Sumitomo Drive Technologies VP2500L User manual

User Manual
VP2500L
Hansen Industrial Transmissions nv UM_VP2500L

Copyright and contact data
Copyright Sumitomo Drive Technologies
This document or parts thereof may not be reproduced, stored in a retrieval system, nor
transmitted, in any form nor by any means, electronic, mechanical, photocopying, recording, nor
otherwise, without the prior written permission of Sumitomo Drive Technologies.
This document could contain technical inaccuracies or typographical errors. Sumitomo Drive
Technologies reserves the right to revise the content of this document from time to time without the
obligation of Sumitomo Drive Technologies to notify any person of such revision or change.
Details and values given in this document are average values and have been compiled with
care. They are not binding, however, and Sumitomo Drive Technologies disclaims any liability for
damage or detriments suffered as a result of reliance on the information given herein or the use of
products, processes or equipment to which this document refers. No warranty is made that the use
of the information or of the products, processes or equipment to which this document refers will not
infringe any third party's patents or rights. The information given does not release the user from
making their own experiments and tests.
Contact data
www.sumitomodrive.com
Hansen Industrial Gearbox Services
Terelststraat 208
BE-2650 Edegem
Belgium
E-mail: [email protected]
24/7 SERVICE HOTLINE
Tel.: [phone]
2

Contents
1 Manual Disclaimer................................................................................... 5
2 About this document................................................................................ 6
2.1 Function of the document............................................................................................................ 6
2.2 Language.....................................................................................................................................6
2.3 Illustrations...................................................................................................................................6
2.4 Use of steps, lists and titles in this document.............................................................................. 6
2.5 How to use this document............................................................................................................6
2.6 Warnings, cautions and notes used in the document.................................................................. 6
2.7 Related documents......................................................................................................................7
2.8 Storage of this document and the related documents................................................................. 7
2.9 Abbreviations............................................................................................................................... 7
2.10 Customer support........................................................................................................................ 7
3 Description............................................................................................... 8
3.1 Intended use................................................................................................................................ 8
3.2 Overview and function of the device............................................................................................8
3.3 Working principle......................................................................................................................... 9
3.4 Overview of the controls............................................................................................................ 10
3.5 Overview of the connections......................................................................................................11
3.6 Type plate.................................................................................................................................. 12
4 Safety.....................................................................................................13
4.1 Restrictions................................................................................................................................ 13
4.2 Approved user............................................................................................................................13
4.3 General safety instructions........................................................................................................ 13
4.4 Safety instructions for installation.............................................................................................. 13
4.5 Safety instructions for use with gear units................................................................................. 14
4.6 Safety instructions for use with hydraulic systems.....................................................................14
4.7 Safety labels.............................................................................................................................. 14
4.8 Instructions in case of a fire....................................................................................................... 14
4.9 Warranty.................................................................................................................................... 15
4.10 Disposal..................................................................................................................................... 15
5 Storage and transport............................................................................ 16
5.1 Storage...................................................................................................................................... 16
5.2 Off-site transport........................................................................................................................ 16
5.3 On-site transport........................................................................................................................ 16
6 Installation..............................................................................................18
6.1 Installation - general instructions............................................................................................... 18
6.2 Remove the packaging material................................................................................................ 18
6.3 Connect the device.................................................................................................................... 18
6.3.1 Connect the suction hose to the device..................................................................... 19
6.3.2 Connect the return hose to the device....................................................................... 19
6.3.3 Connect the suction hose to the gear unit or the hydraulic system........................... 19
Contents
UM_VP2500L_002_EN 3

