FLENDER H Series User manual

FLENDER Gear Units
Gear unit
Operating Instructions 5118en
Edition 10/2017
H..., B..., M..., SOND

18.09.2017 15:44
V7.02

FLENDER Gear Units
Gear unit
5118en
Operating Instructions
H..., B..., M..., SOND
Edition 10/2017
Introduction 1
Safety instructions 2
Description 3
Application planning 4
Assembly 5
Commissioning 6
Operation 7
Servicing 8
Service & Support 9
Disposal 10
Spare parts 11
Quality documents A
Technical data B

Legal information
Warning 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.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates 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 Personnel
The 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 Flender products
Note the following:
WARNING
Flender 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 Flender. 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.
Trademarks
All names identified by ® are registered trademarks of Flender GmbH. 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 Liability
We 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.
Flender GmbH
Alfred-Flender-Straße 77
46395 BOCHOLT
GERMANY
Document order number: 5118en
Ⓟ 09/2017 Subject to change
Copyright © Flender GmbH 2017.
All rights reserved

Table of contents
1 Introduction.................................................................................................................................................11
1.1 General information................................................................................................................11
1.2 Lubricants...............................................................................................................................12
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 Intended use..........................................................................................................................18
3 Description..................................................................................................................................................21
3.1 General description................................................................................................................21
3.2 Output shaft versions.............................................................................................................21
3.3 Housing..................................................................................................................................21
3.4 Oil supply to the gear unit......................................................................................................24
3.4.1 Splash lubrication...................................................................................................................25
3.4.2 Pressure lubrication...............................................................................................................25
3.5 Bearing arrangement of the shafts.........................................................................................25
3.6 Shaft seal...............................................................................................................................26
3.6.1 Rotary shaft sealing rings.......................................................................................................26
3.6.2 Labyrinth seals.......................................................................................................................26
3.6.3 Taconite seal..........................................................................................................................27
3.6.4 Tacolab seal...........................................................................................................................28
3.7 Cooling...................................................................................................................................30
3.7.1 Fan.........................................................................................................................................30
3.7.2 Cooling coil.............................................................................................................................31
3.7.3 Mounted oil supply system.....................................................................................................33
3.7.3.1 Pump......................................................................................................................................33
3.7.3.2 Oil filter...................................................................................................................................34
3.7.3.3 Pressure monitor....................................................................................................................34
3.7.4 Separate oil supply system....................................................................................................34
3.8 Couplings...............................................................................................................................34
3.9 Heating...................................................................................................................................35
3.10 Oil level indicator....................................................................................................................36
3.11 Oil-level monitoring system....................................................................................................37
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3.12 Oil temperature monitoring.....................................................................................................38
3.13 Bearing monitoring.................................................................................................................38
3.13.1 Bearing monitoring using a Pt 100 resistance thermometer..................................................38
3.13.2 Bearing monitoring by shock-pulse transducer......................................................................39
3.13.3 Bearing monitoring by acceleration sensor............................................................................40
3.14 Speed encoder.......................................................................................................................42
3.15 Torque monitoring system......................................................................................................42
3.16 Gear unit monitoring "Condition Monitoring"..........................................................................43
4 Application planning...................................................................................................................................45
4.1 Scope of delivery....................................................................................................................45
4.2 Transport................................................................................................................................45
4.3 Attachment points..................................................................................................................47
4.4 Special aspects of gear unit lubrication and preservation......................................................51
4.4.1 Oil filling and oil drain.............................................................................................................51
4.4.2 Preservation of gear units with Tacolab seals........................................................................53
5 Assembly....................................................................................................................................................55
5.1 General assembly instructions...............................................................................................55
