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FLENDER Gear UnitsGirth gear unit for tubular mills5150en

Operating Instructions

Edition 09/2016

DMG2 18, 22, 25.4, 30

29.11.2016 16:35V1.00

Girth gear unit for tubular mills

FLENDER Gear Units5150en

Operating Instructions

DMG2 18, 22, 25.4, 30

Edition 09/2016

Introduction 1

Safety instructions 2

Description 3

Application planning 4

Assembly 5

Commissioning 6

Operation 7

Maintenance 8

Service & Support 9

Disposal 10

Spare parts 11

Quality documents A

Technical data BMaintenance and servicing work C

Legal informationWarning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGERindicates that death or severe personal injury will result if proper precautions are not taken.

WARNINGindicates that death or severe personal injury may result if proper precautions are not taken.

CAUTIONindicates that minor personal injury can result if proper precautions are not taken.

NOTICEindicates that property damage can result if proper precautions are not taken.If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified PersonnelThe product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens productsNote the following:

WARNINGSiemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

TrademarksAll names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of LiabilityWe have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AGProcess Industries and DrivesPostfach 48 4890026 NÜRNBERGGERMANY

Document order number: Ⓟ 11/2016 Subject to change

Copyright © Siemens AG 2016.All rights reserved

Table of contents

1 Introduction...................................................................................................................................................9

1.1 General information..................................................................................................................9

1.2 Lubricants...............................................................................................................................10

2 Safety instructions......................................................................................................................................11

2.1 Security notes........................................................................................................................11

2.2 The five safety rules...............................................................................................................11

2.3 General information................................................................................................................12

2.4 General warnings and symbols..............................................................................................13

2.5 Special types of danger and personal protective equipment.................................................14

2.6 Intended use..........................................................................................................................16

3 Description..................................................................................................................................................19

3.1 General description................................................................................................................19

3.2 Oil supply to the gear unit......................................................................................................19

3.3 Shaft seal...............................................................................................................................203.3.1 Rotary shaft sealing rings.......................................................................................................203.3.2 Labyrinth seals.......................................................................................................................20

3.4 Bearing monitoring.................................................................................................................203.4.1 Bearing monitoring using a Pt 100 resistance thermometer..................................................20

3.5 Inductive sensor at the intermediate shaft.............................................................................21

4 Application planning...................................................................................................................................23

4.1 Scope of delivery....................................................................................................................23

4.2 Transport................................................................................................................................23

4.3 Attachment points..................................................................................................................25

4.4 Special aspects of gear unit lubrication and preservation......................................................274.4.1 Preservation...........................................................................................................................27

5 Assembly....................................................................................................................................................29

5.1 General assembly instructions...............................................................................................29

5.2 Unpacking the gear unit.........................................................................................................32

5.3 Preparatory measures for mounting the gear unit..................................................................335.3.1 Checking the girth gear..........................................................................................................335.3.2 Determining the centre of the tube mill..................................................................................345.3.3 Checking the foundation........................................................................................................35

5.4 Mounting the baseplate..........................................................................................................36

Girth gear unit for tubular mills 5150enOperating Instructions 09/2016 5

5.5 Mounting the gear unit...........................................................................................................395.5.1 Fastening foundation bolts.....................................................................................................41

5.6 Couplings...............................................................................................................................435.6.1 Assembling the coupling........................................................................................................435.6.2 Aligning the coupling..............................................................................................................45

5.7 Connecting components........................................................................................................475.7.1 Making terminal box connections for pre-wired gear units.....................................................475.7.2 Installing a separate oil supply system...................................................................................475.7.3 Electrical connections............................................................................................................48

5.8 Final work...............................................................................................................................48

6 Commissioning...........................................................................................................................................51

6.1 Measures prior to commissioning..........................................................................................516.1.1 Flushing before first commissioning.......................................................................................526.1.2 Adjusting the inductive sensor...............................................................................................526.1.3 Gear unit with oil supply system.............................................................................................546.1.4 Checking procedure...............................................................................................................55

6.2 Measures during commissioning............................................................................................566.2.1 Initial test run..........................................................................................................................57

7 Operation....................................................................................................................................................59

7.1 Operating data.......................................................................................................................59

7.2 Irregularities in operation........................................................................................................59

7.3 Taking the unit out of service.................................................................................................60

8 Maintenance...............................................................................................................................................61

8.1 General maintenance information..........................................................................................61

8.2 Maintenance schedule...........................................................................................................62

8.3 Maintenance and servicing work............................................................................................638.3.1 Contamination limits...............................................................................................................638.3.2 Servicing................................................................................................................................648.3.3 Measuring the temperature at the rolling-contact bearings....................................................648.3.4 Cleaning the gear unit............................................................................................................658.3.5 Check that all of the fastening bolts are tight.........................................................................658.3.6 General inspection of the gear unit........................................................................................658.3.7 Final work...............................................................................................................................65

8.4 Possible faults........................................................................................................................66

9 Service & Support.......................................................................................................................................69

10 Disposal......................................................................................................................................................71

11 Spare parts.................................................................................................................................................73

11.1 Spare parts drawing...............................................................................................................74

11.2 Spare parts list.......................................................................................................................75

A Quality documents......................................................................................................................................77

A.1 Declaration of Incorporation...................................................................................................77

Table of contents

Girth gear unit for tubular mills 5150en6 Operating Instructions 09/2016

B Technical data............................................................................................................................................79

B.1 Technical representation........................................................................................................79

B.2 General technical data...........................................................................................................81

B.3 Ambient temperature..............................................................................................................82

B.4 Weights..................................................................................................................................82

B.5 Enveloping surface sound pressure level..............................................................................82

B.6 Terminal diagram...................................................................................................................83

C Maintenance and servicing work................................................................................................................85

Glossary.....................................................................................................................................................87

Index...........................................................................................................................................................89

Tables

Table 2-1 Symbols and markings................................................................................................................12Table 2-2 General warnings........................................................................................................................13Table 4-1 Transport conditions....................................................................................................................25Table 5-1 Tools for assembling DMG2 gear units.......................................................................................30Table 5-2 Permissible runout and axial eccentricity of girth gears..............................................................33Table 5-3 Parts required to mount the baseplate........................................................................................36Table 5-4 Technical data of the foundation bolts/nuts.................................................................................42Table 6-1 Rinsing duration..........................................................................................................................52Table 6-2 Permissible axial offsets of the floating shaft from the centre position........................................54Table 7-1 Operating data.............................................................................................................................59Table 8-1 Maintenance and servicing work.................................................................................................62Table 8-2 Possible faults and their rectification...........................................................................................66Table 11-1 Spare parts..................................................................................................................................75Table B-1 Dimensions and torques..............................................................................................................80Table B-2 Weights.......................................................................................................................................82Table C-1 Check list 1..................................................................................................................................85

Figures

Figure 3-1 Inductive sensor at the intermediate shaft...................................................................................21Figure 4-1 Transport symbols.......................................................................................................................25Figure 4-2 Position of the attachment points for gear units of type DMG2...................................................26Figure 5-1 Positioning the dial gauges (A, B, C) on the girth gear...............................................................33Figure 5-2 Foundation drawing.....................................................................................................................35Figure 5-3 Assembly drawing.......................................................................................................................37

Table of contents


Figure 5-4 Mounting the gear unit.................................................................................................................39Figure 5-5 Possible displacements...............................................................................................................45Figure 5-6 Alignment process based on the example of a flexible coupling.................................................46Figure 6-1 Inductive sensor at the intermediate shaft...................................................................................53Figure 11-1 Spare parts drawing 1/2 for drive scenario A/x, B/x, C/x, D/x, E/x and F/x.................................74Figure 11-2 Spare parts drawing 2/2 for drive scenario A/x, B/x and C/x.......................................................74Figure 11-3 Spare parts drawing 2/2 for drive scenario D/x, E/x and F/x.......................................................75Figure B-1 Dimensions..................................................................................................................................79

Table of contents


Introduction 11.1 General information

Purpose of the operating instructionsThese operating instructions describe the gear unit and provide information about handling it - from assembly to maintenance.

Please keep these operating instructions for later use. Please read these operating instructions prior to handling the gear unit and follow the information in them.

NoteDisclaimer

Please make sure that every person who is commissioned to work on the gear unit has read and understood these operating instructions prior to handling the gear unit and adheres to all of the points. Failure to observe these operating instructions can cause product or property damage or personal injury.

Siemens does not accept any liability for damage or operating failures which are due to non-adherence to these operating instructions.

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

In the interest of technical advancements, Siemens AG reserves the right to make changes to the individual components and accessories which are considered necessary for improving their performance and safety, while maintaining their essential features.

Basic knowledge requiredIn order to understand these operating instructions, you will need the following general knowledge about gear units. You will also need a basic understanding of the following topics:

● Application planning

● Assembly

● Commissioning

● Maintenance

Documentation landscapeThese operating instructions form part of the delivery of your gear unit.


These operating instructions form part of the complete documentation supplied with the gear unit. The complete documentation encompasses other documents, including:

● Data sheet

● List of equipment

● Dimension drawing

● Operating instructions for gear unit lubrication and preservation BA 7300

● Operating instructions for mounted components

● Operating instructions for third-party vendor devices

CopyrightThe copyright for these operating instructions is held by Siemens AG.

Without the authorisation of Siemens AG, these operating instructions may not be used wholly or in parts for competitors’ purposes or be given to third parties.

If you have any technical queries, please contact one of our Customer Services addresses (Page 69).

1.2 LubricantsThe oil used must meet the quality requirements specified in the separately enclosed operating instructions BA 7300 or else the warranty issued by Siemens will be invalidated. Siemens strongly recommends use of one of the oils listed in BA 7300 as these have been properly tested and meet the relevant quality requirements.

In order to avoid any misunderstandings, Siemens wishes to point out that this recommendation does not constitute an approval in the sense of a guarantee for the quality of the lubricant obtained from a supplier. Every lubricant manufacturer is required to guarantee the quality of his/her products.

Information such as oil type, oil viscosity and required oil quantity can be found on the rating plate of the gear unit and in the documentation supplied with the gear unit.

The oil quantity specified on the rating plate is an approximate value. The actual quantity of oil required is determined by the marking on the oil dipstick or oil sight glass.

The operating instructions for the current lubricant recommendations of Siemens AG can also be viewed in the Internet (http://support.automation.siemens.com/WW/view/de/44231658).

The oils listed there undergo continuous testing. As a result, the recommended oil types might in future be removed from the list or replaced by more advanced oils.

Siemens therefore advises users to check this list regularly to ascertain whether the selected lubricating oil is still recommended by Siemens. If it is not, another brand of oil should be selected instead.

