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Operating Instructions

1. e With oil supply systems fitted with water oil coolers close the stop valves on the water in and outflow pipes To prevent freezing drain the water from the water oil cooler Interior protection with preservative agent Oil supply systems with forced lubrication should be run idle with preservative prior to any long term storage Duration of protection Preservative agent up to 6 months None Castrol Alpha SP 220 S up to 24 months Close connection pipes For storage periods longer than 24 months the oil supply system must be re preserved For storage periods longer than 36 months FLENDER should be consulted before Table 7 1 Preservation procedure when using mineral oil or PAO based synthetic oil Duration of protection Preservative agent up to 6months Special anti corrosion oil None TRIBOL 1390 1 up to 36 months Close connection pipes For storage periods longer than 36 months FLENDER should be consulted before Table 7 2 Preservation procedure when using PG based synthetic oil 1 Resistant to tropical conditions and sea water Max ambient temperature 50 C Interior preservation procedure e Remove the oil supply system from service and drain off the oil e Fill the oil supply system if necessary via the connected gear unit with a sufficient quantity of preservative agent as indicated in Table 7 1 or 7 2 e Start the oil supply system and allow it to idle for a short time e Drain off the pre
2. C and 35 C Another max temperature is possible see details in the list of equipment BA 9704 EN 02 06 5 32 FLENDER 3 2 3 3 3 4 Obligations of the user e The operator must ensure that all persons involved in installation operation maintenance and repair have read and understood these Operating Instructions BA and comply with them at all times in order to avoid injury or damage ensure the safety and reliability of the oil supply system and avoid disruptions and environmental damage through incorrect use During transport assembly installation dismantling operation and maintenance of the unit the relevant safety and environmental regulations must be complied with at all times The oil supply system must be operated maintained or repaired only by authorised duly trained and qualified personnel The gear unit must not be cleaned using high pressure cleaning equipment All work must be carried out with great care and with due regard to safety All work on the oil supply system must be carried out only when it is at a standstill The drive unit must be secured against being switched on accidentally e g by locking the key switch or removing the fuses from the power supply A notice should be attached to the ON switch stating clearly that work on the oil supply system is in progress If any changes are noticed during operation of the oil supply system e g increased operating temper
3. 83 8 2 1 11 Volumetric flow meter 8 2 1 12 Control valve 85 86 8 2 1 13 Cooling water flow regulator 500 8 2 1 14Stop valve 510 oO oo JJ zl NOOO oad E E P BA 9704 EN 02 06 2 32 FLENDER 8 2 1 15Stop valve 515 8 2 1 16Pipe filter 520 8 2 1 17 General 8 2 2 8 2 2 1 8 2 2 2 8 2 2 3 8 2 2 4 8 2 2 5 8 2 2 6 8 2 2 7 8 2 3 8 2 3 1 8 2 3 2 8 2 3 3 8 2 4 8 2 4 1 8 2 4 2 8 2 5 8 2 5 1 8 2 5 2 8 2 6 8 2 6 1 8 3 8 3 1 8 3 2 8 3 2 1 8 3 2 2 8 3 2 3 8 3 3 8 3 4 8 3 5 8 4 8 5 9 9 1 9 2 9 2 1 9 2 2 10 10 1 10 2 10 3 10 4 11 11 1 11 2 12 High pressure lubrication circuit Radial piston pump 310 Pressure relief valve 316 Pressure release valve 338 Pressure gauge 345 Pressure gauge 348 Pressure measuring transducer 350 Pressure measuring transducer 358 Heating circuit Three way cock 207 217 Heating circuit pump 210 Oil preheater 290 By flow filtration Filter 620 Temperature control valve 632 Filling and emptying circuit Three way cock 707 717 Pump 710 Other Drain cock 3 Interlocking instructions Main circuit Heating circuit By flow filtration Filling and Emptying circuit Variant 2 Variant 3 Variant 4 Enable gear unit Warning gear unit Stop gear unit Response to malfunctions Shut down Faults causes and remedy General information on faults and malfunctions Possible faults Possible faults when installin
4. Ltda Ger sala 1017 Enseada do Vit ria ES Fax 55 0 27 32 24 37 36 flender vitoria uol com br Flender Power z BE Markham Phone 1 0 9 05 3 05 10 21 info flenderpti com CANADA Transmission Inc BIS Sues Coui Units Ontario L3R 8V2 Fax 1 0 9 05 3 05 10 23 www flender ca CHILE ARGENTINA Geesse AROR Flender Cono Sur Ltda Avda Galvarino Gallardo 1534 Providencia Santiago o SH e es a Ee URUGUAY f Flender Liaison Office Colombia S ang L if S ren E uexco ee nn u EE a an Lago Nargis No 11520 Mexico D F GE E e 2 gt E A info flendermexico com aoe Cina O 64660 Monterrey N L IT 52 E Bt bo es a info flendermexico com PERU Flender Cono Sur Ltda Avda Galvarino Gallardo 1534 Providencia Santiago Ea CS a a usa Forder omo 1 gluta Ros Re ZE Zeen Flender Corporation ee Su Bakersfield CA 93308 Ge a a a a x Z 5 e flender1 lightspeed net VENEZUELA F H Transmisiones S A Calle Johan Schafer o Segunda Petare Caracas Phone 58 0 2 12 21 52 61 fhtransm telcel net ve Calle Municipio Sucre Fax 58 0 2 12 21 18 38 www fhtransmisiones com BA 9704 EN 02 06 29 32 FLENDER BANGLADESH er No 2 St George s Gate Road z Phone 91 0 33 2 23 05 45 SC SRI LANKA Flender Limited 5th Floor Hastings Kolkata 700022 Fax 91 0 33 2 23 1857 flender flenderindi
5. guss de WINERGY AG Am Industriepark 2 Postfach 201160 Tel 02871 924 info winergy ag com 46562 Voerde 46553 Voerde Fax 0 28 71 92 2487 www winergy ag com sales motox flender BahnhofstraBe 40 44 Postfach 1709 Tel 0 70 71 707 0 EE 72007 T bingen Fax 920 211 20 400 Motoxcom www flender com LOHER GMBH Hans Loher StraBe 32 Postfach 1164 Tel 0 85 31 3 90 info loher de 94099 Ruhstorf 94095 Ruhstorf Fax 0 85 31 3 94 37 www loher de A FRIEDR FLENDER AG FLENDER SERVICE INTERNATIONAL Am Industriepark 2 46562 Voerde Postfach 201160 46553 Voerde Tel 02871 92 2210 Fax 0 28 71 92 13 47 infos flender service com www flender service com Werk Herne S dstra e 111 44625 Herne Vertriebsburo Penig Thierbacher StraBe 24 09322 Penig Postfach 101720 44607 Herne Postfach 44 45 09320 Penig Tel 0 23 23 940 0 Fax 0 23 23 9 40 3 33 24h Service Hotline 49 0 17 22 81 01 00 Tel 03 73 81 61 520 Fax 03 73 81 61 4 88 infos flender service com www flender service com infos flender service com www flender service com BA 9704 EN 02 06 27 32 FLENDER Addresses International 2006 06 Industriezentrum N S d Phone 43 0 22 36 6 45 70 office flender at AUSTRIA Flender Ges m b H Strasse 4 Objekt 14 2355 Wiener Neudorf Fax 43 0 22 36 6 45 70
6. of a volumetric flow meter The volumetric flow meter sends an output signal in proportion to the square of the oil flow volume 11 Volumetric flow meter 83 The oil flow to the gear unit is monitored by means of a volumetric flow meter The volumetric flow meter sends an output signal in proportion to the square of the oil flow volume 12Control valve 85 86 Setting these valves influences the distribution of the oil flow Caution Setting see item 7 6 13Cooling water flow regulator 500 The cooling water flow is regulated to suit the required cooling performance 14Stop valve 510 The cooling water inflow can be stopped by this stop valve 2 limiting switches are used for the electrical control of the opening condition 15Stop valve 515 The cooling water inflow can be stopped by this stop valve 16Pipe filter 520 The cooling water is filtered by this pipe filter 17General After switching off the main drive the oil supply system must continue to run until the drive has come to a complete standstill High pressure lubrication circuit 1 Radial piston pump 310 These pumps draw the oil for the high pressure lubrication circuit from the low pressure lubrication circuit 8 2 2 2 Pressure relief valve 316 These valves limit the pressure in systems with a heating circuit Caution The factory adjustment of these valves must not be changed BA 9704 EN 02 06 17 32 FLENDER 8 2