6.3.4 Connect the return hose to the gear unit or the hydraulic system............................. 21
6.3.5 Install the wear indicator sensor................................................................................ 22
6.3.6 Install the water saturation - oil temperature sensor.................................................. 23
7 Commissioning...................................................................................... 24
7.1 Use the device - general instructions.........................................................................................24
7.2 Commissioning.......................................................................................................................... 24
8 Operation............................................................................................... 25
8.1 Start the device..........................................................................................................................25
8.2 Stop the device.......................................................................................................................... 25
8.3 Get an oil sample.......................................................................................................................25
8.4 Drain the oil from the device...................................................................................................... 26
9 Maintenance.......................................................................................... 27
9.1 General maintenance instructions............................................................................................. 27
9.1.1 Limits..........................................................................................................................27
9.1.2 Approved work and not approved work..................................................................... 27
9.2 Change the filter.........................................................................................................................27
9.2.1 Remove the filter........................................................................................................27
9.2.2 Install the filter............................................................................................................28
9.3 Cleaning schedule..................................................................................................................... 28
9.4 Clean the device........................................................................................................................ 28
9.5 Clean the wear indicator sensor................................................................................................ 29
10 Technical data........................................................................................30
10.1 Device specifications................................................................................................................. 30
10.2 Dimensions................................................................................................................................ 30
10.3 Oil specifications........................................................................................................................31
10.4 Ambient conditions.....................................................................................................................31
10.5 Connection set specifications.................................................................................................... 31
10.6 Torque values for the connection set.........................................................................................31
10.7 Spare parts................................................................................................................................ 32
10.8 Oil sample equipment................................................................................................................ 32
11 Services................................................................................................. 33
Contents
4UM_VP2500L_002_EN

Manual Disclaimer
This Manual and its instructions and information do not purport to cover all details or
variations of the device and do not claim to provide for every possible contingency
met in connection with handling, installation, operation, or maintenance. Sumitomo Drive
Technologies does not make any representations, warranties or guarantees, express
or implied, as to the accuracy or completeness of the Manual. Users must be aware
that updates and amendments will be made from time to time to the Manual. It is
the user’s responsibility to determine whether there have been any such updates or
amendments. Neither Sumitomo Drive Technologies nor any of its directors, officers,
employees or agents shall be liable in contract, tort or in any other manner whatsoever to
any person for any loss, damage, injury, liability, cost or expense of any nature, including
without limitation incidental, special, direct or consequential damages arising out of or in
connection with the use of the Manual. The user and/or purchaser bears all risks. Should
further information be desired or should particular problems arise which are not covered
sufficiently for the users’ and/or purchaser’s purposes, the matter should be referred to in
writing to Sumitomo Drive Technologies.
Warning: Read and understand all instructions and information prior to any
handling including maintenance, installing or starting the device. Failure to
follow instructions could lead to damage, serious injury, or death.
• Only qualified and trained personnel should be involved with the storage (including
transport), commissioning, operation, installation (including removal), inspection,
maintenance and repairs of this device.
• Make sure all your personnel and operators of this device have been professionally
and adequately trained for safe working practices.
• Operators must wear adequate personal protective equipment.
• Ensure all international, EU, national and local safety regulations and codes are
followed when handling, maintaining, installing (including all related actions) the
device.
• Verify the compatibility of the device with the installation it is meant for.
1
Manual Disclaimer
UM_VP2500L_002_EN 5

About this document
Function of the document
The document is only applicable for the "VP2500L", from here on in the document
referred to as the device.
The document is for approved users and gives the information that is necessary to do
these tasks:
• Installation
• Commissioning
• Operation
• Maintenance
Language
The original instructions of this document are in English. All other language versions are
translations of the original instructions.
If there is any doubt, the English version of the document is binding.
Illustrations
It is not always possible to show the configuration of your device as in the certified
drawing. The illustrations in this document show a typical setup. They are for instruction
or description only.
Use of steps, lists and titles in this document
• The steps in procedures have numbers (123) if the sequence is important.
• The lists and steps with bullets (•) are used if the sequence is not important.
• The lists with letters (abc) are used if the sequence is important.
How to use this document
Procedure
1. Make sure that you know the structure and the contents of the related documents.
2. Read the safety chapter and make sure that you know all the instructions.
3. Do the steps in the procedures fully and in the correct sequence.
Warnings, cautions and notes used in the document
Symbol Type Description
Warning If you do not follow the instruction, this can cause injury.
2
2.1
2.2
2.3
2.4
2.5
2.6
About this document
6UM_VP2500L_002_EN

Symbol Type Description
Caution If you do not follow the instruction, this can cause dam-
age to the device or to property.
Note A note gives more data.
Related documents
Document name Target audience
User Manual LM2 Gears CMS Approved users
Storage of this document and the related documents
This document and the related documents are a part of the device.
• Make sure that you keep the document and the related documents in a dry and clean
location.
• Make sure that the document and the related documents are available to all
personnel.
Abbreviations
Abbreviation Description
S.D.T. Sumitomo Drive Technologies
CMS Condition Monitoring System
Customer support
• If more information is necessary, speak to S.D.T.
• Give the serial number to S.D.T. Refer to the type plate.
2.7
2.8
2.9
2.10
About this document
UM_VP2500L_002_EN 7