5.2 Unpacking the gear unit.........................................................................................................56
5.3 Gear unit assembly................................................................................................................57
5.3.1 Foundation.............................................................................................................................57
5.3.2 Description of assembly work................................................................................................58
5.3.2.1 Alignment...............................................................................................................................60
5.3.3 Mounting the gear unit on the housing mounting foot............................................................62
5.3.3.1 Installation on a foundation frame..........................................................................................62
5.3.3.2 Mounting on a concrete foundation using foundation blocks.................................................63
5.3.3.3 Mounting on a concrete foundation using anchor bolts..........................................................64
5.4 Couplings...............................................................................................................................67
5.5 Connecting components........................................................................................................68
5.5.1 Gear units with mounted components....................................................................................68
5.5.2 Connecting the cooling coil....................................................................................................69
5.5.3 Installing a separate oil supply system...................................................................................69
5.5.4 Connecting the pressure monitor...........................................................................................70
5.5.5 Connecting the heating element............................................................................................70
5.5.6 Connecting the oil-level monitoring system............................................................................70
5.5.7 Connecting the Pt 100 resistance thermometer.....................................................................71
5.5.8 Connecting the bearing monitoring system............................................................................71
5.5.9 Connecting a speed encoder.................................................................................................71
5.5.10 Connecting the torque monitoring system..............................................................................72
5.5.11 Connecting the gear unit condition monitoring system..........................................................72
5.5.12 Electrical connections............................................................................................................72
5.6 Tightening procedure.............................................................................................................73
5.6.1 Introduction............................................................................................................................73
5.6.2 Bolt connection classes..........................................................................................................74
5.6.3 Tightening torques and preload forces...................................................................................74
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5.7 Final work...............................................................................................................................76
6 Commissioning...........................................................................................................................................79
6.1 Measures prior to commissioning..........................................................................................79
6.1.1 Gear units with cooling coil....................................................................................................79
6.1.2 Gear units with oil supply system...........................................................................................80
6.2 Measures during commissioning............................................................................................80
6.2.1 Heating...................................................................................................................................81
7 Operation....................................................................................................................................................83
7.1 Operating data.......................................................................................................................83
7.2 Irregularities in operation........................................................................................................83
7.3 Taking the unit out of service.................................................................................................84
8 Servicing.....................................................................................................................................................85
8.1 General maintenance information..........................................................................................85
8.2 Maintenance schedule...........................................................................................................86
8.3 Maintenance and servicing work............................................................................................87
8.3.1 Cleaning the venting screw....................................................................................................87
8.3.2 Checking the oil temperature.................................................................................................88
8.3.3 Measuring the vibration levels of the rolling-contact bearings...............................................88
8.3.4 Cleaning the fan and gear unit...............................................................................................89
8.3.5 Checking the cooling coil.......................................................................................................89
8.3.6 Check that all of the fastening bolts are tight.........................................................................90
8.3.7 General inspection of the gear unit........................................................................................90
8.3.8 Final work...............................................................................................................................90
8.4 Possible faults........................................................................................................................90
9 Service & Support.......................................................................................................................................97
10 Disposal......................................................................................................................................................99
11 Spare parts...............................................................................................................................................101
A Quality documents....................................................................................................................................103
A.1 Declaration of Incorporation.................................................................................................103
