equipment been connected up in accordance with the terminal diagram?

□ Has the oil supply been checked for correct operation?

□ Has the electric interlock between the gear unit, oil supply and mill drive motor been checked?

Document the following of the checks:

□ Function of the interlock according to interlock specifications.

□ Adjustment and function of flow monitor or flow transmitter, pressure switch or pressure transmitter,

temperature sensor and level monitor.

□ Cooling-water supply opened, on oil-supply systems with water oil-cooler.

□ Sufficient air supply on the vents if the oil-supply system has an air cooler.

□ Has the alignment of the gear unit and adjacent components been checked, logged and documented?

□ Evenness of the foundation.

For further checks, see the operating instructions for the coupling, motor, oil-supply system and vertical mill.

Note

The report must be kept with these instructions.

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7.2 Start-up

7.2.1 Pre-lubrication phase

Prior to each start-up, always pre-lubricate the gear unit for approx. 30 minutes by means of the oil-supply system.

During this time rolling bearings, axial tilting pad thrust bearings and teeth for the initial start are supplied with lubricating oil.

For gear units with high-forced lubrication it has to be noticed that the low-forced lubrication system is started first and then the high-forced lubrication system 2 minutes later. This time is necessary to ensure the pressure balance in the oil circuit.

Note

Start existing high-pressure pumps no later than 5 minutes before the auxiliary or main motor is started.

7.2.2 Initial start-up

• Observe all necessary instructions.

• Start the gear unit.

If possible, the gear unit should run for several hours on part load (50 % to 70 %). If part load is not possible, the gear unit can also be run without load and with the rolls and/or rollers lifted. Unless faults are indicated, the load can be increased to full load under continuous observation.

During this time, the following points have to be observed:

a) Noise

If possible, it must be listened for unusual noises during this time on the gear unit at various points with a suitable instrument (e. g. stethoscope).

b) Foam formation

Is the oil in the oil reservoir (tank of oil-supply system and/or gear unit) low-foaming on the surface? Surface foam of up to approx. 10 mm is acceptable. If there is foam, check all the suction line connections. If necessary, also contact the oil manufacturer. With rising oil temperature, the formation of foam reduces.

c) Vibration measurement

(for this see section 10. "Maintenance and repair" item 10.9)

d) Oil leakages

Monitor all screw connections in the oil lines for oil leaks and reseal them if necessary!

Note

The date of initial start-up must be notified to Siemens within 4 weeks after start-up.

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7.2.3 Checking procedure

The following visual checks must be conducted and recorded when starting up:

□ Presence of the "Ex" marking.

□ Oil level

□ Leak tightness 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

Note

The report must be kept with these instructions.

7.3 Removal from service

• Switch off the drive unit.

DANGER

Danger to life from switched on system

For carrying out work on the gear unit, the gear unit and the oil supply system must generally be shut down. The drive unit must be secured against accidental start-up (e.g. by locking the key switch or removing the fuses from the power supply). Attach a notice on the start switch stating clearly that work is in progress on the gear unit.

• Our recommendation is that during short interruptions the complete oil-supply system be kept operating. If the unit is taken out of service for longer periods, we recommend keeping the oil-supply system running for approx. 60 minutes to prevent heat from building up. If there is a sudden stoppage, e.g. caused by a power failure, however, no damage will result.

• It should be noted that the high-pressure pumps must be shut down first and then the low-pressure pumps, when oil-supply systems with a high-pressure lubricating circuit are shut off.

• During a longer stoppage the shut-off valves in the coolant inlet and outlet lines must be closed. If a

water-oil cooler is used, the water must be drained off to prevent damage from freezing at possible sub-zero temperatures.

• If gear units are operated in a saline environment or in the vicinity of bodies of saline water, the oil-supply system must be run through its cycle to prevent damage from corrosion. In addition, the gear unit has to be turned every two weeks (for 15 minutes every week) powered by the auxiliary drive or main motor (at least one rotation on the output flange). If this is not possible, item 7.3.1 must be observed.

Note

After taking the gear unit out of service, it will be protected on the interior against corrosion with the operating oil for 7 days.

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If it is taken out of service for > 7 days, the lubricating system has to be taken into operation once a week for 1 hour. At the same time, the gear unit has to be turned every 2 weeks (at least one rotation on the output flange).

Note

Before restarting the gear unit, the measures according to section 7.1 and 7.2 have to be carried out.

If it is not possible to start up the lubricating system once a week and to turn the gear unit every 2 weeks at the same time, or if the gear unit is taken out of service for longer than 7 days, the gear unit must be preserved according to items 7.3.1 and 7.3.2.

7.3.1 Renewal of the gear unit interior preservation on gear units having already been in operation

Depending on the specific application, the following measures for renewing the interior preservation of the gear unit can be taken in case it is taken out of service for a longer period (> 7 days).

The durability period of this preservation kind depends on the measure for renewing the interior preservation of the gear unit, the packaging type, and the setup and/or storage place (see Table 12 or Table 13 in item 7.3.1.1).

