FLENDER supplies - support.industry.siemens.com · FLENDER supplies Oil-supply systems 9751en Operating Instructions Edition 10/2016 OLGE 1...10

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FLENDER suppliesOil-supply systems

9751en

Operating Instructions

Edition 10/2016

OLGE

1...10

22.02.2017 01:20V1.01

Oil-supply systems

FLENDER supplies9751en

Operating Instructions

OLGE 1...10

Edition 10/2016

Introduction 1

Safety instructions 2

Description 3

Application planning 4

Assembly 5

Commissioning 6

Operation 7

Maintenance 8

Service & Support 9

Disposal 10

Spare parts 11

Quality documents A

Technical data B

Legal informationWarning notice system

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

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

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

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

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

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

Proper use of Siemens productsNote the following:

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

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

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

Siemens AGProcess Industries and DrivesPostfach 48 4890026 NÜRNBERGGERMANY

Document order number: Ⓟ 02/2017 Subject to change

Copyright © Siemens AG 2016.All rights reserved

Table of contents

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

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

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

2 Safety instructions......................................................................................................................................13

2.1 Security notes........................................................................................................................13

2.2 The five safety rules...............................................................................................................13

2.3 General information................................................................................................................14

2.4 General warnings and symbols..............................................................................................15

2.5 Special types of danger and personal protective equipment.................................................16

2.6 Correct use in hazardous zones (explosive atmospheres)....................................................18

3 Description..................................................................................................................................................23

3.1 General description................................................................................................................233.1.1 Design and principle of operation...........................................................................................233.1.2 Oil supply system equipment.................................................................................................243.1.3 Pump......................................................................................................................................253.1.4 Air-oil cooler...........................................................................................................................25

3.2 Explosion-protection marking of the oil supply system..........................................................26

3.3 Conditions of use...................................................................................................................26

3.4 Valve position.........................................................................................................................26

3.5 Control instructions................................................................................................................27

3.6 Interlocking rules....................................................................................................................28

4 Application planning...................................................................................................................................31

4.1 Scope of delivery....................................................................................................................31

4.2 Transport................................................................................................................................31

4.3 Attachment points..................................................................................................................33

4.4 Special aspects of gear unit lubrication and preservation......................................................344.4.1 Special aspects of top coating...............................................................................................344.4.2 Storage of the oil supply system............................................................................................344.4.3 Preservation...........................................................................................................................344.4.3.1 Oil supply system connected to the gear unit........................................................................354.4.3.2 Oil supply system disconnected from the gear unit................................................................36

5 Assembly....................................................................................................................................................37

5.1 General assembly instructions...............................................................................................37

5.2 Further assembly instructions................................................................................................38

Oil-supply systems 9751enOperating Instructions 10/2016 5

5.3 Unpacking the oil supply system............................................................................................39

5.4 Installation conditions.............................................................................................................39

5.5 Mounted components.............................................................................................................40

5.6 Final work...............................................................................................................................40

6 Commissioning...........................................................................................................................................43

6.1 Measures prior to commissioning..........................................................................................43

6.2 Checking procedure...............................................................................................................44

6.3 Filling with oil and changing oil...............................................................................................44

6.4 Rinsing before first commissioning........................................................................................44

6.5 Filling with oil for operation.....................................................................................................45

7 Operation....................................................................................................................................................47

7.1 General information................................................................................................................47

7.2 Lubrication diagram................................................................................................................47

7.3 Procedure in the event of malfunctions..................................................................................47

7.4 Taking the unit out of service.................................................................................................48

7.5 Operational downtime............................................................................................................48

8 Maintenance...............................................................................................................................................49

8.1 General maintenance information..........................................................................................49

8.2 Maintenance schedule...........................................................................................................49

8.3 Maintenance and servicing work............................................................................................508.3.1 Replacing the pump...............................................................................................................508.3.2 Replacing the air-oil cooler.....................................................................................................518.3.3 Cleaning or replacing the oil filter...........................................................................................528.3.4 Checking the ignition protection system for temperature monitoring.....................................528.3.5 Mounted components.............................................................................................................528.3.6 Cleaning the oil supply system...............................................................................................52

8.4 Possible faults........................................................................................................................538.4.1 Possible errors when assembling the oil supply system........................................................558.4.2 Possible maintenance errors..................................................................................................55

9 Service & Support.......................................................................................................................................57

10 Disposal......................................................................................................................................................59

11 Spare parts.................................................................................................................................................61

A Quality documents......................................................................................................................................63

A.1 Declaration of Incorporation...................................................................................................63

A.2 Declaration of Conformity.......................................................................................................65

B Technical data............................................................................................................................................67

B.1 General technical data...........................................................................................................67

Table of contents

Oil-supply systems 9751en6 Operating Instructions 10/2016

B.2 Ambient conditions.................................................................................................................69

B.3 Oil viscosity and oil grade......................................................................................................69

Index...........................................................................................................................................................71

Tables

Table 2-1 Symbols and markings................................................................................................................14Table 2-2 General warnings........................................................................................................................15Table 3-1 Temperature classes and surface temperature...........................................................................26Table 3-2 Valve positions............................................................................................................................26Table 8-1 Maintenance and servicing work.................................................................................................49Table 8-2 Possible faults and their rectification...........................................................................................54Table B-1 ATEX marking.............................................................................................................................68

Figures

Figure 3-1 Oil supply system equipment......................................................................................................24Figure 4-1 Transport symbols.......................................................................................................................32Figure 4-2 Position of attachment points......................................................................................................33Figure B-1 Rating plate.................................................................................................................................67

Table of contents


Table of contents


Introduction 1Naming convention

The term "gear unit" is used below to refer to gear reduction units or multiplier gear units.

1.1 General information

Purpose of the operating instructionsThese operating instructions describe the oil supply system and provide information about handling it - from assembly to maintenance.

Please keep these operating instructions for later use. Please read these operating instructions before working on the oil supply system and follow the information in them.

NoteDisclaimer

Please make sure that every person who is commissioned to work on the oil supply system has read and understood all of the key points in these operating instructions prior to working with the system. Failure to observe these operating instructions can cause product or property damage or personal injury.

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

The oil supply system described in these instructions reflects the state of technical development at the time these operating instructions went to print.

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

ATEX DirectiveThe term "ATEX Directive" used in these instructions stands for the harmonisation legislation of the European Union in compliance with the declaration of conformance for equipment and protective systems for correct use in hazardous zones.


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

● Application planning

● Assembly

● Commissioning

● Maintenance

Documentation landscapeThese operating instructions are included in the scope of delivery of your oil supply system.

These operating instructions form part of the complete documentation supplied with the oil supply system. The complete documentation encompasses other documents, including:

● List of equipment

● Dimension drawing

● Lubrication diagram

● Operating instructions for gear unit lubrication and preservation BA 7300

● Operating instructions for mounted components

● Operating instructions for third-party vendor devices

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

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

If you have any technical queries, please contact one of our Customer Services addresses (Page 57).