B Technical data..........................................................................................................................................105
B.1 General technical data.........................................................................................................105
B.2 Ambient temperature............................................................................................................106
B.3 Types...................................................................................................................................106
B.4 Weights................................................................................................................................106
B.5 Enveloping surface sound pressure level............................................................................106
Index.........................................................................................................................................................107
Tables
Table of contents
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Table 2-1 Symbols and markings................................................................................................................14
Table 2-2 General warnings........................................................................................................................15
Table 3-1 Taconite seal versions.................................................................................................................28
Table 3-2 Information about the specific heat output..................................................................................35
Table 5-1 Information on tightening fastening bolts.....................................................................................74
Table 5-2 Preload forces and tightening torques.........................................................................................75
Table 7-1 Operating data.............................................................................................................................83
Table 8-1 Maintenance and servicing work.................................................................................................86
Table 8-2 Possible faults and their rectification...........................................................................................91
Figures
Figure 3-1 Gear unit equipment for type H2SH 24 (SOND 622) gear units..................................................22
Figure 3-2 Gear unit equipment for type M1S X 315 gear units...................................................................23
Figure 3-3 Gear unit equipment for type H3SX gear units............................................................................24
Figure 3-4 Rotary shaft sealing ring..............................................................................................................26
Figure 3-5 Labyrinth seal..............................................................................................................................27
Figure 3-6 Taconite seal...............................................................................................................................27
Figure 3-7 Design variants of taconite seals.................................................................................................28
Figure 3-8 Tacolab seal................................................................................................................................29
Figure 3-9 Fan mounted on a gear unit........................................................................................................31
Figure 3-10 Cooling coil connections..............................................................................................................32
Figure 3-11 Heating for gear units, type H... and B........................................................................................36
Figure 3-12 Oil-level monitoring system for gear units, types H... and B........................................................37
Figure 3-13 Oil temperature monitoring system for gear units, types H... and B............................................38
Figure 3-14 Bearing monitoring using a Pt 100 resistance thermometer.......................................................39
Figure 3-15 Bearing monitoring using a shock-pulse transducer...................................................................40
Figure 3-16 Fully assembled acceleration sensor (A), and threaded connector (B) for variants 1 to 4..........41
Figure 3-17 Fully assembled acceleration sensor (C), and the threaded connector (D) for variants 5A
and 5B.........................................................................................................................................41
Figure 3-18 Speed encoder............................................................................................................................42
Figure 3-19 Telemetric measuring system to monitor the torque...................................................................43
Figure 4-1 Transport symbols.......................................................................................................................47
Figure 4-2 Shear and lateral pulling when using eye bolts...........................................................................48
Figure 4-3 Position of the attachment points for gear units of type H2SH 24 (SOND 622)..........................49
Figure 4-4 Position of the attachment points for gear units of type M1S X 315...........................................49
Figure 4-5 Position of the attachment points for gear units of type H3SX....................................................50
Figure 4-6 Oil filling points and oil draining points on type H2SH 24 (SOND 622) gear units......................51
Figure 4-7 Oil filling points and oil draining points on type M1S X 315 gear units........................................52
Figure 4-8 Oil filling points and the oil draining points on type H3SX gear units..........................................53
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Figure 4-9 Preservation of gear units with Tacolab seals.............................................................................54
Figure 5-1 Gap dimension at grease labyrinth..............................................................................................59
Figure 5-2 Alignment surface........................................................................................................................60
Figure 5-3 Alignment surfaces and alignment thread at the gear unit..........................................................61
Figure 5-4 Foundation block.........................................................................................................................63
Figure 5-5 Inserted anchor bolt.....................................................................................................................64
Figure 5-6 Tightened anchor bolt..................................................................................................................65
Figure 5-7 Possible displacements...............................................................................................................67
Figure 5-8 Alignment process based on the example of a flexible coupling.................................................68
Figure B-1 Rating plate...............................................................................................................................105
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Table of contents
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10 Operating Instructions 10/2017