7. oil supply system 1 minute before the gear unit Caution Never operate the gear unit without the oil supply system Before starting up the gear unit for the first time the oil supply system must be run for at least 15 minutes to fill all the oil chambers See operating instructions for Gear Unit Then shut down the oil supply system and if necessary correct the oil level All piping particularly suction pipes inadmissible air intake as well as all screw connections and flanges must be retightened Leaks must be resealed Pumps The direction of discharge of the pumps used is dependent upon the direction Caution of rotation The direction of rotation of the motors must correspond to the direction of the arrow on the pumps Observe our supplier s specific operating instructions for the pumps Water oil cooler The necessary water connections must be manufactured by the customer operator for the water oil cooler If the oil supply system is shut down for a longer period or if there is a danger of freezing the cooling water must be drained off As regards the water oil cooler the specific Operating Instructions of the manufacturer must be observed BA 9704 EN 02 06 13 32 FLENDER 7 5 7 6 General notes on add on components Note For operation and maintenance of the components specified in the equipment list observe the specified operating instructions For technical data refer to the list of eq
8. type For the oil viscosity and oil type refer to the operating instructions BA or the gear unit rating plate The oil supply systems are designed for oil viscosities lt 2200 mm2 s installations with heating circuit up to 7500 mm s at minimum starting temperature see rating plate 8 BA 9704 EN 02 06 4 32 FLENDER 2 1 2 2 3 1 General notes Introduction These Operating Instructions BA are an integral part of the delivery of the oil supply system and must be kept in its vicinity for reference at all times Note The operating instructions BA for the gear unit must be observed All persons involved in the installation operation maintenance and repair of aution the oil supply system must have read and understood these Operating Instructions and must comply with them at all times We accept no responsibility for damage or disruption caused by disregard of these Instructions The FLENDER oil supply system dealt with in these Operating Instructions BA has been developed for use as an oil supply system of gear units Possible areas of use for oil supply system of this type include the cement industry and others The oil supply system is designed only for the application described in section 1 Technical data and the List of Equipment The oil supply system described in these Instructions reflects the state of technical development at the time these Instructions BA went to print In the int
9. you can ensure that the oil supply system is ready for use at any time To order spare parts refer to the list of equipment We guarantee only the original spare parts supplied by us Please note that spare parts and accessories not supplied by us have not been aution tested or approved by us The installation and or use of such products may therefore impair essential characteristics of the oil supply system thereby posing an active or passive risk to safety FLENDER will assume no liability or guarantee for damage caused by spare parts and accessories not supplied by FLENDER Please note that certain components often have special production and supply specifications and that we supply you with spare parts which comply fully with the current state of technical development as well as current legislation When ordering spare parts always state the following Material no Type Size Part no Quantity Spare part and customer service addresses When ordering spare parts or the services of our specialist engineers apply first to FLENDER AG BA 9704 EN 02 06 26 32 FLENDER Adressen Deutschland 2006 06 A FRIEDR FLENDER AG Alfred Flender StraBe 77 Postfach 1364 46395 Bocholt 46393 Bocholt Tel 0 28 71 92 0 Fax 0 28 71 92 25 96 contact flender com www flender com A FRIEDR FLENDER AG Kundenservice Center Nord Alfred Flender Stra e 77 46395 Bocholt Postfach 1364 46393 Bocholt
10. 10 flenderat Postfach 132 BELGIUM amp r Phone 32 0 2 2 53 10 30 LUXEMBOURG N V Flender Belge S A Cyriel Buyssestraat 130 1800 Vilvoorde Fax 32 0 2 2 53 09 66 sales flender be Business Center Bellissimo BULGARIA Auto Profi N GmbH 102 Boul Bulgaria 1680 Sofia e Wa o A S e a Pi flender auto profi com Office 48 Etage 4 S 8 0 2 CROATIA SLOVENIA z S BOSNIA HUM Naklada doo Mandroviceva 3a 10000 Zagreb GE E a E E 2 22 flender hi htnet hr HERZEGOVINA F Branch Office d Phone 420 315 62 12 20 CZECH REPUBLIC A Friedr Flender AG Fibichova 218 27601 Melnik Fax 420 315 62 12 22 info cz flender com E Phone 45 44 77 4477 ad ekspedition dk siemens com DENMARK Siemens A S Borupvang 3 2750 Ballerup Fax 45 4477 40 19 siemens dk gear ESTHONIA LATVIA Addinol Mineral l Suur Sdiamae 32 11415 Tallinn Phone 372 0 6 27 99 99 flender addinol ee LITHUANIA Marketing OU Esthonia Fax 372 0 6 27 9990 www addinol ee Flender Oy P O Box 60 Phone 358 0 10 5 11 51 51 webmaster flender fi ALAN c o Siemens Osakeyhti Majurinkatu 6 02601 Espoo Fax 358 0 10 5 113939 wwwalender fi Head Office 78996 Elancourt Phone 33 0 1 30 66 39 00 FRANCE Rendas 3 rue Jean Monnet B P 5 Cedex Fax 33 0 1 30663513 Saes flender fr Sales Office A 3 Flender Gar Agence de Lyon PS an Garis ae e 5 E sales flender fr Parc Inopolis Route de Vourles 1 rue du Vieux Moulin 67400 Illkirch
11. 2 3 8 2 2 4 8 2 2 5 8 2 2 6 8 2 2 7 8 2 3 8 2 3 1 8 2 3 2 8 2 3 3 8 2 4 8 2 4 1 8 2 4 2 Pressure release valve 338 This valve limits the pressure on the suction side of the high pressure lubrication circuit Caution The factory adjustment of this valve must not be changed Pressure gauge 345 The oil pressure is indicated visually by means of a pressure gauge Pressure gauge 348 This pressure gauge is connected to the high pressure lines by a connector and indicates the corresponding pressure Pressure measuring transducer 350 The pressure on the suction side of the high pressure circuit is monitored by means of this pressure measuring transducer It sends an output signal in proportion to the pressure Pressure measuring transducer 358 The pressure on the pressure side of the high pressure circuit is monitored by means of these pressure measuring transducers They send an output signal in proportion to the pressure Heating circuit Three way cock 207 217 For filling and emptying one three way cock is provided upstream and another downstream of the heating circuit pump Each cock setting must be adjusted to suit the respective function See position symbol on the three way cock and the oil flow path on the lubrication diagram During the filling draining process the main pump must not be operating After aution the process the cocks must be set in operating position again Heating c
12. 22 61 0 2 97 56 1492 sales flender com au www flender com au Siemens Ltd Industrial Automation amp Control Sales Offices BW3 Level 2 885 Mountain Highway Bayswater VIC 3153 Melbourne Phone Fax 61 0 3 97 21 27 65 61 0 3 97 21 7888 sales flender com au Siemens Ltd Industrial Automation amp Suite 5 1407 Logan Rd QLD 4122 Brisbane Phone 61 0 7 34 22 23 89 sales flender com au Mt Gravatt Fax 61 0 7 34 22 2403 Control Siemens Ltd E Suite 2 WA 6104 Phone 61 0 8 94 77 41 66 ai Automaten g 403 Great Eastern Highway Redcliffe Perth De SB esconder com au NEW ZEALAND Flender Australia Pty Lid Zen ZC P O Box 6047 NSW 2164 Sydney GEN a engen sales flender com au BA 9704 EN 02 06 31 32 FLENDER 12 Declaration by the manufacturer Declaration by the manufacturer in accordance with EC Engineering Guideline 98 37 EC Appendix II B We hereby declare that the Oil supply systems of type OWGM described in these Operating Instructions are intended for incorporation in a machine and that itis prohibited to put them into service before verifying that the machine into which they are incorporated complies with the EC Guidelines original edition 98 37 EC including any subse quent amendments thereto This Manufacturer s Declaration takes into account all the unified standards inasmuch as they apply to our products p
