FLOTAX FC 1. TABLE OF CONTENT FLOTAX FC. Installation & Maintenance Manual ATEX UNIT SHIPPED WITHOUT OIL

Transcription

1 ATEX UNIT SHIPPED WITHOUT OIL 1. TABLE OF CONTENT 1. Table of content Scope Sipping Maintenance Installation Mounting position Torque arm assembly Mounting te gearbox Lubrication Oil level Oil quantities Oil quality Filling and draining Backstops Backstop assembly (for unit type FC116) Backstop assembly (for units type FC216 to FC324) Backstop assembly (for units type FC622, FC714 and FC822) Backstop assembly (for oter types of gear units) Motor base mounting Gear units type FC116, FC216, FC316 and FC Page 1 / 18

2 8.2. Gear units type FC414 to FC Grounding Gear unit cleaning Use in azardous areas Monitoring devices connections Control periodicity for use in azardous areas Used materials Marking of units for azardous areas Starting-up Malfunction and remedies Lubricants SCOPE Tis manual contains te operating, lubrication and maintenance instructions relative to te FLOTAX Gear Units. 3. SHIPPING Te FLOTAX gearboxes are sipped witout oil. Neverteless, te grease lubricated bearings are provided wit grease for life. Te torque arm is delivered separately. Te filling, draining or cecking plugs are adapted for te A position (See capter 5 - Installation page 2). 4. MAINTENANCE Maintenance is limited to te control of te oil level and te normal replacement of te lubricant. Replace te first oil after 800 effective operating ours. Tis oil could be re-used after ad adapted filtering (40 µm filter). Ten, renew oil after 8000 ours of service, witout tis period exceeding 2 years. CAUTION: Tese intervals of control do not apply if te reducer functions in explosive environment. See paragrap 11 «Use in azardous areas». Ceck te direction of rotation of te reducers wit backstop 5. INSTALLATION 5.1. MOUNTING POSITION If mounting position is not specified at order, Gear Units are delivered to be used in mounting position A. Ceck te mounting position of te reducer. For usual positions see Figure 1 and Figure 2. Te plugs locations must in accordance wit angular deviations indicated in te 1 & 2. Te reducers wit backstop can only be used in positions A (wit reduced angular deviation), C & D. Page 2 / 18

3 For oter mounting position ; refer to us. Cange te ventilation and drain plugs according to te selected position of assembly. According to te great number of possible combinations of position, of speed and direction of rotation, it can be necessary to add standard piping or pipes in order to protect te ventilation plug against te oil projection. Figure 1: Mounting positions WITHOUT backstop Figure 2: Mounting positions WITH backstop * : Mounting position B impossible for units wit backstop ** : Oil Level Plug for sizes and positions sowing one. For oter cases, refer to Oil Quantities sown on Tableau 2 *** : Tis position must be advised on order for adaptation of unit in Factory TORQUE ARM ASSEMBLY Te torque arm must always work in traction. In case of two directions of rotation, two torque arms must be used. For sizes 414 to 822, it is necessary to dismount te assembling-bolt of te two alf-ousings to assemble te torque arm between tese two alf-ousings. Reassemble te bolt wit a tigtening torque indicated in Tableau 1. Important :Never remove simultaneously more tan 2 assembling bolts. Assemble te torque arm in order tat it forms practically a rigt angle wit te axis passing troug te low speed saft and te assembly bolt connecting te ousing wit te torque arm (see Figure 3). Page 3 / 18