Introduction 1
1.1 General information
Purpose of the operating instructions
These operating instructions describe the gear unit and provide information about handling it
- from assembly to maintenance.
Please keep these operating instructions for later use. Please read these operating instructions
prior to handling the gear unit and follow the information in them.
Note
Disclaimer
Please make sure that every person who is commissioned to work on the gear unit has read
and understood these operating instructions prior to handling the gear unit and adheres to all
of the points. Failure to observe these operating instructions can cause product or property
damage or personal injury.
Flender does not accept any liability for damage or operating failures which are due to non-
adherence to these operating instructions.
The gear unit described in these instructions reflects the state of technical development at the
time these operating instructions went to print.
In the interest of technical advancements, Flender reserves the right to make changes to the
individual components and accessories which are considered necessary for improving their
performance and safety, while maintaining their essential features.
Basic knowledge required
In order to understand these operating instructions, you will need the following general
knowledge about gear units. You will also need a basic understanding of the following topics:
● Application planning
● Assembly
● Commissioning
● Maintenance
Documentation landscape
These operating instructions form part of the delivery of your gear unit.
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Operating Instructions 10/2017 11

These operating instructions form part of the complete documentation supplied with the gear
unit. The complete documentation encompasses other documents, including:
● Data sheet
● List of equipment
● Dimension drawing
● Operating instructions for gear unit lubrication and preservation BA 7300
● Operating instructions for mounted components
● Operating instructions for third-party vendor devices
Copyright
The copyright for these operating instructions is held by Flender.
Without the authorisation of Flender, 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 97).
1.2 Lubricants
The quality of the oil used must meet the requirements of the operating instructions BA 7300,
which is provided as a separate item, otherwise the warranty provided by Flender will be void.
Flender urgently recommends using one of the oils listed in BA 7300, all of which have been
appropriately tested and meet the requirements.
To avoid misunderstandings, Flender points out that, by making this recommendation, Flender
is not approving the product in the sense of expressing a warranty for the quality of the
lubricants supplied by your supplier. Every lubricant manufacturer is required to guarantee the
quality of his/her products.
Information such as oil type, oil viscosity and required oil quantity can be found on the rating
plate of the gear unit and in the documentation supplied with the gear unit.
The oil quantity specified on the rating plate is an approximate value. The actual quantity of
oil required is determined by the marking on the oil dipstick or oil sight glass.
The operating instructions for the current lubricant recommendations of Flender can also be
viewed in the Internet (http://support.automation.siemens.com/WW/view/de/44231658).
The oils listed there undergo continuous testing. As a result, the recommended oil types might
in future be removed from the list or replaced by more advanced oils.
Flender recommends regular inspection to ascertain whether the selected lubricating oil is still
approved by Flender. If it is not, another brand of oil should be selected instead.
Introduction
1.2 Lubricants
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Safety instructions 2
2.1 Security notes
Security notes
Flender 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. Flender 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.
Flender products and solutions undergo continuous development in order to make them even
safer. Flender strongly 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 rules
In 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. Disconnect
Also 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
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When all the work is complete, cancel the safety measures in the reverse sequence.
2.3 General information
Introduction
All work on the gear unit should be performed with care and only by qualified personnel.
Symbols on the gear unit
The following symbols apply to the gear unit; some of which are found as coloured markings
on the gear unit:
Table 2-1 Symbols and markings
Points labelled on the gear unit Symbol Coloured markings
Earth 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
Safety instructions
2.3 General information
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14 Operating Instructions 10/2017

Points labelled on the gear unit Symbol Coloured markings
Eye bolt
Do not unscrew
Alignment 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 symbols
The following table contains general warnings and their associated symbols.
Table 2-2 General warnings
ISO ANSI Warning
Warning - 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
Safety instructions
2.4 General warnings and symbols
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Operating Instructions 10/2017 15

ISO ANSI Warning
--- Warning - hand injuries
ATEX certification
2.5 Special types of danger and personal protective equipment
Requirements
Fulfil the following requirements before commencing work on the gear unit:
● Ensure that the oil pressure lines are depressurised.
● Only perform work on the gear unit when it is not in operation.
● Disconnect electrical systems from the power supply.
DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Protective equipment
Wear the following personal protective equipment when handling the gear unit:
● Safety shoes
● Overalls
● Helmet
● Safety gloves
● Safety goggles
WARNING
Risk of eye injury
Small foreign particles such as sand or dust can enter the cover plates of the rotating parts
and be hurled back by them.
Wear safety goggles.
Safety instructions
2.5 Special types of danger and personal protective equipment
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Dangers during operation
Damage to the gear unit is possible.
Switch the gear unit to standstill immediately if inexplicable changes are noticed during
operation. Such changes may include unusual gear unit noise or a significant increase in
operating temperature.
WARNING
Risk of falling
There is an increased risk of falling when standing or walking on the gear unit during operation.
Only walk or stand on the gear unit and its mounted components for maintenance and repair
work when it is at a standstill. Do not walk or stand on shaft ends, protection covers, mounted
components or pipes.
WARNING
Danger to life through rotating or moving parts
There is danger that rotating or moving parts may catch hold of you or pull you in.
Secure rotating and/or moving parts against contact using safeguards.
Surface temperature
The surface temperatures of the gear unit can become very extreme depending on the
operating conditions.
WARNING
Risk of burns
Possible risk of serious burn injury from hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.
WARNING
Risk of scalding
Risk of serious injury possible through escaping hot operating media when these are being
changed.
Wear suitable protective gloves, safety goggles and protective clothing.
WARNING
Danger due to low temperatures
Possible risk of serious injuries due to frost (pain, numbness, frostbite) on cold surfaces
(< 0 °C).
Wear suitable protective gloves and protective clothing.
Safety instructions
2.5 Special types of danger and personal protective equipment
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Operating Instructions 10/2017 17