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

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

Introduction1.2 Lubricants


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

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

The operating instructions for the lubricants currently recommended by Siemens AG can also be viewed on the Internet (http://support.automation.siemens.com/WW/view/de/44231658).

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

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



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



Safety instructions 22.1 Security notes

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

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

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

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

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

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

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

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

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

2. Safeguard against restart

3. Ensure that the system is de-energised

4. Earth and short circuit

5. Cover or cordon off adjacent live parts

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


2.3 General information

IntroductionAll work carried out on the oil supply system must be performed carefully by qualified personnel.

SymbolsThe following symbolic depictions (some of which are marked in colour) are used:

Table 2-1 Symbols and markings

Marked location Symbol Coloured markingsEarth connection point

Air relief point yellow

Oil filling point yellow

Oil draining point white

Oil level indicator red

Oil level measurement red

Oil overflow

Connection point for vibration monitoring

Lubrication point red

Apply grease

Lifting eye

Eye bolt

Do not unscrew

Safety instructions2.3 General information


Marked location Symbol Coloured markingsAlignment surface, horizontal

Alignment surface, vertical

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

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

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

Table 2-2 General warnings

ISO ANSI WarningWarning - hazardous electrical voltage

Warning - explosive substances

--- Warning - entanglement hazard

--- Warning - hot surfaces

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

--- Warning - caustic substances

--- Warning - suspended load

--- Warning - hand injuries

Safety instructions2.4 General warnings and symbols


2.5 Special types of danger and personal protective equipment

RequirementsMeet the following requirements before starting work on the oil supply system:

● Read and observe the operating instructions for the gear unit in addition to these operating instructions.

● Ensure that the oil pressure lines are depressurised.

● Shut down the oil supply system before commencing any work on it.You can carry out the work described in chapter Cleaning or replacing the oil filter (Page 52) during operation provided that the component has been isolated, depressurised and locked out.

● Disconnect electrical systems from the power supply.

DANGER

Electric shock

Live parts can cause electric shock.

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

Protective equipmentWear the following personal protective equipment when working on the oil supply system:

● Safety shoes

● Overalls

● Helmet

● Safety gloves

● Safety goggles

WARNING

Risk of eye injury

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

Wear safety goggles.

Dangers during operationThe oil supply system can sustain damage.

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


Shut the drive unit down immediately if inexplicable changes are noticed during operation. Such changes may include unusual system noise or a significant increase in operating temperature.

WARNING

Risk of falling

There is an increased risk of falling when standing or walking on the oil supply system.

Take special care when walking or standing on the oil supply system or its mounted components during maintenance and repair work. Do not walk or stand on protection covers, mounted components or pipes.

WARNING

Danger to life through rotating or moving parts

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

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

Surface temperatureThe surface temperatures of the gear unit and the oil supply system can become extremely high depending on the operating conditions.

WARNING

Risk of burns

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

Wear suitable protective gloves and protective clothing.

WARNING

Risk of scalding

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

Wear suitable protective gloves, safety goggles and protective clothing.

WARNING

Danger due to low temperatures

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

Wear suitable protective gloves and protective clothing.

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


Chemical substancesInjuries can be sustained when using chemical substances.

WARNING

Risk of chemical burns due to chemical substances

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

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

CAUTION

Risk of injury due to chemically aggressive operating materials

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

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

2.6 Correct use in hazardous zones (explosive atmospheres)Only use the oil supply system in accordance with the conditions specified in the service and delivery contract and the technical data in the annex (Page 67). Deviating operating conditions are considered improper use. The user or owner of the machine or plant is solely liable for any resulting damage.

When using the oil supply system, please pay particular attention to the following:

● Do not make any modifications to the oil supply system that go beyond the permissible modifications described in these operating instructions. This also applies to safety features designed to prevent accidental contact.

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

● All mounted components must strictly comply with the requirements laid down in the ATEX directive.

Safety instructions2.6 Correct use in hazardous zones (explosive atmospheres)


If you have any queries, please contact Customer Services (Page 57).

WARNING

An explosive atmosphere can be ignited

An explosive atmosphere can be ignited if mounted components are used that do not comply with the ATEX directive.

All mounted components must strictly comply with the requirements laid down in the ATEX directive.

Connect basic electrical equipment (e.g. monitoring devices, switches, Pt 100 measuring resistors) that have no marking according to the ATEX directive using suitable isolating amplifiers so that intrinsic safety is guaranteed.

WARNING

Risk of falling

Risk of possible serious injury through falling.

Take special care when walking or standing on the oil supply system during maintenance and repair work. Do not walk or stand on protection covers, mounted components or pipes.

Using the oil supply systemWhen using the oil supply system, please observe the following basic rules:

● Ensure that the oil supply system is operationally safe.

● The oil supply system may only be operated, maintained or repaired by authorised, trained, instructed and qualified personnel.

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

● The outside of the oil supply system must not be cleaned using high-pressure cleaning equipment.

● Do not loosen any piping threaded connections or flange connections or disconnect any monitoring equipment while the system is pressurised.Switch off the pumps beforehand and depressurise any components that are under pressure. Follow the operating instructions of the relevant components.



● Establish the appropriate potential equalisation connections.

WARNING


An explosive atmosphere can be ignited if sparking occurs as a result of failure to earth an oil supply system.

Perform potential equalisation in accordance with the applicable regulations and guidelines.

Tapped holes are provided on the oil supply system to establish an earth connection. This work must always be done by specialist electricians.

● Protect the oil supply system against falling objects and from becoming covered over.

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

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

● Observe the notices mounted on the oil supply system, e.g. rating plate, direction arrow symbol, etc. The notices must be kept free from paint or dirt. Replace any missing, illegible or damaged notice plates.

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

DANGER

Danger to life due to live system

Death or serious injury will occur.

Shut down the oil supply system before commencing any work on it. Secure the drive unit against being operated accidentally as follows:● Turn off the key-operated switch.● Remove the fuses in the power supply.● Attach a notice to the switch stating clearly that work is being performed on the oil supply

system.

You can carry out the work described in chapter Cleaning or replacing the oil filter (Page 52) during operation provided that the component has been isolated, depressurised and locked out.

WARNING


An explosive atmosphere can be ignited if electrostatic discharge occurs due to the coating becoming charged.

Carefully ensure that highly efficient charge generating mechanisms, which can cause layers and coatings to be electrostatically charged, are reliably avoided.



The mechanisms that can very easily generate electrostatic charges include:

● Fast streaming past of air with a high dust content

● Sudden outflow of pressurised gases containing particles

● Other severe friction (not manual cleaning or rubbing with cleaning cloths)

If explosion protection is necessary according to the ATEX Directive for areas of explosion group IIC or with the minimum ignition energy ≤ 3 mJ, the coating must be conductive enough to remove electrostatic charges.

Alternatively, the coating meets the conductivity requirements and the thickness limitation of the applied coating according to DIN EN 13463-1. The permissible maximum coating thickness is based on the stated explosion group (IIA or IIB or IIC). No build-up of electrostatic charges is to be expected with a coating thickness < 200 μm.