Description
Intended use
Only use the device to move oil through a manifold with sensors as specified in this
document. Do not use the device for other applications.
Overview and function of the device
H
G
B
A
D
E
F
C
ASwitch box
BElectric motor
COil pump
DSample point
EManifold
FFilter
GLM2 Gears CMS
HSensors
Part Function
Switch box To control the electric motor.
Electric motor To operate the oil pump
Oil pump To move the oil through the device
3
3.1
3.2
Description
8UM_VP2500L_002_EN

Part Function
Sample point To get an oil sample
Manifold To hold the sensors
Filter To clean the oil.
LM2 Gears CMS To remotely monitor the condition of the oil. For
more information on the LM2 Gears CMS, refer
to the user manual of the LM2 Gears CMS.
Sensors To measure the condition of the oil. For more
information on the sensors, refer to the user
manual of the LM2 Gears CMS.
Note:
• The LM2 Gears CMS and the sensors are not part of the device and are
available separately.
• To connect the device to a power socket, a cable with a European
connection (DIN 49440-1, 2006) is provided. Use an adapter if your
connection is different.
Working principle
F
G
B
A
D
E
C
The switch box (A) controls the electric motor (B). The electric motor drives the oil pump
(C). The oil pump moves the oil through the manifold (D) and the filter (E). The manifold
contains sensors (F) that are connected to the LM2 Gears CMS (G) to monitor the
condition of the oil.
3.3
Description
UM_VP2500L_002_EN 9

Overview of the controls
A
B
C
AStart button
BStop button
CManometers for the saturation of the filter
Control Function
Start button To start the device
Stop button To stop the device
Manometers for the saturation of the filter To show the saturation of the fillter.
• During correct operation, the difference in
pressure between the two manometers must
be less than 1 bar.
• When the difference in pressure is 1 bar
or more, change the filter. Refer to section
Change the filter on page 27.
3.4
Description
10 UM_VP2500L_002_EN

Overview of the connections
C
D
BA
AOil inlet
BOil outlet
CPosition for the wear indicator sensor
DPosition for the water saturation - oil temperature sensor
Connection Function
Oil inlet To let oil into the device
Oil outlet To move oil from the device
Position for the wear indicator sensor To hold the wear indicator sensor
Position for the water saturation - oil tempera-
ture sensor
To hold the water saturation - oil temperature
sensor
3.5
Description
UM_VP2500L_002_EN 11

Type plate
The type plate gives information about the device.
TYPE
S/N
Year
Power Supply VAC
TYPETYPE
Hz
A
C
B
D
ADevice type
BSerial number
CYear of production
DDevice power supply
3.6
Description
12 UM_VP2500L_002_EN

Safety
Restrictions
Warning: If you use the device in ways other than described in the related
documents, this may result in injury, death, or property and equipment
damage. Use the device only as described in the related documents.
S.D.T. cannot be held responsible for injuries or damages resulting from non-standard,
unintended use of the device. The device is designed and intended only for the purpose
described in the related documents.
Unintended use includes these actions:
• Making changes to the device that have not been recommended in the related
documents.
• Use of parts that are not replacement parts or accessories from S.D.T.
• Use of materials or equipment that are inappropriate or incompatible with the device.
• Use of lubrication oil that is not indicated in the specifications in this document.
• Use of the device in a hazardous (explosive) environment where ATEX guidelines and
other guidelines about explosion free conditions are applicable.
• Use of the device when it shows signs of damage.
• Allowing unapproved personnel to perform any task on or with the device.
Approved user
The term approved user is specified here as a person that fully knows the device and its
safe operation. Approved users obey all related safety regulations and are approved to
safely install, remove, operate, and do maintenance on the device.
It is the responsibility of the company that owns the system where the device and the
gear unit or the hydraulic system are part of to make sure that all users of the device obey
these requirements.
General safety instructions
• If a part of the device shows damage, do not use the device.
• When you do work on or with the device, obey all legislation and regulations that apply
to safety and work requirements, that apply in the country and at the location where
you do work on or with the device.
• Obey the safety instructions of the manufacturer of the lubrication oil. Refer to the
material data sheets of the lubrication oil. Make sure that all personnel that use
lubrication oil receive these safety instructions.
• De-energize the device before you do work on the device.
• When you do work on or with the device, the device must be on a stable surface.
• When you do work on or with the device, make sure that the complete area and the
device are sufficiently lighted.
Safety instructions for installation
• Make sure that the personnel that install the device are approved and obey state-of-
the-art safety procedures.
4
4.1
4.2
4.3
4.4
Safety
UM_VP2500L_002_EN 13