Definition of climatic zones:

North Pole 90°N

Arctic Circle 66.5°N

Northern Tropic 23.5°N

South Pole 90°S

Equator 0°

Southern Tropic 23.5°S

Antarctic Circle 66.5°S

7.3.1.1 Renewal of the interior preservation of the gear unit using the oil- supply system

The prerequisite for this is that the gear unit is still below the mill and connected to the oil-supply system. "Castrol Alpha SP 220 S" or "Tribol1390" can be used as preservative agent. The oil level must never be below the MIN mark on the oil level indicator of the main gear unit, the tilting pad thrust bearing chamber and/or the oil-supply system (if the model has a tank). See also operating instructions of the oil-supply system. For this purpose, turn on the oil-supply system and turn the gear unit without load (at least 1 rotation on the output). Drain the oil, close, mask and seal the gear unit and oil-supply system airtight. Replace air filters for sealing caps and be seal them. Seal the gear unit airtight with a round cord hollow profile between the gear unit housing and the output flange. Mask the labyrinth seals on the input shaft and on the output flange airtight within 1 hour.

Note

Clean the air filters thoroughly (see item 10.3) and keep it in a safe place (these will be required when starting up again).

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Table 12: Maximum durability period of the interior preservation of the gear unit through operating the

oil-supply system.

Packaging for

Storage

packaging

covered at least

with

loose tarpaulin

seaworthy

packaging

Setup in climatic zone A and at

least 50 km distance from larger

Storage place of

packaged unit

exposed outdoors 5 3

covered with loose

tarpaulin

under roof

in closed,

dry room

exposed outdoors 8 5

under roof

in closed,

dry room

exposed outdoors

covered with loose

tarpaulin

under roof

in closed,

dry room

bodies of salt

water

Maximum durability period of the preservation renewal through

operation of the oil-supply system (in months)

8 5

20 14

24 17

20 20

24 24

Setup in climatic zone B and / or

less than 50 km distance from

larger bodies of salt water

1) under roof: no direct exposure to sunlight and no direct contact with water (rain or draining water)

2) Seaworthy packaging: use of wooden box lined with bitumen paper. The content is sealed in foil and it must be protected against moisture by addition of drying agents for the prescribed storage period.

Note

Before restarting the gear unit, the measures according to section 7.1 and 7.2 have to be carried out.

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7.3.1.2 Renewal of the gear unit interior preservation with "Castrol Corrosion Inhibitor N 213"

For prolonging the interior preservation, the VCI-gas discharging fluid "Castrol Corrosion Inhibitor N 213" is recommended.

For sealing the input shaft, a sealing cap (can be obtained from Siemens) must be mounted and tightened on the gear unit for sealing the input shaft.

Note

Oil already filled in does not have to be drained.

CAUTION

Risk of injury

Risk of injury to eyes or hands from chemically aggressive operating substances. Wear suitable protection glasses and protection gloves. Remove any spilled oil immediately using an oil binding agent.

Note

In this renewal of the gear unit interior preservation, it must be ensured that the ambient and gear unit temperature is above 5 °C during filling.

The following procedure is recommended:

• Seal input shaft with a sealing cap.

• Seal bottom and top oil drain of the sealing cap with a screw plug.

• Seal the pressure, suction and/or return lines with blind flanges.

• Fit screw plugs on the oil drain cocks on the gear unit and the tilting pad thrust bearing chamber and seal them.

• Seal input flange with round cord hollow profile (2) (see Figure 5 in item 5.2) on the labyrinth. Mask the labyrinth seal airtight.

• Replace the air filters of the gear unit for screw plugs (replace them again at start-up).

NOTICE

Property damage

Corrosion is possible when the gear unit is opened for too long. Close the gear unit airtight again, at the latest one hour after opening. When opening the gear unit multiple times, "Castrol Corrosion Inhibitor N 213" has to be refilled.

The following table shows the durability period of the gear unit interior preservation with "Castrol Corrosion Inhibitor N 213" depending on the packaging and setup or storage site. The definition of climatic zones can be found in item 4.4.2.1.

Note

If the gear unit is transported after the preservation was renewed, the durability period according to Table 3 in item 4.4.2.1 has to be observed.

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Table 13: Durability period of prolonged interior preservation of the gear unit with

"Castrol Corrosion Inhibitor N 213"

Packaging for

Storage

packaging

covered at least

with

loose tarpaulin

seaworthy

packaging

Setup in climatic zone A and at

least 50 km distance from larger

Storage place of

packaged unit

exposed outdoors 5 3

covered with loose

tarpaulin

under roof

in closed,

dry room

exposed outdoors 8 5

under roof

in closed,

dry room

exposed outdoors

covered with loose

tarpaulin

under roof

in closed,

dry room

bodies of salt

water

Maximum durability period of the preservation renewal with

"Castrol Corrosion Inhibitor N 213" (in months)

8 5

20 14

24 17

20 20

24 24

Setup in climatic zone B and / or

less than 50 km distance from

larger bodies of salt water

1) under roof: no direct exposure to sunlight and no direct contact with water (rain or draining water)

NOTICE

Property damage

With larger filled-in quantities of the "Corrosion Inhibitor N 213" (above 5 % of the operating oil quantity), the mixture of operating oil and "Corrosion Inhibitor N 213" must not be used as operating oil. The gear unit must be flushed thoroughly with operating oil before start-up after draining the mixture of operating and preservative (in this regard, see item 10.4.)