Introduction1.2 Lubricants


http://support.automation.siemens.com/WW/view/de/44231658

Safety instructions 22.1 Security notes

Siemens offers products and solutions with industrial security functions, which support the safe and secure operation of plants, systems, machines and networks.

In order to safeguard plants, systems, machines and networks against cyber threats it is necessary to implement (and continually maintain) a holistic industrial security concept that corresponds to the current state of the art. Siemens products and solutions undergo continuous development in this respect.

Customers are responsible for preventing unauthorised access to their plants, systems, machines and networks. Systems, machines and components shall only be connected to the company network or the Internet when and as far as this is absolutely necessary and appropriate protective measures (e.g. use of firewalls and network segmentation) shall be taken.

In addition the recommendations of Siemens regarding appropriate protective measures shall be observed. You can find further information about industrial security at http://www.siemens.com/industrialsecurity.

Siemens products and solutions undergo continuous development in order to make them even safer. Siemens expressly recommends that you regularly carry out any updates as soon as they are available and that you only use the current product versions. Use of older or no longer supported versions can increase the risk of cyber threats.

To keep yourselves informed of any updates to our products you can register for the Siemens Industrial Security RSS Feed at:http://www.siemens.com/industrialsecurity

2.2 The five safety rulesIn order to protect yourself and prevent any damage to property, always observe the safety relevant information and the following five safety rules (as per EN 50110-1 "Working on isolated equipment") when working on electrical components of the plant.

Prior to starting work on the machine, follow the safety rules listed below:

1. DisconnectAlso disconnect auxiliary circuits such as the anti-condensation heater

2. Safeguard against restart

3. Ensure that the system is de-energised

4. Earth and short circuit

5. Cover or cordon off adjacent live parts

When all the work is complete, cancel the safety measures in the reverse sequence.


2.3 General information

IntroductionAll work on the gear unit should be performed with care and only by qualified personnel.

Symbols on the gear unitThe following symbols apply to the gear unit; some of which are found as coloured markings on the gear unit:

Table 2-1 Symbols and markings

Points labelled on the gear unit Symbol Coloured markingsEarth connection point

Air relief point yellow

Oil filling point yellow

Oil draining point white

Oil level indicator red

Oil level measurement red

Oil overflow

Connection point for vibration monitoring

Lubrication point red

Apply grease

Lifting eye

Eye bolt

Do not unscrew

Safety instructions2.3 General information


Points labelled on the gear unit Symbol Coloured markingsAlignment surface, horizontal

Alignment surface, vertical

These symbols indicate the oil level check‐ing procedure using the oil dipstick.

These symbols indicate that the oil dip‐stick must be firmly screwed in.

2.4 General warnings and symbolsThe following table contains general warnings and their associated symbols.

Table 2-2 General warnings

ISO ANSI WarningWarning - hazardous electrical voltage

Warning - explosive substances

--- Warning - entanglement hazard

--- Warning - hot surfaces

--- Warning - substances that can irritate or which are hazardous to health

--- Warning - caustic substances

--- Warning - suspended load

--- Warning - hand injuries

Safety instructions2.4 General warnings and symbols


2.5 Special types of danger and personal protective equipment

RequirementsFulfil the following requirements before commencing work on the gear unit:

● Ensure that the oil pressure lines are depressurised.

● Only perform work on the gear unit when it is not in operation.

● Disconnect electrical systems from the power supply.

DANGER

Electric shock

Live parts can cause electric shock.

Ensure that the entire plant is de-energised before starting electrical installation work.

Protective equipmentWear the following personal protective equipment when handling the gear unit:

● Safety shoes

● Overalls

● Helmet

● Safety gloves

● Safety goggles

WARNING

Risk of eye injury

Small foreign particles such as sand or dust can enter the cover plates of the rotating parts and be hurled back by them.

Wear safety goggles.

Dangers during operationDamage to the gear unit is possible.

Safety instructions2.5 Special types of danger and personal protective equipment


Switch the gear unit to standstill immediately if inexplicable changes are noticed during operation. Such changes may include unusual gear unit noise or a significant increase in operating temperature.

WARNING

Risk of falling

There is an increased risk of falling when standing or walking on the gear unit during operation.

Only walk or stand on the gear unit and its mounted components for maintenance and repair work when it is at a standstill. Do not walk or stand on shaft ends, protection covers, mounted components or pipes.

WARNING

Danger to life through rotating or moving parts

There is danger that rotating or moving parts may catch hold of you or pull you in.

Secure rotating and/or moving parts against contact using safeguards.

Surface temperatureThe surface temperatures of the gear unit can become very extreme depending on the operating conditions.

WARNING

Risk of burns

Possible risk of serious burn injury from hot surfaces (> 55 °C).

Wear suitable protective gloves and protective clothing.

WARNING

Risk of scalding

Risk of serious injury possible through escaping hot operating media when these are being changed.

Wear suitable protective gloves, safety goggles and protective clothing.

WARNING

Danger due to low temperatures

Possible risk of serious injuries due to frost (pain, numbness, frostbite) on cold surfaces (< 0 °C).


Safety instructions2.5 Special types of danger and personal protective equipment


Chemical substancesInjuries can be sustained when using chemical substances.

WARNING

Risk of chemical burns due to chemical substances

There is a risk of chemical burns when handling aggressive cleaning agents.

Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents. Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to immediately clear up any spilt solvent.

CAUTION

Risk of injury due to chemically aggressive operating materials

There is a risk of injury to eyes and hands when handling chemically aggressive operating materials.

Please observe the safety instructions in the data sheets of the oil used. Wear suitable protective equipment (gloves, safety goggles). Use an oil-binding agent to immediately clean up spilt oil.

Danger of explosionAn explosion may occur in a potentially explosive atmosphere.

DANGER

Danger of explosion through ignition of a potentially explosive atmosphere

Danger to life through ignition of a potentially explosive atmosphere possible when operating the gear unit

Do not use the gear unit in potentially explosive atmospheres.

2.6 Intended useOnly use the gear unit according to the conditions specified in the service and delivery contract and the technical data in the annex (Page 79). Deviating operating conditions are considered improper use. The user or owner of the machine or plant is solely liable for any resulting damage.

Safety instructions2.6 Intended use


When using the gear unit please specifically observe the following:

● Do not make any modifications to the gear unit which go beyond the permissible handling described in these operating instructions. This also applies to safety features designed to prevent accidental contact.

● Only ever use original spare parts.Other spare parts are not tested and approved by Siemens. Non-approved spare parts may possibly change the design characteristics of the gear unit and thus impair its active or passive safety.Siemens will accept no liability or warranty whatsoever for damage occurring as a result of the use of non-approved spare parts. The same applies to any accessories which were not supplied by Siemens.

If you have any queries, please contact Customer Services (Page 69).

WARNING

Risk of falling

Risk of possible serious injury through falling.

Only walk or stand on the gear unit for maintenance and repair work when it is at a standstill. Do not walk or stand on shaft ends, protection covers, mounted components or pipes.

Gear unit use When using the gear unit, please observe the following basic rules:

● Ensure that the gear unit is operationally safe.

● The gear unit should only be operated, maintained or repaired by authorised, trained and suitably qualified personnel.

● The relevant work safety and environmental protection regulations must be complied with at all times during transport, assembly, dismantling, operation, maintenance and servicing.

● The outside of the gear unit must not be cleaned using high-pressure cleaning equipment.

● No welding work must be performed on the gear unit or on parts connected to it. The gear unit and any parts connected to it must not be used as an earthing point for electric-welding operations. Gearing and rolling-contact bearings might be irreparably damaged by welding.

● Perform potential equalisation in accordance with the applicable regulations and guidelines. If no threaded holes are available on the gear unit for an earth connection, please take suitable measures. This work must always be done by specialist electricians.

● In the case of gear units that are operated in combination with electrical machines that generate current or through which current flows (e.g. motors and generators), take measures to ensure that no current can flow through the gear unit.Current flowing through the gear unit can result in irreparable damage to rolling-contact bearings and gearing. Short circuits, voltage flashovers and deposits of conductive dust, for example, can all allow current to flow.Use insulators and earth the gear unit properly.

● When removing any protective devices, retain their fixings safely.

● Removed protective devices must be re-fitted prior to starting up.



● Pay attention to the notices attached to the gear unit such as the rating plate, direction arrow symbol etc. Notices must not be concealed by paint or dirt. Replace missing plates.

● Bolts which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type.

DANGER

Danger to life due to live system

Death or serious injury will occur.

Always shut down the gear unit and any oil supply system (whether separate or mounted on the gear unit) before you carry out any work. Secure the drive unit against being operated accidentally as follows:● Turn off the key-operated switch.● Remove the fuses in the power supply.● Attach a notice to the start switch, clearly stating that work is being carried out on the gear

unit.

Ensure that the tube mill has settled and come to a complete stop, and secure it using a holding brake.

Ensure that the entire unit is load-free so that no danger is posed when you start to dismantle components.

Reactivating the gear unit When installing the gear unit in machines or systems, the machine or system manufacturers must ensure that the regulations, notes and descriptions contained in these operating instructions are incorporated in their own operating instructions.



Description 33.1 General description

The FLENDER® girth gear unit (referred to below simply as "gear unit") described in these operating instructions has been developed to drive tube mills. Potential applications for this series of gear units include, for example, the cement and ore processing industries.

The gear unit is supplied as load sharing helical gear unit. The housing is not closed.

The shafts of the last stages each have an output pinion. These two drive pinions directly mesh in the girth gear, and are designed so that they can compensate unavoidable inclination and offset motion of the girth gear. This facilitates that during operation the gears mesh over most of the gear width.

The gear unit input shaft is fed out at both sides.

3.2 Oil supply to the gear unitThe gears as well as the rolling-contact bearings are force lubricated using an oil supply system. A piping system in the gear unit feeds and distributes the lubricant to the individual lubrication points. The nozzles and throttles used have large free cross-sections, and consequentially have a low tendency to clog up.

WARNING

Defective pressure monitor

Risk of serious injury possible due to a defective pressure monitor.

Install two pressure monitors with two switching points in the oil feeder line to the gear unit. An alarm should be output at a pressure of < 1.3 bar. A pressure ≤ 1.0 bar should shut down the gear unit.

Further informationIf the oil supply system is included in the scope of delivery, you can find additional information and a detailed diagram of the oil supply system in the foundation diagram in the complete gear unit documentation.

Additional information about the oil supply system can be found in the separate data sheet, in the list of equipment and in the oil supply system operating instructions provided in the complete gear unit documentation.


3.3 Shaft seal

IntroductionDepending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt from entering the gear unit.

The input shafts are sealed using a labyrinth seal and a radial shaft sealing ring.

As the housing at the output is open, this must be connected to the girth gear protective cover so that a tight seal is established.

