Related Manuals for Siemens Flender KMP Series
Summary of Contents for Siemens Flender KMP Series
- Page 1 Vertical mill gear unit KMP, KMPS, KMPP Assembly and operating instructions BA 9142 en 02/2015 FLENDER gear units...
- Page 2 Technical data Vertical mill gear unit General notes Safety instructions KMP, KMPS, KMPP Transport and storage Technical Assembly and operating instructions description Translation of the original assembly and operating instructions Fitting Startup Operation Faults, causes and remedy Maintenance and repair Spare parts, customer service Declarations...
- Page 3 All designations to which the registered industrial property mark ® is appended are registered trademarks of Siemens AG. Other designations used in this document may be trademarks the use of which by third parties for their own purposes may infringe holders’ rights.
- Page 4 Foreword The term "Assembly and operating instructions" will in the following also be shortened to "instructions" or "manual". Symbols in these assembly and operating instructions This symbol additionally indicates an imminent risk of explosion in the meaning of Directive 94/9/EC. This symbol additionally indicates an imminent risk of burns due to hot surfaces in the meaning of standard "DIN EN ISO 137321".
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Page 5: Table Of Contents
Contents Technical data ........... . . General technical data . - Page 6 Fitting ............. General assembly information .
- Page 7 Maintenance and repair ..........10.1 General notes on maintenance .
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Page 8: Technical Data
Technical data General technical data The most important technical data are shown on the rating plate. These data and the contractual agreements between Siemens and the customer for the gear unit determine the limits of its correct use. ① ②... -
Page 9: General Notes
All persons carrying out work on the gear unit must have read and understood the instructions and must adhere to them. Siemens accepts no responsibility for damage or disruption caused by disregard of these instructions. The "FLENDER vertical mill gear unit" described in these Instructions is designed for driving vertical mills. -
Page 10: Safety Instructions
Safety instructions WARNING Risk of falling Serious injury from falling is possible. The gear unit and its add-on parts must not be accessed during operation. The gear unit may only be accessed for maintenance and repair works during standstill of the gear unit. WARNING Risk of injury from changes made on own initiative Changes made on own initiative are prohibited. - Page 11 Screws which have been damaged during assembly or disassembly work must be replaced with new screws of the same strength class and type. • Spare parts must be obtained from Siemens (see section 11. "Spare parts, customer service"). BA 9142 en 02/2015 11 / 84...
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Page 12: Special Dangers And Personal Protective Equipment
Special dangers and personal protective equipment Depending on operating conditions, the surface of the gear unit may develop extreme temperatures. WARNING Risk of burns Serious injury caused by burns on hot surfaces (> 55 °C) is possible. Wear suitable protection gloves and protection clothing. WARNING Risk of low temperatures Serious injury from cold damage (pain, numbness, frostbites) on cold surfaces (<... -
Page 13: The Five Safety Rules
The five safety rules For your personal safety as well as avoidance of property damages, please always observe the safety notices and the following five safety rules pursuant to the standard "DIN EN 50110-1" (Operations in powered-down condition) when working on the electrical components of the system. Apply the five safety rules from the start of the work on the machine, in the order cited above. -
Page 14: Transport And Storage
The content of the delivery is listed on the packing slip. The completeness of the scope of delivery must be checked against the packing slip directly on receipt. The packaging must not be opened for the check. Damages on packaging and/or items missing from the package must be reported to Siemens in writing within 2 weeks. - Page 15 WARNING Risk of crushing Risk of being crushed by a transported component when the used lifting gear and load-bearing equipment is not suitable and the component comes loose. Attach the product for transport only on the marked attachment points. Lifting gear and load equipment must be used that has adequate load-bearing capacity.
- Page 16 Fig. 3: Attachment points Note If no transport lobes are provided on the base of the gear unit, the transport lobes that are marked on the fins have to be used. If no cable pulley is on the gear unit head, wooden blocks have to be used for protection of the gear unit (see Figure 4).