Chemical substances
Injuries can be sustained when using chemical substances.
WARNING
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.
CAUTION
Risk of injury due to chemically aggressive operating materials
There is a risk of injury to eyes and hands when handling chemically aggressive operating
materials.
Please observe the safety instructions in the data sheets of the oil used. Wear suitable
protective equipment (gloves, safety goggles). Use an oil-binding agent to immediately clean
up spilt oil.
Danger of explosion
An explosion may occur in a potentially explosive atmosphere.
DANGER
Danger of explosion through ignition of a potentially explosive atmosphere
Danger to life through ignition of a potentially explosive atmosphere possible when operating
the gear unit
Do not use the gear unit in potentially explosive atmospheres.
2.6 Intended use
Only use the gear unit according to the conditions specified in the service and delivery contract
and the technical data in the annex (Page 105). Deviating operating conditions are considered
improper use. The user or owner of the machine or plant is solely liable for any resulting
damage.
Safety instructions
2.6 Intended use
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18 Operating Instructions 10/2017

When using the gear unit please specifically observe the following:
● Do not make any modifications to the gear unit which go beyond the permissible handling
described in these operating instructions. This also applies to safety features designed to
prevent accidental contact.
● Only ever use original spare parts.
Other spare parts are not tested and approved by Flender. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or
passive safety.
Flender 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 Flender.
If you have any queries, please contact Customer Services (Page 97).
WARNING
Risk of falling
Risk of possible serious injury through falling.
Only walk or stand on the gear unit for maintenance and repair work when it is at a standstill.
Do not walk or stand on shaft ends, protection covers, mounted components or pipes.
Gear unit use
When using the gear unit, please observe the following basic rules:
● Ensure that the gear unit is operationally safe.
● The gear unit should only be operated, maintained or repaired by authorised, trained and
suitably qualified personnel.
● The relevant work safety and environmental protection regulations must be complied with
at all times during transport, assembly, dismantling, operation, maintenance and servicing.
● The outside of the gear unit must not be cleaned using high-pressure cleaning equipment.
● No welding work must be performed on the gear unit or on parts connected to it. The gear
unit and any parts connected to it must not be used as an earthing point for electric-welding
operations. Gearing and rolling-contact bearings might be irreparably damaged by welding.
● Perform potential equalisation in accordance with the applicable regulations and guidelines.
If no threaded holes are available on the gear unit for an earth connection, please take
suitable measures. This work must always be done by specialist electricians.
● In the case of gear units that are operated in combination with electrical machines that
generate current or through which current flows (e.g. motors and generators), take
measures to ensure that no current can flow through the gear unit.
Current flowing through the gear unit can result in irreparable damage to rolling-contact
bearings and gearing. Short circuits, voltage flashovers and deposits of conductive dust,
for example, can all allow current to flow.
Use insulators and earth the gear unit properly.
● When removing any protective devices, retain their fixings safely.
● Removed protective devices must be re-fitted prior to starting up.
Safety instructions
2.6 Intended use
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● Pay attention to the notices attached to the gear unit such as the rating plate, direction
arrow symbol etc. Notices must not be concealed by paint or dirt. Replace missing plates.
● Bolts which have been damaged during assembly or disassembly work must be replaced
with new ones of the same strength class and type.
DANGER
Danger to life due to live system
Death or serious injury will occur.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Secure the drive unit against being operated
accidentally as follows:
● Turn off the key-operated switch.
● Remove the fuses in the power supply.
● Attach a notice to the start switch, clearly stating that work is being carried out on the gear
unit.
Ensure that the entire unit is load-free so that no danger is posed when you start to dismantle
components.
Reactivating the gear unit
When installing the gear unit in machines or systems, the machine or system manufacturers
must ensure that the regulations, notes and descriptions contained in these operating
instructions are incorporated in their own operating instructions.
Safety instructions
2.6 Intended use
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