3.3.1 Rotary shaft sealing ringsRotary shaft sealing rings are the standard seal used. Wherever possible, rotary shaft sealing rings are equipped with an additional dust lip which protects the actual sealing lip against external contaminants.

NOTICE

Irreparable damage to the rotary shaft sealing ring caused by high concentration of dust

A damaged rotary shaft sealing ring might not be able to effectively seal the gear unit.

In very dusty atmospheres, do not use rotary shaft sealing rings unless they have additional protection.

3.3.2 Labyrinth sealsLabyrinth seals as non-contact seals prevent shaft wear. They do not require any maintenance and improve the temperature behaviour of the gear unit.

To work reliably, labyrinth seals must be installed in stationary, horizontal positions without dirty water or any substantial amount of dust. Overfilling the gear unit can result in leaks, the same applies to oil with a high foam content.

3.4 Bearing monitoring

3.4.1 Bearing monitoring using a Pt 100 resistance thermometerDepending on the order specification, the gear unit can be equipped with Pt 100 resistance thermometers to monitor the bearings, or prepared for the installation of such thermometers.

You must connect the Pt 100 resistance thermometer to an evaluation unit provided by the customer to be able to measure temperatures or temperature differences. The resistance thermometer has a connection head for the wiring.

Description3.4 Bearing monitoring


Further informationFurther information and a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawing in the complete documentation for the gear unit.

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

3.5 Inductive sensor at the intermediate shaftAn inductive sensor can be installed at the intermediate shaft when specified in the order.

In operation, the inductive sensor monitors the axial offset of the floating shaft.

The inductive sensor at the intermediate shaft is shown in the following diagram:

300 Floating shaft 350 Rolling-contact bearing340 Cover 361 Sensor sleeve341 Cover 363 Inductive sensor344 Screw plug

Figure 3-1 Inductive sensor at the intermediate shaft

Description3.5 Inductive sensor at the intermediate shaft


Description3.5 Inductive sensor at the intermediate shaft


Application planning 44.1 Scope of delivery

The scope of delivery is listed in the shipping documents. Immediately upon receiving the gearbox, check that everything has been delivered. Report any damaged and/or missing parts to Customer Services (Page 69) immediately.

WARNING

Serious injury through defective product

Serious injury may occur.

If the gearbox exhibits any visible damage, you should not put it into operation.

4.2 Transport

General informationThe gear unit is delivered fully assembled. Additional items such as couplings, oil coolers, pipework and valves may be delivered separately packaged, as necessary.

When transporting the gear unit, observe the following instructions to avoid damaging the gear unit:

● Always use suitable equipment to transport the gear unit.

● Transport the gear unit without oil filling and leave it in the transport packaging.

● Do not use incorrect attachment points.The threads in the end faces of the shaft ends may not be used for attaching lifting equipment.

● Do not use the pipework to move the gear unit.

● Ensure that the lifting equipment is adequately designed to accommodate the weight of the gear unit.


WARNING

Risk of crushing

There is a risk of being crushed by a component that becomes detached because the hoisting gear and load suspension device are not suitable for handling it.

When lifting, please observe the load distribution information on the packaging.

When the product is in a raised position, transport it slowly and carefully to avoid injury to persons or damage to the gear unit.

Attaching the gear unitTo transport the gear unit, only attach slings to the marked attachment points that are provided for this purpose.

Please observe the following when attaching slings to the load or raising, lowering or moving it:

● Do not exceed the specified load limits

● If you are using a load suspension device with several load hooks, make sure that the load is evenly distributed between them

● Note the eccentric centre of gravity

● Make sure that the lifting equipment is securely attached

● Keep your speed down when moving the load

● Do not allow the load to sway and do not attach the load to objects or structures inside the building

● Loads must not be suspended from the tip of a load hook

● Always place the products down on a level, non-slip and stable base

DANGER

Falling load

There is a risk of fatal injury from falling loads if these have not been securely attached to the lifting equipment.

Never stand or sit under suspended loads. Do not exceed the load limits of the lifting equipment.

PackagingThe gear unit is delivered fully assembled. Additional equipment is also delivered separately packaged, as necessary.

The gear unit may be packed in various forms, depending on the size of the unit and method of transport.

Application planning4.2 Transport


Please adhere to the symbols applied on the packaging.

Figure 4-1 Transport symbols

Transport conditionsCarefully note the transport conditions listed in the table when transporting the unit from the factory to the customer's site.

Table 4-1 Transport conditions

Gear unit size18 22 25.4 30

Transport vehicle required Flat-bed trailer Flat-bed trailer with special flat bed (observe the height)

Number of chains required to secure the unit when trans‐porting it

4 4 6 8

Material used for transporting the unit

4 x 10 x 12 cm timber beams attached to the gear unit -

4.3 Attachment points

Lifting eyesLifting eyes are fitted to the gear unit to assist with its transportation during manufacture and installation.

Carefully ensure that the angle of the vertical load at the gear units lifting eyes does not exceed 45°.

Application planning4.3 Attachment points


Position of attachment pointsThe diagram below shows the position of the attachment points for gear units of type DMG2:

① Transport braces

Figure 4-2 Position of the attachment points for gear units of type DMG2

The floating intermediate shaft of the gear unit is axially held in place using a transport brace.

Store the transport brace so that it can be reused if the unit has to be transported.

Drive units with additional components mounted on the gear unit (such as drive motor, coupling, etc.) may require an extra attachment point owing to the displacement in the centre of gravity caused by the mounted components.

Further informationFurther information, a detailed illustration of the gear unit and the position of the attachment points can be found in the dimension drawings in the complete documentation for the gear unit.

Application planning4.3 Attachment points


4.4 Special aspects of gear unit lubrication and preservation

4.4.1 PreservationImproper use can damage the gear unit. Take the following precautions to ensure that the preservation remains effective:

● Make sure that the input shaft seals remain covered.

● Make sure that the protective cover (transport cover) remains mounted on the gear unit.

Application planning4.4 Special aspects of gear unit lubrication and preservation


Application planning4.4 Special aspects of gear unit lubrication and preservation


Assembly 55.1 General assembly instructions

The assembly work must be performed very carefully by authorised, trained and suitably instructed personnel. Liability will be disclaimed for damage caused by the incorrect performance of this work.

RequirementsImproper use can damage the gear unit. Be sure to take the following precautions:

● Protect the gear unit against falling objects and from becoming covered over.

● Do not perform any welding work anywhere on the drive.

● Do not use the gear unit as an earthing point for electric-welding operations.

● Use all of the fastening points fitted to the particular unit design.

● Replace any bolts that are no longer fit for use by new bolts of the same strength class and type.

● Make sure that sufficient hoisting gear is available.

● The open gear unit end is sealed with a cover (transport cover) to protect it against corrosion and the ingress of foreign particles. The gear unit is equipped with a transport brace to prevent the intermediate shaft from moving.Remove both parts as late as possible during assembly to ensure corrosion protection.

Mounting position and attachment pointsDuring the actual planning phase, be sure to allow for sufficient space around the gear unit to enable subsequent upkeep and maintenance work. Take suitable measures to ensure that unhindered convection across the housing surface is possible so that the gear unit does not overheat.

The foundation diagram with data regarding the dimensions, weight, load levels, design notes (connections) was already handed over for authorization. You can find this foundation diagram in the complete gear unit documentation.

Do not use incorrect attachment points (Page 25). The position of the attachment points are shown in the dimension drawing in the complete documentation for the gear unit. To ensure that the unit is properly lubricated during operation, please observe the mounting position specified in the dimension drawings.


NOTICE

Heating of the gear unit by external heat sources

The gear unit must not be heated by external heat sources (exposure to direct sunlight, for example) while it is in operation and measures must be taken where necessary to protect it.

You can take the following measures to protect the gear unit against this hazard:● A sun shield● An additional cooling device● A temperature monitoring device with trip function in the oil sump

If you use a sun shield, this may cause a build-up of heat.

If you use a temperature monitoring device, it must be capable of issuing an alarm when the maximum permissible oil sump temperature is reached. It must also be capable of tripping the drive when the maximum permissible oil sump temperature is exceeded. The operator's process might be interrupted when the drive is shut down.

WARNING

Ignition of vapours emitted from solvents.

There is a risk of injury due to ignition of vapours emitted from solvents when carrying out cleaning work.

Please note the following:● Ensure adequate ventilation.● Do not smoke.

The following table contains a selection of the most important tools required for assembly:

Table 5-1 Tools for assembling DMG2 gear units

Tool Provided byAssembly technician Customer

Levelling instrument with parallel plate micrometre X 2 dial gauges with magnet for attachment X Spirit level 0.02 mm/m, 200 mm long X Ruler (to align the baseplate) XGear unit size 18 approx. 2 350 mmGear unit size 22 approx. 2 710 mmGear unit size 25.4 approx. 3 130 mmGear unit size 30 approx. 3 770 mm

Assembly5.1 General assembly instructions


Tool Provided byAssembly technician Customer

Material for the casting frame X(e.g. L profile or boards, 100 to 150 mm wide)Gear unit size 18 Total minimum length 8 mGear unit size 22 Total minimum length 9 mGear unit size 25.4 Total minimum length 10 mGear unit size 30 Total minimum length 13 mIf required, anchors for the L profile, sand for the boardsDigital depth gauge or micrometre gauge (variable lengths) up to a depth of 500 mm

X

Height measuring stand Purchase or constructFoot fastening bolt preload unit, minimum 2 500 bar, including manual lever pump and high-pressure hose

Purchase

Gear unit size 18 Not requiredGear unit size 22 M80x4Gear unit size 25.4 M90x4Gear unit size 30 Not requiredMeasuring bar to align the gear unit XGear unit size 18 Diameter 35 to 40 x 1 450Gear unit size 22 Diameter 45 to 50 x 1 700Gear unit size 25.4 Diameter 50 to 60 x 2 000Gear unit size 30 Diameter 65 to 75 x 2 280Lengths are minimum lengths, material e.g. drawn steelFeeler gauge 0.05 to 2 mm X 2x hydraulic jacks 10 t X2x pumps for hydraulic jacks XVarious materials/tools: For example, solvent for Tectyl, con‐tainers to mix the grouting compound, stirring stick, drill, M30 hexagon wrench, steel cutting machine, plumb bob, tape measure

X

If required, for the piping: Cutting tool, welding equipment, 15% HCl to acidify, 15% NaOH to neutralize

X

1 kg grease X

Assembly5.1 General assembly instructions


5.2 Unpacking the gear unit

Introduction The scope of delivery is listed in the shipping documents.

WARNING

Risk of serious injury due to defective product

A defective gear unit can result in serious injury.

Do not put the gear unit into operation if any damage is visible.

Contact Customer Services (Page 69).

RequirementCheck that everything has been delivered immediately upon receipt.