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Page 17: Storing The Gear Unit
Note The detailed illustration of the gear unit, the position of the attachment points, and the positioning of the wooden blocks for the protection of the gear unit during transport can be found on the dimensioned and transport drawings in the order-specific gear unit documentation. NOTICE Property damage Damage to the gear unit is possible when using the wrong attachment points. -
Page 18: Standard Coating And Corrosion Prevention
─ temperatures up to 120 °C / 248 °F (for short periods up to 140 °C / 284 °F) If a different exterior coating is intended by the customer (contrary to the Siemens standard), the protection of the external coating will be within the customer's responsibility. -
Page 19: Exterior Preservation Of Metallic Bright Exterior Surfaces
4.4.1 Exterior preservation of metallic bright exterior surfaces 4.4.1.1 Maximum durability period of the exterior preservation Table 1: Durability period for exterior corrosion prevention of shaft ends and other bright machined surfaces Durability Preservative agent Layer thickness Remarks of protection Long-term wax-based preservative agent: with indoor storage up... - Page 20 If damaged, the packaging must be restored to its seaworthy condition. Note If different statements were made in agreement with the customer, as to the protective periods on precisely defined conditions, a description can be found in the order confirmation from Siemens. BA 9142 en 02/2015 20 / 84...
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Page 21: Combined Storage/Packaging
4.4.2.2 Combined storage/packaging If the type of packaging and/or storage is changed within the durability period as HD which is applicable to the preservation of the present type of packaging and/or storage, a new HD has to be determined 2 equiv as the equivalent remaining durability period applicable as of the date of the change. - Page 22 If multiple types of packaging and/or storage are combined, the procedure for assessing the equivalent remaining durability period is to be determined according to the following example: + (1 * n*equiv n*1equiv Example: ─ A gear unit is stored exposed outdoors after sea transport, in climatic zone B, while it is kept in seaworthy packaging = 20 months (climatic zone: B, transport method: sea transport, transport packaging: seaworthy packaging,...
- Page 23 Table 3: Examples of combined storage (maximally one change in storage) and the resulting remaining durability of the interior preservation of the gear unit Original storage place of the gear unit In which climatic zone is the construction site Setup in climatic zone A and at least 50 km located? distance from larger bodies of salt water How was the gear unit packaged for transport?
- Page 24 Original storage place of the gear unit In which climatic zone is the construction site Setup in climatic zone B and/or less than 50 km located? distance from larger bodies of salt water How was the gear unit packaged for transport? None or simple Transport in transport packaging...
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Page 25: Renewal Of The Interior Preservation Of The Gear Unit For Longer Periods Of Storage Of The Gear Unit That Has Not Been Taken Into Operation Yet
Filling quantity: 1 litre per cubic metre of the entire free interior volume of the gear unit (to be enquired from Siemens). The interior volume of the gear unit can be ascertained in approximation also by the length x width x height of the gear unit. - Page 26 NOTICE Property damage Corrosion is possible when the gear unit is opened for too long. Close the gear unit airtight again, at the latest one hour after opening. Table shows maximum durability period preservation renewal with "Castrol Corrosion Inhibitor N 213" depending on the packaging and setup or storage site. The definition of climatic zones can be found in item 4.4.2.1.
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Page 27: Renewal Of The Gear Unit Interior Preservation Through Complete Filling With Preservative Or Operating Oil
The durability of this kind of preservation depends on the used oil and has to be enquired from the oil manufacturer. For the complete filling, a sealing cap (can be obtained from Siemens) must be mounted on the gear unit for sealing the input shaft. - Page 28 The following control measures must be taken: • The pressure, suction and/or return lines (6, 8, 9) are sealed with blind flanges. • The oil drain cock of the tilting pad thrust bearing chamber (10) is sealed with a screw plug. •...
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Page 29: Renewal Of The Interior Preservation Of The Gear Unit Using The Oil-Supply System
• Close and seal the vent hole for the tilting pad thrust bearing chamber (11) with a screw plug again. • The lower oil drain cock on the gear unit (7) must be provided and sealed with a screw plug. •... - Page 30 Table 5: Maximum durability period of the interior preservation of the gear unit through operating the oil-supply system. Setup in climatic zone A and at Setup in climatic zone B and/or least 50 km distance from larger less than 50 km distance from bodies of salt water larger bodies of salt water Packaging for...