4 Type FC414 FC422 FC514 FC522 FC614 FC622 FC714 FC722 FC814 FC822 T (Nm) Tableau 1: Tigtening torques Te axis of te fixed point of te torque arm must be parallel wit te axis of te reducer. Te torque arm must be assembled witout any stress. Te support of te fixed point of te torque arm sould not generate any stress oter tan te torque of te reducer. Te stiffness of te support of te fixed point must be enoug to ensure te absence of stress during assembly and operation. Figure 3: Assembly positions of torque arms 5.3. MOUNTING THE GEARBOX Te reducer must be fitted on te macine saft wit te minimum overang. Te recommended tolerance of te saft is j6, wic allows a loose fit wit te ollow saft provided wit H7 tolerance Mounting Te unit is directly mounted on te driven saft by means of a treaded stud (a), a nut (b) and if necessary a spacer (c) olding on a waser (d) supplied wit te unit. Before mounting te unit, coat te macine saft (e) wit a tin layer of oil or molybdenum disulpide grease. d a b c e Figure 4: Mounting te gear unit Securing After mounting te unit on te saft, te treaded stud (a) is replaced by a bolt (f) in order to block te gearbox on te macine saft. Wen te driven saft as no collar, an intermediate sleeve (k) is used, its lengt depending on te position of te gear unit on te saft. Page 4 / 18

5 d k f Figure 5: Securing of ollow saft Removal Remove bolt (f), retaining plate (d) and circlip (g). Insert trust plate (j) to protect te saft treaded ole. Introduce removal tool () and replace circlip (g). Turn bolt till it puses against macine saft, furter turning will gradually pull gearbox from saft. Note: Removal tool kit composed of disc, bolt and trust plate is not part of te supply but can be ordered separately. g j Figure 6: Removal of gear unit Mounting of te V-Belt drive Mount te pulley as close as possible of te retaining soulder of ig speed saft. Te V-belt can be assembled in any direction. However, if one wants to use te torque arm to regulate te tension of te belts, te motor must be located in opposite direction of te torque arm. A protection guard or safety equipment in conformity wit te industrial legislation in te country were is installed te gear unit must be supplied by te user or delivered on request. Tis device must be designed to prevent te product accumulation on te drive unit and as well to allow an easy cleaning. 6. LUBRICATION Te oil level is indicated by an overflow plug. Its position depends on te mounting position of te reducer (see figures page 2). Page 5 / 18

6 Overflow Plugs Overflow Plug Figure 7: Overflow plugs identification For sizes 414 to 822 in mounting position A, a special system of overflow is used in bottom of te reducer. It consists of a plug including a tube penetrating inside te reducer to determine te oil level. Te overflow plug is screwed in tis tube. For te oter mounting positions te overflow system consists in a standard plug screwed in te ousing as sown on Figure 1: Mounting positions WITHOUT backstop and Figure 2: Mounting positions WITH backstop page 3. If mounting position is not indicated at order, Gear Units are supplied to be mounted in Position A. for use in mounting position B or C, plugs must be moved as described in 5.1 Mounting position page 2. If unit size 414 to 822 is not equipped wit an overflow plug wit tube as sown on Figure 7: Overflow plugs identification above oil levels must be adjusted as per Tableau 2: Oil quantities in liters page 7. For usage in position D, te gear units must be ordered mentioning teir use in tis position OIL LEVEL For sizes 116 to 324, oil level is defined by an overflow plug. Its location depends on te assembly position of te gear unit (see figures page 3). If gear unit is inclined, te upper overflow plug is to be used Page 6 / 18

7 Figure 8: Overflow plugs FC 116 to 324 For sizes 414 to 822, fill te gear unit wit quantities stated on Tableau 2 page OIL QUANTITIES Tableau 2 Gives required oil quantities in liters POS. FC116* FC216* FC316* FC324* FC414 FC422 FC514 FC522 FC614 FC622 FC714 FC722 FC814 FC822 A 0.7* 1.3* 2.1* B 0.9* 1.6* 2.7* C 1.0* 1.7* 2.8* D 1.3* 2.5* 4.2* Tableau 2: Oil quantities in liters * : For sizes 116 to 324, oil quantities are indicative only. Unit must be filled up to te overflow plug determining te actual oil level (See 6.1 page 6) 6.3. OIL QUALITY Mineral oils wit extreme pressure additives must be used. Te lubricant must also contain additives preventing te foam formation; it must include an anti-corrosion agent and resist oxidation under ig temperatures. Te oil viscosity given on te nameplate is referred to ambient temperatures between 0 and 30 C. For oter operating conditions, refer to Tableau 3 Ambient Temp. mm²/ s / 40 C AGMA E / 50 C SSU / 100 F C ISO VG EP 11, C ISO VG EP 24, Tableau 3: Oil viscosity 6.4. FILLING AND DRAINING Fill te gearbox in operating position. Remove te overflow plug as well as te filling plug and breater. Fill te gearbox up to te level of te overflow pipe. Drain wile te reducer is still ot. Te operation is facilitated by removing te filling plug. Page 7 / 18