NOTICE

Damage to the gear unit due to corrosion

Exposing the gear unit to moisture can result in damage from corrosion.

Do not damage or open the packaging prematurely if the packaging is designed to preserve the unit.

ProcedureTo unpack and use the gear unit, proceed as follows:

1. Remove packaging and transport devices in accordance with regulations.

2. Perform a visual inspection for damage and accumulations of dirt.

3. Immediately report any damaged and/or missing parts to Customer Services (Page 69).

4. Dispose of packaging material and transport devices in accordance with regulations.

Assembly5.2 Unpacking the gear unit


5.3 Preparatory measures for mounting the gear unit

5.3.1 Checking the girth gear

IntroductionThe radial runout is the difference between the maximum and minimum measurement around the circumference of the girth gear. Record the values of at least 16 measuring points.

It is not permissible for the runout and axial eccentricity of the girth gear to exceed the maximum permissible values. You must realign the girth gear if any of the maximum permissible values are exceeded.

The permissible runout and axial eccentricity values for girth gears are listed in the following table. If lower values are specified in the assembly instructions for the girth gear unit, then you must comply with these lower values.

Table 5-2 Permissible runout and axial eccentricity of girth gears

Tip circle diameter of the girth gear in m

Permissible runout in mm Permissible axial eccentricity in mm

≤ 5.0 0.8 0.8> 5.0 1.0 1.0

The following diagram shows how the dial gauges are positioned on the girth gear:

Figure 5-1 Positioning the dial gauges (A, B, C) on the girth gear

Assembly5.3 Preparatory measures for mounting the gear unit


ProcedureProceed as follows to check the girth gear:

1. Attach three dial gauges to the girth gear. Carefully observe the position of the dial gauges on the girth gear.

2. Ensure that pressure is applied to the hydrostatic bearings.

3. Rotate the tube mill using a winch. Use a winch with reverse locking in order to avoid the tube mill recoiling.

4. Measure the runout and axial eccentricity and record the results. The procedure is described in the measurement report for the girth gear.A deviation higher than 0.2 mm between two consecutive measuring points is not permissible (e.g. between measuring points 4 and 5).

5. Mark the highest point of the runout.

5.3.2 Determining the centre of the tube millTo help make the measurements, at the alignment surface on the face side of the girth gear you can attach two measurement prods, offset through 180°. Determine the centre of the tube mill and mark this (e.g. on a wall).



5.3.3 Checking the foundationThe foundation drawing is shown in the following diagram:

① Girth gear ③ Baseplate② Plumb bob

Figure 5-2 Foundation drawing

ProcedureProceed as follows to check the foundation:

1. Using the foundation drawing, sketch the arrangement of the baseplate to the girth gear on the existing foundation and carefully check this.

2. Using the plumb bob, transfer the outer diameter of the girth gear to the foundation.

3. Take the assembly dimension "X“ from the foundation drawing.

NOTICE

Damage to the gear unit

Gear unit damage is possible due to production deviations.

The assembly dimension "X" can change if permissible production deviations of the girth gear is exceeded (e.g. tooth width, tip circle diameter).

In this case, contact Customer service (Page 69).



5.4 Mounting the baseplateYou must have the following parts to mount the baseplate:

Table 5-3 Parts required to mount the baseplate

Part No. Quan‐tity

Designation Part No. Quan‐tity

Designation

1 1 Baseplate 12 6 Plate2 1 Baseplate 8 Plate for gear unit size 303 4 Pedestal 13 6 Steel U-section4 24 Hexagon bolt 8 Steel U section for gear unit size 305 2 Connecting plate 14 6 Threaded rod6

8 Hexagon bolt for gear unit size 18 8 Threaded rod for gear unit size 308 Hexagon bolt for gear unit size 22 15 12 Hexagon nut16 Hexagon bolt for gear unit size 25.4 16 Hexagon bolt for gear unit size 3020 Hexagon bolt for gear unit size 30 21 Sealing material

11 16 Hexagon bolt for gear unit size 18 23 4 Hexagon bolt20 Hexagon bolt for gear unit size 22 24 4 Hexagon nut16 Hexagon bolt for gear unit size 25.4 30 1 Measuring stand16 Hexagon bolt for gear unit size 30 31 4 Hexagon bolt

Assembly5.4 Mounting the baseplate


The assembly drawing is shown in the following diagram:

① Connecting plate (only screw on after grouting) ⑦ Steel plate② Measuring stand (is part of the system build‐

er's measuring equipment, align to the centre of the girth gear)

⑧ Casting mix of the concrete foundation, (non-shrinking, compression strength ≥ 90 N/mm2)

③ Shuttering ⑨ Holes for the measuring stand④ Hexagon bolts (11) (after the grouting com‐

pound hardens, cut off and scour)⑩ Pedestal (to longitudinally align the gear unit)

⑤ Concrete foundation (cast, approximately 50 mm thick)

⑪ Concrete foundation

⑥ Shuttering

Figure 5-3 Assembly drawing

ProcedureProceed as follows to mount the baseplate:

1. Position the baseplates and check the mounting dimensions.

2. Bolt the measuring stand to the first baseplate (1). The measuring stand has a mark that precisely corresponds to the centre of the main gear unit (height) in the operating state.

3. Using the threaded rods (14) and the accessories (12, 13, 15), clamp the baseplate to the foundation and horizontally align it using the set screws (11).



4. Check that it is in a horizontal position using a spirit level. Using the levelling instrument, check the precise height over the measuring stand/fixed point in the building (tube mill axis).

5. Pre-align the second baseplate (2) using a straight-edge, and mount the second baseplate in the same way as you did the first.

6. Enclose the baseplates in shuttering, and grout them using a non-shrinking material with defined attributes, as specified in the foundation drawing.

7. Seal the foundation holes so that the grouting compound cannot enter them. To do this, individually release the threaded rods (14) to achieve the appropriate seal. Carefully comply with the special instructions for using this grouting compound.

8. Check the baseplates again using a spirit level.

9. Remove the auxiliary fixtures after the grouting compound has hardened.

10.Insert the foot fastening bolts for the gear unit in the foundation holes as it will not be possible to do this later.

11.Cut off the set screws (11).

NOTICE


Gear unit damage is possible due to production deviations.

Ensure that the two baseplates are precisely horizontal and flat with respect to one another. It is not permissible that the maximum deviation exceeds 0.1 mm per 1 m.



5.5 Mounting the gear unitMounting the gear unit is shown in the following diagram:

① Measuring bar ⑧ Rear edge of the gear unit for zero tooth flank backlash

② Gear unit A Dimension A③ Cam on the gear unit housing B Dimension B④ Hydraulic jack C Dimension C (B = C)⑤ Stopper on the baseplates D Dimension D (A = D)⑥ Stop rail Y Retraction distance⑦ Grouting compound

Figure 5-4 Mounting the gear unit

Requirements

CAUTION

Risk of chemical burns due to chemical substances

There is a risk of chemical burns when handling aggressive cleaning agents.

Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents. Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to immediately clear up any spilt solvent.

Assembly5.5 Mounting the gear unit


Improper use can damage the gear unit. Be sure to take the following precautions:

● Remove the cover (transport cover).

● Use a suitable cleaning agent to remove the corrosion protection from the input shafts and mounting surfaces.

● Remove the corrosion protection and dirt from the mounting surfaces before you place the gear unit down on the baseplate.

● Do not allow the cleaning agent to come into contact with the shaft sealing rings.

● Use an assembly fixture (retractor) to mount the input elements (e.g. coupling components) onto the shafts and lock them securely. See chapter Couplings (Page 43).

● Check that the point marked on the girth gear (highest point of the radial runout measurement) is at the height of the tube mill axis.

● Use a suitable crane to position the gear unit.

DANGER

Risk of fatal injury from flying fragments

Failure to align the unit with the required degree of accuracy can cause the shaft to rupture. A ruptured shaft can result in serious or even fatal injuries.

Align the gear unit exactly so that it conforms to the specified alignment values.

Damage to the gear unit or its components or mounted parts is possible.

The accuracy of the alignment between the shaft axes largely determines the service life of the shafts, rolling-contact bearings and couplings. Please therefore always endeavour to achieve zero deviation in the alignment of the shaft axes (does not apply to ZAPEX couplings). In this context, please also refer to the relevant operating instructions for further information about, for example, the requirements of couplings.

NOTICE

Damage to the gear wheels

The gear wheels can be damaged.

Proceed with extreme caution when meshing the gear wheels and approaching a tooth flank backlash of zero. Constantly check the backlash of both meshing positions. Under no circumstances may you continue to move the gear unit if at one meshing position a tooth flank backlash of "zero" is reached.

ProcedureProceed as follows to mount the gear unit:

1. Place the gear unit down on the baseplate.

2. Check the height using the levelling instrument. Determine the centre to the girth gear in the width axis using the helical gears (part Nos. 216 and 217 in the spare parts drawing (Page 74)).Dimensions B and C must be equal (B = C).



3. Mount a lever arm on the input shaft so that the pinions can be turned.

4. Remove the transport brace for the floating shaft. To do this, remove the lock nuts and remove the threaded rods at both sides of the gear unit. Close the hole in the bearing cover using an appropriate plug.

5. Using hydraulic jacks, move the main gear unit towards the girth gear until a tooth flank backlash "equal to zero" is reached.Carefully ensure that the pinion teeth mesh in parallel to the teeth of the girth gear.

6. At this position, insert a measuring bar between two teeth of the girth gear to precisely define the parallel position of the main gear unit to the tube mill axis. Make a measurement between the measuring bar and the flange at the main gear unit, to which the seal is attached. Dimensions A and D must be equal (A = D).

7. Align the gear unit.

8. Retract the complete drive back by dimension "Y" specified in the foundation drawing. This results in the tooth flank backlash required for operation. To ensure that the drive is equally retracted, at the rear of the gear unit mounting feet attach two dial gauges while retracting the gear unit using the hydraulic jacks.

9. Check the shaft height of the gear unit and ensure that it is in parallel with the girth gear. The dial gauges are left in place for checking.

Further informationFurther information about removing the corrosion protection can be found in the operating instructions BA 7300 in the complete documentation for the gear unit.

Further information about attaching gear units to hoisting gear in cases where the gear weight necessitates the use of hoisting gear can be found in Chapter Application planning (Page 23).

If the gear unit is to be transported with mounted parts and components, then it may be necessary to use additional attachment points. The position of these attachment points can be found in the dimension drawing in the complete documentation for the gear unit.

5.5.1 Fastening foundation bolts

ProcedureTo fasten the foundation bolts, proceed as follows:

1. Pull up the foundation bolts and temporarily fasten them with the associated nuts and washers.

2. Tighten the bolts according to the assembly instructions.

3. Check the drive again with the fixed point "centre of tube mill" in the building and the measuring pointer in the housing. Check the reference points attached in the housing using a spirit level.