NOTICE

Property damage

Damage to the gear unit is possible. The gear unit may not be turned.

Note

Before restarting the gear unit, the measures according to section 7.1 and 7.2 have to be carried out.

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7.3.1.3 Renewal of the gear unit interior preservation through complete filling with preservative or operating oil

A further possibility for prolonging the gear unit interior preservation is to fill the gear unit with preservative or operating oil until the oil level indicator on the tilting pad thrust bearing chamber shows it is filled completely with oil. The durability of this kind of preservation depends on the used oil and has to be enquired with the oil manufacturer.

For the complete filling, a sealing cap (can be obtained from Siemens) must be mounted on the gear unit for sealing the input shaft.

The preservation will remain intact for as long as the gear unit remains sealed and the storage durability of the oil is not exceeded.

Note

Oil already filled in must be drained as described in Section 10. "Maintenance and repair".

Note

Refer to the BA 7300 operating instructions supplied separately for the approved preservative oils. The viscosity of the operating oil is stated on the rating plate. For better filling, it is recommended to choose an oil with low viscosity, which however is not suitable for later operation of the gear unit. This oil must be drained completely. It is recommended to use the later operating oil for the complete filling and to drain the oil before start-up until the operating oil level is reached.

NOTICE

Property damage

Corrosion damages on the gear unit possible from the loss of the preservative effect. Filled gear units can become untight and the gear unit oil might escape. Monitor the tightness of the filled gear units. Repair leaks. Siemens does not accept any liability for damages that are caused from leaking gear unit oil during storage.

The following procedure is recommended:

• Seal input shaft with a sealing cap (3).

• Seal bottom oil drain of the sealing cap with a screw plug (2).

• Seal the oil drain cock of the tilting pad thrust bearing chamber (10) with a screw plug.

• Seal the pressure, suction and/or return lines (6,8,9) with blind flanges.

• Seal and mask labyrinth seal on the output flange airtight with a round cord hollow profile (13).

• Replace the air filters of the gear unit (4) with screw plugs (at start-up, the screw plugs must be replaced for the air filters again).

• The oil to be put in must be filtered beforehand with a filter mesh of 25 μm (0.0010 inch).

• Fill sealing cap on the input shaft through the ventilation of the sealing cap (1). Close the ventilation (1) only once the oil filling of the gear unit is completed, unless oil is escaping from this opening before then.

• The gear unit must be filled with oil through the bottom oil drain cock of the gear unit (7).

• The gear unit will be filled completely only when the oil level indicator on the tilting pad thrust bearing chamber (12) is filled completely with oil.

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Fig. 8: Gear unit features for preservation measures

1 Breather of sealing cap 2 Oil drain sealing cap 3 Sealing cap 4 Air filter (gear unit) 5 Oil level indicator (gear unit) 6 Suction line (gear unit) 7 Oil drain (gear unit) 8 Pressure line (gear unit)

9 Pressure line (tilting pad thrust bearing

chamber)

10 Oil drain tilting pad thrust bearing

chamber

12 Indication of oil level (tilting pad thrust

bearing chamber)

13 Round cord hollow profile

• The lower oil drain cock on the gear unit (7) must be provided and sealed with a screw plug.

• If not already done beforehand, close ventilation of the sealing cap (1).

NOTICE

Property damage

Corrosion is possible when the gear unit is opened for too long. Close the gear unit airtight again, at the latest one hour after complete filling.

Note

Before restarting the gear unit, the measures according to section 7.1 and 7.2 have to be carried out.

7.3.2 Exterior corrosion prevention

• Clean the surfaces.

• Apply preservative agent.

Note

Preservative agent, see Table 2 in item 4.4.1.1.

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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 satisfactory operation of the equipment without failures, be certain to observe the operating values specified in section 1. "Technical Data", as well as the information given in the operating instructions of the oil-supply system.

DANGER

Electrostatic discharge

During operation, the gear unit must be monitored for the following:

□ Oil temperature

□ Oil pressure of the oil-supply system or

gear unit lubricating system

□ Changes in gear noise.

□ Possible oil leakage at the housing and

shaft seals

□ Bearing vibrations with

present measuring device

□ Storage temperatures with existing

temperature monitoring

The gear unit is designed for an oil distribution temperature in continuous operation of: 50 °C (122 °F) If the oil-supply temperature reaches critical values (see lubrication plan and equipment list), the gear unit must be shut down immediately and Siemens consulted.

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8.2 Oil level

Note

To check the oil level, the gear unit must be stopped and the oil level has to be checked while the oil-supply systems is running (low-pressure lubrication circuit). The following oil level applies as correct:

– middle between the MIN and MAX mark on the oil level indicator (on the bottom gear unit part)

The cooled down oil should be visible between the MIN and MAX mark on the oil level indicator. Hot oil may slightly exceed the MAX mark on the oil level indicator. If the upper mark on the oil level indicator is exceeded, increased foaming of the oil can arise, as the bevel wheel that is running quickly agitates the oil. If the upper mark on the oil level indicator is exceeded, also leaks can also develop on the input shaft. Adjust oil level if necessary.

Explosion hazard

DANGER

Note

Check the oil level in the oil-supply system. If the oil-supply system is equipped with an additional tank (OWTM), the oil level check on the oil-supply system applies (not the oil level marks on the gear unit). The oil level in the tank must be above the warning mark. If this mark is not reached, refill oil.