8 7. BACKSTOPS For te reducers equipped wit a backstop, ceck if te direction of rotation of te motor is in accordance to te direction of free rotation of te backstop before starting BACKSTOP ASSEMBLY (FOR UNIT TYPE FC116) Backstop is integrated to bearing tat is opposite to te ig speed saft. Direction of rotation is not modifiable and must be specified at order BACKSTOP ASSEMBLY (FOR UNITS TYPE FC216 TO FC324) Tese instructions refer to Figure 9 page 8 Drain oil from te gear unit before starting assembly of te backstop. Remove cover opposite to ig speed saft 1405 and its screws Clean mating surfaces on gear unit ousing. Ceck orientation of te backstop rollers is adequate for te required direction of rotation. If it need to be inverted, remove snap ring 5425 and turn backstop element Mount cover 1425 wit paper gasket Fit screws Fill te unit wit oil (See 6 - Lubrication page 5). Figure 9: Backstop assembly FC 216 to BACKSTOP ASSEMBLY (FOR UNITS TYPE FC622, FC714 AND FC822) Tese instructions refer to Figure 10 page 9 Drain oil from te gear unit before starting assembly of te backstop. Remove cover opposite to ig speed saft 1405 and its screws Clean mating surfaces on gear unit ousing. Fit trust waser Mount key 4144 and ten inner busing 7403 eated at 100 C (212 F). Ceck tat inner busing is rigt against te inner ring of bearing. Let inner bus cool down. Fit O'Ring 8825 in its groove on cover Fit in place backstop element 7400 taking care tat rollers will allow rotation in te required direction Mount cover 1425 wit screws 1425 supplied wit backstop. Page 8 / 18

9 Fill te unit wit oil (See 6 - Lubrication page 5). Figure 10: Backstop assembly FC 622, 714 and BACKSTOP ASSEMBLY (FOR OTHER TYPES OF GEAR UNITS) Tese instructions refer to Figure 11 page 10 Drain oil from te gear unit before starting assembly of te backstop. Remove cover opposite to ig speed saft 1405 and its screws Clean mating surfaces on gear unit ousing. Fit trust waser Fit O'Ring 8825 in its groove on cover Fit in place backstop element 7400 taking care tat rollers will allow rotation in te required direction Mount cover 1425 wit screws 1425 supplied wit backstop. Fill te unit wit oil (See 6 - Lubrication page 5). Page 9 / 18

10 Figure 11: Backstop assembly FC 414 / 422 / 514 / 522 / 614 / 722 / MOTOR BASE MOUNTING 8.1. GEAR UNITS TYPE FC116, FC216, FC316 AND FC324 Dismount te upper cover of te ousing (Figure 12), and replace it by te support cover (pos. 1). Remove te filling plug and install a standard piping to make te filling plug accessible (pos. 2). Mount te reducer on te macine saft and fix te torque arm as indicated in paragrap 5.2. Screw te 4 treaded rods (pos. 4) in nuts welded onto te base plate (pos. 5) and fix it using locking-nuts (pos. 6). Screw 4 nuts (pos. 7) on eac rod. Put te base plate on te support cover (pos. 1) and fix it wit nuts (pos. 8) in its lowest position. Mount te pulleys on te motor and reducer safts as close as possible to te collars. Mount te motor on te base plate and ceck te alignment of te pulleys. Adjust te position of one of te pulleys if necessary. Assemble te V-belts and adjust te distance between axis of motor and reducer safts by using te nuts on four rods. To raise te motor, loosen te nuts (pos. 8) and tigten te nuts (pos. 7) alternately in order to get te rigt belt tension. Tigten te nuts (pos.8 ) Ensure te tigtening of eac bolts and nuts. Page 10 / 18

