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

Vertical mill gear unit
KMS Sizes 225 to 850
Assembly and operating instructions BA 9137 en 12/2015
FLENDER gear units
T
echnical data
T
T
1
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
2
3
4
5
6
7
8
Faults, causes and remedy
Maintenance and repair
Spare parts, customer service
Declarations
9
10
11
12
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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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Contents

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
2
④
⑥
⑧
⑦ Rotation speed n ⑧ Rotation speed n
1
2
in min
in min
-1
-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) - -
1)
T
a min.
T
a min.
T
a max.
T
a
Equipment
category
≤ Ta ≤ T
Explosive
Atmosphere
= permissible ambient temperature range in °C:
a max.
= minimum permissible ambient temperature = maximum permissible ambient temperature = symbol for ambient temperature
Note
The ignition protection type "b" is not available for gear units without electrical explosion hazard monitoring device (e. g. temperature, oil level). The rating plate on the gear unit indicates the marking for the applicable case of application.

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..
1)
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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1
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.
18 / 89
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
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.
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
1)
The gear unit must be stored with a cover on a vibration-free, dry base in a place sheltered from
1)
2)
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.
2)
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
A
Northern Tropic 23.5°N
B
A
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
2)
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
1
2)
in
2
No
packaging
covered at
least with
loose tarpaulin
seaworthy
packaging
2)
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
1)
room
1)
room
1)
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.
21 / 89
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:
LD
HD
LD
HD
HD
HD
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
1
= Maximum durability period of the existing preservation
1
2
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:
HD
n*äq
+ (HD
2äq
+ (1 *
n*1äq
* LD
1
) HD
HD
1
equivalent remaining durability period > HD
n*1
2
) (
HD
, which is applicable
1
HD
2äq
HD
n
)
n*1
has to be
2 äq
)
HD
LD
HD
HD
HD
= 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
n-1
n-
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
22 / 89
Example:
─ A gear unit is stored exposed outdoors after sea transport, in climatic zone B, while it is kept in seaworthy
packaging
= 20 months
HD
1
(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.
HD
= 4 months
2
(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
1
B, transport type: sea transport, transport packaging: seaworthy packaging, packaging
has to be calculated as follows:
2äq
LD
HD
1
) HD
1
5
) 4
20
2
HD
HD
), the gear-unit is placed outdoors exposed without packaging. Now, the
2
3äq
+ (1 *
2äq
+ (1 *
2äq
HD
is to be calculated as follows:
+ 3months
2äq
HD
LD
HD
HD
HD
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)
2
= 3 months (maximum durability period with the present storage conditions
3
2
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
HD
+ (HD
3äq
HD
3äq
* LD2) (
2äq
+ (3 * 1) (
+ 1.5months
3 4
)
HD HD
3
)
2
23 / 89
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
1)
loose tarpaulin
in closed room or under roof
Transport in
seaworthy packaging
1)
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
2)
2)
exposed
outdoors
covered with
loose tarpaulin
or
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
24 / 89
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
1)
loose tarpaulin
in closed room or under roof
Transport in
seaworthy packaging
1)
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
2)
2)
exposed
outdoors
covered with
loose tarpaulin
or
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.
25 / 89
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).
26 / 89
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
No
packaging
covered at least
with
loose tarpaulin
seaworthy
packaging
2)
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
1)
1)
1)
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.
27 / 89
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