Related Manuals for Siemens REDUREX
Summary of Contents for Siemens REDUREX
- Page 1 REDUREX Gear Unit Assembly and operating instructions BA 5200 EN 08/2010 FLENDER gear units...
- Page 2 12 1 Technical data REDUREX 12 2 General notes Gear Unit 12 3 Safety instructions Transport and 12 4 storage Technical 12 5 description Assembly and operating instructions 12 6 Translation of the original assembly and operating instructions Fitting 12 7 Startup...
- Page 3 Notes and symbols in these assembly and operating instructions Note: The term "Assembly and operating instructions" will in the following also be shortened to "instructions" or "manual". Legal notes Warning note concept This manual comprises notes which must be observed for your personal safety and for preventing material damage. Notes for your personal safety are marked with a warning triangle or an "Ex"...
- Page 4 Intended use of Siemens products Observe also the following: Siemens products must be used only for the applications provided for in the catalogue and the relevant technical documentation. If products and components of other makes are used, they must be recommended or approved by Siemens.
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Page 5: Table Of Contents
Contents Technical data ........... . . General technical data . - Page 6 Fitting ............. General information on fitting .
- Page 7 Startup ............Procedure before startup .
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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: Measuringsurface Soundpressure Level
The gear unit complies with a soundpower level which places it in the gearunit type class defined in VDI 2159 which is applied to produce the 80 % characteristic curve of the emission characteristic map. Adherence to limit values can, under specified Siemens test conditions, be assumed with statistical certainty. -
Page 10: Weights
Weights Table 1: Weights (approximate values) Approx. weight (kg) for size Type ‐ ‐ ‐ ‐ All weights are for units without oil filling and addon parts. For the exact weights, refer to the drawings in the gearunit documentation. BA 5200 EN 08/2010 10 / 65... - Page 11 Table 2: Weights (approximate values) Approx. weight (kg) for size Type 1050 1450 2000 2700 3650 5600 6300 9200 1250 1750 2450 3400 4600 6400 8800 12500 1100 1550 2150 3000 4000 5600 7700 1250 1750 2450 3400 4600 6400 8800 12500 1050...
- Page 12 Weights (approximate values) vertical gear unit Table 3: Approx. weight (kg) for size Type 180 200 225 250 360 400 450 500 560 630 SZNS 1215 1620 2300 3065 4330 5825 8170 11270 SZLS 1135 1510 2120 2880 4110 5430 7575 10575 SZAS 1215 1620 2300 3065 4330 5825 8170 11270...
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Page 13: General Notes
All persons carrying out work on the gear unit must have read and understood these instructions and must adhere to them. Siemens accepts no responsibility for damage or disruption caused by disregard of these instructions. The "FLENDER gear unit" dealt with in these instructions has been developed for driving machines in general engineering applications. -
Page 14: Safety Instructions
Safety instructions Entry to the gear unit and its added components is not permitted during operation! Entry for maintenance and repair work is only permitted when the gear unit is at a standstill! Caution! Risk of falling! Any changes on the part of the user are not permitted. This applies equally to safety features designed to prevent accidental contact. -
Page 15: Environmental Protection
Screws which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type. • Spare parts should always be obtained from Siemens (see also section 11). Environmental protection • Compliance with local environmental protection requirements during operation and in particular during maintenance and repair work on the gear unit is the responsibility of the operator. -
Page 16: Transport And Storage
If there is any visible damage, the gear unit must not be put into operation. Transport When transporting Siemens products, use only lifting and handling equipment of sufficient loadbearing capacity! Observe the notes regarding load distribution on the packing. While being transported on vehicles, loads must be properly secured as required by the regulations. - Page 17 Type S.N ≤ 280 Type K.N ≤ 280 Type S.N ≥ 280 Type K.N ≥ 280 Fig. 3: Attachment points Type SZNS Type KZNS Fig. 4: Attachment points A detailed view of the gear unit can be obtained from the drawings in the gearunit documentation. On gear units with an addon drive motor the centre of gravity may shift.