8.3 Irregularities

NOTICE

Property damage

Damage to the gear unit from error states is possible. Turn off the drive unit immediately in the cases stated below.

□ If irregularities are found during the operation.

□ If a monitoring device triggers an alarm (only with correspondingly equipped gear unit).

Note

Determine the cause of the fault, by means of the information regarding faults provided in Table 14 (see item 9.2). Table 14, "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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DANGER

Explosion hazard

Note

If any safety device has triggered, it must only be possible to start the drive again after releasing the reclosing interlock. The operator must ensure this.

Note

Continuous changes in the operating behaviour of the gear unit must be recorded with the aid of trend records.

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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

Failures occurring during the guarantee period, which require repair of the gear unit, may only be carried out by Siemens Customer Service. If failures occur after the guarantee period, the cause of which cannot be precisely identified, we advise our customers to contact our Customer Service.

NOTICE

Property damage

Damage to the gear unit from improper use is possible. Siemens will not be bound by the terms of the guarantee or otherwise be responsible in cases of improper use of the gear unit, modifications carried out without the approval by Siemens or use of spare parts not originally supplied by Siemens.

DANGER

Danger to life from rotating and/or moving parts

Risk of being gripped or drawn in by rotating and/or moving parts. Shut down the gear unit and the oil-supply system to perform maintenance and/or repair work or prior to removing the safeguards. Secure the drive unit against accidental start-up. Attach a notice on the start switch stating clearly that work is in progress on the gear unit.

WARNING

Risk of personal injury from energised parts

Removing covers, improper use of the machine, false operation or inadequate maintenance might lead to death, serious personal injury or property damage.

– Always observe the "five safety rules" when working on the machine.

(see section 3. "Safety instructions"). – Remove covers only in accordance with the instructions of this operating manual. – Operate the machine properly. – Conduct regular and professional maintenance on the machine.

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9.2 Faults, causes and remedy

Table 14: Faults, causes and remedy

Faults Possible causes Remedy

Changes in gear noise. Damage to gear teeth.

Bearing backlash too high or too low.

Bearing defective.

Increased temperature at the bearing points.

Oil leakage from gear unit. Inadequate sealing of housing

Oil level in the gear unit housing too high or too low.

Oil too old.

Mechanical oil pump defective.

Bearing defective.

Electrical equipment defective.

covers and/or joints.

Contact Customer Service. Check toothed components. If necessary exchange damaged components.

Contact Customer Service. Adjust bearing backlash.

Contact Customer Service. Replace defective bearings.

Check oil level at room temperature. Refill oil if necessary.

Contact Customer Service. Check date of last oil change.

Contact Customer Service. Check that oil pump is working correctly. Repair or replace oil pump.

Contact Customer Service. Check and, if necessary, replace bearings.

Check electrical devices and replace them if necessary.

Check and, if necessary, replace seals. Seal joints.

Volume flow measuring device triggers alarm.

Oil level in housing too high.

Oil too cold.

Oil filter dirty.

Pipes leaky.

Device defective.

Check the oil level. Adjust oil level if necessary.

Heat oil.

Clean oil filter. Consult operating instructions for oil-supply system.

Check and, if necessary replace pipes.

Check device and replace it if necessary.

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Faults RemedyPossible causes

Pressure monitor triggers alarm.

Increased operating temperature.

Oil level too low.

Oil pump defective.

Operating temperature increased.

Oil filter dirty.

Pipes leaky.

Device defective.

Oil level in the gear unit housing too high.

Oil too old.

Oil badly contaminated.

Oil pump defective.

Check the oil level. Fill up oil if necessary.

Check oil pump and replace if necessary.

see Faults "Operating temperature too high".

Clean the oil filter. Consult operating instructions for oil-supply system.

Check and, if necessary replace pipes.

Check device and replace it if necessary.

Check the oil level. Adjust oil level if necessary.

Contact Customer Service. Check date of last oil change.

Contact Customer Service. Change oil.

Check oil pump, and if necessary, replace. Consult operating instructions for oil-supply system.

Excessive temperature on temperature sensor in tilting pad thrust bearing.

Oil filter dirty.

Cooler defective (dirty).

Cooling-water feed and/or cooling-air feed defective.

Electrical equipment defective.

Oil filter dirty.

Oil quantity to tilting pad thrust bearing too small.

Monitoring devices defective.

May also be connected with altered grinding parameters, e. g. raising of the temperature of the gas in the vertical mill.

Clean the oil filter. Consult operating instructions for oil-supply system.

Check the cooler and replace it and if necessary, replace. Observe operating instructions for cooler.

Check cooling-water feed and/or cooling-air feed. Observe operating instructions for cooler.

Check electrical devices and replace them if necessary.

Check oil filter for dirt. Consult operating instructions for oil-supply system.

Check setting of the control valves.

Check all monitoring devices. Observe operating instructions of the monitoring devices.

Analyse and check milling parameters.

Electrical equipment defective.

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Check electrical devices and replace them if necessary.

Page 73

Faults RemedyPossible causes

Oil foams. Water in oil.

Oil too old (defoaming agent used up).