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Page 31: Technical Description
Technical description Observe the instructions in section 3. "Safety instructions"! General description The gear unit described is a "FLENDER vertical mill gear unit" designed for driving vertical mills. The vertical mill gear units of the types KMP / KMPS / KMPP are bevel-helical gear units or bevel-planetary gear units for driving a vertical mill. -
Page 32: Lubrication
Lubrication The lubrication and cooling is provided by continuous oil circulation through a separate oil-supply system. To prevent vibration and to compensate for heat expansion, compensators are provided in the pipe system. Note When operating and servicing the components of the oil supply system, observe the operating instructions of the components. -
Page 33: Labyrinth Seals
It cannot be assured by Siemens whether these minimum requirements are sufficient in any case. If stricter requirements in the operating instructions of the supplier or similar document are defined, these will apply. -
Page 34: Heating
Heating At low temperatures, it may be necessary to heat the gear oil before switching on the drive unit or even during operation. In such cases, e. g. heating elements can be used. These heating elements convert electrical energy into heat which is conducted to the surrounding oil. The heating elements are located in protective tubes inside the housing, thus making it possible to replace them without draining the oil beforehand. -
Page 35: Oil Temperature Monitoring
Oil temperature monitoring The gear unit can be equipped with a resistance thermometer or temperature monitor for measuring the oil temperature in the oil sump. In order to measure the temperatures and/or temperature differences, the temperature monitor should be connected to an evaluating device by the customer. Note In order to measure the temperatures and/or the temperature differences with a Pt 100 resistance thermometer without evaluating instrument, the Pt 100 resistance thermometer must be connected to... -
Page 36: Fitting
When transporting the gear unit, observe the notes in section 4. "Transport and storage". Assembly work on the mill must be performed with great care by authorised, trained and qualified personnel. Siemens is not liable/does not extend a warranty for damages caused by incorrect implementation. -
Page 37: Set-Up Conditions
Upstream and downstream machines have to be arranged accordingly. If the pipes connecting the gear unit and oil-supply system are included in the Siemens delivery, the installation plan is enclosed with the documentation. - Page 38 NOTICE Property damage Damage to the sliding bearings is possible. The input shaft of the gear unit may be rotated maximally 1 time for positioning during installation, only when the tilting pad thrust bearing chamber is filled with oil up to the specified level. •...
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Page 39: Maintaining Preservation If The Gear Unit Has Been Opened In The Meantime
6.3.1 Maintaining preservation if the gear unit has been opened in the meantime If a gear unit, which has been opened in the meantime for longer than 1 week, is left standing without transport packing in exposed meanwhile roofed surroundings and if it is not possible every 7 days to flush the gear unit for one hour with the oil-supply system and turn it for 15 minutes, the preservation can be maintained in part by applying the measures specified in item 4.4.3. -
Page 40: Installing The Pipework
NOTICE Property damage Destruction of the gear unit or gear unit parts from wrong rotation direction is possible. The gear unit is approved for one direction of rotation only. The direction of rotation of the motor must correspond to the direction indicated by the arrow on the gear unit input shaft. -
Page 41: Pickling Of Adapted Pipes
Pickling of adapted pipes CAUTION Risk of injury from chemical substances Chemical burns on face and hands from pickling solution. Wear protective glasses and gloves, ensure sufficient ventilation. Observe the manufacturer’s instructions for the handling of pickling solutions. • The lower end of each pipe must be sealed with a plug. •... -
Page 42: Installing The Motor
Note For permissible alignment errors in couplings supplied by Siemens, refer to the instructions manuals for the couplings. When using couplings of other manufacturers, ask these manufacturers which alignment errors are permissible, stating the radial loads occurring. -
Page 43: Assembly Of Loose Add-On Parts Included In The Delivery
Ensure zero voltage before connecting the devices. 6.10 Welding work on the mill Note Siemens will accept no liability for damage caused to the gear unit by welding work carried out on the mill. WARNING Risk of personal injury from electrical shock Risk of electrical shock during welding work. -
Page 44: Final Work
6.12 Final work After installation of the gear unit, check all screw connections for the connection of the gear unit and □ the system for tight fit. Check of the alignment after tightening the fastening elements. The alignment must not have changed. □... -
Page 45: Tightening Torques And Initial Stressing Forces
6.13.2 Tightening torques and initial stressing forces The tightening torques apply to friction coefficients of μ = 0.14. total The friction coefficient μ = 0.14 applies here to lightly oiled steel bolts, black-annealed or phosphatised total and dry, cut counter threads in steel or cast iron. Lubricants which alter the friction coefficient are not permitted and might overload the screw connection. - Page 46 Nominal Strength Initial stressing force for screw Tightening torque for screw diameter of class of the connection classes from Table 7 connection classes from Table 7 the thread bolt M min. 1190000 760000 475000 21500 18500 16500 M80x6 10.9 1690000 1100000 675000 30500...