11 Figure 12: Motor base assembly on units type FC116 to GEAR UNITS TYPE FC414 TO FC822 Important : Never remove more tan 2 assembling-bolts of te ousing at te same time. Reassemble te bolts wit te necessary tigtening torque (Tableau 1 page 4). Determine te mounting position of te motor base (Figure 14). Dismount two assembling-bolts of te ousing and assemble te front and back supports using longer bolts (pos. 3) wic are delivered wit te motor. For sizes 300, 500 and 800, original bolts are used. Remove te filling plug and install a standard piping to make filling plug and breater accessible (Figure 15). Mount te reducer on te macine saft and fix te torque arm as indicated in paragrap 5.2. Screw te 4 adjustment rods (pos. 4) in nuts welded onto te base plate (pos. 5) and fix it using counter-nuts (pos. 6) Screw 4 nuts (pos. 7) on rods. Put te base plate on front and back supports and fix it wit nuts (pos. 8) in its lowest position. Mount te pulleys on te motor and reducer safts as close as possible to te collars. Mount te motor on te base plate and ceck te alignment of te pulleys. Adjust te position of one of te pulleys if necessary. Assemble te V-belts and adjust te distance between axis of motor and reducer safts by using te nuts on four rods. To raise te motor, loosen te nuts (pos. 8) and tigten te nuts (pos. 7) alternately in order to get te rigt belt tension. Tigten te nuts (pos. 8) Ensure te tigtening of eac bolts and nuts. Page 11 / 18

12 Figure 13: Motor base assembly FC 414 to 822 Figure 14: Assembly position of motor base Figure 15: Fitting of relocated breating plug 9. GROUNDING Te gearbox or saft on wic it is mounted must be ground connected. 10. GEAR UNIT CLEANING Do not use pressure cleaner on direct jet on te sealing rings. Do not use aggressive solvent able to corrupt paint or oil seals. 11. USE IN HAZARDOUS AREAS Indications & instructions about te use in azardous areas. Page 12 / 18

13 IMPORTANT : a unit tat is not marked according to paragrap 11.4 must not be used in azardous areas MONITORING DEVICES CONNECTIONS Te PT100 sensor provided wit te gear unit is a 3-wire type : Red Red PT100 sensor Figure 16: Location of te PT100 sensor Wite Figure 17: Wiring of te PT100 sensor Te monitoring devices must be connected and te information given by tese devices must be treated in order to ensure te surfaces temperatures indicated on te nameplate. Te monitoring and control devices provided by te user ave to ensure an immediate stop of te installation in case of te surfaces temperatures indicated on te nameplate will be reaced. Tat is saying: 120 C / 248 F for operation in dust ambiance. 135 C / 275 F for operation in gas ambiance.. Te surfaces temperatures indicated on te nameplate are stopping values. Te monitoring and control device ave to manage te gearbox temperature and point out any increase compare to te usual operation temperature. Any unusual temperature increase must launc an inspection of te gearbox even if te temperature stays below te limit. Page 13 / 18