• Obey the European Directives 2006/42/EG and the local safety regulations.
• Make sure that the motor that operates the device is de-energized. Make sure that the
motor cannot be energized during the installation of the device parts.
• If safety devices are removed for installation or maintenance, make sure they are
correctly installed again before you operate the device.
• Do not touch parts of the device that move.
Safety instructions for use with gear units
• Make sure that no oil can come out of the gear unit.
Note: S.D.T. recommends that you install a drain valve to make it easier to
disconnect and connect the device.
• Use high-quality hoses with the correct internal diameter.
Note: S.D.T. supplies hoses with the device that obey the requirements of
the gear unit or hydraulic system that you use. If you must use hoses with
different specifications, speak to S.D.T.
• Obey the regulations that apply to the power connection.
• The device can be hot. If it is necessary to touch the device, wear protective clothing
and safety gloves or make sure that its temperature is decreased sufficiently.
Safety instructions for use with hydraulic systems
• Before you use the device with a hydraulic system, make sure that the system is
pressure-free and that no oil can come out of the system.
• Use high-quality hoses with the correct internal diameter.
Note: S.D.T. supplies hoses with the device that obey the requirements of
the gear unit or hydraulic system that you use. If you must use hoses with
different specifications, speak to S.D.T.
• Obey the regulations that apply to the power connection.
• The device can be hot. If it is necessary to touch the device, wear protective clothing
and safety gloves or make sure that its temperature is decreased sufficiently.
Safety labels
Label Description
Risk of hot surface
Instructions in case of a fire
Warning: After a fire, protective clothing and respiratory equipment are
mandatory to handle the device. The device can contain dangerous
substances that cause injury when you touch or breathe them.
4.5
4.6
4.7
4.8
Safety
14 UM_VP2500L_002_EN

• Use a carbon dioxide extinguisher to extinguish a fire.
Warning:
• Use caution when you use a carbon dioxide extinghuiser. Low
temperatures of the nozzle can cause injury.
• Do not use a carbon dioxide extinghuisher in small spaces. Injury or
death can occur as a result of a low level of oxygen.
• In case of a large fire, call the emergency services.
• Do not start a device that has burn marks. Speak to S.D.T.
Warranty
The warranty clause of the general conditions of sale applies to devices used as per
instructions contained in this document, including the related documents, and in any
additional instruction leaflets supplied with the device insofar as the device operates
within the service and rating conditions put forward in the order acknowledgment.
Non compliance with these instructions, injudicious choice of lubrication oil or a lack of
maintenance will render warranty agreement invalid.
This warranty clause applies to all parts of the device with the exception of those parts
which are subject to wear.
Disposal
• When you discard the device or the components of the device, obey the local
environmental regulations.
• At the end of the service life of the device or the components of the device, try to
recycle to prevent environmental pollution.
• Obey the local environmental regulations when you discard used
oil. Do not put it on garden soil, wooded areas, in streams or in
sewage drains.
• Remove spilled oil immediately.
• Sort metal and electrical components correctly. Make sure that
these components are recycled.
• Obey the environmental regulations to discard materials that you
cannot recycle.
4.9
4.10
Safety
UM_VP2500L_002_EN 15