Integration in third-party machines and plantWhen machine or plant manufacturers install the oil supply system in their own machines or plant, they must ensure that the instructions, notes and descriptions contained in these operating instructions are incorporated in their own operating instructions.





Description 33.1 General description

The FLENDER® oil supply system described in these operating instructions has been developed as an oil-cooling and/or lubrication system for gear units. This series of oil supply systems is suitable for applications in the chemical, rubber, foodstuff and plastics industries, for example.

3.1.1 Design and principle of operation

The information below explains to you the design and principle of operation of an oil supply system:

● Oil is supplied by a pump assembly.

● The pump sucks the oil out of the gear unit sump through a suction pipe.

● A filter for cleansing the circulating oil is installed in the oil circuit (a variant without filter is also available).

● Heat losses that cannot be dissipated by convection are removed by an oil cooler.

● After the oil has been filtered and cooled, it is returned to the gear unit via a pressure pipe (a variant without filter is available).

● The components described above are mounted on a base frame of the oil supply system.


3.1.2 Oil supply system equipment

The following diagram shows the equipment of a version 2, size 7 oil supply system:

① Lifting eyes 32 Temperature control valve② Terminal box (depending on order specification) 45 Pressure gauge③ Suction port 50 Pressure monitor④ Pressure port 55 Pressure monitorPart No. 60 Thermometer10 Pump assembly 70 Temperature monitor20 Double change-over filter 75 Temperature monitor30 Air-oil cooler 80 Volume flowmeter

Figure 3-1 Oil supply system equipment

Description3.1 General description


Further informationFor more information about the control system, refer to chapter Control instructions (Page 27).

Additional information about the components of the oil supply system and a detailed illustrated description of this system can be found in the list of equipment and the drawings in the complete documentation for the oil supply system.

3.1.3 Pump

RequirementsMake sure that the pump and the suction pipe are filled with oil (e.g. fill via the sleeve connection in the connecting pipe). Vent the pump.

Flow direction of the pumpRefer to the operating instructions of the pump to find out whether the flow direction of the pump used depends on the direction of rotation.

NoteFlow direction of the pump

When connecting the valves, observe the flow direction of the pump.

The direction of rotation of the motor must match the direction of rotation arrow marked on the pump.

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

3.1.4 Air-oil coolerMake sure that you provide the specified clearance for intake of cooling air as shown in the drawings included in the complete documentation for the oil supply system.

Further informationYou will find further information about the air-oil cooler in the operating instructions for the air-oil cooler included in the complete documentation for the oil supply system.

Description3.1 General description


3.2 Explosion-protection marking of the oil supply systemOil supply systems intended for use in potentially explosive atmospheres must have the following marking on the rating plate:

3.3 Conditions of useThe oil supply system is suitable for use under the conditions defined by the ATEX Directive.

Equipment group II (for use above ground) of equipment categories 2 and 3 applies to areas in which explosive gases, vapours, mist and air mixtures are present, and to areas in which dust can create an explosive atmosphere.

The oil supply system is classified according to the maximum potential ambient temperature in the immediate vicinity of the system and/or the maximum surface temperature of the oil supply system.

Table 3-1 Temperature classes and surface temperature

Maximum ambient temperature Temperature class Maximum surface temperature40 °C T3/T4 120 °C

Please also observe the information in chapter General technical data (Page 67).

3.4 Valve positionThe valve positions during various work steps are shown in the following table:

Table 3-2 Valve positions

Work step Part No. 20Filling Mid-positionDraining Mid-positionOperation Flow to active filtration chamber only

DefinitionsFlow to active filtration chamber only: Flow path to the active chamber is open and closed to the inactive chamber

Mid-position: All flow paths are open

Description3.2 Explosion-protection marking of the oil supply system


3.5 Control instructions

IntroductionThe numbers specified in parenthesis (...) in the text below are the parts numbers used in the list of equipment, the assembly drawing and the lubrication diagram.

Follow the control instructions and interlocking rules for the individual components.

Further informationIn addition to the control instructions and interlocking rules, please also note the specifications in the list of equipment.

Only the control instructions and interlocking rules of the part numbers listed in the list of equipment apply to the supplied oil supply system. The specific switching points and values can be found in the list of equipment.

Further control instructions and interlocking rules can be found in the operating instructions for the device.

Please refer to the table in chapter Valve position (Page 26) for the positions of the isolation and three-way valves.

Pump (10)When the pump is in operation, the system pressure is limited by a pressure relief valve integrated in the pump.

The monitoring systems ensure that the pump cannot overheat as a result of running dry.

WARNING

Danger to life

Risk of injury due to rupture of piping or components caused by incorrect valve setting.

Do not change the factory setting of this valve.

Temperature monitor (17)The system temperature is monitored by a temperature monitor.

Filter (20)The filter is monitored by a visual differential pressure indicator and by an electrical differential pressure monitor, or optionally only by a visual differential pressure indicator.

Differential pressure monitor (21)The filter is electrically monitored by a differential pressure monitor.

Description3.5 Control instructions


Oil cooler (30)The cooler cools the oil.

Temperature control valve (32)A temperature control valve is installed in the air-oil cooler bypass.

Pressure gauge (45)The oil pressure is visually displayed on a pressure gauge.

Pressure monitor or optional pressure transmitter (50, 55)The pressure of the oil supply system is monitored by a pressure monitor or by an optional pressure transmitter. The pressure transmitter emits an output signal that is proportional to pressure.

Thermometer (60)The oil temperature is visually displayed on a thermometer.

Resistance thermometer (65)The temperature of the system and of the fan motor of the air-oil cooler is monitored by a resistance thermometer, or optionally by a resistance thermometer with transmitter. The transmitter emits an output signal that is proportional to the oil temperature.

Temperature monitor (70)The system temperature is monitored by a temperature monitor.

Temperature monitor (75)The fan motor of the air-oil cooler is operated by a temperature monitor.

Volume flowmeter (80)The oil flowrate is monitored by a volume flowmeter.

3.6 Interlocking rulesPlease note that the temperature values stated below for the pump enabling and startup conditions refer to VG 320 mineral oil.

Description3.6 Interlocking rules


If you are using another type of oil, make sure that its viscosity is not higher than that of VG 320 at the specified temperature value.

Fan motorFAN MOTOR ON if one of the following conditions is fulfilled:

Oil temperature >temperature value (65.2)Oil temperature >switching point (75.2)

FAN MOTOR OFF if one of the following conditions is fulfilled:

Oil temperature <temperature value (65.1)Oil temperature <switching point (75.1)

WarningWARNING if at least one of the following conditions is fulfilled:

Pump temperature >temperature value (10.1)Filter differential pres‐sure

>switching point (20) after an interval of 30 seconds

Filter differential pres‐sure

>pressure value (21) after an interval of 30 seconds

Oil pressure <switching point (55)Oil pressure <pressure value (55)Oil temperature >temperature value (65.3)Oil temperature >switching point (70.1)Volumetric flow <switching point (80.1)

Shut down oil supply systemShut down the oil supply system if at least one of the following conditions is fulfilled:

Pump temperature >temperature value (10.2)Motor temperature >temperature value (10.3)Oil temperature >switching point (17.1)Motor temperature >temperature value (30.1)Oil pressure <switching point (50)Oil pressure <pressure value (50)Oil temperature >temperature value (65.4)Oil temperature >switching point (70.2)Volumetric flow <switching point (80.2)





Application planning 44.1 Scope of delivery

The scope of delivery is listed in the shipping documents. Check that everything has been delivered immediately upon receipt of the oil supply system Report any damaged and/or missing parts to Customer Services (Page 57) immediately.