Unsuitable oils mixed up.

Water in oil. Cooler leaky.

Water condensing.

Fault in oil-supply system. Operating instructions

Examine oil. Change oil if necessary.

Replace cooler.

Change oil.

Reduce water content by heating the oil.

for the oil-supply system.

NOTICE

Property damage

Damage can be caused to the gear unit if low-quality operating oils are used. The quality of the oil used must meet the requirements of the separately enclosed BA 7300 instructions manual.

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10. Maintenance and repair

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

Once the maintenance and repair work is completed, the information in section 7. "Start-up" should be noted.

10.1 General notes on maintenance

Maintenance comprises all measures for preserving and restoring the target condition and for ascertaining and assessing the actual condition of the technical means of a system.

In this context maintenance is a comprehensive generic concept which can be subdivided into three areas:

─ Inspection

─ Maintenance (including lubrication)

─ Repair

All maintenance and repair work must be carried out carefully and by qualified personnel only (see section "Qualified Personnel" on page 3 of these instructions).

WARNING

Serious personal injury can be caused by switched-on machine

Shut down the gear unit and the oil-supply system to perform maintenance and/or repair work or prior to removing the safeguards. Secure the drive unit against accidental start-up. Attach a notice on the start switch stating clearly that work is in progress on the gear unit. Observe the relevant accident prevention regulations applicable at the location of the setup site.

Note

WARNING

Risk of personal injury from energised parts

Removing covers, improper use of the machine, false operation or inadequate maintenance might lead to death, serious personal injury or property damage.

– Always observe the "five safety rules" when working on the machine.

(see Section 3. "Safety instructions"). – Remove covers only in accordance with the instructions of this operating manual. – Operate the machine properly. – Conduct regular and professional maintenance on the machine.

NOTICE

Property damage

Damage to the gear unit possible from non-compliance with the specified periods for maintenance and repair works is possible. The operator must observe the deadlines specified and adopt these in its own maintenance plans if required.

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10.2 Clean the gear unit

DANGER

Explosion hazard

Ignition of an explosive dust layer by overheating of the gear unit. Dust deposits can affect the heat discharge through the housing surface and lead to 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

Property damage

Damage to the gear unit due to penetration of moisture is possible. The gear unit must not be cleaned with high-pressure cleaning equipment.

10.3 Clean the air filter

Note

A period of 3 months applies to the cleaning of the air filter. If a layer of dust has built up, the air filter must already be cleaned even before the 3-month period has expired.

Note

If the air filter is protected with a filter cap, it must be disassembled before cleaning the air filter. After cleaning the air filter, the filter cap must be reassembled.

• Unscrew the air filter including the reducing screw.

• Clean the air filter using a suitable cleaning agent.

• Dry the air filter and/or blow with compressed air.

WARNING

Risk of injury to the eyes from pressurised air

Residual water and/or dirt particles can injure the eyes. Wear suitable protective glasses.

NOTICE

Property damage

Damage to the gear unit due to penetration of foreign bodies is possible. The penetration of foreign bodies into the gear unit must be prevented.

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10.3.1 Replacing the air filter cartridge

Note Annually or when the air filter is heavily soiled.

• Remove the air filter cover and replace the filter element (cleaning of the paper filter is not possible).

10.4 Flushing

It must generally be distinguished between "flushing during the initial start-up" and "flushing before or after repair work".

Flushing before or after repair work serves for removal of soiling (e.g. bon deposits, oil foam, abraded material) and must be conducted depending on the scope of the repair.

Flushing should be carried out with the selected service lubricating oil. In general, lower viscosities (e.g. VG 46 or VG 100) should be used for the flushing oil that is of the same brand as the oil type chosen as the operating oil.

• For flushing-oil quantity see item 7.1.4.1.

• Flushing times: For flushing, operate the oil pump of the low-pressure lubricating circuit for at least 6 hours.

NOTICE

Property damage

Note

If the oil tends to increasing foaming during flushing, we recommend having the oil analysed by the oil supplier as to its suitability for use.

10.5 Oil filling

NOTICE

Property damage

Damage to the gear unit and oil-supply system is possible. Fill the gear unit with oil after flushing and before the start-up of the gear unit.

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 documentation included in the delivery. The BA 7300 instructions 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).

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10.6 Inspection

The inspection comprises all measures for ascertaining and assessing the actual condition.

The measures must be recorded.

Note

The record must be kept with these instructions.

Table 15: Inspection measures

Measures Periods Remarks

General visual check for cracks, leaks and damage.

Visual check of the tooth-flank condition for damage

Check oil filters of the oil-supply system for contamination.

Check of the instruments installed on site (temperatures, oil pressures).

Inspection of the oil conducting lines for leaks.

Oil level check at the oil level indicators on the gear unit and, if necessary, on the oil-supply system (version with tank)

Check for

- unusual noises,

- temperature,

- safety equipment.

Check of add-on parts such as couplings, possibly auxiliary drive.

every 4 weeks

annually

every 4 weeks or if there is heavy soiling

every 4 weeks

weekly

weekly See also operating instructions oil-supply

weekly

every 6 months See operating instructions for the

Optical display, see also operating instructions oil-supply system.

system.

individual components.

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10.7 Maintenance

Maintenance comprises all measures for preserving the required condition.