4. Record the measured values.



5. Keep the report together with these operating instructions at the tube mill.

6. As additional security, cast non-shrinking material in the space between the stop rail and the gear unit mounting feet.

CAUTION

Injury as a result of incorrect mounting

Incorrect mounting can result in damage and consequential injury.

Tighten the fastening bolts or nuts with the specified tightening torque and tension these to the specified preload force using the hydraulic preload unit.

The following table lists the preload forces and tightening torques for bolt connections with strength class 10.9:

Table 5-4 Technical data of the foundation bolts/nuts

Gear unit size Type of foundation nuts Diameter Preload force in kN Tightening torque in Nm

18 Superbolt M72x4 - M16 1 750 26522 Hexagon bolt M80x4 1 950 -25.4 Hexagon bolt M90x4 2 550 -30 Superbolt M110x6 - M20 3 900 800



5.6 Couplings

IntroductionImproper use can damage the gear unit. Be sure to take the following precautions:

● If necessary, carry out the following preparatory work in accordance with the operating instructions for the coupling:

– Machine the finished bore

– Mill the parallel keyway

– Fit the axial locking element

– Balance

● Align the individual components precisely with one another.

● Refer to the operating instructions for the coupling for instructions on how to install, maintain and operate the coupling.

WARNING

Danger of injury due to coupling rupture

Flying fragments can cause fatal injury.

Observe the operating instructions for the couplings.

NOTICE

Serious or irreparable damage to the gear unit and coupling caused by inaccurate or incorrect alignment

Failure to accurately or correctly align the gear unit and coupling may result in serious or irreparable damage to both components.

Align the individual components precisely with one another when installing the drives. Make sure that the maximum permissible displacement values are not exceeded during operation.

Further informationFurther information about the coupling can be found in the operating instructions for the coupling in the complete documentation for the gear unit.

5.6.1 Assembling the coupling

IntroductionThe method used to assemble the coupling varies according to type. The procedure described in these operating instructions is general rather than specific to one type of coupling.

Assembly5.6 Couplings


Assemble the coupling as described in the operating instructions for the specific coupling.


● Do not use force (hammer blows, etc.) to fit the coupling parts as this can cause internal damage to the gear unit.

● Take care not to damage the shaft sealing rings or shaft running surfaces when fitting the coupling parts.

ProcedureTo fit the coupling, proceed as follows:

1. Carefully clean the shaft ends and the coupling parts.

2. Use a suitable fixture to mount the coupling parts on the shaft ends.

3. Lock the coupling parts to prevent axial displacement.

4. Move the machines to be coupled close to one another and thenalign them (Page 45).

5. Join the coupling parts together.

Heating coupling parts prior to mountingDepending on the order specification, it may be necessary to heat the coupling parts before mounting them.

WARNING

Risk of burns

Possible risk of serious burn injury from hot surfaces (> 55 °C).



● The required joining temperatures can be found in the dimension drawings in the operating instructions for the coupling

● Unless otherwise instructed, heat the coupling parts by an induction heater, with a torch or in an oven.

● Use heat shields designed to protect against radiant heat in order to safeguard the shaft sealing rings against damage or heating to above 100 °C.

● Quickly fit the coupling parts on the shafts. The mounting dimensions can be found in the dimension drawings in the operating instructions for the coupling.

Further informationFurther information about the coupling can be found in the operating instructions for the coupling in the complete documentation for the gear unit.



5.6.2 Aligning the coupling

IntroductionThe coupling parts might become misaligned as a result of:

● Failure to accurately align the parts during assembly

● During operation:

– Due to thermal expansion

– Due to shaft deflection

– Due to machine frames that are too soft

Improper use can damage the gear unit or the coupling. Be sure to take the following precautions:

● Make sure that the maximum permissible displacement values are not exceeded during operation.

– If you are using couplings supplied by Siemens, you will find the maximum permissible displacement values in the operating instructions for the coupling.

– If you are using couplings supplied by other manufacturers, contact them and ask them for the maximum permissible displacement values, making sure that you specify the potential radial loads for your application. Keep the operating instructions for the coupling together with these operating instructions.

● Angular and radial displacement might occur simultaneously.Make sure that the total value of both displacements does not exceed the maximum permissible angular or radial displacement value.

The diagram below illustrates the potential displacements:

Figure 5-5 Possible displacements

AlignmentAlign the individual components in two mutually perpendicular axial planes. The following can be used as alignment tools:

● Ruler (radial displacement)

● Feeler gauge (angular displacement)

● Spirit level



● Dial gauge

● Laser alignment system

You will achieve a greater degree of alignment accuracy by using a dial gauge or laser alignment system.

The diagram below shows the alignment process based on the example of a flexible coupling:

① Ruler ③ Measuring points② Feeler gauge

Figure 5-6 Alignment process based on the example of a flexible coupling

Note

It is advisable to insert shims or metal sheets under the mounting feet in order to align the drive components in the vertical direction. It is helpful to use support paws with adjusting screws on the foundation to adjust the drive components laterally.

Gear unit with motor bell housingIf the gear unit and the motor are connected through a motor bell housing, no alignment of the couplings is necessary.

Further informationFurther information about the permissible alignment errors can be found in the coupling operating instructions in the complete documentation for the gear unit, or contact the manufacturer in question.



5.7 Connecting components

5.7.1 Making terminal box connections for pre-wired gear units

ProcedureProceed as follows to wire up the gear unit:

1. Connect up all pre-wired gear units as shown on the circuit diagram in the terminal box (Page 83).

2. If a pressure monitor is installed, bypass the pressure monitor signal for around 20 seconds during commissioning.This is necessary as the pressure in the gear unit must first stabilise.

WARNING

Explosion and fire hazard

Exposed heating elements pose a fire hazard.

Do not put heating elements into service until you have checked that they are completely immersed in the oil bath.

Further informationYou can find further information about pre-wired gear units in the order-specific list of equipment in the complete gear unit documentation.

5.7.2 Installing a separate oil supply system

ProcedureTo connect the oil supply system to the gear unit, proceed as follows:

1. Remove the dummy flange from the suction and delivery line before connecting the system.

2. Connect the system to the gear unit in accordance with the dimension drawings in the complete documentation and install it as a separate system.

3. When installing the system, make sure that the pipework is not subjected to mechanical stresses.

Further informationFurther information about the oil supply system can be found in the oil supply system operating instructions in the complete documentation for the gear unit.

Assembly5.7 Connecting components


5.7.3 Electrical connections

RequirementsDo not use any motor that exceeds the specified speeds of the gear unit as otherwise the gear unit may become damaged. The speeds are displayed on the rating plate.


● Before connecting the motor, determine the phase sequence of the three-phase power system using a phase-sequence indicator.

● Connect the motor corresponding to the predefined direction of rotation.

Procedure

DANGER

Electric shock

Live parts can cause electric shock.

Ensure that the entire plant is de-energised before starting electrical installation work. Carefully observe the five safety rules (Page 11).

To connect the motors and monitoring devices, proceed as follows:

1. Ensure that the connections of the motors and monitoring devices are not damaged.

2. Connect up the motors and monitoring devices according to the terminal diagram (Page 83) and the relevant operating instructions.

3. Insulate all cable entry points (glands) at electrical equipment as required for the environment in which the equipment will operate.

Further informationYou can find additional information about the electrical connections in the terminal diagrams and equipment lists provided in the complete gear unit documentation.

5.8 Final work

MeasuresOnce all the elements have been assembled or connected, perform the following final work:

● Check whether all devices dismantled for transportation have been reassembled.

● Check all bolt connections for tightness after installation of the gear unit has been completed.

Assembly5.8 Final work


● Check the alignment after tightening the fastening elements. The alignment must not have changed in any way.

● Lock the oil drain valves against accidental opening.

● Protect the gear unit against falling objects.

● Check that the guards over rotating parts are securely fastened.Contact (accidental or deliberate) with rotating parts is not permitted.

● Perform potential equalisation in accordance with the applicable regulations and guidelines. If no threaded holes are available on the gear unit for an earth connection, please take suitable alternative measures. This work must always be done by specialist electricians.

● Protect the cable entries against penetrating moisture.

Further informationYou will find further information about the gear unit and all mounted or separately supplied components in the operating instructions of the relevant components included in the complete documentation for the gear unit.

You can find additional technical specifications in the separate data sheet in the complete gear unit documentation.



Commissioning 6Introduction

The precondition for the warranty is first commissioning by specialists from Siemens or by skilled persons who have been appropriately trained and are authorised by Siemens.

Siemens urgently recommends that the tube mill is first driven by the gear unit under the supervision of the nominated specialists or skilled persons.

Follow the operating instructions, particularly with regard to maintenance work on the tube mill, during which the mill rotates and the gear unit rotates with it.

NOTICE


Every time the drive is set in motion represents a commissioning process. Do not commission the gear unit without having the operating instructions at hand.

6.1 Measures prior to commissioningTake the following measures before commissioning the gear unit:

● Read and observe the operating instructions.

● Follow the checking procedure (Page 55).

● Replace the screw plugs with the air filters. Follow the instructions in BA 7300.

● Gear unit with oil supply system: Check that the oil supply system is working properly.

● Check the oil level.

● Check the gear unit for leaks.

● Gear unit with oil supply system: Follow the instructions in Measures prior to commissioning with oil supply system (Page 54).

● Ensure that all pipes and components are filled with oil.

● Recommissioning: Make sure that the drive cannot be restarted after safety equipment has responded unless the restarting lockout is cancelled.

Further informationFurther information about oil and replacement of air filters can be found in the operating instructions BA 7300 in the complete documentation for the gear unit.


Further information about individual components can be found in the operating instructions for the components in the complete documentation for the gear unit.

6.1.1 Flushing before first commissioningThere is a difference between "rinsing" before first commissioning and "rinsing" before and after repair and maintenance work.

Follow the instructions in BA 7300.

The duration of rinsing before first commissioning depends on the temperature of the oil.

For rinsing before first commissioning, note the information in the following table:

Table 6-1 Rinsing duration

Oil temperature Rinsing duration20 °C 6 h30 °C 5 h40 °C 3.5 h50 °C 2 h

NOTICE

Mixing oils

The gear unit can be damaged by mixing oils.

At low oil temperatures, in the cover, the oil for the girth gear only flows back slowly. Before draining the oil, check that the original level in the oil supply system has been reached again. The oil can only be reused as flushing oil and only after it has been thoroughly cleaned.

6.1.2 Adjusting the inductive sensor

IntroductionAs a result of alignment and gearing deviations of the girth gear, for a gear unit mounted in front of the girth gear, the floating shaft may have moved away from the centre position.