WARNING

Serious injury through defective product

Serious injury may occur.

If you find any visible damage on the oil supply system, do not put it into operation.

4.2 Transport

General informationThe oil supply system is delivered fully assembled. Additional equipment is delivered separately packaged where appropriate.

Depending on the application, the oil supply system might also be delivered fully assembled with the gear unit.

When transporting the oil supply system, observe the following instructions to avoid damaging the system:

● Always use suitable equipment to transport the oil supply system.

● Do not use incorrect attachment points.

● Do not use the pipework to move the oil supply system.

● Ensure that the lifting equipment is able to bear the weight of the oil supply unit plus a safety margin.

WARNING

Risk of crushing

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

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

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


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

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

● Do not exceed the specified load limits

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

● Note the eccentric centre of gravity

● Make sure that the lifting equipment is securely attached

● Keep your speed down when moving the load

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

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

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

DANGER

Falling load

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

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

PackagingThe oil supply system is delivered fully assembled. Additional equipment is also delivered separately packaged, as necessary.

The oil supply system may be packed in various forms depending on the size of the product and the method of transport.

Please adhere to the symbols applied on the packaging.

Figure 4-1 Transport symbols

Application planning4.2 Transport


NOTICE

Damage to the oil supply system

Take special care when transporting the separate oil supply system to avoid causing any damage by use of excessive force or careless loading or unloading of the product.

Use ropes or chains to move the oil supply system. Always attach the ropes or chains to the specially marked lifting eyes on the base frame.

Make sure that the lifting ropes do not cause any damage to valves or pipes. Use of a crossbeam to protect these components is therefore essential. Adjust the lengths of the ropes/chains in such a way to ensure that the base frame is suspended horizontally.

4.3 Attachment points

Lifting eyesLifting eyes are fitted to the oil supply system to assist with its transportation during manufacture and installation.

Carefully ensure that the angle of the vertical load at the lifting eyes of the oil supply system does not exceed 45°.

Position of attachment pointsThe diagram below shows the position of the attachment points on the oil supply system:

Figure 4-2 Position of attachment points

Further informationYou will find further information, a detailed illustration of the oil supply system and the position of the attachment points in the drawings included in the complete documentation for the oil supply system.

Application planning4.3 Attachment points


4.4 Special aspects of gear unit lubrication and preservation

IntroductionUnless otherwise specified in the product-specific operating instructions or the order-specific documentation for the gear unit and the oil supply system, the specifications relating to gear units in operating instructions BA 7300 apply to the oil supply system (as a component of the gear unit).

Observe these specifications, especially in relation to the following issues:

● Storage

● Preservation

● Filling with oil

● Oil drain

● Compatibility of preservative and operating oil

Any special aspects and deviations from the specifications in BA 7300 are described in this document.

4.4.1 Special aspects of top coatingIf it is contractually agreed that the oil supply system is shipped only with the undercoat applied, please ensure that you do the following:

● Observe the information about the preservation state in operating instructions BA 7300 before you apply a top coat.

● Observe the information about coatings in chapter Correct use in hazardous zones (explosive atmospheres) (Page 18).

4.4.2 Storage of the oil supply systemIn addition to fulfilling the requirements laid out in operating instructions BA 7300, a hermetically sealed oil supply system must also meet a further criterion, i.e. that all pipe openings are sealed with plugs or flange covers.

4.4.3 Preservation

IntroductionWhere extending the durability of the interior preservation by operating the oil supply system is permissible for the gear unit, you can extend the durability of the interior preservation of both of these components together. As an alternative, you can extend the durability of the interior preservation of the oil supply system separately from the gear unit.

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


Further informationYou can find further information in the operating instructions for the gear unit and in operating instructions BA 7300.

4.4.3.1 Oil supply system connected to the gear unit

RequirementsThe following requirements must be fulfilled in order to extend the durability of the interior preservation of an oil supply system connected to the gear unit:

● The oil supply system is connected to the gear unit.

● Extending the durability of the interior preservation by operating the oil supply system is permitted for the gear unit.

● Read and observe the gear unit operating instructions.

Preservative oilYou can use the following preservative oils in order to extend the durability of the interior preservation:

● Castrol Alpha SP 220 S

● Castrol Optigear Synthetic 1390/220 (formerly Castrol Tribol 1390/220)

● Castrol Corrosion Inhibitor N 213

ProcedureTo extend the durability of the interior preservation of an oil supply system connected to the gear unit, proceed as follows:

1. If necessary, drain off old preservative or operating oil.

2. Fill the gear unit with the preservative oil.

3. Ensure that the oil reaches the specified level.

4. Start up the oil supply system for a brief period of time (approx. 15 minutes). To do this, follow the gear unit operating instructions.

5. Drain off the preservative oil.

6. Hermetically seal the oil supply system.

ResultThe durability of the interior preservation of the oil supply system is extended.

The precise durability period is stated in operating instructions BA 7300.



Further informationYou can find further information in the operating instructions for the gear unit.

Further information about preservation can be found in the operating instructions BA 7300 in the complete documentation for the oil supply system.

4.4.3.2 Oil supply system disconnected from the gear unit

Preservative oilYou can use the following preservative oils in order to extend the durability of the interior preservation:

● Castrol Alpha SP 220 S

● Castrol Optigear Synthetic 1390/220 (formerly Castrol Tribol 1390/220)

ProcedureTo extend the durability of the interior preservation of an oil supply system disconnected from the gear unit, proceed as follows:

1. If necessary, drain off old preservative or operating oil.

2. Remove the plugs or flange covers from the pipe openings.

3. Connect the oil supply system to a suitable vessel containing the preservative oil.Make sure that the vessel has a large enough storage capacity to contain a sufficient quantity of preservative oil.

4. Start up the oil supply system for a brief period of time (approx. 15 minutes).

5. Disconnect the oil supply system from the vessel.

6. Drain off the preservative oil.

7. Seal all pipe openings with plugs or flange covers and hermetically seal the oil supply system.

ResultThe durability of the interior preservation of the oil supply system is extended.

The precise durability period is stated in operating instructions BA 7300.

Further informationFurther information about preservation can be found in the operating instructions BA 7300 in the complete documentation for the oil supply system.



Assembly 55.1 General assembly instructions

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

RequirementsImproper use can damage the oil supply system. Be sure to take the following precautions:

● Protect the oil supply system against falling objects and from becoming covered over.

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

● Make sure that sufficient hoisting gear is available.