Table 16: Maintenance measures

Measures Periods Remarks

The proper function and measurement accuracy of the ignition protection system for the temperature monitoring should be checked at regular intervals according to the instructions of the manufacturer of the ignition protection device

First oil change after start-up after approx. 1000 operating hours

Oil analyses first one after 1000 operating

Subsequent oil changes depending on the oil analysis

Clean the gear unit as required, at least every 2 years See item 10.2.

Clean the air filter every 3 months

Replacing the air filter cartridge annually or when the air filter is

Checking tightness of the foundation bolts

see instructions of the manufacturer.

or depending on the results of the oil analysis carried out

hours, all subsequent ones annually

results; (without oil analysis: at the latest after 18 months and/or 10000 operating hours)

heavily soiled.

every 12 weeks See item 10.7.3

The operator must ensure this.

See item 10.7.2

See item 10.7.1

See item 10.7.2

See item 10.3.

See item 10.3.1.

General inspection of the gear unit every 2 years See item 10.11

Maintenance work on the oil-supply system

Check couplings every 6 months See operating instructions

see also operating instructions oil-supply system.

See also operating instructions oil-supply system.

individual components.

DANGER

Electrostatic discharge

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10.7.1 Examine water content of oil, conduct oil analyses

Detailed information about testing the oil for water content or conducting oil analyses can be obtained from your lubricant manufacturer or Siemens customer service.

─ A fresh sample of the used operating lubricating oil must be sent as reference to the testing institute

along with the used oil sample for analysis.

─ The oil sample must be taken downstream from the filter of the oil-supply system while the gear unit is

running. A suitable connection point is normally located upstream of the gear unit input (e. g. oil drain cock in the pressure line). A suitable connection possibility is provided on the oil-supply system for taking an oil sample from the filter.

─ 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 and lockable vessel which is suitable for transport.

• The viscosity of the oil sample may not deviate by more than 10 % from the that of the oil specified in the "Technical data".

• The oil purity should not be below -/19/16 according to the standard "ISO 4406".

• Limit values for oil contamination.

Table 17: Material-related contamination limit values of the oil

Material

Iron (Fe) 40 Gear rim with internal teeth, teeth, bearing cage.

Chrome (Cr) + 4 Rolling bearing, teeth.

Aluminium (Al) + 4 Oil-pump bearing.

Copper (Cu) + 4 Cage of bearing.

Lead (Pb) + 6 Plain thrust bearings, pump bearings.

Tin (Sn) + 2 Plain thrust bearings, pump bearings.

Nickel (Ni) + 2 Teeth.

Zinc (Zn) + 10

Silicon (Si) + 5

Water (H2O) 300 ppm Condensation water; water-oil cooler defective (mineral oil).

Limit content

[ mg/kg ]

Possible source

Zinc-based primer (is sometimes used as additive). In this case please contact Siemens.

Concrete dust or other environmental factors, some oils may contain silicium.

The values shown with "+" refer to the reference sample of the fresh oil.

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10.7.2 Change oil

Note

Observe the separately attached operating instructions BA 7300 and the information in item 7.1.

• Drain the oil while the gear unit is still warm, i.e. immediately after stopping it.

WARNING

Serious personal injury can be caused by switched-on machine

NOTICE

Property damage

Damage to the gear unit possible from inadequate lubrication because of 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. When changing to any different oil type, the gear unit must be flushed thoroughly using the new oil type. Flushing is not necessary, if the new service oil is fully compatible with the old service oil in all respects. Compatibility must be confirmed by the oil supplier. If there is a change to another oil grade or make, Siemens recommends flushing out the gear unit with the new grade of service oil.

Note

When changing the oil, the housing and the oil-supply system (if present) must be cleaned thoroughly from sludge, metal particles and oil residue by flushing it with oil. Use the same type of oil as is used for normal operation. High-viscosity oils must be heated beforehand using suitable means. Ensure that all residues have been removed before filling with fresh oil.

Note

In this regard, see Figure 9.

• Place suitable containers under the oil drain cocks of the gear unit housing and of the tilting pad thrust bearing chamber.

• Unscrew the screw plugs of the oil drain cocks and allow the oil to drain into the container.

CAUTION

Risk of scalding

Risk of injury from escaping hot oil. Wear suitable protection gloves, protection glasses and protection clothing. Remove any spilled oil immediately using an oil binding agent. Observe environmental protection regulations.

• If the oil-supply system is equipped with three-way cocks, the gear unit can be emptied through the three-way cocks of the oil-supply system. The remaining residual oil must then be drained off through the oil drain cocks on the gear unit (1, 2).

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Fig. 9: Oil level, oil drain, and ventilating

1 Oil drain of the gear unit 2 Oil drain of tilting pad thrust bearing

4 Oil level tilting pad thrust bearing 5 Air filter gear unit

chamber

3 Oil level gear unit

• Screw the screw plugs of the oil drain cocks (1, 2) back in.

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.

Note

For the oil filling of the gear unit, see the information in item 7.1.5.

In alternative to the oil change intervals indicated in Table 16 (see item 10.7), 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 released for further use.

If further usability has been confirmed, no oil change will be necessary.

Note

Observe the separately attached operating instructions BA 7300 and the information in item 7.1.