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Page 47: Start-Up
Any setting of the drive in motion represents a start-up. Procedure before start-up The start-up must be carried out with great care by authorised, trained and qualified personnel. Siemens is not liable/does not extend a warranty for damages caused by incorrect implementation. -
Page 48: Removal Of Preservative Agent From Interior
7.1.2 Removal of preservative agent from interior Note The required measures prior to start-up are described in the following, as dependent on the basic preservation applied (see Technical data) on the gear unit. Detailed descriptions of the procedure as well as regarding the particularities, which must be taken into account, can be found in the following items 7.1.3 to 7.1.5 and in the separately provided operating instructions BA 7300. - Page 49 NOTICE Property damage With larger filled-in quantities of the Corrosion Inhibitor N 213 (above 5 % of the operating oil quantity), the mixture of operating oil and Corrosion Inhibitor N 213 must not be used as operating oil. The gear unit must be flushed thoroughly with operating oil before start-up, after draining the mixture of operating and preservative (in this regard, see item 10.4.) have already been...
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Page 50: Draining Preservative Oils
7.1.3 Draining preservative oils For the position of the oil draining points is marked on the dimensioned drawing in the gear unit documentation. • Place suitable containers under the oil drain points. • Unscrew the oil drain plug and/or open the oil drain cock. •... -
Page 51: Flushing Before Initial Start-Up
If the oil-supply system and the pipework are not included in the scope of delivery by Siemens, the operating oil quantity for the gear unit is shown on the rating plate (see section 1. "Technical data"). -
Page 52: Oil Level
The quality of the oil used must meet the requirements of the separately supplied BA 7300 instructions manual, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in Table "T 7300" (for a link to the Internet, see back cover), as they have been tested and meet the requirements. - Page 53 Note If gear units have oil-supply systems, the oil circuit must be filled additionally. If systems have a motor pump for the oil circuit, the pump must be turned on briefly. Note Oil pumps and parts with drill holes for oil filling that are marked with a special sign have to be filled with oil before the start-up of the gear unit.
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Page 54: Oil-Supply System
If the quality of the oil used does not meet the requirements of the separately supplied BA 7300 instructions manual, the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in the document "T 7300" (for a link to the internet, see back cover), because they have been tested and meet the requirements. - Page 55 Is all pipework cleaned and installed in accordance with the assembly instructions? □ NOTICE Property damage Damage to the gear unit is possible. Particular care must be taken to ensure that the oil conducting pipework is clean, since any dirt in it would be conducted through the gear unit before it could be filtered out at the filter of the oil-supply system.
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Page 56: Start-Up
Oil leakages Monitor all screw connections in the oil lines for oil leaks and reseal them if necessary! Note The date of initial start-up must be notified to Siemens within 4 weeks after start-up. BA 9142 en 02/2015 56 / 84... -
Page 57: Checking Procedure
7.2.3 Checking procedure The following visual checks must be conducted and recorded when starting up: Oil level □ Leak tightness of the oil cooling or oil supply lines □ Opening condition of the shut-off valves □ Effectiveness of the shaft seals □... -
Page 58: Renewal Of The Gear Unit Interior Preservation On Gear Units Having Already Been In Operation
7.3.1 Renewal of the gear unit interior preservation on gear units having already been in operation Depending on the specific application, the following measures for renewing the interior preservation of the gear unit can be taken in case it is taken out of service for a longer period (> 7 days). The durability period of this preservation kind depends on the measure for renewing the interior preservation of the gear unit, the packaging type, and the setup and/or storage place (see Table 11 or Table 12 in item 7.3.1.1). - Page 59 Table 11: Maximum durability period of the interior preservation of the gear unit through operating the oil-supply system. Setup in climatic zone A and at Setup in climatic zone B and/or least 50 km distance from larger less than 50 km distance from bodies of salt water larger bodies of salt water Packaging for...