DANGER

Danger of explosion

Danger to life through ignition of a potentially explosive atmosphere possible during assembly and disassembly work on the oil supply system.

The oil supply system must not be assembled or disassembled in an explosive environment.

Mounting position and attachment pointsDuring the actual planning phase, be sure to allow for sufficient space around the oil supply system to enable assembly and subsequent upkeep and maintenance work.

The positions of the attachment points are shown in the dimension drawing. To ensure that the unit is properly lubricated during operation, please observe the mounting position specified in the dimension drawing.

Further informationFurther information about dimensions, space requirements and arrangement of supply connections can be found in the drawings in the complete documentation for the oil supply system.


5.2 Further assembly instructionsNote the following assembly instructions:

● Install the base frame in a horizontal position.

● Secure the system against slipping. Bolts and dowels are included in the Siemens scope of supply. Mounting holes are predrilled in the base frame.

● If the base frame is equipped with a drain tap, fit the drain tap before placing the system down on the base frame. Depending on conditions on site, lack of space might mean that you cannot install the drain tap later on without lifting up the system again.

● Wash all preserved flange surfaces with a suitable solvent.

● If connecting pipes are not included in the scope of supply, use seamless pipes of at least P 235 TR 2 quality according to DIN 2391 c (hydraulic pipe, grade C) which are treated by normalizing bright annealing (NBK).

● Provide suitable flanges or threaded connections at the pipe intersections.

● To isolate vibration and compensate for linear expansion, the use of expansion joints for connecting pipes is recommended.

● Use pipe supports (plastic clamps) for on-site piping. The distance between two clamps must be less than 2 m.

● Make sure that the pipes are installed free of mechanical stress.

● Make sure that welded pipes are pickled prior to installation.

● Flush the pipes clean after installation.

● Make the electrical connections of motors and monitoring equipment as shown in the terminal diagrams and lists of equipment and in accordance with regulations. Check the voltage and circuits.

● Remove the sealing plugs and the flange covers and install the separately supplied valves in the system as shown in the lubrication diagram and drawings (see chapter Operation (Page 47)).

● Thoroughly clean separately supplied components with threaded connection and then seal with Loctite 128068.

DANGER

Risk of explosion due to ignition of vapours emitted from solvents

There is danger to life due to ignition of vapours emitted from solvents or another explosive atmosphere when carrying out cleaning work.

Cleaning work on the oil supply system must not be carried out in an explosive atmosphere.

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

Assembly5.2 Further assembly instructions


5.3 Unpacking the oil supply system

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

WARNING

Risk of serious injury due to defective product

A defective oil supply system can cause serious injuries.

Do not put the oil supply system into operation if any damage is visible.

Contact Customer Services (Page 57).

RequirementCheck that everything has been delivered immediately upon receipt.

NOTICE

Corrosion damage to the oil supply system

Exposing the oil supply system to moisture can result in corrosion damage.

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

ProcedureTo unpack and use the oil supply system, please proceed as follows:

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

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

3. Immediately report any damaged and/or missing parts to Customer Services (Page 57).

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

5.4 Installation conditionsWhen planning the spatial layout (e.g. planning carried out by the customer), make sure that there is sufficient space around the oil supply system to permit unimpeded assembly and repair work.

The installed hoisting gear must have a sufficient load-carrying capacity. The weight of the oil supply system is printed on the rating plate (Page 67).

Assembly5.3 Unpacking the oil supply system


The oil supply system must be installed on a level, stable and rigid foundation or foundation frame. Make sure that sufficient space is available to drain out oil and allow a sufficient air intake for the motors. Valves and wearing parts must be easily accessible for inspection.

The permissible deviation of the floor surface for the oil supply system from the horizontal plane is 2 mm per 1 m. Use shims if necessary.

5.5 Mounted componentsDepending on the order specification, the oil supply system can be equipped with various components.

Connect the closed-loop control and open-loop control electrical devices corresponding to the specifications of the device supplier.

Further information You can find additional information about operation and maintenance in the operating instructions included with the complete documentation for the oil supply system.

You can find the technical data of the mounted components in the order-specific list of equipment provided in the complete documentation for the oil supply system.

5.6 Final work

Measures

WARNING


An explosive atmosphere can be ignited if sparking occurs as a result of failure to earth an oil supply system.

Perform potential equalisation in accordance with the applicable regulations and guidelines. Tapped holes are provided on the oil supply system to establish an earth connection. This work must always be done by specialist electricians.

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

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

● When all installation work on the oil supply system is complete, check all pipes, threaded connections and flanges for tightness.

● Protect the oil supply system including the piping against falling objects.

● Attach the protective devices.

● Protect the cable entries against penetrating moisture.

Assembly5.5 Mounted components


NoteAll electrical work must be performed by a qualified electrician

Make sure that all electrical work is carried out by a qualified electrician in accordance with the relevant safety regulations. The relevant installation and operation regulations as well as the standard national and international guidelines must be observed.

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

You will find further information about the technical data in the list of equipment included in the complete documentation for the oil supply system.

Assembly5.6 Final work


Assembly5.6 Final work


Commissioning 66.1 Measures prior to commissioning

WARNING

Risk of serious injury due to defective product

A defective oil supply system can cause serious injuries.

Do not put the oil supply system into operation if any damage is visible.

Contact Customer Services (Page 57).

WARNING

Risk of injury due to rupture of piping or components

Persons might sustain injury if piping or components rupture as a result of incorrect setting of the pressure relief valve.

The factory setting of the pressure relief valve must not be changed. In order to prevent pump damage, make sure that the pump is pumping oil and not running dry.

WARNING


An explosive atmosphere can be ignited if monitoring equipment is not properly connected.

Connect up all monitoring equipment in accordance with the instructions in the separate interlocking rules.

Take the following measures before commissioning the oil supply system:

● Follow the operating instructions of the oil supply system, the gear unit and the mounted components.

● Clean the oil supply system thoroughly to remove all contaminants. This particularly applies to water, e.g. rainwater, so as to prevent the risk of water mixing with the oil.

● Vent all pumps, filters and coolers.

● Check the oil level.


NOTICE

Damage to the oil supply system and the gear unit

Damage can occur to the oil supply system and the gear unit.

You must always fill the system with oil before commencing any commissioning work. Lock isolation valves so that they cannot be accidentally closed. Tools and fixtures for locking isolation valves against accidental operation are not included in the standard scope of supply unless otherwise contractually agreed.

6.2 Checking procedureRemove all material residue, tools and assembly equipment.

To perform the checking procedure, inspect the following items:

☐ Observe the information on the rating plate.☐ Check whether the voltage and frequency of the motor match the supply system values.☐ Check whether the motor is properly protected.☐ Check whether the electrical connections are tight and the monitoring equipment is prop‐

erly connected and set.☐ Check whether the air inlet openings and cooling surfaces are clean.☐ Check whether the terminal box cover is tightly closed and the cable entry points are

properly sealed.

6.3 Filling with oil and changing oilYou will find additional information about oil change intervals in the gear unit operating instructions included in the complete documentation for the gear unit.