13. 3 18 57 flender flenderindia com D Industrial Growth Centre Nimpura Phone 91 0 3222 23 33 07 SES Femer Gate Rakhajungle Kharagpur 721302 Fax 91 0 3222 233364 Works flenderindia com Eastern Regional Sales Office Sech Hastings Phone 91 0 33 22 23 05 45 Rai Flender Limited Ge George s Gate Road Kolkata 700022 Fax 91 0 33 22 23 08 30 ero flenderindia com Western Regional Sales Office Vashi Phone 91 0 22 27 65 72 27 wae Filsmelar Gate Plot No 23 Sector 19 C Navi Mumbai 400705 Fax 91 0 22 27657228 Wf0 flenderindia com or Southern Regional Sales Office Aminjikarai Phone 91 0 44 23 74 39 21 E SSES 41 Nelson Manickam Road Chennai 600029 Fax 91 0 44 23743919 SfO flenderindia com Northern Regional Sales Office d 5 Flender Limited 302 Bhikaji Cama Bhawan New Delhi 110066 Aes pa e Si i zi z nro flenderindia com 11 Bhikaji Cama Palace Flender Singapore Pte Ltd J d a alan Jendral Ahmad Phone 62 0 21 471 50 65 E INDONESIA Representative Office E Jakarta 13210 bobwall cbn net id c o P T Siemens Indonesia Yani 68 Pulomas Fax 62 0 21 471 50 63 P O Box 15745 493 A IRAN Cimaghand Co Ltd No 13 16 East Street Tehran 15156 Ee E e a S E 5 e info cimaghand com Beyhaghi Ave Argentina Sq Phone 972 0 52 4 76 14 26 ram greenshpon de ISRAEL Greenshpon poaz 34487 Halfa Fax 972 0 4 8 14 60 37 www greenshpon co il Takanawa Park Tower 17F Flender Japan Co Ltd d x y Pho
14. 58 3 since 2 seconds BA 9704 EN 02 06 19 32 FLENDER 8 3 2 8 3 2 1 8 3 2 2 Heating circuit By flow filtration Filling and Emptying circuit The interlocking instructions depend on the type refer to equipment list for type specification of the oil supply system Variant 2 ENABLE for the heating circuit pump 210 if Oil temperature gt temperature value 265 2 START for the heating circuit pump 210 if Oil temperature lt temperature value 265 3 STOP for the heating circuit pump 210 if at least one of the following conditions is fulfilled Oil preheater 290 has been out of operation for 3 minutes Oil temperature lt temperature value 265 2 ENABLE for the oil preheater 290 if Heating circuit pump 210 has been in operation for 2 minutes START for the oil preheater 290 if Oil temperature lt temperature value 265 3 STOP for the oil preheater 290 if at least one of the following conditions is fulfilled Heating circuit pump 210 out of operation Oil temperature gt temperature value 265 4 Oil temperature gt switching point 290 Variant 3 ENABLE for the by flow pump 210 if Main pump 10 in operation ENABLE for filter differential pressure monitor 620 if Oil temperature gt temperature value 265 5 ENABLE for the by flow pump 210 if Oil temperature gt temperature value 265 5 WARNING for thed by flow pump 210 if Filter differential pressure gt sw
15. 6 92 34 38 Fax 27 0 13 6 92 34 52 sales flender co za Flender Power Transmission Pty Ltd Unit 14 King Fisher Park Alton Cnr Ceramic Curve amp Alumina Allee P O Box 101995 Richards Bay Meerensee 3901 Phone 27 0 35 751 1563 Fax 27 0 35 751 1564 sales flender co za ARGENTINA Chilicote S A Avda Julio A Roca 546 C 1067 ABN Phone 54 0 11 43 31 66 10 chilicote chilicote com ar Buenos Aires Fax 54 0 11 43 31 42 78 Head Office F 32210 660 Phone 55 0 31 33 69 20 00 BRASIL Flender Brasil Ltda Rua Quatorze 60 Contagem MG Fax 55 0 31 3331 1898 vendas flenderbrasil com Cidade Industrial Sales Offices a Flender Brasil Ltda Rua James Watt 152 Geer Ge O i e flesao uol com br conjunto 142 Brooklin Novo ax i Rua Campos Sales 1095 14015 110 Phone 55 0 16 6 35 15 90 a Bel sala 14 centro Ribeir o Preto SP Fax 55 0 16 6351105 flenderribpretoQuol com br Rua da Mitra quadra 30 lote 16 R e dg 65075 770 Phone 55 0 98 32 25 84 92 Flender Brasil Ltda GE Cristal sala 207 S o Luis MA Fax 55 0 98 32 25 84 93 flendersiz uol com br airro Renascenca A Rua Padre Anchieta 1691 80730 000 Phone 55 0 41 3 36 28 49 n E ear aeei teia conjunto 1110 Bairro Bigorrilho Curitiba PR Fax 465 oa sso2sag dualiyionalheorebolicom br Rua Jos Alexandre Buaiz 29050 545 Phone 55 0 27 32 24 37 35 Sa Flender Brasil
16. Graffenstaden Phone 33 0 3 88 67 60 00 _ FRANCE Flender Graffenstaden SA B P 84 67 402 Illkirch Fax 33 0 3 88 67 06 17 flencomm flender graff com Graffenstaden Phone 30 210 291 72 80 GREECE Flender Hellas Ltd 2 Delfon str 11146 Athens Fax 30 210 291 7102 flender otenet gr soci as Phone 36 0 1 3 45 07 90 flender monornet hu HUNGARY Wentechi Kit Bees ZS 1023 Budapest Fax 36 0 1 3 45 07 92 jambor laszlo axelero hu Parco Tecnologico Manzoni i 2 ITALY Flender Cigala S p A Palazzina G 20040 Caponago MI GE E E go Info flendercigala it Viale delle industrie 17 g THE NETHERLANDS Flender Nederland B V a En doa 2595 BN Den Haag Phone 31 0 70 3336974 sales iflender ni c o Siemens Nederland N V Postbus 16068 2500 BB Den Haag Fax 31 0 70 333 12 12 www flender nl Boterdiep 37 3077 AW Rotterdam Phone 31 0 10 4 97 08 08 info bruinhof nl UE Bani a Postbus 9607 3007 AP Rotterdam Fax 31 0 10 4824350 www bruinhofnl NORWAY Siemens AS stre Aker vei 90 0596 Oslo Phone 47 22 63 30 00 adinfo siemens no Divisjon Automation 8 Drive Postboks 1 0613 Oslo Fax 47 22633105 www siemens no ad Branch Office E x POLAND A Friedr Flender AG Przedstawicielstwo w Polsce 43 190 Mikol w ni e z 2 e Se 1 eier EE ul Wyzwolenia 27 ae ms E P e E g Phone 351 0 21 7 54 24 10 PORTUGAL Rodamientos FEYC S A R Jaime Lopes Dias 1668 CV 1750 124 Lissabon Fax 351 0 21 7 54 24 19 info rfportugal com p B dul Garii O
17. Operating Instructions BA 9704 EN 02 06 Oil supply systems of type OWGM FLENDER A Friedr Flender AG 46393 Bocholt Tel 02871 92 0 Telefax 02871 92 2596 www flender com FLENDER 7 7 7 7 1 7 7 2 8 8 1 8 2 8 2 1 8 2 1 1 8 2 1 2 8 2 1 3 8 2 1 4 8 2 1 5 8 2 1 6 8 2 1 7 8 2 1 8 8 2 1 9 Contents Technical data General technical data Oil viscosity oil type General notes Introduction Copyright Safety notes Proper use Obligations of the user Environmental protection Special dangers Warnings and symbols used in these Instructions Handling and storage Scope of supply Handling Storage of the oil supply system Standard corrosion protection Technical description General Measures required as a function of the start condition Assembly General Check before start up General notes on add on components Final installation work Start up Oil viscosity oil type Oil filling Pumps Water oil cooler General notes on add on components Start up Removal from service Interior protection with preservative agent Interior preservation procedure Operation Lubrication diagram Control information Low pressure lubrication circuit Pump 10 Filter 20 Temperature control valve 32 Pressure gauge 45 Pressure gauge 46 Thermometer 60 Resistance thermometer 65 Volumetric flow meter 8 Volumetric flow meter 0 81 8 2 1 10 Volumetric flow meter 82
18. Operating instructions are being changed without authorisation Possible faults in maintenance e Maintenance intervals are not being adhered to e Leakage in the vicinity of the oil supply system is not being identified and as a result chemically aggressive media are damaging the oil supply system Maintenance and repair Observe the Safety instructions in section 3 Note The operating instructions BA for the gear unit must be observed Oils For the oil viscosity and oil type refer to the operating instructions BA or the gear unit rating plate The oil supply systems are designed for oil viscosities lt 2200 mm s installations with heating circuit up to 7500 mm s at minimum starting temperature see rating plate 8 For the oil change intervals please refer to the operating instructions BA for the gear unit General notes on add on components Note For operation and maintenance of the components specified in the equipment list observe the specified operating instructions For technical data refer to the list of equipment Preservation Refer to Section 7 Start up and Section 8 Operation Cleaning To prevent the build up of dust on the oil supply unit cleaning must be done aution in accordance with operating conditions BA 9704 EN 02 06 25 32 FLENDER 11 Spare parts customer service addresses Stocking spare parts By stocking the most important spare and wearing parts on site
19. Tel Fax 0 28 71 92 0 0 28 71 92 14 35 ksc nord flender com www flender com A FRIEDR FLENDER AG Kundenservice Center Stid BahnhofstraBe 40 44 72072 T bingen Postfach 1709 72007 T bingen Tel 0 70 71 707 0 Fax 0 70 71 7 07 3 40 ksc sued flender com www flender com A FRIEDR FLENDER AG Kundenservice Center Sud AuBenstelle Munchen LiebigstraBe 14 85757 Karlsfeld Tel 0 81 31 90 03 0 Fax 0 81 31 90 03 33 ksc sued flender com www flender com A FRIEDR FLENDER AG Tel 0 30 91 42 50 58 ksc ost flender com Kundenservice Center Schlossallee 8 13156 Berlin Fax 0 30 47 48 79 30 uns tlendercam Ost Osteuropa A FRIEDR FLENDER AG Am Industriepark 2 46562 Voerde Tel 028 71 92 0 contact flender com Werk Friedrichsfeld Fax 0 28 71 92 25 96 www flender com A FRIEDR FLENDER AG Getriebewerk Penig Thierbacher StraBe 24 09322 Penig Postfach 44 45 09320 Penig Tel 03 73 81 60 Fax 03 73 81 8 02 86 ute tappert flender com www flender com A FRIEDR FLENDER AG Kupplungswerk Mussum Industriepark Bocholt Schlavenhorst 100 46395 Bocholt Tel 0 28 71 92 28 68 Fax 0 28 71 92 25 79 couplings flender com www flender com i fl A FRIEDR FLENDER AG Obere Hauptstra e 09228 Chemnitz Tel 0 37 22 64 0 ee a enger FLENDER GUSS 228 230 Wittgensdorf Fax 0 37 22 94 1 38 eee www flender