14 11.2.CONTROL PERIODICITY FOR USE IN HAZARDOUS AREAS Explosion group II 2D 120 C II 2G T4 Control periodicity Te first oil level ceck must be done after 100 ours of operation or one mont at te latest. If tere is no oil leakages or level drop te first oil cange will be done after 700 ours of operation. Te following ceck must be done every 2000 ours of operation or tree monts at te latest. Te following oil cange will be made every 4000 ours of operation or one year maximum. If some oil leakages or level drop ave been noticed an oil cange and a researc of te cause will be done as described in te capter «Malfunction and remedies». In dust ambiance te non-accumulation of dust or product on te gearbox must be inspected at every oil ceck. Te cleaning must be done and te gear unit protection must be provided. Te control periodicity must be started again in case of any modification of operating conditions. CAUTION: To ensure a long and safe operating life in azardous ambiance te gearbox mounting on te macine saft and te torque arm must be carefully cecked. If te values given at capter 5.2 are not respected te gearbox must be consider as damaged and replaced USED MATERIALS Material for ousings: EN-GJL-250 (formerly FGL250). Material for safts: Steel 11.4.MARKING OF UNITS FOR HAZARDOUS AREAS Gear units for use in azardous areas are marked: II 2 D 120 C II 2 G T4 Figure 18: Location of ATEX marking 11.5.STARTING-UP Before starting-up te tigtening of te setscrew (in case of use) and/or te axial blocking screw on macine saft must be cecked. Te angular position and te free-stress mounting of te torque arm must be cecked. Ceck te tigtening of te torque arm bolts. Page 14 / 18

15 In azardous ambiance te bolts and screws must be protected from any possible loosening off, for instance, by te application of a treadlock product to te treads MALFUNCTION AND REMEDIES Malfunction Cause Risk information in azardous areas Solution Noise and vibration wen Torque arm Danger of ignition by 1) Stop te macine. in operation misalignment sparks 2) Eliminate te cause of misalignment (loosing of fastening screw, attacment break, termal expansion, non-respect of parts dimensions, support deflection on load). 3) Ceck te wear of te parts and replace it if necessary. 4) Verify te torque arm alignment at rest and in operation and correct it if necessary. Noise and vibration wen Loosening of Danger of ignition by 1) Stop te macine. in operation torque arm bolt sparks 2) Ceck te wear of te parts and replace it if necessary. 3) Refit te torque arm. 4) Secure te torque arm bolts by using waser or glue. 5) Verify te torque arm alignment at rest and in operation and correct it if necessary. Noise and vibration wen Loosening of Danger of ignition by 1) Stop te macine. in operation axial locking sparks 2) Ceck te wear of te parts and screw on replace it if necessary. macine saft 3) Refit te gearbox on macine saft. 4) Secure te blocking screw by using waser or glue. 5) Verify te torque arm alignment at rest and in operation and correct it if necessary Quick wear of gearing Macine teet Vibration Danger of ignition by 1) Stop te macine. reducer overeating 2) Searc te cause of macine vibration and solve it. 3) Replace te gearbox. 4) Secure te torque arm bolts by using waser or glue. 5) Verify te torque arm alignment at rest and in operation and correct it if necessary Page 15 / 18

16 Malfunction Cause Risk information in azardous areas Solution Oil leakage Loosened plugs Oil leakage Leakage at Danger of ignition due mating surfaces to reducer overeating level due to impact or over torque Oil leakage Oil seal leaking Reducer breakage Te operating Danger of ignition due conditions are to reducer overeating not in accordance wit te gearbox capacities. Reducer breakage Mistake start-up Oil corruption Ambient Danger of ignition due 1) Stop te macine. temperature to reducer overeating 2) Ceck te wear of te parts and outside te limits replace it if necessary. (see 6.3 page 3) Make te oil filling (see 6 page 7) 5).in accordance wit te viscosity depending of te ambient temperature. 1) Stop te macine. 2) Identify and eliminate te reason of te overload. 3) Repair or replace te gearbox. 4) Verify te torque arm alignment at rest and in operation and correct it if necessary. Danger of ignition due 1) Stop te macine. to reducer overeating 2) Remove and replace te oil seals. 3) Identify and eliminate te cause of oil seal degradation. 4) Verify te torque arm alignment at rest and in operation and correct it if necessary. 1) Stop te macine. 2) Verify te operating conditions and select a bigger gearbox. 3) Install te new gearbox. 4) Verify te torque arm alignment at rest and in operation and correct it if necessary. during Danger of ignition due 1) Stop te macine. to reducer overeating 2) Cange te gearbox. 3) Verify te torque arm alignment at rest and in operation and correct it if necessary. 4) Train te operating and maintenance personnel. Product accumulation on Gear unit not gear unit protected from product accumulation. Danger of ignition due 1) Stop te macine. to reducer overeating 2) Ceck te wear of te parts and replace it if necessary. 3) Make te oil filling(see 6 page 5). 4) Verify te tigtening of te plugs before starting up Danger of ignition by 1) Stop te macine. product eating on 2) Clean te gearbox and contact wit te gear accessories. unit. 3) Protect te gear unit from te product accumulation. Page 16 / 18