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10.7.3 Check tightness of screw connections

All screw connections that are used for inspection or maintenance have to be checked for firm seat (see item 6.12 "Screw connection classes, tightening torques and initial stressing forces").

Tighten plate screws with the required initial stressing force or torque. The initial stressing force or torque can be found on the dimensions sheet.

Note

The separate operating instructions have to be observed if "superbolt nuts" are used.

Note

Damaged bolts must be replaced with new bolts of the same type and strength class.

10.8 Welding work on the mill

Note

Siemens will accept no liability for damage caused to the gear unit by welding work carried out on the mill.

DANGER

Risk of personal injury from electrical shock or through electrostatic discharge

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10.9 Vibration measurements

DANGER

Danger to life from rotating and/or moving parts

Risk of being gripped or drawn in by rotating and/or moving parts. If a mobile vibration measurement is taken on a gear unit while it is in operation, it is imperative to ensure that the measurement is not taken directly near rotating parts in order to avoid accidental contact with the rotating parts.

Fig. 10: Measuring points

V Vertical measuring point H Horizontal measuring point

(Measuring points 1 and 2 are located at the bearing points on the motor.)

The measuring points shown in Figure 10 are the standard measuring points in a mobile measurement. All gear units of this type in the field can be measured on these measuring points. This enables direct comparison with other gear units of the same type and same size. A detailed illustration of the gear unit is contained the drawings in the gear unit documentation.

Vibration measurements and their evaluation should be conducted by Siemens personnel and/or in close collaboration with Siemens personnel. This way, experience gained from measurements conducted on comparable bevel-gear planetary gear units can be incorporated into the measurement and the evaluation of its results.

When measuring vibration, the following should be observed in general:

a) Measure only at the measuring points indicated in Figure 10 above.

b) Do not measure on resonance cavities (e. g. fins, inspection covers, pipes, etc.).

c) The motor output should also be recorded at the time of measurement, as output fluctuations may result

in different measurements.

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After start-up and continuous operation of the entire system, an initial measurement should be carried out to obtain the vibration profile of the gear unit. Subsequent measurements at monthly intervals will then enable a trend analysis to be carried out.

Note

For assessing the gear unit according to the standard "DIN ISO 10816" the classification III applies to this machine. It must be noted concerning this assessment, however, that the axial forces arising from the grinding process are conducted to the foundation through the gear unit housing so that it cannot be ruled out that vibrations are due to the grinding process and are not generated by the gear unit. For this reason the standard "DIN ISO 10816" has only limited application for this type of gear unit.

Further information about vibration diagnosis is obtainable from:

http://www.automation.siemens.com/mcms/mechanical-drives/en/gear units/service

10.10 Repair

Note

Maintenance comprises all measures for reinstating the required condition.

NOTICE

Property damage

Damage to the gear unit is possible. When carrying out repair work, especial care must be taken that, when doing electric welding work at any point on the unit, the welding current is not conducted through rolling bearings or other movable connections and measuring equipment. The welding current return wire must therefore be connected directly to the part to be welded.

WARNING

Risk of personal injury from electrical shock.

Risk of personal injury from electrical shock when connecting electrical components. Ensure zero voltage before connecting the devices.

DANGER

Danger to life

or building parts is prohibited – Load hooks may not be loaded at their tip – Set down products only on even, non-slipping and stable underground

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10.11 General inspection of the gear unit

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

10.12 Lubricants

The quality of the oil used must meet the requirements of the separately supplied BA 7300 instructions manual, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in Table "T 7300" (for a link to the Internet, see 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 not intended as a guarantee for the quality of the lubricant delivered by your supplier. Every lubricant manufacturer must provide its own guarantee for the quality of its 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 documentation included in the delivery.

The total operating oil quantity for the gear unit, the oil-supply system, and the pipework can be found in the set-up plan. If the oil-supply system and the pipework are not included in the scope of delivery by Siemens, the operating oil quantity for the gear unit is shown on the rating plate (see section 1. "Technical data").

The quantity value specified in the setup plan and on the rating plate is understood as an approximate quantity. The marks on the oil level indicator of the main gear unit, the tilting-pad thrust bearing and/or the oil-supply system (for models with tank) are decisive for the oil quantity to be filled in.

The BA 7300 instructions 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 subject to continuous testing. Under certain circumstances, the oils recommended there may be removed from the range at a later time or be replaced by 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 consumable 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

Property damage

Damage to the gear unit from improper use. Siemens extends a warranty only for original spare parts supplied by Siemens. Non-original spare parts have not been tested or approved by Siemens. Non-original spare parts may alter the required technical characteristics of the gear unit, thereby causing an active or passive safety hazard. Any liability and warranty of Siemens is precluded for damages caused by the use of non-original spare parts. 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, item type, size part number quantity

11.2 Addresses for ordering spare parts and customer service

First contact Siemens when ordering spare parts or requesting a service specialist.

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

Vertical mill gear unit

KMS

Sizes 225 to 850

for driving vertical mills:

– 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, 1.3.8.1;

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;

1.6.1, 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 partly completed machinery is in conformity with the provisions of the:

Directive 2014/34/EU OJ L 96, 29.03.2014, p.309-356 (effective from 20.04.2016, 00:00 a.m.)