20. a com PEOPLE S Head Office REPUBLIC Flender Power Trans Shuanghu Shuangchen Rd Tianjin 300400 Phone 86 0 22 26 97 20 63 flender flendertj com OF CHINA mission Tianjin Co Ltd West Beichen Economic J Fax 86 0 22 26 97 20 61 www flendertj com Development Area BEDA Sales Offices Flender Power Trans C 414 Lufthansa Center ii Phone 86 0 10 64 62 21 51 is mission Tianjin Co Ltd 50 Liangmagiao Rd Beijing 100016 Fax 486 0 10 64622143 Dellina flenderpre com cn Chaoyang District Flender Power Trans 1101 1102 Harbour Ring Plaza Shanghai 200001 Phone 86 0 21 53 853148 shanghai mission Tianjin Co Ltd 18 Xizang Zhong Rd 9 Fax 86 0 21 53853146 flenderprc com cn Flender Power Trans Rm 1503 Jianyin Building Phone 86 0 27 85 48 67 15 mission Tianjin Co Lid 709 Jianshedadao Hankou Wuhan 430015 Fax 86 0 27 85486836 uhan flenderpre com cn T Rm 2802 Guangzhou k Flender Power Trans SS S Phone 86 0 20 87 32 60 42 guangzhou Ge SEN International Electronics Tower Guangzhou 510095 mission Tianjin Co Ltd 403 Huanshi Rd East Fax 86 0 20 87326045 flenderprc com cn Flender Power Trans G 6 F Guoxin Mansion Phone 86 0 28 86 19 83 72 mission Tianjin Co Ltd 77 Xiyu Street Chengdu 610015 Fax 86 0 28 86 19 88 10 chengdu flenderprc com cn Rm 3 705 Tower D Flender Power Trans City Plaza Shenyang Phone 86 0 24 23 34 20 48 mission Tianjin Co Ltd 206 Nanjin
21. actual flow rate in the pressure line for supplying the bearings either to be read off device with display and switch 81 or to be calculated from the output signal analog device with 4 20 mA output 83 is lower than specified in the equipment list the regulator valve 85 must be closed until the required volumetric flow is obtained For this see also information in the equipment list of the oil supply system If the actual flow rate is higher however the required rate must be set by closing the regulator valve 86 The remaining procedure remains unchanged innl Setting must always be done on one valve only The other valve must be left fully open Closing both valves will cause the pressure relief valve of the pump to act and so reduce the flow rate Moreover a higher noise level can then be expected 6 The volumetric flow in the second pressure line then results from the actual pump output and must not be adjusted or reduced Specifications for the corresponding flow rate must be regarded as guide values only 7 After the flow rate has been set both valves 85 86 must be locked with the locking screw to prevent them getting out of adjustment BA 9704 EN 02 06 14 32 FLENDER 7 7 7 7 1 1 1 2 Removal from service e To remove the oil supply system from service it must be shut off N Secure the oil supply system to prevent it from being started up unintentionally Attach a warning notice to the start switch
22. ature or unusual noises the drive assembly must be switched off immediately If the oil supply system is intended for mounting on plant or equipment the manufacturer of such plant or equipment must ensure that the contents of the present Operating Instructions are incorporated in his own instructions Notices attached to the oil supply system e g rating plate direction arrows etc must always be observed They must be kept free from dirt and paint at all times Missing plates must be replaced Screws which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type e All spare parts must be obtained from FLENDER Environmental protection e When changing oil the used oil must be collected in suitable containers Any spillage of oil must be removed immediately e Preservative agent should be stored separately from used oil e Used oil preservative agent oil binding agents and oil soaked cloths must be disposed of in accordance with environmental legislation Special dangers e Depending on operating conditions the surface of the oil supply system may heat up considerably Danger of burns e When changing oil take care to prevent scalding by hot oil BA 9704 EN 02 06 6 32 FLENDER 3 5 4 1 4 2 Warnings and symbols used in these Instructions N This symbol indicates safety measures which must be observed to avoid personal injury This symbol ref
23. bor nr 8D Phone 40 0 21 2 52 98 61 E ROMANIA CN Industrial Group srl Sector 2 021747 Bucuresti Fax 40 0 21 2 52 98 60 office flender ro A Phone 7 0 8 12 3 20 90 34 RUSSIA Flender 000 Tjuschina 4 6 191119 St Petersburg Fax 7 0 8 12 3 20 90 82 flendergus mail spbnit ru F Branch Office Phone 421 0 51 7 70 32 67 E SLOVAKIA A Friedr Flender AG Vajansk ho 49 P O Box 286 08001 Presov Fax 421 0 51 7 70 3267 micenko flender nextra sk Poligono Industrial San ihari Ea Phone 34 0 91 6 83 61 86 f iberica flender es SPAIN Flender Ib rica S A Marcos Calle Morse 31 28906 Getafe Madrid Fax 34 0 91 6 83 46 50 ww fender cs Parcela D 15 SWEDEN Siemens AB Ostergardsgatan 2 4 43153 M lndal Phone 46 0 31 7 76 86 00 kundcenter ad se siemens com Mechanical Drives Box 14153 40020 G teborg Fax 46 0 31 7 76 86 76 www siemens se flender Phone 41 0 62 8 85 76 00 info flender ch SWITZERLAND Flender AG Zeughausstr 48 5600 Lenzburg Fax 41 0 62 885 76 76 Aender ch er nn IMES Sanayi Sitesi 34776 Dudullu Phone 90 0 216 4665141 cuzkan flendertr com z 123 E Blok 502 Sokak No 22 Istanbul Fax 90 0 216 3645913 www flendertr com Ticaret Ltd Sti DIV Deutsche Phone 380 0 44 230 29 43 gt UKRAINE Industrievertretung Prospect Pobedy 44 03057 Kiev Fax 380 0 44 2 30 29 30 flender div kiev ua Bradford i UNITED KINGDOM amp Flender Power o Phone 44 0 12 74 65 77 00 info flend
24. e system pressure is limited by a pressure relief valve integrated into the pump Caution The factory adjustment of this valve must not be changed Filter 20 The filter 20 is monitored visually by means of a differential pressure indicator and electrically by means of a differential pressure monitor Temperature control valve 32 A temperature control valve is located in the by pass of the cooler Pressure gauge 45 The oil pressure in the pressure line to the gear unit is indicated visually by means of a pressure gauge Pressure gauge 46 The oil pressure downstream of the pump is indicated visually by means of a pressure gauge Thermometer 60 The oil temperature is indicated visually by means of a thermometer Resistance thermometer 65 The temperature of the system is monitored by means of a resistance thermometer with a transmitter The transmitter sends an output signal proportional to the oil temperature BA 9704 EN 02 06 16 32 FLENDER 8 2 1 8 Volumetric flow meter 80 The oil flow to the tilting pad thrust bearing is monitored by means of a volumetric flow meter 8 2 1 9 Volumetric flow meter 81 8 2 1 8 2 1 8 2 ech 8 2 ech 8 2 ech 8 2 1 8 2 ech 8 2 a 8 2 2 8 2 2 The oil flow to the gear unit is monitored by means of a volumetric flow meter 10Volumetric flow meter 82 The oil flow to the tilting pad thrust bearing is monitored by means
25. emperatures outside the range 0 to 20 C Provision for special environmental conditions during transport e g transport by ship and storage climate termites etc must be contractually agreed The openings must be sealed with plugs or flanged covers Standard corrosion protection The properties of the outer paint coat are as follows Resistant to acids weak alkalis solvents atmospheric action temperatures up to 120 C temporarily up to 140 C and to tropical conditions Note Ensure that the paint is not damaged Mechanical damage scratches chemical damage acids alkalis and thermal damage sparks welding beads heat cause corrosion which may cause failure of the external protective coating Unless otherwise contractually agreed the interior preservation is guaranteed for 6 months provided that storage is in dry frostfree sheds The guarantee period starts on the date of delivery For longer periods of storage gt 6 months we advise regular checking and if necessary renewal of the interior and exterior preservation see section 7 Start up BA 9704 EN 02 06 8 32 FLENDER 5 1 Technical description Observe the Safety instructions in section 3 General Note The operating instructions BA for the gear unit must be observed The oil supply system specified below serves to cool the oil and or lubricate gear units see section 1 Technical Data As an option to the sta