Storage and transport
Storage
The storage period starts when the device is not used.
Before storage:
• Drain the oil from the device. Refer to section Drain the oil from the device on page
26.
• Clean the wear indicator sensor. Refer to section Clean the wear indicator sensor on
page 29.
During storage:
• The ambient conditions for storage must be correct. Refer to section Ambient
conditions on page 31.
• Prevent damage to and/or deformation of the device.
Off-site transport
Caution: Prevent vibration of the device. Vibration can cause damage to the
components of the device.
• Move the device carefully to prevent damage to the device and its components.
• The device must be stable during transport.
• Secure the device to a surface to prevent unwanted movement of the device.
On-site transport
Warning: Let the device cool down before you lift the device. The device can
be hot.
Caution:
• Remove the LM2 Gears CMS unit before you transport the device. The
LM2 Gears CMS can fall from the device during transport.
Note: The LM2 Gears CMS unit is installed with magnets.
• Only install the LM2 Gears CMS unit when the device is in its final
operation position. To install the LM2 Gears CMS unit on the device, refer
to the user manual of the LM2 Gears CMS.
• Only lift the device at the frame. If you lift the device at the components on
the frame, damage to these components can occur.
5
5.1
5.2
5.3
Storage and transport
16 UM_VP2500L_002_EN

Procedure
1. Lift the device with the handle (A) at
the top of the frame.
If necessary, support the device at the
bottom of the frame.
A
Storage and transport
UM_VP2500L_002_EN 17

Installation
Installation - general instructions
• Put the device as close as possible to the gear unit or the hydraulic system.
Caution: Do not put the device above the oil level of the gear unit of the
hydraulic system. This can cause under-pressure at the suction side of the
pump.
• The device must be stable and easy to access.
• Use high-quality hoses that meet these requirements:
• The hoses must be a short as possible.
• The hoses must have the correct internal diameter.
Note: S.D.T. supplies hoses with the device that obey the requirements of
the gear unit or hydraulic system that you use. If you must use hoses with
different specifications, speak to S.D.T.
• Make sure that no oil can come out of the gear unit or the hydraulic system when you
connect the device:
• If the gear unit or hydraulic system has a drain valve, close the drain valve.
• If the gear unit or hydraulic system does not have a drain valve, drain the oil from
the gear unit or the hydraulic system. Do not discard the oil.
• Replace all the magnetic plugs on the gear unit or the hydraulic system with non-
magnetic plugs.
• Only install the LM2 Gears CMS unit when the device is in its final operation position.
Remove the packaging material
Procedure
1. Do a check for damage to the package.
2. If you see damage, speak to S.D.T. immediately.
3. Remove the packaging material.
4. Do a check for damage to the device.
5. If you see damage, speak to S.D.T. immediately.
6. Do a check if the device agrees with the shipping papers.
7. If the device does not agree with your order, speak to S.D.T. immediately.
Connect the device
Note: Before you connect the device, refer to the general instructions in
section Installation - general instructions on page 18.
6
6.1
6.2
6.3
Installation
18 UM_VP2500L_002_EN

Connect the suction hose to the device
Procedure
1. Connect the suction hose (A) to the oil
inlet (B).
Make sure that the plug is removed
from the oil inlet.
2. Turn the nut (C) clockwise to tighten
the suction hose to the oil inlet.
Connect the return hose to the device
Procedure
1. Connect the return hose (A) to the oil
outlet (B).
Make sure that the plug is removed
from the oil outlet.
2. Turn the nut (C) clockwise to tighten
the return hose to the oil outlet.
Connect the suction hose to the gear unit or the hydraulic system
Note:
• Install a drain valve on the gear unit or the hydraulic system to make it
easier to disconnect and connect the device.
• A connection set is required to connect the suction hose. For information,
refer to section Connection set specifications on page 31.
Remove the drain plug
Procedure
1. Remove the drain plug and the seal from the gear unit or the hydraulic system. Do
not discard the drain plug and the seal.
6.3.1
BC
A
6.3.2
BC
A
6.3.3
Installation
UM_VP2500L_002_EN 19

Install the connection part
Procedure
1. Install the connection part (A) and the
seal (B) in the hole of the drain plug.
Use a torque wrench to torque the
connection part to the correct value.
For the torque values for the different
connection parts, refer to section
Torque values for the connection set
on page 31.
Install the drain plug
Procedure
1. Install the drain plug (A) and the seal
(B) on the connection part.
• Use the drain plug and the seal
that you removed from gear unit or
the hydraulic system. If necessary,
replace the seal.
• If the drain plug that you removed
from gear unit or the hydraulic
system is magnetic, replace it with
a non-magnetic drain plug.
Install the plug and the nipple
Procedure
1. Install the plug (A) and the nipple (B).
Use applicable sealant on the threads
of the nipple on the side that you install
into the connection part.
A
B
A
B
AB
Installation
20 UM_VP2500L_002_EN