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Page 18: Storing The Gear Unit
Storing the gear unit The gear unit must be stored in a sheltered place in the position of the original packaging or in the position of use, placed on a vibrationfree, dry base, and covered over. When temporarily storing the gear unit and any single components supplied with it, the preservative agent should be left on them. -
Page 19: Interior Preservation With Preservative Agent
For storage periods longer than 24 months, renew the preservative agent. For storage periods longer than 36 months, Siemens should be consulted before. Table 5: Durability period and measures for interior preservation when using PGbased synthetic oil... -
Page 20: Technical Description
Technical description Observe the instructions in section 3, "Safety instructions"! General description The gear unit described is a gear unit developed for driving machines in general engineering applications. The gear unit is supplied as a single, two, three, four, five or sixstage helical or bevelhelical gear unit. It is designed for installation in the horizontal mounting position. - Page 21 Type S.N Type K.N Fig. 5: Gearunit features Housing base Lifting eyes Housing top Transport lugs Cover Transport lugs (≥ 360) Cover Pressure bolts (≥ 360) Cover Alignment surfaces (≥ 360) Inspection and/or assembly cover Housing ventilation Shaft seals Oildrain plug Shaft seals Rating plate Oil dipstick...
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Page 22: Toothed Components
Toothed components The externally toothed components of the gear unit are casehardened. Helicalgear teeth are ground or lapped. The high quality of the teeth leads to a significant noise reduction and ensures safe and reliable running. The gear wheels are joined to the shafts by interference fits and parallel keys. These types of joints transmit with adequate reliability the torques generated. -
Page 23: Labyrinth Seals
5.6.2 Labyrinth seals Labyrinth seals are noncontacting seals. They therefore require no maintenance and ensure favourable temperature characteristics. Fig. 7: Fey labyrinth seal For reliable operation, the labyrinth seals require stationary, horizontal positioning away from dirty water and heavy dust. Overfilling of the gear unit can cause leakage, as can oil with high foam content. -
Page 24: Cooling
Cooling Depending on requirements, the gear unit is fitted with a cooling coil, an addedon oilsupply system with water oilcooler or a separately provided oilsupply system. In the case of a separate oilsupply system, the specific instructions for this oilsupply system must be observed. 5.7.1 The fan is mounted on the highspeed shaft of the gear unit and is protected from accidental contact by an air guide cover. -
Page 25: Water Oilcooler
5.7.4 External oilsupply system It is possible to use an oilsupply system which is separately supplied by Siemens or an external system to ensure cooling of the oil. Be sure to observe the operating instructions of the oilsupply system for operation and maintenance. -
Page 26: Backstop
The stop direction can be changed by turning the cage around. If a change in stop direction is required, Siemens should be consulted beforehand. To avoid damaging the backstop or the gear unit, the motor must not be run adversely to the stop direction of the gear unit. -
Page 27: Oiltemperature Monitoring
Specific heating output P as a function of the ambient temperature Table 7: Ambient temperature (W/cm²) °C + 10 to 0 0 to - 25 - 25 to - 50 Be sure to observe the operating instructions of the heating elements for operation and maintenance. -
Page 28: Fitting
Fitting Observe the instructions in section 3, "Safety instructions"! General information on fitting When transporting the gear unit observe the notes in section 4. Fitting work must be done with great care by authorised, trained and qualified personnel. The manufacturer cannot be held liable for damage caused by incorrect assembly and installation. -
Page 29: Unpacking
The products supplied are listed in the despatch papers. Check immediately on receipt to ensure that all the products listed have actually been delivered. Parts damaged and/or missing parts must be reported to Siemens in writing immediately. The packaging must not be opened or damaged, when this is part of the preservation method! •... -
Page 30: Alignment
Protect shaftsealing rings from damage and heating to over + 100 °C (use heatprotective screens to protect against radiant heat.) The shaftsealing rings and running surfaces of the shaft must not be damaged when pulling in the coupling parts. Fit the coupling with the aid of suitable fitting equipment. The parts must not be driven on by abrupt force, as this may damage the gear unit (see also item 6.7). -
Page 31: Mounting On A Foundation Frame
6.3.2.2 Mounting on a foundation frame • Clean the undersurface of the gearunit base. • Using suitable lifting gear, place the gear unit on the foundation frame. • Tighten the foundation bolts to the specified torque (see item 6.20); if necessary, use stops to prevent displacement. -
Page 32: Mounting On A Concrete Foundation By Means Of Anchor Bolts
• Using suitable lifting gear, place the gear unit on the concrete foundation. • Align gear unit horizontally by in and output shafts: ─ if using stone bolts, with shims. ─ if using foundation blocks, with the aid of the set screws (if available). •... - Page 33 ─ The values punched into the screeds must always be observed. ─ Alignment tolerances in relation to the units on the input and output sides are to be in accordance with the permissible angular and axial displacements of the couplings (see coupling drawings). •...