26. er power co uk EIRE Transmission Ltd Traum Wars eege Reet E Fax 44 0 12 74 66 98 36 www flender power co uk SERBIA MONTENEGRO Kat Phone 381 0 11 60 44 73 ALBANIA G P Inzenjering doo Ill Bulevar 54 19 11070 Novi Beograd Fax 381 0 11 3 11 6791 flender eunet yu MACEDONIA BA 9704 EN 02 06 28 32 FLENDER NORTH AFRICAN 78996 Elancourt Phone 33 0 1 30 66 39 00 COUNTRIES EE EE Cedex Fax 33 0 1 30663513 Sales flender fr E e Phone 20 0 2 5 75 1544 7 EGYPT Sons of Farid Hassanen 81 Matbaa Ahlia Street Boulac 11221 Cairo Fax 20 0 2 575 17 02 hussein sonfarid com Head Office A _ SOUTH AFRICA lender rower Cnr Furnace St amp Quality Rd Isando Johannesburg Phone 27 0 11 5 712000 salesQiender co za Transmission Pty Ltd Fax 27 0 11 392 24 34 www flender co za P O Box 131 Isando 1600 Sales Offices Flender Power Unit 3 Marconi Park 9 Marconi Phone 27 0 21 551 50 03 Transmission Pty Ltd Crescent Montague Gardens Cape Town Fax 27 0 21 552 38 24 SeS Cieee aa P O Box 37291 Chempet 7442 Flender Power Transmission Pty Ltd Unit 3 Goshawk Park Falcon Industrial Estate P O Box 1608 New Germany Durban New Germany 3620 Phone 27 0 31 7 05 38 92 ax 27 0 31 7 05 38 72 n sales flender co za Flender Power Transmission Pty Ltd 9 Industrial Crescent Ext 25 P O Box 17609 Witbank Witbank 1035 Phone 27 0 13
27. erest of technical progress we reserve the right to make changes to the individual assemblies and accessories which we regard as necessary to preserve their essential characteristics and improve their efficiency and safety Copyright The copyright to these Operating Instructions is held by FLENDER AG These Operating Instructions BA must not be wholly or partly reproduced for competitive purposes used in any unauthorised way or made available to third parties without our agreement Technical enquiries should be addressed to the following works A FRIEDR FLENDER AG D 46393 Bocholt Tel 02871 92 0 Fax 02871 92 2728 Internet www flender com or to one of our customer service addresses A list of our customer service addresses is given in section 11 Spare parts customer service addresses Safety notes Note The operating instructions BA for the gear unit must be observed Proper use e The oil supply system has been manufactured in accordance with the state of the art and is delivered in a condition for safe and reliable use Any changes on the part of the user are not permitted This applies equally to safety features designed to prevent accidental contact e The oil supply system must be used and operated strictly in accordance with the conditions laid down in the contract governing performance and supply agreed by FLENDER and the customer e The cooling water temperature at the entry of the cooler must be between 4
28. ers to safety measures which must be observed to avoid damage to aution the oil supply system Note This symbol indicates general operating instructions which are of particular importance Handling and storage Observe the Safety instructions in section 3 Scope of supply 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 during transport or missing parts must be reported in writing immediately to FLENDER AG Caution If damage has occurred the oil supply system must not be put into operation Handling A When handling FLENDER products use only lifting and handling equipment of sufficient load bearing capacity Observe the notes regarding load distribution on the packaging The oil supply system is delivered in the fully assembled condition Additional items are delivered separately packaged Different forms of packaging may be used depending on the size of the oil supply system and method of transport Unless otherwise agreed the packaging complies with the HPE Packaging Guidelines The symbols marked on the packaging must be observed at all times These have the following meanings bild transport at 28 1 This way Fragile Keep Keep Centre of Use no Attach up dry cool gravity hand hook here BA 9704 EN 02 06 7 32 FLENDER 4 3 4 4 Note The oil supply syste
29. es must be taken Start conditions Measures Oil equivalent length of Intermediate pipework viscosity when using mineral oil VG 320 approx intermediate pipework Oil supply system Low pressure lubrication High pressure lubrication Gear unit circuit circuit without heating circuit with heating circuit with heating Circuit insulate commonly with heating circuit with heating circuit insulate commonly with heating insulate commonly circuit and and heat shroud 1 heating strips 1 Heating elements 1 1 e The heating output must be sufficient to heat the oil up to min 0 C e The plant must must not be operated before achieving O C in all pipes e The heat shroud is not included in the delivery of the oil supply system e Heating strips are not included in the delivery of the pipework BA 9704 EN 02 06 10 32 FLENDER 6 1 Assembly Observe the Safety instructions in section 3 General Note The operating instructions BA for the gear unit must be observed All preserved flange surfaces must be washed down with a solvent e g petroleum ether UN Environmental protection requirements must be observed The base frame must be set up horizontally The system must be secured to prevent slippage screws and plugs are included in FLENDER s delivery fixing holes are provided in the base frame On the version with a d
30. ether voltage and frequency of the motors correspond to the mains supply values and whether the motors are duly protected to prescriptions e Check that the electrical connections are properly tightened and the monitoring equipment is properly connected and set e Check that air inlet holes and cooling surfaces are clean e Check that protective measures have been taken e Check that the terminal box cover is closed and the line inlets are properly sealed Connections must be carried out by a specialist in accordance with the current aution safety regulations The relevant installation and operating requirements and the usual national and international requirements must be observed General notes on add on components Note For operation and maintenance of the components specified in the equipment list observe the specified operating instructions For technical data refer to the list of equipment Final installation work After the gear unit has been installed with the oil supply system check that all visible screw connections are correctly tightened and if necessary retighten Start up The oil supply system must not be started up without the required operating autlon instructions being available If damage has occurred the oil supply system must not be put into operation Observe the Safety instructions in section 3 Oil viscosity oil type For the oil viscosity and oil type refer to the operating instructions BA or the
31. for mill drive when at least one of the following conditions is fulfilled Oil temperature gt temperature value 65 3 Oil flow quantity lt volumetric flow value 82 2 or lt switching point 80 2 Oil flow quantity lt volumetric flow value 83 2 or lt switching point 81 2 Oil pressure on pressure side downstream of HP pumps e on 2 adjacent segment lt pressure value 358 1 e or incase of installations with 10 segments on at least 3 segments lt pressure value 12 segments on at least 4 segments lt pressure value 14 segments on at least 5 segments lt pressure value 15 segments on at least 4 segments lt pressure value 17 segments on at least 5 segments lt pressure value 18 segments on at least 6 segments lt pressure value 358 1 358 1 358 1 358 1 mn 358 1 358 1 Ve EE sit Number of installation segments see quantity indication Item no 358 in the equipment list If the oil temperature with STOP gear unit is higher than temperature value 65 3 the pump must remain switched on until the oil temperature has decreased to a value lt 65 2 Response to malfunctions A Irrespective of the following information the local safety requirements will apply in all cases for operation of the oil supply system Monitoring during operation is essential to identify any malfunctions occurring see Section 9 Disturbances reasons and remedy and thus to implement preventive measures The operat