You will find further information about changing the oil in the operating instructions BA 7300.

6.4 Rinsing before first commissioning

IntroductionObserve the general information about changing the oil and the flushing procedure in the operating instructions BA 7300.

Commissioning6.2 Checking procedure


Observe any specific information concerning flushing in the gear unit operating instructions.

CAUTION

Risk of scalding

Risk of injury from leakage of hot oil.

Do not heat the oil to above 50 °C.

Open the oil drain screw or the oil drain tap carefully.

Wear suitable protective gloves, safety goggles and protective clothing. Use an oil-binding agent to immediately clean up any oil spillage.

NOTICE

Damage to the oil supply system

Carefully drain the flushing oil out of the oil supply system, the monitoring equipment and the oil chambers in the gear unit while the oil is still warm (because it is more fluid when warm). The oil can only be reused as flushing oil. You can clean the flushing oil if necessary, and reuse it as flushing oil. If the flushing oil is no longer suitable for a flushing procedure, dispose of it properly.

ProcedureTo flush the system prior to initial commissioning, proceed as follows:

1. Open the filling holes on the oil supply system.

2. Fill the oil supply system with oil.

3. Properly close and seal the filling holes again.

4. Operate the oil supply system for 30 minutes with the gear unit stationary.

5. After shutting down and depressurising the oil supply system, replace the filter elements. To do this, follow the filter operating instructions.

6. Drain off the flushing oil.

6.5 Filling with oil for operation

IntroductionThe oil supply system is filled with oil through the gear unit and/or the oil tank. An auxiliary oil pump can be used.

Commissioning6.5 Filling with oil for operation


ProcedureProceed as follows to fill the oil supply system with oil:

1. Make sure that the pump is not in operation.

2. Make sure that no dirt particles can enter the oil circuit.

3. Fill the system with oil until it reaches the level marked on the oil level indicator on the gear unit.

4. Start up the pump.

5. To ensure that all oil chambers are filled with oil, allow the oil supply system to run for at least 15 minutes before starting initial commissioning of the gear unit. Then shut down the oil supply system again and adjust the oil level if necessary.

6. Retighten all of the pipes, threaded connections and flanges, particularly the suction pipes.

7. Repair any leaks by resealing.

NoteValve positions of three-way valves

Please refer to the table in chapter Valve position (Page 26) for the positions of the three-way valves.

Commissioning6.5 Filling with oil for operation


Operation 7Introduction

Protect the oil supply system and the adjacent piping against falling objects.

7.1 General informationProvide a startup override of 10 seconds for the pressure monitors and the volume flowmeter.

The oil supply system must remain in operation until the main drive reaches a standstill after it has been shut down.

7.2 Lubrication diagramThe relevant drawing number of the lubrication diagram can be found in the list of equipment.

7.3 Procedure in the event of malfunctionsIrrespective of the information given below, the oil supply system must always be operated in accordance with local safety regulations.

It is essential that you monitor the system while it is in operation so that you can promptly detect any malfunctions (Page 53) and have time to take preventive measures. Keep a regular record of operating pressures and oil temperatures.

If you notice any irregularities in the operating behaviour of the system or any changes in the operating values, take immediate action to establish the cause of the problem.

If necessary, shut the system down. Contact Customer Services (Page 57) if you are unable to determine the cause of the fault from the fault-finding list.

WARNING

Accidental startup of the system

The system can cause injuries if it is started up accidentally.

Use a lockable switch to prevent the system from being started up unintentionally during repair work or system faults.

Please observe the relevant accident prevention regulations of the Employer's Liability Insurance Association concerned.


Make sure that the oil supply system cannot be restarted after safety equipment has responded until the restarting lockout is cancelled.

Further informationFor information about restarting the system after a fault, please refer to the information in chapter Commissioning (Page 43).

7.4 Taking the unit out of serviceIf you take the oil supply system out of service for a prolonged period, you must take the following measures:

● Shut down the oil supply system.

● Take measures to prevent the oil supply system from being restarted accidentally. Attach a notice to the starting switch.

7.5 Operational downtimeIn the case of prolonged downtimes (> 4 weeks) of the gear unit and oil supply system, the following measures must be taken:

● The gear unit and oil supply system must remain filled with oil.You must start up the gear unit and the oil supply system every 4 weeks and allow them to run for 1 hour. Observe the specified pre-lubrication and relubrication intervals.

● If you cannot implement these measures, you must preserve the gear unit and the oil supply system.

Operation7.4 Taking the unit out of service


Maintenance 88.1 General maintenance information

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

The oil supply system could sustain damage if the stipulated time limits for maintenance and servicing are not observed.

WARNING


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

Always shut down the gear unit and any oil supply system (whether separate or mounted on the gear unit) before you carry out any work. Take measures to prevent the accidental restarting of the drive assembly. Display a warning notice that clearly states that work is being carried out on the gear unit.

8.2 Maintenance schedule

Maintenance and servicing workThe following table provides an overview of all maintenance and servicing work which you are required to perform continuously or at regular intervals.

Table 8-1 Maintenance and servicing work

Intervals and time limits MeasuresAs required Replace the oil filter

Clean the air filterAccording to manufacturer’s specifications Check the ignition protection systemWeekly Check for leaks

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

Every 2 weeks Clean filter insertsEvery 4 weeks Check the oil temperature

Inspect the protection devices


Intervals and time limits MeasuresEvery 3 months Clean the oil filter

Clean the air filterEvery 6 months Investigate an oil specimen for its lubricating propertiesEvery 12 months Inspect the hose lines

Analyse the oilCheck that all of the fastening bolts are tight

Every 10 000 operating hours, at least every 2 years

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

Every 20 000 operating hours, at least every 4 years

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

6 years after the specified date of manufacture Change the hoses

Further informationYou will find further information about supplementary maintenance and repair work in the list of equipment included in the complete documentation for the oil supply system.

You will find further information about the installed components in the operating instructions for the components included in the complete documentation for the oil supply system.

8.3 Maintenance and servicing work

IntroductionYou can find maintenance and servicing measures relating to gear unit lubrication and preservation that are not included in this chapter in operating instructions BA 7300 in the complete documentation for the oil supply system.

8.3.1 Replacing the pump

ProcedureTo replace the pump, proceed as follows:

1. Shut down the oil supply system.

2. Depressurise the pump.To do this, carefully unscrew and remove the venting screw at the pump or pump flange.

Maintenance8.3 Maintenance and servicing work


3. Drain the oil from the pump and pipes.

4. Remove the pump.

5. Install the new or repaired pump.

6. Screw the venting screw back into the pump or pump flange.

7. Vent the pump.To do this, unscrew the venting screw at the pump or pump flange and wait until the operating medium begins to trickle out.

8. Then screw in the venting screw again until it is tight.

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

8.3.2 Replacing the air-oil cooler

ProcedureProceed as follows to replace the air-oil cooler:

1. Shut down the oil supply system.

2. Depressurise the cooler.To do this, carefully unscrew and remove the venting screws at the cooler.

3. Drain the oil out of the cooler and pipes.

4. Remove the cooler.

5. Install the new or repaired cooler.

6. Screw the venting screws back into the cooler.

7. Start up the oil supply system.

8. Vent the cooler.To do this, unscrew the venting screw at the cooler and wait until the operating medium begins to trickle out.