The inductive sensor at the intermediate shaft is shown in the following diagram:

Commissioning6.1 Measures prior to commissioning


300 Floating shaft 350 Rolling-contact bearing340 Cover 361 Sensor sleeve341 Cover 363 Inductive sensor344 Screw plug

Figure 6-1 Inductive sensor at the intermediate shaft

RequirementsThe following requirements must be fulfilled before the inductive sensor is adjusted:

● The girth gear unit has been mounted in front of the tube mill and is tensioned in the load direction.

● The covers have numbers stamped on them for identification. This identification corresponds to dimension "a“ for the centre position of the floating shaft.

ProcedureProceed as follows to adjust the inductive sensor (Page 21):

1. Perform a check measurement to check the floating shaft offset.

– Remove the sensor sleeve or the screw plug.

– Using a depth gauge, measure dimension "a".

2. Calculate the offset from the centre position from the difference between the measured dimension "a“ and the values stamped on the covers. Also take into account the calculation example.

3. If the axial offset of the floating shaft lies within the permissible range, mount the inductive sensor with a clearance of "b" to the shaft face. You can find dimension "b“ in the list of equipment in the complete gear unit documentation. If required, reinsert the screw plug and tighten.



NOTICE


The gear unit can be damaged as a result of the floating shaft offset.

Check that in operation the maximum permissible dynamic deflection of the floating shaft in the axial direction does not exceed the permissible value. Report any deviations to Customer Services (Page 69).

The permissible axial offsets of the floating shaft are listed in the following table.

Table 6-2 Permissible axial offsets of the floating shaft from the centre position


Maximum permissible axial offset from the centre position in operation, including dynamic deflection

± 4.5 mm ± 5.5 mm ± 6.0 mm ± 7.5 mm

Maximum permissible dynamic deflection during operation

± 0.7 mm

ExampleCalculation example with gear unit size 25.4:

Value stamped on the cover (340): 115.9 mmValue "a“ measured at the cover (340): 114.2 mmAxial offset from the centre position: - 1.7 mmValue stamped on the cover (341): 115.5 mmValue "a“ measured at the cover (341): 117.2 mmAxial offset from the centre position: + 1.7 mmPermissible axial offset from the table: ± 6.0 mm

6.1.3 Gear unit with oil supply systemTake the following measures before commissioning a gear unit with an oil supply system:

● Make sure that the pressure in the oil supply system components does not exceed the maximum permissible pressure.

● Make sure that the temperature of the oil supply system components does not exceed the maximum permissible temperature.

● Using the oil supply system, lubricate the gear unit for 30 - 60 minutes in a pre-lubrication phase. During this time, the rolling-contact bearings and gearing are supplied with sufficient oil for starting.



Further informationYou will find information on the oil supply system in the data sheet, in the list of equipment and in the operating instructions for the oil supply system, which are part of the complete documentation of the gear unit.

6.1.4 Checking procedureCheck all drive components after completion of assembly and before the first cold trial run. Remove all material residue, tools and assembly equipment.

If the oil supply system was supplied by Siemens, it has already been function-tested. Before the test run of the tube mill, test the electrical interlocking between the oil supply system and the drive motors.

To perform the checking procedure, inspect the following items:

☐ Have the baseplates been completely grouted?☐ Have the foundation bolts been tightened to the correct torque?☐ Have the foundation bolts for the main motor been tightened as specified?☐ Has the inside of the girth gear protection cover been cleaned, and is the return line clear?☐ Has the girth gear been aligned according to assembly specifications?☐ Have the fastening bolts of the girth gear been tightened with the specified tightening

torque?☐ Has the girth gear protection cover seal been attached according to specifications and is

it operational?☐ Has the seal where the housing is connected to the girth gear protective cover been

correctly attached?☐ Have all pipes been installed and cleaned according to the assembly instructions?☐ Have the pipes and hoses been correctly installed?☐ Have the oil tanks been filled up to the filling marks? (Check while the oil supply system

is running)☐ Have all monitoring devices been connected according to the circuit diagram?☐ Has the function of the oil supply system been checked?☐ Have the following measurements been recorded: □ Height marks at the foundation and position of the tube mill axes □ Height of the baseplates □ Synchronous operation deviations of the girth gear, axial and radial values □ Tooth flank and tip backlash between the girth gear and pinion □ Alignment - motor, coupling and gear unit☐ Has the interlocking function been checked according to the interlocking diagram or ac‐

cording to the description?☐ Have the flow monitors, pressure switches and temperature sensors been set to the cor‐

rect values?☐ Is the cooling water feed open?☐ Has the transport brace for the floating shaft been removed?



☐ If an inductive sensor belongs to our scope of delivery: Has the inductive sensor been correctly mounted?

☐ Does the axial offset of the floating shaft lie within the permissible range? (When perform‐ing the measurement, the gear unit must be tensioned in the load direction. Permissible values are listed in Chapter Adjusting the inductive sensor (Page 52)).

You will find further checking procedures in the operating instructions of the following components:

● Coupling

● Motor

● Oil supply system

● Girth gear

● Tube mill

6.2 Measures during commissioningPlease observe the following measures to commission the gear unit and document these:

● Keep the report in a safe place together with these operating instructions.

● For gear units with oil supply system: Check that the oil supply system is working properly.

● Check the oil level.

● Check the tightness of the shaft seal on the gear unit (Page 20).

● Check that no contact with rotating parts is possible.

● Check whether the shutoff valves are open.

– Check that all of the oil drain valves are closed.

– Ensure that all of the other shutoff valves are open.

● Check all the connection lines are securely tightened and leak-free.

● Check the position of the floating shaft from the zero position, including the dynamic deflection. The maximum permissible axial and dynamic offsets are specified in ChapterAdjusting the inductive sensor (Page 52).

● For gear units with bearing monitoring using a Pt 100 resistance thermometer: Measure the temperature at the rolling-contact bearings (Page 64) to create initial and comparison values.

● Bypass the pressure monitor signal for around 20 seconds during commissioning. This is necessary as the pressure in the gear unit must first stabilise.

Further informationYou can find additional information on the topic of oil in the operating instructions BA 7300, provided in the complete gear unit documentation.

Further information about the oil supply system can be found in the oil supply system operating instructions in the complete documentation for the gear unit.

Commissioning6.2 Measures during commissioning


6.2.1 Initial test runIf a cold test run (partial load range without the mill being filled) is required, then it is only permissible that you operate the gear unit via the auxiliary drive.

When operating the system using the main motor, ensure that the tube mill is at least 80 % full.

With the tube mill 80% full, check the contact pattern. Over the tooth width, the contact patterns should indicate a contact surface of at least 80 %. Carefully check the contact patterns, and report any deviations to Customer Services (Page 69).

You can add material to the tube mill if a contact surface greater than 80% is reached.



Operation 77.1 Operating data

Introduction To ensure correct, trouble-free operation of the system, observe the operating data of the gear unit and the data in the operating instructions for the oil supply system.

The valid operating data can be found in the annex Technical data (Page 79).

In operation, filter the lubricating oil in the lubricating circuit using a filter with 25 μm nominal filter mesh size.

The following operating data apply to the oil:

Table 7-1 Operating data

Inlet oil temperature 40 - 45 °C

Maximum inlet oil temperature 55 °C is applicable for mineral oil, API groups I or II and saturated synthetic ester

60 °C is applicable for semi-synthetic oils, API group III, PAO and PG oils

You will find information about the oil pressure in the data sheet, in the list of equipment or in the dimension drawing in the complete documentation for the gear unit.

Further informationYou can find additional technical data of the gear unit in the separate data sheet and in the equipment list in the complete gear unit documentation.

7.2 Irregularities in operation

IntroductionSwitch off the drive assembly immediately if it exhibits irregular behaviour during operation.

A few irregularities are listed below as examples:

● Oil temperature exceeds the maximum permissible value

● Alarm tripped by the pressure monitor in the oil cooling system or oil supply system

● Unusual operating noise


NOTICE

Faults can cause damage to the gear unit

The gear unit might sustain damage if it is not shut down when a fault occurs.

Switch off the drive assembly immediately if any fault condition develops.

Rectifying irregularities in operationProceed as follows to rectify any irregularities in operation:

1. Switch off the drive assembly if it exhibits irregular behaviour during operation.

2. Refer to the Fault information (Page 66) to find the cause of the fault.

3. If you still cannot determine the fault cause, contact Siemens Customer Services (Page 69).

7.3 Taking the unit out of serviceIf you take the unit out of service for a prolonged period, you must take the following measures depending on the length of time that the gear unit will remain out of service:

● Switch off the drive assembly.

● For gear units with a water-oil cooler:

– If there is a risk of frost or the unit is to be taken out of service for a prolonged period, drain the water from the water-oil cooler and remove residual water with compressed air.

– Close the shutoff valves for the cooling water inlet and drain lines.

● Take measures to preserve the gear unit if it is to be out of service for a prolonged period. Follow the preservation procedure described in operating instructions BA 7300.

● For gear units with a separate oil supply system, perform the following steps before you preserve the gear unit:

– Disconnect the gear unit from the separate oil supply system.

– Seal the openings at the gear unit and separate oil supply system so that they are air-tight.

WARNING

Risk of eye injury from compressed air

Water residue and dirt particles can injure eyes.

Wear suitable safety goggles.

Operation7.3 Taking the unit out of service


Maintenance 88.1 General maintenance information

The operator must ensure compliance with the stipulated time limits. This also applies if the maintenance activities are included in the operator’s internal maintenance schedules.

The gear unit could be damaged if the stipulated time limits for maintenance and servicing are not observed.

The time limits stipulated in the maintenance schedule are largely dependent on the conditions of use of the gear unit. For this reason, it is only possible to state average time limits here. These refer to the following conditions of use:

● Daily operating time 24 h

● Duty cycle "ED" 100%

● Gear unit input speed 1500 rpm

● Average oil temperature in the oil sump (see operating instructions BA 7300)

WARNING

Danger to life due to live system

Working on a gear unit while it is in operation is hazardous and can result in potentially fatal injuries.

Always shut down the gear unit and any oil supply system (whether separate or mounted on the gear unit) before you carry out any work. Take measures to prevent the accidental restarting of the drive assembly. Display a warning notice that clearly states that work is being carried out on the gear unit. Ensure that the tube mill has settled and come to a complete stop, and secure it using a holding brake.


8.2 Maintenance schedule

Maintenance and servicing workThe following table provides an overview of all maintenance and servicing work which you are required to perform continuously or at regular intervals. Uses the corresponding checklist (Page 85).