32. g Street N Seng MOTH Fax 86 0 24 23342046 Shenyang flenderpre com cn Heping District 7 Rm 302 Shanzi Zhong Da S Flender Power Trans u h d Phone 86 0 29 87 20 32 68 A Saaft International Mansion Xi an 710002 xian flenderprc com cn mission Tianjin Co Ltd 30 Southern Rd Fax 86 0 29 87 20 32 04 Flender Power Trans Rm 23E Xinhua Plaza No 6 Phone 86 0 871 3 12 43 68 mission Tianjin Co Ltd Renmin East Rd rnmtrg G00 we Oeae Ceecee _ Rm 1007 Building A Golden 4 7 mission Tianjin Go Ltd Center Jincheng Intemational Zhengzhou 450008 e a Man s8089 lenderpre com on er Plaza No 68 Jingsan Rd ji Flender Power Trans Rm 908 east No 188 z Phone 86 0 25 83 24 25 50 m mission Tianjin Co Ltd Guangzhou Rd Kenjie 20191 Fax 86 0 25 83244820 anjing flenderpre com cn Rm 1408 Pearl River Flender Power Trans o Her Phone 86 0 411 83 77 93 55 e eet Saaft International Building No 99 Dalian 116011 e _ dalian flenderprc com cn mission Tianjin Co Ltd Xinkai Rd Xigang District Fax 86 0 411 83 77 92 19 Rm 1401 Tianlin Building Flender Power Trans Hunan Gold Source Hotel Changsha 410007 Phone 86 0 731 5167309 changsha mission Tianjin Co Ltd No 279 Second Block 9 Fax 86 0 731 5164746 flenderprc com cn Furong Rd Head Office Ko e Hastings Phone 91 0 33 22 23 05 45 ET INDIA Flender Limited Se George s Gate Road Kolkata 700022 Fax 91 0 33 22 2
33. g the oil supply system Possible faults in maintenance Maintenance and repair Oils General notes on add on components Preservation Cleaning Spare parts customer service addresses Stocking spare parts Spare part and customer service addresses Declaration by the manufacturer 17 17 17 17 17 17 18 18 18 18 18 18 18 18 18 19 19 19 19 19 20 20 21 21 22 22 22 23 23 23 23 25 25 25 25 25 25 25 26 26 26 32 BA 9704 EN 02 06 3 32 FLENDER 1 1 1 2 Technical data General technical data The most important technical data on the oil supply system are shown on the rating plate These data and the contractual agreements between FLENDER and the customer for the oil supply system determine the limits of its correct use D Oil max Max permissible oil operating overpressure t min Minimum starting temperature perm operating pressure of the water Pwater max bar PSI Operating Instructions number dD Special data eg total weight Company logo and production location 2 Material No 3 Production order no 4 Type Size Variant D O Note These operating instructions generally include a list of equipment including the drawings to the oil supply system and the operating instructions for the accessory components For further technical data refer to the list of equipment and the drawings Oil viscosity oil
34. gear unit rating plate The oil supply systems are designed for oil viscosities lt 2200 mm2 s installations with heating circuit up tp 7500 mm s at minimum starting temperature see rating plate BA 9704 EN 02 06 12 32 FLENDER 7 2 7 3 7 4 Oil filling Note The operating instructions BA for the gear unit must be observed To remove preservative residues which could cause the oil to foam the oil supply system must be flushed out together with the gear unit before starting up Before starting up the gear unit oil supply system must be filled with oil After filling the filling holes must be correctly closed and sealed The oil must then be carefully drained out of the oil supply system the monitoring equipment and the oil chambers in the gear unit while it is warm It may be re used only as flushing oil The flushing oil must be cleaned before re use There is a danger of scalding from the hot oil emerging from the housing Wear protective gloves to avoid scalding Caution Remove any oil spillage immediately with an oil binding agent Dh Oil must be put into the oil supply system via the gear unit see operating instructions for Gear Unit Care must be taken that no dirt can get into the oil circuit Oil must be poured in until it is level with the mark on the oil level indicator while the pump is not operating see operating instructions for Gear Unit The pump can then be started Start
35. ing pressures and oil temperatures should be recorded regularly If irregularities at variance with the normal condition are noticed during operation or if the operating data change it is essential that the cause be identified immediately If necessary shut the system off If the causes cannot be identified even with the aid of the Troubleshooting List inform FLENDER at once see Section 11 Stocking spare parts service facility addresses N We URGENTLY recommend that a lockable emergency switch be provided to ensure that the system is secured to prevent accidental switch on during maintenance repairs or malfunctions In addition we would draw attention to the relevant accident prevention regulations on site For restart after malfunction the information in Section 7 Start up should be noted BA 9704 EN 02 06 22 32 FLENDER 8 5 9 1 9 2 Shut down If the gear unit and oil supply system are shut down for longer periods the following measures are necessary a Gear unit and oil supply system should remain filled with oil Every 4 weeks gear unit and oil supply system must be run for 1 hour The necessary prelubrication and lubrication times should be observed b If the measures listed under a are not possible the gear unit and the oil supply system see section 7 Start up must be preserved The operating instructions BA for the gear unit must be observed Note If the oil supply
36. ircuit pump 210 When the pump is operating the system pressure is limited by a pressure relief valve integrated into the pump The factory adjustment of this valve must not be changed It must be ensured aution that the pump is pumping oil and will not run dry Oil preheater 290 This oil preheater is provided for heating the oil A temperature monitor with reclosing interlock is integrated By flow filtration Filter 620 The filter is monitored visually by means of a differential pressure indicator and electrically by means of a differential pressure monitor When changing the filter during operation of the main pump the setting of the 3 way cocks 207 217 must prevent any drawing in air During the process the pump 210 must not be operating After the process the aution cocks must be set in Operating position again Temperature control valve 632 A temperature control valve is provided in the bypass BA 9704 EN 02 06 18 32 FLENDER 8 2 5 8 2 5 1 8 2 5 2 8 2 6 8 2 6 1 8 3 8 3 1 Filling and emptying circuit Three way cock 707 717 For filling and emptying a three way cock is provided each upstream and downstream of the filling emptying pump Each cock setting must be adjusted to suit the respective function see position symbol on the three way cock and the oil flow path on the lubrication diagram During the filling draining process the main pump must not be operating After autio
37. itching point 620 STOP for the by flow pump 210 if at least one of the following conditions is fulfilled Main pump 10 out of operation Oil temperature lt temperature value 265 5 longer than 2 minutes BA 9704 EN 02 06 20 32 FLENDER 8 3 2 3 Variant 4 8 3 3 ENABLE for the heating circuit by flow pump 210 if Oil temperature gt temperature value 265 2 ENABLE for filter differential pressure monitor 620 if Oil temperature gt temperature value 265 5 START for the heating circuit by flow pump 210 if at least one of the following conditions is fulfilled Oil temperature lt temperature value 265 3 Oil temperature gt temperature value 265 5 WARNING for the heating circuit by flow pump 210 if Filter differential pressure gt switching point 620 STOP for the heating circuit by flow punmp 210 if Oil temperature lt temperature value 265 2 ENABLE for the oil preheater 290 if Heating circuit by flow pump 210 has been in operation for 2 minutes START for the oil preheater 290 if Oil temperature lt temperature value 265 3 STOP for the oil preheater 290 if at least one of the following conditions is fulfilled Heating circuit pump 210 out of operation Oil temperature gt temperature value 265 4 Oil temperature gt switching point 290 since 1 second Enable gear unit ENABLE mill drive when all the following conditions are fulfilled Filter differentia