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Page 60: Renewal Of The Gear Unit Interior Preservation With "Castrol Corrosion Inhibitor N 213
For prolonging the interior preservation, the VCI-gas discharging fluid "Castrol Corrosion Inhibitor N 213" is recommended. For sealing the input shaft, a sealing cap (can be obtained from Siemens) must be mounted and tightened on the gear unit for sealing the input shaft. - Page 61 Table 12: Durability period of prolonged interior preservation of the gear unit with "Castrol Corrosion Inhibitor N 213" Setup in climatic zone A and at Setup in climatic zone B and/or least 50 km distance from larger less than 50 km distance from bodies of salt water larger bodies of salt water Packaging for...
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Page 62: Renewal Of The Gear Unit Interior Preservation Through Complete Filling With Preservative Or Operating Oil
The durability of this kind of preservation depends on the used oil and has to be enquired with the oil manufacturer. For the complete filling, a sealing cap (can be obtained from Siemens) must be mounted on the gear unit for sealing the input shaft. -
Page 63: Exterior Corrosion Prevention
Fig. 9: Gear unit features for preservation measures Ventilation sealing cap Pressure line (gear unit) Oil drain sealing cap Pressure line (tilting pad thrust bearing Sealing cap chamber) Air filter (gear unit) Oil drain (tilting pad thrust bearing Oil level indicator (gear unit) chamber) Suction line (gear unit) Air filter (tilting pad thrust bearing... -
Page 64: Operation
50 °C (122 °F) If the oil-supply temperature reaches critical values (see lubrication plan and equipment list), the gear unit must be shut down immediately and Siemens consulted. Oil pressure of the oil-supply system or □... -
Page 65: Oil Level
Table 13, "Faults, causes and remedy", contains a list of possible faults, their causes and suggested remedies. If the cause cannot be found, a specialist from one of the Siemens Customer Service Centres should be called in (see section 2. "General notes"). -
Page 66: Faults, Causes And Remedy
Damage to the gear unit from improper use is possible. Siemens will not be bound by the terms of the guarantee or otherwise be responsible in cases of improper use of the gear unit, modifications carried out without the approval by Siemens or use of spare parts not originally supplied by Siemens. -
Page 67: Faults, Causes And Remedy
Faults, causes and remedy Table 13: Faults, causes and remedy Faults Possible causes Remedy Changes in gear unit noise. Damage to gear teeth. Contact Customer Service. Check toothed components. If necessary exchange damaged components. Bearing backlash too high or too Contact Customer Service. - Page 68 Faults Possible causes Remedy Pressure monitor triggers Oil level too low. Check the oil level. alarm. Fill up oil if necessary. Oil pump defective. Check oil pump and replace if necessary. Operating temperature increased. See Faults "Operating temperature too high". Oil filter dirty.
- Page 69 Faults Possible causes Remedy The oil foams. Water in oil. Examine oil. Change oil if necessary. Oil too old (defoaming agent used Examine oil. up). Change oil if necessary. Unsuitable oils mixed up. Examine oil. Change oil if necessary. Water in oil. Cooler leaky.