Table 8-1 Maintenance and servicing work

Intervals and time limits MeasuresAs required Clean the nozzles and throttles in the oil distribution

systemClean the gear unitReplace the oil filterClean the air filter

According to manufacturer’s specifications Maintain the oil supply systemWeekly Check for leaks

Check the oil levelInspect the oil supply system for dirtInspect instruments installed in situ (temperatures, oil pressures)

Every 2 weeks Clean filter insertsEvery 4 weeks Visually inspect the girth gear system and gear unit for

cracks, leaks and damageCheck the oil temperatureCheck for changes in the gear unit noiseInspect the protection devicesVisually inspect the condition of tooth flanks and the contact pattern

Every 3 months Clean the oil filterClean the air filterClean the nozzles and throttles in the oil distribution systemCheck that the foot fastening bolts are tight

Every 6 months Inspect mounted components (couplings, auxiliary drive)Investigate an oil specimen for its lubricating propertiesCheck the girth gear cover seal

Every 12 months Visually inspect the tooth flanks for damageInspect the hose linesAnalyse the oilClean the overrunning clutchCheck that all of the fastening bolts are tightCheck the drive for alignment errorsMain motor general overhaul

Maintenance8.2 Maintenance schedule


Intervals and time limits MeasuresEvery 10 000 operating hours, at least every 2 years

Change the oil if using mineral oil of API Group I or II or saturated synthetic esters (or depending on the re‐sult of the oil sample test)Check the air‐oil cooler (the same time as you change the oil)Check the water‐oil cooler (the same time as you change the oil)

Every 2 years Carry out a general inspection of the gear unitClean the gear unit

Every 20 000 operating hours, at least every 4 years

Change the oil if using semi-synthetic oil of API Group III, PAO or PG oil (or depending on the result of the oil sampling)

6 years after the specified date of manufacture Change the hoses

Further informationFurther information about additional maintenance and servicing work can be found in the separate data sheet in the complete documentation for the gear unit.

Further information about installed components can be found in the operating instructions for the components in the complete documentation for the gear unit.

8.3 Maintenance and servicing work

IntroductionYou can find maintenance and servicing measures relating to gear unit lubrication and preservation, which are not provided in this chapter, in BA 7300 in the complete gear unit documentation.

8.3.1 Contamination limitsThe following table contains the material-specific contamination values of the oil:

Material Limit proportion in mg/kg

Possible source

Iron (Fe) 40 Girth gear, gear wheels, rolling-contact bearingsChromium (Cr) 4 Plain and rolling-contact bearings, gear wheelsAluminium (Al) 4 Oil pump bearingsCopper (Cu) 4 Rolling-contact bearing cagesLead (Pb) 6 Pump sleeve bearing, tube mill sleeve bearingTin (Sn) 2 Pump sleeve bearing, tube mill sleeve bearingNickel (Ni) 2 Gear wheels

Maintenance8.3 Maintenance and servicing work


Material Limit proportion in mg/kg

Possible source

Zinc (Zn) 10 Zinc-based primer (sometimes used as an addi‐tive). In this case, contact Siemens.

Silicon (Si) 20 Dust or other environmental influencesWater (H2O) 0.10 % Condensation, water-oil cooler defective

Note that the deviation in the viscosity of the oil sample from the viscosity of the oil specified in the technical data should not exceed 10 %.

NOTICE


The gear unit may be damaged by dirty operating oil and mixing different oil grades.

Replace the oil if the contamination limits stated in the table or the purity class 20/18/15 according to ISO 4406 is exceeded.

After changing the oil, fill the gear unit with the oil grade that was previously used. Do not mix oils of different grades or manufacturers.

8.3.2 Servicing

Preparatory measuresServicing includes all measures to restore the desired condition after faults.

Attach and secure the individual components and large assemblies to the lifting equipment carefully during replacement.

8.3.3 Measuring the temperature at the rolling-contact bearings

ProcedureProceed as follows to measure the temperature at the rolling-contact bearings:

1. Measure the temperature at the rolling-contact bearings.

2. Document the measurement results.

3. Compare the measured values with the comparison values that were documented when commissioning the gear unit.

4. Archive the report together with these instructions.

5. Replace defective rolling-contact bearings.



Further informationFurther information about measuring the temperature at the rolling-contact bearings can be found in the Pt 100 resistance thermometer operating instructions in the complete documentation for the gear unit.

8.3.4 Cleaning the gear unit

IntroductionLayers of dust may affect the dissipation of heat through the surface of the gear unit, resulting in overheating. Depending on the operating conditions, it may therefore be necessary to clean the gear unit more frequently than stated in the maintenance schedule.

ProcedureTo clean the gear unit, proceed as follows:

1. Use a hard brush to remove any stubborn dirt from the gear unit. Never use a high-pressure cleaning device.

2. Remove any spots of corrosion.

8.3.5 Check that all of the fastening bolts are tight

ProcedureProceed as follows to check that the fastening bolts are tight:

1. Observe the data regarding connection classes, preload forces and tightening torques.

2. Replace any bolts that are no longer fit for use by bolts of the same strength class and type.

8.3.6 General inspection of the gear unitArrange for Siemens Customer Services to perform a general inspection on the gear unit. Thanks to their experience, these engineers are best placed to assess which gear unit components need to be replaced.

8.3.7 Final workAfter you have finished all the work listed in the maintenance schedule, replace any bolts that are no longer fit for use by bolts of the same strength class and type.



8.4 Possible faultsThe faults listed below are only intended as a troubleshooting guide.

If any faults occur while the unit is still under warranty, do not allow anyone except Siemens Customer Services to attempt a repair.

Even after the warranty period has expired, you should still arrange for faults to be rectified by Siemens Customer Services.

NoteLoss of warranty

You will invalidate the warranty for the gear unit if you modify it in any way without seeking the approval of Siemens beforehand, or if you do not use original spare parts.

Only use original spare parts from Siemens. Always arrange for Siemens Customer Services to repair any faults that develop while the unit is still under warranty.

Possible faults and their rectificationThe following table provides you with an overview of possible faults and indicates how they can be rectified.

Table 8-2 Possible faults and their rectification

Possible faults Causes Possible remediesPressure switch trig‐gers alarm

Oil pressure has dropped below minimum value

● Check the oil level at room temperature● Top up with oil if necessary● Check the oil pump● If required, replace the oil pump● Check the oil filter and coarse filter● If required, replace the oil filter or clean the coarse filter

Noise

Damage to the gear teeth ● Contact Customer Services● Inspect the toothed components● If necessary, replace damaged components

The bearing play is excessive. ● Contact Customer Services● Adjust bearing play

Defective rolling-contact bearings ● Contact Customer Services● Replace defective rolling-contact bearings

Gear unit fastening has worked loose

● Tighten bolts and nuts to the specified tightening torque● Replace damaged bolts and nuts

Outer surface of gear unit soiled with oil

Inadequate sealing of the housing cover or joints

● Seal housing cover or joints

Labyrinth seals soiled with oil, incor‐rect transport position

● Check oil filling● Clean the labyrinths

Maintenance8.4 Possible faults


Possible faults Causes Possible remediesLeakage

Defective seals at the drive pinions, or if available, at the oil separating cover

● Check the seals and if necessary, repair or replace

Oil is foaming in the gear unit

Preservation agent not completely drained off

● Change the oil

Oil supply system left in operation for too long at low temperatures

● Switch off the oil supply system● Degas the oil

Gear unit too cold in operation ● Switch off the gear unit● Degas the oil● Start up without cooling water during cold restart

Water in the oil ● Take test tube sample to examine oil condition for water penetration

● Have the oil examined by a chemical lab● Change the oil if necessary

Oil defoamer has run out ● Examine the oil● Change the oil if necessary

Unsuitable mixture of oils ● Examine the oil● Change the oil if necessary

Oil escaping from the gear unit

Inadequate sealing of the housing cover or joints

● Check the seals and replace if necessary● Seal housing cover or joints● Check the compression seals and retighten screws if

necessaryLeaking pipes ● Check the pipes, and replace or seal if necessary

Oil supply system mal‐function

- ● Follow the operating instructions for the oil supply system

Elevated temperature during operation

Oil is too old ● Find out when the last oil change was done● Change the oil if necessary

Oil is severely contaminated ● Change the oilOil supply system defective ● Inspect the oil supply system

● Replace defective components if necessary ● Follow the operating instructions for the oil supply system

Gear unit with water-oil cooler: Cool‐ant flow too low or too high

● Adjust the valves at the supply and return lines● Check the water-oil cooler for free flow

Gear unit with oil cooling system: Inadequate oil flow through the oil cooler

● Check the oil filter and coarse filter● If required, replace the oil filter or clean the coarse filter

Coolant temperature is too high ● Check the temperature; correct if necessaryDefective oil pump ● Check the oil pump function

● If required, repair or replace the oil pump



Possible faults Causes Possible remediesElevated temperature at bearing points

Oil is too old ● Find out when the last oil change was done● Change the oil if necessary

Oil supply system defective ● Inspect the oil supply system● Replace defective components if necessary● Follow the operating instructions for the oil supply system

Defective rolling-contact bearings ● Contact Customer Services● Inspect the rolling-contact bearings and replace if

necessaryDefective oil pump ● Check the oil pump function

● If required, repair or replace the oil pumpOil is severely contaminated ● Change the oil

Increased vibration amplitude at the bear‐ing points

Foot fastening bolts have become loose

● Tighten the foot fastening bolts with the specified tightening torque

Defective rolling-contact bearings ● Contact Customer Services● Inspect the rolling-contact bearings and replace if

necessaryGear wheels defective ● Contact Customer Services

● Inspect the gear wheels and replace if necessaryReaction arising from a tube mill dis‐turbance

● Observe the tube mill operating instructions● Contact the Customer Services department of the tube

mill supplierFoundation damage ● Contact Customer Services

● Repair the foundationWater in the oil Oil supply system defective ● Inspect the oil supply system

● Replace defective components if necessary● Follow the operating instructions for the oil supply system

Engine room fan is blowing cold air onto gear unit: Water condenses

● Install suitable thermal insulation to protect gear unit housing

● Close the air outlet or change the direction of the air outlet using structural measures.

Climatic conditions ● Contact Customer Services● Use wet-air filter if necessary

Oil foams in the oil sump ● Take test tube sample to examine oil condition for water penetration

● Have the oil examined by a chemical lab



Service & Support 9Contact

When ordering spare parts, requesting a customer service technician or in the case of technical queries, please contact our factory or one of our customer service addresses:

Siemens AG

Am Industriepark 2

46562 Voerde

Germany

Tel.: +49 (0)2871 / 92‐0

Fax: +49 (0)2871 / 92‐1544

E-mail: [email protected]


Service & Support


Disposal 10Disposal of the gear unit

When disposing of the gear unit after its useful life, please observe the following measures:

● Remove operating oil, preservation agents and coolant from the gear unit and dispose of it according to regulations.

● Dispose of the gear unit parts according to applicable national regulations or recycle them.