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Page 34: Assembly Of A Shaftmounting Gear Unit With Hollow Shaft And Parallel Keyway
Assembly of a shaftmounting gear unit with hollow shaft and parallel keyway The end of the drivenmachine shaft (material C60+N or higher strength) must be provided with a parallel key to DIN 6885 Part 1 Form A . Furthermore, two tapped holes for fastening an end plate must be provided on the front end face. -
Page 35: Fitting
6.4.1.1 Fitting • Fit the gear unit by means of nut and threaded spindle. The counterforce is provided by the hollow shaft. The hollow shaft must be exactly aligned with the machine shaft to avoid canting. Fig. 15: Hollow shaft, mounting with threaded spindle Machine shaft End plate Hollow shaft... -
Page 36: Shaftmounting Gear Unit With Hollow Shaft And Shrink Disk
DIN 332 Form DS (with thread) in its end face. Depending on the order hollow shafts can be fitted with redbronze bushes to guide the shafts. Shrink disks are not included in the Siemens delivery. Supply is possible on request. 6.5.1 Fitting •... -
Page 37: Fitting With Redbronze Bush
6.5.1.1 Fitting with redbronze bush • Fit the gear unit by means of nut and threaded spindle. The counterforce is provided by the hollow shaft. The hollow shaft must be exactly aligned with the machine shaft to avoid canting. When fitting, ensure that the position of the teeth between the machine shaft and hollow shaft is correct. -
Page 38: Shrink Disk
Shrink disk The shrink disk realizes a pressfit connection between a hollow shaft and a stub/machine shaft (in the following called "stub shaft"). The interference fit can transfer torques, bending moments and forces. The jointing pressure between the hollow and stub shafts generated by the shrink disk is essential for the torque and force transmission. - Page 39 M 16 M 33 2650 The shrink disk has been identitymarked on the outer ring (4). In case of contacting Siemens this identification must be referred to. For safety reasons, a protective cover should be mounted to prevent contact! This cover must be applied after completion of all works on the shrink disk.
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Page 40: Demounting The Shrink Disk
6.6.2 Demounting the shrink disk • Remove the protective cover. • Remove any rust deposits from the shaft and the hollow shaft. Under no circumstances must the tensioning bolts be unscrewed one after the other. • Undo all tensioning bolts one after the other by approx. 1/4 turn. The stored energy of the outer ring is slowly loosened during disassembly via the bolts to be loosened. -
Page 41: Remounting The Shrink Disk
For permissible alignment errors in the case of couplings supplied by Siemens, please refer to the operating instruction manuals for the couplings. If you use couplings manufactured by other manufacturers, ask these manufacturers which alignment errors are permissible, stating the radial loads occurring. - Page 42 Increased system‐service life and reliability and reduced running noise can be achieved through the least possible radial and angular misalignment. The coupling parts may get out of alignment • due to imprecise alignment during assembly or installation • during operation of the system due to: ─...
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Page 43: Gear Unit With Torque Arm
Gear unit with torque arm • Attaching the torque arm The torque arm must be mounted stressfree. • Foundation type for fastening the torque arm, see item 6.3.1, "Foundation". • A detailed view of the gear unit can be obtained from the drawings in the gearunit documentation. Gear unit with gearunit swing •... -
Page 44: Gear Unit With Oilsupply System
6.13 Gear unit with oilsupply system • Remove the sockets of the suction and delivery lines prior to connecting the system. • Fit the system to the gear unit or install it separately in accordance with the drawings supplied in the gearunit documentation. -
Page 45: Screwconnection Classes, Tightening Torques And Initial Tensioning Forces
6.20 Screwconnection classes, tightening torques and initial tensioning forces 6.20.1 Screwconnection classes The specified screw connections are to be fastened applying the tightening torques specified in the table below. Table 10: Screwconnection classes Distribution Tightening procedure Screwconnection of emitted torque (Usually the tightening processes lie within the stated class on the tool... - Page 46 Nominal Strength Initial tensioning force Tightening torque thread class of the for screwconnection classes for screwconnection classes diameter bolt from table 10 from table 10 M min. 109000 69600 43500 10.9 155000 99200 62000 12.9 181000 116000 72500 1020 170000 109000 68000 1210...