17 Malfunction Cause Quick deteroration safts or oil seals Risk information in azardous areas Solution of Contact wit Danger of ignition by 1) Stop te macine. aggressive reducer overeating 2) Repair or replace te gearbox. products suc as and oil leakages. 3) Protect te gear unit from te ydrocarbon, aggressive product. ozone, acids ATTENTION!: cannot assume any liability or provide guarantee coverage in te event of non-original parts being used. 12. LUBRICANTS Tableau 4: Mineral oils and greases recommended by suppliers mm2/s 40 C ISO VG150 ISO VG220 ISO VG320 Bearing grease Storage oil AGMA 4 EP 5 EP 6 EP Graisse pour roulements Huile antirouille cst/50 C älzlagerfett Rostbeständiges Öl E/50 C ,3 Lagervet Roestwerende Olie SUS/100 F AMOCO ARAL Permagear 320 Degol BG 150 BECHEM EP Degol BG 220 Degol BG 320 Aralub HLP 2 Konit 20W-20 Degol BMB 220 Degol BMB 320 Berugear GS 220 BM Berugear GS 320 BM Becem-Rus L474-3 Becem Einfettöl KSP Energrease LS EP 2 Motorenscutzöl MEK 20W 20 BP Energol GR XF 150 Energol GR XF 220 Energol GR XF 320 CASTROL Alpa SP 150 Alpamax Premium Gear Oil 150 Alpa SP 220 Alpamax Premium Gear Oil 220 Alpa SP 320 Speerol EPL 2 Alpamax Premium Gear Oil 320 Alpa SP 220S CHEVRON Gear compounds Dura lit grease Turbine oil GST EP 320 EP 3 68 ESSO EXXON Spartan EP 150 Spartan EP 220 Spartan EP 320 FUCHS-DEA Beacon EP 2 Rust 623 & 343 Ban Renolin CLP 150 Falcon CLP 220 Renolin CLP 320 Renolit FEP2 Plus ou Renolin CLP Plus 220 Plus KLÜBER Klüberoil GEM 1 Klüberoil GEM 1 Centoplex 2EP Contrakor A40 Page 17 / 18

18 mm2/s 40 C ISO VG150 ISO VG220 ISO VG320 Bearing grease Storage oil AGMA 4 EP 5 EP 6 EP Graisse pour roulements Huile antirouille cst/50 C älzlagerfett Rostbeständiges Öl E/50 C ,3 Lagervet Roestwerende Olie MOBIL Mobilgear 150 OPTIMOL Optigear BM 150 Optigear BM 220 Optigear BM 320 Olista 3EP SHELL Omala F 150 Omala F 220 Omala F 320 Alvania EP 2 Ensis engine oil 30 SRS Wintersall Ersolan G 150 Wintersall Ersolan G 220 Wintersall Ersolan G 320 Wiolub LFP 2 Antikorrol 30 TEXACO Auriga EP 150 Auriga EP 220 Auriga EP 320 Multifak EP 2 Meropa WM 150 Meropa WM 220 Meropa WM 320 TRIBOL XMP Mobilgear 220 XMP Mobilgear 632 ou Mobilux EP 3 XMP /320 Mobilarma 524 Longtime Korrosionsscutt z öl 5028 LN 697 Auriga EP 100 Meropa WM 100 Tribol 3020/ Lubricant suppliers are responsible for selection and composition of teir products. Page 18 / 18