Environmental protectionObserve the following environmental protection measures for disposal:

● Dispose of or recycle packaging material according to applicable national regulations.

● When changing the oil, collect the used oil in suitable containers. Use oil-binding agents to clean up any oil spillages immediately.

● Store preservative agents separately from used oil.

● Dispose of used oil, preservative agents, oil binding agents and oil-soaked cloths according to the applicable environmental protection regulations.


Disposal


Spare parts 11By stocking the most important spare parts at the installation site you can ensure that the gear unit is ready for use at any time.

NoteDamage to the gear unit due to use of unsuitable spare parts

Only use original spare parts from Siemens. Siemens shall not accept any warranty claims for spare parts that are not supplied by Siemens.

Other spare parts are not tested and approved by Siemens. Non-approved spare parts may possibly change the design characteristics of the gear unit and thus impair its active or passive safety.

Siemens will accept no liability or warranty whatsoever for damage occurring as a result of the use of non-approved spare parts. The same applies to any accessories which were not supplied by Siemens.

The contact address of Siemens Customer Services can be found under Service & Support (Page 69).

Information required when ordering spare partsTo order spare parts, refer to the spare-parts list. Only use spare parts that are supplied by Siemens.

When ordering spare parts, please provide the following information:

● Order number with item

● Type and size

● Part number

● Quantity


11.1 Spare parts drawingThe following diagram shows the spare parts drawing 1/2 for drive scenario A/x, B/x, C/x, D/x, E/x and F/x:

Figure 11-1 Spare parts drawing 1/2 for drive scenario A/x, B/x, C/x, D/x, E/x and F/x

The following diagram shows the spare parts drawing 2/2 for drive scenario A/x, B/x and C/x:

Figure 11-2 Spare parts drawing 2/2 for drive scenario A/x, B/x and C/x

The following diagram shows the spare parts drawing 2/2 for drive scenario D/x, E/x and F/x:

Spare parts11.1 Spare parts drawing


Figure 11-3 Spare parts drawing 2/2 for drive scenario D/x, E/x and F/x

11.2 Spare parts listThe following table lists the spare parts:

Table 11-1 Spare parts

Part No. Quanti‐ty

Designation Part No. Quanti‐ty

Designation

71 1 Air filter 216 1 Helical gear100 1 Helical gear shaft 217 1 Helical gear107 4 Parallel key 250 2 Rolling-contact bearing119 2 Radial shaft sealing ring 251 2 Rolling-contact bearing132 2 O ring 262 2 O ring137 2 O ring 263 2 O ring151 1 Rolling-contact bearing 264 2 Rotor152 2 Rolling-contact bearing 299 1 Helical gear shaft complete200 2 Shaft 350 2 Rolling-contact bearing201 2 Helical gear 961 2 Radial shaft sealing ring202 4 Ball-and-socket joint

Spare parts11.2 Spare parts list


Spare parts11.2 Spare parts list


Quality documents AA.1 Declaration of Incorporation


Declaration of incorporation

Company name and full address of the manufacturer:

Siemens AktiengesellschaftAm Industriepark 246562 VoerdeDeutschland – Germany

Name and address of the person, authorised to compile the relevant technical documentation:

Mark ZundelSiemens AktiengesellschaftAm Industriepark 246562 VoerdeDeutschland – Germany

Description and identification of the partly completed machinery:

Girth gear unit for tubular millsDMG2Sizes 18, 22, 25.4 and 30for driving machines

The following "Essential health and safety requirements" are applied and are met:– Directive 2006/42/EC Official Journal L 157, 9.6.2006, pages 24-86, annex I.

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, 1.5.15; 1.6.1, 1.6.2; 1.7.1, 1.7.1.1, 1.7.2, 1.7.4, 1.7.4.1, 1.7.4.2, 1.7.4.3

The special technical documents described in Annex VII part B have been prepared.The manufacturer undertakes, in response to a reasoned request by national authorities, totransmit in electronic form relevant information about the partly completed machinery.

The partly completed machinery must not be put into service until it has been established thatthe machinery into which the partly completed machinery is to be incorporated has beendeclared to be in conformity with the provisions of Directive 2006/42/EC, as appropriate.

Siemens Aktiengesellschaft

Voerde, 2016‐03‐23 i.V.Mark Zundel, Head of PD MD AP VOE

Voerde, 2016‐03‐23 i.V.Björn Podewski, Head of PD MD AP VOE BA

Translation of the original declaration of incorporation

Quality documentsA.1 Declaration of Incorporation


Technical data BB.1 Technical representation

The gear unit dimensions are shown in the following diagram:

Figure B-1 Dimensions


Dimensions and torquesThe dimensions and torques are listed in the following table:

Table B-1 Dimensions and torques


Gear unit

Ratio i 5.45 - 11.65 5.85 - 11.42 6.17 - 11.005 6.232 - 10.32Max. output torque Trms in kNm

173.5 270 484 700

Output pinion Tooth width b1 in mm

480 580 660 780

Module m in mm 18 22 25.4 30Number of teeth z1 31 31 31 31

Girth gear Max. tooth width b2max in mm

475 575 655 770

Max. number of teeth z2max

600 600 600 600

a in mm 1 206 1 428 1 600 1 990a1 in mm 1 768 2 065 2 325 2 870b in mm 1 350 1 700 1 900 2 375d1 (n6) in mm 140 170 190 230I1 in mm 230 250 295 380E in mm 911 1 097 1 224 1 555G1 in mm 750 790 930 1 100h in mm 1 060 1 200 1 450 1 845H in mm 2 275 2 620 3 140 3 885

Further informationFurther information about these technical data can be found in the separate data sheet and the dimension drawings in the complete documentation for the gear unit.

Technical dataB.1 Technical representation


B.2 General technical data

Rating plateThe gear unit rating plate contains the most important technical data.

① Company logo ⑧ Speed n2

② Serial no.: production plant code/order no. item ser. no./year of manufacture

⑨ Oil data: Oil type, oil viscosity, oil quantity

③ Total weight in kg ⑩ Numbers of operating instructions④ For special information ⑪ For special information⑤ Type, size ⑫ Manufacturer and place of manufacture⑥ Power rating P2 in kW or torque T2 in Nm ⑬ Country of origin⑦ Speed n1

The limits of the intended use of the gear unit are defined on the basis of these data and the contractual agreements concerning the gear unit concluded between Siemens and the customer.


Further information about all major accessories including their technical data and control instructions can be found in the order-specific list of equipment in the complete documentation for the gear unit.

Technical dataB.2 General technical data


Example codeThe following is an example of the code printed in line 5 of the rating plate and explains the meaning of the individual letters and numbers.


B.3 Ambient temperatureUnless otherwise contractually agreed, the gear unit must not be exposed to any harmful atmospheres or substances such as aggressive chemical products. By applying various suitable measures, the gear unit can be used in the ambient temperature range extending from 0 °C up to 40 °C. However, this must always be authorised by Siemens and specified in the order text.

B.4 WeightsThe precise weights are specified in the dimension drawings in the complete documentation or on the rating plate.

All weight specifications refer to units without oil filling or mounted components.

Refer to the following table for gear unit weights (approximate values, in kg):

Table B-2 Weights

Type Gear unit size18 22 25.4 30

DMG2 16 000 23 500 36 000 69 000

B.5 Enveloping surface sound pressure levelIt is not possible to specify an enveloping surface sound pressure level for a gear unit in operation because the unit is operated under no load on the Siemens test stand during the trial run.

Technical dataB.5 Enveloping surface sound pressure level


B.6 Terminal diagramTwo pressure monitors, nine resistance thermometers and a position sensor (inductive sensor (Page 21)) can be mounted on the gear unit and wired to a terminal box.

Further informationFurther information can be found in the list of equipment and terminal diagram provided in the complete documentation for the gear unit.

Further information about the components can be found in the component operating instructions in the complete documentation for the gear unit.

Technical dataB.6 Terminal diagram


Technical dataB.6 Terminal diagram


Maintenance and servicing work CCheck the following points, and list the results in the table.

Table C-1 Check list 1

Date Time Operating hours Power drawn by the main motor in kW (over a period of 5 min)

max. min.

Position of the floating shaft in mm Vibration velocity at the measuring point 1 in mm/s

Bearing temperature at the measuring point in °C

1 2 3

Oil temperature in the pipe in °C Oil pressure in the pipe Bot‐

tom

Top Others(for example, noise,machine damage,environmental conditions,etc.)

Change the filter cartridge Oil change Stop the system Start the system Signature


Maintenance and servicing work


Glossary

APIAmerican Petroleum Institute

EDDuty cycle

PAOPoly-alpha-olefin is a synthetic paraffin and naphthenic base oil.

PG/PAGPolyglycol is a synthetic, common water soluble polymer-based base oil.

ZAPEX couplingA ZAPEX coupling is a torsionally rigid gear coupling manufactured by Siemens AG.


Glossary


Index

AAttachment points, 29

BBearing monitoring

Resistance thermometer, 20

CChecking procedure, 55Coloured markings, 12Contact, 69Contamination limits, 63Copyright, 10Coupling

Alignment, 45Assembly, 43

Customer Services, 69

DDanger of explosion, 16Dimensions, 79Disclaimer, 9Disposal, 71Documentation landscape, 9

EEnvironmental protection, 71

FFastening bolts, 65Fault, 66Fault rectification, 66Final work, 48

GGear unit markings, 12General inspection of the gear unit, 65

IInductive sensor, 21Interval, 62Irregularities in operation, 59

LLabyrinth seal, 20Lubricant, 10

MMaintenance activities, 62Maintenance information, 61Maintenance schedule, 62Measures

Checking procedure, 55during commissioning, 56Prior to commissioning, 51

Mounting position, 29

NNote about assembly, 29

OOil, 10

Contamination limits, 63Oil supply system

Commissioning, 54Operating data, 59

Oil, 59Ordering spare parts, 69, 73

PPreservation

Special aspects, 27Protective equipment, 14


RRating plate, 81

Example of type and size, 82Reactivating, 18Rinsing, 52Rolling-contact bearings

Measure temperature, 64Rotary shaft sealing ring, 20

SSafety rules, 11Scope of delivery, 23Servicing, 64Servicing activities, 62Shaft seal, 20Shipping documents, 23Spare parts drawing, 74Spare parts list, 75

TTaking the unit out of service, 60Technical data, 81Torques, 79Transport conditions, 25Transport information, 23Transport symbols, 24Troubleshooting, 66Types of danger, 14

UUnpacking, 32Used oil, 71Using the gear unit, 17

WWarning symbols, 13

Index


AA 5150_en_EBE

Siemens AGProcess Industries and DrivesPostfach 48 4890026 NÜRNBERGGERMANY

www.siemens.com/drives

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