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Page 47: Startup
Startup Observe the instructions in section 3, "Safety instructions"! The gear unit must not be started up if the required instructions are not to hand. Procedure before startup 7.1.1 Removal of preservative agent The location of the oildraining points is marked by a symbol in the dimensioned drawing in the gearunit documentation. -
Page 48: Filling With Lubricant
The quality of the oil used must meet the requirements of the separately supplied BA 7300 EN lubricant recommendation manual, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in BA 7300 EN, because they have been tested and meet the requirements. -
Page 49: Oil Level
If the oil temperature is < 10 °C the oil should be heated up applying suitable measures or Siemens should be consulted. Be sure to observe the operating instructions of the oilsupply system for operation and maintenance. -
Page 50: Gear Unit With Backstop
The difference in temperature from the maximum ambient temperature of + 40 °C must not exceed 50 K. At higher temperatures the gear unit must be shut down immediately and Siemens customer service consulted. 7.2.6 Gear unit with oillevel monitoring When the signal "oil level too low"... -
Page 51: Checking Procedure
7.2.8 Checking procedure The following visual checks must be conducted and recorded when starting up: Oil level □ Leaktightness of the oilcooling or oilsupply lines □ Opening condition of the shutoff valves □ Effectiveness of the shaft seals □ Freedom of the rotating parts from contact □... -
Page 52: Exterior Preservation
7.3.1.3 Interiorpreservation procedure • Stop the gear unit. • Drain oil into a suitable container (see section 10, "Maintenance and Repair"). • Unscrew breather screw. • Pour in the preservative agent through the hole of the breather screw and/or inspection cover up to the top mark on the oilsight glass. -
Page 53: Operation
Operation Observe the instructions in section 3, "Safety instructions", in section 9, "Faults, causes and remedy", and in section 10, "Maintenance and repair"! General To achieve a satisfactory and troublefree operation of the equipment, be certain to observe the operating values specified in section 1, "Technical Data", as well as the information given in the operating instructions of the oilsupply system. -
Page 54: Faults, Causes And Remedy
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 Siemens agreement or use of spare parts not supplied by Siemens. - Page 55 Faults Causes Remedy Oil leakage from the gear unit. Inadequate sealing of housing Check and, if necessary, covers and/or joints. replace sealings. Seal joints. Radial shaftsealing rings defective. Check radial shaftsealing rings and, if necessary, replace. Oil foaming in the gear unit. Preservation agent not completely Oil change.
- Page 56 Faults Causes Remedy Pressure monitor triggers Oil pressure < 0,5 bar. Check oil level at room temperature alarm. and, if necessary, top up oil. Check (Gear unit with water oilcooler) and, if necessary, replace the oil pump. Check and, if necessary, clean oil filter.
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Page 57: 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 All maintenance and repair work must be done with care and by duly trained and qualified personnel only. The following applies to all work in item 10.2: Switch the gear unit and addon components off. -
Page 58: General Oilservice Lives
Maßnahmen Fristen Bemerkungen Check cooling coil Every 2 years see item 10.2.7 Check condition of water oilcooler Approx. every 2 years see item 10.2.8 Check hose lines Yearly see item 10.2.9 Change the hose lines 6 years from the manufacturing date see item 10.2.9 impressed Check tightness of fastening bolts... -
Page 59: Change Oil
10.2.2 Change oil As an alternative to the oilchange intervals indicated in Table 13 (see item 10.1) it is possible to have the oil sample tested at regular intervals by the Technical Service of the relevant oil company and to have it released for further use. -
Page 60: Clean The Gear Unit
Such companies also sell special cleansing agents for removing such deposits. • Before using these cleaning agents, ensure that they will not damage the coil materials (contact Siemens). Observe the manufacturer’s instructions at all times when using different cleaning agents by several manufacturers. BA 5200 EN 08/2010... -
Page 61: Check Water Oil-Cooler
Avoid burns when working with corrosive cleaning agents. Always observe the manufacturers’ instructions for safety and use. Wear personal protective equipment (gloves, safety glasses)! • Seriously contaminated cooling coils must be replaced. Consult our Customer Service. • Reconnect the water in and outflow pipes. 10.2.8 Check water oil-cooler •... -
Page 62: Final Work
Damaged bolts must be replaced with new bolts of the same type and strength class. 10.4 General inspection of the gear unit The general inspection of the gear unit should be carried out by the Siemens Customer Service, as our engineers have the experience and training necessary to identify any components requiring replacement. 10.5... -
Page 63: Spare Parts, Customerservice Addresses
When ordering spare parts, always state the following: Order number, item Type, size Part number Quantity 11.2 Spare parts and customerservice addresses When ordering spare parts or requesting a service specialist, please contact Siemens first (see section 2). BA 5200 EN 08/2010 63 / 65... -
Page 64: Declarations
12.1 Declaration of incorporation Declaration of Incorporation in accordance with Directive 2006/42/EC, Annex II 1 B The manufacturer, Siemens AG, D 46393 Bocholt, declares with regard to the partly completed machinery, REDUREX Gear Unit for driving machines in general engineering applications: ‐... - Page 65 Siemens AG Subject to modifications Industry Sector Mechanical Drives © Siemens AG 2010 Alfred-Flender-Straße 77 46395 Bocholt GERMANY www.siemens.com/drivetechnologie...