38. k No 22 Bandaria Area Dohan Bldg i Phone 966 0 3 8 87 53 32 SAUDI ARABIA South Gulf Sands Est Flat 3 1 P O Box 32150 Al Khobar 31952 Fax 966 0 3 887 53 31 adelameen nesma net sa i Phone 65 0 68 97 94 66 flender singnet com sg SINGAPORE Flender Singapore Pte Ltd 13A Tech Park Crescent Singapore 637843 Fax 65 0 68 97 94 11 flender com sg Mezzeh Autostrade S e e Transportation Phone 963 0 11 6 11 67 94 o f SYRIA Misrabi Co amp Trading Building 4 A 5th Floor Damascus Fax 963 0 11 6 11 09 08 ismael misrabi gmx net P O Box 12450 E ae 1F No 5 Lane 240 E a E Phone 886 0 2 26 93 24 41 TAIWAN Flender Taiwan Limited Nan Yang Street Hsichih Taipei Hsien 221 Fax 886 0 2 26 94 36 11 flender_tw flender com tw Representative Office Talay Thong Tower 53 Moo 9 A Sriracha Phone 66 0 38 49 51 66 8 THAILAND Flender Singapore Pte Ltd 10th Floor Room 1001 Chonburi 20230 Fax 66 0 38 49 51 69 contact flender th com Sukhumvit Rd T Tungsukla Flender Singapore Pte Ltd SCH i The Landmark Building Representative Office Dai Phone 84 0 8 8 25 19 00 VIETNAM c o Siemens AG Branch 2nd Floor Ho Chi Minh City Fax 84 0 8 8 25 15 80 flender_vn flender com vn Office 5B Ton Duc Thang St District 1 AUSTRALIA Siemens Ltd Industrial Automation amp Control Head Office 9 Nello Place P O Box 6047 Wetherill Park NSW 2164 Sydney Phone Fax 61 0 2 97 56 23
39. l pressure lt switching point 20 Oil temperature lt temperature value 65 2 Oil flow quantity gt volumetric flow value 82 1 or gt switching point 80 1 Oil flow quantity gt volumetric flow value 83 1 or gt switching point 81 1 Oil pressure on pressure side downstream of HP pumps e ofall segments lt pressure value 358 2 e no 2 adjacent segments lt pressure value 358 1 e and in case of installations with 10 segments on at least 8 segments gt pressure value 358 1 12 segments on at least 9 segments gt pressure value 358 1 14 segments on at least 10 segments gt pressure value 358 1 15 segments on at least 12 segments gt pressure value 358 1 17 segments on at least 13 segments gt pressure value 358 1 18 segments on at least 13 segments gt pressure value 358 1 Number of installation segments see quantity indication Item no 358 in the equipment list BA 9704 EN 02 06 21 32 FLENDER 8 3 4 8 3 5 8 4 Warning gear unit WARNING for the mill drive when at least one of the following conditions is fulfilled Filter differential pressure gt switching point 20 Oil temperature gt temperature value 65 2 Oil flow quantity lt volumetric flow value 82 1 or lt switching point 80 1 Oil flow quantity lt volumetric flow value 83 1 or lt switching point 81 1 Oil pressure on suction side upstream of HP pump gt pressure value 350 2 Stop gear unit STOP
40. lief valve See separate Operating Instructions BA Filter contaminated unusual or increased filter residues Filter contaminated Pipes dirty Scale welding residues Oil contaminated Abraded material from defective pump Abraded material from gear unit Clean or replace filter Clean the pipes Change oil Repair or replace pump See separate Operating Instructions BA Check gear unit bearings teeth alignment and repair defects Oil consumption too high Leak in pipes connections valves or gear unit Shaft outlets on gear unit leaky Water oil cooler leaky Filter leaky Table 9 1 Faults causes and remedies Tighten screws Reseal Replace sealing rings Seal or replace water oil cooler See separate Operating Instructions BA Seal filter BA 9704 EN 02 06 24 32 FLENDER 9 2 1 9 2 2 10 10 1 10 2 10 3 10 4 Possible faults when installing the oil supply system e Important information for describing the drive and the environment will not be communicated to others e Performance data too high e Cooling water not available of contaminated e Chemically aggressive environment not taken into consideration e The ambient temperature is not permissible e Components with transport or other damage are being fitted e Loosely supplied parts are interchanged e Prescribed tightening torques are not being adhered to
41. m must always be transported with due care to avoid injury to persons and damage to the oil supply system The oil supply system must be transported with suitable equipment only During transport the oil supply system should be left without oil filling and on the transport packaging When handling the oil supply system exercise special care to avoid damage due to the use of force or careless loading and unloading To transport and handle the oil supply system use ropes or chains Only the designated lifting eyes on the base frame must be used for fastening Care must be taken that the carrier ropes do not damage fittings and piping A cross beam is therefore required for protection The lengths of the ropes must be set to ensure that the base frame is suspended horizontally Storage of the oil supply system The oil supply system must be stored in its position of use in a sheltered place it must be placed on a vibration free dry wooden base and covered over A Note Do not stack oil supply systems one on top of another If the oil supply system is being stored out of doors it must be particularly carefully covered and care must be taken that neither moisture nor foreign material can collect on the oil supply system consult FLENDER in any case Unless otherwise agreed by contract the oil supply system must not be exposed to harmful environmental factors such as chemical products high air pollution air humidity and ambient t
42. n the process the cocks must be set in operating position again Pump 710 When the pump is operating the system pressure is limited by a pressure relief valve integrated into the pump The factory adjustment of this valve must not be changed It must be ensured that the pump is pumping oil and will not run dry Other Drain cock 3 This drain cock may be used to conduct liquids out of the catching area of the base frame Interlocking instructions If not specified specially a dealy time of 30 seconds applies Note When enabling and determining starting condition for pumps it must be ensured that temperature values are based on VG 320 mineral oil If other oils are used the viscosity of the oil for that temperature value must not be higher Main circuit ENABLE for the low pressure pump 10 if Oil temperature gt temperature value 265 1 ENABLE for filter differential pressure monitor 20 if Oil temperature gt temperature value 65 1 ENABLE for the HP pumps 310 when all the following conditions are fulfilled Main pump 10 in operation Oil pressure on suction side upstream of HP pumps gt pressure value 350 1 and lt pressure value 850 2 STOP for HP pump 310 if at least one of the following conditions is fulfilled Oil pressure on suction side upstream of HP pumps lt pressure value 350 1 Oil pressure of a segment line supplied by the pump refer to lubrication schedule gt pressure value 3
43. ndard variant 1 the variants 2 to 5 are availabe e E Variant Main functions 123415 Pump group Double change over filter Water oil cooler Tilting pad thrust bearing Pressure line Gear unit supply Low pressure lubrication circuit High pressure lubrication circuit Heating circuit By flow filtration Filling Emptying circuit 1 The filling emptying circuit is functioning by the pump 210 Note For control instructions refer to section 8 Operation Observe for this the drawings and the list of equipment The components specified in the list of equipment can also be found on the drawings with the part number Caution Before starting up all monitoring devices must in all cases be connected Note The direction of discharge of the pump used is dependent upon the direction of rotation innl To ensure optimum cooling performance the specified direction of flow in the water oil cooler must be observed The cooling water inlet and outlet must not be reversed The pressure of the cooling water must not exceed 8 bars If the gear unit is being withdrawn from service for a longer period or if there is a danger of freezing the cooling water must be drained off Remove any remaining water with compressed air BA 9704 EN 02 06 9 32 FLENDER 5 2 Measures required as a function of the start condition Depending on the required starting temperature the following measur