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Page 70: Maintenance And Repair
Maintenance and repair Observe the instructions in section 3. "Safety instructions" and in section 9. "Faults, causes and remedy"! 10.1 General notes on maintenance Maintenance comprises all measures for preserving and restoring the target condition and for ascertaining and assessing the actual condition of the technical means of a system. In this context maintenance is a comprehensive generic concept which can be subdivided into three areas: ─... -
Page 71: Clean The Gear Unit
10.2 Clean the gear unit NOTICE Property damage Damage to the gear unit from overheating is possible. Dust deposits can affect the heat discharge through the housing surface and lead to overheating. To prevent the build-up of dust on the gear unit, cleaning must be adjusted to the local operating conditions. -
Page 72: Flushing
The BA 7300 instructions manual relating to the gear unit lubrication and Table "T 7300" containing the current lubricant recommendations of Siemens can also be consulted on the internet (see back cover). BA 9142 en 02/2015... -
Page 73: Inspection
10.6 Inspection The inspection comprises all measures for ascertaining and assessing the actual condition. The measures must be recorded. Note The record must be kept with these instructions. Table 14: Inspection measures Measures Periods Remarks General visual check for cracks, leaks every 4 weeks and damage. -
Page 74: Maintenance
10.7 Maintenance Maintenance comprises all measures for preserving the required condition. Table 15: Maintenance measures Measures Periods Remarks First oil change after start-up after approx. 1000 operating hours See item 10.7.2 or depending on the results of the oil analysis carried out Oil analyses first one after 1000 operating See item 10.7.1... -
Page 75: Examine Water Content Of Oil, Conduct Oil Analyses
Detailed information about testing the oil for water content or conducting oil analyses can be obtained from your lubricant manufacturer or Siemens customer service. ─ A fresh sample of the used operating lubricating oil must be sent as reference to the testing institute along with the used oil sample for analysis. -
Page 76: Change Oil
Flushing is not necessary, if the new service oil is fully compatible with the old service oil in all respects. Compatibility must be confirmed by the oil supplier. If there is a change to another oil grade or make, Siemens recommends flushing out the gear unit with the new grade of service oil. Note When changing the oil, the housing and the oil-supply system (if present) must be cleaned thoroughly from sludge, metal particles and oil residue by flushing it with oil. - Page 77 The BA 7300 instructions manual relating to the gear unit lubrication and Table "T 7300" containing the current lubricant recommendations of Siemens can also be consulted on the internet (see back cover). Note For the oil filling of the gear unit, see the information in item 7.1.5.
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Page 78: Check Tightness Of Screw Connections
Damaged bolts must be replaced with new bolts of the same type and strength class. 10.8 Welding work on the mill Note Siemens will accept no liability for damage caused to the gear unit by welding work carried out on the mill. WARNING Risk of personal injury from electrical shock. -
Page 79: Vibration Measurements
A detailed illustration of the gear unit is contained the drawings in the gear unit documentation. Vibration measurements and their evaluation should be conducted by Siemens personnel and/or in close collaboration with Siemens personnel. This way, experience gained from measurements conducted on comparable bevel-gear planetary gear units can be incorporated into the measurement and the evaluation of its results. -
Page 80: Repair
For this reason the standard "DIN ISO 10816" has only limited application for this type of gear unit. Further information about vibration diagnosis is obtainable from: http://www.automation.siemens.com/mcms/mechanical-drives/en/gear units/service 10.10 Repair Note Maintenance comprises all measures for reinstating the required condition. -
Page 81: General Inspection Of The Gear Unit
The total operating oil quantity for the gear unit, the oil-supply system, and the pipework can be found in the set-up plan. If the oil-supply system and the pipework are not included in the scope of delivery by Siemens, the operating oil quantity for the gear unit is shown on the rating plate (see section 1. "Technical data"). -
Page 82: Spare Parts, Customer Service
Any liability and warranty of Siemens is precluded for damages caused by the use of non-original spare parts. The same applies to any accessories not supplied by Siemens. -
Page 83: Declarations
12.1 Declaration of incorporation Declaration of incorporation in accordance with Directive 2006/42/EC, Annex II 1 B The manufacturer, Siemens AG, 46395 Bocholt, Germany, declares with regard to the partly completed machinery Vertical mill gear unit KMP, KMPS, KMPP for driving vertical mills: –... - Page 84 Further Information: "FLENDER gear units" on the Internet www.siemens.com/gearunits "FLENDER couplings" on the Internet www.siemens.com/couplings Service & Support: http://support.automation.siemens.com/WW/view/en/10803928/133300 Lubricants: http://support.automation.siemens.com/WW/view/en/42961591/133000 Siemens AG Subject to modifications Industry Sector Mechanical Drives © Siemens AG 2015 Alfred-Flender-Straße 77 46395 Bocholt GERMANY www.siemens.com/drivetechnologies...