9. Then screw in the venting screw again until it is tight.

Further informationYou will find further information about the air-oil cooler in the operating instructions for the air-oil cooler included in the complete documentation for the oil supply system.



8.3.3 Cleaning or replacing the oil filterYou can carry out the work while the system is in operation provided that the component has been isolated, depressurized and locked out.

Further informationYou can find additional information about the oil filter in the oil filter operating instructions included in the complete documentation for the oil supply system.

8.3.4 Checking the ignition protection system for temperature monitoringMake sure that the ignition protection system for temperature monitoring is function-tested and checked for measuring accuracy at appropriate time intervals according to the manufacturer's instructions.

8.3.5 Mounted componentsYou can find additional information about operation and maintenance in the operating instructions included with the complete documentation for the oil supply system.

You can find the technical data of the mounted components in the order-specific list of equipment provided in the complete documentation for the oil supply system.

8.3.6 Cleaning the oil supply system

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

ProcedureProceed as follows to clean the oil supply system:

1. Use a stiff brush to remove stubborn dirt from the oil supply system. Never use a high-pressure cleaning device.

2. Remove any spots of corrosion.



DANGER


An explosive atmosphere can be ignited if the oil supply system overheats as a result of inadequate cooling.

Prevent the build-up of dust deposits on the oil supply system. Adapt the cleaning intervals to the operational situation.

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

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

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

NoteLoss of warranty

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

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

DANGER


Death or serious injury will occur.

Shut down the oil supply system before commencing any kind of work on it. Secure the drive unit against accidental startup. Attach a notice to the switch stating clearly that work is being performed on the oil supply system.

Maintenance8.4 Possible faults


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

Table 8-2 Possible faults and their rectification

Possible faults Causes Possible remediesUnusual or increased levels of filter residues

Filter dirty ● Clean or replace the filterPipes dirty (scaling, welding resi‐dues)

● Clean the pipes

Abrasion dust from the gear unit ● Inspect the gear unit (rolling-contact and plain bearings, gearing, alignment) and repair any defects

Oil dirty ● Change the oilAbrasion dust from a defective pump

● Repair or replace the pump (separate operating instructions)

Oil pressure too high Gear unit not yet warmed up ● Wait until the gear unit has warmed upPressure relief valve incorrectly ad‐justed

● Contact Customer Services

Pressure relief valve damaged ● Repair or replace the pressure relief valve (separate operating instructions)

Oil pipe to and at gear unit blocked ● Search for and clean blocked pipeOil viscosity too high ● Check the oil viscosity

● If necessary, change the oilOil pressure too low Filter clogged up ● Switch over to clean filter, and then clean or replace filter

element (separate operating instructions)Pressure relief valve incorrectly ad‐justed

● Contact Customer Services

Pressure relief valve damaged ● Repair or replace the pressure relief valve (separate operating instructions)

Suction pipe blocked ● Clean the suction pipePump is sucking in air ● Inspect the suction pipe

● Repair any leaks if necessaryOil temperature too high ● Refer to fault "Oil temperature too high" in this tableOil viscosity too low ● Check the oil viscosity

● If necessary, change the oilThe pump or pump drive is dam‐aged

● Repair or replace the pump (separate operating instructions)

Oil temperature too high

Cooler motor not running ● Check the power supply to the cooler motor and/or the temperature transmitter and repair or replace if necessary

Air in cooler ● Vent the coolerCooler is dirty ● Clean or replace the cooler according to manufacturer's

maintenance instructions (separate operating instructions)



Possible faults Causes Possible remediesOil temperature too low Gear unit not yet warmed up ● Wait until the gear unit has warmed upOil consumption too high

Leakage from pipes, connections, valves or gear unit

● Tighten screws● Reseal

Shaft exits at gear unit are not tight ● Replace the sealing ringsCooler leaking ● Seal the cooler and/or replace the cooling unit (separate

operating instructions)Filter leaking ● Seal the filter

8.4.1 Possible errors when assembling the oil supply systemListed below are the possible errors which might be made when the oil supply system is assembled:

● Important information about the description of the drive unit and the environment is not passed on

● Performance data are too high

● Chemically aggressive environment is not taken into consideration.

● The ambient temperature is not within the permissible range

● Components are assembled even though they are damaged (including transport damage)

● Separately supplied components are incorrectly installed

● Stipulated tightening torques are not adhered to

● Inadmissible changes are made to the operating conditions

8.4.2 Possible maintenance errorsListed below are the possible errors which might be made during maintenance of the oil supply system:

● Maintenance is not carried out at the prescribed intervals

● Leak in the area around the oil supply system is not detected so that it is damaged by chemically aggressive substances





Service & Support 9Contact

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

Siemens AG

Am Industriepark 2

46562 Voerde

Germany

Tel.: +49 (0)2871 / 92‐0

Fax: +49 (0)2871 / 92‐1544


Service & Support


Disposal 10Disposing of the oil supply system

When disposing of the oil supply system at the end of its useful life, please observe the following:

● Remove operating oil, preservation agents and coolant from the oil supply system and dispose of them in accordance with regulations.

● Recycle the various parts of the oil supply system and the mounted components or dispose of them in accordance with the applicable national regulations.

Environmental protectionObserve the following environmental protection measures for disposal:

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

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

● Store preservative agents separately from used oil.

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


Disposal


Spare parts 11By stocking the most important spare parts at the installation site, you can ensure that the oil supply system will be ready for use at any time.

NoteDamage to the oil supply system by use of incorrect spare parts

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

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

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

The contact address of Siemens Customer Services can be found under Service & Support (Page 57).

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

When ordering spare parts, please provide the following information:

● Order number with item

● Type and size

● Part number

● Quantity


Spare parts


Quality documents AA.1 Declaration of Incorporation


Declaration of incorporation

Company name and full address of the manufacturer:

Siemens AktiengesellschaftAm Industriepark 246562 VoerdeDeutschland – Germany

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

Mark ZundelSiemens AktiengesellschaftAm Industriepark 246562 VoerdeDeutschland – Germany

Description and identification of the partly completed machinery:

FLENDER supplies, oil-supply systemsOWGD, OWGE, OWGE.1, OWGM, OWGX, OWTD, OWTE,OLGD, OLGE, OLGE.2, OLGM, OLTD, OLTESizes 1 to 315.1for driving machines

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

1.1, 1.1.2, 1.1.3, 1.1.5; 1.2.2, 1.2.4.4; 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.6, 1.3.7; 1.4.1, 1.4.2.1;1.5.1, 1.5.2, 1.5.4, 1.5.5, 1.5.6, 1.5.7, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.5.13, 1.5.15;1.6.1, 1.6.2, 1.6.4; 1.7.1, 1.7.1.1, 1.7.2, 1.7.3, 1.7.4, 1.7.4.1, 1.7.4.2, 1.7.4.3

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

The party completed machinery complies with the requirements in Directive:– Directive 2014/34/EU Official Journal L 96, 29.3.2014, pages 309-356

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

Siemens Aktiengesellschaft

Voerde, 2017‐02‐09 i.V.Mark Zundel, Head of PD MD AP VOE

Voerde, 2017‐02‐09 i.V.Björn Podewski, Head of PD MD AP VOE BA

Translation of the original declaration of incorporation

Quality documentsA.1 Declaration of Incorporation


EU declaration of conformity

Product:

FLENDER supplies, oil-supply systemsOWGD, OWGE, OWGE.1, OWGM, OWGX, OWTD, OWTE,OLGD, OLGE, OLGE.2, OLGM, OLTD, OLTESizes 1 to 315.1

Name and address of the manufacturer:

Siemens AktiengesellschaftAm Industriepark 246562 VoerdeDeutschland – Germany

This declaration of conformity is issued under the sole responsibility of the manufacturer.