Directive 94/9/EC OJ L 100, 19.04.1994, p.1-29 (effective until 19.04.2016, 12:00 p.m.)

– 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 / Head of PD MD AP VOE

Voerde, 2015‐12‐15

Mark Zundel / Head of PD MD AP VOE

Voerde, 2015‐12‐15

Björn Podewski / Head of PD MD AP VOE BA

Translation of the original declaration of incorporation

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12.2 EU declaration of conformity

EU declaration of conformity

within the meaning of EC Directive 94/9/EC of 23.03.1994 and the legal requirements laid down for its implementation

The manufacturer, Siemens AG, 46395 Bocholt, Germany, declares that the equipment described in these assembly and operating instructions:

Vertical mill gear unit

KMS

Sizes 225 to 850

is equipment in the meaning of Article 1 and Article 13, Paragraph 1 c) of Directive 2014/34/EU and complies with the requirements of Directive 2014/34/EU and the following standards:

EN 1127‐1 : 2011 EN 13463‐1 : 2009 EN 13463‐5 : 2011 EN 13463‐6 : 2005 EN 13463‐8 : 2003 EN 60079-0 : 2012 / A11:2013

This declaration of conformity is issued under the sole responsibility of the manufacturer.

The object of the declaration described above is in conformity with the relevant Union harmonisation legislation:

Directive 2014/34/EU OJ L 96, 29.03.2014, p.309-356 (effective from 20.04.2016, 00:00 a.m.)

Directive 94/9/EC OJ L 100, 19.04.1994, p.1-29 (effective until 19.04.2016, 12:00 p.m.)

Voerde, 2015‐12‐15

Mark Zundel / Head of PD MD AP VOE

Björn Podewski / Head of PD MD AP VOE BA

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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 Process Industries and Drives Mechanical Drives Alfred-Flender-Straße 77 46395 Bocholt GERMANY

Subject to modifications

www.siemens.com/drivetechnologies

Siemens KMS, Flender KMP Series, Flender KMPS Series, Flender KMPP Series Assembly And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

1. Technical data

1.1 General technical data

1.2 Marking of the gear unit designed in accordance with Directive 2014/34/EU

1.2.1 Ambient temperature

1.3 Measuring-surface sound pressure level

1.4 List of equipment

2. General notes

2.1 Introduction

2.2 Copyright

3. Safety instructions

3.1 Obligations of the user

3.2 Special dangers and personal protective equipment

3.3 The five safety rules

3.4 Environmental protection

4. Transport and storage

4.1 Content and check of the scope of delivery

4.2 Transport

4.3 Storing the gear unit

4.4 Standard coating and corrosion prevention

4.4.1 Exterior preservation of metallic bright exterior surfaces

4.4.1.1 Maximum durability period of the exterior preservation

4.4.1.2 Prolongation of the preservation of metallic bright exterior surfaces of the gear unit

4.4.2 Preservation of the interior of the gear unit

4.4.2.1 Maximum durability period of the interior preservation of the gear unit

4.4.2.2 Combined storage / packaging

4.4.3.1 Renewal of the gear unit interior preservation with "Castrol Corrosion Inhibitor N 213"

4.4.3.2 Renewal of the gear unit interior preservation through complete filling with preservative or operating oil.

4.4.3.3 Renewal of the interior preservation of the gear unit using the oil- supply system

5. Technical description

5.1 General description

5.2 Delivery condition of the gear unit

5.3 Lubrication

5.3.1 Hydrodynamic lubrication of the axial tilting pad thrust bearings

5.3.2 Hydrodynamic lubrication of the axial tilting pad thrust bearings in gear units with hydrostatic start-up assistance

5.3.3 Hydrodynamic lubrication of the axial tilting pad thrust bearings with radial piston pump

5.3.4 Labyrinth seals

5.4 Drive coupling

5.5 Heating

5.6 Heating element on ex-version

5.6.1 Oil level monitoring of the heating elements

5.7 Indication of oil level

5.8 Oil temperature monitoring

5.9 Oil level monitoring system

6. Fitting

6.1 General assembly information

6.2 Set-up conditions

6.2.1 Dimensions and weights

6.2.2 Lifting device

6.3 Preparatory measures for gear unit installation

6.3.1 Maintaining preservation if the gear unit has been opened in the meantime

6.3.2 Foundation

6.4 Assembly of the gear unit

6.5 Installing the pipework

6.6 Pickling of adapted pipes

6.7 Installing the couplings

6.8 Installing the motor

6.9 Assembly of loose add-on parts included in the delivery

6.10 Welding work on the mill

6.11 Final work

6.12 Screw connection classes, tightening torques and initial stressing forces

6.12.1 Screw connection classes

6.12.2 Tightening torques and initial stressing forces

7. Start-up

7.1 Procedure before start-up

7.1.1 Removal of preservative agent from exterior

7.1.2 Removal of preservative agent from interior

7.1.3 Draining preservative oils

7.1.4 Flushing before initial start-up

7.1.4.1 Oil quantity for flushing

7.1.5 Fill in operating oil

7.1.5.1 Oil level

7.1.5.2 Procedure for filling

7.1.6 Oil-supply system

7.1.7 Checks before start-up

7.2 Start-up