44. ne 81 0 3 54 23 87 05 A JAPAN cla Simone RA 3 20 14 Higashi Gotanda 141 8641 Tokyo Fax 481 0 3 54 23 87 32 contact flender japan com Shinagawa ku 7th FI Dorim Bldg Phone 82 0 2 34 78 63 37 sales flender korea com KOREA Flender Ltd 1823 Bangbae Dong Seoul 137 060 Fax 82 0 2 34 786345 fiander korea com Seocho Ku www Al Showaikh Ind Area Phone 965 0 48297 15 KUWAIT South Gulf Company PO Box 26229 Safat 13123 Fax 965 0 4 82 97 20 adelameen awalnet net sa Dahr el Jamal y LEBANON Gabriel Acar amp Fils s a r Zone Industrielle Sin el Fil Beyrouth enone 961 0 1249 82 72 gacar beirut com Fax 961 0 1 49 4971 B P 80484 Flender Singapore Pte Ltd S z 3 Level 1 Reception CP Tower 5 s e Bhd y Pusat Dagang Seksyen 16 9 PAKISTAN A Friedr Flender AG Postfach 1364 46393 Bocholt Phone 49 0 28 71 922259 ar wittag flender com Fax 49 0 28 71 92 15 16 BA 9704 EN 02 06 30 32 FLENDER PHILIPPINES Flender Singapore Pte Ltd Representative Office 28 F Unit 2814 The Enter prise Centre 6766 Ayala Ave nue corner Paeso de Roxas Makati City Phone Fax 63 0 2 8 49 39 93 63 0 2 8 49 39 17 junt flender com ph BAHRAIN IRAQ Flender G c Aktarma Middle East Sales Office OMAN GATAR Sistemleri Sanayi ve IMES Sanayi Sitesi S4716 SSC Ge ji 2 e s z E meso flendertr com U A E YEMEN Ticaret Ltd Sti E Blok 502 Soka
45. oler contaminated Clean clogged cooler in accordance with manufacturer s maintenance instructions or replace See separate Operating Instructions BA Oil temperature too low Gear unit has not heated up Wait Too much cooling water Reduce cooling water supply Cooling water too cold BA 9704 EN 02 06 23 32 FLENDER Malfunctions Oil pressure too low Oil pressure too high Causes Filter clogged Suction line clogged Pump is drawing in air Oil temperature too high Oil viscosity too low Pump defective pump drive defective Pressure relief valve incorrectly set Pressure relief valve defective Gear unit has not yet heated up Oil pipes to and on gear unit blocked Oil viscosity too high Pressure relief valve incorrectly set Pressure relief valve defective Clean or replace filter element or switch to clean filter and clean or replace filter element See separate Operating Instructions BA Clean suction pipe Check suction pipe and if necessary repair leaks See there Check oil viscosity and if necessary put in correct oil Repair or replace pump See separate Operating Instructions BA Contact FLENDER Repair or replace pressure relief valve See separate Operating Instructions BA Wait Find and clean blocked line Check oil viscosity and if necessary put in correct oil Contact FLENDER Repair or replace pressure re
46. rain cock on the base frame the drain cock must depending on conditions at the site be fitted before setting the system down For reasons of space fitting may not be possible later without raising the system If connection pipes are not supplied with the system seamlessly drawn and bright normalised NBK pipes of ST 35 4 in accordance with DIN 2391 c hydraulic tubing quality grade C must be used The interfaces must be provided with the appropriate flanges or screw connections For connection pipes we recommend using compensators to insulate against vibration and compensate for stretching Pipe fastenings plastic clips must be used to install piping The distance between clips must be less than 2 m 78 7 Make sure the piping is not twisted After installation the pipes must be flushed out Welded pipes must be pickled The motors and monitoring equipment must be connected up electrically in accordance with terminal diagrams equipment lists and regulations Check voltage and circuits Before connecting the water oil cooler remove the plugs from the water connection and flush the water oil cooler well to remove any dirt Install the cooling water in and outflow pipes For the flow direction of the cooling water and the location of the connections please refer to the dimensioned drawing BA 9704 EN 02 06 11 32 FLENDER 6 2 6 3 6 4 ge Check before start up e Observe rating plate indication e Check wh
47. servative agent into a suitable receptacle and dispose of the oil in accordance with the regulations A There is a risk of scalding from the hot preservative agent draining from the gear unit Wear protective gloves to avoid scalding BA 9704 EN 02 06 15 32 FLENDER 8 1 8 2 8 2 1 8 2 1 1 8 2 1 2 8 2 1 3 8 2 1 4 8 2 1 5 8 2 1 6 8 2 1 7 Operation Observe the Safety instructions in section 3 Note The operating instructions BA for the gear unit must be observed The part numbers given in the following text have been taken from the list of equipment assembly drawing and the lubrication diagram The following control information and or locking instructions must be noted for the individual components Note In addition to this control information and or locking instructions the specifications in the list of equipment must always be observed Only the control information and or locking instructions of the part numbers shown in the list of equipment applies to the delivered oil supply system For the specific switching points and or values refer to the list of equipment Further control information and or locking instructions are given in the operating instructions BA Gear Unit Lubrication diagram For the relevant lubrication diagram drawing number refer to the list of equipment Control information Low pressure lubrication circuit Pump 10 When the pump is operating th
48. system is shut down for a longer period or if there is a danger of freezing the cooling water must be drained off Faults causes and remedy Observe the Safety instructions in section 3 General information on faults and malfunctions Note The operating instructions BA for the gear unit must be observed Note Faults and malfunctions occurring during the guarantee period and requiring repair work on the oil supply system must be carried out only by the FLENDER Customer Service In the case of faults and malfunctions occurring after the guarantee period and whose cause cannot be precisely identified we advise our customers to contact our customer service FLENDER will not be bound by the terms of the guarantee or warranty or aution otherwise be responsible in cases of improper use of the oil supply system modifications on the oil supply system carried out without FLENDER s agreement or use of spare parts not supplied by FLENDER IN When remedying faults and malfunctions the oil supply system must always be taken out of service Secure the drive unit to prevent it from being started up unintentionally Attach a warning notice to the start switch Possible faults Malfunctions Causes Oil temperature too high No cooling water Rectify cooling water supply Insufficient cooling water Increase coolung water supply Cooling water too warm Water oil cooler has air in it Ventilate the water oil cooler Water oil co
49. ublished by the European Commission in the Official Journal of the European Community Bocholt 2006 02 28 Signature Manager Engineering TFE BA 9704 EN 02 06 32 32
50. uipment Start up Before starting up the oil supply system check whether these operating instructions and the operating instructions for the gear unit have been correctly adhered to In all cases oil must be put in before starting up aution The cooling water circuit must be checked before starting up Shut off valves must be secured against unintentional closing All impurities must be removed from the oil supply system before starting up and after repair and maintenance work This applies particularly to water e g rainwater and leakage from the water oil cooler to prevent an oil water mixture The three way cocks must be checked for plausibility before start up All pumps filters and coolers must be ventilated A Pressure relief valve safety valve pressure settings made by FLENDER at its works must not be altered as they are not used to control the pressure and the flow rate They serve only as a protection against overload The regulator valves 85 86 are supplied in a preset condition The final setting must be done while they are warm from operating mill under operating load Sequence 1 Nominal widths of the suction and pressure lines must be adhered to 2 It must be ensured before start up that both valves 85 86 are fully open 3 Then start up pump 10 4 The tuning valve on the pump 10 if provided must be set in accordance with the manufacturer s instructions for setting and start up KI If the

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