Object of the declaration is the product specified above.

The object of the declaration described above is in conformity with the relevant harmonisationlegislation of the Union:– Directive 2014/34/EU Official Journal L 96, 29.3.2014, pages 309-356

Harmonised standards or other technical specifications, on which the declaration of conformity isbased:

EN 1127‐1 : 2011EN 13463‐1 : 2009EN 13463‐5 : 2011EN 13463‐6 : 2005EN 13463‐8 : 2003EN 60079-0 : 2012/A11:2013

Signed for and on behalf of:Siemens Aktiengesellschaft

Voerde, 2017‐02‐09 i.V.Mark Zundel, Head of PD MD AP VOE

Voerde, 2017‐02‐09 i.V. Björn Podewski, Head of PD MD AP VOE BA

A.2 Declaration of Conformity

Quality documentsA.2 Declaration of Conformity


Quality documentsA.2 Declaration of Conformity


Technical data BB.1 General technical data

Rating plateThe rating plate of the oil supply system contains the most important technical data.

① Company logo ⑧ pOil, max = maximum permissible operating gauge pressure of oil in bar and PSI

② Serial no.: Plant code / order no. - Item - Serial no. / Year of manufacture

⑨ tmin = minimum starting temperature in °C and °F

③ Total weight in kg ⑩ pWater, max = permissible operating pressure of water in bar and PSItAMB, max = maximum permissible ambient tem‐perature in °C and °F

④ For special information ⑪ Numbers of operating instructions⑤ Type ⑫ ATEX marking⑥ Size ⑬ Manufacturer and place of manufacture⑦ Version ⑭ Country of origin

Figure B-1 Rating plate

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

Further informationFurther information about these technical data can be found in the list of equipment and the drawings in the complete documentation for the oil supply system.


Further information about all major accessories including their technical data can be found in the order-specific list of equipment in the complete documentation for the oil supply system.

ATEX markingThe ATEX marking for open-cast mining applications is shown in the following table:

Table B-1 ATEX marking

Equip‐ment group

Equip‐ment cate‐gory

Explosive atmos‐phere

Explosion group

Tempera‐ture class

Marking

II 3 Gas (G) IIA, IIB, IIC T3, T4 II 3 G IIA T4 bck Ta..Gas (G) or dust (D)

IIA, IIB, IIC T3, T4 II 3 G IIA T4 D 120 °C bck Ta..

Dust (D) II 3 D 120 °C bck Ta..

Please note the following points:

● The explosion groups refer to a gas atmosphere (G).Only one explosion group can be specified.

● Only one temperature class can be specified.

● Ta min. ≤ Ta ≤ Ta max. = permissible ambient temperature in °C:Ta min. = minimum permissible ambient temperatureTa max. = maximum permissible ambient temperatureTa = ambient temperature code

● The specified explosion group and temperature class are examples only.

● For oil supply systems without electrical ignition source monitoring, type of protection "b" is not applicable. An electrical ignition source monitoring can be a temperature or oil level monitoring, for example.

● Oil supply systems from the FLENDER product family are not designed for use in hybrid mixtures.

NOTICE

The oil supply system can be damaged as a result of incorrect use

The oil supply system may be damaged if used for a purpose other than the specified application.

For your particular application, observe the marking on the rating plate of the oil supply system.

Technical dataB.1 General technical data


B.2 Ambient conditionsThe specifications in the ATEX directive are applicable for an ambient temperature range extending from -20 °C up to 40 °C. By applying various suitable measures, the oil supply system can be used in the ambient temperature range up to 60 °C. However, this must always be authorised by Siemens.

In each individual case, the ambient temperature range stamped on the rating plate always applies.

B.3 Oil viscosity and oil gradePlease refer to the operating instructions and the rating plate of the gear unit for information about oil viscosity and oil grade.

The oil supply systems are designed for oil viscosities up to 5 000 mm2/s at the minimum startup temperature (see rating plate ⑨).

Technical dataB.2 Ambient conditions


Technical dataB.3 Oil viscosity and oil grade


Index

AAir-oil cooler, 25, 51Ambient conditions, 69ATEX Directive, 9, 26ATEX marking, 26, 68Attachment points, 33, 37

CChecking procedure, 44Cleaning, 52Coloured markings, 14Conditions of use, 26Contact, 57Control instructions, 27Copyright, 10Customer Services, 57

DDesign, 23Disclaimer, 9Disposal, 59Documentation landscape, 10

EEnvironmental protection, 59

FFault, 53Fault rectification, 54Final work, 40

IIgnition protection system, 52Installation conditions, 39Integration note, 21Interlocking rules, 28Interval, 49

LLifting eyes, 33Lubricant, 10Lubrication diagram, 47

MMaintenance activities, 49Maintenance information, 49Maintenance schedule, 49Marking, 14Measures

Checking procedure, 44Prior to commissioning, 43

Mounted components, 40, 52Mounting position, 37

NNote about assembly, 37

OOil, 10Oil change, 44Oil cooler, 25Oil filling, 44, 45Oil filter, 52Oil grade, 69Oil supply system equipment, 24Oil viscosity, 69Operational downtime, 48Ordering spare parts, 57, 61

PPreservation, 34Principle of operation, 23Protective equipment, 16Pump, 25, 50


RRating plate, 67

ATEX marking, 68Rinsing, 44

SSafety rules, 13Scope of delivery, 31Servicing activities, 49Shipping documents, 31

TTaking the unit out of service, 48Technical data, 67Top coat, 34Transport information, 31Transport symbols, 32Troubleshooting, 53Types of danger, 16

UUnpacking, 39Use, 19Used oil, 59

VValve position, 26

WWarning symbols, 15

Index


AA en_EBEAA KAT3_en_KE

Further Information

www.siemens.com/drives

Siemens AGProcess Industries and DrivesPostfach 48 4890026 NÜRNBERGGERMANY

Documents

FLENDER supplies - support.industry.siemens.com · FLENDER supplies Oil-supply systems 9751en Operating Instructions Edition 10/2016 OLGE 1...10